KS2 Service Manual

Professional testing console

 Foreword

This Manual depicts the operation order and technical diagnosis process for removal, disassembly,
check, adjustment, reassembly and installation of serviceable parts in every assembly of King Long
Light Bus Sea Lion KS2 and is provided for reference by engineers, technicians and service men in
authorized service center for King Long Sea Lion.
This manual is composed of Part I Engine, Part II Chassis and Part III Inner and Outer Trimming, Electrical
Equipment & Body, in which all technical data, illustrations and product description are consistent with the reality at
the moment of publication of this Manual. However, we reserve all rights to amend the manual without prior notice
and any binding conditions. All service centers, please pay attention to this point! Furthermore, if you have any
question regarding any part of this Manual, you are welcome to give your valuable advice and we will make
effective revision based on actual conditions.

Composed and edited by: Light Bus Service Program

Reviewed and approved by: Light Bust Service Program, Technical Program on Light Bus Product

SECRET

Xiamen King Long United Automotive Industry Co., Ltd

September, 2012
 Part I Engine
Chapter I Gasoline engine 4RB
Technical specifications of gasoline engine 4RB2…………………………............002
Overview on advanced performance of gasoline engine 4RB2 ………………......002
Typical structure of gasoline engine 4RB2 and its advantages…………………....003
Disassembly of major parts of gasoline engine 4RB2………………………….......004

1
 Gasoline engine 4RB2
1. Technical specifications of gasoline engine 4RB2:
Engine type Model 4RB2
Cylinder No (mm) 4
Cylinder bore×\u34892X stroke (mm) 95×86
Total displacement (L) 2.438
Idle speed (r/min) 750±50
Total power/rotating speed (KW/ r/min) 102/4500~5000
Maximum torque/rotating speed (KW/ r/min) 217/2600~3200
Fuel oil feeding way Close loop control, point sequential injection

Pollutant emission limit State IV emission regulation

Fuel oil brand 93 or 97 top quality unleaded petrol (GB17930)

Engine oil brand API: SL SAE: 10W-30 or 15W-40

Compression ratio 9.2

External dimension (mm) 760×550×670

2. Overview on advanced performance of gasoline engine 4RB2 :

2.1 Advanced electronic control system
The electronic control system of Gasoline engine 4RB2 is a system with joint electron ME7
engine control module (ECM) as its core (abbr. 7.8 system). From its functional sense, it meets the
relevant technical requirements of State IV emission regulations, but also reserves related
functions of European On-Board Diagnostics (EOBD).
2.2 High power performance:
This model has high-power (102KW), high torque (217N * m) as its characteristics, torque
curve smooth-going, ride performance and acceleration ability good.
2.3 Excellent emission performance:
As a result of applying advanced combustion systems, ignition control technology, modern
electronically controlled fuel injection technology and catalytic converter for purifying the outside,
the engine easily meets State IV regulations on its emission index. (Related emissions were
detected through: 9- mode test cycle, 15- mode test cycle, crankcase ventilation emission
detection, two-speed idle emissions testing, etc.).
2.4 Compact structure, small size and light weight:
In the overall layout: Gasoline engine 4RB2 applies chain-driven double overhead camshaft
(no bearings), uncased gantry cylinder block, ultrashort cylinder center distance (102.5) and short
rod (also at 135), optimized design of waterways and oil passages, these help downsize the whole
engine; in accessories: oil pump and water pump attached to the sprocket chamber, super
lightweight motivation and spin-on filter applied, making the attachment system in light weight and
small size; in selection of materials , aluminum cylinder heads, sprockets chamber, etc. are used,
so that the whole weight of the engine reduce further (total mass 155kg, specific mass 1.62kg/kw).
2.5 Fuel-efficient
Model 4RB2 applies advanced combustion chamber system, high compression ratio and
electronic fuel multi-point sequential injection. It follows strict matching calibration, which lead to
full combustion, thus the engine has a high thermal efficiency and broad economic profit. The use
of long passage inlet air pipe increase volumetric efficiency; the use of a lightweight piston rod
mechanism, typical convex skirt piston and silicone clutch fan structure improve the mechanical
efficiency.
There is a certain angle between the inlet valve, exhaust valve and the vertical direction, so
that the spark plug can be disposed near the center of the combustion chamber, which will be
good for annular flame propagation and improve fuel-efficiency, especially the part load
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fuel-efficiency.
2.6 Low vibration, low noise
For Model 4RB2-type applies advanced structure and combustion process, the use of strict
fire timing calibration and optimization of adjustment in detonation zone, reduce mechanical noise
and combustion noise; the use of double valve chamber cover structure, low down the delivery of
noise in valve chamber; In the design of engine body and cylinder head, there are structures and
measures applied on the outer surface to reduce internal damping force response, and further
reduce noise. Lightweight design of piston crankshaft connecting rod mechanism, use of rubber
damper pulley and silicone clutch fan, low down the vibration and noise. It help to reduce noise,
too, that the camshaft directly working in the aluminum lid.
2.7 Easy maintenance
The design and layout is concise and compact; fire and electric control system is in high and
clear integration, which led to easy overhaul of the components; chain tensioner automatic
constant pressure, etc., greatly simplifies and facilitates the maintenance work.
3. Typical structure of gasoline engine 4RB2 and its advantages
3.1 16 Valve mechanism (4 valves per cylinder body)
For modern cars, there are more requirements on vehicle power - engine performance,
increasing power, improving engine power and sensitivity in different conditions, and also sending
fuel and reducing exhaust pollution, so the four-valve mechanism gets more attention, its
advantages are: the inlet flow area increases; the flow resistance is reduced; so volumetric
efficiency increases and the pumping loss is reduced, thus the engine torque and power
increases.
(1)The design of air Inlet pipe is in free range; combustor switch shape like hemisphere; the
spark plug may be arranged at a position near the center; these conditions help the gas mixture
produce tumble and swirl in the cylinder, to achieve rapid combustion, to increase the
compression ratio, and to low down the emissions of fuel pump and HC compound.
(2)The moving parts of valve train are in small mass, small inertia force and large windy
structure, which is conducive to improve the engine speed and reduce noise.
3.2 The main advantages of double overhead camshaft
structure:
⑴ The valve mechanism is directly driven by a double
overhead camshaft (DOHC), without push rod and rocker arm,
that reduce the inertial mass, i.e. reduce the inertial force of
valve train,
Thereby decrease the vibration of the valve and
deformation of valve body.
⑵ To minimize the valve clearance and reduce noise.
⑶To improve valve mobility for camshaft, increase the
engine speed.
⑷The inertial mass of the structure is small, so that the
valve can be quickly opened and closed.
So there is an extension of the valve opening time,
improving the ventilation of the cylinder conditions, and
increasing combustion cellar efficiency, thus greatly improve
the engine performance.
3.3 Gapless gear transmission (between double overhead
camshafts):
Disadvantages of traditional gear transmission: tooth
surface can be easily worn down, after that engine timing
precision will be reduced; besides, avoiding thermal expansion
to prevent gear stuck, there must be adequate ground
clearance between the two gears, so loud noise will be
produced.

3
 Model 4RB2 applies the gapless gear transmission structure, which is consists of main and
auxiliary gears. There is a torsion spring sandwiched between the main and auxiliary gear; the
two ends tops of torsion spring are fixed in the main and auxiliary gear on the ground pin; the
torsion spring opens a small angle between the main and auxiliary gear tooth surface, shaped
such as scissors. When the temperature decreases, the gap between the main and auxiliary gear
of double overhead camshaft is large, under the elasticity force of torsion spring, the main and
auxiliary gear of gapless gear shape a small angle on the tooth surface, to fill the gap between the
main and auxiliary gear. On the contrary, it’s the converse way.
Advantages of this structure: improve timing accuracy; reduce engine noise.
4. Disassembly of major parts of gasoline engine 4RB2
4.1 Cylinder head assembly
Engine cylinder head is one of the important frame
members. The main components of valve (Camshaft,
valves, tappets, etc.) and components of the ignition
system(Such as spark plugs, etc.) are integrated on top
of it. Thus the air inlet, exhaust, ignition, burning and
acting can be done normally.
Gasoline engine 4RB2 cylinder head uses
Aluminum-alloy casting, cross-flow inlet and
exhaust piping; calash combustion chamber is applied,
the spark plug of which is located in the centre of
combustion chamber, five camshaft bearing seat and
the support seat cover functioned for air inlet and
exhaust, fuel injector mounted on the cylinder head.
The valve chamber cover is made of thin
aluminum-alloy slice with damping and silencing
structure.

●Removing the cylinder head assembly

Put the first cylinder piston on top dead center.
Turn the crankshaft pulley, the pulley timing mark
aligning the "0" mark on chain compartment lid.
As figured.

Remove the high-voltage cables, spark plugs,

cylinder head cover, ignition coil, air inlet manifold
support bar, fuel pipe, and hoses off the cooling water,
etc. Remove the inlet camshaft sprocket bolts, chain
tightener assembly and gaskets. Remove the camshaft
timing sprocket from inlet camshaft, the cam shaft
bearing cover and camshaft..

Loosen the camshaft bearing cap bolts by 2 to 3

steps according to Figure. Remove camshaft and
camshaft bearing cap. Before remove the cylinder
head, firstly unscrew the two bolts in front of cylinder
head. As shown in the figure. Then gradually unscrew
the 10 cylinder head bolts by 2 ~ 3 steps as shown in
the figure, remove the cylinder cover.

4
 ●Checking the cylinder head:
Check valve seat wear:
Check the valve seat wear conditions, and
further check whether there are damages or not.
When necessary, mend the valve seat. Firstly you
should check wear conditions of valve guide pipe, if
it has been excessive wear, you should replace it;
then, polish valve seat with valve seat reamer or
grinder. Valve seats should be processed into the
shape as shown, the contact ring width of valve seat
and valve cone is 1.0mm ~ 1.4mm.
Finally, grind valve and valve seat with grinding
paste to make it close fit without leakage. After
grinding, thoroughly clean the valve seat, valve and
valve guide pipe inner bore.
The finished valve can not be mounted on
wrong position.
For the examination of the remaining parts,
please see relevant technical document.

●Cylinder head parts assembly point

Valve and valve seat should be sealed firmly.
When the spark plug mounted, observe chamber
filled with kerosene for1 minute, to confirm no
significant leakage.
No damage or scratch on the lip when valve
seal is loaded. No scratch on the valve stem when
lock angle is loaded. When installing tappets and
adjusting shims, make sure that air inlet valve gap
should be 0.15mm ~ 0.25mm, exhaust valve gap be
0.25mm ~ 0.35mm.
(1)cylinder head installation
(2)Install the cylinder head to the engine body,
and position it with pin sleeve. Coat with sealant at
the junction (Figure)of the chain wheel chamber and
the engine body, then install cylinder head gasket
and cylinder head.

Coat with a small amount of oil on the threaded

portion of the cylinder head bolts; tighten 10 bolts as
the order shown in the figure. The first tightening
force is 39N * m ± 4N * m, the second 90 °± 5 °\
u65292X the third 90 °± 5 °\ u12290X.

5
 (3)Installation of axle
(4)To assemble the camshaft, clean the junction surface first and apply proper volume of
engine oil on the surface of camshaft journal, then place the camshaft and camshaft bearing cap,
when you must make sure the sequence number of camshaft and camshaft bearing cap in both
front and rear direction as well as the forward signs are correct, and knock the camshaft bearing
cap in place with rubber hammer lightly, next apply a little engine oil on the threads of camshaft
bearing cap bolt and screw down the bolt with torque wrench at the tightening torque
16N*m±3N*m.
Note:
To assemble the inlet camshaft, place camshaft in
upward angle location; to assemble the exhaust
camshaft, align the timing marks on driving gear of inlet
camshaft and exhaust camshaft.
(3)Assemble timing sprocket for inlet camshaft
Lift the sprocket and chain with hand, turn
crankshaft to the extent when the first and fourth
cylinder piston stays on top dead center position; turn
camshaft to align timing marks on both inlet and
exhaust camshaft gears (angle location pin on inlet
camshaft faced up); align the sprocket to the angle
location pin on inlet camshaft and fixed it in before
assembling and tightening bolts.

(4)Installation of chain tensioner:

Loosen the detent to press the rack bar in completely and hook the shackle on adjusting pin to
hold it; install the gasket and tensioner in place together and tighten it with 2 nuts. Turn the
crankshaft to enable the tensioner shackle ripping out of the adjusting pin， then the rack bar pops
out and press the sliding shoe against the chain to tension it.

(5)Check and adjust valve clearance

Check valve clearance:
Turn crankshaft pulley to make it stay at the TDC point for
compression of the first cylinder, check the valve clearance shown
in the upper part in the figure above with feeler. If the clearance is
not correct, then replace the gasket and make adjustment.
Turn the crankshaft pulley for a cycle, align the recess of
pulley to the timing mark “0”, and check the valve clearance
shown in the lower part in the figure above with feeler. If the
clearance is not correct, then replace the gasket and make
adjustment.

6
 Exhaust valve Air inlet valve Valve clearance
adjusting paddle
Clearance (cold 0.5mm~0.25mm 0.25mm~0.35mm
state)
Adjust valve clearance
Press down valve lifter with valve clearance adjusting Valve
clamp and hold it downward with valve clearance adjusting clearance
adjusting
supporting rod, then remove the gasket with adjusting paddle, clamp
check and adjust valve clearance.

4.2 Timing chain sprocket mechanism

●Disassemble timing chain sprocket mechanism:
Remove the cylinder head, then take off fan belt silicon
clutch (fan), water pump pulley, alternating generator,
crankshaft pulley, oil pan, engine oil filter, sprocket chamber,
camshaft timing chain, inlet camshaft timing sprocket, sliding
shoe assembly, damper plate assembly, crankshaft timing
sprocket in turns.

●Check timing chain sprocket mechanism

Straighten the chain, measure the total length of 16-pitch
chain at 3~4 points, which shall be 142.875mm. When the
measurement is above the said value, replace the chain.
The sprocket shall be checked as shown in the diagram,
minimum 113.8mm for camshaft timing sprocket.
To check the sliding shoe and damper plate assembly,
see if the maximum wear is 1mm.

●Assemble timing chain sprocket mechanism

Turn crankshaft to make the spline faced up, fit in the
woodruff key and timing sprocket.
Assemble sliding shoe and damper plate assembly.
Assemble camshaft timing chain and inlet camshaft
timing chain sprocket.
To assemble camshaft timing chain on crankshaft timing
chain sprocket, align the timing mark – black chain unit to the
timing pit on the crankshaft timing chain sprocket.
Align timing marks on camshaft timing chain sprocket and
camshaft timing chain.
Make sure chains are mounted correctly into the sliding
shoe and damper plate.
Bind chains, sliding shoe and damper plate assemblies
together with cord to prevent looseness.
Then assemble sprocket chamber, engine oil filter, oil
pan, crankshaft pulley, alternating generator, water pump
pulley and silicon clutch (fan), fan belt and cylinder head in
turns.

7
 4.3 Cylinder block assembly
Cylinder block is an important framework member of engine on which many important parts
are assembled (e.g. crankshaft, engine oil pump and piston, etc.). It is an essential working
environment for cylinder and enables external acting of engine together with the combustion
chamber. Its water jacket enables the engine to stay under normal operating temperature and the
oil duct offers excellent lubrication to all moving parts on the engine. Through the said major parts
combined, the engine formulates a complete closed operating loop.

Gasoline engine 4RB2 uses gantry type cylinder block, i.e. the base plane of cylinder is lower
than the mounting surface of crankshaft, which clearly improves the bending rigidity in fore-and-aft
plane and torsional rigidity along the crankshaft axis and helps the reinforcement and
improvement of engine. Meanwhile, the underside of cylinder body can form an entire plane
matching with oil pan to make sealing easier.
Since the driver liner for cylinder and cylinder block casted into a single unit is used, it makes
a simple and compact construction and the rigidity is higher than that of dry liner cylinder. The
cylinder body is fully supportive and results in more uniform load distribution.

● Tips on disassembly of cylinder block assembly:

Component of piston rod
To remove component of piston rod, cover the rod bolt with rubber sleeve or plastic sleeve to
prevent damage to crankshaft rod journal.
The disassembled bearing bush for piston rod assembly shall be placed in proper sequence
and it’s not allowed to change their assembly order during mounting.
To disassemble the main bearing cap, main shaft bushing and crankshaft as well as thrust
plate, place them in proper order for the convenience of assembly.
● Check component of cylinder block

Push

Shaft

10mm

Middle

10mm

8
Item Reference values Max. Measures for off-limits

Rod 0.160mm~0.312mm Replace relevant parts

Axial clearance 0.35mm
0.32mm~0.058mm 0.10mm
Radial clearance
0.040~0.212mm - replace thrust plate
Bent axle Axial clearance
Radial clearance 0.030mm~0.057mm 0.10mm replace main shaft
(third main journal) bushing
0.025mm~0.049mm
(other main journal)
Cylinder hole diameter 94.995mm~95.005mm - Exceed max. diameter,
95.005mm~95.015mm - or cylinder bore, bore
95.015mm~95.025mm - cylinder may exist, or
replace cylinder body
-
Flat surface on cylinder body 0.05mm(flatness)
Piston diameter -
94.925mm~94.935mm
-
94.935mm~94.945mm
-
94.945mm~94.955mm
Auxiliary cylinder gap 0.042mm~0.062mm 0.1mm replace piston or bore
cylinder
Ring slot gap No.1:0.030mm~0.70mm - Replace piston
No.2:0.030mm~0.70mm -
Piston ring split gap No.1:0.25mm~0.40mm - Replace piston
No.2:0.040mm~0.55mm -
Piston pin and piston pin hole 0.005mm~0.011mm 0.015
gap
Piston pin and connecting rod 0.005mm~0.011mm
small end gap 0.015
Connecting rod threaded part 7.8mm~7.9mm
7.6mm
diameter
Bent axle main journal radial Max0.03mm -
runout

9
 ●Tipster on assembly of parts for cylinder block

(1) Assembly of camshaft and main shaft bushing

According to the category no. 1, 2&3 for the size of

main shaft hold on the right of lower plane of cylinder
block, choose applicable main shaft bushing and fit it
into the cylinder body and main bearing cap.
Orifice
Note: fit the bushing with oil hold into the cylinder
body and apply a little engine oil on the inner side of
main shaft bushing.

Fix the thrust plate at the position on both sides of

passenger seat for main shaft no. 3 of cylinder bloc and
the place the oil grave outward as shown in the figure.

Place the crankshaft onto the cylinder block with

main shaft bushing, fix the lower thrust plate on both
sides of main bearing cap no. 3, with groove surface
faced outside, then assemble main bearing caps in
place in its original order and as the arrow indicates, as
shown in the figure.

To assemble bolts for main bearing cap，apply a

thin layer of engine oil on the threaded part and screw
down the bolt at twice alternately from the middle to
ends as shown in the figure, tightening torque 39N.m.
Make marks in the front on top of all bolts and
screw them for 90°\u65292X in the order shown in the
figure to tighten them further.
Check the crankshaft for flexible movement and
blocking and check the axial clearance of crankshaft.

10
 (2) Assembly of piston crank mechanism
According to the classification number of hole at the
big end of connecting rod, choose proper bearing bush to
fit into the hole at the big end and connecting rod cap, with
the bush with oil hole fitted into the big end of connecting
rod.
Hold the bolt for connecting rod with hose and apply
little engine oil on the journal of connecting rod between
cylinder wall and crankshaft.
Fix piston crank mechanism into the taper sleeve,
align the piston, with recess mark against the front of
cylinder block, then press piston rod assembly into the
cylinder gently.

Assemble the connecting rod cap, make sure the

front mark of connecting rod cap directs the correct way Front
and the connecting rod cap matches well with the rod, as Front mark
shown in the figure.
Screw down the nuts for connecting rod in two steps,
tightening torque 29 N.m.
Make a mark in the front at the end of nuts and turn
the nuts for 90°\u65292X to tighten them further.
The crankshaft shall move flexibly and free of
blocking. The connecting rod shall be meet all
requirements in terms of axial and radial clearance.

Hot water pipe

4.4 Cooling system assembly
The gasoline engine 4RB2 adopts forced water behind the
cylinder head
cooling circulation, with a thermostat fitted on the inlet
side, as shown in the figure. Check water tank to see if
there’s sufficient cooling water; if not, refill enough
coolant.
With anti-freezing solution used, please follow
operating instructions for anti-freezer for mixed use. Since
the thermostat is fitted at the inlet, top up it to fill or replace
coolant at the first time. Later, run the engine till the water Water
Thermostat
level stay constant before refilling. pump

11
 Check the quality of coolant to see if it is clean and
if there’s any oil stain; in case it has been
contaminated, replace it. Check the coolant system to
see if there’s any leakage.

Check and adjust the fan belt for proper tightness.

Apply a force 98N onto the middle of belt between the
alternating generator and water pump to press down
the belt, then used belt will turn out to be at a winding
degree 7~8mm and 5~7mm for new belt as shown in
the figure.

Make sure the fan belt and pulley groove are well
fitted, as shown in the figure:

Right Wrong Wrong

Check thermostat:
88℃
When valve opening temperature at 88°C, > 8mm.
When valve opening temperature rises, if the
closed status is inconsistent with requirements, replace
the thermostat then.

Check water pump:

Check water pump and timing chain sprocket
chamber for any crack and damage to the fitting
surface and check the bearing to see if it can move
freely and if there’s any noise.

4.5 Lubrication system

Structural feature:
Full filtering pressure and splash combined
lubrication system and rotor type engine oil pump are
used. Both inner and outer rotors for engine oil pump
are fixed in the chain sprocket chamber and driven by
the vibration damping crankshaft pulley directly. The
main oil duct is provided on the cylinder block for
lubricating main shaft journal, connecting rod journal,
camshaft bearing (duct to cylinder head is designed on
the cylinder block) through the oil way; while sprocket,
chain and tensioner are lubricated by injection through
injector on the main oil duct; valve lifter, valve, cylinder
bore, piston pin and pin hose are subject to splash
lubrication.

12
 The fuel pump of gasoline engine is a inner and outer rotor pump and works in this manner:
when the crankshaft moves, it passes the driving force to crankshaft pulley before delivery to the
fuel pump, then the inner rotor of fuel pump stirs outer rotor to make eccentric motion and
therefore boosts volume change in the working chamber, which generates negative pressure to
extract engine oil from the oil pan to the working chamber of fuel pump while at positive pressure,
it pumps engine oil to the main oil duct. In the event of any failure to fuel pump:
1. In the case of foreign materials causing blocking of pump, it will causes serious problems
like damage of camshaft and distributor tooth.
2. In the case of under-pressure of engine oil, it will lead to dry friction among moving parts
within the engine and damage of the whole engine.
Engine oil filter: the engine requires a clean lubricating environment for running. If the oil is
contaminated, it will lead to worse lubricating condition for moving parts and even damage to parts.
The engine oil filter is a fuel filtering device and used to filter unclean fuel.
Fuel cut-off alarm is a pressure sensor, with sensing source in the oil duct. When the fuel
pump works, the oil duct shall be full of lubricating oil at certain pressure, which ensures normal
lubrication condition for all parts of engine and is sensed by the alarm. As a general rule, it is
always on. When the engine starts, the pressure lubricating oil in oil duct will increase to drive the
patch in the alarm to move and cut off at the same time, then when the driver see the indicator is
off, he can tell if the lubricating condition of every part is sound or not.

Assembly tips
(1) Apply sealing agent on the mounting
surface of oil pan as shown in the figure.
Note: The gluing shall be done at a
diameter about 3.5mm and without any break.

4.6 Structural feature of air intake and exhaust systems

The inlet manifold works to distribute air, fuel and air and fuel from crankcase ventilation to
every cylinder: to improve charging efficiency by taking advantage of the shape and length of inlet
manifold and regulator chamber. The exhaust manifold is used to collect waste exhausted by
every cylinder of the engine and deliver the waste into the exhaust trunk.
The inlet manifold uses the type subject to plastic molding and processing and for long airway
for every cylinder in order to ensure free air flow, uniform and high charging efficiency; clamshell
exhaust manifold is used, which has excellent heat endurance and reliability, and made in
optimized design and construction to help preventing exhaust interference among cylinders and
improve consistency.

13
Heat shield for
exhaust manifold

Inlet manifold assembly

Exhaust manifold Exhaust manifold

assembly cushion

14
 PCV valve

Cylinder head
assembly

Sealing ring for

cover of cylinder
head assembly
Spark plug Valve clearance
washer adjusting ring
Valve lifter
Valve key
Camshaft bearing Spark plug
cover Valve spring
Gear spring Valve spring
Exhaust camshaft Inlet camshaft
Exhaust camshaft Intake valve seal
pinion
Lower base of valve
Wave washer spring
Valve guide pipe
Shaft collar

Intake valve

Chain tensioner
assembly
Chain
tensioner
bushing
Component of cylinder
head bolt
Semicircle 1. 39N*m
Cylinder head 2. Turn 90o
plug
3. Turn 90o

Cylinder head
gasket assembly

Specified torque

Non-reusable part

15
 Piston pin retainer Piston ring

Piston pin Piston

Piston pin retainer

Connecting rod bolt

Connecting rod
Connecting rod bearing
Connecting rod cap
Mounting bolt for
Washer
engine oil filter
O-ring
Connecting rod nut
Engine oil O-ring
pressure alarm

Flywheel
Drain valve
Upper bulkhead
of flywheel
Inverse oil seal

Engine oil filter Rear oil seal seat

assembly
Left support
assembly Fuel filter assembly

Main shaft Engine oil dipstick pipe

bushing

Engine oil
dipstick
Bypass hot water pipe

Upper thrust
washer

Left support assembly

Crankshaft
Generator support
Lower thrust washer
A.C. generator assembly

Main bearing cap

Bolt of main bearing cap

16
 Water pump belt

Left washer for sprocket

chamber

Sprocket Washer
chamber
Right washer for
sprocket chamber

A.C. generator belt

tensioner
Belt bolt for
crankshaft pulley Component of
turn angle signal
pulley for
crankshaft
Sliding shoe assembly
Inlet camshaft timing
sprocket

Inlet camshaft timing

sprocket
Crankshaft timing sprocket
Crankshaft
timing
sprocket
stop collar
Oil strainer
Damper plate
assembly

Oil pan

Washer

Oil drain plug

17
 Part I Engine
Chapter II DIESEL ENGINE DK4B

I. Engine maintenance considerations…………………………............ ……………...002

II. Technical features of Diesel Engine DK4B…………………………..………….......005
III. Major marts and specifications ……………………...............................................005
IV. Operation of DIESEL ENGINE DK4B…………………………..........……………....006
V. Breaking-in of DIESEL ENGINE DK4B…………………………............…………......007
VI. Technical service of DIESEL ENGINE DK4B…………………………..…………......008
VII. Electronic control system…………………………..……………………………….... 010
VIII. Mechanical system………………… ………............………………………………... 034
IX. Cylinder head assembl y…………………………....…………………………………...039
X. Intake assembly…………………………..........………………………………………... 046
XI. Cylinder block assembly…………………………...…………………………………... 059
XII. Piston, crankshaft and related parts………………………….……………………….071
XIII. Lubrication system…………………………........…………………………………….074
XIV. Cooling system……… …………………........………………………………………. 077
XV. Function determining and troubleshooting….....………………………………………081

1
2
 DIESEL ENGINE DK4B
I. Engine maintenance considerations:
1. Prevention of intrusion of foreign affairs
(a) It will cause problems whenever any foreign materials such as dust, sand and metallic particle
intrude the engine.
(b) Remove all sands and dirt on the outside of engine.
(c) The disassembled parts shall be protected, e.g. with plastic film, to prevent dust intrusion.
2. Protection of parts against scratch
(a) In the event of nay scratch to the fitting surface of parts or rotary part of component, it may
cause engine oil leakage or burn-through.
(b) To dismantle the fitting surface of components, never use screwdriver but use plastic hammer
to knock it lightly.
(c) Fixe the parts in jaw vice with the help of aluminum plate lined, not on the ground directly.
3. Cleaning of parts
(a) All parts shall be cleaned up, dried with air and coated with specified oil before assembly.
(b) Never use alkaline solutions to clean the following parts: aluminum and rubber parts (cylinder
head, hood pad, etc.)
(c) Never use cleaning oil (kero and gasoline, etc.) to clean the following part: rubber part (cylinder
head, hood pad, etc.)
4. Assembled position and direction
(a) Assemble all parts to the position and in the direction same with that before disassembly.
(b) When it is required to mark the signs for assembled position and direction, follow the
instruction strictly;
(c) Sort and clear up disassembled parts in the disassembly sequence and take care not to
change the assembly location and direction;
(d) When the assembly location and direction are marked, follow the instruction strictly during
operation;
5. To repair the engine, you must place the subassembly of engine on the engine work support
before repairing.
6. Disassembled parts shall be cleared up and put away in the disassembly order.
7. Movable and rotary parts shall be coated with engine oil.
8. Non-reusable parts such as washer and seal ring must be replaced with new ones.
9. Fundamentals
(a) Pre-coat bolts.
(b) Pre-coated bolt refers to a bolt with thread coated with sealant.
(c) Screw it down or off again and designated sealant shall be used to
pre-paint bolts. Sealant
Note: to correct the torque, make sure it’s controlled above the minimum
value allowed by the tightening torque.
(d) To reuse pre-coated parts, remove and clear used sealant on the bolt and within the threaded
hole before degrease with gasoline and dry it with compressed air, then apply designated
sealant on the thread and tighten the bolt at specified torque.
(e) The sealant shall be left for some time before it’s hardened depending on the type of sealant
coated.
10. Disassemble fuel system
(a) Workplace for assembly and disassembly of fuel system
(1) Disassembly shall be done within the environment available with good ventilation and free of
electric welder, grinder, drill, motor and furnace around which carry sparks;
(2) Do not operate in or around the pit which is full of gaseous fuel.
(b) Disassembly of fuel system
(1) Get the fire extinguisher ready before formal operation;
(2) For the propose of preventing static electricity, connect fuel change-over switch, vehicle and oil
tank to the ground and spray sufficient water on the performance ground;
(3) Do not use electrical equipment such as electric pump and working light which may emit
sparks or high heat;

3
 (4) Please do not use iron hammer as it may cause
sparks in operation;
(5) Fabrics with fuel attached must be disposed
separately.
11. Disassemble intake system of engine
(a) In the event to any metallic particle entering the
induction trunk, it will endanger the engine and
turbocharger;
(b) To disassemble components of intake system,
you must block the components of
disassembled intake system and opening on the side of
engine with clean cloth or rubberized fabric;
(c) To assemble parts of intake system, make sure
no intrusion of any metal, sand and so on.

Clamp 12. Handle hose clamp

(a) To disassemble hoses, check and confirm the
hose insertion and location of hose clamp first for the
convenience of full recovery later;
(b) Deformed or gunned hoses must be replaced;
(c) To reuse hoses, hose clamp shall be fixed at the
location with application mark of hose clamp;
(d) Flat spring hose clamp shall be well fixed by
Pipe clamp applying force along the direction of arrow after
mark
assembly.

13. Applicable fuel (recommended):

Summer: 0#
Winter: -10#
Temperature < 20°C: -20#
Temperature <30°C: -35#

14. Applicable fuel lubricating oil (recommended):

API: CI-4 (or above)

Oil make
Environment temperature Applicable area
(SAE)
Regionally used in cold areas in the north of
0W-40 -35°C～＋ 40°C
China
10W-30 -25°C～+ 30°C 24 hours’ use in most areas in China
15W-40 -20°C～+ 40°C 24 hours’ use in most areas in China
15W-50 -20°C～ +50°C Applied in hot areas in the south of China

4
 Note:
(1) Clean engine oil of specified oil make shall be used, not common engine oil, in case of any
accidents, such as scuffing of cylinder bore and bush burning.
(2) The engine oil to be filled in the diesel engine shall be free of impurity and moisture. The
tank filler shall be kept clean around the opening.
(3) Never use any diesel engines from different manufacturer and of different make together.
To change oil for the technical maintenance, never use new oil together with used oil.
(4) Replace engine oil filter in time as specified.

15. Select and apply coolant

(1) The coolant to be used shall be anti-freezing to prevent failures such as high water
temperature and scuffing of cylinder bore due to scaling of waterway (jacket).
(2) The anti-freezing solution is harmful to people and shall be kept in original container to
protect from human contact.

(3) Distilled water or clean soft water (boiled water, snow or rain water) may be used when
without anti-freezing solution. Keep it clean when using hard water, e.g. river water, well water,
spring and tap water and softening shall be performed, i.e. add 2g CP3Na in 1L water to soften it
before use.
Note:
(1) In use of diesel engine, do not add any coolant other than the one specified in the
instructions when the coolant is not so proper.
(2) In case of in sufficient coolant left due to leakage in cooling system, the same make of
coolant shall be used after troubleshooting and shall be refilled after diesel engine has been
cooled down.
(3) Do not use inferior coolant or abuse coolant, or the service life of diesel engine will be
seriously compromised due to corrosion and scaling.
(4) Never use untreated hard water, or it may cause failures, e.g. diesel engine in high water
temperature and scuffing of cylinder bore due to scale deposit.

5
II. Technical feature of DIESEL ENGINE DK4B:

1. Main technical parameters of generator and starter

Name Item Parameter

Voltage 14V
Generator
Rated current 120V
Voltage 12V
Starter
Output power 2．7KW

2. Parameters on torque of major threaded connection parts

Name of bolt
Tightening torque Name of bolt or nut Tightening torque
or nut
Camshaft First: 85N.m
timing gear 90N.m~98N.m Cylinder head bolt Second: tightening again for
bolt 90°
Main bearing First: 50N.m±5.0N.m Third: tightening again for
cap bolt Second: tightening again 90°
for 90°
Crankshaft pulley
Flywheel bolt 178N.m
bolt
Connecting First: 35N.m±3.5N.m 365N.m
rod nut Second: tightening again
for 90°

Note: To tighten main bolts and nuts for diesel engine, dedicated torque wrench must be used.

III. Major parts and specifications:

Name of accessory system Type Name of accessory system Specification

lubrication Oil pump type Rotor type
Water pump Centrifugal
system Full flow type Full flow type
Fuel filter type Full flow type
Pellet type
High-pressure Cooling Thermostat
Plunger type thermostat
Oil supply pump type system
system High-pressure PH high
pump type pressure pump Preheating Glow plug
2V
system voltage
Fuel injector type 6-hole
Electronicall
Intake Supercharger Exhaust gas
y controlled EGR system
system type turbocharging
EGR system

6
IV. Operation of Diesel engine DK4B:
1. Preparation before startup
 Check the diesel engine to see if every part is working soundly, connection are proper and
reliable compete with rotary parts moves freely.
 Fill enough engine oil, fuel, and water coolant as required and check if there’s any
leakage.
Note: when engine oil level is lower than the warning mark made on the engine oil gauge,
refill sufficient engine oil in case of major accident.
 Check the belt of water pump for proper tightness.
 Check the battery for liquid level of electrolyte inside.
 Check connections of electrical appliances, e.g. battery, generator and starter, for proper
fastening.
 In the event that air intrudes fuel system, it must be eliminated before starting of diesel
engine.
Air discharge method:
First, loosen fuel inlet tube, pump out fuel with manual fuel pump till air bubble disappear
before screwing off nuts at the outlet of fuel injection pump, then drive it with starter till fuel flows
out of the outlet of fuel injection pump.

2. Staring of diesel engine

In any circumstances, the diesel engine shall be started at idle state (neutral position);
 Apply power with the key and observe all electric instruments for proper indication.
 Start the diesel engine
 Put the switch on ―start‖ position, then the diesel engine will start within 1.5s; if not, restart
it 2 minutes later; in case of failure to start for 3 times in a row, then identify causes and
troubleshoot it before restarting. Release the switch button right upon the starting of diesel engine
to disengage the starter gear and flywheel gear ring in case of inversing zoning and thus damage
of starter.
 Run diesel engine idly for 3-5 minutes after starting and check to see if engine oil gauge
and cooling water circulation works well. Never adjust and run diesel engine immediately after the
starting.

3. Cold start of diesel engine

When the ambient temperature is very low, it’s hard for the diesel engine to start up. The
colder, the harder. When below -15°C, without supporting measures for cold start, it may be
difficult to start, for which causes are as follows:
 When the ambient temperature is low, the air into cylinder is at low temperature and the
diesel engine shows low temperature at compression terminal, thus it fails to reach the alkene
compression temperature and witnesses difficulty in starting and ignition.
 When the ambient temperature is low, the diesel has high viscosity and poor atomization,
thus it is not easy to ignite.
 When the ambient temperature is low, engine oil has high viscosity and it shows high
starting resisting moment and low starting speed, besides huge air leakage appears in
compression and working medium shows high heat transfer rate in addition to low compression
terminal temperature, it is difficult to ignite.
 When the ambient temperature is low, the battery has higher internal resistance and lower
charge and discharge capability, thus the starting torque decreases and it’s difficult to start.
Measures to address difficulty in cold start
 Use proper diesel.
 Use proper engine oil.
 Choose proper starter & storage battery.
 Preheat diesel engine. You may discharge coolant and use boiled water to preheat the
diesel engine. Add proper amount of boiled water into the radiator, which passes water jacket to
be cooled down before being discharged, then reheat water to start operation. After heating,
discharge hot water and refill anti-freezing solution and antirust fluid.

7
 4. Check during running
 Check if there’s any knock, looseness or any other abnormal noise.
 Check electrical appliances and equipments to see if there’s any abnormal smell of burn.
 Check the fuel, cooling and lubrication systems to see if there’s any leak.
 Check the instrument for indication of engine oil temperature, coolant temperature, electric
current and diesel oil level to see if the readings are correct.
 In the event of any failure mentioned above, check it out and troubleshoot it.

5. Stop
 To stop the diesel engine running at heavy load, lower its speed and load first to run it at
minimum idle speed for 3~5 minutes before stopping. Never stop it abruptly under the condition of
high water temperature and excessive load.
 At 5°C, when the cooling water is not added with anti-freezing solution, discharge all
cooling water inside the diesel engine after stopping to avoid frost cracking of cylinder block.

V. Breaking-in of Diesel engine DK4B

New or newly overhauled diesel engine must go through an escalating breaking in process
starting from low load for use as the breaking-in will enable good surface fitting of all moving parts
of diesel engine, avoiding abnormal wear and damage. The service life, operational reliability and
economy of diesel engine are largely depended on the breaking in at the beginning of operation.
For this reason, customer shall proceed with breaking-in strictly in accordance with breaking-in
specifications.

1. Breaking-in
·New diesel engine is subject to running-in for 2000km on the vehicle as specified in the
breaking-in specification (see the following table).
·The diesel engine which has been overhauled and replaced with piston, piston ring, cylinder
sleeve, main shaft bushing, connecting rod bearing, etc. shall be subject to running-in for 1/3
mileage as specified in the table below. During the running-in, check the diesel engine further to
see the assembly quality of every part and make necessary adjustment.

Mileage (km) Load Engine speed (r/min)

0~300 No load ≤50% of rated speed of diesel engine
>300~1000 ≤ 25% of rated load ≤50% of rated speed of diesel engine
>1000~1500 ≤ 50% of rated load ≤50% of rated speed of diesel engine
>1500~2000 ≤ 75% of rated load ≤ maximum rated speed of diesel engine

2. Breaking-in considerations
 Take care to observe and listen to check the operating condition of every system in the
diesel engine to see if there’s any oil, water and air leakage, engine oil pressure and coolant
temperature are proper, the speed stays stable, the color of exhaust gas is normal, etc.; in the
event of any default or abnormality, troubleshoot it before going on with running-in.
 During the running-in, the vehicle shall move on the pavement, Class 1 or 2, but not
allowed to drive on poor road (especially on the beach). Never drive at full speed or overload.

8
 3. Technical maintenance after breaking-in
The diesel engine shall be checked, cleaned and adjusted after breaking-in so as to clear
metal powder deposited in lubricating oil and adjust improper clearance as follows:
 Drain engine oil in the lubrication system, clean the lubrication system, replace engine oil
filter and engine oil of required make.
 Check and adjust valve lash, cold state clearance inflow (0.2mm~0.3mm) /exhaust
(0.35mm~0.45mm) of inlet and exhaust valve
 Check the fastening of bolts and fasten cylinder head bolts again as required (when air,
water or oil leakage is detected)
Note: The diesel engine will turn into normal operation only after breaking-in and
maintenance in line with technical requirements, or the service life of diesel engine will be
compromised.

4. Notes on operation of new vehicle

To drive a new vehicle, the following rules shall be followed, which can help to extend its
service life and lower diesel consumption.
 Keep proper coolant temperature and engine oil pressure;
 Keep driving at normal speed, try not to drive too fast;
 Do not slash the accelerator to accelerate abrupt when starting the vehicle;
 Try not to brake suddenly within 300km;
 When the transmission gear is put at high speed shift, do not drive the car at low speed;
 Do not keep driving at high speed or low speed gears for long time, but change gears in
time based on driving conditions;
 When the new vehicle has accomplished breaking-in for 2000km, perform technical
maintenance as required.

VI. Technical maintenance of Diesel engine DK4B

To maintain the car on a regular basis will enable the diesel engine to stay in good technical
condition, customer must take careful technical maintenance as instructed. To maintain the car,
take care to clear parts and components; to assemble removed parts, clean them and make sure
they are assembled properly before starting the diesel engine to check if everything is ok.

1. Technical maintenance period

According to the deterioration condition of every part of diesel engine, there are two types of
technical maintenance: routine maintenance and regular maintenance; the operating hours for
diesel engine or driving mileage given below is the recommendation for driving on road of class 1
or 2; under harsh condition, both hours and mileage shall be reduce by half.
 Routine maintenance: at the end of every shift of 8~10h.
 Regular maintenance: every 100 hours the diesel engine operates accumulatively or every
5,000km the vehicle drives; every 200 hours the diesel engine operates accumulatively or every
10,000km the vehicle drives; every 1,600 hours the diesel engine operates accumulatively or
every 80,000km the vehicle drives.

2. Coverage of technical maintenance

To ensure sound operation of diesel engine, the following procedures shall be performed as
technical maintenance in use.
Routine technical maintenance:
(1) Check the liquid level of diesel, coolant and engine oil and refill them when necessary.
Note: only when the diesel engine has been shut down, liquid levels can be checked
properly.
Note: Never refill the tank with fuel when diesel engine is running. When the vehicle works in
hot weather, the fuel tank shall not be filled to the maximum extent, or fuel will expand and
overflow. In the event of any spill, the spilled fuel must be wiped out immediately.

9
 (2) Clear dust, dirty and spilled electrolyte on the battery and make sure air bleeder is
unblocked. Under regular service condition, battery barely requires maintenance; however, in
high heat conditions, check the liquid level regularly, which shall stay 0~15mm above the
counter electrode, and refill distilled water when necessary.
(3) Check if there’s any oil, water and air leakage after starting the diesel engine. In case
of any leakage, troubleshoot it immediately.
(4) Check the stableness and fastening of accessories.
(5) After starting the diesel engine, observe the cover for soundness and check the
working condition of instruments. In case of any broken instrument, repair or replace it in time.
(6) Keep the diesel engine clean, in particular, electrical equipment shall be free of oil
stain, water tank radiator shall be clear of any foreign materials.
Note: when the diesel engine works in a dusty environment, dismantle air filter to clear
dust every day.
3. Regular technical maintenance
Every 100 hours the diesel engine operates accumulatively or every 5,000km the vehicle
drives, in addition to the aforesaid maintenance, the following items shall be covered too:
(1) Clean engine oil filter, air filter and diesel filter elements;
(2) Check the coolant and clean radiator;
(3) Check the firmness of diesel engine;
(4) Check tension of water pump belt;
(5) Check and adjust valve lash when necessary.

Every 200 hours the diesel engine operates accumulatively or every 10,000km the
vehicle drives, in addition to the aforesaid maintenance, the following items shall be covered
too:
(1) Replace engine oil in oil pan and engine oil filter element.
(2) Replace diesel filter element.
(3) Check and adjust valve lash when necessary.
(4) Check the working performance and water seal of water pump.
(5) Check electrical equipments for proper wire connection and replace burned ones.
(6) Clean pipes of cooling system to remove scales.
(7) Clean the ventilation system for crankshaft box.
(8) Check the working condition of supercharger rotor, remove the connecting pipe
between compressor and air filter; rotate the rotor, once it runs smoothly and rotates flexibly
for at least a turn, then everything is ok, or overhaul it.
Note: to check the working condition of rotor, make sure it’s clean round the removed part
and outside. To reassemble the part, there shall be no fore materials falling into the
supercharging system, or it will cause series consequences. In general, the supercharger
manufacturer and authorized service center are qualified and capable, customer shall not
assemble and disassemble the supercharger assembly at its own.
(9) Remove compressor housing as applicable, check if there’s any engine oil leakage
at the compression terminal; in the mean time, and clean the inner compartment of
compression housing and surface of compression impeller. Take care not to operate the
blade when cleaning, which shall be performed by service man from supercharger
manufacturer.

Every 1,600 hours the diesel engine operates accumulatively or every 80,000km the
vehicle drives, in addition to the aforesaid maintenance, the following items shall be covered
too:
(1) Remove and clean diesel engine to get rid of oil stain and scale, clean all lubricating
oil pipes and ducts.
(2).Remove the grinding valve of cylinder as applicable and eliminate carbon
accumulated in the combustion chamber.
(3) Check the wear and tear condition of piston ring, cylinder liner, connecting rod
bushing at the smaller end and bearing bush of connecting rod, make replacement when
necessary.

10
 (4) Check the wear and tear condition of main shaft bushing and thrust plate.
(5) Check the wear and tear condition of transmission mechanism and gear meshing surface
and measure the meshing clearance, make repair or replacement when necessary.
(6) Check engine oil pump, overhaul or measure quick-wear parts and make adjustment
accordingly.
(7) Check gaskets for cylinder, intake and exhaust pipe and replace broken or thrusted ones.
(8) Check generator and starter, clean every part and bearing, dry them and refill fresh
lubricating grease. Check starter gear for wear and tear condition and if transmission is flexible.
(9) Overhaul supercharger assembly when necessary and replace quick-to-wear and failed
parts:
——clean inlet connecting pipe, compressor impeller, compressor casing and clear carbon
deposit in the impeller and volute casing.
——Check the moving parts of supercharger, stir rotor with finger to see if it can move flexibly,
i.e. it can rotate for several turns by means of inertia force; if not, or there’s blocking and impacting
noise, it’s abnormal and adjustment and repair shall be conducted.
——Check the axial movement of rotor spindle, when >0.3mm, the thrust bearing of
supercharger is worn excessively and shall be replaced.
——Check the radial clearance between compressor impeller and housing, press down the
impeller with finger along radial direction, then clearance between impeller and housing shall be
minimum above 0.1mm, if not, then replace the floating bearing of supercharger.
4. Seasonal technical maintenance
(1) You must apply fuel and engine oil for winter use and watch the water content in fuel in
case of freezing.
(2) It’s better to fill anti-freezing solution in the cooling system, or drain out cooking water
after parking the car and water temperature decreases to 40-50°C.
(3) In cold area and season, the vehicle should not be parked in the open air.
(4) In the case of cold start, you can heat engine oil and cooling water.

5. Considerations on technical maintenance

 Operator shall follow technical maintenance procedures to maintain diesel engine item by
item and in high quality, never delete any maintenance items or extend maintenance period at will.
 To disassemble parts for maintenance, take care to prevent dust entering into the
machine.
 Maintenance operation or adjustment which has high technical requirements or is
complicated shall be done by professional technicians or the machine shall be send to authorized
service center of XCE Mianyang Xinchen Engine Co., Ltd. for service.

11
VII. Electronic control system:

3.1.1 High-pressure pump

3.1.2 Fuel injector
3.1.3 Oil rail
1. Fundamental of diesel engine
3.1. Core parts 3.1.4 ECU
2. Overview of common rail
system

3. Parts and components of

common rail system 3.2.1 Crankshaft position
sensor
3.2.2 Phase sensor
3.2.3 Air flow sensor
3.2.4 Glow plug
3.2.5 Glow plug control
unit
3.2.6 Oil return pipe
3.2. Other parts 3.2.7 Fuel filter
3.2.8 Water temperature
sensor
3.2.9 Accelerator pedal
transmitter
3.2.10 High-pressure oil
pipe
3.2.11 EGR valve
3.2.12 Turbocharger

1. Fundamental of diesel engine

Suction stroke Fuel Compression
injector stroke
Intake Exhaus Intake Exhaus
valve on t valve valve t valve
off off off
Intake

Intake
Power Exhaus Intake Exhaust Exhaus
stroke t valve valve stroke t valve
valve on
off off off

Exhaust

12
2．Overview of common rail system
1. Air flow sensor
2. ECU
3. High-pressure pump
4. Oil rail (high-pressure accumulator)
5. Fuel injector
6. Crankshaft position sensor
7. Anti-freezing solution temperature sensor
8. Fuel filter
9. Accelerator pedal transmitter

Engine speed sensor Injector

(crankshaft)
Phase sensor (camshaft)
Signal output
Accelerator pedal Signal assignment
Rail pressure Supply power
Atmospheric pressure
Signal configuration Fuel measuring system
Starting pressure Injection volume
Starting injection EGR
Air quality Injection control
Air temperature Rail pressure control Turbocharging
Supercharging pressure
control
EGR Injector preheating
Coolant temperature
External torque request
Burglar prevention Electronic fuel pump
Clutch Diagnostic system
Spare features Diagnosis lamp
Auto transmission Power stages
ABS/TCS CAN ISO-K Diagnosis tester

Vehicle speed Pressure control valve

Driver stage

13
 Driver’s operation

Accelerator pedal

Control unit
EDC16C Acceleration or
deceleration

High pressure control Torque control

Control injection Control injection
pressure volume
Concerned parts Control injection time
High pressure pump Concerned parts
Oil rail and pipe Fuel injector
Pressure control unit Sensors

High pressure circuit Oil rail

Rail pressure sensor

High Fuel pump

pressure Oil rail Fuel
pump injector

Low pressure
circuit

Fuel
Fuel pump High pressure pump injector

High pressure pump Fuel tank

Fuel injector Fuel tank

High pressure pump Sensor

14
3．Parts and components of common rail system ——core parts

Oil rail
Fuel pump

Fuel
injector

High
pressure
pump

3．1．1 Core parts——high-pressure pump

Fuel pump

15
 Core parts——high-pressure pump
Integrating the common rail high pressure
fuel pump for fuel delivery pump, CPIH with
3 radial plungers, driven by gear and
lubricated with diesel, one inlet metering
valve mounted inside the pump to meter
fuel volume while the compression volume
is determined on oil rail pressure
required.

Main parameters
Material of pump body: cast iron
Max. pressure: 1450bar
Max. fuel supply: 843mm³/Rev.
Revolution direction: clockwise
Drive ratio: 2/3

Inlet valve
Plunger
High
pressure
valve Driveshaft

Inlet Return
Shell

Oil arrival
Triangle Ring rail

Inlet metering
valve
Inlet metering
valve

16
 Not allowed

Wearing parts

Right method

 Transmission shaft, all connections (oil inlet, oil return joint, high pressure connection) and oil
inlet metering valve must be protected with protective cap, which shall not be removed before
assembly of applicable connections;

 Improper and early removal of package may lead to careless falling and thus damage of
high-pressure pump;

Falling dirt

17
Correct packaging of high pressure fuel pump:
A. High pressure fuel pump shall be packed in clean plastic bag to prevent fuel leakage;
B. Fuel pump shall be covered with vibration-proof material on all surfaces to prevent movement
during transportation.

1. High pressure fuel pump shall be packed in clean plastic bag to prevent fuel
leakage;
2. Fuel pump shall be covered with vibration-proof material on all surfaces to
prevent movement during transportation.

Correct assembly of high-pressure pump:

 To assemble fuel pump, remove the protective cap on the shaft first and clear oiliness
on the surface of shaft with cleansing agent, e.g. gasoline, alcohol, glycol or propane;
 Hold fuel pump with hands and place it into the engine flange in proper manners, sense
proper angle to assemble fuel volume control unit; make sure to keep the shaft level while placing
the pump inside. During assembly, turn the pump body slightly or apply some lubricating grease
on the O-ring for flange to help sealing ring to fit into the flange smoothly.
 Fasten high pressure fuel pump on the mounting flange for engine at the tightening
torque for assembly of bolts specified in the service manual.

Fuel pump High

Gear cap Bearing gear Gearbox pressure
Fixing bolt for pump pump
body M8 (hex bolt
recommend)
Tightening torque
30+5Nm

Fastening nuts for

driving wheel M14 x 1.5
Tightening torque
70+5Nm

18
 Assemble and disassemble high pressure
fuel pipe:
Take off protective cap of high pressure
fuel pipe and high pressure joint and screw
down the joint at the tightening torque specified Hold this point
in service manual and the sealing face between still when
fuel pipe and joint shall be fitted closely and free releasing high
pressure fuel
of leakage. pipe
Note: To remove high pressure joint, you
must use a wrench to hold the high pressure
Tightening torque for
joint of pump still. In case the high pressure joint high-pressure oil connector
is released by accident, screw it down 20+2Nm
maximum once; the high pressure joint and
lining must be replaced, or it’s apt to witness leakage.

Fuel charge for high-pressure pump:

Dry running is not allowed for high pressure fuel pump, or it will damage or even destroy parts
due to dry friction inside. As a result, when the high-pressure pump is put into service for the first
time or there’s air in the fuel pipeline, get rid of air in the following operation procedures and the
fuel charge pressure shall be no more than 4bar: To high-pressure pump
 Loosen the bolts for exhaust vent on fuel
filter;
 Press down manual pump on the fuel filter
till all air has been exhausted and fuel flows out of
the vent; Vent bolt
 Screw down bolts for exhaust vent;
 When necessary, repeat the aforesaid
Manual pump
procedures.

Fuel filter assembly

Manual pump

Filter
Vent bolt

Fuel tank

19
Fuel inlet
metering valve

Magnetic element

Pison

Gear pump

20
 Outlet

Pressure
side

Inlet with metering valve

Inlet

The shell is made of cast

aluminum and nickel-plated
Flow = 5.5cm3/rev.
Powder metallurgical gear, mold
once

Coupler Drive gear

Shell
Sealing ring Central bushing Follower gear

21
3.1.2 Core parts——fuel injector

Rail pressure Oil rail

sensor

Fuel pump

Fuel injector

Sensor

High pressure pump with

fuel inlet metering valve High pressure Low pressure
circuit
Electronic control circuit
unit EDC16

The fuel injector is driven by solenoid

valve indirectly, provided with P-shaped
nozzle, spherical base surface, hydraulic
connection between high pressure orifice
and low pressure oil return fixed on the
engine through specific clamp.

Main parameters:
Pressure range: max. 1450bar
Nozzle: tiny nozzle with a single pin valve

22
 High pressure
connector

Injector body

Solenoid valve
Fuel nozzle

Low pressure

High pressure

23
 Schematic of armature set motion (on
position)
Schematic of armature set motion (off
position) Magnet

Magnet Valve spring

Valve spring Sucker

Sucker
Restrictor plate
Restrictor plate Armature return
Armature return spring
spring
Armature bolt
Armature bolt
Ball joint guide
Ball joint guide
Ball joint
Ball joint

Nozzle pin valve Nozzle pin valve

Ball joint
Ball joint
Auto control valve
Auto control valve

Valve position
Valve position

24
3.1.3 Core parts——oil rail

Rail pressure Oil rail

sensor

Fuel pump

Fuel injector

Sensor

High pressure pump with fuel

inlet metering valve
High pressure Low pressure
Electronic circuit circuit
control unit
EDC16

To injector connector for every

cylinder

Metering valve

From high pressure pump

connector

Rail pressure
sensor

The laser welded high pressure oil rail has 4 hydraulic joints to provide fuel for fuel injectors,
of which one hydraulic joint is matched with high pressure fuel pump while the rail pressure sensor
is mounted on the oil rail along the axis.

Main parameters:
Measurable pressure range: 0~1800bar
Temperature range: -40℃~130℃
Supply voltage: 5V (from ECU)

25
 Sealing of oil rail connector

Tubing head
hardness ≤HV250

Sealing through the tapper plane

and head of high pressure pipe Welding surface
Laser welding process
used
Welding surface bears no
high pressure

 The rail pressure sensor is integrated at the

end of oil rail for sensing instant pressure in the oil rail.
 The rail pressure sensor works by
converting pressure signal into electrical signal
through sensor element (semiconductor component),
then amplifying and delivering signal to ECU.
 Location of rail pressure sensor: max. 30o
down vertically allowed; the rail pressure sensor is not
allowed to be hanged upside down.
Excess flow valve:
 The excess flow valve is assembled inside
high pressure connections between oil rail and fuel
injector.
 It is used to stop fuel injector staying on and
injecting fuel in extraordinary case. Once the output of
oil rail is measured to exceed specified standard, the
excess flow valve will close the fuel pipe to the fuel
injector involved.

26
3.1.4 Core parts—— ECU
The common rail 32-digit electronic control unit (ECU)
EDC16C can meet the state emission level IV and can be
extended to meet state emission level IV.

Main parameters:
Rated voltage: 12V
Power consumption: 12.~18W in general
Operating temperature : -40℃≤T≤T (max. environment
temperature)
Still air: max. environment temperature T =70℃
Moving air: max. environment temperature T =85℃

27
 Assemble ECU:
 Make sure liquid like water and oil
will not penetrate into ECU sealing element
and pressure compensating element through
wiring harness;
 It is not allowed to immerse ECU into
water;
 ECU shall not
be flexible; do not remove ECU at will during
repair;
 When it is necessary to remove ECU,
do not unplug battery head for more than 1
minute before the removal;
 Remove ECU before welding and
the removed ECU shall be safekept;
 Never add any lines on the
connecting cable for ECU;

3.2.1 Other position parts——crankshaft position sensor

Function and operating principle:

 The engine speed and crankshaft position sensor is a type of magnetic
sensor and assemble close to crankshaft, working together with 58X gears on
the crankshaft. When the crankshaft runs, the top and crest of 58X gear pass
the sensor at different distance so that the sensor senses the variance of
magnetic resistance. The alternating magnetic resistance generates
alternating output signal, which is used by ECU to determine the rotating
position and speed of crankshaft.
 Installation:
It is assembled close to the crankshaft. To assemble the sensor, press to fit
it, but never knock.

Product feature:
Operating temperature : -40℃~120℃
Working clearance: 0.5 ~1.5mm

Signal (high)

Signal (low)

28
 3．2．2 Other parts——phase sensor

Function and operating principle:

 The camshaft position sensor is Hall Effect
sensor, assembled by the camshaft, working together
with signal wheel on the camshaft, which is matched with
specific position of the engine. ECU can detect digital
voltage signal through the sensor to determine the
operating cylinder for engine and give monitoring
individually.
 Assembly: it is assembled close to the camshaft.
To assemble the sensor, press to fit it, but never knock.
Product feature:
 Operating temperature : -40℃~+150℃
 Operating voltage: 4.7~18V
 Working clearance: 0.2~1.8mm
Ground (-)

Signal output (o)

Power (+)

3.2.3 Other parts——air flow sensor

Function and operating principle:

 The air flow sensor is a hot-film air flow meter and
assembled in the intake system; in the mean time, air flow
volume sensor is built in with temperature sensor to measure
the inlet temperature. ECU will determine the air flow into
engine and its load with the said signal.
 Assembly: it is assembled on the inlet pipe and shall
be kept at certain distance with hot parts such as turbocharger
and exhaust manifold.
 The air flow sensor must be assembled in the same
direction with inlet air flow.

Product feature:
 Operating voltage: 14V
 Thermostat temperature : -40℃~120℃

Air flow
direction

Power (+)
Power (-)
Temperature output signal
Reference frequency
Flow output signal

29
3.2.4 Other parts —glow plug

Function and operating principle:

 The glow plug is used to assist the diesel
engine to cold start and improve warming
performance of diesel engine.
 Assembly: assembled in cylinder head;
ensure the correct position of heating end of glow
plug locates in the combustion chamber.

Product feature:
 Rated voltage: 11V; 12V
 Conduction time to reach 850℃: 5s±1s;
 Temperature after 60s : 1050℃±50℃.

3.2.5 Other parts —glow plug control unit:

Function and operating principle:
 The glow plug control unit is controlled by ECU,
connected through specific pins and applied to 4,
5 and 6-cylinder engine; the glow plug control
unit is also featured in diagnosis of one or more
failures of glow plug.
 Assembly: at a proper position in the engine
compartment, connector straight faced down.

Product feature:
 Rated voltage: 12V
 Power consumption: 10~18W (when the glow
plug is working)
Ground (-)
Coding control
signal (4, 6)

Main relay
Coding control To glow
signal (6) plug
Diagnosis signal

30
 3.2.6 Other parts——oil return pipe
Function and operating principle:
T-shaped
connector The oil return pipe collects returned oil from
fuel injector and deliver it to oil return box. It is
L-shaped composed of L&T–shaped connector and
connector
reinforced rubber braided hose. Connectors are
also equipped with check valve to ensure the
Insert injector stability of oil return pressure.
Return to fuel tank via Assembly: assembled on the head of fuel
the hose
injector for every cylinder
Product feature:
 System pressure: max. 2bar
 Pipe bending radius: ≥30mm

3.2.7 Other parts——fuel filter

Manual pump
Outlet Function and operating principle:

Inlet filter also integrates fuel handling and
pumping device, oil- water separator and
fuel return device, among which fuel
handling and pumping device is used to
discharge air in the pipe during first starting
or after the vehicle being out of service for
long time. The oil-water separator indicator
Heating switch
on the instrument panel can remind the
driver of draining separated water and fuel
heating device helps improve the
performance of vehicle in cold start.
 Assembly: assembled at proper position
on the body, up downward, max. deviation
from upright direction 20
Product feature:
Oil-water separator  Operating temperature : -40℃~+120℃
 Operating pressure: ≤2 bar
 Replacement interval: 30km

31
3.2.8 Other parts——water temperature sensor

Signal ground

Temperature
signal

Function and operating principle:

The coolant temperature sensor is used to detect the engine’s operating temperature: ECU
provides engine with the best control solution based on different temperature;
The coolant temperature sensor uses thermister with negative temperature coefficient as the
sensing element;
Assembly: coolant temperature sensor is assembled in the minor cycle path of coolant for
engine.
Product feature:
 Operating voltage: 5±0.15V;
 Operating temperature :: -40℃~+130℃

3.2.9 Other parts——accelerator pedal sensor

Function and operating principle:

The accelerator pedal sensor is mainly used to
acquire driver’s driving requirements on the vehicle
and make analysis and calculation through ECU to
provide engine with proper power.

Product feature:
 Operating voltage: 5±0.3V;
 Operating temperature :: -40℃~+80℃
 Pedal effort: 500±6N
 Pedal return force: >5N

32
3.2.10 Other parts——high pressure fuel pipe

Assemble high pressure fuel pipe:

Assemble high pressure pipe between oil
rail and fuel injector:

pressure plate and fix fuel injector onto the
engine, then screw down oil rail on the
engine manually (3±1Nm) ;

of high pressure fuel pipe and oil rail
respectively (3±1Nm)

down nuts for high pressure fuel pipe at the
fuel injector end, tightening torque 30±3
Nm;

tightening torque 23±2 Nm;

nuts for high pressure fuel pipe at oil rail
end, tightening torque 30±3 Nm;
Assemble high pressure pipe between
high-pressure pump and oil rail
 Tighten nuts at both ends of high pressure
fuel pipe manually (3 ±1Nm) ;
 Screw down connecting nuts for high
pressure fuel pipe and fuel pump as well oil
rail at both ends, tightening torque 30±3
Nm.

Disassemble high pressure fuel pipe:

Disassemble high pressure pipe between oil rail and fuel injector:
 Screw off nuts for high pressure fuel pipe between fuel injector and oil rail;
 Screw off nuts for high pressure fuel pipe at fuel injector end and you must fix the high
pressure connector for fuel injector;
 Take off high pressure fuel pipe;
 Loosen and remove pressure plate;
 Use dedicated fuel injector disassembly tool to remove fuel injector out of engine cylinder
head;
 Put protective caps back onto fuel injector and oil rail.
Disassemble high pressure pipe between high-pressure pump and oil rail
 Screw off nuts for high pressure fuel pipe between oil rail and high-pressure pump;
 Screw off nuts for high pressure fuel pipe at high-pressure pump end and you must use
wrench to fix high pressure connector for high-pressure pump to prevent movement;
 Remove high pressure fuel pipe;
 Place all protective caps back onto high-pressure pump and fuel pipe.

33
3.2.11 Other parts—— EGR valve

Function and operating principle:

 valve locates on the inlet pipe and enables a
certain volume of waste to flow into the intake system
for re-circulation.
 valve diaphragm connects to pivot bar on one side
and spring on the other side (the spring keeps the valve
always closed). When the vacuum pressure(or
atmospheric pressure) on diaphragm is larger than the
spring force, the pivot bar will be pulled away from its
original position to open the passage so that waste can
enter into the recirculation system. The waste volume in
recirculation is directly linked to air intake.
 Essentially, EGR reduces emission of NOx through worsening combustion because the
generation of NOx requires two conditions: high heat and rich oxygen and guiding certain
combusted waste into inlet pipe via control valve to mix with fresh air before combustion in
cylinder will lead to lower combustion velocity due to the inertia gas, lower combustion
temperature and thus less NOx.

3.1.12 Other parts——turbocharger

Function and operating principle:
 The turbine of turbocharger is connected to
exhaust pipe, while compressor connected to inlet
pipe, and turbine and compressor impellers are
subject to coaxial rotation. The turbocharger drives
turbine through exhaust to drive the compressor so
as to increase inlet pressure and inflating volume.
 To prevent supercharger developing high
revolution when adjusting the load for diesel engine
and excessive supercharge pressure of engine,
adjust high load through exhaust by-pass valve to
discharge certain waste so as to lower supercharger
revolution and control pressure ratio.
Operation tips:
 Thanks to fully floating bearing of turbocharger, it places high requirement on lubricating oil
and use proper supercharged diesel engine oil as specified.
 In order to ensure lubrication of bearing, run it at idle speed for several minutes after
starting so that lubricating oil will reach certain temperature and pressure; likewise, do not
stop it abruptly for shutdown, but reduce its load gradually and run it at idle speed for several
minutes before shutdown.
 Clean air filter on a regular basis and check intake system for leakage as specified.

34
VIII. Mechanical system:
1. Cylinder head assembly:
 The cylinder head cover is made of light resin
Cylinder head
material of excellent vibration resistance, which
reduces engine weight and guarantees the
strength of cylinder head cover. By improving the
profile of cylinder head cover, it lowers engine
Cylinder head
level. The cylinder head cover is provided with cover gasket
baffled inside and vent pipe projecting out of the
cover, resulting in better fuel cutting capacity. In
addition, the baffled and vent pipe are made of
resin material, lightening the engine.
 The cylinder head liner is made of heat resistant,
highly oil resistant acrylic rubber to ensure its
Cylinder
reliability. head
 The cylinder head is made of light but highly heat
conductive aluminum alloy. Besides, DOHC4
valves are used to make fuel injector arranged in Cylinder head
gasket
the center of cylinder head, which has improved
the engine’s performance and reliability, but also helped achieve the objectives of low
emission and compactness.
 The cylinder head liner is made of 4 layers of overlapped steel sheets of excellent tightness
and heat resistance.

2. Cylinder head
Installation opening
for injector

 The air inlet is for independent air inlet, designed

with two air inlets in different shape, which
improves vortex within the cylinder and boosts the
mixing of fuel and air.
 Two-layer water jacket is used, having improved EGR gas outlet
the cooling performance and rigidity. By applying
improved casting process (rigidity strengthening
casting), the reliability of cylinder head has been
improved.
 Glow plug is provided between inlet valves Two-stage water jacket
ensuring reliability and startability. Section A-A
 EGR path is designed within cylinder head, which Exhaust 1# Glow plug
improves the cooling effect of EGR gas and
Central
reduces the volume of cylinder head. configuration
 Integrated single gaskets #1-#4 are provided all for injector
around the cylinder bore on cylinder head gasket
and improve tightness. EGR access
 The cylinder bore adopts twin bead construction, Inlet 1#
with cylinder head gasket spring characteristic
controlled to the minimum extent, having ensured the tightness as air pressure for combustion
rises.

Twin bead
structure

4-cylinder compact Cylinder rim

cylinder gasket bead

35
3. Camshaft timing system
The camshaft timing system is made up Inner cover of
sprocket chamber
with timing gear system and gear belt, Camshaft
Timing belt chamber
having reduced the length of engine and Timing
make it easier to replace gear belt. gearbox
The timing gear belt is made of high
strength material and thus has better
reliability.
Automatic Hydraulic tensioner is used to
keep belt at certain tension.
Gear box and gear cap are made of
aluminum alloy while timing gear box cap is
provided with crankshaft position sensor.
Both inner and outer cap of belt pulley
chamber are made of resin material.
Auto
Washers are provided around the outer cap Timing gearbox
Outer cover tensioner cover
of pulley chamber and it reduces engine of sprocket
vibration and noise. The camshaft oil seal is chamber
assembled on cylinder head.

4. Hydraulic tensioner for camshaft timing

system Dust seal ring
The plunger spring built in tensioner drives
tensioning wheel through push rod to give gear
belt certain tension, while engine oil control the
push rod to move toward the less tight side of Return spring
gear belt under the action of check valve ball so
as to keep gear belt under constant tension.
Once the gear belt is loose, the push rod will
move up with the action of plunger spring, then
engine oil in chamber A will push away check
valve ball to flow into chamber B, or vice versa. Chamber A
Push rod
When engine speed decreases, the tension of
gear belt increases, then tensioner gear pulley
will drive the push rod to move. At this moment, Plunger

check valve ball will cut off the path between

chamber B and A so that chamber B turns into Check valve
high pressure state to prevent thrust rod being ball
pushed into chamber B. As a result, with the
thrust rod’s continuous action up and down, the Chamber B
Plunger
spring
gear belt keeps constant tension.

36
Disassembly

Aligning mark
1. Remove the enclosure of timing gear chamber
(1) Remove the phase sensor and support
(2) Remove wire harness clamp
(3) Screw off 6 bolts and remove the enclosure of
sprocket wheel chamber
2. Remove the timing gear belt
(1) Turn crankshaft forward to align marked lines of the
Aligning mark
two gear pulleys.
(2) Screw off 2 bolts with tools and remove the tensioner
(3) Remove the timing belt and mark arrows on its
operating direction (keep the original running direction
during assembly)

37
 Assembly
1. To rotate camshaft with timing gear belt removed,
first turn crankshaft for 90° inversely incase of
damage to valve and piston.
Note:
When timing gear belt is removed, never turn
crankshaft. (Piston and valve interfere with each
other and will lead to damage)
To assemble timing gear belt, recover the
camshaft to the position with aligning mark, then turn
crankshaft forward till it’s aligned with the aligning
mark.

2. Check timing gear belt tensioner (idler)

(1) Turn the tensioning wheel with hand to confirm it
can move freely.
(2) Make sure the sealing part is applied and coated
with lubricant uniformly.

Note:
When the timing gear and gear pulleys are
attached with water beads and oil stain, do not repair
the leaking position.
Aligning mark
Wipe every gear pulley with cloth and makre sure
no oil stain left before assembly.
Never disassemble timing gear belt idler unless it
is necessary.

3. Assemble timing gear belt

(1) As shown in the figure, align aligning marks for
gear pulley.
(2) Assemble timing gear belt in the order of drive
shaft gear belt, camshaft gear pulley and timing gear
belt idler.

Reference: Assemble timing gear belt, making the

Aligning marked
line
line on the back of timing gear belt align with the gap
of gear pulley.

(3) Fix the tensioner on the compressor and push

down the push rod.
Note:
① To prevent damage to the top of pull rod for
tensioner, please protect it with cloth.
② Compress it when the pull rod of tensioner
stays upward.

38
(4) Compress the thrust rod of tensioner slowly and
align the thrust rod and cylinder hole, then fasten
them with hex socket wrench (1.5mm for that
equally wide on both sides).
Note:
The load applied on draw bar shall be no more than
980N (100kgf) (in cold area, tensioner can be heated
to below 80 ℃ for the convenience of faster
compression at high pressure)
Reference: align draw bar and cylinder holes, then
align holes while compressing pressure plate
downward and apply hex socket wrench.
(5) Assemble tensioner with hex socket wrench.
Reference: T=13N.m
Note: when the tensioner is inclined, it can not work
well. Please screw down bolts uniformly.
(1) Take off hex socket wrench from the tensioner.
(2) Rotate crankshaft for 2 turns from forward
direction to confirm all aligning marks for gear pulley
are aligned.
4. Assemble the outer cover of timing gear belt
chamber
(1) Assemble the outer cover of sprocket wheel
chamber with 6 bolts
Reference: T=6 N.m
(2) Assemble phase sensor support
(3) Connect wiring harness.

39
 XI. Cylinder head assembly
Fuel injector
Bolt for pressure plate
of fuel injector Disassembly
Pressure 1. Remove the cylinder head cap
plate of fuel
injector (1) Loosen bolt and bolt gasket of pressure plate
for fuel injector, remove the pressure plate of fuel
injector for the 4 cylinders.
(2) Remove the fuel injector and record the
number of cylinder corresponding to the fuel
Oil seal for fuel
injector
injector.
(3) Loosen bolts for cylinder head cap the remove
the cap.
(4) Remove oil seal for fuel injector and pressure
plate bolts from the cap.
Oil seal for bolts of
pressure plate 2. Remove oil seal for pivot of pressure plate
from bolts for cylinder head with boss.
Oil seal at the supporting
poing of pressure plate

3. Remove the timing gear belt

(1) Remove the phase sensor
(2) Remove the outer cover of timing gear belt
pulley chamber
(3) Turn crankshaft from the upper compression
stop of cylinder 1.

4. Remove the timing gear belt

(1) Fix camshaft with adjustable wrench; loosen
the mounting bolts for camshaft timing gear pulley.
(2) Loosing the mounting bolts for camshaft
timing pulley till only 2~3 knots left out of camshaft
screw hole (do not take out the bolt completely in
case of pulley falling when being drawn out).
(3) Take out timing gear pulley with special tool
(tension toll) (never knock, the as taper faces
between pulley and camshaft fit and generate
huge engaging force, knocking will cause pulley
deform or break)
(4) Remove the gear pulley spline from camshaft.

