Chapter catalogue

Foreword…………………………………………………………00

Engine..……...……………………………………………………01

Body electrical equipments…..……………………………….…02

Body………………………………………………………………03

Air conditioning system…….……………………………………04

Clutch system…….………………………………………………05

Front axle and rear axle ……...…………………………………06

Brake system…..…………………………………………………07

Suspension system….……………………………………………08

Steering system………..…………………………………………09

Transmission system…..…………………………………………10

Air bag and belt……….…………………………………………11

Electronic equipment system……………………………………12

Wheel and tire system……………………………………………13

 Foreword

Foreword

Preface............................................................................................................................ 1
Preparations .................................................................................................................. 41
Service Specification and Torque Specification........................................................... 72
 Foreword

Preface

Preface............................................................................................................................ 2
About this manual .......................................................................................................... 3
Identification Information (code)................................................................................. 11
Service Hints ............... ................................................................................................ 12
Vehicle Lift ................................................................................................................. 17
Electronic control unit (ECU) troubleshooting ............................................................ 26
Terms ............................................................................................................................ 41

00-1
Foreword

Preface

The risk of injury, property damage and repair failure may occur due to improper operation or a lack
of proper training. The maintenance procedures covered in this manual have been carefully formulated
by professional technicians at Tianjin FAW. This manual is of great use for all users-- those with little
training from Tianjin FAW and the well trained technicians. All users of this manual should understand
basic safety precautions.
It is important to note that this manual contains various "Cautions" and "Notices" that must be
carefully observed in order to reduce the risk of personal injury during service or repair, or the possibility
that improper service or repair may damage the vehicle or render it unsafe. It is also important to
understand that these "Cautions" and "Notices" are not exhaustive, because it is impossible to warn of all
the possible hazardous consequences that might result from failure to follow these instructions. The
service methods written in this manual are very effective to perform repair and service. When
performing the operations following the procedures in this manual, be sure to use tools specified and
recommended. If non-specified or non-recommended tools and service methods are used, please ensure
the safety of the technicians and are aware of any possibility of causing personal injury or damage to the
customer's vehicle before starting the operation.
If it is necessary to replace parts, please use Tianjin FAW original parts or parts with equivalent
quality. If inferior parts are used, please ensure the safety of the technicians and be aware that damage to
the vehicle is possible.
Tianjin FAW is not responsible for any problems caused by using this manual. The reasons for these
problems include a lack of proper training, using incorrect tools and parts with inferior quality, or a lack of
proper understanding of this manual, etc.

00-2
 Foreword

About this manual

Overview:
1．Index
There is a content index on the first page of each chapter to guide you to find the item that needs
repair. The title of each chapter and each section is printed on the header of each page for easy reference.
2．Caution
There is an overview about all maintenance operations (cautions) at the beginning of each chapter,
read these cautions before starting the maintenance.
3．Malfunction Diagnosis
Fault diagnostic testers are listed for checking the malfunction in some systems and finding the
causes of the fault.
4．Preparation
In the preparation section, special service tools (SST), recommended tools, devices, lubricants and
special service materials (SSM) that should be prepared are listed and the purpose of each is also
explained.
5．Maintenance Procedures
Most of the maintenance work begins with a schematic diagram, which shows the various
components and how they are installed together

00-3
Foreword

This maintenance procedure is introduced in the following sequence:

（1）The schematic shows the parts and their specific location.
（2）The title indicates what to do.
（3）Describe the maintenance procedure in detail, and provide other information such as
specifications and warnings etc.
For example：
task title : description of repair

Part FT 9 06 6 5 03：

indicates
Tianjin FAW

indicates the first indicates the

digit of the part tool number
No., stands for
special service indicates the
sub-components
indicates number of
vehicle maintenance tool
series

indicates the vehicle

part number of
maintenance tool

00-4
 Foreword

A. Number definition ：
1. vehicle series （1，2，3…）（FT9 X 2345）
1) indicates the XIALI series;
2) indicates the WEIZHI series；
2. automotive part number（FT91 X 345）
1) '1 'for automotive chassis system;
2) '2 ' for power steering system;
3) '3 ' for automotive ABS system;
4) '4 ' for automotive air conditioning system;
5) '5' for automotive interior and exterior trimming system;
6) '6' for automotive transmission system;
7) '7 ' for automotive engine system;
8) '9 ' for other systems
3. automotive sub-part number Sub-parts of the chassis (FT911 X 45)
1) Rear suspension, number '1 ';
2) Shock absorber, number '2 ';
3) Front and rear axles, number '3 ';
4) Front suspension, number '4 ';
5) Other parts, number '9 ';
4. Sub-parts of the power steering system (FT912X45)
1) Traversing mechanism , number '1 ';
2) Booster pump, number '2 ';
3) Manual steering, number '3 '
4) ‘4’Steering wheel / steering column, number '4 ';
5) Other parts, number '9 '.
5. Sub-parts of the ABS system (FT913 X 45)
1) Rear brake, number '1 ';
2) Front brake, number '2 '
3) Other parts, number '9 '.
6. Automotive air conditioning system(FT914 X 45)
7. 19)Automotive interior and exterior trimming system (FT915 X 45)
00-5
Foreword

8. Sub-parts of the engine system (FT916 X-45)

1) Cooling system, number '1 ';
2) Engine ignition system, number '2 ';
3) Engine lubrication system, number '3 ';
4) Engine starting and charging system, number '4 ';
5) Cylinder head, number '5 ';
6) Cylinder body, number '6 ';
7) Oil pan, number '7 ';
8) Cylinder front head, number '8 ';
9) Other parts, number '9 '.
9. Sub-parts of the transmission system (FT917 X 45)
1) Clutch system, number '1 ';
2) Input shaft and output shaft system, number '2 ';
3) Differential system, number '3 ';
4) Transmission housing system, number '4 ';
5) Gear shift system, number '5 ';
6) Gear select system, number '6 ';
7) Other systems, number '9 ';
10. Other systems (FT919 X 45)

B. Reference :：
Small amount as it accounts for, the reference will be marked out with the page number being notified
in this manual.

C. Detailed parameter specifications

The parameter specifications are printed in extrabold and listed in the maintenance specifications
section for easy reference.

D. Cautions, Notes and Tips

Cautions are printed in extrabold to remind you of the possible injuries that may be caused to you and
others.
Notes are also printed in extrabold to remind you of the possible damage that may be caused to the
components during repair.
00-6
 Foreword

Tips are separated from the text and are not printed in extrabold, they provide further information for
better maintenance.

E. SI units
In this manual the SI units (Standard International Units) are adopted and parameters in both metric
and imperial systems are marked out.
For example: Torque: 300 Nm (30 kg m)

00-7
Foreword

Identification Information (code)

Vehicle identification number and engine number

1．Vehicle identification number
The vehicle identification number is stamped in the
engine cabin, as shown in the illustration.
A. Vehicle Identification Number
B. Manufacturer’s plate

2．The engine serial number is stamped on the

engine block, as shown in the illustration.

00-8
 Foreword

Service Hints

Overview
Basic maintenance requirements
a) Use fenders, cushions and floor covers to keep
the vehicle clean and prevent damage.
b) Arrange the disassembled parts in the
disassembling order to facilitate re-assembly
c) The requirements of repairing battery line
（1） Before carrying out electrical work, be
sure to disconnect the negative (-) terminal cable
from the battery.
（2） Be sure to cut off the power and
disconnect the battery negative(-) terminal cable
before inspection and repair.
（3） When disconnecting the terminal cable, In
order to prevent damage to the battery terminal,
loosen the cable nut and raise the cable straight up
without twisting or prying it.
（4） Clean the battery terminals and cable ends
with a clean shop rag. Do not scrape them with a file
or other abrasive objects.
（5） Install the cable ends to the battery
terminals after loosening the nut, and tighten the nut
after installation. Do not use a hammer to tap the
cable ends onto the battery terminals.
（6） Be sure the cover for the positive (+)
terminal is properly in place
d) Check the hoses and wire connectors and ensure
00-9
Foreword

they are connected solidly and correctly.

e) Non-reusable components
（1） Always replace cotter pins, gaskets, O-rings,
oil seals, etc. with new ones.
（2） Non-reusable components are indicated in
the component illustrations by the " ◆"symbol.
f) Pre-coated components
Pre-coated components are coated with a seal lock
adhesive at the factory.
（1） If a pre-coated part is retightened, loosened
or caused to move in any way, it must be recoated
with the specified adhesive.
（2） When reusing pre-coated parts, clean off the
old adhesive and dry them with compressed air. Then
apply the specified seal lock adhesive to the parts.
（3） The pre-coated components are indicated in
the
component illustrations by the " ★"symbol.
g) If necessary, coat the gaskets with the adhesive
to prevent leakage.
h) Carefully observe all specifications for bolt
tightening torques, be sure to use a torque wrench.
i) Special service tools (SST) and special service
materials (SSM) may be necessary depending on the
nature of the repair. Be sure to follow the proper
operation and use the special service tools (SST) and
special service materials (SSM) on the specified
occasion. The special service tools (SST) and special
service materials (SSM) are listed in the Preparation
Chapter .
00-10
 Foreword

j) When replacing fuses, ensure that the new fuse

has the correct amperage rating. Do NOT exceed the
rating or use one with a lower rating.

k) Care must be taken when jacking up and

supporting the vehicle. Be sure to lift and support the
vehicle at the proper locations.
Note：
●Release the parking brake to horizontal position.
●When only the front section or rear section of the
vehicle is jacked up, be sure to place chocks at the
wheels so as to insure safe operations.
●After the vehicle has been jacked up, be sure to
support it on rigid racks. It is extremely dangerous to
do any work on a vehicle raised on a jack alone, even
for a small job that can be finished quickly.
(1) Observe the following precautions to avoid
damage to the components:
①Do not open the cover or case of the ECU unless
absolutely necessary. (If the IC terminals are touched,
00-11
Foreword

the IC may be destroyed by static electricity.).

②When disconnecting vacuum hoses, pull off the
end instead of the middle part of the hose.
③When pulling apart electrical connectors,pull on
the connector itself instead of the wires.
④Be careful not to drop the electrical components
(such as sensors or relays), if they fall onto hard
ground, they should be replaced immediately.
⑤ When steam cleaning an engine, protect the
electronic components, emission-related components,
distributor, ignition device and air filter from water.
⑥Never use an impact wrench to remove or install
temperature switches or temperature sensors.
⑦When checking continuity at the wire connector,
insert the tester probe carefully to prevent terminals
from bending.
⑧When using a vacuum gauge, never force the hose
onto a connector that is too large. Use a step—down
adapter for adjustment, once the hose has been
stretched, it may leak air.
m) Vacuum hose should be labeled before
removing.
（1） When disconnecting vacuum hoses, use
tags to identify where they should be reconnected to.
（2） After completing a job, double-check that
the vacuum hoses are properly connected.
n) Unless otherwise stated, all resistance is
measured at an ambient temperature of 20 ℃ .
Because the resistance may be outside specifications
if measured at high temperatures immediately after
00-12
 Foreword

the vehicle has been running, measurement should be

made when the engine has cooled down.

00-13
Foreword

Vehicle Lift

00-14
Foreword

00-15
Foreword

The following is suitable for all vehicles.

Notes
1．All models are equipped with SRS airbag and pre-tentioner seat belts
(a)The vehicle is equipped with the SRS (supplemental restraint system), such as: driver and
passenger side airbag and pre-tentioner seat belts, etc.. Improper maintenance operations may cause
unexpected SRS deployment, which could lead to serious accidents.
In addition, wrong operations during maintenance of the SRS (supplemental restraint system) might
cause the airbags to fail to inflate when it’s needed. Before any maintenance procedure (including
components disassembly, inspection and replacement), read and carefully follow all the precautions and
procedures described in this manual.
(b)General Information
(1) Supplemental restrain system failure is difficult to identify, so the diagnosis code is the most
important source of information for troubleshooting. Check the DTC before disconnecting the battery
when diagnosing the SRS.
(2) Be sure to operate after the ignition switch has been turned to LOCK and 90 seconds after
disconnecting the battery negative (-) terminal.
The SRS is equipped with backup power supply, so any maintenance operation within 90 seconds
after removing the battery negative (-) cable may cause crack due to inflation.
After the battery negative (-) terminal is disconnected, the content stored in clock and audio system
will disappear, so properly record the storage content in the systems before any operation. Reset the
system after operation.
Be sure NOT to use the backup power so as to prevent the content stored in each system from being
erased.
(3) Check the trim cover of the steering wheel, front-seat passenger airbag assembly, pretensioner
seat belt and front airbag sensors even if a slight collision occurs and the SRS does not open.
(4) Do NOT use SRS components from other vehicles. Replace the parts if necessary.
(5) Remove the airbag sensor before repair if any impact may be caused to the sensor.
(6) Do NOT remove or repair the airbag sensor assembly, airbag assembly steering wheel trim cover
and seat belt pretensioners.
(7) Replace the airbag sensor assembly, airbag assembly steering wheel trim cover and seat belt

00-16
 Foreword

pretensioners if there are cracks, dents or other defects on the shell bracket or wire connector.
(8) Do NOT expose the airbag sensor assembly, airbag assembly, steering wheel trim cover and seat
belt pretensioners to hot air or flame directly.
(9) Adopt the high-impedance (at least 10 kilo-ohm / volt) volt / ohm meter to diagnose the circuit
system.
(10) The precautions on the instruction plates on the SRS peripheral components must be carefully
observed.
(11) Check the SRS warning light after the maintenance of the SRS is completed.
(c) Spiral cable (in the combination switch)
The steering wheel must be properly mounted on the steering column with the spiral cable in the
middle, so as to avoid the cable discontinuity or other failures.
(d) steering wheel trim cover (with airbags)
(1) When removing or replacing the steering wheel trim cover, place its top surface on the upside.
Improper placement of the steering wheel trim cover may cause accidental deployment of the airbag,
which may lead to serious accidents. In addition, do NOT apply heavy force to the steering wheel trim
cover.
(2) Do NOT measure the resistance of the airbag booster tube. (This may cause the airbag to inflate,
which is very dangerous)
(3) Do NOT apply lubricating grease on the steering wheel trim cover, nor shall it be cleaned with
any type of detergent.
(4) The steering wheel trim cover should be stored at a place where the environment temperature is
below 93 ℃ (200 ° F), the humidity is not high and away from electronic pollution.
(5) Disengage the airbag wire connectors first (yellow, two pins) when applying electric arc welding.
The wire connector is beside the wire connector of the combination switch which is under the steering
column.
(6) Open the airbag with special service tool before the vehicle or only the steering wheel trim cover
is out of service. This work should be done at the place away from electrical pollution.

00-17
Foreword

(e) Passenger’s airbag assembly

(1) Set the airbag opening upwards when storing the removed or new front-seat passenger airbag
assembly.
If the air bag opening is placed downward, the airbag may be deployed unexpectedly, causing serious
accidents.
(2) Do NOT measure the resistance of the airbag booster tube. (This may cause the airbag to inflate,
which is very dangerous)
(3) Do NOT apply lubricating grease on the front-seat passenger airbag, nor shall it be cleaned with
any type of detergent.
(4) The airbag assembly should be stored at a place where the environment temperature is below
93 ℃, the humidity is not high and away from electronic pollution.
(5) Disengage the airbag wire connectors first (yellow, two pins) when applying electric arc welding.
The wire connector is on the dash panel which is on the left of the glove compartment.
(6) Open the airbag with special service tool when the vehicle scrapping or just the airbag assembly
scrapping . This work should be done at a place away from electrical pollution.

(f) Seat belt pretensioner

00-18
 Foreword

(1) Do NOT measure the resistance of the seat belt pretensioner. (This may activate the pretensioner ,
which is very dangerous.)
(2) Do NOT remove the seat belt pretensioner.
(3) Do NOT install the seat belt pretensioner to other vehicles
(4) The seat belt pretentioner should be stored at a place where the environment temperature is
below 80 ℃, the humidity is not high and away from electronic pollution.
(5) Disengage the wire connectors first (yellow, two pins) when applying electric arc welding.
(6) Activate the seat belt pretentioner when the vehicle scrapping or just the seat belt pretentioner
scrapping. This work should be done at a place away from electrical pollution.
(7) The seat belt pretentioner could be very hot after it has been activated, discard the seat belt
pretensioner after it has been fully cooled down, do NOT cool it with water.
(8) Keep the front seat outer belt from water or oil. Do NOT clean it with any type of detergent.

(g) Airbag sensor assembly

(1) Do NOT reuse the airbag sensor assembly after it has been deployed in a collision..
(2) Connect or disconnect the connectors only when the airbag sensor is mounted on the floor to
avoid unexpected deployment of the SRS.
(3) Make sure the ignition switch is on LOCK position and wait 90 seconds after removing the
battery negative (-) terminal before any operation, even loosening the locating screw of airbag sensor
assembly.
(h) Harnesses and wire connectors
The SRS harnesses are set together with the dashboard harnesses. The wire connectors in the whole
system are marked in standard yellow. If because accidents and other reasons cause the SRS harness
disengaging or the wire connector damage, replace them immediately

00-19
Foreword

2. For vehicles equipped with a catalytic converter

Notes：
●If large amount of unburned gasoline flows into the converter, it may overheat and create a fire
hazard. To prevent this, observe the following precautions and explain them to your customer.
(a) Use only unleaded gasoline
(b) Avoid prolonged idling . Avoid running the engine at idle speed for more than 20 minutes.
(c) Avoid spark jump test.
(1) Perform spark jump test only when absolutely necessary. Perform this test as rapidly as possible.
(2) while testing, never race the engine.
(d) Avoid prolonged engine compression measurement.
Engine compression tests must be done as rapidly as possible.
(e) Do not run engine when fuel tank is nearly empty.
This may cause engine to misfire and create an extra load on the converter.
(f) Avoid coasting with ignition turned off.
(g) Do not dispose of used catalyst along with parts contaminated with gasoline or oil.

3．For vehicles equipped with the mobile communication system

If the vehicle is equipped with mobile communication system, such as two-way radio communication
equipments and cellular phones, the following precautions should be observed:
(1) The antenna should be installed far away from the ECU and sensors.
(2) The antenna feeder should be installed over 20cm away from the ECU and sensors. Refer to the
related chapter for the location of the ECU and sensors.
(3) Do NOT intertwine the antenna feeder with other wires, and try to avoid the antenna feeder to be
parallel with other harnesses.
(4) Make certain the antenna and feeder are correctly adjusted.
(5) Do NOT install the mobile communication system with large power.
4．Handheld fault diagnostic tester
Notes：
●Please observe the following precautions for security purposes：
●Read carefully the instructions of the fault diagnostic tester before using it.

00-20
 Foreword

●Before connecting the fault diagnostic tester and starting the car, carefully arrange the wires. (For
example, the wires should be a certain distance away from the pedal, steering wheel and shift lever).
●Two people are needed to carry out the test using the fault diagnostic tester, one for driving and
the other reading the tester.
5．For vehicles equipped with the new brake pipe interface.
For vehicles equipped with new conical brake pipe interface, make sure the equipment with matching
size is adopted when replacing components.

00-21
Foreword

Electronic control unit (ECU) troubleshooting

Overview
A large number of ECU control equipments are equipped on the vehicle. The ECU control system is
usually regarded as a very complex system, which requires proficient technical knowledge and
professional training to troubleshoot failures. However, the fact is that it is not complicated at all if the
wiring is examined closely. A proper understanding of the system and basic electronic knowledge, a
correct diagnosis and repair will be necessary to locate and solve the problems. This manual aims to help
the service technicians be proficient in the troubleshooting procedure through introduction of the ECU
system.
Utilizing the handheld fault diagnostic tester
1. Read carefully the manual before using the handheld fault diagnostic tester.
2. If the cable of the fault diagnostic tester has been connected to the DLC3, and the ignition switch
has been turned to ON position, the tester cannot communicate with the ECU control system when
operating the tester.
(1) If the fault diagnostic tester functions well when connected to other vehicle, check the
vehicle's diagnostic data cable (Bus ⊕ line) or the ECU power circuit.
(2) If the fault diagnostic tester does not function well when connected to other vehicle, the
problem may occur within the tester itself, in this case, check the tester according to the operation manual
of the tester.
Troubleshooting procedures
The following describes only the basic steps for troubleshooting, for the most effective ways of
troubleshooting each circuit fault, refer to the detailed procedures in the diagnosis chapter.. Get a good
knowledge of the troubleshooting steps before conducting the troubleshooting.

00-22
Foreword

00-23
Foreword

1．Customer question analysis

During the troubleshooting, the malfunction must be accurately identified. Meanwhile, it is important
to ask customers about the malfunction and its conditions.
Key points of malfunction analysis：
The following five items are the focus of malfunction analysis. We try to gather more information
about the malfunction so as to provide accurate reference for troubleshootin. The malfunction table is
provided in the diagnosis chapter of each system.

00-24
 Foreword

2．Malfunction diagnosis and diagnostic trouble code(DTC) inspection

Malfunction diagnosis of the automobile is of multiple functions. The first function is DTC storage.
When malfunction occurs from the signal circuit to the ECU, the DTC will be stored in memory and
checked out by the technician when troubleshooting. Another function is input signal inspection, which
will check the accuracy of signals sent to the ECU by various switches. The inspection will help locate
the malfunction area and make the troubleshooting more efficient. Diagnostic functions are synthesized in
the following systems of the automotive.
Systems DTC Input signal Diagnosis test
inspection inspection (sensor mode
inspection) (Active test)
Automatic (with test
transmission mode)
ABS
SRS system
It is important to determine whether the malfunction is occurring or has occurred during the DTC
inspection. In addition, it is necessary to check whether the malfunction indicated by the DTC is directly
related to the manifestation. The DTC should be checked before or after the malfunction is identified as
shown below. It might cause unnecessary failures to the operating system without the check. Improper
DTC inspection may lead to difficult or even wrong malfunction location.

00-25
Foreword

DTC Malfunction DTC Problem state

inspection(eliminat identification inspection
ed after recorded)
DTC display Malfunction The same Problem is occurring in diagnosis
exists DTC display circuit.
No Normal Problem still exists beyond the
malfunction exists diagnosis code diagnosis circuits (DTC indicates
display former or minor malfunction).
Malfunction occurred in the past
in the diagnostic circuit
Normal Malfunction Normal Problem still exists beyond the
diagnosis code exists diagnosis code diagnostic circuit.
display display
No Normal
malfunction exists diagnosis code
display

00-26
 Foreword

The DTC inspection flow chart is shown below, which indicates the effective way to utilize the DTC
or the malfunction table to troubleshoot the problems.

00-27
Foreword

3．Malfunction simulation
It is quite difficult to troubleshoot the malfunction without any manifestation, in which case an
overall malfunction analysis is required and the condition in which the malfunction occurs is to be
simulated. Improper malfunction identification may lead to further failure despite the experience or
skills of the technician.. For example, if the malfunction occurs when the engine is cold or due to vibration
on the road, it cannot be traced when the engine is hot or when the vehicle is stationary. Because such
conditions as vibration or water penetration (moisture) in which the malfunction occurs are difficult to
regenerate, the malfunction simulation inspection introduced here is mainly targeted to the external factors
acted on the overheated vehicle. During the simulation inspection, malfunctions should not only be
identified, but also be located. Before connecting the fault diagnosis tester and checking, narrow down the
possibly faulty circuit, then conduct the simulation inspection for the default, if any, and identify the
malfunction. Refer to the malfunction table given in each chapter to narrow down the possible causes.
1.Vibration method: use connectors when
vibration is considered as the main cause.
Gently shake the connector.
Harness
Gently shake the harness. Pay special attention to
the joint of the connector and the part getting through
the body.

Component and sensor

Tap the sensor that is considered as the cause of the
malfunction to check whether the malfunction occurs.
Tip：
■A strong shake might activate the relay.

00-28
 Foreword

2．Heating method: If the problem is considered

as caused by overheating of some parts, check the
parts for malfunction, using hair drier or similar
tools for heating.
Note：
● Keep the temperature below 60 ℃ (high
temperature might damage parts)
●Do NOT directly heat components in the ECU

3．Sprinkling method: if the malfunction occurs

when it rains or in humidity. Sprinkle the vehicle
to check whether the failure occurs.
Notes：
●Do NOT directly sprinkle the engine parts, you
may sprinkle the front surface of the radiator to
change the temperature and humidity indirectly.
●Do NOT spray water to electronic components
directly
Tip：
■Pay special attention to whether the vehicle leaks,
for the leaking water will damage the ECU.

4．Others: When the malfunction is considered to

be caused by excessive electricity consumption.
Switch all the electrical equipments on, such as the
heater blower, headlights, rear windshield
defroster, etc. to check whether the malfunction
occurs.

00-29
Foreword

Application method of the fault diagnostic tester

and inspection procedures
1．Connector and terminal inspection
（a）The malfunction table and the diagnostic code
table of each circuit system has provided detailed
inspection procedures to troubleshoot malfunctions.
（b）When all parts, harnesses and socket
connectors except the ECU in each circuit function
well in the troubleshooting，it can be determined that
the problem is in the ECU.
Therefore, if no malfunction occurs during the check,
refer to step 8 to replace the ECU.
（c）The instructions for checking harness and
socket connector" and "inspecting and replacing the
ECU" apply to all malfunction inspection.
Open circuit
Open circuit is due to the harness is not connected or
bad contact of connectors.
Tip：
■The harness does not often break in the middle, in
most cases it is the problem of the socket connector,
especially that of the sensor and the actuator. Bad
contact is caused by rusty terminal, exterior objects
in the terminal or the terminal deformation. The
problem may be solved by removing and
re-connecting the harness. The problem may be
inside the harness and the connector in the case that
the outside of the harness and the connector is
normal.
00-30
 Foreword

Short-circuit
Short circuit may be caused by the harness touching
the grounding wire or short circuit inside the switch.
Tip：
■If the harness and body is short circuit to ground,
please check whether the harnesses are pressed or
clamped by the body.
2．Socket connector disposal
Insert the test probe into the socket connector from
the rear side, use small probes if necessary. Do NOT
insert the probe from the rear side if the connector is
waterproofing. Be careful not to deform the
connector terminal.

3．Continuity (discontinuity) inspection

(a) Remove the socket connector on the side of the
ECU and sensor
(b) Measure the resistance between the
corresponding terminals of socket connector.
Resistance value: 1Ω or less
Tip：
■ Gently shake the harness when measuring the
resistance.

00-31
Foreword

4．Resistance inspection (short-circuit inspection)

(a) Remove the socket connectors on both ends.
(b) Measure the resistance between the
corresponding terminals and the grounding wire.
Make sure that the inspection of connectors on both
ends is completed.
Resistance value: 1MΩ or higher
Tip：
■Gently shake the harness up and down, left and
right when measuring the resistance.
5．Visual inspection and contact pressure
inspection
(a) Remove the socket connector on both ends.
(b) Check the socket connector terminals for
rustiness or external objects intrusion,
(c) Check the pressure line for looseness or damage,
and check the locked part of the terminals for
shakiness.
Tip：
■The terminal should not be pulled out when gently
pulling the rear side of the socket connector
terminal.
(d) Insert a positive terminal into a negative
terminal, then pull it out.
Note：
● Use gold-plated positive terminal to test a
gold-plated negative terminal.
Tip：
■If the terminals tested are more easily pulled out
than others, they may have bad contact.
00-32
 Foreword

6．Open-circuit inspection
Inspect the (a) conductivity and (b) voltage to locate
the open circuit in Figure 1.

(a) Conductivity inspection

(1) Remove the socket connector "A" and "C",
measure the resistance between them. The circuit
between terminal 1 of the socket connector "A" and
terminal 1 of the socket connector “C” is open, as
shown in Figure 2.
The circuit between terminal 2 of the socket
connector "A" and terminal 2 of the socket connector
"C" is conductive, so the circuit between terminal 1
of the socket connector "A" and terminal 1 of the
socket connector “C” is open.
(2) Remove the socket connector “B”, measure the
resistance between the socket connector. The circuit
between terminal 1 of the socket connector "A" and
terminal 1 of the socket connector "B1" is conductive,
while the circuit between terminal 1 of the socket
connector "B2" and terminal 1 of the socket

00-33
Foreword

connector “C” is open, as shown in Figure 3.So the

open circuit has been located.
(b) Voltage inspection
Voltage inspection can be conducted in the case that
there exists voltage (the ECU socket connector
terminal) in circuits.
Connect each connector, as shown in Figure 4,
measure the voltage between body ground and the
ECU5V output voltage terminal of the terminal 1 of
the socket connector A, the terminal 1 of the socket
connector B and the terminal 1 of the socket
connector "C"
If the result is:
5V: between terminal 1 of socket connector “A” and
grounding wire.
5V: between terminal 1 of socket connector "B" and
the grounding wire.
OV: between terminal 1 of socket connector "C" and
the grounding wire.
So the open circuit can be located as between terminal
1 of socket connector "B" and terminal 1 of socket
connector “C”.
7. Short circuit inspection
If there is short circuit to ground as shown in Figure 5,
inspect the conductivity of the grounded circuit to
locate the short circuit.

00-34
 Foreword

Grounded circuit inspection

Remove socket connector "A" and "C", measure the
resistance between terminal 1 and 2 of the socket
connector “A” and the grounding wire.
It is conductive between terminal 1 of socket
connector “A” and the grounding wire (short circuit) .
It is not conductive between terminal 2 of socket
connector “A” and the grounding wire.
Therefore, the short circuit can be located as between
terminal 1 of socket connector "A" and terminal 1 of
socket connector “C”.
(2)Remove socket connector "B", measure the
resistance between terminal 1 of socket connector “A”
and the grounding wire.
So the open circuit can be located as between terminal
1 of socket connector “A” and the grounding wire.
It is conductive between terminal 1 of socket
connector “B2” and the grounding wire (short circuit).
So the open circuit can be located as between terminal
1 of socket connector "B2" and terminal 1 of socket
connector “C”.

8. Check and Replace the ECU

First check the ECU grounded circuit. Repair the
ECU if the problem occurs, If no problem occurs, the
ECU may not function properly, replace the ECU
with one that functions well, then check the ECU for
any problems.
(1)Measure the resistance between the ECU ground

00-35
Foreword

terminal and the grounding wire.

Resistance value: 1 ohm or less
(2)Remove the ECU connector and check the
grounding wire terminal on the ECU side and that on
the harness side for bending deflection, or whether
the bending deformation contact force is adequacy.

00-36
 Foreword

Terms

Abbreviations
Abbreviation Implication
ABS Anti- lock brake system
A/C Air conditioning
AC Alternating current
ALT Alternator
AMP Amplifier
ANT Antenna
AUTO Automatic
BAT Battery
CB Relay
CD Compact disc
CRS Child restraint system
CTR Central
DC Direct current
DIFF Differential
DLC Data link connector
DSP Digital signal processor
DTC Diagnostic trouble code
ECT Electronic controlled transmission
ECU Electronic control unit
EFI Electronic fuel injection
E/G Engine
ELR ( Belt ) emergency locking retractor
FF Front engine Front drive
FL Fusible line

00-37
Foreword

FWD Front-wheel drive

GND Grounding
HI High
HWS Heating Windshield system
IFS Independent front suspension
IG Ignition
I/P Instrument panel
IRS Independent rear suspension
J/B Junction box
J/C Junction connector
LCD Liquid crystal display
LED Light-emitting diode
LO Low
LSP&PV Load-sensing proportioning valve and
bypass valve
LSPV Load sensing proportioning valve
MAP Manifold absolute pressure
MAX Maximum
MIL Malfunction indicator lamp
MIN Minimum
MPI Multi-point injection
M/T Manual transmission
N Neutral gear
No. Number
O2S Oxygen sensor
O/D Over drive
PKB Parking brake
PPS Progressive power steering
PS Power Steering

00-38
 Foreword

RAM Random access memory

R/B Relay box
R/F strengthen reinforcement
RLY Relay
ROM Read-only memory
Rr Rear
SEN Sensor
SPEC Specification
SRS Supplemental restraint system
SSM Special Service Material
SST Special Service Tool
STD Standard
SW Switch
SYS System
T/A Transmission axle
TACH Tachometer
TDC Top dead center
TEMP Temperature
T/M Transmission
U/D Under drive
VENT Ventilation equipment
VIN Vehicle identification code
W/H Wire/Harness

00-39
Foreword

Preparations

Clutch ........................................................................................................................... 42
Manual Transmission ................................................................................................... 45
Suspension ................................................................................................................... 50
Front & rear axle............... ........................................................................................... 52
Brake system ................................................................................................................ 55
Steering system ............................................................................................................ 58
Airbag........................................................................................................................... 60
Electrical system .......................................................................................................... 62
Body ............................................................................................................................. 63
Air-conditioning ........................................................................................................... 66
Engine .......................................................................................................................... 68

00-40
 Foreword

Clutch

Special service tools

FT9066401 For locating the clutch discs

Clutch disc locator during the installation

00-41
Foreword

Devices

Caliper

Dial gauge with scale

Torque wrench

00-42
 Foreword

Lubricant
Item Capacity Grade
Brake fluid (liquid) FMVSS DOT4

00-43
Foreword

Manual Transmission

Special service tools

For the removal of
FT9067708 puller transmission bearing
steel bushing

FT9067707bearing For the installation of

installer inner bearing of the
transmission

FT9067706bearing For the installation of

installer inner bearing of the
transmission

FT9067705 puller hit For the removal of

differential front oil
seal
FT9067704 oil seal For the installation of
punch transmission input
shaft seal and shift
shaft seal

FT9067701 For the removal of

transmission bearing transmission bearing
removal tool

00-44
 Foreword

FT9067703 punch For the removal of

transmission bearing

FT9067602 oil seal For the installation of

installer transmission T-type oil
seal

FT9067601 For the installation of

installation tool of selector oil seal
selector oil seal

FT9067404 For the installation of

installation tool of the left and right
differential bearing differential bearing cup
cup

FT9067403 assembly For installing the

tool of output shaft output shaft bearing
bearing cup (left) cup (left)

FT9067105 assembly For installing the

tool of output shaft output shaft bearing
bearing cup (right) cup (right)

00-45
Foreword

FT9067106 removal For the removal of

tool of input and input and output shaft
output shaft bearing bearing

FT9067501 removal For the removal of

tool of reverse gear reverse gear switch
switch

00-46
 Foreword

Devices
Magnetic stand and gauge
Feeler gauge
Magnetic pointer
Micrometer
Torque wrench
Vernier caliper

00-47
Foreword

Lubricant
Item Capacity Grade
Manual transmission oil 1.8~2.0L API GL-4
SAE 80W/90
(75W/90 is recommended
in cold areas)

Velocity selector oil fluid specified by velocity

selector manufacturers

00-48
 Foreword

Suspension

Special service tools

FT9011105 For the removal of left
removal tool components of and right rear axle bush
right rear axle bush

FT9011106-3 For the removal of right

removal tool components of rear axle bush
right rear axle bush

FT9011105 For the removal of right

removal tool components of rear axle bush
right rear axle bush

FT9011104 For the removal of right

removal tool components of rear axle bush
right rear axle bush

FT9011108 For the removal of right

removal tool components of rear axle bush
right rear axle bush
FT9011109 For the removal of right
removal tool components of rear axle bush
right rear axle bush
FT9067701 For removing the
removal tool of bearing bearing

00-49
Foreword

Devices
Torque wrench

Drill

Magnetic stand and gauge

00-50
 Foreword

Front & rear axle

Special service tools

removal tool of driveshaft For the removal of left front
drive shaft assembly.

Front axle hub punch For removing the left bolt of

the front axle hub

removal tool components of For the removal of left hub

left hub bearing inner race bearing inner race

removal tool components of For the removal of left hub

left hub bearing inner race bearing inner race

removal tool components of For the removal of left hub

left hub bearing inner race bearing inner race

removal tool components of For the removal of left hub

left hub bearing inner race bearing inner race

removal tool components of For the removal of left hub

left hub bearing inner race bearing inner race

00-51
Foreword

removal tool components of For the removal of left hub

left hub bearing inner race bearing inner race

FT9067706 For the installation of inner

Bearing Installer bearing

FT9011401 For the removal of left front

puller hit of left axle hub axle hub sub-assembly
sub-assembly

FT9062101 For the removal of the front

stand removal axle hub assembly

FT9012102-2 For the removal and

Bearing installation tool installation of bearing

00-52
 Foreword

Devices
Torque wrench

Drill

Magnetic stand and gauge

00-53
Foreword

Brake system

Special service tools

FT9013101 For removing and installing
Brake tube wrench the brake tubes

FT9013901 For the measurement and

Gauge adjustment of clearance of
the brake master cylinder
and brake booster
FT9011402 For removing the slideslip
Puller hit control sensor

FT9011401 For removing the speed

Puller hit sensor from the hub

FT9067701 For removing the speed

Bearing removal tool sensor from the hub

00-54
 Foreword

Devices
Torque wrench
Micrometer Brake disc
Dial indicator Brake disc
Caliper Drum brake

00-55
Foreword

Lubricant
Item Capacity Grade
Brake fluid FMVSS DOT4

00-56
 Foreword

Steering system

Special service tools

FT9012104 For removing the
steering gear nuts steering gear nuts
removal tool

FT9012105 For adjusting the

steering gear preload steering gear preload
adjustment tool

FT9012107 For disconnection of

Ball head removal yool the steering tie rod end
sub-assembly

00-57
Foreword

Devices
Caliper gauge
Caliper
Dial indicator
Feeler gauge
Micrometer
Torque wrench

00-58
 Foreword

Airbag

Service tools

Parameters
Tools Purposes
（number）

For fastening the connection of

M12 Hexagonal socket wrench or 50Nm
the steering wheel with the
impact wrench tightening torque
steering column

For fastening the connection of

M6Plum wrench M6 8-10Nm the steering wheel with the DAB
tightening torque module

For fastening the connection of

the PAB module with the

8-10Nm dashboard beam

M6 Hexagonal socket wrench or tightening torque

impact wrench For fastening the connection of
the ECU and the bracket

Six-point
For removing or installing the
screwdriver
power control side airbag
（FT 9019801）

00-59
Foreword

Devices

Torque wrench
bolt： length：35m m thread pitch ：1.0m m For handling the airbag
inner diameter： 6.0mm
tire（discarded） width：185m m For handling the airbag
inner diameter：360m m
tire equipped with wheel rim For handling the airbag
width：185m m
inner diameter：360m m
Nylon bag For handling the airbag

00-60
 Foreword

Electrical system

Devices
Voltmeter
Ammeter
Ohmmeter
testing wire
Siphon Brake fluid level alarm switch
Dry cell
Torque wrench
Plastic paper bag Windshield wipers
Tin slice Windshield wipers

00-61
Foreword

Body

Special service tools

FT9069102 For the removal of the

Fuel tank cap removal fuel tank cap
tool

FT9015101 For the removal of the

Screwdriver door holder

FT9011102 For the removal of

Wheel bolt removal wheel bolts
tool

00-62
 Foreword

Devices
Clamp removal tool
Torque wrench
Punch
Hose snap ring pliers
Manual riveting machine
Tape measure Keep damaged surface away
Tape Keep damaged surface away
Adhesive
Cleaning tools
workshop rags
cutter
piano wire
Sealant gun
Brush
Putty spatula
Wooden pad or something with the same
function
Plastic cards Keep damaged surface away
Rope For handling the pre-tentioner seat belt
Tire width：185m m For handling the pre-tentioner seat belt
Inner diameter：360m m
Width of tire equipped with wheel For handling the pre-tentioner seat belt
rim:：185m m
Inner diameter:：360m m
Nylon bag For handling the pre-tentioner seat belt
Hair drier headlight
Edge used on objects headlight

00-63
Foreword

Special service materials

435-41，435-98
Caulking compounds 435-41, caulking compounds 435-98

Windshield
Fuse machine, glass adhesive

X121-Z9-01，
Windshield wiper strip fixture X121-Z9-01

00-64
 Foreword

Air-conditioning

Devices
Voltmeter
Ammeter
Ohmmeter
Testing wire
Thermometer Thermistor
Torque wrench
Indicator dial Electromagnetic clutch
Plastic hammer Electromagnetic clutch

00-65
Foreword

Lubricant
Item Capacity Grade
Compressor oil
When replacing 30ml PAG56
condensate
When replacing 40ml PAG56
evaporator

00-66
 Foreword

Engine

Special service tools:

4GA1 engine valve oil
seal installation tool
FT9066501

4GA1 engine valve

FT9066502-1 guide installation and
FT9066502-2 removal tool

4GA1 engine cylinder

FT9066503 head bolt removal tool

Cutting knife of oil

FT9046301
bottom

4GA1 engine crankshaft

front oil seal installation
FT9046603
tool

4GA1 engine crankshaft

FT9066601-1 rear oil seal installation
FT9066601-2 tools

00-67
Foreword

FT9046601-1
4GA1 engine piston pin
FT9046601-2
removal tools
FT9046601-3

FT9046505 For testing the clearance

Feeler gauge of valve and spark plug

FT9066503 For removing cylinder

Socket wrench of cylinder head bolt head bolts

FT9046508 For adjusting the intake

Socket wrench of cylinder head bolt camshaft gear

FT9116605 For installing flywheel

Flywheel locating tool

FT9046504 For valve clearance

Valve clearance adjusting tool adjustment

FT9076301 For installing oil pressure

Oil pressure switch bushing tool switch bushing

00-68
 Foreword

FT9046203 For installing and

Spark plug removal tool removing spark plug

FT9066401 For aligning the center

Clutch assembly tool hole of clutch plate when
installing clutch plate

FT9046302

FT9046202 For installing crankshaft

Oil seal installation handle rear oil seal

FT9066502 For removing valve

Valve guide removal tool guide

FT9066602 For removing piston pin

Piston pin removal tools

FT9015204
Nylon screwdriver

00-69
Foreword

FT9046507 For the installation of

Valve spring compressor valve spring

FT9046605 For the installation of

Crankshaft piston installation tool crankshaft piston

FT9046503-2 This tool applies only to

valve oil seal pliers the valve oil seal

FT9066501
Valve oil seal installation tool

FT9046510 For picking up valve key

Bendable magnetic bar

FT9046603
Crankshaft front oil seal installation too

FT9066601-1 For the installation of

Guide sleeve - crankshaft rear oil seal crankshaft rear oil seal
installation tool

00-70
 Foreword

Service Specification and Torque Specification

Standard bolts............................................................................................................... 73
Clutch…………………………………………………………………………………..76
Manual Transmission ................................................................................................... 78
Suspension system and shaft ........................................................................................ 79
Brake system ................................................................................................................ 82
Steering system ............................................................................................................ 84
Body electrical system ................................................................................................. 86
Body ............................................................................................................................. 87
Air-conditioning ........................................................................................................... 92
Engine .......................................................................................................................... 93

00-71
Foreword

Standard bolts

How to determine the bolt strength

00-72
 Foreword

Prescriptive torque of the standard bolt

00-73
Foreword

How to determine the nut strength

*： the nut which has one or more marks on one side

Tip: When using bolts and nuts to tighten parts, use nuts whose strength grade is the same with or
larger than that of the bolt.

For example： bolt=4T nut 4N

00-74
 Foreword

Clutch

Service data
Distance from clutch pedal to the ground 181.5-186.5mm
left
Pedal free travel 5.0-15.0 mm
Pedal top pushrod stroke 1.0-5.0 mm
distance from the end point to the release 25mm or slightly larger
point of the clutch
Plate rivet depth minimum 0.3 mm
Disk radial run-out maximum 0.8 mm
Flywheel radial run-out maximum 0.1 mm
Diaphragm spring wear (maximum depth) 0.6 mm
Diaphragm spring wear (maximum width) 5.0 mm
Diaphragm spring top non-locating degree 0.5 mm
maximum

00-75
Foreword

Torque table
Tube connecting the clutch cylinder to flexible
12.7～17.6 Nm
hose × clutch hose assembly

Clutch pedal × instrument panel reinforcement 16.8～25.2 Nm

Tube connecting the master cylinder to the

12.7～17.6 Nm
flexible hose × clutch hose
Torsional torque of clutch tube connector 12.7～17.6 N m

Clutch flexible hose bracket ×transmission 15.3～22.9 Nm

00-76
 Foreword

Manual Transmission

Torque specifications
engine×gearbox(TA1)（1 bolt） 39～53 N m

engine×gearbox(TA1)（3 bolts） 19～29 Nm

gearbox×engine（3 bolts）（T A 1 A M T ）

gearbox×engine（in the assem bly m anual bolt 54～74 Nm

A,B）（A M T ）
gearbox×engine（in the assem bly manual bolt
54～74 Nm
C）（A M T ）

engine line No.3×left bracket 20.6～30.4 Nm

Oxygen sensor ×engine（T A 1） 40～50 Nm

Starter ×gearbox（T A 1） 36～44 Nm

Starter B terminal （nut）（T A 1） 9.8～15.7 Nm

Clutch cylinder to flexible hose tube ×gearbox 12.7～17.6 Nm

Compressor ×Compressor bracket（T A 1） 19.6～29.4 Nm

Alternator ×engine（down）（bolt A）（T A 1） 40～60 Nm

Alternator ×engine（up）（boltC）（T A 1） 19～27 Nm

Exhaust front pipe × exhaust tail pipe 40～60 Nm

Exhaust front pipe×engine 43.4～80.6 Nm

Right isolation block × right bracket

41.6～62.4 Nm
Right insulator × right bracket

the bolt at the oil charging hole of the transmission 30～50 N m

Manual-shift assembly × body floor

12 Nm
AMT shift assembly × body floor

00-77
Foreword

Suspension system and shaft

Service data
Tire pressure Front 230kpa
Tire size Rear 210kpa
175/65R14

Front wheel alignment Caster 3°37′±45′

parameters Camber 0°±45′

Kingpin inclination angle 10°35′±1′
toe-in (mm) 0±2
Rear wheel alignment Camber -0°40′±45′
parameters
toe-in (mm) 5 +−13

wheel alignment check the vertical height of front 64.4±15

state wheel center and the center of
( adjust vehicle height mounting bolt between lower arm
under unloaded state) and body（m m ）
the vertical height of rear 25±15
wheel center and the center of
mounting bolt between lower
control arm No. 1 and
body（m m ）

00-78
 Foreword

Torque table
Front shock absorber ×front axle 107.8～156.8 Nm

Steering gear box with tie rod ×front axle 29.4～44.1 Nm

Front axle×drive shaft 170～230 Nm

Front brake hose ×front axle 19.6～26.5 Nm

Front brake hose ×Front brake tube 12.7～17.6 Nm

lower arm×Front suspension crossmember (horizontal) 70.6～105.8 Nm

Rear stabilizer bar ×rear suspension swing arm

Rear stabilizer bar ×Stabilizer strut rod welding 9.8～15.68 Nm

assembly

Rear stabilizer strut rod welding assembly ×stabilizer

18.62～30.38 Nm
prop stand welding assembly

Front stabilizer bar×front stabilizer bar connecting rod

（left）
40～60 Nm
Front stabilizer bar×front stabilizer bar connecting
rod（righ t）

Front stabilizer bracket × front stabilizer bar mounting

28～45.5 Nm
bracket

EPS steering column × universal joint splined yoke with

shaft

Universal joint splined yoke with shaft sub-assembly ×

22.7～34 Nm
universal joint splined yoke subassembly

Bolt of universal joint splined yoke with shaft

sub-assembly

Front stabilizer bar connecting rod ×lower arm 40～60 Nm

Front axle×lower arm 78.4～117.6 Nm

Rear insulator × rear bracket 51.2～76.8 Nm

00-79
Foreword

Right insulator × rear bracket (nut)

41.6～62.4 Nm
Rear insulator× front suspension crossmember

Front suspension crossmember sub-assembly × rear bush 105.6～158.4 N m

Left stopper × left bracket 39.2～58.8 Nm

Left rear shock absorber × left rear axle bracket 107.8～156.8 N m

Right rear shock absorber × right rear axle bracket 107.8～156.8 N m

Rear suspension lower control arm No.1 × rear axle

110～140 Nm
Rear suspension lower control arm No.2 × rear axle

Rear stabilizer bar × rear suspension lower arm 9.8～15.68 Nm

Rear stabilizer bar× stabilizer strut rod welding assembly 9.8～15.68 Nm

Rear stabilizer strut rod welding assembly ×stabilizer

18.62～30.38 Nm
prop stand

Front stabilizer bar × front stabilizer bar connecting bar

(left)
40～60 Nm
front stabilizer bar × front stabilizer bar connecting rod
(right)

Front stabilizer bracket × front stable pole support 28～45.5 Nm

Front shock absorber ×front axle 107.8～156.8 Nm

Front axle×drive shaft 170～230 Nm

Front axle hub left nut

170～230 N m
Front axle hub right nut

Left rear strut rod ×rear axle

110～140 Nm
Right rear strut rod× rear axle

Lower arm ×front suspension crossmember (horizontal) 70.6～105.8 Nm

Shock absorber ×steering knuckle 107.8～156.8 Nm

Front suspension arm ball head 78.4～117.6 N m

00-80
 Foreword

Brake system

Service data
Brake pedal height (from the braking plate) 134±5 mm
Left-hand drive
Brake pedal free travel （1～6）m m
Brake pedal reserve travel （3～7）m m
Clearance between booster pump push rod Push rod to shell end surface 23.1±0.1 mm
and piston (with SST)
Front brake pad thickness 10 mm
Standard
Front brake pad thickness 1 mm
Minimum
Front brake disc thickness 11 mm
Standard
Front brake disc thickness 10 mm
Minimum
Front brake disc end jump 0.05 mm
Maximum
Rear brake drum inner diameter (standard) 180 mm
Rear brake drum inner diameter (maximum) 181 mm
Rear brake pad thickness (standard) 4 mm
Rear brake pad thickness (minimum) 1 mm
Clearance between rear brake drum and brake Automatically adjusted to the designed
shoe value, manual adjustment not allowable
Travel of the parking brake lever under 196N 4～9
Brake light switch clearance 0～2.4mm

00-81
Foreword

Torque specifications
Rear brake tube No.3 and No.4 × rear brake hub

Rear brake hose × chassis tube 12.7～17.6 Nm

Rear brake hose assembly ×rear brake tube No.3, No.4

Brake pedal × instrument panel reinforcement

16.8～25.2 Nm
TCU bracket × dinstrument panel reinforcement

No-tank master cylinder ×master cylinder to flexible hose

12.7～17.6 Nm
tube

Front brake hose×front axle 19.6～26.5 Nm

Front brake hose assembly×front disk brake caliper 19.6～26.5 N m

Front brake hose × front brake tube

12.7～17.6 Nm
Rear brake hose × rear brake tube

Brake master cylinder × tube

12.7～17.6 Nm
ABS control unit

Vacuum booster x mounting nut 12.7 Nm

Brake light switch assembly lock nut 14～20 N m

Brake master cylinder with booster assembly × dash panel 12.7 Nm

Hub nut 88～118 N m

Handbrake cable retainer × body floor 4～7 N m

Parking brake lever assembly × body floor 15～22 N m

00-82
 Foreword

Steering system

Service data

steering wheel
Steering wheel free travel 30mm
Maximum
steering torque when idling 4.5Nm
Minimum
spring length (force free) Minimum
Mechanical steering gear box
wear capacity of steering gear
Maximum
Total preload adjust nut10±2 Nm locknut35-45 Nm
steering power
wear volume of steering rack Maximum
Total preload adjust nut10±2 Nm locknut35-45 Nm

00-83
Foreword

Torque specifications
EPS steering column × instrument panel reinforcement
16.4～24.7 Nm
(bolts, nuts)
Electric power steering ECU × instrument panel
14.4～21.6 Nm
reinforcement
No-tank master cylinder × master cylinder to flexible hose
12.7～17.6 Nm
tube
Universal joint splined yoke sub-assembly × steering gear
29.4～44.1 N m
box with tie rod
Steering gear box with tie rod ×front suspension
40～60 Nm
crossmember

Steering gear box with tie rod×front axle 29.4～44.1 Nm

EPS steering column × universal joint splined yoke with

shaft
universal joint splined yoke with shaft × universal joint 22.7～34 Nm
splined yoke subassembly

Bolt of universal joint splined yoke with shaft

Steering gear box with tie rod assembly ×front suspension

40～60 Nm
crossmember

Shock absorber × steering knuckle 107.8～156.8 Nm

00-84
 Foreword

Body electrical system

Service data

Fuel gauge
Float position Resistance value
F: 7 ohm
1/2 32.5 ohm
E: 95 ohm
Water temperature sensing meter
60℃ 181.1 ohm
115℃ 33.8 ohm

00-85
Foreword

Body

Torque specifications
Engine hood lock assembly fastening bolt 8.0 Nm

Passenger side airbag assembly× instrument panel 8～10 N m

reinforcement

AMT model instrument panel reinforcement× clutch

pedal
16.8～25.2 N m
Non AMT model instrument panel reinforcement ×
TCU bracket

Airbag ECU×body 17.5 Nm

Front stabilizer bar mounting bracket×body 28～45.5 Nm

Brake master cylinder×body 12.7 Nm

Right isolator×body 36～54 Nm

ABS control unit bracket×body（1 bolt） 15.3～22.9 Nm

ABS control unit bracket×body（2 bolts） 18.8～28.2 Nm

Left front shock absorber×body

19.6～29.4 Nm
Left rear shock absorber×body

Right front shock absorber×body

19.6～29.4 Nm
Right rear shock absorber×body

Left front seat outer belt ( lower)×body

（H exagon flange bolt90105-11036）
42 Nm
Right front seat outer belt ( lower)×body
（H exagon flange bolt90105-11036）

Left front seat outer belt ( upper)×body

42 Nm
Right front seat outer belt (upper)×body

Left rear seat outer belt ( lower)×body 42 Nm

00-86
 Foreword

Right rear seat outer belt ( lower)×body

Left front seat outer belt ( lower)× body（bolt with pad

91631-60612）
4.9 Nm
left front outside seat belts ( lower)×body（bolt with
pad 91631-60612）

Rear seat back lock ring sub-assembly×body、Rear

5.5～10.2 Nm
seat back lock ring sub-assembly×rear seat

Rear seat cushion×body

Left front seat×body 37 Nm

rRght front seat×body

Fuel tank×body 18～39 Nm

Relay block×body 3.0～7.0 N m

Door check assembly×body 30 Nm

Door check assembly×door 5.5 Nm

Door power window regulator assy×door 8.0 Nm

Nut on the battery positive and negative terminal 6.9～8.9 N m

Battery negative terminal×engine left bracket 20.6～30.4 N m

Battery negative terminal×body 9.8～15.7 N m

Fuel tank inlet pipe×body 27.2～40.8 Nm

Right rear combination lamp assembly×body

3～7 N m
Left rear combination lamp assembly×body

Battery positive terminal×harness 9.8～15.7 Nm

Battery positive wire 6.9～8.9 Nm

Battery negative wire 6.9～8.9 Nm

Wiper motor×body 4.0～7.0 Nm

Wiper arm×Wiper motor 15～26 Nm

Front wiper motor assembly ×front wiper link 4.0～7.0 N m

00-87
Foreword

assembly

Engine hood lock assembly×body 8.0 Nm

Install tires (rim × front wheel hub, rim× rear wheel

88～118 Nm
hub)

Clutch hose bracket ×body 15.3～22.9 Nm

Left insulator ×body 70.4～105.6 Nm

Front suspension beam ×body（front） 56～84 Nm

front suspension crossmember×body（middle） 105.6～158.4 Nm

Front suspension crossmember 40～60 N m

subassembly×body（rear）

Chassis tube × 2-way valve 12.7～17.6 Nm

Rear stabilizer bar×body 9.8～15.68 Nm

Rear suspension lower control arm No. 1×body 110～140 Nm

Rear strut rod×body 110～140 Nm

Front suspension crossmember ×body（left rear）

40～60 Nm
Front suspension crossmember×body（right rear）

Left front shock absorber with coil spring

assembly×body 19.6～29.4 N m

Right front shock absorber with coil spring

assembly×body

Upper anchor of right front seat outer belt

assembly×body

Upper anchor of left front seat outer belt

assembly×body
42.0 Nm
Lower anchor of right front seat outer belt
assembly×body

Lower anchor of left front seat outer belt

assembly×body

00-88
 Foreword

Lower anchor of right front seat outer belt retractor ×B

column

Lower anchor of left front seat outer belt retractor ×B

column

Upper anchor of right front seat outer belt retractor ×B

column
4.9 Nm
Upper anchor of left front seat outer belt retractor ×B
column

Upper anchor of right rear seat outer belt

assembly×body

Upper anchor of left rear seat outer belt

assembly×body

Upper anchor of right rear seat outer belt

assembly×body 42.0 Nm
Upper anchor of left rear seat outer belt
assembly×body

Right rear seat outer belt retractor×body

Left rear seat outer belt retractor×body

Right rear seat central belt assembly×body

Left rear seat central belt assembly×body 15～22 Nm

Harness negative terminal× body 6.9～9.8 Nm

Right outer rearview mirror assembly×door

6.0～10.0 N m
Left outer rearview mirror assembly×door

Blower with shroud assembly ×radiator bracket 9.8±1.96 Nm

Radiator bracket×body 3.0～7.0 N m

Top outer panel cowl sub-assembly 5.0 Nm

Front floor neat insulator×body floor 5.5 Nm

Back door supporting bar ball joint×body 11.5 Nm

00-89
Foreword

Back door round bolt stay×back door

Front door electric lock assembly×door 5.0 Nm

Front door lock striker plate assembly×back door

23 Nm
Back door lock striker assembly

Front windshield washer jar and pump assembly×body 5.5 Nm

00-90
 Foreword

Air-conditioning

Torque specifications
Compressor assembly × compressor assembly bracket 19.6～29.4 N m
Exhaust hose sub-assembly × compressor assembly
10～12 N m
Air conditioner tube × compressor assembly
Body air conditioner tube bracket × body 9.8±1.96 Nm
Air conditioner tube × compressor 10～12 Nm
Air conditioner tube × condenser
4.4～6.4 Nm
Exhaust hose × condenser

00-91
Foreword

Engine

Torque specifications
Alternator fastening bolt (upper) torsional torque (up) 19～27 N m
Alternator fastening bolt (lower) torsional torque 40～60 N m
Engine×gearbox C 9～29 N m
Engine×gearbox B 39～53 N m
Gearbox A×engine 54～74 N m
Speed sensor fastening bolt 8.3～14.3 N m
Engine mounting rear bracket × transmission 39.2～58.8 N m
Engine mounting rear insulator × front suspension 41.6～62.4 N m
crossmember
Engine mounting rear bracket × engine mounting rear 51.2～76.8 N m
insulator
Engine mounting left bracket × transmission 51.2～76.8 N m
Engine mounting left insultor×body 70.4～105.6 N m
Engine mounting left bracket × engine mounting left 39.2～58.8 N m
insutlator
Engine mounting right insulator×body 36～54 N m
Engine mounting right insulator×engine bracket 41.6～62.4 N m
Air cleaner mounting bracket × engine mounting right 5.9～8.8 N m
insulator
Air cleaner × mounting bracket 7.8 Nm
Exhaust front pipe assembly × engine exhaust manifold 43.4～80.6 N m
Exhaust tail pipe assembly × front pipe assembly 40～60 N m
Oxygen sensor assembly ×Exhaust manifold 40～50 N m
Engine wire No.3 × left bracket 20.6～30.4 Nm

00-92
01-Engine

Engine

Engine assembly ............................................................................................................ 1

Engine assembly Removal ............................................................................................. 2

Engine assembly Installation ...................................................................................... 9

 01-Engine

Engine assembly

01-1
 01-Engine

Engine assembly Removal

Removal Preparation
Oil collector, Antifreeze recycling container,
Display rack for articles removed from power train，
Common tools, Protective clothing, Air
conditioning refrigerant filling machine and
Closure plugs.
The first step:
1. Release pressure of fuel then remove fuel hoses.
(a) Remove fuel pump relay.
(b) The engine stops automatically after starting.
(c) Turn sparking switch to the “OFF” position.
(d) Make sure that the engine is turned off work
(e) Remove the cover of fuel tank, and let out the air.
(f) Disconnect battery negative terminal post.

