Maintenance Manual

Maintenance Manual 1 - 1 Contents

Maintenance Manual
1.1 Warning and caution ................................1-3 1.4.3.24 Inspecting lower control arm ball joint and
1.1.1 Warning and caution ....................................... 1-3 front stabilizer bar link ......................................... 1-45
1.1.1.1 Warning and caution ................................. 1-3 1.4.3.25 Inspecting suspension assembly .......... 1-45
1.4.3.26 Inspecting underbody ............................ 1-45
1.2 Vehicle label information .......................1-12
1.4.3.27 Inspecting tire ........................................ 1-46
1.2.1 Description and operation ............................. 1-12
1.4.3.28 Inspecting wheel fixing bolt ................... 1-47
1.2.1.1 Vehicle identification number .................. 1-12
1.4.3.29 Inspecting front shock absorber bearing 1-47
1.2.1.2 Vehicle nameplate .................................. 1-12
1.4.3.3 0 Inspecting EPB .................................... 1-47
1.3 Towing and lifting ...................................1-13
1.4.3.31 Inspecting free travel and height of brake
1.3.1 Description and operation ............................. 1-13 pedal ................................................................... 1-48
1.3.1.1 Towing .................................................... 1-13 1.4.3.32 Self-diagnosis: inspecting DTCs ........... 1-48
1.3.1.2 Lifting ...................................................... 1-14 1.4.3.33 Visually inspecting driving axle dust cover
1.3.1.3 Jacking and lifting ................................... 1-15 ............................................................................. 1-49
1.4 Maintenance..............................................1-17 1.4.3.34 Visually inspecting HEV Engine
1.4.1 Specification .................................................. 1-17 compartment
components ........................................................ 1-49
1.4.1.1 Filling volume and specifications of oil & fluid
............................................................................ 1-17 1.4.3.35 Visually inspecting braking device for
leakage and damage .......................................... 1-50
1.4.2 Description and operation ............................. 1-18
1.4.3.36 Visually inspecting exhaust system for
1.4.2.1 Maintenance schedule ............................ 1-18 leakage and damage .......................................... 1-51
1.4.2.2 Unconventional maintenance (in harsh 1.4.3.37 Visually inspecting fuel tank assembly
environments) ..................................................... 1-19 surface for bump marks ...................................... 1-53
1.4.2.3 Description of tire rotation ....................... 1-21 1.4.3.38 Bleeding brake system .......................... 1-54
1.4.3 Maintenance ................................................. 1-23 1.4.3.39 Recovering and adding refrigerant ........ 1-55
1.4.3.1 Inspecting and lubricating door checks ... 1-23 1.4.3.40 Recovering and filling compressor oil ... 1-56
1.4.3.2 Inspecting the working condition of the lock 1.4.3.41 Vacuumizing the HVAC system ............ 1-57
cylinder ............................................................... 1-24
1.4.3.42 Replacing the wiper blade ..................... 1-58
1.4.3.3 Inspecting horn ....................................... 1-24
1.4.3.43 Replacing the spark plug ........................ 1-59
1.4.3.4 Inspecting seat belt ................................. 1-25
1.4.3.44 Changing coolant .................................. 1-60
1.4.3.5 Inspecting the front airbag ...................... 1-28
1.4.3.45 Changing brake fluid ............................. 1-64
1.4.3.6 Inspecting the working status of the electrical
system ................................................................ 1-28 1.4.3.46 Changing HEV Engine oil
.............................. 1-66
1.4.3.7 Inspecting battery ................................... 1-29
1.4.3.47 Replacing the oil filter ............................ 1-68
1.4.3.8 Inspecting washer fluid ........................... 1-31
1.4.3.48 Replacing the wet DCT fluid .................. 1-69
1.4.3.9 Inspecting brake fluid .............................. 1-32
1.4.3.49 Replacing press filter element ............... 1-72
1.4.3.10 Inspecting brake pipeline ...................... 1-33
1.4.3.50 Replacing A/C filter element .................. 1-74
1.4.3.11 Inspecting coolant ................................. 1-34
1.4.3.51 Replacing air filter element .................... 1-76
1.4.3.12 Inspecting water pump belt ................... 1-36
1.4.3.52 Replacing canister filter ......................... 1-77
1.4.3.13 Inspecting V-ribbed belt and tensioner . 1-37
1.4.3.53 Replacing water pump belt .................... 1-78
1.4.3.14 Inspecting HEV Engine oil
............................. 1-38 1.4.3.54 Replacing the V-ribbed belt ................... 1-78
1.4.3.15 Inspecting windshield wiper and washer 1-39 1.4.3.55 Replacing accessory tensioner ............. 1-80
1.4.3.16 Inspecting and adjusting wiper blade 1.4.3.56 Cleaning electronic throttle body ........... 1-82
mounting position ................................................ 1-39 1.4.3.57 Lubricating door lock ............................. 1-85
1.4.3.17 Inspecting free play of steering wheel ... 1-40 1.4.3.58 Conditions for adjusting front combination
1.4.3.18 Inspecting fixing of spare tire ................ 1-40 lamp 1-85
1.4.3.19 Inspecting door lock bolt and child safety lock 1.4.3.59 Adjusting the front combination lamp .... 1-86
............................................................................. 1-41 1.4.3.60 Cleaning the windshield wiper cover plate
1.4.3.20 Inspecting wear pattern of brake lining . 1-42 ............................................................................. 1-86
1.4.3.21 Inspecting brake disc wear pattern ....... 1-43 1.4.3.61 Lubricating the air spring ball sockets of
power liftgate drive rod and balance rod ............. 1-86
1.4.3.22 Inspecting connecting bolt between steering
column and steering gear ................................... 1-43 1.4.3.62 Tightening chassis bolts ........................ 1-87
1.4.3.23 Inspecting outer ball joint and dust boot of 1.4.3.63 Battery boosting .................................... 1-95
steering gear ....................................................... 1-44 1.4.3.64 Never rinse the fuse box with a high-pressure
water gun ............................................................ 1-96
1.4.3.65 Test run ................................................. 1-96
1.5 Health and safety ................................... 1-97
1.5.1 Description and operation .............................
GAC Motor 2023 1-97
Contents 1 - 2 Maintenance Manual

1.5.1.1 Description .............................................. 1-97

1.5.1.2 Acid and alkali ......................................... 1-97
1.5.1.3 Airbag ..................................................... 1-97
1.5.1.4 HVAC refrigerant .................................... 1-98
1.5.1.5 Adhesive and sealant ............................. 1-98
1.5.1.6 HEV Engine coolant
........................................ 1-99
1.5.1.7 Asbestos ................................................. 1-99
1.5.1.8 Battery acid ............................................. 1-99
1.5.1.9 Brake fluid ............................................... 1-99
1.5.1.10 Chemical materials ............................... 1-99
1.5.1.11 Dust .................................................... 1-100
1.5.1.12 Electric shock ...................................... 1-100
1.5.1.13 Exhaust gas ........................................ 1-100
1.5.1.14 Fiber isolation ..................................... 1-100
1.5.1.15 Fire ..................................................... 1-100
1.5.1.16 First aid ............................................... 1-101
1.5.1.17 Foam-polyurethane ............................. 1-101
1.5.1.18 Fuel ..................................................... 1-101
1.5.1.19 Gas cylinder ........................................ 1-101
1.5.1.20 General workshop tools and equipment
........................................................................... 1-102
1.5.1.21 Lubricant and grease .......................... 1-102
1.5.1.22 Noise ................................................... 1-102
1.6 Special tool and equipment .................1-103
1.6.1 Special tool and equipment ......................... 1-103
1.6.1.1 Special tools for powertrain ................... 1-103
1.6.1.2 Special tools for chassis and body ........ 1-106

GAC Motor 2023

Maintenance Manual 1 - 3 Warning and caution

1.1 Warning and caution

1.1.1 Warning and caution
1.1.1.1 Warning and caution
Definitions of "Warning", "Caution" and "Note”
General and specific "Warning", "Caution" and "Note" are included in the diagnosis and repair procedures in the
Maintenance Manual. These help the after-sales service technician in vehicle diagnosis and repair so that the vehicle
can operate normally. Some procedures may be dangerous to the technicians if they do not follow the recommended
method.
"Warning", "Caution" and "Note", which are prominently arranged in the Maintenance Manual, are prepared to prevent
the following:
• Serious injury to personnel.
• Vehicle damage.
• Unnecessary vehicle repairs.
• Unnecessary replacement of parts and components.
• Improper repair or replacement of vehicle components.
Definition of "Warning"
A “Warning” requires you to take a necessary action or not to take a prohibited action. Ignoring the "Warning" may lead
to the following consequences:
• Serious injury to personnel.
• If the vehicle is repaired improperly, it will cause serious personal injury to the driver or passengers of the vehicle.
Definition of "Caution"
A “Caution” requires you to pay special attention to a necessary or prohibited action. If a “Caution” is ignored, the
following consequences may occur:
• Vehicle damage.
• Unnecessary vehicle repairs.
• Unnecessary replacement of parts and components.
• The operation or performance of the system or component being repaired is abnormal.
• Damage to related systems or components.
• Damage to fasteners, basic tools or special tools.
• HEV Engine coolant, oil or other major fluid leaks.
Definition of "Caution"
A “Caution” emphasizes the necessity of certain diagnostic or repair procedures and is designed to:
• Clarify maintenance procedures.
• Provide supplementary information for completing a maintenance procedure.
• Clarify the reasons for operation in accordance with the recommended maintenance procedures.
• help complete the maintenance procedure in a more efficient manner.
• Provide the technician with previous experience information to make it easier to complete the repair procedure.
Warning about vehicle lifting and jacking
Warning!
In order to avoid vehicle damage or serious personal injury or even death, when removing the main component from the
vehicle and supporting the vehicle with a lift, the jack seat should be used to support the vehicle part corresponding to
the component to be removed.
Warning about handling ABS components
Warning!
Some components in the anti-lock brake system (ABS) cannot be repaired separately. Attempts to remove or disconnect
some system components cause personal injuries or abnormal system operation.

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Warning and caution 1 - 4 Maintenance Manual
Warning about approved equipment for collision repair
Warning!
To avoid personal injury from exposure to toxic fumes of welding arc or electroplated (zinc oxide) metal when
grinding/cutting any type of metal or sheet molding, it is essential to work in a well-ventilated area and wear breathing
apparatus, goggles, ear plugs, welder gloves and protective clothing.
Warning about assistant driving
Warning!
When the technician inspects the faulty part for repair, the assistant shall drive the vehicle. Otherwise, personal injuries
may occur.
Warning about battery disconnection
Warning!
All electrical consumers must be turned off and the HEV Engine START/STOP button must be set to OFF position
beforeservicing electric components, unless otherwise stated in the operating procedures. If tools or equipment are
prone tocontact with exposed live electrical terminal, disconnect negative battery terminal. Violation of these safety
instructionsmay result in personal injury and damage to the vehicle.
Warning!
If the airbag is being serviced, the negative battery terminal must be disconnected for at least 90 s before other
maintenance operations can be carried out.
Warning about brake dust
Warning!
Avoid the following operations while repairing wheel brake components:
• Grinding brake lining is prohibited.
• Do not use sandpaper to polish the brake lining.
• Do not use dry brushes or compressed air to clean wheel brake components.
Warning!
Some models or after-sales brake components may contain fibers, which will be mixed with dust. Inhaling dust containing
fibers will seriously damage your body. Please use a wet cloth to clean any dust on the brake components.
Warning about brake fluid Warning!
Brake fluid is highly hygroscopic, so do not use the brake fluid stored in an open container. Improper or contaminated
brake fluid may result in system failure, loss of vehicle control and personal injuries.
Warning about irritation of the brake fluid
Warning!
Brake fluid are irritating to the skin and eyes. In case of contact, the following measures shall be taken:
• Eye contact - Rinse thoroughly with clean water.
• Skin contact - wash with soap and water.
Warning about brake pipe replacement
Warning!
When replacing the brake pipe, please install and fix it carefully. Be sure to use the correct fastener. Otherwise, the
brake pipe and brake system may be damaged and cause personal injury.

GAC Motor 2023

Maintenance Manual 1 - 5 Warning and caution

Warning about inhaling HFC-134a

Warning!
Avoid inhaling HVAC refrigerant HFC-134a and oil vapors or mists. Exposure to them may irritate the eyes, nose and
throat. Work should be done in a well-ventilated area. In order to remove HFC-134a from the A/C system, use the
maintenance equipment (HFC-134a recycling equipment) that is certified to SAEJ2210. If the system is found to be
accidentally drained, make sure the work area is ventilated before proceeding with maintenance.
Warning about crash sectioning
Warning!
Sectioning should only be carried out at the recommended locations, otherwise the integrity of the vehicle structure will
be destroyed, which may cause personal injury in the event of a vehicle collision.
Warning about window cracking
Warning!
If the window glass is cracked but remains intact, the protective tape shall be cross-jointed to the window glass to avoid
further damage to the window glass or personal injury.
Warning about window lifting function
Warning!
During operation of the power window switch at the driver's door, the window without anti-pinch function moves
extremely fast and cannot be stopped, which may cause personal injury.
Warning about eye protection
Warning!
When performing certain procedures, such as welding or cutting, you should wear approved goggles and gloves to
reduce the risk of personal injury.
Warning about foam deadener
Warning!
When an open flame is to be used during body maintenance, the foam sound insulation material within 152.4 mm from
the open flame must be removed. When reinstalling the foam sound insulation material, it is necessary to avoid inhaling
smoke and dust, otherwise it is harmful to health.
Warning about fuel and fuel pipes
Warning!
In order to reduce the risk of fire and personal injuries, observe the following items:
• All fuel pipes that are scratched, cut or damaged during installation should be replaced. Do not attempt to repair the
fuel pipes.
• When installing a new fuel tube, do not directly hit the fuel tube bundle clamp with a hammer.
Warning about leakage of fuel pressure gauge
Warning!
Wrap a rag around the fuel pressure joint to reduce the risk of fire or personal injury. The rag can absorb the fuel leaked
when the fuel pressure gauge is connected. After the fuel pressure gauge is connected, put the rag in an appropriate
container.
Warning about fuel pipe fitting
Warning!
When connecting fuel pipe joints, be sure to apply a few drops of clean HEV Engine oil to fuel pipe joints to reduce the
risk offire and personal injury, so as to ensure to correct reconnection and prevent possible fuel leakage. In normal
operation,the O-ring in the joint will expand, and if it is not lubricated, the O-ring may deform.
Warning about fuel storage
Warning!
Do not store fuel in an open container as fire or explosion may occur.