40
 5. Remove the timing gear belt tensioner (idler)
Remove the timing gear belt tensioner bolt with hex
wrench

Bolt

6. Remove the inner cover of timing gear belt

chamber, fastening bolts and nuts, then the outer
cover of timing gear belt chamber.

7. Remove the camshaft

(1) Screw down bolts in the sequence shown in the
Inlet camshaft figure evenly, remove the camshaft bushing cap.
Note:
①Pry camshaft with tool, but do not apply too much
force.
②Do not damage the thrust surface of camshaft and
Exhaust cylinder head.
camshaft (1) Remove the camshaft oil seal
(2) Remove the intake and exhaust camshafts.

8. Remove the cylinder head

(1) Screw off cylinder head bolts in the order shown in
the figure, remove the cylinder head bolts and
washers.
(2) Check cylinder head bolt and measure the position
shown in the figure with vernier scale.

Reference value: Φ11.67mm~11.97mm

Limit value: Φ11.67mm
Reference: to measure at multiple positions, replace
the item with new products whenever it is found out of
the limit.
9. Remove the cylinder head gasket

41
 Assembly:

1. Assemble cylinder gasket

(1) Measure piston projection with micrometer and
piston projection with flat seat probe (away from the
upper surface of cylinder block)

Projection

Note:
① The measuring probe shall be perpendicular to
the upper surface of cylinder block.
②Select 1 piston to measure position both in front and
rear and measure two points for every cylinder (8points in
total) .

(2) Select proper gasket according to the maximum of

piston projection.
Central
position Note:
① The height of cylinder gasket can be identified
through the gap at the rear end.
②Select cylinder gasket based on piston projection.

Selection Max. piston projection δ
symbol (mm)
A （0.005≤δ≤0.055）
B （0.055≤δ≤0.105）
C （0.105≤δ≤0.155）
D （0.155≤δ≤0.205）
E （0.205≤δ≤0.255）
(3) Assemble selected cylinder gasket onto cylinder
block.
Note:
② Clear the lower surface of cylinder head and upper
surface of cylinder block.
③ Do not let any impurity penetrate into cylinder
gasket.

42
 2. Assemble cylinder head
Note:
② Before assembling cylinder gasket, make sure
the gap of crankshaft pulley is right at the
90°position in front of the stop.
②Screw down cylinder head bolts in plastic zone
method.
(1) Assemble washer to cylinder head bolts and
insert cylinder head.

(2) Pre-tighten bolts for cylinder head for several

times in the order shown in the figure and screw
down them at specified torque.
Reference value: T=85N.m
(3) Make marks at the head of cylinder head bolts
and in the front of engine.

First 90o Secon 90o

(4) Tighten cylinder head bolts for 90°.
Note: Screw down bolts for cylinder head in proper
order.
(5) Tighten bolts cylinder head for 90°again.
(6) Make sure all marks for cylinder head bolts are at
the rear of engine.
Front of engine

Painting mark

Pulley keyslot 3. Assemble camshaft

Note: given small thrust clearance of camshaft (axial
clearance), assemble camshaft horizontally in case
of damage to thrust surface, scratch or spur.
(1) Check to see if the crankshaft stays at 90°in front
the upper stop.
(2) Put the keyway up, assemble inlet camshaft onto
cylinder head.
Note: apply engine oil on the cam of camshaft, thrust
surface, gears and journals of cylinder head.

43
 (3) Engage the inlet and exhaust camshaft gears and
assemble exhaust camshaft
Note: apply engine oil onto the cam of camshaft,
thrust surface, gear and journal of cylinder head.
Aligning
marked line

(4) Apply sealing glue at the position shown in the

Place to apply sealing
glue figure, and assemble to the cylinder head.

(5) As shown in the figure, align camshaft bushing

head and assemble it onto cylinder head.
(6) Screw down camshaft bushing head in the order
shown in the figure.
Reference value: T=19N.m

Top dead center for (7) Check and adjust valve lash
Exhaust
compression of cylinder 1# a) Measure valve lash at the position shown in the
figure (cold state)
Reference: inlet: 0.20~0.30mm
Exhaust: 0.35~0.45mm
Note: measuring valve lash shall be performed under
cold state.
b) Turn camshaft, measure valve lash for other
cylinders and make good record.
Inlet
c) Adjust the valve lash
①Remove the camshaft and valve lifter.
②Measure the height of removed valve liter with
micrometer.
③ Work out valve lash and height of valve liter
consistent with reference value

Reference value: IN: A=B+(C-0.25mm)

EX: A=B+(C-0.40mm)

44
A Valve lifter to select
B Height of valve lifter newly removed
C Measured valve clearance
④ Select valve lifter
④ Assemble selected valve lifter
⑥Assemble camshaft in the center and check valve
lash, if not within the range of reference
requirement, repeat procedures above to make
adjustment till it meets the standard.

4. Assemble camshaft oil seal

(1) Apply little MP lubricating oil at the lip of oil seal.
Note: take care not to leave any impurity on the lip.
(3) Knock in oil seal with special tool.
Reference value: 0.5mm~-1.5mm (away from the
end face of cylinder head)
Note: oil seal can not be assembled to be inclined.

5. Assemble the inner cover of timing gear belt

chamber
(1) Apply sealing glue at the position shown in the
figure.
Note:
①Clean and degrease the mounting surface
②Do not assemble it within 3 minutes after coating
of sealing glue.
③ Do not start the engine within 2 hours after
assembly.
Place to apply sealing glue
(2) Assemble the inner cover of sprocket wheel
chamber with 4 bolts and nuts.
Reference value: T=10N.m

6. Assemble timing gear belt tensioner (idler)

Assemble timing belt idler with a socket hex wrench
Reference value: T=35N.ｍ
Make sure the
tentionser can
move around
the mounting
shaft flexibly
after being
assembled.

7. Assemble camshaft timing gear pulley

To assemble (1) Assemble the spline of gear pulley onto
gasket, make
sure its camshaft;
chamfer is (2) Assemble camshaft timing gear pulley;
against the
tensioner. (3) Fix camshaft with adjustable wrench and
assemble the mounting bolts for camshaft timing
gear pulley. (Before screwing down bolts, make sure
to check the pulley to ensure the mounting surface
is 2mm above the end face of camshaft)
Reference value: T=90~98 N.ｍ

45
 Mounting strap 8. Assemble timing gear belt
for belt pulley Note:
Replace timing gear belt every 50,000 km in
service.
To assemble timing gear belt, make sure its
Mounting bolt for
belt pulley timing mark aligned to that on the belt pulley.

End face of
camshaft

9. Assemble the outer cover of timing gear belt

Upper chamber
thrust
groove of 10. Assemble cylinder head cover
camshaft (1) Assemble oil seal at pressure plate pivot onto
cylinder head bolt.
(2) Assemble oil seals for fuel injector and
pressure plate bolts.
(3) Apply sealing glue at the position shown in
the figure
Note:
①Clean and degrease the mounting surface
② Assemble within 3 minutes after coating
sealing glue and screw down bolts within 15
Timing mark minutes.
Place to apply ③Do not start engine within 2 hours after the
sealing glue assembly.
(4) Assemble cylinder head cap with 10 bolts and
2 nuts.
Reference value: T=9.0Nm

11. Assemble fuel injector

Check fuel injector to see if the copper backing
for sealing is intact and insert numbered fuel
injector into corresponding cylinder.
12. Assemble fuel injector pressure plate
13. Assemble the bolting pad for pressure plate
to its bolt, then mount and screw down the bolt
Bolting pad for
pressure plate
for fuel injector pressure plate.
Reference value: T=30±3Nm

46
X. Inlet and exhaust system
1. Valve related parts
 DOHC4 valve structure used, intake camshaft Pivot Exhaust
driving exhaust camshaft through gears. Driven drive camshaft
 The camshaft is made of cast alloy, with cam gear gear
nose compacted in terms of thickness and Valve lifter
(without gasket)
thus camshaft diameter reduced, then engine Valve
weight lowered. Inlet spring
camshaft
 Valve is made of heat resistant steel and the Camshaft nose
4 valves are oppositely aligned. In addition, Valve
by reducing the diameter of valve rod and Camshaft
timing pulley
weight of valve, inertia is reduced and thus
the objective of high speed revolution at low fuel consumption has been achieved.
 The valve lifter is provided without gasket and thus it reduces the number of parts and weight
of engine.

2. Ventilator for crankshaft casing

Blow-by
 Guide blow-by gas containing high content of gas
hydrocarbon into the intake system for
after-combustion to improve emission
performance. Cylinder head cover section
(blow-by gas passage)
 The blow-by gas path is designed in circular
shape, with ventilation pipe extending out of the
cylinder head cap, the content of engine oil in
blow-by gas and consumption engine oil are
reduced and the objective of lower emission
has been achieved.
 The blow-by gas is recovered and delivered to
the inlet side of turbocharger through ventilation
pipe on top of cylinder head from crankshaft
casing.

Air flow concept map

3. Turbocharger
 Exhaust gas decompression turbocharger
Compressor housing
is used. When the supercharge pressure
is above the preset value, the actuator on
exhaust reducing valve starts moving and
working, relieve tail gas pressure through Turbine
bypass path, reducing the speed of casing
turbocharger to control the increase of
supercharge pressure. The max.
supercharge pressure depends on the
elasticity of exhaust reducing valve.
 By reducing the weight of rotor and
improving intake impeller and blade shape,
it improves booster response and
Exhaust
supercharge capacity, and also ensures gas relief
the reliability of engine completely. valve
 Air cooling method is used to cool down Actuator Exhaust
decompression
gas

compressor housing, lowering inlet turbocharger

temperature with intercooler.

47
4. EGR valve
 Use electronically control EGR system for
lower emission.
Vacuum
 Assemble EGR valve on the inlet path Spring center
fixture
cooling EGR valve with air and achieving
large volume EGR with large capacity
Inlet path
multi-pipe EGR cooler.
 EGR path is set within the cylinder head to
boost circulation of tail gas at the inlet side,
which improves cooling effect of EGR air and
compact the engine.
 Spring center fixture is used, which reduces EGR gas
valve
hysteresis of EGR valve at the opening side EGR gas
and upon shutdown and thus improves the
alignment accuracy for EGR volume.

48
EGR cooler (or EGR
exhaust pipe) Inlet manifold Disassembly:
EGR valve

Vacuum
1. Remove the inlet support
regulator

Throttle body
Inlet support

2. Remove EGR vacuum regulator and its support.

Vacuum
regulator Vacuum regulator
support

3. Screw off the 2 bolts and 2 nuts, remove EGR

cooler or EGR exhaust pipe (some without EGR
cooler)

4. Remove the EGR valve and 2 washers from inlet

manifold

Washer

49
 5. Loosen 4 bolts and 2 nuts and remove the inlet
manifold and inlet manifold liner
6. Screw off 4 bolts and remove the heat shield for
Heat
shield for exhaust manifold.
exhaust
manifold 7. Remove the fuel inlet and return pipe for
turbocharger
(1) Take of the two hollow bolts for oil inlet pipe and
remove the inlet pipe for supercharger.
(2) Remove the two nuts connecting oil return pipe and
supercharger and the 2 bolt connecting cylinder block,
Exhaust
manifold remove oil return pipe for supercharger.
Turbocharger
8. Screw off the 3 bolts, remove the support for
Turbocharger
through-tubing
supercharger.

Turbocharger
9. Screw off the 3 nuts connecting the exhaust manifold,
support
Fuel return pipe
remove the turbocharger
for turbocharger
10. Screw off the 8 nuts and remove exhaust pipe and
pipe liner.

Assembly:

1. Assemble inlet manifold washer

Note: clean the mounting surface of cylinder head and
inlet manifold

2. Assemble inlet manifold, screw down 4 bolts & 2 nuts

3. Assemble vacuum regulator and its support

Vacuum
regulator Vacuum
support regulator

50
 4. Assemble EGR valve and throttle body
(1) Fix EGR temporarily and assemble the 2 washers
(as shown in the figure)
(2) Assemble EGR valve and throttle body to inlet
Washer
manifold with 3 bolts.

5. Assemble EGR cooler (EGR exhaust pipe)

(1) Assemble the end at cylinder head, mount the
EGR cooler (or EGR Inlet
exhaust pipe) manifold
washer and put on but not screw down 2 nuts.
EGR valve (2) Fit on the washer and assemble the EGR end with
Vacuum
2 bolts.
regulator (3) Screw down nuts and bolts on both ends.

Throttle body
Inlet support
6. Assemble the exhaust pipe washer and exhaust
manifold;
7. Fit on the sealing gasket at the outlet of exhaust
Inlet manifold
manifold, fix turbocharger below the exhaust manifold.
Turbocharger 8. Assemble fuel feed and return pipe for
supercharger.
Turbocharger
through-tubing (1) Screw down the 2 hollow bolts for oil inlet pipe of
supercharger and cylinder and supercharger,
Turbocharger assemble oil inlet pipe for supercharger.
Fuel return pipe for
support turbocharger
(2) Assemble return pipe and gasket for supercharger
and cylinder block, assemble oil return pipe for
supercharger.

51
 9. Assemble supercharger support
Cylinder
block
 The cylinder block is made of high rigidity cast
alloy iron and provided without cylinder sleeve.

 Oil pan is made of antirust steel plate, with

engine oil collector designed at the rear of engine
instead, it has improved the carrying capacity of
Oil pan
vehicle; meanwhile, the suction inlet of engine oil filter
insulator has been changed to another position to prevent air
Engine oil penetration due to variance of engine oil level in the
strainer
process of climbing slope or descending and turning.
 Liners of excellent sealing performance are
provided between the edge of oil pan and cylinder
block.
 Insulator is provided between oil pan and
transmission for shock absorption and lower standing
wave noise.

Disassembly

Remove gear train in following procedures:

Nut
 1. Remove the front gear and timing gear belt
system
 2. Remove the water pump, screw off bolts
and nuts, remove water pump and washer
 3. Remove the belt pulley chamber cap

 . Assemble locking bolt (M6) onto the idler

and press out the bolt.

52
  5. Remove the fuel pump gear and fuel pump
Hold
(Fuel supply pump) assembly
 . Remove the crankshaft timing gear
(1) Assemble belt pulley bolts on the crankshaft
temporarily.
(2) Remove the crankshaft timing gear with tool.
(3) Remove the belt pulley bolts from crankshaft;

Drive

 7. Remove the idler thrust plate

 8. Remove the idler pair
Note: make sure there’s no displacement between
master and counter idler gear (pressed tightly with M6
bolts)

 . Remove the idler shaft

 10. Remove oil seal for belt pulley chamber,
know out oil seal with capsuled screwdriver and
hammer

Protective
tape

 . Remove the oil pan

(1) Remove the bolt and nut
Nut
(2) Remove the oil pan with pry

53
 Note:
①Do not make oil pan deform
②Do not tilt oil pan when there’s oil left inside.

 12. Remove the engine oil strainer

Remove bolts and nuts, remove the engine oil filter and
engine oil filter seat

Bolt

Nut

 13. Remove the timing gear box

(1) Screw off bolts and tube connector bolts, remove
the timing gear box
Tube (2) Pry the position shown in the figure with screwdriver
connector bolt and remove the timing gear box
Note: Never let the engine oil pump rotor fall within
timing gear box.

Washer
Engine oil (3) Remove the engine oil pump rotor and washer
pump rotor

54
 (4) Remove the stud bolt

(5) Remove the 2 O-RINGs from cylinder block

O-ring

Assembly
 1. Assemble timing gearbox
(1) Assemble 2 new O-RINGs onto timing gearbox.
(2) Assemble stud bolt at the position shown in the
figure (when replacing the stud bolt)
Reference value: T=0.8N.m (82kfg.cm)

(3) Clean and degrease

Washer ① Clean and degrease the mounting surface
② Clean and degrease bolt and bolt holes
(4) Assemble engine oil pump rotor onto timing gear;
(5) Assemble new engine oil pump washer onto timing
gear box
(6) Apply sealing glue at the position shown in the figure
Engine oil pump (Φ4mm)
rotor

55
 (7) Assemble timing gearbox with 8 bolts and tube
connector bolts
Reference value:
T=13 N.m (133kfg.cm)(bolt)
T=16 N.m(163kfg.cm) (tube connector bolt)

(8) Take off plug screw and inject 50cc engine oil

Tube connector
bolt

 semble engine oil strainer and replace the

washer with a new one, assemble engine oil filter
with bolts and nuts.
Reference value: T=8.0N.m (82kfg.cm)

Bolt

Nut


(1) Clean and degrease the mounting surface
①Clean and degrease the mounting surface;
②Clean and degrease bolts and bolt holes.
(2) Apply 4 mm sealing glue at the position shown in
the figure and assemble oil pan.
(3) Screw down bolts and nuts
Reference value: T=16 N.m (163kfg.cm)

56
 4. Assemble fuel pump gear
(1) Assemble fuel pump (Fuel supply pump)
assembly
Reference value: T=30 N.m (305kfg.cm)

(2) Assemble fuel pump gear

(3) Replace and mount the new O-RING and nuts
(4) Screw down nuts with tool
Reference value: T=70 N.m (714kfg.cm)

 5. Assemble crankshaft timing gear as shown in

the figure, align crankshaft timing gear and
Aligning mark engine oil pump gear, and assemble crankshaft
timing gear with tool and hammer.

 6. Assemble idler shaft

(1) Apply engine oil on idler shaft
(2) Assemble idler shaft

57
 Aligning mark  7. Assemble idler pair
Align fuel pump gear and crankshaft timing gear and
assemble idler pair with tool.

Aligning mark

 Operating principle of idler gear pair

Drive gear for
Drive gear for
fuel feed pump
 Structure: zero clearance gear drive
engine oil The structure is made up of master gear
pump
Drive gear
and pinion, with a torsion spring between them which
for vacuum is fixed on the pin of gears on both ends to facilitate
pump the master gear and pinion to stagger and form an
angle like scissors between the tooth surfaces.
Feature:
When the temperature decreases, there’s
huge gap between the master gear and pinion of
Crankshaft double overhead camshafts. At this moment, the
timing gear Idle gear tooth surface between master gear and pinion
Gear pair stagger and form a small angle under the action of
Crankshaft
timing gear
elasticity of spring for zero clearance gears to fill the
clearance between driven gears, or vice versa.
 Advantage: lower engine noise.
Idle gear

Construction of
scissor gear

 8. Assemble idler thrust plate

(1) Fix the mounting hold with locking bolt for
idler thrust plate
Reference: put the thrust plate against the rear on
the cross recess side.

(2) Assemble idler thrust plate with bolts

Reference value: T=70 N.m (765g.cm)

 . Assemble oil seal

58
 Assemble timing gearbox
(1) Remove the locking bolt from idler
(2) Assemble O-ring at the position shown in the
figure.
(3) Clean and degrease
①Clean and degrease the mounting surface
②Clean and degrease bolts and bolt holes.

(4) Apply sealing right at the position shown in the

figure (Φ4mm), then assemble timing gearbox

(5) Screw down bolts and nuts

Reference value: T=13 N.m (133g.cm)

 12. Assemble water pump assembly

(1) Assemble new water pump washer onto
cylinder block.
(2) Assemble water pump assembly with bolts
and nuts
Reference value: T=13 N.m (133g.cm)
 13. Assemble inner cover of belt pullet and
other parts.

59
 XI. Cylinder block assembly

Disassembly

 1.Check connecting rod

Key point: Check axial clearance
Testing method: measure axial clearance with micrometer
Reference value: 0.10~0.30mm
Limit value: 0.40mm
Reference: Replace connecting rod and crankshaft
whenever out of limit;

 2.Check connecting rod bushing

Key point: Check oil film clearance
Testing procedures:
(1) Remove bolts for connecting rod with socket wrench
(2) While moving connecting rod cap back and forth with
the 2 main bearing bolts, remove the connecting rod cap
and connecting rod bushing.

(3) Clean and clear the inner and outer surface of

Testing sheet
connecting rod bushing and crank pin.
Note: check to confirm if there’s any wear and scratch.
(4) Set the testing sheet along the turning direction of
crankshaft and assemble connecting rod cap.

(5) Apply little engine oil on threads and at the root of

connecting rod bolt.
(6) Tighten connecting rod bolts with socket wrench
Reference value: T=35 N.m (355g.cm)

Pairing mark

60
 (7) Make color marks in the front of bolts for connecting rod
Turn 90o Color mark and engine.
(8) Tighten bolts for 90°according to color marks.
(9) Make sure all color marks orientate at the same
direction.
(10) Remove the connecting rod cap and measure the
Front of engine
widest part of testing sheet.

Reference value: 0.036~0.063mm

Limit value: 0.1mm
Note: Remove the testing sheet right after the check.
Reference: Replace the bushing for connecting rod
whenever out of limit.

Connecting rod and selection method:

Selection of bushing (symbol B) = connecting rod
cap (symbol A) +crankshaft (symbol B)
Grouping
e.g.: when connecting rod cap is 1, then the
symbol B bushing will be (1=1+0)
Group for selection
Connecting rod cap 1 2 3
(symbol A)
Crankshaft (symbol 0 1 2
B)

Grouping symbol A

 3. Remove the connecting rod

① Remove the 2 bolts for connecting rod with
socket wrench
Reference: confirm the pairing mark on the connecting
rod and connecting rod cap.
② When moving connecting rod cap back and
forth, assemble connecting rod cap and connecting rod
bushing with the 2 bolts.

61
 ③Remove the connecting rod with piston from the cylinder.
Note: pair connecting rods.
④Remove the connecting rod bushing from connecting rod

Pairing
mark

4. Remove the piston ring

①. Remove top and lower piston ring with special tool.
②Remove the oil ring with hand.

5. Check piston and piston pin

①. Remove the locking ring for piston pin hole with thin blade
straight screwdriver.
②. Heat the piston carrying connecting rod with piston heater to
about 80℃.
③. Remove the piston pin and piston from the piston carrying
connecting rod

Reference: the disassembled parts must be placed separately

in line with assembled position.

62
 6. Check crankshaft
Key point: Check axial clearance
Testing tool: micrometer
Reference value: 0.040~0.240mm

Limit value: 0.30mm

Reference: Replace thrust washer for crankshaft or the
crankshaft whenever out of limit.

7. Remove the crankshaft

①. Screw off 10 bolts for the main bearing cap in the
order shown in the figure for 2～3 times and remove
them.
②. Remove the main bearing cap, main shaft bushing
and crankshaft thrust washer, then remove the
crankshaft.

Reference: the disassembled parts must be placed

separately in line with assembled position.

8. Remove the Injection nozzle

①Remove the engine oil check valve
②Remove the Injection nozzle

9. Remove the plug screw

①Remove bolts
②Remove plug screws

10. Remove the connection of hose for wheel type water

pump
O-ring 11. Remove the stud bolt
12. Remove the cylinder head pin bush 13. Remove the
locating pin for timing gear cap.
14. Remove the locating pin for engine rear oil seal base
15. Remove the locating pin for rear cover
16. Remove the plug screw

63
 17. Check cylinder block
(1) Check the deformation of cylinder block
Testing tool: ruler and feeler
Testing method: as shown in the left figure, measure the
deformation on the top surface of cylinder with ruler and
feeler.
Limit value: 0.10mm

Packet marking of
cylinder diameter (2) Check the diameter of cylinder bore
Testing tool: cylinder internal dial gauge
Reference value: 92.00~92.03mm
Limit value: 92.23mm

Reference:
Whenever out of the limit value, replace cylinder block or
bore; the grouping number for internal diameter of cylinder
Front Crankshaft axial
is marked on the top surface of cylinder block.
direction B

Symbol of inner diameter Inner diameter of

of cylinder for selection cylinder (mm)
1 92.00~92.01
2 92.01~92.02
3 92.02~92.03

64
 18. Check the piston with piston pin
Key point:
(1)Check the outer diameter of piston
Testing tool: micrometer
Testing position: 63.63mm away from the top
surface of piston
Reference value: 91.92~91.95mm
Limit value: 91.89mm
Note: to replace piston, replace piston ring at the
same time.
Reference: there’s symbol of outer diameter
marked on the top surface of piston.
Selection symbol (2) Check piston clearance
Inner diameter of ①. Testing method:
for outer diameter
piston (mm) Calculate piston clearance based on the minimum
of piston
1 91.92~91.93 inner diameter of cylinder and outer diameter of
2 91.93~91.94 piston.
3 91.94~91.95 Reference value: 0.07~0.09mm
Limit value: 0.14mm
Note: the value along the direction of cylinder
thrust is used as the minimum inner diameter of
0/S type Outer Inner cylinder.
diameter of diameter
piston (mm) of cylinder Reference: whenever out of limit value, replace
(mm) cylinder block or bore the cylinder and use 0/S
0/S 92.42~92.45 92.50~92.53 piston.
(0.50) Fine boring size = (0/S piston dimension) +
0/S 92.67~92.70 92.75~92.78 (piston clearance) - (grinding capacity 0.02mm)
(0.75)
0/S 92.92~92.95 93.00~93.03
② Calculate ovality and taper
(1.00)
After boring cylinder block, measure the inner
diameter of cylinder with internal dial gauge and
work out ovality and taper.
Limit value:
Ovality, taper 0.02mm
Reference: ovality………A-B or a-b
Taper ………A-B or a-b
Check the clearance of pistons again.

(3) Check piston pin

①. Measure the outer diameter of piston pin
Testing tool: measuring the outer diameter of
piston pin with micrometer
Reference value: 34.000~34.008mm
Note: since there’s no mark on piston pin, take
care not to mix it with other piston pins.
Reference: there’s symbol of diameter of piston
pin hole on the top surface of piston.

65
 ②. Heat piston to about 80℃ with piston heater;
Note: according to the packet marking for the diameter
of piston pin hole, choose piston pin of the same size.

Packet
marking for
piston pin
hole

③. Apply little engine oil on piston pin, then insert the

piston and confirm it has been put well in place with
thumb.
Note: Do not change the pair of piston and piston pin at
will.

19. Check piston ring

(1) Check the slot clearance of piston ring, e.g. lateral
clearance

Testing method:
①. Assemble the piston and make sides of piston and
piston ring under stay in the same plane before
Low piston ring, oil measurement.
ring
②. Measure clearance around piston ring and piston
ring slot with feeler gauge.

Reference value:
Top piston Lower piston
Oil ring
Top piston ring ring ring
Lateral
0.065~0.10
clearanc 0.050~0.090 0.030~0.0
5
e 75

(2) Check the opening clearance for piston ring

Testing method:
①Press piston ring into the upper surface 120mm
away from the cylinder block with piston;
②Measure the opening clearance for piston ring with
feeler gauge.
Reference value:
Top piston Lower
Oil ring
ring piston ring
Opening 0.20~0.4
0.25~0.45 0.40~0.60
clearance 0
Maximum 0.85 1.07 0.77

66
 20. Check connecting rod
Key point: Check radial clearance at the small end of
connecting rod
(1) Measure the inner diameter of bushing at the small
end of connecting rod;
Reference value:
Symbol at the small end of connecting rod -1:
34.016~34.020mm
Symbol at the small end of connecting rod -2:
34.020~340.024mm

(2) Calculate radial clearance

Packet marking for Work out radial clearance based on the inner diameter
connecting rod at the of bushing for connecting rod at the small end and outer
small end
diameter of piston pin.
Reference value: 0.012~0.020mm
Limit value: 0.08mm
Reference: Replace the connecting rod bushing or
piston and piston pin whenever out of limit;

21. Check crankshaft radial clearance

(1) Align oil orifice and clamp position, assemble the
main shaft bushing with oil groove onto the cylinder
block;
Note: do not apply engine oil on the mounting surface
and in the back of crankshaft bushing.
Oil groove

(2) Place the crankshaft on the cylinder bloc k;

(3) Apply engine oil on the thrust plate for crankshaft
and turn oil groove outward before assembling the thrust
plate around journal NO.5;
Reference: push the crankshaft back and forth and
complete assembly until the mounting clearance for
crankshaft thrust plate has expanded.
Oil groove

(4) Align clamp position and assemble the main shaft

Stop bushing onto the main bearing cap.
Note: do not apply engine oil on the mounting surface
and in the back of main shaft bushing.

67
 (5) Apply engine oil on the thrust washer for crankshaft
and turn oil groove outward before assembling the thrust
washer around main bearing cap 5#;

(6) Set testing sheet along the direction of crankshaft

journal

Oil groove Note: do not turn crankshaft before the end of radial
clearance testing.

Testing sheet
(7) As shown in the figure, confirm the front mark and
designation of main shaft bushing cap before assembling
it onto the cylinder block;

(8) Apply little engine oil on the threads and at the root of
bolts for main bearing cap before tightening them for 2~3
times evenly in the order shown in the figure.
Reference value: T=50N*m(510kgf．Cm)

(9) Make color marks at the mounting head of bolts for

main shaft bushing and in the front of engine;
(10) Tighten bolts for 90°according to color marks.
(11) Make sure all color marks are at the same direction;

(12) Remove the main shaft bushing cap before testing

the widest position of testing sheet;
Reference value: gear 1, 2, 4 & 5 -0.042~0.069mm;
gear 3 - 0.048~0.075mm

Limit value: 0.10mm

Note: Remove the testing sheet after the check.
Reference: Replace main shaft bushing whenever out of
the limit;

Method to select main shaft bushing:

Packet marking A

Symbol for selection

Cylinder block (symbol A) 1 2 3
Bushing for selection
(symbol B) 1 2 3

Packet marking
B

68
 Assembly
1. Assemble injection nozzle
Align the locating pin at the injection nozzle side to the
locating pin hole on the cylinder block side before
assembling the injection nozzle
Reference value: T=26N*m(265kgf.Cm)

2. Assemble crankshaft
Stop ①Align oil orifice and clamp position, assemble the main
shaft bushing with oil groove onto cylinder block;
Note: do not apply engine oil on the mounting surface and
in the back of main shaft bushing.
②Place crankshaft on the cylinder block;
Oil groove

③Apply engine oil on the thrust washer for crankshaft

and turn oil groove outward before assembling the thrust
washer around journal NO.5;

Reference: Push crankshaft around till the clearance at

the point to assemble the thrust washer for crankshaft is
Oil groove
expanded before assembly.
Stop

④Align clamp position and assemble main shaft bushing

onto the main shaft bushing cap;
Note: do not apply engine oil on the mounting surface and
in the back of main shaft bushing.

⑤Apply engine oil on the thrust washer for crankshaft

Oil groove
and turn oil groove outward before assembling the thrust
washer around journal NO.5；

69
 ⑥ As shown in the figure, confirm the front mark and
designation of main shaft bushing cap before assembling it
onto the cylinder block;

⑦Apply little engine oil at the threads and root of main

bearing cap before screwing down evenly for 2~3 times in
the order shown in the figure.
Reference value: T=50N*m(510kgf.Cm)
Note: Tighten the mounting bolts for main shaft bushing in
Tightening for 90° Color mark plastic zone method..

⑧Make color mark at the head of connecting rod bolt and in

Front of engine the front of engine.
⑨Tighten bolts again for 90°according to color marks.
⑩ Make sure all color marks are at the same direction.

3. Assemble the piston with piston pin:

①Assemble the new locking ring for piston pin hole on one
side;
Note: Align end A or B of locking ring with the gap on piston
during assembly.

②Heat piston to about 80℃ with piston with piston heater;

Front mark

③Align marks in the front of piston and connecting rod;

④Press in piston pin with thumb and assemble connecting
Front mark rod into plug screw;
⑤Assemble the locking ring for new piston pin hole.

70
 4. Assemble piston ring
① Assemble the expansion ring onto piston;
② Assemble oil ring with special tool for piston ring;
③Turn expansion ring and oil ring as shown in the figure;
④Assemble the top and lower piston ring with special tool
for piston ring and take care to put the side with mark up;
⑤Set the top and lower piston ring, oil ring and support
Lower piston ring spring as shown in the figure.
Spiral spring port

Reference:
Piston ring No. Assembly mark
Top piston ring A1or1N
Lower piston ring A2orCYPR

Oil ring Top piston ring

5. Assemble connecting rod

①Align connecting rod bearing clamp and oil hole before
assembling it onto the connecting rod and connecting rod
cap;

Note: do not coat engine oil on the mounting surface and in

the back of connecting rod bearing side.

②Apply engine oil on the inner wall of cylinder, piston outer

ring and surface of connecting rod bearing;

③Confirm the location of piston ring opening;

④Confirm the front side of piston and connecting rod with

piston ring compressor before assembling the piston with
connecting rod.

Note: Do not damage cylinder inner wall and crank pin

during assembly.
⑤Coat a little engine oil at the threaded part and the root of
Color mark
Tightening for 90° connecting rod bolt, tighten connecting rod bolt with socket
spanner.

Reference value: T=35N*m(355kgf.Cm)

Front of engine Note: Tighten connecting rod bolt in plastic zone method.
⑥Make color marks at the head of connecting rod bolt and
in the front of engine.

⑦Tighten bolts for 90°according to color marks.

71
XII. Piston and crankshaft related parts

Piston

Connecting
rod
Main shaft bushing (fine strip
processed)

Oil pump drive gear

Crankshaft

Oil feed pump drive

Crankshaft timing gear
Idler gear
gear

Cylinder head cover is made of light weighted resin

Cylinder head
material with good shock absorption, which both
cover lightens the engine weight and guarantees cylinder
head cover strength. The reformation of cylinder head
cover shape lowers the engine noise. It improves the
ability of oil cut-off to set the baffle in cylinder head
Cylinder head cover, and to stretch out the vent pipe out of the top of
cover gasket cylinder head cover. Besides, baffle and vent pipe are
made of resin material, which lighten the engine
weight.

 Improved PCV tubing diameter, preventing

water freezing in tubing at low temperature.
 Cylinder head gasket is made of acrylic rubber
Cylinder material with high heat resistance and oil resistivity, so
head the reliability is for sure.
 Cylinder head is made of aluminum alloy, light
weighted and good thermal conductivity. Besides,
DOHC4 valve structure is applied, and the fuel injector
Cylinder head
gasket is set upright in the center of cylinder head, these
conditions improve engine performance and reliability,
and fulfill the target of low emission and
miniaturization.
 Cylinder head gasket is made of four layer
steel sheet of high sealability and heat resistance.

72
 1. Piston and piston ring

1. Piston weight packet marking 2. Piston skirt diameter
packet marking 3. Piston pin hole packet marking 4.
Printing direction marking 5. Ring gasket 6. Necking
quadrangular combustion chamber 7. Cooling oil path
Piston
 Material: cast by high heat resistant, light
weight yellow crystalline silicon and
aluminum alloy, tinned on surface to improve
friction performance.
 Structure: as shown in the left figure.
 Main features:
①The cooling oil path is designed on the inner
side of piston ring groove to cool down piston with
engine oil from injection nozzle, which addresses
the problem that the temperature on the top of
piston increases as the output power increases
and thus improves the wear resistance of piston.
② Made in proper shape conforming to necking
round ω-shaped combustion chamber applicable
for injection system, yielding better combustion
efficiency, high output, low fuel consumption and
low emission.

Piston ring
Piston structure
 The top piston ring is alloy steel wear
Face with mark up Top piston ring resistant ring to ensure the wear resistance of
piston.
Lower compression  The lower ring is to lower the tension of piston
ring ring to lower friction for lower fuel
consumption.
Oil ring  The oil ring uses coil spring, good at scraping
fuel.
2. Crankshaft
Cast crankshaft, with 5 journals, 8 heavy duty
crankshafts are provided, given consideration to
improving strength and lowering weight as well as
environmental factors, high quality alloy steel is
used. Besides, the weight balancing state when
crankshaft is running is delivered in addition to
lower vibration and noise. The structure of
crankshaft is shown in the schematic on the left.

3. Flywheel
The flywheel is a dial assembled at the rear of
crankshaft and three slots are provided out of the
friction surface, which are used to discharge wear
debris and heat generated in friction between
friction lining of clutch and flywheel, thus help
extending the service life of flywheel and clutch
friction plate. The flywheel is fitted with geared
ring at the outer edge used for starter to start
diesel engine.

Disassembly
①Fix crankshaft with tools
②Screw off 8 bolts to remove the flywheel
③Remove the rear bulkhead

73
 Disassembly
①Fix the crankshaft with tools
②Screw off 8 bolts before removing the flywheel
③Remove the rear bulkhead.

Hold Assemble flywheel

①Assemble rear bulkhead with bolts
Location pin Location pin hole
hole on on flywheel
Reference value: T=8.0N*m(82kgf．Cm)
crankshaft ②Fix crankshaft and apply sealing glue at the
2nd ～ 3rd section of locking bolt from the top.
Note:
a. Clean and degrease bolt and bolt hole.
b. Do not start the engine within 1 hour after the
assembly.
③The location pin hole on flywheel and pin hole or
pin on the mounting surface between crankshaft
and flywheel
④ Assemble flywheel with 8 bolts
Note: Screw down bolts across and diagonally
Reference value: T= 178±18N*m(1815kgf．Cm)

74
XIII. Lubrication system
Full pressure feed and full filtering lubrication is used.
The engine oil filter is fitted with highly efficient engine oil cooler in the front, which improves
the cooling performance.
Engine oil nozzle is used to improve engine’s durability and reliability by enhancing the
cooling and lubrication effect of engine oil on piston.
1. Construction of lubrication system
Lubrication method: pressure and splash combined lubrication.
Lubrication system: including oil pan, engine oil suction filter, engine oil pump, engine oil filter,
engine oil intercooler, main oil gallery of cylinder block, piston cooling fuel injector, engine oil
pressure sensor and engine oil pressure gauge, etc. (see lubrication system)
Pressure lubrication: parts subject to pressure lubrication are supercharger, main bearing,
connecting rod bearing and camshaft bearing, etc. (see the Oil Circuit of Lubrication System)
For example, the supercharger uses pressure lubrication for the purpose of ensuring
sufficient cooling and lubrication of rotor and bearing under normal operation conditions.
Circulating path of lubricating oil for supercharger: lubricating oil comes out of the main
gallery of diesel engine cylinder and enters the supercharger via the oil inlet, then flows back into
engine oil pan through the return pipe.
Splash lubrication: parts subject to splash lubrication are piston, piston ring, piston pin,
cylinder cover, camshaft, engine oil pump gear and so on.

Main oil orifice

Oil filter
Check
valve
Oil filter rod
element Crankshaft
jounal 2~5# Turboch
Crankshaft arger
jounal 1# Big end of
Oil cooler Injection Exhaust Exhaust
connecting
port camshaf camshaf
rod
t, t,
Fuel pump
Gear oil Idler gear Vacuum Valve Cam Valve Valve
injection shaft nozzle pump cooling lifter lifter
gear
nozzle duct
Oil filter

Oil pan

Lubricating system

Oil circuit of
lubricating system

75
 2. Engine oil filter
Engine oil cooler
Engine oil filter Composition:
The engine oil filter is consisting of engine oil filter
base assembly and spin filter element as well as
seals. The engine oil filter is fitted with safety valve
and relief valve inside that enables excess engine
Engine oil drip oil to return to the oil pan.
tray

Engine oil cooler Engine oil drain

cover Type: full flow filter.
LLC discharge pipe
pipe Specifications of engine oil filter

Type Full flow

Filter type Filter paper
Filtering capacity (cm3) 90
Outer diameter * height 76.3 * 84.4
(mm)

76

Engine oil pump
1．Gear chamber 2．Sealing surface of engine
oil pump 3．Inner rotor of engine oil pump
4．Outer rotor of engine oil pump 5．Pressure
regulator valve plug screw gasket 6．Plug
screw of pressure regulator valve
Oil pan
1．Oil pan 2．Oil drain bolt 3. Oil drain bolt
Locating end
Upper scale
point
Engine oil dipstick and pipe assembly
Advice: the engine oil filter shall be replaced
after the new vehicle has been subject to
breaking-in driving for 2000km; since then, engine
oil and engine oil filter shall be replaced every
8000km the vehicle drives.
Note: unclean engine oil will accelerate the tear
and wear of parts and may block the oil line. For
this reason, maintenance shall be done to engine
oil filter on a regular basis in accordance with
technical requirements. Note: there shall be no oil
leakage and part damage on the joint surface of
engine oil filter housing and base.
3.Engine oil pump
Gear pump (see the figure) is used as the
engine oil pump, fixed on the gear chamber and
driven by screw gear on camshaft.
Advantage:
①Small volume
The engine oil pump is very compact and made
in a 5-blade 6-cycloidal tooth construction and is
driven by the driving force from crankshaft timing
gear through engine oil pump drive gear. Besides,
engine oil pump drive gear and timing gear box are
integrated, which reduces the volume of engine for
downsizing.
②Low friction
It adopts inner pressure relief method to control
the oil inlet resistance and reduce friction.
Technical requirements on assembly:
①When the engine oil pump is assembled, it
shall moves flexibly and smoothly, free of blocking
and clamping.
②The joint surface shall be clear of any leakage.
③Cracking pressure of regulator 480±49kpa
4. Oil pan
Oil pan is used to seal crankshaft box, collect and
store lubricating oil.
The engine oil pan shall be checked for any
leakage through heating and running after the
assembly. In the event of any leakage, screw down
nuts and bolts accordingly; in case of leakage
remaining after tightening of bolts, remove it for
further check.
5. Engine oil dipstick
Engine oil dipstick is a tool to check the oil level of
lubrication system. The engine oil dipstick is
provided with upper (7.5L) and lower (5.5L) marks
for fuel check
77
XIV. Cooling system
 The cooling mode is water-cooling pressure forced circulation and water inlet is provided with
thermostat with bypass valve;
 The water jacket inside cylinder head is made of a two layer construction, which improves its
cooling capacity for the area below cylinder head;
 As to radiator, the newly developed descending current aluminum radiator is used.

Cylinder head
Outlet On

Off

Cylinder
Radiator

block

Engine oil
cooler
Water Off
pump
Thermostat

On

Inlet

From
Water pump: thermostat
To engine oil
 Water pump is made of lightweight cooler
aluminum alloy. Water
pump
 Water pump is in improved colute
casing and reduced volume;

Cylinder
block

78
 Specs of water pump

Rotor diameter (mm) 75

Bearing diameter (mm) 30
With Number of blade 6
air-condition Displacement (L/min) (5000 180
er
r/min)

Cooler
compressor

Tensioner pulley Disassembly

1. Turn on the discharge plug screw and let out coolant
Without 2. Remove the integrated belt.
air-conditioner

Tensioner pulley
3. Remove fixing bolts for engine oil dipstick
4. Remove the generator and generator support
Generator support
5. Remove the air-conditioning compressor and its support
6. Remove the 4 nuts, fan and fan belt pulley
7. Remove the phase sensor
8. Remove the outer cover of timing belt compartment and
timing belt
Engine oil
9. Remove the camshaft timing belt pulley
dipstick 10. Remove the timing belt idler
guide Generator
11. Remove the inner cover of timing belt compartment

12. Remove the water pump assembly

(1) Check if any coolant flows out of the discharge plug
screw
(2) Rotate the belt pulley to confirm no noise and blocking

79
 13. Remove water inlet

14. Remove thermostat

(1) Immerse the thermostat into water and heat it slowly;
(2) Check the valve for temperature upon opening;

Reference value: 80-84℃

Full close
size
(3) Check the lift volume of valve
Reference value: lift > 10mm
Full open temperature 95℃
>10mm
(4) Check if the cooling valve is fully closed when the
thermostat is at low temperature (< 40℃)
Reference: in the event that the valve is not fully closed,
replace the thermostat.

Assembly
1. Assemble the thermostat
Swing valve
(1) Assemble the washer for thermostat;
(2) As shown in the figure, assemble the thermostat,
putting the swing valve upwards;
Reference: 15°right above the swing valve

2. Assemble the inlet

Assemble the inlet with 3 bolts
Reference: T=13N*m

80
 3. Assemble the water pump
assembly
Replace the gasket with a new one, assemble water pump
assembly with 5 bolts and 2 nuts
Reference value: T=13N*m
4. Assemble the inner cover of timing belt compartment
5. Assemble the inner cover of timing belt compartment
6. Assemble camshaft timing belt pulley
7. Assemble timing belt, outer cover of timing belt
compartment and phase sensor.

Generator support
8. Assemble water pump belt pulley, silicon oil clutch
and fan;
9. Assemble air conditioning compressor support & air
conditioning compressor;
10. Assemble the generator support & generator;
11. Fix engine oil dipstick guide;
Engine oil 12. Assemble the integrated belt.
dipstick
guide Generator

81
XV. Function determining and troubleshooting

(i) . Basic control of electronic control system

1. Running status control: set fuel capacity and consider different parameters in doing so.
The following table shows the calculation of fuel injection volume in ECU:

The driver input signals

(accelerator pedal) Constant speed Constant speed from input
signals of other systems
(e.g. ABS, ASR, MSR)

Select the maximum External interference for Select the minimum

injection volume injection volume injection volume

Idle speed governor Activated reducer Injection volume limit

Starting fuel volume Balancing operation

On/Off Starting process governer

Measuring oil Pressure among common Rail pressure control

rails

Control of fuel injector Control of pressure control

valve

2. Calculation of fuel injection volume in ECU:

Switch position A: start, Switch position B: drive operation

Fuel injection volume for starting:

Fuel injection volume for starting covers the process from instant injection upon turning
overrun switch to ―On‖ position (position A in the figure above) to engine runs at the minimum
speed. During driving, the fuel injection volume for starting will not be affected.
In order to start the engine properly in any environment, the vehicle is subject to calibration
tests under plateau, high heat and extremely cold environments to make sure the vehicle will start
and run properly under hostile environment.

Start preheating:
To start the engine when water temperature is below 75℃, turn on the ignition switch and to
ensure smooth starting, the glow plug will some time to preheat. The lower water temperature is,
the longer it takes to preheat, when the glow plug light turns on for 0 ~ 12s. During and after
starting, in the event that water temperature is below 40℃, the glow plug will work for 0 to 180s
based on water temperature; likewise, the lower water temperature is, the longer preheating
82
 takes for the purpose of ensuring proper starting and stable running of engine.

Driving state
When the vehicle is driving (as shown in the figure above, starting switch at position B), fuel
injection volume can be calculated with the transmission diagram based on accelerator pedal unit
(accelerator pedal sensor) and engine speed so as to boost the best matching of driver’s input
and engine’s O/P (output) power.

Idle control
Under idle control, fuel consumption is generally determined on engine efficiency and idle
speed. Under heavy traffic, the fuel consumption of a vehicle is determined on its working
condition. It’s obvious that idling shall stay at the minimum speed. However, no matter under what
operating condition, it is necessary to set idle speed so that the revolution will decrease too much
during loading resulting in almost shutdown of engine.
For example, when to load the electrical system, when the air-conditioner is on, when
shifting automatically, or when the power steering unit is running.
In order to get the required idle speed, the idle speed controller will change fuel injection
volume till actual engine speed is the same with idle speed required. On this point, the governor
control characteristics for idle speed required is affected by the characteristic shift and engine
temperature (coolant temperature sensor). In addition to external loading moment, internal
friction moment shall also be considered and compensated through idle speed control. These
changes are small and stable during the service life of vehicle as well as closely linked to
temperature.

Balancing drive control

As mechanical tolerance and aging will lead to torque deviation among engine cylinders, it
will cause rough running when the engine is running, especially at idle speed. The speed
controller for smooth running can calculate the change of speed based on the combustion every
time and make comparison. Adjust the fuel injection volume of every cylinder based on the
speed difference measured to get them make the same contribution to engine torque; the speed
controller works only when at low speed.

Constraint on control of fuel injection volume

There are a lot of reasons for why it can not inject fuel at the quantity required by the driver
or to the maximum extent physically, including:
 Excessive pollutant emission
 Excessive smoke emission
 Mechanical overload due to excessive torque or engine speed
 Thermal overload due to excessive heat released from condensing agent, engine oil or
turbo-charging
The limit of fuel injection volume is generated from different inputs, e.g. real time air volume,
engine speed and coolant temperature.

Activated anti-vibration control

To step down or release accelerator pedal abruptly, it will cause sharp change of fuel
injection volume and engine torque and the unexpected load will results in violent jittering of
flexible engine base and transmission system, eventually fluctuation of engine speed (as shown
in the figure below)

To activate the shock absorber, change fuel injection volume at periodic speed fluctuation
frequency to reduce periodic speed fluctuation. When the speed increases, there’s low fuel
injection volume; while the speed decreases, there’s high injection quantity, which relieves the
fluctuation effectively.

Activated shock absorber

1. Sudden movement of accelerator pedal (driver enters signal)
83
2. Speed curves for shock absorber not activated
3. Speed curves for shock absorber activated
Engine speed

Time

Engine stop
The diesel engine runs on the basis of automatic ignition, which means that the diesel engine
can only stop operation by cut-off of fuel supply.
To use electronic control device, engine can stop by setting ―fuel injection volume = 0‖
through ECU. The system also sets a range of back-up fuel supply cutoff ways.

84
(ii) . Integrated fault diagnosis feature

Sensor monitoring
Verifying the system comprehensively can monitor the sensor for proper power supply and
truth of O/P signal (temperature at -40~150℃) ; if possible, set a spare signal for important ones,
i.e., whenever there’s a fault, we can switch to the spare signal for continuous use.

Monitoring module
In addition to the microprocessor, ECU contains a monitoring module. ECU and the
monitoring unit can monitor each other. In case of any defect, either of them can stop injection
independently.

Fault identification:
Fault identification can be used only within the monitoring range of sensor. When a fault
arises out of the preset timing, then the signal path will be considered as a failure. In this case,
the fault and surrounding conditions (e.g. coolant temperature, engine speed) will be saved in
ECU fault storage. In the event of huge volume of faults, rebuild ―reset‖ state. On this point, the
signal path must be confirmed to be completed within specified period.

Troubleshooting:
In case the output signal of sensor is out of the allowable range, it can be converted into set
value. The process is also applicable for the following input signal:
—battery voltage
—temperature of coolant, air and lubricating oil
—pressure of supercharged air
—atmospheric pressure and air inflow
In addition, when the accelerator pedal sensor or brake signals are not given correctly, the
backed-up value of accelerator pedal sensor may be used.

(iii) . System lamps

Fault light
Do not start the engine, but turn on the ignition switch, the system fault light will turn on
for 1s to proceed with self-checking before turning off; if the system has any fault, the fault
light will turn on again to alert the driver if there’s any fault. When the engine is running, in
the event that the fault light turns on, the driver shall stop to check the vehicle immediately.

OBD lamp
Do not start the engine, but turn on the ignition switch, then the OBD will stay on; start the
engine, then OBC lamp turns off. During running, in the event of any excessive emission due to
accident fire, OBD lamp will turn on alarming the driver to check the engine.
Fault diagnosis:
1. Major features of diagnosis tester
2. List of fault code
3. Mode of common fault

85
(iv) . Major functions of fault diagnosis tester:

Diagnostic function
Read fault code
Clear fault code
Read data flow
Action test
Read freeze frame
Read version
information
Injection nozzle
matching
Engine test
Page up Page down
Home Back Print Help

Start

Fault code Clear fault code

P0110 circumference period signal, signal
range check error
P2264 Water level sensor is not working
properly in the fuel (included)
P2135 accelerator pedal 2 is not matched
with APP1 and accelerator pedal 1 is not
matched with APP2
P0633 burglar alarm is clear of programming
error Fault code clearing completed
P0193 oil rail pressure and voltage are higher
than the maximum limit;
P0251 metering unit PMW—power level;
metering unit output enables loading
P0118 coolant temperature sensor voltage is
above the maximum limit;
Page up Page down
Home Back Print Help Ok Print
Start Start

86
 Select data flow Data flow
Engine speed Engine speed Orpm
Oil rail pressure Fuel rail pressure Ohpa
Control behavior of air Air condition
conditioning compressor Off
compressor
Current injection volume
Air flow deviation
EGR valve ratio
Status of ignition switch
Status of warm-up indicator
Page up Page down Ok Page
Home Back Print Help Page up Ok Figure—1
down
Start Home Back Print Help
Start

Action test
Air condition compressor signal test Data flow
EGR actuator test
Power-up duration correction test
Preheating lamp signal test
Preheating control test Action test
OBD lamp signal test completed
Metering unit actuator test
Page up Page down Ok
Home Back Print Help
Start Ok Print
Start
Fault code
P0110 circumference period signal, signal
range check error Data flow
P2264 Water level sensor is not working The ratio between current
0.00%
properly in the fuel (included) torque and max. torque
P2135 accelerator pedal 2 is not matched Linear environment
38.94℃
with APP1 and accelerator pedal 1 is not temperature
matched with APP2 Engine Speed 179rom
Original value of vehicle
0km/h
speed
Original value of air flow per
14.89kg/h
unit time
Rail pressure 3669600.00
Page up Page down hpa
Home Back Print Help Original value of ADC 1000.00hpa
Start atmospheric pressure
Page Page Recor
Figure—1
up down d
Home Back Print Help
Start

87
 Diesel engine matching system Diesel engine matching system
Please enter the first 7-digit IQA code
Matching completed

Start
Start

Action test
Compression test 1 Compression test
Correction output of fuel injection
volume of every cylinder
Speed of cylinder without FBC Cylinder 1: 0r/min
High voltage test of fuel rail Cylinder 2: 0r/min
Acceleration test Cylinder 3: 0r/min
Compression test 2 Cylinder 4: 0r/min

Page up Page down Ok

Ok Print
Home Back Print Help
Start
Start

88
(v) . Common faults
Fault symptoms
No movement of crankshaft
Improper idling at high speed
Excessive idling at high
speed
Under-idling at high speed
Unstable idling
Unstable idling
Check location
1.Battery
2.Starter
3.Starter relay
1.Replace fuel filter
2.Fuel injector
3.Engine control unit
4.Fuel feed pump assembly
5.Fuel pressure transmitter
6.Fuel quality
7.Diesel engine water temperature sensor
8.Fuel piping (blockage between oil tank and fuel feed pump)
1. A/C signal circuit
2. Fuel injector
3. Engine control computer
4. Fuel supply pump
5. fuel pressure transmitter
6. Water temperature of diesel engine
7. Accelerator pedal assembly
1. A/C signal circuit
2. Fuel injector
3. EGR system
4. compressor
5. valve lash
6. Fuel pipe
7. Engine control computer
8. Fuel supply pump
9. fuel pressure transmitter
10. Diesel engine throttle body
1. Fuel injector
2. Fuel pipe
3. EGR system
4. Compressor
5. Valve lash
6. Engine control computer
7. Fuel supply pump
8. Fuel pressure transmitter
9. Diesel engine throttle body
10. Fuel property
11. Air-conditioning system
12. Power steering system
13. Alternator
1. EGR system
2. Fuel injector
3. Replace fuel filter
4. Engine control computer
5. Fuel supply pump
6. Fuel pressure transmitter
7. Diesel engine throttle body
8. Fuel property
89

Black smoke appearing
Defected starting and stall of
engine
Under-power
Unstable idling, strong
vibration
Knock & noise
Fluctuation of engine speed
9. Compressor
10. turbocharger
1.Analyze the cause of black smoke
2.Analyze the cause of starting fault and stall of engine
3.Analyze the cause of under-power, under-voltage, fluctuation
of speed
4.Analyze the cause of unstable idling & strong vibration
5.Analyze the cause of knock and noise
6. Fuel injector
7. ECU power loop
8.Compressor
9.Fuel piping
10.Valve clearance
11.Engine control computer
12.Fuel feed pump
13.Fuel pressure transmitter
14.Diesel engine throttle body
15.Air conditioning system
16.Power steering system
90
 Part I Engine
Chapter 3 Engine peripherals setting
I. ECU bracket mounting
ECU bracket mounting method…………………..........................................002
II. Fuel system 4RB2
Fuel feeding system…………………………..........………… ……….….…..…003
Parts and components setting of fuel feeding system…...............................003
Removal and installation ……… ………………............………………………005
III. Fuel system DK4B
Fuel feeding system……………………………...........……………… ………..008
Parts and components setting of fuel feeding syste m........………….……008
Removal and installation……………………............……………… ……..…010
IV. Exhaus t s ys tem…………………………............……………… … ………...…013

1
I. ECU bracket mounting method
1. 4RB2 type
Model KS2 equipped with an ECU bracket,
which usually used in 4RB2 engine car. The
bracket is mounted on the floorboard under the
passenger seat, as see in picture:

Points 1. 2. 3 are fixed with M6 nut, tightening

torque 8~12N*m

2. DK4B type
Model KS2 equipped with an ECU bracket,
which usually used in DK4B engine car. The
bracket is mounted on the floorboard under the
passenger seat, as see in picture:

Points 1. 2. 3 are fixed with M6 nut, tightening

torque 8~12N* m

2
II. 4RB2 fuel feeding system
1. Overview
Fuel feeding system mainly consists of: fuel tank assembly, fuel pump, refueling and exhaust
piping, fuel tank suspender, charcoal canister bracket, fuel filter, fuel filter bracket, fuel delivery
piping and so on.
2. Parts and components setting of fuel feeding system
(1). Fuel tank, refueling and exhaust piping
Fuel tank, refueling and exhaust piping

(2). Fuel tank, piping of fuel inlet, fuel return and evaporation:
Fuel tank, piping of fuel inlet, fuel return and evaporation

3
(3). parts and components details:
Seq. Name Qua Remarks
No. ntity
1 Oil tank mounting bracket 1
2 Assembling bolt M8×30 8 fix the fuel tank to the brackets and fasten
the brackets to the car body
3 Fuel tank body 1
4 Strip elastic hoop 19 6 clamp the connection of rigid tube and hose
in refueling and exhaust piping
5 Exhaust hose on fuel tank filler neck 1
6 Rear Refueling and exhaust pipe 1
7 Assembling bolt M6×16 3 fix the front refueling pipe, front and rear
refueling and exhaust pipe to car body
8 1 exhaust II
connecting rubber tube for refueling and
9 Front filling and exhaust pipe 1
10 Connecting rubber tube for 1
refueling and exhaust I
11 Front refueling pipe 1
12 Turbine rod clampΦ32~50 4 clamp the connection of rigid tube and hose
in refueling pipe
13 Connecting rubber tube of front 1
refueling pipe
14 Assembling bolt M6×20 2 fix the rear refueling pipe to car body
15 Rear refueling pipe 1
16 Rear hose of refueling pipe 1
17 Front suspender of fuel tank 1
18 Rear suspender of fuel tank 1
19 Fuel pump seal ring 1
20 fuel pump with drift assembly 1
21 clamp ring of fuel pump mounting
22 Fuel inlet hose 1 connect fuel pump (20) and fuel inlet hose
(25)
23 Evaporation hose 1 connect fuel pump (20) and rigid tube of
evaporation (26)
24 Fuel return hose 1 connect fuel pump (20) and fuel return hose
(25)
25 Fuel return hose 1
26 Rigid tube of evaporation 1
27 Strip elastic hoop 12 2 to clamp the connection of rigid tube of
evaporation (26) and charcoal canister
assembly (29)
28 Evaporation hose 1 connect rigid tube of evaporation (26) and
charcoal canister assembly (29)

4
29 Charcoal canister assembly 1
30 Strip elastic hoop 14 1 to clamp the connection of charcoal canister
assembly (29) and evaporation hose (31)
31 Evaporation hose 1 connect charcoal canister assembly (29) and
charcoal canister solenoid valve
32 Fuel inlet hose 1 connect rigid tube of fuel inlet (34) and
engine fuel rail
33 Turbine rod clampΦ12~16 8 to clamp the connection of rigid tube of fuel
inlet (34, 38), fuel filter (36) and fuel inlet
hose (32, 35 and 37)
34 Rigid tube of fuel inlet 1 between fuel filter and engine
35 Fuel inlet hose 1 connect fuel filter (36) and rigid tube of fuel
inlet(34)
36 Fuel filter 1
37 Fuel inlet hose 1 connect fuel filter (36) and rigid tube of fuel
inlet(38)
38 Rigid tube of fuel inlet 1 between fuel pump and fuel filter
39 1

3. Removal and installation

Pre-operation before removal

Discharge the fuel to reduce the pressure in fuel piping and hose.
Removal steps:
1．Remove fuel tank and accessory assembly
(1)Disconnect fuel return hose 5 and rigid tube of fuel return 8;
(2)Disconnect evaporation hose 4 and rigid tube of evaporation 7;
(3)Disconnect fuel inlet hose 3 and rigid tube of fuel inlet 6;
(4)Loosen elastic hoop 10, disconnect hose 10 and vent of fuel tank 2;
(5)Loosen turbine rod clamp 12(mounting torque: 4~5N*m), disconnect hose 11 and refueling
pipe 13;
(6)Loosen bolt 1(6 points) from the car body (mounting torque: 30~40 N*m), remove fuel tank
and accessory assembly.

5
2．Remove fuel pump with drift assembly:

(1) Take out the pipe clamp of evaporation hose 3 and fuel return hose 4 from fuel tank.
(2) Disconnect fuel pump 5 with fuel inlet hose 2, evaporation hose 3 and fuel return hose 4;
(3) Loosen fuel pump mounting ring 6(mounting torque: 65~75 N*m), remove fuel pump with
drift assembly.

3. Remove fuel filter, charcoal tank and pipeline

(1) Disconnect fuel return hose 2 and fuel filter 13; loosen turbine rod clamp 16(mounting
torque:
3~4N*m), disconnect fuel inlet hose 14, 17 and fuel filter, loosen bolt 12(mounting torque:
10~14N*m), remove fuel filter;
(2) Loosen elastic hoop 5 and 9, disconnect evaporation hose 4, 6 and charcoal tank, remove
charcoal tank;
(3)Loosen all the elastic hoops and turbine rod clamps (mounting torque: 3~4N*m), remove all
the pipeline.

6
 4. Remove refueling and exhaust piping
Remove refueling and exhaust piping

(1) Loosen elastic hoop 4 and bolt 3(mounting torque: 10~14 N*m), remove rear refueling and
exhaust sub-piping assembly;
(2) Release filler cap 5, remove front refueling and exhaust piping assembly;
(3) Loosen bolt 8(mounting torque: 10~14 N*m), remove rear refueling piping.
Installation steps:
It’s in reverse to removal steps.
Notes:
(1)When install hose, the hose should be inserted into
a hard tube until it reach the boss of tube fittings.
Clamp (2)Special tools should be used in tightening fuel
pump mounting ring, so as not to destroy fuel tank,
with a torque 65N*m~75 N*m
(3)When mount fuel pump flange with drift assembly,
align the marks on fuel pump and on the tank.
(4)In filter mounting, the plane formed by fuel outlet
neck and fuel return neck should parallel to the
ground, the fuel outlet neck near the driver’s side.
(5)When removing push-in connector, pay attention to
first press the boss as showed and then disassemble
pipeline to avoid damage to push-in fitting.

Remark:
When replace pump flange with drift assembly, you can operate from the manhole below rear
seat cushion without having to remove the fuel tank.

7
III. DK4B fuel feeding system:
1. Overview
Fuel feeding system mainly consists of: fuel tank assembly, fuel pump flange with drift assembly,
refueling and exhaust piping, fuel tank suspender, oil-water separator, transport pipe and so on.
2. Parts and components setting of fuel feeding system
(1). Fuel tank, refueling and exhaust piping

(2). Fuel tank and piping of fuel inlet and return

8
 (3). Details of parts and components
Seq. Name Qua Remarks
No. ntity
1 Fuel tank mounting bracket 1
2 Assembling bolt M8×30 8 Fix the fuel tank to the brackets and fasten
the brackets to the car body
3 Fuel tank body 1
4 Strip elastic hoop 19 6 Clamp the connection of rigid tube and hose
in refueling and exhaust piping
5 Exhaust hose on fuel tank filler neck 1
6 Rear refueling and exhaust piping 1
7 Assembling bolt M6×16 3 Fix the front refueling pipe, front and rear
refueling and exhaust pipe to car body
8 Connecting rubber tube for 1
refueling and exhaust II
9 Front refueling and exhaust piping 1
10 Connecting rubber tube for 1
refueling and exhaust I
11 Front refueling pipe 1
12 Turbine rod clampΦ30~50 4 Clamp the connection between rigid tube
and hose of refueling pipe
13 Connecting rubber tube of front 1
refueling pipe
14 Assembling bolt M6×20 2 Fix rear refueling pipe to car body
15 Rear refueling pipe 1
16 Rear hose of refueling pipe 1
17 Fuel tank front suspender 1
18 Fuel tank rear suspender 1
19 Fuel pump seal ring 1
20 Fuel pump with drift assembly 1
21 Fuel inlet hose 1 Connect fuel pump flange (20) and fuel inlet
hose (25)
22 Fuel return hose 1 Connect fuel pump flange (20) and fuel
return hose (25)
23 Fuel pump mounting ring 1
24 Rigid tube of fuel return 1
25 Rigid tube of fuel return 1
26 Fuel inlet hose 1 Connect rigid tube of fuel inlet (25) and fuel
inlet tube (28)
27 Fuel inlet tube II 1 Connect oil-water separator outlet neck and
fuel inlet hose (31)
28 Fuel inlet tube I 1 Connect oil-water separator inlet neck and
fuel inlet hose (26)
29 Fuel-water separator 1
30 Assembling bolt M8×30 Fix oil-water separator to car body

9
31 Fuel inlet hose 1 Connect fuel inlet tube II (27) and fuel inlet
neck of engine high pressure fuel pump
32 Fuel return hose 1 Connect rigid tube of fuel return (24) and fuel
return neck of engine high pressure fuel
pump
33 Turbine rod clampΦ12~16 8 8 Clamp the connection among rigid tube (24,
25), fuel inlet tube (27, 28). Oil-water
separator (29) and fuel inlet hose (26, 31and
32)

3. Removal and installation

Pre-operation before removal

Discharge the fuel to reduce the pressure in fuel piping and hose.

Removal steps:
1．Remove fuel tank and accessory assembly
(1)Disconnect fuel return hose 4 and rigid tube of fuel return 6;
(2)Disconnect fuel inlet hose 3 and rigid tube of fuel inlet 5;
(3)Loosen elastic hoop 8, disconnect hose 7 and fuel tank 2 vent pipe;
(4)Loosen turbine rod clamp 10(mounting torque: 4~5N*m), disconnect hose 11 and refueling
pipe 9;
(5)Loosen bolt 1(6 points) to disconnect the car body (mounting torque: 30~40 N*m), remove
fuel tank and accessory assembly

10
2．Remove fuel pump flange with drift assembly:

(1)Take out the pipe clamp of fuel return hose 3 from fuel tank;
(2)Disconnect fuel inlet hose 2, fuel return hose 3 and fuel pump 4;
(3)Loosen fuel pump mounting ring 5(mounting torque: 65~75 N*m), remove fuel pump flange
with drift assembly.
3．Remove oil-water separator and fuel pipeline:

(1) Loosen turbine rod clamp 4(mounting torque: 3~4N*m), remove pipes(1, 2, 3, 5, 6, 9,
10)from fuel pipeline.
(2) Loosen bolt 8(mounting torque: 30~40N*m), remove oil-water separator.

11
4．Remove refueling and exhaust piping:

(1)Loosen elastic hoop 4 and bolt 3(mounting torque: 10~14N*m), remove rear refueling and
exhaust piping sub-assembly;
(2)Release filler cap 5, remove front refueling and exhaust sub-assembly;
(3)Loosen bolt 8(mounting torque: 10~14N*m), remove rear refueling pipe.

Installation steps:
It’s in reverse to removal steps.
5.Notes:
(1) When install hose, the hose should be
inserted into a hard tube until it reach the boss
Clamp
of tube fittings.
(2) Special tools should be used in tightening
fuel pump mounting ring, so as not to destroy
fuel tank, with a torque 65N*m~75 N*m
(3) When mount fuel pump flange with drift
assembly, align the marks on fuel pump and on
the tank.
(4) When removing push-in connector, pay
attention to first press the boss as showed and
then disassemble pipeline to avoid damage to
push-in fitting.

Remark:
When replace pump flange with drift assembly, you can operate from the manhole below rear
seat cushion without having to remove the fuel tank.

12
IV. Exhaust system
1. Overview:
Gasoline car exhaust system is mainly divided into the following sections: exhaust front pipe and
three-way catalyst assembly, exhaust middle pipe and silencer assembly, exhaust tail pipe
assembly and insulation panels of main components. It can minimize the vehicle pollutant
emissions and noise level to match a reasonable exhaust system to the car.

2. Exhaust system
Exhaust system structure:
Exhaust system structure

(1)Exhaust front pipe assembly (2) bellows (3) three-way catalyst (4) rear oxygen sensor
(5) Lifting lug (6) lifting hook (7) M10 locknut (8) M10×1.25 bolt (9) Asbesto seal gasket
(10) Exhaust middle pipe assembly (11) exhaust silencer (12) exhaust tail pipe assembly
(13) First thermal baffle (14) second thermal baffle (15) silencer thermal baffle (16) M8×16 flange
face bolt (17) M8×30 flange face bolt (18) M10 attachment bolt

13
 3. Removal steps:
Exhaust front pipe and three-way catalyst assembly
1．Remove M10 bolt (18)
2．Remove M10 locknut and bolt (7), (8)
3．Take down asbestos seal gasket (9), check whether it is damaged or not
4．Remove lifting lug (5)
5．Remove exhaust front pipe (1)
Exhaust middle pipe and silencer assembly
1．Remove M10 locknut and bolt (7), (8)
2．Remove lifting lug (5)
3．Take down asbestos seal gasket (9), check whether it is damaged or not
4．Remove exhaust middle pipe (11)
Exhaust tail pipe assembly
1．Remove (5) lifting lug
2．Remove exhaust tail pipe (12)
Remove thermal baffle
1．Remove bolts (16) (17)
2．Take down exhaust thermal baffles (13) (14) (15)

4. Installation steps
Firstly, install (13), (14), (15) to underbody panel through (16), (17) with a tightening torque
15N.m
Secondly, install (1), (11), (12) in turns to radiation and exhaust manifold through (18), (5), with a
bolt tightening torque 50 N.m, meantime manually install the rear oxygen sensor in place.
Finally, connect the exhaust pipe with bolt(8)and nut(7, with a tightening torque 50 N.m. Set up
asbestos gasket between(1)and(11),(11)and(12), then tighten rear oxygen sensor to specified
torque.
5. Notes
1．Catalytic converter is a key part of the exhaust system; you need to handle with care. In
installation, determine the mounting direction according to the arrows on the surface of
components, which point to the direction of air flow.
2．Use the appropriate torque wrench with forces evenly on both sides, according to the
technical requirements.
3．Bellows bent not more than 10 degrees during installation.
4．Avoid burns in the removal of exhaust system.

14
 Part Two Chassis
Chapter Two Clutch
Clutch control …………………………………………………………………….………..… 002
Clutch master cylinder ……………………………………………………………………… 010

1 / 13
 Clutch control
Components

Shifting hand ball

Eave assembly of manual transmission

Air conditioner control panel

Lower middle cover

Left lower protection board assembly of dashboard

Manual brake protection board assembly

Lower protection board assembly of dashboard

Washing solution tank and electrical pump assembly

Appointed button

Number of special tools

2 / 13
 Clutch pedal assembly

Clutch master cylinder push rod Washer

Clutch pedal spring fixing

frame

Torsion spring
Clutch pedal arm

assembly Clutch pedal lining Clutch pedal sleeve pipe

sleeve
No 1 buffer cushion of clutch pedal

Clutch pedal lining

sleeve

Clutch pedal arm

assembly

Pedal cover

Don’t use the part Location coating lubrication grease

Appointed button repeatedly

3 / 13
Remove

1. Disconnect negative of the battery

2. Disassemble the manual air conditioner assembly

3. Disassemble the lower protection board assembly of dashboard

4. Disassemble the manual brake protection board assembly

5. Disassemble the shifting hand ball

6. Disassemble the eave assembly of the manual transmission

7. Disassemble the left lower protection board assembly of dashboard

8. Disassemble the washing solution tank and the electrical pump assembly

9. Disassemble the air channel

4 / 13
10. Disassemble the master pump of the clutch

(a) Disassemble two bolts

11. Disassemble the sub-assemble of the clutch pedal

(a) Push upward and press the push rod of the clutch master

pump, disassemble it from right side of the vehicle.

(b) Disassemble two bolts and the reinforced support frame

5 / 13
 12. Disassemble the torsion spring

(a) Use the soft vice to fix the clutch pedal

(b) After the clutch pedal is completely pressed,

disassemble the torsion spring

13. Disassemble the assemble of the clutch pedal arm

(a) Make the assembly marking on the support frame of

the clutch pedal in advance

(b) After the pedal shaft, the nut and the washer are

disassembled, separate the pedal arm from the clutch

pedal support frame.

14. Disassemble the bushing of the clutch pedal axle

Lining

sleeve (a) Disassemble 2 lining sleeves and 1 bushing

Lining

sleeve

Bushing

6 / 13
 15. Disassemble No 1 buffer cushion of the clutch pedal

(a) Disassemble No 1 buffer cushion of the clutch pedal

16. Disassemble the cover of the foot pedal

(a) Disassemble the cover of the foot pedal from the clutch

pedal

17. Disassemble the spring fixing frame of the clutch pedal

Adjust

1. Inspect and adjust height of the clutch pedal

(a) Open the floor felt layer at bottom of the clutch pedal
Height
adjustment
of pedal (b) Inspect height of the pedal
Adjustment of 157．3~167.3mm
push rod
clearance and
freeclearance
(c) Loose the locking nut, rotate the locking bolt until height

of the pedal is correct

(d) Tighten the locking bolt again after adjustment is

Pedal height
complete

Required torque value is 26N*m

2. Inspect free clearance of the pedal and clearance of the

push rod

(a) Inspect whether free clearance of the pedal and

clearance of the push rod are correct

(1) Push down the clutch pedal until it starts feel resistance.

