LC Workshop Manual

LC Workshop Manual
GEELY INTERNATIONAL CORPORATION
Feburary 2009
Foreword
Geely LC series sedans (HQ7131, HQ7101B1, HQ7101) are brand new superior models developed by
Geely Group who has fully proprietary intellectual property rights. These sedans reach international
leading level in model design, power, comfort, safety and manufacturing technology while featured in
beautiful appearance, economy, environment protection and safety. With respect to the power, Geely LC
series sedans are equipped with 1.3L and 1.0L EFI engines developed and manufactured by Geely itself,
and has reached “National IV” emission standard.
This manual contains a detailed description of the structures and principles, servicing and adjustment,
removal, assembling technology and matching clearance of the parts of the Geely LC sedans with
torque information of the bolts and nuts as well as schematic diagram for special tool operation. This
manual also introduces vehicle electric circuits and elaborates ABS system, SRS, MT20U2 electronic
control fuel injection and ignition system, sound and air conditioning system. You can refer to this
manual for the information about the regular maintenance, servicing, adjustment, troubleshooting,
removal and installation procedure, specific operations of the LC sedans
This manual covers the matching relation among the engine assembly, transmission assembly and the
vehicle, but does not have the further description of the structures and principles of the engine and
transmission assemblies and their servicing process. You can refer to the service manuals solely
prepared for engine assembly and transmission assembly for the information.
All information in this manual is based on the latest products released at the time of publication of this
manual. However, the specifications and procedures may need to be modified, and the subsequent
change will be revealed in later versions.
This manual is prepared by Geely Automobile Research Institute under the assistance of technical staff
from Zhejiang Haoqing Automobile Co., Ltd and Geely International Corporation. Readers discovering
during the use of this manual the errors and careless omissions due to limited skills of the preparers and
tight schedule are encouraged and pled to contact Technical Department of Geely International
Corporation in time for our timely correction of the mistakes.
Geely International Corporation
Feb.2009
1
Contents
Chapter 1 Outline .......................................................................................... 7
Chapter 2 Engine ........................................................................................ 15
Part 1 Engine Assembly.....................................................................................................15

I. Engine Inspection .................................................................................................................15
II. Removal of the Engine Assembly from the Vehicle ..............................................................20
III. Drive Belt Replacement ........................................................................................................22
Part 2 Engine Mechanical ..................................................................................................24

I. Engine Components (3G10 engine) .....................................................................................24
II. Engine Component Assembly (3G10) ..................................................................................25
II. Engine Component Assembly (3G10) ..................................................................................26
III. Engine Component (MR479Q) .............................................................................................27
IV. Valve Clearance ...................................................................................................................28
V. Air intake system ..................................................................................................................30
VI. Exhaust system ....................................................................................................................33
Part 3 Engine Control System (1.0L) .................................................................................35

I. M7.9.7 EFI System ...............................................................................................................35
II. Throttle Body Assembly........................................................................................................38
Part 4 Engine Control System (1.3L Delphi MT20U2) .......................................................39

I. System Components ............................................................................................................39
II. On-Board Diagnostic (EOBD)...............................................................................................51
III. Typical trouble and troubleshooting ......................................................................................68
IV. Typical datastream of DELPHI electronic fuel injection system ............................................77
V. Gear information learning procedure of EOBD system.........................................................82
VI. Circuit Schematic Diagram for MT20U2 System ..................................................................83
Part 5 Cooling System .......................................................................................................84
Part 6 Fuel System ............................................................................................................87

I. Check Fuel System Pressure ...............................................................................................87
II. Fuel Pump Inspection...........................................................................................................88
III. Fuel Pump Replacement ......................................................................................................89
IV. Fuel tank replacement ..........................................................................................................90
V. Fuel Emission Control System..............................................................................................92
VI. Carbon Canister Replacement .............................................................................................94
Chapter 3 Chassis....................................................................................... 96
Part 1 Transmission Control...............................................................................................96

I. Introduction of Transmission Control ....................................................................................96
II. Flexible Shaft for Shifting Gear.............................................................................................98
III. Manual Transmission Shift Assembly .................................................................................100
2
Part 2 Accelerator Pedal Device ......................................................................................102
I. Introduction of Accelerator Pedal........................................................................................102
Part 3 Clutch Assembly....................................................................................................104

I. Introduction of Clutch Control System ................................................................................104
II. Clutch Components and Common Failure..........................................................................105
III. Clutch Pedal .......................................................................................................................108
Part 4 Manual Transmission Assembly (1.0L).................................................................. 117

I. Removal and Installation of Transmission .......................................................................... 118
II. Removal and Installation of Transmission Assembly .......................................................... 119
III. Disassembly of Gear Shift Guide Shaft Sub-assembly.......................................................121
IV. Disassembly of Differential Sub-assembly..........................................................................122
V. Disassembly of Input Shaft Sub-assembly .........................................................................123
VI. Assembly of Input Shaft Sub-assembly ..............................................................................125
VII. Assembly of clutch housing accessories and clutch release mechanism ...........................130
VIII. Installation of Transmission Assembly ................................................................................131
Part 5 Manual Transmission Assembly (1.3L)..................................................................134

I. Assembly Disassembling....................................................................................................134
II. Assembly Assembling.........................................................................................................151
Part 6 Drive shaft/Driveshaft ............................................................................................152

I. Drive shaft, Driveshaft and Transaxle .................................................................................152
II. Front Constant-velocity Drive Shaft ....................................................................................154
Part 7 Brake System ........................................................................................................163

I. Introduction to Brake System..............................................................................................163
II. Brake Fluid .........................................................................................................................165
III. Brake Pedal ........................................................................................................................166
IV. Brake Master Pump............................................................................................................169
V. Vacuum Booster .................................................................................................................175
VI. Front Brake.........................................................................................................................178
VII. Front Wheel Hub and Bearing Assembly............................................................................183
VIII. Rear Brake Drum................................................................................................................189
IX. Rear Wheel Hub and Bearing Assembly ............................................................................194
X. Parking Brake System ........................................................................................................196
XI. ABS system ........................................................................................................................200
Part 8 Wheel ....................................................................................................................209

I. Tire Inspection and Wheel Replacement ............................................................................209
Part 9 Power Steering System .........................................................................................210

I. Power Steering System ......................................................................................................210
II. Steering Drive Mechanism..................................................................................................212
III. Mechanical Steering Gear Fixing Device............................................................................218
IV. Power Assisted Steering System ........................................................................................223
Part 10 Front Suspension System ...................................................................................234

I. Front Suspension System ..................................................................................................234
3
II. Front Suspension ...............................................................................................................236
III. Front Wheel Alignment .......................................................................................................239
IV. Front shock absorber and coil spring..................................................................................241
V. Front suspension lower swinging arm assembly ................................................................244
VI. Front Stabilizer and Linkage Assembly...............................................................................245
Part 11 Rear Suspension System ....................................................................................249

I. Introduction to Rear Suspension System ...........................................................................249
II. Rear Wheel Alignment........................................................................................................252
III. Left and Right Suspension Coil Spring ...............................................................................253
IV. Rear Shock Absorber Installation Assembly .......................................................................254
V. Rear Shaft Member ............................................................................................................255
Chapter 4 Electric System & Accessory ................................................. 258
Part 1 Starting and Charging System...............................................................................258

I. Starting System (3G10. 479Q)............................................................................................258
II. Charging system.................................................................................................................260
Part 2 Wiper and Washer System....................................................................................264

I. Wiper and Washer System Inspection................................................................................264
II. Replacement and Adjustment.............................................................................................267
Part 3 Combination Instrument System ...........................................................................269

I. Schematic circuit diagram of combination instrument and distribution of multi-pin plug-in unit
terminal .........................................................................................................................................269
II. Malfunction Symptom Table and Troubleshooting ..............................................................271
Part 4 Audio System ........................................................................................................281

I. Introduction to Audio System ..............................................................................................281
II. Audio System Connector Terminal Layout..........................................................................283
III. Audio System Inspection ....................................................................................................284
IV. Audio System Replacement ...............................................................................................289
Part 5 Centralized Controller............................................................................................291

I. Centralized Controller System ............................................................................................291
Part 6 Safety airbag system.............................................................................................299

I. Maintenance guidance .......................................................................................................299
II. Maintenance Procedures and Trouble Classification..........................................................312
III. Rejection of safety airbag ...................................................................................................340
Part 7 Air Conditioning System ........................................................................................346

I. General Information............................................................................................................346
II. Symptom table....................................................................................................................348
III. Refrigerant inspection.........................................................................................................353
IV. Discharge and Fill-up of Refrigerant ...................................................................................359
V. Air Conditioning Operating Mechanism ..............................................................................360
VI. Blower Assembly ................................................................................................................363
VII. Air Filter Assembly..............................................................................................................364
VIII. Air Conditioning Assembly..................................................................................................365
4
IX. Compressor Fixing .............................................................................................................369
X. Condenser Fan Motor and Condenser Assembly ...............................................................372
XI. Pipe System Assembly .......................................................................................................373
Part 8 Reversing Radar System ......................................................................................374
Part 9 Light System .........................................................................................................377

I. Introduction to light system .................................................................................................377
II. Light System Malfunction Inspection ..................................................................................379
III. Front HeadLamp Replacement...........................................................................................382
IV. Front Fog Lamp Replacement ............................................................................................383
V. Rear Combination Lamp Replacement...............................................................................384
VI. High mount brake lamp replacement..................................................................................384
VII. Room roof Lamp Replacement...........................................................................................385
VIII. License Plate Lamp Replacement ......................................................................................385
Part 10 Switch System.....................................................................................................386
Chapter 5 Interior & Exterior Trim and Accessories.............................. 398

I. Instrument Panel and Dashboard .......................................................................................398
II. Auxiliary Dashboard Assembly ...........................................................................................402
III. Vent Cover Plate.................................................................................................................404
IV. Front Bumper......................................................................................................................406
V. Rear Bumper ......................................................................................................................408
VI. Fender ................................................................................................................................400
VII. Front Door Interior Trim ......................................................................................................412
VIII. Rear Door Interior Trim.......................................................................................................414
IX. Side Wall Interior Trim ........................................................................................................416
X. Front Seat Assembly ..........................................................................................................419
XI. Rear Seat Assembly ...........................................................................................................421
XII. Safety Belt ..........................................................................................................................423
XIII. Front Windscreen ...............................................................................................................432
XIV. Backdoor Windscreen Assembly ........................................................................................435
XV. Outside Rearview Mirror .....................................................................................................438
XVI. Interior Rearview Mirror ......................................................................................................439
XVII. Roof Trim Components.......................................................................................................440
XVIII. Carpet and Heat Insulating Carpet .....................................................................................442
XIX. Fuel Filler Cap Opening Device..........................................................................................443
XX. Engine Hood Lock Opening Cable Assembly .....................................................................444
XXI. Plug List..............................................................................................................................445
Chapter 6 Body ......................................................................................... 446
Part 1 Summarize ............................................................................................................446

I. Body Structure ....................................................................................................................446
Part 2 Body Repair ..........................................................................................................455

I. Body Damage Forms and requirements For Repair ...........................................................455
II. Typical Technique of Body Panel Repair ............................................................................463
III. Repair after Body Damage .................................................................................................464
IV. Features and Composition of Automobile Body..................................................................473
V. Painting Techniques After Body Repair...............................................................................485
VIII. Service Data for Body.........................................................................................................486
5
Appendix1 ：Body Key Dimension ............................................................ 489
I. Engine Compartment..........................................................................................................489
II. Body left/right side wall .......................................................................................................490
III. Opening part of the body (view from back) .........................................................................491
IV. Body bottom .......................................................................................................................492
Appendix2 ：Harness diagram of LC model electronics ...................................... 493
Appendix3 ：Principle diagram of LC model electronics...................................... 509
6
Outline
Chapter 1 Outline
Table of Basic Parameters

No. Item unit HQ7101,HQ7101B1 HQ7131
Length 3598
Dimensions Width 1630
Height mm 1465
Dimensional Front wheel 1420
1 Wheel span
parameters Rear wheel 1410
Wheel base 2340
Front suspension mm 718
Rear suspension 540
2 Drive type Front-Engine front-drive (FF)
3 Number of occupants Person 5
Gross Vehicle Weight (kg) 937 985
Gross Vehicle Front Axle 560 605
Weight Weight (kg) Rear axle 377 380
4 kg
parameters Max. curb mass (kg) 1312 1360
Max. curb Front Axle 669 710
mass (kg) Rear axle 643 650
Min. turning diameter m ≤9.5
Min. ground clearance mm ≥121
5 Passability
Approach angle ≥19°
Departure angle ≥35°
Front wheel Left inward/outward ° 37.28°/36.92°/32°～40.92°
steering angle Right inner/outer ° 31°/39°
Camber ° -0°47′±45′
Wheel
6 Kingpin inclination ° 9°33′±30′
alignment
Kingpin Caster ° 2°47′±45′
Front wheel toe-in mm 1.1±2
Rear wheel toe-in mm 3±3
Mileage of first malfunction km ≥8000
7 Reliability
Average mileage of malfunction km ≥5000
Max. speed km/h ≥155 ≥155
Dynamic (0～100)km/h acceleration time s ≤15 ≤14
8
performance Min. stable speed at Gear 4 km/h ≤25 ≤25
Max. grade abilitity % ≥20 ≥20
Fuel consumption at constant speed
L/100km ≤4.2 ≤5.6
(60 km/h)
Fuel consumption at constant speed
9 Economy L/100km ≤5 ≤6.85
(90 km/h)
Sliding distance(full load, initial speed
m ≥550 ≥550
50km/h)
7
Outline
Table 2 Models and technical data of major systems
HQ7101/HQ7101B1 HQ7131
No. Item Unit
Type and Parameter
1 Drive type Front-Engine front-drive (FF)
Model JL3G10 MR479Q
12-valve, 3-cylinder, in-line, 16-valve, 4-cylinder, inline,
Type
DOHC electronic injection DOHC electronic injection
Cylinder bore mm 71.5 78.7
Stroke mm 83.5 69
Displacement L 1.006 1.342
2 Engine Compression
10.3 9.3
ratio
Max. power (Kw/r/min) 52/6000 63/6000
Max. torque (N.m/r/min) 91/3600 110/5200
Stable idle
r/min 830±30 800±50
speed
Ignition
1—2—3 1—3—4—2
sequence
Model JL-5LE136 JL-S160G
1st gear 3.545 3.182
2nd gear 1.895 1.895
3rd gear 1.310 1.250
3 Transmission
4th gear 0.972 0.909
5th gear 0.800 0.703
Reverse gear 3.142 3.083
Final gear ratio 3.933 4.267
4 Clutch Type Single-disc, dry type Single-disc, dry type
5 Assisted type Gear and rack type Electrical power assisted
Type Dual-pipe, front vented disc type, rear drum type
Braking
6 Power assisted Vacuum booster, hydraulic braking type with
System
type ABS/proportional valve
Type of front
McPherson independent suspension (with sub-frame)
suspension
7 Suspension
Type of rear
Twist beam, coil spring half independent suspension
suspension
Spec. 165/60R14
8 Tire Pressure (F/R) kPa 230/210
Wheel rim 5J 15X6J(or 14X5 1/2JJ)
9 Rated capacity of fuel tank L 35 35
10 Body Body Structure Integral body
8
Outline
Vehicle Maintenance
A Road Conditions
1. drive on rough, muddy or skiddy roads
2. drive on dusty roads
B. Driving Conditions
1. Repeat driving within 8km a few times, or when the outdoor temperature is below 0℃;
2. Idle the car drive at a low speed for a long time, such as police car, taxi, or door to door delivery
vehicles;
3. Continuously drive the car at high speed for more than 2 hours (80% of the max speed or above).
Regular Inspection
1. Weekly Inspection
● inspect engine oil level and cleanness;
● inspect engine coolant level;
● inspect brake fluid level;
● inspect windshield washer fluid level;
2. Monthly Inspection
● inspect water pump belt;
● inspect tire air pressure and wear;
● inspect steering wheel;
● inspect brake;
● inspect acceleration pedal.
3. Inspection when driving (low speed)
● Check the speedometer and the water temperature gauge;
● check steering wheel power and if vehicle has deviation;
● check if the front wheels break away or wobble;
● inspect if brake works normally or if the vehicle has deviation when vehicle brakes.
4. Other Inspection Items
Eliminate problems immediately when there is anything abnormal.
Regular replacing parts table
Parts No. Regularly Replacing Parts Interval

Brake master cylinder cup valve and
1 Every 2 years(or as required)
dust cover
2 Brake master cylinder cup Every 2 years(or as required)
3 Brake hose Every 2 years(or as required)
Braking
System 4 Wheel-braking cylinder valve Every 4 years(or as required)
5 Brake booster rubber Every 2 years(or as required)
6 Brake booster vacuum hose Every 2 years(or as required)
7 Brake fluid Yearly (or as required)
9
Outline
Parts No. Regularly Replacing Parts Interval

8 Manual transmission oil Every two years or 40,000km(or as required)
Braking
System Initially after 2,500km, afterwards every 2 years or
9 Auto transmission oil
40,000km(or as required)
10 Element of air filter Every 15,000~20,000km(or as required)
Engine
(API)SG grade or Every 1,500～2,500km or within 2 months, afterwards every
11 lubricating
above 7,500km or 6 months(or as required)
oil
Every 1,500～2,500km or within 2 months, afterwards every
12 Oil filter
7,500km (or as required)
13 Fuel filter Every 20,000km(or as required)
14 Coolant Yearly (or as required)
Engine
15 All hoses Every 2 years(or as required)
16 Canister Every 60,000km(or as required)
17 Timing belt Every 120,000km(or as required)
Wedge belt(including belts of AC air
18 Every 30,000km(or as required)
compressor and generator)
19 PCV system Every 20,000km or 12 months(or as required)
20 Spark plug Every 20,000km(or as required)
Maintenance Schedule
The user should performance the maintenance of at least 10,000km in light of mileage and time
whichever comes first. Inspection and maintenance may be advanced based on actual situation in the
case of influence of particular environmental conditions. 〇 ......Inspect, adjust or replace when
necessary ●......Replace
Inspection X1000km 7.5 15 22.5 30 37.5 45 52.5 60 67.5 75

Location
item Year 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5
Abnormal
sound at
Braking connection of
〇〇
system steering
knuckle and
Braking steering linkage
Free stroke and
reserve working 〇〇〇〇〇〇〇〇〇〇
stroke
Efficiency 〇〇〇〇〇〇〇〇〇〇
Working stroke 〇〇〇〇〇〇〇〇〇〇
Efficiency 〇〇〇〇〇
Parking
braking Parking brake
cable fastening,
〇〇
abnormal noise
and damage
Brake Reservoir level 〇〇〇〇〇〇〇〇〇〇

booster Function 〇〇
Brake master Fluid leakage 〇〇〇〇〇〇
cylinder,
wheel Function, wear
cylinder, 〇〇
and damage
brake caliper
10
Outline
Inspection X1000km 7.5 15 22.5 30 37.5 45 52.5 60 67.5 75

Location
item Year 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5
Clearance
between brake
〇〇〇〇〇
drum and
frictional plate
Brake drum Damage to and
and brake wear of brake 〇〇
shoe drum
Wear of brake
shoe sliding
〇〇〇〇〇
part and
frictional plate
Wear of
〇〇 ● 〇 ●
frictional plate
Brake disc
and linings Wear and
damage of 〇〇
brake disc
Free stroke,
Steering fastening and 〇〇〇〇〇
wheel abnormal noise
Motion 〇〇〇〇〇
Steering
Fastening 〇〇
gear
Fastening,
abnormal
〇〇〇〇〇
sound or
damage
Steering
Steering linkage and Crack or
system joint damage of
steering linkage
〇〇〇〇〇
ball end,
steering rack
joint, dust boot
Steering Abnormal
〇〇〇
knuckle sound at joint
Wheel
〇〇〇〇
adjustment
Front wheel Turning angles
of left and right 〇〇
wheels
Running Wheel Tire pressure 〇〇〇〇〇〇〇〇〇〇
system
Tire crack and
〇〇〇〇〇〇〇〇〇〇
damage
Tire pattern and
uneven wear
Metal scraps,
little stones or
other foreign
matters
Looseness of
hub nuts and 〇〇〇〇〇
bolts
Abnormal
sound of front 〇〇
axle
11
Outline
Inspection X1000km 7.5 15 22.5 30 37.5 45 52.5 60 67.5 75

Location
item Year 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5
Abnormal
sound of rear 〇〇
axle
Clutch Free stroke 〇〇〇〇〇〇〇〇〇〇
Motion 〇〇〇〇〇
Manual
transmission Oil leak and oil
〇〇〇〇〇
level
Abnormal
sound at control 〇〇
Auto t mechanism
transmission
Oil leak and oil
〇〇〇〇〇
level
Transmission
system Fastening of
〇〇〇〇〇
joints
Crack and
damage of
〇〇〇〇〇
universal joint,
Driver dust boot
Abnormal
〇〇
sound at spline
Abnormal
sound at 〇〇
universal joint
Spring Damage 〇〇
fastening and
damage of 〇〇
Fixing and fixing part
connection
part Abnormal
sound at 〇〇
connections
Suspension Sound at
system Suspension connections
〇〇
arm and arm
damage
Oil leak and
〇〇
damage
Shock
absorber Abnormal
sound at fixing 〇〇
points
Working
Eclectic
condition of 〇〇〇〇〇〇〇〇〇〇
system Igniter spark plug
Ignition time 〇〇〇〇〇
Battery Status of joints 〇〇〇〇〇

Fastening and
Wire harness damage of
〇〇
and clamp connecting
parts
All lights Function 〇〇〇〇〇〇〇〇〇〇
Combination
Function 〇〇〇〇〇
instrument
12
Outline
Inspection X1000km 7.5 15 22.5 30 37.5 45 52.5 60 67.5 75

Location
item Year 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5
Washer,
Function 〇〇〇〇〇
horn, wiper
Defroster,
power door Function 〇〇〇〇〇
lock
Starting,
abnormal
sound, idle 〇〇〇〇〇
speed and
General acceleration
Engine condition of
engine Valve
〇〇
clearance
Oil leak of
〇〇〇〇〇〇
engine
Function of
〇〇
door lock
Door,
luggage Fastening,
compartment abnormal
〇〇
door, engine sound and
Body and hood damage
accessories
Seats Condition of
seats and 〇〇
safety belts
Lubrication of 〇
Other 〇〇〇〇
body parts
——Additional Maintenance Schedule

Vehicles run in special circumstances require higher frequency of maintenance as listed below.
A-1. driving on bumpy, muddy or melted snow road

Check the brake friction lining and brake drum Every 5,000km or 6 months
Check the friction plate and brake disc Every 5,000km or 3 months
Check the brake line and hose Initially after 1,000km, afterwards every
5,000km or 6 months
Check the tie rod end, joint and dust cap Every 5,000km or 6 months
Check the dust boot of drive shaft Every 10,000km or 12 months
Check the steering wheel, linkage and steering Every 5,000km or 6 months
gearbox oil
Check front and rear suspension devices Every 5,000km or 6 months

Fasten the bolts and nuts of chassis and vehicle Every 5,000km or 6 months
body
A-2. driving on dusty road
Replacement of the engine oil Every 5,000km or 3 months
Replacement of engine oil filter Every 5,000km or 3 months
Inspection and replacement of air filter Every 2,500km or 3 months
Inspection of the brake friction lining and braking Every 5,000km or 3 months
drum
13
Outline
Check the friction frictional plate and brake disc Every 5,000km or 3 months
Replace the AC air filter Every 10,000km
B-1. repeated short-distance driving and at outer air temperature 0℃ within 8km (kilometer);
Replacement of the engine oil Every 2,500km or 3 months
Replace the engine oil filter. Every 2,500km or 3 months
B-2. Idle run for a long time and/or run long distance at low speed, such as police car, taxi and
door-to-door cars
Inspection of the brake friction lining and Every 10,000km or 3 months
braking drum
Check the frictional plate and brake disc Every 5,000km or 3 months
R-3. Run at high speed continually for more than 2 hours (at 80% of max. speed or above)
Replacement the fluid of manual transaxle Every 40,000km or 24 months
Check or replace the fluid of automatic transaxle Every 40,000km or 24 months
14
Engine—Engine Assembly—Engine Inspection
Chapter 2 Engine
Part 1 Engine Assembly
Information about engine parts in LC Maintenance Manual deals with only that concerned with complete
vehicle. Please refer to Maintenance Manual for information about the engine body. Engines concerned
are JL-3G10 and MR479Q.
I. Engine Inspection
1. Check the engine oil
(1) Check the oil level.
(2) Start the engine and operate it for 20 min at low speed, and reach warm-up temperature.
(3) Shut the engine down, wait for 2-3min, and check the oil level.
(4) Check whether the oil level is in within the range marked by the scale; if it is lower than the limit (mark
L), fill oil to mark “F”.
(5) Keep the oil clean without any coolant or petrol mixed in and with appropriate viscosity
2. Replace oil.
(1) Start the engine. When normal temperature is reached, shut down the engine.
(2) Screw off the oil filler cap and oil drain plug, drain the engine oil;
(3) Remove and replace oil filter.
(4) Tighten oil drain plug to specificated torque 54N.m.
(5) Fill fresh engine oil into the crankcase. For JL-3G10 engine: filling volume with filter unreplaced: 2.7L ;
Filling volume with filter replaced: 2.9L; for MR479Q engine: filling volume with filter unreplaced: 2.8L,
filling volume with filter replaced: 3.0L; add to 3.5L if empty.
(6) Screw on the oil filling cap.
(7) Start the engine.
(8) Shut down the engine and check the oil quantity, and fill oil to the mark F on the oil scale if necessary.
3. Replace the oil filter.
(1) Remove the oil filter.
(2) Before mounting the oil filter, apply a small quantity of engine oil to the O-ring of the new oil filter.
(3) Tight the oil filter to a specified torque (12.7N.m).
(4) Start the engine, and check whether there is any leakage
(5) Shut down the engine, check the oil quantity and fill as required.
4. Oil selection
Oil over API SG grade is preferred.
15
SAE 10W-30 or SAE 15W-40 is preferred, and ASE5W-30 is used in cold region in the winter.
Note: For the best effect and the greatest safety, it is advisable to use the following lubrication
oil.
a. Meet the requirements of API level.
b. Select proper SAE viscosity rating within expected ambient temperature.
It is forbidden to use the lubrication oil that can not meet the requirements of SAE viscosity and
API lavel.
5. Check the coolant.
(1) After the engine is cooled down, remove the radiator cap.
(2) Make sure that the coolant level is above the neck of the radiator.
(3) Screw on the radiator cap and pressurize to 2.0Mpa, and keep the pressure for 1minute unless the
coolant leaks. (Mount a tester on the radiator cap, start the engine, and then shut down under a pressure
2.0Mpa).
(4) Check whether the coolant quantity in the expansion vessel (expansion kettle) is between the mark
"L" and "F".
(5) Check whether the radiator cap is clean; test whether the opening pressure of the main valve is
107.8KPa with a radiator cap tester. The minimum opening pressure is 58.5KPa.
6. Check the battery.
(1) Relative density of battery electrolyte: standard value 1.25~1.29 at 20℃. The battery should be
charged if the density is less than specified value.
(2)The terminal voltage of the battery is 12.5-12.9V at 20°C, and charge when the voltage value is less
than the specified value. Check whether the fuses are loose, corrosive or continuity.
7. Check the air filter.
(1) Whether the cover, the case or the element of the filter is distorted, corroded or damaged.
(2) Whether the air hose is damaged.
(3) Whether the gas chamber is distorted or damaged.
(4) Check the element for pollutant obstruction and damage, and if element is blocked slightly, top blow
the element on the top and remove the pollutant; and check if the filter carrier has any pollutant or gets
polluted.
8. Check the spark plug.
(1) Spark generating check
a. Disconnect the coupler of the injector.
b. Remove the high tension cable from the spark plug.
c. Remove the spark plug.
d. Connect the spark plug to the high tension cable.
e. Ground the spark plug.
16
f. Start the engine, and check whether spark is generated.
Tip: The starting time is not more than 1-2s.
(2) Clean the spark plug: The air pressure is not greater than 588kp and the time is not more than 20s.
(3) Check whether the thread and the insulator of the spark plug are damaged. Replace if necessary.
(4) Check the clearance and electrode gap of spark plug: 1.1mm±0.1mm for 3G10 engine,
0.8mm±0.1mm ofr MR479Q engine
9. Check the drive belt
Belt distortion (see Table 1): Belt pressure: 98N
Table 1
New belt
Model Type of belt Old belt mm
mm
3G10 Drive belt 6～8 9～11
Generator belt 7～9 11.5～13.5
MR479Q A/C compressor belt 6.5～7 8～9
Power steering belt 5～6 6～8
3G10 机 MR479 engine

MR479机
3G10 engine Generator belt
发电机皮带
Drive belt
A/C belt
空调皮带
动力转
Power
steering belt
向皮带
Fig.1-1
Note:
Check the belt distortion at the specified point (see Figure 1-1).
When mounting a new belt, set the tensioning force to specified value
After the belt has been operated more than 5 minutes, check and ensure the distortion not
exceeding specified
After the belt is re-mounted and operates more than 5 minutes, check the distortion based on old belt
distortion.
Check the tensioning force and the distortion of the V-belt after the crankshaft of the engine has
rotated 2 turns.
10. Check the ignition timing.
(1)Start the engine to warm up;
(2) Use the diagnosis tester:
17
① Connect the tester the diagnosis socket;
② Observe the engine water temperature to be above 80℃;
③ Select the ignition timing activation order;
④ Use the timing lamp to check the ignition timing
Ignition timing: BTDC at idle speed, for 3G10: 10°±20′ MR479Q: 10°±20′
Tips: Refer to the User’s Manual for Diagnosis Tester when using.
Notes:
Check the ignition timing with the transmission placed at neutral position.
Check when the engine runs at idle speed.
11. Check the engine idle speed
(1) The engine warms up.
(2) Check the idle speed: 3G10: 830±30 r/min；479Q：800±50r/min。
Note:
Check idle speed when the cooling fan motor is disconnected.
Switch off all the electric accessories and air conditioners.
12. Check the compression pressure (see Figure 1-2).
(1) Warm up and switch off the engine.
(2) Remove the high tension cable.
(3) Remove the spark plug.
(4) Check the compression pressure in the cylinder.
a. Insert the pressure gauge into the spark plug hole.
b. Throttle widely opens. Fig.1-2
c. Rotate the engine crankshaft and measure the compressing pressure (see Table 2).
Table 2
3G10 MR479Q
Cylinder compressing pressure (KPa)
1250 1250
Pressure difference range of each cylinder of this model (KPa) 100
Minimum compressing pressure (KPa) 980
Note:
The electric quantity in the battery should be always enough, and the engine speed should be not
less than 250r/min.
Check the compression pressure in other cylinders in the same way.
Measure as soon as possible.
18
Tip:
If the compression pressure is improved after the oil is filled, the piston ring or the cylinder may be
worn or damaged.
If the pressure is still low, the valve may be jammed or sealed badly, or the gasket may be leaked.
13. Check CO/HC.
(2) Keep the engine running at a speed of 2500 r/min for about 180s.
(3) At idle speed, insert the test bar of CO/HC instrument into exhaust pipe at least 40cm;
(4) Check the concentration of emission of CO/HC at idle speed and at a speed of 2500 r/min
respectively.
Tip:
Measure within 3 minutes.
Test the concentration of emission andλof CO/HC at idle speed and at a speed of 2500 r/min
respectively according to GB18352.3-2005 standard.
(5) If the concentration of CO/HC is not up to standard, carry out diagnosis by following the steps below.
a. Check oxygen sensor.
b. Refer to Table 3 to find possible causes, check and repair
19
Engine—Engine Assembly— Removal of the Engine Assembly from the Vehicle
II. Removal of the Engine Assembly from the Vehicle
1. Avoid gasoline overflowing (Disconnect from the fuel tank and burn the fuel up).
2. Turn on the radiator drain plug and receive the coolant with a container.
3. Disconnect the engine inlet and outlet water pipes and discharge the
coolant.
4. Remove the air filter assembly with hose (see Figure 1-3 for MR479Q)
(1) Detach the vent pipe from the hose of air filter;
(2) Loose the clamp bolts on throttle body and disconnect the air filter hose;
(3) Remove 3 bolts and the air filter assemblies。
5 Remove the battery connectors and battery assembly. Fig. 1-3
6. Remove the battery support.
7. Remove fuel pipes
8. Disconnect A/C high pressure pipe and low pressure pipe from A/C compressor.
9. Disconnect the inlet and outlet water pipes from heater.
10. Unscrew the nut and remove the throttle control cable.
11. Remove left and right front wheels.
12. Detach the harness connectors connecting to the vehicle body.
13. Remove the front exhaust pipe assembly
14. Remove the nuts of front wheel hub(same method for other side).
15. Detach the front wheel speed sensor(with ABS).
16. Separate the steering tie rod ball end assembly
17. Separate the front suspension arm subassembly.
18. Separate the front drive shaft assembly (see Fig. 1-4).
19. Separate the front drive shaft from the hub using a plastic hammer
20. Detach the transmission shift cable, transposition cable.
21. Detach the clutch cable Fig. 1-4
22. Loosen the engine rear mounting bolts connecting with subframe.
23. Remove the subframe assembly.
24. Remove the engine assembly together with the drive axle.
(1) Use a hoist to suspend the engine slightly;
(2) Remove 3 bolts from the right engine support (see Fig. 1-5); (2 bolts at top and 1 at bottom)
(3) Remove 3 bolts from the left engine support (see Fig. 1-6);
(4) Remove the engine together with the drive axle and lay them on the ground.
20
Engine—Engine Assembly— Removal of the Engine Assembly from the Vehicle
(5) Lift the vehicle body.
Engine left
bracket
Engine right
bracket
Fig. 1-5 Fig.1-6
21
Engine—Engine Assembly—Drive Belt Replacement
III. Drive Belt Replacement
1. Remove the drive belt from 3G10 engine (see Fig. 1-7)
(1) Loosen the fixing bolt B of tensioning wheel A

(2) Unscrew the bolt A of tension regulator to get tension ing
wheel loose.
B
(3) Remove the drive belt.
2. Install the drive belt of 3G10 engine (see Fig. 1-7)
(1) Loosen the bolt A of tensioning regulator to a less-tight

state and set the belts in order.
Fig. 1-7
(2) Slowly tighten the regulator bolt A till the belt tension
accords with requirement.
(3) Fasten the fixing nut of tensioning wheel Torque: 58N·m.
3. Remove the generator belt of MR479Q engine (see Fig. 1-8)
(1) Loosen the fixing bolt A of tensioning wheel and fixing bolt B of generator.
(2) Unscrew the bolt C of tensioning regulator to get tensioning wheel loose.
Fig.1-8 Fig.1-9 Fig.1-10
8. Remove A/C belt of MR479Q engine (see Fig. 1-9)
(1) Loosen the fixing bolt A of tensioning wheel.
(2) Unscrew the bolt B of tensioning regulator to get tensioning wheel loose.
9. Remove the power steering pump belt of MR479Q engine (see Fig. 1-10)
(1) Loosen the fixing bolt A of steering pump.
(2) Unscrew the bracket adjusting bolt B to loosen the belt pulley.
10. Install the generator belt of MR479Q engine (see Fig. 1-8)
(1) Loosen the fixing bolts of tensioning wheel and generator to a less-tight state and set up the belt
22
Engine—Engine Assembly—Drive Belt Replacement
(2) Slowly tighten the regulator bolt C till the belt tension accord with requirement.
(3) Fasten the fixing bolts of generator and tensioning regulator. Torque: 58N·m.
11. Install A/C belt of MR479Q engine (see Fig. 1-9)
(1) Unscrew the fixing bolt of tensioning wheel and regulator bolt to loosen the tensioning wheel to a
less-tight state and set up the belt.
(2) Slowly tighten the regulator bolt B till the belt tension accords with requirement.
(3) Fasten the fixing bolt of tensioning wheel and regulator bolt. Torque: 58N·m
12. Install the power steering pump belt of MR479Q engine (see Fig. 1-10)
(1) Loosen the fixing bolt of steering pump and the bracket adjusting bolt to get the fixing bracket loose,
and set up the belt.
(2) Slowly move the steering pump and its bracket till the belt tension accords with requirement.
(3) Fasten the fixing bolt of steering pump and the bracket adjusting bolt. Torque 58N.m
23
Engine—Engine Mechanical—Engine Components（3G10）
Part 2 Engine Mechanical
I. Engine Components (3G10 engine)
Component I
3G10 Air filter assy.

3G10空滤器总成
Battery
Filter
滤芯 element. Battery mounting bracket
Expansion tank Radiator assembly

膨胀箱
散热器总成
Water inlet pipe

进水管
Water Outlet pipe出水管

Cooling fan assembly
冷却风扇总成
紧耦合三元催化器
Coupling 3-way catalystic convertor Rear muffler assembly
后消声器总成
24
Engine Components (3G10 engine)
Engine 发动机右悬置
right mounting
Engine rear mounting

发动机后悬置
Engine left mounting

发动机左悬置
发动机驱动皮带及调节装置
Engine drive belt and adjuster
Engine with transmission assy

发动机带变速器总成
Left /right drive shaft
左、右驱动轴
Drive shaft, L & R
Subframe assy
副车架总成
Subframe assy.
25
II. Engine Component Assembly (3G10)
Cylinder head
气缸盖
Fuel injector assembly Cylinder head cover
喷油器总成气缸盖罩
Front cover
前端盖及安装支架 and
mounting bracket
Combination of cylinder block,

缸体、缸盖及凸轮轴等组合
head and camshaft
Cylinder block
Oil pan
Starting motor
26
Engine—Engine Mechanical—Engine Component (MR479Q)
III. Engine Component (MR479Q)
Fuel pipe subassembly
Fuel pipe clamp
Vent pipe
O-ring High tension wire

No 1 Fuel
injector fastener
Fuel injector
Gasket
O-ring
Air intake manifold
Throttle body assy.
Distributor assy.
Gasket
With power steering
strut 1
With power steering
vane pump assy. O-ring
Bypass water pipe

With power steering pump
bracket
Water inlet pipe housing

Knock sensor
Water temp.
gauge sensor
Rear end cap
Crankshaft position
sensor Water outlet pipe
Exhaust manifold
insulating panel 1
Engine oil filter assy.
Gasket
Exhaust manifold
Exhaust manifold
Generator assy. Fan belt adjuster bracket
No.1 compressor
bracket
A/C compressor
27
Engine—Engine Mechanical—Valve Clearance
IV. Valve Clearance
Valve Clearance (cold

3G10 MR479Q
state)
Air intake Valve (mm) 0.20±0.04 0.20±0.04
Exhaust valve（mm） 0.30±0.04 0.30±0.04
Adjust the valve clearance (see Figure 2-1).
Calculate the thickness of new washer to allow the Up

Cam top
clearance of the inlet valve to reach a specified value.
N=T+ (A-0.2mm)
Note:
Vehicle front
N -- Thickness of new washer
Notch
T -- Thickness of the removed washer Fig. 2-1
A -- Measured valve clearance
Calculation formula of the exhaust valve is: N= T+ (A-0.3mm).
(1) Remove the adjusting washer.
a. Rotate the crankshaft until the top of the cam is upwards.
b. The notch of the valve tappet faces toward the front.
c. Press the valve tappet down with a special tool, and place the tool between the camshaft and the
valve tappet (see Figure 2-2).
Tips:
Place one end, with a mark "9", of the special tool to the position shown in Figure 2-2 a bit aslant.
If the special tool (B) is put into a deep position too much, it will be clipped by the washer. In order to
avoid the special tool (B) being too hard to take out, put it into slowly by decreasing the inclination
angle from the air intake side.
It is difficult for the special tool (B) to insert due to the shape of the cam when inserting it from the air
intake side to the back side of No.3 cylinder (see Figure 2-2). When adjusting the washer, therefore,
it is advisable to insert from the exhaust side.
d. Press the valve tappet down alternately with the special tool (A) and (B) to check the valve clearance.
28
Engine—Engine Mechanical—Valve Clearance
Back side of the No.3 cylinder
Notch Notch
Fig.2-2 Fig.2-3
(2) Re-mount the adjusting washer.
a. Mount a new adjusting washer on the valve tappet.
b. Press the valve tappet down with the special tool (A), and remove the special tool (B).
c. Re-check the valve clearance to meet the requirement
29
Engine—Engine Mechanical—Air intake system
V. Air intake system
I. Air intake System Inspection
1. Check the air intake pipe, upper & lower housings and element of air filter for distortion, corrosion and
damage
2. Check the engine air intake hose and crankcase exhaust discharge hose for damage
3. Check if air filter element is blocked and contaminated (if slightly blocked, blow the element to remove
the dir from topt; if heavily blocked or contaminated, replace the element)
4. Check the bracket of air filter for pollutants and contamination.
II. MR479Q engine (see the figure below)
1. Clean and replace the filter element
Open two clips to separate upper housing of air filter and remove the element for cleaning or
replacement
2. Remove the air intake device
(1) Remove the bolts in front of air filter air intake pipe and remove air filter air intake pipe.
(2) Remove resonance chamber.
(3) Loosen the elastic ring clamp of steel band and disconnect the exhaust hose of crankcase from the
engine.
(4) Loosen the screw-driven hose clamp on throttle body and disconnect the engine intake hose
(5) Pull open two clips to separate upper housing of air filter and remove the element.
(6) Screw off 3 bolts fixing the lower housing of air filter and the vehicle body, and remove the bracket of
air filter.
30
Torque Specification
No. Item Spec. Qty. Torque/N.m Remark
Hexagon head bolt, spring

Air filter lower housing
1 washer and plain washer M6 3 8
and vehicle body
assembly
To fix the engine air

2 Worm-driven hose ring clamp 2 6
intake hose
Hexagon head bolt and plain Air filter air intake pipe
3 M6 1 8
washer assembly and vehicle body
III. JL-3G10 Engine (air intake system and air filter connecting with the engine together, See the figure
below)
1. Clean and replace the filter element
Open 4 clips on the housing to separate upper housing of air filter and remove the element for cleaning
or replacement
2. Remove the air filter
(1) Pull open 4 clips to separate upper housing of air filter and take out the element.
31
(2) Screw off three connecting bolts fixing lower housing of air filter and the vehicle body, and remove
lower housing
Torque Specification
No. Item Spec. Qty. Torque/N.m Remark
Hexagon head bolt, spring

Air filter lower housing
1 washer and plain washer M6 3 8
and engine
assembly
32
Engine—Engine Mechanical—Exhaust system
VI. Exhaust system
Components
For JL3G10
配JL3G10
2 7 9 11
10
1
8
5 3
4
配MR479Q
For MR479Q
6
11
4 7 9
2 10
5
1
8
3
1.Front exhaust pipe assy. 2. Exhaust pipe gasket 3. Front rubber support 4. Spring 5.Hexagon flange
bolt with shoulder 6. Front muffler heat insulating plate 7. Full metal hex flange lock nut 8. Rear muffler
assy. 9. Exhaust pipe rubber pad 10. Hexagon head bolt, spring washer and plain washer assembly 11.
Rubber hanger
Replace
1. Remove the front exhaust pipe assembly.
Unscrew off 2 hexagon flange bolts with shoulder and 2 hexagon head bolt, spring washer and plain
washer assemblies, remove front exhaust pipe assembly, exhaust pipe gasket and packing.
2. Remove the rear muffler assembly.
Remove rear muffler assembly from left and right rubber hangers.
3. Install the front exhaust pipe assembly.
Measure free length of the spring with vernier calipers
Free length: 42mm
Mount the front exhaust pipe onto exhaust manifold with new exhaust pipe gasket and packing,
assemble the rear muffler assembly and screw up the bolts.
Note: Do not reuse the removed gaskets.
4. Install the front exhaust pipe assembly.

Exhaust manifold
side
Torque: 43N·m
5. Install the rear muffler assembly

Exhaust manifold
Mount rear muffler assy. onto the front exhaust pipe assy. with a cushion
33
Engine—Engine Mechanical—Exhaust system
new gasket (see the right illustration).
Torque: 43N·m
6. Check the exhaust gas leak.
Typical Troubles and Troubleshooting of Exhaust System
1. If the exhaust pipe leaks, the rub-a-dub could be heard in engine acceleration
2. If exhaust system is blocked, the sound of backfire explosion could be heard in engine acceleration.
For trouble 1: Check if the packing of exhaust pipe is damaged.
If so, timely replace the seal; if No, check if exhaust pipe leaks due to corrosion, and timely replace the
damaged pipe
For trouble 2: Timely replace the exhaust system.
34
Engine—Engine Control System—EFI System
Part 3 Engine Control System (1.0L)
I. M7.9.7 EFI System
On board Inspection
1. Check the step motor
(1) With the engine running at idle speed, unplug the step motor connection wire and the engine RPM
should change, indicating that the motor works normally.
(2) Unplug the step motor connection wire, measure the current of its terminal with a multimeter and
when the engine runs, this terminal should have the impulse current output, indicating that ECU and step
motor control system work normally; if idle speed is unstable and differs from specified value significantly,
the step motor should be replaced. In case of no pulse current output, test again after turning on air
conditioner and if unavailable again, it indicates that ECU and the step motor control system lines have
failed.
(3) Use a diagnosis tester to examine the trouble of step motor lines.
Inspection
1. VVT solenoid control valve assembly
(1) Resistance check
(a) Measure the resistance between terminals using an ohmmeter.
Resistance value: 7.2±0.5Ω at 20°C.
(2) Action check
Connect the positive (+) conductor with the battery to Terminal 1 and negative(-)conductor with Terminal
2, and check the valve action.
Note: confirm that the valve is not jammed
Tips: Poor valve return due to entry of impurities will cause minor pressure rise toward the
advance.
2. Components of throttle body
Check the throttle body
(1) Throttle spindle shall not sway;
(2) Each pass shall not be blocked;
(3) Throttle plate shall rotate freely and act smoothly;
(4) With the throttle closed, there shall be no clearance between the throttle catch bolt and throttle lever.
Note: Do not adjust the throttle catch bolt.
3. Throttle position sensor
Resistance check
(1) Remove the wire connector of throttle position sensor
35
(2) Use an ohmmeter to measure the resistance between Pin 1 and Pin 2,
resistance: 1.6～2.4kΩ.
(3) Attach two ohmmeter probes to the sensor positive power pin and signal pin
respectively, rotate the throttle and its resistance value should increase linearly
and gradually without abrupt fluctuation, while this is contrary for Pin 2 and 3.
Note: Observe if the resistance value skips obviously when looking into the replace of resistance
value.
4. Knock sensor
1. Vibration
block
2. Housing
3. Piezoelectric
ceramic body
4. Contact
5. Electric joint
Measurement: (remove the joint) set the digital multimeter to ohm gear and attach two probes to Pin 1
and 2 of the sensor respectively, and when at normal temperature its resistance value should be greater
than 1 MΩ. Set the multimeter at mV gear, gently knock near the knock sensor using a small hammer
and there should have the voltage signal output.
5. Water temperature sensor
Within this sensor is encompassed the NTC thermistor and its resistance value varies with ambient
temperature, thus even minor change of outside temperature can be measured accurately and timely.
The temperature of contact medium can be shown according to its output resistance. Where, Terminal A
and C output the signal to ECU, Terminal B and earth terminal output the signal to the gauge.
Working Principle (see Fig. I):
Note: A, B and C represent three pins of the sensor; see the pin foot for their marks.
Test with a multimeter: temperature sensor resistance – temperature characteristic
Range of
Resistance of Terminal A & C( KΩ)
temperature(℃)
-20±0.1 13.71—16.49
Instrum
25±0.1 1.825—2.155 ent
80±0.1 0.303—0.326
110±0.1 0.138—0.145
Terminal B resistance(Ω)
Fig. 1
50±0.2 176—280
80±0.2 63.4—81.4
110±0.2 24.6—30.6
6. Air intake temperature sensor
36
Temperature
Air intake temperature sensor NTC resistor
characteristic curve
The air intake temperature sensor is a resistance with negative temperature coefficient (NTC), and the
resistance changes with temperature. This sensor will deliver to the controller a voltage showing change
of air intake temperature.
Simple measurement:(remove the joint) set the digital multimeter to the ohm gear and attach two probes
to Pin 1 and 2 of the sensor respectively; at 20℃, the rated resistance is 2.5KΩ±5%, other
corresponding resistance values may be determined from the characteristic curve above. Simulation
method may also be used; specifically, blow the air to the sensor with a electric fan (not to close) and
observe the change of sensor resistance, here the resistance should drop.
7. Step motor Idle speed actuator step motor
Schematic and Pins
Pins: Pin A to ECU Pin 22 Electric

circuit of
idle speed
Pin B to ECU Pin 21 actuator
step motor
Pin C to ECU Pin 35
Idle speed actuator
Pin D to ECU Pin 36 step motor
Service notices:
1. Never attempt to axially apply force to press in or pull out the shaft;
2. Before the idle speed regulator of step motor installed into the throttle body, its shaft must be at
fully-retracted position;
3. Clean and maintain the bypass air passage;
4. After removal of battery or ECU, timely cause the step motor to learn itself.
M7 system self-learning method: turn on the ignition switch but do not start the engine instantly, wait 5
seconds and start the engine. Here, if the engine idling is detected poor, repeat the steps described
above.
● Simple measurement: (remove the joint) set the digital multimeter to the ohm gear and attach two
probes to Pin AD and Pin BC of the regulator; at 25℃, the rated resistance is 53±5.3Ω
37
Engine—Engine Control System—Throttle Body Assembly
II. Throttle Body Assembly
Removal, Installation and Dismantlement, Assembly
1. Drain the coolant
2. Remove the air filter hose assembly.
3. Remove the components of engine plastic hood
4. Remove the throttle cable assembly.
5. Remove the throttle body assembly.
(1) Remove the throttle position sensor connector and the step motor connector;
(2) Take apart the vent hose
(3) Remove 2 bolts and throttle control cable support;
(4) Remove 2 throttle preheater inlet and outlet water pipes;
(5) Remove 2 bolts and 2 nuts, remove the throttle body from air intake manifold.
6. Remove the step motor of throttle body.
Remove 3 screws and the step motor.
7. Install the step motor of throttle body
Install the step motor.
8. Install the throttle body assembly
(1) Set the new sealing gasket onto the air intake manifold.
(2) Mount 2 bots and 2 nuts of the throttle body
Torque: 25±5N．m
9. Add the coolant.
10. Check the coolant for leakage.
38
Engine—Electric Injection—System Components
Part 4 Engine Control System (1.3L Delphi MT20U2)
I. System Components
Engine management system hardware works under the control of engine control module(ECM) and
consists of such subsystems as the control & signal acquisition, fuel supply, ignition, air intake control,
exhaust control, trouble diagnosis and communication.
Engine Management
发动机管理系统
System
(EMS)
Control Signal Acquisition Fuel Supply Ignition Air Intake Control Exhaust Control Fault Diagnosis and
控制信号采集系统 System
供油系统
System 点火系统
System
进气控制系统 System
排放控制系统
System
故障诊断及通讯系统
Communication System
Control & Signal Acquisition

控制及信号采集系统 System
Engine Control Unit

发动机控制单元(ECM)
（ECM）
EMS Control Harness

发动机管理系统
控制线束
Crankshaft Speed &

曲轴转速及位置 Air Intake Manifold
进气歧管压力冷却液温度
Coolant 排气氧含量
Exhaust Oxygen Throttle Position
节气门位置 Air Intake
进气温度 Vehicle
车速
Position Sensor Pressure Sensor Temperature sensor Sensor Temperature Speed
传感器传感器传感器
Sensor 传感器传感器传感器
Sensor 传感器
Sensor
Fuel Supply System

供油系统
油泵总成
Fuel Pump Assy.
管路
Pipeline
油轨总成
Fuel Rail Assy.
Fuel
油泵
Pump 油位传感器
Oil level Sensor Oil inlet Pipe
进油管 Filter
滤清器 Oil inlet Pipe
进油管 Oil rail
油轨油压调节器
Oil pressure
Regulator 进油管
Inlet Pipe
进气控制系统
Air Intake Control System
(Throttle Valve Body)
点火系统
Ignition System
（节流阀体）
Valve Body Throttle Sensor

点火线圈
Ignition Coil Spark Plug Lead
火花塞引线 Spark Plug
火花塞阀体节气门传感器怠速控制阀
Idle Control Valve
排放控制系统
Exhaust Control System
Fault Diagnosis/Communication and Anti-theft
故障诊断/通讯及防盗系统 System
尾气排放控制
Exhaust Gas Control
蒸发排放控制
Evaporative exhaust
Control 故障诊断及通讯 Fault
Diagnosis/Communication 防盗器控制
Anti-theft Alarm
Control
氧传感器
Oxygen sensor
三元催化器
3-way Catalyst
Convertor 碳罐电磁阀
Canister Solenoid System Communication
系统通讯接口Interface
Engine Fault Indicator
发动机故障指示灯防盗控制器
Anti-theft Controller
密码发射器
Password Emitter
39
List of Basic Function Parts and Components of Delphi MT20U2 EMS
No. Part name Qty. No. Part name Qty.
Engine control
1 1 Fuel rail assy 1
module(ECM)
12
2 Crankshaft position sensor 1 Fuel injector 4
3 Air intake manifold pressure 1 Fuel pressure regulator 1
Air intake manifold

4 1 13 Gasoline pump assy 1
temperature
Air intake manifold

5 1 14 Ignition coil assy. 1
pressure/temperature
Throttle valve body

6 Coolant temperature sensor 1 1
assembly
15
7 Oxygen sensor 2 Idle speed control valve 1
8 Camshaft position sensor 1 Throttle position sensor 1
Canister control solenoid

9 Knock sensor 1 16 1
valve
Vehicle speed
10 sensor(provided by vehicle 1 17 3-way catalyst convertor 1
manufacturer)
A/C evaporator temperature G sensor or ABS wheel

11 1 18 1
sensor speed sensor(option)
1. Engine control module(ECM)
(1) CPU parameters: 16-bit core chip
32M clock frequency
256K FLASH memory
12K RAM memory
4K EEPROM memory
(2) Working parameters
(a) Range of working voltage
Range of normal working voltage: 9.0V～16V
Overvoltage and reverse polarity protection: +24V/-12V＜60 sec.
(b) Installation
MT20U2 ECM is designed to be installed within the engine compartment (but not on the engine body),
however should be placed for easy service.
40
ECM housing and fixing bolts must be electrically insulated from the chassis.
(C) Temperature
Storage temperature: -40～125℃
Working temperature: -40～105℃
Function MT20U2发动机控制模块功能图
chart of MT20U2 Engine Control Module
12V battery power 12V电瓶电源
supply Ignition coil A/B(Cylinder 1/4)
点火线圈A/B(1/4缸)
supply
点火系统
12V ignition power 12V点火电源
supply Ignition coil A/B(Cylinder 2/3)
点火线圈C/D(2/3缸)
控制
系统电源控制
Ignition
system
control
12V power supply earth wire
12V电源地线 Ignition coil点火线圈
power
5V sensor reference supply
5V传感器参考电源 Ignition coil点火线圈
5V sensor reference supply earth
5V传感器参考电源接地
Injector A (Cylinder 1)
System
control
Ignition module点火模块驱动器接地
driver earth 喷油器A(1缸)
Fuel injection
喷油嘴控制 control
主电源继电器控制
Main power supply relay control Injector B (Cylinder 3)
喷油器B(3缸)
Injector (Cylinder
喷油器(4缸) 4)
nozzle
进气歧管压力传感器（MAP）
Intake manifold pressure (MAP) sensor Injector (Cylinder
喷油器(2缸) 2)
Throttle position sensor (TPS)
节气门位置传感器（TPS）
Idle speed valve control coil A(HI)
进气温度传感器（IAT）
Air intake temperature (IAT) sensor 怠速阀控制线圈A(HI)
valve
怠速阀控制
MT20U2
模拟信号输入
Idle speed valve control coil A(LO)

Coolant temperature sensor (CTS)
冷却液温度传感器（CTS）怠速阀控制线圈A(LO)
Analog signal input
Engine Idle speed valve control coil B(HI)

前氧传感器（F-02）怠速阀控制线圈B(HI)
发
control
Front oxygen sensor (F-02) Control

Idle
后氧传感器（R-02）
Rear oxygen sensor(R-02) Module 怠速阀控制线圈B(LO)
Idle speed valve control coil B(LO)
(ECM)
油箱油位传感器
Tank fuel level sensor 动
加速度传感器（G）
Acceleration sensor (G) Fuel pump relay
燃油泵继电器
机
System components
supply control
废气再循环反馈信号（LEGR）
Linear exhaust gas recirculation (LEGR) signal Front oxygen sensor heating
前氧传感器加热
系统部件
电源控制
控 Rear oxygen sensor heating

后氧传感器加热
58X engine58X发动机转速及曲轴位置传感器
revolution speed and crankshaft Canister solenoid valve
碳罐电磁阀
频率信号输入
制
power
position sensor
signal input
凸轮轴位置传感器 LEGR废气再循环阀(LEGR)
Frequency
valve
Camshaft position sensor
Knock sensor
爆震传感器模
车速传感器 A/C clutch relay
空调离合器继电器
supply
Vehicle speed sensor

块
附件电源控制
A/C rear evaporator shutoff valve

空调后蒸发器切断阀
Front-mounted A/C evaporator temperature
Accessories
sensor 前置空调蒸发器温度传感器
(ECM) A/C 空调冷凝器风扇继电器
condenser fan relay
Accessories control signal
control
Rear-mounted A/C evaporator temperature

附件控制信号输入
后置空调蒸发器温度传感器散热器低速风扇继电器
power
Radiator low-speed fan relay

sensor 空调请求开关散热器高速风扇继电器
Radiator high-speed fan relay
A/C request switch
鼓风机开关
Blower switch
大灯开关 Engine revolution
发动机转速 speed
Headlight switch
Coolant temperature
仪表信号
P/N position switch P/N档位开关冷却液温度

input
Instrument
助力转向开关
Power-assisted steering switch 油量信号
Oil level signal
signal
System系统故障指示灯
fault indicator lamp
Other其他系统故障指示灯
system fault indicator lamp
Electronic电子防盗器
anti-theft alarm
Anti-theft
commun
通讯
Electronic anti-theft signal

防盗
ication
KW2000通讯
and及
KW2000 communication 电子防盗器信号

Anti-theft
diagnosi
信号
诊断
, 防盗
s signal
Fault diagnosis request signal

CAN bus CAN总线通讯
communication 故障诊断请求信号
基本功能
Basic function Optional选装功能
function
2. Crankshaft position sensor
(1) Performance
41
No need of power supply;
Temperature range: -40～150℃
Output voltage: increasing with revolution speed
(400mV@60RPM)
Clearance with 58×ring gear: 0.3～1.5mm;
Coil resistance: 560Ω±10%@25±5℃;
Coil inductance: 240mH±15%@1KHz
(2) Mounting position
The sensor is mounted in a place vertical to the crankshaft and

works with 58× ring gear installed on the crankshaft.
(3) Connectors
Terminals:
Tailed terminals: A - signal +, B - signal -, C- shielded layer;
Tailless terminals: A – signal +, B – signal -.
3. Air intake temperature sensor
(1) Performance
Working voltage: 5V DC
Dissipation constant: 9Mw/℃
Thermal response time: ＜15sec.;
Air Intake Temperature Sensor Unloaded Resistance -

Temperature Characteristic Table:
Temp. Resistance Reference Temp. Resistance Reference Temp. Resistance Reference Temp. Resistance Reference
Accuracy Accuracy Accuracy Accuracy
(2)Mechanical properties
Hexagon nut: 18.90mm
Thread size: M12×1.5
Effective seal pressure: 145KPa
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Mounting torque: 60Nm
(3) Mounting position:
Generally, the air intake temperature sensor is mounted on the intake pipe before throttle body or the
engine air cleaner.
(4) Connectors:
Terminals: A – signal ground, B – temperature signal.
4. Air intake manifold absolute pressure sensor
(1) Performance
Pressure range: 15～102kpa
Working voltage: 5.0±0.1V
Working current: 12mA(max.)
Output impedance: ＜10Ω
DC load: 30kΩ(min.)
51kΩ(recommendation)
Output function: Eo=Er(0.01059P-0.10941)(P unit is kpa).
Generally, it is mounted on the stabilized pressure chamber of intake manifold;
While the use of manifold pressure for cylinder detection requires it be mounted on Cylinder 1 or 4 air
passage of intake manifold
(3) Connectors: Terminals: A – signal ground, B – pressure signal, C - +5V.
5. Air intake manifold pressure/temperature sensor
(a) Manifold pressure sensor:
Pressure range: 10～110kpa
Working voltage: 5.0±0.1V
Working current: 12mA(max.)
Output voltage: -100～100mV
Output impedance: ＜10Ω;
DC load: 30kΩ(min.), 51kΩ(recommended);
Pressure sensor output function: Eo=Er(0.01059P-0.10941)
P unit is kpa; the reference values are listed below(only for reference):
43
Engine—Electric Injection— System Components
Pressure(kpa) 15 40 94 102
Output voltage(V) 0.12～0.38 1.52～1.68 4.44～4.60 4.86～5.04
(b) Air intake temperature sensor:
Air Intake Temperature Sensor Unloaded Resistance - Temperature Characteristic Table:
Temp. Resistance Reference Temp. Reference Temp. Resistance Reference Resistance Reference
Resistance Temp.
Accuracy Accuracy Accuracy Accuracy
Typical working voltage: 5V DC;
Working temperature: -40～135℃;
Dissipation constant: 9mW/℃;
Thermal response time: ＜15 sec.;
For the model using the manifold pressure for cylinder identification,
this sensor is mounted on the pipe of engine’s cylinder 4 intake
manifold.
For the model using the camshaft position sensor for cylinder
identification, this sensor is mounted on the stabilized pressure
chamber of the engine.
(3) Connector:
Terminals: A- pressure signal, B - +5V, C – temperature signal, D – signal ground.
(4) Instructions for operation and maintenance:
This sensor should be mounted at an angle less than 30°with vertical direction to avoid the condensate
on terminals retaining in the sensor. Any installation against these instructions will directly affect the
sensor reliability and durability.
When necessary, the sensor may be cleaned with isopropyl alcohol and air dried. Immersion time with
isopropyl alcohol shall not be longer than 1min and during the cleaning, prevent the washing solution
from entering the sensor
6. Coolant temperature sensor
(1) Performance
Typical working voltage: 5V DC;
Dissipation constant: 25mW/℃;
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Thermal response time: 17～27 sec.
(2)Mechanical properties
Hexagon nut: 18.90mm
Thread size: M12×1.5;
Effective seal pressure: 145KPa;
Mounting torque: 20Nm.
The coolant temperature sensor is usually mounted on main water passage of the engine.
(4) Connectors: terminals: A – signal ground, B – temperature signal
7. Camshaft position sensor
(1) Performance
Working voltage: 4.5～13V;
Working clearance:0.3～2mm
It is mounted near the camshaft.
(3) Connectors: terminals: A – signal, B – signal ground, C - +5V
8. Knock sensor
(1) Performance
Output signal: Frequency Output signal
5kHz 17～37mV/g
8 kHz +15% at 5kHz
13 kHz +30% at 5kHz
18 kHz Double at 13kHz
In any case ＞17 mV/g
Frequency response range: 3～18 kHz
Capacitance:1480～2220pf@25℃@1000Hz
Resistance:＞1M@25℃
This sensor is mounted at the location sensitive to engine knock.
Due to relatively weaker sensor signal, the sensor's lead is the shielded wire.
45
(3) Connectors: terminals: A – signal, B – earthing through the shield.
9. Oxygen sensor
(1) Features: waterproof;
No need of air penetration and filtration device;
Resistance to high temperature, backpressure and thermal

impact;
Ultra-low temperature property;
Ultra-strong antipoisoning ability;
Low energy consumption heater;
This sensor uses teflon insulated wire and stainless steel elements.
(2) Performance
Performance parameters
Temperature 260℃ 450℃ 595℃
Rich output voltage(mV) ＞800 ＞800 ＞750
Thin output voltage(mV) ＜200 ＜200 ＜150
Thin to rich response time(ms) ＜75 ＜75 ＜50
Rich to thin response time(ms) ＜150 ＜125 ＜90
Internal resistance (Ω) ＜100K
Max. working temperature(continuous): exhaust temperature:＜930℃
Temperature at the mounting support:＜600℃
Temperature at 6 corners of outer housing: ＜500℃
Temperature at wire and sleeve: ＜275℃
Temperature at wire gasket: ＜250℃
Temperature at connector: ＜125℃
Storage temperature: -40～100℃
Recommended working condition: exhaust temperature: 200～850℃
Allowed content of fuel impurities: lead – below 0.005g/L
phosphor – below 0.0002g/L
sulfur – below 0.04%(weight ratio)
silicon – below 4ppm
MMT – below 0.0085g/L
Engine oil consumption is not above 0.02L/hr.
46
Mounting position: this sensor is mounted between the exhaust valve and 3-way catalyst.
Connectors: A –low signal, B –high signal; C -heating power -, D – heater power +.
10. Fuel rail
It is mounted on the air intake manifold.
11.Fuel injector
(1) Features:
Min. working voltage: 4.5V
Coil resistance:12±0.4Ω
It is fixed to the air intake manifold through the fuel rail.
(3) Connectors: A - +12V, B – ECM
12. Fuel pressure regulator
Pressure invariableness: oil return type: 300kpa±2%(static);
Non-fuel-return type: 350kpa±2%
Flow limit of pressure regulation: 3～60g/s
Min. explosion pressure: 2000MPa.
For model of fuel-return design, the regulator is mounted at the end of fuel rail.
For model of non-fuel-return design, the regulator is mounted on the fuel pump assy.
13. Fuel pump assembly
(1) Features:
Fuel pump: Output pressure: ＞350kpa;
Output flow: ＞10g/s;
Safety pressure relleased: ＜900kpa;
Pressure holding: 24 kpa;
Working voltage: 8～16V;
Overpressure protection: -13.5～26V(＜60 sec.);
47
Engine —Electric Injection —System Components
Operation without fuel: ＜60sec.
Fuel level sensor: resistance ＜130Ω;
Max. working current: ＜150mA.
The assembly is integrally built in the fuel tank.
(3) Connectors:
1×4 type: A- relay, B – instrument, C- instrument, D – ground;
2×2 type: A- instrument, B – relay, C- ground, D –instrument;
3-wire connector: A – system ground, B – fuel pump +, C –
fuel level sensor +.
14.Ignition coil
(1) Features:
Primary resistance: 0.5±0.05Ω;
Secondary resistance: 9840±980Ω;
Primary inductance: 2.75±0.25mH
Secondary inductance: 17.5±1.2H;
Voltage range：6～16V；
Interruption current peak: 9.5A;
Secondary output voltage: 34KV;
Shortest duration of ignition: 0.8ms.
Ignition coil may be in the engine compartment or on the engine
(3) Connectors: terminals: A – Cylinder1-4 drive, B - +12V, C – Cylinder 2-3 drive.
15. Throttle body
(1) Features:
Diameter of valve hole: depending on the engine displacement;
It is mounted before the air intake manifold.
48
16. Throttle position sensor
(1) Features:
Range: 7%～93% opening;
Working voltage: 5.0±0.1V;
Close throttle: 12% of reference voltage;
Fully opened throttle: 83%～93% of reference voltage;
AB impedance: 3k～12kΩ;
This throttle position sensor is mounted on the throttle body

assembly and shares the shaft with accelerator rod and throttle valve
plate.
(3) Connectors:
Terminals: A - +5V, B – signal ground, C – throttle position signal.
17. Idle speed control valve
(1) Features:
Coil resistance: 53Ω±10%;
Coil inductance:33mH±20%;
Working voltage: 7.5～12V;
Limiting voltage: 3.5～14V.
In this model, this valve is mounted on the throttle body
(3) Connectors:
Terminals: A – coil B-, B – coil B+, C – coil A-, D – coil A+.
18. Canister control solenoid valve
(1) Features:
Rated overvoltage: +12V
Range of working voltage: 8～16V;
Limiting voltage: 25V(＜60s)
Coil resistance:19~20Ω
Coil inductance: 12～15mH.
49
This valve is mounted between fuel vapor canister and air intake
manifold and the engine compartment
(3) Connectors:
Terminals: A – ECM, B - +12V.
50
Engine—Electric Injection—On-Board Diagnostic (EOBD)
II. On-Board Diagnostic (EOBD)
1. Description of EOBD
After the system begains to work and the engine runs, ECM controls the operation of all system
components and detects those connected with it. When one or several components work abnormally, the
system will automatically alarm, every malfunction state is assigned with an exclusive code, and so long
as malfunction occurs, the system will send this code (i.e. trouble code) via the diagnostic interface and
simultaneously activate the "engine malfunction indicator” to inform the driver for timely service. A trouble
code indicates the possible location of malfunction
In the event of malfunction, the system may also use the temporary emergency plan to control the
engine operation to ensure that the user may drive to the service station instead of breaking down on the
way.
2. Description of malfunction indicator (MI)
MI is an indicator connected with on-board diagnostic (OBD) system to inform the driver
when any emission related component or OBD system develops a trouble, as shown by
the right schematic
3. Criteria of MI action
MI must be activated at the required moment when the malfunction of a component or system causes
the vehicle emission to exceed regulatory requirements. Based on the effects of trouble affecting the
emission, MI is activated as per the followings:
Code of trouble affecting emission:
Class A: MI lights up and trouble code is recorded for a single occurrence;
Class B: MI lights up and trouble code is recorded for occurrence once in two continuous strokes
Class E: MI lights up and trouble code is recorded for an occurrence in three continuous strokes each;
Code of trouble not affecting emission:
Class C: trouble code is recorded with MI off, the manufacturer may turn on SVS lamp based on needs.
Class D: trouble code is recorded with no MI on.
Turnoff of MI: In three continuous strokes, if detection system for MI activation fails to detect a trouble or
does not detect other malfunction which may separately activate MI, then MI turns off.
Elimination of trouble code: if one malfunction does not occur in over 40 engine warm-up cycles again,
OBD system will clear this trouble code and the mileage at the time of its occurrence and freeze the data
information.
Note: A stroke refers to a drive cycle where all OBD tests could be completed and it may take the testing
procedure (Part I and Part II) of National III Emission Standard as standard.
51
4. Detailed explanation of diagnostic trouble code (DTC)
DTC List of DELPHI MT20U2 Engine Management System