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Warning and caution 1 - 6 Maintenance Manual
Warning about fuel
Warning!
Fuel are very easy to burn, and if there is a fire source, it may cause a fire. To prevent fire or explosion hazards, do not
use open container to drain or store fuel. Prepare a dry powder fire extinguisher nearby.
Warning about handling glass and sheet metal
Warning!
While handling any glass or sheet metal with sharp edge or burrs, wear goggles and gloves in order to reduce the risk of
personal injuries.
Warning about injector O-ring removal
Warning!
Check the O-ring of each injector, and do not leave it on the cylinder head during disassembly, so as to avoid that the
injector with new O-ring cannot be correctly placed in the injector seat during maintenance and installation of injector,
because improper placement will cause oil leakage.
Warning about moving parts and high-temperature surface
Warning!
When working around a running HEV Engine, avoid contact with moving components and hot surfaces to prevent
personalinjury.
Warning about repairing exhaust system
Warning!
To avoid burns, do not repair exhaust system related components when HEV Engine is hot.
Always wear goggles and gloves when removing exhaust system parts, otherwise rust and sharp edges falling from worn
exhaust system parts can cause serious personal injury.
Warning about removal of expansion tank cap
Warning!
To avoid burns, do not remove the expansion tank cap before the HEV Engine has cooled down. If the expansion tank
cap isremoved while the HEV Engine and radiator are not cooled down, the cooling system will release high-
temperature steam andliquid.
Warning about maintenance of the coolant system
Warning!
As long as there is pressure in the cooling system, the coolant temperature will be much higher than the boiling
temperature even if the coolant in the radiator does not boil. If the expansion tank cap is opened when the HEV Engine
is notcooled and the pressure is still high, the coolant will immediately boil and may spray on the operator and cause
seriousburns.
Warning about releasing fuel pressure
Warning!
Before repairing the fuel system, remove the fuel fuel tank cap and release the fuel system pressure to reduce the risk of
personal injury. After releasing the fuel system pressure, a small amount of fuel can spill while servicing the fuel pipeline,
injector or connectors. Wrap the fuel system components with a rag before disconnection in order to reduce the risk of
personal injury. This can absorb the leaked fuel. Place the rag in a suitable container after disconnection.
Warning about road test
Warning!
Road test vehicle and comply with all traffic regulations on the premise of ensuring safety. Do not try any operation that
may endanger the vehicle control. Violation of the above safety instructions may cause serious personal injury and
damage to the vehicle.
Warning about goggles and fuel
Warning!
When handling the fuel, be sure to wear goggles to prevent fuel from splashing into your eyes.

GAC Motor 2023

Maintenance Manual 1 - 7 Warning and caution
Warning about SRS
Warning!
Before removing an airbag, be sure to set the HEV Engine START/STOP button to OFF position, disconnect the
negativebattery terminal and wait 90 s before proceeding with the removal.
This vehicle is equipped with a SRS. If the correct operating procedures are not followed, the following conditions will
occur:

• Airbag deployment.
• seatbelt pretensioner deployment

• Personnel injury.
• Unnecessary SRS maintenance.
Warning!
In order to avoid the above conditions, observe the following guidelines:
• You should refer to the SRS components view to determine if you are performing a service operation on, around, or
in the circuit of the SRS components.
• If you are performing maintenance operations on, around or on the circuit of the SRS components, deactivate the
SRS.
Warning about high-temperature deployed airbag
Warning!
After deployment, the metal surfaces of the SRS components may be very hot. In order to avoid a fire or personal injuries:
• Allow sufficient cooling time before touching any metal surface of the SRS components.
• Never place an inflated SRS components next to any flammable material.
Warning about SRS clock spring
Warning!
Incorrect installation of the clock spring assembly will damage the internal spiral coil of the clock spring, which may cause
coil failure and cause the SRS to fail to work normally, resulting in personal injury.
Warning about airbag scrapping
Warning!
In order to prevent accidental deployment of airbag causing personal injury, undeployed airbag shall not be disposed of
as conventional workshop waste. Undeployed airbags contain substances that could cause severe illness or personal
injuries if their sealed containers are damaged during disposal. Safely discard undeployed airbags according to the
deployment procedure.
Warning about airbag taking and storage
Warning!
When transporting undeployed airbag:
• Do not lift the airbag by its leads or connectors.
• Make sure the airbag opening is not facing you or others.
Warning!
When storing undeployed airbag, the airbag opening shall not face down. It is forbidden to place any objects on the
airbag. There should be enough space around the airbag for the airbag to accidentally deploy, otherwise it will cause
personal injury.
Do not immerse the undeployed airbag in water or allow it to come into contact with other liquids.
Never place the undeployed airbag close to fire or in a high-temperature area so as to prevent personal injuries due to
unexpected deployment of the airbags.

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Warning and caution 1 - 8 Maintenance Manual
Warning about handling SRS impact sensor
Warning!
Never hit or shake a SRS impact sensor. Make sure the impact sensor is firmly fixed before powering on it. Failing to
observe proper installation procedures may cause false airbag deployment or deployment failure, thereby leading to
personal injuries.
Caution of filling brake system with brake fluid
Caution
When adding the brake fluid to brake master cylinder reservoir, use only brake fluid from clean, sealed brake fluid
container. Type DOT-4 only.. Failure to use the recommended brake fluid can lead to system contamination and damage
to rubber seals or rubber gaskets inside the hydraulic brake system component.
Caution of V-ribbed belt
Caution
Do not use V-ribbed belt wax on the V-ribbed belt. Belt wax will cause broken V-ribbed belt materials, and violating this
caution will damage the belt.
Caution of the brake caliper
Caution
While removing the brake caliper, support it with a wire or the special tool to prevent damage to the brake lines.
Special caution of effects of brake fluid on paint and electrical components
Caution
Prevent brake fluid from splashing to paintwork, electrical connectors, wires or cables. as the fluid can damage paintwork
and corrode electrical components. If any brake fluid comes in contact with paintwork, immediately flush the area with
water. If any brake fluid comes in contact with electrical connectors, wires or cables, use a piece of clean cloth to wipe
away the brake fluid.
Caution of protecting fuel tank strap
Caution
Do not bend the fuel tank straps; otherwise the straps can damage the fuel tank.
Caution of HEV Engine emission
Caution
Modification to the following systems may impact the vehicle emission control system and turn on the emission fault
indicator lamp and MIL:
• HEV Engine
• Transmission
• Exhaust system
• Fuel system
Caution
If the replaced tire does not meet the performance standard of the original one, the vehicle emission control may be
affected as well, which may turn on the emission fault indicator lamp and MIL.
Modification to these systems and installation of tires conforming to incorrect performance standards may result in fault
beyond the warranty scope of the manufacturer and get the vehicle failed in required emission inspection.
Caution of HEV Engine lifting and jacking
Caution
While lifting or supporting the HEV Engine for any reason, do not set a jack under the oil sum or the crankshaft pulley.
Liftingthe HEV Engine in an improper manner may cause component damage or personal injuries.

GAC Motor 2023

Maintenance Manual 1 - 9 Warning and caution
Caution of HEV Engine mount
Caution
Broken HEV Engine mount can cause misalignment of certain powertrain components, and further eventual damage
to thepowertrain components.
If an HEV Engine mount breaks, other HEV Engine mounts will have increased stress put on them, leading to
breaking ofothermountings.
Caution of avoiding excessive sealant on flywheel bolt
Caution
Apply a proper amount of sealant to fasteners while assembling the assembly; excessive sealant will lead to improper
assembling or loosening of fasteners, which may get the components or fasteners loosened or dropped off to bring
serious damage to the HEV Engine.
Caution of exhaust pipe and oxygen sensor
Caution
When the HEV Engine temperature is higher than 48°C (120°F), it will be difficult to remove the oxygen sensor,
and
overexertion may damage the threads of exhaust pipe or exhaust pipe.
Caution of timing driving chain reaction torque
Caution
To avoid damage to components, be sure to use a wrench to hold the hexagon part of camshaft during removal or
installation; failure to avoid the timing chain reaction torque may cause the timing driving chain to break down.
Caution of exterior trim emblem removal
Caution
Use a plastic flat-bladed tool to prevent paint damage while removing an emblem/nameplate.
Caution of fastener
Caution
Use the correct fastener at the correct location. Replacement fasteners must be of the correct part number. The
fasteners that need to be replaced or coated with thread lock and sealant are specified in repair procedures. Do not
apply paint, lubricating oil or corrosion inhibitor to fasteners or fastener joint surfaces, unless otherwise specified.
Otherwise, fastener torque and clamping force may be affected and fasteners may get damaged. During installation,
tighten the fasteners to correct torque according to correct sequence in order to avoid damage to parts and systems.
Caution of handling ESD sensitive parts
Caution
Electrostatic discharge (ESD) can damage many solid-state electrical components. Components susceptible to ESD may
or may not be labeled with ESD symbol. Handle than genuine electrical components carefully. Observe the following
precautions in order to avoid ESD damage:
• Before repairing any electrical component, touch metal grounding points to discharge static electricity from the body.
• Do not touch exposed terminals as they may be connected to circuits susceptible to ESD damage.
• Do not allow tools to contact exposed terminals when repairing connectors.
• Never remove parts from the protective housing unless specifically instructed to do so.
• Avoid the following operations, unless otherwise required by the diagnostic procedures:
• Bridge or ground the component or connector.
• Connect test equipment probes to components or connectors. Connect the ground lead first while using test probes.
Ground the protective case of any component before opening. Do not rest solid-state components on metal workbenches,
or on top of TVs, radios or other electrical devices.

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Warning and caution 1 - 10 Maintenance Manual
Special caution of heated oxygen sensor and oxygen sensor
Caution
Do not remove the lead from the heated oxygen sensor. Removing the lead or the harness connector will affect sensor
operation.
Handle the oxygen sensor carefully. Do not drop it. Keep the in-line connector and the radiating end free of grease, dirt
or other contaminants. Do not use any type of cleaning agent.
Do not repair the wires, harness connectors or terminals. Replace the oxygen sensor if any lead, harness connector or
terminal is damaged.
External clean air reference is obtained by way of signals and heater wires. Any attempt to repair the wires, harness
connectors or terminals will result in the obstruction of the air reference and degraded sensor performance.
The following guidelines must be followed during maintenance of the heated oxygen sensor:
• Never apply contact cleaner or other materials to the sensors or vehicle harness connectors as these materials may
get into the sensor causing poor performance.
• Do not damage the lead and harness of the sensor for fear that the wires inside get exposed and provide a path for
foreign materials to enter the sensor and cause performance problems.
• Ensure the sensor or vehicle leads are not bent sharply or kinked.
• Ensure that the peripheral seal remains intact on the harness connector in order to prevent damage due to water
intrusion.
Caution of setting HEV Engine START/STOP button to the "OFF" position before disconnecting battery
Caution
Whenever connecting or disconnecting the negative battery terminal, battery charger or jumper cables, be sure to set the
HEV Engine START/STOP button to the "OFF" position, otherwise damage to the control unit or other electrical
componentsmay occur.
Caution of installing hoses without twists or bends
Caution
The inlet and outlet hoses shall not be twisted during installation. Do not bend or deform the inlet or outlet hoses for
purpose of facilitating installation; otherwise, components may be damaged.
Caution of protecting machined surface
Caution Do not nick, scratch or damage the sealing surface. The sealing surface is a machined surface, which if
damaged, will cause leakage.
Special caution of PCM and ESD
Caution
Do not touch the connector pins or welded components on the circuit board in order to prevent possible electrostatic
discharge (ESD) damage to the electronic control module.
Caution of sealant
Caution
Do not allow the sealant cured at room temperature to enter blind threaded holes; otherwise, hydraulic locking effect may
occur during fastening, resulting in damage to fasteners or other parts, failure of fasteners to get proper clamping force
during fastening, and further sealing failure of components, which will bring forth leakage, loosening or separation of
parts and serious damage to the HEV Engine, etc.

GAC Motor 2023

Maintenance Manual 1 - 11 Warning and caution
Caution of using diagnostic scan tool
Caution
Before diagnosis of the vehicle, pay attention to the following conditions for fear of damage to the control unit.
• The diagnostic scan tool and terminal software shall be of the latest version.
• The battery voltage shall be between 12 V and 14V.
• The connection between the diagnostic scan tool and terminal cables shall be secure.
• During programming of control module, the battery charger shall not be connected to the battery.
Caution of test equipment probe
Caution
Do not insert the test equipment (such as DMM) probes into any harness connector or fuse box terminal; otherwise, the
diameter of the test probes will deform most terminals and cause poor contact, which will result in a system failure.
Always use a special tool to detect the terminals from the front end, and never test terminals with a clip or other
substitutes.
While testing the assembly with a special tool, ensure the terminal test adapter selected is suitable for size of the
connector terminal. Do not visually choose the terminal test adapter because some connector terminal holes may appear
larger than the actual terminal in the hole and using a larger terminal test adapter will damage the terminal.
Caution of stopping or parking
Caution
Carefully park the vehicle in areas where protrusions or fixed stop blocks exist; otherwise, the bumpers and other
components may be damaged.
Carry your key with you when you leaving the vehicle.

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Information on vehicle labels 1 - 12 Maintenance Manual

1.2 Information on vehicle labels

1.2.1 Description and operation
1.2.1.1 Vehicle identification number

1 The location of the vehicle identification number (VIN) is

shown in the figure below:
-VIN ①: located on the left side of the instrument panel.

2 Numbering method of VIN

- VIN contains the following information:
① Geographical area
② Country
③ Manufacturer
④ Vehicle characteristic code
⑤ Check digit
⑥ Year
⑦ Assembly plant
⑧ Production sequence number

1.2.1.2 Vehicle nameplate

Note:
The vehicle nameplate is located at lower part of the right
B-pillar.

1 The vehicle nameplate contains the following

information:

Manufactured by GAC Motor Co., Ltd. ① VIN, vehicle model

Vehicle model: ② Brand, gross vehicle weight rating

XXXXXXXXX
XXX brand
Gross vehicle weight ③ HEV Engine displacement, seating capacity
HEV Engine
HEV Enginedisplacement: rating: XXXkg
XXXXmL
displacement: ④ HEV Engine model, date of manufacture
HEV Engine model: XXXXX Seating capacity: XX
XXX mL
Maximum net power of Date of manufacture: MM ⑤ Maximum net power of HEV Engine, country of
HEV Engine: XXXX YYYY
kW
manufacture
Country of manufacture:
China

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Maintenance Manual 1 - 13 Towing and lifting

1.3 Towing and lifting

1.3.1 Description and operation
1.3.1.1 Towing

Towing procedure
Note:
If towing is required, the towing eye must be first installed.
Towing eye is a driver’s tool.

1 Front towing
a. Wrap the slotted screwdriver in a soft cloth to pry off the
front towing eye cover ① as arrowed.

b. Screw in the towing eye ① and tighten it with the wheel

wrench ②.

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1.3.1.2 Lifting
Warning!
Lifting at correct points is very important for the safety during lifting. Failure to do so may cause damage to the vehicle or
personal injuries.
During vehicle lifting with a two-post lift (as shown below), horizontal lining blocks as arrowed shall be used under the
lifting points.

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Maintenance Manual 1 - 15 Towing and lifting

1.3.1.3 1.3.1.3 Jacking and lifting

Warning!
Always park the vehicle on a hard and flat ground. If the vehicle is to be jacked up on soft ground, a load-dispersing
block must be placed under the jack. Always chock the wheel diagonal to the point where the jack will be placed. Failure
to follow these instructions may result in personal injuries.
When a jack is required for vehicle maintenance, it is important to fully understand the following instructions. Always
identify the correct jacking points by locating the jack at the chassis reinforcement plate between the front and rear
wheels. A lining shall be used to protect the paintwork from damage while using the jack.

