smb00003287-ZP11MCE3AUS维修手册-英文 20180711

Service Procedures Manual
MG 3
The Service Procedures Manual provides information about the specification, system introduction, service procedure and
adjustment of the new MG 3 vehicle.
After mastering the content of this manual and materials in the service bulletins of SAIC Motor Passenger Vehicle Co., the
technicians of Authorised Repairers of SAIC Motor Passenger Vehicle Co. can provide better service for MG 3 vehicle
owners.
For relevant information about product brands, part number or special tools mentioned in this manual, we recommend
you to contact with SAIC Motor Passenger Vehicle Co.
SAIC Motor Passenger Vehicle Co.
All Rights Reserved.
Information is due in May, 2018
Without prior written approval from SAIC Motor Passenger Vehicle Co., no part of the manual shall be reproduced,
stored in retrieval system or transmitted in any form or by any means (including but not limited to electronic, mechanical,
photocopy and recording). The statement above applies to all texts, illustrations and tables.
How To Use This Manual NOTE statements emphasize a necessary characteristic of
General a diagnostic or repair procedure. NOTE statements are
designed to do the following:
To assist in the use of this Manual, it is divided into sections
and sub-sections. The relevant sub-section title is given at the • Clarify a procedure.
header of each page. • Present additional information for accomplishing a
procedure.
There is a single Contents section at the front of the Manual,
which is divided by section and sub-section. The book is • Give insight into the reason or reasons for performing a
numbered from page 1. The page number is given at the procedure in the manner recommended.
bottom of each page. • Present information that will help to accomplish a
procedure in a more effective manner.
The individual actions of the repair operations must be
followed in the sequence in which they appear. Item numbers • Present information that gives the technician the benefit
in the illustrations refer to the relevant numbered text under of past experience in accomplishing a procedure with
the illustration. greater ease.
Adjustment and repair operations include reference to Service TIP: Gives helpful information.
tool numbers and the associated illustration depicts the tool in References
use. Adjustment and repair operations also include reference
References to the LH or RH side given in this Manual are made
to wear limits, relevant data, torque figures, and specialist
when viewing the vehicle from the rear. With the engine and
information and useful assembly details. Each adjustment or
gearbox assembly removed, the crankshaft pulley end of the
repair operation is given a unique Repair Operation number.
engine is referred to as the front.
WARNINGS, CAUTIONS, NOTES and TIPS have the
Operations covered in this Manual do not include reference
following meanings:
to testing the vehicle after repair. It is essential that work
When encountering a WARNING, you will be asked to take is inspected and tested after completion and if necessary a
a necessary action or not to take a prohibited action. If a road test of the vehicle is carried out. This is of particular
WARNING is not heeded, the following consequences may importance where safety related items are concerned.
occur: Dimensions
• Serious bodily injury or death to the technician.
The dimensions quoted are to design engineering specification.
• Serious bodily injury or death to other technicians in the Service limits are included where applicable.
workplace area.
Our company are constantly seeking to improve the
• Serious bodily injury to the driver and/or passenger(s) of
specification, design and production of their vehicles and
the vehicle, if the vehicle has been improperly repaired.
alterations take place accordingly. While every effort has been
CAUTION call special attention to a necessary action or to a made to ensure the accuracy of this Manual, it should not be
prohibited action. If a CAUTION is not heeded, the following regarded as an infallible guide to current specifications of any
consequences may occur: particular vehicle.
• Damage to the vehicle.
• Unnecessary vehicle repairs.
• Unnecessary component replacement.
• Improper operation or performance of the system or
component under repair.
• Damage to any systems or components which are
dependent upon the proper operation of the system or
component under repair.
• Improper operation or performance of any systems
or components which are dependent upon the proper
operation or performance of the system or component
under repair.
• Damage to fasteners, basic tools, or special tools.
• The leakage of coolant, lubricant, or other vital fluids.
1.0 1
Repairs and Replacements
Parts
When replacement parts are required it is essential that only
our company’s recommended parts are used.
Attention is particularly drawn to the following points

concerning repairs and the fitting of replacement parts and
accessories.
• Safety features and corrosion prevention treatments

embodied in the vehicle may be impaired if other than
SMC recommended parts are fitted.
• Torque wrench setting figures given in this Manual must
be used.
• Locking devices, where specified, must be fitted. If the
efficiency of a locking device is impaired during removal
it must be renewed.
• The terms of the vehicle warranty may be invalidated by
the fitting of parts other than SMC recommended parts.
All SMC recommended parts have the full backing of the vehicle
warranty.
SMC Dealers are obliged to supply only SMC recommended

parts.
Special tools
Special tools have been developed to facilitate removal,
dismantling and assembly of mechanical components in a cost
effective and time efficient manner. The use of special tools
also helps prevent the potential for damage to components.
Some operations in the manual cannot be carried out properly

without the aid of the relevant special tools.
Special tools can be obtained from the following supplier.
Shanghai Runyue Industrial Development Co., Ltd
Address: Skirt Building, Lianhua Building, 159 Tianzhou Road,

Shanghai
Post Code: 200233
Tel: 021-54234810
1.0 2
Contents
General Information ........................... 1 Flywheel-MT ................................................ 66
General Information .............................................1 Crankshaft Pulley.......................................... 68
General Precautions ........................................... 1 Timing Chain Upper Cover Plate................... 69
Safety Instructions .............................................. 2 Timing Chain Lower Cover Plate................... 70
Environmental Precautions.................................. 3 Timing Chain................................................ 72
General Fitting Instructions................................. 5 Camshaft Cover ........................................... 74
Ball and Roller Bearings ...................................... 6 Camshaft - Intake or Exhaust ........................ 76
Oil Seals ............................................................ 7 Mechanical Tappet ........................................ 79
Joints and Joint Faces .......................................... 8 Valve............................................................ 80
Locking Devices ................................................. 8 Cylinder Head Assembly............................... 81
Screw Threads ................................................... 9 Cylinder Head Check ................................... 83
Fasteners Identification....................................... 9 Cylinder Gasket ........................................... 88
Flexible Pipes and Hoses................................... 11 Lower Crankcase ......................................... 89
Fuel Handling Precautions................................. 12 Connecting Rod Bearing Shell Check............. 90
Electrical Precautions ....................................... 13 Piston Check................................................ 91
Supplementary Restraint System Crankshaft Check......................................... 92
Precautions...................................................... 14 Rear Crankshaft Oil Seal ............................... 94
SRS Component Replacement Policy................. 20 Oil Strainer .................................................. 95
Air Conditioning System Precautions ................ 21 Oil Pump ..................................................... 96
Air Conditioning Compressor Oil Control Valve ......................................... 97
Replacement .................................................... 23 Engine Oil Filter ........................................... 98
Vehicle Identification Number ...........................24 Engine Oil Pressure Check............................ 99
Vehicle Identification Number........................... 24 Intake Manifold Gasket.................................. 99
Position Of Other Plates .................................. 25 Exhaust Manifold Gasket ............................. 102
Lifting & Towing...................................................26 Cylinder Pressure Test ................................ 103
Lifting .............................................................. 26 Special Tools .................................................. 104
Roadside Assistance ......................................... 27 Engine Cooling System .....................................106
Lubrication & Maintenance ................................29 Specifications ................................................. 106
Capacity .......................................................... 29 Torque ....................................................... 106
Fluid ................................................................ 29 Parameter .................................................. 107
Lubricating Fluid............................................... 30 Description and Operation............................. 108
Engine................................................. 31 System Layout ............................................ 108
Description ................................................ 110
Engine Mechanical...............................................31
Operation .................................................. 112
Specifications ................................................... 31
Service Procedures......................................... 114
Torque ......................................................... 31
Coolant - Drain and Refill ........................... 114
Parameter .................................................... 33
System Pressure Test .................................. 115
Description and Operation............................... 41
Pressure Seal Cap - Pressure Test................ 116
System Layout .............................................. 41
Coolant Expansion Tank.............................. 116
Description .................................................. 54
Cooling Fan................................................ 117
Operation .................................................... 56
Cooling Fan Low Speed Resistor ................. 117
Service Procedures........................................... 58
Radiator..................................................... 118
Powertrain Remove and Refit - AT ................ 58
Radiator Water Inlet Hose.......................... 119
Powertrain Remove and Refit - MT ............... 61
Radiator Water Outlet Hose ...................... 120
Powertrain Mount ........................................ 64
Engine Overflow Pipe - 1.5L........................ 120
Torque Converter Drive Plate - AT ............... 65
1.0 1
Contents
Heater Water Inlet Hose ............................ 121 Fuel System - Pressure Relief - 1.5L ............. 155
Heater Water Outlet Hose......................... 121 Fuel System - Pressure Test - 1.5L ............... 156
Radiator Drain Valve................................... 122 Tank-Drain & Refill ..................................... 157
Radiator Upper Shock Pad .......................... 122 Filler Neck ................................................. 157
Radiator Lower Shock Pad .......................... 123 Electronic Throttle Self-learning - UMC
Wind Scooper - Left................................... 123 System ....................................................... 158
Wind Scooper - Right ................................. 124 Special Tools .................................................. 159
Thermostat - 1.5L ...................................... 124 Engine Manifold & Exhaust System .................160
Water Pump............................................... 125 Specifications ................................................. 160
Transmission Oil Cooler Inlet Pipe Torque ....................................................... 160
Assembly - 4AT .......................................... 126 Description and Operation............................. 161
Transmission Oil Cooler Outlet Pipe System Layout ............................................ 161
Assembly - 4AT .......................................... 126 Description ................................................ 163
Special Tools .................................................. 127 Operation .................................................. 164
Engine Fuel & Management .............................128 Service Procedures......................................... 165
Specifications ................................................. 128 Air Filter Assembly ..................................... 165
Torque ....................................................... 128 Air Filter Element ....................................... 165
Parameter .................................................. 129 Air Inlet Pipe Assembly ............................... 166
Description and Operation............................. 130 Electronic Throttle ..................................... 166
System Layout ............................................ 130 Front Exhaust Pipe Assembly ...................... 167
System Control Diagram............................. 131 Rear Exhaust Pipe Assembly........................ 168
Description ................................................ 133 Exhaust Passage Heat Shield........................ 169
Service Procedures......................................... 141 Fuel Tank Heat Shield ................................. 169
Spark Plug .................................................. 141 Engine Electrical System ..................................170
Ignition Coil ............................................... 141 Specifications ................................................. 170
Engine Control Module (ECM) .................... 142 Torque ....................................................... 170
Engine Coolant Temperature Sensor Description and Operation............................. 171
(ECT) ........................................................ 142
System layout ............................................. 171
Engine Oil Temperature Sensor ................... 143
Description ................................................ 172
Crankshaft Position Sensor ......................... 143
Operation .................................................. 174
Camshaft Position Sensor ........................... 144
Camshaft Phase Modulator ......................... 144
Alternator.................................................. 175
Oil Pressure Switch .................................... 146
Auxiliary Drive Belt .................................... 176
Knock Sensor............................................. 147
Auxiliary Drive Belt Tensioner..................... 177
Fuel Rail ..................................................... 147
Starter Motor ............................................ 177
Fuel Injector............................................... 148
Battery Positive Cable................................. 178
Oxygen Sensor........................................... 149
Battery Negative Cable............................... 179
Downstream Oxygen Sensor ...................... 149
Battery....................................................... 180
Manifold Absolute Pressure/Temperature
Sensor ....................................................... 150 Battery Tray ............................................... 180
Charcoal Canister ...................................... 150 Battery Tray Front Bracket.......................... 181
Carbon Canister Control Valve ................... 151 Battery Tray Rear Bracket ........................... 181
Pipe Assembly - Body Underfloor Fuel Accessory Belt Idle Pulley ........................... 182
Lines .......................................................... 151
Transmission .................................... 183
Fuel filter .................................................. 152
Tank - Fuel ................................................. 153 Shift Lock Control-NEW 4AT..........................183
Fuel pump .................................................. 154 Specifications ................................................. 183
2 1.0
Contents
Torque ....................................................... 183 Torque ....................................................... 259
Description and Operation............................. 184 Description and Operation............................. 260
System Layout ............................................ 184 System Layout ............................................ 260
Description ................................................ 185 Service Procedures......................................... 261
Service Procedures......................................... 187 Shift Lever Knob and Sleeve - Manual........... 261
Shift Lever Knob - Automatic ...................... 187 Gear Shift Mechanism Assembly -
Shift Lever Assembly - Automatic ................ 188 Manual ....................................................... 261
Gear Panel ................................................. 189 Tools List ....................................................... 263
Transmission-AT................................................190 Transmission-MT ...............................................264
Specifications ................................................. 190 Specifications ................................................. 264
Torque ....................................................... 190 Torque ....................................................... 264
Parameter .................................................. 191 Parameter .................................................. 265
System Layout ............................................ 193 System Layout ............................................ 267
System Control Diagram............................. 198 Description ................................................ 276
Description ................................................ 202 Operation .................................................. 277
Operation .................................................. 212 Service Procedures......................................... 279
diagnosis ........................................................ 230 Manual Transmission Assembly.................... 279
Overview ................................................... 230 Gear Selection/Shift Shaft Oil Seal -
Manual ....................................................... 281
Machinery Diagnosis ................................... 231
Transmission Fluid - Drain and Refill ............ 282
Reverse Lamp Switch.................................. 283
Hydraulic Pressure Test .............................. 241
Left Differential Oil Seal.............................. 283
Automatic Transmission Assembly............... 242
Right Differential Oil Seal ............................ 284
Automatic Transmission Fluid - Drain and
Refill .......................................................... 244 Manual Transmission Disassembling ............. 284
Automatic Transmission Fluid - Refill ........... 246 Drive Shaft Assembly .................................. 290
Transmission Control Module (TCM)........... 247 Driven Shaft Assembly ................................ 291
Automatic Transmission Harness................. 247 Differential Assembly .................................. 293
Neutral Start Switch ................................... 248 Special Tools .................................................. 295
Neutral Start Switch - Check and Clutch .................................................................296
Adjustment ................................................ 249 Specifications ................................................. 296
Input Speed Sensor..................................... 250 Torque ....................................................... 296
Output Speed Sensor ................................. 250 Parameter .................................................. 297
Automatic Transmission Housing End Oil Description and Operation............................. 298
Seal............................................................ 251 System Layout ............................................ 298
Torque Converter Housing End Oil Description ................................................ 301
Seal............................................................ 252
Operation .................................................. 302
Hydraulic Torque Converter ....................... 253
Valve Body Cover ....................................... 253
Clutch Assembly......................................... 303
Valve Body Assembly .................................. 254
Clutch Release Bearing ............................... 304
Oil Pump Oil Seal ....................................... 256
Clutch Master Cylinder............................... 305
Filter Assembly........................................... 257
Clutch Slave Cylinder.................................. 306
Automatic Transmission Oil Cooler Pipe
Connector ................................................. 257 Clutch Pipeline System Bleeding .................. 306
Special Tools .................................................. 258 Clutch Position Sensor................................ 307
Shift Lock Control-MT......................................259 Special Tools .................................................. 308
Specifications ................................................. 259
1.0 3
Contents
HVAC System.................................. 309 Specifications ................................................. 342
HVAC Structure ................................................309 Torque ....................................................... 342
Specifications ................................................. 309 Description and Operation............................. 343
Torque ....................................................... 309 System Layout ............................................ 343
Parameters................................................. 309 System Control Diagram............................. 345
Description and Operation............................. 310 Description ................................................ 346
System Layout ............................................ 310 Operation .................................................. 347
Description ................................................ 313 Service Procedures......................................... 348
Service Procedures......................................... 318 A/C Panel - MTC ....................................... 348
Refrigerant Recovery and Refill ................... 318 Mode Damper Cable .................................. 348
Compressor - 1.5L ..................................... 319 Recirculated Damper Actuator.................... 349
Compressor Breather Hose - 1.5L .............. 320 Steering System .............................. 351
Compressor Exhaust Hose - 1.5L................ 321
Front Wheel Steering .......................................351
A/C Hard Pipe Assembly - 1.5L ................... 322
Specifications ................................................. 351
Pressure Switch .......................................... 323
Torque ....................................................... 351
Condenser ................................................. 323
Parameters................................................. 351
A/C Box Assembly ..................................... 324
Description and Operation............................. 352
Evaporator Core ........................................ 325
System Layout ............................................ 352
Expansion Valve.......................................... 326
Description ................................................ 355
Blower Motor Assembly ............................. 327
Operation .................................................. 356
Blower Speed Regulation Resistor ............... 327
A/C Filter Cover ....................................... 328
Power Steering System - Pressure
A/C Filter Element ..................................... 328 Test ........................................................... 360
A/C Drain Pipe........................................... 329 Steering Gear Outer Tie Rod...................... 361
Heater Core Assembly ............................... 329 Steering Gear Boot..................................... 361
Instrument Panel Air Duct .......................... 330 Steering Gear Inner Tie Rod ....................... 362
Body Relief Valve - Left ............................... 330 Steering Gear Subassembly ......................... 362
Body Relief Valve - Right ............................. 331 Power Steering Pump ................................. 364
HVAC-ETC.........................................................332 Oil Inlet Pipe (Reservoir to Steering
Specifications ................................................. 332 Pump) ........................................................ 366
Torque ....................................................... 332 Oil Inlet Pipe - Steering Pump to Steering
Description and Operation............................. 333 Gear .......................................................... 366
System Layout ............................................ 333 Steering Gear Oil Outlet Pipe ..................... 368
System Control Diagram............................. 335 Steering Cooling Pipe ................................. 370
Description ................................................ 336 Reservoir Oil Return Pipe Assembly............ 371
Operation .................................................. 338 Power Assisted Steering (PAS) System
Bleeding ..................................................... 372
Special Tools .................................................. 373
A/C Controller Assembly - ETC.................. 339
Steering Wheel and Column ...........................374
A/C Panel - ETC......................................... 339
Specifications ................................................. 374
Mode Damper Actuator ............................. 340
Torque ....................................................... 374
Internal/External Recirculated Damper
Actuator .................................................... 340 Service Procedures......................................... 375
Evaporator Core Temperature Steering Wheel Assembly ........................... 375
Sensor ....................................................... 341 Steering Wheel
Temperature Damper Actuator................... 341 Positioning/Adjustment ............................... 375
HVAC-MTC........................................................342
4 1.0
Contents
Steering Column Combination Rear Damper Assembly .............................. 407
Switch........................................................ 376 Rear Spring ................................................ 407
Steering Wheel Entertainment Rear Hub Bearing ....................................... 408
Switch........................................................ 377
H Frame Assembly ..................................... 408
Upper Steering Column .............................. 377
Tires and Wheels ..............................................410
Intermediate Shaft ...................................... 378
Specifications ................................................. 410
Steering Column Lower Trim Cover............ 379
Torque ....................................................... 410
Mechanical Steering Column Lock ............... 379
Parameter .................................................. 411
Suspension System.......................... 381 Service Procedures......................................... 412
Wheel Alignment ..............................................381 Wheel........................................................ 412
Specifications ................................................. 381 Tyre Pressure Monitoring Controller........... 413
Torque ....................................................... 381 Tyre Pressure Sensor .................................. 413
Parameters................................................. 381 Brake System................................... 415
Brake ..................................................................415
Description ................................................ 382
Specifications ................................................. 415
Torque ....................................................... 415
Four-wheel Alignment................................. 383
Front Suspension ...............................................384
System Layout ............................................ 416
Specifications ................................................. 384
Description ................................................ 417
Torque ....................................................... 384
Specifications.............................................. 384
Brake Fluid Level Indicator Switch ............... 418
Brake Master Cylinder and Reservoir
System Layout ............................................ 385 Assembly ................................................... 418
Description ................................................ 388 Vacuum Booster Assembly.......................... 419
Service Procedures......................................... 390 Brake pedal ................................................ 420
Front Hub .................................................. 390 Brake lamp switch ...................................... 421
Front Hub Bearing ..................................... 392 Brake Caliper – Front ................................. 422
Front Lower Arm ...................................... 393 Brake Pads – Front .................................... 423
Front_Lower_Ball_Pin ................................ 394 Brake Disc – Front ..................................... 424
Front Lower Arm Rear Bush....................... 394 Thickness and Run-Out Check-Front Brake
Front Lower Arm Front Bush...................... 395 Disc ........................................................... 424
Front Damper ............................................ 395 Brake Drum ............................................... 425
Anti Roll Bar .............................................. 397 Brake Shoes - Rear ..................................... 426
Anti Roll Bar Bush ...................................... 397 Brake Shoes – Manually Adjust .................... 427
Anti Roll Bar Link ....................................... 398 Hydraulic Wheel Cylinder........................... 427
Front Subframe Assembly ........................... 398 Brake System Bleeding ................................ 428
Special Tools .................................................. 400 Electronic Vacuum Pump............................. 429
Rear Suspension ................................................402 Special Tools .................................................. 430
Specifications ................................................. 402 Park Brake .........................................................431
Torque ....................................................... 402 Specifications ................................................. 431
Specifications.............................................. 402 Torque ....................................................... 431
System Component Layout ......................... 403 System Layout ............................................ 432
Description ................................................ 406 Description ................................................ 433
Service Procedures......................................... 407 Service Procedures......................................... 434
1.0 5
Contents
Handbrake Cable - Adjust ........................... 434 A Pillar Lower Trim Panel ........................... 458
Handbrake Cable – Equaliser....................... 434 B/C Pillar Upper Trim Panel ........................ 459
Handbrake Cable – Rear............................. 435 B/C Pillar Lower Trim Panel ........................ 459
Handbrake Lever ........................................ 436 D Pillar Upper Trim Panel ........................... 460
Brake Module.....................................................437 D Pillar Lower Trim Panel ........................... 460
Specifications ................................................. 437 Rear Coat Rack .......................................... 461
Torque ....................................................... 437 Carpet ....................................................... 461
Description and Operation............................. 438 Luggage Compartment Side Trim
System Layout ............................................ 438 Panel.......................................................... 462
System Control Diagram............................. 439 Luggage Compartment Sill Trim Panel........... 463
Description ................................................ 440 Tail Gate Interior Trim Panel ....................... 463
Service Procedures......................................... 441 Roof Interior Trim ...................................... 464
ABS Sensor - Front..................................... 441 Sun Visor and Bracket................................. 465
ABS Sensor - Rear ...................................... 441 Insulation Pad of Engine Compartment
Heat Shield................................................. 465
Brake Modulator (SCS) ............................... 442
Front Insulation Pad.................................... 466
Driveline/Axle.................................. 443 Driver Side Glasses Box.............................. 467
Driveline/Axle ....................................................443 Inner Roof Handle ...................................... 467
Specifications ................................................. 443 Fascia and Console ...........................................468
Torque ....................................................... 443 Specifications ................................................. 468
Description and Operation............................. 444 Torque ....................................................... 468
System Layout ............................................ 444 Service Procedures......................................... 469
Description ................................................ 446 Instrument Panel End Cover Plate
Assembly ................................................... 469
Diagnostic...................................................... 447
Driver Side Lower Trim Panel
Diagnosis ................................................... 447 Assembly ................................................... 469
Mechanical Check....................................... 447 Glove Box Assembly................................... 470
Service Procedures......................................... 448 Instrument Panel Side Air Outlet
RH Shaft & Both Joints................................ 448 Assembly ................................................... 470
LH Shaft & Both Joints ................................ 449 Central Instrument Panel Air Outlet
Outer CV Joint Gaiter ................................ 450 Assembly ................................................... 471
Inner joint .................................................. 450 Central Control Panel and Switch of
Instrument Panel ........................................ 472
Inner Joint Gaiter ....................................... 451
Instrument Panel IPK Frame
Special Tools .................................................. 452 Assembly ................................................... 473
Interior Fitting................................. 453 Instrument Panel Assembly ......................... 473
Instrument Panel Beam Assembly ................ 475
Interior Trim and Paneling ...............................453
Centre Console Upper Trim Panel
Specifications ................................................. 453
Assembly and Switch .................................. 476
Torque ....................................................... 453
Centre Console Assembly .......................... 476
Centre Console Heater Closing Plate
Front Door Interior Trim Panel and Assembly ................................................... 477
Waterproof Membrane............................... 454
Seats ...................................................................478
Front Door Inner Handle............................ 455
Specifications ................................................. 478
Rear Door Interior Trim Panel and
Torque ....................................................... 478
Waterproof Membrane............................... 456
Rear Door Inner Handle ............................. 457
System Layout ............................................ 479
A Pillar Upper Trim Panel............................ 458
Description ................................................ 480
6 1.0
Contents
Operation .................................................. 481 Exterior Rearview Mirror Cover ................. 504
Service Procedures......................................... 482 Interior Rearview Mirror ............................ 505
Front Seat .................................................. 482 Wipers and Washer ..........................................506
Front Seat Squab ........................................ 482 Specifications ................................................. 506
Front Seat Backrest Cover .......................... 483 Torque ....................................................... 506
Front Seat Cushion..................................... 484 Description and Operation............................. 507
Front Seat Cushion Cover .......................... 484 System Layout ............................................ 507
Front Seat Outer Trim Panel ....................... 485 System Control Diagram............................. 508
Rear Seat Cushion ...................................... 485 Description ................................................ 509
Rear Seat Squab Hinge................................ 486 Operation .................................................. 510
Rear Seat Squab.......................................... 486 Service Procedures......................................... 512
Windshield Wiper Blade Assembly.............. 512
Exterior Fitting................................ 487
Windshield Wiper Arm Assembly ............... 512
Fixed Windows ..................................................487 Windshield Wiper Linkage Assembly -
Service Procedures......................................... 487 With Motor ............................................... 513
Front Door Quarter Window..................... 487 Washer Reservoir Assembly ....................... 513
Rear Door Quarter Window ...................... 487 Washer Pump Assembly ............................. 514
Windshield................................................. 488 Windshield Washer Pump Hose.................. 514
Rear Window............................................. 488 Rear Window Washer Pump Hose.............. 515
Bumpers, Fascias and Grille .............................489 Rear Window Wiper Arm Assembly ........... 516
Specifications ................................................. 489 Rear Window Wiper Motor ....................... 517
Torque ....................................................... 489 Special Tools .................................................. 518
Lighting Systems ............................. 519
Front Bumper and Bracket .......................... 490
Front Bumper Beam ................................... 491 Lighting...............................................................519
Rear Bumper Beam .................................... 492 Specifications ................................................. 519
Rear Bumper and Bracket ........................... 492 Torque ....................................................... 519
Exterior Trim and Paneling ..............................494 Description and Operation............................. 520
Specifications ................................................. 494 System Layout ............................................ 520
Torque ....................................................... 494 System Control Diagram............................. 521
Service Procedures......................................... 495 Description ................................................ 522
A/C Air Inlet Grille Assembly...................... 495 Operation .................................................. 523
Front Wheelhouse Liner............................. 495 Service Procedures......................................... 524
Rear Wheelhouse Liner .............................. 496 Interior Lamp Assembly .............................. 524
Bottom Deflector....................................... 497 Rearview Mirror and Light Leveling
Switch........................................................ 524
A Pillar Exterior Trim Panel......................... 498
Lamps .................................................................525
Mirrors................................................................499
Specifications ................................................. 525
Specifications ................................................. 499
Torque ....................................................... 525
Torque ....................................................... 499
System Layout ............................................ 526
System Layout ............................................ 500
System Control Diagram............................. 527
Description ................................................ 528
Description ................................................ 502
Operation .................................................. 530
Operation .................................................. 503
Headlamp Assembly.................................... 532
Exterior Rearview Mirror Assembly ............ 504
1.0 7
Contents
Integrated High/Low Beam Bulb .................. 532 Torque ....................................................... 555
Front Position Lamp ................................... 533 Service Procedures......................................... 556
Front Direction Indicator Lamp................... 533 Fender ....................................................... 556
Headlamp Lighting Calibration..................... 534 Front-end Module....................................... 557
Bulb – Indicator – Side Repeater ................. 534 Bonnet Assembly and Hinge........................ 558
High-mounted Stop Lamp Assembly ............ 535 Bonnet Adjustment..................................... 559
Tail Lamp Assembly .................................... 535 Bonnet Lock Assembly ............................... 560
Tail Lamp Assembly Bulb ............................. 536 Bonnet Release Cable and Handle ............... 561
Rear License Plate Lamp Assembly .............. 536 Rear Closures.....................................................562
Light Sensor ............................................... 537 Specifications ................................................. 562
Torque ....................................................... 562
Body Systems ................................. 539
Door....................................................................539 Tail Gate Gas Spring and Mounting
Specifications ................................................. 539 Bracket ...................................................... 563
Torque ....................................................... 539 Tail Gate Assembly and Hinge ..................... 564
Service Procedures......................................... 540 Tail Gate Adjustment .................................. 565
Front Door Adjustment.............................. 540 Tail Gate Lock Assembly ............................. 566
Front Door Assembly and Hinge ................. 540 Tail Gate Lock Catch .................................. 566
Driver Side Door Outer Handle and Lock Fuel Filler Door Assembly........................... 567
Cylinder Assembly...................................... 541 Fuel Filler Door Release Cable
Driver Side Door Lock Assembly ................ 542 Assembly ................................................... 567
Front Passenger Side Door Outer Horns ..................................................................568
Handle ....................................................... 543 Specifications ................................................. 568
Rear Door Adjustment ............................... 543 Torque ....................................................... 568
Rear Door Assembly and Hinge .................. 544 Service Procedures......................................... 569
Rear Door Outer Handle ........................... 545 Tweeter ..................................................... 569
Rear Door Catch/CDL Motor..................... 545 Body Control Module........................................570
Front Door Upper Molding......................... 546 Specifications ................................................. 570
Rear Door Upper Molding .......................... 547 Torque ....................................................... 570
Door Window Outer Weatherstrip ............ 547 Description and Operation............................. 571
Front Door Window Glass ......................... 548 System Layout ............................................ 571
Rear Door Window Glass .......................... 548 System Control Diagram............................. 572
Front Door Window Regulator................... 549 Description ................................................ 573
Rear Door Window Regulator.................... 549 Operation .................................................. 576
Front Door Window Regulator Service Procedures......................................... 578
Adjustment ................................................ 550
Body Control Module (BCM) ...................... 578
Rear Door Window Regulator
Adjustment ................................................ 550 Add Key and Disable Key ............................ 578
Front Door Glass Channel .......................... 551 Body Repair ..................................... 579
Rear Door Glass Channel ........................... 551
Panel Repair.......................................................579
Front Door Division Bar ............................. 552
Roof Panel ................................................. 579
Rear Door Division Bar .............................. 552
Engine Compartment Panel......................... 580
Power Window Switch - Driver Side ........... 553
Dash Panel ................................................. 581
Power Window Switch - Others ................. 553
Bodyside Panel ........................................... 582
Central Control Door Lock Switch ............. 554
Front Floor ................................................ 583
Front Closures ...................................................555
Rear Floor ................................................. 584
Specifications ................................................. 555
8 1.0
Contents
Door Panel ................................................ 585 System Control Diagram............................. 674
Bonnet Panel Assembly............................... 586 Description ................................................ 675
Tail Gate Panel Assembly ............................ 587 Operation .................................................. 676
Collision Repair .................................................588 Alarm System....................................................678
Body Material ............................................. 588 Description and Operation............................. 678
Damage Diagnosis ...................................... 589 System Layout ............................................ 678
Repair Plan Determination .......................... 591 System Control Diagram............................. 679
Body Correction ........................................ 592 Description ................................................ 680
Panel Repair ............................................... 594 Operation .................................................. 681
Sheet Metal Replacement............................ 595 Service Procedures......................................... 682
Painting...............................................................599 Anti-theft Coil............................................ 682
Overview ................................................... 599 Seat Belts ..........................................................683
Painting Process.......................................... 601 Specifications ................................................. 683
General Film Coating Defects ..................... 606 Torque ....................................................... 683
Seal .....................................................................610 Description and Operation............................. 684
Overview ................................................... 610 System Layout ............................................ 684
Sealing Performance Test ............................ 612 System Control Diagram............................. 685
Position Information of Sealant.................... 613 Description ................................................ 686
Gasket Position Information........................ 626 Operation .................................................. 688
Corrosion Protection .......................................629 Service Procedures......................................... 689
Overview ................................................... 629 Front Seat Belt Assembly ............................ 689
Anti-corrosion Products and Front Seat Belt Buckle ................................ 690
Construction.............................................. 632 Rear Seat Belt Assembly ............................. 690
Welding Process ................................................638 Rear Seat Belt Buckle.................................. 692
Welding Process Overview ......................... 638 Rear Middle Seat Belt Assembly .................. 693
Welding Protection Measures...................... 639 Supplemental In�atable Restraints .................694
Welding Parts Remove................................ 640 Specifications ................................................. 694
OEM Welding Information .......................... 642 Torque ....................................................... 694
Body Dimension ................................................662 Description and Operation............................. 695
Point to Point Dimensional Information........... 662 System Layout ............................................ 695
Bodyside and Top Information..................... 662 System Control Diagram............................. 696
Bottom Plate Information ........................... 664 Description ................................................ 697
Rear End Information.................................. 665 Operation .................................................. 701
Internal Information.................................... 666 Service Procedures......................................... 703
Front End Information ................................ 667 Steering Wheel Airbag................................ 703
Gap Information............................................. 668 Instrument Panel Airbag.............................. 703
Body Side and Fuel Filler Cap Head Curtain Airbag................................... 704
Information ................................................ 668
Side Impact Sensor ..................................... 705
Front End Information ................................ 669
Airbag Control Module............................... 706
Rear End Information.................................. 671
Park Assistant System ......................................707
Sunroof Information ................................... 672
Safety and Restraints ...................... 673 System Layout ............................................ 707
Vehicle Access....................................................673 System Control Diagram............................. 708
Description and Operation............................. 673 Description ................................................ 710
System Layout ............................................ 673 Operation .................................................. 712
1.0 9
Contents
Ultrasonic Sensor ....................................... 713
Camera...................................................... 713
Information and
Entertainment ................................. 715
Entertainment and Navigation ........................715
Specifications ................................................. 715
Torque ....................................................... 715
System Layout ............................................ 716
Description ................................................ 718
Operation .................................................. 721
Radio Antenna............................................ 722
Front Door Woofer ................................... 722
Rear Door Woofer..................................... 723
Tweeter ..................................................... 723
Player......................................................... 724
Microphone................................................ 724
Displays and Gauges..........................................725
Specifications ................................................. 725
Torque ....................................................... 725
System Layout ............................................ 726
Description ................................................ 728
Operation .................................................. 732
Instrument Pack ......................................... 733
Power and Signal ............................. 735

Power and Signal ...............................................735
Specifications ................................................. 735
Torque ....................................................... 735
Engine Compartment Fuse Box ................... 736
Instrument Panel Harness ........................... 737
Body Harness............................................. 737
Front Door Harness ................................... 743
Rear Door Harness .................................... 744
Centre Console Power Socket .................... 744
Glossary List ......................................................745
10 1.0
General Information
General Information Health Protection Precautions
General Precautions The following precautions should be observed at all times.
Dangerous Substances
• Wear protective clothing, including impervious gloves
Modern vehicles contain many materials and liquids which if not where practicable.
handled with care can be hazardous to both personal health • Avoid prolonged and repeated contact with oils,
and the environment. particularly used engine oils.
Warning: Many liquids and other substances used in • Do not put oily rags in pockets.
vehicles are poisonous and should under no circumstances • Avoid contaminating clothes (particularly those next to
be consumed and should, as far as possible, be kept the skin) with oil.
from contact with the skin. These liquids and substances
• Overalls must be cleaned regularly. Discard heavily soiled
include acid, antifreeze, brake fluid, fuel, windscreen
clothing and oil impregnated footwear.
washer additives, lubricants, refrigerants and various
adhesives. • First aid treatment should be obtained immediately for
open cuts and wounds.
Warning: Always read carefully the instructions printed
• Apply barrier creams before each work period to help
on labels or stamped on components and obey them
prevent lubricating oil from contaminating the skin.
implicitly. Such instructions are included for reasons of
your health and personal safety. Never disregard them. • Wash with soap and water to ensure all oil is removed
(proprietary skin cleansers and nail brushes will help).
Synthetic Rubber
• Use moisturisers after cleaning; preparations containing
Many O-rings, seals, hoses, flexible pipes and other similar lanolin help replace the skin's natural oils which have been
items which appear to be natural rubber, are in fact, made removed.
of synthetic materials called Fluoroelastomers. Under normal
• Do not use petrol/gasoline, kerosene, diesel fuel, oil,
operating conditions this material is safe and does not present
thinners or solvents for cleaning skin.
a health hazard. However, if the material is damaged by fire
or excessive heating, it can break down and produce highly • Where practicable, degrease components prior to
corrosive Hydrofluoric acid. handling.
• If skin disorders develop, obtain medical advice without
Contact with Hydrofluoric acid can cause serious burns on
delay.
contact with skin. If skin contact does occur：
• Wear eye protection (e.g. goggles or face shield) if there
• Remove any contaminated clothing immediately. is a risk of eye contamination. Eye wash facilities should
• Irrigate affected area of skin with a copious amount of be provided in close vicinity to the work area.
cold water or limewater for 15 to 60 minutes.
• Obtain medical assistance immediately.
Should any material be in a burnt or overheated condition,

handle with extreme caution and wear protective clothing
(seamless industrial gloves, protective apron etc.).
Decontaminate and dispose of gloves immediately after use.

Lubricating Oils
Avoid excessive skin contact with used lubricating oils and
always adhere to the health protection precautions.
Warning: Avoid excessive skin contact with used engine
oil. Used engine oil contains potentially harmful
contaminants which may cause skin cancer or other
serious skin disorders.
Warning: Avoid excessive skin contact with mineral oil.
Mineral oils remove the natural fats from the skin, leading
to dryness, irritation and dermatitis.
1.0 1
General Information
Safety Instructions • Observe absolute cleanliness when working with
Jacking hydraulic components.
Caution: It is best to use the lift when working under the Cooling System Caps and Plugs
vehicle. Be sure to hold the wheels with chocks and apply When the engine is hot, especially if it is overheated, pay
parking brake. special attention when removing expansion tank caps and
Always use the recommended jacking points. coolant drain or bleed screws. To avoid the possibility of
scalding, allow the engine to cool before attempting removal.
Always ensure that any lifting apparatus has sufficient load
capacity for the weight to be lifted.
Ensure the vehicle is standing on level ground prior to lifting

or jacking.
Apply the parking brake and chock the wheels.
Warning: Do not work on or under a vehicle supported

only by a jack.Always support the vehicle on safety stands.
Do not leave tools, lifting equipment, spilt oil, etc. around or

on the work bench area. Always keep a clean and tidy work
area.
Brake Shoes and Pads
Always fit the correct grade and specification of brake linings.
When renewing brake pads and brake shoes, always replace as
complete axle sets.
Brake Hydraulics
Observe the following recommendations when working on the
brake system:
• Ensure that hoses run in a natural curve and are not

kinked or twisted.
• Ensure that hoses run in a natural curve and are not
kinked or twisted.
• Fit brake pipes securely in their retaining clips and ensure
that the pipe cannot contact a potential chafing point.
• Containers used for brake fluid must be kept absolutely
clean.
• Do not store brake fluid in an unsealed container, it will
absorb water and in this condition would be dangerous
to use due to a lowering of its boiling point.
• Do not allow brake fluid to be contaminated with mineral
oil, or put new brake fluid in a container which has
previously contained mineral oil.
• Do not re-use brake fluid removed from the system.
• Always use clean brake fluid or a recommended
alternative to clean hydraulic components.
• After disconnection of brake pipes and hoses,
immediately fit suitable blanking caps or plugs to prevent
the ingress of dirt.
• Only use the correct brake fittings with compatible
threads.
1.0 2
General Information
Environmental Precautions Discharges to Water
General Oil, petrol, solvent, acids, hydraulic oil, antifreeze and other
This section provides general information which can help to such substances should never be poured down the drain and
reduce the environmental impacts from the activities carried every precaution must be taken to prevent spillage reaching
out in workshops. the drains.
Emissions to Air Handling of such materials must take place well away from the
Many of the activities that are carried out in workshops emit drains and preferably in an area with a kerb or wall around it, to
gases and fumes which contribute to global warming, depletion prevent discharge into the drain. If a spillage occurs it should
of the ozone layer and/or the formation of photochemical be soaked up immediately. Having a spill kit available will make
smog at ground level. By considering how the workshop this easier.
activities are carried out, these gases and fumes can be Checklist
minimised, thus reducing the impact on the environment.
Always adhere to the following disposal and spillage prevention
Exhaust Fumes instructions.
Running car engines is an essential part of workshop activities • Never pour anything down a drain without first checking
and exhaust fumes need to be ventilated to atmosphere. that it is environmentally safe to do so, and that it does
However, the amount of time engines are running and the not contravene any local regulations.
position of the vehicle should be carefully considered at all
• Store liquids in a walled area;
times, to reduce the release of poisonous gases and minimise
• Protect bulk storage tanks from vandalism by locking the
the inconvenience to people living nearby.
valves;
Solvents
• Transfer liquids from one container to another in an area
Some of the cleaning agents used are solvent based and will away from open drains;
evaporate to atmosphere if used carelessly, or if cans are left
• Ensure lids are replaced securely on containers;
unsealed. All solvent containers should be firmly closed when
• Make sure that taps on liquid containers are secure and
not needed and solvent should be used sparingly. Suitable
cannot be accidentally turned on;
alternative materials may be available to replace some of the
commonly used solvents. Similarly, many paints are solvent • Have spill kits available near to points of storage and
based and the spray should be minimised to reduce solvent handling of liquids.
emissions. Spill Kits
Refrigerant Special materials are available to absorb a number of different
Discharge and replacement of these materials from air substances. They can be in granular form, ready to use and
conditioning units should only be carried out using the correct bought in convenient containers for storage. Disposal of used
equipment. spill-absorbing material is dealt with in 'Waste Management'
section.
Engines:
Land Contamination
Always adhere to the following.
Oils, fuels and solvents etc. can contaminate any soil that
• Don't leave engines running unnecessarily; they are allowed to contact. Such materials should never be
• Minimise testing times and check where the exhaust disposed of by pouring onto soil and every precaution must be
fumes are being blown. taken to prevent spillage reaching soil. Waste materials stored
Materials: on open ground could also leak, or have polluting substances
washed off them that would contaminate the land. Always
• Keep lids on containers of solvents;
store these materials in suitable robust containers.
• Only use the minimum quantity;
Checklist
• Consider alternative materials;
Always adhere to the following.
• Minimise over-spray when painting.
Gases: • Don't pour or spill anything onto the soil or bare ground;
• Use the correct equipment for collecting refrigerants; • Don't store waste materials on bare ground, see‘Spillage
prevention' list.
• Don't burn rubbish on site.
1.0 3
General Information
Local Issues Dispose of waste in accordance with the following guidelines.
A number of environmental issues will be of particular concern • Fuel, hydraulic fluid, anti-freeze and oil: keep separate
to residents and other neighbours close to the site. The and dispose of to specialist contractor.
sensitivity of these issues will depend on the proximity of the • Refrigerant: collect in specialist equipment and reuse.
site and the layout and amount of activity carried on at the site.
• Detergents: safe to pour down the foul drain if diluted.
Car alarm testing, panel beating, hammering and other such • Paint, thinners: keep separate and dispose of to specialist
noisy activities should, whenever possible, be carried out contractor.
indoors with doors and windows shut or as far away from
• Components: send back to supplier for refurbishment,
houses as possible.
or disassemble and reuse any suitable parts. Dispose of
Be sensitive to the time of day when these activities are carried the remainder in ordinary waste.
out and minimise the time of the noisy operation, particularly • Small parts: reuse any suitable parts, dispose of the
in the early morning and late evening. remainder in ordinary waste.
Another local concern will be the smell from the various • Metals: can be sold if kept separate from general waste.
materials used. Using less solvent, paint and petrol could help • Tyres: keep separate and dispose of to specialist
prevent this annoyance. contractor.
Local residents and other business users will also be concerned • Packaging: compact as much as possible and dispose of
about traffic congestion, noise and exhaust fumes, be sensitive in ordinary waste.
to these concerns and try to minimise inconvenience from • asbestos material ： keep separate and dispose of to
deliveries, customers and servicing operations. specialist contractor.
Checklist • Oily and fuel wastes (e.g. rags, used spill kit material):
Always adhere to the following. keep separate and dispose of to specialist contractor.
• Air filters: keep separate and dispose of to specialist
• Identify where the neighbours who are likely to be
contractor.
affected are situated;
• Rubber/plastics: dispose of in ordinary waste.
• Minimise noise, smells and traffic nuisance;
• Hoses: dispose of in ordinary waste.
• Prevent litter by disposing of waste in the correct
manner; • Batteries: keep separate and dispose of to specialist
contractor.
• Have waste containers emptied regularly.
Waste Management • Airbags - explosives: keep separate and dispose of to
specialist contractor.
One of the major ways that pollution can be reduced is by the
• Electrical components: send back to supplier for
careful handling, storage and disposal of all waste materials that
refurbishment, or disassemble and reuse any suitable
occur on sites. This means that it is necessary to not only know
parts. Dispose of the remainder in ordinary waste.
what the waste materials are, but also to have the necessary
documentation and to know local regulations that apply. • Catalysts: can be sold if kept separate from general waste
• Used spill-absorbing material: keep separate and dispose
Handling and Storage of Waste
of to specialist contractor.
They should be stored in such a way as to prevent the escape
of the material to land, water or air.
They must also be segregated into different types of waste

e.g. oil, metals, batteries, used vehicle components. This will
prevent any reaction between different materials and assist in
disposal.
Disposal of Waste
Disposal of waste materials must only be to waste carriers who
are authorised to carry those particular waste materials and
have all the necessary documentation. The waste carrier is
responsible for ensuring that the waste is taken to the correct
disposal sites.
1.0 4
General Information
General Fitting Instructions • Never inspect a component for wear or dimensional
Component Removal check unless it is absolutely clean; a slight smear of grease
can conceal an incipient failure.
Whenever possible, clean components and surrounding area
before removal. • When a component is to be checked dimensionally
against recommended values, use the appropriate
• Blank off openings exposed by component removal. measuring equipment (surface plates, micrometers,
• Immediately seal fuel, oil or hydraulic lines when dial gauges etc.). Ensure the measuring equipment is
apertures are exposed; use plastic caps or plugs to calibrated and in good serviceable condition.
prevent loss of fluid and ingress of dirt. • Reject a component if its dimensions are outside the
• Close the open ends of oilways exposed by component specified tolerances, or if it appears to be damaged.
removal with tapered hardwood plugs or conspicuous • A part may be refitted if its critical dimension is exactly
plastic plugs. to its tolerance limit and it appears to be in satisfactory
• Immediately a component is removed, place it in a condition. Use ‘Plastigauge' for checking bearing surface
suitable container; use a separate container for each clearances.
component and its associated parts.
• Clean bench and provide marking materials, labels and
containers before dismantling a component.
Dismantling
Observe scrupulous cleanliness when dismantling components,
particularly when brake, fuel or hydraulic system parts are
being worked on. A particle of dirt or a cloth fragment could
cause a serious malfunction if trapped in these systems.
• Blow out all tapped holes, crevices, oilways and fluid

passages with an air line. Ensure that any O-rings used
for sealing are correctly replaced or renewed, if disturbed
during the process.
• Use marking ink to identify mating parts and ensure
correct reassembly. Do not use a centre punch or
scriber to mark parts, they could initiate cracks or
distortion in marked components.
• Wire together mating parts where necessary to prevent
accidental interchange (e.g. roller bearing components).
• Attach labels to all parts which are to be renewed, and
to parts requiring further inspection before being passed
for reassembly; place these parts in separate containers
from those containing parts for rebuild.
• Do not discard a part due for renewal until after
comparing it with a new part, to ensure that its correct
replacement has been obtained.
Cleaning Components
Always use the recommended cleaning agent or equivalent.
Ensure that adequate ventilation is provided when volatile
degreasing agents are being used. Do not use degreasing
equipment for components containing items which could be
damaged by the use of this process.
General Inspection
All components should be inspected for wear or damage
before being reassembled.
1.0 5
General Information
Ball and Roller Bearings • In the case of grease lubricated bearings (eg. hub
General bearings) fill the space between bearing and outer seal
with the recommended grade of grease before fitting
When removing and installing bearings, ensure that the
seal.
following practices are observed to ensure component
serviceability. • Always mark components of separable bearings (eg.
taper roller bearings) when dismantling, to ensure
• Remove all traces of lubricant from bearing under
correct reassembly. Never fit new rollers in a used outer
inspection by cleaning with a suitable degreasant;
ring; always fit a complete new bearing assembly.
maintain absolute cleanliness throughout operations.
• Hold inner race of bearing between finger and thumb of
one hand and spin outer race to check that it revolves
absolutely smoothly. Repeat, holding outer race and
spinning inner race.
• Rotate outer ring gently with a reciprocating motion,
while holding inner ring; feel for any check or obstruction
to rotation. Reject bearing if action is not perfectly
smooth.
• Lubricate bearing with generous amounts of lubricant
appropriate to installation.
• Inspect shaft and bearing housing for discoloration or
other markings which indicate movement between
bearing and housing.
• Ensure that shaft and housing are clean and free from
burrs before fitting bearing.
• If one bearing of a pair shows an imperfection, it
is advisable to replace both with new bearings; an
exception could be if the faulty bearing had covered a
low mileage, and it can be established that damage is
confined to only one bearing.
• Never refit a ball or roller bearing without first ensuring
that it is in a fully serviceable condition.
• When hub bearings are removed or displaced, new
bearings must be fitted; do not attempt to refit the old
hub bearings.
• When fitting a bearing to a shaft, only apply force to the
inner ring of the bearing. When fitting a bearing into a
housing, only apply force to the outer ring of the bearing.
1.0 6
General Information
Oil Seals
General
Always renew oil seals which have been removed from their
working location (whether as an individual component or
as part of an assembly). NEVER use a seal which has been
improperly stored or handled, such as hung on a hook or nail.
• Carefully examine seal before fitting to ensure that it is

clean and undamaged.
• Ensure the surface on which the new seal is to run is
free of burrs or scratches. Renew the component if the
original sealing surface cannot be completely restored.
• Protect the seal from any surface which it has to pass
• Use the recommended service tool to fit an oil seal. If
when being fitted. Use a protective sleeve or tape to
the correct service tool is not available, use a suitable
cover the relevant surface.
tube approximately 0.4 mm (0.015 in.) smaller than
• Lubricate the sealing lips with a recommended lubricant the outside diameter of the seal. Use a hammer VERY
before use to prevent damage during initial use. On dual GENTLY on drift if a suitable press is not available.
lipped seals, smear the area between the lips with grease.
• Press or depress the oil seal to the bottom of the bearing
• If a seal spring is provided, ensure that it is fitted correctly. seat, and the edge of the oil seal faces the lubricant.
Place lip of seal towards fluid to be sealed and slide into Lubricate the shaft shoulder of the sealing surface to
position on shaft. Use fitting sleeve where possible to ensure that the oil seal is not inclined in the bearing seat.
protect sealing lip from damage by sharp corners, threads
or splines. If a fitting sleeve is not available, use plastic
tube or tape to prevent damage to the sealing lip.
• Grease outside diameter of seal, place square to housing

recess and press into position using great care, and if
possible a 'bell piece' to ensure that seal is not tilted. In
some cases it may be preferable to fit seal to housing
before fitting to shaft. Never let weight of unsupported
shaft rest in seal.
1.0 7
General Information
Joints and Joint Faces Locking Devices
General General
Fit joints dry unless specified otherwise. Always replace locking devices with one of the same design.
• Always use the correct gaskets as specified. Tab Washers

• When sealing compound is used, apply in a thin uniform Always release locking tabs and fit new locking washers. Do
film to metal surfaces; take care to prevent sealing not re-use locking tabs.
compound from entering oilways, pipes or blind tapped Locking Nuts
holes.
Always use a backing spanner when loosening or tightening
• If gaskets and/or sealing compound is recommended for
locking nuts, brake and fuel pipe unions.
use; remove all traces of old sealing compound prior to
reassembly. Do not use a tool which will damage the Roll Pins
joint faces and smooth out any scratches or burrs using Always fit new roll pins of an interference fit in the hole.
an oil stone. Circlips
• Prior to reassembly, blow through any pipes, channels or
Always fit new circlips of the correct size for the groove.
crevices with compressed air.
Keys and Keyways
Remove burrs from edges of keyways with a fine file and clean
thoroughly before attempting to refit key.
Clean and inspect key closely; keys are suitable for refitting only
if indistinguishable from new, as any indentation may indicate
the onset of wear.
Split Pins
Always fit new split-pins of the correct size for the hole in the
bolt or stud.
1.0 8
General Information
Screw Threads Fasteners Identification
General Bolt Identification
Metric threads to ISO standards are used.
Damaged nuts, bolts and screws must always be discarded.

Cleaning damaged threads with a die or tap impairs the
strength and fit of the threads and is not recommended.
Always ensure that replacement bolts are at least equal in

strength to those replaced.
Castellated nuts must not be loosened to accept a split-pin,

except in recommended cases when this forms part of an
adjustment.
Do not allow oil or grease to enter blind threaded holes. The

hydraulic action on screwing in the bolt or stud could split the
housing. An ISO metric bolt or screw made of steel and larger than 6
mm in diameter can be identified by either of the symbols ISO
Always tighten a nut or bolt to the recommended torque
M or M embossed or indented on top of the bolt head.
figure. Damaged or corroded threads can affect the torque
reading. In addition to marks identifying the manufacturer, the top of the
bolt head is also marked with symbols indicating the strength
To check or re-tighten a bolt or screw to a specified torque
grade, e.g. 8.8; 10.9; 12.9; 14.9. As an alternative, some bolts
figure, first loosen a quarter of a turn, then re-tighten to the
and screws have the M and strength grade symbol stamped on
correct torque figure.
the flats of the hexagon.
Oil thread lightly before tightening to ensure a free Encapsulated Bolts and Screws
running thread, except in the case of threads treated with
sealant/lubricant, and selflocking nuts.
Encapsulated bolts and screws have a microencapsulated

locking agent pre-applied to the thread. They are identified
by a coloured section which extends 360° around the thread.
The locking agent is released and activated by the assembly
process and is then chemically cured to provide the locking
action.
Unless a specific repair procedure states otherwise,

encapsulated bolts may be reused providing the threads are
undamaged and the following procedure is adopted:
• Remove loose adhesive from the bolt and housing

threads.
• Ensure threads are clean and free of oil and grease.
• Apply an approved locking agent.
1.0 9
General Information
An encapsulated bolt may be replaced with a bolt of equivalent also marked and some have the metric symbol M on the flat
specification provided it is treated with an approved locking opposite the strength grade marking.
agent.
When tightening a slotted or castellated nut, never loosen it
Self-locking Bolts and Screws to insert a split pin except where recommended as part of an
adjustment. If difficulty is experienced, alternative washers or
nuts should be selected, or the washer thickness reduced.
Where bearing preload is involved, nuts should be tightened in

accordance with special instructions.
Self-locking Nuts
Self-locking bolts and screws, i.e. nylon patched or trilobular

thread can be reused providing resistance can be felt when the
locking portion enters the female thread.
Nylon patched bolts and screws have a locking agent

pre-applied to the threads. They are identified by the presence
of a coloured section of thread which extends for up to 180°
Self-locking nuts, e.g. nylon insert or deferred thread nuts, can
around the thread.
be reused providing resistance can be felt when the locking
Trilobular bolts (i.e. Powerlok) have a special thread form portion of the nut passes over the thread of the bolt or stud.
which creates a slight interference with the thread of the hole
Where self-locking nuts have been removed, it is advisable to
or nut into which it is screwed.
replace them with new ones of the same type.
DO NOT reuse self-locking fasteners in critical locations (e.g.
Don't use non self-lock nuts in the area where self-lock nuts
engine bearings, flywheel). Always use the correct replacement
must be used.
self-locking nut, bolt or screw.
DO NOT fit non self-locking fasteners in applications where a

self-locking nut, bolt or screw is specified.
Nut Identification
A nut with an ISO metric thread is marked on one face or on

one of the flats of the hexagon with the strength grade symbol
8, 12, or 14. Some nuts with a strength grade 4, 5 or 6 are
1.0 10
General Information
Flexible Pipes and Hoses Hose Orientation and Connection
General
When removing and installing flexible hydraulic pipes and
hoses, ensure that the following practices are observed to
ensure component serviceability.
• Clean end fittings and the area surrounding them as

thoroughly as possible.
• Obtain appropriate plugs or caps before detaching hose
end fittings, so that the ports can be immediately covered
to prevent the ingress of dirt.
Clean hose externally and blow through with airline.

Examine carefully for cracks, separation of plies, security
of end fittings and external damage. Reject any faulty
Correct orientation of cooling hoses is important in ensuring
hoses.
that the hose does not become fatigued or damaged through
• When refitting a hose, ensure that no unnecessary bends contact with adjacent components. Where ‘timing' marks (1)
are introduced, and that hose is not twisted before or are provided on the hose and corresponding connection, these
during tightening of union nuts. must be used to ensure correct orientation. Hoses must be
• Fit a cap to seal a hydraulic union and a plug to its socket pushed fully onto their connection points. Usually, a moulded
after removal to prevent ingress of dirt. form (2) on the stub pipe provides a positive indicator.
• Absolute cleanliness must be observed with hydraulic Hose Clip

components at all times.
After any work on hydraulic systems, carefully inspect

for leaks underneath the vehicle while a second operator
applies maximum brake pressure to the brakes (engine
running) and operates the steering.
Flexible Pipes
Markings (1) are usually provided on the hose to indicate the

correct clip position. If no markings are provided, position the
clip directly behind the retaining lip at the end of the stub as
shown. Worm drive clips should be oriented with the crimped
side of the drive housing (2) facing towards the end of the hose,
or the hose may become pinched between the clip and the stub
pipe retaining lip. Worm drive clips should be tightened to 3
All flexible pipes are made up of two laminations, an armoured Nm unless otherwise stated. Ensure that hose clips do not foul
rubber outer sleeve and an inner viton core. If any of the adjacent components.
flexible pipes have been disconnected, it is imperative that the
Heat Protection
internal bore is inspected to ensure that the viton lining has
not become separated from the armoured outer sleeve. A Always ensure that heatshields and protective sheathing are
new pipe must be fitted if separation is evident. in good condition. Replace if damage is evident. Particular
care must be taken when routing hoses close to hot engine
Cooling System Hoses
components, such as the exhaust manifold and the Exhaust Gas
The following precautions MUST be followed to ensure that Recirculation (EGR) pipe. Hoses will relax and deflect slightly
integrity of cooling hoses and their connections to system
components are maintained.
1.0 11
General Information
when hot; ensure this movement is taken into account when Fuel Handling Precautions
routing and securing hoses. General
Fuel vapour is highly flammable and in confined spaces is
also explosive and toxic. The vapour is heavier than air
and will always fall to the lowest level. The vapour can be
easily distributed throughout a workshop by air currents;
consequently, even a small spillage of fuel is potentially very
dangerous.
The following information provides basic precautions which

must be observed if fuel is to be handled safely. It also
outlines other areas of risk which must not be ignored. This
information is issued for basic guidance only, if in doubt consult
your local Fire Officer.
Always have a fire extinguisher containing FOAM, CO2, GAS

or POWDER close at hand when handling or draining fuel or
when dismantling fuel systems. Fire extinguishers should also
be located in areas where fuel containers are stored.
Always disconnect the vehicle battery before carrying out

dismantling or draining work on a fuel system.
Whenever fuel is being handled, drained or stored, or when

fuel systems are being dismantled, all forms of ignition must be
extinguished or removed; any lead lamps must be flameproof
and kept clear of spillage.
Warning: No one should be permitted to repair
components associated with fuel without first having
specialist training.
Warning: Do not remove fuel system components while

the vehicle is over a pit.
Fuel Tank Draining
Fuel tank draining should be carried out in accordance with
the procedure outlined in the FUEL DELIVERY section of this
manual and observing the following precautions
Warning: Do not remove fuel system components while

the vehicle is over a pit. Extraction or draining of fuel
must be carried out in a well ventilated area.
The capacity of containers must be more than adequate for

the amount of fuel to be extracted or drained. The container
should be clearly marked with its contents and placed in a safe
storage area which meets the requirements of local authority
regulations.
Fuel Tank Removal
When the fuel line is secured to the fuel tank outlet by a
spring steel clip, the clip must be released before the fuel line
is disconnected or the fuel tank is removed. This procedure
will avoid the possibility of fumes in the fuel tank being ignited
when the clip is released.
1.0 12
General Information
As an added precaution, fuel tanks should have a 'FUEL Electrical Precautions
VAPOUR' warning label attached to them as soon as they are General
removed from the vehicle.
The following guidelines are intended to ensure the safety of
Fuel Tank Repairs the operator while preventing damage to the electrical and
No attempt should be made to repair a plastic fuel tank. If the electronic components fitted to the vehicle. Where necessary,
structure of the tank is damaged, a new tank must be fitted. specific precautions are detailed in the individual procedures of
this manual.
Body Repairs
Equipment
Plastic fuel pipes are particularly susceptible to heat, even
at relatively low temperature, and can be melted by heat Prior to commencing any test procedure on the vehicle ensure
conducted from some distance away. that the relevant test equipment is working correctly and any
harness or connectors are in good condition. It is particularly
When body repairs involve the use of heat, all fuel pipes which
important to check the condition of the lead and plugs of mains
run in the vicinity of the repair area must be removed, and the
operated equipment.
tank outlet plugged.
Polarity
Warning: If welding is to be carried out in the vicinity of
Never reverse connect the vehicle battery and always ensure
the fuel tank, the fuel system must be drained and the tank
the correct polarity when connecting test equipment.
removed before welding commences.
High Voltage Circuits
Whenever disconnecting live HT circuits always use insulated
pliers and never allow the open end of the HT lead to contact
other components, particularly ECUs. Exercise caution when
measuring the voltage on the coil terminals while the engine is
running, high voltage spikes can occur on these terminals.
Connectors and Harnesses
The engine compartment of a vehicle is a particularly hostile
environment for electrical components and connectors:
• Always ensure electrically related items are dry and oil

free before disconnecting and connecting test equipment.
• Ensure disconnected multiplugs and sensors are
protected from being contaminated with oil, coolant
or other solutions. Contamination could impair
performance or result in catastrophic failure.
• Never force connectors apart using tools to prise apart
or by pulling on the wiring harness.
• Always ensure locking tabs are disengaged before
disconnection, and match orientation to enable correct
reconnection.
• Ensure that any protection (covers, insulation etc.) is
replaced if disturbed.
Having confirmed a component to be faulty:
• Switch off the ignition and disconnect the battery.

• Remove the component and support the disconnected
harness.
• When replacing the component keep oily hands away
from electrical connection areas and push connectors
home until any locking tabs fully engage.
1.0 13
General Information
Battery Disconnection Supplementary Restraint System Precautions
Before disconnecting the battery, disable the alarm system and General Precautions
switch off all electrical equipment. The SRS system contains components which could be
potentially hazardous to the service engineer if not serviced
Caution: To prevent damage to electrical components,
and handled correctly. The following guidelines are intended
always disconnect the battery when working on the
to alert the service engineer to potential sources of danger
vehicle's electrical system. The ground lead must be
and emphasise the importance of ensuring the integrity of
disconnected first and reconnected last.
SRS components fitted to the vehicle.
Caution: Always ensure that battery leads are routed
Warning: It is imperative that before any work
correctly and are not close to any potential chafing
is undertaken on the SRS system the appropriate
points.
information is read thoroughly.
Battery Charging
Always ensure any battery charging area is well ventilated and
that every precaution is taken to avoid naked flames and sparks.
Disciplines
Warning: The airbag module contains sodium azide which
Remove the handset prior to making any connection or is poisonous and extremely flammable. Contact with
disconnection in the system to prevent electrical surges water, acid or heavy metals may produce harmful or
caused by disconnecting ‘live' connections damaging electronic explosive compounds. Do not dismantle, incinerate or
components. bring into contact with electricity, before the unit has
Ensure hands and work surfaces are clean and free of grease, been deployed.
swarf, etc. Grease collects dirt which can cause electrical Warning: Always replace a seat belt assembly that has
tracking (shortcircuits) or high resistance contacts. withstood the strain of a severe vehicle impact, or if the
When handling printed circuit boards, treat with care and hold webbing shows signs of fraying.
by the edges only; note that some electronic components are Warning: Always disconnect the vehicle battery before
susceptible to body static. carrying out any electric welding on a vehicle fitted with
Connectors should never be subjected to forced removal or an SRS system.
refit, especially inter-board connectors. Damaged contacts can Caution: Do not expose an airbag module or seat belt
cause short-circuit and open-circuit fault conditions. pre-tensioner to heat exceeding 85℃.
Prior to commencing test, and periodically during a test, touch It should be noted that these precautions are not restricted
a good vehicle body earth to discharge static charge. Some to operations performed when servicing the SRS system,
electronic components are vulnerable to the static electricity the same care must be exercised when working on ancillary
that may be generated by the operator. systems and components located in the vicinity of the SRS
Electrical Multiplugs Lubricate components; these include, but are not limited to:
In order to prevent corrosion, Some multiplugs under bonnet • Steering system steering wheel airbag, rotary coupler.
and carpet is wiped special lubricate in factory. If these is • Front fascia passenger front airbag.
destroyed in maintaining, repair and replacing process, special
• Interior trim ICS Head Curtain Airbags（‘A'-post trim,
lubricate should be newly wiped
‘B'-post upper trim, grab handles, headlining above front
doors）; SRS Electronic Control Unit (ECU) (beneath
centre console); side impact crash sensors (under carpet
beneath front seats)
• Seats side (thorax) airbags; front seat belt pretensioner.
• Electrical system–SRS harnesses, link leads and
connectors.
Making the System Safe
Before working on, or in the vicinity of SRS components,
ensure the system is rendered safe by performing the following
procedures:
1.0 14
General Information
• Ensure the SRS ECU is always installed correctly. There
must not be any gap between the SRS ECU and the
bracket to which it is mounted. An incorrectly mounted
SRS ECU could cause the system to malfunction.
• Do not supply power to the SRS ECU before all SRS
components connected.
Caution: Ensure SRS components are not contaminated

with oil, grease, detergent or water.
Caution: Torque wrenches should be regularly checked for

accuracy to ensure that all fixings are tightened to the
correct torque.
Caution: Following seat belt pretensioner deployment,

• Remove the handset from the docking station.
the seat belts can still be used as conventional seat
• Disconnect both battery leads, earth lead first. belts, but will need to be replaced as soon as possible to
• Wait 10 minutes for SRS ECU the SRS ECU back-up re-establish full SRS protection.
power circuit to discharge.
Caution: If the SRS component is to be replaced, the bar
The SRS system uses energy reserve capacitors to keep code of the new unit must be recorded.
the system active in the event of electrical supply failure SRS Component Testing Precautions
under crash conditions. It is necessary to allow the capacitor
sufficient time to discharge (10 minutes) in order to avoid the
risk of accidental deployment.
Caution: Disconnect the battery before starting the SRS
operation. Disconnect the battery negative terminal first.
DO NOT disconnect the battery in the reverse order.
Installation
In order to ensure system integrity, it is essential that the
SRS system is regularly checked and maintained SRS so that
it is ready for effective operation in the event of a collision.
Carefully inspect SRS components before installation. SRS
Do not install a part that shows signs of being dropped or
improperly handled, such as dents, cracks or deformation.
The SRS components are triggered using relatively low
Warning: The integrity of the SRS system is critical for operating currents, always adhere to the following precautions:
safety reasons.
Warning: Do not use a multimeter or other general
Ensure the following precautions are always adhered to: purpose test equipment on SRS system components
• Never install used SRS components from another vehicle or accidental deployment may occur. Only use the
SRS or attempt to repair an SRS component. recommended diagnostic equipment to diagnose system
faults.
• Never use the SRS parts without a clear identification
SRS label. Warning: Do not use electrical test equipment on the SRS
• Never use an airbag or SRS ECU that has been dropped. harness while it is connected to any of the SRS system
components. It may cause accidental deployment and
• When repairing an SRS system only use SRS genuine new
personal injury.
parts.
• Never apply electrical power to an SRS component
unless instructed to do SRS so as part of an approved
test procedure.
• Ensure the bolts are tightened to the correct torque.
Always use new fixings SRS when replacing SRS
components.
1.0 15
General Information
Handling and Storage
Warning: Store the airbag module with the deployment

Always comply with the following handling precautions. side uppermost. If it is stored deployment side down,
accidental deployment will propel the airbag module with
Warning: The SRS components are sensitive and
enough force to cause serious injury.
potentially hazardous if not handled correctly; always
comply with the following handling precautions: Warning: Airbag modules and seat belt pre-tensioners are
classed as explosive devices. For overnight and longer
• ECU and airbag must be stored in a cabinet in a dry
term storage, they must be stored in a secure steel cabinet
room at normal room temperatures not exceeding
which has been approved as suitable for the purpose and
85° C. Ensure that heating, fire, water and other
has been registered by the local authority.
chemical corrosive substances cannot contaminate
the stored SRS components. Warning: When recovering the seat belt pretensioner, DO
• For safety reasons, do not store inflammable goods NOT aim the piston pipe at yourself or others. Keep the
close to the area where the SRS components are pistons facing the ground. Hold the case instead of the
stored. seat belt.
• Keep new airbag module in the original packaging, Warning: Store the airbag module or seat belt
until just before fitting. pre-tensioners in a designated storage area.
• The storage area must comply with all legal Caution: Improper handling or storage can internally
requirements. It must have suitable fire extinguishers damage the airbag module, making it inoperative. If you
or other fire extinguishing equipment. suspect the airbag module has been damaged, install
• Never drop an SRS component. The airbag a new module and refer to theDeployment/Disposal
diagnostic control unit is a particularly shock Procedures for disposal of the damaged module.
sensitive device and must be handled with extreme
SRS Harnesses and Connectors
care.
• Never wrap your arms around an airbag module. If
an airbag module has to be carried, hold it by the
cover, with the cover uppermost and the base away
from your body.
• Never transport airbag modules or seat belt
pre-tensioners in the cabin of a vehicle.
Warning: Never attach anything to an airbag cover or any
trim componentcovering an airbag module. Do not allow
anything to rest on top of an airbag module.
Caution: Do not apply grease or cleaning solvents to seat

belt pretensioner units, component failure could result.
Always observe the following precautions SRS with regards to
SRS system electrical wiring:
• Never attempt to modify, splice or repair SRS wiring.
1.0 16
General Information
• Never install electronic equipment (such as a mobile Never fit cover on seat which fitting side airbag.
telephone, two-way radio or in-car entertainment
Children under 12 years old should not sit in the front seat.
system) in such a way that it could generate electrical
interference in the airbag harness. Seek specialist advice Only genuine accessory parts are allowed to be installed.
when installing such equipment. Only authorised people can remove airbag modules, SRS
Note: SRS system wiring can be identified by a special ECU and SRS system wiring harness and connectors.
yellow outer sleeve protecting the wires (black with yellow If the airbag and seat belt pre-tensioner are deployed during an
stripe protective coverings are sometimes used). accident, SRS ECU must be replaced and discarded.
Every SRS system on every car has been paired and identified,
SRS illegally adding or modifying the SRS system and the wiring
harness could injure people.
Modifying the vehicle structure or SRS system is strictly not

allowed SRS and may cause wrong airbag deployment or
failure to deploy when required.
Rotary Coupler Precautions
Caution: Always follow the procedure for fitting and
checking the rotary coupler as instructed in the SRS
repairs section. Comply with all safety and installation
procedures to ensure the system functions correctly.
Warning: Always ensure SRS wiring is routed correctly. Observe the following precautions:
Be careful to avoidtrapping or pinching the SRS wiring.
• Do not unlock and rotate the rotary coupler when it is
Do not leave the connectors hanging loose or allow SRS
components to hang from their harnesses. Look for
• Do not turn the road wheels when the rotary coupler is
possible points of chafing.
• Always ensure the rotary coupler is removed and
installed in its centred position and with the front road
wheels in the straight ahead position - procedure. SRS
refer to the SRS repair section for the correct removal
and installation
• If a new rotary coupler is being installed, ensure the
locking tab holding the coupler's rotational position is
not broken; units with a broken locking tab should not
be used.
Warning Labels
Warning symbols are displayed at various positions in the
vehicle. SRS components have additional warning labels
Precautions for Vehicle Owners
displayed on them to indicate that particular care is needed
For the airbag to work effectively and protect vehicle owners, when handling them. These include airbag modules, SRS
follow the precautions listed below. ECU, seat belt pre-tensioners and the rotary coupler.
Driver and passengers must use seat belts correctly. Correctly The following warning symbols may be displayed at various
using the seat belts can protect the body and reduce injuries locations on the vehicle:
in the event of an accident.
Never fit any accessory that obstructs or impairs the operation

of the seat belt pretensioners or airbags.
Do not place any object on the steering wheel or instrument

panel that could penetrate an inflating airbag or be a thrown
item likely to cause injury.
1.0 17
General Information
4. Bar code. The code number must be recorded if the
rotary coupler is to be replaced.
A The need for caution when working in close proximity to

SRS components. SRS in close proximity to SRS components.
Bar Codes
B Refer to the publication where the procedures, SRS
instructions and advice can be found (usually Workshop Bar codes SRS are fitted to SRS system components and
Manual or Owner's Handbook) for working on the SRS components SRS which are critically related to SRS operation.
system. The code number(s) must be recorded if the component is to
be replaced.
C Do not use rear facing child seats in the front passenger seat
if the vehicle is fitted with a passenger airbag. Components featuring bar codes include the following:
Warning: It is imperative that before any work • Driver's front airbag module – label attached to rear of
is undertaken on the SRS system the appropriate module housing.
information is read thoroughly. • Passenger’s front airbag module – label attached at side
of module housing.
The following list indicates possible locations and content
for warning labels. Exact positions and content may vary • SRS ECU – Included the label on top of SRS ECU.
dependent on model year, legislation and market trends. • Rotary coupler – several labels on front face.
Vehicle Recovery
Towing SRS Components Not Deployed
Normal towing procedures are unlikely to cause an airbag to
deploy. However, as a precaution, remove the handset from
the docking station and then disconnect both battery leads.
Disconnect the negative ‘-’ lead first.
Towing SRS Components Not Deployed
Once the driver’s airbag has been deployed, the vehicle must
have a suspended tow. However, as a precaution remove the
handset from the docking station and then disconnect both
battery leads. Disconnect the negative ‘-’ lead first.
SRS Components Deployed
Do not use rear facing child seat in front passenger seat of
vehicles fitted with passenger airbag. If a vehicle is to be scrapped and contains an undeployed airbag
module, the module must be manually deployed.
Rotary Coupler
Always observe the following precautions:
1. The need for caution when working SRS in close
proximity to SRS components. Warning: Only personnel who have undergone the
2. Refer to Workshop Manual for detailed instructions. appropriate training should undertake deployment of
airbag and seat belt pre-tensioner modules.
3. Ensure the wheels are in the straight ahead position
before removal and refitting. Warning: A deployed airbag or seat belt pre-tensioner is
very hot, DO NOT return to a deployed airbag module
until at least 30 minutes have elapsed since deployment.
1.0 18
General Information
Warning: Only use approved deployment equipment, Warning: Compliance with the following precautions
and only deploy SRS components in a well-ventilated MUST be ensured:
designated area. Ensure SRS components are not • Only use deployment equipment approved for the
damaged or ruptured before deployment. intended purpose.
Warning: Contact with chemicals from deployed and • Before commencing deployment procedure, ensure
damaged SRS components could present a health hazard, the deployment tool functions properly.
wear protective clothing when handling. DO NOT eat, • Deployment of airbag/pre-tensioner modules should
drink or smoke when handling SRS components. be performed in a well ventilated area which has
Warning: Deployment of airbag modules and seat belt been designated for the purpose.
pre-tensioners can cause injury to personnel in the close • Ensure airbag/pre-tensioner modules are not
vicinity of the deploying unit. In case of injury seek urgent damaged or ruptured before attempting to deploy.
medical advice. Possible sources of injury include: • Notify the relevant authorities of intention to deploy
• impact - due to inflating airbag or pretensioner airbag and pretensioner units.
operation causing component 'kick'. • When deploying airbag and seat belt pre-tensioner
• hearing - due to noise produced by deploying airbags units, ensure that all personnel are at least 15 metres
and seat belt pretensioner units. away from the deployment zone.
• burns - hot component parts and gases. • When deploying seat belt pretensioners in the
• irritation to eyes and lungs - from deploying gases or vehicle, ensure the pre-tensioner unit is fully secured
combustion residue. to its fixing point.
• When removing deployed airbag and seat belt
Warning: Ensure the SRS component to be deployed is
pre-tensioner modules, wear protective clothing.
securely fastened to its mounting.
Use gloves and seal deployed units in a plastic bag.
• Following deployment of any component of the SRS
system within the vehicle, all SRS components must
be replaced. DO NOT re-use or salvage any parts of
the SRS system.
• Do not lean over airbag modules or seat belt
pre-tensioner units when connecting deployment
equipment.
1.0 19
General Information
SRS Component Replacement Policy • SRS ECU
Impacts Which Do Not Deploy the Airbags or • Side impact crash sensors (both sides of vehicle)
Pre-tensioners
In addition, the following should be inspected for damage and
Check for structural damage in the area of the impact, paying
replaced as necessary:
particular attention to bumper armatures, longitudinals, crash
cans and bracketry. • Front seat belts (retractors, webbing, tongue latching, ‘D'
loop and body anchorage points)
Impacts Which Deploy the Airbags or
Pre-tensioners • Rear seat belt buckles (webbing, buckle covers, tongue
latching and body anchorage)
The replacement and inspection policy is dependent on the
type and severity of the crash condition. SRS. The following • Front seat frame (if there is evidence of external or airbag
guidelines are the minimum that should be exercised as a result deployment damage to seat frame)
of the deployment of specific SRS components: • ‘B' post internal finishers and fixings
Front Airbag Deployment (driver and passenger) • Door casings
If the front airbags are deployed, the following parts must be • Seat belt automatic height adjusters on ‘B' post
replaced: • Rear seat belt escutcheons in parcel shelf trim
• Driver airbag module Inflatable Curtain Structure (ICS) Airbags
Modules
• Passenger airbag module
If the Inflatable Curtain Structure airbag modules are deployed,
• Flyleads (where applicable) connecting SRS front airbag
the following parts must be replaced, (ICS) on the side of the
modules to SRS harness
vehicle for which deployment occurred:
• Seat belt pre-tensioners
• ICS airbag module
• Driver's seat belt retractor
• Link lead between airbag gas generator SRS and SRS
• Rotary coupler
harness
• SRS ECU
• Airbag retaining clips above window aperture
In addition, the following should be inspected for damage and • ‘A' post internal finisher
• Front seat belt pre-tensioners
• Front passenger's seat belt retractor (webbing, tongue • SRS ECU
latching, ‘D' loop, body anchorage point)
• Side impact crash sensors (both sides of vehicle)
• Rear seat belt buckles (webbing, buckle covers, body
anchorage and tongue latching function) In addition, the following should be inspected for damage and
• Fascia moulding adjacent to passenger airbag module
• Steering wheel (if damage is evident) • Headlining
• Front seat frames and head restraints (if there is evidence • ICS mounting brackets
of damage to the seat frame or cushion pan) • Alarm sensor
• Steering column (if adjustment is lost or there are signs • Front seat belts (retractors, webbing, tongue latching, ‘D'
of collapse) loop and body anchorage points)
• Seat belt automatic height adjusters on ‘B' posts • Rear seat belt buckles (webbing, buckle covers, tongue
• Rear seat belt escutcheons in parcel shelf trim latching and body anchorage)
Side (Thorax) Airbags • ‘B' post upper finisher and fixings
If the side (thorax) airbags are deployed, the following parts • Door casing
must be replaced, on the side of the vehicle on which the • Seat belt automatic height adjusters on ‘B' post
deployment occurred: • Rear seat belt escutcheons in parcel shelf trim
• Seat (thorax) airbag module Rear Impacts
• Seat squab foam Rear impacts may cause the seat belt pretensioners to deploy.
• Seat squab cover If this occurs, all pretensioner units must be replaced. In
addition, the following components should be inspected for
• Front seat belt buckle pre-tensioners
damage and replaced as necessary:
1.0 20
General Information
• Front seat frames Air Conditioning System Precautions
• Seat belt automatic height adjusters on ‘B'- post General
• Front seat belts (retractors, webbing, tongue latching, ‘D' The air conditioning system contains fluids and components
loop and body anchorage points) which could be potentially hazardous to the service engineer
• Rear seat belt buckles (webbing, buckle covers, tongue or the environment if not serviced and handled correctly. The
latching and body anchorage) following guidelines are intended to alert the service engineer
to potential sources of danger and emphasise the importance
• Rear seat belt escutcheons in parcel shelf trim
of ensuring the integrity of the air conditioning operating
• SRS ECU
conditions and components fitted to the vehicle.
Periodic Replacement of SRS Components
Where necessary, additional specific precautions are detailed
The performance of the propellants within airbags and in the relevant sections of this Manual which should be referred
pre-tensioners will deteriorate over a period of time. As a to prior to commencing repair operations.
result, it is essential that the airbags and pre-tensioners are
periodically replaced to maintain occupant safety. Airbags, The refrigerant used in the air conditioning system is HFC-134a
seat belt pre-tensioners and the rotary coupler should be (Hydrofluorocarbon) R134a.
replaced at 10 year intervals. Warning: Servicing must only be carried out by personnel
familiar with both the vehicle system and the charging and
testing equipment. All operations must be carried out in
a well ventilated area away from open flame and heat
sources.
Warning: R134a is a hazardous liquid and when handled

incorrectly can cause serious injury. Suitable protective
clothing, consisting of face protection, heat-proof gloves,
rubber boots and rubber apron or waterproof overalls,
must be worn when carrying out operations on the air
conditioning system.
Remedial Actions
If an accident involving R134a should occur, conduct the
following remedial actions:
• If liquid R134a enters the eye, do not rub it. Gently run
large quantities of eye wash over affected eye to raise the
temperature. If an eye wash is not available, cool, clean
water may be used to flush the eye. After rinsing, cover
the eye with a clean pad and seek immediate medical
attention.
• If liquid R134a is splashed onto the skin, run large
quantities of water over the affected area to raise the
temperature. Implement the same action if the skin
comes in contact with discharging cylinders. Wrap
the contaminated body parts in blankets (or similar
materials) and seek immediate medical attention.
• If the debilitating effects of inhalation of R134a vapour
is suspected, seek fresh air. If the affected person is
unconscious, move them away from the contaminated
area to fresh air and apply artificial respiration and/ or
oxygen and seek immediate medical attention.
1.0 21
General Information
Warning: Due to its low evaporating temperature, R134a • Whenever the refrigerant system is opened, the
must be handled with care. R134a splashed on any part receiver/drier must be renewed immediately before
of the body will cause immediate freezing of that area. evacuating and recharging the system.
Also, refrigerant cylinders and replenishment trolleys • Use alcohol and a clean lint-free cloth to clean dirty
when discharging will freeze skin to them if contact is connections.
made.
• Ensure that all new parts fitted are marked for use with
Service Precautions R134a.
Observe the following precautions when handling components Refrigerant Oil
used in the air conditioning system: Refrigerant oil easily absorbs water and must not be stored for
• Air conditioning units must not be lifted by their hoses, long periods. Do not pour unused refrigerant oil back into the
pipes or capillary lines. container. Always use an approved refrigerant oil.
• Hoses and lines must not be subjected to any twist or When replacing components in the A/C system, drain the
stress; the efficiency of the system will be impaired by refrigerant oil from the component being replaced into
kinks or restrictions. Ensure that hoses are correctly a graduated container. On assembly, add the quantity of
positioned before tightening couplings, and ensure that refrigerant oil drained to the new component.
all clips and supports are utilised.
Compressor
• Flexible hoses should not be positioned close to the
A new compressor is sealed and pressurised with Nitrogen gas.
exhaust manifold (less than 100 mm) unless protected
When fitting a new compressor, slowly release the sealing cap;
by heat shielding.
gas pressure should be heard to vent as the seal is broken.
• Completed assemblies must be checked for refrigeration
lines touching metal panels. Any direct contact of Caution: Do not remove the cap(s) until immediately
components and panels may transmit noise and so must prior to connecting the air conditioning pipes to the
be eliminated. compressor.
• The appropriate torque wrench must be used when Rapid Refrigerant Discharge
tightening refrigerant connections to the stipulated If the air conditioning system is involved in accident damage and
value. An additional spanner must be used to hold the the system is punctured, the refrigerant will discharge rapidly.
union to prevent twisting of the pipe when tightening The rapid discharge of refrigerant will also result in the loss
connections. of most of the oil from the system. The compressor must be
• Before connecting any hose or pipe, ensure that removed and all the remaining oil in the compressor drained
refrigerant oil is applied to the seat of the new O-rings, and refilled as instructed in the air conditioning section of this
BUT NOT to the threads of the connection. manual.
• All protective plugs must remain in place to seal the Precautions for Refrigerant Recovery, Recycling
component until immediately prior to connection. and Recharging
• Ensure components are at room temperature before When the air conditioning system is recharged, any existing
uncapping, to prevent condensation of moisture from refrigerant is first recovered from the system and recycled.
the air that enters it. The system is then charged with the required weight of
• Components must not remain uncapped for longer than refrigerant and volume of refrigerant oil.
15 minutes. In the event of a delay, the caps must be Warning: Refrigerant must always be recycled before
fitted. re-use to ensure that the purity of the refrigerant is high
• When disconnecting, immediately cap all air conditioning enough for safe use in the air conditioning system.
pipes to prevent ingress of dirt and moisture into the
Warning: Recycling should always be carried out with
system.
equipment which is design certified by Underwriter
• The receiver/drier contains desiccant which absorbs Laboratory Inc. for compliance with SAE J1991. Other
moisture. It must be positively sealed at all times. A equipment may not recycle refrigerant to the required
receiver/drier that has been left uncapped must not be level of purity.
used, fit a new unit.
Warning: A R134a Refrigerant Recovery Recycling
• The receiver/drier should be the last component
Recharging Station must not be used with any other type
connected to the system to ensure optimum dehydration
of refrigerant.
and maximum moisture protection of the system.
1.0 22
General Information
Warning: Refrigerant R134a from domestic and Air Conditioning Compressor Replacement
commercial sources must not be used in motor vehicle air Replacement Instructions
conditioning systems.
A new compressor is supplied filled with a full charge of
Caution: The system must be evacuated immediately refrigerant oil. The new compressor must be drained and a
before recharging commences. Delay between evacuation calculated quantity of oil added before fitting. To calculate the
and recharging is not permitted. quantity of oil to be added, carry out the following procedure:
1. Remove the filler/drain plug from the old compressor.

2. Invert the compressor and gravity drain the oil into a
calibrated measuring cylinder. Rotate the compressor
clutch to ensure the compressor is completely drained.
3. Record the quantity of oil drained, discard the oil.
4. Remove the filler/drain plug from the new compressor.
5. Invert the compressor and gravity drain the oil into a
calibrated measuring cylinder. Rotate the compressor
clutch to ensure the compressor is completely drained.
6. Add the same amount of oil drained from the old
compressor to the new compressor.
7. Discard the remaining oil drained from the new
compressor.
8. Fit and tighten the compressor filler/drain plug.
1.0 23
General Information Vehicle Identification Number
Vehicle Identification Number

Vehicle Identification Number
Vehicle Identification Number (VIN)
Example : LSJZ14E96JSXXXXXX
Figures Code Description
1–3 LSJ Manufacturer's Identifier
4–5 Z1 Vehicle Type
Vehicle Body Structure,
6 4
4 = 2–compartment & 5–door
7 E Engine E = 1.5L Gasoline Engine
Occupant Restraint System
8 9 9 = Safety belt, driver and front-seat

passenger airbag & seat-side airbag ,
and front & rear curtain airbag
Check bit (represented by any figure
9 6
from 0 to 9 or letter X)
Model Year
10 J
J = 2018
Assembly Plant
11 S
S = Lingang, Shanghai
6 digits = Production Sequential
12–17 XXXXXX
Number
VINis also stamped in the following locations:
• On a plate behind the LH lower corner of the windshield.

• On the right dash panel of the engine compartment.
• On the vehicle identification plate.
Location of Vehicle Identification Plate

The vehicle identification plate is located under the right B
pillar striker. For details, please refer to the specific VIN plate.
1.0 24
Vehicle Identification Number General Information
Position Of Other Plates
Engine Number (1.5L Engine)
Printed on the left rear of the cylinder block, as shown in the
arrow.
Automatic Transmission Number - 4AT

Printed on the top surface of the front part of the transmission
housing.
Manual Transmission Number - 5MT

Attached on the top surface of the front part of the
transmission housing.
1.0 25
General Information Lifting & Towing
Lifting & Towing

Lifting
Lifting Description
Note the following points before lifting the vehicle from the
ground:
• The vehicle should be parked on a level and firm ground.

• Apply the hand brake.
• The transmission is in P or N.
To avoid damage to the lower body components of the vehicle,

be sure to follow the support procedures below:
DO NOT place the jack or the axle support under the

Vehicle Jack
following components:
• Body Structural Parts

• Bumper
• Fuel Line
• Brake Line
• Front Suspension Arm
• Steering Linkage
• Rear Suspension Arm
• Fuel Tank
• Engine Oil Pan
• Transmission Case
Note: Jacking and supporting the front of the vehicle The jack of the vehicle is only applied to replace wheels in
should only be done under the customer front jacking emergency. Never use it for other purposes.
points and/or the jacking bracket on the front section of
If using the jack to replace wheels, be sure to place the jack on
the front subframe.
a solid level ground and position it under the supporting point
Lifting and Supporting Vehicle near the wheel to be removed. Note that the snap head of the
Front and Rear Supporting Points of Vehicle jack must be placed in the appropriate groove of the deck.
Place the head of the jack on the supporting points of the front Hydraulic Jack
and rear sills on the vehicle. The hydraulic jack must have a load capacity of at least 1,500
Caution: Do not jack or support the vehicle on any other kg (3,300 lbs).
points than those indicated. Failure to comply is likely to Column Lifter
result in damage to the body or chassis components.
Warning: Always chock the wheels when jacking.

Warning: Do not commence work on the underside of the

vehicle until suitable safety supports have been positioned
under the sill reinforced brackets.
1.0 26
Lifting & Towing General Information
Put the mat under the jacking point on the sill. Roadside Assistance
Instructions for Roadside Assistance
It is recommended that a rescue trailer or a two-wheel rescue
vehicle shall be used. In emergency, use a towing vehicle with
front towing point.
Front Towing Eye
In the front of the vehicle, removable towing eye can be used

for rescue operation. The front towing eye is usually kept in
the vehicle toolbox and should be put back after using. When
fitting the towing eye, remove the towing eye cover at the right
side of the front bumper first, then screw the towing eye into
the mounting position of the front bumper assembly (bumper
beam).
Manual Transmission
For four wheels towing, operate from the front via the towing
eye.
Before towing, release the hand brake, put the shift lever at
the neutral gear and the ignition switch at “ON” position. The
towing speed shall not exceed 50km/h (30mph).
The following precautions must be taken:
In order to ensure that the vehicle still has steering capability

when it is towed, it is necessary to insert the ignition key and
1.0 27
General Information Lifting & Towing
put it to “ON” position. This state must be maintained when Note: A vehicle with an automatic transmission cannot be
the vehicle is moving. started by towing or pushing.
• When the transmission or drive shaft fails, the vehicle Vehicle Shipping
could not be towed.
If your vehicle needs to be shipped, we recommend you to use
• Ensure that the shift lever is at the neutral gear and special transporter to ship.
parking brake is disabled.
• If the engine is not in operation during towing, more care
must be taken in brake and steering operation.
Caution: If the transmission case occurs malfunction and

the transmission fluid level is too low, the four wheels of
the vehicle cannot be towed absolutely.
Automatic Transmission
Generally, vehicles with automatic transmission should be
towed with the front wheels off the road (with front wheels
hanged up).
Fix the vehicle on the transporter as follows:

• Apply the parking brake and place the transmission shift
lever in N position.
• Position the brake pads on the front and rear wheels.
• Fit the tether around the tyre and secure it to the trailer,
tighten the tether to fix the vehicle firmly.
Caution: A rear suspended tow must not be used for
vehicles with an automatic transmission, as serious
damage will be caused to the transmission.
In order to ensure that the vehicle still has steering capability

when it is towed, it is necessary to insert the ignition key and
put it to “ON” position. This state must be maintained when
the vehicle is moving.
For vehicles with automatic transmission, when towing the

four wheels from the front, attention must be paid to the
followings:
Warning: When the vehicle is being towed.

• The selector must be at ‘N'.
• The vehicle must not be towed at speeds greater than
30 km/h or for a distance exceeding 50 km.
• Do not tow if the gearbox or a drive shaft is faulty.
• Ensure the gear lever is in neutral and the parking
brake is released.
• Remember that greater effort than normal will be
necessary to operate the brakes and steering if the
vehicle is being towed without the engine running.
Caution: Do not tow on four wheels if the gearbox or drive
shafts are touching the body or frame.
1.0 28
Lubrication & Maintenance General Information
Lubrication & Maintenance Fluid
Capacity Fuel
Liquid Capacity Following recommended oils must be applied:
The following capacity values are merely approximate value for For gasoline engines
the corresponding system. 91# and above gasoline RON is recommended. DO NOT use
Component/System Capacity gasoline containing methanol.
Fuel Tank : 45L Antifreeze Fluid
Engine Oil - 1.5L: The mixture with 50% water and 50% OAT shall be used.
The antifreeze containing organic acid technology (OAT)
Refill from Dry State 4.4L
preservative and summer coolant or ethylene-glycol-based
Replacement of the Engine Oil 4.1L antifreeze (methanol not contained) are applied to protect
and Oil Filter the cooling system. Only the antifreeze with OAT antiseptic
Manual Transmission Oil - 5MT: can be used.
Refill 1.8L Do not use other types of antifreeze to supplement or refill

the cooling system. In emergency, if the antifreeze of this
Refill from Dry State 2.0L type is unavailable, the clean water can be used to fill the
Auto Transmission Oil - 4AT： cooling system. However, this may lower the frost protection
capability. The correct antifreeze concentration must be
Refill 4.85L
recovered as soon as possible.
Cooling System Coolant:
When it is time for inspection specified in the Maintenance List,
Expansion Tank 0.7L drain the cooling system and clean it, then refill the cooling
Cooling System 4.9L system with appropriate coolant.
Steering System 0.92L After refilling antifreeze, attach the warning label at a
prominent position of the vehicle to show the type of
Brake Fluid for Brake System:
antifreeze used in the cooling system, so that correct antifreeze
Refill from Dry State 0.73L can be used for next refill.
Windshield Washer Reservoir 2.5L Concentration of Antifreeze Fluid
The overall antifreeze concentration shall not be less than 50%
of the volume, meanwhile make sure the antisepsis property
of the coolant. Antifreeze concentration more than 60% is not
recommended as it will weaken the cooling efficiency.
The antifreeze capacity recommended in the following table

shall provide frost protection at -37℃ - -40℃.
Engine :
Concentration 50%
Capacity of Antifreeze Fluid 2.8L
Brake Fluid
Use brake fluid DOT 4 only.
PAS Fluid
Use the liquid that conforms to the Dexron III specification.
1.0 29
General Information Lubrication & Maintenance
Lubricating Fluid Lock, Lock Body and Hinge

Overview Do not apply any lubricating grease on the fixing end of the
The engine and other lubrication systems are filled with torsion bar spring, however, Krupp Isoflex Topas L32CN
high-performance lubricating fluid to extend the service life. lubricating grease is recommended for its rotating end.
Caution: Always use a high quality oil of the correct Washer Fluid
viscosity range in the engine. The use of oil of the Use QX-35 washer fluid.
incorrect specification can lead to high oil and fuel
consumption and ultimately to damaged components.
The use of the engine oil of recommended specifications

containing additives may decrease the corrosive acid caused
by combustion and prevent formation of residues. These
residues may block the oil passage. Other engine oil additives
should not be used.
Repair and maintenance must be carried out within the

specified interval.
Engine Oil
1.5L engine uses 5W–30 engine oil in compliance with ACEA
A5/B5 specification and 0W-20 engine oil in compliance with
C5 specification.
The engine oil viscosity/temperature range refers to the

following table:
Transmission Fluid
Failure to use specified transmission fluid may result in serious
damage to the transmission.
Manual Transmission - 5MT
Refill or fill up with MTF94 oil.
Automatic Transmission - NEW 4AT
Refill or fill up with AW-1 oil.
General Lubricating Grease
Use FN745/94 lubricating grease produced by Fuchs.
Bonnet Lock Body
Use FN745/94 lubricating grease produced by Fuchs.
1.0 30
Engine Mechanical Engine
Engine Mechanical
Specifications
Torque
Description Value
Bolt-Under The Tie-bar Bracket to Automatic Transmission (45-55)Nm+(85-95)deg
Bolt-Under The Tie-bar Bracket to Under The Tie-bar (81-99)Nm+(85-95)deg
Bolt-Steering Fluid Pipe Bracket to Steering Pump 7-10Nm
Nut-Steering Fluid Pipe to Steering Pump 36-40Nm
Nut-Oil-cooled Pipe to Automatic Transmission 33-37Nm
Bolt-Oil-cooled Pipe Bracket to Automatic Transmission 7-10Nm
Bolt-Under The Tie-bar Bracket to Manual Transmission （45-55）Nm+（85-95）deg
Bolt-Under The Tie-bar Bracket to Under The Tie-bar （81-99）Nm+（85-95）deg
Bolt-Slave Cylinder to Manual Transmission 40-50Nm
Bolt-Engine Mount to Engine (63-77)Nm+(85-95)deg
Bolt-Engine Mount to The Right Side Rail 90-110Nm
Bolt-Engine Mount to Body 26-34Nm
Bolt-Automatic Transmission Mount to The Left Side Rail 55-65Nm
Nut-Automatic Transmission Mount to Automatic (63-77)Nm+(85-95)deg
Transmission Mount Bracket
Bolt-Manual Transmission Mount to The Left Side Rail 55-65Nm
Nut-Manual Transmission Mount to Manual Transmission (63-77)Nm+(85-95)deg
Mount Bracket
Bolt-Flywheel to Crankshaft 35Nm+60°
Bolt - flywheel to crankshaft (32-38)Nm+60°±5°
Bolt-Torsion Vibration Damper to Crankshaft 60Nm+120°
Bolt - cover upper front to cylinder head 8-12Nm
Bolt - cover lower front to cylinder block and crankcase 8-12Nm
lower
Bolt - water pump pulley to water pump 23-27Nm
Bolt-Engine Mounting Bracket to Cylinder Body 40Nm+60deg
Bolt-Chain Guide Rail And Chain Tensioner Rail 20-24Nm
Bolt - chain guide rail upper to cylinder head front cam 8-12Nm
bearing
Bolt - timing chain tensioner to cyclinder head 18-22Nm+(22-28°)
Bolt - oil pump procket to oil pump 22-28Nm
Bolt-Cam Bearing Cap to Cylinder Head 7-10Nm
Bolt - ignition coil 8-12Nm
Bolt-Cam Bearing Cap to Cylinder Head 7-11Nm
Bolt - VCT unit to camshaft 70-80Nm
Bolt - cylinder head to cylinder block 30Nm （ 90°+60°)
Bolt - patch cylinder head to cylinder block 8-12Nm
Bolt - thermostat to cylinder head 8-12Nm
Bolt - crankcase lower to cylinder block 27-33Nm
Bolt -Connecting Rod (13-17)Nm+（77-83）°
1.0 31
Engine Engine Mechanical
Description Value
Bolt-Piston Cooling Jets to Crankcase 22-28Nm
Bolt - bearing cap to cylinder block (20±2)Nm+（90°+45°）±5°
plug blanking-plug blanking to crankcase 35-45 Nm
Bolt - bearing cap to cylinder block 8-12Nm
Bolt - oil pump to crankcase lower 8-12Nm
Bolt -baffle plate to crankcase lower 8-12Nm
Bolt - ocv to cylinder head 5-7Nm
Oil filter 16-20Nm
Plug - crankcase lower 35-40Nm
Nut-Intake Manifold to Crankcase 22-28Nm
Bolt-to Cylinder Block 8-12Nm
Bolt-Exhaust Manifold to ENG 22-28Nm
Bolt-Intake Manifold Housing 7-10Nm
1.0 32
Parameter
1.5DVCT - Main Block
Model 1.5 L gasoline engine, with 16 valves, dual overhead camshaft,
variable intake/exhaust cam timing
Cylinder Arrangement 4-cylinder, in-line, transverse, 1st cylinder at the front of engine
Cylinder Bore Diameter 75mm
Stroke 84.8mm
Displacement 1498cm 3
Ignition Sequence 1-3-4-2

Compression Ratio 11.5:1
Direction of Rotation Clockwise when viewed from engine front end
Rated Power 86kW@6000rev/min(AT);80kW@6000rev/min(MT)
Max. Torque 150Nm@4500rev/min(AT);135Nm@4500rev/min(MT)
Idle Speed 740rev/min
Max. Speed of Engine 6800rev/min
Weight 115.7kg
1.0 33
1.5DVCT - Crankshaft
Crankshaft
Crankshaft Axial Clearance 0.205 ± 0.1mm
Service Limit 0.34mm

Main Bearing Bore Diameter:
Grade A 53.690-53.700mm
Grade B 53.680-53.690mm
Main Journal Tolerance:
Grade 0 49.993-50.000mm
Grade 1 49.992-49.984mm
Crankshaft Connecting Rod Journal Diameter 43.000-42.984mm
Max. Out-of-Roundness 0.005mm

Main Bearing Shell:
Quantity 5 pieces each up and down

Model Steel backed, alloy steel and top half bearing shell has oil
passages.
Two halves of thrust washer on the left and right at the third
Thrust Washer
main bearing shell, sticks to the thrust surface.
Thrust Washer Thickness 2.810-2.855mm
Bearing Clearance 0.026-0.070mm
1.0 34
1.5DVCT - Cylinder Block and Piston
Cylinder Block:
Material Cast Iron, HT250
Type of Cylinder Liner No cylinder liner, honing process of spiral bevel gear motion
Cylinder Liner Diameter 74.985-75.000mm

Cylinder Block Size Correction:
Connecting Rod:
Model Fractured Connecting Rod, Material C70S6
Distance Between Centres 143.7 ± 0.05mm

Piston Pin Model Full-floating type
Fitted Connecting Rod Clearance
Length 44.8-45mm
Connecting Rod Bearing Shell:
Clearance 0.020-0.071mm
Axial Endplay 0.100-0.246mm

Piston:
Model Aluminum alloy, graphite finish, NANO anti-friction coated
skirt surface, offset to piston pin during thermal expansion
Piston Diameter:
74.941-74.959mm
Tolerance in Piston Pin Bore
0.005-0.013mm
Max. Ovality
0.002mm
Piston Ring:
Model: 2 compression rings, 1 oil ring
Top Compression Ring Half-barrel faced excircle, PVD treated surface
Second Compression Ring Nose shaped, phosphate coated surface
Oil Ring Three-piece oil ring, PVD treated blade

Tolerance Between Piston Ring and Ring Groove:
Top Compression Ring 0.040-0.080mm

Second Compression Ring 0.030-0.070mm
Oil Ring 0.03-0.16mm

Piston Ring Assembly Clearance in Bore (measured at 20mm
from cylinder liner bore):
0.20-0.30mm
Top Compression Ring
0.40-0.60mm
Second Compression Ring
0.20-0.70mm
Oil Ring
Width of Piston Ring:
Top Compression Ring 0.970-0.990mm
Second Compression Ring 0.970-0.990mm
1.0 35
Oil Ring 1.870-1.980mm
1.0 36
1.5DVCT Cylinder Head and Valve
Cylinder Head:
Material Aluminum alloy
Cylinder Head Height:
New 118.95-119.05mm
Flatness 0.08mm
Camshaft:
Model Double overhead camshaft directly acted on mechanical tappet
Bearing 5 for each camshaft, in-line
Drive Chain drive at crankshaft gear
Camshaft Axial Clearance: 0.06-0.19mm

Bearing Clearance: The first one 0.025-0.066mm, the rest four 0.03-0.07mm

Mechanical Tappet:
Mechanical tappet, DLC coated surface, directly driven by
Model
camshaft
Outside Diameter of Mechanical Tappet φ29.964mm-φ29.980mm
Valve Timing:
Intake Valve:
ON 20.5°ATDC
OFF 78.5°BTDC
Max. Lift 9.2mm

Exhaust Valve:
ON 65.5°BBDC
OFF 10°ATDC
Max. Lift 8.1mm

Valve:
Valve Stem Diameter:
Intake Valve φ4.967-φ4.981mm
Exhaust Valve φ4.957-φ4.971mm

Clearance Between Valve Stem and Valve Guide:
Intake Valve 0.019-0.053mm
Exhaust Valve 0.029-0.063mm

Valve Stem Fit Height:
New Intake Valve 50.033-50.893mm
New Exhaust Valve 49.948-50.808mm
1.0 37
Valve Head Diameter:
Intake Valve φ30.02-φ30.18mm
Exhaust Valve φ25.6-φ25.8mm
Valve Seat Width

1.1mm-1.3mm
Intake Valve
1.369mm-1.828mm
Exhaust Valve
Intake 150°, 90°, 65°
Valve Seat Surface Angle - Intake Valve & Exhaust Valve
Exhaust 90°, 60°
Valve Surface Angle - Intake Valve & Exhaust Valve 45°
Intake Valve: 0.17-0.23mm
Valve Clearance
Exhaust Valve: 0.27-0.33mm
Valve Spring:
Free Length 40.2mm
Mounting Length Intake side 33.6mm; Exhaust side 33.1mm
Assembly Load (L1=17mm) Intake side 115±9.2Nm; Exhaust side 125±10Nm
Intake Valve Open Load (L2=28mm) 297±14.8Nm

Exhaust Valve Open Load (L2=28mm) 291±14.6Nm
1.0 38
Lubrication
Lubrication:
Model Cast Aluminum Lower Crankcase

Oil Pump Model: Driven by belt
Outer and Inner Rotor Mesh Clearance 0.03-0.11mm
Rotor to Pump Cover End Clearance 0.05-0.086mm

Free Length of Pressure Relief Valve Spring 67.95 ± 1mm
Oil Filter Rotary Full-flow Oil Filter
Cutoff Pressure of Pressure Relief Valve at 3500rev/min 540-660 kPa
1.0 39
Usage Times of Bolt

Part No. Name Usage Times
BLT200010 Bolt - Main Bearing Cover 1
90004180 Screw - Crankshaft Sensor Signal Wheel 1
BLT200011 Bolt - Connecting Rod 1
90003592 Bolt - Oil Pump to Oil Pan 1
90003620 Stud - Intake Manifold to Cylinder Head 1
99000073 Cylinder Head Bolt 1
99000007 Bolt - Cylinder Head to Engine Block 1
BLT200012 Bolt - Crankshaft Shock Absorber 1
90004291 Bolt - Front Cover to Cylinder Head 1
90000433 Bolt - Lower Front Cover to Engine 1
Block
BLT200013 1
Bolt - Flywheel
BLT200015 1
Bolt - Tensioner
90000829 1
Hexagonal Flange Bolt - Exhaust
Manifold
1.0 40
Description and Operation
System Layout
NSE Engine Layout
1. 1.5DVCT Engine
1.0 41
Cylinder Block Exploded View
1. Cylinder Block 17. O-ring - Lower Crank Case to Cylinder Block (Oil
2. Bolt - Connecting Rod Passage)
3. Crankshaft Assembly 18. Plug - Oil Passage
4. Main Bearing (Upper) 19. Plug - Oil Pressure Switch
5. Main Bearing (Lower) 20. Washer - Cylinder Block Oil Passage Plug
6. Connecting Rod Big End Bearing 21. Plug - Timing Hole
7. Main Bearing Thrust Plate 22. Location Pin - Main Bearing Cap
8. Cylinder Block Rear End Surface Cover Plate 23. Bolt - Main Bearing Cap
9. Crankshaft Sensor Signal Plate 24. Top Ring
10. Crankshaft Rear Oil Seal 25. 2nd Ring
11. Screw - Crankshaft Sensor Signal Plate 26. 3rd Ring
12. Bolt - Crankshaft Rear Oil Seal 27. Piston
13. Location Pin - Crankshaft Sensor Signal Plate 28. Connecting Rod
14. Location Pin - Between Crankshaft and Flywheel 29. Piston Pin
15. Location Pin - Cylinder Block to Transmission Case 30. Main Bearing Cap
16. Location Pin - Front Cover to Cylinder Block 31. Main Bearing Cap
1.0 42
Camshaft Cover Exploded View
1. Ignition Coil 6. Oil Filler Cap

2. Spark Plug 7. Camshaft Cover
3. Stud - Camshaft Cover 8. Seal Ring - Camshaft Cover (Inner)
4. Bolt - Camshaft Cover 9. Seal Ring - Camshaft Cover (Outer)
5. Seal - Oil Control Valve Body
1.0 43
Cylinder Head Exploded View
1. Cylinder Head Assembly 15. Stud - Intake Manifold

2. Upper Body Assembly 16. Cylinder Head Plug
3. Oil Control Valve 17. Bolt - Camshaft Front Shaft
4. Bolt - Oil Control Valve 18. Bolt-Camshaft Bearing Cap
5. Intake Camshaft Assembly 19. Check Valve
6. Exhaust Camshaft Assembly 20. Cylinder Head Plug
7. Oil Check Valve 21. Cylinder Head Plug
8. Tappet 22. Locating Pin - Timing Belt Upper Front Cover
9. Valve Lock Clamp 23. Cylinder Head Gasket
10. Valve Spring Seat 24. Locating Pin - Cylinder Head To Engine Block
11. Valve Spring 25. Stud - Exhaust Manifold
12. Valve Stem Seal 26. Bolt - Cylinder Head
13. Exhaust Valve 27. Bolt - Cylinder Head
14. Intake Valve 28. Bolt - Cylinder Head
1.0 44
Oil Pump and Oil Filter Exploded View
1. Oil Pump 6. Oil Pump Pulley

2. Bolt - Oil Pump To Lower Crankcase 7. Bolt - Oil Pump Pulley
3. Oil Pump Belt 8. Oil Mounting Stud
4. Locating Pin - Oil Pump To Lower Crankcase 9. Oil Filter
5. Crankshaft Pulley - Oil Pump Drive
1.0 45
Lower Crankcase Exploded View
1. Lower Crankcase 8. Oil Baffle Plate

2. Locating Pin - Lower Crankcase 9. Bolt - Oil Baffle Plate
3. Pin Bush - Air Compressor to Lower Crankcase 10. Bolt - Oil Suction Pipe to Lower Crankcase Assembly
4. Oil Drain Plug 11. Oil Dipstick
5. Gasket - Oil Drain Plug 12. Bolt -Lower Crankcase to Crankcase Block
6. Oil Suction Pipe Assembly 13. Plug
7. O-ring - Oil Suction Pipe to Engine Oil Pump
1.0 46
Timing Chain System Exploded View
1. Front Upper Cover 12. Bolt - Front Upper Cover to Cylinder Head
2. Front Lower Cover 13. Bolt - Crankshaft Vibration Damper
3. Crankshaft Front Oil Seal 14. Bolt - Intake Phase Modulator
4. Timing Chain 15. Rock Rail
5. Crankshaft Sprocket - Timing Drive 16. Upper Guide Rail
6. Intake Phase Modulator 17. Chain Guide Rail
7. Exhaust Phase Modulator 18. Bolt - Chain Tensioner to Engine Body
8. Bolt - Front Lower Cover to Engine Body 19. Timing Hydraulic Tensioner
9. Bolt - Front Lower Cover to Engine Body 20. Engine Oil Control Sleeve
10. Bolt - Sprocket Upper Guide Rail to Cylinder Head Front 21. Damper Vibration Pulley
Bearing Cap
11. Bolt - Front Upper Cover to Cylinder Head
1.0 47
Exhaust Manifold Exploded View
1. Exhaust Manifold Assembly 3. Bolt - Exhaust Manifold

2. Exhaust Manifold Gasket 4. Nut - Exhaust Manifold
1.0 48
Intake Manifold Exploded View
1. Intake Manifold Assembly 7. Bolt - Canister Solenoid

2. Bolt - Intake Manifold Pressure Stabilizing Cavity 8. Canister Desorption Control Valve Bracket
3. Nut - Intake Manifold 9. Gasket - Throttle Body
4. Pipeline Assembly - Canister Control Solenoid To 10. Intake Manifold Gasket
Manifold 11. Clamp - Canister Control Valve Pipeline
5. Canister Desorption Control Valve 12. Clamp - Canister Control Valve Pipeline
6. Canister Solenoid Rubber Sleeve
1.0 49
Accessory Belt System
1. Accessory Belt 4. Belt Idler Pulley Bracket

2. Accessory Belt Tensioner 5. Belt Idler Pulley
3. Bolt - Idler Pulley Bracket 6. Bolt - Tensioner
1.0 50
Engine Sensor
1. Oil Temperature Sensor 11. Front Oxygen Sensor Assembly

2. Oil Temperature Sensor Gasket 12. Crankshaft Sensor Assembly
3. Intake Air Temperature/Pressure Sensor 13. O-Ring - Crankshaft Sensor
4. Bolt - Intake Air Temperature/Pressure Sensor 14. Screw - Crankshaft Sensor
5. Knock Sensor 15. Oil Pressure Switch Cover
6. Screw - Knock Sensor 16. Rear Oxygen Sensor Assembly
7. Oil Pressure Switch 17. Clip - Oxygen Sensor
8. Oil Pressure Switch Gasket 18. Front Oxygen Sensor Bracket
9. Camshaft Position Sensor 19. O-Ring - Camshaft Position Sensor
10. Screw - Camshaft Position Sensor
1.0 51
Water Pump and Thermostat
1. Water Pump 3. Water Pipe

2. Thermostat
1.0 52
Fuel Rail Assembly
1. Fuel Rail Assembly 4. O-Ring - Fuel Injector

2. Fuel Injector 5. Clip - Fuel Injector
3. Bolt - Fuel Rail
1.0 53
Description engine is at rest, pin of an elastic load locks both halves of the
Overview modulator; when the engine operates, they are loosened in a
hydraulic way to ensure stable starting.
The NSE engine features in-line 4-cylinder, 16-valve, DOHC,
timing chain drive and electronically-controlled multi-point fuel Two oil control valves are fitted on the front camshaft bearing
injection system. cap and fixed with an O-ring and a bolt respectively. The
control valve is a four-way proportioning valve and consists of
It is mainly composed of cylinder block, cylinder head,
an oil inlet port, an oil return port and two oil ducts connected
crankshaft, connecting rod and camshaft. The cylinder head
with the phase modulator working chamber.
is made of cast aluminum and connected with the cast iron
cylinder block through the multi-layer cylinder gaskets by using Cylinder Block Components
10 high-strength bolts, and there are 3 additional high-strength The cylinder block is constructed from cast iron material
bolts directly connected with the cast iron cylinder block, HT250, this provides high overall strength, reducing the
providing high overall strength and reliable structure. likelihood of deformation. The cylinder liner is formed by
Cylinder Head Component cylinder hole honing. Y-shaped water passages are processed
between two adjacent cylinders to ensure heat dissipation
The cylinder head adopts 4 valves per cylinder structure
effect of the cylinder block.
with a spark plug mounted at the centre of the combustion
chamber. Due to adoption of overhead valve structure, The aluminum alloy thermal expansion piston is provided with
powerful whirlpool will be formed in the combustion chamber a full-floating piston pin which can rotate freely to reduce the
to make the mixed gas evenly distributed, which is good for friction resistance and the generation and delivery of heat, so
transmission of flame to improve combustion condition, so that the reliability and smoothness of high speed of engine
as to enhance the fuel economy, power performance and rotation can be enhanced.
emission performance of the engine.
The forging steel connecting rod has the structure of the
The mechanical tappets are fitted at the top of each valve H-section. The big end of connecting rod moves on the
and directly driven by the camshaft. The bottom bosses bearing shell of crankshaft journal. The connecting rod adopts
of the mechanical tappets are grouped by size, and the forging+cracking process.
valve clearance is optionally fitted with appropriate grouped
The crankshaft has four balance weights and is supported by
mechanical tappets. The valve stem oil seal is press-fitted on
five bearing shells. The end float is controlled by the thrust
the cylinder head oil seal seat and can be used as the valve
washer on the top of the central main bearing shell. The radial
spring seat to support the valve spring.
clearance of the bearing shell is optional, which is controlled
The exhaust valve is of a carbon deposit removal type, and the by the bearing shells of two different grades. The oil groove
valve stem with a machined side can clean the carbon buildup offered in the upper half part of the main bearing shell supply
at the end of valve duct and in combustion chamber so as to oil to the connecting rod big end bearing shell through the oil
prevent valve from seizing. hole in the crankshaft.
The metal cylinder gasket is of a multi-layer structure, the Lower Crankcase Components
cylinder opening adopts a pressing ring structure, which The lower crankcase assembly consists of lower crankcase, oil
enhances sealing at cylinder opening; local rubber coat pump assembly, oil strainer and oil filter.
technology is adopted to ensure the sealing performance.
The aluminum lower crankcase is designed into a shape that is
There are four oil ducts at the front bearing cap of the suitable for accumulating oil around the strainer, the oil pump
camshaft, one oil inlet duct, one oil return duct and two and oil strainer are fitted to bottom of crankcase after being
operating oil ducts. Oil enters the oil control solenoid valve combined, and oil passes through the oil strainer with screen
via the oil ducts. The tail end of the intake/exhaust camshaft and then the oil filter by pressurization of the oil pump.
is equipped with a camshaft signal wheel to provide signals
Clean oil is distributed to the main bearing and cylinder head
for the camshaft position sensor. There is a timing pin hole
via the main oil passage of the engine block to lubricate the
on the camshaft for controlling camshaft timing phase during
crankshaft, connecting rod and camshaft, etc. The mating
assembly.
surface of the lower crankcase and engine block is sealed with
A phase modulator is fitted at the drive ends of the intake and sealant and secured with bolts, and the oil drain plug is located
exhaust camshafts, which is fixed by bolts. Main parts of the at the left side of the lower crankcase (in the direction of engine
phase modulator are made of aluminum. The housing (stator) front end surface).
driven by timing chain is connected with inner rotor through
five blades fixed at camshaft end in a hydraulic way. When the
1.0 54
Engine Accessories intake system vacuum level, then sends it to the cylinder for
combustion, so as to reduce the air pollution.
The accessories are a single 5-ribbed belt drive system driven
by crankshaft pulley, the system drives the water pump, Oil and gas in the crankcase are separated via an oil separating
alternator and A/C compressor and tensions the belt via a device in the camshaft cover, and oil flows back to the
damping tensioner. crankcase.
Crankcase Ventilation
The ventilation system redirects the exhaust gas escaped to
the crankcase back into the intake system with the help of
1.0 55
Operation
Lubricating Oil Circuit
1. Cylinder Head Oil Duct 6. Engine Oil Pump

2. Cylinder Block Main Oil Duct 7. Main Oil Duct
3. Crankshaft Cross Oil Duct 8. Timing Chain Tensioner
4. Engine Oil Inlet Pipe 9. Oil Control Valve
5. Engine Oil Filter
The lubrication system is a full-flow filtration, forced oil supply is blocked, this valve will open and ensure the free flow of oil,
system. Oil is drawn from the oil pan through the oil strainer but the oil filter shall be replaced as soon as possible.
by the oil pump, and the oil strainer is equipped with a screen
Then, the oil enters into the main oil passage, and lubricates the
which can prevent impurities from entering the oil pump.
main bearing shell directly via the cross oil circuit. The cross oil
The oil pump with a pressure limiting valve is driven by the circuit on the crankshaft delivers the oil from the main bearing
crankshaft via a belt. When the oil pressure reaches a certain shell to the connecting rod big end bearing shell.
value, the pressure relief valve will open, the excess oil returns
The cylinder head has two side oil passages connecting with
to the inlet side of oil pump, and this helps maintain the oil
the main oil passage of the engine block. After entering the
pressure within a certain operating pressure range and ensure
side oil passages, the oil flows into 2 horizontal oil passages of
the normal operation of engine. Oil flowing from the oil pump
the standard length and is supplied to each mechanical tappet
outlet enters into the full-flow oil filter.
and camshaft journal.
The full-flow oil filter is directly fitted on the oil pan. The oil
filter is equipped with a by-pass valve. When the filter element
1.0 56
The oil splashed by the crankshaft lubricates the cylinder the piston pin from the connecting rod small end through the
wall, the oil collected by the lower side of the piston crown oil circuit.
lubricates the connecting rod small end, and oil is supplied to
1.0 57
Service Procedures
Powertrain Remove and Refit - AT
Remove
1. Disconnect the battery negative.
2. Drain the coolant.
Coolant Drain
3. Drain the automatic transmission fluid.
Automatic Transmission Fluid Drain

4. Recycle the refrigerant.
Refrigerant Recycle
5. Remove the air filter assembly.
12. Disconnect the clamp fixing the radiator water outlet
Air Filter Assembly Remove hose to the engine.
6. Remove the front/rear brackets of the battery tray.
Front Bracket of Battery Tray Remove
Rear Bracket of Battery Tray Remove

7. Remove the left drive shaft assembly.
Left Drive Shaft Assembly Remove
8. Remove the right drive shaft assembly.
Right Drive Shaft Assembly Remove

9. Remove the front exhaust pipe assembly.
Front Exhaust Pipe Assembly Remove

10. Disconnect the clamp fixing the engine overflow pipe
to the thermostat. 13. Disconnect the clamp fixing the water inlet/outlet pipes
of the heater core to the thermostat.
11. Disconnect the clamp fixing the radiator water inlet

hose to the thermostat. 14. Remove 1 bolt (1) fixing the bracket of the automatic
transmission oil cooler pipe to the automatic
transmission.
15. Remove the automatic transmission oil cooler pipe to
fix to the automatic transmission (2).
1.0 58
steering fluid pump.
16. Disconnect the harness connector connecting to the

automatic transmission TCM. 22. Disconnect the fuel vapor pipe from the canister
17. Remove the clip fixing the automatic transmission cable solenoid.
to the automatic transmission.
18. Remove the automatic transmission cable rocker arm
to fix to the automatic transmission ball joint.
23. Disconnect the fuel pipe from the fuel rail.
19. Remove the A/C compressor.
Compressor Remove
20. Disconnect the clamp fixing the pipeline (reservoir to
water pump) to the water pump.
24. Disconnect all harness connections of the automatic

transmission.
25. Fix the engine with special tools T10007 and
TEN00070.
21. Remove 1 bolt fixing the steering fluid pipeline to the

steering pump and the nut fixing the pipeline to the
1.0 59
check the torque.