2. Recollect air-conditioning refrigerant.

3. Drain engine lubricating oil.
4. Drain lubricating oil in transmission case.
5. Drain antifreeze coolant in cooling system.

The second step;

1. Remove battery terminal post connection and
the ground wire of body.

2. Remove air cleaner assembly.

01-2
 01-Engine

3. Remove manual transmission shift cable

and support bracket. (MT)

4. Remove engine wire harness.

5. Remove air-conditioner pipe.

( compressor side)

Note：
●Seal both sides of the pipe.

6. Disconnect cooling water pipes (No. 1 and

NO.2)

7. Remove the connection between heating

water pipe and heating water tank

01-3
 01-Engine

8. Disconnect reverse switch connector.

● Disconnect AMT wire harness connector if there
is an automatic transmission.

9. Remove all hoses connecting engine.

10. Remove ECU plugs connecting engine wire
harness.
11. Remove transducer connecting engine.
12. Remove pipes connecting clutch pump (MT).
Using the following SST. Remove the fuel pipe,
SST: FT 9013101

13. Remove 2 bolts which connect engine vibration

isolator RH with body.
14. Remove 1 bolt which connects engine
vibration isolator LH with body.

01-4
 01-Engine

15. Remove the transmission side ground wire

The third step:

1. Lift car and install power train assembly bracket
2. Remove the wheels

3. Remove front wheels RH and LH and drive shaft.

Note：
● Inside of drive shaft, there is no retainer for
universal joint, so hold this part when removing.

4. Remove the front stabilizer bar

01-5
 01-Engine

5. Remove suspension lower cross-arm bracket

sub-assembly.

6. Remove the lower engine mounting beam LH

subassembly of engine

7. Remove the exhaust pipe and take it from the

exhaust
manifold

8. Remove the lower installation beam

subassembly of engine.

01-6
 01-Engine

9. Remove belt cover of compressor

10. Remove 2 bolts which connect transmission

rear bracket with body.

11. Remove power train assembly from the vehicle,

and
put it on the specified bracket slowly.
Note：
● Before remove the engine, double- check that all
parts are disassembled as accordingly..

12. Remove starter motor assembly from

transmission.

01-7
 01-Engine

13. Remove compressor assembly from engine

assembly.

14. Put engine assembly on the specified bracket

01-8
 01-Engine

Engine assembly Installation

The first step

1. Remove engine from the specified rack and
slowly put it on the specified bracket.

2. Install transmission (MT) assembly on engine

assembly.
（a）Install transmission on engine assembly (7
bolts) in reference to the illustration

3. Install starter motor on transmission (MT) and

tighten
the bolts after centralizing the starter motor.
Tightening torque: 36-64N.m

4. Install compressor assembly.

（a）Install compressor assembly (4 bolts).
Torque: 19.6---29.4N.m
Note：
Install compressor and tighten the bolts in sequence
according to demonstration.
.

01-9
 01-Engine

The second step

Lift the engine on specified bracket to a position
for engine installation

2. Install the engine rear mounting bracket

Tightening torque;39.2～58.8 N ·m

3. Install the engine mounting bracket LH.

Tightening torque: 51.2～76.8 N ·m

4. Install the engine mounting bracket RH.

Tightening torque:(36~54)N. m

01-10
 01-Engine

5. Install the front drive shaft.

Note:
● Install the front drive shaft on the differential
carrier carefully and slowly so as not to damage the
oil seal

●Apply 5 gram of grease to the connector gear type

shaft evenly.

6. Join transmission shaft

（a）Keep the grease off the brake disc.
（b）After threading, open the pin from the root.
Tightening torque :( 170~230)N. m

7. Install the lower cross-arm bracket.

8. Install the front stabilizer bar.

(a) Install the front stabilizer bar (4bolts)
Torque:28～45.5 N·m

9. Install the front assembly of exhaust pipe

silencer.
Tightening torque:43.4～80.6 N ·m

01-11
 01-Engine

10. Install the wheels.

(a) Tighten the wheels slightly. After removing
the backstop of the car, tighten the wheels
thoroughly.
Tightening torque :(88~118)N. m

The third step:

1. Install pipes connecting the clutch pump.
Tightening torque of tube outlet:12.7～17.6 N ·m
Install the fuel pipe ,using the following SST.
SST: FT9013101

2. Install the manual transmission shift cable and

support bracket
（a）Insert part 2 along the direction of the center of
the bracket opening.
（b）Do not tap the cable or the guide tube to avoid
deformation or distortion
（c）Ensure that the part 2 (disposable) loaded to the
bottom of tank, don’t tilt it
（d）Before assembly is finished, ensure that the
dust-proof cover and cables are not distorted and
rectify any problems.

01-12
 01-Engine

3. Install the radiator hoses (No. 1 and No.2)

(a) Insert the hoses (No.1 and No.2) into the limit
flange.
(b)
The distance between the pipe clamp and the hose
terminal is 3 to 5mm
(c) Clamp the pipe clamps, and make sure that the
hoses don't affect other parts.

4. Install the heating water hoses.

(a) Insert the hoses into the terminal of engine.
(b) The distance between the pipe clamp and the
hose terminal is 3to 5mm
(c) Pay attention to the marks on the hoses.

(d) Paint marks as shown

5. Install the fuel hoses.

(a) Join the fuel hoses with the engine fuel
distribution pipes and fix with clips.
(b) The distance between the clip and the hose is 4
to 6mm

6. Install the high-pressure pipe and low-pressure

pipe of air conditioner.
Tightening Torque:：10～12 N• m

01-13
 01-Engine

7. Install air cleaner assembly.

8. Join all cable plugs and ground wires, including

starter motor, ECU etc..

9. Install all hoses connecting engine, including the

gasoline pipe.
10. Join battery terminal post connection and the
ground wire of body.

11Connect the transmission side ground wire..

12. Fill lubricating oil into transmission case

Transmission oil capacity:1.8~2.0L

Transmission oil specification: API

GL-4,SAE:80W/90
Cold areas are recommended for SAE 75W/90

13. Fill engine oil into the engine.

Engine oil capacity:4.0L
Engine oil specification: APISL 5W/40

Note:
Check the engine oil level

01-14
 01-Engine

14. Pour coolant into radiator and fluid reservoir

Total capacity: 5.8L

Type: Glycol
Note:
●After finished, check the leakage.

15. Fill with air-conditioning refrigerant

（a) CI KLEA134a capacity: 480±15g
（b) Refrigerant of all brand names can be used.

01-15
 02-Body Electrical Equipments

Body Electrical Equipments

Body electrical system .......................................................................................................... 1

Ignition Switch .................................................................................................................... 15
Lighting system................................................................................................................... 16
Head light ............................................................................................................................ 27
Front fog lamp..................................................................................................................... 29
Left turn signal lamp ........................................................................................................... 30
Left rear combination lamp assembly ................................................................................. 31
Stop lamp ............................................................................................................................ 33
License plate light ............................................................................................................... 34
Combination switch ............................................................................................................ 35
Left wiper blade rubber ....................................................................................................... 45
Windshield wiper switch assembly ..................................................................................... 46
Audio system ...................................................................................................................... 48
Radio Assembly .................................................................................................................. 50
Front Speaker Assembly ..................................................................................................... 51
Antenna Sub-assembly........................................................................................................ 52
Cigarette lighter assembly................................................................................................... 53
Horn System........................................................................................................................ 54
Woofer Assembly ................................................................................................................ 56
Power window control system ............................................................................................ 57
Wireless door lock control assembly .................................................................................. 68
Gate controlled remote controller ....................................................................................... 72
Rear defrost control system ................................................................................................ 73
 02-Body Electrical Equipments

Body electrical system

Maintenance Precautions
Inspection
When removing and replacing the electronics, please note:
Headlamp
Scratching or falling may cause an explosion. Only the plastic or metal parts of the bulb can be
held by hand .Do not touch the bulb glass with bare hands.
audio system
Vita V2 is installed with CD audio system which supports for the MP3 playing.
The chapter demonstrates the mechanical disassembly. The circuit in section can refer to the
circuit diagram.
Malfunction Table
Ignition switch
Problems Malfunction Area
Ignition switch 1.Ignition switch
2.Power Switch

Headlamp and taillights

Problems Malfunction Area
Only one headlight works. 1． Bulb
2． Fuse
3． Wiring
The low beam lights do not 1.Light control switch
work. 2.Wiring
The high beam lights do not 1.Headlamp dimmer switch
light. 2.Wiring
The headlamp does not work. 1. Light control switch
2. Wiring
The headlamp does not work. 1. Bulb
2. Wiring

The headlamps flash 1. Bulb

2. Wiring

The light of headlamp is dim. 1. Bulb

2. Wiring

02-1
02-Body Electrical Equipments

Only one taillight works 1. Bulb

2. Wiring

The taillight does not work 1.Light control switch

(while headlamps work 2.Taillight fuse
normally). 3. Wiring

The taillights do not work 1. Light control switch

(while headlights work 2. Wiring
abnormally).
The rear combination lamps 1. Bulb
do not work 2. Wiring

Rear fog lamp

Problems Malfunction Area
When turning on the taillight or headlamp ,the 1.Bulb
rear fog lamp does not light (while headlamp 2.15A Front fog lamp fuse 15A
works normally) 3.Rear fog lamp switch
4.Wiring
5.Compact controller for shield wipers, turn
signal lights and fog lights
When turning on the taillight or headlamp ,the 1.Headlamp and taillight system
rear fog lamp does not light (while headlamp 2.Wiring
does not work ) 3.Combination switch
The rear fog lamp does not light 1.Bulb
2.Wiring
3.Compact controller for shield wipers, turn
signal lights and fog lights

Turn signal lamp and hazard warning indicator lamp

Problems Malfunction Area
The turn signal lamp and warning indicator lights 1.Warning indicator lights switch
do not light 2.Compact controller for shield wipers, turn
signal lights and fog lights
3.Wiring
The flash rate is abnormal 1.bulb
02-2
 02-Body Electrical Equipments

2.Compact controller for shield wipers turn

signal lights and fog lights
3.Wiring
The warning indicator lights do not light（turn 1.Horn / hazard warning fuse

signal lamp is normal） 2.Wiring

The warning indicator lights at one side do not 1. Compact controller for shield wipers turn
light signal lights and fog lights
2. Wiring
The turn signal lamp at one side does not light 1Ignition switch
2Meter fuse ，10A ； EFI-IG fuse，7.5A
3Turn signal switch
4. Wiring
5. Compact controller for shield wipers turn
signal lights and fog lights
The turn signal at one side does not light 1.Turn signal switch
2.Wiring
Only one bulb does not light 1Bulb
2Wiring

Interior light
Problem Malfunction Area
The interior light does not light 1 Interior light fuse 10A
2Bulb
3Interior light
4Wiring

Reversing light

Problems Malfunction Area

The reversing light does not light 1Meter fuse 10A
2Ignition switch
3Wiring
4Bulb
The reversing light works normally Reversing light switch

02-3
02-Body Electrical Equipments

Wiring

Stop lamp
Problems Malfunction Area
The stop lamp does not light （1） Brake light fuse 10A
（2）Stop lamp switch
（3）Wiring
Only one light lights normally 1. Wiring
Only one light does not light 1.Bulb
2.Wiring

02-4
 02-Body Electrical Equipments

Wiper and washer

Problems Malfunction area

The front wiper and washer do not work 1.Wiper fuse 20A
2Front Wiper switch
3Front Wiper Motor
4Wiring
The front wiper does not work at low-or 1.Front Wiper switch
high-speed 2Compact controller for shield wipers, turn signal
lights and fog lights
3Front Wiper Motor
4Wiring
The front wiper does not work when the wiper 2.1 Front Wiper switch
switch is set to the intermittent position 2Compact controller for shield wipers, turn signal
lights and fog lights
3Front Wiper Motor
4Wiring
The front Wiper Motor does not work 1Wiper fuse
2Wiring
The front wiper does not work when turning on 1.Wiring
the washer
The washer fluid can not be sprayed 1. The washer hose and nozzle
When turning off the wiper, the wiper fail to 1.Wiper switch
return or return to the wrong position 2.The initial installation position of wiper arm
3.Wiring

02-5
02-Body Electrical Equipments

Dashboard indicator lights and Illumination Lights

Instrument Cluster

Problems Malfunction area

The tachometer, fuel gauge and water temperature （1）Instrument fuse 10A
meter are abnormal （2）Dashboard circuit board
（3）Wiring
The speedometer does not work 1.Speed sensor
2.Dashboard circuit board
3.Wiring
The tachometer does not work 1. Engine
2. Dashboard circuit board
3. Wiring
The fuel gauge does not work or does not work 1.Fuel gauge
normally 2.Fuel sensor
3.Dashboard circuit board
4.Wiring
None of the illumination lights work. (1) Taillight fuse 7.5A
(2) Dashboard circuit board
(3) Wiring
Only one illumination light does not light (1)Bulb
(2)Wiring

02-6
 02-Body Electrical Equipments

Warning indicator lamp

Instrument Cluster
Problems Malfunction area
The warning indicator lamp does not light (except (1) Instrument fuse 10A
the charging, door opening and supplemental (2) Dashboard circuit board
restraint system) (3) Wiring
The warning indicator lamp for low oil pressure 1Bulb
does not work 2Low oil pressure warning switch
3Dashboard circuit board
4.Wiring
The ABS warning indicator lamp does not work 1.Bulb(Water temperature warning indicator
light )
2. Electronic control unit of anti-lock braking
system
3. Wiring
The breaking warning indicator lamp does not 1Bulb
work 2. Parking brake switch
3. Brake fluid level warning switch
4. Dashboard circuit board
5 Wiring
The warning indicator lamp for the open door 1.Interior light fuse10A
does not work 2.Bulb
3.Gate controlled switch
4.Dashboard circuit board
5.Wiring
The AMT warning indicator lamp 1.Bulb
2.TCUAMT control unit
3.Dashboard circuit board
4. Wiring

The airbag warning indicator lamp 1. Bulb

2. Airbag control unit
3. Dashboard circuit board
4. Wiring

02-7
02-Body Electrical Equipments

The safety belt warning indicator lamp 1. Bulb

2. Safety belt control unit
3. Dashboard circuit board
4. Wiring
The malfunction warning indicator lamp does not 1. Bulb
work 2. Engine electronic control unit
3. Dashboard circuit board
4. Wiring
The safety belt warning indicator lamp 1. Bulb
2 Electronic control unit of electronic power
steering
3 Dashboard circuit board
4. Wiring
EBD warning lights 1.Bulb
2. Dashboard circuit board

3.Wiring
4. Electronic control unit of anti-lock braking
system

charging warning lights 1.Bulb

2. Dashboard circuit board

3.Wiring
4.Generator voltage regulator

02-8
 02-Body Electrical Equipments

Indicator lamp
Instrument Cluster
Problems Malfunction area
The dimmer indicator lamp does not work 1Bulb
2.Dashboard circuit board
3.Wiring
4.Headlamp system
The direction indicator lamp does not light 1.Bulb
2.Dashboard circuit board
3.Wiring
4.Direction indicators and warning indicator lights
system
The indicator lamp does not light（exceptfor the 1. Instrument fuse 10A
direction、high beam 、front and rear fog 2.Wiring
indicator lamps
The rear fog indicator lamp does not light 1. Instrument
2. Wiring
The front fog indicator lamp does not light 1. Instrument
2. Wiring
Background light 1.Taillight fuse 7.5A
2.Wiring
3. Bulb of dashboard background light

Defrost system
Problems Malfunction area
The defrost system does not work 1. Defroster fuse25A
2.Defroster switch
3.Wiring
The rear heater fan does not work （1）Defroster switch wire
（2）Heating wire broken
（3）Wiring

02-9
02-Body Electrical Equipments

Power Window control system

Problems Malfunction Area
All power windows do not work (electric door lock 1.Instrument fuse
does not work) 2.Power Window fuse 30A
3.Door locks and Power Windows
controller
4.Wiring
All power windows do not work (electric door lock 1.Ignition switch
work normally) 2.Power Window Switch
3.Wiring
Only one window glass does not work 1.Power Window master switch
2.Power Window Switch
3.Power Window motor
4.Wiring
“The power window locking system" does not Power Window master switch
work

Power door lock control system

Problems Malfunction area
The whole "door lock system" does not work （1）Door lock fuse 15 A
（2）Instrument fuse10A
（3）Door lock and power window
controller
（4）Wiring
The manual door lock system does not work 1.Door lock and power window controller
2.Door lock control switch
3.Wiring
Key can not control the door lock system 1.Lock and unlock switch of the door
2.Wiring
3.Door lock cable disengage
Only one door lock does not work 1.Door lock motor
2.Wiring

Power rear view mirror control system

Problems Malfunction Area
02-10
 02-Body Electrical Equipments

The power rear view mirror does not move (a) Cigarette lighter fuse 15A
(b) Power rear view mirror switch
(c) Power rear view mirror motor
(d) Wiring
The power rear view mirror does not move 1.Power rear view mirror switch
normally 2.Power rear view mirror motor
3.Wiring

02-11
02-Body Electrical Equipments

Battery

02-12
02-Body Electrical Equipments

02-13
02-Body Electrical Equipments

02-14
 02-Body Electrical Equipments

Ignition Switch
Replacement
1. Remove the cover of the steering column.

2. Remove the ignition or starting switch

assembly.
(a) Disconnect the ignition switch connector
from the unlocking warning switch connector.
(b) Remove the clamp
(c) Remove the 2 screws and the ignition switch.
Inspection
Inspect the ignition or starting switch assembly
Standard
Switch Continuity Regulation
Position Test State
LOCK off
ACC 1↔3 On
1↔2↔3
ON 5↔6 On
4↔5↔6 On
START（on） 1↔2

If the continuity does not met the specifications,

replace the switch.

02-15
02-Body Electrical Equipments

Lighting system
Defense system
a) When replacing the headlamps, the
following situations should be prevented from
happening.
b) The halogen bulb (headlamp and front fog
lamp) reaches a very high temperature while it is
put into use. If stained by lubricants or oil, the
lamp life will be significantly reduced..
c) Operate with caution. The high pressure in
the halogen bulbs(headlamp and front fog lamp)
may result in explosion once the the bulb is
broken and the shards may shatter.
d) If the lamp glass and bulbs are taken down
for a long time, the glass will be stained by the
dust and water vapor. Therefore, a piece of new
glass is needed when replacing bulbs
e) When replacing, always use bulbs of the
same power.
f) After installing the bulbs, the socket should
be plugged tightly. Otherwise, the glass will be
fuzzy or the steam will be leaked.

02-16
 02-Body Electrical Equipments

Details

02-17
02-Body Electrical Equipments

02-18
 02-Body Electrical Equipments

Vehicle Inspection
Inspection
1. Combination switch assembly of headlamp
a) Check whether the light control switch is in
conducting state.
(1) Check whether continuity exists between the
respective terminals as indicated in the
following table, when the switch is set to each
position.
Standards：
Switch Terminal Regulation
Position Test State
OFF 9↔10 off
11↔12
TAIL 11↔12 on
HEAD 9↔12 on
10↔11
HEAD 10↔11 on

If the requirements are not met, replace the

switch.
b) Check whether the headlamp combination
switch is in conducting state.
(1)Check whether continuity exists between the
respective terminals as indicated in the
following table, when the switch is set to each
position..
Standards：
Switch Terminal Regulation
Position Test State
High beam 8↔10 on
light
Low beam 7↔10 on
light

Overtaking 9↔10 on
flasher

02-19
02-Body Electrical Equipments

Instruction：
■When checking the "the high beam " and " the
passing beam“，set the combination switch to
the headlamp position
If the requirements are not met, replace the switch
c) Check whether the turn signal switch is in
conducting state.
(1)Check whether continuity exists between the
respective terminals as indicated in the
following table, when the switch is set to each
position.
Standard：
Switch Terminal Regulation
Position Test State

Right-turn 5↔6 on
Space 4↔5↔6 off
Left-turn 5↔4 on

If the requirements are not met, replace the

switch
d) Check whether the front, rear fog lamp
switch is in conducting state
(1) Check whether continuity exists between the
respective terminals as indicated in the
following table, when the switch is set to each
position.
Standard：
Switch Terminal Regulati
Position Test on State
OFF 1↔2↔3 off
Front fog lamp 1↔3 on
OFF
Front and rear 1↔2↔3 on
fog lamp ON

If the requirements are not met, replace the

switch
2. Reversing light switch assembly

02-20
 02-Body Electrical Equipments

a) Check whether the reversing light switch

assembly is in conducting state
(1) when the switch is working, check whether
continuity exists between terminal No.1 and
No.2
Standard：
Switch Terminal Regulation
position test state
ON 1↔2 on
OFF 1↔2 off

If the requirements are not met, replace the

switch
3. stop light
a) Check whether the stop light switch
assembly is in conducting state
(1) when the switch is working check whether
continuity exists between terminal No.2and
No.4
Standards：AMT
Switch Terminal Regulation
Position Test State
Push in the switch 1↔3 on
pin（P ress the pedal） 2↔4 off
Pop up the switch pin 1↔3 off
（R elease the Pedal） 2↔4 on

If the requirements are not met, replace the

switch
(2)When the switch is working， check whether
continuity exists between terminal No.1 and
No.2.
Standard：MT
Switch Terminal Regulation
Action Test State
Push in the switch pin 1↔2 On
（P ress the pedal）
Pop up the switch pin 1↔2 Off
（R elease the Pedal）

02-21
02-Body Electrical Equipments

4. Integrated control panel assembly

a) Check whether the warning signal switch is
in conducting state
(1) When the switch is working, check whether
continuity exists between terminal No.1 and
standards：
Switch Terminal Regulation
Position Test State
ON 1↔2 ON
OFF 1↔2 OFF

If the requirements are not met, replace the

switch
b) Check the illumination system
(1)battery positive (+) to terminal No.4 , negative
(-)to terminal No.3. Check whether the
illumination system works.
If continuity does not exist, replace the integrated
control panel assembly
5. The front door indicator lamp switch
assembly
a) Check whether the indicator lamp switch
assembly of the front door is in conducting state.
(1) When the switch is working ,check whether
continuity exists between terminal No.1 and the
body ground.
Standards：
If the requirements are not met, replace the
switch
Switch Terminal Regulation
R ear door gate control Position Test State
switch assembly
OFF 1↔ Body OFF
ground
OFF 1↔ Body OFF
ground

02-22
 02-Body Electrical Equipments

b) Check whether the rear door indicator lamp

switch assembly is in conducting state
(1) When the switch is working， check whether
continuity exists between terminal No.1 and
body ground
Standards：
Switch Terminal Regulation
Position Test State
ON 1↔ Body OFF
ground
OFF 1↔ Body ON
ground

If he requirements are not met, replace the

switch
6. Interior light assembly
(a) Check whether the Interior light assembly is
in conducting state
(b) When the switch is working， check whether
continuity exists between terminal No.1 and
No.2
Standards：
Switch Terminal Regulation
Position Test State
ON 1↔2 OFF
DOOR 1↔2 ON
OFF 1↔2 OFF

If the requirements are not met, replace the bulb

02-23
02-Body Electrical Equipments

02-24
 02-Body Electrical Equipments

Front combination lamp assembly

02-25
02-Body Electrical Equipments

Replacement
Instruction：
Details：
1. Remove the radiator grille sub assembly
2. Remove the front bumper
3. Remove the left headlamp assembly
(a) Remove the 2 screws and 2 bolts
(b) Remove the connector
(c) Pull out the headlamp assembly by pulling
forward
(d) Remove the headlamp assembly
4. Remove the bulb of the width lamp
(a) As shown in the figure, remove the width
lamp together with the lamp socket
(b) Pull out the width lamp bulb from the socket
5. Remove the bulb of the front turn signal lamp
(a) As shown in the figure, remove the front turn
signal lamp bulb and the socket
(b) Remove the front turn signal lamp bulb from
the socket
6. Remove the headlamp cover
7. Adjust the headlamp beam

02-26
 02-Body Electrical Equipments

Head light
ADJUSTMENT
1.Adjust the headlamp beam
(a) Adjust the vehicle to the following conditions
（1）Ensure the body near the headlamps is not deformed
（2）Park the vehicle on a level surface.
（3）The tire pressure is within the standard value
（4）The Driver sits in the cab and is ready to start (the tank is filled up)
(b) Check the headlamp beam
（1） Prepare a piece of thin white paper
（2） Place the paper vertically in front of the headlamp with a distance of 3m (9.84ft)
（3） As shown in the figure, ensure that the angle between the vehicle center line and the
paper is 90 degree
（4） Draw a horizontal line ( H line) on the paper, indicating the possible light distribution
area of the headlamp
（5） Draw a vertical line (V line)which indicates the center of the vehicle
（6） Draw two vertical lines indicating the possible light distribution area of the headlamps on
both right and left sides
（7） Draw a horizontal line (connect the center mark of two passing lamps) which intersects
the headlamp's possible light distribution area (H line on the right and Left sides)
（8） Measure correctly to prevent other light from interfering
Instruction:The H lines on the both right and left sides are 0.57º lower than horizontal
line (H line) at the light axial direction

（9） Start the engine

（10） Open the headlamp
（11） Check whether the headlamp's light distribution area is as the one indicated in the
figure.
（12） If not, adjust the headlamp in the vertical direction.

02-27
02-Body Electrical Equipments

Instruction: As shown in the figure ,adjust the

position on the right and left side at the same
time
■ When adjusting in the vertical direction:
Adjust bolt A within the allowable range
■ When adjusting in the horizontal direction:
Adjust bolt B within the allowable range

02-28
 02-Body Electrical Equipments

Front fog lamp

Replacement
1.Remove the radiator grille sub assembly
2. Remove the front bumper
3. Remove the left fog lamp assembly
（a）Disconnect the connector
（b） Loosen the 5 clips and remove the fog
lamp cover
（c）Remove the 3 screws and remove the left
fog lamp assembly
4. Remove the fog lamp bulb
5. Adjust the vehicle state
6. Adjust the fog lamp beam
Adjust the fog lamp beam
(a) The fog lamp beam can be adjusted in the
vertical direction by rotating the adjusting
screw.

02-29
02-Body Electrical Equipments

Left turn signal lamp

Replacement
1. Remove the left front headlamp assembly
(a) Remove the 2 screws and 2 bolts
(b) Remove the connector
2. Remove the socket of the front turn signal
lamp, disconnect the connector, unscrew the
front turn lamp bulb

3.Remove the left rear headlamp assembly

(a)Remove the bolt connecting the rear
combination lamp to the body

4. Remove the socket of the rear turn signal

lamp, disconnect the connector, unscrew the rear
turn lamp bulb

02-30
 02-Body Electrical Equipments

Left rear combination lamp assembly

Replacement

1.Remove the left rear headlamp assembly

(a)Remove the bolt connecting the rear
combination lamp to the body
(b) Disconnect the connector
2. Pull out the rear combination lamp assembly
by pulling forward

3. Remove the rear combination lamp assembly

02-31
02-Body Electrical Equipments

4.Remove the rear turn signal lamp bulb

(a) As shown in the figure, unscrew the turn
signal bulb from the socket, pay attention to the
locking position

5.Remove the rear brake light

(a) Remove the LED rear brake light from the
rear combination lamp socket, disconnect the
connector

6. Remove the reversing light

(a) As shown in the figure, unscrew the bulb of
the reversing light from the socket, pay attention
to the locking position

02-32
 02-Body Electrical Equipments

Stop lamp
Replacement
1. Remove the left rear headlamp assembly
（a）Remove the bolt connecting the rear
combination lamp to body
（b）Disconnect the connector
2. Pull out the the rear combination lamp
assembly by pulling forward
3. Remove the rear combination lamp assembly

4. Remove the rear brake light

(a) Remove the LED rear brake light from the
socket , disconnect the connector

5. Central brake light assembly

remove the central brake light assembly
（a）As shown in the figure, pull down the
central brake light assembly, unscrew the 2
screws.
（b）Disconnect the connector

02-33
02-Body Electrical Equipments

License plate light

Replacement
1. Remove the lock cylinder of the trunk or set
with the key
2. Remove the trim bar outside the trunk door
3. Remove the license plate lamp assembly
As shown in the figure, pull out the license plate
light assembly, loosen the caliper, disconnect the
connector.
4. Remove the bulb of the license plate lamp
5. Remove the socket and wires of the license
plate lamp

02-34
 02-Body Electrical Equipments

Combination switch
Removal
1. Remove the air bag, the steering wheel, the
spiral cable
(Please refer to the air bag removal and
installation )
2. Remove the steering column cover
(a) Remove the 2 screws
(b) Remove the steering column cover
3. Remove the light control switch
(a) Disconnect the light control switch
connector
(b) Remove the light control switch from the
turn signal switch bracket.
4.Remove the wiper and the washer switch
(a) Remove the wiper and the washer switch
connector
(b)Remove the switch from the turn signal
switch bracket

02-35
02-Body Electrical Equipments

02-36
 02-Body Electrical Equipments

Wiper and the washer system

Parts Position

02-37
02-Body Electrical Equipments

Malfunction Table
Instruction：
The following table will help you to find out the cause of the malfunction. The numbers in the
table indicate the priority of possible causes to malfunction,. Check each part according to the order of
the list and replace them if necessary
1. The wiper and the washer system
Problem Possible Malfunction Area
The wiper does not work 1.Wiper fuse
2.Windshield wiper switch assembly
3. Wiring
The wiper does not work when the wiper 1. Windshield wiper switch assembly
switch is set to the intermittent position 2. Windshield wiper motor assembly
3. Wiring
The washer motor does not work 1.Wiper fuse
2.Windshield wiper switch assembly
3.Washer motor assembly
4.Wiring
When the washer is turned on, the front 1. Windshield wiper switch assembly
wiper does not work 2. Windshield wiper motor assembly
3. Wiring
The washing fluid can not be sprayed 1.Washer hose and nozzle
• When the wiper is turned off,the wiper
blade can not return or return back to the
1.Windshield wiper motor
wrong position
assembly（w iper arm and blade position ）
•The wiper blade and the body touch each
other
Inspection of washer motor
1.Washer motor
a) Inspection of working state
b) Install the washer motor and the pump to the
tank system, pour water into the tank
c) Disconnect the connector of the washer
motor.
d) Connect terminal No.1 of the washer motor
to the battery positive (+) , terminal No.2 and the
negative (-) . Check whether the water in the tank
02-38
 02-Body Electrical Equipments

flows out or not.

If there is no outflow, replace the washer motor
and the pump.
Wiper Inspection
1. Windshield wiper switch assembly
(a) Continuity Inspection
(1)Check whether each terminal on the
connector is in conducting state
Standards：
front wiper switch
Switch Terminal Regulation
Positon Test State
MIST 7（+1）-8（+B ） on
OFF 6 (+S) -7 (+1) on
INT 6 (+S) -7 (+1) on
LO 7（+1）-8（+B ） on
HI 8 (+B) -9 (+2) on

The front washer switch

Switch Terminal Regulation
Position Test State
OFF - off
ON 4（W ）-5(EW) on

If it is off, replace the switch

(b) Inspection of intermittence state
（1）Connect the voltmeter positive (+) to
terminal No.7(+1) of the connector, the negative
(-) to the terminals No.5 (EW )
（2）Connect the battery positive (+) to terminal
02-39
02-Body Electrical Equipments

No.8(+B) of the connector, the negative (-) to

the terminals No.5(EW) and No.6(+S)
（3）Turn the wiper switch to the position of
INT for 5 minutes
（4）Connect the battery positive (+) and
terminal No.6 (+ S) of the connector for 5
minutes
（5）Connect the battery negative (-) and
terminal No.6 (+ S)of the connectors . Start the
intermittent wiper relay, measure the voltage
between terminal No.7 (+ 1) and terminal No.5
(EW)
Standards: refer to the figure
If the requirements are not met, replace the
switch

(c) Inspection of working state (wiper switch)

（1） Turn the wiper switch to the OFF
position
（2） Connect the battery negative (+) to
terminal No.8 (+ B)of the connector ,the negative
(-) to terminal No.6 (+ S)
（3） Connect the voltmeter positive (+) to
terminal No.7(+1) of the connector, negative (-) to
terminal No.5 (EW) .Turn the wiper switch to the
ON and OFF position, measure the voltage
between terminal No.7 (+) and terminal No. 5
(EW)
Standard: refer to the figure
If the requirements are not met, replace the
switch

02-40
 02-Body Electrical Equipments

Windshield wiper motor assembly

(a)inspection of low-speed state
(1)Connect the battery positive (+) to terminal 1
(+) of the connector，the negative (-) to terminal
2(E) , check the motor speed in low speed state.
If the requirements are not met, replace the
motor

(b) Inspection of high-speed state

(1) Connect the battery positive (+) to terminal
No. 3 (+2）of the connector, negative (-) to
terminal No.2 (E). Check the motor speed in
high speed state
If the requirements are not met,, replace the
motor

(c) Inspection of automatic reset

(1) Connect the battery positive (+) to terminal
No. 1 (+1）of the connector, the negative (-) to
terminal No.2 (E). Make the motor rotate at low
speed, disconnect terminal No. 1 (+)to stop the
motor rotating at any position.

(2) Connect terminal No.1 (+) to terminal No.5

(S), the negative (-) to terminal No.2 (E) of the
connector, the positive (+) to terminal No. 4 (B)
to make the motor restart at low speed.

(3) Check whether the automatic reset is normal.

Standards: refer to the figure
If the requirements are not met, replace the the
motor.

02-41
02-Body Electrical Equipments

Windshield wiper motor assembly

Replacement
（1） Remove the windshield wiper arm
cover
（2） Remove the front right windshield
wiper arm
(a) Start the wiper, let it stop at the automatic
reset position
(b) Remove the nuts of the front right
windshield wiper arm
（3） Remove the nuts of front left windshield
wiper
(a) Remove the nuts of front left windshield wiper
arm
（4） Remove the cover on the engine hood
seal
(a) Loosen the 7 clamps with a clamp remover ,
then remove the cover on the engine hood seal,
（5） Remove the louver at the right side of
the engine hood
(a) Remove the 3 calipers and loosen the 4 clips
with a clamp remover, then remove the louver at
the right side of the engine hood.

（6） Remove the louver at the left side of

hood
(a) Remove the clamps and loosen the 4 clips
with a clamp remover. Then remove the louver
at the left side of the hood ..

（7） Remove the connecting assembly of

windshield wiper
(a) Disconnect the connector.
(b) Remove the 2 bolts.
(c) Move the wiper connecting assembly
toward .the passenger. Loosen the rubber pin,
remove the wiper connecting assembly

02-42
 02-Body Electrical Equipments

（8） Remove the windshield wiper motor

assembly
(a) Loosen the 2 pins on the crankshaft of
windshield wiper motor assembly with a
screwdriver.
■ Wrap the head of the screwdriver up before
using.

(b) Remove the 2 torque bolts and windshield

wiper motor assembly.

（9） Install the windshield wiper motor

assembly
(a) Smear the MP lubricant on the crankshaft
arm shaft of the windshield motor assembly.

(b) Install the windshield wiper motor assembly

to the windshield wiper connecting assembly
with 2 torque bolts.
torque：7.5N•m

（10） Install the windshield wiper connecting

assembly
(a)Install the rubber pin
(b) Install the windshield wiper connecting
assembly with 2 nuts
Torque：4.0—7.0N•m

(c)Connect the connector

02-43
02-Body Electrical Equipments

（11） Install the front left wiper arm

(a) Start the wiper, let it stop at automatic reset
position
(b) Scrape wiper's gear hole with a round rasp or
similar tools
(c) Clean the gear hole of the wiper with wire
brush

(d) As shown in the figure, install the front seat

wiper arm with nuts
torque：15～26N•m
Installation position mark
15—35mm
Tip：
■ Fasten the nut by pulling the hinge
downwards with the hand

（12） Install the front right wiper arm

(a) Scrape the gear hole of the wiper with a
round rasp or similar tools
(b) Clean the wiper gear hole with a wire brush
the front right wiper arm with nuts

(c) As shown in the figure, install the front right

wiper arm with nuts
Installation position mark
15～35mm
tip：
■Fasten nut by pulling the hinge downwards
with the hand
(d) Start the wiper, sprinkle water or cleaning
fluid on the glass and check the wiping process.
The rear wiper should not hit the body.

02-44
 02-Body Electrical Equipments

Left wiper blade rubber

Replacement
（1） Remove the left wiper blade
(a) Remove the left wiper blade from the front
left wiper arm
CAUTION：
●When removing the wiper blade, do not fold
the wiper arm

（2） Remove the rubber from the left wiper

(a) Remove the left front wiper blade rubber
from the front left wiper blade
(b) Remove 2 support plates from the left front
wiper blade rubber

（3） Install the left wiper blade rubber

(a)Install 2 support plates to the left wiper blade
rubber

CAUTION：
●Be careful with the direction of the support
plate

(b) Install the left wiper blade rubber with the

head of it (the longer side) facing the axis.
CAUTION：
●Press the blade into the the groove of the
rubber to make them combine firmly
●Put passenger-side wiper arm back before
putting the wiper arm back on driver's side

02-45
02-Body Electrical Equipments

Windshield wiper switch assembly

Replacement
（1） Remove the steering column upper
cover
（2） Remove the windshield wiper switch
assembly
(a) Disconnect the connector
(b) Loosen the clip with a screwdriver and pull
out the windshield wiper switch assembly,
CAUTION：
Pressing hard may damage the clip
TIP：
■Wrap the head of the screwdriver up before
using

02-46
 02-Body Electrical Equipments

Washer Nozzle
Adjustment
1 Check the washer nozzle
(a) Start the engine. Check the location of the washer fluid sprayed on the windshield, and check
whether the rear window is in the range indicated by the hatched area

02-47
02-Body Electrical Equipments

Audio system
Precautions
1 CAUTIONS:
(a) Please explain to clients that when the battery negative terminal is removed, the information
of the channels stored the radio will be cleared. If necessary, please record the channel information
before removing the negative terminal and reset the channel after connecting the negative terminal.
(b) The removal and installation of radio can be conducted only after all the cassette tapes and
CDs have been taken out.
TIPS：
If the cassette tape and CD can not be taken out because of the radio malfunction, do not try to
drag them out. Please drive the car to the maintenance station.
(c) When removing and installing the antenna, make sure that the ground bolts are fastened.
TIPS：
■If the ground bolts are not fastened, noise will be produced while receiving radio waves.
(d) Do not touch the paper cone of the speaker.

02-48
 02-Body Electrical Equipments

Component Diagram

02-49
02-Body Electrical Equipments

Radio Assembly
Replacement
Instruction ：
component diagram
（1） Remove the central dashboard control
assembly
（2） Remove the trim panel assembly at the
lower part of the central dashboard
（3） Remove the radio assembly with
brackets
(a) Remove the 4 screws
(b) Disconnect the connector, remove radio
assembly with brackets
（4） Remove radio bracket No. 1
(a) Unscrew the 2 screws, remove radio bracket
No. 1

（5） Remove radio bracket No. 2

(a) Unscrew the 2 screws, remove radio bracket
No.2

（6） Remove the radio assembly

02-50
 02-Body Electrical Equipments

Front Speaker Assembly

Replacement
（1） Remove the rubber strips on the door

（2） Remove the upper trim panel of front

column

（3） Remove the speaker

（4） Remove the 4 screws, disconnect the

connector, then detach the speaker

02-51
02-Body Electrical Equipments

Antenna Sub-assembly
Replacement

1. Remove the antenna assembly

(a) Disconnect the 4 wiring clips
connecting the antenna to the body
(b) Unscrew the bolt connecting the antenna to
the roof

02-52
 02-Body Electrical Equipments

Cigarette lighter assembly

Replacement
Tips
Component Diagram
（1） Remove the upper trim panel
subassembly of the central dashboard
（2） Remove the lower trim panel
subassembly of the central dashboard

（3） Remove the cigarette lighter cover

(a) Loosen the 2 calipers, remove the cigarette
lighter cover

（4） Remove the cigarette lighter assembly

(a) Rotate the socket according to the direction
in the figure, loosen the calipers between the
cigarette lighter and socket, and pull out the
socket
(b) Set the grooves on the base of the cigarette
lighter and socket in a line, remove the cigarette
lighter assembly

（5） Install the cigarette lighter assembly

(a) Set the grooves on the base of the cigarette
lighter and socket in a line, push in the cigarette
lighter assembly forcefully, then install them

02-53
02-Body Electrical Equipments

Horn System

02-54
 02-Body Electrical Equipments

Malfunction Table
Problem Possible Malfunction Area

The horn does not sound 1.Horn button switch

2.Woofer
3.Horn relay
4.Wiring

Inspection

1 Check the woofer assembly

(a) Connect the battery positive (+) to the
terminal, the negative (-) to the horn cover,
check the sound of the horn

2 Check the horn relay assembly

(a) Remove the horn relay from the engine
compartment R / B
(b) Check whether the horn relay is in
conducting state
Standard：
Terminal Condition Regulation
Number State
1and2 Under any on
circumstances
3and5 Applying the battery
voltage between
terminal No.1 and
No.2

If the requirements are not met, replace the relay

assembly

02-55
02-Body Electrical Equipments

Woofer Assembly
Replacement
（1） Remove the woofer assembly
(a) Disconnect the connector
(b) Remove the bolt and the speaker assembly
（2） Install the woofer assembly
(a) Put the horn base on the radiator support to
install the horn assembly with bolts
Torque：20N•m
(b) Connect the connector

02-56
 02-Body Electrical Equipments

Power window control system

Details

02-57
02-Body Electrical Equipments

Vehicle Inspection
1 Check the basic functions (manual operation)
(1) To check each window switch of the regulator main switch assembly: while pressing the UP
switch the window glass should move upward, and while pressing the DOWN switch the window
glass should move downward..
(2) To check each window switch of the regulator switch assembly: when pressing the UP switch
the window glass should move upward, and when pressing the DOWN switch all the window glass
should not move except the window glass at the driver's side.
(3)When the doors are locked, all the window glass cannot move except the door glass at driver’s
side.
Malfunction Table
Problem Possible Malfunction Area
Power window does not work (all) (power door lock 1AM1 Fuse
does not work) 2 Power Fuse30A
3.POWERH Fuse +B 50A
4.Instrument fuse10A
5.Wiring
Power window does not work (all) ( power door lock （1）Power Window30A
works normally) （2）Power Window Main Switch
（3）Wiring
（4）Instrument fuse10A
Only one window glass does not move 1. Power Window Main Switch
2. Power Window Switch
3. Power windows motor
4. Wiring
"Window locking system" does not work 1. Child lock switch

02-58
 02-Body Electrical Equipments

Inspection
1.Circuit of power window system (picture)

02-59
02-Body Electrical Equipments

2. Check the main switch assembly of the power

window regulator
3.Check the continuity of the main switch

The window switch on the driver’s side

Standards
Switch Terminal Regulatio
Position n State
UP 1-3-9 on

DOWN 2-3-9 on

The window switch on the side of vice-driver

Standards
Switch terminal Regulation
position state
UP 3↔5↔9 on

DOWN 3↔4↔9 on

02-60
 02-Body Electrical Equipments

Left rear window switch

Standards
Switch Terminal Regulation
Position State
UP 3-6-9 on

DOWN 3-7-9 on

Right rear window switch （Window lock）

Standards
Switch Terminal Regulation
Position State
UP 3-9-12 on

DOWN 3-9-11 on

If the result does not meet the specifications,

replace the regulator switch assembly
When the window locking switch is off, all the
terminals are disconnected

4.Check the regulator motor of the power

window

02-61
02-Body Electrical Equipments

(a) Check the motion of the regulator motor

TIPS：
 The regulator motor at driver’s side and right
rear side should be checked with the same steps
 The regulator motor at the front passenger side
and left rear side should be checked with the same
steps
（1）When applying positive voltage to each
terminal of the connector , check the motion of
the motor is smooth
Right rear side of driver
Standard
Measurement State Regulation State
Battery positive - terminal 2 Clockwise
Battery negative - terminal 1
Battery positive - terminal 1 Counterclockwise
Battery negative - terminal2

L
eft rear side of driver
standard

Measurement State Regulation State

Battery positive - terminal 1

Clockwise
Battery negative - terminal2
Battery positive - terminal 2
Counterclockwise
Battery negative - terminal1
If the specifications are not met, replace the
motor
5.Relay Inspection（MARK：POWER）

(a) Remove the power window relay from the

junction box of the meter panel assembly
(b) Check the continuity

02-62
 02-Body Electrical Equipments

Standards：
Situation Terminal Regulation State
Normal 1↔2 on
connect terminal 3↔5 on
No.1 and No.2 to the
I
battery positive
f
the specifications are not met, replace the relay

02-63
02-Body Electrical Equipments

Power door lock control system

02-64
 02-Body Electrical Equipments

Vehicle Inspection
1. Door lock malfunction

(a) When the door lock control switch (manual

switch, interlock key operation) fails, the
locking/ unlocking operation of the door lock
can not be carried out

2. The power door lock inspection

(a) Check the basic functions
（1）When the door lock control switch (manual
switch) is in LOCK position, all the doors are
locked; when the switch is in UNLOCK position,
all the doors are unlocked

（2）When the door lock on the door of the

driver’s side is set to LOCK position by a key,
check whether all the doors are locked

02-65
02-Body Electrical Equipments

Inspection
1.Check the door lock assembly of the left
front door
(a)Applying the battery voltage, check the
working state of the door lock motor ,

Unlocked standard
Measurement State Standard State
Battery positive - terminal1 Lock
Battery negative - terminal2
Battery positive - terminal2 Unlock
Battery negative - terminal1
If the standard is not met, replace the door lock
assembly
Locked （b）Check the continuity when the doors are
unlocked and locked
standard ：
Terminal Door Lock Standard State
Number Position
Unlocked 3and4 lock on
3and5 unlock on
If the standard is not met, replace the door lock
assembly
2. Check the door lock assembly of the right
front door
(a)Battery voltage, check the working state of
the door lock motor.
Locked Standards:
If the standards are not met, replace the door
lock assembly

02-66
 02-Body Electrical Equipments

3 Check the door lock assembly of left rear

door
Locked
(a) Apply the battery voltage, check the
working state of the door lock motor,
Standards：
Measurement State Standard State
Battery positive - terminal2
Lock
Battery negative - terminal1
Battery positive - terminal1
Unlock
Battery negative - terminal2
Unlocked If the the standards are not met, replace the the
door lock assembly

4. Check the door lock assembly of the right

rear door
(a) Check the working state of the door lock
motor.
(b) Apply the battery voltage, check the
working state of the door lock motor.
Standards:
Measurement State Standard State
Battery positive - terminal1
unlock
Battery negative - terminal2
Battery positive - terminal2
lock
Battery negative - terminal1
If the standards are not met, replace the the door
lock assembly

02-67
02-Body Electrical Equipments

Wireless door lock control assembly

Precautions

CAUTIONS:
(a) The wireless door lock remote control can work only when the following three conditions are
all met
(1)All the doors are closed. Otherwise, with any door open others can not be locked.
(2)The key is not in the ignition keyhole.
(3)The power door lock system works normally.
(b)The control area of the wireless door lock remote controller varies under different
circumstances
(1) The control area depends on the operating distance and the way in which the transmitter is
held.
(2) In some places, the control area will be reduced because of the body and surrounding
environment，or the remote control functions partially.
(3) As the transmitter functions by emitting a small amount of electromagnetic waves, strong
electromagnetic waves or the noise with same frequency will reduce the control area or stop the
remote controller from functioning.
(4 When the electromagnetic part
is short of power，the control area will be reduced or the remote controller does not work.

TIPS：
■If the door control transmitter is put at some place exposing to direct sunlight, such as on the
instrument panel, battery power shortage or other malfunctions will be caused.

02-68
 02-Body Electrical Equipments

Vehicle Inspection
Check the wireless door lock and control function
TIPS：
■The switch here refers to the switch of the transmitted signal(LOCK switch , UNLOCK switch),
it is placed in the door control transmitter.
(a) Put the vehicle in the place where the wireless control function can be carried out.
(b) Check the basic functions
(1) When any switch on the key is pressed for 3 seconds, check whether the LED light flashes 3
times.
TIPS：
■If the LED lights do not flash after pressing for no less than 3 seconds, power must be
insufficient.
(1) Press the switch in the control area, check whether all the door are all locked or unlocked.
(However, when the key is in the ignition keyhole or any door is open, this will not happen）
TIPS：
■The UNLOCK switch can still work when any door is open.
(c) Check the automatic lock function
(1) If all doors are locked or the ignition switch is not in ON position, check that all doors should
be locked automatically, 30 seconds after all door are unlocked by pressing the switch.
(2) If any door is unlocked or the ignition switch is in ON position, the automatic lock function
will not be carried out, 30 seconds after all door are unlocked by pressing the switch.
(d) Check the fail-safe function of the switch
(1) When the key is inserted in the ignition keyhole, c heck whether the door be unlock or lock by
the remote controller.
(e) When any door is open or not fully closed, check the operation termination function.
(1) When any door is open or not fully closed, the door can not be locked by the remote switch
(f) Check the flashing of the warning indicator lights and the siren alarming function (response)
(1) When pressing the LOCK switch, check that the warning indicator light should flash one time
and all the doors lock at the same time
(2) When pressing the UNLOCK switch, check that the warning indicator light should flash twice
and all the doors unlock at the same time.

02-69
02-Body Electrical Equipments

Remote Control Battery

Replacement
1 Replace the remote control battery
CAUTION：
●Operate with caution, because these electronic
components are precision.
(a) Remove the screw with a screwdriver. Pry
the remote control shell
CAUTION：
●Do not pry the shell forcefully
(b) Remove the 2 screws ,open the battery cover
(c) Remove the battery (lithium battery)
CAUTIONS：
●Do not use fingers to touch the electrode's
terminals.
●Pry up the battery (lithium battery),prying too
hard may cause deformation, do not touch the
battery with your hands and water will produce
rust.
●Do not touch or move any components in the
transmitter, otherwise, the normal operation will
be affected.
(d) As shown in the figure, insert a new battery
(lithium battery) with the positive (+) facing up
CAUTIONS：
●Ensure that the positive and negative of the
transmitter battery are facing the right direction.
●Do not bend the electrode terminal of the
battery in the transmitter
●Do not contaminate the transmitter box with
dust and oil.
(e) Check whether the rubber cap is twisted or
off, then install the remote controller shell.
CAUTION:
02-70
 02-Body Electrical Equipments

●Any damage will cause poor contact between

the battery (lithium battery) and the electrode
shrapnel.

02-71
02-Body Electrical Equipments

Gate controlled remote controller

Register
The information of remote control key is stored in remote control signal receiver, so the
registration, cancellation and other operations of the key must be conducted through some specific
steps.. When the user loses a master key, all the key remote control signal can be canceled by the
operation forbidden mode , then the remaining remote control keys can be re-registered through the
adding mode or confirming mode.
CAUTION
Through the above operations, the missing key can no longer control the user’s vehicle, but one
can still get into the vehicle by unlocking the lock cylinder
Initial conditions of key matching：A It is not opened by the remote control, because there are 30 seconds
for automatic locking if opened by remote control
B. The door is closed
Action sequence：1. Insert the key→pull→insert→pull Within 40
2. Open the door（It is of own level when the door is opened ） seconds
3. Insert the key→pull
4 Close the door→open the door→close the door→open the door Within 40
5. Insert the key→pull seconds
6. Close the door→open the door→close the door→open the door Within 40
7. Insert the key seconds
8. Close the door
9. Ignition switch ON→OFFtwo times Within 40
10. Pull the key seconds
11. Press the first remote control handle which will be registered Within 40
（Normal Registration：locked→unlocked，no flash seconds
12. Press the second remote control handle which will be registered
（Normal Registration：locked →unlocked，no flash）
13. Registration ends

02-72
 02-Body Electrical Equipments

Rear defrost control system

Components

02-73
02-Body Electrical Equipments

Malfunction Table
Problems Possible Malfunction Area
Rear view mirror does not work 1. Outside rear-view mirror switch assembly
2. Outside rear-view mirror assembly
3. Wiring
1. Outside rear-view mirror switch assembly
Rear view mirror is not working normally 2. Outside rear-view mirror assembly
3. Wiring

02-74
 02-Body Electrical Equipments

Inspection
1. Check the control panel assembly
(a) Check the defogger switch assembly
Standards：

Measurement State Switch Regulation

State
Battery positive ↔（3） ON Indicator
Battery negative ↔（2） light

If the specifications are not met, replace the

control panel assembly.

Check the continuity of the defogger switch.

Standard：

3↔4 ON ON
3↔4
I OFF OFF
f the specifications are not met, replace the
control panel assembly

02-75
 03-Body

Body

Power Window Control System.....................................................................................................1

Front Windshield .........................................................................................................................14
Rear Windshield...........................................................................................................................26
Rear-view mirror..........................................................................................................................35
Inner rear view mirror ..................................................................................................................42
Dashboard / Meter .......................................................................................................................43
Dashboard ....................................................................................................................................50
Front Seat .....................................................................................................................................60
Rear seat.......................................................................................................................................65
Door Lock ....................................................................................................................................68
Remote control door lock control system ....................................................................................75
Hood/ Door ..................................................................................................................................79
Front door ....................................................................................................................................81
Rear door .....................................................................................................................................89
Inside Trim / Outside Trim ..........................................................................................................96
Rear Bumpe ...............................................................................................................................100
Outer weather strip ....................................................................................................................103
Back Door Outside Trim (spoiler) .............................................................................................105
Inside Trim ................................................................................................................................. 110
 03-Body

Windscreen / Front and Rear Windshield / Rearview Mirror

Power Window Control System

Location diagram

03-1
03-Body

Malfunction Table

Problems Inspection areas

Power window failure (completely) (power 1. AMIH fuse

door lock failure) 2. Power supply relay
3. POWERH fuse
4. Meter fuse
5. Wiring
6. Power window controller
Power window failure (completely) (power 1. Ignition switch
door lock works normally) 2. Power window master switch
3. Wiring
4. Power window motor
AUTODOWN( automatic descent) function 1.Power window master switch
failure 2. Power window motor
Only one window does not move. 1Power window master switch
2. Power window regulator switch
3. Power window motor
4. Wiring
“Window locking system" failure 1. Power window master switch

03-2
 03-Body

Components

03-3
03-Body

Vehicle inspection
1．Remove the door glass regulator.
(a) with power door and window
Disconnect the socket connectors.