Lifting

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Towing and lifting 1-16 Maintenance Manual

Support

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Maintenance Manual 1 - 17 Maintenance

1.4 Maintenance
1.4.1 Specifications
1.4.1.1 Filling volume and specifications of oil & fluid

Item Specifications Capacity

92# or above high-quality
Fuel Capacity 55L
lead-free gasoline*1
Intercooler coolant DF-6, -35 ℃ Capacity 3.3L±0.1L
HEV Engine coolant DF-6, -35 ℃ Total filling volume*2 8.2±0.1L
Viscosity grade: SAE 0W- Total filling volume * 3 4.5L
20
HEV Engine oil
Quality grade: API Replacement * 4 4.2L
SN/ILSAC GF- 5
Wet DCT fluid Shell Spirax S5 DCT 12 Capacity 5±0.2L
Brake fluid DOT4 Capacity 0.77±0.05L
44% methanol with freezing
point of -30 °C,
Windshield washer fluid Methanol and 56% water Capacity 2±0.5L
with hardness not more
than 205 g/t
A/C refrigerant HFC-134a Capacity 530±25g
Compressor oil PAG(SP-10) Total filling volume * 5 5mL

*1: Long-term use of fuels with a sulfur content higher than the standard value may result in excessive emissions. Please
pay attention and use fuels that comply with local standards for vehicles.
*2: Including the coolant in the expansion tank and the residual coolant in the HEV Engine.
*3: The oil capacity for overhaul of HEV Engine assembly.
*4: Including the oil capacity for replacement of oil filter.
* 5: Compressor oil filling volume only for maintenance of A/C cooling system.

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1.4.2 Description and operation

1.4.2.1 Regular maintenance schedule
Perform the maintenance Km x1000 20 40 60 80 100 120 140 160 180 200
according to the specified
mileage or time interval Months 12 24 36 48 60 72 84 96 108 120
(whichever comes first)

★Change the HEV Engine oil First at 5,000km or 3 months, and thereafter every 5,000km or 6 months
Replace the HEV Engine oil filter First at 5,000km or 3 months, and thereafter every 5,000km or 6 months
Check the spark plug Exemption
Replace the spark plug * 1 Every 60,000km
Check the accessory belt Every 20,000 km or 12 months
Replace the accessory belt Every 60,000 km or 36 months
Replace the canister filter Every 60,000 km or 36 months
Check and clean the air cleaner First at 5,000km or 3 months, and inspection free thereafter
Clean the cover of air cleaner and replace
Every 20,000 km or 12 months
the air cleaner element
Check the cooling system for leakage and
First at 5,000km or 3 months, and thereafter every 5,000km or 6 months
add the coolant when necessary

★Change HEV Engine coolant Every 40,000 km or 24 months

★Change the intercooler system coolant Every 40,000 km or 24 months

★ Check the transmission fluid (WDCT) Exemption

★ Change the ATF (WDCT) First at 50,000km or 36 months, and thereafter every 60,000km or 36 months

★Replace the press filter element First at 5,000 km or 3 months, second at 50,000 km or 36 months, and thereafter every
(WDCT) 60,000km or 36 months

★ Change the brake fluid Every 40,000 km or 24 months

Check the exhaust (only for leakage; the
exhaust compositions are to be inspected 10,000km or 6 months
during the annual inspection)
Check the parking brake and the brake pedal
(check the function and free travel of the First at 5,000km or 3 months, and thereafter every 5,000km or 6 months
pedal and parking brake)
Check the brake disc and brake lining (check
their thickness and wear pattern, and replace First at 5,000km or 3 months, and thereafter every 5,000km or 6 months
them when necessary)
Check the wheel fixing bolt (check and
First at 5,000km or 3 months, and thereafter every 5,000km or 6 months
tighten the bolt to the specified torque)
Check the wear pattern of the tire/ hub
(including the spare tire), carry out tire
First at 5,000km or 3 months, and thereafter every 5,000km or 6 months
rotation and correct the tire pressure when
necessary
Check the chassis bolts (check and tighten
First at 5,000km or 3 months, and thereafter every 20,000km or 12 months
the bolts to the specified torque)
Check the brake system (check the brake
fluid pipes for leakage and check the brake
First at 5,000km or 3 months, and thereafter every 5,000km or 6 months
fluid level and add the brake fluid when
necessary)

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Maintenance Manual 1 - 19 Maintenance

Check the steering tie rod (check for loose

tie rod end or leaky dust cover, and check First at 5,000km or 3 months, and thereafter every 20,000km or 12 months
whether the connection is firm)
Check the underbody (check the fuel pipe,
brake fluid pipe and underbody protective
First at 5,000km or 3 months, and thereafter every 5,000km or 6 months
layer for damage, and the exhaust pipe for
leakage and looseness)
Replace the fuel (gas) hose Every 96 months (or when any crack is found)
Check the suspension ball joint and dust
cover (check for loose ball joint or leaky dust ● ● ● ● ● ● ● ● ● ●
cover)
Check the suspension assembly (check that
the bush is free from aging and breakage,
the connecting bolt and nut are tightened to ● ● ● ● ● ● ● ● ● ●
specified torque and the linkage is free from
deformation and cracks)
Check the wiper/washer (check the operation
of wiper blade and replace the wiper blade if
First at 5,000km or 3 months, and thereafter every 5,000km or 6 months
necessary, add the washer fluid, and check
the function of wiper/washer)
Check whether there are leaves or other
First at 5,000km or 3 months, and thereafter every 5,000km or 6 months
debris on the surface of the wiper cover
Check the door check, dowel pin, door lock,
HEV Engine hood/ liftgate hinge and latch
Every 10,000km or 6 months
(checktheir functions and clean the dust on
the doorcheck and lubricate the check)
Grease the PLG drive rod/ balance rod/ air
spring ball socket (without removing two
rods); required grease: lithium soap base Every 10,000km or 6 months
synthetic hydrocarbon with high viscosity and
operating temperature of -30°C~120°C
Check the interior and exterior lamps and
First at 5,000km or 3 months, and thereafter every 5,000km or 6 months
electrical consumers of the vehicle body
Self-diagnosis (check the fault message with
The self-diagnosis is synchronized with vehicle maintenance
the professional diagnostic scan tool)
Check the battery (check the battery
condition with the special tool, check if the
connections to the positive and negative First at 5,000km or 3 months, and thereafter every 5,000km or 6 months
terminals of battery are firm and check the
battery voltage)
Check the headlamp (check the lamplight
Every 10,000km or 6 months
and adjust it when necessary)
Check the A/C filter element Every 10,000km or 6 months
Add the cleaning agent of fuel system First at 5,000 km or 3 months, and later every 5,000 km or 6 months
Replace the A/C filter element ● ● ● ● ● ● ● ● ● ●
Test run (performance inspection) Each time maintenance is done
Visually check the following items
Dust cover of drive shaft (check for oil
First at 5,000km or 3 months, and thereafter every 5,000km or 6 months
leakage or damage)

★: Be sure to check the levels of HEV Engine oil, coolant and brake fluid before driving.
* 1: If there is impurity in the gasoline used, please replace the spark plug frequently. If the HEV Engine idle speed is
unstable,the spark plug should be replaced immediately.
1.4.2.2 Unconventional maintenance (in harsh environments)
Harsh driving conditions include the followings:
1. The vehicle often runs for a short trip (not more than 8km);
2. The HEV Engine is kept running at an idle speed constantly and the vehicle runs intermittently (for example: the
vehicle isused as a taxi);

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Maintenance 1 - 20 Maintenance Manual

3. The vehicle runs in a muddy, dusty area or environment;

4. The vehicle is used for towing a trailer frequently, or luggage is placed on the roof luggage rack during vehicle running,
or the vehicle runs on a mountain road;
5. The vehicle runs for a long time in extremely cold (below the freezing point) or hot (above 35℃) environments.
6. The vehicle runs for more than 20,000 km every year or runs at high speed frequently;
7. The vehicle runs for a long distance at a low speed.

Item Harsh conditions Maintenance requirements

Change the HEV Engine oil and
1，2，3，5，7 2,500km or 3 months
replace theoil filter
Change the HEV Engine coolant 3，5，6 40,000km
Check the wheel fixing bolt 1，2，3，4，5，6 5,000km or 3 months
Check the chassis bolts (check and
tighten the bolts to the specified 1，2，3，4，5，6 10,000km or 6 months
torque)
Check the suspension ball joint and
dust cover (check for loose ball joint 1，2，3，4，5，6 10,000km or 6 months
or leaky dust cover)
Check the suspension assembly
(check that the bush is free from
aging and breakage, the connecting
1，2，3，4，5，6 10,000km or 6 months
bolt and nut are tightened to specified
torque and the linkage is free from
deformation and cracks)
Replace the A/C filter element 3，5 10,000km

Note:
The maintenance frequency of air cleaner element, V-ribbed belt and water pump belt shall be increased when the
vehicle is used under harsh conditions.

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Maintenance Manual 1 - 21 Maintenance

1.4.2.3 Description of tire rotation

Caution
Obvious uneven tire wear, if any, shall be troubleshooted. In case of tire rotation, it is suggested to check the balancing
of tire and wheel assemblies at the same time.
1 Wear conditions of front and rear tires are quite different because of different loads during running. Therefore, tire
rotation shall be performed regularly to avoid tire wear in single direction, to achieve even tire wear and thus extend the
tire life. It is recommended to perform tire rotation every 5,000km or 6 months. The main purposes of tire rotation are:
a. to ensure even tire wear and fatigue and guarantee stability and economy.
b. to check the tire condition during the tire rotation, find problems in time and forestall troubles.
2 Perform tire rotation of the wheel assemblies as shown below.

Caution
Carry out the cross rotation of “non-directional” wheel assemblies, as shown in the figure above.

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Maintenance 1 - 22 Maintenance Manual

Caution
Carry out the parallel rotation of “directional” wheel assemblies, as shown in the figure above.

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Maintenance Manual 1 - 23 Maintenance

1.4.3 Maintenance
1.4.3.1 Inspecting and lubricating door checks
Check procedure
1 Check the door check
a. Open and close a door repeatedly to check if the door
check makes any unusual noise.

2 Lubricate the door check

a. Open the door to the maximum extent.

b. Remove dust and other dirt from the surface of the black
lever of the door check with a piece of soft cotton cloth.
Recommended grease: SYH-PH36E
Caution
It is forbidden to use the greases that are not specified or
recommended (such as HEV Engine oil or ATF) to
lubricate thedoor checks.

c. Apply the specified lubricating grease to the sliding

surface of the door check arm with a small brush.
d. Open and close the door for five times to ensure the
sliding surface is evenly covered with grease.

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1.4.3.2 Inspecting lock cylinder operation

Check procedure

1 Check the driver's door lock

a. Press the part indicated by the arrow to open the left
front door outside handle assembly ①.

b. Insert the mechanical key ① into the door lock.

c. Turn the key ① leftwards and rightwards as arrowed,
the lock cylinder shall freely rotate without seizure.
d. Visually check the lock cylinder and remove dirt from its
surface, if necessary, with a piece of clean shop towel.

1.4.3.3 Checking the horn

Check procedure

1 Check the horn

a. Press the horn switch as arrowed for more than five
times. The horn system shall be repaired even if the horn
does not sound for one time only during the inspection.

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Maintenance Manual 1 - 25 Maintenance

1.4.3.4 Inspecting seat belt

Check procedure

1 Check the seat belt

a. Pull the seat belt ① completely out from the inertia reel.
b. Check if the seat belt is dirty and clean it with neutral
soap solution if necessary.

c. Replace the seat belt if the belt is broken, torn or

scratched.

d. Replace the seat belt if the fabric coil on one edge of the
belt tears.

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e. Replace the seat belt if it has the scorch caused by

cigarette, etc.

f. Replace seat belt if one side of its edge is deformed or if

the seat belt edge is wavy.

2 Check the inertia reel (locking function)

a. Pull the seat belt out from the inertia reel quickly and
hard.
- If the inertia reel cannot lock the belt, replace the seat
belt and seat belt buckle assembly as a whole.
- If a fault occurs when the seat belt is pulled out or reeled
back, first check if the inertia reel has moved.
3 Visually check the seat belt buckle assembly
a. Check the seat belt buckle assembly for chink or crack.
Caution
If any damage is found on the inertia reel, replace the seat
belt and seat belt buckle assembly as a whole.

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4 Check function of seat belt buckle assembly

a. To check the locking device:
– Push the tongue ① into the seat belt buckle assembly
② until a click is heard. Pull the seat belt hard to check if
the locking device is clipped into.
Caution
Conduct the above inspections for more than 5 times, and
the seat belt and buckle assembly shall be replaced as a
whole if the tongue is not clipped into the buckle assembly
only once.

b. To check the unlocking device:

- Press the button on the seat belt buckle assembly in the
direction as arrowed to release the seat belt.
- The tongue shall automatically eject out from the seat belt
buckle assembly when the seat belt is not fastened.
Note:
If it has been confirmed that these parts are damaged, the
seat belt and buckle assembly must be replaced as a
whole.
Caution
Do not apply lubricating oil to the key of the seat belt
buckle assembly in order to eliminate noise or
unsmoothness caused by operating the belt.

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1.4.3.5 Checking the front airbag

Check procedure

1 Driver's airbag
a. Driver's airbag identification is the "AIRBAG" marked on
the steering wheel pad.
b. Visually check the plastic housing ① for damage and
replace it if necessary.

2 Passenger’s airbag
a. The identification of the passenger side airbag is the
"SRS AIRBAG" marked above the glove box on the right
side of the instrument panel.

Caution
The user shall be reminded not to bond, pull out or perform
other machining to the airbag housing so as to ensure the
normal function of the airbag.
The airbag housing may only be cleaned with a piece of
dry or slightly damp cloth.
1.4.3.6 Inspecting working condition of
electrical system
Check procedure
1 Check the following of the electrical system
• Brightness and operating conditions of the front
combination lamp, rear combination lamp, turn signal
lamp, hazard warning lamp, license plate lamp, rear
fog lamp, reversing lamp and brake lamp.
• Operating conditions of the interior lamps and ambient
lights.
• Operating conditions of the buzzer, control unit,
central passage and all switches and horn in the
instrument panel.
• Operating conditions of the power windows, exterior
rearview mirrors, central locking and comfort system.
• Reception and anti-interference performance of the
radio, navigation and the loudspeakers.

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1.4.3.7 Checking the battery

Check procedure
Note:
Turn off all electrical consumers and set the HEV
Engine
START/STOP button to "OFF" position before the
inspection.

1 Follow the steps below

a. Undo the fixing clip as arrowed and open the positive
battery terminal cover ①.

b. Shake the negative battery terminal ① and positive

battery terminal ② side-to-side to check if the terminals
are securely.

2 If the positive battery terminal is not fixed

a. Unscrew the fixing nut (arrow A) and disconnect the
negative battery terminal ①.
b. Reinstall the positive battery terminal ② and tighten the
fixing nut (arrow B).
c. Install the negative battery terminal ① and tighten the
fixing nut (arrow A).
• Tightening torque of nut (arrow A): 6±1N·m
• Tightening torque of nut (arrow B): 6±1N·m

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3 If the negative battery terminal is not fixed

a. Reinstall the negative battery terminal ① and tighten
the fixing nut as arrowed.
• Tightening torque of nut: 6±1 N ·m

4 Visually check the battery

a. Visually check the external condition and connection of
the battery and if it is fixed before the complete inspection.
b. Visually check if the battery case is damaged. Battery
acid may flow out in case of battery case damage and it
may cause serious damage to the vehicle, in this case,
apply the battery acid diluent or soap solution to deal with
parts which battery acid contacts immediately.
c. Check whether the battery terminals are damaged. If the
battery terminal is damaged, good contact of battery
terminal cannot be guaranteed. When connecting the
battery terminals, please refer to the corresponding vehicle
maintenance manual. If the battery terminals are not
properly installed and tightened, fire may occur to the
circuit. Subsequently, this may lead to malfunctioning of
the electrical equipment, which can hinder the vehicle from
safely operating.
Caution
If the battery is not properly fixed, it may be damaged.
Damage caused by vibration shortens the service life of
the battery, brings risk of explosion and may cause
damage to battery case.
Check if the battery is secure and tighten the fixing nut to
the specified tightening torque if necessary.
5. Check the static voltage of the battery
a. Special tools and service equipment required:
• Handheld multimeter.
b. Inspection conditions:
• The battery has been neither charged nor discharged
for at least two days.
• Measure the battery voltage with a handheld
multimeter.
Measured value Required action
Static voltage ≥ 12.6 V The static voltage is
normal
Static voltage <11 V Battery charging
Note:
Within the specified maintenance range, it is only allowed
to measure the static voltage of the batteries when the
vehicle is parked or in stock, as a measure of the battery
status.