Free clearance of the pedal is 5.0~15.0mm

7 / 13
 (2) Use one finger to push the pedal slightly until resistance is
just felt.
Clearance of the push rod at upper end of the pedal
Clearance of push
rod 1．0~5.0mm
(b) Adjust free clearance of the pedal and clearance of
the push rod
Free clearance of pedal (1) Loose the locking nut, and rotate the push rod until free
clearance of the pedal and clearance of the push rod
are correct
(2) Required torque value for tighten the locking nut is 12N*m
25mm or greater (3) After free clearance of the pedal is adjusted, inspect height
Release point of
clutch of the pedal again
3. Inspect release point of the clutch
Distance to (a) Inspect the release point of the clutch
end point of Travel of pedal
travel (1) Pull up the pull rod of the manual brake and place the
stopping block of the wheel
(2) Start the engine and maintain operation at idle speed
(3) Don’t step the clutch pedal, slowly turn the holding shift
level to reverse gear until the gear in the transmission case is
contacted (there is noise)
Coat MP (4) Slowly step down the clutch pedal, measure distance from
lubrication grease
stop point of the gear noise (release point) and end point of
travel
Standard distance: 25mm or greater (from end point of the
pedal travel to the release point)
Whole travel of the pedal is 150mm
If distance isn’t in accordance with specification, carry out
following operation
Inspect height of the pedal
Inspect the clearance of the push rod and free clearance of
the pedal
Exhaust air in the pipeline of the clutch
Inspect the clutch cover and the clutch disc

Assembly
1. Assemble the spring fixing frame of the clutch pedal
(a) Firstly coat suitable lubrication grease on rotation position
at its inner side before assembly of the spring fixing frame
(b) Assemble the spring fixing frame of the clutch pedal
2. Assemble the foot pedal protection cover of the clutch
pedal
(a) Assemble the foot pedal protection cover on the clutch
pedal arm
3. Assemble No. 1 buffer cushion of the clutch pedal
8 / 13
 (a) Use the nipper pliers to assemble the buffer cushion on
the clutch pedal

Lining 4. Assemble the bushing of the clutch pedal axle

sleeve
(a) Coat suitable lubrication grease on the inner side, outer
side and the end surface of the bushing respectively.
Lining (b) Shown as figure, assemble 1 bushing and 2 lining sleeves.
sleeve

Bushing
Coat MP
lubrication grease
5. Assemble the assemble of the clutch pedal arm
Marking (a) Align to the marking position on the pedal arm and the
frame;
（b）Connect the pedal arm and the clutch pedal support
together by means of the pedal axle, the washer and the nut?
（required torque value: 34Nm， 340kgf*cm．25ft．lbf）.

6. Assemble the torsion spring

(a) Coat suitable lubrication grease on two ends of the spring
before assembly;
(b) Assemble the torsion spring

Coat MP
lubrication grease
7. Assemble the sub-assemble of the clutch pedal
(a) Take advantage of the fixing support hole position on the
body, align the fixing buckles on the assembly surface of the
clutch pedal, and assemble the clutch pedal assembly.
Note:
Ensure the fixing buckle (located at the assembly surface of
the clutch pedal) to be fixed on the round hole of the
positioning support frame on the body accurately and reliably.

(b) Use two bolts to assemble the reinforced support frame

Required torque value of bolt A is 24N*m
Required torque value of bolt B is 31N*m

9 / 13
 (c) Shown as figure, coat suitable lubrication grease on the pin
end of the clutch master cylinder push rod and the clutch pedal
respectively
(d) Assemble the clutch master cylinder push rod for right side of
the vehicle and press downward
Note:
Coat MP Inspect whether the clutch master cylinder push rod can rotate
lubrication grease
30°and more so as to confirm whether assembly of the push rod
and the pedal are assembled on position.

8. Assemble the clutch master pump assembly

(a) Use two nuts at basic point to assemble the clutch master
pump
Torque: 14N*m
9. Inspect and adjust height of the clutch pedal
10. Assemble the air channel
11. Assemble the washing solution tank and the electrical pump
assembly
12. Assemble the left lower protection board assembly of
dashboard
13. Assemble and handle the eave assembly of the transmission
14. Assemble the shifting hand ball
15. Assemble the manual brake protection board assembly
16. Assemble the left lower protection board assembly of
dashboard
17. Assemble the manual air conditioner assembly
18. Connect negative of the battery
19. Start again

Some systems are started only when the vehicle starts again
after the negative of the power supply is disconnected.

10 / 13
 Clutch master cylinder
Components

Clutch master cylinder

assembly

Clutch oil pipe

Hoop

Locking nut

Clutch master cylinder

shifting fork joint

Cleaning liquid tank and Appointed button

pump assembly
Coat MP
lubrication grease

Remove
1. Drain out brake liquid
Note:
If brake liquid is splashed on any painting surface, immediately clean.
2. Disassemble the cleaning liquid tank and the pump assembly
3. Disassemble the master cylinder assembly of the clutch
(a) Take out of the hoop and disconnect the clutch oil pipe
Information: Use a vessel to collect liquid.
(b) Use the special tools to separate the clutch hard pipe from the master cylinder of
the clutch.
Information: Use a vessel to collect liquid.

11 / 13
 (c) Push the shifting fork joint upward, and then separate it
from right side direction of the vehicle

(d) Disassemble two installation nuts and the clutch

master cylinder

4. Disassemble the shifting fork joint of the clutch master

cylinder
(a) Loose the locking nut and move the shifting fork joint
(b) Disassemble the locking nut.
Shifting fork joint Information:
Measure distance A on the drawing,
This measurement is taken as reference during assembly
of the shifting fork joint.

Locking nut
Assembly:
1. Assemble the shifting fork joint of the clutch
Shifting fork joint
master cylinder
Push rod (a) Assemble the locking nut on the push rod
(b) Assemble the shifting fork push rod and temporarily
tighten the locking nut.
Information:
Locking nut Ensure position of the locking nut is same as that before
disassembly.
Completely tighten the locking nut when the clutch pedal is
adjusted.

2. Assemble the master cylinder assembly of the clutch

(a) Assemble 2 fixing nuts on the master cylinder of the
clutch.
Torque: 20N*m

12 / 13
 (b) Coat MP lubrication grease on the sliding surface
between the shifting fork joint and the clutch pedal
(c) Assemble the shifting fork joint on the opening of
the pedal from right side of the vehicle, and then push
it downward.
Note:
In order to ensure firm conjunction between the
shifting fork joint and the pedal, please inspect the
Coat MP lubrication
grease rotating angle of the push rod which shall not be
greater than 30°.

(d) Use the special tools to connect the clutch hard

pipe and the clutch master cylinder.
Torque: 20N*m
(e) Use the hoop to connect the clutch oil pipe.
Note:
Fixed on the yellow marking.
Yellow marking

3 Assemble the cleaning liquid tank and the pump

assembly
4 Fill in brake liquid
5 Drain oil in the clutch pipeline
(a) Full the liquid storage tank of brake liquid,
exhaust the clutch system.
Torque: 11N*m
6 Inspect whether brake liquid is leaked
Information:
Inspect whether there is leakage in the clutch
system
7 Inspect position of brake liquid level in the liquid
storage tank
8 Inspect and adjust height of the clutch pedal

13 / 13
 Part Two Chassis
Chapter Six Steering column
Steering column assembly …………………………………………………………… 002

1/11
 Steering column assembly
Component

With airbag

Driver airbag module (vehicle type configured with

airbag)

Steering column upper cover

Steering wheel
proper body

Clock spring
assembly Steering
Steering column column
assembly upper cover
Combined switch
assembly

Combined switch cover

(upper)

Combined switch cover

(lower)

Dashboard left lower

protection board assembly
Lower protection
cover of column

Appointed button

2/11
 Ignition switch lighting ring/thief
proof coil

Ignition switch assembly Steering column upper

column and ignition
fixing clip assembly

Snap ring
Thief proof bolt

Ignition lock fixing

clamp

Column fixing clamp

Snap ring

Ignition lock
assembly

Spring snap ring

Steering column

Upper axle of
steering column

Lower axle of
steering column
Upper axle bearing of
steering column

Don’t use the parts

Appointed button repeatedly

3/11
 Remove
1 Disconnect the negative (-) pole cable of the
battery
2 Place the wheel on straight position of the vehicle
3 In case of the vehicle type equipped with the
safety airbag, wait for 90 seconds and then operate
after the power supply is disconnected, so as to avoid
accidental triggering the airbag.
Use the tools to remove the left and right two blank on
the protection cover below the steering wheel.
4 Use the internal hexagonal spanner to loose two
screws from the blank on left and right two basic
points.
5 Take out of the airbag module (with the airbag
configuration) or take out of the upper cover of the
steering wheel (without the airbag configuration) and
support on the hand, pull out of the harness
connected with the steering wheel proper body, place
the safety airbag module or the upper cover of the
steering wheel in safety location.
Marking
6 Use the tools to loose the nut fixed on the
steering wheel body and the steering column, make
the match marking at the shaft connection location of
the steering wheel and the steering column.
7 Use the special tools for drawing out of the
steering wheel; remove the steering wheel proper
Special tools body.
8 Remove the combined switch cover (lower)
(a) Adjust the regulation angle of the steering
column on the lowest position.

(b) Remove 2 crossing slot screws on the lower cover

of the steering column.

4/11
 (c) Newly added: remove 1 screw connected between
the combined cover (lower) and the column combined
switch support.

(d) Press down left side of the combined switch cover

(lower), separate the connected buckle A.
(e) Press down right side of the combined switch cover
(lower), separate the connected buckle B.
Note: If it is difficult to separate the buckle B, expand
the clearance from lower part at right side of the steering
column and separate the buckle.
Note: Twist the cover of the steering column through
pulling down the cover of the steering column.

9. Remove the lower protection board of the dashboard.

10. Remove the lower axle of the steering column
(a) Remove 3 bolts on the lower cover of the steering
column.

(b) Remove the locking bolt between the lower axle of

the steering column and the steering intermediate axle.
(c) Slide the lower axle of the steering column upward,
and make match mark between the lower axle and the
steering intermediate axle.

11. Remove the steering column assembly

(a) Remove 3 bolts on the lower cover of the steering
column.

5/11
Driving at left (b) Disconnect 3 bolts between the steering column and
the crossing beam of the dashboard.

12. Remove the horn contact disc.

13. Remove the combined switch cover (upper)
14. Disconnect the harness of the clock spring assembly
(with the safety airbag)

Disassembly
1. Remove the lower axle of the steering column
Marking
(a) Make match marking on the lower axle fork and the
upper axle.
(b) Remove 2 bolts between the lower axle and the
upper axle of the steering column.

2. Remove the locking body support on the column

(a) Use the centre punch to make the centre point in the
middle of the taper headers of 2 thief proof bolts.
(b) Use the drilling head to drill hole on the heads of 2
bolts.

6/11
 (c) Use the bolt extractor to remove to 2 bolts and
separate the locking body support from the steering column
3. Remove the upper axle of the steering column
(a) When the steering column is fixed on the vise, place
the aluminum shim between the column and the opening of
the vise so as to avoid damaging the column.
Note: Don’t clamp the vise excessively.

(b) Use the spring snap ring to remove the bearing snap
ring at external side of the upper axle of the steering column

(c) Use the brass rod and the hammer to remove the
upper axle of the steering column and the bearing
Note: Be careful to operate, protect the upper axle of
the steering column against falling down.

(d) Use the spring snap ring to remove the bearing snap
ring at internal side of the upper axle of the steering column
4. Remove the ignition lock core and the lighting ring
assembly
(a) Release two clamping feet on the lighting loops,
remove the lighting ring from the ignition lock body.
5. Remove the ignition switch lock core assembly
(a) Insert the key into the lock core, and turn to ACC shift
position.

(b) Use the screw driver to press down the fixing clamp
spring of the lock core, slightly swing and extract the locking
core assembly.

7/11
7. Remove the ignition switch assembly
(a) Release the fixing bolts of two ignition switches;
remove the ignition switch from the steering column
Note: if the ignition switch assembly is replaced,
please handle in professional maintenance station of
Kinglong, don’t remove the ignition switch assembly by
yourself, otherwise it will cause great hidden problem to
safety of the vehicle.

Inspection
1. Remove the column of the steering column assembly
(a) Check whether the bearing in the column can rotate
smoothly, and no obvious axial clearance and abnormal
noise exists.
Information: Replace in time when the bearing rotates
abnormally.

Assembly after repair

1. Assemble the ignition switch assembly
(a) Assemble the ignition switch assembly on the upper
part of the steering column through two bolts.
2. Assemble the ignition switch lock core assembly
(b) Firstly ensure the lock core on ACC shift position
(c) Slightly insert the ignition lock core into the ignition
switch along suitable angle.
3. Function confirmation of the ignition switch
(a) Confirm that the column lock body mechanism can
lock the column and the steering wheel can’t rotate when
the key is taken away.
(b) Confirm that the column lock body mechanism will
release the column and the steering wheel can rotate
when the key is inserted into and turn to ACC shift
position.
Note: when any abnormality is found, please replace
the ignition lock core assembly

8/11
 6. Assemble the upper axle assembly of the steering column
(a) Use the spring snap ring to assemble a new snap ring
(inner side) on the supper axle assembly
(b) Assemble the upper axle assembly on the steering
column
(c) When the steering column is fixed on the vise, place
the aluminum shim between the column and the opening of
the vise so as to avoid damaging the column.
Note: Don’t clamp the vise excessively.

(d) Use the spring snap ring to assemble a new snap ring
(external side) on the supper axle assembly

7. Assemble the upper axle bearing of the column

(a) Fix the steering column by the vise, place the
aluminum shim between the column and the opening of the
vise
Note: When the lower support of the column is fixed on
the vise, don’t clamp the vise opening tightly; use the
column to fix firmly, the lower support shall be free of
obvious deformation.
Special
(b) Use the special maintenance tools and hammer, tap
tools the new bearing to the corresponding position on the upper
axle of the column.
8. Install the fixing support of the ignition lock
(a) Use 2 thief proof bolts to temporarily assemble the
ignition lock on the lower steering column
(b) Tighten the thief proof bolt until the bolt head falls.

9. Assemble the ignition switch lighting ring

10. Assemble the lower axle of the steering column

assembly
(a) Align the lower axle and the upper axle of the steering
column

9/11
 (b) Assemble the bolts
Marking Tighten torque: 36N* m

Assemble
1. Assemble the steering intermediate axle
(a) Align the match markings on the steering
intermediate axle and the lower axle of the column
assembly

(b) Temporarily assemble the bolts

Marking

Driving at left 2. Assemble the steering column assembly

(a) Use 3 bolts to temporarily assemble the steering
column assembly

10/11
 (b) Tighten 3 bolts by specified torque
Tighten torque: 21N* m
(c) Tighten the clamping bolts between the steering
column and the steering intermediate axle by specified
torque
Tighten torque: 36N* m
Note: The adjustment angle of the steering column
shall be on lowest position during assembly

(d) Use the bolt to fix the lower cover of the steering
column
Tighten torque: 8.0N* m
3. Place the front wheel on straight position of the vehicle
4. Assemble the clock spring (such as configure the safety
airbag)

5. Assemble the lower cover of the steering wheel steering

column

6 Assemble the steering wheel proper body

(a) Align the steering wheel and the combination switch
as marking shown on the figure
(b) Align the steering wheel and the steering column as
marking made during removing the steering wheel.
(c) Assemble the nut (Tighten torque: 50N* m)
7. Check whether the steering wheel and the steering
column are installed firmly
8. Connect the plug in of the safety airbag, the clock spring
and the steering wheel (Only used for the vehicle type with
the airbag configuration)
Connect the plug-in of the upper cover and the steering
wheel (used for the vehicle type without the airbag
configuration)
9. Use the screw (each one at left and right side) to fix the
safety airbag (or the upper cover of the steering wheel) on
the steering wheel.
10. Press down middle and four corners of the cover,
check whether function of the suspension horn is normal.
11. Assemble the left and right blanks of the lower
protection cover
12. Connect the harness connected with the negative pole
(-) of the battery
13. Inspect the SRS warning lamp

11/11
 Part Two Chassis

Chapter Seven Power steering system

Precautions …………………………………………………………………………………002
Blade pump （4RB2）…………………………………………………………………….004
Steering driving axle ………………………………...………………………………….… 005
Steering reducer assembly ……………………………………………………….……… 009
Power steering device ………………………………………………..…...……………… 015

1 / 38
 Power steering system

Precautions
1. Precautions during operation of safety airbag
Note: Some maintenance operation may affect the safety airbag, be sure to learn precautions of
the safety airbag before operation.
2. Precautions during removal, installation and replacement of components in the power steering
system
(a) When the steering driving axle, the steering reducer assembly and the power steering device
assembly are removed, ensure that the front wheel is placed on the straight driving position of the
vehicle.
(b) Be make marking on their connected components before following parts are disconnected:
1. Low axle of the steering column assembly and the steering intermediate axel;
2. Steering intermediate axle and the steering reducer assembly;
3. Steering reducer assembly, driving axle input universal joint assembly and steering driving
axle assembly;
4. Steering driving axle assembly and power steering device assembly.

2 / 38
4RB2 (whole vehicle status)

When the low pressure oil

Assemble all pipelines connected with the steering oil tank pipe and the oil suction pip
are connected, make color
marking align with marking
on the oil tank

Assemble the hose

loop and make its
claw upward

Connect the oil

returning hose, make its
color marking upward

Assemble the hose

loop and make its
claw upward
Assemble pipeline connected with
the forging nut shown in figure
Demanded special tools

Appointed button

3 / 38
 Blade pump （4RB2)
Components

Oil flow bolt

Sealing shim

High pressure oil

supply pipe
assembly

Oil tank to oil incoming hose

of steering pump

Blade pump belt

Blade pump assembly

Power steering belt

Don’t use part repeatedly Appointed button

4 / 38
 Steering driving axle
Removal of components

Steering driving
axle assembly

Driving axle input universal

joint assembly

Appointed button

5 / 38
 Remove
1 Place the front wheel on straight position of the
vehicle
2 Fix position of the steering wheel
(a) Use the safety belt to fix the steering wheel so
as to avoid rotating
Information: operation of this step can avoid
damaging the clock spring
3. Remove the lower protection board of the engine

4. Remove the steering driving axle assembly

(a) Loose the bolt A, remove the bolt B, slide the
steering driving axle
Information: don’t remove the bolt A.
Don’t disconnect the steering driving axle from
the steering drive.

(b) Make the match marking at the connection

location between the steering driving axle and the
steering device.
(c) Disconnect the steering driving axle from the
steering drive.
Marking

(d) Remove the bolt and slide the steering driving

axle assembly

6 / 38
 (e) Make the match marking at connection
between the driving axle input universal joint
assembly and the steering reducer assembly.
Marking (f) Remove the driving axle input universal joint
assembly from the steering reducer.

5. Remove the driving axle input universal joint

Marking assembly
(a) Make the match marking at connection
between the driving axle input universal joint
assembly and the steering driving axle.
(b) Remove the bolt and remove the driving axle
input universal joint assembly from the steering
driving axle.

Assemble
1.Place the front wheel on straight position of the
vehicle
2.Assemble the driving axle input universal joint
assembly
(a) Align the match markings on the driving axle
input universal joint and the steering driving axle
assembly.
(b) Temporarily connect the bolts
Information: Don’t tighten the bolts.
Marking

3. Assemble the steering driving axle assembly

(a) Align the match markings on the driving axle
input universal joint assembly and the steering
reducer assembly.

(b) Assemble the bolts

Tighten torque: 36N* m

7 / 38
 (c) Align the match markings at connection
location of the steering driving axle assembly and
the power steering device assembly.

Marking

(d) Assemble the bolt (B) and tighten 2 bolts (A

and B)
Tighten torque: 36N* m
4. Assemble the lower protection board of the
engine

Front

8 / 38
 Steering reducer assembly
Removal of components

Steering column assemble

(column lower axle)

Column floor hole cover Steering column protection

assembly cover

Steering intermediate axle

Driving axle input universal

joint assembly

Steering reducer assembly

Steering reducer support

Water tank fan

ECU

Water tank fan

Appointed button

9 / 38
 Remove
1. Place the front wheel on straight position of the
vehicle
2. Remove the lower axle cover of the steering
column
(a) Remove 3 fixing bolts on the lower axle cover of
the lower column.

3. Disconnect the lower axle of the steering column

from the steering intermediate axle
(a) Use the safety belt to fix the steering wheel so
as to avoid rotating
Information: operation of this step can avoid
damaging the clock spring

(b) Loose the bolt A, remove the bolt B, the bolt

slides upward and rotate the lower axle of the column,
but don’t make the lower axle separated from the
steering intermediate axle.
Don’t remove the bolt A.
Don’t make the lower axle separated from the
steering intermediate axle.

(c) Make the match marking at connection location

between the lower axle and the steering intermediate
axle.
(d) Disconnect the lower axle from the steering
Marking intermediate axle.

10 / 38
 4. Remove the column floor hole cover assembly
(a) Remove 4 bolts on the column floor hole cover
assembly connected with the front separation board
of the vehicle body.

5. Remove the steering intermediate axle

(b) Make the match marking at the connection
location between the steering intermediate axle and
the steering device assembly.
(b) Remove the bolt and remove from the steering
reducer assembly.
6. Remove the water tank fan ECU

Marking

8. Disengage the driving axle input universal joint

assembly
(a) Loose the bolt A, remove the bolt B, slide the
input axle universal joint assembly.
Information:
Don’t remove the bolt A.
Don’t disconnect connection between the driving
axle input universal joint assembly and the steering
reducer assembly.

Front
(b) Make the match marking at connection location
between the driving axle input universal joint
assembly and the steering reducer device.
Marking
(c) Remove the driving axle input universal joint
assembly from the steering reducer.

11 / 38
 9. Remove the steering reducer support
(a) Remove 3 bolts on the support of the steering
reducer.

10. Remove the steering reducer assembly.

(a) Remove the bolts on the steering reducer
assembly connected with the vehicle body.

Inspection
1. Inspect no load torque
(a) Rotate the steering reducer assembly.

(b) Use the special maintenance tools to measure

no load t torque of the gear axle at input end of the
Special
tools steering reducer.
No-load torque shall be within the scope from
0.15N*m to .39N*m
If no-load rotation exceeds scope, replace the
steering reducer assembly.

1. Assemble the steering reducer assembly.

(a) Assemble the bolts on the steering reducer
assembly connected with the vehicle body.
Tighten torque: 44N* m

2. Assemble the steering reducer support

(a) Assemble 3 bolts on the support of the
steering reducer.
Tighten torque: 44N* m
3. Place the front wheel on straight position of the
vehicle

12 / 38
 4. Connect the driving axle input universal joint
assembly
(a) Align the match markings on the driving axle
Marking
input universal joint assembly and the steering
reducer assembly.

(b) Assemble the bolt A and tighten 2 bolts (A and

B)
Tighten torque: 35N* m

5. Assemble the lower protection cover of the

engine
6. Assemble the steering intermediate axle
(a) Align the match markings on the steering
intermediate axle and the steering reducer assembly
Marking (b) Assemble the bolts
Tighten torque: 36N* m

7. Assemble the column floor hole cover assembly

(a) Assemble the column floor hole cover
assembly
Tighten torque: 8.0N* m

13 / 38
 8. Connect the steering intermediate axle and the
steering column lower axle
(a) Align the match markings on the steering
intermediate axle and the lower axle of the steering
column.
Marking

(b) Assemble the bolt B and tighten 2 bolts

Tighten torque: 36N* m

9. Assemble the lower axle cover of the steering

column
(a) Use 3 bolts to assemble the lower axle
installation frame of the steering column
Tighten torque: 8.0N* m

14 / 38
 Power steering device
Components

Steering driving axle

Right fixing frame of assembly
steering device

Opening
pin Right fixing frame
sleeve of steering
device

High and low pressure

oil pipe assembly

Power steering device

assembly

Opening
pin
Pile clip

Oil returning pipe joint

Tighten torque when the special

maintenance tools are used

Appointed button

Don’t use part repeatedly

15 / 38
 Steering valve
Dust proof cover casing

Left oil cylinder oil Upper bearing of

returning oil pipe steering valve

Sealing ring of
steering valve

Upper oil sealing of

steering valve

Steering valve
Lower oil sealing of
steering valve

Washer

Right oil cylinder oil

returning oil pipe

Gear bar supporting

seat lining seat

Gear bar support

Compression spring seat

Tighten torque when the special Gear bar supporting

maintenance tools are used seat screw plug
Coat power steering liquid

Coat molybdenum disulfide

lithium base grease
Part which is pre-coated with
thread sealing glue
Locking nut
Appointed button

Don’t use part repeatedly

16 / 38
 Right steering draw bar Gear bar protection cover
external ball joint assembly

Gear bar protection

cover bucket Gear bar clip

Steering draw bar inner

ball joint assembly
Oil cylinder limitation sleeve

Locking
shim

O type Limitation inner

sealing ring lining sleeve
O type
sealing ring
Limitation bushing
Oil sealing
Oil sealing high oil sealing
at limitation sleeve end High pressure oil sealing
Gear bar of oil cylinder at input axle
end

Washer
Gear bar
enclosure

Steering draw bar inner

Snap ring of gear ball joint assembly
bar protection Locking
cover shim

Gear bar protection

cover

Gear bar protection cover

Tighten torque when the special
maintenance tools are used
Coat silicon lubrication grease

Coat power steering liquid

Left steering draw bar
Coat molybdenum disulfide external ball joint assembly
lithium base grease
Appointed button

Parts can not be used repeatedly

17 / 38
 Remove
1.Place the front wheel on straight position of the
vehicle
2.Fix position of the steering wheel
(a)Use the safety belt to fix the steering wheel so
as to avoid rotating
(b)Information: operation of this step can avoid
damaging the clock spring
3.Drain out steering liquid
4.Remove the front wheel
5.Remove the lower protection board of the engine

6.Disconnect connection between the steering

driving axle assembly and the power steering device
(a) Loose the bolt A, remove the bolt B, slide the
steering driving axle assembly
Information: don’t remove the bolt A.
Don’t disconnect the power steering device and
the steering driving axle assemble before the match
marking is made.

Front

Front
(b) Make the match marking at the connection
location between the steering driving axle assembly
and the power steering device assembly.
(c) Remove the steering driving axle from the
power steering device.
7. Disconnect the steering device external ball joint
assemble at left side
(a) Disconnect the opening lock and the
Marking hexagonal opening nut

(b) Use the special maintenance tools to remove

Special the steering device outer ball head assembly from
tools
the knuckle pivot.
Note: Use the cable to hoist the special
Rotate
maintenance tools, or use other methods so as to
avoid falling.
Don’t damage the front brake disc dust proof
cover.
Don’t damage the dirt proof cover of the ball
head pin. Don’t damage the knuckle pivot.
Clamp 8. Disconnect the steering device external ball joint
assemble at right side
Information: operation method is same as left
side.

18 / 38
 9. Remove the high pressure and low pressure oil pipe
assembly
(a) Use the calipers to remove the snap ring and
remove the low pressure oil pipe from the steering
device.

(b) Use the special maintenance tools to remove the

oil returning pipe.

Special tools

(c) Use the special maintenance tools to remove the

high pressure and low pressure oil pipe assembly from
the power steering device assembly.
Special tools

(d) Remove 2 bolts on the high pressure and low

pressure oil pipes connected with the steering device.

19 / 38
 10. Remove the power steering device assembly.
() Remove 4 bolts on the steering device connected
with the auxiliary frame.

() Make match marking between the right fixing frame

and the lining sleeve of the steering device and the
Special tools power steering device.
() Remove the right fixing frame and the lining sleeve
from the power steering device assembly.

Disassembly
1. Remove the left oil cylinder oil pipe of the steering
device.
() Use the special maintenance tools to remove the
left oil cylinder oil pipe.
Special tools

2. Remove the right oil cylinder oil pipe of the steering

device.
() Use the special maintenance tools to remove the
right oil cylinder oil pipe.

Special tools

20 / 38
 3. Fix the power steering device assembly.
(a) Use the special maintenance tools to
Special tools protect the booster steering device assembly
Information: use the protection tape after
surface of the special maintenance tools are
wrapped with the protection tape.

Protection
tape
4. Remove the steering device external ball
joint assemble at right side
(a) Make match marking at connection
location between the external ball joint
assembly and the steering draw bar.
(b) Firstly loose the locking nut, and then
remove the external ball joint assembly, finally
remove the locking nut.

5. Remove the steering draw bar external ball

joint assembly at right side
Information: operation method is same as
left side.
Marking 6. Remove the steering draw bar external ball
joint assembly at right side
(a) Use the calipers to remove 2 clips on
external side of the protection cover.
7. Remove the snap ring of the protection cover
at right side of the steering device gear bar
(a) Use the calipers and the screw driver;
remove the snap ring at inner side of the
protection cover as the method shown in the
figure.
Information: be careful to operate and
avoid damaging the protection cover
8. Remove the snap ring of the protection cover
at left side of the steering device gear bar
Information: operation method is same as
right side.
9. Remove the protection cover at right side of
the steering device gear bar

10. Remove the protection cover at left side of

the steering device gear bar
11. Remove the steering device internal draw
ball internal ball joint assembly.
(a) Use the screw drive and the hammer to
remove the left and right internal ball joint
assembly locking shim.
Note: avoid accidental impact on the gear bar
during operation.

21 / 38
 (b) Use the special tools to remove the steering
device draw bar internal ball joint assembly (left
Grasp
side) and locking shim.
Special Rotate
Information: Operate the special maintenance
tools
tools to remove with the method shown in the figure.

Special tools

(c) Use the special maintenance tools to remove

Rotate Rotate the steering draw bar internal ball joint assembly
(right side) and locking shim.
Note: Operate the special maintenance tools to
Special remove with the method shown in the figure.
tools
Information: use the special maintenance tools
to fix the gear bar and remove the steering draw bar
internal ball joint assembly.

Special tools

12. Remove the gear bar support seat

(a) Use the special maintenance tools to remove
Special
tools the steering draw bar internal ball joint assembly
(right side) and locking shim.
Note: Operate the special maintenance tools to
remove with the method shown in the figure.
(b) Use the 24mm hexagonal spanner to remove
the nut cup.
(c) Remove the compression spring and the gear
bar support seat.
(d) Remove the resin lining sleeve from the gear
bar support sea

22 / 38
 (b) Remove the dust proof cover

Protection
tape

(c) Remove 2 bolts and remove the steering valve

casing together with the steering valve.
(d) Remove the shim
(e) Wrap the protection tap on the gear at lower
end of the steering valve so as to avoid damaging
the oil sealing during removal.

Protection (f) Use the plastic hammer to remove the steering

tape
valve from the casing.

Protection
tape (g) Use the screw driver to remove 4 sealing rings
on the steering valve.
Note: be careful to operate and avoid operating
the steering valve.
Information: use the protection tape to wrap the
front end of the screw drive before operation.

Rotate
14. Remove the oil sealing at lower end of the
steering valve.
(a) Use the special maintenance tools to remove
Grasp
the oil sealing at lower end of the steering valve.

Special tools

23 / 38
 Special 15. Remove the oil sealing at upper end of the
tools
steering valve.
Special
tools (a) Use the special maintenance tools and the
press to remove the oil sealing at upper end of the
Special
steering valve, and remove the upper end bearing of
tools the steering valve from the casing of the steering
valve.

16. Remove the oil cylinder limitation sleeve

(a) Narrow body vehicle
(1) Loosen the nut.

(2) Use the special maintenance tools to remove

the limitation sleeve from the gear bar casing of the
steering device.
(3) Remove the oil pipe support.

Special
tools

(b) Wind body vehicle

(1) Use the special maintenance tools to remove
the limitation sleeve from the gear bar casing of the
Special
tools steering device;
(2) Use the screwdriver to remove O ring from
the limitation sleeve;
Note: be careful to operate so as to avoid
damaging the limitation sleeve.
Information: firstly use the tape to wrap the front end
of the screw drive before operation.
(3) Use the screw driver to remove the lining
sleeve from inner part of the limitation sleeve.
Note: be careful to operate so as to avoid
damaging the limitation sleeve.
Information: firstly use the tape to wrap the front
end of the screw drive before operation.

24 / 38
 17. Remove the steering device gear bar
(a) Temporarily assemble the bolts for maintenance at
one end of the gear bar close to the input end.
Diameter of bolt: 14mm
Thread distance: 1.5mm
(b) Use the press to remove the steering gear bar.
(c) Remove the limitation sleeve oil sealing from the
steering gear bar.
Maintenance
bolt

(d) Use the screw driver to remove the oil sealing and O
Protection tape sealing ring from the gear bar.
Note: be careful to operate and avoid damaging the
oil sealing groove on the gear bar.
Information: firstly use the adhesive tape to wrap the
front end of the screw drive before operation.

Special tools

18. Remove the high pressure oil sealing in the oil cylinder
of the steering device.
(a) Assemble the special maintenance tools.
Note: coat less MP lubrication grease on tip of the
special maintenance tools and inner part of the special
maintenance tools.
Completely assemble the special maintenance tools
on the special maintenance tools so as to avoid damaging
the gear bar casing during operation.
(b) Insert the special maintenance tools into the casing
of the steering device at certain angle until the special
Special tools Special tools maintenance tools contacts the high pressure oil seal of
the oil cylinder; assemble the special maintenance tools
on the special maintenance tools.
Note: don’t damage the steering device casing.

25 / 38
 (c) Fix the special maintenance tools, draw the special
maintenance tools to position of the special maintenance
tools in the casing of the steering gear bar.
Special tools
Information: ensure the special maintenance tools
are placed on the slope between the steering oil cylinder
Special tools and the gear bar casing.

(d) Assemble the special maintenance tools on the

special maintenance tools, and insert the tip of the
special maintenance tools into the maintenance hole of
the special maintenance tools in the steering device
casing.
Special tools
Note: don’t damage the casing of the gear bar.
Special tools
Information: if different length is required, use the
same series maintenance tools to operate.

Inspection
1. Inspect the steering device external ball joint
assemble at right side
(a) Use the vise to fix the steering external draw bar.
(b) Assemble the nut on the external ball pin.
(c) Slightly swing the ball pin forward and backward for
at least 5 times.
(d) Use the torque spanner to continuously rotate at
speed of 3~5 seconds per turn, record reading of the
torque spanner of fifth turn.
Rotation torque: 0.29~1.96N*m
If rotation torque is out of the scope, replace the
external ball joint assembly.
2. Inspect the steering draw bar external ball joint
assembly at right side
Information: operation method is same as left side.

26 / 38
 3. Inspect the gear bar
Dial (a) Use the dial indicator to inspect clearance of the
indicator
steering gear bar
Maximum clearance: 0.15mm
Note: ensure the gear bar is horizontally placed
during measurement.
(b) Inspect abrasion at surface of the gear bar.
(c) Inspect surface abrasion and damage of the
gear bar. If there is any problem, replace the gear bar
of the steering device.

4. Inspect no load torque of the assembly

(a) Use a 24mm straight hexagonal spanner to
tighten the steering device gear bar supporting seat
screw cup
Torque: 69N*m
(b) Use a 24mm straight hexagonal spanner to
loose the steering device gear bar supporting seat
screw cup.
(c) Temporarily assemble the steering draw bar
internal ball joint assembly at both sides so as to
avoid movement exceeding the design travel during
operation of the gear bar.
Note: when the steering draw bar internal ball
joint assembly isn’t assembled on two sides of the
steering gear bar, which causes movement of the
gear bar has no limitation, don’t try to move the gear
bar on the limitation position, because it will damage
the high pressure oil sealing and the lining sleeve in
the casing of the gear bar.

(d) Use the special maintenance tools to move the

gear bar left and right repeatedly for 10 complete
travels.
Special
tools

(e) Use a 24mm straight hexagonal spanner to

tighten the steering gear bar supporting seat
compression spring nut cup until no-load torque of the
assembly is in accordance with design requirement.
Special
tools
No-load torque of the assembly: 0.65~1.35N*m
Note: When no-load torque is reduced to be lower
than specified value, loose and then tighten the
steering gear bar support seat compression spring
screw plug.

27 / 38
 (f) Use the special maintenance tools to assemble the
gear bar support seat compression spring screw nut

Tighten torque: 49N* m

Note: operation the special tools at direction shown
in the figure.
Special tools
Length of the force arm of the used torque spanner
Length of
force arm is 345mm

(g) Use the special maintenance tools to inspect no

load torque of the assembly
No load torque: 0.65~1.35N*m

Assembly after repair

Special
tools Note: when the steering device is assembled, coat
steering liquid, silicon lubrication grease or molybdenum
disulfide lithium base grease on surface of the part.
1. Assemble the steering internal cylinder high pressure
oil sealing.
(a) Assemble the limitation sleeve in the steering gear
bar cylinder body.
Note: don’t damage inner part of the the steering
device casing.
Special (b) Coat steering liquid on lip of the steering oil cylinder
tools
high pressure oil sealing.
(c) Assemble the steering oil cylinder high pressure oil
sealing on the gear bar casing at certain angle.

Special Note:
tools Ensure that the steering oil cylinder high pressure oil
sealing is assembled at direction shown in the figure.
Assemble the high pressure oil sealing of the oil cylinder
at about angle of 15°to assemble the part at lowest point,
avoid damaging when the oil sealing runs through 2 oil
openings.

(d) Use the special maintenance tool, push the special

maintenance tools by hand and insert the high pressure
oil sealing into the oil cylinder until the oil sealing passes
through 2 oil openings.
Note: Don't rotate the special maintenance tools
when the oil sealing is assembled.
(e) Assemble the special tools on the special
maintenance tools with upper part of the special tools
downward.

28 / 38
Special (f) Push the special maintenance tools by hand
tools
and place the oil sealing on horizontal position.
Special
tools (g) Use the special maintenance tools and the
press to assemble the high pressure oil sealing of
the oil cylinder.

2. Assemble the steering gear bar

Special
tools Special (a) Assemble the new O ring on the steering gear
tools
bar after it is coated with steering liquid.

(b) Open the new oil sealing by finger.

(c) Coat steering liquid on the oil sealing.

(d) Adjust by hand, and assemble the oil sealing

on the steering gear bar.

29 / 38
 (e) Coat molybdenum disulfide lithium base grease
Steering gear
on two ends of each gear of the steering gear bar.
Information: remove spur on each gear surface
and polish if necessary.
() Couple the special maintenance tools on the
steering gear bar
() Coat steering liquid on the special maintenance
tools.
() Assemble the steering gear bar in the gear bar
casing.
() Remove the special maintenance tools.

Special tools
3. Assemble the limitation screw sleeve
() Narrow body vehicle model
(1) Wrap right end of the steering gear bar by
Oil Protection
protection tape and coat steering liquid;
sealing tape
(2) Coat steering liquid on lip of the new oil
sealing;
(3) Assemble the oil sealing at right end of the
steering gear bar casing.
Note: Ensure the oil sealing is assembled at
direction shown in the figure.
Don’t damage the high pressure oil sealing of the
limitation screw sleeve end.
(4) Remove the protection tape from the gear
bar.
(5) Coat steering liquid on O ring of the new
limitation screw sleeve.
(6) Assemble the O ring on the limitation screw
Lubrication
grease sleeve.
(7) Assemble the lining sleeve on the limitation
screw sleeve.
(8) Coat molybdenum disulfide lithium base
grease on surface of the whole limitation screw
sleeve.
(9) Assemble the oil pipe support.

30 / 38
 (10) Use the special maintenance tools to
assemble the limitation screw sleeve in the steering
gear bar casing.

Special Tighten torque: 78N* m

tools

(11) Tighten the clamp bolt of the oil pipe

support.
Tighten torque: 19N* m

(b) Wind body vehicle model

Oil Protection (1) Wrap right end of the steering gear bar by
sealing tape
protection tape and coat steering liquid;
(2) Coat steering liquid on lip of the new oil
sealing;
(3) Assemble the oil sealing at right end of the
steering gear bar casing.
(4) Remove the protection tape from the gear
bar.
(5) Assemble the limitation sleeve in the casing;
Lubrication
grease (6) Coat steering liquid on O ring of the new
limitation screw sleeve.
(7) Assemble the O ring on the limitation screw
plug;
(8) Assemble the new lining sleeve on the
limitation screw plug;
(9) Coat molybdenum disulfide lithium base
grease in the limitation screw sleeve plug.

31 / 38
 (10) Use the special maintenance tools ton
assemble the limitation screw plug on the casing;
Special
tools Tighten torque: 78N* m

4. Inspect tightness
(a) Assemble the special maintenance tools and the
vacuum pump on the steering cylinder body
(b) Extract vacuum to 53kpa, maintain about 30
seconds.
(c) Check whether vacuum degree is drop down.
If vacuum degree is changed, replace the new
high pressure oil sealing.
5. Assemble the oil sealing at upper end of the steering
Special
tools valve.
(a) Coat steering liquid on the upper end bearing of
Oil the steering valve and the oil sealing lip.
sealing
(b) Use the special maintenance tools and the press
to assemble the upper end oil sealing of the steering
valve,
Special Note: Ensure the oil sealing is assembled at
tools
direction shown in the figure.
Special
tools (c) Use the special maintenance tools and the press
to assemble the upper end bearing of the steering
valve,
Note: Ensure the bearing is assembled at direction
shown in the figure.
6. Assemble the oil sealing at lower end of the steering
valve.
Special
Upper bearing tools (a) Coat steering liquid on the lower end oil sealing
Steering valve lip of the steering valve.
Oil sealing side side
Wide Narrow

32 / 38
 (b) Use the special maintenance tools and the press
to assemble the lower end oil sealing of the steering
valve,
Special Note: Ensure the lower oil sealing of the steering
tools valve is assembled at direction shown in the figure.

7 Assemble the steering valve

(a) Open 4 steering valve sealing rings by finger.
Note: don’t open the sealing ring excessively.
(b) Coat steering liquid on the sealing ring of the
steering valve.

(c) Use the finger to adjust, and assemble 4 sealing

rings on the steering valve.
(d) Wrap the protection band on the spline axle at
input end of the steering valve.
(e) Coat steering liquid on the steering valve.
(f) Assemble the steering valve in the casing.
Note: be careful to operate, and avoid damaging
the steering valve sealing ring and the oil sealing lip

(g) Use 2 bolts and shims to assemble the casing of

the steering valve on the gear bar casing.
Tighten torque: 18N* m

(h) Assemble the dust proof cover.

1. Assemble the gear bar support seat
(a) Assemble the lining sleeve on the supporting
seat.
(b) Coat molybdenum disulfide lithium base grease
on adhesion surface of the compression spring, the
Protection
tape gear bar and the supporting seat.
(c) Assemble the compression spring and the
supporting seat.
(d) Coat sealing glue on 2 to 3 threads of the gear
bar supporting seat screw cup, type of sealing glue.
(e) Use a 24mm straight hexagonal spanner to
assemble the gear bar supporting seat screw cup.

33 / 38
 9. Inspect no load torque of the assembly
Rotate
10. Assemble the steering draw bar internal ball joint
Special tools
Grasp assembly
(a) Assemble two new locking shims.
Length of Special tools
force arm (b) Use the special maintenance tools to assemble
the steering draw bar internal ball joint assembly at
right side.
Tighten torque: 72N* m
Note:
Operate the special maintenance tools with the
method shown in the figure.
Length of the force arm of the used torque
spanner is 345mm
Grasp Information: use the special maintenance tools to
fix the gear bar and assemble the steering draw bar
Special Special internal ball joint assembly.
tools tools
Length of
force arm
(c) Use the special maintenance tools to assemble
the steering draw bar internal ball joint assembly at
left side.
Tighten torque
Note:
Use the special tools at direction shown in the
figure.
Length of the force arm of the used torque
spanner is 345mm

(d) Use the copper bar and the hammer to tap 2

locking shims.
Note: avoid impacting the steering gear bar.

34 / 38

Assemble snap ring from back of
protection cover
Assemble snap ring from side of
protection cover, don’t open snap
ring
11. Assemble the inner ball joint cover
(a) Coat silicon grease on opening at small end of
the protection cover.
(b) Temporarily assemble the snap ring at the position
shown as arrow of the protection cover.
Note:
Use the new snap ring;
Don’t open the clip excessively, take suitable
assemble.
Don’t make the clip of the protection cover
deformed during assemble;
Shown as figure, excessive open will cause
uneven tension force of the snap ring, which causes
the gap. Water enters into the draw bar inner ball joint
assemble and inner part of the steering device
through the gap between the protection cover and the
casing, which causes rust of the component, and
further causes failure of the steering device.
In order to ensure tightness of the protection
cover, only use the snap ring appointed by our
company, which is suitable to the steering device of
this vehicle model.
Information: when the bucket of the new
protection cover snap ring is released, temporarily
assemble the snap ring at end and avoid
un-necessary tension of diameter of the snap ring.
(c) Assemble the protection cover on the groove of
the steering device casing.
Note:
Be careful to operate and avoid damaging or
twisting the protection cover;
Don’t damage the steering gear bar protection
cover
Ensure the snap ring is already assembled
before the protection cover is assembled on the
steering gear bar casing.
12. Assemble the gear bar protection cover
Information: operation method is same as left side.
13. Assemble the snap ring of the gear bar protection
cover
(a) Use the calipers and the screw-driver to
assemble the snap ring of the protection cover.
Note: be careful to operate and don’t damage the
protection cover
Don’t twist the protection cover during operation.
14. Assemble the snap ring of the protection cover
Information: operation method is same as left
side.
15. Assemble the snap ring of the protection cover
(a) Use the calipers to assemble 2 clips.
35 / 38
 (b) Use the special maintenance tools to rotate the
Special tools input axle of the steering device repeatedly, check
whether extension and compression of the protection
cover are smooth.

16. Assemble the steering device external ball joint

assemble at right side
(a) Assemble the left steering draw bar external ball
joint assembly and the locking nut until the match
marking is aligned.
Information: tighten the locking nut before
adjustment of the front wheel is complete.

17. Assemble the steering device external ball joint

Marking
assemble at right side
Information: operation method is same as left
side.
Special tools
18. Assemble the right side oil cylinder high pressure
oil pipe
(a) Use the special maintenance tools to assemble
Length of the right oil cylinder high pressure pipe of the steering
force arm device.
Tighten torque: 23N* m
Note: length of the force arm of the used torque
spanner is 300mm
Special tools
19. Assemble the left side oil cylinder high pressure
oil pipe
(a) Use the special maintenance tools to assemble
the left oil cylinder high pressure pipe of the steering
device.
Length of Tighten torque: 23N*m
force arm Note: length of the force arm of the used torque
spanner is 300mm

Assemble
Travel direction of vehicle 1. Assemble the power steering device assembly.
(a) Align the match marking of the right fixing frame
Marking of the steering device, the right fixing frame lining
sleeve and the steering device.
Arrow marking Information: confirm the arrow indication on the
right fixing frame of the steering device is appointed to
travel direction of the vehicle.

36 / 38
 (b) Use 4 bolts to assemble the power steering
device on the auxiliary vehicle frame.
Tighten torque: 123N*m

2. Connect the high pressure and low pressure oil

pipe assembly
(a) Assemble the supports of the high pressure
and low pressure oil pipe assembly on the power
steering device assembly.
Tighten torque: 12N* m

(b) Use the special maintenance tool to connect

the high pressure and low pressure oil pipe with the
power steering device assembly.
Tighten torque: 41N* m
Note: length of the force arm of the used torque
spanner is 345mm
Length of
force arm

Special
tools
(c) Use the special maintenance tool to assemble
the low pressure oil pipe (oil returning pipe) on the
power steering device assembly.
Tighten torque: 41N* m
Note: length of the force arm of the used torque
spanner is 345mm
(d) Use the clip to fix the low pressure oil pipe on
Length of the pie joint.
force arm

Special
3. Connect the steering device external ball joint
tools assemble at left side
(a) Connect the steering draw bar external ball
head assembly at left side with the steering joint and
tighten the opening nut.
Tighten torque: 50N* m

37 / 38
 (b) Assemble the new opening pin
Note: when the opening of the nut and the round
hole of the draw bar external ball joint are not aligned,
continue tighten the nut.
4. Connect the steering device external ball joint
assemble at right side
Information: operation method is same as left side.
5. Connect the steering driving axle assembly
(a) Align the match marking of the steering driving
axle assembly and the input axle of the steering device.

Marking

(b) Assemble the bolt (B) and tighten 2 bolts

Tighten torque: 35N* m
6. Fill in power steering liquid
7. Exhaust air in the steering system
8. Inspect leakage of steering liquid
9. Assemble the front wheel
Tighten torque
10. Place the vehicle wheel on straight travel position
11. Assemble the lower protection board of the engine
12. Inspect and adjust the positioning parameters of the
front wheel
Front

38 / 38
 Part Two Chassis
Chapter Three Transmission shaft
Transmission shaft assembly …………………………………………..……………………… 002

1/8
 Transmission shaft assembly (Long axle)
Composition

Universal joint
flange
Bearing of
crossing shaft
Dust proof cover
Shim

Axle tube
Crossing shaft
Intermediate
Sliding fork support

Bearing of Input flange

crossing shaft
Dust proof
Flange fork cover
Bearing of
crossing shaft

Dust proof cover

Transmission shaft
assembly crossing shaft
Crossing shaft assembly
assembly Crossing shaft
assembly

Don’t use part

repeatedly Coat lubrication grease
Appointed button

2/8
 1. Disassemble the transmission shaft with intermediate
support.
（a）Make assembly markings on two flanges;
（b）Remove 4 bolts and nuts.
Information:
If the flange connection is too tight and it is difficult
Marking to disassemble, use the copper hammer etc. to tap the
connection flanges.
（c）Disassemble 2 bolts on the intermediate support.
（d）Take out of the intermediate support.

（e）Insert the special tools into the transmission to

protect against oil leakage.
Note:
Not damage the oil seal.
(1) Application of automatic transmission

(2) Application of manual transmission

Special tools

Remove
1．Use the screw driver and the hammer to jack the
crushed nut.
Note:
Ensure the nut perfect when the nut is jacked,
otherwise the thread of the non-sliding shaft is liable to
be damaged.

2. Check the rear transmission shaft

(a) Use the dial indictor to check run-out value of the

shaft which shall not exceed 0.5mm.
Information:
The dial indicator shall be placed in the middle of
the transmission shaft.
If run-out of the shaft exceeds limit, replace the
transmission shaft.

3/8
 3. Check the front transmission shaft
(a) Use the dial indictor to check run-out value of the shaft
which shall not exceed 0.5mm.
Information:
The dial indicator shall be placed in the middle of the
transmission shaft.
If run-out of the shaft exceeds limit, replace the
transmission shaft.
Marking
4. Disassemble the universal joint assembly
(a) Make marking on the universal joint of the
transmission shaft.

(b) Use the copper bar and the hammer to tap top of the
crossing shaft.
(c) Use the special calipers to remove 4 jump rings.
(d) Use the vice to clamp the transmission shaft.
Note: Don’t clamp too tight.

(e) Use the special tools to draw the crossing shaft out.

Note:
Special
tools Draw the part A in the figure high enough to avoid
contacting with the crossing shaft.

(f) Use the vice to clamp the outer ring of the bearing, and
use the hammer to tap the transmission shaft out.
Note:
· Don’t clamp too tight
Tap point of
hammer · Don’t tap the axle tube bending.
Information:
Use the same method to disassemble the bearing at
another end.
(g) Assemble two removed bearing outer rings on the
crossing shaft.
(h) Use the vice to clamp the flange.
Note:
Don’t clamp too tight

4/8
 (i) Use the special tools to remove the crossing shaft.
Special
tools
Information: Draw the part A in the figure high
enough to avoid contacting with the crossing shaft.

Tap point of (j) Use the vice to clamp the outer ring of the bearing,
hammer
and use the hammer to tap the transmission shaft out.
Note:
Don’t clamp too tight
(k) Disassemble the crossing shaft.
Note:
Don’t damage the flange fork
Use the same method to disassemble the bearing
at another end.
Information: Use the same method to disassemble the
bearing at another end.

Inspection
1 Inspect the intermediate support assembly
(a) Rotate the bearing of the intermediate support,
and check its smoothness.
(b) Inspect whether the oil seal is damaged.
Information: If the intermediate support is
damaged, broken or not rotate flexibly, it shall be
replaced.

Assembly again
1. Assemble the universal joint assembly
(a) Coat MP lubrication grease on the crossing shaft.
(b) Place the crossing shaft into the flange fork.

5/8
 (c) Use the special tools to assemble the bearing on the
Special
tools crossing shaft.
(d) Use the special tools to adjust two bearings, and
make width of the jump ring slot same and maximum.
(e) Assemble 2 jump rings with same thickness, and
make clearance as 0~0.5mm.
Note:
Don’t use the jump ring repeatedly, thickness of the
jump ring is shown as following;
Thickness of two jump rings must be consistent.

Type Thickness
SY/2-27-29-1 1.5
SY/2-27-29-2 1.55
SY/2-27-29-3 1.6
SY/2-27-29-4 1.65
SY/2-27-29-5 1.7
SY/2-27-29-6 1.78
SY/2-27-29-7 1.78

Tap point of (f) Use the hammer to tap the flange form until there is
hammer
no clearance between the bearing and the jump ring.
Note:
Don’t damage the flange fork
Information:
Use the same method to assemble another side.
(g) Make marking on the flange fork of the transmission
shaft.
(h) Use the special tools to adjust two bearings, and
make width of the jump ring slot same and maximum.
(i) Assemble 2 jump rings with same thickness, and
make clearance as 0~0.5mm.
Note:
Don’t use the jump ring repeatedly, thickness of the
jump ring is shown as following;
Special
tools Thickness of two jump rings must be consistent.

6/8
 (j) Use the hammer to tap the flange form until there
is no clearance between the bearing and the jump
ring.
Note:
Don’t damage the flange fork.
Information:
Tap point of Use the same method to assemble another side.
hammer

2. Inspect the universal joint assembly

(a) Inspect whether rotation of the crossing shaft is
flexible.
(b) Inspect axial clearance of the crossing shaft.
Information:
Replace the intermediate transmission shaft if it is
necessary.

(c) Use the spring dynomometer, the hook is hung in

the hole of the flange fork and measure rotation force.
Torque: 1.1N*m
Note:
Measure rotation torque at two diagonal positions for
each universal joint. If it is lower than standard value,
use the jump ring with great thickness. If it is greater
than standard value, use the thinner jump ring.

Assembly
1. Assemble the transmission shaft with intermediate
support.
(a)Take away of the special tools from the
transmission case.
Special tools
(b) Assemble the transmission shaft on the output
end of the transmission.
(c) Assemble the intermediate support and install 2
bolts.

7/8

Marking
Centre line of bearing
Centre line of case of
intermediate support
(d) Align the marking of the transmission shaft with
marking of the rear bridge.
(e) Use 4 nuts, 4 bolts and 4 shims to connect the
transmission shaft.
Torque: 74N*m
(f) Ensure the axle line of the intermediate support
vertical to the axle line of the transmission shaft.
(g) Adjust position of the intermediate support.
Note:
· Adjust the intermediate support to correct
position shown in the figure on no load status.
· Inspect centerline at axial direction at same
position. Adjust the bearing if necessary.
·Adjust axial distance between the centerline of
the intermediate support bearing and the axle line of
the case to ±1mm.
(h)Tighten 2 bolts.
Torque: 36N*m
8/8
 Part Two Chassis
Chapter Four Suspension
Torsion bar spring ……………………………………………………………………………………002
Torsion bar assembly ………………………………………………………………………………..003
Push bar assembly …………………………………………………………………………………..009
Disassembly figure of front vibration absorber ……………………………………………………012
Assembly figure of front upper swing arm ………………………………………………………….015
Disassembly figure of front lower swing arm ………………………………………………………021
Disassembly figure of front lower swing arm ………………………………………………………021
Ball head pin of front lower swing arm ……………………………………………………………..026
Front stabilizer bar ……………………………………………………………………………………028
Leaf spring assembly …………………………………………………………………………………032
Rear vibration absorber ………………………………………………………………………………041
Suspension …………………………………………………………………………………………….047

1/48
 Torsion bar spring
Disassembly figure of part

Adjustment arm assembly

Adjustment bolt

Torsion bar fixing arm rotation axle

Torsion bar seat assemble

Dust proof cover

Lower cushion block

Adjustment nut

Torsion bar spring

Mudguard

Appointed button Set torque

2/48
 Torsion bar assembly
Remove
1. Remove the front wheel
2. Remove the mudguard
(a)Remove 4 buckles and the mudguard

Adjustment arm end Torsion bar seat end 3. Remove the torsion spring
(a) Take out of the dust proof cover from the
adjustment arm, mark match marking on the torsion
bar spring, the torsion bar seat and the adjustment
arm.
Marking Marking
(b)Grasp the adjustment nut of the adjustment arm
and use the spanner of 22×24mm to remove the
locking nut.

(c) Measure the exposed length A of the bolt (this

dimension is used during adjustment of vehicle
height)
(d) Loose the adjustment nut and make the torsion
bar spring on loose status

(e) Remove following parts from the adjustment arm.

(1) Adjustment nut（component A）；
(2) Lower cushion block（component B）；
(3) Adjustment bolt（component C）;
(4) Fixed arm rotating axle of the torsion bar
（component D）;
(f) Remove the adjustment arm and the torsion bar
spring;
(g) Remove the dust proof cover from the torsion bar
spring.

3/48
4. Remove the torsion bar seat
(a) Remove 2 bolts and the torsion bar seat from the
upper swing arm assembly
Inspection

1. Inspect the torsion spring

(a) Use the V-shaped block and the dial indicator to
measure straightness of the torsion bar spring.
Maximum value: 2mm
Note:
The dial indicator shall be placed in the middle of
the torsion bar spring.
If measurement value exceeds allowable scope, replace
a new torsion bar spring.

Assembly
1. Assemble the torsion bar seat
(a) Assemble the torsion bar seat on the upper swing
arm by 2 bolts.
Torque: 81N*m

2. Temporarily assemble the torsion bar spring

(a) Inspect the left and right marking at end of the
torsion bar spring.
Note:
The end with the left and right markings of the torsion
bar must face towards rear part (b) of the vehicle during
installation, and the protection band is coupled on the
spines at two ends of the torsion bar.
(c) Assemble the dust proof cover on the torsion bar
spring.
Note:
Don’t damage the lip of the dust proof cover during
installation.

4/48
 (d) Take out of the protection band, and coat MP2#
lubrication grease on the spines at two ends.

Adjustment arm end

(e) Align the match marking; assemble the torsion bar
Torsion bar seat end
spring in the torsion bar seat.
(f) Align the match marking; assemble the adjustment
arm on the torsion bar spring.

Marking Marking

(g) Assemble following parts on the adjustment arm

(1) Fixed the arm rotating axle of the torsion bar
(component A);
(3) Lower cushion block (component C)；
(4) Adjustment nut (component D)；

（h）Feeding quantity of adjustment nut A=54.1mm

5/48
 3. Assemble the mudguard
Inspect the torsion spring
(a) Use 4 buckles to assemble the mudguard.
4. Assemble the front wheel
Torque: 100N*m
5. Swing the body upward and downward, and make the
suspension system stable

6. Tighten the torsion bar spring

(a) Fix the adjustment nut and tighten the locking nut
Torque: 78N*m

7. Inspect and adjust height of the body

Locking nut

Adjustment nut

Assembly
1. Assemble the torsion bar seat
(a) Assemble the torsion bar seat on the upper swing
arm by 2 bolts.
Torque: 81 N*m

2. Temporarily assemble the torsion bar spring

(a) Inspect the left and right marking at end of the
torsion bar spring.
Note:
The end with the left and right markings of the torsion
bar must face towards rear part (b) of the vehicle during
installation, and the protection band is coupled on the
spines at two ends of the torsion bar.
(c) Assemble the dust proof cover on the torsion bar
spring.
Note:
Don’t damage the lip of the dust proof cover during
installation.
(d) Take out of the protection band, and coat MP2#
lubrication grease on the spines at two ends.

6/48
 (e) Align the match marking; assemble the torsion bar
spring in the torsion bar seat.
(f) Align the match marking; assemble the adjustment
Adjustment arm end Torsion bar seat end
arm on the torsion bar spring.

Marking
Marking

(g) Assemble following parts on the adjustment arm

(1) Fixed the arm rotating axle of the torsion bar
(component A)
(2) Adjustment bolt(component B)
(3) Lower cushion block(component C)
(4) Adjustment nut(component D)

(h) Feeding quantity of adjustment nut A=54.1mm

7/48
 3. Assemble the mudguard
Inspect the torsion spring
(a) Use 4 buckles to assemble the mudguard
4. Assemble the front wheel
Torque: 100N*m
5. Swing the body upward and downward, and make the
suspension system stable

6. Tighten the torsion bar spring

(a) Fix the adjustment nut and tighten the locking nut
Torque: 78N*m
7. Inspect and adjust height of the body
Locking nut

Adjustment nut

8/48
 Push bar
Assembly

Push bar snap ring

Sleeve
Washer
Push bar snap ring
Push bar rubber cushion
Washer

Adjustment nut
Push bar rubber cushion

Push bar

9/48
 Remove

1. Remove the front wheel

2. Remove the push bar

(a) Measure distance A (taken as reference for
successive step) and record length of the thread of the
push bar.

(b) Use SST to remove the nut, the push bar snap ring,
the rubber cushion and the sleeve at rear side of the push
bar.

(c) Screw out of 2 bolts and 2 nuts, and disengage the

push bar from the front swing arm.
(d) Screw out of the nut form the push bar.

Assemble the push bar

1. Pre-tighten the push bar
(a) Measure length A and record.
Information:
If the new push bar is used, tighten the nut to standard
size scope.

(b) Assemble the sleeve, the rubber cushion of the push

bar, the snap ring of the push bar and the washer on the
push bar, temporarily tighten the nuts.
Note:
Don’t assemble the snap ring of the push bar and the
rubber cushion of the push bar wrongly

10/48
 (c) Connect the push rod with the lower suspension arm
with the bolt and the nut. Tighten torque
(d) Temporarily tighten the nut.
2. Assemble the front wheel
Tighten torque.
3. Stabilize the suspension system

4. Stabilize the suspension system

(a)Tighten the nut, and make the exposed thread size A
of the push bar same as distance before movement.

(b)Use SST to tighten the nut at rear side of the push

bar.
Tighten torque

5. Inspect positioning of the front wheel

11/48
 Disassembly figure of front vibration absorber

Upper and lower pad

Locking nut

Washer

Elastic pad

Washer

Elastic pad

Upper and lower pad

Front vibration absorber

Appointed button Not be used repeatedly

Remove
1. Remove the front wheel
2. Remove the front vibration absorber

(a) Clamp the upper bar flat interface of the vibration

absorber, and remove the locking nut by the spanner.
(b) Remove the upper and lower cushions, the spring
cushion and the washer of the vibration absorber.

12/48
 (c) Remove the lower bolt of the front vibration
absorber, and then remove the front vibration absorber

Inspection of front vibration absorber

1. Inspect the vibration absorber
(a) Push in and draw out of the piston ring of the
vibration absorber, check whether there is abnormal
resistance or noise. If function of the vibration absorber
is improper, replace with a new vibration absorber.
Note:
Abide by following procedures when replacing the
vibration absorber.

Assembly
1. Temporarily tighten the front vibration absorber
(a) Assemble the upper and lower cushions and the
flat cushion sub-assembly of the vibration absorber.
Note:
Pay attention to correct direction during installation of
the flat cushion
(b) Assemble the front vibration absorber, assemble
the upper and lower cushions and the flat cushion of the
vibration absorber sub-assemblies, and tighten a new
locking nut.

(c) Clamp the upper bar flat interface of the vibration

absorber, tighten the locking nut with the spanner, make
exposed length of the thread part of 2~4mm.

13/48
 (d) Assemble the front vibration absorber on the lower
swing arm, insert into the bolt from front part of the vehicle
and temporarily tighten the bolt.
2. Assemble the front wheel
Torque: 100N*m
3. Stabilize the suspension system
(a) Swing the vehicle upward and downward for several
times, and make the suspension stable.

4. Tighten the front vibration absorber

(a) Tighten the bolts of the front vibration absorber.
Torque: 105N*m

5. Discard treatment of the front vibration absorber

Welding seam part
(a) Completely draw out of the piston bar of the vibration
absorber.
(b) Drill a small hole shown in the figure, and exhaust
insider air.
Note:
Gas is harmful. The chip may splash during hole drilling,
be careful during operation.

14/48
 Assembly figure of front upper swing arm

Adjustment arm assembly

Adjustment bolt

Rotating axle of torsion bar fixing arm

Torsion bar seat assembly

Lower cushion block

Adjustment nut

Torsion bar spring

Mudguard

Appointed button Grease filling

15/48
Rear rubber lining sleeve of front swing arm Rear rubber lining sleeve of front swing arm

Big shim

Core axle of front upper swing arm Front ABS sensor

Small shim

Torsion bar seat

Proper body of front upper swing arm

Opening pin
Appointed button
Don’t use the parts repeatedly

Disassembly of the upper swing arm

1 Remove the front wheel
2 Remove the mudguard
3 Remove the torsion bar seat
4 Connection between ABS sensor and the
swing arm and the knuckle pivot
(a) Remove two fixing bolts shown in the
figure.

16/48
 5. Disconnect the front upper swing arm the knuckle pivot
(a) Remove the opening pin and loose the slotted nut.

Rotate
Note:
Special Don’t remove the slotted nut.
tools
(b) Apply the special tools to jack the front upper swing
Hold
ball head pin out from the knuckle pivot, and screw out of
the nut.
Note:
·Use the slope to fix the steering joint reliably so as to
avoid damaging caused by extra force of the brake hose;
·Avoid the dust proof cover of the upper swing ball head
against bumping and scratching during disassembly
process.

6. Remove the power steering storage liquid tank

(a) Remove 2 fixing bolts and then take out of the liquid
storage tank
Note:
The storage liquid tank shall be hung reliably by the
slope, so as to avoid overflowing and running off

7. Remove the front upper swing arm

(a) Remove 3 installation bolts and then take out of the
upper and lower swing arms

Disassembly of the front upper swing arm

1. Remove the rubber lining of the upper swing arm
(a) Jack the front and real locking nuts by the hammer
and the chisel.
(b) Screw out of the locking nut and take out of the shim.

17/48
 (c) Jack the flange edge of the front lining sleeve outer
bushing of the upper swing arm by the hammer and the
chisel, it shall jack two locations at diagonal direction

(d) Draw the front rubber lining sleeve of the front upper
swing arm out of the proper body of the swing arm with the
Special tools special tools.
(e) Remove the locking nut and the shim at rear end, and
then take out of the core shaft of the lower swing arm.

Special
tools Special tools

(f) Draw the rear rubber lining sleeve of the front upper
swing arm out of the proper body of the swing arm with the
Special
tools special tools.

Inspection
1. Inspect the proper body of the front upper swing arm
(a) Shown as the figure, swing the ball head pin forward
and backward for 5 times before installation of the nut.
(b) Assemble a nut on the ball head pin, and then
continuously rotate the ball head pin stably at speed of 3~5
seconds per each ring by the torque spanner, and record
rotation torque during tightening fifth ring.
Judgment standard:
Rotate continuously and smoothly, no obvious free
travel occurs.
If measurement value isn’t within the specified scope,
place replace a new swing arm body.
(c) Inspect whether there is crack or grease leakage in
the ball head pin dust proof cover of the swing arm. If there
is crack or grease leakage, please replace a new swing
arm proper body.

18/48
 Sub-assembly
Special tools 1. Assembly of the swing arm lining sleeve
(a) Press a new rear rubber lining sleeve into the swing
arm proper body by the special tools.
(b) Assemble the core axle of the swing arm on the swing
arm proper body.
Special tools
(c) Press a new front rubber lining sleeve into the swing
arm proper body by the special tools.

Special tools
(d) Assemble two shims and two locking nuts.
Key points during assembly:
Assemble at angle specified in the figure.
Tighten torque: 225N* m
Special
tools
Special tools

(e) Shown as the figure, rivet two locking nuts tightly by the
hammer and chisel.

Assembly of the front upper swing arm

1. Assemble the front upper swing arm
(a) Fix the front upper swing arm with the vehicle body by
a bolt.
Tighten torque: 190N* m

19/48
2. Assemble the power steering liquid storage tank
(a) Fix the liquid storage tank with 2 bolts.
Tighten torque: 8.0N* m

3. Connection of the front upper swing arm

(a) Use the slotted nut to connect the ball head pin and
the knuckle pivot of the upper swing arm
Tighten torque: 113N* m
(b) Assemble a new slotted pin
Precautions:
· · If specified torque is reached, and the installation
hole of the ball head pin is aligned to the slot of the nut,
continue to tighten 60° more so as to make the opening
pin smoothly inserted.
·Avoid damaging the dust proof cover of the ball head
pin during assembly process.

4. Connect the ABS wheel speed sensor

(a) Use 2 bolts and a clamp to fix the wheel speed
sensor harness. Tighten torque: 8.0N* m
Precautions:
·The harness of the sensor shall not be twisted during
installation.
· Protect the sensor harness against scratching and
bumping caused by sharp edge of the around parts.

5. Assemble the torsion bar seat

6. Temporarily assemble the torsion bar spring
7. Assemble the mudguard
8. Assemble the front wheel
Tighten torque: 100N*m
9. Make the suspension system maintain stable
10. Completely tighten the adjustment nut of the torsion
bar
11. Inspect and adjust the positioning parameters of the
front wheel

20/48
 Disassembly figure of front lower swing arm

Connection bar of front stabilizer bar

Push bar shim

Front vibration absorber

Push bar support

pipe

Push bar
Upper jump limitation rubber cushion
block of wheel Flat washer

Flat washer
Push bar
rubber cushion
Adjustment nut
Shim

Rubber Push bar shim

cushion
Push bar

Shim

Flat washer
Extravert adjustment
eccentric bolt Extravert adjustment
eccentric shim

Front lower swing

arm assembly
Front lower swing
arm lining sleeve

Front lower swing arm lining

Rubber sleeve ball head pin
cushion

Shim Self-locki
ng nut

Don’t use the part

Appointed button repeatedly

21/48
 Remove step
1. Remove the front wheel
2. Disconnect the connection bar of the front stabilizer
bar
(a) Fix the connection bar of the front stabilizer bar with
the spanner, and then remove its connection nut with the
lower swing arm.
(b) Take out of the shim and the rubber lining sleeve
(c) Take the connection bar of the front stabilizer bar
out of the front lower swing arm
Rotate (d) Take out of the additional 2 shims and the rubber
lining sleeve

3. Remove the front vibration absorber

(a) Remove the connection bolt, and disconnect the
Grasp
lower end of the front vibration absorber with the lower
Rotate swing arm

4. Remove the push bar

Rear side
(a) Remove the fixing nuts on the push rod and rear of
the auxiliary vehicle frame, take out of the washer, the
shim of the push bar, the rubber cushion of the push bar
and the support sleeve.

(b) Remove 2 bolts and nuts on the push bar

connecting with the front lower swing arm

22/48
 5. Remove the front lower swing arm
(a) Remove 2 bolts and nuts on the ball head pin of the
front lower swing arm connecting with the lower swing
arm.

(b) Adjust the aligning cam, and adjust the shim and
the front auxiliary vehicle frame and make match
Match marking marking. Take out of the shim and the rubber lining
sleeve.
(c) Loosen the connection nut and following parts.
(1) Flat shim
(2) Aligning eccentric shim
(3) Aligning eccentric bolt
(4) Front lower swing arm

Disassembly of the front lower swing arm

1. Take out of the limitation buffer block of the wheel
(a) Remove the connection nut and the limitation
buffer block.

Special 2. Remove the rubber lining of the upper lower swing arm
tools
(a) Use the special tools to push the rubber lining
sleeve out of the swing arm proper body.

Sub-assembly of the front lower swing arm

1. Assembly of the rubber lining sleeve of the lower
Special
swing arm
tools (a) Press a new rubber lining sleeve into the swing arm
proper body by the special tools.
Special tools

23/48
 2. Assemble the upper limitation buffer block of the wheel
(a) Fix the limitation buffer block and the front lower
swing arm by the connection nuts.
Tighten torque: 36N* m

Assembly of the front lower swing arm

1. Temporarily tighten the front lower swing arm and the
Marking
auxiliary vehicle frame
(a) Temporarily connect the front lower swing arm with
the auxiliary vehicle frame by the nut.
(b) Align the eccentric bolt and the eccentric shim to
the marking made on the auxiliary vehicle frame in
advance.
(c) Temporarily tighten the connection bolt of the lower
swing arm with the auxiliary vehicle frame.
Precautions: ensure align the marking made in
advance during tightening.
(d) Use 2 bolts and the nuts to connect the lower swing
arm and the ball head pin.
Tighten torque: 52N* m

2. Assemble the push bar

(a) Assemble the support bushing, the rubber cushion
of the push bar, the shim of the push bar and the washer
in order, and tighten the hexagonal nut.
Precautions:
Don’t assemble the shim of the push bar and the
rubber cushion of the push bar wrongly, refer to figure for
direction.

(b) Fix the push bar and the front lower swing arm with
2 bolts and nuts
Tighten torque: 90N* m

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 3. Connect the front vibration absorber and the front lower
swing arm
(a) Fix the lower end of the front vibration absorber and
the lower swing arm with the bolt
Tighten torque: 105N* m
4. Connect the connection bar of the front stabilizer bar
with the front lower swing arm
(a) Assemble 2 shims and the rubber lining sleeve
(b) Insert the connection bar of the stabilizer bar into the
corresponding installation hole in the front lower swing arm
(c) Assemble the shim and the rubber lining sleeve
(d) Replace new self-locking nut and tighten, ensure
length of the exposed thread in accordance with standard
value requirements.
Exposed length standard of thread: 5±1mm

5. Assemble the front wheel

Tighten torque: 100N* m
6. Make the suspension system maintain stable

Marking
7. Completely tighten the connection bolt of the front lower
swing arm with the auxiliary vehicle frame.
(s) Confirm that the eccentric bolt and the eccentric shim
align to marking on the auxiliary vehicle frame in advance;
completely tighten the connection eccentric bolts of the
front lower swing arm and the auxiliary vehicle frame.
Tighten torque: 170N* m
Rear side

8. Completely tighten the connection nut s of the push bar

and the auxiliary vehicle frame
(s) Completely tighten the hexagonal nuts at rear of the
push bar and the auxiliary vehicle frame.
Tighten torque: 138N* m
9. Inspect and adjust the positioning parameters of the
front wheel

25/48
 Ball head pin of front lower swing arm

Front wheel speed sensor

Front brake caliper assembly

Opening pin

Opening pin

Front wheel edge

assembly

Cross drawing rod of

steering gear

Steering knuckle

Brake dust proof

cover
Opening pin

Brake disc

Front lower swing

arm ball head pin

Appointed button Don’t use the part repeatedly

26/48
 Disassembly of ball head pin of front lower swing arm
1 Remove the front wheel
2 ABS wheel sensor harness
3 Remove the front brake caliper assembly
4 Disconnect the steering tie rod with the knuckle pivot
5 Remove the wheel edge assembly of the front wheel
6 Disassembly of ball head pin of front lower swing arm
(a) Use the vise to clamp the knuckle pivot (place the
aluminum alloy sheet etc. between the knuckle pivot and the
opening of the vise in advance).
Precautions:
Pay attention to not damage the knuckle pivot

(b) Remove the opening pin

(c) Loosen the connection nut of the ball head pin and the
knuckle pivot
(d) Draw the ball head pin out of the knuckle pivot by the
special tools
Precautions:
·Don’t damage the dirt proof cover of the ball head pin
·Coat suitable lubrication grease on the thread of the ball
head pin and the screw head of the special tools
(e) Remove the nut and the ball head pin of the front
lower swing arm
Special tools Grasp

Inspection
1. Inspect the ball head pin of front lower swing arm
(a) Shown as the figure, swing the ball head pin forward
and backward for 5 times before installation of the nut
(b) Assemble a nut on the ball head pin, and then
continuously rotate the ball head pin stably at speed of 3~5
seconds per each ring by the torque spanner, and record
rotation torque during tightening fifth ring.
Judgment standard:
Rotating torque shall not exceed 6.5N*
If measurement value isn’t within the specified scope,
place replace a new ball head pin of the lower swing arm.
(c) Inspect whether there is crack or grease leakage in the
ball head pin dust proof cover of the swing arm. If there is
crack or grease leakage, please replace a new lower swing
arm ball head pin.