(b) with power door and window

Remove seven bolts before removing the glass
regulator.
Torque：8.0 N·m
Tip：
■Remove the glass regulator from the service hole.
Note：
■When re-installing please refer to the following
instructions.
■Apply MP grease to the sliding and rotating parts
of the glass regulator.

2．Remove the door outer weather strip.

Remove the door outer weather strip.

3．Remove the door glass run.

(a) Remove the door glass run.
(b) Pull out the glass run from the top.

4. Remove the front and rear lower window

frames.

03-4
 03-Body

Remove the two bolts and two lower window frames.

Tip：
■Remove the lower window frame from the service
hole.
5. Remove the door lock.
(a) Remove the inner locking button of the door.
(b) Remove the cable from the clamp.
(c) Remove two pull-rods from the outside handle
and lock cylinder.
(d) With power door lock.
Disconnect the socket connectors. Remove the three
screws.
Torque：5.0 N·m
Tip：
■When re-installing please refer to the following
instructions.
■Apply sealant to the three screws.

(e) Remove the door lock from the service hole.

Tip：
■When re-installing please refer to the following
instructions.
■Apply MP grease to the sliding and rotating parts
of the door lock.

6．Remove the locking button seat and clamp.

(a) Remove the locking button seat and clamp.
Tip：
■Wrap up the tip of the screwdriver with tape before
using it.
03-5
03-Body

7．Remove the outside handle.

(a) Remove the two bolts and with-lockcylinder
outside handle..
Torque：5.0 N·m
(b) Remove the bolts and lock cylinder from the
outside handle.
Torque：5.0 N·m

03-6
 03-Body

Vehicle inspection
1. Check the basic functions (manual operation functions).
Turn on the ignition switch.
(1) Check whether the window glass moves upward when each window switch of the regulator master
switch assembly is pressed UP (up),. Check whether the window glass moves downward when each
window switch of the regulator master switch assembly is pressed DOWN (down). Halfway
(2) Check whether the window glass moves upward when each window switch of the regulator master
switch assembly is pressed UP (up), and the other way round when the switch is pressed DOWN halfway.
(3) Check whether all the door glass except that of the driver side does not move when the window
door lock is locked.
2. Check the automatic operation function (of the glass on the driver's side only).
Turn on the ignition switch.
(1) Check the operation of the auto-down function: whether the glass is opened fully when the AUTO
key switch on the driver's side of the regulator master switch assembly is pressed DOWN (down) entirely.
Check whether the window glass stops to move when it is switched to AUTOUP from
AUTODOWN.(However, if the switch stays in the up position, it will change to the manual operation.)

03-7
03-Body

Inspection
Power window system circuit (figure)

03-8
 03-Body

1. Check the master switch assembly of the power

Window locking switch
window regulator.
Check the master switch continuity.
Window switch of driver side.
Standard
Switch Terminal Specifications
position
UP 1-3-9 Conductive

DOWN 2-3-9 Conductive

Window switch of vice-driver side

standard
Window locking switch
Switch Terminal Specifications
position
UP 3-5-9 Conductive

DOWN 3-4-9 Conductive

03-9
03-Body

Left rear window switch

standard
Window locking switch Switch position Terminal specificatio
ns
UP 3-6-9 Conductive

DOWN 3-7-9 Conductive

Window locking switch

Right rear window switch
Standard
Switch position Terminal regulations
UP 3-9-12 Conductive

DOWN 3-9-11 Conductive

If the result does not conform to the specifications,

replace the regulator switch assembly.

When the window locking switch is turned off, all

terminals are in OFF state.

03-10
 03-Body

2. Check the motor of the power window

regulator.
(a) Check the movement of the regulator motor.
Tip：
The regulator motor of the driver side and right rear
driver side should be checked with the same
procedure.
The regulator motor of front passenger side and left
rear side of front passenger should be checked with
the same procedure.

(1)Check whether the motor moves smoothly, when

each terminal on the connectors is applied with
positive voltage of the battery

Right rear side of the driver

Standard
Measurement Specifications
2Battery positive pole - Clockwise
Terminal 2
1Battery negative pole-
terminal 1
1Battery positive pole- Counterclockwise
Terminal 1
2Battery negative pole-
terminal 2
Left rear side of the driver
Standard
Measurement Specifications
1Battery positive pole- Clockwise
Terminal 1
2Battery negative pole-
terminal 2
2Battery positive pole- Counterclockwise

03-11
03-Body

Terminal 2
1Battery negative pole-
terminal 1
If the result does not conform to the specifications,
replace the motor.

03-12
 03-Body

3. Check the relay. （Mark：POWER）

(a)Remove the power window relay from the
dashboard assembly junction box.
(b)Check the conductivity.
Standard：
Conditions Terminal Specifications
Normal 1↔2 Conductive
Terminals 1 and 3↔5 Conductive
2 are connected
to the positive
pole of the
battery.

If the result does not conform to the specifications,

replace the relay.

03-13
03-Body

Front Windshield

Components

03-14
 03-Body

Replacement
Removal
1．Remove the inner rearview mirror.
2．Remove the sun visor and the sun visor
bracket.

Cut 3．Remove the wiper arm.

Remove the two head covers of the wiper arm, two
nuts and two arms.
Cut
4．Remove the ventilator louver.
(a) Remove the rear seal of the hood.
(b) Remove the seven clips Then pull out the left and
right ventilator louvers.

5．Remove the armrest.

6．Remove the foreside of the roof headlining.
7．Remove the windshield trim.
(a) Cut off part of the trim with a knife.
Note：
High-carbon steel wire
●Be careful not to damage the body with a knife.
(b) Remove the rest of the trim.
Stop block
8. Remove the outside of the windshield frame.
（a）As shown, cut off the framework with a knife.
Note：

Protective tape ●Be careful not to damage the body.

（b）Remove the rest of the framework
body
Tip：
Windshield ■During removal, some part needs cutting by a knife.
Then pull it by hand and remove it.

03-15
03-Body

9．Remove the windshield.

(a) Pass a piano wire between the body and the glass
from the interior.
(b) Tie each end of the piano wire to a wooden piece
or the like.
Tip：
■Post protective tape on the outer surface of the
body so as not to scratch it.

Note：
●When separating the glass, care must be exercised
Protective tape not to damage the paint finish surface and inside and

Plastic board outside trims. In order to prevent the safety plate

being scratched during windshield removal, place a
plastic sheet between the piano wire and the safety
plate.

Installation
1．Clean up the matching surface of the body.
Body
(a) Smooth any irregularity on the body with a knife.
Tip:
Seala
■Keep the sealant on the body as much as possible.
(b) Clean the surface where the sealant is cut off with
a soft cloth soaked with detergent.
Tip：
■Even if all the sealant is removed, it is necessary
to clean the body all the same.

2．Clean the removed windshield.

03-16
 03-Body

(a) Remove the damaged stop block, adhesive dam

and the sealant glued to the glass with a scraper.
(b) Clean the glass
Note：
●After cleaning the glass , do not touch the surface

Notch with hands.

Backside
●Be careful not to damage the glass.

3．Install new stoppers.

（a）As shown, install two new stoppers on the
glass.
The distance between the upside of the brake silpper
and the outermost upside of the glass is 11.7mm.
（b）Install windshield stopper No.1. As shown，
install two new stoppers on the body.

4．Install new adhesive dams.

Install new adhesive dams with double-sided
adhesive tape.
5. Install the window glass adhesive weather
strip.
（a）Install the window glass adhesive weather
strip.
Note：
●Allow the section to dry at least three minutes
after the application.
●Do not apply too much primer.
（b）As shown, besides the parts where the weather
strip has been installed, install new weather strip with
double-sided tape around the glass.
03-17
03-Body

7mm

7mm

7mm

23.5mm

In the figure, ② is the stop per, ⑤ is the outer moulding of the front windshield.
Technical requirements ：
（1）、Allow the glass primer to dry at least two
minutes after application. Then apply adhesion agent
with a glue gun. The application size range is
specified in the figure.
（2）、Allow the body primer 435-98 to dry at least
two minutes after application. Then install the glass
applied with adhesion agent.
（3）、Shake the primer well before using.
Re-apply three hours after the application.
（4）、560-C Adhesion agent use: summer (April to
October) 560-C.
560F-C Winter (November to March ) 560F-C.
（5）、 ③ and ④ the process numbers. These
parts are cut out by the windshield adhesive dam
90899-99999.
（6）、The distance between the upside of part ②

03-18
 03-Body

and the outermost upside of the glass is 11.7mm. The

left and right location is determined by the locating
mark of parts ① and ②.
（7）、If the manipulator fails to apply adhesion
agent, switch to a pneunatic glue gun for emergency
use. The application size range is specified in the
figure.
（8）、The installation of part ① is a key process.

6. Install outer framework of the windshield.

（a）Apply primer G to the glass edge and the
Reference mark
contact surface with a brush or sponge.
Note：
●Allow the primer to dry at least three minutes after
application.
●Do not apply the primer G to the adhesion agent.
●The remaining primer G should not be reused.
（b）Install outer framework of the windshield.

7．Determine the installation location.

(a) Place the glass on the right position with
suction cups.
(b) Check whether the contacting section of the parts
and the periphery of the wind shield is correct.
(c) Make reference marks on the glass and body.
(d) Remove the glass.

8．Clean the mating surface of the glass.

Clean the black areas around the glass with detergent.

03-19
03-Body

Note：
●Do not touch the cleaned surface with hands.

Primer 9．M Apply primer M to the contact surface of

the body.

Primer Apply primer M to the exposed part of the body with

Seala a brush.
Note：
●Allow the primer to dry at least three minutes
after application.
●Do not apply the primer M to the sealant.
Primer G
Primer G ●For later use, do not leave the primer M container
open.10．

10．Apply primer to the contact surface of the

Adhesive glass.
(a) Apply primer G to the glass edge and the contact
surface with a brush or sponge.
(b) If primer is applied beyond the specified area,
wipe off the primer with a clean cloth before it
hardens.

Note：
●Allow the primer to dry at least three minutes
Sealant
after application.
●For later use, do not leave the primer M container
open.
11．Apply sealant.
(a) Cut off the nozzle of the sealant hose.

03-20
 03-Body

Tip：
■After cutting off the nozzle of the sealant hose, use
sealant under the conditions specified in the
following table.

03-21
03-Body

Temperature Effective Time

35℃ Fifteen minutes
20℃ One hundred minutes
5℃ Eight hours
(b) Install the sealant hose on a sealant gun.
(c) As shown, apply sealant to the glass.

12．Install windshield and trims.

(a) Align the reference mark. Then install the glass
with suction cups.
Reference mark
Tip：
■Check whether the stopper is attached to the
correct position of the body.
(b) Gently press the front surface of the glass to
make it match closely.
Windshie
(c) Fix the sections with extra or insufficient sealant
with a spatula.
Sea Tip：
■Apply sealant to the periphery of the windshield.

Note：
■The application ranges of primer 435-41 on left
and right front windshield should be the same. The
11.7m
7
range on the periphery should be not less than the
values specified in the figure.

11mm

Note：
■The application ranges of primer 435-98 on left
03-22
 03-Body

and right front window frame should be the same.

The range on the periphery should be not less than the

1
values specified in the figure.
2

(d) Before the sealant hardens, install a new

1 windshield trim on the windshield.

03-23
03-Body

Tip：
■When installing the trims, make the center of the
trims symmetrical with that of the body.
(e) Remove the excess sealant before it hardens.
(f) Fix the glass and trims on correct position with
protective tape or the like until sealant hardens
completely.
Note：
●Do not drive the car within the time specified in
the table below.
Temperature Minimum time before driving
35℃ One and a half hours
20℃ Five hours
5℃ Twenty-four hours
13．Check for leakage and repair timely.
Note：
●After the sealant hardens completely, perform the
leak test.
14．Install the foreside of the roof headlining.
15．Install the armrest.
16．Install the ventilator louver and the rear seal
of hood.
17．Install the wiper arm.
(a) Operate the wiper motor one time. Then set the
wiper switch to OFF".
(b) Install the wiper arm and tighten the nuts by
hand.
(c) Adjust the wiper arm to the position shown in
the figure.
(d) Tighten the nuts.
Torque: 15～26 N·m
03-24
 03-Body

(e) Install the two head covers of the wiper arm.

18．Install the front pillar garnish.
19．Install the sun visor and sun visor bracket.
20．Install the inner rearview mirror.

03-25
03-Body

Rear Windshield

Components

03-26
 03-Body

Replacement
Tip：
■The installation is opposite to the removal in
order. The main points will be pointed out.
1 Remove the whole-type rear seat cushion
assembly.
2 Remove the seat backrest assembly.
3 Remove the roof.
（a）Remove the rear seat seal (left).
（b）Remove the rear seat seal(right).
（c）Remove the rear seat cushion assembly.
（d）Remove the rear backrest assembly (right).
（e）Remove the rear side cowl inside trim (left).
（f）Remove the rear side cowl inside trim (right).
（g）Remove the two auxiliary handles.
（h）Remove the roof.

4. Remove the center high mounted stop lamp

assembly.
5. Remove the upper outer part of the rear
window frame work .
(a) As shown, cut the framework with a knife.
Note：
C
●Be careful not to damage the body with a knife.
(b) Remove the remaining framework.
C
Tip：
■During removal, some part needs cutting by a
knife. Then pull it by hand and remove it.

03-27
03-Body

6. Remove the rear window glass.

（a）Pass a steel wire between the body and the
glass from the interior.
（b）Tie each end of the wire to a wooden piece or
the like.
Tip：
● Attach protective tape to the outer surface to
prevent it from being scratched.
Note：
● When separating the glass, be careful not to
damage the paint finish surface and inside and outside
trims .
●Place a plastic sheet between the steel wire and
safety pad to prevent the safety pad being scratched.
（c）when removing rear window glass around the
glass, use a steel wire to cut off binder
（d）Remove the stoppers.
（e）Remove the glass with suction cups.
Note：
●When removing the glass, leave as much adhesion
agent as possible on the body.

7. Clean the rear window.

（a）Remove the damaged stopper , weather strip
and adhesion agent from the glass with a scraper.
（b）Clean the outside periphery of the glass with
clean gasoline.
Note：
●Do not touch the cleaned glass surface.

03-28
 03-Body

8. Install the stopper No.2 of rear window.

（a）Apply primer G to the installation section of the
stopper.
Note：
● Allow the primer to dry at least three minutes after
application.
● Do not apply too much primer.
●The remaining primer can not be kept for later use.

9. Install the stop per No.1 of rear window.

（a）As shown, install two new rear window stoppers
on the body.

03-29
03-Body

10. Install the rear window glass adhesive tape.

（a）Apply primer G to the glass edges and the
contact surface with a brush or sponge.
Note:
● Allow the primer to dry at least three minutes after
application.
●Do not apply primer G to the adhesion agent.
●The remaining primer can not be kept for later use.
（b）Install windshield adhesive tape .

11. Install rear window glass adhesive weather

strip.
（a）Apply primer G to the installation section of rear
Adhesive agent window glass.
Note：
Adhesive agent
●Allow the primer to dry at least three minutes after
application.
●Do not apply too much primer.

13. Install the rear window glass.

（a）Clean up the body contact surface.
（1）Clean the body contact surface by removing the
adhesion agent on it with a razor blade.
Tip：
■ Leave as much adhesion agent on the body as
possible.
（2）Clean the body contact surface with a cloth
soaked with detergent.
Tip：
■Even all the adhesion agent has been removed,
03-30
 03-Body

clean the body all the same.

（b）Place the glass
（1）Place the glass on the correct position with
suction cups.
（2）Check whether the entire glass contact surface is
smooth.
（3）Make reference marks on the glass and the body.
Note：
●Check whether the stoppers adhere to the body
properly.
Correct
Prime Tip：

Incorrect ● When using the original glass, check the position of

Prime calibration marks.

Adhesion agent （4）Remove the glass
（c）Apply primer M to the exposed section of the
body with a brush.
Note：
● Allow the primer to dry at least three minutes after
application.
●Do not apply primer to the adhesion agent.
●The remaining primer can not be reserved for
future use.
（d）Apply primer G on the glass edges and the
contact surface with a brush or sponge.
1 9.
Tip：
1 ■If other sections are stained with paint accidentally,
wipe it off with a cloth before it dries.
9. 1
1 Note：
● Allow the primer to dry at least three minutes after
application.
03-31
03-Body

● The remaining primer can not be reserved for later

use.
（e）Adhesion agent
Note：
● The upper and lower application ranges of back
door primer 435-98 should be the same. It is the same
case with left and right. The relevant application
ranges are shown in the figure.

6
5
1 Note:
2
●（11mm）The left and right application ranges of
back door primer 435-41 should be the same. The
application ranges on the periphery should be not
less than the values shown in the figure（11mm）.
（1）As shown, cut off the nozzle tip of the adhesion
agent.

03-32
 03-Body

Tip：
■After opening, operate according to the time
specified in the table below.
Adhesion time
Temperature Adhesive time
35℃ Fifteen minutes
20℃ One hundred minutes
5℃ Eight hours
（2）Prepare the with-sleeve capsule.
（3）Apply adhesion agent to the glass.
Size：
（f）Install the glass.
（1）Place the glass with suction cups. Align with
the reference marks. Then gently press along the
border.
Note：
● Allow the primer to dry at least three minutes after
application.
●Check whether the stoppers are properly attached to
the body.
● Check the gap between the body and the glass.
（2）Gently press the front section of the glass to
make them contact closely.
（3）Remove the excessive adhesion agent with a
Adhesion agent spatula.
Tip：
■ Apply adhesion agent to the edge of the glass.
Note：
● Be careful not to start the car within the time
specified in the table below.
Minimum time
03-33
03-Body

Temperature Minimum time

before starting the car
35℃ One and a half hours
20℃ Five hours
5℃ Twenty four hours

14. Check for leakage and maintenance.

（a）Perform leakage check after the adhesion agent
is completely solidified.
（b）Seal all the leaks with car glass sealant.

15. Install the rear wiper arm.

(a) Install the rubber ring.
(b) Operate the wiper motor one time. Then set the
wiper switch to "OFF".
(c) Install the rear wiper arm and tighten the nut by
hand.

Technical requirements
（1）Allow the glass primer 435-41 to dry at least two
Glass adhesion minutes after application. Then apply adhesion
agent with a glue gun. The application size ranges are
shown in the figure;
（2）Allow the body primer 435-98 to dry at least two
minute safe application. Then install the glass applied

Glass adhesion with adhesion agent.

（3）Shake the primer well before using. Re-apply
three hours after application;
（4）Adhesion agent use：
Summer (April to October) 560-C;
Winter (November to March) 560F-C.

03-34
 03-Body

Rear-view mirror

Components

03-35
03-Body

Power rearview mirror

Malfunction table

Problems Possible areas

Rearview mirror failure 1．Outer rearview mirror switch assembly
2．Outer rearview mirror assembly
3．Wiring
4．Adjustment switch
Abnormal operation of rearview mirror 1．Outer rearview mirror switch assembly
2．Outer rearview mirror assembly
3. Wiring
4．Adjustment switch

03-36
 03-Body

Power rearview mirror

Inspection
1 ． Check the outer rearview mirror switch
assembly.
（a）Left: adjust the switch leftwards and rightwards.
Check the switch continuity.
Standard(left)：
Terminal Switch position Specifications
1-2-4-6 OFF Not conductive
1-7 UP Conductive
2-4-6
1-6 DOWN Conductive
2-4-7
4-6 LEFT Conductive
1-2-7
4-7 RIGHT Conductive
2-4-7
If the result does not conform to the specifications,
replace the switch assembly.
（ b ） Right ： adjust the switch leftwards and
rightwards.
Check the switch continuity.
Standard(Right)：
Terminal Switch position Specifications
2-3-5-6 OFF Not conductive
5-7 UP Conductive
2-3-6
5-6 DOWN Conductive
2-3-7
3-6 LEFT Conductive
2-5-7
3-7 RIGHT Conductive
2-5-6
If the result does not conform to the specifications,
replace the switch assembly.

03-37
03-Body

Power rearview mirror

Replacement
Tip：
■The installation is opposite to the removal in order.
The main points will be pointed out.
■The same steps are followed for handling both the
left side and the right side.

1．Remove the maintenance hole cover of left

front door.
(a) Remove the door handle.
(b)Remove the left inside handle.
(c)Remove the main switch assembly of power
window regulator.
(d)Remove the inside garnish of doors.
(e)Remove the left maintenance hole cover.

2．Remove the outside rearview mirror assembly

on the left side.
(a)Disconnect the connector.
(b)Remove the three bolts and left rearview mirror.

3．Remove the outside rearview mirror cover on

the left side.
(a) Insert a cloth between the rearview mirror and the
rearview mirror body.
(b) Pull the lower part of the cloth and disconnect the
rearview connector.
（ c ） Remove the four buckles connecting the

03-38
 03-Body

rearview mirror and rearview mirror cover.

03-39
03-Body

（d）Pull out the rearview mirror. Then remove the

mirror.
（e）As shown, slacken the hook, and remove the
outside rearview mirror cover.

03-40
 03-Body

4. Install the outside rearview mirror assembly on

the left side.
（a）Install the rearview mirror cover to the
rearview mirror body. Then install four buckles.

（b）Install the three screws on the turn signal.

（c）Connect the hook (A). Install the rearview

mirror into the rearview mirror body.
（d）Push the rearview mirror into the hook and fix it
into position.
（e）Install the rearview mirror with three nuts.
Torque：6.0～10.0 N.m

（f）Connect the wiring connector.

03-41
03-Body

Inner rear view mirror

Replacement
Tip：
Slide ■The installation is opposite to the removal in order,
1. Remove inner rearview mirror assembly.
(a)As shown, remove inner rearview mirror
assembly.
Note：
Do not apply excessive force to prevent windshield
rupture.

03-42
 03-Body

Dashboard / Meter

Combination meter

The car equipped with a MT gearbox.

1 Speedometer 2 Fuel gauge 3 Water temperature gauge 4 Tachometer

5 Failure alarm lamp and indicator light area 6 Reset button of one-way odometer
7 Odometer and one-way odometer

The car equipped with an AMT gearbox

1 Speedometer 2 Fuel gauge 3 Water temperature gauge 4 Tachometer

5 Failure alarm lamp and indicator light area 6 Reset button of one-way odometer
7 Odometer and one-way odometer 8 Gear display of AMT transmission

03-43
03-Body

Malfunction table
Tip：
■The following table will help to locate the cause of the failure. Figures in the table indicate the
possibility priority of malfunctioning parts. Check each part in order. Replace them if necessary.
Illumination ：
Problems Possible areas
All lights do not work. 1．Combination meter assembly
2．Wiring or connector
Only the lights on one circuit do not work. 1．Combination meter assembly

Warning light：
Problems Possible areas
The check engine warning light does not 1．Wiring or connector
work 2．ECU
3．Combination meter assembly
The charging warning light does not work. 1. Wiring or connector
2．ECU
3．Combination meter assembly
The warning light of brake fluid level does 1．Wiring or connector
not work. 2．Parking brake switch
3．The alarm switch of brake fluid level.
4．Combination meter assembly
The ABS warning light does not work. 1．Wiring or connector
2．Brake actuator
3．Combination meter assembly
The SRS warning light does not work. 1．Wiring or connector
2．Central air bag sensor assembly
3．Combination meter assembly
The door-open warning light does not 1．Wiring or connector
work. 2．Door-control lamp switch assembly
3．Combination meter assembly
The oil pressure warning light does not 1．Wiring or connector
work. 2．The low pressure switch assembly of oil
pressure.
3．Combination meter assembly
The warning light of driver seat belt does 1．Wiring or connector
not work. 2．Driver lock catch switch
3．Combination meter assembly
The turn signal does not work. 1． Wiring or connector
2．Turn signals and hazard warning systems.
3． Combination meter assembly

03-44
 03-Body

The high beam indicator light does not 1． Wiring or connector

work. 2． Headlight dimmer switch
3． Combination meter assembly
The failure diagnostic lights of AMT 1． Wiring or connector
transmission 2． Combination meter assembly
3． Control TCU
The front fog lamp does not work. 1． Wiring or connector
2． Headlight dimmer switch
3． Combination meter assembly
The rear fog lamp does not work. 1． Wiring or connector
2． Headlight dimmer switch
3． Combination meter assembly

Inspection
1. Check the operation of vehicle speed sensor
(a) Connect the battery's positive (+) pole to terminal
1 , the negative (-) pole to terminal 2.
(b) Connect the positive probe (+) of the detector to
terminal 3, the negative robe (-) to terminal 2.
(c) Turn the sensor axis.
(d) Check whether there is voltage which ranges
from 0V to 11V or greater between Terminal 2 and
Terminal 3.
Tip：
■For each circle the MT sensor axis turns, the voltage
should change four times.
■For each circle the AMT sensor axis turns , the
voltage should change 8 times.
■If the operation is abnormal, replace the sensor.

2. Check the tachometer on the vehicle.

(a)Connect the revolving speed detector. Start the
engine.

03-45
03-Body

Note：
●If the tachometer is connected with the polarity
reversed, it will damage the transistors and diodes.
●When removing and installing the tachometer , be
careful not to drop them or cause severe vibration.
(b)Compare the indicating values of the tachometer
and those of the detector.
DC13.5V 25℃
If the resistance value does not conform to the one
above, replace the fuel gauge.

3. Check the resistance of fuel sensor.

Measure the resistance values between terminal 2 and
terminal 3 when the floater is at various locations .
Floater position (mm) Resistance values(Ω)
F： About 92.0 ±3 about 4.0 ±0.5
1/2 About 25.4 about 55.0 ±1.5
E About 46.6 ± 3 about 107.0 ±2.5
If the resistance values do not conform to the
specifications, replace the fuel sensor.
(b) Check whether the bulk goes out when the switch
is immersed into gasoline. If not, replace the fuel
sensor.

4. Check the resistance of water temperature

sensor.

Sliding rheostat As shown, connect the wirings. Adjust the sliding

rheostat until the ammeter indicates zero. Read the

03-46
 03-Body

resistance value.
Water temperature(℃) Resistance values(Ω)
50 160～240
120 17.1 ～21.2
If the resistance values do not conform to the
specifications, replace the water temperature sensor.

5. Check the warning light of oil pressure.

(a) Remove the socket connector of oil pressure
sensor and connect the side terminal of wiring to
ground wire.
(b) Turn the ignition switch to "ON" position .
Check whether the warning light works. If the
warning light does not work, check the bulb.

03-47
03-Body

6. Check the oil pressure switch continuity.

(a) Remove the socket connector from the switch.
(b) After the engine stops rotating, check whether it is
conductive between the terminal and the shell as
indicated in the figure.
(c) When the engine is running, check whether it is
non-conducting between the terminal and the shell.
Tip：
■The oil pressure should be higher than 24.5KPa.
If it does not conform to the specifications above,
replace the switch.

7. Check the conductivity of brake fluid level

warning light switch.
(a) Remove the reservoir lid and filter.
(b) Disassemble the socket connector.
(c) Check whether it is non-conducting between the
terminals when the switch is turned OFF (the floater
is floating).
(d) Suck out the brake fluid from the reservoir cup by
means of siphonage.
(e)Check whether it is conductive between the
terminals when the switch is turned ON (the floater is
sinking) .
(f) Fill the brake fluid back into the reservoir cup.
If it does not conform to the specifications above,
replace the switch.

8. Check the parking brake switch continuity.

(a) Check whether it is conductive between the
03-48
 03-Body

terminal and the shell when the switch is turned ON

(the switch pin is free).
(b) Check whether it is non-conducting between the
terminal and the shell when the switch is turned OFF
(the switch pin is pressed). If it does not conform to
the specifications above, replace the switch or check
the ground point.

9. Check the door-open warning light.

Remove the socket connector of door control switch
from the wiring. Connect the side terminal 1 of
wiring to ground wiring. Check whether the warning
light works. If the warning light does not work, check
the bulb or the wiring.

Replacement
1. Remove the ornament of combination meter.
(1)As shown, remove the ornament of combination
meter with a screwdriver.
Tip：
■ Wrap up the tip of the screwdriver with tape before
using it.
（b）Disconnect the socket connector.

2. As shown in the picture at left, replace the

combination meter by removing three self-tapping
screws.

03-49
03-Body

Dashboard

Service notes
1．Modern automotive electronic instruments are sophisticated, and require high level maintenance
technology. The relevant provisions in the practical automotive maintenance manual should be followed
during overhaul. The electronic instrument devices should be sent to professional maintenance unit for
overhaul if necessary.
2．Modern automotive electronic instrument display board and the motherboard (logic board) are
easily damaged, as well as expensive. So care should be exercised when using and repairing them., It is
not allowed to apply all the battery voltage to any input terminal of the dashboard unless otherwise noted.
A high impedance instrument should be applied (rather than a simple one) during voltage and resistance
check. It should be noted in particular that the instrument should be properly used during automotive
instrument over haul, otherwise the microcomputer circuit will be seriously damaged.
3．Cut off power supply before removing the electronic dashboard Then perform removal in order. It
should be particularly noted that the electronic components should not be struck or vibrated during removal
to avoid damage.
4．The electronic dashboard should be removed in order. Do not apply excessive force to prevent
good components from being damaged. When removing the dashboard assembly, detach the battery
terminals before detaching the connector or terminals. When replacing the electronic instrument
components, be careful to keep your body away from the integrated unit lead wire terminals of replaced
components (spare components). The spare components should be kept in nickel-plated packaging bags Do
not take them out from the bag in advance. When taking them out, be careful not to touch the connectors to
prevent the them from being damaged by static.
5．When overhauling the electronic dashboard, whether on the vehicle or on the workbench, operation
location or maintenance personnel should not be with static electricity. So static protection devices should
be applied during operation, which are usually a wrist strap connecting the body and bond strap and a
conductive plate for placing electronic components.
6．It is not allowed to disconnect the battery when the engine is running, for which would cause a
momentary counter EMF, resulting in damage to the instrument.

03-50
 03-Body

7．A cold cathode tube is applied to the electronic instrument. It should be noted that the cold cathode
tube connector is charged with high-voltage alternating current when powered. So do not touch these
powered parts.
8．In order to avoid damage caused by static induction, it is required to use the original plastic box
when handling the circuit board of electronic speedometer / odometer. An accidental touch of the
connector of circuit board will cause the instrument reading to disappear. At this time, the instrument must
be sent for professional maintenance before it can be used again.

03-51
03-Body

Components assembly

03-52
 03-Body

Replacement
The table of bolts, screws and nuts
Descriptions：
The bolts, screws and nuts used in dashboard removal and installation are listed in the table below
with the letters as orders.

03-53
03-Body

Removal
1. Remove the front pillar garnish.
2. Remove the front pillar lower garnish.
(a) Hold the front pillar lower garnish, and pull out
the garnish in the direction indicated in the figure.
(b) The garnish on the other side should be removed
in the same way

3．Remove the steering wheel cover.

4．Remove the steering wheel.

5．Remove the upper and lower covers of the

steering column.

6．Remove the wiper and washer switch.

7 ． Remove light-control switch and headlamp

dimmer switch.

8．Remove the central-lower cover.

Remove the clip and central-lower cover.
9．Remove the glove compartment.

03-54
 03-Body

(a) Open the glove box.

(b) Push the glove compartment from both sides and
pull it out (as shown).

03-55
03-Body

10． Remove the combination meter.

(a) Remove three screws.
(b)Disconnect socket connectors and remove the
combination meter.

11．Remove the central-upper ornament.

(a) Remove the eight screws. Remove the car audio

and air conditioning control panel.
(b) Remove the central-upper ornament with a
screwdriver.
Tip：
■ Wrap up the tip of the screwdriver with tape before
using it.
(c) Disconnect socket connectors.

Screw position 12．Remove the radio assembly.

(a) Remove the four screws.
(b) Disconnect the socket connectors,. Then remove
the radio assembly.

13 ． Remove the ashtray and the lower

ornament.

03-56
 03-Body

Note：
●Clip position

14． Remove the floor console box.

clip position
(a) Remove the dust cover of shift lever hole and the
handle.
(b)Pry the floor console and ornament with a
screwdriver.
(c)Disconnect the power window switch socket
connectors.
(d) Remove four screws and floor console box.

15．Remove the dashboard.

(a) Remove four screws.
(b) Remove the two side covers and bolts.
(c) Detach the clips.
(d) Pull outward the upper part of the dashboard.

03-57
03-Body

16．Remove the defrost air outlet.

17．Remove the heater control assembly.
18．Remove the lower part of the dashboard.
(a) Remove the hood lock lever.
(b) Remove the five bolts and two clips.
(c) Disconnect the socket connectors.
(d) Remove the lower part of the dashboard.

19．Remove the steering column.

20．Remove the lower bracket of the dashboard.
Remove the bolts and nuts. Then remove the lower
bracket of the dashboard.
21．Remove the reinforcement pillar.
(a) Remove the seven bolts and one screw.
(b) Detach the wiring clip. Disconnect the connector
of fuse box.
(c) Remove the steering wheel and the steering
column.
(d) Remove the reinforcement pillar.
Note：
● Be careful not to damage the body and wiring.

03-58
03-Body

03-59
03-Body

Front Seat

Components

03-60
 03-Body

Maintenance
Tip：
■The right side is handled in the same steps as
those of the left side.
1．Remove the front seat.
(a)Remove the headrest.
(b)Remove both the inside and outside seat track
covers.
(c)Remove the four bolts.
(d)Disconnect the connector from the back of the seat
cushion.
(e)Remove the seat.

2．Remove the left front seat cushion shield.

(a)Remove the reclining release handle.
(b)Loosen the three calipers. Remove the seat
cushion shield.

3 ． Remove the inner shield of left front seat

cushion.
(a) Remove the screws.
(b) Loosen the two claw buckles. Remove the seat
cushion shield.

4 ． Remove the left front seat inside belt

assembly.
(a) Disconnect the seat inside belt wiring from the
front seat adjuster.
(b) Remove the bolts and seat inside seat belt.

5．Remove the left front seat backrest cover.

(a) Loosen the outer edge of seat backrest cover.
(b)Turn over the back of seat backrest. Remove the
arch rings.
03-61
03-Body

(c)Remove two headrest supports and the seat

backrest cover together with the seat back cushion.
(d) Remove the arch rings and the seat backrest cover
from the seat backrest cushion.

6．Remove the left front seat cushion cover.

(a) Remove the arch ring from the back of the seat
cushion.
(b) Insert a screwdriver between the seat cushion
cover and the seat cushion frame. Loosen the seat
cushion cover.
(c) Remove the seat cushion together with the seat
cushion cover.
(d) Remove the arch ring and the seat cushion cover.

7．Remove the front seat adjuster.

(a) Remove the arch ring from the back of the seat
cushion.
(b) Remove the handle of the seat track.
(c) Remove the seat cushion together with the seat
cushion cover.
(d) Remove the arch ring and the seat cushion cover.

8．Install the front seat adjuster.

(a) Install the seat cushion frame with 4 screws.
(b) Install the handle of seat track.
(c) Install two reclining adjusters inside the cover
with four screws.

9． Install the left front seat cushion cover.

03-62
 03-Body

(a) Install the seat cushion cover on the seat cushion

with new arch rings.
(b)Install the seat cushion on the seat cushion frame.
(c) Fix the edge of seat cushion cover firmly on the
seat cushion frame.
(d)Install the arch rings on the seat cushion backrest.

10．Install the left seat backrest cover.

(a) Install seat backrest cover on the seat backrest
cushion with new arch rings.
(b)Install the seat backrest cushion to the seat
adjuster.
(c) Install two headrest supports.
(d)Install the new arch rings to the back of seat
backrest.
(e) Fix the edge of seat backrest cover.

11． Install the inside seat belt assembly of left

front seat.
(a）Connect the front seat inside seat belt wiring to
the front seat adjuster.
(b）Install inside seat belt with bolts.
Torque ：4
2 N·
m

12 ． Install the inner shield of left front seat

cushion.
(a)Fix two buckles. Install the seat cushion shield.
(b)Install the shield of seat cushion with screws.

03-63
03-Body

13．Install the left front seat cushion shield.

(a)Fix three buckles. Install the seat cushion shield.
14．Install the front seat.
(a)Put the seat into compartment.
Front seat(left)
(b)Connect the connector on the back of the seat
cushion.
(c)Install the four bolts.
Torque ：4
9 N·
m
(d)Install the inside and outside seat track covers.
(e)Install the headrests.

03-64
 03-Body

Rear seat

Components

03-65
03-Body

Overhaul
Removal
1. Remove the rear seat cushion assembly.
(a)Pull up the front section of seat cushion.
(b) Remove the inside belt of rear seat.
(c) Remove seat cushion assembly.

2. Remove the backrest assembly.

（a）Remove the three bolts at the lower part of the
backrest.
（b）Pull out the backrest assembly upward.

Disassembly
1. Headrest
（a）Press the button of headrest bracket. Pull out the
headrest upward.
2. Headrest support.
（a）Remove the headrest support.

Installation
1. Install the headrest support and headrest.
2. Install the backrest assembly.
（a）Lock the two hooks at the back of the backrest
into the lock tube. Then install the backrest assembly
with three bolts.
3. Install the rear seat cushion assembly.
(a) Hook the wiring of seat cushion to the prominence
at central seat cushion
(b) Pull out the inside belt of rear seat from the seat
03-66
 03-Body

cushion assembly.
(c) Press the front part of seat cushion assembly. Then
install it properly.
Tip：
■Ensure that the seat cushion assembly is securely
installed.

03-67
03-Body

Door Lock

Components

03-68
 03-Body

Vehicle inspection
1.Door lock failure
2.When door lock control switch breaks down
(manually operate the switch or operate the left
front door with the key) , the locking / unlocking
operation of the door lock fails.
3. Check the operation of power door lock.

Left front door (a) Check the basic functions.

（1）Check whether all the doors are locked when
the door lock control switch(manually operated
switch) is turned to "LOCK" position and all the
doors are unlocked when the switch is turned to
"UNLOCK" position.
（2）Check whether all the doors are locked when the
driver side door lock is turn to "LOCK" position with
a key.

03-69
03-Body

Door lock inspection

 Check the door lock assembly of left front
door.
(a) Apply battery voltage. Check the operation of
door lock motor.
Standard
Measurement conditions Standard state
1Battery positive pole - Locked
Terminal 1
Unlocked 2Battery negative pole-
terminal 2
2Battery positive pole- Unlocked
Terminal 2
1Battery negative pole-
terminal 1
If the operation does not meet the standard, replace
the door lock assembly.

(b) Check the conductivity when the door lock is

unlocked and locked.
Locked
Standard：
Terminal Door lock standard
number position state
3and4 LOCK Conductive
3and5 UNLOCK Conductive
If the operation does not meet the standard, replace
the door lock assembly.

2. Check the door lock assembly of right front

door.
(a)Apply battery voltage. Check the operation of
door lock motor.
Standard：

03-70
 03-Body

If the operation does not meet the standard, replace

the door lock assembly.

03-71
03-Body

3 Check the door lock assembly of left rear door.

locked (a)Apply battery voltage Check the operation of door
lock motor.
Standard：
Measurement conditions standard state
2Battery positive pole- Locked
Terminal 2
1Battery negative pole-
terminal 1
1Battery positive pole- Unlocked
Terminal 1
2Battery negative pole-
terminal 2
If the operation does not meet the standard, replace
the door lock assembly.

locked
4 Check the door lock assembly of right rear door.
(a) Check the operation of door lock motor.
(b) Apply battery voltage. Check the operation of
door lock motor.
Standard：
Measurement conditions standard state
1Battery positive pole - Unlocked
Terminal 1
2Battery negative pole-
terminal 2
2Battery positive pole- Locked
Terminal 2
1Battery negative pole -
terminal 1
If the operation does not meet the standard, replace
the door lock assembly.

03-72
 03-Body

Replacement
1. Remove the door lock.
(a) Remove the door inside locking button.
(b) Remove the cable from the clamp.
(c) Remove the two rods from the outside handle and
the lock cylinder.
(d) Power door lock.
Disconnect the socket connectors. Remove the three
screws.
Torque：5.0 N·m
Tip：
■When re-installing please refer to the following
instructions.
■ Apply sealant to the three screws.
(e) Remove the door lock from the maintenance hole.
Tip：
■When re-installing please refer to the following
instructions.
■Apply grease MP to the sliding and rotating parts of
the door lock.

2. Remove the locking button seat and the clamp.

(a) Remove the locking button seat and the clamp
with a screwdriver.
Tip：
■ Wrap up the tip of the screwdriver with tape before
using it.

3. Remove the outside handle.

03-73
03-Body

(a) Remove the two bolts and the outside with-lock

cylinder handle .
Torque: 5.0N·m
(b) Remove the bolts and lock cylinder from the
outside handle.
Torque: 5.0N·m

03-74
 03-Body

Remote control door lock control system

Service notes
1．Inspection notes
(a)The remote control function of wireless door lock can work only when the following three
conditions are met.
(1) All doors are closed. Otherwise, all the other doors can not be locked as long as one door is
opened.
(2) The key is not inserted into the keyhole of ignition switch.
(3) The power door lock system works normally.
(b) The remote control area of wireless door lock varies on different circumstances.
(1) The control area varies depending on the operation distance and the way the transmitter is held.
(2) In some places, as a result of the influence of the body conditions and the surrounding environment,
the control area will be narrowed down, or the remote control functions only work partially.
(3) As the transmitter applies faint electromagnetic waves, strong electromagnetic waves or noise of
the same frequency will narrow down the control area , or cause the failure of the remote control
function .
(4) When the battery power is low, the control area will be narrowed down, or the remote control
function does not work.
Tip：
■If the door control transmitter is placed somewhere exposed to direct sunlight, for example, on the
dashboard, it will cause a power short age of the battery or other failures.

03-75
03-Body

Remote control battery

Replacement
Replace the old battery with CR1616 lithium battery
or its equivalent.
Replace the battery in accordance with the following
steps:
1. Open the key cover with tools. Take out the
transmitter from the key.
2. Open the transmitter . Take out the battery.
Insert the new battery and make the anode side of
the battery(+) face up.
3. Put back the transmitter cover. Insert the
transmitter into the key. Put the key cover back.
Note：
● Be sure that the anode and cathode of the
transmitter battery face toward the right direction.
● Be careful not to bend the electrode of battery
holder. Keep the transmitter away from dust and oil.
●Ensure that the transmitter cover is securely put
back.
After replacing the battery, check whether the
transmitter works normally.

03-76
 03-Body

Remote key registration steps:

1. the remote controller can log two remote controllers at most
2. Login method：
3.Programs for duplicating the key
The initial conditions for duplicating the key: A.the lock is unlocked ( not by remote control,
because it will be automatically locked 30 minutes later. )
B. The door is closed.
Action sequences: 1 insert the key → pull out the key→ insert→ pull out. Within 40
2. Open the door (it is low level when the doors are opened). seconds
3. Insert the key → pull out the key.
4. Close the door→ open the door→ close →open. Within 40
5. Insert the key → pull out the key. seconds
6. Close the door→ open the door→ close →open. Within 40
7. Insert the key. seconds
8. Close the door.
9. Turn the ignition switch ON then OFF twice. Within 40
10. Pull out the key. seconds
11. Press the first remote control handle which will be registered Within 40
( normal registration: lock→ unlock , without flashing light). seconds
12. Press the second remote control handle which will be registered
(normal registration: lock → unlock , without flashing light).
13. Registration ends.

Wireless remote control transmitter

The wireless remote control transmitter is an electronic component. In order to prevent the transmitter
from being damaged, users should observe the following instructions:
●Do not place the transmitter on the dashboard whose temperature may become very high.
●Do not disassemble the transmitter.
●Do not tap the transmitter with other objects or throw the transmitter.
●Do not place the transmitter into water.
If the wireless remote control transmitter can not manipulate the door, or can not work in the normal
distance, you should take the following steps.
●Check whether the transmitter is near other wireless signal transmission area. The wireless signal
transmitted by radio station or airport may affect the normal work of the wireless remote control transmitter.
● Check the transmitter battery. It may be dead.
If the following situations happen, the battery may be dead.
03-77
03-Body

●The remote controller does not work.

●The effective range of the remote controller becomes very small.
●The indicator on the key is very faint or does not work.

03-78
 03-Body

Hood/ Door

Hood

03-79
03-Body

Adjustment
Tip：
■ The locating bolts are used to locate the hood
hinge and lock ,so they can not be used to adjust the
hood hinge and lock. Use standard bolts instead .

1. Adjust the hood from the front and rear, left

and right.
Loosen the fixing bolts on the hood sidepiece hinge.
Adjust the hood.

2. Adjust the front section of the hood in vertical

direction.
Adjust the height of the hood by rotating the cushion.

3． Adjust the hood lock.

Loosen three bolts. Adjust the hood lock.
Torque: 8.0N·m

03-80
 03-Body

Front door

03-81
03-Body

Adjustment
1. Adjust the door from the front / rear and
vertically.
Loose the side hinge bolt of body. Adjust the door
with special tool SST.
2． Adjust the door from the left / right and
vertically.
Loose the side hinge bolt of door. Then adjust the
door.
Use standard bolts instead of locating bolts.

3． Adjust the door lock striker plate.

(a) Check the match of doors and whether the door
lock connecting rods are adjusted properly.
(b) Loose the lock striker plate bolts. Then adjust the
striker plate.
Torque：23N·m
(c) Adjust the lock striker plate by tapping it with a
rubber hammer.

03-82
 03-Body

Maintenance
Removal
1. Remove the lower window frame bracket
garnish.
2. Remove the door inside trim board.
(a)Remove the screws and handle.
(b)Remove the screws and six clips with the SST
FT9015204 nylon screwdriver.
(c)Insert the SST FT9015204 nylon screwdriver
between the door inner panel and inside trim board.
Clip Pry the door inside trim board.
Note:
●Do not damage the door inner panel, inside trim
board and clips.
Tip：
■ Wrap up the tip of the screwdriver with tape before
using it.
(d) Pull out the door inside trim board from the top.
(e) Remove the door inside locking button seat.

3. Remove the outer rearview mirror.

(a)Power rearview mirror: detach the socket
connectors.
(b) Remove three nuts and outer rearview mirror.
Torque：6.0～10.0 N·m

4. Remove the inside handle of front door.

(a)As shown, remove the inside handle of front door.
(b)Remove the door lock cable from the door inside

03-83
03-Body

handle.

5. Remove the bracket of handle.

Remove the two screws and the bracket of handle.

6．Remove the maintenance hole cover.

Remove the maintenance hole cover.
Tip：
■When re-assembling, please follow the
requirements below.
Drill bit
■Pull out the door lock cable from the maintenance
hole cover.

7． Door speaker
Remove the door speaker.
Pneumatic rivet gun
(a)Mill off the rivet head with a milling head and
remove the speaker.
(b)Disconnect the socket connector.
(c)Clean the milled rivets from inside the door
board with a vacuum cleaner.
Tip：
■The milled rivets and milling head are very hot, so
Shaft do not touch them with hands.
Note：
●Do not shake during use. Wear goggles.
● Expanding the rivet holes will damage the milling
head.
Tip：
■Do not mill holes on the door inside board.
03-84
 03-Body

Tip：
■When re-assembling, please refer to the following
requirements.
■ Shoot the rivets into the door inside board with a
pneumatic rivet gun. Install speaker on the door
inside board.
Note：
●When re-assembling, please refer to the following
requirements.
●If rivets are not installed vertically, the shaft core
will be bent. The gun will be damaged as a result
when pulled out.

8．Remove the door glass.

(a) Open the door window. The bolts can be seen
from the maintenance hole.
(b) Remove the two bolts.
Note：
●Be careful not let the door glass fall off.
(c) Pull out the glass from outside top.

9．Remove the door glass regulator.

(a) Power door and window.
Disconnect the socket connector.
(b) Power door and window.
Remove the six bolts and the glass regulator.
Torque: 8.0N·m
Power door and window Tip：
■ Remove the glass regulator from the maintenance
hole.
03-85
03-Body

Tip：
■When re-installing please refer to the following
instructions.
■ Apply grease to the glass regulator rail .
Note：
●When re-installing please refer to the following
instructions.
●Do not apply grease to the spring of glass riser.

10． Remove the door outside weatherstrip.

Remove the door outside weather strip.

11．Remove the door glass run.

(a) Remove the door glass run.
(b) Pull out the glass run from the top.

12. Remove the front and rear lower window

frames.
Remove two bolts and two lower window frames.
Tip：
■ Remove the lower window frame from the
maintenance hole.
13. Remove the door locks.
(a) Remove the inside locking button of door.
(b) Remove the cable from the clamp.
(c) Remove the two rods from the outside handle and
the lock cylinder.
(d) Power door lock.
Disconnect the socket connectors. Remove the three
screws.
03-86
 03-Body

Torque: 5.0N·m
Tip：
■When re-installing please refer to the following
instructions.
Apply sealant to the three screws.
(e)Remove the door locks from the maintenance hole.
Tip：
■When re-installing please refer to the following
instructions.
■Apply grease MP to the sliding and rotating parts of
the door lock.

14 ． Remove the locking button seat and the

clamp.
(a)Remove the locking button seat and the clamp with
a screwdriver
Tip：
■ Wrap up the tip of the screwdriver with tape before
using it.

15．Remove the outside handle.

(a)Remove two bolts and the outside with-lock
cylinder handle.
Torque: 5.0N·m
(b)Remove the bolts and lock cylinder from the
outside handle.
Torque: 5.0N·m

03-87
03-Body

Installation
The re-installation is opposite to the removal in
order. Please note the following points when
installing.
●If the door lock with front door motor is to be used
again, replace the adapting pieces repair kit with a
new one. Using the removed or damaged repair kit
will result in water seepage and then door lock
failure.
●Never try to turn the motor downward before the
window glass is installed.
●Do not add grease to the spring of window regulator.
●check the sealing situation after installing the inside
trim board。

03-88
 03-Body

Rear door

03-89
03-Body

Adjustment
1．Adjust the door from the front / rear and
vertical ly.
(a) Remove lower trim boards of front and rear door.
(b) Remove the lower trim board of central pillar.
(c) Remove the outer belt of front seat.
(d) Loosen the body side hinge nut. Then adjust the
door.
(e)Install the outer belt of front seat and the lower
trim board of central pillar.
(f) Install lower trim board of front and rear door.

2 ． Adjust the door from the left / right and

vertically.
Loose the door side hinge bolt of door, then adjust the
door with a door hinge wrench.

3. Adjust the door lock striker plate.

(a)Check the match of doors and whether the door
lock rods are adjusted properly.
(b)Loosen the mounting screws of the lock striker
plate. Then adjust the striker plate.

Torque: 23N·m
(c) Adjust the striker plate by tapping it with a rubber
hammer.

03-90
 03-Body

Maintenance
1．Remove the door inside trim board.
(a) Remove the screws and the handle.
(b) Remove the screws and inside handle.
(c)Insert the SSST FT9015101 nylon screwdriver
between the door inside board and inside trim board.
Pry the door inside trim board.
Six clips
Note：
● Be careful not to damage the door inside board
and inside trim board.
Tip：
■ Wrap up the tip of the screwdriver with tape before
using it.
(d) Pull out the door inside trim board from the top.
(e) Power doors and window.
Disconnect the connection parts of the power door
and window switch.
(f) Power door and window.
Remove the power door and window switch from the
door inside trim board.

2. If necessary, replace the door glass inside

weather strip.
3. Remove the door inside handle.
(a) Remove the door inside handle.
(b) Remove the door lock cable from the door inside
handle.

4. Remove the bracket of handle.

03-91
03-Body

Remove the two screws and the bracket of handle.

5．Remove the maintenance hole cover.
Remove the maintenance hole cover.
Note：
If any of the maintenance hole covers of the four
doors is damaged, replace it.

Tip：
■When re-installing please refer to the following
instructions.
■Pull out the door lock cable from the maintenance
hole cover.
6．Remove the door outside weather trip.
7．Remove the door quarter window glass.
(a) Remove the glass run.
Tip：
■Pull out the glass run from the top.
(b) Turn the weather strip and remove the screws.
(c) Remove the two bolts and the division bar.
(d)Remove the with- weather trip quarter window
glass.
(e)Remove the weather strip from the quarter window
glass.

8．Remove the door glass.

(a) Slide the door glass backward from the glass riser
Note：
Be careful not to drop the door glass.
(b) Pull out the glass from the top.

03-92
 03-Body

9. Remove the glass regulator.

Motor-driven doors and windows (a) Power door and window.
Disconnect the connection parts. Then remove the 4
bolts and the glass regulator.
Torque: 8.0N·m
Tip：
■ Remove glass regulator from the maintenance
hole.
Tip：
■When re-installing please refer to the following
instructions.
■ Apply grease to the glass regulator.
Note：
●When re-installing please refer to the following
instructions.
●Do not apply grease to the spring of the glass
regulator.

10. Remove the door locks.

(a) Remove the locking button of the door.
(b)Remove the crank seat of door locks and
disconnect the two rods of door locks.
(c) Take out the door lock rod and cable from the door
lock rod clamp.
(d) Power door lock.
Disconnect the socket connectors, three screws and
the with-rod door locks.
(e)Remove the door locks from the maintenance hole.
Tip：
■When re-installing please refer to the following
03-93
03-Body

instructions.
■ Apply sealant to the three screws.
■Apply grease MP to the sliding and rotating parts of
the door lock.

11 ． Remove the locking button seat and the

clamp of the door .
Remove the locking button seat and the clamp with a
With-washer bolt
screwdriver.
Tip：

With-washer bolt ■Wrap up the tip of the screwdriver with tape before
With-washer boltWith-washer bolt using it.

12．Remove the outside handle.

Remove two bolts and the outside handle.
Torque: 5.0N·m

03-94
 03-Body

Trunk lid
Adjustment
1.Adjust the trunk lid from the left / right and
vertically.
Loosen the side hinge bolt of the back door. Then
adjust the trunk lid.
2．Adjust the door from the front / rear and
vertically.
(a) Remove the three clips and the rear section of the
roof headlining.
(b) Loosen the side hinge nut of the body. Then adjust
the trunk lid.

3．Adjust the lock striker plate of the trunk lid.

(a)Insert the SST FT9011102 between the rear cowl
garnish cover and the body. Then pry it .
(b)Check the match of doors and whether the door
lock rods are adjusted properly.
(c)Loosen the mounting bolts of the lock striker plate.
Then adjust the lock striker plate.
Torque: 23N·m
(d)Adjust the lock striker plate by tapping it with a
rubber hammer.

03-95
03-Body

Inside Trim / Outside Trim

Front Bumper

03-96
 03-Body

Replacement
Tip：
■The installation is opposite to the removal in order.
With-washer bolt
1．Remove the radiator shield sub-assembly.
clip
(a)Remove a clip.
With-washer
b lt (b)Unscrew the two bolts with a screw driver.
Remove the radiator shield.
Note：
● Be careful not to damage the radiator shield. Wrap
Radiator shield up the tip of the screwdriver with tape before using.

2. Remove the front bumper.

(a) Remove the four bolts and two screws.
(b)Detach a clip. Remove the front bumper.

03-97
03-Body

3. Remove the left fog lamp assembly.

（a）Remove the three screws. Remove the fog lamp
shade.
4. Remove the right side fog lamp assembly.
（a）Remove the three screws. Remove the fog lamp
shade.

5．Remove the upper cross member assembly of

water tank.
(a) Detach the wiring clip.
(b)Remove the nuts and the reinforcement plate.

6. Remove the left mounting bracket of front

bumper.
（a）Remove the two nuts and mounting bracket.
7. Remove the right mounting bracket of front
bumper.
（a）Remove the two nuts and mounting bracket.

8. Remove the front bumper hole cover.

9. Install the left mounting bracket of front
bumper.
（a）Install the two nuts and mounting bracket.
10. Install the right mounting bracket of front
bumper.

03-98
 03-Body

（a）Install the two nuts and mounting bracket.

11. Install the upper cross member assembly of

water tank.
(a)Install the front bumper reinforcement plate.