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Maintenance Manual 1 - 31 Maintenance

By measuring the static voltage, it is possible to determine

if the batteries in parked and stock vehicles shall be
recharged.
1.4.3.8 Checking the washer fluid
Check procedure

1 Check the washer fluid level

a. The washer fluid is consumable, so please check its
level at regular interval (two weeks or one month). In case
of low level, add the washer fluid.
b Open the filling port cap ① to fill the washer fluid to the
level in visible area below the port. Do not add it
excessively!

• Total filling volume of washer fluid: 2±0.05 L

Note:
The washer fluid prevents the nozzles, reservoir and
connecting hoses from freezing.
The washer fluid is 44% methanol with freezing point of -
30°C, and 56% water with hardness not more than 205g/t
Even in the warm months, it is necessary to add washer
fluid as it removes wax and grease residues from the
windshield via its strong cleaning ability.
Always ensure that the windshield washer will not freeze at
the temperature down to about -25°C (-35°C for some
regions with harsh weather conditions).

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1.4.3.9 Inspecting brake fluid

Check procedure
Caution
Do not mix the brake fluid with mineral oil (e.g., oil,
gasoline and washer fluid) because the mineral oil may
cause damage to the seals and sealing sleeves of the
braking device.
Brake fluid is corrosive and may cause damage to the
paintwork. If brake fluid spills while being added, absorb it
immediately with an absorbent cloth and clean it with the
mixture of vehicle cleaning agent and water.
Use only new brake fluid in a sealed container (brake fluid
is hygroscopic, so brake fluid stored in an opened
container or previously drained from the system has
absorbed moisture from the air and can have a negative
effect on braking performance).
Since brake fluid is toxic, keep the container closed and
store it in a place that is not easily reached by children. If it
is swallowed, call a doctor immediately.
Prevent brake fluid from coming into contact with skin or
eyes. If an accidental contact occurs, rinse the skin or eyes
immediately with water.
Do not drive the vehicle if the brake fluid level is below the
MIN mark on the reservoir.
If a customer reports unexpectedly long travel of brake
pedal or a noticeable drop of brake fluid level, check for
brake fluid leakage.
Please comply with the regulations on brake fluid disposal!

1 Check the brake fluid level

a. The brake fluid level shall be between MAX and MIN.
Note:
Prevent the brake fluid from flowing out from the reservoir,
the brake fluid level shall not exceed MAX after adding
brake fluid.

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Maintenance Manual 1 - 33 Maintenance

2 Check the brake fluid level during routine maintenance

a. It is required to decide whether to add brake fluid based
on the wear conditions of brake linings.
b. Recommended brake fluid level when brake lining is
about to reach its wear limit:
- When the brake fluid level is at or slightly above MIN, it is
unnecessary to replenish with the brake fluid.
c. Recommended brake fluid level when the brake linings
are new or a long way from the wear limit:
-The brake fluid level shall be between MIN and MAX
marks.

• Total filling volume of brake fluid: 0.77±0.05 L

• Brake fluid specification: DOT4
Note:
While operating the actual vehicle, the level in the brake
fluid reservoir may drop slightly due to worn brake linings
and it is necessary to add the brake fluid.
If the level has fallen below MIN, check for leakage before
adding the brake fluid.
1.4.3.10 Check the brake pipeline
Check procedure

1 Check the brake pipeline

a. Check the brake lines (the brake tubes and hoses) for
cracks, deterioration or other damage.
b. Set the HEV Engine START/STOP button to the "
ON"position, depress the brake pedal with a force of 785
N (80kg) and hold it for about 5 s. Check for brake fluid
leakage.
Caution
If any leakage is found at the fittings of the brake tubes
and hoses, re-tighten them, or replace the damaged parts
(if any).
Prevent the brake lines from interfering with any vehicle
components when the steering wheel is at the maximum
steering angle.

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1.4.3.11 Checking the coolant

Check procedure

1 Check the HEV Engine coolant level

a. Check the HEV Engine coolant level in the
expansion tankwhen the vehicle is in normal condition.
B. The coolant level shall be between MAX and MIN.
c. If the HEV Engine coolant level is too low, add the
coolant.
• HEV Engine coolant model: DF-6, -35℃; total filling
volume:
8.2±0.1 L.

2 Check the intercooler coolant level

a. Check the intercooler coolant level in the expansion tank
when the vehicle is in normal condition.
B. The coolant level shall be between MAX and MIN.
C If the intercooler coolant level is too low, add coolant.
• Intercooler coolant model: DF-6, -35 ℃ coolant, total
filling volume: 3.3±0.1 L.

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3 Check the coolant freezing point

a. Use a sucker to drop the coolant onto the refractometer
glass and observe the coolant freezing point.
Note:
Read the value at the cut-off line. In order better identify
the cut-off line, place a drop of water on the refractometer
glass with a sucker so as to clearly identify the cut-off line
via the “water line”.

B. Read the coolant freezing point value.

Note:
Do not dilute the coolant at will.
Ensure that the coolant freezing point is below -35°C (the
freezing point may change according to the regions and
climate).
If the coolant freezing point does not correspond to the
specified value, change the coolant.

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1.4.3.12 Check the water pump belt

Check procedure

1 Check the water pump belt

a. Check the water pump belt ① for the following
conditions:
• Base cracks (central fracture, cross-sectional fracture)
• De-lamination (surface layer, reinforcement)
• Base rupture
• Loose reinforcement
• Rib surface wear (blunt material, loose or hardened rib
surface, surface cracks)
• Traces of HEV Engine oil and grease

Caution
If any of the above defects is found in the water pump belt
during inspection, replace the water pump belt to avoid
malfunctioning. Refer to Maintenance Manual - 4A15J2
HEV Engine (I)

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1.4.3.13 Checking the V-ribbed belt and

tensioner
Check procedure

1 Check the V-ribbed belt and tensioner

a. Check the V-ribbed belt ① for the following conditions:
• Base cracks (central fracture, cross-sectional fracture)
• De-lamination (surface layer, reinforcement)
• Base rupture
• Loose reinforcement
• Rib surface wear (blunt material, loose or hardened rib
surface, surface cracks)
• Traces of HEV Engine oil and grease
b. Check the tensioner ② for the following conditions:
• Squeaking while HEV Engine is running.
• Deep dents in the outer wall of the rim.
• The tensioner makes a "buzzing" sound
Caution
If any of the above defects is found in the V-ribbed belt
during inspection, replace the V-ribbed belt to avoid
malfunctioning. Refer to Maintenance Manual - 4A15J2
HEV Engine (I)
If any of the above defects is found in the tensioner during
inspection, replace the tensioner to avoid malfunctioning.
Refer to Maintenance Manual - 4A15J2 HEV Engine (I)

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1.4.3.14 Checking the HEV Engine oil

Check procedure
1 Inspection conditions
-Park the vehicle on a level ground.
- The oil pan is not deformed.
- When the HEV Engine has been stopped, wait 10 min to
allowthe oil to flow back to the oil pan.

2 Check the HEV Engine oil

a. Pull out the dipstick ①, dry it with a shop towel, then
reinsert it, push it all the way down, and wait a moment.
B. Pull out the oil dipstick ① again and read the oil level.

Marks on the oil dipstick

H—MAX mark
L—MIN mark
If the oil level is between H and L, the oil volume is normal.
If the oil level is above H, the oil shall be drained until the
oil level is between H and L.
If the oil level is below L, the oil shall be added until the oil
level is between H and L.
Caution
Do not mix HEV Engine oils of different grades.
Do not let any HEV Engine oil spill on the HEV Engine
whilefilling theHEV Engine oil; otherwise the HEV Engine
may
be onfiredue to hightemperature caused by HEV Engine
running!

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1.4.3.15 Checking the windshield wiper and

washer
Check procedure
Note:
For this vehicle model, the washer nozzle is integrated in
the wiper blade. Therefore, if clogged or damaged, the
washer nozzle should be replaced with the wiper blade.
1 Check the windshield wiper/cleaning device
a. If the spray area is uneven due to impurities in the
nozzle, remove the nozzle, rinse it with water in the
opposite direction of spray, and then purge it with
compressed air in the opposite direction of spray. If the
nozzle still does not work normally after cleaning, replace
the wiper blade.
b. Replace the front wiper blade. Refer to Maintenance
Manual - Electrics (I)
1.4.3.16 Inspecting and adjusting installation
position of wiper blade

1 Check the mounting position of the front wiper blade:

a. Check whether the rubber part of the wiper blade
coincides with the five small dots on the lower edge of the
front windshield as arrowed.

– Adjust the mounting position of the front wiper blade.

a. If excessive deviation is found during the above
inspection, it is necessary to set the wiper arm to the
normal resting position, remove the wiper arm and wiper
blade assembly, align the rubber part of the wiper blade
with the five small dots on the lower edge of the front
windshield as arrowed, and then install the wiper arm and
wiper blade assembly.
b. Remove the wiper arm and wiper blade assembly. Refer
to Maintenance Manual - Electrics (I)

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1.4.3.17 Inspecting free play of steering wheel

Check procedure

1 Check the free play of the steering wheel

a. Make the front wheels face right ahead.
b. Measure the side-to-side turn (arrow a) of steering
wheel ① when the front wheels are still.
-Free play of steering wheel: ≤ 15 °

1.4.3.18 Checking the fixing of the spare tire

Check procedure
1 Open the trunk lid.
2 Remove the trunk carpet assembly. Refer to
Maintenance Manual - Body, HVAC

3 Check the fixing of the spare tire

a. Tighten the spare tire mounting bolt as arrowed.
b. Ensure that the spare tire ② is fixed on the vehicle
body securely.

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1.4.3.19 Checking the door lock bolt and child

safety lock
Check procedure

1 Check the door lock bolt

a. Check whether the door lock bolts as arrowed are loose,
and tighten them to the specified torque if necessary.
• Tightening torque of bolt: 6±1 N ·m

2 Check the child safety lock

a. Turn the child safety lock switch ① from the "Open” to
the "Close" position to close the rear door. In this case the
door can only be opened from the outside because the
child safety lock has been activated.
Note:
In order to prevent children in the vehicle from
unintentionally opening the door, you can activate the child
safety lock.
Doors with the child safety lock activated can only be
opened from outside.

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1.4.3.20 Checking the wear of brake lining

Check procedure

1 Check the brake lining of front wheel

a. Remove the front wheel brake lining. Refer to
Maintenance Manual - Chassis
b. Visually check the thickness of the inner and outer brake
linings (arrow a).
c. If necessary, remove the brake lining and measure with
a scale rule.

• Standard thickness: 10 mm
• Wear limit: 2 mm
Note:
If the thickness of the brake lining (without backplate) is
less than 2 mm, it indicates that the brake lining has
reached its wear limit and shall be replaced.
While replacing the brake lining, be sure to check if the
front brake disc has reached its wear limit (i.e., 20 mm),
and replace the front brake disc if necessary.

2 Check the rear wheel brake lining

a. Remove the rear wheel brake lining. Refer to
Maintenance Manual - Chassis
b. Visually check the thickness of the inner and outer brake
linings (arrow a).
c. If necessary, remove the brake lining and measure with
a scale rule.

• Standard thickness: 10 mm
• Wear limit: 2 mm
Note:
If the thickness of the brake lining (without backplate) is
less than 2 mm, it indicates that the brake lining has
reached its wear limit and shall be replaced.
While replacing the brake lining, be sure to check if the
rear brake disc has reached its wear limit (i.e., 9 mm), and
replace the rear brake disc if necessary.

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1.4.3.21 Inspecting wear of brake disc

Check procedure
1 Remove the wheel assembly. Refer to Maintenance
Manual - Chassis

2 Check the front wheel brake disc

a. Measure the thickness of the front brake discs (arrow a).

• Thickness of front brake discs: 28 mm

• Size for maintenance limit: 26 mm

Note:
When the brake disc wear exceeds the specified limit, the
brake disc must be replaced.

3 Check rear wheel brake discs

a. Measure the thickness of the rear brake discs (arrow a).
• Thickness of rear brake disc: 10 mm

• Size for maintenance limit: 9 mm

Note:
When the brake disc wear exceeds the specified limit, the
brake disc must be replaced.

1.4.3.22 Checking the connecting bolt of

steering column and steering gear
Check procedure
1 Park the vehicle on a level ground, with the tire facing
right ahead.

2 Check the connecting bolt of steering column and

steering gear
a. Check the connecting bolt of steering column and
steering gear ① for looseness, and if any, tighten it.
b. Turn the steering wheel to check whether there is a gap
in the steering knuckle ② of the steering column, and if
any, replace the steering column. Refer to Maintenance
Manual - Chassis
• Tightening torque of bolt: 60±5 N ·m

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1.4.3.23 Checking the steering gear outer ball

joint and dust cover
Check procedure

1 Check the outer ball joint of steering gear and dust boot
a. Lift the vehicle to the proper height and shake the
steering gear outer ball joint ① with hand to check for
clearance. If any clearance exists, replace the steering
gear outer ball joint. Refer to Maintenance Manual -
Chassis
b. Check the dust cover of the steering gear outer ball joint
② for damage, and replace the steering gear outer ball
joint if any damage is found. Refer to Maintenance Manual
- Chassis

c. Check the steering gear dust cover ① for damage, and

replace it if it is damaged. Refer to Maintenance Manual -
Chassis

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1.4.3.24 Checking lower control arm ball joint

and front stabilizer bar link
Check procedure

1 Lift the vehicle.

2 Check the lower control arm ball joint
a. Check the dust cover of the lower control arm ball joint
① for damage, and if it is damaged, replace the lower
control arm ball joint. Refer to Maintenance Manual -
Chassis
b. Check the lower control arm ball joint ① for looseness
and replace it if it is loose. Refer to Maintenance Manual -
Chassis

3 Check the front stabilizer bar link

a. Check the front stabilizer bar link dust cover ① for
damage, and if it is damaged, replace the front stabilizer
bar link assembly. Refer to Maintenance Manual - Chassis
b. Check the front stabilizer bar link ball joint for looseness,
and if it is loose, replace the front stabilizer bar link
assembly. Refer to Maintenance Manual - Chassis

1.4.3.25 Inspecting the suspension assembly

Check procedure
Check the suspension assembly
• Lift the vehicle.
• Visually check if any connecting bush is aging and
damaged.
• Tighten all connecting bolts and nuts to the specified
torque.
• Visually check all connection components for
deformation and cracks.
• Check the shock absorbers for oil leakage and the
dust cover for damage.
1.4.3.26 Inspecting underbody
Check procedure
Check the underbody
• Lift the vehicle.
• Check the fuel pipes and brake fluid lines for leakage.
• Visually check the underbody protective layer, wheel
covers and side rails for damage.
• Visually check all connection components for
deformation and cracks.
• Visually check if any exhaust pipe mounting is aging
and if all exhaust pip are installed reliably.