Assemble ball head pin of front lower swing arm

1. Assembly of the front lower swing arm head pin
(a) Use the vise to clamp the knuckle pivot (place the
aluminum alloy sheet etc between the knuckle pivot and the
opening of the vise in advance).
Precautions:
Pay attention to not damage the knuckle pivot

27/48
 Front stabilizer bar
Disassembly figure of part

Stabilizer bar right upper support

Stabilizer bar left upper support

Stabilizer bar connection bar assembly

Crossing stabilizer bar

Stabilizer bar connection bar assembly

Stabilizer bar lining sleeve

Shim
Stabilizer bar lining sleeve

Rubber cushion

Middle shim

Stabilizer bar lower support

Rubber cushion

Stabilizer bar lower support

Shim

Appointed torque Don’t use the part repeatedly Locking nut

28/48
 Disassembly of the stabilizer bar
1. Remove the connection bar of the side stabilizer bar
() Take out of the nut and the connection rod from the
Grasp
stabilizer bar
Information:
If the bolt of the ball head rotates together with the nut,
please use the inner hexagonal spanner to fix the ball
head bolt.
Rotate
() Fix the connection bar assembly of the stabilizer bar
by the spanner, screw out of the nut
() Take out of the shim and the rubber cushion
() Take out of the connection bar of the left stabilizer bar
from the lower swing arm
() Take out of the shim and the rubber cushion
Grasp
2. Remove the connection bar of the left side stabilizer bar
Information:
Apply step same as left side

Rotate

3. Remove the left lower support of the stabilizer bar

() Take out of 2 bolts from the lower support of the
stabilizer bar
4. Remove the right lower support of the stabilizer bar
Information:
Apply step same as left side
5. Take out of the lining sleeve of the stabilizer bar
() Take out of the stabilizer bar lining sleeve from the
stabilizer bar
6. Remove the front stabilizer bar
() Remove the stabilizer bar from the vehicle

7. Remove the upper support of the stabilizer bar

() Remove five bolts and the upper support of the
stabilizer bar at left side
() Remove five bolts and the upper support of the
stabilizer bar at right side

29/48
 Inspection
1. Inspect the connection bar assembly of the stabilizer bar
(a) Pull the head ball forward and backward 5 times before
installation of the nut, confirm that it is normal
(b) Use the torque spanner to continuously pull the nut at
speed of 3~5 seconds/time, take reading of fifth pulling, Use
the torque spanner to continuously pull the nut at speed of
3~5 seconds/time, take reading of fifth pulling,
Torque shall be less than 1.98N*m
If torque exceeds specified value, replace the new
connection bar of the stabilizer bar.
(c) Inspect whether there is crack and oil leakage in the
dust proof cover. If it isn’t in accordance with specified value,
replace with the new connection bar of the stabilizer bar.

Assembly
1. Assemble the upper support of the stabilizer bar
(a) Assemble the upper support of the stabilizer bar
(1) When the upper support of the stabilizer bar is
assembled on suitable position, temporarily tighten the bolt
(A)
(2) Assemble 4 bolts (B), and then tighten bolts (A)
Arrow Torque: 36N*m
Note:
Arrow marking faces toward the front of the vehicle,
firstly tighten the bolt (A)
And then tighten the bolt (B)
2. Assemble the upper support of the stabilizer bar
Front
(a) Assemble the lining sleeve of the stabilizer bar at outer
side of the snap ring of the stabilizer bar
Information:
The side with the protruding part must be adhered to the
snap ring of the stabilizer bar

3. Assemble the front stabilizer bar

Lining sleeve snap ring (a) Assemble the front stabilizer bar on the vehicle body
4. Assemble the lower support of the stabilizer bar at left side
(a) Assemble the lower support of the stabilizer bar with
Travel direction of vehicle
two bolts
Torque: 36N*m
Note: The arrow faces towards the front part of the
vehicle
5. Assemble the lower support of the stabilizer bar at right
side
Information:
Arrow Assembly step is same as that of the lower support of the
stabilizer bar at left side
6. Assemble the connection bar assembly of the stabilizer bar
at left side
(a) Assemble the shim, the middle shim and the rubber
cushion
(b) Connect the connection bar assembly of the stabilizer
bar at left side with the lower swing arm

30/48
 Grasp (c) Assemble the shim and the rubber cushion on the
lower swing arm
(d) Assemble and tighten the locking nut, exposed
length of the screw rod is 4~6mm

Rotate

(e) Assemble the connection bar of the stabilizer bar on

Grasp
the stabilizer bar with the nut
Torque: 80N*m
Information:
If the bolt of the ball head rotates together with the
nut, please use the inner hexagonal spanner to fix the ball
head bolt.
Rotate

7. Connect the connection bar assembly of the stabilizer

bar at left side with the lower swing arm
Information:
Assembly step is same as that of the connection bar
of the stabilizer bar at left side
8. Assemble the front wheel
Torque: 100N*m
9. Inspect and adjust positioning of the front wheel

31/48
 Leaf spring assembly

Disassembly figure

Saddle bolt

Rear vibration absorber assembly

Leaf spring hoisting lug

seat sleeve

Rear bridge assembly

Leaf spring hoisting

Large hole lower shim lug pin sleeve

Leaf spring
assembly Leaf spring
Leaf spring hoisting lug
Parking rear hoisting lug external board
drawing rope inner board assembly
support assembly

Rear leaf spring

support assembly

Appointed torque

Don’t use the part repeatedly

32/48
 Rear lining sleeve

Support
Centre bolt
First leaf

Middle shim

Anti-abrasion
Front lining
cushion
sleeve

Second leaf

Anti-abrasion cushion

End cushion

End cushion

Third leaf

Support

First leaf

Middle shim

Appointed torque

Don’t use the part repeatedly

33/48
 Remove
1. Remove the spare tire
2 Remove the wheel
3 Remove the parking drawing wire support
(a) Remove two bolts and the parking drawing wire
support

4. Remove the rear vibration absorber assembly

(a) Use the jack to lift the rear bridge, place a wood
block between the rear bridge and the jack in order to
avoid damaging the rear bridge

Wood cushion block

(b) Screw out of the bolt, and remove the vibration

absorber assembly
(c) Take out of the rubber cushion and the shim

Shim

5. Remove the leaf spring support

(a) Remove 4 nuts and the washers, 2 U shaped bolts
and the leaf spring support separately

34/48
 Front
6. Loosen the leaf spring assembly
(a) Loosen the nut
Note:
Don’t remove the loose bolt and the nut
7. Remove the leaf spring assembly
(a) Use the jack to lift the rear bridge, place a wood block
between the rear bridge and the jack in order to avoid
damaging the rear bridge

Front

Front (b) Remove the nut, 2 bolts and the lifting lug of the leaf
spring
Note:
Don’t remove the leaf spring by force so as to avoid
damaging the sawtooth protuberance at two ends of the leaf
spring lining sleeve and the lining sleeve

(c) Remove the bolt, the nut and the leaf spring assembly
Note:
Don’t drop down the jack supported under the axle
housing before the left and the right leaf springs are
separated from the vehicle body

35/48
Leaf spring hoisting lug 8. Remove the lifting lug seat sleeve of the leaf spring
pin sleeve
(a) Use the long bar and the hammer to remove the lifting lug
pin sleeve
(b) Use the long bar and the hammer to remove the lifting lug
Leaf spring hoisting lug
pin sleeve
seat sleeve

9. Disassemble the leaf spring assembly

(a) Use the clamp caliper for aluminium disc to fix the steel s
heet spring
(b) Use the hammer and the steel rod to open the clamp of
the leaf spring
Note:
Don’t’ damage the leaf spring
(c)Use the clamp caliper for aluminium disc to fix the steel s
heet spring
(d) Remove the centre bolt

10. Remove the end cushion of the leaf spring

(a) Remove 2 nuts and two end cushions
11. Remove the anti-friction pad of the leaf spring

36/48
Rear 12. Use the special tools and the press bed to remove the
lining sleeve of the leaf spring to inspect

Inspection
1. Inspect the leaf spring assembly
(a) Inspect the leaf
(1) Inspect the finish painting and crack etc.
(b) Inspect the U-shaped bolt
(1) Inspect appearance and damage conditions of the
U-shaped bolt
Rear (c) Inspect appearance and damage conditions of the
spring clip

Assembly
1. Assemble the leaf spring lining sleeve
(a) Assemble a new lining sleeve on the leaf spring
(b) Use the special tools and the press to assemble the
lining sleeve on the leaf spring

2. Assemble the leaf spring lining sleeve

(a) Use 2 nuts to assemble 2 end cushions of the leaf
spring
Torque: 38N*m
3. Assemble the anti-friction pad of the leaf spring
4. Assemble the leaf spring
(a) Assemble the intermediate pad on the leaf spring
(b) Use the hammer and the steel rod to open the clamp
of the leaf spring
Temporarily assemble the intermediate bolt and the nut

(c) Use the hammer and the steel rod to open the clamp
of the leaf spring

(d) Use the spanner and the pliers to tighten the nut
Torque: 49N*m

37/48
 5. Assemble the frame
(a) Use 2 nuts to assemble the leaf spring frame
Torque: 37N*m

Assembly
Leaf spring hoisting lug
pin sleeve 1. Assemble the lifting lug seat sleeve of the leaf spring
(a) Assemble the lifting lug seat sleeves of 2 leaf
springs and one lifting lug pin sleeve

Leaf spring hoisting lug

seat sleeve

2. Temporarily assemble leaf spring assembly

Front
(a) Temporarily use the new bolt and the nut to
assemble the leaf spring assembly on the vehicle body
(b) Temporarily use 2 new bolts and nuts to assemble
the leaf spring assembly and the lifting lug of the leaf
spring

Rear

Type without harmonic block

38/48
 3. Temporarily tighten the U-shaped bolt and the leaf
spring frame
(a) Use 2 new U-shaped bolts, 4 shims and 4 nuts to
temporarily fix the leaf spring
Note:
Tighten the centre bolt when the U-shaped bolt is
tightened

4. Assemble the rear vibration absorber assembly

(a) Assemble the shim and the lower collar of the rear
vibration absorber
(b) Temporarily tighten the rear vibration absorber
Shim assembly with bolts

5. Assemble the manual brake drawing wire support

(a) Use 2 bolts to assemble the manual brake drawing
wire support
Torque: 14.5N*m
6. Assemble the rear wheel
Torque: 100N*m
7. Assemble the spare tire
8. Make the suspension stable
(a) After the vehicle is put down, swing the vehicle
upward and downward and make the rear suspension
stable

39/48
 Front 9. Tighten the rear leaf spring assembly
(a) Tighten the bolts
Torque: 147N*m

(b) Tighten the bolt (A) and (B)

Rear Torque: 147N*m

10. Tighten the leaf spring support

(a) Tighten 4 nuts
Torque: 95N*m
Note:
·Tighten 4 nuts evenly
·Tighten torque of 4 nuts shall be same

11. Tighten the rear vibration absorber assembly

(a) Tighten the bolts
Torque: 43N*m

40/48
 Rear vibration absorber
Disassembly figure of parts

Rear vibration
absorber upper loop

Washer
Rear vibration
absorber assembly

Washer

Rear vibration
absorber lower loop

Appointed torque

Remove
1. Remove the rear vibration absorber assembly
() Use the jack to lift the rear bridge, place a wood block
between the rear bridge and the jack in order to avoid
Wood cushion block damaging the rear bridge

41/48
 (b) Remove the bolt and separate the vibration
absorber assembly
(c) Remove the shim

Shim

Shim (d) Remove the bolt and the rear vibration absorber
(e) Remove the washer

(f) Remove the upper and lower loops of the vibration

absorber

Inspection
1. Inspect the rear vibration absorber assembly
(a) Compress and extend the vibration absorber
upward and downward, check whether there is no
abnormal resistance and abnormal sound. If there is
abnormal phenomenon, replace with a new vibration
absorber.
Note:
When the vibration absorber is discarded

42/48
 Assembly
Upper
1. Temporarily assemble the rear vibration absorber
Small assembly
(a) Assemble the upper and lower loops of the vibration
absorber on the rear vibration absorber
Note:
Sizes of the upper and lower loops are different, don’t
Big
assemble wrongly
Lower
Information: if the lower loop of the vibration absorber
is separated, assembly as shown in the figure

Shim
(b) Assembler the washer of the vibration absorber
(c) Temporarily fix the upper end of the rear vibration
absorber with the bolts

(d) Assembler the washer of the vibration absorber

(e) Temporarily fix the upper end of the rear vibration
absorber with the bolts

2. Make the suspension stable

Shim
(a) After the vehicle is put down, swing the vehicle
upward and downward and make the rear suspension
stable

3. Tighten the rear vibration absorber assembly

(a) Tighten the upper bolt of the vibration absorber
Torque: 24N*m

43/48
 (b) Tighten the lower end of the vibration absorber
Torque: 43N*m

Discard and reject

1. Discard the rear vibration absorber assembly
(a) Make the piston rod of the vibration absorber drawn
to maximum status
(b) Use the drilling machine to drill a hole at one position
between A and B shown as figure, and exhaust air.
Note:
·Be care of chip during hole drilling, it is better to use
the protection device
·Exhausted gas is colorless, harmless and toxic free.

Positioning of the wheel

1. Inspect the toe-in angle
() Swing the vehicle upward and downward to make the
suspension stable, and then inspect height of the vehicle
body
() Inspect the toe-in angle
A-B
Total toe-in angle 2+-2mm（0.08+-0.08in）
Information: if tie-in angle isn’t within the specification,
adjust the end bar of the gear bar

1. Adjust the tie-in angle

(a) Measure length of the left and right steering drawing
bar
Standard value:
Left and right difference is less than 3mm
(b) Remove the dirt proof sleeve clip
(c) Loose the end locking nut of the cross drawing bar
(d) Equivalently rotate the end bars of the left and right
gear bar to adjust the toe-in angle
Information:
·Try to adjust toe-in to the middle value
·Confirm that lengths of the end bars at left and right
side of the gear rod are same
(c) Lock the end locking nut of the cross drawing bar
Torque: 74N*m
(f) Place the dust proof sleeve on the seat, and then
install the fixing clip
Information:
Confirm that the dust proof sleeve is free of torsion
Note:
Grasp the hexagonal part at end of the gear bar to
make the locking nut and the rotating draw bar not rotate
together, temporarily tighten the locking nut, grasp the flat
part of the drawing bar and tighten the locking nut.

44/48
Adjustment
1. Inspect
2. Measure height of the vehicle body
() Swing the body upward and downward, and measure
the vehicle height
Measurement point at front end A:
Measure distance between the ground and the centre
of the adjustment bolt at front end of the lower suspension
arm (257)
Measurement point at rear end B:
Measure distance between the ground and the centre
of the adjustment bolt of the suspension arm (264)
Note: adjust the vehicle height to the specified value
before inspection of the wheel positioning
If the vehicle height isn’t in accordance with
regulation, press down or lift up to adjust height of the
vehicle
A=257
B=264

3. Inspect the toe-in angle

()Swing the vehicle upward and downward to make the
suspension stable, and then inspect height of the vehicle
body
() Inspect the toe-in angle
Information:
If tie-in angle isn’t within the specification, adjust the
end bar of the gear bar

4. Adjust the tie-in angle

(a) Measure length of the left and right steering drawing
bar
Standard value: Left and right difference is less than 3mm
(b) Remove the dirt proof sleeve clip
(c) Loose the end locking nut of the cross drawing bar
(d) Equivalently rotate the end bars of the left and right
gear bar to adjust the toe-in angle
Information:
Try to adjust toe-in to the middle value
Confirm that lengths of the end bars at left and right side of
the gear rod are same
(c) Lock the end locking nut of the cross drawing bar
Torque: 74N*m
(f) Place the dust proof sleeve on the seat, and then install
the fixing clip
Information: Confirm that the dust proof sleeve is free of
torsion

45/48
 5. Inspect the steering angle
(a) Rotate the steering wheel left and right to maximum
position, and measure the steering angle. If the steering
Front angles of the left and right wheels are not within the
specified scope, adjust length of the steering drawing bar.

6. Inspect the camber angle of the wheel, the caster angle

of the main pin and the inclination angle of the main pin
(a) Place the front wheel on the centre of the rotating
disc
(b) Remove the centre decoration parts
(c) Assemble the camber angle, the caster angle of the
main pin and the inclination angle of the main pin
measurement instruments at centre of the hub axle
(d) Inspect the camber angle of the wheel (-0.3°±0.75),
the caster angle of the main pin (2.6 °±0.75°) and the
inclination angle of the main pin (12.6 °±0.75°).
Note: Detect when the vehicle is on no load.
Left and right difference between the camber angle and
the caster angle shall not be greater than 45 points.
(e) Take out of the positioning angle measurement
instrument
(f) Assemble
If the positioning parameters can’t reach specified
value after adjustment, inspect whether the suspension
component is damaged.
7. Adjust the camber angle
(a) Loose the cam nut of the lower swing arm.
(b) Rotate and adjust the adjustment camber angle of
the cam.
Camber angle: -18 point ±45 point
Note:
Detect when the vehicle is on no load.
Left and right difference between the camber angle
and the caster angle shall not be greater than 45 points.
Inspect the tie-in angle after adjustment of the camber
angle is complete.
Information:
Adjust the cam to rotate one scale, the camber angle
changes 13 points.
(c) Tighten the adjustment nut.
Torque: 170N*m

8. Adjust inclination of the main pin

(a) Loose the locking nut of the push bar (rear)
(b) Rotate and adjust the adjustment nut to adjust the
caster angle.
Note:
Detect when the vehicle is on no load. Left and right
Rear difference between the camber angle and the caster angle
Front
shall not be greater than 45 points, inspect the tie-in angle
after adjustment of the camber angle is complete.
Information: adjust the nut to move 1, the caster angle is
changed 8 points.
(c) Tighten the locking nut of the push bar. Torque:
138N* m

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 Suspension (General for the gasoline vehicle and the
diesel vehicle)

Standard parts Quantity Torque

Assemble the left suspension Assemble bolts
2 35~45
assembly and the auxiliary frame M10*1.25*27
Assemble the left suspension
assembly and the left support of Nut M10*1.25 1 36~44
the engine

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 Standard parts Quantity Torque
Assemble the rear hoisting Assemble bolts M13*1.5*108 1 70±21
seat assembly and the rear Nut M13*1.5 1 70±21
suspension beam Shim 2
Assemble the rear hoisting
seat assembly and the Bolt M8*1.25*22 4 29±5
transmission

48/48
 Part Two Chassis

Chapter Five Brake system

Section One Brake system
Brake pedal …………………………………………………………………………..…002
Brake master cylinder …………………………………………………………….……009
Brake vacuum booster………………………………………………………….………017
Front brake …………………………………………………………………………...…024
Rear brake ………………………………………………………………………………032
Rear brake hose ……………………………………………………………………..…041

Section Two Parking brake

Problem symptom table ……………………………………………………………..…043
Parking draw bar ……………………………………………………………………..…044

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 Brake pedal
Parts

Vehicle model with intermediate cooler Vehicle model without intermediate cooler

No 1 air guiding cover No 2 air guiding cover Support sealing part on water tank

Dashboard lower panel

Washing liquid tank assembly

Heat radiator grill

2 / 62
Left hand vehicle

Vacuum booster assembly

Brake valve body push bar fork

Pin clip

Casing cushion

Pin axle

Spring
clip

Vacuum tube

Brake master
cylinder

Manual gear

Clutch hose

Clutch hard
Spring pipe
clip

Brake hard pipe

Brake hard pipe

Lithium base grease

Appointed button Don’t use the part repeatedly

3 / 62
Brake pedal and
support assembly

Electronic throttle
pedal assembly

Brake pedal fixing

beam

Energy absorption
support

Brake lamp switch Brake pedal support

Adjustment cushion

Buffer cushion
Brake pedal returning
spring

Pedal cover

Appointed button

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Remove
1. Drain out brake liquid
2, Remove the brake master cylinder assembly
3. Remove the heat radiator grill (vehicle model without
intermediate cooler)
4. Remove the sealing element on support of the water
tank (vehicle model without intermediate cooler)
5. Remove No 1 air deflector (vehicle model with
intermediate cooler)
6. Remove No 2 air deflector (vehicle model with
intermediate cooler)
7. Remove the lower protection board assembly of
dashboard
8.Disconnect the U shape clip of the master cylinder push
rod
9. Disconnect the brake pipe
10. Remove the brake booster assembly
11. Remove the booster cushion
12. Disconnect the harness
()Shown as figure, disconnect 2 harness plug-in

13. Remove the electronic throttle pedal assembly

() Remove the electronic throttle through loosing two
nuts.

14. Remove the brake pedal support assembly

() Loosen the bolt.
Note: Don’t remove the bolt, make the bolt maintain
rotating status through loosing the nut.

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 (b) Remove the bolt, the nut and brake pedal support
assembly at 5 locations shown as figure

Failure
1. Remove the energy absorption support
(a) Make the assembly marking on the energy absorption
support and the brake pedal support assembly.
(b) Remove the bolt, the brake pedal fixing frame and the
energy absorption support.
2. Remove the returning spring
3. Remove the brake pedal cover
4. Remove the brake lamp switch
(a) Rotate and remove the brake lamp switch
anti-clockwise
(b) Remove the adjustment cushion
5. Remove the buffer cushion

Adjustment
1. Detect whether height of the brake pedal is correct
(a)Height between the pedal and the bottom board of the
vehicle body: 151.0-161.0mm

2. Adjust height of the brake pedal

(a) Pull off the brake lamp switch plug-in.
(b) Rotate the brake lamp switch clockwise and remove it.
(c) Remove the vacuum booster.
Height of pedal
(d) Loose the U shaped clip locking nut.
(e) Rotate the push rod of the booster to adjust height of
the pedal.
(f) Tighten the U shaped clip locking nut.
Torque requirement: 26N*
(g) Install the vacuum booster.

Regulator

(h) Embed the brake lamp switch into the adjustment

cushion until the switch body slightly contacts the buffer
cushion.
Brake lamp switch Note: Don’t press down the brake pedal.
Cushion

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 。
(i) Rotate about 90 clockwise, and install the brake
lamp switch. Note: Don’t press down the brake pedal.
(j) Connect the brake lamp switch plug-in
(k) Check free clearance of the brake lamp switch.
Free clearance: 0.5~2.6mm

Brake lamp switch

3. Detect free clearance of the brake pedal

(a) Stop the engine, step down the brake pedal for
several times until vacuum degree of the vacuum booster
has no obvious rise.
(b) Press down the pedal until resistant is felt, measure
distance shown as the figure.
Free clearance of the pedal: 1-6mm

4. Inspect distance of the brake pedal travel tolerance

(a) Stop the engine, step down the brake pedal for
Free travel of pedal several times until vacuum degree of the vacuum booster
has no obvious rise.
(b) Loose the parking drawing bar
(c) Open the engine, step down the pedal and
measure distance of the pedal travel tolerance shown as
the figure
Travel distance of the pedal from the floor shall be
greater than 121mm under pedal force of 50N.
Note: move the felt on the floor before
measurement.
Tolerance distance
of pedal travel

Re-assemble
1 Assemble the buffer cushion
2 Assemble the brake lamp switch
(a) Assemble the adjustment cushion.
(b) Rotate and assemble the brake lamp switch
clockwise.
Note: When height of the brake pedal is adjusted,
adjust the installation position of the brake lamp switch.
3 Assemble the returning spring
4 Assemble the pedal cover
5 Assemble the energy absorption support
(a) Assemble the energy absorption support on the
fixing support of the brake pedal.
(b) Align the marking position on the fixing supports of
the energy absorption support and the brake pedal.
(c) Assemble the bolts.
Torque requirement: 26N*m

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Assemble
1. Pre-tighten the brake pedal support assembly
(a) Pre-tighten the brake pedal support assembly and
the dashboard by 5 bolts and 1 nut.

2. Assemble the electronic throttle pedal assembly

(a) Fix the electronic throttle pedal assembly by 2
nuts.
Torque requirement: 5N* m

3. Connect the harness plug-in

(a) Shown as the figure, connect the harness plug-in
at connection location.
4. Assemble the sealing cushion of the vacuum booster
5 Assemble the vacuum booster

6. Tighten the brake pedal support assembly

(a) Tighten 5 bolts and 1 nut on the brake pedal
support assembly.
Torque requirement: 31N* m

(b) Tighten nuts shown in the figure

Torque requirement: 34N* m
7. Assemble the brake pipeline
8. Assemble the push bar of the brake master cylinder
9. Assemble the manual air conditioner assembly
10. Assemble the left headlamp
11. Assemble the right headlamp
12. Assemble No 2 air channel

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 Brake master cylinder
Component

Left hand:

Brake master cylinder and liquid

storage tank sub-assembly

Booster

Manual gear
Alarm switch joint
Clutch hose

Spring clip

Cover

Filter screen

Fixing spring

Rubber cushion
Brake liquid storage tank

Brake master cylinder assembly

Appointed button

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 Second piton

Spring
Master cylinder proper
body

Primary
leather cup

Retaining
shim
First piston

O ring

Primary
leather cup
Nylon sleeve

Force leather
cup
O ring

Secondary
leather cup

Rear cylinder
body

O ring

Lithium base
grease

Appointed button Don’t use parts repeatedly.

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 Remove
1 Drain out brake liquid;
2 Remove the brake master cylinder
(a) Use the spanner to remove tow brake hard pipes
from the brake master cylinder
(b) Remove the alarm harness

Automatic transmission box

(c) Remove the alarm harness

(1) Move the spring clip and remove the clutch
hose

(d) Remove two nuts and remove the fixing support

of the harness.
(e) Remove the booster from the brake master
cylinder
3. Remove the liquid storage tank from the brake
master cylinder
(a) Remove the fixing spring, the liquid storage tank
and 2 rubber cushions from the master cylinder

Disassemble
1. Remove the brake master cylinder
(a) Place the brake master cylinder on the vise and
clamp tightly.

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Special tools
(b) Use the spanner to remove the rear cylinder body
Special tools 09922 — 10010
Note: use the spanner according to schematic.

(c) Remove the rear cylinder body from the master

cylinder.
Note: fix the first piston and avoid falling

(d) Use the screwdriver to remove the secondary

leather cup from the rear cylinder body
Note: Don’t damage the internal surface of the rear
cylinder
Information:
Check direction of the rear cylinder body
Use the adhesive tape to wind the screwdriver
before application
(e) Use the screwdriver to remove the O ring from the
cylinder body
Note: Don’t damage the rear cylinder body
Information: use the adhesive tape to wind the
screwdriver before application
(f) Remove the retaining plate and main leather cup on
the first piston
Information: check direction of the rear cylinder body

(g) Draw out the first piston, the nylon sleeve and the
second sleeve from the master cylinder proper body
Note: don’t damage internal surface of the master
cylinder proper body and the surface of the piston
(h) Remove the spring
(i) Remove the main leather cup and the second piston
from the nylon sleeve
Information: check direction of the rear cylinder body

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 (j) Use the screwdriver, remove the pressure leather
cup from the nylon sleeve
Note: prohibit damage the nylon sleeve.
Information: check direction of the pressure leather
cup
(k) Use the screwdriver to remove O ring from the
nylon sleeve.
Note: prohibit damage the nylon sleeve.

Assemble
1. Assemble the brake master cylinder
(a) Coat lubrication grease on 2 leather cups, the
rear cylinder body and the O ring.
(b) Assemble the pressure leather cup and the O ring
on the nylon sleeve
Note: check direction and dimension of the leather
cup
(c) Assemble the primary leather cup and the spring
on the second spring
Note: check direction and dimension of the leather
cup
(d) Assemble the main leather cup, the second piston
and the spring on the nylon sleeve together.
Lithium base grease
(e) Assemble the primary leather cup and the spring
on the first spring
Note: check direction of the leather cup

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 (f) Assemble the spring, the secondary piston, the
nylon sleeve and the first sleeve on the cylinder body
Note:
Hold the nylon sleeve during assemble
Inspect the nylon sleeve and completely
assemble on the bottom of the cylinder body

(g) Cost lubrication grease on the secondary

leather cup and O sealing ring
(h) Assemble the secondary leather cup and the O
sealing ring on the rear cylinder body
Note: check direction and specification of the rear
cylinder.
(i) Assemble the secondary leather cup and the O
sealing ring on the rear cylinder body
(j) Fix the master cylinder on the vise

Lithium soap base ethylene

glycol grease
(k) Use the spanner to tighten the rear cylinder
body
Special tools Special tools 09922 — 10010
Torque: 11.8N* m
Note: use the spanner according to schematic.
Assemble
1. Detect and adjust the push bar of the booster
Note: adjust the vacuum booster under the
condition without vacuum (step down the brake pedal
for several times when the engine is shut off)
Information: When the new master cylinder is
replaced, adjust the push bar of the vacuum booster.
Don’t adjust the booster when the new master
cylinder is replaced, but the master cylinder shall be
adjusted.

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 (a) Use the marker pen to coat the special
Coat marking
additional end
Information: a new brake master cylinder drives
an additional tool
(b) Place the auxiliary tools on the vacuum booster
(c) Confirm that there is no clearance between the
Auxiliary tools
tools and the vacuum booster
Clearance: 0mm（Oin.）
Information:
Clearance adjustment method:
If there is clearance between the tools and the
casing of the vacuum booster (swing the tools),
Special tools clearance is very small
If the push bar of the booster has no imprint of
the marker pen, there is great clearance
(d) If the clearance exceeds the appointed scope,
use the tools to adjust length of the push bar
Information: When length of the push rod is
adjusted, completely step down the pedal in order to
ensure the push bar completely extrude out.

2. Assemble the liquid storage tank

(a) Assemble 2 metal loops on the liquid storage
tank assembly
(b) Use the fixing clamp tool to assemble the liquid
storage tank on the master cylinder
Note: Detect whether the liquid storage tank is
fixed safely
3. Assemble the brake master cylinder
(a) Use two screws to assemble the brake master
cylinder and the warning harness support
Torque: 12.7N*m
Note: Detect whether the liquid storage tank is fixed
safely

(b) Manual gear

(1) Use the spring clip to fix the clutch hose

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Manual transmission (c) Use SST to fix the brake pipe 2 on the
brake master cylinder
Torque: 15N*m
(d) Assemble the liquid alarm switch

4 Fill in brake liquid

5. Exhaust of the brake master cylinder
6 Exhaust of the brake pipeline
7 Check brake liquid level
8 Detect leakage of brake liquid
Automatic transmission

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 Brake vacuum booster
Parts

Vehicle model with Vehicle model without

intermediate cooler intermediate cooler

No 1 air guiding cover No 2 air guiding cover Support sealing part on

water tank

Dashboard lower
panel

Washing liquid tank

assembly

Heat radiator grill

17 / 62
 Booster assembly

Push bar fork

Pin clip

Booster cushion

Pin axle

Spring clip

Vacuum
tube

Brake master cylinder

Manual gear
Clutch hose

Clutch hard
Spring pipe
clip

Brake pipe Brake pipe

Lithium base
grease
Don’t use the part repeatedly
Appointed button

18 / 62
 Vehicle detection
Correct Wrong 1 Detect the vacuum booster
(a) Air sealing detection
(1) Start up the engine and shut down in 1~2
minutes. Slowly step down the brake pedal for several
times.
Note: if the pedal can be stepped down to the floor
Third in first time, but travel of second time and third time are
First Second not greater than first travel, the booster is sealed.
(2) Step down the brake pedal when the engine
starts up, shut down the engine and continues step
down.
Note: if position of the pedal isn’t changed in 30
seconds, the booster is sealed.
(b) Start detection
(1) When the ignition switch is on off position, step
down the brake pedal for several times, detect change
position of the pedal position.
(2) Step down the brake pedal when the engine
starts up, shut down the engine and continues step
down.
Information: if reduction distance of the pedal is too
small, check whether start-up is normal.

Remove
1. Drain out brake liquid
2, Remove the brake master cylinder
3. Remove the water tank
4. Remove the left cover plate
5. Remove the right cover plate
6. Remove the front bumper
7. Remove the front bumper left support
8. Remove the right headlamp
Removal of the right headlamp is similar to removal of
the left headlamp
9. Remove the left headlamp
Removal of the left headlamp is similar to removal of
the right headlamp
10. Remove the washing liquid tank
11. Remove the lower decoration part of the dashboard
12. Push bar fork of master cylinder
(a) Remove the locking pin, the pin axle and the push
bar fork from the brake pedal

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 13. Remove the brake pipe
(a) Manual gear
(1) Use the spanner and remove the lower clutch
hard pipe from the clutch master cylinder.

(2) Remove 3 hard pipes from the pipe clamp.

(b) Automatic gear transmission
(1) Use the spring hoop to connect two pipelines.

4RB2 engine 14 Remove the vacuum booster

(a) Move the pipe clamp and move the vacuum
pipe.
(b)DK4B engine
(1) Disconnect the vacuum pipeline from the
vacuum booster.

DK4B engine

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 (c) Take out of 4 nuts and the booster assembly
15. Take out of the shim of the vacuum booster
16. Take out of the single direction valve
（） Take out of the single direction valve and the
rubber cushion
17． Take out of the U shape fork of the tappet
（） Lock the locking nut and the U fork shown as
following.
18. Take out of the vacuum alarm switch

Through Inspection
1. Inspect the single direction valve
(a) Inspect the vacuum single valve
(1) Remove the spring clip and remove the
Block
vacuum pipe.
(2) Take out of the single direction valve.
(3) Inspection: Air flows from the booster end to the
engine end; Vice versa, air can’t flow.
(4) If problem is found, replace the single valve.

Assemble
1． Assemble the U shape fork of the tappet
(a) Temporarily assemble the U shape fork and the
locking nut of the tappet.
(b) Rotate the U shape fork according to legend,
meet dimension A
A length: 177±0.5
(c) Tighten the locking nut.
Torque: 26N*m
2 Assemble the single direction valve
(a) Assemble the rubber cushion and the single
direction valve.
3. Assemble the booster cushion
(a) Assemble a new cushion on the casing of the
booster.

4. Assemble the vacuum booster assembly

(a) Use 4 screws to fix the vacuum booster assembly.
Torque: 18~26N*m

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4RB2 engine (b) Connect the vacuum pipe, and fix with the
spring clamp.
5. Assemble the brake hard pipe
(a) Automatic gear transmission
(1) Use the spring clip to connect two pipelines.

DK4B engine

(b) Manual gear

(1) Fix 3 pieces hard pipes by the pipe clips.

(2) Use the spanner to tighten the clutch hard

pipe on the clutch master cylinder.
Torque: 15N* m

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 Pin clip 1. Assemble the U shape fork of the booster tappet.
U shaped fork
（）Coat lubrication grease on the pin screw.
（） The pedal arm matches the U shape fork of the
tappet, use the pin screw and the pin clip to fix.
2. Assemble the U shape fork of the booster tappet.
Pin screw
3. Assemble the brake master cylinder
4. Fill in brake liquid
Lithium grease
10. Exhaust of the master cylinder
11. Exhaust of the brake pipeline
12. Check brake liquid level
13. Check whether the brake system is leaked
14. Check height of the brake pedal

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 Front brake
Components

Front friction shim with

noise reduction shim

Front friction shim

Exhaust bolt
protection cup
Front brake
hose Sealing
shim
Friction abrasion indicator

Exhaust bolt
Front brake
calipers sliding pin
Front brake calipers sliding
pin sleeve
Brake slave
cylinder Protection
sleeve

Front friction shim

support shim

Piston shaft
sealing

Piston

Protection Front friction shim

sleeve support shim

Positioning
clip ring

24 / 62
 Front rotation
speed sensor

Lock
pin

Lock Front brake

pin assembly

Steering ball
head pin

Knuckle
pivot

Lock Front brake disc

pin dust proof cover

Front brake disc

Front lower swing

arm ball head seat

Front hub with bearing

assembly

Appointed button Don’t use parts repeatedly

25 / 62
Replace the friction disc
1.Remove the front wheel
2.Inspect thickness of the front friction disc
(a)Inspect thickness of the friction disc from the
inspection hole of the slave cylinder. If it isn’t within
specified scope, replace the friction disc.
Minimum thickness: 1.0mm
3. Inspect the front wheel
Torque value: 100N*m

Remove
1.Remove the front wheel
2.Drain out brake liquid
3.Disconnect the front brake hose
(a) Remove the oil inlet bolt and the sealing shim from
the brake caliper, and then disconnect the front brake
hose.

4. Remove the brake slave cylinder

(a) Remove 2 wheel bolts and the brake slave cylinder

Remove
1. Remove the front brake friction disc
(a) Remove 2 friction discs with the noise reduction
shim
2. Remove 2 friction discs with the noise reduction shim
(a) Remove 4 the noise reduction shims from the
friction disc
(b) Remove the abrasion indicator from the friction disc
3 Remove the support shim of the front friction shim
4 Remove the support shim of the front friction shim
5 Remove the sliding pin of the front brake caliper
(a) Remove the front brake caliper pin from the brake
caliper

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6.Remove the sliding pin sleeve of the front brake
caliper
(a) Use one screwdriver brake caliper to remove
the sliding pin sleeve of the front brake caliper
Information: Protect the screwdriver by adhesive
tap before use.
7. Remove the sliding pin of the second brake caliper
(a) Remove the second brake caliper pin from the
brake caliper

8. Remove the front brake caliper

(a) Remove two bolts and the brake caliper
9. Remove the protection sleeve
(a) Fix the brake caliper on the vise
(b) Knock down 2 protection sleeves by the screw
driver and the hammer.

10. Remove the protection sleeve of the brake slave

cylinder
(a) Use the screw driver to remove the positioning
clamp ring
Note: Don’t damage inner side of the slave
cylinder and the groove of the slave cylinder
Information: Protect the screwdriver by adhesive
tap before use.
(b) Remove the protection sleeve

11. Remove the piston

(a) Place a rag or the product with similar class
between the piston and the slave cylinder
(b) Use compressed air to remove the piston from
the slave cylinder
Warning:
When compressed air is used, don’t place the
finger in front of the piston
Note: Don’t make brake liquid splash.

27 / 62
12. Remove the piston oil sealing
(a) Use a screw driver to remove the piston oil seal
from the slave cylinder.
Information: Protect the screwdriver by adhesive
tap before use.
13. Remove the protection cup of the exhaust bolt
14. Remove the mechanical bolt
15. Disconnect the front speed sensor
16. Disconnect the steering ball head pin
17. Remove the front brake assembly
18. Remove the ball head seat of the front lower swing
arm
19. Remove the knuckle pivot
20. Remove the front brake disc to check

1. Remove the front brake disc

(a) Inspect rust degree of the slave cylinder and the
piston
2. Measure thickness of the front friction disc
(a) Use the straight rule to measure thickness of the
friction disc
Standard thickness: 10.0mm
Minimum thickness: 1.0mm
3. Inspect the first support shim of the front friction disc
(a) Ensure the No 1 cushion has sufficient support
elasticity, there is no deformation, crack or abrasion,
clean all rust and dirt, replace the first support shim of
the brake disc if necessary.
4. Inspect the second support shim of the front friction
disc
(a) Ensure the No 2 cushion has sufficient support
elasticity, there is no deformation, crack or abrasion,
clean all rust and dirt, replace the second support shim
of the brake disc if necessary.
5. Measure thickness of the brake disc
(a) Use the dial indicator to measure thickness of the
friction disc
Standard thickness: 28.0mm
Minimum thickness: 26.0mm

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 Re-assemble
1． Assemble the front brake disc
2． Assemble ball head seat of front lower swing arm
3． Assemble the knuckle pivot
4． Assemble the front brake
5． Assemble the steering ball head pin
6． Assemble the speed sensor of the front wheel
7． Measure run out of the brake disc
(a) Use the dial indicator to measure run out of the brake
disc at 10mm away from outer edge of the brake disc
Maximum run out of the brake disc: 0.07mm
(b) If run out value exceed maximum value, replace the
brake disc or machine
8. Temporarily tighten the exhaust bolt
9. Assemble and tighten the protection cup of the exhaust
bolt
10. Assemble the piston oil sealing
(a) Coat Lithium soap base ethylene glycol grease on
the oil sealing of the new piston
(b) Assemble the oil sealing of the piston on the piston
Note: Ensure assemble the oil sealing of the piston on
position.

11. Assemble the piston

(a) Coat Lithium soap base ethylene glycol grease on
the piston and the protection sleeve.
(b) Assemble the protection sleeve on the piston
Note: Ensure assemble the protection sleeve on the
piston groove.
Lithium soap base ethylene glycol grease (c) Assemble the piston on the brake slave cylinder.
Note: Don’t assemble the piston on the brake slave
cylinder by force.

12. Assemble the protection sleeve

(a) Assemble the protection sleeve on the brake slave
cylinder
Note: Ensure assemble the protection sleeve on the
brake slave cylinder groove.
(b) Use a screwdriver to assemble a new positioning
snap spring
Note: Don’t damage the protection sleeve.
Information: Protect the screwdriver by adhesive tap
before use.
13. Assemble the protection sleeve of the first sliding pin
(a) Use the vise to fix the brake slave cylinder.

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 (b) Coat Lithium soap base ethylene glycol grease on
surface of the protection sleeve sealing opening of two
new sliding pins.
(c) Use the opening spanner of 21mm and the
hammer to assemble the protection sleeves of two
guiding pins

14. Assemble the front brake caliper

(a) Use two bolts to assemble the front brake
calipers.
Torque: 123N*m
15. Assemble the sliding pin of the second brake
caliper
(a) Coat lithium soap base ethylene glycol grease on
the sliding pin groove and the surface of the front brake
caliper
(b) Assemble second sliding pin on the brake
Lithium soap base calipers.
ethylene glycol grease

16. Assemble the front brake slave cylinder

(a) Coat lithium soap base ethylene glycol grease on
the surfaces of the new brake slave cylinder and the
sliding pin
(b) Assemble the brake slave cylinder on the sliding
pin

17. Assemble the sliding pin of the front brake caliper

(a) Assemble the brake caliper on the sliding pin of
the brake caliper.
18. Assemble the front brake caliper

19. Assemble the front friction shim with the noise

reduction shim
(a) Coat grease between the first clearance reduction
shim and the friction block.
(b) Assemble the clearance reduction shim on the
friction block
Disc type friction grease
(c) Assemble the indicators of two abrasion shims on
the friction block
20. Assemble the front friction shim
(a) Assemble two friction shims with the friction shim
abrasion indicator on the brake calipers.

Grasp Assemble
1. Assemble the front brake slave cylinder
(a) Use two bolts to assemble the front brake slave
cylinder.
Torque value: 34N* m

30 / 62
2. Connect the front brake hose
(a) Use the oil inlet bolt and the new shim to connect the
front brake hose
Torque value: 30N*m
Note: Ensure assemble safety of the front brake hose
oil inlet bolt
3 Fill in brake liquid
4. Exhaust of brake liquid
5. Check height of brake liquid
6. Inspect whether brake liquid is leaked
7. Assemble the front wheel
Torque value: 100N*m

31 / 62
 Rear brake
Components
Positioning pin

Rear hub shim

Rear brake drum

Shoe clearance
adjustment bar
Shoe draw bar

Rear shoe

Tension spring
Parking brake
draw bar

Front shoe

Automatic
adjustment bar

C type shim

Tension spring

Spring
Shoe positioning positioning seat
spring

Shoe low support

Shoe positioning Tension spring

spring

Spring Shoe returning

positioning seat spring

Don’t use part repeatedly High temperature grease

32 / 62
 Brake pipeline

Inspection hole plug Protection

cover

Piston

Exhaust bolt Compression

protection cup spring

Exhaust bolt

Leather cup
Rear brake slave Leather cup
Protection cylinder
cover Piston

Lithium soap base

ethylene glycol grease Rear brake slave
cylinder assembly
Appointed button Don’t use part repeatedly

Remove the rear brake

1. Inspect thickness of the friction disc
(a) Remove the inspection hole, and then
inspect thickness of the inspection hole. If it is less
than minimum value, replace the friction shoe.
Minimum thickness: 1.0mm

Remove
1. Remove the rear wheel
2. Drain out brake liquid

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 3. Remove the rear brake drum
(a) Loose the parking brake, and remove the brake
drum.
Information: if the brake drum is difficult to
Shrink remove, implement following steps.
(b) Remove the inspection hole plug on the rear
board, use the screw driver run through the inspection
hole on the rear board, and then fix the automatic
regulation bar and make it away from the regulation
bolt
(c) Use another screw driver to rotate the regulator
so as to reduce travel of the friction shoe regulator.
4. Remove the rear hub shim

5. Remove the automatic regulation bar

(a) Remove the self-regulation spring and the
tension spring.

6. Remove the brake shoe

(a) Use the special tools to remove the returning
spring.

Special tool

7. Remove the brake shoe

(a) Use the nipper pliers to remove the returning
spring.

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 (b) Use the special tools to remove the positioning
spring, the positioning spring seat and the latch.

Special tool

(c) Remove the lower support frame of the shoe

(d) Remove the returning spring and the front brake
shoe

8. Remove the rear brake shoe

(a) Use the special tools to remove the positioning
spring, the positioning spring seat and the latch.

(b) Disconnect the parking draw wire, and then

remove the rear brake shoe

9. Remove the automatic regulation bar

C type shim
Shoe draw bar (a) Use the screw driver to remove the C ring, the
automatic regulation bar, the parking brake draw bar
Shoe clearance
adjustment bar and the shoe draw bar from the brake shoe.
(b) Remove the adjustment bar and the tension
spring from the automatic adjustment bar.
Brake shoe

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10. Remove the rear brake slave cylinder
(a) Use the special tools to disconnect the brake
pipeline and use a vessel to contain brake liquid.
(b) Remove two bolts and the slave cylinder
11. Disassembly of the rear brake slave cylinder
(a) Disassemble two protection sleeves
(b) Remove two pistons
(c) Remove two piston leather cups
12. Remove the exhaust bolt

Detection
1. Measure inner diameter of the brake drum
(a) Use the vernier callipers gauge to measure
inner diameter of the brake drum
Standard inner diameter: 256mm
Maximum innder diameter: 254mm
Note: if the brake drum is scratched or abraded,
machine the brake drum, but it is only machined to
maximum inner diameter.

2. Measure thickness of the brake friction disc

(a) Use the straight rule to measure thickness of
the friction disc
Standard thickness: 5.1mm
Minimum thickness: 1.0mm
Information: if thickness of the shoe is less than
minimum value or abrasion is uneven, replace the
brake shoe.

3. Check whether contact between the friction disc

and the brake drum is suitable
(a) Measure the inner surface of the brake drum
and the external surface of the friction disc.
Information: if contact between the brake
friction disc and the brake drum is unsuitable, sue
the brake shoe shim grinder to correct and replace
the brake shoe assembly.

4. Inspect the brake slave cylinder

(a) Measure inner diameter of the brake drum and
diameter of the brake shoe, check whether diameter
between them is correct brake shoe clearance.
Information: if is incorrect, check the parking
brake system.

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 Assemble
1. Assemble the exhaust bolt
2. Assemble the rear brake slave cylinder
assembly
(a) Coat grease on two new leather cups and the
piston.
(b) Assemble two leather cups on the piston.
(c) Assemble the compression spring and the two
pistons on the rear brake slave cylinder.
(d) Assemble the protection cover on the rear
brake slave cylinder.
3. Assemble the rear brake slave cylinder assembly
(a) Use two bolts to assemble the rear brake slave
cylinder.
Torque value: 9.5N* m
(b) Use the special tools to connect the brake
pipeline.
Torque value: 15N*m

4. Coat high temperature grease

(a) Coat high temperature grease on the rear
brake base board.

High temperature
grease

5. Assemble the automatic regulation bar

(a) Coat high temperature grease on the
automatic regulation gear.
(b) Assemble the tension spring on the automatic
regulation bar.

High temperature
grease

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 6. Assemble the rear brake shoe
Shoe draw bar C type shim
(a) Use the calipers to assemble the rear brake
Shoe clearance shoe, the automatic regulation bar, the shoe draw
adjustment bar
bar and the parking brake draw bar through C shape
cushion.

Brake shoe

(b) Connect the parking brake draw wire with the

front brake shoe.

(c) Use the special tools to assemble the rear

brake shoe, the positioning pin, the positioning
spring and the positioning spring seat.

7. Assemble the front brake shoe

Special tool
(a) Assemble the returning spring on the brake
shoe.

(b) Use the special tools to assemble the front

brake shoe, the positioning pin, the positioning
spring and the positioning spring seat.
Special tool

(c) Assemble the brake shoe support frame

Note: ensure the brake shoe support frame and
the parking brake drawing bar are assembled on
position.

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 (d) Use the nipper pliers to assemble the tension
spring

8. Connect the shoe clearance regulation bar

(a) Use the special tools to assemble the upper
tension spring.

Special tool

9. Assemble the automatic regulation bar

(a) Assemble the automatic regulation bar and
the tension spring.
Note: ensure the automatic regulation bar is
between the shoe clearance regulation bar and the
brake shoe.
10. Assemble the automatic regulation bar
(a) Check whether assembly of each part is
correct.

Left

Front

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 Note: don’t coat oil and grease on the surfaces of
the shoe and the brake drum.
(b) If assembly is wrong, assemble according to
above steps again.

11. Assemble the rear hub shim

(a) Assemble the new hub shim on the hub bearing.
12. Assemble the rear brake drum
13. Adjust the shim clearance regulation bar
(a) Assemble the new hub shim on the hub bearing.

Expand

(b) Use another screwdriver to adjust the automatic

regulation bar and make the shoe shrink and not
contact the brake drum.
(c) Assemble the hole plug.
14 Fill in brake liquid
15. Exhaust of brake liquid
Shrink 16. Check height of brake liquid
17. Assemble the rear wheel
Torque value: 100N*m
18. Inspect the parking operation mechanism
19. Adjust the parking operation mechanism

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 Rear brake hose
Components

Clip

Rear brake hose

Appointed button Don’t use part repeatedly

Remove
1. Remove the rear wheel
2. Drain out brake liquid
3. Remove the rear brake hose
(a) Use the special tools to disconnect the brake
pipeline and remove the brake hose.
Note: don’t bend and damage the brake pipeline
(b) Remove the clip
(c) Use the special tools to remove the rear brake
hose

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Assemble
1. Assemble the rear brake hose
(a) Use the special tools to assemble the rear
brake hose
Torque value: 23N* m
(b)Use the new clip to assemble the rear brake
hose
Note: when the rear brake hose is assemble,
align the installation hole of the frame and make
the twist of the brake hose minimum;
Assemble the clip firm as possible;
Prohibit dirt etc sundries falling into the brake
pipeline from the connection point.
(c)Use the special tools to connect the brake
pipeline with the brake hose.
Torque value: 15N* m
Note: don’t bend and damage the brake
pipeline
2 .Fill in brake liquid
3.Exhaust of brake liquid
4.Check height of brake liquid
5.Inspect whether brake liquid is leaked
6.Assemble the rear wheel
Torque value: 108N*m

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 Parking brake system
Problem symptom table
Symptom Problem area
Brake is lagged Parking drawing bar (lose adjustment)
First parking draw wire (adhesion)
Third parking draw wire (adhesion)
Brake shoe clearance (lose adjustment)
Brake shoe sleeve (broken or twisted)
Drawing spring (damaged)

Adjust
1. Inspect travel of the parking brake handle
() Pull up the parking brake handle balanced
() Release the parking brake locking button and return
the brake handle on the closed position
() Slowly pull up the parking handle to full travel and
count its sound.
Travel of the parking brake handle: it is 200N*m when
it is 10~16 sounds
Information:
Nut
If sound is out of the specified scope, release the
parking brake locking button and adjust it.
If sound is less than specified value, loose the
Parking adjustment regulation nut and the locking nut of the parking draw
nut
wire. Loose the parking drawing wire; adjust clearance
between the brake drum and the sleeve.
2. Remove the rear wheel
3. Adjust clearance of the rear brake shoe
4. Assemble the rear wheel
Torque: 100N*m
5. Adjust travel of the parking brake handle
(a) Lift up the handle
(b) Press down the parking brake handle, and use the
spanner to control the parking adjustment nut and loose
the locking nut.
(c) Rotate the parking adjustment nut until travel of the
parking brake handle is in accordance with above
specification, travel of the parking brake handle is 200N*m
when it is 10~16 sounds.
(d) Lift up the vehicle
(e) Press down the parking brake handle, and use the
spanner to control the parking adjustment nut and loose
the locking nut.
(f) When the parking brake handle starts to work,
inspect whether the parking brake indicator can work
Standard: the brake warning lamp is always on when first
sound is sounded
(g) Use the spanner to control the parking brake
adjustment nut, tighten the locking nut
Torque: 14.5N*m
(h) Drop down the vehicle

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 Parking draw bar
Components

First lower protection board

assembly of dashboard

Manual air conditioner

assembly

Manual brake gap protection

board

Parking brake handle assembly

Appointed button Apply MP lubrication oil

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 Parking brake draw bar
protection sleeve

Parking brake draw bar

pin

Parking brake clip

Parking brake draw bar
assembly
Parking brake clip spring

Parking brake draw bar

sleeve

Parking brake switch

assembly

Parking brake
Inner surface of hole pin
guiding bar

Parking brake draw

bar guiding bar Parking brake
protection cover

Pin

Parking brake draw wire

pulley

Clip
Parking brake draw wire
pulley hole pin

Support

First parking brake draw rope

assembly
Apply MP lubrication oil

Appointed button Don’t use part repeatedly

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Widen lower protection board of vehicle body

Lower protection board at front of engine

Lower protection board 2 of

engine

Appointed button

Remove
1. Remove the engine lower protection board 1
2. Remove the engine lower protection board 2
3. Disassemble the manual air conditioner assembly
4. Remove the dashboard lower protection board
assembly 1
5. Remove the hand brake gap cover
6. Remove the dashboard to the assembly of the floor
support
7. Remove the parking brake handle assembly
(a) Release the parking brake handle
(b) Remove 2 bolts

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 (c) Disconnect the parking brake switch connector

(d) Release the parking brake handle

(e) Remove 2 fixing nuts and separate the parking

brake handle from the vehicle body
(f) Remove 4 fixing nuts and separate the parking
brake draw rope assembly 1 from the vehicle body
(Program A)

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(g) Separate the parking brake draw rope 1 from the manual
brake operation rocker arm (program B)
(h) Remove the clip.

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(i) Remove 2 fixing nuts and separate the parking brake draw rope
assembly 1 from the vehicle body.
(j) Draw the parking brake draw rope assembly 1 into the cabin;
remove the parking brake control handle

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Disassembly
1. Remove the parking brake draw rope assembly 1
(a) Remove the parking brake draw bar cover

(b) Remove the clip

(c) Remove the clip from the parking brake draw rope
pulley hole pin

(d) Remove the parking brake draw rope pulley hole

pin and the pulley

(e) Remove the parking brake switch assembly

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 (f) Move the parking brake clip, loose the locking,
push in the parking brake draw bar assembly, shown
as figure.

(g) Separate the parking brake draw rope assembly

1 from the parking brake draw bar assembly

(h) Separate the parking brake draw rope assembly

1 from the frame

2. Remove the parking brake draw bar assembly.

(a)Use a punch roller （Φ 3mm） and a hammer to
remove the parking brake draw bar pin.

(b) Use a small screw driver to remove the parking

draw bar protection ring.
Information: rotate the parking draw bar
protection ring and remove it from its end.
Use the tape to wrap the tip of the screw driver
before use.
(c) Remove the parking brake draw bar from the
parking brake draw bar guiding bar.

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 (d) Use a small screw driver to remove the parking
draw bar sleeve.
Note: Don’t damage the parking draw bar guiding
bar.
Information: Use the tape to wrap the tip of the
screw driver before use.

(e)Use a drill （Φ 4mm）to remove the marking part

of the parking brake rotation pin.
Note: Don’t damage the parking draw bar guiding
bar.
(f) Remove 2 manual brake clip rotation pins, 2
manual brake clips and 2 springs.

Assembly again
1. Assemble the parking draw bar assembly
(a) Coat MP grease on 2 new parking brake clips
and 2 rotation pins
(b) Assemble 2 manual brake clips and springs on
the parking brake draw bar guide bar.
(c) Assemble 2 manual brake clip rotation pins.
(d) Use a metal block under one end of the manual
brake clip, and slightly tap at another end, pile enters
into.
Note: Don’t damage the draw bar guiding bar.

(e) Use the screw driver and assemble one new

parking brake draw bar sleeve on the guiding bar of
the parking brake draw bar.
Note: Don’t damage the draw bar guiding bar.
Information: Use the tape to wrap the tip of the
screw driver before use.

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 (f) Move the 2 manual brake clips (A), loose the
locking, push in the parking brake draw bar assembly
(B), shown as figure.

(g) Assemble one new parking brake draw bar

protection ring on the parking brake draw bar
assembly.

(h) Use the hammer; assemble the parking brake

Parallel
draw bar rotation pin on the position shown in figure.
Note: Parallel to the installation draw bar rotation
pin of the parking brake switch frame.

2. Assemble the parking brake draw rope assembly 1

(a) Assemble the parking brake draw rope
assembly 1 on the frame.

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 (b) Move the 2 manual brake clips (A), release
and push in the parking brake draw bar assembly
(B), shown as figure.

(c) Connect the parking brake draw rope

assembly 1 with the parking brake draw bar
assembly
(d) Assemble the frame on the parking brake draw
bar guide bar.

(e) Coat MP grease on the parking draw wire

pulley pin.
(f) Push the parking brake draw wire pulley,
shown as figure; assemble the parking draw wire
pulley rotation pin.
Use MP grease

(g) Assemble the clip on the parking draw wire

pulley rotation pin.

(h) Assemble the clip.

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 (i) Assemble the parking brake switch
Torque: 8.8N*m

(j) Assemble the parking brake draw bar cover

Assemble
1. Assemble the parking brake handle assembly
(a) Run the parking brake handle assemble 1
through the cabin.

(b) Use 2 bolts to assemble the parking brake draw

rope assembly 1.
Torque: 8.5N*m

(c) Use the nut and assemble the parking handle on

the vehicle body. Torque: 20N*m
Information: drop down the handle when the
parking brake handle is assembled.

(d) Return the parking handle back to its initial

position.

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 (e) Assemble 2 bolts on the parking handle.
Torque: 20N*m

(f) Connection the parking brake switch assembly

(g) Coat MP grease in the connection part of the
parking brake draw rope assembly 1 and the parking
intermediate level.
(h) Assemble the parking brake draw rope
assembly 1 on the intermediate level (program B)
(i) Assemble the clip on the parking draw rope
assembly 1.
(j) Use 4 bolts to assemble the parking brake draw
rope assembly 1 on the vehicle body.
(Program A)
Torque: 14.5N*m

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3. Remove the sub-assembly between the dashboard and the floor.
4. Assemble the parking brake gap cover
5. Assemble the lower protection board assembly 1 of dashboard
6. Assemble the manual air conditioner assembly
7. Assemble the engine lower protection board 2
8. Assemble the engine lower protection board 2
9. Assemble the engine lower protection board 1
10. Remove the rear wheel
11. Adjust clearance of the rear brake shoe
12. Assemble the rear wheel
Torque: 100N*m
13. Adjust travel of the parking brake handle

57 / 62
Wide vehicle body:

Parking brake draw rope

assembly 2

Parking park adjustment

nut
Locking nut

Parking brake draw

rope assembly 3

Appointed button

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 Shoe compression
spring

Rear brake
Parking brake shoe
shoe support
Automatic device
adjustment level
Shoe
Front brake shoe compression
spring washer
Brake shoe
lower support

Shoe compression
spring

Tension spring
Tension spring Shoe returning
spring
Shoe compression
spring Shoe
compression
spring washer

Rear brake hub washer

Rear brake drum

Lithium soap base
ethylene glycol grease Don’t use part repeatedly

Remove
1. Remove the rear wheel
2. Remove the rear brake drum

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 9. Remove the parking brake draw rope assembly 3
(wide vehicle body)
(a) Remove 2 fixing nuts and separate the parking
brake draw rope assembly 3 from the support
surface.

(b) Remove 6 bolts, nuts and the parking brake

draw rope assembly 3.

() Remove the parking brake draw rope assembly 3 from the parking brake
balancer.

Assemble
1. Assemble the parking brake draw rope assembly 3 (Narrow vehicle body)
(a) Assemble the parking brake draw rope assembly 3 on the parking brake
balancer.
(b) Assemble bolts and nuts on the parking brake draw rope assembly 3.
Torque: 14.5N*m

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 (c) Use 2 bolts to assemble the parking brake
draw rope assembly 3 from back
Torque: 8.0N*m
3. Use high temperature grease
4. Assemble the rear brake shoe
5. Assemble the front brake shoe
6. Connect the support equipment of the parking
brake shoe
7. Assemble the automatic regulation bar
8. Assemble the rear axle brake hub lining sleeve
9. Assemble the rear brake hub
10. Inspect travel of the parking brake control handle
11. Remove the rear wheel
12. Adjust clearance of the rear brake shoe
13. Assemble the rear wheel
Torque: 100N*m
14. Adjust travel of the control handle

61 / 62
 Problem symptom table

Symptom Doubt area

Abnormal noise Inflation of front wheel is improper, abrasion of tire is uneven
Liquid level of the steering oil tank is low
Positioning parameters of the front wheel is improper
Front suspension
Abrasion of hub bearing of front wheel
Fault of the steering column assembly
Lower axle fault of the steering column assembly
Fault of steering driving axle assembly
Fault of steering reducer assembly
Fault of steering oil pump (4RB2)
Fault of steering oil pump (DK4B)
Fault of power steering assembly

On-board inspection
1. Inspect free travel of the steering wheel
Maximum free travel (rotation clearance of the steering wheel)
(a) Stop the vehicle and place the vehicle on
the straight position.
(b) Rotate the steering wheel left and right
slightly and slowly, check movement distance
of one point on wheel edge.
Maximum free travel: 30mm
If maximum free travel exceeds specified
maximum value, inspect the steering system.

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 Part Two Chassis
Chapter One KS2-- Transmission 025D/025A model
Structure features ……………………………………………………………………….….……002
Structure schematic figure…………………………………...…….……………………...……002
Technical parameters ……………………………………………………………………….…...003
Reasonable application and servicing ………………………………….…………………....…003
Disassembly of transmission …………………………………………….…………………….…004
Assembly of transmission ……………………………………………….……………………..…006
Adjustment technical conditions ………………………………………………………….………014
Assembly precautions ………………………………………………….…………………….…014
Fault and troubleshooting …………………………………………………………………………014

1
I. Structure features:

The product is manual mechanical type three axles transmission, operation way is the floor

type direct operation, and there are five forward gears and one reverse gear. All gears apply the

sliding block type synchronizers (first gear and second gear are multiple taper synchronizers), the

reverse gear is sliding moving system; the whole product applies the cordwood type divided

structure, wholly aluminum alloy case, die casting aluminum alloy transmission fork, the gear

applies small modulus and slender gear, and carries out strengthening spot peening treatment; so

the product is characterized with compact structure, strong variant capability (match several

engines), high strength, high performance, low noise and light weight etc advantages.

II. Structure schematic figure:

Third gear and fourth First gear and second

gear synchronizer gear synchronizer
Clutch case First gear Fifth gear
component component

Front cover Third gear Intermediate plate; Driving gear of odometer

Second gear Bearing baffle of output axle Cover plate

Output axle

Input axle

Rear body
Intermediate fifth gear
Linkage gear of component
intermediate axle Fifth gear and sixth gear
Reverse idle wheel synchronizer component
Disengagement Reverse idle wheel component Reverse gear synchronous taper
shifting fork
component of clutch Transmission case
Slave cylinder assembly of
clutch

▲Warning: This product shall be engaged

on some one gear during transportation and
installation process, prohibit upright or
make it bear strong impact on idle status.

2
III. Technical parameters

Centre distance 82
(mm)
Input torque (N.m) 350
Net weight (kg) 52
Gear
Gear 1 2 ratio
Gear 1 2
Gear
ratio Speed Speed
ratio
4.313 2.330 ratio
4.313 2.330
Speed ratio of
3.167（19/6）
odometer
Type of lubrication Gear oil 75W/90（GL‐4）
oil
Lubrication oil 2.8L
capacity ( L )
DK4A/4RB2
Matched engine
Drawing wire long distance operation
Operation type
type

Gear mode

IV. Reasonable application and servicing

1. Correct gear shifting

a. Select appropriate time to carry out normal gear shifting according to vehicle speed and road
conditions. The clutch shall be completely disengaged during shifting, gear shifting force shall
be flexible, prohibit use force hardly so as to avoid synchronization fail.
b. Prohibit start at high speed so as to avoid damaging the gear.
c. Don’t always put the hand on the gear shifting bar during running process of the automobile,
so as to avoid early abrasion of the gear shifting fork.
d. It must stop to shift gear when the vehicle is reverse so as to avoid gear shifting noise and
damaging the gear.
2. Sufficiently lubricate
a. Use the standard lubrication oil, brand of lubrication oil is: API GL‐4 SAE75W/90; prohibit
use the bad lubrication oil, lubrication oil of different brands is not allowed to be mixing used.
b. Lubrication way of the product is splashing lubrication, lubrication oil shall be filled in
according to requirement (2.8L), i.e.: when the vehicle is parked on the level road, lubrication oil
shall be filled in at same level with the oil filling port.

3
 3. Inspection and replacement of lubrication oil
a. Lubrication oil in the transmission must be replaced after the new vehicle (run in status)
travels about 1500km.
b. Check oil level once when it travels every 10 thousands kilometer. Supply lubrication oil when
it is insufficient until lubrication oil is filled in to same level as the oil filling port; replace
lubrication oil in case there is dilution, gumming and too dirt etc. phenomenon.
c. Replace oil once when it travels every forty thousand kilometer, and disassemble for
inspection and cleaning.
v. Disassembly of the transmission
1. Remove the disengagement bearing sub-assembly of the clutch, the disengage shifting fork,
the clutch case, the front cover component, the bearing snap ring of the input axle, the front
bearing snap ring of the intermediate axle, the shifting rod sub-assembly, the operation cover
component, remove the component of the positioning mechanism, the rear body sub-assembly
and the case body. Refer to attached figure 1 and attached figure 5 for details.
2. Remove the operation part in the intermediate plate (take away of the positioning screw plug,
the gear, the steel ball, the shifting fork positioning bolt, the elastic pin, the fork axle of each gear,
the interlock pin, the interlock guiding pole and the shifting fork in each gear in order). Refer to
attached figure 2 for details.
Concrete steps are:
a. Remove each fork axle positioning screw
plug, the spring, the steel ball, and remove
each elastic round pin, the positioning screw
and the clamping snap ring. (use the punch to
move the pin out when each elastic round pin is
removed)

b. Remove the gear shifting fork axles of the third gear and the fourth gear in order; remove the
gear shifting fork axles of the first gear and the
second gear, take out of the interlock pin and
the interlock guiding pole; Remove the reverse
gear shifting fork axle, the interlock guiding pole
and the steel ball; remove the fifth gear and
sixth gear shifting fork axle.

c. Remove the reverse gear rocker arm, the

reverse shifting rod, the fifth gear and the sixth

4
gear shifting forks, the first gear and the second gear shifting forks, the third gear and the fourth

gear shifting forks.

3. Remove the operation part in the in the intermediate plate component. Refer to attached
figure 3 and attached figure 4 for details.
a. Remove the snap ring for the driving wheel
of the odometer, the driving gear of the
odometer, the steel ball, the snap ring for the
axle and the deep groove ball bearing in
order.
b. Remove the snap ring for the axle, the
middle sixth gear sleeve, the middle sixth
gear component, the roller bearing and the
steel ball; remove the fifth gear and the sixth
gear synchronizers component, middle fifth
gear component, the roller bearing, the
middle fifth gear sleeve and the steel ball in
order.
c. Remove the output axle bearing baffle, the
reverse idle wheel axle and the reverse idle
wheel component in order.
d. Remove the intermediate axle
sub-assembly and the bearing in the
intermediate axle.
e. Take out of the input axle component, the
third gear and the fourth gear synchronizer
gear rings, the roller bearing.
f. Remove the output axle sub-assembly; and
then remove the reverse rocker arm support.

5
4. Finally disassemble the input axle component, the output axle sub-assembly in order, refer to
attached figure 4 for details.
Note: Refer to assembly of the transmission
which is described later (disassembly is
reverse process of assembly).
Gap of gear VI. Assembly of transmission
sleeve
1. Assembly of the output axle sub-assembly:
(a) Assemble the third gear and the fourth
gear synchronizer components as figure:
Hub slope
install the third gear roller bearing, the third
gear component, the third gear
synchronizer gear ring, the third gear and
the fourth gear synchronizer components in
turn, finally assemble the snap ring for the
axle.
(Optionally assemble, axial clearance is 0.1mm and below).
Note: one side of the third gear and the fourth gear synchronizer gear hub with slope faces toward
the input axle, one side of the third gear and the fourth gear synchronizer gear sleeve with the
chamfer gap faces toward the input axle (shown as above figure); opening directions of the two
spring piston rings shall be staggered.
Gear ring （b） Assemble the first gear and the second
Inner ring
gear synchronizer components shown as
figure: assemble the second gear roller
bearing, the second gear component, the
second gear synchronizer gear ring, the first
gear and the second gear synchronizer
Middle ring components, the snap ring for the axle in
order（optionally assemble, axial clearance is
0.1mm and below）, the shock insulator; and
then assemble first gear roller bearing, the
first gear synchronizer gear ring, the first gear
component, the round pin (coat lubrication
grease) in order;
finally assemble the sixth gear, the spacer sleeve and the fifth gear.
Note: The extruded position on the synchronizer gear ring component shall be aligned with the
gap on the gear hub and the combination gear (shown as above figure). There is small
protuberance on the tooth missing location of the first gear ring (distinguish with the second gear
ring).

2. Assemble the output axle sub-assembly on the intermediate plate.

6
 (a) Assemble the hollow round pin (4 pieces)
and the reverse rocker arm support on the
intermediate plate.
(b) Draw the output axle with taping the
intermediate plant, and assemble the output
axle on the intermediate plate.
(c) Install the bearing snap ring by the snap ring
plier (the snap ring shall adhere to surface of
the intermediate plate).

3. Assemble the input axle on the output axle.

Align (a) Assemble the input axle on the axle,

assemble the bearing snap ring by the
snap ring plier (Optionally assemble, axial
clearance is 0.1mm and below).

(b) (b) Assemble the roller bearing and the

third gear synchronizer gear ring;
assemble the output axle sub-assembly on
the output axle, make three slots of the
gear ring align to the sliding block of the
synchronizer.

4. Assemble the intermediate axle on the intermediate plate

(a) Assemble the front bearing of the
intermediate axle on the intermediate axle, and
then assemble the snap ring for the axle
(Optionally assemble, axial clearance is 0.1mm
and below).
(b) Assemble the intermediate axle
sub-assembly on the intermediate plate, and
hold the intermediate axle and assemble on the
bearing in the intermediate axle.
5. Assemble the reverse idle wheel and the bearing baffle
(a) Assemble the reverse idle wheel and the
axle.
(b) Assemble the intermediate bearing baffle
(the baffle foot is assembled in the axle groove
of the idle wheel), tighten the screw.
Tighten torque: (refer to table)

7
 6. Install the intermediate sixth gear components.
Coat lubrication grease on the steel ball and
then assemble on the output axle, and then
assemble the intermediate sixth gear sleeve,
the roller bearing and the intermediate gear
component.

7. Assemble the fifth gear and the sixth gear synchronizer components and the intermediate fifth
gear component.
Assemble the third gear synchronizer gear ring, the
fifth gear and the sixth synchronizer component,
and then assemble the steel ball, the third gear
synchronizer gear ring, the intermediate fifth gear
component, the roller bearing, and the intermediate
fifth gear sleeve, and finally assemble the snap ring
for the axle (Optionally assemble, axial clearance is
0.1mm and below).
Note: One side of the fifth gear and the sixth gear synchronizer gear sleeve with the large chamfer
(distinguish with the third gear and the fourth gear tooth sleeve) faces towards the intermediate
fifth gear.
8. Assemble the rear bearing of the output axle and the driving gear of the odometer.
(a) Use the special tool to assemble on the rear
bearing of the output axle, and assemble the snap
ring for the axle (Optionally assemble, axial
clearance is 0.1mm and below).
(b) Assemble the snap ring for the odometer axial,
the steel ball, the driving gear of the odometer and
the snap ring for the axle (Optionally assemble,
axial clearance is 0.1mm and below).
9. Assemble the shifting fork of each gear.
Assemble the shifting forks of the first gear and
second gear, the third gear and the fourth gear,
the fifth gear and the sixth gear.