12. Install the left fog lamp assembly.

（a）Install the three screws. Install the fog lamp
shade.

13. Install the right side fog lamp assembly.

（a）Remove the three screws. Install the fog lamp
shade.
14. Install the front bumper.
(a) Install the four bolts and two screws.
(b)Install a clip. Remove the front bumper.

With-washer bolt
clip 12. Install the radiator shield sub-assembly.
With-washer bolt
（a）Attach the two bolts and a clip. Then install the
radiator shield.

Radiator shield

03-99
03-Body

Rear Bumpe

03-100
 03-Body

Replacement
Tip：
■The installation is opposite to the removal in order.
1. Remove the left inside trim cover of the trunk.
(a)Remove the three clips and the trim cover.
2. Remove the right inside trim cover of the trunk.
(a) Remove the three clips and the trim cover.
3. Remove the rear combination lamp assembly
(see 2-34).
4. Remove the rear steering light bulb.
5. Remove the rear brake light.
6. Remove the rear bumper.
（a）Remove the four screws and four nuts.
Scre
Screw （b）Remove the bumper.

Bolt
7. Remove the mounting bolts of bumper bracket.
（a）Remove the four bolts from the bumper.

03-101
03-Body

Installation
1. Install the mounting bolts of bumper bracket.
（a）Screw four bolts on the bumper.

2. Install the rear bumper.

(a)Install the rear bumper with two screws and four
nuts.
Note:
The nuts installation is opposite to the nuts
removal in order .
3. Remove the rear combination lamp assembly.
Screw
4. Remove the rear steering light bulb.

Screw 5. Remove the rear brake light.

Bolt

03-102
 03-Body

Outer weather strip

Replacement
Tip：
■The installation is opposite to the removal in order.
It will be pointed out in particular if there is any
different step from the removal during installation.
■The installation and removal process of right side is
the same with that of the left side.
1．Remove the left front door outer glass weather
strip assembly.
(a)Post protective tapes under the weather strip
assembly.
(b)Remove the weather strip assembly with a trim
Protective tape detacher or a scraper.
Tip：
■ Wrap up the scraper with tape before using it.
Tip：
■The installation is opposite to the removal in order.
It will be pointed out in particular if any steps differ
between removal and installation.
■ The installation and removal process of right side is
the same with that of the left side.

2. Remove the right front door outer glass weather

strip assembly.
Protective tape
(a)Post protective tapes under the weather strip
assembly.
(b)Remove the weather strip assembly with a trim
detacher or a scraper.
03-103
03-Body

Tip：
■ Wrap up the scraper with tape before using it.

03-104
 03-Body

Back Door Outside Trim (spoiler)

03-105
 03-Body

Replacement
The steps of installation are the same as those of
Spoiler assembly the removal.
1. Remove the three bolts and replace the spoiler.

Nuts
Hexagonal flange bolts
Hexagonal flange

03-106
 03-Body

Drip side finish trim

03-107
03-Body

Replacement
Tip：
■The installation and removal process of right side is
the same as that of the left side.
1. Remove the left sink trim.
(a)Post protective tape around the trim.
(b)Loosen the clips at both ends of the trim with a
roof trim detacher. Then remove the roof side sink
trim.
Note：
●Do not remove the clip.
● Replace the clip if it is damaged or accidentally
removed.

2．Install the roof left sink trim.

Note：
●Only when replacing new clips should the following
steps be taken.
(a)Tear off the trim tape on the body surface. Wipe it
off with clean gasoline.
(b) Heat the surface area where the clips are to be
installed with heat lamps
Heating temperature
Note：
●Do not overheat the trim .
(c) As shown in I , press fit the clip with hands and
install the clip at its original position.
(d)Install the trim 30 minutes after the clip is
completely pressed fit.

03-108
 03-Body

Tip：
■Basic fastening time: 30 minutes.
■The best fastening time：24 hours.

03-109
03-Body

Inside Trim

03-110
 03-Body

03-111
03-Body

03-112
 03-Body

Replacement
Removal
1．Remove the front pillar lower garnish.
(a) Hold the front pillar lower. garnish. Pull it in the
direction shown in the figure.
(b) The front pillar lower garnish on the other side
can be removed in the same way.

2. Remove the rear door opening lower garnish.

3. Remove the front door opening trims.
4. Remove the rear door opening trims.
5 ． Remove the rear seat (see the rear seat
structure of two compartment car).
6. Remove the central pillar lower garnish.
(a)Insert the SST FT9015204 nylon screwdriver
between the garnish and the body. Pry the garnish.
Tip：
■ Wrap up the tip of the screwdriver with tape before
using it.
(b)The central pillar lower garnish on the other side
can be removed on the same way.

7． Remove the central pillar upper garnish.

(a) Remove the cover of seat belt fixed point with a
screwdriver.
Tip：
■Wrap up the tip of the screwdriver with tape before
using it.
(b) Remove the bolts and the sash fixed point of front

03-113
03-Body

seat outer belt.

Torque: 42N·m
(c)Remove the central pillar upper garnish with a
screwdriver.
Tip：
■ Wrap up the tip of the screwdriver with tape before
using it.
(d) The central pillar upper garnish on the other side
can be removed in the same way.

8．Remove the front pillar upper garnish.

(a)Remove the front pillar upper garnish with a
screwdriver.
Tip：
■ Wrap up the tip of the screwdriver with tape before
using it.
(b) The front pillar upper garnish on the other side
can be removed in the same way.

9. Remove the deck side trim panel.

(a) Remove the clips and screws.
(b) Remove the bolts and the floor fixed point of rear
seat outer belt.
(c)Remove the deck side trim panel with a
screwdriver.
Tip：
■ Wrap up the tip of the screwdriver with tape before
using it.
(d) The deck side trim panel on the other side can be
removed in the same way.
03-114
 03-Body

10．Remove the rear quarter upper garnish.

(a) Insert a screwdriver between the garnish and the
body. Pry the garnish.
Tip：
■ Wrap up the tip of the screwdriver with tape before
using it.
■ Pull out the floor fixed point of rear seat outer belt
from the rear quarter upper garnish. Then remove the
garnish.
(b) The rear quarter upper garnish on the other side
can be removed in the same way..

11．Remove the interior lights.

(a)Remove the interior light shade with a screwdriver.
Tip
Wrap up the tip of the screwdriver with tape before
using it.
(b) Remove the two screws and the interior lights.
(c) Disconnect the socket connectors.

12．Remove the armrest.

(a) Remove the two screws.
(b) Remove the armrest.
Tip：
■If there are 3 armrests, remove the second one in the
same way.

13． Remove the sun visor.

(a) Remove the four screws and the visor.
03-115
03-Body

(b) Remove the two screws and the bracket.

14．Remove the roof headlining.

Remove the three clips and roof headlining.

03-116
 04-Air Conditioning System

Air Conditioning System

Maintenance Cautions…………………………………………………………………..1
Air Conditioning System Configuration…………………………………………….....5
Refrigerant……………………………………..............................................................17
Belt Replacement and Adjustment……………….………………………………........18
Air Conditioning Unit Assembly…………………....................................................... 21
Air Conditioning Compressor……………………........................................................31
Compressor and Magnetic Clutch…………………………………………………......32
Condenser Assembly………………………………......................................................38
 04-Air Conditioning System

Air Conditioning System

Maintenance Cautions

Cautions
1．Caution: do not handle refrigerant in an
enclosed area or near flame.
2．Be sure to wear goggles to protect your eyes
when charging or draining the refrigerant .
3．Do not heat the container. Keep it away from
flame.
4. Handle the refrigerant tank with care to
prevent sharp objects from hitting the tank.
5．For handling the refrigerant, keep in mind
that contact with the eyes or skin should be
avoided.

Warning:
If the refrigerant splashes into your eyes or skin,
do not rub your eyes or skin.
(a) Wash the inflicted body surface with plenty of
cold water.
(b) Wipe off the oil on the skin properly.
(c) Seek medical treatment immediately.

6 ． When the refrigerant in the system is

inadequate, do not start the compressor.
(a)A shortage of refrigerant in the system followed by
a lack of lubricant, will lead to the compressor
burnout, which should be noted to prevent this from

04-1
04-Air Conditioning System

happening.

7．Do not open the manifold pressure gauge valve

when the compressor is running.
If the high-pressure valve is opened, the refrigerant
will flow in the opposite direction, leading to rupture
of the filling cylinder. Only the low-pressure valve
can be opened and closed.
8.Be careful not to charge excessive refrigerant.
Excessive refrigerant will cause a series of
problems, including incomplete refrigeration, fuel
efficient reduction and engine superheat.

04-2
 04-Air Conditioning System

Malfunction Table
This table will contribute to troubleshooting. The numbers represent the priority of the problems.
Examine in order and replace the parts if necessary.
Problems Possible malfunction areas
Blower failure 1.GAUGE fuse
2.HTR fuse
3 Blower relay
4 Integrated control panel assembly (blower switch)
5 Blower resistor
6 Blower / fan motor
7 Wiring
Compressor failure 1. Refrigerant amount
2A / C fuse
3Magnetic clutch relay
4Pressure switch
5Air conditioning compressor assembly
6Integrated control panel assembly
7A/C thermostat
8Wiring

Incomplete refrigeration 1Refrigerant amount

2Refrigerant pressure
3Drive belt
4Air conditioning thermostat
5Integrated control panel assembly
(A/C switch)
6Air conditioning compressor assembly
7Condenser
8Reservoir
9Expansion valve
10Evaporator
Refrigerant pipeline
11Pressure switch
12Wiring
No idling speed when the air 1wiring
conditioner is on. 2ECM
Condenser fan failure 1. ECU-IG fuse
(low-speed status) 2 Heater fuse 40A
3.Fan relay No.3
4 Cooling fan motor
5 Wiring
Condenser fan failure 1Heater fuse 40A

04-3
04-Air Conditioning System

2Fan relays No. 3

3A/C condenser fan motor
4Fan relays No.2
5Pressure switch

04-4
 04-Air Conditioning System

Air Conditioning System Configuration

04-5
04-Air Conditioning System

Vehicle Inspection
1. Check pressure switch No. 1
(a) Magnetic clutch control
Check the operation of pressure switch.
(1) Install the manifold instrument.
(2)Connect the positive (red) probe of the ohmmeter
to terminal No.4 , the negative (black) lead to
terminal No.1
(3) As shown in the figure, check the continuity of
each terminal when the refrigerant pressure changes.
(b) Fan control
Check the operation of pressure switch. Connect the
positive probe of the ohmmeter to terminal No.2, the
negative probe to terminal No.3.
As shown in the figure, check the continuity of each
terminal when the refrigerant pressure changes.
If the operation does not conform to the specifications,
replace the pressure switch

3.Air-conditioning compressor assembly with

magnetic clutch
Connect the positive terminal the battery to the
terminal, the negative terminal to the shell. Check the
magnetic clutch when powered.
If the operation does not conform to the specifications,
replace the magnetic switch assembly.

04-6
 04-Air Conditioning System

Inspection
1.Air conditioning system thermostat
(a) As shown in the chart, check the resistance value
between terminal No.1 and No.2 under different
temperatures.
Resistance value of air conditioning thermostat
OFF T1：4377±150Ω (2℃)
ON ：4163Ω (3℃)
T2
Stop-start temperature difference T1-T2：
214±83Ω (1℃)

Pressure switch value

Low pressure（MPa） Medium pressure（MPa） High pressure（MPa）
0.196±0.02 1.52±0.1 3.14±0.2

If the resistance value does not conform to the

specifications, replace the sensor.

2. Integrated control panel assembly

(a) Check the continuity of the blower switch .
Cold wind Terminal conduction
st
1 level 4-5
2st level 3-4-5
3st level 2-4-5

04-7
04-Air Conditioning System

4st level 1-4-5

If the continuity does not conform to the
specifications, replace the integrated control panel
assembly.
(b) Check the illumination operation. Connect the
positive lead of the battery to terminal No.1 and
negative lead terminal to terminal No.4. Check
whether the illuminator works. If the bulb does not
work, replace the bulb. If the continuity does not
conform to the specifications, replace the motor relay
of the heater blower.

3. Magnetic clutch relay

（a）Connect the positive lead of the battery to the
terminal, the negative lead to the shell.
（b）Check the operation of the magnetic clutch.
If the operation does not conform to the specification,
replace the magnetic clutch assembly.

4. Magnetic clutch relay

(a) Check the continuity of the relay
If the continuity does not conform to the
specifications, replace the magnetic clutch relay.
Condition Tester Specifications
connection
Condition Tester Specifications
connection
Constant 1-2 Conducted

04-8
 04-Air Conditioning System

Refrigerant inspection
1．Check the amount of refrigerant
Observe the observation window on the liquid pipe.
Test conditions：
(1) Engine speed: 1500rpm
(2) Blower speed control switch: "Hl" speed
(3) A / C switch ON
(4)Temperature control selector：the coldest level
(5) All doors opened

Item Problem Refrigerant Maintenance methods

amount
1 Bubbles seen from the Insufficient (1) Detect leakage with a leak
observation window detector. Do repairing if necessary.
(2) Add an appropriate amount of
refrigerant to dispel the bubbles .
2 No bubbles seen from the Too much Relate to items 3 and 4
observation window
3 No temperature difference A little (1) Detect leakage with a leak
between the inlet and outlet detector. Do repairing if necessary.
of the compressor (2) Add an appropriate amount of
refrigerant to dispel the bubbles.
4 Obvious temperature Normal Relate to items 5 and 6
difference between the
inlet and outlet of the
compressor.
5 The refrigerant in the Excessive (1) Release an appropriate amount of
observation window refrigerant.
becomes transparent when (2) After vaccumization, add an
the A/C system is turned appropriate amount of refrigerant.
off.
6 The refrigerant seen from Normal
the observation window
becomes foamy and then
transparent when the A/C
system is turned off.
*：If the refrigerant is sufficient, it is normal to see bubbles from the observation window under an
ambient temperature higher than usual.

04-9
04-Air Conditioning System

2．Check refrigerant pressure with the manifold

pressure gauge .
The following methods will explain how to locate the
causes of system failure with the manifold pressure
gauge.
Test conditions:：
（1）Set the air inlet switch to "inner loop" . The
temperature is 30 ~ 35 ℃.
（2）Engine speed：1500rpm
（3）Set the blower speed control switch to high "Hl"
speed.
（4）Set the temperature control switch to cold
level.
TIP：
■The value of the manifold pressure gauge may vary
slightly as the ambient temperature changes.
(1) Normal refrigeration system performance
Measured data：
Pressure on low pressure side：
0.15～0.25Mpa
Pressure on high-pressure side：
1.37～1.57Mpa
(2) There is water in the cooling system.

04-10
 04-Air Conditioning System

Problems in the Possible causes Diagnosis Measures

refrigeration system
In operation, the The water in the .Desiccant is (1) Replace the
pressure on low cooling system saturated reservoir.
pressure side alternates freezes at the .The water in (2) Prolong the vacuum
between vacuum and expansion valve the cooling pumping to drain the
normal. closure and system freezes water in the system.
temporarily blocks at the expansion (3) Add an appropriate
the refrigerant valve closure amount of refrigerant.
cycle. It will return and temporarily
to normal when the blocks the
ice melts. refrigerant
cycle.
(3)Insufficient refrigerant

Problems in the Possible causes Diagnosis Measures

refrigeration system
Low pressure on both Leakage in some ·Insufficient (1)Detect leakage with a
low and high pressure parts of the refrigerant leak detector. Do
sides. refrigeration ·Refrigerant repairing if necessary.
Continuous bubbles system leakage (2) Add an appropriate
seen from the amount of refrigerant.
observation window. (3 If the pressure value is
Poor cooling close to zero when the
performance. refrigeration system is
connected to the manifold
pressure gauge,
vacuum and repair the
leakage part after the test.

04-11
04-Air Conditioning System

(4) Poor circulation of refrigerant

Problems in the Possible causes Diagnosis Measures

refrigeration system
·Low pressure on both Dirt in the The refrigerant Replace the receiver
low and high pressure receiver drier is blocked. drier.
sides. blocks refrigerant
·The tube connecting flow.
the evaporator to the
receiver drier frosts.
(5)No circulation of refrigerant.

Problems in the Possible causes Diagnosis Measures

refrigeration system
Vacuum on low Water or dirt in No circulation of (1)Check the expansion
pressure side the system blocks refrigerant valve.
Extemely low refrigerant flow. (2) Blow air into the
pressure on high Gas leakage at the expansion valve to
pressure side. expansion valve remove the dirt in the
Frost or dew on blocks refrigerant valve.
pipelines around the flow (3) Replace the receiver
expansion valve. drier.
(4) Vacuumize and add
a right amount of
refrigerant.
(5) Replace the expansion
valve if there is gas
leakage.

04-12
 04-Air Conditioning System

（6）Excessive refrigerant or incomplete refrigeration of the condenser.

Problems in the Possible Diagnosis Measures

refrigeration system causes
·High pressure on both ·Too much ·Too much (1) Clean the condenser.
high and low pressure refrigerant to refrigerant in the (2) Check the operation
sides. be effective. system - excessive of condenser fan.
·No bubbles seen from ·Incomplete refrigerant charged. (3) If (1) and (2) are
the observation refrigeration of ·Incomplete normal, check the amount
window as the engine the condenser refrigeration of the of refrigerant charged..
speed drops. condenser—blocke Add a right amount of
d condenser refrigerant
radiator or
condenser fan
failure.

04-13
 04-Air Conditioning System

（7）There is air in the refrigeration system

Note：
●If refrigerant is charged without bleeding air from the cooling system after the cooling system has
started, the meter will look like the below figure.

Problems in the Possible causes Diagnosis Measures

refrigeration system
· High pressure on both Air in the · Air in the cooling (1) Check whether the
low and high cooling system. system. compressor oil is clean
pressuresides.· A heating · Incomplete and adequate.
low-pressure pipe. Vacuumization. (2) Vacuumize and charge
· Bubbles can be seen new refrigerant.
through the observation
windows.

（8）Expansion valve is not installed correctly.

Problems in the Possible causes Diagnosis Measures

refrigeration system
·High pressure on both Expansion valve ·The opening of Replace the expansion valve
low and high pressure sides. failure. the expansion if it has defects.
valve is too big.
·Excessive frost or dew on ·Excessive
the pipes on the refrigerant in
low-pressure side. low-pressure pipe.

04-14
 04-Air Conditioning System

（9）Compressor failure

Problems in the Possible causes Diagnosis Measure

refrigeration system
·High pressure on low ·Internal leakage Compression failure Repair or replace
pressure side. of the ··Suction valve piece is the compressor.
·High pressure on high compressor. damaged or poorly
pressure side. sealed.

3．Check the increase of idle speed

(a) Engine warm up.
(b) Check the increase of idle speed when the following conditions are met.
(1) Engine warm up.
(2) Set the blower control switch to "HI".
(3) Set the air conditioning switch to "ON".
(4) Set the transmission to neutral speed.
(5) Set the temperature control switch to "cool".
Rpm Stable idle speed：700±50rpm
Rpm Idle speed with the A/C on：850±50rpm
If the idle speed does not conform to the specifications, check the idling control system.
(c) The double speed design of the A/C condenser fan of Weizhi V2.
When the pressure of the A/C system reaches 0.196Mpa, the fans are running at low speed.

When the pressure of the A/C system reaches 1.52Mpa, the fans are running at low

speed.

04-15
04-Air Conditioning System

Instrument reading（table）

04-16
 04-Air Conditioning System

Refrigerant

Replacement
1. Drain the refrigerant from the cooling system.
(1)Turn on the air conditioning switch.
(2)Adjust the engine speed to about 1000 rpm. Keep the A/C compressor working for five to six
minutes to circulate the refrigerant and collect the residual oil of the components to the compressor.
(3) Engine flameout.
(4) Drain the refrigerant.
2. Charge refrigerant.
(1)Vacuumize with a vacuum pump.
(2)Charge HFC–134a(R134a)

Standard：500 15g

3. Engine warm-up
4. Check for refrigerant leakage. Check for refrigerant leakage with a gas leak detecting
instrument..

04-17
04-Air Conditioning System

Belt Replacement and Adjustment

Drive belt

Inspection
(a) Visual inspection for excessive wear.Replace the
drive belt if it is damaged.
Note:
■Cracks on the belt reinforcement are acceptable. If
the belt has chunks missing, it should be replaced.
(b) Measure the tension force of the belt.
Ribbed belt tension force of the engine：500～600
N·m
If the belt tension force does not meet the requirement,
adjust it.
Note：
■Check whether the belt is properly installed.
■Check the belt by hand . Make sure it does not slide
out of the lower groove of the belt pulley
■After installing a new belt, make it run for five
minutes then re-check the belt tension force.
■A new belt is the belt that has run for less than five
minutes.
■ An old belt is the belt that has run for more than five
minutes.

04-18
 04-Air Conditioning System

Replacement
1. Check the drive belt.
2. Replace the belt if necessary.
(1) Unscrew the bolt and adjust the lock bolt.
(2) Loosen the belt by turning the adjusting bolt
counter-clockwise.

(3) Adjust the drive belt tension force by turning the

adjustment bolt clockwise.
(4) Fasten bolt and lock bolt.
Torque：40～60 N·m
Adjust the lock bolt：
Torque：19～27N·m

04-19
04-Air Conditioning System

Blower

Replacement
Inspection
1．Remove the door of the glove box.
2．Remove the engine ECU (MT model).
(a) Remove the connector.
(b) Remove the two bolts and the engine ECU (MT
model).
3．Remove the blower motor.
Remove the three screws and the blower motor.

4．Check the operation of the blower motor

Connect the positive (+) lead of the battery to
terminal 1, the negative (-) lead to terminal 2.
Check whether the blower motor runs smoothly. If
the operation does not meet the requirements, replace
the blower motor.

5．Install the blower motor.

6．Install the engine ECU (MT model).
7. Install the glove box.

04-20
 04-Air Conditioning System

Air conditioning Unit Assembly

Components

04-21
04-Air Conditioning System

04-22
 04-Air Conditioning System

Remove the air conditioner

1. Remove the dashboard
Pull out the pin from the body. Remove the
dashboard.
Warnings:
■It is dangerous to remove the dashboard without a
support frame. The dashboard may fall off and harm
you. The attendance of at least one person should be
ensured while conducting these operations..

2.. Remove the air conditioning control

instruments.
Unscrew the five bolts. Remove the air conditioning
control instruments.
3. Remove the dashboard glove box.

4. Unscrew the mounting bolts of the dashboard

and body. Remove the dashboard.

04-23
04-Air Conditioning System

5. After removing the dashboard， unscrew the

bolts connecting the horizontal stiffeners and the
body. Remove the horizontal stiffeners.

6. Drain the refrigerant from the condenser.

Disconnect the air conditioning pipe
assembly.
(a) Remove the bolt. Disconnect the air conditioning
pipe assembly.
(b) Remove two O-rings from the air conditioning
pipe assembly.

7.Disconnect the heater drainpipe A(from the

heater unit).
(a) Clamp the ends of the clip with hand pliers. Make
the clip slide out (of the heater unit).
Disconnect the heater drainpipe A

8. Remove the air conditioning evaporator unit

assembly.
(a) Loosen the clamp.
(b) Disconnect the connector.
(c) Unscrew the five bolts connecting the A/C
assembly to the body. Remove the
air-conditioning assembly.

04-24
 04-Air Conditioning System

9． Remove the thermistor of the air conditioning

unit.
As shown in the picture, remove the thermistor from
the air-conditioning unit assembly .

10. Remove the heater and radiator unit

sub-assembly. Loosen the bolts and remove the air
duct sub-assembly.

11.Pull out the air filter.

12．Remove the cooler wiring.

Disconnect the connector. Remove the
cooler wiring.

13． Remove the fan resistor.

Remove the two screws and the blower resistor.

04-25
04-Air Conditioning System

14． Remove the blower assembly.

Remove the five screws and the heater
without an evaporator core assembly.

15. Remove the blower sub-assembly with a

fan motor.

16. Remove the mode damper motor assembly.

Remove the three screws and mode damper motor
assembly.
Mode damper motor

inside and outside

17.Remove the inner and outer air damper motor
assembly.
Remove the two screws and the inner and outer air
damper motor assembly.

18. Remove the inner and outer air damper motor

assembly.
Remove the two screws and the inner and outer air
damper motor assembly.

inside and outside air

damper motor

04-26
 04-Air Conditioning System

19．Remove the heater assembly housing.

As shown in the picture, remove the eight lock catches and the shell of the heater assembly.

20.Remove the cooler and evaporator

sub-assembly.
(a)Remove the eight screws connecting the air
conditioning system and open the air conditioning
assembly.
(b)Remove the cooling evaporator sub-assembly
from the lower cover of the heater.
(1) Unscrew the two bolts from the cooling
evaporator. Remove the expansion valve.
(2) Remove the two O-rings from the evaporator
assembly .

04-27
04-Air Conditioning System

21.Install the evaporator and cooler sub-assembly.

(a) Apply sufficient compressor oil to the two O-rings
and expansion valve interface surfaces .
Compressor oil：PAG56
(b) Install two O-rings on the evaporator and
cooler sub-assembly,
(c) Install the air-conditioning expansion valve with a
hex wrench of 5.00mm.

22. Install the evaporator and cooler

subassembly into the air conditioning
system assembly.
Screw the eight screws connecting the air
conditioning system assembly .

23. Install the blower motor assembly.

As shown in the picture, install the blower motor
assembly with three screws .

24. Install the mode damper motor assembly

Install the mode damper motor with three screws

25. Install the inner and outer damper motor

assembly.
Install the inside and outside damper motor with two
screws .

04-28
 04-Air Conditioning System

26. Install the cooling and heating damper

motor assembly.
Install the cooling and heating damper motor with
two screws.

27. Install the air conditioning unit assembly

a) Tighten the five bolts connecting the
air-conditioning assembly and body. Install the
air-conditioning assembly.
b) Install the upper connector.
c) Install the clamps.

28.Install the shell of the heater assembly .

As shown in the picture, fasten eight lock catches and
install the heater assembly housing on the
air-conditioning system assembly.

29. Install the ECU (AMT model)

(a) Install the ECU with two bolts.
Note: (MT model)
●Do connect the ECU connector with much effort.
●ECU No collision with the ECU.

04-29
04-Air Conditioning System

30．Connect the dashboard of the air conditioner.

As shown in the picture, tighten the five screws on the
air conditioner and fix it on the dashboard of the
body.

31.Install the air-conditioning pipeline assembly.

(a) Apply sufficient compressor oil to the contact
surface of the two O-rings and air conditioning
pipeline bus.
Compressor oil：PAG56
(b) Install two O-rings on the air-conditioning
pipeline assembly .
(c) Install the air-conditioning pipeline assembly with
screws.

32．Add refrigerant. Amount to add: 500 ± 15g

04-30
 04-Air Conditioning System

Air Conditioning Compressor

Components (Graphical representation)

04-31
04-Air Conditioning System

Compressor and magnetic clutch

Vehicle Inspection
1. Check for oil leakage of the clutch bearing..
2. Check for oil on the pressure plate or the rotor.
3. Check for noise of the magnetic clutch bearing.
(a) Start the engine.
(b) Check for abnormal noise of the compressor when
turning the air conditioner on and off.
Replace the magnetic clutch If there is abnormal
noise.

4．Check the pull- in action of the magnetic clutch.

(a) Disconnect the connectors.
(b) Connect the positive terminal(+) of the battery to
the connector terminal of the magnetic clutch, the
negative terminal (-) to the body.
(c) Check the pull-in action of the magnetic clutch.
Replace the magnetic clutch if the pull-in action is
abnormal.

5．Check for metallic noise of the pressure plate .

Check for abnormal metallic noise of the pressure
plate when turning the air conditioner on.
If there is abnormal metallic noise, replace the
pressure plate assembly.

6. Check the pressure of the refrigerant.

7. Visually check for refrigerant leakage.
Detect refrigerant leakage with gas leak detectors.
04-32
 04-Air Conditioning System

If there is leakage，check the tightening torque at the

interface or replace the compressor.

Disassembly
1 Drain the refrigerant from the system.
2.Remove the belt of the compressor.
3.Disconnect No. 1 refrigerant intake
(a) Remove the bolts. Disconnect the refrigerant
intake No.1 from the magnetic clutch and
compressor.
(b) Remove the O-ring from the refrigerant intake
No.1.
Note：
●Seal the openings of all the disconnected parts with
PVC tape to prevent moisture and foreign matter
from entering .

4．Disconnect the refrigerant outlet No. 1.

(a) Remove the bolts and disconnect the refrigerant
outlet No. 1 from the compressor and magnetic
clutch.
(b) Remove the O-ring from the refrigerant outlet
No.1.
NOTE：
●Seal the openings of all the disconnected parts with
PVC tape to prevent moisture and foreign matter
from entering .

04-33
04-Air Conditioning System

5 ． Remove the lower cover of the right-hand

engine.
6． Remove the compressor and magnetic clutch.
(a) Disconnect the connector.
(b) Remove the four bolts, the compressor and the
magnetic clutch。

7．Remove the magnetic clutch assembly.

(a) Clamp the compressor and magnetic clutch in the
vise.
(b) Clamp the clutch hub with slip joint pliers.
(c) Remove the bolt, the magnetic clutch hub and the
gasket.
(d) Remove the snap ring and the magnetic clutch
rotor with snap ring pliers.
(e) Remove the screws. Disconnect the connector.

(f) Remove the snap ring and magnetic clutch stator

with snap ring pliers.
8. Remove the air-conditioning control wiring
sub-assembly.
9. Remove the bracket.
10 Remove the compressor assembly.
11 Install the magnetic clutch assembly.
(a) As shown in the picture, install the magnetic
clutch stator.
(b) Install a new snap ring with snap ring pliers, the
side with an oblique angle up. .
(c) Install the bolts. Connect the connectors
04-34
 04-Air Conditioning System

(d) Install the magnetic clutch rotor and the new

snap ring with snap ring pliers, the side with an
oblique angle up .
(e) Install the clutch hub and gasket.
NOTE：
●Before disassembly, do not change the combination
gasket of the magnetic clutch.
(f) Clamp the magnetic clutch hub with a slip joint
pliers . Install the bolts.

12．Check the clearance of the magnetic clutch.

(a) Install a dial indicator. Align it to the magnetic
clutch hub.
(b) Connect the positive lead of the battery to
terminal 1 and the negative lead to ground wire.
Turn on and off the clutch. Measure the clearance.
Standard clearance：0.25～0.50mm
If the measured value is out of the range, remove the
magnetic clutch hub and adjust with the gasket.
The number of gaskets adjusted should not exceed
three.
13. Check the compressor oil.
(a) Drain the refrigerant from the maintenance valve
slowly. Drain all the compressor oil from the new
compressor and magnetic clutch before replacing the
old ones .
Standard：
The amount of oil in the new compressor and
magnetic clutch ：80±15cc-
The amount of residual oil in the old compressor and
04-35
04-Air Conditioning System

magnetic clutch equals to that of the oil drained

during replacement .
Note:
●When checking the compressor oil amount, pay
attention to the assembly and disassembly notes of
the cooling system.
●Drain some compressor oil from the new
compressor and magnetic clutch. Otherwise the oil in
them combined with the residual oil on the pipeline
will hamper the heat exchange of refrigerant
circulation, causing refrigerant failure.
● If there is a little residual oil in the old compressor
and magnetic clutch, check for oil leakage.
● Make sure the compressor oil is PAG56.

14. Install the compressor and magnetic clutch.

(a) Install the compressor and magnetic clutch with 4
bolts.
Note：
●Install the compressor and magnetic clutch in
accordance with the order shown in the figure.
Tighten the bolts.
(b) Connect the connector.

15. Install No.1drain hole of refrigerant

(a) Tear off the PVC tape from the nozzle.
(b) Apply sufficient compressor oil to the contact
surface of the new O-ring and the compressor as well
as magnetic clutch.
(c) Install the O-ring on No. 1 refrigerant outlet.
04-36
 04-Air Conditioning System

(d) Connect No. 1 refrigerant outlet to the magnetic

clutch and the compressor with bolts.
Torque：10～12N·m

16. Install No. 1 refrigerant inlet.

(a) Tear off the PVC tape from the nozzle.
(b) Apply sufficient compressor oil to the contact
surface of the new O-ring , and the compressor as
well as the magnetic clutch.
Compressor oil：PAG56
(c) Install an O-ring on No. 1 refrigerant outlet.
(d) Connect No.1 refrigerant inlet to the compressor
and the magnetic clutch with bolts.
Torque：10～12N·m

17． Install the belt.

18． Adjust the belt.
19． Tighten the belt fully.
20．Add refrigerant.
Specified amount：500±15g.
21． Engine warm-up.
22．Check for refrigerant leakage.

04-37
04-Air Conditioning System

Condenser Assembly

Components

04-38
 04-Air Conditioning System

Maintenance
1. Drain refrigerant from the system.
2. Disconnect the refrigerant drain pipe .
（a）Remove the bolts.， Disconnect the drain pipe
of refrigerant from the condenser assembly with a
reservoir.
（b）Remove the O-ring from the drain
Note：
● Seal the openings of all the disconnected parts with
PVC tape to prevent moisture and foreign matters
from entering .

3. Disconnect the air conditioning pipeline

assembly.
(a) Remove the bolts. Disconnect the air conditioning
pipeline assembly from the condenser assembly with
a reservoir.
(b) Remove the O-ring from the refrigerant
Note：
● Seal the openings of all the disconnected parts with
PVC tape to prevent moisture and foreign matter
from entering .

4. Remove the condenser assembly with a

reservoir.
(a) Remove the condenser assembly with a reservoir.

04-39
04-Air Conditioning System

5. Install the condenser assembly with a reservoir.

（a）Install the condenser assembly with a reservoir.

6. Install the air conditioning pipeline assembly.

Torque：4.4～6.4 N.m
（a）Tear off the PVC tape on the pipeline. Connect
all parts of the condenser assembly.
（b）Apply sufficient compressor oil to the interface
of the new O-ring and the pipeline.
Compressor oil：PAG56
(c) Install an O-ring on the air conditioning pipeline.
(d) Connect the air conditioning pipeline assembly
and the condenser assembly with a reservoir by using
a bolt.
Torque：4.4～6.4 N.m

7. Install the drain pipe of refrigerant.

(a) Tear off the PVC tape on the pipeline. Connect all
parts of the condenser assembly.
(b) Apply sufficient compressor oil to the interface
of the new O-ring and the pipeline.
Compressor oil：PAG56.
(c) Install an O-ring on the refrigerant drain pipe.
(d) Connect the refrigerant drain pipe A and the
condenser assembly with a reservoir by using bolts.
Torque：4.4～6.4 N.m
8. Add refrigerant.

Specified amount ：500 15g

9 Engine warm-up.

04-40
 04-Air Conditioning System

10. Check for refrigerant leakage.

04-41
 05-Clutch System

Clutch System
Failure Symptom Table ..........................................................................................................1
Clutch Pedal ...........................................................................................................................3
Clutch Master Cylinder ........................................................................................................10
Clutch Cylinder ....................................................................................................................15
Clutch ...................................................................................................................................21
 05-Clutch System

Clutch System

Failure Symptom Table

The following table will help to find out the causes of failure. Figures in the table indicate the order of

the possibility of failure. Please check each part in sequence, and replace the parts if necessary.
Problems Diagnosis
Clutch jamming /vibration 1. Engine mounting loosened.
2. Excessive clutch disc runout.
3. Oily clutch disc.
4. Clutch disc hardened.
5. Damaged torsional rubber buffer of the clutch disc.
6. Worn clutch disc.
7. The tips of the diaphragm spring are not in the horizontal
plane.
Clutch pedal 1. Air in the clutch oil groove.
2. Damaged master cylinder piston cup.
3. Damaged slave cylinder piston cup.
Clutch noise 1. Worn, contaminated or damaged release bearing hub.
2. Damaged torsional rubber buffer of the clutch disc.
Slipping clutch 1. Clutch pedal for excessive free travel.
2. Clutch disc for oily.
3. Clutch disc for wear.
4. Diaphragm spring for damage.
5. Clutch pressure plate for distortion.
6. Flywheel for distortion.
Uncleanliness of clutch release 1. Clutch pedal for excessive free travel.
2. Air in the clutch oil groove.
3. Damaged master cylinder piston cup.
4. Damaged slave cylinder piston cup.
5. Clutch disc for distortion.
6. Excessive clutch disc runout.
7. Crushed clutch disc linings.
8. Contaminated or burned clutch disc.
9. Oily clutch disc.
10. The splined hub of the clutch disc is in short of lubricating
grease.
11. Damaged diaphragm spring.
12. The tips of the diaphragm spring are not in the horizontal
plane.
13. Clutch disc for distortion.

05-1
 05-Clutch System

Components（Explosive View）

05-2
 05-Clutch System

Clutch Pedal

Components

05-3
 05-Clutch System

Adjustment
1. Check and adjust the clutch pedal.

(a) Open the floor mat.

(b) Check the pedal height.

Pedal height from the linoleum：134.3～144.3mm

(c) Adjust the pedal height.

(1) Slacken the lock nut and turn the stopper bolt

until the pedal height is proper, then tighten the lock

nut.

Torque：16 N·m

(d) Check the pedal free travel and push rod travel.

(1) Depress the pedal until you feel a resistance

from the clutch.

The free travel of clutch pedal ：5～15mm

(2) Depress the pedal gently until the resistance

increases.

Push rod travel of the pedal top：1.0～5.0mm

(e)Adjust the pedal free travel and the push rod

travel.
25mm or more (1) Slacken the lock nut and turn the push rod until
The maximum
travel the pedal free travel and the push rod travel are
Disengaging point
The ultimate
proper.
position
(2) Tighten the lock nut.

(3) Check the pedal height after adjusting the pedal

free travel.

(f)Check the disengaging point of the clutch.

(1) Tighten the brake and install the wheel stop

(2) Start the engine and rotate the idling.

05-4
 05-Clutch System

(3) Don't depress the clutch pedal. Shift the gears

to reverse until the gears are in mesh with each

other.

(4) Depress the clutch pedal slowly and measure

the travel distance between the noise vanishing

point (disengaging point) of the gears and the

maximum travel distance of the ultimate position.

Standard distance：25mm 25mm or more

(from the maximum travel distance of the ultimate

position to the disengaging point )

Note：

●Make the following operations if the distance

does not meet the standard.

Check the pedal height.

●Check the push rod travel and the pedal free

travel.

●Discharge the air in the clutch fuel tube.

●Check the clutch cover and the clutch disc.

●Check the pedal travel.

●The pedal travel:120～130mm.

05-5
 05-Clutch System

Replacement

1. Remove the brake pedal assembly first.

2.Remove the fixing bolt from the clutch pedal.

3. Remove the fixing bolt from the push rod of

the clutch master cylinder.

(a)Remove the clip and the mounting bolt.

4. Remove the adjusting screws.

5. Remove the clutch pedal assembly, the

tensional spring 、bush and spacer.

6. Remove the clutch pedal bracket.

(a)Remove the two nuts 、bolts and take dow n the

clutch pedal bracket.

05-6
 05-Clutch System

7. Remove the clutch pedal.

(a)Remove the bolts and nuts.

(b)Remove the clutch pedal from the clutch pedal

bracket.

8 Remove the clutch pedal spacer.

9 Remove the clutch pedal spacer No.1

（a）Remove the clutch pedal spacer No.1.

10. Remove the clutch pedal bush.

(a) Remove the two bushes from the clutch pedal.

11. Remove the clevis bush from the push rod of

Damage、wear
damage the clutch master cylinder.
damage
Remove the clevis bush from the clutch pedal with

8mm hex wrench and hammer.

damage
Note：
Damage、
deformation Check the following components：

● The bush for wear or damage.

● The spacer for wear or damage.

● The pedal arm for damage or distortion.

05-7
 05-Clutch System

● The torsional spring for ineffectiveness.

● The pedal pad for wear or damage.

12. Install the clutch pedal.

Tips：

■Apply grease to the following parts:

（a）Inside of bush and spacer.

（b）Connecting section of clutch pedal and release

cable.

13. Install the spring, bush, and spacer to the

clutch pedal assembly. Then, install the assembly

to the pedal bracket.

14．Install the clevis bush of the clutch cylinder

push rod.

(a)Apply the multi-purpose grease to the new clevis

bush.

(b)Install the clevis bush to the clutch pedal.

Tips：

■ Install the clevis bush from the right of the

automobile.

15．Install the clutch pedal bush.

(a) Apply the grease to each side of the two new

bushes.

(b) Install the two bushes to the clutch pedal.

05-8
 05-Clutch System

16. Install the clutch pedal spacer.

(a) Install the spacer to the clutch pedal

17. Install the clutch pedal.

(a) Install the clutch pedal to the clutch pedal

bracket with bolts and nuts.

Tips：

■Install bolts from the left of the automobile.

18．Install the clutch pedal bracket.

(a) Install the clutch bracket with two nuts and bolts.

19．Install the fixing clevis of the clutch cylinder

push rod .

(a) Apply grease to the contacting surface of bolt

bush.

(b) Screw up the clutch pedal with bolts

Note：

■ Install the fixing pin from the right of the

automobile.

(c) Install a clip on the fixing pin.

20. Install the clutch pedal spring.

21. Install both ends of the clutch cable and

tighten the cable bracket on the body with bolts.

05-9
 05-Clutch System

Clutch Master Cylinder

COMPONENTS（EXPLOSIVE VIEW）

05-10
 05-Clutch System

Repairment
1. Release the clutch fluid.

2. Remove the clutch reservoir tube.

(a) Loosen the clip and remove the clutch reservoir

tube from the master cylinder. Fix the clip with a

plier, slide toward the reservoir chamber ， and

remove the reservoir hose. Contain the brake fluid.

Tips：

Prepare a container for clutch fluid.

Note：

●The residue sprinkled on the surface of the paint

should be cleaned immediately.

3. Remove the clutch master cylinder.

Special Unscrew the two connecting nuts to remove the

clutch master cylinder from the vehicle body.

4. Separate the hose from the clutch master

cylinder.

(a) Remove the hose with SST.

Tips：

■Receive the clutch fluid with a container.

5．Remove the clutch pedal spring.

05-11
 05-Clutch System

Disassembly
1. Remove the inlet union.

(a) Punch out the slotted spring pin with a pointed

punch and a hammer.

(b) Remove the inlet union and grommet.

2. Remove the push rod.

(a) Open the spring ring with a spring ring plier

when pulling the push rod.

(b) Remove the push rod and the washer

3．Remove the clutch master cylinder.

(a) Unscrew the two nuts and the clutch master

cylinder.

(b) Remove the lock nut from the push rod.

(c)Remove the boot from the master cylinder.

(d)Remove the spring ring with spring ring plier

when pressing the push rod.

(e) Remove the push rod from the master cylinder.

Note：

●Remove the push rod from the cylinder body

slowly to avoid the ejection of the piston from the

cylinder body.

(h)Remove the stop plate from the push rod.

(i)Remove the spring-loaded piston from the

cylinder.

Note：

● Attention! Beware not to damage the inner

surface of the cylinder body.

05-12
 05-Clutch System

Installation
1. Install the components of clutch master

cylinder.

(a) Apply lithium–based grease to the components

as shown in the figure.

bulge (b) Install the spring-loaded piston into the master

cylinder.

Note：

■Attention! Beware not to spoil the inner surface

of the cylinder body.

(c) Install the push rod into the cylinder body.

(d) Install the stop plate on the push rod.

(e) Install the spring ring with a spring ring plier

while pressing the push rod.

(f) Install the stop nut on the cylinder body.

(g) Install the lock nut on the push rod.

(h) Install the clevis with a lock nut on the push rod

temporarily.

(i) Install the inlet union and a new grommet.

(j) Install the slotted spring pin with punch and

hammer.
Multi-purpose grease

2. Install the clutch master cylinder.

3．Install the clevis in the clutch master cylinder

push rod.

(a) Apply the multi-purpose grease to the

connecting section of pin hole and the clevis bush.

(b) Connect the clevis to the clutch pedal with a pin

05-13
 05-Clutch System

hole.

Note：

■ Install the pin hole from the right of the

automobile.

(c)Insert a clip into the pin hole,

4．Install the clutch pedal spring.

5．Connect the clutch master cylinder and the

hose.

(a) Connect the hose with the SST FT9013101.

Torque：12.7～17.6 N·m

6．Connect the clutch reservoir tube.

(a)Connect the clutch reservoir tube and clutch

master cylinder with the clip.

Note：

■Make sure not to distort the tube when connecting

the clutch reservoir tube.

White mark

7． Install the brake assembly.

8． Install the brake master cylinder.

9． Release air in the braking line.

10．Release air in the clutch line.

(a) Fill the brake reservoir with clutch fluid and

release the air in the clutch system.

11．Check and adjust the brake pedal height.

12．Check and adjust the clutch pedal height.

13．Check the leakage of brake fluid.

05-14
 05-Clutch System

14．Check the leakage of clutch fluid.

15．Check the fluid level of the reservoir.

05-15
 05-Clutch System

Clutch Slave Cylinder

COMPONENTS（EXPLOSIVE VIEW）

05-16
 05-Clutch System

Repairmen t
1.Release the brake fluid.

Note：

●The residue sprinkled on the surface of the paint

Special tool
should be flushed immediately.

2. Remove the clutch oil line from the release

cylinder.

Remove the clutch oil line with special tools.

Contain the brake fluid.

3. Separate the hose from the clutch slave

cylinder.

(a)Remove the fuel tube with SST.

Tips：

■Contain the clutch fluid.

4. Remove the clutch slave cylinder assembly.

(a) Remove the two bolts and take down the clutch

slave cylinder.

5. Remove the clutch release coupling.

(a) Remove the joint bolt.。

(b) Remove the clutch release coupling and two

clips

6. Remove the clutch slave cylinder components.

(a) Remove the boot from the cylinder body.

(b) Remove the push rod from the cylinder body.

(c) Remove the piston from the cylinder body.

05-17
 05-Clutch System

Note：

■ Attention! Beware not to damage the inner

surface of the cylinder body.

(d) Remove the spring from the cylinder body.

(e) Remove the plug cap from the bleeder plug.

7. Remove the bleeder plug from the slave

cylinder.

8.Install the bleeder plug of the slave cylinder.

9. Install the clutch slave cylinder assembly.

(a) Install the plug cap on the bleeder plug.

(b) Install a new spring in the cylinder.

(c) Apply lithium–based grease to the components

as shown in the figure.

(d) Install the piston in the cylinder.

Note：

■ Beware not to spoil the inner surface of the

cylinder body.

(e) Install the push rod on the cylinder body.

(f) Install the dust cover to the cylinder body and

assemble the dust cover with a push rod to the slave

cylinder.

10. Install the clutch slave cylinder coupling.

(a)Install release clip and washer with jointing

bolts as shown in the figure.

Note：

05-18
 05-Clutch System

■ The include angle between the joint and the

cylinder body ranges from -3℃ to +3℃

11. Install the clutch slave cylinder.

(a)Install the clutch slave cylinder with two bolts.

12. Connect the clutch slave cylinder with hose.

(a)Connect the fuel tube with SST FT9066401.

Torque：12.7～17.6N·m

13. Release the air in the clutch fuel tube.

（a）Fill the brake reservoir with fluid and release

the air in the clutch system.

14. Connect the oil line to the clutch slave

cylinder.

Install the clutch oil line with special tools.

05-19
 05-Clutch System

Specified torque：12.7～17.6 N·m

15. Release the air in the clutch system.

16. Fill the reservoir with brake fluid to the limit.

17. Install the cap on the reservoir.

18. Check the leaking of the clutch fluid

05-20
 05-Clutch System

Clutch

Components（Explosive View）

05-21
 05-Clutch System

Inspection

Removal

1. Remove the filler cap from the reservoir.

2. Drain the brake fluid.

Special tool Note：

●The residue sprinkled on the surface of the paint

should be flushed immediately.

3. Remove the reservoir hose from the master

cylinder.

Slide the clip toward the reservoir chamber with a

plier，and remove the reservoir hose. Contain the

brake fluid.

4. Remove the clutch fuel tube from the clutch

master cylinder.
Specia
Remove the clutch fuel tube with SST FT9066401

and contain the brake fluid.

5. Remove the return spring, clip and plain pin.

(a) Remove the return spring with a nipper plier.

(b) Remove the clip with a nipper plier.

(c) Remove the plain pin.

6. Remove the clutch master cylinder.

Unscrew the two connecting nuts and remove the

clutch master cylinder from the vehicle body.

05-22
 05-Clutch System

Removal
1. Remove the inlet union.

(a) Punch out the slotted spring pin with a pointed

punch and a hammer.

(b) Remove the inlet union and grommet.

2. Remove the clevis and the dust cover.

(a) Slacken the lock nut and remove the clevis and

the lock nut.

(b) Remove the dust cover.

3. Remove the push rod.

(a) Open the spring ring with a spring ring plier

when pulling the push rod.

(b) Remove the push rod and the washer.

4. Remove the spring-loaded piston.

05-23
 05-Clutch System

Reassembly
1. Apply the lithium-based grease to the

components as shown in the figure.

2. Insert the spring-loaded piston into the master

cylinder.

3. Install the push rod and dust cover.

(a) Install the washer on the push rod.

(b) Push the push rod into the piston and install the

spring ring with a spring ring plier.

(c) Install the dust cover.

b 4. Install the lock nut and the clevis temporarily.

5. Install the inlet union.

(a) Install the inlet union and a new grommet.

(b) Install the slotted spring pin with a punch and

hammer.

05-24
 05-Clutch System

Installation
1. Install the master cylinder.

Install the master cylinder to the vehicle body with

two nuts.

Special 2. Install the plain pin, clip and return spring.

(a) Install the plain pin.

(b) Install the clip with a nipper plier.

(c) Install the return spring with a nipper plier.

3. Connect the clutch fuel tube and the master

cylinder.

Connect the clutch fuel tube with special tools.

Specified torque ：12.7～17.6N·m

4. Connect the reservoir hose and the master

cylinder.

Connect the reservoir hose and the reservoir, and

then install the clip with a plier.

5. Fill the reservoir with brake fluid, and then

release the air in the clutch system.

6. Check the leaking of the system

7. Adjust the clutch pedal

8. Fill the reservoir with brake fluid to the

maximum.

9. Install the filler cap on the reservoir.

05-25
 05-Clutch System

Maintenance
MT gearbox

1. Remove the clutch(MT) release yoke.

AMT gearbox

1. Remove the transmission (AMT) assembly

from the automobile.

2. Slacken the lock plate and remove the screws

and lock plate.

3. Pull out the clutch release lever and take down

the bush、 release yoke spring and the clip.

4. Remove the boot from the clutch release yoke.

5. Remove the release bearing hub clip.

6. Remove the clutch release bearing hub.

(a) Remove the clutch release lever yoke.

Mark
7. Remove the clutch release lever yoke.

8. Remove the clutch cover

(a) Align the marks on the flywheel and the clutch

cover.

(b) Slacken each bolt a circle a time until the spring

tension is released completely.

Mark

05-26
 05-Clutch System

(c) Remove the mounting bolt and the clutch cover.

Note：

●Hold the clutch plate assembly carefully.

9.Remove the clutch plate.

10. Check the clutch plate assembly.

(a) Measure the depth of the rivet with a vermier

caliper.

Minimum depth of rivet：1.6mm

Replace the clutch plate if necessary.

(b) Install the clutch plate on the drive axle

assembly.

Note:

● Right installation direction.

(c)Check the swing of the clutch disc assembly

with a dial indicator.

The maximum swing：0.8mm

Replace the clutch plate if necessary.

11. Check the clutch cover.

(a) Check the wearing depth and width of the

diaphragm spring with a slide caliper.：

05-27
 05-Clutch System

A(depth)：0.5mm

B(width)：6.0mm

Replace the clutch cover if necessary.

12. Check the flywheel.

(a) Check the swing of the flywheel with a dial

indicator.

The maximum swing：0.3mm

Replace the flywheel if necessary.

13. Check the release bearing hub .

Rotate the release bearing by your hand, while

applying an axial compression to the bearing. Check

the bearing rotates abnormally or in a manner of

stagnation.

Note：

■The bearing is in a state of stable lubrication.

Need no cleaning or lubricating.

Replace the release bearing hub if necessary.

14. Check the clutch plate.

(a) Insert the SST FT9066401 into the clutch plate.

Then, insert them into the flywheel.

Note：

●Right direction of the clutch plate.

05-28
 05-Clutch System

15. Check the release bearing hub,

clip-contacting surface and hub-to-housing

sliding section for damage and wear

Note：

■Replace them if necessary.。

16. Check if the clip has the configuration as

shown in the figure in its horizontal plane.

Note：

■Replace them if necessary.

17. Install the clutch cover.

(a) Match the marks on the flywheel and the clutch

cover.

(b) Tighten the bolts evenly, starting with those

bolts provided near the locating pin.

Note：

■Tighten bolts evenly each time, following the

steps shown in the picture. Shake the SST slightly

from up to bottom, from left to right and make sure

the matches of clutch plates, and then tighten the

bolts

05-29
 05-Clutch System

18. Check and adjust the clutch cover.

(a) Check the smoothness of the diaphragm spring

tips with a roller dial indicator.

(b) Adjust with SST if the smoothness doesn’t meet

the standard.

19. Install the release lever yoke.

The position
of applying Install the release lever yoke to the drive axle
grease
assembly.

20．Install the clutch release lever yoke.

Apply grease to the yoke-to-hub section,

yoke-to-rod section and lever yoke.

Note：

■Apply lithium-based grease to the fork-to-hub

sliding section and bearing-to-housing case sliding

section.。

21. Assemble the clutch release bearing hub and

Rotate
release bearing clip to the clutch release fork.

（a）Install the clutch release bearing hub.

（b）Assemble the release fork by turning it 180

degrees.

Note：

●After installation, move the release yoke forward

and backward to check the smoothness of the

release bearing hub.

05-30
 05-Clutch System

22. Install the clutch release yoke boot.

23. Install the release bearing hub clip.

24. Assemble the bolt with washer, with the lock

plate interposed.

25. Check the release bearing hub and fork for

proper operation.。

Operate the clutch release lever about 50 times.

Check the section A of the clutch release clip. If the

clip exhibits excessive spread and there is a

likelihood that the clip may be detached, replace it

with a new clip.。

26. Install the transmission assembly to the

automobil

05-31
 06-Front Axle & Rear Axle

Front Axle & Rear Axle

Front axle&Rear axle……………………………………….. 1

Front drive shaft……………………………………………. 4
Front axle hub sub-assembly………………………………. 11
Rear axle hub sub-assembly………………………………. 16
 06-Front Axle & Rear Axle

Front Axle & Rear Axle

Malfunction Table

The following table will contribute to troubleshooting. The numbers show the priority of the reasons

for the failures. If necessary, replace these parts.

Problems Possible Malfunction Areas

1. Wheel

2. Front wheel alignment

3. Rear wheel alignment

4. Front hub bearing(wear)

Run out
5. Rear hub bearing(wear)

6. Front shock absorber coil spring

7. Steering joint(looseness or wear)

8. Stabilizer bar

1. Wheel balance

Front wheel vibration 2. Hub bearing(wear)

3. Shock absorber coil spring

1. Outboard joint
Noise（drive shaft）
2. Inboard joint

06-1
06-Front Axle & Rear Axle

Vehicle Inspection
1. Inspect the front axle hub bearing
（a）Jack up vehicle w ith a jack,supportitstably and

remove the front wheel.