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1.4.3.27 Inspecting tires

Check procedure
1 Lift the vehicle.

2 Check the tires

a. Check the tires for abnormal wear.
b. Check the tire tread for damage and foreign materials.
c. If any bilateral or central wear is found on the tire tread,
adjust the tire pressure.
d. If any single-side wear or sawtooth wear is found on the
tire tread, check the front wheel toe-in and wheel camber,
Two-side wear Central wear and adjust them if necessary.

Sawtooth wear Single-side wear

e. Check the tyre tread depth as arrowed.

f. Check for wear, sponginess, cuts and piercing on one
side of the tire tread.
g. Ensure that the depth of the tire tread grooves is greater
than the thickness of the tire wear indicator.
h. If necessary, replace tires that do not correspond to the
specified value.

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1.4.3.28 Inspecting the wheel fixing bolt

Check procedure

1 Check the wheel fixing bolt

a. Check the wheel fixing bolts as arrowed for missing or
damage.
b. Tighten the wheel bolts diagonally as arrowed.
• Tightening torque of bolt: 125±10 N ·m

1.4.3.29 Inspecting front shock absorber

bearing
Check procedure
Caution
This test shall be performed when the original tires and
wheels have the correct tire pressure.
Check the front shock absorber bearing
• Park the vehicle on a level ground.
• Turn the steering wheel back and forth to listen
carefully for any abnormal sound from the front shock
absorber bearing.
• Drive the vehicle over a speed bump to listen carefully
for any abnormal sound from the front shock absorber
bearing.
Caution
Do not drive too fast over a speed bump during road test.
If any abnormal sound is heard, find out the cause and
replace the relevant part(s).
1.4.3.30 Inspecting the EPB
Check procedure
Check the EPB for slipping
• Perform parking on a slope to verify if brake efficiency
is reduced.
• Fasten the driver's seat belt, drive the vehicle on a
slope with a gradient of 15% and brake to stop the
vehicle.
• Set the gearshift lever to “N” position.
• Activate EPB. When parking is complete, release the
service brake pedal.
• Check whether the vehicle is completely parked. If it
slips downwards, it indicates that the parking
efficiency is reduced.
Check the EPB for dragging
• Release the EPB normally.
• If the red indicator lamp lights up or flashes during
driving, it indicates that the residual brake force is
excessive, then test or repair the EPB.

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1.4.3.31 Inspecting free travel and height of

brake pedal
Check procedure

1 Check the free travel and height of brake pedal

a. The distance, a, between the highest point the brake
pedal and the lowest point when the brake pedal is
depressed.
• Height and travel of brake pedal: 106 ± 3mm

2 Check the free travel of brake pedal

a. Set the HEV Engine STRAT/STOP button to "OFF"
position,and push the brake pedal with hand as arrowed
to check
the free travel of the brake pedal ① (arrow a).
b. If the free travel of the brake pedal exceeds the
specified range, it may cause incomplete braking. In case
of insufficient free travel of the brake pedal, it may cause
brake dragging.
• Free travel of brake pedal: ≤ 11 mm

1.4.3.32 Self-diagnosis: inspecting DTCs

Check procedure
Note:
The test equipment shall always be installed on the rear
seat while performing a test drive.
The test equipment shall be operated by another
technician during the test drive.

1 Check DTCs
a. Connect the vehicle’s diagnostic scan tool as arrowed.
b. Set the HEV Engine START/STOP button to the
“ON”position, and check the fault message as instructed
by the
diagnostic scan tool ①.
c. If an active DTC is found, carry out troubleshooting.
d. Clear the fault message as well as the fault message
history.
e. Set the HEV Engine START/STOP button to the
“ON”position again, wait 5 s and read the fault message
againto ensure that there is no active DTC and the
fault hasbeen cleared.

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1.4.3.33 Visually inspecting driving axle dust

cover
Check procedure
1 Lift the vehicle.

2 Visually check the driving axle dust cover

a. Check the driving axle dust cover ① for damage and
leakage.
b. If any damage is found, replace the driving axle
assembly. Refer to Maintenance Manual - Chassis

1.4.3.34 Visually check the HEV

Enginecompartment components
Check procedure
1 Open the HEV Engine hood.

2 Visually check the HEV Engine compartment

components
A. Eliminate the fault(s) found in the inspection
immediately.
b. Check the ducts, hoses and joints of the followings for
leakage, damage or looseness.
-Fuel system
- Lines of A/C system and cooling system
- raking devices
Note:
Eliminate all faults found during the inspection.

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1.4.3.35 Visually inspecting braking device for

leakage and damage
Check procedure
Visually check the following components for leakage and
damage:
-Brake master cylinder
-Vacuum booster
- Brake caliper
-Brake pipeline
• Visually check the aging degree of brake hoses and
the assembly clearance of body.
• Visually check brake hoses and brake lines for bruise.
• Visually check the brake line interfaces and
anchorages are secure and check them for leakage
and rust.
Caution
Do not twist the brake hose.
The brake hoses shall not interfere with the surrounding
components when the steering wheel is at the maximum
steering angle.
Be sure to eliminate all faults found (via maintenance
measures).

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1.4.3.36 Visually inspecting exhaust system for

leakage and damage
Check procedure
Caution
Inhaling carbon monoxide is dangerous and potentially
fatal. Carbon monoxide concentration is high when the
HEV Engine is idling; the exhaust removal device shall be
usedwhen the HEV Engine is running in a workshop or
anyotherconfined area.

1 Visually check the exhaust system

a. Lift the vehicle and check the exhaust system
components for leakage and damage.
b. Check the muffler ① housings for corrosion and
damage.

c. Check whether there is leakage at the connection (as

arrowed) of silencer, catalytic converter and middle
exhaust pipe assembly.

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d. Check whether the exhaust pipe suspension cushion I

① is aging.

e. Check whether the exhaust pipe suspension cushion II

① is aging.
Caution
Eliminate all faults found during the inspection.

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1.4.3.37 Visually inspecting fuel tank assembly

surface for bumps
Check procedure

1 Visually check fuel tank assembly

a. Lift the vehicle.
b. Visually check ① the surface of fuel tank assembly for
bumps.
c. Visually check the fuel lines and the pipe joints for
leakage and damage.

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1.4.3.38 Bleeding the brake system

Bleeding procedure
Note:
The brake fluid approved by our company must be used.
Other brake fluids may cause corrosion and shorten the
service life of the brake system.
Check that the brake fluid is not contaminated by foreign
matter.
Do not spill brake fluid on the vehicle. Otherwise, the paint
may be damaged. If the brake fluid has been spilled on the
paint, it shall be cleaned immediately with clean water.
The brake fluid level in the brake fluid reservoir shall be at
the MAX (highest) mark when you begin to bleed the
reservoir. After bleeding, check each brake caliper for
leakage.
1 Remove the wheel assembly. Refer to Maintenance
Manual - Chassis

2 Bleeding the brake system

a. Check that the brake fluid level in the brake fluid
reservoir is above MAX mark.

b. The brake system shall be bled by two technicians

together.
c. Life the vehicle.
d. Remove the blanking piece of the brake caliper and
install a collecting container ①.
e. Unscrew the bleed bolt of the brake caliper as arrowed;
one technician presses the brake pedal from above and
the other technician loosens/tightens the drain bolt from
below so as release air from the system until there is no air
in the system.
Note:
The brake fluid of the front and rear wheels are bled in the
same way.

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f. Bleed the brake of each wheel in the order of ① to ④

as shown until there is no air in the brake fluid.
Caution
During bleeding, make sure that the brake fluid in the
reservoir does not fall below MIN mark.

Front Front
left right

Left Rear
rear right

g. Add brake fluid until the brake fluid level reaches MAX
mark of the reservoir.

1.4.3.39 Recovering and adding refrigerant

1 Turn off all electrical consumers and set the HEV
EngineSTART/STOP button to “OFF” position.
2 Power on the equipment.

3 Recover the refrigerant.

a. Connect the high- and low-pressure pipes of the cooling
circuit.
b. Turn on the low-pressure valve switch ① and high-
pressure valve switch ② of the equipment.
c. Select “Recover Refrigerant” of the equipment, and start
the equipment for recovery.
d. Check the pressure of the low pressure gauge of the
equipment. When the vacuum indicated on the pressure
gauge reaches -34kPa, shut down the equipment and stop
recovery.

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Note:
Vacuumize the HVAC system before filling the refrigerant.
The refrigerant should be added after the A/C compressor
oil is applied.

4 Add refrigerant
a. Select ‘‘Add Refrigerant’’ of the equipment, and adjust
the filling amount.
b. Turn on the low-pressure valve switch ①, turn off the
high-pressure valve switch ②, and start the equipment for
filling.
c. Observe the display screen of the equipment. When the
set filling amount is reached, “OK” will be displayed on the
screen.
d. Close the valve to complete filling.
Please add the refrigerant according to the following
standards.
Refrigerant model Refrigerant filling amount
HFC-134a 530±25g
If the equipment displays that the filling speed is too low,
please refer to the following filling methods.
- Disconnect the high-pressure connector of the cooling
circuit, and only connect the connector at the low-pressure
end.
– Close the high- and low-pressure valves of the
equipment.
- Engage the parking gear, start the vehicle, turn on the
A/C, and activate the low temperature mode.
- Open the low-pressure valve of the equipment, and inject
the refrigerant into the cooling pipe from the low-pressure
end.
- When the pressure gauge shows that the standard low
pressure is reached, turn off the low pressure valve switch
and disconnect the connector at the low-pressure end.
-Refrigerant filling is completed.
1.4.3.40 Recovering and adding compressor oil
Note:
The A/C compressor oil can be discharged only after
refrigerant recovery.
The waste lubricating oil and refrigerant should be
recovered and disposed of in accordance with relevant
regulations.
The oil collection bottle of the filling machine should be
emptied.

1 Discharge the compressor oil

a. Connect the high- and low-pressure pipes of the cooling
circuit.
b. Turn on the low-pressure valve switch ① and high-
pressure valve switch ② of the equipment.
c. Open the oil drain valve on the control panel of the A/C
refrigerant filling machine, start the equipment, and check if
the A/C compressor lubricating oil is discharged into the oil
collection bottle.
d. After the A/C compressor oil is discharged, stop draining
the oil, and close the oil drain valve.
e. Check the oil collection bottle, and record the oil level.

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Add the compressor oil

Note:
The compressor oil can be added only after vacuumization.
Install the filling bottle, and add the compressor oil
according to the standard.
• Compressor oil filling amount: 5 mL

• Compressor oil model: PAG (SP-10)

- Connect the high- and low-pressure pipes of the cooling
circuit, open the high-pressure valve of the equipment, and
turn on the compressor oil filling switch.
- Start the A/C refrigerant filling machine, and observe the
oil level in the filling bottle until the required oil level is
reached.
– Close the high-pressure valve.
1.4.3.41 Vacuumizing the HVAC system
Note:
The refrigerant should be recovered before the HVAC
system is vaccumized.

1 Vacuumize the HVAC system

a. Connect the high- and low-pressure pipes of the cooling
circuit.
b. Open the low-pressure valve ① and high-pressure
valve ② of the equipment, select “Vacuumize”, and set
the time to 15min. Start the equipment for vacuumization.
When the set time is reached, the equipment will stop
working automatically.
c. Close the low-pressure valve ① and high-pressure
valve ② of the equipment, and check the pressure of the
low-pressure gauge.
d. If the pressure doesn’t increase within a certain period
after the set value is reached, the compressor oil and
refrigerant can be added when it is confirmed that the
cooling circuit is free of leakage.
e. If the pressure increases, check the cooling circuit for
leakage.

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1.4.3.42 Replacing the wiper blade

Replacement procedure
Note:
This section describes the removal and installation of the
left front wiper blade, and the right front wiper blade may
be removed and installed by reference to left one.
1 Set the front wiper to maintenance mode.
Note:
With the HEV Engine hood closed, turn theHEV
EngineSTART/STOP button to the "ON" position andthen
to the"OFF" position. Within 10 seconds after theprevious
step,set the wiper combination switch to the "MIST"
position. Atthis time, the front wiper will move tothe
highest positionand then stop.
The wiper maintenance function can be activated by
setting “System Setting - Body Accessories - Other
Accessories - Wiper Maintenance Mode” on the multimedia
touch screen.

2 Replace the front wiper blade

a. Pull the wiper arm ① from the front windshield
assembly.

b. Press the wiper blade lock button (arrow A), and remove
the wiper blade ① (arrow B).
Note:
After removing the front wiper blade, wrap the wiper arm
with sufficient cloth to prevent the wiper arm from
damaging the windshield.

Installation procedure
The installation procedure is in reverse of removal
procedure.

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1.4.3.43 Replacing the spark plug

Removal procedure
Note:
After removing the spark plug, plug up the spark plug hole
with a cloth to prevent debris from falling into the cylinder.
1 Turn off all electrical consumers and set the HEV
Engine
START/STOP button to “OFF” position.
2 Disconnect the negative battery terminal. Refer to
Maintenance Manual - 4A15J2 HEV Engine (I)
3 Remove the ignition coil. Refer to Maintenance Manual -
4A15J2 HEV Engine (I)

4 Replace the spark plug

a. Use the spark plug removal tool ① to unscrew the
spark plug in the direction of arrow.

• Tightening torque of spark plug: 20±2 N·m

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Installation procedure

The installation procedure is in reverse of removal

procedure, and the following points apply:
- When installing the spark plug, be sure to check whether
the spark plug is the correct type.
- Check the spark plug as arrowed for residual oil and
carbon deposits, and clean it if necessary.

• Spark plug model: SILKFR8E8S

– Check the gap (a) between the spark plug electrodes.

• Standard value of a: 0.75~0.85 mm

1.4.3.44 Changing coolant

Replacement procedure
Note:
If the HEV Engine is hot, wait until it cools down naturally.
Do not open the expansion tank cap when the HEV
Engine ishot. It shall be opened when the HEV Engine is
cooled down toroom temperature. Otherwise, the
high-temperaturecoolant or steam comes out, causing
personal injury.
1 Turn off all electrical consumers and set the HEV
Engine
START/STOP button to “OFF” position.

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2 Discharge coolant
a. Unscrew the expansion tank cap ①.

b. Lift the vehicle.

c. Place a container for collecting the coolant under the
vehicle.
d. Loosen the fixing clamp as arrowed, disconnect the
radiator water outlet hose from the radiator water outlet
hose I, and drain the coolant.
e. After the coolant is completely discharged, connect the
radiator water outlet hose to the radiator water outlet hose
I, and install the fixing clamp in its original position as
arrowed.

3 Coolant filling method

a. Slowly add the intercoolant coolant until it reaches the
MAX mark of the expansion tank.
b. Install the expansion tank cap, keep the HEV Engine
hoodopen, turn the ignition switch to "ON" position, step
on theaccelerator pedal and the brake pedal for more
than 5 s,and then release them. At this time, activate
the fillingmode of the temperature control module, adjust
its openingto a reasonable position, and then start the
HEV Engine within1min. After start, maintain the state
for5min to fullycirculate the coolant in the system.
c. Set the HEV Engine START/STOP button to “OFF”,
checkthe coolant level, and add the coolant if necessary
until itslevel is between MIN and MAX marks.
• Coolant model: DF-6/-35 ℃

• Total coolant filling amount: 8.2±0.1 L

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4 Drain the intercooler coolant

a. Unscrew the expansion tank cap ①.

b. Lift the vehicle

c. Place a container for collecting the coolant under the
vehicle.
d. Unscrew the fixing bolt as arrowed, and move the HVAC
high and low pressure pipe bracket ① to one side.