Trouble Trouble
Description Class Description Class
code code
P0106 MAP/TPS signal rationality E P1392 Sensor G voltage too low C
P0107 Manifold pressure sensor circuit voltage too low A P1393 Sensor G voltage too high C
P0108 Manifold pressure sensor circuit voltage too high A P0325 Knock control system fault C
P0112 Intake air temperature sensor circuit voltage too low E P0327 Knock sensor circuit fault C
P0113 Air intake temperature sensor circuit voltage too high E P0336 Crankshaft position sensor circuit performance problem E
P0117 Coolant temperature sensor circuit voltage too low A P0337 Crankshaft position sensor circuit fault A
P0118 Coolant temperature sensor circuit voltage too high A P1336 Crankshaft position gear information unlearned A
P0122 Throttle position sensor circuit voltage too low A P0342 Camshaft position sensor circuit no signal A
P0123 Throttle position sensor circuit voltage too high A P0351 Ignition circuit 1 fault A
P0131 Front oxygen sensor circuit voltage too low E P0352 Ignition circuit 2 fault A
P0132 Front oxygen sensor circuit voltage too high E P0420 Catalyst efficiency below threshold A
P0133 Front oxygen sensor response slow E P0443 Canister purge circuit failure E
P0134 Front oxygen sensor activity inadequate or open circuit A P0462 Fuel level sensor circuit input too low C
P0135 Front oxygen sensor heater circuit can’t work A P0463 Fuel level sensor circuit input too high C
P1167 Front oxygen sensor AFR high in DFCO mode E P0480 Fan 1 fault C
P1171 Front oxygen sensor AFR low in PE mode E P0481 Fan 2 fault C
P0137 Rear oxygen sensor circuit voltage too low E P0482 Fan 3 fault C
P0138 Rear oxygen sensor circuit voltage too high E P0483 PWM fan fault C
P0140 Rear oxygen sensor activity inadequate or open circuit E P0502 No vehicle speed signal E
P0141 Rear oxygen sensor heater circuit can’t work A P0506 Idle speed control system fault – revolution speed too low E
P0171 Fuel correction too thin E P0507 Idle speed control system fault – revolution speed too high E
P0172 Fuel correction too rich E P0562 System voltage high C
P0201 Cylinder 1 injector circuit failure A P0563 System voltage low C
P0202 Cylinder 3 injector circuit fault A P0532 A/C pressure circuit voltage too high C
P0203 Cylinder 4 injector circuit fault A P0533 A/C pressure circuit voltage too low or open C
P0204 Cylinder 2 injector circuit fault A P1545 A/C clutch output circuit fault C
P0230 Fuel pump relay fault C P2001 Rear A/C evaporator sensor fault C
P0300 Misfire B/A P0615 TCM fault A
DTC P0106: unreasonable correspondence between manifold absolytely pressure sensor signal and
throttle position sensor signal.
Test condition: no DTC relevant to manifold absolute pressure sensor, throttle position sensor and
coolant temperature sensor.
Malfunction judgement: altitude compensating intake pressure value exceeds the limits set by the control
system based on the engine RPM and throttle opening
Emergency control plan: disable the fuel correction pulse width
Do not update self-learning value anymore
Prohibit adjusting the target idle speed
Do not update atmospheric pressure anymore
Possible causes: MAP sensor trouble
Sensor pick-up hole blocked
The circuit between MAP sensor and ECM damaged
Poor connection
DTC P0107: MAP sensor circuit voltage too low
Test condition: no malfunction of throttle position sensor
Battery voltage higher than 11.45V
Engine speed lower than/equal to 1000RPM and throttle opening above 0%, or the engine speed higher
than 1000RPM and throttle opening above 5%.
Malfunction judgement: ECM detects that manifold pressure is 12kpa
Emergency control plan: disable the fuel trim pulse width
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Take MAP value as the default
Possible causes: between MAP sensor and ECM develops a short circuit to ground or open circuit
MAP sensor trouble
Poor connection
Engine air intake system abnormal
DTC P0108: MAP sensor circuit voltage too high
Test condition: no malfunction of the throttle position sensor
Engine running time longer than 2 sec
The engine speed lower than/equal to 2400RPM and throttle opening below 2.7%, or the engine speed
higher than 2400RPM and throttle opening above 10%
Malfunction judgement: ECM detects that manifold pressure value is greater than 103kpa
Emergency control plan: disable the fuel trim pulse width
Take MAP value as the default
Possible causes: between MAP sensor and ECM develops a short circuit to ground or open circuit
MAP sensor trouble
Poor connection
Engine air intake system abnormal
DTC P0112: IAT sensor circuit voltage too low
Test condition: no malfunction of the vehicle speed sensor
Vehicle speed greater than 50km/h
Engine running time longer than 60 sec.
Malfunction judgement: ECM detects that IAT sensor signal voltage is less than 0.1V
Emergency control plan: use the system default air intake temperature value.
Possible causes: between IAT sensor and ECM develops a short circuit to ground.
Sensor trouble
Poor connection
DTC P0113: IAT sensor circuit voltage too high
53
Test condition: no malfunction of vehicle speed sensor and coolant temperature sensor
Vehicle speed lower than 25km/h
Coolant temperature greater than 70℃
Engine running time longer than 60 sec
Malfunction judgement: ECM detects that IAT sensor signal voltage is higher than 4.9V
Emergency control plan: use the system default air intake temperature value
Possible causes: between IAT sensor and ECM develops a short circuit to power supply or open circuit
Poor connection
Ground wire open circuit
DTC P0117: coolant temperature sensor (CTS) circuit voltage too low
Test condition: the engine running time longer than 60 sec
Malfunction judgement: ECM detects that CTS signal voltage is too low and indicated temperature is
higher than 149℃
Emergency control plan: Control system estimates the maximum temperature not exceeding 90.75℃ as
per the default formula based on the engine running time and air intake temperature
After trouble code setup, high-speed fan starts working after 0.5sec.
Possible causes: between CTS and ECM develops a short circuit to ground.
Poor connection
CTS trouble
DTC P0118: coolant temperature sensor (CTS) circuit voltage too high
Test condition: the engine running time longer than 60 sec.
Malfunction judgement: ECM detects that CTS signal voltage is too high and indicated temperature is
below -38℃.
Emergency control plan: Control system estimates the maximum temperature not exceeding 90.75℃ as
per the default formula based on the engine running time and air intake temperature.
After trouble code setup, high-speed fan starts working after 0.5sec.
Possible causes: between CTS and ECM develops a short circuit to power supply or open circuit
Ground wire open circuit
Poor connection
CTS sensor trouble
DTC P0122: throttle position sensor (TPS) circuit voltage too low
Test condition: the engine in operation
Malfunction judgement: ECM detects that TPS signal value is less than 2.8%
Emergency control plan: estimate the throttle opening based on engine RPM
54
Possible causes: between TPS and ECM develops a short circuit to power supply or open circuit
Poor connection
TPS trouble
DTC P0123: throttle position sensor (TPS) circuit voltage too high
Malfunction judgement: ECM detects that TPS signal value is greater than 98%
Emergency control plan: estimate the throttle opening based on engine RPM
Possible causes: between TPS and ECM develops a short circuit to power supply or open circuit
Poor connection
TPS trouble
DTC P0131: front oxygen sensor (O2A) circuit voltage too low
Test condition: no trouble code like P0106, P0171 and P0172, no trouble code relating to MAP sensor,
CTS, TPS, fuel injector, misfire, crankshaft position sensor, ignition system, idle speed control system
and canister cleaning circuit.
Coolant temperature higher than 70℃
System voltage higher than 10V
Malfunction judgement: ECM detects that oxygen sensor signal value is less than 0.03 V
Emergency control plan: stop the closed loop fuel control
Possible causes: between oxygen sensor and ECM develops a short circuit to ground
Insufficient fuel injection due to blockage of fuel pump, fuel supply pipeline or fuel injector
Fuel pressure regulator damaged
Poor grounding from ECM to the engine block
Air intake vacuum leak
Exhaust pipeline leaking
Fuel contamination
DTC P0132: front oxygen sensor (O2A) circuit voltage too high
Malfunction judgement: ECM detects that oxygen sensor signal voltage is higher than 3.8V
Possible causes: between oxygen sensor and ECM develops a short circuit to ground.
55
Fuel pressure too high
Fuel injection leaking
DTC P0133: front oxygen sensor (O2A) response slowly
1600RPM＜engine revolution speed＜3000RPM
Malfunction judgement: the time of oxygen sensor response to the change of oxygen concentration in
exhaust gas exceeds the limit set by the system
Possible causes: heavy metal poisoning or phosphorus/sulfur poisoning of oxygen sensor due to fuel
contamination
Carbon poisoning of oxygen sensor due to large engine oil consumption
DTC P0134: insufficient activity or open circuit of front oxygen sensor
Malfunction judgement: ECM detects that oxygen sensor signal voltage is higher than 1.3V but lower
than 3.8V
Possible causes: poor circuit contact or damaged circuit between oxygen sensor and ECM
Trouble of oxygen sensor heater circuit or the heater
Exhaust gas leaking
Fuel contamination
Excessive engine oil consumption
DTC P0135: front oxygen sensor (O2A) heater does not work
Test condition: the engine running time longer than the setting
Malfunction judgement: ECM detects that voltage of heater circuit is continuously too high or low
Possible causes: between the heater and ECM develops a short circuit to power supply, a short circuit to
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ground or open circuit
Poor connection
Heater damaged
DTC P1167: In DFCO mode, front oxygen sensor (O2A) indicates a rich air fuel ratio.
Engine gets into the deceleration fuel cutoff (DFCO) mode
Malfunction judgement: ECM detects that oxygen sensor signal voltage is higher than 0.55V
Possible causes: between oxygen sensor and ECM develops a short circuit to power supply
Fuel injector leaking
DTC P1171: In PE mode, front oxygen sensor (O2A) indicates a lean air fuel ratio.
Engine gets into the power enrichment (PE) mode
Malfunction judgement: oxygen sensor signal voltage is lower than 0.35V
Possible cause: between oxygen sensor and ECM develops a short circuit to ground
Insufficient fuel injection due to blockage of fuel pump, fuel supply pipeline or fuel injector
Poor grounding from ECM to the engine block
Intake vacuum leaking
Exhaust pipeline leaking
Fuel contamination
DTC P0137: rear oxygen sensor (O2B) circuit voltage too low
Malfunction judgement: ECM detects that rear oxygen sensor signal voltage is lower than 0.03V
Emergency control plan: disable the rear oxygen sensor signal
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Poor connection
DTC P0138: rear oxygen sensor (O2B) circuit voltage too high
Malfunction judgement: ECM detects that rear oxygen sensor signal voltage is higher than 3.8V
Poor connection
Sensor trouble
DTC P0140: rear oxygen sensor activity inadequate or open circuit
Malfunction judgement: ECM detects that oxygen sensor signal voltage is higher than 1.3V but lower
than 3.8V
Possible causes: poor connection
Short circuit to ground between oxygen sensor and ECM
Oxygen sensor trouble
DTC P0141: the circuit of rear oxygen sensor heater does not work
Malfunction judgement: the voltage of rear oxygen sensor heater is too high or low
Possible causes: between the heater of rear oxygen sensor and ECM develops a short circuit to power
supply, a short circuit to ground or open circuit.
DTC P0171: fuel correction system too lean
Test condition: no trouble code like P0106, no trouble code relating to MAP sensor, ITA sensor, CTS,
TPS, oxygen sensor, fuel injector, crankshaft position sensor, camshaft position sensor, idle speed
control system, misfire and canister cleaning circuit.
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Enter the closed loop fuel control mode
Engine RPM, coolant temperature, throttle opening and air intake pressure meeting the system default
requirements.
Malfunction judgement: the fuel self-learning value bigger than the limit set by the system
Emergency control plan: None
Possible causes: air leaking
Fuel pressure inadequate
Positive crankcase ventilation valve jammed
Fuel injector blocked
DTC P0172: fuel correction system too rich
Test condition: no trouble code like P0106, no trouble code relating to MAP sensor, ITA sensor, CTS,
TPS, oxygen sensor, fuel injector, crankshaft position sensor, camshaft position sensor, idle speed
control system, misfire and canister cleaning circuit.
Enter the closed loop fuel control mode
Engine RPM, coolant temperature, throttle opening and air intake pressure meeting the system default
requirements.
Malfunction judgement: the fuel self-learning value bigger than the limit set by the system
Possible causes: air intake system blocked
Fuel injection leaking
DTC P0201: Cylinder 1 electric circuit trouble
Test condition: system voltage higher than 9.0V
Engine speed greater than 700RPM
Malfunction judgement: the voltage of fuel injector control circuit too high or too low
Emergency control plan: get the fuel into the open-loop control
Possible causes: between fuel injector and ECM develops a short circuit to power supply, a short circuit
to ground or open circuit
DTC P0202: Cylinder 3 injector electric circuit trouble
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DTC P0203: Cylinder 4 injector electric circuit trouble
DTC P0230: fuel pump relay trouble
Test condition: the ignition switch is at the energized position and the power-on time is greater than the
limit set by the system.
Malfunction judgement: the voltage of fuel pump relay too high or too low
Possible causes: between fuel pump relay and ECM develops a short circuit to power supply, a short
circuit to ground or open circuit
Relay trouble
DTC P0300: misfire
Test condition: no trouble code relevant to MAS sensor, CTS, TPS, crankshaft position sensor, camshaft
position sensor and vehicle speed sensor.
Malfunction judgement: Under normal condition, ECM detects that the fluctuation of crankshaft rotational
speed exceeds the limit set by the system.
Emergency control plan: if the misfire is not serious, only affecting the emission, there is no such plan,
only with DTC recorded, data flow froze and MI turned on.
If the misfire is serious, causing the catalystic convertor overheating:
Positively enter the open-loop fuel control mode
Disable the rear oxygen sensor correction learning
When engine speed exceeds 2000RPM or MAP exceeds 50KPA, MI flashes at 1Hz, reminding the driver
to reduce the engine RPM and load immediately, and go to the service station for repair as soon as
possible.
Possible causes: ignition system trouble
Air leaking
Clearance of crankshaft position sensor incorrect
Ignition timing incorrect
Fuel injection trouble
Fuel pressure incorrect
Engine compression ratio incorrect
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ECU trouble
DTC P1392: G sensor signal voltage too low
Test condition: run the engine for a while
Malfunction judgement: ECM detects that G sensor output signal value is too small
Emergency control plan: determine whether to disable the misfire diagnosis without reference to the
signal of G sensor
Possible causes: between G sensor and ECM develops a short circuit to ground.
Poor connection
G sensor trouble
DTC P1393: G sensor signal voltage too high
Test condition: run the engine for a while
Malfunction judgement: ECM detects that G sensor output signal value is too big
Emergency control plan: determine whether to disable the misfire diagnosis without reference to the
signal of G sensor
Possible causes: between G sensor and ECM develops a short circuit to ground.
Poor connection
G sensor trouble
DTC P0325: the knock control system trouble
Test condition: the engine revolution speed higher than 1600RPM
Malfunction judgement: ECM detects that the mean value of cylinders’ maximum signals of knock sensor
is smaller than the threshold limit value set by the system, or the mean value of cylinders’ minimum
signals greater than the threshold limit value set by the system.
Emergency control plan: take the system default value as the spark advance angle
Possible causes: poor connection
Open circuit of the line between knock sensor and ECM
Knock sensor trouble
DTC P0327: trouble of knock sensor circuit
Test condition: engine speed above 1600RPM
Malfunction judgment: ECM detects that difference among knock signals from various cylinders is lower
than the limit value set by the system
Emergency control plan: ignition advance angle applies the default value set by the system
Possible cause: poor connection
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Signal interference
Knock sensor trouble
DTC P0336: Problem of circuit performance of crank position sensor
Test condition: engine running
Malfunction judgement: ECM detects that pulse signals of crank position sensor lose too much
Emergency control plan: none
Possible cause: poor electric connection
Noise interference
Circuit trouble between crank position sensor and ECM
Target wheel trouble
ECM trouble
DTC P0337: circuit trouble of crank position sensor
Test condition: during starting
No camshaft indicates main sensor trouble
System voltage decreases about by 1V
Malfunction judgement: ECM can not receive signals from crank position sensor
Possible cause: Circuit trouble between crankshaft position sensor and ECM
Air clearance between crankshaft position sensor and ring gear does not conform to the specification
Trouble of crankshaft position sensor
DTC P1336: gear information of crankshaft position not learnt
Test condition: no trouble codes related to coolant temperature sensor, throttle position sensor, crank
position sensor, camshaft position sensor, speed sensor, fuel injector, ignition system etc.
Malfunction judgement: gear information learning mark is not positioned
Possible cause: the vehicle hasn’t executed gear information learning program (refer to Appendix 2 for
gear information learning program)
DTC P0342: no signal from the circuit of crank position sensor
Test condition: engine running
Malfunction judgement: ECM does not receive any signal from crank position sensor
Open circuit between crank position sensor and ECM
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Crank position sensor is damaged
DTC P0351: trouble of ignition circuit 1
Power voltage is above 10V
Malfunction judgement: ignition circuit of cylinder 1, 4 is open or shorted to power supply or ground
Emergency control plan: stop fuel injection of cylinder 1, 4
Disable closed-loop fuel control
Possible cause: ignition circuit between ignition coil and ECM is shorted or open
Poor contact of ignition coil connector
Ignition coil is damaged
DTC P0352: trouble of ignition circuit 2
Malfunction judgement: ignition line of cylinder 2, 3 is open or shorted to power supply or ground
Emergency control plan: stop fuel injection of cylinder 2, 3
Disable closed-loop fuel control
Possible cause: ignition circuit between ignition coil and ECM is shorted or open
Poor contact of ignition coil connector
Ignition coil is damaged
DTC P0420: catalyst efficiency is below the limit
Test condition: no trouble codes related to MAP sensor, coolant temperature sensor, TPS sensor,
cooling system, oxygen sensor, fuel correction, speed sensor, fuel injector, fire, crankshaft position
sensor, camshaft position sensor, ignition system, idle speed control, system voltage
With fuel system loop-closed, stop the vehicle and run at idle speed after driving for a certain distance at
even speed.
Malfunction judgement: the system calculates oxygen storage time of catalytic converter by comparing
signals from front and rear oxygen sensor, when weighted oxygen storage time is less then the set limit,
the system will report this trouble
Possible cause: catalystic convertor performance deterioration
DTC P0443: trouble of canister cleaning circuit
Test condition: ignition switch is at power-on position
System voltage is above 11V
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Malfunction judgement: control circuit voltage of canister solenoid valve too high or too low.
Emergency control plan: stop canister cleaning function
Possible cause: control circuit between canister solenoid valve and ECM is open or shorted to power
supply or ground.
Canister solenoid valve is damaged
DTC P0462: fuel level sensor circuit input is too low
Malfunction judgement: sensor signal voltage is higher than 4.3V
Emergency control plan: system should apply default fuel level value
Disable fire diagnosis
Circuit between the sensor and ECM is shorted to the power supply
Poor connection
DTC P0480: trouble of Fan 1
Test condition: engine in operation
Malfunction judgement: ECM detects that the control line is shorted or open to power supply or ground
Emergency control plan: when coolant temperature is too high, start high-speed fan
Possible cause: control circuit between the fan and ECM is open or shorted to power supply or ground
DTC P0483: trouble of Fan PWM
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DTC P0502: no vehicle speed signal
Coolant temperature is higher than 60℃
No trouble codes related to MAP sensor, TPS sensor etc.
Malfunction judgement: under acceleration condition, vehicle speed is lower than 10kph; and under
deceleration condition, vehicle speed is lower than 5kph
Emergency control plan: disable closed-loop control at idle speed
Under heavy-load condition, disable air conditioning no more
Circuit between speed sensor and ECM is shorted or open
Speed sensor is damaged
DTC P0506: trouble of idle-speed control system – rotating speed is too low
cooling system, oxygen sensor, fuel correction, speed sensor, fuel injector, misfire, crankshaft position
Engine in operation
Malfunction judgement: the duration that idle speed is lower than target idle speed 100RPM set by the
system is longer than 10s
Emergency control plan: disable idle-speed adjustment
Possible cause: trouble of idle-speed control circuit
Trouble of idle-speed step motor
Ignition system trouble
DTC P0507: trouble of idle-speed control system – rotating speed is too high
cooling system, oxygen sensor, fuel correction, speed sensor, fuel injector, misfire, crankshaft position
Engine in operation
Malfunction judgement: the duration that idle speed is lower than target idle speed 200RPM set by the
system is longer than 10s
Emergency control plan: disable idle-speed adjustment
Possible cause: circuit trouble between idle-speed control valve and ECM
Trouble of idle-speed control valve
Ignition system trouble
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Vacuum leaking
DTC P0562: system voltage is too high
Malfunction judgement: system voltage is higher than 16V
Possible cause: charging system trouble
Poor connection
Internal damage of ECM
DTC P0563: system voltage is too low
Malfunction judgement: system voltage is higher than 11V
Possible cause: charge system trouble
Poor connection
Harness is shorted or open to the ground
Internal damage of ECM
DTC P0532: voltage of air conditioning pressure circuit is too high
Malfunction judgement: ECM detects that air conditioning pressure signal is lower than 0.05V
Emergency control plan: cut off air conditioning clutch immediately
Ai conditioning pressure signal applies system default value
Possible cause: the circuit between air conditioning pressure sensor and ECM is shorted to the power
supply
Poor connection
Trouble of air conditioning pressure sensor
DTC P0533: voltage of air conditioning pressure circuit is too low or open
Malfunction judgement: ECM detects that air conditioning pressure signal is lower than 4.95V
Emergency control plan: cut off air conditioning clutch immediately
Ai conditioning pressure signal applies system default value
Possible cause: the circuit between air conditioning pressure sensor and ECM is shorted or open to the
power supply
Poor connection
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Trouble of air conditioning pressure sensor
DTC P1545: trouble of output circuit of air conditioning clutch
Malfunction judgement: ECM detects circuit trouble of air conditioning clutch relay
Possible cause: the harness between air conditioning clutch relay and ECM is shorted or open to the
power supply or to the ground
DTC P2001: trouble of rear air conditioning evaporator sensor
Malfunction judgement: ECM detects that the signal from rear evaporator sensor is too high or too low
Harness between evaporator sensor and ECM is shorted or open to the power supply or to the ground
Trouble of rear evaporator sensor
DTC P0615: TCM trouble
Malfunction judgement: ECM received trouble information transmitted from TCM
Possible cause: trouble of transmission control system
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Engine – Electronic fuel injection part – Typical troubles and troubleshooting
III. Typical trouble and troubleshooting
1. Repair notice
(1) Preparation before repair:
(a) Do not repair vehicle at petrol station
(b) Do not repair fuel system at the place where fire source exists
(c) No smoking is allowed during repair operation
(2) When removing parts of fuel system (e.g. replacing filter, removing oil pump or oil inlet/outlet pipe of
fuel rail)
(a) Disconnect battery cathode first to prevent fuel vapor being ignited by discharge spark produced from
accidental short circuit.
(b) Cover oil pipe connector with cloth, then loose the connector carefully to release oil pressure from the
pipe
(c) Prevent fuel from splashing onto the engine and high-temperature exhaust pipe;
(d) Keep gasoline away from rubber or leather parts
(e) Replace fuel inlet/return pipe, pressure resistant fuel pipe against bursting pressure higher than
2MPa shall be used.
(3) When removing and repairing parts of electronic control system:
(a) Electronic-Controlled Fuel Injection System parts is reliable, when the vehicle or engine works
abnormally, check related mechanical parts, system connectors and harness, grounding wire, high
pressure line connector of spark plug and vacuum pipe of oil pressure adjustor etc.; perform
replacement test repeatedly to check before determining that Electronic-Controlled Fuel Injection parts
are damaged;
(b) When battery voltage is low or engine fails, do not start the engine with external force for a long
period in order to prevent three-way catalystic convertor from being damaged;
(c) If repair is essential, cut off ignition switch or disassemble battery cathode first, it is prohibited to
assemble or disassemble electronic parts with power switched on;
(d) Do not check electric signal of the system in the manner of

detecting the harness with probe;
(e) When the engine in operation, do not plug out battery connector;
(f) When it is required to perform electric welding etc. using tools from
external electric system, battery and ECM connector must be
disconnected;
(g) Do not check that ignition system by plugging out spark plug lead,
because the nozzle is still working, gasoline injected but not used will
burn in three-way catalystic convertor thus resulting in damage quickly;
(h) When checking during ECM replacement, please note whether the vehicle is equipped with computer
burglar alarm. If so, cut off the power supply to burglar alarm, and replace a new ECM, or else the new
ECM will be locked by the burglar alarm and can not work on other vehicles;
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(i) Prevent parts from violet knocking during assembling and disassembling;
(j) Do not open ECM cover;
(k) When replacing and removing oxygen sensor, do not let the sensor touch water or other liquid.
(l) Fuel pump shall not run for a long period without fuel or run with gasoline in the air
(m) Most of electronically-controlled fuel injection parts are unrepairable, after determining that the part is
damaged, it is usually replaced;
(n) The system shall use anti-interference spark plug and high-pressure wire, non-anti-interference spark
plug and high-pressure wire may not only release interference wave,
but also may make affect influence on drive module of ignition coil
inside the ECM, and it may even damage ECM.
(4) End of work:
(a) Check that all wire connectors and fuel pipeline are connected and
fixed appropriately;
(b) If there is any damage on the pipeline, the damage part must be
wrapped during repair;
(c) High-voltage conductor must be connected appropriately;
(d) When connecting battery connector, please note: never connect anode and cathode reversely, and
ensure that the lamp on battery connector is connected securely.
2. Detection procedure for off-line vehicle
Detection unit for off-line vehicle or after-sales service station can detect vehicle operating condition
using computer equipped with PCHUD monitor software or trouble diagnosis tester. Appendix 1: "Typical
datastream of DELPHI electronic fuel injection system" lists operating parameters of the vehicle at
normal condition and possible causes in abnormal condition.
3. Trouble diagnosis with trouble code and corresponding troubleshooting
When trouble lamp illuminates, use the diagnosis tester to read trouble code, and repair according to
trouble code description in “On-board diagnosis system”.
After finishing troubleshooting at service station, perform trial driving as per the following procedures to
ensure that trouble is repaired completely.
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90km/h, Gear 5 or D
Vehicle speed
70km/h, Gear 5 or D for 5min

for 5min
50km/h, Gear 3 for

5min
Idle
speed Idle speed Idle speed Idle speed
Time (Min)
4. Trouble diagnosis without trouble code and corresponding troubleshooting
Trouble 01: Trouble diagnosis tester can not communicate with the system
Possible cause Troubleshooting for reference
1. Diagnosis wire is not connected securely 1. Reconnect diagnosis wire

2. Functions of diagnosis tester do not conform to 2. Use a diagnosis tester conforming to the vehicle
the system model and system
3. Diagnosis tester trouble 3. Eliminate diagnosis tester trouble
4. corresponding relation between diagnosis 4. Repair the harness
interface and ECM connector terminal is wrong 5. Repair the harness
5. shorted to the lead relevant to diagnosis port 6. Replace ECM
6. ECM communication trouble
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Trouble 02: Start trouble

Trouble lamp:
1. Flashing 1. Whether the key is correct or damaged
1) Anti-theft key error 1) Re-learn the key
2) Circuit trouble of anti-theft system 2) Check the line and reconnect the connector
3) Alarm is damaged 3) Replace alarm, and perform learning steps
according to the procedure
2. Off 2.
1) Fuse/fusible line 1) Replace
2) Grounding wire is open 2) Check and repair
3) ECM connector 3) Reconnect
4) Lamp and circuit 4) Repair harness and lamp
5) ECM trouble 5) Replace ECM
3. On – check with diagnosis tester 3. Diagnose with trouble diagnosis tester
1) With trouble code 1) Eliminate the existing trouble
2) Without trouble code 2) Check: system power supply, signal acquisition
system, fuel supply system, ignition system,
idle-speed control system, engine and whole
vehicle mechanical system
System power supply:
1. System voltage when starter is working 1. Diagnose with trouble diagnosis tester
1) ＜8V 1) Replace battery or charge
2) ＞8V 2) Check other systems
Signal acquisition system:
1. Without rotating speed datastream 1.
1） Harness of crank position sensor is open 1) Repair the harness
2) Connector terminal of crank position sensor is 2) Repair the harness
connected reversely 3) Adjust the clearance: 0.3～1.5mm
3) Clearance between sensor and 58× target gear 4) Clean sensor
is incorrect 5) Replace sensor
4) Foreign matter is attached with the sensor
5) Sensor magnetic force is degenerated or sensor 2. With rotating speed datastream
is damaged 1) Check: falling edge of Gear 20 is the top dead
2. With rotating speed datastream point of Cylinder 1-4
1) Relative position of 58×gear to top dead point is
incorrect
Fuel supply system: 1. Connect in correct manner
1. Oil inlet/return pipe is connected reversely 2. Repair vehicle harness, and reconnect oil pump
2. Fuel pump open circuit connector
3. Cylinder is overflowing 3. Slight overflowing: Open the throttle fully and
4. start the engine
Serious overflowing: remove spark plug and start
the engine, recover them after the cylinder and
5. Oil inlet pipe pressure ＞250kpa
residual oil in the spark plug is dry
1) Fuel injection is blocked
4.
6. Oil inlet pipe pressure ＜250kpa 1) Replace nozzle
1) Insufficient fuel in the tank 5.
2) Fuel filter is blocked 1) Fill oil
3) Oil inlet pipe is leaking 2) Replace fuel filter
4) Fuel pressure adjuster is damaged 3) Replace oil inlet pipe
5) Fuel pump pressure is not sufficient 4) Replace fuel pressure adjuster
6) Fuel evaporability is proper or not 5) Replace fuel pump
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6) Use fuel with proper evaporability as per season

Ignition system:
1. Connector of ignition coil 1. Reconnect connector
2. Cylinder sequence is incorrect 2. Connect coil and spark plug according to coil tip
3. Spark plug is damaged 3. Replace spark plug
4. Ignition coil is damaged 4. Replace ignition coil
Idle speed control system:
1. Unable to start by depressing the throttle slightly 1. Check other reasons
2. Able to start by depressing the throttle slightly 2.
1) Idle valve plug falls off 1) Reconnect
2) Connector terminal of idle valve does not 2) Repair the harness
conform to ECM terminal 3) Clean throttle body
3) Idle valve is blocked 4) Repair the harness
4) ECM common power is interrupted 5) Replace idle valve
5) Idle valve is damaged 6) Replace ECM
6) ECM trouble
Air intake/exhaust system:
1. Air filter is blocked 1. Clean up air intake pipeline, and replace filter
2. Three-way catalystic convertor is blocked element
1) Catalystic convertor is broken 2.
2) Blocked due to foreign matter burning 1) Replace three-way catalystic convertor
2) Repair engine and replace three-way catalystic
convertor
Trouble 03: Engine is ignited but can not start

Fuel supply system:
1. Inlet pipe pressure ＜250kpa 1.
1) Insufficient fuel in the tank 1) Fill fuel
2) Fuel filter is blocked 2) Replace fuel filter
3) Inlet pipe is leaking 3) Replace oil inlet pipe
4) Oil pressure adjuster is damaged 4) Replace fuel pressure adjuster
5) Fuel pump pressure is not sufficient 5) Replace fuel pump
6) Fuel evaporativty is proper or not 6) Use fuel with proper eveporativity as per season
Idle speed control system:
1. Able to start by depressing the throttle 1.
1) Idle valve plug falls off 1) Reconnect
2) Connector terminal of idle valve does not 2) Repair the harness
conform to ECM terminal 3) Clean throttle body
3) Idle valve is blocked 4) Repair the harness
4) ECM common power is interrupted 5) Replace idle valve
5) Idle valve is damaged 6) Replace ECM
6) ECM trouble
Air intake/exhaust system:
1. Air filter is blocked 1. Clean up air intake pipeline, and replace filter
2. Three-way catalystic convertor is blocked element
1) Catalystic convertor is broken 2.
2) Blocked due to foreign matter burning 1) Replace three-way catalystic convertor
2) Repair engine and replace three-way catalystic
convertor
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Trouble 04: Idle speed is abnormal

1. Whole vehicle is power-off 1. Switch off ignition switch and restart it 10s later
2. ECM common power is switched off during 2. Recover ECM common power supply
parking
Trouble 05: Idle speed is low

1. Idle valve plug falls off 1. Reconnect
2. Connector terminal of idle valve does not 2. Repair the harness
conform to ECM terminal 3. Clean throttle body
3. Idle valve hole is blocked 4. Replace idle valve
4. Idle valve is damaged 5. Fill fuel
5. Insufficient fuel in the tank 6. Replace fuel filter
6. Whether the fuel filter is blocked 7. Replace oil inlet pipe
7. Oil inlet pipe is leaking 8. Replace catalystic convertor, if necessary, repair
8. Three-way catalystic convertor is blocked or not the engine
9. Air intake system is blocked or not 9. Clean up intake pipeline, and replace filter
10. Fuel pressure adjuster is damaged element
11. Fuel pump pressure is not sufficient 10. Replace fuel pressure adjuster
12. ECM trouble 11. Replace fuel pump
12. Replace ECM
Trouble 06: Idle speed is high

1. Consistent with target idle speed 1.
1) Reading on coolant temperature sensor is 1) Replace coolant temperature sensor
abnormal 2) Normal phenomena
2) Reading on coolant temperature sensor is 2.
normal 1) Adjust throttle cable
2. Inconsistent with target idle speed 2) Eliminate leaking trouble for intake pipe; refer to
1) Throttle does not return to the home position “Idle speed is low” for trouble of idle-speed control
2) Step pitch of idle valve ＜ 5 steps – intake pipe system
leaking; trouble of idle-speed control system
3) 5 steps ＜ step pitch of idle valve ＜150 steps -
trouble of idle-speed control system
Trouble 07: Idle speed is not stable

1. Poor connection to spark plug lead 1. Reconnect
2. Clearances between spark plugs are not 2. Adjust all of them to 1.0～1.2mm
consistent 3. Repair or replace vacuum pipe
3. Vacuum pipe of oil pressure adjuster falls off or 4. Clean or replace trouble fuel injector
is damaged 5. Check: falling edge of Gear 20 is the top dead
4. Certain fuel injector is blocked point of Cylinder 1-4
5. 58× ring gear is mis-positioned
Trouble 08: Engine flames out suddenly during normal operation

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1. Poor connection of electric system 1. Check all related connectors in anode and
2. Insufficient fuel in the tank cathode circuits of power supply
3. Oil inlet pipe is leaking 2. Fill fuel
3. Replace oil inlet pipe
Trouble 09: Engine flames out during deceleration

1. ECM common power is switched off during 1. Recover ECM common power supply
parking 2. Repair the harness
2. Connector terminal of idle valve does not 3. Clean throttle body
conform to ECM terminal 4. Replace idle valve
3. Idle valve is blocked 5. Replace ECM
4. Idle valve is damaged
5. ECM trouble
Trouble 10: Powerless/lagging acceleration

1. Air intake system is not smooth 1. Clean up air intake pipeline, and replace filter
2. Pressure sensor hole of air intake manifold is element
blocked 2. Clean up detecting hole on the pressure sensor
of air intake manifold, if necessary, replace the
3. Throttle can not be opened fully sensor
4. Fuel injector is blocked 3. Adjust retaining screws of the throttle to ensure
5. Exhaust system is not smooth that it is opened fully
4. Clean or replace damaged fuel injector
5. Check exhaust system and three-way catalystic
convertor
Trouble 11: Engine power is insufficient

1. Air intake system is not smooth 1. Clean up air intake pipeline, and replace filter
2. Throttle can not be opened fully element
3. Exhaust system is not smooth 2. Adjust retaining screws of the throttle to ensure
4. Resistance of power transmission system is too that it is opened fully
large 3. Check exhaust system and three-way catalystic
5. Engine is overheat convertor
6. Fuel injector is blocked 4. Repair parts relevant to power transmission
system
5. Repair engine cooling system
Trouble 12: Idle speed unstable during driving

1. High-pressure circuit leakage of ignition system 1. Reconnect all connectors and replace damaged
2. Nozzle is blocked parts
Trouble 13: Vibration during acceleration

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1. High-pressure circuit leakage of ignition system 1. Reconnect all connectors and replace damaged
parts
Trouble 14: Knocking

1. Fuel does not conform to the standard 1. Ensure that fuel with octane number greater
2. Engine is overheat than 90 is used
3. 58× ring gear is mispositioned 2. Repair engine cooling system
3. Check: falling edge of Gear 20 is the top dead
point of Cylinder 1-4
Trouble 15: After burn (and exhaust temperature is too high)

1. Cylinder shortage of engine ignition system 1. Recover ignition of that cylinder, if it is
impossible temporarily, plug out the nozzle control
2. Trouble of engine exhaust valve plug of that cylinder to protect the three-way
3. 58× ring gear is mis-positioned catalystic convertor
2. Repair engine
3. Check: falling edge of Gear 20 is the top dead
point of Cylinder 1-4
Trouble 16: Cycle testing over emission

1. Abnormal condition of the engine 1. Repair engine
2. Control of electronic fuel injection system is 2. Repair electronic fuel injection system according
abnormal to “Off-line trial driving procedure and detecting
technical conditions for 462/465 series vehicles”
3.Connector between cylinder head and three-way 3. Fix relevant bolts, if necessary, replace gasket
catalystic convertor is air-leaking 4. Fix oxygen sensor
4. Screws of oxygen sensor is air-leaking 5. Repair or replace
5. Vacuum pipe of oil pressure adjuster falls off 6. Replace fuel pressure sensor
6. Trouble of fuel pressure adjuster 7. Lifecycle is longer than 80000km under
7. Usage term of three-way catalystic convertor standard condition, if necessary, replace it
and oxygen sensor has been exceeded 8. Replace catalystic convertor and oxygen sensor
8. Heavy metal poisoning of three-way catalystic 9. Run it for 10 minutes at 70km/h at 3rd gear
convertor and oxygen sensor, or they are damaged 10. Improve position of system grounding wire
due to overheating 11. Isolate ECM housing
9. Sulfur poisoning of three-way catalystic 12. Check: falling edge of Gear 20 is the top dead
convertor and oxygen sensor point of Cylinder 1-4
10. Poor grounding of ECM or electronic fuel
injection system
11. ECM housing is grounded
12. 58× ring gear is mis-positioned
Trouble 19: Emission of fuel vapor is abnormal

1. Canister connecting pipe is broken 1. Replace connecting pipe
2. Canister is damaged 2. Replace canister
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3. Canister specification is too small 3. Choose proper canister

4. Harness of canister solenoid valve trouble 4. Repair the harness
5. Connector is not connected securely 5. Reconnect
6. Canister solenoid valve is damaged 6. Replace canister solenoid valve
7. ECM trouble 7. Replace ECM
Trouble 20: Fuel consumption is abnormal

1. Measurement method is not correct 1. Use reliable measurement method
2. Whole vehicle condition 2. Repair the vehicle
3. Engine condition 3. Repair engine
4. Thermostat is damaged 4. Replace thermostat
5. Coolant temperature sensor is damaged 5. Replace coolant temperature sensor
6. Condition of electronic fuel injection system 6. Repair electronic fuel injection system according
to “Off-line trial driving procedure and detecting
7. Nozzle is oil-leaking technical conditions for 462/465 series vehicles”
8. Fuel pressure adjuster is damaged 7. Replace damaged nozzle
9. oxygen sensor is troubley 8. Replace adjuster
10. ECM trouble 9) Replace oxygen sensor
10. Replace ECM
The vehicle not equipped with air conditioner displays trouble relevant to air
Trouble 21:
conditioning system
1. Spare plug for air conditioning control of 1. Clean spare plug of air conditioner, provide
electronic fuel injection system is contaminated proper dustproof and waterproof protection, cut off
power supply to ECM for 10 minutes
Trouble 22: ECM is locked by alarm

1. Alarm-related harness trouble 1. Repair the harness
2. Connector is not connected securely 2. Reconnect
3. Anti-theft key is damaged 3. Replace and relearn new anti-theft key
4. Unlocking is required 4. ECM sends back DELPHI decoding
5. Others 5. Contact alarm supplier, and request
corresponding services
Trouble 23: Anti-theft key gets lost or alarm is damaged

1. Anti-theft key gets lost or alarm is damaged 1. Contact alarm supplier, and request
corresponding services; Send back ECM to
DELPHI for unlocking
Trouble 24: Trouble lamp is on/off rulelessly during vehicle running

1. Connector is connected poorly 1. Check all connector terminals of electronic fuel
injection system, and then reconnect connectors
76
Engine – Electronic fuel injection – Typical datastream of DELPHI electronic fuel injection system
IV. Typical datastream of DELPHI electronic fuel injection system
1. Routine inspection
(1) Harness connectors are connected reliably
(2) Oil circuit and vacuum pipe are fixed reliably
(3) Fix end bolts of oxygen sensor and three-way catalystic convertor interface, ensure seal of interface
end; if necessary, check the exhaust system with atmospheric pressure of 1.3, there should be no
obvious leakage.
2. System initialization setting
(1) Initialization of electronic fuel injection control system: turn the ignition switch to running position, and
turn off 3s later, system initialization setting will be finished 10s later.
(2) Initialization of fuel supply system: turn the ignition switch to running position, and turn off 3s later,
restart it after 1s and repeat it 5 times, then initialization setting of fuel supply system will be finished.
3. Inspection of system and vehicle condition
(1) Step 1: cold vehicle, turn the key switch to “ON” position, deactivate the engine (for about 30s)
No. Detection items
1 Display trouble code No
2 Engine trouble indicator On
3 Battery voltage 11.5～13V
4 Coolant temperature sensor Normal temperature
5 Air intake temperature sensor Ambient temperature
6 Absolute pressure sensor for intake manifold Ambient atmosphere (about 100kpa)
Working range of air intake valve position

7 0～99.6%
sensor
8 Oxygen sensor 1127mV
40～159 steps (coolant temperature: high～

9 Idle speed control valve
low)
(2) Step 2: Key switch turns to “OFF" position
Detection items
1 Actual position of idle-speed motor Remain at 128 steps after about 8s
2 ECM power supply is cut off or not PCHUD/diagnosis tester stops display
3 Engine trouble checking lamp OFF
(3) Step 3: Start engine (Note: do not operate any mechanism and throttle on the engine during start)
77
Detection items
1 Start time ＜5s
2 Starting speed at normal temperature ＜1600RPM
(4) Step 4: Idle speed inspection (after start, warm up engine to normal coolant temperature)
(a) Low idle speed
Detection items
2 Display trouble code or not No
3 Coolant temperature 80～94℃
Coolant temperature Cooling fan condition
Cooling fan 92.25 low-speed fan ON
4 (Single-speed fan is only used for data of 87.00 low-speed fan OFF
low-speed fan) 98.25 high-speed fan ON
93 high-speed fan OFF
5 Battery voltage 13.5～14.5V
850±30RPM
6 Rotating speed 900±30RPM (when cooling fan, head lamp
and blower are on)
7 Ignition advance angle 5～13°
8 Air intake manifold pressure 35～55kpa
9 Actual position of idle-speed motor 15～30 steps
10 Pulse width of fuel injection 2～4ms
11 Oxygen sensor/jump times within 10s 100～900mV/≥6 times
(b) High idle speed (depress the throttle lightly to accelerate the engine to 2000RPM)
Detection items
1 Engine trouble check indicator OFF
2 Display harness trouble code or not No
6 Rotating speed Actual value (it should be controlled within
78
2000±50RPM)
7 Ignition advance angle 20～30°
8 Pulse width of fuel injection 2～4ms
9 oxygen sensor/jump times within 10s 100～900mV/≥10 times
(5) Step 5: Air conditioning system inspection
(a) Normal idle speed, air conditioning system is OFF
Detection items
1 Status 3 - A/C system Appearing
2 Status 5 – front evaporator Appearing
(b) Start air conditioner, after keep stable for 10s
Detection items
1 Engine idle speed 1000±50RPM
2 Status 3 - A/C request signal Appearing
3 Status 3 - A/C relay Appearing
4 Status 3 - A/C system Appearing
5 Status 4 – Fan 1 Appearing
6 Status 5 – Fan 2 Appearing
7 Status 5 – front evaporator Appearing
(6) Step 6: Driving inspection
The following operation must be performed during driving inspection:
(a) Throttle opening is larger than 10% and remain above 15s
(b) Direct gear, when the speed reaches 80km/h, release the throttle and slip for over 5s
Detection items
2 Display harness trouble code or not No
Absolute pressure sensor for air intake

5 20kpa～ atmosphere pressure
manifold
6 Working range of throttle position sensor 0～99.6%
7 oxygen sensor 50～950mV
4. Description
79
(1). Routine inspection
(a) Loose connection of connectors will cause misalignment of signal transmission and control;
(b) Oil inlet/return pipes can not be connected reversely, pressure balancing vacuum pipe of the oil
pressure adjustor can not be omitted, or it may lead to abnormal exhaust and increase fuel consumption;
(c) Canister cleaning pipe should not be connected reversely or omitted, otherwise it may lead to
abnormal idle speed;
(d) If seal from engine cylinder head to three-way catalystic convertor is poor, outer air will get in during
engine operation, which will destroy the balance of air/fuel ratio, thus reduce converting efficiency of
three-way catalystic convertor.
(2) System initialization setting
(a) When the first power supply to ECM is cut off after ECM is installed, ECM will perform initialization
setting for the system
(b) Every time the key switch is turned on, fuel pump will work for 1.5s. When the vehicle is off line, there
is no fuel in fuel pipeline, therefore fuel shall be filled into the pipeline first.
(3) Inspection of system and vehicle condition
(a) Turn key switch to running position, and leave the engine static.
● Engine trouble indicator lamp is on, but there should be no trouble code
● Absolute pressure sensor of air intake manifold should display local atmosphere pressure value at
that time
● Adjust throttle cable and pedal screw, ensure enclosure and full opening of the throttle
● When warming up the oxygen sensor, its display should decrease from 450mV and keep balance
below 200mV after warm-up;
● The position of idle valve is based on engine temperature, its opening is small when warming up and
large when the engine gets cold.
(b) Turn key switch to parking gear
● After turning off key switch, if idle control valve does not act, ECM power supply should be cut off
immediately at the same time, check that ECM common power wire is connected incorrectly to
ignition switch; it may cause difficult engine restarting and flame-out during deceleration, as well as
affecting exhaust performance.
(c) Idle speed inspection
● Engine trouble indicator lamp is OFF without trouble code;
● Battery voltage indicates that whether the generator operates normally
Too high: maybe generator adjustor is troubley
Too low: maybe generator wiring is inappropriate or generator trouble;
● Air intake manifold pressure can indicate leakage of air intake and valve clearance problem. If valve
clearance is too small, this value is higher, which will affect engine power performance, in addition,
because exhaust valve is open too early and exhaust temperature increases, lifecycles of oxygen
sensor and three-way catalystic convertor will be shortened greatly.
80
In addition, blockage of exhaust system (e.g. there is foreign matter in exhaust pipeline or three-way
catalystic convertor is broken inside) will cause this value higher too;
● Actual position value of idle-speed motor is too low, which indicates that intake system is leaking,
and too high indicates throttle body and idle control valve are blocked;
● Changing times of oxygen sensor value is too few, it indicates that oxygen sensor fails.
(d) A/C system inspection
When air conditioner starts, target idle speed increases by 100RPM, and when air conditioning fan is
turned on, it increases by 50RPM additionally, in general they start at the same time, therefore, after the
air conditioner starts, idle speed of the engine should increases by 150RPM on the basis of the original
idle speed.
(e) Driving inspection
Vehicle speed trouble and sensor trouble during this course are diagnosed, meanwhile the alternative
control solution will become effective after the trouble is detected.
81
Engine —Electronic fuel injection part — Gear information learning procedure of EOBD system
V. Gear information learning procedure of EOBD system
Operation 1: Learn target gear teeth error of crank position sensor
1. When the vehicle installed new computer has not learned gear information, trouble lamp will be on
after it starts, and diagnosis tester displays trouble of P1336.
2. When water temperature reaches 60℃ after starting, vehicle running time is longer than 10s, and
other onboard loading should be closed;
3. Send “Gear information learning” command by diagnosis tester (Command “30 2c 07 ff”)
4. Depress the throttle to the extreme position and remain, ECM should perform gear information
learning at this time, engine speed circulates 2-5 cycles within 1300-4500, and finally vibrating at about
4500rpm, learning is completed;
(The content above is typical characteristics of engine speed when performing gear information learning,
it can be used to determine whether learning is in process or completed)
5. Send “Stop gear information learning” command by diagnosis tester (Command “30 2c 00”)
6. Engine flames out, key-on after about 15s, then eliminate trouble code, key-off;
7. Start the engine after 15s, check that P1336 is qualified by diagnosis tester;
82
73-pin
73针接插件
connector
Battery power MT20U2 F22 15A
F12 10A supply 电瓶电源 J1-17 5V power supply No.1 B
Battery power J1-20 1号5V电压源正
positive
Ignition switch MT20U2 Ignition coil A 1 List of Fuses
点火开关IG1
supply 电瓶电源 J1-18 J1-05 5V power supply No.1
1号5V电压源地保险丝使用表
IG1 F22 15A switch power
Ignition 点火开关电源 ground J1-32 点火线圈A驱动
drive A
supply J1-01 Dual-core shielded 4 ECM battery
5V power supply No.2 双芯屏蔽线
J1-04 2号5V电压源正 wire 3 ECM电瓶电源
power
F6 20A positive
Main relay
J1-21 2号5V电压源地
5V power supply No.2
Ignition coil B
点火线圈B驱动 C F12 10A 诊断接口
diagnostic
主继电器输出
output J1-52 drive
ground 2 interface
ECM ignition
Main relay J1-58 ECM点火开关电源
output F22 15A switch power
PCP ignition coil supply
点火线圈 ignition
PCP点火线圈 coil
主继电器
Main relay o A/C A/C A/C A/C Fuel injector,
fuel
喷嘴、 pump,
Idle speed control A
怠速空气控制A高 D Idle speed air Spark plug F6 20A oxygen
油泵、 sensor
J1-54 火花塞
high 怠速空气
control valve 氧传感器加热、
怠速空气控制B高 B heating, and
J1-33 Idle speed control B 1 2 3 4 碳罐电磁阀
Battery 怠速空气控制A低控制阀 Injection canister
电瓶 System J1-53 high C 喷嘴 solenoid valve
Earthing point at 系统接地
earthing Idle speed control A
怠速空气控制B低
nozzle
接地点选发动机 J1-73 J1-34 A
generator body or low
机体或电瓶负极
battery negative B A B A B A B A
pole Cylinder 1
1缸喷嘴
Dual-core shielded J1-55
nozzle
wire双芯屏蔽线 58-tooth signal 2缸喷嘴
Magnetoelectric A
J1-70 Cylinder 2
磁电式曲轴 high58齿信号高 J1-12 3缸喷嘴
crankshaft 58-tooth signal J1-56 nozzle
58X C
position
位置传感器 sensor high58齿信号低 J1-28 Cylinder
4缸喷嘴 2
B Diagnostic interface J1-71
F12 10A 18 诊断接口 nozzle
Serial data
J1-11
KW2000 串行数据
7 Main relay
Vehicle speed 30 87
52
72
Vehicle speed sensor signal 车速信号 output

主继电器输出
车速传感器 J1-03 5 Fuel relay
73
油泵继电器控制
control 85 86
J1-47
4 Fuel pump
Single-core M 油泵
单芯屏蔽线
shielded wire Knock 5V power supply No.2 B
16
32
Knock sensor 爆震信号

signal Intake air positive2号5V电压源正
J1-69 Intake manifold absolute
爆震传感器进气压力
pressure A 进气歧管绝对压力 Canister solenoid
J1-42 pressure/temperature Canister solenoid valve 碳罐电磁阀
sensor valve
温度传感器 J1-63 碳罐电磁阀控制
control Main relay output
A B 主继电器输出
1号5V电压源地
5V source No. 1 5V power supply No.2 D
2号5V电压源地
ground ground
Main relay output
主继电器输出 Intake air Tachom
转速表 Instrument
仪表电源 power
Front oxygen sensor 进气温度
J1-27 temperature C eter supply
OSP D B signal 前氧传感器信号高
high J1-62
Front
加热式前 Front oxygen sensor Tachometer
RPM
heated A signal low氧传感器信号低转速表
J1-06 J1-45 Malfunction
氧传感器
oxygen C Front oxygen sensor Malfunction
故障指示灯诊断指示灯
indicator
sensor heating 前氧传感器加热 J1-61 J1-31 indicator
EOBD
Main relay output
主继电器输出
VI. Circuit Schematic Diagram for MT20U2 System
Rear oxygen sensor

D B signal 后氧传感器信号高
high
OSP J1-38
Rear heated Battery 30
A/C
87 空调压缩机
加热式后
oxygen sensor A 电瓶电源
power compressor
A/C
1
C 空调压缩机 85 86
33
17
Rear oxygen sensor

53
氧传感器 J1-46 compressor IG2

heating 后氧传感器加热 J1-64
5V source No. 1 空调压缩机继电器
A/C compressor
positive relay
A 1号5V电压源正 Throttle position
Throttle position sensor 节气门位置信号
signal Schematic of
节气门位置传感器 C J1-24
5V source No. 1 接插件针脚示意
connection pins
B
1号5V电压源地
ground A/C high/low pressure
switch空调高低压开关 A/C request
A/C request high 空调请求开关
switch
Coolant temperature
冷却液温度信号
signal 空调请求高有效
valid Blower relay Low-speed fan
3 J1-43 J1-39 鼓风机继电
低速风扇控制
control
To water Medium pressure signal output
器输出（+） (+) J1-67
Coolant temperature 2 中压信号高有效
冷却液温度传感器 temperature
去水温表 gauge
J1-41 high valid S2 20A
sensor Battery
1 5V source No. 1
1号5V电压源负电瓶电源
power
negative A/C medium pressure
空调中压开关 Low-speed fan
低速风扇继电器
switch relay
Blower high valid
J1-57 鼓风机高有效 High-speed fan
Front evaporator 高速风扇控制
control
J1-50
B 前蒸发器温度信号
temperature signal J1-26
Front
前蒸发器温度传感器 evaporator
temperature sensor
A 5V source No. 1 negative High-speed
高速风扇继电器 fan
1号5V电压源地 Fan
relay 风扇
Engine —Electronic fuel injection part — Circuit Schematic Diagram for MT20U2 System
83
Engine—Cooling System
Part 5 Cooling System
I. System Inspection
1. Check leakage in the cooling system (see Figure 3-1).
(1) Fill coolant in the radiator, and mount the tester at the radiator cover port.
(3) Keep the pump pressure at 118KP without drop. If the pressure drops, check whether there is any
leakage of the water inlet/outlet radiator 、radiator drain scres and water pump; if not, check the radiator
heating core, cylinder block and cylinder head.
2. Check the engine coolant quantity in the expansion tank.
The coolant level should be between L and F. (Fig 3-2)
Radiator cap tester
Fig. 3-1 Fig. 3-2
3. Check the coolant quality.
(1) Remove the radiator cover.
Do not remove the radiator cover when the engine and the radiator are still hot in order to avoid scalding
since the liquid vapor may inject.
(2) Check whether there are excessive deposit and rust or sundries around the radiator cover. The
coolant is not allowed to contact with oil.
(3) Remount the radiator cover.
4. Thermostat
Notes: The temperature indicated on the thermostat is marked as

open temperature of the valve (see Figure 3-3).
(1) Submerge the thermostat into water and heat gradually.
(2) Check the open temperature of the valve.
Open temperature of the valve: 80-84°C Fig. 3-3
(3) Check the lift of the valve (see Figure 3-4 and Figure 3-5)
Lift of the valve: 8mm or more at 95°C
(4) When the thermostat is at low temperature (lower than 77°C), the
valve should close completely
Fig. 3-4
84
5、Cooling fan assembly
(1) At low temperature (lower than 87°C), check the operation of the
cooling fan.
8.0mm or
a. The ignition switch is set to ON. above
b. The cooling fan should stop.
c. Disconnect the connector of the water temperature sensor. (see Fig. 3-5
Figure 6-6)
d. Use wire to connect the connector of water temperature sensor and and vehicle body.Connect the
ground with a wire.
e. Check if the cooling fan rotates.
f. Re-connect the connector of the water temperature sensor.
(2) At high temperature (more than 92°C), check the operation of the fan
a. Start the engine, and enable the coolant temperature higher than 92°C.
b. Check whether the cooling fan rotates. If not, replace the water temperature switch
(3) Check the cooling fan.
a. Disconnect the joint of the cooling fan.
b. Connect the battery and the ammeter with the connector.
c. The cooling fan should rotate stably and check the current readings.
Standard current: (6-8) A.
d. Re-connect the connector of the cooling fan.
II. Cooling system malfunction maintenance

1. Remove and replace cooling system components
(1) Disconnect wiring harness of cooling fan motor.
(2) Open the cover of radiator and expansion canister.
(3) Open water drain valve to drain coolant.
(4) Unfix 4 bolts connecting radiator and condenser.(Fig.3-6)
(5) Remove the lower cross member on radiator (fig. 3-7).
Note: when disassembling lower crossmember from the radiator, please hold the radiator and the
cooling fan to prevent them falling.
(6) Remove entire cooling module.
(7) Remove both damping washers on/under the radiator.
(8) Disconnect the expansion tank overflow pipe and radiator; unfix 3 bolts between expansion tank and
cooling fan; remove the expansion tank with overflow pipe assembly.
(9) Remove 6 fixing bolts between cooling fan and radiator, to divide the cooling fan and radiator.
85
(10) Replace the parts and reassemble the the parts according to reverse order; fill the coolant.
Fig. 3-7
Fig. 3-6
2. Fill coolant and the notice
(1) Fill full coolant to radiator and expansion canister respectively with volumes of 4.9～5.2L.
(2) Start engine (while radiator cup is open). The coolant level will fall, since the air remained in cooling
system is exhausted continuously.
(3) Supplement coolant, until the level is stable, as well as no more bubbles appear from cooling system.
(4) Close radiator and expansion canister cover and survey whether there is any coolant leakage. Filling
is not finished, until cooling fan is started normally.
Torque table
Torque/N.
No. Part name Specification Quantity Remark
m
Hex bolt and spring washer Connecting radiator

1 M6 6 7.5
assembly and cooling fan
Cross slotted pan head screw Connecting expansion

2 M6 3 9
and plain washer assembly canister and cooling fan
3 Hose clip, worm drive, type A 4 6 Water pipe clip
Hex bolt, spring washer and Connecting radiator

4 M6 4 7.5
plain washer assembly and condenser
Fixing radiator lower

5 Hex bolt M6 8 9
cross beam
86
Engine—Fuel System—Check Fuel System Pressure
Part 6 Fuel System
I. Check Fuel System Pressure
On-board inspection
1. Check the operation of the fuel pump.
(1) Connect the positive and the negative of the battery to appropriate
connector sockets of the fuel pump (see Figure 4-1).
Attention: Do not start the engine.

Battery
If there is pressure present, you will hear that the fuel is flowing.
Fig. 4-1
If there is no pressure present, check the fusible link, fuse, EFI
open-circuit relay, fuel pump, ECM (Electronic Control Module) and circuit joint.
(2) Turn the ignition switch to "OFF"
2. Check the fuel pressure.
(1) Check whether the battery voltage is more than 12V. Clamp
(2) Disconnect the negative wiring cable from the battery. T-connector
(3) Mount a pressure gauge on the fuel input pipe (see Figure 4-2).
(4) Connect the negative terminal of the battery.
(5) Measure the fuel pressure. (Pipe)
Fuel pressure: 350～400kPa

Fuel pipe
If the pressure is low, check the fuel pipe and connection, fuel pump,
and fuel filter. If the pressure is too high, replace the regulator. Fuel pipe
connector
(6) Start the engine. Measure the fuel pressure at idle speed.
Fuel pressure is 350～400kPa. Fig. 4-2
If the pressure is unsatisfactory, check the fuel pump, pressure regulator, and injector, and replace if
necessary.
(7) After shutting down the engine, check the fuel pressure and keep the specified pressure for about 5
minutes.
Fuel pressure: 170kPa.
Maintenance precautions: During maintenance:
1. Never impact the diaphragm element with high pressure gas;
2. Never clean it with aggressively corrosive liquid;
3. No distortion caused by external force.
Easy measuring method: For the system with oil return, connect a pressure gauge for the fuel on the oil
inlet pipe, start the engine, and run at idle speed. Now, the fuel pressure in the engine should be about
400KPa.
87
Engine—Fuel System—Fuel Pump Inspection
II. Fuel Pump Inspection
1. Fuel pump
(1) Check whether the resistance of the fuel pump is 0.2~3.0 ohm¸ at 20°C. If not, replace the fuel pump
(see Figure 4-3).
(2) Fuel pump running:
Switch on the fuel pump with a battery and check. If the operation is unsatisfactory, replace the fuel
pump or wires (see Figure 4-4).
The test should be done within 10s to protect the coil from burning out.
2. Fuel injector assembly
Fuel injecting quantity: 40~50cm3.
Error of each injector: not more than 10 cm3.
If the fuel injecting quantity can’t meet specification, replace the injector.
Check leakage: Under above conditions, disconnect the wire from the battery, the fuel should not drip
one per minute
Ohmmeter
Battery
Fig. 4-3 Fig. 4-4
88
Engine—Fuel System—Fuel Pump Replacement
III. Fuel Pump Replacement
Structure
Fuel
油箱盖tank cap
Fuel vapor pipe

燃油蒸汽管
From filter hose
出滤清软管
燃油软管
Fuel hose Fuel pump assy.
燃油泵总成
Seal ring
密封圈
1. Operations avoiding petrol overflowing.
2. Disconnect the fuel oil hose from the oil tank.
3. Disconnect the fuel hose.
4. Disconnect the fuel vapor hose
5. Remove the fuel pump assembly (see Figure 4-5)
Loosen the fuel tank cap with a special tool. Take care not to bend the
arm of the oil quantity sensor when taking the fuel pump out
★ Note: Bending float lever of fuel sensor may cause displaying oil
level of instrument inaccurately. Fig. 4-5
6. When mounting the fuel oil pump assembly, replace the sealing ring.
Align the arrow on the oil pump with the arrow on the oil tank port; tighten the oil tank cap with special
tool with tightening torque of 40~50 N.m
7. Mount the fuel oil hose
8. Mount the oil vapor pipe
9. Install outlet tube of the filter;
★ Note: when installing tubes, if you hear a click, it indicates it is installed in place
89
Engine—Fuel System—Fuel tank replacement
IV. Fuel tank replacement
Structure diagram
Filler pipe assy.