2. Inspect the front axle hub bearing

(a)Remove the front wheel
(b) Remove the front brake caliper assembly
(c) Remove the front brake disc
(d) Inspect the bearing clearance
(1)Get close to the center of the front axle hub,
check the clearance with the dial indicator
maximum：0.05mm
If the clearance exceeds the maximum, replace the
front axle hub bearing

(e) Inspect the front axle hub run out

(1)Check the run out of the hub surface from the
outboard of the hub bolt with a dial indicator
maximum：0.07mm
If the clearance exceeds the maximum, replace the
front axle hub sub-assembly
(f) Install the front brake disc
(g) Install the front brake caliper assembly
(h) Install the front wheel
torque：113N•m

3. Inspect the rear axle hub bearing

(a) Remove the rear wheel
(b) Remove the rear brake caliper assembly
(c) Remove the rear brake disc
(1)Get close to the center of the rear axle hub,

06-2
 06-Front Axle & Rear Axle

check the clearance with the dial indicator，

maximum：0.05mm
If the clearance exceeds the maximum, replace the
rear axle hub bearing

(d) Inspect the rear axle run out

（1）Check the run out of the hub surface from the
outboard of the hub bolt with a dial indicator
maximum：0.07mm
If the clearance exceeds the maximum, replace the
rear axle hub sub-assembly
(e) Install the rear brake disc

(f) Install the rear wheel

torque：113N•m

06-3
06-Front Axle & Rear Axle

Front Drive Shaft

Components

06-4
06-Front Axle & Rear Axle

06-5
06-Front Axle & Rear Axle

CAUTION：
●Do not use a punch to make marks

1. Remove the tripod universal joint assembly

from the outboard joint bearing assembly with
copper bar and hammer

CAUTION：
●Do not hit the roller

2. Remove the left inboard joint dust cover

clamp No.2, inboard boot and left inboard joint
dust cover clamp

3. Remove the drive shaft absorber clamp

TIP：
■Operate according to the following step only when
disassembling the drive shaft on the right side
Loosen the absorber clamp with a screwdriver
4. Remove the right front drive shaft absorber
TIPS：
■Operate according to the following step only when
disassembling the right drive shaft

5. Remove the right drive shaft absorber

6. Remove the left front axle outboard joint dust

cover clamp No.2
(a) Loosen the left outboard joint dust cover clamp
No.2 with a screwdriver

06-6
 06-Front Axle & Rear Axle

7. Remove the left front axle outboard joint dust

cover clamp
(a) Loosen the left front outboard joint dust cover
clamp with a screwdriver

8. Remove the front axle outboard joint dust

cover clamp
(a) Remove the outboard joint dust cover from the
outboard joint shaft assembly
(b) Wipe off the lubricant from the outboard joint
assembly

CAUTIONS：

●Be careful not to damage the outboard ball joint

dust cover
●Be careful not to damage the speed sensor rotor

9. Install the left steering tie rod ends

sub-assembly
(a) Install steering tie rod ends sub-assembly on the
steering knuckle with nuts
torque：36N•m
(b) Install a new cotter pin
CAUTION：
●If the pin hole is not aligned, tighten the nut
another 60 degrees
10. Install the lower of left front suspension arm
sub-assembly No.1
(a) Install the lower part of left front suspension arm
sub-assembly No.1 on the steering knuckle with
nuts
(b) Install a new cotter pin

CAUTION：
●If the pin hole is not aligned, tighten the nut
another 60 degrees

06-7
06-Front Axle & Rear Axle

11. Install the front stabilizer bar

(a) As shown in the figure, install the front stabilizer
bar with two cushion retainer No.1 two cushions and
nuts

CAUTION：
●Ensure that the cushions and cushion retainers are
at the correct position

(b) Screw the nuts with a 10mm wrench

torque：20N•m
12. Install the left front speed sensor
(a) Install the brake hose and the left front speed
sensor on the front shock absorber with nuts and
clamps
(b) Install the speed sensor on the steering knuckle

with bolt.

CAUTIONS：
●Be careful not to damage the speed sensor
●Maintain the speed sensor clean
●When installing the sensor, do not twist the sensor
wiring

13. Install the left front axle hub nut

(a) Close the cotter pin with a prier, fixe the front
axle hub nuts

14. Install the lower part of the engine cover

15. Install the front wheel

06-8
 06-Front Axle & Rear Axle

16.Refuel to the manual transmission axle（M/T

transmission axle）
17.Check and adjust the manual transmission
axle fluid（M/T transmission axle）
18. Check and adjust the front wheel alignment
19. Check the ABS speed sensor signal
20. Install the front brake disc
21. Install the left front brake disc caliper
assembly
22. Install the front wheel
torque：113N•m
CAUTION：
●When connecting, do not twist the sensor wire

23. Check the bearing clearance

24. Check the axle hub run out
25. Install the rear wheel brake drum
sub-assembly
26. Install the rear wheel
torque：113N•m
27. Check the ABC speed sensor signal

06-9
06-Front Axle & Rear Axle

Replacement
TIPS：
1. Remove the rear wheel

2. Remove the rear wheel brake drum

sub-assembly
3. Remove the left rear axle hub bolts
(a) Remove the left hub bolts with SST，screwdriver
or similar tool

4. Install the left rear axle hub bolts

(a) As shown in the figure, install the washers and
nuts on the new left hub bolts
(b) Clamp the hub and bearing assembly with SST，
screwdriver or similar tool, tighten the nuts to install
the left hub bolts

5. Install the rear brake drum sub-assembly

6. Install the rear wheel
torque：113N•m

06-10
 06-Front Axle & Rear Axle

Front hub sub-assembly

Components

06-11
06-Front Axle & Rear Axle

Replacement
1. Remove the front wheel
2. Remove the left front axle hub nut
3. Remove the left front speed sensor
4. Remove the left front brake disc caliper
assembly
(a) Remove the two bolts, then remove the left front
brake disc caliper assembly from the steering
knuckle

5. Remove the front brake disc

6. Remove the front stabilizer bar
7. Remove the lower part of left No.1 front
suspension arm sub-assembly
8. Remove the left tie rod ends sub-assembly
9. Remove the left front axle assembly
10. Remove the left front shock absorber
assembly
(a) Remove the two bolts and two nuts ， then
remove the left front shock absorber assembly from
the left front axle assembly

11Remove the left front axle hub snap ring

(a) Remove the left snap ring from the front axle hub
with snap ring prier

12. Remove the left front axle hub sub-assembly

(a) Remove the left front axle hub sub-assembly
with SST

06-12
 06-Front Axle & Rear Axle

(b) Remove the left bearing inner race from the left
hub sub-assembly hub with SST

13. Remove the dust cover of the front left brake

disc
(a) Remove the three bolts and the left front dust
cover

14. Remove the left front axle hub bearing

(a) Put the left bearing inner race into left bearing
outer race
(b) Remove the left hub bearing from the steering
knuckle with press and SST

15. Install the left front axle hub bearing

(a) Install the new left hub bearing on the steering
knuckle with press and SST

16. Install the left front brake disc dust cover

(a) Install the left front dust cover three bolts

17. Install the left front axle hub sub-assembly

(a) Install the left hub sub-assembly with SST and
press

06-13
06-Front Axle & Rear Axle

18. Install the left front axle hub snap ring

(a) Install the new left snap ring with a snap ring
plier

19. Install the left front shock absorber assembly

(a) Install the left front shock absorber assembly on
the left front axle assembly with 2 bolts and 2 nuts
torque：145N•m
CAUTION：
●Pack the nut thread part with engine oil only when
use the bolts and nuts again

20. Install left front axle assembly

21. Install the left tie rod ends sub-assembly
22. Install the lower part of No.1 left front
suspension arm sub-assembly
23. Install the front stabilizer bar
24. Install the front brake disc
25.Install the left front brake disc caliper
assembly
(a) Install the front brake disc caliper assembly on
the steering knuckle with two bolts

26. Install the left front axle hub nut

(a) Install the new left hub nut
Torque：170～230N•m
27. Remove the left front brake disc caliper
assembly
28. Remove the front brake disc
29. Check the bearing clearance
30. Check the axle hub run out
31. Install the front brake disc
32. Install the left front brake disc caliper
assembly
33. Install the left front speed sensor

06-14
 06-Front Axle & Rear Axle

34. Install the left front axle hub nut

(a) Close the cotter pin with a prier, ，fix front axle
hub nut

35. Install the front wheel

Torque :113N•m
36. Check and adjust the front wheel alignment
37. Check the ABS speed sensor signal

Replacement
1. Remove the front wheel
2. Remove the left front brake disc caliper
assembly
3. Remove the front brake disc
4. Remove the left front axle hub bolts
(a) Remove the left hub bolts with SST ，
screwdriver or similar tool

5. Install the left front axle hub bolts

(a) As shown in the figure, install the washer and
nuts on the new left hub bolts
(b) Clamp the left hub sub-assembly with a
screwdriver or similar tool,, tighten the nuts to
install the left hub bolts

6. Install the front brake disc

7. Install the left front brake disc caliper
assembly
8. Install the front wheel
torque：113N•m

06-15
06-Front Axle & Rear Axle

Rear hub sub-assembly

Components

06-16
 06-Front Axle & Rear Axle

Replacement
1. Remove the rear wheels

2. Remove the rear wheels

3. Remove the slip control sensor wire

4. Remove the left rear axle hub and bearing

assembly
5. Install the left rear axle hub and bearing
assembly
6. Connect the slipping control sensor wire
CAUTION：
●When connecting, do not twist the sensor wire

7. Check the bearing clearance

8. Check the axle hub run out
9.Install the rear wheel brake drum
sub-assembly
10 Install the rear wheel
torque：113N•m
Check the ABC speed sensor signal

06-17
06-Front Axle & Rear Axle

Replacement
TIPS：
1. Remove the rear wheel

2. Remove the rear wheel brake drum

sub-assembly
3. Remove the left rear axle hub bolts
(a) Remove the left hub bolts with SST，screwdriver
or similar tool

4. Install the left rear axle hub bolts

(a) As shown in the figure, install the washers and
nuts on the new left hub bolts
(b) Clamp the hub and bearing assembly with SST，
screwdriver or similar tool, tighten the nuts to install
the left hub bolts

5. Install the rear brake drum sub-assembly

6. Install the rear wheel
torque：113N•m

06-18
 07-Brake System

Brake System

Cautions .................................................................................................................................1

Malfunction Table ..................................................................................................................2

Brake Pedal ............................................................................................................................8

Vacuum Booster and Brake Master Cylinder ......................................................................13

Front Disc brake ..................................................................................................................23

Rear drum brake ..................................................................................................................30

Parking Brake ......................................................................................................................36

Wheel speed sensor..............................................................................................................47

 07-Brake System

Brake System

Cautions

1. Be sure to replace each part correctly, otherwise the brake performance will be impaired, easily
causing accidents. Parts should be replaced with the ones of the same part number.
2. It is very important to ensure that the parts and the working area are clean when repairing the brake
system.

7-1
07-Brake System

Malfunction Table
Problems Diagnosis
1 A lack of brake fluid in the brake system .
2 Air in the brake system.
The (brake) pedal is too low or too soft. 3 Piston cup wear or damage.
4 Brake master cylinder failure.
5 Improper adjustment of the booster pushrod.
1 Small pedal free travel.
2 Improper adjustment of the parking brake lever
stroke.
3 Parking brake cable clamping stagnation.
4 Broken or twisted brake pads or linings .
5 Piston clamping stagnation.
Brake drag
6 Rear brake pads adjustment mechanism
clamping stagnation.
7 Return spring failure.
8 Improper adjustment of the booster pushrod.
9 Vacuum leakage of the boost system.
10Master cylinder failure.
1 Piston catching.
2 Fluid on the brake pads or linings.
Brake deviation 3 Front wheel cylinder boot clamping stagnation.
4 Scratches on the brake disc .
5 Broken or twisted brake pads or linings .
1 A lack of brake fluid in the brake system.
The brake pedal is low or it springs against the 2 Air in the brake system.
foot. 3 Brake pads or linings wear.
4 Broken or twisted brake pads or linings.
5 Fluid on the brake pads or linings.

07-2
 07-Brake System

6 Hard points on the brake pads or linings.

7 Scratches on the brake disc.
8 Improper adjustment of the booster pushrod.
9 Vacuum leakage of the boost system.
1 Broken or twisted brake pads or linings.
2 The mounting bolts are loose.
3 Scratches on the brake disc.
4 The brake pad support plate is loose.
5 Slide pin wear.
Abnormal sound of the brake.
6 Dirty brake pads or linings.
7 Hard points on the brake pads or linings.
8 Return spring failure.
9 Damping pads damage.
10 Shoe positioning spring damage.

07-3
07-Brake System

Brake Fluid Replacement

Air bleeding

TIP：
Bleed the air in the brake system before repairing it
or if there is air in it.

NOTE：
●Do not mix the original brake fluid in the vehicle
with fluid of different vehicle model.

1. Fill the reservoir with brake fluid between the

max and min marks..

2. Bleed the air in the master cylinder.

TIP：
■ Air should be bled from the master cylinder if the
master cylinder is to be replaced or the reservoir is
empty.
(a) Detach the tube connector from the master
cylinder.

(b) Slowly depress the brake pedal and hold it in a

depressed state..

(c) Block the brake tube mouth with a finger from

outside the master cylinder to prevent air from
entering. Then release the brake pedal.
(d) Repeat steps b and c three or four times.

07-4
 07-Brake System

3. Brake tubes air bleeding

(a) Connect the hose to the brake fluid outlet.
(b) Perform the operation with two persons. One
person should depress the brake pedal slowly and
hold it in a depressed state.
(c) The other person should slacken the bleeder plug
1 / 3 through 1 / 2 turn at a time. Tighten the
bleeder plug and release the brake pedal when the
brake fluid ceases to flow out.
(d) Repeat (b) and (c) steps above, until all the air is
bled from the brake fluid.
(e) Repeat the steps above. Bleed the air from all the
wheel slave cylinders.

4. Check the fluid level in the brake fluid

reservoir.
Check the liquid level. Ensure that each section of
the tube exhibits no leakage. Add brake fluid if
necessary.
Brake fluid ：DOT4

07-5
07-Brake System

ABS Air Bleeding and Fluid Charging

1. Connect the diagnostic instrument and enter the ABS anti -lock brake system.

2. Enter the manual air bleeding function program.

（a）B e sure to press the brake pedal repeatedly in the w hole process to fully bleed the air.
（b）B leed air in the follow ing order: left rear w heel→left front w heel→right front w heel→right
rear wheel.
（c）A llow the m agnetic valve to coolfor five m inutes before repeating a certain stage or the whole
air bleeding process. Otherwise, the magnetic valve may be damaged by overheating..
（d）C lick on O K and start the air bleeding function perform ance.
（1） ① D etach the left rear wheel air bleeding bolt and attach all the others Click on OK and start
air bleeding operation on the left rear wheel. Be sure to press the brake pedal repeatedly.
② Press the brake pedalrepeatedly for atleast25 seconds w hile the E C U is processing.
③ Press the brake pedal repeatedly w hile perform ing left rear w heel air bleeding. W hen
there are no bubbles in the brake fluid flowing out, press the brake pedal to the floor and hold it in a
depressed position. Then click on OK.
④ A ttach the left rear wheel air bleeding bolt before releasing the brake pedal. Repeat the air
bleeding process if necessary until the air is fully bled.
（2） ① D etach the leftfrontw heelair bleeding boltand attach allthe others.C lick on O K and start
air bleeding operation on the left front wheel. Be sure to press the brake pedal repeatedly.
② Press the brake pedalrepeatedly for atleast 25 seconds w hile the E C U is processing.
③ Press the brake pedal repeatedly w hile perform ing left front w heel air bleeding. W hen
there are no bubbles in the brake fluid flowing out, press the brake pedal to the floor and hold it in a
depressed position. Then click on OK.
④ A ttach the left front w heel air bleeding bolt before releasing the brake pedal.R epeat the
air bleeding process if necessary until the air is fully bled.
（3） ① D etach the right front w he el air bleeding bol t and attach all the othe rs. C lick on O K and
start air bleeding operation on the right front wheel. Be sure to press the brake pedal repeatedly.

07-6
 07-Brake System

② Press the brake pedal repeatedly for at least 99 seconds while the ECU is processing.
③ Press the brake pedal repeatedly w hile perform ing right front w heel air bleeding. W hen
there are no bubbles in the brake fluid flowing out, press the brake pedal to the floor and hold it in a
depressed position. Then click on OK.
④ A ttach the rightfrontw heelair bleeding boltbefore releasing the brake pedal.R epeatthe
air bleeding process if necessary until the air is fully bled.
（4） ① D etach the right rear w heel air bleeding bolt and attach all the others. Click on OK and
start air bleeding operation on the right rear wheel. Be sure to press the brake pedal repeatedly.
② Press the brake pedalrepeatedly for atleast 79 seconds w hile the E C U is processing.
③ Press the brake pedal repeatedly while performing right rear wheel air bleeding. When
there are no bubbles in the brake fluid flowing out, press the brake pedal to the floor and hold it in a
depressed position. Then click on OK.
④ A ttach the rightfrontw heelair bleeding bolt before releasing the brake pedal. Repeat the
air bleeding process if necessary until the air is fully bled

07-7
07-Brake System

Brake Pedal

Components

07-8
 07-Brake System

Adjustment

Brake pedal inspection and adjustment

1. Check the brake pedal height
Distance between the brake pedal and the floor：
134±5mm
If the pedal height does not conform to the
specification above, adjust it.

2. Adjust the pedal height if necessary

(a) Remove the brake light switch plug.
(b) Slacken the brake light switch locknut. Remove
the brake light switch.
(c) Slacken the the U-shaped connector locknut.
(d) Turn the pedal pushrod. Adjust the brake pedal
height.
(e) Tighten the pushrod locknut.
(f) Install the brake light switch.
(g) Connect the brake light switch plug.
(h) Depress the pedal 5～15mm.Turn the brake light
switch. Screw up the locknut where the brake light
went out.
(i) Depress the pedal 5~15mm.Check whether the
brake light works.
(j) Adjust the pedal height. Check the pedal free
travel.
3. Check the pedal free travel
(a) After stopping the engine, depress the brake
pedal repeatedly until no vacuum remains in the
booster .
(b) Depress the pedal until resistance is felt. Then,
measure the clearance as shown in the picture.
Pedal free travel：1～6mm
If the free travel is not right, check the brake light
switch clearance；
If the clearance is normal, diagnose the brake
system.
Brake light switch clearance 0～2.4 mm
Brake light switch assembly locking nut torque：
14～20Nm

07-9
07-Brake System

4. Check the pedal braking distance.

Release the parking brake lever.
When the engine is running, depress the pedal and
measure the reserve stroke as shown in the picture.
When the pedal is depressed with a force of 500N,
the distance from the front surface to the pedal
should be more than 65mm. If the distance does not
conform to this specification, diagnose the brake
system.

07-10
 07-Brake System

Replacement

Step one Removal

TIP：
■After the assembly, check and adjust the brake
pedal height, free travel and braking distance.
1. Remove the combination meter components.
Remove the brake light switch wire plug.

2. Remove the clip and with-hole pin from the

connecting section of the brake pedal with the
brake master cylinder push rod.

3. Detach the U-shaped connector of the brake

master cylinder push rod.
(a）Remove the clip and pushrod pin. Detach the
master cylinder pushrod from the brake pedal.

4 Remove the brake pedal bracket.

(a)Remove the bolts from the brake pedal bracket.
(b)Detach the brake light connector.

(c)Remove the four nuts and the brake pedal

bracket.

5. Remove the brake pedal sub-assembly.

(a)Remove the bolts and nuts from the brake pedal
bracket.
(b)Remove the return spring, two bushes, spacer,
brake pedal pad and cushion from the brake pedal.

6. Remove the brake light switch components.

(a)Slacken the brake light switch locking nut.
(b)Remove the brake light switch from the brake
pedal.

07-11
07-Brake System

7. Remove the brake pedal pad.

Remove the brake pedal pad from the brake pedal.

Step 2 Installation

1. Install the brake pedal pad.

Install the brake pedal pad on the brake pedal.

2. Install the brake light switch components.

Mount the brake light switch to the brake pedal.

3. Install the brake pedal

(a)Apply lithium soap hexanediol glycol grease to
the end face and the side of two new bushes .
(b)Install the brake pedal and the two bushes on the
brake pedal bracket with bolts and nuts.

4. Install the brake pedal bracket.

(a)Install the brake pedal bracket with four nuts.
(b)Connect the brake light switch connector.

5. Install the U-shaped connector of the brake

master cylinder push rod.
(a)Apply lithium soap base hexanediol glycol grease
to the push rod plug..
(b)Connect the master cylinder push rod with push
rod pins and clips.

6. Install the combination meter components.

7. Check and adjust the brake pedal height.
8. Check the brake pedal free travel.
9. Check the brake pedal braking distance.
07-12
 07-Brake System

Vacuum Booster and Brake Master Cylinder

Vehicle Inspection

1. Check the vacuum booster

(a) Air tightness inspection.
(1)Start the engine. After running the engine for one
to two minutes, stop the engine. Depress the pedal
slowly several times. The position of the brake pedal
should rise progressively at successive two
applications. Intervals between successive two
applications should be at least five seconds.
TIP：
■ If the pedal drops significantly at the first
application and the position rises gradually, the air
tightness is good.

(2)Depress the brake pedal when the engine is

running.
TIP：
■ Stop the engine after the second or third
application. If the braking distance remains the
same 30 seconds after depressing the pedal, it
indicates that the air tightness is good .

(b)Operation inspection
(1)Set the ignition switch to OFF. Depress the pedal
several times. Ensure that the pedal braking distance
will not vary at each brake application.
(2)Depress the pedal and start the engine.

07-13
07-Brake System

TIP：
■If the pedal sinks slightly, the booster is
functioning properly.

（c）Load tightness inspection

Start the engine. After running the engine for one to
two minutes, depress the brake pedal. Remain the
pedal force applied and stop the engine. The pedal
height should remain at the same level for at least 30
seconds.。

（d）Function inspection
With the engine stopped, depress the brake pedal
several times, applying the same force at each brake
application. Ensure that the brake pedal height will
not vary. Then, start the engine while depressing the
brake pedal. The pedal should move in slightly.

2. Check the vacuum check valve

(a) check the vacuum check valve.
(1)Slide the clamp and detach the vacuum tube.
(2)Remove the vacuum check valve.
(3)Ensure it is ventilated from the booster to the
engine, and unventilated the other way round .
(4)If any problem is found, replace the vacuum
check valve.

07-14
 07-Brake System

Replacement

1 Drain the brake fluid

Note：
●Do not spill the brake fluid over the paint-finish
surface, otherwise wipe it off immediately.

2. Detach the clutch reservoir tube (manual

transmission).
3. Remove the brake master cylinder.
（a）Detach the vacuum hose.
4. Remove the tube connecting with the ABS
actuator.

5. Remove the brake vacuum booster.

(a)Remove the vacuum hose from the brake vacuum
booster.
(b)Remove the return spring, clip and pushrod pin.
(c)Remove the four nuts and U-shaped clip.
(d)Pull out the brake vacuum booster and pads.

6. Inspect the brake master cylinder pushrod

clearance.
Measure the brake master cylinder pushrod
clearance with a gauge SST FT9013901.

7．Install the vacuum brake booster.

(a)Install the vacuum brake booster and new gasket.
(b)Install and tighten the brake vacuum booster nut.
Torque: 12.7 N · m
(c)Install the return spring, clip and pushrod pin.

07-15
07-Brake System

8. Install the vacuum brake booster pushrod.

9. Install the ABS actuator connecting hose.
10. Install the brake master cylinder.
（a）Install the vacuum hose.
（b）Connect the clutch reservoir tube (manual
transmission).

11．Pour brake fluid into the reservoir.

12 ． Drain the air in the brake master
cylinder(see the section of fluid charging and air
bleeding).
13．Bleed the air in the brake tube.
14．Check and adjust the brake pedal height(see
07-5).
15．Check the pedal free travel.
16．Check the pedal braking distance.
17．Drain the air in the clutch tube(manual
transmission).
18．Check and adjust the clutch pedal (manual
transmission).
19．Check the fluid level in the reservoir.
20．Check for brake fluid leakage.
21. Check for clutch fluid leakage(manual
transmission).

07-16
 07-Brake System

Exploded view of the vacuum booster and brake master

07-17
07-Brake System

Vacuum booster

07-18
 07-Brake System

Replacement and overhaul of the brake master cylinder

1．Drain the brake fluid

Note：
●Be careful not to spill the brake fluid over the
paint-finish surface, otherwise wipe off the brake
fluid rapidly.

2. Remove the brake master cylinder.

(a)Detach the liquid level warning light switch
connector.
(b)Slide the clip. Pull out No. 1 clutch reservoir tube
(manual transmission).
(c)Remove two brake tubes from the brake master
cylinder with the SST FT9013101.

(d)Remove the two lock nuts. Remove the master

cylinder and the mounting pad from the vacuum
booster.

3. Remove the reservoir.

(a)Clamp the brake master cylinder in a vise.
(b)Remove the pin from the brake master cylinder
body with a punch and hand hammer (Drift pin: SST
FT9067703)
(c)Pull out the reservoir.
(d)Remove the cap and filter from the reservoir.
(e)Remove the reservoir and two hole connectors.

4．Remove the brake master cylinder

(a)Clamp the brake master cylinder in the vise .
(b)Remove the O-ring.
(c)Push the piston by hand and remove the ring with
clasp pliers.

07-19
07-Brake System

(d)Push the piston by hand. Turn the cylinder and

remove the straight pin.

(e)Straightly pull out the No. 1 piston, piston guide

block, spring, cup and gasket.
NOTE：
●If they are pulled out tilted, the master cylinder
wall may be damaged.

（f）Place two wood blocks and a piece of cloth on

the table Press the master cylinder flange against the
wood edge and knock it, until the No. 2 piston and
spring fall off the cylinder body.

TIP：
■ Ensure that the distance (A) from the table to the
top of the wood is at least 100mm.
NOTE：
●If they are pulled out tilted the master cylinder wall
may be damaged.

5. Check the brake master cylinder.

(a)Check for rust or scratches on the cylinder wall.
(b)Check for wear or damage on the cylinder wall.
NOTE：
●If necessary, clean or replace the master cylinder.
TIP：
■Clean the disassembled parts with compressed air.

6. Install the brake master cylinder.

(a)Fix the brake master cylinder in the vise.
(b)Apply lithium soap base glycol grease to the
rubber parts indicated by the arrow heads.
(c)Install the No.2 and No. 1 piston, spring, piston
guide blocks, cup and gasket.
NOTE：
07-20
 07-Brake System

●If the piston is installed tilted, the master cylinder

wall may be damaged. Be careful not to damage the
cup edge on the piston.
(d)While pushing the piston, install the pin on the
cylinder body.

(e) While pushing the piston, install the new gasket

and new piston stop bolts.

（f）While pushing the piston, install the snap ring

with the snap ring pliers.
（g）Install the O-shaped graph on the brake master
cylinder.

7. Install the reservoir.

（a）Apply lithium soap base glycol grease to the
reservoir hole connector. Then install it on the
master cylinder.
（b）Install the pin into the brake master cylinder
with the punch and hand hammer.

8 ． Check and adjust the vacuum booster

pushrod.
(a) Install special tool SST FT9067703 on the the
brake master cylinder. Lower the special tool ejector
bar until it touches the piston slightly.
(b)Apply chalk powder to the ejector rod flat surface
of the SST FT9013901.
(c)Turn over the special tools, check the clearance
between the special tool and the vacuum booster.
Clearance：0mm
TIP：
■If there is clearance between the special tool body
and the booster shell, it indicates the standard value.
If there is no chalk mark on the booster pushrod, it
indicates that the clearance exceeds the standard
value.

07-21
07-Brake System

9．Install the brake master cylinder.

(a)Install the master cylinder on the booster with
two nuts.

(b)Connect the two brake tubes to the brake master

cylinder with the SST FT9013101.
Torque：12.7～17.6N·m
(c)Connect No. 1 clutch reservoir tube with the clip
(manual transmission axle type).
(d)Plug in brake fluid level warning switch
connector.

10. Pour brake fluid into the reservoir.

11．Bleed the air in the master cylinder(see
07-04).
12．Bleed the air in the brake tube.
13．Check the reservoir fluid level.
14．Check for brake fluid leakage.

07-22
 07-Brake System

Front Disc brake

Components

07-23
07-Brake System

Maintenance

1．Remove the front wheel.

（a）Jack up the front end of the vehicle. Support the
body with safety. Remove the front wheel.
（b）Inspect the brake pad gasket thickness through
the inspection hole of the calipers.

2．Drain the brake fluid.

NOTE：
●Be careful not to spill the brake fluid over the
paint-finish surface, otherwise wipe it off
immediately.

3．Remove the front disc brake cylinder.

(a)Remove the connector bolts and washers from
the front disc brake cylinder. Then. detach the hose.

(b)Fix the front disc brake cylinder slide pin. Then

remove two bolts.

4. Remove the front brake pads suite

(a)Remove the two brake pads with damping plates.

(b)Remove the damping plates from each pad.
NOTE：
●Be sure to carry out the pad replacement operation
for one wheel at a time, for there is a possibility that
the piston at the opposite side may be jumped out.

5. Remove the front brake pads support plate.

(a)Remove two friction pads from the brake
cylinder bracket.

6. Remove the front disc brake cylinder slide

pin.
(a)Remove the slide pin from the disc brake cylinder

07-24
 07-Brake System

bracket.

7．Remove the front disc brake slide pin dust

covers.
(a)Remove two dust covers from the front disc
brake cylinder bracket.
NOTE：
 The dust cover must be replaced if it is damaged.

8．Remove the disc brake cylinder bracket.

(a)Remove two bolts. Then detach the disc brake
cylinder bracket.

9．Remove the brake cylinder dust cover.

(a)Remove the retaining ring and the dust cover
with a screwdriver.

10．Remove the front disc brake bleeder plug

11．Remove the front brake piston
(a) Put a piece of cloth or similar material between
the brake cylinder and the piston.
(b) Drive the piston out by applying compressed air.
Warnings：
■Keep your finger away from the front of the piston
while applying compressed air.
NOTE：
■Do not spill the brake fluid.

12．Remove the piston oil seal.

（a) Remove the oil seal from the brake cylinder
with a screwdriver.

13．Check the brake cylinder and piston.

(a) Check for rust or scratches on the cylinder wall.

14．Check the brake lining thickness.

(a) Measure the lining thickness with a ruler.
Standard Thickness: 10.0mm
Minimum Thickness: 1.0mm

07-25
07-Brake System

15．Check the front brake wear indicator steel.

(a)Ensure that the wear indicator steel is flexible
enough, with no deformation, cracks or wear. Be
sure to clean all the rust, dirt and other
contaminants.

16. Check the brake disc thickness.

(a) Measure the brake disc thickness with a screw
micrometer.。
Standard Thickness: 11.0mm
Minimum Thickness: 10.0mm

17．Remove the front brake disc.

(a)Mark on the brake disc and the hub.
(b)Remove the brake disc.

18．Install the brake disc.

TIP：
■ Install the brake disc where it swings most slightly.

19．Check the brake disc swing.

(a) Tighten the brake disk temporarily.
Torque：88～118N·m
(b)Measure the brake disc swing at the position
10mm away from the outer edge of the brake disc
with a dial indicator.
Brake disc maximum swing ：0.05 mm
(c) If the brake disc swing reaches or exceeds the the
limit, check the axial clearance of the bearing and
hub swing. If the bearing and the hub are normal,
adjust the brake disc swing.

20 ． Tighten the brake bleeder screw

temporarily.
(a) Tighten the brake bleeder plug on the front
brake cylinder temporarily.
21．Install the piston oil seal.
(a) Apply lithium soap base glycol grease to the
new piston oil seal.
(b) Install the new piston oil seal into the brake

07-26
 07-Brake System

cylinder.

22．Install the brake piston.

(a) Apply lithium soap base glycol grease to the
new piston seal.
(b) Install the piston into the front disc brake
cylinder.
NOTE：
●Do not force the piston into the brake cylinder.

23．Install the brake slave cylinder dust cover.

(a) Apply lithium soap base glycol grease to the
new brake slave cylinder dust cover. Install it into
the the brake cylinder.
TIP：
■ Install the dust cover firmly on the brake slave
cylinder and piston groove.
(b)Install the positioning ring with a screwdriver.
NOTE：
● Be careful not to damage the brake slave cylinder
dust cover.

24. Install the disc brake slave cylinder bracket.

(a)Fix the front disc brake slave cylinder bracket
with two bolts.

25. Install the front disc brake bush dust cover.

(a)Apply lithium soap base glycol grease to the
surface of the two new dust covers.
(b)Install two dust covers on the front disc brake
cylinder bracket.

26. Install the front disc brake cylinder slide pin.

(a)Apply lithium soap base glycol grease to the
sliding section of the slide pin and the oil seal
surface.

(b)Install the two slide pins into the front disk brake
cylinder bracket.

27. Install the front brake pad support plate.

（a）Remove the two brake pads support plates from
the front disc brake cylinder bracket.

07-27
07-Brake System

28. Install the brake pad components.

NOTE：
(d) With the wear indicator up, install the Inner
brake pads, and then the outer brake pads.
NOTE：
● Be sure that no oil or grease is attached to the
friction surface of brake pad and brake disc.

NOTE：
For the convenient installation of the brake gasket,
drain a small amount of the brake fluid from the
reservoir. Then, push the piston into the clamp body.
With a hammer.
NOTE：
Be sure to carry out the gasket replacement
operation for one wheel at a time, for there is a
possibility that the piston at the opposite side may be
jumped out

29. Install the brake calipers.

(a）Install the guide plate on the steering knuckle.
(b）Install the alarm plate on the brake pad.
Then, install them on the brake calipers.
(c ） Install the brake calipers assembly on the
steering knuckle.

NOTE：
●Care must be exercise so that the dust cover may
not be pinched during the installation.

(d）Install the brake hose.

（1）Attach the brake hose to the brake calipers with
special maintenance tools.
（2）Attach the inter medium tube connector of the
brake tube to the damper bracket with a card.
（3）Connect the brake tube and the brake hose by
hand.
（4）Tighten the brake tube and brake hose with SST
FT9013101.
Torque：12.7～17.6N·m
07-28
 07-Brake System

NOTE：
●Make sure that the hose is not twisted or stretched
excessively.
（5）Install the card on the vehicle body bracket.
NOTE：
●After completion of the installation, turn the
steering wheel to the locked position.. Make sure
that the brake hoses is not interfering with any part
of the body.

30．Install the front disc brake slave cylinder.

(a) Install the front disc brake slave cylinder with
two bolts.

(b) Install new pads and hoses with joint bolts.

TIP：
■ Attach the hose firmly to the locking hole on the
brake slave cylinder.
31．Pour the brake fluid into the reservoir.
32．Bleed the air in the brake pump.
33．Drain the air in the brake pipeline.
34．Check the liquid level height in the reservoir.
35．Check the brake fluid for leakage.
36．Install the front wheel.
Torque：88～118 N·m
Fill with the fluid and bleed the air. (see page 07-4)

07-29
07-Brake System

Rear drum brake

Components

07-30
 07-Brake System

Maintenance

1．Remove the rear wheel.

Jack up the rear section of the vehicle. Remove the
rear wheel

2．Remove the brake drum.

a) Adjust the rear brake pads automatic
adjustment mechanism to maximum clearance
with a straight screwdriver.
b) Tighten the brake drum removal hole with
the two bolts.
c) Remove the brake drum.

3．Drain the brake fluid.

NOTE：
●Be sure not to spill the brake fluid over the paint
–finish surface, otherwise wipe it off immediately.

4．Remove the rear brake drum.

5．Check the bore diameter of the brake drum.
(a)Measure the bore diameter of the drum with a
brake drum gauge or the equivalent.
Standard Diameter：180mm
Maximum Diameter：181mm

6．Detach the left side positioning strut of the

parking brake shoe.
(a)Remove the tension spring from the front and
rear brake shoes with the special tool SST
FT9013203. Detach the left side positioning strut of
the parking brake shoe.
NOTE：
● Be careful not to damage the brake cylinder dust
cover.

07-31
07-Brake System

7．Remove the front brake shoe.

(a)Remove the end cap, and the positioning spring
of the brake shoe and pin with sharp-nose pliers.
(b)Detach the return spring. Remove the front brake
shoe.
(c)Remove the left side positioning strut of the
parking brake shoe.

8．Remove the brake shoe return spring.

(a)Remove the return spring from the brake shoe.

9．Remove the rear brake shoe.

(a)Remove the end cap, shoe positioning spring and
pin with sharp-nose pliers.

(b)Remove the parking brake cable from the parking

brake lever with sharp-nose pliers.

10 ． Remove the parking brake shoe lever

accessories.
(a)Remove the C-shaped gasket and parking brake
shoe lever with a screwdriver.

11．Check the brake shoe lining thickness.

(a)Measure the brake shoe lining thickness with a
ruler.
Standard Thickness：4.0mm
Minimum Thickness：1.0mm
If the lining thickness reaches or exceeds the
minimum thickness, or there is severe or uneven
wear, replace the brake shoe.

07-32
 07-Brake System

12 ． Check whether there is normal contact

between the brake drum and the brake shoe
lining.
(a)Apply chalk powder to the inner surface of the
brake drum. Fit the brake shoe with the inner surface
of the drum. Perform abrading.
If there is poor contact between the drum and
shoe lining, abrade or replace the brake shoe.

13．Remove the brake slave cylinder.

(a)Detach the brake tubing with the SST FT9013101.
Put the brake fluid in a container.
(b)Remove the bolts and the brake slave cylinder.

14．Remove the brake cup.

(a)Remove two dust covers from the brake cylinder.
(b)Remove two pistons and springs.
(c)Remove two brake cylinder caps from each
piston.

15．Check the brake cylinder.

(a)Check the cylinder wall and the piston for rust or
scratches.
16．Remove the rear bleeder plug of the brake
drum.
17．Tighten the rear bleeder plug of the brake
drum temporarily.

18．Install the brake slave cylinder cup.

(a)Apply two brake slave cylinder and the piston
with lithium soap base glycol grease.
(b)Install two brake cylinder caps on each piston.
(c)Install the compression spring and two pistons on
the brake slave cylinder.
(d)Install two new dust covers on the brake slave
cylinder on the new two dust covers.

19. Install the brake slave cylinder.

(a)Install the brake cylinder with bolts.
(b)Connect the brake lines with SST FT9013101.
Torque：12.7～17.6N·m
20. Install the parking brake shoe lever
07-33
07-Brake System

attachments.
(a)Install a new C-shaped gasket. Then install the
parking brake lever.

21．Install the brake shoe.

（a)Connect the parking brake cable to the parking
brake lever with sharp nose pliers.

（b)Install the brake shoe, pins, shoe positioning

spring and shoe positioning spring caps with sharp
nose pliers.

22．Install the brake shoe return spring.

(a)Install the return spring on the brake shoe with
SST FT9013203.

23．Install the left brake automatic adjustment

lever.
(a)Mount the automatic adjustment lever and the
automatic adjustment lever spring on the front brake
shoe.

24．Install the parking brake shoe strut.

(a)Apply the adjustment bolt with high temperature
resistant grease.
(b)As shown in the picture, install the left strut of the
parking brake shoe.

07-34
 07-Brake System

25．Install the front brake shoe.

(a)Install the return spring on the front brake shoe.
(b)Install the front brake shoe , pins, shoe
positioning spring, and positioning spring caps with
sharp nose plier.

26．Install the parking brake shoe left strut.

(a)Connect the tension springs to the front and rear
brake shoes with the SST FT9013203.

NOTE：
● Be careful not to damage the dust covers of the
brake slave cylinder.

27. Brake adjustment

（a）Turn the pawl in the direction of the arrow with
a screwdriver or the like. Adjust the engagement
position of the adjustment lever and the pawl. Make
the shoe contract so that it is easy to install the brake
drum.

28．Check the installation of the brake drum.

(a)Check whether each part is installed correctly.
(b)The brake shoe clearance should be adjusted
automatically rather than manually.
NOTE：
●There should be no oil or grease on the friction
surface of the brake shoe lining and the brake drum.

29．Install the rear brake drum sub assembly.

30．Pour brake fluid into the reservoir.
31．Bleed the air in the master cylinder.
32．Bleed the air in the brake pipeline.
33．Check the liquid level in the reservoir.
34．Check for brake fluid leakage.
35．Install the rear wheel.
Toque: 88～118N·m.
36．Check the parking brake lever stroke.
37．Adjust the parking brake lever stroke.

07-35
07-Brake System

Parking Brake

Malfunction Table

The following table contributes to identifying the causes of the malfunction. The numbers represent
the possible orders of the problems. Check all parts in order. Replace them if necessary.

Problems Diagnosis
Brake block 1.Parking brake lever stroke (misadjust)
2.Parking brake cable clamping (stagnation）
3.Parking brake shoe clearance (misadjust）
4.Parking brake lining(crack or deformation)
5.Return or tension spring (damage）

07-36
 07-Brake System

Adjustment

Components

07-37
07-Brake System

Parking brake handle

Vehicle Inspection

1. Check the parking brake control handle

stroke.
Pull the parking brake handle up. Record the
number of teeth.
The number of teeth should be 4 ～ 9 when the
tension force is 200N.
If the number does not conform to the specification,
adjust the parking brake.

2. Adjust the parking brake if necessary.

TIP：
■Make sure the rear brake shoe clearance has been
adjusted before adjusting the parking brake.
■Adjust the rear shoe plate clearance.
(a) Remove the channel box.
(b) Slacken the lock nut. Turn the adjustment nut
until the stroke is proper.
(c) Tighten the lock nut.
(d) Install the channel box.

07-38
 07-Brake System

Replacement

1. Remove the console accessories.

2. Remove the control lever protective jacket.
3. Remove the floor-type shift head accessories.
4. Remove the control lever protective jacket
hole cover.
5. Remove the adjustment nut wire.
（a）Remove the adjustment nut wire.

6. Remove the parking brake lever accessories.

（ a ） Remove the parking brake lever switch
connectors.
（ b ） Remove the two bolts. Then remove the
parking brake lever.

7. Remove the parking brake switch

components.
（a）Remove the screws and the parking brake
switch components.

8. Install the parking brake switch components.

（a）Install the parking brake switch components
with screws.

9. Install the parking brake lever.

（a）Install a lever on the parking brake cable. Then
install adjustment nut wire on them.
（b）Fix the parking brake lever with two bolts.
Torque: 15～22N·m
(c) Connect the parking brake switch connector.

10. Install the control lever protective jacket

rear accessories.
11. Install the control lever protective jacket
rear hole cover.
12. Install floor-type shift lever accessories.
13. Install the control lever protective jacket.
14. Install the console accessories.
15. Check and adjust the parking brake lever
stroke.
07-39
07-Brake System

Brake tube

Components

07-40
 07-Brake System

ABS actuator assembly

07-41
07-Brake System

Vehicle Inspection

Connect a hand-held detector

（a）D L C 3 C onnect the hand-held detector to the DLC3.

（b）Startand idle the engine.
（c）S electanti-lock brake system on the hand-held detector.
1．Attach the handheld detector.
(a) Connect the detector to the DLC3.
(b) Turn the ignition switch to the ON position.
(c) Click the anti-lock brake system on the detector.
(d) Click on the actuator test.
(e) Click on the hydraulic control unit test.

2．Hydraulic control unit test

(a) Hydraulic pump test (to check for work
sound).Click on OK.
(b) Open the normally open valve and close the
normally closed valve. Check whether the wheels
are locked or not. Click on ok.
(1) Close the normally open valve and close the
normally closed valve. Check whether the wheels
are locked or not. Click on ok..
(2) Close the normally open valve and open the
normally closed valves Check whether the wheels
can turn freely. Click on OK.
(3) Close the normally open valve and close the
normally closed valves. Check whether the wheels
can turn freely. Click on OK.
(4) Close the normally open valve and close the
normally closed valves. Check whether the wheels
can turn freely. Click on OK.
(5) Open the normally open valve and close the
normally closed valve. Check whether the wheels
are locked or not. Click on OK.
(6) When the wheels test is completed, release the
brake pedal. Click on OK.
(c) Begin the right front wheel test. (Method ibid.)
(d) Begin the left rear wheel test. (Method ibid.)
(e) Begin the right rear wheel test (Method ibid.)

07-42
 07-Brake System

If the test is not normal, replace the ABS assembly.

07-43
07-Brake System

Replacement

1.Drain the brake fluid.

NOTE：
● Be careful not to spill the brake fluid over the
paint-finish surface of the vehicle. Otherwise wipe it
off immediately.

2. Remove the battery.

3. Remove the with-bracket ABS actuator.

（ a ） Disconnect the connector from the
with-bracket ABS actuator.
（b）Detach the brake tube from the with-bracket
ABS actuator with special tools.

（c）Remove four bolts. Then, remove the ABS

actuator.

4. Remove the ABS actuator assembly.

（a）Remove four bolts and the ABS actuator from
the with-bracket ABS actuator.
NOTE：Seal the brake tube with rubber tape to
prevent dust and sundries from entering.

Installation

1. Install the ABS actuator.

（a）Install the ABS actuator with four bolts.

（b）As shown in the picture, install the brake tubes

on the proper position of the with-bracket ABS
actuator with SST.
Torque: 12.7～17.6N·m
（c）Connect the ABS actuator connector.

2. Install the battery.

07-44
 07-Brake System

3. Pour brake fluid into the reservoir.

4. Bleed the air in the brake master
cylinder.(For fluid charging and air bleeding,
see 07-4 above.)
5. Bleed the air in the brake tube.
6. Check the liquid level in the reservoir.
7. Check for brake fluid leakage.

07-45
07-Brake System

Malfunction diagnosis of the ABS test.

Problems Check area

1Check whether the ABS and EBD
ABS failure alarm lights work.
2．Read the fault codes and identify the
problems.
3．Check the ignition switch power UZ
circuit.

4．Inspect for brake tube leakage.

1．Read the fault codes and identify the
Poor performance of the ABS problems.
2．Inspect for brake tube leakage.
3．Check the ignition switch power UZ
circuit.
4．Check the power supply capacity of
the vehicle battery.
1．Check whether the ABS and EBD
The diagnosis instrument fails to read alarm lights work.
the fault codes 2．Check the with-ECU ABS hydraulic
regulator power wire and ground wire.
3．Check the ignition switch power UZ
circuit.
4．Check the power supply capacity of
the vehicle battery.

5．DIAGK Check the with-ECU ABS

hydraulic regulator DIAGK wire.
6．Check the connection reliability of
the diagnosis instrument.

07-46
 07-Brake System

Wheel speed sensor

Exploded view of the components

07-47
07-Brake System

Replacement

1. Remove the front wheels.

2.Remove the vehicle speed sensor.
(a)Remove the resin clamp and the vehicle speed
sensor wiring from the vehicle body and retaining
clamp.
(b)Remove the vehicle speed sensor connector.
The clearance between the wheel sensor and the
wheel rim is commonly 0.6～0.7mm.It should not
be beyond 1.5mm.

(c)Hold the vehicle speed sensor wiring and remove

two bolts from the vehicle body and the shock
absorber.

(d)Remove the bolts and vehicle speed sensor.

NOTE：
●Keep foreign matters away from the sensor tip

3. Install vehicle speed sensor.

(a)Tighten the vehicle speed sensor with bolts.

NOTE：
●Keep foreign matters away from the sensor tip.
(b)Install the vehicle speed sensor wiring on the
vehicle body and the shock absorber.
07-48
 07-Brake System

(c)Attach the vehicle speed sensor connector.

(d)Install the resin clamp and vehicle speed sensor
wiring on the body and retaining clamp.

4. Install the front wheels.

Torque: 88～118N·m

5. Check ABS vehicle speed sensor signal.

Wheel speed sensor

Replacement
1. Remove the rear wheels.
2. Remove the vehicle speed sensor wiring.
(a)Detach the connector from the vehicle speed
sensor.

3. Remove the brake drum.

4. Remove the hub and axial bus.
5. Remove the vehicle speed sensor.
(a)Install the rear hub sub-bus in the vise.
NOTE：
●Replace the rear hub assembly if it falls off or it is
strongly impacted.
(b)Knock the two pins with a drift pin and a hammer.
Remove two accessories from the SST.
(c)Remove the vehicle speed sensor from the rear
hub with the STT ： FT9067701 、 FT9067705 、
FT9013901.

NOTE：
● Replace the hub assembly if the sensor rotor is
damaged.
● Be careful not to scratch the contact surface of the
hub and the vehicle speed sensor.

07-49
07-Brake System

Vehicle speed sensor inspection

1.Visually inspect for looseness,

damage, foreign matters, and improper
installation of the wheel speed sensor and
the gear ring. Replace the damaged parts.
Wheel speed sensor Remove the foreign matters. Tighten the
loose parts.
2. Inspect whether the wheel speed
sensor wiring is properly arranged.
Ensure that the wheel speed sensor wiring
is not interfered by mechanical parts.
3. With the help of an assistant, watch
the diagnosis instrument wheel speed
sensor data display. Conduct road test of
the vehicle, check for data display.

1. Install the vehicle speed sensor.

(a)Clean the contact surface of the rear hub and the
vehicle speed sensor.
TIP：
■ Keep foreign matters away from the sensor rotor.
(b)Install the vehicle speed sensor on the rear hub.
Keep the connector as low as possible.
(c)Press the vehicle speed sensor into the rear hub
with the SST FT9011402 and the hold-down
NOTE：
●Do not knock the sideslip control sensor directly
with the hammer.
●Keep the vehicle speed sensor inspection section
away from foreign matters.
● Install the sensor vertically and slowly.

2. Install the rear hub bearing assembly.

3. Install the side brake drum.
4. Install the vehicle speed sensor wire.
5. Install the rear wheels.
07-50
 07-Brake System

Torque: 113N·m
6. Inspect and adjust the rear wheels location.
7. Inspect the ABS vehicle speed sensor signal.

07-51
 08-Suspention System

Suspension System

Front Suspension…………………………………………………………………….….1

Front Wheel Alignment………………………………………………………………....4

Front Shock Absorber with Coil Spring………………………………………………...7

Suspension lower arm…………………………………………………………………13

Rear Suspension............................................................................................................ 20

Rear Wheel Alignment...................................................................................................21

Rear Shock Absorber with Coil Spring..........................................................................23

Rear Axle........................................................................................................................31
 08-Suspention System

Front Suspension

Front Suspension System

Malfunction Table

The following table indicates the possible causes of problems. The possibility of the causes is
numbered in descending order. Inspect the following parts. Replace the disabled ones.
1. Tire (wear or improper inflation)
2. Wheel alignment(incorrect)
3. Steering knuckle (looseness or wear)
Pass-line deflection
4. Wheel hub bearing(wear)
5. Steering gear (maladjustment or damage)
6. Suspension parts (wear)
1. Vehicle (overload)
Body sag 2. Springs (softened)
3. Shock absorber (wear)
1. Tire (wear or distortion)
Vibration or shock 2. Stabilizer bar (bend or wear)
3. Shock absorber(wear)
1. Tire (wear or improper inflation)
2. Wheel(unbalance)
3. Shock absorber(wear)
4. Wheel alignment (incorrect)
Front wheels shimmy
5. Ball head(wear)
6. Wheel hub bearing(wear)
7. Steering knuckle (looseness or wear)
8. Steering gear (maladjustment or damage)

08-1
08-Suspention System

1. Tire (wear or improper inflation)

2. Wheel alignment (incorrect)
Anomalous tire wear
3. Shock absorber(wear)
4. Suspension (wear)

08-2
 08-Suspention System

Front Suspension

Components

08-3
08-Suspention System

Front Wheel Alignment

Front wheel alignment inspection

1. Measure the height of the vehicle 160±20mm

Tire size Front Rear

175/65R14 82H 192 276

（a）Front measuring point

From ground to front center of the mounting bolt on
the lower arm
（b）Rear measuring point.
From ground to center of the mounting bolt on the
rear cross member
Note：
●Adjust the height of the vehicle to prescribed value
before checking the wheel alignment.
●Depress or lift the body to adjust the height in the
case that the height is inconsistent with the standard.

2. Toe-in inspection
Toe-in：
Toe-in A+
±12′
main） B：0° （0°
±0. 2°
C-D：0±2m m ）
If the toe-in is not in prescribed limit, adjust the
adapter of the toothed rack.

3. Toe-in adjustment
(a) Disassemble the toothed rack boot.
(b) Slacken the locknut of the tie rod ends.
(c) Turn the racks at the right and left sides by the
same amount.
Tips：
■It is suggested that the toe-in be adjusted to the
median of the specified range.

08-4
 08-Suspention System

(d) The length of the left and right tie rods must be
the same.
Length difference：less than 1.5mm
(e) Tighten the locknut.
( f ) Install the boot and clamp.
Tips：
■Make sure the boot is not distorted.

4. Inspect the wheel steering angle.

Turn the steering wheel to the end, and measure the
steering angle.
Wheel turning angle
Inside
37°00’±2° 37°06’±2°
wheel
（37.00°±2°） （37.10°±2°）
(reference)
Outside
wheel 32°09’ 32°19’
（reference （32.15°） （32.32 °）
）
Check the lengths of the left and right toothed rack
adapter if the inside steering angles of the front
wheels differ from the prescribed values.

5.Install camber 、 kingpin caster 、 kingpin

inclination gauge or place the car on wheel
positioning device.
Follow the guidance of the instruments to install
them.
6. Check the camber, caster and kingpin angles.
Caster 1°25′±45′
Difference between right and left< 45′
Camber 0°30′±45′
Difference between right and left<45′
Kingpin inclination 9°55′±45′
Difference between right and left< 45′
Recheck the suspension parts for wear if the kingpin
caster angle or kingpin inclination is not in
prescribed range after the camber has been adjusted
correctly.
7. Adjustment the camber
Note：
08-5
08-Suspention System

●Check the toe-in after adjusting the camber angle.

(a) Disassemble the front wheel.
(b) Remove the two nuts at the shock absorber
under-part. Apply engine oil on the nut thread if the
bolt or nut is to be reused.
(c) Clean the mounting surfaces of the shock
absorber and steering knuckle.
(d) Install the two nuts temporarily.
(e) Adjust the camber by pushing or pulling the
under-part of shock absorber in demanded direction.
(f) Tighten the nuts.
torque：107.8～156.8N·m
(g) Install the front wheel.
torque：88～118N·m
(h) Check the camber angle.
Tips：
■Try to adjust the camber angle to the median of the
specified range.
■Specified value of bolt adjustment ： 6' ～
30'( 0.1°～0.5°)
If the camber angle cannot be set to the prescribed
value, choose camber angle adjusting bolt according
to extra camber angle needed by using the following
table.
Note：
●Fasten the adjusting bolt with new spacer and nut.

08-6
 08-Suspention System

Front Shock Absorber with Coil Spring

Components：

08-7
08-Suspention System

Disassembly

1. Remove the wiper arm cap.

2. Remove the right wiper arm.
3. Remove the left wiper arm.
4. Remove the seal of the hood and cowl top.
5. Remove the right cowl top ventilation louver.
6. Remove the left cowl top ventilation louver.
7. Remove the windshield wiper link assembly.
8. Remove the cowl top panel.
(a)Remove bolts and two clamps and disconnect
wires.
(b)Remove hoses and wires（wiper）.
(c)Remove the eight bolts on the cowl top
ventilation louver.
9. Remove the front wheel.
10. Remove the brake hose and wire clamps of
the ABS speed sensor.
Remove the bolts，and remove the brake hose and
wire clamps of the ABS speed sensor from the shock
absorber bracket.

11. Remove the shock absorber with coil spring.

（a）Remove the two bolts and nuts, then remove
the shock absorber from the steering knuckle.

（ b ） Remove the three bolts then the shock

absorber.

08-8
 08-Suspention System

12. Fasten the front shock absorber with coil

spring.
（a）Mount the two nuts and one bolt on the shock
absorber bracket, then clutch the lower end of the
shock absorber with a bench clamp.
（b）Compress the spring with special tools.
Note：
●Do NOT use an impact wrench to prevent the
special tools from being damaged.

13. Remove the dust cover of the left front

suspension support.
（ a ） Remove the dust cover from the front
suspension support.

14. Remove the front support after the nuts of

left front shock absorber has been removed.
（ a ） Secure the support with two nuts and
screwdriver, then remove the central nut.
Note：
●Do NOT damage the stud bolt of the front
suspension support.

15. Remove the left front suspension support

assembly.
16. Remove the dust cover oil seal of the left
front suspension support.
17. Remove the front coil spring upper left seat.
18. Remove the upper left front coil spring
insulator.
19. Remove the left front coil spring.
20. Remove the left front spring bumper.
21. Remove the left front shock absorber
assembly.
22. Check the left front shock absorber
assembly.
Shock absorber operation inspection

（ a ） Push or pull the piston rod of the shock

absorber at a constant speed. Ensure that the force
required moving the rod is uniform over the entire

08-9
08-Suspention System

stroke. However, when the piston rod is pulled

strongly, the pulling force may become slightly
greater over the stroke 30 mm (1.2 inches) toward
the end of the pulling stroke. It should be noted that
this phenomenon is not abnormal.
（ b ） Move the piston rod quickly in an
up-and-down direction with a stroke of 5 - 10 mm.
Ensure that the force required moving the rod will
not change.
（c）If any abnormal feeling or noise is encountered
during the inspection above, replace the shock
absorber.
Note:
■Discard the shock absorber（consult the discard
details）.
23. Install the left front shock absorber
assembly.
24. Install the left front spring bumper.
25. Install the left front coil spring
（a）Compress the coil spring, using SST.
Note：
■Do Not use an impact wrench to prevent the SST
from being damaged.

（b）Install the coil spring to the shock absorber.

Tips：
■Fix the lower end of the coil spring to the recessed
section of the spring lower seat.

26. Install the left front coil spring insulator.

（a）Install the upper insulator with the “△” mark
facing outwards
Bearing Fron 27. Install the upper seat of the left front coil
spring.
t spring
（a）Install the upper seat with the “out” mark
upper facing outwards.
seat
28. Install the dust cover oil seal of the left front
suspension support.
29. Install the upper seat of the front spring and
bearing.