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e. Loosen the fixing clamp as arrowed, and disconnect the

intercooler water inlet pipe ①.

5 Add the intercooler coolant

a. Slowly add the intercoolant coolant until it reaches the
MAX mark of the expansion tank.
b. Install the expansion tank cap, keep the HEV Engine
hoodopen, turn the ignition switch to "ON" position, and
at thesame time, step on the accelerator pedal and brake
pedalfor more than 5s, at this time, the intercooler electric
waterpump will automatically start to run; After the water
pumpstops running, repeat the above operations twice.
c. After the water pump stops running, open the expansion
tank cap again, replenish the coolant to the MAX line, and
then cover the expansion tank cap, so that the filling is
completed.
Note:
Do not dilute the intercooler coolant at will.
The coolant cannot be reused, mixed or changed with the
intercooler coolant of different color.
• Intercooler coolant model: DF-6,-35 ℃
• Intercooler coolant filling amount: 3.3±0.1L

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1.4.3.45 Changing brake fluid

Replacement procedure
Note:
Brake fluid type: DOT4, total filling volume: 0.77±0.05L.
Do not mix the brake fluid with other mineral oils, which
may cause damage to the seals of the brake system.
Always seal the brake fluid for storage, as it is highly
hygroscopic and absorbs moisture from the surrounding
environment.
1 Remove the wheel assembly. Refer to Maintenance
Manual - Chassis

2 Change the brake fluid

a. Unscrew the brake fluid reservoir cap ① as arrowed.
b. Drain the brake fluid from the brake fluid reservoir.
c. Add new brake fluid directly to the brake fluid reservoir.

d. The brake fluid shall be changed by two technicians

together.
e. Life the vehicle.
f. Remove the blanking piece of the brake caliper and
install a collecting container ①.
g. Unscrew the bleed bolt of the brake caliper as arrowed;
one technician presses the brake pedal from above and
the other technician unscrews/tightens the drain bolt as
arrowed from below.
Note:
The brake fluid of the front and rear wheels are bled in the
same way.

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h. Change the brake fluid for each brake wheel cylinder in

the order (① to ④) shown in the figure until the brake fluid
of four brake wheel cylinders is renewed.
Caution
When changing the brake fluid, make sure that the brake
fluid in the reservoir does not fall below the “MIN” mark.
Front Front
left right

Left Rear
rear right

i. After replacing the brake fluid in the four brake wheel

cylinders, bleed the brake system. Refer to Maintenance
Manual - Chassis
j. After bleeding, add brake fluid until the brake fluid level
reaches MAX mark of the reservoir.

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1.4.3.46 Changing HEV Engine oil

Draining procedure
1 Turn off all electrical consumers and set the HEV
Engine
START/STOP button to “OFF” position.

2 Discharge HEV Engine oil

a. Unscrew the HEV Engine oil filler cap ①.

b. Lift the vehicle.

c. Place the oil collector under the oil sump drain plug.
d. Unscrew the oil sump drain bolt as arrowed, and drain
the HEV Engine oil.
Caution
Dispose of the drained oil as specified!

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e. Replace the disposable oil drain plug washer ①.

f. Tighten the drain plug as arrowed to the specified torque.

• Tightening torque of screw plug: 30±2 N·m

Adding procedure

Filling requirements of HEV Engine oil

Oil grade Oil viscosity Total filling volume Filling amount

API SN/ILSAC GF-5 SAE 0W-20 4.5L 4.2L

1 Add HEV Engine oil

a. Add a proper amount of oil as specified.
b. Take out the oil dipstick, wipe down it with a clean shop
towel and reinsert the oil dipstick to the bottom.
c. Take out the oil dipstick again to check the oil level,
which shall be between the upper mark (arrow H) and the
lower mark (arrow L).
d. Start the HEV Engine, and check that the oil filter
is notleaking when the HEV Engine reaches normal
temperature.
e. Shut down the HEV Engine and wait for 3 to 5
minutes, andthen take out the oil dipstick again to check
the oil level,which shall be between the upper mark (H)
and the lowermark (L).

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1.4.3.47 Replacing the oil filter

Replacement procedure
1 Turn off all electrical consumers and set the HEV
EngineSTART/STOP button to “OFF” position.

2 Replace the oil filter

a. Place the oil collector under the oil filter.
b. Remove the HEV Engine oil filter ① with the oil filter
removaltool.

Installation procedure

The installation procedure is in reverse of removal

procedure, and the following points apply:
- Clean the contact surface of the oil filter.
-Before installing a new filter, apply a little HEV Engine oil
to thesurface of the sealing ring as arrowed.

- Tighten the HEV Engine oil filter ① with the oil filter
removaltool.

Tightening torque of oil filter: 15±1.5 N·m

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1.4.3.48 Replacing the wet DCT fluid

Replacement procedure
Note:
Perform further operation after the HEV Engine has cooled
downnaturally and the transmission fluid flows back to
the oilpan.
Start the HEV Engine and have it run at an idle speed
so thatthe oil line is full of oil, then turn off the HEV Engine
andpark thevehicle horizontally; if the transmission fluid
doesnot dripdown in a line, that is to say, the
transmissionfluid hasbeen drained, at this time, the
transmission
filling amountis 5±0.2 L.
The place where the vehicle is located shall be free of
dust, and entry of foreign matters such as visible particles
to the transmission should be avoided in the fluid change
process.
Please comply with the regulations on disposal!
The seal ring assembly of the oil drain bolt and the oil filler
bolt shall not be reused after removal.
The graduated container helps you to determine the
approximate filling volume.
1 Turn off all electrical consumers and set the HEV
EngineSTART/STOP button to “OFF” position.
2 Check that the transmission or vehicle is horizontal.

3 Drain the wet DCT fluid.

a. Lift the vehicle.
b. Place the container collecting the transmission fluid
under the transmission.
c. Unscrew the transmission drain bolt as arrowed.
d. Drain the wet DCT fluid until it is in the state of droplets.
·Tightening torque of bolt: 40±4 N·m

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e. Replace with a new transmission drain bolt gasket ①.

f. After the draining, tighten the transmission fluid drain bolt

as arrowed.
·Tightening torque of bolt: 40±4 N·m

Adding procedure
1 Remove the air cleaner assembly. Refer to Maintenance
Manual - 4A15J2 HEV Engine (I)

2 Add the wet DCT fluid

a. Clean the oil filler bolt and the nearby housing surface,
where there should be no visible dust, oil and water stains,
and other foreign objects.
b. Unscrew the transmission fluid filler bolt as arrowed. The
bolt should be placed such that the threaded end is
upward.
c. Add the fluid by a clean funnel and other auxiliary
means.

• Tightening torque of bolt: 40±4 N·m

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d. Replace with a new transmission fluid filler bolt gasket

①.

e. After the adding, tighten the transmission fluid filler bolt

as arrowed.

• Tightening torque of bolt: 40±4 N·m

• Wet DCT fluid specification: Shell Spirax S5 DCT 12

• Total filling volume: 5±0.2 L

Note: The fluid drained from the transmission must not be
reused, and the transmission must be filled with new
qualified fluid.

3 Install the air cleaner assembly. Refer to Maintenance

Manual - 4A15J2 HEV Engine (I)
4 Check the transmission fluid level and whether the
transmission works normally

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1.4.3.49 Replacing the press filter element

Removal procedure
Note:
Perform further operation after the HEV Engine has cooled
downnaturally and the transmission fluid flows back to
the oilpan.
1 Turn off all electrical consumers and set the HEV
EngineSTART/STOP button to “OFF” position.
2 Remove the air cleaner assembly. Refer to Maintenance
Manual - 4A15J2 HEV Engine (I)
3 Remove battery tray. Refer to Maintenance Manual -
4A15J2 HEV Engine (I)
4 Remove battery tray. Refer to Maintenance Manual -
4A15J2 HEV Engine (I)

5 Replace the press filter element

a. Unscrew the set bolt of the press filter cover as arrowed.

• Tightening torque of bolt: 9±1 N·m

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b. Use a tool to unscrew the press filter cover ① as

arrowed

• Tightening torque of press filter cover: 10±1 N·m

Note:
The press filter cover must be screwed to the installation
end face and then tightened to the specified torque.

c. Take out the press filter element (1).

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Installation procedure

The installation procedure is in reverse of removal

procedure, and the following points apply:
-Replace with the new press filter cover seal ring ①.

- Tighten the locating bolt as arrowed, and make sure that

the flange surface of the bolt falls into the groove of the
press filter cover.
-Tightening torque of bolt: 9±1 N·m

1.4.3.50 Replacing the A/C filter element

Removal procedure
1 Turn off all electrical consumers and set the HEV
EngineSTART/STOP button to “OFF” position.

2 Remove the glove box outer cover plate assembly

a. Open the glove box assembly and unscrew the glove
box stopper clip ① (arrow A).
b. Push the left side of the glove box outer cover plate
assembly in the direction arrow B, and disconnect the
glove box outer cover plate assembly ① from the glove
box frame assembly.
c. Remove the glove box outer cover plate assembly ②.

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3 Replace the A/C filter element

a. Press the fixing clip as arrowed and take out the filter
element cover ①.

b. Take out the A/C filter element ①.

Installation procedure

The installation procedure is in reverse of removal

procedure, and the following points apply:
- Install the A/C filter element ① with the arrow mark
facing downwards.

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1.4.3.51 Replacing air cleaner element

Removal procedure
1 Turn off all electrical consumers and set the HEV
EngineSTART/STOP button to “OFF” position.

2 Replace the air cleaner element

a. Unscrew the fixing screws as arrowed, and open the air
cleaner upper housing ①.

b. Take out the air cleaner element ①.

Installation procedure
The installation procedure is in reverse of removal
procedure, and the following points apply:
- To replace the air cleaner element, use the original
product.
- Remove debris and dust in the air cleaner housing.

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1.4.3.52 Replacing canister filter

Removal procedure
1 Turn off all electrical consumers and set the HEV
Engine
START/STOP button to “OFF” position.
2 Remove the right rear wheel assembly. Refer to
Maintenance Manual - Chassis
3 Remove the right rear wheel mudguard assembly. Refer
to Maintenance Manual - Body, HVAC

4 Replace the canister filter

a. Loosen the fixing clamp (arrow A), and disconnect the
canister filter with canister vent pipe ① from the canister
filter ②.
b. Undo the fixing clip (arrow B), and take out the canister
filter ②.

Installation procedure
The installation procedure is in reverse of removal
procedure.

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1.4.3.53 Replacing water pump belt

Removal procedure
1 Turn off all electrical consumers and set the HEV
Engine
START/STOP button to “OFF” position.
2 Remove the right front wheel assembly. Refer to
Maintenance Manual - Chassis
3 Remove the right front wheel mudguard assembly. Refer
to Maintenance Manual - Body, HVAC

4 Replace the water pump belt

a. Use appropriate tools ① to fix the water pump belt ②
from the inside to the outside.
b. Rotate the crankshaft damper pulley ③ in a clockwise
direction and take out the water pump belt ②.

Installation procedure
The installation procedure is in reverse of removal
procedure, and the following points apply:
- Remove foreign objects from the water pump belt before
installation.
- Visually check the water pump belt for excessive wear or
cord pulled out, and replace it with a new one if necessary.
- After installing the water pump belt, make sure that it is
correctly installed in the ribbed groove of crankshaft
damper pulley.
- After the installation, turn the crankshaft damper pulley
clockwise to check whether the water pump belt is driven
smoothly.
1.4.3.54 Replacing the V-ribbed belt
Removal procedure
1 Turn off all electrical consumers and set the HEV
Engine
START/STOP button to “OFF” position.
2 Remove the right front wheel assembly. Refer to
Maintenance Manual - Chassis
3 Remove the right front wheel mudguard assembly. Refer
to Maintenance Manual - Body, HVAC

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4 Remove the water pump belt. Refer to Maintenance

Manual - 4A15J2 HEV Engine (I)

5 Replace the V-ribbed belt

a. Use a tool to pull the accessory tensioner ① clockwise
as arrowed until the V-ribbed belt can be removed.
b. Remove the V-ribbed belt ②.

Installation procedure
The installation procedure is in reverse of removal
procedure, and the following points apply:
-Clear the foreign object on the V-ribbed belt before
installation.
- Visually check the V-ribbed belt for excessive wear or
cord pulled out, and replace with the new V-ribbed belt if
necessary.
- After installing the water pump belt, make sure that it is
correctly installed in the ribbed groove of crankshaft
damper pulley.
- After the installation, turn the crankshaft damper pulley
clockwise to check if the V-ribbed belt is driven smoothly.

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1.4.3.55 Replacing the accessory tensioner

Removal procedure
1 Turn off all electrical consumers and set the HEV
Engine
START/STOP button to “OFF” position.
2 Remove the right front wheel assembly. Refer to
Maintenance Manual - Chassis
3 Remove the right front wheel mudguard assembly. Refer
to Maintenance Manual - Body, HVAC

4 Replace the accessory tensioner

a. Use a tool to pull the accessory tensioner ① clockwise
as arrowed until the V-ribbed belt can be removed.
b. Remove the V-ribbed belt ②.

c. Unscrew the fixing bolt as arrowed, and take out the

accessory tensioner ①.
·Tightening torque of bolt: 50±5 N·m

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Installation procedure

The installation procedure is in reverse of removal

procedure, and the following points apply:
- Before installing the accessory tensioner, make sure that
the accessory tensioner bolt is fitted in the water pump
bracket hole.
- Rotate the accessory tensioner to align the dowel pin
(arrow A) on it with the pin hole on the bracket (arrow B).
- Tighten the fixing bolt of the accessory tensioner to the
specified torque.

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1.4.3.56 Cleaning the electronic throttle body

Removal procedure
1 Turn off all electrical consumers and set the HEV
Engine
START/STOP button to “OFF” position.
2 Disconnect the negative battery terminal. Refer to
Maintenance Manual - 4A15J2 HEV Engine (I)

3 Clean the electronic throttle body

a. Disconnect the MAP/IAT sensor connector (arrow A).
b. Disconnect the lock pin (arrow B), and disconnect the
relief pipe II from the intercooler assembly.
c. Press the quick connector (arrow C), and disconnect the
fuel vapor pipe assembly I from the intercooler assembly.

d. Unscrew the fixing nuts (arrow A) and bolts (arrow B).

• Tightening torque of nut (arrow A): 8±2 N ·m
• Tightening torque of bolt (arrow B): 8±2 N ·m

e. Undo the clamp as arrowed, and disconnect the

intercooler air intake hose from the intercooler assembly.

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f. Unscrew the fixing bolt as arrowed, and move the

intercooler assembly ① to one side.
• Tightening torque of bolt: 15±2 N ·m

g. Disconnect the electronic throttle body connector (arrow

A).
h. Unscrew the fixing stud (arrow B), and take out the
electronic throttle body ①.
• Tightening torque of stud (arrow B): 4±1 N ·m
Caution:
Cover the intake manifold inlet with dust-free cloth to
prevent dust and foreign objects from entering the pipe.

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Installation procedure

The installation procedure is in reverse of removal

procedure, and the following points apply:
- Open the throttle by hand and use a soft object ① of
suitable size to lock the throttle in the fully open position.