6. Remove the special tools T10007 and TEN00070.
7. Connect all harness connections of the automatic
transmission.
8. Connect the fuel pipe to the fuel rail.
9. Connect the fuel vapour pipe to the canister solenoid.
10. Fit 1 bolt fixing the bracket of the steering fluid pipeline
to the steering pump, tighten to 7-10Nm, and check
the torque.
11. Fit 1 nut fixing the steering fluid pipeline to the steering
pump, tighten to 36-40Nm, and check the torque.
12. Fit the A/C compressor.
26. Remove the powertrain mount.
Compressor Refit
Powertrain Mount Remove
13. Fix the automatic transmission oil cooler pipe to the
27. Remove and discard 1 bolt fixing the lower tie rod to automatic transmission, tighten to 33-37Nm, and
the lower tie rod bracket (1). check the torque.
28. Remove and discard 3 bolts fixing the lower tie rod 14. Fit 1 bolt fixing the bracket of the automatic
bracket to the automatic transmission (2). transmission oil cooler pipe to the automatic
transmission, tighten to 7-10Nm, and check the
torque.
15. Fit the clamp fixing the water inlet/outlet pipes of the
heater core to the thermostat.
16. Fit the clamp fixing the radiator water outlet hose to
the engine.
17. Fit the clamp fixing the radiator water inlet hose to
the thermostat.
18. Fit the clamp fixing the engine overflow pipe to the
thermostat.
19. Fit the front exhaust pipe assembly.
Front Exhaust Pipe Assembly Refit
29. Raise the vehicle on a lift.
20. Fit the left axle shaft assembly.
30. Support the powertrain with hydraulic jack.
Left Drive Shaft Assembly Refit
31. Fix the powertrain to the hydraulic jack, and remove
21. Fit the right axle shaft assembly.
the special tools T10007 and TEN00070.
Right Drive Shaft Assembly Refit
Refit
22. Fit the front/rear brackets of the battery tray.
1. Fix the powertrain to the hydraulic jack, and place at
Front Bracket of Battery Tray Refit
the bottom of the body.
2. Lower the vehicle, place the engine in the engine Rear Bracket of Battery Tray Refit
compartment, and fix the engine with special tools 23. Fit the air filter assembly.
T10007 and TEN00070. Air Filter Assembly Refit
3. Fit the powertrain mount. 24. Fill the refrigerant.
Powertrain Mount Refit Refrigerant Refill
4. Fit 3 new bolts fixing the lower tie rod bracket 25. Fill the automatic transmission fluid.
to the automatic transmission, tighten to Automatic Transmission Fluid Refill
(45-55)Nm+(85-95)deg, and check the torque. 26. Fill the coolant.
5. Fit 1 new bolt fixing the lower tie rod to the lower tie Coolant Refill
rod bracket, tighten to (81-99)Nm+(85-95)deg, and
27. Connect the battery negative.
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Powertrain Remove and Refit - MT
Remove
Coolant Drain
3. Drain the manual transmission fluid.
Manual Transmission Fluid Drain

4. Recycle the refrigerant.
Refrigerant Recycle
Air Filter Assembly Remove 13. Disconnect the clamp fixing the radiator water outlet
6. Remove the air intake pipe Assembly. hose to the engine.
Air Intake Assembly Remove





11. Disconnect the clamp fixing the engine overflow pipe 14. Disconnect the clamp fixing the water inlet/outlet pipes
to the thermostat. of the heater core to the thermostat.
12. Disconnect the clamp fixing the radiator water inlet 15. Disconnect the connector of the reverse lamp switch.
hose to the thermostat. 16. Pay attention to the mounting position, and disconnect
2 cable ball joints of the gear selection/shift rocker arm
of the manual transmission.
1.0 61
17. Loosen the clips fixing the gear selection/shift cable to 21. Remove 1 bolt fixing the steering fluid pipeline to the
the bracket. steering pump and the nut fixing the pipeline to the
steering fluid pump.
18. Remove 2 bolts fixing the slave cylinder to the manual

transmission.
22. Disconnect the fuel vapor pipe from the canister
Caution: Don’t hang the slave cylinder for a long time ，
solenoid.
or the hose of slave cylinder will become deformed.
23. Disconnect the fuel pipe from the fuel rail.

19. Remove the A/C compressor.
Compressor Remove
20. Disconnect the clamp fixing the pipeline (reservoir to
water pump) to the water pump.
1.0 62
Refit
1. Fix the powertrain to the hydraulic jack, and place at
the bottom of the body.
2. Lower the vehicle, place the engine in the engine
compartment, and fix the engine with special tools
T10007 and TEN00070.
3. Fit the powertrain mount.
Powertrain Mount Refit
4. Fit 3 new bolts fixing the lower tie rod bracket to
the Manual transmission, tighten to （45-55））Nm+
（ 85-95））deg, and check the torque.
Caution: Yielding technique is applied to this bolt . For
24. Fix the engine with special tools T10007 and virgin installation, the bolt is allowed to use twice. For
TEN00070. second use of bolt in the same station, the bolt must be
loosened to zero Nm, then tighten it according to specified
technique; when the bolt is used over twice or unknown
times, new bolt must be taken.
5. Fit 1 new bolt fixing the lower tie rod to the lower tie
rod bracket, tighten to （ 81-99））Nm+（（85-95））
deg, and check the torque.
virgin installation, the bolt is allowed to use twice. For
second use of bolt in the same station, the bolt must be
25. Remove the powertrain mount. 6. Remove the special tools T10007 and TEN00070.
Powertrain Mount Remove 7. Connect the fuel pipe to the fuel rail.
26. Remove and discard 1 bolt fixing the lower tie rod to 8. Connect the fuel vapour pipe to the canister solenoid.
the lower tie rod bracket (1). 9. Fit 1 bolt fixing the bracket of the steering fluid pipeline
27. Remove and discard 3 bolts fixing the lower tie rod to the steering pump, tighten to 7-10Nm, and check
bracket to the Manual transmission (2). the torque.
10. Fit 1 nut fixing the steering fluid pipeline to the steering
11. Fit the A/C compressor.
Compressor Refit
12. Fit 2 bolts fixing the slave cylinder to the manual
torque.
13. Connect the clips fixing the gear selection/shift cable
to the bracket.
14. Connect 2 cable ball joints of the gear selection/shift
rocker arm of the manual transmission.
15. Fit the clamp fixing the water inlet/outlet pipes of the
28. Raise the vehicle on a lift. heater core to the thermostat.
29. Support the powertrain with hydraulic jack. 16. Fit the clamp fixing the radiator water outlet hose to
30. Fix the powertrain to the hydraulic jack, and remove the engine.
the special tools T10007 and TEN00070. 17. Fit the clamp fixing the radiator water inlet hose to
1.0 63
the thermostat. Powertrain Mount

18. Fit the clamp fixing the engine overflow pipe to the Remove
thermostat. 1. Disconnect the battery negative.
19. Fit the front exhaust pipe assembly. 2. Remove the front/rear brackets of the battery tray.
Front Exhaust Pipe Assembly Refit Front Bracket of Battery Tray Remove
20. Fit the left axle shaft assembly. Rear Bracket of Battery Tray Remove
Left Drive Shaft Assembly Refit 3. Fix the powertrain with special tools T10007 and
21. Fit the right axle shaft assembly. TEN00070.
4. Remove and discard 1 nut (1) fixing the automatic
transmission mount to the automatic transmission
22. Fit the front/rear brackets of the battery tray. mount bracket.
Front Bracket of Battery Tray Refit 5. Remove and discard 4 bolts (2) fixing the automatic
transmission mount to the left longitudinal beam.
Rear Bracket of Battery Tray Refit
23. Fit air intake pipe assembly.
Air Intake Pipe Assembly Refit.
24. Fit the air filter assembly.
Air Filter Assembly Refit

25. Fill the refrigerant.
Refrigerant Refill
26. Fill the Manual transmission fluid.
Manual Automatic Transmission Fluid Refill

27. Fill the coolant.
Coolant Refill
6. Remove and discard 1 nut (1) fixing the Manual
transmission mount to the Manual transmission mount
bracket.
7. Remove and discard 4 bolts (2) fixing the Manual
transmission mount to the left longitudinal beam.
8. Remove and discard 1 bolt (1) fixing the engine mount

to the body.
9. Remove and discard 2 bolts (2) fixing the engine mount
to the right longitudinal beam.
10. Remove and discard 3 bolts (3) fixing the engine mount
to the engine.
1.0 64
Torque Converter Drive Plate - AT
Remove
1. Remove the automatic transmission.
Automatic Transmission Remove

2. Remove the plug from the timing hole of the engine
block.
3. Rotate the drive plate, when the flywheel mounting pin
hole of the crankshaft is horizontally aligned with the
air intake side, the flywheel timing pin hole is aligned
with the pin hole of the engine block.
4. Insert into the drive plate pin hole through the engine
block timing hole with the TEN00002 to lock it up.
11. Remove the powertrain mount.
Refit
1. Fit 3 new bolts fixing the engine mount to the engine,
tighten to (63-77)Nm+(85-95)deg, and check the
torque.
2. Fit 2 new bolts fixing the engine mount to the right
longitudinal beam, tighten to 90-110Nm, and check
the torque.
3. Fit 1 new nut fixing the engine mount to the body,
tighten to 26-34Nm, and check the torque.
4. Fit 4 new bolts fixing the automatic transmission mount
to the left longitudinal beam, tighten to 55-65Nm, and
check the torque.
5. Unscrew 6 bolts fixing the drive plate to the crankshaft
5. Fit 1 new nut fixing the automatic transmission mount
and discard them.
to the automatic transmission mount bracket, tighten
to (63-77)Nm+(85-95)deg, and check the torque.
6. Fit 4 new bolts fixing the Manual transmission mount
to the left longitudinal beam, tighten to 55-65Nm, and
check the torque.
7. Fit 1 new nut fixing the Manual transmission mount
to the Manual transmission mount bracket, tighten to
(63-77)Nm+(85-95)deg, and check the torque.
8. Remove the special tools T10007 and TEN00070.

6. Remove the drive plate from the crankshaft.
1.0 65
Flywheel-MT
Remove
1. Remove the clutch assembly.
Clutch Assembly Remove

2. Remove the plug from the timing hole of the engine
body.
3. Rotate the flywheel, observe from the flywheel end,
when the flywheel mounting pin hole is horizontally
aligned with the air intake side, the flywheel timing pin
hole is aligned with the pin hole of the engine body.
7. Remove the special tool TEN00002 for flywheel

timing pin.
Refit
1. Use a saw to make two saw cuts on the bolt removed
from the drive plate at an angle of 45° to the bolt
shank, and clean the bolt hole on the crankshaft with
the sawed bolt.
2. Clean the mating face of the drive plate and the
crankshaft.
3. Fit the drive plate to the crankshaft.
4. Fit the new glue bolts, but do not tighten them.
4. Insert the flywheel timing pin special tool
5. Rotate the drive plate,when the flywheel mounting pin TEN00002into the flywheel pin hole through the
of the crankshaft is horizontally aligned with the air engine body timing hole to lock the flywheel.
intake side, insert the flywheel timing pin special tool
TEN00002 into the engine block timing hole to lock
it up.
6. Tighten the bolt to 35Nm+60° using a diagonal
sequence.
5. Unscrew 6 bolts fixing the flywheel to the crankshaft

and discard.
7. Remove the special tool TEN00002 of the drive plate

timing pin.
8. Refit the plug.
9. Fit the automatic transmission.
Automatic Transmission Refit
1.0 66
6. Remove the flywheel from the crankshaft. 7. Remove the flywheel timing pin special tool
TEN00002.
8. Fit the plug.
9. Fit the clutch assembly.
Clutch Assembly Refit
7. Remove the flywheel timing pin special tool

TEN00002.
Refit
1. Use a saw to make two tooth grooves on the bolt
removed from the flywheel at an angle of 45°to the
bolt shank, and clean the bolt hole on the crankshaft
with the sawed bolt.
2. Clean the joint face of the flywheel and crankshaft.
3. Fit the flywheel to the crankshaft.
4. Fit new bolts coated with adhesive and tighten them
by hand.
5. Rotate the flywheel, observe from the flywheel. When
the flywheel mounting pin hole is horizontally aligned
with the air intake side, insert the flywheel timing pin
special tool TEN00002to lock the flywheel.
6. Tighten the bolt to (32-38)Nm+60°±5°in diagonal
sequence.
1.0 67
Crankshaft Pulley
Remove
2. Raise the front of the vehicle.
3. Remove the camshaft cover.
Camshaft Cover Remove

4. Remove the right front wheel.
Wheel Remove
5. Remove auxiliary drive belt.
Refit
Auxiliary Drive Belt Remove
1. Insert the TEN00002 into the engine body timing pin
6. Fix the crankshaft pulley with the TEN00008. hole and flywheel pin hole to lock the flywheel.
7. Loosen and remove the bolt fixing the pulley to the 2. Rotate the camshaft with the timing hole up, and lock
crankshaft, and discard the bolt. the camshaft phase with the TEN00004.
8. Remove the crankshaft pulley.
Caution: Avoid damaging the crankshaft front oil seal lip

when removing the pulley.
1.0 68
Timing Chain Upper Cover Plate
Remove
2. Remove the engine mount.
3. Remove the auxiliary drive belt.
5. Release 8 bolts securing the timing chain upper cover
plate.
3. Push the crankshaft pulley to the crankshaft sprocket
for contact.
4. Fix the crankshaft shock absorber with a special tool
TEN00008.
5. Fit the pulley bolt, tighten to 60Nm+120°, and check
the torque.
6. Fit the camshaft cover.
Camshaft Cover Refit

7. Fit the auxiliary drive belt.
Auxiliary Drive Belt Refit

8. Fit the right front wheel.
Wheel Refit 6. Remove 8 bolts securing the timing chain upper cover
plate.
9. Lower the vehicle.
Caution: When removing the timing chain upper cover
plate, ensure that the cover plate does not deform.
7. Remove the timing chain upper cover plate.
Refit
1. Check the timing chain upper cover plate.
Caution: Ensure that there is no damage on the timing
chain upper cover plate, otherwise, it may cause oil leak.
2. Along the seal strip, apply glue (width: 1.5 – 2.0mm) to

the mating face of the timing chain upper cover plate
and the cylinder head.
1.0 69
Timing Chain Lower Cover Plate

Remove
Warning: Always replace both crankshaft front oil seal and
timing chain lower cover plate together.
2. Remove the engine mount.

3. Remove the engine mount bracket.
4. Drain the engine oil.
Engine Oil Filter Remove

5. Remove the crankshaft pulley.
3. Fix the timing chain upper cover plate to the cylinder
Crankshaft Pulley Remove
head, fit 8 bolts and tighten to 8-12Nm.
6. Remove the pulley of water pump with the pulley
refit/remove special tool TEN00009.

7. Remove the bolt fixing the lower timing chain cover.

6. Fit the engine mount.

8. Remove the lower timing chain cover and discard the

front crankshaft oil seal and lower timing chain cover.
Caution: Be sure to keep the flatness of the timing chain
lower cover plate when removing it, otherwise, it will
cause oil leak.
1.0 70
Refit 5. Locate the timing chain lower cover plate assembly

1. Clean the sealant on the engine block and the contact to the cylinder block, fit and tighten 16 bolts in the
surface of the timing chain lower cover plate, ensure sequence of 1 - 16 as shown, complete the installation
there is no sealant residue on the engine block. within 3 to 5 minutes and tighten to 8-12Nm.
2. Clean the journal of the crankshaft pulley.
3. Fit the lower cover plate locating pin of the timing chain
(no need to refit it if not removed).
6. Fit the water pump pulley with the special tool

TEN00009, the tightening torque is 23-27Nm.
7. Fit the crankshaft pulley.
Crankshaft Pulley Refit
8. Fit the engine oil filter.
Engine Oil Filter Refit

9. Fit the engine mount bracket, the tightening torque is
40Nm+60deg.
10. Fit the engine mount.

11. Refill the engine oil.
Lubricating Fluid Refill

4. Apply sealant of about 2.5mm in width with an

appropriate tool according to the path shown in the
following figure, ensure continuity of the sealant.
1.0 71
Timing Chain
Remove


3. Remove the upper cover plate of the timing chain.
Timing Chain Upper Cover Plate Remove

4. Remove the lower cover plate of the timing chain.
Timing Chain Lower Cover Plate Remove

Refit
5. Remove the timing chain tensioner, and discard the
1. Remove the plug in the timing pin hole of the engine
sealing washer.
body.
2. Rotate the flywheel until the flywheel pin hole is aligned
with the pin hole of the engine body.
3. Insert the TEN00002 into the engine body timing pin
hole and flywheel pin hole to lock the flywheel.
6. Remove the upper guide rail.
4. Rotate the camshaft with the timing hole up, and lock
the camshaft phase with the TEN00004.
7. Remove and discard the intake & exhaust phase

modulator bolts.
8. Remove the crankshaft sprocket - timing drive and
timing chain.
9. Remove the guide rail pivot pin, take out the tensioner
rail and chain guide rail from the upper end of the chain
locker.
1.0 72
5. Check parts for handling mark, oil stain, rust or dirt 11. Fit a new timing hydraulic tensioner washer, screw the
before assembly. If handling mark exists, do not use it, timing hydraulic tensioner into the cylinder head, and
if oil stain exists, wipe off it. tighten to 18-22Nm+(22-28°).
6. Put in the chain guide rail from the upper right side of
the guide rail locker, fit the pivot pin and secure it in
sequence, then tighten to 20-24Nm.
7. Put in the tensioner guide rail from the upper left side
of the guide rail locker, fit the pivot pin and tighten it to
20-24Nm.
12. Fit the oil pump sprocket with the TEN00006, the
tightening torque is 22-28Nm.
8. Fit a crankshaft sprocket-timing drive into the front

end of the crankshaft. Put in the timing chain from the
upper end of the cylinder head guide rail locker, fit the
crankshaft sprocket into the lower end of the chain,
and hang the chain onto the upper rail mounting boss.
9. Fit phase modulators to the intake and exhaust
camshafts, mount the chains into the two sprocket, and
pre-tighten the bolts.
10. Fit the upper guide rail to the front bearing cap of the
13. Fit the crankshaft sprocket - oil pump drive into the
camshaft, fix with two bolts, the tightening torque is
front end of the crankshaft, then fit the oil pump belt.
8-12Nm.
Caution: At the foot of the crankshaft sprocket-oil pump
teeth side is a dent mark that is used to distinguish it with
the crankshaft sprocket-timing chain.
14. Fit the lower cover plate of the timing chain.
Timing Chain Lower Cover Plate Refit
1.0 73
15. Fit the upper cover plate of the timing chain. Camshaft Cover
Timing Chain Upper Cover Plate Refit
Remove
16. Fill the engine oil.
2. Remove the dipstick.

4. Release and remove the harness bracket bolt, release
and remove the high voltage coil bolt, confirm the
position of each bolt and keep the bolts properly.
5. Remove the ignition coil and the ignition coil bracket.

Ignition Coil Remove
6. Release the clips of the full load breather pipe and the
part load breather pipe.
1.0 74
3. Position the camshaft cover on the cylinder head.
4. Fit the bolt and tighten to 7-10Nm in sequence shown
in the figure below.
7. Remove the full load and part load breather pipe.

8. Loosen and remove 19 bolts securing the camshaft
cover and confirm the position of each bolt.
5. Fit the ignition coil and the ignition coil bracket, and
tighten the retaining bolts to 8-12Nm.
Ignition Coil Refit


7. Fit the dipstick.
9. Remove the camshaft cover, pay attention to the

protection of check valve diaphragm and keep it clean.
10. Remove the jack.
Refit
1. Check the upper surface of the cylinder head, take
care not to damage it. Clean the upper surface of the
cylinder head and remove the oil.
2. Apply silica gel (Dia.: 4mm) to the seam of the timing
chain upper cover plate and the camshaft cover.
1.0 75
Camshaft - Intake or Exhaust

Remove
2. Remove the timing chain.
Timing Chain Remove
sealing washer.
7. Loosen 19 bolts on the camshaft bearing cap in

sequence shown until the valve spring does not apply
any pressure to the camshaft.
8. Loosen the bolts fixing the camshaft bearing cover,

identify the position of each camshaft bearing cover,
and remove the camshaft bearing covers.

modulator bolts.
6. Remove the intake phase modulator and exhaust phase
modulator, and hang the chain on the upper guide rail
mounting boss.
9. Identify the position of each camshaft, and remove the

camshafts.
Caution: The intake/exhaust camshaft and signal

wheel shall be removed as an assembly, without
removing the signal wheel.
1.0 76
Refit 5. Put the camshaft into the bearing seat, fit the camshaft
1. Clean the camshaft. bearing cap and camshaft bolt (do not tighten). Rotate
the camshaft with the timing hole up, and lock the
2. Clean the upper cylinder head plane, top of the
camshaft phase with the TEN00004.
mechanical tappet and camshaft bearing cap.
3. Apply engine oil to the camshaft journal, bearing seat
and top tappet evenly.
4. Put the camshaft into the bearing seat, fit the camshaft
bearing cap, fit the camshaft bolt (do not tighten),
rotate the camshaft and measure the valve clearance.
Intake side clearance of the model to be repaired
is 0.17-0.23mm and the exhaust side clearance is
0.27-0.33mm, calculate the valve clearance and acquire
a proper mechanical tappet.

wheel shall be fitted as an assembly, without
6. Tighten the camshaft bearing cap in sequence shown

with tightening torque of 7-11Nm.
1.0 77
tighten to 18-22Nm+(22-28°).
7. Rotate the flywheel until the flywheel pin hole is aligned

with the pin hole of the engine body. 12. Secure the intake and exhaust phase modulators to the
8. Insert the TEN00002 into the engine body timing pin camshaft, tighten the bolt to 70-80Nm.
13. Fit the timing chain.

9. Position the phase modulators assembled on the intake
Timing Chain Refit
and exhaust camshafts to the appropriate camshaft,
mount the chains into both modulators, and pre-tighten 14. Connect the battery negative cable.
the bolts.
10. Fit the upper guide rail to the front bearing cap of the
camshaft, fix with two bolts, the tightening torque is
8-12Nm.
11. Fit a new timing hydraulic tensioner washer, screw the

timing hydraulic tensioner into the cylinder head, and
1.0 78
Mechanical Tappet Q 10187107 T=3.414
Remove
R 10187108 T=3.438
S 10187109 T=3.465
2. Remove the camshaft - intake or exhaust.
T 10187110 T=3.495
Camshaft - Intake or Exhaust Remove
U 10187111 T=3.525
3. With a viscous magnet, take away the mechanical tappet
carefully, and put it aside. V 10187112 T=3.555
W 10187113 T=3.585
4. Fit the camshaft - intake or exhaust.
Camshaft - Intake or Exhaust Refit

5. Connect the battery negative cable.
Refit
1. Clean the tappet hole.
2. Lubricate the standard tappet (H group) and fit it into
the tappet hole. Fit the camshaft, select correct tappet
group according to valve clearance.
3. Fit the selected tappet group.
The list of mechanical valve tappet series is as follows:
Group Part No. Tappet Thickness

A 10187088 T=3.000
B 10187090 T=3.030
C 10187091 T=3.060
D 10187092 T=3.090
E 10187093 T=3.120
F 10187094 T=3.150
G 10187096 T=3.174
H 10187097 T=3.198
I 10187098 T=3.222
J 10187099 T=3.246
K 10187100 T=3.270
L 10187101 T=3.294
M 10187103 T=3.318
N 10187104 T=3.342
O 10187105 T=3.366
P 10187106 T=3.390
1.0 79
Valve Refit
Remove 1. Remove the carbon deposits and other foreign
1. Disconnect the battery negative. objects from the valve duct, valve, valve seat ring and
2. Remove the cylinder head assembly. combustion surface.
2. Check the diameter of the existing valve stem. Check
Cylinder Head Assembly Remove
the valve guide clearance with new valves.
3. Compress the valve spring with the T10005.
3. Check the conditions of the valve seat and valve before
another use.
4. Check the matching height of the valve stem.
5. Check the condition of the valve spring.
6. Ensure that the mechanical tappet, valve, valve spring,
spring cap and lock clamp are clean.
7. Lubricate the valve and valve stem oil seal.
8. Fit the valve stem oil seal to the valve guide with the
TEN00014.
4. Remove the valve lock clamp and release the valve

spring.
5. Remove the T10005.
6. Remove the valve spring, valve spring seat and valve.
9. Fit the valve, spring and spring cap, compress the valve
spring with the T10005, and mount the lock clamps.
7. Remove the valve oil seal with the T10006.
10. Loosen the valve spring, and remove the T10005.

11. Fit the cylinder head assembly.
Cylinder Head Assembly Refit

1.0 80
Cylinder Head Assembly
Remove
3. Drain the engine coolant.
Coolant Drain
4. Remove the alternator.
Alternator Remove
5. Remove the intake manifold and discard the intake
manifold gasket.
Refit
Intake Manifold Remove
1. Clean the sealing area of the cylinder head and upper
6. Remove the exhaust manifold and discard the exhaust cover plate of the timing chain. Clean the camshaft
manifold gasket. cover and joint face between the intake and exhaust
Exhaust Manifold Remove manifolds with foam remover and plastic scraper.
7. Unscrew the bolt fixing the thermostat assembly to the Caution: Don’t use scraper to deal with sealed surface.
cylinder head and remove the thermostat assembly. 2. Blow the oil passage and coolant passage dry.
3. Fit a new cylinder gasket.
8. Remove the contaminants in the spark plug gap.

9. Remove the spark plug. 4. Place the cylinder head to the engine body, put in 10
cylinder head bolts and 3 chain locker bolts carefully,
Spark Plug Remove then pre-tighten with bolts.
10. Remove the mechanical tappet. Warning: The cylinder head bolts cannot be lubricated by
Mechanical Tappet Remove lubricants.
11. Remove the cylinder head assembly, and discard the
cylinder head gaskets.
1.0 81
10. Fit the intake manifold and fit a new intake manifold
gasket.
Intake Manifold Refit

11. Fit the alternator.
Alternator Refit
12. Fill the engine coolant.
Coolant Refill

5. Tighten 10 cylinder head bolts with special sleeve in

sequence shown (torque: 30Nm（（90°+60°)), then
tighten three bolts near the chain locker (torque:
8-12Nm).
6. Fit the mechanical tappet.

Mechanical Tappet Refit
7. Fit the spark plug.
Spark Plug Refit
8. Fit the thermostat housing, and tighten to 8-12Nm.
9. Fit the exhaust manifold and fit a new exhaust manifold

gasket.
Exhaust Manifold Refit
1.0 82
Cylinder Head Check
Remove
3. Drain the engine coolant.
Coolant Drain
Alternator Remove
5. Remove the intake manifold and discard the intake
manifold gasket.
Intake Manifold Remove
6. Remove the exhaust manifold and discard the exhaust
manifold gasket.
Exhaust Manifold Remove

7. Unscrew the bolt fixing the thermostat assembly to the
cylinder head and remove the thermostat assembly.
14. Remove the oil control valve.
Oil Control Valve Remove
8. Remove the contaminants in the spark plug gap.

9. Remove the spark plug.
Spark Plug Remove

Timing Chain Upper Cover Plate Remove


12. Remove the timing chain tensioner, and discard the 15. Remove and discard the intake & exhaust phase
sealing washer. modulator bolts.
mounting boss.
1.0 83
17. Check the end offset of the camshaft with a dial gauge. 22. Identify the position of each camshaft, and remove the
18. If the end offset exceeds the tolerance, replace with a camshafts.
new camshaft and recheck, if the end offset still exceeds Caution: The intake/exhaust camshaft and signal
the tolerance, replace the cylinder head assembly. wheel shall be removed as an assembly, without
Camshaft axial clearance: 0.06-0.19mm removing the signal wheel.
19. Gradually release the cylinder head bolts, remove the

cylinder head assembly, put the cylinder head on a
wooden shelf, take care to protect the combustion
surface from scratch.
20. Remove and discard the cylinder head gaskets.
23. Remove 16 mechanical tappets from the cylinder head,

put them in sequence to avoid confusion.
21. Loosen the bolts fixing the camshaft bearing cover,

identify the position of each camshaft bearing cover,
and remove the camshaft bearing covers.
24. Measure the outer diameter of each mechanical

tappet (outer diameter of mechanical tappet:
29.964mm-29.980mm).
25. Clean the camshaft, camshaft bearing cover and cylinder
head bearing base.
1.0 84
26. Inspect the camshaft and replace if it is scratched, pitted
or excessively worn.
27. Fix the camshaft to the cylinder head, put a plastic
gauge on each journal, then refit the camshaft bearing
cover, do not rotate the camshaft.
28. Slowly unscrew the camshaft bearing cover bolts, and
remove the camshaft bearing cover.
33. Remove the valve oil seal with the T10006.
29. Measure the widest portion of the plastic gauge on each

journal, if the clearance exceeds the tolerance, replace
with a new camshaft and recheck. If the clearance still
exceeds the tolerance, replace with a new cylinder
head assembly.
Bearing clearance Service Clearance
34. Clean each mating face of the cylinder head.
Previous gear 0.025-0.066mm 0.1mm
35. Check the cylinder head for damage, and especially the
Next 4 gears 0.03-0.07mm 0.1mm combustion surface of cylinder head.
30. Support the exhaust manifold side of the cylinder head 36. Check the combustion surface of cylinder head for
with a wooden block, remove the intake valve in this scratches according to the illustrated method, crossed
position. or diagonally.
31. Compress the valve spring with the T10005, remove
2 clips from the valve, release the valve spring and
remove the tool.
37. Check the cylinder head height.

Cylinder head height:
32. Remove remaining valve spring retainer, valve spring New 118.95－119.05mm
and valve, put them aside in original refit sequence. 38. Remove carbon deposits from the valve, valve duct,
valve seat and combustion chamber surface.
1.0 85
Valve Seat Width
Intake Valve 1.1mm-1.3mm
Exhaust valve 1.369mm-1.828mm
Valve Seat Surface Angle Intake 150°, 90°, 65°

- Intake Valves & Exhaust
Exhaust 90°, 60°
Valves
Valve surface angle B:
Intake 45°
Exhaust 45°
42. Push the valve onto the seat with even abrasive.
39. Check the diameter of the existing valve stem and
43. Apply Prussian-blue to the valve seat, put it into the
check the valve guide clearance with new valves.
valve and press it in place without rotation, remove it
Valve stem diameter: and check the evenness and central alignment with the
Intake valve φ4.967-φ4.981mm valve seat, the position of valve seat shown in blue must
be in the central of the valve surface.
Exhaust valve φ4.957-φ4.971mm
44. Apply the color to the valve seat and recheck.
Clearance between Valve
45. Check the matching height of the valve stem.
Stem and Valve Guide:
0.019-0.053mm New intake valve 50.033-50.893mm
Intake Valve
0.029-0.063mm New exhaust valve 49.948-50.808mm
Exhaust Valve
Replace with a new valve as necessary, if the valve guide is to
46. If it still exceeds the limit, you need to replace the
be replaced, replace the cylinder head assembly.
cylinder head assembly.
40. If the cylinder head is to be reused, please check the
47. Check the valve spring:
valve seat and valve conditions.
Free length 40.2mm
Mounting length Intake 33.6mm; exhaust
33.1mm
Load - Valve Closed Intake 115±9.2Nm; exhaust
125±10Nm
Load - Intake Valve Open 297±14.8Nm
Load - Exhaust Valve Open 291±14.6Nm
Refit
1. Clean the sealing area of the cylinder head and upper
cover plate of the timing chain. Clean the camshaft
cover and joint face between the intake and exhaust
41. Machine the valve surface angle and valve seat to the manifolds with foam remover and plastic scraper.
following standards: Caution: Don’t use scraper to deal with sealed surface.
2. Blow the oil passage and coolant passage dry.

3. Fit the valves.
Valve Refit
Cylinder Head Refit
5. Fit the mechanical tappet.
Mechanical Tappet Refit
1.0 86
6. Lubricate the camshaft bearing surface, and position the
camshaft on the cylinder head. Then close the camshaft
bearing cap properly, and pre-tighten with bolts.

wheel shall be fitted as an assembly, without
12. Fit the exhaust manifold and fit a new exhaust manifold
gasket.
Exhaust Manifold Refit

13. Fit the intake manifold and fit a new intake manifold
gasket.
Intake Manifold Refit

7. Measure the clearance of each mechanical tappet,
14. Fit the alternator.
methods: rotate the camshaft, make the base circle
above the mechanical tappet, measure the clearance Alternator Refit
between the camshaft and the mechanical tappet and 15. Fill the engine coolant.
record the clearance. Repeat the operation on each
mechanical tappet. Calculate the clearance, select Coolant Refill
appropriate mechanical tappet so that correct clearance 16. Fill the engine oil.
can be achieved. Intake side clearance: 0.17-0.23mm, Lubricating Fluid Refill
exhaust side clearance: 0.27-0.33mm.
8. Remove the camshaft, fit the mechanical tappet of

correct size into the corresponding mechanical tappet.
9. Fit the camshaft - intake or exhaust.
Camshaft - Intake or Exhaust Refit

10. Fit the spark plug.
Spark Plug Refit

11. Fit the thermostat housing, and tighten to 8-12Nm.
1.0 87
Cylinder Gasket Cylinder Head Assembly Refit

Remove 9. Refill coolant.
Coolant Refill
Lubricating Fluid
Coolant Drain
4. Remove the cylinder head assembly.
Cylinder Head Assembly Remove
5. Remove the cylinder head gasket from the cylinder
block and discard it.
Refit
1. Clean the mating surface of the cylinder head and
cylinder block.
2. Check the surface of the cylinder head for scratch.
3. Check the cylinder head height.
4. Clean the passages of the engine oil and the coolant.
5. Clean the cylinder head bolts and wipe them, check the
thread for any sign of damage.
6. Apply a thin oil film on the cylinder head bolt.
7. Fit a new and clean cylinder head gasket to the cylinder
block.
1.0 88
Lower Crankcase
Remove
2. Raise the front part of the vehicle.
3. Remove the powertrain.
Powertrain - AT Remove
Powertrain - MT Remove
Timing Chain Upper Cover Plate Remove 10. Remove the lower crankcase.
5. Remove the lower cover plate of the timing chain. Refit
Timing Chain Lower Cover Plate Remove 1. Ensure the junction surface of the lower crankcase and
6. Remove the timing chain tensioner, and discard the the engine block is clean.
seal washer. 2. Please apply the sealant recommended by the
manufacturer for the junction surface of the lower
crankcase.
7. Remove the oil pump belt, and remove the crankshaft

sprocket (oil pump drive).
Caution: When fitting the lower crankcase, try to make
the lower crankcase close to the flywheel end as near
as possible to avoid creating a gap when connecting the
lower crankcase and the transmission case.
3. Tighten the lower crankcase bolts to 27-33Nm in the

sequence as shown.
8. Remove the rear crankshaft oil seal.
Rear Crankshaft Oil Seal Remove

9. Unscrew all bolts fixing the lower crankcase to the
engine block.
1.0 89
4. Fit the rear crankshaft oil seal. Connecting Rod Bearing Shell Check
Rear Crankshaft Oil Seal Refit
Remove
5. Fit the crankshaft pulley (oil pump drive) to the front
end of the crankshaft, and fit the oil pump belt. 2. Remove the cylinder head assembly.
Caution: At the foot of the crankshaft sprocket-oil pump Cylinder Head Remove
teeth side is a dent mark that is used to distinguish it with 3. Remove the lower crankcase assembly.
the crankshaft sprocket-timing chain. Lower Crankcase Remove
6. Fit the oil pump belt to the oil pump sprocket. 4. Mark the cylinder order on the connecting rod big end.
Caution: Keep bearing caps, bearings and bolts in their
fitted order.
5. Rotate the crankshaft to allow the connecting rod bolts

to respectively be located at a easy removal position.
6. Unscrew the connecting rod bolt, remove the
connecting rod lower end cap (connecting rod big end
cap).
7. Fit the lower cover plate of the timing chain.
Timing Chain Lower Cover Plate Refit

8. Fit the upper cover plate of the timing chain.

9. Refit the powertrain.
Powertrain - AT Refit
Powertrain - MT Refit 7. Remove the connecting rod shell on the connecting rod
lower end cap (connecting rod big end cap).
8. Push the piston connecting rod assembly out of the
cylinder bore through the combustion surface with
a plastic bar or a stick, and remove the remaining
connecting rod shell.
Caution: When fitting the piston, DO NOT scratch the
cylinder liner with the connecting rod fracture.
9. Fit the connecting rod big end cap into the connecting
rod, and lightly tighten the connecting rod bolt.
Refit
1. Clean the mating surface between the cylinder block
and bearing base.
2. Clean the pin and the pin hole.
3. Clean the connecting rod and the retaining position of
the bearing shell on the connecting rod cap.
4. Clean the crankshaft and check for damage.
5. Align two connecting rod shells with the shell groove
and press them into the big end bore of the connecting
rod respectively, make sure the end face of the bearing
1.0 90
shell is in the same plane as the fracture surface of the Piston Check
connecting rod big end bore. Remove
Caution: The connecting rod bearings are not grouped. 1. Remove the piston connecting rod assembly.
Caution: Record the main bearing mark number on the Connecting Rod Bearing Shell Remove
front of the crankshaft. 2. Remove the used piston ring with an expander (tool)
and discard it.
6. Fit the piston connecting rod assembly into the
TEN00003 from top to bottom, and align the guide Refit
tooling with the cylinder bore, note that the arrow "↑" 1. Clean the piston ring groove and purge the oil passage.
on the top surface of the piston shall point to the front 2. Position the new piston ring 20 mm from the top
end of the engine. surface of the cylinder bore and measure the clearance.
3. Check the pistons for deformation and crack.

4. Measure the piston diameter at vertical angles to the
piston pin, 11 mm from the bottom of the skirt, refer
to "Parameter" for details.
Caution: Piston and connecting rods are only supplied as

an assembly. Connecting rods refitted must be the same
weight group.
5. Fit the oil ring spring.

6. With the "TOP" mark facing the top of the piston, fit it
with the expander in sequence: oil ring scraper, second
compression ring, top compression ring.
7. Push the piston hard into the cylinder bore. 7. Ensure the piston ring can rotate freely, separate the
gap A and B of two compression rings at an angle of
Tip: It is recommended to replace the piston connecting 120° and away from the thrust side of the piston.
rod assembly as a set.
8. Scraper gap C and spring gap D shall be located 30°apart
8. Fit the connecting rod big end cover, tighten the from each other at both sides of the piston pin.
connecting rod bolt to (13-17)Nm+（（77-83））°.
9. Fit the lower crankcase assembly.
Lower Crankcase Refit

Cylinder Head Assembly Refit

1.0 91
Crankshaft Check
Remove
1. Remove the piston connecting rod assembly.
Connecting Rod Bearing Shell Remove
2. Unscrew the main bearing cap bolt, remove the main
bearing cap and remove the main bearing shell from
the bearing seat.
3. Remove the crankshaft.
9. Check the gap between the new piston ring and the
ring groove, refer to "Parameter" for details.
4. Remove 2 thrust washers from the 4th main bearing.

5. Remove the other half of bearing shell from the
removed main bearing cap.
6. Remove 4 bolts fixing 4 piston cooling nozzles to the
cylinder block.
10. Fit the connecting rod assembly. Refit

1. Clean the mating surface between the cylinder block
Connecting Rod Bearing Shell Refit
and bearing base.
2. Clean the pin and the pin hole.
3. Clean the retaining position of the bearing shell and
thrust plate in the cylinder block.
4. Clean the retaining position of the bearing shell on the
bearing seat.
5. Clean the retaining position of the bearing shell on the
connecting rod and the cap (refer to EPC for the group
of piston connecting rod assembly).
1.0 92
Caution: The weight groupings of the piston connecting "Parameter" for details.
rod assemblies on the same engine should be same, fit
Caution: The bearings with oil grooves and oil holes are
them correctly. If the piston connecting rod assembly
fitted in the main bearing holes of the cylinder block, and
in the same group cannot be selected and fitted when
bearings without oil grooves and oil holes are fitted in the
servicing, replace all the piston connecting rod assemblies
main bearing caps.
to ensure the piston connecting rod assembly weight is in
the same group. 12. The matching principle of the main bearing shell: the
upper part shall be grouped according to the engine
6. Clean the crankshaft and check for damage.
dimension (A: blue, B: red).
7. Align two connecting rod shells with the shell groove
GRADE DIAMETER
and press them into the big end bore of the connecting
rod respectively, make sure the end face of the bearing
A 53.690＜φ≤53.700
shell is in the same plane as the fracture surface of the
connecting rod big end bore. B 53.680≤φ≤53.690
Caution: The connecting rod bearings are not grouped.

Caution: Record the main bearing mark number on the
front of the crankshaft.
8. Fix 4 piston cooling nozzles to the cylinder block, fit 4

bolts, tighten to 22-28Nm and check the torque.
9. Record the main bearing shell mark no. on the flange
face at the rear part of the crankshaft, the grouping 13. The lower part shall be grouped according to the
rule is as follows: crankshaft dimension (1: blue, 0: red).
JOURNAL DIA. GRADE 14. Use a piece of cloth without rough edges and
appropriate solvents to clean the sealing surface of the
φ50.000-φ49.993 0
cylinder block and bearing seat.
φ49.992-φ49.984 1
Tip: Please use SAIC MOTOR recommended solvent.
15. Fit the selected crankshaft main bearing shell and fit it
to the cylinder block and bearing seat.
16. Clean the new thrust washer and fit it to both sides of
the 4th gear of the cylinder block main bearing.
Tip: The oil groove surface of the thrust washer is the

surface contacting with the crankshaft thrust surface,
and never fit it reversely.
17. Place the crankshaft, apply appropriate lubricating oil
to the main journal, and then fit the main bearing cap.
Torque:(20±2)Nm+（（90°+45°））±5°
18. Fit the connecting rod assembly.
Connecting Rod Bearing Shell Refit
10. Check the diameter of main crankshaft journal, refer

to "Parameter" for details.
11. Determine proper main bearing shells to be fitted
according to the size and model selected, refer to
1.0 93
Rear Crankshaft Oil Seal

Remove
2. Remove the transmission assembly.
Automatic Transmission Remove
Manual Transmission Remove

3. Remove the torque converter drive plate.
Torque Converter Drive Plate Remove

4. Unscrew 5 bolts around the rear crankshaft oil seal.
5. Remove the oil seal and discard it.
4. Push the oil seal into the locating pin of the oil seal
slowly along the special tool TEN00013 and drive it
into the pin hole of the engine block.
6. In case of oil passage plug leakage, please remove and

replace the oil passage plug with TEN00118, and the 5. Press and hold the oil seal flange, and pull out the
torque for replacement is 35-45 Nm. special tool slowly.
6. Fit all bolts, and tighten them to 8-12Nm.
7. Fit the torque converter drive plate.
Torque Converter Drive Plate Refit

8. Fit the transmission assembly.
Automatic Transmission Assembly Refit
Manual Transmission Assembly Refit

Refit
1. Clean the mating area of the crankshaft flange neck and
the oil seal, and ensure there is no stain on it.
2. Fit the TEN00013 to the rear end of the crankshaft.
3. Apply clean oil to the oil seal lip.
Caution: Take care to avoid damaging the oil seal lip,

while fitting it.
1.0 94
Oil Strainer
Remove
3. Remove the lower crankcase.
Lower Crankcase Remove

4. Unscrew all bolts fixing the oil baffle to the lower
crankcase, and remove the oil baffle.
Refit
1. Clean the oil strainer and the mating face.
2. Lubricate the new O-ring with engine oil and fit it to the
oil strainer. Insert the oil strainer into the new oil pump
from the opposite direction shown in the figure above.
3. Secure the oil pump and oil strainer to the lower
crankcase, fit the bolt, tighten to 8-12Nm.
4. Fit the oil baffle, and tighten to 8-12Nm.
5. Fit the lower crankcase.

5. Remove the oil pump and oil strainer to the lower
crankcase. 6. Fit the oil filter.

6. Separate the oil pump and the oil strainer according

to the direction shown, take out the seal ring of the
oil strainer and discard it.
1.0 95
Oil Pump
Remove
2. Remove the powertrain.
Powertrain - AT Remove
Powertrain - MT Remove
3. Remove the lower crankcase.
Lower Crankcase Remove

4. Unscrew all bolts fixing the oil baffle to the lower
crankcase, and remove the oil baffle.
Refit
1. Clean the oil strainer and the connecting surface.
2. Lubricate the new O-ring with engine oil and fit the oil
strainer. Insert the oil strainer into the new oil pump in
the opposite direction shown in the figure above.
3. Fit the oil pump mounting bolt and the oil strainer
mounting bolt, and tighten them to 8-12Nm.
4. Fit the oil baffle, and tighten to 8-12Nm.
5. Fit the lower crankcase.

6. Fit the powertrain.
5. Remove the bolts fixing the oil pump and the oil
strainer to the lower crankcase. Powertrain - AT Refit
Powertrain - MT Refit
6. Disengage the oil pump and the oil strainer in the

direction shown, remove and discard the seal ring of
the oil strainer.
1.0 96
Oil Control Valve
Remove
2. Disconnect the oil control valve connector.

4. Connect the oil control valve connector.

4. Loosen the bolt fixing the oil control valve, and remove
the oil control valve.
Refit
1. Refit a new oil control valve onto the front bearing cap,
fix it with bolts, and the tightening torque is 5-7Nm.
2. Check the oil seal of oil control valve, if any leakage or
aging appearance and crack occur, renew the oil seal of
the oil control valve. Fit the oil seal of the oil control
valve to the camshaft cover.
1.0 97
Engine Oil Filter

Remove
1. Raise the vehicle with a lift.
2. Remove the bottom deflector.
Bottom Deflector Remove
3. Place a suitable container under the oil drain plug of
the engine oil pan, unscrew the plug and discard the
sealing washer. Drain the oil.
Warning: Observe due care when draining engine oil as

the oil can be very hot.
Warning: Avoid excessive skin contact with used engine

oil. Used engine oil contains potentially harmful 2. Lubricate the filter seal ring with clean engine oil.
contaminants which may cause skin cancer or other 3. Fit a new filter and tighten to 16-20Nm.
serious skin disorders.
4. Clean the oil drain plug and fit a new sealing washer.
5. Fit the oil drain plug and tighten to 35-40Nm.
6. Take away the engine oil filler cap and fill the engine
oil to a correct level.
7. Fit the bottom deflector.
Bottom Deflector Refit

8. Fit the oil filler cap.
10. Start and run the engine until the oil pressure warning
lamp goes out.
4. Clean the area around the filter head, and place 11. Stop the engine, recheck the engine oil level.
a suitable container under the filter to collect the 12. Check for any signs of leakage.
possible spillage.
5. Remove the engine oil filter counterclockwise and
discard it.
Refit
1. Clean the mating surface of the oil filter head.
1.0 98
Engine Oil Pressure Check Intake Manifold Gasket
Check Remove
1. Disconnect the battery negative. 1. Disconnect the battery negative.
2. Remove the bottom deflector. 2. Remove the intake pipe assembly.
Bottom Deflector Remove Intake Pipe Assembly Remove
3. Disconnect the connector of oil pressure switch. 3. Loosen the clamps and disconnect the canister solenoid
hose from the intake manifold.
4. Remove the oil pressure switch.
4. Pull out the C clip mounted on the intake manifold,

5. Remove the seal ring from the oil pressure switch, and loosen the clamps and disconnect the part load
fit it to the connector of the oil pressure gauge. breather pipe clips from the intake manifold.
6. Refit and tighten the connector of the oil pressure
gauge to the original oil pressure switch position.
7. Connect the oil pressure gauge T10001 and T10002
and tighten the connector.

9. Check the engine oil, and refill if necessary.
10. Start and run the engine until the normal operating
temperature is reached.
11. Note the readings indicated on the oil pressure gauge
when the engine runs at 3500 rev/min. Refer to the
section “Parameter”.
5. Disconnect the connector from the electronic throttle
12. Turn off the engine, unscrew the pressure gauge sensor.
connector and remove the gauge.
13. Unscrew the connector.
14. Wipe off the spilled oil.
15. Refit the oil pressure switch.
16. Connect the oil pressure switch connector.
6. Depress the plastic collars, disconnect the brake
1.0 99
booster tube from the intake manifold.
9. Fix an absorbent cloth under the fuel rail.

7. Pull out the harness clip A from the oil rail bracket, 10. Release the fuel inlet pipe from the fuel rail.
disconnect the fuel injector connector B and canister
solenoid connector C.
Caution: Always fit plugs to open connections to prevent

contamination.
11. Remove bolt A connecting the intake manifold to the

engine body first, and then remove 5 nuts fixing the
intake manifold to the cylinder head in sequence shown.
8. Disconnect the connector from the intake manifold

absolute pressure/temperature sensor.
12. Remove the intake manifold, remove and discard 4

sealing washers.
1.0 100
Intake Pipe Assembly Refit
Refit
1. Ensure that the mating surface is clean, and the metal
insert has been fitted into the intake manifold bolt and
bolt hole.
2. Refit a new washer onto the intake manifold.
Tip: Be careful of the error proofing design on the washer.
3. Tighten 5 nuts in the sequence shown, and then fix the
mounting bolt A of the intake manifold and the engine
block, tighten to 22-28Nm and check the torque.
4. Remove the plug from the fuel hose and fuel rail.
5. Fix the fuel inlet pipe to the fuel rail.
6. Connect theTMAP sensor connector.
7. Connect the fuel injector connector, fit the harness clip
into the fuel rail bracket hole, and connect the canister
solenoid connector.
8. Insert the brake booster tube into the quick connector
of the intake manifold.
9. Connect the electronic throttle sensor connector.
10. Connect the part load breather pipe to the intake
manifold and secure it with clamps, insert the C-shape
pipe clip into the intake manifold mounting hole.
11. Connect the canister solenoid hose to the intake
manifold and secure it with clamps.
12. Fit the intake pipe assembly.
1.0 101
Exhaust Manifold Gasket

Remove
2. Remove the bolt fixing the exhaust manifold shell.
4. Fit 8 bolts fixing the upper manifold to the engine in

the following sequence below, tighten to 22-28Nm
and check the torque.
3. Remove 8 nuts fixing the exhaust manifold assembly to

the engine.
4. Remove the 8 stubs fixing the exhaust manifold to the
engine with special tool TEN00001 and discard it.
5. Fit the bold fixing the exhaust manifold shell, tighten to

7-10Nm and check the torque.
5. Remove the exhaust manifold gasket from the mating

face of the cylinder head and the exhaust manifold, and
discard it.
Refit
1. Clean the mating surface of the cylinder head and the
exhaust manifold, ensure it is clean and smooth without
any debris.
2. Refit the stud on to the cylinder block with special tool
TEN00001, tighten to 8-12Nm and check the torque.
3. Fit the exhaust manifold gasket to the stud of cylinder
head correctly subject to its error prevention design.
1.0 102
Cylinder Pressure Test will increase substantially. Refill engine oil (about
Test 15ml) through the spark plug hole, and retest the
1. Run the engine until it reaches normal operating cylinder pressure.
temperature. The battery must be fully charged or c. If the low compression pressure is caused by valves,
almost fully charged. low compression pressure will be measured in the
2. Stop the engine. 1st stroke, and it will not increase even when the
3. Disable the fuel system (e.g, pull out the harness oil is refilled.
connector of the fuel pump). d. The same consequence can be resulted from leaking
4. Start the engine again until it stops so as to consume cylinder head gasket and worn valves, but for the
the fuel remaining in the fuel rail. crankcase, the problem may be due to engine
5. Disable the ignition system (e.g, disengage the ignition coolant. In addition, a leaking cylinder head gasket
coil for each cylinder and engine harness connector). will result in low compression pressure readings of
the cylinders in pairs.
6. Remove the ignition coil for each cylinder.
7. Remove the spark plug for all cylinders. 12. Resume the ignition system.
8. Measure the compression pressure of the engine with 13. Resume the fuel system.
the following procedures:
a. Fit the adapter of the spark plug hole into the spark
plug hole.
b. Fit the compression pressure gauge into the adapter
of the spark plug hole.
c. Fully depress the accelerator pedal.
d. With assistance, turn the key to start the starter
until no increased pressure is indicated by the
compression pressure gauge.
Note: Do not keep the starter motor running for 5s at a
time, and the interval for next start shall not be less than 10s.
e. Check and record the readings on the pressure gauge.
f. Remove the compression pressure gauge from the
adapter of the spark plug hole.
g. Remove the adapter of the spark plug hole from the
spark plug hole.
9. Repeat step 8 to test the pressure of other cylinders.
The lower limit value for the engine cylinder (under
normal pressure/temperature) is 7 Bar.
10. Difference between each cylinder pressure and average
pressure for each cylinder: for gasoline engines, it shall
not be greater than 8%.
11. Here are some examples of measurement:
a. When the compression pressure is normal, the
compression pressure of each cylinder will increase
quickly and evenly to the specified value.
b. If the low compression pressure is caused by piston
rings, the compression pressure will drop in the
1st stroke and gradually increase in the subsequent
strokes, however, it will never reach the normal
value. After oil refilling, the compression pressure
1.0 103
Special Tools Tool Description Picture

Tool Description Picture Number
Number
Retainer belt
TEN00009
Engine lift wheel
T10007
bracket
Retainer oil
TEN00006
pump gear
TEN00070 Engine support
Valve spring
T10005
Holding pin compressor
TEN00002
flywheel timing
Remover valve
Retainer T10006
stem seal
TEN00008 crankshaft belt
wheel
Replacer valve
TEN00014
Camshaft timing stem seal
TEN00004
locking
1.0 104
Tool Description Picture Tool Description Picture
Number Number
Piston ring Adaptor engine

TEN00003 T10002
guider oil pressure test
Remover and
Plug remove
TEN00118 TEN00001 replacer M8
tool
stud
Protector
sleeve
TEN00013
crankshaft rear
oil seal
Engine oil
T10001 pressure test
equipment
1.0 105
Engine Engine Cooling System
Engine Cooling System

Specifications
Torque
Description Value
Bolt-Expansion Tank to Body 7–10Nm
Bolt-Condenser to Radiator 5–7Nm
Bolt-Thermostat to Engine（1.5L） 8-12Nm
Bolt-Water Pump to Engine（1.5L） 8-12Nm
Bolt-Water Pump Pully to Water Pump（1.5L） 23-27Nm
1.0 106
Engine Cooling System Engine
Parameter
Model Temperature-controlled, pressure overflow backflow type cooling
system with forced circulation of water and OAT mixture solution
Cooling fan: 8 Vanes, Temperature-controlled Electric Axial Flow Type
Coolant capacity: 5.6L

Cooling fan switch - for A/C system
High speed:
• ON 17.7Mpa
• OFF 13.7Mpa
Cooling fan switch - for cooling during normal engine
operation
ON:
100 ℃
• Low speed
112 ℃
• High speed
OFF:
94 ℃
• Low speed
106 ℃
• High speed
Cooling fan switch - for cooling after engine stop
ON:
• Low speed 110 ℃

• High speed 104 ℃
OFF:
• Low speed 106 ℃

• High speed
100 ℃
Duration
No more than 30s
Radiator Longitudinal-flow Type
Coolant pump Mechanical, radial flow impeller
Drive ratio of coolant pump 1: 1
Dual-thermostat Wax-type component
Primary thermostat:
• Initial activation 80 ± 2 ℃
• Fully Open 94 ℃
• OFF
≤ 80 ± 2 ℃
Secondary Thermostat:
• Initial activation
88 ± 2 ℃
• Fully Open
102 ℃
• OFF
≤ 88 ± 2 ℃
Relief valve of radiator pressure cover
• High pressure ON 93 - 123KPa

• Low pressure ON 0 - 9.8KPa
1.0 107

System Layout
Engine Cooling System
1. Cooling System Radiator 9. Radiator Upper Shock Pad

2. Radiator Drain Valve 10. Cooling System Wind Scooper Assembly
3. Condenser Assembly 11. Cooling System Wind Scooper Assembly
4. Engine Cooling Fan Assembly 12. Staple Bolt - Radiator Airflow Side Deflector
5. Screw - Cooling Fan Speed Control Resistor 13. Screw - Cooling Fan Relay
6. Cooling Fan Speed Control Resistor 14. Bolt - Radiator Lower Bracket
7. Cooling Fan Relay 15. Exhaust Bolt
8. Radiator Lower Shock Pad
1.0 108
Cooling System Pipeline
1. Radiator Expansion Tank Assembly 12. Clamp - Engine Expansion Tank Overflow Pipe
2. Washer - Engine to Radiator Pipeline 13. Clip - Engine Expansion Tank Overflow Pipe
3. Radiator Expansion Tank Cap 14. Clamp - Heater to Engine Pipeline
4. Screw - Radiator Expansion Tank 15. Clamp - Cooling System Pipeline
5. Radiator Expansion Tank Bracket 16. Pipeline Assembly - Heater to Engine
6. Bolt - Radiator Expansion Tank Bracket 17. Clamp - Radiator Expansion Tank Overflow Pipe
7. Pipeline Assembly - Engine to Radiator 18. Pipeline Assembly - Engine to Heater
8. Clamp - Cooling System Pipeline 19. Clamp - Heater to Engine Pipeline
9. Clip - Engine to Radiator Pipeline 20. Clamp - Heater to Engine Pipeline
10. Pipeline Assembly - Radiator to Engine 21. Clip - Engine Expansion Tank Overflow Pipe
11. Clamp - Radiator to Engine Pipeline 22. Engine Overflow Pipe
1.0 109
Description Thermostat
Overview This thermostat is a wax-type component with pressure relief
The cooling system circulates the engine coolant in the loop characteristics. It is located in the sealing housing on engine
of engine and heater core. The coolant is the mixture of 50% pipe.
water and 50% organic acid technique (OAT), which helps to When starting a cold engine, the coolant temperature is low,
maintain the optimum operating temperature of the engine the wax-type component of the thermostat is in solid state,
when the environment and engine working conditions are and the thermostat valve switches off under the action of the
different. spring. At this point, the cooling system is in a small circulation
Caution: Engine coolant will damage paint finished status, namely, the coolant cannot enter into the radiator for
surfaces. If spilled, immediately rinse area with plenty of circulation. But, it can circulate between the bypass circuit
water. and heater core. When the coolant temperature rises, the
wax-type component starts melting into liquid state gradually
The coolant shall be replaced regularly to keep its optimum
followed by the increase of volume, then the thermostat valve
efficiency and corrosion resistance performance.
will open gradually under the action of the push rod, at this
Components of Cooling System point, the cooling system is in a big circulation status. The
Coolant Pump coolant will flow into the cylinder block through the bottom
hose of the radiator, allow the hot coolant to flow through
The coolant circulates through the rotor type pump on the
the radiator from the top hose to balance heat flow and keeps
rear upper part of the engine crankcase drive, which is sealed
the temperature at the optimal for engine operation. When
to the cylinder block by an O-ring and driven by the crankshaft
the thermostat is fully open, the coolant flows through the
timing belt.
radiator.
Coolant Hose
Radiator and Cooling Fan
The rubber coolant hose delivers coolant among all
The radiator is of aluminum longitudinal-flow type with
components. The coolant hose is fixed to each component
injection moulding water tanks on both ends (for automatic
by spring clamps. The heater core completes the fluid inlet
transmission model, automatic transmission oil cooler is
by connecting the outlet elbow of the engine to the inlet pipe
locate in the water chamber below the radiator. The cooling
of the inlet hard pipe of heater core passing through the dash
hose linked with transmission is connected to the bushing of
panel, then goes to oil cooler water inlet pipe through the
the transmission oil cooler with nuts). The radiator supports
water outlet pipe of heater core and flows back to the engine
the cooling fan assembly, air conditioning (A/C) condenser.
cylinder block through the oil cooler.
The top of the radiator is located in the rubber bushing
Radiator Pressure Seal Cap
supported by the upper radiator beam bracket. The bottom
Radiator pressure cap is mounted on the top of the radiator,
of the radiator is located in the rubber bushing supported
which is equipped with a relief valve and vacuum valve. When
by the bracket fixed on the front longitudinal beam. Sponge
the system pressure is within 0.93 - 1.23 bar, relief valve opens
sealing strips fitted on both sides of the radiator are used to
to release system pressure; when the system pressure is within
guide the airflow through the radiator. The condenser fixed
0 - 0.098 bar, vacuum valve opens, and fluid is replenished to
by bolts is fitted on the front end of the radiator.
the system from outside, so that the cooling system can run
within a certain pressure range. The cooling fan and motor assembly is fitted on the fan shroud
at the rear of the radiator. The "Suction" type fan draws out air
Expansion Tank through the radiator. Besides, the fan shroud is equipped with
The coolant expansion tank is fitted on the left side of the additional vent holes allowing more air flow through radiator
cooling module cooling fan, one overflow/return pipe is when driving at high speed together with cooling fan. Low
connected to the pressure cover at the top of the radiator speed resistance of the cooling fan is fitted at the left side of
through the bottom part of the expansion tank. When the the radiator.
coolant is expanded during warm-up, additional coolant in the
Engine Coolant Temperature (ECT) Sensor
cooling system will flow back to the expansion tank through
the overflow/return pipe; when the coolant in the cooling ECTThe engine coolant temperature sensor is fitted on the
system is insufficient, coolant in the expansion tank will flow engine cylinder block with a packaged negative temperature
back to the cooling system through the overflow/return pipe. coefficient (NTC) thermistor contacting with the engine
coolant, which is part of the bleeder circuit. The circuit is
composed of a 5V rated power supply, an engine control
1.0 110
module (ECM) internal resistance and a variable resistor
related to temperature (ECT sensor).
1.0 111
Operation
Coolant Flow
1.5 DVCT Engine
The cooling system utilizes the heat conduction principle, air in the coolant. The radiator pressure seal cap with relief
conducting heat from the engine components to the coolant. valve and vacuum valve isolates the cooling system from the
When the engine is at low temperature, the coolant pump will ambient atmosphere, the coolant expands as the temperature
circulate the coolant among the engine block, cylinder head rises, and the pressure of the cooling system will increase
and passenger compartment heater core. The thermostat will accordingly. The increased pressure raises the boiling point
be kept closed to prevent the coolant from flowing through of the coolant, allowing the engine to run at a higher, more
the radiator, however, a small amount of coolant may pass efficient operating temperature without the risk of coolant
through the bypass, this helps to prevent the accumulated boiling. The pressurization of the cooling system is limited, so
pressure from getting too high. When the engine reaches a pressure relief valve is provided on the expansion tank cap.
the normal operating temperature, the thermostat opens, By this way, when the max. operating pressure is reached, the
the cool coolant enters into the cylinder block through the excess pressure in the cooling system can be released.
hose at the bottom of the radiator, and the hot coolant will Cooling Fan Control Policy
flow into the radiator through the hose at the top of the
The cooling fan will operate at high or low speed, and the
radiator, so that the cool and hot coolant may be balanced
control is achieved by the ECM and relay unit. ECM The ECM
to maintain the engine at the best temperature. When the
utilizes the information provided by the ECT sensor, BCM
thermostat is fully open, all coolant flow through the radiator.
and A/C pressure switch to control the fan speed and engine
The excess coolant produced by thermal expansion returns
coolant temperature.
to the expansion tank through the overflow pipe at the top of
the radiator. Meanwhile, the expansion tank will remove the
1.0 112
During the normal operation, the cooling fan will operate at winding. The cooling fan relay is powered by a 12 V power
the following coolant temperatures: supply through Fuse 13 of the engine compartment fuse box.
Cooling Fan Status Low speed High speed When the cooling fan runs at low speed, the low-speed relay
provides the power supply; when the cooling fan runs at high
ON 100 ℃ 112 ℃
speed, the high-speed relay provides the power supply.
OFF 94 ℃ 106 ℃
The cooling fan relay may have faults under the following
When the A/C system is working, the cooling fan will operate conditions:
under the following pressure conditions: • High-speed relay coil is open.
Cooling Fan Status High speed • High-speed relay coil is short-circuited.
ON 17.7 Mpa • High-speed relay contact has a high resistance.
OFF 13.7 Mpa • High-speed relay contact is open.
• Low-speed relay coil is open.
The cooling fan control policy includes the engine idle speed
• Low-speed relay coil is short-circuited.
adjustment, which can compensate the additional load after the
fan is on. After the ignition key is removed: • Low-speed relay contact has a high resistance.
• External wire is open.
Cooling Fan Low speed High speed
Status • External wire is short to the 12V power supply.
ON 104 ℃ 110 ℃ • External wire is short to the ground.
OFF 100 ℃ 106 ℃ • External wire has a high resistance.
The cooling fan will operate for 30s to provide additional Warning: Keep clear of the cooling fan. The fan may start
cooling for the engine at high temperature. In case of ECT automatically without warning, even after the engine is
failure, the fan will operate at low speed. turned off.
Cooling Fan Relay Unit

The cooling fan relay unit is connected to the ECM by 2
wires, and one wire provides the ground for the internal relay
1.0 113
Service Procedures
Coolant - Drain and Refill
Drain
1. Remove the coolant expansion tank cap.
Warning: Since injury such as scalding could be caused by

escaping steam or coolant, do not remove the filler cap
from the coolant expansion tank while the system is hot.
2. Secure a proper container to collect the coolant.

4. Open the drain valve at the bottom of the engine
cooling system radiator. 5. Ensure that the A/C is turned off.
6. Start the engine and allow it to operate at the speed of
1500 - 2500 RPM. Fill the expansion tank as required
to keep the level just below the neck of the expansion
tank. When the coolant level reaches the neck of
the expansion tank due to thermal expansion, fit the
expansion tank cap.
7. Continuously run the engine at the speed of 1500 -
2500 RPM until the cooling fan operates, and then run
the engine at idle speed until the cooling fan stops.
8. Turn off the engine and cool it down for 30 minutes.
9. Check the cooling system for leak.
10. Check whether the coolant level is between MIN and
5. Drain the engine cooling system. MAX. If not, open the expansion tank cap and top up
Refill the tank with coolant or drain it to be between MIN
and MAX as required.
1. Close the coolant drain valve at the bottom of the
radiator.
2. Prepare the coolant of specified concentration.
Fluid
3. Open the expansion tank cap. Fill coolant to the
expansion tank until the coolant level reaches the neck
of the expansion tank and keeps still.
4. When filling coolant to the vehicle with 1.5 DVCT
engine, unscrew the bleeder bolt on the radiator.
When founding that the coolant is about to spill, screw
up the bolt.
1.0 114
System Pressure Test
Check
1. Visually check the expansion tank cap for signs of
leakage.
2. Check the hose for signs of rupture and distortion and
the attachment strength of pipeline connection.
3. Open the coolant expansion tank cap.
Warning: Since injury such as scalding could be caused by

escaping steam or coolant, do not remove the filler cap
from the coolant expansion tank while the system is hot.
4. Fit the TEN00010 to the expansion tank cap.
8. Remove the T14001 pressure hose from the

TEN00010.
9. Remove the expansion tank cap from the TEN00010
and fit it to the expansion tank.
5. Connect the T14001 pressure hose to the

TEN00010.
6. Pressurize the expansion tank cap slowly to the

specified pressure, then check the pressure; if the
pressure range is maintained within 140 - 160KPa, the
expansion tank cap is normal.
7. Release pressure through the relief valve on the
pressurizer.
1.0 115
Pressure Seal Cap - Pressure Test Coolant Expansion Tank

Check Remove
1. Check the hose for signs of rupture and distortion and 1. Drain the coolant.
the attachment strength of pipeline connection.
Coolant Drain
2. Open the coolant expansion tank cap.
2. Remove 2 bolts (1) fixing the coolant expansion tank
Warning: Since injury such as scalding could be caused by to the body.
escaping steam or coolant, do not remove the filler cap 3. Remove the clamp (2) fixing the engine overflow pipe
from the coolant expansion tank while the system is hot. to the coolant expansion tank.
3. Fit the TEN00015 to the expansion tank. 4. Remove the clamp (3) fixing the water outlet pipe of
4. Connect the T14001 pressure hose to the the heater to the coolant expansion tank.
TEN00015.
5. Pressurize the system to the pressure of 140 - 160KPa
slowly and check it for leakage.
Warning: Do not exceed the setting pressure value, or the

cooling system will be damaged.
5. Remove the coolant expansion tank.

Refit
1. Fit the clamp fixing the water outlet pipe of the heater
to the coolant expansion tank.
6. Visually check the engine and cooling system for signs coolant expansion tank.
of coolant leakage. 3. Fit 2 bolts fixing the coolant expansion tank to the
7. Release pressure through the relief valve on the body, tighten to 7–10Nm, and check the torque.
T14001. 4. Fill the coolant.
Coolant Refill
8. Disconnect the T14001 hose from the TEN00015.

9. Remove the TEN00015 from the expansion tank and
fit the expansion tank cap.
1.0 116
Cooling Fan Cooling Fan Low Speed Resistor
Remove Remove
1. Remove the cooling fan low speed resistor. 1. Disconnect the battery negative.
Cooling Fan Low Speed Resistor Remove 2. Disconnect the harness connector of the cooling fan
low speed resistor.
3. Remove 1 screw fixing the cooling fan low speed
resistor to the cooling fan.
3. Remove the air inlet pipe assembly.
Remove air inlet pipe assembly

4. Disconnect 4 clips fixing the cooling fan to the radiator.
4. Measure about 5cm lead at resistor end and cut the

resistor off the lead.
5. After cutting off the resistor, remove about 7mm
insulation respectively from both ends of the remaining
5. Pull out the cooling fan.
lead.
Refit
Refit
1. Fix the cooling fan to the radiator.
1. Take a resistance to be fitted and cover the heat-shrink
2. Fit the air inlet pipe assembly. tubes on the leads of resistance.
Fit air inlet pipe assembly

4. Fit the cooling fan low speed resistor.
Cooling Fan Low Speed Resistor Refit
2. Insert the metal part of the lead whose insulation

has been removed into the double end connector
connected to the lead of the resistance to be fitted, and
impact it with the terminal clamp in T84001, taking the
standard of at least 10 kg tension of the joint without
loosing.
3. Cover the heat-shrink tube on the double end
connector and heat it with proper heat supply to shrink
and agglutinate it with the lead.
4. Fix the resistance and to the wind scooper; fit
1.0 117
and tighten the screw, and fix the lead well with Radiator
tapes to ensure no displacement of the lead and the Remove
serpentuator sleeve, otherwise, it will or may interfere 1. Drain the coolant.
the blade.
Coolant Drain
5. Connect the harness connector of the cooling fan.
2. Remove the cooling fan.
6. After replacement, connect the battery negative and
start the engine to check the fan operation. If there is Cooling Fan Remove
no high humming when the fan is running, resume the 3. Disconnect the clamp fixing the radiator water inlet
low speed operating condition. pipe to the radiator.
4. Disconnect the clamp fixing the radiator water outlet

pipe to the radiator.
5. Disconnect the automatic transmission oil

cooler/inlet/outlet pipes fixed to the radiator.(if equip)
1.0 118
6. Remove the front-end module. Radiator Water Inlet Hose
Front-end Module Remove
Remove
7. Remove 2 bolts (1) fixing the condenser to the radiator.
8. Unscrew the clip (2) fixing the condenser to the Coolant Drain
radiator. 2. Disconnect the clamp fixing the radiator water inlet
hose to the radiator.
9. Remove the radiator.

10. Remove the radiator upper shock pad. 3. Disconnect the clamp fixing the radiator water inlet
hose to the thermostat.
Radiator Upper Shock Pad Remove
11. Remove the radiator lower shock pad.
Radiator Lower Shock Pad Remove

Refit
1. Fit the radiator lower shock pad.
Radiator Lower Shock Pad Refit

2. Fit the radiator upper shock pad.
Radiator Upper Shock Pad Refit

3. Fit the clip fixing the condenser to the radiator.
4. Fit 2 bolts fixing the condenser to the radiator, tighten
to 5–7Nm, and check the torque.
5. Fit the front-end module. 4. Remove the radiator water inlet hose.
Refit
Front-end Module Refit
6. Fit the automatic transmission oil cooler/inlet/outlet
the thermostat.
pipes fixed to the radiator.（if equip)
7. Fit the clamp fixing the radiator water outlet pipe to
the radiator.
the radiator.
8. Fit the clamp fixing the radiator water inlet pipe to the
radiator. Coolant Refill
9. Fit the cooling fan.
Cooling Fan Refit

Coolant Refill
1.0 119
Radiator Water Outlet Hose Engine Overflow Pipe - 1.5L

Remove Remove
1. Drain the coolant. 1. Drain the coolant.
Coolant Drain Coolant Drain

2. Disconnect the clamp (1) fixing the radiator water 2. Disconnect the clamp fixing the engine overflow pipe
outlet hose to the radiator. to the thermostat.
3. Disconnect the clamp (2) fixing the radiator water
outlet hose to the water pump pipeline.
3. Disconnect the clamp fixing the engine overflow pipe

4. Remove the radiator water outlet hose.
Refit
the water pump pipeline.
the radiator.
Coolant Refill
4. Remove the engine overflow pipe.

Refit
coolant expansion tank.
thermostat.
Coolant Refill
1.0 120
Heater Water Inlet Hose Heater Water Outlet Hose
Remove Remove
1. Drain the coolant. 1. Drain the coolant.
Coolant Drain Coolant Drain
2. Remove the air filter assembly. 2. Remove the air filter assembly.
Air Filter Assembly Remove
3. Disconnect the clamp (1) fixing the water outlet hose
3. Disconnect the clamp (1) fixing the water inlet hose of
of the heater to the heater core.
the heater to the heater core.
4. Disconnect the clamp (2) fixing the water outlet hose
4. Disconnect the clamp (2) fixing the water inlet hose of
of the heater to the tee fitting.
the heater to the engine.
5. Disconnect the clamp fixing the water outlet hose of

5. Remove the water inlet hose of the heater. the heater to the coolant expansion tank.
Refit
1. Fit the clamp fixing the water inlet hose of the heater
to the engine.
2. Fit the clamp fixing the water inlet hose of the heater
to the heater core.

Coolant Refill
6. Remove the water outlet hose of the heater.

Refit
1. Fit the clamp fixing the water outlet hose of the heater
to the tee fitting.
to the heater core.
Coolant Refill
1.0 121
Radiator Drain Valve Radiator Upper Shock Pad

Remove Remove
1. Drain the coolant. 1. Remove the front-end module.
Coolant Drain Front-end Module Remove

2. Unscrew the radiator drain valve from the radiator. 2. Pull out the radiator upper shock pad.
Refit Refit
1. Fix the radiator drain valve to the radiator and tighten 1. Press the radiator upper shock pad.
it up.
2. Fit the front-end module.
Coolant Refill
1.0 122
Radiator Lower Shock Pad Wind Scooper - Left
Remove Remove
1. Remove the front-end module. 1. Remove the front bumper.
Front-end Module Remove Front Bumper Remove

2. Pull out the radiator lower shock pad. 2. Remove 4 plastic clips fixing the left wind scooper to
the upper radiator beam.
Refit
1. Press the radiator lower shock pad. Refit
2. Fit the front-end module. 1. Fit 4 plastic clips fixing the left wind scooper to the
upper radiator beam.
2. Fit the front bumper.
Front Bumper Refit
1.0 123
Wind Scooper - Right Thermostat - 1.5L

Remove Remove
1. Remove the front bumper. 1. Drain the coolant.
Front Bumper Remove Coolant Drain

2. Remove 4 plastic clips fixing the right wind scooper to 2. Disconnect the clamp fixing the radiator water inlet
the upper radiator beam. hose to the thermostat.
Refit 3. Disconnect the clamp (1) fixing the engine overflow

pipe to the thermostat.
1. Fit 4 plastic clips fixing the right wind scooper to the
upper radiator beam. 4. Disconnect the clamp (2) fixing the water inlet hose of
the heater to the thermostat.
Front Bumper Refit
5. Remove 6 bolts fixing the thermostat to the engine.
6. Remove the thermostat.
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Refit Water Pump
1. Fit 6 bolts fixing the thermostat to the engine, tighten Remove
to 8-12Nm, and check the torque. 1. Drain the coolant.
2. Fit the clamp fixing the water inlet hose of the heater Coolant Drain
to the thermostat.
thermostat. Auxiliary Drive Belt Remove
4. Fit the clamp fixing the radiator water inlet hose to 3. Remove 3 bolts fixing the water pump pulley to the
the thermostat. water pump.
Coolant Refill
4. Remove 3 bolts fixing the water pump to the engine.
5. Remove the water pump.

Refit
1. Fit 3 bolts fixing the water pump to the engine, tighten
to 8-12Nm, and check the torque.
2. Fit 3 bolts fixing the water pump pulley to the water

Coolant Refill
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Transmission Oil Cooler Inlet Pipe Assembly - Transmission Oil Cooler Outlet Pipe Assembly
4AT - 4AT
Remove Remove
1. Drain the automatic transmission fluid. 1. Drain the automatic transmission fluid.
Automatic Transmission Fluid Drain Automatic Transmission Fluid Drain

2. Remove 1 bolt (1) fixing the bracket of the inlet 2. Remove 1 bolt (1) fixing the bracket of the outlet
pipe of the transmission oil cooler to the automatic pipe of the transmission oil cooler to the automatic
transmission. transmission.
3. Remove 1 nut (2) fixing the inlet pipe of the transmission 3. Remove 1 nut (2) fixing the outlet pipe of the
oil cooler to the automatic transmission. transmission oil cooler to the automatic transmission.
4. Disconnect the inlet pipe of the transmission oil cooler 4. Disconnect the outlet pipe of the transmission oil
from the radiator. cooler from the radiator.
5. Remove the inlet pipe of the transmission oil cooler. 5. Remove the outlet pipe of the transmission oil cooler.
Refit Refit
1. Fix the inlet pipe of the transmission oil cooler to the 1. Fix the outlet pipe of the transmission oil cooler to
radiator. the radiator.
2. Fit 1 nut fixing the inlet pipe of the transmission 2. Fit 1 nut fixing the outlet pipe of the transmission
oil cooler to the automatic transmission, tighten to oil cooler to the automatic transmission, tighten to
33-37Nm, and check the torque. 33-37Nm, and check the torque.
3. Fit 1 bolt fixing the bracket of the inlet pipe of the 3. Fit 1 bolt fixing the bracket of the outlet pipe of the
transmission oil cooler to the automatic transmission, transmission oil cooler to the automatic transmission,
tighten to 7-10Nm, and check the torque. tighten to 7-10Nm, and check the torque.
4. Fill the automatic transmission fluid. 4. Fill the automatic transmission fluid.
Automatic Transmission Fluid Refill Automatic Transmission Fluid Refill
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Special Tools
Tool Description Picture
Number
Pressure test
TEN00010
connector, cap
Cooling system
T14001
pressure test kit
Pressure test
TEN00015 connector,
cooling system
Harness repair
T84001
kit
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Engine Engine Fuel & Management
Engine Fuel & Management

Specifications
Torque
Description Value
Spark plugs 22-28Nm
Bolt - ignition coil 8-12Nm
Bolt-ECM to Battery Bracket 7-10Nm
Oil temperature sensor 14-18Nm
Bolt - crank sensor 8-12Nm
Bolt - camshaft.sensor 8-12Nm
Bolt - chain guide rail upper to cylinder head front cam 8-12Nm
bearing
Bolt - timing chain tensioner to cyclinder head 18-22Nm+(22-28°)
Bolt - VCT unit to camshaft 70-80Nm
Oil pressure sensor 14-18Nm
Bolt - knock sensor 15-25Nm
Bolt - rail fuel to inlet manifold 8-12Nm
Bolt-Oxygen sensor 40-60Nm
Bolt - TMAP sensor to inlet manifold 4-5Nm
Bolt - fuel filter to filter support bracket 7–10Nm
Fuel tank unit locking ring 75–85Nm
Bolt - fuel tank strap 22–28Nm
Bolt - fuel filler to body 5–7Nm
Bolt - fuel filler neck to body 5–7Nm
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Engine Fuel & Management Engine
Parameter
Engine Management System
Manufacturer/Model Bosch UAESME 17
Emission Standard (EU V)

Spark plug:
TORCH K6RTC
Clearance 0.8 - 0.9mm

Ignition Coil:
Manufacturer UAES (Bosch)
Model 1x1 single ignition coil, top mounted, one ignition coil for one cylinder
Primary resistance (typical) 0.530Ω (±12%)
Secondary resistance (typical) 9.5kΩX (±12%)

Fuel injection system:
Model Fuel returnless system, MFI system, electronically controlled by ECM.
ECM Engine management system of Bosch contactless, electronic, whole control

chart type
Nozzle:
4 × EV6
Operating pressure
0.38 MPa
Static flow rate of nozzle
154.2 g/min
Sensor
Crankshaft position sensor:
Manufacturer/Model UAES BOSCH, Hall sensor which obtains signal from the side of the signal wheel
Camshaft position sensor:
Manufacturer/Model UAES BOSCH, Hall sensor which obtains signal from the side of the camshaft
signal wheel
Oxygen sensor:
Manufacturer/Model UAES BOSCH LSF4.2
Heating element power (nominal value) 7W
Sensor voltage - high ≈ 800mv
Sensor voltage - low ≈ 50mv

Electronic throttle:
Manufacturer UAES BOSCH
Total rail resistance 1.25KΩ ± 30%

Engine coolant temperature sensor:
Manufacturer/Model TEMB / NTC

TMAP sensor:
Manufacturer UAES BOSCH
Sensor supply voltage 5V ± 4%
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System Layout
Control System - 1.5L
1. Oil Temperature Sensor 10. Screw - Camshaft Position Sensor

2. Oil Temperature Sensor Liner 11. Front Oxygen Sensor Assembly
3. Intake Air Temperature/Pressure Sensor 12. Crankshaft Sensor Assembly
4. Bolt - Intake Air Temperature/Pressure Sensor 13. O-ring - Crankshaft Sensor
5. Knock Sensor 14. Screw - Crankshaft Sensor
6. Screw - Knock Sensor 15. Front Oxygen Sensor Bracket
7. Oil Pressure Switch 16. Rear Oxygen Sensor Assembly
8. Oil Pressure Switch Liner 17. Clip - Oxygen Sensor
9. Camshaft Position Sensor
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System Control Diagram
Engine Control System Control Diagram
A = Hard Wire; B = CAN Bus
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A = CAN Bus
1.0 132
Description 1M Brake Vacuum Sensor
Overview 1N -
The engine management system (ECM) is applied to control 1O -
each aspect of the engine operation. The system receives 1P Non-continuous Power
inputs from various sensors, and then utilizes them to Supply
determine outputs, including the fuel volume delivered to the 1Q Non-continuous Power
combustion chamber, ignition time, air supply control, etc. Supply
Engine uses BOSCH ME 1.7.8.8 ECM which is a continuous 2A CANBus 1 Low
multi-point fuel injection system controlled by ECM and
2B -
adopts the speed/density principle combined with electronic
throttle control. The control intentions of the engine 2C Brake Vacuum Sensor
management system are to: enhance power performance, 2D Continuity Power Supply
reduce fuel consumption and exhaust pollution. 2E -
Engine Control Module (ECM) 2F -
The engine control module is the control centre of the fuel 2G Brake Switch
injection system. It monitors continuously the information 2H -
from various sensors, controls various systems influencing 2J Brake Lamp
the vehicle performance. It also executes system diagnosis
2K -
function. It is able to identify the operation fault, remind the
driver with malfunction indicator lamp (MIL) and store the 2L A/C Medium Pressure
Switch
DTC at indication fault position to facilitate the repair of the
service personnel. 2M A/C High/Low Pressure
Switch
ECMEnd View and Pin Information of Connector - 1.5L (1) 2N -
2O Accelerator Pedal Sensor 2
2P Fan Speed Control 2
2Q Anti-theft Input
3A -
3B -
3C Ignition Switch
3D Accelerator Pedal 2.5V
Power Supply
3E Accelerator Pedal 1.5V
Power Supply
3F -
3G -
Pin No. Description 3H -
1A HS CAN Bus 1 High 3J Fuel Pump Relay
1B -
3K A/C Compressor Relay
1C - -
3L
1D - -
3M
1E Main Relay 3N Accelerator Pedal Sensor 1
1F Clutch Top Switch 3O -
1G Accelerator Pedal 1 Ground 3P Sensor Ground
1H - -
3Q
1J - -
4A
1K - -
4B
1L -
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4C - 13 Throttle Position Sensor 1

- Signal
4D
- 14 Throttle Position Sensor 2
4E
Signal
4F Electronic Vacuum Pump
15 Downstream Oxygen
Relay (AT only)
Sensor
4G -
16 Upstream Oxygen Sensor
4H Fan Speed Control 1 Ground
4J - 17 -
4K - 18 -
4L Accelerator Pedal 2 Ground 19 -
4M - 20 Speed/Exhaust Phase Sensor
Ground
4N -
21 Coolant/Oil Temperature
4O -
Sensor Ground
4P ECM Ground 2 22 Throttle Ground
4Q ECM Ground 1 23 Throttle Actuator
ECM End View and Pin Information of Connector - 1.5L (2) 24 Ignition Coil 4 Cylinder 1
25 Knock Sensor B
26 Knock Sensor A
27 Main Load Sensor
28 -
29 Phase Position Sensor
(intake)
30 Canister Valve
31 Downstream Oxygen/Intake
Phase Position Sensor
Ground
32 Engine Speed Sensor Input
33 -
Pin No. Description 34 Phase Position 5V Power

Supply
1 - 35 Ignition Coil 2 Cylinder 4
2 - 36 Ignition Coil 1 Cylinder 3
3 Fuel Injector 4 (Cylinder 1) 37 Engine Coolant Temperature
4 Fuel Injector 1 (Cylinder 3) Sensor Signal
5 Variable Camshaft Timing 38 Intake Air Temperature
(exhaust) Sensor
6 - 39 Oil Temperature Sensor
Signal
7 Variable Camshaft Timing
(intake) 40 Upstream Oxygen Sensor
Signal
8 Fuel Injector 2 (Cylinder 4)
41 Phase Position Sensor
9 Upstream Oxygen Sensor (exhaust)
Heater
42 Alternator Feedback Signal
10 Fuel Injector 3 (Cylinder 2) (for non stop/start)
11 Throttle Actuator 43 Throttle 5V Power Supply
12 Ignition Coil 3 Cylinder 2 44 Speed/Exhaust Phase
Position 5V Power Supply
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45 Intake Air Failure
Pressure/Temperature
5V Power Supply The main relay may have failures occurred under the following
conditions:
46 Downstream Oxygen
Sensor Heater • Relay winding short-circuited
47 ECM Ground 4 • Relay winding open-circuit
48 ECM Ground 3 • Relay winding high resistance
• Relay contact normally open
The engine management system is composed of the following
6 components • Relay contact normally closed
• Relay contact high resistance
according to control principle:
• Relay harness open-circuit
• External Control
• Relay harness high resistance
• Engine Air Supply Control System
• Relay harness connected to the 12V power supply is
• Engine Ignition Control System short-circuited
• Engine Fuel Supply Control System • Relay harness short to ground
• Auxiliary 1 (heat management) • ECMFailure to provide ground access
• Auxiliary 2 (external assistance)
In order to determine whether the main relay works normally,
External Control the following checks may be carried out:
The external control of the engine mainly includes:
• Sound check - place the ignition key in "ON" position to
• Main relay check whether the fuel pump will work for 2s.
• Ignition switch • Whether the fuel injector or ignition coil is supported by
• Battery power (apply multimeter to check the voltage of battery)
• CANCommunication If the above are verified, it indicates that the main relay works
• Immobiliser power supply normally.
CANCommunication
The external control mainly refers to the power supply and
communication. One line of power supply of the engine The engine management system applies CAN communication
control module (ECM) is directly connected to the power network for the communications between ECM and ABS,
supply through fuse to ensure ECM is in powered state. BCM and TCM, and diagnoses outputs through diagnostic
When the ignition switch is in "ON" or "IGN" position, the interface.
engine control module can control the opening of the main Immobiliser Power Supply
relay or connect to ignition power supply.
When the ignition switch is turned to Gear 2, the engine
The engine control can communicate with controllers of control module (ECM) and body control module (BCM)
other nodes on the network through CAN to ensure each communicate through CAN bus for mutual information
performance of the system. It can also be connected with verification, after verification, BCM will control the operation
the data link connector (DLC) to facilitate the diagnostic of starter motor, ECM will control ignition, fuel injection, and
operation of the service personnel. the engine will be started.
Main Relay Engine Air Supply Control System
The main relay is in the engine compartment fuse box. It is The engine air supply control system mainly includes:
a 4-pin relay adopting the DIN pin layout. The relay doesn't
• Electronic throttle body
contain the reverse electrode protection diodes, this function
is performed by the ECM. • Accelerator pedal module
• Intake air pressure/temperature sensor
When the engine control module (ECM) detects that the
ignition switch is in "IGN" position, it will output a low level • Camshaft position sensor
signal, control the relay to engage, and the UBR pin of ECM is • Variable camshaft timing valve
connected to the power supply voltage so as to meet the start
conditions.
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If the ratio of the air to fuel mass is 14.7:1, the fuel can be burnt the throttle form a part of whole electronic throttle control
sufficiently, and the engine is at the best working state for this system monitoring function, which can provide the redundancy
moment. protection expected by system control.
As for air supply portion, the optimal fuel air ratio is achieved Intake Air Pressure/Temperature Sensor (TMAP)
mainly by the control of air inflow and the master stroke of oil The intake air pressure/temperature sensor measures intake
cylinder. air manifold absolute pressure and intake air temperature and
Electronic Throttle provides engine load and intake air temperature information.
The electronic throttle is composed of throttle, throttle The intake air pressure portion is measured by a piezoelectric
actuator (DC motor) and throttle position sensor, etc. type sensor which can provide the "Load Signal" to the
controller in accordance with the pressure difference
ECM gives instructions to make the DC motor act and affect
between atmosphere and intake manifold; the controller
the throttle opening through the drive mechanism. There are
provides a 5V voltage and feedbacks a 0 - 5V voltage to the
two potentiometers acting as position sensors, which are fit
controller depending on the intake air pressure. The intake
in reverse phase. When the position of the throttle changes,
air temperature portion is measured by a NTC (Negative
the two resistances vary linearly, one increases and the other
Temperature Coefficient) type sensor, whose resistance
decreases. When a +5V voltage is added, the pedal position
changes with the intake air temperature and which transfers
will be transformed into the voltage output corresponding to
a voltage showing the change of the intake air temperature
the changes of the resistance value.
to the controller. The pressure (P) is proportional to output
These two potentiometers along with two potentiometers on voltage and the temperature is inversely proportional to
the accelerator pedal module used for monitoring the stroke of output resistance.
the accelerator pedal form a part of whole electronic throttle
Camshaft Position (CMP) Sensor
control system monitoring function, which can provide the
redundancy protection expected by the system control. The camshaft position sensor is applied to cooperate with
the rotational speed sensor in the circumstances without
Throttle Position Sensor
electricity distributor, to provide the ECM with the camshaft
The throttle position sensor is used to provide throttle angle phase information, namely, identify the compression top dead
information for the ECM. ECM can obtain the engine load centre and exhaust top dead centre of the cylinder 1.
information and operating conditions (such as start, idle
The camshaft position sensor is composed of a hall sensor and
speed, motored condition, part load, full load), acceleration
a rotor made of steel plate. The hall sensor is fixed, and the
and deceleration information according to this information.
rotor with a 36° arc boss is fitted on the camshaft. The inner
Actually, the throttle sensor is an angle potentiometer magnetic field of the hall sensor will change when the boss
characterized by linear output. The potentiometer rotor arm passes it, which leads to the change of output signal voltage. In
and throttle are fitted coaxially. When the throttle rotates, this way, the two top dead centres are identified.
the potentiometer rotor arm will be driven to slide into a
Failure
certain position and the potentiometer output a voltage signal
proportional to the throttle position. CMPThe sensor or magnetic ring may have failures or provide
incorrect signals due to the following conditions:
Accelerator Pedal Module
• CMPSensor gap fails to comply with the specifications.
There are two potentiometers in the accelerator pedal
module acting as sensors, their resistance value will vary • CMPSensor is contaminated by metallic debris.
with the position changes of the electronic accelerator pedal, • CMPSensor hall-effect semiconductor is damaged.
while the ECM can response precisely to the movement • CMPSensor magnetic field is too weak.
of the accelerator pedal, therefore, the movements of the
• CMPSensor harness is open-circuit.
accelerator pedal may be monitored.
• CMPSensor harness is short-circuited.
Because both potentiometers are fitted in the same phase,
• CMPSensor harness has a high resistance.
when the accelerator pedal position changes, their resistances
• Magnetic ring is contaminated by metallic debris.
will increase or decrease linearly. When a +5V voltage is
added, the pedal position will be transformed into the voltage • The precision of magnetic ring is low due to mechanical
output corresponding to the changes of the resistance value. damage.
These two potentiometers and two potentiometers fitted on • Exhaust camshaft timing is incorrect.
the electronic throttle used for monitoring the position of • Intake camshaft timing is incorrect.
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Engine Oil Temperature Sensor Failure
The engine oil temperature sensor (EOT) is applied to The ignition coil may have failures under the following
monitor the engine oil temperature and control variable conditions:
camshaft timing valve (i.e. VCT valve). The variable camshaft
• Primary winding open-circuit
timing valve is adjusted at different temperatures to obtain
optimal intake air. • Primary winding short-circuited
• Resistance of primary winding out of tolerance
Failure
• Secondary winding open-circuit
The EOT sensor may have failures or provide incorrect signals
due to the following conditions: • Secondary winding short-circuited
• The circuit connecting secondary winding with primary
• System lack of oil
winding is short
• External harness open-circuit
• Resistance of secondary winding out of tolerance
• External harness short to ground
• Coil top insulation mechanically damaged
• External harness connected to the 5V power supply is
Crankshaft Position (CKP) Sensor
short-circuited
CKPThe crankshaft position sensor is applied to provide
• External harness high resistance
information of the engine speed and crankshaft top dead
• ECMFailure to provide ground access
centre in the ignition system without electricity distributor. It
• EOTSensor thermistor damaged is a hall-effect sensor matched with pulse wheel in application.
Variable Camshaft Timing (VCT) Valve The pulse wheel is a teeth plate, with 58 small teeth separated
by 6°and a 2-teeth gap on magnetic ring. The pulse wheel
The engine control module outputs pulse width modulation
is fitted on the crankshaft, and rotates with the crankshaft.
(PWM) signal to drive the solenoid. Change in duty ratio may
When the tooth tips pass by sensor ends, the pulse wheel
adjust the opening of the solenoid.
made of steel magnetic materials cuts the magnetic force
The VCT system can, under the condition of low speed, line of the permanent magnets in the sensor to produce the
reduce the fuel consumption and improve the performance of induced voltage in the coil, which acts as the rotational speed
engine in the process of exhaust emission, especially torque output signal.
performance.
Failure
ECMIt receives signals from the CKP sensor and CMP
CKPThe sensor or magnetic ring may have failures or provide
sensor. With these signals, the valve timing can be determined
incorrect signals due to the following conditions:
by ECM by consulting control chart. Then ECM operates the
VCT engine oil control valve installed on one side of cylinder • CKPSensor gap fails to comply with the specifications.
head. These solenoid valves control the oil to flow into phase • CKPSensor is contaminated by dust.
modulator and change the relative position to the camshaft of • CKPSensor hall-effect semiconductor is damaged.
the phase modulator so as to adjust the valve timing.
• CKPSensor magnetic field is too weak.
Engine Ignition Control System
• CKPSensor harness is open-circuit.
The engine ignition control system mainly includes: • CKPSensor harness is short-circuited.
• Ignition coil 1、2、3、4 • CKPSensor harness has a high resistance.
• Engine speed sensor • Magnetic ring is contaminated by dust.
• Knock sensor • The precision of magnetic ring is low due to erosion or
• Ignition sequence mechanical damage.
Ignition Coil • The CKP sensor signal is distorted due to out-of-round
flywheel or drive disc.
The ignition coil turns the DC low voltage of battery to high
voltage and ignites the air mixture in cylinder through the spark • The CKP sensor signal is changed due to crankshaft
generated by the discharge of spark plug. Each ignition coil radial movement.
consists of a pair of coil windings around laminated iron core. In order to check the ECM for receiving the signal from CKP
There are four ignition coils fitted on the camshaft cover of sensor, following operations may be conducted:
the engine, and each cylinder has an independent ignition coil
connected with the spark plug.
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• Check the operation of the fuel pump in the engine • HO2SWhen the output voltage changes, the increased
starting process; if the fuel pump supplies fuel when the temperature of HO2S is sufficient for normal operation.
ignition is on but not operating, it indicates that ECM • ECTThe temperature of the sensor is higher than the
does not receive CKP sensor signal. specified temperature.
Knock Sensor • The engine has started for a specified period of time.
The knock sensor is used to provide electronic controller With respect to above conditions, different engines have their
ECM with the engine knock information to carry out knock specific values which are stored in an electronic erasable
control. programmable read only memory (EEPROM). After these
The knock sensor is a vibration acceleration sensor. It is values are met, the system begins closed-loop operation.
fitted on the engine cylinder block. The sensitive element During the closed-loop running, the control module calculates
of the sensor is a piezoelectric crystal. The vibration of the the air fuel ratio and opening time of the injectors according to
engine cylinder block is transferred to the piezoelectric crystal the signals from various sensors, especially the heated oxygen
through the mass block in the sensor. Due to the pressure senor, so that the air fuel ratio is always close to 14.7:1.
generated from the vibration of mass block, the piezoelectric Oxygen Sensor
crystal produces voltage on both pole surfaces to transform
The oxygen sensor measures the oxygen content in the
the vibration signal into voltage signal to output.
engine exhaust to determine if the gasoline and air are
Failure burnt completely. The electronic controller implements the
The knock sensor may have failures or provide incorrect signals closed-loop control aiming at excessive air coefficient λ =
due to the following conditions: 1 according to the information to ensure that three-way
catalytic converters have the highest conversion efficiency in
• Sensor open-circuit
such three kinds of pollutant as HC, CO and NOx in the
• Sensor to ground short-circuited exhaust.
• Sensor circuit intermittently open
Its sensing element is a ceramic tube, the inner surface and
• Incorrect knock sensor refit outer surface of which are contacted with exhaust gas and
In case of knock sensor signal failure, the following symptoms ambient air respectively. When the sensing ceramic tube
may occur: temperature reaches 350℃, it will have the property of solid
electrolyte. With this property, the concentration difference
• Store the failure code of oxygen is turned to electric potential difference so as
• ECMFailure to inspect engine combustion knock to form electric signal output. If the mixture is rich, the
• ECMRestore default settings concentration difference of oxygen inside and outside the
Engine Fuel Supply Control System ceramic tube is high, the electric potential difference is high,
a large amount of oxygen ions move from inside to outside
The engine fuel supply control system mainly includes: and the output voltage is high (approximate to 900mV); if the
• Upstream oxygen sensor mixture is thin, the concentration difference of oxygen inside
• Downstream oxygen sensor and outside the ceramic tube is low, the electric potential
difference is low, only a few of oxygen ions move from inside
• Fuel injectors 1 - 4
to outside and the output voltage is low (approximate to
• Canister valve 100mV).
• Fuel pump relay
The oxygen sensor consists of the front oxygen sensor and
The engine fuel supply control system is mainly applied to rear oxygen sensor. The former is used to measure the
control the fuel supply for the engine under different working oxygen content in the engine exhaust to implement the closed
conditions. loop control, and the latter is used to monitor the conversion
function of the three-way catalyst.
When the engine starts for the first time and engine speed
is higher than the preset speed, the system begins open loop Failure
operation. The control module ignores the signals from the HO2SIt may have failures or provide incorrect signals due to
heated oxygen sensor (HO2S). The control module calculates the following conditions:
the air fuel ratio according to the input signal from the ECT,
TMAP and TP sensors. The system stays in open loop state • Contaminated by leaded fuel
until the following conditions are met: • Contaminated by carbon or silicon deposits
• Impact damage/mechanical impact
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• External harness open-circuit At the time of start
• External harness connected to the 12V power supply is • If the fuel system pressure falls to zero, the engine will
short-circuited fail to ignite.
• External harness short to ground • If the fuel system pressure is lower than normal operating
• External harness high resistance pressure (0.38MPa), the engine may try to ignite, but fails
• Heating device open-circuit to work normally.
• Heating device short-circuited • If the fuel system pressure is normal, the engine will ignite
to operate, but will flame out finally with decrease in fuel
• ECMFailure to provide ground access for heating device
pressure, and fails to restart.
• Harness shielding not connected to the ground
During driving
Fuel Injector
If the fuel pump relay fails during driving, the engine will lose
The fuel injector, according to the commands of the ECM,
power and finally shuts down due to shortage of fuel.
injects fuel within the specified time to supply the engine
with fuel and have it atomized. ECMThe ECM energizes the The fuel pump relay may have failures under the following
injector coil to form magnetic force. When the magnetic conditions:
force is strong enough to overcome the resultant force of
• Relay coil short-circuited
the return spring pressure, needle valve gravity and friction,
the needle valve begins to rise, and the fuel injection process • Relay coil open-circuit
starts. When fuel injection pulse ends, the pressure of return • Relay coil high resistance
spring makes the needle valve close again. • Relay contact normally open
Failure • Relay contact normally closed
The fuel injector may fails under the following conditions: • Relay contact high resistance
• Nozzle is contaminated by dust or wax (flow is reduced) • Relay harness open-circuit
• Nozzle offset (injection positioned incorrectly) • Relay harness high resistance
• Fuel filter blockage • Relay harness connected to the 12V power supply is
short-circuited
• Winding open-circuit
• Relay harness short to ground
• Winding short to ground
• ECMFailure to provide ground access
• Winding connected to the 12V power supply is
short-circuited Carry out the following checks and check the fuel pump relay
• Winding resistance out of tolerance for normal operation:
• External harness open-circuit • Sound check - place the ignition key in "ON" position to
• External harness short to ground check whether the fuel pump will work for 2s.
• External harness connected to the 12V power supply is Check the ECM for providing an access to ground for the fuel
short-circuited pump relay when the ignition switch is in "ON" position (for 2s)
Electric Fuel Pump and during the starting. Remove the fuel pump relay, connect
a multimeter between the 12V power supplied by the vehicle
The electric fuel pump transfers the fuel from the fuel tank to
and the fuse box pin connected with fuel pump pin 85, check
the engine and provides sufficient fuel pressure and rich fuel.
the output according to the circuit diagram after the ignition
It is a DC motor driven vane pump, which is fitted in the fuel is on.
tank and immersed in the fuel. It applies fuel for heat dissipation
As the ECM internal drive circuit consumes voltage, the
and lubrication. The battery supplies power to the electric fuel
measured voltage may be lower than the battery voltage.
pump via fuel pump relay, which allows the electric fuel pump
Canister Control Valve
circuit to be closed only when the relay starts and the engine
operates. When the engine stops running due to accident, the The canister control valve is applied to control the
fuel pump will stop operating automatically regeneration air flow of the fuel evaporation control system.
Failure The canister in the fuel evaporation control system absorbs
If the fuel pump relay fails, the following symptoms will occur: fuel steam from fuel tank till it cannot absorb any more.
ECMIt controls the canister control valve to open and allows
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fresh air and saturated fuel steam in the canister to form Failure
regeneration air flow, then sends it to the engine air inlet pipe.
ECTThe sensor may have failures or provide incorrect signals
The electronic controller, based on the different working
due to the following conditions:
conditions of engine, changes the duty ratio of the pulse signal
transmitted to the canister control valve electromagnetic coil • The system is lack of coolant due to leakage
to control the regeneration air flow. Moreover, the flow is • External harness open-circuit
also influenced by the pressure difference on both ends. • External harness short to ground
Failure • External harness connected to the 5V power supply is
The canister control valve may have failures occurred under short-circuited
the following conditions: • External harness high resistance
• Electromagnetic winding open-circuit • ECM Failure to provide ground access
• Electromagnetic winding short-circuited • ECT Thermistor damaged
• External harness connected to the 12V power supply is Cooling Fan Relay Unit
short-circuited The cooling fan relay unit is fitted on the left side of the
• External harness short to ground radiator, which is equipped with two relays.
• External harness high resistance The cooling fan is controlled by the ECM, and is manipulated
• ECMFailure to provide PWM signal through the relay unit. ECM It uses the information provided
• Mechanical problems occur in the valve by the ECT sensor, BCM and A/C pressure sensor to limit
the cooling temperature of the engine.
Auxiliary 1 (Heat Management)
Auxiliary 2 (External Assistance)
The heat management portion mainly includes:
The external assistance portion mainly includes:
• A/C compressor relay
• Alternator control input
• A/C request (On/Off)
• Clutch switch
• Engine coolant temperature sensor
• Brake pedal switch
• Cooling fan relay (low speed, high speed)
• Brake lamp
• A/C pressure sensor
Alternator Control Input
The engine adjusts the opening or closing of the high/low speed
cooling fan relay according to the coolant temperature. The alternator control input is used by the ECM to control the
alternator for the battery charge while the engine operates.
After the driver presses the A/C request (ON/OFF) on
Brake Switch
the instrument panel, ECM monitors the status of the A/C
pressure sensor signal and decides whether to turn on the The brake switch is located on the pedal box in the cab. ECMIt
A/C according to the current engine coolant temperature monitors the switch status and transfers the data to the TCM
sensor signals and engine speed signals. via the CAN bus, and the TCM controls the gearbox clutch
Engine Coolant Temperature Sensor to open. When the brake pedal is operated, the brake switch
is activated.
The coolant temperature sensor is used to provide the engine
Clutch Switch (MT only)
coolant temperature information. Whereby, the controller
can correct the fuel injection and ignition. It is a negative The clutch sensor is powered by the ECM. When the clutch
temperature coefficient (NTC) thermistor, whose resistance pedal is depressed, the ECM will receive the clutch release
value is reduced as the temperature rises, but it is not a linear signal; when the clutch pedal is reset, the ECM will receive
relationship. The thermistor is mounted inside a copper heat the clutch engagement signal.
sleeve.
1.0 140
Service Procedures Ignition Coil
Spark Plug Remove
Remove 1. Disconnect the battery negative.
1. Disconnect the battery negative. 2. Remove the air filter assembly.
2. Remove the ignition coil. Air Filter Assembly Remove
Ignition Coil Remove 3. Disconnect the harness connector and the bolt.
3. Clean the area around the spark plug. Remove the dust
around the spark plug with high pressure gas.
4. Remove 4 spark plugs with the spark plug socket.
4. Hold the end of the ignition coil rubber bush, and pull
out the ignition coil from the spark plug (if difficult to
pull out, you can rotate the ignition coil right and left
to loosen it).
Refit
Refit
1. Identify the model of the original spark plug before
fitting a new one. Spark plug of the same model shall 1. Fit the ignition coil onto the spark plug, and connect
be selected for replacement. the harness connector.
2. Adjust the initial gap of each new spark plug to 2. Tighten the bolts fixing the ignition coil to8-12Nm
0.80-0.90mm. 3. Connect the high voltage wire to the spark plug.
3. Fit the spark plug and tighten it to 22-28Nm. 4. Fit the air filter assembly.
4. Fit the ignition coil. Air Filter Assembly Refit
Ignition Coil Refit 5. Connect the battery negative.
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Engine Control Module (ECM) Engine Coolant Temperature Sensor (ECT)

Remove Remove
2. Remove 4 bolts (1) fixing the ECM to the battery 2. Remove the coolant expansion tank cap to release the
bracket. pressure of the cooling system, and then refit the cap.
3. Disconnect the harness connector (2) from the ECM. Warning: Since injury such as scalding could be caused by
Caution: ECMWhen disconnecting the connector, escaping steam or coolant, do not remove the filler cap
avoid shaking the connector all round; avoid from the coolant expansion tank while the system is hot.
applying force on one side only; avoid damaging 3. Disconnect the harness connector.
the connector structure. 4. Drain the coolant.
Coolant Drain
5. Remove the circlip fixing the engine coolant
temperature sensor.
6. Remove the engine coolant temperature sensor.
4. Remove the ECM.