08-10
 08-Suspention System

30. Install the left front suspension support

subassembly.

Cut-out

31. Install the front support to the nuts of the

left front shock absorber.
（a）Install the new central nut with the assistance
of 2 nuts and a screwdriver or some similar tools.
Note：
●Do NOT damage the stud bolt of the suspension
support.
（ b ） Apply multi-purpose lubricant on the
suspension support.

32. Install the dust cover of the left front

suspension support.
33. Install the front shock absorber with coil
spring.
（a）Install the suspension support No.2.
（b）Install the front shock absorber with coil spring
by 3 nuts.

（ c ） Install the shock absorber to the steering

knuckle.
（d）Apply engine oil on the thread of the 2 nuts.
（e）Install the 2 bolts and nuts.
Torque：107.8～156.8N.m

34. Install the brake hose.

Torque：19.6～26.5 N.m
35. Install the front wheels.
Torque：88～118 N.m

08-11
08-Suspention System

Discard the shock absorber consulting the

following steps:
1. Discard the left front shock absorber
assembly.
（a）Pull out the shock absorber rod to the end.
(b) Punch and deflate the rod as shown in the
picture.
Note：
●Watch out for the flying iron filings when
punching the rod.
●The gas is colorless, odorless and nontoxic.

08-12
 08-Suspention System

Front Suspension Lower Arm Subassembly

Replacement

08-13
08-Suspention System

1. Remove the front wheel.

2. Remove the engine bonnet.
3. Hoist the engine assembly.
4. Remove the left front suspension lower arm
subassembly.
（a）Remove the clamp and nut.
（b）Remove the suspension lower arm from the
steering knuckle, using SST.
5. Remove the front stabilizer bar.
（a）When fastening the stabilizer bar bolts, remove
the nuts,3 retainer rings and 2 pads.
（b）Conduct the same operation on the other side.
（c）Remove the 4 bolts and remove the front
stabilizer bar.

6. Disassemble the rack and pinion power

steering assembly.
Remove the 3 bolts, and disassemble the rack and
pinion power steering assembly.
Tips：
■Hoist the rack and pinion power steering assembly.

7. Disassemble the front suspension cross

member subassembly.
（a）Remove the bolts and 3 nuts.

08-14
 08-Suspention System

（b）Jack up the front suspension cross member

subassembly.
（c）Remove the 4 bolts, then dismount the front
suspension cross member subassembly.

8. Remove the left front suspension lower arm

subassembly.
Remove 2 bolts, and remove the left front
suspension lower arm subassembly.

Note：
●Do not turn the nuts.
9. Check the left front suspension lower arm
subassembly.
a) Shake the ball joint stud bolt back and forth for 5 times
before tightening the nuts as shown in the picture.
b) Tighten the nut at the speed of 2~4 seconds a round
with a torque wrench, and record the torque reading at the
fifth round.
Tighten torque：0.78～3.43N·m

10. Tighten the left front suspension lower arm

subassembly temporarily.
Secure the left front suspension lower arm
subassembly temporarily by 2 bolts.

11. Connect the front suspension cross member

subassembly.
（ a ） Install the front suspension cross member
subassembly by 4 bolts.
Torque：
Bolt A：56～84 N.m
Bolt B：105.6～158.4N.m

（b）Install the bolts and 3 nuts.

Torque：41.6～62.4N.m

08-15
08-Suspention System

12. Install the rack and pinion steering

assembly.
(a)Install the rack and pinion steering assembly by 3
bolts.
Torque：40～60N.m

13. Install the front stabilizer bar.

(a) Install the front stabilizer bar with 4 bolts.
Torque：28～45.5N.m
(b) Install nuts, 3 retainer rings and 2 pads when
fixing the stabilizer bolts （ Shown in the left
picture）.
Front stabilizer bar ×front stabilizer bar tie rod
torque：40～60 N.m
Tips：
 Jack up the lower arm.
 Conduct the same operation on the other side.

14. Install the left front suspension lower arm

subassembly.

15. Install the lower arm on the steering knuckle

with nuts.
Torque：78.4～117.6 N.m
16.Install a new clip.
Note：
●If the hole of clip is not properly aligned, turn the
nut for another 60º.
17. Install the front wheel.
Torque：88~118N.m
18. Secure the suspension.
19. Secure the front suspension.
20. Secure the left front suspension lower arm
subassembly adequately
08-16
 08-Suspention System

21.Fasten the suspension lower arm with 3 bolts.

Torque：
Bolt A：78.4～117.6 N.m
Bolt B：105.6～158.4 N.m
Note：
■Do NOT turn the nuts.

22. Install the engine bonnet.

23. Check and adjust the front wheel alignment.

08-17
08-Suspention System

Front Stabilizer Bar

Replacement

Components

08-18
 08-Suspention System

1. Remove the front wheel.

2. Remove the bolts of the front stabilizer bar.
（a）When turning the bolts, remove 2 nuts, 5
retainer rings, 4 pads and stabilizer bolts
（b）Conduct the same operation on the other side.

3. Remove the set bolts of the stabilizer bracket.

4. Remove the front stabilizer bar.

Remove the 4 bolts and the front stabilizer bracket.

5. Install the front stabilizer bar.

Install the stabilizer bar, 2 bushes, 4 brackets and 4
bolts.
Torque：28～45.5N.m
Note：
●Ensure that the grooving faces the backwards of
the vehicle when installing the bushes.
Tips：
●Install the bushes on the outboard side of the
paint line.

6. Remove the set bolts of the stabilizer bracket.

7. Install the front suspension arm.

（a）Secure the front suspension arm with 3 bolts.
（b）Conduct the same operation on the other side.
8. Install the front wheel.
Torque：88～118N.m

08-19
08-Suspention System

Rear suspension system

Malfunction Table

Problems Diagnosis
1. Tire(wear or improper air inflation)
2. Wheel alignment(incorrect)
Pass-line deflection
3. Wheel hub bearing(wear)
4. Suspension(wear)
1. Vehicle(overload)
Body sag 2. Spring(softened)
3. Shock absorber(wear)

1. Tire(wear or improper air inflation)

Vibration or shock
2. Shock absorber(wear)

1. Tire(wear or improper air inflation)

2. Wheel(unbalance)
Rear wheels shimmy
3. Shock absorber(wear)
4. Wheel alignment(incorrect)

1. Tire(wear or improper air inflation)

2. Wheel alignment(incorrect)
Anomalous tire wear
3. Shock absorber(wear)
4. Suspension(wear)

08-20
 08-Suspention System

Rear Wheel Alignment

Inspection

Inspect the tire.

Measure the height of the vehicle.
Note：
●Adjust the height of the vehicle to the prescribed
value before checking wheel alignment.

1. Check the rear wheel toe-in.

（a）Rock the vehicle so that the vehicle height may
stabilize.
（b）Move the vehicle forward about five meters so
that the front wheels will straighten.
（c）Align the height of the toe-in gauge pointers
with the center height of the front wheels.
（d）Put a mark on the tread center of each rear
wheel tire at the rear side. Measure the distance
between the two marks (Dimension D) in the figure.
（e）Slowly move the vehicle forward by pushing
the vehicle, until the wheels turn 180 degrees.
（f）Measure the distance between the two marks
which were put in step (d) (Dimension C) in the
figure.
If the toe-in is not within the prescribed range, check

and replace the relative suspension components.

2.Check the camber.

（a）Install the camber, caster and kingpin angle
gauge, and place the vehicle on the wheel
positioning device.
（b）Check the camber.

Kingpin caster 3°37ˊ

angle
Front Camber angle 0°±45ˊ
wheel Kingpin 10°35ˊ±

08-21
08-Suspention System

alignment inclination angle 1°

parameters Toe-in(mm) 0±2
Vehicle 64.4±15
height(mm)
Rear wheel Camber angle -0°40ˊ±45
alignment ˊ
parameters Toe-in (mm) 5 -+13
Vehicle height 25±15
(mm)
Check the suspension parts for damage or
performance degradation if the measurement does
not comply with the specified value. Replace
relative parts if necessary

3. Toe-In Adjustment
（a）Slacken the set bolt of the toe adjust cam.

（b）Insert a hexagon wrench key to the hexagonal

hole provided at the back side of the two adjust cam.
Turn the hexagon wrench key. When each of the
adjust cams provided at both sides is turned by one
graduation, the toe-in will change approximately 5
mm.
Turn inside, the toe-in will increase, otherwise, it
hex will decrease.
(Inside: IN, Outside: OUT)

（c）Check the side clip.

Check the sideslip, using a sideslip tester.

08-22
 08-Suspention System

Rear Shock Absorber with Coil Spring

Repair

08-23
08-Suspention System

1. Remove the rear wheel.

2. Disconnect the wire of the sideslip control
sensor.
a) Remove the connector of the sideslip control sensor.
b) Remove the bolts and detach the sideslip control sensor
from the rear axle support.
Tips：
■Disconnect the wire of sensor on the right side
with the same operation.

3. Remove the rear brake tube.

（ a ） Remove the rear brake tube, using SST
FT9013101.
（b）Detach the clip.
Tips：
■The clip cannot be reused.
■Remove front brake tube in the same way as
removing the rear brake tube.

4. Disconnect the flexible hose from the shock

absorber.

5. Remove the parking brake cable assembly.

Remove the parking brake cable assembly from the
rear axle carrier after removing the nuts.

6. Remove the parking brake cable assembly.

Tips：
■Remove the parking brake cable assembly in the
same way as removing the rear brake tube.

7. Detach the rear axle carrier assembly.

Slacken the 2 bolts.

08-24
 08-Suspention System

8. Remove the coil spring.

（1）Compress the coil spring, using the SST

9. Remove the rear shock absorber cushion, rear

suspension
support, rear coil spring insulator, rear spring
bumper and coil spring.

10. Assemble the coil spring.

(a) Install the spring bumper at a point below the
cut-out section of the piston rod.
(b) Compress the coil spring, using the SST.
(c) Install the rear shock absorber cushion to the rear
suspension support.
(d) Install the rear coil spring insulator to the rear
suspension support.

NOTE：
●Be sure to align the cut-out section of the rear coil
spring insulator with the stud bolt section of the rear
suspension support during the assembly.

08-25
08-Suspention System

11. Tighten the right rear shock absorber assembly

temporarily.

Tips：
■Conduct the same operation on the other side.
12. Install the parking brake cable assembly.
Install the parking brake cable assembly, using nuts.

Tips:
■Conduct the same operation on the other side.
13. Install the rear brake tube.
（a）Connect the brake tube and the flexible hose,
using SST FT9013101.
Torque：12.7～17.6N.m
（b）Install the clip.

Tips：
■Conduct the same operation on the other side.
14. Install the wire of the sideslip control sensor.
（a）Tighten the wire of the sideslip control sensor,
using bolts.
（b）Install the wire of sideslip control sensor.
Tips：
■Conduct the same operation on the other side.

15. Tighten the rear axle assembly securely.

（a）Secure the shock absorber assembly.
Jack up the vehicle at the rear axle carrier section
and apply a force of 90kg on the trunk if the bolts
cannot be tightened in the proper position.
（b）Tighten the bolts securely.
Torque：107.8～156.8N.m

08-26
 08-Suspention System

16. Tighten the left rear shock absorber

assembly securely.
Tighten the bolts securely.
Torque：107.8～156.8 N.m

17. Tighten the right rear shock absorber

assembly securely.

Tips：
■Conduct the same operation on the other side.

18. Deflate the brake tube.

19. Install the rear wheel.
Torque：88～118N.m
20. Check the rear wheel alignment.
21. Check the signal of ABS speed sensor.

08-27
08-Suspention System

Replacement

1 Remove the rear wheel.

2.Remove the left rear shock absorber assembly.
（a）Jack up the vehicle and support the body with
safety stands.

(b)Clamp the piston rod, and then remove the 2 nuts.

（c）Remove the cushion and the upper suspension
support.

（d）Remove the nut, cushion and left rear shock

absorber assembly.
（e）Remove the shock absorber shell.

3. Check the left rear shock absorber assembly.

Push or pull the piston rod of the shock absorber,
and check if there is any abnormal feeling or noise
If any abnormality is encountered during the
inspection above, replace the shock absorber.

Note:
●Discard the shock absorber consulting the discard
details.

08-28
 08-Suspention System

4. Install the left rear shock absorber assembly.

（a）Install the coil spring to the shock absorber.
（b）Install the shock absorber upper shell.

（c）Install the shock absorber, upper suspension

support and the cushion to the body.
（d）Clamp the piston rod, then install the lower nut
to make the piston rod 15~18mm higher than the
lower nut.
（e）Install and tighten the upper nut referring to the
lower nut.

5. Install the flexible hose and brake tube.

（a）Install the flexible hose to the bracket on the
lower part of the shock absorber. Secure it with the
L-clamp.
（b）Install the brake tube to the flexible hose，using
professional tools.

6. Install the wheels.

Torque：88～118 N.m
7. Check the rear wheel alignment.
Discard
Discard left rear shock absorber assembly
（a ）Pull out the piston rod of shock absorber
temporarily
（b）Punch at the position as shown in the figure,
and deflate the cylinder
Note：
■Exercise caution while punching and watch for
flying iron pieces

08-29
08-Suspention System

■The gas is colorless, tasteless and nontoxic.

Note：
■Discard right shock absorber by same steps

08-30
 08-Suspention System

Rear Axle Carrier assembly

Components

08-31
08-Suspention System

Replacement
Remove the rear wheels.
1. Disconnect the wire of the sideslip control
sensor.
2.Remove the rear brake tube.

3.Disassemble the parking brake cable assembly.

4. Remove the rear brake drum sub-assembly.

5. Remove the left rear hub & bearing assembly.
（a）Remove the nuts, and disconnect the parking
brake cable assembly from the axle carrier.
（b）Remove the 4 bolts, left and right hubs and the
bearing assembly.
（c）Disassembly the rear brake assembly from the
rear axle carrier.

6. Remove the rear right hub and bearing

assembly.
Tips：
■Conduct the same operation on the right side.

7. Slacken the rear axle carrier assembly.

8. Disassemble the left rear shock absorber
assembly.
9. Disassemble the right rear shock absorber
assembly.
Tips：
■Conduct the same operation on the other side.
10. Remove the left rear coil spring.
11. Remove the right rear coil spring.
Tips：
■Conduct the same operation on the right side.

Bending part 12. Remove the rear axle carrier assembly.

（a）Jack up the vehicle at the rear section.
（ b ） Remove bolts and the rear axle carrier
assembly.

13. Remove the rear stabilizer bar bush.

14. Remove the left rear axle carrier bush.
(a）Distort the 2 flanges of the bush, using chisel and
08-32
 08-Suspention System

hammer.
Tips:
■ Bend the flange until it can be caught by the claws
of the SST.
（b）Remove the bush from the axle, using the
following SST:
SST: FT9011103 FT9011104 FT9011107
FT9011108 FT9011109
Note：
●Apply paint on the axle carrier to protect it if t has
been scratched.
f

15. Remove the right rear axle carrier bush.

Tips：
■Conduct the same operation on the right side.

16. Install the left rear axle carrier bush.

（a）Install the left rear support to the axle carrier, as
shown in picture.
（b）Install the bush to the axle carrier, using the
following SST:
SST: FT9011103 FT9011104 FT9011107
FT9011108 FT9011109
Note：
●Fasten the claws of the SST to the bush.
●Do NOT scratch the rubber of the bush.
●Do NOT break the flange of the bush.

17. Install the right rear axle carrier bush.

Tips：
■Conduct the same operation on the right side.

18. Install the rear stabilizer bar bush.

19. Tighten the rear axle carrier temporarily.
（a）Jack up the vehicle at the rear section.
（b）Install the rear axle carrier temporarily by
tightening the 2 bolts.

08-33
08-Suspention System

20. Install the left rear coil spring.

21. Install the right rear coil spring.
22. Tighten the left rear shock absorber
assembly temporarily.
23. Tighten the right rear shock absorber
assembly temporarily.
24. Install the right rear hub & bearing
assembly.
Install the right rear hub and bearing assembly with
4 bolts
25. Install the right rear hub & bearing
assembly.
Tips：
■Conduct the same operation on the other side.
26. Install the rear brake drum subassembly.
27. Adjust the distance between the rear brake
drum and the brake shoe.
28. Install the parking brake cable assembly.
Tips：
■Conduct the same operation on the other side.

29. Install the rear brake tube. Tips: Conduct

the same operation on the other side.
30. Install the speed sensor.
31. Fasten the rear axle carrier assembly.
32. Fasten the left rear shock absorber assembly.
Torque: 107.8～156.8 N.m
33.Fasten the right rear shock absorber
assembly.
Torque: 107.8～156.8 N.m
Tips:
Conduct the same operation on the other side.
34. Deflate the brake tube (referring to the
Brake Section).
35. Install the rear wheels.
Torque：88～118N.m
36. Check the rear wheel alignment.
37. Check the signal of the ABS sensor.

08-34
 09-Steering System

Steering system

Notes ..............................................................................................................................................1
Failure symptoms table ..................................................................................................................2
On-Vehicle Inspection ...................................................................................................................3
Steering Column Assembly ...........................................................................................................4
Maintenance ...................................................................................................................................6
Inspection .....................................................................................................................................14
Steering Tie Rod ..........................................................................................................................15
Section 2 Vehicle Electrical Power Steering................................................................................26
Maintenance .................................................................................................................................35
 09-Steering System

Notes

1. Notes on the steering system

Care must be taken when replacing parts. Incorrect replacement may affect the performance of
steering system and may lead to driving accidents
2. Notes on SRS (supplemental restraint system)
(a)The vehicle is equipped with SRS (supplemental restraint system) such as driver's air bag. Failure
to carry out service operation in the correct sequence may cause the air bag to unexpectedly deploy during
servicing, possibly leading to a serious accident. Before servicing (including removal or installation of
parts, inspection or replacement), be sure to read the notes of the supplemental restraint system.

09-1
09-Steering System

Failure symptoms table

Hint：

The following table will help to find the causes of the failures. The numbers in the table indicate
the possible failures and the part-checking order. Check each part in order, and replace them if
necessary

Symptom Possible cause

1．Tires (Improperly inflated)
2．Front wheel alignment (Incorrect)
Hard steering
3．Steering ball joint (Worn)
4． Suspension arm ball joint (Worn)
5． Steering column (Locked)
6．Rack and pinion steering gear assembly
7．Electronic power steering system failure
1．Tires (Improperly inflated)
2．Front wheel alignment (Incorrect)
Poor return
3．Steering column (Locked)
4．Rack and pinion steering gear assembly
1．Steering system ball joint (Worn)
2．Suspension arm ball joint (Worn)
Excessive play
3．Front wheel bearing(Worn)
4．Rack and pinion steering gear assembly
1．Steering system ball joint (Worn)
2．Rack and pinion steering gear assembly
Abnormal noise
3．Electronic power steering system motor
4. Steering coupler

09-2
 09-Steering System

Section 1 Manual steering system

On-Vehicle Inspection
1. Check steering wheel free play.
（a）Stop the vehicle and face the tires straight
ahead.
（b）Rock the steering wheel gently, check the
steering wheel free play.
Maximum free play：1～10mm

09-3
09-Steering System

Steering Column Assembly

Components

09-4
 09-Steering System

Main Structure

09-5
09-Steering System

Maintenance
Removal
Step 1: Removal
1. Disconnect battery negative (-) terminal .
2. Confirm front wheels facing straight ahead.
3. Remove horn button assembly
Notes：
● If the air bag connector is disconnected with
ignition switch being at ON，DTCs will be recorded

4. Hold the bottom of the steering wheel cover,

then pull toward arms, remove the steering
wheel cover, disconnect the harness plug
5. Using a screwdriver, release the lock part of
the air bag connector, then remove the air bag
connector.
（a） Using a trod socket wrench, loosen the two
trod screws until the groove along the screw
circumference catches on the screw case.
（b）Pull out the horn button assembly from the
steering wheel.
（c）Using a screwdriver ,release the lock part of the
air bag connector, remove the air bag connector.
Notes：
●When removing the horn button assembly, pay
attention not to pull the air bag wire harness

09-6
 09-Steering System

Caution
◆When placing the horn button assembly ，ensure
the upper surface faces upward.
◆Do not disassemble the horn button assembly.

6 Remove the lock nut of steering wheel

7. Remove the steering wheel assembly

（a）Disconnect the connector
（b）Remove the steering wheel set nut.
（c）Place a match mark on the steering wheel
assembly and main shaft assembly SST-FT9012401

8. Remove the steering column lower cover

（a）Remove the three screws and the steering
column upper cover and steering column lower
cover
9. Remove the spiral cable assembly
Notes：
● Do not start the operation for 90 seconds after
removing the battery terminal
（a）Turn the cable reel counterclockwise until it
becomes difficult to turn.
Then rotate the cable approximately 2.5 turns
clockwise to align the marks.
Hint：
■The cable reel will rotate 2.5 turns to either right or
left of the center.
10. Remove the headlight dimmer switch
assembly.
（ a ） Disconnect the connector and remove the
headlight dimmer switch assembly.

11. Remove the windshield wiper switch

assembly

09-7
09-Steering System

(1)Disconnect the connector and remove the

windshield wiper switch assembly

12. Remove the steering column hole cover

13．Disconnect the steering intermediate shaft
assembly
（a）Place match marks on the universal joint and
intermediate shaft.
（ b ） Loosen the bolts, then disconnect the
intermediate shaft.

14. Remove steering column assembly

（ a ） Disconnect the wire harness clips of the
connector box from the steering column assembly
（b）Remove the three bolts and steering column
assembly.

15. Remove steering column upper switch

bracket.
（a） Using a centering punch, mark the center of
the two tapered-head bolts
（b）Using a 3 ~ 4mm drill, drill into the two bolts
（c）Using a screw extractor, remove two bolts and
the steering column upper switch bracket.

16. Remove the steering column upper clamp

plate.
17. Remove ignition switch lock cylinder
assembly.
（a）Turn the ignition switch to the ACC position.
（b）Press the retaining pin with a screw extractor,
pull out the lock cylinder assembly

18. Remove ignition or starter switch assembly

（ a ） Remove the two screws and remove the
ignition or starter switch assembly from the steering
column bracket.

09-8
 09-Steering System

Step 2 Installation

1. Install the ignition or starter switch assembly

（a）Install ignition or starter switch assembly to the
steering column bracket with the two screws

2. Install the lock cylinder assembly of ignition

switch
（ a ） Ensure the ignition switch is at the ACC
position.
（b）Install the lock cylinder assembly of ignition
switch.

3. Check the operation of steering lock

（a）Check that the steering lock mechanism stops
when pulling out the key.
（ b ） Check that the steering lock mechanism
locking is relieved when inserting the key and
turning it to the ACC position.

4. Install the steering column upper switch

bracket.
（a）Temporarily install the steering column upper
switch bracket assembly and steering column upper
clamp with two new tapered-head bolts.
（b）Tighten the two bolts until the bolt heads break
off.

5. Install steering intermediate shaft assembly

No.2.
（a）Align the match marks on the intermediate
shaft and the main shaft
（b）Install the intermediate shaft with screws

6. Install steering column assembly.

（a）Install the steering column assembly with 3
bolts
（b）Connect the connectors and the wire harness
clips

09-9
09-Steering System

09-10
 09-Steering System

7. Connect the intermediate shaft assembly

No.2.
（a）Align the match marks on the intermediate
shaft and universal joint
（b）Install the bolts and tighten them

8. Install the steering column hole cover.

9. Install windshield wiper switch

Install the windshield wiper switch assembly and
connect the connectors

10．Install headlight dimmer switch assembly.

Install the headlight dimmer switch assembly and
connect the connectors

11．Place front wheels facing straight ahead.

12Install spiral cable
13．Check the operation of key interlock.
14. Install the steering column upper cover
15. Center the spiral cable
（a）Check that the ignition switch is at OFF
（b）Check that the battery negative terminal is
disconnected
Hint：

09-11
09-Steering System

■Confirm the turns according to the figure marked

on the cable reel (the mark is 5 as shown in the
figure). Rotate 2.5 turns to either right or left of the
center to align the marks.

16．Install steering wheel assembly

（a）Align the match mark with the one on the
steering wheel assembly and steering main shaft
assembly.
（b）Install the steering wheel with the set nut.
（c）Connect the connector.

17．Inspect horn button assembly.

18．Install horn button assembly.

Notes：
● Do not use the air bag parts removed from another
vehicle. When replacing parts, replace with new
ones.
● Make sure that the horn button assembly is
installed to the specified torque.
●If the horn button assembly has been dropped, or
there are cracks, dents or other defects in the case or
connector, replace the horn button assembly with a
new one.
●When installing the horn button assembly, take
care so that the wires do not interfere with other
parts and that they are not pinched between other
parts.

（a）Connect the air bag connectors.

（b）Install the horn button after confirming that the
circumference groove of the tort screws is caught on
the screw case.
（c）Using a torque wrench to install two tort screws

09-12
 09-Steering System

19. Center steering wheel.

20. Inspect SRS warning light
Inspect SRS warning light
Turn the ignition switch ON，confirm that the SRS
warning light lights up. After the light staying on for
six seconds, confirm that the warning light goes out.
Diagnostic test is also needed.

09-13
09-Steering System

Inspection

Inspect the following parts and items in the figure:

Install combination switch on the steering column

09-14
 09-Steering System

Steering Tie Rod

Failure Symptoms Table

symptom possible cause

1．Dust cover (worn, damaged, deteriorated）
Hard steering 2．Steering rack dust cover clamp(aging ）
3．Suspension arm ball joint (worn or damaged)
1．Steering rack clamp（loosen, aging）
2．Steering rack locknut (damaged)
Poor return 3．Rack case rubber gasket( aging, worn)
4．Steering rack (worn or damaged)
5．Steering rack ends (worn or damaged)
1．Steering system ball stud (excessive opening)
2．Guide block sub-assembly(worn or damaged)
Excessive play
3．Steering ball joint (worn and damaged)
4．Suspension arm ball joint (worn)
1．Steering system ball joint (worn and damaged)
Abnormal noise
2．Rack and pinion steering gear(worn or damaged)

09-15
09-Steering System

Configuration

09-16
 09-Steering System

Removal
1. Lift the vehicle
2. Remove front wheels.
3.Remove steering column hole dust cover
sub-assembly.
（a）Remove the four bolts

4. Remove universal joint of steering shaft

（a）Remove the bolts
（b） Remove the universal joint

5. Remove end of steering tie rod

（a）Remove the cotter pin and castle nut
（ b ） Remove the end of steering tie rod from
steering knuckle arm with special service tool
SST-FT9012106
6. Remove steering assembly
（a）Remove the four set bolts of the rack housing
clip.

（b）Remove the steering assembly from the vehicle

7. Remove steering case.

8. Remove steering tie rod end sub-assembly

（ a ） Make a mark on the steering rack end
sub-assembly before removal for reassembling.
（b）Loosen the lock nut. Remove the steering tie
rod end sub-assembly.

9. Remove dust cover lock spring and dust cover

clamp; remove dust cover of steering rack.

09-17
09-Steering System

10. Remove steering rack end sub-assembly

（a）Using the flat sections of the steering rack
(width 19mm) and the flat sections of the steering
rack end nut (width 26mm), release the end nuts of
the steering rack.
（b）Remove the steering rack end assembly from
the steering rack end.
（c）Remove the steering rack end nuts from the
steering rack end.

11.Remove the lock nut (hexagon nut) with

steering adjustment tool ：SST-FT9012104

12. Remove guide nuts of compression spring.

（a）Remove the guide nuts of the compression
spring with a wrench (17mm).
（b）Remove the compression spring and a guide
block sub-assembly from the steering rack housing
assembly with the SST-FT9012105

13. Remove steering rack

（a）Draw out the rack towards the housing side to
prevent bushing from being scratched.
（b）Draw out the rack straight, never rotate the
rack.

09-18
 09-Steering System

14. Using ordinary screwdriver or the like,

remove the oil seal. Do not scratch the housing
when removing,

15. Remove snap rings with internal snap ring

pliers.

16. Remove steering pinion and bearing from

steering rack housing.
17. Remove radial ball bearing.
（a）Remove the shaft snap ring with external snap
ring pliers
（b）Check the bearing pinion, if it is damaged,
replace with a new one.

09-19
09-Steering System

Inspection

Check the following parts and items in the figure:

09-20
 09-Steering System

Assembly

1. Coat with grease on the following parts in the figure .

09-21
09-Steering System

2. Assemble radial ball bearing.

（a）Install the bearing to the pinion with special
service tool(SST).
（b）Install the shaft snap ring with external snap
ring pliers.

3. Install steering pinion.

（ a ） Install the steering pinion into the rack
housing with special service tool (SST).

（b）Install the snap ring with internal snap ring

pliers
（c）Install the oil seal into the rack housing with
special service tool (SST).

4. Assemble the steering rack

（a）Coat with lithium base grease No. 2 on the
tooth surface and whole peripheral portion of the
steering rack.
（b）Install the steering rack, be careful not to
scratch the rack bushing.

5. Install guide block sub-assembly to rack

housing, compression spring and compression
spring guide nut.
6. Adjust rack pre-load.
（a）Torque the compression spring guide nuts with
a homemade wrench.
（b）Move the steering rack back and forth about 15
times to stabilize the rack. Then torque the
compression spring guide nuts.
（c）Back off the compression spring guide nut
45° + 100°° with wrench
（d）Measure the pre-load of rack with special
service tool (SST).
（e）Repeat the operation(1) to (4) until the pre-load
is within the specification.
09-22
 09-Steering System

7. Assemble hexagon nuts (lock nut)

（a）Torque the lock nut with special service tool
(SST) when holding the compression spring guide
nut with homemade wrench so as to prevent
compression spring guide nut from rotating.
（b）Recheck the beginning torque of the pinion.
Notes：
●Actual reading of the torque wrench is the
tightening torque value given above multiplying the
coefficient.
Coefficient=Torque wrench length/Torque
wrench length+6mm
End nut Torque wrench reading=Torque×Coefficient

8. Assemble steering rack end sub-assembly

（ a ） Screw the steering rack end nut into the
steering rack end (When installing the steering rack
end nut, make the bigger flange come to the rack end
side).
（b）Screw the steering rack end sub-assembly into
the steering rack.
（c）Fix the steering rack, and tighten the steering
rack end nut.

9. Install dust cover of steering rack. Install dust

cover lock spring and dust cover clamp.
10. Install the left and right clips, dust cover
clamp, and dust cover
(a) Clamp the dust cover clamp with pliers.
(b) Fix the clip, dust cover clamp and dust cover.
Notes：
Be careful not to damage the dust cover
Hint：
■Mark the left and right dust cover
(c) Use the same manner to the other side.

11. Install steering tie rod end sub-assembly

（a）Screw the lock nut and the steering tie rod end
sub-assembly to the steering rack end sub-assembly
up to the mark. Temporarily torque the lock nut.
（b）After adjusting toe-in, torque the lock nut

09-23
09-Steering System

Installation
1. Install steering assembly
（ a ） Install the rack housing grommet on the
steering tie rod assembly. Then insert it to the
vehicle.
Notes：
● Do not scratch the steering rack dust cover during
insertion.
（b）Install the steering shaft universal joint on the
pinion. Torque the bolts temporarily.
（c）Install the steering tie rod assembly to the body.

（d） Install the mechanical steering assembly to

the front suspension beam with four bolts and nut.,

2. Tighten fastening screw of the steering shaft

universal joint assembly
Notes：
●When tightening the bolt ，make sure that the
exposed length between the pinion spine and the
universal joint is 5mm

09-24
 09-Steering System

3. Install steering tie rod end

（a）Insert the ball stud rod of the steering tie rod
end sub-assembly into the steering knuckle arm,
tighten the castle nuts
（b）Install a new cotter pin

4. Install wheels, and Jack down the vehicle.

5. Check the free play of steering wheel.
6. Adjust toe-in
7. Check the straight-ahead position of steering
wheel

09-25
09-Steering System

Section 2 Vehicle Electrical Power Steering

Chapter 1 Summary

Vehicle electrical power steering is the next-generation electro-mechanical power steering system. It
consists of EPS controller, torque sensor, motor assembly and mechanical column. The principle of
vehicle electrical power steering is that EPS controller determines the magnitude and direction of the
motor steering power according to a certain algorithm with the torque sensor, velocity sensor, engine
rotation speed sensor and so on and then drives the motor to assist the steering system to produce steering
operation through a gear reduction device .

09-26
 09-Steering System

With airbag

09-27
09-Steering System

Main structure

09-28
 09-Steering System

1. EPS controller

EPS controller is installed under the driver dashboard. EPS controller is a precise control component
which is composed of the microcomputer, A / D (analog / digital) converter, I / O(input / output)
interface ,etc..
It is a critical component of vehicle electrical power steering system, which determines the vehicle's
best operating function under various conditions, but also has self-diagnosis and fail-safe function
Self-diagnosis function
When the driver has turned on the vehicle power, "EPS" indicator is always on (indicate that the
vehicle is equipped with electrical power steering system).During the process that the driver starts the
engine, EPS controller carries out self-diagnosis for the following components. When there is no
malfunction for the following components, EPS indicator turns off automatically; when the following
components fail, EPS light is always on or flashing. Then we can diagnose the fault by connecting the
diagnosis I/O terminal B1 to the negative of the power (battery) . The failure codes are shown in the failure
codes table
 Torque sensor
 Velocity sensor
 Engine rotation speed sensor
 Circuit
 Power
 Battery
 Motor
 EPS controller

Notes：

When the ignition switch is turned on and the engine stops working, EPS controller will output
DTC22 failure code. Therefore, when inspecting the DTC22 failure code, the engine must start, and then
the DTC22 failure code disappears automatically.
Fail-safe functions
When the EPS system is abnormal, EPS controller will cut off the EPS system power, automatically
convert to mechanical steering system without power assistance with the EPS indicator light is always on

09-29
09-Steering System

(or flashing)
● Steering column assembly
●Motor
The motor assembly mounted on the steering column consists of a worm, a worm wheel and a DC
motor. When the worm and the worm wheel installed on the output shaft of steering column mesh together,
it reduces the motor speed and delivers the motor output torque to the output shaft

●Torque sensor
Torque sensor consists of slip block, steel ball, input and output shafts and potentiometer. It receives
the quantity and direction signal of operating torque on the steering wheel and converts them into voltage
value, and passes them to the P / S control box.
There is a torque rod inter hole of the output shaft connecting the torque rod via pin. There is a spiral
groove on the cylindrical surface of the output shaft. Steel ball is fixed in ball hole between the spiral
groove on the outer face of the output shaft and the inter face of the slider. The slider, relative to the input
shaft , slides in the spiral direction. When turning the steering wheel, the torque is passed to the torque rod
by the input shaft. As the torque rod is an elastic shaft, an angle displacement takes place between the
torque and the output shaft , which produces an angle displacement in rotation direction between the input
shaft and output shafts and also a displacement of slider in the axial direction. These biases make the slider
move in the axial direction, these axial movements is converted to rotation angle of potentiometer, then
converted to voltage signal and passed to the P / S controller. The controller receives the quantity and
direction signal of the operation torque on the steering wheel.

09-30
 09-Steering System

Connection position of the sensor, input and output shafts

3 VSS (vehicle velocity sensor)

Vehicle velocity sensor is placed on the transmission (or other components). It produces pulse
signals relative to the vehicle velocity. .

4 Engine speed signal

The ignition coil signal (or electrical injection ECU signal), is taken as the engine speed signal.
Failure Code Diagnosis
1 Display the diagnostic trouble code (DTC)
1）Connect the diagnosis terminal B2 to the power (battery) negative terminal with maintenance
wires.
2）Chock the left and right wheels (tire) and lift the parking brake.
3）Start engine (If engine does not start, DTC22 will be shown).
4）EPS indicator begins to indicate all failure codes. The failure code (DTC) are always displayed
orderly from the smallest code. Each code is displayed 3 times
2 Clear the diagnostic trouble code (DTC)
●The diagnostic trouble codes (DTC) is stored in backup memory of the EPS controller, so after
maintenance, when ignition and engine start and operate normally, connect the B1 terminal to negative
terminal of power (battery) with maintenance wires for 5 seconds or more. When DTC12 is indicated,
disconnect the wires
3 Notes in failure diagnosing
[Notes in identifying the diagnostic trouble codes]
09-31
09-Steering System

●Never connect the positive terminal of power (battery) to B1, B2 terminals.

●When the ignition switch is turned on while engine does not start, DTC22 is indicated ( no engine
velocity signal).But when engine starts and DTC22 is not indicated which means normality.
●Write down the failure code that is shown
4 .Diagnosis flow chart

Step Operation YES NO

1）Make sure battery voltage is Proceed to

greater than 11V or higher. Step 2
2）When the ignition switch is Proceed to Figure A-1 in page 8.
turned on, pay attention to "EPS" ("Inspection of EPS indicator
1
light. circuit ")
3）when the ignition switch is turned
on, is "EPS" light on for about 2
seconds
1）Connect both diagnosis terminals Proceed to
with connection line. step 3
Proceed to Figure A-2 in page 8
2）Check the wheels, and put M / T
("Inspection of EPS indicator
2 to the middle (A / T to P gear) and lift
circuit ")
the parking brake.
3）Start the engine.
4）Dose "EPS" light flash?
Check and repair according to
3 Dose "EPS"" light display DTC12?
the flowchart corresponding code.

09-32
 09-Steering System

Warning：

Once the inspection and maintenance are completed, check the system according to the following
steps.
1）When ignition and engine start and operate normally , connect the B1 terminal to negative
terminal of power (battery) with maintenance wires for 5 seconds or more. When DTC12 is displayed,
disconnect it to clear the diagnostic trouble code stored in EPS controller.
2）Take the specified test.
3）Chock the wheels and set the M / T to the middle (A / T to P gear)
4）Connect the B2 terminal to the negative terminal of power (battery) with maintenance wires
5）Start engine and the "EPS" light.
6）Check the displayed diagnostic trouble code is DTC12

Notes：

●When the ignition switch is at the ON and the engine does not start, DTC22 will be shown. But
when engine starts, DTC12 will be shown which means normality.
●When there are two or more failures, the diagnosis trouble code always display orderly from the
smallest code.

Conclusion

EPS controller electrical circuit board has the self-diagnostic function. When each simulating failure
occurs, EPS controller electrical circuit board should stop working, that means the motor, electromagnetic
clutch, the relay are in the open state and EPS light is always on. Turn on the self-diagnosis switch, and the
corresponding DTC shows.
1. When engine signal frequency is less than 13Hz or more than 500Hz, DTC25 displayed.
2. When engine signal is zero, DTC22 is displayed.
3. When the clutch is at open or short circuit, DTC51 is displayed. (Only for the DFL-01 type)
4. When battery voltage is less than 8V, DTC54 will be displayed.
5. When the increasing circuit is not normal, that means there is no increasing voltage, DTC55 is
displayed.
09-33
09-Steering System

6. When the operating voltage of the sensor is abnormal, that is the voltage is too high or too low,
DTC14 is displayed.
7. When the main sensor circuit is open or short, DTC11 is displayed.
8.When the sensor auxiliary circuit is open or short, DTC15 is displayed.
9. When the output between sensor main circuit and auxiliary circuit differ significantly, DTC13 is
displayed.
10. When the voltage on both ends of the DC motor is too high or too low, DTC41is displayed.
11. When the actual current on both ends of the DC motor is too high, DTC42 is display coded.
12. When the actual current on both ends of DC motor is too low, DTC45 is displayed. When the
vehicle signal is open during running , DTC24 is displayed.

09-34
 09-Steering System

Maintenance
(Steps of removing the steering column upper and
lower cover, airbag, steering wheel, spiral cable,
light switch, windshield wiper switch, please refer
to last chapter in this section)
1. Remove the fixing screws (self-tapping screws)
of the steering wheel cover and open the steering
wheel cover.
2. Disconnect the horn button wire harness
connector
3. Remove the steering wheel Lock nut
4. Remove the steering wheel (with special
service tools)
5. Remove the lower panel of dashboard (two
self- tapping screws)
6. Remove the lower steering column cover (five
self-tapping screws)
7. Remove the reinforcement of dashboard (two
self - tapping screws)
8. Remove two interior fuse boxes (three bolts)
9. Disconnect the combination switch plugs
(three)
10. Remove the ignition switch plug. Disconnect
EPS (three plugs)
11. Disassemble two fuse box brackets (two
bolts)
12. Disassemble EPS, ECU bracket (two bolts)
Remove the EPS controller.
13. Remove the upper steering column fixing
board (two bolts)
14. Remove two bolts on combination switch.
15. Remove the upper steering column cover.
16. Remove the bolts on the shaft connector.

09-35
09-Steering System

17. Remove the nuts on the lower fixing board of

the steering column ( two nuts)

18. Remove the steering column assembly

19. Disassemble motor.

(a) Disassembly: motor and speed reduction worm
are connected by spine.
Loosen the screws connecting the motor and the
case to remove the motor.

(b) Installation: In order to ensure the motor shaft

and worm are coaxial and the motor is in good
working state, rotate the screws in place by hand
before tightening the motor screws. Turn the
steering wheel with the right hand and hold the
motor with the left hand to check whether the motor
swings. If the motor does not swing, tighten the
screws; if it swings, adjust the motor until it stops
swinging and fasten it. If adjustment can not be
finished, replace the motor, then repeat the operation
above.
09-36
 09-Steering System

The tightening torque of motor screws is 20～

30N.m 。

20．Disassemble torque sensor.

(a) Removal
（1）Remove the protective cover bolts of torque
sensor
Remove the protective cover of torque sensor
（2）Loosen the fixing screws of the sensor;

（3）Remove the torque sensor

(b) Installation
Put the sensor into EPS mounting hole. put the
rocker bearing of the sensor into the slider mounting
installation groove. Install adjustment screws.

(c) Adjustment
Connect one terminal of millimeter to the main
circuit (white wire C5) of sensor plug, and the other
to the ground. Check whether the main circuit
voltage of the sensor is 2.5 ± 0.05V. If not, loosen
the fixing screws of sensor, and tap the sensor gently.
Adjust the main circuit voltage of the sensor to
voltage of return to 2.5 ± 0.05V
The symmetry specification of the two - way output
is shown in the right figure:
Output voltage（V）：
Main circuitC5 4.17× (1±4 %) V
Auxiliary circuitC4 0.83× (1±4 %) V
When operating voltage C2 is +5 × (1 ± 0.1%) V, the
intersection point voltage of the main circuit and the
auxiliary circuit output should be 2.5 × (1 ± 4%) V.
At any other position, a voltage of V A8 + V A10 =
5 × (1 ± 4%) V should be satisfied.
Suggestions: Before re-adjusting the sensor
potential, remove the sensor, and turn the slider to
another angle.
Notes
1 ） When adjusting the potentiometer, any force
should not be applied on the steering wheel.
2）When tightening the sensor ,the tightening torque
is 6～7N.m.

09-37
09-Steering System

After tightening the sensor, inject sealant into the

kidney-shaped groove to prevent the sensor from
loosening.

21 ． Installation requirements of the lower

transmission shaft and the steering column
assembly
In order to achieve the best performance of
electrical power steering assembly, the installation
steps of the lower transmission combination are as
followings:
(a) Align the bearing seat with the yellow mark on
double nut according to the figure.
(b) Align the open groove on the universal joint fork
with the yellow mark.
(c) Tighten the washer screws with a torque wrench.
Tightening torque：22.7～34N·m。

09-38
 09-Steering System

Other Mechanical Inspection

1. Inspect the steering wheel free play

Move the steering wheel in the axial direction and the horizontal direction to check whether the
steering wheel is loosen or clicking.
If there is any fault, repair or replace it.
Check the steering wheel when the engine stops and the vehicle is fixed on the ground with the wheel
facing ahead.
The range of steering wheel free play is 1 ~ 10mm.
If the steering wheel moves out of the specified range of free play, check the steering wheel as
following. If there is any failure, replace it
● Check the steering tie rod end ball for wear.
● Check the lower ball end stud for wear.
● Check the steering shaft end for wear.
● Check the steering pinion or pinion and rack for wear and crack .
● Check any other component for looseness.

2. Steering torque inspection

1）Park the vehicle on the level road with steering wheel straight ahead.
2）Check whether the tire inflation pressure meets the requirements (see Tire instructions).
3）Start the engine and at idle running condition.
4）Measure the steering torque in two directions. Steering torque (Reference) is less than 7N.m

Hint: Consider the tire type, pressure and contact surface before judgment.

09-39
09-Steering System

09-40
 09-Steering System

Ordinary EPS failure analysis and troubleshooting

1 Abnormal noise

Reason: Steering noise is abnormal

Troubleshooting: Replace motor

2 Displacement

Reasons: The mechanical friction leads to the sensor potential offsetting the designed value.
Troubleshooting: Adjust it according to the adjustment methods of torque sensor.

3 Failure

Connect the diagnosis switch (Terminal B2) to the ground. "EPS" indicator flashes. P / S controller
box outputs the trouble code.

Trouble code Reason Troubleshooting

41；42；43；44；45；51 Motor failure Replace the motor

11；13；14；15 Sensor failure Replace the sensor

52；54；55 Controller failure Replace the controller

No engine speed signal Check whether there is signal on the

22
input speed signal line. If not, connect it well.
Check whether there is vehicle velocity
21；23；24 No speed signal input
signal. If not, connect it well.

09-41
 10-Transmission

Transmission

Manual transmission....................................................................................................................... 1

Transmission（A M T ）..................................................................................................................25
10-Transmission

Manual Transmission

Manual transmission.................................................................................................................. 2
Transmission gear oil................................................................................................................. 4
Transmission control cable assembly......................................................................................... 5
Transmission case seal............................................................................................................ 21

10-1
 10-Transmission

Manual Transmission (MT)

Operation Methods and Cautions

To bring your automobile and transmission case into the best performance, the following suggestions
should be taken closely.：
1、When in use, a regular examination of the clutch pedal travel is necessary to guarantee a full
separation and engagement so as to maintain the transmission case performance and synchronizer's life..
2、When in use, try to keep the vehicle travel at upper gears to maintain an economic crankshaft
revolution speed so as to maximize fuel efficiency.
3、Drive smoothly. Jabbing the accelerator and then hitting the brake pedal wastes fuel and may
damage the automobile.
4、When shifting, depress the clutch pedal to the end and then shift into the adjacent gear so as to
maintain the transmission case's shifting performance and synchronizer‘s life.
5、Shift the gear into reverse after the car has come to a stop to avoid damaging the gear sleeve,
reverse gear, and related parts.

10-2
 10-Transmission

Manual Transmission

Malfunction Table

The following table indicates the possible causes of problems. The

possibility of the causes is numbered in descending order, Inspect the

following parts. Replace the disabled ones.

Problems Diagnosis
1.Oil (oil level is low)
2.Oil (use error)
Noise
3.Gear (wear or damage)
4.Bearing (wear or damage)
1.Oil (oil level is high)
2.Pad (damage)
Oil leakage
3.Seal (wear or damage)
4.O-ring (wear or damage)
1.Control cable (failure)
shifting difficulty or shifting failure 2.Synchronizer lock ring (wear or damage)
3.Shift spine spring (damage)
1. Lock ball spring (damage)
2. shift fork (damage)
out of gear
3. Gear (wear or damage)
4. Bearing (wear or damage)

10-3
10-Transmission

Transmission Gear Oil

Vehicle Inspection

1.Check the transmission gear oil.

（a）P ark the vehicle on a flat surface.
（b）Remove the manual plug and gasket.
（c）The oil level should be under the lower edge
of the pouring orifice within 5mm.
Note：
● Both excessive and inadequate oil may cause
failure.
● Drive the vehicle after oil changing to check the
oil level

（d）Check the transmission gear oil to see whether

it leaks in the case that the oil level is too low.
（e）Install the manual plug and a new gasket.
Torque：30～50N•m

10-4
 10-Transmission

Transmission Control Cable Assembly

Replacement

1.Remove the shift lever handle.

2.Remove the cover of the shift lever hole.

3.Remove the rear console box.

4 ． Remove the transmission control cable

assembly.
（ a ） Remove the transmission control cable
assembly after disengaging the two jaws.

（b）Remove the two clips and two gaskets and

disengage the two cables from the transmission.
（c）Remove the two clips, disengage the two
cables from the bracket.

10-5
10-Transmission

（d）Remove the two bolts.

（e）Disassemble the retainer from the control
cable.
（f）Pull out the control cable from the body.

5. Install the transmission control cable

assembly.
（a）Install the retainer on the control cable.
（b）Push the control cable of the transmission into
the floor.
（c）Install the transmission control cable assembly
with two bolts.

（d）Connect the ends of the two cables and install

the two gaskets and two clips.
（e）Install two new clips on the cable bracket.

（f）Connect the control cable to the shift lever.

Note：
● Ensure that the jaws bite firmly.

6. Install the rear console box.

10-6
 10-Transmission

7. Install the cover of the shift lever hole.

8. Install the shift lever handle.

10-7
10-Transmission

Shift Lever Assembly

Components

10-8
 10-Transmission

Replacement

1.Remove the shift lever handle.

2.Remove the cover of the shift lever hole.
3.Remove the rear console box.
4.Remove the transmission control cable
assembly.
（a）Remove the two clips and separate the ends of
the transmission control cables

（ b ） Disengage the jaws and separate the

transmission control cables.

5. Remove the shift lever assembly.

（a）Loosen the four bolts and remove the shift
lever assembly.

6. Install the shift lever assembly.

(a)Install the shift lever assembly with the four bolt

10-9
10-Transmission

7. Assemble the transmission control cable

assembly.
（a）Connect the transmission control cable to the
shift lever assembly.
Note：
● Ensure that the hooks clamp firmly.

8. Install the rear console box.

9. Install the cover of the shift lever hole.
10.Install the shift lever handle.

10-10
 10-Transmission

Manual Transmission Assembly

Components

10-11
10-Transmission

Replacement

Removal
1. Remove the engine hood.
2. Remove the battery.
3. Remove the battery carrier.
4. Disconnect the following wires.
a) Starter wire
b) Transmission bond strap

5. Remove the starter assembly.

a）Remove the nuts and disconnect the starter
harness.
b) Disengage the connectors.
c) Remove the bolts and starter.

6.Remove the clutch slave cylinder assembly.

Remove the five bolts and separate the clutch slave
cylinder with oil tube from the manual transmission

7.Remove the transmission control cable

assembly.
（a）Remove the two clips and gaskets, disengage
the two cables from the transmission.
（b）Remove the two clips and disengage the two
cables from the cable bracket.
8．Disengage the wire connectors of the back-up
Light switch.

10-12
 10-Transmission

9．Disengage the wire connectors of the speed

sensor.
10. Remove the forepart of the exhaust pipe.

11. Drain the transmission gear oil.

（a）Remove the manual plug and gaskets.
（b）Remove the oil drain plug and gaskets and
drain the manual transmission gear oil.
（c）Install new gaskets and oil drain plug.
Torque：39N•m
12. Remove the front wheel

13. Remove the hub nuts of the left and right

front wheels.

10-13
10-Transmission

14. Remove the left and right front speed

sensors.

15. Remove the front stabilizer bars.

16. Remove the left and right ball head tension
rods.

17. Remove the left and right lower armarm No.

1.
18. Remove the left and right front shaft
assemblies.
19. Remove the left one.

20. Support the engine assembly with a lifting

device.
21. Support the beam of the front suspension.
(a) Jack up the beam of the front suspension.

22. Separate the rubber engine mount.

（a）Remove the bolt and disengage the rubber
engine mount from the right front bracket of the
engine.

23. Remove the front suspension cross member.

（a）Remove the six bolts and disengage the front
suspension cross member.

10-14
 10-Transmission

24. Support the manual transmission.

(a) Support the transmission assembly with a
transmission jack.

25. Disengage the engine bracket.

（b）Remove the three bolts, Disengage the right
rear engine bracket.

26. Remove the attaching bolts of the transmission

assembly.
Note：Be sure to leave the one bolt located at the
front central part NOT loosened (See arrow).

27. Remove the manual transmission assembly.

（a）Remove the seven bolts and disassemble the
manual transmission from the engine.

28. Remove the engine bracket.

（a）Remove the two bolts and detach the right rear
engine bracket from the manual transmission
assembly.

10-15
10-Transmission

Installation

1.Install the transmission assembly on the

engine as follows
（a）Ensure that the clutch disc is centered in
position, using the SST given below:
Special Service Tool ：SST FT9066401

（b）Align the input shaft and clutch disc, install

the manual transmission to the engine.
Note: Be aware NOT to damage the clutch disc
assembly.
Temporarily tighten the attaching bolts.
（c）Tighten the transmission assembly attaching
bolts securely.
Bolt A：54～74 N•m
Bolt B：39～53 N•m
Bolt C：9～29 N•m
2. Install the engine mounting bracket.
（a）Install the right rear engine mounting bracket
on the manual transmission with three bolts.
Torque：39.2～58.8N•m

3. Link the engine mounting bracket.

（a）Install the left engine bracket on the propeller
shaft with three bolts.
Torque：51.2～76.8N•m

10-16
 10-Transmission

4. Install the beam of the front suspension.

（a）Install the front suspension cross member with
six bolts.
front suspension cross member sub-assembly ×
body front side
56～84N•m
front suspension cross member sub-assembly ×
body backside
40～60N •m
front suspension cross member sub-assembly ×
rear bush
105.6～158.4N •m
5. Install the rubber engine mount of the engine
（a）Install the right rear rubber engine mount to
the right rear bracket
Torque：51.2～76.8N•m

6. Install the starter assembly.

（a）Install the starter to the transmission with two
bolts.
（b）Connect the connectors of the starter.
（c）Install the wire and nuts to the starter.
Torque：9.8～15.7N•m

7. Install the left and right front drive shaft

assembly.
Torque：170～230 N·m。

10-17
10-Transmission

8．Connect the left and right lower arms No. 1.

9. Assemble the left and right ball head tension

rods.
10. Connect the front stabilizer bar.
11. Install the nuts of the left and right front
shaft.
Torque：170～230 N·m。

12. Install the forepart of the exhaust pipe.

13. Connect the speed sensor.
（a）Connect the speedometer sensor connector.

14. Connect the connectors.

（a）Connect the connectors of the back-up light
switch.

15. Connect the transmission control cable

assembly.
（a）Connect the ends of the two cables. Install the
gaskets and clips.
（b）Install the two new clips to the cable bracket.

10-18
 10-Transmission

16. Install the clutch slave cylinder assembly.

（a）Install the clutch slave cylinder with five bolts.

17. Install the battery.

18. Install the engine hood assembly.
19. Check and adjust the engine hood assembly.
20. Check and fill the transmission gear oil.
21. Install the left engine under cover.
22. Install the front wheel.
Torque：88～118N•m
23 Check and adjust the front wheel alignment.
24. Check the ABS signal.

10-19
10-Transmission

Speed Sensor

Replacement

1. Disengage the speed sensor.

（a）Disengage the speed sensor.

2. Disassemble the speed sensor.

（a）Remove the nuts and the speed sensor.
（b）Remove the clamps and driven gear from the
speed sensor.

3 .Install the speed sensor.

（a）Apply transmission gear oil on the new
O-ring , and install it on the speed sensor.
（b）Attach the driven gear to the speed sensor
with clamps.
（c）Tighten the speed sensor with bolts.

4. Connect the speed sensor.

（a）Connect the connectors of the speed sensor.

10-20
 10-Transmission

Transmission Housing Seal

Replacement

1 Drain the transmission gear oil.

2 Remove the right front wheel.
3 Remove the engine under cover RH.
4 Remove the hub nuts of the front wheel.
5 Disengage the right front speed sensor.
6 Disengage the front stabilizer bar.
7 Disengage the ball head tension rod RH.
8 Disengage the right front lower arm.
9 Disengage the right front shaft.
Tip：
■ The right-hand shaft can be disengaged referring
to the same procedure with the left-hand shaft.

10. Remove the right front drive shaft assembly.

11. Remove the transmission case oil seal.
（a）Remove the oil seal with SST.
SST：FT9067705

12 .Install the transmission case oil seal.

（a）Lubricate the lip section of the new oil seal
with multipurpose lubrication.
（b）Install the oil seal with SST.
SST：FT9067602–
Depth：1±0.3mm
Note:
Be careful not to damage the lip section of the oil
seal
13.Assemble the right front drive shaft
assembly.
14. Install the right front drive shaft assembly.

10-21
10-Transmission

15. Install the right ball head tension rod.

16. Install the right lower arm No. 1.
17.Install the front stabilizer bar.
18. Install the right front speed sensor.
19 Install the hub nuts of the front wheel.
Tip：
■ The right-hand shaft can be installed referring to
the same procedure with the left-hand shaft.
20.Assemble the right engine under cover.
21. Assemble the right front wheel.
Torque：88～118N•m
22. Fill the manual transmission gear oil.
23 .Check the manual transmission gear oil.
24 Check and adjust the front wheel alignment.
25 Check the signal of the ABS speed sensor.