10. Assemble the shifting fork axle of the fifth gear and the sixth gear.

8
(a) Assemble the reverse gear shifting fork on the reverse rocker arm, assemble the opening snap
ring; and then assemble the opening end of the reverse gear rocker arm on the support of the
reverse gear rocker arm.
(b) Assemble the shifting fork axle of the fifth gear and the sixth gear on the reverse gear shifting
rod, the intermediate plate and the shifting fork of the fifth gear and the sixth gear.
11. Use the magnetic bar to assemble the
interlock steel ball on the intermediate plate.

12. Assemble the interlock guiding pole.

Coat lubrication grease on the interlock guiding pole, and make it assembled on the reverse gear
shifting fork axle.
13. Assemble the reverse gear, the first and the second gear, the third and the fourth gear shifting
fork axle.
Run the reverse gear shifting fork axle through the intermediate plate and the reverse gear shifting
rod, use the magnetic rod to assemble the interlock pin on the intermediate plate; assemble the
interlock guiding pole into the first gear and the second gear shifting fork axle, run the shifting fork
axles of the first gear and the second gear through the intermediate plate and the gear shifting fork
of the first gear and the second gear; use the magnetic bar to assemble the short interlock pin into
the intermediate plate, use the interlock guiding pole to assemble into the gear shifting fork axle of
the third gear and the fourth gear, run the gear shifting fork axles of the third gear and the fourth
gear through the intermediate plate and the gear shifting fork of the third gear and the fourth gear,
the gear shifting fork of the first gear and the second gear.

9
(Refer to figure in step 10, 11 and 12)
14. Assemble the positioning screw, the elastic round pin and the clamping snap ring
(a) Use the steel bar and the hammer to tap into
the clamp snap ring of the fork axle.
(b) Use the punch and the hammer to punch the
elastic round pin into the pin hole.
(c) Assemble the positioning screw of the gear
shifting fork, and tighten the screw. Tighten
torque: (Refer to table)

15. Assemble the steel ball, the spring and the screw plug.
(a) Coat sealant agent on the thread of the
positioning spring screw plug.
(b) Assemble the steel ball and the positioning
spring (each 4 pieces).
(c) Use the torque spanner to tighten the screw
plug during assembly of the positioning spring
screw plug. Tighten torque: (refer to table)

16 Assemble the transmission case

(a) Shown as figure, coat sealant agent on the
conjunction surface between the transmission
case and the intermediate plate (the glue line is
enclosed at inner side of the thread hole).

10
 (b) Assemble the transmission case on the
intermediate plate.
(c) Use the snap ring plier to assemble two
bearing snap rings on the bearing of the input
axle and the front bearing of the intermediate
axle respectively.

17. Assemble the front cover component.

(a) Assemble the oil seal of the front cover into
the front cover (pay attention to installation
direction); coat the sealant on the conjunction
surface (the glue line is enclosed at inner side
of the thread hole).
(b) Coat the sealant on the thread of the bolt.
(c) Assemble the front cover, tighten the bolt.
Tighten torque: (refer to table)

18. Assemble the rear body component

(a) Assemble the components in the rear body:
the oil guiding nozzle, the roller bearing.
Sealing material
(b) Shown as above figure, coat sealant on the
rear body (the glue line is enclosed at inner side
of the thread hole).Tighten torque: (refer to
table)
(c) Place the gear shifting fork block from the
opening on the rear case, make the gear
shifting axle run through the gear shifting fork
block, and temporarily not tighten the bolt.

11
 (d) Engage the transmission on position of the
third gear; insert the gear shifting axle into the
fork axle shifting grooves of the third gear and
the fourth gear, push into the rear body.

(e) Assemble and tighten the rear body bolts.

Tighten torque: (refer to table)
(f) Assemble and tighten the gear shifting fork block bolts.
Tighten torque: (refer to table)
19. Assemble the self-locking steel ball, the spring and the screw plug of the fifth gear.

(a) Coat the sealant on the thread of the screw

plug.
(b) Assemble the locking ball, the spring and
the screw plug. Tighten torque: (refer to table)

20. Inspect following items after assembly of the rear case or the transmission case body.
(a) Check whether rotation of the input axle and the output axle are flexible.
(b) Check whether shifting of each gear is clear and reliable, check whether there is reverse gear
locking function.
21. Assemble the transmission operation cover.

(a) Coat the sealant before the transmission operation cover is assembled (the glue line is
enclosed at inner side of the thread hole).

12
(b) Assemble the bolts and tighten the bolts.
Tighten torque: (refer to table)
22. Assemble the slave gear of the odometer.

(a) Assemble the slave gear of the speedometer.

(b) Assemble the bolts and tighten the bolts.
Tighten torque: (refer to table)
23. Assemble the clutch case.

(a) Assemble the clutch case.

(b) Assemble and tighten the bolts.
Tighten torque: (refer to table)
24. Assemble external parts: oil filling plug and oil draining plug, vent plug, wire clip, separation
support column, fork cover, separation fork, clutch slave cylinder.

13
VII. Adjustment technical conditions
·Check tolerance a value of the synchronizer gear ring at each gear
Standard clearance (mm): 0.75~1.65
Limit clearance (mm): 0.5
·Check gear clearance of each gear according to following table.
Gear First gear Second gear Fifth gear and
and third gear sixth gear
Axial clearance 0.15~0.45 0.1~0.25 0.1~0.35
(mm)
VIII. Assembly precautions
1. Various oil sealing, the snap ring for axle and the elastic pin are not used repeatedly after
they are removed.
2. All parts must be kept clean, no dirt, chip, rust, oil dirt and other foreign matter are allowed.
3. Coat lubrication oil on the friction surface of all parts with relative movement.
4. Coat lubrication grease on the lip of each oil sealing, which is vertically pushed into.
5. Don’t use the roller body to transfer pressure during assembly of each bearing.
6. Openings of the spring piston rings at two sides shall be staggered during assembly of the
synchronizer component.
7. Some one gear must be engaged in during transportation and installation process of the
assembly, prohibit make it upright on idle status or make it bear strong impact.
IX. Fault and troubleshooting
Fault type Possible reason Exclusion methods
Noise is too great or The bearing is damaged Replace the bearing
abnormal sound Bump or spot corrosion on Inspect or replace the gear
the gear surface
Axial position or clearance Inspect, repair and adjust
of the gear is improper or
scratch of the internal part
Lubrication oil level is too Fill oil to the calibration
low or lubrication is position
insufficient
Use the bad lubrication oil Replace with specified
which isn’t in accordance lubrication oil
with quality requirements
There is damage Inspect, repair and adjust
phenomenon in the inner
part of the clutch
Engagement is difficult Adjustment of the clutch is Adjust
improper, and
disengagement is
incomplete

14
 Adjustment of the operation mechanism is Adjust
improper
Abrasion of the synchronizer gear ring is Replace the gear ring
serious
Oil leakage The oil sealing is abraded or damaged Replace the oil sealing
Oil is filled too much, and oil level is too high Inspect and adjust
Coating of the sealant is uneven or the Coat sealant again or
sealing mate is damaged replace the mate
The conjunction surface is bumped, which Repair
isn’t repaired in time
The ventilation plug is blocked Clean and dredge
Abrasion of the gear sleeve or the Replace
Disengagement conjunction gear is serious
Installation of the operation mechanism is Inspect, adjust or replace
improper or damaged
The shifting fork is seriously deformed or Replace
abraded
The positioning spring or the steel ball is Inspect and replace
seriously deformed or abraded
The axial clearance of the gear is too great Inspect and adjust
Disorder gear The interlock pin is missed or damaged Replace
seriously
Bearing is Lubrication is insufficient or lubrication isn’t Inspect and replace
abnormally qualified
failed

15
Part Three Interior and exterior, electrical appliances and
car body
Chapter Twelve exterior
Composition of front bumper part ………………………………………………………002
Composition of rear bumper part ………………………………………………………006
Front door external rainproof bar component ……………………… ……008
Composition of drive door pedal box part ……………………………………………….010

1 / 10
Composition of front bumper part

Heater grating

Right assembly support of front bumper

Upper cross beam assembly of bumper

Pilot driver pedal box

Left assembly support

of front bumper

Front bumper cross beam

Driver pedal box

Front bumper

Defined torque

2 / 10
 Front bumper cover

Right towing shackle cover

Left towing shackle cover r

Left fog lamp cover

Left fog lamp assembly

Right fog lamp cover Right fog lamp assembly

Assembly removal
1 Pull out of the cathode power supply
2 Remove the heat dissipater grating
(a) Remove 3 buckles and 2 self-driving
screws.
(b) Remove 6 clamp corners and 2 buckles
and remove the heat dissipater grating.
3 Remove the driver pedal box
(a) Remove 4 buckles
(b) Remove the clamp corner and remove
the driver pedal
4 Remove the pilot driver pedal box
5. Remove the front bumper
(a) Remove 6 buckles and 2 bolts.
(b) Remove 12 clamp corners and remove
the front bumper
(c) Remove the fog lamp harness

3 / 10
Removal of single components
1 Remove the left fog lamp cover
Remove 3 screws
Remove the left fog lamp cover
2. Remove the right fog lamp cover
3 Remove the left fog lamp (with the fog lamp
configuration)
Remove 2 screws
Remove the left fog lamp
4 Remove the right fog lamp (with the fog lamp
configuration)
5 Remove the left towing shackle cover
6 Remove the right towing shackle cover
7. Remove the left assembly support of the front
bumper
Remove 2 special screws and remove the right
assembly support of the front bumper
8. Remove the right assembly support of the front
bumper
9 Remove the upper cross beam assembly of the front
bumper
Remove 5 bolts and the upper crossing beam
assembly of the bumper

10 Remove the upper cross beam of the front bumper

Remove 6 bolts and remove the upper cross beam of
the front bumper
Assembly of single component
1 Assemble the left assembly support of the front
bumper
2 Assemble the right assembly support of the front
bumper

4 / 10
3 Assemble the cross beam of the front bumper
(a) Assemble 8 bolts on the cross beam of the front
bumper.
Torque: 40N*m

4 Assemble the upper cross beam assembly of the

front bumper
(a) Use 5 bolts to assemble the upper crossing beam
assembly of the bumper
* *
Toque: 61 N m for bolt A and 12 N m for bolt B
5 Assemble the left fog lamp (with the fog lamp
configuration)
6 Assemble the right fog lamp (with the fog lamp
configuration)
7 Assemble the left fog lamp cover
8 Assemble the right fog lamp cover

Installation of assembly
1 Assemble the front bumper
2 Assemble the driver pedal box
3 Assemble the pilot driver pedal box
4 Assemble the heat radiator grating
5 Connect the cathode power supply
6. Implement initialization
Reminder:
Some systems shall be initialized when the cathode
power supply is pulled down

5 / 10
 Composition of rear bumper part

Right rear tail lamp

Lower assembly support of rear bumper Right assembly support of rear bumper

Left assembly support of rear bumper

Right upper trim board assembly support of rear bumper

Right upper trim board of rear bump
Right rear tail lamp

Left upper trim board assembly support of rear bumper

Backward radar

Sensor assembly clip ring of backward radar

Backward radar harness Backward radar sensor

Left upper trim board of rear bump

Sensor assembly clip ring of backward radar

Backward radar sensor

Sensor assembly clip ring of backward radar
Backward radar sensor

Rear bumper

6 / 10
Assembly removal
1. Remove the rear bumper
(a) Remove 6 buckles
(b) Remove 6 screws
(c) Remove 10 clip feet and remove the rear
bumper
(d) Remove the harness of the backward radar
(configuration with backward radar)

2. Remove the rear bumper installation support

(a) Remove 4 bolts and remove the lower
installation frame of the rear bumper.

3. Remove the left installation support of the rear

bumper
(a) Remove 2 special screws and remove the
installation support of the rear bumper
4. Remove the right installation support of the rear
bumper
5 Remove the left rear combination lamp assembly
6 Remove the right rear combination lamp assembly

7 Remove the left upper cover decoration board of the

rear bumper
(a) Remove screws
(b) Remove the buckle and 2 clamp corners and
remove the left upper decoration board of the rear
bumper
8 Remove the right upper decoration board of the rear
bumper
9 Remove the left upper decoration board installation
support of the rear bumper
(a) Remove 2 special screws and remove the
installation support of the rear bumper
10. Remove the right upper decoration board
installation support of the rear bumper
Assembly of single component
1 Assemble the left upper decoration board assembly
support of the rear bumper
2 Assemble the right upper decoration board
assembly support of the rear bumper
3 Assemble the right assembly support of the rear
bumper
4 Assemble the left assembly support of the rear
bumper
5 Assemble the lower assembly support of the rear
bumper
6 Assemble the backward radar sensor (configuration
with backward radar)
Installation of assembly
1 Connect harness of the backward radar
(configuration with backward radar)
2 Assemble the rear bumper

7 / 10
Front door external rainproof bar component

Left front door exterior rainproof bar assembly

Interior trim of exterior rear view mirror

Outer rear view mirror

Removal method
1 Remove the internal decorative cover of the
external view mirror of the front door

2 Remove the external rear view mirror

assembly (removal methods of the manual and
electric rear view mirror are same)

8 / 10
3 Remove the internal decorative board
sub-assembly of the front door (applicable to electric
adjustment rear view mirror vehicle type, it is
necessary to disconnect the connection buckle of the
harness; this step isn’t necessary for the manual
adjustment rear view mirror)
Note:
Please refer to vehicle body part for concrete removal
method of the interior decoration board sub-assembly
of the front door.

4 Remove the outer rear view mirror assembly.

5. Remove the external rainproof bar assembly of the
front door
(a) Firstly press down the external waterproof bar
along direction of the middle fender (1) and separate
the lower claw from the vehicle body, and then slightly
lift up the external rainproof bar along (2) direction
until all installation points are released, take out of the
external rainproof bar assembly.

Assembly method:
1. Assemble the external rainproof bar assembly of
the front door
2 Assemble the external rear view mirror assembly
(refer to the vehicle body rear view mirror part for
assembly method)
3 Assemble the internal decoration board
sub-assembly of the front door
Note:
Please refer to vehicle body part for concrete removal
method of the interior decoration board sub-assembly
of the front door.
4 Assemble the outer rear view mirror assembly

9 / 10
Composition of drive door pedal box part

Driver door pedal box

Assembly removal
1 Remove the driver pedal box
(a) Remove 4 buckles.
(b) Remove the clamp corner and remove the
driver door pedal

Removal of single components

1 Remove the driver pedal box

10 / 10
Part Three Interior and exterior, electrical appliances and
car body
Chapter Thirteen Vehicle body part

1/5
 Unit of size: mm

Hole Hole
Marking Position Marking Position
diameter diameter
Front window – upper left outer Pilot driver door frame ‐
A. I
opening lower front opening
Left positioning hole of
A column main
B separation board upper cover Ф13 J Ф18
positioning hole
board
Right positioning hole of
Opening before
C separation board upper cover Ф13 K
threshold
board
Front window – upper right
D L Opening after threshold
outer opening
Pilot driver door frame ‐ upper Installation hole of
E M Ф14
front opening drawing door lock hook
Installation hole of
Pilot driver door frame ‐ upper
F N drawing door upper Ф11
rear opening
limiter
Threshold of drawing
Installation hole of pilot driver
G Ф9 O door – upper front
door lock
opening
Pilot driver door frame ‐ lower
H
rear opening

2/5
 Unit of size: mm

Marking Position Hole diameter

P.p Installation hole of rear lamp 9*9 square hole
Q.q Installation hole of floor press bar 8.5*8.5 square hole
Installation hole of rear door hinge – outer
R.r Ф14
side; lower end

3/5
Wheel base

Low part of vehicle body – frame

Unit of size: mm

Marking Hole Hole

Position Marking Position
diameter diameter
Engineering
A．a Ф20 G．g Engineering positioning hole Ф15
reserved hole
Engineering
B．b Ф20 H．h Engineering positioning hole 21×18
positioning hole
Installation hole Installation hole of buffer
C．c of front auxiliary Ф20 I．i block in rear suspension Ф13
vehicle frame system
Installation hole Rear vibration absorber
D．d of front auxiliary Ф20 J．j installation bushing hole – Ф10
vehicle frame inner side
Rear vibration absorber
Engineering
E．e Ф20 K．k installation bushing hole – Ф30
positioning hole
inner side
Engineering
F．f Ф20 L．l Engineering reserved hole Ф20
positioning hole

4/5
Unit of size: mm

Low part of vehicle body – frame

Marking Hole Hole

Position Marking Position
diameter diameter
Engineering
A．a Ф20 G．g Engineering positioning hole Ф15
reserved hole
Engineering
B．b Ф20 H．h Engineering positioning hole 21×18
positioning hole
Installation hole Installation hole of buffer
C．c of front auxiliary Ф20 I．i block in rear suspension Ф13
vehicle frame system
Installation hole Rear vibration absorber
D．d of front auxiliary Ф20 J．j installation bushing hole – Ф10
vehicle frame inner side
Rear vibration absorber
Engineering
E．e Ф20 K．k installation bushing hole – Ф30
positioning hole
inner side
Engineering
F．f Ф20 L．l Engineering reserved hole Ф20
positioning hole

5/5
Part Three Interior and exterior, electrical appliances and
car body
Chapter Fourteen Door
Door …………………………………………………………… …………………………002

1 / 41
Manual lifting glass

Decoration of front door lower frame support

Front door glass handle crank assembly

Front door glass assembly

Front door glass lifter

assembly
Front door maintenance hole cover

Front door external rainproof bar

Appointed torque External rear view mirror assembly

2 / 41
 Manual lifting glass

Front door main sealing bar

Front door guiding slot sealing bar

Front door lock assembly

Front door inner handle

No 2 process hole cover

of front door

Rivet
Front loudspeaker cover Front door glass rear guiding

rail lower assembly

Front loudspeaker

Front door external handle cover

Rivet

Plug

Front door limiter assembly

Front door external handle assembly

Front loudspeaker component

Appointed torque

Don’t use the part repeatedly

3 / 41
Electrical lifting glass

Decoration of front door lower frame support

Vehicle door master control switch with

handrail assembly

Front door glass assembly

Front door maintenance hole cover

Front door glass lifter

Front door external rainproof bar

Appointed torque
External rear view mirror assembly

4 / 41
 Electrical lifting glass

Front door main sealing bar

Front door guiding slot sealing bar

Front door lock assembly

Front door inner handle

No 2 process hole cover

of front door

Rivet
Front door glass rear guiding
Front loudspeaker cover
rail lower assembly

Front loudspeaker

Rivet Front door external handle cover

Plug

Front door limiter assembly

Front door external handle assembly

Front loudspeaker component

Appointed torque

Don’t use the part repeatedly

5 / 41
Remove
1 Remove the lower frame support trim board of front
door
(a) Separate 3 clips and then remove the lower
frame support trim board of front door
(b) Remove 3 clips remaining on the vehicle body,
and then assemble them on the lower frame support
trim board of the front door.

2 Remove the electric window switch assembly

(vehicle type with electric window)
(a) Remove two screws
(a) Use a screwdriver to remove 3 clips and 4
buckles
(c) Disconnect the switch joint and then remove the
inner trim board sub-assembly of the front door.

3 Remove the front door inner trim board

sum-assembly (vehicle type without electric window)
(a) Remove three screws
(b) Separate 12 clips

4 Remove the front door inner trim board

sum-assembly (vehicle type with electric window)
(a) Remove screws
(b) Separate 12 clips and then remove the front door
inner trim board sub-assembly

5 Remove the outer rear view mirror assembly.

6 / 41
 7 Remove the outer rear view mirror assembly (electric
rear review mirror)
8 Take out of the front door exterior rainproof bar
9. Remove the driver door maintenance opening cover
(a) Remove 6 bolts

clips
10 Remove the front door glass (manual lifter)
(a) Take out of the installation hole rubber plug
(b) After the lifting handle is assembled, move the glass
to maintenance position
(i.e. observe the glass fix bolt through the installation
hole)
(c) After two bolts are loose, the glass can be taken
away.

11 Remove the front door glass (electric lifter)

(a) Take out of the installation hole rubber plug
(b) Connect the lifter plug-in, and move the glass to the
maintenance position
(i.e. observe the glass fix bolt through the installation
hole)
(c) After two bolts are loose, the glass can be taken
away.

12 Remove the lifter assembly (electric)

(a) Remove connection part
(b) After 6 fixing bolts are loose, the lifter assembly can
be taken out of.

7 / 41
13 Remove 6 bolts and the front door glass lifter
assembly

14 Remove the front door guiding slot sealing bar

(a) Directly remove the guiding slot sealing bar

15 Take out of the rear lower moving guiding rail of the

front door

16 Remove the fixing cover of the external handle.

(a) Take out of the rubber plug

(b) The front door external handle cover (including the

lock core) can be taken out of when the bolt is loose.

8 / 41
 17. Remove the external handle assembly of the front door
(a) Loosen the nut

(b) Pull the external handle outward, and then take out
of the external handle.

18. Remove the external handle assembly of the front door

Loose A point
(a) Loosen the nut
Loose B point
(b) Displace the handle backward, firstly loose A point
and then loose B point.

19 Remove the lock body of the front door

(a) Loose 3 bolts used to fix the lock body.
(b) Take out of the lock body together with the inner
handle from the vehicle door.

20 Remove No 2 engineering hole cover of the front door

(a) Remove 2 screws and No 2 engineering hole cover
of the front door

9 / 41
 21 Remove the front door limiter
(a) Remove the bolts on the limiter connected with
the vehicle body.

(b) Remove 2 bolts on the limiter connected with the

vehicle body, and take out of the front door limiter.

22 Remove the front door main sealing bar

(a) Use the buckle driver to jack each buckle, and
then the sealing bar is removed.

buckle

10 / 41
 Adjustment
1 Remove the front door main sealing bar
(a) Check whether clearance of D area is within the scope
of the standard values.

Standard
Area Size Area Size
A 5.0+‐1.0mm C 5.0+‐1.0mm
B 5.0+‐1.0mm D 5.0+‐1.0mm

Adjust front door

(a) Disconnect negative of the harness from
the battery.
(b) Use sst to loose the bolts in A column to
adjust upper and lower, left and right of the
vehicle body.
Torque: 27N*m
(c) Loose the bolts on the vehicle body to
adjust upper and lower, left and right of the
vehicle body.
Torque: 27N*m

11 / 41
 (d) Position of the lock hook shall be adjusted when
rear part of the door is adjusted, use the crossing
screwdriver to loose to adjustment status, slightly tap the
lock hook to adjust position.
Torque: 23N*m

Re-assembly
1 Assemble the front door sealing bar
2 Assemble the front door limiter assembly
(a) Use 2 bolts to assemble the limiter on the front door,
torque: 5.5N* m

(b) Use 1 bolts to assemble the limiter on the A

column, torque: 21N*m
3 Assemble the front door loudspeaker assembly

4 Assemble the front door engineering hole plug

(a) Use two screws to assemble the front door
engineering hole cover
5 Assemble the front door lock body assembly

(a) After the external handle lock bar is inserted into

the lock body, and then place at corresponding position
of the vehicle body
(b) Confirm that the external handle lock rod is still at
correct position, and it is correctly connected with the
lock body.

12 / 41
 (c) Use 3 bolts to fix the lock body.
6 Assemble the inner handle assembly of the front
door
7 Assemble the external handle assembly
(a) After the external handle is assembled at
corresponding position, use the bolts to fix
(b) And then use the bolts to fix after the external handle
cover is assembled.
(c) Blank the rubber plug

8 Assemble the front door external handle cover

(a) Use the T30 spanner to assemble the front door
external handle cover, torque: 7.0 N*.m

(b) Assemble the plug.

9 Assemble the rear lower moving guiding rail of the front
door
(a) Use 1 bolt to assemble the rear lower moving guiding
rail of the front door on the front door.

10 Assemble the guiding slot sealing bar of the front door

(a) Assemble the guiding slot sealing bar of the front
door

11 Assemble the glass lifter assembly

(a) After the lifter is placed at correct position, use the
*
bolts to fix (8N m)

(b)Connect the plug-in.

13 / 41
12 Assemble the glass lifter assembly by manual
(a) After the lifter is placed at correct position, use the bolts
*
to fix (8N m)

13 Assemble the front door glass

(a) After the front door glass is assembled in the inner side
of the vehicle body, align the glass to position of the lifter.
Note:
If the glass can’t be fixed together with the lifter, connect
the plug in part or move the lifter upward and downward to
correct position by manual.
(b) Assemble two bolts used to fix the front door glass.
(c) Blank the rubber plug

14 Assemble the front door glass exterior rainproof bar

15 Assemble the front door maintenance hole cover
(a) Use 6 bolts to assemble the front door maintenance
hole cover.
Note:
If the sealing rubber bar is damaged, please replace
immediately.

16 Assemble the manual lifter handle of the front door

(a) Take advantage of the manual lifter handle to close
glass.
(b) And then press the lifter handle firmly at position shown
in the figure.

14 / 41
 17 Assemble the lower frame support trim
board of the front door
18 Inspect and adjust the front door
19 Adjust the electric window control
motor.

15 / 41
Drawing door Structure

External handle of drawing door

Internal handle of drawing door

Internal handle of drawing door

Drawing lock assembly

Front lock body of

drawing door

Lower concave limiter Rear lock body of drawing door

of drawing door

Engineering hole cover of drawing door

Internal handle frame cover of drawing

door (simple configuration)

Drawing door interior sub-assembly

Appointed torque

16 / 41
 External handle of drawing door

Internal handle of drawing door

Remote control mechanism of drawing door

Front lock body of

drawing door

Lower concave limiter of Rear lock body of drawing door

drawing door

Drawing door interior sub-assembly

Appointed torque

17 / 41
 Rear upper concave limiter and limiter support of rear door

Upper pulley mechanism assembly

of side drawing door

Drawing door

Middle pulley mechanism assembly of

side drawing door

Rear end cover of sliding guide

Lower pulley mechanism assembly of side drawing door

Lower sliding raceway spring shim of drawing door

Anti-abrasion board of

drawing door

18 / 41
Remove
1 Take out of the inner handle cover of the
drawing door
(a) Remove two fixing bolts.
(b) Take out of the inner handle of the drawing door

2 Remove the internal trim board sub-assembly of the

front door
(a) Use the special tools to remove 20 clips and the
interior board sub-assembly.

3 Remove the inner handle of the drawing door

(a) Loosen two bolts
(b) After the lock bar is removed from the fixed
buckle, the inner handle of the drawing bar can be
removed.

4 Remove the external handle of the drawing door

(a) Remove the connection lock rod
(b) Firstly loose the bolt on the lock core of the
drawing door, and then take out of the lock core of the
drawing door
(c) Loose the bolts of the external handle, and
remove the external handle.

19 / 41
 (a) Disconnect the connection
(b) Remove the bolts and the external handle
assembly of the drawing door .

5 Remove the front lock body of the drawing door

(a) Remove the drawing wire from the remote control
mechanism
(b) Loose the bolt, and then the front lock body of the
drawing door is removed.

Grip

6 Remove the concave position of the drawing door

(a) Remove 2 bolts used to assemble the concave
limiter, and then take out of the concave limiter at same
time.

7 Remove the drawing door limiter

(a) Loosen the drawing wire

20 / 41
 (b) Loose the bolts, and the drawing door limiter can
be removed.

8 Remove the rear lock body of the drawing door

(a) Remove the drawing wire from the remote control
mechanism
(b) Loose the bolt, and then the rear lock body of the
drawing door is removed.

9 Remove the remote control mechanism of the

drawing door
(a) Remove all lock rod connections which are
connected with the remote control mechanism

(b) Loose all bolts and the remote control mechanism

can be removed.

21 / 41
10 Remove the pedal box of the drawing door
(a) Separate 1 clip and the pedal box of the drawing
box

11 Remove the end decoration board of the sliding rail

(a) Pull outward when the end decoration board cover
is sliding backward, separate the clip and then remove
the end decoration board cover of the sliding rail.

22 / 41
 12 Remove the rear upper guiding rail cushion of the
drawing door
(a) Remove the bolts used to assemble the drawing
door on the guiding rail, and then take out of the rear
upper guiding rail proper body at same time.

13 Remove the lower slide-way spring shim of the

drawing door
(a) Remove the combination bolts and take out of the
lower slide-way spring shim of the drawing door.

14 Remove the upper pulley mechanism assembly of

the side drawing door
(a) Remove 2 combination bolts and take out of the
upper pulley mechanism assembly of the side
drawing door
15 Remove the middle pulley mechanism assembly of
the side drawing door
(a) Remove 2 combination bolts and take out of the
High roof
middle pulley mechanism assembly of the side
drawing door
16 Remove the lower pulley mechanism assembly of
the side drawing door
(a) Remove 4 combination bolts and take out of the
lower pulley mechanism assembly of the side drawing
door
Adjustment
1 Inspect the drawing door
(a) Inspect whether distance between A area and D
area is within the scope of the standard.

Standard
Area Measurement value
A. 6 1.0mm
B 5 1.0mm
C 6 1.0mm
D 5±1.0mm

23 / 41
2 Adjust the side drawing door
(a) Loose the combination bolt on the middle pulley
mechanism assembly of the side drawing door, adjust
front and rear, upper and lower position of the drawing
door. *
Torque value: 27±3N m

(b) Loose the nut on the pulley mechanism assembly of

the side drawing door, adjust left and right relative
positions between the* drawing door and the fender.
Torque value: 27±3N m

(c) Loose the bolts on the lower pulley mechanism

assembly of the side drawing door, adjust front and
rear, upper and lower*position of the drawing door.
Torque value: 27±3N m
Information:
 When the bolt on the lower pulley mechanism
assembly of the drawing door is adjusted, please
remove the interior board of the drawing door firstly.
 When the bolt on the lower pulley mechanism
assembly of the drawing door is adjusted, please
remove the interior board of the drawing door firstly,
and temporarily tighten the bolts.

Assemble
1 Assemble the lower pulley mechanism assembly of
the side
a) Loose the bolts on the lower pulley mechanism
assembly of the side drawing door, adjust front and
rear, upper and lower
* position of the drawing door.
Torque: 27±3N m
2 Assemble the middle pulley mechanism assembly of
the side drawing door
(a) Use 2 combination bolts to assemble the middle
pulley mechanism assembly
* of the side drawing door
Torque value: 27±3N m
3 Assemble the upper pulley mechanism assembly of
the side drawing door
(a) Use 2 combination bolts to assemble the upper
pulley mechanism assembly
* of the side drawing door
Torque value: 8.5±2N m

24 / 41
4 Assemble the side drawing door assembly
5 Assemble the lower slide-way
spring shim of the drawing door
(a) Use the combination bolts to assemble the lower
slide-way spring shim of the drawing door.

6 Assemble the rear upper guiding rail cushion of the

drawing door
(a) Use the bolts to assemble the guiding rail cushion
on the drawing door.
7 Assemble the rear upper concave limiter and the
limiter support of the drawing door.
(a) Use the combination bolts to assemble the rear
upper concave limiter and the limiter support

8 Assemble the pedal box of the drawing door

(a) Assemble the clip and then assemble the pedal
box

9 Assemble the remote control mechanism of the

drawing door
(a) Use the bolts to fixe after the remote control
mechanism of the drawing door is assembled.
Torque value: 5.5N*m

25 / 41
 10 Assemble the rear lock body of the drawing door
(a) After the rear lock body of the drawing door is fixed
by three bolts.
(b) Connect the drawing wire with the remote control
mechanism

11 Assemble the drawing door limiter

(a) Use 2 bolts to fix the drawing door limiter
(b) Connect the drawing wire with the remote control
mechanism

Grip

12 Assemble the lower concave limiter of the drawing

door
(a) Use 2 bolts to assemble the lower concave limiter
of the drawing door

13 Assemble the front lock body of the drawing door

(a) After the front lock body of the drawing door is fixed
by three bolts.
(b) Connect the drawing wire with the remote control
mechanism
Grip
14 Assemble the external opening lock rod of the
drawing door

26 / 41
 15 Assemble the external handle of the
drawing door
(a) Fix the external handle of the drawing
door by bolts
Torque value: 5.5N*m
(b) Connect the lock rod
(c) Use the bolts to fix the lock core of the
drawing door
(d) Connect the lock rod

16 Assemble the inner handle of the drawing

door
(a) Use 2 bolts to fix the inner handle of the
drawing door
(b) And then connect the lock rod

17 Assemble the interior board sub-assembly

of the drawing door
(a) Assemble the clips and the buckle, and
then assemble the interior board
sub-assembly of the drawing door

(b) Assemble 2 screws

27 / 41
 18 Assemble the inner opening handle of the
drawing door

Remove
Remove the support bar of the tail door
Note: support the tail door and ensure it
doesn’t fall down during removal of the tail
door support bar.
(a) Loose 4 bolts used to fix the support bar

Assemble

1. Assemble the support bar of the tail door

(a) Assemble 4 bolts on the support bar of
the tail door
Torque value: 22N*m

28 / 41
Parts of tail door

Engineering hole cover of rear door

High position brake lamp assembly

With rear wiper

Rear door upper interior board assembly

Rear door upper interior board assembly

Rear lighting lamp

Rear door harness 3

Rear windshield harness 1 Rear windshield harness 1

Vehicle model with rear door internal handle

Internal handle of rear door

Rear door interior board

Internal handle frame cover

of rear door
Rear wiper motor assembly

Washer

Rear wiper axle cover

Rear door interior board

Rear wiper arm assembly

Appointed torque

29 / 41
 Remote control mechanism of

rear door

Vehicle model with rear door internal handle

Internal handle assembly of rear door

Remote control mechanism of rear door

Right hinge of rear door

Left hinge of rear door

Right support rod of tail door

Left support rod of tail door Right limiter of rear door

Rear door harness 2

Left limiter of rear door

For rough road

Right limiter of rear door

For rough road

Left limiter of rear door

Rear door lock body assembly
External handle of rear door

Rear door lock assembly

License plate bar of rear door

Buffer block
Rear door lock protection frame
sub-assembly

of rear door

Appointed torque

30 / 41
 Remove
1 Remove the rear floor lighting mirror
assembly.
2 Remove the engineering hole cover of the tail
door
3 Remove the interior board assembly of the
tail door (vehicle type without rear wiper)

4 Remove the interior board assembly of the

tail door (vehicle type with rear wiper)
5 Remove the rear wiper arm and the wiper
blade.
6 Remove the axle cover of the rear wiper
7 Remove the rear wiper washer 1
8. Remove the rear wiper motor assembly
9 Remove the high position brake lamp
assembly

10 Remove the tail door harness 3

11 Remove the rear window harness 1

31 / 41
 12 Remove the inner handle of the tail door
(a) Loose the bolt and remove the inner
handle of the tail door

13 Remove the inner handle frame cover of the

tail door
(a)Loose 2 bolts and take out of the inner
handle of the tail door

14 Remove the interior board of the tail door

15 Remove the interior board of the tail door

32 / 41
 16 Remove the inner handle of the tail door
(a)Remove the lock rod connection
(b) Loose 3 bolts and take out of the inner handle of the tail door

17 Remove the remote control mechanism of

the tail door

(a) Remove the lock rod connection

(b) Remove the lower drawing wire connection

(c) Loose the bolts and remove the remote
control mechanism of the tail door

Grip
18 Remove the external handle of the tail door
(a) After 2 nuts are removed, the external
handle can be removed.
19 Remove the license plate bar of the tail door,
it can be removed after other nuts are loose

33 / 41
 20 Remove the tail door harness 2
21 Remove the tail door harness 1

Grip

22 Remove the middle convex limiter (used on

rough road) of the tail door
(a) Remove 2 bolts used to assemble the
middle convex limiter on the tail door, take out
of the middle convex limiter of the tail door.

23 Remove the lock protection frame of the tail

door

34 / 41
 24 Remove the lock body of the tail door
(a) Loose 3 bolts and remove the lock of the tail
door

25 Remove the left concave limiter of the tail

door
(a) Remove 2 bolts used to assemble the
concave limiter, and then take out of the left
concave limiter at same time.
26 Remove the right concave limiter of the tail
door

27 Remove the support bar of the tail door

Note: support the tail door and ensure it doesn’t
fall down during removal of the tail door support
bar.
(a) Loose 4 bolts used to fix the support bar
28 Remove the support bar at another side

Adjustment
1 Inspect the tail door
(a) Inspect whether distance between M and P
area is in accordance with standard value.

Door-035

35 / 41
Area Size Area Size
A 18mm C 12mm
B 5mm —— ——

2 Adjust tail door

(a) Remove the cable from negative of the
battery
Note: this work is done only after the engine
stops fro 90 seconds, the negative cable shall
be separated from the battery
(b) Loose the hinge bolt of the tail door, the
upper and lower, the left and right adjustment
tail door hinges.
Torque: 19N* m
(c) When the tail door is adjusted left and
right, loose the bolts of the tail door locking
buckle, and make the locking buckle move, use
1 hammer to tap the locking buckle slightly to
carry out adjustment.
Torque: 19N*m

36 / 41
Door ‐036 (d) After adjustment is complete, confirm
position of the tail door is correct, confirm that
position of the limiter at the tail door side is
correct.
Torque: 7.5N*m
(e) Connect the negative with the battery
(f) Initialize each system
(g) Inspect the SRS warming lamp.

Re-assembly
1 Assemble the support bar of the tail door
(a) Use 4 bolts to assemble the support bar
of the tail door
2 Assemble the support bar of the tail door at
another side

3 Assemble the left limiter of the tail door

(a) Use 2 bolts to assemble the left limiter
of the tail door:
Torque: 7.5N*m
4 Assemble the right limiter of the tail door:
Torque: 7.5N*m

Door ‐037

37 / 41
 5 Assemble the lock body of the tail door

(a) Use 3 bolts to fix the lock body of the tail

door

6 Assemble the middle convex limiter of the tail

door

(a) Use 2 bolts to assemble the middle

convex limiter of the tail door:

7 Assemble the license plate bar of the tail door

Grip

Door ‐038

38 / 41
 8 Assemble the external handle of the tail door

(a) Use 2 bolts to fix the external handle of the

tail door

9 Assemble the remote control mechanism of

the tail door

(a ) Use the bolts to fix the remote control

mechanism of the tail door

(b) Connect the lock rod

(c) Connect the drawing wire

Grip

10 Assemble the inner handle of the tail door

(a) Use 3 bolts to assemble the inner bar of the

tail door

Grip

Door ‐039

39 / 41
 (b) Connection lock rod

11 Assemble the interior board of the tail door

12 Assemble the interior board of the tail door

13 Assemble the inner handle frame of the tail

door

(a) Use 2 bolts to fix the internal handle frame

Door ‐040

40 / 41
 14 Assemble the inner handle of the tail door
(a) Use 1 bolt to fix the inner handle of the tail
door

15 Assemble the rear window harness 1

16 Assemble the tail door harness 3

17 Assemble the high position brake lamp

assembly
18. Assemble the rear wiper motor assembly
19 Assemble the rear wiper axle washer 1
assembly

20. Assemble the rear wiper axle cover

assembly
21. Assemble the rear wiper arm wiper blade
assembly
22. Assemble the trim board assembly of the tail
door.

23 Assemble the interior board assembly of the

tail door (without rear wiper)
24 Assemble the rear floor lighting mirror
assembly.
25 Inspect and adjust the tail door

41 / 41
Part Three Interior and exterior, electrical appliances and
car body
Chapter Fifteen Windshield and side window glass
Front windshield glass component ----------------------------------002
Front side window component --------------------------------- -------010
Rear side window component --------------------------------- -------015
Rear windshield glass component ---------------------------------- 020
Rear door glass component ------------------------------------------025
Windshield glass defrost system ------------------------------------031

1 / 35
Front windshield glass
Components

Front ceiling interior board

Right A column upper trim

Pilot driver handrail

Front column handrail cover

Front column handrail Front column handrail

Front column handrail cover

Right sun visor

Front indoor ceiling lamp assembly

Left A column upper trim

Support
Left sun visor

Support

2 / 35
 Inner rear view mirror assembly

Windshield limit block

Windshield glue

blocking bar
Windshield external

wrapping bar

Front windshields

Wiper arm cover

Right wiper

Left wiper

Right decoration cover of

inlet grating

Inlet grating

Left decoration cover of inlet grating

Front wiper motor and the connection bar assembly

Appointed torque

Parts can’t be used repeatedly

3 / 35
 Remove
1. Remove the pilot driver handrail insertion pin
2 Remove the pilot driver handrail
3. Remove the left front door vertical column
trim board
4. Remove the right front door vertical column
trim board
5. Remove the sun visor hook
6. Remove the left sun visor
7. Remove the right sun visor
8. Remove No1 indoor ceiling lamp
9 Remove the rear inner view mirror assembly.
10. Remove the cover of the front windshield
wiper arm
11. Remove the cover of the right windshield
wiper arm
12. Remove the cover of the left windshield
wiper arm
13. Remove the right ventilation vent cover
14. Remove the left ventilation vent cover
15. Remove the ventilation vent sub-assembly
16. Remove the windshield wiper motor
17. Remove the external slab of windshield
(a) Use the knife to cut the external slab at
Cut Slab the position shown in the figure
Note:

Cut
Don’t damage the vehicle body
(b) Remove the remaining part of the slab
Windshield glass Vehicle body Information:
Cut an opening and then draw open by
hand

4 / 35

Plastic board
Protection adhesion tape
18. Remove the front windshield glass
(a) Use the protection adhesive tape to protect
external surface of the vehicle body so as to avoid
damage the vehicle body
(b) Shown as the figure, insert a steel wire
between the vehicle body and the glass
(c) Bind a handle each at two ends of the steel
wire (such as a wood block)
Note:
Avoid damaging the glass printing, interior, exterior
and vehicle body during rubber cutting process.
In order to avoid scratching the dashboard, place a
plastic board between the steel wire and the
dashboard.
(d) Cut the adhesion glue of one turn of the
windshield through drawing the steel wire.
(e) Separate the spacing
(f) Use the suction disc to take away of the front
windshield glass
Note: remain glue on the vehicle body as more as
possible when the glass is taken away
Assemble
1. Clean the front windshield glass
(a) Use the scraper to remove the glue blocking
bar and the residual glue
(b) Use gasoline free of lead to clean external
boundary of the windshield glass
Note
 Don’t touch the glass surface after cleaning
 Even though a new front windshield is used, it
shall be cleaned by gasoline free of lead

Glue Glue 2. Clean vehicle body

(a) Clean external surface at connection location
of the vehicle body
(1) Use the knife to cut excessive residual glue on
the vehicle body, shown as figure
Information:
Remain glue on the vehicle body as more as
possible
Note:
Don’t damage the vehicle body
Vehicle body (2) Use the detergent to clean the vehicle body
and surface at connection location of the glass
Information:
Even the glass glue has been removed, the vehicle
body shall be cleaned.
3. Assemble the positioning pin of the windshield
glass
(a) Position according to printing band
Note:
 Primer (3M94#) shall be dried more than 3
min
 Reject excessive primer.
 Primer shall not be used much
(b) Assemble two new positioning pins according
to following figure

5 / 35
 Ceramics Porcelain printing boundary

Primer
Printing boundary

Specification
Area Measurement
a 10
b 10
4. Assemble the rubber bar of the windshield glass
(a) Coat primer (3M94#) at installation position of the glass
adhesion rubber bar
Note:
Primer shall be dried for more than 3 min and reject
excessive primer
Reject remaining primer.
Primer shall not be used much
(b) Assemble the glue blocking bar (except the position of
the positioning pin) in a turn along the glass, shown as
following figure

Cutting boundary

Printing boundary

Printing boundary

Specification
Area Measurement
a 14
b 51

6 / 35
 5. Assemble the windshield glass
(a) Positioning of glass
(1) Use the suction disc to place the windshield
glass on the correct position
(2) Inspect the whole connection surface, edge
of the glass shall be even and consistent
(3) Use the suction disc to remove the glass

(b) Use the brush to coat primer on the

corresponding position of the vehicle body
After washing of DW646 + DV947 Note:
Primer shall be dried for more than 3 min
Don’t take primer as adhesion agent
Correct
Reject remaining primer.
Primer shall not be used much
After washing of DW646 + DV947

Adhesion agent
Not correct

After washing of DW646 + DV947

After washing of DW646 + DV947

Adhesion centre line

After washing of DW646 + DV947

Adhesion centre line

7 / 35
 (c) Use adhesion agent
Part number:
F500 or equivalent glass glue
(1) Shown as figure, cut an opening on the glass
glue nozzle
Specification
Area Measurement
a 14
b 10
Information
After it is used, use all glue, refer to following table
for time requirement
Temperature Time limit
35 15 min
20 1 hour and 40 min
5 8 hours
(2) Fill glue into the glue gun
(3) Coat glue on the windshield glass shown as
following figure

Rear

Specification
Area Measurement
a 14
b 10
(d) Assemble the windshield glass on the vehicle
body, pay attention to observe clearance between
the upper edge of the glass and the top cover
(1) Use the suction disc to place the glass on
the vehicle body, and tap along edge
(2) Press surface of the glass slightly, confirm
the glass completely matches the vehicle body
safely
Note:
Primer shall be dried for more than 3 min

8 / 35
 (3) Apply the protection adhesion tape or
equivalent article to maintain position of the front
windshield glass stable until the adhesion agent
is solidified.

7. Inspect and repair leakage

(a) Carry out leakage inspection after adhesion
agent is completely solidified
8. Assemble the windshield wiper motor etc.
9. Assemble the inlet grating
10. Assemble the left inlet grating hole cover
11. Assemble the right inlet grating hole cover
12 Assemble the left wiper arm
13 Assemble the right wiper arm
14. Assemble the wiper arm cover
15 Assemble the inner rear view mirror
16 Assemble the front forming ceiling
17. Assemble the front indoor ceiling lamp
18. Assemble the right sun visor
19. Assemble the left sun visor
20. Assemble the sun visor hook
21 a vertical column trim board
22 a vertical column trim board
23 Assemble the pilot driver handrail
24 Assemble the plug in of the front pilot driver
handrail

9 / 35
Front side window glass
Components

Left decoration of drawing door and window

Left trim board sub-assembly after door

Front window limit block Sliding window

Front side sliding window glass

Front side window glass

One used part, don’t use repeatedly

Sliding window water flowing hole cover

10 / 35
 Remove
1, Remove the left decoration of the sliding door and
window
2. Remove the left rear trim board sub-assembly of
the door
3. Remove the left decoration behind door

Vehicle type door rear trim sub-assembly Vehicle type door rear trim sub-assembly

4. Remove the left decoration behind door

(a) Use the protection tape to protect external
surface of the vehicle body so as to avoid damage the
vehicle body
(b) Insert one steel wire between the glass and the
vehicle body in the vehicle, shown as figure
(c)Bind a handle each at two ends of the steel wire
(such as a wood block)
Note:
When the glass is separated from the vehicle
body, pay attention to not damage paint surface of the
vehicle or the interior and exterior part
(d)Cut a round of glass glue of the glass through
drawing the steel wire
(e) Use the suction disc to take away of the glass
Note:
Make glue on the vehicle body as more as
possible during cutting
Assemble
1. Clean the front side window glass
(a)Use the blade to scratch the shim etc auxiliaries
and remaining glue from the glass.
(b)Clean edge of the glass with gasoline free of
lead
Note:
·Don’t touch after cleaning

11 / 35
 Even though a new front windshield is used, it
shall be cleaned by gasoline free of lead
2. Clean vehicle body
(a) Clean and repair connection surface
between the vehicle body and the glass
(1) Use the knife to cut excessive glass glue at
connection position between the glass and the
vehicle body shown as figure
Information:
Remove glue on the vehicle body as more as
possible
Note:
Rear Don’t damage the vehicle body
3. Assemble the front side window glass cushion
block
(a) Coat primer at position of the adhesion
Window glass buckle
cushion
Information:
If primer is coated at other position, use
gasoline free of lead to move before 3M94# is dry
Note:
·Primer shall be dried more than 3 min
·Reject remaining primer.
Primer shall not be coated too much
(b) Assemble two buckles shown as figure
After cleaning of

DW646 DV947
4. Assemble the front side window glass
(a)After it is cleaned by DW646， coat DV947
on the corresponding glass adhesion surface of
the vehicle body
Note:
·Primer shall be dried more than 3 min
After cleaning of DW646 DV947
·Primer shall not be used as adhesion agent
·Remove excessive primer
Adhesion agent
·Primer shall not be excessive

12 / 35
 (b) Use the brush or sponge to coat primer on the
adhesion surface of the glass

Rear

After cleaning of DW646 DV947

Side of drawing door

After cleaning of DW646 DV947 Adhesion centre line

After cleaning of DW646 DV947

Adhesion centre line

Side without drawing door

Adhesion centre line

After cleaning of DW646 DV947

After cleaning of DW646 DV947

Adhesion centre line

Adhesion centre line

Information:
If primer is coated at unnecessary position, use
alcohol free of water to wash away before it is
dry
Note:
·Primer shall be dried more than 3 min
·Primer shall not be used as adhesion agent
·Primer shall not be excessive
(c) Coat glass glue on the glass
Part number:
3015526,( F500) or equivalent glass glue

(1) Cut the glue nozzle, size is shown as figure:

Standard
Area Data
a 10
b 14
Information:
After the glue nozzle is cut, use all glass glue in
reference to following time effect time.
Time limit
Temperature Time limit
35 15 min
20 1 hour and 40 min
5 8 hours
(2) Fill glass glue into the glue gun

13 / 35
 (3) Coat glass glue on the glass after the door

Rear

Side of drawing door

Side without drawing door

Standard
Area Data
a 10
b 14
c 13
d 13
e 13
(d) Assemble the glass on the vehicle body
(1) Slightly press the glass until it is assembled on the vehicle
body safely
Note:
Inspect whether the cushion matches the vehicle body
correctly
(2) Fix the glass on correct position by adhesion tape until
glass glue is solidified.
Note:
Look through following time table, determine time for adhesion
Temperature Duration after adhesion
35 degree 1 hour and 30 min
20 degree 5 hours
5 degree 24 hours
5. Inspect leakage and repair
(a) Carry out leakage testing after glue is completely dried
6 Assemble the left trim of the drawing door and window

14 / 35
Rear side window glass
Components

Fender interior vertical column (left)

Top ceiling inner upper trim board (left)

Buckle
Left front seat safety belt

Rear door sealing bar

Middle window glass

Left rear inner fender trim

Rear floor press bar

15 / 35
Remove
1. Remove the sealing bar of the rear door
2. Remove the middle window glass
(a) Use the adhesion tape to protection external
surface of the vehicle body so as to avoid scratching
(b) Insert one steel wire between the glass and the
vehicle body in the vehicle
(c) Bind a handle each at two ends of the steel wire
(such as a wood block)
Note:
Try to avoid damaging the interior and exterior of
paint surface of the vehicle body when glass glue is
cut
(d) Cut the glass glue in one round along the glass
through drawing the steel wire
(e) Use the suction disc to take away of the glass

Assemble
1. Clean the glass
(a) Use the blade to remove the cushion etc
auxiliaries.
(b) Use alcohol free of water to clean adhesion
position of the glass edge
Note:
Don’t touch after cleaning
Even though a new front windshield is used, it
shall be cleaned by gasoline free of lead

2. Clean vehicle body

(a) Clean and repair connection position with the
glass on the vehicle body
(1) For the adhesion surface of the vehicle body,
use the knife to cut the excessive glass glue shown as
figure
Information:
Remain glue on the vehicle body as more as
possible
Note:
Don’t damage the vehicle body
(2) Use the detergent to clean adhesion surface
between the vehicle body and the glass
Information:
Even all glass glue are removed, the vehicle
body shall still be cleaned.

16 / 35
 Rear
3. Assemble the buckles
(a) Coat primer on corresponding position of the
buckle
Information: If primer is coated at unnecessary
Side glass buckle position, use alcohol to move before drying
Note:
·Primer shall be dried for more than 3 min
·Reject any remaining primer
Pri ·Primer shall not be used too much

After cleaning of
4. Assemble the middle window glass
(a) Use the brush or sponge to coat paint on the
DW 646 DV947 Correct
surface of the vehicle
Information:
·Primer shall be dried for more than 3 min
After cleaning of DW 646 DV947 Wrong ·Reject any remaining primer.
·Primer shall not be used much
Adhesion agent
·Don’t take primer as adhesion agent
(b) Use the brush or sponge to coat primer on the
adhesion surface of the glass

Rear
After cleaning of DW 646 DV947

Side of drawing door

After cleaning of DW 646 DV947

Adhesion centre line

Adhesion centre line

After cleaning of DW 646 DV947 Side without drawing door

After cleaning of DW 646 DV947

Adhesion centre line

Adhesion centre line

Information:
If primer is coated at unnecessary position, use
alcohol free of water to move before drying

17 / 35
 Note:
·Primer shall be dried for more than 3 min
·eject any remaining primer.
·Primer shall not be used much

(c) Coat glass glue on the glass

Part number:
3015526, (F500) or equivalent glass glue
(1) Cut the glue nozzle, size is shown as figure:
Standard
Area Data
a 10
b 14
Information:
After the glue nozzle is cut, use all glass glue in
reference to following time effect time.
Time limit
Temperature Time limit
35 degree 15 min
20 degree 1 hour and 40 min
5 degree 8 hours
(2) Fill glass glue into the glue gun
(3) Coat glass glue on the glass shown as figure

Rear

Side without drawing door

18 / 35
 Standard
Area Data
a 10
b 14
c 7
d 13
e 13
f 13

(d) Assemble the glass on the vehicle body

(1) Slightly press the glass until it is assembled on the
vehicle body safely
Note:
Inspect whether the cushion matches the vehicle body
correctly
(2) Fix the glass on correct position by adhesion tape
until glass glue is solidified.
Note:
Look through the time table, move the vehicle only after
later interval for adhesion.

Temperature Time duration at least

35 degree 1 hour and 30 min
20 degree 5 hours

Temperature Time duration at least

5 degree 24 hours
5. Inspect leakage and repair
(a) (a)Carry out leakage testing after hardness of glue

19 / 35
Rear windshield glass
Components

Sealing bar of rear door

Right front safety belt

Top ceiling inner upper trim board (left)

Side fender column trim (left)

Rear floor press bar

Left rear inner fender trim

20 / 35
 Buckle of rear side wind glass

Rear side window glass

Parts can’t be used repeatedly

Remove
1 Disassemble the rear side window glass
(a) Use the protection tape to protect external
surface of the vehicle body so as to avoid damage
the vehicle body
(b) Insert one steel wire between the glass and
the vehicle body in the vehicle, shown as figure
(c) Bind a handle each at two ends of the steel
wire (such as a wood block)
Note:
When the glass is separated from the vehicle
body, pay attention to not damage paint surface of
the vehicle or the interior and exterior part
(d) Cut a round of glass glue of the glass through
drawing the steel wire
(e) Use the suction disc to take away of the glass
Note:
Make glue on the vehicle body as more as
possible during cutting

Assemble
1. Clean the rear side window glass
(a) Use the blade to scratch the shim etc
auxiliaries and remaining glue from the glass.
(b) Clean edge of the glass with gasoline free of
lead
Note:
Don’t touch after cleaning
Even though a new front windshield is used, it
shall be cleaned by gasoline free of lead

21 / 35
 2. Clean vehicle body
(a) Clean and repair connection surface
between the vehicle body and the glass
(1) Use the knife to cut excessive glass glue at
connection position between the glass and the
vehicle body shown as figure
Information:
Remove glue on the vehicle body as more as
possible
Note: Don’t damage the vehicle body
(2) Use detergent to clean the connection
surface
Information:
Even all glass glue are removed, the vehicle
body shall still be cleaned.
Rear 3. Assemble the rear side window glass cushion
block
(a) Coat primer 3M94# at position of the
adhesion cushion
Rear side window buckle Information:
If primer is coated at other position, use
gasoline free of lead to move before primer is dry
Note:
·Primer shall be dried more than 3 min
·Reject remaining primer.
(b) Assemble two buckles shown as figure
After cleaning of DW
·Primer shall not be coated too much
646 DV947
Correct 4. Assemble the rear window glass
(a) Coat primer on corresponding adhesion
surface of the glass on the vehicle body
Note:
Wrong
After cleaning of DW 646 DV947 ·Primer shall be dried for more than 3 min
·Primer shall not be used as adhesion agent
Adhesion agent
·Primer shall not be excessive
(b) Use the brush or sponge to coat primer on
the adhesion surface of the glass

22 / 35
Rear

After cleaning of DW 646 DV947

After cleaning of DW 646 DV947

Adhesion centre line

Adhesion centre line

After cleaning of DW 646 DV947

After cleaning of DW 646 DV947

After cleaning of DW 646 DV947

Adhesion centre line
Adhesion centre line

Adhesion centre line

Information:
If primer is coated at unnecessary position, use
gasoline free of lead to wash away before it is dry
Note:
·Primer shall be dried for more than 3 min
·Don’t take primer as adhesion agent
·Primer shall not be excessive
(c) Coat glass glue on the glass
Part number:
3015526, (F500) or equivalent glass glue
(1) Cut the glue nozzle, size is shown as figure:
Standard

Area Data
a 10
b 14
Information:
After the glue nozzle is cut, use all glass glue in
reference to following time effect time.
Time limit

Temperature Time limit

35 degree 15 min
20 degree 1 hour and 40 min
5 degree 8 hours
(2) Fill glass glue into the glue gun
(3) Coat glass glue on the glass shown as figure

23 / 35
Rear

Area Data
a 10
b 14
c 13
d 13
(1)Slightly press the glass until it is assembled on the
vehicle body safely
Note:
·Inspect whether the cushion matches the vehicle
body correctly
(2) Fix the glass on correct position by adhesion tape
until glass glue is solidified.
Note:
Look through the time table, move the vehicle only
after later interval for adhesion.

Temperature Time limit

35 degree 15 min
20 degree 1 hour and 40 min
5 degree 8 hours
5. Inspect leakage and repair
(a) Carry out leakage testing after hardness of glue

24 / 35
Rear door glass
Components

Buckle of rear windshield

Positioning pin of rear windshield Positioning pin of rear

windshield

Rear windshield

glass

Positioning pin of rear

windshield

Buckle of rear windshield

Positioning pin of rear windshield

Parts can’t be used repeatedly

Appointed torque

25 / 35
 Disassemble
1. Remove the rear wiper arm
2. Remove the rear door glass
(a) Use the protection tape to protect external
Protection adhesion tape surface of the vehicle body so as to avoid damage
the vehicle body
(b) Insert one steel wire between the glass and
the vehicle body in the vehicle, shown as figure
(c) Bind a handle each at two ends of the steel
wire (such as a wood block)
Note:
When the glass is separated from the vehicle
body, pay attention to not damage paint surface of
the vehicle or the interior and exterior part

(d) Cut a round of glass glue of the glass through

drawing the steel wire
(e) Use the suction disc to take away of the glass
Note:
Make glue on the vehicle body as more as
possible during cutting

Assemble
1. Clean the front side window glass
(a) Use the blade to scratch the shim etc
auxiliaries and remaining glue from the glass.
(b) Clean edge of the glass with alcohol free of
water
Note:
·Don’t touch after cleaning
·Even though a new front windshield is used, it
shall be cleaned by gasoline free of lead

2. Clean vehicle body

(a) Clean and repair connection surface between
the vehicle body and the glass
(1) Use the knife to cut excessive glass glue at
connection position between the glass and the
vehicle body shown as figure
Information:
Remove glue on the vehicle body as more as
possible
Note:
Don’t damage the vehicle body
(2) Use the detergent to clean adhesion surface
of the vehicle body
Information:
Even the glass glue has been removed, the
vehicle body shall be cleaned

26 / 35
 3. Assemble the left position pin
Rear (a) Coat primer at adhesion position of the
positioning pin
Positioning pin of rear windshield (left) Information:
If primer is coated at other position, use alcohol
free of water to move before 3M94# is dry
Note:
·Primer shall be dried more than 3 min
·Reject remaining primer.
·Primer shall not be coated too much
(b) Assemble a new positioning pin on the glass,
shown as figure

Rear 4. Assemble the right position pin

Positioning pin of rear windshield (right)
(a) Coat primer at adhesion position of the
positioning pin
Information:
If primer is coated at other position, use alcohol
free of water to move before 3M94# is dry
Note:
·Primer shall be dried more than 3 min
·Reject remaining primer.
Primer shall not be coated too much
(b) Assemble a new positioning pin on the glass,
shown as figure

5. Assemble the right position pin

Rear (a) Coat primer 3M94# at adhesion position of the
positioning pin
Information:
If primer is coated at other position, use alcohol
free of water to move before 3M94# is dry
Note:
·Primer shall be dried more than 3 min
·Reject remaining primer.
·Primer shall not be coated too much
(b) Assemble a new positioning pin on the glass,
shown as figure

Positioning pin of rear windshield

27 / 35
 6. Assemble the buckles
Rear
(a) Coat primer 3M94# at adhesion position of the
buckle
Information:
If primer is coated at other position, use
gasoline free of lead to move before 3M94# is dry
Rear side window buckle Note:
·Primer shall be dried more than 3 min
·Reject remaining primer.
·Primer shall not be coated too much
(b) Assemble a new buckle on the glass, shown
as figure

7 Assemble the rear door glass

After cleaning of DW 646 DV947
Correct (a) Coat primer on corresponding adhesion
surface of the glass on the vehicle body

Wrong
After cleaning of DW 646 DV947

Adhesion agent

Note:
·Primer shall be dried for more than 3 min
·Primer shall not be used as adhesion agent
After cleaning of DW 646 DV947
·Primer shall not be excessive

28 / 35
 (b) Use the brush or sponge to coat primer on the
adhesion surface of the glass

Rear

After cleaning of DW
646 DV947 Adhesion centre line
After cleaning of

DW 646 DV947
Adhesion centre line After cleaning of DW 646 DV947 After cleaning of DW 646 DV947
Adhesion centre line

Adhesion centre line

After cleaning of DW 646 DV947

Adhesion centre line

Information:
If primer is coated at unnecessary position, use
gasoline free of lead to wash away before it is dry
Note:
·Primer shall be dried for more than 3 min
·Primer shall not be used as adhesion agent
·Primer shall not be excessive
(c) Coat glass glue on the glass
Part number:
3015526, (F500) or equivalent glass glue
(d) Cut the glue nozzle, size is shown as figure:
Area Data
a 10
b 14
Information:
After the glue nozzle is cut, use all glass glue in
reference to following time effect time.
Time limit
Temperature Time limit
35 degree 15 min
20 degree 1 hour and 40 min
5 degree 8 hours
(e) Fill glass glue into the glue gun

29 / 35
 (f) Coat glass glue on the glass after the door
Rear

Specification
Area Data
a 10
b 14
c 13
d 13
(g) Assemble the rear door glass on the vehicle body
(1) Slightly press the glass until it is assembled on the
vehicle body safely
Note:
·Inspect whether the cushion matches the vehicle body
correctly
·Check whether there is an even gap between the vehicle
body and the rear door glass
(2) Fix the glass on correct position by adhesion tape until
glass glue is solidified.
Note: Look through the time table, move the vehicle only
after later interval for adhesion.
Temperature Time limit
35 degree 15 min
20 degree 1 hour and 40 min
5 degree 8 hours
8. Inspect leakage and repair
(a) Carry out leakage testing after hardness of glue
9. Assemble the rear wiper motor assembly
10. Assemble the upper part of the rear door trim board
11 Assemble the rear wiper arm

30 / 35
Windshield glass defrost system
Preventive measures
Note:
when the negative cable terminal of the battery is
disconnected, the cable after initialization is connected with the
system again

31 / 35
Parts
Defrost relay
Defrost fuse
Defrost switch

Defrost line

32 / 35
 System description
1.It means the fine fuse of the defrost system is attached on
the inner surface of the glass, which can quickly remove
frost on surface of the glass
2 Main working element
How to exclude fault
Information:
·Use these steps to exclude faults of the defrost system
·Use intelligent testing

1 Drive the vehicle to the workshop

Next step
2 Inspect voltage of the battery

Standard voltage is 11-14 v

If it is lower than 11v, replace the battery before it
continues to be used

Next step
3 Problem symptom table

Result Drive to
Wrong isn’t within problem list A
Wrong is within problem list B

To step 6

4 Whole analysis and solve problem

Next step
5 Repair or replace
Next step
Next step

33 / 35
6 Confirm testing
Next step
End

Problem symptom table

Defrost of Rear windshield
Symptom Doubt area
Not defrost Defrost fuse
gauge fuse
Defrost relay
Defrost control switch
Harness

ecu of the terminal

1. Inspect the defrost switch

(a)Measure voltage and resistance of every terminal

34 / 35
 Defrost line of the rear door glass
Repair
1 Inspect the defrost line of the glass
Note:
Use the soft dry cloth when the glass is
removed, be careful no damage the defrost line,
don’t use the washing agent, glass detergent or the
grinding material when voltage is measured. Bind
the head of the detection pen on a tin paper, press
the tin paper and the detection pen on the defrost
line by hand
(a) Inspect conductivity of each defrost line with
the method shown in the figure

2 Repair the defrost line of the glass

Maintenance point
(a) Use the grease, wax, silicon glue to clean the
damaged defrost line.
(b) Adhere the adhesion taps at both sides of the
defrost line which shall be repaired.
(c) Completely mix the remediator (Type of
Adhesion tape
Broken wire Dupont remediator. no. 4817)

(d) Use a good small brush to coat less

Small brush remediator on the
(e) Take out of the adhesion tape after several
minutes
(f) The defrost line can be repaired after 24 hours
Maintenance at least.
point

Glass

35 / 35
 Part Three Interior and exterior, electrical
appliances and car body
Chapter Eight Interior
Top cover ----------------------------------------------------------------------------------------------002

1 / 27
 Top cover (simplified interior)
Composition

With air conditioner Left A column upper

decoration

Right front frame

sealing bar

Right A column

upper

decoration

Right front floor press bar

Front vertical column

handrail

Front column handrail cover

Right sun visor board Pilot driver handrail

Front column handrail cover

Front vertical
Top lamp assembly column handrail

Sun visor center support

Left sun visor board

Left front door frame sealing bar

Sun visor center support

Left front floor press bar

2 / 27
With rear air conditioner

Common three points type safety belt assembly of front row seat

Right B column upper

decoration board

Right B column lower decoration board

Drawer door frame seal bar

Left hook of engine maintenance hole

Left B column upper decoration board

Common three points type safety belt of front row seat

3 / 27
 Driver seat assembly

Engine cover hinge decoration cover

Left B column lower decoration board

Appointed button

Widened vehicle type (with rear air conditioner)

Rear ceiling interior board assembly

Top ceiling buckle

Middle and rear top ceiling

interior board assembly

Rear indoor lamp assembly

Top ceiling buckle

4 / 27
Middle and front top ceiling

interior board assembly

Rear indoor lamp assembly

Front ceiling interior board assembly

Top ceiling interior board press bar assembly

5 / 27
Widened vehicle type (with rear air conditioner)

Rear ceiling interior board assembly

Middle and rear top ceiling interior board assembly

Top ceiling buckle

Rear indoor lamp assembly

Front ceiling interior board assembly

Rear indoor lamp assembly

Top ceiling interior board

press bar assembly

Outlet grid

6 / 27
 Remove:
1．Disconnect negative of the battery
2. Remove the left front door floor press
bar
(a) Remove 5 buckles and the left front
door floor press bar
3. Remove the right front door floor press
bar
4. Remove the left front door frame
sealing bar
5. Remove the right front door frame
sealing bar
6. Remove the drawing door frame
sealing bar
7. Remove the front vertical column
handrail cover
(a) Use the screw driver to jack the
handrail cover.
Information:
The head of the screw driver shall
wrapped by tape before using.
Use the same method to treat right side.

8. Remove the front vertical column

handrail assembly
(a) Remove two screws and the
handrail.
Information: Use the same method to
treat right side.

9. Remove the left A column interior board

(a) Remove two buckles
(b) Use the screw driver to remove 3
buckles and the left front A column interior
board.
10. Remove the right A column interior
board

7 / 27
 11. Remove the left A column interior board
(a) Use the screw driver to remove the
buckle, the clamp angle and the A column
interior board
12. Remove the right A column interior
board

13 Remove the handrail of the pilot driver

(a) Use the screw driver to remove the
cover of the pilot driver handrail
Information:
The head of the screw driver shall wrapped
by tape before using.

(b) Use the screw driver to remove 2

screws and the driver handrail

14. Remove the centre support of the sun

visor
(a) Remove screws

Information:
Use the same method to treat the right
support.

15. Remove the left sun visor

(a) Remove 2 screws and the left sun
visor

16. Remove the right sun visor Information:

Use the same method to treat the right
support.

8 / 27
17. Remove the top lamp assembly
(a) Use the screwdriver to remove 4 clip
foot and the lamp cover.
Information:
The head of the screw driver shall wrapped
by adhesive tape before using.

(b) Remove 2 screws

(c) Remove the conductor wire and
remove the top lamp assembly.

18. Remove the common three points type

safety belt assembly of the pilot driver seat
at front row.
(a) Remove the screw and the common
three points type safety belt assembly of the
pilot driver seat at front row.

(b) Use the screwdriver to remove 2 clip

feet and the lamp cover.
Information:
The head of the screw driver shall wrapped
by adhesive tape before using.

(c) Remove the screw and the common

three points type safety belt assembly of the
pilot driver seat at front row.

9 / 27
 19. Remove the right B column lower
interior board
(a) Remove the buckle.
(b) Remove four buckles and the right B
column lower interior board
Information:
The head of the screw driver shall
wrapped by adhesive tape before using.

20. Remove the cover hinge decoration

cover (with rear air conditioner)
(a) Use the screwdriver to remove 4 clip
angle and remove the cover hinge
decoration cover
Information:
The head of the screw driver shall
wrapped by adhesive tape before using.
21. Remove the driver seat assembly
(with rear air conditioner)
(a) Remove connection.
(b) Remove the screw cup and 3
screws.
(c) Remove the driver seat assembly.

22. Remove the seat safety belt screw

cover
(a) Remove two buckles
(b) Remove the clip angle and then
remove the seat safety belt screw cover.

23. Remove the external safety belt of

the right front seat assembly
(a) Remove the screw and then remove
the external safety belt of the left front
seat assembly.

10 / 27
 (b) Use the screwdriver to remove 2 clip
angles and the cover.
Information: The head of the screw driver
shall wrapped by adhesive tape before
using.

24. Remove the external safety belt of the

right front seat assembly
(a) Remove the screw and then remove
the external safety belt of the left front seat
assembly.

25. Remove the left B column lower interior

board
(a) Use the screwdriver to remove 4 buckles
and then remove the left B column lower
interior board assembly.

26. Remove the right B column lower

interior board
(a) Remove the buckle.
(b) Use the screwdriver to remove 2 clips
and buckles and then remove the right B
column lower interior board assembly.
Information:
The head of the screw driver shall wrapped
by adhesive tape before using.

27. Remove the left hook of the engine

maintenance hole cover.
(a) Remove the screw and the left hook of
the engine maintenance hole cover.

11 / 27
 28. Remove the left B column upper
interior board
(a) Use the screwdriver to remove 3
buckles and the clip angle and then
remove the left B column interior board
assembly.

29. Remove the rear indoor lamp

assembly
(a) Use the screwdriver to remove 4
clip angles and then remove the indoor
lamp assembly.
Information:
The head of the screw driver shall
wrapped by adhesive tape before
using.

(b) Remove 2 screws

(c) Remove the connection
conductor wire and the rear indoor
lamp assembly.

12 / 27
 30. Remove the top ceiling press bar

Information:
If there is buckle remained in the vehicle body, use
a clip to take out of other top ceiling press bar with
same method.
31. Remove the top ceiling clip.

32. Remove the top ceiling 4

Widened vehicle type

Widened vehicle type
(No rear air conditioner)
(No rear air conditioner)

13 / 27
 33. Remove the top ceiling 3

Widened vehicle type Widened vehicle type

(No rear air conditioner) (No rear air conditioner)

34. Remove the top ceiling 2

35. Remove the rear air conditioner
controller panel (with rear air conditioner)
36. Remove the front top ceiling interior
assembly
(a) With the rear air conditioner: remove 4
screws.

Widened vehicle type

Widened vehicle type
(with rear air conditioner cold wind)
(No rear air conditioner cold wind)

14 / 27
Assemble
1. Assemble the front top ceiling interior assembly
2. Assemble the centre support of the sun visor
3. Assemble the right sun visor
4. Assemble the left sun visor
5. Assemble the rear air conditioner panel
6. Assemble the middle front top ceiling interior assembly
7. Assemble the rear top ceiling interior assembly
8. Assemble the rear top ceiling interior assembly
9. Assemble the top ceiling buckle
10. Assemble the top ceiling interior board front press bar
assembly
11. Assemble the top ceiling interior board rear press bar assembly
12. Assemble the top ceiling rear indoor lamp assembly
13. Assemble the left B column upper interior board
14. Assemble the engine maintenance cover left hook
15. Assemble the right B column upper interior board
16. Assemble the left B column lower interior board
17. Assemble the front seat left safety belt

(a) Assemble the front seat left safety

belt
Torque: 42N*m

(b) Use two clip angles to assemble the

cover.

15 / 27
(a) Use the bolt to assemble the front seat left
outer safety belt assembly.
Torque: 42N*m
18. Assemble the decoration press cover at seat
safety belt installation location
19. Assemble the left seat assembly
20. Assemble left engine cover hinge decoration
cover
21. Assemble the lower independent support of
the cross beam
22. Assemble the right outer safety belt
assembly of the front seat
(a) Use the bolt to assemble the front seat right
outer safety belt assembly.
Torque: 42N*m
(b) Align 2 clip feet to assemble the decoration
cover.
(c) Use the bolt to assemble the front seat right
outer safety belt assembly.
Torque: 42N*m
23. Assemble the front indoor top lamp
assembly
24. Assemble the handrail
25. Assemble the right A column upper interior
board
26. Assemble the right A column lower interior
board
27. Assemble the left A column upper interior
board
28. Assemble the left A column lower interior
board
29. Assemble the rear handrail assembly
30. Assemble the right front handrail screw
cover
31. Assemble the drawing door frame sealing
bar
32. Assemble the right front door frame sealing
bar
33. Assemble the left front door frame sealing
bar
34. Assemble the right front floor press bar
assembly
35. Assemble the left front floor press bar
assembly
36. Transmit the cathode battery terminal
equipment
37. Implement initialization
Note:
When some systems can’t be connected with
the cathode battery terminal, it shall be
initialized.