加油管总成
Filler lid cap assy.

加油软管
Filler hose
加油口盖总成
Fuel filler 加油
vent
hose
通气
软管
Fuel
供油管supply pipe
Fuel tank assy.
燃油箱总成
Vent
通气管 pipe
配 3G10
For 发动
3G10Engine
Canister control valve Canister

mounting bracket
碳罐控制阀安装支架碳罐支架
bracket
Canister碳罐控制阀control Canister absorption
valve 碳罐吸附软管
hose Metal vent
金属通气管
tube
Fuel tank
Canister 燃油箱总成
assy.
碳罐
Canister 碳罐脱附软管
desorption
hose
Control valve engine
hose控制阀发动机软管
Fuel pump
燃油泵总成
assy.
Fuel return
回油软管
hose
Metal fuel tube

金属燃油管
Metal return
金属回油管 Fuel filler hose
tube 加油软管
Fuel filler pipe
加油管
Seal
Fuel filler vent 密封圈
ring
hose 加油通气软管 Filler neck
加注口盖
cap
For 479Q Engine
1. Before replacing the fuel tank, engine must be shut down, and turn ignition switch to “OFF” position.
2. Prevent gasoline overflowing;
3. Remove the second section of exhaust pipeline;
★ Note: when removing exhaust pipe, the operation must be carried out until the exhaust pipe gets cold
90
Engine—Fuel System—Fuel tank replacement
to prevent being scalded by the exhaust pipe.
4. Disconnect nylon hose to the fuel tank;
5. Loose fixing clamps on the rubber tube connecting filler pipe with fuel tank with a slotted screwdriver,
and then pull out rubber tube.
★ Note: when plugging out the rubber tube, please avoid liquid fuel splashing onto person body.
6. Place the jack under the fuel tank, and put the fuel tank on the jack slowly after removing fixing bolts;
7. Plug out electric connector of the fuel tank;
★ Note: when removing the fuel tank, pull apart electric connector harness of the fuel tank carefully;
Replace filling pipe
1. Open the plate of fuel cap and screw out fuel cap slowly;
★ Note: when screwing out fuel cap, prevent gaseous fuel injecting.
2. Loose fixing clamps on the rubber tube connecting filling pipe with fuel tank with a slotted screwdriver,
and then plug out rubber tube.
3. Lift up the vehicle and release retaining bolts on filling and vehicle body;
4. Pull out filling pipe;
91
Engine—Fuel System—Fuel Emission Control System
V. Fuel Emission Control System
On-board Inspection
1、Check the operation of fuel supply cut off.
(1) Warm the engine up to 2500r/min at least, and check the noise of the injector with a sound level
meter (see Figure below).
(2) When the throttle releases, the noise from the injector should stop immediately; repeat several times.
声级计
Sound level meter
2 Check the fuel vapor discharge control system (see Figure below).
(1) After starting the engine, disconnect desorption tube of the canister;.
碳罐脱附软管
Canister desorption hose
碳罐控制阀
Canister control valve
Air intake manifold

Canister absorption hose
进气岐管
碳罐吸附软管
Canister
碳罐
(2) Select “Act Test" and "Canister Cleaning" based on the display on the trouble diagnosis instrument.
(3) Make sure that there is vacuum present at the canister control valve (TEV) port.
(4) After "Act Test", shut off the canister control valve operation instruction, then connect the Canister
92
Engine—Fuel System—Fuel Emission Control System
desorption hose.
(5) Start up the vehicle after the engine warms up, use the diagnosis tester to “read data stream”; check
the opening status of the canister control valve and make sure the TEV
ON.
3. Check whether there is any distortion or damage on the filling cap

and the washer
Washer
93
Engine—Fuel System—Carbon Canister Replacement
VI. Carbon Canister Replacement
1. Check and replace the canister.
(1) Check for crack or damage on the canister visually.
(2) Check the operation of the canister.
a. Plug the discharge port (see Figure 4-6). Absorption port
b. Blow air (4.71KPa) into the absorption port when keeping the discharge Vent Desorption port
port closed, and check the air should flow out from the exit port. If the
operation is unsatisfactory, replace the canister.
c. Blow air into the absorption port, the air should flow from other ports
without any resistance.
If the operation is unsatisfactory, replace the canister.
(3) Clean the canister: plug the desorption port, blow the air (4.71 kPa)
into absorption port and flow out the vent port.
2. Canister control valve (TEV) (See Figure below) Fig. 4-6
Mounting position: On the vacuum pipeline of the canister – air intake manifold.
Troubles: poor idle speed, malfunction, etc.
General cause: entry of foreign materials into inside of the valve results in corrosion and Poor tightness.
Maintenance precautions: During maintenance:
1. Air flowing direction must conform to specifications;
2. If the control valve fails due to black particles in the valve body, and it is necessary to replace the
control valve, please check the condition of the canister;
3. Avoid liquid such as water and oil entering into the valve during maintaining as possible;
4. It is recommended to mount the canister control valve on the hose hanging in the air or fasten with soft
rubber to avoid transmission of solid borne noise
94
Engine—Fuel System—Carbon Canister Replacement
碳罐脱附软管
Canister desorption hose
碳罐控制阀
Canister control valve
Canister absorption hose Air进气岐管

intake manifold
碳罐吸附软管
Canister
碳罐
Easy measuring method: (disconnect the connector) Set the digital multi-meter to ohm position, with two
leads connected to two pins of the canister control valve respectively, rated resistance 22-30Ωat 20°C
3. Vent valve (PCV) sub-assembly
Air should flow through the cylinder cap side easily.
Attention:
Cylinder side Air intake side
● Do not suction air through the valve.
● Never put anything into the valve. If the operation is Purge pipe
unsatisfactory, replace PCV.
Easy Difficult
● Blow air into from the suction side, and the air should be
hard to flow through. If the operation is unsatisfactory, refer
to Fig 4-7 to replace PCV. Fig. 4-7
95
Chassis—Transmission Control—Introduction of Transmission Control
Chapter 3 Chassis
Part 1 Transmission Control
I. Introduction of Transmission Control
1. Description on Transmission Control

This model is equipped with flexible shaft type manual Transmission Controls device, respectively used
for 3G10 1.0L and 479Q 1.3L engine. Their gears are: 5 forward gears + 1 reverse gear.
2. Symptom Table
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the
likely cause of the problem. Check each part in order. If necessary, replace these parts.
Symptom Suspected Area
1. Transmission Control selector (position changing) flexible shaft

(improperly assembled)
Transmission out of gear 2. Flexible shaft or gear shift lever (worn)
3. Flexible shaft assembly (incorrect)
4. Transmission (faulty)
1. Transmission control selector (position changing ) flexible shaft

(improperly assembled)
Transmission shift difficult 2. Flexible shaft or gear shift lever (worn)
3. Flexible shaft assembly (incorrect)
4. Transmission (faulty)
96
Chassis—Transmission Control—Introduction of Transmission Control
Component view
Spring clip Lock pin

Gear shift lever 弹簧卡片锁销（Q50108）
换档手柄球头
handle ball Plain
Lock pin
锁销（Q50110）平垫圈（Q40208）
Bolt
螺栓（Q1400825） washer
Manual gear shift lever
手动换档器
Flexible shaft for gear
selection and shift
选换档软轴
Fixing bolt for thrust plate

选换档软轴压板固定 Fixing bolt for bracket of
选换档软轴支架固
of flexible shaft for gear flexible shaft for gear
螺栓（Q1400616）
selection and shift 定螺母（Q32006）
selection and shift (Q32006)
(Q1400616)
97
Chassis—Transmission Control—Flexible Shaft for Shifting Gear
II. Flexible Shaft for Shifting Gear
Replacement
1. Remove the upper cover assembly in dashboard panel.
2. Remove the lower cover assembly in dashboard panel.
3. Remove the cup-holder in the middle console.
4. Loosen transmission control cover.
5. Remove the handle of the gear shift lever and boot.
6. Remove the middle console body.
7. Remove the flexible shaft assembly of the transmission
(1) Remove the two lock pins and unfix the head of the flexible shafts of the
transmission (see the right figure).
(2) Remove the flexible shafts assembly after loosening the connector of
flexible shaft and gear shift lever.
(3) Remove the two lock pins and two washers, and then unfix the two
flexible shafts from the manual transmission.
(4) Remove the two spring clips and unfix the two flexible shafts from the
bracket.
(5) Remove the bolt and unfix the flexible shafts.
(6) Remove the two bolts.
(7) Pull the flexible shafts out of the body.

(8) Remove the fixing plate from the flexible shafts.
98
Chassis—Transmission Control—Flexible Shaft for Shifting Gear
8. Install the flexible shafts assembly of the transmission

(1) Push the flexible shafts into the floor.
(2) Install the flexible shafts assembly with two bolts.
Torque: 5.0N·m
(3) Connect the flexible shafts assembly and fix the flexible shaft with bolts.
Torque: 5.0N·m
(4) Connect the ends of the two flexible shafts, and then install two washers
and two lock pins.
(5) Install two new spring clips on the cable bracket.
(6) Connect the flexible shafts to gear shift lever.

Note: Make sure the claws engage firmly.
(7) Connect the ends of the flexible shafts to the gear shift lever selectively,
and then install the lock pin.
Note:
● When connecting the flexible shafts, the tooth part of their ends
shall be made upwards.
● The lock pins are inserted in a direction as shown in the figure
(8) Connect the ends of the gear shift flexible shafts to the gear shift lever
assembly.
9. Install the middle console body
10. Install the handle and boot of the gear shift lever
11. Install the cup-holder
12. Install the upper cover in dashboard panel
13. Install the lower cover in dashboard panel
99
Chassis—Transmission Control—Manual Transmission Shift Assembly
III. Manual Transmission Shift Assembly
Replacement
1. Remove the upper cover in dashboard panel.
2. Remove the lower cover in dashboard panel.
3. Remove the cup-holder in the middle console
4. Loosen transmission control boot
5. Remove the handle of the gear shift lever and boot
6. Remove the middle console body.
7. Remove the flexible shafts assembly of the transmission
(1) Remove the two lock pins and unfix the head of the flexible shafts of the
transmission.
(2) Remove the spring clips and separate the flexible shafts from the
bracket.
8. Remove the manual gear shift lever assembly

Remove the four bolts and manual gear shift lever assembly
9. Install the manual gear shift lever assembly.

Install the manual gear shift lever assembly with four bolts.
Torque: 12N·m
10. Connect the flexible shafts assembly

(1) Connect the flexible shafts to gear shift lever assembly.
100
Chassis—Transmission Control—Manual Transmission Shift Assembly
(2) Connect the ends of the flexible shafts to the manual gear shift lever
assembly, and then install the lock pins.
Note:
● When connecting the ends, the serration shall be made upwards.
● The lock pins are inserted in a direction as shown in the figure.
(3) Connect the flexible shaft to the gear shift lever assembly.
11. Install the middle console body.
12. Install the gift shift control lever handle.
13. Install the gift shift control lever boot.
14. Install the cup-holder
15. Install the lower cover in dashboard panel.
16. Install the upper cover in dashboard panel
101
Chassis—Accelerator Pedal Device—Introduction of Accelerator Pedal
Part 2 Accelerator Pedal Device
I. Introduction of Accelerator Pedal
Component View
Bracket
支架 Bracket
支架
Throttle Adjusting
cable
油门拉线调节螺母（Q360B08)
nut
Connecting
与节气门连接
with throttle
前围板
Front wall
Mounting bolt of
加速踏板安装螺栓
accelerator pedal
（Q1400620）
Accelerator
加速踏板 pedal
Replacement
1. Disconnect the accelerator cables.
Loosen the accelerator cables and the bolts on the accelerator cable fixing
bracket of the engine, and then disconnect the accelerator cables from the
throttle rocker arm.
2. Remove the accelerator pedal and throttle cable.

(1) Remove the two fixing bolts that connect the accelerator pedal and the
body.
(2) Disconnect the throttle cables and accelerator pedal.

(3) Take off accelerator pedal
(4) Disconnect throttle cable and dash panel (passing hole blocked)
(5) Disconnect throttle cable and the bracket

(6) Take off throttle cable
102
Chassis—Accelerator Pedal Device—Introduction of Accelerator Pedal
3. Install the throttle cables and accelerator pedal assembly in a reverse order.
Note:
(1)The torque of fixing bolt of accelerator pedal assembly is: 22～29N.m
(2)Adjust the fixing nut position of the accelerator cables properly to obtain a proper tension.
(3)Check that the acceleration control runs freely and reliably.
103
Chassis—Clutch Assembly—Introduction of Clutch Control System
Part 3 Clutch Assembly
I. Introduction of Clutch Control System
1. Description
The vehicle is equipped with 2 kinds of clutch control system: cable clutch control system for vehicle with
engine displacement of 3G10 1.0L, and hydraulic clutch control system for vehicle with engine
displacement iof 479Q 1.3L
2. Symptom Table
The table below lists the common symptoms and possible causes of the failures. The number means the
possible sequence of the causes. Check the parts, and replace the corresponding parts if necessary.
Failure Inspection part

1. Clutch pedal (free stroke maladjusted)
2. Control mechanism (seized)
3. Clutch plate (oil dirt or grind)
Clutch slipping
4. Diaphragm spring (damaged)
5. Pressure plate (deformed)
6. Flywheel (deformed)
Clutch can not be separated or can not be 1. Clutch pedal (free play maladjusted)
separated thoroughly 2. Clutch cable (installed or adjusted incorrectly)
1. Release bearing of clutch (wearing, dirty or damaged)
Abnormal sound of clutch
2. Torsional spring of clutch plate (damaged)
104
Chassis—Clutch Assembly—Clutch Components and Common Failure
II. Clutch Components and Common Failure
I. Clutch components
Generally, the clutch can be divided into pressure plate assembly and driven plate assembly.
Clutch driven disc assy.

离合器从动盘总成 Clutch press plate assy.
离合器压盘总成
II. Clutch common failure and cause analysis

(I) Clutch slipping
1. Symptom: when the vehicle starts driving, it can starts only when the clutch pedal is lifted very high;
vehicle speed can not increase accordingly when accelerating during driving. They are all symptoms of
clutch slipping
2. Causes and troubleshooting:
(1) There is oil dirt on clutch disc, surface aging reduces friction coefficient and drive torque.
Troubleshooting: clean oil dirt, grind pressure plate and flywheel friction surface as appropriate.
(2) Positive pressure of diaphragm spring decreases due to lack of elasticity, deformation, burnt or
damage due to long-term usage.
Troubleshooting: replace clutch.
(3) Excessive abrasion to the disc causes diaphragm spring extending excessively, resulting in decrease
of positive pressure.
Troubleshooting: replace clutch.
(4) Improper adjustment of free stroke and effective stroke of the pedal affects effect of pressing force.
Troubleshooting: re-adjust to specified range.
(II) Clutch can not separate thoroughly, and it is hard to engage gear
1. Symptom: when the engine is running at idle speed, though clutch pedal is depressed to the extreme
position, it is still difficult to engage gear, and transmission gear produces knocking sound. After
engaging gear reluctantly, the vehicle has driven or flamed out with clutch pedal not released.
Check: remove the bottom cover of clutch, and put the transmission into neutral gear, then depress
clutch to the extreme position. After that, toggle the driven disc with screwdriver. If it can be toggled
easily, it indicates that clutch can separate well; if not, it indicates that the clutch does not separate
105
thoroughly.
2. Troubleshooting:
(1) Check whether the free stroke of clutch pedal is too large, and adjust it.
(2) Check whether releasing levers are of the same height or too low. Toggle the release fork under the
vehicle to make the front end touching the inner end face of release lever lightly, then check it by rotating
the clutch one turn, if the inner ends of release lever fails to touch the release levers simultaneously, it
indicates that release levers are not of the same height, and they should be adjusted. If they are of the
same height, but releasing is still not thorough, it is required to check lever height. Adjust release levers
to the same height, if releasing is thorough, it indicates original adjustment is improper or wearing is too
serious. After adjustment of release levers, free stroke of clutch pedal must be readjusted.
(3) If the releasing is still not thorough after adjustment above, it is necessary to remove the clutch to
check whether driven disc is installed reversely, axial movement is hard, pressure plate and driven disc
are warping, release lever screws are loose or floating pin has fallen off.
(4) For the clutch with newly-riveted frictional plate, check whether driven disc and the frictional plate are
too thick. If so, add gasket between the clutch cover and the flywheel.
(5) For hydraulically-driven clutch, in addition to inspection above, it is also required to check whether
brake fluid is insufficient or pipe is leaking and exhausts the air in hydraulic system.
(III) Clutch vibration when engaging
1. Symptom: when the clutch engages gently as normal operation, the vehicle starts intermittently
instead of accelerating gradually and smoothly, and the vehicle even vibrates until the clutch engages
completely.
2. Causes and troubleshooting:：
(1) Pressure between driving and driven discs is not distributed evenly. The elasticity of pressure spring
on engaging clutch is not even, release levers are not adjusted consistently or releasing end of
diaphragm spring is not flat, all above may cause compacting time inconsistent, uneven force applied on
pressure plate, even cause pressure plate sway, resulting in poor contact between driving and driven
discs, thus clutch vibration. In this case, clutch pressure spring should be replaced and release levers
should be adjusted.
(2) Clutch torsion, elasticity reduction of damper spring and clutch pressure spring and cracks on
diaphragm spring may all cause clutch vibration during engaging. In this case, springs should be
replaced.
III Removal and installation of clutch
(I) Clutch removal
Clutch assembly contains clutch pressure plate assembly and clutch driven disc assembly, removal
procedure is as follow;
1. Remove the transmission from the engine
2. Insert special locating spindle into the spline of splined hub of clutch driven disc
3. Loose fixing bolts on clutch cover of the flywheel by 2-3 times diagonally
4. Since the clutch assembly rotates together with crank at high speed, excellent balance performance is
required, before removing the pressure plate, it must be marked properly to facilitate precise positioning
for reassembly.
5. Remove clutch pressure plate assembly and driven disc assembly
106
(II) Clutch installation

In principle, clutch is installed in reverse order to the removal
1. Assemble clutch pressure plate and driven disc assembly
2. Driven disc and pressure plate should be put into the flywheel housing together with the face of
damper spring facing to the plate.
3. Insert the special locating spindle into frictional plate spline hole.
4. After aligning with the assembling mark made at disassembly, screw up fixing bolts of clutch pressure
plate onto the flywheel manually.
5. Put the special locating spindle flat and insert its front end into the bearing inner race of supporting
hole at rear of crank.
6. Screw up clutch fixing bolts by 2-3 times in diagonal direction and order。
107
Chassis—Clutch Assembly—Clutch Pedal
III. Clutch Pedal
Component View
Bolt
螺栓 Nut母
螺螺栓
Bolt
Clips
带焊母卡片 with welding nut
Mounting nut
安装螺母
Clutch
离合制动
brake pedal
Clutch
离合拉线踏板
cable
Clutch
离合器分离 release
fork
拨叉摇臂rocker
2. Hydraulic type clutch control system (model 1.3L)
108
Oil inlet of
总泵进油软
master cylinder Clutch brake
管离合及制动
pedal
踏板带支架with
bracket
总成
assembly
Hydraulic hose
液压软管
Fixing bracket of Oil 总泵出油管

outlet pipe
液压软管固 components of Clutch
hydraulic tube 组件离合器总泵master
定支架 the master cylinder
总成
cylinder assembly
Adjustment
1. Check and adjust the clutch pedal.
(1) Lift the carpet on the floor.
(2) Check the pedal’s height is proper.
Pedal's height from oil felt: 110-120mm
(3) Adjust the pedal's height.
Loosen the lock nut, and turn the lock bolt till the correct pedal's
height is reached, and then tighten the lock nut.
Torque: 16N.m
(4) Check whether the pedal’s free travel and push rod are
proper
a. Step the pedal down till a resistance appears.
Pedal's free stroke: 5-15mm
b. Step the pedal down lightly till the resistance increase a little.
Push rod (on the pedals top) travel: 1.0-5.0mm
(5) Adjust the pedal's free travel and push rod travel.
① Loosen the lock nut, and turn the push rod till the pedal's free
travel and push rod travel are proper.
② Tighten the lock nut.
Torque: 12N·m
109
③ Check the pedal's height after adjusting the pedal's free travel.
(6) Check the clutch's separating point.
① Tension the parking brake device and install a wheel stopper.
② Start the motor and make it run idle.
③ Don’t step the clutch pedal,and put the gear shift lever to the reverse gear slowly till the gears engage.
④ Step the clutch pedal down slowly,and measure the travel distance between the gear abnormal sound
disappearing point (separating point) to the pedal travel end position.
Standard distance: 25mm or above (pedal travel end position to separating point)
If the distance doesn't meet standard, carry out the following steps.
● Check the pedal's height.
● Check the push rod stroke and pedal's free travel.
● Discharge the air in the clutch fluid pipe.
● Check the clutch cover and clutch disc.
● Check the pedal's travel.
Pedal travel：85-95mm
Replacement
1. Cable type clutch control system replacement (model 1.0L)
1. Remove the battery negative terminal.
2. Remove the upper cover in dashboard panel
4. Remove the control panel
5. Disconnect the connecting of clutch cable and pedal
6. Remove the clutch pedal bracket.
Remove 4 nuts and 2 bolts, and then remove the clutch pedal bracket
7. Remove the clutch pedal
(1) Remove the clutch pedal shaft and nuts.
(2) Remove the clutch pedal from the clutch pedal bracket. Lubricating gasket
Clutch pedal shaft
Lubricating bushing
110
8. Remove the clutch pedal boot
Clutch pedal gasket
9. Remove the clutch pedal buffer stopper.
Remove buffer stopper from the clutch pedal.
Lubricating gasket
10. Remove the clutch pedal shaft bushing. Clutch pedal shaft
Lubricating bushing
Remove the two shaft bushings from the clutch pedal.
Lubricating gasket
11. Install the clutch pedal shaft bushing Clutch pedal shaft
Lubricating bushing
(1) Apply multi-function grease on both sides of the two new shaft bushings.
(2) Install the two shaft bushings on the clutch pedal.
12. Install buffer stopper on the clutch pedal.
Put buffer stopper on the clutch pedal.
13. Install the clutch pedal
Install the clutch pedal on the clutch pedal bracket with bolts and nuts.
Torque: 37N·m
Lubricating gasket
Clutch pedal shaft
Tips: Install the bolts from the right side. Lubricating bushing
111
14. Install the clutch pedal bracket.
Install the clutch bracket with 4 nuts and 2 bolts.
Torque: 12N·m
15. Connect the clutch cable and pedal
17. Connect the battery negative terminal
Note:
(1) Adjust position of adjusting nuts on clutch cable properly to ensure that the tension of clutch
cable is appropriate.
(2) Check whether clutch operation is flexible and reliable.
(3) Tightening torque for fixing bolts of clutch pedal: 20～25N.m
(4) Check the clutch pedal for its installation height, working stroke and free play
a. Installation height of clutch pedal: 10～120 mm
b. Working stroke of clutch pedal: 85～95 mm
c. Free stroke of clutch pedal: 5～15 mm
112
2. Replacement of hydraulic type clutch operating system (model 1.3L):
1. Remove the battery negative terminal.
2. Remove the upper cover in dashboard panel
4. Remove the panel of the control board
5. Disconnect the clutch master cylinder and pedal
6. Remove clutch brake pedal with bracket assembly
Remove 5 nuts and 2 bolts, then take off clutch brake pedal with bracket
assembly
7. Disassemble and assemble of clutch pedal
(1) Remove the pedal shaft and nuts.
(2) Remove the clutch pedal from the clutch pedal bracket.
Clutch pedal gasket
(3) Remove the clutch pedal gasket
(4) Remove the clutch pedal buffer stopper.
Remove buffer stopper from the clutch pedal.
113
(5) Remove the clutch pedal lubricating shaft bushing.
Remove the two lubricating shaft bushings from the clutch pedal.
(6) Install shaft bushing of clutch pedal
(a) Coat multi-functional lubricating grease on both sides of 2 new

bushings.
(b) Install 2 shaft bushings into clutch pedals.
(7) Install the clutch pedal buffer stopper.
Install buffer stopper from the clutch pedal.
(8) Install the clutch pedal arm
Install the clutch pedal on the clutch pedal bracket with bolts and nuts.
Torque: 37N·m
Tips: Install the bolts from the left side.
8. Remove and install clutch master cylinder and its pipeline
(1) Remove hydraulic hose of the clutch
Loose 2 pipe bolts and plug out 2 spring clips, then take off hydraulic
hose.
(2) Remove outlet pipe components of the master cylinder
Loose pipe bolts connected to the clutch master cylinder, then take out
outlet pipe components of the master cylinder.
(3) Remove oil inlet hose of the master cylinder.
Remove 2 steel belt elastic clamps, then take out inlet hose of the
master cylinder.
114
(4) Remove clutch master cylinder assembly
Unfix a nut of installing master cylinder (the other is a common nut shared
with installing hole of clutch pedal bracket).
(5) Install clutch master cylinder assembly
Put the master cylinder onto front wall assembly in correct direction and
then tighten the nut.
(6) Install oil inlet hose of the master cylinder
Install steel belt elastic clamp by inserting the oil inlet hose on oil inlet of
the master cylinder and the oil tank of vacuum booster.
(7) Install oil outlet pipe components of the master cylinders
Put the connecting end of outlet pipe master cylinder at oil outlet of the master
cylinder, and then tighten pipe bolts.
(8) Install hydraulic hose of the clutch
Connect hydraulic hose to oil outlet pipe components and hard pipe of
cylinder, tighten pipe bolts, and install elastic clips.
115
(9) Install bracket of clutch pedal
Install clutch bracket with 5 nuts and 2 bolts.
Torque: 12N·m
10. Connect the clutch master cylinder and pedal
12. Connect the battery negative terminal
Note:
(1) Adjust retaining bolts on clutch pedal and adjusting nuts of the master cylinder to ensure that
there is free stroke and no clearance in clutch control system
(2) Check whether clutch control is flexible and reliable.
(3) Tightening torque for fixing nuts of clutch pedal: 20～25N.m
(4) Check the clutch pedal for its installation height, working stroke and free stroke
a. Installation height of clutch pedal: 130～140 mm
b. Working stroke of clutch pedal: 125～135 mm
c. Free stroke of clutch pedal: 5～15 mm
116
Chassis—Manual Transmission Assembly (1.0L)
Part 4 Manual Transmission Assembly (1.0L)
Component View
Shift
换挡器 gear
Release fork
Clutch release Clutch housing
shaft component 离合器壳体 Transmission
bearing
离合器分离轴承
分离拨叉轴组件
body 变速箱体
Clutch
离合器分离拨叉
release fork
Input shaft
assembly
Output shaft First, second and fifth
assembly reverse interlock pins
Differential Fifth reverse shift

assembly fork assembly
Third-and-fourth
shift fork assembly
1st and 2nd

gear shifting
fork assembly
117
Chassis—Manual Transmission Assembly (1.0L)—Removal and Installation of Transmission
I. Removal and Installation of Transmission
Ⅰ. Remove the transmission from the vehicle individually
1. Jack up the vehicle, make front and rear wheels suspended, and then remove two front wheels.
2. Remove the drain plug of transmission, and then reassemble it after draining up gear oil in the
transmission.
3. Remove battery cable, filter and other pipes.
4. Remove the socket of reverse lamp switch and the flexible shaft of speedometer.
5. Remove fixing bolts on shift lever of transmission, and then remove the shift lever.
6. Remove connecting bolts on engine mudguard and engine exhaust pipe.
7. Remove engine fixing bolts and then remove the starter.
8. Release the connection with drive shaft and both sides of transmission, and then remove left and right
drive shafts.
9. Remain engine at original position by special bracket, or lift the engine with crane.
10. Lift transmission assembly with crane, or jack up it with a special jack.
11. Remove fixing nuts on the bracket of transmission assembly, and then take off fixing bracket
assembly.
12. Loose and take out transmission housing and engine connection bolts.
13. Separate the transmission and the engine, and then take off transmission assembly carefully.
Ⅱ. Install the transmission on the vehicle.
The order is reverse to the removal sequence, in addition, attention should be paid on following points:
1. A thin layer of high-quality lubricant of specified brand should be coated on input shaft of the
transmission
2. During installation, ensure that installing position is correct, and tighten bolts and nuts as per the
specification.
3. Install oil seal for upper left and upper right drive shafts, and then install upper left and upper right
drive shafts.
4. Fill gear oil (2.05L).
5. After all installation is completed; check whether working condition of the transmission is normal.
118
Chassis—Manual Transmission Assembly (1.0L)—Removal and Installation of Transmission Assembly
II. Removal and Installation of Transmission Assembly
Ⅰ. Transmission removal:
1. Loose 4 installing screws on the cover of shift control device, and rotate the shift rocker to neutral
position, and then take off gear shift assembly.
Roll pin of shift cover
Reverse lamp
switch seat Shift guide shaft
assembly
2 wire Tightening bolts

clamps of shift cover
Flange
nuts
2. Make the clutch housing of transmission assembly facing downwards,
loose 12 connecting bolts on transmission housing, and then take off
transmission housing.
3. Take out reverse intermediate wheel, loose fixing screws on the support
of reverse swinging arm, and take out reverse swinging arm
sub-assembly from clutch housing.
Reverse swingingSet screws on bracket ofReverse

2 centering pins
arm sub-assembly reverse swinging arm intermediate
shaft
4. Remove interlock pins of first & second and fifth & reverse gear. Take
out output shaft assembly, input shaft assembly, shifter fork assembly of
first and second gear, shifter fork assemblies of third and fourth gear and
fifth reverse gear from the clutch housing at the same time, then remove
shifter fork assemblies of third and fourth gear and fifth reverse gear from
input shaft assembly, disassemble shifter fork assemblies of first and
second gear from output shaft assembly, and finally take away differential
assembly from the clutch housing.
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Chassis—Manual Transmission Assembly (1.0L)—Removal and Installation of Transmission Assembly
Interlock cam Ring A of fifth Shift rocker Interlock cam ball of Shift guide shaft
spring of fifth/ reverse shift sub-assembly fifth/reverse gear boot
reverse gear f
Interlock cam pin
of fifth/ reverse
gear
Interlock cam of
fifth reverse gear
Gear shift
swinging lever
Gear shift
Ring B of shift Gear shift rocker
guide shaft cover sub-assembly
Return Return spring Gasket of return

spring B Nylon washer off Elastic Interlock A spring A
shift guide shaft cylinder bracket of shift
pin swing lever
Vent plug sub-assembly
Disassemble shift guide shaft sub-assembly
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Chassis—Manual Transmission Assembly (1.0L)—Disassembly of Gear Shift Guide Shaft Sub-assembly
III. Disassembly of Gear Shift Guide Shaft Sub-assembly
Screw out the vent plug from transmission housing directly, and remove return spring B, nylon washer of
gear shift guide shaft, ring B of gear shift guide shaft, elastic cylinder pin, shift swing lever, interlock
support of shift swing lever, return spring A, gasket of return spring A, clip A of shift guide shaft from the
shift guide shaft orderly. Take out shift rocker sub-assembly and rotation rocker sub-assembly.
Assemble gear shift guide shaft sub-assembly:
1. Put interlock cam of fifth reverse gear through interlock cam spring of fifth reverse gear, into interlock
cam hole of fifth reverse gear on shift cover, insert one end of interlock cam spring into the hole on the
interlock cam, install interlock cam pin and interlock cam ball of fifth reverse gear into the pin hole orderly,
and align the pin with interlock cam groove by rotating interlock cam, then knock interlock cam ball to
install it in place.
2. Install rotation rocker sub-assembly
3. Pass shift rocker sub-assembly through shift guide shaft guard and shift cover
4. Install ring A of shift guide shaft, gasket of return spring A, return spring A, interlock support of shift
swing lever, shift swing lever, elastic cylinder pin, clip B of shift guide shaft, nylon washer of shift guide
shaft and return spring B onto the shift guide shaft orderly.
5. Install the vent plug into transmission housing and tighten it, tightening torque is 10-13N.m.
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Chassis—Manual Transmission Assembly (1.0L)—Disassembly of Differential Sub-assembly
IV. Disassembly of Differential Sub-assembly
Planetary gear shaft
Side gear
Side gear gasket
Planetary gear
Planetary gear gasket

Front bearing of
differential
Differential
housing
Differential Drive gear of Rear bearing

Elastic
ring gear 10 pieces speedometer of differential
cylinder pin
Disassemble differential sub-assembly
Pull two bearings from the differential housing with a special tool. Install the ring gear hole side of
differential with large chamfer into the differential housing, and then take out differential ring gear by
loosing 10 bolts M12. Knock out the elastic cylinder pin from differential housing and planetary gear shaft.
Remove differential housing, planetary gear gasket and planetary gear from planetary gear shaft. And
then remove planetary gear gasket, planetary gear, side gear gasket and side gear from differential
housing orderly.
Assembly of differential sub-assembly:
1. Put side gear, planetary gear and side gear gasket, planetary gear gasket into differential housing,
and then pass planetary gear shaft through differential housing, planetary gear gasket and planetary
gear.
2. Knock elastic cylinder pin through differential housing and planetary gear shaft.
3. Install the ring gear hole side of differential with large chamfer into the differential housing, and tighten
it with 10 bolts, tightening torque is 100～110N.m.
4. Press 2 bearings in place into differential housing individually with pressure of 1000kg.
Requirements after assembly: bearing can rotate freely without seizing or abnormal sound; planetary
gear and side gear rotate freely, engagement clearance should be 0.05-0.25mm, no seizing or abnormal
sound; planetary shaft is aligned with the housing.
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Chassis—Manual Transmission Assembly (1.0L)—Disassembly of Input Shaft Sub-assembly
V. Disassembly of Input Shaft Sub-assembly
Spacing ring of fifth needle Thrust washer ring Thrust washer of fourth gear Input fourth gear Fourth gear ring
roller bearing of fourth gear
Locating steel ball for axial
shim of fourth gear
Fourth needle roller
bearing Input third/fourth
Rear bearing of Spacing ring of fourth synchronizer
input shaft needle roller bearing
Gear hub ring of
Input fifth synchronizer Input third gear
synchronizer
Third-and-fifth
synchronizer ring
gear (2 pieces) Needle roller
bearing of third gear
Input fifth gear
Needle roller
bearing of fifth gear
Input shaft Front bearing of input shaft
Disassemble input shaft sub-assembly
Pull rear bearing from input shaft with a special tool, then remove fifth synchronizer, third-and-fifth
synchronizer ring gear, input fifth gear, needle roller bearing of fifth gear, spacing ring of fifth needle roller
bearing, thrust washer ring of fourth gear, thrust washer of fourth gear, locating steel ball for axial shim of
fourth gear, fourth gear, third-and-fourth synchronizer ring gear, fourth needle roller bearing, spacing ring
of fourth needle roller bearing, gear hub ring of synchronizer, third-and-fourth gear sleeve assembly,
third-and-fourth synchronizer ring gear, third gear from the input shaft orderly, install needle roller
bearing of third gear on input shaft, and do not scratch the surface
of input shaft during disassembly.
Measure wearing condition of input shaft with micrometer,

minimum diameter of surface A is 33.975mm, and that of surface
B is 30.975mm, if the diameter is out of the range, replace the
input shaft.
Detect axial clearance of third gear with a feeler gauge
Axial clearance of third input shaft: 0.15-0.30mm.
Axial clearance of fourth gear: 0.13-0.34mm. Third gear
Detect input shaft radial run-out by the method shown in the figure
Maximum diameter run-out is 0.03mm
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Chassis—Manual Transmission Assembly (1.0L)—Disassembly of Input Shaft Sub-assembly
Detect axial clearance of third gear with a feeler gauge, its

standard value is 0.1～0.35mm
Third gear
Detect axial clearance of the fifth gear as shown in the figure,, its standard
value is 0.1～0.50mm
Fifth gear
Detect radial clearance of fourth gear and fifth gear as shown in the figure:
Standard value ≤ 0.058mm
Detect axial clearance of the fourth gear, its standard value is 0.1～0.55mm
Third gear
Measure wearing condition of input shaft with micrometer,

minimum diameter of surface A is 33.975mm, and that of surface
B is 30.975mm, if the diameter is out of the range,, replace the
input shaft.
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Chassis—Manual Transmission Assembly (1.0L)—Assembly of Input Shaft Sub-assembly
VI. Assembly of Input Shaft Sub-assembly
1. Smear the gear oil on input shaft, rotating and sliding parts.
2. Press front bearing of input shaft into the input shaft with the pressure of 500kg.
3. Install needle roller bearing of third gear, third gear, synchronizer ring gear of third-and-fourth gear,
gear sleeve assembly of third-and-fourth gear, gear hub ring of synchronizer, spacing ring of fourth
needle roller bearing, fourth needle roller bearing, third-and-fourth synchronizer ring gear, fourth gear,
locating steel ball for axial shim of fourth gear, thrust washer of fourth gear, thrust washer ring of fourth
gear, spacing ring of fifth needle roller bearing, needle roller bearing of fifth gear, input fifth gear,
third-and-fifth synchronizer ring gear, input fifth synchronizer and rear bearing of input shaft onto the
input shaft orderly.
4. Install the rear bearing in place by depressing with the pressure of 500kg.
Disassembly of output shaft
Locating bush of Input third Second gear Ring of needle

third/fourth gear gear needle roller roller bearing
bearing Gear hub ring of
synchronizer
Output second
gear assembly
Rear bearing of
input shaft First/second teeth
sleeve assembly
Fifth gear
ring
Output fifth
gear
Output
fourth gear
Triple-cone ring
Output Front bearing of first/second Output first gear Needle roller
shaft of output shaft synchronizer assembly bearing
Disassemble output
shaft sub-assembly
Pull rear bearing from the output shaft with a special tool. Remove
fifth gear ring, output fifth gear, output fourth gear, locating bush of
third-and-fourth gear, output third gear, output second gear
assembly, second needle roller bearing, triple-cone ring of
first-and-second synchronizer, clip of needle roller bearing, clutch hub clip of synchronizer,
first-and-second teeth sleeve assembly, triple-cone ring of first-and-second synchronizer, output first
gear assembly and needle roller bearing from the output shaft. Do not scratch output shaft surface
during removal. Check wearing and damage condition of the output shaft. Check outer diameter
dimension of needle roller bearing table with a micrometer, the minimum value is 33.975mm, when the
actual is below this value, replace the output shaft.
125
Detect axial clearance from the back of synchronizing ring to end

face of gear spline with a feeler gauge: the minimum clearance is
0.8mm, if it is lower than minimum value, the synchronizing ring
should be replaced.
Check circle run-out as shown in the figure, allowable maximum

run-out is 0.03, and the output shaft should be replaced if the value
is exceeded
Check the clearance between fork groove of teeth sleeve and the fork
with a feeler gauge, the maximum clearance value is 0.35mm, and the
fork should be replaced if actual value is above this value
Check circle run-out as shown in the figure, allowable maximum run-out is

0.03, and the output shaft should be replaced if the value is exceeded
Measure axial clearance between first and second gears with a Second gear
First gear
feeler gauge
First gear: 0.15-0.32mm
Second gear: 0.13-0.34mm.
Assemble output shaft:
1. Smear gear oil on output shaft, rotating and sliding parts.
2. Install needle roller bearing, output first gear assembly, triple-cone ring of first-and-second
synchronizer, first-and-second teeth sleeve assembly, gear hub ring of synchronizer, ring of needle roller
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bearing, triple-cone ring of first-and-second synchronizer, second needle roller bearing, output second
gear assembly, output third gear, locating bush of third-and-fourth gear, output fourth gear, output fifth
gear, fifth gear ring and rear bearing of output shaft onto output shaft.
Third/fourth shift
fork assembly
Interlock pins of
third, fourth and
reverse gear
Fifth shift fork

3 rings of fork
shaft
Return spring Fifth/ reverse Elastic cylinder Fifth gear shift

shift fork shaft pin guide block Reverse and shift
block
Disassemble reverse and shift fork shaft sub-assembly
3. Install the rear bearing in place by depressing with the pressure of 500kg.
Disassembly of reverse and shift fork shaft sub-assembly is as shown in the figure above.
Assemble reverse and shift fork shaft sub-assembly:
1. Install fifth shift guide block into fifth reverse shift fork shaft, aligning with the cylinder pin hole, knock
the elastic cylinder pin by hammer.
2. Install return spring and fifth shift fork into the fifth shift fork shaft, then install fork shaft ring to seize up
the fifth shift fork.
3. Install reverse and shift block under third-and-fourth shift fork shaft, and install interlock pins of third,
fourth and reverse gear from the hole at the side of reverse and shift block, then install the ring of fork
shaft.
4. Install fifth reverse and shift fork shaft into fifth reverse hole of reverse and shift block mentioned in
Step 3 (pay attention to the direction), then install the clip of fork shaft.
127
Third/fourth shift fork Third/fourth shift fork shaft
Ring of fork
shaft
Lock bolts of
shift fork
Disassemble third/fourth shift

fork sub-assembly
Disassembly of third-and-fourth shift fork sub-assembly is as shown in the figure above.
Assemble third-and-fourth shift fork sub-assembly:
1. Install third-and-fourth shift fork into its shaft, and tighten lock bolts of shift fork, the tightening torque is
7-10N.m.
2. Install fork shaft ring into its groove.
Ring of fork Firs/second Elastic cylinder

shaft shift fork shaft pin
Lock bolts of
shift fork
First/second
shift fork block
First/second
shift fork
Disassemble first/second shift fork sub-assembly
Disassembly of first-and-second shift fork sub-assembly is as shown in the figure above.
Assemble first-and-second shift fork sub-assembly:
1. Install first-and-second shift fork into its shaft, and tighten lock bolts on the shift fork, the tightening
128
torque is 7-10N.m;
2. Install first-and-second shift fork guide block into first-and-second shift fork shaft, and punch elastic
cylinder pin;
3. Install fork shaft r into its groove.
129
Chassis—Manual Transmission Assembly (1.0L)—Assembly of clutch housing accessories and clutch release
mechanism
VII. Assembly of clutch housing accessories and clutch release mechanism
Front bearing of inputt

shaft (outer race) Oil seal of input shaft
Dustproof pad Front bushing of Torsion Locking
release lever spring plate
Guide oil shim
Lock bolts of
Side gear oil seal of release fork
clutch
Rear bushing
of release
Clutch housing lever
Cable bracket
Cable bracket bolt

Clutch release Release Release
Harness clamp of cable bracket lever bearing fork
Assembly of clutch housing and clutch release mechanism
Disassembly of clutch housing accessories and clutch release mechanism assembly is as shown in the
figure above.
1. Press oil seal of input shaft soaked with oil into the hole on input shaft.
2. Put guide shim of output shaft into the hole on output shaft.
3. Press bearing outer race into the hole on output shaft.
4. Press oil seal of side shaft soaked with oil into the hole on differential.
5. Pass release lever through dustproof pad and front dustproof sleeve of release lever orderly, then
through release lever hole on the housing, after that, install torsion spring, release fork and rear bushing
of release lever on release lever.
6. Tighten release fork and release lever with tightening torque of 15-22N.m, then install release bearing.
7. Tighten cable bracket and its harness clamp with tightening torque of 15-22N. m.
130
Chassis—Manual Transmission Assembly (1.0L)—Installation of Transmission Assy.
VIII. Installation of Transmission Assembly
1. Press oil seal soaked with oil into the hole on differential;
Reverse Retaining bolts Oil seal of side
2. Install intake/drain plug on the transmission housing by passing it Oil

intake/drain
plug
2 sealing gaskets of
intake/drain plug
intermediate of reverse
gear groove intermediate
gear shaft
shaft of
transmission
Transmission
housing
through its gasket, and then tighten it with tightening torque of

25-30N.m;
3. Install the shaft of reverse intermediate gear into transmission Gear shift
stopper bolt
assembly
housing, tighten its retaining bolts with tightening torque of
15-22N.m;
4. Install shift lock bolt assembly into transmission with the screw at
half way;
5. Install oil guide groove into transmission housing;
6. Install transmission assembly into clutch housing;
7. Install first-and-second shift fork assembly into output shaft assembly

8. Install third-and-fourth and fifth reverse shift fork assembly into output
shaft assembly;
9. Install output shaft assembly, input shaft assembly, Input shaft assembly
Interlock pins of first,
Output shaft assembly second and fifth gear
first-and-second shift fork assembly, third-and-fourth and fifth
reverse and shift fork assembly into clutch housing at the same Differential assembly
Fifth reverse gear shift
fork assembly
time; Third/fourth shift

fork assembly
10. Install interlock pins of first, second and fifth reverse gear; First/second
shift
131
11. Install reverse swinging arm sub-assembly into clutch, and tighten
it with retaining screws of reverse swinging arm support, tightening
torque is 15-22N.m;
12. Knock locating pin;
13. Put in magnetic body assembly;
14. Put in reverse intermediate wheel;
Reverse swingingSet screws on the Reverse

2 centering pins arm sub-assembly bracket of reverse intermediate
swinging arm shaft
15. Make glue circle on the clutch housing, and then connect block with
end, no opening is permitted;
16. Put adjusting shims onto output shaft and input shaft;
17. Put transmission housing on the clutch housing;
Flange bolt
18. Tighten flange bolts on flange face, tightening torque is 16-22N.m
(when tightening bolts, they must be tightened on the cross)
Cable bracket
19. Install cable bracket I and cable bracket II onto clutch housing, and harness clamp
tighten them with tightening bolts of cable support, the torque should be
Cable bracket I
15-22N.m;
Cable bracket II
Tightening bolts of
cable bracket
132
20. Install hollow locating pin of shift cover into locating pin hole of shift Hollow centering pin
of shift cover
cover;
Reverse lamp
switch seat Shift guide
21. Install shift guide shaft assembly into transmission housing; shaft
assembly
22. Install 2 tightening bolts of shift cover by passing them through wire
clamp, 1 tightening bolt of shift cover through back-up lamp switch seat
with tightening torque of 15-22N.m; 2 wire Tightening bolts
clamps of shift cover
23. Install speedometer driven gear assembly, then put bolt M6×16
through the lock blade to install it into the screw hole on transmission
housing, clip the lock blade into the slot of speedometer driven gear
Speedometer
sleeve, and then tighten bolt M6×16 with torque of 7-10N.m. driven gear
sub-assembly
Observe glass
of speedometer
driven gear Tightening bolts of
speedometer driven
Torque for calibrating bolts of transmission assembly: sub-assembly
gear sub-assembly
Tightening bolts of Tightening bolts of Shift lock bolt Filler/drain

jointing surface shift cover plug
Tightening bolts of Tightening bolts of Reverse lamp Lock bolts of release

speedometer cable bracket switch fork
Assembly bolt distribution
1. Calibrate 13 bolts M8 on combination surface, torque is 15-22N.m;

2. Calibrate 4 bolts M8 on shift cover, torque is 15-22N.m;
3. Calibrate shift lock bolt M18, torque is 25-30N.m;
4. Calibrate bolts M18 on filler/drain plug, torque is 25-30N.m;
5. Calibrate lock bolts of release fork, torque is 15-22N.m;
6. Calibrate bolts M18 on back-up lamp switch, torque is 30-50N.m;
7. Calibrate 4 bolts M8 on the support of clutch cable, torque is 15-22N.m;
8. Calibrate speedometer tightening bolt M8, torque is 7-10N.m
133
Chassis – Manual Transmission Assembly (1.3L) – Assembly Disassembling
Part 5 Manual Transmission Assembly (1.3L)
I. Assembly Disassembling
Connecting bolts of end cover
End cover
Bearing thrust spring of
output shaft
Tightening bolts of Rear bearing gland of

shift cover output shaft
Connecting bolt
Release connecting bolts on the end cover first, take out end cover and bearing thrust spring of output
shaft, then put a special spanner whose end face has 4 cylinder projections into the 4 holes on rear
bearing gland of output shaft for screwing it out; release tightening bolts of shift cover to take out shift
cover assembly; then take off transmission housing by releasing connecting bolts of transmission.
Take out interlock pin with magnetic stick
Take out fork shaft clip as shown in the figure
134
As shown in the figure, clamp the upper part of fork shaft protected by
something like cloth with pliers to pull it out.
Take out reverse gear and its shaft
As shown in the figure, remove 2 bolts and the support of reverse

swinging arm
Remove interlock pin with magnetic stick, and pull out fork shaft and
fork
Remove bolt and fork shaft as shown in the figure
Remove clip in the manner shown in the figure
Remove clip and then take out fork
135
Remove lubricant oil pipe
Take out bushing in the manner shown in the figure
Take out oil seal
As the figure shows, take out bearing outer race with a special tool
Remove end cover of oil guide
Detect axial clearance of third gear with a feeler gauge, its standard
value is 0.1～0.35mm
Third gear
136
As shown in the figure, detect axial clearance of the fifth gear, its
standard value is 0.1～0.50mm
Fifth gear
Detect radial clearance of fourth gear and fifth gear as shown in the
figure:
Standard value ≤ 0.058mm
Locate input shaft assembly with pressure machine as shown in the

figure, meanwhile; hold the input shaft lower by hand to remove teeth
sleeve, teeth hub and fifth gear
Detect axial clearance of the fourth gear, its standard value is 0.1～ Third gear
0.55mm
Take off shaft clip with clip pliers

Note: do not scratch shaft surface
Take out locking ball with magnetic stick, and take off gear and
third-and-fourth synchronizer ring gear
137
Take off clip with clip pliers

Note: do not scratch surface
Locate synchronizer assembly, synchronizing ring and third gear with

pressure machine as shown in the figure
Note: Hold shaft lower part by hand to prevent it falling
Take off radial ball bearing with press machine. Hold shaft lower part
by hand to prevent it falling
Disassemble synchronizer assembly as the figure shows
As shown in the figure, take out elastic cylinder pin from shift swinging
arm with pin remover and hand hammer
138
Remove clip in the manner shown in the figure
Disassemble interlock support, shift swinging lever, spring and gasket

A in the manner shown in the figure
Remove shift swinging lever and connecting bolts
Remove the clip and disassemble it as shown in the figure
Remove shift guide shaft and dust cover from shift cover, and take off
gaskets as shown in the figure.
Take out oil seal of shift cover with a screwdriver as shown in the
figure
139
Take out the other oil seal on shift cover in the same way
Take off tapered bearing from differential housing in the manner

shown in the figure
Note: locate end face of bearing cone reliably
Take off cylinder bearing at the drive gear side of speedometer as

shown in the figure
Take off drive gear of speedometer
Remove tightening bolts of differential
Take out elastic cylinder pin with pin remover, and then take out 1
planetary gears and gaskets, 2 side gears and gaskets, and planetary
gear shaft orderly
Detect input shaft run-out by the method shown in the figure.
The maximum diameter is 0.03mm
140
Detect distance between the back of synchronic ring and the end face
of gear with a feeler gauge
The minimum value is 0.8mm, or else synchronic ring should be
replaced
Detect distance between teeth sleeve and shift fork with a feeler
gauge
The maximum value is 0.35mm, or else teeth sleeve and shift fork
should be replaced
Measure wearing condition of input shaft with micrometer, minimum

diameter of surface A is 33.985mm, and that of surface B is
30.985mm, if it is out of the range, replace the input shaft.
First gear Second gear

Measure axial clearance between first and second gears with a feeler
gauge
First gear: 0.1～0.35mm
Second gear: 0.1～0.35mm
Measure run-out of first and second gears as shown in the figure, the
maximum run-out is 0.056mm
Take off tapered bearing in the manner shown in the figure

Note: 1. Hold shaft lower part to prevent it falling
2. Clamp bearing cone reliably
Remove tapered bearing at the other side in the same way
141
Remove spring snap ring from output shaft in the manner shown in
the figure
Take off fourth and fifth gear with pressure machine

Note: hold shaft lower part to prevent it falling
Move first-and-second teeth sleeve to first gear
Remove third gear with pressure machine. Hold shaft lower part to
prevent it falling. And remove needle roller bearing, synchronic ring
and second gear.
Remove clip with clip pliers, do not scratch bearing surface of the
shaft
Check circle run-out as shown in the figure, allowable maximum

run-out is 0.03, and the output shaft should be replaced if the value is
exceeded.
142
Detect axial clearance from the back of synchronic ring to end face of
gear spline with a feeler gauge: the minimum clearance is 0.8mm, if it
is lower than the minimum value, the synchronic ring should be
replaced.
Check the clearance between teeth sleeve fork groove and the fork
with a feeler gauge, the maximum clearance value is 0.35mm, and the
fork should be replaced if actual value is larger than this value
Check wearing and damage condition of the output shaft, check outer
diameter dimension of bearing table with a micrometer, the minimum
value is 33.985mm, when the actual is below this value, replace the
output shaft.
Install first gear and synchronic ring in the direction shown in the
figure
Press first-and-second synchronizer assembly into input shaft with

pressure machine, the direction is as shown in the figure
Replace bulged shaft clip with a new one

Note: do not scratch shaft surface
143
Install synchronic ring, needle roller bearing and second gear
Press third gear into output shaft with pressure machine as the figure
shows, and the direction is as shown in the figure
Press fourth gear and fifth gear into output shaft with pressure
machine in the manner shown in the figure, and the direction is as
shown in the figure
Press bearing shaft into input shaft with pressure machine in the way
shown in the figure
Note: adjust the bearing cone to locate reliably
As shown in the figure, install needle roller bearing, third gear and
third synchronic ring, and install synchronizer assembly in the
direction shown in the figure
Install a new clip onto the input shaft
144
Install needle roller bearing, then install third-and-fourth synchronizer

assembly in the direction the figure shows, and install fourth gear onto
input shaft
Install locating ball as the figure shows, and pass the fifth thrust pad
through the ball and install it into input shaft
Install clip in the same way as mentioned before
As shown in the figure, install needle roller bearing, fifth gear and fifth
synchronic ring
Install synchronizer assembly with pressure machine in the direction

the figure shows
145
Press radial ball bearing with pressure machine
Knock a new clip into input shaft in the direction shown in the figure
Press front tapered bearing into output shaft in the way shown in the
figure
Note: bearing cone must be located reliably
Press rear tapered bearing into output shaft in the way mentioned
above
Note: bearing cone must be located reliably
Knock in oil seal of shift cover in the way shown in the figure, after that,
the distance from end face of rear oil seal to end face of oil seal hole
should be 2.0～2.5mm
Knock in the other oil seal as the figure shows, after that the distance
from end face of rear oil seal to end face of oil seal hole should be 0～
0.5mm
146
Install gasket onto shift guide shaft, and install dust cover into shift
guide shaft, then install both onto shift cover together.
Knock a new clip onto shift reverse shaft in the direction shown in the
figure.
Install two new fork shaft clips, and install interlock pin to the position
shown in the figure
Install 2 new fork shaft clip as the figure shows
Install first-and-second shift fork to fork shaft, and put fork corner into
first-and-second teeth sleeve, install first-and-second guide block and
tighten bolts with torque of 16N.m
Knock elastic cylinder pin into guide block as the figure shows
Install lubricant oil pipe as the figure shows
147
Knock a new fork shaft clip into third-and-fourth fork shaft in the way
shown in the figure
Install reverse block and fork shaft clip as shown in the figure
Install third-and-fourth fork shaft into clutch housing, and install

third-and-fourth shift fork into teeth sleeve groove, and then tighten it.
Bolt: torque is 16N·m
Install interlock pin into reverse block as shown in the figure
As the figure shows, install reverse swinging arm support by

connecting two bolts, torque is 17N·m, and then place the head of
reverse block into corresponding hole on the support of reverse
swinging arm.
As shown in the figure, place the head of reverse swinging arm into
the interaxle groove of reverse gear
As the figure shown, install reverse fork, spring and fifth reverse guide
block onto fifth gear fork shaft, and then place fifth reverse fork into
fifth teeth sleeve, finally install them into clutch housing together.
148
Coat the bolt with sealant, then connect rotation swinging lever and its
shaft into rotation cover with bolts; the torque is 16N·m
Install gasket A, spring, interlock support and shift swinging lever onto
shift reverse shaft in the order and direction shown in the figure, then
knock elastic cylinder pin into the hole of shift swinging lever, after that
the distance from its end face to the hole should be 0～0.5mm
Knock a new clip as shown in the figure
Take out oil seal in the manner shown in figure, then install a new oil
seal into transmission housing
Install 2 side gears and gaskets into differential housing orderly, screw
2 planetary gears and gaskets into differential housing, and then put in
planetary gear shaft and install a new elastic cylinder pin as the figure
shows
Install differential ring gear in the direction shown in the figure, then
tighten connecting bolts of differential
Install drive gear of speedometer in the direction shown in figure
149
Install adjusting gasket choosed previously into transmission housing
Coat housing jointing surface with sealant as shown in figure
Tighten corresponding bolts as shown in figure with torque of 29Nm
Coat connecting bolts of reverse shaft with lock adhesive glue, and
install a new gasket to the bolt, then tighten reverse shaft onto
transmission housing, the torque should be 29N·m.
Install shift positioning assembly to transmission housing, and the

torque should be 37N·m
150
Chassis—Manual Transmission Assembly（1.3L）—Assembly Assembling
II. Assembly Assembling
Connecting bolts of end cover

Bearing thrust spring of
output shaft
End cover
Rear bearing gland of
output shaft
Screw rear bearing gland of output shaft into transmission housing with a spanner until screwing torque
reaches 40N·m, put bearing thrust spring of output shaft into rear bearing gland of output shaft in the
direction shown in figure, then press the end cover and tighten its connecting bolts with tightening torque
of 12N·m.
151
Chassis—Drive shaft/Driveshaft—Drive shaft, Driveshaft and Transaxle
Part 6 Drive shaft/Driveshaft
I. Drive shaft, Driveshaft and Transaxle
A. Symptom Table
The table below can help you find the causes of the troubles. The numbers indicate the priority of the
causes of the problem. Replace the parts if necessary.
Symptom Inspection Area
1. Wheel
2. Front wheel alignment
3. Rear wheel alignment
4. Front wheel hub bearing (worn)
Deviation
5. Rear wheel hub bearing (worn)
6. Front shock absorber with coil spring
7. Steering linkage (loose or damaged)
8. Stabilizer bar
1. Wheel balance
Front wheel vibration 2. Wheel hub bearing (worn)
3. Front shock absorber with coil spring
1. Outer joint (worn)

Noise (drive shaft)
2. Inner joint (worn)
B. On-board Inspection
1. Check front wheel hub bearing
(1) Remove front wheel.
(2) Remove front brake caliper assembly.
(3) Remove front brake disc.
(4) Check the bearing clearance.
Set a dial measuring gauge near the front wheel hub center to check the clearance.
Maximum: 0.05mm
If the clearance exceeds the maximum value, replace the front wheel hub bearing.
(5) Check the front wheel hub deviation.
Using a dial measuring gauge, check the deviation of the surface of the
wheel hub outside the hub bolt.
Maximum: 0.07mm
If the clearance exceeds the maximum value, replace the front wheel
hub subassembly.
(6) Install front brake disc.
152
Chassis—Drive shaft/Driveshaft—Drive shaft, Driveshaft and Transaxle
(7) Install front brake caliper assembly
(8) Install font wheel.
Torque: 103N.m
2. Check rear wheel hub bearing
(1) Remove rear wheel.
(2) Remove rear brake drum subassembly.
(3) Check bearing clearance.
Set a dial measuring gauge near the rear wheel hub center to check the
clearance.
Maximum: 0.05mm
If the clearance exceeds the maximum value, replace the rear wheel hub
and bearing assembly
(4)Check rear wheel hub deviation
Using a dial measuring gauge, check the deviation of the surface of the rear
wheel hub inside the hub bolt.
Maximum: 0.07mm
If the clearance exceeds the maximum value, replace the rear wheel hub and bearing assembly.
(5) Install rear brake subassembly
(6) Install rear wheel
Torque: 103N.m
153
Chassis—Drive shaft/Driveshaft—Front Constant-velocity Drive Shaft
II. Front Constant-velocity Drive Shaft
Component View I
Right constant velocity

drive shaft assembly
Left constant velocity

drive shaft assembly
Nut
Stabilizer link gasket
retainer
Stabilizer
Slotted nut
Latch Cotter pin
Slotted nut
retainer
Front auxiliary frame

lower swinging arm
Steering tie rod
Fixing nut ball joint
154
Component View II
Outer rzeppa
Dust cover
Large clamp of outer rzeppa
Small clamp of inner

rzeppa

rzeppa
Dust cover of inner
rzeppa
rzeppa
Tripod
Snap ring
Inner rzeppa
Spring ring
155
Inspection
1. Drain manual transmission oil (M/T transmission)
Torque: 39N.m
2. Remove front wheel
3. Remove engine bottom shield assembly
4. Remove front axle wheel hub left fixing bolt
(1) Using a hammer and a drive shaft nut chisel, release the staked part
of the left wheel hub nut.
(2) While stepping the brake pedal, remove the left wheel hub nut.
Notice: the staked part of the nut should be fully released, otherwise it may damage the thread of
the drive shaft.
5. Remove left front vehicle speed sensor (with ABS)
(1) Remove the bolt and clip, remove vehicle speed sensor and brake
hose from left front shock absorber assembly
(2)Remove the bolt, separate the left front vehicle speed sensor from
steering knuckle.
6. Remove front stabilizer bar

(1) Use a 10mm wrench to hold the bolt, remove the nut
(2) Remove two retainers, No.1 and No.2 gaskets, remove front
stabilizer bar
7. Separate left lower swing arm assembly

(1) Remove cotter pin and slotted nut
(2) On steering knuckle, remove the left lower swing arm assembly with
ball joint puller
156
8. Separate steering gear with tie rod assembly

(1) Remove cotter pin and slotted nut
(2) On steering knuckle, remove the steering gear with tie rod assembly
with ball joint puller
9. Separate left front steering knuckle assembly

Using a plastic hammer, separate left front drive shaft assembly from left front steering knuckle
assembly.
Notice
● Do not damage the dust cover
● With ABS: Be careful not to damage the vehicle speed sensor rotor.
10. Remove left constant velocity drive shaft assembly

Using a differential side gear shaft remover, remove the left constant
velocity drive shaft assembly.
Notice
● Do not damage the dust cover and oil seal.
● Be careful not to drop the drive shaft assembly
11. Remove right constant velocity drive shaft assembly
Using a brass bar and a hammer, remove the right constant velocity
drive shaft assembly.
Notice
● Do not damage the boot and oil seal.
● Be careful not to drop the drive shaft assembly
12. Install left front steering knuckle assembly
Notice:
The hub bearing could be damaged if it is subjected to the vehicle
weight, such as when moving the vehicle with the drive shaft bearing
removed.
Therefore if it is absolutely necessary to place the vehicle weight on
the hub bearing, first support it with the special service tool for front hub bearing
13. Check left constant velocity drive shaft assembly
(1) Check the universal joint of fix end for apparent looseness.
(2) Check that the inboard joint slide smoothly.
(3) Check the inboard joint for radial looseness.
(4) Check the dust cover for damage.
Notice: Place the drive shaft assembly on level during the inspection
157
14. Remove inboard joint big clamp

Using a screw driver, loosen the inboard joint big clamp
15. Remove left flexible end small clamp

Using a screw driver, loosen the small clamp
Mark
16. Separate flexible end dust cover
Separate the fixed end dust cover from the left Rzeppa joint assembly.
17. Remove left tripod joint assembly

(1) Wipe off the old grease from the tripod joint assembly.
(2) Place the marks between the tripod joint assembly and the fixed end
joint.
Notice: Do not punch the marks
(3) Remove the tripod joint assembly from the Rzeppa joint assembly.
Mark
(4) Using a snap ring plier, remove the left drive shaft inner snap ring.
(5) Place marks on the tripod joint assembly and outboard Rzeppa joint
assembly.
Notice: Do not punch the marks.
(6) Using a brass bar and a hammer, remove the tripod joint from the outboard Rzeppa joint assembly.
Notice: Do not tap the roller
(7)Remove the inboard joint cover clamp, dust cover, inner cover and left cover small clamp
18. Remove left constant velocity fixed end joint cover big clamp
Using a screwdriver, loosen the left constant velocity drive shaft
outboard joint cover big clamp
158
19. Remove left fixed end joint cover small clamp

Using a screw driver, loosen the fixed end joint cover small clamp
20. Remove fixed end joint cover

(1) Remove the fixed end joint cover from the outboard Rzeppa joint
assembly.
(2) Wipe off the old grease from the Rzeppa joint assembly
21. Remove left front drive shaft tripod joint spring retainer
Using a screw driver, loosen the left front drive shaft tripod joint retainer
22. Install left front drive shaft tripod universal joint spring retainer
Install a new tripod universal joint spring retainer
23. Install fixed end joint dust cover
(1) Wrap vinyl tape around the spline of the Rzeppa joint to prevent damaging the covers.
(2) Install the new parts on the tripod joint in the following sequence.
a. Left fixing end dust cover big clamp
b. Left fixing end dust cover
c. Left fixing end dust cover small clamp
(3) Coat the left Rzeppa joint assembly with grease.
Grease amount: 69-79g
(4) Install the fixed end joint cover on the Rzeppa joint assembly
24. Install outboard joint boot small clamp
As shown in the figure, use a screwdriver to install the outboard joint
boot clamp
25. Install left fixing end joint cover big clamp

As shown in the figure, use a screwdriver to install the left fixed end
joint cover big clamp.
159
26. Install tripod joint assembly

Tip: Before installing the cover, wrap vinyl tape around the spline of the
Rzeppa joint to prevent damaging the covers.
(1) Install the new parts on the tripod joint in the following sequence.
a. Inboard joint cover small clamp
b. Inboard joint cover
c. Inboard joint cover big clamp
(2) Align the marks, install the tripod assembly on the

tripod joint outer shaft assembly.
(3) Using a brass bar and a hammer, install the tripod assembly.
Notice
● Do not knock the roller.
● Make sure the tripod is correctly installed
(4) Using a snap ring plier, install the new retainer. Mark
(5) Coat the tripod joint assembly with grease.