Refit
1. Fit 4 bolts of the battery bracket, tighten to 7-10Nm,
2. Connect the harness connector to the ECM.
Refit
Caution: ECMWhen connecting the connector, make
1. Clean the thread of the coolant temperature sensor.
sure to align the connector, and insert it with
2. Fit a new sealing washer onto the coolant temperature
even force applied on both ends. Attempt of tilting
sensor.
assembly or assembly with great effort on one side
shall be not allowed. If the connector is damaged, 3. Fit the engine coolant temperature sensor and tighten
replace the engine harness. to 14-18Nm.
4. Connect the engine coolant temperature sensor
harness connector.
4. Programme and encode the ECM.
5. Perform self-learning for the electronic throttle.
6. Refill coolant.
Electronic Throttle Self-learning - UMC System
Coolant Refill
6. Place the ignition switch in "ON" position, and perform
"Engine Module Reset Self-learning Value" with VDS.
7. Wait for 2 - 5 seconds, turn off the ignition switch and
restart the vehicle.
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Engine Oil Temperature Sensor Crankshaft Position Sensor
Remove Remove
2. Disconnect the harness connector from the oil 2. Remove the bottom deflector.
temperature sensor.
3. Place the oil sink under the switch to collect the spilled
3. Disconnect the harness connector from the crankshaft
oil.
position sensor.
4. Remove the oil temperature sensor.
4. Remove the bolt fixing the crankshaft position sensor
to the cylinder block.
5. Remove the crankshaft position sensor.
Refit
1. Clean the thread of the oil temperature sensor.
2. Fit a new sealing washer to the oil temperature sensor Refit
and tighten the switch to 14-18Nm. 1. Clean the mating surface of the crankshaft position
3. Connect the temperature sensor connector. sensor and the cylinder block.
4. Remove the oil sink. 2. Locate the crankshaft position sensor, fit the retaining
5. Connect the battery negative. bolt and tighten it to 8-12Nm.
6. Check the engine oil level, and refill if necessary. 3. Connect the crankshaft position sensor harness
connector.

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Camshaft Position Sensor Camshaft Phase Modulator

Remove Remove
2. Disconnect the harness connector from the camshaft 2. Drain the engine oil.
position sensor.
3. Remove the bolt fixing the camshaft position sensor,
remove the camshaft position sensor and discard the
O-ring. Timing Chain Upper Cover Plate Remove

sealing washer.
Refit
1. Clean the camshaft position sensor and mating surface,
and fit an O-ring to the camshaft position sensor.
2. Fit the camshaft position sensor to the cylinder head
and tighten the bolts to 8-12Nm. 6. Remove the upper guide rail.
3. Connect the camshaft position sensor harness
connector.
7. Remove the oil control valve.

Oil Control Valve Remove
1.0 144

modulator bolts.
mounting boss.
4. Position the phase modulators assembled on the intake

and exhaust camshafts to the appropriate camshaft,
mount the chains into both modulators, and pretighten
the bolts.
5. Fit the oil control valve.
Refit Oil Control Valve Refit
1. Rotate the flywheel until the flywheel pin hole is aligned 6. Fit the upper guide rail to the front bearing cap of the
with the pin hole of the engine body. camshaft, fix with two bolts, the tightening torque is
2. Insert the TEN00002 into the engine body timing pin 8-12Nm.
7. Fit a new timing hydraulic tensioner washer, screw the

3. Rotate the camshaft with the timing hole up, and fix the timing hydraulic tensioner into the cylinder head, and
intake/exhaust camshaft with the TEN00004. tighten to 18-22Nm+(22-28°).
1.0 145
Oil Pressure Switch

Remove
3. Disconnect the harness connector from the oil
pressure switch.
4. Place the oil sink under the switch to collect the spilled
oil.
5. Remove the oil pressure switch.
8. Secure the intake and exhaust phase modulators to the

camshaft, tighten the bolt to 70-80Nm.
Refit
1. Clean the thread of the oil pressure switch.
2. Fit a new sealing washer to the oil pressure switch and
9. Fit the lower cover plate of the timing chain. tighten the switch to 14-18Nm.
Timing Chain Lower Cover Plate Refit 3. Connect the oil pressure switch harness connector.
10. Fit the upper cover plate of the timing chain. 4. Remove the oil sink.
11. Fill the engine oil. Bottom Deflector Refit
7. Check the engine oil level, and refill if necessary.
1.0 146
Knock Sensor Fuel Rail
Remove Remove
2. Disconnect the knock sensor harness connector. 2. Release the pressure of the fuel system.
3. Remove the bolt fixing the knock sensor onto the Warning: Fuel vapour is highly flammable and in confined
cylinder block, and take away the sensor. spaces is also explosive and toxic. Always have a fire
extinguisher containing foam, CO2, gas or powder close
3. Disconnect the harness connector from the fuel rail
assembly.
Refit
1. Clean the mating surface of the knock sensor and the
cylinder block.
2. Fit the knock sensor, ensure that the harness is properly 4. Release the fuel inlet pipe from the fuel rail.
placed, and tighten the bolts to 15-25Nm.
3. Connect the knock sensor harness connector. contamination.
5. Remove 2 bolts fixing the fuel rail to the intake manifold.
6. Remove the fuel rail assembly.

Refit
1. Clean the fuel injector and the intake manifold groove.
2. Locate the fuel rail assembly on the intake manifold, and
push each fuel injector into the corresponding hole of
the intake manifold.
3. Fix the fuel rail assembly to the intake manifold with 2
bolts, and tighten the bolts to 8-12Nm.
4. Connect the fuel inlet pipe to the fuel rail.
5. Connect the fuel injector harness connector.
1.0 147
6. Connect the battery negative. Fuel Injector

Remove
2. Disconnect the fuel injector harness connector.
3. Remove the fuel rail assembly.
Fuel Rail Assembly Remove

4. Release the spring clamp fixing the fuel injector to the
fuel rail, and remove the fuel injector.
5. Remove 2 O-rings from each fuel injector, and discard
them.
6. Fit the end cap to the end of each fuel injector.
Refit
1. Remove the end cap from each fuel injector.
2. Clean the groove of the fuel injector and fuel rail.
3. Lubricate new O-rings with oil, and fit them to both
ends of each fuel injector.
4. Fit the fuel injector to the fuel rail.
5. Fix the fuel injector to the fuel rail with spring clamps.
6. Fit the fuel rail assembly.
Fuel Rail Assembly Refit

7. Connect the fuel injector harness connector.
1.0 148
Oxygen Sensor Downstream Oxygen Sensor
Remove Remove
2. Disconnect the upstream oxygen sensor harness 2. Remove the bottom deflector.
connector (1).
3. Use the special tool for the oxygen sensor TEN00011
3. Disconnect the downstream oxygen sensor connector
to remove the upstream oxygen sensor (2).
(1).
4. Use the special tool TEN00011 for the oxygen sensor
to remove the downstream oxygen sensor (2).
Refit
1. Fit the oxygen sensor with TEN00011, and tighten to
40-60Nm, check the torque.
Refit
Caution: Before the old part is refitted, apply the 1. Fit the oxygen sensor with TEN00011, tighten to
high temperature antiwelding agent onto the thread. 40-60Nm and check the torque.
2. Connect the upstream oxygen sensor harness Caution: Before the old part is refitted, apply the
connector. high temperature antiwelding agent onto the thread.
2. Connect the upstream oxygen sensor harness
connector.
3. Fit the upper bottom deflector.

1.0 149
Manifold Absolute Pressure/Temperature Sensor Charcoal Canister

Remove Remove
1. Disconnect the battery negative. 1. Raise vehicle on suitable hoist.
2. Remove the starter motor. 2. Raise canister to release from retaining clip.
Starter Motor Remove
3. Disconnect the manifold absolute pressure/temperature
sensor harness connector.
4. Remove the bolts fixing the manifold absolute
pressure/temperature sensor to the intake manifold,
and remove the sensor.
3. Lower canister to access pipes.

4. Disconnect vent pipe, canister to fuel tank and canister
to engine pipes.
5. Remove canister.

contamination.
Refit Refit
1. Clean the mating surface of the manifold absolute 1. Position canister to vehicle.
pressure/temperature sensor and the intake manifold.
2. Refit pipes to canister.
2. Fit the manifold absolute pressure/temperature sensor,
3. Position canister in bracket, secure.
and tighten the bolts to 4-5Nm.
4. Lower hoist.
3. Connect the manifold absolute pressure/temperature
sensor harness connector.
4. Fit the starter motor.
Starter Motor Refit

1.0 150
Carbon Canister Control Valve Pipe Assembly - Body Underfloor Fuel Lines
Remove Remove
1. Disconnect battery earth lead. 1. Disconnect battery earth lead.
2. Disconnect purge valve electrical connector. Warning: Fuel vapour is highly flammable and in confined
3. Disconnect vacuum hose from purge valve spaces is also explosive and toxic. Always have a fire
4. Disconnect fuel ventilating hose from purge valve
2. Depressurise fuel system.
5. Remove purge valve from retaining bracket.
Fuel System - Depressurise
Before disconnecting any part of the fuel system, it
is imperative that all dust, dirt and debris is removed
from around components to prevent ingress of foreign
matter into fuel system.
3. Drain fuel tank.
Drain and Refill
4. Disconnect carbon canister pipe at purge valve.
Refit
1. Connect under-floor pipe to valve of carbon canister.
2. Connect vacuum pipes to valve of carbon canister.
3. Connect the connector of carbon canister valve.
4. Fit carbon canister valve to bracket.
5. Connect battery earth lead.
5. Disconnect fuel supply pipe at fuel rail.

6. Raise vehicle on suitable hoist.
7. Disconnect pipes from carbon canister.
Charcoal Canister
8. Disconnect pipes from fuel filter.
Fuel filter
9. Release 11 clips securing underfloor pipes to body
(one is on the fuel tank, 10 are on the underbody and
engine bay).
1.0 151
Refit Fuel filter

1. Position pipe assembly to vehicle. Remove
2. Secure pipe retention clips. 1. Disconnect battery earth lead.
3. Reconnect pipe at fuel filter. 2. Depressurise fuel system.
Fuel filter Fuel System - Depressurise

4. Reconnect pipe at charcoal canister. Caution: Always fit plugs to open connections to prevent
contamination.
Charcoal Canister
5. Lower the vehicle. Warning: Depressurise the system before disconnecting
any components. Fuel pressure will be present in the
6. Reconnect pipe at purge vale.
system even if the ignition has been switched off for some
7. Reconnect pipe at fuel rail.
time.
8. Refill fuel tank..
3. Raise vehicle on suitable hoist.
9. Reconnect battery earth lead.
4. Position a suitable container to catch any spillage.
5. Disconnect earth lead.
6. Disconnect pipes/hoses from filter, note original fitted
position.
7. Remove clamp screw.
8. Remove filter.
Refit
1. Position fuel filter in clamp, secure screw, tighten
to7–10Nm
2. Refit pipes to filter.
3. Reconnect earth lead.
4. Lower hoist.
1.0 152
Tank - Fuel
Remove
1. Disconnect battery earth lead.
Warning: Fuel vapour is highly flammable and in confined

spaces is also explosive and toxic. Always have a fire
Fuel System - Depressurise

3. Drain the fuel system. 10. Lower fuel tank to access top of tank.
11. Disconnect feed and return pipes to fuel pump.
Drain and Refill
12. Disconnect the connector of fuel pump.
Caution: Before disconnecting any part of the fuel
system, it is imperative that all dust, dirt and debris is
removed from around components to prevent ingress of
foreign matter into fuel system.
4. Remove carbon canister.
Carbon Canister Remove

5. Remove fuel filter.
Fuel Filter Remove

6. Remove fuel tank heat shield.
Fuel Tank Heat shield
7. Remove clips securing fuel filler and breather pipes to
tank, remove pipes. 13. Remove tank, use T18007remove the lock ring of fuel
pump.
Refit
1. Position the new pump seal to fuel tank, fit the fuel
pump, do not damage the pump seal.
2. UseT18007fit lock ring of fuel pump to fuel tank, and
tighten to75–85Nm.
3. With assistance position fuel tank on jacking equipment,
position to vehicle.
4. Connect the connector to fuel pump. Connect fuel
feed and return pipes to fuel pump.
5. Raise fuel tank, align straps.
Caution: Take care not to trap any pipes or cables when
Warning: The spilling of fuel is unavoidable during this fitting fuel tank.
operation. Ensure that all necessary precautions are
6. Raise the fuel tank assembly to under-floor, Fit strap
taken to prevent fire and explosion.
bolts and tighten to 22–28Nm.
8. Use a suitable jacking device to support fuel tank.
7. Reconnect fuel filler pipes to fuel tank, secure clips.
9. Release 4 bolts securing retaining straps to body,
8. Refit fuel filter.
remove straps.
Fuel Filter Refit
9. Refit charcoal canister.
Carbon Canister Refit
1.0 153
10. Refit fuel tank heatshield. Fuel pump

Fuel Tank Heat shield
Remove
1. Disconnect battery earth lead
12. Refill fuel tank.
13. Reconnect battery earth lead. Fuel System - Depressurise
Warning: The spilling of fuel is unavoidable during this
3. Remove rear seat cushion
Rear Seat Cushion Assembly Remove
4. Pull back sound insulation and carpet (where applicable).
5. Using a suitable lever, remove fuel pump unit access
cover.
6. Cover surrounding area to protect against fuel spillage.

7. Disconnect electrical connector from fuel pump.
8. Release fuel feed and fuel return pipes from the fuel
pump.
Caution: Before disconnecting any part of the fuel

system, it is imperative that all dust, dirt and debris is
removed from around components to prevent ingress of
foreign matter into fuel system.
1.0 154
Warning: The spilling of fuel is unavoidable during this Fuel System - Pressure Relief - 1.5L
operation. Ensure that all necessary precautions are Check
taken to prevent fire and explosion. 1. Release the fuel filler cap to release the steam pressure
9. Using T18007 to release and remove fuel pump locking in the fuel tank.
ring.
10. Carefully release fuel pump assembly. spaces is also explosive and toxic. Always have a fire
11. Remove seal, discard. extinguisher containing foam, CO2, gas or powder close
Refit 2. Remove the fuel pump fuse from the engine
1. Fit new seal to fuel tank. compartment fuse box.
2. Fit fuel pump, taking care not to dislodge the seal. 3. Place the ignition switch in "ON" position and keep the
3. UsingT18007 to fit the fuel pump locking ring and engine idle until it stops.
tighten to 75–85Nm. 4. Place the ignition switch in "OFF" position, restart the
engine with the ignition key and keep for 10s to confirm
Caution: Verify that the triangle mark on fuel pump is
that the engine has no fuel.
aligned with the mark (three parallel line segments) on
fuel tank, and that the outer two line segments are not 5. Fix the fuel filler cap.
exceeded.
4. Connect fuel feed and fuel return pipes to fuel pump.

5. Connect electrical connector to fuel pump.
6. Apply glue, refit access cover.
7. Position sound insulation and carpet.
8. Fit rear seat cushions.
Rear Seat Cushion Assembly Refit

1.0 155
Fuel System - Pressure Test - 1.5L fuel pump for normal operation.
Check 7. Respectively disconnect the high-pressure fuel pump
1. Place a piece of absorbent cloth around the joint of the low-pressure fuel pipe and the fuel supply pipe from
high-pressure fuel pump low-pressure fuel pipe and the TCH00106.
underfloor fuel pipeline to collect the spilled fuel. 8. Drain the fuel remaining in the tool to the container.
Warning: Fuel vapour is highly flammable and in confined 9. Connect the high-pressure fuel pump low-pressure fuel
spaces is also explosive and toxic. Always have a fire pipe to the fuel supply pipe.
Warning: The spilling of fuel is unavoidable during this
2. Disconnect the high-pressure fuel pump low-pressure
fuel pipe from the fuel supply pipe.
3. Respectively connect the joints of the high-pressure

fuel pump low-pressure fuel pipe and the underfloor
fuel pipe to the quick joints of the TCH00106.
4. Fix the TCH00106 to the fuel pressure gauge T18002.
5. Start the engine to allow the fuel pump to work,

observe the readings on the fuel pressure gauge within
a minute; if the readings are in the range of 3.5 - 3.9 bar,
the fuel system is normal.
6. Shut down the engine to stop the fuel pump; if the
system pressure drops below 2 bar after 20 minutes,
there may be something wrong with system pressure
maintaining. Check the pressure regulating valve of the
1.0 156
Tank-Drain & Refill Filler Neck
Drain and Refill Remove
Warning: Fuel vapour is highly flammable and in confined 1. Disconnect battery earth lead.
1. Release fuel filler cap from the filler neck. extinguisher containing foam, CO2, gas or powder close
2. Using a fuel recovery appliance, drain fuel from the tank 2. Drain fuel tank.
into a sealed container.
Drain fuel tank
3. Remove Wheelhouse Lining Board
Wheelhouse Lining Board-Remove

4. Remove clips securing fuel filler and breather pipes to
tank, remove pipes.
3. Follow manufacturer's instructions for connection and

safe use of appliance.
Warning: The capacity of containers must be more than

adequate for the amount of fuel to be extracted or
drained. The container should be clearly marked with its
contents and placed in a safe storage area which meets 5. Remove fuel filler cap.
the requirements of local authority regulation. 6. Remove bolts securing upper filler neck to body.
7. Remove bolts securing filler neck and cover to body .
1.0 157
Electronic Throttle Self-learning - UMC System

1. Confirm if the vehicle speed is 0 km/h, engine speed is 0
r/min, battery voltage is higher than 10V, opening of the
accelerator pedal is 0, coolant temperature is within 5℃
- 100℃ and the intake air temperature is higher than 5℃.
2. Check if the harness is properly connected and shows no
other faults, mainly including throttle fault.
3. Place the ignition switch in "ON" position, wait for 30s,
at this interval, do not do any other operations.
4. The self-learning is then completed.
8. Remove filler neck assembly.

Refit
1. Position fuel filler neck in vehicle.
2. Refit upper filler neck retaining bolts, tighten to
5–7Nm.
3. Refit filler neck and cover retaining bolts, tighten to
5–7Nm.
4. Fit filler and breather pipes to fuel tank, secure clips.
5. Refit Wheelhouse Lining Board
Wheelhouse Lining Board-Refit

7. Refit filler cap.
1.0 158
Number
Three-way pipe
TCH00106 of fuel pressure
Holding pin gauge
TEN00002
flywheel timing
Fuel pressure
T18002
Camshaft timing test equipment
TEN00004
locking
Wrench O2
TEN00011
sensor
Wrench fuel
T18007
tank lock ring
1.0 159
Engine Engine Manifold & Exhaust System
Engine Manifold & Exhaust System

Specifications
Torque
Description Value
Bolt-Metal-hose Clamps 3-4Nm
Screw-Air Cleaner Body 1.4-1.8Nm
Bolt-Inflow Pipe to Water Beam 5-7Nm
Bolt-Electronic Throttle to Intake Manifold 8-12Nm
Nut-Exhaust Front Tube to Exhaust Back Tube 19-25Nm
Bolt-Exhaust Front Tube to Engine 19-25Nm
Nut-Exhaust Front Tube to Three-way Catalyst 19-25Nm
Bolt-Exhaust Channel Insulation to Body 4-6Nm
1.0 160
Engine Manifold & Exhaust System Engine
System Layout
1. Air Filter Assembly 7. Bolt - Air Filter Inlet Pipe

2. Air Filter Element 8. Air Filter Outlet Pipe Assembly
3. Air Filter Liner 9. Air Filter Outlet Pipe Bushing
4. Bolt - Air Filter 10. Air Filter Outlet Pipe Bushing
5. Bolt - Air Filter 11. Clamp - Air Outlet Pipe
6. Air Filter Inlet Pipe Assembly 12. Resonator
1.0 161
1. Exhaust Tail Pipe 7. Front Exhaust Pipe Assembly

2. Middle Exhaust Pipe Rear Lug 8. Front Exhaust Pipe Lug
3. Exhaust Pipe Rear Mounting Bracket 9. Bolt - Front Exhaust Pipe
4. Bolt - Exhaust Pipe Rear Hook Bracket 10. Nut - Exhaust Manifold
5. Exhaust Tail Pipe Liner 11. Sealing Gasket - Exhaust Manifold
6. Nut - Exhaust Tail Pipe
1.0 162
Description the exhaust system is located on the front exhaust pipe. The
Air Filter tail pipe is designed with an one-piece pipe with single hole,
which is treated by the stainless steel polishing technology. The
The air filter outlet pipe is fitted between the air filter and the
exhaust system is connected with the vehicle body through 4
throttle body, which is fixed by the worm drive clamp. The air
rubber lugs. The rubber lugs can decrease the vibration of
filter assembly is fixed to the upper part of the engine with 4
the exhaust pipe during driving. Two thermal baffles are fitted
air filter mounting pins.
respectively on the upper part of the exhaust muffler and on
Exhaust System the outer surface of the fuel tank, this can decrease the thermal
The exhaust system consists of the front exhaust pipe and rear radiation from the exhaust pipe to protect the shift device and
exhaust pipe which are connected by nuts. The muffler of fuel system.
1.0 163
Operation Three-Way Catalytic Converter (TWC)

Air Filter Warning: TWCs operate at very high temperatures;
Air enters into the air filter through the air filter inlet pipe therefore, extreme caution is necessary when handling
located at the front end cooling module. The impurities in the this component.
air are filtered by the air filter element and kept in the air filter
Caution: For the TWC to work efficiently and to prevent
lower housing.
premature failure do not run on leaded fuel and do not
Air from the air filter is transferred to the throttle body via allow unburnt fuel to pass through the exhaust system.
the air filter outlet pipe.
The primary combustion happens in the combustion chamber
Exhaust Manifold and Exhaust System and the exhaust gas enters into the TWC through the exhaust
The high temperature/pressure gas generated during the manifold. TWCIt operates effectively only when its minimum
operation of the engine will enter into the exhaust manifold working temperature is achieved. The exhaust gas enters into
through each exhaust port. The manifold branches integrally an integral structure coated with Pt and Rh (catalyst), and
enter into a flange and transport the gas into the exhaust two procedures (reduction and oxidation) are performed here.
system via the three-way catalytic converter, and finally The nitrogen oxide (NOx) is restored to nitrogen, from which
discharge it through the exhaust tail pipe. With the exhaust the oxide is combined with carbon monoxide (CO) to form
system mufflers, flow noise of the gas can be greatly reduced carbon dioxide. The hydrocarbon (HC) and CO will continue
to meet relevant noise regulations at last. to conduct combustion in the three-way catalytic converter
with the oxygen in the air, which forms water and CO2.
1.0 164
Service Procedures Air Filter Element
Remove 1. Remove 1 bolt securing the metal clamp of the air filter
1. Disconnect the battery negative. outlet pipe.
2. Remove 1 bolt securing the metal clamp of the air filter 2. Remove 5 screws fixing the upper housing of the air
outlet pipe. filter to the lower housing of the air filter.
3. Pluck off the air filter inlet pipe from the air filter 3. Remove the air filter element.
assembly. Refit
4. Pull to remove the air filter assembly directly. 1. Fit the air filter element.
Refit 2. Fit 5 screws fixing the upper housing of the air filter
1. Fix the air filter assembly to the engine. to the lower housing of the air filter, tighten to
2. Fit 1 bolt securing the metal clamp of the air filter 1.4-1.8Nm, and check the torque.
outlet pipe, tighten to 3-4Nm, and check the torque. 3. Fit 1 bolt securing the metal clamp of the air filter
3. Fix the air filter inlet pipe to the air filter assembly. outlet pipe, tighten to 3-4Nm, and check the torque.
1.0 165
Air Inlet Pipe Assembly Electronic Throttle

Remove Remove
1. Remove 2 bolts fixing the air inlet pipe assembly to the 1. Disconnect the battery negative.
upper radiator beam. 2. Remove the intake manifold assembly.
Intake Manifold Liner Remove
3. Fit 3 bolts fixing the electronic throttle to the intake
manifold assembly.
2. Remove 1 bolt of the metal clamp fixing the air inlet

pipe assembly to the resonator.
4. Disconnect the electronic throttle from the intake

manifold assembly, and remove the O-ring.
Refit
1. Clean the junction surface of the throttle and the
intake manifold assembly, and ensure there is no foreign
material.
2. Fit the new O-ring.
3. Fit 3 bolts fixing the electronic throttle to the intake
manifold assembly, tighten to 8-12Nm, and check the
torque.
4. Fit the intake manifold assembly.
Refit Intake Manifold Liner Refit
1. Fit the air inlet pipe assembly. 5. Connect the battery negative.
2. Fit 1 bolt of the metal clamp fixing the air inlet pipe 6. Perform self-learning for the electronic throttle.
assembly to the resonator, tighten to 3-4Nm, and Electronic Throttle Self-learning - UMC System
check the torque.
3. Fit 2 bolts fixing the air inlet pipe assembly to the
upper radiator beam, tighten to 5-7Nm, and check
the torque.
1.0 166
Front Exhaust Pipe Assembly
Remove
Warning: Exhaust components get extremely hot during
operation. Ensure exhaust components are sufficiently
cooled before handling.
2. Remove 2 bolts (1) fixing the front exhaust pipe
assembly to the three-way catalytic converter.
3. Remove 1 bolt (2) fixing the front exhaust pipe
assembly to the engine.

Refit
1. Fit 2 nuts fixing the front exhaust pipe assembly to the
rear exhaust pipe assembly, tighten to 19-25Nm, and
check the torque.
2. Fit the rubber lug securing the front exhaust pipe
assembly.
3. Fit 1 bolt fixing the front exhaust pipe assembly to the
engine, tighten to 19-25Nm, and check the torque.
4. Fit 2 nuts fixing the front exhaust pipe assembly to the
three-way catalytic converter, tighten to 19-25Nm,
4. Remove the rubber lug securing the front exhaust pipe
assembly.
5. Remove 2 nuts fixing the front exhaust pipe assembly

to the rear exhaust pipe assembly.
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Rear Exhaust Pipe Assembly 2. Fit 2 nuts fixing the rear exhaust pipe assembly to the
Remove front exhaust pipe assembly, tighten to 19-25Nm, and
Warning: Exhaust components get extremely hot during check the torque.
operation. Ensure exhaust components are sufficiently 3. Lower the vehicle on a lift.
cooled before handling.
2. Remove 2 nuts fixing the rear exhaust pipe assembly to
the front exhaust pipe assembly.
3. Remove the rubber lug securing the rear exhaust pipe

assembly.
Refit
1. Fit the rubber lug securing the rear exhaust pipe
assembly.
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Exhaust Passage Heat Shield Fuel Tank Heat Shield
Remove Remove
1. Remove the front exhaust pipe assembly. 1. Remove the rear exhaust pipe assembly.
Front Exhaust Pipe Assembly Remove Rear Exhaust Pipe Assembly Remove
2. Remove 6 metal retainers fixing the heat shield of the 2. Remove 5 metal retainers fixing the heat shield of the
exhaust passage to the body. fuel tank to the fuel tank.
3. Remove the heat shield of the exhaust passage. 3. Remove the fuel tank heat shield assembly.
Refit Refit
1. Fit 6 metal retainers fixing the heat shield of the exhaust 1. Fit 5 metal retainers fixing the heat shield of the fuel
passage to the body, tighten to 4-6Nm, and check the tank to the fuel tank, tighten to 4-6Nm, and check
torque. the torque.
2. Fit the front exhaust pipe assembly. 2. Fit the rear exhaust pipe assembly.
Front Exhaust Pipe Assembly Refit Rear Exhaust Pipe Assembly Refit
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Engine Engine Electrical System
Engine Electrical System

Specifications
Torque
Description Value
Bolt-Accessory Drive Belt Tensioner to Engine 62-68Nm
Bolt-Start Motor to Engine 19-25Nm
Nut-Battery positive cable to start motor 11–15Nm
Bolt-Battery positive cable to transmassion 7–10Nm
Bolt-Battery positive cable to fuse block 6–9Nm
Nut-Battery positive cable to battery positive clamp 4–6Nm
Bolt-Battery negative cable to transmission case 15–20Nm
Bolt-Battery negative cable bracket to the left side rail 19–25Nm
Nut-Engine harness to Battery negative cable 7–10Nm
Nut-Battery negative cable to clamp 4–6Nm
Bolt-Battery clip to battery 19–25Nm
Bolt-Battery bracket to battery tray 19–25Nm
Bolt-Battery tray to engine fuse box 6–8Nm
Bolt-Battery tray to battery tray bracket 19–25Nm
Bolt-Battery tray front of bracket to transmission mount 19–25Nm
Bolt-Battery tray rear of bracket to body 19–25Nm
Bolt-Battery tray rear of bracket to the left side rail 19–25Nm
Idler -Idler to Engine 45-55Nm
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Engine Electrical System Engine
System layout
Starting and Charging System Layout
1. Starter Motor 2. Generator
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Description Transistors of the regulator can adjust the output voltage

Alternator through the quick switch of the internal induced voltage. The
regulator has an output terminal of the charging indicator
The alternator is fitted on the right front of the engine. The
which can control the operation of the indicator. When the
drive pulley is fitted on one end of the rotor, which is driven
output voltage of the alternator is lower than the battery
by the multislot V-shaped belt of the crankshaft. The location
voltage, the indicator illuminates. The alternator load signal
of the alternator is fixed, and the belt tension is maintained by
output is also provided by the regulator, and the output data
the automatic tension pulley of the wheel train.
is provided to ECM, and ECM adapts to a variety of electrical
The alternators are similar in structure, including a stator, a loads by adjusting the idle speed.
rotor, a rectifier and a regulator. The one-way output terminal
The ignition system provides excitation current to the rotor
is connected to the battery positive with a thick cable via
through the collector ring on the alternator rotor shaft
150A fuse. The alternator is grounded through its bracket.
when the alternator is at low speed. When the speed of the
A three-pin connector is the load signal connecting terminal
alternator increases, the alternator becomes self-excited.
of charging warning lamp output, ignition signal input and
alternator output. Starter Motor
The rotor consists of a field coil, which is wound on the iron The starter motor is located at the left rear side of the engine,
core and fitted on the shaft. Both ends of the iron core extend, it is fixed to the mounting hole on the transmission housing
forming the north and south poles of the magnetic line in the with 2 flange bolts.
coil. The rotor is located in the stator, which is fitted on The starter motors are of the pre-engaged type, which
the bearing so as to guarantee stable rotation and enable it includes a solenoid, a one-way clutch and a motor body.
to support the high load in the drive belt tension application. When the ignition switch is in "START" position and the engine
The stator includes a stator core and a stator coil which is requested for start, the BCM integrated with anti-theft
has brackets supporting at both ends. The stator is made of function will output signals to switch on the starter relay after
soft iron sheet, which has a slot suitable for the stator coil passing anti-theft verification.
and is fixed on the alternator housing. The stator has three Battery
sets of coils which are made of copper wires with insulating Battery Instruction
paint. These 3 coil windings are connected in a "triangle
connection" scheme, thus the tail end of each winding is All vehicles have a 12V maintenance-free lead-acid battery
connected together. The output current is provided from the equipped at the left side of the engine compartment, which is
other end of each winding. The stator coil allows the magnetic fitted on the pressed steel bracket fixed on the transmission
flux generated by the rotor pole to flow through the stator mount, fastened by the battery retaining strap, and covered
coil. Rotation of the rotor makes the coil generate AC. by the battery heat shield. The battery electrodes are of
chuck-connected pole type.
The rectifier is located at the rear side of the alternator,
converts the AC generated by the stator coil to DC required Warning: Battery fluid (electrolyte) contains sulphuric
for the vehicle electrical system. The rectifier includes 8 acid. It may cause severe burns if it gets on your skin or
semiconductor diodes which are mounted on a heat sink for in your eyes. Wear protective clothing and a face shield.
heat dispersion. Three diodes are mounted on the front, If electrolyte gets on your skin or clothes, immediately
three on the opposite side, and the other two in the middle. rinse it off with water. If electrolyte gets in your eyes,
When the output voltage of the alternator is lower than the immediately flush eyes with water for at least 15 minutes
battery voltage, the rectifier also prevents the current from and seek medical help.
flowing from the battery to the alternator. The battery has three main functions. Firstly, it provides
The integrated circuit regulator is also located at the rear power for starting the engine. Secondly, it is used as a voltage
side of the alternator, controls the output voltage of the regulator of the electrical system. Lastly, it can provide energy
alternator to avoid battery overcharging and protect the in a certain amount of time when the electrical demand
vehicle electrical system. The regulator optimizes the battery exceeds the engine output.
charging according to relevant temperatures, sets a rated Compared with the conventional battery, the packaging
output voltage of 14.5V and changes the output voltage battery have following advantages:
according to the battery load and required load for the vehicle
• There is no need to add water during the entire life cycle
electrical system.
of the battery.
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• It adopts the overcharge protective measures. If the Battery Charging Operation:
voltage applied to the battery is too high, it will not
• Connect two positive poles between charger and battery,
receive the excess current as the conventional battery
and connect two negative poles between charger and
will. For the conventional battery, if the battery
battery as well. If the battery is not removed from the
continues to be charged when the voltage is too high, air
vehicle, PLEASE connect the negative cable of the charger
leakage will occur, causing fluid loss.
negative pole to the body ground well.
• Compared with the conventional battery, self discharge
• Ensure the poles are clean, and the charging circuit loop
does not tend to occur for this kind of battery. This is
is all right.
especially important when the battery is not used for a
long time. • During charging process, if the battery temperature is
higher than 40℃, MUST stop charging, and after he
• For the cigar lighter and smaller electrical equipment, the
battery temperature falling to environment temperature,
electric quantity supplied is more reliable.
the battery can be charged again.
Battery Charging • DO NOT charge the battery under 0℃.
When the engine is not running, by the reasons of electric For the battery whose voltage value is under 11.0V, at the
equipments opening for long time, vehicle creepage and first of charging it may appear the phenomena that the battery
longtime parking, or some malfunction in the alternator, the cannot be charged. Because badly discharging, the inverse
battery might not be charged and will be flat, the vehicle even proportion of vitriol in battery is too small, the liquid is close
not can be started. On this condition, the battery need to be to pure water, battery’s inner resistance value is too high.
charged. With the charging going on, the inverse proportion of vitriol in
Caution: When charging or Emergency Starting, the battery will rise up, the charging process could become breath
negative cable should be connected to the body earth again.
well, while not the negative pole. Battery Measure
Battery Appearance Checking Before Charging: Battery can be measured by familiar equipment on the after
• If the shell is broken or there is a leak, DO NOT charge sales market, such as Midtronics series instruments. If the
the battery and replace it after finding the reason. equipment is not type-suited, the measured data can not be
used to judge the battery’s status.
• If the pole is broken, DO NOT charge the battery and
replace it after finding the reason. Battery Replacement
• The bulge battery for over discharging or over charging, Caution: When removing the battery, ensure that the
CAN NOT be charged. The battery should be replaced. alarm is disarmed and that the ignition is switched off.
• Before charging, clean the poles, rub off rust. And smear Always disconnect the negative terminal first and then
some butter to avoid electricity corroding. the positive terminal. When refitting the battery, always
fit the positive terminal first followed by the negative
Charging Announcements:
terminal.
• PLEASE pull on the security glass.
Refer to "Battery - Remove/Refit" when replacing the battery.
• Keep ventilation and normal temperature when charging.
• DO NOT smoke when charging, and avoid kindling in.
• Before charging, connect the positive cable at first. After
charging, disconnect the negative cable at first.
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Operation lamp will go out. At this moment, the alternator can generate
Alternator sufficient self-excited current via the diode in the magnetic
field and begin to charge the battery. If the charging warning
Alternator uses the self-excited system, where many diodes
lamp remains on, the charging system fails and a check must
supply part of the current generated by the alternator for the
be performed, otherwise, the battery will be damaged.
rotors. Alternator can not supply the initial current required
for start-up of the charging procedure. Initial current is Starter Motor
supplied by the battery power supply through ignition switch When the ignition switch is in "START" position, the coil will
to activate the exciting winding to start up the charging supply power to connect the pinion and the flywheel gear ring.
procedure. When the ignition switch is turned on, the battery The pinion moves spirally around the motor reel, thus the
voltage is also supplied through the charging warning lamp motor reel can achieve the connection through the gear ring.
and grounds via the field winding of the alternator, so that the On the starter motor, the motor drives the pinion through the
LED warning lamp illuminates. transmission instead of the motor reel directly.
When starting the engine, the rotor is rotating in the stator, When starting the engine, the one-way clutch prevents motor
generating the 3-phase alternating current (AC). When the armature overspeed. The driver should not remove the key
rotor speed increases, the output voltage will rise quickly, from the "START" position so that the motor can keep running.
and the potential difference of the diode output end of
After start-up of the engine, when the ignition switch is
the magnetic field will raise. When the voltage increases,
released, the solenoid coil will release energy to pull out the
the charging warning lamp will darken gradually. When the
pinion from the gear ring.
alternator output voltage is equal to the battery voltage, the
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Service Procedures 5. Connect the battery negative wire.
Alternator 6. Put down the vehicle.
Remove

2. Disconnect the battery negative wire.
3. Remove the connector of the alternator and the engine
harness.
Auxiliary Drive Belt Removal

5. Remove 3 bolts connecting the alternator to the
cylinder head and cylinder block.

Refit
1. Clean the mating surface of the alternator, cylinder
head and cylinder block.
2. Refit 3 bolts connecting the alternator to the cylinder
head and cylinder block.
3. Refit the auxiliary drive belt.
4. Refit the connector of the alternator and the engine
harness.
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Auxiliary Drive Belt

Remove
1. Raise the vehicle to a suitable height for operation.

2. Disconnect the battery negative wire.
3. Insert the mounting tool into the square in the tensioner,
wrench the torque spanner counterclockwise, and the
torque shall be not more than 82Nm. Disconnect the
tensioner from the pulley.
3. Release the tensioner slowly, make sure the pulley is

located in the centre of the tensioner after refit, a 2mm
margin shall be kept on both sides of the tensioner.
4. Take out the tool.
6. Put down the vehicle.
4. Take out the pulley.
5. Allow the tensioner return slowly, and take out the

tool.
Refit
1. Insert the mounting tool into the square in the tensioner,
wrench the torque spanner counterclockwise, and the
torque shall be not more than 82Nm.
2. In the sequence shown, refit the auxiliary drive belt
into each pulley groove, tensioner and idler pulley.
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Auxiliary Drive Belt Tensioner Starter Motor
Remove Remove
1. Remove the auxiliary drive belt. 1. Disconnect the battery negative.
Auxiliary Drive Belt Remove 2. Remove the bottom deflector.

2. Remove 1 bolt fixing the auxiliary drive belt tensioner Bottom Deflector Remove
to the engine. 3. Disconnect the harness connector (1) from the starter
motor.
4. Remove 2 bolts (2) fixing the starter motor to the
engine.
5. Remove 1 bolt (3) fixing the battery negative cable to
the starter motor.
3. Remove the auxiliary drive belt tensioner.

Refit
1. Fit 1 bolt fixing the auxiliary drive belt tensioner to the
engine, tighten to 62-68Nm, and check the torque.
6. Remove the starter motor.
Refit
1. Fit 2 bolts fixing the starter motor to the engine,
2. Fit and tighten 1 nut fixing the battery negative cable
to the starter motor.
3. Connect the harness connector to the starter motor.
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Battery Positive Cable

Remove
2. Unscrew 1 nut fixing the battery positive cable to the
positive battery post, and remove the cable
3. Remove the upper cover of the engine compartment
fuse box.
4. Remove 1 bolt fixing the battery positive cable to the
engine compartment fuse box, and remove the cable.
8. Loosen the harness clip, and remove the battery

positive cable.
Refit
1. Arrange the battery positive cable in the engine
compartment, ensure correct route, and secure with
clips.
2. Fix the battery positive cable to the starter motor, fit 1
nut, tighten to 11–15Nm, and check the torque.
3. Fix the bracket of the battery positive cable to the
transmission housing, fit 1 bolt, tighten to 7–10Nm,
and check the torque (4AT only).
4. Lower the vehicle on a lift.
5. Fix the battery positive cable to the engine
6. Remove 1 bolt fixing the bracket of the battery positive
compartment fuse box, fit 1 bolt, tighten to 6–9Nm,
cable to the transmission housing (4AT only).
6. Fix the battery positive cable to the battery positive
terminal, fit 1 nut, tighten to 4–6Nm, and check the
torque.
7. Remove 1 nut fixing the battery positive cable to the

starter motor, and remove the cable.
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Battery Negative Cable longitudinal beam, fit 1 nut, tighten to 19–25Nm and
Remove check the torque.
1. Loosen 1 nut fixing the battery negative cable to the 4. Fit the battery.
negative terminal, and remove the cable. Battery Refit
2. Remove 1 nut fixing the engine harness to the battery
5. Fit the engine compartment fuse box.
negative cable, and remove the harness.
Engine Compartment Fuse Box Refit
6. Fix the engine harness to the battery negative cable, fit
1 nut, tighten to 7–10Nm, and check the torque.
7. Fix the battery positive cable to the terminal, fit 1 nut,
tighten to 4–6Nm, and check the torque.
3. Remove the engine compartment fuse box.

Engine Compartment Fuse Box Remove
4. Remove the battery.
Battery Remove
5. Remove 1 bolt fixing the battery negative cable to the
left front longitudinal beam.
7. Loosen the harness clip, and remove the battery

negative cable.
Refit
1. Arrange the battery negative cable in the engine
compartment, ensure correct route, and secure with
clips.
2. Fix the battery negative cable to the transmission
housing, fit 1 bolt, tighten to 15–20Nm, and check
the torque.
3. Fix the battery negative cable to the left front
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Battery Battery Tray

Remove Remove
1. Loosen 1 nut (1) fixing the battery sensor to the 1. Remove the battery assembly.
negative terminal, and remove the cable.
Battery Assembly Remove
2. Loosen 1 nut (2) fixing the battery positive cable to the
2. Remove the engine control module.
positive terminal, and remove the cable.
Engine Control Module Remove
3. Remove the battery sleeve.
4. Remove 1 bolt (3) fixing the battery fascia to the 3. Remove 4 bolts (1) fixing the battery tray to the
battery tray, and remove the battery fascia. front/rear brackets of the battery tray.
5. Remove 1 bolt (4) fixing the battery block to the 4. Remove 2 bolts (2) fixing the battery tray to the engine
battery tray, and remove the block. compartment fuse box.
5. Disconnect the clip fixing the harness to the battery

6. Remove the battery assembly.
tray and remove the battery tray.
Refit
Refit
1. Secure the battery on the tray.
1. Fix the harness clip to the battery tray.
2. Secure the battery with blocks, fit 1 bolt, tighten to
2. Fix the battery tray to the engine compartment fuse
19–25Nm, and check the torque.
box, fit 2 bolts, tighten to 6–8Nm, and check the
3. Secure the battery with battery fascia, fix the fascia
torque.
bracket to the battery tray, fit 1 bolt, tighten to
3. Fix the battery tray to the battery tray bracket, fit 4
bolts, tighten to 19–25Nm, and check the torque.
4. Fit the battery sleeve.
4. Fit the engine control module.
5. Fix the battery positive cable to the positive terminal
and tighten the nut firmly. Engine Control Module Refit
6. Fix the battery sensor to the negative terminal and 5. Fit the battery assembly.
tighten the nut firmly. Battery Assembly Refit
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Battery Tray Front Bracket Battery Tray Rear Bracket
Remove Remove
1. Remove the battery tray. 1. Remove the battery tray.
Battery Tray Remove Battery Tray Remove

2. Remove the engine compartment fuse box. 2. Remove the harness clip from the rear bracket of the
battery tray.
Engine Compartment Fuse Box Remove
3. Remove 1 bolt fixing the rear bracket of the battery
3. Remove 3 bolts fixing the front bracket of the battery
tray to the left front longitudinal beam.
tray to the transmission mount.
4. Remove 1 bolt fixing the rear bracket of the battery
tray to the body.
4. Remove the front bracket of the battery tray.

Refit
5. Remove the rear bracket of the battery tray.
1. Fix the front bracket of the battery tray to the
Refit
transmission mount, fit 3 bolts, tighten to 19–25Nm,
and check the torque. 1. Fix the rear bracket of the battery tray to the body, fit
1 bolt, tighten to 19–25Nm, and check the torque.
2. Fix the rear bracket of the battery tray to the left front
Engine Compartment Fuse Box Refit longitudinal beam, fit 1 bolt, tighten to 19–25Nm, and
3. Fit the battery tray. check the torque.
Battery Tray Refit 3. Fix the harness clip to the rear bracket of the battery
tray.
4. Fit the battery tray.
Battery Tray Refit
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Accessory Belt Idle Pulley

Remove
1. Remove the accessory belt.
Accessory Belt Remove

2. Remove the bolt dust cover.
3. Remove the idler pulley fixing bolt.
4. Remove idle pulley

Refit
1. Confirm the cleanliness of all mating surfaces of the
idle pulley.
2. Place the idle pulley in the fitting place.
3. Fit the idle pulley bolts, the tightening torque is
45-55Nm.
4. Fit the bolt dust cover.
5. Fit the accessory drive belt.
Accessory Belt Refit
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Shift Lock Control-NEW 4AT Transmission
Shift Lock Control-NEW 4AT
Specifications
Torque
Description Value
Nut-Shift Cable to Floor 7-10Nm
Nut-CONTROL-A/TRNS to Floor 7-10Nm
Bolt-Resonator to The Left Side Rail 7-10Nm
Screw-Block a Display Panel to Console 1.0-1.4Nm
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Transmission Shift Lock Control-NEW 4AT

System Layout
1. Automatic Transmission Gear Shift Mechanism Knob 8. Nut - Transmission Gear Shift Mechanism
Assembly 9. Automatic Transmission Gear Shift Jumper Cable Bracket
2. Clip Assembly
3. Shift Panel 10. Bolt - Transmission Gear Shift Jumper Cable Bracket
4. Transmission Gear Display Module 11. Automatic Transmission Shift Lever Assembly
5. Screw - Panel 12. Nut - Transmission Shift Lever Sleeve
6. Nut - Transmission Gear Shift Mechanism 13. Striker - Transmission Shift Lever Cable
7. Automatic Transmission Gear Shift Mechanism Assembly 14. Clip - Transmission Shift Lever Cable
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Description manual shift controlling. Move the shift lever forward (+) to
Gear Shift Control Mechanism finish upshift, and move the shift lever backward (-) to finish
downshift. To exit Tiptronic mode, return the shift lever to
The gear shift control mechanism mainly consists of a shift
"D" position.
lever, a base, a gear shift lock-up solenoid valve, a gear shift
cable, etc. The gear shift control mechanism base is fixed to Gear Shift Lock-up Solenoid Valve
the body central passage with 4 screws. The inner latch of the The transmission is equipped with a gear shift lock-up solenoid
shift lever is engaged with the inner groove of the base. valve located at the bottom of the shift lever. The operation of
the solenoid valve is determined by the BCM-controlled gear
shift lock-up relay in the passenger compartment fuse box.
When the shift lever is in "P" position, with the ignition switch
on and the brake pedal not applied, the lock-up solenoid valve
is not activated at the time. The lock tongue of "P" position
lock block contacts with the corresponding groove at the shift
lever bottom so as to prevent the accidental movement of shift
lever. The lock-up solenoid valve is activated only when the
brake pedal is depressed. Enable the solenoid valve to make
the solenoid valve push rod move towards front part of the
vehicle, so as to push the lock tongue of "P" position lock block
away from the corresponding groove at the shift lever bottom.
Simultaneously, press the lock button on the shift lever knob
1. Shift Lever to allow the shift lever freely change to other positions from
2. P Gear Unlock Lever "P" position.
The shift lever position operation is as follows: Shift Lever Moving out of P Position in Emergency
With the ignition on and brake pedal depressed, when the shift
lever cannot be moved out from P gear, turn off the ignition
switch, pull out the ignition key and apply the parking cable,
depress the brake pedal, pry up the upper trim panel of the
centre console with a proper tool, press the P gear emergency
unlock button located at the left upper corner of the gear shift
mechanism, move the shift lever to N position simultaneously,
start the engine and shift to the required gear.
• P: Lock the transmission to prevent the wheel glides.

• R: Choose it only when the vehicle is still and the engine
is idling.
• N: No torque passes to wheel.
• D: All 4 forward gears can be used while in this position.
This is the default choosing position of normal driving.
• S: Sport mode.
• +/-: Tiptronic. Gear Shift Cable
Tiptronic Shift The gear shift cable connects the shift lever to the shift rocker
If the shift lever moves from "D" position to the right side, the arm on the transmission. The outer cable is fixed to the shift
system will automatically enter into sport mode with different lever assembly end with a C-clip and fixed to the body and
shifting parameters. Then move the shift lever to separate transmission end by two bolts respectively. The inner cable
the Tiptronic mode and sport mode, offering completely at the shift control mechanism end is connected with the shift
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lever, and the inner cable at the transmission end is buckled to

the transmission shift rocker arm via a cable ball joint.
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Service Procedures
Shift Lever Knob - Automatic
Remove
1. Remove the gear panel.
Gear Panel Remove

2. Pull up the sleeve. Loosen and discard the metal clamp
on the knob.
4. If unable to avoid or mistake let the lock button in the

shift lever knob, please do the following:
a. Remove the red limit lever of the "new" shift lever

knob.
b. Insert the limit lever into the very bottom of the shift
lever knob.
3. Pull up the shift lever knob with care, and remove the
knob and sleeve assembly from the shift lever. Note
that do not touch the lock button by hands.
Caution: Do not press the lock button to the shift

lever knob when removing the knob.
c. Pull out the limit lever, and the lock button of the
shift lever knob can restore to the normal state.
5. Insert the knob assembly into the second slot of the

shift lever.
6. Press the lock button and check if it can retract freely. If
it does, the knob and the shift lever are correctly fitted.
Refit 7. Clamp the bulge of the clip with a caliper. Ensure that
1. Place the shift lever in "P" position. the knob can't be pulled.
2. Locate a new metal clip to the knob. 8. Fit the gear panel.
3. Make sure the lock button of the shift lever knob is in Gear Panel Refit
the correct position.
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Shift Lever Assembly - Automatic

Remove
1. Place the shift lever in "P" position.
2. Remove the battery tray.
Battery Tray Remove
3. Remove 2 bolts fixing the resonator to the left
longitudinal beam, and remove the resonator.
8. Remove 2 nuts fixing the gear cable to the body.
4. Loosen the cable ball joint from the gear selection/shift

rocker arm, and loosen the clip fixing the gear
selection/shift cable to the cable bracket.
9. Remove the shift lever assembly.

Refit
1. Fix the shift lever assembly to the central passage.
2. Fit 2 nuts fixing the shift cable to the underbody, tighten
3. Fit 4 screws fixing the shift lever assembly to the body,
4. Connect the connector of the gear shift control
mechanism.
5. Remove the shift lever knob. 5. Straighten out the cable route. Clamp the cable clip
on the gear shift jumper cable bracket assembly of the
Shift Lever Knob Remove
automatic transmission (press the cable mounting seat
6. Remove the heat shield of the exhaust passage. till it clicks, ensure the two ends of the clip are inserted
Exhaust Passage Heat Shield Remove into the bracket). Then insert the cable sleeve into the
7. Remove 4 screws fixing the shift lever assembly to the thermostat bracket (in the driver's perspective, the
body. front end of the sleeve is inside the thermostat bracket).
6. Shift the gear shift control mechanism to the N gear.
7. Press the cable joint clip into the automatic transmission
shift lever knob (before the connection, ensure that the
automatic transmission shift lever is in "N" position -
the raised point aligns with the TCM bolt), then press
the cable adjusting striker to fasten the cable (when it
clicks, it is fastened).
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Gear Panel
Remove
2. Place the shift lever in "P" position.
3. Pry up the upper trim panel assembly with care.
4. Disconnect the connector of the gear panel.
5. Remove 4 screws fixing the gear panel to the upper
trim panel assembly, and remove the upper trim panel
assembly.
8. After completion of the system refit, pull out the N

gear striker (if equipped). Pull out the shift lever sleeve
(if equipped) before the knob refit. Then, shift the shift
lever between PRNDSS+S- gears, check if the gears are
clear and shifting force moderate, otherwise, release
the cable adjusting striker in the N gear to re-adjust
and then fasten it.
Caution: The cable clip is worn easily, if shifter is

reassembly, clip should be checked & if it is worn, it
should be replaced by new one.
6. Remove the gear panel from the knob and sleeve
Caution: Shift the lever to p position after assembling the
assembly.
knob for safe.
Refit
9. Fit 2 bolts fixing the resonator to the left longitudinal
1. Fit the gear panel to the knob and sleeve assembly.
beam, tighten to 7-10Nm, and check the torque.
2. Fit 4 screws fixing the gear panel to the upper trim
10. Remove the heat shield of the exhaust passage.
panel assembly, tighten to 1.0-1.4Nm, and check the
Exhaust Passage Heat Shield Refit torque.
11. Remove the shift lever knob. 3. Connect the conncetor of the gear panel.
Shift Lever Knob Refit 4. Fit the upper trim panel assembly with care.
12. Fit the battery tray. 5. Connect the battery negative.
Battery Tray Refit
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Transmission Transmission-AT
Transmission-AT
Specifications
Torque
Description Value
Bolt-Automatic Transmission to Engine 75-90Nm
Bolt-Automatic Transmission Mount Bracket to Automatic (45-55)Nm+(85-95)deg
Transmission
Bolt-Under The Tie-bar Bracket to Automatic Transmission (45-55)Nm+(85-95)deg
Nut-Cable Arm to Automatic Transmission 14-20Nm
Bolt-Cable Bracket to Automatic Transmission 15-23Nm
Oil Drain Plug 14.7-19.6Nm
Oil Over Flow Plug 23-25Nm
Oil Filler Plug 35-44Nm
Nut-Transmission Control Module to Bracket 6-8Nm
Bolt-Neutral Start Switch to Automatic Transmission 4.3-6.5Nm
Nut-Shift Rocker Arm to Neutral Start Switch 14-20Nm
Bolt-Input Speed Sensor to Transmission 3.9-6.9Nm
Bolt-Output Speed Sensor to Transmission 3.9-6.9Nm
Bolt-Valve Body Cover 6-7.9Nm
Bolt-Valve Body Assy to Automatic Transmission 9.8-11.8Nm
Bolt-Oil Temperature Sensor to Valve Body Assy 5.8-7.8Nm
Union 19.6–29.4Nm
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Transmission-AT Transmission
Parameter
Automatic Transmission
Model AISIN TS-41SN new 4-speed gear automatic transmission
Stall Speed 2631 ± 150rpm
Speed Ratio
·1st gear 2.875
·2nd gear 1.568
·3rd gear 1.000
·4th gear 0.697
·R gear 2.300
·Countershaft 1.023
·Main Reduction 4.277

Clutch:
C1 Flange: 1; clutch plate: 4; clutch disc: 4
C2 Flange: 1; clutch plate: 2; clutch disc: 2
C3 Flange: 1; clutch plate: 2; clutch disc: 2; shock absorber: 1

Brake:
B1 Flange: 2; clutch plate: 2; clutch disc: 2
B3 Flange: 1; clutch plate: 4; clutch disc: 4

One-way clutch:
F2 Roller type
Solenoid valve
·Switch solenoid 1: S1
·Linear solenoid 5: SLC1, SLC2, SLB1, SLU, EMOP

ATFModel AW-1
Oil level adjustment Overflow port type
Main oil circuit pressure
Idle:
·D 0.625 - 0.775 Mpa
·R 0.499 - 0.539 Mpa
Stall:
·D 1.450 - 1.630 Mpa
·R 1.725 - 2.085 Mpa
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High: 12 - 16 mA
Output/input speed sensor
Low: 4 - 8 mA
ATFOil temperature sensor (OT)
-40℃ 161 kΩ (MAX)
-30℃ 36.3 - 52.1 kΩ
10℃ 5.626 - 7.303 kΩ
25℃ 3.5 kΩ (reference value)
110℃ 0.224 - 0.271 kΩ
145℃ 0.102 - 0.121 kΩ
150℃ 0.087 kΩ（MIN）
Clearance
Note Clearance
Automatic transmission housing - hydraulic torque converter 17.3mm
Oil seal - oil pump assembly -0.3 - 0.3mm
Oil seal - automatic transmission housing end 2.6 - 3.6mm
Oil seal - torque converter housing end 1.7 - 2.7mm
Manual shift lever oil seal - automatic transmission housing end 0.75 - 1.25mm
1.0 192
System Layout
Automatic Transmission Components Layout
1. Automatic Transmission 3. Shift Lever Assembly

2. Body Control Module (BCM) 4. Ignition Switch
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5. Automatic Transmission Fluid (ATF) Cooler (integrated 7. Neutral Start Switch (NSW)
in the radiator) 8. Data Link Connector
6. Brake Pedal Switch 9. Automatic Transmission Control Module (TCM)
Automatic Transmission Accessories Layout
1. Output Speed Sensor 4. Automatic Transmission Vent Pipe Assembly

2. Bolt and Gasket - Speed Sensor 5. Automatic Transmission Vent Pipe
3. Input Speed Sensor 6. O-ring - Breather Plug
1.0 194
7. Automatic Transmission Vent Plug 27. Bolt and Washer - Oil Pan
8. O-ring - Automatic Transmission Oil Cooler Pipe 28. Bolt and Washer - Internal Harness Connector
Connector 29. Automatic Transmission Internal Harness Assembly
9. Automatic Transmission Oil Cooler Pipe Connector 30. O-ring - Internal Harness Connector
10. Automatic Transmission Overflow Plug 31. Clip - Temperature Sensor
11. O-ring - Automatic Transmission Oil Drain Plug 32. Bolt - Temperature Sensor
12. Overflow Pipe - Automatic Transmission Oil Pan 33. Washer - Housing and Valve Body Assembly
13. Automatic Transmission Oil Drain Plug 34. Compression Spring
14. Hydraulic Torque Converter Assembly 35. O-ring - C3 Accumulator Piston
15. Oil Seal - T Type - Right - Differential 36. C3 Accumulator Piston
16. Oil Seal - T Type - Left - Differential 37. O-ring - C3 Accumulator Piston
17. Oil Seal - T Type - Input Shaft 38. Compression Spring
18. Manual Shift Shaft Oil Seal 39. Bolt - Valve Body Assembly
19. Shift Control Switch 40. Bolt - Valve Body Assembly
20. Bolt and Washer - Shift Control Switch 41. Automatic Transmission Valve Body Assembly
21. O-ring - Filter Assembly 42. Automatic Transmission Oil Hole Screw
22. Filter Assembly 43. O-ring - Automatic Transmission Oil Hole Screw
23. Magnet 44. Washer - Automatic Transmission Fluid Filler Plug
24. Washer - Oil Pan 45. Automatic Transmission Fluid Filler Hole Plug
25. Automatic Transmission Oil Pan
26. Bolt and Washer - Oil Pan
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Automatic Transmission Section View
1. Hydraulic Torque Converter Assembly 6. C1 Clutch

2. C2 Clutch 7. F2 Single Direction Clutch
3. B3 Brake 8. Countershaft Driving Gear
4. C3 Clutch 9. Countershaft Driven Gear
5. B1 Brake 10. Differential Assembly
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Solenoid Valve Assembly
1. Shift Solenoid Valve (S1) 4. Shift Control Solenoid Valve (SLC2)

2. Lock-up Clutch Control Solenoid Valve (SLU) 5. Shift Control Solenoid Valve (SLC1)
3. Shift Control Solenoid Valve (SLB1) 6. *Electromagnetic Oil Pump (EMOP) (Start/Stop)
1.0 197

Automatic Transmission Control Diagram
A = Hard Wire
1.0 198
A = HS CAN Bus
1.0 199
Hydraulic Control System
A: Hard Wire; B: Low-pressure Automatic Transmission Fluid (ATF); C: High-pressure Automatic Transmission Fluid (ATF);
1. Automatic Transmission Control Module (TCM) 8. Oil Operating Pressure

2. TCMOutput Signal 9. Clutch, Brake
3. Valve Body Assembly 10. Lubrication
4. Switch Solenoid 11. Output Automatic Transmission Fluid (ATF)
5. Linear Solenoid 12. Oil Circuit
6. Regulating Valve 1 13. Planetary Gear Mechanism
7. Regulating Valve 2 14. Oil Pump
1.0 200
15. Oil Cooler Assembly 17. Hydraulic Torque Converter Assembly
16. Oil Pump Pressure
1.0 201
Description
Overview
This model is equipped with an AISIN AW TS-41SN
electronically controlled 4-speed automatic transmission. This
transmission is applicable to front-engine front-drive vehicles,
with maximum input torque of 150 Nm.
TCMIt controls the system in a way similar to that used by

otherECUequipped on the vehicle. It receives information
from the sensor or otherECU, calculates according to the
pulse spectrum information stored in theTCMmemory and
then outputs signals to the actuators or otherECU. The signal
exchange with otherECUis mainly conducted through the
controller area network (CAN) bus.
The RAVIGNEAVX planetary gear has 2 pairs of sun gears,
The diagnostic test can be conducted through the data link pinions in the same planetary gear unit have different sizes, so
connector. When the transmission has some failures,TCMwill it have more transmission ratios compared with the traditional
store related diagnostic trouble code (DTC), which can be planetary gear unit.
retrieved with the scan tool. See "Diagnosis" for more details.
All gear ratios are obtained through the planetary gear set
Diagnosis in the transmission housing. The single component in the
planetary gear set is driven or locked by 3 clutches, 2 brakes
The gear selection is conducted through the shift lever on
and 1 one way clutch. The clutch, brake and one way clutch
the centre console. The shift lever supplies the driver with 5
control the engagement and rotation direction of these
selectable gears, including P (Park), R (Reserve), N (Neutral),
elements in the planetary gear set, so as to generate the
D (Drive) and S (Sport mode).
selection of "P" gear and "N" gear, 4 drive gear ratios and 1
TCMThe shift mode is controlled according to one of the reserve gear ratio. The P.T.O (power take off) of the drive
preprogramming parameter sets that grouped to different system will be transmitted to the differential through the main
driving modes. reduction gear.
Available Modes: Transmission Gear Ratio
• Economy Mode Gear Speed Ratio
• Sport Mode (the sport mode can activate the Tiptronic 1st Gear 2.875
mode and supply manual control) 2nd Gear 1.568
The current driving mode can be displayed on the instrument 3rd Gear 1.000
pack after the vehicle is started. 4th Gear 0.697
• It will not be displayed if the economy mode is selected. Reverse Gear 2.300
• When selecting the Tiptronic mode, the information of Main Reduction Gear 4.277
the selected gear will be displayed on the instrument
Countershaft 1.023
pack.
Transmission assembly Hydraulic Control System
TS-41SN adopts lightweight and compact RAVIGNEAVX Based on the hydraulic pressure generated by the oil
planetary gears, compared with traditional automatic pump,TCMsends signals to each solenoid valve. These signals
transmissions needing 2 planet gear sets to realize upshift will control the pressure applied to the hydraulic torque
and downshift, TS-41SN can realize the gear shift with converter, planetary gear set, clutch and brake according to
1 RAVIGNEAVX planetary gear set. It makes the drive vehicle driving conditions.
mechanism simpler and lighter. Valve Body Assembly
The transmission uses 6 solenoid valves on the valve body.
The solenoid valves are activated or deactivated by theTCM,
and controls theATFflow (shift sequence) supplied to the
clutch and the brake, hydraulic torque converter, lubrication
and cooling. The solenoid valve may be divided into linear
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control solenoid valves and switch solenoid valves according
to their operations.
• Switch Solenoid Valve: S1
• Linear Control Solenoid Valves: SLC1, SLC2, SLB1, SLU,
EMOP
Each solenoid valve is provided with one inner coil and one
needle valve. The needle valve is activated by the voltage that
passes through the solenoid coil, and it opens or closes the
hydraulic circuit. The shift solenoid valve closes the hydraulic
circuit to accommodate to the current liquid flow. The linear
control solenoid valve can control the hydraulic circuit with a
better linearity.
All solenoid valves are powered byTCM, the grounding of the Shift Control Solenoid Valves (SLC1, SLC2 and
SLB1)
shift solenoid valves (SLC1, SLC2 and SLB1), lock-up clutch
control solenoid valve (SLU) and electromagnetic oil pump
(EMOP) is provided by theTCMand the grounding of the shift
solenoid valve (S1) is provided by the valve housing.
Solenoid Valve
Shift Solenoid Valve (S1)
1. Shift Control Solenoid Valve SLC1

2. Shift Control Solenoid Valve SLC2
3. Shift Control Solenoid Valve SLB1
The shift control solenoid valves (SLC1, SLC2, SLB1) are fitted
on the valve body,TCMcontrols the solenoid valves (SLC1,
SLC2 and SLB1), and the shift control solenoid valve linearly
The shift solenoid valve S1 is fitted on the valve
controls the oil pressure to the clutches (C1, C2 and C3) and
body,TCMcontrols the on/off of the shift solenoid valve S1.
the brakes (B1 and B3) to realize smooth shift. According to
It switches the oil passage according to the on/off state of
the combination of different states of the shift control solenoid
shift solenoid valve S1 to realize the fuel economy. As a
valves, the transmission realizes the gear shift (from 1st gear to
failure protection function, when any shift solenoid valve is
4th gear or from 4th gear to 1st gear). As a failure protection
abnormal,TCMcan cut off the current to the solenoid valve.
function, when any shift solenoid valve is abnormal,TCMcan
Shift solenoid valve S1 is normally closed.
cut off the current to the solenoid valve.
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Lock-up Clutch Control Solenoid Valve (SLU)
The lock-up clutch control solenoid valve SLU is fitted on

the valve body, and it linearly controls the operating pressure
of the lock-up clutch in the hydraulic torque converter
based on the engine speed, throttle opening, input speed
sensor (NC2) signal and output speed sensor (SP) signal so
as to realize the lock-up control. As a failure protection
function, when any lock-up clutch control solenoid valve SLU
is abnormal,TCMcan cut off the current to the solenoid valve.
1. Inlet
2. Outlet
3. Discharge
The shift solenoid valves (SLC1 and SLC2) are normally open,
and the oil pressure decreases with the increase of the current.
The shift control solenoid valve (SLB1) is normally closed, and

the oil pressure increases with the increase of the current.
1. Inlet
2. Outlet
3. Discharge
The lock-up clutch control solenoid valve is normally closed,

and the oil pressure increases with the increase of current.
1.0 204
1. Inlet
2. Outlet
Valve Body Solenoid Valve Transmission End
Harness Assembly
Electromagnetic Oil Pump (EMOP)
Valve Body Harness Connector
1. Electromagnetic Oil Pump (EMOP)
EMOP is fitted on the front of the valve body. EMOP is of

the same structure as the linear solenoid valve with its piston
moving based on the ON/OFF signal sent byTCMto generate
hydraulic pressure. The hydraulic pressure generated by
Pin No. Description
the EMOP is only used for controlling C1 clutch under the
stop state of Stop/Start to enable the smooth transition of 1 Oil temperature sensor (OT) (+)
the engine to start state. If any abnormality is detected, the 2 Electromagnetic oil pump
operation of EMOP is not permitted under the stop state of (EMOP) (+)
Stop/Start for failure protection. Meanwhile, the current of 3 Lock-up clutch control solenoid
EMOP will be cut off. valve (SLU) (+)
4 Pressure control solenoid
valve (SLB1) (+)
valve (SLC2) (+)
valve (SLC1) (+)
7 Oil temperature sensor (OT) (-)
8 Electromagnetic oil pump
(EMOP) (-)
9 Lock-up clutch control solenoid
valve (SLU) (-)
10 Shift solenoid valve (S1)
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Pin No. Description is on the one way clutch between the pump impeller and the
11 Pressure control solenoid turbine.
valve (SLB1) (-) The pump impeller obtains oil and swings it into the turbine,
12 Pressure control solenoid making the turbine rotate and transmit power. The guide
valve (SLC2) (-) wheel makes the liquid flow returning from the turbine change
13 Pressure control solenoid direction and enter the pump impeller again in the rotation
valve (SLC1) (-) direction same with that of the pump impeller and at the
optimal angle of highest power transmission efficiency.
The valve body solenoid valve harness combines the harnesses
of the shift solenoid valve (S1), the lock-up clutch control The one way clutch prevents the guide wheel from moving
solenoid valve (SLU), the shift control solenoid valves (SLC1, backwards, so as to obtain accurate liquid change direction.
SLC2 and SLB1), the EMOP andATFthe oil temperature When the engine is idling, the pump impeller transmits
sensor (OT) into a connector, and mounts it in an automatic extremely little liquid flow and the turbine remains no rotation,
transmission. and therefore, no power is transmitted to the transmission.
Hydraulic Torque Converter When the engine speed increases, the pump impeller swings
more liquid flow to make the turbine rotate. With the increase
of the engine speed, the turbine speed begins to increase. The
turbine speed becomes faster and faster, more and more liquid
flow is swung to the back of the guide wheel, causing the guide
wheel to rotate in the same direction with the turbine. When
the turbine speed is close to the pump impeller speed, the
centrifugal forces of both are almost equal, and all the three
components rotate roughly in the same speed. This is called
"coupling point".
The torque increases by times or the transmission rate

remains changing until reaching to the 1:1 coupling point. For
obtaining the required power to climb mountain road, the
driver steps down the accelerator pedal, and the hydraulic
1. Hydraulic Torque Converter Assembly torque converter will promote the torque increment as
2. Hydraulic Torque Converter Housing response. When driving on the flat road at the cruise speed,
3. Lock-up Clutch the required power is not big. Therefore, the hydraulic torque
converter remains the speed ratio of 1:1.
4. Turbine
5. Guide Wheel Transmission Control Module (TCM)
6. Pump Impeller
7. Oil Pump
8. Input Shaft
The hydraulic torque converter is in its housing in the right

The hydraulic torque converter functions to combine the

engine and the transmission. The power output by the engine
is transmitted to the transmission through the hydraulic force
and mechanism (through the lock-up clutch of the hydraulic
torque converter under certain gears and working conditions).
The hydraulic torque converter is connected with the engine
through the drive plate.
TCMis located on the dash panel at the driver side. It is
The hydraulic torque converter comprises the pump impeller, connected with the automatic transmission harness through
guide wheel and turbine. The engine drives the pump impeller, two connectors. The connector A has 24 pins, and the
while the turbine drives the transmission. The guide wheel connector B has 26 pins.
1.0 206
TCMUse the electrically erasable programmable read TCMadjusts the operation of the transmission through the
only memory (EEPROM). Therefore, the new or following actuators:
replacedTCMcan be used to conduct the external • Shift solenoid valve (S1)
configuration.EEPROMcan alsoTCMupdate the new
• Lock-up clutch control solenoid valve of the hydraulic
information and market-specific data. To input new
torque converter (SLU)
information, theTCMmust be configured with a scan
• Shift control solenoid valve (SLC1, SLC2, SLB1)
tool.EEPROMcanTCMbe reconfigured for many times as
required, so as to meet the constantly changing parameters • Electromagnetic oil pump (EMOP)
and regulations. TCMIt also connects with the following units through
TCMstores the signal values of the transmission sensor theCANbus:
and the actuator. These stored signals guarantee that the • ECM
transmission can always obtain the optimal performance. If • BCM
the battery voltage is too low, such as battery discharges, the
• Instrument Pack
information will be lost. When the engine starts for the first
time after the battery is discharged or disconnected,TCMwill • Data Link Connector
resume to the default value.TCMinside theEEPROMallows TCMreceives the input signals such as the throttle opening
the stored values to be rapidly accessed again. fromECM, engine coolant temperature, engine speed, engine
Input and Output torque, brake switch, etc.;TCMalso receives the input signals
such as the contact positions of the neutral start switch
The sensor signal enablesTCMto monitor the transmission
and input and output speed,ATFoil temperature, valve
state.TCMprocesses the signals and compares them with
body solenoid valve state, mode switch, etc. In addition,
the data stored in the memory. If these signals are not in
theTCMoutputs the torque decrease request, shift gear
theTCMrange of parameters stored,TCMwill adjust the
information and failure warning information toECMand
operation of the transmission through the actuator to provide
outputs execution signal, etc. to the valve body solenoid valve.
the optimal driveability and other performances.
1.0 207
Wiring Terminal of Automatic Transmission Pin No. Description

Control Module (TCM)
TCMEnd View and Pin Information of Connector valve (SLC1) (+)
GB006 and GB007 23 Ground (-)
24 Ignition switch voltage
Pin No. Description

1 Ground (-)
Pin No. Pin Functions
valve (SLU) (-) 1 "R" signal (NSW)
3 Lock-up clutch control solenoid 2 -
valve (SLU) (-) 3 -
4 Pressure control solenoid 4 -
valve (SLU) (+)
5 Output speed sensor (SP) (-)
5 Lock-up clutch control solenoid
valve (SLU) (+) 6 Input speed sensor (NC2) (-)
6 Supply voltage (+) 7 "D" signal (NSW)
7 CANCommunication signal (low) 8 "N" Signal (NSW)
8 - 9 Manual gearshift mode switch
9 Pressure control solenoid 10 -
valve (SLC) (-) 11 -
10 Electromagnetic oil pump 12 -
(EMOP) (-)
13 -
11 Oil temperature sensor (OT) (+)
14 Output speed sensor (SP) (+)
12 Oil temperature sensor (OT) (-)
13 - 15 -
14 - 16 Input speed sensor (NC2) (+)
17 -
15 CAN high
18 -
16 Shift solenoid valve (S)
19 -
17 CANCommunication signal (high)
20 "P" signal (NSW)
18 -
21 Manual gearshift switch (upshift)
valve (SLC2) (-) 22 Manual gearshift switch
- (downshift)
20
23 -
valve (SLC2) (+) 24 -
1.0 208
Pin No. Pin Functions
25 -
26 -
1.0 209
Neutral Start Switch (NSW) • Input speed

• Output speed
• Vehicle speed
The transmission speed sensor is the Hall type and generates

square wave signal which is converted into speed byTCM.
TCMThe vehicleCANspeed signal generated by
theABScontrol module is collected through the bus.
Based on these signals,TCMcontrols the engine torque, shift

time and lock-up.
The neutral start switch is located on the manual

valve gear selection shaft at the front end of the
transmission.TCMreceives the voltage output provided
by the neutral start switch to determine the gear of the
automatic transmission.
1. Input speed sensor

2. Clutch hub
3. Output speed sensor
4. Countershaft drive gear
Input Speed Sensor (NC2)
The input speed sensor is on the transmission housing for

measuring the speed of the transmission input shaft. The
magnetic resistance distribution ring on the hub of clutch C2
TCMdetermines the position of the shift lever by monitoring
will rotate when the hydraulic torque converter drives the
the 5 groups of gear contacts on the neutral start switch.
input shaft. When passing through the input speed sensor, each
Each group of contacts correspond to 1 shift lever position
gear will generate a signal and send it toTCM.
respectively, and only one group of contacts always provide
battery voltage for TCM,TCMmonitors this switch output. Output Speed Sensor (SP)
The electric input of the neutral start switch is supplied by the The output speed sensor is on the transmission housing for
fuse in the passenger compartment fuse box. measuring the speed of transmission output shaft. The output
speed sensor operates in the same manner as the input speed
Only when the shift lever is in N or P gear can the contact
sensor, but its signals are generated when the gear teeth pass
ST close the loop. In this case, the starter motor relay will be
through the magnetic resistance distribution ring on the park
controlled byBCMto engage and the vehicle will be started.
gear.
Speed Sensor
TCMUse the input of the following three speed signals to set
the correct shift sequence:
1.0 210
Oil Temperature Sensor Brake Pedal Switch
1. Oil Temperature Sensor The brake pedal switch is located on the pedal box in the
cab.TCMUse this switch to monitor the state of the brake
The oil temperature sensor is integrated with the transmission
pedal.ECMmonitors the switch state and transmits the data
internal harness and mounted on the valve body. It directly
viaCANbus toTCM.
detects the temperature of the oil in the hydraulic control
circuit, and sends the oil temperature signal toTCM.TCMuses If signal error of the brake pedal switch occurs,
oil temperature sensor to monitor the oil temperature in the • the shift lever can not shift to other gears from P or N
transmission to accommodate the oil temperature change, and gear.
realize smooth gear shift in a wide temperature range. The
• No additional engine braking will be generated.
oil temperature sensor has an electric output and grounds
viaTCM. Transmission Oil Cooler
The fluid temperature sensor is a negative temperature The transmission oil cooler is located in the collector of the
coefficient sensor. When the temperature rises, the sensor radiator. The oil cooler pipe connects the transmission and
resistance lowers; when the temperature decreases, the the oil cooler.
sensor resistance increases. The resistance change is inversely Controller Area Network (CAN) Bus
proportional to the transmission oil temperature. calculates TCMcommunicates viaCANbus with otherECUand controls
the transmission oil temperatureTCMthrough the sensor the followings:
resistance.
• Shift Torque
• Engine Coolant Temperature
• Engine Torque And Speed
• Vehicle Speed
• Selected Gear
• Shift Information
• Reduction Of Engine Torque
• Engine Braking
1.0 211
Operation
Power Flow
The following data shows the power flow of each forward gear
and reverse gear in the transmission.
1.0 212
Data Notes
Clutch, Brake and Planetary Gear Set Operation
Connect the intermediate shaft
C1 Clutch C1
with the front sun gear
Connect the input shaft with the
C2 Clutch C2
planetary carrier
Connect the intermediate shaft
C3 Clutch C3
with the rear sun gear
B1 Brake B1 Lock the rear sun gear
B3 Brake B3 Lock the planetary carrier
Lock the planetary carrier to prevent
F2 One-way Clutch F2
counterclockwise rotation
1.0 213
Operating Components
One-way
Solenoid Valve Clutch Brake
Clutch
Gear
SLC1 SLC2 SLB1 SLU S1
C1 C2 C3 B1 B3 F2
N/O N/O N/C N/C N/C
P × × × × × × × ×
V≤9 × × × × × ×
R
V ＞ 11 × × × × × ×
N × × × × × × × ×
1st × × *1 × × × ×
1st E/B × × × ×
2nd ⊙ *1 × × × ×
N cont. × × × ×
D
2nd - 3rd → →× ⊙ × ×→ × →× × ×
3rd × ⊙ × × × × ×
3rd - 4th ×→ ⊙ × →× × ×→ × ×
4th ⊙ × × × × ×
ON (N/O: OFF，N/C: ON)
× OFF(N/O: ON，N/C: OFF)
Remarks Lock ON
⊙
Lock OFF
controled (linear oil circuit pressure)
Lock range: 2nd - 4th gear *1: （V≤13km/h)/×(V﹥13 km/h)
1.0 214
D - 1st Gear
One-way
Clutch
Gear
C1 C2 C3 B1 B3 F2
N/O N/O N/C N/C N/C
D 1st × × *1 × × × ×
*1: （V≤13km/h)/×(V﹥13km/h)
1.0 215
D - 1st Gear
Functional element: C1, F2 (lock counterclockwise rotation)

Input Locking Output
Planetary Gear Set
Sun Gear Planetary Carrier Gear Ring
1. Input shaft rotates clockwise. 7. Planetary gear ring rotates clockwise.

2. Clutch C1 rotates clockwise. 8. Countershaft drive gear rotates clockwise.
3. Front sun gear rotates clockwise. 9. Countershaft driven gear rotates counterclockwise.
4. Short planetary gear rotates counterclockwise. 10. Differential gear rotates clockwise.
5. Long planetary gear rotates clockwise.
6. One-way clutch F2 operates to prevent counterclockwise
rotation of planetary carrier.
1.0 216
D - 1st Gear (Engine Brake)
One-way
Clutch
Gear
C1 C2 C3 B1 B3 F2
N/O N/O N/C N/C N/C
D 1stE/B × × × ×
1.0 217
D - 1st Gear (Engine Brake) locked by one-way clutch F2, it tries to rotate clockwise during
engine braking, but brake B3 locks its rotation after it is on, and
Functional element: C1, F2 (lock counterclockwise rotation),
the driving force is transmitted to the engine from wheels.
B3 (open during engine braking)
The wheel provides drive force when the engine brake works.
Because the counterclockwise rotation of planetary carrier is
1.0 218
D - 2nd Gear
One-way
Clutch
Gear
C1 C2 C3 B1 B3 F2
N/O N/O N/C N/C N/C
D 2nd ⊙ *1 × × × ×
*1: （V≤13 km/h)/×(V﹥13km/h)
1.0 219
D - 2nd Gear
Functional element: C1, B1 (lock the front sun gear rotation)

Planetary Gear Set Input Locking Output
Sun Gear Rear Sun Gear Gear Ring
1. Input shaft rotates clockwise. 7. Planetary carrier rotates clockwise.

2. Clutch C1 rotates clockwise. 8. Planetary gear ring rotates clockwise.
3. Front sun gear rotates clockwise. 9. Countershaft drive gear rotates clockwise.
4. Short planetary gear rotates counterclockwise. 10. Countershaft driven gear rotates counterclockwise.
5. Long planetary gear rotates clockwise. 11. Differential gear rotates clockwise.
6. Brake B1 operates to prevent the rotation of front sun
gear.
1.0 220
D - 3rd Gear
One-way
Clutch
Gear
C1 C2 C3 B1 B3 F2
N/O N/O N/C N/C N/C
D 3rd × ⊙ × × × × ×
1.0 221
D - 3rd Gear
Functional element: C1, C2

Front Sun Gear and - Gear Ring
Planetary Carrier
1. Input shaft rotates clockwise. 5. Countershaft drive gear rotates clockwise.

2. Clutch C1 rotates clockwise. 6. Countershaft driven gear rotates counterclockwise.
3. Clutch C2 rotates clockwise. 7. Differential gear rotates clockwise.
4. Planetary carrier rotates clockwise.
1.0 222
D - 4th Gear
One-way
Clutch
Gear
C1 C2 C3 B1 B3 F2
N/O N/O N/C N/C N/C
D 4th 4 ⊙ × × × × ×
1.0 223
D - 4th Gear
Functional element: C2, B1

Planetary Carrier Front Sun Gear Gear Ring
1. Input shaft rotates clockwise. 7. Front sun gear rotates clockwise.

2. Clutch C2 rotates clockwise. 8. Planetary gear ring rotates clockwise.
3. Planetary carrier rotates clockwise. 9. Countershaft drive gear rotates clockwise.
4. Brake B1 operates to prevent the rotation of front sun 10. Countershaft driven gear rotates counterclockwise.
gear. 11. Differential gear rotates clockwise.
5. Long planetary gear rotates clockwise.
6. Short planetary gear rotates counterclockwise.
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R Gear
One-way
Clutch
Gear
C1 C2 C3 B1 B3 F2
N/O N/O N/C N/C N/C
V≤9 km/h × × × × × ×
R
V﹥11 km/h × × × × × ×
1.0 225
R Gear
Functional element: C3, B3

Sun Gear Planetary Carrier Gear Ring
1. Input shaft rotates clockwise. 6. Front sun gear rotates counterclockwise.

2. Clutch C3 rotates clockwise. 7. Planetary gear ring rotates counterclockwise.
3. Brake B3 operates to prevent the rotation of planetary 8. Countershaft drive gear rotates counterclockwise.
carrier. 9. Countershaft driven gear rotates clockwise.
4. Long planetary gear rotates counterclockwise. 10. Differential gear rotates counterclockwise.
5. Short planetary gear rotates clockwise.
1.0 226
Overview Lock-up Clutch Control of Hydraulic Torque
Converter
TCMIt controls the following functions:
• Gear Shift Control

• Oil Circuit Pressure Control
• Reduction of Engine Torque
• Adaptive Rule
• Lock-up Clutch Control of Hydraulic Torque Converter
• Use of Driving Mode
• Uphill Mode
• Downhill Mode
• Heating Mode
• Gear Display
• Driving Mode Display 1. Pump Impeller
• Malfunction Condition 2. Turbine
• DTC Storage 3. Lock-up Clutch Mechanical Device
• Emergency/Failure Protection Program Control 4. Hydraulic Torque Converter Oil Supply (Release)
Automatic Transmission Shift Control 5. Use of Supply Device
TCMAdjust the sequence of the shift according to the 6. Input Shaft
relationship between the vehicle speed and the throttle
position. According to these inputs, the TCM sends electric
signal to the shift solenoid (S1, SLC1, SLC2, SLB1) in the valve
to control the gear shift, the lock-up clutch control solenoid
(SLU) controls the lock-up clutch.
Gear SLC1 SLC2 SLB1 S1
1st × *1
1stE/G ×
brake
2nd *1
3rd × ×
4th × 1. Pump Impeller
Tiptronic Shift Control 2. Turbine

3. Lock-up Clutch Mechanical Device
If the shift lever moves from "D" position to the right side, the
system will automatically enter into sport mode with different 4. Hydraulic Torque Converter Oil Supply (Lock)
shifting parameters. Then move the shift lever to separate 5. Input Shaft
the Tiptronic mode and sport mode, offering completely
The pump impeller and turbine inside the hydraulic torque
manual shift controlling. Move the shift lever forward (+) to
converter may slide somewhat, which can reduce fuel
finish upshift, and move the shift lever backward (-) to finish
economy. This situation can be eliminated by using the lock
downshift. And the TCM can upshift automatically to prevent
device of the hydraulic torque converter, and the lock device
overspeed. If the vehicle speed is low, it downshifts and locks
is connected with the turbine. According to the engine
the control.
speed, throttle opening and vehicle speed information, the
TCM will activate the lock-up clutch solenoid and lock the
clutch solenoid so as to control the lock-up control valve
and guide the liquid flow to lock or release the hydraulic
torque converter. Lock the lock-up supply pipe imposed by
the hydraulic pressure on the hydraulic torque converter
1.0 227
and force the friction liner of the lock device to locate on Economy Mode
the pump impeller so as to create mechanical connection
Normally, the TCM will consider the economy mode as
and eliminate the sliding between the pump impeller and
the default mode to be started. The economy mode is a
the turbine. Release the release supply pipe imposed by the
compromise between the sport mode and the snow mode,
hydraulic pressure on the hydraulic torque converter and
in this mode, the shift point and the engaging point to be
force the friction liner to leave the pump impeller and return
locked are within a lower speed range, this helps to reduce
to the hydraulic connection between the pump impeller and
engine speed, provide shift sequence for economical driving
the turbine.
and improve fuel economy.
The transmission has the lock function among the 2nd/3rd/4th
When some specified conditions are met, the automatic
gear, the TCM monitors the relationship between the vehicle
transmission will automatically shift to a specific mode even in
speed and throttle position and determines when to lock the
the economy mode.
hydraulic torque converter.
Sport Mode and Tiptronic Mode
In addition, add speed signal input to detect the sliding ratio
and realize slide control. When locking the clutch by sliding In the sport mode, the TCM uses the shift pulse map with the
within the lock-up cancel range, the slide control can expand engine speed in higher gear higher than that in the economy
the lock-up range to the low speed range. This prevents mode, this strategy helps acceleration and vehicle response.
increased engine speed and drive efficiency and improves fuel However, once the shift lever moves forward or backward,
economy. Meanwhile, with the sliding of the lock-up clutch, the transmission enters into the Tiptronic mode. Then gently
the hydraulic torque converter absorbs the engine vibration. push the shift lever to upshift/downshift manually.
(AW-1 automatic transmission fluid shall be used) In the Tiptronic mode, the TCM controls automatic upshift
N-D and N-R Shift Control and the engine speed can be raised to the maximum. But the
TCM allows manual shift to be done only when the engine
N-D and N-R shift control can improve the shift quality from
speed is within the preset value. If the vehicle returns to the
N gear to D/R gear.
parking state, the 1st gear will be selected automatically. In
After engine start, by controlling/adjusting the shift solenoid the Tiptronic mode, all gears can be selected manually, and the
(SLC1, SLC2), the system controls/adjusts the pressure of the current gear can be displayed on the instrument pack at the
oil flowing to the clutch (C1, C2) and applies the optimum oil driver side. In the Tiptronic mode, the vehicle can start in the
pressure to control the shift quality from N gear to D/R gear. 1st/2nd/3rd gear.
Reverse Control Snow Mode
When the vehicle is in D gear and coasts at a speed above In the snow mode, the vehicle starts in the 2nd gear. TCMShift
11km/h, the reverse control is activated and brake B3 is sequence will be changed to help vehicle control under slippery
released. For safety reasons, the TCM will also prohibit the or icy conditions. Shift operations are done at a low engine
transmission to shift to R gear even when the shift lever moves speed.
from N gear to R gear. Reverse control takes priority over
Uphill Mode
the shift control from N gear to R gear.
This mode changes the general shift sequence and helps to
Self-diagnosis and Failure Protection Function
maintain the driving performance on steep slopes. TCMThe
TCMThese functions monitor the communication status of uphill mode is activated by monitoring the engine torque,
each sensor, actuator and control module (including ECM, etc). throttle angle and engine speed. This mode selects high speed
When any failure occurs, the TCM will warn the driver and shift point and avoids frequent shift according to the gradient.
save the failure in the form of DTC. Deletion of the DTC and
Downhill Mode
initialization learning can only be done by the special scan tool.
When the accelerator pedal is fully released, and the vehicle
With the failure protection function, when the automatic
acceleration is still increasing, TCMdetermine if the vehicle is
transmission system fails, the TCM will output control signal
in the downhill mode, in this mode, change the high speed shift
and achieve movement within a short distance. If the shift
point to control engine brake.
solenoid fails, the TCM will cancel the control signal for the
solenoid, and the shift of the automatic transmission is then Heating Mode
controlled by the oil pressure circuit only. When the shift The purpose of the transmission fluid cooling strategy is to
lever is in the R gear, fix it in the reverse gear; when it is in reduce the temperature of the engine and transmission under
the D gear, fix it in the 3rd gear. high load. Under these conditions, the engine and transmission
1.0 228
can produce excess heat. If the sensor sends the signal that the Warning: Never use the stall method to raise the ATF
ATF temperature is higher than 130℃, the TCM will adopt temperature, adaptive procedure can be performed
the "heating mode" shift strategy. TCMWhen the heating only when the ATF temperature is between 65℃ and
mode is selected, the gear will upshift in advance and the 80℃. Before performing the adaptive procedure,
lock-up clutch will act between the 2nd gear and the 4th gear. check for shift impact or speed change impact.
This can reduce the engine speed or the sliding in the hydraulic
2. N-D and N-R Shift Adaptive Learning
torque converter and lower the possibility of heat generation.
If the ATF temperature is below 125℃, normal shift strategy During static braking, shift to N gear and maintain for 3s.
will be resumed. Then, shift to D gear from N gear and maintain for 3s,
and then return to N gear. Repeat the above procedures
In the heating mode, the warning lamp on the instrument pack
for 5 times.
will not illuminate.
During static braking, shift to N gear and maintain for 3s.
Failure Protection
Then, shift to R gear from N gear and maintain for 3s,
When the automatic transmission is in the failure protection and then return to N gear. Repeat the above procedures
mode, if the current automatic transmission is in the D gear, for 5 times.
shift to the 3rd gear and maintain the gear; if it is in the R gear,
3. Shift Control Adaptive Learning
maintain the gear.
Shift to D gear, and apply a throttle opening of 25-35％
Adaptive Rule
to accelerate to the 4th gear, the vehicle speed shall be
Caution: Adaption data must be cleared after 80km/h or above. Then release the accelerator pedal and
replacement of the automatic transmission or after a allow the vehicle to coast till it stops (within 60s). Repeat
software update. And readaption will then be required. the above procedures for 10 times.
Perform Adaptive Learning 4. Confirm Adaptive Learning Effect
1. Warm-up
Confirm the shift quality (shift impact or speed change
The ATF temperature can be raised between 65℃ and impact, etc) is better than that before the adaptive
80℃ by driving at idle speed or by driving on city roads. operation.
Use the scan tool to confirm the ATF temperature.
1.0 229
diagnosis Transmission Malfunction State

Overview If the TCM detects any failure in the transmission system, such
Overview as solenoid valve or sensor failure, the TCM will enter into
If the TCM detects any failure, related diagnostic trouble code the failure protection mode. TCMMultiple failure protection
(DTC) will be stored in the TCM memory. The scan tool can modes can be adopted. TCMThe failure protection mode
be used to download these DTCs to identify the failure causes. most acceptable for the driver will be adopted to ensure
TCMThe TCM memory can store up to 8 DTCs and can not minimum damage to the transmission. When any failure is
store any more codes, unless the stored DTCs are cleared. detected, TCM will send CAN information to the IPK, and
the IPK displays "EP" to inform the driver of the automatic
The DLC produced in accordance with ISO 15765 is located
transmission failure.
in the driver's footwell. The DLC is directly connected to
the CAN bus and can regain the diagnostic information and Caution: Not all the DTCs can illuminate the warning
program some functions to be executed. light of the instrument pack.
1.0 230
Machinery Diagnosis Harness and Connector Diagnosis
Deflection of Drive Disc Check Warning: The following operating instructions
should be followed when checking:
•Do not hale the harness when disconnecting the
connector.
•Place the detector on the harness side instead of the

connector terminal side when checking the harness.
•Make sure the polarity is correct when connecting the

battery. Polarity connection error will damage parts.
•Be careful when handling parts to avoid damage or

impact.
•Do not damage or bend the terminals when it is necessary

to connect the detector directly to the terminals to check
the parts.
Harness and Connector
1. Check if the deflection of the drive disc is within the

standard value.
Standard Value Within 0.2mm

• TCMConnector (Harness Side)
2. If the measured value exceeds the standard value, replace
the drive disc. Ignition Switch Power Supply System
Caution: Take care to fit correct bolt securing torque Step 1

converter to drive plate. If not, the longer bolt will 1. Disconnect the connector from the TCM.
damage the lock-up clutch. 2. Place the ignition switch in "ON" position.
Caution: DO NOT use the mechanical wrench when 3. With the voltage measurement function of a multimeter,
tightening the bolt. measure the voltage between the combined connector
3. If abnormal wear occurs or hydraulic torque converter terminals.
sleeve/oil pump sticks, replace the hydraulic torque Check the voltage according to the instructions in the
converter and automatic transmission. following table:
Standard:
Terminal No. [Name] Voltage [V]
A24 [IG] - A1 [GND] 10 - 14
A24 [IG] - A23 [GND] 10 - 14
Caution: Do not damage the terminal.
Step 2
1. Place the ignition switch in "OFF" position.
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2. With the resistance measurement function of a 1. Disconnect the connector from the TCM.
multimeter, measure the conductivity between the 2. With the voltage measurement function of a multimeter,
combined connector terminals and the body ground. measure the voltage between the combined connector
Check the conductivity according to the instructions in terminals.
the following table: Check the voltage according to the instructions in the
Standard: following table:
Terminal No. [Name] Conductivity Standard:
A24 [IG] - Body GND No Terminal No. [Name] Voltage [V]
A6 [B+] - A1 [GND] 10-14
A6 [B+] - A23 [GND] 10-14
CAN Communication System
Step 1 Caution: Do not damage the terminal.
1. Disconnect the connector from the TCM. Step 2

2. Disconnect the connector from the ECM. 1. With the voltage measurement function of a multimeter,
3. With the resistance measurement function of a measure the voltage between the combined connector
multimeter, measure the conductivity between the terminals.
combined connector terminals. Check the voltage according to the instructions in the
Check the conductivity according to the instructions in following table:
the following table: Standard:
Standard:
Terminal No. [Name] Voltage [V]
TCM Side - ECM Side Conductivity
A6 [B+] - Body GND 10 - 14
Terminal No. [Name]
A7 [CANL] - [ECM Side/ Caution: Do not damage the terminal.
CANL] Step 3
Yes
A17 [CANL] - [ECM 1. With the resistance measurement function of a
Side/ CANL] multimeter, measure the conductivity between the
combined connector terminals and the body ground.
Check the conductivity according to the instructions in
Step 2
the following table:
1. With the resistance measurement function of a
Standard:
multimeter, measure the conductivity between the
combined connector terminals or between the combined Terminal No. [Name] Conductivity
terminals and the body ground. A1 [GND] - Body GND Yes
Check the conductivity according to the instructions in A23 [GND] - Body GND Yes
Standard: Caution: Do not damage the terminal.
TCM Side Terminal Conductivity Tip Gear Shift Switch System

No. [Name] Step
A17 [CANL] - A7 [CANL] 1. Disconnect the connector from the TCM.
A7 [CANL] - Body GND No 2. With the resistance measurement function of a
A17 [CANL] - Body GND multimeter, measure the conductivity between the
Battery Power Supply System the following table:
Step 1 Standard:
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Tiptronic B9 [MS] - B21 [MS+] - B22 [MS-] - Switch Solenoid Valve S1
Mode Body GND Body GND Body GND Step
Tiptronic
No No No 1. Disconnect the connector from the TCM.
Mode OFF
Tiptronic 2. With the resistance measurement function of a
Yes No No multimeter, measure the resistance between the
Mode ON
Upshift Yes Yes No
Check the resistance according to the instructions in the
Downshift Yes No Yes
following table:
Caution: Do not damage the terminal. Standard:
Oil Temperature Sensor System Terminal No. [Name] Resistance [Ω] 20℃
Step 1 A16 [S1] - Body GND 11 - 15
1. Disconnect the connector from the TCM. Caution: Do not damage the terminal.
2. With the resistance measurement function of Linear Solenoid
a multimeter, measure the resistance between
the combined connector terminals at various oil Step 1
temperatures. 1. Disconnect the connector from the TCM.
Check the resistance according to the instructions in the 2. With the resistance measurement function of a
following table: multimeter, measure the resistance between the
Standard: combined connector terminals.
Automatic Check the resistance according to the instructions in the

Terminal No. Transmission following table:
Resistance [KΩ]
[Name] Oil Temperature Standard:
[℃]
Terminal No. [Name] Resistance [Ω] 20℃
-40℃ 161 (MAX)
A22 [SLC1] - A9 [SLC1G] 5.0 - 5.6
-30℃ 36.3 - 52.1
A21 [SLC2] - A19
5.0 - 5.6
10℃ 5.626 - 7.303 [SLC2G]
A11 [OT] - A12
(25℃) (3.5) A4 [SLB1] - A2 [SLB1G] 5.0 - 5.6
[OTG]
110℃ 0.224 - 0.271 A5 [SLU] - A3 [SLUG] 5.0 - 5.6
145℃ 0.102 - 0.121
150℃ 0.087 (MIN)
Step 2
Caution: Do not damage the terminal. 1. With the resistance measurement function of a
Step 2 multimeter, measure the conductivity between the
multimeter, measure the conductivity between the Check the conductivity according to the instructions in
combined connector terminals and the body ground. the following table:
Check the conductivity according to the instructions in Standard:

the following table: Terminal No. [Name] Conductivity
Standard: A22 [SLC1] - Body GND No
Terminal No. [Name] Conductivity A9 [SLC1G] - Body GND No
A11 [OT] - Body GND No A21 [SLC2] - Body GND No
A12 [OTG] - Body GND No A19 [SLC2G] - Body GND No
A4 [SLB1] - Body GND No
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Terminal No. [Name] Conductivity Step 1
A2 [SLB1G] - Body GND No 1. Disconnect the connector from the TCM.
A5 [SLU] - Body GND No 2. With the resistance measurement function of a

multimeter, measure the resistance between the
A3 [SLUG] - Body GND No combined connector terminals.
Caution: Do not damage the terminal. Check the resistance according to the instructions in the
following table:
Speed Sensor
Standard:
Step
Terminal No. [Name] Resistance [Ω] 20℃
1. Disconnect the connector from the TCM.
2. With the resistance measurement function of a A15 [EMOP+] - A10
5.0 - 5.6
multimeter, measure the conductivity between the [EMOP-]
combined connector terminals.
Step 2
Standard:
Terminal No. [Name] Conductivity combined connector terminals and the body ground.
B14 [SP+] - B5 [SP-] Yes Check the conductivity according to the instructions in
B16 [NC2+] - B6 [NC2-] Yes the following table:
Standard:
Terminal No. [Name] Conductivity
Neutral Start Switch (NSW)
A15 [EMOP+] - Body
Step No
GND
1. Disconnect the connector from the TCM. A10 [EMOP-] - Body
No
2. With the resistance measurement function of a GND
combined connector terminals. Caution: Do not damage the terminal.