10-22
 10-Transmission

Differential Case Oil Seal

Replacement

1 .Drain the transmission gear oil.

2 .Remove the left front axle.
3.Remove the engine under cover LH
4 .Remove the hub nuts of the left front wheel.
5.Disengage the ball head tension rod of the left
side.
6.Disengage the front stabilizer bar.
7. Disengage the left front speed sensor.
8.Disengage the left front lower arm No.1.
9.Disengage the left front axle assembly.
10.Disassemble the left front drive shaft
assembly.
11.Remove the oil seal of the differential case.
(a)Remove the oil seal with SST.
SST：FT9067705

12 .Assemble the differential case oil seal.

（a）Lubricate the lip section of the new oil seal
with multipurpose lubrication.
（b）Assemble the oil seal with SST and hand
hammer.
SST：FT9067602
Depth：1.5 ± 0.3mm
Note：
● Be careful not to damage the lip section of the oil
seal.
13. Assemble the left front drive shaft assembly.
14. Install the left front axle assembly.
15. Install the left tension rod ball head.
16. Install the left lower arm No. 1.
17. Install the front stabilizer bar.

10-23
10-Transmission

18. Install the left front speed sensor.

19. Assemble the hub nuts of the left front wheel.
20. Assemble the left engine under cover.
21. Install the left front wheel.
22. Check and fill the differential gear oil.
23. Check and adjust the front wheel alignment.
24 Check the signal of the ABS speed sensor.

10-24
 10-Transmission

Automatic transmission

Transmission（AMT） .......................................................................................................26
Transmission Gear Oil Inspection .......................................................................................29
Vehicle Inspection ................................................................................................................33
Velocity Selector Assembly .................................................................................................34
Maintenance of Oiler and Lid ..............................................................................................36
Pump Motor and Drive Circuit ............................................................................................37
Clutch Actuator ....................................................................................................................38
Position Sensor ....................................................................................................................40
Shift Lever Assembly ..........................................................................................................42
Speed Sensor ........................................................................................................................44

10-25
10-Transmission

Transmission（AMT）

Introduction of Manual/Automated Gearbox of AMT

The manual/automated gearbox of Tianjin FAW is a manual mechanical gearbox equipped with
electro-hydraulic control unit. The automatic control system of 5T065 gearbox is designed to improve the
performance of manual mechanical transmission components. The system is designed to automatically
control the clutch and shift lever of the traditional manual mechanical gearbox with the assistance of the
e-hydraulic power.
Note：Be sure to vent the internal pressure of the velocity selector to 0 bar before any removal or
assembly during repair. Cleanliness is necessary to avoid the high-pressure oil passage from being clogged.
Be sure to avoid any wear or damage to the harnesses by surrounding environment so as to maintain
the signal transmission. Keep the socket connectors of the harness clean and dry and insulate them from
oil or water.

Malfunction Table

The following table indicates the possible causes of problems. The possibility of the causes is
numbered in descending order, Inspect the following parts and replace the disabled ones.

Problems Diagnosis
1. Oil (oil level is low)
2 Oil (use error)
Noise
3 Gear (wear or damage)
4 Bearing (wear or damage)
1. Oil (oil level is high)
2 Pad (damage)
Oil leakage
3 Oil seal (wear or damage)
4 O-ring (wear or damage)
1 Synchronizer lock ring (wear or damage)
Shifting difficulty or shifting
2 Shift spine spring (damage)
failure
3 Hydraulic components (Leaking oil or

10-26
 10-Transmission

idleness)
1 Lock ball spring (damage)
2 shift fork (damage)
Out of gear
3 Gear (wear or damage)
4 Bearing (wear or damage)

10-27
10-Transmission

Components

10-28
 10-Transmission

Transmission Gear Oil Inspection

Vehicle Inspection

1. Check the transmission axle oil.

（a）Park the vehicle on a flat surface.
（b）Remove the manual plug and washer.
（c）The oil level should be under the lower edge
of the pouring orifice within 5mm.
Note：
●Both excessive and inadequate oil are likely to
cause failure, so drive the car to check the oil level
after changing the oil.

（d）Check the transmission axle oil to see whether

it leaks in the case that the oil level is too low.
（e）Install the manual plug and a new washer.
Torque：30～50N·m

10-29
10-Transmission

Disassembly of Velocity Selector Assembly

1. Vent the pressure (using diagnostic

equipment).
2. Turn off the power and detach the battery
carrier, remove the battery.

3. Remove the battery tray.

4. Disconnect the AMT (to the AMT - TCU)

connector.

5. Disconnect solenoid valves and sensors of the

AMT gearbox.

10-30
 10-Transmission

6. Remove the connector of the clutch release

fork and the clutch actuator.

7. Remove the bolts of clutch actuator.

8. Remove the bolts of the upper AMT velocity

selector.

9. Open the cover of the selector plunger on the

upper velocity selector.

10-31
10-Transmission

10. Press the selector plunger on the upper

velocity selector to the bottom, using a flat
screwdriver, and turn the plunger 90 degrees.

11. Pull up both the upper and lower parts of the

velocity selector and remove them as a whole.

Note：
● The installation and removal procedures of the
velocity selector of the AMT gearbox are in
reverse.
（a）The tighten torque of the clutch actuator
fastening bolt ：
M8： 18～26N·m
M10： 60～70 N·m
（b）The integrity of the gasket at the joint of the
AMT upper velocity selector and the transmission.
（c）The tighten torque of the connecting bolts of
the AMT upper velocity selector and the
transmission：M8： 18～26N·m
（d）A self-learning of the clutch position and gears
of the AMT system is necessary after the
installation (using diagnostic equipment).

10-32
 10-Transmission

Vehicle Inspection

Inspection of Transmission Hydraulic Oil

1．Selection of hydraulic oil

Only transmission fluid provided by Magnetic Merely Company should be used by service station's
or user's refueling. The use of improper fluid, for example, ordinary gearbox oil, brake fluid, or
steering fluid may cause physical and chemical reactions with the hydraulic oil already in the system,
which may damage the seals and produce precipitation or excessive air bubbles. Improper fluid may
also be immiscible with the hydraulic oil in the system, causing stratification, resulting in problems
such as instantaneous low pressure in the velocity selector as it works, and severe stroke deviation
from the designed stroke of the dynamic pistons. This may further result in other problems such as
ineffective separation or close of the clutch, gear engagement failure, fluid leakage, and so on.

2．Method for judging whether to fuel or not

For any concern that the hydraulic oil is insufficient in the velocity selector system, please vent the
velocity selector pressure to 0 bar first, using a diagnostic equipment, then observe the liquid level in the
oiler, Fill a certain amount of hydraulic oil until the liquid level reaches the standard in the case that the
level is below the scale mark on the oiler. Be aware not to fuel before the pressure of the velocity selector
system retches to 0bar, so as to avoid oil spill.

3．Additional Process for Fueling after Replacing Hydraulic Components

In the case that major hydraulic components in the system, such as the clutch actuator, oiler,
hydraulic motor, high-pressure oil tube, pressure sensors, and accumulator have been replaced, the system
exhaust should be tested five times and the gears should be calibrated three times.

10-33
10-Transmission

Velocity Selector Assembly

Replacement

1. Remove the bolts on the upper AMT velocity

selector.
（a）Unscrew the three bolts, disconnect velocity
selector and transmission.

2. Open the cover of the selector plunger on the

upper velocity selector.

3. Press the selector plunger on the upper

velocity selector to the bottom with a flat
screwdriver, and turn the plunger 90 degrees.

4. Pull up both the upper and lower parts of the

velocity selector and remove the assembly.
Note：
The installation and removal procedures of the
velocity selector of the AMT gearbox are in
reverse.
The tighten torque of the clutch actuator fastening
bolt：
M8： 18～26N·m
M10： 60～70 N·m

10-34
 10-Transmission

5. The integrity of the gasket at the joint of the

AMT upper velocity selector and the
transmission.

6. The tighten torque of the connecting bolt of

the AMT upper velocity selector and the
transmission：
M8：18～26N·m

7. A self-learning of the clutch position and gears

of the AMT system is necessary after the
installation (using diagnostic equipment).

10-35
10-Transmission

Maintenance of Oiler and Lid

1．Keep the vent hole of the oiler lid unblocked.
Regular inspections to the vent hole of the oiler lid
is necessary, be sure to keep the lid unblocked by
soil and other substances to avoid any swell or
cracks caused by negative pressure at low
temperature and positive pressure at high
temperature in the course of working. Replace the
oiler lid (containing gasket) if necessary.

2．Remove the gasket on the oiler lid.

The red gasket on the new oiler lid is used to avoid
oil leakage from the vent hole due to improper
placement and abnormal vibration during transport
and storage of the velocity selector. It should be
removed after installation on the vehicle to ensure
the vent hole to be unblocked.

3．Installation and Maintenance of the Oiler

Pay attention to the O-Ring at the joint of the oiler
and the velocity selector motor as the oiler is
replaced (the O-Ring may be left at the oil outlet of
the motor, and ignored by workers). The O-Ring
cannot be neglected nor over assembled, it should
be replaced to avoid oil leakage should any damage
occurred. Keep the oiler from being squeezed or
burned with high-temperature objects in service
and repair.

10-36
 10-Transmission

Pump Motor and Drive Circuit

Maintenance

1．Selection of the O ilP um p D rive P ow er

The operating voltage of the oil pump motor is 12V, its peak current may be up to 20A in the course of
working; Therefore, the 12V vehicle battery should be used or connected in parallel with the 12V
stabilized power, if any, to absorb the momentary high-current in daily maintenance and off-line testing.

2．Selection of the O ilP um p D rive R elay

The motor drive circuit is controlled by the TCU through the relay. The relay must be selected strictly
up to standard, instead of randomly. The relay contacts should be inspected regularly to exclude any
ablation which may cause damage to the motor. Replace the relay if necessary.
Make sure the power supply harness of the motor is well insulated to avoid short circuit which may
burn out the motor.

3．M aintenance of the Motor

Avoid the motor from being hit by hard objects or falling on hard floors so as to avoid the magnetic
pole cracking. Keep the motor surface from dirt, oil stain and other attaching substances so as to avoid
motor overheating.
In the case that the motor is inspected individually, the continuous operating time cannot exceed 0.5
minutes, the motor must be stopped when the outlet pressure of the hydraulic pump (velocity selector
system pressure) exceeds 52bar so as to avoid the motor from being burned out due to overheat or
overload.
Beware to vent the internal pressure of the velocity selector to 0 bar before any removal or assembly
during repair. Cleanliness is necessary to avoid the high-pressure oil passage from being clogged.

10-37
10-Transmission

Clutch Actuator

Maintenance

1. Inspection method of the installation quality

of the clutch actuator
Conduct the inspection of the mounting dimension
under the condition that the system pressure is
about 0 bar after the transmission has been installed.
The distance between the inboard side of the clutch
control arm and the inboard side of the clutch
actuator must be kept within specifications
(measuring method shown in the left picture) and
the clutch cable should be centered in the end hole
of the clutch actuator (shown in the picture below)
so as to avoid the oil leakage from the clutch
actuator.

2．Installation Initialization
Conduct air exhaustion for the system for five
times with diagnostic equipment to drain out all
residual air bubbles in the system so as to ensure
enough pressure for the velocity selector to work;
then conduct self-learning of gears and clutch
engagement point for five times， turn off the
ignition key for about 10 seconds after each time of
self-learning to ensure the latest learnt data to be
written to the ECU memory.

3．Clutch Actuator Dust Boot

Wipe the end surface of the clutch actuator clean

10-38
 10-Transmission

after being installed， then sheathe the dust boot

firmly on it, keep the boot from damage to prevent
dust from entering inside the clutch actuator, which
may result in oil leakage and other problems.

Replacement

1. Remove the clutch actuator oil tube.

（ a ） Unscrew the bolts to remove the clutch
actuator oil tube as shown in the picture.

2. Remove the connector of the clutch release

fork and the clutch actuator.
（a）Unscrew the bolts to remove the connector of
the clutch release fork as shown in the picture.

3. Remove the clutch actuator

（a）Unscrew the three bolts to remove the clutch
actuator as shown in the picture.

Note：
● The installation and removal procedures are in
reverse.

10-39
10-Transmission

Position Sensor

Replacement

1. Remove the position sensor.

Unscrew the screws with a wrench and detach the
position sensor.

2. Install the position sensor.

（a）Tighten the screws with a wrench and install
the position sensor.
Torque：3.0~4.2Nm
（ b ） Conduct self-learning of the clutch
engagement point for three times after the velocity
selector has been installed. Turn off the ignition
key for about 10 seconds immediately after the
self-learning.
Note：
(a) On installing the clutch position sensor, be sure
that the waterproof O-Ring seal on the spare part is
installed between the sensor and the sensor base so
as to ensure the waterproof performance of the
sensor and avoid abnormal output signal from the
position sensor, which may result in a series of
problems such as starting failure and gear
engagement failure.

Caution in Installing the Gear Position Sensor：

（1）Locate the sensor with the two screws, the
tighten torque is 3.6~4.2 Nm
（2）Reconnect the harness and conduct the gear
self-learning for three times with the diagnostic
10-40
 10-Transmission

equipment， turn off the ignition key for about 10

seconds immediately after each self-learning.
Caution in installing the selector position
sensor:
(1)Locate the sensor with the two screws, the
tighten torque is 3.6~4.2 Nm
(2)Conduct the gear self-learning for three times
with the diagnostic equipment ， turn off the
ignition key for about 10 seconds immediately after
each self-learning.

Caution in Using the Position Sensor

Too much water inside the position sensor may
cause damage to the flexible circuits and
momentary abnormal operation, so be sure not to
rinse the velocity selector with a high-pressure
water jet in service and repair.

10-41
10-Transmission

Shift Lever Assembly

Replacement

1． Power off the system.

2． Remove the five bolts of the center console
box.
3．Remove the hand brake guard.
4．Disconnect the plugs of the electric rearview
mirror and power window on the console box
panel.

5．Remove the center console box panel and

center console box.

6．Disconnect the two plugs on the hand control

mechanism.

7．Remove the four bolts on the hand control

mechanism.

10-42
 10-Transmission

8. Detach the hand control mechanism assembly.

Note：
● The installation and removal procedures are in
reverse.

10-43
10-Transmission

Speed Sensor

Replacement

1. Disengage the speed sensor.

(a) Disengage the speed sensor.

2. Remove the speed sensor.

(a) Remove the bolts and speed sensor.
(b) Remove the clamps and the driven gear from
the speed sensor.

3. Install the speed sensor.

(a) Lubricate the new O-ring with transaxle oil and
install the ring on the speed sensor.
(b) Install the driven gear to the speed sensor with a
clamp.
(c) Fasten the speed sensor with bolts.
Torque：11N· m
4. Connect the speed sensor.
(a)Connect the speed sensor connector.

10-44
 10-Transmission

Engine Failure

1、If the starter motor works properly during starting, which can be recognized through the sound,
the failure has nothing to do with the AMT System. (Please inspect the battery voltage before making any
determination or conducting any maintenance measures.
2、If the system is in neutral gear, read the diagnostic trouble code first, if the code is DTC0750 (odd
gear solenoid valve) or DTC0755 (even gear solenoid valve), check the harnesses (mainly between the
TCU and the solenoid valve), unplug the plug and check the pins to see whether they have been eroded or
oxidized, check the harnesses to see whether they are short to ground and whether the power supply is
normal. Check the starting relay and related circuit if none of the above is the matter.
3、If the system is not in neutral gear, read the diagnostic trouble code first.
Check the harnesses and inspect whether the power supply is normal if the code is DTC0805 (clutch
position sensor), DTC0750 (odd gear solenoid valve),DTC0755 (even gear solenoid valve) or DTC0900
(clutch solenoid valve).
If the code is DTC0945 (oil pump relay), please check the condition of battery voltage, related fuses,
power supply and TCU grounding, replace the relay and double-check it, inspect the pin to see whether it
has been eroded or oxidized, check the condition of the harnesses.
If the code is DTC2902 (TCU grounding), please check the TCU grounding to preclude any pin
oxidation, pin corrosion, harness abnormality or bad contact with the ground.
4、Check the gearbox to see whether it has any mechanical problems.

Engine Functions, but Could Not Engage the Gear.

1、Read the diagnostic trouble codes to see whether the problem is from clutch, shift solenoid valve,
oil pump relay, TCU computer or shift lever, check the harness, power supply, grounding and the related
components if it is the above mentioned matter.
2、If the problems are not from the above parts, please check the following items:
Step One, check the oil level inside the tank, refuel if necessary. Check whether the oil leaks, and
the vent bolts on the clutch actuator are closed properly.
Step Two, check the oil pump.
Step Three, check the brake switch signal.

10-45
10-Transmission

Step Four, check the gearbox to see whether it has any mechanical problems.

Warning Light on and Buzzer Alarm Rings

The buzzer alarm will be activated when one of the following situations occurs.
● Reverse gear is engaged.
● vehicle flameout in neutral gear
● The gear will automatically turn neutral in the case that no other operations are conducted three
minutes after releasing the brake pedal.
● The gear will automatically turn neutral if the vehicle is installed with the brake being stepped on
and no other operations being conducted for more than 10 minutes.
● The gear will automatically turn neutral if the door is opened for three seconds, this is an improper
operation.

The Gear Skips to Neutral

1、System features：
①The gear will automatically turn neutral in the case that no other operations are conducted three
minutes after releasing the brake pedal.
②The gear will automatically turn neutral if the vehicle is installed with the brake being stepped on
and no other operations being conducted for more than 10 minutes.
③The gear will automatically turn neutral if the door is opened for three seconds.
④Under the condition that the vehicle is running below 80 km / h without accelerating, the gear will
turn neutral if you put your hand on the shift lever or mistakenly touch it.
2、Check the following items:
（1）Check the oil level inside the tank, refuel if necessary. Check if the oil leaks, check whether the
vent bolts on the clutch actuator are closed properly.
（2）Check the oil pump relay and the oil pump.
（3）C heck the door sw itch signal
（4）C heck the clutch position sensor,select sensor and shift sensor,and conduct self-learning.
（5）C heck the condition of the clutch disc.
（6）C heck the transm ission gear to see whether it is stuck, and check the engine flywheel and the
10-46
 10-Transmission

gearbox input shaft to see whether they are disengaged.

Voluntary Mode Skip

1、Automatically skip to manual mode from auto mode (“A” disappears from the display screen)
（1）The mode remains to be “auto” after the driver has shifted the gear through the shift lever.
Malfunction code DTC2903 (wrong accelerator pedal information) may cause the mode to skip from
auto to manual. Please note that the accelerator pedal signal is transmitted from the ECU to the TCU via
CAN.
If DTC1701 (CAN receiving error) or DTC1601 (CAN conveying error) is recorded by TCU ，check
the transmission condition of the CAN with the AMT diagnostic equipment.
The mechanical problem occurs If DTC2905 (cannot implement reverse gear) is recorded by TCU.
Remove the AMT kit from the gearbox and check the gearbox’s function. Repair or replace the gearbox If
it’s hard to engage or reverse to any gear. Re-install the AMT kit on the gearbox and conduct the checks
again.
If DTC0750 (odd gear solenoid valve error) or DTC0755 (even gear solenoid valve error) is recorded,
the condition of the harnesses (especially those between the TCU and the faulty sensor or the solenoid
valve) and the corresponding solenoid valve.
（2）In the case that the letter “A” on the display disappears but none of the above code is recorded
by TCU, it is recommended that the display and the associated harnesses to be checked to see whether they
function properly.
2、Automatically skip to auto mode from manual mode (“A” appears on the display)
（1）If DTC0820 (GSL0), DTC0821 (GSL1), DTC0822 (GSL2) or DTC0823 (GSL3) is recorded,
please check the condition of the harnesses (especially those between the TCU and shift lever). If there is
no problem with the harnesses, replace the shift lever and check it. Note: If the above failures occur in
the process of engine starting, (rather than all the time),the system will present the following problems:
automatically skip into the "auto "mode; cannot be put into the reverse gear; engine could be started, but
the system automatically turns to 1st gear and buzzer alarm rings when the brake pedal is stepped on; if the
system automatically put into the neutral gear, it will turn to the 1st gear when stepping on the brake again.
（2）If DTC0825 (shift lever illogic) is recorded, the system will skip to auto mode, please note that
the shift lever should be set to a stable position in a certain time (about 72 seconds), the above failure may
10-47
10-Transmission

be caused by the improper operation of the shift lever, . If it is not the matter of improper operation or the
harnesses, replace the shift lever and check it.

10-48
 10-Transmission

Appendix DTC Table

Type
Code Description Type Description
Code
Voltage signal is lower than the shift
0010
limit.

P0560 Supply voltage is too low 0100 Voltage signal is below the "low" limit

Voltage signal is below the "medium"

1000
limit

P0561 Voltage is too low 0100 Power supply voltage is below the limit

0100 RAM - data changes

Flash - Solenoid valve self - learning

1000
P0604 Microprocessor error data change

0001 Flash - System self-learning data change

0010 ROM - data change

0010 level 2 error detected by Level 3

Main microprocessor
P060C 0001 MMP A\D converter
error (MMP)
1000 level 2 error detected by Level 1

The information sent to the SMP from

Security microprocessor 0100
the MMP is fragmented.
P0613
1000 SMP cannot output information
(SMP)
0010 external speed signal input of the SMP

1000 Device on

Internal drive of the 0100 Device off

P0701
solenoid valve 0010 SPI_ device error

0001 Overheat alarm

0001 Switch stuck

information of the CAN
P0703 0010 Beyond the dynamic range
brake switch
1000 Inconsistent switch signal

10-49
10-Transmission

0100 Invalid signal

0100 Invalid engine water temperature signal

P0710 Engine water temperature

0010 No signal
P0715 Clutch Speed
1000 Signal error

0100 Wrong fixed value

Harness brake switch 0001 Brake switch stuck

P0719
signal 1000 Inconsistent switch signal

0010 Beyond the dynamic range

0010 Invalid signal

P0720 Speed signal 0100 No signal

1000 Wrong signal

0010 Invalid signal

P0725 Engine speed 0100 No signal

1000 Wrong signal

0010 Invalid signal

P0750 Solenoid valve EV1 error 0001 No signal

0100 Wrong signal

1000 Short circuit to ground

0010 Short circuit to power

0001 Open circuit

P0755 Solenoid valve EV2 error
0100 Open or short circuit to power

1000 Short circuit to ground

P0780 System misoperation 1000 short circuit to power

0010 Open circuit

P0805 Clutch position sensor 0001 Open or short circuit to power

1000 Rationality

P081A Starter motor relay 0010 Higher than the maximum limit

10-50
 10-Transmission

0001 Lower than the minimum limit

0010 sensor error

P0820 Shift lever switch-GSL0
0001 Open or short circuit to ground

0010 short circuit to power

P0821 Shift lever switch-GSL1
0001 Lower than the minimum limit

0010 Higher than the maximum limit

P0822 Shift lever switch-GSL2
0001 Lower than the minimum limit

0010 Higher than the maximum limit

P0823 Shift lever switch-GSL3
0001 Lower than the minimum limit

Rationality of the shift 0100 Higher than the maximum limit

P0825
switch signal 1000 Lower than the minimum limit

0001 Higher than the maximum limit

TCU +5 V power 0100 Invalid

P0880
supply 1000 Operation error

0010 Short circuit to power

0010 Open circuit

P0881 TCU+12V
0001 Device error

0010 Device off

0001 Device on
P0900 Clutch solenoid valve
0100 Device off

1000 Short circuit to ground

0010 short circuit to power

P0904 0001 Open circuit

Shift position sensor
1000 Open or short circuit to power

0010 Lower than the minimum limit

P0914 Shift position sensor, 0001 Higher than the maximum limit

1000 Wrong signal

P0932 Hydraulic oil pressure 0010 Lower than the minimum limit

10-51
10-Transmission

sensor Hydraulic oil 0001 Higher than the maximum limit

pressure sensor 1000 Wrong signal

P0933 Oil pump relay 1000 Lower than the minimum limit

0100 Higher than the maximum limit

P0942 Hydraulic oil related
1000 Wrong signal

0010 Relay locked

Hydraulic oil pump
P0945 1000 Pressure is too low
power supply error
0001 Hydraulic oil pump Overheating

Hydraulic oil circuit

P2712 1000 Short circuit to ground
leakage

P2900 ECO switch 0010 Open circuit

P2901 Hydraulic oil related 1000 Short circuit to power

P2902 TCU grounding 0100 Excessive leakage

the information of the

P2903 accelerator pedal received 1000 Switch stuck
by the GAN

0100 Accumulator pressure relief diagnosis

P2904 Clutch system error 1000 Open circuit

0010 Invalid signal

0001 Clutch cannot be opened before shifting

0100 Clutch close during shifting

P2905 Gearbox system error
1000 Clutch overheating

0010 Unexpected gear reverse

0001 gear engagement failure

0100 gear reverse failure

P2906 CAN engine torque
0010 Clutch overspeed

1000 Engine friction power invalid signal

P2907 CAN engine maximum 1000 Torque produced by the engine no signal

10-52
 10-Transmission

torque

P2908 Clutch error 0010 Engine standard torque no signal

0010 Engine target torque no signal

P2909 Transmission error
1000 Invalid signal

Sensor power supply 0001 Clutch control

P290A
error 0010 Gear select locked

0001 Shift failure

P290D Solenoid valve EV3 error
0010 Voltage is too high

0001 Voltage is too low

P290E Solenoid valve EV4 error
0001 Open or short circuit to power

10-53
 11-Airbag and Belt

Airbag and Belt

Airbag ............................................................................................................................................1
Belt ...............................................................................................................................................51
 11-Airbag and Belt

Airbag

Supplementary Restraint System / SRS..................................................................................... 2

Horn button assembly............................................................................................................... 16

Spiral cable sub-assembly........................................................................................................ 31

instrument panel passenger airbag assembly............................................................................ 30

11-1
11-Airbag and Belt

Supplementary Restraint System / SRS

NOTE
CAUTION:
◆ V2 is equipped with SRS, which comprises a

driver airbag, front passenger airbag and side

airbag. Failure to carry out service operations in the

correct sequence could cause the SRS to

unexpectedly deploy during servicing, possibly

leading to a serious accident. Further, if a mistake

is made in servicing the SRS, it is possible that the

SRS may fail to operate when required. Before

performing servicing (including removal or

installation id parts, inspection or replacement), be

sure to read the following items carefully, then

follow the correct procedures described in the

repair manual.

◆ Work must be started 90 seconds after the

ignition switch is turned to the LOCK position and

the battery negative terminal is disconnected from

the battery. (The SRS is equipped with a back-up

power source so that if work is started within 90

seconds from disconnecting the negative battery

terminal , SRS may be deployed).

HINT: Instantaneous power off protection function

of ACU allows ACU to keep power supplying

within a short period of time after power off.

Operation should be performed when the internal

protection function fails after power off.

11-2
 11-Airbag and Belt

◆ Do not expose the horn button assembly,

instrument panel passenger airbag assembly, airbag

sensor assembly center or airbag front sensor to hot

air or flame .

◆ Airbag component may deploy when a tester is

used for inspection which may cause a serious

injury. Check airbag component using OBD instead

of another tester.

◆ Operation on an unexpectedly deployed airbag

component facing you may cause a serious injury.

When dealing with an unexpanded airbag keep the

deployed side to you in order to reduce the

possibility of injury.

◆ It is highly dangerous _to place an undeployed

airbag component with deployment side facing

ground. If the airbag component is deployed

unexpectedly, it may result in serious injury. When

placing an unexpanded airbag component, keep the

deployed side upward.

NOTE：
●DTC is the most important source of information when troubleshooting due to the difficulty in

confirming SRS malfunctions .When troubleshooting the SRS, always check the DTCs before disconnect

the battery.

●Even minor collisions may lead to the SRS failing to deploy in future collisions., Checks on the

horn button assembly, instrument panel passenger airbag assembly, central airbag sensor assembly or

11-3
11-Airbag and Belt

frontal airbag sensors should be followed.

●Before maintenance and repair, remove the airbag sensor if shocks are likely to applied to the sensor

during repairs.

●Never use SRS parts from other vehicles. Replace them with new ones.

●Never disassemble or repair airbags because of the horn button assembly, instrument panel

passenger airbag assembly, airbag sensor assembly center or front airbag sensor in order o reuse it.

●If the horn button assembly, instrument panel passenger airbag assembly, airbag sensor assembly

center or front airbag sensor has been dropped, or if there are cracks ,dents or other defects in the case,

bracket or connectors , replace it with new one.

●Check the system’s electrical circuit failure, using high impedance volt / ohmmeter (10k / V or

more) .

●Information labels are attached to the periphery of the SRS components. Follow the instructions on

the notes.

●After work on the SRS is completed, perform the SRS warning light check.

●Keep record the contents memorized in clock and audio systems beforehand, in case that all the

memory be canceled as negative cable is disconnected from the battery Reset the audio systems as they

were before and adjust the clock . In avoidance of data loss, never use a back-up power supply from

outside the vehicle.

11-4
 11-Airbag and Belt

Safety Standard

CAUTION: ： Please strictly follow the requirements below, otherwise an

unexpected deployment of airbag module may cause serious injury.

Never repair, deploy or remove the airbag module.

Never process airbag module by mechanic methods

(turning, drilling, welding and heat treatment

processing method).

Never check airbag module with non-specified

measurement device.

Never install airbag module more than specified

torque.

Avoid electrostatic interaction

Never expose airbag module to the flame above the

temperature of 85°C

Technicians working on airbag module should be

under the ESD protection, such as earplugs,

working with anti-static shoes and more than 80%

cotton content clothes on, etc...

Wear protective gloves and working clothes when

handling with deployed airbag module,.

Deployed module is not dangerous which can be

treated by classification by factory.

11-5
11-Airbag and Belt

11-6
11-Airbag and Belt

11-7
11-Airbag and Belt

When the vehicle is involved in a frontal collision

in the hatched area (shown as the Figure 1) and the

shock is larger than the pre-determined level, SRS

is activated automatically. A staffing sensor is

designed to go on at a smaller deceleration rate

than the airbag sensor. As shown, ignition is caused

when current flows to the squib, which happens

when the staffing sensor and deceleration sensor go

on simultaneously. When a deceleration force

acts on the sensor, two squibs in the driver bag and

front passenger airbag ignite and generate gas. The

gas fill into the steering wheel airbag and front

passenger airbag. As the pressure increase rapidly,

the air breaking open the steering wheel airbag (in

the steering wheel cover) and the instrument panel

airbag. Bag inflation then ends, and the bags

deflate as the gas is discharged through the

discharge holes at the bag’s rear or side.

1. SRS Connector
（a）All the SRS connectors are colored to yellow

as a distinction, those with special functions and

specially designed for the SRS are used in the

locations as shown to ensure safety and reliability.

The connectors use durable gold-plated terminals.

（b）Electrical connection inspection mechanism：

This mechanism automatically checks that

connectors are connected correctly and completely.

The electrical connection check mechanism is

11-8
 11-Airbag and Belt

designed so that the discconnection pin connects

with the diagnosis terminals when the connector

housing is locked

（c）Half connection prevention mechanism：

If the connector is not fully connected, the

connector is disconnect due to the spring operation

to the extent that no continuity exists.

（d）Connector lock mechanism：

Lock the connector lock button securely to ensure

that the connector is connected.

2. Release the connector of the horn button
assembly and the instrument panel airbag
assembly
3. Connect the connector of the horn button
assembly and the instrument panel airbag
assembly
（a）Align a lock part of male connector and a

slider of a female connector in the same direction ,

fit in them without rubbing..

（b）Be sure to insert until they are locked . After

fitting in, pull them slightly to check that they are

locked (When locked, make sure that the outer

returns to it's original position and sound at the

time of fitting in can be heard)

11-9
11-Airbag and Belt

On-Vehicle Inspection
1. Horn button assembly (Vehicle not involved
in collision）
（a）Check the diagnostic system

（b）Visually check the following item with the

horn button assembly (with an airbag) installed

in the vehicle.

2. Horn button assembly( vehicle involved in

collision and airbag is not deployed)
（a）Check the diagnostics system

（b）Visually check the following items with the

horn button assembly (with an airbag) removed

from the vehicle,

（1）Check cuts, minute cracks on the horn button

assembly top surface.

（ 2 ） Check marked discoloration on the horn

button assembly top surface.

（3）Check cuts and cracks in wire harness, and

clipping in connectors.

（4）Check the deformation on the steering wheel.

（5）Check the deformation on the horn button

contact plate of the horn button assembly .

HINT：
■ If the horn button contact plate of the horn

button assembly is deformed, never repair it.

Always replace the horn button assemble with a

new one.

11-10
 11-Airbag and Belt

（6）There should be no interference between the

horn button assembly, and the clearance should be

uniform all the way around when the new horn

button assembly is installed on the steering wheel.

Caution：
◆ For removal and installation of the horn

button assembly, be sure to follow the correct

procedure.
3. Horn button assembly (vehicle involved in
collision and airbag is deployed)
（a）Check the diagnostic system

（b）Visually check the following items with the

horn button assembly (with an airbag) removed

from the vehicle

Check the damage on the spiral cable connectors

and wire harness.

HINT：
■ There should be no interference between the

horn button assembly and the steering wheel，and

the clearance should be uniform all the way around

when the new horn button assembly is installed on

the steering wheel.

4. Instrument panel passenger airbag assembly

(vehicle not involved in collision)
（a）Check the diagnostic system

（b）Visually check the following items with the

instrument panel passenger airbag assembly (with

an airbag) installed in the vehicle .

Check cuts, minute cracks or marked discoloration

11-11
11-Airbag and Belt

on the instrument panel passenger airbag assembly

and instrument panel.

5. Instrument panel passenger airbag assembly
(Vehicle involved in collision but the airbag is
not deployed)
（a）Check the diagnostic system

（b）Visually check the following items with the

instrument panel passenger airbag assembly (with

an airbag) removed from the vehicle.

（ 1 ） Check cuts, minute cracks or marked

discoloration on the instrument panel passenger

airbag assembly

（2）Check cuts and cracks in wire harness and for

chipping in connectors.

（3）Check the deformation and crack on the

instrument panel and instrument panel

reinforcement.
HINT：
■ If the instrument panel or instrument panel

reinforcement is deformed or cracked, never repair

it, Always replace it with a new one.

（4）There should be no interference between the

instrument panel and instrument panel passenger

airbag assembly.
CAUTION：
◆ For removal and installation of the instrument

panel passenger airbag assembly, be sure to follow

the correct procedure.

6. Instrument panel passenger airbag assembly
(vehicle involved in collision and the airbag is
11-12
 11-Airbag and Belt

deployed )
（a）Check the diagnostic system

（b）Visually check the following items with the

instrument panel passenger airbag assembly (with

an airbag) removed from the vehicle.

（1）Check the deformations and cracks on the

instrument panel reinforcement.

（2）Check the damage on the connector and wire

harness

HINT：
■ If connector , wire harness or instrument panel

reinforcement is deformed or damaged, never

repair it. Always replace it with a new one.

7. Airbag sensor assembly center (vehicle not
involved in collision)
（a）Check the diagnostic system.
8. Airbag sensor assembly center ( vehicle
involved in collision and the airbag is not
deployed)
（a）Check the diagnostic system.
9. Airbag sensor assembly center ( vehicle
involved in collision and the airbag is deployed)
（a）Replace the airbag sensor assembly center
10. Airbag front sensor (vehicle not involved in
collision)
（a）Check the diagnostic system.
11. Airbag front sensor (vehicle involved in
collision)
（a）Check the diagnostic system.

（b）If the front fender of the car or its periphery is

damaged, visually check for damage to ,the airbag

front sensor , which includes the following items

11-13
11-Airbag and Belt

even if the airbag was not deployed:

（1）Cracks, dents or chips in the case

（2）Cracks, dents or chipping in the connectors

（3）Peeling off of the label or damage to the serial

number
12. Wire harness and connector (vehicle
involved in no collisions)
Check the diagnostic system.
13. Harness and connector (vehicle involved in
collision)
（a）Check the diagnostic system

（b）Check breaks in all wires of the SRS harness

and the exposed connector

（c）Check the SRS wire harness are cracked or

chipped
HINT：
■ The SRS harness is integrated with the main

cable of the engine room, instrument panel wire

and floor wire. All connectors in the system are

standard yellow.

11-14
 11-Airbag and Belt

Airbag System Installation

Before installation, make sure that vehicle’s power supply of battery is cut off. Installation with

vehicle power on is prohibited.

CAUTION: Installation of airbag with power on is highly dangerous due to

possible personal injury resulting from airbag system error ignition.

Airbag System Working Temperature

Work should be performed under the temperature of 90 ℃ due to the airbag system containing plastic

materials not resistant to high-temperature. Therefore, when performing some high-temperature operation

(such as painting, coating etc. ) , ACU, airbag modules, clock springs and other components should be

removed, then installed after high-temperature operation is completed.

CAUTION: Operation performed under the temperature more than 90 ℃ is highly

dangerous due to possible personal injury resulting from airbag system error

ignition.

11-15
11-Airbag and Belt

Horn Button Assembly

Components

11-16
 11-Airbag and Belt

Replacement
1. Make sure the vehicle battery power supply
is cut off before installation. Installation with
vehicle power on is prohibited.
CAUTION:
Installation of airbag system with power on is

highly dangerous due to possible personal injury

resulting from system error ignition.

2. Disconnect the battery negative terminal

3. Remove the horn button assembly

NOTE：
●DTC will be recorded when the ignition switch

is turned ON and the airbag connector is

disconnected.

（a）Check the front wheels facing straight ahead.

（b）Using a torn socket wrench (T30) ,loosen the

two torx screws until the groove along the screw

circumference latched on the screw case.

（c）Remove the steering wheel cover from the

horn button assembly.

11-17
11-Airbag and Belt

（d）Loosen the speaker connector.

NOTE：
● Be careful not to pull the airbag harness when

removing the horn button assembly

（ e ） Disconnect the airbag connector with a

screwdriver

（f）Remove the horn button assembly.

4. Install the horn button assembly

（a）Connect the airbag connectors and the horn

connectors.

（ b ） Install the horn button assembly after

confirming groove along the screw circumference

hatched on the screw case

（c）Install two the torn screws with a torn socket

wrench

5. Check the horn button assembly

（a）Visually check the following item with the

horn button assembly (with airbag) installed in the

vehicle.

Check the cuts, minute cracks or marked

discoloration on the horn button assembly top

surface in the grooved portion.

6. SRS warning light check

Turn the ignition switch to the ON position, check

that SRS warning light lights up. Check that the

light goes out after 6 seconds.

Diagnostic inspection is also needed.

11-18
 11-Airbag and Belt

Turn on key switch, ECU activates the light to

check the system. The system is normal if the light

goes out after 6s staying on during the initialization,

Malfunction can be considered likely at present if

the light stays on for 6s , goes out，and is always lit.

The light stays on for six seconds before going out

if malfunction occurs for no more than 6 times in

the history record. ECU can not detect the collision

or deployment until ECU circuit is stabilized after

initialization.

Under the following conditions, airbag system is

required for testing and troubleshooting:

A. SRS warning light goes out after 6s staying on,

then lights up again and always keeps lit after a 1s

interval. This is an indication of malfunction in

airbag system in which ECU malfunction record

should be checked and malfunction cleared. During

troubleshooting make sure to cut off the power of

airbag system, and operate after at least 60s pause.

Three states of malfunctions are as followings:

1、Front collisions have been recorded ( sometimes

caused by operation of ECU with power on)

2 、 The accumulated number of different

malfunctions is more than 10, occurrence in one

kind of malfunction is at least 10 times.

3、There is a malfunction at present.

B. If ECU side socket connector and side wire

harness are not plugged securely, a circuit is

11-19
11-Airbag and Belt

formed between power wire and ground wire.

Warning light always lights.

11-20
 11-Airbag and Belt

Disposal
HINT：
■ When scrapping vehicle equipped with an SRS

or disposing of a horn button assembly, always first

deploy the airbag in accordance with the following

procedure.

If there are an accident when deploying the airbag,

please contact the service department of distributor.

CAUTION:
◆ Never dispose of a horn button assembly which

has an undeployed airbag.

◆ The airbag produces a sizeable exploding sound

when it deploys, so perform the operation out of

doors and the place where it will not create a

nuisance to nearby residents

◆ When deploying the airbag, be sure to use the

specified SST (SRS Airbag Deployment Tool).

Perform the operation in a place away from

electrical pollution.

◆ When deploying an airbag, Perform the

operation at least 10 meters (33 ft) away from the

horn button assembly

◆ The horn button assembly is very hot when the

airbag is deployed, , so leave it alone at least 30

minutes after deployment.。

◆ Wear gloves and safety glasses when handling a

deployed airbag

◆ Do not splash water to the horn button

11-21
11-Airbag and Belt

assembly with deployed airbag.

◆ Always wash you hand with water after

completing the operation

1. Dispose the horn button assembly (airbag's

deployment method when scrapping vehicle )
HINT：
■ Prepare a battery as the power source to
deploy the airbag.
（a）Check the function of SST.
CAUTION:
◆ When deploying the airbag, be sure to use the

specified SST(SRS airbag deployment tool)

（1）Connect the red clip of the SST to the positive

terminal of battery, the black clip to negative

terminal of the battery.

HINT：
■ Do not connect the yellow connector, which is

used to connect the SRS

（2）Check the performance of the SST

Press the activation switch of the SST to check the

LED light.
CAUTION:
◆ If the activated switch which has not been
pressed and the LED light lights, it may be an SST
failure. Do not use the SST.
（3）Disconnect the SST from the battery.

（b）Set SST.
CAUTION:
◆ Check the steering wheel and horn button

assembly and be sure they are not loose.

11-22
 11-Airbag and Belt

（1）Remove three bolts and the steering column

cover lower when turning the steering wheel.

（2）Disconnect the spiral cable from the airbag

connector

（3）Connect the SST connector to the airbag

connector of the spiral cable.

（4）Move the SST at least 10 meters (33 ft) away

from the vehicle

（5）Close all doors and windows of the vehicle.

NOTE：
● Be careful not to damage the SST wire.

（6）Connect the red clip of the SST to the positive

terminal of battery, the black clip to negative

terminal of the battery.

（c）Deploy the airbag

（1）Check that no one is inside the vehicle or

within 10 meters (33 ft) area around the vehicle

（2）Press the SST activation switch and deploy the

airbag.
HINT：
■ The airbag deploys simultaneously when the

LED light of the SST activation switch lights up.

（d）Dispose the horn button assembly (with an

airbag)

CAUTION:
◆The horn button assembly is very hot when the

airbag is deployed,, so leave it alone at least 30

11-23
11-Airbag and Belt

minutes after deployment.

◆Wear gloves and safety glasses when moving the

disposed vehicle with the deployed airbag,.

◆Wear gloves and safety glasses when handling

the deployed horn button assembly..

◆ Always wash your hand with water after

completing the operation,.

◆Do not splash water to the horn button assembly

with deployed airbag

HINT：
■ When scrapping a vehicle, deploy the airbag

and scrap the vehicle with horn button assembly be

installed.

2. Dispose the horn button assembly (when

disposing of airbag assembly method)
NOTE：

● When disposing the horn button assembly (with

an airbag), never use the customer's vehicle to

deploy the airbag.

● Be sure to follow the procedure given below

when deploying the airbag

HINT：
■ Prepare a battery for the power source to

deploy the airbag.

（a）Remove the horn button assembly.

CAUTION:
◆ Store the horn button assembly with the airbag

deployment side facing upward.

（b）Using a service-purpose wire harness for the

11-24
 11-Airbag and Belt

vehicle, tie down the horn button assembly to the

steel ring .
Wire harness: Stripped wire harness section
1.25mm or more

CAUTION:
◆ If the horn button assembly is tied down with

too thin wire harness or used wire, it may snap

because of the vibration when the airbag is

deployed .This is highly dangerous. Be sure to use

a wire harness which is at least 1.25mm.

HINT：
To calculate the area of the stripped wire harness

section:
2
Area = 3.14 × (Diameter) divided by 4

（1）Install two bolts with washers in the 2 bolt

holes of horn button assembly.

Bolt：
Length ：35.0mm
Diameter：6.0mm
Thread pitch ：1.0mm
NOTE：
● Tighten the bolts by hand until the bolt

becomes very difficult to turn.

● Do not tighten the bolts too much.

（2）Connect the wire to the horn button assembly

after connecting to the SST.

（3）Using three wire harness, wind the wire

harness at least twice each around the bolts

installed on the left and right side of the horn

button assembly.

11-25
11-Airbag and Belt

CAUTION：
◆ Tightly wind the wire harness around the bolt

so that there is no slack.

◆ If there is slack in wire harness, the horn button

assembly may come loose due to the shock when

the airbag is deployed. This is highly dangerous

（ 4 ） Face the upper surface of horn button

assembly upward. Separately tie the left and right sides
of the horn button assembly to the disc wheel through
the hub nut holes. Position the horn button assembly
connector so that it hangs downward through a hub
hole in the disc wheel.

CAUTION：
◆ Make sure that the wire harness is tight. It is

very dangerous when the loosened wire harness

results in the horn button assembly coming free

through the shock from the airbag deployment.

◆ Always tie down the horn button assembly with

the pad side facing upward. It is very dangerous if

the horn button assembly is tied down with the

metal surface is facing upward as the wire harness

will be cut by the shock from the airbag

deployment and the horn button assembly will be

flown into the air.

NOTE：
● The wheel will be damaged when the airbag is

deployed, so when disposing of the airbag, use a

redundant wheel.

（c）Check the function of SST.

11-26
 11-Airbag and Belt

（d）Set SST

11-27
11-Airbag and Belt

CAUTION:
◆ Place the wheel on the level ground
（1）Connect the connector to the SST

NOTE：
● To avoid damaging the SST connector and wire

harness, do not to lock the secondary lock of the

twin lock. Also secure some slack for the SST wire

harness inside the wheel.

（2）Move the SST at least 10 meters (33 ft) away

from the wheel tied down with the horn button

assembly

（ e ） Cover the horn button assembly, using

cardboard box or tires.

（1）Covering method using cardboard box

Cover the horn button assembly with the cardboard

box, and weight the cardboard box down in 4

places with at least 190N (20kg)

Size of cardboard box:
Must exceed the following dimensions:
X=460mm
Y=650mm

NOTE：
● When dimension Y of the cardboard box

exceeds the diameter of the wheel tied with the

horn button assembly, X should be the following

size.
X = 460mm tire width
● If a cardboard box smaller than the specifies

size is used, the cardboard box will be broken by

11-28
 11-Airbag and Belt

the shock from the airbag deployment.

（2）Covering method using tires:

Place at least three tires without disc wheel on top

of the disc wheel with tire to which the horn button

assembly is tied.
Tire size: Must exceed the following dimensions
Width：185mm
Inner diameter：360mm
CAUTION:
◆ Do not use tires with disc wheels.
NOTE：
● The tire may be damaged when airbag is

deployed, , please use the redundant tires.

（f）Deploy the airbag.

（1）Connect the red clip of the SST to the positive

terminal of battery, the black clip to negative

terminal of the battery

（2）Make sure that no one is within 10 m area

around the disc wheel tied with the steering wheel

cover

（3）Press the SST activation switch to deploy the

airbag.

NOTE：
■ The airbag deploys simultaneously when the

LED of SST activation switch lights up.

（g）Dispose of the horn button assembly (with

airbag).
CAUTION:
◆ The horn button assembly is very hot when the

airbag is deployed ,so leave it alone for at least 30

11-29
11-Airbag and Belt

minutes after deployment.

◆ Wear gloves and safety glasses when handling

the horn button assembly with deployed airbag.

◆ Do not splash water to the horn button

assembly with deployed airbag.

◆ Always wash your hand with water after

completing the operation.

（1）Remove the horn button assembly from the

disc wheel.

（2）Put the horn button assembly in a vinyl bag,

tie the end tightly and dispose of it in the same way

as other general parts disposal.

11-30
 11-Airbag and Belt

Spiral Cable Sub-assembly

Replacement
NOTE：
1. Disconnect the battery negtive terminal
2. Check that the front wheels are facing
straight ahead.

3. Remove the horn button assembly

4. Remove the steering wheel assembly

5. Remove the steering column cover lower .

（a）Remove the three screws and the steering

column cover lower.

6. Remove the steering column cover upper.

11-31
11-Airbag and Belt

7. Remove the spiral cable sub-assembly

（a）Disconnect the airbag connector and spiral

cable connector

（b）Release the three clasp claws, and remove the

spiral cable sub-assembly.

8. Check the spiral cable sub-assembly

（a）If the following condition is found, replace the

spiral cable sub-assembly with a new one.

Conditions:
Cracks or scratches on the connector

Cracks, dents or chipping of the spiral cable

sub-assembly .。

9. Place the front wheels facing straight ahead.

（a）Check that the front wheels facing straight

ahead
10. Install the spiral cable sub-assembly
（a）Set the turn signal switch in neutral position.
NOTE：
● Make sure of the neutral position that the pin of

the turn signal switch may be snapped.

（b）Engage the three clasp claws and install the

spiral cable.
NOTE：
● When replacing the spiral cable with a new one,

remove the lock pin before installing the handle.

（c）Connect the airbag connector

（d）Install the steering column cover with three

screws.

11-32
 11-Airbag and Belt

11. Center spiral cable

（a）Make sure that the ignition switch is turned to

OFF.

（b）Make sure the battery negative terminal is

disconnected.
NOTE：
● Do not start the operation for 90 seconds after

removing the battery terminals.

（c）Turn the spiral cable counter-clockwise until it

becomes difficult to turn.

（d）Then rotate the spiral cable clockwise about

2.5 turns, and align the mark.

NOTE：
■ Turns of rotating to either left or right should be

in accordance with what is marked on the cable

disk. 5 turns as shown in the mark, rotate the cable

about 2.5 turns to either left or right of the center

after aligning the installing mark.

12. Install the steering wheel assembly
13. Install the horn button assembly
14. Check the horn button assembly
15. Check the SRS warning light
Confirm that the SRS warning light is lighting up

when the ignition switch is turned the ON. 6

seconds after lighting up confirm the warning light

is off permanently.

The diagnostic check is also needed.

11-33
11-Airbag and Belt

Instrument panel Passenger Airbag Assembly

Components

11-34
 11-Airbag and Belt

Replacement
NOTE
1. Disconnect battery negative terminal
2. Remove the central instrument panel
sub-assembly (see 04-22)
3. Remove the instrument panel sub-assembly
lower
4. Remove the combined instrument assembly
(see 03-44)
5. Remove the glove compartment door .
6. Remove the front pillar garnish RH
7. Remove the front pillar garnish LH
8. Remove speaker cover No.1 and No.2 and
speaker (see 02-56)
9. Disconnect passenger airbag connector
10. Remove the instrument panel sub-assembly
11. Remove the instrument panel passenger
airbag assembly
（a）Remove the two nuts and instrument panel

passenger airbag assembly.

12. Check the instrument panel passenger
airbag assembly
13.Install the instrument panel passenger airbag
assembly
14. Install the instrument panel sub-assembly
Torque：20N.m
15 Check the SRS warning light
Turn the ignition switch ON, confirm the SRS

warning light is lighting up. After lighting up for 6

seconds, make sure that the warning light is off

permanently.

Diagnostic check is also needed.

11-35
11-Airbag and Belt

Disposal
HINT：
■ When scrapping vehicle equipped with an

SRS or disposing of a instrument panel passenger

airbag assembly, always first deploy the airbag

according to the following procedure, If any

abnormality occurs the airbag deployment, please

contact the service department of dealer.

CAUTION：
◆ Never dispose an undeployed instrument panel

passenger airbag assembly.

◆ The airbag produces a sizeable exploding sound

when it deploys, so perform the operation out of

doors and the place where it will not create a

nuisance to nearby residents

◆ When deploying the airbag, be sure to use the

specified SST (SRS airbag deploying tool).Perform

the operation in a place away from electrical noise.

◆The instrument panel passenger airbag assembly

is very hot when the airbag is deployed, so leave it

alone for at least 30 minutes after deployment.

◆ Wear gloves and safety glasses when handling

the instrument panel passenger airbag assembly

with deployed airbag

◆ Do not splash water to the instrument panel

passenger airbag assembly with deployed airbag.

◆ Always wash your hand with water after

completing the operation

11-36
 11-Airbag and Belt

NOTE：
● Be careful not to damage the SST connector

and cable; do not lock the secondary lock of the

twin lock.

（a）SST Move the SST at least 10 meters away

from the vehicle.

（b）Close all doors and windows of the vehicle.

NOTE：
●Be careful not to damage the SST wire.

（c）Connect the red clip of the SST to the positive

terminal of battery, the black clip to negative

terminal of the battery

（d）Deploy the airbag

（1）Make sure that no one is inside the vehicle or

within

（2）Press the SST activation switch and deploy the

airbag.
HINT：
■ The airbag deploys simultaneously when the

LED of SST activation switch lights up .

（e）Dispose the instrument panel passenger airbag

assembly
CAUTION:
◆ The instrument panel passenger airbag

assembly is very hot when the airbag is

deployed ,so leave it alone for at least 30 minutes

after deployment.

◆ Wear gloves and safety glasses when handling

the instrument panel passenger airbag assembly

with deployed airbag

11-37
11-Airbag and Belt

◆ Do not splash water to the instrument panel

passenger airbag assembly with deployed airbag

◆ When deploying an airbag, perform the

operation at least 10 meters (33 ft) away from the

instrument panel passenger airbag assembly

◆ Always wash your hand with water after

completing the operation

NOTE：
■ When scrapping a vehicle, deploy the airbag

and scrap the vehicle with the instrument panel

passenger airbag assembly being installed

1. Dispose the instrument panel passenger
airbag assembly (when disposing of airbag
assembly deployment method)
NOTE：
● When disposing the instrument panel passenger

airbag assembly, never use the customer's vehicle

to deploy airbag.

● Be sure to follow the procedure given below

when deploying the airbag

HINT：
■ Prepare a battery for the power source to

deploy the airbag.

（a）Remove the instrument panel passenger airbag

assembly
CAUTION:
◆ When removing the instrument panel passenger

airbag assembly, work must be started 90 seconds

after the ignition switch to LOCK position and

disconnect the negative terminal from the battery.

◆ Place the instrument panel passenger airbag

11-38
 11-Airbag and Belt

assembly with the airbag deployment side facing

upward.

（b）Using a service-purpose wire harness for the

vehicle, tie down the instrument panel passenger

airbag assembly to the tire.

Wire harness: Stripped wire harness section

1.25mm or more
CAUTION：
◆ If the instrument panel passenger airbag

assembly is tied down with too thin wire harness,

it may snap. This is highly dangerous. Always use a

wire harness which is at least 1.25mm.

HINT：
To calculate the area of the stripped wire harness

section:
Area = 3.14 × (Diameter) ²divided by 4
Place the instrument panel passenger airbag

assembly in the tire with the airbag deployment

side facing inside.

Tire Size: Be sure to exceed the following

dimensions
Width:：185mm
Inner diameter: ：360mm
（1）Install the two nuts to the instrument panel

passenger airbag assembly

（2）Wind the wire harness around the brackets, as

shown in the fig.

（3）Place the instrument panel passenger airbag

assembly in the tire with the airbag deployment

side facing inside.

11-39
11-Airbag and Belt

Tire Size: Be sure to exceed the following

dimensions
Width: 185mm：185mm
Inner diameter: 360mm ：360mm
CAUTION：
◆ Make sure that the wire harness is tight, If the

instrument panel passenger airbag assembly is tied

down with too thin wire harness, it may snap.

This is highly dangerous.

◆ Always tie down the instrument panel

passenger airbag assembly with the airbag

deployment side facing inside

NOTE：
The tire will be marked by the airbag deployment,

so be sure to use a redundant tire.

11-40
 11-Airbag and Belt

（c）Check the function of SST

（d）Place tires.

（1）Put at least two tires under the tire to which

the instrument panel passenger airbag assembly is

tied.

11-41
11-Airbag and Belt

（2）Put at least two tires over the tire to which the

instrument panel passenger airbag assembly is tied

The top tire should have the wheel installed.

（ 3 ） Tie all the tires together with two wire

harness.
CAUTION：
◆ Make sure that the wire harness is tight, It is

very dangerous if loosened wire harness result in

the tires coming free due to the shock from the

airbag deploying.
CAUTION:
■ Place the SST connector and wire harness in the

tire. Secure at least 1m of slack for the wire

harness.

（e）Set SST

Connect the SST connector to the instrument panel

passenger airbag assembly connector

NOTE：
● To avoid damaging the SST connector and wire

harness, do not lock the secondary lock of the twin

lock.