16 / 27
 Right C and D column upper trim assembly

Right B column upper trim assembly

Right E column upper

trim assembly

Rear handrail assembly

Right front door frame sealing bar

Right A column
upper trim assembly

Screw cover of rear handrail Right rear fender

Right B column lower trim decoration assembly

assembly

Handrail assembly

Screw cover of front handrail Right drawing door

frame sealing bar

Tail door sealing bar

Front seat right external safety

Right front floor press
belt assembly
bar assembly

Left seat assembly

Pedal box assembly of drawing door

Rear floor press bar assembly

17 / 27
 Screw cover of front Front seat left external safety belt assembly

handrail

Handrail assembly

Left E column upper

Left A column upper trim
trim assembly
assembly

Left C and D column upper

trim assembly

Left B column upper trim assembly

Left hook of engine maintenance hole cover

Left front door frame

sealing bar
Left rear fender
decoration assembly

Engine cover hinge

decoration cover
Left front fender decoration
assembly
Seat safety belt guiding
ring decoration cover

Left front floor press bar

assembly

18 / 27
 Front ceiling interior board assembly

Right sun visor assembly

Rear indoor lamp
assembly

Flagship type: floor lamp assembly

Side turnover
seat assembly
Rear air conditioner
controller panel

Handrail assembly

Side turnover seat

assembly

Left sun visor assembly

Rear ceiling interior
Centre support of sun visor
board assembly

Rear indoor lamp assembly

19 / 27
 Remove:
1. Disconnect the cathode battery
2. Remove the single seat assembly
3. Remove the double seat assembly
4. Remove the rear turnover seat
assembly
5. Remove the external installation point
of the rear seat safety belt assembly
6. Remove the external installation point
of the left rear double seat safety belt
assembly
7. Remove the external installation point
of the left rear turnover seat safety belt
assembly
8. Remove the left front floor press bar
assembly
9. Remove the right front floor press bar
assembly
10. Remove the left door frame sealing
bar
11. Remove the right front door frame
sealing bar
12. Remove the external safety belt
assemble of the right front seat
13. Remove the engine cover hinge
decoration cover
14. Remove the left seat assembly
15. Remove the decoration press cover
at seat safety belt installation location
16. Remove the external safety belt
assemble of the left front seat
17. Remove the drawing door pedal box
assembly
(a) Use the lifting driver to remove 11
buckles and the drawing door pedal box.
Note: Tip shall be wrapped by the
adhesive tape before the lifting driver is
used.
18. Remove the right drawing door frame
sealing bar
19. Remove the rear floor press bar
assembly
(a) Use the lifting driver to remove 7
buckles and 4 clip feet, and then remove
the rear floor press bar assembly.
Note: Tip shall be wrapped by the
adhesive tape before the lifting driver is
used.
20. Remove the rear door frame sealing
bar

20 / 27
 21. Remove the left rear fender
decoration assembly.
(a) Use the lifting driver to remove 16
buckles and remove the rear fender
decoration assembly.
Note: Tip shall be wrapped by the
adhesive tape before the lifting driver is
used.

22. Remove the left rear fender

decoration assembly.
(a) Use the lifting driver to remove 16
buckles and remove the rear fender
decoration assembly.
Note: Tip shall be wrapped by the
adhesive tape before the lifting driver is
used.
23. Remove the right rear fender
decoration assembly.

24. Remove the left front fender

decoration assembly.
(a) Use the lifting driver to remove 18
buckles and remove the left right fender
decoration assembly.
Note: Tip shall be wrapped by the
adhesive tape before the lifting driver is
used.

21 / 27
 25. Remove the left hook of the engine
maintenance hole cover.
(a) Remove the left hook of the engine
maintenance hole cover.

26. Remove the left B column upper interior

board
(a) Use the lifting driver to remove 3 buckles
and 2 clip feet, and then remove the left
upper decoration assembly.
Note: Tip shall be wrapped by the adhesive
tape before the lifting driver is used.

27. Remove the drawer cover

(a) Use the screwdriver to remove the
drawer cover.
Note: Tip shall be wrapped by the adhesive
tape before the screwdriver is used.

28. Remove the rear drawer.

(a) Use the screwdriver to remove 2 screws
and the rear drawer.

29. Remove the right B column lower

interior board
(a) Remove 3 buckles and remove the right
B column lower decoration assembly.

22 / 27
 30. Remove the right B column upper
interior board
(a) Remove 3 buckles and remove the
right B column lower decoration assembly.

31. Remove the left C and D columns

upper interior assemblies.
(a) Remove 6 buckles and remove the left
C and D columns lower decoration
assemblies.
32. Remove the right C and D columns
upper interior assemblies.

33. Remove the left E column upper

interior board
(a) Use the lifting driver to remove 6
buckles and remove the left column E
column upper decoration assembly.
Note: Tip shall be wrapped by the
adhesive tape before the lifting driver is
used.
34. Remove the right E column upper
interior board

35. Remove the rear seat hook (side

turnover seat)
(2) Remove 2 bolts and the side turnover
seat hook.

23 / 27
 36. Remove the rear indoor lamp
assembly (luxury type)
(a) Use the screwdriver to remove 4 clip
feet and remove the indoor lamp
transparent cover.
Note: Tip shall be wrapped by the
adhesive tape before the screwdriver is
used.

(b) Remove 2 screws

(c) Disconnect the wire plug and remove
the rear indoor lamp assembly.

37. Remove the rear indoor lamp

assembly (flagship type)
(a) Use the screwdriver to remove 4 clip
feet and remove the indoor lamp
transparent cover.
Note: Tip shall be wrapped by the
adhesive tape before the screwdriver is
used.
(b) Remove 2 screws

(c) Pull back the rear indoor lamp and

make the clip foot disengaged.
(d) Disconnect the wire plug and remove
the rear indoor lamp assembly.

38. Remove the rear top ceiling interior

assembly
(a) Use the lifting driver to remove 24
buckles and remove the top ceiling interior
board assembly.
Note: the buckle in the figure shall be
removed together with the rear top ceiling.
39. Remove the front handrail decoration
cover
40. Remove the handrail assembly

24 / 27
 41. Remove the left A column upper interior
board
(a) Use the lifting driver to remove the
buckle and remove the left A column upper
decoration assembly.
Note: Tip shall be wrapped by the adhesive
tape before the lifting driver is used.
42. Remove the right A column upper
interior board
43. Remove the handrail assembly
44. Remove the centre support of the sun
visor
45. Remove the left sun visor assembly
46. Remove the right sun visor assembly
47. Remove the front indoor lamp assembly
(luxury type)
(a) Use the screwdriver to remove 4 clip feet
and remove the indoor lamp transparent
cover.
Note: Tip shall be wrapped by the adhesive
tape before the screwdriver is used.

(b) Remove 2 screws

(c) Disconnect the wire plug and remove the
rear indoor lamp assembly.

48. Remove the front indoor lamp assembly

(flagship type)
(a) Use the special screwdriver to remove 4
clip feet and remove the indoor lamp
assembly.
(b) Disconnect the wire plug and remove the
rear indoor lamp assembly.
49. Remove the rear air conditioner
controller panel

25 / 27
50. Remove the front top ceiling interior assembly
(a) Take out of 4 clip feet.
(b) Use the lifting driver to remove 15 buckles and
remove the top ceiling interior board assembly.
Note:
The buckle in the figure shall be removed together
with the rear top ceiling.
Assemble
1. Assemble the front top ceiling interior assembly
2. Assemble the centre support of the sun visor
3. Assemble the right sun visor
4. Assemble the left sun visor
5. Assemble the rear air conditioner control panel
6. Assemble the front indoor lamp assembly
(flagship type)
7. Assemble the front indoor lamp assembly (luxury
type)
8. Assemble the handrail
9. Assemble the right A column upper interior board
10. Assemble the left A column upper interior board
11. Assemble the handrail assembly
12. Assemble the front handrail decoration cover
13. Assemble the rear top ceiling interior assembly
14. Assemble the rear top ceiling interior assembly
15. Assemble the rear indoor lamp assembly
(flagship type)
16. Assemble the rear indoor lamp assembly (luxury
type)
17. Assemble the turnover seat hook
18. Assemble the right E column upper interior
board assembly
19. Assemble the left E column upper interior board
assembly
20. Assemble the right C and D columns upper
interior assemblies.
21. Assemble the left C and D columns upper
interior assemblies.
22. Assemble the right B column upper interior
board
23. Assemble the rear handrail assembly
24. Assemble the handrail decoration cover
25. Assemble the left B column upper interior board
26. Assemble the engine maintenance hole cover
hook
27. Assemble the left front fender decoration
assembly.
28. Assemble the right rear fender decoration
assembly.
29. Assemble the rear door windshield bar
30. Assemble the rear floor press bar assembly

26 / 27
30. Assemble the left outer safety belt assembly of
the front seat
31. Assemble the decoration press cover at seat
safety belt installation location
32. Assemble the front seat left safety belt assembly
33. Assemble left engine cover hinge decoration
cover
34. Assemble the right outer safety belt assembly of
the front seat
35. Assemble the right front door frame sealing bar
36. Assemble the left front door frame sealing bar
37. Assemble the right front floor press bar assembly
38. Assemble the left front floor press bar assembly
39. Assemble the left outer safety belt assembly of
the turnover seat
40. Assemble the left outer safety belt assembly of
the rear double seat
41. Assemble the rear seat outer safety belt
assembly
42. Assemble the turnover seat assembly
43. Assemble the rear double seats assembly
44. Assemble the rear single seat assembly
45. Connect the cathode battery terminal
46. Implement initialization
Note: When some systems are connected with the
terminal of the upper cathode battery, they shall be
initialized

27 / 27
Part Three Interior and exterior, electrical appliances and
car body
Chapter Two Lamp
Headlamp component……………………………………………………………………..………002
Front fog lamp component……………………………………………………....................……010
Rear combination lamp……………………………………………………………………….…...011
License plate lamp…………………………………………………………………………….…...013
High position brake lamp……………………………………………………………………..…...015

1/18
Headlamp component

Headlamp assembly

Harness of direction signal lamp

PY21W bulb

Rear cover

H1 bulb

Lamp body

2/18
Remove
1 Remove the front grill
2 Remove the left foot pedal
3 Remove the right foot pedal
4 Remove the front bumper assembly
5 Remove the fixing support at side of the front bumper

3/18
 5 Remove the headlamp (extract out)
Adjustment
knob C
Adjustment
（a） Remove 1 screw and one bolt
Adjustment
knobD knob A
Adjustment （ b ） Draw the headlamp out along indication
knob B
direction of the arrow.
（c） Take out of the headlamp after the plug-in is
drawn out

Remove and assemble the headlamp

1 Remove the rear cover of the NO.1 headlamp
(a) Remove the rear cover of the NO.1 headlamp

2 Remove the bulb of the NO.1 front lamp

(a) Release the jump ring (a) in the figure and
remove the bulb

3 Remove the front direction signal lamp

(a) Rotate following direction shown in the figure and
then take out of

4 Remove the front direction signal lamp seat

(a) Take out of the front direction signal lamp bulb
from the bulb seat

4/18
 Lamplight adjustment of the headlamp

7 Park the vehicle according to requirements

(a) Vehicle preparation
·Ensure there is no damage on the vehicle body and
around the headlamp.
·The vehicle is full of fuel and lubrication oil.
·The tire is inflated according to specified bearing
pressure.
·Place the spare tire and tools etc. auxiliaries on the
appointed position.
·Confirm that the parking brake is released, and the
transmission is on idle position.
·One person with weight of 75kg can seat on the
driver seat.
2. Light adjustment reference screen preparation of
headlamp
(a) Detect environment preparation
·The ambient environment shall be dim enough so as
to facilitate observe the cut-off line of lamplight of the low
beam headlamp, lower part of the cut-out line is visible

25m
light lighting part, the upper part is dim area.
3m
·Check whether the screen is vertically placed. Check
whether distance between the screen and the vehicle
(centre of the headlamp bulb) is 25m.
· Maintain level and flat during measurement of the
ground
·Repeat to adjust the suspension frame, and make
the vehicle on horizontal position.
Note
Distance between the detection screen and the vehicle
must be kept at 25m. If it can’t guarantee, the span of 3
m must be reserved for measurement and adjustment.
(But corresponding adjustment must be made according
to following sample during detection)
(b) Prepare a thick whiter paper with height of about 2m
and width of 4m as the detection screen.

5/18
 (c) Draw the horizontal straight line (V line) on the white
paper.
(d) Place the screen as following figure.
Information
·The screen shall be placed vertically to the ground.
· V line on the screen is aligned to the centre of the
vehicle.
Distance is 25m
Distance is 25m
V RH line
V RH line

V line V line
3m
25m
V LH line
V LH line

H line
H line

3m 25m

VLH line V line V RH line H line Ground

V LH line V line V RH line

(c) Shown as the figure draws the reference lines (H line,
VLH line, VRH line) on the screen.

H line
Information:
·The reference line shall be consistent with the lamplight
Ground height specified by the vehicle manufacturer.
·Make the marking on the screen corresponding to the
centre of the bulb. If it can’t be found, try to mark according
to position of the lamp centre given by the vehicle
manufacturer.
(1) H line
Draw a horizontal line passing through the bulb on the
screen. Height of the horizontal lien shall be consistent with
height of the lamp centre of the low beam headlamp.

(2) VLH line, VRH line: the horizontal lines which pass
through the lamp centre of the left and the right headlamp

6/18
 respectively.

3 Lamplight inspection of the headlamp

(a) Detect a lamp independently, cover lamplight at another
side or draw out the plug-in.
Note
Time when the surface of the lamp is covered shall not
exceed 3 minutes, otherwise the mask part of the lamp is
liable to be overheat, which causes fuse.
If the lamp is the separated upper beam headlamp and the
low beam headlamp. Lamplight of the low beam headlamp
shall be covered during measurement of the upper beam
headlamp, or draw out the plug-in of the low beam
headlamp.
(b) Start the engine
Note
Rotation speed of the engine shall not be lower than
1500RPM.
(c) Adjust the adjustment switch of the headlamp.
(1) Adjust the switch to the O shift.

(d) Open the headlamp, and make the cut-out line of the low
beam headlamp below the appointed position in the
following figure.

Distance of 25m:
Distance of 3m:
Low beam headlamp V LH line
Low beam headlamp V LH line
V RH line
V RH line
48mm 6mm

H line H line

249mm 698mm 30mm 84mm

Cut-out line Cut-out line

Upper beam headlamp: Upper beam headlamp:

V LH line V LH line

V RH line V RH line

H line
H line

15mm
130mm

Information:
·When detection distance is 25m:

7/18
Actual height of lamplight is 48 ~ 698mm lower than the H line of the low beam headlamp.
·When it is measured at distance of 3m:
Actual height of lamplight is 6 ~ 84mm lower than the H line of the low beam headlamp.
·When the detection distance is 25m, the cut-out line is 249mm lower than the H line
·When the detection distance is 3m, the cut-out line is 30mm lower than the H line
·When the upper beam headlamp and the low beam headlamp use the same light
adjustment unit, ensure two light are correct at same time.
Adjustment 4 Manual adjustment of the headlamp
knob C
Adjustment Adjustment （a） Use the adjustment knob A and the adjustment knob B
knob D knob A
Adjustment to adjust upper and lower directions and horizontal direction
knob B
of low beam
（b） Use the adjustment knob A and the adjustment knob B
to adjust upper and lower directions and horizontal direction
of upper beam

Assemble the headlamp

1 Assemble the direction signal lamp

2 Assemble the upper beam headlamp

3 Assemble the low beam headlamp

8/18
3 Assemble the rear cover

Assembly
1 Assemble the headlamp
(a) Connect the plug-in
(b) Connect 2 buckles.
(c) Tighten 1 screw and one bolt
2 Assemble the support of the front bumper (side of the vehicle
body)
3 Assemble the front bumper rod assembly
4 Assemble the left and the right pedals.

9/18
Front fog lamp component

Front bumper cover

Right side traction

hook cover

Left side traction

hook cover

Left side fog lamp

cover

Left side fog lamp

Right side fog lamp assembly
Right side fog lamp
assembly
cover

Remove
1 Remove the front grill
2 Remove the left and the right foot pedals
3 Remove the front bumper rod assembly

10/18
Rear combination lamp component

Rear combination
lamp assembly

Installation P21W bulb

bolt
Harness
sub-assembly

Shock absorption
cushion

Ventilation pipe
Rear lamp
P21W bulb body

11/18
 Remove
1 Remove the rear combination lamp assembly

Insertion (a) Remove 2 screws

pin
(b) Draw out the rear combination lamp along
direction shown in the figure.
(c) Draw out the dismantled parts.

Remove and assemble the rear combination

lamp
1 Take away of the bulb seat
(a) Rotate the bulb seat along the arrow direction;
take out of the bulb seat and the harness
sub-assembly
2 Assemble the bulb seat and the harness
sub-assembly.
Assembly
Insertion
pin 1 Assemble the rear combination lamp assembly.
(a) Connect the plug-in.
(b) Assemble the lamp on the vehicle, and
tighten the screw.

12/18
License plate lamp composition

Internal handle of rear door

Internal handle
assembly of
rear door
Internal handle
frame of rear
door

Interior board of
rear door
Wide body
Internal handle
assembly of
rear door

Interior board of
Interior board of rear door
rear door

Assemble decoration board

of rear door license plate

License plate lamp

Harness of license plate lamp

Bulb of license
plate lamp
Bulb of license
plate lamp

13/18
 Remove
1 Remove the rear door interior board
2 Remove the rear door outer decoration

3 Remove the license plate lamp

(a) Remove 2 screws and the bulb
(b) Shown as the figure, remove the license plate
lamp
Clamp

Remove
1 Remove the bulb of the license plate lamp
(a) Rotate along direction of the installation arrow,
remove the bulb and the harness of the license plate
lamp
2 Remove the bulb of the license plate lamp
(a) Remove the bulb from the harness.

Assembly
1 Assemble the bulb of the license plate lamp
2 Assemble the harness of the license plate lamp

Assembly
1 Assemble the license plate lamp assembly
2 Assemble the rear door outer decoration
3 Assemble the rear door interior board
4 Assemble the handle frame of the rear door
5 Assemble the high position brake lamp in the
handle assembly in the rear door.

14/18
High position brake lamp

Wide body
With rear wiper (high top)

Interior board assembly of rear door

Interior board assembly of rear door

High position brake lamp

Remove

1 Remove the interior board in the

rear door
2 Remove the high position brake
lamp assembly
(a) Pull out of the plug-in
(b) Loose four clutches and take out of
the lamp

15/18
 Assembly
1 Remove the high position control lamp assembly
(a) Place the 4 clutches at appointed position after assembly.
(b) Connect the plug-in.
2 Assemble the interior board in the rear door
Danger warning switch
Inspection
1 Check the danger warning switch
(a) Check operation of the danger warning switch.
（1） Remove the danger warning switch
（2） Measure resistance according to resistance value in the following table.
Resistant

Testing connection Switch operation Appointed conditions

3-4 OFF 10kΩ or higher
3-4 ON Lower than 1Ω

If the result isn’t in accordance with setting, replace the danger warning switch.

(b) Check operation of lighting.

（1） Impose voltage of the battery on the plug-in of the switch.

Correct conditions
Test conditions Appointed conditions
Positive (+) terminal 1 of battery Continuous lighting
Positive (+) terminal 2 of battery

If the result isn’t in accordance with setting, replace the danger warning switch.
Switch of the rear fog lamp
On-line inspection
1 Check the switch of the rear fog lamp
(a) Disconnect the plug-in of the rear fog lamp
(b) Measure resistance and voltage between the plug-in at the harness end of the
grounding of the vehicle body.
(1) Measure resistance according to resistance value in the following table.
Resistant

Testing connection Conditions Appointed conditions

1—Body grounding Continuous Lower than 1Ω
The dimmer switch of the headlamp
6—Body grounding 10kΩ or higher—lower than 1Ω
turns off one headlamp
The switch of the rear fog lamp turns
7—Body grounding 10kΩ or higher—lower than 1Ω
off – switches on
8—Grounding — Body Continuous Lower than 1Ω

16/18
Voltage
Testing connection Conditions Appointed conditions
The dimmer switch of the headlamp
3—Body grounding Lower than 1Ω10—14V
turns off one lamp
4—Body grounding Continuous 10—14V

If the result isn’t in accordance with setting, the harness end may be failed.
(a) Connect the terminal with the switch of the rear fog lamp again.
(b) Measure voltage according to value in the following table.
Voltage
Testing connection Conditions Appointed conditions
The dimmer switch of the headlamp
8—Grounding — Body Lower than 1V
turns off
The dimmer switch of the headlamp
8—Grounding — Body turns to the headlamp, the rear fog 10—14V
lamp turns on
The dimmer switch of the headlamp
8—Grounding — Body Lower than 1V
turns off
The dimmer switch of the headlamp
8—Grounding — Body turns to the headlamp, the front fog
and the rear fog lamp turn on
If the result isn’t in accordance with setting, replace the rear fog lamp switch.
Horizontal regulation switch of the headlamp
Inspection
1 Inspect the horizontal regulation switch of the
headlamp
(a) Inspect operation of the horizontal regulation switch
of the headlamp
(1) Take out of the horizontal regulation switch of the
headlamp
(2) Impose voltage of the battery on the horizontal
adjustment switch plug-in of the headlamp.

Voltage
Positive (+) of battery → terminal 2 Switch Testing Voltage of battery under
Negative (-) of battery → terminal 1 condition connection appointed conditions (12V)
Positive (+) of battery → terminal 2 0 4‐1 10.44V—11.16V
Negative (-) of battery → terminal 1 5‐1
Positive (+) of battery → terminal 2 1 4‐1 8.52V—9.24V
Negative (-) of battery → terminal 1 5‐1
Positive (+) of battery → terminal 2 2 4‐1 6.60V—7.32V
Negative (-) of battery → terminal 1 5‐1
Positive (+) of battery → terminal 2 3 4‐1 4.68V—5.4V
Negative (-) of battery → terminal 1 5‐1
Positive (+) of battery → terminal 2 4 4‐1 2.76V—3.48V
Negative (-) of battery → terminal 1 5‐1
Positive (+) of battery → terminal 2 5 4‐1 0.84V—1.56V
Negative (-) of battery → terminal 1 5‐1

17/18
If the result isn’t in accordance with setting, replace the horizontal adjustment switch of the
headlamp.
(b) Check operation of lighting.
(1) Impose voltage of the battery on the horizontal adjustment switch plug-in of the headlamp.
(2) Check whether lighting appears.

Correct
Measurement conditions Appointed conditions
Positive (+) of battery → terminal 3 Lighting is on
Negative (-) of battery → terminal 6

If the result isn’t in accordance with setting, replace the horizontal adjustment switch of the
headlamp.
Inspection of the headlamp relay
1 Check the headlamp relay
(a) Pull out of the headlamp relay.
(b) Detect the relay according to following table.

Measurement pin Measurement result

3‐‐5 10kΩ or higher
Lower than 1Ω (When
3‐‐5 voltage of the battery is
imposed on 1-2 pins)
If it isn’t in accordance with the above table, please
replace the relay.
Inspection of the fog lamp relay
1 Check the fog lamp relay
(a) Pull out of the fog relay
(b) Detect the relay according to following table.

Measurement pin Measurement result

3‐‐5 10kΩ or higher
Lower than 1Ω (When voltage of the
3‐‐5
battery is imposed on 1-2 pins)

18/18
Part Three Interior and exterior, electrical appliances and car
body
Chapter Nine Dashboard
Component ………………………………………………………………….……………..002

1 / 17
 Dashboard part
Components:

Combination switch protection cover (upper)

Combination switch

Combination switch protection cover (lower)

Steering wheel proper body

Upper cover of steering wheel

Configuration with safety airbag

Steering wheel

Right blank cover of steering wheel

Driver airbag

Left blank cover of steering wheel

Appointed torque

2 / 17
Radio

Radio with frame

Combination instrument cover

Combination instrument

Centre panel assembly of dashboard

Left air outlet vent panel assembly of dashboard

Right defrost vent panel assembly of dashboard

Left defrost vent panel assembly

3 / 17
Left A column upper interior assembly
Right A column upper interior assembly
Pilot driver front airbag

Front vertical column handrail

Front vertical column handrail

Pilot driver front airbag module assembly

Front column handrail cover

Front column handrail cover

Danger warning switch

Dashboard proper body assembly

Shifting operator assembly

Glove box assembly

Shifting hand ball

Air conditioner control panel

Manual transmission shift assembly

Middle and lower protection board assembly of dashboard

Manual brake protection board assembly

Left and lower protection board assembly of dashboard

Appointed torque Lower protection board assembly of dashboard

4 / 17
Dashboard harness

Configuration without pilot driver airbag

Upper storage box cover assembly

Dashboard proper body assembly

Configuration with pilot driver airbag

Auxiliary airbag connection board

5 / 17
 Remove
1. Remove the wiper switch
2. Remove the right defrost vent panel
assembly of the dashboard
(a) Use the removal tools to disengage
three assembly claws and remove the right
defrost vent panel assembly of the dashboard
3. Remove the centre panel assembly of the
dashboard
(a) Use the removal tools to disengage the
assembly claws according to sequence
shown in the figure.

6 / 17
 (b) In order to protect the centre panel of
the dashboard against damaging, adhere the
adhesive tape at position shown in the figure.
(c) Use the removal tools to disengage the
Protection adhesive tape
assembly claws.

(d) Grasp the panel and pull back to rear

part of the vehicle as figure and make the
assembly claws disengaged.

(e) Support the panel by right hand and pull

back to rear part of the vehicle as figure and
make the assembly claws disengaged.

7 / 17
 (f) Grasp the panel as figure and make
the assembly claw disengaged.

(g) Grasp the panel and pull the part back

as figure and make the assembly claws
disengaged. Remove the centre panel
assembly of the dashboard
Note:
When the centre panel assembly of the
dashboard is removed, the harnesses of
lower three switches of the middle CD
player shall be firstly removed.

4. Remove the left dashboard defrost vent

assembly.
(a) Use the removal tools to disengage
three assembly claws and remove the
dashboard defrost vent assembly.

5. Remove the left defrost vent panel

assembly of the dashboard
(a) Use the removal tools to disengage
four assembly claws and remove the left air
outlet panel assembly of the dashboard

8 / 17
6. Remove the combination instrument cover
assembly
(a) Remove the combination instrument cover
assembly after 5 assembly claws are disengaged.

7. Remove the combination instrument assembly

(a) Remove 2 bolts

(b) Disengage 2 clips

(c) Disconnect the harness joint and then remove
the combination instrument assembly.

8. Remove the radio and the support

9 / 17
 9. Remove the left lower protection board
assembly of dashboard
Clip
(a) Use the clips removal tools to remove two
clips A.
(b) Make five clips B disengaged.
Clip (c) Disconnect the connection location.
Clip

(d) Shown as figure, loose and take out of the

screw, and take out of the opening handle of the
oil tank door and the front cover opening handle
along direction of the arrow. Remove the lower
protection board assembly of the dashboard.
Note: Confirm that the harness at rear of the
switch on left upper area is removed before the
left lower protection board assembly of the
dashboard is removed.

10. Remove the left lower protection board

assembly of dashboard
(a) Use the clips removal tools to remove two
clips A.
(b) Use three assembly claws to remove the
lower protection board assembly of the
dashboard.

11. Remove the manual brake protection board

assembly
(a) Remove seven assembly claws and
remove the manual brake protection board
assembly.

10 / 17
 12. Remove the shifting hand ball
(a) Rotate the shifting hand ball and remove
the shifting hand ball according to direction of the
arrow shown in the figure.

13. Remove the eave assembly of the manual

transmission
(a) Manual transmission
Make eight assembly claws disengaged and
remove the eave assembly of the manual
transmission.

14. Remove the middle lower protection board

assembly of the dashboard
(a) Remove 11 claws and take out of the
middle and lower protection board of the
dashboard.
15. Remove the shifting mechanism assembly.
16. Remove the air conditioner controller panel
assembly.

17. Remove the glove box assembly

(a) Push the glove box and make two locking
position release at direction of the arrow shown in
the figure.

Limitation lock

11 / 17
 (b) Pull the glove box at direction of the arrow
shown in the figure, and make two hinges
disengaged.
(c) Remove the glove box assembly
18. Remove the shifting mechanism
19. Remove the front vertical column handrail cover
20. Remove the front vertical column handrail cover
21. Remove the left A column upper decoration
assembly (vehicle type with rear warm air)
22. Remove the right A column upper interior
assembly
Hinge
23. Remove the proper body of the dashboard
(a) Remove six bolts and three nuts.
(b) Remove two bolts
(c) Pull out of the proper body assembly of the
dashboard to direction of own body, and confirm
whether there is harness connected with the
instrument.
Note: when the proper body of the dashboard is
taken out of the vehicle, don’t damage by collision
between the proper body of the dashboard and the
steering column etc.

Clip

12 / 17
 25. Remove the upper storage box cover
assembly (vehicle type without pilot driver
airbag)
(a) Use eight assembly claws to disengage
and remove the upper storage cover assembly

26. Remove the proper body of the dashboard

Re-assemble
1、 Assemble the dashboard proper body
assembly

2. Assemble the upper storage box cover

assembly (vehicle type without pilot driver
airbag)
(a) Assemble the upper storage cover
assembly on the dashboard proper body
through eight assembly claws.

13 / 17
 Clamp

Assemble
1、Assemble the dashboard proper body assembly
(a) Connect all harness joints
(b) Use six bolts and three screws and two nuts to
assemble the dashboard proper body assembly.

Clamp

14 / 17
 2. Assemble the right A column upper interior
assembly
3. Assemble the left A column upper interior
assembly
4. Assemble the front vertical column handrail
5. Assemble the front vertical column handrail
cover
6. Assemble the shifting operator assembly
7. Assemble the middle lower protection board
assembly of the dashboard
8. Assemble the manual air conditioner controller
9. Assemble the middle lower protection board of
the dashboard
(a) Clamp connect 11 claws and assemble the
middle and lower protection board of the
dashboard.

10. Assemble the eave assembly of the manual

transmission
(a) Manual
Connect with the manual air conditioner
controller through 8 assembly claws.
11. Assemble the shifting hand ball

12. Assemble the manual brake protection board

assembly
(a) Connect with the dashboard through 7
assembly claws.

15 / 17
 13. Assemble the lower protection board
assembly of the dashboard
(a) Fix 3 assembly claws
(b) Use two clips to assemble the lower
protection board assembly of the dashboard

14. Assemble the left lower protection board

Clip
assembly of the dashboard
(a) Fix 5 assembly claws B
(b) Use two clips A to assemble the left lower
protection board assembly of the dashboard
Clip Note:
Clip Harness connection of the switch must be
complete before the left lower protection board
of the instrument is complete.
15. Assemble radio

16. Assemble the combination instrument

assembly

16 / 17
 17. Assemble the combination instrument cover
assembly
(a) Fix 5 assembly claws
18. Assemble the left air outlet vent panel
assembly of the dashboard
19. Assemble the left defrost vent panel
assembly of the dashboard
20. Assemble the centre panel assembly of the
dashboard
Note:
Please check whether the harness
connection of the middle three switches are
complete before the centre panel assembly of
the dashboard is complete.
21. Assemble the pilot driver airbag module
assembly (Pilot driver airbag configuration )
22. Assemble the glove box assembly
23. Assemble the right defrost vent panel
assembly of the dashboard
24. Adjust the clock spring (with airbag),
harness, plug-in, run through the cover under
the steering wheel and extend to the upper area
of the steering wheel.
25. Assemble the steering wheel.
26. Assemble the upper cover of the steering
wheel(no safety airbag)
27. Assemble the driver airbag module (with
safety airbag).

17 / 17
 Part Three Interior and exterior, electrical
appliances and car body
Chapter Six Combined instrument
Inspection specification ………………………………………………………….002
Outline and socket pin of combined instrument…………………………………..004
Fault and troubleshooting …………………………………………………………014

1/8
Inspection specification
Refer to QC/T 727—2004 Instruments for automobile and motorcycle for inspection of the
combined instrument

1. Odometer
Basic error of the odometer km/h
Indication speed of
Actual speed Input frequency (Hz)
odometer
20 17---23 14.16
40 35---40 28.32
60 55---60 42.48
80 75---80 56.64
100 95---100 70.80
120 114---120 84.96
140 133---140 99.12
160 152---160 113.44
180 171---180 127.44

2. Revolution indicator of engine

Basic error of the revolution indicator r/min
Indication speed of Basic error (% value of
Input frequency (Hz)
revolution indicator inspected point)
1000 33.3 ±10
2000 66.7 ±10
3000 100 ±5
4000 133.3 ±5
5000 166.7 ±5
6000 200 ±5
7000 233.3 ±5

3. Fuel meter
Parameter value of fuel meter
Scale of fuel meter Input resistance (Ω) Indication error （°）
Empty (E) 165±3
1/4 65±3
1/2 35±3 ±10
3/4 25±3
Full （F） 17±3

2/8
4. Water temperature meter
Parameters of water temperature meter
Scale of temperature meter Actual temperature ℃ Indication error （°）
C 50
1/4 70
1/2 90 ±6
Alarm point 115
H 125
5. Description of various alarm and indication lamp
No Color Control level Control way
Name
Drive not fasten safety belt Red Low level Direct
2
Left turning Green High level Direct
3
Upper beam of headlamp Blue High level Direct
4
Fender (side) lamp Green High level Direct
6
Right turning Green High level Direct
7
8 Fuel alarm Yellow Software control
9 Red Direct
Battery charging indication lamp
Safety airbag Red Low level Direct
10
Door open alarm Red Low level Direct
11
Engine oil level Yellow Low level Direct
12
Front fog lamp Green Low level Direct
13
Rear fog lamp Yellow High level Direct
14
Brake system Red High level Direct
15
Engine oil pressure Red Low level Direct
16
17 ABS Yellow Software control
Engine fault lamp (OBD) Yellow Low level Direct
18
Pre-heat indication lamp Yellow Low level Direct
19
Oil and water separator indication lamp Yellow High level Direct
20

3/8
Outline and socket pin of combined instrument
1. Outline of combined instrument

2. Function table of socket pin

Socket A：40 cores （AMP1318384） blue
No Function No Function
1 21
2 22
3 OBD indication switch 23
4 Copilot door open etc. 24
5 Positive of battery 25
6 Ignition switch 26 Right turning indication lamp
7 Ground of instrument 27 Engine oil pressure indication
switch
8 Ground of instrument 29 Grounding
9 Vehicle speed output 30 Front fog lamp indication lamp
10 Small lamp switch 31 Left turning indication lamp
11 32 Engine fault switch
12 Drive cabin door open switch 33 Charging and discharging indication
switch
13 Fuel sensor 34 Rear fog lamp indication lamp
14 Engine speed signal 35 Lock indication lamp
15 Odometer sensor 36 Brake alarm switch
16 37 Brake alarm switch
17 38 Dipped beam indication lamp
18 Temperature meter signal 39 ABS alarm switch
19 Safety belt isn’t tightened 40 Safety air-bag alarm switch
20 Engine oil liquid alarm switch

4/8
Fault inspection
1. Odometer
(a) Possible fault reason
Possible reason
Odometer doesn’t work ·The odometer proper body is failed
·The harness or the plug-in is failed
·ECU of the engine has no vehicle speed signal output
(b) Inspection flow chart

Remove the harness plug-in of the combined instrument socket A

Move the vehicle forward and backward, use the oscillator to measure
whether there is square wave signal output between 24th pin and 18th pin
(there is marking number on the plug-in) of the 28 cores plug-in at the
harness end.

Yes No

Replace the combined Inspect ECU vehicle speed signal output, the harness or
instrument the plug-in of the vehicle, please repair if necessary.

2. Revolution indicator of engine

(a) Possible fault reason
Revolution indicator of engine doesn’t work
Possible reason
·The revolution indicator proper body is failed
·The harness or the plug-in is failed
· ECU of the engine has no vehicle speed
signal output

5/8
 (b) Inspection flow chart

Remove the harness plug-in of the combined instrument socket A

Ignite and start the engine, use the oscillator to measure whether there is
square wave signal output between 24th pin and 16th pin (there is marking
number on the plug-in) of the 28 cores plug-in at the harness end.

Yes No

Replace the combined Inspect ECU vehicle speed signal output, the harness or
instrument the plug-in of the vehicle, please repair if necessary.

3. Fuel meter
(a) Possible fault reason
Fuel meter doesn’t work
Possible reason
·The fuel meter proper body is failed
·The harness or the plug-in is failed
·ECU of the engine has no vehicle speed
signal output

(b) Inspection flow chart

Remove the harness plug-in of the combined instrument socket A

Use the oscillator to measure whether there is square wave signal

output between 24th pin and 22nd pin (there is marking number on
the plug-in) of the 28 cores plug-in at the harness end.

Yes No

Replace the combined Inspect ECU vehicle speed signal output, the harness or
instrument the plug-in of the vehicle, please repair if necessary.

6/8
4. Water temperature meter
(a) Possible fault reason
Fuel meter doesn’t work
Possible reason
·The fuel meter proper body is failed
·The harness or the plug-in is failed
· ECU of the engine has no vehicle speed
signal output

(b) Inspection flow chart

Remove the harness plug-in of the combined instrument socket A

Use the oscillator to measure whether there is square wave signal

output between 24th pin and 20th pin (there is marking number on the
plug-in) of the 28 cores plug-in at the harness end.

Yes No

Replace the combined Inspect ECU vehicle speed signal output, the harness or
instrument the plug-in of the vehicle, please repair if necessary.

5. Various warning and indication lamp

(a) Possible fault reason

Various warning and indication lamps are Possible reason

abnormal ·The instrument proper body is failed
·Parts related to various indication lamp are
failed

7/8
(b) Inspection flow chart

Remove the harness plug-in of the combined instrument socket A

No 28th and no 26th (there is marking number on the plug-in) of the 28

cores plug-in of the combined instrument are connected to 12V, no 24
pin is grounded, validate whether the indication lamp is lit according to
parameters of various high level and low level in the control way of the
indication lamp.

Yes No

Corresponding instrument indication lamps shall be Replace the instrument

normal, inspect the connection parts related to the
indication lamp, repair if necessary

8/8
Part Three Interior and exterior, electrical appliances and
car body
Chapter Seven ABS system
Catalogue ·············································································································001
Pictures and table index ·····················································································005
Instruction and operation ·······················································································007
1.1 English interpretation of abbreviation in this manual ···································007
1.2 Maintenance precautions ·············································································007
1.3 Demanded basic knowledge ····································································009
1.3.1 Basic electrical circuit ··············································································009
1.3.2 Application of circuit testing tools ································································009
Description of ABS system ······················································································010
2.1 Hydraulic control unit（ HCU）··················································································010
2.1.1 Pump, motor ··································································································011
2.1.2 Anti-block brake system（ ABS) valve ····························································011
2.2 Electronic control unit（ ECU）··············································································010
2.2.1 Wheel speed sensor and tone wheel ································································013
2.2.2 ABS alarm lamp (amber) ················································································016
2.2.3 EBD alarm lamp (red) ·······················································································016
2.2.4 Brake switch ····································································································016
2.3 Tire ················································································································016
2.3.1 Small size spare tire ····················································································016
2.3.2 Replace tire ·····································································································017
2.4 Anti-block brake mode ·····················································································016
2.5 Electronic brake power assembly mode ···································································016
2.6 ABS composition layout figure ················································································016
2.7 Hydraulic figure (ABS acts) ·················································································016
2.8 ECU harness connector pin definition figure（ ABS）················································020
2.9 Module installation description ··············································································022
2.10 Laser marking on ABS ················································································022
2.11 International standard and Japanese standard interface ···································023

1
3. Hydraulic medium ·······················································································025
4. Storage ············································································································026
4.1 Storage time (From production date) ······························································026
4.2. Storage environment ·························································································026
5. ABS noise ·········································································································027
5.1 Self-inspection sound of system ·····························································027
5.2 Sound when ABS acts ················································································027
5.3 If Sound is too great during self-inspection of system or action of ABS ············027
6. Validation steps which are suggested to be completed before replacement of ABS ···············028
7. Relevant requirements when product is returned back to Yuanfeng for analysis ···················029
8. Diagnosis information and flow ·····································································030
8.1 Inspection before diagnosis ················································································030
8.2 System description ·····················································································030
8.3 Clear diagnosis fault code ··············································································030
8.4 Incidental fault or improper contact ··································································031
8.5 Initialization sequence ·························································································031
8.6 Diagnosis flow ··································································································031
8.6.1 Fault diagnosis when there is no fault code ····················································033
8.6.2 Fault diagnosis when there is fault code ····························································033
9. No communication with ECU ·············································································035
9.1 Circuit description ·····························································································035
9.2 Diagnosis assistant ··························································································030
10. ABS/EBD alarm lamp constantly off & no diagnosis fault code output ·················038
10.1 Circuit description ·····························································································038
10.2 Diagnosis assistant ················································································038
11. ABS/EBD alarm lamp constantly on & no diagnosis fault code output ·················041
11.1 Circuit description ·····························································································041
11.2 Diagnosis assistant ··························································································041

2
12. C2112- Solenoid valve relay fault ··································································043
12.1 Circuit description ························································································043
12.2 Condition that diagnosis fault code is generated ·················································043
12.3 Action applied during setting of diagnosis fault code ·········································043
12.4 Condition that diagnosis fault code is cleared ·················································043
12.5 Diagnosis assistant ·····················································································043
13. C2402- Oil returning pump (motor) fault ···························································046
13.1 Circuit description ·······························································································046
13.2 Condition that diagnosis fault code is generated ·················································046
14.3 Action applied during setting of diagnosis fault code ·············································046
13.4 Condition that diagnosis fault code is cleared ·················································046
13.5 Diagnosis assistant ······················································································046
14.C1202- left right, C1205- right front, C1208- left rear, C1211- right rear — wheel speed sensor
input signal invalid/no signal ·············································································049
14.1 Circuit description ·······························································································049
14.2 Condition that diagnosis fault code is generated ·················································049
14.3 Action applied during generation of diagnosis fault code ······································049
14.4 Condition that diagnosis fault code is cleared ·················································049
14.5 Diagnosis assistant ·····························································································049
15.C1201- left right, C1204- right front, C1207- left rear, C1210- right rear — wheel speed sensor
input signal performance/clearance fault ····························································054
15.1 Circuit description ·······························································································054
15.2 Condition that diagnosis fault code is generated ·················································054
15.3 Action applied during generation of diagnosis fault code ·······································054
15.4 Condition that diagnosis fault code is cleared ·················································054
15.5 Diagnosis assistant ·····························································································054
16.C1200- left right, C1203- right front, C1206- left rear, C1209- right rear — wheel speed sensor
input signal open circuit/short circuit fault ···························································059
16.1 Circuit description ·······························································································059
16.2 Condition that diagnosis fault code is generated ·················································059
16.3 Action applied during generation of diagnosis fault code ·······································059
16.4 Condition that diagnosis fault code is cleared ·················································059
16.5 Diagnosis assistant ·····························································································059

3
17 Low voltage of C1102 system ··········································································063
17.1 Circuit description ························································································063
17.2 Condition that diagnosis fault code is generated ·················································063
17.3 Action applied during generation of diagnosis fault code ··································063
17.4 Condition that diagnosis fault code is cleared ·················································063
17.5 Diagnosis assistant ·····························································································063
18 High voltage of C1101 system ··············································································066
18.1 Circuit description ························································································066
18.2 Condition that diagnosis fault code is generated ·················································066
18.3 Action applied during generation of diagnosis fault code ··································066
18.4 Condition that diagnosis fault code is cleared ·················································066
18.5 Diagnosis assistant ···············································································066
19.C1604 ECU- internal fault ················································································068
19.1 Circuit description ························································································068
19.2 Condition that diagnosis fault code is generated ·················································068
19.3 Action applied during generation of diagnosis fault code ··································068
19.4 Condition that diagnosis fault code is cleared ·················································068
19.5 Diagnosis assistant ·····························································································068
20.C2308,C2312,C2316,C2320,C2324,C2328,C2332,C2336- booster or pressure reduction
solenoid fault ·································································································070
20.1 Circuit description ·······························································································070
20.2 Condition that diagnosis fault code is generated ·················································070
20.3 Action applied during generation of diagnosis fault code ··································070
20.4 Condition that diagnosis fault code is cleared ·················································070
20.5 Diagnosis assistant ·····························································································070

4
Pictures and table index

Figure 1-1 ABS assembly only replaced in a whole ··················································08

Figure 1-2 Apply heat shrinkage pipe sleeve ································································08
Figure 2-1 Schematic figure of Yuanfeng ABS ··························································010
Figure 2-2 Sample of hydraulic control unit（ HCU）·················································011
Figure 2-3 Sample of electronic control unit （ECU）··············································012
Figure 2-4 Passive type and active type of wheel speed sensor ······························013
Figure 2-5.Working principle of electromagnetic inductive type ·······························014
Figure 2-6.Working principle of Hall effect type ····························································014
Figure 2-7. Alternation induction ···············································································015
Figure 2-8 Layout figure of ABS composition ·····························································018
Figure 2-9 Basic brake ·································································································019
Figure 2-10 Pressure reduction of ABS ···································································019
Figure 2-11 Pressure holding of ABS ··········································································019
Figure 2-12 Booster of ABS ························································································019
Figure 2-13 ECU harness connector pin definition figure ···············································020
Figure 2-1 Hydraulic ABS harness pin definition of Yuanfeng ········································020
Figure 2-14 Assemble schematic figure of module ·····················································022
Figure 2-15 Laser marking of Yuanfeng ABS ·································································023
Figure 2-16 International standard and Japanese standard interface ················· ·······023
Table 2-2. Pipe diameter and joint type optional f or proper body and customer
interface ·························································································································023
Figure 8-1 Fault diagnosis flow of ABS system ·····················································019
Table 8-1 Symptom ········································································································032
Table 8-2 Fault diagnosis when there is no fault code ················································033

5
Table 8-3 ABS fault code DTC listing ·································································033
Table 9-1 No communication with ECU ·····························································035
Table 10-1. ABS/EBD alarm lamp constantly off & no diagnosis fault cod································038
Table 11-1. ABS/EBD alarm lamp constantly on & no diagnosis fault code output ·················041
Table 12-1.C2122- Solenoid valve relay fault ··························································044
Table13-1. C2402- Oil returning pump (motor) fault ·················································047
Table 14-1 C1202,C1205,C1208,C1211 - Wheel speed sensor input signal invalid/no
signal ··························································································································050
Table 15-1 C1201,C1204,C1207,C1210 - Wheel speed sensor input signal performance/clearance
fault ·················································································0 5 5
Table 16-1 C1200,C1203,C1206,C1209 - Wheel speed sensor input signal open circuit/short
circuit ···································································································060
Table 17-1 Low voltage of C1102 system ·····················································064
Table 18-1 High voltage of C1101 system ······························································066
Table 19-1. C0055-ECU- internal fault ···································································068
Table 20-1.C2308,C2312,C2316,C2320,C2324,C2328,C2332,C2336 - booster or pressure
reduction solenoid fault ·············································································070

6
1. Instruction and operation

1.1 English interpretation of abbreviation in this manual

：AntilockBrakeSystem

：TractionControlSystem

：WheelSpeedSensor

：HydraulicControlUnit

：ElectronicControlUnit

：ElectronicBrakeforceDistribution

：DataLinkConnector

：ElectromagneticInterference

：BatteryVoltage

1.2 Maintenance precautions

Pay attention to following general items during maintenance of ABS, otherwise ABS may be
damaged:
1. Disconnect the ECU harness from ECU before electrical welding operation.
2. Prohibit use the quick charger to charge the engine during starting or the battery which is still
connected, otherwise it may cause the battery invalid or parts of ABS are damaged.
3. Please switch off the ignition switch before the ECU harness is disconnected. (prohibit live pull
or insert ABS, ECU and the sensor)
4. ABS assembly is only replaced in a whole, don’t disassemble for inspection or partially replace
and exchange. Yuanfeng company doesn’t provide independent spare parts, and there is no
guarantee on the ABS assembly after disassembly.

7
 Figure 1-1 ABS assembly only replaced in a whole
5. After the ABS assembly is replaced, be sure to exhaust the brake pipeline (refer to relevant
exhaust specification of each whole vehicle factory).

6. The hydraulic unit can’t continue be used after falling down: it may cause the magnet of the
pump motor broken and damage of the ECU circuit etc.

7. Don’t hang the wheel speed sensor harness on eh suspension parts, otherwise the harness will
be damaged.
8. The ABS harness must be properly grounded, sealing glue shall be coated on the exposed end
of the harness, and the heat shrinkage sleeve shall be applied.

Figure 1-2 Apply heat shrinkage pipe sleeve

9. ECU shall not be placed in the environment higher than 120℃.

8
1.3 Demanded basic knowledge
Be sure to basically learn following knowledge before this chapter is used. Difficulty on using the
diagnosis program in this chapter will be increased if there is no these basic knowledge.
1.3.1 Basic electrical circuit
1. Bu sure to learn basic principle of electricity, learn meanings and basic calculation formulas of
voltage (volt), current (ampere) and resistance (ohm).
2. Be sure to learn meanings of open circuit, short circuit, series connection and parallel
connection of the circuit.
3. Be sure to read and learn the wiring figure.
1.3.2 Application of circuit testing tools
Be familiar to the digital multiple meter and be familiar to instrument control and how to use
correctly.

9
2. Description of ABS system

The brake anti-block system (ABS) can freely monitor revolution speed signal of all wheels. In
case some one or several wheels have trend of brake blocking, the hydraulic regulation module
can act in time, and terminate pressure of the wheel cylinder further increase or start to reduce
brake pressure. The wheel always maintains stable status under action of this pressure regulation,
and therefore ensure operation stability and shortest brake distance of the vehicle.

Proper
Electronic control unit ECU
Booster

Motor
Oil returning pump

Coil group

Pressure reduction valve

Accumulator

Figure 2-1 Schematic figure of Yuanfeng ABS

2.1 Hydraulic control unit（ HCU）

The hydraulic control unit（ HCU）is assembled in the engine cabin, which control on/off and
pressure of the hydraulic circuit during anti-block brake.

10
 Figure 2-2 Sample of hydraulic control unit（ HCU）
★ The hydraulic control unit （ HCU） belongs the part which can’t be repaired, don’t disassemble.
It is only replaced in case of fault.
HCU applies four circuits (or three circuits) configuration, each circuit is left front, right front, left rear
and right left wheels respectively.
HCU consists of the oil returning oil pump, the motor, the accumulator and the HCU solenoid,
described later.
2.1.1 Pump and motor
The oil returning pump is driven by the DC permanent torque motor, its function is to pump brake
liquid stored in the accumulator into the master cylinder, and make brake liquid in the brake circuit
circulate to use, and regulation pressure of the brake circuit.
2.1.2 Anti-block brake system （ABS) valve
ABS valve can reduce or maintain pressure of brake liquid in each wheel circuit. They consists of
four (or three) booster valves or four (or three) pressure reduction valves. ECU can indicate these
valve to reach the correct position during brake anti-blocking. Pressure in each hydraulic circuit
can be maintained or released through starting the corresponding valve under brake anti-block
mode. Normal status is status that the booster valve is open and the pressure reduction valve is
closed, pressure of the master cylinder can directly reach the brake during normal brake. ABS
valve is an essential part of HCU, which can’t be maintained separately.

11
2.2 Electronic control unit（ ECU）

Figure 2-3 Sample of electronic control unit （ECU）

Main functions of ECU are shown as following:

1. Monitor signal input of the wheel speed sensor and the brake pedal.

2. Detect sliding trend of the wheel.

3. Control the brake system under anti-block mode.

4. Monitor and control the system, and ensure electrical operation normal.

ECU continuously monitors and controls speed of every wheel so as to determine whether
the wheel starts to slide. If sliding trend of the wheel is detected, ECU adjust the HCU valve to
corresponding position, adjust pressure of brake liquid in some or all circuits so as to prevent
skidding of the wheel and provide optimum brake. ECU continues control pressure in each
hydraulic circuit of HCU until no sliding trend occurs any more.
ECU can continuously monitor whether operation of ABS is normal. If ECU detects fault, it can
disconnect function of ABS, open the ABS alarm lamp in the dashboard and control display of ABS
diagnosis fault code under diagnosis mode.

12
★ ECU can’t be repaired dependently.
2.2.1 Wheel speed sensor and tone wheel
 Introduction about the wheel speed sensor
Passive (electro-magnetic type) Active (Hall effect )

Construction

Main part 1. Cable/harness 1. Cable/

2. Magnet/ 2. Over mold/
3. Holder/ 3. Holder/
4. Coil/ 4. Magnet/
5. Pole pin/ 5. IC/
6. Tone wheel/ 6. Tone wheel/
7. Over mold/
Major difference in Active type wheel speed sensor uses the Hall IC to substitute original
structure coil (copper) and the pole pin these two parts.
Figure 2-4 Passive type and active type of wheel speed sensor
Important difference in structure: The active type wheel speed sensor applies Hall chip to
substitute original winding (copper) and the magnetic induction bar these two metal parts.

 Magnetic-electric type wheel speed sensor

The magnetic-electric type wheel speed sensor takes advantage of a small AC voltage to transmit
speed information of every wheel to ECUM. Strength and frequency of this AC voltage are in
proportional to wheel speed; both will increase following speed increase.

Working principle:

13
 (a)When tooth gap faces toward end of magnet core (b)When tooth tip faces toward end of magnet core

High speed

Low speed
Voltage

(c)Output voltage of sensor

1 - . Tone wheel 2 - . End of magnet core; 3 – Lead of induction coil; 4 – Induction coil; 5 – Permanent magnet core; 6 -

Magnetic line; 7 – Electro-magnetic type sensor; 8- Magnetic pole; 9 – Tone wheel and tooth top

Figure 2-5.Working principle of electromagnetic inductive type

 Hall type wheel speed sensor

The Hall type wheel speed sensor takes advantage of two weak and stable alternating current to
transmit speed information of every wheel to ECU. Strength of this alternating current is constantly
7mA and 14mA.

Working principle:

14
Hall element Hall element

Tone Tone

Permanent magnet wheel wheel

Permanent magnet

(a)Magnetic field of Hall element is weak (b)Magnetic field of Hall element is strong

Figure 2-6.Working principle of Hall effect type

Each wheel is equipped with the wheel speed sensor. Alternating induction of signal is generated
from alternating induction through rotation of the tone wheel and the static wheel speed sensor.
Shown as figure:

Air gap
Tone wheel
Wheel speed sensor

Maximum clearance: 1.2 mm

Terminal 2: white wire and

Terminal 1: black wire and
cable supplies signal
cable supplies signal

Figure 2-7. Alternation induction

★ The speed wheel sensor and the tone wheel can be independently repaired or replaced.

15
2.2.2 ABS alarm lamp (amber)
The ABS alarm lamp is located in the dashboard. When the ABS harness connector isn’t
connected or ABS is failed, the ABS alarm lamp can be lit by itself. Only when the ABS alarm lamp
is lit, it can brake normally. Conditions that ECU controls status of the ABS alarm lamp are
shown as following:
1. When function of the ABS system is normal, ECU draws down the ABS alarm lamp signal
wire to close the ABS alarm lamp.
2. When ABS detects there is fault, ECU will not control the ABS alarm lamp signal wire, and
let it suspension.
3. ECU will carry out self-inspection of the system in about first three seconds during ignition
operation. ECU can’t control the ABS alarm lamp signal line, and let it suspension.
2.2.3 EBD alarm lamp (red)
The EBD alarm lamp in the dashboard is switched on, warn the driver that fault occurs in EBD,
some invalidation mode in the ABS system will make this lamp lit, let the drive know that EBD can’t
be used any more.
2.2.4 Brake switch
The brake switch outputs signal to ECU when it outputs power supply voltage to the brake tail
lamp.
ECU judges whether the brake pedal is stepped down according to status of the brake switch.
1. When the brake pedal is stepped down, voltage transmitted by the ABS brake signal line is
voltage of the battery.
2. When the brake pedal is loose, the ABS brake signal wire shall be grounded (it is realized
through grounding of the brake tail lamp). When the ABS brake signal line isn’t grounded, ECU will
detect that brake signal is broken circuit.

2.3 Tire

2.3.1 Small size spare tire

Using the spare tire supplied with the vehicle will not affect operation of ABS. ECU software
can compensate small tire. Parking distance may be increased because thread depth of this spare
tire is too shallow.
★ Please refer to application instruction and information of the vehicle for application of the
small spare tire for details.

16
2.3.2 Replace tire
Size of the tire has great influence on performance of ABS. Size, load scope and shrinkage rate of
the replaced tire shall be same as those of the original tire. Set up the replaced tire as axel, its
performance standard and specification number of the replaced tire shall be same as original tire.
Using any tire with other size or types may seriously affect effect of ABS.
2.4 Anti-block brake mode
If sliding phenomenon of the wheel is found during brake period, ABS will enter into the
anti-blocking brake mode. Pressure in the hydraulic circuit of each wheel is under control during
anti-block brake, so as to prevent sliding of the wheel. Each wheel is equipped the independent
hydraulic pipeline and the concrete valve, or each front wheel and one rear wheel is equipped with
independent hydraulic pipeline and the concrete valve. ABS can reduce, maintain or increase
hydraulic pressure for braking of each wheel. But ABS can’t increase hydraulic pressure to exceed
pressure value transmitted by the master cylinder during brake period. The brake pedal can feel a
series of quick pulse during anti-block brake period. Position of every valve is quickly changed
following required wheel speed and then pulse is generated. Pulse of the pedal occurs during
anti-blocking brake, it stops during normal brake or the vehicle is completely parked. Because the
solenoid is quickly circularly used, tick or blast sound can be sounded. When the anti-block brake
is applied on the dry road surface, the tire may send out intermittent sharp sound when the tire is
near to skid. These sound and pedal pulse belong to normal phenomenon during anti-blocking
brake operation. Operation of the brake pedal is same as no ABS system during normal brake.
Maintain strength used to stepping down the pedal even and maintain stability of the vehicle,
ensure shortest stop distance.

2.5 Electronic brake power assembly mode

The electronic brake power distribution （ EBD） is a proportion system, which is used to maintain
stability of the vehicle during brake period. Effective balance brake needs equal wheel speed
under normal brake conditions. Because weight of the vehicle is moved to the front wheel when
brake is difficult, brake force of the rear wheel is relatively small. EBD takes advantage of ABS
rear booster and the pressure reduction valve to maintain brake pressure demanded by the rear
wheel, so as to provide effective brake and stability of the vehicle.
If following faults occur, EBD alarm lamp will be lit (the ABS alarm lamp is also lit at same time):
1. Two wheel speed sensors at same axle don’t act.
2. Any one solenoid valve doesn’t act.
3. The battery is open circuit or grounded short circuit.
4. ECU is grounded open circuit and the battery is shorted circuit.
5. The ignition switch is open circuit or grounded short circuit.
6. Internal fault of ECU.
7. The relay of the solenoid is failed.
2.6 ABS composition layout figure

17
 Brake master

Front wheel Rear wheel

cylinder

Wheel Brake slave Brake slave Wheel

speed cylinder cylinder speed

sensor Brake pressure sensor

regulator

ABS alarm lamp

Electronic

controller
Wheel Wheel
(ECU)
speed Brake slave speed
Brake slave
sensor cylinder sensor
cylinder

Front wheel Rear wheel

Figure 2-8 ABS composition layout figure

18
2.7 Hydraulic figure (ABS acts)

(4). (4).
(1). (1).
(2). (3). (2). (3).

(5). (5).

(6). (6).
(9). (9).

(8). (8).

(7).
(7).
(11). (11).
(10). (10).

Figure 2-9. Basic brake Figure 2-10.ABS pressure reduction

(4). (4).
(1).
(1).

(2). (3). (2). (3).

(5). (5).

(6). (6).

(9). (9).

(8). (8).

(7).
(7).
(11). (11).
(10). (10).

Figure 2-11. ABS pressure maintain Figure 2-12. ABS booster

(1) Hydraulic regulation unit (7) Brake

(2) Damper (8) Output valve
(3) Throttle valve (9) Input valve
(4) Master cylinder (10) Wheel
(5) Returning pump (11) Electronic control unit (ECU)
(6) accumulator

19
2.8 ECU harness connector pin definition figure（ ABS）

Figure 2-13. ECU harness connector pin definition figure

Table 2-1 Hydraulic ABS harness pin definition of Yuanfeng

Pin foot Code Chinese name Remark

1 MOTOR 12V Power source terminal (positive ) of motor 60A at moment of start,
operation peak is 30A,
match the fuse of 30A
2 —— —— ——
3 SPD3OUT Speed signal output of right rear wheel Optional
4 LAMP0 Active type ABS alarm lamp ——
5 —— —— ——
6 SPEED1 Signal terminal of wheel speed sensor (right Twisted wire with
front) corresponding wire
7 —— —— ——
8 —— —— ——
9 —— —— ——
10 —— —— ——
11 —— —— ——
12 —— —— ——
13 MGND Grounding terminal of motor 60A at moment of start,
operation peak is 30A,

20
14 CANL CAN low Optional
15 —— —— ——
16 LAMP1 Alarm lamp of active type EBD Optional
17 K_LINE Diagnosis K line ——
S_PWR1 Power supply terminal/ground (right Twisted wire with corresponding
18
front) of wheel speed sensor wire
S_PWR3 Power supply terminal/ground (right Twisted wire with corresponding
19
rear) of wheel speed sensor wire
SPEED2 Signal terminal of wheel speed Twisted wire with corresponding
20
sensor (left rear) wire
21 —— —— ——
SPEED0 Signal terminal of wheel speed Twisted wire with corresponding
22
sensor (left front) wire
23 —— —— ——
24 —— —— ——
BAT12V Power supply terminal of valve relay 60A at moment of start,
operation peak is 30A, match
25
the fuse of 30A

26 CANH CAN high ——

VSPEED Wheel speed output ——
27

28 —— —— ——
29 —— —— ——
BRKSW Brake lamp switch input ——
30

SPEED3 Signal terminal of wheel speed Twisted wire with corresponding

31
sensor (right rear) wire
IGN Power supply terminal of ECU ——
32
(ignition power supply line)
S_PWR2 Power supply terminal/ground (left Twisted wire with corresponding
33
rear) of wheel speed sensor wire
S_PWR0 Power supply terminal/ground (left Twisted wire with corresponding
34
front) of wheel speed sensor wire
35 —— —— ——
36 —— —— ——
37 —— —— ——
GND ECU ground 60A at moment of start,
38
operation peak is 30A

21
2.9 Module installation description

Wheel cylinder pipeline interface (left front wheel, right front wheel, left rear wheel, right rear wheel)

Joint to vehicle

harness Joint of master cylinder

pipeline (double circuits of

master cylinder )

Figure 2-14 Assemble schematic figure of module

2.10 Laser marking on ABS

22
 Yuanfeng ABS

version

Yuanfeng

drawing number
Vehicle type

Series number code

of product

Figure 2-15 Laser marking of Yuanfeng ABS

Series number of this product is 12/06/06/01/0006：
12/06/06 means production date of this product is June 06, 2012; /01/0006 means No 1
production line and sixth product manufactured at present day.

2.11 International standard and Japanese standard interface

Connect

Connect Connect master

wheel wheel cylinder

Connect
cylinder cylinder
master

cylinder

Figure 2-16. International standard and Japanese standard interface

Table 2-2. Pipe diameter and joint type optional for proper body and customer interface

23
 ABS TCS/ESC
Diameter of Diameter of Diameter of Diameter of
Proper body master cylinder wheel cylinder master cylinder wheel cylinder
Pipe diameter connection pipe connection pipe connection pipe connection pipe
Φ3.2mm Φ3.2mm Φ4.2mm Φ3.2mm

Optional standard pipeline interface

Diameter of oil M10X1 M10X1 N/A M10X1
pipe Φ4.75mm M12X1 M12X1 M12X1
Diameter of oil M12X1
pipe Φ6mm M12X1 M12X1 M12X1
M14X1.5
Diameter of oil M12X1
pipe Φ8mm N/A N/A N/A
M14X1.5
Assemble torque: 16±2N.m for M10, 18±2N.m for M12,
Repeated assemble shall not exceed 5 times.

24
3 Hydraulic medium

Only following alcohol group brake liquid can be filled into the hydraulic unit:

·DOT4

·DOT4+（plus）

·SuperDOT4+（plus）

·DOT5.1

When above brake liquid meets regulation requirements, it is allowed to be mixed.

If brake liquid out of above appointed liquid is filled into the brake system, please replace the
hydraulic unit.
Furthermore the brake circuit isn’t allowed to contain chlorine and sulphur etc inorganic matter, it
isn’t allowed to contain mine oil or Ester plasticizer/soften agent (including component which can
diffuse this type of matter).
The automobile equipped with ABS shall be replaced the brake liquid once every year. Otherwise,
hygroscopicity of brake liquid is very strong, not only boiling point is reduced and corrosion is
generated but also brake effect is reduced after it is contained water.
For the liquid storage tank, the brake master cylinder, the brake pipeline and the calipers, be sure
to use original components and ensure inner area clean.

25
4. Storage

4.1 Storage time (From production date)

Hydraulic unit (dry type)

1 ≤ 12 months

2 The hydraulic unit must be full of brake liquid in 12 months from manufacturing date .

Hydraulic unit (wet type)

1 ≤ 60 months

2 ABS must be returned back to the manufacturer for inspection after 60 months.

4.2 Storage environment

General relative humidity 55%±30%

Temperature during whole storage process -20℃~50℃

Allowable temperature within 50h limitation time -40℃~20℃

When the pipe joint is sealed by the rubber part or the plastic cover, allowable temperature within
50h limitation time 50℃~100℃

When the pipe joint is sealed by the adhesive tape, allowable temperature within 50h limitation
time 50℃~80℃
Consult Yuanfeng when storage conditions are out of above conditions.

26
5.ABS noise

5.1 Self-inspection sound of system

After the engine starts and the vehicle travels at 15km/h, short ―buzz‖ sound is sent out from
the engine cabin, this is self-inspection sound of ABS, it belongs to normal phenomenon.

5.2 Sound when ABS acts

1 Sound of the electric motor in ABS hydraulic unit.

2. Sound generated together with vibration of the brake pedal

3. When ABS is working, vibration sound of the pipeline caused by brake.

4. Sound that the returning pump is pumping brake liquid from the accumulator.

5.3 If Sound is too great during self-inspection of system or action of ABS

It may be caused by following reasons:

1. Fixing location of ABS support is loose.

2.Fixign location of the brake oil pipe is loose.

27
6. Validation steps which are suggested to be completed before replacement of ABS

1. Dynamic self-inspection: let ABS to carry out dynamic self-inspection after fault is excluded,
speed of the vehicle shall not be lower than 15km/h.

After some faults are eliminated (such as signal of the wheel speed sensor is instable or the motor
is failed) and it is ignited again, the ABS alarm lamp will not go off, only when the vehicle travels at
about 15km/h and ABS passes through dynamic self-inspection, the ABS alarm lamp will be turn
off.

2. Crossing validation: it is suggested to remove ABS and assemble on another vehicle without
fault and using same type of ABS, don’t assemble the oil connection pipe, only insert the ABS
harness connector. Ignite the vehicle again and travel, let ABS to carry out dynamic self-inspection,
speed of the vehicle shall not be lower than 15km/h.

28
7.Relevant requirements when product is returned back to Yuanfeng for analysis

1. The returned product must be within warranty period.

2. For the product which is returned back for analysis, it shall be check whether it meets following
items:

1) The product has no appearance damage.

2) ABS isn’t disassembled.

3) The ECU pin of ABS is free of breakage.

4) ECU slot of ABS is free of rust and water mark.

5) It is necessary to clean and seal ABS HCU oil opening.

Information: the plastic enclosure of ABS ECU is liable to be damaged, carry out special
transportation protection of ABS.
3. The customer shall provide relevant information so as to facilitate Yuanfeng to carry out fault
analysis (only focus on returned parts of the market).
1) Information of dealer/maintenance network.

2) Fault information description, which diagnosis has been made in the maintenance point.

3) Mileage, purchase date of the vehicle.

4) Fault date, maintenance date.

5) When does fault occur, such as: speed, road surface and environment etc.

6) VIN code of vehicle.

7) All pictures or photos of above information.

29
8. Diagnosis information and flow

8.1 Inspection before diagnosis

1. Ensure the vehicle is only assembled the tire (including small spare tire) with size which is
recommended in the application instruction of the vehicle. Be consistent with specification and
type of the axle.

2. Inspect whether connections of the hydraulic regulator and the brake pipeline and the connector
are correct, whether there are leakage; when connection of the pipeline is wrong and ABS control
unit can’t distinguish, wrong pipeline connection may cause serious accident.

3. Inspect the fuse of ABS.

4. Ensure voltage of the battery is normal （ 9.3V –16.8V）.

5. Check whether there is corrosion at connection location of the battery or whether the terminal is
loose. 6. Check whether the ABS component harness and the terminal are connected correctly,
whether are clamped or cut.

7. The ABS component is very sensitive to electro-magnetic interface (EMI). If it is doubt there is
intermittent fault, inspect whether the thief proof unit, the lamp or the mobile phone assembled by
after sale are not correct.

8.2. Description of system

ECU takes advantage of the diagnosis instrument to diagnose fault code, the diagnosis

instrument can detect any problem caused by ABS/EBD system faults.

After the diagnosis instrument receives fault information correctly, the maintenance

technical shall analyze ABS/EBD fault. Inspection of the diagnosis instrument can guide the

maintenance technician to carry out next step for fault diagnosis.

ECU sends out Kline series data through No 17th pin. ECU receives constant voltage of the

battery through No 25th, grounding terminal of ECU is No 38th pin, and induce ignition voltage to

start the system through No 32nd pin.

8.3 Clear diagnosis fault code

Diagnosis fault codes in ECU memory can be cleared through two methods:
1. Diagnosis instrument method.

2. Method that vehicle speed reaches 15km/h.

No matter which method is applied, check whether diagnosis fault code appears again after clear
step is complete.

30
8.4 Incidental fault or improper contact

Incidental fault is mostly caused by following conditions:

1. Connection of the electrical apparatus is improper.

2. Historic fault caused by mis-operation of the repair worker.

3. Gap of the wheel speed sensor is too great.

Please refer to fault troubleshooting program etc sections in electrical diagnosis part of the
complete maintenance manual for positioning and repairing the intermittent fault.

8.5 Initialization sequence

ECU carries out initialization testing before each ignition. Initialization sequence: solenoid and
master gate of the pump, check whether operation of the part is normal. If fault is detected, ECU
will set corresponding diagnosis fault code. Some action may be sensed or felt when initialization
sequence is carried out, this belongs to one part during operation of the normal system.

Vehicle speed can reach 15km/h after starting, ECU self-inspection judgment will immediately

carried out.
8.6 Diagnosis flow

Step for maintenance of ABS/EBD system is shown as following.

1. Check whether the vehicle has mechanical fault related to the brake system.

1) Liquid level of the brake liquid tank is normal.

2) Check whether brake liquid in the brake liquid tank is free of pollution.

3) Check whether the brake master cylinder, HCU and each interface position are free of leakage.

4) Check whether brake is stable, whether there is no towing slag phenomenon.

5) Check whether the brake friction shoe and the brake disc are free of abrasion/damage.

6) Check wiring of the wheel speed sensor.

7) Check whether there is no damage in the tone wheel.

8) Check depth/abrasion of tire thread.

9 ) Test the vehicle on road, check whether conditions are corrected.

31
2. Carry out inspection of the diagnosis instrument. Carry out according to suitable diagnosis fault
figure if necessary.
After all system faults are excluded, clear ABS diagnosis fault code.

Repair vehicle, prepare diagnosis

equipment

Equipment is accessed into the vehicle,

energize.

Maintenance is end

No Inspect diagnosis Yes

Is communication
instrument and
successful
communication No
line Fault is solved

Yes

Read out fault code

Clear fault code

Yes No
There is fault code Incidental fault Repair according to fault code

No Yes

Fault maintenance without fault code Maintenance of incidental fault

Figure 8-1 Fault diagnosis flow of ABS system

Table 8-1 Symptom
No communication
ABS alarm is open
ABS alarm lamp is on/no diagnosis fault code is generated
EBD alarm is open
EBR alarm lamp is on/no diagnosis fault code is generated

32
8.6.1 Fault diagnosis when there is no fault code
Table 8-2 Fault diagnosis when there is no fault code
Symptom Inspection
1. Inspect DTC and confirm output code is normal.
2. Inspect circuit of .the power supply
3. Inspect circuit of the speed sensor.
4 Use the hand holding type inspection instrument to inspect
ABS doesn’t work
ABS.
If it is still abnormal, inspect whether there is leakage in the
liquid pipeline. In case 1～4 items are normal and fault still
exists, replace the ABS driver assembly
1. Inspect DTC and confirm output code is normal.
2. Inspect circuit of the speed sensor.
3. Inspect circuit of the parking lamp switch.
4. Inspect circuit of.the power supply
Working efficiency of ABS is
5 Use the hand holding type inspection instrument to inspect
improper
ABS.
If it is still abnormal, inspect whether there is leakage in the
liquid pipeline. In case 1～5 items are normal and fault still
exists, replace the ABS driver assembly
1. Inspect circuit of the ABS warning lamp.
ABS warning lamp is
2. Inspect ABS and ECU.
abnormal
3. Inspect status of the battery.
1. Inspect circuit of the ABS warning lamp.
2. Inspect circuit of .the TC terminal
DTC code can’t be output
In case above inspections are normal and fault still exists,
replace the ABS driver assembly
Signal inspection of the
speed sensor can’t be carried ABS and ECU.
out

8.6.2 Fault diagnosis when there is fault code

Table 8-3 ABS fault code DTC listing
Possible fault
DTC DTC description
symptom
C1101 0100 ECU voltage: high voltage
C1102 0100 ECU voltage: low voltage
C1200 0100 Left front wheel speed sensor: open circuit/short circuit
C1201 1000 Left front wheel speed sensor: scope, performance and clearance

33
C1202 0100 Left front wheel speed sensor: invalid/no signal
C1203 0100 Right front wheel speed sensor: open circuit/short circuit
C1204 1000 Right front wheel speed sensor: scope, performance and clearance
C1205 0100 Right front wheel speed sensor: invalid/no signal
C1206 0100 Left rear wheel speed sensor: open circuit/short circuit
C1207 1000 Left rear wheel speed sensor: scope, performance and clearance
C1208 0100 Left rear wheel speed sensor: invalid/no signal
C1209 0100 Right rear wheel speed sensor: open circuit/short circuit
C1210 1000 Right rear wheel speed sensor: scope, performance and clearance
C1211 0100 Right rear wheel speed sensor: invalid/no signal
Sensing frequency wrong (General sensing error, sliding or tooth
C1213 0100
number wrong)
C1604 0100 ECU hardware wrong
C2112 0100 Valve relay wrong
C2308 0100 Left front booster valve fault
C2312 0100 Left front pressure reduction valve fault
C2316 0100 Right front booster valve fault
C2320 0100 Right front pressure reduction valve fault
C2324 0100 Left rear booster valve fault
C2328 0100 Left rear pressure reduction valve fault
C2332 0100 Right rear booster valve fault
C2336 0100 Right rear pressure reduction valve fault
C2402 0100 Oil returning pump fault (motor)

34
9. No communication with ECU

9.1 Circuit description

ECU receives and transmits Kline series data through No 17th pin of the plug-in, and convert the
ignition voltage through No 32nd pin. Receive voltage of the battery at No 25th pin. Grounding end
of ECU is No 38th.