Valve Body Harness Check
Standard:
B20 B19
B1 [R] B8 [N] B7 [D]
[P] - [W]
Gear - A24 - A24 - A24
A24 - A24
[IG] [IG] [IG]
[IG] [IG]
P Yes No No No No
R No Yes No No No
N No No Yes No No
D No No No Yes No
W No No No No Yes
• Valve Body Harness Connector
Caution: Do not damage the terminal. Oil Temperature Sensor (OT) System
1.0 234
Gear Shift Solenoid Valve S1
1. Disconnect the connector of the valve body harness and

body harness.
multimeter, measure the resistance between the terminal
of valve body harness connector 10 [S1] and the body
ground.

following table:
Standard:
1. Disconnect the connector of the valve body harness and Terminal No. [Name] Resistance [Ω] (at 20℃)
body harness.
10 [S1] - Body GND 11 - 15
2. Heat the automatic transmission oil and immerse the oil
temperature sensor into it. Caution: Do not damage the terminal.
3. Corresponding to the temperature of the automatic
Linear Solenoid
transmission oil, with the resistance measurement
function of a multimeter, measure the resistance between Step 1
terminal 1 [OT] and 7 [OTG] of the valve body harness 1. Disconnect the connector of the valve body harness and
connector. body harness.
Standard: 2. With the resistance measurement function of a
Automatic Transmission multimeter, measure the resistance between the
Resistance [KΩ] terminals of the valve body harness connector.
Oil Temperature [℃]
-40℃ 161 (MAX) Check the resistance according to the instructions in the
following table:
-30℃ 36.3 - 52.1
Standard:
10℃ 5.626 - 7.303
Terminal No. [Name] Resistance [Ω] (at 20℃)
(25℃) (3.5)
6 [SLC1] - 13 [SLC1G] 5.0 - 5.6
110℃ 0.224 - 0.271
5 [SLC2] - 12 [SLC2G] 5.0 - 5.6
145℃ 0.102 - 0.121
4 [SLB1] - 11 [SLB1G] 5.0 - 5.6
150℃ 0.087 (MIN)
3 [SLU] - 9 [SLUG] 5.0 - 5.6
Step 2
Step 2
multimeter, measure the conductivity between the 1. With the resistance measurement function of a
combined terminals of the valve body harness connector multimeter, measure the conductivity between the
and the body ground. combined terminals of the valve body harness connector
and the body ground.
the following table: Check the conductivity according to the instructions in
Standard:
Standard:
1 [OT] - Body GND

No
7 [OTG] - Body GND
1.0 235

6 [SLC1] - Body GND terminals of the output speed sensor (SP).
13 [SLC1G] - Body GND Check the conductivity according to the instructions in
5 [SLC2] - Body GND the following table:
Standard:
12 [SLC2G] - Body GND
No Terminal No. [Name] Conductivity
4 [SLB1] - Body GND
1 [SP-] - 2 [SP+] Yes
11 [SLB1G] - Body GND
3 [SLU] - Body GND Caution: Do not damage the output speed sensor (SP)
9 [SLUG] - Body GND and terminal.
Step 2
Step 1
1. Disconnect the connector of the valve body harness and

body harness.
multimeter, measure the resistance between the
terminals of the valve body harness connector.
following table:
Standard:
Terminal No. [Name] Resistance [Ω] (at 20℃)
2 [EMOP+] - 8 [EMOP-] 5.0 - 5.6
Step 2

1. Release the connector of the output speed sensor,
connect terminal 2 to the battery positive as shown in
combined terminals of the valve body harness connector
the figure, and connect terminal 1 to the battery negative
and the body ground.
via the resistance (100Ω) and ampere meter.
Caution:
•Do not mix the polarity.
Standard:
•Do not damage the output speed sensor (SP).
•Do not damage the terminal.
2 [EMOP+] - Body GND No
2. When waving the metal piece (magnetic object) back and
8 [EMOP-] - Body GND No forth at the end of the output speed sensor (SP) (less
than 5mm), measure the current.
Standard:
Speed Sensor
Signal Current [mA]
Output Speed Sensor (SP)
High 12.0 - 16.0
Step 1
Low 4.0 - 8.0
1. Disconnect the connector of the output speed sensor
(SP) and body harness. Input Speed Sensor (NC2)
1.0 236
Step 1 Standard:
1. Disconnect the connector of the input speed sensor Signal Current [mA]
(NC2) and body harness. High 12.0 - 16.0
Low 4.0 - 8.0
terminals of the input speed sensor (NC2). Solenoid Valve
Check the conductivity according to the instructions in Gear Shift Solenoid Valve
the following table: Test the resistance of gear shift solenoid valve S1
Standard:
1 [NC2-] - 2 [NC2+] Yes
Caution: Do not damage the input speed sensor (NC2)

and terminal.
Step 2
Temperature [℃] Resistance [Ω]

20 11 - 15
1. Remove the automatic transmission valve body cover,

and remove the gear shift solenoid valve S1 of the
transmission.
Caution:
•Do not impact the solenoid valve.
2. With a multimeter, measure the resistance between the

solenoid terminal and the solenoid valve body.
Check the operating condition of gear shift solenoid
1. Remove the input speed sensor (NC2). valve S1
2. Release the connector of the input speed sensor, connect 1. Connect the battery positive to the solenoid valve
terminal 2 to the battery positive as shown in the figure, terminal and battery negative to the solenoid valve
and connect terminal 1 to the battery negative via the housing, and check the solenoid valve operation.
resistance (100Ω) and ampere meter. 2. Connect the battery positive to the solenoid valve
terminal and battery negative to the solenoid valve
Caution:
housing, operate the solenoid valve and apply air, then
•Do not mix the polarity. check if air is flowing in the direction as shown in the
•Do not damage the input speed sensor (NIN). figure.
3. When waving a sheet metal (magnetic material) back and

forth at the end of the input speed sensor (NC2) (less
than 5mm), measure the current.
1.0 237
Caution: DO NOT damage the strainer when checking the Connect the battery positive to terminal 1 of each solenoid
operation condition of each solenoid valve. valve via 1 bulb (12 - 21 W), when connecting the battery
negative to terminal 2 of the solenoid valve, check the
Check the resistance of the gear shift control solenoid
valve (SLC1, SLC2, SLB1), lock-up control solenoid operation of the solenoid valve.
valve (SLU) or electromagnetic oil pump (EMOP) Check ATF
When the automatic transmission internal failure occurs, the
quality of ATF will change accordingly, therefore the condition
of ATF will be the key element in failure diagnosis.
1. Low fluid level: oil pump will inhale air which can
result in low oil pressure and functional malfunction of
transmission.
2. High fluid level: a large number of bubbles produced by
the stir of the gear set will overflow from the vent pipe.
3. Normal ATF: red, with moderate viscosity. Abnormal
ATF: water (white emulsion) or a mixture of different
ATF will lead to "shift impact" and "rough running",
degrading the performance.
Check ATF Level
Temperature [℃] Resistance [Ω]
20℃ 5.0 - 5.6Ω Automatic Transmission Fluid Refill
Check ATF Quality
1. Remove the automatic transmission valve body cover,
and remove the valve body assembly. 1. Check the quality of ATF (with or without metal
particles, powder of friction plate, burning smell, white
Caution:
emulsion and nigrescence). Excessive metal chips and
•Do not remove the gear shift control solenoid valve or bushing powder could cause the automatic transmission
lock-up control solenoid valve or EMOP from the valve body internal wear.
assembly. 2. Check if the ATF discolors. If yes, it indicates that ATF
•Do not impact the solenoid valve. may be mixed with water, special attention shall be paid
and the cooling system will be inspected.
2. With a multimeter, measure the resistance between
3. If required, replace the automatic transmission assembly
terminal 1 and 2 of each solenoid valve.
(with AT internal failure).
Check the operating condition of each solenoid valve Fluid Leak
Check the following components for fluid leak: junction
surface of the automatic transmission and engine, housing
junction, oil seal and O-ring.
1.0 238
For the fluid leak from the joint of the automatic transmission • When the ATF temperature is within 50 - 80℃ and the
and engine, check the fluid leak and determine whether it driving condition is normal.
leaks from the engine or the automatic transmission. If it is • A/C, lamps, etc are off.
automatic transmission fluid, it is probably leaked from the fuel
• Cruise control function is off.
pump oil seal or O-ring.
Warning: When performing the road test on common
For the fluid leak from the housing junction: re-apply the
roads, check road safety first.
sealant.
For the fluid leak from the side cover junction: re-apply the Item Step
sealant. Drive under normal
conditions, check the
For the fluid leak from the joint of the oil pan and housing: Gear Shift Function (D
gear shift, 1st to 2nd gear,
Gear)
repair the oil pan sealing washer. 2nd to 3rd gear and 3rd to
4th gear.
Drive under normal
Horizontal Vibration During
conditions, check if the
Driving
upshift is smooth.
Check the kick-down
function of each gear
Kick-down Function
and check for horizontal
vibration.
Check the operating state
Engine Braking of the engine braking in the
1st gear of the sport mode.
With the shift lever at sport
Gear Shift Control Function
mode, check if it can shift to
at Sport Mode
any gear manually.
When driving on level
roads, slightly depress the
Fluid Leaked from the Outside of Oil Seal accelerator pedal within the
Lock-up Control Function
lock-up speed range to see
a. Check if the oil seal is properly fitted. Replace the oil seal if the engine speed changes
and fit it properly if necessary. dramatically.
When the vehicle is parking
b. Check the condition of the contact surface between on the slope (greater than
transmission housing and oil seal, ensure there is no scratch 5% or 3°), place the shift
or dent. Replace the automatic transmission assembly if lever in P gear and release
P Gear Test
the parking brake, the
necessary.
vehicle shall not move under
Fluid Leaked from the Inside of Oil Seal the action of the parking
pawl.
a. Check the drive shaft for any scratch, dent or wear. Replace
After road test, check each
the oil seal and fit it properly if necessary. Fluid Leak
component for fluid leak.
b.Check and ensure there is no foreign material, cutting mark Function Test
or wear on the oil seal lip. Replace the oil seal and fit it properly
if necessary. Carry out the road test under the following conditions:
Caution: When fitting the drive shaft, it should • After engine check and adjustment.
be erectly inserted into the spline hole of the • A/C, lamps, etc are off.
transmission differential. • Cruise control function is off.
Road Test Warning: To prevent accidental start of the vehicle,
Road tests can be used for precise fault symptom diagnosis and ensure the vehicle is locked before function test.
fault symptom check after the handling procedures, ensure that Delay test
road tests are carried out under the following conditions:
Delay refers to the duration of the slight vibration when
• After engine check and adjustment. switching the shift lever from N gear to D/R gear under idle
engine condition.
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Caution: Make 3 measurements and average the value. 1. Block four vehicle wheels with wood wedges and fully
Ensure there is an interval longer than 1min apply the parking brake to lock the vehicle.
for each delay test so that the pressure of the 2. Depress the brake pedal with the left foot heavily, place
clutch/brake can be fully released. the shift lever in D or R gear, and depress the accelerator
1. Block four vehicle wheels with wood wedges and fully pedal with the right foot to measure the max. speed at
apply the parking brake to lock the vehicle. idling or stalling.
2. With the stopwatch, record the duration of the slight Stall Speed Around 2631 ± 150rpm
vibration when switching the shift lever from N gear to
D/R gear. Stall Test Results Failure Cause
Low engine power
N - D gear Less than 1.5s Both values at D and R gear
are below the standard value Hydraulic torque converter
N - R gear Less than 1.5s one-way clutch failure
Low oil circuit pressure (shift
Delay test results Failure Cause
solenoid valve SLC1/primary
Valve body failure (SLC1 pressure regulating valve
or SLC2 hydraulic system) failure)
Only the value at D gear is
Delay from N gear to C1 failure (slip) above the standard value Valve failure (SLC1 hydraulic
D gear is longer than system)
F2 failure
standard value
C1 failure (slip)
Oil pump failure
F2 failure
Oil filter failure (blockage)
Low oil circuit pressure (shift
Valve body failure (SLC1,
solenoid valve SLC2/primary
SLC2 or S1 hydraulic
pressure regulating valve
system)
Delay from N gear to failure)
C3 failure (slip) Only the value at R gear is
R gear is longer than above the standard value Valve failure (SLC2 hydraulic
standard value B3 failure (slip) system)
Oil pump failure C3 failure (slip)
Oil filter failure (blockage) B3 failure (slip)
Stall Test Low oil circuit pressure

(shift solenoid valve SLC1
The stall test applies the stall speed of the D/R gear to check
or SLC2/primary pressure
the overall performance of the automatic transmission and Both values at D and R gear
are above the standard value regulating valve failure)
engine. Prior to test, ensure the ATF temperature is within
50 - 80℃, and the electrical equipment is off such as A/C, Oil pump failure
headlamp, etc. Filter failure (blockage)
Warning: The operation shall not be longer than
5s, or the ATF will become hot. Ensure there is
an interval longer than 1min for each stall test.
Test for at least 3 times and calculate the average
value.
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Service Procedures 6. Fit the special tool T26001 on the D gear testing hole
Hydraulic Pressure Test of the automatic transmission.
Check 7. Start the engine, depress the brake pedal and place the
During hydraulic test, check the working conditions of the shift lever in "D" position. When the vehicle meets the
automatic transmission by measuring the idling and stall oil requirement, switch to the start/stop state.
pressure at D and R gear. 8. When the engine stops under the start/stop state,
check the fluid pressure.
Warning: The operation shall not be longer than 5s,
or the temperature of the ATF will become too high. Description:
Ensure there is a spacing longer than 1 min between
Gear D Gear
every two stall tests.
ATFTemperature 20 - 110°C
1. Block four vehicle wheels with wood wedges and fully
apply the parking brake to lock the vehicle. C1 Oil Pressure 0.154 Mpa or above
2. Fit the special tool T26001 on the D or R gear testing
hole of the automatic transmission.
Caution: Ensure there is no oil leakage after the

pressure gauge refit.
1. D gear testing hole
2. R gear testing hole
3. Depress the brake pedal with the left foot heavily,

place the shift lever in D or R gear, and depress the
accelerator pedal with the right foot to measure the oil
circuit pressure in idle or stall state.
Idle Speed
• D 0.625 - 0.775 Mpa

• R 0.499 - 0.539 Mpa
Stall
• D 1.450 - 1.630 Mpa

• R 1.725 - 2.085 Mpa
Stall Speed 2631 ± 150rpm
4. To fit the automatic transmission assembly with the

start/stop function, oil pressure test can also be
conducted in the start/stop state.
5. The ignition switch is turned off.
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Automatic Transmission Assembly

Remove
1. Fix the vehicle on lift.
4. Remove 2 bolts (1) fixing the bracket of the automatic
transmission cable to the automatic transmission.
5. Remove 1 nut (2) fixing the automatic transmission
cable rocker arm to the automatic transmission. 11. Lift the engine with special tools T10007 and
TEN00070.
6. Disconnect the harness connector from the automatic

transmission. 12. Remove and discard 3 bolts fixing the lower tie rod
bracket to the automatic transmission
7. Disconnect the harness connector from the
input/output speed sensor and temperature sensor.
13. Remove and discard 4 bolts fixing the automatic

transmission mount bracket to the automatic
8. Remove the left drive shaft assembly. transmission.
9. Remove 1 bolt (1) fixing the bracket of the automatic
transmission.
10. Remove the nut (2) fixing the automatic transmission
oil cooler pipe to the oil cooler pipe connector.
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14. Remove 3 bolts fixing the upper part of the automatic 18. Lower the hydraulic jack slowly and carefully, and
transmission to the engine. remove the automatic transmission assembly.
Refit
1. Clean the junction surface of the engine and automatic
transmission.
2. Clean the locating pin and pin hole of the automatic
transmission.
3. Support the engine with a lifting equipment.
4. Fix the automatic transmission on the jack, and raise
the jack to locate it to the vehicle carefully.
5. Align the front end of the hydraulic torque converter
with the engine crankshaft hole, and simultaneously
align the locating pin of the engine with that of
the automatic transmission, then fit the automatic
15. Remove the starter motor. transmission and engine.
Starter Motor Remove 6. Fit 4 bolts fixing the lower part of the automatic
transmission to the engine, tighten to 75-90Nm, and
16. Support the automatic transmission assembly with
check the torque.
hydraulic jack.
17. Remove 4 bolts fixing the lower part of the automatic
transmission to the engine. Starter Motor Refit
8. Fit 3 bolts fixing the upper part of the automatic
transmission to the engine, tighten to 75-90Nm, and
check the torque.
9. Fit 4 new bolts fixing the bracket of the automatic
transmission mount to the automatic transmission,
tighten to (45-55)Nm+(85-95)deg, and check the
torque.

10. Fit 3 new bolts fixing the lower tie rod bracket
to the automatic transmission, tighten to
(45-55)Nm+(85-95)deg, and check the torque.
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Caution: Yielding technique is applied to this bolt . For Automatic Transmission Fluid - Drain and Refill
virgin installation, the bolt is allowed to use twice. For Drain
second use of bolt in the same station, the bolt must be Warning: Observe due care when draining gearbox fluid
loosened to zero Nm, then tighten it according to specified as the fluid can be very hot.
times, new bolt must be taken. Caution: The transmission oil can be drained only
when the transmission is at normal operating
11. Clamp the transmission breather pipe clip about temperature.
vertically at the transmission harness without fixed tie,
and keep the breather pipe clip facing up as much as 1. Place a suitable container below the transmission to
possible. collect the ATF.
12. Fit the left drive shaft assembly. 2. Clean the area around the oil drain plug and overflow
plug.
3. Remove the overflow plug and discard the seal ring.
13. Fit the nut fixing the automatic transmission oil cooler
pipe to the oil cooler pipe connector, tighten to
33-37Nm, and check the torque.
14. Fit 1 bolt fixing the bracket of the automatic
torque.
15. Connect the harness connector to the input/output
speed sensor and temperature sensor.
16. Connect the harness connector to the automatic
transmission.
17. Fit 1 nut fixing the automatic transmission cable
rocker arm to the automatic transmission, tighten to
14-20Nm, and check the torque. 1. Overflow Plug
18. Fit 2 bolts fixing the bracket of the automatic 2. Drain Plug
transmission cable to the automatic transmission, 4. Remove the oil drain plug and discard the seal ring.
tighten to 15-23Nm, and check the torque. 5. Drain the oil.
19. Fill the automatic transmission fluid. 6. Record the total amount of drained oil as necessary.
Automatic Transmission Fluid Refill Refill
20. Fit the front/rear brackets of the battery tray. 1. Ensure that the vehicle is on a horizontal level.
Front Bracket of Battery Tray Refit 2. Block four vehicle wheels with wood wedges and fully
apply the parking brake to lock the vehicle.
3. Move the shift lever to P gear.
21. Lower the vehicle on a lift.
4. Clean the oil drain plug and fit the new seal ring.
Caution: Ensure that the washer is fitted in the

correct direction as shown!
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11. Fit the overflow plug, tighten to 23-25Nm, and check
the torque.
12. Clean the area around the oil filler and the oil filler
plug, and fit the new seal ring.
13. Fit the oil filler plug, tighten to 35-44Nm, and check
the torque.
14. Refit the battery tray.
Battery Tray Refit
5. Fit the oil drain plug, tighten to 14.7-19.6Nm, and

check the torque.
Battery Tray Remove
7. Clean the area around the oil filler plug.
8. Remove the oil filler plug and discard the seal ring.
9. Add an appropriate amount of transmission oil through

the oil filler.
Fluid
10. Clean the overflow plug and fit the new seal ring.
Caution: Ensure that the washer is fitted in the
correct direction as shown!
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Automatic Transmission Fluid - Refill Caution: ATFFluid level is different in cold and
Check and Refill hot states, so it needs to test the ATF level in
Important precautions: faults in the automatic transmission are hot state.
always accompanied with ATF deterioration (metal particles, 12. When the engine is in idle state, depress the brake and
powder of friction plate, smell of burning, white emulsion, etc.), so move the shift lever from P gear to all gears, stay at each
ATF testing is critical. gear separately for min. 3 seconds before returning to
Important precautions: Low oil level: oil pump may inhale air, the P gear, and perform the shift process for 2 times.
which can result in low oil pressure and transmission functional 13. Lift the vehicle, remove the overflow plug, and discard
malfunction. High oil level: a large number of bubbles will be the seal ring.
produced by the stir of the gear set and the oil will overflow from 14. Check the state of the ATF dripping from overflow
the breather pipe. hole.
Important precautions: Normal ATF: red, with moderate viscosity. 15. Confirm if the ATF temperature is within 50℃ - 60℃,
Abnormal ATF: water (white emulsion) or a mixture of different and wait until the ATF drips from the overflow hole.
ATF will lead to "shift impact" and "rough running", degrading the 16. Clean the overflow plug, fit the new seal ring, fit the
performance. overflow plug, tighten to 23-25Nm, and check the
1. Ensure that the vehicle is on a horizontal level, block torque.
the four vehicle tyres with wood blocks, and apply the Caution: After tightening the overflow plug,
park brake to lock the vehicle. make sure that the overflowed oil is wiped off
2. Move the shift lever to P gear. completely.
3. Clean the surrounding area of the oil filler plug, remove 17. Lower the vehicle and shut down the engine.
the oil filler plug and discard the seal ring.
Warning: As the exhaust system components may have

a very high temperature, be careful to avoid burns
and other personal injuries.
5. Clean the surrounding area of the overflow plug,
remove the overflow plug and discard the seal ring.
6. Check if the ATF drips from the overflow hole.
7. If no ATF drips, add specified fluid (AW-1) until the
ATF drips from the overflow hole.
Caution: If the ATF level is too low, there may be

a leak somewhere, check corresponding parts of the
automatic transmission carefully.
Caution: Make sure that only specified ATF is used.
8. If the ATF drips from the overflow hole, it is

unnecessary to add any fluid.
9. Clean the overflow plug, fit the new seal ring, fit the
overflow plug, tighten to 23-25Nm, and check the
torque.
10. Clean the oil filler plug, fit the new seal ring, fit the oil
filler plug, tighten to 35-44Nm, and check the torque.
11. Lower the vehicle, start the engine, and confirm if the
ATF temperature rises to 50℃ with the scan tool.
Caution: Do not make the ATF temperature rise

quickly by a stalling testing method.
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Transmission Control Module (TCM) Automatic Transmission Harness
Remove Remove
Warning: The Transmission Control Module (TCM) is 1. Remove the battery tray.
uniquely coded to this vehicle and therefore will not work
Battery Tray Remove
if fitted to another vehicle.
2. Disconnect the connector of the input speed sensor.
3. Disconnect the connector of the output speed sensor.
2. Disconnect the harness connector (2) of the TCM.
4. Disconnect the connector of the neutral start switch.
3. Remove 2 nuts (1) fixing the TCM to the bracket.
5. Disconnect the harness connector of the transmission.
6. Disconnect the connector of the TCM.
4. Remove the TCM.

Refit
7. Disconnect the harness connector from the instrument
1. Fit 2 nuts fixing the TCM to the bracket, tighten to panel.
8. Loosen 3 clips fixing the harness to the transmission
2. Connect the harness connector of the TCM. and remove the harness.
3. Connect the battery negative. Refit
4. Turn on the ignition switch but do not start the engine, 1. Fit the harness and secure with clips.
shift the lever to P gear or N gear, and make sure that
2. Connect the harness connector to the instrument
the vehicle is in stationery state.
panel.
5. Connect the scan tool to the vehicle and access the
3. Connect the connector of the TCM.
SIPS.
4. Connect the harness connector of the transmission.
6. Operate as per "Programming and Coding - TCU -
Replacement" and interface prompts to update the 5. Connect the connector of the neutral start switch.
TCM and perform the self-learning. The procedures 6. Connect the connector of the input speed sensor.
for replacement already include procedures for update 7. Connect the connector of the output speed sensor.
and self-learning. If it prompts "Failed" during the 8. Fit the battery tray.
replacement, please operate as per the interface
prompts. Battery Tray Refit
1.0 247
Neutral Start Switch seal to the transmission housing.

Remove Caution: Take care not to damage the oil seal.
1. Ensure that the vehicle is in neutral gear.
3. Release the control rocker arm from the neutral start
switch and put the rocker arm and cable aside.
4. Disconnect the connector from the neutral start switch.
2. Specification: 1 ± 0.25mm (from the bottom of the

automatic transmission housing)
3. Fit the neutral start switch and bolts to the transmission,
but do not tighten fullly.
4. Connect the connector to the switch.
5. Remove 2 bolts fixing the neutral start switch to 5. Adjust the neutral start switch.
automatic transmission, and remove the switch. Check
the removed neutral start switch for any obvious Neutral Start Switch Adjustment
deformation or damage. If yes, refit a new neutral start 6. Fit the retaining bolt of the neutral start switch, tighten
switch. to 4.3-6.5Nm, and check the torque.
6. If it is necessary to remove the manual shift lever oil 7. Locate the control rocker arm to the neutral start
seal, insert the flat-blade screwdriver between the switch and ensure it is fixed correctly. Fit and tighten
transmission housing and oil seal to remove the oil seal. the nut to 14-20Nm, and check the torque.
Caution: Bind tape on the head of the flat-blade 8. Check if the engine can be started at P and N gear but
screwdriver before use. Take care not to damage can not be started at other gears.
the transmission housing and shift shaft.
7. Pry up the oil seal with flat-blade screwdriver.

Caution: Take care not to damage the contact surface
of the housing.
Refit
1. If the manual shift lever oil seal is removed, use the
special tool TPT00164 and hammer to fit the new oil
1.0 248
Neutral Start Switch - Check and Adjustment switch and ensure it is fixed correctly. Fit and tighten
Check the nut to 14-20Nm, and check the torque.
1. Remove the neutral start switch. 6. Check if the engine can be started at P and N gear but
Neutral Start Switch Remove can not be started at other gears.
2. Test if it can be energized at each gear position

according to the polarity as shown and the connector
end view.
Caution: The current applied shall not exceed 0.1A,

or it will cause contact failure of the neutral
start switch.
3. If any wrong gear position is displayed during the test,
replace the neutral start switch.
4. After the test, fit the neutral start switch.
Neutral Start Switch Refit
Adjustment
1. Ensure that the shift lever is in "N" position.
2. Release the control rocker arm from the neutral start
switch and put the rocker arm and cable aside.
3. Fit the TPT00220 to the manual valve stem. Check
if the scale line on the TPT00220 is aligned with the
baseline on the neutral start switch.
4. Align the scale line on the TPT00220 with the baseline

on the neutral start switch.
5. Locate the control rocker arm to the neutral start
1.0 249
Input Speed Sensor Output Speed Sensor

Remove Remove
Warning: Switch off ignition switch and wait for 90 Warning: Switch off ignition switch and wait for 90
seconds before starting work. seconds before starting work.
Warning: Position the earth lead carefully and prevent to Warning: Position the earth lead carefully and prevent to
contact the disconnected battery earth lead again. contact the disconnected battery earth lead again.
1. Disconnect the harness connector from the input 1. Disconnect the harness connector from the output
speed sensor. speed sensor.
2. Remove 1 bolt fixing the input speed sensor to the 2. Remove 1 bolt fixing the output speed sensor to the
transmission, and remove the input speed sensor. transmission, and remove the output speed sensor.
Caution: Be careful not to damage the input speed sensor Caution: Be careful not to damage the output speed
and transaxle housing. sensor and transaxle housing.
Refit Refit
1. Fit the new O-ring applied with ATF to the input speed 1. Fit the new O-ring applied with ATF to the output
sensor. speed sensor.
2. Fit 1 bolt fixing the input speed sensor to the 2. Fit 1 bolt fixing the output speed sensor to the
transmission, tighten to 3.9-6.9Nm, and check the transmission, tighten to 3.9-6.9Nm, and check the
torque. torque.
Note: Always use a new seal bolt. Note: Always use a new seal bolt.
1.0 250
Automatic Transmission Housing End Oil Seal 4. Fill the automatic transmission fluid and check the fluid
Remove level.
1. Drain the automatic transmission fluid. Automatic Transmission Fluid Refill
3. Insert the flat-blade screwdriver between the
differential housing and oil seal to remove the oil seal.
Caution: Bind tape on the head of the flat-blade

screwdriver before use. Take care not to damage
the transaxle housing and differential housing.

of the housing.
Refit
1. Fit the new oil seal to the transaxle housing with the
special tool TPT00218 and hammer.
Caution: Take care not to damage the oil seal.
2. Specification: 3.1 ± 0.5mm (from the bottom of the

transmission housing).
3. Fit the left drive shaft assembly.
1.0 251
Torque Converter Housing End Oil Seal level.

Remove Automatic Transmission Fluid Refill
3. Insert the flat-blade screwdriver between the
differential housing and oil seal to remove the oil seal.
screwdriver before use. Take care not to damage
the transaxle housing and differential housing.

of the housing.
Refit
1. Fit the new oil seal to the transaxle housing with
TPT00219 and hammer.
Caution: Take care not to damage the oil seal.
2. Specification: 2.2 ± 0.5mm (from the bottom of the

torque converter housing end)
3. Fit the right drive shaft assembly.
4. Fill the automatic transmission fluid and check the fluid
1.0 252
Hydraulic Torque Converter Valve Body Cover
Remove Remove
1. Remove the automatic transmission assembly. 1. Raise the vehicle on a lift.
Automatic Transmission Assembly Remove 2. Drain the automatic transmission fluid.
2. Remove the hydraulic torque converter. Automatic Transmission Fluid Drain
Caution: Take care not to damage the oil seal, and 3. Remove 17 bolts securing the valve body cover, remove
do not drop the torque converter assembly. the valve body cover, and discard the valve body cover
washer.
Caution: Be careful not to damage the valve body cover
and transaxle housing.
Refit
1. Fit the torque converter to the automatic transmission.
Caution: Take care not to damage the oil seal, and
do not drop the torque converter assembly. 4. Remove 4 magnets for oil cleaning from the valve body
cover, check and remove the impurities on the valve
2. Measure the dimension from the tail end of the
body cover and magnets.
transaxle housing to the bolt hole surface of the
hydraulic torque converter assembly.
5. Clean the contact surface between the valve body

3. Check if the hydraulic torque converter has been fitted cover and transaxle housing.
correctly. Caution: Take care and ensure there is no impurity
4. Specification : A = 17.3mm (from the tail end of the on the contact surface between the valve body cover
transaxle housing) and transaxle housing.
5. Fit the automatic transmission assembly. Refit

Automatic Transmission Assembly Refit 1. Remove the packaging materials from the contact
surface of the transaxle and the oil from the contact
6. Fit the oil drain plug, tighten to 14.7-19.6Nm, and
surface.
check the torque.
Caution: Ensure that the mating faces are free from oil.
7. Fit the overflow plug, tighten to 23-25Nm, and check
the torque. 2. Fit 4 magnets for oil cleaning to the valve body cover.
1.0 253
3. Fit the new washer to the valve body cover. Valve Body Assembly
4. Fit the valve body cover to the transaxle housing. Remove
5. Fit 17 new bolts, tighten to 6-7.9Nm, and check the 1. Remove the automatic transmission valve body cover.
torque. Valve Body Cover Remove
Note: Always use a new seal bolt. 2. Remove the automatic transmission filter assembly.
6. Fit the oil drain plug, tighten to 14.7-19.6Nm, and Filter Assembly Remove
check the torque. 3. Remove the bolts and clips securing the automatic
7. Fill the ATF and check the fluid level. transmission temperature sensor, and pull the
Automatic Transmission Fluid Refill temperature sensor out of the valve body assembly.
4. Disconnect the connectors of 6 valve body harnesses.

5. Support the valve body assembly, remove 11 bolts
securing the valve body assembly, and remove the valve
body assembly.
6. Remove the valve body assembly oil seal from the

1.0 254
housing.
4. Connect the manual valve control rod to the manual
valve operating rod.
7. Remove the C3 accumulator piston and compression

spring with flat-blade screwdriver.

screwdriver before use. 5. Fit 11 valve body assembly bolts 1 and 2, tighten to
9.8-11.8Nm, and check the torque.
Caution: When fitting the valve body assembly to

the transmission housing, do not tilt the C3
accumulator, and do not hold the solenoid valve.
8. Remove 2 O-rings from the C3 accumulator piston

with the flat-blade screwdriver and discard them.
6. Connect the connectors of 6 valve body harnesses.

7. Fit the clips and bolts securing the automatic
transmission temperature sensor, tighten to
5.8-7.8Nm, and check the torque.
8. Fit the automatic transmission filter assembly.
Filter Assembly Refit

9. Fit the automatic transmission valve body cover.
Valve Body Cover Refit
10. Turn on the ignition switch but do not start the engine,
Refit shift the lever to P gear or N gear, and make sure that
1. Fit 2 new O-rings applied with ATF to the C3 the vehicle is in stationery state.
accumulator piston. 11. Connect the scan tool to the vehicle and access the
2. Fit the C3 accumulator piston applied with ATF and the SIPS.
compression spring to the valve body assembly. 12. Operate as per "Programming and Coding - TCU -
3. Fit the new oil seal applied with ATF to the transmission Replacement" and interface prompts to update the
1.0 255
TCM and perform the self-learning. The procedures Oil Pump Oil Seal
for replacement already include procedures for update Remove
and self-learning. If it prompts "Failed" during the 1. Remove the hydraulic torque converter.
replacement, please operate as per the interface
prompts. Hydraulic Torque Converter Remove
2. Remove the oil seal at the oil pump with tools.
Caution: Be careful not to damage the oil seal and the

input shaft.
Refit
1. Fit the new oil seal to the oil pump with the special tool
TPT00161 and hammer.
Caution: Be careful not to damage the oil seal and the

input shaft.
2. Specification: 0 ± 0.3mm (from the tail end of the oil
pump).
3. Apply grease to the oil seal lip.
4. Fit the hydraulic torque converter to the automatic
transmission.
Hydraulic Torque Converter Refit
1.0 256
Filter Assembly Automatic Transmission Oil Cooler Pipe
Remove Connector
1. Remove the automatic transmission valve body cover.
Remove
1. Remove the inlet/outlet pipe of the automatic
Valve Body Cover Remove
transmission oil cooler.
2. Remove the filter assembly from the valve body
assembly. Automatic Transmission Oil Cooler Inlet Pipe
Remove
Automatic Transmission Oil Cooler outlet Pipe

Remove
2. Remove 2 connectors of the automatic transmission oil
cooler pipe and discard the sealing gaskets.
3. Remove and discard the O-ring on the filter assembly.
Refit
1. Clean the oil cooler pipe connector and fit the new
seal ring.
2. Fit the oil cooler pipe connector, tighten to
19.6–29.4Nm, and check the torque.
3. Fit the inlet/outlet pipe of the automatic transmission
oil cooler.
Automatic Transmission Oil Cooler Inlet Pipe

Refit Refit
1. Fit the new O-ring applied with ATF to the filter Automatic Transmission Oil Cooler Outlet Pipe
assembly. Refit
2. Fit the filter assembly to the valve body assembly.
3. Fit the automatic transmission valve body cover.
Valve Body Cover Refit
1.0 257

Number
Replacer driven
Transmission TPT00218 shaft oil seal
T26001 pressure test - LH
equipment
Replacer driven
TPT00219 shaft oil seal
Engine lift - RH
T10007
bracket
Replacer, oil
TPT00161
pump seal
TEN00070 Engine support
Replacer,
TPT00164 manual shaft
oil seal
Adjuster ，
TPT00220 neutral start
switch
1.0 258
Shift Lock Control-MT Transmission
Shift Lock Control-MT
Specifications
Torque
Description Value
Bolt - gear change mechanism to floor 7–10Nm
1.0 259
Transmission Shift Lock Control-MT

System Layout
Exploded View of Gear Shift Control Mechanism
1. Gear Shift Knob Assembly - Manual Transmission 3. Manual Gear Shift Control Mechanism
2. Clip - Gear Shift Knob Assembly 4. Bolt - Gear Shift Cable to Body
1.0 260
Service Procedures Gear Shift Mechanism Assembly - Manual
Shift Lever Knob and Sleeve - Manual Remove
Remove 1. Remove the shift lever knob and sleeve.
1. Place the shift lever in "N" position. Shift Lever Knob and Sleeve - Manual Remove
2. Remove the centre console upper trim panel assembly. 2. Pay attention to the mounting position, and loosen the
Centre Console Upper Trim Panel Assembly cable ball joint from the gear selection/shift rocker arm
Remove of the manual transmission.
3. Remove and discard the metal clip fixing the knob and
sleeve assembly to the shift lever.
Caution: The clip should be replace when it disassembly.
3. Loosen the clip fixing the gear selection/shift cable to

the bracket.
4. Disconnect the clip fixing the knob and sleeve to the

centre console upper trim panel.
4. Remove the cable from the cable bracket.

5. Remove the heat shield of the exhaust passage.
Exhaust Passage Heat Shield Remove

5. Pull up the knob and sleeve assembly with care, loosen 6. Remove 4 screws fixing the gear shift mechanism
and remove the assembly from the shift lever. assembly to the body.
Refit
1. Fix the shift lever sleeve assembly to the centre console
upper trim panel, and press the clip.
2. Fix the knob and sleeve assembly to the shift lever, and
clamp with new metal clamps.
3. Fit the centre console upper trim panel assembly.
Centre Console Upper Trim Panel Assembly Refit
1.0 261
Transmission Shift Lock Control-MT
7. Remove the gear shift mechanism assembly.

Refit
1. Embed the clip nut into 2 holes of the central passage.
2. Locate the gear shift mechanism assembly to the central
passage, fit the bolt and tighten to 7–10Nm.
3. Fit the shift lever knob and sleeve.
Shift Lever Knob and Sleeve Refit

4. Fix the gear selection cable to the cable bracket.
5. Fit the exhaust passage heat shield.
Exhaust Passage Heat Shield Refit

6. Fix the gear selection/shift cable to the bracket with
clips.
7. Pay attention to the mounting position, and connect the
cable ball joint to the gear selection/shift rocker arm.
8. Adjust the gear selection/shift cable to a proper length.
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Tools List
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Transmission Transmission-MT
Transmission-MT
Specifications
Torque
Description Value
Bolt-Manual Transmission Mount Bracket to Manual （45-55）Nm+（85-95）deg
Transmission
Bolt-Under The Tie-bar Bracket to Under The Tie-bar （81-99）Nm+（85-95）deg
Bolt-Under The Tie-bar Bracket to Manual Transmission （45-55）Nm+（85-95）deg
Bolt- transmission to engine 75–90Nm
Bolt-Slave Cylinder to Manual Transmission 40-50Nm
Bolt-Battery negative cable to transmission case 15–20Nm
Bolt-Reverse Gear Lock 15-22Nm
Bolt-Control Cover to Rear Housing 15-25Nm
Bolt-Gear Selector Lever to Control Cover 15-25Nm
Bolt-Oil Drain plug to Transmission 25-35Nm
Bolt-Oil Filler Plug to Transmission 25-35Nm
Bolt-Switch Reverse Light to Transmission 12-18Nm
Self – locking bolt 15–20Nm
Bolt - reverse gear lever to front housing 22–28Nm
Bolt - front housing to rear housing 22–28Nm
Bolt - selector and shift cable support bracket to front 22–28Nm
housing
Bolt - reverse idler shaft to rear housing 15–22Nm
Bolt - rear bearing baffle to rear housing 13–15Nm
Nut - output shaft 80–100Nm
Screw plug - 5th gear selector fork 5–8Nm
Bolt - control cover to rear housing 15–25Nm
Bolt - rear cover to rear housing 8–13Nm
Bolt - final drive gear to differential housing 110–150Nm
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Transmission-MT Transmission
Parameter
Model SH63Z Manual Transmission (1.5L) Big Ratio
Gear 5 forward gears (engaged by synchronizer), 1 reverse gear
Speed Ratio SH63Z:
·1st gear 3.727
·2nd gear 2.050
·3rd gear 1.323
·4th gear 0.973
·5th gear 0.795
·Reverse gear 3.454
·Main Reduction 4.235

Transmission Centre Distance 63mm
Allowable Maximum Input Torque
SH63Z 135Nm
Maximum Input Speed 6000r/min
Mass (without oil) 30.6kg
Lubricating Oil MTF 94
Transmission standard oil capacity:
·Drain and Refill 1.8L
·Refill in Dry State 2.0L

Maximum Transmission Boundary
Dimension
342mm
·Length
488mm
·Width
391mm
·Height
Lubrication grease:
·Clutch rocker arm bushing inner bore

Lithium based grease
·Release bearing bore and shifting fork
junction surface Lithium based grease
·Inner and outer surfaces of gear Lithium based grease

selection nylon taper block
Plane sealant:
·Connecting surface of front and rear

Tonsan 1596F
housings
Tonsan 1596F
·Rear cover plate - rear housing
Tonsan 1596F
·Control cover - rear housing
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Thread sealant:
·Reverse idler gear shaft bolt - rear

Tonsan 1243C
housing
Tonsan 1243C
·Self-locking bolt - front housing
Tonsan 1243C
·Reverse gear stop bolt - rear housing
Tonsan 1243C
·4 couter-hit bolts of front housing
Clutch rocker arm shaft sleeve
Input shaft oil seal
Differential oil seal
Input shaft rear bearing adjusting gasket
Circlip Ø29
Shaft circlip Ø18.5
Output shaft rear bearing adjusting gasket
Circlip Ø32
Disposable parts:
Output shaft locking nut
Differential rear bearing adjusting gasket
Spring pin
Pin Ø5×28
Pin Ø3×22
Pin Ø5×22
Gear selection/shift shaft oil seal
Gear selection/shift shaft bearing
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System Layout
Transmission Assembly Layout
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Transmission Control and Housing Exploded View
1. Dust Shield - Gear Selection/Shift Shaft 20. Combination Spring Pin

2. Oil Seal - Gear Selection/Shift Shaft 21. Gear Selection/Shift Taper Head
3. Bearing - Gear Selection/Shift Shaft 22. Gear Shift Interlock Baffle
4. Gear Selection/Shift Rocker Arm Positioning Sleeve 23. 5th/Reverse Gear Selection Stop Spring Cushion
5. Control Cover 24. 5th/Reverse Gear Selection Stop Circlip
6. Bolt M8×25 25. 5th/Reverse Gear Selection Return Spring
7. Pin Ø5×28 26. 5th/Reverse Gear Selection Return Spring Cushion
8. Gear Shift Rocker Arm 27. Pin Ø3×22
9. Bolt M8×50 28. Circlip
10. Gear Selection Rocker Arm 29. 1st/2nd Gear Selection Return Spring Cushion
11. Nylon Block 30. 1st/2nd Gear Selection Return Spring
12. Reverse Gear Stop Torsion Spring 31. 1st/2nd Gear Fork Shaft
13. Reverse Gear Lock Plate 32. Spring Pin
14. Oil Baffle 33. 1st/2nd Gear Taper Block
15. Bolt - Oil Baffle 34. 1st/2nd Gear Fork
16. Reverse Gear Lock Shaft 35. 3rd/4th Gear Fork Shaft
17. Pin Ø5×22 36. 3rd/4th Gear Taper Block
18. Shift Positioning Camshaft 37. 3rd/4th Gear Fork
19. Gear Selection/Shift Shaft 38. 5th Gear Fork Shaft
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39. Reverse Gear Fork Shaft 58. Clutch Rocker Arm Shaft Bushing
40. Steel Ball 8 59. Self-locking Bolt
41. Locking Spring - Reverse Gear Taper Pin 60. Self-locking Spring
42. Reverse Gear Taper Pin 61. Front Housing
43. Reverse Gear Taper Block 62. Set Pin - Rear Housing
44. 5th Gear Fork Screw Plug 63. Set Pin - Front Housing
45. 5th Gear Fork 64. Magnetic Steel
46. Retaining Circlip 65. Gear Shift Stop Bolt
47. Bolt - Reverse Gear Rocker Arm Assembly 66. Shim - Gear Shift Stop Bolt
48. Reverse Gear Rocker Arm Assembly 67. Ventilation Plug Assembly
49. Bolt - Housing Connecting Bolt 68. Rear Bearing Baffle
50. Bolt - Housing Connecting Bolt 69. Screw - Rear Bearing Baffle
51. Shim Ø10 - Reverse Gear Lock Shaft 70. Bolt - Rear Cover Plate
52. Clutch Rocker Arm Shaft Bushing 71. Rear Cover Plate
53. Clutch Release Rocker Arm 72. Aluminum Gasket 8
54. Bolt - Release Fork and Rocker Arm 73. Bolt - Reverse Gear Idler Gear Shaft
55. Clutch Release Rocker Arm Shaft 74. Rear Housing
56. N/A 75. Bolt - Oil Groove
57. Clutch Release Fork 76. Oil Groove
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Gear Drive Mechanism Exploded View
1. Drive Shaft Oil Seal 16. Shaft Circlip Ø18.5

2. Drive Shaft Front Bearing 17. 4th/5th Gear Synchronizer Slider
3. Drive Shaft 18. 5th Gear Synchronizer Assembly
4. Drive 3rd Gear Assembly 19. 1st/2nd Gear Synchronizer Assembly
5. 3rd/4th/5th Gear Needle Bearing 20. 1st/2nd Gear Synchronizer Slider Assembly
6. 4th/5th Gear Synchronizer Ring 21. Circlip Ø32
7. 3rd/4th Gear Synchronizer Assembly 22. 1st/2nd Gear Synchronizer Outer Cone Ring
8. Circlip Ø29 23. 1st/2nd Gear Synchronizer Intermediate Ring
9. Drive 4th Gear Assembly 24. 1st/2nd Gear Synchronizer Inner Cone Ring
10. 4th Gear Space Ring 25. 1st/2nd Gear Driven Gear Needle Bearing
11. Drive Shaft Rear Bearing 26. Driven 2nd Gear
12. Adjusting Gasket - Drive Shaft Rear Bearing 27. Driven 3rd Gear
13. 3rd Gear Synchronizer Ring 28. 3rd/4th Gear Space Ring
14. 5th Gear Bushing 29. Driven 4th Gear
15. Drive 5th Gear Assembly 30. Output Shaft Bearing
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31. Adjusting Gasket - Output Shaft Rear Bearing 35. Driven 1st Gear
32. Driven 5th Gear 36. Reverse Idler Shaft
33. Nut - Driven Shaft Locking 37. Reverse Idler Assembly
34. Driven Shaft 38. Nylon Washer - Reverse Idler
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Differential Assembly Exploded View
1. Oil Seal - Left Differential 7. Differential Washer

2. Differential Rear Bearing Adjusting Gasket 8. Oil Seal - Right Differential
3. Differential Bearing 9. Circlip
4. Bolt - Differential Housing to Main Reduction Driven 10. Planetary Gear
Gear 11. Planetary Gear Shaft
5. Main Reduction Driven Gear 12. Axle Shaft Gear
6. Differential Housing
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Transmission Accessories Layout
1. Reverse Lamp Switch Assembly 6. Oil Filler Plug

2. Gear Shift Cable Bracket 7. Clip - Reverse Lamp Harness
3. Bolt - Gear Selection/Shift Cable Bracket 8. Drain plug
4. Gear Selection Cable Bracket 9. Neutral Sensor
5. Washer - Oil Plug 10. Bolt - Neutral Sensor
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Transmission Section View
1. Reverse Idler 10. 5th Gear Synchronizer Assembly

2. Reverse Idler Shaft 11. Driven Shaft
3. Drive Shaft 12. Driven Shaft Bearing
4. Drive Shaft Front Bearing 13. Driven 1st Gear
5. Drive 3rd Gear 14. 1st/2nd Gear Synchronizer Assembly and Driven Reverse
6. 3rd/4th Gear Synchronizer Assembly Gear
7. Drive 4th Gear 15. Driven 2nd Gear
8. Drive Shaft Rear Bearing 16. Driven 3rd Gear
9. Drive 5th Gear 17. Driven 4th Gear
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18. Driven 5th Gear 21. Main Reduction Driven Gear
19. Driven Shaft Locking Nut 22. Differential
20. Differential Bearing
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Description housing, the fork shaft is connected with the fork, turn an
Overview appropriate synchronizer to shift to the forward gear, or turn
the sliding idler gear to shift to the reverse gear.
This vehicle is equipped with a 5-speed manual transmission.
The shift lever is located at the centre console of the passenger Reverse Gear Protection and Reverse Lamp Switch
compartment, it provides the driver with 6 choices for variable The reverse gear lock mechanism is used to prevent accidental
speed position, namely, 1st gear, 2nd gear, 3rd gear, 4th gear, shift from the 5th gear to the reverse gear directly. Therefore,
5th gear and reverse gear. The forward gears are engaged by you must ensure that the reverse gear can only be shifted to
the synchronizer, and the reverse gear is driven by the sliding from the neutral position. The reverse lamp plunger switch is
idler gear without a synchronizer. The drive shaft is fitted in fitted on the transmission rear housing.
the differential assembly at the rear of the transmission, and it
Differential
is used to transmit the driving force to the wheel.
Differential with traditional design fixes the main reduction
The transmission housing is made of cast aluminum, and
driven gear to the differential housing by bolts, differential
is connected to the engine cylinder block with bolts. The
housing supports the planetary shaft pin, planetary gear and
transmission input shaft and output shaft are supported by
sun gear. The differential assembly is supported by bearings in
bearings.
the transmission housing.
The transmission housing is equipped with an oil filler plug, Neutral Position Sensor (start/stop system)
which is located at the front lower side of the housing,
The neutral position sensor fixed on the transmission main
and there is an oil drain plug at the rear lower side of
housing is a hall-effect sensor, which is used to identify when
the transmission housing, both of them are sealed with an
the transmission is in neutral position.
aluminum washer. The transmission is filled with lubricating
oil so as to lubricate the internal components in a splashing When the neutral position is selected, if the neutral position
manner. The breather plug is fitted at the rear of the control signal block is aligned with the sensor, the ECM will identify this
seat. The stamped steel closing panel seals the opening signal as the neutral position and the areas within 12° range at
between the transmission and engine cylinder block. both left and right sides are considered as the neutral area.
Gear Shift and Gear Selection If the neutral position signal block is not aligned with the sensor,
Gear selection is realized by manipulating the shift lever fitted the ECM will identify this signal as gear-selected.
at the centre console of the passenger compartment. Both The neutral signal is used for the start/stop of the engine,
cables have one end connected to the bottom of the shift please refer to
lever. The other end is connected to the gear selection rocker Engine Fuel and Control System - Description
arm and gear shift rocker arm fitted outside the transmission for details.
through the connector ring assembly. In the transmission
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Operation
Transmission Assembly
Drivetrain changes the speed and direction of rotation through
the engagement between different gears of the drive shaft and
driven shaft, thereby generating 5 forward gears of different
speed ratio and 1 reverse gear. Except the reverse gear, the
gear wheels of all other gears are constantly engaged.
If the 1st gear is selected, the synchronizer gear ring is

pressed by the synchronizer gear bushing so as to contact
with the conical ring of the corresponding gear selected. In
this way, the speeds of both synchronizer hub and gear are
synchronized. Then, the synchronizer gear bushing protrudes
in the gear wheel through the synchronizer slider assembly When the shift lever is moved to reverse gear position, one
and the protrusion tooth of the synchronizer gear bushing. side of the gear selection/shift taper head turns reverse gear
Ensure that the taper head on the gear selection/shift shaft taper block to let the reverse gear fork drive the reverse
can select the gear accurately and the gears are remained in gear rocker arm assembly, slide the reverse idler gear to
the work position. The torque is transmitted from the engine respectively engage it with the drive shaft reverse gear
to the transmission input shaft through the clutch. Then, the and driven shaft reverse gear (driven shaft reverse gear is
torque is transmitted to the output shaft pinion and main integrated in the 1st/2nd gear synchronizer assembly) so as to
reduction driven gear and then to the drive shaft through the change the rotation direction of the driven shaft.
gear selected. Reverse gear protection
The operation of the 2nd, 3rd, 4th and 5th gear is the same
with that of the 1st gear.
When the reverse gear is selected, the reverse gear tooth

(integrated with the drive shaft) is engaged with the driven shaft
reverse gear tooth and reverse idler gear, hence, the rotation
direction of the driven shaft is changed and the reverse gear is
achieved.
Gear Shift and Gear Selection
When the shift lever is moved to the 1st gear position, the
shift lever will control the gear selection/shift rocker arm
through the cable. The gear selection rocker arm rotates
and moves the gear selection/shift shaft through the torque
of the cable, and the gear selection/shift taper head on the 1. Reverse gear lock plate
gear selection/shift shaft moves along with it and locates at 2. 5th/R gear selection return spring cushion
the groove of the 1st/2nd taper block, at this time, the gear 3. Control seat housing
selection/shift taper head shall be completely separated from
4. Reverse gear lock plate return spring
the groove of the 3rd/4th taper head. One end of the interlock
ring will lock the groove of the 3rd/4th gear, 5th/reverse gear When it is shifted to 5th gear, 5th/R gear selection return
taper block, the other end will be completely separated from spring cushion will push against the reverse gear lock plate to
the groove of the 1st/2nd gear taper block. Then the gear move up together, then the gear selection/shift shaft rotates
shift rocker arm rotates the gear selection/shift shaft through to the left until snapping into the groove of the gear shift
the torque of the cable, and the gear selection/shift taper head positioning cam. When it is shifted directly from 5th gear to R
rotates along with the gear selection/shift shaft, one side of the gear, since 5th/R gear selection return spring cushion is blocked
gear selection/shift taper head turns 1st/2nd gear taper block by the reverse gear lock plate whose motion is restricted by
to drive the operation of the 1st/2nd gear synchronizer so as the control seat housing, so it is impossible to shift to the R
to achieve the gear selection/shift function of the 1st gear. gear. When it is shifted from the neutral position between 5th
gear and R gear to R gear, 5th/R gear selection return spring
The operations of other forward gears are the same as that of
cushion will push against the reverse gear lock plate to move
the 1st gear.
up together, then the gear selection/shift shaft rotates to the
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right until snapping into the groove of the gear shift positioning applied to the whole assembly, and the planetary gear does
cam, so the reverse gear can be shifted to. not rotate. The torque is transmitted to the wheels through
Differential the drive shaft.
The differential allows the wheels to rotate at different speeds When the vehicle takes a turn, the inner wheels will pass a
when the output torques are the same. The pinion integrated shorter distance at a lower speed. Thus it drives the planetary
with the driven shaft is engaged with the main reduction driven gear to rotate, and the outer sun gear offers a higher speed for
gear of the differential assembly. When the driven shaft rotates, outer wheels.
and the wheels swivel straight forward, the torque will be
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Service Procedures
Manual Transmission Assembly
Remove

2. Disconnect the connector of the reverse lamp switch.
3. Pay attention to the mounting position, and disconnect
6. Drain the manual transmission fluid.
Manual Transmission Fluid Drain

7. Remove the left/right drive shaft assembly.

8. Remove the starter motor.
Starter Motor Remove

9. Remove 2 bolts fixing the slave cylinder to the manual
transmission.
4. Loosen the clips fixing the gear selection/shift cable to Caution: Don’t hang the slave cylinder for a long time ，
the bracket. or the hose of slave cylinder will become deformed.

11. Support the manual transmission with hydraulic jack.
12. Remove and discard 3 bolts fixing the bracket of the
manual transmission mount to the manual transmission.
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13. Remove 3 bolts fixing the upper part of the manual 17. Disconnect the manual transmission from the engine,
transmission to the engine. adjust the height of the jack, and lower the manual
transmission to the floor slowly and carefully.
Refit
1. Clean the junction surface of the engine and
transmission.
2. Clean the locating pin and pin hole of the transmission.
4. Fit 3 new bolts fixing the bracket of the manual
transmission mount to the manual transmission, tighten
to （ 45-55））Nm+（（85-95））deg, and check the
torque.
14. Remove 4 bolts fixing the lower part of the manual second use of bolt in the same station, the bolt must be
transmission to the engine. loosened to zero Nm, then tighten it according to specified
5. Fit 1 new bolt fixing the lower tie rod bracket to the
lower tie rod, tighten to （ 81-99））Nm+（（85-95））
deg, and check the torque.
6. Fit 3 new bolts fixing the lower tie rod bracket to

the manual transmission, tighten to （ 45-55））Nm+
15. Remove and discard 1 bolt (1) fixing the lower tie rod
（ 85-95））deg, and check the torque.
bracket to the lower tie rod.
16. Remove and discard 3 bolts (2) fixing the lower tie rod
bracket to the manual transmission.
7. Fit 4 bolts fixing the lower part of the manual
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transmission to the engine, tighten to 75–90Nm, and Gear Selection/Shift Shaft Oil Seal - Manual
check the torque. Remove
8. Fit 3 bolts fixing the upper part of the manual 1. Remove the battery tray.
transmission to the engine, tighten to 75–90Nm, and Battery Tray Remove
check the torque.
2. Ensure that the shift lever is in neutral position.
9. Fit 2 bolts fixing the slave cylinder to the manual
3. Pay attention to the mounting position, and disconnect
torque.
Starter Motor Refit

11. Fit the left/right drive shaft assembly.

12. Fill the manual transmission fluid.
Manual Transmission Fluid Refill

13. Fit 1 bolt fixing the battery negative cable to the
transmission housing, tighten to 15–20Nm, and check
the torque.
14. Connect the clips fixing the gear selection/shift cable 4. Remove 2 bolts fixing the shift rocker arm to the
to the bracket. control cover, remove the gear selection rocker arm
15. Connect 2 cable ball joints of the gear selection/shift and collect the nylon block.
rocker arm of the manual transmission.
16. Connect the connector of the reverse lamp switch.
5. Knock out and discard the spring pin fixing the shift
rocker arm to the gear selection/shift shaft, and remove
the shift rocker arm.
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6. Remove 3 bolts fixing the control cover to the rear Transmission Fluid - Drain and Refill
housing, and remove the control cover assembly. Drain and Refill
7. Loosen the reverse gear lock shaft, and remove the 1. Lift the vehicle, and place a proper container below
reverse gear lock plate and reverse gear stop torsion the transmission.
spring. 2. Clean the area around the oil filler plug, remove the oil
8. Pull out the gear selection/shift shaft assembly. filler plug (a) and discard the sealing gasket.
9. Remove and discard the gear selection/shift shaft oil 3. Clean the area around the oil drain plug, remove the oil
seal. drain plug (b) and discard the sealing gasket.
Refit
1. Knock the new gear selection/shift shaft oil seal in place
with the special tool TPT00066 and hammer.
4. Drain the transmission fluid.

5. Clean the filler and oil drain plug.
6. Place the new sealing gasket on the oil drain plug, fit
2. Insert the gear selection/shift shaft assembly. and tighten the oil drain plug to 25-35Nm, and check
3. Locate the reverse gear stop torsion spring and reverse the torque.
gear lock plate, tighten the reverse gear lock shaft to 7. Fill the transmission fluid into the transmission through
15-22Nm, and check the torque. the filler with appropriate and clean funnel until
4. Shift the gear selection/shift shaft assembly to "N" reaching the specified value.
position. ·Drain and Refill 1.8L
5. Clean the junction surface of the control cover and
·Refill from Dry State 2.0L
rear housing, and apply sealant evenly.
6. Fit 3 bolts fixing the control cover to the rear housing, 8. Place the new sealing gasket on the oil filler plug, fit
tighten to 15-25Nm, and check the torque. and tighten the oil filler plug to 25-35Nm, and check
the torque.
7. Locate the gear shift rocker arm to the gear
selection/shift shaft, and knock in a new spring pin with 9. Lower the vehicle.
T24026.
8. Apply lubricating grease to the inner and outer surfaces
of the nylon block, locate the nylon block to the gear
selection/shift rocker arm, fit 2 bolts fixing the gear
selection rocker arm to the control cover, tighten to
9. Connect the cable ball joint to the gear selection/shift
rocker arm.
10. Check the performance of the gear selection and shift
operation.
Battery Tray Refit
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Reverse Lamp Switch Left Differential Oil Seal
Remove Remove
1. Remove the battery tray. 1. Drain the manual transmission fluid.
Battery Tray Remove Manual Transmission Fluid Drain

2. Disconnect the harness connector from the reverse 2. Remove the left drive shaft assembly.
lamp switch.
3. Remove the reverse lamp switch from the manual
3. Carefully remove and discard the oil seal, be careful not
transmission.
to damage the oil seal groove.
Refit
1. Clean the oil seal groove.
Caution: Oil seals are waxed and must not be lubricated

prior to fitting.
2. Fit the new oil seal with TPT00064.
Refit
1. Clean the junction surface of the reverse lamp switch
and manual transmission.
2. Fit the reverse lamp switch, tighten to 12-18Nm, and
check the torque.
3. Connect the harness connector of the reverse lamp
switch. 3. Fit the left drive shaft assembly.
4. Fit the battery tray. Left Drive Shaft Assembly Refit
Battery Tray Refit 4. Fill the manual transmission fluid.
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Right Differential Oil Seal Manual Transmission Disassembling

Remove Remove
1. Drain the manual transmission fluid. 1. Remove the manual transmission assembly.
Manual Transmission Fluid Drain Manual Transmission Assembly Remove
2. Remove the right drive shaft assembly. 2. Remove the reverse lamp switch.
Reverse Lamp Switch Remove
3. Remove the clutch release bearing.
3. Carefully remove and discard the oil seal, be careful not
to damage the oil seal groove. Clutch Release Bearing Remove
Refit 4. Remove 8 bolts securing the rear cover plate, and

remove the rear cover plate.
1. Clean the oil seal groove.

prior to fitting.
2. Fit the new oil seal with TPT00064.
5. Knock out the circlip at the 5th gear synchronizer gear

hub.
3. Fit the right drive shaft assembly.

4. Fill the manual transmission fluid.
6. Remove the circlip on the reverse gear fork shaft with a

circlip plier.
7. Shift to N gear, and release the 5th gear fork bolt.
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8. Remove the steel ball with a magnetic screwdriver. 13. Remove and discard the output shaft locking nut.
14. Remove the output shaft 5th gear.

9. Shift to R gear, and knock out the spring pin on the 5th
15. Loosen 8 screws securing the rear bearing baffle.
gear fork shaft with the punch and hammer.
16. Remove the rear bearing baffle and rear bearing
adjusting gasket.
17. Loosen 4 bolts securing the gear selection/shift cable
bracket, and remove the gear selection/shift cable
bracket.
18. Loosen the bolts securing the gear selection rocker
arm, remove the gear selection rocker arm and collect
the nylon block.
19. Remove the spring pin fixing the gear shift rocker arm
to the gear selection/shift shaft, and remove the gear
selection rocker arm.
10. Remove the 5th gear fork together with the 5th gear
synchronizer assembly.
11. Remove the input shaft 5th gear and the needle bearing.
12. Shift to 4th gear, and lock the transmission input shaft
with TPT00068.
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20. Remove the remaining 3 bolts fixing the control cover 24. Remove the bolts connecting the front and rear
assembly to the rear housing. housings.
21. Remove the gear shift stop bolt and washer. 25. Knock the platform at the front housing large end face
gently with a nylon hammer, disconnect and remove
the rear and front housings.
26. Loosen 3 self-locking bolts at the side of the front
housing.
27. Remove 3 self-locking springs and 3 steel balls in the
hole.
22. Shift to N gear, and remove the control cover assembly.
28. Loosen 2 bolts at the reverse gear rocker arm assembly.
23. Unscrew the reverse idler gear shaft bolt and gasket.
29. Remove the reverse gear rocker arm assembly, reverse

idler gear assembly, reverse idler gear shaft and washer
respectively.
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30. Shift to 4th gear, and remove the 5th/R gear fork shaft
assembly upward.
31. Hold the output shaft assembly, input shaft assembly,
1st/2nd gear fork shaft assembly and 3rd/4th gear fork
shaft assembly with both hands and hold them up out
of the front housing. When there is any difficulty, knock
the front housing platform to disengage it with a nylon
hammer.
3. Fit the output shaft front bearing outer ring into the
front housing output shaft bearing bore, and knock it in
place gently with a nylon hammer.
4. Fit the differential assembly into the front housing, and
knock it in place gently with a nylon hammer when it
is difficult to fit.
5. Insert the 1st/2nd gear fork shaft assembly into the
output shaft assembly 1st/2nd gear synchronizer,
32. Remove the differential assembly from the front and 3rd/4th gear fork shaft assembly into input shaft
housing. When there is any difficulty, shake the assembly 3rd/4th gear synchronizer. After the two shaft
differential assembly accordingly and knock the bearing assemblies are engaged, hold them with both hands into
gently to disengage it. the front housing, at the same time, please ensure that
Refit the fork shaft is aligned with the fork shaft bore at the
housing and the two shaft bearings are aligned with the
1. Fit the new input shaft oil seal into the front housing
housing bearing bores.
with TPT00066.
6. Shift up the 3rd/4th gear fork shaft assembly to the 4th
gear position, and fit the 5th gear and reverse gear fork
shaft assemblies into the front housing.
7. Fit the steel ball and self-locking spring respectively
into the 3 self-locking holes at the side of the front
housing. Apply thread sealant to the thread, fit the new
self-locking bolt, and tighten to 15–20Nm.
8. Fit the reverse idler gear assembly, reverse idler gear
nylon washer and reverse gear shaft into the front
housing.
9. Fit the reverse gear rocker arm assembly into the
front housing, fit 2 bolts, and tighten to 22–28Nm.
After fitting the reverse gear rocker arm assembly,
2. Fit the new front housing oil seal with TPT00069.
the reverse idler gear must be able to rotate flexibly,
and the bolt hole of the reverse idler gear shaft
perpendicular to the gear faces outward.
10. Measure the distance between the front housing plane
and differential rear bearing outer ring plane as well as
the depth of the rear housing differential rear bearing
bore with the differential adjusting gasket measuring
tool. Select the adjusting gasket with the principle of a
pretightening force of 0.1mm. Apply an appropriate
amount of lubricating grease to the adjusting gasket,
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and then put it into the rear housing differential rear Output shaft rear bearing adjusting gasket (cont'd.)
bearing bore.
11. Clean the junction surface of the housing, apply plane 0.35
sealant to the front housing plane and cover the rear
0.4
housing. Apply thread sealant to the 4 counter-hit bolts
of the front housing, fit 11 connecting bolts and tighten 0.45
to 22–28Nm. 0.5
12. Fit the gear selection/shift cable bracket, screw the 0.6
retaining bolt and tighten to 22–28Nm.
15. Press down the rear bearing baffle, fit 8 new screws
13. Align the reverse idler gear shaft hanging hole with the
and tighten to 13–15Nm.
hole at the rear housing reverse gear. Apply thread
sealant to the thread of the reverse idler gear shaft 16. Turn the 3rd/4th gear fork shaft to shift the transmission
hanging bolt, fit the bolt and aluminum washer, and gear to the 4th gear, and lock the transmission input
tighten to 15–22Nm. shaft with TPT00068.
14. Measure the altitude difference between the input
shaft rear bearing outer ring plane and rear housing
plane, the altitude difference between the output shaft
rear bearing outer ring plane and rear housing plane
with the input shaft rear bearing and output shaft rear
bearing adjusting gasket measuring tool, then select a
new appropriate adjusting gasket. Apply an appropriate
amount of lubricating grease to the adjusting gasket, and
then put it into the input shaft bearing. The selecting
principle is with an clearance of 0 - 0.05mm. If it is
put into the output shaft rear bearing, the selecting
principle is with a pretightening force of 0.1 - 0.15mm.
Input shaft rear bearing adjusting gasket
17. Fit the output shaft 5th gear into the output shaft, and
Thickness: mm fit the 3rd/4th gear needle bearing into the 5th gear
bushing and then fit the input shaft 5th gear, screw the
0.1 new output shaft locking nut to the output shaft, and fit
0.15 the rubber gasket at the engaged part of the 5th driving
and driven gear, and tighten the nuts to 80–100Nm.
0.2
18. Lock the nut with a punch.
0.25
0.3
0.35
0.4
0.45
0.5
Output shaft rear bearing adjusting gasket
Thickness: mm
0.1
0.15
19. Apply an appropriate amount of gear oil to the inner
0.2 tapered surface of the 3rd/4th/5th gear synchronizer
0.25 gear for lubrication, then fit it into the 5th driving gear
joint gear tapered surface; insert the 5th gear fork into
0.3
the 5th gear synchronizer gear bushing, and fit them
1.0 288
together into the 5th gear fork shaft assembly. Manual Transmission Assembly Refit
20. Select an appropriate circlip to snap into the 5th gear
synchronizer gear hub.
21. Press the new spring pin into the pin hole of the 5th
gear fork shaft. And put the steel ball into the hole at
the side of the 5th gear fork, fit the 5th gear fork bolt
22. Fit and secure the new circlip with circlip plier.
23. Apply plane sealant to the control window plane on the
rear housing. Fit the control cover assembly to the rear
housing, and fit the gear selection rocker arm assembly,
screw 5 connecting bolts and tighten to 15–25Nm.
24. Locate the gear shift rocker arm to the gear
selection/shift shaft, and knock in a new spring pin with
T24026.
25. Fit the new rear housing oil seal with TPT00069.
26. Apply plane sealant to the rear plane of the rear

housing. Fit the rear cover plate assembly, screw 8 rear
cover plate bolts and tighten to 8–13Nm.
27. Fit the clutch release bearing.
Clutch Release Bearing Refit
28. Fit the reverse lamp switch.
Reverse Lamp Switch Refit
29. Fit the manual transmission assembly.
1.0 289
Drive Shaft Assembly

Remove
1. Remove the input shaft assembly.
Manual Transmission Disassembling

2. Remove the input shaft rear bearing and 5th gear
bushing together with puller and T32001.
3. Remove the input shaft 4th gear, needle bearing and 4th
gear synchronizer gear ring in sequence.
Refit
1. Knock the input shaft front bearing in place with
TPT00065.
4. Remove the 3rd/4th gear synchronizer gear bushing

and slider assembly.
5. Knock out the synchronizer circlip.
2. Lubricate the needle bearing, fit the input shaft needle

bearing and 3rd gear.
3. Fit the 3rd gear synchronizer gear ring and synchronizer
gear hub.
4. Select an appropriate circlip and knock it in place.
6. Remove the 3rd/4th gear synchronizer gear hub.

7. Remove the input shaft 3rd gear synchronizer gear ring,
3rd gear and needle bearing in sequence.
8. Pull out the input shaft front bearing with puller and
T32001.
5. Fit the 3rd/4th gear synchronizer gear bushing and

slider assembly, ensure that the slider assembly is
correctly located at the slider groove of the gear
bushing and synchronizer gear hub.
1.0 290
Caution: Ensure parts are fitted in correct order and Driven Shaft Assembly
orientation. Remove
6. Lubricate the needle bearing, and fit the input shaft 4th 1. Remove the input shaft assembly.
gear synchronizer gear ring, needle bearing and 4th Manual Transmission Disassembling and Remove
gear in sequence.
2. Remove the input shaft rear bearing and 5th gear
7. Knock the input shaft rear bearing and 5th gear bushing bushing together with puller and T32001.
in place with TPT00065.
3. Remove the input shaft 4th gear, needle bearing and 4th
gear synchronizer gear ring in sequence.
8. Fit the input shaft assembly.
Manual Transmission Disassembling 4. Remove the 3rd/4th gear synchronizer gear bushing
and slider assembly.
5. Knock out the synchronizer circlip.
6. Remove the 3rd/4th gear synchronizer gear hub.

7. Remove the input shaft 3rd gear synchronizer gear ring,
3rd gear and needle bearing in sequence.
8. Pull out the input shaft front bearing with puller and
T32001.
1.0 291
Refit 6. Knock the output shaft 3rd gear in place with

TPT00066.
1. Knock the driven shaft front bearing inner ring in place
with TPT00065.
2. Lubricate the needle bearing, and then fit the output
shaft needle bearing, 1st gear and 1st/2nd gear
synchronizer gear ring in sequence.
3. Fit the 1st/2nd gear synchronizer gear hub, select an
appropriate circlip and knock it in place.
7. Knock the input shaft rear bearing in place with

TPT00065.
4. Fit the synchronizer gear bushing, slider and

synchronizer gear ring, and ensure that the slider
assembly is correctly located at the slider groove of the
gear bushing and synchronizer gear hub.
Caution: Ensure parts are fitted in correct order and
orientation.
5. Lubricate the needle bearing, and then fit the output

shaft needle bearing, 4th gear and 3rd/4th gear space 8. Fit the driven shaft assembly.
ring in sequence. Manual Transmission Disassembling and Refit
1.0 292
Differential Assembly
Remove
1. Remove the differential assembly.
Manual Transmission Disassembling and Remove

2. Pull out the bearings at both ends respectively with a
puller and T32001.
Caution: Support bolt of the drawing die (T32001) cannot

be used to support the propeller shaft hole directly, place
a spacer block between them.
6. Remove the planetary gear shaft, and remove the

axle shaft gear, planetary gear and washers from the
differential housing in sequence.
3. Remove 8 bolts fixing the main reduction driven gear

to the differential housing.
4. Knock down the main reduction driven gear from the
differential housing with a nylon hammer.
Refit
1. Check the differential rear bearing adjusting gasket for
wear or scratch, replace it when necessary.
Differential rear bearing adjusting gasket
Thickness (mm)
0.1
0.15
0.2
0.3
5. Knock out the circlips at both ends of the planetary 0.4
gear shaft.
2. Put the differential washer into the differential housing
cavity.
1.0 293
3. Put the planetary gear and axle shaft gear into the
differential housing cavity in place.
4. Insert the planetary gear shaft and secure the two ends
with circlips.
5. Knock 2 differential bearings in place respectively with

TPT00067.
6. Fit the main reduction driven gear to the differential

housing, and tighten 8 retaining bolts to 110–150Nm.
7. Fit the differential assembly.
Manual Transmission Disassembling and Refit
1.0 294
Number
Replacer, oil T32001 Puller universal

seal, input shaft
TPT00066
and control
cover
Replacer, input
TPT00065 and output shaft
Replacer, Ø5 bearing
T24026
spring pin
Replacer,
TPT00067 differential
Replacer, LH oil bearing
TPT00064
seal, differential
Locking plate,
TPT00068
input shaft
Replacer, RH oil
TPT00069
seal, differential
1.0 295
Transmission Clutch
Clutch
Specifications
Torque
Description Value
Bolt-Clutch Cover to Flywheel 24-26Nm
Bolt - clutch release fork to release shaft 20–25Nm
Bolt - clutch master cylinder to pedal bracket 7–10Nm
Union - clutch master cylinder to pipe 15–19Nm
Bolt - slave cylinder bracket to rear housing 40–50Nm
Union - clutch slave cylinder to pipe 15–19Nm
Bleed plug - clutch slave cylinder 10Nm
1.0 296
Clutch Transmission
Parameter
Model Dry Single Disc, Diaphragm Spring, Hydraulic Booster Clutch
Diameter of driven plate 200mm
Diameter of pressure plate 200mm
Depth of rivet:
·New 1.2mm (above the rivet head)
·Service limit 0.2mm (above the rivet head)
1.0 297
Transmission Clutch

System Layout
Clutch Mechanical System (5MT)
1. Clutch Friction Plate 3. Clutch Release Bearing

2. Clutch Cover 4. Screw
1.0 298
Clutch Transmission
Clutch Master Cylinder and Pipeline Assembly
(5MT)
1. Pin - Clutch Master Cylinder Push Rod 6. Clutch Master Cylinder Low-pressure Hose
2. Clutch Master Cylinder 7. Sleeve - Clutch Master Cylinder Pipeline
3. Clip - Clutch Master Cylinder Push Rod Pin 8. Clutch Master Cylinder Hard Pipe
4. Bolt - Clutch Master Cylinder 9. Clutch Sensor
5. Clutch Master Cylinder Pipeline Assembly 10. Clip - Clutch Hose
1.0 299
Transmission Clutch
Clutch Slave Cylinder and Pipeline Assembly (5MT)
1. Clutch Slave Cylinder Pipeline Assembly 4. Clip

2. Clutch Slave Cylinder 5. Clutch Slave Cylinder Pipeline
3. Bolt - Clutch Slave Cylinder
1.0 300
Clutch Transmission
Description driven plate. There are 3 pull rings on the outer ring of the
Overview pressure plate, which is then connected to the housing through
a spring. The spring is composed of three quenched and
This is a traditional three-piece diaphragm clutch with a
tempered steel sheets. When the clutch pedal is depressed, it
hydraulic clutch release system, which has no need to adjust
will pull the pressure plate away from the driven plate. Clutch
the clutch to compensate clutch wear.
housing is punched by steal plate.
Clutch Hydraulic System
The diaphragm spring is a cast ring with 18 release fingers in
MT model: The master cylinder of the clutch is directly fitted
its inner ring. There are two round support rings fitted on
on the pedal bracket in the passenger compartment, and the
the housing so that the diaphragm spring can rotate between
push rod of the master cylinder piston is fixed to the clutch
them. The diaphragm spring is not directly connected to the
pedal with clips and pins. Two ends of the hydraulic pipeline
pressure plate. When the release bearing applies stress on the
are connected to the master and slave cylinders with threaded
release finger of the diaphragm spring, the diaphragm spring
joints. The clutch salve cylinder fitted on the bracket of the
will rotate around the support ring to leave the pressure plate.
manual transmission housing, release rocker arm, release fork
And meanwhile, the spring of the pressure plate connected to
and release bearing compose a release mechanism, while the
the housing will also be away from the driven plate.
release bearing is supported and fixed by the guide sleeve
Driven Plate
fitted on the transmission input shaft. The clutch pipeline from
the slave cylinder is connected to the pipeline of the master
cylinder through a quick connector. The release fork leans the
release bearing on the diaphragm spring of the clutch during
separation.
Clutch Mechanical System
The clutch cover assembly is fitted on the flywheel and secured
with six bolts.
Clutch Cover Assembly
1. Driven plate body

2. Friction plate
3. Spline hub
4. Torsional shock absorber
The driven plate is fitted between the flywheel and the

pressure plate. Its feature is that the spline hub engages the
spline on the transmission input shaft. The friction plate is
composed of two discs, which are riveted on each side of the
driven plate body. The rivets are fitted in the notches in the
1. Diaphragm spring friction plate as well as that at the other side to protect the
2. Clutch cover pressure plate and flywheel from damage.
3. Pressure plate Clutch Sensor - MT
4. Support ring The clutch sensor is fitted on the master cylinder of the
5. Leaf spring clutch and is powered by the ECM. When the clutch pedal
is depressed, the ECM will receive the clutch release signal;
The clutch cover assembly is composed of the diaphragm
when the clutch pedal is reset, the ECM will receive the clutch
spring, pressure plate and cover. The pressure plate is made
engagement signal.
of cast iron and has a smooth plane machined to connect the
1.0 301
Transmission Clutch
Operation plate, and the pressure plate will overcome the resistance of
Hydraulic Operation the spring, move towards the flywheel and apply pressure on
the driven plate.
MT model: when the clutch pedal is depressed, the piston is
pushed into the master cylinder. The piston drives the fluid The pressure on the driven plate applied by the pressure plate
in the master cylinder to move along the clutch pipeline. This increases the frictional force between the driven plate and
pressure is applied on the piston of the slave cylinder and the flywheel. When the clutch pedal is released, the frictional
piston will move under the action of hydraulic pressure. When force will increase, the rotational motion of flywheel is
the clutch pedal is released, the force on the release finger of transmitted to the driven plate, and then it is transferred to
the diaphragm spring will drive the release bearing. The release the transmission input shaft.
bearing then pushes the piston back to the slave cylinder by the
When the pedal is fully released, the force on the pressure
release fork and release rocker arm, and further drives the fluid
plate applied by the diaphragm spring will press the driven plate
back to the clutch pipeline and master cylinder.
on the flywheel, making no skidding between them.
Mechanical Operation
Clutch Sensor - MT
When the fluid in the slave cylinder drives the piston to
When the clutch pedal is depressed, the clutch sensor is
move, piston's movement pushes the clutch release bearing
activated. ECM uses the signal from the clutch sensor for the
to the release finger of the diaphragm spring by the release
following functions:
rocker arm and release fork and the diaphragm spring
will rotate around the support ring on the pressure plate • Reduce impact during gear the shift
housing. Following the deformation of the diaphragm spring, Reduce impact to prevent sharp increase of engine speed
its pressure on the pressure plate will disappear. Three leaf during the gear shift The reduction of the impact can improve
springs will pull the pressure plate away from the driven plate. drivability in the following aspects:
Disappearance of the pressure on the driven plate applied by • Smoother gear shift
the pressure plate reduces the frictional force between the
• Better exhaust emission control
driven plate and flywheel. The driven plate will skid on the
flywheel and can not transmit the power of the flywheel to • Fuel consumption improvement
the transmission input shaft. The clutch sensor receives a 12V reference voltage from the
When the clutch pedal is released, the pressure on the slave ECM. When the clutch pedal is in the reset position, the clutch
cylinder piston will disappear. Disappearance of this pressure sensor is connected to the ground. When the clutch pedal is
allows the release finger of the diaphragm spring to push the depressed, ECM will receive a 12V signal.
release bearing to skid along the guide sleeve, so that the In case of failure of the clutch sensor, any following signs may
release fork and release rocker arm are driven to push the occur:
slave cylinder piston back to the slave cylinder.
• Shifting impact reduction is not available
The diaphragm spring rotates around the support ring on the
pressure plate housing, and applies pressure on the pressure
1.0 302
Clutch Transmission
Service Procedures
Clutch Assembly
Remove
1. Remove the transmission assembly.
Manual Transmission Assembly Remove

2. Insert into the drive plate pin hole through the engine
block timing hole with the TEN00002 to lock it up.
Thickness of driven plate (compressed) A
New driven plate 7.5mm

Service limit 5.9mm
4. Measure the depth of rivets, replace the driven plate if

the depth is less than the service limit.
Depth of rivet B
New driven plate 1.2mm

3. Gradually loosen and remove 6 bolts fixing the clutch
Service limit 0.2mm
cover assembly to the flywheel.
5. Check the pressure plate for any sign of wear or
damage. Check the drive plate for any sign of overheat
(with color from deep yellow to blue). Replace the
pressure plate if necessary.
Caution: Renew a clutch pressure plate which has been
accidentally dropped.
6. Check the surface levelness of the pressure plate at 4

separate points with a square edge gauge and feeler
gauge. Replace the pressure plate if deformation
exceeds the service limit value.
4. Remove the clutch cover assembly and take out the

driven plate.
5. Remove the release bearing.
Clutch Release Bearing Remove

Check
1. Visually check the diaphragm release finger for wear
or irregular height.
2. Check the clutch driven plate for any sign of wear or
oil contamination. Replace the driven plate if necessary.
Deformation of pressure plate
3. Measure the thickness of the clutch plate, replace the
driven plate if the thickness is less than the service limit. Service limit 0.15mm
7. Check the release bearing for any sign of wear or

damage, replace it if necessary.
8. Clean the pressure plate, flywheel, locating pins and
1.0 303
Transmission Clutch
pin holes. Clutch Release Bearing

9. Check the flywheel for any sign of scratch or other Remove
damages. Replace it if it is scratched or damaged. 1. Remove the transmission assembly.
Refit Manual Transmission Assembly Remove
1. Fit the release bearing. 2. Remove the release fork locating bolt, and remove the
Clutch Release Bearing Refit release fork.
2. Apply molybdenum disulphide grease to the spline of 3. Loosen the clip from the release fork, and remove the
the clutch driven plate. release bearing from the transmission input shaft guide
3. Locate the clutch cover assembly on the flywheel. sleeve.
4. Make sure that the driven plate is aligned with the

centre of the pressure plate.
5. Insert the TEN00040 into the driven plate, and ensure
that the driven plate is aligned with the centre of the
crankshaft hole.
Refit
1. Clean the junction surface of the release bearing and
bearing guide sleeve.
2. Lubricate the bearing movement surface with
molybdenum disulfide grease.
6. Fit 6 bolts fixing the pressure plate to the flywheel and 3. Fit the release bearing to the release fork, and fix it into
tighten manually. the groove of the release fork with clips.
7. Lock the flywheel with TEN00002, tighten the bolts 4. Fit the clutch release rocker arm shaft of the front
fixing the pressure plate to the flywheel gradually to housing, screw 2 release fork bolts and tighten to
24-26Nm in diagonal sequence, and check the torque. 20–25Nm.
Pay attention to lock the pressure plate with bolts. 5. Fit the transmission assembly.
8. Remove the TEN00040. Manual Transmission Assembly Refit
9. Fit the transmission assembly.
Manual Transmission Assembly Refit
1.0 304
Clutch Transmission
Clutch Master Cylinder 3. Connect the low pressure hose of the master cylinder
Remove to the master cylinder, and fasten with clips.
1. Drain the brake fluid from the brake fluid reservoir. 4. Connect the front hard pipe of the master cylinder to
the threaded joint of the master cylinder, and tighten
Caution: Brake fluid will damage paint finished surfaces.
to 15–19Nm.
If spilled, immediately remove fluid and clean area with
water. 5. Fit the driver side lower trim panel assembly.
2. Remove the driver side lower trim panel assembly. Lower Dashboard Trim Panel-Driver
6. Fill brake fluid into reservoir up to the MAX mark.
Lower Dashboard Trim Panel-Driver
7. Bleed the clutch pipeline system.
3. Place a piece of absorbent cloth to absorb the spilled
fluid. Clutch Pipeline System Bleeding
4. Disconnect the clip fixing the low pressure hose of the
master cylinder to the master cylinder connector.
5. Release the thread connection of the master cylinder
front hard pipe and master cylinder.
6. Loosen the clip, and pull out the pin of the master
cylinder push rod.
7. Remove 2 bolts fixing the clutch master cylinder to the
pedal bracket.
8. Remove the clutch master cylinder.

Refit
1. Locate the master cylinder to the pedal bracket, fit the
bolt and tighten to 7–10Nm.
2. Insert the pin connecting the clutch pedal and master
cylinder push rod, and secure with clips.
1.0 305
Transmission Clutch
Clutch Slave Cylinder Clutch Pipeline System Bleeding

Remove Bleeding
1. Drain the brake fluid from the brake fluid reservoir. Bleed the air that enters into the hydraulic system when
disconnecting the pipeline for repair. During the air bleeding,
the brake fluid in the brake fluid reservoir must be maintained
at or above the MIN mark.
water.
Warning: Do not allow brake fluid to come into contact
2. Disconnect the slave cylinder from the rear clutch
with eyes or skin.
pipeline.
3. Loosen 2 bolts fixing the slave cylinder to the manual Caution: Do not reuse the brake fluid drained from the
transmission. clutch pipeline system.
1. Lift the vehicle on the lifting platform.

2. Unscrew the bleed plug dust cover from the cylinder
slave cylinder, and fit the hose to the bleed plug.
Immerse the free end of the hose into the glass
container half-filled with fresh brake fluid.
4. Remove the clutch slave cylinder.

Refit
1. Support the seat hole of the release rocker arm with
the end of the slave cylinder push rod.
2. Fix the slave cylinder to the manual transmission, and
tighten the bolt to 40–50Nm. 3. Press the clutch pedal to the maximum stroke and hold,
so as to ensure the maximum system pressure.
3. Connect the slave cylinder and rear clutch pipeline, and
tighten to 15–19Nm. 4. Loosen the bleed plug, remove the air in the fluid, the
system pressure will drop at this time.
5. Tighten the bleed plug firstly to avoid the suck-back
5. Bleed the clutch pipeline system.
of the fluid.
Clutch Pipeline System Bleeding
6. At last, release the clutch pedal to the maximum stoke
steadily, allowing the master cylinder piston to return
to its original position without any external force.
Supplement with sufficient brake fluid.
7. Repeat the operation in the above sequence for several
times until the brake fluid without any air flows into the
container, then fix the clutch pedal to the maximum
stroke, tighten the bleed plug to 10Nm.
8. Remove the hose from the bleed plug, and fit the bleed
plug dust cover.
1.0 306
Clutch Transmission
Clutch Position Sensor
Remove
2. Remove driver’s lower dashboard trim panel assembly.
3. Access the clutch master cylinder.
4. Disconnect electrical connection.
5. Prise switch from holder, remove switch.
Refit
1. Position switch to master cylinder.
2. Secure in retaining clip.
3. Reconnect electrical connector.
4. Refit driver’s lower dashboard trim panel.

1.0 307
Transmission Clutch
Special Tools
Number
Holding pin
TEN00002
flywheel timing
Aligner, clutch
TEN00040
plate
1.0 308
HVAC Structure HVAC System
HVAC Structure
Specifications
Torque
Description Value
Bolt-Air conditioner compressor to engine 19-25Nm
Bolt-Air conditioner pipe to compressor 19-25Nm
Nut-evaporator/compressor pipe A to 7-10Nm
evaporator/compressor pipe B
Bolt-Air conditioner pipe to condenser 19-25Nm
Bolt-Air conditioner pipe to expansion valve 19-25Nm
Bolt-Condenser to Rad 5-7Nm
Nut/Bolt-Air conditioner case assembly to body 7-10Nm
Nut-Air conditioner case assembly to body 5-7Nm
Bolt-Expansion valve to evaporator 5–7Nm
Bolt-IPK duct to IPK 1.4–1.8Nm
Parameters
Parameter - 1.5L
Type of Refrigerant R134a

Volume of Refrigerant 510±20g
Compressor:
Displacement: 140cm³/r
Speed
∙Minimum Speed 600r/min
∙Maximum Speed 9200r/min
Lubricating Oil: SP10
Refill Amount (new) 140±10ml
Evaporator Temperature Sensor:
∙Compressor ON ≥3℃
∙Compressor OFF Off immediately @ ≤1℃
Pressure Protection:
∙High Pressure Protection ON When pressure ≥ 3.14 Mpa, the switch disconnects.
∙Low Pressure Protection ON When pressure ≤ 0.196 Mpa, the switch disconnects.
Amount of lubricating oil for replacement of A/C system components - 1.5L (parameters including oil
recovered):
Total amount of lubricating oil 140±10ml

Compressor replacement Remaining lubricating oil in the original compressor
Condenser replacement 30ml
Evaporator replacement 40ml
Replace one or more pipes 30ml
Note: 1. Large leak, cracked hose, impact or open relief valve can cause sudden loss of the refrigerant. Refrigerant leak
or slow leak will not cause this degree of fluid loss. When replacing components which cause a huge loss of refrigerant,
add an appropriate amount of fluid to specific components. 2. If the lost fluid of the components exceeds the specified
value, add as per the amount of loss.
1.0 309
HVAC System HVAC Structure

System Layout
Heating and Ventilation Components
1. Side Face Air Outlet - Left 5. Footwell Air Outlet - Right

2. Internal Circulation Inlet 6. Side Face Air Outlet - Right
3. Central Face Air Outlet - Left 7. Central Face Air Outlet - Right
4. Footwell Air Outlet - Left 8. External Circulation Inlet
1.0 310
A/C Box Assembly
1. Recirculated Damper Actuator 5. A/C Drain Pipe

2. Mode Damper Actuator 6. Blower Speed Regulation Resistor
3. A/C Box 7. Blower Assembly
4. Temperature Damper Actuator 8. A/C Filter
1.0 311
A/C Cooling System
1. Evaporator and Thermostatic Expansion Valve (TXV) 5. A/C Pipeline

2. A/C Pressure Switch 6. Condenser
3. High Pressure Service Connector 7. Compressor
4. Low Pressure Service Connector
1.0 312
Description the windshield and front side window are integrated in the
Overview instrument panel.
The heating, ventilation and air conditioning system controls 4 air outlet assemblies in the instrument panel allow occupants
the vehicle interior temperature and air distribution. The to control the flow and direction of air distribution to face.
system contains the A/C box assembly (A/C filter, heater
The front seat footwell air outlet is fitted in the port beside
assembly and evaporator box assembly), air duct, refrigerant
the A/C box assembly.
pipe, controller and control panel. The air outlets are
integrated in the luggage compartment. Fresh air flows into A/C Box Assembly
the A/C box assembly through the A/C filter assembly, and The A/C box assembly heats and distributes the fresh air or
flows through the entire system by the blower operation. circulating air according to the mode selected on the control
According to the setting on the control panel, the heated or panel. The A/C box assembly is below the instrument panel.
cooled air is supplied to the air outlets of "face", "footwell" The A/C box includes the blower, A/C air filter, heater core,
and "defrost" via the air distribution duct. evaporator core and control damper. The passage in the A/C
According to models, the vehicle will be provided with one of box assembly introduces air into the A/C box and divides it into
the two air conditioning systems, i.e. MTC or ETC: three parts, air is delivered to the air outlets for the "face",
"footwell" and "defrost". A fresh recirculating air damper is
• In the MTC system, functions such as the air circulation,
mounted on the A/C box assembly housing, which adjusts the
air temperature, air distribution and blower speeds
vehicle interior air or outside air and takes it as the circulating
are selected manually, and the air temperature and air
air. The drain outlet at the bottom of the box body directs
distribution are operated and controlled with cables.
condensed water from the box body to the lower side of the
• In the ETC system, functions such as air recirculation, air
vehicle.
temperature, air distribution and blower speeds, etc. are
selected manually. The damper is in the A/C box, which controls the inlet air,
outlet air temperature and position of the outlet air.
Ventilation Components
Recirculation damper: the damper actuator drives the
Ventilation components: A/C filter, A/C air duct, A/C box
recirculation damper to open and close the fresh and
(housing, damper, damper actuator, blower) and air outlet.
recirculating air inlets so as to control the inlet air.
A/C Air Filter
Temperature damper: the damper actuator or the damper
The A/C air filter is used to improve the quality of the fresh air cable drives the temperature damper to vary the mixing ratio
supplied to the interior of the vehicle and filter fine particles of the cold/warm air so as to control the temperature of the
such as dust and pollen, etc. A/C outlet air.
The A/C air filter is fitted on the A/C box assembly, it shall be Mode damper: the damper actuator or the damper cable
checked on a regular basis, and replace when necessary. drives the mode damper to vary the air passing through the
A/C Air Duct A/C box and air duct so as to meet the user's different needs,
such as, face, footwell, windshield, etc.
Blower
The blower is the power source of the whole ventilation

system. Use the blower to drive interior air circulation or
introduce fresh air into the vehicle.
The blower is in the A/C box assembly. Control of the blower

air volume can be realized by using the button on the control
panel to control the blower speed control resistor of the A/C
box assembly.
Body Relief Valve
The body relief valve allows the warm air and vent air to go
through the passenger compartment freely.
The face air outlet in the instrument panel is fitted with an
individual air distribution duct. Air distribution ducts for The body relief valve is located at both sides of the luggage
compartment, which allows air in the passenger compartment
to be discharged to the covered area between the body and
1.0 313
rear bumper. The air vent is an effective check valve and an aluminum unidirectional flat-tube heat exchanger. Two
each vent contains grille covered by soft rubber damper. The aluminum tubes are fitted on the heater core, they extend
damper can open or close automatically according to the through the engine compartment wall and connect the heater
pressure difference between the passenger compartment and core assembly to the engine coolant circulation system. When
the external environment. the engine works, coolant constantly flows through the heater
Heater Components core under the action of coolant pump.
It provides heat for the A/C heating.

Heater Core
The heater core heats the air supplied to each distribution

outlet. The heater core fitted in the A/C box assembly is
1.0 314
Cooling System
A/C System Schematic
A = Liquid Refrigerant; B = Gas Refrigerant

1. Evaporator 6. Filter
2. TXV 7. Desiccant
3. A/C Pressure Switch 8. Condenser
4. High-pressure Service Connector 9. A/C Compressor
5. Cooling Fan 10. Low-pressure Service Connector
The cooling system transfers heat from the vehicle to the the pressure and temperature of the refrigerant increase as
outside atmosphere and provides the heater assembly with it passes through the compressor, then it releases heat to
dehumidified cool air. The system comprises a compressor, a the atmosphere via the condenser and changes from high
condenser, TXV, A/C pipeline and an evaporator. The system temperature vapour to moderate-high temperature liquid.
is a closed loop system which applies R134a refrigerant as
Compressor
the heat transfer medium. Add A/C oil to the refrigerant to
lubricate the internal components of the compressor.
To accomplish the transfer of heat, the refrigerant is

circulated around the system where it passes through two
pressure/temperature modes. In each pressure/temperature
mode, the state of the refrigerant changes. During this process,
the refrigerant absorbs and releases maximum heat. The low
pressure/temperature mode starts with the TXV, through the
evaporator to the compressor, in the TXV, the refrigerant
decreases in pressure and temperature, then it changes from
moderate temperature liquid to low temperature vapour in
the evaporator before absorbing heat from the ambient air of
the evaporator. The high pressure/temperature mode starts
with the compressor, through the condenser to the TXV, 1. Air intake port
1.0 315
2. Relief valve Thermostatic Expansion Valve (TXV)

3. Exhaust port TXV TXV and Evaporator
4. Electromagnetic clutch connector
The compressor circulates the refrigerant by compressing the

low pressure/low temperature vapour from the evaporator
and converting it into the high pressure/high temperature
vapour to the condenser.
The compressor under the mounting bracket of the

transmission is driven by a high-pressure motor.
With fixed displacement, the compressor provides the A/C

system with required amount of refrigerant by the change of
high-pressure motor speed.
Condenser
1. Evaporator
2. O-ring
3. TXV
4. Bolt
The TXV regulates the flow of the refrigerant and matches the
refrigerant flow with the heat load of the air passing through
the evaporator core. The TXV is fitted on the inlet and outlet
ports of the evaporator. The valve consists of an aluminum
housing containing inlet and outlet passages. A metering
valve is fitted in the inlet passage and the metering valve is
controlled by a temperature sensitive tube connected to a
diaphragm. The top of the diaphragm is filled with refrigerant
1. Condenser
and senses evaporator outlet pressure and the tube senses
2. Air intake port
evaporator outlet temperature. By regulating the opening of
3. Liquid outlet port the thermostatic expansion valve, the force can be balanced,
The condenser transfers the refrigerant heat into the ambient this keeps a proper degree of superheat for the evaporator
air and changes the refrigerant vapour from the compressor outlet and balances the refrigerant flow and the thermal load
into liquid. The condenser also removes moisture and of the air.
solid impurities from the refrigerant with its drying module Thermostatic Expansion Valve
and functions as a reservoir for liquid refrigerant so as to
accommodate changes of heat load in the evaporator.
With the impact effect and/or cooling fan, the air passing
through the heat exchanger absorbs heat from the refrigerant
and changes the refrigerant from a vapour to liquid. The
condenser cools and liquifies the refrigerant before it enters
the modulator. In the modulator, most of the remaining gas in
the refrigerant is separated. The refrigerant uses the desiccant
and filter to remove moisture and particles before entering
into the secondary cooler. The refrigerant is further cooled
as it flows through the secondary cooler, this results in the
refrigerant from the condenser outlet to the evaporator is
almost 100% converted into liquid.
1. Membrane
2. Housing
3. Metering valve
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4. Inlet passage to evaporator Evaporator
5. Outlet passage from evaporator The evaporator is in the air inlet of the heater assembly and
6. Thermo-sensitive tube absorbs heat from the exterior or recirculated inlet air. Low
pressure and low temperature refrigerant changes from liquid
The liquid coolant flows from the metering valve to the
to vapour in the evaporator, absorbing large quantities of heat
evaporator. The metering valve reduces the pressure and
during this process.
temperature of the refrigerant, changes the solid stream of
refrigerant into a fine spray and improves the evaporation A/C Pipeline
effect. As the refrigerant passes through the evaporator, Aluminum A/C pipelines connect the system components
it absorbs heat from the ambient air flowing through the together with O-rings between the connections to ensure a
evaporator core. The increase of the temperature causes the secure seal. To maintain a similar flow velocity in the system,
refrigerant to vaporize and increases its pressure. the diameter of the refrigerant lines may vary so as to suit
the two pressure/temperature modes. The pipelines with
The temperature and pressure of the refrigerant from the
larger diameters are fitted in the low pressure/temperature
evaporator drive the diaphragm and temperature sensitive
mode and those with smaller diameters are fitted in the high
tube to move and regulate the metering valve opening,
pressure/temperature mode, and integrate the refrigerant
thereby controlling the volume of the refrigerant flowing
refill port into the A/C pipelines so as to facilitate the system
through the evaporator. The warmer the air flowing through
service.
the evaporator core, the more heat available to evaporate
refrigerant, and this allows more refrigerant to pass through
the metering valve.
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Service Procedures Drain

Refrigerant Recovery and Refill 1. Check if the high-pressure side and low-pressure side
Refrigerant Recovery hoses are connected to the A/C system. Open the
1. Connect the high-pressure side hose with a quick high/low-pressure side valves on the refilling station
disconnection interface to the high-pressure service control panel.
side connector of the A/C system. 2. Open the gas and liquid valves on the refrigerant
Tip: Use refrigerant tank designed only for service reservoir.
station. Overcharging restraint system is designed based Caution: The evacuating procedure must be carried out
on this kind of refrigerant tank. The tank valve is also before recharging process.
designed for the restraint system.
3. Start the vacuum pump and start the drain process.
2. Open the interface valve. In the process of recirculation, non-condensable gases
3. Connect the low-pressure side hose with a quick (mostly air) will be automatically exhausted from the
disconnection interface to the low-pressure service reservoir. A sound of pressure release may be heard.
side connector of the A/C system. 4. Check the system for leak. For information about the
4. Open the interface valve. refilling station, refer to the manufacturer's instructions
5. Check the high-pressure side and low-pressure side for use.
gauges on the refilling station control panel, and ensure A/C System Lubricating Oil Refill
there is pressure in the A/C. If there is no pressure, At this time, the lubricating oil discharged from the A/C system
there is recoverable refrigerant in the system. during recovery must be supplemented.
6. Open the high-pressure side and low-pressure side
Note:
valves.
• Always keep the lubricating oil bottle cap tight to prevent
7. Open the gas and liquid valves on the refrigerant
moisture or contaminants from entering the lubricating
reservoir.
oil.
8. Drain refrigerant in the oil separator.
• This operation requires a vacuum A/C system. It is
9. Close the drain valve. forbidden to open the lubricating oil filling valve when
10. Connect the refilling station to the appropriate power the A/C system is at positive pressure. This will result in
socket. backflow of lubricating oil through the bottle air vent.
11. Connect the main power switch. • An oil level lower than the suction pipe is prohibited
Caution: Reuse the recycled lubrication is prohibited. The when refilling or supplementing lubricating oil; otherwise,
recycled lubrication will damage the equipment. air will enter the A/C system.
Caution: Part of A/C lubrication (PAG) could be recycled 1. Use the special polyether type lubricating oil (contained
together with refrigerant but service station can separate in graduated bottle) for R-134a system.
lubrication from refrigerant to calculate the quantity of 2. For information about the refilling station, refer to the
lubrication. manufacturer's instructions for use. Add an appropriate
amount of lubricating oil to the A/C system.
12. Start the recycle process. For information about the
refilling station, refer to the manufacturer's instructions 3. When the oil refilled reaches the required point, close
for use. the valve.
13. Wait for 5min before checking the low-pressure side Refill
gauge on the control panel. If the A/C system is capable Refrigerant Refill
of keeping vacuum, the recovery is completed. 1. Close the low-pressure side valve on the control panel.
Warning: If warning indicator illuminates, it means the 2. Open the high-pressure side valve on the control panel.
tank is overfull and service station will stop, install a new 3. For information about the refilling station, refer to the
empty tank to continue this process. The different type manufacturer's instructions for use.
of tank is prohibited using.
4. Fill refrigerant of the required amount into the A/C, and
14. If the pressure at the low-pressure side starts to ensure the unit of measurement is correct, for example,
rise from 0, there remains refrigerant in the system. kg or lb.
Recover the residual refrigerant. Repeat this step until
5. Start refill.
the system can keep vacuum for 2 minutes.
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Refrigerant Refill Completion Compressor - 1.5L
Refrigerant Refill Completion Remove
1. Close the high-pressure side valve on the refilling station 1. Recycle the A/C system refrigerant.
control panel. Both valves shall be closed. A/C System Refrigerant Recycle
2. Start the vehicle and A/C system. 2. Disconnect the battery negative.
3. Keep the engine running until the readings on the 3. Remove the bottom deflector.
high-pressure side pressure gauge and the low-pressure
side pressure gauge are stable. Bottom Deflector Remove
4. Compare the readings with the system specifications. 4. Remove the engine auxiliary drive belt.
5. Check the outlet temperature of the evaporator, and Engine Auxiliary Drive Belt Remove
ensure that the A/C system operation conforms to the 5. Disconnect the harness connector (1).
system specifications.
6. Remove 2 bolts (3) fixing the A/C pipeline to the
6. Keep the A/C running. compressor, disconnect the pipeline, and discard the
7. Close the high-pressure side interface valve. seal ring.
8. Disconnect the high-pressure side hose from the vehicle. Caution: Always fit plugs to open connections to prevent
9. Open the low-pressure side valve on the control panel. contamination.
The system will quickly suck in refrigerant from two
7. Remove 4 bolts (2) fixing the A/C compressor to the
hoses through the low-pressure side hose.
engine, and remove the compressor assembly.
10. Close the low-pressure side interface valve.
11. Disconnect the low-pressure side hose from the vehicle.
Refrigerant Refill Failure
Refrigerant Refill Failure
Sometimes, the refrigerant is not completely refilled into the
A/C system. There are two reasons:
1. The pressure of the refrigerant reservoir in the refilling
station is close to that of the A/C system,
• which leads to slow oil delivery.
• For information about the refilling station, refer to the

manufacturer's instructions for use.
2. There is not enough refrigerant in the refrigerant reservoir Refit

of the refilling station.
1. Fix the compressor to the engine, fit 4 bolts, tighten to
• Therefore, part of the refrigerant refilled must be 19-25Nm, and check the torque.
recovered from the vehicle, then drain the A/C system 2. Remove the plug, fit the new seal ring to the A/C
before refilling. pipeline, and apply clean compressor oil.
• For information about the refilling station, refer to the 3. Fix the A/C pipeline to the compressor, fit 2 bolts,
manufacturer's instructions for use. tighten to 19-25Nm, and check the torque.
4. Connect the harness connector of the compressor.
5. Fit the engine auxiliary drive belt.
Engine Auxiliary Drive Belt Refit


8. Fill the A/C system refrigerant.
A/C System Refrigerant Refill
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Compressor Breather Hose - 1.5L 3. Remove the plug, fit the new seal ring to the A/C
Remove pipeline, and apply clean compressor oil.
1. Recycle the A/C system refrigerant. 4. Fix the compressor breather hose to the compressor,
A/C System Refrigerant Recycle fit 1 bolt, tighten to 19-25Nm, and check the torque.
2. Disconnect the battery negative. 5. Fit the bottom deflector.
3. Remove the bottom deflector. Bottom Deflector Refit

Bottom Deflector Remove 6. Connect the battery negative.
4. Remove 1 bolt fixing the compressor breather hose to 7. Fill the A/C system refrigerant.
the compressor, disconnect the pipeline, and discard A/C System Refrigerant Refill
the seal ring.
contamination.
5. Remove the bolt connecting the compressor breather

hose and the A/C hard pipe assembly, disconnect the
pipeline, and discard the seal ring.
contamination.
6. Remove the compressor breather hose.