（f）Deploy the airbag

（1）Connect the red clip of the SST to the positive

terminal of battery, the black clip to negative

terminal of the battery.

（2）Make sure that no one is within 10 m radius

around the tire which the tire is tied

（3）Press the SST activation switch to deploy the

airbag.

11-42
 11-Airbag and Belt

NOTE：
■ The airbag deploys simultaneously when the

LED of SST activation switch lights up.

（g）Dispose the instrument panel passenger airbag

assembly
CAUTION：
◆ The instrument panel passenger airbag

assembly is very hot when the airbag is

deployed ,so leave it alone for at least 30 minutes

after deployment.

◆ Wear gloves and safety glasses when handling

the instrument panel passenger airbag assembly

with deployed airbag.

◆ Do not splash water to the instrument panel

passenger airbag assembly with deployed airbag

◆ Always wash your hand with water after

completing the operation

（1）Remove the instrument panel passenger airbag

assembly from the tire

（2）Put the instrument panel passenger airbag

assembly into a vinyl bag, tie the end tightly and

dispose of it in the same way as other general parts

11-43
11-Airbag and Belt

Airbag System Inspection

CAUTION: Inspect airbag system, using specified malfunction tester only.

Inspection on airbag system by using other tester is prohibited.

Before inspecting airbag system , check the voltage of vehicle battery with a multimeter to, confirm

the normal range of voltage . The required operating voltage of airbag system is from 9V to16V

One、Inspection by using warning lights

Warning light on the vehicle's instrument panel is

designed for checking the working state of airbag

system via light changing.

1．Warning light dose not light or always lights
Turn ignition switch to the ON position, airbag

warning light should light up. If the airbag warning

light either stays lit or does not light at all,, there is

likely a malfunction in airbag warning light or

warning light circuit. Repair warning light or

warning light circuit according to the vehicle’s

electrical maintenance method.

2．Warning light always lights after flashing
The airbag warning light goes out after

approximate six seconds. If the warning light lights

up again, there is probably a malfunction in airbag

system which needs repairing.

3．Warning light goes out after flashing
The airbag warning light goes out after

approximate six seconds If the warning light lights

up no more before the ignition switch is turned on

again, this indicates that the airbag system is

normal.
11-44
 11-Airbag and Belt

Two、Inspection by using malfunction tester.

After inspecting the malfunction in SRS by using

the warning lights, confirm the specific

malfunction by using a specified tester.

11-45
11-Airbag and Belt

Airbag Maintenance

Maintenance and repair of SRS malfunction should be conducted by service technicians only.

Non-technicians are prohibited to operate any maintenance or repair work.

CAUTION: Maintenance and repair of airbag system should be conducted by service

technicians only, in order to prevent possible personal injury

One、Maintenance preparation
Remove vehicle’s power supply before

maintenance as followings: remove the vehicle

negative terminal of the battery and wrap the wire

harness with insulating tape for insulation, and wait

for 60 seconds. As shown in Fig 3.

HINT:
Instantaneous power off protection function of

ACU allows ACU to keep power supplying within

a short period of time after power off. Operation

should be performed when the internal protection

function fails after power off (60s).

CAUTION: Maintenance or repair of airbag system with power on is highly

dangerous due to possible personal injury resulting from airbag system error

ignition.

Two、Malfunction description and treatment method

1．Airbag warning light does not display

Possibility
 Fail to supply power (open in fuse)
 Meter combination failure (warning lights damage)
 Wire harness failure between instrument and airbag system
11-46
 11-Airbag and Belt

Maintenance Procedure

After maintenance completed, re-check airbag system by using malfunction tester. Specific

procedure sees the chapter: Airbag System Inspection.

11-47
11-Airbag and Belt

CAUTION: Before repairing and replacing the corresponding components of airbag，

it is required to cut off the vehicle’s power supply of battery.

2．D river’
s airbag (D A B ) failure
Possibility
●Wire harness connection failure of ACU and airbag system

●Airbag wire harness assembly failure

●Connection failure of airbag system wire harness assembly and spiral cable

●Spiral cable internal failure,

●Connection failure of spiral cable and driver’s airbag module

●Driver’s airbag module failure

11-48
 11-Airbag and Belt

After maintenance completed, re-check the airbag system by using malfunction tester. Specific

procedure sees the chapter: Airbag System Inspection

CAUTION: Before repairing and replacing the corresponding components of airbag,

cut off the vehicle’s power supply of battery.

Disposal of Accident Vehicle

Accident vehicle refers to the vehicle which has a collision irrespective of airbag deployment, as well

as the vehicle which has no obvious collision, but the airbag deploys. Inspection and maintenance methods

of accident vehicle are as followings.

11-49
11-Airbag and Belt

One、Visual Inspection

Cut off the power supply of vehicle battery before inspection. Cutting method sees: repair

preparation.

CAUTION: Installation of airbag system with power on is highly dangerous

due to possible personal injury resulting from airbag system error ignition.

(1) Check DAB airbag module loaded by vehicle. If the model is deployed, replace the module with a

new one of same model.

(2) Check clock spring in steering column cover. If there is crack or wire harness cut, replace the

clock spring with a new one of same model.

(3) Check ACU case, if there is depression, crack or deformation, replace with the SCU case with a

new one of same model.

(4) Replace ACU if ignition circuit has acted in accordance with ACU failure report,.

(5) Check the wire harness and socket connectors in airbag system. If there is any damage, replace the

harness with a new one of same model.

The above parts, if damaged, replace with new parts only. Those parts which have been

repaired are not allowed to reuse.

Two、Electric Inspection

After visual inspection, confirm that the airbag system components are installed, socket connectors

are connected correctly and securely, then connect vehicle’s battery of power supply .Turn on vehicle

ignition switch, check the display of the airbag warning light on instrument panel. Procedure sees: Airbag

System Inspection.

If a failure exists, execute as failure maintenance procedure, the procedure sees: Airbag System

Maintenance.

11-50
 11-Airbag and Belt

Belt

Belt warning system………………………………………………………………………….... 52

Front belt……. ……………………………………………………………………..………… 54

Rear seat belt…………………………………………………………………………………… 64

11-51
11-Airbag and Belt

Belt warning system

Position

11-52
 11-Airbag and Belt

Problem Symptom Table

Problem Symptom Table Suspected Area

Driver’s seat belt warning lamp does 1.GAUGE fuse

not light up Combination meter

2.Airbag sensor assembly center

(1)front seat inner belt assembly LH

(2)wire harness

11-53
11-Airbag and Belt

Front Seat Belt

Components

11-54
 11-Airbag and Belt

Replacement
HINT：
■ Installation direction is the reverse order of the

removal. But the installation is indicated only when

it has a point.

■ On the left side, work in the same procedure as

in the right side.

1.Disconnect the battery negative terminal
2.Remove the front seat assembly RH
3.Remove the front seat inner belt assembly RH
（a）Loosen the nut and front seat inner belt

assembly.

（1） Remove the front door scuff plate cover

upper

（2） Remove the rear door scuff plate cover

lower RH

（3） Remove the front door opening trim frame

RH

（4） Remove the rear door opening trim RH

（5） Remove the center pillar garnish lower

4. Remove the front seat belt assembly RH
（a）Remove the floor anchor cover

（b）Remove bolts and loosen the outer belt (floor

anchor side)

（c）Remove the shoulder anchor cover with a

screwdriver (Tape the screwdriver tip before use)

（d）Remove the screw and outer belt assembly

(shoulder anchor side)

11-55
11-Airbag and Belt

NOTE：
● Removal operation of the seat belt with a

pretension must be started in 90 seconds or more

after the ignition switch is turned OFF and the

battery negative terminal is disconnected

● Carefully read the NOTE for the pretension in

the SRS airbag system and front seat outer belt

assembly

（a）Disconnect the connector and remove the bolt

2. Remove the center pillar garnish upper

3. Remove front shoulder belt anchor adjuster
assembly
（a）Remove the two bolts and front shoulder belt

anchor adjuster assembly

Inspection
1. Inspect front seat inner belt assembly LH
(a) Inspect the continuity of the inner belt

Standard

Terminal No. Belt Specified condition

1↔2 Fixing No continuity

1↔2 Loose Continuity

11-56
 11-Airbag and Belt

Installation
1. Install front shoulder belt anchor adjuster
assembly
（a）Install the anchor adjuster assembly with

two bolts
torque：42N•m
2. Install the right front outer belt assembly
NOTE：
●Do not disassemble the retractor.

（a）Check the degree of tilt when beginning to

lock the ELR.

(1) Check that the belt will not be locked within 15

degrees of tilt in all directions, but when belt will

lock over 45 degrees of tilt when moving the

installed retractor gently.

If the operation is not specified, replace the front

seat outer belt assembly.

（b）Install the retractor with two bolts

torque：4.9N•m upper part
42N•m lower part

(c)Install the shoulder anchor with bolts

torque：42N•m
（d）Install the belt anchor cover

（e）Install the floor anchor with bolts

torque：42N•m

（f）Install the floor anchor cover

（g）Check the ELR lock

NOTE：
Inspection should be performed with the assembly

process installed.

(1) Check that the belt will lock when pulling out

11-57
11-Airbag and Belt

the belt quickly with the belt installed. If the

operation is not as specified, replace the front seat

outer belt assembly

3. Install the seat inner belt assembly RH

（a）Install the front seat inner belt assembly with

the nut.
Torque：42N•m
HINT：
■ When scrapping vehicles equipped with a seat

belt pretenioner or disposing a front seat outer belt

(with seat belt pretension), always first active seat

belt pretension according to the procedure

described below. If any abnormity occurs in seat

belt pretension operation, please contact the

Service DEPT. of the Tianjin FAW. When disposing

of a front seat outer belt (with seat belt pretension)

activated in a collision please operate according to

the same procedure given in step 1 - (f).

CAUTION
◆ Do not dispose of front seat belt outer belt

assembly which has an inactivated pretension.

◆ The seat belt pretension produces a sizeable

exploding sound when it activates , so perform the

operation out of door and where it will not create a

nuisance to nearby residents.

◆ When activating a front seat outer belts (with a

seat belt pretension), perform the operation at least

10 meters from the front seat outer belt

◆ Wear gloves and safety glasses when handling a

11-58
 11-Airbag and Belt

front belt with activated pretension.

◆ Always wash your hand with water, after

completing the operation.

◆ Do not splash water, etc. to the seat belt

pretension with activated pretension.

◆ When activating the seat belt pretension, be

sure to use the specified tool (SRS Airbag

Deployment Tool).Perform the operation in a place

away from electrical noise.

Dispose of the front seat outer belt assembly RH

(when installed with vehicle)

NOTE：
Check that the battery positive voltage is 12 V.

（a）Check the function of specified tools.

CAUTION：
◆ When activating the safety seat belt pretension,

always use a specified tool

■ Connect the red clip of the special tool to the

positive terminal of battery, the black clip to

negative terminal of the battery

HINT：
■Do not connect the yellow connector, which is

used to connect the seat belt pretension.

（2）Check the function of the specified tool

Press the activation switch and check that the LED

light of specified tool activation switch lights up.

CAUTION：
◆ If the LED light lights up when the activation

switch is not pressed, the special tool may have a

11-59
11-Airbag and Belt

defect, so do not use it..

（a）Disconnect the special tools from battery

（b）Disconnect the pretension connector.

（1）Disconnect the battery negative terminal

（2）Check the SRS airbag system

（3）Remove the front door scuff plate lower RH

（4）Remove the rear door scuff plate lower RH

（5）Remove the front door opening trim RH

（6）Remove the rear door opening trim RH

（7）Remove the center pillar garnish lower RH

（8）Disconnect the pretension connector as shown

in the fig

（c）Connect the specified tool：

（1）Install the floor anchor of the seat belt

（2）Connect the specified tools, and then connect

them to the seat belt pretension.

NOTE：
● To avoid damaging to the specified tool and

wire harness, do not lock the second level of the

twin lock.

（3）Move the specified tool at least 10 meters

away from the vehicle.

（4）Close all the doors and windows of the

vehicle.
NOTE：
Do not damage the special tool and wire harness.

（5）Connect the red clip of the special tool to the

positive terminal of battery, the black clip to

negative terminal of the battery.

11-60
 11-Airbag and Belt

（d）Activate the seat belt pretension.

（1）Confirm that no one is inside the vehicle or

within 10 m area around the vehicle

（2）Press the specified tool activation switch and

activate the seat belt pretension.

HINT：
The seat belt pretension operate simultaneously

with the LED of specified tool activation switch

lighting up.

（e）Dispose of the front seat outer belt assembly

(with seat belt pretension).

CAUTION：
◆ The front seat outer belt assembly is very hot

when the seat belt pretension is activated, so leave

it alone at least 30 minutes after activation.

◆ Wear gloves and safety glasses when handling a

front belt with activated seat belt pretension.

◆ Always wash your hand with water after

completing the operation.

◆ Do not splash water, etc. to the activated seat

belt pretension.
HINT：
■ When scrapping a vehicle, activate the seat belt

pretension and scrap the vehicle with activated

front seat belt pretension.

4. Dispose of the front seat belt assembly RH
(when not installed with vehicle)
NOTE：
● When disposing of a front seat outer belt

assembly (with a seat belt pretension) only do not

11-61
11-Airbag and Belt

use the customer's vehicle to activate the seat belt

pretension.

● Be sure to follow the procedure given below

when activating the seat belt pretension

（a）Remove the front seat outer belt assembly

HINT：
Cut the belt near the belt deep lock device.

（b）Check the function of specified tool

（c）Connect the specified tool.

（1）Connect the specified tool, then connect them

to the seat belt pretension.

NOTE：
● To avoid damaging the connector of specified

tool and wire harness, do not lock the secondary

lock of the twin lock.

（2）Put the outside belt on the ground and cover it

with a wheel with tire

NOTE：
● Place the front seat outer belt assembly as

shown in the fig.

（3）Move the specified tool at least 10 meters

away from the wheel.

NOTE：
● Do not damage the harness wire of specified

tool.

（d）Activate the seat belt pretension.

（1）Connect the red clip of the specified tool to

the positive terminal of battery, the black clip to

negative terminal of the battery.

（2）Check that no one is within 10 m area around

11-62
 11-Airbag and Belt

the wheel.

（3）Press the activation switch of special tool to

activate the seat belt pretension.

NOTE
The seat belt pretension operates simultaneously

with the LED light of specified tool lighting up.

（e）Dispose of the front seat outer belt assembly

(with seat belt pretension).

CAUTION:：
◆ The front seat outer belt assembly is very hot

when the seat belt pretension is activated , so leave

it alone for at least 30 minutes after activation.

◆ Wear gloves and safety glasses when handling a

front seat outer belt with activated seat belt

pretension.

◆ Always wash your hand with water after

completing the operation.

◆ Do not splash water, etc. to an activated front

seat belt pretension

（1）Remove the wheel and specified tool.

（2）Place the front seat outer belt assembly to a

vinyl bag, tie the end tightly and dispose of it in the

same way as other general parts

11-63
11-Airbag and Belt

Rear Belt

Component

11-64
 11-Airbag and Belt

Replacement
HINT：
■ Installation is in the reverse order of the

removal, But the installation is indicated only when

it has a point.
1. Remove the rear door opening trim RH (see
3-96 section)
2. Remove the rear door opening trim LH
3. Remove the rear seat cushion assembly
4. Remove the rear seat back assembly
5. Remove the rear seat back box inner garnish
assembly
6. Remove the roof side garnish inner RH
7. Remove the roof side garnish inner LH
8. Remove the room partition board assembly
9. Remove the right side board of rear seat
10. Remove the rear seat side board LH
11. Remove the rear seat 3-point outer belt
assembly RH
（a）Remove the bolts and disconnect the belt

assembly (floor anchor)

（b） Remove the bolts and belt assembly

12.Remove the rear seat 3-point outer belt

assembly LH
（a）Remove the bolts and disconnect the belt

assembly (floor anchor).

（b）Remove the bolts and the belt assembly.

13. Remove the three-point inside belt assembly

of right rear seat
（a）Remove the bolts and the belt assembly.
14. Remove the rear seat 3-point inner belt
assembly
（a）Remove the bolts and the belt assembly.
15. Install the rear seat 3-point inner belt

11-65
11-Airbag and Belt

assembly RH
（a）Install the belt assembly with bolts as shown.
torque：42N•m
NOTE：
● Do not make the anchor part run onto the

protrusion part of the vehicle floor panel.

16.Install the rear seat 3-point inner belt
assembly LH
（a）Install the belt assembly with bolts as shown.
Torque：42N•m
NOTE：
● Do not make the anchor part run onto the

protrusion part of the vehicle floor panel.

17.Install the rear seat 3-point outer belt

assembly
NOTE：
● Do not disassemble the retractor

（a）Check the degree of tilt when the belt begins

to lock the ELR

（1）Check that the belt will not lock within 15

degrees of tilt in all directions but the belt will lock

over 45 degrees of tilt when moving the installed

retractor gently.

If the operation is not as specified, replace the rear

seat outer belt assembly (in retractor side)

（ b ） Install the belt assembly with bolts (in

retractor side)
Torque：42N•m
（c）Install the belt assembly with bolts (floor

anchor).
Torque：42N•m

11-66
 11-Airbag and Belt

（d）Check the ELR lock

NOTE：
● Check should be performed with the assembly

installed.

● Check that the belt cannot be pulled out

anymore, but can be rewound after the belt is fully

pulled out.

● Check that the belt can be pulled out and be

rewound after the belt is fully rewound.

● If the operation is not as specified, replace the

rear seat belt assembly.

18.Install the rear seat back assembly
19.Appendix: Diagnostic Trouble Code Chart

11-67
11-Airbag and Belt

Diagnostic Trouble Code which can be detected

8101 High voltage power supply

8102 Low voltage power supply

8201 Too high resistance value of driver’s side airbag

8202 Too low resistance value of driver’s side airbag

8203 Driver’s side airbag resistance value short to ground

8204 Driver’s side airbag resistance value short to power

8211 Too high resistance valve of front seat passenger’s side airbag

8212 Too low resistance valve of front seat passenger’s side airbag

8213 Front seat passenger’s airbag resistance short to ground

8214 Front seat passenger’s airbag resistance short circuit to power

8221 Too high driver pre-load resistance value

8222 Too low driver pre-load resistance value

8223 Driver’s pre-load resistance short to ground

8224 Driver’s pre-load resistance short to power

8226 Too high front seat passenger 's pre-load resistance value

8227 Too low front seat passenger’s pre-load resistance value

8228 Front seat passenger’s pre-load resistance short to ground

8229 Front seat passenger’s pre-load resistance short to power

8710 Driver’s buckle switch short to power

8711 Driver’s buckle switch short to ground

8712 Front seat passenger buckle switch short to the power

8713 Front seat passenger buckle switch short to ground

8714 Driver buckle switch failure

8725 Front seat passenger buckle switch failure

8726 Front seat passenger’s airbag inactivation switch short to ground

8727 Front seat passenger’s airbag inactivation switch failure

11-68
 11-Airbag and Belt

8616 Collision output short to ground

8617 Collision output short to power

8611 Collision recorded in the first stage only

8614 Collision recorded in belt pre-loader only

8615 Seatbelt pre-loader ignition (6 times)

8610 ACU Internal error - replace

8300 Warning light error - open circuit

8301 Warning light error - Short to ground

8302 Warning light error - Short to power

8303 Front seat passenger’s airbag warning light error

8750 Vehicle configuration not match

Failure code clearance

Failure Description Exclude

1 Ignition circuit 1, resistance value too high or open in circuit YES

2 Ignition circuit 1, resistance value too low or short in circuit YES

3 Ignition circuit 1, connect to the ground YES

4 Ignition circuit 1, connect to the power YES

5 Ignition circuit 2, resistance value too high YES

6 Ignition circuit 2, resistance value too low YES

7 Ignition circuit 2,connect to ground YES

8 Ignition circuit 2,connect to power YES

9 Ignition circuit 3, resistance value too high YES

10 Ignition circuit 3, resistance value too low YES

11 Ignition circuit 3,connect to ground YES

12 Ignition circuit 3,connect to power YES

13 gnition circuit 4, resistance value too high YES

11-69
11-Airbag and Belt

14 Ignition circuit 4, resistance value too low YES

15 Ignition circuit 4,connect to ground YES

16 Ignition circuit 4,connect to supply YES

17 PPD failure - PPD internal failure YES

PPD communication error - PPD open in circuit or connect to

18 YES
power

PPD communication error - frame error or short-circuit ,connect

19 YES
to ground

PPD communication error - parity error

20 YES

21 Too high supply voltage YES

22 Too low supply voltage YES

Warning light failure - connect to power supply or bulbs short in

23 YES
circuit

24 Warning light failure - connect to ground or Bulb open in circuit YES

25 Algorithm parameters missing / error (ReplaceECU)

(Replace
26 Collision history recorded
ECU)

27 Internal failure (Replace ECU)

11-70
12- Electronic equipment system

Electronic equipment system

Malfuction table .................................................................................................................1

composition of engine electronic control system .......................................................13

 12- Electronic equipment system

Electronic equipment system

Malfunction table

Malfunction code table for electronic control system

Failure
Diagnosis Problems Inspection area
code
·Trouble light on Harness and socket connectors and continuity

·Bad engine idling between

P0010 OCV
·Bad driving ·Oil Control Valve

·Bad exhaustion ·Engine control unit

·Valve timing
·Malfunction indicator
·OCV
light on
P0011 VVT ·Camshaft timing sprocket
·Bad engine idling
·VVT-i oil path
·Bad driving
·Engine control unit

·Valve timing
·Trouble light on
·OCV
·Improper engine
P0012 VVT ·Camshaft timing sprocket
idling
·VVT-oil path
·Bad driving
·Engine control unit

·Harness and socket connectors and

·Trouble light on connection status

02Sensor heater
P0031 ·Worsening tailpipe ·02Sensor(high)
(high)
emission ·02Sensor heater

·Engine control unit

·Trouble light on ·Harness and socket connectors and

02Sensor heater
P0037 ·Worsening tailpipe connection status
(low)
emission ·02Sensor(low)

12-1
12- Electronic equipment system

·02Sensor heater(low)

·Engine control unit

·Trouble light on ·Harness and socket connectors and

Intake pressure sensor ·Improper engine connection status

P0106
feature idling ·Intake pressure sensor

·Bad driving ·Engine control unit

· Trouble light on ·Harness and socket connectors and

Intake pressure sensor ·Improper engine connection status

P0107
(Low) idling ·Intake pressure sensor

·Bad driving ·Engine control unit

·Trouble light on ·Harness and socket connectors and

Intake pressure sensor ·Improper engine connection status

P0108
(High) idling ·Intake pressure sensor

·Bad driving ·Engine control unit

·Trouble light on ·Harness and socket connectors and

Intake temperature sensor ·Improper engine connection status

P0111
feature idling ·Intake temperature sensor

·Bad driving ·Engine control unit

·Trouble light on
·Harness and socket connectors and
·Improper engine idling
Intake temperature sensor connection status
P0112 ·Bad driving
(Low) ·Intake temperature sensor
·Worsening tailpipe
·Engine control unit
emission

·Trouble light on ·Harness and socket connectors and

Intake temperature sensor ·Improper engine idling connection status

P0113
(High) ·Bad driving ·Intake temperature sensor

·Worsening tailpipe ·Engine control unit

12-2
 12- Electronic equipment system

emission

·Trouble light on ·Harness and socket connectors and

Water temperature sensor ·Improper engine idling connection status

P0116
feature ·Bad driving ·Water temperature sensor

·Engine control unit

·Trouble light on
·Harness and socket connectors and
·Improper engine idling
Water temperature connection status
P0117 ·Bad driving
sensor(Low) ·Water temperature sensor
·Worsening tailpipe
·Engine control unit
emission

·Trouble light on
·Harness and socket connectors and
·Improper engine idling
Water temperature sensor connection status
P0118 ·Bad driving
(High) ·Water temperature sensor
·Worsening tailpipe
·Engine control unit
emission

·Trouble light on ·Harness and socket connectors and

Master throttle position
·Improper engine idling connection status
P0122 sensor
·Bad driving ·Throttle position sensor
(Low)
·Engine control unit

·Trouble light on ·Harness and socket connectors and

Master throttle position ·Improper engine idling connection status

P0123
sensor(High) ·Bad driving ·Throttle position sensor

·Engine control unit

·Trouble light on ·Harness and socket connectors and

02Sensor feature
P0131 ·Worsening tailpipe connection status
(high)
emission .02Sensor (high)

12-3
12- Electronic equipment system

·Engine control unit

·Harness and socket connectors and

·Trouble light on
02Sensor feature connection status
P0132 ·Worsening tailpipe
(high) .Sensor (high)
emission
·Engine control unit

·Harness and socket connectors and

connection status

.Sensor （high)
·Fault light on ·02Sensor heater (high)
02Response of the sensor
P0133 ·Worsening tailpipe ·Intake system
(high)
emission ·Fuel pressure

·Fuel Injector
·PCV pipe and the connection status

·Engine control unit

·Harness and socket connectors and

·Trouble light on
connection status
P0134 02Sensor ·Worsening tailpipe
.Sensor (high)
emission
·Engine control unit

·Harness and socket connectors and

connection status

.Sensor （high)

·Trouble light on ·02Sensor heater (high)

02Sensor feature
P0137 ·Worsening tailpipe ·Intake system
(Low)
emission ·Fuel pressure

·Fuel Injector

·PCV pipe and the connection status

·Engine control unit

12-4
 12- Electronic equipment system

·Harness and socket connectors and

connection status

.Sensor （high)
·Trouble light on ·02Sensor heater (high)
02Sensor feature
P0138 Worsening tailpipe ·Intake system
(low)
emission ·Fuel pressure

·Fuel Injector
·PCV pipe and the connection status

·Engine control unit

·Harness and socket connectors and

connection status
·Trouble light on
·intake system
·Improper engine idling
·Fuel pressure
P0171 Fuel system Partial thin ·Bad driving
·Ignition system
·Worsening tailpipe
·Exhaust system leaks
emission
·02Sensor (high)

·02Sensor(low)

·Harness and socket connectors and

·Trouble light on connection status

·Improper engine ·Intake system

Fuel system partial idling ·Fuel pressure

P0172
concentration ·Bad driving ·Ignition system

·Worsening tailpipe ·Exhaust system leaks

emission ·02.Sensor (high)

·02Sensor(low)

··Trouble light on ·Harness and socket connectors and

Vice throttle position
P0222 ·Improper engine idling connection status
Sensor (Low)
·Bad driving ·Throttle position Sensor

12-5
12- Electronic equipment system

·Engine control unit

·Trouble light on ·Harness and socket connectors and

Vice throttle position ·Improper engine idling connection status

P0223
Sensor (High) ·Bad driving ·Throttle position Sensor

·Engine control unit

·Harness and socket connectors and

connection status

·Vacuum tube and the connection status

·Ignition system
·Trouble light on
·Fuel Injector
·Improper engine
·Fuel pressure
idling
P0300 Misfire detection ·Intake manifold pressure sensor
·Bad driving
·Water temperature sensor
·Worsening tailpipe
·Cylinder pressure
emission
·Valve clearance

·Valve timing

·PCV pipe and the connection status

·Engine control unit

·Harness and socket connectors and

connection status
·Trouble light on ·Vacuum tube and the connection status

·Improper engine idling ·Ignition system

P0301 Misfire detection(#1) ·Bad driving ·Fuel Injector

·Worsening tailpipe ·Fuel pressure

emission ·Intake manifold pressure sensor

·Water temperature sensor

·Cylinder pressure

12-6
 12- Electronic equipment system

·Valve clearance

·Valve timing

·PCV pipe and the connection status

·Engine control unit

·Harness and socket connectors and

connection status
·Vacuum tube and the connection status

·Ignition system
·Trouble light on ·Fuel Injector
·Improper engine idling ·Fuel pressure

P0302 Misfire detection(#2) ·Bad driving ·Intake manifold pressure sensor

·Worsening tailpipe ·Water temperature sensor

emission ·Cylinder pressure

·Valve clearance

·Valve timing

·PCV pipe and the connection status

·Engine control unit

12-7
12- Electronic equipment system

·Harness and socket connectors and

connection status
·Vacuum tube and the connection status

·Ignition system
·Trouble light on ·Fuel Injector
·Improper engine idling ·Fuel pressure

P0303 Misfire detection(#3) ·Bad driving ·Intake manifold pressure sensor

·Worsening tailpipe ·Water temperature sensor

emission ·Cylinder pressure

·Valve clearance

·Valve timing

·PCV pipe and the connection status

·Engine control unit

·Harness and socket connectors and

connection status
·Vacuum tube and the connection status

·Ignition system
·Trouble light on ·Fuel Injector
·Improper engine idling ·Fuel pressure

P0304 Misfire detection(#4) ·Bad driving ·Intake manifold pressure sensor

·Worsening tailpipe ·Water temperature sensor

emission ·Cylinder pressure

·Valve clearance

·Valve timing

·PCV pipe and the connection status

·Engine control unit

Detonation Sensor ·Trouble light on ·Harness and socket connectors and

P0327
(Low) ·Bad driving connection status

12-8
 12- Electronic equipment system

·Detonation control Sensor

·Engine control unit

·Harness and socket connectors and

Detonation Sensor ·Trouble light on connection status

P0328
(High) ·Bad driving ·Detonation control Sensor

·Engine control unit

·Harness and socket connectors and

connection status
·Trouble light on
P0335 Crankshaft position Sensor ·Crankshaft position Sensor
Bad start-up
·Crankshaft angle bar(flywheel)

·Engine control unit

·Harness and socket connectors and

connection status
·Trouble light on
P0340 Camshaft Position Sensor ·Camshaft Position Sensor
.Bad start-up
·Camshaft angle bar(Intake camshaft)

·Engine control unit

·Trouble light on
·Exhaust leaks
·Worsening tailpipe
·02Sensor(low)
P0420 Catalyst deterioration emission
·02Sensor(high)

·Catalyst

·Trouble light on ·Harness and socket connectors and

connection status
P0443 Clean control valve
·Clean control valve

·Engine control unit

·Harness and socket connectors and

Radiator-fan ·Trouble light on
P0480 connection status
·water temperature rise
·radiator-fan

12-9
12- Electronic equipment system

·Engine control unit

·Harness and socket connectors and

·Trouble light on
connection status
Speed sensor .Bad start-up
P0500 ·Speed sensor
·Combined meter

·Engine control unit

·Trouble light on
·Engine control unit
P0607 ECU ·Improper engine idling

·Bad driving

·Harness and socket connectors and

connection status
·Trouble light on
P0616 Starter OFF ·Ignition Switch
.Bad start-up
·Clutch switch

·Engine control unit

·Harness and socket connectors and

connection status
·Trouble light on
P0617 Starter ON ·Ignition Switch
.Bad start-up
·Clutch switch

·Engine control unit

·Harness and socket connectors and

·Trouble light on
connection status
Reverse power .Bad start-up
P1510 ·Engine control unit
·Improper engine idling

·Bad driving

·Trouble light on ·Harness and socket connectors and

Motor drive circuit
P2101 ·Improper engine idling connection status
·Bad driving ·Throttle Body

12-10
 12- Electronic equipment system

·Engine control unit

·Harness and socket connectors and

·Trouble light on
connection status
P2102 Motor relay OFF ·Improper engine idling
·Throttle Body
·Bad driving
·Engine control unit

·Harness and socket connectors and

Motor relay ON ·Trouble light on
connection status
P2103 ·Improper engine idling
·Throttle Body
·Bad driving
·Engine control unit

·Harness and socket connectors and

·Trouble light on
Return spring connection status
P2111 ·Improper engine idling
·Throttle Body
·Bad driving
·Engine control unit

·Trouble light on
·Engine control unit
·Improper engine idling
P2119 ETC opening rationality
·

Bad driving

Master accelerator position ·Harness and socket connectors and

sensor(Low) ·Trouble light on connection status

P2122 ·Improper engine idling ·Accelerator position

·Bad driving sensor(Accelerator pedal assembly)

·Engine control unit

Master accelerator position ·Harness and socket connectors and

sensor(High) ·Trouble light on connection status

P2123 ·Improper engine idling ·Accelerator position

·Bad driving sensor( Assembly)

·Engine control unit

12-11
12- Electronic equipment system

Vice accelerator position ·Harness and socket connectors and

sensor(Low) ·Trouble light on connection status

P2127 ·Improper engine idling ·accelerator position sensor(accelerator

·Bad driving pedal assembly)

·Engine control unit

Vice accelerator position ·Harness and socket connectors and

sensor(High) ·Trouble light on connection status

P2128 ·Improper engine idling ·Accelerator position

Bad driving sensor(Accelerator pedal assembly)

·Engine control unit

Throttle position sensor ·Harness and socket connectors and

·Trouble light on
feature connection status
P2135 ·Improper engine idling
·Throttle position sensor
·Bad driving
·Engine control unit

Accelerator position ·Harness and socket connectors and

sensor feature ·Trouble light on connection status

P2138 ·Improper engine idling ·Accelerator position

·Bad driving sensor(Accelerator pedal assembly)

·Engine control unit

Speed sensor(ABS) ·Harness and socket connectors and

connection status
P1000 ·Failure light off
·Wheel speed sensor in ABS

·Engine control unit

12-12
 12- Electronic equipment system

Composition of engine electronic control system

The engine electronic control system consists of various sensors, actuators and electronic control

units.

The composition of the engine electronic control system

Component Name
Crankshaft position Sensor

Camshaft Position Sensor

Intake pressure temperature sensor

Coolant temperature Sensor

Detonation Sensor
Sensor
Front oxygen sensor

Rear oxygen sensor

Accelerator pedal position sensor

Electronic throttle position sensor

Speed sensor

Ignition coil and spark plug

Injector assembly

Actuator Electronic throttle body assembly

Pulsation damper assembly

Canister solenoid valve

Engine electronic control unit Engine electronic control unit

Solenoid valve Camshaft timing oil control valve

ECU Master relay

Throttle relay

Relay Fuel pump relay

Air conditioning compressor

magnetic clutch relay

12-13
12- Electronic equipment system

Low speed fan relay

High speed fan relay

Brake switch

Air-condition pressure switch1

Switch Air-condition pressure switch2

Brake light switch

DEF(Defroster) switch

Installation location for engine electronic control components

12-14
 12- Electronic equipment system

CA4GA1 Engine electronic control system components

No. Part number Component name Number
1 3603020-28K Fuel rail assembly 1

2 3603025-28K Pulsation damper assembly 1

3 3603026-28K Sealing gasket 1

4 3603060-28K Fuel rail sub-assembly 1

5 3603031-28K Injector retaining clip 4

6 3603030-28K Injector assembly 4

7 Q1840816 Hex head flange bolt 2

8 3724023-28K Bracket Ⅲ - fixing engine harness 2

9 Q1840625 Hex head flange bolt 4

10 3603040-28K Rod-type ignition coil assembly 4

11 CQ1460650 Assembling bolt 4

12 3603010-28K Electronic throttle body assembly 1

13 Q673B12 Metal spring hoop 6

14 3603011-28K Electronic throttle body inlet 2

15 3603077-28K Canister solenoid valve outlet 1

16 3602035-28K Intake pressure temperature sensor 1

17 Q1840612 Hex head flange bolt 2

18 3602065-28K Knock sensor assembly 1

19 Q1840830 Hex head flange bolt 1

20 Q1840616 Hex head flange bolt 1

21 3602055-28K Camshaft Position Sensor 1

22 3602015-28K Coolant temperature sensor assembly 1

23 3602095-28K Rear oxygen sensor assembly 1

24 3602085-28K Front oxygen sensor assembly 1

25 Q2360510 Cruciform slot button head combination screw 1

12-15
12- Electronic equipment system

26 3602045-28K Crankshaft position Sensor assembly 1

27 3603076-28K Canister solenoid valve bracket 1

28 3603075-28K Canister solenoid valve assembly 1

29 3707010-28K Spark plug assembly 4

Engine electronic control system diagram

12-16
 12- Electronic equipment system

1.Electronic control unit ECU

Installation location: in the foreside of front wall

panel.

Disconnect the ECU wire, unscrew the 4 fixing

bolts of the control unit , then remove the

electronic control unit (ECU)

Function: The engine electronic control unit is the core

of the electronic control system, which consists of the

hardware circuit and control software. It is responsible for

information collection, processing, evaluation and

execution, and outputs the results as a control command to

the actuator, meanwhile communicating with other ECU to

display some running states and conducts the failure

diagnosis for the entire control system. The engine ECU

continuously checks the state of the engine via the sensor

input signal to calculate the correct injection time and

injection volume, etc., starts the actuator and brings the

engine to the best state. The ECU has a diagnostic feature

which can be used to record system failure.

table 13.1 ECU parameter characteristics

Parameters Value

Rated voltage 12V(DC)

Working voltage 6V～12V

Working Temperature ﹣30℃～﹢80℃

Storage temperature ﹣40℃～﹢85℃

12-17
12- Electronic equipment system

2. Crankshaft position Sensor

Installation location: The crankshaft position sensor

is installed on the engine flywheel shell.

Remove the crankshaft position sensor.

Unscrew the bolt connecting the crankshaft sensor

and engine, then remove the crankshaft position

sensor.

Function of the Crankshaft position sensor: The

crankshaft position sensor is the magnetoelectric

sensor, it detects the signal of the crankshaft angle

and engine speed ,and transmits the signal to the

engine ECU used as the master control signal of

fuel injection and ignition control.

table 13.2 Crankshaft position sensor parameter characteristics

Parameter Value
Working temperature ﹣30℃～﹢135℃

Storage temperature ﹣40℃～﹢140℃

Resistance 1100±150Ω(﹢20℃)

835～1400Ω(﹣10～50℃)
Output resistance
1060～1645Ω(50～100℃)

Inductance 760mh(1KHz, ﹢20℃)

12-18
 12- Electronic equipment system

3. Camshaft position sensor

Installation location: The camshaft position sensor

is installed on the back-end of engine cylinder head

Remove the camshaft position sensor

Unscrew the bolt connecting the camshaft sensor

and engine ,then remove the camshaft position

sensor

Function: The camshaft position sensor provides

the signal of camshaft rotation position to the ECU,

together with information from the crankshaft

position sensor to determine the ignition and fuel

injection time of ECU. And the signal can also

serve as the VVT control signal.

table13.3 Camshaft position sensor parameter characteristics

Parameter Value
Working Temperature ﹣30℃～﹢135℃

Storage temperature ﹣40℃～﹢140℃

Resistance 2150±300Ω(﹢20℃)

1630～2740Ω(﹣10～50℃)
Output Resistance
2065～3225Ω(50～100℃)

Inductance 1220mh(1KH z, ﹢20℃)

12-19
12- Electronic equipment system

4. Intake pressure temperature sensor

Installation location: The intake pressure

temperature sensor is installed on the intake

manifold.

Remove the intake pressure and temperature

sensors.

Unscrew the two bolts connecting the intake

pressure and temperature sensor and engine, and

then remove the intake pressure temperature sensor.

Function: The intake pressure sensor detects the

air pressure within the intake manifold, and

transmits the signal to ECU as the main control

signal of fuel injection and ignition control..The

intake temperature sensor detects the temperature

within the intake manifold and provides the intake

temperature signal to the ECU as the correction

signal of fuel injection and ignition time control.

Table 13.4 Intake pressure temperature sensor parameter characteristics

Parameter Value
Supply voltage 5±0.25V
Working Temperature ﹣30℃～﹢120℃

Working pressure 13.332～119.990KPa

Pressure accuracy (25℃) ΔP ±1.066 KPa

12-20
 12- Electronic equipment system

5. Coolant temperature sensor

Installation location :the sub-water pipe near the

thermostat.

Remove the intake pressure temperature sensors.

Unscrew the intake pressure temperature sensor

from the engine, then remove the intake pressure

temperature sensors.

Function: It tests the coolant temperature of the

engine and transmits the signal to the engine ECU

for oil correction and warm-up control.

Table 13.5 Intake air temperature sensor temperature and resistance parameter
characteristics
Parameter Value Value
﹣20℃ (16.2KΩ)

20℃ 2.45～±0.24 KΩ

80℃ 0.322～±0.032 KΩ

12-21
12- Electronic equipment system

6. Detonation Sensor

Installation location: the engine cylinder block.

Remove the detonation sensor.

Unscrew a hex flange bolt connecting the engine

and detonation sensor , remove the detonation

sensor.

Function: It can detect the detonation signal that

any engine cylinder sends, and convert it into a

voltage signal ,then transmits this voltage signal to

the engine ECU. The ECU then determines the

detonation intensity according to the volume of the

voltage thus delaying the ignition time

correspondingly to avoid the detonation.

Table 13.6 Coolant temperature sensor parameter characteristics

Parameter Value
Working Temperature ﹣30℃～﹢130℃

Sensor pin A Signal(ECU)

Sensor pin B Signal(instrument)
Sensor pin C Sensor (ground)
Between the sensor pin A and C

温 Temperature(℃) Resistance value(KΩ)

﹣20±0.1 13.71～16.49

25±0.1 1.825～2.155

80±0.1 0.303～0.326

12-22
 12- Electronic equipment system

110±0.1 0.1383～0.1451

Between the sensor pin B and C

Temperature(℃) Resistance value(KΩ)

55 220.5+−48.6
38.7

60 181.8+−38.7
27.7

112 33.8+−5.1
4.0

117 29.8+−43

12-23
12- Electronic equipment system

7. Front oxygen sensor

Installation location: the exhaust pipe of vehicle.

Remove the front oxygen sensor.

Unscrew the front oxygen sensor from the engine ,

then remove the front oxygen sensor.

Function: This sensor tests the signal whether

the engine exhaust contains excess oxygen after

combustion ,i.e. the oxygen content, and transfers it

into voltage signal ,which is transmitted to the

engine electronic control unit(ECU),so the engine

can realize the closed-loop control targeting the

excess air factor; it can ensure that catalytic

converter has the greatest conversion efficiency to

three pollutants from the exhaust, i.e. hydrocarbon

(HC), carbon monoxide (CO) and nitrogen oxides

(NOX) meanwhile can transform and purify the

emission pollutants to the greatest extent .

12-24
 12- Electronic equipment system

table13.7 Detonation Sensor parameter characteristics

Application environment Value

Working Temperature ﹣30℃～﹢130℃

Storage temperature ﹣40℃～﹢130℃

2
Allowable vibration G 245m/ s (25G)

25℃±10℃

Product Specification Initial value Durable value

26±8 mVO − P
Output voltage 14.4±40.8 mVO − P G(8kHZ)
G(8kHZ)
Electrostatic capacitance 1400±350pF 1400±350pF
Internal impedance(DC) 200kΩ±80Ω 200kΩ±80Ω
Insulation impedance Min.2MΩ Min.1MΩ

12-25
12- Electronic equipment system

8. Rear oxygen sensor

Installation location: the exhaust pipe of vehicle

and backside of the catalytic converter.

Remove the rear oxygen sensor

Unscrew the rear oxygen sensor from the engine,

then take down the rear oxygen sensor.

Function: The rear oxygen sensor is installed on

the catalytic converters backside and is used to

measure the oxygen content of exhaust gas and

transmit the signal to the ECU. The front oxygen

sensor provides important data for testing the

performance of catalytic converter.

table13.8 Front oxygen sensor parameter Characteristics

Parameter Value
Service temperature ﹣30℃～900℃

Working Temperature 300℃～900℃

12-26
 12- Electronic equipment system

9. Accelerator pedal position sensor

Installation location: the accelerator pedal assembly

under driver dashboard.

Remove the accelerator pedal assembly under

driver dashboard; remove the 2 screws on the

accelerator pedal.

Function: It is composed of the two sensors and is

used to test the opening of the accelerator pedal ,

And the basic fuel injection amount and torque

requirements can be adjusted by the signals

dispatched by the sensors.

table 13.9 Rear oxygen sensor parameter characteristics

Parameter Value
Service temperature ﹣30℃～900℃

Working Temperature 300℃～900℃

12-27
12- Electronic equipment system

10. Electronic throttle position sensor

Installation location: the intake manifold.

Remove the electronic throttle position sensor.

Unscrew the three bolts connecting the electronic

throttle position sensor and engine, remove the

electronic throttle position sensor.

Function: The electronic throttle position sensor is

installed on the electronic throttle body and

contains the two sensors which are used to detect

the throttle opening, and transmit the signal to the

ECU. The ECU then can check the actual throttle

opening and whether the sensor itself has a failure

by these two sensors' signal input.

12-28
 12- Electronic equipment system

Table 13.10 Accelerator pedal position sensor parameter characteristics

Parameter Initial characteristics

Service temperature
﹣30℃～85℃
range
Working
Storage temperature
range ﹣40℃～85℃
range
Rated voltage 5.0V
Sensor output
Output1 Output2
voltage

0.8±0.05V 1.6±0.05V
Fully closed voltage
The output voltage reference point for the
θ1
Characteristics
Basic slope:0.149V/deg.

linearity ±0.040V( θ1 ～2°)

±0.070V(2～4°)

±0.120V(4～10°)

±0.135V(10～15.9°)

12-29
12- Electronic equipment system

11. Speed sensor

Installation Location: the foreside of gearbox.

Remove the speed sensor.

Unscrew the two bolts connecting the engine speed

sensor and engine, take down the speed sensor.

Function: The speed sensor detects the speed of

vehicle and transmits the speed signal to the ECU

for the cruise control and speed-limit oil-off control.

This signal can be used as the basis of air-fuel ratio

control of the engine idle condition, acceleration

and deceleration sliding conditions.

Table13.11 Electronic throttle position sensor parameter characteristics

Parameter Value
Service temperature range ﹣30～120℃

Driving voltage 9～16V

Service voltage
Non-contact sensor 5V
3
Fully closed position missing variable Max. 2.1 m / h
Project Test item Initial value Test condition
Throttle sensor
Fully 0.6±0.1V
signal VTA1
closed Power supply：5VDC
Throttle sensor 1.48±0.1V
position
signal VTA1

12-30
 12- Electronic equipment system

Actuator

12. Ignition coil and spark plug

The installation position for ignition coil is shown

in Figure.

Unscrew the bolt connecting the engine, remove

the ignition coil and spark plugs, unscrew the

spark plug from the engine assembly , remove the

ignition coil.

The function of spark plug: It is used to lead the

high-voltage electricity into the combustion

chamber and produce a spark to ignite the

combustible mixture gas.。

Installation position: ignition coil is installed on the

spark plug of each cylinder.

The function of the ignition coil :It acts as an

auto-transformer and can transform the low voltage

into a high voltage required for breaking down the

spark plug gap.

12-31
12- Electronic equipment system

Table13.12 Ignition coil parameter characteristics

Parameter Value
Rated voltage 12V

Working voltage 5～16V

Working Coil part ﹣30℃～130℃

environment
Ignition part ﹣30℃～120℃
Temperature
Storage Coil part ﹣40℃～130℃
environment
Ignition part ﹣40℃～130℃
temperature

12-32
 12- Electronic equipment system

13. Injector

Installation position of the injector is shown

in figure.
Disassemble the injector.

Unscrew the injector from the engine intake

manifold , take down the injector.

The function of injector: It is used to inject a proper

amount of fuel into the intake manifold according

to the signal provided by the electronic control unit

(ECU).

Table 13.13 Injector parameter characteristics

Parameter Value
Environmental temperature ﹣30℃～130℃

Vibration Maximum30G
Coil resistance 12.0±0.5Ω(20℃)

Inductance 1.0mh(20℃)

12-33
12- Electronic equipment system

14. Vane type VVT controller

Installation location: on the intake camshaft.

Function: The Vane VCT (variable cam timing)

controller, and the oil control valve of camshaft

timing OCV comprise the variable valve timing

system. The engine electronic control system uses a

variable valve timing technology, which makes the

engine power and torque output more linear, while

ensuring the power output of the high and low

speed..The engine speed can be designed to be

higher, thus it can get more power output.

12-34
 12- Electronic equipment system

15. Camshaft timing oil control valve

Installation location: the chain chamber cover.

Function: It is used to control the oil pressure of

advance chamber and delay chamber in the VCT

controller to make the intake camshaft change

phase continuously by OCV (Oil-Flow Control

Valve)installed on the chain chamber cover .

Table 13.14 The camshaft timing oil control valve parameter characteristics
Parameter Value
Power supply 10～16V

Control current 100～1000 mA

Oil pressure 0～1000kP

Oil temperature ﹣30～130℃

Coil impedance 6.9～7.9Ω(20℃)

12-35
12- Electronic equipment system

16. Canister solenoid valve

Installation position: between the charcoal canister

and the engine intake manifold.

Remove the canister solenoid valve.

Remove the canister solenoid valve's fixing bolt

from the engine as shown in figure , take down the

canister solenoid valve.

Function: When the solenoid valve is not working,

the gasoline vapor in tank will be stored in the

charcoal canister. When certain conditions are met,

the ECU will open the canister solenoid valve, this

will make the gasoline vapor carried by clean air

into the cylinder burn under the action of the

vacuum from the intake manifold and this will not

only reduces the emissions but also reduces the fuel

consumption.

Table 13.15 Canister solenoid valve parameter characteristics

Parameter Value
Power supply 12V
Coil impedance 24.5Ω±1.5Ω(20℃)

Operating temperature range ﹣40～120℃

12-36
 12- Electronic equipment system

17. Pulsation damper

Installation position: on the fuel rail.

Remove the pulsation damper.

Unscrew the pulsation damper from engine and

remove it.

Function :It is used to reduce the volatility of the

fuel oil pipeline, keeping the system pressure

stable.

Table 13.16 Pulsation damper parameter characteristics

Parameter Value

Service temperature ﹣30℃～120℃

When the pressure increases from 147 kPa to 304

Operating Characteristics
kPa, the valve's displacement (1.9 ± 0.4) mm

12-37
 13-Wheel and Tire System

Wheel and Tire System

FailureSymptoms Table……………………………………………….. 1

Tire Model Parameter………………………………………………….. 3

Tire Replacement………………………………………………………. 5

Tire Rotation…………………………………………………………… 7

Wheel balance Inspection……………………………………………… 8

 13-Wheel and Tire System

Wheel and tire system

Failure Symptoms Table

Use the following table to help determine the cause of the problem symptom. Numbers are put in

order of possibility in the “Suspected area” column of table. Check each symptom by checking the

suspected areas in the order as listed. Replace parts, if necessary。

Symptom Suspected area
1. Tire (Worn or improperly inflated)

2. Wheel alignment (Incorrect)

3. Knuckle (loosen, worn)

Deviation
4. Hub bearing (Worn)

5. Steering Gear (Beyond the adjustment range, damaged)

6. Suspension parts (Worn)

1. Tire (Worn or deformed)

2. Stabilizer bar(Bent, damaged)

Swing ,bump, jitter 3. Shock absorber(Worn)

4. Hub(Deformed)

5. Wheel bolts not tightened

1. Tire (Worn or improperly inflated)

2. Wheels (Unbalanced)

3. Shock absorber (Worn)

4. Wheel alignment (Incorrect)

Front wheel swing
5. Ball head (Worn)

6. Hub bearing (Worn)

7. Knuckle (Loosen, worn)

8. Steering gear (Beyond adjustment range, damaged)

13-1
13-Wheel and Tire System

1. Tire (Worn or inflated improperly )

2. Wheel alignment (Incorrect)

Abnormal tire wear 3. Shock absorber (Worn)

4. Suspension parts (Worn)

5. Hub (Deformed)

13-2
 13-Wheel and Tire System

Tire Model Parameter

1. Tire inspection
Check the tires for proper cold inflation pressure。

(Tire Type: 175/65R14 or 185/65R14)

When vehicle’s load capacity is two occupants

Front Rear
Speed
kPa(kgf／cm2, psi) kPa(kgf／cm2, psi)

Any speed 230(2. 3 ,33 ) 210(2. 1 ,33 )

When vehicle’s load capacity is five occupants

Front Rear
Speed
kPa (kgf／cm2, psi) kPa (kgf／cm2, psi)

＜160km／h
230(2. 3 ,33 ) 210(2. 1 ,33 )
(100mph)

≥160km／h
230(2. 3 ,33 ) 220(2. 1 ,32 )
(100mph)

NOTE：

●Measure the inflation pressure with specified gauge

13-3
13-Wheel and Tire System

Inspection
2. Check tread wear indicator, replace tire when
excessive wear is shown.
Note:
●When replacing tires, make sure that the tires are

of the same

●Structure and size as the original ones

●Make sure that load capacity of tires are

same with or slightly larger than the original tires

●Do not use used tires

13-4
 13-Wheel and Tire System

Tire Replacement
1. Remove spare tire
(a) Remove the spare tire cover

(b) Loosen the bolts and remove the spare tire.

Then remove the spare tire out of the vehicle

2. Chock wheels
(a)Chock the wheel diagonally opposite to the flat

tire to prevent the wheels rolling when

jacking up the vehicle

(b) When chocking the front wheel, put

the wedge in front of the front wheel. When

chocking the rear-wheel, put the wedge in the back

of the rear wheel.

3. Remove wheel decoration cover

Pry the wheel decoration cover with the beveled

end of the wheel wrench or wheel decoration cover

removal tool as shown in the figure

Note：

●Do not attempt to pry the wheel decoration cover

by hand, Force exerted should be appropriate to

avoid injury.

4. Loosen wheel nuts

（a）Loosen the nut when the vehicle is jacked up

and the wheel is fixed

（ b ） Loosen the nut with a wrench. Rotate

13-5
13-Wheel and Tire System

counterclockwise

5. Place jack
Place jacks as shown in the figure. There are

four jack fulcrums under the body. Put two at each

side

6. Jack up vehicle
Confirm that no one is inside the vehicle. Jack

the vehicle up high enough to install the spare tire

Note：

●Make sure that no one is under the vehicle when

jacking up. the vehicle.

●Load should be put in the middle position of the

jack bracket

●Pull the hand brake thoroughly before jacking up

the vehicle

●Chock the wheel which is diagonally opposite to

the replaced tire

7. Using dial indicator, check tire run out

Tire run out 3mm or less

13-6
 13-Wheel and Tire System

Tire Rotation

1. Tire
Hint：
■Rotate tires according to the figure

The figure is for where to rotate each tire when

the spare tire is included in the rotation and where it

is not included.。

13-7
13-Wheel and Tire System

Wheel Balance Inspection

1. Inspect wheel balance.
(a) Check and adjust the wheel balance.

(b)Check and adjust the on-the-car balance

if necessary. Imbalance after adjustment should be

8g or less.
Note:
● Adjust the balance of outer wheel, then the

balance of inner wheel。

●Do not scratch the wheel.

2. Wheel adhesive counterweight (outer)

(a) Remove the old counterweight of the wheel。
Assembly
Adhesive along the play (b) Remove the double-sided tape on the wheels.
counterweight
Clean and degrease the welding areas.。
Whee (c) Put the wheel on the wheel balance machine.
l Central
counterweight Measure the imbalance and position. Set the mode

to impact counterweight.
Inner Outer
Position indicated
by the wheel balance (d) The counterweight value is
machine
the imbalance degree multiplying 1.6。

(e) The counterweight value should be closest

to the weight. Load counterweigh to the position of

the wheel balance machine as shown in the figure

(outer).
Note：
●The counterweight value should be closest to the

calculated one.

● Use original counterweight or equivalence

(steel).

13-8
 13-Wheel and Tire System

●When fixing balance block, the force should be

exerted in accordance with each 5g with the force

of 25 N. Press counterweigh 2 seconds or longer.

13-9
13-Wheel and Tire System

3. If the two counterweights are required to fix,

fix the counterweights on each side of the
position indicated by the wheel balance
machine.
Note:
●Do not fix the counterweight in a row.

●Do not layout the counterweight overlap.

●The total weight shall not exceed 160g (5.65oz).

4. Impact- type counterweight(inner)

(a) Measure the imbalance with a wheel balance

machine.

(b) Place the counterweight on the position

indicated by the wheel balance machine. The

counterweight shall be equal to the measured value.

Note:
●Do not load three or more blocks of the

counterweight.

●A single counterweight shall not exceed 60g, and

the two counterweight blocks shall not exceed100g.

5. Confirm remaining imbalance:

Spa Ru (a) Install the outer and inner counterweight

ce n out blocks.

Then perform the operation of the wheel balance

counterweight.

(b)Confirm the remaining imbalance of each side

not exceed the standard value.

6. Wheel bearing clearance inspection.

13-10
 13-Wheel and Tire System

(a) Using a dial indicator, check the clearance in

periphery of the hub center.

Maximum clearance: 0.05mm.

If the maximum is exceeded, replace the bearing.

(b)Using a dial indicator, check hub end surface

with the hub bolt excluded (check run out

Maximum run out: 0.07mm.

If the maximum is exceeded, replace the hub.

13-11