Grease amount: 99-109g
(6) Align the marks, install the left intermediate shaft assembly on the
tripod joint assembly
27. Install inboard joint cover
Install the inboard joint cover on the intermediate shaft and tripod joint
outer shaft.
28. Install inboard joint cover small clamp
As shown in the figure, use a screwdriver to install the inboard joint
cover small clamp
29. Install inboard joint big clamp

As shown in the figure, use a screwdriver to install the inboard joint
big clamp
30. Check front drive shaft

(1) Check the fixed end joint for apparent looseness.
(2) Check that the inboard joint slide smoothly.
(3) Check the inboard joint for radial looseness.
(4) Check the dust cover for damage.
Notice: Place the drive shaft assembly on level surface during the inspection
160
Tips: Please refer to the following table for dimension (A).

LH mm RH mm
JL-5LE136 574 778
JL-S160G 503.8 851.3
31. Install left constant velocity drive shaft assembly

(1) Coat the spline of the tripod joint assembly with gear oil.
(2) Align the spline teeth, use a brass bar and hammer to install the
left drive shaft assembly.
Notice:
Face the retainer open end downward.
Be careful not to damage the cover and oil seal.
Tip: You can find out whether the tripod joint shaft contacts the pinion shaft by rotating the shaft assembly,
listening to the sound and feeling.
32. Install right constant velocity drive shaft assembly
Tip: The installation of the right side is the same as that of the left side.
Notice:
Install the retainer with its open end facing downward.
Be careful not to damage the dust cover and oil seal
33. Install left steering knuckle assembly
Install the left constant velocity drive shaft assembly on the left steering knuckle assembly.
Notice:
Be careful not to damage the fixed end joint boot.
With ABS: Be careful not to damage the vehicle speed sensor rotor
34. Install left steering gear with tie rod assembly
(1) Install the steering gear with tie rod assembly on the steering
knuckle assembly with nuts.
Torque: 33N.m
(2) Install the new cotter pins.
Notice: If the pin holes are not aligned, further tighten the nut by
60°
161
35. Install left lower swing arm assembly

(1) Install the left lower swing arm assembly on the steering knuckle assembly with nuts.
Torque: 98N.m
(2) Install the new cotter pins.
Notice: If the pin holes are not aligned, further tighten the nut by 60°
36. Install front stabilizer bar
(1) As shown in the figure, install the stabilizer bar with two 1#
retainers and two gaskets and nuts.
Notice: Make sure the gaskets and collars are correctly installed
(2)Tighten the nut with a 10mm wrench.
Torque: 18N.m
37. Install left front vehicle speed sensor (with ABS)

(1) Install the left front vehicle speed sensor and brake hose on the
front shock absorber with bolts and clips.
Torque: 29N.m
(2)Install the vehicle speed sensor on the steering knuckle with bolts.
Torque: 8.0N.m
Notice:
Be careful not to damage the wheel speed sensor.
Keep the vehicle speed sensor clean.
When installing the sensor, do not twist the sensor wire harness
38. Install left steering knuckle wheel hub nut
(1) Install new left steering knuckle hub nuts
Torque: 216N. m
(2) Using a chisel and hammer, stake the hub locking nut
39. Install engine bottom plate
40. Install front wheel
Torque: 103 N. m
41. Fill the manual transmission fluid
42. Check and adjust the automatic transmission fluid
43. Check and adjust front wheel alignment
44. Check ABS vehicle speed signal (with ABS)
162
Chassis—Brake System—Introduction to Brake System
Part 7 Brake System
I. Introduction to Brake System
Brake system diagram
1. Precaution
1. It's very important to keep the parts and area clean when repairing the brake system.
2. Care must be taken to replace each part properly as it could affect the performance of the brake
system and result in a driving hazard.
3. Do not let brake fluid remain on a painted surface when repairing any parts. Otherwise wash it off
immediately.
4. If any work is done on the brake system or air in the brake pipelines is suspected, bleed the system of
air.
5. Check the brake system for leakage after repairing the brake system.
6. Use specified brake fluid. Do not mix with other brand of brake fluid
2. Symptom table

1 Brake system fluid leaking
2 Air in the hydraulic brake system
3 Piston Cup in wheel cylinder (worn or damaged)
4 Rear brake shoe clearance (misadjustment)
Low brake pedal or recoil foot
5 Master brake cylinder (trouble)
6 Booster push rod length (misadjustment)
7 Brake shoe or lining (oil dirt)
8 Brake disc/drum (scratched)
163
Chassis—Brake System—Introduction to Brake System

1. Brake pedal free stroke (too small)
2. Parking brake lever stroke (misadjustment)
3. Parking brake cable (stuck)
4. Rear brake shoe clearance (misadjustment)
Brake Drag 5. Brake pad or lining (damaged)
6. Wheel cylinder piston (stuck or frozen)
7. Return spring (trouble)
8. Vacuum booster (trouble)
9. Brake master cylinder (trouble)
1. Wheel cylinder piston (stuck)
2. Brake shoe lining (oil dirt)
3. Brake disc (scratched)
Brake Deviation
4. Brake shoes or lining (damaged)
5. Wheel hub bearing (worn or damaged)
6. Tire pressure (not as specified)
1. Brake shoe lining (damaged)
2. Installation bolt (loose)
3. Brake disc (scratched)
Noise from brake 4. Brake shoe (poor quality)
5. Brake shoes or lining (oily)
6. Sound isolating shim (damaged)
7. Retaining spring of brake shoe (damage)
164
Chassis—Brake System—Brake Fluid
II. Brake Fluid
1. Bleeding
1. Fill brake reservoir with brake fluid
Brake fluid: DOT4 complying with GB12981-2003
2. Brake pipeline system bleed
(1) Connect the plastic pipe to the wheel cylinder bleeder screw
discharge port
(2) Depress the brake pedal several times, and then loosen the
bleeder screw with the pedal held down.
(3) Tighten the bleeder screw when fluid flows, and then release
the brake pedal.
(4) Repeat (2) and (3) until all the air in the fluid has been bled out.
(5) Repeat the above steps to bleed the brake pipeline of the air
for each wheel cylinder.
Notice: Fill brake fluid into the reservoir all the time when bleeding.
3. Check fluid level in reservoir
Check the fluid level and fill fluid if necessary.
Tips: Do not mix and use with other brand of brake fluid
165
Chassis—Brake System—Brake Pedal
III. Brake Pedal
Component View
Clutch cable Nut

Brake signal lamp
assembly Bushing switch assembly
Clutch brake pedal

assembly
Brake signal lamp

switch gasket
Lubricating bushing
Clutch pedal shaft Lubricating
Latch bushing
Lubricating
bushing
Connecting Brake
pin pedal shaft
Connecting joint
fork of booster
Lubricating
bushing
Brake pedal
Clutch pedal drive lever
drive lever
Clutch pedal
pad
Specified torque Brake pedal
pad
One-off parts
Lithium soap based glycol grease
166
1. Adjustment
1. Check and adjust the height of brake pedal.
a. Check the height of brake pedal to the floor: 135.8～145.8mm
b. Adjust the height of brake pedal.

① Remove the lower cover of the console.
② Remove the coupler from the brake lamp switch.
③ Loosen the lock nut of the brake lamp switch, and remove the brake
lamp switch.
④ Loosen the lock nut of the U-connector.
⑤ Turn the pedal push rod and adjust the height of brake pedal.
⑥ Tighten the lock nut of the push bar.
Torque: 20～25N·m
⑦ Install the brake lamp switch.

⑧ Insert the connector of the brake lamp switch
⑨ Push the brake pedal (1.5～2.5mm), and turn the brake lamp switch
till it goes out. Lock the nut in this position
⑩After installation, step down the brake pedal (1.5～2.5mm), and check
the brake lamp is on.
Check the pedal free stroke.
(1) Shut down the motor, and step on the brake pedal repeatedly till the
there is no vacuum in the booster.
(2) Step down the pedal till resistance appears, and measure the
distance as shown in the figure.
Pedal free travel: 1-6mm
If the clearance does not meet the requirement, check the clearance of
the brake lamp switch. Clearance: 0.5-2.4mm If the clearance is correct, make diagnosis on the braking
system.
(3) Check the pedal reserved distance.
a. Loosen the parking brak
e extension rod.
b. When the motor is running, step down the pedal, andeasure
m the pedal reserved distance as shown in
the figure.
c. When stepping on the pedal with force of 490N, the reserved distance from the asphalt floor is larger
than 79mm
If the distance doesn't meet the requirement, make diagnosis on the
braking system
2. Removal and assembling
1. Remove the combination instrument component.
2. Unfix the brake master cylinder push rod U-connector.
167
Remove the lock pin and connecting pin, and unfix the master
cylinder push rod from the brake pedal.
3. Remove the brake pedal bracket.
(1) Remove the bolt from the brake pedal bracket (see right figure).
(2) Unfix the brake lamp coupler.
(3) Remove the four nuts and brake pedal bracket (see right figure)
4. Remove the brake pedal sub-assembly.
(1) Remove the bolt and nut from the brake pedal bracket.
(2) Remove the brake pedal and the two shaft bushings.
5. Remove the brake lamp switch component.
(1) Loosen the lock nut of the brake lamp switch.
(2) Remove the brake lamp switch from the brake pedal bracket.
6. Remove the brake pedal pad.
Remove the brake pedal pad from the brake pedal
7. Install the brake pedal pad.
Install the brake pedal pad on the brake pedal
8. Install the brake lamp switch component.
Install the brake lamp switch on the brake pedal bracket.
9. Install the brake pedal.
(1) Apply lithium soap-base glycol lube on the end surface and side surface of the two new shaft
bushings.
(2) Install the brake pedal and the two shaft bushings on the brake pedal bracket with bolts and nuts.
Torque: 23～28N·m
10. Install the brake pedal bracket.

(1) Install the brake pedal bracket with four nuts.
Torque: 20～25N·m
(2) Connect the connector of the brake lamp switch.

(3) Install the bolt on the brake pedal bracket (see figure 3).
Torque: 20～25N·m
11. Connect and install the brake cylinder push rod U-connector.
(1) Apply the lithium soap-base glycol lube on the handspike pin.
(2) Connect the master cylinder handspike with connecting pin and lock pin
12. Install the combination instrument components.
13. Check and adjust the brake pedal height.
14. Check the brake pedal's free stroke.
15. Check the brake pedal's reserved distance
168
Chassis—Brake System—Brake Master Pump
IV. Brake Master Pump
Component View 1
Vacuum booster
Brake master cylinder
sub-assembly
Vacuum hose
Without ABS
Manual transmission: Switch connector of oil

Clutch 1 reservoir pipe lever warning lamp
Specified torque
One-off parts
169
Component View 2
With ABS
Reservoir
cover Reservoir
Strainer
O ring
pin
Snap ring
Hole
Straight pin connector Piston guide
Cup block
Hole connector Gasket
Piston 1 and spring
Brake master Piston 2
cylinder
Spring
Without Reservoir
ABS
cover
Strainer
Pin O ring
Snap ring
Gasket
Hole connector
Piston guide
Hole Cup block
connector
Piston 1 and spring
Brake master
cylinder Piston 2 and spring
Gasket Specified torque

One-off parts
Piston stopper bolt Lithium soap based glycol
grease
170
Repair
1. Discharge the brake fluid.
With ABS
Note: Never spray the brake fluid on the paint surface, otherwise
wash it immediately
2. Remove the brake master cylinder.
(1) Pull out the connector of the level alarm light switch.
(2) Slide the fixing clip, and pull out #1 clutch reservoir oil pipe Without
(manual transaxle). ABS
(3) Remove the two brake oil pipes from the brake master cylinder
with special tool.(with ABS)
(4) Remove the three brake oil pipes from the brake master pump
accessory with special tool. (Without ABS)
(5) Remove the two retaining nuts, and pull out the brake master
cylinder
3. Remove the reservoir.

(1) Put the brake master cylinder on the plyer.
(2) Remove the pin from the brake master cylinder block with special
tool and hammer.
(3) Pull out the Brake fluid reservoir.
(4) Remove the cover and strainer from the reservoir.
(5) Remove the reservoir and the two hole connectors
(1) Put the brake master cylinder on the plyer.
(2) Remove the O-ring.
(3) Push the piston with hand, and remove the snap ring with snap ring
pliers
171
(4) Push the piston with hand, and turn the cylinder block to remove the
straight pin. (with ABS)
(5) Push the piston with hand, and remove the piston stopper bolt and
washer. (without ABS)
(6) Pull out #1 piston, piston guide block, spring, cup and washer
straightly.
Note: If angle appears in the pulling process, it may cause damage
to the cylinder wall.
(7) Put two blocks and cloth on the work bench. Put the flange of the
master cylinder against the block edge and knock it till #2 piston and
spring get out of the cylinder.
Tips: Make sure the distance (A) between the working cloth and the block's top is at least 100mm.
Note: If angle appears in the pulling process, it may cause damage to the cylinder wall
5. Check the brake master cylinder.
(1) Check the cylinder wall whether there is any rust or scratch.
(2) Check the cylinder wall whether there is any abrasion or damage.
Note: If necessary, clean or replace the brake master cylinder.
Tips: Clean the assembled parts with compressed air.
6. Install the brake master cylinder.
(1) Fix the brake master cylinder on the plyer.
(2) Apply the lithium soap-base glycol lube on the rubber parts with
arrow.
(3) Install # 2 and # 1 pistons, spring, piston guide block, cup and
washer.
Note: If angle appears in the installation process, it may cause
damage to the cylinder wall. Be careful not to damage the edge
of the cup on the piston
(4) Push the piston, and install the straight pin on the cylinder body. (with ABS)
172
(5) Push the piston, and install the new washer and piston stopper
bolt.
Torque: 12～15N·m
(6) Push the piston, and install the snap ring with snap ring pliers.
(7) Install the O-ring on the brake master cylinder.
7. Install the Brake fluid reservoir.

(1) Apply the lithium soap-base glycol lube on the Brake fluid reservoir
connector, and install it on the brake master pump.
(2) Install the pin on the brake master pump with punch and hammer
8. Check and adjust the vacuum booster push rod.

(1) Install a brake boost push rod gauge on the brake master cylinder,
and lower the top of brake boost push rod gauge till it touches the
piston.
(2) Mark the top surface of the brake boost push rod gauge with chalk.
(3) Overturn the brake boost push rod, and leave a clearance between
the brake boost push rod and the vacuum booster.
Tips: If there is clearance between the special tool main body and
the booster housing, it means that the clearance is standard
value. If there is no chalk trace on the booster push rod, it means
that the clearance exceeds the standard value.
(4) Adjust the length of the vacuum booster push rod with the brake
push rod till the push rod touches the top rod

(1) Install the brake master cylinder on the booster with two bolts.
Torque: 12～15N·m
173
(2) Connect the two brake oil pipes to the brake master cylinder with
a special tool. (with ABS) With ABS
Torque: 15～20N·m
(3) Connect the three brake oil pipes to the brake master cylinder
with a special tool. (without ABS)
Torque: 14～18N·m
Without
(4) Insert the brake fluid level alarm switch connector. ABS
10 Add the brake fluid to the Brake fluid reservoir.

11. Discharge the air in the brake master cylinder.
12. Discharge the air in the brake pipeline.
13. Check the level height of the Brake fluid reservoir.
14. Check the brake fluid whether there is any leakage
174
Chassis—Brake System—Vacuum Booster
V. Vacuum Booster
Component View
Connecting hose of vacuum booster
Brake hard pipe of

brake master
cylinder 2 Grommet
Brake hard tube of brake

master cylinder 1
Level warning Booster
controller
Booster
Retaining bolt
installing pad
for lever
Clamp
Brake master
cylinder O ring
Specified torque Connecting

One-off parts joint fork
175
Check
1. Check the vacuum booster. Good Poor
(1) Air tightness check

a. Start the motor, and shut it down after one or two minutes, then step
on the pedal several times slowly.
Tips: If the pedal goes down greatly at the first step, but it 3rd
nd
gradually goes up after the second and third steps, it means the 2
1st
air tightness is good.
b. When the engine is running, step down the brake pedal, and then shut down the engine.
Tips: If the reserved distance does not change thirty seconds
after the pedal is stepped down, it means the air tightness is
good
(2) Operation check
a. When the ignition switch stays in OFF position, step on the pedal
several times, and then check that the reserved distance should not
change.
b. Step down the pedal, and start the engine. Not
Tips: If the pedal goes down a little, it means the operation is Vented vented
normal.
2. Check the vacuum one-way check valve.
a. Slide the clip to unfix the vacuum hose.
b. Remove the vacuum one-way check valve.
c. Check the booster is ventilated to the engine.
d. In case of any failure, replace the vacuum one-way check valve
Replacement
1. Discharge the brake fluid.
wash it immediately.
2. Unfix the fluid outlet pipe component of master cylinder.
4. Remove the vacuum booster.
(1) Unfix the vacuum hose from the brake booster.
(2) Remove the return spring, lock pin and connecting pin.
(3) Remove the four nuts and U-clip.
(4) Pull out the vacuum booster and installation washer
5. Install the vacuum booster.
(1) Install the vacuum booster and new washer.
(2) Install and fasten the vacuum booster nut.
176
Torque: 28～32N·m
(3) Install the return spring, lock pin and connecting pin
6. Install the vacuum booster push rod.
7. Install the vacuum booster
9. Connect the fluid outlet pipe component of master cylinder.
10. Add the brake fluid to the reservoir.
11. Discharge the air in the brake master cylinder.
12. Discharge the air in the brake pipeline.
13. Check and adjust the height of the brake pedal.
14. Check the free stroke of the pedal
15. Check the reserved distance of the pedal.
16. Discharge the air in the clut ch oil pipe (manual transmission).
17. Check and adjust the clutch pedal (manual transmission).
18. Check the level height in the brake reservoir.
19. Check the brake fluid w hether there is any leakage.
20. Check the clutch fluid whether there is an y leakage (manual transmission with hydraulic control
device clutch)
177
Chassis—Brake System—Front Brake
VI. Front Brake
Component View
Copper Brake
washer disc
Front brake hose
Bleeding screw
Guide pillar
Guide bush
Dust cover of
bleeding screw Piston sealing ring
Piston dust cover Guide

piece
Overall caliper
assembly Piston
Column
Guide pillar
bushing
Guide
Guide
bush piece
Disc Caliper bracket
Disc
Specified torque
One-off parts
178
1. Repair
(1) Remove the front wheel.
Take off wheels by screwing down their bolts on them.
Torque: 100～105N·m
(2) Screw down dust cover of bleeding screw and bleeding screw;
wash it immediately.
(3) Remove front brake hose;
Screw down bolts and washers fixing front brake hose from caliper.
(4) Remove front caliper body;

a. Remove 2 retaining bolts and washers shown in right figure from front
disc brake caliper;
b Fasten the front guide pillar, and remove the two bolts
(5) Remove the front brake plate kit.

a. Remove the two brake plat es with muffle washers.
b. Remove muffle and heat isolati on washers from the brake plates.
(6) Remove the friction plate of the front disc brake.
(7) Remove the two guide pillar of front disc brake.

Guide
pillar
Guide
pillar
179
(8) Remove the dust cover of front disc guide pin.

Remove the two dust cover of front disc guide pin from front disc brake
caliper bracket.
Guide
bush
Guide
pillar
(9) Remove bushing between guide pillar and guide bush;
(10) Remove 2 retaining bolts from the support of front caliper body;
(11) Remove the front brake caliper.

a Put a piece of cloth or equival ent between the brake cylinder and the
piston.
b Blow the piston out of the brak e cylinder with compressed air.
Warning: In the blowing process, the finger shall not be placed before
the piston.
Note: Don't spray the brake fluid
Tool
c. Remove the piston dust cover from brake caliper with awl.
d. Remove the piston seal ring from brake caliper with awl.
e. Take out the piston
(12) Check the brake pump wall and piston whether there is rust or scar
(13) Check the lining thickness of the brake plate.
Measure the lining thickness with ruler.
Standard thickness: 11.0mm
Minimum thickness: 1.0mm
Standard Thickness: 10.0mm Minimum Thickness:1.0mm
180
(14) Check the abrasion indicator steel strap of the front brake.
Make sure the abrasion indicator steel strap has adequate flexibility and has no deformation, crack or
damage.
All rust, dirt and other impurities shall be cleaned.
(15) Check the thickness of the brake disc.
Measure the thickness of the brake disc with screw micrometer. Standard
Thickness: 20.0mm
Minimum Thickness: 18.0mm
(16) Remove the front brake disc.
a. Make mark on the brake disc and wheel hub.
b. Remove the brake disc.
(17) Install the brake disc.
Tips: Install the disc at the minimum swing position
(18) Check the swing of the brake disc.
a. Fasten the brake disc temporarily.
Torque: 103N.m
b. Measure the swing of the brake disc at the 10mm from the disc edge
with a dial measuring gauge.
Maximum Swing: 0.05 mm
c.If the swing of the brake disc reaches or exce eds the limit, check the bearing's axial clearance and
the wheel hub's swing. If the bearing and wheel hub run normally, adjust the swing of the brake disc, or
finish it with onboard finishing machine.
(19) Tighten the brake discharge bolt temporarily.
Tighten the brake discharge screw plug on the front brake cylinder temporarily.
(20) Install the piston oil seal.
a. Apply the lithium s oap-base glycol lube on the new piston oil seal.
b. Install the new piston oil seal on the brake cylinder
(21) Install the brake piston.
a. Apply the lithium soap-base glycol lube on the brake piston.
b.Install the piston on the front disc brake cylinder.
Note: Don't tighten the piston into the brake cylinder forcefully
(22) Install the dust cover of the brake wheel cylinder.
a. Apply the lithium soap-bas e glycol lube on the dust cover of the new brake wheel cylinder, and install
it on the brake cylinder.
Tips: Install the dust cover in the groove of the brake wheel cylinder and piston reliably.
b. Install the set ring with screwdriver. Note:
Be careful not to damage to the dust cover of the brake wheel cylinder
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(23) Install the left front disc brake wheel cylinder support.
Fasten the front disc brake wheel cylinder support with two blots.
Torque: 88～92N·m
(24) Install the dust cover of the front disc guide pin.
Apply the lithium soap-base glycol lube on the surface of the two new dust covers. Install the two dust
covers on the front disc brake cylinder support.
(25) Install the guide pin of the front disc brake cylinder.
Apply the lithium soap-base glycol lube on the surface of the two sliding parts of guide pin and oil seal.
Install the two guide pins on the front disc brake cylinder support
(26) Install the frictional plate of the front brake.
Install the two removed frictional plate into front brake caliper
(27) Install the brake lining block component.
Note: When replace the abrasion brake lining block, replace the muffle
pad simultaneously.
a. Apply the disc brake lube on both sides of all muffle pads
b. Install muffle pads on all brake lining blocks.
c. The abrasion indicator faces upwards. Install a inner brake lining block, then
install a outer lining block.
Note: Don't apply the oil or lube on the friction surface of the brake pad
and brake disc.
(28) Install the front disc brake.
a. Install the front disc brake caliper with two bolts.
Torque: 32～36N·m
b. Install the new washer and hose with joint bolt.
Torque: 28～32N·m
Tips: Fasten the hose in the lock hole of the brake wheel cylinder
reliably.
(29) Add the brake fluid to the reservoir.
(30) Discharge the air in the brake cylinder.
(31) Discharge the air in the brake pipeline.
(32) Check the level height in the reservoir.
(33) Check the brake fluid whether there is any leakage.
(34) Install the front wheel.
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Chassis—Brake System—Front Hub and Bearing Assembly
VII. Front Wheel Hub and Bearing Assembly
Component View
Steering knuckle
Dust cover
Elastic ring for

hole
Bearing
Wheel hub
bolt
Wheel hub
Specified torque
One-off parts
183
1. Repair
(1) Remove left front wheel;
(2) Remove fixing nuts on left front drive shaft;
Special tool
a. Pry dented part of fixing nuts with special tool and hammer;
b. Remove fixing nuts.
(3) Remove left front wheel speed sensor assembly (with ABS);
a. Remove bolts, and remove sensor harness and brake hose
from shock absorber;
b. Remove wheel speed senor from steering knuckle by

removing bolts.
(4) Remove left front brake caliper assembly;

Disassemble brake caliper support by removing 2 bolts.
(5) Remove left front brake assembly;
Special tool
(6) Remove left tie rod assembly;

a. Remove cotter pin and nut;
b. Remove tie rod assembly from steering knuckle with special
tool.
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(7) Remove left lower control arm assembly;

Remove 2 nuts, then remove lower control arm from lower ball
joint.
(8) Remove left front shaft hub assembly;

a. Remove drive shaft from shaft hub with plastic hammer;
Note: do not damage dust cover and ABS speed sensor
rotor.
b. Remove steering knuckle with shaft hub assembly by
removing 2 bolts and nuts.
Special tool
(9) Remove ball joint assembly of left front lower control arm;
a. Remove cotter pin and nut;
b. Remove ball joint with special tool.
(10) Remove the snap ring in left front bossing hole;

Remove snap ring with snap ring pliers
Special tool
(11) Remove left front shaft hub assembly;
a. Remove shaft hub with special tool;
b. Remove inner race (outer) from shaft hub with special tool.
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(12) Remove left front brake dust cover;

Take off brake dust cover after removing 3 bolts.
Special
tool
(13) Remove left front wheel hub bearing;

a. Place inner race (outer) on the bearing; Special
tool
b. Remove bearing from steering knuckle with special tool and
press machine.
Special tool
(14) Install left front wheel hub bearing;
Install new bearing at steering knuckle with special tool and
press machine.
Special tool
(15) Install left front brake dust cover;
Install the dust cover with 3 bolts.
(16) Install left front shaft hub assembly;

Install shaft hub with special tool and press machine. Special tool
Special
tool
(17) Install snap ring of left front shaft hub hole;
Install snap ring with snap ring pliers.
(18) Install ball joint assembly of left front lower control arm;
a. Install lower ball joint and locking nuts;
Torque: 103±10N·m
b. Install new cotter pin.
If position of cotter pin hole can not be at one line, then tighten
nuts by 60° additionally.
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(19) Install left front shaft hub assembly;

a. Install 2 bolts and nuts, and install shaft hub assembly to shock
absorber;
Torque: 153±10N·m
Note: when it is required to use bolts and nuts repeatedly, coat
nut threads with engine oil.
b. Push front shaft hub assembly to vehicle outer, then install drive
shaft assembly into teeth groove of front shaft hub assembly.
Note:
● Do not push front shaft hub assembly to outer side excessively.
● Pay attention not to damage dust cover of outer joint of drive shaft.
● Pay attention not to damage wheel speed sensor rotor.
(20) Install left lower control arm assembly;
Install lower control arm and ball joint with 2 nuts and bolts.
Torque: 142±10N·m
(21) Install left tie rod assembly;
a. Connect tie rod to steering knuckle;
b. Install nuts and new cotter pin.
Torque: 49±5N·m
(22) Install left front brake assembly;
(23) Install front brake caliper assembly;
Install brake caliper assembly to steering knuckle with 2 bolts.
Torque: 106±10N·m
(24) Install fixing nuts on left front drive shaft;

Install new fixing nuts with torque wrench.
(25) Remove left front wheel cylinder assembly;
(26) Remove left front brake assembly;
(27) Check axial clearance of bearing;
Check axial clearance of shaft hub center with dial measuring gauge.
Maximum value: 0.05mm
If axial clearance exceeds maximum value, the bearing should be changed.
(28) Check run out of shaft hub end face;
Check run out of outer surface of shaft hub with dial measuring gauge.
Maximum value: 0.05mm
If the run out exceeds maximum value, the measuring gauge should be replaced.
187
(29) Install left front brake assembly;

(30) Install left front brake caliper assembly;
Install brake caliper assembly to steering knuckle with 2 bolts.
Torque: 106±10N·m
(31) Install left front wheel speed sensor assembly

a. Install wheel speed sensor harness and brake hose to shock
absorber with bolts;
Torque: 29N·m
b. Install wheel speed sensor to steering knuckle with bolts.
Torque: 8～10N·m
Note:
● Pay attention not to damage wheel speed sensor.
● Avoid attaching with foreign matter.
When installing sensor, sensor harness should not be
twisted.
(32) Install fixing nuts on left front drive shaft;
a. Install new fixing nuts;
Torque: 216±15N·m
b. Fix fixing nuts with chisel and hammer.
(33) Install front wheels;
Torque: 103±10N·m
(34) Check and adjust front wheel alignment;
(35) Check signal from ABS wheel sensor (with ABS).
Tip: repair procedure for right side is the same as that for left side.
188
Chassis—Brake System—Rear Brake Drum
VIII. Rear Brake Drum
Component View
Rear brake hard tube Dust cover of

bleeding screw
Pin
Wheel cylinder
assembly
Bleeding screw
Chassis hole plug
Retaining spring
guard for shoe
Brake shoe
Stopper spring
Pin
Shoe retaining
spring
Shoe return spring
Parking brake cable
Automatic adjusting
lever
Brake shoe
Shoe stopper
spring
Shoe retaining
spring Brake drum
Retaining spring cover

for shoe
Specified torque
One-off parts
189
1. Repair
(1) Remove the rear wheel
(2) Discharge the brake fluid.
Note: Never spray the brake fluid on the paint surface, otherwise wash
it immediately
(3) Remove the rear brake drum.
a. Loosen the parking brake cable rod, and remove the brake drum.
b. Take off brake drum after loosing screws with hose caliper.
(4) Remove stop spring;
(5) Remove shoe return spring;
(6) Remove shoe stop spring;
(7) Remove left retaining spring cover of brake shoe, left retaining spring of
brake shoe, screws and left brake shoe by plier.
(8) Remove automatic adjusting lever assembly;
Note; do not damage or bend automatic adjusting lever assembly.
(9) Remove right retaining spring cover of brake shoe, right retaining spring
of brake shoe, screws and right brake shoe in the same way as (7);
(10) Remove parking brake cable from brake shoe;
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(11) Remove rear wheel cylinder assembly;

a. Loose bolts on rear brake hard hose with tools, and then collect brake
fluid flown out with a container after removal;
b. Loose bolts fixing rear wheel cylinder and take off wheel cylinder;
c. Disassemble dust cover of bleeding screw and bleeding screw from
wheel cylinder.
(12) Check wheel cylinder;
Check that there is any rust or scratch on cylinder wall and piston.
(13) Check inner diameter of brake drum;
Measure inner diameter of drum with brake drum gauge or equivalent:
Standard inner diameter: 200.0mm
Maximum inner diameter: 201.0mm
(14) Check the thickness of brake shoe lining
Check the thickness of brake shoe lining with ruler:
Standard thickness: 4.5mm
Minimum thickness: 1.0mm
Note: if the lining thickness is equal to or smaller than minimum, or there is serious and uneven
worn, replace the brake shoe assembly.
(15) Check whether the brake drum contacts brake shoe lining normally.
Smear the chalk in the brake drum, and stick the brake shoe to the drum surface to grind. If the brake
drum connects with lining poorly, use grinding brake shoe or replace brake
shoe.
(16) Install bleeding screw and its dust cover to wheel cylinder;
(17) Install wheel cylinder of rear brake:
a. Install fixing bolts of wheel cylinder;
Torque: 8～12N·m
b. Connect rear brake hard hose with special tool.
Torque: 14～18N·m
(18) Coat with high-temperature-resistant grease;

Coat contact surface of brake bottom plate and brake shoe with
high-temperature-resistant grease.
(19) Install right rear brake shoe assembly:

a. Connect parking brake cable to brake shoe with special tool;
191
b. Install right brake shoe, screws, retaining spring of right brake shoe and
its cover to brake with special tool.
(20) Install automatic adjusting lever assembly:

a. Coat adjusting bolts with high-temperature-resistant grease.
Bottom plate
b. Install left regulator assembly as shown in right figure.
Left adjuster assembly
(21) Install left rear brake shoe assembly:

a. Install left brake shoe, screws, retaining spring of left brake shoe and its
cover to brake with special tool;
b. Position shoe stopspring to the brake and install in place;
c. Install shoe return spring;
d. Install stop spring.
192
(22) Check installation condition of brake drum:

a. Check that all parts are installed correctly;
Left rear Right rear
Front Front
b. Measure inner diameter of brake drum and diameter of brake

shoe, check that the clearance between them is allowable.
Brake shoe clearance: 0.6mm
Note: it is forbidden to stick oil dirt or lubricating grease on the
surface of brake shoe liner and brake drum
(23) Adjust the shoe clearance of the brake shoe.

a. Install two wheel hub nuts temporarily.
b. Turn around eight teeth of the regulator.
c. Install the hole plug.
(24) Install the rear brake drum assembly
(25) Add the brake fluid to the reservoir
Extend
(26) Discharge the air in the master cylinder.
(27) Discharge the air in the brake pipeline.
(28) Check the level height in the reservoir.
(29) Check the brake fluid whether there is any leakage.
(30) Install the rear wheel.
(31) Check the stroke of the parking brake pull rod.

(32) Adjust the stroke of the parking brake pull rod
193
Chassis—Brake System—Rear Hub and Bearing Assembly
IX. Rear Wheel Hub and Bearing Assembly
Component View
Wheel speed
sensor harness
With ABS
Wheel hub bolt
Brake drum
Specified torque
Rear wheel
One-off parts hub unit
194
Chassis—Brake System—Rear Hub and Bearing Assembly
1. Maintenance
(1) Remove left rear wheel
(2) Remove rear wheel brake drum assembly
(3) Remove wheel speed sensor wire harness (with ABS)
(4) Remove left rear axle wheel hub and bearing assembly
Remove 4 bolts, left wheel hub and bearing assembly
(5) Install left rear axle wheel hub and bearing assembly
Install left wheel hub and bearing assembly with 4 bolts
Torque: 63N·m
(6) Connect ABS wheel speed sensor wire harness (with ABS)
Notice:
Do not twist the sensor wire harness during connection
(7) Check bearing clearance
(8) Check left rear axle wheel hub deviation
(9) Install left rear wheel brake drum assembly
(10) Install left rear wheel
Torque: 103N·m
(11) Check ABS wheel speed sensor signal (with ABS)
Tip: service procedure for right side is the same as that for left side.
195
Chassis—Brake System—Parking Brake System
X. Parking Brake System
Component View
Rear wheel
speed sensor
Balance block
Parking brake cable

assembly
Specified torque
One-off parts
196
1. Malfunction table
The table below can help you find out the possible failure reasons. The number means the possible
sequence of the reasons. Check the parts, and replace the corresponding parts if necessary.
Symptom Suspected location

1. The stroke of the parking brake extension rod is misadjusted.
2. The parking brake cable is trapped.
Brake is blocked. 3. The clearance of the parking brake shoe is misadjusted.
4. The parking brake lining is cracked or deformed.
5. The return or tension spring is damaged.
2. Adjustment
1. Remove the rear wheel.
2. Adjust the clearance of the brake shoe.
3. Install the rear wheel
4. Check the stroke of the parking brake pull rod.

Pull the parking brake pull rod, and count the number of sound. Parking Brake Pull Rod Stroke: Pull with
196N force till 6-9 clicks
5. Adjust the stroke of the parking brake pull rod.
(1) Remove the parking cover plate.
(2) Turn #1 adjustment nut cable till the stroke is ok.
(3) Install the parking cover plate
3. Replace parking brake control lever assembly
1. Remove the accessories of the console.
2. Remove the auxiliary console.
Cable of adjusting nut 1
3. Remove #1 adjustment nut wire.
4. Remove the accessories of the parking brake control lever.
(1) Remove the connector of the parking brake control lever switch.
(2) Remove the two bolts, and remove the parking brake control lever
assembly
5. Remove the screw and parking brake switch component
6. Install the parking brake switch component.
7. Install the parking brake control lever assembly.
(1) Install the pull rod on the parking brake cable, and install #1 adjustment nut wire.
(2) Fasten the parking brake control lever with two bolts.
Torque: 13～16N·m
(3) Connect the connector of the parking brake switch.

8. Install the auxiliary console assembly.
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9. Install the accessories console.

11. Adjust the stroke of the parking brake pull rod
4. Replace parking brake cable
(1) Remove the accessories of the console
(2) Remove the auxiliary console
(3) Remove the cable adjusting nut
(4) Remove the front floor pull rod.
Remove the two bolts to take out the front floor pull rod.
(5) Remove the front exhaust pipe component.
(6) Remove the two bolts to take out the front floor heat insulating pad
(7) Remove parking brake cable component:
(a) Remove the four bolts to remove parking brake cable from the body.
(b) Remove left parking brake cable component from the parking brake balancer, and remove the cable
component.
8. Remove the rear wheel.
9. Remove the accessories of the brake drum.
10. Remove the left brake shoe.
11. Remove the automatic adjustment pull rod.
12. Remove the right brake shoe assembly.
13 Remove left parking brake cable assembly;
Disengage left parking brake cable assembly from bottom plate after removing bolts.
14 Install left parking brake cable assembly:
a. Install left parking brake cable assembly to parking brake cable balancer.
b. Secure left parking brake cable with 4 bolts.
Torque: 6～10N·m
198
15 Install left parking brake cable assembly

Fix the left parking brake cable assembly on the bottom plate with bolts and smear some lubricating
grease.
Torque: 6～10 N·m
16 Install right brake shoe assembly

17 Install the return spring of the brake shoe.
18 Install the automatic adjustment pull rod.
19 Install the left brake shoe assembly
20 Install the brake drum.
21 Check the installation of the brake drum.
22 Install the accessories of the brake drum.
23 Adjust brake shoe clearance
24 Install the rear wheel.
Torque : 100～105N·m
25.Fasten adjustment nut wire temporarily.
26 Fasten front floor heat insulating pad with two bolts. Torque: 6～10N·m
27 Install the front exhaust pipe component.

28. Install the front floor pull rod.
30. Adjust the stroke of the parking brake pull rod
Tip: apply the same procedure to right parking brake cable assembly as the left.
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Chassis—Wheel—ABS system
XI. ABS system
Component View I
Right front brake hard pipe

Left front brake hard pipe
Brake hard pipe for brake

Brake hard pipe for brake master cylinder 2
master cylinder 1 Right rear brake hard pipe 1
Left rear brake hard pipe 1

HECU controller assembly
Harness
Specified torque HECU controller

bracket
One-off parts
200
Component View II
Front wheel speed sensor assembly
Specified torque
One-off parts
201
Component View III
Harness pipe clamp
Rear wheel speed sensor assembly
Specified torque
One-off parts
202
ABS system layout diagram (sketch)
Wheel cylinder
Wheel speed sensor
Wheel speed sensor Wheel cylinder
Wheel speed sensor

Wheel cylinder
Warning lamp
Brake lamp switch
Brake pedal/master cylinder/booster
Wheel speed sensor

Wheel cylinder
1. ABS working principle

When ABS system realizes ABS and EBD functions, it is used to prevent wheel locking during brake and
to keep it within ideal working range of slip rate, thus ensure that the vehicle has sufficient direction
stability and steering capability, and obtains optimum ground brake force at the same time.
ECU of ABS system determines dynamic movement condition of current wheel and vehicle by obtaining
wheel speed signal according to wheel speed sensor, and prevents wheels locking by implementing a
series of control circulation of brake pressure during brake, meanwhile, remain vehicle wheels in ideal
movement condition, thus obtain optimum ground brake force.
E.g.:
● When wheels will lock, control motion of corresponding valves and pumps to reduce brake pressure
of wheel cylinder, thus prevent wheel locking;
● When wheel speed rises, control corresponding valve motion to keep brake pressure of wheel
cylinder, thus prevent wheel speed rising too fast;
● When wheel speed is too high, control corresponding valve motion to increase brake pressure of
wheel cylinder, thus prevent ground brake force reducing.
All above constitutes basic pressure adjustment circulation of ABS operation.
203
Low-pressure accumulator
Master
cylinder Booster
Suction valve
Hydraulic
pump Normally
Pressure Normally
close valve
valve open valve
Wheel
brake
2. ABS trouble diagnosis

(1) Diagnosis process:
During vehicle usage, if ABS warning lamp is on constantly or is off completely at ignition, it indicates
ABS is faulty; diagnosis can be carried out according to the following process:
Start
Connect fault diagnosis tester in power-off Refer to trouble check list (with trouble code)
condition to repair
Turn key switch to “ON” position Clear trouble code
Communicate with ABS with diagnosis tester Switch off key switch, and then remove fault
diagnosis tester
Perform inspection by referring No Driving inspection

to trouble check list (without Can communicate
or not
trouble code)
Yes No
Normal or not
Diagnoses with diagnosis tester
Yes
Record trouble code End
(2) Using method of diagnosis tester:

a. Plug connector D of the diagnosis tester to diagnostic socket under power-off condition;
b. Switch on ignition switch;
c. Press “OK” button on the diagnosis tester, and then enter function interface of the diagnosis tester
after establishing communication with ABS;
204
d. Read trouble code and trouble description, or perform functions supported by other diagnosis testers;
e. Switch off after usage and remove the diagnosis tester.
(3) Fill fluid and exhaust for ABS system with the diagnosis tester:
Fill oil and exhaust air for Depress brake pedal and
brake system normally hold
Connect with diagnosis Release pedal and front

tester and enter filling caliper bleeding bolts
and exhausting function according to hint
Operate according to
hints from diagnosis Depress brake pedal 10
tester times repeatedly
Filling and exhausting is

completed
Tighten bleeding bolts of
brake caliper
Repeat procedure 7
times on left and right
front calipers
(4) Notices during trouble diagnosis:

ABS applies electronic hydraulic control, therefore, if phenomena listed in following table appears during
normal operation of ABS system, it is normal instead of fault.
Phenomena Description
Self-check
After starting the engine, sound like knocking may produce from engine compartment
sound of the
sometimes, it is due to self-check of ABS system and is normal.
system
1. Motor sound in ABS hydraulic unit.
Sound
produced when 2. Sound produced together with vibration of brake pedal.
ABS is
3. When ABS is working, suspension hitting sound due to braking or rattling sound
operating
due to contact of tire and ground.
ABS is
On snowy road or sandstone road, brake distance of the vehicle equipped with ABS
operating, but
may be longer than that of the vehicle without ABS. Therefore, driver must be alerted
brake distance
that be careful when driving on roads mentioned above.
is long
3. HECU Controller assembly
(1) Open the cover of engine compartment;
(2) Exhaust brake fluid;
Note: do not splash brake fluid on painting surface, or else, please
rinse it immediately.
(3). Remove HECU controller assembly:
205
a. Disengage the harness connector connecting HECU controller interface;

b. Loose 6 brake hard pipe bolts connecting to HECU controller with special To hard tube 2 of master cylinder To left rear
hard tube
tool;
c. Stick corresponding labels on 6 brake hard pipe disengaged to
distinguish them: To right front
hard tube
To right rear
hard tube
To left front
hard tube To hard tube 1 of
master cylinder
d. Loose bolts fixing HECU controller support and vehicle body.
(4) Loose bolts connecting HECU controller assembly and support, then
take off HECU controller;
(5) Install support and HECU controller assembly;

Install HECU controller assembly to the support with bolts.
Torque: 6～10N·m
(6) Install HECU controller and support:

a. Install HECU controller and support to vehicle body with bolts;
Torque: 18～22N·m
b. As shown in right figure, install brake hard pipe to the hole of HECU controller assembly correctly with
special tool;
Torque: 15～20N·m
c. Connect the harness connector with HECU controller interface; To hard tube 2 of master cylinder To left rear
hard tube
(7) Fill brake fluid to reservoir;

(8) Drain up air in master cylinder; To right front
hard tube
To right rear
(9) Drain up air in brake pipeline; hard tube
To left front
(10) Check brake fluid level; hard tube To hard tube 1 of
master cylinder
206
(11) Check that brake fluid is leaking;

(12) Check HECU controller assembly with hand-held tester.
4. Front wheel speed sensor
(1) Remove left front wheel;
(2) Remove left front fender gasket;
(3) Remove left front wheel speed sensor:
a. Remove resin clamp and wheel speed sensor harness from retaining clamp of vehicle body;
b. Remove sensor connector;
c. Remove bolts on retaining clamp of sensor harness from vehicle body
and shock absorber, see right figure for position;
d. Remove bolts and left front wheel speed sensor.

Note: no foreign matter is allowed to attach on the top of sensor.
(4) Install left front wheel speed sensor
a. Install left front sensor with bolts;
Torque: 8～12N·m
b. Install retaining clamps of sensor harness to vehicle body and shock

absorber with blots;
Torque: 15～20N·m
c. Connect wheel speed sensor connector;

d. Connect resin clamps and wheel speed sensor harness to vehicle body
and retaining clamps.
(5) Install left front wheel fender gasket;
(6) Install left front wheels;
(7) Check signal from ABS wheel sensor.

Tip: Replacement process for right front wheel speed sensor is the same as that for the left one.
5. Rear wheel speed sensor
(1) Remove left rear wheel;
(2) Remove rear wheel speed sensor:
a. Remove resin clamp and wheel speed sensor harness from retaining
clamp of vehicle body;
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b. Remove sensor connector;

c. Remove bolts on retaining clamp of sensor harness from vehicle body and shock absorber, see right
figure for position;
d. Release buckle and pull wheel speed sensor harness from vehicle body;
e. Pull out clamps shown in right figure;
f. Remove bolts and left rear wheel speed sensor.

Note: no foreign matter is allowed to attach on the top of sensor.
(3) Install left rear wheel speed sensor:

a. Install left rear sensor with bolts;
Torque: 8～12N·m
b. Install clamps;
c. Position wheel speed sensor harness to vehicle body and connect with
buckle;
(4) Install left rear wheels;
(5) Check and adjust rear wheel alignment;

(6) Check signal from ABS wheel sensor.
Tip: Replacement process for right rear wheel speed sensor is the same as that for the left one.
208
Chassis—Wheel—Tire Inspection and Wheel Replacement
Part 8 Wheel
I. Tire Inspection and Wheel Replacement
Check
1. Check tire
(1) Check appearance of tire and its pressure
Cool tire pressure
Model Tire dimension Front(kPa) Rear(kPa)

HQ7131
165/60 R14 75H 230 210
HQ7101/HQ7101B1
(2) Check the run out of tire by dial measuring gauge.
Run out of tire: ≤1.5mm
Front
2. Tire replacement
Notes: As showed in graphic, replacement position of every tire including
and not including the spare tire
3. Check tire dynamic balance

(1) Check and adjust wheel on the off-car balancing machine.
(2) Check and adjust wheel use the on-vehicle balancing machine if
necessary.
Balance deviation after adjustment: less than 8.0g
4. Check bearing clearance
5. Check hub terminal deviation
6. Check that front suspension is loose;
7. Check that steering pull rod is loose;
8. Check that shaft joint is loose;
9. Check that shock absorber is working normally:
(1) Check that there is any oil leakage;
(2) Check that bushing seat is wearing;
(3) Shake front and rear of the vehicle.
209
Chassis—Power Steering System—Power Steering System
Part 9 Power Steering System
I. Power Steering System
1. Power Steering System Description

Power steering system consists of the steering wheel, steering drive device, power steering fixed device
and steering pipelines. The steering gear is rack and pinion type.
2. Major parameters for steering system
Item Parameter
Steering wheel rotation 3.3±0.1
Front wheel max turning Left: inner/outer 32.38°±2°
angle Right: inner/outer 36.92°～40.92°
Min turning diameter ≤9.5m
3. Precaution:
(1) Precaution for steering system
Make sure of the correct replacement of parts, incorrect replacement might affect the performance of the
steering system and lead to driving accidents.
(2) Precaution for SRS System
This vehicle is equipped with SRS (Supplemental Restraint System), driver side air bag and front
passenger side air bag.
Failure to carry out service operations in the correct sequence could cause the unexpected deployment
of the air bag during servicing, possibly leading to a serious accident
4. Symptom Table
The table below is helpful to find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. Repair or replace these parts or assemblies if
necessary.
Symptom Possible cause
Heavy steering 1. Tire (improperly inflated)

2. Power assisted steering column assembly
3. Front wheel alignment (incorrect)
4. Steering knuckle (worn)
5. Suspension arm ball joint (worn)
6. Steering column (bent or binding)
Poor return 1. Tire (improperly inflated) 2. Front wheel alignment (incorrect)
3. Steering column (bent or binding) 4. Manual steering gear assembly
Too large windage 1. Steering knuckle (worn) 2. Suspension arm ball joint (worn)
3. Intermediate shaft, sliding fork (worn) 4. Front wheel bearing (worn)
5.Manual steering gear assembly (worn)
210
Chassis—Power Steering System—Power Steering System
Abnormal noise 1. Power assisted steering column assembly (damaged)

2. Steering system connecting ball joint (worn)
3. Manual steering gear assembly (damaged)
5. On-vehicle inspection
1 Check steering wheel free stroke
(1) Stop vehicle and keep the tires straight ahead.
(2) Rotate the steering wheel slightly, check the steering wheel free stroke.
Maximum free stroke: 30 mm
Max free stroke
211
Chassis—Power Steering System—Steering Drive Mechanism
II. Steering Drive Mechanism
Component View 1
Horn button assembly

Steering wheel
assembly
Spiral plate
Combination
switch assembly
Steering column
assembly
Steering lower
shaft assembly
Hole cover plate of

steering column
212
Replacement
1. Precaution (refer to the steering system precaution)
2. Confirm that the wheel stays at a straight line running status.
3. Unfix the storage battery cathode terminal.
4. Remove the airbag assembly.
(1) Align the front wheel to the front by rotating the steering wheel
(2) Remove the two screws on both sides, and pull out the harness
connector.
(3) Disconnect the horn connector
Note: When removing the airbag assembly, never pull the airbag harness.
Caution: ¡ When put down the airbag assembly, make sure its top surface stays upward.
¡ Never disassemble the airbag assembly.
Using
使用套筒sleeve
5. Remove the steering wheel assembly.

(1)Unfix the connector.
(2)Remove the fixing bolts of the steering wheel.
(3)Make a fit mark on the steering wheel assembly and main shaft assembly.
(4)Remove the steering wheel with special tool.
6. Remove steering column cover
(1) Remove 2 screws
(2) Remove upper and lower covers of steering column.
213
7. Remove tachometer
(1) Release the connection
(2) Remove screws and tachometer
8. Remove clock spring assembly.
(1) Release button connection
(2) As the figure shows, release the air bag connection:
Note: when removing air bag assembly, do not drag air bag
harness!
(3) Remove spiral plate
9. Remove instrument assembly

(1) Remove 2 screws
(2) Release the connection and remove instrument assembly
10. Remove the combination switch assembly.

(1) Release connections at 3 places
(2) Remove combination switch assembly as shown in figure.
214
11. Remove interior instruments and ECU
12. Remove the splined dust cover
13 Detach steering lower shaft
215
(1) Make a fit mark between slide fork and countershaft.

(2) Loosen bolts A and B
14. Remove the splined dust boot
15. Detach steering lower shaft
Making
(1) Make a mark on the fit between slide fork and countershaft. marks
(2) Loosen bolts A and B

16. Remove the steering column pipe assembly.
(1) Release connections at 2 places
(2) Remove 3 clamps and cut off power supply
(3) Remove 3 screws and steering column assembly
17. Remove lower steering shaft assembly

(1) Mark as shown in figure
(2) Remove steering screws and lower steering shaft assembly from steering column assembly
18. After checking or replacing the steering column pipe assembly, install all parts in a reverse
order.
Note:
(1) After installing the ignition switch lock core, check the operation of the steering locking function: when
pulling out the key, the steering device is locked; when the key is inserted and turned to ACC position,
the steering device is unlocked.
(2) Tighten the bolts of steering column.
216
(3) Make sure all cables are connected reliably.

(4) After adjusting the combination switch as well as the top housing and bottom housing of the steering
pipe cap, fasten the three screws connecting the combination switch and the steering column assembly.
(5) The universal joint fork and the steering gear assembly lock bolt with a torque of 35 N. m.
(6) Install dust cover and its press plate.
(7) When installing the steering wheel assembly, align the steering wheel assembly and the fit mark of
the steering main shaft assembly. Tighten the special quincunx bolt with a torque of 50 N. m.
(8) Check the airbag. It is not allowed to use a airbag part removed from another vehicle.
(9) Check the SRS warning lamp
217
Chassis—Front Suspension System—Mechanical Steering Gear Fixing Device
III. Mechanical Steering Gear Fixing Device
Component View I
Cotter pin
Dust cover of steering

gear
Manual steering gear with tie

rod assembly
Front suspension bracket

member sub-assembly
218
Replacement
1. Adjust wheel positions to align wheels to the front
2. Disengage cathode terminal of battery
3. Remove engine hood
4. Plug out intake pipe

(1) Release clamping screws
(2) Remove clamps with screwdriver and pliers
(3) Remove air pipe
Clamp
5. Remove front window wiper
6. Remove upper seal of engine hood
7. Remove ventilation equipment
219
8. Remove the panel of ventilation ceiling
9. Remove dust cover of steering column spline dust cover
10. Disassemble lower steering shaft assembly

(1) Tie steering disc with seat belt to prevent steering disc
rotating resulting in damage to spiral plate
(2) Mark on sliding fork and intermediate shaft for match
(3) Release bolt A and B Clamp A
11. Disassemble dust cover of steering gear
Clamp B
Remove clamp A and dust cover of steering gear
Note: do not damage clamp B
12. Disassemble steering tie rod and tie rod arm

(1) Remove screws and nuts
(2) Remove steering knuckle
13. Remove front stabilizer link

(1) Hold screws with wrench, and remove nuts
(2) Remove gasket retainer and gasket, and then remove
stabilizer link.
220
14. Remove swinging arm assembly

(1) Remove screws and nuts
(2) Remove swinging arm sub assembly at steering knuckle
15. Remove oxygen sensor
16. Remove front exhaust pipe assembly

(1) Remove screws and clamps
(2) Remove 2 screws, compression spring and gaskets
(3) Remove exhaust pipe support and exhaust pipe assembly
17. Lift up engine
Engine hook 1
Engine hook 2
221
18. Remove front suspension support member

sub-assembly
(1) Remove 3 screws, and then remove engine mounting
(2) Remove screws, and then separate control lever from engine
control support
(3) Support front suspension support member sub-assembly

with jack.
(4) Remove screws and front suspension support member

sub-assembly
19. Remove steering drive device assembly

(1) Remove the cover of steering column hole from steering
drive device.
(2) Remove 2 screws, 2 nuts and steering drive device
assembly from suspension member
20. After completion of repair, install them in reverse order
222
Chassis—Front Suspension System—Power Assistant Steering System
IV. Power Assisted Steering System
1. General
Power assisted steering system consists of electronic control module, speed sensor, engine speed
sensor, and parts such as torque sensor and motor installed steering column. System control module
determines power and its direction and drives motor to assisted steering operation according to signals
transmitted from torque sensor and speed sensor.
2. Control process diagram
Engine speed Vehicle speed Battery Torque sensor
sensor
Control module
△Control motor according to input signal
△Control clutch operation
△Form automatical fault diagnosis
Driving current of Clutch closing/separating Output diagnosis trouble code

motor
3. Circuit diagram and various connector functions (with diagram)

4. Control module
Control module is a kind of controller including microcomputer, A/D (analog/digital) conversion, I/O
(input/output) devices etc, it can control power steering and its direction, as well as hold the functions of
on-board diagnostics system (self-diagnosis function) and safety protection function.
5. Self-diagnosis function:
When ignition switch is at ON position and engine starts, control module can diagnose faults occurred on
following parts and show fault result by means of fault indicator.
1. Torque sensor
2. Speed sensor
3. Engine speed sensor
4. Motor
5. Clutch
6. Control module
Operate the control module and fault indicator as shown below
When ignition switch is at ON position, engine is in starting state and diagnosis wire connector is not
grounded, if no fault occurs on parts mentioned above, the indicator is off after illuminating for 2s, it
means checking indicator bulb and system circuit. When control module detects fault inside parts above,
indicator illuminates to alert driver to fault, and trouble code is stored in backup memory of control
module.
When diagnosis switch is grounded, indicate trouble code by mean of indicator flashing by fault indicator
223
that control module controls.

When checking fault, engine must run.
6. Safety protection function, when abnormal DTC appears, control module will switch off motor
and clutch.
7. VSS (vehicle speed sensor)
VSS produces proportional signal according to speed (some sensor signals can be input into module
directly), speedometer converts these signals into corresponding speed reading, meanwhile they are
also converted into square wave signals with double cycle which are then input into control module.
8. Engine speed signal
Ignition signal from ignition coil can be used as engine speed signal, and it is converted into digital signal
through ECU, and it is sent to instrument on one end, and input into control module on the other end.
9. Diagnosis (with trouble code table)
Notices during trouble diagnosis
1. When two or more faults occur, diagnostic trouble code is always displayed from the smallest one
orderly.
2. When electric ignition switch turns on and engine fails in starting, DTC22 (engine speed signal) is
displayed, but when engine starts, if display changes normally, it indicates normal condition.
3. Because DTC (diagnostic trouble code) is stored in backup memory of control module, after repair,
codes in the memory must be cleared, clearing method is to ground trouble diagnostic wire and then to
display trouble code 3 times.
4. Refer to trouble code diagnosis table, and record trouble code displayed, then handle these troubles.
5. DTC (diagnostic trouble code) display
(1) Find trouble diagnosis wire “A2”
(2) Connect trouble diagnosis wire “A2” to ground
(3) Start engine (if engine does not start, it will display DCT22)
(4) When two or more faults occur, diagnostic trouble code (DTC) is always displayed from the smallest
one orderly.
10. Inspection of “EPS” marking lamp circuit (when ignition switch turns on, “EPS” indicator is
off)
1. Battery
2. Main fuse
3. Ignition switch
4. Circuit fuse (15A)
5. Control module
6. EPS lamp
7. Main fuse
8. Socket of control box
9. Connector
224
Step Operation Yes No
Main fuse and circuit fuse are Main fuse and circuit fuse are
1 Go to Step 2
good or not? broken
1. Turn on ignition switch

2. Check voltage between
“B/W” wire is disconnected or
2 terminal “A6” and module box Go to Step 3
shorted
grounding
3. Is it battery voltage or not?
1. Check voltage between
terminal “A8” and module box “B/R” wire is disconnected or
3 grounding Go to Step 4
shorted
2. Battery voltage or not?
1. Turn off ignition switch,
disconnect connector “8” from
control module
2. Disconnect vehicle body Bulb is burnt or “V/G” wire is
4 Go to Step 5
grounding terminal “A3” on disconnected
connector “8”
3. Turn on ignition switch again,
“EPS” lamp is on or not
1. Connection between connector Terminal “A6”, “A7”, “A3”

“8” and control module is secure or “A8” contacts poorly,
5 or not control module box is Poor connection
grounding poorly, “B” wire
+12V is disconnected
Inspection of “EPS” indicator circuit (“EPS” indicator is off or jumper connection between diagnosis
switch terminal and grounding terminal is always on)
1. Connector “9” and terminal " A2" is connected to
1 Go to Step 2 Poor contact
control module in good condition
1. With connector and control module connected 1. Repair wire is
together, ground “A2” terminal with wire disconnected
Recheck after
2 2. Turn on ignition switch, “EPS” lamp is flashing or 2. “B/W” circuit is replacing good
not disconnected or “B” control module
wire is grounding
poorly
225
11. DTC11 Main circuit of torque sensor (main circuit is disconnected or shorted)
1. Remove protective cover of steering column 1. “W” wire is
hole disconnected
2. Turn on ignition switch, face steering wheel to 2. Terminal “B5” is
the front of vehicle, check that voltage of “B5” connected poorly
1 Go to Step 2
wire terminal in the center of torque sensor lever
3. If both items above
seat is about 2.5V
are normal, replace a
new control module and
check again
1. Turn off main switch, and disconnect torque 1. “W” wire is shorted to
sensor lever head battery or is grounding
Torque sensor is
2 2. Check resistance between torque sensor 2. Poor contact between
defective
terminal “B2” and " B5" torque sensor connector
and line
3. Is it about 0.96KΩ or not
DTC13 torque sensor (output between main line and auxiliary line of torque sensor is totally different)
1. Remove protective cover of steering column
hole
2, Turn off ignition switch and disconnect
torque sensor
3. Check resistance between connector
terminals of torque sensor under following
condition
Face steering
About 0.96 KΩ wheel to the
front
1. Poor “W” or “B” circuit
Turn steering
2. Terminal “B5” or “”B4 is
“R—B” About 0.48 KΩ wheel utmost Torque
connected poorly
1 right sensor
3. If both items above are normal, trouble
Turn steering
replace a new control module and
About 1.02 KΩ wheel utmost
check again
left
Face steering
About 0.96 KΩ wheel to the
front
Turn steering
“R—W” About 1.02 KΩ wheel utmost
right
Turn steering
About 0.48 KΩ wheel utmost
left
226
DTC14 torque sensor (power voltage of torque sensor too high or too low)
1. Remove protective cover of steering column hole

2. Turn on ignition switch, and check voltage between
Recheck after changing
1 “R” line of torque sensor connector and grounding Go to Step 2
good control module
terminal
3. About 5V?
1, Turn off ignition switch and disconnect torque 1) Terminal “B2” or “”B3
sensor connector is connected poorly
2. Check voltage between “R” line of torque sensor 2) Poor contact between
connector and grounding terminal torque sensor connector
harness Torque
2 3. Is it about 1.09 KΩ? sensor
3) “R” or “G” line is trouble
disconnected
4) “R” or “G” line is
shorted to ground and
battery
DTC15 Auxiliary line of torque sensor (auxiliary circuit is open or shorted)

1. Remove protective cover of steering 1. “B” wire is disconnected
column hole
2. Terminal “B4” is connected
2. Turn on ignition switch, steering wheel poorly
1 should be at the place where make vehicle Go to Step 2
3. If both items above are
moving forwards, check line “B” terminal
normal, replace a new control
voltage of torque sensor connector
module and check again
3. Is it about 5V?
1, Turn off ignition switch and disconnect 1. Line “B” is shorted to ground
torque sensor insert or battery
2. Check voltage between line “R” and “W” 2. Poor contact between torque Torque sensor
2
or line “R” and “B” of torque sensor sensor connector and harness trouble
connector
3. Is it about 0.96 KΩ?
227
12. DTC22 engine speed signal (no engine signal input)

1. Connector is
connected poorly or
Tachometer shows engine speed signal or line is open
1 Go to Step 2
not? 0-1V 2. There is no speed
signal output from
ECU
1. When ignition switch is OFF, remove
control module and connect control
module connector.
Poor connection of “A4”,
2. Ignition switch is ON, check voltage
if connection is normal,
2 between terminal “A4” of control module Circuit “B” is open
please replace it with a
and ground. 2. Check voltage between “R”
good control module.
circuit of torque sensor connector and
grounding terminal
3. Is it 8-12V or not?
13. DTC21 Vss circuit

DTC21 Vss circuit (engine is running at 2500 rpm or higher (engine is running at 4000rpm or higher once
it starts) and there is no high speed signal input for 60s continuously)
DTC23 Vss circuit (engine is running at 2500 rpm or higher (engine is running at 4000rpm or higher once
it starts) and there is no high speed signal input for 60s continuously)
DTC24 Vss circuit (there is no vehicle speed input continuously for 5s after engine deceleration exceeds
standard level)
1. Connection of “A5” and “V” harness

is poor Replace good
Tachometer shows speed signal
1 vehicle speed
or not? 2. If connection is good, replace control sensor
module and check again
14. DTC41 motor
DTC41 motor (motor voltage too high or too low)
DTC43 motor (motor current too high)
DTC42 motor (current displayed by control module is different from actual current flowing to the motor)
DTC44 motor (control module has output signals, but motor does not start)
DTC45 motor (actual current flowing to motor is lower than the current output from control module)
228
1 With DTC or not? Motor trouble Go to Step 2

1. Remove steering column hole cover
2. When ignition switch is OFF,
disconnect motor and clutch connector
2 Go to Step 3 Motor trouble
3. Check conduction among motor
terminals
4. Is it conductive?
1. “R” or “B1” circuit is
disconnected
2. “R” or “B1” circuit is shorted
1. Check resistance between motor
to the ground
3 and clutch and vehicle body grounding Motor trouble
3. Connector contacts poorly
2. Is it infinite?
4. If items above are normal,
replace a good control module
and check again
15. DTC51 clutch circuit (clutch circuit is open or shorted)
1. Remove steering column

hole cover
2. When ignition switch is OFF,
disconnect motor and
1 connector Go to Step 2 Clutch trouble
3. Check conductivity among

clutch connector terminals
4. Is it conductive?
1. “B/B1” or “B/R” circuit is disconnected
2. “B/B1” or “B/R” circuit is shorted to
1. Check resistance between ground
motor & clutch connector 3. Poor contact of motor and clutch
2 terminal and power supply. Clutch trouble
connector
2. Is it infinite? 4. Poor contact of terminal “A9” and “A10”
5. If items above are normal, replace a
good control module and check again
229
16. Power circuit of DTC54 control module (battery voltage low)

1. When ignition switch is OFF, remove 1. Terminal “A7” contacts
control module and connect control module poorly
connector.
2. If items above are
1 2. When ignition switch is ON, check voltage normal, replace a good Battery trouble
between terminal “A7” of control module and control module and check
ground. again
3. 10-14V or not?
17. DTC52, DTC55 control module (control module fault)
Replace with a good control module and then check control module and its circuit again, they can be
checked by measuring voltage and resistance of module inserts, it is prohibited to measure control
module with multimeter at its ohm scale when it is not connected with module connector.
18. Voltage inspection
1. When ignition switch is OFF, remove control module from body
2. Connect control module connector to control module
3. Refer to following table to check voltage of connector terminals
4. When ignition switch is ON, confirm that battery is 11V or higher
Terminal
Circuit Normal voltage Fault phenomena
No.
Control module voltage of
A6 10-14V Engine is at idle speed
ignition switch
When ignition switch is ON, rotation
A5 Vss 0-1V and 4-6V range of front left tire under the
condition of locking front wheel
When ignition switch is ON, check
B2 Power supply of torque sensor About 5V voltage between terminal “B2” and
“B3”
B1 Blank —— ——
With engine at idle speed, “EPS”

A3 “EPS” fault indicator 0-2V, 10-14V
lamp is ON or OFF
With engine at idle speed, steering
A9 Clutch positive 10-14 wheel fixes the vehicle at straight
forward position
A4 Engine signal —— ——
B3 Torque sensor (GND) 0V
With engine at idle speed and vehicle
B4 Torque sensor is positive About 2.5V driving forward, voltage between
terminal “B4” and “B3”
B5 Torque sensor is negative About 2.5V With engine at idle speed and vehicle
230
driving forward, voltage between

terminal “B4” and “B3”
A10 Clutch is negative 0V ——
A2 Disconnect to terminal 5V Ignition switch is ON

A11 Motor output is positive 5-7V wheel fixes the vehicle at straight
forward position