Refit
1. Remove the plug, fit the new seal ring to the A/C
pipeline, and apply clean compressor oil.
2. Connect the compressor breather hose to the A/C
hard pipe assembly, fit 1 bolt, tighten to 7-10Nm, and
check the torque.
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Compressor Exhaust Hose - 1.5L 2. Fix the compressor exhaust hose to the condenser, fit
Remove 1 bolt, tighten to 19-25Nm, and check the torque.
1. Recycle the A/C system refrigerant. 3. Remove the plug, fit the new seal ring to the A/C
A/C System Refrigerant Recycle
4. Fix the compressor exhaust hose to the compressor, fit
1 bolt, tighten to 19-25Nm, and check the torque.
5. Fit the front bumper assembly.
Front Bumper Assembly Refit
4. Remove the front bumper assembly.
Front Bumper Assembly Remove
5. Remove 1 bolt fixing the compressor exhaust hose to
the compressor, disconnect the pipeline, and discard
the seal ring. 8. Fill the A/C system refrigerant.
Caution: Always fit plugs to open connections to prevent A/C System Refrigerant Refill
contamination.
6. Remove 1 bolt fixing the compressor exhaust hose to

the condenser, disconnect the pipeline, and discard the
seal ring.
contamination.
7. Remove the compressor exhaust hose.

Refit
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A/C Hard Pipe Assembly - 1.5L seal ring.

Remove Caution: Always fit plugs to open connections to prevent
1. Recycle the A/C system refrigerant. contamination.
A/C System Refrigerant Recycle
4. Remove 1 nut securing the clamp of the power steering
reservoir, and remove the power steering reservoir
without removing the fluid.
5. Disconnect the harness connector of the A/C pressure
switch.
6. Remove 1 bolt fixing the A/C hard pipe assembly to the
thermostatic expansion valve, disconnect the pipeline,
and discard the seal ring.
9. Loosen the clip securing the A/C hard pipe assembly,
and remove the A/C hard pipe assembly.
contamination.
Refit
1. Fix the A/C hard pipe assembly to the body and secure
with clips.
3. Fix the compressor hard pipe assembly to the
condenser, fit 1 bolt, tighten to 19-25Nm, and check
the torque.
5. Connect the compressor breather hose to the A/C
hard pipe assembly, fit 1 bolt, tighten to 7-10Nm, and
check the torque.
7. Remove the bolt connecting the compressor breather
hose and the A/C hard pipe assembly, disconnect the 6. Remove the plug, fit the new seal ring to the A/C
pipeline, and discard the seal ring. pipeline, and apply clean compressor oil.
7. Fix the A/C hard pipe assembly to the thermostatic
expansion valve, fit 1 bolt, tighten to 19-25Nm, and
contamination.
check the torque.
8. Connect the harness connector of the A/C pressure
switch.
9. Fix the power steering reservoir to the bracket, fit the
nuts securing the clamp of the power steering reservoir
and tighten them up.

8. Remove 1 bolt fixing the A/C hard pipe assembly to

the condenser, disconnect the pipeline, and discard the
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Pressure Switch Condenser
Remove Remove
1. Recycle the A/C system refrigerant. 1. Recycle the A/C system refrigerant.
A/C System Refrigerant Recycle A/C System Refrigerant Recycle

3. Disconnect the harness connector of the A/C pressure 3. Remove the front-end module assembly.
switch.
Front-end Module Assembly Remove
4. Remove 1 bolt (2) fixing the A/C pipeline to the
condenser, disconnect the pipeline, and discard the
seal ring.

contamination.
5. Remove 2 bolts (1) fixing the condenser to the radiator.

6. Loosen the clip (3), and remove the condenser
assembly.
4. Remove the A/C pressure switch from the A/C

high-pressure pipe and discard the O-ring.

contamination.
Refit
1. Lubricate the new O-ring with clean A/C lubricating oil.
2. Fit the O-ring to the A/C pressure switch.
3. Fit and secure the A/C pressure switch to the A/C
high-pressure pipe.
Refit
4. Connect the connector of the A/C pressure switch.
1. Fix the condenser to the radiator with clips, fit 2 bolts,
5. Connect the battery negative. tighten to 5-7Nm, and check the torque.
6. Fill the A/C system refrigerant. 2. Remove the plug, fit the new seal ring to the A/C
A/C System Refrigerant Refill pipeline, and apply clean compressor oil.
3. Fix the A/C pipeline to the condenser, fit 1 bolt, tighten
4. Fit the front-end module assembly.
Front-end Module Assembly Refit
1.0 323
A/C Box Assembly

Remove
2. Recover the A/C system refrigerant.
A/C Refrigerant Recovery
Coolant Drain

5. Remove 1 nut fixing the A/C hard pipe assembly to the
expansion valve, disconnect the pipeline, and discard
8. Remove the instrument panel beam assembly.
the seal ring.
Instrument Panel Beam Assembly Remove
contamination. 9. Pull the A/C drain pipe out of the door.
10. Loosen the harness clips around the A/C box and
disconnect the harness connector.
11. Remove 2 bolts (1) and 3 nuts (2) fixing the A/C box
assembly to the body.
6. Loosen clips of water pipe and disconnect water pipe.
12. Remove the A/C box assembly.

Refit
1. Fix the A/C box to the body, fit 2 bolts and 3 nuts,
2. Fit the harness clip, and connect the harness connector.
3. Fit the A/C drain pipe.
4. Fit the instrument panel beam assembly.
Instrument Panel Beam Assembly Refit
7. Remove 3 nuts fixing the A/C box assembly to the 5. Fix the A/C box assembly to the front firewall, fit 3
front firewall. nuts, tighten to 5-7Nm, and check the torque.
6. Fit the water pipe clips and connect the water pipe.
7. Remove the plug, fit a new seal ring to the A/C pipeline,
and apply clean compressor oil to it.
8. Fix the A/C hard pipe assembly to the expansion valve,
fit 1 bolt, tighten to 19-25Nm, and check the torque.
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Air Filter Assembly Refit Evaporator Core
10. Refill the coolant. Remove
Coolant Refill
11. Refill the A/C system refrigerant. A/C Box Assembly Remove
2. Remove the expansion valve.
12. Connect the battery negative. Expansion Valve Remove
13. Perform a self-learning for the A/C servo motor. 3. Remove the heater core.
a. Connect the scan tool to the vehicle and access the Heater Core Remove
VDS. 4. Remove the screw and clip fixing the vent box to the
heater, and remove the vent box.
b. Select "Fast Channel - Learning Value/Adjustment -
A/C Servo Motor Self-learning", and operate as per 5. Remove the evaporator temperature sensor.
the instructions on the screen. 6. Remove the clip and screw securing the heater cover,
and disassemble the heater box.
7. Remove the evaporator core.
Refit
1. Fit the evaporator to the heater assembly.
2. Secure the heater cover with clips, fit and tighten the
screw.
3. Fit the evaporator temperature sensor.
4. Fix the vent box to the heater box, secure with clips,
fit and tighten the screw.
5. Fit the heater core.
Heater Core Refit
6. Fit the expansion valve.
Expansion Valve Refit

7. Fit the A/C box assembly.
A/C Box Assembly Refit
1.0 325
Expansion Valve check the torque.

Remove 5. Connect the battery negative.
1. Recycle the A/C system refrigerant. 6. Fill the A/C system refrigerant.
A/C System Refrigerant Recycle A/C System Refrigerant Refill
3. Remove 1 bolt fixing the A/C hard pipe assembly to the
thermostatic expansion valve, disconnect the pipeline,
and discard the seal ring.
contamination.
4. Remove 2 screws fixing the expansion valve to the A/C

box, remove the expansion valve, and discard the seal
ring.
contamination.
Refit
2. Fix the expansion valve to the A/C box, fit 2 screws,
4. Fix the A/C hard pipe assembly to the thermostatic
expansion valve, fit 1 bolt, tighten to 19-25Nm, and
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Blower Motor Assembly Blower Speed Regulation Resistor
Remove Remove
2. Disconnect the harness connector of the blower. 2. Disconnect the harness connector of the blower speed
3. Remove 3 screws fixing the blower assembly to the regulation resistor.
A/C box. 3. Remove 2 screws fixing the blower speed regulation
resistor to the A/C box.
4. Remove the blower assembly.

Refit 4. Remove the blower speed regulation resistor.
1. Fix the blower to the A/C box, fit and tighten 3 screws. Refit
2. Connect the harness connector of the blower. 1. Fix the blower speed regulation resistor to the A/C
box, fit and tighten 2 screws.
2. Connect the harness connector of the blower speed
regulation resistor.
1.0 327
A/C Filter Cover A/C Filter Element

Remove Remove
1. Remove the glove box assembly. 1. Remove the A/C filter cover.
Glove Box Assembly Remove A/C Filter Cover Remove

2. Loosen the clip, and remove the A/C filter cover. 2. Remove the A/C filter element.
Refit
1. Fit the A/C filter element.
2. Fit the A/C filter cover.
A/C Filter Cover Refit
S3210706
Refit
1. Fit the A/C filter cover and secure with clips.
2. Fit the glove box assembly.
Glove Box Assembly Refit
1.0 328
A/C Drain Pipe Heater Core Assembly
Remove Remove
1. Pry off the clip and remove the passenger side heater 1. Remove the A/C box assembly.
closing plate.
A/C Box Assembly Remove
2. Disconnect the pipeline from the body and A/C box.
2. Remove the sealing gasket of the pipeline.
3. Remove the A/C drain pipe.
3. Remove 2 screws fixing the water pipe clamp of the
Refit heater core to the A/C box, and remove the pipe clamp.
1. Fix the A/C pipe to the body and A/C box.
2. Fit the A/C drain pipe.
3. Fit the passenger side heater closing plate and secure
with clips.
4. Remove 3 screws fixing the heater core shroud to the

A/C box, and remove the shroud.
S3210900
5. Remove the heater core assembly.

Refit
1. Clip the heater core into the A/C box.
2. Fix the heater core shroud to the A/C box, fit and
tighten 3 screws.
3. Fix the water pipe clamp of the heater core to the A/C
box, fit and tighten 2 screws.
4. Fit the sealing gasket of the pipeline.
1.0 329
Instrument Panel Air Duct Body Relief Valve - Left

Remove Remove
1. Remove the instrument panel assembly. 1. Remove the rear bumper assembly.
Instrument Panel Assembly Remove Rear Bumper Assembly Remove

2. Remove 9 screws fixing the instrument panel air duct 2. Pry off the clip, and remove the body relief valve (left).
to the instrument panel.
Refit
3. Remove the instrument panel air duct. 1. Fit the body relief valve - left.
Refit 2. Fit the rear bumper assembly.
1. Fix the instrument panel air duct to the instrument
Rear Bumper Assembly Refit
panel, fit 9 screws, tighten to 1.4–1.8Nm, and check
the torque.
2. Fit the instrument panel assembly.
Instrument Panel Assembly Refit
1.0 330
Body Relief Valve - Right
Remove
1. Remove the rear bumper assembly.
Rear Bumper Assembly Remove

2. Pry off the clip, and remove the body relief valve (right).
Refit
1. Fit the body relief valve - right.
2. Fit the rear bumper assembly.
Rear Bumper Assembly Refit
1.0 331
HVAC System HVAC-ETC
HVAC-ETC
Specifications
Torque
Description Value
Bolt-Controller to cross member dash 2-4Nm
Screw-A/C control panel to IPK 2–3Nm
Bolt-Distribution flap servo motor to heater case 0.6–1Nm
Bolt-Blend flap servo motor to heater case 0.6–1Nm
1.0 332
HVAC-ETC HVAC System
System Layout
A/C Control Panel
1. Temperature Control Knob 6. Blower Speed Control Knob

2. Defrost/Defog Button 7. Windshield and Footwell Mode Button
3. AC On/Off Button 8. Footwell Mode Button
4. Circulation Mode Button 9. Face/Footwell Mode Button
5. Heated Rear Window Button 10. Face Mode Button
1.0 333
A/C Control System
1. A/C Pressure Switch 4. Blower Speed Regulation Resistor

2. A/C Control Panel 5. Evaporator Temperature Sensor
3. A/C controller
1.0 334
A = HS CAN Bus; B = Hard Wire
1.0 335
Description
Overview To "Face + Footwell". Direct the air to distribute
through the footwell, side and centre air outlets.
Select blower speed, air temperature, air circulation, air
distribution, etc. by operating the A/C control panel. In
the electronic A/C system, functions such as blower speed, To "Footwell". Direct the air to distribute through
air temperature, air circulation, air distribution, etc. are the footwell air outlets.
selected manually. The whole system consists of the following Note: In this mode, a small amount of airflow
components: will be directed to distribute through the side,
• A/C control panel windshield side and windshield air outlets.
• A/C controller
• Evaporator temperature sensor To "Footwell + Windshield". Direct the air to
distribute through the windshield and footwell air outlets.
• Blower
• Damper actuator Heated Rear Window
Control Panel - ETC

Press the Heated Rear Window button to enable
The temperature control knob and blower speed control the heated rear window function, and the indicator on the
knob are incremental rotary switches, and the rest of the button will illuminate. The heated rear window function will
switches on the control panel are not self-locking switches. automatically turn off after operating for 15 minutes. Operate
The functions include: it for a second time within 5 minutes, and automatically turn
System Switch* off after heating for 8 minutes. When the heated rear window
works, press the button again to turn off the heating function,
Press the system switch to start the A/C system, press again then the indicator on the button goes out.
to turn it off.
Note: The heated rear window function works only
Air Volume Adjustment
when the engine is running.
Rotate the air volume adjustment knob Air Circulation
clockwise/anti-clockwise to increase/decrease the air volume.
Note: The air volume adjustment knob is also the Press the air circulation mode button on the control
A/C system switch knob. Adjust the air volume to 0 panel, switch the circulation damper to internal circulation, and
to turn off the A/C system. the indicator on the button illuminates.
Temperature Adjustment When the vehicle receives a reverse signal and a windshield
Rotate the temperature adjustment knob washing signal, internal/external circulation will be
clockwise/anti-clockwise to increase/decrease the air outlet automatically switched, and the automatic switching function
temperature. will be disabled in the defrost/defog mode.
A/C Switch Note: Keeping the circulation damper closed may

result in windshield frosting/fogging. If this
When the A/C switch button is pressed, the A/C system gives happens, rotate the air distribution mode knob to
request to activate the cooling system, meanwhile the indicator Windshield mode, and regulate the air volume to
on the button illuminates, and all functions are restored to the maximum.
state before the system is turned off. Press the button again
to turn off the cooling system. The indicator lamp goes out. Defrost/Defog
Air Distribution Mode

Press the defrost/defog button on the control panel,
Select the corresponding button to regulate the air distribution and the indicator on the button will illuminate. Meanwhile the
mode as required. system will enter into the temperature and air volume set by
the user to brighten windshield and side windows.
To "Face". Direct the air to distribute through the Press the defrost/defog button again to exit the defrost/defog
side and centre air outlets. state. Then the indicator will go off, and the system will return
to the previous state.
1.0 336
If the defrost/defog mode is selected, operate the A/C When the temperature monitored is lower than a certain
switch button to turn on/off the compressor; operate the value, the compressor will be requested to turn off to prevent
air circulation mode button to switch between internal and the evaporator freezing.
external circulation, without quiting the defrost/defog mode
A/C Pressure Switch
in either case; operate other air distribution functions to
switch to corresponding air distribution mode and quit the The A/C pressure sensor signal varies within 0.2 - 4.8V.
defrost/defog mode. When the A/C refrigerant pressure is low, its signal value will
approach to 0V. When the A/C refrigerant pressure is high, its
Sensors
signal value will approach to 5V. The engine control module
Evaporator Temperature Sensor (ECM) converts the A/C pressure sensor voltage signal to a
The evaporator temperature sensor is a negative temperature pressure value. When the pressure is too high or too low, the
coefficient thermistor. The sensor is in the evaporator, which engine control module will stop the A/C compressor.
is used to measure the surface temperature of the evaporator.
1.0 337
Operation Mode Control

Overview When the request of mode change is shown on the A/C
The electric A/C controller operates according to the control panel, the A/C controller enables the mode actuator
followings inputs: to drive the damper angle.
• Mode signal Temperature Control
• Internal/external circulation signal When the request of temperature change is shown on
• Blower speed the A/C control panel, the A/C controller controls the
• Evaporator temperature value compressor switch indirectly to achieve the control of outlet
air temperature.
• A/C pressure value
Compressor Control
The electric A/C controller controls the followings after
manual settings on the panel: When the cooling request is shown on the A/C control panel,
the A/C controller receives the switch signal and transmits
• Blower speed
the signal to the ECM via the bus; the ECM engages the
• Position of mode damper actuator compressor clutch, meanwhile the engine accessory belt
• Position of internal/external recirculated damper motor drives the compressor to operate, driving the refrigerant to
Air Volume Control circulate.
When the request of air volume change is shown on the A/C During the operation of compressor, the ECM may cut off the
control panel, the A/C controller controls the speed of the power supply of clutch in the following situations:
blower motor by increasing or decreasing the voltage at the • The ECM receives feedback from the pressure switch,
blower motor ground end with the blower speed regulation and the value is higher or lower than certain threshold;
resistor. • The ECM receives the temperature value from the A/C
Intake Control evaporator temperature sensor, and the value is lower
When the request of intake air source change is shown than certain threshold;
on the A/C control panel, the A/C controller enables the • The ECM receives the request of acceleration.
internal/external circulation actuator to change the damper
angle.
1.0 338
Service Procedures A/C Panel - ETC
A/C Controller Assembly - ETC Remove
Remove 1. Remove the centre console upper trim panel assembly.
1. Disconnect the battery negative. Centre Console Upper Trim Panel Assembly
2. Remove the A/C panel - ETC. Remove
A/C Panel - ETC Remove 2. Remove 4 screws fixing the A/C panel to the instrument
3. Remove 2 bolts fixing the A/C controller to the panel.
instrument panel beam.
3. Disconnet the harness connector, and remove the A/C

4. Disconnect the harness connector, and remove the panel (ETC).
A/C controller assembly. Refit
Refit 1. Connect the harness connector of the A/C panel.
1. Connect the harness connector of the A/C controller. 2. Fix the A/C panel to the instrument panel, fit 4 screws,
2. Fix the A/C controller to the instrument panel beam, tighten to 2–3Nm, and check the torque.
fit 2 bolts, tighten to 2-4Nm, and check the torque. 3. Fit the centre console upper trim panel assembly.
3. Connect the battery negative. Centre Console Upper Trim Panel Assembly Refit
4. After replacing the A/C controller, the following
operations must be carried out:
a. Connect the scan tool to the vehicle and access the

SIPS.
b. Select "Programming and Coding - HVAC -

Replacement" and operate as per the instructions
on the screen.
c. The procedures for replacement already include

procedures for update, configuration and setting
(diagnostic procedures for A/C servo motor
self-learning).
d. If it prompts "Failed" during the replacement, please

operate as per the interface prompts. If it only
prompts that the A/C servo motor self-learning fails,
repeat the diagnostic procedure with VDS.
5. Fit the A/C panel - ETC.
A/C Panel - ETC Refit
1.0 339
Mode Damper Actuator Internal/External Recirculated Damper Actuator

Remove Remove
1. Disconnect the battery negative. 1. Remove the glove box assembly.
2. Remove the glove box assembly. Glove Box Assembly Remove
Glove Box Assembly Remove 2. Disconnect the harness connector.
3. Disconnect the harness connector of the mode damper 3. Remove 2 screws fixing the internal/external
actuator. recirculated damper actuator to the A/C box.
4. Remove 2 screws fixing the mode damper actuator to
the A/C box.
4. Disconnect the connection of the motor and

fresh/recirculated air damper linkage mechanism.
5. Remove the internal/external recirculated damper
5. Disconnect the connection of the motor and mode
actuator.
damper linkage mechanism.
Refit
6. Remove the mode damper actuator.
1. Connect the motor and fresh/recirculated air damper
Refit
linkage mechanism.
1. Connect the motor and mode damper linkage
2. Fix the servo motor of the recirculated air damper
mechanism.
to the A/C box assembly, fit 2 screws, tighten to
2. Fix the mode damper actuator to the A/C box, fit 2 0.6–1Nm, and check the torque.
screws, tighten to 0.6–1Nm, and check the torque.
3. Connect the connector of the recirculated damper.
3. Connect the harness connector.
5. Perform a self-learning for the A/C servo motor.
a. Connect the scan tool to the vehicle and access the VDS.
VDS.
b. Select "Fast Channel - Learning Value/Adjustment - A/C Servo Motor Self-learning", and operate as per
A/C Servo Motor Self-learning", and operate as per the instructions on the screen.
the instructions on the screen.
1.0 340
Evaporator Core Temperature Sensor Temperature Damper Actuator
Remove Remove
1. Remove the heater core. 1. Disconnect the battery negative.
Heater Core Remove 2. Disconnect the harness connector.

2. Remove the screw and clip fixing the vent box to the 3. Remove 2 screws fixing the temperature damper
heater, and remove the vent box. actuator to the A/C box.
3. Remove the evaporator core temperature sensor.

Refit
1. Fit the evaporator core temperature sensor to the
evaporator core.
2. Fix the vent box to the heater box, secure with clips,
fit and fasten the screws.
3. Fit the heater core.
Heater Core Refit

temperature damper linkage mechanism.
5. Remove the temperature damper actuator.
Refit
1. Connect the actuator and linkage mechanism of the
temperature damper.
2. Fix the temperature damper actuator to the A/C
box, fit 2 screws, tighten to 0.6–1Nm, and check the
torque.
3. Connect the connector of the temperature damper
actuator.

VDS.

A/C Servo Motor Self-learning", and operate as per
1.0 341
HVAC System HVAC-MTC
HVAC-MTC
Specifications
Torque
Description Value
Screw-A/C control panel to IPK 2–3Nm
Bolt-Fresh recirculated air flap servo motor to heater case 0.6–1Nm
1.0 342
HVAC-MTC HVAC System
System Layout
A/C Panel
1. Temperature Control Knob 4. Heated Rear Window (if equipped)

2. Air Circulation Mode 5. Air Distribution Mode Knob
3. Blower Speed Control Knob 6. A/C Button
1.0 343
A/C Control System
1. A/C Pressure Switch 3. Blower Speed Regulation Resistor

2. A/C Control Panel 4. Evaporator Temperature Sensor
1.0 344
MTC System Control Diagram
1.0 345
Description off after heating for 8 minutes. When the heated rear window
Overview works, press the button again to turn off the heating function,
then the indicator on the button goes out.
In manual A/C system, functions such as air temperature, air
distribution and blower speed are selected manually. Note: The heated rear window function works only
when the engine is running.
Manual Air Conditioning System
A/C Switch:
The control system consists of the following components:
• Manual controller Press the A/C switch to switch on the air conditioner. Press
the switch again to switch off the air conditioner.
• Evaporator temperature sensor
• Blower speed regulation resistor Blower Switch:
Manual Controller Rotate the air volume adjustment knob

clockwise/anti-clockwise to increase/decrease the air volume.
Manual controller and BCM are connected by hard wire so as The air volume has a total of 5 gears, which is 0 gear to 4 gear
to control the rear window heater and mode control, etc. arranged from small to large.
Heating and ventilation system control the temperature and Air Circulation Button
distribution of the air inside the vehicle. This system consists of
the following parts: filter cover, heater assembly, distribution When the ignition is switched on, you may change the
duct and controller assembly. internal/external circulation status with the air circulation
control button.
The fresh air or recycled air from the filter cover flows into the
heater assembly is heated or cooled according to the settings Press the air circulation control button, the indicator in the
on the control panel, then the heated air or cooled air is button will illuminate, the circulation damper will be closed and
supplied to the windshield via the distribution pipe. the internal air is separated from the ambient environment,
the system enters into the internal circulation mode. Press
Control Panel
this button again, the indicator in the button will go off, the
The switch on the control panel has the following functions: circulation damper will be opened and the system switches to
Air Distribution Switch: the external circulation mode.
Sensor
When the switch is pressed every time, the air distribution
will change, and the change range is only face, face and Evaporator Temperature Sensor
footwell, only footwell, footwell and windshield/front side The evaporator temperature sensor is a negative temperature
window defrosting, windshield/front side window defrosting, coefficient thermistor. The sensor is in the evaporator, which
only windshield/front side window defrosting. is used to measure the surface temperature of the evaporator.
Temperature Control: When the temperature monitored is lower than a certain
value, the compressor will be required to be turned off to
Rotate the temperature control knob
prevent evaporator freezing.
clockwise/counterclockwise to increase/decrease the
temperature. A/C Pressure Switch
Heated Rear Window * The A/C pressure sensor signal varies within 0.2 - 4.8V.
When the A/C refrigerant pressure is low, its signal value will
Press the Heated Rear Window button to enable approach to 0V. When the A/C refrigerant pressure is high, its
the heated rear window function, and the indicator on the signal value will approach to 5V. The engine control module
button will illuminate. The heated rear window function will (ECM) converts the A/C pressure sensor voltage signal to a
automatically turn off after operating for 15 minutes. Operate pressure value. When the pressure is too high or too low, the
it for a second time within 5 minutes, and automatically turn engine control module will stop the A/C compressor.
1.0 346
Operation Mode Control
Overview Adjust the mode damper cable manually and drive the angle of
Manual A/C controller operates according to the followings the damper.
inputs: Compressor Control
• Blower speed When refrigeration request is shown on the A/C control
• Evaporator temperature value panel, the A/C controller will receive the switch signal and
• A/C pressure value then transmit to the engine control module via the bus; the
engine control module will engage the compressor clutch,
The manual A/C controller controls the followings after
meanwhile the engine accessory belt drives the compressor
manual settings on the panel:
to operate, thereby driving the refrigerant to circulate.
• Blower speed
During the operation of compressor, the engine control
• Internal/external circulation damper motor position
module may cut off the supply of clutch in the following
Blower Speed Control situations:
When the request of blower speed change is shown on the • The engine control module receives feedback from the
A/C control panel, the A/C controller controls the speed of pressure switch, and the value is higher or lower than
the blower motor by increasing or decreasing the voltage at certain threshold;
the blower motor ground end with the blower speed control • The engine control module receives the temperature
resistor. value from the A/C evaporator temperature sensor, and
Intake Control the value is lower than certain threshold;
When the request of intake air source change is shown • The engine control module receives the request of
on the A/C control panel, the A/C controller enables the acceleration.
internal/external circulation actuator to change the damper
angle.
Temperature Control
Adjust the temperature damper cable manually and change the
angle of the damper.
1.0 347
Service Procedures Mode Damper Cable

A/C Panel - MTC Remove
Remove 1. Remove the A/C panel - MTC.
1. Disconnect the battery negative. A/C Panel - MTC Remove
2. Remove the centre console upper trim panel assembly. 2. Remove the clip fixing the mode damper cable to the
Centre Console Upper Trim Panel Assembly air plate linkage, and disconnect the connection.
Remove
3. Remove 4 screws fixing the A/C panel to the instrument
panel.
3. Remove the mode damper cable.

Refit
1. Fix the cable to the mode damper linkage, and tighten
4. Loosen the clip, and disconnect the mode damper and with clips.
temperature damper cables from the A/C panel. 2. Fit the A/C panel - MTC.
5. Disconnect the harness connector, and remove the
A/C Panel - MTC Refit
A/C panel (MTC).
Refit
1. Connect the harness connector of the A/C panel.
2. Fit the mode damper and temperature damper cable.
3. Fix the A/C panel to the instrument panel, fit 4 screws,
1.0 348
Recirculated Damper Actuator
Remove
1. Remove the glove box assembly.
Glove Box Assembly Remove

2. Disconnect the harness connector (2).
3. Remove 3 screws (1) fixing the recirculated damper
actuator to the A/C box.

fresh/recirculated air damper linkage mechanism.
5. Remove the recirculated damper actuator.
Refit
1. Connect the motor and fresh/recirculated air damper
linkage mechanism.
2. Fix the servo motor of the recirculated air damper
to the A/C box assembly, fit 3 screws, tighten to
0.6–1Nm, and check the torque.
3. Connect the connector of the recirculated damper.

VDS.

A/C Servo Motor Self-learning", and operate as per
1.0 349
1.0 350
Front Wheel Steering Steering System
Front Wheel Steering
Specifications
Torque
Description Value
Bolts-Steering pump to Steering oil pipe 26–30Nm
Nuts-Steering outer tie rod 63–73Nm
Nuts-Steering outer tie rod to steering arm 28–32Nm
-Steering inner tie rod 70-80Nm
Bolts-Steering oil pipe bracket to Steering pump 7–10Nm
Bolts-Steering machine flowline fixed to the machine 7–10Nm
Bolts-Steering pump to Steering oil pipe 36–40Nm
Bolt - subframe to body 90–110Nm
Nuts - anti-roll bar to links 45–55Nm
Bolts-Steering gear to front subframe 90–110Nm
Bolts-Steering column intermediate shaft to Steering gear 19–25Nm
Bolts-Steering pump to Steering bracket 19–25Nm
Bolts-Steering pulley to Steering pump 9–11Nm
Bolts-Steering pump to the machine into the tubing is fixed 7–10Nm
to the right front longitudinal beam
Bolts-Steering pump to the machine into the tubing is fixed 7–10Nm
on the steering pump
Bolts-Turning machine flowline fixed to the left front 7–10Nm
longitudinal beam
Bolts-Steering oil pipe bracket to Subframe 7–10Nm
Bolts-Steering cooling pipe to Bulkhead 6.5–7.5Nm
Parameters
Model Hydraulic servo-assist type steering gear can reach linear
transmission ratio steering system
Steering Column:
Model Foldaway and compressible with energy absorbing, steering

wheel can be tilted
Diameter of steering wheel 373 mm
Steering wheel turns - from a dead centre at one side to 2.55
another dead centre at the other side
1.0 351
Steering System Front Wheel Steering

System Layout
Steering System Component Layout
1. Steering Wheel 5. Steering Reservoir Assembly

2. Steering Column Assembly 6. Steering Oil Inlet Pipe Assembly
3. Steering Gear Assembly 7. Steering Oil Return Pipe Assembly
4. Steering Pump
1.0 352
Power Steering Gear Exploded View
1. Power Steering Gear Subassembly 6. Nut - Steering Gear

2. Nut - Steering Gear Outer Tie Rod 7. Bolt - Steering Gear
3. Steering Gear Outer Tie Rod Assembly 8. Steering Gear Input Shaft Seals
4. Nut - Steering Gear Outer Tie Rod to Knuckle 9. Steering Gear Outer Tie Rod Assembly
5. Steering Gear Boot 10. Steering Gear Inner Tie Rod
1.0 353
Power Steering Hydraulic System Layout
1. Steering Reservoir Assembly 9. Steering Cooling Pipe Assembly

2. Cooler to Reservoir Oil Return Pipe Assembly 10. Bolt - Steering Cooling Pipe
3. Steering Reservoir to Steering Pump Oil Suction Pipe 11. Steering Pump Assembly
Assembly 12. Bolt - Power Steering Pump
4. Clamp - Steering Reservoir to Steering Pump Oil Suction 13. Bolt - Power Steering Pump
Pipe
14. Nut - Power Steering Pump
5. Steering Reservoir Bracket
15. Steering Gear to Cooler Oil Return Pipe Clamp
6. Clamp - Steering Reservoir to Steering Pump Oil Suction
16. Bolt - Steering Pump to Steering Gear Oil Inlet Pipe
Pipe
17. Bolt - Steering Pump to Steering Gear Oil Inlet Pipe
7. Steering Pump to Steering Gear Oil Inlet Pipe Assembly
18. Bolt - Steering Gear to Cooler Oil Return Pipe
8. Steering Gear to Cooler Oil Return Pipe Assembly
1.0 354
Description Warning: Care is required when working on the hydraulic
Overview systems, since the high pressure fluid can be hot and, when
the pump is operating, reach pressures in excess of 10000
The steering system mainly includes: a two-part foldaway
KPa(1450 lbf/in2) causing a risk of personal injury.
steering column, a power steering gear, a power steering fluid
pump, a power steering fluid reservoir, a steering fluid cooler Power Steering Fluid Flow
and steering fluid hard pipe and hose. The fluid pressure from the power steering fluid pump is
Power Steering Gear transferred to the conversion valve via the steering pinion, the
control valve controls the fluid pressure and changes the fluid
The power steering gear is fitted in an appropriate position
flow direction. The fluid is directed to the pressure cylinder
under the rear beam of the front subframe. Since the mounting
on the corresponding side of the steering gear, generating
point of the power steering gear and the suspension pivot are
steering pinion and rack propelling forces. The pressure
determined by the precisely machined rigid front subframe,
fluid returns from the pressure cylinder of the steering gear
it is possible to maintain the relative designed geometric
through a circular channel of the fluid return pipe. Before
dimensions between the steering pinion and rack mechanism
the power fluid returns to the steering fluid reservoir, in this
and the suspension at any time. The power steering gear
circular channel the power steering fluid cools. The steering
is fixed by two bolts and nuts. The power steering gear
fluid reservoir stores the power steering fluid.
shall rotate 2.85 cycles from one locking position to another
and the rubber bellows hood covers the moving area of the Power Steering Fluid Reservoir
steering pinion and rack. One end of the steering outer tie The power steering fluid reservoir consists of the body, lid
rod is fitted on the threaded steering gear and fixed with and filter assembly. On the lid, there is a fluid level gauge of
locking nuts, which can be used to adjust alignment of the steering fluid reservoir integrated with the lid and an O-ring
steering system. The other end of the steering outer tie rod is preventing fluid leakage. The filter assembly is fitted at the
entirely fixed with locking nuts to the steering arm stretching bottom of the steering fluid reservoir. The filter is made of
out from the front wheel hub. fine stainless steel wire mesh molded in the filter bracket. The
Power Steering Pump filter detracts particles in the steering fluid reservoir before
the steering fluid enters into the fluid supply pipeline. The
The pressure of the steering system is supplied by the vane
filter is a maintenance-free component. The basic function of
power steering pump which is driven by the crankshaft through
the steering fluid reservoir is to maintain a certain amount
steering pump belt. When the engine operates, hydraulic oil is
of surplus steering fluid in the hydraulic system to allow the
pumped out of the fluid reservoir by the steering pump. The
expansion and contraction of the steering fluid at different
fluid amount to be transferred and pressure are adjusted by the
temperatures. Ensure that the fluid supply pipe is always
flow control valve in the power steering pump, and the excess
covered by the steering fluid under all operating conditions.
fluid returns to the inlet of the oil pump through internal oil
Any air in the hydraulic system will be discharged from the
passage.
liquid inside the steering fluid reservoir.
1.0 355
Operation through the gear and rack. When the engine and the power
The turning of the steering wheel is transferred to the steering pump operate, the high pressure fluid flow in the
conversion valve on the rack mechanism of steering gear by steering gear offers steering power.
the steering column. The rotational motion of the steering Neutral Position
wheel is transformed to a linear motion of the steering rack
1. Rotor 5. Pressure Oil in Power Steering Pump

2. Torsion Bar 6. Oil Return to Reservoir
3. Slide Valve 7. Reservoir Supply
4. Pressure Oil Flow in the Cylinders of Steering Gear
When the steering wheel is in the driving forward state, the and sensed by pistons on both sides of the power steering
power steering fluid will flow from the power steering pump cylinder. As the power steering cylinder has equal pressure
to the conversion valve. Slots of the outer cylindrical slide on both sides, the steering wheel shall be kept in the middle
valve are in line with the rotor slots, so that the fluid pressure position. Because most fluid has returned to the steering fluid
is over the conversion valve. Some pressures are applied to reservoir, the pressure at each side of the piston is very low.
the fluid inlet and outlet side of the power steering cylinder
1.0 356
Turn Left

3. Slide Valve 7. Oil Flow in the Right Cylinder of Steering Gear
4. Pressure Oil Flow in the Left Cylinder of Steering Gear
When the steering wheel is rotated counterclockwise, the power steering cylinder through the aligned slot, so that
rotor and torsion bar rotate in the same direction. The slot the pressure of the left power steering cylinder increases.
position on the rotor moves from the middle aligned position, The return flow port of the right power steering cylinder is
blocking the fluid flow from returning to the steering fluid open, allowing the fluid to flow into the power steering fluid
reservoir. From now on, the fluid pressure from the power reservoir from the right power steering cylinder piston. The
steering pump flows into the slot newly aligned by the rotor pressure difference between left and right power steering
and the outer cylindrical slide valve from the power steering cylinder pistons generates steering power.
pump; the liquid pressure is directed to the left side of the
1.0 357
Turn Right

3. Slide Valve 7. Pressure Oil Flow in the Right Cylinder of Steering Gear
4. Oil Flow in the Left Cylinder of Steering Gear
When the steering wheel is rotated clockwise, the rotor and steering column, making the rotor shaft rotate in the same
torsion bar rotate in the same direction. The slot position amount of rotation as the steering wheel. The rotational
on the rotor moves from the middle aligned position, blocking motion is also passed to the torsion bar from the rotor. If
the fluid flow from returning to the steering fluid reservoir. the wheel resistance is very high (for example in the parking
From now on, the fluid pressure from the power steering state), the torsion bar will rotate. The rotation of the torsion
pump flows into the slot newly aligned by the rotor and the bar means that the amount of rotation of the pinion and slide
outer cylindrical slide valve from the power steering pump; the valve is slightly less than that of the rotor. The rotation of
liquid pressure is directed to the right power steering cylinder the torsion bar makes the slots in the rotor and the torsion
through the aligned slot, so that the pressure of the right power bar out of the alignment position, the gap between the two
steering cylinder increases. The return flow port at the left slots becomes bigger. The greater the road resistance of the
side of the power steering cylinder is open, allowing the fluid to wheels to the steering rotation is, the larger the misalignment
flow into the power steering fluid reservoir from the left power of the slots in the rotor and the torsion bar becomes. As the
steering cylinder piston. The pressure difference between left misalignment increases, the liquid pressure flowing through the
and right power steering cylinder pistons generates steering corresponding side of the power steering cylinder increases.
power. When the road resistance of the wheels or the steering force
Cumulative Power applied to the steering wheel decreases, the torque applied
to the rotor decreases, the torsion bar is released, thus the
The cumulative power steering depends on the road resistance
misalignment of the slots in the rotor and the torsion bar
of the wheels opposite to the rotation direction of the front
decreases and the fluid pressure applied to the corresponding
wheels. When the steering wheel is turned left or right, the
side of the power steering cylinder decreases.
rotational motion is passed to the rotor shaft through the
1.0 358
Hydraulic Circuit
1. Steering Oil Reservoir 6. Pressure Area of Power Steering Cylinder

2. Low-pressure Oil Inlet Pipe 7. Rack Mechanism of Steering Gear
3. Power Assisted Steering (PAS) Pump 8. Conversion Valve Unit
4. Oil Outlet 9. Power Steering Oil Cooling Pipe
5. Flow Control/Safety Valve
After the engine start, the power steering pump sucks the fluid pressure is directed to the corresponding side of the
power steering fluid from the steering fluid reservoir into power steering cylinder piston to offer steering power so
the low-pressure fluid inlet pipe and turns the fluid to the as to reduce the necessary steering force. The discharged
high-pressure fluid at the fluid outlet. Though a high-pressure power steering fluid due to piston movement in the power
fluid pipe, the high-pressure fluid comes to the conversion steering cylinder returns to the steering fluid reservoir from
valve. If no steering force is applied, the pressures at both the conversion valve through a power steering fluid cooling
sides of the power steering cylinder piston are equal. The pipe. The power steering fluid cooling pipe reduces the
remaining fluid returns to the steering fluid reservoir from temperature of the power steering fluid, extending the service
the conversion valve through a power steering fluid cooling life of the hoses and seals of the system.
pipe. If a steering force of turning to any side is applied, the
1.0 359
Service Procedures a. Ensure there is no leakage in the steering system and

Power Steering System - Pressure Test the liquid level is at the maximum position at the
Check time of testing.
1. Test Equipment b. Start the engine when the test equipment valve is
open.
c. Slowly rotate the steering wheel and keep it at lock

position when the engine is running at idle speed
and at normal operating temperature.
d. Repeat this pressure test at relative lock positions.
e. The test pressure shall be increased gradually from

5bar to 100bar. And the pressure may rise to 100bar
according to road conditions when the steering
wheel is at full lock position.
f. Release the steering wheel when the engine is running

at idle speed, and the reading shall be 5bar or less.
a. Fit the pressure gauge T38001 and hoses to the g. If the pressure exceeds the above value, there may
valve assembly T38002, and tighten the connectors. be something wrong.
b. Fit 2 hoses T38003 to the valve assembly T38002, Adjustment

and tighten the connectors. 1. Keep the test valve closed for no more than 5 seconds,
determine if the failure occurs in the steering pump
or in the steering gear. If the test valve is off for an
Caution: Care must be taken to ensure that oil or fluid extended time, the pump will be damaged.
does not enter or contaminate the alternator. 2. If the readings on the pressure gauge can not reach
3. Place a container to collect the oil spilled from the 85-95bar (maximum pump pressure), there may be
PAS system. something wrong with the pump.
4. Clean the power steering pump, connecting pipe and 3. If the maximum pump pressure is correct, there may be
pipe connectors. something wrong with the steering gear.
5. Remove the connector connecting the oil inlet pipe of 4. Stop the engine after the test.
the steering gear to the power steering pump. 5. Disconnect the battery negative.
6. Fit the connector T38005 and seal washer to the 6. Remove the connector of the test equipment.
power steering pump. 7. Remove the connector connecting the oil inlet pipe of
7. Fit the connector TCH00094 to the oil inlet pipe of the steering gear to the power steering pump.
the steering gear. 8. Fit the new seal washer, fit the oil inlet pipe to the
8. Connect the hoses T38003 to the TCH00094 and power steering pump, and tighten to 26–30Nm.
the T38005. 9. Clean the chassis and its surrounding area.
9. Ensure all pipes and mounting parts are not in contact 10. Check the liquid level of the steering system.
with rotating parts.
Capacity
10. Hang the pressure gauge at a safe place below the
Fluid
bonnet.
12. Start the engine and bleed the steering system.
Steering System Bleeding

13. Check the liquid level of the steering pump reservoir
and refill it.
Capacity
14. Test Procedure:
1.0 360
Steering Gear Outer Tie Rod Steering Gear Boot
Remove Remove
1. Remove the front wheels. 1. Remove the bottom deflector.
Wheels Remove Bottom Deflector Remove

2. Raise the vehicle on a lift. 2. Remove the outer tie rod of the steering gear.
Warning: Do not work on or under a vehicle supported Steering Gear Outer Tie Rod Remove
only by a jack.Always support the vehicle on safety stands. 3. Remove and discard the outer boot clamp of the
3. Remove and discard 1 nut fixing the steering gear outer steering gear.
tie rod to the knuckle. Disconnect the steering gear 4. Remove and discard the inner boot clamp of the
outer tie rod from the knuckle. steering gear.
4. Loosen the locking nut of the steering gear outer tie
rod.
5. Remove the steering gear boot from the steering gear.

Refit
5. Remove the steering gear outer tie rod from the power
1. Fit the steering gear boot to the steering gear. Ensure
steering gear, and mark the position of the locking nut.
the steering gear boot is fitted in the mounting groove
Refit
of the steering gear.
1. Fit the steering gear outer tie rod to the marked
2. Fit and secure the new inner boot clamp of the steering
location of the locking nut, and keep the ball joint
gear to the steering gear boot.
upward.
3. Fit and secure the new outer boot clamp of the steering
2. Tighten the locking nut of the steering gear outer tie
gear to the steering gear boot.
rod to 63–73Nm.
4. Fit the outer tie rod of the steering gear.
3. Connect the steering gear outer tie rod to the knuckle,
fit the new nut and tighten to 28–32Nm. Steering Gear Outer Tie Rod Refit
4. Fit the front wheels. 5. Fit the bottom deflector.
Wheels Refit Bottom Deflector Refit

5. Check the wheel alignment. 6. Check the wheel alignment.
Wheel Alignment Wheel Alignment
1.0 361
Steering Gear Inner Tie Rod Steering Gear Subassembly

Remove Remove
1. Remove the steering gear boot. 1. Remove the front wheels.
Steering Gear Boot Remove Wheels Remove

2. Unscrew the steering gear inner tie rod from the 2. Remove the bottom deflector.
steering gear.
3. Remove and discard 1 bolt fixing the intermediate shaft
to the steering gear.
3. Remove the inner tie rod of the steering gear.

Refit
1. Fit the steering gear inner tie rod to the steering gear, 4. Release the universal joint from the steering gear.
and tighten to 70-80Nm.
Caution: Before disconnecting any part of the steering
2. Fit the steering gear boot.
linkage, ensure the road wheels are positioned straight
Steering Gear Boot Refit ahead and the steering wheel is prevented from turning.
3. Check the wheel alignment. Unrestricted turning of the steering wheel will damage the
SRS rotary coupler.
Wheel Alignment
5. Raise the vehicle to the appropriate height.
6. Remove and discard 2 bolts fixing the steering gear to
the subframe.
7. Remove and discard the nut (2) fixing the front

horizontal stabilizer bar to the connecting rod of the
front horizontal stabilizer bar.
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pipe to the steering gear.
14. Remove 2 bolts (1) fixing the bracket of the steering
gear oil outlet pipe to the steering gear bracket, and
remove the oil outlet pipe.
8. Remove the outer tie rod of the steering gear.

Steering Gear Outer Tie Rod Remove
9. Remove and discard 1 bolt fixing the mount bracket
to the subframe.
15. Locate the appropriate position to remove the pipe
connector bolt (1) connecting the steering gear oil inlet
16. Remove 1 bolt (2) fixing the bracket of the steering
gear oil inlet pipe to the steering gear bracket, and
remove the oil inlet pipe.
contamination.

11. Support the front subframe assembly with the hydraulic
lifting equipment, remove and discard 6 bolts fixing
the front subframe to the body, and lower the front
subframe.
17. Remove the steering gear subassembly from the

subframe.
Refit
1. Locate the steering gear assembly to the subframe and
lift the subframe to the body.
2. Locate the bracket of the steering gear oil inlet pipe
to the steering gear bracket, fit 1 bolt and tighten to
7–10Nm.
3. Fit the steering gear oil inlet pipe to the steering gear
and tighten the pipe connector to 26–30Nm.
12. Place a container to collect the spilled fluid. 4. Fix the bracket of the steering gear oil outlet pipe to
13. Locate the appropriate position to remove the pipe the steering gear bracket, fit 2 bolt and tighten to
connector (2) connecting the steering gear oil outlet 7–10Nm.
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5. Fit the steering gear oil outlet pipe to the steering gear Power Steering Pump
and tighten the pipe connector to 36–40Nm. Remove
6. Locate the front subframe to the body with the 1. Disconnect the battery negative.
hydraulic lifting equipment, fit 6 bolts and tighten to 2. Remove the bottom deflector.
90–110Nm.
3. Place a container to collect the spilled liquid.
4. Remove 1 bolt fixing the bracket of the oil inlet pipe
8. Fit 1 bolt fixing the mount bracket to the subframe and (steering pump to steering gear) to the steering pump.
tighten to 90–110Nm.
Steering Gear Outer Tie Rod Refit

10. Locate the front horizontal stabilizer bar to the
connecting rod of the front horizontal stabilizer bar, fit
1 nut and tighten to 45–55Nm.
11. Fix the steering gear assembly to the subframe, fit 2
bolts and nuts, and tighten to 90–110Nm.
12. Fix the intermediate shaft universal joint to the steering
gear, fit 1 bolt and tighten to 19–25Nm.

5. Disconnect the steering gear oil inlet pipe from the
14. Fit the front wheels. power steering pump.
Wheels Refit

7. Remove 3 bolts connecting the power steering pump
pulley to the power steering pump.
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inlet pipe to the power steering pump, and tighten to
26–30Nm.
6. Fix the bracket of the oil inlet pipe (steering pump to
steering gear) to the steering pump, fit 1 bolt, tighten

9. Bleed the power steering system.
Power Steering System Bleeding
8. Remove 3 bolts connecting the power steering pump

to the bracket.
9. Remove the power steering pump.

Refit
1. Clean the power steering pump and the mating surface.
2. Fit 3 bolts connecting the power steering pump to the
bracket, tighten to 19–25Nm, and check the torque.
3. Fit 3 bolts connecting the power steering pump pulley
to the power steering pump, tighten to 9–11Nm, and
check the torque.
5. Clean the connector connecting the steering gear oil
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Oil Inlet Pipe (Reservoir to Steering Pump) Oil Inlet Pipe - Steering Pump to Steering Gear
Remove Remove
1. Place a container to collect the spilled liquid. 1. Place a container to collect the spilled liquid.
2. Disconnect the clamp fixing the oil inlet pipe (reservoir 2. Remove 1 bolt fixing the bracket of the oil inlet pipe
to steering pump) to the steering pump, and disconnect (steering pump to steering gear) to the steering pump.
the pipeline.
contamination.
3. Disconnect the connector of the oil inlet pipe (steering

pump to steering gear) from the steering pump.
3. Disconnect the clamp fixing the oil inlet pipe (reservoir contamination.
to steering pump) to the reservoir, and disconnect the
pipeline.

Caution: Always fit plugs to open connections to prevent 5. Remove 2 bolts fixing the oil inlet pipe (steering pump
contamination. to steering gear) to the right front longitudinal beam.
4. Remove the oil inlet pipe (reservoir to steering pump).
Refit
1. Clean the oil inlet pipe (reservoir to steering pump).
2. Remove the plug, fix the oil inlet pipe (reservoir to
steering pump) to the reservoir and secure with clamps.
3. Remove the plug, fix the oil inlet pipe (reservoir to
steering pump) to the steering pump and secure with
clamps.
4. Bleed the power steering system.
Power Steering System Bleeding
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12. Remove 1 bolt (2) fixing the bracket of the steering

gear oil inlet pipe to the steering gear bracket.
13. Locate the appropriate position to remove the
7. Remove the outer tie rod of the steering gear. connector (1) of the steering gear oil inlet pipe from
the steering gear.
8. Remove the front lower swing arm assembly.
Front Lower Swing Arm Assembly Remove

to the subframe.

contamination.
Caution: To prevent damage to components, cushion the

part pad with a block of wood or hard rubber.
10. Remove the front exhaust pipe assembly. 14. Remove the oil inlet pipe (steering pump to steering
gear).
Refit
lifting equipment, remove and discard 6 bolts fixing 1. Remove the plug to fit the new seal ring, fix the oil inlet
the front subframe to the body, and lower the front pipe connector (steering pump to steering gear) to the
subframe. steering gear, tighten the pipe connector to 36–40Nm,
2. Fix the bracket of the steering gear oil inlet pipe to the
steering gear bracket, fit 1 bolt, tighten to 7–10Nm,
3. Locate the front subframe to the body with the
hydraulic lifting equipment, fit 6 bolts and tighten to
90–110Nm.
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5. Fit 1 bolt fixing the mount bracket to the subframe and Steering Gear Oil Outlet Pipe
tighten to 90–110Nm. Remove
6. Fit the front lower swing arm assembly. 1. Remove the bottom deflector.
Front Lower Swing Arm Assembly Refit Bottom Deflector Remove
7. Fit the outer tie rod of the steering gear. 2. Remove 1 bolt fixing the bracket of the steering gear
oil outlet pipe to the subframe.
9. Fix the oil inlet pipe (steering pump to steering gear)
to the right front longitudinal beam, fit 2 bolts, tighten

11. Remove the plug to fit the new seal ring, fix the oil inlet
pipe (steering pump to steering gear) to the steering
pump, tighten the pipe connector to 26–30Nm, and
check the torque.
12. Fix the oil inlet pipe (steering pump to steering gear)
to the steering pump, fit 1 bolt, tighten to 7–10Nm,
13. Bleed the steering system.
Steering System Bleeding
4. Remove the outer tie rod of the steering gear.

5. Remove the front lower swing arm assembly.
Front Lower Swing Arm Assembly Remove

to the subframe.
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gear oil outlet pipe to the left front longitudinal beam,
and disconnect the pipeline.
13. Disconnect the clamp (2) fixing the steering gear oil
outlet pipe to the steering cooling pipe, and disconnect
the pipeline.

lifting equipment, remove and discard 6 bolts fixing
the front subframe to the body, and lower the front
subframe. Caution: Always fit plugs to open connections to prevent
contamination.
14. Remove the steering gear oil outlet pipe.
Refit
1. Remove the plug, fix the steering gear oil outlet pipe to
the steering cooling pipe and secure with clamps.
2. Fix the bracket of the steering gear oil outlet pipe to
the left front longitudinal beam, fit 2 bolts, tighten to
3. Remove the plug to fit the new seal ring, locate the
steering gear oil outlet pipe to the steering gear, tighten
the pipe connector to 7–10Nm, and check the torque.
9. Place a container to collect the spilled fluid. 4. Fix the bracket of the steering gear oil outlet pipe to
the steering gear bracket, fit 2 bolt and tighten to
10. Remove 2 bolts (1) fixing the bracket of the steering
7–10Nm.
gear oil outlet pipe to the steering gear bracket.
5. Locate the front subframe to the body with the
11. Locate the appropriate position to remove the pipe
hydraulic lifting equipment, fit 6 bolts and tighten to
connector (2) connecting the steering gear oil outlet
90–110Nm.
7. Fit 1 bolt fixing the mount bracket to the subframe and
8. Fit the front lower swing arm assembly.
Front Lower Swing Arm Assembly Refit
12. Remove 2 bolts (1) fixing the bracket of the steering 11. Fix the bracket of the steering gear oil outlet pipe to
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the subframe, fit 1 bolt, tighten to 7–10Nm, and check Steering Cooling Pipe
the torque. Remove
12. Fit the bottom deflector. 1. Remove the front bumper assembly.
Bottom Deflector Refit Front Bumper Assembly Remove
13. Bleed the steering system. 2. Remove the bottom deflector.
Steering System Bleeding Bottom Deflector Remove
3. Place a container to collect the spilled liquid.
4. Disconnect the clamp (2) fixing the steering gear oil
outlet pipe to the steering cooling pipe, and disconnect
the pipeline.

contamination.
5. Remove 2 bolts (1) fixing the steering cooling pipe to
the radiator beam.
6. Disconnect the clamp (2) fixing the reservoir oil return
pipe to the steering cooling pipe, and disconnect the
pipeline.

contamination.
7. Remove the steering cooling pipe.
Refit
1. Remove the plug, fix the reservoir oil return pipe to
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2. Fix the steering cooling pipe to the radiator beam, fit 2 Reservoir Oil Return Pipe Assembly
bolts, tighten to 6.5–7.5Nm, and check the torque. Remove
3. Remove the plug, fix the steering gear oil outlet pipe to 1. Remove the front bumper assembly.
the steering cooling pipe and secure with clamps. Front Bumper Assembly Remove
4. Fit the bottom deflector. 2. Place a container to collect the spilled liquid.
Bottom Deflector Refit 3. Disconnect the clamp (2) fixing the reservoir oil return
5. Fit the front bumper assembly. pipe to the steering cooling pipe, and disconnect the
pipeline.

contamination.
4. Disconnect the clamp fixing the reservoir oil return

pipe to the reservoir, and disconnect the pipeline.

contamination.
5. Remove the reservoir oil return pipe assembly.

Refit
1. Clean the reservoir oil return pipe (reservoir to
steering cooling pipe).
the reservoir and secure with clamps.
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Power Assisted Steering (PAS) System Bleeding

Adjustment
1. Clean the area around the steering reservoir filler and
the fluid level indicator.
2. Unscrew the cap of the steering reservoir, refill the
steering fluid to a level between the minimum scale and
the maximum scale of the dipstick.
Capacity
Fluid
Caution: Care must be taken to ensure that oil or fluid

does not enter or contaminate the alternator.
3. Start the engine and operate it for 10 seconds at idle

speed, then stop it.
4. Top up the power steering reservoir.
5. Start the engine, turn the steering wheel fully to the left
and right lock points, then stop the engine.
6. Top up the power steering reservoir again.
7. Start the engine and operate it for 2 minutes and turn
the steering wheel fully to the left and right lock points.
Caution: Do not hold steering at full lock for longer than

10 seconds.
8. Stop the engine.

9. Check the steering reservoir; if there is any bubble
discharged from the fluid, wait until no bubble
discharges, then refill the steering fluid to a level
between the minimum scale and the maximum scale.
10. Fit the filler cap of the power steering reservoir.
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Special Tools
Number
PAS pressure
T38001
test equipment
Adaptor
T38002 hydraulic
pressure test
Adaptor
hydraulic
T38003
pressure test
hose
Adaptor power
T38005
steering pump
Adaptor
TCH00094 power steering
pressure Test
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Steering System Steering Wheel and Column
Steering Wheel and Column

Specifications
Torque
Description Value
Bolts- Steering wheel to steering column 60–70Nm
Nut-Steering outer tie rod locking 63-73Nm
Bolts-steering gear to fascia bracket 19–25Nm
Bolts-Steering column intermediate shaft to steering gear 19–25Nm
Bolts-Steering column intermediate shaft to Steering gear 19–25Nm
Bolt - steering column lock-steering column 11–14Nm
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Steering Wheel and Column Steering System
Service Procedures Steering Wheel Positioning/Adjustment
Steering Wheel Assembly Check
Remove 1. Ensure correct tyre pressure and maintain the vehicle
1. Disconnect the battery negative. in unladen mass condition.
2. Remove the steering wheel airbag. 2. Shake the vehicle back and forth to release the stress
for steering and suspension.
Steering Wheel Airbag Remove
3. Please apply the four-wheel aligners recommended
3. Put the steering wheel in the centre and allow the
by our company when measuring the front wheel
wheel to be in the front.
alignment parameters.
4. Disconnect the harness connector of the steering
4. Check if the front wheel alignment parameter is within
wheel.
the specified tolerance range.
5. With the steering wheel stopped, loosen the bolt fixing
the steering wheel to the steering column, after the Four-wheel Alignment Check
steering wheel is fully loosened from the splines of the Adjustment
steering column, remove the bolt. 1. If the steering wheel exceeds the alignment value
clockwise:
a. Loosen the right locking nut.
b. Turn the right outer tie rod to the left by a hexagonal

plane.
c. Tighten the right locking nut to 63-73Nm.
d. Loosen the left locking nut.
e. Turn the left outer tie rod to the left by a hexagonal

plane.
f. Tighten the left locking nut to 63-73Nm.
2. If the steering wheel exceeds the alignment value

6. Remove the steering wheel assembly from the steering counterclockwise:
column. a. Loosen the left locking nut.
7. Stick tape along the edge of the steering column lever
b. Turn the left outer tie rod to the right by a hexagonal
combination switch to keep it in the correct mounting
plane.
position.
c. Tighten the left locking nut to 63-73Nm.
Refit
1. Remove the tape on the combination switch of the d. Loosen the right locking nut.
steering column lever. e. Turn the right outer tie rod to the right by a
2. Ensure that the wheel is in the front, and fit the steering hexagonal plane.
wheel to the steering column according to the mark.
f. Tighten the right locking nut to 63-73Nm.
3. Fix the steering wheel to the steering column, fit 1 bolt,
tighten to 60–70Nm, and check the torque. 3. Repeat 1 or 2 until the wheels face forward, and the
steering wheel is in the centre position.
4. Connect the harness connector of the steering wheel.
5. Fit the steering wheel airbag.
Steering Wheel Airbag Refit
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Steering Column Combination Switch

Remove
2. Remove the steering wheel assembly.
Steering Wheel Assembly Remove
3. Fix the clock spring with tapes, ensure it will not
move left and right (relative to the combination switch
bracket) and is always in the centre.
4. Remove the steering column trim cover.
Steering Column Trim Cover Remove

5. Remove 4 screws fixing the lever switch to the steering
column. 3. Fit the clock spring to the steering column and connect
the harness connector.
4. Connect the harness connectors of the lever switches
of direction indicator lamp/high beam and wiper/washer
respectively, and fix them to the combination switch
bracket with 4 screws.
5. When fitting a new combination switch assembly to the
steering column, ensure the front wheels face the front,
place the combination switch assembly right above the
steering column, fit it into the steering column as an
assembly and locate it by turning from side to side.
6. Fit the steering column trim cover.
Steering Column Trim Cover Refit
6. Disconnect the harness connectors of the clock spring, 7. Fit the steering wheel assembly.
wiper/washer and direction indicator lamp/high beam
Steering Wheel Assembly Refit
lever switches.
7. Remove the lever switches of the wiper/washer and
direction indicator lamp/high beam. 9. Perform a self-learning for the angle sensor.
8. Remove the screws to remove the clock spring from a. Connect the scan tool to the vehicle and access the
the steering column, and take care not to damage the VDS.
tape.
b. Select "Fast Channel - Learning Value/Adjustment
Refit - SAS Reset Self-learning", and operate as per the
Caution: If the peg on a new rotary coupler is broken, or instructions on the screen.
if you suspect that the rotary coupler has been dropped
c. Select "Fast Channel - Learning Value/Adjustment -
or mishandled, discard the coupler.
SAS Zero Position Self-learning", and operate as per
1. Before fitting, ensure the red locating pin of the clock the instructions on the screen.
spring is not removed or damaged and the front wheels
10. Perform a system check, rotate each lever of the
face the front.
steering switch and check if it can work.
2. Ensure the clock spring to be fitted is in the centre, if
11. Check if the buttons of the entertainment switch on
it is not, gently rotate the rotor counterclockwise to
the steering wheel can work.
the end, then turn it clockwise for about 2.7 circles.
Align the connector clip with the Lock Pin position (this
location is the centre).
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Steering Wheel Entertainment Switch Upper Steering Column
Remove Remove
1. Disconnect the battery negative. 1. Pull out the key from the ignition switch, disconnect the
2. Remove the steering wheel airbag. negative battery cable. After 10s, disconnect the SRS
backup circuit before it works.
2. Remove the combination switch.
3. Pry off the clip gently and remove the steering wheel
Combination Switch Remove
entertainment switch.
3. Remove the driver side lower trim panel assembly.
4. Disconnect the connector of the steering wheel
entertainment switch. Driver Side Lower Trim Panel Assembly Remove
Refit 4. Disconnect the clip fixing the harness to the upper
1. Connect the harness connector on the back of the steering column.
steering wheel entertainment switch. 5. Remove and discard 1 bolt fixing the universal joint of
2. Fix the steering wheel entertainment switch to the the upper steering column to the intermediate shaft.
steering wheel.
3. Fit the steering wheel airbag.
Steering Wheel Airbag Refit

6. Release the universal joint from the intermediate shaft.

7. Remove 4 bolts fixing the upper steering column to
the instrument panel beam.
8. Remove the upper steering column assembly.

Refit
1. Fix the upper steering column to the instrument panel
beam, fit 4 bolts, tighten to 19–25Nm, and check the
torque.
2. Locate the universal joint to the intermediate shaft and
ensure correct orientation, fit 1 new bolt, tighten to
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3. Fix the harness to the steering column and secure with Intermediate Shaft
clips. Remove
4. Fit the driver side lower trim panel assembly. 1. Keep the wheels facing forward and lock the steering
Driver Side Lower Trim Panel Assembly Refit wheel.
2. Remove the driver side lower trim panel assembly.
5. Fit the combination switch.
Driver Side Lower Trim Panel Assembly Remove
Combination Switch Refit
6. Connect the battery negative and the SRS circuit. 3. Remove and discard 1 bolt fixing the upper steering
column to the intermediate shaft.
4. Remove and discard 1 bolt fixing the intermediate shaft

to the steering gear.
5. Remove the intermediate shaft.

Refit
1. Locate the intermediate shaft universal joint to the
steering gear, fit 1 new bolt and tighten to 19–25Nm.
2. Connect the intermediate shaft and the upper steering
column with new bolts, and tighten to 19–25Nm.
3. Fit the driver side lower trim panel assembly.
Driver Side Lower Trim Panel Assembly Refit
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Steering Column Lower Trim Cover Mechanical Steering Column Lock
Remove Remove
1. Release the steering column to the lowermost position. 1. Remove the upper steering column.
2. With a screwdriver, carefully disconnect the upper trim Upper Steering Column Remove
cover from the lower trim cover, and remove the gap
2. Fix the upper steering column to the drilling machine.
cover strip of the steering column together.
3. Drill a small hole in the retaining screw head of the
3. Remove 3 screws fixing the lower trim cover of the
steering column lock, choose a broken screw extractor
steering column to the steering column.
with an appropriate diameter to rotate the screw out,
and do not damage adjacent parts.
4. Remove the steering column lock.
Refit
1. Put the steering column lock into the upper steering
column.
2. Secure with new mounting screws, tighten them to
11–14Nm, and twist off the screw heads.
3. Fit the upper steering column.
Upper Steering Column Refit
4. Release the steering column adjusting handle, and

remove the lower trim cover of the steering column.
Refit
1. Fix the steering column lower trim cover to the
steering column, fit 3 screws and fasten.
2. Place the upper trim cover of the steering column on
the steering column, and secure it on the lower trim
cover with care.
1.0 379
1.0 380
Wheel Alignment Suspension System
Wheel Alignment
Specifications
Torque
Description Value
Nuts - steering rod 63–73Nm
Parameters
Four-wheel Alignment Parameter
Front Wheel
Camber –36′±45′
King Pin Caster Angle 3°33′±45′
King Pin Inclination Angle 12°22′±45′
Toe Angle (total toe) 0°8′±15′

Rear wheel
Wheel Camber -1°16′±45′
Toe Angle (total toe) 29′±20′
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Suspension System Wheel Alignment
Description and Operation Front Wheel Toe-in

Description
The primary goal of mechanical design is to ensure the
safety and reliability of the steering system and suspension
system. Each component shall be strong enough to bear and
absorb extreme impact. The steering system and front/rear
suspension system shall be in a geometrical shape with the
body. The steering system and suspension system require the
front wheels can return automatically, keeping the rolling force
of the front wheel and the road friction within the minimum
value so that the user can control directions easily and
comfortably. A thorough wheel positioning inspection involves
rear wheel toe angle and camber measurement. Four-wheel
positioning can ensure the four wheels to rotate towards the
same direction. Geometric positioning can help the vehicle to The front wheel toe-in is observed from the top, the wheels
realize optimum fuel economy and maximum tyre service life, rotate inwards (or outwards). Normally, the actual value of
and thus improve the steering and performance. the toe-in angle is less than one degree, merely several cents.
The toe-in of the static wheel enables the wheel to roll levelly
under a dynamic state. Large toe-in or the front tensioner
may increase the wheel friction. For the rear-wheel driving
vehicles, a smaller toe angle (the value measured when the
vehicle is stopped) shall be used to compensate the weak
disturbance caused by rolling resistance and brake operation,
this disturbance may cause the wheel open outward.
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Wheel Alignment Suspension System
Service Procedures
Four-wheel Alignment
Inspection
1. Only the recommended equipment by the company can
be used for four-wheel positioning adjustment.
2. The equipment must be calibrated according to the
manufacturer's requirements.
3. Ensure that the vehicle data input into the equipment
is correct.
4. Check the steering rod ball joint, front lower arm ball
joint and wheel bearing for wear or proper running.
Replace or repair it if necessary.
5. Check and adjust the tyre pressure.
6. Raise the vehicle on a four-wheel aligner.
7. Ensure that the vehicle is in unladen mass condition.
8. Ensure that the wheel mounting clamp has been
adjusted to a correct specification and has been fixed
firmly to the vehicle.
9. Ensure that the camera has been fitted and aligned
properly.
10. Align and adjust the wheels according to the
manufacturer's instruction. Lower the vehicle and keep
the vehicle suspension in normal state.
11. Ensure that the steering wheel is positioned in the
centre.
Adjustment
1. Observe the readings indicated on the test equipment,
and adjust the four-wheel positioning dada according
to the requirements.
2. Front Wheel Alignment Adjustment:
• Release the locking nuts of the steering rod.

• Adjust the steering rod and allow the front wheel
positional parameter to achieve the specified value.
• Tighten the locking nuts to 63–73Nm.
• For the other side, repeat the above steps.
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Suspension System Front Suspension
Front Suspension
Specifications
Torque
Description Value
Bolts - front damper to knuckle 90–110Nm
Bolt - lower arm outer ball joint to swivel hub 50–65Nm
Nuts - steering rod outer ball joint 28–32Nm
Screws - front speed wheel sensor 7–10Nm
Screws - front brake disc to knuckle 30–36Nm
Bolts - front brake caliper to knuckle 90–110Nm
Nuts - rear spindle 320–350Nm
Nuts - lower arm outer ball joint （60±5）Nm+60°±5°
Nut - lower arm outer ball joint to swivel hub 50–65Nm
Nut - lower arm rear bush to subframe lock 90Nm+90°
Nut - lower arm front bush to subframe lock 90Nm+90°
Nuts - piston rod top 54–62Nm
Bolts - subframe brace to body 60–80Nm
Nut - anti-roll bar links to damper 50–65Nm
Bolts - anti-roll bar bush and clamp to subframe 22–28Nm
Bolt - subframe to body 90Nm+180°
Specifications
Front Lower Arm L shaped, steel forged with lightening holes. Ball joints at forward
inner and outer joints
Anti Roll Bar Diameter 20.5mm
Front Spiral Spring Data:
Total Turns 4.8
Active coils 3.8
Wire diameter 11.6mm
1.0 384
Front Suspension Suspension System
System Layout
Front Suspension
1. Front Suspension Shock Absorber Assembly 5. Front Wheel Hub Assembly

2. Front Anti Roll Bar Link 6. Front Anti Roll Bar Bush Clamp
3. Front Subframe Assembly 7. Front Lower Arm Assembly
4. Front Anti Roll Bar
1.0 385
Front Suspension Components
1. Front Shock Absorber Column 9. Front Suspension Knuckle Dust Cover

2. Front Anti Roll Bar Link 10. Front Wheel Hub
3. Front Anti Roll Bar 11. Front Wheel Hub Bearing
4. Front Anti Roll Bar Bush 12. Front Wheel Hub Circlip
5. Front Anti Roll Bar Anchorage Bracket 13. Front Wheel Hub Flange
6. Front Lower Arm Front Bushing 14. Front Drive Shaft Nut
7. Front Lower Arm Assembly 15. Front Shock Absorber Coil Spring
8. Front Lower Arm Rear Bushing
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Front Damper Components
1. Front Shock Absorber Column 7. Front Shock Absorber Bearing Seat

2. Front Suspension Coil Spring 8. Nut
3. Front Shock Absorber Column Dust Cover 9. Front Shock Absorber Upper Spring Cushion
4. Front Shock Absorber Column Auxiliary Spring 10. Front Shock Absorber Rebound Gasket
5. Front Suspension Shock Absorber Column Insulating Pad 11. Nut
6. Front Shock Absorber Lower Spring Cushion
1.0 387
Description The twin tube construction allows the damper piston to

Front suspension comprises of: operate on an inner tube with an oil/gas cavity between the
inner and outer tubes.
• Front MacPherson Strut Dampers
This minimises oil cavitation and eliminates the effect of
• Front Lower Arms
damage to the outer tube affecting piston operation.
• Anti Roll Bar
The damper is attached at its lower end to a location on the
• Anti Roll Bar Links
swivel hub and is secured with 2 nut/bolts.
• Front Subframe
Correctly orientation is achieved by a machined section of the
• Front Wheel Hub, Bearing and Drive Flange
front hub being inserted in-between 2 steel tangs welded to
The front suspension design features anti-dive and anti-squat the base of the damper, the machined hub and tangs contain
geometry via the anti-roll bar and 1:1 strut movement ratio. holes which allow the fitment of the retaining nut/bolts.
The layout and design of the struts minimizes camber loss due The damper rod is located in steel inserts in rubber bushes,
to side forces, improving handling and steering response. which are integral with the top mounting plate, and are secured
Front Subframe Assembly with a washer and nut.
The front subframe is a fabricated steel construction made up A hexagon is provided in the outer end of the damper rod to
of precise components welded together to form a light weight, restrain the rod from rotating when the nut is tightened.
high structural strength assembly. The damper rod is sealed in the damper with a low friction
Geometric machining of all key positions takes place after seal.
construction to ensure the precise locations of front An angled spring seat is integral with the damper body.
suspension and steering system components.
A welded bracket on the body of the damper provides the
The subframe is attached to the body via 6 solid mounting location point for the anti roll bar link.
points, this helps to increase the stiffness of the front subframe.
The arrangement of the supporting points avoids the

Front Lower Arm Assembly
displacement of the front subframe under high lateral forces
which could affect handling characteristics. The front lower arm connects the front wheel hub to the front
subframe.
MacPherson Strut
Two MacPherson struts control the damping of the front The fabricated steel front lower arm features an outer ball
suspension. joint, a front bush and a rear bush, all components are
serviceable.
Each strut assembly comprises a damper unit, a coil spring and
a top mount assembly. The outer ball joint features a parallel pin with a
circumferentially machined groove that locates into the hub
The coil spring is retained in a compressed condition between assembly and is clamped/secured using a nut and bolt.
the strut spring seat and the top mount assembly. Isolators
at each end of the spring reduce noise transmitted from the
suspension to the body. Anti Roll Bar and Links
A bearing is fitted to the underside of the top mount assembly A solid spring steel ARB is used that operates via ARB links
and allows the spring to rotate as the steering is operated. secured to each damper (dedicated bracket).
A dust cover is fitted between the bump stop and the damper The ARB is attached to the front of the subframe with two
and protects the damper rod from dirt and damage. Polytetrafluoroethylene (PTFE) bushes that are secured with
clamp plates and bolts.
The coil spring axis is offset to the axis of the damper.
The low friction bushes PTFE require no additional greasing
This arrangement provides side load compensation, which and allow the ARB to rotate freely with quiet operation.
reduces friction within the damper.
This allows the bar to respond quickly to roll inputs and allows
Damper
stiffer bushes to be used as there is relatively little compression
Each damper is handed, is gas charged and oil filled, and is of or twisting.
twin tube construction.
Washers are attached to the ARB to locate the outside of each
bush and prevent sideways movement of the bar.
1.0 388
The ends of the ARB are attached to each strut spring seat via The lower ball joint is mounted at 180° to the axis of the link
an ARB link. and attaches to the ARB and is secured with a locknut.
This arrangement allows the ARB to act on a ratio of The link must be attached to the ARB with the ball joint on
approximately 1:1 with the wheel travel providing maximum the outboard side of the bar and the locknut facing inwards.
roll bar effectiveness.
The ball joints on the ARB links are not serviceable and if
Each ARB link has a ball joint fitting at each end, which improves replacement of either is necessary, a new link will be required.
response and efficiency.
The top ball joint is mounted on the axis of the link and attaches
directly to the damper strut and is secured with a locknut.
1.0 389
Service Procedures
Front Hub
Remove
1. Raise vehicle on lift.
2. Remove front wheel.
Wheel Remove
3. With an assistant applying brakes, remove and discard
drive shaft hub nut.
12. Remove M10 nut from ball pin and release track rod
ball joint from hub.
13. Remove screw securing ABS speed sensor, release
sensor and position aside.
4. Remove 2 bolts securing brake caliper to hub.

5. Release brake hose and ABS sensor wiring from
damper.
14. Remove nut and bolt securing lower arm to hub.
6. Release caliper from hub and tie aside.
Caution: Do not tie or allow caliper to hang on brake

hose.
7. Remove countersunk screw securing brake disc to

drive flange.
8. Remove brake disc. 15. Remove lower ball pin shield.
9. Remove nut securing track rod to steering arm and 16. Remove 2 nuts/bolts securing damper to hub.
discard nut.
10. Fit an M10 nut to ball pin, flush with end of pin.
11. Using T38008 release track rod ball joint from steering
arm.
1.0 390
90–110Nm.
19. Position brake hose and ABS sensor harness to
damper, secure.
20. With an assistant applying brakes, fit drive shaft hub nut
21. Stake drive shaft hub nut.
22. Fit road wheel.
Wheel
24. Check wheel alignment.
Wheel Alignment
17. Using T32011release hub from lower arm ball joint.
18. Release drive shaft from hub.
19. Remove hub assembly from damper.
Caution: Do not store hub bearings near magnetic fields

or iron filings as damage may occur.
Caution: Do not remove protective cover from bearing

until hub is about to be fitted.
Refit
1. Clean hub to damper mating faces.
2. Clean drive shaft and flange splines.
3. Clean hub to lower arm ball joint mating faces.
4. Fit hub to damper.
5. Position drive shaft into drive flange.
6. Locate lower arm ball joint in hub.
7. Fit nuts/bolts securing damper to hub and tighten to
90–110Nm.
8. Position lower ball pin shield.
9. Fit nut and bolt securing lower arm to hub and tighten
to 50–65Nm.
10. Ensure ball joint is fully engaged in hub and bolt is in
ball joint groove.
11. Clean track rod to steering arm ball joint mating faces.
12. Connect track rod ball joint to steering arm, fit new
nut and tighten to 28–32Nm.
13. Clean wheel ABS sensor to hub mating faces.
14. Lightly lubricate ABS sensor and hub mating faces with
correct grade of grease.
Capacities, Fluids and Lubricants

15. Fit ABS sensor to hub and secure with screw and
16. Fit brake disc to drive flange, fit countersunk screw and
17. Release brake caliper and position to brake disc.
18. Fit bolts securing caliper to hub and tighten to
1.0 391
Front Hub Bearing

Remove
1. Remove hub assembly.
Front Hub Remove
2. Position hub assembly on suitable press.
3. Using TCH00020 to press drive flange from
bearing/hub.
Refit
1. Clean hub and bearing mating faces.
2. Using TCH00019 support hub, use TCH00067 to
press the new bearing into hub.
4. Remove circlip from hub.
3. Fit circlip to hub.

4. Using TCH00019 support the hub bearing, using
TCH00018 press the hub flange into hub bearing.
5. Re-position hub on suitable press using support tools

TCH00021 and TCH00068.
5. Fit hub.
Front Hub Refit
6. If necessary use T32001 and TCH00020 to remove

the inner ring of bearing from drive flange.
1.0 392
Front Lower Arm
Remove
1. Remove wheel.
Wheel Refit
2. Remove nut/bolt securing lower arm ball joint to hub,
remove ball pin shield.
Refit
1. If necessary position ball pin to lower arm, fit nuts/bolts,
tighten to （60±5））Nm+60°±5°.
2. Position lower arm to vehicle, locate front and rear
bushes.
3. Insert bolt in front bush, start nut, do not fully tighten
at this stage.
3. Release ball joint from hub.
4. Insert bolt in rear bush, loosely tighten.
4. Remove bolt from lower arm rear pivot bush.
5. Position lower ball pin shield.
6. Locate lower arm ball pin in hub, fit nut/bolt, tighten
to 50–65Nm.
7. Tighten lower arm rear bush bolt to 90Nm+90°.
8. Tighten lower arm front bush nuts/bolts to 90Nm+90°.
9. Fit wheel.
Wheel Refit
10. Carry out wheel alignment check.
Wheel Alignment
5. Remove nut/bolt from lower arm front bush.
6. Remove lower arm.

7. If necessary remove nuts/bolts X3 securing ball pin to
lower arm.
1.0 393
Front_Lower_Ball_Pin Front Lower Arm Rear Bush

Remove Remove
1. Remove wheel. 1. Remove front lower arm.
Wheel Remove Front Lower Arm Remove

2. Remove nut/bolt securing lower arm ball joint to hub. 2. Position lower arm on suitable press.
3. Using TCH00069 and TCH00070 press bush from
lower arm.
3. Release ball joint from hub.

4. Remove nuts/bolts X3 securing ball pin to lower arm.
4. Discard bush.
Refit
1. Position new bush to arm on suitable press.
2. Using TCH00069 and TCH00070 press bush into
lower arm.
Reift
1. Position ball pin to lower arm, fit nuts/bolts, tighten to
（ 60±5））Nm+60°±5°.
2. Locate lower arm ball pin in hub, fit nut/bolt, tighten
to 50–65Nm.
3. Fit wheel.
3. Refit front lower arm.
Wheels Refit
Front Lower Arm Refit
4. Carry out wheel alignment check.
Wheel Alignment
1.0 394
Front Lower Arm Front Bush Front Damper
Remove Remove
1. Remove front lower arm. 1. Raise vehicle on lift.
Front Lower Arm Remove 2. Remove road wheel.

2. Position lower arm on suitable press. Wheel Remove
3. Using TCH00071 and TCH00072 press bush from 3. Release ABS sensor harness and brake hose from
lower arm. damper. Release harness and brake hose from clip.
4. Discard bush. 4. Use an open ended spanner on the flats machined on

Refit the anti-roll bar link to prevent ball stud from rotating,
remove nut, release anti roll bar link from damper.
1. Position new bush to arm on suitable press.
2. Using TCH00071 and TCH00072 press bush into
lower arm.
5. Remove bolts securing damper to hub.
3. Refit front lower arm.
Front Lower Arm Refit
6. Release hub from damper.
1.0 395
7. Lower vehicle. damper. Ensure bump stop and bump stop washer are
8. Remove nut securing damper to body, retrieve washers. correctly located in dust cover.
5. Fit spring to damper.
6. Position spring/damper assembly to spring compressor
T32016 and T32017. Compress spring.
7. Ensuring correct orientation, fit spring mounting plate
and rubber to damper shaft.
8. Fit washer and new nut.
9. Hold shaft with an Allen key, tighten nut to 54–62Nm.
10. Release spring tension, release shoes, remove spring
compressor.
11. Clean damper/spring location on underside of wing.
12. Position damper/spring assembly to body, fit washers,
tighten nut to 60–80Nm.
9. Remove spring and damper assembly.
13. Locate hub to damper, fit nuts/bolts, tighten to
10. Position spring compressor T32016 and T32017 in 90–110Nm.
suitable vice.
14. Clean anti-roll bar link, fit to damper, tighten nut to
11. Position spring and damper assembly to spring 50–65Nm. Use an open ended spanner on the flats
compressor. Compress spring. provided to prevent ball stud rotation.
15. Secure brake hose and ABS sensor harness to
brackets. Secure ABS sensor harness and brake hose
in swivel clip.
16. Fit road wheel.
Wheel Refit
18. Check wheel alignment.
Wheel Alignment
12. Hold shaft with an Allen key, remove piston rod top
nut. Discard nut.
13. Remove washer and mounting turret with bearing.
14. Remove isolator.
15. Remove spring.
16. Remove bump stop washer, bump stop and dust cover.
17. Remove isolator.
18. Release spring tension, release shoes and remove spring
from compressor.
Refit
1. Inspect damper, spring mounting rubbers and bearing
for deterioration and damage.
2. Inspect damper dust cover and bump stops for signs of
deterioration and damage.
3. Wipe damper shaft and bump stop cup.
4. Fit bump stop, bump stop washer and dust cover to
1.0 396
Anti Roll Bar Anti Roll Bar Bush
Remove Remove
1. Remove front subframe. 1. Raise vehicle on hoist.
Front Subframe Remove 2. Remove bolts securing anti roll bar brackets to
subframe.
2. Remove bolts securing anti roll bar brackets to

subframe. 3. Remove anti roll bar bush brackets, discard bushes.
Refit
1. Position new bushes on anti roll bar.
Caution: Anti roll bar bushes have a special coating and

must not be lubricated.
2. Secure anti roll bar brackets, tighten to 22–28Nm.

3. Lower vehicle.
3. Remove anti roll bar, discard bushes.

Refit
1. Position new bushes on anti roll bar.
2. Position anti roll bar on front subframe.
3. Secure anti roll bar brackets, tighten to 22–28Nm.
4. Refit front subframe.
Front Subframe Refit
1.0 397
Anti Roll Bar Link Front Subframe Assembly

Remove Remove
1. Remove wheel. 1. Raise the vehicle on a lift.
Wheels Remove 2. Remove the front wheels.

2. Use an open ended spanner on the flats machined on Wheels Remove
the anti-roll bar link to prevent ball stud from rotating, 3. Remove the exhaust pipe.
remove nut, release anti roll bar link from damper.
Exhaust Pipe Remove
4. Remove the lower rear tie rod of the engine.
5. Disconnect the steering tie rod from the steering
knuckle assembly with the tool T38008.
3. Use an open ended spanner on the flats machined on

the anti-roll bar link to prevent ball stud from rotating,
remove nut, release anti roll bar link from anti roll bar.
6. Disconnect the connecting rod of the stabilizer bar

from the horizontal stabilizer bar.
4. Remove anti roll bar link.

Refit
1. Position new link in anti roll bar and damper.
7. Loosen the rear bushing of the front lower swing arm
2. Fit nut to link at anti roll bar, use an open ended spanner from the front subframe.
on the flats machined on the anti-roll bar link to prevent
ball stud from rotating , tighten to 45–55Nm.
3. Fit nut to link at damper, use an open ended spanner on
the flats machined on the anti-roll bar link to prevent
ball stud from rotating , tighten to 50–65Nm.
4. Refit wheel.
Wheel Refit
1.0 398
8. Loosen the front bushing of the front lower swing arm Refit
from the front subframe. 1. Locate 2 new bolts to the corresponding holes of the
body but do not tighten them.
2. Locate 4 new bolts to the corresponding holes of the
body but do not tighten them.
3. Tighten 2 bolts to 90Nm+180°.
4. Tighten 4 bolts to 90Nm+180°.
5. Connect the rear bushing of the front lower swing
arm to the front subframe, and tighten the bolt to
90Nm+90°.
6. Connect the front bushing of the front lower swing
arm to the front subframe, and tighten the bolt to
90Nm+90°.
7. Connect the connecting rod of the stabilizer bar to
9. Remove and discard 6 bolts fixing the front subframe the horizontal stabilizer bar, and tighten the nut to
to the body in white. 45–55Nm.
8. Fit the exhaust pipe to the vehicle.
Exhaust Pipe Refit

9. Fit the wheels.
Wheels Refit
11. Check the wheel alignment parameters.
10. Remove the front subframe assembly from the vehicle.
1.0 399

Number
T32001 Puller universal

Remover ball
T38008
joint
Support front
Lever front TCH00019
hub
T32011 lower arm ball
joint
Support front
TCH00067 hub bearing and
Remover front drive flange
TCH00020
hub bearing
Replacer front
TCH00018
Support front hub bearing
TCH00021
hub
Remover and
replacer front
Support front TCH00069
lower arm bush
TCH00068 hub bearing and (big)
drive flange
1.0 400
Number
Support front
TCH00070 lower arm bush
(big)
Remover and
replacer front
TCH00071
lower arm bush
(small)
Support front
TCH00072 lower arm bush
(small)
Coil spring
T32016
compressor
Adaptor
T32017 coil spring
compressor
1.0 401
Suspension System Rear Suspension
Rear Suspension
Specifications
Torque
Description Value
Nut - rear damper to body 55–65Nm
Bolts - rear damper to trailing arm 140–170Nm
Nuts - rear spindle 320–350Nm
Bolts - rear subframe to bracket 90–110Nm
Screw - hand brake clip bracket 7–10Nm
Specifications
Rear suspension
Total coils 6.48
Wire diameter 11.3mm
Free Length 302mm
1.0 402
Rear Suspension Suspension System
System Component Layout
Rear Suspension Layout
1. Rear Damper Assembly 3. H Frame Member Assembly

2. Rear Suspension Coil Spring Assembly 4. Rear Hub Assembly
1.0 403
Rear Suspension Disassembled View
1. Rear Suspension Damper Assembly 4. Rear Suspension Lower Spring Vibration Isolator
2. Rear Suspension Upper Spring Vibration Isolator 5. H Frame Member Mounting Bracket Assembly
3. Rear Suspension Spring 6. H Frame Member Assembly
1.0 404
Rear Shock Absorber Disassembled View
1. Rear Damper Assembly 7. Bolt

2. Rear Damper Gasket 8. Rear Suspension Limit Disc
3. Bolt 9. Rear Suspension Damper Column Piston Rod Bushing
4. Rear Suspension Damper Column Dust Cover 10. Rear Damper Rebound Gasket
5. Rear Suspension Spring 11. Nut
6. Cap － Rear Suspension Spring
1.0 405
Description The lower isolator is positively retained by a location pip on

Rear suspension includes: the lower arm.
• Coil springs A hole in the lower isolator is provided for water drainage
and must be aligned with corresponding hole in the lower arm
• Dampers
when fitted.
• H frame member
Rear Shock Absorber
H Frame Member
The dampers are gas charged and oil filled and are of twin tube
The H frame member consist of a couple of trailing arm, a
construction.
cross beam , a lower coil spring seat , a damper fixing point
and a stub axle. The twin tube construction allows the damper piston to
operate on an inner tube with an oil/ gas cavity between the
The trailing arms are fabricated structure which is attached to
inner and outer tubes.
the body via two fabricate mounting brackets, forward of the
rear wheels. This minimises oil cavitation and eliminates the effect of
damage to the outer tube affecting piston operation.
A fabricated bracket inboard of each stub axle connected to
the trailing arm and cross beam provides the lower coil spring The lower damper mounting is fitted with a non-serviceable
seat. bush that is attached to the trailing arm with a bolt and washer.
The trailing arm, rearward of the stub axle provides the lower This mounting position gives the damper an approximate ratio
damper fixing point. of 1:1, which is beneficial for damping control.
A stub axle is bolted with four bolts to each side of the frame The damper rod is located in a bush in a top mounting and is
and provides location for the rear brakes and road wheels. secured with a rebound plate and a locknut.
The ‘twist beam ’ principle use angled pivot bushes which have The top mounting is attached to the body with two bolts.
a special construction to decrease the vertical vibration of the The rebound plate fitted between the damper rod locknut and
body. the top mounting cushions forces as the damper rod reaches
Coil Spring full extension.
Coil springs, manufactured from chromium steel, are fitted A spring aid plate and a spring aid are fitted over the rod
between the body and the lower arm. and cushion the damper operation if maximum bump travel
is reached.
Each spring is located in upper and lower spring isolators which
reduce noise transmitted to the body from the suspension.
Both isolators are positively retained to the spring.
1.0 406
Service Procedures Rear Spring
Rear Damper Assembly Remove
Remove 1. Remove wheel.
1. Remove wheel. Wheel Remove
Wheels Remove 2. Place suitable support under rear lower arm.
2. Place suitable support under rear lower arm. 3. Remove lower damper mounting to subframe bolt.
3. Remove rear damper upper mounting to body fixings.
4. Lower support device/suspension arm, remove spring.

4. Remove lower damper mounting to subframe bolt. 5. Remove isolator pads.
Refit
1. Position spring isolator pads.
2. Position spring.
3. Raise support device/suspension arm to align lower
damper fixing.
4. Fit lower damper to subframe bolt, tighten
to140–170Nm.
5. Remove support.
6. Refit wheel.
Wheel Refit
5. Remove the shock absorber.

Refit
1. lower damper
2. Fit lower damper to subframe bolt, do not fully tighten
at this stage.
3. Fit upper damper mounting to body bolts, tighten to
55–65Nm.
4. Fully tighten lower mounting fixing bolt to
140–170Nm.
5. Remove support.
6. Refit wheel.
Wheel Refit
1.0 407
Rear Hub Bearing H Frame Assembly

Remove Remove
1. Remove brake drum. 1. Remove handbrake cables from brake shoes.
Brake Drum Handbrake Cable

2. Remove grease cap. 2. Remove handbrake cable to subframe fixing clips.
3. Knock back lock nut stake, remove nut, discard. 3. Remove rear ABS sensors.
4. Remove rear drive flange/hub bearing, collect washer. ABS Sensor - Rear
4. Disconnect rear brake pipes from rear flexible hoses at
subframe fixing clips.
5. Release rear flexible brake hoses from subframe
brackets.
6. Using suitable jacking equipment support rear subframe.
7. Remove lower damper fixings.
Refit
1. Fit rear drive flange/hub bearing.
2. Position washer.
3. Fit new nut, tighten to 320–350Nm.
4. Using a suitable chisel knock in locking stake.
5. Fit grease cap.
8. Lower subframe, remove rear springs.
6. Refit brake drum.
9. Remove subframe mounting fixings.
Brake Drum
10. Lower subframe, remove from jacking equipment.

Refit
1. Position subframe on suitable jacking equipment.
2. Raise subframe to vehicle, align and loosely fit front
mounting bolts.
3. Ensure correct fitment of spring isolator pad/s
4. Position springs, fit lower damper fixings.
5. Fully tighten front subframe mountings to 90–110Nm.
1.0 408
6. Fully tighten lower damper bolts to 140–170Nm.
7. Refit brake flexible hose to subframe, fit brake pipe,
secure clip.
8. Position handbrake cable clips to subframe, tighten
to7–10Nm.
9. Refit ABS sensors.
ABS Sensor - Rear

10. Refit handbrake cable.
Handbrake Cable
11. Bleed brakes.
Brake System Draining

12. Carry out alignment check.
1.0 409
Suspension System Tires and Wheels
Tires and Wheels

Specifications
Torque
Description Value
Bolt - road wheel 105–115Nm
Nut-Tire press sensor locknut 4.5–5.5Nm
1.0 410
Tires and Wheels Suspension System
Parameter
Wheel Rim Specification 6.0J×15 6.5J×16 5.5J×14
Tyre Specification 185/65 R15 195/55 R16 185/70 R14
Tyre Pressure (no-load) 210kPa/2.1bar/30psi 210kPa/2.1bar/30psi 210kPa/2.1bar/30psi
Category Wheel Wheel Spare Tyre
1.0 411
Suspension System Tires and Wheels
Service Procedures
Wheel
Warning: Do not use silicone lubricant on the or wheel rim
or tyre edge. Clean tyre edge before removing. Use 50%
non-silicone lubricant and 50% water based lubricant to
these areas prior to refitting.
Remove
1. Remove the wheel trim cover assembly with a
screwdriver.
2. Remove 4 highway type wheel bolts with a circular
ended wrench of the vehicle hand tools.
3. Place the vehicle at the lifting platform and lift to a
certain height. Warning: If there is oil leakage between the wheel and the
4. Remove wheels. brake disc or drum, it will cause the wheel bolts to become
loose and result in injury with the vehicle out of control.
5. Remove the tyre and the wheel valve assembly.
Never use heat to remove a seized wheel. This will shorten
Warning: Use a tyre changer to remove the tyre. Manual the life of the wheel, wheel bolts, hub and bearing. Wheel
tools or prybar could damage the road wheel or tyre. bolts must be tightened in correct sequence and to correct
Caution: Do not place the wheel face down on the ground torque to avoid distortion of wheel, brake drum or disc.
to avoid scratching. 5. Refit the wheel trim cover assembly.
Refit
Caution: Please clean the corrosive on the surface of the
road wheel, drum and brake disc before refitting. If wheel,
disc and drum contact surfaces are not properly cleaned,
the wheel bolts could become loose and may cause the
wheel to fall off while the vehicle is moving. This will cause
the vehicle to go out of control, and could cause injury.
1. Refit the wheel valve assembly.

2. Refit the tyre with a tyre changer and charge the tyre
until the rim is put in place. Ensure that the locating
ring at the outside of the tyre bead is around the wheel
rim flanges. This method can ensure the right position
of tyre bead.
3. Perform the wheel dynamic balance operation again,
refit new and appropriate wheel balance blocks.
4. Refit wheels, tighten 4 steel highway type wheel bolts
to 105–115Nm. For tightening order, please see the
picture below (1 to 4).
1.0 412
Tires and Wheels Suspension System
Tyre Pressure Monitoring Controller Tyre Pressure Sensor
Remove Remove
1. Disconnect the battery negative. 1. Remove the wheels.
2. Remove the centre console assembly. Wheels Remove
Centre Console Assembly Remove 2. Exhaust the tyres.
3. Disconnect the electrical connector of the tyre 3. Press the tyre at the valve core on the tyre changer
pressure monitoring controller. until the tyre pressure sensor is exposed.
4. Loosen 2 nuts and remove the tyre pressure monitoring 4. Remove the locking nut fixing the tyre pressure sensor
controller. and the valve core assembly to the wheel, and remove
the tyre pressure sensor and the valve core assembly.
Refit
1. Fix the tyre pressure monitoring controller to the Refit
centre console bracket with nuts and tighten the nuts
1. Fit the new tyre pressure sensor and the valve core
up.
base assembly to the wheel hub, fit and tighten the
2. Connect the electrical connector of the tyre pressure locking nut to 4.5–5.5Nm.
monitoring controller.
Keep the tyre from the electronic module during the tyre
3. Fit the centre console assembly.
mounting process.
Centre Console Assembly Refit 2. Inflate the tyres.
4. Connect the battery negative. 3. Fit the wheels.
5. Perform a self-learning for the tyre pressure monitoring
Wheels Refit
system (TPMS).
4. Perform a self-learning for the tyre pressure monitoring
system (TPMS).
1.0 413
1.0 414
Brake Brake System
Brake
Specifications
Torque
Description Value
Nuts - master cylinder to servo 21–29Nm
Bolt - hose to panel 7–10Nm
Nuts -Brake pipe unions to master cylinder 15–19Nm
Nuts - pedal box to body 19–25Nm
Nuts - servo to ped 19–25Nm
Bolts - pedal box to body 19–25Nm
Nuts - ped box to body 19–25Nm
Blots - clutch cylinder to pedal box 7–10Nm
Screw - accelerator to body 8Nm
Bolt - brake lamp switch to pedal box 8–12Nm
Bolt - brake caliper 90–110Nm
Front brake hose to caliper housing 16–18Nm
Screw - front brake bleeding 7–9Nm
Screw - front brake disk to hub 7–10Nm
Bolt - front caliper housing to hub 85–105Nm
Screw - cap drum-brake 6–8Nm
Bolt - wheel cylinder to back-plate 7–13Nm
Rear brake hose to rear brake drum connection 15–19Nm
Screw - rear brake bleeding 9–13Nm
Bolt - EVP to bracket 7–10Nm
1.0 415
Brake System Brake

System Layout
Brake Hydraulic System Layout
1. Front Brake Disk 6. Brake Fluid Reservoir

2. Front Brake Caliper Assembly 7. Rear Wheel Brake Drum Assembly
3. Brake Modulator 8. Rear Brake Pipeline
4. Brake Booster Assembly 9. Rear Wheel Brake Drum Guard Plate
5. Brake Master Cylinder 10. Electronic Vacuum Pump
1.0 416
Brake Brake System
Description The tandem master cylinder contains two chambers and
Vacuum Servo Assembly associated pistons.
The vacuum servo/booster assembly provides boost during Each piston/chamber controls a circuit, the rear piston
braking to reduce the pedal force required for braking. produces brake pressure for the primary circuit, this covers
LHF & RHR, the front piston produces brake pressure for the
In a case of the vacuum booster assembly failure, the hydraulic
secondary circuit, and this covers RHF & LHR.
system maintains brake function, but greater pedal braking
force is required due to lack of vacuum assistance. The remote brake fluid reservoir is installed higher than the
master cylinder in order to maintain a gravitational feed.
The vacuum booster assembly is connected to the bulkhead
(LHD)/pedal box (RHD) via 4 studs. The fluid reservoir is partitioned inside to feed fluid to each
brake circuit independently, thus avoiding the condition that
The brake master cylinder assembly is connected via two fixing
both circuits could become devoid of fluid.
bolts at the front end of the vacuum booster assembly.
The brake fluid reservoir utilizes a fluid level switch.
The brake servo assembly consists of a circular housing which
contains two diaphragms, a central plate, a control valve A reed style switch, featuring a permanent magnet and float is
assembly, input and output push rods and a filter. installed in the fluid reservoir which is linked to the fluid level,
handbrake and EBD warning lamp in the instrument pack.
The input push rod is connected to the brake pedal.
Front Brake
The output push rod locates in the primary piston of the
master cylinder. Each front brake consists of a single-piston sliding brake caliper
assembly fitted to the hub and a ventilated brake disc.
A protective gaiter is installed on the control valve assembly
Rear Brake
where it extends from the rear of the housing.
Each rear brake consists of a back plate, a brake drum, brake
A port in the front face of the housing is connected to a vacuum
shoes, a hydraulic wheel cylinder, a self adjusting rod and return
line from the engine.
springs.
A non return valve is incorporated into the vacuum line.
The back plate is installed on the stub axle, retained by the stub
The control valve assembly consists of a valve body containing axle bolts and provides location for brake shoes and hydraulic
a valve, a piston, a valve spring and an input rod spring. wheel cylinder.
The valve controls a vacuum port in the valve body. The brake drum is fitted to the flange of bearing, and rotates
The piston controls an air inlet port between the valve and the with the wheels.
piston. Each rearward brake shoes is fitted with a handbrake cable
A reaction disc and a ratio disc separate the piston from the lever.
output push rod. Brake Pedal and Brake Lamp Switch
A guide tube on the front of the valve body is attached to the The brake pedal is installed on a pivot shaft in the pedal
front diaphragm and supported in a bush in the central plate. mounting bracket on the engine bulkhead.
A return spring locates in the open end of the guide tube. A clevis pin and clip connect the input rod of the brake servo
to the brake pedal.
Brake Master Cylinder Assembly
A tandem brake master cylinder is installed on the brake servo A tang on the end of the brake pedal activates a plunger style
assembly. brake switch in the pedal mounting bracket.
Fluid is supplied via a remote reservoir connected to the The brake switch is adjustable and secured in position using a
master cylinder via two rubber hoses. lock nut.
The master cylinder is fixed to the front of the brake servo via The brake lamp switch provides two brake pedal state outputs,
2 stud fixings. one power, the other ground.
When the brake pedal is pressed, the brake master cylinder This signal is supplied to the ECM and used to illuminate the
assembly produces hydraulic pressure so that the brake stop lamps.
operates.
1.0 417
Brake System Brake
Service Procedures Brake Master Cylinder and Reservoir Assembly

Brake Fluid Level Indicator Switch Remove
Remove 1. Put a cloth under the brake master cylinder to absorb
1. Disconnect the connector from the brake fluid level the spilled fluid.
switch (1). Caution: Brake fluid will damage paint finished surfaces.
water.
2. Drain the brake master cylinder with an appropriate

container.
3. Disconnect the connector (1) of the brake fluid
reservoir level switch.
2. Loosen the clip fixing the brake fluid level switch to the
brake fluid reservoir and remove the switch.
Refit
1. Fit the brake fluid level switch to the brake fluid
reservoir and secure with clips.
2. Connect the connector to the brake fluid level switch.
4. Loosen 2 brake pipes (1) from the brake master
cylinder.
5. Remove 2 nuts and washers (2) fixing the master
cylinder to the vacuum booster and discard the nuts.
6. Loosen the reservoir mounting bolts.
1.0 418
Brake Brake System
Vacuum Booster Assembly
Remove
1. Remove the brake master cylinder and reservoir
assembly.
Brake Master Cylinder and Reservoir Assembly

Remove
2. Disconnect the harness connector of the vacuum pipe.
3. Disconnect the vacuum pipe from the vacuum booster.
Caution: The force to remove the hose shouldn’t too

heavy to damage the connector of vacuum hose.Do not
damage the connector and keep the connector away
7. Remove the master cylinder and reservoir assembly. from water when removing or fixing the hose with vacuum
sensor.
Refit
1. Locate the brake master cylinder to the vacuum 4. Remove the driver side lower cover plate assembly.
booster and secure with 2 new nuts. Tighten the nuts Driver Side Lower Cover Plate Assembly Remove
to 21–29Nm. 5. Remove and discard 4 nuts fixing the vacuum booster
2. Fix the reservoir to the body, fit 3 bolts and tighten to its cover plate.
to 7–10Nm.
3. Clean the brake pipe connector, fit the brake pipe to
the brake master cylinder, and tighten to 15–19Nm.
4. Connect the clutch pipeline to the reservoir.
5. Connect the connector of the brake fluid level switch.
6. Bleed the brake system.
Brake System Bleeding
6. Remove and discard the axis pin and block pin (2) fixing
the push rod of the vacuum booster to the brake pedal.
7. Remove and discard 5 nuts (1) fixing the cover plate of

the vacuum booster to the dash panel of the body.
1.0 419
Brake System Brake
Brake pedal
Remove
2. Remove steering column closing panel base.
Steering Column
3. Remove brake pedal push rod clip and clevis pin.
4. Remove clutch master cylinder push rod clip and clevis
pin.
5. Remove clutch master cylinder fixings, manipulate
cylinder to one side.
6. Disconnect brake light switch, clutch pedal switch and
8. Remove the vacuum booster assembly. throttle position sensor electrical connectors.
Refit 7. Remove pedal box/brake servo fixings X4.
1. Locate the vacuum booster assembly to the body.