9.2 Diagnosis assistant

Typical reasons not communicate with ECU are:

1. Contact of the terminal is not good.

2. No 38th pin of ECU isn’t grounded.

3. No 25th pin of ECU has no battery voltage.

4. No 32nd pin of ECU has no ignition voltage.

5. Data circuit is open/grounded.

6 Resistance of the data line is too high

Table 9-1. No communication with ECU

Step Diagnosis action Expect value YES No
Does inspection of the diagnosis
1 To step 2 To step 8
instrument complete
1) Switch off
2. Disconnect the ECU harness
3) Connect one volt meter
between No 25th pin of the ECU
2 Battery voltage To step 3 To step 9
harness terminal and grounding of
the vehicle body.
Is voltage within specified scope?

1) Ignite
2) Connect one volt meter
between No 32nd pin of the ECU
3 harness terminal and grounding of Battery voltage To step 4 To step 10
the vehicle body.
Is voltage within specified scope?

35
 1) Switch off
2) Connect one ohmmeter between No 38th pin of the
Lower than
4 ECU harness terminal and grounding of the vehicle To step 5 To step 11
2Ω
body.
Is resistant value within specified scope?
1) Switch off
2) ECU harness is still disconnected with ECU
Lower than
5 3) Connect one ohmmeter between No 17th pin of the To step 6 To step 12
2Ω
ECU harness terminal and DLC KW2000 terminal . Is
resistant value within specified scope?
1) Switch off
2) ECU harness is still disconnected. The diagnosis
instrument is still disconnected with DLC OL (Open
6 To step 7 To step 13
3) Connect one ohmmeter between No 17th pin of the circuit )
ECU harness terminal and grounding of the vehicle
body. Is resistant value within specified scope?
To step
7 Connect another new ABS, is repair complete?
14
Replace the
8 Carry out inspection of diagnosis instrument. To step 2 diagnosis
instrument
Repair the low voltage power supply of No 25th pin of
the terminal Check whether there is open circuit fuse, To step
9
improper contact or improper grounding. 14
Is repair complete?
Repair the low voltage power supply of No 32nd pin of
the terminal Check whether there is open circuit fuse, To step
10
improper contact or improper grounding. 14
Is repair complete?
Repair high resistance source between No 38th pin of
the terminal and grounding of the vehicle body. After
To step
11 the grounding line of the vehicle body is connected,
14
find out and inspect the grounding device.
Is repair complete?
Repair resistance value between No 17 pin of the
To step
12 terminal and Kline terminal of DLC.
14
Is repair complete?

36
 Find out and repair grounding short circuit in data line. To step
13
Is repair complete? 14
Use the diagnosis instrument to clear the diagnosis
System is
14 fault code To step 1
OK
Does index function not meet standards?

37
10. ABS/EBD alarm lamp constantly off & no diagnosis fault code output

10.1 Circuit description

ECU controls action of the ABS/EBD alarm lamp through low position driving output of the
driving vehicle interface.
When the ignition switch is closed off, the battery supplies power to the terminals of the
dashboard and No 25th pin and No 32nd pin of the ECU terminal which are always live.
The alarm lamp driving module automatically open the ABS/EBD alarm lamp under default status,
its way is to provide grounding route through the alarm lamp driving module.
When ECU commands ABS/EBD lamp are closed, the alarm lamp control wire will make the
alarm lamp driving module to disconnect the grounding route of the bulb.
When the ignition switch is on start position of the engine, ECU carries out self-inspection for
3 seconds, ABS/EBD alarm lamp is automatically lit by the dashboard alarm lamp driving module
during this period. In case fault is detected in ABS, ECU will not control the ABS/EBD alarm lamp
control wire, ABS/EBD alarm lamp is still on, inform the driver that ABS shall be repaired.

10.2 Diagnosis assistant

Typical reason for ABS/EBD alarm lamp constantly off and no diagnosis fault code output:
1. ABS/EBD bulb is failed ／socket is loose.

2. Fuse of the dashboard is fused.

3. Driving module of the dashboard alarm lamp is failed.

4. Driving of the ECU alarm lamp is fault.

5. Grounding of line between ECU and the dashboard is improper.

Table 10-1. ABS/EBD alarm lamp constantly off & no diagnosis fault code output
Expect
Step Diagnosis action YES No
value
1 Does inspection of the diagnosis instrument complete To step 2 To step 8
1) Disconnect ECU plug-in from ECU
2 2) Ignite To step 9 To step 3
Is ABS/EBD lamp on?

38
 Inspect the dashboard fuse. Is contact between the
3 To step 4 To step 10
fuse and the terminal normal?
1) Switch off 2) ECU harness is still disconnected.
3) Remove the harness assembly from the dashboard.
4) Disconnect the instrument harness connector from
the instrument assembly. 5) Ignite 6) Connect a Battery
4 To step 5 To step 11
volt meter to the instrument harness, the power supply voltage
terminal is connected with one volt meter, and then
connect with grounding of the vehicle body. Is voltage
within specified scope?
1) Switch off 2) The instrument harness and the
ECU harness are still disconnected. 3) Connect a
ohmmeter between the control terminal of the OL (Open
5 To step 6 To step 12
instrument harness ABS/EBD alarm lamp and circuit )
grounding of the whole vehicle. Is resistant value
within specified scope?
Remove the ABS/EBD bulb from the instrument,
check whether the filament is broken or contact of the
6 To step 7 To step 13
socket is improper? Are the socket and the bulb are
normal?
Replace the instrument assembly To step
7
Is repair complete? 14
Replace the
8 Carry out inspection of diagnosis instrument. To step 2 diagnosis
instrument
Connect another new ABS. To step
9
Is repair complete? 14
Replace the broken fuse and repair loose terminal If
possible, find out short circuit reason for fuse To step
10
breakage 14
Is repair complete?
Find out and repair reason which causes voltage of
To step
11 the power supply line is too low.
14
Is repair complete?

39
 Find out and repair reason which causes grounding
To step
12 short circuit between the instrument harness and
14
grounding of the whole vehicle. Is repair complete?
Replace the bulb/socket on demand. To step
13 Is repair complete? 14

Use the diagnosis instrument to clear the diagnosis

System is
14 fault code To step 1
OK
Does index function not meet standards?

40
11. ABS/EBD alarm lamp constantly on & no diagnosis fault code output

11.1 Circuit description

ECU controls action of the ABS/EBD alarm lamp through low position driving output of the
driving vehicle interface.
When the ignition switch is closed off, the battery supplies power to the terminals of the
dashboard and No 25th pin and No 32nd pin of the ECU terminal which are always live.
The alarm lamp driving module automatically open the ABS/EBD alarm lamp under default
status, its way is to provide grounding route through the alarm lamp driving module.
When ECU commands ABS/EBD lamp are closed, the alarm lamp control wire will make the
alarm lamp driving module to disconnect the grounding route of the bulb.
When the ignition switch is on start position of the engine, ECU carries out self-inspection for
3 seconds, ABS/EBD alarm lamp is automatically lit by the dashboard alarm lamp driving module
during this period. In case fault is detected in ABS, ECU will not control the ABS/EBD alarm lamp
control wire, ABS/EBD alarm lamp is still on, inform the driver that ABS shall be repaired.

11.2 Diagnosis assistant

Typical reason for ABS/EBD alarm lamp constantly on and no diagnosis fault code output:

1. Circuit between the instrument and ECU is open circuit.

2. ECU isn’t grounded.

3. The alarm lamp control wire and the battery between the instrument and ECU are short circuit.

4. Driving module of the dashboard alarm lamp is failed.

5. ECU is failed.

Table 11-1. ABS/EBD alarm lamp constantly on & no diagnosis fault code output
Expect
Step Diagnosis action YES No
value
Does inspection of the diagnosis instrument
1 To step 2 To step 6
complete
1) Switch off
2) Disconnect the ECU harness from ECU.
3) Ignite
2 4) Connect a jumper series connected with a 100Ω To step 7 To step 3
resistance between No 4th pin or No 16th pin of the
ECU harness terminal and grounding of the vehicle
body.

41
 Is ABS/EBD lamp off?
1) Switch off
2) ECU harness is still disconnected.
3) Remove the instrument assembly from the
dashboard.
4) Disconnect the instrument assembly from the OL (Open
3 To step 4 To step 9
instrument assembly. circuit )
5) Connect a ohmmeter between the control terminal
of the instrument harness alarm lamp and power
supply wire of the battery of the whole vehicle.
Is resistant value within specified scope?
1) Switch off
2) ECU harness is still disconnected.
3) Remove the instrument assembly from the
dashboard.
4) Disconnect the instrument assembly from the
Lower
4 instrument assembly. To step 5 To step 8
than 2Ω
5) Connect a resistance instrument between the
control terminal of the instrument harness alarm
lamp and No 4th pin or No 16th pin of the
corresponding terminal of ECU.
Is resistant value within specified scope?
Replace the instrument assembly To step
5
Is repair complete? 10
Replace the
6 Carry out inspection of diagnosis instrument. To step 2 diagnosis
instrument
Connect another new ABS. To step
7
Is repair complete? 10
Repair open circuit between ECU and the instrument
To step
8 or fault with high resistance.
10
Is repair complete?
Repair short circuit fault of the battery in the harness. To step
9
Is repair complete? 10
Use the diagnosis instrument to clear the diagnosis
System is
10 fault code To step 1
OK
Does index function not meet standards?

42
12. C2112- Solenoid valve relay fault

12.1 Circuit description

The solenoid relay is an essential part of ECU. The battery continuously supplied power to the
solenoid relay power supply through No 25th pin of the terminal. When the ignition switch is on,
ECU judges whether energizing self-inspection of the system is normal. If self-inspection passes,
ECU will continuously open the solenoid relay, and supply durable battery voltage to the coil of the
solenoid. If no fault occurs after the ignition switch is closed, the solenoid relay is still on close
position, otherwise ECU will open the solenoid relay.

12.2 Condition that diagnosis fault code is generated

When the ignition switch is initially closed, the solenoid relay is on open status. If the coil
of the solenoid relay still has durable power supply voltage, the diagnosis fault code C2112
will appear.
When the ignition switch is closed to self-inspection, ECU commands the solenoid relay to
close and supply power to the coil. If supply voltage of the solenoid coiling exceeds voltage scope
of the battery, the diagnosis fault code C2112 will appear.

12.3 Action applied during setting of diagnosis fault code

1. The electro-magnetic relay is commanded to be open, all coils of the solenoid will not have

battery voltage.

2. Diagnosis fault code C2112 is saved.

3. ABS is invalid; the ABS alarm lamp is on

4. EBD is invalid; the EBD alarm lamp is on

12.4 Condition that diagnosis fault code is cleared

If conditions generating the diagnosis fault code C2112 doesn’t appear, use the diagnosis
instrument to clear the diagnosis fault code.

12.5 Diagnosis assistant

Typical reasons for diagnosis fault code C2112:

1. Voltage of the battery is weak or is discharged.

43
2. Wiring terminal of the battery is loose or rust.

3. Contact of the ABS fuse is improper or loose.

4. Contacts of No 25th pin and No 38th pin of ECU terminal are improper.

5. Voltage of No 25th pin of the ECU terminal is too low.

6. Internal fault of ECU.

Table 12-1. C2122- Solenoid valve relay fault

Step Diagnosis action Expect value YES No

To
1 Does inspection of the diagnosis instrument complete To step 6
step 2
1) Carry out load test of the battery. The battery
2) Inspect the charging system. shall maintain
To
2 3) Carry out additional load test. Does the battery, the voltage of 9.6V To step 7
step 3
charging system and the additional load test pass? and above for
10 seconds.
1) Switch off
2) Check whether following contacts are good:
A. Battery wiring.
To
3 B. ABS fuse. To step 8
step 4
C. No 25th pin and No 38th pin of ECU terminal
D ECU grounding wire to chassis grounding.
Are contacts of above connections good?
1) The plug-in of ECU is disconnected.
2) The cable of the battery is broken
3) Connect one ohmmeter between No 25th pin and No To
4 Lower than 2Ω To step 9
38th pin of the ECU harness terminal and negative of step 5
the battery cable.
Is resistant value within specified scope?
1) Connect the battery cable again
2) ECU harness is still disconnected.
To
3) Ignite
5 Battery voltage step To step 10
4) Use the volt meter to measure voltage of No 25 pin
11
of ECU harness terminal
Are voltage of above terminals within specified scope?
Replace the
To
6 Carry out inspection of diagnosis instrument. diagnosis
step 2
instrument

44
 Repair the charging system or charge the battery
again/replace the battery or find out and repair To step
7
reason on excessive usage. 12
Is repair complete?
Repair the terminal or the connector on demand. To step
8
Is repair complete? 12
Find out and repair reason why resistance between
the negative battery cable and the connector of the To step
9
ECU harness is too high. 12
Is repair complete?
Find out and repair reason why voltage of the ECU
To step
10 terminal is too low.
12
Is repair complete?
Connect another new ABS. To step
11
Is repair complete? 12
Use the diagnosis instrument to clear the diagnosis
To step System
12 fault code
1 is OK
Does the diagnosis fault code appear again?

45
13.C2402- Oil returning pump (motor) fault

13.1 Circuit description

The pump motor is included in HCU. Voltage of the pump motor is provided by No 1st pin of the
terminal, which is driven and controlled by the motor relay. It is grounded through No 13 th pin of
ECUM terminal.

13.2 Condition that diagnosis fault code is generated

When the ignition switch is initially closed, the motor relay is on open status. If the motor still
has durable power supply voltage, the diagnosis fault code C2402 will appear.

If the ignition switch is closed and the vehicle starts self-inspection at starting speed of

15km/h, ECU commands the motor relay instantaneously close and supplied power to the motor to

carry out self-inspection. If supply voltage of the electric motor exceeds the voltage scope of the

battery, the diagnosis fault code C2402 will appear.

13.3 Action applied during setting of diagnosis fault code

1. ECU will disconnect the power supply of the pump motor.
2. Diagnosis fault code C2402 is saved.
3. ABS is invalid, the ABS alarm lamp is on
4. EBD is invalid, the EBD alarm lamp is on

13.4 Condition that diagnosis fault code is cleared

If conditions generating the diagnosis fault code C2402 doesn’t appear, use the diagnosis
instrument to clear the diagnosis fault code.

13.5 Diagnosis assistant

Typical reasons for diagnosis fault code C2402:
1. Voltage of the battery is weak or is discharged.

2. Wiring terminal of the battery is loose or rust.

3. Contact of the ABS motor fuse is improper or loose.

46
4. Contacts of No 1st pin and No 13th pin of ECU terminal are improper.

5. High impedance when grounding circuit of No 13th pin of ECU terminal is grounded.

6. Voltage of No 1st pin of the ECU terminal is too low.

7. Internal fault of ECU.

Table 13-1.C2402- Oil returning pump (motor) fault

Expect
Step Diagnosis action YES No
value
To
1 Does inspection of the diagnosis instrument complete To step 5
step 2
1) Switch off
2. Disconnect the ECU harness on ECU.
3) Ignite Lower To
2 To step 6
4) Connect one volt meter between No 13nd pin of the ECU than 0.5V step 3
harness terminal and grounding of the vehicle body.
Is voltage within specified scope?
1) Switch off
2) Disconnect negative and positive of the battery cable.
3) ECU harness is still disconnected with ECU
4) Connect one ohmmeter between negative of the battery Lower To
3 To step 7
cable and No 13th pin of the ECU harness terminal. than 1Ω step 4
5) Connect one ohmmeter between positive of the battery
cable and No 1st pin of the ECU harness terminal.
Is resistant value within specified scope?
Connect along the negative battery cable to grounding of
To
the ECU harness, check whether it is clean, whether
4 step To step 8
connection is firm.
10
Is connection is clean and firm?
Replace the
To
5 Carry out inspection of diagnosis instrument. diagnosis
step 2
instrument
Find out and repair reason for voltage short circuit of No 13th To
6 grounding circuit of the terminal. step
Is repair complete? 10
Find out and repair reason that resistance between the To
7 grounding circuit of No 13th pin of ECU terminal and step
grounding of the battery is too high. 10

47
 Is repair complete?
If necessary, repair improper grounding connection. Is
8 repair complete? To step 10

9 Connect another new ABS. Is repair complete? To step 10

Use the diagnosis instrument to clear the diagnosis

System
10 fault code To step 1
is OK
Does the diagnosis fault code appear again?

48
14. C1202- left front, C1205- right front, C1208- left rear, C1211- right rear — wheel speed
sensor input signal invalid/no signal

14.1 Circuit description

When the wheel rotates, the speed sensor generates an alternating signal which is increased
following speed of the wheel. ECU takes advantage of frequency of alternating signal to
calculate rotation speed of the wheel. The speed sensor is connected to ECU through ―double
twisted‖ wire. The double twisted wire can reduce interface caused by noise.

14.2 Condition that diagnosis fault code is generated

Following conditions shall be available if C1202/C1205/C1208/C1211 are generated:
Speed of the corresponding wheel equals to 0, and speed of all other wheel speed sensors
are: not greater than 8km/h in 2.5 seconds.
14.3 Action applied during generation of diagnosis fault code

1. Store the fault diagnosis code.

2. ABS is invalid.
3. ABS alarm lamp is constantly on.

14.4 Condition that diagnosis fault code is cleared

If conditions generating the diagnosis fault code C1202/C1205/C1208/C1211 doesn’t appear,
use the diagnosis instrument to clear the diagnosis fault code.
14.5 Diagnosis assistance
When diagnosis assistant detects intermittent diagnosis fault code, please thoroughly inspect
the line and the connector of the wheel speed sensor. It will include:
1. Remove the protective conduit and check whether the line is damaged, shorted circuit and
polluted.

2. Check whether the terminal of the sensor connector is deformed, reversely connected or
damaged.

3. Check whether gap between the sensor detector and the gear ring is seriously polluted.

49
If above steps are not carefully and thoroughly carried out, it may cause wrong diagnosis,
unnecessary part replacement and re-occurrence of fault.
Table 14-1 C1202,C1205,C1208,C1211 - Wheel speed sensor input signal invalid/no signal

Step Diagnosis action Expect value YES No

To step To step
1 Does inspection of the diagnosis instrument complete
2 12
1) Switch off
2) Check whether there is physical damage on the wheel To step To step
2
speed sensor, the harness and the gear ring? 13 3
Is any physical damage found?
Judge whether fault code occasionally exists or always To step To step
3
exists after it is cleared by the diagnosis instrument? 14 4
1) Connect the diagnosis instrument or the special
equipment.
2) Monitor and control the wheel speed sensor.
3) Test the vehicle at speed of 24km/h, and then slowly To step To step
4
reduce vehicle speed to zero, do in this way for several 5 15
times. Does fault appear again or is rotation speed of the
fault vehicle suddenly dropped to zero before the vehicle
is completely stopped?
1) Switch off
2) Lift up and suitably support the vehicle.
Magnetic-electric type detection method:
A) Disconnect the ECU harness from ECU.
B. Connect the volt meter to two terminals of the ECU
harness corresponding to the fault wheel speed sensor.
C. Select AC millivolt calibration. Magnetic-elec
D. Rotate the corresponding wheel, and observe the volt tric type: at
meter. (Voltage shall be increased when rotation speed least 100
of the wheel is increased. ） millivolt Hall To step To step
5
Is AC voltage within specified scope? type: Jump 16 6
Hall type detection method: change
A, Ensure ECU connection is normal, ignite, one end of between 0.6V
the volt meter is connected with grounding of the whole and 1.2V.
vehicle, another end is connected to signal terminal of
the wheel speed sensor of the ECU connector.
B. Select DC millivolt calibration.
C. Rotate the corresponding wheel, and observe the volt
meter. (Slow is rotation speed of the wheel is better. ）
Is DC voltage within specified scope?

50
 (This step is skipped for the Hall type sensor) 800-1600Ω
1) Disconnect the connector of the fault wheel speed (resistance
To To
sensor. scope may be
6 step step
2) Connect the ohmmeter between two terminals of the slightly changed
7 17
corresponding wheel speed sensor. following
Is resistant value within specified scope? temperature )
Magnetic-electric type detection method:
1) Disconnect the connector of the fault wheel speed
sensor.
2) Connect the volt meter to two terminals of the
corresponding fault wheel speed sensor.
3) Select AC millivolt calibration.
4) Rotate the corresponding wheel, and observe the volt
meter (when rotation speed of the wheel is increased,
voltage shall be increased).
Is AC voltage within specified scope? To To
7 Hall type detection method: At least 100 mv step step
1) Ensure connections of ECU and the wheel speed 8 17
sensor are normal, ignite.
2) One terminal of the volte meter is connected to ground
of the whole vehicle, another end is connected with the
signal terminal of the corresponding wheel speed sensor
connector.
3) Select DC millivolt calibration.
4) Rotate the corresponding wheel, and observe the volt
meter (Slow is rotation speed of the wheel is better.)
Is DC voltage within specified scope?
1) Disconnect the connector of the fault wheel speed
sensor.
To To
2) Disconnect the ECU harness from ECU. OL (Open
8 step step
3). Connect the ohmmeter to two terminals of the ECU circuit )
9 18
harness corresponding to the fault wheel speed sensor.
Is resistant value within specified scope?
1) ECU harness is still disconnected with ECU
2) Disconnect the connector of the fault wheel speed
sensor. To To
9 3) Connect the ohmmeter with terminal 1 of the fault Lower than 2Ω step step
wheel speed sensor connector and corresponding 10 19
terminal of the ECU harness.
Is resistant value within specified scope?

51
10 1) ECU harness is still disconnected with ECU Low To step 11 To step
2) Disconnect the connector of the fault wheel speed sensor. er 20
3) Connect the ohmmeter with terminal 2 of the fault wheel than
speed sensor connector and corresponding terminal of the 2Ω
ECU harness.
Is resistant value within specified scope?

1) Replace the harness of the fault wheel speed sensor.

System
11 2) Test the vehicle at variable speed and road surface. To step 16
is OK
Does fault appear again?
Replace
the
Carry out inspection of the diagnosis instrument before this diagnosi
12 To step 2
fault tree is carried out. s
instrume
nt
Repair the damaged fault wheel speed sensor, the
13 connection harness or the gear ring. To step 21
Is repair complete?
Firstly
Check whether the diagnosis instrument has other
complete
14 corresponding wheel speed fault before detection steps in To step 2
other fault
this table are implemented.
diagnosis
Occasional possibility of diagnosis fault code is extremely
System is
15 low, repeatability is almost zero, it is ok after historic faults
OK
are cleared.
Connect another new ABS.
16 To step 21
Is repair complete?
Replace the corresponding wheel speed sensor.
17 To step 21
Is repair complete?
Find out and repair short circuit fault between two wires of the
18 wheel speed sensor harness. To step 21
Is repair complete?
Repair open circuit or high impedance between terminal 1 of
the wheel speed sensor and corresponding terminal of ECU
19 To step 21
connector.
Is repair complete?

52
 Repair open circuit or high impedance between terminal 2 of
the wheel speed sensor and corresponding terminal of ECU To step
20
connector. 21
Is repair complete?
Use the diagnosis instrument to clear the diagnosis fault code System
21 To step 1
Does the diagnosis fault code appear again? is OK

53
15.C1201- left front, C1204- right front, C1207- left rear, C1210- right rear — wheel speed
sensor input signal performance/clearance fault

15.1 Circuit description

When the wheel rotates, the speed sensor generates an alternating signal which is increased

following speed of the wheel. ECU takes advantage of frequency of alternating signal to

calculate rotation speed of the wheel. The speed sensor is connected to ECU through ―double

twisted‖ wire. The double twisted wire can reduce interface caused by noise.

15.2 Condition that diagnosis fault code is generated

Following conditions shall be available if C1201/C1204/C1207/C1210 are generated: Signal

acceleration or deceleration of the corresponding wheel sensor exceed reasonable limit.

15.3 Action applied during generation of diagnosis fault code

1. Store the fault diagnosis code.

2. ABS is invalid.

3. ABS alarm lamp is constantly on.

15.4 Condition that diagnosis fault code is cleared

If conditions generating the diagnosis fault code C1201/C1204/C1207/C1210 doesn’t appear,

use the diagnosis instrument to clear the diagnosis fault code.

15.5 Diagnosis assistant

When diagnosis assistant detects intermittent diagnosis fault code, please thoroughly inspect the
line and the connector of the wheel speed sensor. It will include:

1. Remove the protective conduit and check whether the line is damaged, shorted circuit and
polluted.

2. Check whether the terminal of the sensor connector is deformed, reversely connected or
damaged.

3. Check whether gap between the sensor detector and the gear ring is normal.
If above steps are not carefully and thoroughly carried out, it may cause wrong diagnosis,
unnecessary part replacement and re-occurrence of fault.

54
Table 15-1 C1201,C1204,C1207,C1210 - Wheel speed sensor input signal performance/clearance
fault
Step Diagnosis action Diagnosis action YES No
To To step
1 Does inspection of the diagnosis instrument complete
step 2 12
To
Does DTCC0032 set to current or historic diagnosis To step
2 step
fault code? 3
13
1) Switch off
2) Check whether there is physical damage on the
wheel speed sensor and the harness? To
To step
3 3) Carry out complete and thorough inspection of the step
4
corresponding gear ring, learn whether there is 14
damage (crack, tooth loose and loose).
Is any physical damage found?
1) Park.
2) Lift up and suitably support the vehicle.
3) Connect the diagnosis instrument.
4) Ignite, monitor and control the wheel speed sensor
To
when the engine is on idle speed and the vehicle To step
4 step
doesn’t move. 5
15
5) Slightly step down the pedal of the nozzle to
improve idle speed of the engine. Does fault occur
again or does reading of the fault wheel exceed 0km/h
when the vehicle is parked and the engine is running?
1) Still connect the diagnosis instrument.
2) Monitor and control the wheel speed sensor.
3) Carry out physical vehicle testing until maximum
limit speed, and then slowly reduce to zero. Do in this To To step
5
way for several times. step 6 16
Does fault occur again or does rotation wheel speed
change of the fault vehicle exceed 5km/h compared to
any one wheel during driving period?
(This step is skipped for the Hall type sensor) 800-1600Ω
1) Disconnect the connector of the fault wheel speed (resistance scope
sensor. may be slightly To To step
6
2) Connect the ohmmeter between two terminals of changed following step 7 17
the corresponding wheel speed sensor. Is resistant temperature )
value within specified scope?

55
 Magnetic-electric type detection method: At least 100 To step 8 To step 17
1) Disconnect the connector of the fault wheel speed mv
sensor.
2) Connect the volt meter to two terminals of the
corresponding fault wheel speed sensor.
3) Select AC millivolt calibration.
4) Rotate the corresponding wheel, and observe the
volt meter. (Voltage shall be increased when rotation
speed of the wheel is increased. ）
Is AC voltage within specified scope?
Hall type detection method:
7
1) Ensure connections of ECU and the wheel speed
sensor are normal, ignite.
2) One terminal of the volte meter is connected to
ground of the whole vehicle, another end is
connected with the signal terminal of the
corresponding wheel speed sensor connector.
3) Select DC millivolt calibration.
4) Rotate the corresponding wheel, and observe the
volt meter. (Slow is rotation speed of the wheel is
better)
Is DC voltage within specified scope?
1) ECU harness is still disconnected with ECU
2) Disconnect the connector of the fault wheel speed
sensor.
Lower than
8 3) Connect the ohmmeter with terminal 1 of the fault To step 9 To step 18
2Ω
wheel speed sensor connector and corresponding
terminal of the ECU harness.
Is resistant value within specified scope?
1) ECU harness is still disconnected with ECU
2) Disconnect the connector of the fault wheel speed
sensor.
Lower than To step
9 3) Connect the ohmmeter with terminal 2 of the fault To step 19
2Ω 10
wheel speed sensor connector and corresponding
terminal of the ECU harness.
Is resistant value within specified scope?

56
 1) Disconnect the connector of the fault wheel speed OL (Open
sensor. circuit )
2) Disconnect the ECU harness from ECU.
To step
10 3). Connect the ohmmeter to two terminals of the To step 20
11
ECU harness corresponding to the fault wheel speed
sensor.
Is resistant value within specified scope?
1) Replace the harness of the fault wheel speed
sensor. To step System is
11
2) Test the vehicle at variable speed and road 21 OK
surface.
Does fault appear again?
Replace the
Carry out inspection of the diagnosis instrument
12 To step 2 diagnosis
before this fault tree is carried out.
instrument
Firstly
Check whether the diagnosis instrument reports complete
13 C1200/C1203/C1206/C1209 wheel speed fault other To step 2
before detection steps in this table are implemented. fault
diagnosis
Repair the damaged fault wheel speed sensor, the
To step
14 connection harness or the gear ring. Is repair
22
complete?
Fault reason is that ignition noise is coupled and
induced to the circuit of the fault speed sensor.
Check whether there is potential ignition noise
source in the ABS module harness and the To step
15
corresponding wheel speed harness, such as 22
conduction wire of the spark plug. Route the
conduction wire again on demand. Is repair
complete?
Occasional possibility of diagnosis fault code is
System is
16 extremely low, repeatability is almost zero, it is ok
OK
after historic faults are cleared.
Replace the fault wheel speed sensor. Is repair To step
17
complete? 22
Repair open circuit or high impedance between
terminal 1 of the wheel speed sensor and To step
18
corresponding terminal of ECU connector. Is repair 22
complete?

57
 Repair open circuit or high impedance between
terminal 2 of the wheel speed sensor and To step
19
corresponding terminal of ECU connector. Is repair 22
complete?
Find out and repair short circuit fault between two
To step
20 wires of the wheel speed sensor harness. Is repair
22
complete?
Connect another new ABS. Is repair complete? To step
21
22
Use the diagnosis instrument to clear the diagnosis
System is
22 fault code Does the diagnosis fault code appear To step 1
OK
again?

58
16.C1200- left front, C1203- right front, C1206- left rear, C1209- right rear — wheel speed
sensor input signal open circuit/short circuit fault

16.1 Circuit description

When the wheel rotates, the speed sensor generates an alternating signal which is increased

following speed of the wheel. ECU takes advantage of frequency of alternating signal to

calculate rotation speed of the wheel. The speed sensor is connected to ECU through ―double

twisted‖ wire. The double twisted wire can reduce interface caused by noise.

16.2 Condition that diagnosis fault code is generated

Following conditions shall be available if C1200/C1203/C1206/C1209 are generated: ignite,

ECU can detect open circuit, short circuit to ground or short circuit to the battery on the fault wheel

speed sensor at any time.

16.3 Action applied during generation of diagnosis fault code

1. Store the fault diagnosis code.
2. ABS is invalid.
3. ABS alarm lamp is constantly on.
16.4 Condition that diagnosis fault code is cleared

If conditions generating the diagnosis fault code C1200/C1203/C1206/C1209 doesn’t appear,

use the diagnosis instrument to clear the diagnosis fault code.

16.5 Diagnosis assistant

When diagnosis assistant detects intermittent diagnosis fault code, please thoroughly inspect the
line and the connector of the wheel speed sensor. It will include:

1. Remove the protective conduit and check whether the line is damaged, shorted circuit and
polluted.

2. Check whether the terminal of the sensor connector is deformed, reversely connected or
damaged.

3. Check whether gap between the sensor detector and the gear ring is normal.

59
If above steps are not carefully and thoroughly carried out, it may cause wrong diagnosis,
unnecessary part replacement and re-occurrence of fault.
Table 16-1 C1200,C1203,C1206,C1209 - Wheel speed sensor input signal open circuit/short
circuit
Step Diagnosis action Expect value YES No
To To step
1 Does inspection of the diagnosis instrument complete
step 2 14
1) Switch off
To
2) Check whether there is physical damage on the
2 step To step 3
wheel speed sensor, the harness and the gear ring?
15
Is any physical damage found?
Test the vehicle at variable speed and road surface. To To step
3
Does fault appear again? step 4 16
(This step is skipped for the Hall type sensor) 800-1600Ω
1) Disconnect the connector of the fault wheel speed (resistance
sensor. scope may be To To step
4
2) Connect the ohmmeter between two terminals of slightly changed step 5 17
the corresponding wheel speed sensor. following
Is resistant value within specified scope? temperature )
1) Disconnect the connector of the fault wheel speed
sensor.
2) Disconnect the ECU harness from ECU.
OL (Open To To step
5 3). Connect the ohmmeter to two terminals of the ECU
circuit ) step 6 17
harness corresponding to the fault wheel speed
sensor.
Is resistant value within specified scope?
1) ECU harness is still disconnected with ECU
2) Disconnect the connector of the fault wheel speed
sensor.
To To step
6 3) Connect the ohmmeter with terminal 1 of the fault Lower than 2Ω
step 7 18
wheel speed sensor connector and corresponding
terminal of the ECU harness.
Is resistant value within specified scope?
1) ECU harness is still disconnected with ECU
2) Disconnect the connector of the fault wheel speed
sensor.
To To step
7 3) Connect the ohmmeter with terminal 2 of the fault Lower than 2Ω
step 8 19
wheel speed sensor connector and corresponding
terminal of the ECU harness.
Is resistant value within specified scope?

60
 1) ECU harness is still disconnected with ECU
2) Disconnect the connector of the fault wheel speed
sensor. Lower
8 3) Connect the volt meter to corresponding fault wheel than To step 9 To step 20
harness terminal 1 of ECU, and then the vehicle body is 1V
grounded.
Is voltage within specified scope?
1) ECU harness is still disconnected with ECU
2) Disconnect the connector of the fault wheel speed
Lower
sensor.
9 than To step 10 To step 21
3) Connect the volt meter to corresponding fault wheel
1V
harness terminal 2 of ECU, and then the vehicle body is
grounded. Is voltage within specified scope?
1) ECU harness is still disconnected with ECU
2) Disconnect the connector of the fault wheel speed
OL
sensor.
(Open
10 3) Connect the volt meter to corresponding fault wheel To step 11 To step 22
circuit
harness terminal 1 of ECU, and then the vehicle body is
)
grounded.
Is resistance within specified scope?
1) ECU harness is still disconnected with ECU
2) Disconnect the connector of the fault wheel speed OL
sensor. (Open
11 To step 12 To step 23
3) Connect the volt meter to corresponding fault wheel circuit
harness terminal 2 of ECU, and then the vehicle body is )
grounded. Is resistance within specified scope?
1) ECU harness is still disconnected with ECU
2) Disconnect the connector of the fault wheel speed OL
sensor. (Open
12 To step 13 To step 24
3) Connect the volt meter to two terminals of circuit
corresponding fault wheel harness of ECU. )
Is resistance within specified scope?
1) Replace the harness of the fault wheel speed sensor.
System is
13 2) Test the vehicle at variable speed and road surface. To step 25
OK
Does fault appear again?
Replace the
Carry out inspection of the diagnosis instrument before
14 To step 2 diagnosis
this fault tree is carried out.
instrument
Repair the damaged fault wheel speed sensor, the
15 To step 26
connection harness or the gear ring.

61
 Is repair complete?
Occasional possibility of diagnosis fault code is
System is
16 extremely low, repeatability is almost zero, it is
OK
ok after historic faults are cleared.
Replace the fault wheel speed sensor. Is repair To step
17
complete? 26
Repair open circuit or high impedance between
terminal 1 of the wheel speed sensor and To step
18
corresponding terminal of ECU connector. Is 26
repair complete?
Repair open circuit or high impedance between
terminal 2 of the wheel speed sensor and To step
19
corresponding terminal of ECU connector. Is 26
repair complete?
Repair corresponding fault wheel terminal 1 of
To step
20 the ECU connector short circuit to voltage. Is
26
repair complete?
Repair corresponding fault wheel terminal 2 of
To step
21 the ECU connector short circuit to voltage. Is
26
repair complete?
Repair corresponding fault wheel terminal 1 of
To step
22 the ECU connector short circuit to grounding. Is
26
repair complete?
Repair corresponding fault wheel terminal 2 of
To step
23 the ECU connector short circuit to grounding. Is
26
repair complete?
Find out and repair short circuit fault between
To step
24 two wires of the wheel speed sensor harness. Is
26
repair complete?
Connect another new ABS. Is repair complete? To step
25
26
Use the diagnosis instrument to clear the
System is
26 diagnosis fault code Does the diagnosis fault To step 1
OK
code appear again?

62
17 Low voltage of C1102 system

17.1 Circuit description

This circuit is used to monitor and control level of voltage supplied to ECU. If voltage is

dropped to some level, it can’t ensure all performances of the system normal. There are generally

several conditions which cause voltage of the battery dropped down during operation period of

ABS. Therefore it means good charging status if voltage is monitored and controlled before

operation of ABS, it is so during ABS operation period with great voltage drop.

17.2 Condition that diagnosis fault code is generated

Following conditions shall be available if C1102 is generated: after ABS is ignited, duration

that voltage the No 32nd pin of the ignition terminal or No 25th pin of the terminal is lower than 10V

and higher than 8V lasts for 1 second and move.

17.3 Action applied during generation of diagnosis fault code

1. Store the fault diagnosis code.
2. ABS is invalid.
3. ABS alarm lamp is constantly on.
17.4 Condition that diagnosis fault code is cleared

If conditions generating the diagnosis fault code C1102 doesn’t appear, use the diagnosis

instrument to clear the diagnosis fault code.

17.5 Diagnosis assistant

Typical reason for generation of C1102:
1. Voltage of the battery is weak or is used off.
2. Contact of the battery terminal is improper.
3. Grounding of the battery on the cylinder body or the chassis is improper. 4. Contact of the
terminal on ECU is improper.
5. Grounding connection of ECU is improper.
6. The charging system (generator) is fault. Completely inspect the line and the connector. If wring
and the connector are not inspected carefully and completely, it may cause unnecessary part
replacement, and fault can't be repaired.

63
 Table 17-1.Low voltage of C1102- system
Step Diagnosis action Expect value YES No
Does inspection of the diagnosis
1 To step 2 To step 6
instrument complete
1) Load detection of the battery. Refer to The battery must
battery maintenance manual of each maintain voltage of
manufacturer. 9.6V and above for
2) Inspect the charging system. Refer to more than 10 seconds.
2 starter and charging system maintenance Does hidden current of To step 3 To step 7
manual of each manufacturer. physical vehicle
3) Carry out additional load test. exceed limit value of
Does the battery, the charging system and the manufacturer
the additional load test pass?
1) Switch off
2) Disconnect positive and negative of the
battery.
3) Disconnect the harness from ECU.
4) Check whether following contacts are
good:
A. Terminal cable of the battery.
3 B. Negative cable to the engine block or To step 4 To step 8
chassis
C. Positive cable to the starter coil or the
terminal box.
D. No 25th pin, No 38th pin and No 32nd pin
of ECU terminal E ECU grounding wire
to chassis grounding.
Are all above connection good?
1) ECU harness is still disconnected.
2) The cable of the battery is still broken
3) Connect one ohmmeter between No
4 Lower than 2Ω To step 5 To step 9
38th pin of the ECU harness terminal and
negative of the battery cable.
Is resistance within specified scope?
1) Connect the battery cable.
2) ECU harness is still disconnected.
3) Ignite To step
5 Battery voltage To step 10
4) Use a volt meter to measure voltage of 11
No 25th pin and No 32nd pin of ECU
harness terminal

64
 Are voltage of two terminals higher than specified
scope?
Replace the
Carry out inspection of the diagnosis instrument
6 To step 2 diagnosis
before this fault tree is carried out.
instrument
Repair the charging system or re-charge/replace the
To step
7 battery or find out and repair reason for more extra
12
power leakage. Is repair complete?
If necessary, repair the terminal or connector. To step
8
Is repair complete? 12
Find out and repair reason why resistance between
To step
9 the negative cable of battery and the connector of the
12
ECU harness is too high. Is repair complete?
Find out and repair reason for low voltage of ECU To step
10
terminal. Is repair complete? 12
Connect another new ABS. Is repair complete? To step
11
12
Use the diagnosis instrument to clear the diagnosis
System is
12 fault code Does the diagnosis fault code appear To step 1
OK
again?

65
18 High voltage of C1101 system

18.1 Circuit description

This circuit is used to monitor and control level of voltage supplied to ECU. In case voltage rises up
to some level, the system may be damaged.

18.2 Condition that diagnosis fault code is generated

Following conditions shall be available if C1101 is generated: after ABS is ignited, duration that
voltage the No 32nd pin of the ignition terminal or No 25th pin of the terminal is higher than 16V
and lower than 17.4V lasts for 1 second and move.

18.3 Action applied during generation of diagnosis fault code

1. Store the fault diagnosis code.
2. ABS is invalid.
3. ABS alarm lamp is constantly on.

18.4 Condition that diagnosis fault code is cleared

If conditions generating the diagnosis fault code C1101 doesn’t appear, use the diagnosis
instrument to clear the diagnosis fault code.

18.5 Diagnosis assistant

Typical reason for generation of C1101:
1. The charging system is fault.
2. Connection is improper.
3. ECU is failed.

66
 Table 18-1 High voltage of C1101-system

Expect
Step Diagnosis action YES No
value

To step
1 Does inspection of the diagnosis instrument complete To step 4
2

1) Connect a volt meter between negative and positive

of the battery.
2) Switch off all fittings.
3) Start the engine. Lower than To step
2 To step 5
4) When the engine operates for several seconds at 17.0V 3
speed of 2000 rpm/min, monitor and control voltage of
the volt meter.
Is voltage within specified scope?
1) Connect the diagnosis instrument.
2) When the engine operates for several seconds at
Lower than To step
3 speed of 2000 rpm/min, monitor and control voltage of To step 7
17.0V 6
the ABS battery.
Is voltage within specified scope?
Replace the
Carry out inspection of the diagnosis instrument before To step
4 diagnosis
this fault tree is carried out. 2
instrument
Refer to diagnosis of the starter and the charging To step
5
system of each manufacturer. 8
Occasional possibility of diagnosis fault code is
System
6 extremely low, repeatability is almost zero, it is ok after
is OK
historic faults are cleared.
Connect another new ABS. To step
7
Is repair complete? 8
Use the diagnosis instrument to clear the diagnosis
To step System is
8 fault code
1 OK
Does the diagnosis fault code appear again?

67
19. Internal fault of C1604ECU.

19.1 Circuit description

This diagnosis fault code determines possible fault in ECU.

19.2 Condition that diagnosis fault code is generated

This fault occurs when there is problem in the internal part or the micro-processor.

19.3 Action applied during generation of diagnosis fault code

1. The solenoid relay is open, ABS and EBD are invalid.

2. Store the fault diagnosis code.

3. The ABS alarm lamp and EBD alarm lamp are constantly on.

19.4 Condition that diagnosis fault code is cleared

If conditions generating the diagnosis fault code C1604 doesn’t appear, use the diagnosis

instrument to clear the diagnosis fault code.

19.5 Diagnosis assistant

Firstly maintain low voltage, driving performance or other electrical fault before analysis of C1604

fault tree is carried out.

Ensure connection between ECU and HCU is reliable and firm in a whole, and there is no

corrosion, leakage or damage.

68
 Table 19-1 Internal fault of C0055-EUC

Expec
Step Diagnosis action YES No
t value

Does inspection of the diagnosis instrument complete

1 To step 2 To step 5

1) Connect the diagnosis instrument.

2) Ignite when the engine is switched off.
3) Take advantage of the diagnosis instrument, and
I2 To step 6 To step 3
observe diagnosis code information.
Does other any diagnosis fault code appear in the current
or historic data out of C1604?
1) Switch off
2) Disconnect the ECU harness from ECU.
3 3) Check whether the connector has damage, corrosion To step 7 To step 4
and mutual contact of the terminal.
Is any problem found?
Connect another new ABS.
4 To step 8
Is repair complete?
Replace the
Carry out inspection of the diagnosis instrument before this
5 To step 2 diagnosis
fault tree is carried out.
instrument
Carry out diagnosis of relevant diagnosis fault code for
6 To step 8
other diagnosis fault code.
Carry out maintenance on demand.
7 To step 8
Is repair complete?
Use the diagnosis instrument to clear the diagnosis fault
System is
8 code To step 1
OK
Does the diagnosis fault code appear again?

69
20.C2308,C2312,C2316,C2320,C2324,C2328,C2332,C2336- booster or pressure reduction

solenoid fault ‘

20.1 Circuit description

The coils of the booster or pressure reduction solenoid are essential part of ECU. When ignition is

on conductive position, use the battery to supply power to the solenoid relay, and then supply

power to the coil of the solenoid. If necessary, ECU can control the corresponding solenoid

through grounding the corresponding circuit of the solenoid coil.

20.2 Condition that diagnosis fault code is generated

When any ECU coil is open circuit or short circuit to ground or short circuit to power supply, the

corresponding diagnosis fault code is generated.

20.3 Action applied during generation of diagnosis fault code

1. The relay of the solenoid is open circuit, disconnect the power supply of the solenoid coil.

2. Store corresponding fault code.

3. ABS is invalid, the ABS alarm lamp is constantly on.

4. EBD is invalid, the EBD alarm lamp is constantly on.

20.4 Condition that diagnosis fault code is cleared

If conditions generating the diagnosis fault code C2112 doesn’t appear, use the diagnosis

instrument to clear the diagnosis fault code.

20.5 Diagnosis assistant

Ensure connection between ECU and HCU is reliable and firm in a whole, and there is no

corrosion, leakage or damage.

Because the solenoid coil is a part of the whole ECU, setting of any diagnosis fault code is

generally internal fault of ECU.

70
 Table 20-1.C2308,C2312,C2316,C2320,C2324,C2328,C2332,C2336- booster or pressure
reduction solenoid fault
Expect
Step Diagnosis action YES No
value
1 Does inspection of the diagnosis instrument complete To step 2 To step 5
1) Switch off To step 6 To step 3
2) Check whether there is physical damage on ECU and
2
HCU.
Is any physical damage found?
1) Disconnect the ECU harness from ECU.
2) Inspect whether there is liquid leakage, corrosion or
3 damage in the ECU plug-in and socket. Is there is any To step 6 To step 4
liquid leakage, damage or corrosion in the plug-in and
socket?
1) Connect the diagnosis instrument.
2) Ignite when the engine is switched off.
3) Use the diagnosis instrument to clear the diagnosis Intermittent
4 fault code To step 6 problem
4) Drive the vehicle under condition with operation To step 5
diagnosis fault code.
Does the diagnosis fault code appear again?
Replace the
Carry out inspection of the diagnosis instrument before
5 To step 2 diagnosis
this fault tree is carried out.
instrument
Connect another new ABS.
6 To step 9
Is repair complete?
Use the diagnosis instrument to clear the diagnosis fault
System is
7 code To step 1
OK
Does the diagnosis fault code appear again?

71
Part Three Interior and exterior, electrical appliances and car
body
Chapter Three Wiper and washer
Position of parts ...................................................................................................002
Front wiper motor components ……………………………………………………….002
Front rubber wiper blade …………………………………………………………… .. 009
Rear wiper motor components ……………………………………………………… .011
Rear rubber wiper blade ………………………………………………………………016
Washing nozzle …………………………………………………………………… ..….017

1 / 19
Position of parts

Front wiper blade (left)

Front wiper arm (left)

Front wiper blade (right)

Front wiper arm (right)

Front washing nozzle

Front wiper motor

Washing liquid tank

Front washing motor

Rear washing motor

2 / 19
 Rear washing nozzle

Rear wiper motor

Rear wiper arm

Rear wiper blade

Dashboard

Rear wiper, rear washing fuse

Wiper fuse

Washing fuse

Wiper switch

3 / 19
 Symptom Double position
When the washing motor normally works, not Washing water pipe and nozzle
inject washing liquid

When the rear wiper switch is switched off, Wiper motor

the wiper blade doesn’t return or returning Harness or plug-in
position is wrong

4 / 19
Front wiper motor components

Wiper arm cover

Front wiper arm blade assembly (right)

Inlet grill hole cover (right)

Front wiper arm blade assembly (left)

Inlet grill assembly

Inlet grill hole cover (left)

Front wiper motor and connection bar assembly

Front wiper motor

Appointed button

Use lubrication oil

5 / 19
 On-board inspection:

1. Inspect the front wiper motor

(a) Operate the front wiper motor

(b) Stop operating the front wiper motor

(c) Inspect the automatic stop position

Stop position of the front wiper is shown as

figure
If stop position isn't here, the wiper motor may
be failed

1. Remove the inlet grill hole at right lower

Automatic stop position
side
(a) Remove two wiper arm covers

Remove the front left and the front right wiper

assemblies

(a) Remove the nut and the front left and the
front right wiper assemblies

Remove the inlet grill hole cover at right side

(a) Release 2 clutches, and then take away of

the inlet grill hole cover at right side.
Shown as figure:

4. Remove the inlet grill hole at left side

(a) Release 2 clutches, and then take away of

the inlet grill hole cover at left side. Shown as
figure:

6 / 19
 2. Assemble the front wiper motor and
the connection bar assembly

(a) Firstly assemble the connection bar

into the U shape slot: shown as figure

(b) Use 2 bolts to assemble the front wiper

motor and the connection bar assembly.

(c) Connect the plug-in well.

Vehicle body type: Wide 3. Assemble the inlet grill assembly

(a) Use 11 card feet and 7 self-driving
screws to fix the inlet grill assembly.
(b) Connect the washing water pipe

4. Assemble the inlet grill hole at left

side
5. Assemble the inlet grill hole at right
side

Saw-tooth of wiper arm 6. Assemble the front wiper arm

assembly (left)
(a) Operate the wiper motor, and make the
wiper motor stop at automatic returning
position

(b) Clean the saw-tooth of the wiper arm.

(c) Use the brush made of the metal wire

roll to clean the output axle saw-tooth
Metal wire brush
Output axle saw-tooth (re-assembly)

7 / 19
 (d) Use the nuts to assemble the front wiper
arm blade assembly (left)
Assemble on the position shown as figure:
Torque: 25N·m
Information:
Grasp the wiper arm by hand before the nut is
tightened

Saw-tooth of wiper arm

7. Assemble the wiper arm blade
assembly of the front wiper (right)

(a) Operate the wiper motor, and make the

wiper motor stop at automatic returning
position

(b) Clean the saw-tooth of the wiper arm.

(c) Use the brush made of the metal wire roll

Output axle saw-tooth to clean the output axle saw-tooth
Metal wire brush
(re-assembly)

8 / 19
 (d) Use the nuts to assemble the front
wiper arm blade assembly (left)
Assemble on the position shown as figure:
Torque: 25N·m
Information:
Grasp the wiper arm by hand before the nut
is tightened

8. Assemble the wiper arm cover

(a) Assemble two wiper arm covers

(b) Operate the wiper system; ensure

there is no interface with the body during
normal working when water or washing liquid
is sprayed.

9 / 19
Front rubber wiper blade
Parts

Front wiper blade

Front rubber wiper blade

Rubber wiper blade lining board

Rubber wiper blade lining board

10 / 19
 Wide vehicle body, high top

Assemble rear door board assembly

Wide vehicle body, intermediate top

Assemble rear door board assembly

Assemble rear door board assembly

11 / 19
Rear wiper motor components

Rear wiper rotary sealing ring

Rear wiper motor

Sealing ring
Tightening nut
Rear wiper output axle cover

Rear wiper arm blade assembly

12 / 19
 1. Inspect the rear wiper motor
Automatic stop position
(a) Operate the rear wiper motor
(b) Stop operating the rear wiper motor

(c) Inspect the automatic stop position

Stop position of the rear wiper is shown as

figure
If stop position isn't here, the rear wiper motor
may be failed

Remove

1. Remove the rear wiper

arm wiper blade assembly

(a) Loose 3 claws, separate the cover, shown
as figure:

(b) Remove the rear wiper arm nut and take

out of the rear wiper blade assembly.

2. Take out of the rear wiper arm wiper blade

assembly
(a) Take out of the rear wiper output axle
cover

13 / 19
 3. Take out of the rear wiper rotary sealing
ring
(a) Use the spanner to screw out of the nut and
the sealing ring
Note: Don’t damage glass
4. Remove the upper and lower rear door
interior trim assembly

5. Remove the rear wiper motor

(a) Disconnect the plug-in and take out of the
clip.
(b) Screw out of 3 bolts and take out of the rear
wiper motor.

(c) Take out of the sealing ring from the rear

Sealing ring wiper motor.

14 / 19
 Assemble
1. Assemble the rear wiper motor
(a) Assemble the sealing ring, shown as
figure:
Sealing ring

(b) Use 3 bolts to assemble the rear wiper

motor
Torque: 5.4N·m
(c) Assemble the clip and connect the plug-in.
2. Assemble the trim board assembly on
the rear tail door.

3. Assemble the rear wiper rotary sealing

ring
(a) Assemble the rear wiper rotary sealing ring
Assemble marking
out of the body, there is assemble marking to
top.

15 / 19
 (b) Use the spanner to assemble the nut.
Torque: 12N·m
Note: Don’t damage glass

4. Assemble the rear wiper output axle

cover

Wiper arm saw-tooth

5. Assemble the rear wiper arm wiper

blade assembly

(a) Operate the rear wiper, and make the rear

wiper stop on the automatic returning position.

(b) Clean the saw-tooth of the wiper arm.

Output axle saw-tooth

(c) Use the metal brush to clean the output
Metal brush
axle tooth-saw.
(re-assembly)
(d) Use the nuts to assemble the rear wiper
arm blade assembly

Torque: 9.8N·m

Information: grasp the wiper arm by hand

when the nut is tightened

Installation marking

(e) Operate the rear wiper, ensure there is no

interface with the body during normal working
when water or washing liquid is sprayed.

16 / 19
Rear wiper rubber blade
Parts

Rear wiper blade

Rear rubber wiper blade

Rear rubber wiper blade lining board

Rear rubber wiper blade lining board

17 / 19
 Washing nozzle
On-board inspection
Inspect nozzle

(a) Start the engine

(b) Inspect position standard of the washing liquid spraying on the windscreen glass.
Area of washing liquid spraying on the windscreen glass is shown as figure:
(1) Front

Vehicle body type: wide

Injection point of

washing liquid

18 / 19
 (2) Rear

Rear washing nozzle

Injection point of washing liquid

Center of rear wiper

output axle

Adjustment

1. Adjust the washing nozzle

(a) Use Toyota 4 direction nozzle adjustment tools, concave and convex positions of the
adjustment tools are inserted into the extruded position of the nozzle to adjust.
Note: Don’t use metal object or similar object to adjust the nozzle because it will damage
the nozzle.

Nozzle core
Nozzle core

Adjustment tools
Adjustment tools

19 / 19
Part Three Interior and exterior, electrical appliances and
car body
Chapter Eleven Switch part
Rear fog lamp switch …………………………………………………………002
Danger warning switch ……………………………………………………… .002
Rear ceiling lamp switch …………………………………………………… ..003
Headlamp level regulation switch ………………………………………… ...003
Electric rear view mirr or switch ……………………………………………… 004
Electric window switch ……………………………………………………… ..004
Combination switch ………………………………………………………… …005

1/8
 Rear fog lamp switch

The rear fog lamp switch is assembled below the

middle DVD of the dashboard, which is clamp
connected with the dashboard. Firstly connect the
harness during installation, and then align the
installation hole along the arrow direction of the
installation hole shown as figure. When a “chatter”
sound is heart, it means installation of the switch is
Electrical principle figure complete; take out of the switch panel during
removal, remove the harness, press down the
Small lamp relay
switch clip and push at direction reverse to
installation direction of the switch by force at
Headlamp relay

Combination switch Rear fog lamp

directions of a pair of the arrows shown in the figure,
Front fog lamp relay the switch will automatically disengaged from the
panel, removal is complete.

Definition of the pin is shown as figure. If there is

problem, detection the switch according to definition
of the pin.

Danger warning switch

The danger warning switch is assembled below the

middle DVD of the dashboard, which is clamp
connected with the dashboard. Firstly connect the
harness during installation, and then align the
installation hole along the arrow direction of the
Electrical principle figure
installation hole shown as figure. When a “chatter”
Controller input sound is heart, it means installation of the switch is
complete; take out of the switch panel during
Low frequency removal, remove the harness, press down the
self-locking
output
switch clip and push at direction reverse to
installation direction of the switch by force at
directions of a pair of the arrows shown in the figure,
the switch will automatically disengaged from the
panel, removal is complete.

2/8
 Rear ceiling lamp switch
The rear ceiling lamp switch is assembled below the
middle DVD of the dashboard, which is clamp
connected with the dashboard. Firstly connect the
harness during installation, and then align the
installation hole along the arrow direction of the
installation hole shown as figure. When a “chatter”
sound is heart, it means installation of the switch is
complete; take out of the switch panel during
removal, remove the harness, press down the
switch clip and push at direction reverse to
Electrical principle figure installation direction of the switch by force at
directions of a pair of the arrows shown in the figure,
Controller input the switch will automatically disengaged from the
panel, removal is complete.
Low frequency
self-locking output Definition of the pin is shown as figure. If there is
problem, detection the switch according to definition
of the pin.

Headlamp level regulation switch

The headlamp level regulation switch is assembled
on the left lower protection board of the dashboard,
which is clamp connected with the dashboard.
Firstly connect the harness during installation, and
then align the installation hole along the arrow
direction of the installation hole shown as figure.
When a “chatter” sound is heart, it means
installation of the switch is complete; take out of the
switch panel during removal, remove the harness,
press down the switch clip and push at direction
reverse to installation direction of the switch by force
at directions of a pair of the arrows shown in the
figure, the switch will automatically disengaged from
the panel, removal is complete.
Wiring figure
+12v power supply

Definition of the pin is shown as figure. If there is

Regulation switch of headlamp problem, detection the switch according to definition
Left motor Right motor of the pin.
Grounding

3/8
 Electric rear view mirror switch
The electric rear view mirror switch is assembled on
the left lower protection board of the dashboard,
which is clamp connected with the dashboard.
Firstly connect the harness during installation, and
then align the installation hole along the arrow
direction of the installation hole shown as figure.
When a “chatter” sound is heart, it means
installation of the switch is complete; take out of the
switch panel during removal, remove the harness,
press down the switch clip and push at direction
reverse to installation direction of the switch by force
at directions of a pair of the arrows shown in the
figure, the switch will automatically disengaged from
the panel, removal is complete.
Definition of the pin is shown as figure. If there is
problem, detection the switch according to definition
of the pin.

Electric window switch (left door and right door are

symmetrical)

The electric window switch is assembled on the door

board, which is clamp connected with the door
board and fixed by the screws. Firstly insert and
connect the harness during installation, align the
Electric window lifting switch to the installation hole, and then tap the panel
Battery Relay
slightly, and ensure all buckles are basically on
position at same time, when a “chatter” sound is
Motor of drive door

heart, it means the switch is assembled on position,

and then tighten two screws at bottom of the drawer
and window

box, installation is complete, sequence is reverse

during removal.

Control switch of right

window Definition of the pin is shown as figure. If there is
Door lock controller
problem, detection the switch according to definition
of the pin.

4/8
 Combination switch
Removal of the lamp controlled switch and the
wiper switch:
1. Remove the combined switch cover (upper and
lower)
2. Remove the lamp controlled switch
(a) Remove the joint.
(b) Remove 2 screws
(c) Remove the switch.
3. Remove the wiper and the cleaner
switch
(a) Remove the joint.
(b) Remove 2 screws
(c) Remove the switch.

Assembly of the lamp controlled switch and the

wiper switch:

Assembly sequence is reverse to removal

sequence.

Disassembly of the combination switch assembly

Proper body of switch

Comprehensive switch
Lamp controlled lamp
Lighting switch of

ceiling lamp
Comprehensive switch
Wiper and cleaner switch

Spiral wire

5/8
 Inspection of the combination switch assembly – left
light control switch group

1. Inspect the lamp controlled switch

Number of If conductivity isn't in accordance with
Switch terminal Specified specification, replace the switch
position connected with condition
tester
OFF -------- Not
conductive
14----16 Conductive
Small lamp

13----14----16 Conductive
Headlamp

10----11 Conductive
Fog lamp

2. Inspect light changing switch of the

Switch Number of
headlamp
position terminal Specified
If conductivity isn't in accordance with
connected with condition
specification, replace the switch
tester
Flash 7----8----16 Conductive
(overpass)
Low beam 16----17 Conductive
Low beam 7----16 Conductive

6/8
3. Inspection of the steering lamp switch
(a) If conductivity isn't in accordance with
specification, replace the switch
Switch position Number of terminal
Specified
connected with
condition
tester
Turn left 1----2 Conductive
Neutral --- Not
conductive
Turn right 2----3 Conductive
Inspection of the combination switch-right wiper
control switch group
1. Inspect conductivity of the wiper switch
Switch Number of
Specified
position terminal connected
condition
with tester
OFF 7----16 Conductive
INT 7----16 Conductive
LO 7----17 Conductive
HI 8----17 Conductive
If conductivity isn't in accordance with specification,
replace the switch
2. Inspect conductivity of the front washing switch
Switch Number of
position terminal
Specified condition
connected
with tester
OFF --- Not conductive
ON 2----11 Conductive
If conductivity isn't in accordance with specification,
replace the switch
3. Inspect intermittent action of the wiper
(a) Rotate the wiper switch to INT position
(b) Rotate the intermittent time control switch to
AST position, place the positive conductor of the
battery on No 16 terminal, and place the negative
conductor on No 2 terminal.
(c) Connect positive (+) of the volt meter with No 7
terminal, and connect negative (-) with No 2 terminal.
Check whether reading of the volt meter is voltage
of the battery

7/8
INT time control Position of INT time control Voltage
marking switch
About 1-3 seconds
Slow
SLOW Battery voltage
0V

About 10-15 seconds

FAST Battery voltage
Fast
0V

If conductivity isn't in accordance with specification, replace the switch

4. Inspection conductivity of the rear wiper and the

cleaner switch.

Switch Number of terminal

Specified
position connected with
condition
tester
Cleaner 1 2----12 Conductive
Wiper OFF ---- Not
conductive
Wiper INT 2----13 Conductive
Wiper ON 2----10 Conductive
Cleaner 2 2----10----12 Conductive
If action condition isn’t in accordance with regulation,
place the wiper and the cleaner switch.

Inspection of the brake lamp switch

Inspect conductivity of the switch

If conductivity isn't in accordance with specification,
Rotate the brake lamp switch 45 degree
replace the switch
anti-clockwise and then remove
Switch position Terminal Specified
number condition
Tip of switch is 3----4 Not conductive
released (pedal is
step down)
Tip of switch is 1----2 Conductive
pushed (pedal is
released)

8/8
 Part Three Interior and exterior, electrical
appliances and car body
Chapter Ten Seat
Front seat assembly----------------------------------------------------------------------------002
Rear single seat assembly--------------------------------------------------------------------009
Rear double seats assembly-----------------------------------------------------------------018
Rear turnover seat assembly----------------------------------------------------------------027

1 / 37
 Front seat assembly
Components:

Front seat assembly

Defined torque

2 / 37
 Disassemble front seat backrest Front seat headrest

Front seat foaming

Front seat headrest guide sleeve

Snap ring
Front seat frame assembly
Right angle regulator adjustment
inner protection cover

Front seat cushion inner protection cover

Front seat inner side safety belt

Angle regulator left inner side protection cover

Front seat cushion

Snap ring

Angle regulator regulation handle

Front seat cushion left inner protection cover

Front seat cushion foaming

3 / 37
 Assemble removal
1. Remove the front seat assembly
(a) Adjust the seat to last end.
(b) Remove two bolts at rear of the seat
used to assemble the support.
(c) Move the front seat to the full back
position.
(d) Remove two bolts in front of the seat.
(e) Move the seat to the middle position of
the slide-way, and then place at vertical
position back to back.
(f) Release the seat safety belt alarm
interface connection
(g) Remove the front seat assembly

Removal of parts
1. Remove operation handle of the angle
regulator.
(a) Use the screwdriver to separate the
plastic internal claw from the angle regulator.
Note:
Tip of the screwdriver shall be wrapped by
tape before using so as to avoid damaging
the plastic parts.

2. Remove the left side and inner side cover

of the front seat cushion (No.1)
(a) After two screws of the seat are removed,
use two claws to separate from the seat
frame.

3. Remove the left side and inner side cover

of the front seat cushion
(a) Separate the safety belt harness from the
seat safety belt and the inner protection
cover.

4 / 37
 (b) After two screws of the seat are
removed, use two claws to separate from
the seat frame.
4. Remove the front seat safety belt
assembly

5. Remove the seat cushion

(a) Remove two snap rings.

Snap ring

(b) Separate the plastic part covered on

the seat basin of the skinning from the seat
basin.

6. Remove the skinning of the front seat

cushion
(a) Remove nine seat snap rings on the
front seat cushions, separate the cushion
skinning from the cushion foaming.
7. Remove the foaming of the front seat
cushion
8. Remove the front seat headrest
Snap ring assembly

9. Remove the front seat headrest guide

sleeve
(a) Remove three seat snap rings.

Snap ring

5 / 37
 (b) Scrape the guide sleeve hook from the
frame and take out of the front seat
headrest guide sleeve.
10. Front seat headrest guide sleeve
Information:
Use the same method to remove other
headrest guide sleeves.

11. Remove the front seat backrest

(a) Remove three snap rings.
12. Remove the front seat backrest foaming

Snap ring

13. Remove the left inner plastic cover of

the seat angle regulator
(a) Remove the thread crossing and
separation claw and the inner protection
board of the angle regulator; finally take out
of the plastic cover.
14. Removal is complete

6 / 37
 Assemble parts
1. Place the seat frame assembly
2. Assemble the right inner cover of the
angle regulator
3. Assemble the left inner cover of the
angle regulator
4. Assemble the front seat backrest
foaming
5. Assemble the front seat backrest
skinning
(a) Use three new snap rings to fix the
front seat backrest skinning with the
foaming by the snap ring calipers.
Snap ring calipers Note:
Be careful not damage the seat skinning.
Try to reduce wrinkle of the skinning
during assemble process of the snap ring
Information:
Same method is applicable to the left and
right backrest skinning.
6. Assemble the seat backrest skinning on
Snap ring the backrest foaming
7. Assemble the front seat headrest guide
sleeve
8. Assemble the front seat headrest
assembly
9. Assemble the foaming of the front seat
cushion foaming
10. Assemble the skinning of the front seat
cushion
11. Assemble the front seat cushion
skinning on the seat cushion foaming.
(a) Use 9 new snap rings to assemble the
front seat cushion skinning together with
the seat cushion by the snap ring calipers.
Reminder:
Not damage the skinning.
Snap ring calipers Try to reduce wrinkle of the skinning
during assemble process of the snap ring
12. Assemble the front seat safety belt
assembly
13. Assemble the front seat cushion left
cover
14. Assemble the front seat cushion left
cover (No.1)
15. Assemble the handle of the angle
Snap ring
regulator

7 / 37
 Installation of assembly
1. Assemble the front seat assembly
(a) Assemble the seat safety belt harness
plug-in.
(b) Insert the lower tip of the seat slide-way
into the installation hole on the vehicle
body.
(c) Move the seat to back end.
Note:
Ensure the seat maintain lock status during
installation and fixing process.
(d) Pre-tight two installation M10 bolts in
front of the front seat.
(e) Move the front seat to the forefront.
Note:
Ensure the seat maintain lock status during
installation and fixing process.
(f) Pre-tight two installation M10 bolts at
rear of the front seat.
(c) Move the front seat to the full back
position of the slide-way.
Note:
Ensure the seat maintain lock status during
installation and fixing process.
(h) Tighten two bolts in front of the front
seat, installation sequence: firstly
assemble the outer bolt, and then
assemble the inner bolt.
Torque: 40N*m
(i) Move the seat to forefront.
Note:
Ensure the seat maintain lock status during
installation and fixing process.
(j) Tighten two bolts at rear of the front
seat, installation sequence: firstly
assemble the outer bolt, and then
assemble the inner bolt.
Torque: 40N*m

8 / 37
Rear single seat assembly
Components

Rear single seat assembly

First row: rear single

seat assembly

Defined torque

9 / 37
 Right angle regulator protection cover

Left angle regulator

protection cover

Single seat cushion skinning

Snap ring

Single seat angle regulator handle

Single seat cushion foaming

Rear seat inner side safety belt insertion lock

Single seat safety belt

Single seat angle regulator handle

Parts in following figure are used as the

installation leg for fender connection

Single seat pipe leg sub-assembly

Rear seat pipe leg inner protection cover

Defined torque

Parts which are not used repeatedly

10 / 37
 Rear seat headrest assembly

Rear seat headrest guide sleeve

Single seat backrest foaming

Snap ring
Single seat backrest frame assembly

Single seat backrest skinning

Rear single seat left inner protection cover

Rear single seat right inner protection cover

11 / 37
 Assemble removal
1. Remove the rear single seat assembly
(a) First row of seat:
(1) Remove three bolts and the back nut
with cap.

(b) Second and third rows of seats:

(1) Remove two bolts and two nuts with
cups and then remove the rear single seat.

Removal of parts
1. Remove the single seat angle regulator
handle
(a) Use the screwdriver to separate the
plastic internal claw from the angle
regulator.
Note:
Tip of the screwdriver shall be wrapped by
tape before using so as to avoid damaging
the plastic parts.

2. Remove the left plastic cover of the

angle regulator
(a) Take advantage of the screwdriver to
remove two screws, and separate the
three claws of the plastic parts from the
metal sheet of the seat, and then remove
the left plastic cover of the angle regulator.

12 / 37
 3. Remove the right plastic cover of the
angle regulator
(a) Remove 3 screws, and separate two
claws from the metal sheet of the seat,
and then remove the right plastic cover of
the angle regulator.

4. Remove the pipe plastic part at the rear

seat side.
(a) Remove the pipe plastic part at the rear
seat side.
Note:
Use the same method to remove the first
row, the second row and third row of the
seats.

5. Remove the front side leg cover of the

rear seat (for first row and second row of
the seats)
(a) Remove the front side leg cover of the
rear seat.
6. Remove the safety belt assembly

7. Remove the seat cushion assembly

(a) Separate the skinning hook from the
seat metal sheet, and then take out of the
seat cushion.

13 / 37
 8. Remove the seat cushion accessories.
(a) Remove 8 snap rings.
9. Remove and obtain the seat cushion
foaming

Snap ring

10. Remove the single seat pipe leg

accessory
(a) Remove 4 bolts connected with the
pipe leg of the seat.
11. Remove the rear seat headrest
assembly

12. Remove the rear seat left inner cover

(a) After the screws are taken out of , and
then take out of the rear seat inner cover.
13. Remove the rear seat right inner cover
(a) After the screws are taken out of , and
then take out of the rear seat inner cover.

14. Remove the rear headrest guide

sleeve
(a) Release the zipper of the skinning.

14 / 37
 15. Remove the seat headrest
(a) Remove the seat backrest assembly and
take out of the relevant accessories.

18. Remove the seat headrest

(a) Take two snap rings out of the skinning,
and then separate the backrest foaming and
the skinning.
19. Remove the seat headrest

Snap ring
Parts composition
1. Fix the foaming on the seat backrest
frame.
2. Assemble the seat backrest foaming with
the seat skinning
(a) Use two new snap rings to fix the
foaming with the skinning.
Note:
Be careful not damage the backrest
skinning.
·Try to reduce winkle during installation of
new snap ring.
3. Assemble the seat headrest guide sleeve
Snap ring calipers
into the seat backrest.
4. Draw the zipper of the skinning.
5. Assemble the rear single seat right inner
cover
6. Assemble the rear single seat left inner
cover
Snap ring 7. Assemble the seat backrest and headrest
assembly

15 / 37
 8. Assemble the single seat pipe leg
assembly
(a) Use 4 bolts to fix the seat pipe leg
assembly on the seat backrest.
Torque: 41N* m
9. Assemble the foaming of the single seat
cushion

10. Assemble the skinning of the single seat

and cushion
(a) Use 8 new snap rings to fix the seat and
cushion foaming with the cushion skinning
through the snap ring calipers.
Note:
Be careful not damage the seat backrest
skinning.
Try to reduce winkle when the new snap
ring is tightened.
11. Fix the foaming together with the
skinning
12. Assemble the seat safety belt buckle.
13. Assemble the rear seat rear plastic
cover
Snap ring calipers 14. Assemble the rear seat front plastic
cover (only second row and third row of the
single seats have such plastic covers)
15. Assemble the right cover of the angle
regulator
16. Assemble the left cover of the angle
regulator
Snap ring 17. Assemble the single seat angle
regulator handle

16 / 37
 Installation of assembly
1. Assemble the rear single seat
(a) First row of seat:
(1) Use 3 M10 bolts and 1 M1o nut with
cup to fixe the first row of the seat
assembly on the vehicle body.
Torque: 45N*m

(b) Second and third rows of seats:

(1) Use 2 M10 bolts and 2 M1o nut with
cup to fixe the second row and third row of
the seat assemblies on the vehicle body.
Torque: 45N*m

17 / 37
Rear double seats
Components

Third row: rear double

seats assembly

Second row: rear double

seats assembly

First row: rear double

seats assembly

Defined torque

18 / 37
 Right protection cover
3+2 safety belt double seats of angle regulator
right angle regulator handle

Left protection cover of angle regulator

Safety belt
assembly

Seat safety belt rear seat

inner insertion lock

Rear seat inner insertion lock

Snap ring

Double seats angle regulator left handle

Rear seat and cushion skinning assembly

Rear seat cushion foaming

Double seats pipe leg

Rear seat side protection cover

Defined torque

Parts which can’t be used any more

19 / 37
 Rear seat headrest

Double seats right backrest frame

Rear seat headrest guide sleeve

Double seats right

backrest foaming

Auxiliary handle

Rear seat backrest frame

Left inner protection

cover of angle
regulator
Snap ring Rear seat headrest

Rear seat cushion right inner protection cover

Rear seat right backrest skinning

Rear seat headrest
guide sleeve Rear seat backrest frame

Right inner protection cover of angle regulator

Double seats left backrest foaming

Auxiliary
Rear seat left backrest
handle
skinning

Double seats left

backrest frame

Parts which can’t be

Snap ring Rear seat cushion left inner protection cover
used any more

20 / 37
 Assemble removal
1. Remove the rear double seats assembly
(a) Remove 4 M10 bolts and 2 M10 bolt with
cup.
Information:
Use the same method to remove the second
row and the third row of the seats.