- Spray the throttle cleaning agent to a dust cloth or wiping

paper to the extent no droplet of the cleaning agent falls.
- Use the dust cloth or wiping paper to wipe the valve plate
and air duct inner end face, especially the closing area of
throttle as arrowed.
- Install the electronic throttle body only after the throttle
cleaning agent has completely evaporated.
Caution:
Do not use compressed air to clean the throttle.
Do not spray the throttle cleaning agent directly to the air
duct and valve plate (as the cleaning agent is a liquid with
fluidity, flowing through the axial clearance can cause the
needle roller bearing grease failure, increase axial friction,
and eventually trigger the response or return delay, or
even trigger the fault indicator lamp).
During wiping, replace the dust cloth or wiping paper i time
if it is dirty.

-Replace the O-ring ①.

- After the electronic throttle body is installed, be sure to
perform self-learning on it. Refer to Maintenance Manual -
4A15J2 HEV Engine (I)

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1.4.3.57 Lubricating door locks

Lubrication procedure

1 Lubricate the door lock

a. Apply lubricating grease to the door lock as arrowed.

1.4.3.58 Conditions for adjusting front

combination lamp
1 Conditions for adjusting front combination lamp
• The tire inflation pressure is normal.
• The headlamp shade shall not be damaged or get
dirty.
The reflectors and bulbs are normal.
• Drive the vehicle some distance, compress the front
and rear suspensions for several times to adjust the
suspension into place.
• The vehicle must be loaded.
Load: The driver's seat is occupied by only one person or
75 kg weight and the vehicle is unladen (weight of empty
vehicle).
• If filled fuel volume is less than 90% of the fuel tank
capacity, load the vehicle as follows:
- Read the fuel level in the fuel tank via the fuel gauge.
- Calculate the additional weight according to the following,
and then place the weight in the trunk.
Additional weight:
(Unit of additional weight:
Fuel level on fuel gauge
kg)
1/4 30
1/2 20
3/4 10
Full 0
For example,
• If filled fuel volume is equal to half of the fuel tank
capacity, additional 20 kg weight shall be placed in the
trunk.
• For the vehicle equipped with the gas discharge
headlamps and AFS.
• If the vehicle is equipped with the gas discharge
headlamps, check the fault memory with the
diagnostic scan tool every time before headlamp
adjustment.
• Delete the failure messages in memory and AFS to
the basic settings.

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1.4.3.59 Adjusting front combination lamp

Adjustment procedure
Note:
Adjust the headlamps in accordance with local laws.

1 Adjusting the front combination lamp

a. The front combination lamp adjusting bolts are
symmetrically distributed on the left and right sides.
- The adjusting bolt (arrow A) is used for adjusting the
high/low beam horizontally.
- The adjusting bolt (arrow B) is used for adjusting the low
beam vertically.
- The adjusting bolt (arrow C) is used for adjusting the high
beam vertically.

1.4.3.60 Cleaning the windshield wiper cover

Cleaning procedure

1 Clean the windshield wiper cover

a. Clean the fallen leaves on the windshield wiper cover
①.

1.4.3.61 Lubricating the air spring ball sockets

of PLG drive rod and balance rod
Lubrication procedure

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Note:
During the removal of the PLG drive rod and balance rod,
another technician is required to hold on to the PLG and
keep it open.

1 Lubricate the air spring ball sockets of liftgate drive rod

and balance rod
a. Pry up the fixing clamp (arrow A) of the power liftgate
drive rod by the miniature slotted screwdriver.
b. Disconnect the PLG drive rod ① from the ball joint
seat.
c. Pry up the fixing clamp (arrow B) of the PLG balance bar
② by the miniature slotted screwdriver.
d. Disconnect the PLG balance bar ② from the ball joint
seat.
e. Grease the inside of air spring ball socket.
Required grease: lithium soap base synthetic hydrocarbon
with high viscosity and operating temperature of ﹣30℃
~120℃.
Caution
The fixing clamps of PLG drive rod and balance bar must
not be pried completely out of the ball seat; otherwise the
fixing clamps will be damaged, thus causing failure to fix
the PLG. The PLG drive rod and balance bar will bounce
out of the ball pin, causing damage to parts or personal
injury.
1.4.3.62 Fastening chassis bolt
Tightening procedure
Note:
Below describes the tightening position and torque of the
chassis fastening bolts on one side only, which are the
same as the fastening bolts on the other side.
1 Remove wiper cover assembly. Refer to Maintenance
Manual - Body, HVAC
2 Remove the HEV Engine compartment lower guard
plate.
Refer to Maintenance Manual - Body, HVAC
3 Remove the four wheel assemblies. Refer to
Maintenance Manual - Chassis

4 Fasten chassis bolts

a. Tighten the fixing nuts as arrowed for securing the front
sliding pillar assembly to the body.
• Tightening torque of nut: 70±7 N ·m

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b. Tighten the connecting bolt/nut as arrowed between the

front strut assembly and the front steering knuckle.
• Tightening torque of bolt/nut: 110±10N·m

c. Tighten the fixing bolt/nut as arrowed of front stabilizer

bar assembly.
• Tightening torque of bolt: 70±7 N ·m

d. Tighten the fixing nut as arrowed of front stabilizer bar

link assembly ①.
• Tightening torque of nut: 110±10 N ·m

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e. Tighten the fixing bolt/nut as arrowed of the electric

power steering gear assembly.
• Tightening torque of bolt/nut: 120±10 N ·m

f. Tighten the connecting nuts of front steering knuckle and

front lower control arm ball joint (arrow A).
g. Tighten the connecting bolts (arrows B and C) between
the front lower control arm assembly and front subframe.

• Tightening torque of bolt (arrow A): 110±10 N·m

• Tightening torque of bolt (arrow B): 200±10 N·m

• Tightening torque of bolt (arrow C): 200±10 N·m

h. Tighten the front wheel toe-in locking nut as arrowed.

• Tightening torque of nut: 60±5 N·m

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I. Tighten the fixing nut for securing the steering gear outer
ball joint and the front steering knuckle as arrowed.

• Tightening torque of nut: 50±5 N·m

j. Tighten the fixing bolt (arrow A) of the torsion rod

assembly.
k. Tighten the fixing bolt of transmission lower bracket and
torsion rod assembly (arrow B).
l. Tighten the fixing bolt (arrow C) of the transmission lower
bracket.
• Tightening torque of bolt (arrow A): 160±15 N ·m

• Tightening torque of bolt (arrow B): 160±15 N·m

• Tightening torque of bolt (arrow C): 100±10 N·m

m. Tighten the fixing bolt (arrow A), and remove the front
subframe front reinforced crossbeam assembly.
n. Tighten the connecting bolt of front subframe left/right
buffer beam assembly and front subframe assembly
connect (arrow B).

• Tightening torque of bolt (arrow A): 120±10 N·m

• Tightening torque of bolt (arrow B): 120±10 N ·m

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o. Tighten the fixing bolt of front end of front subframe

assembly ① as arrowed
• Tightening torque of bolt: 200±10 N ·m

p. Tighten the fixing bolts (arrows A, B and C) at the rear

end of the front subframe assembly.

• Tightening torque of bolt (arrow A): 120±10 N·m

• Tightening torque of bolt (arrow B): 200±10 N·mN ·m

• Tightening torque of bolt (arrow C): 200±10 N ·m

q. Tighten the fixing bolt (arrow A) between the rear strut

assembly ① and the vehicle body.
r. Tighten the connecting bolt/nut (arrow B) between the
rear strut assembly ① and the rear lower control arm
assembly.
• Tightening torque of bolt (arrow A): 110±10 N ·m
• Tightening torque of bolt (arrow B): 120±10 N ·m

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s. Tighten the fixing bolt/nut as arrowed of the rear upper

arm assembly ①.
• Tightening torque of bolt/nut: 125±10 N ·m

t. Tighten the fixing bolt/nut (arrow A) between rear lower

arm assembly ① and rear axle joint assembly.
u. Tighten the fixing bolt/nut (arrow B) between the rear
lower arm assembly ① and rear subframe assembly.
• Tightening torque of both/nut (arrow A): 125±10 N ·m

• Tightening torque of both/nut (arrow B): 125±10 N·m

v. Tighten the connecting bolt (arrow A) between rear

trailing arm assembly ① and rear axle joint assembly.
w. Tighten the connecting bolt (arrow B) between rear
trailing arm assembly ① and the vehicle body.
• Tightening torque of bolt (arrow A): 125±10 N ·m

• Tightening torque of bolt (arrow B): 70±7 N·m

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x. Unscrew the fixing bolt/nut (arrow B) between rear toe

arm assembly ① and rear subframe assembly.
y. Tighten the fixing bolt/nut (arrow B) between rear toe
arm assembly ① and rear axle joint assembly.
• Tightening torque of both/nut (arrow A): 125±10 N ·m

• Tightening torque of both/nut (arrow B): 125±10 N·m

z. Tighten the connecting bolt as arrowed between rear

stabilizer bar assembly ① and rear subframe assembly.
• Tightening torque of bolt: 70±7 N ·m

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aa. Tighten the connecting nut (arrow A) between the rear

stabilizer bar link assembly and the stabilizer bar
assembly.
ab. Tighten the connecting bolt/nut (arrow B) between the
rear stabilizer bar link assembly and the rear lower control
arm assembly.
• Tightening torque of nut (arrow A): 110±10 N ·m

• Tightening torque of both/nut (arrow B): 110±10 N·m

ac. Tighten the fixing bolt as arrowed between the rear

subframe assembly ① and the vehicle body.

• Tightening torque of bolt: 180±10 N·m

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1.4.3.63 Battery boosting

Boosting procedure
Note:
If the vehicle's 12V battery is depleted, the vehicle can be
started by the following steps, which require a set of
jumper (or auxiliary) cables and another vehicle with a 12V
battery.
Caution
The positive jumper cable and the negative jumper cable of
the battery must not touch each other!

1 Battery boosting
a. Undo the fixing clip of the positive battery terminal cover
as arrowed and open the positive battery terminal cover
①.

b. Connect the clamp of the positive jumper cable to the

positive electrode (arrow A) of the vehicle’s 12V battery,
and connect the other end to the positive electrode of
another vehicle’s 12V battery; connect the clamp of the
negative jumper cable to the negative electrode (arrow B)
of the vehicle’s 12V battery, and connect the other end to
the negative electrode of another vehicle’s 12V battery.
c. Start the vehicle. After battery boosting, disconnect the
negative jumper cable and then the positive jumper cable.

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1.4.3.64 Never rinse the fuse box with a high-

pressure water gun

1 Never rinse the fuse box with a high-pressure water gun

a. Never rinse the HEV Engine compartment fuse box ①
with ahigh-pressure water gun.

1.4.3.65 Conduct test run

The following conditions depend on the vehicle equipment
and (urban/ extra-urban) road conditions. Evaluate the
following conditions at test drive:
- HEV Engine: power, idling, acceleration and condition
of hotstart.
- Automatic transmission: selector lever position, status of
shifting.
- Service brake: function, free travel, effect, braking
distance, runout and braking noise.
- Steering system: function, steering wheel clearance and
the steering wheel at the middle position while the vehicle
is traveling straight.
- Radio & navigation system: function, reception and
interfering noise.
- A/C: function (test the function of A/C at low
temperature).
- Wheels: pull to one side during straight-line running (on a
flat road).
- Unbalance: wheels, drive shaft.
- Wheel bearings: noise.
- Seat belt: working conditions of the inertia reel.
- Instrument cluster: working conditions of all instruments.

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1.5 Health and safety

1.5.1 Description and operation
1.5.1.1 Description
Many vehicle maintenance operations will affect personal safety or health. This section introduces some concerned
dangerous operations, materials and equipment, and safety rules for avoiding such hazards.
This section does not cover all concerned health and safety issues; therefore, all operations, procedures and materials
processing shall be conducted on the premise of safety and health. Before using any product, please read operating
instructions provided by the manufacturer or supplier.
1.5.1.2 Acid and alkali
Refer to 1.5. 1.8 Battery acid.
Take corrosive sodium carbonate and sulfate for example.
They are used to clean batteries and other materials.
They are irritant or corrosive to eyes, skin, olfactory sensation and throat, and may result in ambustion and damage
ordinary protective clothing.
Take measures to prevent them from being splashed into eyes, on skins and clothes, and wear proper protective clothing,
gloves and goggles to prevent inhalation.
Be sure to have rinsing devices nearby, such as eye rinsing bottle and soap for the convenience of timely aid at any time
when any splashing happens.
Place "Danger to Eyes" marks at striking positions.
1.5.1.3 Airbag
Refer to 1.5.1.10 Chemical materials and refer to 1.5.1.15 Fire.
Airbags are installed in steering wheel, the front passengers’ seat backs, passengers' front instrument panel and B-pillar
and C-pillar as an auxiliary safety system.
Airbag expander contains a kind of high-energy propellant which will produce gases at extremely high temperature
(2500ºC/4532ºF) when ignited.
Such propellant is sealed in an enclosed assembly for storage and gases will fill the whole bag when the airbag is
deployed. Do not open airbags during the maintenance, because such operation will result in contact with the propellant,
thus causing dangers; if the inflator is broken, always wear overall protective clothing when handling the spilled
chemicals.
After normal deploying of airbags, wear safety goggles and gloves in the process of repairing.
The deployed airbags shall be disposed according to relevant local laws and regulations.
After direct contact with gas derivative, please:
• Rinse the contact part completely with clean water
• Seek medical assistance as required
Essential operations of airbag
For the sake of your safety, please wear protective articles before the following operations; Before removing an airbag,
be sure to set the ignition switch to “OFF” position, disconnect the negative battery terminal and wait 90 s before
proceeding with the removal.
• Keep the airbag assembly upright for storage.
• Keep the airbag assembly dry during storage.
• When handling the airbag assembly, be careful not to contact its electrode joint and keep the airbag as far away as
possible from your body.
• Keep the protective cover upward while placing the airbag assembly.
• Check the airbag assembly carefully for any damages.
- Stand on one side of the airbag assembly, disconnect the negative battery terminal and then wait for 90 s before
connecting the airbag.
• Calibrate and maintain all devices correctly.
• Be sure to wash your hands after handling the deployed airbag.
Operations to be avoided for airbag
• Do not store inflammable materials and assemblies together with the inflator.