2. Locate the cover plate of the vacuum booster to the
dash panel of the body, fit 5 new nuts and tighten to
19–25Nm.
3. Fit the vacuum booster to the axis pin and block pin of
the pedal assembly.
4. Locate the vacuum booster to the cover plate of
the vacuum booster, fit 4 new nuts and tighten to
19–25Nm.
5. Fit the driver side lower cover plate assembly.
Driver Side Lower Cover Plate Assembly Refit

6. Connect the vacuum pipe to the vacuum booster. 8. Remove bolts securing throttle position sensor to
Caution: Keep the dust and foreign matter from vacuum pedal box.
hose.If having trouble to fix vacuum hose ， please using 9. Remove throttle pedal & sensor.
grease special for fixing vacuum hose to lubricate ， other 10. Remove bolts securing pedal box to bulkhead panel.
liquid or grease is prohibited.
11. Remove pedal box assembly.
7. Connect the harness connector of the vacuum pipe. 12. Remove clutch pedal switch.
8. Fit the brake master cylinder and reservoir assembly. 13. Remove brake light switch.
Refit
14. Remove clutch/brake pedal pivot pin retaining clip.

15. Release pedal springs.
16. Slide out pivot pin.
1.0 420
Brake Brake System
17. Remove clutch pedal. Brake lamp switch
18. Remove brake pedal. Remove
2. Remove the steering column lower cover plate.
Steering Column Lower Cover Plate Remove
3. Release the brake lamp switch harness connector.
4. Refit the inner nut securing the brake lamp switch to
the pedal bracket with an open spanner, remove the
outer nut and the brake lamp switch.
Refit
1. Position brake pedal and spring.
2. Partially insert pedal pivot.
3. Position clutch pedal and spring.
4. Fully insert pivot pin.
5. Fit clutch/brake pedal pivot pin retaining clip.
6. Fit pedal springs.
Refit
7. Position clutch pedal switch.
1. Adjust the initial position at the time of brake lamp
8. Position brake light switch.
switch refit. Release the pedal first and keep it in the
9. Position pedal box assembly to brake servo and initial position. Then allow the brake lamp switch
bulkhead. contact to contact with the brake pedal, adjust the
10. Fit pedal box to body fixings, tighten to19–25Nm stretching length of the brake lamp switch contact
11. Fit pedal box/brake servo fixings, secure to 19–25Nm (between the pedal and the outer nut), ensure that the
stretching length is kept within 0.5-1.5mm.
12. Fit brake pedal clevis pin and clip.
2. Secure the inner nut of the brake lamp switch with
13. Refit clutch master cylinder, tighten fixings to 7–10Nm
an open spanner, refit the outer nut and tighten to
14. Fit clutch pedal push rod pin and clip. 8–12Nm.
15. Refit throttle pedal/position sensor, tighten fixings to 3. Connect the brake switch connector.
8Nm.
4. Refit the steering column lower cover plate assembly.
16. Refit all electrical connectors.
Steering Column Lower Cover Plate Refit
17. Adjust clutch and brake pedal switches.
18. Fit steering column closing panel.
Steering Column Closing Panel

19. Reconnect battery.
1.0 421
Brake System Brake
Brake Caliper – Front 8. Bleed brake system.

Remove Brake Bleed
9. Fit wheel/s.
Wheel
2. Remove front wheel/s.
Wheels
3. Remove brake pads.
Brake Pads - Front
4. Place a container beneath vehicle to collect any fluid
spillage.
5. Clamp brake flexible hose using suitable brake pipe
clamp.
6. Loosen brake hose to caliper union.
Caution: Before disconnecting or removing components,
ensure the immediate area around joint faces and
connections are clean. Plug open connections to prevent
contamination.
7. Remove 2 brake caliper fixing bolts.
8. Remove brake caliper from flexible brake hose.

Refit
1. Clean components and mating faces.
Warning: Do not use compressed air to clean brake
components. Dust from friction materials can be harmful
if inhaled.
2. Remove any scale and loose corrosion from around
edge of disc.
3. Fit brake caliper to flexible brake hose – do not fully
tighten at this stage.
4. Fit brake pad to caliper housing.
5. Position caliper to hub, fit bolts, tighten to 90–110Nm
6. Fully tighten flexible brake hose to 16–18Nm – ensure
hose is not twisted.
7. Fit brake pads.
Brake Pads - Front
1.0 422
Brake Brake System
Brake Pads – Front sensor must be renewed, otherwise the warning light will
Remove still be illuminated.
Warning: Do not work on or under a vehicle supported 9. Untie caliper housing and position to caliper carrier
only by a jack.Always support the vehicle on safety stands. and align. Fit guide pins and tighten..
Warning: Brake pads must be renewed in axle sets only, 10. Fit caps to guide pin dust covers.
otherwise braking efficiency may be impaired. 11. Fit anti-rattle spring clip to carrier housing.
1. Raise vehicle on lift. 12. Check and top up brake fluid reservoir.
2. Remove front wheels. Caution: Never re-use fluid that has been bled from the
Wheels brake system.
3. Remove anti-rattle spring from caliper housing. 13. Fit wheels.
4. Remove 2 caps from guide pin dust covers.
Wheels
5. Remove 2 guide pins from caliper housing.
6. Release caliper housing from caliper carrier and tie
15. Operate brake pedal several times to seat brake pads.
aside.
Tip: Pedal travel may be longer than normal during first
Caution: Don’t tie brake caliper on brake hose.
brake applications.
7. Remove brake pads from caliper housing.
Refit
edge of disc. Clean caliper housing and caliper carrier
using brake cleaning fluid.
if inhaled.
2. Inspect caliper and seals for damage.
3. Remove bleed screw cap, connect bleed hose and
bottle to bleed screw. Loosen bleed screw.
4. Press piston into caliper housing then tighten bleed
screw to 7–9Nm.
5. Disconnect bleed hose and remove bottle.
6. Secure bleed screw cap.
7. Fit brake pads to caliper housing.
8. Lubricate guide pins with anti-seize grease.
Caution: If brake pads low warning light was illuminated
on the instrument pack before changing brake pads, the
1.0 423
Brake System Brake
Brake Disc – Front Thickness and Run-Out Check-Front Brake Disc

Remove Check
Warning: Do not work on or under a vehicle supported 1. Raise vehicle on lift.
only by a jack.Always support the vehicle on safety stands. Warning: Do not work on or under a vehicle supported
Caution: Brake discs must be renewed in pairs, unless one only by a jack.Always support the vehicle on safety stands.
disc requires renewal before 1000 miles (1500 km) from 2. Remove front wheels.
new. Wheel
1. Raise vehicle on lift. 3. Remove 2 bolts securing caliper carrier to hub, release
2. Remove front wheels. caliper carrier from hub and tie aside.
Wheels Caution: Do not tie or allow caliper to hang on brake

hose.
3. Remove 2 bolts securing caliper carrier to hub.
4. Release caliper carrier from hub and tie aside 4. Using a micrometer, measure the thickness of disc
at 4 equally spaced points around disc, 10 mm from
Caution: Do not tie or allow caliper to hang on brake outer edge of disc. Disc thickness must be 20.0 mm
hose. minimum; Renew disc if outside limit(s).
5. Remove Torx screw securing brake disc to drive flange. Caution: Brake discs must be renewed in pairs, unless one
disc requires renewal before 1000 miles (1500 km) from
new.
5. Mount a Dial Test Indicator (DTI) toTCH00022 and

secure to inboard side of hub using caliper assembly
bolt hole.
6. Remove brake disc.

Refit
1. Ensure mating surfaces of disc and drive flange are clean.
2. Fit disc to drive flange, fit countersunk screw and
3. Check brake disc run-out. 6. Position DTI probe 5 mm from outside edge of disc.
7. Zero DTI and rotate disc one complete turn to measure
Thickness and Run-out Check
disk runout. Disc runout must not exceed 0.05 mm.
4. Examine brake pads and renew if necessary.
8. If disc runout is outside limits:
5. Fit caliper assembly to hub, tighten bolts to 85–105Nm.
• Remove countersunk screw securing brake disc to hub
6. Fit wheel. and remove disc.
Wheel • Ensure disc to hub flange mounting faces are clean.
7. Lower the vehicle. • Fit disc to hub and tighten countersunk screw and tighten
to 7–10Nm.
• Check disc run-out again as detailed.
• If run-out is still outside limits, renew disc and/or hub.
9. Remove DTI and TCH00022 from inboard side of hub.
10. Fit caliper assembly to hub, fit and tighten bolts to
85–105Nm.
1.0 424
Brake Brake System
11. Fit wheel. Brake Drum
Wheel
Remove
12. Press brake pedal several times to seat brake pads.
Warning: Brake pads must be renewed in axle sets only,
otherwise braking efficiency may be impaired.
2. Remove rear wheels.
Wheels
3. Remove brake drum retaining screw/s.
4. Withdraw brake drum/s.

Refit
edge of drum. Clean brake shoes and components

if inhaled.
2. Manually adjust brake shoes.
3. Fit brake drum/s.
4. Secure brake drum retaining fixing/s 6–8Nm
5. Fit wheels.
Wheel
7. Operate brake pedal several times to seat brake shoes.

brake applications.
1.0 425
Brake System Brake
Brake Shoes - Rear

Remove
Warning: Brake pads must be renewed in axle sets only,

otherwise braking efficiency may be impaired.
1. Release handbrake.
Handbrake Cable - Adjust
3. Remove rear brake drums.
Brake Drum
Refit
4. Clean brake shoes and components using brake cleaning
fluid. 1. Remove any scale and loose corrosion from around
edge of drum. Clean brake shoes and components
if inhaled. Warning: Do not use compressed air to clean brake
5. Compress clips and rotate to release brake shoe
if inhaled.
retaining pins, remove retaining pins.
2. Fit adjuster wheel ratchet plate and vertical spring.
6. Ease one shoe out of lower retaining groove in
abutment followed by other shoe. 3. Position adjuster on leading shoe.
7. Detach shoe abutment return spring from leading shoe 4. Locate upper spring in both brake shoes.
end and remove spring. 5. Manipulate brake shoes over adjuster rod.
Tip: The forward shoe is leading shoe, and the shoe 6. Remove elastic band from wheel cylinder.
connecting with parking brake cable is trailing shoe. 7. Position brake shoes onto brake drum and wheel
8. Release hand brake cable from brake shoe lever. cylinder.
9. Manoeuvre shoe assembly around wheel cylinder and 8. Locate handbrake cable in lever.
remove. 9. Position lower brake shoe spring in both shoes.
Caution: Ensure edges of brake shoes do not damage 10. Position shoes on abutment.
wheel cylinder dust covers. 11. Fit brake shoe retaining pins and clips.
10. Fit an elastic band around wheel cylinder to retain 12. Manually adjust brakes.
pistons. Brakes - Adjust
11. Manipulate trailing shoe to remove from adjuster 13. Fit brake drums.
mechanism.
Brake Drum
12. Detach upper spring from shoes.
14. Adjust handbrake cable.
13. Remove adjuster wheel ratchet plate and vertical spring.
14. Screw adjuster mechanism fully in. Handbrake Cable - Adjust

brake applications.
1.0 426
Brake Brake System
Brake Shoes – Manually Adjust Hydraulic Wheel Cylinder
Manually Adjust Remove
Warning: Do not work on or under a vehicle supported Warning: Do not work on or under a vehicle supported
only by a jack.Always support the vehicle on safety stands. only by a jack.Always support the vehicle on safety stands.
1. Release handbrake. Warning: Brake pads must be renewed in axle sets only,
Handbrake Cable - Adjust otherwise braking efficiency may be impaired.
2. Raise vehicle on lift. 1. Raise vehicle on lift.
3. Remove rear brake drums. 2. Remove brake drum/s.
Brake Drum Brake Drum
4. Clean brake shoes and components using brake cleaning 3. Place suitable brake hose clamp on flexible brake hose.
fluid. 4. Remove bleed nipple.
Warning: Do not use compressed air to clean brake 5. Release brake pipe union, remove pipe from cylinder.
components. Dust from friction materials can be harmful 6. Remove wheel cylinder to back-plate fixings.
if inhaled. 7. Withdraw wheel cylinder.
5. Use suitable screwdriver to rotate brake shoe adjuster Refit
nut 1 notch.
1. Clean brake shoes and components using brake cleaning
6. Refit brake drum, ensure no resistance. fluid.
7. Repeat above until light resistance felt.
8. Back off adjuster 1 notch. components. Dust from friction materials can be harmful
9. Fit brake drum/s. if inhaled.
Brake Drum 2. Position hydraulic wheel cylinder.
10. Adjust handbrake cable. Caution: Ensure edges of brake shoes do not damage
wheel cylinder dust covers.
11. Lower the vehicle. 3. Fit cylinder to back-plate fixings, secure to 7–13Nm.
12. Operate brake pedal several times to seat brake shoes. 4. Fit brake pipe union, secure to 15–19Nm.
5. Fit bleed nipple, do not fully tighten at this stage.
brake applications. 6. Manually adjust brake shoes.
7. Fit brake drum/s – do not refit wheel/s.
Brake Drum
8. Remove brake flexible hose clamp.
9. Bleed brakes.
Brake Bleed
10. Fit wheel/s.

brake applications.
1.0 427
Brake System Brake
Brake System Bleeding brake calipers in the following order: left rear, left
Bleeding front, right front.
Warning: Do not allow brake fluid to come into contact
with eyes or skin.
Caution: Never re-use fluid that has been bled from the
brake system.
The following steps contain the method of bleeding the

entire system, however, if the primary or secondary circuit is
separated as an independent circuit, only operate the circuit
that needs to be bled. Only when the brake pipe or brake
hose is disconnected, and there is only a small amount of oil
loss, the hydraulic system is allowed to drain partly.
1. Refill the brake fluid reservoir to the MAX mark.
Caution: During the entire bleeding process, ensure the 9. Lower the vehicle.
new brake fluid level in the brake reservoir is between the
10. Refill the brake fluid reservoir to the MAX mark.
Min. and Max. position.
11. Apply the brake and check for leakage.
12. Test the vehicle on the road. Check the minimum
3. Remove the bleed screw dust cover at the right rear stroke of the brake pedal when the brake is functioning.
brake caliper, and fit the hose to the bleed screw.
Immerse the free end of the hose into the container
with new brake fluid.
4. Depress the brake pedal for several times and apply

stable pressure.
5. Release the bleed screw to separate the brake fluid and
air. Allow the pedal to return without any external
force.
6. Depress the brake pedal to the maximum stroke
steadily, and allow it to return without any external
force. Repeat the operation for several times until the
brake fluid without any air flows into the container,
then fix the brake pedal to the maximum stroke, tighten
the front bleed screw to 7–9Nm and the rear bleed
screw to 9–13Nm.
7. Remove the hose from the bleed screw and fit the
bleed screw dust cover.
8. Repeat the bleeding procedures for the remaining 3
1.0 428
Brake Brake System
Electronic Vacuum Pump
Remove
2. Disconnect the harness connector of the electronic
vacuum pump.
3. Disconnect the electronic vacuum pump from the
vacuum brake hose.
4. Remove 2 bolts fixing the electronic vacuum pump to
the bracket.
5. Remove the electronic vacuum pump.

Refit
1. Fix the electronic vacuum pump to the bracket, tighten
2 bolts fixing the electronic vacuum pump to the
bracket to 7–10Nm.
2. Connect the vacuum hose assembly to the electronic
vacuum pump.
Caution: Keep the dust and foreign matter from vacuum

hose.If having trouble to fix vacuum hose ， please using
grease special for fixing vacuum hose to lubricate ， other
liquid or grease is prohibited.
3. Connect the harness connector of the electronic

vacuum pump.
1.0 429
Brake System Brake
Special Tools
Number
Brake disc
TCH00022
runout test kit
1.0 430
Park Brake Brake System
Park Brake
Specifications
Torque
Description Value
Bolt - brake cable to body 7–10Nm
Bolt - brake cable to rear frame 19–25Nm
1.0 431
Brake System Park Brake

System Layout
Hand Brake Layout
1. Nut - Hand Brake Adjustment 3. Hand Brake Cable Tensioner/Compensation Rod

2. Hand Brake Control Assembly 4. Rear Brake Cable Assembly
1.0 432
Description A warning switch on the lever operates a warning lamp in the
Parking Brake instrument pack.
The parking brake consists of a transmission tunnel mounted When applying the hand brake, the warning switch connects
lever assembly that features a standard ratchet locking system the instrument pack warning lamp with ground, if the ignition
with a push button release. switch is ON, the warning lamp illuminates.
An adjustable compensator rod connects the lever to twin The instrument pack performs a self-check on the bulb every
cables. ignition cycle.
Each cable is connected to the handbrake lever fitted to the

rearward brake shoe in each drum brake.
1.0 433
Service Procedures Handbrake Cable – Equaliser

Handbrake Cable - Adjust Remove
Adjust Warning: Do not work on or under a vehicle supported
Warning: Do not work on or under a vehicle supported only by a jack.Always support the vehicle on safety stands.
only by a jack.Always support the vehicle on safety stands. 1. Release handbrake cable adjustment.
1. Raise rear of vehicle. Handbrake Cable - Adjust
2. Ensure rear brakes are correctly adjusted 2. Remove adjuster nut.
3. Remove consol cover to access handbrake cable 3. Raise vehicle on lift.
adjuster.
4. Remove exhaust heatshield.
Exhaust Heatshield
5. Release handbrake cables from equaliser assembly.
6. Release grommet.
7. Remove equaliser.
Refit
1. Position equaliser through floor.
2. Position floor grommet.
3. Fit cables to equaliser assembly.
4. Fit exhaust heatshield.
Exhaust Heatshield
4. Tighten adjuster nut until: 5. Lower the vehicle.
Notch 1 - rear brake drums turn without resistance, handbrake 6. Fit adjusting nut.
warning lamp in instrument pack on or off. 7. Adjust handbrake cable.
Notch 2 - rear brake drums turn with light resistance, Handbrake Cable - Adjust
handbrake warning lamp in instrument pack on.
Notch 3 and above - rear brake drums locked, handbrake

warning lamp in instrument pack on.
5. Refit console cover.

6. Lower vehicle.
1.0 434
Handbrake Cable – Rear
Remove
1. Release handbrake cable adjustment.
3. Remove rear brake shoes.
4. Release hand brake cable from back-plate.
5. Remove handbrake cable from floor retaining clips.
9. Remove cable.
Refit
1. APosition cable, fit floor retaining clips 7–10Nm.
2. Secure rear subframe retaining clips 19–25Nm.
3. Fit cable to equaliser assembly.
4. Fit exhaust heatshield.
Exhaust Heatshield
5. Position cable in back-plate.
6. Fit brake shoes.
6. Remove handbrake cable from rear subframe retaining 8. Adjust handbrake cable.
clips.
7. Remove exhaust heatshield.
Exhaust Heatshield
8. Release handbrake cable from equaliser assembly.
1.0 435
Handbrake Lever
Remove
1. Remove centre console.
Centre Console
2. Remove handbrake adjuster nut.
3. Release handbrake switch electrical connector
4. Remove handbrake lever to floor fixings.
5. Remove handbrake lever assembly.

Refit
1. Position handbrake lever to floor.
2. Fit fixings, tighten to 19–25Nm.
3. Fit handbrake adjuster nut.
4. Adjust handbrake cable.

5. Fit centre console.
Centre Console
1.0 436
Brake Module Brake System
Brake Module
Specifications
Torque
Description Value
Screws - front speed wheel sensor 7–10Nm
Screws - rear speed wheel sensor 7–10Nm
Blots - SCS to bracket 7–10Nm
Brake pipe to SCS 15-19Nm
1.0 437
Brake System Brake Module

System Layout
Brake System Control Component Layout
1. Brake Fluid Reservoir 5. Brake Modulator

2. Brake Fluid Level Sensor 6. Front Wheel Speed Sensor Assembly
3. Vacuum Booster 7. Rear Wheel Speed Sensor Assembly
4. Brake Master Cylinder
1.0 438
Brake System ABS Control Logic Diagram
A = Hard Wire; B = HS CAN Bus
1.0 439
Description If the wheel locks in emergency, the inlet/outlet valves will be

Anti-lock Brake System (ABS) closed at the same time to keep the brake pressure in the
wheel cylinder so as to exert the best brake performance.
During braking, the function of the ABS prevents wheel lock,
and thus the vehicle can stay stable even in emergency. Electronic Brake Distribution (EBD)
Warning: ABS is an aid to retaining steering control and EBDThe function of the EBD is to optimize the distribution
stability while braking: of the hydraulic pressure between the front and rear axles to
keep the vehicle at a stable state in brake process according to
• ABS cannot defy the natural laws of physics acting
the vehicle load condition and road conditions.
on the vehicle
• ABS will not prevent accidents resulting from With the ABS ECU in the normal brake mode, the vehicle
excessive cornering speeds, following another vehicle deceleration of 0.3g and above (i.e., moderate to high
too closely, aquaplaning, etc. brake pedal load), the EBD function can be automatically
implemented in forward or reverse mode.
• The additional control provided by ABS must never
be exploited in a dangerous or reckless manner which EBDIts operation is similar to the ABS, but the EBD operates
could jeopardise the safety of the driver or other road at lower wheel slip limit, and the EBD is only applicable to the
users rear wheel brake.
• The fitting of ABS does not imply that the vehicle will During braking, if the ABS ECU detects that the rear axle
always stop in a shorter distance. wheel is slower than the front axle wheel, that is, the possibility
Tip: During normal braking the feel of the brake pedal on of wheel slip exists, the ABS ECU will send a signal to the
vehicles equipped with ABS will be the same as that on hydraulic pressure regulator to turn off the fluid inlet solenoid
non ABS vehicles. During anti-lock braking operation, the valve of the rear wheel brake.
driver will experience feedback in the form of a pulsating This prevents further increase of the hydraulic pressure of
brake pedal and solenoid/pump motor noise from the ABS the rear wheel brake but allows the hydraulic pressure of the
modulator. front wheel brake to increase, the whole brake force is thus
In conventional brakes, the ABS does not work. maximized.
Brake fluid directly flows into each wheel cylinder from the If the rear wheel speed returns to the calibration wheel slip
reservoir through HCU channel to apply brake to each wheel. limit range, the ABS ECU will send a signal to turn on the
fluid inlet valve gradually, which allows progressive increase of
Once ABS ECU detects that a wheel locking occurs through the hydraulic pressure of the rear axle brake.
the wheel speed sensor, ECU will give an order to close the
inlet valve, and the brake fluid will no longer flow into the EBDIts operation can be felt through the following ways: the
wheel cylinder. movement of the brake pedal is more violent by turning off the
fluid inlet solenoid valve and the brake pedal has a slight pulse
Meanwhile, the outlet valve is opened to discharge the as a result of the fluid inlet solenoid valve's turning on.
hydraulic oil from the wheel cylinder to allow the wheel to
rotate. When the brake pedal is released, the EBD will stop
immediately.
If it is detected that a wheel slips normally, the outlet valve will
be closed due to low brake pressure and the brake fluid will EBDThe wheel slip limit that enables the EBD varies with the
flow into the wheel cylinder from the inlet valve to increase vehicle speed.
the brake force.
1.0 440
Service Procedures ABS Sensor - Rear
ABS Sensor - Front Remove
Remove Warning: Do not work on or under a vehicle supported
Warning: Do not work on or under a vehicle supported only by a jack.Always support the vehicle on safety stands.
only by a jack.Always support the vehicle on safety stands. 1. Raise vehicle on lift.
1. Raise vehicle on lift 2. Remove ABS sensor to back-plate fixing.
2. Remove wheel/s. 3. Withdraw sensor.
Wheels 4. Locate and disconnect ABS sensor block connector.
3. Remove ABS sensor fixing. 5. Release sensor wiring from retaining clips.
4. Withdraw sensor from hub assembly. Refit
5. Locate and disconnect ABS sensor block connector. 1. Insert ABS sensor into back-plate, secure fixing to
6. Release sensor wiring from retaining clips. 7–10Nm.
Refit 2. Secure ABS sensor harness in retaining clips.
1. Insert ABS sensor into hub assembly, secure fixing to 3. Connect ABS sensor block connector.
7–10Nm 4. Lower the vehicle.
2. Secure ABS sensor harness in retaining clips. 5. Clear any fault codes using diagnostic equipment.
3. Connect ABS sensor block connector
4. Fit wheel/s.
Wheel
6. Clear any fault codes using diagnostic equipment.
1.0 441
Brake Modulator (SCS) 6. Connect the connector to the brake modulator.

Remove 7. Connect the battery negative cable.
1. Remove the ignition key, and disconnect the battery 8. Drain the brake system.
ground terminal.
Brake System Drain
2. Put the cloth under the brake modulator to absorb the
spilled oil.
water.
3. Disconnect the connector from the brake modulator.

4. Record the positions of the oil inlet pipes on 2 brake
modulators for assembly, then disconnect 2 oil inlet
brake pipes from the brake modulator.
Caution: Before disconnecting or removing components,
ensure the immediate area around joint faces and
connections are clean. Plug open connections to prevent
contamination.
5. Record the positions of the oil outlet pipes on 4 brake

modulators for assembly, then disconnect the brake
pipe oil outlet pipe from the top of the brake modulator.
6. Remove 3 rubber plugs fixing the brake modulator and
bracket to the body.
7. Remove 3 bolts fixing the brake modulator to the
bracket.
8. Remove the brake modulator assembly.
Refit
1. Locate the brake modulator to the lower bracket, fit
the bolts and tighten to 7–10Nm.
2. Fit the brake modulator lower bracket to the body,
ensure that the seal ring is embedded correctly.
3. Clean the connector of the brake hard pipe.
4. Connect the oil inlet/outlet brake pipes to the brake
modulator, ensure that the pipes are connected to the
right ports.
5. Tighten the connector of the brake hard pipe to
15-19Nm.
1.0 442
Driveline/Axle Driveline/Axle
Driveline/Axle
Specifications
Torque
Description Value
Bolt - lower arm outer ball joint to swivel hub 50–65Nm
Nuts - steering rod outer ball joint 28–32Nm
Nut - front drive shaft 350 – 370 Nｍ
1.0 443

System Layout
Right Drive Shaft Disassembled View
1. Constant Velocity Joint Assembly 7. Clip

2. Constant Velocity Joint Circlip 8. Internal Joint Gaiter
3. Clip 9. Clip
4. Constant Velocity Universal Joint Gaiter 10. Circlip
5. Clip 11. Tripod Joint
6. Power Vibration Damping Ring 12. Circlip
1.0 444
Left Drive Shaft Disassembled View
1. Constant Velocity Joint Assembly 7. Clip

2. Constant Velocity Joint Circlip 8. Internal Joint Gaiter
3. Clip 9. Clip
4. Constant Velocity Universal Joint Gaiter 10. Circlip
5. Clip 11. Tripod Joint
6. Power Vibration Damping Ring 12. Circlip
1.0 445
Description All joints are packed with grease and protected by gaiters.
Each drive shaft comprises of a solid shaft with inner and outer Both drive shafts are fitted with dynamic dampers.
constant velocity joints.
The drive shaft transmits engine torque, via the gearbox, to
The inner joint is of the tripode type with spherical bushing to the front wheels.
reduce sliding resistance.
The dynamic dampers reduce any vibration produced by the
The shaft and joint are one assembly. drive shaft's rotation.
The outer joint is a constant velocity ball and socket type which
is splined to the shaft and secured with a snap ring.
1.0 446
Diagnostic shake may also refer to the swing occurs in the front and the
Diagnosis rear of the vehicle.
Mechanical Check The start shake of the front-wheel drive vehicle may caused by
When rotating, a rattle sound can be heard. the followings:
When the worn or damaged constant velocity universal joint • Internal tee universal joint is worn or damaged.
of the front wheel drive shaft rotates, a rattle sound may be • Internal universal joint is severely worn or ceratoid.
heard. If there's a rattle sound, check the constant velocity
The universal joint shows severe ceratoid angle, which is
universal joint shield of the front wheel drive shaft for crack or
normally caused by the excessive height of the front cocked
damage.
head or the spring. When the power assembly suspension is
A "clunk" sound can be heard during accelerating
damaged or mismatched, following situations may occur:
and sliding.
• Angle of the universal joint is oversize.
If a "click" sound can be heard during rotation, check the
followings: • Start Shake
• Check the external universal joint for wear or damage. During rapid acceleration, high torque of the vehicle power
assembly causes increase of the front suspension. When the
• Check the seal for breakage or damage.
suspension raises, the angle of the internal tee universal joint
Shake or Vibration When Accelerating
will increase accordingly. Start shake may occur when following
Start Shake situations appear:
Start shake refers to the vibration felt on the steering wheel • Universal joint is worn.
and/or the front of the vehicle when the vehicle is shifted from
• Oversize angle exists before acceleration.
static starting to rapid accelerating. During acceleration, start
1.0 447
Service Procedures
RH Shaft & Both Joints
Remove
2. Remove wheel.
Wheel Remove
3. Prise locking device from nut. With an assistant pressing
brake pedal, remove and discard drive shaft nut.
4. Remove nut from track rod end, fit an M10 nut to ball
pin, flush with end of pin.
5. Break taper joint using toolT38008and release end
from track rod.
13. Remove and discard drive shaft circlip.
6. Remove nut from ball pin.
Refit
1. Fit new drive shaft circlip.
2. Clean ends of drive shaft and locations in hub and
differential.
3. Fit drive shaft to differential and push fully home.
4. Clean mating face of drive shaft support bracket and
cylinder block.
5. Pull hub outwards, engage drive shaft to hub and fit
hub to lower ball joint.
6. Fit nut and bolt securing hub to lower arm and tighten
to 50–65Nm.
7. Ensure lower ball joint is fully engaged in hub and bolt is
located in ball joint groove.
7. Remove nut securing link to anti roll bar and release
link. 8. Ensure tapers in track rod end and steering arm are
clean and rubber boot is not damaged.
8. Remove nut and bolt securing hub to lower arm.
9. Fit track rod end to steering arm and tighten nut to
9. UsingT32011 release lower arm ball joint.
28–32Nm.
10. Ensure anti-roll bar and link mating faces are clean.
11. Position link to anti roll bar, fit and tighten nut
to45–55Nm.
12. Fit new drive shaft nut and tighten nut to 350 – 370
Nｍｍ.
13. Stake the nut to drive shaft.
14. Fit wheel
Wheel Fit
10. Take care not to damage lower ball joint rubber gaiter.
11. Pull hub outward to release drive shaft from hub.
12. Release drive shaft from differential using TCH00001,
remove shaft.
1.0 448
LH Shaft & Both Joints
Remove
2. Remove wheel.
Wheel Remove
3. Prise locking device from nut. With an assistant pressing
brake pedal, remove and discard drive shaft nut.
4. Remove nut from track rod end, fit an M10 nut to ball
pin, flush with end of pin.
5. Break taper joint using toolT38008and release end
from track rod.
6. Remove nut from ball pin.
13. Remove and discard drive shaft circlip.
Refit
1. Fit new drive shaft circlip.
2. Clean ends of drive shaft and locations in hub and
differential.
3. Fit drive shaft to differential and push fully home.
4. Clean mating face of drive shaft support bracket and
cylinder block.
5. Pull hub outwards, engage drive shaft to hub and fit
hub to lower ball joint.
6. Fit nut and bolt securing hub to lower arm and tighten
to 50–65Nm.
7. Remove nut securing link to anti roll bar and release 7. Ensure lower ball joint is fully engaged in hub and bolt is
link. located in ball joint groove.
8. Remove nut and bolt securing hub to lower arm. 8. Ensure tapers in track rod end and steering arm are
clean and rubber boot is not damaged.
9. UsingT32011 release lower arm ball joint.
9. Fit track rod end to steering arm and tighten nut to
28–32Nm.
10. Ensure anti-roll bar and link mating faces are clean.
11. Position link to anti roll bar, fit and tighten nut
to45–55Nm.
12. Fit new drive shaft nut and tighten nut to 350 – 370
Nｍｍ.
13. Stake the nut to drive shaft.
14. Fit wheel
Wheel Fit
10. Take care not to damage lower ball joint rubber gaiter.
11. Pull hub outward to release drive shaft from hub.
12. Release drive shaft from differential using TCH00001,
remove shaft.
1.0 449
Outer CV Joint Gaiter Inner joint

Remove Remove
1. Remove driveshaft and both joints 1. Remove driveshaft and both joints
Right Drive Shaft Remove Right Drive Shaft Remove
Left Drive Shaft Remove Left Drive Shaft Remove
2. Place driveshaft in suitable vice. 2. Place driveshaft in suitable vice.

3. Release both gaiter clips and discard. 3. Release both gaiter clips and discard.
4. Slide gaiter along drive shaft to gain access to outer

joint. 4. Remove outer section of tripod joint.
5. Using circlip pliers, release circlip, remove joint from 5. Using circlip pliers, release circlip, remove tripod joint
drive shaft and discard. from drive shaft, discard circlip.
6. Remove circlip from drive shaft and discard.

Refit
1. Clean drive shaft and gaiter..
2. Fit new circlip to drive shaft.
3. Position outer joint to drive shaft, using a tool press
circlip into its groove, push joint fully onto drive shaft.
4. Apply grease to the joint.
5. Position gaiter to joint and secure with new clips.
6. Remove tripod section from driveshaft.

7. Slide of gaiter.
Refit
1. Clean drive shaft and gaiter.
2. Position gaiter on shaft.
3. Refit inner tripod joint.
4. Fit new circlip to drive shaft.
6. Refit the drive shaft assembly. 5. Apply grease to the joint.

6. Fit outer section of tripod joint.
Right Drive Shaft Refit
7. Refit the drive shaft assembly.
Left Drive Shaft Refit
Right Drive Shaft Refit
Left Drive Shaft Refit
1.0 450
Inner Joint Gaiter
Remove
1. Remove inner CV joint
Inner Joint Remove
2. Remove inner joint gaiter from drive shaft.

Refit
1. Clean drive shaft.
2. Fit new gaiter to drive shaft.
3. Fit inner joint.
Inner Joint Refit
1.0 451
Special Tools
Number
Remover ball
T38008
joint
Lever front
T32011 lower arm ball
joint
Remover drive
TCH00001
shaft
1.0 452
Interior Trim and Paneling Interior Fitting
Interior Trim and Paneling
Specifications
Torque
Description Value
Bolt-‘BC’upper post trim to Body 1.5–2.2 Nm
Bolt-front seat belt to body 35–45Nm
Bolt - rear seat belt to lower ‘D’ post 30–35Nm
Bolt-‘D’upper post trim to Body 1.5–2.2 Nm
1.0 453
Interior Fitting Interior Trim and Paneling
Service Procedures 5. Pry off the screw hole cover, and remove 1 screw fixing
Front Door Interior Trim Panel and Waterproof the front door interior trim panel to the rear side of
Membrane the door.
Remove
2. Pry off the inner handle screw hole cover, and remove
1 screw fixing the inner door handle to the door.
6. Pry off the clip fixing the front door interior trim panel
to the door, remove and discard the clip.
3. Pry off the screw hole cover of the power window

switch, and remove 1 screw fixing the power window
switch to the door.
7. Disconnect the stay wire of the inner handle cable

assembly and the harness connector.
8. Remove the front door interior trim panel.
9. Remove 2 screws fixing the front door interior trim
panel mounting bracket, and remove the front door
4. Pry off the screw hole cover, and remove 1 screw fixing interior trim panel mounting bracket. Firstly remove
the front door interior trim panel to the front side of the electrical connectors from the corresponding
the door. positions of the waterproof membrane.
10. Remove the front door waterproof membrane from
the door panel.
Refit
1. Have the electrical connectors pass through the
corresponding positions of the waterproof membrane,
align the locating hole of the waterproof membrane
with the door trim panel mounting bracket, and the
upper edge is parallel to the upper edge of the door
panel, then fit the door waterproof membrane.
2. Fit and tighten 2 screws fixing the mounting bracket of
the front door interior trim panel.
3. To remove the power window switch, the power
1.0 454
window switch must be fitted to the front door interior Front Door Inner Handle
trim panel. Remove
4. Fit the new clip to the door trim panel, fit the stay wire 1. Remove the front door interior trim panel and
of the inner handle cable assembly, connect the harness waterproof membrane.
connector, align the interior trim panel clip with the
Front Door Interior Trim Panel and Waterproof
corresponding panel mounting hole, and fit the rear
Membrane Remove
door interior trim panel.
2. Remove 3 screws fixing the front door inner handle to
5. Fit and tighten 1 screw fixing the power window switch
the back of the door interior trim panel.
to the door, and fit the screw hole cover.
6. Fit and fix 1 screw fixing the inner handle to the door,
and fit the screw hole cover.
7. Fit and tighten 2 screws (front and rear) fixing the front
door interior trim panel to the door. Fit the screw
cover.
3. Pry off the clip and remove the front door inner handle
from the door interior trim panel.
Refit
1. Locate the inner door handle to the front door interior
trim panel, press the clip in place and secure with 3
screws.
2. Fit the front door interior trim panel and waterproof
membrane.

Membrane Refit
1.0 455
Rear Door Interior Trim Panel and Waterproof the rear door interior trim panel to the rear side of
Membrane the rear door.
Remove
2. Pry off the inner handle screw hole cover, and remove
1 screw fixing the inner door handle to the door.
6. Pry off the clip fixing the rear door interior trim panel
to the door, remove and discard the clip.
3. Pry off the screw hole cover of the power window

switch, and remove 1 screw fixing the power window
switch to the door.
7. Disconnect the stay wire of the inner handle cable

assembly and the harness connector.
8. Remove the rear door interior trim panel.
9. Pry off and remove the power window switch if
necessary.
4. Pry off the screw hole cover, and remove 1 screw fixing 10. Remove 2 screws fixing the door trim panel mounting
the rear door interior trim panel to the front side of bracket, and remove the door trim panel mounting
the rear door. bracket. Firstly remove the electrical connectors
from the corresponding positions of the waterproof
membrane.
11. Remove the rear door waterproof membrane from the
door panel.
Refit
1. Have the electrical connectors pass through the
corresponding positions of the waterproof membrane,
align the locating hole of the waterproof membrane
with the door trim panel mounting bracket, and the
upper edge is parallel to the upper edge of the door
panel, then fit the rear door waterproof membrane.
2. Fit and tighten 2 screws fixing the mounting bracket of
5. Pry off the screw hole cover, and remove 1 screw fixing the rear door interior trim panel.
1.0 456
3. To remove the power window switch, the power Rear Door Inner Handle
window switch must be fitted to the rear door interior Remove
trim panel. 1. Remove the rear door interior trim panel and
4. Fit the new clip to the door trim panel, fit the stay wire waterproof membrane.
of the inner handle cable assembly, connect the harness
Rear Door Interior Trim Panel and Waterproof
connector, align the interior trim panel clip with the
Membrane Remove
corresponding panel mounting hole, and fit the rear
door interior trim panel. 2. Remove 3 screws fixing the rear door inner handle to
the back of the door trim panel.
5. Fit and tighten 1 screw fixing the power window switch
to the door, and fit the screw hole cover.
6. Fit and fix 1 screw fixing the inner handle to the door,
and fit the screw hole cover.
7. Fit and tighten 2 screws (front and rear) fixing the rear
door interior trim panel to the door. Fit the screw
cover.
3. Pry off the clip, and remove the rear door inner handle
from the door interior trim panel.
Refit
1. Locate the inner door handle to the rear door interior
trim panel, press the clip in place and secure with 3
screws.
2. Fit the rear door interior trim panel and waterproof
membrane.
Rear Door Interior Trim Panel and Waterproof

Membrane Refit
1.0 457
A Pillar Upper Trim Panel A Pillar Lower Trim Panel

Remove Remove
1. Pry off the front door body side weatherstrip outside 1. Pry off the front door body side weatherstrip outside
the A pillar upper trim panel assembly. the A pillar lower trim panel assembly.
2. Pry off the A pillar upper trim panel assembly clip. 2. Remove and discard the release handle of the bonnet.
3. Disconnect the connector of the tweeter and the 3. Pry off the clips of the A pillar lower trim panel
retaining clips of the airbag. assembly, and remove the A pillar lower trim panel
assembly.
4. Remove the A pillar upper trim panel assembly.

Refit
is undertaken on the SRS system the appropriate 1. Locate the A pillar lower trim panel assembly to the
information is read thoroughly. vehicle body and press the clip in place.
Refit 2. Fit the new release handle of the bonnet, and ensure
the handle is pressed till the end.
1. Fit the special clips of the side curtain airbag, and
connect the connector of the tweeter. 3. Fit the front door body side weatherstrip of the A pillar
lower trim panel assembly.
Warning: The clip for side air curtain must be changed
when A pillar need refit, otherwise it may cause the side
curtain invalidate.
2. Locate the A pillar upper trim panel assembly to the
body, and press the clip in place.
3. Fit the front door body side weatherstrip of the A pillar
upper trim panel assembly.
1.0 458
B/C Pillar Upper Trim Panel B/C Pillar Lower Trim Panel
Remove Remove
1. Pry off the door weatherstrips on both sides of the B 1. Pry off the door weatherstrips on both sides of the B/C
pillar upper trim panel assembly. pillar lower trim panel assembly.
2. Pry off the bolt cap fixed on the B pillar upper trim 2. Pry off the front part of the doorsill trim panel and the
panel and remove 1 screw. rear part of the A pillar lower trim panel.
3. Pry off the clips of the B/C pillar lower trim panel
assembly, and remove the B/C pillar lower trim panel
assembly.
3. Remove 1 bolt fixing the driver seat belt to the

underbody.
4. Pry off the clips of the B pillar upper trim panel, pull
the seat belt out of the hole of the B pillar upper trim Refit
panel, and remove the B pillar upper trim panel. 1. Locate the B/C pillar lower trim panel assembly to the
Refit B/C pillar and press the clip in place.
1. Pass the seat belt through the hole of the B pillar upper 2. Restore the doorsill trim panel and the A pillar lower
trim panel assembly. trim panel.
2. Locate the B pillar upper trim panel assembly to the B 3. Fit the door weatherstrip at the B/C pillar lower trim
pillar and press the clip in place. panel assembly.
3. Fit 1 bolt fixing the B pillar upper trim panel to the
body, tighten to 1.5–2.2 Nm, and check the torque.
4. Fit the screw cap of the B pillar upper trim panel.
5. Fit 1 bolt fixing the driver seat belt to the underbody,
6. Fit the door weatherstrips on both sides of the B pillar
upper trim panel assembly.
1.0 459
D Pillar Upper Trim Panel D Pillar Lower Trim Panel

Remove Remove
1. Pry off the tail gate and the body weatherstrip outside 1. Pry off the body weatherstrip outside the D pillar.
the D pillar. 2. Remove the D pillar upper trim panel.
2. Remove the rear coat rack assembly.
D Pillar Upper Trim Panel Remove
Rear Coat Rack Assembly Remove 3. Pry off the D lower trim panel.
3. Loosen 2 bolts fixing the D pillar upper trim panel to
the body.
Refit
1. Locate the D pillar lower trim panel on the body and
4. Pry off the clip, and remove the D pillar upper trim press the clip in place.
panel.
2. Fit the D pillar upper trim panel.
5. Fold down the rear seat back, remove 1 bolt fixing the
D Pillar Upper Trim Panel Refit
rear seat belt to the body, and draw the seat belt from
the hole of the D pillar upper trim panel assembly. 3. Fit the body weatherstrip outside the D pillar.
Refit
1. Pass the seat belt through the hole of the D pillar upper
trim panel assembly.
2. Fix the lower rear seat belt to the body, fit 1 bolt,
3. Fix the D pillar upper trim panel assembly to the body,
and press the clip in place.
4. Fit 2 bolts fixing the D pillar upper trim panel to the
body, tighten to 1.5–2.2 Nm, and check the torque.
5. Fit the rear coat rack assembly.
Rear Coat Rack Assembly Refit

6. Fit the tail gate and the body weatherstrip outside the
D pillar.
1.0 460
Rear Coat Rack Carpet
Remove Remove
1. Open the tail gate. 1. Open the tail gate.
2. Remove the rope hanging the rear coat rack. 2. Disconnect the battery negative.
3. Remove the rear coat rack assembly. 3. Remove the rear seat cushion assembly.
Refit Rear Seat Cushion Assembly Remove
1. Fit the rear coat rack assembly. 4. Remove the lower trim panel of the left/right A pillars.
2. Fit the rope hanging the rear coat rack. A Pillar Lower Trim Panel Remove
3. Close the tail gate. 5. Remove 2 bolts fixing the left/right front seat belts to
the body.
6. Remove the left/right B/C pillar lower trim panels.
B/C Pillar Lower Trim Panel Remove
7. Remove the doorsill trim panel assembly.
8. Remove the front seat assembly.
Front Seat Assembly Remove
9. Remove 4 clips fixing the carpet to both left and right
sides of the base plate.
10. Remove the centre console heater closing plate
assembly.
Centre Console Heater Closing Plate Assembly
Remove
11. Remove the centre console assembly.
Centre Console Assembly Remove
12. Remove the carpet.
Refit
1. Fit the carpet.
2. Fit 4 clips fixing the carpet to both left and right sides
of the floor.
3. Fit the centre console heater closing plate assembly.
Refit
4. Fit the centre console assembly.
Centre Console Assembly Refit
5. Press the clip, and fit the door sill trim panel assembly.
1.0 461
6. Fit the B/C pillar lower trim panel assembly. Luggage Compartment Side Trim Panel
B/C Pillar Lower Trim Panel Refit
Remove
1. Remove the coat rack.
7. Fit 2 bolts fixing the left/right front seat belts to the
underbody, tighten to 35–45Nm, and check the 2. Remove the D pillar upper trim panel.
torque. D Pillar Upper Trim Panel Remove
8. Fit the A pillar lower trim panel assembly. 3. Remove the carpet of the luggage compartment.
A Pillar Lower Trim Panel Refit 4. Remove the luggage compartment sill trim panel.
9. Fit the front seats. Luggage Compartment Sill Trim Panel Remove
Front Seat Assembly Refit 5. Remove the weatherstrip outside the side trim panel of
10. Fit the rear seat cushion assembly. the luggage compartment.
Rear Seat Cushion Assembly Refit 6. Remove the retaining screw of the trim panel and
remove the luggage compartment side trim panel.
12. Close the tail gate.
Refit
1. Locate the side trim panel of the luggage compartment
to the body, and fit the retaining screw to fix it.
2. Fit the luggage compartment sill trim panel.
Luggage Compartment Sill Trim Panel Refit

3. Fit the weatherstrip outside the side trim panel of the
luggage compartment.
4. Fit the carpet of the luggage compartment.

6. Fit the coat rack.
1.0 462
Luggage Compartment Sill Trim Panel Tail Gate Interior Trim Panel
Remove Remove
1. Pry off the body weatherstrip outside the luggage 1. Open the tail gate.
compartment sill trim panel. 2. Pry off the screw covers, remove 2 screws fixing the
2. Remove the carpet of the luggage compartment. tail gate interior trim panel to the tail gate, pry off the
3. Remove 4 clips and the upper clip fixing the luggage clip, and remove the tail gate interior trim panel.
compartment sill trim panel to the vehicle body.
Refit
4. Remove the luggage compartment sill trim panel. 1. Fix the tail gate interior trim panel to the tail gate,
Refit ensure the clip is fitted in place, fit and tighten 2 screws,
and fit the screw covers.
1. Fit the luggage compartment sill trim panel, and ensure
the clip is fitted in place. 2. Close the tail gate.
2. Fit the carpet of the luggage compartment.

3. Fit the body weatherstrip outside the luggage
compartment sill trim panel.
1.0 463
Roof Interior Trim

Remove
1. Open the tail gate.
3. Remove the front reading lamp assembly.
Front Reading Lamp Assembly Remove

4. Remove the microphone.
Microphone Remove
5. Remove the sun visor and bracket assembly.
Sun Visor and Bracket Assembly Remove

6. Remove the door weatherstrip at the column, etc.
Refit
7. Remove the inner roof handle.
1. Move the roof interior trim panel into the vehicle to
Inner Roof Handle Remove seat it with the roof panel, while press two rear clips
8. Remove the driver side glasses box. into the roof beam hole.
2. Fit the inner roof handle.
Driver Side Glasses Box Remove
9. Remove the A pillar upper trim panel. Inner Roof Handle Refit
3. Fit the driver side glasses box.
A Pillar Upper Trim Panel Remove
10. Remove the B/C pillar upper trim panel. Driver Side Glasses Box Refit
4. Fit the sun visor and bracket assembly.
B/C Pillar Upper Trim Panel Remove
11. Remove the D pillar upper trim panel. Sun Visor and Bracket Assembly Refit
5. Fit the front reading lamp assembly.
D Pillar Upper Trim Panel Remove
12. Release the clip securing the roof interior trim panel. Front Reading Lamp Assembly Refit
13. Fold down the rear seat, and tilt two front seats. 6. Fit the microphone.
14. Remove the roof interior trim panel from the luggage Microphone Refit
compartment lid carefully. 7. Fit the weatherstrip at the column.
8. Fit the A pillar upper trim panel.
A Pillar Upper Trim Panel Refit

9. Fit the B/C pillar upper trim panel.
B/C Pillar Upper Trim Panel Refit


1.0 464
Sun Visor and Bracket Insulation Pad of Engine Compartment Heat
Remove Shield
1. Open the sun visor downward.
Remove
2. Pry off the screw trim cover of the sun visor, and 1. Remove the engine transmission assembly.
remove 1 screw fixing the sun visor to the roof interior Automatic Transmission Assembly Remove
trim panel. Manual Transmission Assembly Remove
3. Remove the sun visor from the sun visor bracket. 2. Remove the braking modulator.
braking Modulator Remove
3. Remove the brake master cylinder and reservoir
assembly.
Remove
4. Remove the vacuum booster assembly.
Vacuum Booster Assembly Remove
5. Disconnect the water inlet/outlet pipes of the A/C
4. Pry off the screw trim cover of the sun visor bracket, heater.
and remove 1 screw fixing the sun visor bracket to the
6. Disconnect the A/C water inlet/outlet pipes from the
roof interior trim panel.
expansion valve.
5. Remove the sun visor bracket.
7. Remove 5 plastic nuts fixing the insulation pad of the
Refit engine compartment heat shield to the front body.
1. Fix the sun visor bracket to the roof interior trim panel,
fit and tighten 1 retaining screw, and fit the screw trim
cover.
2. Fix one end of the sun visor to the sun visor bracket
and the other end to the roof interior trim panel, fit
and tighten 1 retaining screw.
3. Fit the screw trim cover of the sun visor.
4. Reset the sun visor.
8. Remove the insulation pad of the engine compartment

heat shield.
Refit
1. Fit the insulation pad of the engine compartment heat
shield to the front body with 5 plastic nuts.
2. Connect the A/C water inlet/outlet pipes to the
expansion valve.
3. Fit the water inlet/outlet pipes of the A/C heater.
4. Fit the vacuum booster assembly.
Vacuum Booster Assembly Refit
5. Fit the brake master cylinder and reservoir assembly.
Refit
6. Fit the braking modulator.
Braking Modulator Refit
1.0 465
7. Fit the engine transmission assembly. Front Insulation Pad

Automatic Transmission Assembly Refit
Remove
Manual Transmission Assembly Refit 1. Remove the instrument panel assembly.
Instrument Panel Assembly Remove

2. Remove the pedal.
Brake Pedal Remove

4. Remove the front carpet.
Carpet Remove
5. Remove 5 clips fixing the front insulation pad to the
front body.
6. Remove the front insulation pad.
Refit
1. Lay the front insulation pad to the corresponding
position of the body, and put the locating hole over
the locating pin.
2. Fix the front insulation pad to the body with 7 clips.
3. Fit the main carpet.
Carpet Refit

5. Fit the brake pedal.
Pedal Assembly Refit

6. Fit the instrument panel.
Instrument Panel Refit
1.0 466
Driver Side Glasses Box Inner Roof Handle
Remove Remove
1. Open the glasses box, and pry off the screw trim cover 1. Open the trim cover to expose the screw of the inner
in it to expose the screw securing the glasses box. roof handle.
2. Loosen 2 screws fixing the glasses box to the roof. 2. Loosen 2 screws fixing the inner roof handle to the
roof.
3. Remove the driver side glasses box.

3. Remove the inner roof handle.
Refit
Refit
1. Locate the driver side glasses box to the roof interior,
fit and tighten 2 screws. 1. Locate the inner roof handle to the roof, fit and tighten
2 screws.
2. Cover the inside screw trim cover and close the glasses
box. 2. Open 2 screw trim covers.
1.0 467
Interior Fitting Fascia and Console
Fascia and Console

Specifications
Torque
Description Value
Bolt-front passenger airbag to facia bracket 6–8Nm
Bolt-Fasic Main to Fasic Bracket 19–25 Nm
Bolt-Fasic Bracket to Body 19–25 Nm
Bolts- Steering column to facia framework 19-25Nm
Bolt-Console Main to Console front bracket 1.6–2.0Nm
1.0 468
Fascia and Console Interior Fitting
Service Procedures Driver Side Lower Trim Panel Assembly
Instrument Panel End Cover Plate Assembly Remove
Remove 1. Remove 2 screws fixing the driver side lower trim panel
1. Pry off the clip fixing the right instrument panel end assembly to the instrument panel body.
cover to the instrument panel assembly.
2. Pry off the clip of the driver side lower trim panel,
2. Pull the right instrument panel end cover out of the disconnect the harness connector and remove the
door weatherstrip covering the edge of the end cover. driver side lower trim panel assembly.
Take care not to scratch it. 3. Remove 3 screws fixing the card slot to the driver side
3. Remove the left instrument panel end cover assembly lower trim panel from the back. Remove the card slot
in the same way. with the release handle of the oil filler cap.
Refit
1. Extend the edge of the right instrument panel end
cover to the bottom of the door weatherstrip, fit the
right instrument panel end cover and press the door
weatherstrip tightly.
2. Fit the left instrument panel end cover assembly in the
same way.
4. Remove the headlamp leveling switch as necessary.

Refit
1. If the headlamp leveling switch needs to be replaced,
insert the switch into the driver side lower trim panel
first.
2. Locate the card slot and the release handle of the oil
filler cap to the driver side lower trim panel, fit and
tighten 3 screws.
3. Connect the harness connector of the headlamp
leveling switch, fix the driver side lower trim panel to
the instrument panel, press the clip in place, fit and
tighten 2 screws.
1.0 469
Glove Box Assembly Instrument Panel Side Air Outlet Assembly

Remove Remove
1. Open the glove box door to a certain angle. 1. Pry off the clip of the right side air outlet and remove
2. Press the inner wall of the glove box with both hands so the right side air outlet.
that the stopper can be released from the instrument
panel body, then release the upper glove box assembly.
2. Pry off the clip along the edge of the instrument panel
upper moulding and remove the instrument panel
upper moulding.
3. Press and hold the glove box assembly to remove it
from the instrument panel body.
4. Remove the glove box.
Refit
1. Align the glove box to a position of the lower panel
where the glove box could be opened completely.
2. Align two semicircular bushings on the lower part of the
glove box assembly to the instrument panel frame shaft.
3. Gently push the glove box stopper into the instrument
panel body and ensure it is fitted in place.
3. Remove 1 screw fixing the left side air outlet to the

instrument panel, pry off the clip, and remove the left
side air outlet.
Refit
1. Locate the right side air outlet to the instrument panel,
and press the clip in place.
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2. Locate the left side air outlet to the instrument panel, Central Instrument Panel Air Outlet Assembly
press the clip in place, fit and tighten 1 retaining screw. Remove
3. Locate the instrument panel upper moulding to the 1. Pry off the clip along the edge of the instrument panel
instrument panel, and press the clip in place. upper moulding and remove the instrument panel
upper moulding.
2. Remove 4 screws fixing the central air outlet assembly

to the instrument panel upper moulding from the back,
pry off the clip, and remove the central instrument
panel air outlet assembly.
Refit
1. Locate the central air outlet to the central control
panel of the instrument panel, and press the clip. Fit
and tighten 4 screws.
2. Fix the instrument panel upper moulding to the
instrument panel assembly, press the clip, and ensure it
is fitted in place.
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Central Control Panel and Switch of Instrument

Panel
Remove
2. Pry off the clip fixing the central control panel to the
instrument panel, and remove the central control panel.
(Here's a storage box in vehicles with low configuration,
but the remove method is the same.)
3. Connect the harness connector of the entertainment

control switch.
4. Fit the central control panel of the instrument panel
and press the clip in place. (Here's a storage box in
vehicles with low configuration, but the refit method
is the same.)
3. For vehicles with an independent knob cap, first remove

the knob cap (1) from the front of the entertainment
control switch separately.
4. Remove 2 screws (3) fixing the entertainment control
switch to the central control panel.
5. Release the clip to remove the entertainment control
switch (2).
Refit
1. Fix the entertainment control switch to the central
control panel of the instrument panel from the back, fit
and tighten 2 screws.
2. For vehicles with knob caps, align any one clip of the
knob caps with any one mounting slope, then fit it to
the knob cap from the front of the central control panel
of the instrument panel until a sound of "click" is heard,
which indicates the knob cap is correctly fitted.
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Instrument Panel IPK Frame Assembly Instrument Panel Assembly
Remove Remove
1. Adjust the steering wheel to the very bottom to leave 1. Remove the instrument panel end cover assembly.
enough space. Instrument Panel End Cover Assembly Remove
2. With a screwdriver, carefully disconnect the upper trim 2. Remove the driver side lower trim panel assembly.
cover from the lower trim cover of the steering column.
Driver Side Lower Trim Panel Assembly Remove
3. Pry off the clip on the IPK frame of the instrument
3. Remove the instrument panel side air outlet assembly.
panel, and remove the instrument panel IPK frame.
Instrument Panel Side Air Outlet Assembly
Remove
4. Remove the central control panel and switch of the
instrument panel.
Panel Remove
5. Remove the player.
Player Remove
6. Remove the left/right A pillar upper trim panels.
A Pillar Upper Trim Panel Remove
7. Remove the centre console assembly.
Refit Centre Console Assembly Remove

1. Fix the IPK frame of the instrument panel to the
instrument panel IPK, press the clip and fit the IPK Glove Box Assembly Remove
frame of the instrument panel. 9. Remove the steering column trim cover.
2. Place the steering column upper trim cover on the Steering Column Trim Cover Remove
steering column, and fix it to the lower trim cover with 10. Remove the steering wheel assembly.
clips.
Steering Wheel Assembly Remove
3. Adjust the steering wheel to the initial position.
11. Remove the instrument pack.
Instrument Pack Remove
12. Remove 12 bolts fixing the instrument panel assembly
to the instrument panel beam assembly and pry off the
clip.
13. Remove the harness clip on the instrument panel, move

the instrument panel assembly, and disconnect the
harness connector. Loosen the clip fixing the solar
sensor to the instrument panel, and disconnect the
connector of the solar sensor.
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14. Remove the GPS antenna. Glove Box Assembly Refit

15. Remove 2 bolts of the passenger airbag bracket and 12. Fit the centre console assembly.
disconnect the harness connector of the passenger
Centre Console Assembly Refit
airbag.
13. Fit the left/right A pillar upper trim panels.

14. Fit the player.
Player Refit
15. Fit the central control panel and switch of the
instrument panel.

Panel Refit
16. Fit the instrument panel side air outlet assembly.
Instrument Panel Side Air Outlet Assembly

Refit
16. With assistance, remove the instrument panel body 17. Fit the driver side lower trim panel assembly.
from the vehicle.
17. Remove 6 screws fixing the instrument panel air duct
18. Fit the instrument panel end cover assembly.
to the instrument panel body, and remove the air duct.
18. When replacing the instrument panel assembly, remove Instrument Panel End Cover Assembly Refit
the instrument panel airbag module.
Instrument Panel Airbag Remove
Refit
1. Fit the instrument panel airbag to the instrument panel.
Instrument Panel Airbag Refit
2. Fit and tighten 6 screws fixing the instrument panel air
duct to the instrument panel body.
3. With assistance, fit the instrument panel body into
the vehicle, press the clip and connect the electrical
connector.
4. Fit the GPS antenna.
5. Connect the connector of the solar/temperature
sensor and secure the harness clip.
6. Fix the passenger airbag module bracket to the
instrument panel frame, fit 2 bolts, tighten to 6–8Nm,
7. Fit 12 bolts fixing the instrument panel body to the
instrument panel beam, tighten to 19–25 Nm, and
check the torque.
8. Fit the instrument pack.
Instrument Pack Refit
9. Fit the steering wheel assembly.
Steering Wheel Assembly Refit
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Instrument Panel Beam Assembly 2. Locate the instrument panel beam assembly.
Remove 3. Fit 8 bolts fixing the instrument panel beam assembly to
1. Remove the instrument panel assembly. the body, tighten to 19–25 Nm, and check the torque.
Instrument Panel Assembly Remove 4. Fit the harness clip fixing the electrical harness assembly
of the instrument panel to the instrument panel beam
2. Remove 4 bolts fixing the steering column to the
assembly, and connect the harness.
instrument panel beam assembly.
5. Fit 1 bolt fixing the instrument panel beam assembly
to the front body, tighten to 19–25 Nm, and check
the torque.
6. Fit the windshield wiper linkage mechanism assembly.
Windshield Wiper Linkage Mechanism Assembly

- With Motor Refit
7. Fit the A/C air inlet grille.
A/C Air Inlet Grille Assembly Refit

8. Fit 4 bolts fixing the steering column assembly to the
instrument panel beam, tighten to 19-25Nm, and
check the torque.
3. Disconnect the harness clip fixing the electrical harness
Instrument Panel Assembly Refit
assembly of the instrument panel to the instrument
panel beam, and remove the harness.
4. Remove the A/C air inlet grille assembly.
A/C Air Inlet Grille Assembly Remove

5. Remove the windshield wiper linkage mechanism
assembly.
Windshield Wiper Linkage Mechanism Assembly -

With Motor Remove
6. Remove 1 bolt (1) fixing the instrument panel beam
assembly to the front body.
7. Remove 8 bolts (2) fixing the instrument panel beam
assembly to the body.
8. Remove the instrument panel beam assembly from the

vehicle.
Refit
1. Fit the instrument panel beam assembly into the vehicle.
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Centre Console Upper Trim Panel Assembly and Centre Console Assembly
Switch Remove
1. Disconnect the battery negative. 2. Remove the centre console upper trim panel assembly
2. Pry off the clips fixing the centre console upper trim and switch.
panel to the instrument panel and center console.
Centre Console Upper Trim Panel Assembly and
Switch Remove
3. Remove the centre console heater closing plate
assembly.

Remove
4. Remove 4 screws (1) fixing the centre console to the
instrument panel.
5. Pry off the centre console screw cover, and remove
4 screws (2) fixing the centre console to the centre
console bracket.
3. Disconnect the harness connector,disconnect the shift

lever sleeve from the clip of the centre console upper
trim panel,remove the centre console upper trim panel.
4. Remove 4 screws from the back fixing the A/C control
switch frame to the upper trim panel assembly, and
remove the A/C control switch frame.
5. Remove the 12V power socket from the centre console
upper trim panel.
6. Remove 2 screws fixing the centre console switch to
the centre console upper trim panel, release the clip,
and remove the centre console switch.
6. Pry off the hand brake cover plate and remove the
Refit
centre console.
1. Fit and tighten 2 screws fixing the centre console switch
Refit
from the back to the centre console upper trim panel
assembly. 1. Locate the centre console in the vehicle and fit the
hand brake cover plate.
2. Fix the 12V power socket to the centre console upper
trim panel. 2. Fit and tighten 4 screws fixing the centre console to
the instrument panel.
3. Fit and tighten 4 screws fixing the A/C control switch
frame to the upper trim panel assembly. 3. Fit 4 screws fixing the centre console to the centre
console bracket, tighten to 1.6–2.0Nm, and check the
torque. Fit the centre console screw cover.
5. Locate the centre console upper trim panel assembly
4. Fit the centre console upper trim panel assembly and
to the centre console, and press the clips.
switch.
6. Fit the shift lever sleeve with the centre console upper
trim panel with clips. Centre Console Upper Trim Panel Assembly and
Switch Refit
5. Fit the centre console heater closing plate assembly.

Refit
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Remove
1. Pry off the clip of the centre console heater closing
plate and remove the centre console heater closing
plate.
2. Repeat the above step to remove the centre console

heater closing plate on the other side.
Refit
1. Fix the right centre console heater closing plate to the
centre console, and ensure the clip is fitted in place.
2. Repeat the above step to fit the centre console heater
closing plate on the other side.
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Interior Fitting Seats
Seats
Specifications
Torque
Description Value
Screw - front seat to floor 40–50Nm
Bolt - squab to cushion 40–50Nm
Bolt - striker to body 19–25Nm
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Seats Interior Fitting
System Layout
Seat Layout
1. Front Passenger Seat

2. Driver Seat
3. Rear Seat
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Description The front seat assembly may have different configurations

Front Seat Assembly according to vehicle configuration and seat exterior, for
Overview example, 4 way manual seat (forward/backward adjustment,
seat back inclination); 6 way manual seat (forward/backward
adjustment, seat back inclination and seat height adjustment).
Rear Seat Assembly
1. Seat Headrest
2. Seat Back Assembly
3. Seat Back Cover and Foam
4. Seat Back Frame The rear seat of this model is a 4/6 type seat with reclinable
seat back. If you want to expand the luggage compartment
5. Seat Cushion Assembly
space, first fully lower (or remove) all the rear seat headrests,
6. Seat Cushion Cover and Foam then pull up the unlock straps (1) on both sides respectively
7. Seat Cushion Frame and fold the seat back forward. When unfolding the rear seat
The common seat mainly consists of headrest, seat back, back, pull up the seat back unlock straps, push the seat back
seat cushion and accessories. Among them, both seat back until it reaches an appropriate position, and the seat back is
assembly and seat cushion assembly consist of cover, foam locked when it clicks.
and frame. The seat assembly and the main components
are repaired as fittings according to the vulnerability and
maintainability of the components.
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Operation 3. Seat Back Adjusting Handle
Manual Seat The front/rear position of the seat can be adjusted by the
Driver Seat handle in the front of the seat. Lift the handle and pull it to
the desired position. Release the handle to lock the seat to
the selected position. The 2nd adjusting handle is located in
the front of the trim panel outside the seat cushion, which can
adjust the seat height. Lift or press the handle repeatedly to
raise or lower the seat. The 3rd adjusting handle is located in
the rear of the height adjusting handle, which can adjust the
seat back inclination. Lift the handle and pull it to the desired
position. Release the handle to lock the seat to the selected
position.
Front Passenger Seat
The passenger seat is adjusted in the same way as the driver
seat. The front/rear position of the seat can be adjusted by the
1. Seat Longitudinal Position Adjusting Handle handle in the front of the seat. The position of the sear back
can be adjusted by the side handle.
2. Seat Height Adjusting Handle*
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Service Procedures Front Seat Squab

Front Seat Remove
Remove 1. Remove the front seat.
1. If the seat is adjustable, raise the seat fully. Front Seat Remove
2. Fully move the seat backward. 2. Release the interior trim panel fixing screw, remove
3. Using a suitable lever, remove fixing trim covers. the inner seat trim panel.
4. Remove 2 bolts fixing front of seat to body, discard.
5. Fully move the seat forward.
6. Using a suitable lever, remove fixing trim covers.
7. Remove 2 bolts fixing front of seat to body, discard.
8. Disconnect all electrical connectors.
9. Remove seat from vehicle.
Refit
1. Place the front seat in the body front seat mounting
position.
2. Connect all electrical connectors.
Warning: Always ensure SRS wiring is routed correctly.

Be careful to avoidtrapping or pinching the SRS wiring. 3. Remove outer seat trim panel.
Do not leave the connectors hanging loose or allow SRS Driver's Seat Exterior Trim Panel Remove
4. Loosen the cables and J-clamps fixing the backrest
upholstery to the seat frame.
3. Fix the seat to the vehicle body, fit 2 new rear bolts and
5. Remove the 4 bolts connecting the cushion assembly
tighten them to 40–50Nm.
with the squab assembly.
4. Refit fixing trim covers.
5. Fully move the seat backward.
6. Fit 2 new front retaining bolts and tighten them to
40–50Nm.
7. Refit fixing trim covers.
6. Carefully separate squab from cushion, release block

connector from seat frame and thread airbag harness
through cushion.
7. Remove seat squab.
Refit
1. Locate the cushion assembly and squab assembly,
refit 4 bolts and tighten to 40–50Nm, thread airbag
wiring through seat cushion.Always ensure SRS wiring
is routed correctly. Be careful to avoidtrapping or
pinching the SRS wiring. Do not leave the connectors
hanging loose or allow SRS components to hang from
their harnesses. Look for possible points of chafing.
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2. Fix the squab upholstery to the seat frame with cables Front Seat Backrest Cover
and J-clamps. Remove
3. Refit the exterior trim panel. 1. Remove the front seat backrest assembly.
Front Seat Outer Trim Panel Refit Front Seat Backrest Remove
4. Locate the interior trim panel, refit the screw and 2. Pull the headrest to the top, loosen the buckle fixing
tighten it. the headrest and remove the headrest.
5. Refit the front seat. 3. Remove 2 guide pipes of the headrest.
Front Seat Refit 4. Release J-clamps of the backrest upholstery under the
seat.
5. Pull the upholstery upward, and open the C-rings
connecting the backrest foam and the interior of the
upholstery, note and mark their exact positions.
6. Remove the upholstery.
Refit
1. Locate the upholstery to the backrest, fix the interior
of the upholstery to the marked position of the back
foam with C-ring.
2. Close J-clamps of the backrest upholstery under the
seat.
3. Fix the backrest upholstery to the frame with J-clamps.
4. Refit 2 headrest guide pipes.
5. Locate and secure the headrest.
6. Refit the front seat backrest assembly.
Front Seat Backrest Refit
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Front Seat Cushion Front Seat Cushion Cover

Remove Remove
1. Remove the front seat. 1. Remove the front seat cushion assembly.
Front Seat Remove Front Seat Cushion Assembly Remove

2. Remove seat cubby box (if fitted). 2. Loosen the J-clamp and C-ring fixing the cushion
3. Remove the exterior trim panel. upholstery to the frame.
3. Open the C-rings connecting the cushion foam and the
Driver's Seat Exterior Trim Panel Remove
interior of the upholstery, note and mark their original
4. Loosen the cables and J-clamps fixing the backrest
fitted positions.
upholstery to the seat frame.
4. Remove seat cushion cover.
5. Remove 4 bolts connecting the cushion assembly to
Refit
the backrest assembly.
1. Place front seat cushion cover in position on cushion
6. Remove the cushion assembly.
foam, fix the interior of the upholstery to the marked
Refit position of the cushion foam with C clips.
1. Refit 4 bolts connecting the cushion assembly and the 2. Fix the cushion upholstery to the frame with J-clamps
squab assembly and tighten to 40–50Nm . and C clips.
2. Fix the squab upholstery to the seat frame with cables
3. Refit the front seat cushion assembly.
and C-rings.
Front Seat Cushion Assembly Refit
3. Ensure any SRS wiring follows original route.Always
ensure SRS wiring is routed correctly. Be careful to
avoidtrapping or pinching the SRS wiring. Do not leave
the connectors hanging loose or allow SRS components
to hang from their harnesses. Look for possible points
of chafing.
Always ensure SRS wiring is routed correctly. Be

careful to avoidtrapping or pinching the SRS wiring. Do
not leave the connectors hanging loose or allow SRS
4. Refit the exterior trim panel.
Front Seat Outer Trim Panel Refit

5. Refit the front seat.
Front Seat Refit
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Front Seat Outer Trim Panel Rear Seat Cushion
Remove Remove
1. Remove the front seat. 1. Release the seat belt buckle from the belt through-hole.
Remove-Front Seat 2. Pull the front end of the cushion upward until it is
released from the retaining clips.
2. Partially raise recline and seat height handles (where
applicable).
3. Remove screws at front (behind recline handle) and
rear of trim.
3. Slide seat cushion forwards to release from rear

retainers and remove.
4. Release rear clip, push trim toward front of seat to

release front clip.
5. Remove the outer trim panel fixing screw under the
handle.
Refit
1. Place trim in position on seat frame, push rearward
to engage front retainer.
2. Press trim to locate rear clip.
3. Fit retaining screws, front and rear.
4. Position recline and height adjustment handles (where
applicable), push to engage retaining clip.
Refit
5. Fit the front seat。
1. Position rear of seat cushion in aperture, push
Refit-Front Seat rearwards, ensure engagement of retaining clips, take
care to correctly locate seat belts etc.
2. Align seat cushion front clips.
3. Pull the belt buckle out of the cushion belt buckle
through-hole.
4. Push down on cushion to secure.
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Rear Seat Squab Hinge Rear Seat Squab

Remove Remove
1. Turn down the rear seat backrest assembly. 1. Remove rear seat cushion.
2. Remove the D pillar lower trim panel assembly. Rear Seat Cushion Remove
D Pillar Lower Trim Panel Remove 2. Operate seat tilt release button, tilt seat fully forward.
3. Mark the position of the lower seat backrest hinge 3. Holding the squab at the bottom, pull upwards to
buckle. partially release from fixing bracket.
4. Unscrew 2 bolts fixing the hinge to the vehicle body. 4. Using a suitable device, press plastic hinge clip to
release, pull seat squab upwards to fully release fixing.
5. Manipulate seat squab inner hinge from other seat
section and hinge retainer.
Refit
1. Position the hinge to the vehicle body, refit the bolt
2. Refit the D pillar lower trim panel assembly. 6. Release squab from centre bracket and remove squab.
D Pillar Lower Trim Panel Refit Refit
3. Refit the rear seat backrest assembly. 1. Position squab inner hinge/pin onto opposite seat
squab/centre bracket.
2. Tilt seat squab to fully forward position.
3. Insert outer pivot clip into bracket, push fully home,
ensure clip, guide and pivot are fully engaged and secure.
4. Refit rear seat cushion.
Rear Seat Cushion Refit

5. Return squab to upright position, engage in catch.
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Fixed Windows Exterior Fitting
Fixed Windows Rear Door Quarter Window
Service Procedures Remove
Front Door Quarter Window 1. Remove the outer weatherstrip of the door window.
Remove
Door Window Outer Weatherstrip Remove
1. Remove the outer weatherstrip of the door window.
2. Remove the inner guide rail weatherstrip of the rear
Door Window Outer Weatherstrip Remove door window.
2. Remove the inner guide rail weatherstrip of the front 3. Remove the rear door window.
door window.
Rear Door Window Remove
3. Remove the front door window.
4. Remove the rear door separating pillar.
Front Door Window Remove
Rear Door Separating Pillar Remove
4. Remove the front door separating pillar.
5. Remove the rear door quarter window from the
Front Door Separating Pillar Remove vehicle.
5. Remove the front door quarter window from the 6. Remove the weatherstrip of the quarter window.
vehicle. Refit
6. Remove the weatherstrip of the quarter window from 1. Fix the weatherstrip of the rear door quarter window
the quarter window. to the quarter window.
Refit 2. Fit the rear door quarter window.
1. Fix the weatherstrip of the front door quarter window 3. Fit the rear door window chute weatherstrip.
to the quarter window.
4. Fit the rear door separating pillar.
2. Fit the front door quarter window.
Rear Door Separating Pillar Refit
3. Fit the front door separating pillar.
5. Fit the rear door window.
Front Door Separating Pillar Refit
Rear Door Window Refit
4. Fit the front door window.
6. Fit the inner guide rail weatherstrip of the rear door
Front Door Window Refit window.
5. Fit the inner guide rail weatherstrip of the front door 7. Fit the outer weatherstrip of the door window.
window.
Door Window Outer Weatherstrip Refit
6. Fit the outer weatherstrip of the door window.
Door Window Outer Weatherstrip Refit
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Exterior Fitting Fixed Windows
Windshield Rear Window

Remove Remove
1. Remove the A pillar upper trim panel. 1. Disconnect the battery negative.
A Pillar Upper Trim Panel Remove 2. Disconnect the connector of the rear window defogger.
2. Remove the interior rearview mirror. 3. Remove the rear window wiper motor.
Interior Rearview Mirror Assembly Remove Rear Window Wiper Motor Remove
3. Remove the A pillar exterior trim panel. 4. Put 2 suction cups symmetrically on both sides of the
rear window (outer side).
A Pillar Exterior Trim Panel Remove
5. Remove the adhesive on the rear window assembly and
4. Remove the A/C air inlet grille assembly.
the rear window frame with the glass sealant remover.
A/C Air Inlet Grille Assembly Remove 6. Remove the rear window with suction cups on both
5. Put suitable coverings on the vehicle body to protect sides aided by an assistant.
it from scratch. 7. Remove the adhesive on the original rear window and
6. Put 2 suckers symmetrically on both sides of the rear window frame.
windshield (outer side). Refit
7. Remove the adhesive around the windshield assembly 1. Thoroughly clean the mounting position of the rear
with the glass sealant remover. window on the body and the rear window with cleaner.
8. Remove the windshield with suckers on both sides 2. Apply glass primer to the body assembly area of the
aided by an assistant. rear window.
9. Remove the adhesive on the original windshield and 3. Apply adhesive to the rear window assembly, and press
windshield frame. the rear window into the rear window frame with
Refit suction cups.
1. Thoroughly clean the mounting position of the 4. Fix the rear window to the rear window frame with
windshield on the body and the windshield with cleaner. tapes, and allow the adhesive to dry for 24 hours.
2. Apply glass primer to the body assembly area of the 5. Remove the tape.
windshield. 6. Pour the water on the windshield assembly, and check
3. Apply adhesive to the windshield assembly, and press for leak. If any leak is found, dry the windshield
the windshield into the windshield frame with suction assembly and block the leaking location with adhesive.
cups. If it still leaks, remove the windshield assembly and
4. Fix the windshield to the windshield frame with tapes, repeat all service procedures.
and allow the adhesive to dry for 24 hours. 7. Fit the rear window wiper motor.
5. Remove the tape. Rear Window Wiper Motor Refit
6. Pour the water on the windshield assembly, and check 8. Connect the electrical connector of the rear window
for leak. If any leak is found, dry the windshield defogger.
assembly and block the leaking location with adhesive. 9. Connect the battery negative.
If it still leaks, remove the windshield assembly and
repeat all service procedures.
7. Fit the A/C air inlet grille assembly.

8. Fit the A pillar exterior trim panel.
A Pillar Exterior Trim Panel Refit

9. Fit the interior rearview mirror.
Interior Rearview Mirror Assembly Refit

10. Fit the A pillar upper trim panel.
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Bumpers, Fascias and Grille Exterior Fitting
Bumpers, Fascias and Grille
Specifications
Torque
Description Value
Bolt-From front bumper to fender 2–2.5Nm
Bolt-From rearbumper to wheel casing 2–3Nm
Bolt-From under flow duct to front bumper 4–6Nm
Bolt-From front bumper to fend upper tie bar 3–5Nm
Bolt-From front bumper impact bar to body in white 40–50Nm
Screw-From front bumper impact bar to fend upper tie bar 7–10Nm
Bolt-From rear bumper impact bar to body in white 19–25Nm
Bolt-From rear bumper brackt to bodyside 3–4Nm
Bolt-From rearbumper to wheel casing 3–4Nm
Bolt-From rear bumper to body in white 3–4Nm
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Exterior Fitting Bumpers, Fascias and Grille
Service Procedures
Front Bumper and Bracket
Remove
2. Remove 2 screws (1) fixing the front bumper to the
upper part of the left (right) wheelhouse liner, and
remove 1 screw (2) fixing the left (right) side of the
front bumper to the left (right) fender.
5. With assistance, lift both sides of the front bumper

carefully and pull it outward to remove the front
bumper from the brackets on both sides of the body.
6. Disconnect the harness of the ambient temperature
sensor on the air inlet grille under the front bumper,
and remove the front bumper.
7. If necessary, remove 4 screws fixing the mounting
brackets on both sides of the front bumper to the body
to remove the mounting brackets.
3. Remove 4 bolts (1) and 2 clips (2) fixing the front
bumper to the upper radiator beam. Refit
1. If the mounting brackets on the left and right sides of
the front bumper have been removed, fit 4 screws
securing the mounting brackets on both sides at first,
tighten to 2–2.5Nm, and check the torque.
2. Connect the harness of the ambient temperature
sensor on the air inlet grille under the front bumper.
3. With assistance, fit the front bumper assembly to the
body, press both sides into the left and right brackets
of the front bumper, align the upper and lower parts
with the mounting holes in the upper radiator beam
and bottom deflector respectively, and press the clip
in place.
4. Fit 6 screws fixing the front bumper to the bottoms of
4. Remove 6 screws (1) fixing the front bumper to the the left/right wheelhouse liners, tighten to 2–3Nm,
lower part of the left/right wheelhouse liner, and and check the torque.
remove 3 bolts (2) fixing the front bumper to the
5. Fit 3 bolts fixing the front bumper to the bottom
bottom deflector.
deflector, tighten to 4–6Nm, and check the torque.
6. Fit 1 screw fixing the left (right) side of the front
bumper to the left (right) fender, tighten to 2–2.5Nm,
7. Remove 2 screws fixing the front bumper to the left
(right) wheelhouse liner, tighten to 2–3Nm, and check
the torque.
8. Fit 4 bolts fixing the front bumper to the upper radiator
beam, tighten to 3–5Nm, and check the torque.
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Front Bumper Beam Front Bumper and Bracket Refit
Remove 8. Connect the battery negative.
2. Remove the front bumper and bracket.
Front Bumper and Bracket Remove
3. Disconnect the harness connector.
4. Remove the tweeter.
Tweeter Remove
5. Remove the wind scoopers on both sides.
Wind Scooper - Left Remove
Wind Scooper - Right Remove
6. Remove 2 nuts (1) and 6 bolts (2) fixing the left and
right sides of the front bumper beam to the body and 4
bolts (3) to the front-end module.
7. Remove the front bumper beam.

Refit
1. Locate the front bumper beam to the body, fit 6 bolts
fixing the left and right sides of the front bumper
beam to the body, tighten to 40–50Nm, and check
the torque.
2. Locate the front bumper beam to the body, fit 2 nuts
fixing the left and right sides of the front bumper
beam to the body, tighten to 40–50Nm, and check
the torque.
3. Fit 4 bolts fixing the left and right sides of the front
bumper beam to the front-end module, tighten to
4. Fit the wind scoopers on both sides.
Wind Scooper - Left Refit
Wind Scooper - Right Refit
5. Fit the tweeter.
Tweeter Refit
7. Fit the front bumper and bracket.
1.0 491
Exterior Fitting Bumpers, Fascias and Grille
Rear Bumper Beam Rear Bumper and Bracket

Remove Remove
1. Remove the rear bumper. 1. Disconnect the battery negative.
Rear Bumper Remove 2. Open the tail gate.

2. Remove 6 bolts (1) and 2 nuts (2) fixing the left and 3. Remove 2 bolts fixing the rear bumper to the body.
right sides of the rear bumper beam to the rear end
of the body.
4. Remove 2 bolts and 2 screws fixing the lower rear

bumper to the body bracket.
3. Carefully remove the rear bumper beam from the rear

end of the body.
Refit
1. Locate the rear bumper beam to the body, fit 6 bolts
and 2 nuts fixing the left and right sides of the rear
bumper beam to the rear end of the body, tighten to
2. Fit the rear bumper.
Rear Bumper Refit
5. Remove 1 screw (1), 1 split pin (2) and 1 clip (3) of the
left (right) side of the rear bumper and the left (right)
rear wheelhouse liner.
6. Carefully disconnect the rear bumper from the body,

disconnect the rear fog lamp connectors on the left and
right sides and the harnesses of the rear bumper rear
1.0 492
radar sensor, and remove the rear bumper.
7. If the brackets on both left and right sides of the rear
bumper are required to be removed, remove 6 bolts
fixing the left/right rear bumper brackets to the rear
end panel.
Refit
1. If the brackets on both left and right sides of the rear
bumper have been removed, fix 3 screws of the left
(right) bracket of the rear bumper at first, tighten to
2. Connect the rear fog lamp connectors on the left and
right sides and 4 connectors of the rear bumper rear
radar sensor.
3. Gently push the rear bumper in place to allow the
bumper on each side to engage with the bumper
bracket.
4. Fit 1 clip, 1 split pin and 1 screw of the lower part of
the left (right) rear bumper and the left (right) rear
wheelhouse liner, tighten to 3–4Nm, and check the
torque.
5. Fit 2 screws and 2 bolts fixing the lower rear bumper
to the body bracket, tighten to 3–4Nm, and check
the torque.
6. Fit 2 screws fixing the rear bumper to the body, tighten
1.0 493
Exterior Fitting Exterior Trim and Paneling
Exterior Trim and Paneling

Specifications
Torque
Description Value
Screw-A/C air intake grille to body 1.5–2Nm
Bolt-From under flow duct to front wheel casing 2–3Nm
Bolt-From front wheel casing to front bumper 2–3Nm
Bolt-From front wheel casing to front bumper and sill 2.5–3.5Nm
Bolt-From rear wheel casing to rear bumper 2–3Nm
Nut-From under body shield to body 4-6Nm
Bolt-From under flow duct to former vice frame 4-6Nm
Bolt-From front bumper to under flow duct 3-4Nm
1.0 494
Exterior Trim and Paneling Exterior Fitting
Service Procedures Front Wheelhouse Liner
Remove 1. Raise the vehicle on a lift.
1. Open the bonnet. 2. Remove the front wheels.
2. Pry off the clips at the side corners of the A/C air inlet Wheels Remove
grille, and remove the side corners.
3. Remove 5 screws (1) fixing the left front wheelhouse
3. Remove the windshield wiper arm assembly. liner to the left side of the front bumper.
Windshield Wiper Arm Assembly Remove 4. Remove 3 bolts (2) fixing the left front wheelhouse
4. Remove 2 screws (1) and 2 clips (2) fixing the A/C air liner to the body.
inlet grille to the body. 5. Remove 1 hexalobular socket screw (3) fixing the left
front wheelhouse liner to the pedal.
6. Remove 1 plastic nut (4) fixing the left front wheelhouse
liner to the body.
7. Remove 1 bolt (5) fixing the left front wheelhouse liner
to the left side of the bottom deflector.
5. Disconnect the connection of the windshield washer

pump hose and the windshield nozzle hose.
6. Disconnect the windshield nozzle hose from the nozzle
and remove both of them.
Refit
8. Remove the left front wheelhouse liner.
1. Fit the windshield nozzle and nozzle hose.
9. Remove the right front wheelhouse liner according to
2. Connect the windshield washer pump hose and the
the above steps.
windshield nozzle hose.
Refit
3. Locate the A/C air inlet grille to the body, press the
clip, fit 2 screws fixing the middle part of the A/C air 1. Lift the wheelhouse and pre-fasten the wheelhouse to
inlet grille to the body, tighten to 1.5–2Nm, and check the body in white with split pins.
the torque. 2. Remove 1 plastic nut fixing the left front wheelhouse
4. Fit the windshield wiper arm assembly. liner to the body.
3. Fix the left front wheelhouse to the relative position of
Windshield Wiper Arm Assembly Refit
the bottom deflector, fit 1 bolt, tighten to 2–3Nm,
5. Locate the A/C air inlet grille side corner and press check the torque.
the clip in place.
4. Fit 3 bolts fixing the left front wheelhouse liner to the
6. Close the bonnet. body, tighten to 2–3Nm, and check the torque.
5. Fit 5 screws fixing the left front wheelhouse liner to
the left side of the front bumper, tighten to 2–3Nm,
6. Fit 1 screw connecting the left front wheelhouse liner
to the bottom of the front bumper and the pedal,
tighten to 2.5–3.5Nm, and check the torque.
7. Fit the right front wheelhouse according to the above
steps.
1.0 495
8. Fit the front wheels. Rear Wheelhouse Liner

Wheels Refit
Remove
2. Remove 2 screws (1) fixing the left rear wheelhouse
to the rear bumper.
3. Remove 2 plastic nuts (2) and 1 clip (3) fixing the left
rear wheelhouse to the body.
4. Remove the left rear wheelhouse liner.

5. Refer to the steps for removing the left rear wheelhouse
liner to remove the right rear wheelhouse liner.
Refit
1. Lift the wheelhouse liner, fit and tighten 1 clip and 2
plastic nuts fixing the left wheelhouse liner to the body.
2. Fit 2 screws connecting the left rear wheelhouse liner
to the rear bumper, tighten to 2–3Nm, and check the
torque.
1.0 496
Exterior Trim and Paneling Exterior Fitting
Bottom Deflector
Remove
2. Follow steps 3 - 4 to remove the bottom deflector with
high configuration; follow steps 5 - 6 to remove the
bottom deflector with low configuration. Follow steps
7 - 8 to remove the bottom deflector on both sides of
the middle part.
3. If it is the bottom deflector with a big head, remove 3
bolts connecting the bottom deflector and the bottom
of the front bumper.
4. Remove 6 bolts fixing the bottom deflector to the front
wheelhouse liner and the front subframe, and remove Refit
the bottom deflector. 1. Follow steps 2 - 3 to fit the central guard plate on both
sides of the middle part; follow steps 4 - 5 to fit the
deflector with low configuration; follow steps 6 - 7 to
fit the bottom deflector with high configuration.
2. Fit 6 clips fixing the central guard plate to the
underbody, and press the clip in place.
3. Fit 6 bolts fixing the central guard plate to the
underbody, tighten to 4-6Nm, and check the torque.
4. Fix the bottom deflector in place, fit 4 bolts fixing the
bottom deflector to the front subframe and the right
front wheelhouse liner, tighten to 4-6Nm, and check
the torque.
5. Fit 1 bolt connecting the bottom deflector and the
5. If it is the bottom deflector with small right side, bottom of the front bumper, tighten to 3-4Nm, and
remove 1 bolt connecting the bottom deflector and the check the torque.
bottom of the front bumper. 6. Insert the bottom deflector into the lower revers of
6. Remove 4 bolts fixing the bottom deflector to the right the front bumper, fit 6 bolts fixing the bottom deflector
front wheelhouse liner and the front subframe, and to the front subframe and the front wheelhouse liner,
remove the bottom deflector. tighten to 3-4Nm, and check the torque.
7. Fit 3 bolts connecting the bottom deflector and the
bottom of the front bumper, tighten to 3-4Nm, and
check the torque.
7. If it is the central guard plate on both sides of the

middle part, remove 6 bolts (1) fixing the left central
guard plate to the underbody.
8. Remove 6 clips (2) fixing the central guard plate to the
underbody, and remove the central guard plate.
1.0 497
A Pillar Exterior Trim Panel

Remove
1. Open the front door.
2. Remove 3 screws fixing the exterior trim panel of the
A pillar to the body.
3. Pry off 4 clips and remove the exterior trim panel of
the A pillar.
Refit
1. Locate the exterior trim panel of the A pillar to the A
pillar, and press the clip in place.
2. Fit and tighten 3 screws fixing the exterior trim panel
of the A pillar to the A pillar.
3. Close the front door.
1.0 498
Mirrors Exterior Fitting
Mirrors
Specifications
Torque
Description Value
Screw - exterior mirror 9–10Nm
1.0 499
Exterior Fitting Mirrors

System Layout
Exterior Rearview Mirror Layout
1. Left Exterior Rearview Mirror Assembly 2. Right Exterior Rearview Mirror Assembly
1.0 500
A=Hard Wire
1.0 501
Description Headlamp Leveling Switch

Overview
The power exterior rearview mirror assembly is fitted on all
models as a standard configuration. Each exterior rearview
mirror assembly is controlled by the circular control switch of
the headlamp leveling switch.
Exterior Rearview Mirror Assembly
The left and right exterior rearview mirror assemblies shall
be distinguished, but the basic structures are the same. The
housing of the exterior rearview mirror assembly is a plastic
mould which includes the mirror and side direction indicator
lamp. The exterior rearview mirror assembly is fixed on the
front door by 2 bolts which are visible only when the front trim
panel of the exterior rearview mirror cover is removed.
The headlamp leveling switch is located on the lower trim panel
The housing of the exterior rearview mirror assembly is at the driver side.
unrepairable and shall be replaced as an assembly. The
The headlamp leveling switch has a circular control knob which
exterior rearview mirror, the exterior rearview mirror cover,
can operate the vertical and horizontal motors in the exterior
side direction indicator lamp bulb and the seal gasket are
rearview mirror assembly. The circular control knob can be
repairable.
adjusted to 4 directions and rotate. Turn the two LEDs (L & R)
above the circular control knob counterclockwise/clockwise to
select one of the exterior rearview mirrors. When the width
lamp or the headlamp illuminates, the LED flashes.
1.0 502
Operation Exterior Rearview Mirror Manual Folding
Exterior Rearview Mirror Fold manually to achieve the folding/expansion of the exterior
The steering gear of the exterior rearview mirror includes rearview mirror.
2 bidirectional motors (vertical motor and horizontal motor) Interior Rearview Mirror
which provide horizontal and vertical motions for the rearview
Manual Anti-dazzle Function
mirror. The vertical motor is responsible for the up-and-down
motion while the horizontal motor is for the left-and-right During driving, the strong light from the interior rearview
motion. mirror may affect the driver. To avoid such visual shock, pull
the lever at the base of the interior rearview mirror and change
The exterior rearview mirror can provide the following
the view to 'dip' the mirror. Push back the lever to return the
functions:
interior rearview mirror to the normal position.
• Exterior rearview mirror manual folding
• Side direction indicator lamp
1.0 503
Service Procedures Exterior Rearview Mirror Cover

Exterior Rearview Mirror Assembly Remove
Remove 1. Remove the mirror glass.
1. Remove the front door interior trim panel. 2. Unscrew 2 bolts securing the mirror cover to the
Remove of Front Door Interior Trim Pane exterior rearview mirror assembly.
2. Pry the outside trim shell.
3. Using a suitable lever remove mirror cover.
3. Remove the door trim panel and the waterproof film,

now you can see the plug of the exterior review mirror
connector, disconnect the connector.
4. Remove the 2 bolts securing the exterior review mirror
to the body, and remove the exterior review mirror
assembly.
Refit
1. Refit mirror cover to exterior rearview mirror
assembly.
2. Refit 2 screws securing mirror cover.
3. Refit the mirror glass.
Refit
1. Position the exterior review mirror with the location
pin on it to corresponding location hole on the door,
fit 2 bolts, and tighten to 9–10Nm.
2. Connect the exterior review mirror connector, and fit
the waterproof film.
3. Fit the outside trim shell.
4. Fit the front door interior trim panel.
Refit of Front Door Interior Trim Pane
1.0 504
Interior Rearview Mirror
Remove
1. Knock down the interior rearview mirror assembly
with a rubber hammer with care to remove it from
the base.
Refit
1. Locate the interior rearview mirror to the mounting
bracket and push it into the slot with care to fit it in
place.
1.0 505
Exterior Fitting Wipers and Washer
Wipers and Washer

Specifications
Torque
Description Value
Nut - front windscreen wiper arm 14–16Nm
Screw - motor and Linkage 7–10Nm
Screw - washer tank 7–10Nm
Screw - washer filler neck 4–6Nm
Nut-Rear wiper arm to motor shaft 8–10Nm
Nut-Rear wiper motor to tailgate 7–10Nm
1.0 506
Wipers and Washer Exterior Fitting
System Layout
Wiper and Washer Layout
1. Washer Reservoir and Washer Pump 4. Body Control Module (BCM)

2. Wiper/Washer Lever Switch 5. Windshield Wiper and Motor Assembly
3. Rear Window Wiper and Motor Assembly
1.0 507
1.0 508
Description The rear wiper is located at the bottom of the rear window.
Overview Its motor is fitted on a linkage mechanism on the tail gate. The
linkage mechanism can drive the wiper arm and the wiper blade
The wiper and washer system is controlled by the body control
to operate.
module (BCM), which will operate after receiving commands
from the wiper/washer lever switch on the right side of the Washer Exploded View
steering wheel. The washer system includes:
The diagnostic information for the wiper and washer system
can be read with the scan tool.
Wiper Exploded View
The wiper system includes:
1. Washer Reservoir
2. Windshield Washer Pump
3. Windshield Washer Reservoir Hose
4. Windshield Washer Hose Assembly
1. Front Wiper Motor 5. Washer Reservoir Neck
2. Passenger Side Wiper Arm Assembly 6. Washer Reservoir Cap
3. Driver Side Wiper Arm Assembly 7. Washer Reservoir Neck Seal Ring
4. Passenger Side Wiper Blade Assembly 8. Tail Gate Washer Nozzle Hose
5. Driver Side Wiper Blade Assembly 9. Tail Gate Washer Reservoir Hose
6. Shaft Cap 10. Rear Window Washer Nozzle
7. Shaft Cap 11. Windshield Washing Nozzle
8. Rear Wiper Motor The washer reservoir is fitted in the right wheelhouse, with a
9. Rear Window Seal Ring capacity of about 4 liters. The engine compartment is provided
10. Rear Wiper Blade with a filler neck with a seal cap which can be used to refill the
washer reservoir.
11. Rear Wiper Arm
The washer pump is fitted below the washer reservoir. When
The windshield wiper motor is below the air inlet grille
the washer pump is enabled, it will pump the fluid in the washer
at the bottom of the windshield, which is fitted to a
reservoir into the washer nozzle under the action of pressure.
linkage mechanism on the bracket between inner and outer
compartment walls. The linkage mechanism can drive the
wiper arm and the wiper blade to operate.
1.0 509
Operation wipe vary with the vehicle speed level and the setting of wiper
Overview delay potentiometer.
The front/rear wipers and washers are controlled by the BCM. When the switch is in intermittent, low speed or high speed
When the BCM receives an ON signal from the washer/wiper position, the BCM will adjust the interval of intermittent wipe
lever switch connected by the hard wire, it drives the washer according to the vehicle speed. ABS ECU monitors the wheel
pump and wiper motor to work. The bidirectional washer speed signal and transmits it to the BCM through HS CAN
pump provides washer fluid for the front and rear windows, bus.
the front washer pump is indirectly controlled by the BCM,
If the wiper/washer lever switch is in the intermittent wipe,
and the rear washer pump is directly controlled by the rear
the BCM adjusts the selected delay time by comparing vehicle
window washer switch.
speed with the resistance corresponding to the intermittent
Front Wiper/Washer System delay rotary switch.
The front wiper includes the BCM, washer/wiper lever switch Programmed Wash/Wipe
and two relays. One of the relay (1) is used to turn on/off the
When the ignition switch in "ACC" or "ON" position and the
wiper, and the other (2) is used to control the wiper speed.
front wiper switch is enabled, the BCM controls the front
When the BCM receives signals from the washer/wiper lever
wiper to work at low speed, enables the washer pump and
switch, it drives the front wiper to work by closing the two
triggers the internal counter. When the counter value achieves
wiper relays in the engine compartment fuse box.
the set value, the BCM closes the relay, and the front wiper
The switches for single wipe, intermittent wipe and low/high starts to work. When the driver release the washer/wiper
speed wipe form a closed circuit with the BCM through relay lever, the washer pump and front wiper stop.
1 or 2.
Caution: During engine start, the windshield wiper
When the ignition switch is in "ACC" or "ON" position, the and washer function is disabled.
output status of the front wiper is as follows:
Caution: The wiper continues operating for three
Front Wiper
Switch 1 Switch 2 times after the lever switch is released. After
Mode
several seconds, the wiper will wipe once more to
Stop 0 0 eliminate the washer fluid on the windshield.
Single Wipe 1 1 Front Wiper Stop
Auto Wipe 1 0
With the ignition switch ON, turn the wiper switch of
Low Speed Wipe 0 1 the washer/wiper lever to "OFF" position, the wiper relay
High Speed Wipe 1 1 disconnects immediately and the front wiper then stops
0 = Disconnected 1 = Closed promptly.
High Speed Wipe If the ignition switch is turned off when the wiper is working,
the wiper relay will remain closed, even if the washer/wiper
When choosing high speed mode for the front wiper, the BCM
lever is in "OFF" position; when the wiper shifts to the "RESET"
will send a signal to the wiper relay. When relay 2 closes, the
position at low speed, the relay disconnects automatically and
power supply connects the motor directly through the resistor
the wiper stops working.
for deceleration, at this stage, the wiper works at high speed.
Front Wiper Failure Protection
Low Speed Wipe
When choosing low speed wipe mode, the BCM sends a signal When the front wiper is enabled, the BCM monitors the
to the wiper relay. The power supply passes through relay 1 position signal of the front wiper switch. If the ignition switch
before connecting with the motor by a resistor. The resistor is in "OFF" position, but the switch of the front wiper remains
reduces the power, so the wiper works at low speed. in the original status, the relay of the front wiper will also
disconnect automatically.
Auto Wipe-Variable Intermittent Wipe
Rear Wiper/Washer System
The function of variable intermittent wipe: the vehicle is
provided with a wiper delay potentiometer. BCMWhen a valid request from the rear wiper switch is
received, it will control the corresponding relay to work.
When receiving valid wiper interval request, the BCM will
control the wiper at slow speed. The times of intermittent
1.0 510
Intermittent Wipe speed/intermittent mode, if the shift lever is turned to the R
When the ignition switch is in "ACC/ON" position, if the BCM gear, the BCM will apply the rear wiper relay automatically
detects that the rear wiper switch is ON, it controls the rear after several seconds and activate the rear wiper, this does
wiper to work at low speed, enables the washer pump and not affect the front wiper.
triggers the internal counter. When the counter value achieves Rear Window Washer/Wiper Failure
the set value, the BCM closes the relay, and the rear wiper
If the tail gate is open, the wiper/washer of the rear window
starts to work.
will be disabled for any mode.
Programmed Wipe If the BCM detects that the tail gate is open when the rear
When the rear wiper switch is activated, the washer pump is wiper is working, the rear wiper will be disabled immediately.
enabled, and the BCM monitors the status of the rear wiper After the tail gate is closed, the rear wiper returns to normal
switch and counts. If the switch is not released, the BCM will state after appr. 5s, this provides enough time for the user to
activate the rear wiper relay to start the rear wiper. take his hands away from the wash/wipe area.
R Gear Wipe
When the ignition switch is in "ACC/ON" position, and
the front washer/wiper lever switch is in high speed/low
1.0 511
Service Procedures Windshield Wiper Arm Assembly

Windshield Wiper Blade Assembly Remove
Remove 1. Open the Bonnet.
1. Raise the wiper blade from the windshield. 2. Remove the wiper arm shaft cover to expose the wiper
arm nuts.
2. Take out the blade from the wiper arm and remove
while pressing the safety clips. 3. Remove the nuts fixing the wiper arm to the linkage
Refit mechanism.
1. Engage the wiper blade assembly into safety clips, and 4. Remove the wiper arm assembly.
refit on the wiper arm assembly. Refit
2. Secure the wiper arm to the windshield. 1. Fix the wiper blade assembly into the safety buckle and
fit to the wiper arm assembly.
2. Fit the wiper blade and arm assembly to the pivot of
mechanism assembly.
3. Ensure that the adhesive tapes of two wiper blades are
fitted in initial positions properly and align with the dots
on the black printing edge of the glass.
4. Fit the nuts to the pivot of mechanism assembly and
5. Fit the wiper shaft cover to the pivot.
6. Close the bonnet.
1.0 512
Windshield Wiper Linkage Assembly - With Washer Reservoir Assembly
Motor Remove
Remove 1. Remove the front bumper and the bracket.
Front Bumper and Bracket Remove
2. Remove the windshield wiper arm assembly.
2. Remove the washer pump assembly.
Windshield Wiper Arm Assembly Remove
Washer Pump Remove
3. Remove the air inlet grille assembly.
3. Loosen 1 bolt securing the washer fluid filler pipe.
4. Remove 3 bolts of the windshield wiper linkage
mechanism assembly.
4. Loosen 2 nuts (1) and 1 bolt (2) securing the washer

reservoir.
5. Remove the windshield wiper linkage mechanism
assembly.
Refit
1. Fit 3 bolts to fix the windshield wiper linkage mechanism
assembly and tighten the bolts to 7–10Nm.
2. Fit the air inlet grille assembly.
3. Fit the windshield wiper arm assembly.
Windshield Wiper Arm Assembly Refit

5. Remove the washer reservoir.

Refit
1. Locate the washer reservoir to the body, and fit the lug
nut to the mounting hole of the reservoir neck.
2. Fit 2 nuts securing the washer reservoir, tighten to
3. Fit 1 bolt securing the washer reservoir, tighten to
4. Fit 1 bolt securing the washer fluid filler pipe, tighten
5. Fit the washer pump assembly.
Washer Pump Refit
6. Fit the front bumper and the bracket.
Front Bumper and Bracket Refit
1.0 513
Washer Pump Assembly Windshield Washer Pump Hose

Remove Remove
1. Remove the front bumper and the bracket. 1. Remove the front bumper and the bracket.
Front Bumper and Bracket Remove Front Bumper and Bracket Remove
2. Put one container under the washer reservoir. 2. Remove the front wheelhouse liner.
3. Disconnect the connector of the washer pump (1). Front Wheelhouse Liner Remove
4. Remove the washer pump from the washer reservoir. 3. Put one container under the washer reservoir.
5. Disconnect the windshield washer pump hose (2). 4. Disconnect the windshield washer pump hose from the
6. Disconnect the rear window washer pump hose (3). washer pump.
7. Remove the washer pump. 5. Disconnect the connection of the windshield washer
Refit pump hose and the windshield nozzle hose.
1. Fit the washer pump to the washer reservoir. 6. Remove the clip fixing the windshield washer pump
hose to the body, and remove the windshield washer
2. Connect the windshield washer pump hose.
pump hose.
3. Connect the rear window washer pump hose.
Refit
4. Connect the connector of the washer pump.
1. Fit the new hose and connect it to the washer pump.
5. Refill the windshield washer fluid.
2. Route the new hose according to the used one and
fit the clip.
Front Bumper and Bracket Refit 3. Connect the windshield washer pump hose and the
nozzle hose.
5. Fit the front wheelhouse liner.
Front Wheelhouse Liner Refit

Front Bumper Refit
1.0 514
Rear Window Washer Pump Hose 8. Fit the trim panel assembly of right door sill.
Remove 9. Fit the clip to the rear of the roof interior in place.
1. Remove the front bumper and the bracket. 10. Fit the right luggage compartment side trim panel.
Front Bumper and Bracket Remove Luggage Compartment Side Trim Panel Refit
2. Put one container under the washer reservoir. 11. Fit the tail gate interior trim panel.
3. Disconnect the rear window washer pump hose from
Tail Gate Interior Trim Panel Refit
the washer pump.
4. Remove the lower trim panel of the right A pillar.

A Pillar Lower Trim Panel Remove
5. Remove the lower trim panel of the right B pillar.
B Pillar Lower Trim Panel Remove
6. Remove the trim panel assembly of the right door sill.
7. Remove the right luggage compartment side trim panel.
Luggage Compartment Side Trim Panel Remove
8. Pry off the rear part of the roof interior.
9. Remove the interior trim panel of the tail gate.
Tail Gate Interior Trim Panel Remove
10. Disconnect the connection of the rear window washer
pump hose and the rear window nozzle hose.
11. Remove the hose of the rear window washer pump.
Refit
1. Fit the new fluid pipe and connect it to the washer
pump.
2. Route the new pipe according to the used one and
twine it with strips.
3. Connect the rear washer fluid pipe to the check valve.
Front Bumper and Bracket Refit
6. Fit the lower trim panel of the right A pillar.
A Pillar Lower Trim Panel Refit
7. Fit the lower trim panel of the right B pillar.
B Pillar Lower Trim Panel Refit
1.0 515
Rear Window Wiper Arm Assembly Refit

Remove 1. Fix the rear window wiper arm to the wiper motor
Caution: Remove the nozzle to use the special tool, shaft, fit 1 nut, tighten to 8–10Nm, and check the
otherwise the nozzle will be damaged. torque.
1. Remove the mounting shaft cap of the rear wiper arm, 2. Fit the nozzle to the wiper motor shaft in the right
and remove 1 nut fixing the rear window wiper arm direction and tap it to fit in place. Check if the spray
assembly to the rear wiper motor shaft. direction of the washer fluid is correct, if necessary,
insert a needle into the nozzle hole to adjust the nozzle
by prying the needle gently, enabling the washer fluid to
be sprayed directly to the center of the windshield.
3. Fit the mounting shaft cap of the rear wiper arm.
4. Ensure that the blade tape is fitted in the correct
initial position and is aligned with the dot on the black
printing edge of the glass.
2. Gently clip the upper nozzle with a proper tool to

remove the nozzle.
3. Remove the rear window wiper arm assembly with the
special tool TBO00015.
1.0 516
Rear Window Wiper Motor
Remove
2. Remove the rear window wiper arm assembly.
Rear Window Wiper Arm Assembly Remove
3. Remove the seal ring of the rear wiper motor from the
wiper motor output shaft.
4. Remove the tail gate trim panel.