Removal of parts
1. Remove the double seats angle regulator
right handle
(a) Use the screwdriver to jack the inner
claw of the plastic part of the handle, and
then remove the angle regulator handle.
Information:
Head part of the screwdriver shall be
wrapped well before using so as to avoid
scratching the plastic parts.
2. Remove the double seats angle regulator
left handle
Information: removal method is same as that
of right side.
3. Remove the right cover of the angle
regulator
(a) Use the screw driver to jack three snap
rings and remove 2 screws and take out of
the right cover of the angle regulator.
Information: Head part of the screwdriver
shall be wrapped well before using so as to
avoid scratching the plastic parts.
4. Remove the left cover of the angle
regulator
Information: removal method is same as that
of right side.
5. Remove the rear seat front cover

21 / 37
 6. Remove the rear seat rear cover
7. Remove the rear seat safety belt.

8. Remove the double seats cushion

assembly
(a) Separate the skinning from the claw
connected with the metal sheet of the
seat, and then take out of the cushion
assembly.

9. Remove the rear seat skinning

(a) Remove 5 snap rings shown in left
figure.

Snap ring

(b) Remove 5 snap rings shown in left

figure.
10. Remove the double seats cushion
foaming
Snap ring

22 / 37
 11. Remove the double seat pipe legs
(a) Remove 8 bolts, and then remove the
double seats pipe legs.
12. Remove the rear seat safety belt locking
assembly.
13. Remove the rear seat headrest assembly

14. Remove the rear seat and cushion right

inner cover
(a) The method is consistent with removal
method of the single seat
15. Remove the rear seat and cushion lfet
inner cover
Information:
Removal method is consistent with the removal
method of rear seat and cushion right inner
cover.

16. Remove the rear seat backrest right cover

(a) After the claw of the plastic part is
separated from the metal sheet, and then take
out of the protection cover.
17. Remove the rear seat backrest left cover
Information:
Removal method is consistent with the removal
method of rear seat backrest right inner cover.

18. Remove the rear seat headrest guide

sleeve
(a) Open the double seat backrest zipper.

23 / 37
 (b) After 2 claws are press down, and then
take out of the headrest guide sleeve.
21. Remove the double seats backrest
sub-assembly (skinning and foaming)
(a) Take away the double seat backrest
from the double seats backrest frame.
Information:
Methods for left and right backrests are
same.
22. Remove the double seat backrest
skinning
(a) Remove two snap rings on the skinning.
Information: use the same method to
remove the left and right backrest snap
rings of the double seat.
23. Remove the double seat backrest
foaming
24. Remove the double seat backrest
frame
25. Remove the double seats left backrest
frame
Assemble parts
1. Assemble the double seats left backrest
frame
2. Assemble the double seats right
backrest frame
3. Assemble the double seats left and right
backrest foaming
4. Assemble the double seats left and right
backrest skinning
(a) Clamp two new snap rings into the
skinning of the left and right backrests
through the snap ring calipers.
Note:
Be careful not damage the seat skinning.
When the snap ring is tightened, try to
reduce winkle of the skinning.
Information: Same method is applicable to
the left and right backrest skinning.
5. Fix the skinning together with the
Snap ring calipers
backrest foaming
6. Assemble the rear seat headrest guide
sleeve
7. Assemble the rear seat right cover
8. Assemble the rear seat left cover
9. Assemble the rear seat cushion left inner
cover
Snap ring
10. Assemble the rear seat cushion right
inner cover
11. Assemble the rear seat headrest
12. Assemble the rear seat intermediate
safety belt insertion lock
13. Assemble the rear seat safety belt.

24 / 37
 14. Assemble the double seat pipe legs
(a) 8 bolts shall be needed for installation
of the double seats pipe legs.
Torque: 45N* m

15. Assemble the double seats foaming

16. Assemble the skinning of the double

seats
(a) Clamp 16 new snap rings into the
skinning by the snap ring calipers.
Note:
Be careful not damage the seat skinning.
Snap ring calipers When the snap ring is tightened, try to
reduce winkle of the skinning.

Snap ring

25 / 37
 (b) Clamp 5 new snap rings into the
skinning by the snap ring calipers.
Note:
Be careful not damage the seat skinning.
When the new snap ring is assembled, try
to reduce winkle of the skinning.
17. Assemble the skinning and foaming of
the double seats and cushions
18. Assemble the rear seat side pipe leg
cover
19. Assemble the left cover of the angle
regulator
20. Assemble the right cover of the angle
Snap ring calipers regulator
21. Assemble the double seats angle
regulator left handle
22. Assemble the double seats angle
regulator right handle

Snap ring

Installation of assembly
1. Assemble the rear double seats
(a) Use 4 M10 bolts and two nuts with cups
to assemble the double seats
Torque: 45N* m
Information: Use the same method to
remove the second row and the third row of
the seats.

26 / 37
Rear side turnover seat assembly
Components

Right side:
rear side turnover seat

assembly

Left side:
Rear side turnover seat assembly

27 / 37
 Right protection cover of angle regulator

Regulator handle

Side turnover seat cushion skinning

Snap ring

Rear seat insertion lock

Rear seat insertion lock

Side turnover seat Left protection cover of angle regulator

Safety belt fixing protection cover cushion foaming

Rear seat cushion protection cover

Safety belt assembly

Rear seat locking handle

Rear seat and cushion frame

Rear seat cushion protection cover

Seat safety belt assembly

Rear seat leg linkage

Pipe leg of side turnover seat

Lower protection cover of rear seat

Side turnover seat and cushion hook assembly

Defined torque

Parts which can’t be used any more

28 / 37
 Rear seat headrest

Rear seat headrest guide sleeve

Front support protection cover of side turnover seat Rear seat and cushion

Snap ring
Side turnover seat

backrest skinning

Side turnover seat backrest frame assembly

Side turnover seat backrest foaming

29 / 37
 Assemble removal
1. Remove the rear side turnover seat
assembly
(a) Remove 3 M10 bolts and 2 M10 bolts
with cups.
(b) Push the operation rod at direction
shown in the figure, make two lock on the
turnover board loose, and then remove the
side turnover seat.

Removal of parts
1. Remove the side turnover seat rear
support leg
(a) Remove the bolt shown in left figure,
and then remove the rear support leg.

2. Remove the left handle of the angle

regulator
(a) Remove the bolt shown in left figure,
and then remove the handle of the angle
regulation.

3. Remove the handle of the angle

regulator
(a) Remove two screws and jack the
installation support, and then remove the
left cover of the angle regulator.

30 / 37
 4. Remove the right cover of the angle
regulator
(a) The method is same as removal
method of the angle regulator left cover of
the side turnover seat
(Step 3).
5. Remove the seat safety belt close to
the side fender.
6. Remove the fixing point cover of the
external seat safety belt.
7. Remove the external safety belt.

8. Remove the side turnover seat cushion

assembly
(a) The method is same as removal
method of the angle regulator left cover of
the side turnover seat (step 3).

(b) Remove 2 buttons and separate the

plastic hook, and then take out of the side
turnover seat cushion.

31 / 37
 9. Remove the side turnover seat cushion
skinning

(a) Remove 4 snap rings.

Snap ring

(b) Remove 12 snap ring shown in left

figure.
10. Remove the side turnover seat cushion
foaming

Snap ring

11. Remove the rear seat cushion hinge

support leg
(a) Remove the bolts shown in the figure,
and then remove the rear seat cushion
hinge support leg.

12. Remove the rear seat and cushion

locking hook assembly.
(a) Remove the screw, and then remove
the rear seat and cushion locking hook
assembly.

32 / 37
 13. Remove the rear seat and cushion
lower cover
(a) Remove 8 screws, and then take out of
the rear seat and cushion lower cover.
14. Remove the rear seat safety belt
insertion lock.

15. Remove the rear seat and cushion

separation board
(a) Remove the screw, and then remove
the rear seat and cushion separation
board.
16. Remove the rear seat turnover board
17. Remove the rear seat and cushion
frame
18. Remove the rear seat headrest
19. Remove the rear seat and cushion
(a) Remove the screw, and then remove
the rear seat and cushion
20. Remove the rear seat headrest guide
sleeve
(a) Open the side turnover seat backrest
zipper.
(b) Open the seat backrest skinning
(c) After 2 claws are separated, and then
take out of the rear seat headrest guide
sleeve.
21. Remove the rear seat headrest guide
sleeve
Information:
Use the same method to remove the rear
left and right headrest guide sleeves.

22. Remove the side turnover seat

backrest skinning
(a) Remove 4 snap rings, and then take
out of the side turnover seat backrest
skinning.
23. Remove the side turnover seat
backrest foaming

Snap ring

33 / 37
 24. Remove the side turnover seat front
support leg cover
(a) Remove the screw, and then take out
of the side turnover seat front support leg
cover.
25. Remove the side turnover seat
backrest frame

Assemble parts
1. Assemble the side turnover seat
backrest frame
2. Assemble the side turnover seat front
support leg cover
3. Assemble the side turnover seat
backrest foaming
4. Assemble the side turnover seat
backrest skinning
(a) Clamp 4 new snap rings at positions
shown in the figure with the snap ring
calipers.
Note:
Be careful not damage the seat skinning.
When the snap ring is tightened, try to
Snap ring calipers
reduce winkle of the skinning.
5. Assemble the rear seat headrest guide
sleeve
6. Assemble the rear seat and cushion
7. Assemble the rear seat headrest
8. Assemble the rear seat and cushion
Snap ring frame
9. Assemble the rear seat and seat
separation board
10. Assemble the rear seat turnover
board
11. Assemble the rear seat and cushion
separation board
12. Assemble 2 rear seat safety belt
insertion locks
13. Assemble the lower protection boards
of the rear seat and cushion
14. Assemble the rear seat and cushion
hooks

15. Assemble the rear seat and cushion

hinge support leg
(a) Use a bolt and a shim to assemble the
rear seat and cushion hinge support leg.
Torque: 29N* m
16. Assemble the foaming of the side
turnover seat and cushion

34 / 37
 17. Assemble the skinning of the double
seats
(a) Clamp 16 new snap rings into the
skinning by the snap ring calipers.
Note:
Be careful not damage the seat skinning.
When the snap ring is tightened, try to
reduce winkle of the skinning.

Snap ring calipers

Snap ring

(b) Take advantage of the snap ring

calipers to assemble 4 new snap rings on
the positions shown in the figure.
Note: Be careful not damage the seat
skinning.

Snap ring calipers

Snap ring

35 / 37
 18. Assemble the turnover seat and
cushion
(a) Use two buttons and reverse clips to
assemble the seat and the cushion.

(b) Use 4 bolts to assemble the side

turnover seat and the cushion.
Torque: 42N* m
19. Assemble the rear seat external safety
belt.
20. Assemble the fixing point cover of the
rear seat external safety belt.
21. Assemble the rear seat internal safety
belt.

22. Assemble the right cover of the angle

regulator
23. Assemble the left cover of the angle
regulator
24. Assemble the operation handle of the
angle regulator
25. Assemble the side turnover seat rear
support leg
(a) Take advantage of 1 bolt and the shim
to assemble the side turnover seat rear
support leg.
Torque: 29N*m

36 / 37
 Installation of assembly
1. Assemble the rear side turnover seat
(a) Ensure the side turnover seat is fixed on
two locking hooks.
(b) Use 3 M10 bolts and two nuts with cups
to assemble the side turnover seat.
Torque: 45N* m
Note:
After the side turnover seat is assembled,
fold the seat backrest on the seat cushion,
lift up the side turnover seat and place
down close the middle side so as to ensure
the side turnover seat lock is fixed on the
floor hook safely.

37 / 37
Part Three Interior and exterior, electrical appliances and
car body

Chapter Four Sound

Sound field positioning of sound system ……………………………………………..002
CD player components …………………………………………………………………003
Antenna of radio ………………………………………………………………………...007
Front loudspeaker assembly …………………………………………………………..009
Rear loudspeaker assembly …………………………………………………………...010

1 / 11
Sound field positioning of sound system

Antenna pole

Antenna

Receiver and transmitter

assembly Ceiling loudspeaker assembly

Front loudspeaker assembly

Rear loudspeaker assembly

2 / 11
CD player Components

Cd player assembly

Centre panel assembly of dashboard

Cd player support 2

Cd player support 1

Assemble screw: ST4.2×12

Remove steps
1. Remove the dashboard
2. Remove 4 screws on the main machine
3. Pull the sound main machine outward,
pay attention to direction of the plug-in and
pull out of the plug-in during movement

Precautions:
1. During removal of the main machine, pay
attention to torque is: 5-7N·m
2. Don’t scratch other relevant parts and
each panel during removal process

3 / 11
Ceiling loudspeaker assembly
Top ceiling loudspeaker
Front ceiling interior board assembly

Rear indoor lamp assembly

With air conditioner
configuration

Right sun visor Rear air conditioner

assembly controller panel
Flagship type: map lamp
assembly

Turnover seat assembly

Handrail assembly

Turnover seat hook

Left sun visor assembly
Centre support of sun
visor

Rear top ceiling interior

board assembly Rear indoor lamp assembly

4 / 11
 Remove the ceiling loudspeaker
(a) Remove the connection support
(b) Remove two pins used to fix the
loudspeaker system.

Remove screws used to fix sound

assembly

Cd player with support assembly

Combined instrument cover

Combined instrument
Centre panel assembly of
dashboard

Left outlet panel assembly of

dashboard

Right defrost panel assembly of

dashboard

Left defrost panel assembly of

dashboard

5 / 11
 Including front seat
occupant airbag
Front column decoration (right)
Front column decoration (left)

Auxiliary handle
assembly
Auxiliary handle
Including front seat assembly
occupant airbag assembly

Auxiliary handle Auxiliary handle

screw screw
Auxiliary handle
assembly

Danger indication single lamp switch

assembly
Dashboard assembly

Glove box assembly Shifting operator assembly

Radio harness

Shifting hand ball

Air conditioner control

panel

Manual transmission edge

assembly
Middle lower protection board
assembly of dashboard

Manual brake protection board

assembly

Left lower protection board

assembly of dashboard
Lower protection board
Appointed torque assembly of dashboard

6 / 11
Antenna of radio
Parts

Left lower protection board

assembly of dashboard

Antenna

Remove
1. Remove the lower panel of the dashboard
2. Remove the antenna of the sound radio
(a) Disconnect and two clips
Clamp
(b) Bind the radio antenna

Bind

(c) Remove two screws and the antenna

(d) Loose binding of the antenna

7 / 11
 Assemble
1. Assemble the antenna of the radio
(a) Bind the antenna tightly
(b) Assemble two screws and the antenna

Clamp

Bind

(c) Bind the radio antenna

(d) Connect three clips
2. Assemble the centre panel assembly of the
dashboard

8 / 11
Front loudspeaker
Assembly

Front loudspeaker
assembly

Self-driving screw

Manual direction switch of

front window

Front trim board

assembly

Don’t use parts repeatedly

On-board inspection
1. Inspection of the loudspeaker
Information: the loudspeaker is seen only after the interior parts are removed.
(a) Inspect assemble of the loudspeaker: OK, the loudspeaker is normally assembled.
If results are not above appointed contents, assemble the loudspeaker again.
(b) Visually inspect the loudspeaker: OK, paper basin of the loudspeaker isn’t broken.
If result is broken, replace the loudspeaker
(c) Inspection of loudspeaker impedance
(1) Remove the loudspeaker
(2) Measure wiring resistance of two loudspeakers. Resistance value is 4Ω, replace the
loudspeaker if resistance value is abnormal.

9 / 11
Rear loudspeaker system

Rear threshold trim board

Left rear middle trim

assembly

Rear loudspeaker system

On-board inspection

1. Inspect the loudspeaker

Information: the loudspeaker is seen only after the interior parts are removed.
(a) Inspect assemble of the loudspeaker: OK, the loudspeaker is assembled correctly
If results are not above appointed contents, assemble the loudspeaker again.
(b) Visually inspect the loudspeaker OK: Paper basin of the loudspeaker isn’t broken.
If result is broken, replace the loudspeaker

10 / 11
 (c) Inspection of loudspeaker impedance
(1) Remove the loudspeaker
(2)Measure wiring resistance of two
loudspeakers.
Correct impedance is 4Ω
If it isn’t correct, replace the loudspeaker

Removal
1. Remove the anti-abrasion board of the rear
door
2. Remove the interior board assembly of the
left rear door
3. Remove the rear loudspeaker assembly
(a) Disconnect the connection parts
(b) Remove 3 nuts and the rear bolt assembly

Assemble
1. Assemble the rear loudspeaker
assembly
(a) Assemble the connection part
(b) Assemble 3 bolts and the rear loudspeaker
assembly
2. Assemble the left rear interior board
assembly
3. Assemble the anti-abrasion board of the
rear door

11 / 11
Part Three Interior and exterior, electrical appliances and
car body
Chapter Five Harness
Position of fuse box …………………………………………………………..002

1/7
Fuse box

1. Left fuse box of the dashboard

2. Right fuse box of the dashboard

3. Fuse box of the engine cabin

4. Fuse box of the battery cabin

2/7
1. Left fuse box of the dashboard

Reserve

Reserve

Reserve
Reserve

Reserve

F21. Dipped and dim light of headlamp, fuse of light regulation fuse motor 30A
F22. Far light lamp fuse 15A
F23. AMI fuse 60A
F24. Dim light lamp fuse 15A
F25. Electric horn fuse 15A
F26. Rear fog lamp fuse 10A
F27. Fender lamp and license plate lamp fuse 7.5A
F28. Front fog lamp fuse 15A
F29. Switch on/off backlight lamp fuse 7.5A
R13. Dipped beam lamp relay
R14. Dim beam lamp relay
R15. Headlamp relay
R16. Rear ceiling lamp relay
R17. Electric horn relay
R18. Front fog lamp relay
R19. Small lamp relay

3/7
 Reserve

Reserve

Reserve
Reserve

Reserve

Reserve
Reserve
Reserve

F30. Fuse of turning lamp Reserve 10A

F31. Fuse of front wiper motor 20A
F32. Fuse of rear wiper motor 10A
F33. Fuse of washing motor 10A
F34. Fuse of combined instrument 10A
F35. Fault diagnosis fuse 7.5A
F36. Radio fuse 15A
F37. Indoor lamp fuse 10A
F38. Fuse of brake lamp 15A
F39. Fuse of radio and electric rear view mirror 10A
F40. Fuse of cigarette igniter 15A
F41. Fuse of charging indication lamp 7.5A
F42. E CU一 IG fuse 10A
F43. Reserve/instrument indication lamp fuse 10A
F44. Reserve/safety air-bag fuse 10A

4/7
2. Right fuse box of the dashboard

Reserve
Reserve

Reserve
Reserve

Reserve
Reserve Reserve Reserve

Reserve

F7. Fuse of front blower fan relay 40A R4. Relay of front blower fan
F8. Fuse of electric window 30A R5. Rear air conditioner relay
F9. Rear air conditioner fuse 30A R6. Rear defrost relay
F10. Centre control fuse 30A R7. Fuse of electric window
F11. Rear defrost fuse 30A R8. Reserve/ignition locking lighting relay
F12. Rear warm air fuse 15A R9. Rear warm air relay
F13. Air conditioner fuse 15A R10. Air conditioner compressor relay

5/7
3. Fuse box of the engine cabin

Diode

Reserve

Reserve

F0. Master fuse, generator 120A

F1. Front and rear oxygen (gasoline vehicle) 10A／EFI1（diesel vehicle） 10A
F2. Reserve / ETI3 fuse （diesel vehicle） 15A
F3. EFI2 fuse 7.5A
F4. EFI fuse (gasoline vehicle) 25A/oil filter heating (diesel vehicle) 25A
F5. High speed fuse of electronic fan 50A
F6. Low speed fuse of electronic fan 40A
R1. Low speed relay of electronic fan
R2. High speed relay of electronic fan
R3. EFI relay (main relay)

6/7
Fuse box of the battery cabin

Reserve Reserve

Reserve

F14. ST starting fuse 7.5A

F15、ABS—IG fuse 7.5A
F16、ABS solenoid fuse 25A
F17、Constant power fuse of generator 7.5A
F18、Oil pump fuse (gasoline vehicle) 15A
F19、AM2 fuse 30A
F20、ABS oil pump fuse 40A
R11、Starting relay
R12、Oil pump relay (gasoline vehicle)

7/7
Part Three Interior and exterior, electrical appliances and
car body
Chapter One Air conditioning system
Component of each part ………………………………………………………………003
Transmission belt ……………………………………………………………..……… 004
Cooling system ……………………………………………………… ………….…..…007
Cooling pipeline ………………………………………………………………… ...…...013
A i r co nd i ti oni ng s ys tem a s semb l y … ……… ……… ……… …… …… ……… ……… 014
Rear cooling equipment ………………………………………………………….……030
Rear warm air fan assembly ………………… …………… ….………………......… 038
Ai r b lo we r u ni t ……… ………… … ……… …… ………… ……… ……… …… ..… ..… 04 5
Condenser …………………………………….……………………………………...…053
Air conditioning controller assembly ……………………… …………………….....…059
Rear air outlet grill band switch assembly ……………………………………………067
Rear air channel outlet grill component ……………………………………..……..…070
Maintenance of cooling system ……………………… ……………………………… ..074
..

1 / 81
Component of each part

Heat generator and heat dissipater assembly Expansion valve

Front air draft motor

Front air drafter

speed control resistor

Temperature sensor of
evaporator

2 / 81
 Rear air draft motor (right)

Rear air drafter speed

control resistor

Rear air draft motor (left)

Rear temperature sensor of

evaporator

Rear air draft motor

switch

Rear air draft motor

switch

Expansion valve

Rear air drafter speed

control resistor

Rear air draft motor

3 / 81
Component of driving belt

From cooling air compressor to

crank shaft pulley

On-board inspection
1 Inspect V (from cooling air compressor to
the belt wheel of the crank shaft) driving belt
No.1
(a) Deflection of belt. Pressure: 90N
New belt 11-15mm
Old belt 15-20mm

Position of belt

4 / 81
 (b) Tension of belt
Belt tension
measurement Use the belt tension measure instrument to inspect
instrument tension of the V belt.
(DENSO model)

Measurement
New belt Old belt
point
Tension of
372-608 196-392
belt

Note:
·Measure the V belt at specified point.
Correct Wrong ·When a new belt is assembled, adjust tension of the
belt to specified scope.
Before tension of the belt is adjusted again, let it wait
5 min and make tension of the belt maintain in the
specified scope.
· ·When a new belt is assembled, it also waits 5 min
when tension is adjusted again to maintain tension of the
belt within specified scope.
·Maintain certain distance between the V belt and
the pulley
V belt
Nut Remove
(a) Loosen the nut
(b) Loose the bolt and remove the V belt.

Bolt

Assemble
(a)Assemble the V belt shown as figure.

2 Commissioning

(a) Tighten the bolt and adjust tension of the V belt.

(b) Rotate the bolt and adjust tension of the driving
belt.
(1) The driving belt runs deflection.
New belt 11-15mm
Bolt
Old belt 15-20mm
Measurement
position

5 / 81
 Nut

(c) Rotate the bolt and adjust tension of the driving

belt.
(d) Tighten the nut
Torque: 43N*m

Coolant system
(1) Coolant system works normally
Reading of instrument
Low pressure end 0.15‐0.25Mpa
High pressure end 1.37‐1.57Mpa
(2) There is water content in the cooling system
Symptom
Intermittently cool and then cooling is failed

Symptom Possible reason Analysis Solution measures

Pressure of low Water and steam in 1. Dry agent is on 1 Replace dry agent
pressure end the cooling system excessive saturation 2. Remove water content
circulates between are froze in the status. in circulation through
normal and expansion valve, 2. Water steam in the repeated ventilation
vacuum during which causes cooling system is froze 3 Provide suitable new
operation. circulation stop in the expansion valve, coolant
temporarily, but in which blocks cooling
case it is melt, the circulation
system returns back
normal

6 / 81
 (3) Cooling is insufficient
Symptom: coming system can’t work effectively

Symptom Possible reason Analysis Solution measures

It is low pressure at There is air leakage in Coolant is Check whether there is
high pressure end and the cooling system insufficient air leakage, repair if
low pressure end. Coolant is leaked necessary
Bubble is Provide suitable new
continuously seen coolant
through the When the measurement
microscope instrument is connected, if
Cooling effect is displayed pressure value
insufficient is 0, crate a vacuum status
after the leakage point is
inspected and repaired.

(4) Coolant circulation is improper

Symptom: coming system can’t work
effectively

Symptom Possible reason Analysis Solution measures

It is low pressure at The liquid receiver of Receiver is Replace the condenser
high pressure end and the condenser is blocked
low pressure end. blocked by soil
There is frost on the
pipeline from the
condenser to the
dashboard

7 / 81
 (5) Coolant isn’t circulated
Symptom: coming system can’t work
effectively
Status: the cooling system doesn’t work
or occasionally works

Symptom Possible reason Analysis Solution measures

Low pressure side is Coolant is blocked Coolant isn’t 1 Inspect the expansion valve
vacuum, pressure at by water steam or circulated 2 Replace the condenser
high pressure side is garbage 3 Gas evaporation and newly
vey low, pipelines at Coolant is blocked fill in
two sides of the by leakage of the 4 Expansion valve is leaked
expansion valve are expansion valve and replace
froze or condensate
water occurs

(6) Filling is excessive or capability of

the condenser
Symptom: coming system can’t work
effectively

Symptom Possible reason Analysis Solution measures

 Pressure at both  Cooling system is  Excessive coolant 1 Clean the condenser
sides are too high excessive, which is filled in during 2 Inspect the cooling fan
 No bubble is seen can’t supply cooling circulation 3 if 1 and 2 are normal,
even the engine is at capacity  Capability of the inspect capacity of coolant
low speed  Capability of the condenser is and newly fill in
condenser is insufficient Fin of the
insufficient, which condenser is
causes bad cooling blocked
efficient.

8 / 81
 (7) There is air in cooling system
Status: the air conditioner doesn’t cool
Note:
These inspections must be carried out
when the air conditioning system is open
and no vacuum purification exists during
filling

Symptom Possible reason Analysis Solution measures

 Pressure at both There is air in  There is air in 1 Check whether compressor
sides are too high system system engine oil is dirt or insufficient
 Low pressure pipe is  Don’t purify 2 Fill in again after it is
high temperature sufficiently extracted vacuum
 Bubble is seen from
the microscope

(8) Expansion valve is failed

Symptom: Cooling is
insufficient

Symptom Possible reason Analysis Solution measures

Pressure at both Expansion valve Excessive coolant Inspect expansion valve
sides are too high is failed in low pressure
Frost of low pressure pipeline
tube or a large quantity  Open degree of
of condensate water expansion valve is
too great

9 / 81
 (9) Compressor problem
Symptom: Cooling is
insufficient

Symptom Possible reason Analysis Solution measures

Pressure at both Internal leakage of The compressor is Repair or replace the
sides are too high the compressor failed compressor
Pressure at high Leakage is caused by
pressure side is invalid valve or broken
too low pulley

Pressure at low
pressure side

High blowing air

area

Low blowing air

area

Pressure at
high pressure
side

Release coolant
1. Start the engine
(a) Open the air conditioner
(b) Make the compressor to operate and the engine run at 1000 turns for 5 ~ 6 min, coolant
circulates and make the compressor engine oil return back the compressor as possible
(c) Switch off the engine
(d) Use the special tools to drain out coolant.
2 Fill in coolant
(a) Extract vacuum (b) Fill in

10 / 81
Standard
Independent front air conditioner 520‐580g
Front and rear air conditioners 750‐850g
Remark

no coolant.
After bubble disappears, it shall be filled in about 100g, the filling quantity shall be controlled, it
not only depends on the liquid microscope.

Information
If the coolant collection equipment can only reach 90% effect, it shall prepare the filling equipment
to fill in.

3 Engine temperature rises up

(a) Heat up the engine for 2 min at least; it shall not be lower than 1850 rpm.
Pay attention to open the air conditioner after removal and replacement of the pipeline
(including the compressor), confirm that the compressor temperature rises up and prevent against
damaging.

4 Inspect leakage
(a) After it is filled in again, use the halogen inspection instrument to check whether there is
leakage.
(b) Repeat following tests:
Switch off the engine
Ensure ventilation (volatility of gasoline or waste gas may cause the halogen instrument act)
Repeat two to three times
Ensure there is certain cooling agent in the system to switch off the compressor: about 392
to 588 kpa.

11 / 81
 (c) Use the gas leakage inspection instrument to check
Stop leakage
leakage of the pipeline.
Detection head

(d) Close the instrument and place the detector close

to water droplet
Water dropping
pipe Information
The air blower is switched off, and places the air
conditioner still for 15 min.
Place the detector close to water droplet
When the detector is close to water droplet pipe,
Detection head the detection instrument will not act because of violate
gas. When there is information in the instrument, lift up
the vehicle.

12 / 81
Cooling pipeline

Engine type:

Type of vehicle
body wide:

Liquid pipe B

Liquid pipe A Exhaust pipe 1

Compressor and
clutch

Air suction pipe 1

Air suction pipe B

Condenser with liquid

Liquid pipe A storage tank
Exhaust pipe A

Appointed button

13 / 81
Air conditioning system

With radio

Radio and
support

With radio Without radio

Radio and Vertical opening cover and

support support

Combined
instrument
cover

Instrument board centre Combined instrument

panel assembly

Instrument board centre

panel assembly
Left outlet vent panel assembly of
dashboard
Right outlet vent panel assembly
of dashboard

Left de-frost vent panel

assembly

14 / 81
 Right front column trim

Left front column trim

Drawer
Drawer

Airbag

Drawer cover Drawer cover

Double trip
lamp switch
Dashboard
assembly

Manual gear:

Shifting operator
assembly

Glove box
assembly

Shifting handle

Air conditioning
control panel

Manual transmission edge

Middle and lower assembly
protection board assembly
of dashboard

Manual brake protection

board assembly

Left lower protection board

assembly of dashboard

Lower protection board

Appointed button assembly of dashboard

15 / 81
 Water outlet pipe
Air suction pipe A

Liquid pipe B

O ring

Water inlet pipe

Dashboard cross
beam assembly

Heater support

Foot blowing air Cross beam lower support

channel at drive side assembly of dashboard

Air blower assembly

Foot blowing air channel

at pilot drive side

Distributor assembly

Appointed button Compressor engine oil ND-OIL 8

or equivalent
Parts can’t be used repeatedly

16 / 81
 Connection air
channel

Model drawing
wire

Warm air

Mixed drawing
wire

Expansion valve

O ring

Evaporator assembly

Evaporation
temperature sensor Water dropping pipe

Parts which can’t be repeatedly used, compressor oil ND-oil8 or equivalent.

Remove
1 Remove negative of the battery: wait for 90 s after it is disconnected, and protect the airbag
against working.
2 Remove the engine cover plate
3 Drain out coolant
4 Remove the air inlet grill of the water tank.

17 / 81
5 Remove the air inlet air channel
6 Remove washing liquid for the vehicle glass
7 Remove the washing liquid bottle for the vehicle glass
8 Remove the overflow cup of the water tank
9 Remove the engine cover lock
10 Remove the installation cover of the water tank
11 Remove the intermediate cooler

12 Loose the air suction pipe A

(a) Loose the bolt and move the
Liquid pipe B
Air suction pipe A
press board
(b) Remove the air suction pipe A
(c) Remove the O ring
Note:
Protect against water steam and
Connect hook impurity for the joint which sealing is
loose.

13 Remove the liquid pipe B

Note:
Protect against water steam and
impurity for the joint which sealing is
loose.

18 / 81
 14 Remove the warm air outlet water pipe
Water outlet pipe
(a) Use the caliper to loose the bucket and disconnect the
of heater water pipe
Water inlet
pipe of 15 Remove the water inlet pipe
heater A

16 Remove the damper

17 Remove the intermediate operation bar

18 Remove the connection rod assembly of the steering

wheel

19 Remove the foot blowing air channel at driver side

(a) Remove the fixed bucket at left side
(b) Loose two buckles at right side and remove the air
channel

20 Disconnect the brake plate

(a) Remove 2 bolts and disconnect the brake plate

21 Remove the lower supper assembly of the dashboard

cross beam
(a) Remove 5 bolts and the lower support assembly of the
dashboard cross beam

19 / 81
 22 Remove the cross beam of the instrument board
(a) Remove the buckle and connection, and disconnect the
line.

(b) Remove the bolt, the nut and the connection block
(c) Remove 2 blanks and 2 bolts.

Torsion bolt Neck

Mechanical driving

(d)Remove 2 bolts and nuts.

(e)Remove 3 bolts and nuts.
(f) Use the spanner to remove the bolt.
Information:
Bolts at occupant side can be removed, regulation of the
lining ring.
(g) Use a 12mm hexagonal spanner to remove 2 lining
rings and the cross beam

20 / 81
23 Remove the air conditioner assembly
(a) Remove 3 bolts and the air conditioner box

24 Remove the foot blowing air channel at driver side

(a) Loose two buckles at left side and remove the air
channel

25 Remove the air conditioner distribution box

(a) With PTC
(1) Loose the screw, and power is off

(b) Loose 3 screws and the distribution box

21 / 81
Remove
1 Remove the mode drawing rope
(a) Use the screw driver, wrap the adhesive tape,
loose the buckle and remove the drawing rope

2 Remove the mode drawing rope

(b) Use the screw driver, wrap the adhesive tape,
loose the buckle and remove the drawing rope

3 Remove the connection air channel

(a) Remove 4 buckle, remove the connection air
channel.

4 Remove PTC
(a) Remove 2 screws and PTC

5 Remove the warm air fan

(a) Remove the screw and the warm air fan

22 / 81
6 Remove the water dropping pipe
(a) Remove the water dropping pipe

7 Remove the heater support

(a) Remove the screw and the heater support

8 Remove the expansion valve

(a) Use a 4mm inner hexagon to remove 2 hexagon
bolt and the expansion valve

9 Remove the bottom cover of the evaporator

(a) Remove 4 screws
(b) Loose 2 buckles and remove the bottom cover

(c) Loose the buckle and remove the evaporator

23 / 81
10 Remove the evaporation temperature sensor
(a) Remove the evaporation temperature sensor

Re-assemble
1 Remove the evaporation temperature sensor
(a)Assemble the evaporation temperature sensor
(b) Assemble the temperature sensor shown as
figure
Check whether it is inserted tightly
Note: If the evaporator is taken advantage of,
don’t insert the sensor in the same position; it shall be
inserted at C position.

2 Assemble the evaporator assembly

(a) Coat oil on O ring, assemble on the evaporator
Compressor engine oil ND-OIL8 or equivalent
(b) Assemble the evaporator assembly

(c) Assemble the joint

24 / 81
 (d) Assemble the bottom cover with 2 buckles and
4 screws.

3 Assemble the expansion valve

(a) Use a 4mm inner hexagonal spanner to
assemble the expansion valve

4 Use the bolt to assemble the heater support

5 Assemble the water dropping pipe

6 Assemble the auxiliary assembly of the warm air

radiator
(a) Use the screw to assemble the auxiliary
assembly of the warm air radiator.

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7 Assemble the warm air assembly (with PTC
module)
(a)Use 2 screws to assemble the warm air assembly

8 Assemble the dashboard connection assembly

centre
(a) Use 4 buckles to assemble the dashboard
connection assembly centre.

9 Assemble the air mixing control harness

(a) Completely rotate the air mixing assembly
gear. Adjust to ―MAX, COOL‖ according to direction
shown in the figure.
(b) Assemble the air mixing control harness

10 Assemble mode control harness

(a) Rotate the mode control harness gear and the
connection part according to direction shown in the
figure, set to ―FACE‖
(b) Assemble mode control harness

Assemble
1. Assemble the air conditioner radiator assembly
(a)Use 3 screws to assemble the air conditioner
assembly.

26 / 81
 (b) With PTC module
(1) Use the screw to assemble

2 Assemble the foot blowing air channel of the pilot

driver
(a) Assemble 2 buckles at the interface on
position.

3 Assemble the air conditioner assembly

(a) Use 3 screws to assemble the air conditioner
assembly

27 / 81
 4 Assemble the dashboard to fix the assembly
(a) Driver seat
(1)Use a torque spanner sleeve (T40) and two torque bolts to
assemble the dashboard fixing assembly
(b) Occupant seat
(1)Use a 12mm spanner and 2 bolts to assemble the dashboard fixing
assembly.
Torque: 6.0N*m
(2)Use a torque spanner sleeve (T40) and two torque bolts to
assemble the dashboard fixing assembly

Neck Torsion bolt

Mechanical driving

(c) Assemble 2 bolts and nuts (automatic driving)

(d) Assemble 3 bolts and nuts (mechanical driving)
(e) Assemble 2 groups of bolts and the blank cups

5 Assemble the dashboard assembly

Information:
Refer to instruction on assemble of the dashboard
6. Assemble the coolant pipeline
(a) Remove the adhesive tape on the pipeline
(b) Coat sufficient compressor engine oil on the new O ring and
surface of the fitting in the coolant pipe B
Compressor engine oil: ND-OIL8 or other applicable engine
oil
(c) Assemble O ring on the coolant pipeline
(d) Assemble the coolant pipe B

28 / 81
 7 Assemble the coolant inlet pipe A
(a) Remove the adhesive tape on the hose
(b) Coat sufficient compressor engine oil on the new
O ring and surface of the fitting in the coolant inlet pipe
A
Compressor engine oil: ND-OIL8 or other
applicable engine oil
(c) Assemble O ring on the coolant inlet pipeline
(d) Remove the connection part shown as arrow in
the figure
(e) Connect the coolant pipe with the corresponding
joint, tighten the bolt

8 Assemble the intermediate heat radiator assembly

(including the intermediate cooler)
Suction pipe Low pressure pipe
9 Assemble the radiator supporting component
(including the intermediate cooler)

10 Assemble the hood lock assembly (including the

Connection
hook intermediate cooler)

11 Assemble the radiator water tank (including the

intermediate cooler)

12 Assemble the windshield glass washer cylinder

assembly (including the wiper and the intermediate
cooler)

13 Assemble the windshield glass washer cylinder

assembly (not including the wiper and the intermediate
cooler)

14 Assemble the windshield washer liquid (including

the intermediate cooler)

15 Assemble the air inlet pipe (including the

intermediate cooler)

16 Assemble the radiator protection grill (including the

intermediate cooler)

29 / 81
Components of rear cooling equipment

Rear cooling
unit

Air conditioning pipe and O ring

accessory assembly

O ring

Appointed button Cooling coolant hose 1 bushing

Part which can’t be used repeatedly

Compressor engine oil ND-OIL 8 or

equivalent

30 / 81
 Speed control resistor of
rear cooling box
Air box motor assembly

Cooler enclosure fitting

Air box motor assembly

Plate washer

Rear fan fitting

Rear evaporator
fitting
Plate washer

Clip

Rear fan fitting

Cooler 2 thermostat

Cooler harness

Cooler enclosure
fitting

Appointed button

31 / 81

Water extraction hose of
cooler unit 2
Water extraction hose of
cooler unit 3
Remove
1 Remove top cover 1 top ceiling (half repair)
Information:
Refer to instruction on removal of top ceiling,
2 Remove top cover 1 top ceiling (complete repair)
Information:
Refer to instruction on removal of top ceiling,
3 Disconnect the cooler 2 water extraction hose
(a) Disconnect the cooler 2 water extraction hose
4 Disconnect the cooler 3 water extraction hose
(a) Disconnect the cooling equipment 3 water
extraction hose
5 Remove the cooler coolant hose 1 insulation layer
(a) Remove the cooler coolant hose 1 insulation layer
6 Remove the air conditioning pipeline and the fitting
assembly
(a) Remove 2 bolts, air conditioning pipeline and
the fitting assembly.
7 Remove the rear cooler
(a) Disconnect the connector
(b) Remove 5 bolts and the cooling equipment.
32 / 81
Disassemble
1 Remove the cooler harness fitting
(a) Remove 4 clips, 4 connector and the cooler
harness fitting

2 Remove the speed control resistor of the rear air

box
(a) Remove 2 screws and the speed control resistor
of the rear air box

3 Remove the cooler enclosure component

(a) Remove 18 screws and the cooler enclosure
component.

4.Remove 2 thermistor of the cooler

(a)Remove 2 thermistor of the cooler

33 / 81
5 Remove the rear evaporator fitting
(a) Remove the screw and the clip
(b) Remove the rear evaporator fitting

6 Remove the rear fan fitting

(a) Remove 2 nuts, 2 clips and the rear air fan fitting

7 Remove the air box motor assembly

(a) Remove 2 washers on plate.
(b) Remove 2 screws and 2 air box motor assemblies

Re-assemble
1 Assemble the air box motor assembly
(a) Assemble 2 air box motor assemblies with 2
crews
Torque: 0.69N*m
(b) Assemble the cushion ring.

2 Assemble the rear air box fitting

(a) Remove 2 nuts to assemble 2 rear air fan fittings
Torque: 2.9N*m

34 / 81
3 Assemble the rear evaporator fitting
(a) Assemble the rear evaporator fitting
(b) Use the screw to assemble the clip

4 Assemble 2 thermistor of the cooler

(a) Assemble 2 thermistor of the cooler

5 Assemble the cooler enclosure fitting

(a) Use 18 screws to assemble the cooler
enclosure fitting

6 Assemble the speed control resistor of the air box

(a) Use 2 screws to assemble the speed control
resistor of the air box.

35 / 81
7 Assemble the cooler harness fitting
(a) Use 4 clips and 4 connector to connect and
assemble the cooler harness fitting

Re-assemble
1 Assemble the rear cooler equipment
(a) Use 5 bolts to assemble the rear cooler
equipment
Note:
Assemble the bolt as sequence in the figure
(b)Connect the connector

2 Assemble the air conditioning pipeline and the fitting

assembly
(a) Remove the connected adhesive tape from the
hose
(b) Coat sufficient compressor oil (ND-OIL8) on the
assemble surface of the new O ring of the rear cooling
equipment
(c) Assemble the O ring on the air conditioning
pipeline and the fitting assembly
(d) Use 2 bolts and assemble the air conditioning
pipeline and the fitting assembly on the rear cooling
equipment.

36 / 81

Water extraction hose of
cooler unit 2
Water extraction hose of
cooler unit 3
3 Assemble the air conditioning pipeline and the fitting
assembly
(a) Assemble the rear condenser cold hose 1
insulation layer
4.Assemble the cooling equipment 3 water extraction
hose
(a) Assemble the cooling equipment 3 water
extraction hose
5 Assemble the cooling equipment 2 water extraction
hose
(a) Assemble the cooling equipment 2 water
extraction hose
6 Remove top cover 1 top ceiling (complete repair)
Information:
Refer to assemble instruction of the dashboard
assembly
7 Remove top cover 1 top ceiling (half repair)
Information:
Refer to assemble instruction of the dashboard
assembly
8 Fill in coolant
9 Pre-heat the engine
10 Check whether coolant is leaked.
37 / 81
Part of rear warm air fan assembly

Rear warm air fan

assembly

Power supply Warm air hood

harness

Rear heater blower

resistor

Rear warm air fan heater

sub-unit

Rear warm air fan blower Rear warm air fan vent
sub-unit

Water outlet pipe of rear

warm air fan
Warm air hood

Water inlet pipe of rear

Warm air hood warm air fan

38 / 81
Use the caliper to clamp the pipe clip of the water pipe,
and then separate the rear warm air fan water pipe
from the warm air water pipe

Remove 3 screws used to fix the rear warm air fan and
the vehicle body

Remove the warm air fan

1. Remove the warm air fan
(a) Remove 3 screws used to fix the warm air cover.

2 Remove the resistor of the rear heater blower fan.

(a) Disconnect the resistance connection line.
(b) Remove two screws to fix the blower fan resistor.

39 / 81
3 Remove the water inlet pipe of the warm air fan
(a) Use the caliper to clamp the pipe clip of the
water pipe, and then separate the warm air fan inlet
water pipe from the rear warm air fan.

4 Remove the water outlet pipe of the warm air fan

Information:
Method used to remove the outlet water pipe of the
warm air fan is same as method used to remove the
inlet water pipe of the warm air fan.
5 Remove the warm air fan cover (water pipe cover)
(a) Left hand
(1)Remove 3 screws used to fix the warm air fan.

(b) Right hand

(1) Remove 4 screws used to fix the warm air
cover.

40 / 81
6 Remove the rear warm air fan heater sub-unit
(a)Remove the rear warm air fan heater sub-unit

7 Remove the warm air fan cover (blower fan )

(a) Remove 3 screws used to fix the warm air cover.

8 Remove the rear warm air fan blower sub-unit

(a) Disconnect harness connection of the air blower.

(b) Remove three screws use to fix the rear warm air
fan blower sub-unit.

9 Remove the rear warm air fan vent

(a) Remove 3 screws used to fix the rear warm air
vent.

41 / 81
Assemble
1 Assemble the rear warm air fan vent
(a) Assemble three screws used to fix the rear warm
air fan vent.

2 Assemble the rear warm air fan blower sub-unit

(a) Assemble three screws used to fix the rear warm
air fan blower fan sub-unit.

(b) Assemble the harness connection of the air blower.

3 Assemble the warm air fan cover (blower fan

cover)
(a) Assemble three screws to fix the warm air fan
cover

4 Assemble the rear warm air fan heater sub-unit

(a) Assemble the rear warm air fan heater sub-unit

42 / 81
5 Assemble the warm air fan cover (water pipe cover)
(a) Left hand
(1) Assemble three screws used to fix the warm air
cover.

(b) Right hand

(1) Assemble four screws used to fix the warm air
cover.

6 Assemble the water inlet pipe of the warm air fan

(a) Assemble the water inlet pipe of the warm air fan

7 Assemble the water outlet pipe of the warm air fan

(a) Assemble the water outlet pipe of the warm air
fan

8 Assemble the resistor of the rear heater blower fan.

(a) Assemble two screws to fix the blower fan
resistor.

9 Assemble the air blower cover

(a) Assemble three screws used to fix the air blower
cover.

43 / 81
Assemble
1 Assemble the rear warm air fan assembly
(a) Assemble three screws used to fix the rear warm
air fan assembly.
Note:
Tighten the screws as figure, and fix the rear
warm air fan assembly.

(b) Use the pipe clips to connect the water pipe of

the rear warm air fan and the warm air fan.
2 Fill in engine coolant
3 Inspect engine coolant

44 / 81
Part of air blower unit

Combination switch
cover (upper)

Combination switch

Combination switch
cover (lower)

Proper body of steering

wheel

Upper cover of steering

wheel

Configuration with safety

airbag

Ignition switch
Proper body of steering
wheel

Small hole disc of

steering wheel

Upper cover of steering

wheel

Small hole disc of

steering wheel

Appointed button

45 / 81
 Front column trim
Including occupant air right
Front column trim bag of front seat
left

Auxiliary handle
assembly
Auxiliary handle
assembly

Occupant airbag assembly

of front seat
Auxiliary handle
Auxiliary handle
screw
screw

Danger indication signal lamp

switch assembly

Dashboard assembly

Shifting operator
assembly

Glove box assembly

Shifting handle

Air conditioning
control panel

Manual transmission edge

assembly
Instrument middle and low
protection board assembly

Manual brake protection

board assembly

Instrument board left lower

protection board assembly

Instrument board lower

protection board assembly
Appointed button

46 / 81
 Air box unit

Foot blowing air channel at pilot

driver side

Wide vehicle Air conveying pipe

body component

Air pipe
sub-assembly

Heat generation air

valve

Air inlet pipe control

line

Fan motor component

Air box motor speed

control resistor

47 / 81
Remove
1 Remove negative of the battery
Information:
Wait 90s after connection is disconnected after
preventing the airbag against operating.
2 Remove the dashboard assembly
Information
Refer to removal instruction of the dashboard
assembly.
3 Remove the intermediate lock of the steering wheel
4 Remove the steering column of the steering wheel.
5 Remove the air fan equipment

6 Remove the steering column of the steering wheel.

(a) Remove 2 nuts and connection parts (RHD)

(b) Remove the nut connection part (Outline of the

equipment is narrow).

(c) Remove 2 clips and 2 connection parts, and

then disconnect the harness connection.
(d) Disconnect 2 connector (including PTC).
(e) Remove 3 bolts and the air box equipment.

48 / 81
 (f) Remove the screw and the harness.

Disassemble
1 Remove the air inlet control line
(a) Open 3 side buckles and remove the air inlet
control line.

2 Remove air conveying pipe component

(a) Open 3 side buckles and remove the gas
conveying pipe assembly

3 Remove the heating valve

(a) Open 2 side buckles and remove the gas
conveying pipe assembly

4 Remove the speed control resistor of the rear air box

(a) Remove 2 screws and the speed control resistor
of the rear air box

49 / 81
5 Remove the speed control resistor of the rear air box
(a) Remove 3 screws and the air box motor
component with the air box.

Re-assemble
1 Assemble the air box motor component
(a) Use 3 screws to assemble the air box motor
component with the air box.

2 Assemble the speed control resistor of the air box

(a) Use 2 screws to assemble the speed control
resistor of the air box.

3 Assemble the heating valve

(a) Close 2 side buckles to assemble the heating air
valve.

4 Assemble air conveying pipe component

(a) Close 2 side buckles to assemble the gas
conveying component.

50 / 81
5 Assemble the air inlet control line
(a) Close 3 side buckles and assemble the air
inlet control line.

Assemble
1 Assemble the air fan equipment
(a) Use the screw to assemble harness (including
PTC).

(b) Use 4 bolts to assemble the air box equipment.

(c) Assemble 2 clips and 2 connectors.
(d) Assemble 2 connectors (including PTC).

(e) Use the nut to assemble connection part (Outline

of the equipment is narrow).

51 / 81
 (f) Use 2 nuts to assemble the connector (RHD)
2 Assemble the gas conveying pipe 2
3 Assemble the intermediate axle of the steering wheel
4 Assemble the steering column of the steering wheel.
5 Assemble the dashboard assembly
Information:
Refer to removal instruction of the dashboard
assembly.
6 Connect the line with the negative of the battery
7 Initialization
Information
Carry out initialization when line connection is
disconnected from negative of the power supply.

Front air box motor

Inspection
1 Inspect the front air box motor
(a) Connect the positive terminal to terminal 2, the
negative terminal is connected to terminal 1.
And then inspect whether the motor works
smoothly, if working can’t meet regulation, substitute
the front air fan motor component.
(b) Measure current according to following table

Specified current
Rotation direction
Monitor Conditions Specified
connection conditions
1-2 Air motor
Below 1.8A
works
If working can’t meet regulation, substitute the front
air fan motor component.

52 / 81
Condenser component

Heat dissipater grill

Right pedal

Coolant storage pipe A of

cooler
O ring

Including
Hood lock support receiving Left pedal
component condenser enclosure
assembly
O ring

Coolant storage pipe A of

cooler

Front floor cross beam fixing

component

Front bumper fixing

component

Front bump

Appointed button

Part which can’t be used repeatedly

Compressor engine oil ND-OIL 8 or

equivalent

53 / 81
 Cooler and drier

Appointed button

Compressor engine oil ND-OIL 8 or

equivalent

On-board inspection
1. Inspect the receiving condenser assembly
(a)If there is dirt on the receiving condenser fin assembly, use water
to clean and dry by compressed air.
Note:
Don’t damage the condenser assembly fin.
2 Inspect the condenser whether there is coolant leakage
(a) Use the halogen detection equipment to check whether there is
air leakage in the pipe joint.
(b) If air leakage is detected, inspect torsion at joint.

Remove
1 Drain out coolant from the condensing system.

54 / 81
2 Remove the radiator grill
3 Remove the left pedal enclosure
4 Remove the right pedal enclosure
5 Remove the front bumper
6 Remove the hood lock support frame component
(a) Remove the hood lock support frame
component and 3 bolts.
7 Remove the front floor cross beam fixing
component
8 Remove the front bumper fixing part

9 Remove coolant drainage pipe A of cooler

(a) Remove bolt and remove coolant drainage pipe
A of the cooler
(b) Remove O ring.
Note:
Use the adhesive tape to enclose the opening at
disconnected location so as to prevent ingression of
water steam and foreign matter.

10 Remove coolant liquid pipe A of cooler

(a) Remove the screw and the clip

(b) Remove bolt and remove coolant liquid pipe A of

the cooler
(c) Remove O ring.
Note: Use the adhesive tape to enclose the
opening at disconnected location so as to prevent
ingression of water steam and foreign matter.

55 / 81
 11 Remove coolant liquid pipe A of cooler
(a) Remove 4 bolts.

Remove
1 Remove coolant liquid pipe A of cooler
(a) Use the 14mm hexagonal spanner to remove
the adjuster cover.
14mm
hexagonal
straight
spanner
Regulator

(b) Use the screw driver to remove the cooler and

the dryer.

Assemble
1 Assemble the cooler and the drier.
(a) Use the screw driver to assemble the cooler and
the dryer.

(b) Coat sufficient compressor oil on the new O ring

and blank the assembly surface.
Compressor engine oil:
ND-PIL8 or equivalent

56 / 81
 (c) Use the 14mm hexagonal straight spanner to
assemble the blank cover.
Tighten torque: 2.9N*m

14mm
hexagonal
straight
spanner
Regulator
Assemble
1.Assemble the receiving condenser assembly
(a)Use 4 bolts to assemble the acceptance condenser
assembly.
Note Tighten bolts following sequence shown in the
figure.
Information:
If the condenser is replaced, fill in compressor
engine oil into the condenser.
2 Assemble coolant liquid pipe A of cooler
(a) Remove the original adhesion tape and connection
part.
(b) Coat sufficient compressor oil on the new O ring
and fitting conjunction location of pipe.
(c) Assemble O ring on the coolant liquid pipe A
(d) Use the bolts to assemble the cooler coolant liquid
pipe A on the cooler condenser assembly.
3 Assemble coolant liquid pipe A of cooler
(a) Move the adhesive tape and its connection part on
the cooler condenser pipe.
(b) Coat sufficient compressor oil on the new O ring
and fitting conjunction location of pipe.
(c) Assemble O ring on the coolant liquid pipe A

(d) Use the bolts to assemble the cooler coolant liquid

pipe A on the cooler condenser assembly.

4 Assemble the front bumper rod assembly to fix

5 Assemble the front floor cross beam fixing component

57 / 81
6 Assemble the hood lock support frame component
(a) Use 3 bolts to assemble the hood lock
supporting frame component
Tighten torque:
Bolt A
12N*m
Bolt B
5.5N*m
7 Assemble the front bumper
8 Assemble the right pedal enclosure
9 Assemble the left pedal enclosure
10 Assemble the radiator cover
11 Fill in coolant
12 Pre-heat the engine
13 Check whether coolant is leaked.

58 / 81
Part of air conditioner controller assembly

Shifting hand ball

Air conditioner control panel

Manual transmission edge

assembly

Instrument board middle

and lower protection board
assembly

Instrument board lower

protection board assembly

Manual brake protection

board assembly

Instrument board left lower

protection board assembly

59 / 81
 Remove and assemble
1 Use the crow bar to insert into joint between
the manual controller cover and the dashboard,
after the manual air conditioner controller is
lifted, grasp the jacked edge by two hands and
use force outward, the assembly can be
removed.

2 Pull out of the mixing air valve soft drawing

wire mechanism at rear of the controller and the
mode air valve soft drawing wire mechanism
and the plug-in.

Jack the clip

here

Installation step of the manual air conditioner

controller and the storage box assembly mode
air vent drawing wire.
1 Assemble the mixing air valve soft drawing
wire mechanism at rear of the controller and the
mode air valve soft drawing wire mechanism
and the plug-in at rear part.

60 / 81
H2 Electrical principle figure of manual air conditioning control system
Note:
1. It is suggested that the solenoid is energized by G.
2. Circuit of the cooling fan is only for information; actual control is determined by the main machine manufacturer

Ignition
switch G

Modify according to

High speed relay of cooling

principle figure of
main machine Rear
manufacturer Cooling fan air
conditio
ner

Series and parallel switching

relay
Compressor
relay

fan
Blast fan
High speed Electro-magnetic
relay clutch
Cooling fan

relay

Rear switch
Rear solenoid
Engine ECU
Low speed
High and low Rear
Rear warm air
voltage

switch)

voltage switch
Middle

switch

evapor
fan
(tube

(tube valve) Small ation

lamp fan
Rear evaporation speed regulation resistor
Front blower Low level
fan
Front speed regulation resistor A/C amplifier

To rear defrost

thermistor
electrical relay
(high level)

Front

thermistor
Rear warm
Cooling and
air speed
heating/ rear

Rear
regulation
Front air defrost composition Air capacity switch of
resistor rear evaporation fan
capacity switch Air
switch capacity
switch of
Mode/AC rear
composition switch warm air

Small lamp power supply fan

61 / 81
 Rear evaporation speed
regulation resistor

M shift H shift

Schematic figure of each electrical

L shift Empty
apparatus and plug-in (side view)

Front speed Front blower Mode knob 1-Empty Front and rear temperature sensors Pressure switch
regulation resistor fan Harness (White)-Mode 2-Grounding
end knob of small lamp
3-Positive of 1-16 in of amplifier
Front: 1- 15 pin of 2-To ECU
Positive small lamp
amplifier; 3-K3 coil
4-6 pin of
2- 3 pin of amplifier; 4-Grounding
Negative amplifier
Rear: 1- 15 pin of
5-Positive of
amplifier (grounding)
indication
2- 5 pin of amplifier
lamp
6-Grounding
Solenoid Front air capacity switch A/C amplifier REAR Air capacity switch of rear evaporation
switch and rear warm air DJ7062-6.3-10
Substitution

(Yazaki )

1-7 pin of 1-Defrost relay/high, defrost indication lamp; 2-Defrost

amplifier single input/low; 3-2 pin of front temperature sensor; 1-Grounding; 2-8 pin of amplifier;
2-K5 1-Grounding of small lamp; 2-Positive 4-Power supply; 5-2 pin of rear temperature sensor; 3-Grounding; 4-L shift; 5-M shift; 6-H shift
contact/positive of small lamp; 3-M1 shift; 4-M2 shift 6-AC request; 7-1 pin of solenoid/low; 8-Rear AC 1-Power supply; 2-Positive of small lamp; Rear warm air capacity switch
3-Rear air conditioner relay K5; 4-Empty; doesn’t use 1 and 2 pin
5-L shift; 6-Grounding; 7-Empty request; 13＆15-Grounding; 16＆17- AC output/low 5-Grounding of small lamp; 6-Grounding
8-H shift

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Rear evaporation harness and count Harness interface of rear Cooling Harness end 174923-2(Black)- Cooling
connection part of main harness warm air fan and warm and warm knob
knob
1- Ground 3.0 1-Empty;
2- Power supply 2.0 H shift – blue black 2.0 2-Grounding of
3- Temperature sensor positive Positive – blue 2.0 small lamp
4- Temperature sensor grounding 3-Positive of small
5- Power supply 2.0 lamp
6- 8 pin of amplifier, rear AC M shift – yellow blue 4-2pin of amplifier
request 2.0 L shift – white black 5-1pin of amplifier
2.0 6-Grounding

Marking Number Number of changed document Signature Day Month Year

New Haishi
Design Wang Standardiza
Jincheng tion Electrical principle figure of Haishi 6550
Check Phase marking Weight Scale

Audit
SHANGHAI JIALENG SONGZHI
Process Approval AUTOMOBILE AIRCONDITION CO., LTD
Page 1 1 page in total

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Troubleshooting of H2 manual air conditioner control part
1 Troubleshooting of electric air blower
(a) If the blower only runs at high speed, the speed regulation
module or relevant electrical wiring of the blower may be failed:
(b) If the blower only runs at other speed and the high speed gear
don’t work, the high speed relay and relevant electrical wring of the
blower may be failed:
(c) If the blower completely doesn’t work, the electric motor or
relevant electrical wiring of the blower may be failed.
2. The compressor of the air conditioner must carry out suction
operation in order that cooling of the air conditioner system works
normally.

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 Temperature signal of
engine cooling liquid

Manual or electric air conditioning

High and low voltage
switch of air conditioner

Relay

controller
Compressor of
air conditioner

Ignition voltage Temperature signal of

2 evaporator

When parts of the whole electrical air conditioning system are on

normal working status, there are three important conditions to ensure
closing of the air conditioning system compressor. Only these
conditions are met at same time, the compressor can be closed; it can’t
work if one is missed:
(a) Pipeline pressure of the air conditioning system is shown as
figure

Pressure status of Pressure switch is switched Pressure switch is switched from

pipeline from open to close close to open
Low pressure 0.225MPa 0.196 MPa
Middle pressure 1.77±0.08 MPa（Condensate 1.37±1.2 MPa （ Condensate fan is
fan is running at high speed） running at low speed）
High pressure 2.55 MPa 3.14 MPa

(b) Evaporator temperature, shown as figure

Operation status Setting temperature (0C) Tolerance (0C)

Switch off air conditioner +3.0 ±0.20
Status holding area +1.5 ±0.20
Start up air conditioner +4.5 ±0.20

(c) Temperature of engine coolant

Tempera -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7 8 9 10
ture (℃)
Rmin 60 57 54 51 49 46 44 42 40 38 36 34 32 31 29 28
(Ω) 31 24 34 60 02 58 28 10 04 10 26 53 88 32 85 45
R(Ω) 62 59 56 53 51 48 56 43 41 39 37 35 34 32 31 29
82 62 60 75 06 52 12 85 71 69 77 97 25 63 09 64
Rman 65 62 58 55 53 50 47 45 41 41 39 37 35 33 32 30
(Ω) 33 00 86 90 10 46 96 60 28 28 28 41 62 94 33 83

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2 When the evaporator temperature sensor is judged whether there is
fault, firstly make the air conditioning system is normally energized to
work, set the multiple meter to the current shift when the evaporator
temperature sensor isn’t removed, connect to the measurement circuit
of the evaporator temperature sensor in series, carry out I
measurement of the circuit, obtain corresponding resistance R
according to law R=U/I, refer to above table, in which U=5V. Because
resistance change of the evaporator temperature sensor has certain
lag phenomenon. Internal temperature can’t be measured; only judge
the sensor according to trend of resistance value R of the temperature
sensor, i.e. resistance shall drop down correspondingly following
temperature rises up.
(a) If trend isn’t correct, it means the evaporator temperature sensor
is damaged;
(b) If trend is correct and resistance is lower than 5100Ω, and the
compressor is still on work status, it is problem of the controller.
(c) If resistance of the temperature sensor drops down after it
reaches certain resistance, and it can’t reach about 4171Ω
(considering error existing in the evaporator temperature sensor), i.e.
about 3℃, it testifies that there may air blockage in the air condition
evaporator core body, the A/C switch of the air conditioner is closed,
the draft fan still runs at high speed for 5 min, and then open the A/C
switch (the draft fan is still at high speed), inspect resistance of the
temperature sensor to inspect whether the sensor is damaged. There
are many reasons which can cause ice blockage in the evaporator,
high installation position of the sensor, damage of the sensor,
deflection of the compressor control threshold etc.
3 When short circuit or open circuit fault occurs in the evaporator
temperature sensor, the A/C button working indication lamps on the
manual and electric air conditioner controller and the storage box
assembly will flash at frequency of 0.5 s. The compressor of the air
conditioner system can’t work normally, the air conditioner compressor
can resume normal cooling working until this fault is repaired, the A/C
button working indication lamp stop flashing at same time.

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Rear air outlet grill band assembly

Cross grid component

Speed regulation switch

assembly

Plate

Button

1 Remove the rear air outlet grill band assembly

(a)Use the plate tool to jack the edge of the panel, and loose 4 claws and 4 spring clips
(b)Pull out of the harness plug-in, and take out of the outlet grating with the switch assembly

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 2 Remove the button

3 Remove the commissioning switch assembly

(a) Loose the buckle at position shown in the figure,
carry out commissioning of the switch assembly.

4 Remove the marking foot

(a) Remove the marking foot.

Inspection:
1 Inspect the commissioning switch assembly
(a) Remove the commissioning switch assembly
(b) Measure resistance of each shift shown as
following table. Refer to following table for standard
resistance value. If the measured resistance isn’t in
accordance with appointed status, please replace the
speed regulation switch assembly.

Testing connection Switch position Appointed status

All terminals OFF ≥10KΩ
4—8 LO ＜ 1Ω
1—4—8 ME ＜ 1Ω
4—6—8 HI ＜ 1Ω

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Assemble
1 Assemble plate
(a) Tear the adhesion paper at back of the plate,
adhere the plate on the panel.

2 Assemble the speed regulation switch assembly.

(a) Assemble the speed regulation switch assembly,
assemble the buckle on position.

3 Assemble the button

(a) Inset the button into the steel lifting bar

4 Assemble the outlet grill switch assembly

(a) Connect the harness

(b) Assemble the outlet grill band switch assembly,

ensure four clip feet and four spring clips at positions.

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Rear air channel outlet grill component

Rear air channel outlet grid

component
Spring clip

Spring clip

Remove
1 Remove the air channel outlet grill component at rear
side
(a) Use the flat plate category tools to jack the edge,
make three spring clips at positions shown in the figure
loose, and remove the grill.

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 (b) Use the screw driver to remove 3 spring clips.

Assemble
(a) Assemble Remove three spring clips and assemble
on position.

(b) Assemble the grill on the top ceiling, tap the edge
of the grill by hand, and make three spring clips on
position.

Outlet grill band switch assembly

Inlet air grid base

seat

Inlet air with

filter screen
assembly

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Remove
1 Inlet grill band switch assembly
(a) Press the grill as direction of the arrow shown in
the figure, the grill is disengaged from the inlet grill
base seat when ―clatter‖ sound is sounded.

(b) Draw the grill backward following direction shown

in the figure, the grill is removed.

Assemble
1 Inlet grill band switch assembly
(a) Insert the grill into the inlet grill base seat
following direction of the arrow in the figure, insertion is
on position.

(b) Press the grill as direction and position of the

arrow shown in the figure, it means the switch is locked
when ―clatter‖ sound is sounded.

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 Cooling system
General
The cooling system is used to make each part of the
engine maintain at suitable temperature. No matter which
condition the engine runs, cooling way is water cooling,
use the water pump to pressurize cooling liquid, and make
it circulate in the engine. If temperature of cooling liquid
exceeds specified temperature, the thermostat starts, and
cooling liquid is circulated through the heat radiator, and
heat absorbed by cooling liquid is dissipated into air.

Leakage inspection of cooling liquid

1 Firstly find out whether liquid level of cooling liquid
Liquid storage box reaches FULL (full) scale, and then carry out testing of one
cover joint
liquid storage box cover and impose pressure of 150Kpa,
Joint
inspect whether there is leakage in the heat radiator, the
liquid storage tank, the hose or the joint of the cooling
system.
Note:
(1) Be sure to completely clean all water and steam at
inspection location.
(2) When the tester is taken out, be sure to not let
cooling liquid inject out.
(3) When the tester is removed and it is tested, be
careful not damage neck of the filling port of the storage
Liquid storage box
box.
cover joint 2 If leakage is found, repair and replace the cover vavle of
the relevant part storage box and inspect the opening
pressure.
1. Connect the cover of the storage box with the tester by
the storage box cover joint.
2 Increase pressure until the needle of the pressure meter
stops moving.
Limit valve: 108Kpa
Standard value 74.3‐102.3 Kp
3 If reading can’t be maintained or is greater than limit,
replace the cover of the radiator.
Remark
Ensure the cover of the radiator clean before testing,
indication may be incorrect if there is rust or other foreign
matter in the sealing component of the storage box cover.

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 Replacement of coolant
1 Remove the water drainage switch of the heat
radiator assemble, drain out coolant in the cooling
system when the liquid storage box cover is removed.

2 Remove the water drainage plug of the cylinder body,

and drain out coolant in the engine.
3 After coolant in the engine is drained out, fill in clean
water from the filling opening of the liquid storage tank
so as to clean the coolant pipeline of the engine.
4 Coat specified sealing glue at the thread position of
the cylinder drainage plug, and tighten to specified
torque.
5 Tighten the water drainage switch of the heat
dissipater firmly
6 Slowly fill engine coolant into the storage box through
Water drainage plug of the filling port of the storage box, until some water flows
cylinder body
out of the water drainage screw plug, and coat
specified sealing glue on the thread part of the water
drainage plug of the cylinder body, and tighten to
specified torque.
7 Continue fill until liquid level reaches FULL (full)
Exhaust bolt scale, recommended anti-freezing liquid.
Water outlet High quality ethylene glycol anti-freezing coolant,
joint
capacity: 12dm3
Pay attention
to plate 8 Assemble the storage box cover firmly.
9 Start the engine and dissipate heat to the thermostat,
start up (check whether water in the heat dissipater
flows by feeling the hose of the heat dissipater with
hand)
10 After the thermostat starts, operate the engine at
speed of 3000 rpm for 3 times.
11 After the engine is stopped, remove the storage box
cover after it is cool down, inspect coolant level. If level
is too low, please repeat operation in step 7.

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Structure of parts in cooling system

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Parts list
No Part name Quantity No Part name Quantity
1 Heat dissipater assembly 1 25 M6 combination nut 1
2 Upper rubber cushion of heat 1
2 26 Clamp of worm
dissipater assembly
3 Lower water 1
Lower rubber cushion of heat
2 27 pipe-rubber pipe 1 of
dissipater assembly
heat dissipater
4 From water pipe expansion box 1
1 28 Clamp of worm
to rubber pipe of heat dissipater
5 Lower water pipe 1
Rigid tape type elastic loop 2 29 hard pipe of heat
dissipater
6 From water pipe expansion box 1
1 30 Clamp of worm
to hard pipe of heat dissipater
7 Lower water
From water pipe expansion box
1 31 pipe-rubber pipe 2 of
to support of heat dissipater
heat dissipater
8 M6 combination bolt 1 32 Clamp of worm 1
9 Fan assembly 1 33 M8 combination bolt 1
10 M5 combination bolt 4 34 M8 combination bolt 1
11 Rigid tape type elastic 1
M5 combination bolt 2 35
loop
12 M6 combination bolt 2 36
13 Rigid tape type elastic 1
M8 combination bolt 2 37
loop
14 Rigid tape type elastic 1
M6 combination nut 2 38
loop
15 Clamp of worm 1 39 Air flow of water pipe 1
16 From water pipe heat radiator to 1
2 40 Pipe clip
rubber pipe 1 of thermostat
17 Rigid tape type elastic 1
Clamp of worm 1 41
loop
18 Rubber ring of 2
From water pipe heat radiator to
1 42 expansion box
hard pipe of thermostat
assembly
19 Expansion box 1
Clamp of worm 1 43
assembly
20 From water pipe heat radiator to 1
1 44 M6 combination bolt
rubber pipe 2 of thermostat
21 Right guiding plate of 1
Clamp of worm 45
heat dissipater
22 M6 combination nut 2 46 M6 combination bolt 4
23 Left guiding plate of 1
Water pipe support 1 47
heat dissipater
24 M6 combination bolt 1

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Pre-operation before removal
1 Drain out coolant in the cooling system
(1) Open the external board of the front fender, open
the coolant storage box cover anti-clock
(2) Use the lifter to lift the vehicle up, rotate and open
the water drainage switch of the heat dissipater
assembly anti-clock, drain out coolant.

Remove and assemble

Remove step
1 Remove the front bumper cover assembly (with the
fog lamp), the inlet grill assembly, the engine front
cabin cover sealing bar support, the front bump upper
cross beam, the condenser, the front lower protection
board of the engine:
2 Water pipe ‐ air through two rigid belt type spring
clamp one pipe clamp

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4 Liquid storage box
One M6 combination bolt
Torque: -9N*m

5 Left and right guiding plates of the heat dissipater

Four M6 combination bolts
Torque: -9N*m

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 6 Remove the fan support
Two M8 combination nuts
Torque: 21-25N*m
Two M8 combination bolts
Torque: 21-25N*m

7 Remove the fan cover

Six M5 combination bolts
Torque: 5±0.5N*m

8 Remove water pipe – heat dissipater to

thermostat
(1) Connect the engine
A clamp of worm
Torque: 3-5N*m

(2) Intermediate hard pipe part

Two clamps of worm
Torque: 3-5N*m
Three M6 combination bolts
Torque: 6-9N*m

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9 Remove the lower water pipe of the heat
dissipater
(1) Connect the engine
One clamp of worm
Torque: 3-5N*m

(2) Intermediate hard pipe part

Two clamps of worms
Torque: 3-5N*m
Two M8 combination bolts
Torque: 21-25N*m

10 Remove the upper support of the heat

dissipater

11 Remove the heat dissipater assembly

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 12 Remove water pipe – heat dissipater to
thermostat
Connect the heat dissipater
One clamp of worm
Torque: 3-5N*m

13 Remove the wind protection cover

Two M6 combination bolts
Torque: 6-9N*m

14 Remove the lower water pipe of the

heat dissipater
Connect the heat dissipater
One clamp of worm
Torque: 3-5N*m

15 Remove the water pipe – storage box

to heat dissipater
Two M6 combination bolts
Torque: 6-9N*m
Two rigid tape type elastic loops

Precautions during removal and assembly

Insert each water pipe into the concave of
the outlet joint or the inlet water joint.

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