A12 Motor output is negative 5-7V wheel fixes the vehicle at straight
forward position
A7 Power is positive 10-14V Engine idle speed
A8 Power is negative 0V ——
A1 Blank —— ——
19. Mechanical assembly

1. Steering column assembly can not be assembled, if any defect is found on any part, the whole
assembly should be replaced.
2. When replacing steering column assembly, attention must be paid not to cause impact
Plug-in function diagram

1 3 5
B1 B2 B3 B4 B5 A7 A8 A11 A12
● ● ● ● ●
A1 A2 A3 A4 A5 A6
A9 A10
● ● ● ● ● ●
Blank
A5 to instrument vehicle speed signal
A4 to instrument and engine speed signal
A1 is blank
A3 to instrument fault lamp
A6 to switch power supply 12V
6
A7 to continuous power supply 12V
A8 to power grounding line
● ● ● ● ●
B1 B2 B3 B4 B5 A11 A9
4
A12 A10
A2
Note: both A4 and A5 are digital signal input

1 control module connector
2. torque sensor connector of steering column
4. Diagnosis switch connector
231

6 motor clutch connector of steering column
No. Circuit No. Name Loading Color Circuit diameter

1 B1 Blank — — —
2 B2 +5V 5～10mA R 0.5mm2
3 B3 GND 5～10mA G 0.5mm2
4 B4 Torque signal 1 <5mA B 0.5mm2
5 B5 Torque signal 2 <5mA W 0.5mm2
6 A1 Blank — — —
7 A2 Diagnosis control <10mA B1/W 0.5mm2
8 A3 Indicator lamp 5～20mA V/G 0.5mm2
9 A4 Engine speed ﹤10mA Br 0.5mm2
10 A5 Speed signal <10mA V 0.5mm2

11 A6 ON switch <10mA B/W 0.75mm2
12V power
12 A7 <32A B/R 2.5mm2
supply
Power supply
13 A8 <32A B 2.5mm2
grounding
14 A9 Clutch positive <1A B/B1 0.75mm2
15 A10 Clutch negative <1A B/r 0.75mm2

16 A11 Motor positive <30A R 2.5mm2
17 A12 Motor negative <30A B1 2.5mm2
Trouble box schematic
B线B
Line
Connection
两导线联接 of both lines
A线A
Line
Description of eliminating storage fault:

1. Open engine:
232
2. Open engine hood;

3. Find out fault diagnosis box ay right upper corner of engine hood;
4. Open the cover of fault diagnosis box;
5. Connect circuit “A” and “B”; (attached with schematic)
6. Record trouble code, and eliminate trouble according to code description.
Diagnosis trouble code table
E.g. Only when setting up DTC21: Code 21 Code 21
Multi-functional
indicator (” EPS”
lamp is ON)
Time
(s)
Diagnosis trouble code

Diagnosis content Diagnosis
No. Oscillogram of “ EPS” lamp flashing
Normal This code will be showed if no

other code appears
Torque
sensor
VSS signal
Engine speed signal Diagnose trouble

according to
corresponding code in
“Diagnosis process
diagram”
Motor
Clutch
P/S control module
233
Chassis—Front Suspension System—Front Suspension System
Part 10 Front Suspension System
I. Front Suspension System
Description on front suspension structure

This model uses strut swing arm independent suspension with stabilizer bar.
The shock absorber upper end is flexibly connected to the body through the shock absorber mounting
seat, the lower end is rigidly connected to the steering knuckle. The coil spring encloses the shock
absorber, and is supported between the upper and lower spring seats.
Both ends of the stabilizer bar are connected to the front suspension lower swing arm with bolt with
cushion block and the intermediate part is supported on the front suspension crossmember assembly
with front stabilizer bar bushing and retaining clip. Front suspension crossmember assembly connects
vehicle body with 6 bolts
The front cushion covers the shock absorber piston rod head to restrict the wheel jump limit position and
plays the role of buffer action.
The thrust ball bearing, installed between the spring upper seat and the shock absorber mounting seat,
is used for the relative rotation upon steering of the shock absorber rigidly connected to the steering
knuckle to the shock absorber mount flexibly connected to the body.
"L" type lower swing arm is secured to the lower engine compartment with the press plate through elastic
rubber bushing and hinge, and its outer end is connected to the steering knuckle through the ball stud
pin which is attached to the lower swing arm by 3 high intension bolts. The ball stud pin can be removed
and replaced when it is worn. The ball seat material is saturated polyester containing oil, featured in
comparatively high intensity and wearability and good self-lubrication performance. Proper amount of
grease has been added during the assembly and there is no need for additional filling during the normal
operation.
See the table for the front suspension technical parameters
Item Parameter Item Parameter

Shock absorber
44.7 Wheel camber -0°47′±45′
diameter /mm
Shock absorber piston
18 Wheel toe-in /mm 1.1±2
diameter /mm
Shock absorber stroke
195 King pin inclination 9°33′
/mm
King pin caster 2°47′±45′
Remark: the wheel alignment parameter in the table is at free load.
234
Chassis—Front Suspension System—Front Suspension System
Symptom Table
likely cause of the problem. Check each part in order. If necessary, replace parts

1. Tires (Worn or improperly inflated)
2. Wheel alignment (Incorrect)
3. Steering system joint (Loose or worn)
Deviation
4. Hub bearing (Worn)
5. Steering gear (Maladjustment or worn)
6. Suspension parts (Worn or damaged)
1. Vehicle (Overloaded)
Body Descent 2. Spring (stiffness not comply with or damage)
3. Shock absorber (Worn)
1. Tire (Worn or improperly inflated)
2. Steering linkage (Loose or damaged)
Wobbing and inclination
3. Stabilizer bar (Bent or broken)
4. Shock absorber (Worn or damaged)
2. Tire (Dynamic balance is not as specified)
Front wheel shimmy
5. Ball end (Worn or damaged)
6. Wheel hub bearing (Worn or damaged)
7. Steering linkage (Loose or worn)
8. Steering gear (Maladjustment or worn)
Abnormal tire wear
235
Chassis—Front Suspension System—Front Suspension
II. Front Suspension
General structure：
Upper seat of front

suspension
Front coil spring
Front shock
absorber
Front transverse
stabilizer
236
Component View I
Upper seat of front

suspension
Front shock absorber (with

coil spring)
Steering knuckle
Cotter pin
Front wheel speed sensor
Front disc caliper
Tie rod terminal sub-assembly

Front stabilizer retainer
Front stabilizer gasket Front shaft hub nut
Front transverse stabilizer
Latch
Front stabilizer gasket
Front stabilizer retainer
Front suspension lower

swinging arm
Specified torque
Non-reusable parts
237
Component View II
Front suspension upper seatt
of sub-assembly
Installation bearing Connecting nuts of front seat

of pillar and front shock absorber
Upper seat of front

coil spring
Upper cushion of
front coil spring
Front coil spring

bumper
Front coil spring
Front shock
absorber assembly
Specified torque
238
Chassis—Front Suspension System—Front Wheel Alignment
III. Front Wheel Alignment
Adjustment:
1. Check tire
(1) Check whether the worn and pressure of the tire are normal

HQ7131
165/60 R14 75H 230 210
HQ7101/HQ7101B1
Consider that vehicle speed is lower and higher than 160km/h or not?
(2) Check tire run out with dial measuring gauge.
Tire run out: ≤1.4mm
2. Measure vehicle height
Vehicle height:
Tire dimension Front Rear

165/60 R14 75H 191 265
Front Rear
Consider various kinds of engines or not?
Measuring point
A: Distance from front wheel center to ground.
B: Distance from lower swinging arm ball pin center of front
suspension to ground
C: Clearance from rear wheel center to ground.
D: Clearance from retaining bolt center of rear axle member to ground.
Notice: Before the wheel alignment, adjust the body to the specified height.
Tip: If the body height is out of spec, adjustment shall be done by pressing or raising vehicle
body
3. Check the toe-in
Toe-in:
Front
A+B C-D
-0°06′～0°21′ -0.9mm～3.1mm
If the toe-in is out of spec, adjust the ends of rack

Tip: if A+B can’t be measured, measure C-D
4. Adjust the toe-in
Clamp
(1) Remove the clamp of the rack dust cover Rack end
(2) Loose the lock nut of tie rod Lock nut
239
Chassis—Front Suspension System—Front Wheel Alignment
(3) Adjust the Toe-in by rotating the same turns of both ends of rack.
Toe-in: 0.1mm～2.1mm Length of

rack end
Tips: Adjust the toe-in to the intermediate value of spec
Lock nut
(4) Make sure the same length for both ends
The length difference of left and right: 1.5mm or smaller
(5) Tighten the lock nut of the tie rod
Torque: 47N·m
(6) Install the dust cover on the seat and then install the clamp
Tips: Dust cover must not be twisted
5. Check the steering angle of wheel
Fully steer the wheel and measure the angle
The angle of wheel
Inside wheel Outside wheel
36°55′～40°55′ 32°23′
If there is deviation with spec for right and left wheel angle, check the rack length of left and right ends
6. Check the camber, caster and steering axle inclination angle
(1) Install camber – kingpin caster - steering axis inclination gauge at center of wheel shaft or drive shaft,
and put front wheels on wheel alignment tester.
(2) Check camber, kingpin caster angle and steering axis inclination.
Camber, caster and steering axle inclination angle Wheel
alignment
Gauge
tester
Kingpin caster steering axle

Camber angle
angle inclination angle
-1°32′～0°02′ 2°02′～3°32′ 9°33′
Note: perform inspection in the condition that vehicle is without loading (except backup tire and tools
attached);
Allow offset for wheel caster and kingpin inclination angle.
Tip: there is no camber, kingpin caster angle and steering axis inclination adjusting device. If measured
value is not within specified range, if necessary, check suspension parts and replace a new one.
240
Chassis—Front Suspension System—Front Shock Absorber and Coil Spring
IV. Front shock absorber and coil spring
Removal
1. Remove connecting circuit of battery cathode
2. Remove front window wiper arm
3. Remove trim inside engine hood and weather strip of ventilation cover plate.
4. Remove left/right ventilation cover plate assembly
5. Remove wiper motor and link assembly
6. Remove front compartment guide main plate sub-assembly
7. Remove front wheels
8. Remove front shaft wheel hub nut
(1) Release front shaft hub nut with special tools and iron hammer. Special
tool
Note: ensure that lock nuts are released completely, or threads on

drive shaft may be damaged.
(2) While depressing brake, remove front shaft hub nuts as well
9. Disconnect front wheel speed sensor
(1) Disconnect vehicle speed sensor circuit from shock absorber harness
support.
(2) Remove front wheel speed sensor from steering knuckle by removing
bolts.
Note: a. Ensure that wheel sensor terminal and installation position is
free of foreign matter.
b. When removing front wheel speed sensor from steering knuckle, do
not rotate wheel speed sensor.
10. Remove front brake disc caliper assembly

(1) Remove nuts and disengage brake hose from shock absorber assembly.
(2) Remove 2 nuts and disengage front brake disc caliper assembly from
steering knuckle.
Note: suspend caliper with thread or equivalent.
241
11. Remove steering tie rod terminal end sub-assembly

(1) Remove cotter and slotted nuts.
(2) Remove transverse stabilizer terminal from steering knuckle with special
tool. Special tool
Note: a. Do not damage steering knuckle spacer.

b. Do not damage ball pin dust cover.
12. Remove front transverse stabilizer
Rotation
(1) Hold bolts (10mm) with wrench and loose nuts at the same time.
(2) Take off two gasket retainers and gaskets, then remove front transverse
stabilizer.
Fixing
13. Remove front suspension lower swinging arm

(1) Remove clamps and slotted nuts.
(2) Remove front suspension swinging arm sub-assembly from steering
knuckle with special tool.
14. Remove lower front shaft assembly.
Special tool
(1) Hit front drive shaft assembly terminal to disengage it from the device
between front drive shaft assembly and front shaft assembly with ram.
Tip: if it is difficult to disengage from the device, hit drive shaft end lightly with copper stick and ram.
(2) Remove front shaft assembly from front drive shaft by pushing it out of vehicle body.
Note: a. Do not push front shaft assembly out of vehicle beyond necessary distance
b. Do not damage jointing clamp of outside front shaft.
c. Do not damage wheel speed sensor rotor.
d. Suspend front drive shaft assembly with thread or equivalent.
e. Do not hit sensor when removing drive shaft.
15. Fix front shaft assembly
Note: if the vehicle moves when removing drive shaft, wheel hub bearing Special tool
may be damaged due to bearing gross weight. Therefore, if it is necessary

for wheel hub bearing to load gross weight, special tool should be used to
support first.
16. Remove steering knuckle

(1) Release nuts.
(2) To prevent steering knuckle falling off, suspend it with thread or

equivalent.
242
(3) While pulling off steering cut with screwdriver, take out steering knuckle
from front shock absorber.
Note: do not exceed 10mm when pulling off steering cut.
17. Remove front shock absorber with coil spring

(1) Fix shock absorber lever with hexagon pipe clamp, and remove nuts and
front shock absorber equipped with coil spring.
(2) Remove front suspension column 2.
243
Chassis—Front Suspension—Front suspension lower swinging arm assembly
V. Front suspension lower swinging arm assembly
Removal
2. Remove front stabilizer bolt
(1) Hold front stabilizer with wrench and remove 2 bolts.
(2) Remove 4 retainers, 4 gaskets, retainer 2 and stabilizer bolt 2.
3. Remove front suspension lower swinging arm
(1) Remove clamps and slotted nuts.
(2) Separate front suspension lower swinging arm with special tool.
Special tool
(3) Take off 2 bolts and front suspension lower swinging arm.
244
Chassis—Front Suspension—Front Stabilizer and Linkage Assembly
VI. Front Stabilizer and Linkage Assembly
Removal
1. Disconnect battery cathode wire.
2. Remove front window wiper arm cover
3. Remove front window wiper arm

(1) Start wiper, then stop motor when windshield wiper reaches automatic
stop position.
(2) Remove nuts and main front wiper arm.
(3) Disengage auxiliary arm from wiper motor and link assembly.
Note: do not bend auxiliary arm when removing it.
4. Remove trim inside engine hood and weather strip of ventilation cover
plate
5. Remove left ventilation cover plate assembly
6. Remove right ventilation cover plate assembly
7. Remove wiper motor and link assembly.
8. Remove front compartment guide main plate sub-assembly

(1) Remove harness clamps.
245
(2) Remove harness grommet.
(3) Remove 10 bolts from front compartment guide main plate sub-assembly.
10. Before removing exhaust pipe assembly
(1) Remove bolts and clamps.
(2) Remove front exhaust pipe lock nuts and exhaust pipe support 4.
(3) Take off nuts, clamps and front exhaust pipe assembly.
11. Take off steering column hole cover plate.
12. Separate intermediate shaft from steering gear.

(1) Fix steering wheel with seat belt to avoid damage to coil wire due to its
rotation.
(2) Mark installation symbol on spline sleeve and intermediate shaft.
Assembly
marks
(3) Release bolt A and take off bolt B, and then remove intermediate shaft.
Clamp A
13. Remove steering column hole cover 1 sub-assembly. Clamp B
Note: do not damage clamp B.
14. Remove left sub-assembly of steering tie rod. Special tool
(1) Remove cotter and slotted nuts.

(2) Remove steering tie rod from steering knuckle with special tool.
Note: a. Do not damage front spacer of steering knuckle.
b. Do not damage ball pin dust cover.
15. Separate right sub-assembly of tie rod
16. Remove front stabilizer bolt.
(1) Hold front stabilizer bolt with wrench and remove 2 nuts.
246
(2) Remove 4 retainers, 4 gaskets, retainer 2 and stabilizer bolt 2.

(3) Repeat procedures above on the other end.
17. Take off left lower swinging arm of front suspension
(1) Take off clamps and slotted nuts. Special tool
(2) Remove front suspension lower swinging arm sub-assembly from

steering knuckle with special tool.
18. Take off right lower swinging arm of front suspension
Tip: removal procedure is the same as that of left lower swinging arm.
19. Hang engine assembly.
(1) Hook engine sling device, and hang engine with crane.
20. Remove sub frame sub-assembly

(1) Remove bolts shown in figure, then take off control lever from engine
installation control support.
(2) Support front sub frame sub-assembly with crane.
(3) Remove 6 bolts and front sub frame.
21. Remove steering mechanism

(1) Remove steering column dust cover from steering mechanism.
(2) Remove 2 bolts and 2 nuts, and then remove steering mechanism from
sub frame.
22. Remove left front stabilizer support 1.

(1) Remove 2 bolts and support.
247
23. Remove right front stabilizer support 1.

(1) Remove 2 bolts and support.
24. Remove engine rear insulator
assembly
(1) Remove 2 bolts, 2 nuts and engine rear
insulator assembly.
25. Take off front stabilizer bushing 1
26. Remove front transverse stabilizer
248
Chassis—Rear Suspension System—Introduction to Rear Suspension System
Part 11 Rear Suspension System
I. Introduction to Rear Suspension System
General structure:
Upper seat of rear

suspension
Rear
Rear coil spring shock
absorber
Torsion
member
Rear shaft side
member bushing
Component View I:
Right rear shock

absorber assembly
Upper spacer of right

rear coil spring
Right rear
coil spring Left rear shock
absorber assembly
Upper spacer of left

Lower spacer of right
rear coil spring
rear coil spring
Right bushing of rear Left rear coil spring

shaft side member
Upper spacer of right

rear coil spring
Rear shaft cross

member bushing
Specified torque Left bushing of rear

shaft side member
Non-reusable part
249
Component View II
Upper spacer of left
rear coil spring
Left
rear
Left rear coil spring coil
spring
Lower spacer of left Left rear shock

rear coil spring absorber assembly
Rear wheel speed

sensor
Clamp
Left rear brake hose
Parking brake cable 3
Specified torque
Non-reusable part
I. Rear suspension structure description

The main body part of dependent suspension is the member which the left connects to right together. It’s
front part connects to vehicle body with longitudinal hinge. The shock absorber and coil spring are
supported under lower part of vehicle body.
Rear suspension See the table below for the major technical parameters of the rear suspension
Item Parameter Item Parameter

Shock absorber diameter
39 Camber -0°56′±45′
/mm
Shock absorber piston rod
12.5 Toe-in/mm 3±3
diameter /mm
Shock absorber stroke /mm 245.5mm
Remark: Wheel alignment parameter is no load
II. Symptom Table
250
1. Tires (Worn or improperly inflated)

Deviation
3. Wheel hub bearing (Worn or damaged)
1. Vehicle (Overloaded)
Body descent 2. Spring (Stiffness small)
3. Shock absorber (damaged)

Inclination 2. Wheel (not within specification)

Rear wheel shimmy
4. Wheel (not meeting specification)

Abnormal tire wear
251
Chassis—Rear Suspension System—Rear Wheel Alignment
II. Rear Wheel Alignment
Check
1. Check the tire
(1) Check whether the worn and pressure of the tire are normal.

HQ7131
165/60 R14 75H 230 210
HQ7101/HQ7101B1
Consider that vehicle speed is lower and higher than 160km/h or not.
(2) Check tire run out with dial measuring gauge.
Tire run out: ≤1.5mm
2. Measure vehicle height
A-B C-D
88mm 22mm
Consider future engine modification or not.

Front Rear
A: Distance from front wheel center to ground.
B: Distance from center of bolt at front end of lower control arm to
ground.
C: Distance from rear wheel center to ground.
D: Distance from retaining bolt center of rear axle member to
ground.
Note: before checking wheel alignment, vehicle level should be adjusted to specified value.
3. Check rear toe-in
Toe-in
Front
A+B C－D
0°09′～0°39′ 1.4mm～5.8mm
Check and replace the related suspension parts if the toe in out of spec.
4. Check the camber
(1) Mount the camber-caster-kingpin measuring tool, place the vehicle on the wheel alignment tester
(2) Check camber
Camber: -1°26′～-0°26′
Note: the difference between the left and right camber is less than 30′.
Check the damage and performance decline of suspension parts and replace if necessary, if
measurement out of spec.
252
Chassis—Rear Suspension System—Left and Right Suspension Coil Spring
III. Left and Right Suspension Coil Spring
Removal
1. Disconnect power circuit from battery cathode
2. Remove rear wheels
3. Drain out brake fluid
Attention: rinse brake fluid flowing onto paint coat immediately.
4. Remove rear wheel speed sensor
(1) Take off 3 calipers.
(2) Remove screws with T30 torsion pipe clamp, then take off wheel speed
sensor.
Tip: removal procedure for right side is the same as that for left side.
5. Disconnect left rear hose Special tool
(1) Remove brake hose with special tool.

(2) Take off clamps, and disconnect hose from rear shaft member.
Note: do not damage rear brake pipe and hose.
6. Disconnect right rear hose
7. Disconnect parking brake cable 3
(1) Remove nuts shown in figure, and then take off parking brake cable.
Right side
Tip: removal procedure for right side is the same as that for left side. Left side
9. Release rear shaft member

(1) Release 2 bolts shown in figure.
Note: do not remove bolts.
10. Remove left rear shock absorber
(1) Support left and right ends of rear shaft member with crane.
Insert wood block between crane and rear shaft spring seat to prevent
damage.
(2) Remove bolts shown in figure, and then remove rear shock absorber.
11. Remove right rear shock absorber.
Tip: removal procedure for right side is the same as that for left side. Wood
12. Remove left rear coil spring block
(1) Lower the crane slowly.

(2) Remove coil spring and upper & lower spring spacers.
13. Remove right rear coil spring
253
Chassis—Rear Suspension System—Rear Shock Absorber Installation Assembly
IV. Rear Shock Absorber Installation Assembly
Removal
1. Remove rear seat cushion assembly
2. Remove rear seat back assembly
3. Remove trunk separator trim plate
4. Remove seat belt assembly
5. Remove back door windshield trim strip
6. Remove side trim of rear seat
7. Remove trim strips around rear trunk cover plate
9. Remove shock absorber dust cover
10. Remove rear shock absorber

(1) Support rear shaft member with crane. Insert a wood block between crane and rear shaft spring seat
to prevent damage.
(2) Hold piston rod, and then remove 2 nuts.
(3) Remove rear damper gasket retainers and rear suspension.
(4) Remove bolts and rear shock absorber. Wood
block
254
Chassis—Rear Suspension System—Rear Shaft Member
V. Rear Shaft Member
Removal
1. Disconnect power circuit from battery cathode
3. Drain out all brake fluid
Attention: rinse brake fluid flowing onto paint coat immediately.
4. Remove rear brake drum
(1) Release parking brake lever
(2) Remove screws with T30 torsion tube clamp, then take off rear brake
drum.
5. Remove rear wheel speed sensor
(1) Take off 3 calipers.
(2) Remove screws with T30 torsion pipe clamp, then take off wheel
speed sensor.
6. Disconnect left rear hose
(1) Remove brake hose with special tool.
(2) Take off clamps, and disconnect hose from rear shaft member. Special tool
Note: do not damage rear brake pipe and hose.
7. Disconnect right rear hose
8. Remove parking brake hard pipe 4
(1) Remove brake hard pipe with special tool.

Special tool
255
(2) Separate brake hard pipe from brake hose clamp.
(3) Remove brake hose clamp from rear shaft member.
9. Remove parking brake hard pipe 3
(1) Remove nuts shown in figure, and then take off parking brake cable.
12. Remove left rear shaft hub and bearing components
(1) Remove 4 bolts.
(2) Remove rear shaft hub and bearing components, and disengage with
supporting plate at the same time.
Note: a. Do not bend parking brake cable.
b. Hang supporting plate with cord.

Left side Right side
13. Remove right rear shaft hub and bearing components
14. Release rear shaft member
(1) Release 2 bolts shown in figure.
Note: do not remove bolts.
15. Remove left rear shock absorber
(1) Support left and right ends of rear shaft member with crane.
Wood
Insert wood block between crane and rear shaft spring seat to prevent block
damage.
(2) Remove bolts shown in figure, and then remove rear shock absorber. Left side Right side
16. Remove right rear shock absorber
17. Remove left rear coil spring
(1) Lower the crane slowly.
(2) Remove coil spring and upper & lower spring spacers.
18. Remove right rear coil spring
256
19. Remove rear shaft member assembly.
(1) Remove 2 bolts and rear shaft member.
257
Electric System & Accessory- Starting and Charging System- Starting System (3G10. 479Q)
Chapter 4 Electric System & Accessory

Part 1 Starting and Charging System
I. Starting System (3G10. 479Q)
1. Starter inspection
Note: These tests must be completed within 5s, so as to prevent coil from burning out.
1. Electromagnetic switch test
(1) As shown in the figure, use wire to connect starter.
(2) As shown in the figure, connect electromagnetic switch with storage battery.
(3) Disconnect field coil from terminal post A.
(4) Check whether clutch pinion moves outboard.
If clutch pinion does not move, replace electromagnetic switch.
(5) As shown above, connect battery, disconnect positive pole (+) of
battery from terminal post, disengage clutch pinion.
(6) Check whether clutch pinion returns.
If clutch pinion does not return, replace electromagnetic switch.
2. Starter no-load test

(1) Connect field coil and terminal post.
(2) As shown in the figure, connect ammeter and battery to starter.
(3) When check whether clutch pinion moves outwards, starter
should rotate slowly and smoothly.
(4) Check whether current reading of ammeter is normal or not.
(5) Normal current: less than 90 A at 11. 5 V
258
Electric System & Accessory- Starting and Charging System- Starting System (3G10. 479Q)
If current is abnormal, replace starter.

3. Circuit
103-0.5Bl
C.E BOX
Battary
(12V)
(1) Check that connecting wire between positive pole of storage battery and starter must be firm and reliable,
outside cover must be in good condition, so as to prevent generating electric spark and causing fire.
(2) Check whether wire is conducted, whether cover is broken, if wiring harness is damaged, replace wiring
harness.
II. Starter assembly replacement
1. Remove starter assembly
(1) Disconnect starter connector.
(2) Remove nuts, disconnect starter cable.
(3) Remove 2 bolts and starter assembly.
2. Install starter assembly
Installation should be conducted in reversed direction of removal
Torque:
Bolt: 37N.m
Wire harness 9. 8N.m
259
Electric System & Accessory- Starting and Charging System- Charging system
II. Charging system
1. Battery
Maintenance-free battery is applied in this vehicle. Its termination voltage is 12V. It is connected inline by six 2V
single cell in tandem with walls between every pole. 1. Battery warning signs
Be care of Read the Keep away No smoking Wear protective Be attention

sulfuric acid instruction from children glasses to explosion
1- Danger of corrosion
The battery electrolyte is very corrosive. DO NOT overturn the battery.
2- Read the instructions for battery
3- Children are forbidden to touch the battery
4- Avoid fire, electromagnetic wave and strong lamp.
Avoid electric spark while repair; avoid short.
5- Wear protecting glasses
6- Danger of explosion
The explosive mixed gas will be produced while charging.
7- How to deal with a scrapped battery
The scrapped battery should be delivered to the collection station.
2. Battery removal and installation Tip:
(1) The battery is not allowed to contact lubricating grease.
(2) The battery terminal is only allowed to be softly pulled out, in order to void damaging the battery.
Removal
(1) Remove the negative (-) ground cable
(2) Remove the battery positive (+) cable
(3) Loosen the fixing clamp on the battery.
Installation
Install according to the inverted order of removal. Tighten the torque
Tighten the battery cable clip to 6N.m Tighten the fixing clamp to 12N . m
2. Charging system inspection
1. Check battery working voltage
(1) After having driven the vehicle and in the case that 20 minutes
have not passed after having stopped the engine,turn the ignition
switch ON and turn on the electrical system (headlight,blower motor) for
260
60 seconds to remove the surface charge.

(2)Turn the ignition switch OFF and turn off the electrical systems. Then measure the battery voltage
between the negative and positive terminals of the battery.
Standard voltage: 12.5-12.9V at 20° C
Tip: If the voltage is less than specification, charge the battery.
2. Check that the battery terminals are not loose or corroded.
(1) Check if fuse box and fuse for continuity.
3. Inspect drive belt
(1) Check the belt for excessive wear, cords damage etc.
Tip:
y If any defect has been found, replace the drive belt.
y Cracks on the rib side of a belt are considered acceptable. If the
belt has chunks missing from the ribs, it should be replaced.
(2) Check that the belt fits properly in the ribbed grooves.
Tip:
Check with your hand to confirm that the belt has not slipped out of the
groove on the pulley.
4. Check alternator wiring
y Check that the wiring is in good condition.
5. Listen for abnormal noises from alternator
y Check that there is no abnormal noise from the alternator while the engine is running
6. Inspect charge warning lamp circuit
Turn the ignition ON. Check that the charge warning lamp comes on. Start the engine. Check whether the lamp is
off.
Tip:
If the lamp does not work as normal, troubleshoot the charge warning lamp circuit
7. Inspect charging circuit without load
(1) If a battery/starter tester is available, connect the tester to the
Ammeter
charging ciruit as per instructions. Disconnect cable
from Terminal B
(2) If a tester is not available, connect an ammeter and voltmeter to
the charging circuit as follows. Battery
a. Disconnect to the wire from terminal B of the alternator and Alternator

connect it to the negative (-) pole of the ammeter. Voltmeter
b. Connect the positive (+) pole of the ammeter to terminal B of the alternator.
c. Connect the positive (+) pole of the voltmeter to terminal B of the alternator.
d. Ground the negative (-) pole of the voltmeter.
(3) Check the charging circuit
With the engine running from idle to 2,000 rpm, check the reading on the ammeter.
261
Standard amperage: 10A or less

Standard voltage: 12.9V-14.9V
8. Inspect charging circuit with load
(1) With the engine running at 2,000 rpm, turn on the high beam headlights and place the blower switch
at "4".
Check the reading on the ammeter.
Standard amperage: 20A or more
(2) Tip:
If the ammeter reading is less than standard amperage, repair the alternator.
If the battery is fully charged, the indicationvalue will sometimes be less than standard amperage.
3. Alternator inspection
Alternater Component View
Bearing
Rotor cover
Bearing locating
plate
Bearing
Stator
Belt pulley Bearing
Brush
IC adjustor
Cable clip
Rear end cover
Brush bracketBrush bracket cover
Connecting end insulator
Rectifier bracket
Washer Rectifier end
bracket
262
(1) Inspection of rotor winding

a. Check resistance value of rotor winding
Set multimeter on R x 1 position, so two meter pens may contact
with two slip rings of rotor.
Standard: 2. 7 - 3. 1 ohm
b. Rotor bending inspection:
Rotor winding check
Standard: radial wobble is less than 0. 5 mm
If abnormal, correct or replace rotor.
(2) Stator winding inspection
a. Winding resistance value inspection
Set multimeter to R x 1 position, connect two meter pens with any
two leads of armature winding respectively. They should be
powered on, if resistance is infinitely great, there is open circuit.
b. Winding earth inspection Armature winding earth lead check
Set multimeter on R x 1 position, connect a meter pen with any

lead of armature winding respectively, contact one meter pen with stator core, if resistance is infinitely
great, it shows that armature winding insulation is good. Otherwise repair or replace.
4. Alternator assembly replacement
1. Removel of alternator assembly
(1) Disconnect generator connector
(2) Loosen bolts A, B, C
(3) Loosen V-belt, remove generator.
2. Install generator assembly
Torque:
M 10 x 1.25 bolt 15 N.m
Tension adjustment of V-belt: Deflection is about 10mm when belt middle part bears pressure of about
50N.
263
Electric System & Accessory- Wiper and Washer System - Wiper and Washer System Inspectio
Part 2 Wiper and Washer System
I. Wiper and Washer System Inspection
I. Wiper and washer system fault diagnosis

Remark: The table below can help you find the causes of malfunction. These figures show the most
possible malfunctions in order of priority. Inspect each part in the order given. If necessary, repair or
replace these parts.
Front wiper does not work. Suspected Area
Front wiper does not work. 1. Wiper fuse

2. Wiper switch assembly
3. Harness
4. Wiper motor
Front wiper in intermittent shift does not work. 1. Wiper switch assembly
2. Wiper motor assembly
3. Harness
4. Wiper intermittent relay
Front washer motor does not work 1. Wiper fuse
2. Washer switch and washer motor
4. Harness
When the wiper switch is at ON, front wiper is not 1. Wiper switch assembly
working
3. Harness
4. Wiper delay relay
Cleaning solution is not injected. 1. Washer hose and nozzle
2. Washer motor
1. When the washer switch places on OFF, wiper 1.Wiper motor assembly (The position of wiper arm)
blade can not return, or stay in a wrong place.
2. Wiper blade scratches with vehicle body
II. Troubleshooting
1. Check front washer pump
(1) Install washer pump on reservoir system, pour cleaning fluid
into the reservoir.
(2) Disconnect connector of washer pump.
(3) As shown in the right figure, connect No. 1 terminal of washer
pump with positive pole (+) of storage battery; connect No. 2
terminal with negative pole (-) of storage battery.
Check whether cleaning fluid flows from reservoir.
264
(4) If there is no outflow, replace washer pump

2. Check rear washer pump
(1) Install washer pump on tank system, pour cleaning fluid into
the reservoir.
(2) Disconnect connector of washer pump.
(3) As shown in the figure below, connect No. 1 terminal of washer
pump with positive pole (+) of storage battery; con nect No. 2
terminal with negative pole (-) of storage battery. Check whether
cleaning fluid flows from reservoir.
(4) If there is no outflow, replace washer pump
3. Wiper, washer switch assembly
(1) Circuit check
Check whether terminals on connector are on.
Standard: Front wiper switch
Switch Testing Specified

motion terminal status
1 18
9(+) —6(+) 2 17
MIST ON
10(+) —13(-) 3 16
OFF 9(+) —6(+) ON 4 15
INT
9(+) —6(+)
ON
14
11(+) -15(-)
13
LO 14(+) —15(-) ON
5 12
HI 14(+) —3(-) ON
6 11
Rear washer switch
7 10
8 9
OFF not ON
ON 5(+) —18(-) ON
(2) Check work (washer switch)

a. Turn wiper switch to OFF position.
b. Connect positive pole (+) of storage battery with No. 8 terminal of connector,connect negative pole (-)
with No. 2 terminal of wiper connector.Turn washer switch to ON and OFF,measure the voltage between
No. 8 terminal and wiper motor connector No. 2 terminal.
265
Standard: see the figure

Front washer switch

OFF not ON
ON 10(+) —13(-) ON
If it is not ON, replace the switch

Rear washer switch

OFF not ON
5(+) —18(-)
ON ON
5(+) —7(-)

(1) Low speed gear inspection
Connect positive pole (+) of storage battery and No. 3 terminal of connector, connect negative pole (-)
and No. 2 terminal (E) of connector, check motor speed at low speed gear.
If it does not meet stipulation, replace the motor.
(2) High gear inspection
Connect positive pole (+) of storage battery with No. 4 terminal of connector, connect negative pole (-)
with No. 2 terminal (E) of connector, check motor speed at high speed gear.
(3) Automatic reset inspection
(4) Connect positive pole (+) of storage battery with No. 3 terminal of connector, connect negative pole (-)
with No. 2 terminal (E) of connector. Rotate motor at low speed gear, disconnect No. 3 terminal (+) to
stop motor at any position.
a. Connect No. 5 terminal and No. 3 terminal, connect positive pole (+) of storage battery with No. 1
terminal, restart the motor at low speed gear.
b. Check whether automatic reset works normally.
HI
266
Electric System & Accessory- Wiper and Washer System - Replacement and Adjustment
II. Replacement and Adjustment
I. Replace wiper motor assembly
1. Remove wiper motor and connecting rod assembly
(1) Disconnect the connector.
(2) Remove 2 fixing bolts
(3) Take out wiper motor and connecting rod assembly
(4) Remove fixing bolts on the wiper and connecting rod assembly, and take out wiper motor assembly
Fixing bolt
Fixing
固定螺栓 bolt
2. Replace with a new wiper motor
(1) Use special tool to press motor crank arm shaft and wiper connecting rod into right position
(2) Fasten 3 bolts according to specified torque
(3) Connect connector
(4) Start wiper, spray cleaning fluid onto glass, check wiping state, whether original position of wiper arm
is normal, Otherwise remove wiper arm and blade assembly and make appropriate adjustment
Tip: crank arm shaft head of newly replaced wiper motor must always be filled with lubricating oil
II. Wiper blades replacement
267
Electric System & Accessory- Wiper and Washer System - Replacement and Adjustment
1. Remove wiper blade of wiper assembly
y Remove wiper blade from wiper assembly respectively
2. Replace with new blade
y Replace with new blade of wiper assembly.
III.Rear wiper motor assembly replacement
1. Remove the rear wiper nut cover with screw driver, loosen the nut and remove the wiper arm.
2. Disconnect the connector.
3. Remove the rubber retainer ring, one nut and two bolts.
IV. Washer nozzle
Adjustment
1. Inspect washer nozzle
(1) Start the engine, check if the position where the washer fluid from the nozzle sprays the windshield is
in the upper center wiped by the blades.
(2) Adjust the height (left/right) of the nozzle hole to adjust the point where washer fluid sprays
268
Electric System & Accessory—Combination Instrument System
Part 3 Combination Instrument System
I. Schematic circuit diagram of combination instrument and distribution of multi-pin plug-in

unit terminal
1. Schematic circuit diagram of combination instrument (see the figure)
Front fog lamp
Vehicle speed Tachometer

Left turn lamp
sensor signal Right turn lamp

Odometer
Rear demist
Rear fog lamp
Engine speed signal
Back light
Water temperature
signal Water temperature display
Fuel signal
Fuel display
Battery
Gear display
Mileage display
temperature
Charging
Fuel alarm
Brake trouble
Water
alarm
Oil pressure
Engine trouble
Driver safety belt

High beam lamp
Airbag
Door ajar
2. Distribution of digital combination instrument plug-in unit terminals. (from input wire)
3. Definition of multi-pin plug-in unit terminal
Terminal Terminal
Definition Definition
No. No.
1 GND 19
Left turning indicator Rear fog lamp
2 20
lamp
3 Safety belt switch 21 Airbag
269
Terminal Terminal
Definition Definition
No. No.
4 EPS 22 Front fog lamp
5 ABS 23 High beam lamp -
6 24 High beam lamp +
Vehicle speed sensor
7 25
power supply
Vehicle speed signal Charging indicating
8 26
input
Engine speed signal Brake malfunction
9 27
input
Right turning indicator Door ajar warning
10 28
lamp indicating
11 Instrument illumination 29
12 Battery 30 R
13 IG1 31 P
14 Buzzer(-) 32 N
Water temperature D
15 33
sensor
16 Fuel sensor 34 2
17 Rear defroster 35 L
18 Oil pressure 36 Engine trouble
270
II. Malfunction Symptom Table and Troubleshooting
I. Symptom table
The table below lists the typical malfunction symptoms of the combination meter. These malfunctions
can be troubleshot step by step in the section of the malfunction diagnosis.
Serial No. Symptom

1 The whole combination meter does not work
2 Speedometer fault
3 Tachometer fault
4 Water temperature gauge fault
5 Fuel gauge fault
6 Odometer fault
7 Instrument illumination lamp fault
8 Instrument warning lamp fault
II. Specific troubleshooting steps
1. The entire combination instrument does not work
(1) Check fuse (refer to schematic diagram of combination instrument)
a. Check cluster (10 A) fuse in fuse box of instrument desk is on
b. Check AM 1 (30 A) fuse in fuse box of engine room is on
c. Check MAIN (80 A) fuse in fuse box is on
Result and measures: if there is any blowout, replace with a fuse of the same capacity
(2) Check combination instrument connector
a. Inspect continuity
y Disconnect connector from combination instrument assy.
y Check connection between terminals
Standard:
Tester connection Condition Standard condition

1- grounding Normal ON
b. Check voltage
Disconnect connector from combination instrument assy.
Turn ignition switch to ON
Check voltage between terminals
Standard:
Tester connection Conditions Standard condition

13- ground Turn ignition switch to ON position 10-14V
12- ground Any status 10-14V
271
Result and measures:
Normal, replace combination instrument assy.
Abnormal, repair or replace wiring harness or connector
2. Speedometer fails
Check
(1) Check combination instrument assy.
a. Remove combination instrument assy.keep connection of connector.
b. Check the voltage between the terminals.
Standar:
Tester connection Conditions Standard condition

Turn ignition switch to ON
7- ground 7.5～9V
position
Abnormal, go to (2) Check combination instrument assy. vehicle speed input signal
Normal, go to (3) Check combination instrument assy.
(2) Check combination instrument assy. vehicle speed input signal
a. Check voltage
y Prop up two front wheels
y Push transmission lever to neutral position
y Turn on ignition switch
y Turn front wheel slowly, measure the voltage between terminal 8 and terminal 1
Standard voltage is shown in the figure below:
Voltage changes alternatively
Lower than 0.5V
Rotating wheel
Normal, replace combination instrument assy.
Abnormal, check vehicle speed sensor
272
b. Check vehicle speed sensor
Check on status
Standard:

2- ground Normal ON
Check voltage between terminals
Standard:
3- ground Turn ignition switch to ON position 7.5~9V

Normal, check vehicle speed sensor output signal.
c. Check the vehicle speed sensor output signal
Grouped instrument assembly

Engine ECU
Engine speed
signal
Check the voltage:
Prop up two front wheels
Push transmission lever to neutral position
Turn on ignition switch
Turn front wheel slowly, measure the voltage between terminal 1 and terminal 2
Standard voltage is shown in the figure below:
Normal, replace speed sensor.
(3) Check combination instrument assembly
a. Remove the combination instrument assembly and disconnect the connector
b. Check on status
Check the connectiong between terminals.
273

1- ground Normal ON
c. check the connection between terminals
Connector recovered

12- ground Any status 10-14 V
13- ground Turn ignition switch to ON position 10-14 V
Normal, replace combination instrument assembly.
3. Tachometer trouble
Engine ECU
Engine speed
signal
Checkout procedure
(1) Check combination instrument assy. rotating speed input signal
a. Remove combination instrument assy. , keep connection of connector.
b. Connect oscillograph to terminal 9 and ground.
c. Start up engine
d. Check signal waveform
Standard:
Display correct waveform
Normal, check and replace combination instrument assy.
Abnormal, check engine ECU rotating speed output signal
(2) Check engine ECU rotating speed output signal
a. Remove engine ECU ware, keep connection of connector.
b. Connect oscillograph to terminal ECU 9# pin and ground.
c. Start up engine
d. Check signal waveform
274
Standard:
Display correct waveform
Normal, repair or replace wiring harness or connector
Abnormal, check revolution speed transducer and engine control system
4. Water temperature display fails
Circuit diagram

Engine ECU
Water
temperature
signal
(1) Use diagnostic instrument to read engine water temperature value
a. Connect diagnostic tool to diagnostic interface
b. Turn on ignition switch
c. Read water temperature value displayed on diagnostic tool
Standard: the same as actual engine cooling water temperature
Normal, water temperature display does not fail
Abnormal, check combination instrument assembly.
a. Check resistance
y Remove combination instrument assembly , disconnect connector.
Standard:
Tester connection Conditions Standard state

First scale(65℃) 139±7Ω
15- ground Sixth scale(90℃) 59±3Ω
H(115℃) 28±1Ω
Normal, replace combination instrument assembly
Abnormal, check water temperature sensor
275
b. Check water temperature sensor
Remove water temperature sensor and put it in thermautostat.
Adjust temperature of thermautostat and measure resistance value of water temperature sensor
Standard:
Conditions Standard state

First scale(65℃) 139±7Ω
Sixth scale(90℃) 59±3Ω
H(115℃) 28±1Ω
Normal, repair or replace wiring harness and connector
Abnormal, replace water temperature sensor
5. Fuel gauge display fails
Circuit diagram
Combination
Fuel sensor instrument assembly
Fuel signal
a. Check resistance
Remove combination instrument assembly , disconnect connector.
Check connection between terminals
Standard:
Tester connection Conditions Standard state

Second scale(warning point) 89±1Ω
16- ground Sixth scale(1/2) 54±1Ω
Twelfth scale(F) 13±1Ω
Normal, replace combination instrument assembly
Abnormal, check fuel sensor
276
b. Check fuel sensor
y Remove fuel sensor.
y Adjust the height of fuel sensor and measure its resistance value.
Standard:
Conditions Standard state

Second scale(warning point) 89±1Ω
Sixth scale(1/2) 54±1Ω
Twelfth scale(F) 13±1Ω
Normal, repair or replace wiring harness and connector
Abnormal, replace fuel sensor
6. Odometer fails
Firstly check according to speedometer problem, if speedometer is normal, odometer fails, replace
combination instrument assembly
7. Illuminating lamp fails and Warning lamp fails
Symptom Suspected area

1. Wiring harness or connector
Check that engine warning lamp
2. ECM
does not illuminate
3. Combination instrument assy.
Charge warning lamp does not 1. Wiring harness or connector
illuminate 2. Alternator
Brake trouble warning lamp does
2. Brake fluid switch
not illuminate
3. Combination instrument assy
ABS warning lamp does not 1. Wiring harness or connector
illuminate 2. ABS controller or ABS warning lamp driving module
SRS warning lamp does not 1. Wiring harness or connector
illuminate 2. Airbag ECU controller
High beam indicator lamp does not
2. Lamp combination switch
illuminate
Front fog lamp indicator lamp does
2. Lamp combination switch
not illuminate
Rear fog lamp indicator lamp does 1. Wiring harness or connector
not illuminate 2. Lamp combination switch
Rear defrosting indicator does not
2. Rear defrosting switch
illuminate
3. Combination instrument assy
EPS warning indicating lamp does 1. Harness or connector.
277
Symptom Suspected area

not illuminate 2. Electric booster steering controller
Water temperature warning 1. Wiring harness or connector
indicator lamp does not illuminate 2. Water temperature sensor
Safety belt warning indicator lamp 1. Wiring harness or connector
does not illuminate 2. Safety belt buckle switch
III. Inspection on vehicle
1. Use speedometer detector to check indication error permitted by speedometer, check odometer
service condition.
Analog instrument (Km/h)

Instrument indication Displayed value of detector
20 20—23
40 40—45
60 60—65
80 80—85
100 100—105
120 120—126
140 140—146
160 160—167
Note: Insufficient or too high tire pressure will increase error.
2. Check input signal
(1) Connect positive pole (+) of voltmeter with terminal 8, connect negative pole (-) with terminal 1.
(2) W hen vehicle runs at 10km/h, check the voltage between terminal 8 and 1 of combination instrument
assembly
Standard: 7 high low level fluctuation waveforms per second.
Note: To check, keep ignition switch in ON position, connector in on state
3. Check tachometer
Check work condition
(1) Start up engine, use hand-held tachometer for comparison.
(2) Displayed value of hand-held tachometer and indicated value of tachometer are shown in the table
on next page.
Analog instrument
Tachometer (r/min) Hand revolution counter (r/min)

1000 900—1100
2000 1900—2100
3000 2900—3100
278
Tachometer (r/min) Hand revolution counter (r/min)

4000 3800—4200
5000 4800—5200
6000 5800—6200
4. Check fuel gauge
(1) Check resistance
Check resistance between 16 terminal and 1 terminal on combination instrument connector.
Standard:
Standard indication Resistance (ohm)

Second scale(warning point) 88—90
Sixth scale(1/2) 53—55
Twelfth scale(F) 12—14
Note: To measure, disconnect the connector.
5. Check water thermometer
(1) Check resistance
When water thermometer indicates water temperature to red area, check the resistance between 15
terminal and 1 terminal on combination instrument connector.
Standard
Standard indication Resistance (ohm)

First scale(65℃) 132—146
Sixth scale(90℃) 56—62
Twelfth scale(warning point) 27—29
Note: To measure, disconnect the connector.
6. Check water temperature warning lamp
(1) Disconnect water temperature sensor connector.
(2) Turn ignition switch to ON, water temperature warning lamp should go out.
(3) Combination instrument connector 15 terminal, water temperature warning lamp should illuminate.
7. Check engine oil pressure warning lamp
(1) Disconnect engine oil pressure sensor connector.
(2) Turn ignition switch to ON, engine oil pressure warning lamp should go out.
(3) Use conductor to short connector terminal to earth, engine oil low pressure warning lamp should
illuminate.
8. Check engine oil pressure sensor
Disconnect connector from engine oil pressure sensor
Check connection between terminal and ground
Engine stop: on
279
Engine running: off
9 Brake fluid level warning lamp
(1) Disconnect connector from brake fluid level sensor
(2) Turn ignition switch to ON, brake fluid level warning lamp should go out.
(3) Use conductor to connect its connector terminal wiring harness terminals directly, brake fluid level
warning lamp should illuminate.
10. Check brake fluid level warning switch
(1) Remove reservoir cap
(2) Disconnect connector from reservoir
(3) Check whether terminals are connected.
Floater on top: off
(4) Use sucker to suck out liquid from reservoir
(5) Check whether terminals are connected.
Floater down: on state
(6) Pour liquid back into reservoir
11. Rear fog lamp indicator
(1) The indicator will be on when the rear fog lamp is on, and the terminal is of high level.
12. Safety belt warning indicator lamp
(1) Disconnect safety belt switch connector from driver side, now safety belt warning indicator lamp
should be off.
(2) Short connector terminal to ground, safety belt warning indicator lamp should illuminate.
280
Electric System & Accessory—Audio System—Introduction to Audio System
Part 4 Audio System
I. Introduction to Audio System
1. Radio wave band
Wave bands used in radiobroadcast are as follows:
Frequency 30KHZ 300KHZ 3MHZ 30MHZ 300MHZ
Wave band LF MF HF VHF
Radio wave AM FM
Modulation Amplitude modulation Frequency modulation

LF: low frequency
MF: medium frequency
HF: high frequency
VHF: very high frequency
2. Area coverage
Scope of AM and FM broadcasting coverage area differs greatly.

FM (stereo)
Sometimes although AM broadcast may be received clearly, FM
binaural broadcasting cannot be received. Not only listening zone FM (monaural)
of FM binaural broadcasting is small, but also static noise or other

cacophony (noise) tends to occur.
3. Receiving problem
Notes: Besides static noise problem, there is also interference, multiplex and attenuation. These
problems are not caused by electric cacophony, but the problem of radio wave itself.
(1) Interference
Interference Ionosphere
Besides static noise problem, AM broadcast tends to receive
other types of noise, especially at night. This is because
ionosphere reflects AM radio wave at night, these interference
electric waves interfere with signals from the same signal
source while entering into vehicle antenna directly, this kind of
noise is called "interference".
(2) Multiplex
Noise caused by radio wave reflected from barrier is called Multi-transfer
"multiplex". When radio signal emitted by broadcast antenna is

reflected by high buildings or high mountains, and disturbs directly
received other signals, multiplex phenomenon occurs.
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Electric System & Accessory—Audio System—Introduction to Audio System
(3) Attenuation
Attenuation
Since its frequency is higher than AM, FM wave is more easily
reflected by high buildings or high mountains. Therefore, FM signal
often disappears gradually, or when vehicle is blocked by barrier, it
cannot receive any signal,such phenomenon is called "attenuation".
4. Noise problem
Detailed description of noise problem fed back by customers is of great importance for analyzing and
eliminating noise interference, the table below may be used for diagnosis.
Radio wave Noise condition Cause
Noise occurs in special position Most probably external noise
AM Noise occurs when receiving small Broadcast from local station might broadcast the
signal same program. If program is the same, one of them
might be disturbed
Noise only occurs at night Most probably from remote interference

FM Noise occurs in special position Most probably is multiplex interference due to FM
during driving frequency change
Notes: If noise occurred does not belong to any of the above-mentioned situations, please find out the
cause according to "receiving problem
5. CD player
CD player (hereafter referred to as CD) uses laser beam to read digital signals recorded on CD, then
revert to analog signal of music.
Tip: Don't attempt to break down or apply oil to any component of the player. Do not insert anything
other than a CD into optical disk cartridge.
Notes: CD player with invisible laser beam, could generate harmful radialization, always operate
player according to instructions.
6. Cleanness of CD player and disc
If CD is dirty, use soft cloth to wipe the surface from CD center radially
outwards.
Notes: Don't use ordinary recorder detergent or antistatic

protectant.
282
Electric System & Accessory—Audio System—Audio System Connector Terminal Layout
II. Audio System Connector Terminal Layout
1. Connector terminal layout on wire harness
2. Connect terminal definition
No
Terminal Condition Standard Voltage
Function
B1 FR+ The audio system is on Wave form is synchronized with the output
sound
B2 FL+ The audio system is on Wave form is synchronized with the output
sound
B3 ACC Ignition switch turned to ACC 10~14V
B4 B+ Normal Status 10~14V
B5 FR- The audio system is on Wave form is synchronized with the output
sound
B6 FL- The audio system is on Wave form is synchronized with the output
sound
B7 GND Normal Status ON
B8 Null
B9 Mute
B10 TAIL Position lamp switch turned to ON 10~14V
A1 RR+ The audio system is on Wave form is synchronized with the output
sound
A2 RL+ The audio system is on Wave form is synchronized with the output
sound
A3 RR- The audio system is on Wave form is synchronized with the output
sound
A4 Null
A5 Null
A6 RL- The audio system is on Wave form is synchronized with the output
sound
283
Electric System & Accessory—Audio System—Audio System Inspection
III. Audio System Inspection
I. Symptom analysis
The system doesn't work when pressing power 1. Radio assembly circuit faulty
switch. 2. Radio assembly
The radio backlight does not light up with the 1. Radio assembly backlight terminal
illumination switch ON 2. Radio assembly
Speaker soundless in all modes 1. Speaker circuit

2. Radio assembly power circuit faulty
3. Radio assembly
Poor sound quality in all modes (Volume faint) 1. Speaker circuit

2. Radio assembly power circuit faulty
3. Radio assembly
Unable to receive radio broadcast (poor reception) 1. Antenna circuit

2. Radio assembly
CD could not be inserted or ejected 1. CD power circuit faulty

2. CD
II. Trouble shooting
1. Power switch system does not work
Circuit diagram
(1) Check radio assembly (+ B, ACC, GND)
a. As shown in the table below, check connection between terminals in each operating condition.
Standard:
284
Tester connection Condition Standard state
GND and vehicle earth Normal status ON

b. As shown in the table below, check voltage between terminals in each operating condition. Standard:
+B and GND Normal status 10-14V
ACC and GND Ignition switch is in ACC or ON 10-14V

Abnormal, repair or replace wiring harness, connector
Normal, check and replace radio assembly
2. Turn on lighting switch, but radio backlight does not illuminate
Circuit diagram
(1) Check radio assembly (TAIL)
Dashboard fuse box
Fuse box
As shown in the table below, check voltage between terminals in each operating condition. Standard:
TAIL and GND Combination switch (light switch) 10-14V

Abnormal, repair or replace wiring harness, connector
Normal, check and replace radio assembly
3. Loudspeakers is silent in all modes
Circuit diagram
285
Dashboard fuse box
Left rear Right rear

loudspeaker loudspeaker
Engine compartment
fuse box
Fuse box
Left front
Right front loudspeaker loudspeaker
Left front alt loudspeaker

Right front alt loudspeaker
(1) Check LCD Illumination
a. Turn the ignition switch to ACC
b. Turn on radio assembly
c. Turn on the position lamp
Standard: The LCD indicator of the radio assembly goes on
Abnormal: go to step (7)
Normal: go to the next step
(2) Control volume and adjust the volume balance
y Adjust the volume and its balance of the radio assembly to find out the inaudible speaker.
If all speakers are mute, check and replace the radio assembly
If individual speaker is mute, then respectively check and replace the inaudible speaker.
(3) Tweeter assembly inspection
a. Disconnect the speaker connector
b. Check the resistance
Notice: Standard Value: 4Ω
Do not remove the speaker during inspection.
Abnormal: Replace tweeter speaker assembly
Normal: Check wire harness and connector
286
(4) Check front speaker assembly
a. Disconnect speaker connector
b. Check resistance
Standard Value: 4 Ω
Abnormal: Replace front speaker assembly
(5) Check rear speaker assembly
a. Disconnect speaker connector
b. Check resistance
Standard Value: 4Ω
Abnormal: Replace rear speaker assembly
(6) Check wire harness and connector
Abnormal Repair or replace wire harness and connector
Normal Check and replace radio assembly
(7) Check and replace radio assembly (+B, ACC, GND)
a. Check the continuity between terminals under each operating condition as shown in the table below.
Standard:
Tester connection Condition Standard Status
GND Normal ON
b. Check the voltage between terminals under each operating condition as shown in the table below.
Standard:
Tester Connection Condition Standard Status
+B - GND Normal 10~14V
ACC - GND Ignition switch is at ACC or ON 10~14V

Abnormal: Repair or replace wire harness and connector
Normal: Check and replace radio assembly
4. Unable to receive radio broadcast (poor reception)
(1) Check if the radio auto-research function works
Perform the radio auto-research function to see if it works
Abnormal: Check the antenna for noise
(2) Check the antenna for noise
287
a. Turn on radio to AM with the ignition switch ACC.
b. Touch the antenna of the seated antenna assembly with the tip of the screwdriver. Check the speaker
for noise.
Standard: with noise
Abnormal: Check antenna assembly
(3) Check antenna assembly
a. Remove the antenna plug from the antenna assembly
b. Check the noise
Connect the radio assembly connector and turn the ignition switch to ACC.
Turn on the radio to AM
Insert a flat head screwdriver or metal object similar to thin wire into the hole in the antenna coaxial
cable. Check the speaker for noise.
Standard: There is noise.
Abnormal: Check and replace antenna coaxial cable sub-assembly
5. CD can not be inserted or failed to pop-up after inserted
(1) Check radio power supply circuit according 1
Normal: Replace radio assembly
Abnormal: Repair or replace wire
288
Electric System & Accessory—Audio System—Audio System Replacement
IV. Audio System Replacement
I. Notice when operation
Please explain to the customer that the AM/FM broadcast channel information will be cleared when
removing the battery negative terminal cable. Record the channel information before removing the
negative terminal cable if necessary. Reset after connecting the negative terminal cable.
All cassette tapes and CDs must be taken out before radio removal and installation.
If the cassette tapes and CDs can not be taken out due to radio fault, do not take them out by force.
Drive the vehicle to Service Station.
Make sure the grounding bolts are tightened before antenna removal and installation.
There will be noise when receiving electric wave if the grounding bolts are not tightened.
Don't touch the speaker cone basin.
II. Radio assembly
1. Remove middle instrument panel (see internal decorations)
2. Remove radio with bracket assembly
a. Remove four screws
b. Disconnect connector
3. Remove left bracket
4. Remove right bracket
5. Remove radio assembly
III. Instrument panel loudspeaker assembly
1. Remove the louderspeaker housing
2. Remove front louderspeaker assembly
a. Disconnect connector
b. Remove 2 self-tapping screw and louderspeaker assembly.
IV. Tweeter assembly
1. Remove front pillar trim
2. Remove front door tweeter assembly
a. Disconnect the connector
b. Remove 2 self-tapping screws and tweeter assembly.
V. Rear loudspeaker assembly
1. Remove door handle
289
Electric System & Accessory—Audio System—Audio System Replacement
2. Remove rear door electrical window lift switch assembly
3. Remove rear door inner trim cover assembly
4. Remove loudspeaker assembly
a. Disconnect connector
b. Remove 2 self-tapping screw and louderspeaker assembly.
VI. Remove antenna conductor
1. Remove vehicle roof inner trim
2. Remove A pilar trim panel
3. Disconnect connector
4. Remove instrument upper body
5. Remove wire clip and antenna conductor
VII. Top-mounted antenna assembly
1. Remove the trim of roof
2. Remove trim panel of A pillar
3. Disconnect connector
4. Remove fastener of top-mounted antenna assembly
5. Remove top-mounted antenna assembly
290
Electric System & Accessory—Centralized Controller—Centralized Controller System
Part 5 Centralized Controller
I. Centralized Controller System
1. Connector terminal distribution of centralized controller system:
Centralized
2. Upper wire connector, shows as follows (from wire output end)
1 12
111 H8-1 551 H06 A21 A22 78 H13

0.5YR 0.5RW 0.5BR 0.5BG A7 H9 291 B06 0.5BG 0.5WG 0.5Br 0.5WB
352 351 350 H05 0.5WR 0.5BY 1.5RW 1.25B 353 H9 H10 H03
0.5GB 0.5GW 1.0G 0.5WB1 0.5GB1 0.5BY 0.5BR 0.5BL
13 5 6 7 8 20
中央集控器
Centralized controller
AMP 368457-1
（此件在保险丝盒内）
(in fuse box)
3.Definition of centralized controller terminals: AMP368457-1
Pin Signal
1 Safety airbag signal input
2 Left front door unlocking
3 Ignition switch
4 Anti-theft indicator lamp
5 Central control lock locking
6 Central control lock unlocking
7 Central control lock, electric horn power supply, battery power supply
8 Negative power supply
9 Right turn lamp switch
10 Left turn lamp switch
11 Turn lamp warning switch
12 Door controlled switch input
13 Right turn lamp
14 Left turn lamp
291
Pin Signal
15 Lighting power supply
16 Rear backup door unlocking
17 Electric horn output
18 Internal locking switch
19 Internal unlocking switch
20 Antenna
4. Malfunction symptom list and solution procedure
Malfunction symptom list
It lists typical malfunction symptom of controller in following table. All defaults can be solved according
procedures in default diagnosis section. Enter each default diagnosis code then check circuit and parts
according malfunction diagnosis procedure.
No. Malfunction symptom

1 Centralized controller can’t work
2 Flasher
3 Central control lock

1. Centralized controller can’t work
Circuit drawing
Ignition
switch
Battery
Power supply
system
(1) Check fuse (refer centralized controller drawing)
292
①Check fuse D/LK(20A) continuity
②Check fuse POWER(40A) continuity
③Check fuse AM2(15A) continuity
④Check fuse REMOTE(10A) continuity
⑤Check fuse MAIN(80A) continuity

8-ground Any status ON
(2) Check voltage
Disconnect connector from centralized controller assembly
● Turn ignition switch to position ON
● Check voltage between terminals
Standard:

7-ground Any status 10-14V
Ignition switch Lower than
3-ground OFF→ON 1V→10-14V
Ignition switch is at ON 10-14V
Result and measure:
Normal: Replace centralized controller assembly
Abnormal: Repair or replace wires and connectors
2. Flasher
Circuit diagram
293
Ignition
switch
Hazard warning
switch
Right turn
lamp
Left turn
lamp
Battery
Flasher system
1. Flasher control system not working
2. Turn lamp, hazard warning lamp system trouble

(1) Flasher control system not working
Check the fuse (refer to principle diagram of flasher system)
① Check the fuse HAZARD(15A) ON
② Check the fuse D/LK(20A) ON
Results and measures: replace the one with the same volume in case of blownout
③ Check the voltage
● Check the voltage among terminals
Standards:
Tester connection Conditions Standard status

294

3-ground Ignition switch ON 10-14V
3-ground Ignition switch OFF Lower than 1V

Results and measures:
Abnormal Repair or replace harness or connector
(2) Turn lamp, hazard warning lamp system trouble
(refer to principle diagram of flasher system)
Check the harness connector
①Check ON
● Disconnect the connector from centralized controller assembly
● Check whether ON among terminals
Standard:

9-ground Right turn switch closing Below 1Ω
10-ground Left turn switch closing Below 1Ω
9-ground Right turn switch OFF 10KΩ or higher
10-ground Left turn switch OFF 10KΩ or higher
8-ground Always Below 1Ω
11-ground Hazard warning switch OFF 10KΩ or higher
11-ground Hazard warning switch ON Below 1Ω
Abnormal Check the harness, connector, switch
Normal Reconnect connector of centralized controller
Standard:

13-ground Hazard warning switch OFF Below 1V
10-14V
13-ground Hazard warning switch ON
(60-120 times per min.)
13-ground Right turn switch OFF Below 1V
10-14V
13-ground Ignition switch ON, Right turn switch ON
14-ground Hazard warning switch OFF Below 1V
10-14V
14-ground Hazard warning switch ON
14-ground Left turn switch OFF Below 1V
10-14V
14-ground Ignition switch ON, Left turn switch ON
10-ground Ignition switch ON, turn switch OFF 10-14V
10-ground Ignition switch ON, Left turn switch ON Below 1V
9-ground Ignition switch ON, turn switch OFF 10-14V
295

9-ground Ignition switch ON, Right turn switch ON Below 1V
11-ground Hazard warning switch OFF 10-14V
11-ground Hazard warning switch ON Below 1V
Abnormal Replace the centralized connector
3. Central control lock
Circuit diagram
Ignition switch
Antenna
Connect to airbag
ECU
Horn switch
Electrical horn
Left front door lock
Anti-theft motor
indicator
Right front door lock
motor
Battery Open lock
Left rear door lock
motor
Close lock Right rear door

lock motor
Left front door
switch
Right front Back door lock
door switch motor
Left rear
door switch
Right rear Central controlling lock
door switch system
Symptom list
1. Unable to lock/unlock all vehicle doors, door lock at the driver’s side not working, other three door
locks not working, and lock of trunk compartment not working via the vehicle door control switch and key
2. Anti-theft lamp trouble
3. Anti-theft horn trouble
(1) Unable to lock/unlock all vehicle doors, door lock at the driver’s side not working, other three door
locks not working, and lock of trunk compartment not working via the vehicle door control switch and key.
(Refer to principle diagram of central control lock system)
① Disconnect the connector
② Measure the voltage and resistance according to the values below.
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Standard:

12-ground Driver’s door closed→open 10KΩ or higher→Below 1Ω
12-ground Co-river’s door closed→open 10KΩ or higher→Below 1Ω
12-ground Left rear door closed→open 10KΩ or higher→Below 1Ω
12-ground Right rear door closed→open 10KΩ or higher→Below 1Ω
8-ground Always Below 1Ω
Driver’s door controlled switch
18-ground 10KΩ or higher→Below 1Ω
OFF→LOCK
Driver’s door controlled switch
19-ground 10KΩ or higher→Below 1Ω
OFF→UNLOCK
15-ground Always 10-14V
In case of disconformities, there may be trouble of harness
① Reconnect the connector of centralized controller
② Measure the voltage according to the values below.
Standard:
Tester
Conditions Standard status
connection
3-ground Ignition switch ON→OFF 10-14V→Below 1V
19-ground Driver’s door switch OFF→unlocking 10-14V→Below 1V
18-ground Driver’s door switch OFF→locking 10-14V→Below 1V
2-ground Driver’s door switch OFF→unlocking→OFF Below 1V →10-14V→Below 1V
5-ground Driver’s door switch OFF→closing→OFF Below 1V →10-14V→Below 1V
Door key cylinder at the driver’s side
6-ground Below 1V →10-14V→Below 1V
OFF→UNLOCK→OFF
Door key cylinder at the driver’s side
OFF→LOCK→OFF
Press unlocking key of rear door for 1s
OFF→UNLOCK→OFF
Press remote locking key
OFF→LOCK→OFF
In case the result does not conform to specifications, replace the controller or check the motor.
(2) Anti-theft lamp trouble
Connect the connector of centralized controller
Precondition: the fastener could work normally when pressing the remote
If not working normally, change to the fastener
① Check the voltage
Standard:

4-ground Protection status Pulse
Abnormal replace the centralized controller
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Normal harness, connector, anti-theft lamp
(3) Alarm horn trouble
Precondition: manual control normal
Abnormal horn system (switch)
Normal: check unlocking, locking horns are normal via remote:
Abnormal check the connector of centralized controller
① Check the voltage
● check the voltage among terminals
Standard:

Horn switch opening 0V
17-ground
Horn switch closing Pulse
Results and measures:
Abnormal replace the centralized controller assembly
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Electric System & Accessory—Safety Airbag System—Maintenance guidance
Part 6 Safety airbag system
I. Maintenance guidance
Warning: if operation isn’t carried out according to correct operating order during maintenance, safety
airbag may be exploded, causing serious accidents. In case operation doesn’t follow correct regulations
during maintenance, even if without accidents, it may cause ineffectiveness of safety airbag when
accident occurs to the vehicle, and detonation may not be possible accordingly. Therefore, operation
must be executed according to correct sequences described in the maintenance manual during
maintenance (including disassembling or installation, inspection or replacement of parts and
components). The following must be confirmed before maintenance:
● Place ignition switch on “LOCK” status, and pull out start key;
● Remove connecting wire of cathode of battery, and carry out maintenance after waiting for 60s;
● Wrap up the removed cathode for insulation. (capacitance within electronic control unit (ECU) of
safety airbag shall be able to keep a certain electric energy after the battery is powered off to ensure
deployment of safety airbag. Therefore, in case operation is carried out without waiting for a certain
time during maintenance, serious injury accident may occur due to incorrect deployment of safety
airbag.)
When removing safety airbag system/safety belt pretightener that has not been deployed:
● Do not hold the conductor or connector of safety belt pretightener with hands, with hands far away
from ignition device of safety belt.
● Ensure opening end of piston pipe of safety belt pretightener is not pointed to yourself or others.
● Do not cover the opening of piston pipe of safety belt pretightener with hands; otherwise, it may
cause personal injury.
● When the pretightener is deployed to be rejected, carry out proper corresponding procedures
according to sequences listed in this chapter; otherwise, it may cause personal injury.
To prevent accidental deployment of safety airbag and injuries, do not dispose of airbag module that has
not been deployed according to sequences of normal workshop wastes. In case sealed container is
damaged during rejection, some substances contained in the charging device module that has not been
deployed may cause serious illness or personal injury. Airbag module that has not been deployed shall
be safely rejected according to corresponding procedures of this chapter; if not, it will violate some local
laws.
When storing the charging module that has not been deployed:
● Ensure airbag is not opening towards the surface of charging module.
● There shall be sufficient space around safety airbag to prevent accidental deployment.
● When the steering wheel is placed, the airbag opening shall not be downward, and steering wheel
not vertical. Place it at the side.
If recommended operating rules of special tools are not observed, it may cause deployment of safety
airbag, thus causing personal injury or other unnecessary repairs.
Note: carry out trouble diagnosis with the diagnostic instrument firstly according to methods of this
operation manual for maintenance. Check whether trouble code exists before removing the battery wire.
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● No disassembling or repairs is allowed at unauthorized service station.
● Installation, disassembling and maintenance personnel shall be specially trained.
● Technical parameters of safety airbag system match with whole vehicle model. Do not use parts and
components of safety airbag of other vehicle models. Confirm that parts and components of this
vehicle model are replaced before replacing new ones.
● Please shut down key switch and better to cut off power supply anode thoroughly for maintenance of
vehicle (especially electric welding).
● When the airbag is deployed, safety airbag assembly, electronic control unit (ECU) of safety airbag
and clock spring must be replaced as a whole. When the safety airbag is disassembled or removed,
the cover must be pointed upward, and the safety airbag assembly shall not be overlapped directly
to avoid incorrect detonation causing accidents.
● Internal trouble of electronic control unit (ECU) of safety airbag is unrepairable. In case of troubles,
replace it. Safety airbag assembly shall be stored where the temperature is below 40℃, relative
humidity <75% and far away from interference of electromagnet field.
● Do not disassemble airbag assembly and its interior gas generator.
● Do not switch on DC or AC exceeding 20V to ECU to avoid damages.
1. Special tools and measuring instruments available in the safety airbag service station
Name and model Application

6S allen wrench Installation and disassembling of the driver’s airbag assembly
18S socket wrench Installation and disassembling of fixing nuts of steering wheel
10S wrench Installation and disassembling of fixing bolts of ECU
Installation and disassembling of fixing nuts of side airbag at the seat,
fixing bolts of passenger’s safety airbag assembly within instrument panel,
10S socket wrench
bolts of side crash sensor of lower part of B pillar and fixing bolts of curtain
type safety airbag of A pillar-C
Type DT992 digital
Electrical measurements on the harness
multimeter
Trouble diagnostic
Trouble diagnosis of safety airbag system
instrument of safety system
2. Replacement of parts and components
Warning: parts and components of safety airbag system must be replaced strictly according to
instructions of this section.
1. Inspection and maintenance of front safety airbag module
Note:
● In case safety airbag of front row is not deployed even under slight impact, check the modules of the
driver’s safety airbag and passenger of front safety airbag, etc.
● Do not decompose, repair or reuse modules of driver’s safety airbag and passenger of front safety
airbag after impact.
● In case modules of driver’s safety airbag and passenger of front safety airbag fall on the ground, or
in case of scratches, drop pit or other defects of the support or connector, replace it with new one.
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● Do not expose modules of driver’s safety airbag and passenger of front safety airbag directly to hot
air or flame.
2. Replacement of the driver’s safety airbag
On-board check:
(1) Vehicle is not collided
①Check the diagnosis system;
② Visually check the driver’s safety airbag module installed on the vehicle for the following items: cuts,
slight cracks or obvious color changing of surface and gapping part of airbag module assembly.
(2) Airbag not deployed while the vehicle is bumped
① Check the diagnosis system;
② Take out the driver’s safety airbag module from the vehicle and visually check the following:
③ Cracks, slight cracks or obvious color changing of surface and gapping part of the driver’s airbag.
④ Check whether the wire is pulled apart, cut, or connector peeled off.
⑤ Check the steering wheel is deformed.
Warning: when the driver’s airbag module is removed, follow correct procedures below:
Horn
喇叭接触连接片 touch Horn
喇叭接触连接片 touch
connector connector
① Disconnect the negative terminal of the battery, and repair it at least after one minute.
② The wheel is toward right ahead.
③ Loosen two internal six-spline bolts via internal six-spline socket wrench
④ Take out airbag module from steering wheel assembly.
⑤ Loosen the horn connector.
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Note: do not pull the airbag harness when taking out airbag
module assembly.
① Disconnect the airbag connector with the screwdriver.
② Take out airbag module assembly.
③ The module that is taken out shall be covered and placed

upward.
Warning: Follow the procedures below when the driver’s

airbag module is disassembled or installed: Airbag mounting
安装气囊螺丝孔
Airbag mounting screw hole
安装气囊螺丝孔
screw hole
① Connect the airbag module connector and horn
connector.
② Install the airbag module after making sure the screw slot touches screw casing.
③ Loosen two internal six-spline bolts with internal six-spline socket wrench (torque: 8.8N·m)
(3) Safety airbag deployed while the vehicle is collided
① Check the diagnosis system
② Take out safety airbag module from the vehicle, and visually check the following: check whether clock
spring connector and harness are damaged.
3. Replacement of front passenger safety airbag
(1) Vehicle not under impact
① Check the diagnosis system；
② Take out the passenger of front safety airbag module assembly that is installed on the vehicle and
visually check the following: cuts, slight cracks or obvious color changing around airbag module
assembly.
(2) Safety airbag not deployed while the vehicle is collided
① Check the diagnosis system
② Take out the passenger of front safety airbag module assembly from the vehicle and visually check
the following:
③ Cracks, slight cracks or obvious color changing of surface and gapping part of co-driver’s front airbag
④Check cracks and scratches of the cable, and connector fragments
⑤ Check whether instrument panel and its reinforced bar are deformed or cracked
Tips:
● In case instrument panel and its reinforced bar are deformed or damaged, do not repair but replace.
● Instrument panel and passenger’s safety airbag without interference
Warning: Follow the procedures below when the driver’s airbag module is disassembled:
① Disconnect the negative terminal of the battery
② Remove panel sub-assembly of central instrument control console
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③ Take out instrument console panel
④ Take out combination instrument panel
⑤ Disconnect the passenger’s safety airbag connector
⑥ Take out two screw caps and passenger’s safety airbag

module
⑦ Check co-driver’s front safety airbag module
⑧ Install co-driver’s front safety airbag module
⑨ Install instrument panel subassembly 安装螺丝孔

Mounting screw hole
(Installation torque for screws of safety airbag: 20N·m)
Note: Do not pull airbag harness when taking out airbag module assembly.
① Open the safety airbag connector.
② Take out the airbag module assembly.
③ Airbag module that has been taken out shall be covered and placed upward.
4. Replacement of side safety airbag
Warning: Switch off the power supply before disassembling, replace the airbag after 60s.
侧面气囊
Side airbag
(1) Draw away the zip fastener on the seat backrest
拉链
Zip
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After pulling aside, it could be seen clearly that nuts are used for fixing side airbag and seat framework.
(2) Screw off the nut with the wrench and take out side airbag.
(3) Install a new side safety airbag assembly
Note: ① When the airbag module is installed, pay attention to

matching of airbag module and support, which shall be evenly
pressed against seat material. Make sure the hook is well fastened for
installation of support on the seat.
② Install the nut to bolts, and zip up with the wrench.
5. Replacement of curtain safety airbag
Warning: Switch off the power supply before disassembling, replace the airbag after 60s.
(1) Take out fixing clip of the roof.
Fixing
固定卡扣
clamp
(2) Remove the roof, and the side gas curtain could be seen clearly as fixed on the plate work of body.
侧面气帘
Side air curtain
车身钣金
Body sheet metal
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(3) Remove upper trim board of A pillar and interior trim board of B pillar
AA柱上装饰板
pillar upper trim plate
B柱上装饰板
B pillar upper trim plate
驾驶员侧气帘
Driver side air curtain
拆掉A柱和B柱内饰板后
After interior trim plate of A pillar and B pillar removed
(4) For safety gas curtain of this vehicle, disassembling sequence is “two ends firstly and then middle”.
Screw off bolts with the wrench and take out the hook. After disassembling two terminals, remove the
gas generator assembly.
Fixing bolt
固定螺栓
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Gas generator fixing bolt

气体发生器固定螺栓
(5) Remove guider parts of B pillar and C with the wrench
固定螺栓
Fixing bolt
B
柱
B pillar guider part

导
向
件
C
柱 C pillar guide
导
向
件
(6) Remove the gas curtain.
Installation procedures of curtain airbag
① Check whether the gas curtain is damaged, or with slide side, etc. Check whether the surface of gas
generator has cracks, color changing, etc.
② Install guider parts of C pillar and B.
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B
柱
B pillar guider part

导
向
件
C
柱
C pillar guider part

导
向
件
③ For gas curtain of this vehicle, disassembling sequence is “middle firstly and then two ends”, that is,
gas generator assemble shall be installed firstly.
气体发生器总成
Gas generator assembly
④ After installation of gas generator assembly, install two ends, and then install the roof.
⑤ Install interior trim boards of B pillar and A.
⑥ Confirm all fasteners are properly installed.
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B A
A pillar interior
B pillar interior
柱柱
内内
trim plate
trim plate
饰饰
板板
6. Replacement of control unit of safety airbag
Warning: Switch off the power supply before disassembling, replace it after 60s.
(1) Take out covers of auxiliary instrument and expose control unit of
safety airbag.
(2) Remove control unit harness of safety airbag.
(3) Remove control unit of safety airbag.
(4) Install a new control unit of safety airbag
Installation is reverse process of disassembling. Fix the unit of safety airbag to the support, and connect
the connector, and then install relevant interior trims properly.
Note: The connector shall be well plugged and locked. Be careful as not to damage ECU pin for
installation of connector.
7. Sensor replacement
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(1) Remove interior trims below the middle pillar.
(2) Take out crash sensor.
(3) Remove the sensor and harness connector.
(4) Install a new sensor
Installation is a reverse process as disassembling. Please make sure the connector is well plugged and
locked, and then fix the sensor. Make sure relevant interior trims are properly installed according to
corresponding procedures.
Note: The connector shall be well plugged and locked. Be careful as not to damage sensor pin
for installation of connector.
8. Replacement of steering wheel assembly
(1) Remove the driver’s airbag.
① Pry off covers at two sides of lower shield of steering wheel;
② Remove fixing bolts at two sides with hexagonal screwdriver;
③ Remove the driver’s airbag and take out connector of

connecting wire;
④ Take out the connector of (black) connecting wire of horn

switch.
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(2) Remove the steering wheel to be replaced.
① Remove fixing nuts of steering wheel with the lengthened socket wrench;
② Remove the steering wheel to be replaced upward along steering axis;
③ Fix the push rod of clock spring well while removing steering wheel.
(3) Install a new steering wheel assembly.
① Thread connecting wires of airbag and horn switch to interior of steering wheel through its lower part,
and then align with corresponding holes on the push rod of clock spring and steering wheel, and connect
the steering wheel to the steering columns. Then screw down fixing nuts of steering wheel (fastening
torque is 50N.m±2N.m).
② Install the connector of connecting wire of horn switch and install the connecting wire of the airbag to
the driver’s airbag, which shall be placed within the steering wheel, and properly adjust the clearance left
and right;
③ Install fixing bolts at two sides of lower shield of steering wheel (fastening torque is 8N.m±1 N.m) and
place it with side cover.
(4) Connect the cable conductor of cathode of the battery.
9. Replacement of clock spring assembly
(1) Adjust the steering wheel to the center position, and keep its rotating position unchanged.
(2) Remove the steering wheel according to (1)-(3) sections of 8 – Replacement of steering wheel
assembly.
(3) Remove the clock spring assembly to be replaced.
Remove three fixing screws of clock spring;
Remove the connector of lower connecting wire of clock spring.
(4) Install a new clock spring assembly.
Connect lower connecting wire of clock spring well;
Install three fixing screws of clock spring.
(5) Install the steering wheel assembly.
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① Thread connecting wires of airbag, and horn connecting wire of clock spring to interior of steering
wheel through its lower part, and then align with corresponding holes on the push rod of clock spring and
steering wheel, and slowly connect the steering wheel to the steering columns. Then screw down fixing
nuts of steering wheel (fastening torque is 50N.m±2N.m).
② Take out fail-safe bolt on the clock spring;
③ Install the steering wheel assembly according to “8 – Replacement of steering wheel”.
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Electric System & Accessory—Safety Airbag System—Maintenance Procedures and Trouble Classification
II. Maintenance Procedures and Trouble Classification
Ⅰ Inspection
Inspections on safety airbag system are divided into three categories:
1. Routine inspection;
Maintenance on safety airbag system is not required unless system trouble indication occurs. However,
in case of severe scratches/cracks or corrosion of airbag, replace relevant parts.
2. Inspection when the airbag is not deployed when the vehicle reaches required impacting speed;
3. Inspection when the vehicle is impacted and airbag deployed.
(1) Inspection on the driver’s safety airbag
① Routine inspection
Check the diagnosis system
Visually check the driver’s safety airbag module assembly that is

installed on the vehicle for the following items: cuts, slight cracks or
obvious color changing of the surface and gapping parts of airbag
module assembly.
Warning: in case of severe scratches, cracks or color changing, replace the whole airbag module
assembly;
Do not knock any parts of airbag with heavy articles;
Do not paint anything on the airbag surface with any tools;
Do not post any articles on outer surface of airbag.
② Inspection when the airbag is not deployed when the vehicle reaches required impacting speed:
Cracks, slight cracks or obvious color changing of the surface and gapping parts of the driver’s airbag
surface.
Check whether the wire is snapped, scratched, or connector is peeled off.
Check whether steering wheel is deformed.
Check whether the horn contact piece of the driver’s safety airbag assembly is deformed; if so, do not
repair. Replace it with a new driver’s airbag module.
③ Inspection when the vehicle is impacted and airbag deployed.
Warning: As this airbag module is one-off part and could not be

recycled, do not repair this airbag assembly. As this airbag
module is for one-off use and could not be recycled, do not
repair this airbag assembly.
(2) Inspection on the co-driver’s front safety airbag
Visually check the passenger of front safety airbag module assembly that is installed on the vehicle for
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the following items: cuts, slight cracks or obvious color changing around the airbag module assembly.
Take out the passenger of front safety airbag module assembly that is installed on the vehicle and
visually check for the following items:
Cuts, slight cracks or obvious color changing on surface of the front passenger airbag.
Check cracks and scratches on the cable and fragment of connector. Check whether instrument panel
and its reinforced bar are deformed or cracked.
Tips: In case instrument panel and its reinforced bar are deformed or damaged, do not repair but
replace; Instrument panel and passenger’s safety airbag without interference
Warning: As this airbag module is one-off part and could not be recycled,
do not repair this airbag assembly.
(3) Inspection on the side safety airbag
Inspections on the side airbag module of front row are divided into:
① Routine inspection:
Carry out trouble diagnosis inspection.
Visually check the side safety airbag that is installed at outer side of seats of front
row mainly for the following items: check whether the surface of airbag cover is
scratched, cracked or its surface with obvious color changing, etc.
Check whether the clearance between the airbag and seat surface is even.
Warning: in case of severe scratches, cracks or color changing, replace the whole airbag module
assembly;
Do not knock any parts of airbag with heavy articles;
Do not paint anything on the airbag surface with any tools;
Do not post any articles on outer surface of airbag.
② Inspection that the airbag is not deployed when the vehicle reaches required impacting speed: ：
Carry out trouble diagnosis inspection.
Visually check the removed safety airbag mainly for the following items:
● Check whether the surface of airbag is scratched, cracked or its surface with obvious color changing,
etc.
● Check whether harness part is scratched, cracked or broken, etc.;
● Take out the harness joint and check whether it is damaged, deformed, loosening, etc.;
Warning:
● in case of severe scratches, cracks or color changing, replace the whole airbag module
assembly;
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● In case of scratches, damages, fractures and deformed and damaged joint of the harness,
please replace it immediately;
③ Inspection when the vehicle is impacted and airbag deployed:
● Check the seat is deformed;
● Check whether harness part is scratched, cracked or broken, etc.;
● Take out the harness joint and check whether it is damaged, deformed, loosening, etc.;
● When the airbag is deployed, please immediately replace it for a new airbag module assembly
Warning: As this airbag module is one-off part and could not be recycled, do not repair this
airbag assembly.
(4) Inspection on curtain safety airbag
Check it iwth the trouble diagnostic instrument
Visually check the side gas curtain that has been installed on
the vehicle; in case of the following conditions, use a new trim
or roof; for those matching the side gas curtain, in case of any cracks or obvious stains or color changing,
please replace trims or roofs.
Tips: Disassembling and installation procedures of the curtain gas airbag shall be executed
strictly according to “disassembling and installation” of the side gas airbag.
Diagnose it with the trouble diagnostic instrument;
Remove the side gas airbag from the vehicle, and in case of the following conditions, replace it for a new
one;
Any cracks, slight cracks or obvious stains or color changing on the side gas curtain are found;
The connector is with any cracks, slight cracks or obvious stains or color changing.
Check whether the curtain safety airbag support is deformed; if so, replace with new one.
Check the roof trim, relevant trims are cracked or deformed; if so, replace it for new ones.
Check whether the harness of curtain airbag has cracks, or is working normally with power on, and
connector is normal; if case of any troubles, please replace it.
(5) Inspection on control unit of safety airbag
Check the system;
Check whether the controller casing has cracks, sagging, corrosion or

deformation; if so, replace with new one.
② Inspection when the vehicle is impacted but the airbag not deployed
Check the system and whether there is trouble code not cleared.
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Check safety airbag controller:
● Whether the support is sagging, cracked, or deformed, etc.
● Galvanizing coat of the support is damaged;
● Controller casing is cracked, sagging or deformed;
● Joint is damaged, terminal deformed, and harness bitten into.
Check collision direction and angle, and damages of the vehicle,

and learn relevant conditions from the interested party and analyze
the reason why the airbag is not functioning.
Check the system;
Check the safety airbag controller;
● Check whether the support is sagging, cracked, or deformed, or

its galvanizing coat is damaged; if so, replace ECU support. And new ECU of safety airbag could
only be replaced after repairs on deformed vehicle body.
● Controller casing is cracked, sagging or deformed;
● Whether the joint is damaged, terminal deformed, and harness bitten into. In case of any problems,
replace whole harness of safety airbag system.
Warning: In case of collision, please replace the airbag module and control unit of safety airbag.
(6) Inspection on the side crash sensor
Inspection or replacement on the crash sensor is not required in case of trouble; unless system trouble
warning occurs.
Check the system.
② Inspection when the vehicle is impacted but the airbag not deployed
Check the system.
In case the front safety airbag is not deployed after collision, then it is unrelated to the
side crash sensor. However, the sensor shall be checked for damages in case the middle
column or its trims are deformed or damaged after collision.
In case the side airbag or curtain airbag is not deployed after side collision, please check
the collision area and the direction when collision occurs, and damages. And also analyze
the reason that the airbag is not deployed, and determine whether there is trouble of side sensor.
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Warning: In case of side collision, the side airbag is

deployed. Please replace the airbag module and
also the crash sensor.
(7) Inspection on steering wheel and clock spring
Warning: As steering wheel and clock spring are

closely related to safety airbag system, in case of
deformation, cracks, etc. during operation, please
replace with new one.
Ⅱ Trouble classification of safety system
According to results indicated by the trouble diagnostic instrument, troubles are divided into: power
trouble, ECU internal trouble, configuration error, periphery sensor trouble, system warning lamp trouble,
ignition circuit trouble.
1. Power trouble
Voltage inspection Voltage inspection

Voltage too low gray area Normal working voltage Voltage too high
gray area
Limit value of supply voltage
Power trouble refers to too high or too low supply voltage. Normal working voltage of ECU is 9～16V.
When ignition switch reaches ACC, ECU is power on and starts self-check, and the indicating lamp is
OFF after ON for 4s, which indicates that ECU and its external parts are trouble-free, and could function
normally. When the supply voltage is lower than 8.25V and higher than 17.25V, the system trouble alarm
lamp will be normally ON; if supply voltage is between 8.25V-9V, or between 16V-17.25V, the system
trouble lamp is not clear, which may be ON or not.
In case of power trouble during uses, which means the voltage is lower than 8.25V and higher than
17.25V, or battery damages, charge, discharge or replace the battery.
2. ECU internal trouble
As there is 1, 2, 3 and 6 ignition circuits of safety airbag for selection, if the extra ignition circuits are not
shielded, system warning lamp will be ON for a long time due to configuration error. ECU of 8 circuits is
used as ECU of 4 circuits, and its system warning lamp of channel B of 8-circuit ECU will be ON for a
long time due to configuration error.
3. Configuration error
It mainly indicates the trouble not due to ECU itself. In case of trouble of ECU itself, ECU will record
corresponding trouble code, and meanwhile, the system warning lamp will be ON for a long time, till the
trouble is eliminated and trouble code is cleared. In case of collision during this trouble, ECU could not
make airbag deployed and record collision accelerating speed. If ECU internal hardware trouble is
indicated by the trouble code, replace with new ECU and write vehicle information into ECU.
4. Periphery sensor trouble
ECU will detect and record the trouble of periphery acceleration sensor, which mainly indicates those
related to side crash sensor, including harness connection trouble, communication trouble, reliability and
configuration trouble. In case of trouble of periphery sensor, ECU will record corresponding trouble code,
and meanwhile the system trouble warning lamp will be ON for a long time, till the trouble is eliminated
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and trouble code is cleared. In case of collision during this trouble, the side airbag and curtain airbag
may not be deployed under low-speed collision; or airbag is deployed under high-speed collision, but
unable to have excellent protective action.
5. System warning lamp trouble
In case the system warning lamp is short-circuited or open-circuited, the trouble lamp will not be ON or
ON for a long time, under which condition, ECU will record corresponding trouble code, till the trouble is
eliminated and trouble code is cleared.
6. Ignition circuit trouble
Ignition circuit trouble refers to those between airbag ECU and each airbag and pretightening safety belt.
ECU could detect resistance values of all ignition circuits regularly.
Circuit table of safety airbag system
Circuit Resistance to low Normal Resistance too high

Driver’s safety airbag <1.7Ω 2.01Ω～4.24 Ω >5.5Ω
Co-driver’s front safety airbag
Safety belt pretightener
﹤1.1Ω 1.77Ω～3.49 Ω >5.5Ω
Side airbag
Curtain airbag
When too high or too low resistance of ignition circuit is detected, ECU will record corresponding trouble
code, and meanwhile the system trouble warning lamp will be ON for a long time, till the trouble is
eliminated and trouble code is cleared.
Ignition circuit trouble could be caused by periphery part itself and line trouble. The table below is
definition of ECU pin and color of conductor. When it is confirmed that the system trouble lamp is ON for
a long time not caused due to periphery part, check harness is faulty. The pin figure is that of 8-circuit
ECU of Type HQ7101 safety airbag system. When there is only the driver’s airbag and passenger of
front row’s airbag configured in the vehicle, port of channel B is closed.
13 14 15 16 17 18 19 20 2122 23 24 13 14 15 16 17 18 19 20 2122 23 24
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12
Channel B
Channel A 通道B
通道A
317
Definition table for pin and conductor color
PIN# Color Pin definition PIN# Color Pin definition
A1 G-W K diagnose interface B1 -- Not used

A2 -- Not used B2 -- Not used
Crash sensor at the driver’s
A5 R-BL impact output signal B5 R-G
side (-)
Crash sensor at the driver’s
A6 -- Not used B6 R-Gr
side (+)
Crash sensor at the co-driver’s
A7 -- Not used B7 B-W
side (-)
Crash sensor at the co-driver’s
A8 -- Not used B8 W-G
side (+)
A12 R Power (+) B12 -- Not used

Side safety airbag generator at
A13 -- Not used B13 Gr-G
the co-driver’s side (-)
A14 -- Not used B14 O-W
the co-driver’s side (+)
A15 P Driver’s airbag generator (-) B15 Bl-Gr
the driver’s side (+)
A16 Br-W Driver’s airbag generator (+) B16 V-O
the driver’s side (-)
Co-driver’s front airbag Co-driver’s curtain safety
A17 W-R B17 Br-W
generator (+) airbag generator (-)
Co-driver’s front airbag Co-driver’s curtain safety
A18 B-R B18 Lg-W
generator (-) airbag generator (+)
Driver’s safety belt Left curtain safety airbag
A19 O-R B19 Br-P
pretightener (-) generator (+)
Driver’s safety belt Left curtain safety airbag
A20 G B20 G-W
pretightener (+) generator (-)
Co-driver’s safety belt
A21 W B21 -- Not used
pretightener (+)
Co-driver’s safety belt
A22 R-G B22 -- Not used
pretightener (-)
A23 B Earthing B23 -- Not used
A24 R-Y System warning lamp B24 -- Not used
Color: R-red, Bl-blue, Y-yellow, B-black, P-pink, G-green, W-white, O-orange, Gr-grey, Br-brown,
V-purple, Lg-grass green.
Ⅲ Trouble diagnosis procedure and information of safety airbag system
1. Self-check procedures and trouble diagnosis
318
(1) After new electronic control unit of safety airbag is installed, the indicating lamp of safety airbag
system will go off after flashing for 4s when the ignition switch is placed to ON, which means safety
airbag system is working normally. At this point, maintenance is not needed for the system, but system
diagnosis and inspection other than this shall be carried out.
(2) In case the indicating lamp of safety airbag system doesn’t light when the ignition switch is placed to
ON, check the circuit of indicating lamp, and then operate it under working condition.
(3) In case warning lamp doesn’t go off after light for 4s, carry out the following operating flow.
Warning lamp is Apply diagnosis to scan

警告灯点亮使用诊断仪与K
ECU, connecting with K Trouble Troubleshooting Clarify trouble code
lit for 4s after 发现故障处理故障清除故障代码
4s后未熄灭 line discovered
lighted 线连接扫描ECU
2. Information on trouble diagnosis of safety airbag system
A series of cycle test is executed by control unit of safety airbag to check the function of safety airbag
system is ready, which will prevent incorrect deployment of the system and meanwhile ensure necessary
deployment during collision. In case of trouble, monitor unit of safety airbag will store one proper trouble
code and open the trouble indicating lamp to indicate a trouble status for maintenance.
When checking safety airbag system each time, start it with diagnosis on whole safety airbag system via
the trouble diagnostic instrument, through which, trouble diagnosis code is displayed. The table below is
listed with all trouble information of ECU and corresponding trouble codes, trouble description and
possible causes.
ECU trouble code table for safety airbag
No. Description Trouble code

1 ECU internal trouble B1000
2 Configuration error B1001
3 Driver’s airbag open-circuited B0026
4 Resistance too low or wire tapping of the driver’s safety airbag B0022
5 The driver’s safety airbag short-circuited to ground B0024
6 The driver’s safety airbag short-circuited to power supply B0025
7 Co-driver’s front safety airbag open-circuited B0017
8 Resistance too low or wire tapping of co-driver’s front safety airbag B0016
9 Co-driver’s front safety airbag short-circuited to ground B0018
10 Co-driver’s front safety airbag short-circuited to power supply B0019
11 Driver's safety belt pretightener open-circuited B0065
12 Resistance too low or wire tapping of driver's safety belt pretightener B0064
13 Driver's safety belt pretightener short-circuited to ground B0066
14 Driver's safety belt pretightener short-circuited to power supply B0067
15 Safety belt pretightener at co-driver’s side open-circuited B0058
16 Resistance too low or wire tapping of safety belt pretightener at co-driver’s side B0057
319
No. Description Trouble code

17 Safety belt pretightener at co-driver’s side short-circuited to ground B0059
18 Safety belt pretightener at co-driver’s side short-circuited to power supply B0060
19 Side safety airbag of the driver open-circuited B0041
20 Resistance too low or wire tapping of side safety airbag of the driver B0040
21 Side safety airbag of the driver short-circuited to ground B0045
22 Side safety airbag of the driver short-circuited to power supply B0046
23 Side safety airbag of the co-driver’s side open-circuited B0029
24 Resistance too low or wire tapping of side safety airbag of the co-driver’s side B0028
25 Side safety airbag of the co-driver’s side short-circuited to ground B0030
26 Side safety airbag of the co-driver’s side short-circuited to power supply B0032
27 Curtain safety airbag at the driver’s side open-circuited B0062
28 Resistance too low of curtain safety airbag at the driver’s side B0061
29 Curtain safety airbag at the driver’s side short-circuited to ground B0068
30 Curtain safety airbag at the driver’s side short-circuited to power supply B0063
31 Curtain safety airbag at the co-driver’s side open-circuited B0070
32 Resistance too low of curtain safety airbag at the co-driver’s side B0069
Curtain safety airbag at the co-driver’s side short-circuited to ground or wire
33 B0071
tapping
34 Curtain safety airbag at the co-driver’s side short-circuited to power supply B0076
35 Operating trouble or wire tapping of crash sensor at the driver’s side B0077
36 Incorrect installation of crash sensor at the driver’s side B0079
37 Damage or stability trouble of crash sensor at the driver’s side B0080
38 Operating trouble or wire tapping of crash sensor at the co-driver’s side B0078
39 Incorrect installation of crash sensor at the co-driver’s side B0081
40 Damage or stability trouble of crash sensor at the co-driver’s side B0082
41 Supply voltage too high B0028
42 Supply voltage too low B0027
43 System trouble lamp short-circuited to ground or open-circuited B0071
44 System trouble lamp short-circuited to power supply B0073
45 Front airbag already deployed B0051
46 Side safety airbag or curtain safety airbag already deployed B0034
47 Safety airbag controller reaching maximum using limit and unable to be used B0052
48 Impact output line short-circuited to power supply B0049
49 Impact output line short-circuited to ground or open-circuited B0048
3. Trouble diagnosis procedure
320
(1) Power supply trouble
① Supply voltage too high
Symptom: safety airbag system warning lamp is ON for a long time, and trouble code as detected by the
trouble diagnostic instrument is B1328 – supply voltage too high
Diagnostic program:
Step Operations Yes No

1 When safety airbag ECU is checked with the trouble diagnostic
To Step 2 Others
instrument, trouble code is B1328?
2 After power off, supply voltage value is not high?
Carry out discharging for power supply; refer to maintenance for To Step 3 --
power supply system for specific operations.
After repairs, switch on power, and observe status of trouble
3 lamp. And at this point, this lamp should go off after lighting for To Step 4 To Step 1
4s (self-check).
Trouble eliminated already; eliminate the trouble with the
4 －－
diagnostic instrument. Update the latest maintenance date.
② Supply voltage too low
Symptom: safety airbag system warning lamp is ON for a long time and trouble code as detected by the
trouble diagnostic instrument is B1327 – supply voltage too low.
Diagnostic program:

1 When ECU trouble is checked with the diagnostic instrument,
To Step 2 Others
trouble code is B1327?
2 After power off, voltage value is larger than 8.25V? To Step 3 To Step 4
Charge the power; refer to maintenance for power supply
3 To Step 7 －
system for specific operations.
Check the harness between the battery and fuse box. Remove
Check and
the fuse box and place ignition switch to ON position without
4 To Step 5 repair the
loosening connector. Measure whether the voltage of two
harness
contact columns of fuse box is higher than 8.25V?
Check the harness between the fuse box and unit connector of
safety airbag system.
1. Place the ignition switch to “LOCK” position.
2. Loosen the negative cable of the battery and wait for at least 1 Replace the
5 To Step 6
minute, and remove ECU connector of safety airbag. harness
3. Install the negative cable back, and place ignition switch to
ON position, and measure the voltage between harness A12
and A23 is above 8.25V?
Replace
Check safety airbag ECU. Check whether the pin is deformed or
6 ECU －
fractured.
To Step 7
4s (self-check).
8 －－
(2) ECU internal trouble
① ECU internal trouble
321
trouble diagnostic instrument is B1000.
Diagnostic program:

When ECU trouble is checked with the diagnostic instrument,
1 To Step 2 Others
2 Replace the faulty ECU with a new one. To Step 3 －
After switching on ignition switch, the trouble lamp shall be
under flashing condition. According to configuration on the
3 To Step 4 To Step 1
vehicle, reset ECU (confirm the number of airbags) and activate
ECU.
4 diagnostic instrument. Write in vehicle information, replacement －－
date.
(3) Configuration error
① Configuration trouble
Diagnostic program:

1 To Step 2 Others
Check whether ECU setup state is consistent with actual
2 － To Step 3
configuration on the vehicle?
Check actual configuration on the vehicle, and shield or switch
on corresponding circuits accordingly. Switch on the power, and
observe status of trouble lamp. And at this point, this lamp
should go off after lighting for 4s (self-check).
4 －－
(4) Periphery sensor trouble
① Operating trouble or wire tapping of crash sensor
trouble diagnostic instrument is B0077 or B0078.
Diagnostic program:

When ECU trouble is checked with the diagnostic instrument, trouble
1 To Step 2 Others
code is B0077 or B0078?
Check whether lines between ECU and sensor are short-cicuited, To Step
2 To Step 4
open-circuited? 3
3 Check sensor connector of ECU is well contacted? To Step 4 －
After repairs, switch on the power, and observe status of trouble
To Step
4 lamp. And at this point, this lamp should go off after lighting for 4s To Step 4
1
(self-check).
5 Trouble eliminated already; eliminate the trouble with the diagnostic －－
322

instrument. Update the latest maintenance date.
② Incorrect installation of crash sensor
trouble diagnostic instrument is B0079 or B0081
Diagnostic program:

1 To Step 2 Others
trouble code is B0079 or B0081?
2 Is ECU and sensor’s pin incorrectly connected? To Step 3 －
After repairs, switch on the power, and observe status of
3 trouble lamp. And at this point, this lamp should go off after To Step 4 To Step 1
lighting for 4s (self-check).
4 －－
③ Damage or stability trouble of crash sensor
trouble diagnostic instrument is B0080 or B0082.
Diagnostic program:

1 To Step 2 Others
Replace for a new sensor.
2 Warning: Place ignition switch to LOCK position. Operation is To Step 3 －
only executed after disconnecting battery cathode for at least
60s.
After replacing with a new sensor, switch on the power, and
3 observe status of trouble lamp. And at this point, this lamp To Step 4 To Step 1
should go off after lighting for 4s (self-check).
4 －－
(5) System trouble lamp trouble
① System trouble lamp short-circuited to ground or open-circuited.
Symptom: safety airbag system warning lamp is not lit, and trouble code as detected by the trouble
diagnostic instrument is B0671.
Diagnostic program:

1 To Step 2 Others
With power off, check ECU harness is well connected? (short
circuit?)
Check the connector of trouble lamp on the ECU harness?
(short circuit?)
323

4 Connections of LED and harness? － To Step 5
4s (self-check).
6 －－
② System trouble lamp short circuit to power supply
Symptom: safety airbag system warning lamp is not lit, and trouble code as detected by the trouble
diagnostic instrument is B0673.
Diagnostic program:

1 To Step 2 Others
With power off, check ECU harness is well connected? (short
circuit?)
Check the connector of trouble lamp on the ECU harness?
(short circuit?)
4 Connections of LED and harness? － To Step 5
5 lamp. And at this point, this lamp should be go off after lighting To Step 6 To Step 1
for 4s (self-check).
6 －－
(6) Loop fault
① Driver air bag fault
● Driver air bag is open circuit
Fault symptom: warning lamp of air bag system always illuminates, detection trouble code on trouble
diagnosis tester is B0026.

When detecting ECU fault with diagnosis tester, trouble code is
1 To Step 2 Other
B0026 or not?
Cut off power supply, and then check that ECU connector is
plugged properly (harness is connected properly or not)
Disconnect battery cathode cable for 60s, check that driver bag
3 module and clock spring are connected properly (harness is To Step 4 To Step 6
connected properly or not)
4 Resistance of driver bag module is normal or not? To Step 5 To Step 6
５ Resistance of clock spring is normal or not? － To Step 6
Switch on power supply after repair and reserve the status of fault
６ To Step 7 To Step 1
lamp. In this case, fault lamp should light for 4s and then go off.
Fault has been eliminated, clear fault with diagnosis tester and
7 －－
update recent repair date.
Diagnosis procedure:
324
● Resistance of driver air bag is too low

1 To Step 2 Other
B0022 or not?
Disconnect battery cathode cable for 60s, check that driver bag
3 module and clock spring are connected properly (harness is To Step 4 To Step 6
4 Resistance of driver bag module is normal or not? To Step 5 To Step 6
５ Resistance of clock spring is normal or not? － To Step 6
Switch on power supply after repair and reserve the status of
６ fault lamp. In this case, fault lamp should light for 4s and then go To Step 7 To Step 1
off.
７－－
● Driver air bag is shorted to ground

1 To Step 2 Other
B0024 or not?
Cut off power supply, and then check that ECU connecting
harness is in good condition.
Disconnect battery cathode cable for 60s, check that connecting
harness of driver bag module is connected properly.
4 Clock spring is connected normally or not? － To Step 5
５ fault lamp. In this case, fault lamp should light for 4s and then go To Step 6 To Step 1
off.
６－－
● Driver air bag is shorted to power supply

1 To Step 2 Other
B0025 or not?
325

Cut off power supply, and then check that ECU connecting
harness is in good condition.
Disconnect battery cathode cable for 60s, check that
connecting harness of driver bag module is connected properly.
4 Clock spring is connected normally or not? － To Step 5
５ fault lamp. In this case, fault lamp should light for 4s and then To Step 6 To Step 1
go off.
６－－
② Front air bag fault of auxiliary driver
● Front air bag of auxiliary driver is open circuit

1 To Step 2 Other
B0017 or not?
Disconnect battery cathode cable for 60s, check that front bag
3 module of auxiliary driver is connected properly (harness is To Step 4 To Step 5
Resistance of front bag module of auxiliary driver is normal or
4 － To Step 5
not?
５ fault lamp. In this case, fault lamp should light for 4s and then To Step 6 To Step 1
go off.
６－－
● Front air bag resistance of auxiliary driver is too low

1 To Step 2 Other
B0016 or not?
3 module of auxiliary driver is connected properly (harness is To Step 4 To Step 5
4 － To Step 5
not?
326

6 －－
● Front air bag of auxiliary driver is shorted to ground

1 To Step 2 Other
B0018 or not?
Cut off power supply, and then check that ECU harness is
connected properly.
module harness of auxiliary driver is connected properly.
4 － To Step 5
not?
５ fault lamp. In this case, fault lamp should be on for 4s and then To Step 6 To Step 1
be off.
６－－
● Front air bag of auxiliary driver is shorted to power supply

1 To Step 2 Other
B0019 or not?
Cut off power supply, and then check that ECU harness is
connected properly.
3 － To Step 4
module harness of auxiliary driver is connected properly.
4 fault lamp. In this case, fault lamp should light for 4s and then go To Step 5 To Step 1
off.
５－－
③ Fault of side air bag
● Driver side air bag is open circuit
327

1 To Step 2 Other
B0041 or B0029?
Turn ignition switch to LOCK position, check that ECU connector
is plugged and locked properly, air bag harness under seat and
floor harness are plugged and locked properly, and that the
harness of air bag module is plugged and locked properly.
Cut off battery cathode cable for 60s, check that there is any
3 deformation on connector terminal of corresponding side air bag To Step 5 To Step 4
loop, or that pin can not be pressed tightly.
Check that any harness is disconnected.
4 Check circuit with multimeter, refer to “Harness fault inspection” To Step 5 To Step 6
for specific method.
5 Change faulty harness. To Step 8 －
6 Resistance of side bag module is normal or not? － To Step 5

7 Change side air bag. To Step 8 －
9 －－
● Resistance of driver side air bag is too low

1 To Step 2 Other
B0040 or not?
Turn ignition switch to LOCK position, check that ECU connector
is plugged and locked properly, air bag harness under seat and
floor harness are plugged and locked properly, and that the
harness of air bag module is plugged and locked properly.
Cut off cattery cathode cable for 60s, open ECU connector of air
3 bag and air bag harness connector, and then check that harness To Step 4 To Step 5
is shorted.
4 Change faulty harness. To Step 4 －
5 Resistance of side bag module is normal or not? To Step 6 －
6 Change faulty side air bag. To Step 7
8 －－
● Side safety airbag at the driver’s side short circuit to ground or with wire tapping
Diagnostic program:
328

1 To Step 2 Others
2 With power off, check ECU harness is well connected? To Step 3 To Step 5
With negative cable of the battery being disconnected for 60s,
3 check the harness of side safety airbag module at the driver’s To Step 4 To Step 5
side is well connected?
Is resistance value of side airbag module at the driver’s side
4 － To Step 5
normal?
4s (self-check).
6 －－
● Side safety airbag module at the driver’s side short circuit to power supply
Diagnostic program:

1 To Step 2 Others
3 check the harness of side safety airbag module at the driver’s － To Step 4
4s (self-check).
5 －－
④ Trouble of side safety airbag at the co-driver’s side
● Side safety airbag at the co-driver’s side open-circuited
Diagnostic program:

1 When ECU trouble is checked with the diagnostic instrument,
To Step 2 Others
Place the ignition switch to LOCK position, and check whether
ECU connector is well locked, and airbag harness below the seat
and floor harness are well locked, and harness of airbag module
itself is well locked?
3 With negative cable of the battery being disconnected for 60s,
check connector terminal of corresponding side airbag circuit is To Step 5 To Step 4
deformed? Or the pin is unable to be well pressed?
4 Check whether the harness is disconencted?
To Step 5 To Step 6
Check the circuit with the multimeter; for specific methods, refer to
329

“check on harness trouble”
5 Replace faulty harness. To Step 8 －
6 Is resistance value of side airbag module normal? － To Step 5

7 Replace the side airbag. To Step 8 －
8 lamp. And at this point, this lamp should go OFF after lighting for To Step 9 To Step 1
4s (self-check).
9 －－
● Resistance too low of side safety airbag at the co-driver’ side
Diagnostic program:

1 To Step 2 Others
Place the ignition switch to LOCK position, and check whether
ECU connector is well locked, and airbag harness below the seat
and floor harness are well locked, and harness of airbag module
itself is well locked?
open ECU connector of safety airbag and harness connector at
the airbag terminal, and check whether the harness is short
circuit?
4 Replace faulty harness. To Step 4 －
5 Is resistance value of side safety airbag module normal? To Step 6 －
6 Replace faulty side safety airbag. To Step 7
7 lamp. And at this point, this lamp should go off after lighting for 4s To Step 8 To Step 1
(self-check).
8 －－
● Side safety airbag at the co-driver’s side short circuit to ground or wire tapping
Diagnostic program:

1 To Step 2 Others
3 check the harness of side safety airbag module at right side of To Step 4 To Step 5
front row is well connected?
4 Is resistance value of side safety airbag module at the co-driver’s － To Step 5
330

side normal?
4s (self-check).
6 －－
● Side safety airbag at the co-driver’s side short circuit to power supply
Diagnostic program:

1 To Step 2 Others
3 check the harness of side safety airbag module at right side of － To Step 4
front row is well connected?
4s (self-check).
5 －－
⑤ Trouble of curtain safety airbag
● Curtain safety airbag at the driver’s side open-circuited
Diagnostic program:

1 To Step 2 Others
With power off, check ECU connector is well connected?
(Harness connection is OK?)
3 check the curtain safety airbag module at the driver’s side is To Step 4 To Step 5
well connected? (Harness connection is good?)
Is resistance value of curtain safety airbag module at the
4 － To Step 5
driver’s side normal?
4s (self-check).
6 －－
● Resistance too low of curtain safety airbag at the driver’s side
331
Diagnostic program:

1 To Step 2 Others
(Harness connection is OK?)
3 check the curtain safety airbag module at left side is well To Step 4 To Step 5
connected? (Harness connection is OK?)
Is resistance value of curtain safety airbag module at the driver’s
4 － To Step 5
side normal?
(self-check).
6 －－
● Curtain safety airbag at the driver’s side short circuit to ground or with wire tapping
trouble diagnostic instrument is BO068.
Diagnostic program:

1 To Step 2 Others
trouble code is BO068?
3 check the harness of curtain safety airbag module at the driver’s To Step 4 To Step 5
Is resistance value of curtain safety airbag module at the driver’s
4 － To Step 5
side normal?
4s (self-check).
6 －－
● Curtain safety airbag at the driver’s side short circuit to power supply
Diagnostic program:

1 To Step 2 Others
3 check the harness of curtain safety airbag module at the driver’s － To Step 4
4 After repairs, switch on the power, and observe status of trouble To Step 5 To Step 1
lamp. And at this point, this lamp should go off after lighting for
332

4s (self-check).

5 －－
⑥ Trouble of curtain safety airbag module at the co-driver’s side
● Curtain safety airbag module at the co-driver’s side open-circuited
Diagnostic program:

1 To Step 2 Others
(Harness connection is good?)
3 check the curtain safety airbag module at the co-driver’s side is To Step 4 To Step 5
4 － To Step 5
co-driver’s side normal?
4s (self-check).
6 －－
● Resistance too low of curtain safety airbag module at the co-driver’s side
Diagnostic program:

1 To Step 2 Others
3 check the curtain safety airbag module at the co-driver’s side is To Step 4 To Step 5
4 － To Step 5
(self-check).
6 －－
● Curtain safety airbag module at the co-driver’s side short circuit to ground or with wire tapping
333
Diagnostic program:

1 To Step 2 Others
3 check the harness of curtain safety airbag module at the To Step 4 To Step 5
co-driver’s side is well connected?
4 － To Step 5
4s (self-check).
6 －－
● Curtain safety airbag at the co-driver’s side short circuit to power supply
Diagnostic program:

1 To Step 2 Others
3 check the harness of curtain safety airbag module at the － To Step 4
co-driver’s side is well connected?
4s (self-check).
5 －－
⑦ Trouble of safety belt pretightener at the driver’s side
● Safety belt pretightener at the driver’s side open-circuited
Diagnostic program:

1 To Step 2 Others
3 check the safety belt pretightener at the driver’s side is well To Step 4 To Step 5
connected? (Harness connection is good?)
334
Is resistance value of safety belt pretightener at the driver’s side

4 － To Step 5
normal?
4s (self-check).
6 －－
● Resistance too low of safety belt pretightener at the driver’s side
Diagnostic program:

1 To Step 2 Others
3 check the safety belt pretightener at the driver’s side is well To Step 4 To Step 5
connected? (Harness connection is good?)
4 － To Step 5
normal?
(self-check).
6 －－
● Safety belt pretightener at the driver’s side short circuit to ground or with wire tapping
Diagnostic program:

1 To Step 2 Others
3 check the harness of safety belt pretightener at the driver’s side To Step 4 To Step 5
is well connected?
4 － To Step 5
normal?
5 lamp. And at this point, this lamp should be OFF after ON for 4s To Step 6 To Step 1
(self-check).
6 －－
● Safety belt pretightener at the driver’s side short circuit to power supply
335
Diagnostic program:

1 To Step 2 Others
3 check the harness of safety belt pretightener at the driver’s side － To Step 4
is well connected?
4s (self-check).
5 －－
⑧ Safety belt pretightener at co-driver’s side
● Safety belt pretightener at driver’s side open-circuited
Diagnostic program:

1 To Step 2 Others
(harness connection is good?)
3 check safety belt pretightener at the co-driver’s side is well To Step 4 To Step 5
connected? (harness connection is good?)
Is resistance value of safety belt pretightener at co-driver’s side
4 － To Step 5
normal?
4s (self-check).
6 －－
● Resistance value too low of safety belt pretightener at co-driver’s side
Diagnostic program:

1 To Step 2 Others
With power off, check ECU connector is well connected? (harness
connection is good?)
3 check safety belt pretightener at the co-driver’s side is well To Step 4 To Step 5
connected? (harness connection is good?)
4 Is resistance value of safety belt pretightener at co-driver’s side － To Step 5
336

normal?
(self-check).
Trouble eliminated already; eliminate the trouble with the diagnostic
6 －－
instrument. Update the latest maintenance date.
● Safety belt pretightener at co-driver’s side short circuit to ground or with wire tapping
Diagnostic program:

1 To Step 2 Others
3 check the harness of safety belt pretightener at the co-driver’s To Step 4 To Step 5
Is resistance value of safety belt pretightener at co-driver’s side
4 － To Step 5
normal?
5 lamp. And at this point, this lamp should be OFF after ON for 4s To Step 6 To Step 1
(self-check).
6 －－
● Safety belt pretightener at co-driver’s side short circuit to power supply
Diagnostic program:

1 To Step 2 Others
3 check the harness of safety belt pretightener at the co-driver’s － To Step 4
4s (self-check).
5 －－
⑨ Impact output trouble
● Impact output line short circuit to power supply
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Diagnostic program:

1 To Step 2 Others
With power off, check ECU harness is well connected? Check
ECU A5 terminal is short circuit, or directly earthed?
Check connector of vehicle door lock control system and electric
ejection control system of the generator is well connected.
4 To Step 5 －
check impact output line is good, or wire tapping?
4s (self-check).
6 －－
⑩Impact output line short circuit to ground or open-circuited
Diagnostic program:

1 To Step 2 Others
With power off, check ECU harness is well connected? Check
2 ECU A5 terminal is deformed? Or corresponding connector To Step 3 To Step 5
harness is well pressed? Or A5 pin is well pressed?
Check ECU earth line is well connected? Or resistance too
large?
3 Check connector of vehicle door lock central control system and To Step 4 To Step 5
electric fuel injection control system is well connected. Or the pin
is well pressed?
4 To Step 5 －
check impact output line is good, or open-circuited?
4s (self-check).
6 －－
(8) Safety airbag controller reaching maximum using limit and unable to be used

1 To Step 2 Others
Switch off the power and cut off the battery cathode and wait for
2 To Step 3 －
60s. Replace the control unit of safety airbag.
3 lamp. Set up ECU according to actual vehicle configuration. And To Step 5 To Step 1
at this point, the trouble lamp should go off after lighting for 4s
338

(self-check).
Trouble eliminated already; write in vehicle information and
4 －－
replacement date.
339
III. Rejection of safety airbag
Warning:
● When a vehicle with SRS is rejected or safety airbag module is disposed, deploy the airbag firstly
according to steps below.
● In case of any unusual conditions for deployment of airbag, please contact the service center or
vehicle factory.
Note:
● Do not dispose of safety airbag module that has not been deployed by yourself
● A huge explosive sound will occur when the airbag is deployed, thus, which shall be executed
outside the vehicle to avoid affecting others.
● Battery voltage is 12±1V for deployment of airbag
● For deployment of airbag, the operator shall be far away from the module to be deployed, and make
sure there is nobody around within at least 10m
● For disposing of airbag module that has been deployed, wear the glove and safety goggles.
● When the airbag is deployed, module has a high temperature, and it will generate lots of unusual
smell; thus do not dispose of deployed airbag within 30 minutes upon deployment
● Do not spray water on the airbag module that has been deployed
● Please wash your hands with cleaning water after completion of above-mentioned operations
Ⅰ Extension within the vehicle
1. Park the vehicle on the flat ground.
2. Remove anode and cathode of the battery, and remove the battery from the vehicle.
Note: Carry out relevant operations after removing anode and cathode of the battery for 60s.
3. Safety airbag module is deployed according to sequences below.
(1) Front safety airbag module at the driver’s side
①Remove the knee shield board
②Remove the joint (yellow) connecting lower end of clock spring and harness of instrument panel (see
figure below)
Note: Take out the joint of clock spring from instrument harness, and this
joint will be automatically short circuit, which could prevent extension of to horn
to driver
front safety airbag module at the driver’s side due to static electricity,
module
thus preventing serious accidents.
③Connect the switching harness of safety airbag with two harness above 6m
for extension, and use insulating tape to wrap up connecting parts for
insulation.
The other end of harness for extension shall be connected to each other (short-circuit) to prevent
mistaken extension due to static electricity.
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④ Lead the switching harness of safety airbag outside the vehicle via extension harness on the yellow
joint of clock spring (see figure below).
⑤To prevent noise, close all windows and doors, and cover it up.
Note: Cover it up as the glasses are easily broken due to cracks.
⑥Cut off the joint of extension harness of front safety airbag module at the driver's side at the position
far away from the vehicle, and connect it with two ends of the battery that is taken from the vehicle, and
make it extend (see figure below).
Note:
● Firstly, make sure there is nobody on and around the vehicle.

And operate it only with nobody. Body shall be covered
● After front safety airbag at the driver’s side is deployed, its gas
generator is with high temperature; thus use it only after cooling
for 30min. Extension wire harness
● In case front safety airbag module at the driver’s side is not

deployed, please consult the local authorized service station.
⑦Front safety airbag module at the driver’s side after being deployed is disposed in terms of rejected
product.
Ⅱ Extension outside the vehicle
Note: ●Safety airbag shall be deployed on the wide and flat ground above 6m away from obstacles or
people.
●Strong wind shall be avoided for extension outdoor. For gentle breeze, light up in the wind.
1. Remove the cathode (－) and anode (＋) of the battery and take out the battery from upward.
Note: Carry out relevant operations after removing the battery for 60s.
2. Safety airbag module is deployed according to sequences below.
(1) Front safety airbag module at the driver’ side
①Take out front safety airbag module at the driver’ side from the vehicle
Note: For front safety airbag module at the driver’ side, with the joint being unconnected, two ends of the
terminal is short circuit automatically, which could prevent
Deployment wire harness
mistaken extension due to static electricity. In case of mistaken Short circuit point
extension, make extending surface upward and place it on the flat
ground, without placing any other articles above.
②Prepare two harnesses for extension above 6m and connect

the other end (short-circuit) to prevent accidents due to static
electricity, and make it extend (see right figure). Above 6m
③Touch the vehicle body with hands to eliminate all static electricity.
Note: Please strictly follow above-mentioned steps which could prevent mistaken extension due to static
electricity.
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④Cut off the harness of front safety airbag module at the driver’s
驾驶员安全气囊
Driver airbag
side and connect with two harnesses for extension, and use
insulating tape to wrap up connecting parts for insulation (see right Short circuit
短路处
figure).
展开用线束
Deployment wire
绝缘胶带
Insulating tape
⑤ Install bolts that will not be used to interior bolts of front safety
airbag at the driver’s side, and fasten a thick wire rope for fixing
the hub. Wires or ropes for
捆扎轮胎用的
⑥Connect the extension harness of front safety airbag module 钢丝或绳子
fastening tyre
at the driver’s side to lower part of old tire for installation of hub,
and fix this module upward with wire rope connecting on the bolt
Scrapped tyre
(see right figure). 废旧轮胎
⑦Place three hub-free old tires on the tires for fixing front safety airbag module at the driver’s side (see
figure below).
蓄电池
Battery
⑧Cut off connections of extension harness of front safety airbag module at the driver’s side as far away
from the vehicle, and take out the battery for connection of two ends, and make it extend (see figure
below).
⑨Front safety airbag module at the driver’s side that has been deployed shall be rejected according to
corresponding requirements.
Note:
● Firstly, make ensure there is anybody around the front safety airbag module at the driver’s side.
● After front safety airbag module at the driver’s side is deployed, its gas generator is with high
temperature; thus use it only after cooling for 30min.
● In case front safety airbag at the driver’s side is not deployed, please consult the local authorized
service station.
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(2) Front safety airbag at the co-driver’s side
① Remove the passenger's glove box of instrument panel

Co driver front airbag
② Remove the joint (yellow) connecting front safety airbag at the 副驾驶前安全气囊
co-driver’s side and harness of instrument panel
③ Shear off the yellow connector, and strip of insulating parts of two
harness heads, and expose 5mm line for connecting extension harness.
④ Connect the switching harness of safety airbag with two harnesses for
Deployment
展开用线束
extension above 6m, and use insulating tape to wrap up connecting parts wire harness
for insulation.
⑤ Lead the switching harness of safety airbag outside the vehicle via extension harness on the yellow
joint of clock spring (see figure below).
⑥ To prevent noise, close all windows and doors, and cover it up. Body shall be covered
Note: Cover it up as the glasses are easily broken due to cracks.
⑦Cut off the joint of extension harness of front safety airbag module
Deployment wire harness
at the driver's side at the position far away from the vehicle, and
connect it with two ends of the battery that is taken from the vehicle,
and make it extend (see figure below).
Note:
● Firstly, make ensure there is anybody on and around the vehicle. And operate it only with nobody
● After front safety airbag at the driver’s side is deployed, its gas generator is with high temperature;
thus use it only after cooling for 30min.
● In case front safety airbag module at the driver’s side is not deployed, please consult the local
authorized service station.
⑧ Front safety airbag module at the driver’s side after being deployed shall be
rejected according to relevant requirements.
(3) Side safety airbag
Preparations before deployment:
● Park the vehicle on the open and flat ground Zip

拉链
● Remove the cathode (－) and anode (＋) of the battery and take out the
battery from the vehicle.
Warning: Do not carry out operations within one minute upon removing
the battery.
① Zip the seat backrest;
② Remove the connector of harness and airbag.
③ Connect the switching harness of safety airbag with one above 10m extension harness respectively,
and use insulating tape to wrap up for insulation, thus avoiding mistaken deployment due to static
electricity;
④ Lead the connected extension harness outside the vehicle;
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⑤ Close all windows and doors, and cover it up.
⑥After making sure there is nobody around, connect the extension harness with two ends of the battery
that is taken out from the vehicle on the position far away from the vehicle, and make the airbag deploy.
⑦Reject it properly.
Warning:
● After deployment of side safety airbag, due to high temperature of gas generator, carry out
disassembling and other relevant treatments after cooling for 30 minutes.
● In case side airbag could not be deployed with power on, please contact the local authorized
service station.
Only reject side airbag module assembly.
①Prepare a battery with voltage of 12±1V for deployment power;
②Remove the side safety airbag assembly, and connect the airbag
harness to the gas generator; 绳子
Rope
③Place the airbag properly, with the cover upward and fixing end 废
Scrapped tyre
downward into stacked rejected tire; 旧
轮
④Fix the tires together with the rope; 胎
⑤Place the container on the open ground with nobody around, and connect the extension harness with
airbag harness, with the other end short circuit;
⑥Cut off connection of extension harness of side safety airbag assembly on the position far away from
the vehicle, and connect it with two ends of the battery.
Battery
蓄电池
⑦Take out side safety airbag from the container, and put it into a plastic bag and fasten.
⑧End.
(4) Curtain safety airbag
Preparations before deployment:
● Park the vehicle on the open and flat ground
● Remove the cathode (－) and anode (＋) of the battery and take out the battery from the vehicle.
Warning: Do not carry out operations within one minute upon removing the battery.
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① Remove the roof;
②Remove the connector of the harness and airbag;
③Connect the switching harness of safety airbag with one above 10m extension harness respectively,
and use insulating tape to wrap up for insulation, thus avoiding mistaken deployment due to static
electricity;
④Lead the connected extension harness outside the vehicle;
⑤Close all windows and doors, and cover it up.
⑥After making sure there is nobody around, connect the extension harness with two ends of the battery
that is taken out from the vehicle on the position far away from the vehicle.
⑦Reject it properly.
Warning:
● After deployment of side curtain safety airbag, due to high temperature of gas generator,
carry out disassembling and other relevant treatments after cooling for 30 minutes.
● In case side curtain airbag could not be deployed with power on, please contact the local
franchised maintenance station.
①Prepare a battery with voltage of 12±1V for deployment power;
②Remove the side curtain safety airbag assembly, and connect the airbag harness to the gas generator;
③Place the curtain airbag on the flat and open ground, and cover it with one cloth or useless quilt.
Wire harness
线束
Tarpaulin
篷布
④Connect the extension harness with curtain airbag harness, with the other end short circuit;
⑤Cut off connection of extension harness of side safety airbag assembly on the position far away from
the vehicle, and connect it with two ends of the battery.
⑥Put the side curtain airbag into a plastic bag and fasten.
⑦End.
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Electric System & Accessory—Air Conditioning System—General Information
Part 7 Air Conditioning System
I. General Information
Overview: Air-conditioning system consists of refrigeration and heating parts. Refrigerating system
mainly consists of compressor, condenser and evaporator etc, it adsorbs heat in the air through
circulation of refrigerant, so as to reduce air temperature in car body and eliminate water vapour in air, to
achieve the purpose of temperature drop and dehumidification. Heating system mainly consists of heat
exchanger and heater unit. It utilizes heat of engine cooling water to heat air via heat exchanger, so as to
achieve the purpose of heating. Regulation and control of temperature, humidity and flow rate of air in
car body is realized via heating and refrigeration systems separately or jointly.
For parameters of refrigerating system, see the table:
Item Parameter
Temperature adjustment method Control cold and heat air mixing
Cooling capacity/W 4000
Displacement/(mL/r) 143
Compressor Type SW10D13-1000
(3G10 engine 6-slot. 479Q engine4-slot)
Solenoid clutch power 43
consumption/W
Lubricant/mL PAG/135 ml
Blower Max.air volume /(m3/h) 430
Air volume adjustment 5-gear manual
Motorpower consumption/W 180
Dimension/mm 16×345×630
Heat exchange quantity/W 8000
Condenser
Air force/Pa ≤156
Fan motor current/A ≤15
Evaporator Refrigerating capacity/W 4000
Heat expansion valve Inner balance 1.0 cooling
Drive belt 4PK-815(479Qengine)
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Electric System & Accessory—Air Conditioning System—General Information
Precautions:
1. Don't operate refrigerant in confined space or near open fire.
2. Always wear eyeglass.
3. Be careful don't let liquid refrigerant contact your eyes and skin, if liquid
refrigerant contacts your eye or skin.
(a) Please wash with fresh water.
Warning:
Don't knead your eyes or scrub your skin
(b) Apply soft petroleum ointment on your skin.
(c) See doctor or go to hospital immediately for specialized treatment.
4. Don't heat container or put it near open fire.
5. Be careful not to fall off, object should not touch container.
6. If there is no sufficient refrigerant in refrigerating system, don't operate

Incorrect correct
the compressor. If there is no sufficient refrigerant in the system,
insufficient oil lubrication might cause burning out of compressor. Be
careful to avoid occurrence of such things.
7. When compressor runs, don't turn on pressure gauge high-pressure

valve. If high-pressure valve is turned on, refrigerant will flow in reverse
direction, and cause bursting of refrigerant tank, so only low pressure
valve may be turned on or off.
8. Be careful to avoid excess refrigerant Excess refrigerant will result in poor refrigerating capacity,
worse fuel economical efficiency, engine overheat problems etc.
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Electric System & Accessory—Air Conditioning System—Symptom table
II. Symptom table
Use the following table to find out the cause of fault, number indicates probable priority of problem,
check each part according to priority, replace components if required.