5. Disconnect the electrical connector (1) and the rear
washer fluid pipe (2).
6. Remove 2 nuts (3) and 1 bolt (4) fixing the rear window
wiper motor assembly to the tail gate.
7. Remove the rear window wiper motor assembly.

Refit
1. Fix the rear window wiper motor assembly to the tail
gate, fit 2 nuts, tighten to 7–10Nm, and check the
torque.
2. Fit 1 bolt, tighten to 7–10Nm and check the torque.
3. Connect the electrical connector and the rear washer
fluid pipe.
4. Fit the tail gate trim panel.

5. Fit the seal ring and the rear window wiper arm
assembly.
Rear Window Wiper Arm Assembly Refit

1.0 517
Special Tools
Number
Remover rear
TBO00015
wiper bar
1.0 518
Lighting Lighting Systems
Lighting
Specifications
Torque
Description Value
Screw self-tapping - reading lamp 1.5–2Nm
1.0 519
Lighting Systems Lighting

System Layout
Interior Lighting Layout
1. Body Control Module (BCM) 3. Luggage Compartment Lamp

2. Front Reading Lamp Assembly
1.0 520
A = HS CAN Bus; B = RF Signal; C = Hard Wire
1.0 521
Description The interior lamp is fitted with a single filament bulb. The
Overview assembly is connected to the body harness.
The interior lighting system is controlled by the body control The lens can be removed to allow for replacement of the bulb.
module ( BCM ) which is located on the passenger side of the Boot Lamp
vehicle, behind the glovebox.
The boot (loadspace) lamp is located in the RH trim panel in
The interior lighting comprises: the load space.
• Front reading lamp The lamp comprises a plastic moulding which incorporates a
• Boot lamp lens and also provides location for a bulb holder.
Front Reading Lamp The boot lamp operates automatically when the boot is
The front interior lamp assembly is located centrally in the head opened, a door is opened.
lining above the windscreen. Bulb Specification
The assembly is retained with two screws which locate in Lamp Bulb Type Voltage Power
brackets attached to the roof panel. Front Reading C10W 12V 10W
Lamp
Spring clips provide retention to the headlining.
Luggage C5W 12V 5W
The interior lamp assembly has one non-latching switch for the Compartment
interior lamp operation. Lamp
The lamp is located in a plastic moulding which also provides

the location for the passenger airbag disabled warning lamp.
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Operation • When pressing the LOCK button on the remote key, or
Overview using the mechanical key to lock the door, the interior
lamps will dim gradually.
Interior Lighting
• When all doors are in the closed state and the ignition
Interior lighting includes:
switch is in "ACC" or "ON" position, the interior lamps
• Front Reading Lamp will dim gradually.
• Luggage Compartment Lamp • If any door is opened, the interior lamps will illuminate
• Interior Backlight and gradually dim in 15min for the energy-saving function
of the battery is on.
BCMThe BCM receives signals of the interior lighting system.
When the BCM receives the reading lamp switch signal, door Note: In auto mode PWM control, once the impact
switch signal or tail gate OPEN signal, it will illuminate the sensor is triggered, the interior lamps will
corresponding lamp inside the vehicle. illuminate immediately, and when the interior
lighting switch is pressed, the interior lamps
PWMInterior Lighting Controlled (by PWM)
will go out at once.
PWMThe interior lamps under control include the front Manual Mode PWM Control
reading lamp and luggage compartment lamp. The interior
door lighting system can be controlled by auto mode or Press the master switch on the front reading lamp assembly to
manual mode. turn on/off the front reading lamp. When the interior lamps
are turned on/off manually, the auto delay function will be
Auto Mode PWM Control
cancelled.
No need to press the switch, the BCM will control the Manual Shift Between Control Modes
working status of the interior lamp according to the signal
received. Press the master switch on the front reading lamp assembly to
activate the auto mode. Press the master switch again to turn
Caution: At the moment of engine start,the interior light off the auto mode.
with turned on will be off,after that it will relight on
automatically. The interior lighting delay power control includes:
• Front Reading Lamp
The interior lamp will illuminate automatically under the
following conditions: BCMIt controls the interior lighting system by the relay.
• When pressing the UNLOCK button on the remote key, Under the following situations, the BCM controls the delay of
or using the mechanical key to unlock the door, the the front reading lamp by disconnecting the delay relay.
front reading lamp illuminates gradually. If the door is • When the ignition switch is in "ACC" or "ON" position
not unlocked within 30s, the front reading lamp will dim
• When the UNLOCK button on the remote key is
gradually.
pressed, and the door is unlocked by the mechanical key
• After the ignition switch is off and the position lamp is
on, the reading lamp will illuminate gradually. If the door The delay function may fail under the following conditions:
is not unlocked within 30s, the reading lamp will dim • 15min since the ignition switch is OFF
gradually.
• When the LOCK button on the remote key is pressed,
• When the ignition switch is off within 30s after the and the door is locked by the mechanical key
position lamp goes out, the reading lamp will illuminate
• When the vehicle is in anti-theft state
gradually.
• When the vehicle is locked externally
• If any door is opened, the reading lamp will illuminate
• When the ignition switch in "START" position
gradually.
LEDInterior Backlight
• If the interior lamps illuminate, all doors are in a closed
state. When the ignition switch is shifted to "OFF" When the position lamp is on or the BCM determines that
position from "ACC" or "ON" position, the interior the signal of the light sensor (if equipped) is for night driving,
lamps will dim gradually in 30s. the interior backlight illuminates.
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Service Procedures Rearview Mirror and Light Leveling Switch

Interior Lamp Assembly Remove
1. Disconnect the battery negative. 2. Remove the driver side lower trim panel assembly.
2. Remove the glass cover of reading lamp. Driver Side Lower Trim Panel Assembly Remove
4. Remove the instrument panel light control switch.
Refit
1. Connect the connector of the light control switch.
2. Insert the instrument panel light control switch into the
driver side lower trim panel.
3. Fit the driver side lower trim panel assembly.

3. Remove 2 self-tapping screws from reading lamp

bracket.
4. Pry up the clips, remove the reading lamp.
5. Disconnect the electrical connector.

Refit
2. Refit 2 self-tapping screws to the lamp bracket, tighten
to 1.5–2Nm.
3. Refit the glass cover of reading lamp.
5. Reading Lamp Refit.
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Lamps Lighting Systems
Lamps
Specifications
Torque
Description Value
Bolt - headlamp assy 3–5Nm
Screw-Headlamp lighting calibration 0.1–0.5Nm
Bolt - rear lamp assy 3–5Nm
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Lighting Systems Lamps

System Layout
Exterior Lighting Layout
1. Headlamp 6. Rear fog lamp

2. Hazard Warning Lamp Switch 7. Tail Lamp
3. Lamp Lever Switch 8. Side Direction Indicator Lamp
4. High-mounted Stop Lamp 9. Body Control Module
5. Rear License Plate Lamp
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1.0 527
Description Headlamp
Overview Headlamp (low configuration)
The exterior lighting system includes all external lamps, which
are controlled by the master light switch and auto lamp control
sensor. Exterior lighting system includes:
• Headlamp
• Side Direction Indicator Lamp
• Tail Lamp
• High-mounted Stop Lamp
• Rear Fog Lamp
• Rear License Plate Lamp
Lamp Lever Switch
1. Front Width Lamp/Daytime Running Lamp (bulb)
2. Front Direction Indicator Lamp (bulb)
3. High/Low Beam (bulb)
The headlamp is fixed on the upper radiator beam with

screws. There are two types of headlamps: high configuration
headlamp and low configuration headlamp.
The headlamp assembly includes the high/low beam, front

width lamp/daytime running lamp and front direction indicator
lamp. The high/low beam of the high configuration headlamp
and the front direction indicator lamp are equipped with
halogen bulbs, the front width lamp/daytime running lamp
are LEDs, while the low configuration front width lamp is
The lamp lever switch is located at the left side of the steering provided with the halogen bulb.
column, which controls the front lamps and rear lamps. Tail Lamp
Headlamp
Headlamp (high configuration)
1. Rear Width Lamp (LED)

1. Front Width Lamp/Daytime Running Lamp (LED) 2. Brake Lamp (bulb)
2. Front Direction Indicator Lamp (bulb) 3. Reverse Lamp (LED)
3. High/Low Beam (bulb) 4. Rear Direction Indicator Lamp (bulb)
The tail lamp is fitted on the body by bolts, which includes the
rear width lamp, brake lamp, reverse lamp and rear direction
indicator lamp.
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Rear Fog Lamp Bulb Specification
Bulb Type Voltage Power
High Beam and HB3 LL 12V 60W
Low Beam
Front Direction PY21W 12V 21W
Indicator Lamp
Front Width LED
Lamp/Daytime
Running
Lamp (high
configuration)
Front Width W5W 12V 5W
Lamp (low
1. Rear Fog Lamp (bulb) configuration)
Side Direction WY5W 12V 5W
Rear fog lamps are on the rear bumper. The bulbs extend from Indicator Lamp
the lens gaps of the lamps and illuminate the area around the High-mounted W5W 12V 5W
lens. Stop Lamp
Rear Fog Lamp P21W 12V 21W
Side Direction Indicator Lamp
Rear Width Lamp LED
The bulb of the side direction signal lamp is integrated in the
Reverse Lamp LED
exterior rearview mirror.
License Plate W5W 12V 5W
Centre High-mounted Stop Lamp (CHMSL) Lamp
The high-mounted stop lamp is above the rear window, which Brake Lamp P21W 12V 21W
is a bulb high-mounted stop lamp fixed with clips to the tail Rear Direction WY16W 12V 16W
gate panel. Indicator Lamp
Rear License Plate Lamp
The two rear license plate lamps are fitted on the rear bumper.
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Operation provides the current status of the direction indicator lamp for
Overview the driver by acoustic warning.
BCMIt controls the following exterior lamps: Rear Fog Lamp
• Low Beam When the ignition switch is in "ON" position, the low beam
• High Beam headlamp is enabled, then the activation of the rear fog lamp
switch can illuminate the rear fog lamp. The BCM sends the
• Rear Fog Lamp
ON/OFF status of the rear fog lamp to the IPK by receiving
• Position Lamp/Tail Lamp the activation signal of the rear fog lamp, and the indicator of
• Rear License Plate Lamp rear fog lamp on the IPK illuminates. When the rear fog lamp
• Daytime Running Lamp (if equipped) switch, low beam headlamp or front fog lamp (if equipped) is
disabled, the rear fog lamp is cancelled. If the rear fog lamp is
BCMIt monitors the following exterior lamps:
already activated at the time of engine start, it will remain ON.
• Reverse Lamp
Hazard Warning Lamp
BCMIt controls and monitors the following exterior lamps:
The hazard warning lamps are comprised of the front/rear
• Direction Indicator Lamp (excluding side direction direction indicator lamps and side direction indicator lamps.
indicator lamp)
The hazard warning lamp switch is marked with a triangle,
• Hazard Warning Lamp which is a touch switch. When the hazard warning lamp is
Auto Lamp Control (if equipped) activated, the triangle mark on the switch will flash. When the
position lamp or headlamp is enabled, the triangle mark dims,
When the lamp lever switch is in "AUTO" position (if
but it will still flash. The hazard warning lamp can be activated
equipped), the light sensor (if equipped) will turn on/off the
manually regardless of current position of the ignition switch.
headlamp automatically according to the intensity of the
outside light (visible light). When the lamp lever switch is Operation Priority of Direction Indicator Lamp and Hazard
in other positions, the priority of the switch command is Warning Lamp
higher than that of the request signal from the light sensor (if
If the direction indicator lamp switch is enabled when the
equipped).
hazard warning lamp is working, the direction indicator lamp
When the lamp lever switch is in "AUTO" position (if equipped) will cancel the hazard warning lamp. Then, the hazard warning
for night driving, the following lamps will: lamp will still flash after the direction indicator lamp switch or
ignition switch is disabled.
• When the ignition switch is in "OFF" position, the low
beam headlamp and position lamp do not illuminate. If the hazard warning lamp switch is enabled when the direction
• When the ignition switch is in "ACC" position, the indicator lamp is working, the hazard warning lamp will cancel
position lamp illuminates. the direction indicator lamp. The direction indicator lamp will
resume after the hazard warning lamp is disabled.
• When the ignition switch is in "ON" position, the low
beam headlamp illuminates. The hazard warning lamp can be activated automatically under
• When the ignition switch is in "CRANK" position, the the following situations:
low beam headlamp goes out and the position lamp In case of impact, when the BCM detects an impact signal, it
illuminates. will activate the hazard warning lamp automatically. Accidental
Brake lamp activation of the hazard warning lamp during impact can be
cancelled by pressing the hazard warning lamp switch for more
When the brake pedal is depressed, the brake lamp illuminates,
than 5s.
and the ECM monitors the brake lamp through the hard wire
and sends the braking status signal to other ECUs to use Low Beam Headlamp
through the CAN bus. When the ignition switch is in "ON" position, and the lamp
Direction Indicator Lamp lever switch is turned to the low beam or when the light sensor
detects a dark light, the low beam headlamp illuminates. The
When the ignition switch is in "ON" position and the
low beam headlamp is controlled by the relay in the BCM.
direction indicator lamp switch is enabled, the BCM flashes
the corresponding direction indicator lamp by identifying High Beam Headlamp
the switch status of the direction indicator lamp. Then the When the ignition switch is in "ON" position, the BCM closes
direction indicator lamp on the instrument pack flashes and the high beam relay and illuminates the high beam headlamp
1.0 530
by identifying the status of the lamp lever switch. When the The Follow Me Home function can be set by manual mode as
high beam is enabled, the indicator of high beam on the IPK follows:
illuminates.
After the ignition switch is off, turn the lamp lever switch to
Position Lamp / Tail Lamp & License Plate Lamp the steering wheel, the system enters the Follow Me Home
mode.
The position lamp/tail lamp and license plate lamp are
controlled by the same output port of the BCM. When With the Follow Me Home activated, pull the high beam
moving the headlamp and width lamp knobs to "WIDTH headlamp lever or shift the ignition switch to disable the
LAMP" position or when the light sensor detects a dark light, Follow Me Home.
the BCM can detect the ON signal of the width lamp/tail
When enabled ignition switch, alternator failure or battery
lamp and license plate lamp and output signals to turn on an
overdischarge is detected, the Follow Me Home cannot work
external relay, so that the width lamp/tail lamp and license
properly.
plate lamp will illuminate simultaneously.
Daytime Running Lamp (if equipped)
Reverse Lamp
BCMThe daytime running lamp is controlled through HSD.
With the ignition switch in "ON" position, the reverse lamp When the ignition switch is in "ON" position, and the light
illuminates when the shift lever is moved to "R" gear. sensor (if equipped) determines as daytime, or when the
Note: For vehicles with automatic transmission, to position lamp is off, the daytime running lamp illuminates.
avoid shifting to "R" gear and illuminating the When the position lamp is on, the daytime running lamp
reverse lamp accidentally, when the BCM detects extinguishes automatically.
that the shift lever is in "R" gear, it will hold Lamp of Security System
it there for more than 1s before illuminating the
reverse lamp. If the BCM receives a valid request signal of the outside lock,
and the vehicle is in the security system, locked or completely
Additional Functions in the anti-theft state, it controls the direction indicator lamp
Follow Me Home to give 3 flashes.
When the driver turns off the ignition switch and is about to If the anti-theft function of the security system is disabled, the
leave the vehicle, the Follow Me Home function can control the direction indicator lamp gives 1 flash.
illumination of the low beam headlamp to illuminate the area
around the vehicle. The following lamp can provide Follow Me If the vehicle is not fully locked (bonnet, tail gate and door are
Home function: low beam headlamp. open), the direction indicator lamp will not flash.
The BCM can identify the status of the Follow Me Home

function according to the activation signal of this function.
1.0 531
Service Procedures Integrated High/Low Beam Bulb

Headlamp Assembly Remove
1. Disconnect the battery negative. 2. Turn the high/low beam bulb cover counterclockwise
2. Remove the front bumper. to an appropriate position, and remove the bulb cover.
Front Bumper Remove 3. Turn the integrated high/low beam bulb

counterclockwise, and disconnect the harness
3. Remove 4 bolts fixing the headlamp to the body.
connector.
4. Disconnect the connector from the headlamp assembly. Refit

5. Remove the headlamp assembly. 1. Connect the harness connector, and fit the integrated
Refit high/low beam to the headlamp assembly.
1. Connect the electrical connector. 2. Fit the high/low beam bulb covers.
2. Fix the headlamp assembly to the body, fit 4 bolts, 3. Connect the battery negative.
Front Bumper Refit

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Front Position Lamp Front Direction Indicator Lamp
Remove Remove
2. Turn the front position lamp bulb cover 2. Turn the front direction indicator lamp bulb cover
counterclockwise to an appropriate position, counterclockwise to an appropriate position, and
and remove the bulb cover. remove the bulb cover.
3. Turn the front position lamp holder counterclockwise 3. Turn the front direction indicator lamp holder
and remove the holder. counterclockwise and remove the holder.
4. Remove the bulb from the lamp holder and discard it. 4. Remove the bulb from the lamp holder and discard it.
Refit Refit
1. Fit the new bulb into the lamp holder. 1. Fit the new bulb into the lamp holder.
2. Fit the bulb holder to the headlamp assembly. 2. Fit the bulb holder to the headlamp assembly.
3. Fit the front position lamp bulb cover. 3. Fit the front direction indicator lamp bulb cover.
4. Connect the battery negative. 4. Connect the battery negative.
1.0 533
Headlamp Lighting Calibration Bulb – Indicator – Side Repeater

Adjustment Remove
1. Turn the screw (Figure 1) to adjust the low beam in 1. Disconnect battery earth lead.
horizontal direction, the torque is 0.1–0.5Nm. 2. Carefully prise off appropriate door mirror glass.
2. Turn the screw (Figure 2) to adjust the low beam in 3. Remove bulb holder from mirror base.
vertical direction, the torque is .0.1–0.5Nm
4. Remove bulb
Refit
1. Fit bulb to holder.
2. Lightly lubricate bulb rubber holder.
3. Fit bulb holder to mirror.
4. Align mirror glass, press to engage clips.
1.0 534
High-mounted Stop Lamp Assembly Tail Lamp Assembly
Remove Remove
2. Open the tail gate, pry off the trim panel of the 2. Remove 2 bolts fixing the tail lamp assembly to the
high-mounted stop lamp with an appropriate tool, and body.
remove the high-mounted stop lamp assembly.
3. Disconnect the connector of the high-mounted stop
lamp (1).
4. Remove 3 screws (2) fixing the high-mounted stop lamp
to the trim panel of the high-mounted stop lamp, and
remove the lamp to replace the bulb.
3. Release the tail lamp assembly and disconnect the

connector.
4. Remove the tail lamp assembly.
Refit
1. Connect the connector of the tail lamp, fix the tail lamp
assembly to the body, fit 2 bolts, tighten to 3–5Nm,
Refit and check the torque.
1. Connect the harness connector, locate the trim panel of 2. Connect the battery negative.
the high-mounted stop lamp to the mounting position
of the tail gate, press the trim panel gently, and fit the
clip in place.
1.0 535
Tail Lamp Assembly Bulb Rear License Plate Lamp Assembly

Remove Remove
1. Remove the tail lamp assembly. 1. Disconnect the battery negative.
Tail Lamp Assembly Remove 2. Remove the rear bumper.

2. Turn the rear brake lamp holder (1) counterclockwise Rear Bumper Remove
to remove it. 3. Loosen the clip securing the rear license plate lamp
3. Turn the direction indicator lamp holder (2) from the outside of the bumper, and remove the rear
counterclockwise to remove it. license plate lamp assembly.
4. Remove the bulb from the lamp holder and discard it. Refit
Refit 1. Insert the rear license plate lamp into the rear bumper.
1. Fit the new bulb into the lamp holder, and fit the holder 2. Fit the rear bumper.
into the tail lamp assembly.
Rear Bumper Refit
2. Fit the tail lamp assembly.
Tail Lamp Assembly Refit
1.0 536
Light Sensor
1.
Remove
2. Remove the instrument panel assembly.

4. Pry off the clip and remove the light sensor.
Refit
1. Connect the harness connector of the light sensor.
2. Insert the light sensor into the upper instrument panel.

1.0 537
1.0 538
Door Body Systems
Door
Specifications
Torque
Description Value
Bolt - door hinge to door 22–28Nm
Bolt - striker to door body 25±5Nm
Bolt - door hinge to body 30–36Nm
Bolt - door checker to body 19–25Nm
Bolt - door handle–outer to door panel 3.5–5Nm
Bolt - latch assy to door inner panel 8–10Nm
Bolt - division bar to door 6–8Nm
Bolt - glass to regulator 2–4Nm
Nut - regulator to door 6.5–7.5Nm
Bolt - window regulator guide rail to door 7–10Nm
Bolt - glass holder 7–10Nm
Bolt - glass to window regulator guide rail 7–10Nm
1.0 539
Body Systems Door
Service Procedures Front Door Assembly and Hinge

Front Door Adjustment Remove
Protect the edges of the door panel from scratch with tapes. 1. Disconnect the battery negative.
An assistant is required to support the door in the adjustment 2. Open the front door.
process.
3. Put the wood block on the jack, and put the jack under
Door Hinge Adjustment the door to support the front door.
1. Put the wood block on the jack, and put the jack under 4. Remove and discard 1 bolt fixing the door check to
the body to support the front door. the body side.
2. Unscrew 4 bolts fixing the upper/lower door hinges to
the front door.
5. Pry off the rubber seal ring, pull out the body harness,
and disconnect the harness connector of the body.
3. Support the door with the jack and adjust it to the 6. With the help of an assistant, hold the door, remove
correct position. and discard 4 bolts (2) fixing the upper/lower hinges to
4. When the required effect is achieved by adjustment, the door side.
tighten the door hinge bolts to the specified torque 7. Remove the front door assembly.
22–28Nm.
8. Remove and discard 2 bolts (1) fixing the upper hinge
Striker Adjustment to the body, and remove the front door upper hinge.
1. Open/close the door to evaluate its close property. 9. Remove and discard 3 bolts (1) fixing the lower hinge
2. Loosen 2 striker screws. to the body, and remove the front door lower hinge.
3. Adjust the striker to an appropriate position.
4. Tighten the striker to the body screw to 25±5Nm.
Refit
1. Fit 2 new bolts fixing the upper hinge to the body,
2. Fit 3 new bolts fixing the lower hinge to the body,
3. With the help of an assistant, locate the door to the
1.0 540
Door Body Systems
body. Driver Side Door Outer Handle and Lock
4. Connect the harness connector of the body, and insert Cylinder Assembly
the rubber seal ring into the mounting hole of the body. Remove
5. Fit the new bolts fixing the front door upper/lower 1. Ensure that the window is fully lifted.
hinges to the door side respectively, but do not tighten 2. Disconnect the battery negative.
them. 3. Remove the driver side door interior trim panel and
6. Fit the new bolts fixing the door check to the body waterproof membrane.
side, tighten to 19–25Nm, and check the torque.
7. Close the door and check if the door can be properly Membrane Remove
opened or closed, and make the adjustment. Tighten
4. Loosen the clip (1) securing the outer handle link and
the bolts fixing the upper/lower hinges to the door side
lock cylinder link.
6. Remove 2 bolts (3) fixing the outer door handle to the
door.
7. Remove the door lock cylinder assembly from the

inside of the door.
8. Remove the driver side door outer handle.
Refit
1. Align the outer door handle with the mounting hole of
the front door.
2. Fit the driver side door lock cylinder assembly to the
outer door handle.
3. Fit 2 bolts fixing the outer door handle to the door,
tighten to 3.5–5Nm, and check the torque.
4. Fit the outer handle link and lock cylinder link into
the corresponding clips, and connect the harness
connector.
5. Fit the front door interior trim panel and waterproof
membrane.

Membrane Refit
1.0 541
Body Systems Door
Driver Side Door Lock Assembly

Remove
1. Ensure that the window is fully lifted.
3. Remove the front door interior trim panel and
waterproof membrane.

Membrane Remove
4. Loosen the 2 link clips connecting to the outer door
handle and door lock cylinder.
5. Remove 3 screws fixing the door lock to the door.
Refit
1. Fit the door lock into the door cavity from the inside
of the door carefully and locate it.
2. Fit the inner door cable into the corresponding slot
of the lock body.
3. Fit 3 screws from top to bottom to fix the door lock to
the door, tighten the screws to 8–10Nm, and check
the torque.
4. Carefully secure 2 door lock cables connecting to the
outer door handle and door lock cylinder with clips by
using a flat blade screwdriver.
5. Connect the electrical connector.
6. Pull the lock body out of the door cavity to disconnect
6. Fit the door interior trim panel and waterproof
the electrical connector of the door lock.
membrane.

Membrane Refit
7. Pull the outer door handle, and check if it is firmly
connected with the door lock cable.
7. Disconnect the inner handle cable from the lock body

to remove the lock body assembly.
1.0 542
Door Body Systems
Front Passenger Side Door Outer Handle Rear Door Adjustment
Remove Protect the edges of the door panel from scratch with tapes.
1. Ensure that the window is fully lifted. An assistant is required to support the door in the adjustment
2. Disconnect the battery negative. process.
3. Remove the front door interior trim panel and Door Hinge Adjustment
waterproof membrane. 1. Put the wood block on the jack, and put the jack under
the body to support the rear door.
Membrane Remove 2. Loosen 4 bolts fixing the upper/lower door hinges to
the rear door.
4. Loosen the clip at outer handle link and outer handle
side.
5. Remove 2 bolts fixing the outer door handle to the
door.
3. Adjust the door to an appropriate position.

4. When the required effect is achieved by adjustment,
tighten the hinge bolts to the specified torque
22–28Nm.
6. Remove the outer door handle.
Striker Adjustment
Refit
1. Open/close the door to evaluate its close property.
1. Locate the passenger side door outer handle to the
mounting hole of the right front door. 2. Loosen 2 striker screws.
2. Fit the retaining bolts of the outer door handle from the 3. Adjust the striker to an appropriate position.
door cavity, tighten to 3.5–5Nm, and check the torque. 4. After the adjustment, tighten the screws to 25±5Nm.
3. Fit the link into the clip of the outer handle.
4. Fit the driver side door interior trim panel and
waterproof membrane.

Membrane Refit
1.0 543
Body Systems Door
Rear Door Assembly and Hinge body.

Remove 4. Connect the harness connector of the body, and insert
1. Disconnect the battery negative. the rubber seal ring into the mounting hole of the body.
2. Open the rear door. 5. Fit the new bolts fixing the rear door upper/lower
3. Put the wood block on the jack, and put the jack under hinges to the door side respectively, but do not tighten
the door to support the rear door. them.
4. Remove and discard 1 bolt fixing the door check to 6. Fit the new bolts fixing the door check to the body
the body side. side, tighten to 19–25Nm, and check the torque.
7. Close the door and check if the door can be properly
opened or closed, and make the adjustment. Tighten
the bolts fixing the upper/lower hinges to the door side
5. Pry off the rubber seal ring, pull out the body harness,
and disconnect the harness connector of the body.
6. With the help of an assistant, hold the door, remove
and discard 4 bolts (2) fixing the upper/lower hinges to
the door side.
7. Remove the rear door assembly.
8. Remove and discard 2 bolts (1) fixing the upper hinge
to the body, and remove the rear door upper hinge.
9. Remove and discard 3 bolts (1) fixing the lower hinge
to the body, and remove the rear door lower hinge.
Refit
1. Fit 2 new bolts fixing the upper hinge to the body,
2. Fit 3 new bolts fixing the lower hinge to the body,
3. With the help of an assistant, locate the door to the
1.0 544
Door Body Systems
Rear Door Outer Handle Rear Door Catch/CDL Motor
Remove Remove
1. Ensure that the window is fully lifted. 1. Ensure door glass is fully raised.
2. Disconnect the battery negative. 2. Disconnect battery earth lead.
3. Remove the rear door interior trim panel. 3. Remove door trim panel.
The Rear Door Interior Trim Panel Remove Rear Door Trim Panel Remove
4. Remove the waterproof membrane. 4. Remove the waterproof membrane, take care not to
5. Loosen the clip 1 of outer handle connecting rod. damage membrane.
6. Remove 2 bolt 2 securing the outer handle from door 5. Release out handle to catch release rod clip, remove
cavity. rod.
6. Disconnect electrical connector.
7. Remove the outer door handle.

Refit 7. Remove 3 door lock/CDL motor retaining bolts.
1. Locate the outer door handle to the via-hole of rear

door.
2. Engage the lock body connecting rod into the clips of
outer handle.
3. Refit 2 bolts securing the outer handle from the door
cavity, secure to 3.5–5Nm.
4. Refit the waterproof membrane.
5. Refit the rear door interior trim panel.
Rear Door Interior Trim Panel Refit

8. Manipulate catch/motor to remove release cable.
1.0 545
Body Systems Door
Front Door Upper Molding

Remove
1. Remove door outer weatherstrip.
Outer Weatherstrip Remove
2. Remove front quarter light glass.
Front Quarter Light Glass Remove
3. Release seal at upper door pillar corner, remove torx
screw.
9. Remove catch/motor.
Refit
1. Position door catch/CDL motor in door.
2. Refit release cable.
3. Fit door catch bolts, tighten to8–10Nm.
4. Refit handle release rod to clip, secure clip.
5. Reconnect electrical connector.
6. Refit waterproof membrane.
4. Remove inner door glass weatherstrip (felt trim).
7. Refit door trim panel.
5. Release door glass channel from door.
Rear Door Trim Panel Refit
6. Drill out upper moulding pop rivets, ensure all debris
8. Connect battery earth lead. is retrieved.
7. Remove trim.
Refit
1. Position upper moulding on door.
2. Secure using new pop rivets.
3. Refit torx screw.
4. Refit front quarter light glass.
Front Quarter Light Glass Refit
5. Refit door glass channel to door.
6. Refit inner door glass weatherstrip.
7. Refit outer weatherstrip on door.
Outer Weatherstrip Refit
1.0 546
Door Body Systems
Rear Door Upper Molding Door Window Outer Weatherstrip
Remove Remove
1. Remove door outer weatherstrip. 1. Using suitable trim tool, prise weatherstrip up from
Outer Weatherstrip Remove door starting at front end.
2. Remove rear quarter light glass. 2. Remove weatherstrip.
Rear Quarter Light Glass Remove Refit
3. Release seal at upper door pillar corner, remove torx 1. Position weatherstrip on door.
screw. 2. Use suitable rubber mallet to locate clips onto door
starting at front.
4. Remove inner door glass weatherstrip (felt trim).

5. Release door glass channel from door.
6. Drill out upper moulding pop rivets, ensure all debris
is retrieved.
7. Remove trim.
Refit
1. MPosition upper moulding on door.
2. Secure using new pop rivets.
3. Refit torx screw.
4. Refit rear quarter light glass.
Rear Quarter Light Glass Refit
5. Refit door glass channel to door.
6. Refit inner door glass weatherstrip.
7. Refit outer weatherstrip on door.
Outer Weatherstrip Refit
1.0 547
Body Systems Door
Front Door Window Glass Rear Door Window Glass

Remove Remove
1. Open the front door. 1. Open the rear door.
3. Remove the front door interior trim panel and the 3. Remove the rear door interior trim panel and the
waterproof membrane. waterproof membrane.
Front Door Interior Trim Panel and Waterproof Rear Door Interior Trim Panel and Waterproof
Membrane Remove Membrane Remove
Caution: Before taking down the panel, please raise the Caution: Before taking down the panel, please raise the
glass so that the bolts is just in the mounting holes of the glass so that the bolts is just in the mounting holes of the
door. door.
4. Remove 2 screws fixing the front door window glass 4. Remove 2 screws fixing the rear door window glass
to the window regulator. to the window regulator.
5. Release 2 fasteners of the guide rail of the front door 5. Release 2 fasteners of the guide rail of the rear door
window glass. window glass.
6. Carefully remove the door window glass from the door 6. Carefully remove the door window glass from the door
cavity. cavity.
Refit Refit
1. Fit the glass into the door cavity and then to the guide 1. Fit the glass into the door cavity and then to the guide
rail of the front door window glass. rail of the rear door window glass.
2. Fit the bolt of the guide rail of the front door window 2. Fit the bolt of the guide rail of the rear door window
glass, and tighten to 6–8Nm. glass, and tighten to 6–8Nm.
3. Fit the glass to the window regulator, secure with 2 3. Fit the glass to the window regulator, secure with 2
screws, and tighten to 2–4Nm. screws, and tighten to 2–4Nm.
4. Fit the front door interior trim panel and the 4. Fit the rear door interior trim panel and the waterproof
waterproof membrane. membrane.
Membrane Refit Membrane Refit
1.0 548
Door Body Systems
Front Door Window Regulator Rear Door Window Regulator
Remove Remove
1. Remove door glass. 1. Remove door glass.
Front Door Glass Remove Rear Door Glass Remove

2. Disconnect door mirror harness connector, position 2. Remove 7 glass regulator fixings.
aside.
3. Remove 7 glass regulator fixings.
3. Manipulate glass regulator from door.

Refit
4. Manipulate glass regulator from door. 1. Position regulator in door.
Refit 2. Fit 7 fixings, tighten to 6.5–7.5Nm.
1. Position regulator in door. 3. Refit door glass.
2. Fit 7 fixings, tighten to 6.5–7.5Nm.
Rear Door Glass Refit
3. Connect door mirror harness, secure connection to
door.
4. Refit door glass.
Front Door Glass Refit
1.0 549
Body Systems Door
Front Door Window Regulator Adjustment Rear Door Window Regulator Adjustment
Adjustment Adjustment
1. Open the front door. 1. Open the rear door.
3. Remove the front door interior trim panel and the 3. Remove the rear door interior trim panel and the
waterproof membrane. waterproof membrane.
Membrane Remove Membrane Remove
Caution: Before taking down the panel, please raise the Caution: Before taking down the panel, please raise the
glass so that the bolts is just in the mounting holes of the glass so that the bolts is just in the mounting holes of the
door. door.
4. Loosen 2 clamping screws (1) fixing the front door 4. Loosen 2 clamping screws (1) fixing the rear door
window glass to the window regulator. window glass to the window regulator.
5. Loosen 7 mounting nuts (2) securing the window 5. Loosen 7 mounting nuts (2) securing the window
regulator. regulator.
6. Adjust the window so as to make it engage well with the 6. Adjust the window so as to make it engage well with the
seals on both ends and ensure the window works well. seals on both ends and ensure the window works well.
7. Tighten 7 mounting nuts securing the window regulator 7. Tighten 7 mounting nuts securing the window regulator
to 7–10Nm, and check the torque. to 7–10Nm, and check the torque.
8. Tighten 2 clamping screws of the window to 7–10Nm, 8. Tighten 2 clamping screws of the window to 7–10Nm,
and check the torque. and check the torque.
9. Raise and lower the window glass to check the 9. Raise and lower the window glass to check the
operation and positioning. operation and positioning.
10. Fit the front door interior trim panel and the 10. Fit the rear door interior trim panel and the waterproof
waterproof membrane. membrane.
Membrane Refit Membrane Refit
12. Check if the window glass regulator can work. 12. Check if the window glass regulator can work.
1.0 550
Door Body Systems
Front Door Glass Channel Rear Door Glass Channel
Remove Remove
1. Remove front door glass. 1. Remove rear door glass.

2. Release glass channel from division bar, door and rear 2. Release glass channel from division bar, door and front
channel guide. channel guide.
3. Remove rubber channel. 3. Remove rubber channel.
Refit Refit
1. Position rubber channel in door. 1. Position rubber channel in door.
2. Fit channel into rear channel guide, door and division 2. Fit channel into front channel guide, door and division
bar. bar.
3. Refit front door glass. 3. Refit rear door glass.
Front Door Glass Refit Rear Door Glass Refit
1.0 551
Body Systems Door
Front Door Division Bar Rear Door Division Bar

Remove Remove
1. Remove front door glass. 1. Remove rear door glass.

2. Release glass channel from division bar. 2. Release glass channel from division bar.
3. Remove 2 fixing screws. 3. Remove 2 fixing screws.
4. Remove division bar. 4. Remove division bar.

Refit Refit
1. Position division bar in door. 1. Position division bar in door.
2. Fit screws, tighten to 6–8Nm. 2. Fit screws, tighten to 6–8Nm.
3. Refit glass channel to division bar. 3. Refit glass channel to division bar.
4. Refit front door glass. 4. Refit rear door glass.
Front Door Glass Refit Rear Door Glass Refit
1.0 552
Door Body Systems
Power Window Switch - Driver Side Power Window Switch - Others
Remove Remove
2. Pry off the power window switch screw cover. 2. Pry off the power window switch screw cover.
3. Remove 1 screw fixing the power window switch to 3. Remove 1 screw fixing the power window switch to
the door. the door.
4. Remove the power window switch from the door 4. Remove the power window switch from the door
interior trim panel, and disconnect the harness interior trim panel, and disconnect the harness
connector. connector.
Refit Refit
1. Connect the connector of the power window switch. 1. Connect the connector of the power window switch.
2. Fix the power window switch to the door interior trim 2. Fix the power window switch to the door interior trim
panel, fit and tighten 1 screw. panel, fit and tighten 1 screw.
3. Fit the power window switch screw cover. 3. Fit the power window switch screw cover.
1.0 553
Body Systems Door
Central Control Door Lock Switch

Remove
2. Remove the driver side door interior trim panel.
Front Door Interior Trim Panel Remove
3. Remove the door lock switch from the door interior
trim panel.
Refit
1. Fix the door lock switch to the door interior trim panel.
2. Fit the driver side door interior trim panel.
Front Door Interior Trim Panel Refit

1.0 554
Front Closures Body Systems
Front Closures
Specifications
Torque
Description Value
Nut - fender to body 7–10Nm
Screw - front bumper support bracket 3–4Nm
Bolt - headlamp assy 3–5Nm
Bolt - head lamp bracket to MFE 7–10Nm
Bolt-Expansion Tank stand to Body 7–10Nm
Bolt-intercooler to platform 4–6Nm
Bolt - hood hinge to body 26–34Nm
Nut - hood hinge to hood panel 19–25Nm
Nut - hood hinge to hood 26–34Nm
Bolt - hood latch to platform 7–10Nm
1.0 555
Body Systems Front Closures
Service Procedures
Fender
Remove

2. Loosen 1 bolt above the headlamp.
12. Remove the bolt (4) fixing the middle bracket of the
fender to the fender, and remove the middle bracket.
13. Remove 2 clips (8) connecting the fender to the
acoustic pad, and remove the acoustic pad of the fender.
Refit
1. Locate the acoustic pad of the fender to the fender,
and fit the clip.
3. Remove the A pillar exterior trim panel.
2. Locate and adjust the fender.
A Pillar Exterior Trim Panel Remove 3. Locate the middle bracket to the fender, fit the bolt
4. Remove 4 screws securing the left and right mounting fixing the middle bracket to the fender, tighten to
brackets of the front bumper, and remove the brackets. 7–10Nm, and check the torque.
5. Remove 2 bolts (1) fixing the fender to the front 4. Fix the fender to the body, do not tighten the bolt.
bracket of the fender. 5. Adjust the gap between the fender and adjacent panels
6. Remove 2 bolts (2) fixing the fender to the front upper and ensure uniform gap. Then tighten 6 bolts fixing the
bracket of the fender. fender to the body to 7–10Nm, and check the torque.
7. Remove 1 bolt (3) at the side corner of the A/C air And tighten 2 screws fixing the fender to the body.
inlet grille. 6. Fit the front bumper bracket, tighten 4 screws fixing
8. Remove 1 bolt securing the middle bracket of the the left and right brackets of the front bumper to the
fender from the door. body to 3–4Nm, and check the torque.
9. Remove 1 screw (5) connecting the bottom of the 7. Fit the A pillar exterior trim panel.
fender to the body. A Pillar Exterior Trim Panel Refit
10. Remove 1 bolt (6) connecting the bottom of the fender 8. Tighten the bolt above the headlamp to 3–5Nm, and
to the bodyside outer panel and 1 screw (7) to the check the torque.
wheelhouse liner.
11. Remove the fender.
1.0 556
Front-end Module 10. Disconnect the bonnet lock release cable assembly
Remove from the lock assembly to remove the lock assembly.
1. Remove the front bumper assembly. Bonnet Lock Assembly Remove
Front Bumper Remove 11. Remove the front bumper beam.
2. Remove the headlamp assembly. Front Bumper Beam Remove
Headlamp Assembly Remove 12. Remove the tweeter harness from the front-end
3. Remove the wind scoopers on both sides. module.
Wind Scooper - Left Remove 13. Remove the reservoir oil return pipe assembly.
Wind Scooper - Right Remove Reservoir Oil Return Pipe Assembly Remove
4. Remove 4 bolts fixing the middle support bracket of 14. Remove 2 screws connecting the front-end module to
the front bumper to the upper part of the front-end the radiator shock pad to disconnect the front-end
module, and remove the middle support bracket of the module intercooler and radiator, and remove the
front bumper. front-end module.
5. Remove the bolt fixing the bottom deflector to the

front-end module.
Air Inlet Pipe Remove
7. Remove 2 bolts connecting the upper mounting panel
of the right headlamp and the front-end module.
Refit
1. Fix the front-end module to the intercooler and
radiator.
2. Fit the reservoir oil return pipe assembly.
Reservoir Oil Return Pipe Assembly Refit
3. Fit the tweeter harness to the front-end module.
4. Fit the front bumper beam.
8. Remove 2 bolts (1) connecting the upper mounting Front Bumper Beam Refit
panel of the left headlamp and the front-end module. 5. Fit the bonnet lock assembly.
9. Remove 2 bolts (2) fixing the bracket of the coolant Bonnet Lock Assembly Refit
expansion tank to the front-end module. 6. Locate the upper mounting panel of the right headlamp
to the front-end module, tighten 2 bolts connecting the
upper mounting panel of the right headlamp and the
front-end module to 7–10Nm, and check the torque.
7. Locate the upper mounting panel of the left headlamp
to the front-end module, tighten 2 bolts connecting
the upper mounting panel of the left headlamp and the
front-end module to 7–10Nm, and check the torque.
8. Fit 2 bolts fixing the bracket of the coolant expansion
tank to the front-end module, tighten to 7–10Nm, and
check the torque.
9. Fit the air inlet pipe assembly.
Air Inlet Pipe Refit
1.0 557
10. Fit the bolt fixing the bottom deflector to the front-end Bonnet Assembly and Hinge
module. Remove
Bottom Deflector Refit Warning: Take special attention to avoid vehicle damage
11. Fix the middle support bracket of the front bumper and personal injury.
to the upper part of the front-end module, fit 4 bolts, 1. Open and support the bonnet properly.
tighten to 4–6Nm, and check the torque. 2. Mark the position of the hinges relative to the bonnet
12. Fit the wind scoopers on both sides. for positioning during refitting.
3. Remove 4 nuts (2) fixing the hinges (bonnet side) on
Wind Scooper - Left Refit
both sides to the bonnet.
Wind Scooper - Right Refit
4. With assistance, remove the bonnet.
13. Fit the bonnet support rod assembly.
5. Remove 4 bolts (1) fixing the hinges (body side) on
14. Fit the headlamp assembly. both sides to the front-end of the body.
Headlamp Assembly Refit
Front Bumper Refit
6. Remove the hinges on both sides.

Refit
Warning: Bonnet will drop under its own weight during
removal and refit, ensure panel is fully supported.
1. Properly locate the hinges (body side) on both sides
to the original position of the front-end hinge of the
vehicle body respectively.
2. Fit 4 bolts fixing the hinges (body side) on both sides
to the front-end of the body, tighten to 26–34Nm,
3. With assistance, locate the bonnet to the vehicle, and
align it with the position marked when removing.
Caution: DO NOT damage the thread on the bolt when
inserting the bolt into the fit hole.
4. Fit 4 nuts securing the bonnet and the hinges (bonnet

side) on both sides, but do not tighten to the specified
torque.
5. Check if the bonnet is located properly, carefully adjust
the gap and surface distance between the bonnet
and the front fender to make them meet the DTS
(dimension technical specification) requirements.
6. After adjustment, tighten 4 retaining nuts to 19–25Nm,
7. Close the bonnet.
1.0 558
Bonnet Adjustment
Adjustment
1. Adjust the rear part of the bonnet.
a. Mark the profile of the bonnet hinges with a non

permanent marker.
b. Loosen the nuts (2) fixing the hinges to the bonnet.
c. Adjust the clips and the bonnet bumper block to align

the bonnet with the fender.
d. Tighten the locking nuts of the clips.
e. Adjust the bumper block.
4. Adjust the gap/front rake.
a. Mark the profile of the two hinges on the vehicle

body with a non-permanent marker.
c. Adjust the bonnet and align it with the fender.
b. Loosen the bolts (1) fixing the hinges to the body.
d. Tighten the hinge nuts to 19–25Nm.
2. Rear Bonnet Height Adjustment
a. Loosen the locking nuts of the bonnet hinge.
b. Rotate the detent lever to adjust the rear part of the

bonnet to an appropriate height.
c. Adjust the position of the bonnet at lateral and

front/rear direction to align the bonnet with the
fender, and the front rake of the bonnet should be
horizontal with the fender.
d. Tighten the hinge bolts to 26–34Nm, and check

3. Adjust the front part of the bonnet.
the torque.
a. Rotate the bumper block to the end.
b. Loosen the locking nuts of the clips.
1.0 559
Bonnet Lock Assembly torque at this step.

Remove 5. Close the bonnet, observe the relative position of the
1. Open and support the bonnet properly. lock and lock catch, adjust the lock and allow the lock
2. Mark the lock position on the front-end module so that catch to enter into the lock tongue.
proper location can be found for refitting. 6. After adjustment, tighten 3 bolts to 7–10Nm, and
3. Disconnect the harness connector (1) of the bonnet check the torque.
lock. 7. Close the bonnet.
4. Remove 3 bolts (2) fixing the bonnet lock to the
front-end module.
5. Disconnect the bonnet lock release cable assembly

from the lock assembly to remove the lock assembly.
Refit
1. Connect the lock end of the bonnet release cable
assembly and the lock assembly firmly, i.e. fit the
spherical end of the cable core wire into the hook slot
of the bonnet lock, put the core wire into the long slot
of the bonnet lock case, and align the circular groove of
the main cable pipe connector with the mounting slot
of the lock case, then press it hard until it clicks.
2. Locate the bonnet lock assembly to the bracket of the
front-end module, and align it with the position marked
when removing.
3. Connect the harness connector of the bonnet lock.
4. Fit 3 bolts fixing the lock assembly to the bracket of the
front-end module, and do not tighten to the specified
1.0 560
Bonnet Release Cable and Handle and fit the clip into the panel.
Remove 3. Fit the bonnet lock assembly.
1. Open the bonnet and support it with a rod firmly.
Bonnet Lock Assembly Refit
2. Remove the bonnet lock assembly.
4. Insert the end of the cable assembly into the base of
Bonnet Lock Assembly Remove the release handle.
3. Remove and discard the release handle of the bonnet. 5. Fit the A pillar lower trim panel.
6. Fit the new release handle of the bonnet, and ensure
the handle is pressed till the end.
7. Pull the release handle of the bonnet in the driver
compartment, and check if the bonnet works properly
when it is opened.
4. Remove the A pillar lower trim panel.

A Pillar Lower Trim Panel Remove
5. Remove the end of the cable from the base of the
release handle.
6. Loosen the clips fixing the bonnet release cable to the

upper mounting panel of the left headlamp in proper
order.
7. Release the bonnet release cable from the engine
compartment.
8. Pull the cable assembly out of the engine compartment.
Refit
1. Locate the bonnet release cable assembly to the engine
compartment, fit the flat blade end to the driver
compartment through the bulkhead hole of the front
engine compartment, and secure it in the bulkhead hole
with the rubber seal ring of the cable assembly.
2. Arrange the cable into the engine compartment and
onto the upper mounting panel of the left headlamp,
1.0 561
Body Systems Rear Closures
Rear Closures
Specifications
Torque
Description Value
Bolt -Tailgate kniqhthead to body 7–10Nm
Nut - tailgate hinge to body 26–34Nm
Bolt - tailgate hinge to tailgate panel 7–10Nm
Bolt - Tailgate hinge to tailgate 7–10Nm
Bolt - tailgate lock to tailgate panel 6–8Nm
Bolt - striker to body 8.5–11.5Nm
Bolt - fuel filler flap to body 8–12Nm
1.0 562
Rear Closures Body Systems
Service Procedures Caution: To avoid damaging the airtightness of the air
Tail Gate Gas Spring and Mounting Bracket spring, never hold the centre of the air spring and laterally
Remove apply force to it by hand.
1. Open the tail gate, and when removing the tail gate, 6. Align the ball cup at piston end of the left gas spring
make sure it is securely supported. with the ball head on the tail gate inner panel. Hold the
end of the piston, push the ball cup into the ball head
Warning: As the large weight of the tailgate, operations
with thumb, if the two parts are fitted well, a "crack"
should be performed after the safety feature is set, and
sound will be heard.
take extra care to prevent the vehicle from damaging and
personal injury. 7. Repeat step 1-6 to fit the right gas spring and the
mounting bracket of the tail gate.
2. Carefully pry off the steel spring retaining clip on both
sides of the left gas spring, forcibly unplug the ball cup 8. Close the tail gate.
at piston end from the ball head of the tail gate.
3. Then pull the ball head socket of gas spring sleeve from
the ball head of left body bracket.Then forcibly unplug
the ball cup at socket end of the gas spring from the ball
head of the left body side bracket.
4. Remove 2 bolts fixing the mounting bracket of the
left gas spring to the body, and remove the gas spring
mounting bracket.
5. Repeat step 2-4 to remove the right gas spring and its
mounting bracket.
Refit
1. Align the mounting bracket of the left gas spring with
the hole on the luggage compartment.
2. Fit 2 bolts fixing the mounting bracket of the tail gate
gas spring to the body, tighten to 7–10Nm, and check
the torque.
3. Check the steel spring piece on both ball cups of the
air spring, ensure it is properly located in the spring
piece slot.
4. Align the ball cup at socket end of the gas spring with
the ball head on the left mounting bracket, and make
sure the gas spring piston is downward.
5. Hold the sleeve, push the ball cup into the ball head
with thumb, if the two parts are fitted well, a "crack"
sound will be heard.
1.0 563
Tail Gate Assembly and Hinge

Remove
1. Open the tail gate.
3. Release the cables of the coat rack from the hooks of
the tail gate.
4. Remove the high-mounted stop lamp assembly.
High-mounted Stop Lamp Assembly Remove
5. Remove the interior trim panel of the tail gate.

6. Disconnect the harness connector of the rear window
wiper motor. 11. Pry off the steel spring retaining clip on both sides of
the gas spring, forcibly unplug the ball cup at piston end
7. Disconnect the connector of the tail gate lock.
from the ball head of the tail gate, and remove the tail
8. Release the interface of the resistance heater wires at
gate assembly.
both sides of the rear window.
Warning: As the large weight of the tailgate, operations
9. As indicated by the arrow, release the harness sheath at
should be performed after the safety feature is set, and
both sides of the tail gate, draw the electrical harness
take extra care to prevent the vehicle from damaging and
from the tail gate cavity.
personal injury.
12. Remove the lock assembly and the rear window wiper
motor from the tail gate assembly as necessary.
Tail Gate Lock Assembly Remove
Rear Window Wiper Motor Remove
13. Release the roof interior trim panel at the tail gate to
access the retaining nut of the tail gate hinge.
14. Remove 2 nuts (1) fixing the left/right tail gate hinges to
the body so as to remove the tail gate hinge assembly.
Refit
1. Locate the tail gate hinge assembly to the body, fit 2
nuts, tighten to 26–34Nm, and check the torque.
10. Mark the position of the tail gate hinge on the tail 2. With the help of an assistant, locate the tail gate to the
gate with a non-permanent marker. With assistance, body, and align it with the marked position.
remove 4 bolts (2) fixing the hinges on both sides to 3. Fit the connecting bolt between the tail gate and the
the tail gate. hinge, but do not tighten to the fixed torque.
Warning: As the large weight of the tailgate, operations Warning: As the large weight of the tailgate, operations
should be performed after the safety feature is set, and should be performed after the safety feature is set, and
take extra care to prevent the vehicle from damaging and take extra care to prevent the vehicle from damaging and
personal injury. personal injury.
4. Press the ball cup at piston end of the gas spring on
both sides into the ball head of the tail gate side panel
till it clicks.
prior to fitting.
5. Fit the harness into the tail gate cavity, and connect the
interface of the resistance heater wires at both sides of
the windshield.
6. Connect the harness connector of the lock, and fit the
1.0 564
tail gate lock assembly. Tail Gate Adjustment
Tail Gate Lock Assembly Refit
Adjustment
1. Mark the position of the tail gate hinge on the tail gate
7. Connect the harness connector of the rear window
with a non-permanent marker.
wiper motor, and fit the wiper motor.
2. Loosen 4 bolts fixing the left and right hinges to the
Rear Window Wiper Motor Refit
tail gate.
8. Fit the high-mounted stop lamp.
High-mounted Stop Lamp Assembly Refit

9. Check and adjust the fit clearance and surface distance
between the tail gate and the bodyside/rear end panels.
After adjustment, tighten the bolt to 7–10Nm, and
check the torque.
10. Fit the interior trim panel of the tail gate.

11. Hang the cables on both sides of the coat rack on the
hooks of the interior trim panel of the tail gate.
3. Adjust the tail gate to make the gap between the tail
gate and the tail lamp and that between the tail gate and
the rear bumper fascia uniform and make the tail gate
flush with the tail lamp and the rear bumper fascia.
4. For gap information, please refer to Body Repair, "Body
Dimension".
5. Tighten the bolts on the tail gate hinge to 7–10Nm,
1.0 565
Tail Gate Lock Assembly Tail Gate Lock Catch

Remove Remove
1. Open the tail gate. 1. Open the tail gate.
2. Disconnect the battery negative. 2. Unscrew 2 bolts on the tail gate lock catch to remove
3. Remove the interior trim panel of the tail gate. the lock catch.

4. Remove 2 bolts securing the lock and 1 bolt inside.
Refit
1. Locate the lock catch to the tail gate sill of the body,
ensure the arrow on the lock catch towards the inner
5. Remove the tail gate lock sleeve. of the vehicle, and pay attention to the correspondence
6. Pull the lock out of the tail gate cavity, disconnect the between the position tick mark on the lock catch and
connector, and remove the tail gate lock assembly. the tick mark on the vehicle body.
Refit 2. Secure the lock catch of the tail gate to the body with
1. Fit the lock assembly into the tail gate cavity, and bolts, but do not tighten them.
connect the connector. 3. Close and open the tail gate repeatedly for several
2. Fit 3 mounting bolts, but do not tighten them. times, check and adjust the fit clearance and the surface
distance between the tail gate and the surrounding
3. Check and adjust the fit clearance and the surface
sheet metal parts. After the adjustment is done, secure
difference between the tail gate lock and the
the bolts to 8.5–11.5Nm.
surrounding panels, then tighten the lock bolt to
6–8Nm, and check the torque. 4. Make sure that the tail gate lock is fully locked, and
check if the electrical signal of the tail gate lock is
4. Fit the tail gate lock sleeve.
correct.

1.0 566
Fuel Filler Door Assembly Fuel Filler Door Release Cable Assembly
Remove Remove
Warning: Apply masking tape to painted body edges to 1. Open the fuel filler door.
avoid paint damage. 2. Open the tail gate, and remove the right trim panel of
1. Pull up the fuel filler door release handle under the the luggage compartment.
driver side instrument panel assembly to open the fuel Luggage Compartment Side Trim Panel Remove
filler door.
3. Remove the luggage compartment carpet, and loosen
2. Release the fuel filler door release handle from the the clip fixing the cable to the floor.
fuel filler door.
4. Remove the driver side A pillar lower trim panel.
3. Remove 2 mounting bolts connecting the fuel filler
door and the body. A Pillar Lower Trim Panel Remove
5. Remove the B/C pillar lower trim panel.
B/C Pillar Lower Trim Panel Remove
6. Remove the sill trim panel of the right rear door.
7. Remove the lower trim panel of the right D pillar.
D Pillar Lower Trim Panel Remove
8. Remove the cable from the base of the release handle.
9. Loosen all clips of the cable, and pull the cable out of
the fuel filler door.
Refit
1. Fit the handle of the fuel filler door release cable
assembly into the luggage compartment through the
mounting hole on the right bodyside panel, push the
4. Remove the door assembly.
filler door of the fuel filler door release cable into the
Refit mounting hole along the hole axis till it clicks and clips
1. Locate the fuel filler door to the body, fit 2 bolts, on both sides are completely stuck into the bodyside
tighten to 8–12Nm, and check the torque. panel.
2. Fit the fuel filler door release cable. 2. Fit the cable assembly to the rear compartment through
3. Verify the release operation. the right luggage compartment, and secure the cable in
sequence with clips along the bottom of the rear seats
to the right compartment, then fit the cylindrical end of
the cable assembly into the notch of the release handle
base along the D pillar lower trim panel at the left side
of the body and the right sill.
3. Fit the driver side A pillar lower trim panel.
4. Fit the B/C pillar lower trim panel.
B/C Pillar Lower Trim Panel Refit
5. Fit the sill trim panel of the right rear door.
6. Fit the right D pillar lower trim panel.
D Pillar Lower Trim Panel Refit
7. Fit the luggage compartment carpet.
8. Fit the right trim panel of the luggage compartment.
Luggage Compartment Side Trim Panel Refit
9. Pull the fuel filler door release handle at the driver side
sill, check the connections of the fuel filler door release
cable assembly.
1.0 567
Body Systems Horns
Horns
Specifications
Torque
Description Value
Nut-Horn to Front impact bar 7–10Nm
1.0 568
Horns Body Systems
Service Procedures
Tweeter
Remove

4. Remove 1 nut (2) fixing the horn to the front bumper
beam.
5. Remove the horn.

Refit
1. Fix the horn to the front bumper beam, fit 1 nut,
1.0 569
Body Systems Body Control Module
Body Control Module

Specifications
Torque
Description Value
Bolt-Body control module to body 5–7Nm
1.0 570
Body Control Module Body Systems
System Layout
1. Body Control Module (BCM)
1.0 571
1.0 572
Description 8 Rear Wiper Homing Signal
Mounting position: 9 Rear Wiper Switch
BCMThe BCM is on the left front bodyside panel. 10 Front Wiper Mode Selection
Switch 1
BCMThe BCM consists of the low power microprocessor,
11 Right Direction Indicator Lamp
EEPROM, CAN transceiver and power supply. BCM Switch
contains discrete input/output terminals which controls most
12 Position Lamp Switch
of the body functions. It interacts with other primary electrical
13 Driver Window Up Switch
systems through the HS CAN bus. The power mode master
control module (PMM) of the BCM provides power for most 14 Tail Gate Unlock Switch
of the vehicle electric components. 15 Driver Door Ajar Warning
Switch
The BCM communicates directly with the following
16 Driver Door Locked with Key
components through the HS CAN bus:
Signal
• HVAC(Air conditioning system) 17 High Beam Flash Switch
• FICM 18 IMMO SPI Bus Data Line
• IPK 19 IMMO SPI Bus Clock Line
• ECM 20 N Gear/Clutch Switch
• ABS/SCS 21 KL.R (ACC switch)
• TCM (if equipped) 22 KL.15 (ignition switch)
• SDM 23 Reverse Gear Switch
• TPMS (if equipped) 24 Low Beam Switch
BCM Connector 25 -
The BCM has four connectors which interacts with other 26 -
related systems via the harness and provides input/output 27 Heated Rear Window
signals for the BCM.
28 Front Wiper Homing Signal
BCM Harness Connector BY026 29 Front Wiper Mode Selection
Switch 2
30 Hazard Warning Lamp Switch
31 Left Direction Indicator Lamp
Switch
32 -
33 Luggage Compartment Lid Ajar
Warning Switch
34 Passenger Door Ajar Warning
Switch
35 Driver Door Unlocked with
Pin No. Description Key Signal
1 - 36 High Beam Switch
2 KL.50 37 Rear Fog Lamp Switch
3 Rear Wiper/Washer Switch 38 CAN L
4 Front Wiper/Washer Switch 39 CAN H
5 Driver Window Down Switch 40 -
6 -
7 Driver Side One-button Down
Switch
1.0 573
BCM Harness Connector BY025 BCM Harness Connector BY027
Pin No. Description

Pin No. Description
1 Right Direction Indicator Lamp
1 - Output
2 High Beam Relay Coil 2 Rear Fog Lamp Output
3 Horn Relay Coil 3 Tail Gate Motor
4 Drive the Driver Window 4 Washer Relay
Down
5 Power Supply
5 Starter Motor Relay Coil
6 -
6 -
7 Window Up/Down Function
7 - Enable
8 Safety Lock Relay Coil 8-10 -
9 - 11 Power Supply
10 -
BCM Harness Connector BY084
11 -
12 Door Lock Status Indicator
13 Front Compartment Lid Switch
Status Signal
14 Wiper Intermittent Time
Selection Signal
15 Front Wiper Speed Relay
16 Rear Wiper Relay Coil
17 Width Lamp Relay Coil
18 Front Wiper Enable Relay Coil
19 Wiper Analog Ground
Pin No. Description
20 -
21 - 1 Power Supply
22 - 2 Low Beam Output
23 - 3 Door Lock Output
24 - 4 Power Supply
25 Daytime Running Lamp Relay 5 Ground 1
26 - 6 Left Direction Indicator Lamp
Output
27 Internal Central Lock Switch
7 Front Reading Lamp Output
28 -
8 -
9 Warning Request Signal
1.0 574
10 Door Unlock Output
11 Ground 2
1.0 575
Operation Sleep Mode

Overview With the ignition switch off, and the CAN and LIN buses
When the ignition switch is enabled, the BCM will wake up the disabled, if the battery is still connected, the BCM will stay in
security system, lighting system and diagnostic system. When sleep mode and be prepared for receiving the signal from the
the ignition switch is in "ACC" position, the BCM allows the CAN and LIN buses.
washer/wiper and power window system to operate. When Wake-up Mode
the ignition switch is in "ON" position, the fuel system starts to
In sleep mode, when one of the following operations is done,
work, and the BCM communicates and transmits information
the BCM will be waked up.
with other ECUs through the CAN and LIN bus.
Load Management • Activation signal of hazard warning lamp switch is
received.
BCMThe BCM can manage the load of some electric
• Activation signal of direction indicator lamp switch is
appliances by configuration and ensure low battery power
received.
consumption during storage and transportation or idle time.
• LOCK signal of internal lock is received.
Production Mode
• UNLOCK signal of internal lock is received.
It is configured for the BCM during vehicle assembly. • Activation signal of driver door switch is received.
Transportation Mode • Activation signal of passenger door switch is received.
After vehicle assembly, programme the BCM so that the • Receive the activation signal of the luggage compartment
transportation mode can be used during transportation. lid switch.
And low battery problem can be avoided when the factory • Receive the activation signal of the luggage compartment
delivers the vehicle to the authorized local after-sales service lid Release switch.
centre. This mode may restrict the function of some electric
• Activation signal of driver door lock switch is received.
appliances:
• Activation signal of driver door unlock switch is received.
• The rear fog lamp does not work when the engine is off.
• Ignition switch is in "ACC" position.
• The high beam headlamp does not work when the engine
• Ignition switch is in "ON" position.
is off.
• Activation signal of internal lamp switch
• The low beam headlamp does not work when the engine
• LINWake-up signal from LIN bus
is off.
• CANWake-up signal from CAN bus
• The reverse lamp does not work when the engine is off.
• Wake-up signal from local hard wire
• The direction indicator lamp does not work when the
engine is off. • Valid radio frequency signal
• The daytime running lamp (if equipped) does not work Load Management
when the engine is off. To meet the demand of the starter motor for high current
• "Follow Me Home" function cannot be realized. during engine start, some electric appliances shall be powered
• If the engine is disabled, the hazard warning lamp off. For example, disconnect the power of the HRW, high
backlight does not work, but the function of this lamp is beam headlamp, reverse lamp, horn and interior lamp, etc.
not affected. After the engine is started, reactivate each electric appliance
to limit the current consumption of the battery.
• When the engine is disabled, the window can be
ascended, but cannot be descended. Diagnosis
With the aftermarket diagnostic tool, the local MG Authorised BCMThe BCM monitors information input and output, if
Repairer can shift the vehicle load management configuration any fault is detected, the corresponding DTC will be stored
from transportation mode to normal mode. in the fault records. BCMThe BCM can detect short and
open circuits as well as wrong signals of the CAN and LIN
Normal Mode
buses. When any fault is detected, the BCM will close the
This mode applies the default setting, after completion of the corresponding functions. When the fault is eliminated, the
PDI, the vehicle can enter into normal operation. corresponding function will be activated next time when the
activation request is received.
1.0 576
The BCM can exchange information with the aftermarket of the driver side instrument panel (driver's leg) and is made
diagnostic tool through the DLC. It is on the closure panel according to the ISO standards.
1.0 577
Service Procedures Add Key and Disable Key

Body Control Module (BCM) Add Key
1. 1. Ensure the key to be added locates in the key slot, place
Remove the ignition switch in "RUN" position (position 2) and
ensure the engine is still.
2. Connect the diagnostic tool and communicates with
the vehicle successfully.
Glove Box Assembly Remove 3. Use the "Key Match - Add" function of the diagnostic
3. Disconnect the connector of the BCM. tool and strictly follow the interface prompts.
4. Remove 2 bolts fixing the BCM to the body. 4. Use the key added to start the vehicle and confirm if
the key can start, lock or unlock the vehicle.
Disable Key
1. Connect the diagnostic tool and communicates with
the vehicle successfully.
2. Use the "Key Match - Disable" function of the diagnostic
tool and strictly follow the interface prompts.
3. After the key is successfully disabled, please read the
key information again and ensure the key is disabled.
5. Remove the BCM.

Refit
1. Fix the BCM to the body, fit 2 bolts, tighten to 5–7Nm,
2. Connect the connector of the BCM.
4. Programme and encode the BCM.

SIPS.
b. Select "Programming and Coding - BCM -

Replacement", and operate as per the instructions
on the screen.
1.0 578
Panel Repair Body Repair
Panel Repair
Roof Panel
1. Roof Panel - Sunroof

2. Roof Panel
3. Roof Rear Cross Beam
4. Sunroof Reinforcement Plate Assembly
5. Roof Front Cross Beam Assembly
6. Roof Middle Cross Beam
1.0 579
Body Repair Panel Repair
Engine Compartment Panel
1. Right Dash Panel Side Panel Assembly

2. Right Frame Assembly
3. Right Tower Cover Plate Front Assembly
4. Right Front Longitudinal Beam Outer Panel Assembly
5. Right Front Longitudinal Beam Inner Panel Assembly
6. Right Front Longitudinal Beam Extension Panel
7. Right Front Bumper Mounting Bracket Assembly
8. Right Front Longitudinal Beam Assembly
9. Left Front Longitudinal Beam Extension Panel
10. Left Front Longitudinal Beam Inner Panel Assembly
11. Left Front Longitudinal Beam Outer Panel Assembly
12. Left Front Bumper Mounting Bracket Assembly
13. Left Front Longitudinal Beam Assembly
14. Left Frame Assembly
15. Left Tower Cover Plate Front Assembly
16. Left Dash Panel Side Panel Assembly
1.0 580
Dash Panel
1. Dash Panel Upper Panel Assembly

2. Vent Panel Assembly
3. Dash Panel Lower Panel Assembly
4. Dash Panel Beam Assembly
5. Dash Panel Upper Beam
1.0 581
Bodyside Panel
1. Bodyside Panel Assembly

2. Front Door Frame Reinforcement Assembly
3. Frame Inner Panel
4. Bodyside Closing Plate Assembly
5. Rear Bodyside Inner Panel Assembly
6. Bodyside Outer Panel Assembly
7. Tail Lamp Mounting Frame Assembly
8. Bodyside Outer Panel
9. Fuel Filler Panel Assembly
10. D Pillar Crash Panel Reinforcement Assembly
11. A Pillar Outer Panel Vibration Isolator
12. B Pillar Outer Panel Vibration Isolator
13. Rear End Outer Panel Vibration Isolator
14. C Pillar Lower Vibration Insulator
15. A Pillar Outer Panel Vibration Isolator
16. Front Bodyside Outer Panel
17. Rear Bodyside Outer Panel
1.0 582
Front Floor
1. Front Floor Assembly

2. Right Sill Inner Panel Assembly
3. Left Sill Inner Panel Assembly
4. Sill Reinforcement Plate Assembly
1.0 583
Rear Floor
1. Rear Floor Assembly

2. Spare Tyre Compartment Assembly
3. Right Rear Longitudinal Beam Assembly
4. Left Rear Longitudinal Beam Assembly
5. Rear Floor 1st Beam Assembly
1.0 584
Door Panel
1. Front door assembly

2. Rear door assembly
1.0 585
Bonnet Panel Assembly
1. Bonnet Panel Assembly
1.0 586
Tail Gate Panel Assembly
1. Tail Gate Panel Assembly
1.0 587
Body Repair Collision Repair
Collision Repair
Body Material
For different strength requirements of different body parts, this model adopts various high strength steel plates and ultra high
strength steel plates (hot formed steel plate). The detailed positions of different materials are as follows:
Only services as per relevant instructions in the Manufacturer's Service Manual and services of high strength steel plates
and hot formed steel plates as per the modern inverter technology are allowed.
During the service of the galvanized steel plate, the following matters should be noted:
• The paint and zinc coating should be completely ground off before grinding. Be careful when grinding.
• Apply the spot welding paint between the weld contact surfaces before the spot welding (with a hairbrush or a spray).
• Particles on the surfaces will be absorbed by the electrode, so it is necessary to clean the electrode tip frequently.
1.0 588
Collision Repair Body Repair
Damage Diagnosis
Damage Detection
During damage detection, visually inspect the location collided
to determine the direction and size of the impact, and check
for potential damages. For vehicles damaged in an accident,
query the vehicle speed, impact location or rollover location,
direction and angle when the accident happens, and understand
the impact form, location and angle of the impacted vehicle,
etc, use an intuitive method to determine the location damaged • Characteristics of damage caused by middle impact
by the impact and areas that may be affected by the impact.
Test drive and measuring instrument can also be used for the
thorough check of the vehicle, confirm if the underbody is
deformed, and if the whole body is damaged and twisted, check
if the door can function properly, etc to determine the level of
damage and the method of repair.
1. Vehicle Visual Inspection
• Characteristics of damage caused by rear impact
2. Detail Visual Inspection
Damage Measurement
Accurate measurement is one of the necessary processes for
completion of impact repair. For integral bodies, measurement
is more important for a successful damage repair, because the
steering system and suspension are on the body, and some
suspensions are designed according to the requirement for
assembly. To ensure correct steering and driveability, the
fit tolerance of the key machining size shall be within the
permissible range.
Measurement shall combine with remove operation, or it is

Damage Determination impossible to determine the damage. To facilitate body repair
Deformation occurs not only at the impact location, but also and thorough examination of damage and avoid damage of the
at the whole body such as beam, suspension and engine, parts removed due to repair, remove the related parts. The
etc. Along the course of the impact, systematically check the principle for remove is to avoid any component damage.
related parts for damage until there is no any sign of damage Measuring Point Selection
and the damage in the surrounding area is found. • Screw hole, process hole of the component;
Characteristics of body damage: • Overlap of the body steel sheet;
• Characteristics of damage caused by front impact • Machining gap or raised imprint on the steel sheet.
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Method of measurement:
• Distance measurement: the simplest and most practical
method is to measure the distance between the
reference points of the component with a steel tape.
• Centreing: measure by locating the centre.

• Three-dimensional coordinate measurement: measure
the data of the three-dimensional coordinate on the
measuring point selected, and compare the data with
those of the vehicle to determine body damage.
• Electronic measurement: more accurate and more
effective.
Reasons for error in body size measurement:
The error is due to the accuracy of the measuring tool or

equipment itself;
Error due to human factor:
• Failure to locate the measuring point;

• Wrong method is used for measurement;
• Failure to use the measuring tool and equipment in a
proper way.
Precautions for measurement:
• Level the body before measurement;
• Mark measuring point on the body to prevent confusion;
• Make accurate measurements;
• Carry out multiple measurements;
• Recheck the results of the measurement.
1.0 590
Repair Plan Determination
Underbody Correction
When the vehicle is severely damaged, the underbody is
deformed, no need to replace the whole body, correct
the underbody first. Underbody correction ensures the
three-dimensional position of the underbody and the general
position of the body, determines the position of the engine
assembly and front suspension and recovers the angle for
wheel alignment and the position of other assemblies. After
underbody correction, repair the body panel.
Body and Covering Component Correction
After an impact, if the body and covering component only
have repairable depression or deformation, no serious damage
occurs, no need to replace the component, recover its shape
by correction.
Sheet Metals Replacement
When the body part has a damage at one location or more
than one location, and the damage or corrosion is beyond the
specified degree, it is worthless to repair it or a repair cannot
help it to achieve the specified technical standard and function
requirement, then replace the sheet metals.
Body Replacement
When the vehicle is severely damaged, the whole body is
smashed by the impact, the underbody is seriously deformed,
the two sides, roof cover, engine hood and trunk lid are
almost destroyed, and the whole body is unrepairable, then
replace the body according to user's demands. Remove
usable assembly and component from the damaged vehicle,
thoroughly check and repair the major assembly such as
engine. Replace the body assembly and parts that shall be
replaced, and reassemble them according to the assembly
process of the vehicle.
Partial Replacement
When impact occurs, and only local damage appears, for
example, damage to the front/rear fender, door, engine hood
or trunk lid, partial replacement can be performed for the
body, this saves trouble, time and reduces the cost.
Body Pillar Replacement
When the body pillar, windshield pillar, front or rear pillar is
badly damaged and cannot be corrected by a simple repair,
replace it. Recover the large-scale deformation before
replacing the pillar.
1.0 591
Body Correction
The purpose of body correction is to recover the correct
position and size of the sheet metal by eliminating the
deformation (plastic deformation) and residue stress caused
by collisions.
Introduction of Correcting Equipment
The correcting equipment shall provide the following features:
• The equipment shall have high-strength body positioning
device and fixture. Correction/Drawing Method
• It shall have a service puller with various shapes and Drawing Sequence
different functions that can meet the repair requirements Note the method and procedure for drawing: during drawing,
for different locations. draw for a little while, then release the chain, unload and make
• Be able to perform multipoint and comprehensive measurements. Operate from inside to outside.
correction/drawing. 1. Take length as the priority. Draw the vehicle in the
• Be able to accurately measure and detect the deviation longitudinal direction along the centreline of the vehicle.
and repair error for each reference point. 2. Then correct the width. Correct the vehicle in the
Operation Process for Correcting Equipment horizontal direction.
Regardless of the type of the equipment used, its operation is 3. Finally correct the height.
broadly divided into the following 4 steps: Stress Elimination
1. Get on the vehicle. Eliminate the stress during drawing;
2. Position, clamping. • Knock the raised location beside the deformed region
3. Drawing. and the back;
4. Measurement. • Knock the welding location of the deformed region;
Auxiliary fixture: • Knock the ridge of the deformed region;
• Prevent motion of the vehicle; • Knock the reinforcement of the deformed region;
• Force caused by even and disperse drawing;
The high-strength integral body is susceptible to heat, so

do not attempt to complete the correction/drawing just by
Auxiliary support:
operation of one step. Generally, follow the cyclic process:
• Prevent secondary damage to the body due to drawing; draw - keep balance - draw - keep balance. If some bodies
• Focus the drawing force on the damaged location, and are tightly folded after an impact, and there is a risk of metal
improve the efficiency of the drawing operation; damage, then heat it. When heating, only heat the corner
• Prevent moment resulted from drawing; or the location where the two panels are tightly connected.
Heating is merely a means to eliminate metal stress, not a
method to be used to soften some location.
Note: Do not service the body by heating oxygen-acetylene.
Apply tensile force to the predetermined location, recover the

size and shape of the damaged steel sheet carefully and slowly,
1.0 592
completely eliminate the stress of the curved steel sheet to
achieve accurate repair of the body.
Note: overstretch shall be avoided during body correction.

The only solution to overstretch is to replace the damaged
sheet metals.
1.0 593
Panel Repair obvious defect that can be sensed by a touch are not allowed.
Panel Repair Method Especially for large scale repair, ensure the integrity, streamline
feature, continuity and fineness of the continuous surface.
Puller Method for Sheet Metal Repair (Meson
Machine) Sufficient Strength and Rigidity
The puller traction method for sheet metal repair is introduced The body of the original design has sufficient strength and
in recent years, for this method, a number of flat gasket pullers rigidity, the body repaired shall ensure sufficient strength and
is welded according to the size of the damaged sheet metals, rigidity. The vibration noise of the body repaired shall be within
the flat gasket puller is a traction medium, insert the wire into the permissible range, abnormal vibration noise shall not occur.
the medium, and draw the wire with a manual or mechanical Ensure the body has no any fatigue damage within the certain
manner, apply force to the damaged sheet metals through distance, the entire body shall have the specified rigidity, make
the medium so that it can be drawn outwards and resume sure the body panels is able to maintain its shape in use.
its position and shape, especially for larger deformation,
bilayer structure, inaccessible location, corner transition and
door pillar, etc, the puller traction method provides a more
convenient method for repair.
Heat Shrinkage Method
Local heat shrinkage is a commonly used method for sheet

metal repair. Deformation of the sheet metals refers to tensile
deformation of the related position, use heat shrinkage method
to eliminate tensile stress and resume the shape.
Hammer and Jacking Block Method
The hammer and jacking block method is a conventional

method for sheet metal repair. The metaler holds the hammer
with one hand and the jacking block with the other hand or
uses other tools to strike the sheet metal for repair. The
manual work of the sheet metal requires the metaler to have
the appropriate skill and experience, good repair skill cannot
be obtained overnight, repair of the sheet metal includes
repair of the deformed surface and correction of the shape
line.
Technical Requirement for Panel Repair
No matter which method is used to repair the body surface,
the specified technical requirement shall be met, and the
performance and appearance quality of the vehicle shall be
resumed.
Shape Recovery
For repair, the shape of the large smooth structure and the
wedge structure of the local transition shall be recovered.
When it is hard to recover the shape, change the original shape
in an appropriate way, the shape shall be symmetrical, beautiful,
firm and durable.
Integrity and Fineness of Continuous Surface
Most of the car bodies are produced by mould stamping, which

have the integrity and fineness of the surface. For repair,
the streamline surface shall have a continuous transition; the
transition point of the surface shall have a smooth transition;
the external surface repaired shall be as bright as a new surface,
ripple, wrinkle, dent, knock mark, scratch and visible defect or
1.0 594
Sheet Metal Replacement
The process for sheet metal replacement is as follows:
1. Preparation before cutting new/old sheet metals.

2. Remove damaged sheet metals.
3. Position, adjustment and cutting of new parts.
4. Treatment and corrosion prevention before welding.
5. Final position and welding of the panel.
6. Treatment after Welding
7. Accessory installation and inspection after operation
Principle for Sheet Metal Replacement
Thin Panel Replacement
3. Indicate the actual cutting position on the old body parts
Thin panel replacement is made for aesthetic purpose and shall
(reserve 15mm paper adhesive tape), and indicate the
follow the requirements below:
location for welding spot elimination.
1. Cutting is performed on the shortest position 15mm Welding Information Provided by
from the foam, damage to the foam by welding shall be Manufacturer
avoided;
Position of the foam
2. When replacing the A pillar and rear fender, please
remove the windshield;
3. Do not cut locations including any reinforcement.
Thick Panel Replacement
Thick panel replacement is made for strength purpose and shall
follow the requirements below:
1. Do not cut the energy absorption area;

2. No cutting is allowed within 50mm from the front/rear of
the position for laser welding;
3. Cutting is performed on the shortest position 15mm
4. Indicate the actual cutting position on the new body
from the foam, damage to the foam by welding shall be
parts, and paste the paper adhesive tape.
avoided;
Position of the foam Damaged Sheet Metals Remove
4. Do not cut locations including any reinforcement; 1. Position the welding spot.
5. To ensure welding penetration, the size of the cutting 2. Grind the welding spot.
seam shall be equal to the thickness of a panel.
Preparation before cutting new/old sheet metals
1. Remove all sealer residues with hot air gun to reduce the
toxic fumes generated due to heat during welding.
2. Straighten the existing panel side seams with form block
and hammer.
3. Carry out rough cut and remove the welding spot.
1.0 595
3. Mark the punch position for welding the plug hole.

Treatment and corrosion prevention before
welding
1. New body parts: grind the location for welding and
sealant application to remove the paint film.
2. Grind the location for welding and sealant application to
remove the old paint film, burr and rust (20mm from
the welding joint), but do not grind the cross section of
the joint.
4. Remove the damaged sheet metals.

Position, adjustment and cutting of new parts
1. Position the new panel on the body and adjust its position
and size.
• Compare the hole;
3. Clean the location for welding and sealant application on

the new parts and body, and wait for 5-10min to volatilise
the detergent.
4. Paint zinc spray to the welding junction of the new parts
and body that does not need sealant, and control the
thickness of the zinc spray.
5. Apply structure sealant: before application, remove and
discard the sealant (10cm), to ensure uniform bond of the
panel, welding shall be finished within the time specified
• Adjust the clearance; by the structure sealant, or bond of the panel will be
affected.
Final position and welding of the panel.
Adjusting Panel Refit
1. Confirm the position of the ridge;
• Adjust the difference between the high surface and the low
surface;
2. Cut the new/old panel by overlap, take care not to cut

the reinforcement inside the body, remove the new panel,
and cut the excess old panel section by section. 2. Compare the hole;
1.0 596
3. Adjust surrounding clearance; Caution: Use arms not exceeding 300 mm in length.
2. Fit the resistance spot welding arm and test equipments

with test silicon slice so as to meet the operation
requirements. If there is no monitoring device, the weld
strength can be tested by checking welding pool pull wires
around the metal under tensile force during the stretch.
4. Adjust the difference between the high surface and the

low surface.
Position of gas shielded welding
1. Select a gas ratio of 80% argon, 20% CO2.
2. To ensure the accuracy of the position, positioned
welding shall be performed on both sides of the ridge Welding Sequence
instead of on the ridge, and the distance of the positioned
• Welding sequence: to decrease the possibility of strength
welding shall be above 30mm.
reduction due to welding shunt, it is recommended
Trial Welding before Spot Welding that you begin with the direct welding, and follow
1. Select an electric welding arm for resistance spot welding the sequence shown below, the distance between the
and shape the electrode head with nozzle finisher. Finish welding spots shall be 25mm.
the nozzle, making its diameter equal to 2 times the
welding thickness and plus another 3.0mm.
1.0 597
Welding Requirement • Gas shielded welding - butt welding.

• If the resistance spot welding has been used in
production, a new resistance spot welding must be done
at any other feasible position. During spot welding, to
ensure the quality of the welding, test coupons of the
same metal gauge and material are recommended for
peeling test. If condition permits, the welding quality
monitor can be used to ensure welding quality. If the
satisfactory spot welding can not be achieved, plug weld
welding must be used.
Treatment after Welding

Process for Corrosion Prevention
1. Use P36 disc polisher or belt polisher to grind or finish
all welding locations, and clean the location.
• Length of the welding rod holder of hand spot welding

gun must be no more than 300mm.
• Single sided spot welding is not allowed;
• Neither braze welding nor gas welding is allowed unless
it is specified in production.
• Gas shielded welding - plug welding: when welding the
region with 3 layers or more than 3 layers of panel or
the welding nozzle is close to the restricted area, and
resistance spot welding is impossible, use the hole made 2. Paint anti-corrosion primer which can prevent corrosion
by the cutter for spot welding, or punch or drill a hole to and improve the adhesion of the sealant.
perform the MAG plug welding. The diameter of the hole 3. Apply sealant, fill the seam between the panels to realise
for plug welding of the structural component is 8mm, the leak prevention purpose.
and that for plug welding of the covering component is Position of Sealant
5mm, the ratio of the welding spot for plug welding to
4. Deliver the vehicle to the painter for painting.
the manufacturer's welding spot is 1:1.
5. Apply wax to the cavity before fitting the accessory.
Information of Cavity Wax Application
1.0 598
Painting Body Repair
Painting
Overview
The purpose of automotive painting is to provide an excellent
appearance, decoration, gloss protection, colour protection,
corrosion resistance and a longer service life, so it has
distinctive features:
• Automotive painting is a high-level protective painting,

the coating shall have a superb corrosion resistance,
weather resistance, acid/alkali resistance, inclusion
resistance and an extensive adaptability, etc.
• Automotive painting (mainly refers to body painting) is
a high-level decorative painting, and careful design, good
working environment and conditions are required for Function of Each Coating
providing the coating with good decoration. Vehicle 1. Zinc Coating: with a good function of
decoration mainly relies on painting, the quality of the anti-corrosion/anti-rust, good paint adhesion,
painting has a direct influence on the commercial value decorative performance and forming property.
of the vehicle. 2. Zinc Phosphate Coating: the first paint that is directly
• Automotive painting is the most typical industrial applied to the treated workpiece surface and is the base
painting, it requires reasonable and effective for the whole coating. Its characteristics are as follows:
pretreatment method, drying method and process
• It shall have a good adhesion to the treated surface of
preparation.
the workpiece, and the primer film formed shall have an
• Automotive painting is a multi-coating painting system, excellent mechanical strength;
and the painting quality and process control of each
coating is of great importance. • It shall serve as a corrosion inhibitor, and the primer
coating shall have an excellent corrosion resistance, water
Coating Introduction
resistance and chemical resistance;
Coating Composition
• It shall well fit the intermediate coating or top coat;
During manufacture, paint application consists of the corrosion
resistant coating (zinc coating) of the raw material, zinc • It shall have a good workability.
phosphate coating, electrocoating, intermediate coating and 3. Electrocoating: enhance cavity corrosion resistance;
top coat. improve the uniformity and leveling of the paint film
thickness; raise the quality of the paint film, painting
efficiency and paint utilization efficiency.
4. Putty Coat: used for the object surface with primer
precoat so as to fill the pit, weld seam, scratch, rust hole,
etc. on the object surface. until the surface becomes
smooth.
5. Intermediate Coating: it is the last intermediate coat
before applying the top coat, its binder content is
between the primer and the top coat, and the paint film is
bright and semi-bright. It provides the following functions:
• Enhance the adhesion between the primer and the top
coat;
Aftermarket paint repair is composed of the primer coat, putty • Increase the total thickness of the coating and improve the
coat, intermediate coating, pigmented paint coating and varnish film build;
coating. • Improve the corrosion resistance and weather resistance
of the primer/top coat;
• Repair minor defects on the substrate surface;
• Raise the decoration performance of the top coat.
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Body Repair Painting
6. Top Coat: top coat is used for the final coating of 7. In order to thoroughly clean the area of exposed metal
the multi-coatings, it directly affects the decoration due to damage of the painted surface, the cleaning area
performance, weather resistance, gloss protection, shall be larger than the original damaged area.
colour protection, chemical resistance, contaminant 8. Use phosphate to eliminate the dust, contaminant, etc on
resistance and appearance of the vehicle. the exposed metal, and offer a good repair environment
Classification of Top Coat for the new coating.
The classification of the top coat by colour effect is as follows:
• Pure pigmented paint: containing resin, pigment and
additive only.
• Metallic paint: containing metal powder, with better gloss
and saturation.
• Pear paint: comparing with the metallic paint, instead
of using metallic paint, it uses mica powder coated with
titanium dioxide and ferrum dioxide to improve the
texture and gloss of the paint film.
By application procedure, it can be classified into the following

processes:
• Single-process: a system that uses one type of paint to
form a complete surface coating. Single-process pure
pigmented paint and metallic paint are included.
• Double-process: a system that uses two different types of
paints to form a complete surface coating, generally, the
pigmented paint is applied before the finishing varnish is
painted. Double-process pure pigmented paint, metallic
paint and pearl paint are included.
• Three-process: usually, a layer of primer is required for
this system, then a layer of pearl paint, and finally a layer of
finishing varnish, the combination of these three coatings
forms a complete surface coating. Three-process pearl
paint and coloured varnish are included.
Principle of Paint Repair
The following principles must be followed when repairing the
painted surface:
1. Use the certified jointing sealant to seal the inner and

outer jointing.
2. Repair all damaged parts of the sealant under the vehicle
body.
3. Use two-pack paint to repair the system and it shall be
consistent with the original production parts.
4. Apply the inner wax to the entire inner surface without
paint finishing.
5. Steam cleaner or high pressure cleaner must be used to
clean the vehicle thoroughly before paint repair.
6. Clean the local part needing requirement with warm and
water soluble cleaning solution, then thoroughly clean it
with solvents. Painting must be done immediately after
this operation.
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Painting Process
Generally, automobile painting can be divided into two parts: 1.
metal treatment before painting (also known as pretreatment);
2. application process.
Surface Pretreatment
Surface pretreatment consists of the following works:
1. Surface cleaning: before painting, thoroughly remove the
mud, dirt other foreign materials on the vehicle, especially
the dirt on the door frame, luggage compartment, engine
cover seam and wheel house, failure to do so may cause
the new paint film to be contaminated.
• Treatment of dissolved substance: apply degreaser to the

surface with the special cloth, then remove the degreaser
and grease residue, etc with a clean and dry cloth.
• Treatment of moisture and dust: use a clean and dry cloth

to remove moisture and dust, and dry with a high-pressure
air gun.
2. Coating identification and damage assessment:
• Coating identification: identification of the coating on

the body panel is crucial for the reapplication process.
Improper identification may lead to serious problems for
top coat application. If no respray is performed, the type
of the coating can be determined by the vehicle manual,
but the type of the coating for the resprayed body shall Precautions for mechanical grinding:
be determined for repair.
a. Do not use an electric grinding machine to grind
• Damage assessment: correct assessment of the damage surfaces with a big radian, highly raised surfaces or
is one of the key factors for determining the service concave surfaces in a cross way;
cost and ensuring the quality of painting. Range of the
b. Do not use an electric grinding machine to grind the
repair/treatment process, transitional region, location to
corner, wrinkle seam, weld, junction or location with
be covered for protection and part to be removed, etc
plastic sealant;
are determined by correct assessment of the damage,
this lays the foundation for correct implementation of c. For grinding, the grinding machine can be started only
the subsequent processes and guarantee of a satisfactory when it contacts the surface of the sheet metal, in this
repair quality. Assessment of the damage to the paint film process, do not apply too much force, or deep groove
includes visual inspection, touch and ruler evaluation: may occur, and the grinding machine shall be aligned
with the edge line to be ground before initiation of
3. Removing old paint film: clean the body, and check the
the machine;
body paint carefully to see if there is any sign of damage
such as bubble, crack, peeling, rust and partial damage d. To avoid thermal deformation of the sheet metal, do
caused by baking/repair, gas welding, etc. For the above not stay the grinding machine at one position for a
damages, the old paint film shall be removed, selection of prolonged time;
partial elimination or full elimination of the old paint film e. Do not allow coarse grinding material to contact
is made according to the degree of the damage and the with the intact paint surface of the accessory in the
quality requirements after recoating. Sandpaper P80–P180 grinding area, it's better to protect the intact coating
is recommended for grinding feather edge (not less than with tapes.
3cm). Operation of sanding: a fine processing of the surface
treated by coarse grinding, its purpose is to acquire a
flatter surface. Align the front of the rotating grinding
wheel the surface to be ground, and slightly keep the
rear away from the surface. Maintain this angle, move the
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grinding machine up and down, the proper coverage area

of each grinding mark is 50%-60%.
Replacing sheet metal: use sandpaper P280–P320 to grind

the electrophoretic primer by dry grinding.
4. Degreasing and descaling of the metal surface:
• Remove surface rust. Descaling of the metal includes

manual descaling (polishing, grinding and high-pressure
water, etc.), mechanical method, chemical method
and ultrasonic method. Different rusts apply different
methods for descaling.
• Clean the metal surface again.
1.0 602
Coating Application care not to grind the surrounding area. When using a
grinding block, grind in the horizontal direction, and begin
For paint repair of the pretreated sheet metal of the finished
with the top, then move down gradually;
surface, please refer to the detailed processes below:
• Clean the repair surface with an air gun.
1. Primer application
• Cover the area around the region to be repaired;
• Use a soft cloth with detergent to wipe the surface to
be painted, and use another clean cloth to wipe off the
detergent residue on the surface;
• Purge the surface with compressed air;
• Spray anti-rust primer and dry it;
• Use a soft cloth with detergent to wipe, and dry with

another clean cloth;
3. Intermediate Coat Application
• Cover the area around the repair region, prepare to apply

intermediate coat, the surrounding of the covered area
shall be larger than the area to be sprayed (above 10cm);
• Use a soft cloth with detergent to wipe the surface to

2. Putty application (not required for new parts)
be painted, and use another clean cloth to wipe off the
• Mix the putty and curing agent according to the ratio detergent residue on the surface;
specified by the instruction;
• Purge the surface with compressed air;
• Use a clean putty mixing plate; only mix putty enough for
• Mix intermediate coat, curing agent and diluent according
current use;
to the ratio specified by the instruction;
• Fill sandpaper mark and pore first, then apply putty in the
full scale; • Apply a thin film of intermediate coat first, flash off for
5min, and make two wet applications;
• Flash off for 5min after application, and bake it with the
infrared baking lamp according to the instruction of the • After a levelling of 10-15min, cure the paint film with an
putty; infrared baking lamp;
• Wear dust mask, select appropriate sandpaper and hard • Coat a grinding indicator layer on the surface so that the
grinding block, rail grinding machine can be used, and take uneven surface can be easily found during grinding;
1.0 603
• Cover the surrounding of the repair area, paste paper from

the inside of the repair area, and take care not to tear the
covering paper;
• Purge the panel to be painted and the vehicle with

compressed air, take care not to damage the covering
paper, then wipe the surface with a cloth;
• To prevent dust, particle, etc from entering into the paint,

use a strainer to pour the mixed paint into the cup of the
spray gun;
• Carry out a trial application, check the barometric

pressure, paint output, sector and atomization;
• Spray two wet paste coatings, the leveling of each shall be

• Perform coarse grinding with P240 – P400 sandpaper first,
5-10min;
then perform fine grinding with sandpaper P600 – P800;
• For silver paint, virtual spraying can be carried out at the
last to guarantee the silver powder is uniform;
5. Varnish Application
• After the pigmented paint is applied, flash off for about

15min (when the paste coating loses its gloss completely),
apply varnish, spray wet varnish first, flash off for 5-10min;
spray the second wet varnish, flash off for 15min before
baking; (note: do not turn off the ventilation system of
the spray booth during drying.).
• Use the temperature and duration specified by the

product to bake the paint film. Infrared baking lamp can
also be used to perform a forced drying for 15min;
• Remove the covering paper from the surrounding of the • After baking, further treatment can be done only when the
repair area, purge the inner/outer surface of the repair paint film is completely cool (such as grinding, polishing,
area with compressed air, and thoroughly remove the etc).
abrasive debris and moisture; 6. Polishing/waxing
4. Top Coat Application • When the paint film is completely cool, use sandpaper
• Check the colour code, and check the colour formulation P1500 or P2000 to grind the dust, sag, etc on the paint
according to the code; film;
• Polish the body surface around the repair area to acquire • Use slack wax and wool wheel to grind the location to
correct colour; be polished. At the beginning of polishing, the speed of
the polisher shall not be high, the speed shall be increased
• Check for the difference between the colour mixed and
gradually;
that of the original body in the stage fluorescent lamp or
sunlight; • Polish with polishing wax and sponge wheel.
• When it is consistent with the vehicle to be painted • Use a clean sponge wheel, use polishing wax to remove
(dilution ratio, distance, pressure, paint output, the swirl mark caused by polishing to restore the gloss of
temperature, flash-off time, etc), paint the colour test the paint film;
panel; • Check if the colour of the painted location is correct in
• Flash off the test panel for 15min, bake the test panel as the lamplight, then check it in the sunlight.
per the specified temperature and time. Take care not to
7. Hairdressing/cleaning
overheat the test panel during baking;
• Use a soft cloth with detergent to wipe the area to be
repaired, and dry with another clean cloth;
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8. Process information for paints of different brands
Recommend paint brand information
PPG Sherwin-Williams Akzo Nobel
P565-895 E2G973 Priming Filler 680 Grey
P565-9850 GBP988-AR Primer Surfacer EP
Primer
P565-9085 UPO7299 Sikkens 1K All Plastics Primer
UPO7226-3 Washprimer 1K 1CF/EF
P551-1050 18380221 Kombi Filler
Putty P551-1052 Polykit IV Set
P551-1057
Buffer P565-510/511 P30 Autosurfacer Classic
layer P565-5601/5605/5607 P50 Autosurfacer Rapid
P190-376 CC645HS Autoclear Plus HS (HSR)
P190-6850 HPC15 Autoclear Xcel SET
P190-6060 CC939 Autoclear II
Varnish P190-6208+P210-6863 CC931 Autoclear Rapid
P190-588AP210-790/938/939 CC930 Autoclear Mat
P190-588+P210-760/790 CC655
NEXA Autocolor 2K（Oily paint） Ultra 7000（Oily paint） Sikkens（Oily paint）

Topcoat Aquabase plus（Water-based paint） AWX（Water-based paint） Sikkens Autowave（Water-based
paint）
1.0 605
General Film Coating Defects • Low product temperature, low spraying pressure, slow
Paint Film Defects Caused by Application and gunning speed, short distance to spray gun, thicker film;
Treatments • Large caliber of spray gun, poor atomization of spray gun;
Particles • Slow solvent evaporation rate and low paints' viscosity;
The phenomenon that bumps in the film coatings are spread • Short distance between spray gun and workpiece, slower
over the whole or local surface in granular form. gunning speed, thicker spraying coatings;
Analysis of Possible Causes: • Insufficient flash-off intervals between layers;
• Poor air cleanliness and impurities in the painting Preventive Measures:

environment, such as dust;
• Improve the painting environment, control the
• Workers wear dirty clothes or the fibers contained in appropriate ambient temperature, humidity and wind
the materials are easy to fall out, substrates that are not speed.
properly handled have bumps, the vehicle body is not
• Choose the correct solvent and pay attention to select
cleaned thoroughly, etc.
the dissolving capacity and evaporation rate of the
• The painting pressure is insufficient, atomization is poor, solvent;
the spray gun is not cleaned up and an improper screen
• Strictly control the viscosity and the temperature for
is selected;
coating application;
• The pigments or flashing materials in the paints are
• Reduce the amount of paints from spray gun, and increase
badly dispersed, the paints are unfiltered or filtered
the gun distance and gunning speed;
improperly, the paints become deteriorated and show
• Full flash-off between layers;
abnormal signs, such as separate out, flocculation.
• The film is moved out of the baking booth before drying Defect treatments: For the slightly local varnish sagging, it
the surface to dust-free. can be sanded to eliminate the sagging defects before being
polished if this defect exists; or if the sagging defect is more
Preventive Measures:
severe or it appears on the surfacer layer and the color paint
• Ensure that the spraying environment is clean; layer (finally revealed on the layer of varnish), the sagging must
• Ensure that the objects to be painted and workers are be sanded thoroughly and make the spraying again.
cleaned thoroughly before entering the baking booth; Pin Holes/Eyes
• Ensure the paints' performance, the deteriorated and The blisters or solvent bubbles appear on the film and there are
poorly dispersed paints are not applicable; small needle holes on the top of them, which are referred to as
• Set the optimal parameters for paints' application and use pin holes (the solvent contained in the film coatings evaporates
the spray gun to spray after the paints being filtered. rapidly during the surface drying, its left trace forms hole );
these pin holes are known as defects that the holes are still
Defect treatments: The tiny dirty spots can be polished after
visible on the surface after spraying the finish due to some holes
removed by abrasive paper; if the impurity particles are large
on the substrate are not filled up. They are easily generated at
or the dirty spots on the surfaces of primer and even surfacer
the corners of workpieces.
can only be ground to the extent that the spots disappear
completely, perform the spraying again. Analysis of Possible Causes:
Sags • Pin hole: The paints are mixed with impurities, for
example water enters into the solvent based coating; the
Upon the liquid paint is sprayed onto the workpiece surfaces,
painted objects have dirt on their surfaces; the flash-off
some wet film surface runs down, creating unevenly stripes
intervals between layers is insufficient during application;
and sags, which are thin on the top and thick on the bottom,
the continuous spraying is too thick; the temperature
resulting in the local thicker film on vertical surface. It can
rises up suddenly and the surface is dried rapidly when
be divided into sinking, sagging and running depending on the
stoving.
shapes of sags.
• Pin eyes: The uneven locations on the original workpiece
Analysis of Possible Causes: surface are not filled up;
• The painted workpieces' surface is too cold;
Precautions and Improvements:
• Low application environment temperature, slow wind
speed and high solvent vapor content in the ambient air; • Set appropriate temperature and humidity for
application. Wind speed and other conditions;
1.0 606
• Mix the paint and solvent in proportion to ensure the • The substrate is not flat or the finish coating is sprayed
proper fluidness; to the surfacer surfaces without having the orange skin
• It should be heated up slowly to avoid the rapid solvent ground smooth;
evaporation. • The ambient temperature is high, the wind speed is fast
• Full flash-off intervals between layers; and the substrate temperature is high;
• The diluent volatilizes rapidly, the paint has high viscosity
Defect treatments: The defects should be completely ground
and the film is too thin;
to remove the pin holes and pin eyes, then repaint it.
• The distance from spray gun is too far, the gunning speed
Blistering is too fast, the spraying pressure is low and the amount
Part of the film coating floats off the painted surface or prime of paint out of spray gun is little;
coat and is filled with liquid or gas, which is about 1 ~ 5mm in
diameter or floats off in large pieces. If there is some water
under the film, the vapor generated by evaporation of water • Grind the intermediate coating completely smooth
will plump up the film to form blister when the temperature according to the process requirements;
rises up. • Control the ambient temperature and wind speed (0.2 -
Analysis of Possible Causes: 0.6m/s);
• Use the diluent suitable for that temperature, and
• The ambient humidity is high and the film is dried
adjust the paint viscosity as per the paint manufacturers'
naturally after spraying, resulting in moisture infiltrating
product instructions.
into the film;
• Adjust the gun pressure, then regulate the gun to
• The substrate is not dried properly, the drying time is
proper distance and reduce the gunning speed as per the
short between coatings, the heating and drying are too
manufacturers' instructions;
fast;
• Spray the appropriate layers to ensure that the film get
• Grind the putty while adding water and the putty absorbs
the desired thickness;
water;
•
• There is oil or water in the compressed air lines;
Defect treatments: Only perform the grinding and polishing if
the defect of orange skin is slight; the orange skin should be
• Grind the dry putty; ground to completely removed and then be resprayed if the
• Ensure that the previous coating has met the defect is serious.
requirements for cleanness and dryness before spraying; Sanding Scratches
• Reduce the humidity in the painting and spraying room;
The sanding scratches left by sanding substrate are visible
• Use the curing agent and diluent suitable for environment on the film after spraying the paint. Sometimes, the sanding
temperature, make it dry as soon as possible once the scratches on the substrate will extend due to the erosion
spraying is completed to prevent the moisture from caused by solvent contained in the film, the upper film would
infiltrating into the film. be subsided gradually after a period, resulting in the sanding
Defect treatments: Once blisters appear on the film surface, scratches more and more obvious.
this surface should be ground to remove the blistering Analysis of Possible Causes:
defects completely, then respray it depending on the surface
• If the improper abrasive papers are used to sand the
conditions.
substrate, the sanding scratches will be wide and unable
Orange Skin to be covered and filled up by upper film;
The orange skin is used to describe the leveling property of • If the lower film is sanded and sprayed with upper film
the film: When you observe the film surface against the light, over it before it isn't totally dry, it is easy to make the
you can see different ripples of 1 - 5mm presenting on the sanding scratches to extend due to the erosion caused by
film surface, and the brightness and plumpness vary in different solvent in the upper film and form the sanding scratches
ripple areas, such texture on the film surface, which is similar defect;
to orange peel, is known as orange skin.
• The diluent that has high solubility for upper paint or too
Analysis of Possible Causes: slow to dry has been misused.
1.0 607
• When you select the abrasive paper number to make Defect treatments: Once the putty marks appear, those areas
sanding, you should observe the principle that the should be sanded, and apply the putty again and respray the
abrasive paper number should not be jumped by 2 levels surfacer and finish.
each replacement;
Lifting
• Ensure that the lower film is totally dry before sanding;
The lower-layer paint is single-component, or even if it is
• Select the correct upper film solvent as per the product two-component, it is not dry and cured completely (including
instructions; improper amount of curing agent is used), when the paint
Defect treatments: For slight sanding scratches, they can be is sprayed above it, the solvent contained in upper film will
removed or made less obvious by sanding and polishing as they erode the lower film, causing the uplift and shrinks present on
have been filled up by paint; For the sanding scratches that the lower film surface.
are more obvious, they cannot be removed by sanding and Analysis of Possible Causes:
polishing, it should be resprayed after removing the scratches.
• The lower film is not totally dry;
Putty Marks
• The lower film becomes deteriorated;
A putty mark means the defect that trace is left along the edges
• The continuous spraying of surfacer or finish results in
of putty application areas after spraying the surfacer or finish.
too thick surface, or the used curing agent and diluent
Analysis of Possible Causes: are too slow to dry, or the diluent with high solubility
is used, or the flash-off intervals between layers are too
• The feather edges are improperly treated before putty
short when spraying the surfacer or finish, or the low
application;
air temperature during the spray causes the infiltration
• The putty is mixed with curing agent in improper
and erosion of solvent contained in the surfacer or
proportion;
finish, resulting in the lifting occurred at the putty edges,
• The next action is taken before the putty is completely one-component putty or surfacer edges.
dry (sanding, spraying the surfacer, etc.);
• The putty is not flat enough, the feather edges do not
meet the standard, and it is higher or lower than the old • For the film not totally dry, it must be sanded and sprayed
surrounding coatings or metal; with the next layer paint after it is completely dry. If
it cannot be totally dry due to the improper adding of
• The curing agent and diluent mixed in the surfacer or
curing agent, it needs to respray the paint mixed with
finish are dried slowly, or the flash-off intervals between
proper curing agent after film removal.
layers are too short when spraying the surfacer or finish,
and the solvent penetrates and erodes the putty, resulting • For the deteriorated film, shown as chalking, cracking,
in the edges expanded and extended. loss of gloss, they must be removed totally and resprayed
with two-component surfacer or finish;
• Use the correct mating curing agent and diluent, and
• The width of the feather edges must be 20 - 30mm ensure the flash-off interval between layers is enough.
and the surface is smooth without steps before putty
• Use the two-component putty and surfacer.
application;
Defect treatments: When the lifting defect appears, it should
• Adding the curing agent in proper proportion according
be sanded to remove any defects at the lifting area, if the lifting
to the product instructions;
is severe, the film that has lifting should also be sanded and
• Make sure to perform the sanding and spray the surfacer
removed completely, then spray the two-component surfacer
when the putty is totally dry.
and finish.
• Use the correct curing agent and diluent, and ensure the
Paint Film Defects Caused by Operating
flash-off interval between layers is enough. Environment and Treatments
• The periphery of putty must be sanded to be qualified. Paint film defects caused by external corrosive
Not only the putty, but also the extended old materials
surrounding coatings should be sanded when you sand
Defect phenomenon: The film defects occur when the film
the putty edges to allow the putty together with the
is affected by the acidic and alkaline materials as well as
surroundings to form flat surface.
industrial fall-outs, such as asphalt, oil, battery electrolyte,
bird droppings, sap, acid rain, pollen, dust produced by steel
plant and black carbon from boiler stack. It generally appears
1.0 608
as uplift, discolor and even cracking and peeling caused by the
contaminants infiltrating into the film.
Defect treatments: If the film defect is tiny, it can be

recovered only by polishing the surface damage; if the film has
been discolored, the defective areas should be sanded until
eliminating the defect, then respray it.
Water Spots
Defect phenomenon: When the rainwater on the film surface
or the tap-water left by car washing is heated to evaporate, a
white ring drop mark will be left on the water-drop area and
cannot be removed by common cleaning methods.
Causes: As the water contains mineral substances, such as

calcium, when the water is heated to evaporate, some warm
water will infiltrate into the softened film with heat, and the
left mineral substances infiltrate into the coating.
Defect preventions and treatments: Try not to wash the car

under the sunlight, and wipe the water drops off the vehicle
surface after washing to avoid evaporation caused by heating.
It should only be polished when water spots appear.
Stone-crash Damages
Defect phenomenon: Some small stones may hit the film and
cause the film peeling during vehicle traveling, the area where
the film is peeled off usually form the surface with sharp and
jagged edges, sometimes a small indentation will appear in the
middle of this area. The front edges of the vehicle engine hood
or the roof is usually damaged by stones.
Defect treatments: When the stone-crash damages occur,

the film on the defective area must be removed and sanded
to feather edges, and filled up with putty or surfacer, then
continue to apply the surfacer and finish; if the area hit by
stones is rusted, the rust must be removed thoroughly.
When new original parts are sprayed, if the finish is directly

sprayed onto the electrophoretic coating without spraying
surfacer, and when the plastic parts are sprayed, if the surfacer
and finish are not added with softening agent depending on the
plastic hardness, the stone crash protection for the film will
be reduced and the film is easy to hit off by stones and sands.
Discolor/Chalking/Loss of gloss
Defect phenomenon: As the vehicle exposes to the ultraviolet
rays, the pigment deterioration of the film causes color fading,
the resin deterioration causes yellowing, the film peels off as
powder and loses gloss.
Defect treatments: Color fading is a representation of film

aging, it is usually shown up together with chalking and full loss
of gloss. Once any one of these defects occurs, the defective
film must be sanded and removed thoroughly, then respray the
two-component surfacer and finish.
1.0 609
Body Repair Seal
Seal Clean the affected seam, re-process the exposed metal area
Overview with proper etch primer;
Process Area of Underbody Seal Coat proper sealant at the required places;
Underbody areas and doorsill outer panels should be Process the affected area with acid-etch primer (chassis sealant
processed with plastisol PVC underbody sealer. This sealer is also acceptable), and apply proper colour paint film.
shall not be reused. When repairing the sealer for the
After reassembly or refit of parts, if the seam is plugged, then
underbody areas, the underbody sealer upon delivery should
apply paste seam sealant to such seam. Blockage of the seam
be removed and returned to the proper breakpoint. Expose
may occur after panel repair. In this case, apply sealant and
the clean metal surface, and the current sealing edge shall also
paint before final assembly. If the inlet is of proper size, apply
fit firmly to the panels.
seam sealant to the two sides of the joint to be repaired. If the
Use new chassis sealant between the primer and the spray can be only done to one side (such as compartment),
intermediate primer. If necessary, use the seam sealant before then use cavity wax to process the affected compartment
applying the chassis sealant. Before coating the chassis sealant, beam.
fit the plugs and insulating ring on the disk type floor (except
Seams which require sealant when assembling in the plant is
the part for wax spray). Refit the heat-fusible plugs damaged in
described in the figure below.
repair with heat blower or replace them with rubber insulating
ring. Caution: Look through all the joints near the fixed areas.
If necessary, all the combined ,fixed or replaced areas
Before using new chassis sealant, cover the suspension, wheel,
should be sealed. These areas can’t be ruined. Sealing
tyre, power unit, exhaust system and brake system (including
could protect from waters and wind noises and so on.
all mounting points).
Before the final inspection, it is necessary to look through
Seam Sealant all the sealed areas.
For factory assembly, apply PVC sealant treated by baking to
special joint weld and sheet metal edge. This kind of material
is not suitable for repair, so approved special sealant shall be
used for aftersales service.
Seam sealant is used after the primer and before the

intermediate primer and outer coat. The spray of the seam
sealant must be smooth and continuous, and the spray line
depends on the type of the seam. If the sealant is coated by
brush, pay special attention to the coverage area required for
the weld. At the places needing sealant formation, use cloths
dipped in the solvent oil to complete the required operations.
Remember to seal all the seams to be processed after each

repair. The area away from the joggled joints often distorts
when the vehicle is damaged. Thus, sealant for these places will
frequently occur in the following repair and correction. Check
all the welds around the area to be repaired to see whether it
is damaged, then process the damages as required, then coat
new sealant. Specific steps are as follows:
1.0 610
Seal Body Repair
Application of PVC sealant:
Operation
Process Implementation effect section view Application location
method
Mating faces for fitting the parts, welds
Sealant with appearance requirement; such as
Elimination tail lamp, side body and roof joint, visible
location after assembly
PVC Welds without appearance requirement
sealant Sealant or assembly requirement (covered weld,
Application with a width < 50mm); such as seam of
interior floor, underbody
Sealant Edge of four doors and two covers (thickness:
Injection 1-2.5mm, width: 5-9mm)
Plug
Plug type One-component plug Two-component plug
Workshop Painting workshop or general assembly Painting workshop
workshop
Material EPDM, TPE, PA6, TEEE, etc. (PA6-GF) + hot melt adhesive, metal sheet + hot melt
TPE + hot melt adhesive, etc
Sealing 30mm water column, 10min, no water leak 500mm water column, 10min, no water leak
Performance
Application 4 doors, side body, etc Floor, spare tyre compartment, etc
Location
Remark Seals holes with no direct connection with Used to seal holes directly connecting passenger
passenger compartment or waterproof holes compartment and external horizontal holes
1.0 611
Body Repair Seal
Sealing Performance Test damaged, aged or displaced. Meanwhile, align the door with
Overview the seal.
Process of the leaking problem needs to combine techniques, Note: Check the colour of the water around the leak. If
experiences and instincts to take proper and effective the water is dirty, the leak is from under the vehicle. If the
measures. Do not come to conclusions fast only by naked water is clean, it is from above.
eyes.
When a leaking spot is found, the methods below are
Test Tool and Instrument necessary for resolution of the leak problem:
When checking and correcting the leaking problems, the below 1. Replace all of the damaged, displaced and aged door hole
tools and instruments are recommended to use: seal and weatherstrip.
1. Garden Sprayer (manual) 2. Check all the body seals and ensure it is fixed on the
2. Wet/Dry Vacuum Cleaner fixing flange/fixing face correctly. If necessary, the simitar
can be used.
3. Dry, Absorbent Cloth
3. Blow the body weld seam to be processed with
4. Battery Torch
compressed air and/or hot blower when necessary.
5. Mirror
4. If necessary, apply sealant to the outside of the connector
6. Weatherstrip Locating Tool
to prevent water.
7. Trim Panel Remover
5. When correcting leakage of the windshield and
8. Small Wooden or Plastic Wedges weatherstrip (or polish between the upper glass and
9. Dry Compressed Air Supply the body directly), try not to remove the glass. Use
10. Hot Blower qualified materials at proper places (such as glass to the
weatherstrip or glass to the body).
11. Sealer Applicators
Initial Door Seal Replacement
12. Ultrasonic Leak Detector
The initial seals for both front and rear doors are stuck on the
When checking for leak, at least the following parts should be
specified positions. Always comply with the regulations below
checked:
when replacing the weatherstrip:
• Front Inner Space;
• Clean the position where the door weatherstrip is
• Rear Seat Space; located. Do not clean the doors with paint diluent agent.
• Storage Compartment or Luggage Compartment • The ideal temperature for sticking the weatherstrip is
Test Method and Measure 25℃ (77℉). For either the door or the weatherstrip,
The operators at the fittings center can judge from where to when the temperature is less than 18℃ (64℉), it is hard
check the leakage by information offered by the customers. to stick the weatherstrip.
The next step is to find the leaking spot after the leaking place • Do not apply too much force to stick the weatherstrip,
is founded. this will make disassembly or re-installation much easier.
If the weatherstrip shall be refitted, do not touch the
For the first case, an easy and effective method is the common
contact face or stain it.
garden sprayer. Nozzle of this extruding garden sprayer ought
to be adjusted, so that water can be sucked into the nozzle
directly and spray out proper spray. At the dark corners, a
mirror or battery torch cab be used (the test light using supply
voltage is not available).
The test order is very important. Begin from the lowest point
and go up gradually, this can avoid blocking off the other leaking
place when an area is being checked. If the test is begun from
the windscreen, any water flowing into the pumping chamber
may drop on the pedal by baffle insulating ring. Even though, it
may be judged wrongly that seal of the windscreen fails.
Another part for leaking check is to visually observe whether

the door hole sealer, insulating ring or weather strip is
1.0 612
Seal Body Repair
Position Information of Sealant
Body Seal Identification
1. Between Panels - Connected with Bolts 7. Riveting Joints - Type (a)