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• Do not immerse the airbag assembly in water or allow it to come in contact with other liquids.
• Do not store the inflator in the environment at a temperature higher than 80 ºC/176 ºF.
• Do not place the airbag assembly upside down for storage.
• Do not try to open the shell of inflator.
• Do not get the inflator exposed to open flame or hot sources.
• Do not put other articles on the protective cover of the airbag assembly.
• Do not use the damaged assembly.
• Do not touch the airbag assembly or inflator within 10 min after its deploying.
• Do not use any electrical probe in the circuit.
1.5.1.4 HVAC refrigerant
The refrigerant can cause frostbite on contact with skin.
Follow the instructions provided by the manufacturer, and wear proper goggles and protective gloves.
In case of the contact of the refrigerant with skins or eyes, rinse the affected area with clean water immediately. And use
proper solution to rinse the eyes, do not rub the eyes, and seek medical assistance as required.
Operations to be avoided for the A/C refrigerant
• Do not store the refrigerant in places exposed to sunlight or heat sources.
• Do not put the refrigerant bottle upright when filling it; instead, keep the valve downward.
• Do not make the refrigerant bottle exposed to frost and snow.
• Do not drop the refrigerant bottle.
• Do not directly discharge the refrigerant to the atmosphere in any cases.
• Do not mix refrigerants such as R12 (dichlorodifluoromethane) and R134a (tetrafluoroethane).
1.5.1.5 Adhesive and sealants
Caution of application of adhesives/sealants
Before applying the adhesives/sealants, clean the surface to be coated and wipe it with special cleaning agent in order
not to affect the bonding effect. When applying the room temperature curing sealant, do not let it enter blind threaded
holes; if such sealant enters the holes, fasteners will give rise to hydraulic locking effect when being fastened, resulting in
damage to the fasteners and (or) other parts, failure of fasteners to get proper fastening force when being fastened, poor
sealing effect of sealant, failure to achieve proper fastening of fasteners, loosening or separation of parts, serious
damage to HEV Engine, etc.
Health and safety
The materials of the adhesives/sealants contain harmful substances to which long-time exposure can lead to acute and
chronic intoxication, occupational disease, skin disease, etc. When applying glue, use ventilation device to keep the
ventilation of the workshop; During operation, protective gloves, masks, protective clothing, etc. shall be worn. After work,
wash hands carefully and keep the workshop clean, tidy and hygienic.
• Waste contaminated by waste glue or solvent shall be cleaned up in time, without long-term accumulation.
• As a rule, the products shall be stored in no-smoking area; pay attention to cleanliness and use applicators or
containers for the application whenever possible.
Repair of adhesives/sealants
• When the vehicle breaks down or has an accident, such symptoms as body deformation, steel plate crack, and
weld spot falling off usually occur, and sometimes other assembly components such as HEV Engine and chassis
may bepartially damaged to result in falling off and destruction of some adhesives/sealants. During the vehicle
maintenance,choose adhesives of the same performance based on the material and function requirements of the parts;
below is listedthe adhesives/sealants that may be used during the vehicle maintenance; you may choose proper ones in
such process.
Body repair
After deformation or cracking of body interior trim and steel plate, adhesives applied to the body will fall off or crack;
therefore the part applied with adhesives shall be repaired in the process of maintenance.
• First use tools to clear the adhesives on the body surface, and wipe the remaining adhesives with alcohol;
• Use special cleaning agent to wipe the gluing part to avoid residual impurities such as residual glue on the gluing
surface;
·Apply the adhesives for repair to the original application area to reach the bonding and sealing effect.

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Repair of components
Bonding and sealing repair will be needed in case of any damage to some interior trim parts, reducer, etc. The bonding
surfaces should be cleaned before sealant application to avoid poor bonding effect due to burrs or cracks.
Precautions for operation
• Adhesives/sealants are used to prevent entry of water and dust to the vehicle and also play the role of corrosion
prevention. The original seal joints are easily for visual check and shall be resealed in case of any damage. Choose
filler of high consistency while sealing the open joints with adhesives/sealants. Operate by following the instructions
of the selected material.
• When spraying or applying the adhesives/sealants, be sure to take precautions to avoid spraying into openings of
the components (such as door locks, window run channel, window regulators and seat belt retractors) and any
moving or rotating components. After applying adhesives/sealants, ensure that all bleed holes of the body are open.
• During the operation, always wear goggles and gloves to prevent personal injuries.
• The body sheet metals are all subject to painting before delivery. After maintenance and/or replacement of the parts,
all exposed sheet metal surfaces must be coated with anti-rust primer prior to the application of the
adhesives/sealants.
• For the repair of the adhesives/sealants, some adhesives/sealants shall be cured by baking under such curing
conditions as the temperature of (70-80)°C and the duration of 20-30 min.
1.5.1.6 HEV Engine coolant
Steam may be produced when the HEV Engine coolant reaches a high temperature due to heating; try to avoid
inhalation ofsuch steam.
After direct contact with the HEV Engine coolant, the directly absorbed HEV Engine coolant by skin may reach a
deleterious orharmful amount. The person who swallows the HEV Engine coolant may have life danger and shall
besent to hospitalimmediately for medical assistance.
Such products shall not be processed together with common foods or connected to drinking water supply system.
1.5.1.7 Asbestos
Inhalation of asbestos dust may lead to pulmonary injury and even cancer.
As for the disposal, the asbestos waste shall be moistened and put into sealed containers of which the surface shall be
obviously marked with label for ease of safe disposal. If cutting or drilling is required for the materials containing asbestos,
such materials shall be moistened first and only manual tool or low-speed power tool shall be used.
1.5.1.8 Battery acid
The gas released from the charging battery is explosive; do not conduct any open flame operation near the charging
battery or the battery that has just finished charging.
Good ventilation must be maintained.
1.5.1.9 Brake fluid
If the brake fluid is splashed on skin and in eyes, a bit of irritation may be caused; please try best to avoid direct contact
of the brake fluid with skin and eyes; the risk caused by inhalation of the brake fluid steam at normal temperature is low
as the steam pressure is extremely low.
1.5.1.10 Chemical materials
Attention shall be specially paid to the use, storage, and disposal of such chemical materials as solvent, sealant,
adhesive, paint, resin foam, battery acid, HEV Engine coolant, brake fluid, lubricating oil, lubricating grease, etc. They
may betoxic, harmful, corrosive, irritant or highly flammable, and give off peculiar smell and dust of high risk.
The influence of long-time overexposure to the environment containing chemical materials may be acute or chronic,
temporary or permanent, cumulative, superficial, life-threatening or life-shortening.
Chemical materials - operations that shall be conducted
• Read carefully and comply with the warnings and cautions on the material containers and any attached leaflet or
poster, or other operating instructions; the health and safety data sheet can be requested from the manufacturer.
• In case of contact with the chemical materials, remove them from skins and clothes as soon as possible, and
immediately change clothes contaminated severely and then clean them thoroughly.
• Strictly follow instructions and wear protective clothing to avoid direct contact with skin and eyes.
• Clean hands first before rest, eating and drinking, smoking, or using washing facilities during the operation of the
chemical materials.
• Keep the working area clean and neat, and protect the chemical materials from being splashed.

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Chemical materials - operations that shall be avoided
• Do not mix chemical materials at will unless specified by the manufacturer; Some chemical materials may produce
other toxic or harmful chemical materials, and they may release other toxic or harmful gases, cause explosions, etc.
after being mixed.
• Do not spray chemical materials in a closed environment.
• Unless specified otherwise by the manufacturer, do not heat the chemical materials as some chemical materials are
highly flammable and some may release toxic or harmful gases.
• Do not keep the chemical material containers open as the gases sent out may be gathered to a toxic, harmful or
explosive level. Some gases are heavier than air and may be gathered in an enclosed space.
• Do not put chemical materials into the unmarked container.
• The chemical materials, especially solvents and fuels may dry the skin and cause allergy, dermatitis, or absorption
of toxic and harmful substances through the skin, affecting personal health.
• Unless the containers are cleaned up under supervision, do not randomly use empty containers to store the
chemical materials.
• Do not sniff or smell chemical materials at will. Temporary exposure to gases of high concentration may result in
poisoning or injuries as well.
1.5.1.11 Dust
Powder, dust, and dirt may be irritant, deleterious, or harmful. Take measures to avoid inhaling powdery chemical
materials and dust due to dry friction operations; in the event of poor ventilation, wear breathing mask to avoid inhalation
of dust.
Fine dust of combustible materials may bring explosion hazard; take measure to avoid ignition source.
1.5.1.12 Electric shock
Incorrect use of electrical equipment not according to instructions may result in electric shock.
Be sure to maintain electrical equipment within the time limit and test it frequently. Mark out the faulty equipment and it is
better to move and place it out of the working areas.
Do not make wires, cables, plugs and sockets subject to friction, twisting, cutting, breakage or other damages, or allow
the electrical equipment to have contact with wires and water.
Ensure the electrical equipment under protection of correct fuse.
Do not misuse the electrical equipment; do not use any equipment with hidden risks which may affect personal safety.
Ensure that no cables of the electrical equipment are clamped or damaged in the event of movement.
Carry out basic first-aid training for special operators of the electrical equipment.
When electric shock occurs:
• Turn off the power supply before touching the victim.
• If the power supply can not be turned off, use a dry insulating material to remove it from the victim.
• Have the person who is trained for first aid immediately carry out the first aid on the site.
• Request medical assistance.
1.5.1.13 Waste gas
Exhaust gas contains deleterious and harmful chemical substances, such as carbon oxide, nitric oxide, acetaldehyde,
plumbum, aromatic hydrocarbon, etc. The HEV Engine is not allowed to be started if there is no proper exhaust gas
ventilationequipment or common ventilation equipment and the space is enclosed.
1.5.1.14 Fiber isolation
Refer to 1.5.1.11 Dust.
The fiber is used for isolating noise and sound.
The fibrous material and sharp edges of the surface may lead to skin allergy.
Always observe the operating instructions and wear gloves during the operation to protect the skin from excessive
contact with fiber.
1.5.1.15 Fire
Many materials related to vehicle maintenance are extremely flammable. Some materials may produce poisonous and
harmful gases.

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Observe the fire safety requirements when storing when the handling the flammable materials or solvents, especially at
the place near electrical equipment or where the welding operation is being performed.
Before using electrical and welding equipment, confirm that there is no fire hazard.
While welding or using heating equipment, prepare a proper fire extinguisher around the working area.
1.5.1.16 First aid
Comply with the laws; a person who is specially trained for first aid is recommended on the site.
If something is splashed into eyes, the eyes shall be rinsed with clean water for at least 10min. If the skin is
contaminated, the contaminated part shall be rinsed with soap and clean water.
In the event of frostbite, the injured person shall be escorted to a medical unit as soon as possible, and be careful to
keep him/her warm and prevent trauma during the escort. Upon arrival at the medical unit, rewarm the injured person
with warm water.
Transfer the persons who inhale the poisonous gases to a place with fresh air; if adverse reactions continue, send them
to a hospital for medical assistance.
If the person swallows any liquid, tell the physician the information indicated on the container or label; unless otherwise
indicated on the label, do not induce vomiting at will.
1.5.1.17 Foam-Polyurethane
Cured foam is applied for buffering cushion of seat and trim. Follow the instructions of the manufacturer.
Assembly that has no chemical reaction is stimulating and may be harmful to the skin and eyes, so please wear gloves
and goggles during the operation.
No person who has chronic respiratory disease, asthma, bronchial disease or inherited allergies is allowed to handle or
come near the uncured substances.
Its spare parts, steam or spray can cause direct irritation and allergic reactions which may be toxic and harmful.
Remember not to inhale steam or spray of these materials which shall be only used under the condition that good
ventilation and respiratory protection are in place. Do not take off masks immediately after spraying; instead, wait until
the steam and spray are completely dispersed.
Combustion of the uncured assembly and the cured foam can produce toxic and harmful gases. During the foam
operation, do not smoke, or use open flame and electrical equipment unless the vapor and spray are completely
eliminated; hot cutting of foam materials or special foam materials shall be conducted in the environment with good
ventilation.
1.5.1.18 Fuel
Reduce direct contact of the skin with fuel to a minimum level; in case of contact with the fuel, rinse the skin contact area
with soap and clean water immediately.
Gasoline
Highly flammable material - comply with no-smoking rules.
Accidental swallow may get the mouth and throat irritated; absorption by the stomach may cause general weakness and
unconsciousness; even a tiny amount of gasoline can threaten the child's life, so it is very dangerous if gasoline enters
the stomach.
The gasoline can dry the skin; long-time or regular contact may cause the skin allergy and dermatitis; severe irritation
can be caused if it is splashed into the eyes.
Automobile gasoline may contain a large amount of benzene, which can cause poisoning after inhalation; therefore, the
concentration of the gasoline vapor shall be kept at a low level as the gasoline vapor of high concentration can stimulate
the eyes, nose and throat, and bring discomfort such as nausea, headache, depression and temulentia, and the gasoline
vapor of extremely high concentration can cause rapid loss of consciousness.
Maintain good ventilation conditions when treating the gasoline, especially in an enclosed space to avoid dangers
caused by inhalation of the gasoline steam due to spilling.
Special caution should be given when cleaning and maintaining the gasoline storage equipment.
Gasoline can not be used as a detergent, and absolutely can not be sucked by mouth.
1.5.1.19 Gas cylinders
Gases such as oxygen, acetylene, argon and propane are generally stored in gas cylinders under pressure of 13.8 Mpa
(2,001 psi). Please be extremely careful when handling these cylinders and avoid mechanical damage to these cylinders
or valves in the process of handling. The gas filled in the cylinders shall be indicated by clear and proper marks.
The cylinders shall be stored in a place with good ventilation, avoiding ice or direct sunlight. Fuel gases such as
acetylene and propane shall not be stored around the oxygen cylinder.

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Pay particular attention to preventing leakage of the gas cylinders and pipelines and avoiding combustion source.
Only professionally trained personnel are allowed to be engaged in the work related to the gas cylinders.
1.5.1.20 General workshop tools and equipment
It is very important to maintain all tools and equipment in good working state and take correct operations during the use.
Remember not to use the tools or equipment for the unintended design functions. Do not let hoist, jack, axle/chassis
bracket, sling, etc. bear a load exceeding its allowable maximum value. Damages due to overload may not occur
immediately and may result in serious accident during the next use.
Do not use tools or equipment that are damaged or in poor working condition, such as grinding wheels. The damaged
grinding wheel may be broken accidentally and cause serious personal injuries.
Always wear proper eye protections when using the grinding wheel, chisel or sand blaster.
Always wear proper breather masks when using the sand blaster, handling the materials containing asbestos, or using
the spraying equipment.
Ventilation equipment must be available to control the amount of dust, spray and smoke in the environment.
1.5.1.21 Lubricant and lubricating grease
Avoid long-time repeated exposure to mineral oil as all kinds of lubricating oil and lubricating grease can stimulate the
eyes and skin.
Used HEV Engine oil
Long-time and repeated exposure to mineral oil will bring loss of the skin natural oil to result in dry skin, stimulation and
dermatitis. In addition, the used HEV Engine oil is likely to contain harmful substances that may cause skin cancer. Be
sure touse skin protection equipment and provide proper washing equipment.
Do not take the used HEV Engine oil as lubricating oil or for any purposes that may get it in direct contact with the skin.
Health protection and safety rules
• Avoid long-term and repeated contact with HEV Engine oil, especially HEV Engine oil that has already been used.
• Wear protective clothing, including impermeable gloves.
• Do not put rags stained with the HEV Engine oil into pocket.
• Do not get your clothes contaminated by the HEV Engine oil, especially intimate apparel.
• Do not wear clothes and shoes which are highly contaminated by the HEV Engine oil. Wash work clothes at
regularintervals and keep them clean.
• First aid for open wound shall be ready at any time.
• Apply sun screen to the skin to prevent the skin from direct contact with the HEV Engine oil during work.
• Remove the HEV Engine oil by cleaning with soap and clean water. Application of protective agent containing
woolgrease is helpful to compensate the removed natural oil of the skin.
• In case of any pathological changes to the skin, please seek medical assistance.
• Remove the residual HEV Engine oil on the assembly before working as much as possible.
• In case of possible direct contact with the eyes, wear goggles, such as chemicals goggles or mask; In addition,
equipment for eye irrigation shall be provided.
Precautions for environment
The used HEV Engine oil waste and oil filter shall be recycled and disposed by the authorized or licensed waste disposal
entityor by the waste HEV Engine oil recycling entity. In case of any doubt, please contact the disposal site of
the relevantdepartments of the local authorities timely.
Direct pouring the used HEV Engine oil into underground, sewer, drainage equipment or water pipe is illegal.
1.5.1.22 Noise
Some operations may produce noise of extremely high decibel, resulting in hearing damage. In such case, please wear
proper hearing protections.

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