Blower does not work 1.Blower fuse
2. Blower relay
3 Blower switch
4. Blower
5. Wiring harness.
No air temperature control 1. Engine coolant quantity
2. Servo motor of motor water valve
3. Operation mechanism assembly of cold/warm valve
4. Refrigeration system assembly
5. Heating system assembly
Compressor does not work 1. Refrigerant quantity
2. Electromegnatic clutch relay
3. Pressure switch
4. Magnetic clutch assembly
5. Air conditioning compressor assembly
6. Control mechanism and air conditioner switch
7. Air conditioner thermistor
8. Engine ECU
9. Wiring harness and compressor connector
Insufficient refrigeration 1. Refrigerant quantity
2. Refrigerant pressure
3. Driving belt or tension pulley
5. Cold/heat control button and air conditioner switch
6. Magnetic clutch assembly
7. AC compressor assembly
8. Condenser assembly
9. Pressure switch and expansion valve and evaporator
10. Refrigerant pipe
11. AC operation mechanism assembly
12. Harness
No engine idle speed when air 1. Wiring harness
conditioning switch is ON (switch 2. Engine ECU
on)
No air input control 1.Air conditioner blower control mechanism assembly
No mode control 1.Air conditioner control mechanism assembly
Radiator fan does not work 1. Radiator fan fuse
2. Radiator fan relay
3. Radiator cooling fan motor
4. Wiring harness
348
Inspection
1. Check pressure switch

Air conditioning pressure switch plug-in
(a) Magnetic clutch control:
Check operation of pressure switch
(1) Install manifold instrument
(2) Connect positive meter pen of ohmmeter to terminal 4, negative meter

pen to terminal 1respectively.
(3) As shown in the figure, check connection of each terminal when

refrigerant pressure changes
If operation does not conform to specification, replace pressure switch.
ON (connected)
(b) Check operation of cooling fan
(1) Connect positive meter pen to terminal 2, negative meter pen to

terminal 3 respectively.
(2) As shown in the figure, check continuity of each terminal when

refrigerant pressure changes
If operation does not conform to specification, replace pressure switch.
2. Compressor magnetic clutch
(a) Connect positive pole of storage battery to binding post, negative pole to compressor shell.
(b) Check magnetic clutch in energized condition.
If abnormal, replace magnetic clutch.
3. A/C switch
For maintenance on corresponding A/C switch, please see relevant maintenance on switch.
(a) As shown in the figure, check resistance value of air conditioner thermistor between terminal 1 and2
at each temperature,
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Resistance:
Thermistance
热敏电阻接插件
connector
1 2
5. Blower switch assembly
(a) Check conduction of blower switch.
With cathode of the battery to terminal 4 and anode to terminal 3,

and blower switch being adjusted to corresponding air quantity 鼓风机开关接插件
Wind blower switch connector
position, corresponding driven voltage shall be able to be
detected between terminal 6 and 4 (rising as blower position
increases), and terminal 5 and 4 shall be ON.
If conduction does not conform to relevant requirements, replace

6 5
blower switch assembly. 1 2 3 4
(b) Check lighting operation
Connect positive wire of battery to terminal 2, negative wire to

terminal 1, then check whether back lamp illuminates. If bulb does not illuminate, replace the bulb.
(c) Check action compatibility of air valve
Adjust interior and exterior cycle position of blower switch and check action compatibility of air valve. If
valve of interior and exterior cycle is not working or statuses of interior and exterior cycles do not
correspond to action of valve, check blower switch assembly and its valve elements of interior and
exterior cycles. In case blower switch assembly is faulty, replace it.
6. Operation mechanism assembly of mode air valve
(a) Check lamping operation
Connect the negative wire of the battery to terminal 1 and positive Mode air valve operation
模式风门操纵机构
wire to terminal 2, and re-check back lamp is ON; if not, replace mechanism assembly connector
operation mechanism assembly of mode valve.
总成接插件
(b) Check action compatibility of air valve
Open the blower switch and adjust each position of valve operation
mechanism, and check whether air out mode is correct. If the valve 1 2
does not function or its action does not correspond to air out mode,
check the operation mechanism assembly or valve elements. If the
350
operation mechanism is faulty, replace it.
7. Operation mechanism assembly of cold, warm air valve
(a) Check lighting operation

冷、暖风门操纵机
Cold/warm valve operation
mechanism assembly connector

　构总成接插件
Connect the negative wire of the battery to terminal 1 and positive
wire to terminal 2, and re-check back lamp is ON; if not, replace
operation mechanism assembly of cold, warm air valve.
(b) Check action compatibility of valve and of electric water valve

1 2
①Open the position 3 or 4 of blower switch; for high temperature
outside, also open A/C switch. Adjust each position of operation
mechanism assembly of cold, warm air valve, and check cold/warm
air out is correct. If the cold/warm valve does not function or its action does not correspond to cold/warm
status, check operation mechanism assembly of cold, warm air valve or valve elements; if operation
mechanism assembly of cold, warm air valve is faulty, replace it.
②Step 1: open the blower switch and keep position 3 or 4 of interior cycle mode, and make the engine
under idling speed. Without opening A/C switch, adjust each position of operation mechanism of
cold/warm air valve, making it at either position 4 or 5 of cold air mode. (slight vibration generated from
action of servo motor could be detected by hands during switching of position 3 and 4 of cold air). Note:
this operation shall avoid high temperature metal parts of engine compartment to prevent
scalding. After ten minutes, check the vent temperature of instrument panel, which shall not be
obviously increased compared to the temperature inside the vehicle under this condition (exceeding 5℃);
adjust operation mechanism of cold/warm air valve, making it at either position 4, 5 or 6 of warm air
mode (slight vibration generated from action of servo motor could be detected by hands during switching
from position 4 of cold air to position of warm air). Note: this operation shall avoid high temperature
metal parts of engine compartment to prevent scalding. After five minutes, obvious temperature rise
at vent of instrument panel shall be detected (exceeding 7℃) to prove that control circuit of servo motor
of operation mechanism of cold/warm air valve and its electric water valve are working normally;
③Step 2: if abnormal, check as follows: connect the battery anode to terminal 3, and cathode to terminal
4; adjust position of operation mechanism of cold/warm air valve, making it shift between position 3, 4
under cold air mode. Then, voltage output close to voltage of battery end shall be able to be detected
between terminal 5 and 6, and its voltage polarity is switched synchronously during position switching; if
normal, it indicates that control circuit of servo motor of operation mechanism of cold/warm air valve is
working normally; (check output rule of this voltage at two ends of harness of electric water valve with
methods as above-mentioned. If working normally, it indicates that this section of harness is good; if not,
it means it needs to be repaired)
④Step 3: if working abormally, check as follows: with electric water valve being removed, and the red
harness end being connected with the battery anode and black harness end being connected with
battery anode. After action of servo motor of electric water valve, the water valve shall be closed; with
the battery cathode being connected with red harness end and battery anode being connected with
black harness end, after action of servo motor of electric water valve, the water valve shall be opened; if
not conforming to this condition, replace electric water valve.
351
8. Blower motor relay assembly
(a) Check connection of relay
Tester Standard
Condition
connection condition
Constant 1——2 ON
Apply positive
voltage of battery
3——4 ON
between terminal 1
and 2.
If connection does not conform to specification, replace blower relay.
9. Solenoid clutch relay
(a) Check connection of relay
Tester Standard
Condition
connection condition
Constant 1——2 ON
Apply positive
voltage of battery
3——5 ON
between terminal
1 and 2.
If connection does not conform to specification, replace magnetic clutch relay
10. Blower inspection
(a) Check its action
Connect negative wire of the battery to terminal 2, positive wire to terminal 3, 1

and apply driving voltage (below 6-12V) to terminal 1, and the blower shall be
able to run.
2 3
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Electric System & Accessory—Air Conditioning System—Refrigerant inspection
III. Refrigerant inspection
1. Check refrigerant quantity
(a) Observe sight glass on refrigerating liquid pipe.
Test condition:
Engine speed: 1500 rpm Sight glass
Blower speed control switch: HI "high "
Air conditioning switch: switch on
Temperature setting: maximum refrigeration
Refrigeration runs for 5 minutes
Fully open door
Symptom Refrigerant quantity Correct treatment
1. Check gas leakage, repair if

1 With foam Insufficient necessary
2. Add refrigerant until foam disappears
Empty, insufficient or
2 Without foam Refer to 3 and 4
beyond
No temperature difference 1. Use detector to check gas leakage,

3 between input and output Empty or nearly full repair if necessary
of compressor 2. Add refrigerant until foam disappears.
There is considerable
temperature difference
4 Proper or beyond Refer to 5 and 6
between compressor input and
output
After air conditioner is turned 1. Discharge refrigerant

5 off, refrigerant should be Excess 2. Eliminate air, add appropriate
cleared immediately quantity of pure refrigerant
After air conditioner is turned

6 off, refrigerant foams Appropriate quantity
immediately, then clears
*: If refrigerating capacity is sufficient, environmental temperature is higher than normal condition, bubble
in sight glass may be deemed as normal.
353
2. Use manifold meter to check refrigerant pressure
(a) This method is to utilize installed instrument to determine

where the fault is. Use manifold pressure meter reading to
evaluate fault condition.
Test condition:
Switch sets temperature of cyclical air inlet: 30-35°C Engine

speed: 1500 rpm
Blower speed control switch: high
Temperature control panel: refrigeration
Air conditioning switch: switch on
So door is completely open
(1) Refrigerating system meter reading during normal work:
Low pressure side: 0.15-0.25MPa (1.5—2.5Kgf/cm2)
High pressure side: 1. 37-1. 57MPa (14—16Kgf/cm2)
(2) System contains moisture
System contains water manifold pressure gauge indication
Symptom Possible cause Diagnosis Correct treatment
1. During work, pressure Moisture in the 1. Dryer is in saturated 1. Replace fluid dryer
on low pressure side system freezes at state 2. By drawing off air
sometimes becomes orifice of expansion 2. System moisture repetitively to remove
vacuum valve, circulation freezes at orifice of water vapor in the
2.Intermittent suspends, but expansion valve, system, fill in appropriate
refrigeration, finally no system re- stores to obstructs refrigerant quantity of new
refrigeration normal after ice circulation refrigerant
thaws
354
(3) Poor cooling
1. Pressure on high, low Refrigerant leakage 1. System refrigerant 1. Use leak detector to
pressure side is a bit low occurs in refrigerat- is insufficient check whether there is
2. Successive bubble ing system 2. Refrigerant leaks gas leakage, repair if
appears in glass window there is any.
3. Refrigeration efficiency 2. Fill in appropriate
deteriorates quantity of refrigerant
3. Connect a pressure
gauge, if pressure is zero,
repair leaking part, and
vacuumize the system
(4) Poor refrigerant circulation
1. Pressure on high, low pressure Dirt in refrigeration Fluid drier does Replace fluid drier
side is a bit low drier obstructs flow of not circulate
2. Pipeline from fluid drier to main refrigerant
unit frosts
3. Refrigeration is insufficient
355
(5) Refrigerant does not circulate
1. Indicates vacuum on low pres- System contains Refrigerant does 1. Check expansion valve
sure side, indicates too low pres- moisture or dirt not circulate 2. Use compressed air to
sure on high pressure side which obstructs eliminate dirt of expansion
2. There is dew or frost on pipe flow of refrigerant valve, but it cannot be
before and after expansion valve Expansion valve eliminated, replace
or fluid drier trouble expansion valve.
3. Vacuumize and fill in
appropriate quantity of new
refrigerant
4. Expansion valve leaks,
replace expansion valve
(6) Too much refrigerant or heat dissipation of radiator is poor

1. Pressure on high, low 1. Over quantity of 1. Over quantity of 1. Clean condenser
pressure side is too high refrigerant in system refrigerant in circle 2. Check blower motor
2. No bubbles can be 2. Deficient 2. Deficient condenser rotating condition
saw through observation condenser cooling cooling. Radiator 3. Check refrigerant
window, even engine blocked or blower quantity and fill up if
speed decreased. trouble. necessary
3. Insufficient
refrigeration
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(7) There is air in the system
1. Pressure on high, low There is air in 1. There is air in 1. Check whether

pressure side is too high refrigerating refrigerating compressor lubricating oil is
2. Touch the low pressure pipe, it system system dirty or insufficient
is hot 2. Vacuumizing is 2. Pump off air and fill in
3. Bubble appears in glass not complete appropriate quantity of
window, cooling is not good refrigerant
(8) Expansion valve fault
1. Pressure on high, low pressure Expansion valve 1. Refrigerant in low Check expansion
side is too high fails pressure line is too much valve
2. There is frost or a great deal of 2. Expansion valve is
water drops on pipeline of opened too large
low pressure side
(9) Compressor poor compression fault
357
1 pressure is too high on low Inside sealing of Compressor fails, valve Repair or replace
pressure side, pressure on compressor is poor leaks or is damaged. compressor
high- pressure side is too low
2. Without cold air
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Electric System & Accessory—Air Conditioning System—Discharge and Fill-up of Refrigerant
IV. Discharge and Fill-up of Refrigerant
Discharge of refrigerant
In case of depletion, surrounding environment should always be well-ventilated, do not approach naked
fire, otherwise toxic gas might be generated.
Liquid
observer
to high pressure
charging valve
to low pressure
charging valve
Oil canister
(1) Firstly turn off meter valve high low manual valve, connect pipeline according to the figure below,
then adjust air conditioner to maximum refrigeration operating condition, adjust engine speed to 1000 -
2000 r/min, run for 5 min. Circulate refrigerant and collect residual oil in parts as far as possible into
compressor.
(2) Loosen throttle, let engine restore to normal idle speed, turn off engine.
(3) Slowly open high voltage manual valve, cover a white towel on hose outlet, observe whether there is
oil stain on the towel, adjust flow of refrigerant.
(4) When high pressure gauge reading decreases to below 0. 35MPa, slowly open low pressure manual
valve. Close manual valve until reading of high low pressure gauge is zero.
Fill-up of refrigerant
(1) Use vacuum pump to vacuumize the system
During repair of refrigerating system, once refrigerating system is exposed to air or certain refrigerating
system part is to be replaced, automobile air conditioner must be vacuumized. So as to eliminate air and
water vapour in the system.The time is not less than 15 minutes.
(2) Fill in R134 a
Standard:500±20g.
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Electric System & Accessory—Air Conditioning System—Air Conditioning Operating Mechanism
V. Air Conditioning Operating Mechanism
Replacement
1. Remove middle operation mechanism panel assembly of instrument panel
(1) Remove two fixing bolts according to the arrow, and pry and remove mechanism panel with the
slotted screwdriver, and take out connector of control button.
(2) As each button has two fixing screws (the arrow), after removing corresponding fixing screws, the
button could be removed.
2. Remove exterior trim panel of CD and remove upper part assembly of instrument panel (refer
to relevant descriptions on interior trim instrument panel).
3. Remove mode dial of interior and exterior button of blower as follows:
360
After removing fixing bolts of mode dial of interior and exterior cycles (as directed by the arrow), remove
operation mechanism of blower button and replace it. For installation, carry out with reverse process of
disassembling.
Note: For installation, rotate the blower button to maximum air quantity position of exterior cycle, and the
rocker arm is also installed on the position of exterior cycle as shown in the figure above. During
installation, ensure the rocker arm is clipped in the mode dial, and also locating pin of mode dial on the
A/C casing clipped in the fixing hole of mode dial, and fasten the fixing screws.
4. Remove mode dial of cold/warm air valve button as follows:
After removing fixing bolts of mode dial of cold/arm valve (as directed by the arrow), remove operation
mechanism of blower button and replace it. For installation, carry out with reverse process of
disassembling.
Note: For installation, rotate the button of cold/warm valve to maximum refrigerating position, and the
rocker arm is also installed on the maximum refrigerating position (limit stroke of lower part) as shown in
the figure above. During installation, ensure the rocker arm is clipped in the mode dial, and also
positioning pin of mode dial on the A/C case clipped in the fixing hole of mode dial, and fasten the fixing
screws.
5. Remove mode dial of cold/warm air valve button as follows:
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After removing fixing bolts of mode dial of valve (as directed by the arrow), remove operation mechanism
of the button and replace it. For installation, carry out with reverse process of disassembling.
Note: For installation, rotate the valve button to vent mode of face blowing, and defrosting rocker arm
and its valve of foot blowing are also installed properly as shown in the figure below. During installation,
ensure auxiliary rocker arms of two valves are clipped in the mode dial, and also locating pin of mode
dial on the A/C case clipped in the fixing hole of mode dial, and fasten the fixing screws.
362
Electric System & Accessory—Air Conditioning System—Blower Assembly
VI. Blower Assembly
Replacement
1. Remove exterior trim panel of CD and remove upper part assembly of instrument panel (refer
to relevant disassembling descriptions on instrument panel of interior trim).
2. Remove fixing bolts of steering wheel column (refer to relevant disassembling descriptions on
chassis part).
3. Remove blower assembly.
(1) Remove fixing bolts of the blower
(2) Loosen the clip of AC main machine and blower, and hold the blower backshell and rotate about 15°
anticlockwise (see figure below). And take out the blower.
4. Carry out reverse process during installation.
363
Electric System & Accessory—Air Conditioning System—Air Filter Assembly
VII. Air Filter Assembly
Replacement
1. Take out air filter assembly carefully from the opening of lower part of instrument panel at the
co-driver’s side; see figure below.
2. Carry out reverse process during installation.
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Electric System & Accessory—Air Conditioning System——Air Conditioning Assembly
VIII. Air Conditioning Assembly
Component
Thermistance
connector
Blower
Expansion
valve Air filter assembly
Evaporator Thermistance
element
Heater
element
365
Overhaul
1. Drain the coolant (refer to Coolant for details).
2. Disconnect A/C pipeline assembly.
(1) Remove the expansion valve fixing bolt, disconnect A/C

pipeline assembly
(2) Remove two O-rings form the A/C pipeline assembly.
Notice: O-ring is a one-off part.
3. Disconnect the water pipe assembly connecting the heater core.
(1) Loosen the dual steel wire circlip, disconnect the water pipe connecting the heater core.
366
(2) For maintenance on electric water valve, its disassembling process is as follows: disconnect the
harness connector of electric water valve, and pull out the clip of harness end; remove two fixing screws;
loosen double steel wire hoop, and disconnect the warm air core of A/C machine and water pipe
connecting to the engine.
AC main machine heater element end

空调主机暖风芯体端
Electric water valve fixing screw

电动水阀固定螺钉
Engine
发动机端 end
(3) Loosen double steel wire hoop, and disconnect water pipe connecting to the electric water valve.
4. Remove button of operation mechanism assembly
Refer to A/C operation mechanism assembly: button disassembling
5. Remove instrument panel assembly.
Refer to interior trim: disassembling of instrument panel assembly.
6. Remove steering column and its central beam assembly.
Refer to disassembling of steering column of chassis and beam (disassembling of framework device of
instrument panel)
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7. Take out the connector of blower, thermister, and remove five fixing bolts as shown by the
arrow, then the A/C machine could be removed.
8. Carry out reverse process of disassembling for installation.
Note: As O ring for sealing of pipeline and expansion valve is one-off part, it must be replaced.
368
Electric System & Accessory—Air Conditioning System—Compressor Fixing
IX. Compressor Fixing
Components
Compressor bracket
Compressor bracket fixing 压缩机支架
压缩机支架固定螺栓
bolt
Compressor
压缩机总成固定螺栓 assembly
fixing bolt
Compressor
压缩机总成 assembly
3G10 engine compressor fixing

3G10发动机压缩机固定
Tension bolt
张紧螺栓
Compressor bracket
压缩机支架
Tensioner
张紧轮
压缩机支架固定螺栓
Compressor bracket fixing bolt
压缩机总成固定螺栓
Compressor bracket fixing bolt
Compressor
压缩机总成assembly
479Q发动机压缩机固定
479Q engine compressor fixing
369
Replacement
1. Overall discharge refrigerant (for details, see the Refrigerant).
2. For disassembling of the compressor configured in 479Q engine: loosen tensioning bolts of
tensioning wheel, and remove multi-wedge belt.
479Ｑ发动机所配压缩机拆卸
479Q engine compressor removal 3G10发动机所配压缩机拆卸
3G10 engine compressor removal
For fixing compressor of 3G10 engine, see multi-wedge belt of the engine;
3. Disconnect the suction port
(1) Remove the bolts and disconnect suction port.
(2) Take out O-ring from the pipe joint and replace with a
new one.
4. Disconnect exhaust port (see figure above)
(1) Remove the bolts and disconnect exhaust port.
(2) Take out O-ring from the pipe joint and replace with a new
one.
Note:
● Seal all joints of disconnecting parts with PVC tape to

prevent entry of water and foreign substances.
479Q engine compressor removal
● O-ring is one-off part.
370
5. Remove the compressor
(1) Disconnect the harness connector.
(2) After removing four bolts, the compressor could be removed.
479Q479Ｑ发动机所配压缩机拆卸
engine compressor removal 3G10发动机所配压缩机拆卸
6. Remove the compressor support
(1) Remove bolts as shown by the arrow, and remove the compressor support.
3G10发动机所配压缩机拆卸
479Q engine compressor removal
7. For installation, carry out corresponding reverse process.
371
Electric System & Accessory—Air Conditioning System—Condenser Fan Motor and Condenser Assembly
X. Condenser Fan Motor and Condenser Assembly
On-board Inspection
1. Check condenser assembly
(1) If the radiator in the condenser is dirty, wash it with clean water and dry it with compressed air.
(2) If the radiator in the condenser is distorted, use the proper tool to correct it.
2. Check the condenser for coolant leakage.
(1) Use the leakage tester to check the connection area of the pipeline for leakage.
(2) If there is leakage, check the connector fixing bolt for tightening condition
Overhaul
1. Remove front bumper and left/right wind guide boards, and if necessary, remove front
crash-proof beam.
2. Discharge the refrigerant (for details, see the refrigerant).
3. Remove fixing bolts of inlet/outlet pipeline of the condenser end, and take out O-ring from pipe
connection, and replace it with a new one. The condenser assembly could be taken out by
removing four bolts fixing the condenser and radiator.
Note: Seal all joints of disconnecting parts with PVC tape to prevent entry of water and foreign
substances.
4. For installation, ensure a new O-ring has been replaced. Carry out operations according to
corresponding reverse process.
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Electric System & Accessory—Air Conditioning System—Pipe System Assembly
XI. Pipe System Assembly
Component
管路系统总成
Pipe system assembly
Double pipe clip 2

双管夹2
Upper and lower pipe clip assembly

上下管夹组合件
高压管总成
High pressure pipe assembly
双管夹1
Double pipe clip 1
Compressor
压缩机吸气软管 intake hose
Compressor
压缩机排气软管 exhaust hose
For disassembling of relevant pipeline systems, refer to relevant descriptions of A/C machine,
condenser and its compressor.
Note: O-ring is one-off part
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Electric System & Accessory—Reversing Radar System
Part 8 Reversing Radar System
I. System principle
Reversing radar system mainly adopts ultrasonic ranging technology, utilizes piezoelectric property of
transducer (ultrasonic sensor), excites piezo sheet with voltage with frequency of 48KHZ intermittently,
this piezo sheet is then converted from electric energy to mechanical energy and sent out. When emitted
sound wave contacts object, it will reflect weak sound wave energy to transducer according to sound
wave reflection principle, i. e. convert received weak acoustic vibration signal to electrical signal, after
signal amplification processing, it is transmitted to microprocessor to calculate the distance between
vehicle and the object and display the distance. Then microprocessor determines whether to give
caution remind for dangerous object according to varying degrees.
II. Circuit diagram
Ignition switch
Reversing switch
Sensor
Right Left
reversing reversing Reversing radar
lamp lamp mainframe
III. Wire multi-pin connector terminal arrangement (from insert end)
374
A socket type B socket type
Plug-in type B socket plug-in type
No. Function No. Function

A1 Not available B1 Power supply (+)
A2 Not available B2 Not available
A3 B sensor (-) B3 Not available
A4 B sensor (+) B4 Not available
A5 A sensor (-) B5 Buzzer (-)
A6 A sensor (+) B6 Ground
A7 Not available
A8 Not available
IV. Trouble diagnosis
When ignition switch locates at position ON and shifted at reverse gear, the inner buzzer of combination
instrument shall alarm twice.
1. No alarm
(1) Connect terminal 14 to earth, the buzzer shall alarm constantly.
Abnormal: Check combination instrument assembly and other circuits.
(2) Check voltage
● Remove reverse radar and keep connector conducting
● Inspect the voltage between terminals.

Ignition switch locates at
B1-B6 position ON, gearbox shifted 10-14V
at reverse gear.
Result and measurement:
Abnormal: Repair or replace wire and connector
(3) Check voltage
● Disconnect connector
● Voltage between terminals:

Ignition switch locates at
B1-B5 10-14V
position ON
375
Result and measurement:
Abnormal: Repair or replace wire and connector
Normal: Replace reverse radar main unit
2. Alarm lasts 3 sec.
(1) Check reverse radar wire, whether it contains disconnection or short circuit.
(2) Replace reverse radar main unit
(3) Replace reverse radar probe
3. Alarm twice
Reverse radar system is normal.
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Electric System & Accessory—Light System—Introduction to Light System
Part 9 Light System
I. Introduction to light system
I. Composition
1. Front combination lamp assembly

2
2. Side turn lamp 1
3. Front fog lamp
4. Rear combination lamp
5. High mount brake lamp

4
5
6 Rear fog lamp
7. License lamp assembly
II. Precaution for service
1. Precaution when repairing electrical equipments
Disconnect the battery ground cable.
2. Precaution when replacing a headlamp bulb
(1) Before replacing a halogen bulb, turn the headlamp OFF to make it cool.
(2) When installing a new halogen bulb, do not touch the glass part of the bulb with bare hands.
(3) If there is oil stain on the surface of halogen bulb (headlamp and front fog lamp) when the lamps are
turned ON, its service life will be shortened.
(4) Halogen bulbs (headlamp and front fog lamp) have pressurized gas inside and require special
handling.
They can explode if dropped to ground. The glass fragments will splash up.
(5) When replacing, make sure to use the bulbs with the same power, same model.
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Electric System & Accessory—Light System—Introduction to Light System
(6) After the bulb is installed, make the lamp holder tight.
3. Bulb specifications
Name Specification
High beam/low beam H4 12V 60/55W
Front combination
Turn signal lamp PY21W 12V 21W
lamp
Front position lamp W5W 12V 5W
Front fog lamp H3 12V 55W
Turn signal lamp PY21W 12V 21W
Rear combination Brake lamp/position lamp P21/5W 12V 21/5W
lamp Position lamp W5W 12V 5W
Reverse lamp P21W 12V 21W
Indoor roof lamp C5W 12V 5W
License lamp W5W 12V 5W
Side turn lamp WY5W 12V 5W
High mount brake lamp W5W 12V 5W
Rear fog lamp P21W 12V 21W
378
Electric System & Accessory—Light System—Light System Malfunction Inspection
II. Light System Malfunction Inspection
Light system problem symptoms table:
Description: The table below can help you find the causes of malfunction. These figures show the most
possible malfunctions in order of priority. Inspect each part in the order given. If necessary, repair or
replace these parts.
1.Headlamp and tail lamp

"Low beam" off (One side) 1. Bulb
2. Left or right headlamp fuse
3. Harness
"Low beam" off (All) 1. Lamp switch assembly
2. Harness
"High beam" off (One side) 1. Bulb
2. Left or right headlamp fuse
3. Harness
"High beam" off (All) 1. Lamp switch assembly
2. Harness
Light dose not flash (Dimmer) 1. Lamp switch assembly
2. Harness
Headlamp is dim 1. Bulb
2. Harness
Only one side tail lamp on 1. Bulb
2. Harness
Tail lamps on both sides off (Headlamp is 1. Fuse
normal) 2. Lamp control switch
3. Harness
Tail lamps on both sides off (Headlamp 1. Lamp control switch
is abnormal) 2. Harness
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2. Front fog lamp system

Front fog lamp off with light control switch on 1. Fog lamp fuse
HEADLAMP position(Head lamp is normal). 2. Front fog lamp relay
3. Light switch assembly
4. Harness
Only one side front fog lamp off 1. Bulb
2. Harness
3. Rear fog lamp system

Rear fog lamp off with light control switch at FRONT 1. Bulb
FOG LAMP (Small lamp is 2. Light switch assembly
normal). 3. Harness
Rear fog lamp off with lamp control switch at FRONT 1. Bulb
FOG LAMP (Small lamp is abnormal). 2. Tail lamp fuse
3. Harness
Only one side rear fog lamp off 1. Bulb
2. Harness
4. Turn signal and hazard warning system

"Hazard lamp" and "Turning signal lamp" does not 1. HAZARD Fuse
work 2. Centralized controller
3. Harness
Hazard warning lamp does not work (Turning is 1. Hazard warning switch
normal) 2. Harness
Hazard warning lamp abnormal (Hazard is abnormal) 1. Turn signal switch
2. Harness
Turn signal abnormal in one direction 1. Turn signal switch
2. Harness
Only one bulb abnormal 1. Bulb
2. Harness
5. Brake lamp system

Brake lamps on both sides off 1. Brake lamp fuse
2. Brake lamp switch
3. Harness
Brake lamp remains always ON 1. Brake lamp switch
2. Harness
Brake lamp off (One side) 1. Bulb
2. Harness
High mount Brake lamp off (Stop lamp is normal) 1. Bulb
2. Harness
6. Reverse lamp system
380

Reverse lamps on both sides off 1. Reverse lamp fuse
2. Reverse lamp switch assembly
3. Harness
Reverse lamps remain always ON 1. Reverse lamp switch assembly
2. Harness
Reverse lamp off (one side) 1. Bulb
2. Harness
7. Room lamp system

Room lamp off (All) 1. ROOM fuse
2. Harness
Room roof lamp off 1. Bulb
2. Room lamp assembly
3. Harness
Any one door is ajar, Room roof lamp off at 1. Door courtesy lamp switch
DOOR position, (It is normal on ON) 2. Centralized controller
3. Harness
Left, right reading lamp of room roof lamp off 1. Bulb
2. Switch
Rear row reading lamp off (room lamp assembly is 1. Bulb
normal) 2. Rear row reading lamp assembly
3. Harness
8. License lamp
Symptom Possible parts

License lamp off (taillight is normal) 1. Bulb
2. Wire harness
9. Trunk lamp
Symptom Possible parts

Trunk lamp does not illuminate (room lamp is 1. Bulb
normal) 2. Trunk lamp switch
3. Wire harness
381
Electric System & Accessory—Light System—Front HeadLamp Replacement
III. Front HeadLamp Replacement
I. Removal
1. Remove front bumper
2. Remove 3 fixing screws of front head lamp (as shown in the

figure
3. Remove electrical connector.
4. Move carefully forward, upward, remove front head lamp

assembly.
II. Installation
1. Install electrical connector of front head lamp assembly.
2. Install front head lamp assembly and 3 fixing screws.
3. Install front bumper.
4. Adjust vehicle state.
5. Adjust front head lamp beam.
III. Replacement of front head lamp bulb
1—Turn lamp dust shield
2—Low beam dust shield
3—Front position lamp / High beam dust shield
1. Bulb replacement
Remove dust shield by rotating anticlockwise
Pull out bulb plug
Press and loosen steel wire clip
Pull out lamp holder, take off bulb
Replace bulb
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Electric System & Accessory—Light System—Front Fog Lamp Replacement
IV. Front Fog Lamp Replacement
I. Removal
1. Remove front bumper. (see bumper replacement)
2. Remove electrical connector.
3. Remove fixing bolt (as shown in the figure).
4. Remove front fog lamp assembly.
II. Installation
1. Install front fog lamp assembly.
2. Mount fixing bolt.
3. Mount electrical connector.
4. Mount front bumper.
5. Adjust vehicle state.
6. Adjust front fog lamp beam.
III. Replacement of front fog lamp bulb
1. Press and rotate anticlockwise, take off dust shield
2. Take out bulb
3. Replace bulb
IV. Adjustment of front fog lamp beam
1. Adjust tire pressure in standard value
2. Start up engine
3. Turn on fog lamp switch
4. Adjust fog lamp beam
Turning screw can adjust fog lamp beam in the vertical direction.
Description: Turn screwdriver anticlockwise to make beam upward, or turn screwdriver clockwise to
make it downward.
383
Electri System—Light System—Rear Combination Lamp Replacement
V. Rear Combination Lamp Replacement
I. Removal
1. Remove trunk inner trim
2. Remove 3 installation nuts (as shown in the figure).
3. Remove rear combination lamp electrical connector.
4. Pull out rear combination lamp assembly towards vehicle

backside.
II. Installation
1. Mount rear combination lamp, mount 3 installation nuts.
2. Mount electrical connector.
3. Mount trunk trim.
4. Mount weather strip.
III. Replacement of rear combination lamp bulb
1. Remove the rear combination lamp (refer to the replacement of rear combination lamp)
2. Turn lamp holder anticlockwise, take off lamp holder
3. Take off bulb, replace bulb
VI. High mount brake lamp replacement
1. Remove 2 tap bolts as show above.
2. Disconnect the connector.
384
Electri System—Light System—Interior Roof Lamp Replacement
VII. Room roof Lamp Replacement
1. Use a screwdriver to slightly pry off room roof lamp cover
2. Use a screwdriver to remove two screws (be careful not to

contact bulb)
3. Remove the connector
VIII. License Plate Lamp Replacement Forcibly

press
1. Remove license lamp as shown in the figure
2. Remove the electric connector
Take off
385
Electric System & Accessory—Switch System
Part 10 Switch System
I. Combination switch
Connector:
H2 TB
SM L
QHM1 +2
+1 R
WB E HM
W1 HS Qw2Qw1
H3 F
INT2 WS
H1 W2
Hw INT1
1. Wiper switch:
(1) Principle diagram of front and rear wiper switches:
Terminal
手柄端子
前 Handle +2 +1 W2 WB WS INT1INT2 W1 H1 H2 H3
位置
position
刮
水 MIST
Front wiper switch
器 OFF
开 INT
关
LO
HI
Front
前洗涤 OFF
washer
器开关
switch WASHER
后 OFF
Rear wiper and washer
雨刮 Rear wiper
洗涤后雨刮
器开
Rear washer
后洗涤
switch
开关
386
Standard: front wiper switch
Switching action Testing terminal Specified status

MIST (one touch) +1—WB ON
OFF (closed) +1—WS ON
INT (intermittent) +1—WS INT1—INT2 ON
LO (low speed) +1—WB ON
HI (high speed) +2—WB ON
Front washing (ON) W2—W1 ON
Rear washing (ON) H1—H2—H3 ON
Rear wiper (ON) H2—H3 ON
If not ON, replace the switch or repair switch contact.
(2) Check (washer switch)
① Switch the washer switch to OFF position.
② Connect the battery anode to W2 terminal of the connector, cathode to +1 terminal of wiper connector.
Switch the washer switch to ON and OFF, and measure the voltage between 3 terminal and 2 terminal of
wiper motor connector.
Standard: as shown in figure
If not conforming to requirements, replace the switch
2. Lighting switch
(1) Headlight and small lamp:
Principle diagram of the switch:
Terminal
灯端子
Terminal 大灯
端子 TB SM E E HS HM HMJ1 HMJ2 Head light
开关
Lamp
switch
开关
switch handle
手柄位置
handle position 手柄位置 position
超车
Overtake
近beam
Low 光
照 High
远beam
光
明
Overtake
超车
开
Lighting switch
关近beam
Low 光
远beam
High 光
超车
Overtake
Low
近beam
光
High
远beam
光
Check dimmer switch of small lamp is ON:
387
Switching action Testing terminal Status

Low beam TB -E ON
High beam NOT ON
Overtaking SM-E, E-HM, HMJQ-HMJ2 ON
Check whether each terminal is ON with the switch on each position according to the table.
Replace the switch if not conforming to requirements.
Check dimmer switch of headlight is ON:

Low beam TB-SM-E, E-HS ON
High beam E-HM, HMJ1-HMJ2 ON
Overtaking E-HM, HMJ1-HMJ2 ON
(2) Turn signal switch
Principle diagram:
Terminal
转端子
Turn lamp switch
Handle F L R
向手柄位置
position
灯 R R
开
N
关
L L
Check the turn signal switch is ON.

Turn left F-L ON
Straight F-L-R NOT ON
Turn right F-R ON
(3) Front and rear fog lamp switch:
Principle diagram:
388
Terminal
Lamp
switch
handle
position
Light switch
Check front and rear fog lamp switch is ON:

OFF NOT ON
Front fog lamp QWj-QHw1 ON
Rear fog lamp HW-QWj-QHw1 ON
3. Replacement of combination switch
Replacement: Remove four screws as shown to make combination switch separate from steering
column, and remove combination switch.
389
Ⅱ Switch with panel assembly
1. Safety belt indicating lamp at passenger’s side
6 1
5 2
(a) Check safety belt lamp at passenger’s side is ON.
Standard:
Indicating lamp Testing terminal Status

Normal 1-2 ON
Abnormal 1-2 NOT ON
Check two terminals are ON when the switch is working.
(b) Check lighting system
With the battery (+) being connected to terminal 1, battery (-) to terminal 2, check illuminating system is
working. if not ON, replace this switch.
2. Warning lamp switch
6 1
5 2
(a) Check connection status of warning lamp switch.
Standard:
Switch operation Test terminal Condition

ON 1-2 Connected
OFF 1-2 Disconnected
390
If abnormal, replace the swtch.
3. A/C switch:
6 1
5 2
(a) Check A/C switch is ON.
Standard:

ON 4-6 ON
OFF 4-6 NOT ON
(b) Check illuminating system
working. If not ON, replace this switch.
Ⅲ Electric rearview mirror switch with panel assembly:
1. Electric rearview mirror switch
4 1
7 6
391
(a) Left side: rotary switch (b) Right side: rotary switch
Check the conduction of switch Check the conduction of switch
Standard: Standard:
Switch Switch
Terminal Specifications Terminal Specifications
position position
3——7 3——7
Left ON Left ON
1——5 1——6
5——7 6——7
Right ON Right ON
1——3 1——3
1——3 1——3
Up ON Up ON
4——7 2——7
1——4 1——2
Down ON Down ON
3——7 3——7
—— Off NOT ON —— Off NOT ON
Replace the switch if not conforming Replace the switch if not conforming
to requirements to requirements.
2. Defrosting switch:
6 1
5 4 3 2
Check
(a) Check the conduction of defrosting switch.
Standard:

ON 4-6 ON
OFF 4-6 NOT ON
Replace the switch assembly if not conforming to requirements
With the battery (+) being connected to terminal 1, battery (-) to terminal 2, check lighting system is
working. If not ON, replace this switch assembly.
392
3. Height adjust switch of front headlight:
1 2 3 4 5 6
Principle diagram
3档
Gear 3 2档
Gear 2
R1 9.56V R2 10.30V
1
R3 R4
2
3 0档
Gear 0 Gear 1 R5
1档
4 12.17V 11.56V
R7 R8
5
6
D2 D1
Gear 0
—0档
R6 —1档
Gear 1
—2档
Gear 2
—3档
Gear 3
Check:
(a) Check height adjust switch of headlight is on shift position.
Check voltage between two terminals when the switch is working.
Standard:
Position Input voltage

Gear 0 12.17V
Gear 1 11.56V
Gear 2 10.30V
Gear 3 9.56V
Replace the switch assembly if not conforming to requirements
With the battery (+) being connected to terminal 3, battery (-) to terminal 6, check lighting system is
393
4. Anti-theft indicating lamp:
1
2
Check lighting system
Ⅳ Door control switch:
Front door Rear door

前门的门控开关
controlling switch
后门的门控开关
controlling switch
Check door lamp switch is ON
Check the terminal is conducted with vehicle body when the switch is working
Testing
Switching action Status
terminal
1-vehicle
ON (vehicle door
body ON
closed)
earthed
1- vehicle
OFF (vehicle NOT
body
door ajar) ON
earthed
394
Ⅴ. Rear door window regulator switch:
Check whether the switch is ON:
Standard:
插片Plug plate
2 4
1 5 3
档位
Gear
拉
Pull
压
Press
Replace the switch assembly if not conforming to requirements.
Ⅴ Co-driver’s window regulator switch:
395
Standard:
插片 Plug plate
2 4
1 5 3
档位
Gear
拉
Pull
压
Press
Ⅵ Main driver’s window regulator switch:
Standard:
插片 Plug plate
2 4
1 5 3
档位
Gear
拉
Pull
压
Press
396
Ⅶ Brake lamp switch:
Check brake lamp switch assembly is ON.
原理图
Diagram
1 2
1 2
Check whether it is ON between two terminals of brake lamp switch
Standard:

Brake pedal stepped on 1-2 ON
Brake pedal released 1-2 NOT ON
397
Interior & Exterior Trim and Accessories—Instrument Panel and Dashboard
Chapter 5 Interior & Exterior Trim and Accessories

I. Instrument Panel and Dashboard
I. Instrument Panel Assembly Component View
II. Dashboard and Related Component View
Dashboard speaker trim

仪表板扬声器装饰
Dashboard
仪表台上罩总成 upper
B cover assy.
Dashboard panel assy.

仪表板面板总成
Combination
组合仪表罩
instrument cover
CD player
CD机
组合仪表总成
Combination instrument assy.
仪表台下罩分总成lower
Dashboard
cover sub assembly
Outer rear view
mirror turning 398
switch
外后视镜转向开关
Fuse box cover
保险丝盒盖板
III. Removal and installation of instrument panel

1. Disconnect the negative terminal of storage battery
2. Remove A/C switch panel sub assembly:
a. Loosen 2 tap screws;
b. Loosen 5 clips to remove A/C switch panel sub assembly.
3. Remove the instrument panel assembly

a. Remove the clamp
b. Loosen 10 clips and remove the instrument panel assy.
399
4. Remove the steering wheel, airbag, upper and lower housing of
steering column.
a. Remove the steering wheel;
b. Remove the airbag;
c. Release 3 tap screws and remove upper and lower cover of

steering column.
5. Remove upper trim panels of left and right front pillars

a. Release 2 clips with a screwdriver and remove upper trim
panels from left and right front pillars.
Tip: Before using a screwdriver, wrap its head with tapes.
6. Remove the speaker after taking down the left and right trim
covers of dashboard speaker
a. Release the clips with a screwdriver to remove left and right trim
covers of dashboard speaker.
b. Release 2 tap screws with a screwdriver and remove the
speaker.
7. Remove the dashboard left lower guard and disassemble the

combination instrument
a. Open the dashboard left lower guard manually;
b. Manually open the combination instrument cover and release 3 tap
screws with a screwdriver, then take off the instrument.
400
8. Remove the glove box assembly
a. Loosen 6 clips to remove the assembly.
9. Remove the front passenger airbag

a. Remove 2 covers of the glove box;
b. Unscrew 2 mounting bolts of airbag and the cross beam;
c. Loosen the connector;
d. Remove the front passenger airbag.
10. Remove the dashboard upper cover sub assembly

a. Loosen 6 nuts and pull out the dashboard upper cover sub
assembly.
11. Remove the auxiliary dashboard assembly

a. Unscrew the mounting bolt and pull out the auxiliary
dashboard.
12. Remove the dashboard lower assembly

a. Take out the auxiliary dashboard assembly after removing 6
bolts and 2 J-type clips.
401
Interior & Exterior Trim and Accessories—Auxiliary Dashboard Assembly
II. Auxiliary Dashboard Assembly
Auxiliary dashboard assembly consists of dashboard main body, gearshift dust cover base, gearshift
dust cover and cross recessed pan head tap screws Q2714213.
I. Structure of auxiliary dashboard assembly
II. Exploded view of auxiliary dashboard assembly
Gearshift dust cover
Auxiliary dashboard main

body
Gearshift dust cover base
Cross recessed pan head tap screw
III. Removal and mounting of auxiliary dashboard assembly

1. Removal of auxiliary dashboard assembly
(1) Adjust the position of front seat set to the last;
(2) Set the parking brake lever to the last position, as shown below;
(3) Screw out the gearshift lever as shown below;
(4) Take out the console rear mounting cover plate and remove Bolt <B> using a Ф10 socket wrench,
gently pull out backwards the auxiliary dashboard assembly to separate the dashboard lower cover main
body, and then remove this assembly.
402
Interior & Exterior Trim and Accessories —Auxiliary Dashboard Assembly
Gear Shift Lever handle Left front seat device
Cover plate of auxiliary

Instrument panel dashboard back mounting point
lower cover body
Parking brake
control lever
2. Remove the gearshift dust cover and its base

(1) Remove the auxiliary dashboard assembly;
(2) Screw off 4 screws <D> to remove the gearshift dust cover and its base.
403
Interior & Exterior Trim and Accessories—Vent Cover Plate
III. Vent Cover Plate
I. Relative parts of installation

1. Mount related components
Front windscreen weather strip

前风窗玻璃密封条
Front
前风窗玻璃windscreen
Wiper rocker arm assy.

雨刮器摇臂总成
Vent cover 通风盖板密封条

plate weather
strip
G-type clip
G型卡扣
Front washer
前洗涤器喷嘴nozzle
Right vent panel outer

右通风盖板外板总成
plate assy.
Left vent panel outer
plate assy.
Right vent panel inner plate
右通风盖板内板左通风盖板外板总成
Vent通风盖板密封条
panel weather
strip
2. Removal and mounting of vent cover plate

The mounting is reverse to the removal process, if there is difference, it will be specifically indicated.
(1) Remove the wiper rocker arm assembly;
a) Remove the rocker mounting bolt trim cover and the rocker mounting bolt;
b) Remove the wiper rocker assembly.
Note: remove when the engine hood closed.
(2) Open and support the engine hood;
(3) Remove the weather strip of vent cover plate (Note: total 8 fixing clips);
(4) Remove the left/right vent plate assembly;
a) Remove 2 G-type clips;
b) At left-side part of vent plate (including the left vent cover plate outer panel assy., vent plate rear
weather strip and front washer nozzle), remove the clips in 3 locations fit with front compartment water
main board; see the schematic below for specific removal.
Note: take off the front washer hose when removing the left-side part of vent cover plate.
404
Interior & Exterior Trim and Accessories —Vent Cover Plate
c) Remove right-side part of vent cover plate in the same way with the left side.
Right 右通风盖板外板总成
vent cover plate outer plate
assy.
Front
前风窗玻璃 windscreen
Front cabin water board (body)

前舱导水主板（车身）
1
(5) Remove the inner panel of right vent cover plate (it is secured by 3 clips as shown in the right figure);
see the right figure for specific removal.
(6) Remove 1 front washer nozzle at left and right;
Right vent cover plate outer panel assy.
(7) Remove rear weather strip of vent cover plate. 右通风盖板外板总成
Right右通风盖板内板
vent cover plate inner
panel
405
Interior & Exterior Trim and Accessories—Front Bumper
IV. Front Bumper
I. Components of front bumper
Front bumper left mounting

前保险杠左安装支架
bracket
Front bumper radiator cover assy.
前保险杠散热器面罩总成
Front bumper
前保险杠
Front tow-hook cover plate
前拖钩盖板
Front bumper right
mounting bracket
前保险杠右安装支架
II. Removal and installation of front bumper

Notes: Installation is basically the reverse of removal and different operation(s) in the process of
installation, if any, it will be pointed out specifically
1. Remove the front bumper assembly
a. Remove 4 J-type clips;
b. Remove 2 J-type clips.
406
Interior & Exterior Trim and Accessories—Front Bumper
2. Remove the radiator cover assembly of front bumper
Front bumper radiator cover assy.

前保险杠散热器面罩总成
3. Remove the cover plate of front tow-hook
Front
前拖钩盖板tow hook cover
plate
4. Remove the left mounting bracket of front bumper

a. Remove 2 screws.
Front bumper left

前保险杠左安装支架
mounting bracket
5. Remove the right mounting bracket of front bumper (the same with left mounting bracket)
6. Install in the order reverse to the removal.
407
Interior & Exterior Trim and Accessories—Rear Bumper
V. Rear Bumper
I. Rear Bumper Component View

Right side wall assy.
右侧围总成
Left side wall assy.
左侧围总成
Rear bumper mounting bolt/nut

后保险杠安装螺栓螺母
后侧围总成
Rear side wall assy.
D-type clip
D型卡扣
Rear后保杠险总成
bumper assy.
Rear license mounting plate

后牌照框安装板
II. Disassembly and assembly of the rear bumper

installation, if any, will be pointed out specifically.
1. Dismount the rear lamp assembly
2. Remove 6 J-type clips;
3. Screw off 3 rear bumper mounting
bolts and nuts
4. Remove the rear bumper
assembly
5. Remove left/right mounting
brackets of rear bumper
a. Remove 4 tap screws;
b. Remove left/right mounting
brackets of rear bumper;
c. Remove 4 through-hole insert
plastic nuts.
6. Remove the rear bumper sub
assembly
a. Remove 2 nuts;
b. Remove the rear license frame mounting plate;
408
Interior & Exterior Trim and Accessories—Rear Bumper
c. Remove 8 B-type spring nuts;

d. Remove 3 rear bumper mounting bolts and high-density sponge washers;
e. Remove 2 D-type clips.
7. Mount the rear bumper
Installation is basically the reverse of removal.
(Tip: mount the rear bumper with 3 rear bumper mounting bolts, 4 through-hole insert plastic nuts, 2
D-type clips, 2 J-type clips, 2 plastic expansion clips (φ7), 3 high-density sponge washers, 8 B-type
spring nuts, 6 cross recessed hexagon head tap screw with indentation and large plain washer
assemblies, and 3 nuts; for nuts, the torque is 5.5N·m).
409
Interior & Exterior Trim and Accessories—Fender
VI. Fender
I. Replacement of fender lining

1. Components of fender lining
Cross recessed hexagon bolt with

十字槽凹穴六角头螺栓
plain washer assembly
和平垫圈组合件
J-type
J型卡扣 clip
J-type
J型卡扣clip
J-type clip
J型卡扣 Through-hole insert
通孔嵌装塑料螺母
plastic nut
Left front fender
左前翼子板衬板
liner
Cross recessed hexagon
十字槽凹穴六角
head tap screw with plain
J-type clip
J型卡扣平垫自攻螺钉
washer
2. Removal and mounting of fender lining

Tip: The mounting is reverse to the removal process, if there is difference, it will be specifically
indicated.
(1) Remove left front fender lining
a. Remove 3 screws and through-hole insert plastic nuts;
b. Remove 6 J-type clips;
c. Remove 1 J-type clip;
d. Remove 3 cross recessed hexagon bolt and plain washer assemblies;
e. Remove left front fender lining.
(2) Removal of right front fender lining is the same above.
410
Interior & Exterior Trim and Accessories—Fender
II. Replacement of engine bottom guard assembly

1. Components of engine bottom guard assembly
Cross recessed hexagon bolt and

十字槽凹穴六角头螺栓
plain washer assembly
和平垫圈组合件
Engine发动机底部护板
bottom guard
Engine bottom baffle guard

发动机底部挡板
J-shaped
J型卡扣clip
2. Removal and mounting of engine bottom guard assembly

Tip: The mounting is reverse to the removal process, if there is difference, it will be specifically
indicated..
(1) Remove the engine bottom guard assembly
a. Remove 8 bolts;
b. Remove the engine bottom guard assembly.
(2) Remove the engine bottom guard
a. Remove 11 J-type clips;
b. Remove the engine bottom baffle guard;
411
Interior & Exterior Trim and Accessories—Front Door Interior Trim
VII. Front Door Interior Trim
I. Front Door Interior Trim View
II. Removal and installation of front door trim assembly

Installation and removal on the right side is identical with
that on the left side
1. Remove left front door corner trims;
a. Release the screw hole trim cover with a flat head
screwdriver;
b. Loosen the screws with a cross screwdriver;
c. Loosen 1 clip at top and bottom with a flat head
screwdriver to remove left front door corner trims.
Clip
卡扣
2. Remove the interior trim panel of left front door;
a. Remove 2 screws;
b. Prize up 10 clips with a flat head screwdriver and hold up the interior trim panel of left front door to
remove it.
412
Interior & Exterior Trim and Accessories—Front Door Interior Trim
Clip
卡扣
Caution: Be careful to prevent the left front glass regulator assembly from damage when
removing the bolts.
Notes: Remove the left front door glass regulator assembly through the service hole.
413
Interior & Exterior Trim and Accessories—Rear Door Interior Trim
VIII. Rear Door Interior Trim
I. Rear Door Interior Trim View
II. Removal and Installation of the Rear Door Interior trim

Tip: Installation is basically the reverse of removal and different operation(s) in the process of
The removal and installation at the right side are the same as those at the left side
1. Remove the handle cover of left rear door interior trim panel
Prize an opening with a flat head screwdriver and remove the handle cover.
Tip: Wrap the head of screwdriver with tape before using it.
414
Interior & Exterior Trim and Accessories—Rear Door Interior Trim
2. Remove the interior trim panel of left rear door;

a. Remove 2 screws;
b. Prize up 12 clips with a flat head screwdriver and hold up the interior trim panel of left rear door to
remove it.
Tip: Wrap the head of screwdriver with tape before using it.
415
Interior & Exterior Trim and Accessories—Side Wall Interior Trim
IX. Side Wall Interior Trim
I. Side Wall Interior Trim Component View
1
5
7
8
1. Left front pillar speaker cover 2. Left front pillar upper trim panel 3. Left center pillar upper trim panel 4.
Left rear pillar upper trim panel
5. Left rear tail lamp service hole cover 6. Left rear pillar lower trim panel 7. Left center pillar lower trim
panel 8. Left front pillar lower trim panel
II. Removal & installation Side Wall Trim Assy.
Tips: Installation is basically the reverse of removal and different
operation(s) in the process of installation, if any, will be pointed out
specifically. Mounting and taking down at right side is the same as the
left side
1. Remove the upper trim panel of right front pillar.
Prize up 2 clips with a screwdriver and remove upper trim panel of right front
pillar.
Notes: Wrap the head with tape before using screwdriver.
2. Remove upper trim panel of left front pillar.
3. Remove lower trim panel of right front pillar

Prize up 3 clips with a screwdriver and remove lower trim panel of right front
pillar.
416
Interior & Exterior Trim and Accessories —Side Wall Interior Trim
4. Remove lower trim panel of left front pillar

5. Remove lower trim panel of right rear pillar
a. Screw off the bolt and remove the safety belt eye from the vehicle body;
b. Prize up 1 clip and 5 clips with a screwdriver, remove lower trim panel
of right rear pillar.
6. Remove lower trim panel of left rear pillar
7. Remove upper trim panel of right rear pillar

a. Remove right tail lamp service hole cover plate;
b. Prize up 4 clips, 1 E-type clip and 1 tap screw with a
screwdriver, and remove upper trim panel of right rear pillar;
c. Pull out the safety belt from the cut.
E
-
tap screw
8. Remove upper trim panel of left rear pillar

9. Remove lower trim panel of right center pillar
a. Screw off the bolt and remove the safety belt eye plate from the body;
b. Prize up 2 clips and 2 clips with a screwdriver, remove lower trim panel
of right center pillar.
417
Interior & Exterior Trim and Accessories—Side Wall Interior Trim
10. Remove lower trim panel of left center pillar
11. Remove upper trim panel of right center pillar

a. Prize up 1 clip and remove upper trim panel of right center pillar with a
screwdriver.;
b. Pull out the safety belt from the cut.
12. Remove upper trim panel of left center pillar
418
Interior & Exterior Trim and Accessories—Front Seat Assembly
X. Front Seat Assembly
I. Front Seat Assembly Component View

II. Removal and installation of front seat assembly
Headrest
头枕 Backrest foam
靠背泡沫
Front seat (left)

前座椅（左）
Backrest cover
靠背套
Arc
C-◆拱环
rings
Specified torque 37N.m Headrest support

规定力矩37N.m 头枕支撑
Side safety
侧安全气囊air bag
Specified torque 43N.m
规定力矩43N.m
With
带锁扣buckle
座椅垫框架
Seat cushion framework
Seat cushion
cover
坐垫套
Seat坐垫泡沫
cushion
foam Arc rings
C-◆拱环
Specified torque 21N.m

规定力矩21N.m
Seat 座椅滑轨手柄
slide rail handle
◆ One-off
一次性零件 par
The operation procedure on the right side is identical with that on the left side
1. Remove the front seat
a. Remove the headrest;
b. Remove 4 screws;
c. Disconnect the connector on the back of seat cushion
d. Remove the front seat.
2. Remove the left front seat belt buckle assembly
a. Disconnect the connecting wiring harness
b. Remove bolt and the left front seat belt buckle assembly
3. Remove the left front backrest outer panel
a. Turn the backrest over and remove the arch rings;
419
Interior & Exterior Trim and Accessories—Front Seat Assembly
b. Remove 2 headrest brackets;

c. Remove the left front backrest trim
4. Remove the left front seat cushion outer panel
a. Remove the arch rings from the back of seat cushion;
b. Remove the left front seat cushion outer panel
5. Remove the seat adjuster;
a. Remove the slide path handle
b. Remove screw and seat cushion frame
6. Remove the side safety airbag
a. Remove 2 nuts;
b. Remove the side safety airbag.
7. Install the front seat assembly
Tips: Install in reverse order of removal.
420
Interior & Exterior Trim and Accessories—Rear Seat Assembly
XI. Rear Seat Assembly
I. Rear Seat Assembly Component View
Headrest
头枕
Right rear seat backrest

右后座椅靠背 Left rear seat
左后座椅靠背
backrest
Rear seat cushion

后座椅坐垫
II. Removal & Installation of Rear Seat Assembly

1. Remove the rear seat cushion assembly
a. Pull upward the front part of rear seat cushion;
b. Pull out the metal hook from rear seat cushion and remove seat cushion assy.
2. Remove the left rear seatback assembly
a. Remove the rear seat headrest;
b. Unlock the left rear seat backrest;
c. Fold the seat backrest；
d. Remove 2 bolts and nuts of fixing hinge;

e. Remove the rear seat backrest assembly.
3. Remove the right rear seatback assembly
Tip: Apply the procedures the same as aforesaid for the left side
421
Interior & Exterior Trim and Accessories—Rear Seat Assembly
4. Assemble the rear seat assembly

Tip: Follow the sequence reverse to removal.
All the bolts shall be installed with the torque: 18N·m
422
Interior & Exterior Trim and Accessories—Safety Belt
XII. Safety Belt
Notice:
Tip: Follow the steps below before scrapping vehicle equipped with the safety belt pre-tensioning
retractor or disposing a safety belt (configuring pre-tensioning retractor).
If there is any malfunction, please contact GEELY INTERNATIONAL CORPORATION.
For a impacted vehicle with pre-tensioning retractor not exploded, its disposal is the same with the Step
1~2 below.
Warning:
◆ Never dispose pre-tensioning retractor without collision.
◆ Explosion of pre-tensioning retractor will produce explosive sound, therefore it must be operated
outside the vehicle in a place not disturbing residents nearby.
◆ SRS specific tools shall be used for explosion of pre-tensioning retractor and the working place must
be far away from electronic interference.
◆ Explosion of pre-tensioning retractor must be at least 10M away from pre-tensioning retractor
assembly.
◆ When pre-tensioning retractor explodes, safety belt becomes very hot, hence leave it alone in 30min
after its explosion.
◆ Gloves and safety eyeglass is required for handling exploded pre-tensioning retractor.
◆ Do wash your hands with water after this operation.
◆ Never spray any water to the exploded pre-tensioning retractor.
I. Front safety belt
Replacement
Tip: Installation is reverse to the removal. Mounting instructions are given whenever necessary. The
procedures for left-side and right-side belts replacement are same.
Refer to the components drawing of front safety belt.
423
7/16″
7/16英bolt Center post upper trim plate assy.
中柱上装饰板总成
制螺栓
Center post lower
中柱下装
trim plate assy.
Rear post lower

饰板总成
trim后柱下
plate
Front safety
装饰板前安全
belt assy. Front safety
belt
前安全带 buckle
带总成 assy.
M6X16 锁扣总成
7/16″
7/16英
bolt
制螺栓 7/16″
7/16英
bolt
制螺栓
7/16″ bolt
7/16英制螺栓
1. Unfix the negative cable of the battery

2. Remove left front safety belt buckle assembly
(a) Remove the bolt connecting left front safety belt buckle and driver’s seat slide rail;
(b) Remove the wring connectors of upper buckle end of safety belt reminder from the body;
(c) Remove left front safety belt buckle assembly
3. Remove lower trim panel of left rear pillar
4. Remove left front door weather strip device
5. Remove left rear door weather strip device
6. Remove lower trim panel assembly of left center pillar
7. Remove upper trim panel assembly of left center pillar
8. Remove left front safety belt retractor assembly
(a) Remove the trim cap of safety belt lower fixing bolt;
(b) Remove the bolt and floor safety belt lower fixing bolt;
(c) Remove the guide ring fixing bolt;
(d) Remove the bolt and retractor assembly.
Note: Before removing safety belts, turn the ignition switch to LOCK position and work after unfixing the
negative (-) cable of battery for 90sec.
(e) Unfix the retractor connector.
9. Mount left front safety belt assembly
(a) Examine the inclination angle when ELR starts locking.
(1) Confirm if safety belt can not be pulled out when the inclination angle exceeds 45°.
424
Note: Do not dismantle the retractor.

(b) Use a bolt to mount the retractor via lower connecting plate with torque of 45N·m, and another bolt to
limit the retractor mounting angle via upper connecting plate with torque of 15N·m.
(c) Use a bolt to set the guide ring into corresponding hole of the top of left center pillar; use another bolt
to pass through the left center trim panel assembly’s webbing hole at the webbing end and then secure
this bolt into corresponding hole at the lower of center pillar.
Torque: 45N·m.
(d) Check the locking of ELR;
(e) After mounting the safety belt on the vehicle, check whether it can be locked when pulled out rapidly.
10. Mount left front safety belt buckle assembly
Torque: 45N·m.
Please tighten the fixing bolts timely, if loose over long-time vehicle running.
II. Rear safety belts
Replacement
Tip: Installation is reverse to the removal process. Mounting instructions are given whenever
necessary.
The procedures for left side and right side belts replacement are same.
Refer to the components drawing of rear safety belts.
Right rear safety Left rear

Right
右后座椅 rear 右后安全带锁扣左后座椅
seat backrest belt buckle and seat
靠背总成
靠背总成及中间腰带总成
intermediate lap backrest
assy.
belt assy.
Rear
后座椅座 seat
cushion
垫总成 assy.
Left左后安全带 rear
safety
锁扣总成belt
buckle assy.
Rear floor middle section
后地板中段分总成
sub assembly
425
Rear post
后柱上装
upper trim plate Webbing
织带出口 outlet
饰板 7/16″ bolt
7/16英
制螺栓
Rear
后柱下装 post lower
trim plate
M6X16 饰板
Rear
后安全
safety 安全带
Safety belt
带总成
belt bolt 螺栓孔
hole
Rear 后 7/16英
7/16″
wheel轮 bolt
制螺栓
Tail
后尾灯维 lamp house
service hole 罩
修孔盖板 assy.
cover plate 总
成
7/16″
7/16英 bolt
制螺栓
1. Remove the rear seat cushion assembly.

2. Remove the right rear seat backrest assembly
3. Remove the left rear seat backrest assembly
4. Remove the lower part fixing bolt of rear safety belt wheel
Rear seat safety belt fixing
house 后排安全带固定点
point
5. Remove upper trim panel assy of right rear pillar Rear post lower trim plate
后柱下装饰板
6. Remove lower trim panel assy. of right rear pillar
Safety belt bolt hole
安全带螺栓孔
7. Remove upper trim panel assy. of left rear pillar
7/16″ bolt
7/16英制螺栓
8. Remove lower trim panel assy. of left rear pillar
9. Remove the rear safety belt assembly
(a) Remove the fixing bolt at guide ring;
(b) Remove upper locating bolt and lower fixing bolt at the retractor;
(c) Remove the rear safety belt assembly;
(d) Remove the bolt, right rear safety belt buckle and intermediate lap belt assembly.
10. Remove right rear safety belt buckle and intermediate lap belt assembly.
11. Remove left rear safety belt buckle assembly
(a) Remove the bolt and left rear safety belt buckle assembly.
12. Remove left rear safety belt buckle assembly
(a) Mount left rear safety belt buckle assembly with the bolt.
Torque: 45 N·m
13. Mount right rear safety belt buckle and intermediate lap belt assembly
(a) Mount right rear safety belt buckle and intermediate lap belt assembly with the bolt.
Torque: 45 N·m
426
14. Mount the rear safety belt assembly

(a) Examine the inclination angle when ELR starts locking.
(1) Confirm if safety belt can not be pulled out when the inclination angle exceeds 45°.
Note: Do not dismantle the retractor.
(b) Mount upper fixing point of rear safety belt retractor assembly with the bolt.
Torque: 20N·m.
(c) Mount lower fixing point of rear safety belt retractor assembly with the bolt.
Torque: 45N·m.
(d) Mount the rear safety belt guide ring fixing point.
Torque: 45N·m.
(e) Thread the webbing through upper trim panel webbing hole of rear pillar and mount lower trim panel
of rear pillar.
(f) Mount rear safety belt wheel house lower fixing point.
Torque: 45N·m.
(g) Check the locking of ELR.
(1) After mounting the safety belt onboard, check whether it can be locked when pulled out rapidly.
Trouble Diagnosis and Troubleshooting
Safety belt pre-tensioning trouble
Safety belt pretensioner malfunction(resistance too high or too low, ground short circuit)
Warning
◆ Improper handling may trigger the safety airbag assembly and pretensioner seat safety
belt, resulting in serious personal injury, hence read the service warnings before
handling carefully.
◆ Refer to the warning for SRS maintenance.
Test
◆ In the case of safety belt pretensioner
condition
◆ Resistance between Pin 1, 2 or Pin 3, 4 of unit connector of SRS not within specified
range
◆ Wire between Pin 1, 2 or Pin 3, 4 of SRS develops a short circuit
◆ Open circuit between Pin 1,2 or 3, 4 of unit connector of SRS, if no passenger side
safety airbag
◆ Safety belt pretensioner malfunction
◆ Malfunction of connectors between safety belt pretensioner and SRS electronic control
unit
Possible ◆ Malfunction of connectors between safety belt pretensioner and earth point
Causes
◆ Open or short between safety belt pretensioner and SRS electronic control unit
◆ Open or short between SRS unit and earth point
◆ Trouble of SRS unit
Diagnosis procedures
1. Check the warning of safety belt pre-tensioning connectors
Improper handling may cause triggering the pretensioner to the safety belt, resulting in serious personal
injury, hence carefully read the service warnings before handling.
(1) Set the ignition switch to “LOCK” position
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(2) Release the battery negative cable for at least 1min

(3) Take out the guard plate of pillar B
(4) Unfix the safety belt pretensioner connector
(5) Does the safety belt pretensioner connector work normally?
Yes: to next step
No: replace the wire
2. Confirm the trouble is on the pretensioner safety belt or other components
(1) Connect a good safety belt to the safety belt pretensioner connector
(2) Connect the battery negative cable
(3) Set the ignition switch to “ON” position
(4) Can the trouble code be eliminated?
No: to next step
Yes: replace the pretensioner safety belt
Refer to the safety airbag system for removal and mounting of pretensioner safety belt.
3. Check the wire between passenger side pretensioner safety belt and SRS electronic control unit
(1) Set the ignition switch to “LOCK” position
(2) Release the battery negative cable for at least 1min
(3) Unfix the connector of safety belt pretensioner module
(4) Unfix all connector of SRS units
(5) Check if electric circuit between connectors of SRS electronic control unit and between connectors of
safety belt pretensioner has developed the grounding, or a short circuit to power supply, or an open
circuit.
(6) Is the above wring normal?
Yes: the trouble diagnosis ends
No: replace the related wire
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Interior & Exterior Trim and Accessories —Safety Belt
Scraping
1. Safety belt pre-tensioning retractor at the time of scrapping a
vehicle 电瓶
Tip: prepare a battery as a power supply of exploding the

pre-tensioning retractor. Special
tool
专用工具
预紧式
卷收器
(1) Confirm the function of special tool

Warning: To detonate the safety belt pre-tensioning retractor,
ensure to use the designated special tool: SRS explosion tool. Special tool
专用工具
(a) Connect the special tool to the battery

Attach the red clamp of special tool to positive pole(+) and black
Battery
clamp to negative pole(-). 电瓶
Tip: different from yellow connector to the safety belt

pre-tensioning retractor.
专用工具
Pre-tensionin
预紧式
g retractor
卷收器
(b) Confirm the function of special tool

Pressing the active switch of special tool will turn on LED.
Warning: if LED is on and active switch is not pressed, indicating
Special
专用工具 tool
that special tool fails, therefore this tool shall not be used
anymore.
(2) Remove the safety belt pre-tensioning retractor joint

(a) Remove the front door step trim plate;
(b) Remove the rear door step trim plate;
(c) Remove safety belt lower fixing bolt and trim cover;
(d) Remove lower inner trim panel of center pillar;
(e) Remove the safety belt pre-tensioning retractor joint as shown in
the illustration.
(3) Mount special tools
(a) Mount lower fixing bolt and trim cover of safety belt;
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(b) Attach 2 special tools to the safety belt pre-tensioning retractor.