2. Panel Edges - Connected with Bolts 8. Riveting Joints - Type (b)
3. Between Panels - Spot Welding 9. Riveting Joints - Type (c)
4. Panel Edges - Spot Welding 10. Panel Gaps - Type (a)

5. Between Panels - Bonding 11. Panel Gaps - Type (b)
6. Panel Edges - Bonding 12. Lap Joints
Sealant Information • For any place not specifically described in the figure
below, brushing glue is applied.
After the panel is welded or replaced for repair, it is required
to use PVC sealant to seal the weld seam and the new
panel according to the following construction principles
and the instructions on gluing position given by the original
manufacturer to guarantee the repair quality:
• PVC brushing glue requirements: cover the weld seam
to make the surface smooth and even without fillets, and
the width < 50mm.
• PVC tube glue requirements: cover the weld seam to
make the surface smooth and even, the width is within
5-9mm and the thickness within 1-2.5mm.
• PVC frictioning glue requirements: cover the weld seam
to make the surface smooth and even without pinholes
or bubbles.
1.0 613
Body Repair Seal
Front Compartment
1.0 614
Seal Body Repair
1.0 615
Body Repair Seal
Front Floor
1.0 616
Seal Body Repair
Dash Panel
1.0 617
Body Repair Seal
Rear Floor
1.0 618
Seal Body Repair
Bodyside Panel
1.0 619
Body Repair Seal
1.0 620
Seal Body Repair
Front Door
1.0 621
Body Repair Seal
Rear Door
1.0 622
Seal Body Repair
Bonnet
1.0 623
Body Repair Seal
Tail Gate
1.0 624
Seal Body Repair
Position Information of Foam Parts
1.0 625
Body Repair Seal
Gasket Position Information

Damping mats are used in the base plate, dash panel, rear end panel, rear wheelhouse and central passage. When making
sheet metal repairs or replacements in these areas, tailor new gaskets according to the size of original ones and paste
them as the following instructions:
• Clean the position pasted-to-be on the sheet metal before pasting new gaskets.
• Follow the size requirements in the figure below.
1.0 626
Seal Body Repair
Gasket Pasting Position Information
1.0 627
Body Repair Seal
Gasket Size Information
1.0 628
Corrosion Protection Body Repair
Corrosion Protection During service, do not remove the protective wax or paint
Overview from the underbody or lower part of the engine cover. If the
above areas shall be cleaned with steam, then apply a new layer
Treatment in Production
of protective wax or an underbody protection layer as soon as
During production, the vehicle body applies the following possible.
methods for anti-corrosion treatment:
Maintenance Check
• Use galvanized steel sheet;
When doing the anti-corrosion check on the body, observe
• Phosphate anti-corrosion primer dip-coating, the following steps:
electrophoresis;
• Lift the vehicle, visually inspect the underbody sealant for
• Chip-resistant coating;
any damage;
• Underbody coating: spray on the underbody of the main
• Lower the vehicle, check the body exterior paint for
floor and rear floor, and on the rear wheel opening;
damage, and the body panel for corrosion.
• Cavity wax: spray on the sheet metal parts such as
doorsill and rear window sill, side extensions and the Note: If the vehicle is dirty, it will need to be washed prior
lower sheet metal of the door; to inspection of bodywork.
• Protective wax: spray on the opening not covered by the The above check refers only to visual check. When checking
wheel house. for corrosion and paint damage, do not remove the decorative
panels or sound insulation materials.
Whenever repairing the body, make sure the anti-corrosion
materials from the repair area is also repaired or updated. 1. Lift the vehicle, and use the test lamp or spotlight to
Ensure the materials used are the approved anti-corrosion perform a visual check for the following:
materials. • Corrosion damage and paint damage, and conditions of
Precautions for Body Repair and Operation the lower panels of the front/rear vehicle, doorsill and the
underbody sealant at the wheel opening;
In the workshop, it is necessary to exercise caution in the
operation of the vehicle. For example, when lifting the vehicle, • Damage to underbody sealant. Erosion conditions in
any carelessness and negligence can cause damage to the surrounding areas of the suspension mounting point and
underbody sealant, seam sealing materials, underbody sealing fuel tank mounting point.
wax and body panels, etc. Note: for unexposed metals, the little bubble on the underbody
When fitting the accessories, ensure that the vehicle sealing material can be neglected.
anti-corrosion protection is not impaired by broken protective Pay special attention to damage of the sheet metal or
layer or moisture. anti-corrosion material due to incorrect lifting method.
Do not screw the self-tapping screws directly into the body

Warning: It is essential to follow the correct jacking and
panels. Pre-fix the matching plastic inserts to the body panels.
lifting procedures.
Always brush the sheet metal, chassis component and drill hole
edge of other body parts with proper zinc-rich or acid-etch
2. After lowering the vehicle, visually check all the visible
primer, and brush the surrounding area with wax.
painted surfaces for sign of damage and corrosion, and
Never contact the painted metal surface of the part with pay special attention to the following areas:
the body without taking appropriate protection measures.
• Leading edge of the engine cover;
Between the metal surfaces requiring bolt connection, be sure
to have appropriate media, such as weldable zinc-rich primer • Visible flanging of the engine compartment;
or zinc strip, etc. • Underbody and door panel.
The heat from the steam cleaning equipment has the risk of Take feasible measures to correct or repair any body
damaging some decorative parts, softening or liquefying certain damage or corrosion found during the inspection as soon
adhesives and anti-corrosion materials, so the equipment shall as possible. These include diminishing breakage and
be adjusted so that the nozzle temperature does not exceed ensuring the long-term effectiveness of the anti-corrosion
90℃ (194℉). Do not have the steam nozzle stay in one place treatment performed in the production. If the corroded
for a long period of time, the distance between the nozzle and area is increasingly clear, and diffuses or expands from
the sheet metal surface shall be at least above 300mm. the bottom of the replaceable parts (such as various trim
panels, window glass, seats, etc.), then replace the parts
to achieve the most effective repair.
1.0 629
Body Repair Corrosion Protection
Underbody Protective Maintenance 7. Use approved underbody sealant for service to spray the
affected area;
Whenever doing maintenance work of the body, ensure that
the body sealing and anti-corrosion protection is recovered 8. Remove all the covering on the mounting surfaces of the
to the original condition. This applies not only to the repair components.
work on damaged areas, but also to the recovery work on the After refitting the above mechanical parts, including hoses,
protective layer of certain areas indirectly weakened due to pipes and other clips, cover the brake disc, spray a layer of
accidents or maintenance operations. approved underbody protective wax. After repairing the sheet
Before straightening or doing panel repairs, you must remove metal at the damaged wheel opening, spray new wax which is
the corrosion protection layer of the damaged area. It's also applicable for the painted surface and underbody sealant.
particularly important, especially for the panels with a Remove the old wax on the underbody, and the range of the
protective wax layer, the underbody with polyvinyl chloride underbody wax is at least 200mm larger than the range of the
(PVC) sealing materials, and the sound barrier areas. new underbody sealant.
Warning: DO NOT use oxy-acetylene gas equipment to Note: Where repairs include the application of finish
remove corrosion prevention materials. Large volumes of paint coats in the areas requiring underbody wax, carry
fumes and gases are liberated by these materials when out paint operations before applying wax.
they burn. Cavity Wax Injection
Note: The device used for removing strong After repair, be sure to use approved cavity wax for treatment.
anti-corrosion sealant can provide several speeds In addition, for all inner surfaces damaged by the repair,
and efficiency. The scraper (not pneumatic chisel) whether these areas have been treated in the production
driven by compressed air provides a relatively process, they shall be subject to a cavity wax treatment. This
quiet mechanical method by using a very rapid includes all the cavities and the door interior. If necessary,
reciprocating motion. Move the operating edge of allow additional holes to be made for wax injection, but these
the tool along the workpiece surface to remove the holes can not be located in the load-bearing parts. Make sure
sealing material. that these holes are treated by using the proper zinc-rich
primer, and brushed with protective wax, and finally sealed
The most common way is to remove the sealing material
with the rubber ring.
by using hot air dryer integrated with a blade. One of the
most effective ways is to use a "hot knife" with fast cutting Before injecting the wax, make sure the cavity to be treated
characteristics. This tool uses a wide blade that can easily is free of contaminants and foreign materials. If necessary, use
access the outline area where it is difficult to reach in some compressed air to remove the debris in the cavity.
other way.
Always ensure cavity wax injection is performed after the final
When doing the repair on the underbody sealants, follow the finish and before re-assembling other components.
following steps:
During the spray process, ensure that the cavity wax covers
1. Remove the existing underbody coating; all the flanges and seams, and be fully distributed to the repair
2. After the sheet metals are repaired, use solvents to clean areas of all new and existing sheet metals.
the affected area and use the etching phosphate materials It is noteworthy that there is no wax injection process when
to process bare metal; assembling new sheet metal and complete body shell. Such
3. Apply new primer to the affected areas; operation shall be performed after repair.
Caution: DO NOT, under any circumstances, apply It is quite essential to take efficient cavity wax protective
underbody sealer directly to bare metal surfaces. measures. Always observe the following points:
4. Replace all damaged heat-fusible plugs. If this type of plug • Before wax injection, ensure the paint repair work is
does not use such rubber grommet of appropriate size, completed;
ensure this type of plug be implanted to the sealant; • If necessary, clean the body panel areas and blow the
5. After the mechanical parts, hoses and pipe clips on the cavity prior to the operation;
underbody are removed, cover all the mounting surfaces. • During wax injection and drying, the temperature should
The underbody sealant must be sprayed before the above be at 18 ℃ (64 ℉);
components are refitted:
• Check the pattern of the injection equipment;
6. Brush all exposed seams with sealant;
1.0 630
• Cover all areas where no protective layer is needed and
the area that may be contaminated due to overspray;
• In case of possible contamination, remove the body
device, such as seat belt retractor;
• Before dealing with the internal structure of the door, lift
the door glass up to the completely closed position;
• Before refitting the components, spray wax on the body
areas which are usually covered by trims;
• After the wax layer is completely dry, check whether the
drain hole on the body and door is clean;
• Keep the equipment clean and tidy, especially the wax
nozzle.
1.0 631
Anti-corrosion Products and Construction Caution: Do not force the lance into access holes when
Equipment and Supplier using this attachment.
Cavity Waxing Machine and Technology 1100 mm movable nylon spray gun pipe: the elastic nylon
spray gun shares the same type with the rigid spray gun, but
it provides a stronger penetrability, it can be used to spray the
inaccessible vessel of the curved section or nozzle. The main
disadvantage of the elastic nylon spray gun is that it cannot
precisely position the internal compartment. When spraying,
spray outwards by the stroke of the spray gun. When pulling
the spray gun out, retract it slowly and ensure the integrity of
the finished spray. Do not pull the spray gun out with a rush.
Ensure the nylon pipe of the spray gun is away from the edge
and located in the hole so that wear of the nylon pipe can be
avoided and the service life of the nylon pipe can be prolonged.
Ensure the spray operation is stopped before removing the
nozzle from the port. To assist in the completion of this step,
1. Air Inlet use red paint to mark the rear of the nozzle (30 mm).
2. Flow Control (adjust spray mode) Hook Nozzle of Movable Spray Gun
3. Pressure Cup (1L) Max. Pressure 140 PSI (9.7 bar, 9.84 The spray gun with rigid hook nozzle provides a forward
kg/cm³) spray, its conical spray is characterised by long range and good
4. Spray Gun Connector dispersion. The combination of these two features provides a
good capability of orientation and a good effect on the short
5. Nozzle Connection of Spray Gun Pipe
and narrow locations to be sprayed, besides, it can also be
6. Retractable Spray Gun Pipe used for direct spray of the inner wheel arc, etc.
7. Rigid Hook Rod (forward, conical spray)
When using, place the smooth area at the end of the spray gun
8. Movable nylon spray gun pipe (1100 mm), 360° spray to form an angle of 180° with the location to be sprayed. For
9. Rigid spray gun pipe (1100 mm), 360° spray locations hidden in a box or hole, this helps to finish the spray
For repair, if the waxing area is scratched, handle it again. successfully.
Compressed air spray guns with the integral pressure cup and For general spray, arch the nozzle, and move from one end
replaceable spray gun pipe shall be used. to the other as required, and ensure complete spray of the
According to the configuration of the add-on device, please surface.
strictly observe the following in use: Note: Always clean gun after use with appropriate solvent
• When handling the film area, use the rigid or movable to maintain efficiency.
spray gun to give a 360° spray to ensure a maximum Recommended Equipment
coverage; 3M Schutz Pistol Spray Gun 08996 for Body: The pistol spray
• For restricted openings, use a hook nozzle to provide gun is constructed of the housing and machined light alloy,
a more directional spray (narrow inside or short which is fitted by 3M bolts to the Schutz container.
compartment);
3M Pneumatic Cartridge Pistol Spray Gun 08012: The direct
• Wax is directly sprayed to the bottom surface through feed pneumatic gun is used for the 3M cartridge product. It has
the smaller spray pipe of the spray gun, disconnect the a good performance in smooth spray, and an adjusting valve for
liquid. additional control is provided.
1100 mm rigid spray gun: the nozzle of the rigid spray gun gives 3M pneumatic pistol spray gun-08006/7: direct feed pneumatic
a forward conical spray of 360° circumference. Though the guns are used for the 3M product sealed in bags (spray gun
wax film is sprayed by a single stroke, it can affect all surfaces 08006 is used for products of 200 ml and 310 ml in bags, and
of the compartment, internal and external spray can provide spray gun 08007 is used for products of different models in
effective and complete wax coverage for the long/straight bags, including products of 600 ml).
structure and compartment. By visual inspection, the rigid
spray pipe also provides position accuracy for handling the Other applicable spray guns: heavy pistol 08013.
shapely location.
1.0 632
3M glue gun 08190: this model is used for 3M structure gluing • The cutting surface or damaged coating of the sheet
08120. metal panel requires zinc spray;
3M cavity wax film glue gun 08997: This machine can load • Zinc shall be sprayed on the contact surface of the
a tank of 1L, it is equipped with a hose of 750 mm. The welding to prevent rust of the spot welding.
approved system can be obtained from the 3M surface repair
coefficient. The Cooper Greux falcon preliminary spray gun
(airtight) is used for spraying transit wax, which has a 5L
container with a complete manual pump and achieves effective
spray without compressed air or additional operation. Use
of the nozzle, spray gun, hose length and a trigger valve
with complete filter can facilitate the application. Other
applications include general service, wax spray liquid and paint
spray. The operation may use heavy materials. All components
can be replaced and configured with different nozzles.
SATA Schutz gun UBE: the SATA gun is used for retreatment of
the bottom vehicle coated with protective paint, the spray gun
is in the special one-way container (1L). Thread parts (inner
thread of the gun) conform to the standard of most of the
Schutz product packages.
Specification of UBE:
Air consumption 7 ft3/min (200 litres/min) @
45 lbf.in2
Weight: 23.3 oz (220 grams)
SATA HKD1 waxing machine: used for retreatment of cavity

wax. SATA HKD1 device consists of the following parts:
high quality forging, gun with 1L pressure feed container,
retractable nylon spray gun pipe, 1100 mm steel pipe and hook
pipe. The replacement quick connector of the standard parts
can be used to transfer the pipe. Each spray gun is provided
with a complete nozzle machined for spray purpose, which is
applicable for the compartment to be treated.
Note: Always clean gun after use with appropriate solvent

to maintain efficiency.
Contact information of 3M supplier
3M (China) Co. Limited
Address: No. 38 building, Maxdo Centre, No. 8 Xing Yi Road,

Shanghai, China
Zip Code: 200336
Tel: 86 21 62753535
Website: www.3M.com
Zinc Spray
For locations needing MIG/MAG welding or spot welding, apply
the primer rich in zinc to the area near the connector surface,
and do not process the welding area.
Zinc spray is used for the following two situations:
1.0 633
Information of Cavity Wax Application

Doorsill
1.0 634
Door and Luggage Compartment Lid
Spray cavity wax from the process hole inside the door and luggage compartment lid to cover the internal sheet metal and
frame with a layer of protective film. Most of the cavity wax deposit is at the bottom of the sheet metal cavity, and it will be
finally drained from the hole at the bottom.
1.0 635
1.0 636
Chassis Adhesive
Function of chassis adhesive:
• Improve the stone-chipping resistance of the underbody;
• Improve the corrosion resistance of the underbody sheet
metal;
• Improve the seam sealing performance of the underbody
sheet metal;
• Improve the sound insulation performance of the
underbody.
Caution: Ensure that suspension units, wheels, tyres,
power unit, exhaust and brakes (including all mounting
points) are shielded prior to application of fresh
underbody sealer.
Operation procedures for chassis adhesive:
1. Cleaning: to ensure the maximum viscosity of the
product, the underbody surface shall be clean and free
from any dirt, oil stain, grease or wax residue.
2. Inspection: before operation, thoroughly inspect the
underbody for any potential damage or rust. Key location:
wheel arch, lower side, seam and overlap joint.
3. Dust elimination: eliminate the rust spot on the
underbody with a shovel or wire brush. Pay particular
attention to the inaccessible locations, for example,
wheel frame, overlap or seam.
4. Check the type of the underbody coating: check the type
of the underbody coating and select a suitable product.
5. Read use instruction: before operation, please carefully
read the instruction on the package of the product and
view the technical data sheet. Read the safety instruction
in the Material Safety Data Sheet carefully so that you
can minimize some potential risk and hazard and achieve
the optimum effect.
6. Use cross spray technique: spray the rust prevention
product at a distance of around 30cm, spray in the
horizontal direction first, then spray the stiffener of the
base plate from a proper angle (cross spray technique).
To achieve an optimum thickness (1.5mm) of the wet
film, at least three sprays shall be done.
7. Drying time: a specific drying time shall be defined, the
coating material shall adhere to the underbody firmly and
permanently. Different solutions and different coating
thicknesses may require different drying time. Products
with high volatile solution require 2hr drying time at least.
8. Clean spray gun: use spray gun detergent to clean the
spray gun immediately after use.
1.0 637
Body Repair Welding Process
Welding Process Resistance spot welding

Welding Process Overview The resistance spot welding is the most common method for
Characteristics of welding process: welding the integral body. This method can be used for the
non-deformable thin steel sheet on the body which requires a
• It is applicable to any shape and can be used to connect
high welding strength. Suitable for roof, window, doorsill and
the integral body, and the vehicle body integrity can be
external components, etc. The quality of the resistance spot
maintained after welding;
welding depends on the voltage, current, pressure time and
• Mass reduction can be achieved due to lack of the
thickness of the metal panel to be welded, etc, the details are
connecting parts;
as follows:
• Good sealing performance for air and water;
• Material and cleanness of the weldment: the location
• High production efficiency; between the weldments or the contact point between
• The welding connector strength is affected by the skill the weldment and the electrode shall be clean;
level of the operator; • Electrode pressing force: insufficient force can cause
• Excessive heating may cause surrounding panels spatter on the contact point; excessive force can
deformation. generate large current, but it will lead to small welding
spot diameter and penetration due to increase of the
For modern vehicles, the body welding repair usually adopts
heat distribution zone;
MAG shielded arc welding, resistance spot welding and
soldering. For the body panel welding repair, an optimum • Welding current: the welding spot diameter and welding
welding method that will not reduce the original strength and strength increase with the current, and large current
durability of the body shall be applied depending on the specific and small pressure may also lead to spatter between the
situations, spot welding or inert gas welding is preferred. panels; the spatter will be otherwise minimized;
MAG Shielded Arc Welding • Welding time: long welding time will cause much heat,
large diameter and deep penetration of the welding spot.
MAG shielded arc welding is mainly used for welding high However, prolonged welding time will lead to electrode
strength, low alloy steel body and aluminum casting, etc. impress and thermal deformation rather than increase of
Advantages of the MAG shielded arc welding include: the welding spot.
• Easy operation; • Arrangement of the welding spot: the gap and margin
• This method can melt the base metal completely, low of the welding spot (distance between the spot and the
current can be used to weld thin metal, which can panel edge) is also crucial for determining the welding
diminish damage to the adjacent area strength; spot strength. Welding spot gap decrease can improve
• Stable and controllable arc; the weldment connection strength, but the effect is
• Suitable for welding locations with gap and misalignment; actually limited. Excessive gap may cause the welding
current to transfer through the last welding spot or
• Temperature and duration of the welding is controllable,
leak, then the added welding spot will not strengthen
short heating time of the welding zone reduces fatigue
the connection strength of the weldment any more, and
and deformation of the base metal.
it will have an adverse impact, therefore, the gap of the
Typical welding locations and methods: welding spot shall be beyond the area of current leak.
• Butt welding. Fit two adjacent metal edges together, fit Correct welding sequence shall be applied for the resistance
mutually along the two metal panels or weld the butted spot welding, continuous welding in one direction is generally
edge; not allowed, when the electrode tip is hot and discolours, stop
• Overlap welding. Weld two overlapping metal panels; welding and allow it to cool down. To avoid crack due to stress
• Plug welding. Punch a hole on one or several exterior concentration, do not weld the boundary of the corner.
workpieces, arc passes through the hole before entering
into the interior workpiece, and the hole is filled with the
melting metal;
• Spot welding. When the wire feed timing pulse is
triggered, current will be introduced into the two metal
panels to be welded.
1.0 638
Welding Process Body Repair
Welding Protection Measures
Electronic Control Unit
Before welding repair is operated, in consideration of the
electronic control unit (ECU) refitted on the vehicle, the
following protection measures must be followed. The plentiful
heat and sharp vibration produced during these operations
may damage the electronic control unit.
When disconnect or remove the airbag control module

SDM, pay special attention to the following proper protection
measures.
Protection Measures for Assistant Protection
System
Implement and remove or replace any item related to the
assistant protection system (SRS), be especially careful and
comply with proper protection measures.
Equipments
When starting any test on the vehicle, ensure that the
related test equipments work normally and all harnesses and
connectors are in good state. This is especially important to
the electronic control unit.
Seat Belt Rivet Joint
Seat belt rivet joint is crucial for safety. When repairing
these areas, it is important to follow the following design
specifications. Note: High strength low alloy steel (HSLA)
can be used at the installation position for seat belts.
Try best to use the original production assembly, including rivet

joints of seat belts, or the layout of cutting line should not
interfere with the original rivet joints of seat belts.
Carefully check the welding quality of the jointing for seat belts
rivet joints within 250mm, including the spot welding spacing.
1.0 639
Welding Parts Remove

1. Expose the resistance spot welding. Use a rotary bowl
grinder or a wire brush installed into the air drill, or
manual wire brush for the spot welding is not obvious.
3. Location for laser welding: use grinder and grinding disk.
Caution: In wheel arch areas it may be necessary to soften

underbody coating, using a hot air gun, prior to exposing
spot welds.
2. The drill or clamping platoon welder for spot welding can

be used to remove the welding spot.
4. CO2-MAG Arc Welding Location
5. Rivet Junction
1.0 640
6. Big panel cutting • d. Overlap cutting

• a. Cutting by edge of steel panel
Caution: On certain panel joints MIG welds and braze

• b. Plastic sample panel cutting should be removed using a sander where possible, before
cutting out the panel bulk.
7. Separate the electric welding point with hammers, base

plate chisels and pincers, and remove the penal scraps.
• c. Dimension measurement
1.0 641
OEM Welding Information

Welding Identification
—2 layers of welding
—3 layers of welding
—MAG welding/CMT welding
1.0 642
Welding Information of Main Parts
Engine Compartment
Structure
A - Front Wheelhouse Assembly

B - Dash Panel Upper Beam Assembly
C - Dash Panel Upper Beam
D - Dash Panel Assembly
E - Front Longitudinal Beam Front Bumper Mounting Bracket
Assembly
1.0 643
Front Wheelhouse Assembly
1. Weld the front wheelhouse assembly (A) to the front

longitudinal beam assembly.
Front Longitudinal Beam Front Bumper Mounting Bracket Assembly
1. Weld the front longitudinal beam front bumper mounting

bracket assembly (E) to the front longitudinal beam assembly
(MAG welding length is 8mm).
2. Weld the dash panel upper beam assembly (B) to the front
wheelhouse assembly (A).
3. Weld the dash panel upper beam (C) to the front

wheelhouse assembly (A).
4. Weld the dash panel assembly (D) to the front wheelhouse

assembly (A).
1.0 644
Bodyside
Structure
A - Bodyside Outer Panel

B - D Pillar Crash Panel Reinforcement Assembly
C - Tail Lamp Mounting Frame Assembly
D - Rear Wheelhouse - Bodyside Extension Panel
E - Front Door Frame Reinforcement Assembly
F - Frame Inner Panel
G - Bodyside Closing Plate Assembly
H - Rear Bodyside Inner Panel Assembly
1.0 645
The bodyside assembly is welded with A, B,C, D, E, F, G and 4. Weld the fuel filler housing assembly to the right bodyside
H. Firstly weld A, B, C and D into the bodyside outer panel outer panel (A).
assembly, then weld the bodyside outer panel assembly to E, F,
G and H.
1. Weld the D pillar reinforcement assembly (B) to the

bodyside outer panel (A).
5. Weld E, F, G, H and the bodyside outer panel assembly in

turn into an assembly.
2. Weld the tail lamp mounting frame assembly (C) to the

bodyside outer panel (A).
3. Weld the rear wheelhouse - bodyside extension panel (D)

to the bodyside outer panel (A).
a - Bodyside Outer Panel
b - Front Door Frame Reinforcement Assembly
c - Bodyside Closing Plate Assembly
1.0 646
b - Rear Bodyside Inner Panel Assembly
1.0 647
A - Bodyside Assembly
B - Front Outer Frame Assembly
1.0 648
Weld the bodyside assembly to the body assembly and weld
the frame assembly to the body assembly.
1. Weld the bodyside assembly to the body assembly.
c - Rear Wheelhouse Inner Panel Assembly
b - Front Door Frame Reinforcement Assembly
c - Dash Panel Side Panel Assembly
1.0 649
2. Weld the frame assembly to the body assembly.
a - Front Wheelhouse Assembly
b - Frame Inner Panel
c - Front Outer Frame Assembly
1.0 650
Bodyside Outer Panel Service in Sections
Structure
A - Front Bodyside Outer Panel

B - Rear Bodyside Outer Panel
1.0 651
"Service in Sections" is widely used in the service of bodyside outer panel, because in accidents, the damaged parts are always
the front bodyside outer panel or the rear bodyside outer panel.
1. Weld the front bodyside outer panel
1.0 652
2. Weld the rear bodyside outer panel
c - Rear Wheelhouse Inner Panel Assembly
1.0 653
Rear End Panel Assembly

Structure
A - Rear End Panel Assembly
1.0 654
1. Weld the rear end panel (A) to the bodyside assembly.
2. Weld the rear end panel (A) to the rear door assembly.
1.0 655
Roof Panel
Structure
A - Front Roof Beam Assembly

B - Middle Roof Beam
C - Rear Roof Beam
D - Roof Panel
1.0 656
Weld the roof beam (A, B, C) to the body assembly then to the roof panel (D).
1.0 657
1.0 658
Sunroof
Structure
A - Sunroof Window Reinforcement Assembly

B - Rear Roof Beam
C - Roof Panel - With Sunroof
1.0 659
Weld the roof beam (A, B) to the body assembly then to the roof panel - with sunroof (C).
1.0 660
1.0 661
Body Repair Body Dimension
Body Dimension
Point to Point Dimensional Information
Bodyside and Top Information
1.0 662
Body Dimension Body Repair
1.0 663
Bottom Plate Information
1.0 664
Rear End Information
1.0 665
Internal Information
1.0 666
Front End Information
1.0 667
Gap Information
Body Side and Fuel Filler Cap Information
1.0 668
Front End Information
1.0 669
1.0 670
Rear End Information
1.0 671
Sunroof Information
1.0 672
Vehicle Access Safety and Restraints
Vehicle Access
System Layout
1. Horn
2. Body Control Module
3. Left Front Door Lock Assembly
4. Left Rear Door Lock Assembly
5. Tail Gate Lock Assembly
6. Right Rear Door Lock Assembly
7. Driver Side Door Lock Assembly
8. Central Lock Switch
9. Remote Key
10. Ignition Switch
11. Instrument Pack
12. Engine Control Module
1.0 673
Safety and Restraints Vehicle Access

Vehicle Access and Safety Control Diagram
1.0 674
Description
Security System
The function of the security system is to prevent illegal vehicle
start. When the ignition switch is turned to ACC position,
the anti-theft system can be disabled by the transmitter on the
remote key, this transmitter can be identified by the reader
coil around the ignition switch, and the coil transmits electric
power and data to the remote key in a frequency within a
certain distance away from the signal reader coil. The security
system includes:
• Door switch
• Tail gate switch
• Bonnet switch (if equipped)
• Safety warning lamp
• Hazard warning lamp button
• Remote key
• Ignition switch
• Body control module (BCM)
Door Switch
Each door lock assembly contains a microswitch to notify
the BCM of the door status. When the door is open, the
microswitch contact will close to connect the ground circuit of
the BCM. When the door is closed, the microswitch contact
will disconnect and convert into an open circuit. Door switch,
bonnet and luggage compartment open switches are the main
components of the alarm system. When the alarm system
works, these switches will monitor the external intrusion into
the vehicle. The door open signal is also used by the BCM to
indicate the door status information in the instrument pack
information centre and control the interior lighting.
Luggage Compartment Switch
The luggage compartment lock motor contains a microswitch
used to notify the BCM of the luggage compartment lid status.
When the luggage compartment lid is closed, the microswitch
contact disconnects and the circuit of the BCM becomes an
open circuit. When the luggage compartment lid is open, the
switch will be closed and the ground circuit of the BCM will
be connected. CANWhen the bus detects that the ground
circuit is connected, it will trigger the alarm. The luggage
compartment open microswitch is also used by the BCM to
indicate the luggage compartment status information in the
instrument pack information centre and automatically control
the interior lighting.
1.0 675
Safety and Restraints Vehicle Access
Operation Complete Anti-theft Status to Partial Anti-theft

Overview Status
Operation of Vehicle Access System In the complete anti-theft system, if a valid UNLOCK request
of the tail gate is received, the BCM opens the tail gate and
The vehicle security system includes the following three parts:
the security system enters the partial anti-theft status.
1. Peripheral system:
Partial Anti-theft Status
• Bonnet ajar alarm (if equipped), door and tail gate open
If the error lock is caused by zone 1 only (for example, the
switches
bonnet is open), zone 2 and 3 will enter the complete anti-theft
• Ignition switch status.
• Central lock (LOCK/UNLOCK) switch If the error lock is caused by zone 2 only except for the driver
2. Acoustic alarm: vehicle horn side (for example, 1 door or more doors are open), zone 1
and 3 will enter the complete anti-theft status.
3. Visible alarm: hazard warning lamp
If the error lock is caused by zone 3 only (for example, the tail
The security system is divided into three independent zones,
gate is open), zone 1 and 2 will enter the complete anti-theft
and each zone includes many discrete input signals (see the
status.
table below).
Safety zone Discrete signal
Partial Anti-theft Status to Complete Anti-theft
Status
1 (front) • Bonnet open switch (if equipped)
When each safety zone is in the security system, the vehicle
• Driver door open switch will enter the complete anti-theft status.
• Front passenger door open switch For partial locks caused by error lock due to open door,
• Left rear door open switch when the security system enters the anti-theft status, it can be
• Right rear door open switch disabled after being enabled within 5 seconds, and the alarm
2 • Driver door key unlock (timed for will not be triggered.
(middle/inside)
15s) If the partial anti-theft is caused by several zones, when the
• Wrong key is inserted into and relevant doors/lids of these zones are closed, these zones
placed in "ACC/ON" position will enter the complete anti-theft status. The entire security
• Central lock LOCK/UNLOCK system enters the complete anti-theft status only when all the
switch zones enter the status.
3 (rear) • Tail gate release switch Error Lock Alarm
With the door (bonnet, tail gate) open, and the ignition switch
Complete Anti-theft Status
in ACC, ON or START position or the engine running, when
When the three zones of the security system are closed, if using the mechanical key or remote key to send the LOCK
a LOCK request from the remote control or mechanical key request outside the vehicle, the BCM will activate the horn to
is received, the security system formally enters the complete send an acoustic alarm (appr. 30ms) to indicate error lock.
anti-theft status. Once in the complete anti-theft status, all
Disable Security System
activated safety zones will be monitored at all times. When
the switch of zone 2 or 3 is enabled, if you attempt to lock Any of the following operations will cause the BCM to disable
the system from outside, the vehicle will enter the partial lock the security system:
status and give an error lock alarm. • Valid UNLOCK request from the remote key is received.
BCMIt will monitor the following outside LOCK request • Valid UNLOCK request from the driver door switch is
signals: received.
• Valid LOCK request from the remote key is received. • A valid emergency key is inserted into and the ignition
• Valid LOCK request from the driver door lock switch is switch is shifted from the ACC position to the ON
received. position.
When the security system enters the complete anti-theft Caution: If the driver door unlock switch is stuck
status, the BCM will allow the direction indicator lamp to or the switch circuit is short-circuited, the
give three flashes.
1.0 676
emergency key will not be used to disable the
alarm; while the remote key will not be affected.
When the security system is disabled, the BCM will allow the
direction indicator lamp to flash once.
Unlock Triggered by Impact
When the airbag control module senses an impact, it will send

an UNLOCK request, and the door will unlock automatically
except in the case of external locking.
Auto Relock
After being unlocked with the remote key, the vehicle will
automatically return to the previous locked status if there is
no operation within 30 seconds. In the auto relock status, if
the ignition switch is in ACC position or a valid key exists, the
current timing of the relock timer is cancelled, and the auto
relock function is cancelled.
Auto Lock
If the driver door is closed and the vehicle is unlocked, when

the vehicle speed reaches a certain value (preset), the door
will lock automatically.
Auto Unlock
With the vehicle internally locked, turn the ignition switch to

the "OFF" position or pull out the key, the vehicle will unlock
automatically.
Door Lock Controlled by Internal Central Lock
Switch
With the driver door closed and the impact signals disabled,
press the LOCK button of the central lock switch to lock all
doors.
With the vehicle internally locked, press the UNLOCK button

of the central lock switch to unlock all doors.
When an impact occurs and the impact signal is triggered,

the door unlocks automatically. The door cannot be relocked
within current ignition cycle even if the LOCK button of the
central lock switch is pressed. With the vehicle externally
locked, the LOCK/UNLOCK button of the central lock switch
does not work.
1.0 677
Safety and Restraints Alarm System
Alarm System
System Layout
1. LF Anti-theft Coil
1.0 678
Alarm System Safety and Restraints
1.0 679
Description
The vehicle is configured with an anti-theft system connected
with the ECM. The characteristic value from the RF transceiver
will be verified, if the value matches the corresponding data,
the engine can be started. When the power is connected, the
key sends the characteristic value to the LF anti-theft coil and
the serial data circuit to the BCM through the hard wire.
Mounting Position
• LF anti-theft coil: on the IGN lock cylinder.
End View and Pin Information of LF Anti-theft Coil
Harness Connector FC009
Pin No. Description

1 IMMO Transmission Line –
2 -
3 IMMO Transmission Line +
1.0 680
Alarm System Safety and Restraints
Operation
The function of the anti-theft system is provided by the BCM,
ECM and modules which can store signals.
• LF anti-theft coil: when the ignition key is inserted into

the IGN lock cylinder and the ignition switch is in "ON"
position, the RF transceiver of the key will be switched on
by the LF anti-theft coil of the IGN lock cylinder. Then,
the RF transceiver transmits a signal which contains its
characteristic value. BCMThe BCM receives the signal
and compares the value with that stored in the memory.
If the two values match, the BCM sends a pre-cancellation

password to the ECM through the serial data circuit. If the
characteristic value of the RF transceiver is wrong, the BCM
sends fuel disable password to the ECM.
When the ECM receives the pre-cancellation password from

BCM, the ECM will verify the password. ECMThe ECM
returns the password verified to the BCM through the serial
data circuit. ECMThe ECM and BCM calculate the password.
If the result calculated by the BCM and ECM is consistent,

the ECM will allow the vehicle to start.
1.0 681
Service Procedures
Anti-theft Coil
Remove
2. Remove the steering column trim cover.
Steering Column Trim Cover Remove

3. Disconnect the connector of the anti-theft coil.
4. Release the clip and remove the anti-theft coil.
Refit
1. Connect the connector of the anti-theft coil.
2. Fasten the clips and fit the anti-theft coil.

1.0 682
Seat Belts Safety and Restraints
Seat Belts
Specifications
Torque
Description Value
Bolt - front seat belt retractor to ‘BC’ post 30–35Nm
Bolt - front seat belt to upper ‘BC’ post 30–35Nm
Bolt - front seat belt to body 30–35Nm
Bolt - front seat belt buckle 43–53Nm
Bolt - rear seat belt to upper ‘D’ post 30–35Nm
Bolt - rear seat belt retractor to rear inner wheelarch 30–35Nm
Bolt - rear seat belt double buckle 30–35Nm
Bolt-rear middle seat belt retractor 35-45Nm
Bolt - rear seat middle lap belt 30–35Nm
1.0 683
Safety and Restraints Seat Belts

System Layout
1. Rear Seat Belt Assembly 7. Front Seat Belt Assembly

2. Rear Seat Belt Retractor 8. Front Seat Belt Retractor
3. Rear Seat Central Belt 9. Front Seat Belt Buckle
4. Rear Seat Belt Assembly 10. Front Seat Belt Assembly
5. Rear Seat Belt Retractor 11. Seat Belt Not Tied Warning Lamp
6. Rear Seat Belt Buckle
1.0 684
Airbag Control Logic Diagram
1.0 685
Description webbing loose, so that the loads acting on the occupants are
Front Seat Belt Pretensioner reduced.
Front Seat Belt
In case of collision, the front seat belt pretensioner tightens,

this ensures the occupants are securely kept in their seats. The retractor of the front seat belt is fitted on the body, in the
The seat belt pretensioner unit is fixed by bolts to the seat cavity at the bottom of the B/C pillar lower trim panel. Pull
belt retractor assembly in the B/C pillar. The seat belt the belt webbing from the retractor, and fix it to the mounting
pretensioner connector is a 2-pin connector connected with point under the B/C pillar.
the body harness. Rear Seat Belt
In case of collision, the seat belt pretensioner is controlled
by the signal from the SRS ECU. The retractors of the two
pretensioners are positioned and work in the same way. Each
pretensioner unit is provided with an initiator and a propulsion
generator which act on the rotor of the seat belt retractor.
Warning: Once the pre-tensioner has been operated, it

cannot be reset. The gas generator will be exhausted. The
unit must be replaced.
Seat Belt
The seat belts provide the most basic protection for all
occupants. The restraint system also provides further
protection for the front occupants through the airbag module
and the pretensioning seat belts. The front seats are all fitted The retractor of the rear seat belt at both sides is fixed to the
with appropriate retractors and three-point belts. The vehicle reinforcement panel of the rear wheelhouse inner panel with
retractor is a type of emergency locking retractor (ELR). bolts. One end of the webbing is fixed to the upper end of the
The retractor is provided with an additional lock mechanism C pillar, the other end is fixed to the mounting point of the
which includes a webbing sensor and an automotive sensor. body floor; the retractor of the central seat belt is fixed to the
If the webbing is suddenly pulled, the webbing sensor will seat frame with bolts, and the other end is fixed to the lower
immediately start the lock mechanism. If the vehicle is part of the rear seats.
suddenly slowed down or tilts at a large angle, the automotive The right rear seat belt buckle and the central seat belt buckle
sensor will start the lock mechanism. form an assembly which is fixed by one bolt between the right
The retractor will lock in case of impact, so the front seat belt rear seat and the central rear seat. The left rear seat belt
retractor is equipped with load limiters. If the load limit has buckle is located at the occupant's right hip.
exceeded the critical level, the load limiter makes the seat belt
1.0 686
Seat Belt Warning The front seat belt buckles are integrated with the seat belt not
tied warning switch, which is connected to the instrument pack
through SRS ECU. The seat belt warning will be triggered if
the seat belt is not tied firmly during driving. The warning
message comprises an acoustic alarm and a warning lamp on
the instrument panel. To prevent unnecessary warning, some
vehicle specification specifies that a pressure sensor shall be
fitted within the foam of the passenger seat when there is no
passenger on the seat. If there is any passenger on the seat, but
the pressure sensor is not activated, then the seat belt warning
will not be triggered even if the occupant does not wear the
seat belt.
1.0 687
Operation ECU will store a related DTC in a nonvolatile memory and

Overview output a signal to illuminate the SRS warning lamp. The failure
information in the memory can be read with the scan tool.
When the remote key is inserted, the restraint system is
activated. With the ignition switch in "ON" position, the SRS Low Voltage Failure
warning lamp illuminates for 6 seconds, then goes out, this When the voltage supply is not within the specified range, the
indicates that the system is in normal condition. malfunction indicator lamp will illuminate. The DTC is stored
Side Impact in the memory.
Normal operation of the side seat airbag and head curtain Intermittent Failure
airbag depends on whether the severity level of the side impact The warning lamp will illuminate at the moment and remain
detected by the side impact sensor exceeds the threshold on in subsequent driving cycles. The warning lamp will not
for triggering the side impact sensor. When the SRS ECU illuminate in the next ignition unless the failure occurs again,
receives a trigger signal from the side impact sensor, it will but the DTC is still stored in the SRS ECU memory.
activate the side seat airbag and curtain airbag module. The
Permanent Failure
triggered gas generator can produce a large quantity of gas to
expand the airbag. The expanded airbag will eject from the For a permanent failure, the SRS lamp will illuminate when
seat upholstery, similarly, if the head curtain airbag module is the test is started, and it will remain on in every subsequent
triggered, the head airbag will eject from the interior trim panel ignition cycle until the cause of the failure is solved. In addition,
above the door to protect the passenger from head injury. The the diagnosis system will also record the information of the
fully expanded airbag will release excess gas to reduce the risk failure occurred.
of passenger injury. When any failure is detected, the system will retain certain
Warning Lamp Check operating functions:
When the ignition switch is turned on, the SRS warning lamp • If it is detected that the circuit of the SRS outside the
shall illuminate, then check the lamp. If no failure occurs in the SRS ECU is faulty, SRS ECU will still activate the airbag
SRS, the warning lamp shall go out after about 6 seconds to and seat belt pretensioner module.
monitor the subsequent ignition cycles. System check includes • When the SRS ECU failure or power supply failure is
the states of SRS ECU and SRS harness. detected, the whole system will not work.
System Continuity Fault • If the circuit of the SRS warning lamp is faulty, the
With the ignition switch ON, if any of the following faults warning lamp will not illuminate when the ignition switch
occurs in the system, the SRS warning lamp will illuminate is turned on for initial check of the warning lamp; if
and remain on during subsequent ignition cycles: there is no other faults in the system, all functions of the
system are available in case of a crash.
• ECUand SRS failures
Additional information provided by the "scan tool" for DLC
• Harness failure
includes:
• Ground connection failure
• SRS ECUDTC
• Open circuit
• Version Levels of Hardware and Software
• Airbag module failure
• Impact Mode State
• Seat belt pretensioner failure
• Vehicle Identification Number (VIN) Data
If the system detects any failure during driving, the warning
lamp will also illuminate to indicate failure of the SRS system. SRS ECUThe SRS ECU records fault information in the
When the warning lamp illuminates, the SRS will not work memory, and the information can be read by connecting the
when any impact occurs. scan tool to the DLC below the closure plate of the driver
side instrument panel.
With the ignition switch ON, the diagnosis function of the SRS
ECU will monitor the SRS. If any fault is detected, the SRS
1.0 688
Service Procedures
Front Seat Belt Assembly
Remove
1. Remove key from ignition switch, disconnect battery
leads, earth first and wait 10 minutes for theSRS
back-up power circuit to discharge before commencing
work.

2. Remove bolt securing seat belt lower anchorage.
6. Disconnect pre-tensioner multiplug, remove front seat

belt.
Refit
1. Position upper seat belt guide to pillar, fit bolt, tighten
to 30–35Nm.
2. Connect pre-tensioner multiplug.
3. Position seat belt reel to body, tighten bolt to
30–35Nm.
4. Fit lower B post trim.

5. Fit bolt securing seat belt lower anchorage, tighten to
3. Remove lower B post trim. 30–35Nm.
B Pillar Lower Trim Panel Remove 6. Connect battery leads, earth last.
4. Remove bolt securing seat belt guide to pillar. 7. Carry out system check by turning the ignition on
and checking the SRS warning light illuminates for 4
seconds and then extinguishes.
5. Remove bolt securing seat belt reel to body.
1.0 689
Front Seat Belt Buckle Rear Seat Belt Assembly

Remove Remove
1. Remove front seat. 1. Remove the rear seat cushion.
Front Seat Remove Rear Seat Cushion Remove

2. Remove bolt securing seat belt buckle to seat. 2. Unscrew 1 bolt fixing the rear seat belt to the lower
part of C-pillar.
3. Remove buckle, carefully extract buckle switch wiring.

Refit 3. Remove 1 bolt fixing the rear seat belt to the body.
1. Position seat belt buckle to seat frame, position buckle

switch wiring.
2. Fit retaining bolt, tighten to43–53Nm.
3. Refit front seat.
Front Seat Refit
4. Unscrew 1 bolt fixing the seat belt buckles of the rear

seats to the body and remove the seat belt buckles of
the rear seats.
5. Remove the rear seat backrest.

Rear Seat Back Remove
1.0 690
6. Remove the C-pillar upper trim panel. 7. Refit luggage compartment trim..
C-pillar Upper Trim Panel Remove Luggage Compartment Trim
7. Remove the C-pillar lower trim panel. 8. Refit rear seat cushion.
C-pillar Lower Trim Panel Remove Rear Seat Cushion
8. Remove the luggage compartment side trim panel.
Luggage Compartment Side Trim Panel Remove
9. Unscrew 1 bolt fixing the rear seat belt to the upper
part of C-pillar.
10. Unscrew 1 bolt fixing the rear seat belt retractor to the
rear wheelhouse inner panel.
11. Remove the rear seat belt assembly.

Refit
1. Position seat belt to body, fit bolt, tighten to 30–35Nm.
2. Position seat belt guide to C post, fit bolt, tighten to
30–35Nm.
3. Pass seat belt through C post trim.
4. Position seat belt bracket to floor, fit bolt, tighten to
30–35Nm.
5. Refit lower C post trim.
C-pillar Lower Trim Panel Refit
6. Refit upper C post trim.
C-pillar Upper Trim Panel Refit
1.0 691
Rear Seat Belt Buckle

Remove
1. Remove rear seat cushion.
Rear Seat Cushion

2. Remove bolt securing seat belt to floor.
8. Remove seat belt.

Refit
1. Position seat belt buckle to floor.
2. Fit retaining bolt, tighten to 30–35Nm.
3. Refit rear seat cushion.
3. Remove luggage compartment side trim. Rear Seat Cushion
Luggage Compartment Trim
4. Remove seat belt reel bolt.
5. Remove upper C post trim.
Upper C Post Trim

6. Remove lower C post trim.
Lower C Post Trim

7. Remove seat belt guide bolt.
1.0 692
Rear Middle Seat Belt Assembly
Remove
1. Remove the rear seat cushion.
Rear Seat Cushion Remove

2. Remove 1 bolt fixing the rear middle seat belt to the
floor.
11. Remove the rear seat back foam and take out the rear
middle seat belt retractor.
12. Pass the middle seat belt webbing through the
decorative frame hole of the seat belt on the rear seat
back, and remove the rear middle seat belt assembly.
Refit
1. Pass the rear middle seat belt webbing through the
3. Release and remove 2 headrest guide pipes.
decorative frame hole of the seat belt on the rear seat
4. Remove the screw securing the seat back release lever, back.
disconnect the connection of the rear seat back release
2. Fix the rear middle seat belt retractor to the rear seat
lever and the cable, and remove the seat back release
back frame, fit 1 bolt, tighten to 35-45Nm, and check
lever.
the torque.
5. Pull the elastic clip out of the upholstery.
3. Recover the rear seat back upholstery.
6. Release and remove the clip securing the rear seat back
4. Fix the rear middle seat belt and buckle to the body, fit
backboard.
1 bolt, tighten to 30–35Nm, and check the torque.
7. Remove the C-ring securing the rear seat back
5. Fit the rear seat cushion.
upholstery.
8. Mark the locations of the C-rings securing the seat back Rear Seat Cushions Refit
upholstery and foam, remove the C-rings, and remove
the upholstery.
9. Remove the rear seat back backboard.

10. Uncover the rear seat back upholstery, remove 1 bolt
fixing the rear middle seat belt retractor to the rear
seat back frame.
1.0 693
Safety and Restraints Supplemental In�atable Restraints
Supplemental In�atable Restraints

Specifications
Torque
Description Value
Screw-front passenger airbag to instrument panel 1.3–1.9Nm
Bolt-front passenger airbag to facia bracket 6–8Nm
Bolt - side curtain 7–9Nm
Bolt-Side impact sensor to body 7–10Nm
Bolt-Airbag control module to body 7–10Nm
1.0 694
Supplemental In�atable Restraints Safety and Restraints
System Layout
Airbag Control Diagram
1. Airbag Warning Lamp

2. Passenger Side Airbag
3. Body Control ModuleBCM
4. Left Curtain Airbag
5. Seat Side Airbag
6. Side Impact Sensor
7. Airbag Control ModuleSDM
8. Driver Seat Airbag
1.0 695

Airbag Control Diagram
1.0 696
Description severity of the side impact exceeds the preset trigger value,
Overview the SRS ECU will send a signal to activate the corresponding
side airbag, curtain airbag module and seat belt pretensioner.
The SRS can provide passive protection for the passenger
when severe impact occurs. This system is usually based on If the severity of the rear impact exceeds the preset trigger
application of the standard protection system (seat belts). value, the SRS ECU will send a signal to activate the seat belt
pretensioner.
The SRS consists of the following components:
Caution: It is important that the SRS ECU is correctly
• Supplementary restraint system ECU (SRS ECU)
mounted and is fitted in the designated location and
• Driver airbag module orientation to ensure correct operation.
• Front passenger airbag module
ECUMonitoring
• Seat side airbag module (if equipped)
After the vehicle is powered on, the SRS ECU monitors the
• Head curtain airbag module (if equipped) preparation of the SRS module. After start, it monitors the
• Seat belt pretensioner (if equipped) system continuously. SRS ECUThe SRS ECU monitors the
• Side impact sensor (if equipped) status of the following modules:
• Rotary coupler • SRS ECUInternal accelerometer
• SRS warning lamp (on the IPK) • SRS ECUMicro-processor
• Seat belt not tied warning lamp (on the IPK) • Side impact sensor (if equipped)
SRS ECUThe SRS ECU connects the vehicle DLC through • Driver side airbag module
the HS CAN bus. • Passenger side airbag module
Supplementary Restraint System ECU (SRS ECU) • Side airbag module (if equipped)
• Side curtain airbag module (if equipped)
• Seat belt pretensioner (if equipped)
• Diagnosis count
If any system failure is detected, the SRS warning lamp will

illuminate to warn the driver.
The recommended diagnostic device can be used to check

the SRS malfunction. The diagnostic information can be read
includes current malfunction, frequency of malfunction and
duration of each malfunction.
Power Supply and Backup Situation
The power supply provides voltage for the SRS ECU through
a special system fuse in the passenger compartment fuse box.
SRS ECUIt determines the affected range of the front impact,
side impact or rear impact through the internal and external In case of power failure, check the connection status of the
impact sensors (if equipped), so as to control the SRS. passenger compartment fuse box and the fuse and harness of
the SRS ECU. When the ignition switch is in "ON" position,
SRS ECUIt is fitted on the central passage beneath the centre
the SRS will be activated.
console, which is secured with three screws.
SRS ECUThe SRS ECU contains a capacitor which can save
SRS ECUIt monitors the vehicle impact through the internal
electricity and ensure the corresponding trigger device and
accelerometer and the external sensors. SRS ECUIt can
ignition circuit can still work within a specific time when regular
identify the type and severity level of the impact according to
power supply is cut off by an impact.
these input data and ensure normal operation of the airbag.
Side Impact Sensor
If the severity of the front impact exceeds the preset trigger
value, the SRS ECU will send a signal to activate the front For vehicles with side airbag module, the side impact sensor is
airbag module and seat belt pretensioners. beside the body sill frame, which is fixed on the body by screws.
The sensor is designed with a mounting position for correct
When fitting the side airbag/curtain airbag, two side impact
refit. Each sensor includes an electronic circuit and a sensing
sensors shall be fitted to monitor the side impact. If the
unit. The side impact sensor sends an acceleration signal to the
1.0 697
ECU, and the ECU determines whether to trigger it through

calculation.
Caution: The side impact crash sensors must be fitted in

the correct orientation. Ensure the fixing screws do not
damage the sensors or sensor harness when refitting the
front seats.
Driver Airbag Module
1. Airbag housing
2. Airbag cover
3. Airbag connector
4. Gas generator
The front passenger airbag module is on the glove box of the

instrument panel, right before the front passenger seat. The
airbag module is fixed on the instrument panel with bolts.
The front passenger airbag module is triggered by the control

signal from the SRS ECU. A folding airbag and a gas generator
are mounted in the module. When severe front impact is
1. Airbag cover
detected by the SRS ECU, it will trigger the gas generator
2. Housing and expand the nylon bag rapidly.
3. Gas generator Side Airbag (if equipped)
4. Airbag connector
Warning: If a new airbag module shows any sign of
The driver airbag module is fitted on the steering wheel by damage, do not use.
three bulged pins and one airbag module connector. When
fitting the driver airbag module, push the airbag module
towards the steering wheel firmly to embed the wire spring
around the airbag module into the opening of the 3 pins.
The electrical connection between the driver airbag module

and the SRS ECU is realized by the rotary coupler, which is
connected to the steering wheel by a connector.
The driver airbag module is triggered by the control signal

from the SRS ECU. A folding airbag and a gas generator are
mounted in the module. When severe front impact is detected
by the SRS ECU, it will trigger the gas generator and expand
the nylon bag rapidly.
Front Passenger Airbag Module
1. Airbag housing
Warning: After replacing the vehicle windscreen the 2. Airbag connector
Passenger Restraint System may not be capable of normal
3. Bracket
operation for 24 hours.
The side airbag is outside the seat bracket below the seat
upholstery. It can protect the rib, pelvis and upper visceral
damage, do not use.
organs in case of side impact. If the side impact is strong
enough to deploy the side airbag, the SRS ECU will send a
control signal to trigger the side airbag.
The side airbag module connector is a 4-pin connector, which

is below the seat cushion.
1.0 698
Caution: Do not try to remove the connector at the
module end, it is a permanent connection.
1.0 699
Head Curtain Airbag Module (if equipped)

damage, do not use.
1. Clip
2. Airbag connector
3. Mounting point
4. Gas generator assembly
5. Side curtain airbag
The head curtain airbag is provided to ensure all occupants'

heads will not touch the vehicle body and intruded external
objects will not hurt the occupants' bodies in case of collision.
The head curtain airbag module is in the interior trim panel

above the front and rear doors. The airbag housing and gas
generator are fixed on a bracket in the middle of the airbag
module. The front cables are at the lower part of the A pillar.
The airbag is fixed by plastic clips, which allows the airbag to
disconnect from the vehicle body after inflation.
1.0 700
Operation and passenger airbags and seat belt pretensioner are
Overview activated (side airbag may also be triggered).
When the ignition switch is in "ON" position, the SRS will be Warning Lamp Check
activated. With the ignition switch in "ON" position, the SRS When the ignition switch is turned on, the SRS warning lamp
warning lamp illuminates for several seconds, then goes out, shall illuminate, then check the lamp. If no failure occurs in the
this indicates that the system is in normal condition. SRS, the warning lamp shall go out after several seconds to
Front Impact monitor the subsequent ignition cycles.
If the front impact is severe and exceeds the threshold set in System Continuity Fault
the SRS ECU, the front airbag module and front pretensioning With the ignition switch ON, if any of the following faults
seat belt will work. occurs in the system, the SRS warning lamp will illuminate:
When the accelerometer and front impact sensor in the SRS • SRS ECUFailure
ECU detect any impact, the ECU will produce current to
• Harness failure
trigger the front airbag module:
• Ground connection failure
• The driver side front airbag module is activated to expand
• Open circuit
the airbag.
• Airbag module failure
• The passenger side front airbag module is activated to
• Seat belt pretensioner failure
expand the airbag.
If the system detects any failure during driving, the warning
When the front airbag is fully expanded, it will release the gas
lamp will also illuminate to indicate failure of the SRS system.
immediately from the passage port and provide the passenger
When the warning lamp illuminates, the SRS may not work
moving forward with gradual deceleration, this reduces the risk
when any impact occurs.
level of injury to the occupants.
With the ignition switch ON, the diagnosis function of the SRS
SRS ECUThe SRS ECU can determine the type and severity
ECU will monitor the SRS. If any fault is detected, the SRS
level of the impact. If the front impact detected by the sensor
ECU will store a related DTC in a nonvolatile memory and
is severe, the SRS ECU will send an ignition signal to the front
output a signal to illuminate the SRS warning lamp. The failure
airbag module and seat belt pretensioner.
information in the memory can be read with the scan tool.
Side Impact
Low Voltage Failure
Normal operation of the side seat airbag and head curtain
When the voltage supply is not within the specified range, the
airbag depends on whether the severity level of the side impact
malfunction indicator lamp will illuminate. The DTC is stored
detected by the side impact sensor and acceleration sensor
in the memory.
in the SRS ECU exceeds the threshold for triggering the
side impact sensor. When the SRS ECU detects severe side Intermittent Failure
impact, it will activate the side airbag, curtain airbag module When intermittent failure occurs, the warning lamp
and seat belt pretensioner. The triggered gas generator can illuminates, and it will be disabled after the failure is eliminated.
produce a large quantity of gas to expand the airbag. The The warning lamp will not illuminate in the next ignition unless
expanded airbag will eject from the seat upholstery, similarly, the failure occurs again, but the DTC is still stored in the SRS
if the head curtain airbag module is triggered, the airbag will ECU memory.
eject from the interior trim panel above the door to protect
Permanent Failure
the passenger from head injury. The fully expanded airbag will
release excess gas to reduce the risk of passenger injury. For a permanent failure, the SRS lamp will illuminate when
the test is started, and it will remain on in every subsequent
Front Impact with Angle
ignition cycle until the cause of the failure is solved. In addition,
When a front impact with angle happens, whether the airbag the diagnosis system will also record the information of the
and seat belt pretensioner work depends on the speed and failure occurred.
angle of the impact. There are several conditions:
Additional information provided by the "scan tool" for DLC
• The impact is below the threshold of the impact sensor
includes:
in the SRS ECU, and no airbag or seat belt pretensioner
is activated. • SRS ECUDTC
• The speed and angle of impact exceed the triggering • Version Levels of Hardware and Software
threshold of the front impact sensor, and the front driver • Vehicle Identification Number (VIN) Data
1.0 701
SRS ECUThe SRS ECU records fault information in the scan tool to the DLC below the closure plate of the driver
memory, and the information can be read by connecting the side instrument panel.
1.0 702
Service Procedures Instrument Panel Airbag
Remove 1. Disconnect the battery negative. Wait for 10 minutes
Warning: It is imperative that before any work until the SRS backup circuit is discharged.
is undertaken on the SRS system the appropriate 2. Remove the instrument panel assembly.
1. Disconnect the battery negative. Wait for 10 minutes
3. Remove 2 screws fixing the passenger front airbag
until the SRS backup circuit is discharged.
module to the instrument panel.
2. Adjust the steering wheel to the lowest position.
3. Adjust the depth of the steering wheel and pull it
outwards to the end.
4. Pry off the upper trim cover of the steering column to
spare room for removing the airbag lock ring.
5. Rotate the steering wheel to expose the airbag lock
ring.
6. Pry off three lock rings from the lower part of the
steering wheel with a flat-bladed screwdriver to release
three PINs fixing the airbag to the steering wheel.
4. Remove 9 clamping jaws fixing the passenger front

airbag module to the instrument panel, and remove the
passenger front airbag module.
7. Disconnect the airbag connector.

8. Remove the steering wheel airbag.
Refit
1. Connect the driver airbag connector.
2. Place the driver airbag in the steering wheel mounting
Refit
position, with the three protruding pins of the airbag
aligned with the three concave holes in the steering 1. Fix the passenger front airbag module to the instrument
wheel. panel, and fit 9 clamping jaws.
3. Push the driver airbag into the steering wheel till a click 2. Fit 2 screws fixing the passenger front airbag module
can be heard. onto the instrument panel, tighten to 1.3–1.9Nm and
check the torque.
4. Position the steering column upper trim cover onto the
lower trim cover, and fit the clip. 3. Fit the instrument panel body assembly.
5. Restore the steering wheel. Instrument Panel Body Assembly Refit
6. Connect the negative battery. Check the system, rotate 4. Fix the passenger side airbag module bracket onto the
the ignition switch, and check whether the SRS warning instrument panel frame, fit 2 bolts, tighten to 6–8Nm
lamp illuminates for several seconds, and then goes out. and check the torque.
5. Connect the airbag module connector.
6. Connect the negative battery. Check the system, rotate
1.0 703
the ignition switch, and check whether the SRS warning Head Curtain Airbag
lamp illuminates for several seconds, and then goes out. Remove
1. Remove the key from the ignition switch, and
disconnect the battery positive and negative (disconnect
the ground first). Wait for 10 min until the SRS backup
circuit is discharged.
2. Remove the roof interior.
3. Disconnect the electrical connector from the curtain
airbag.
4. Untie the airbag drawstring from the A pillar.
5. Remove the screw fixing the curtain airbag to the body

and the curtain airbag hooks on the body.
6. Remove the bolt fixing the airbag motor to the bracket
and the curtain airbag.
Refit
1. Locate the side curtain airbag to the roof panel and
press the clips. Fit 4 retaining bolts, tighten to 7–9Nm,
2. Fit 1 bolt securing the gas generator of the curtain
airbag, tighten to 7–9Nm, and check the torque.
3. Fix the front drawstring of the side curtain airbag to the
A pillar, fit the hooks, and press the clips.
1.0 704
4. Connect the harness connector of the side curtain Side Impact Sensor
airbag. Remove
5. Fit the roof interior. 1. Disconnect the battery negative.
Roof Interior Refit 2. Remove the front seat assembly.
6. Connect the battery negative. Front Seat Assembly Remove
7. Turn on the ignition switch, and check if the SRS 3. Remove 1 bolt fixing the front seat belt to the carpet,
warning lamp illuminates for 6s and then goes out. and remove the seat belt.
4. Remove the B pillar lower trim panel.
B Pillar Lower Trim Panel Remove

5. Lift the carpet, and remove 1 bolt fixing the side impact
sensor to the body.
6. Disconnect the harness connector and remove the side
impact sensor.
Refit
1. Fix the side impact sensor to the body, fit 1 bolt, tighten
3. Fit the B pillar lower trim panel.

4. Fit and tighten 1 bolt fixing the front seat belt to the
carpet.
5. Fit the front seat assembly.
Front Seat Assembly Refit

1.0 705
Airbag Control Module

Remove
1. Disconnect the battery negative, and wait for 10
minutes until the SRS ECU internal circuit is discharged.
2. Remove the centre console upper trim panel.
Centre Console Upper Trim Panel Remove
3. Remove 3 bolts fixing the airbag control module to the
body.
4. Disconnect the harness connector and remove the
airbag control module.
Refit
1. Fix the airbag control module to the body, fit 3 bolts,
4. Programme and encode the sensing and diagnostic
module (SDM).
SIPS.
b. Select "Programming and Coding - SDM -

Replacement", and operate as per the instructions
on the screen.
c. The procedures for replacement already include

procedures for update, configuration and setting
(lock module).
d. If it prompts "Failed" during the replacement, please

operate as per the interface prompts.
5. Fit the centre console upper trim panel.
Centre Console Upper Trim Panel Refit

6. Place the ignition switch in "ON" position, and check if
the SRS warning lamp illuminates for several seconds
and then goes out.
1.0 706
Park Assistant System Safety and Restraints
Park Assistant System
System Layout
Parking Distance Control System Layout
1. Instrument Pack
2. Rear Ultrasonic Sensor (if equipped)
3. Rearview Camera (if equipped)
4. (I) Radio (if equipped); (II) Entertainment mainframe (if
equipped)
5. Body Control Module (BCM)
6. Gear Shift Selection Switch (AT)
1.0 707
Safety and Restraints Park Assistant System

PDC System Control Diagram - MT
1.0 708
PDC System Control Diagram - AT
1.0 709
Description End View and Pin Information of Harness

Rear Obstacle Detection (if equipped) Connector
During reversing, if the vehicle has to go through obstructions End View and Pin Information of Rear Camera
on the road, the PDC will send a warning to the driver. The Connector BY025
system consists of the ultrasonic sensor fitted on the rear
bumper and the instrument pack. When the vehicle is in
reverse gear, the ultrasonic sensor is used to monitor the area
around the rear bumper, if any object is detected within the
monitoring area, the acoustic alarm device in the instrument
pack will send an acoustic alarm. The system is able to detect
relatively hard solid objects and objects like wire fence.
If the rear camera is fitted, the image of the rear vehicle will
be displayed on the entertainment mainframe display during
reversing.
Rear Ultrasonic Sensor (if equipped)
The ultrasonic sensors are fixed on the rear bumper. All the
sensors share the same structure, with the colors matching the
Pin No. Description
vehicle.
1 Signal Ground
The detection range of the rear ultrasonic sensor involves the
2 Ground
area 1200mm away from the back of the bumper. The alarm
3 Video Signal
frequency increases with the shortened distance between the
object and the vehicle when the distance ranges from 300mm 4 Camera Power Supply
to 1200mm. When the object is 300mm away from the vehicle,
End View and Pin Information of Right PDC Sensor
the alarm becomes consecutive alarm. Connector BY202
Acoustic Alarm
The acoustic alarm in the instrument pack can inform the
driver of the system status by acoustic alarm.
Rear Camera (if equipped)
Pin No. Description

1 Ground
2 -
3 LIN2
The rear camera is between the two rear license plate lamps
4 Power supply
under the tail gate, which can provide the driver with real-time
image around the rear of the vehicle and help the reverse
operation.
1.0 710
End View and Pin Information of Middle PDC Sensor
Connector BY203
Pin No. Description

1 Ground
2 LIN1
3 LIN2
4 Power supply
End View and Pin Information of Left PDC Sensor

Connector BY204
Pin No. Description

1 Ground
2 Ground
3 LIN2
4 Power supply
1.0 711
Operation Detection Zone

Overview
The system starts to run when the ignition switch is in "ON"
position.
After the ultrasonic sensor receives the reverse gear signal,

it outputs signals to the acoustic warning device, then the
acoustic warning device will give an acoustic alarm ("beep"),
this indicates that the system is activated. Then, it receives
the distance information from the ultrasonic sensor and
determines whether there is any object in the detection range.
If there is no object, it will not send an acoustic alarm; if any
object is detected, it outputs signals to the acoustic warning
device and controls the device to provide a repetitive acoustic
alarm.
The table below shows the relationship between the alarm
From the edge of the detection zone, about 1200mm from the level/obstacle distance and the acoustic alarm:
rear vehicle, the alarm frequency increases with the shortened
distance between the object and the vehicle, when the object is
300mm away from the vehicle, the alarm becomes consecutive
alarm.
SN. Alarm Level Distance (mm) Alarm Cycle (msec)
1 00 = No >1200
Obstacle
2 01 = Zone 1 0 - 300
3 02 = Zone 2 300 - 450
4 03 = Zone 3 450 - 600
5 04 = Zone 4 600 - 750
6 05 = Zone 5 750 - 900
7 06 = Zone 6 900 - 1050
8 07 = Zone 7 1050 - 1200
Caution: Blind spots, areas where the sensor cannot

detect obstructions, may occur if obstructions are present
at distances of around 200 mm from the sensors.
1.0 712
Service Procedures Camera
Ultrasonic Sensor Remove
1. Disconnect the battery negative. 2. Remove the rear bumper.
2. Remove the rear bumper. Rear Bumper Remove
Rear Bumper Remove 3. Release the clip to remove the rearview camera
3. Disconnect the connector of the ultrasonic sensor. assembly.
Refit
1. Fit the rearview camera to the rear bumper.
Rear Bumper Refit

4. Remove the ultrasonic sensor from the ultrasonic

sensor bracket.
Refit
1. Snap the ultrasonic sensor in its bracket on the rear
bumper.
2. Connect the connector of the ultrasonic sensor.
Rear Bumper Refit

1.0 713
1.0 714
Entertainment and Navigation Information and Entertainment
Entertainment and Navigation
Specifications
Torque
Description Value
Nut-Roof antenna to body 3–4Nm
Bolt-Colour radio to instrument panel 1.4–1.8Nm
1.0 715
Information and Entertainment Entertainment and Navigation

System Layout
1. Instrument Pack 7. Rear Door Woofer (if equipped)

2. Steering Wheel Entertainment Switch 8. USB Port
3. Entertainment Player 9. Front Door Woofer
4. Microphone 10. Tweeter
5. Radio Antenna 11. Entertainment Control Panel
6. Rearview Camera 12. Body Control ModuleBCM
1.0 716
Entertainment Player System Control Diagram
A = Hard Wire; B = HS CAN Bus; C = LIN Bus
1.0 717
Description
Overview
Entertainment mainframes with medium configuration support
radio, USB, bluetooth phone, video, picture, etc.
Entertainment Player Control Button
1. Sound Source Switch Button 4. Next Track Button

2. Previous Track Button 5. Mute Button
3. VOL Knob and On/Off Button
1.0 718
Audio Control Button on Steering Wheel Antenna
The audio device can be controlled by the remote switches Radio antenna.
on the steering wheel. These function buttons can allow the
most common functions in the ICE system to be used in a
much more convenient manner.
Harness Connector of Entertainment Player

End View and Pin Information of Harness Connector
BY096 (Entertainment Player)
Woofer
The woofers are fitted inside the door and fixed on the door
panel with 3 screws.
Pin No. Description

A1 Right Rear Audio +
Tweeter A2 Right Front Audio +
The tweeters are fitted on the left/right A pillars and fixed on A3 Left Front Audio +
the A pillar trim panel with clips. A4 Left Rear Audio +
A5 Right Rear Audio -
A6 Right Front Audio -
A7 Left Front Audio -
A8 Left Rear Audio -
B9 -
B10 Battery Power (when the lamp
switch is in position 1/2)
B11 -
B12 -
B13 -
B14 Battery Power (when the ignition
switch is in ACC position)
1.0 719
Pin No. Description End View and Pin Information of Harness Connector
BY220 (Entertainment Player)
B15 Battery Power
B16 Ground
C1 -
C2 -
C3 Steering Wheel Button Signal
Ground
C4 Steering Wheel Button Signal 1 +
C5 Microphone Ground
C6 High Speed CAN Bus
C7 -
C8 -
C9 -
C10 Steering Wheel Button Signal 2 +
Pin No. Description
C11 Microphone +
1 USB Power Supply
C12 HS CAN Low
2 USB Data -
D1 -
3 USB Data +
D2 -
4 -
D3 -
5 USB Ground
D4
D5 Rear Camera SHLD Shield
D6
D7 End View and Pin Information of Harness Connector
BY226 (Radio with Medium Configuration)
D8 -
D9 -
D10 Lin
D11 Rear Camera GND
D12
Pin No. Description

1 AM/FM signal
2 Ground
1.0 720
Operation
For more information about the operation of the
entertainment system, please refer to "User Manual" and the
operating instructions inside the entertainment mainframe.
1.0 721
Service Procedures Front Door Woofer

Radio Antenna Remove
Remove 1. Remove front door trim panel.
1. Disconnect the battery negative. Front Door Trim Remove
2. Remove the roof interior. 2. Disconnect speaker electrical connector.
Roof Interior Remove 3. Remove 3 fixing screws.
3. Remove 1 nut fixing the radio antenna to the roof and
disconnect the harness connector.
4. Remove the radio antenna.
4. Remove speaker
Refit
1. Position speaker in door.
Refit
2. Fit and tighten the screws.
1. Fix the roof antenna to the body, fit the harness, fit the
3. Refit electrical connector.
retaining nut, tighten to 3–4Nm, and check the torque.
4. Refit front door trim.
2. Fit the roof interior.
Front Door Interior Trim Panel Refit
Roof Interior Refit
1.0 722
Rear Door Woofer Tweeter
Remove Remove
1. Remove the rear door interior trim panel. 1. Remove the tweeter from A pillar upper trim panel.
Rear Door Interior Trim Remove

2. Loosen the rear door woofer connector.
3. Unscrew 3 screws fixing the woofer to the rear door,
and remove the woofer.

Refit
1. Connect the tweeter connector.
2. Refit the tweeter into the A pillar upper trim panel.
Refit
1. Fix the woofer to the rear door, refit and tighten 3
screws.
2. Connect the woofer connector.
3. Refit the rear door interior trim panel.
1.0 723
Player Microphone
Remove Remove
2. Remove the central control panel of the instrument 2. Pry off the microphone assembly.
panel.
Central Control Panel of Instrument Panel
Remove
3. Remove 4 screws fixing the entertainment mainframe
to the instrument panel, disconnect the harness
connector, and remove the entertainment mainframe.
3. Disconnect the connector of the microphone.

4. Remove the microphone from the microphone bracket.
Refit
1. Embed the microphone into the bracket.
2. Connect the connector of the microphone.
3. Fit the microphone assembly.
Refit
2. Fix the mainframe to the instrument panel, fit 4 screws,
tighten to 1.4–1.8Nm, and check the torque.
4. Fit the central control panel of the instrument panel.
Central Control Panel of Instrument Panel

Refit
1.0 724
Displays and Gauges Information and Entertainment
Displays and Gauges
Specifications
Torque
Description Value
Bolt-Clusters to instrument panel 1.3–1.9Nm
1.0 725
Information and Entertainment Displays and Gauges

System Layout
1. Instrument Pack
1.0 726
1.0 727
Description Information type Transmitted by Received by

Overview Oil Pressure
Hard Wire Instrument Pack
The instrument pack is connected to the instrument panel Status
harness and secured on the instrument panel assembly with TPMS Status TPMS Instrument Pack
3 screws. SCS Status SCS Instrument Pack
The instrument pack is a packaged component (assembly), so TC Status SCS Instrument Pack
it cannot be disassembled for maintenance. Press the trip Brake Fluid Status SCS Instrument Pack
computer button on the top of the lamp lever switch to switch High Beam Status BCM Instrument Pack
the interface of the information centre and to reset Trip A, Trip
B, average fuel consumption and average speed. Status of
Right/Left
Communication Signal BCM Instrument Pack
Direction
The instrument pack receives/sends information via the HS Indicator Lamp
CAN. Nodes of the HS CAN include: ECM, BCM, TCM,
Key Battery Low BCM Instrument Pack
SDM, SCS, etc. The table below shows the signals received
and sent by the instrument pack. Anti-theft Alarm
BCM Instrument Pack
Status
Information type Transmitted by Received by
Tail Gate Open BCM Instrument Pack
Wheel Speed
ABS/SCS Instrument Pack Engine Speed ECM Instrument Pack
Pulse Signal
ABS Malfunction Start by Key ECM Instrument Pack
ABS Instrument Pack
Indicator Lamp Status of Width
BCM Instrument Pack
Status of Seat Belt Lamp
SDM Instrument Pack
(driver/passenger) Status of Rear Fog
BCM Instrument Pack
Airbag Warning Lamp
SDM Instrument Pack
Lamp Gear Information TCM Instrument Pack
Door Status BCM Instrument Pack Transmission
Cruise Control Failure TCM Instrument Pack
ECM Instrument Pack Information
Status
Engine Some of the models are connected with the PDC sensor by
Malfunction ECM Instrument Pack
Indicator Lamp the hard wire and receive signals from the sensor to assist the
driver with parking.
Engine Emission
Malfunction ECM Instrument Pack
Indicator Lamp
1.0 728
Harness Connector Pin No. Description
End View of Instrument Pack Harness 29 High Beam
Connector (FC006) 30 PDC Acoustic Alarm Input
31 Fuel Sensor Signal +
32 -
The instrument pack mainly includes the following

functions:
Tachometer
The tachometer indicates the engine speed in revolutions per

minute (RPM) (X1000). The red section of the high-speed end
of the tachometer is used to warn the driver high engine speed
can damage the engine. When the ignition switch is in ON
Detailed Pin Information of Instrument Pack position, the instrument pack uses the HS CAN bus to receive
Harness Connector the engine speed signal from the ECM.
Pin No. Description Speedometer
1 KL.30
The speedometer indicates the vehicle speed with pointer.
2 -
ABSThe vehicle speed is calculated by collecting the wheel
3 IMMO Transmission Line_2 speed pulse signal. The instrument pack receives the vehicle
4 IMMO Transmission Line_1 speed signal from the ABS module via HS CAN bus and
5 IMMO Clock Line displays it after correction computation.
6 IMMO Data Line Fuel Gauge

7 - The fuel level of the fuel tank is indicated in the speedometer
8 Ground by the number of the bar segments illuminated.
9 - Warning Information
10 BCM Acoustic Request For warning information, please refer to "Information Centre"
in the "Instrument and Control" section of the User Manual.
11 -
12 Brake Fluid Level Warning Lamps and Indicators
13 Seat Belt (Driver) Cruise Control Indicator (if equipped)

14 -
It receives the signal from the ECM to inform the
15 Hand Brake
driver of the current state of cruise control system.
16 Fuel Sensor Signal -
Engine Coolant Temperature Warning Lamp
17 KL.15
18 KL.R It receives the signal from the ECM to inform the
19 Seat Belt (Passenger) driver of the high/low engine coolant temperature.
20 Left Direction Indicator Lamp Signal Engine Malfunction Indicator Lamp
21 Alternator Charging
22 Engine Oil Pressure It receives the signal from the ECM to inform the
23 Driver Door Open driver that failure seriously affecting the engine performance
exists in the EMS.
24 Trip Computer Switch
25 Right Direction Indicator Lamp Signal Engine Emission Malfunction Indicator Lamp
26 HS CAN H
It receives the signal from the ECM to inform the
27 HS CAN L
driver that failure seriously affecting the engine performance
28 -
and emission exists in the EMS.
1.0 729
Alternator Malfunction Indicator Lamp Width Lamp Indicator
It receives the signal from the ECM to inform the It receives the signal from the BCM to remind the
driver of the alternator failure. driver that the width lamp illuminates.
Low Oil Pressure Warning Lamp Rear Fog Lamp Indicator
It receives the signal from the hard wire to inform It receives the signal from the BCM to remind the
the driver that the current oil pressure is low, which may cause driver that the rear fog lamp illuminates.
serious damage to the engine.
Direction Indicator Lamp
TPMS Warning Lamp (if equipped)
It receives the signal from the BCM to remind the
It receives the TPMS status signal from the TPMS driver that the direction indicator lamp illuminates. If the
to inform the driver of the low tyre pressure or TPMS failure. hazard warning lamps are enabled, both direction indicator
lamps will flash together.
ABS Malfunction Indicator Lamp
Anti-theft System Warning Lamp
It receives the signal from the ABS to inform the
driver of the ABS failure. It receives the signal from the BCM. If the anti-theft
system cannot identify the valid key, the lamp illuminates.
SCS/TC Warning Lamp
When the BCM receives a RF signal of low remote key battery,
It receives the signal from the SCS to inform the the lamp flashes.
driver whether the SCS/TC fails. Door Open Warning Lamp
If this lamp flashes during driving, the system is operating to
assist the driver. It receives the signal from the BCM. If any door, tail
gate or bonnet is open, the lamp illuminates.
SCS/TC OFF Warning Lamp
Transmission Malfunction Indicator Lamp
It receives the signal from the SCS to inform the
driver that the SCS/TC is in OFF state. It receives the signal from the TCM to inform the
driver of the automatic transmission failure.
Brake System Malfunction Indicator Lamp
Information Centre
It receives the signal from the SCS to inform the The information centre provides the followings:
driver of the brake system failures such as lack of brake fluid
or electronic braking force distribution (EBD) failure.
6 140
160
5 7 180
Untied Seat Belt Warning Lamp 4

8
120
100
200
3 80
60
2 km/h
It receives the signal from the SDM to remind the 40

1/min x 1000
1 20
0 0
driver to fasten the seat belt.

2
Airbag Warning Lamp
1 0ABL/100km/ h
It receives the signal from the SDM to inform the

SRS failure. 1. Gear Information（if equipped)
High Beam Indicator 2. Vehicle Information Display
（if equipped)
Gear Information（
It receives the signal from the BCM to remind the
With the ignition switch in ON position, it displays the current
driver that the high beam illuminates.
shift lever position (P, R, N, D, 1, 2, 3, 4, S) of the automatic
transmission.
1.0 730
Vehicle Information Display 9,999km, it will reset automatically. Trip A and Trip B can
be reset independently so that the vehicle can record the trip
The vehicle information display provides the followings:
separately.
Range to Empty
It displays the approximate mileage without refueling. "Range
to Empty" will be recalculated after refueling.
The "Range to Empty" is calculated by the average fuel

consumption and the remaining fuel in the fuel tank of the
latest driving record.
Instantaneous Fuel Consumption
"Instantaneous Fuel Consumption" is calculated by the vehicle
automatically. When the vehicle is stationary or the vehicle
speed is very low, the "Instantaneous Fuel Consumption"
displays "—L/100km".
• Total Mileage Average Fuel Consumption
• Trip A This function is to calculate the average fuel consumption of the
• Trip B current trip since last resetting (the average fuel consumption
• Range to Empty is calculated based on the amount of fuel consumed in a certain
• Instantaneous Fuel Consumption mileage). "Average Fuel Consumption" can be reset at any time
so as to record the average fuel consumption in a certain trip
• Average Fuel Consumption
or under certain driving conditions.
• Average Speed
Note: "Average Fuel Consumption" is related to the
• Next Maintenance
driver's driving style, road condition, vehicle
Short press (less than 2s) the button on the tail end of the load, tyre pressure, power of the electrical
steering lever switch (as indicated by the arrow) repeatedly, equipment, oil product, etc.
the above information will be displayed in cycles.
Average Speed
When Trip A, Trip B, Average Fuel Consumption or Average This function is to calculate the average speed of the current
Speed is selected for display, long press (more than 2s) the trip since last resetting. "Average Speed" can be reset at any
button on the tail end of the steering lever switch, the selected time so as to record the average speed in a certain trip or
item can be reset. under certain driving conditions.
Total Mileage Next Maintenance
It displays the total mileage of the vehicle. It displays maintenance symbols, remaining mileage till next
Trip A and Trip B maintenance.
It displays the mileage since last resetting. Note: "Mileage till Next Maintenance" can only be
reset by the MG Authorised Repairer.
Trip A and Trip B are two independent mileage records. The
display range is within 0-9,999km. When the mileage exceeds
1.0 731
Operation activated, after self-check, the following warning lamps remain

Operation Mode ON:
The specific function of the instrument pack available at a given • Low Oil Pressure Warning Lamp
time depends on the position of the ignition switch. • Engine Emission Malfunction Indicator Lamp
Ignition Switch OFF • Alternator Malfunction Indicator Lamp
When the ignition switch is off, if the vehicle battery is Ignition Switch "Start"
connected, the instrument pack will be kept in "standby When the engine is started, all the lamps will go out. If there's
mode". any warning lamp remains ON, the corresponding system is
Ignition Switch ON failed.
It refers that the ignition switch is powered on, check before
driving is performed by the instrument pack, and CAN bus is
1.0 732
Service Procedures
Instrument Pack
Remove
2. Remove the instrument pack frame.
Instrument Pack Frame Remove

3. Remove 3 screws fixing the instrument pack to the
instrument desk.
4. Disconnect the connector of the instrument pack.

5. Remove the instrument pack.
Refit
1. Connect the connector of the instrument pack.
3. Connect the scan tool to the vehicle and access the
SIPS.
4. Select "Programming and Coding - IPK - Replacement",
and operate as per the instructions on the screen.
5. Fix the instrument pack to the instrument desk, fit 3
screws, tighten to 1.3–1.9Nm, and check the torque.
6. Fit the instrument pack frame.
Instrument Pack Frame Refit
1.0 733
1.0 734
Power and Signal Power and Signal
Power and Signal
Specifications
Torque
Description Value
Bolt-Engine compartment fuse box to battery bracket 6–8Nm
Nut-Engine compartment fuse box to body 6–8Nm
Bolt-Engine cable to Engine compartment fuse box 6–9Nm
Bolt-Battery positive cable to Engine compartment fuse box 6–9Nm
1.0 735
Service Procedures 8. Connect the battery negative.

Engine Compartment Fuse Box
Remove
2. Remove the upper cover of the engine compartment
fuse box.
3. Remove 1 bolt (1) fixing the positive battery cable to
the fuse box.
4. Remove 1 bolt (4) fixing the engine harness to the fuse
box.
5. Remove 1 nut (2) fixing the engine compartment fuse
box to the body.
6. Remove 2 bolts (3) fixing the engine compartment fuse
box to the battery bracket.
7. Remove 2 bolts fixing the coolant expansion tank to

the body and remove the expansion tank.
8. Disconnect the harness connector on the back of the
engine compartment fuse box and remove the engine
compartment fuse box.
Refit
1. Connect the harness connector on the back of the
fuse box.
2. Fix the coolant expansion tank to the body, fit and
tighten 2 bolts.
3. Fix the engine compartment fuse box to the battery
bracket, fit 2 bolts, tighten to 6–8Nm, and check the
torque.
4. Fix the engine compartment fuse box to the body, fit 1
nut, tighten to 6–8Nm, and check the torque.
5. Fix the engine harness to the engine compartment
fuse box, fit 1 bolt, tighten to 6–9Nm, and check the
torque.
6. Fix the positive battery cable to the engine
compartment fuse box, fit 1 bolt, tighten to 6–9Nm,
7. Fit the upper fuse box cover.
1.0 736
Instrument Panel Harness Body Harness
Remove Remove
2. Remove the instrument panel assembly. 2. Remove the front bumper assembly.
Instrument Panel Assembly Remove Front Bumper Assembly Remove

3. Disconnect the body harness connector. 3. Disconnect the harness connector of the horn.
4. Disconnect the harness connector of the engine
compartment lock.
4. Disconnect the harness connector of the

communication module, and remove the instrument
panel harness. 5. Disconnect the harness connector of the cooling fan
Refit motor.
1. Fit the instrument panel harness and secure with clips. 6. Disconnect the harness connector of the cooling fan
2. Connect the body harness connector. relay.
3. Fit the instrument panel assembly. 7. Remove the engine compartment fuse box.
Instrument Panel Assembly Refit Engine Compartment Fuse Box Remove

4. Connect the battery negative. 8. Loosen the ground point of the left front longitudinal
beam.
Battery Tray Remove

10. Remove the brake modulator.
Brake Modulator Remove

11. Disconnect the harness connector of back up lamp
switch.
1.0 737
12. Disconnect the harness connector of the left head lamp. 19. Disconnect the harness connector of the inertia switch.
13. Loosen the ground point under the ABS modulator. 20. Disconnect the harness connector of the brake fluid
level sensor.
21. Disconnect the harness connector of the brake vacuum
sensor.
22. Disconnect the harness connector of the right front
wheel speed sensor.
14. Disconnect the harness connector of the left front

wheel speed sensor.
15. Disconnect the engine harness connector.
23. Disconnect the harness connector of the right head

lamp.
24. Remove the washer reservoir assembly.
Washer Reservoir Assembly Remove
25. Loosen the ground points fixed to the right front
longitudinal beam.

27. Remove the carpet assembly.
16. Remove the A/C Hard Pipe Assembly. Carpet Assembly Remove
A/C Hard Pipe Assembly Remove 28. Disconnect the harness connector of the BCM.
17. Remove the A/C air inlet grille. 29. Loosen the ground point under the BCM.

18. Disconnect the harness connector of the front wiper
motor.
1.0 738
38. Remove the roof interior.
Roof Interior Remove

39. Disconnect the harness connector of the tweeter.
40. Disconnect the harness connector of the sunroof
motor.
30. Disconnect the harness connector of the accelerator

pedal.
31. Disconnect the harness connector of the brake pedal.
32. Disconnect the harness connector of the clutch pedal.
33. Disconnect the harness connector of the DAB.
41. Disconnect the harness connector of the curtain airbag.
34. Loosen the ground point under the DAB.

35. Disconnect the connector between body harness and 42. Disconnect the harness connector of the radio antenna.
instrument panel harness.
43. Disconnect the harness connector of the airbag control

36. Disconnect the harness connector of the wiper lever module.
switch.
37. Disconnect the harness connector of the lamp lever
switch.
1.0 739
44. Disconnect the connector between body harness and 52. Loosen 3 ground points around the left tail lamp
front door harness. assembly.
45. Disconnect the harness connectors of the seat belt
pretensioners on both sides.
46. Disconnect the harness connectors of the impact
sensors on both sides.
47. Loosen the ground point under the front seat.
53. Disconnect the harness connector of diode.

54. Remove the tail gate interior trim panel.

55. Disconnect the harness connectors of the rear window
heating elements on both sides.
48. Disconnect the harness connector of the rear door.
56. Disconnect the harness connector of the rear wiper
49. Remove the luggage compartment side trim panel. motor.
Luggage Compartment Side Trim Panel Remove 57. Disconnect the harness connector of the tail gate lock.
50. Remove the tail lamp assembly. 58. Disconnect the harness connector of the tail gate
release switch.
Tail Lamp Assembly Remove
51. Loosen 2 ground points under the right tail lamp
assembly.
1.0 740
59. Remove the high-mounted stop lamp assembly. switch.
High-mounted Stop Lamp Assembly Remove 8. Connect the harness connector of the tail gate lock.
60. Remove the rear bumper assembly. 9. Connect the harness connector of the rear wiper
motor.
Rear Bumper Assembly Remove
10. Connect the harness connectors of the rear window
61. Pry off the fuel pump cover, and disconnect the fuel
heating elements on both sides.
pump harness connector.
12. Connect the harness connector of the diode.
13. Tighten 3 ground points around the left tail lamp
assembly.
14. Tighten 2 ground points under the right tail lamp
assembly.
15. Fit the tail lamp assembly.
Tail Lamp Assembly Refit
16. Fit the luggage compartment side trim panel.
Luggage Compartment Side Trim Panel Refit
17. Connect the harness connector of the rear door.
62. Disconnect the harness connector of the right rear
wheel speed sensor. 18. Tighten the ground point under the front seat.
63. Disconnect the harness connector of the left rear 19. Connect the harness connectors of the impact sensors
wheel speed sensor. on both sides.
20. Connect the harness connectors of the seat belt
pretensioners on both sides.
21. Connect the connector between body harness and
front door harness.
22. Connect the harness connector of the airbag control
module.
23. Connect the harness connector of the radio antenna.
24. Connect the harness connector of the curtain airbag
on both sides.
25. Connect the harness connector of the sunroof motor.
26. Connect the harness connector of the tweeter.
27. Fit the roof interior.
64. Loosen the harness clip, and remove the body harness.
Roof Interior Refit
Refit
28. Connect the harness connector of the lamp lever
1. Arrange the harness to the body and secure with clips.
switch.
2. Connect the harness connector of the left rear wheel
29. Connect the harness connector of the wiper lever
speed sensor.
switch.
3. Connect the harness connector of the right rear wheel
30. Connect the connector between body harness and
speed sensor.
instrument panel harness.
4. Connect the harness connector of the fuel pump.
31. Tighten the ground point under the DAB.
5. Fit the rear bumper assembly.
32. Connect the harness connector of the DAB.
Rear Bumper Assembly Refit 33. Connect the harness connector of the clutch pedal.
6. Fit the high-mounted stop lamp assembly. 34. Connect the harness connector of the brake pedal.
High-mounted Stop Lamp Assembly Refit 35. Connect the harness connector of the accelerator
7. Connect the harness connector of the tail gate release pedal.
1.0 741
36. Tighten the ground point under the BCM. 63. Fit the front bumper assembly.
37. Connect the harness connector of the BCM. Front Bumper Assembly Refit
38. Fit the carpet assembly. 64. Connect the battery negative.
Carpet Assembly Refit
40. Tighten ground point fixed to the right front longitudinal
beam.
41. Fit the washer reservoir assembly.
Washer Reservoir Assembly Refit
42. Connect the harness connector of the right headlamp.
43. Connect the harness connector of the right front wheel
speed sensor.
44. Connect the harness connector of the brake vacuum
sensor.
45. Connect the harness connector of the brake fluid level
sensor.
46. Connect the harness connector of the inertia switch.
47. Connect the harness connector of the front wiper
motor.
48. Fit the A/C air inlet grille.
49. Fit the A/C Hard Pipe Assembly.
A/C Hard Pipe Assembly Refit
50. Connect the engine harness connector.
51. Connect the harness connector of the left front wheel
speed sensor.
52. Tighten the ground point under the ABS modulator.
53. Connect the harness connector of the left headlamp.
54. Connect the harness connector of the back up lamp
switch.
55. Fit the brake modulator.
Brake Modulator Refit
Battery Tray Refit
57. Tighten the ground point of the left front longitudinal
beam.
Engine Compartment Fuse Box Refit
59. Connect the connector of the cooling fan relay.
60. Connect the connector of the cooling fan motor.
61. Connect the harness connector of the engine
compartment lock.
62. Connect the harness connector of the horn.
1.0 742
Front Door Harness 7. Fit the front door interior trim panel.
Remove Front Door Interior Trim Panel Refit
2. Remove the front door interior trim panel.
Front Door Interior Trim Panel Remove
3. Disconnect the connector between front door harness
and body harness.
4. Disconnect the harness connector of the window
regulator motor.
5. Disconnect the harness connector of the speaker.
6. Disconnect the harness connector of the exterior
rearview mirror.
7. Disconnect the harness connector of the front door

lock.
8. Release the clip and remove the front door harness.

Refit
1. Fit the front door harness and secure with clips.
2. Connect the harness connector of the front door lock.
3. Connect the harness connector of the exterior
rearview mirror.
4. Connect the harness connector of the speaker.
5. Connect the harness connector of the window
regulator motor.
6. Connect the body harness connector.
1.0 743
Rear Door Harness Centre Console Power Socket

Remove Remove
2. Remove the rear door interior trim panel. 2. Remove the centre console upper trim panel assembly.
Rear Door Interior Trim Panel Remove Centre Console Upper Trim Panel Assembly
3. Disconnect the connector between rear door harness Remove
and body harness. 3. Remove the 12V power socket from the centre console
4. Disconnect the harness connector of the window upper trim panel.
regulator motor. Refit
5. Disconnect the harness connector of the speaker. 1. Fix the 12V power socket to the centre console upper
trim panel.

6. Disconnect the harness connector of the rear door

lock.
7. Release the clip and remove the rear door harness.
Refit
1. Fit the rear door harness and secure with clips.
2. Connect the harness connector of the rear door lock.
3. Connect the harness connector of the speaker.
4. Connect the harness connector of the window
regulator motor.
5. Connect the body harness connector.
6. Fit the rear door interior trim panel.

1.0 744
Glossary List Name Description
Name Description NOx Oxides of Nitrogen
A/C Air Conditioning NSW Neutral Start Switch
ABS Anti-lock braking system NTC Negative Temperature
ATF Automatic Transmission Coefficient
Fluid OAT Organic Acid Technology
BCM Body Controller Module PAS Power Assisted Steering
CAN Controller area network PVC Polyvinyl Chloride
CHMSL Centre High Mounted Stop PWM Pulse Width Modulation
Lamp
RON Research Octane Number
CKP Crankshaft Position
SCS Stability Control System
CMP Camshaft Position
SDM Sensing Diagnostic Module
CO Carbon Monoxide
SIPS SAIC Integrated Program
CO2 Carbon Dioxide
System
DTC Diagnostic Trouble Code SRS Supplementary Restraint
EBD Electronic Braking-force System
Distribution TC Traction Control
ECM Engine Control Module TCM Transmission Control
ECT Engine Coolant Temperature Module
ECU Electronic Control Unit TMAP Temperature, Manifold
EEPROM Electronic Erasable Absolute Pressure
Programmable Read Only TP Throttle Position
Memory TPMS Tyre Pressure Monitoring
ELR Emergency Locking System
Retractor TWC Three-way Catalyst
EMS Engine Management System TXV Thermostatic Expansion
EOT Engine Oil Temperature Valve
HC Hydro Carbons VDS Vehicle Diagnostic System
HCU Hybrid control module VIN Vehicle Identification
HO2S Heated Oxygen Sensor Number
HRW Heated Rear Window

HSLA High Strength Low Alloy
HVAC Heating, Ventilation and Air
Conditioning
ICE In Car Entertainment
ICS Inflatable Curtain Structure
ISO International Organization
for Standardization
LED Light Emitting Diode
LIN Local Interconnect Network
MIL Malfunction Indicator Lamp
1.0 745

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Service Procedures Manual

SAIC Motor Passenger Vehicle Co.

All Rights Reserved.

Information is due in May, 2018

Attention is particularly drawn to the following points

• Safety features and corrosion prevention treatments

SMC Dealers are obliged to supply only SMC recommended

Some operations in the manual cannot be carried out properly

Special tools can be obtained from the following supplier.

Shanghai Runyue Industrial Development Co., Ltd

Address: Skirt Building, Lianhua Building, 159 Tianzhou Road,

Post Code: 200233

Power and Signal ............................. 735

Should any material be in a burnt or overheated condition,

Decontaminate and dispose of gloves immediately after use.

Ensure the vehicle is standing on level ground prior to lifting

Apply the parking brake and chock the wheels.

Warning: Do not work on or under a vehicle supported

Do not leave tools, lifting equipment, spilt oil, etc. around or

• Ensure that hoses run in a natural curve and are not

They must also be segregated into different types of waste

• Blow out all tapped holes, crevices, oilways and fluid

• Carefully examine seal before fitting to ensure that it is

• Grease outside diameter of seal, place square to housing

• Always use the correct gaskets as specified. Tab Washers

Damaged nuts, bolts and screws must always be discarded.

Always ensure that replacement bolts are at least equal in

Castellated nuts must not be loosened to accept a split-pin,

Do not allow oil or grease to enter blind threaded holes. The

Encapsulated bolts and screws have a microencapsulated

Unless a specific repair procedure states otherwise,

• Remove loose adhesive from the bolt and housing

Where bearing preload is involved, nuts should be tightened in

Self-locking bolts and screws, i.e. nylon patched or trilobular

Nylon patched bolts and screws have a locking agent

DO NOT fit non self-locking fasteners in applications where a

A nut with an ISO metric thread is marked on one face or on

• Clean end fittings and the area surrounding them as

Clean hose externally and blow through with airline.

• Absolute cleanliness must be observed with hydraulic Hose Clip

After any work on hydraulic systems, carefully inspect

Markings (1) are usually provided on the hose to indicate the

The following information provides basic precautions which

Always have a fire extinguisher containing FOAM, CO2, GAS

Always disconnect the vehicle battery before carrying out

Whenever fuel is being handled, drained or stored, or when

Warning: Do not remove fuel system components while

Warning: Do not remove fuel system components while

The capacity of containers must be more than adequate for

• Always ensure electrically related items are dry and oil

Having confirmed a component to be faulty:

• Switch off the ignition and disconnect the battery.

Caution: Ensure SRS components are not contaminated

Caution: Torque wrenches should be regularly checked for

Caution: Following seat belt pretensioner deployment,

Warning: Store the airbag module with the deployment

Caution: Do not apply grease or cleaning solvents to seat

• Never attempt to modify, splice or repair SRS wiring.

Modifying the vehicle structure or SRS system is strictly not

Never fit any accessory that obstructs or impairs the operation