Note: To avoid damaging special tools joints and wires, do not lock up
the secondary lock of dual-lock unit.
Special
专用工具 tool
专用工具
Special tool
(c) Move the special tool to be at least 10M away from front end of the
vehicle;
Battery
电瓶
(d) Close all doors and windows. Special
专用工具 tool
At least
10米以上10M
Note: Be careful not to damage the wire of special tool.
(e) Attach the red clamp of special tool to positive pole(+) of the battery and black clamp to negative
pole(-).
(4) Explode the safety belt pre-tensioning retractor.
(a) Confirm that there is no body within the vehicle and 10M around the vehicle.
(b) Press the active switch of special tool and explode the safety belt pre-tensioning retractor.
Tip: when LED of special tool’s active switch lights up, the pre-tensioning retractor will explode
and inflate.
(5) Dispose of the safety belt pre-tensioning retractor
Tip: when scrapping a vehicle, the pre-tensioning retractor must be exploded and then scrapped
with the vehicle together.
Battery
电瓶
2. Just dispose of the safety belt pre-tensioning retractor
(method of exploding front safety belt)
Note: ◆ In the case of exploding the retractor only, NEVER use
a customer's vehicle for such explosion. Special
专用工具 tool
Pre-tensionin
预紧式
◆ To explode the safety belt pre-tensioning retractor, operate g retractor
卷收器
carefully as per the following steps.
(a) Remove the safety belt
Tip: Cut off the safety belt at the location near to the
retractor.
(b) Confirm the function of special tool
(c) Mount the special tools
Special
专用工具 tool
(1) Attach 2 special tool joints to the connectors of safety belt 专用工具
Special tool
pre-tensioning retractor.
Note: To avoid damaging special tool joints and wires, do
not lock up the secondary lock of dual-lock unit.
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(2) Lay the safety belt pre-tensioning retractor on the ground and
cover it with the tire.
Tire
Note: Place the retractor as shown in the figure. 轮胎
(3) Put the special tool in a place at least 10M away from the tire. Retractor
卷收器
Note: Be careful not to damage the special tool and wire. Special tool
专用工具
Battery
电
瓶
At least
10m以上
10M
(d) Explode the safety belt pre-tensioning retractor.

(1) Attach the red clamp of special tool to positive pole (+) of the
Tire
battery and black grip to negative pole (-). 轮胎
(2) Ensure there is nobody within 10M from the tire binding the Retractor
卷收器
pre-tensioning retractor. Special tool
专用工具
Battery
电
(3) Press the active switch of special tool to explode the retractor.
瓶
Tip: when LED indicator of special tool’s active switch lights up, At least
10m以上
10M
the pre-tensioning retractor will explode and inflate.
(e) Dispose of the safety belt pre-tensioning retractor

(1) Remove the tire and special tool.
(2) Put the retractor into a plastic bag and bind the bag, and dispose of it together
with other components.
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Interior & Exterior Trim and Accessories—Front Windscreen
XIII. Front Windscreen
I. Related Component View
Roof panel interior trim

顶盖内饰
Safety handle assy.

安全拉手总成
Left sun visor assy.

左遮阳板总成
Interior mirror Right
rearview 前右雨刮器摇臂总成 front
内后视镜总成
assy. wiper rocker
arm assy.
Right sun
右遮阳板总成
visor assy.
Left front post

左前柱上装饰板
upper trim plate
Right front post
右前柱上装饰板
upper trim plate
Front windscreen
前风窗玻璃密封条
weather strip
Left air chute cover plate assy.

左通风道盖板总成
右通风道盖板总成
Right air chute cover plate assy.
II. Install and replace front windscreen glass Cutting
1. Remove the rearview mirror assy.

2. Remove the air chute cover plate assy. Cutting
a. Unfasten two installing bolts on the wiper and remove the

wiper assy.
b. Remove installing screws and clips from air chute cover plate, and take down the left part of the cover
plate.
c. Remove the right part of the air chute cover plate.
3. Remove the exterior weather strip of the windscreen glass.
Stop block
a. As per the drawing, cut the weather strip with a knife;
Attention: Avoid damaging the body.
High-carton steel wire
b. Draw back the weather strip by hand and remove it
4. Remove windscreen glass
a. Guide iron wire through inner side right body and glass;
b. Fasten a wood block or similar object by both ends of the wire
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(Tips: Stick a protective film on the exterior surface to avoid Safety cushion
it being scratched)
c. Draw the steel wire and cut the polyurethane adhesive sealant
material around the glass;
d. Remove the stop block;
e. Use a rubber cupule to detach the glass.
Attention: Protection belt
When detaching the glass, be careful not to scratch the paint or the interior and exterior trims;
When removing the glass, leave as much as possible polyurethane adhesive sealant materials.
5. Clean the windscreen glass
a. Use scraper to remove the remaining stop block and
polyurethane adhesive sealant;
b. Use clean gasoline to clean outer race of glass.
Attention: Do not touch the glass surface after cleaning.
6. Install the stop block of windscreen glass (I)
a. Clean the mounting position of stop block for glass;
b. Install two new stop blocks (with pressure sensitive adhesive) onto the glass
7. Install stop block of windscreen (II)
As per the drawing, install two new stop blocks onto the body
8. Install the polyurethane adhesive sealant onto the windscreen
Mark
a. Apply M priming paint onto the mounting position of
polyurethane adhesive sealant for windscreen glass
Attention:
3 minutes for adhesive drying
Once opened, the adhesive can not be used anymore.
Do not apply too much adhesive.
Correct
9. Install the weather strip for windscreen
M priming paint
a. Apply priming paint M on glass edge and touching surface using
Wrong
brush or sponge;
M priming paint
b. Install the weather strip for windscreen.
10. Install windscreen Adhesive
(1) Clean and tidy the body contact surface;

a. Cut the polyurethane adhesive sealant material on the contact surface with a knife and clean it.
(Tips: Leave as much as possible polyurethane adhesive sealant material )
b. Clean the contact surface using cloth wetted with detergent.
(Tips: Even though all the polyurethane adhesive sealants are removed, the body yet has to be
cleaned.)
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(2)Place glass
a. Use rubber cupule to place the glass at a proper position;
b. Check whether the contact surface around the glass is smooth;
c. Put reference marks between glass and body.
Attention:
Check whether the stop block is well glued on car body and whether it is correctly positioned.
(Tips: When using the original glass again, check and correct the position of reference marks.)
d. Detach glass
(3) Use a brush to apply priming paint M on the exposed parts of body.
Attention:
It takes three minutes for priming paint drying;
Once opened, priming paint M can not be used anymore;
Avoid daubing priming paint onto the adhesive.
(4) Use a brush to apply priming paint M onto the glass edge and contacting parts.
(5) Add the polyurethane adhesive sealant materials.
a. Prepare a sealing gun with sleeve;
b. Use the gun to apply the polyurethane adhesive sealant materials on relative positions of body.
(6) Install glass
a. Use cupule to place glass and align with the reference marks and press it gently along the edge.
b. Press the outside surface of glass gently so that it contacts tightly.
c. Use a scraper to clean the remaining polyurethane adhesive sealant materials.
(7) Inspect leakage and service
a. Leakage test will be carried out after the polyurethane adhesive sealant materials are fully solidified.
b. Use the polyurethane adhesive sealant materials to seal up all the leaking areas
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Interior & Exterior Trim and Accessories—Backdoor Windscreen Assembly
XIV. Backdoor Windscreen Assembly
I. Components of rear windscreen
顶盖
Backdoor
背门密封条 weather strip
Backdoor
背门玻璃glass
Backdoor glass hinge

背门玻璃铰链
Air spring
气弹簧
Rear
后雨刮 wiper
Logo标徽
Wiper
雨刮电机罩 motor cover
Backdoor outside
背门外拉手handle
Backdoor
背门线束装饰条 harness trim strip
II. Removal and replacement of rear windscreen

Tip: The mounting is reverse to the removal process, if there is any difference, it will be indicated
specifically.
1. Remove the air spring of backdoor windscreen;
2. Remove the backdoor windscreen hinge;
3. Remove the backdoor windscreen assembly;
4. Remove the wiper motor cover;
5. Remove the wiper motor;
6. Remove the backdoor handle;
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Interior & Exterior Trim and Accessories—Backdoor Windscreen Assembly
7. Remove the backdoor logo;

8. Remove the backdoor harness trim strip;
9. Clean the rear windscreen;
(1) Remove the remaining 3M tape from the windscreen with a scraper;
(2) Clean the outer race of windscreen with clean gasoline.
Note: Do not touch the glass surface after cleaning.
III. Removal/mounting of window regulator
1. Loosen the fixing screws (as shown below):
Fixing
固定螺钉
screw
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Interior & Exterior Trim and Accessories —Backdoor Windscreen Assembly
2. Take out the window regulator from the square hole on the left side of the door.
Front door
前门组件
components Power window regulator
电动玻璃升降器电机
motor
Power window regulator

电动玻璃升降器主体
main body
Power电动玻璃升降器执行器
window regulator actuator
3. The mounting is reverse to the removal process.

Power Window Typical Problems and Solutions
Problem Cause Solution

Foreign matters in rail
Abnormal sound in guide rail Clean the slot and add lubrication oil
slot
Fuse burnout Replace the fuse
Poor switch contact Replace the switch
Motor malfunction Electric motor
Window fails to work as normal
Control module
Replace the control module
malfunction
Mechanics damaged Replace the mechanics
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Interior & Exterior Trim and Accessories—Outside Rearview Mirror
XV. Outside Rearview Mirror
The outside rearview mirrors are mounted on the left and right doors. With specially designed rubber
sheath, the rearview mirrors are seamlessly and smoothly joined to the body of vehicle. Meanwhile, they
block neither upward nor backward turn of rearview mirrors upon knocking. Such installation also plays
an important role in decreasing the air resistance coefficient of the whole vehicle.
The mirror glasses are fixed to the supporting plates with acrylic foam tape. The supporting plates are
connected to the shell of rearview mirrors with ball hinge in order to make sure no glass will scatter that
causes secondary injury, as well as replacing the damaged glasses easily. When the glasses are
damaged, the supporting plates can be taken out of the ball-head mount with tools, and then pressed
into the mount again after replacing the glasses. The turning force of rearview mirror is designed as 30N,
which enables easy turn and less hurt/damage in case human or object knocks the mirror.
Notes: When turning over the rearview mirror, please don't put your finger between the outside
rearview mirror and the mirror corner in order to avoid extrusion injury!
Replacement of Rearview Mirror

I. Removal procedures
1. Remove the cathode lead wire off the battery
2. Remove the corner decoration of door;
3. Disconnect the plug of electric outside rearview mirror;
4. Remove the 3 screws;
5. Remove the electric outside rearview mirror
II. Installation procedures
1. Mount the rearview mirrors onto the doors
2. Fasten the screws from the lower-left side clockwise
Fasten the screws of outside rearview mirrors with the torque of
8.0N.m
3. Connect the plug of electric outside rearview mirrors
4. Install the corner decoration of door
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Interior & Exterior Trim and Accessories—Inner Rearview Mirror
XVI. Interior Rearview Mirror
Interior rearview mirror is attached to a bracket secured on the front windscreen. This bracket is mounted
by the windscreen supplier using aluminum pieces. Front windscreen for service has a rearview bracket
adhibited to the windscreen assembly.
I. Installation procedure
1. Measure the distance from the roof lining to the bottom of rearview mirror bracket on the front
windscreen glass.
2. Mark this position on the outside glass with a crayon or pastel. Draw a large diametrical circle around
the position of rearview bracket on the outside glass.
3. Wash the glass inner surface with domestic cleaner, glass washer fluid or polish agent and tissue.
Clean the glass till it gets dry completely. Wipe with the tissue dipped in alcohol to remove the scouring
powder or glass washer fluid residues.
4. If the rearview mirror bracket is new, use #320 or #360 thin sandpaper to grind the bonding face. In the
case of using original bracket, remove all adhesive residues left behind at the time of delivery before
reassembly.
5. Dip the alcohol with clean tissue to wipe the polished rearview mirror bracket. Let the bracket dry
alone.
6. Before mounting the rearview mirror on the windscreen, apply the adhesive following the
manufacturer’s instructions and prepare the rearview mirror bracket.
7. Set the rearview mirror bracket at the position previously marked. Press the bracket for 30~60sec. on
the windscreen using steady force.
8. Five minutes later, use the alcohol dipped tissue or glass cleaner to remove excessive adhesive.
9. Mount the inner rearview mirror onto the bracket with the mounting screws.
II. Fastening
Fasten the rearview mirror mounting bolt to 1.2N.m.
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Interior & Exterior Trim and Accessories—Inside Roof Trim Components
XVII. Roof Trim Components
I. Components of roof trim components
Right rear safety handle

Front safety handle bracket 右后安全拉手支架
bracket
前安全拉手支架
Safety handle assy. Roof interior trim plate
安全拉手总成顶盖内饰板
Left sun visor

左遮阳板总成 Left rear safety
左后安全带总成
assy.
Left front roof Left
右后顶盖内衬板 rear roof belt assy.
Left sun visor assy.
左遮阳板总成 interior lining
interior
左前顶盖内衬板 lining
Left sun visor assy. panel
左遮阳板总成 panel
Ceiling
室内顶灯 dome
lamp
Ceiling
室内顶灯盖 dome lamp
cover
II. Removal and mounting of inside roof trim components

Tip: The mounting is reverse to the removal process, however the difference between the two will be
specifically indicated. Installation and removal procedures for left and right-sides are the same.
1. Remove the side-wall interior trim components;
2. Remove the right sun visor assembly;
a. Remove 2 screws;
b. Remove the right sun visor assembly.
3. Remove the left sun visor assembly;
4. Remove the ceiling dome lamp assembly
a. Unfix 4 clips with a screwdriver to remove the lamp housing;
b. Remove 2 screws and take off the ceiling dome lamp assembly.
5. Remove the safety handle subassembly
a. Take apart the safety handle cover
b. Remove 2 screws and take off safety handle subassembly.
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Interior & Exterior Trim and Accessories—Inside Roof Trim Components
Safety handle
安全拉手盖 cover
6. Remove the sun visor clip

Remove 1 crosshead self-tapping screw and pull apart the sun visor clip.
7. Remove the roof interior trims

Remove 4 E-type clips with a clip puller to take off the roof interior panel assembly.
8. Install in the order reverse to the removal.
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Interior & Exterior Trim and Accessories—Carpet and Heat Insulating Mat
XVIII. Carpet and Heat Insulating Carpet
I. Carpet and heat insulating carpet component view
Front wall external panel heat insulating

前围外板隔热垫 carpet
Front wall silencer

前围隔音垫
Driver left驾驶员左搁脚垫
footrest mat
Carpet assy.
地毯总成
Driver right footrest mat

驾驶员右搁脚垫
Right 右搁脚垫总成
footrest mat
assy.
II. Removal
1. Remove front & rear seats, lower interior trims of left and right center pillars, lower interior trims of left
rear pillar, right center pillar lower interior trim auxiliary console and parking brake lever trim panels;
2. Remove the carpet assembly;
3. Remove driver’s left and right footrest mat, right footrest mat assemblies;
4. Remove appropriate clips of brake pedal assembly, accelerator pedal assembly and blower assembly.
5. Remove the front-wall silencer, front-wall out panel silencer.
III. Mounting
1. Mount accelerator pedal assembly, brake and clutch pedal assembly, brake assembly onto the
vehicle body.
2. Set up the carpet as per corresponding holes and set its left and right sides under the left center pillar
lower interior trim, right center pillar lower interior trim, left rear pillar lower interior trim and right center
pillar lower interior trim.
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Interior & Exterior Trim and Accessories—Fuel Filler Cap Opening Device
XIX. Fuel Filler Cap Opening Device
I. Drawing of filler cap control unit and pull cable assembly
Filler cap control handle

加油口盖操纵手柄总成
assy.
Filler加油口盖开启拉线总成
cap opening cable assy.
加油口盖操纵手柄总成
Filler cap control handle assy.
II. Removal and mounting of filler cap opening device

1. Remove driver’s seat;
2. Remove the left door sill trim panel;
3. Lift left side of the carpet;
4. Remove the control handle fixing bolt;
5. Take out the control handle and separate it from the pull cable;
6. Remove the luggage compartment shield, take out the pull cable clip from the vehicle body fixing hole
and separate the pull cable from harness;
7. Unscrew the pull cable opening end and take out the pull cable from filler cap fixing hole;
8. Mount the filler cap control handle and pull cable assembly.
Tip: The mounting is the reverse of the removal process.
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Interior & Exterior Trim and Accessories—Engine Hood Latch Release Cable Assembly
XX. Engine Hood Lock Opening Cable Assembly
I. Component view of engine hood lock opening cable assembly
Engine hood lock pull cable and opening handle

Engine hood lock pull
cable
Opening handle
II. Removal and mounting of engine hood lock opening pull cable assembly
1. Take out the pull cable clip from the pull cable fixing hole on the engine hood lock;
2. Remove the pull cable from the mounting bracket;
3. Take out the pull cable and clips on front engine compartment crossbeam;
4. Separate the pull cable from the engine compartment harness;
5. Remove lower trim panel of left front pillar;
6. Remove the handle fixing bolt with a M6 socket wrench;
7. Take out the pull cable from front wall through-hole.
8. Mount the engine hood lock opening pull cable assembly
Tip: The mounting is the reverse of the removal process.
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Interior & Exterior Trim and Accessories—Plug List
XXI. Plug List
No. Picture Material code Position Diameter
1 1805004 Side wall Φ25.5
2 1805001 Front floor, rear floor Φ44.5
3 1805003 Front floor, Φ30.5
4 1805006 Side wall Φ11
5 1805012 Side-wall outer panel lower part Φ21.5
6 1805013 Rear floor Φ15
7 6800028 Front wall shield Φ18
8 1805015 Door sill Φ30
9 1805016 Roof panel Φ60
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Body—Summarize—Body structure
Chapter 6 Body
Part 1 Summarize
I. Body Structure
The body is made up of main structure, movable plate work, interior/exterior trim parts, and body
accessories.
A. Main Structure
As shown in Fig.1-1, the main structure is made up of various assemblies and parts including engine
compartment assembly & front wall parts, floor assembly, left/right wall assembly, rear wall assembly
and roof assembly and trunk main cover assembly etc
3
2
1
4
Fig. 1-1 Main Structure

1 Engine compartment assembly & front wall parts 2. Roof assembly
3. Left/right side wall assembly 4. Rear wall assembly 5. Floor assembly
(1) Engine Compartment Assembly & Front Wall Parts
The main function of the engine compartment assembly and front wall parts is to form an engine
compartment and absorb most energy generated when the vehicle is collided from the front. The
compartment provides a hood for the engine and its accessories, which can prevent the front wheel from
throwing mud. In the appearance, it represents the body's design requirements. As shown in Fig. 1-2,
the engine compartment assembly includes front cross beam assembly, left/right longitudinal beam
assembly, radiator cross beam assembly, front wall guard assembly, front wall upper assembly, left/right
front shock absorber bracket lower front plate assembly and right front shock absorber inner vertical
angle bracket.
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1 4 5 6
2
Fig. 1-2 Engine Compartment Assembly & Front Wall Parts

1. Front cross beam assembly 2. Radiator cross beam assembly
3. Left/right longitudinal beam assembly 4. Front compartment water leading main panel
5. Front wall guard assembly 6 Front wall upper assembly
1. Front cross beam assembly
The front cross beam assembly includes front cross beam left/right support assembly, front cross beam
sub- assembly, front cross beam side support etc
2. Left/right longitudinal beam assembly
The left/right longitudinal beam assembly includes left/right longitudinal bean front and mid- block
assembly, energy-absorbing beam big assembly, and left/right front shock absorber support assembly
etc.
It is mainly used to install engine left/right suspension support abutment, left/right front suspension shock
absorber support abutment, and other mounting bracket. In the outside, it can be equipped with left/right
front fender
3. Radiator cross beam assembly
The radiator cross beam assembly includes radiator left/right post big assembly, radiator lower cross
beam big assembly, radiator central support sub-assembly, and radiator upper cross beam big assembly
etc.
It is mainly used to install radiator, condenser, engine hood lock, radiator hood, front bumper, and front
headlight.
4. Front wall assembly
The front wall assembly connects to the floor, which separates the engine compartment from the cabin.
It includes front wall frame assembly, front wall sub-assembly, brake installation reinforced plate, and
front wall left/right support assembly etc.
It is mainly used to install the pipes and accessories of the brake system and clutch system
5. Front wall upper assembly
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The front wall upper assembly includes left/right hinge base fixing plate big assembly, front wall upper
front cover big assembly, VIN number fixing plate, and front wall upper rear cover big assembly etc.
It forms a high-stiffness frame structure together with the engine compartment assembly and the front
wall assembly. It can generate strong resistant to the transverse collision and rolling deformation. It can
also separate the engine compartment form the cabin, preventing the odor entering into the cabin.
Consequently, it can isolate the noise, heat and vibration
(2) Floor Assembly
The floor assembly is the base work of the main structure. It is a key component that connects various
assemblies and carries the load. The vehicle performance is subject to its strength and stiffness. For the
floor assembly, see the Fig. 1-3.
10
2 3 5 7
4
9
1 Front
6
8 前
Fig. 1-3 Floor Assembly

1 Left/right door frame lower side beam inner plate assembly 2 Front floor main plate assembly
3 Front left/right longitudinal beam assembly
4 Front seat rear slide bracket assembly 5 Front floor upper beam assembly 6 Rear floor mid-block
assembly 7.Rear main frame assembly 8.Rear axle and body connecting plate 9.Rear floor left/right side
plate assembly 10.Rear floor rear block assembly.
The floor assembly includes front floor assembly and rear floor assembly. The front floor mid-block goes
through a rigid channel in longitudinal direction. It can increase the longitudinal rigidity together with the
lower floor longitudinal beam. The space below under the channel is used to install various parts and
components, such as transmission gearshift rod, parking brake cable, exhaust pipe with three-way
catalytic converter etc. In the cabin, there is carpet and muffle pad. The floor frame structure is made up
of front floor main plate assembly, front floor left/right beam assembly, front floor upper beam assembly,
left/right door frame lower side beam inner plate assembly, rear main frame assembly, rear floor rear
block assembly, rear floor mid-block assembly and rear floor left/right side plate assembly etc. These
parts and components provide strong and reliable carry capacity and ensure that the vehicle meets the
strict driving requirement on the body
(3) Side Wall Assembly
The left/right side wall assembly is a frame structure, which is a side component that connects the front
and rear parts of the body. As shown in Fig. 1-4, it includes left/right side wall outside plate
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sub-assembly, left/right front post reinforced plate assembly, left/right intermediate post reinforced plate
assembly, left/right side wall doorframe reinforced plate assembly, left/right rear wheel cover assembly,
left/right front post inner plate assembly, and left/right intermediate post inner plate assembly etc
4
3
5
6 2
1
10
8
Front
4
5
3
2 6
1
7
10
Front
Fig. 1-4 Side Wall Assembly

1 Left/right front post inner plate assembly 2 Left/right front post reinforced plate assembly 3
Left/right intermediate post reinforced plate assembly 4 Left/right intermediate post inner plate
assembly 5 Left/right side wall outer plate sub-assembly 6 Left/right rear post inner plate
assembly 7 Left/right rear combination lamps reinforced plate assembly 8 Left/right rear wheel
cover inner plate assembly 9 Left/right rear wheel cover outer plate 10 Left/right side wall
reinforced plate assembly
(4) Rear Wall Parts
` 449
As shown in Fig.1-5, the rear wall assembly includes rear wall plate, rear wall reinforced plate, back door
lock mounting plate etc.
Fig. 1-5 Rear Wall Assembly

1 Rear wall upper beam
assembly
2 Rear wall plate sub-assembly
1
2
It is mainly used as a cross beam to improve the strength of the rear part of the vehicle and form a
luggage compartment door.
(5) Roof Assembly
The roof assembly includes roof outer panel, roof No. 1, No.2 cross beam assembly and roof rear cross
beam assembly etc. Inside the roof, there is top interior decoration. There is a heat insulation pad in the
center and there is bond between the cross beam and the roof. The rain from the roof is discharged out
of the rear part through the channels at both sides. These cross beams are used to reinforce the roof's
transverse stiffness. For disassembled parts, see Fig. 1-6.
4
2
3
Fig. 1-6 Roof Assembly

1 Roof outer panel 2 Roof No. 1 cross beam assembly 3 Roof No. 2 cross beam 4 Roof rear cross
beam assembly
` 450
B. Movable Plate Work

(1) Engine Hood & Front Fender
The engine hood is used to protect the engine and fit the vehicle design. It is also helpful to the repair
and maintenance, and isolates the engine's noise. The engine hood has a double-lock device. The
unlocking function of the first locking is controlled by the cable handle under the instrument board. The
unlocking function of the second locking can raise the hood to a certain height and pluck lock hook by
hand when the first locking has been opened. The second locking which uses double-locking is designed
in consideration of safety. Especially when the vehicle is running at a high speed, it can prevent the
engine hood from being raised, which may cause traffic accident. The maximum angle at which the
engine hood opens is 84°(See Fig. 1-7,1-8)
3 5 7
6
4
Fig. 1-7 Engine Hood
1 Engine hood outer plate 2 Engine hood hinge fixing plate
3 Engine hood right hinge 4 Engine hood lock
5 Engine hood lock fixing plate 6 Engine hood left hinge 7 Cover support lever fixing bracket
Max opening angle is 84°

全开时84°
Fig 1-8 Engine opening
` 451
(2) Fender
For the match relationship between the fender & engine hood and the front door, see Fig.1-9
Engine
发动机罩 hood
fender
翼子板
fender front
前车门 door
翼子板
Fig 1-9 Front fender relative section

+1.0 +1.0
A) With Engine Hood ( 4.0−0.5 mm) B) With Front Door ( 4.0−0 mm)
(3) Door Assembly

The door uses stopper、hinge、front hinge and rear opening which is an open structure.
The door includes door outside plate, door inside plate, bumper and hinge reinforced plate etc.
The door has a complex structure, which is a movable component on the body. It helps the passengers
get on/off the vehicle and form an enclosed cabin with the body main structure and the relevant parts.
Meanwhile, the doors are used frequently, so there is high requirement on their reliability and durability.
The outside/inside plate is molded by one complete steel sheet, which can improve the stiffness and
precision. In order to improve the safety when the vehicle is collided from the side, four doors are
equipped with door bumpers.
As shown in Fig. 1-10 and Fig. 1-11, the door plate assembly is made up of outside plate assembly and
inside plate assembly.
` 452
13
1
14
6
2
3 4
12 5
7
11 10
8
9
Fig. 1-10 Front Door plate
1 Front door lower hinge assembly 2 Front door upper hinge assembly
3 Mounting bolt 4 Front door inner plate lock mounting panel
5 Front door inner panel hinge reinforced plate 6 Rear door glass rail
7 Front door inner panel 8 Front door outer panel
9 Door bumper assembly
` 453
3
1 2
4 5
7
8 6
9
Fig 1-11 Left rear door (open from side)

1 Left rear door inner plate 2Left rear door glass mounting bracket fixing plate
3 Left rear door outer plate 4 Left rear door handle bracket
5 Door lock reinforced plate 6 Left rear door upper hinge
7 Left rear door hinge reinforced plate 8 rear door bumper assembly
9 Left rear door lower hinge
` 454
Body—Body repair—Body Damage Forms and requirements For Repair
Part 2 Body Repair
I. Body Damage Forms and requirements For Repair
A. Damage Type
The damage type includes deformation, crack, rust-through, water leakage, dust leakage and the like
caused by collision, overload, fatigue, and corrosion. The body damage is not merely caused by the
huge force. As some parts (such as door etc.) are damaged, the vehicle stays in an abnormal status,
which also can cause damage. In most cases, the bend and torsion is caused by huge local load in the
impact or turnover accident.
Typical Body Damage
1. Front Center Collision (Fig. 2-1)
Fig. 2-1 Front Center Collision

For the damage caused by the collision on the front center, it usually makes the engine compartment
front part and the engine hood left/right side extend inwards so the following positions shall be checked:
a. Ambience of the left/right assembling position of the hood plate
b. Ambience of the joints of the front cross beam and the left/right longitudinal beam
455
Body—Body repair—Typical Technique of Body Panel Repair
2. Front External Force or Left External Force (Fig 2-2)
Fig 2-2 Front External Force or Left External Force

As shown in Fig. 2-2, when the front is pressed or the left side end is acted by the external force, the
external force will spread to around the front suspension mounting position from the left/right side of the
hood, so deformation occurs easily in this position.
3. External Force Having an Angle with Vehicle Centerline (Fig 2—3)
Exter
nal
Force
Fig 2-3 External Force Having an Angle with Vehicle Centerline

As shown in Fig. 2-3, when the vehicle is acted by an external force having an angle with its centerline,
the force will affect the hood root and the front window side post if it is strong enough.
` 456
4. Body Center Acted by External Force in Upright Direction (Fig 2—4)
force
External
Fig 2-4 Body Center Acted by External Force in Upright Direction

As shown in Fig. 2-4, when the body side center is acted by an external force in the upright direction,
check the following positions:
a. Front window side post upper/lower installation position;
b. Side window intermediate post upper/lower installation position;
c. Side window rear post deformation;
d. Distortion of the roof and top frame.
When the body is acted by an external force on the rear part, its damage is the same as that caused by
an external force on the front part. Check the parts in full consideration of the rear structure and feature
` 457
B.General repair rule Windshield covering
1. Precaution
(a) Vehicle Protection
In the welding process, make sure to protect the
paint, windshield, seat and carpet with
heat-resistant and fireproof covering. Seat covering
(b) Safety Measures

(1)When pulling the body or crossbeam with
drawing device, do not stand at the position in the
same line of the drawing cable, and make sure to
use safe cable.
(2)Before repairing, make sure to check whether
Wrong
there is any leakage. In case of any leakage hole,
remove it immediately.
(3)When welding near to the oil tank, make sure
to remove the oil tank first, and block the oil pipe.
(c) Protective Article
In the repairing process, make sure to wear
uniforms, safety helmet and safety shoes. In
Wrong
addition, according to the different work types,
wear proper gloves, welding mask, goggle,
earplug, face cover, and dust respirator etc. Wear
the protective devices properly as the table below
Fig 2-5
Code Item
A Dust Respirator
B Mask
C Goggles
D Safety Shoes
E Welded Goggle
F Earplug
G Welded Mask
H Welded Gloves
` 458
C. Correct & Efficient Repair

1. Removal
(a) Measure dimension before removal
Before removal and cutting operation, make
measurement as the body dimension drawings.
Make sure to pull the damaged body or
crossbeam with drawing device.
Cutting position
Reinforced plate
(b) Cutting part
When working on the cutting part, make the
cutting in a straight position without reinforced
plate. Bend position
(c) Boring/cutting precaution

In the boring or cutting operation, make sure
whether there is any oil pipe or cables etc on its
back side, otherwise they may be damaged.
Wrong
(d) Removal of ambient components
When removing the ambient components, make
sure to adhere protective tape on the body and
disassembly tool to prevent the body or ambient
components being damaged.
Fig 2-6
` 459
2. Installation Preparation
(a) Precaution
smaller than 3mm
When the steel plate to be welded exceeds 3mm (0.12 in)
thick, make hole-filling welding with MIG(Metal Inert Gas)
welder. Tips: If the total thickness exceeds 3mm (0.12 in),
the spot can not provide adequate welding strength
(b) Apply special paint for point welding

Remove the paint film from the new parts to be welded and
the body, and apply the special paint for point welding
(c) Hole drilling of hole filling welding

(1) As for the location where can’t apply point welding, drill
hole or drill bit to apply hole filling welding
Reference: mm (in)
Welding steel plate Hole Diameter Hole filling

Thickness
<1.0 (0.04) >5.0 (0.20)
1.0 (0.04)-1.5 (0.06) >6.4 (0.26)
>1.5 (0.06) >8 (0.31)
(d) Precaution for electronic parts

(1) In the welding process, the electronic parts may be
damaged due to the current in the body.
(2) Before the welding, cut the cathode connection of the
storage battery, and put the ground end of the welder on Pneumatic saw Overlap
the ambiance of the welding area
(e) Rough cutting of joint parts
(1) In the rough cutting process in the connecting area, an
overlap of 20~30 mm (0.79-1.18 in) must be reserved on
the new parts
Fig 2-6, Fig 2-7
` 460
3. Installation
(a) Measure before Welding
Before installing the lower body or the parts of the
engine compartment, make sure to make
measurement as the body dimension drawing to
Body dimension
ensure the correctness. After the installation, drawing
reconfirm whether the assembling is proper.
(b) Precaution
(1) For the number of point welding, it depends on
the following principles.
Point welding: 1.3 times of the number specified
by the manufacturer
Hole-filling welding: more than the number Wrong
specified by the manufacturer
(2) When carrying out the hole-filling welding,
MIG welder shall be used. It is not allowed to use
the oxyacetylene welding or braze welding
outside the specified area
(c) Abrasion after welding
(1) After the welding, make sure to check the
Correct Wrong
welding position whether it is welded firmly.
(2) When abrading the welding position with disc
abrader, never abrade it too much, which may
weakens the strength of the welding position
(d) Position of point welding
(1) In the point welding process, overlap with the
old welding position shall be avoided
Point welding head
(e) Precaution of point welding scraper
New welding position

(1) The shape of the point welder head may affect
the strength of the welding. Old welding
position
(2) Make sure to remove the paint film on the
surface of the point welding and the contact
surface of the welder head.
Fig 2-8
` 461
4. Anti-rust Processing
(a) Apply body sealant Sealant gun
In the waterproof and antirust part operation,

make sure to apply the sealant on the joint of the
steel plates, door and engine hood pleat corner.
(b) Apply first coat

In order to prevent rust and protect the body steel
plate from being damaged by the bouncing stone,
sufficient first coat is applied onto the body base
and inner fender trim.
(c) Apply antirust (wax)

In order to prevent the painting part from rusting,
sufficient antirust is applied on the engine cover,
door inner corner, hinge ambiance, or in the
inside welding part of the box section structures
such as side beam, body post.
Fig2-9
` 462
5. Anti-rust Processing of Painting (a) Anti sandstone impact-proof Coat

In order to avoid corrosion and Apply the anti sandstone impact-proof coat on the
protect the body from being
damaged by bouncing stone on Impact-proof coat
the road, a layer of anti Surface paint
sandstone impact-proof coat is Intermediate priming
applied on the door panel, fender Electrophoresis primer
trim area and balancing plate etc.
Steel sheet
Tips: There are two types of
painting: anti sandstone Apply the impact-proof coat on the electophoretic primer
impact-resistant coat on the
Surface paint
electrophoresis first coat or on the
Intermediate primer
surface paint according to
different types and painting Impact-proof coat
positions. (See Fig. 2-10)
Electophoretic primer
Steel sheet
Fig 2-10
D. Repair Requirement
1. As the body is an integral carrying structure and the steel panels used are not thick, special attention
shall be paid to reinforce the parts acted in the reshaping process in the plate work processing. For the
parts that burden the stress intensively, measures shall be taken to lower the partial stress.
2. After the plate work processing, note to apply the antirust first coat on the inside and outside surfaces
to avoid corrosion.
3. In the body repair process, repair the old parts; or remove the parts with serious defects and order
new parts from the manufacturer.
4. When making body reshaping or parts welding, make sure that all main control points of the body are
within the specified scope in the design.
5. The strength and durability of the repaired body shall not be lower than those of the new vehicle.
6. The outside decoration of the repaired body shall meet the requirements by the new vehicle body and
the drivers in various aspects, such as modern aesthetics and ergonomics etc
II. Typical Technique of Body Panel Repair
Repair Process Flow:
Exterior Remove Remove Appraise

Inspection and Paint
Appraisal
Plate work Assemble Paint

Repair
` 463
Body—Body repair—Repair after Body Damage
III. Repair after Body Damage
The body damage repair includes rectification, reshaping, reinforcing, partial change, and complete
replacement. Generally, CO2 gas welding method is used.
A Reshaping Repair
1. Rectification
In general, the deformation of body is caused by accident. It can be rectified in a supporting method. In
the rectification process, apply the force in the direction against the force of accident or deformation. In
most cases, cold rectification can be used. Partial heating can reduce internal stress, and the
corresponding processing shall be carried out.
For the sedan, it is preferred to rectify it with the body rectification machine. All dimensions and
tolerances of all parts shall be returned to the original standard, so the power performance, economic
performance and comfortableness can be guaranteed. (Fig.2-11)。
Fig 2-11 Mounting Bench of Universal Dressing Machine

The body repair starts from the primary rectification or rough rectification. The deformation can be
removed with the supporting method. The angle of the supporting force shall be close to the angle of the
external force that caused the damage. Apply a counterforce at the back of the pulling force point to
adjust the supporting force. Make measurement on the deformation generated in the supporting process.
To remove the internal stress, heat the corresponding parts. For different rectification methods, see
Fig.2-12.
464
Fig 2-12 (a) Drawing Rectification
Fig 2-12 (b) Drawing & Supporting

Rectification
Gasket
Fig 2-12 (c) Auxiliary Force-receiving Point Rectification
2. Reinforcement
When the partial damage, rupture or crack occurs on various components, repair can be made by
reinforcement. Especially for those parts on which damage occurs frequently, special reinforcement
measures shall be taken. However, random reinforcement or welding component shall be avoided,
which may affect the body's status.
The reinforcement includes insert reinforcement, patching reinforcement, arc inlay angle, and angle
plate reinforcement.
3. Partial Removal & New Parts Replacement
For the parts with serious corrosion, they must be removed partly. For the ruptured parts, they shall be
replaced entirely. For the posts manufactured with thin plate by punch, they shall be ordered from the
` 465
manufacturer. When the molding is made by self, all specifications (including material, section
dimensions and thickness etc.) shall meet the original design requirement. For the ruptured post
(including cross beam), if it is replaced entirely, it must be connected in the same manner as that of the
original post.
B. Repair for Body outside Panel

1. Damage Type
① Crack & Rupture
In the running process, the body vibrates continuously and burdens the alternate loads. When the
vehicle happens to abrupt acceleration, sharp curve and emergency brake, the body will keep in an
inertial status. When the vehicle runs on the rough road, bend and distortion will happen on the body.
Affected by these external forces for a long time, crack and rupture may occurs on the stress
concentrated parts and weak structure on the body outside plate.
The stress mostly concentrate on the corner, edging and narrow part of the outside plate, so crack and
rupture often occur on these parts.
② Corrosion
The corrosion on the body outside plate is mostly caused by the mud water on the metal surface. Only in
special case, it results from the chemical corrosion by chemicals. When the corrosion occurs, rust may
appear on the outside plate and fall gradually, resulting in a drill hole and expand gradually. On the skirt
outside plate and roof drip channel, corrosion usually occurs on the seams between door and frame and
the interlayer between the outside plate and the bar frame.
③ Center-pente
The center-pente is mainly caused by collision and extrusion. For the light center-pente damage, the
metal doesn't extend, which is plastic deformation. If the collision or extrusion is serious, the metal outer
plate will be rupture. For the vehicles running in the city, it is common that scuffing damage occurs on the
side wall outer plate.
④ Bend & Distortion
Bend and distortion belong to mechanical damage. Bend and distortion may have a variety of causes,
such as collision or extrusion of body, alternating loads generated by the vibration, abrupt acceleration,
emergency brake, sharp curve and body torsion caused by poor road.
For the light distortion, it shall be confirmed by test. For the serious bend and distortion, it is obvious in
the appearance. Generally, the distortion can be fixed according to the clearance of the frames and the
change of their relative positions.
⑤ Sealed-off
The sealed-off is caused by the poor fusion between different metal plates.
2.Outside Plate Repair
① Repair for Crack
(a) CO2 Welding

The crack on the metal outside plate can be repaired by CO2 welding. In the welding process, align the
two metal plates, and weld the outside crack of the plate first. If the crack doesn't exceed 50mm, the
welding shall start from the rear part of the crack and continue along the crack and edge. If the crack is a
little longer, several points shall be welded first at a certain space. After welding several points, finish
` 466
them and then weld the crack block by block. By doing so, it can prevent the seaming metal over
roasting and plate curling deformation caused by too high temperature.
If the crack is located in the position that burden heavy force and it is convenient to carry out the welding
operation, a double-welding method can be used. After the point welding fixation is made outside, carry
out the welding inside firstly. After the inside welding is completed, weld a seaming outside uniformly in
the same manner.
After the welding, put a block inside, and beat from the outside weld seaming line with hammer to
remove the retaining stress. Finally, patch the welding seam properly to make it even and smooth for
paint repair.
(b) Welding solder filling repair
For the small rough plate which is not easy to repair with damage and crack on its surface, it can be
repaired with a welding solder filling method. (Fig.2-13）。
Fig 2-13 Concave Body Filling Repair
② Repair for Outside Partial Damage
For the partial corrosion or serious mechanical damage on the outside plate, if it can't be repaired in
common method, the patching or pasting repair method can be used.
Repair Method
(a). Fix the patching scope;
(b). Cut the paper template;
(c). Cut the plate as per the template;
(d). Adhere the molded plate on the surface of the patching part;
(e). Line out the profile along the plate edge with needlepoint, and cut off the damaged or corroded part
along profile line.
(f). Flatten the cut edge with hammer or block, and remove the burr with file to make sure that it is
aligned with the both side alternative plates with a clearance not more than 1mm;
(g). Replace the plate, and clamp it with crampon. Fix the point welding along the seam at a space of
approximately 50mm;
(h). Apply sectional welding method to make the welding from the center to both sides alternately block
by block firstly. Which can reduce the deformation;
(i). Strike the welding line with the hammer or block to remove the retaining stress. Polish the welding
line with the file or manual grinding wheel to make it even and smooth for the painting.
③Repair for convex concave damage of outer plate impact
` 467
(a) Plate work flattening

When the convex concave damage occurs on the plate work of the body, it can be repaired by means of
knocking. In the repair process, start from Point C as shown in Fig. 5-14. Put the block on the convex
point, and knock it with the hammer and change the block's position correspondingly. When the convex
point is flattened, the concaved part in Point B will rise. Similar with the original profile of the plate, for the
remaining dent, a block with the same radian can be used. Press the bottom of the plate with hand, and
knock the high point of the dent with the hammer. (Fig. 2—15）。
Fig.2-14 Plate Work Flattening (I)

A. Impact point B. Concaved point after impact
C. Convex point after impact
Fig. 2-15 Plate Work

Flattening (II)
A. Hammer B. Plate work
C. Block
In the knocking process, knock heavily at the

beginning and lightly at the end. Attention
shall be paid to reduce the number of
knocking as possible as it can. Don't knock
the same points repeatedly to prevent the
metal plate extending partial, which can
complicate the repair work.
Fig. 5-27 Heating & Planishing Convex Point
For the larger arc concave, a block can be
1 Heating point
used under the center of the concave. The
area of the block shall be a little larger. Jack the concaved plate up with a supporting tool. Sometime,
heat the concaved part to dark red to reduce the force. When jacking the plate up, a little excess is
acceptable. (Fig.2—16）。
(b) Thermal contraction

When the concave is jacked up, if the plate extends seriously and the convex area is large, the thermal
contraction method can be used in case that the traditional methods don't work. (Fig.2－17)。
Heat it to cherry red with oxyacetylene flame. The heating scope depends on the degree of extension. If
the extension is serious or the area is large, the heating point shall be larger relatively (diameter: approx.
20-30 mm). If the extension is not serious or the area is small, the heating point shall be a little smaller
(diameter: approx. 10-15 mm). After the heating, knock the heating point immediately. In the knocking
process, a proper block is used under the plate. After it is cooled down, knock it lightly with the hammer.
The contraction sequence starts from the highest point to the center, and then to the edge. Heat and
flatten the extended part repeatedly till the plate is flattened fully. If the convex part is too high, compress
it to one half of the original height. After it is cooled down, heat it at the original heating point till the other
half of convex part is removed.
` 468
Heating
Compress
load Cooling
Extend load Plate work

Metal bar thermal thermal contraction
contraction
Fig 2-17 Thermal Contraction Method

For those parts that are not sure whether they will contract or not, the thermal contraction method shall
not be used to avoiding any side effect. Especially for those thin plates, great attention shall be made to
prevent them from melting down or burning through.
(c) Welding ring method
The welding ring method is used to repair the most seriously damaged part of the concave on the plate
work surface. Some rings are welded to connect the rods. (Shown as Fig. 2-18) When the area of the
concave is large, several rings can be welded in a parallel manner, and gets through the rod to make the
pulling force act on the plate surface evenly. The ring can be replaced by the washer. The rod drags the
washer or shaft through a connecting device. After the concaved plate is flattened by the inertia hammer
puller, remove the ring or washer and grind the welding points.
Rod
Washer Shaft
Shaft Shaft
Washer
Washer
Fig 2-18 Welding Washer Stretching

In addition, there are some other repair methods, such as knocking repair (Fig. 2-19), plate reshaping
repair (Fig. 2-20), damaged plate work cutting repair (Fig. 2-21) and welding point cutting repair (Fig.
2-22).
` 469
Sizing block
Use block
Knife
Knife Fig 2-19(d) Flat Surface Repair
Fig 2-19 (a) Beating Repair

Steel plate
Hammer
Knock out Knock
Block Block
Finish Knock Hammer
Block
Fig 2-20(a) Knocking Modification

Fig 2-19 (b) Direct Knocking
on Deformed Surface
File
Check Plate surface
evenness
Flexible file
Fig 2-19(c) Edge angle Repair Fig 2-20(b) Check Slight Roughness with File
` 470
Brush
Welding position
Cutting line
Determinate position
of welding point
Fig 2-21(a) Cutting with Gas
Fig 2-22 (b) Drill Welding Point with

Cutting line Common Drill bit
Electric drill Drill bit

h d
Damaged body
Removable piece
Mill welding point

Fig 2-21(b) Cutting with Saw
Welding point
Wedge
Flat blade drill
Mill welding point Separate Fig 2-22 (c) Separating example of

Welding Point
Fig 2-22 (a) Milling Welding Point of

single plate with Flat Blade drill
` 471
Grinding wheel
Welding seam
Grinding wheel
Welding seam
Fig 2-22 (d) Separating Of Welding Joint

If the collision is not serious and the concave belongs to elastic deformation, the plate can be returned to
its original shape by pressing from the inside surface.
For some concaved parts, they can be repaired in a prizing method. The prizing method is a repair
method that needs not to disassemble the parts. According to the degree of deformation, repair the plate
by means of various clearances and the lever principle. As the prizing method doesn't disassemble the
parts, it can keep the original installation quality and improve the work efficiency.
④ Repair for Unsoldering of plate
The unsoldering of outside plate is mostly caused by the poor fusion between the welding wire and the
metal plate surface. For the common unsoldering, weld the metal plate again after removing the welding
wire accumulated in the welding seam. For the unsoldering of the point weld, weld the metal plate near
the unsoldered point with a single-side point welder. The new welding point is about 10-15 mm from the
original point. Before the point welding, remove the oil dirt and rust in the welding point to ensure the
plates are jointed in a good status.
For the unsoldering in some edging parts, after the two plates are jam jointed, weld the plates in gas
spasmodically on the edges to make the plates joining together. The welding seam at every block is
about 30 mm long. The weld seam space depends on the original welding point space.
Another repair method for the unsoldering is plug welding. This method needs CO2 welding. Bore a dia.
6mm hole on the outside plate, and then joint the two plates. Weld the hole leveled with the CO2 welding
method. In the welding process, the welding wire shall point to the inner plate and move in a circling
motion, which can make the inner and outside plates welded together. After the welding, grind and paint
it.
` 472
Body—Body Repair—Features and Composition of Automobile Body
IV. Features and Composition of Automobile Body
A. Body Feature
The body is an integral structure. Its main structure also is a frame, which can carry all loads. The vehicle
is designed with three compartments and five doors. With the same overall length, the space is utilized
fully, which is helpful to arrangement of passengers. (Fig. 2—23）
1465
1630 718 2340 540

3598
Fig 2-23 Outline dimension

1. Material of stamping
In order to improve the body's rigidity, high-strength steel plates are used at many key parts on the body.
For the parts under forces, reinforced measures are carried out. (Fig.2—24）。
1
2
3
Fig 2-24 High-strength Steel Panel
1 Engine compartment hood outside panel 2 Left/right fender
3 . Left/right mid-door post inside panel
4 Left/right door outside panel
2. Shock Absorption & Noise Isolation
473
① The measure of body structure
a. Arrange the reinforced bar reasonably to improve the parts' rigidity, reduce the shock and lower the
noise.
b. Apply the sealant in the floor seam to improve the floor sealing and reduce the noise in the cabin (Fig
2—25)
Fig 2-25 Front Wall Panel

1 Front wall gangway reinforced panel 2 Front wall lower main frame
3 Front wall panel
② Apply sound insulation material to reduce noise
It is an interactive and systemic work to make the body isolate heat, shock and noise. Besides the
measures carried out to improve the body's stiffness and sealing performance, the following measures
shall be taken in the design and manufacture process:
a. Sound insulation material: add sound insulation pad on the front wall and floor.
b. Sound absorption material: add molded carpet on the front floor and rear floor.
3. Sealing
Special consideration has been given to the sealing of the body both in design process and in
manufacture process. Sealing plays an important role in many aspects, such as dust resistance, water
resistance, corrosion resistance, heat resistance, heat preservation, and noise reduce etc. Especially
when the body floor and front wall stay in a tough external condition, the mud, dust, noises (from the tire
and engine) and hot air will invade into the cabin any time.
After the body assembly is welded, sealant will be applied on all joints to prevent the water and steam
penetrating into the metal seam and ensure the quality of subsequent painting.
In addition, a thick layer of impact-proof PVC coat is applied on the base of the body, which has excellent
sealing performance. For the sealing to those assemblies, the traditional sealing method is used, such
as rubber seal ring, cover, tape and dust resistance etc. But these parts are more precise both in design
process and in manufacture process. For those contact seal pieces, the two-way dimension relation is
more reliable. For the front windshield and rear wall glass, a naturally hardened high-strength sealant is
used, whose reliability and practicability reach the state-of-the-art level.
` 474
Front
Fig 2-26 (a) Body steel plate bottom

1 Front mud guard 2 Rear side wall 3 Rear wheel cover
` 475
Apply sealant
Apply sealant
Apply sealant
Fig 2-26 (b) Engine Compartment
` 476
Apply sealant
Apply sealant
Fig 2-26 (c) Body Inside (I)
` 477
Apply sealant
Fig 2-26(d) Body Inner (II)
` 478
Apply sealant
Apply sealant
Fig 2-26 (e) Trunk
` 479
Apply sealant
Apply sealant
Apply sealant
Apply sealant
Apply sealant
Apply sealant
Fig 2-26 (f) door
` 480
Apply sealant
Apply sealant
Fig 2-26 (g) Engine hood
` 481
Engine hood
Engine hood hinge
Door
Front door upper hinge Rear door upper hinge
Front door lower hinge Rear door lower hinge Oil tank cap
Fig 2-26 (h) Antirusting agent Position on Body Steel Panel
` 482
Fig 2-26 (i) Filling Position of Foaming Material
PVC Impact-proof Sandstone

PVC抗沙石撞击涂料
coat
Fig 2-26 (j) Coating Position of Impact-proof Sandstone of Body steel panel
` 483
Body —Body Repair—Features and Composition of Automobile Body
4 Surface Treatment of Body

Surface treatment shall be strict, careful and considerate. Though this car is not a sedan, it nearly has no
difference with the deluxe sedan in the surface treatment.
① Phosphoric acid processing
Phosphoric acid processing is also called pretreatment before painting. After degreasing on the body by
washing, apply zinc phosphate onto the body, with a thickness under 3 µm can protect the first layer but
also can help to increase adhesion in the next painting process
②Cathode electophoretic
In the practical application, the electrophoresis coating shows many advantages, such as high efficiency,
good quality, safety and cost effectiveness. It is accompanied with four electrochemical phenomena
including electophoretic, electrolytic, electrowinning and electro osmosis. The cathode electophoretic is
much better than the anode electophoretic both in the features and advantages. Incomparably, the
technology process is strict extremely.
③ Intermediate coat
The intermediate coat is also called intermediate layer, which is located between the priming paint and
the surface paint. It’s function is to improve the evenness of the painted work piece and the priming paint
single layer and provide the surface paint with a good base to improve the paint's brightness and
richness and improve the decoration of the entire coating.
④ Surface paint
The surface paint is the last coat in the multiple coats, which directly affect the vehicle's decoration,
weatherability and appearance etc. Great attention shall be made when selecting the surface paint,
including its adaptability, cost-effectiveness and usability. All performance indexes shall meet the
national standard and industrial standard. The paint shall be even and smooth.
⑤ Protective coat storage
For those vehicles parked outside for a long time (more than three months) or used for marine
transportation, water-soluble protective wax shall be applied on the outside surface of the body. This
agent contains ultraviolet radiation absorbent. Before selling the vehicle, wash it with soap detergent and
flush it with clean water, to make the paint brighter.
` 484
V. Painting Techniques After Body Repair
In the practical use, various factors may cause painting damage, such as traffic accident, component
rust, premature damage due to bubble, and partial color change etc. It is necessary to make repair
locally as the following steps:
A. Base Processing (Pretreatment)
1. Remove the paint layer, and remove the coating on the plate work.
2. Cut the edges and corners, and polish the paint layer exfoliation of steel plate and the uneven paint
film at the edge.
3. Blow and clean the dust and dirt, and remove the grease with degreasing agent
B. Primer Processing
1. Paint priming paint and apply the self-drying priming paint on the bare metal surface.
2. Leave the priming paint drying naturally, or dry it with the infrared ray radiator.
3. Apply the self-drying oily putty or polyester putty on the plate work surface.
4. Leave the putty drying naturally or artificially.
5. Grind the putty manually to remove the uneven parts.
6. Grind it manually in water to clear the sand paper path.
7. Wash the dirt, grind the oil dirt , putty slurry and dry.
8. Wipe the oil dirt on the grinding surface.
9. Cover the part not to be repaired with protective shield or paper
C. Painting Intermediate Coat
1. Paint the second priming paint.
2. Leave it drying naturally or dry it.
3. Putty and find out the sand hole or sandpaper path.
4. Grind it manually in wet condition.
5. Wash the part clean, and leave it drying naturally. (The number of putty applying and grinding
depends on the evenness of the surface to be repaired.)
D. Preparing to Coat Surface Paint
1. Paste paper on the surface which is not to be painted.
2. Remove the dust and grease on the partial surface paint.
3. Mix the color the same with that of the vehicle's surface paint.
4. Mix the paint
E. Painting Surface Paint
1. Paint the part with fast-drying surface paint 3-4 times and synthetic resin paint 2-3 times.
2. Leave it drying naturally or dry it.
F. Polishing
1. After painting, burnish the part with wax to clear the shadow and improve the effect.
2. After painting, tear off the paper and wipe the ground paint.
3. Check the appearance and quality.
` 485
Body—Body Repair—Service Data for Body
VIII. Service Data for Body
A. Technical Repair Data (Table 1-1)
` 486
Table 1-1 Technical Repair Data

No. Section
序号剖面 Part
控制部位简 Drawing 图 No. Section
序号剖面 Part
控制部位简 Drawing 图
Engine Engine hood

hood and inner plate
发动机罩内板 Engine hood Fuel filler
LH fender outer
发动机罩外板plate lid and
加油口盖
LH/RH
发动机罩与
1 A-A 左/翼子板 8 H-H 与左/右
side wall
Fuel filling
侧围外板
Side wall
侧围
加油口盖
port outer plate

Fender
4±1
翼子板
Side wall LH/RH

outer panel rear door
and LH/RH assembly Rear door
fender Side wall sealing后车门密封条
strip
侧围外板与 outer plate
侧围外板 and
左/右后车 Rear door
2 B-B 9 J-J
LH/RH
+1
门总成与
0
左/右翼子板 inner plate

后车门内板
2.5
side wall Side wall

左/右侧围后车门外板
侧围外板
outer plate
翼子板
Fender Rear door 5.5± 1
outer plate
LH/RH front LH/RH Front Rear door

door Side 侧围外板
wall Rear door sealing
11±1
outer plate
front door Front 前车门总成 door
前车门密封条后车门总成
assembly strip
后车门密封条
assembly assembly door sealing5.5±1

and
左/右前车门 front 左/右前车 bl ti
前风挡玻璃 and
3 C-C windscreen
总成与前风
post Front door 10 K-K
门总成与
LH/RH
左/右后车
窗支柱前车门总成
assembly rear door
门总成
assembly
Side wall
侧围B柱总成
B pillar Front
assembly door
前车门总成 bl 后车门总成
LH/RH front Front

5.5± 1
Rear door
Roof
door trim Side wall door assembly
Roof outer 顶饰条侧围外板
assembly LH/RH bl
顶盖外板
panel strip outer panel

and upper front door
5
1.
2±
LH/RH side 5.5± 1 assembly

左/右前车
左/右前车
wall and
门总成与
11 L-L
4 D-D 门总成与
左/右侧围 Front
前车门总成
door
LH/RH
左/右后车
rear door
前车门密封条
assembly 门总成 Front door 后车门密封条

上部 assembly sealing strip
侧围外板
Rear door
sealing strip
Side wall
outer panel
侧围外板
Side wall outer
Roof panel 后车门外板
LH/RH rear 顶盖外板
outer LH/RH Rear door
outer plate
door
后车门内板
plate顶饰条 rear door

左/右后车
assembly Rear door
assembly
左/右后车 inner plate
5 E-E 门与左/右
and upper Roof trim and
门总成与 lower
12 M-M
后车门密封条
6±1.5
LH/RH
后侧围上部 side strip
LH/RH
左/右侧围 Rear door
wall side
后车门总成下部wall sealing strip 2.5±
1.5
Rear door
assembly Side wall 侧围外板
后车门总成 outer panel
前车门内板后车门内板
Front door Rear door

inner plate inner plate
Roof 顶盖外板
LH/RH
涂胶
asse 7 +1
0
背门外板
6 ±1.5
前车门密封条
mbly
顶盖总成顶盖后横梁加强板 Smear glue Roof outer plate front door
Back door outer plate 左/右前车
assembly Front door
and
6 F-F 与背门总 sealing strip 2.5 ±
1.5
门总成与
背门内板
Roof rear cross
back
成
beam reinforcement
l t 背门密封条
13 N-N and
左/右侧围
LH/RH
lower
door 顶盖后横梁 Back door inner plate
侧围外板
asse Back door sealing 下部 wall

side
Roof rear cross Side wall
mbly beam outer panel
前车门外板
LH/RH side 5± 1
Front door
wall and LH/RH outer plate
back door 后风挡玻璃
冻胶
左/右前车
front door
assembly Rear window
glass Jelly glue
侧围外板
14 P-P 门总成与
assembly 前车门密封条
前车门内板
左/右翼子
翼子板
背门外板
Side wall outer and Front door inner plate
panel 侧围外板
背门内板
LH/RH
板 Fender Front door sealing strip
左右侧围与 fender
7 G-G
Back door Back door Side wall outer panel
outer plate
背门总成 inner plate
后组合灯固定板连接板
Rear combined lamp fixing

plate joint plate
B. Supplemental Specifications on Tightening Torque (Table1-2)
` 487
For those fastening pieces either not specified in the "Body" part or not stated in other assemblies, the
following specifications shall apply.
Table 1—2 Supplemental Specifications for Vehicle Body and All Assembly Fastening Piece
Tightening Torque
Thread Pitch
Thread Dia (mm) Standard Value
(mm) Max. Value (N·m) Min. Value (N·m)
(N·m)
6 1 9 12 6
8 1.25 18 22 16
8 1 25 28 17
10 1.5 59 75 37
10 1.25 63 79 45
10 1 64 80 46
12 1.75 95 111 73
12 1.5 97 113 75
12 1.25 99 115 78
14 2 160 185 122
14 1.5 180 205 146
16 2 215 245 182
16 1.5 240 270 199
18 2.5 268 298 229
18 1.5 316 346 287
20 2.5 430 470 389
20 1.5 440 480 396
` 488
Appendix：Body Key Dimension
I. Engine Compartment
` 489
II. Body left/right side wall
` 490
III. Opening part of the body (view from back)
` 491
IV. Body bottom
` 492
Protecting
sleeve White
Terminal
Chassis harness assembly (deluxe)
F/PUMP GND/F
2 1
1
2
5 SENSOR GND/S 3
Harness diagram of LC model electronics
DJ7011-6.3-20
5 10
1 3
8 4
493
White
Terminal
F/PUMP GND/F
2 1
1
2
5 SENSOR GND/S 3
Chassis harness assembly (Standard)
DJ7011-6.3-20
5 10
494
Engine compartment harness assembly (1.0L manually)
495
Engine compartment harness assembly (standard, left-mounted manually)
DJ7021A-2.3-20
ALT
496
Engine harness assembly (3G10 manually)
一圈
497
Engine harness assembly (1.3L DELPHI system)
498
Rear door harness assembly
499
Rear door harness assembly (deluxe)
500
Rear door harness assembly (standard)
501
Door harness assembly at the driver’s side (deluxe)
502
Door harness assembly at the driver’s side (standard)
503
Rear wheel speed sensor
504
Door line assembly at front passenger's side (deluxe)
505
Door line assembly at front passenger's side (standard)
506
Instrument panel harness assembly (deluxe 1.0L manually)
20
10
DJ7022-6.3-20
11
30
30
r e la y
D e f r o s t d e la y
1
507
Instrument panel harness assembly (standard 1.0L manually )
20
10
DJ7022-6.3-20
11
30
30
r e la y
D e f r o s t d e la y
1
508
509
510

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LC Workshop Manual

GEELY INTERNATIONAL CORPORATION

Geely International Corporation

Chapter 2 Engine ........................................................................................ 15

Part 1 Engine Assembly.....................................................................................................15

Part 2 Engine Mechanical ..................................................................................................24

Part 3 Engine Control System (1.0L) .................................................................................35

Part 4 Engine Control System (1.3L Delphi MT20U2) .......................................................39

Part 5 Cooling System .......................................................................................................84

Part 6 Fuel System ............................................................................................................87

Part 1 Transmission Control...............................................................................................96

Part 3 Clutch Assembly....................................................................................................104

Part 4 Manual Transmission Assembly (1.0L).................................................................. 117

Part 5 Manual Transmission Assembly (1.3L)..................................................................134

Part 6 Drive shaft/Driveshaft ............................................................................................152

Part 7 Brake System ........................................................................................................163

Part 8 Wheel ....................................................................................................................209

Part 9 Power Steering System .........................................................................................210

Part 10 Front Suspension System ...................................................................................234

Part 11 Rear Suspension System ....................................................................................249

Chapter 4 Electric System & Accessory ................................................. 258

Part 1 Starting and Charging System...............................................................................258

Part 2 Wiper and Washer System....................................................................................264

Part 3 Combination Instrument System ...........................................................................269

Part 4 Audio System ........................................................................................................281

Part 5 Centralized Controller............................................................................................291

Part 6 Safety airbag system.............................................................................................299

Part 7 Air Conditioning System ........................................................................................346

Part 8 Reversing Radar System ......................................................................................374

Part 9 Light System .........................................................................................................377

Part 10 Switch System.....................................................................................................386

Chapter 5 Interior & Exterior Trim and Accessories.............................. 398

Chapter 6 Body ......................................................................................... 446

Part 1 Summarize ............................................................................................................446

Part 2 Body Repair ..........................................................................................................455

Appendix2 ：Harness diagram of LC model electronics ...................................... 493

Appendix3 ：Principle diagram of LC model electronics...................................... 509

Table of Basic Parameters

Table 2 Models and technical data of major systems

Parts No. Regularly Replacing Parts Interval

Parts No. Regularly Replacing Parts Interval

Inspection X1000km 7.5 15 22.5 30 37.5 45 52.5 60 67.5 75

Brake Reservoir level 〇 〇 〇 〇 〇 〇 〇 〇 〇 〇

Inspection X1000km 7.5 15 22.5 30 37.5 45 52.5 60 67.5 75

Inspection X1000km 7.5 15 22.5 30 37.5 45 52.5 60 67.5 75

Battery Status of joints 〇 〇 〇 〇 〇

Inspection X1000km 7.5 15 22.5 30 37.5 45 52.5 60 67.5 75

——Additional Maintenance Schedule

A-1. driving on bumpy, muddy or melted snow road

Check front and rear suspension devices Every 5,000km or 6 months

Part 1 Engine Assembly

1. Check the engine oil

(1) Check the oil level.

(3) Remove and replace oil filter.

(4) Tighten oil drain plug to specificated torque 54N.m.

(6) Screw on the oil filling cap.

(7) Start the engine.

3. Replace the oil filter.

(1) Remove the oil filter.

Brake Reservoir level 〇〇〇〇〇〇〇〇〇〇

Battery Status of joints 〇〇〇〇〇