Geely FC PDF

Preface
Geely FC is an automobile with high performance/price ratio and it meets the requirement
of national safety, energy saving, emission regulations and personal use. This automobile is
a completely new and excellent model produced by Zhejiang Geely Automobile Co., Ltd with
development in self-reliance of Geely group and with self-dominated intellectual property
right. It characterizes elegant appearance, energy conservation and environmental protection,
safety and comfort. FC is a product opening a completely new viewpoint of automobile
selection, because it is developed on the basis of creative design thinking that breaks through
all established customs and it features perfectly balanced performance of power, space,
safety, manipulation and comfort. FC is a competitive product for Geely developing brand
and exploring mid-level automobile market, which takes over the company philosophy make
good cars that common people can afford, and let Geely cars go to the whole world of Geely
automobile. FC is combination of creativity and intelligence of quite a large number of
automobile experts, who have been developing and searching with great concentration for
more than 30 months, and it fully embodies persistent Geely style of fashion appearance
and high performance/price ratio.
FC is equipped with engine JL4G18 completely developed and produced by Geely group.
Engine JL4G18 applies the following advanced technology such as VVT, full aluminum cylin-
der body, plastic intake manifold, completely new VVT inside seal method, completely new
OCV valve filtering method etc. with M7.9.7 electric injection system of BOSCH, and its
index on power efficiency, economical efficiency, and safety efficiency etc. reaches leading
level of national model with the same type. This engine features strong power, low fuel
consumption, low noise and high power per liter etc.
We start to compile FC Automobile Maintenance Manual, which is divided into 27 sec-

tions with detailed description of overall structure and maintenance of engine 4G18.VVT;
inspection and repair of engine BOSCH M7.9.7 electric control fuel injection system; struc-
ture and maintenance of chassis; structure and maintenance of FC electrical equipment;
structure and maintenance of ABS anti-lock brake system; structure and maintenance of
SRS air bag; structure and maintenance of auto air conditioning system; structure and main-
tenance of vehicle body etc. Information is detailed and accurate, contents are in systematic
coherence and description is concise and comprehensive.
This manual is compiled from structure, which prompts FC service personnel to master
necessary maintenance, repair and malfunction knowledge on the basis of understanding
main structure characteristics and simple principle of vision automobile. Electric control sys-
tem of FC automobile is particularly described with detail, and detailed steps and methods
are given for trouble shooting process. All kinds of malfunction could be eliminated quickly
and efficiently within the shortest time as long as you detect as the repair steps of this manual.
In addition, this manual is compiled with the following characteristics: in proper sequence,
clear demarcations, easy to understand, excellent in picture and its accompanying essay,
simple and clear, which is very applicable for a quite large number of FC automobile main-
tenance technicians and service personnel to refer to.
This manual is mainly compiled by Geely International Corporation; Geely Automobile En-
gine No. 2 Plant and engineering technicians of service corporation help complete this work.
Defects and mistakes are inevitable in this manual for limited level of compiler and limited
time, please contact Geely International Corporation if you find mistakes and careless omis-
sions in using and we can correct in time and reverse in next version.
Geely International Corporation

Nov. 2007
Note
This manual is mainly for qualified vehicle technicians, but it does not in-
clude all items on repair and maintenance.
In order to avoid personnel injury and vehicle damage caused by dangerous

operation, please observe the following regulations.
z Please read this manual carefully, and particularly fully master all con-
tents in Precautions.
z Maintenance methods described in the manual are quite useful for vehicle
maintenance. Please adopt specified or recommended tools in maintain-
ing vehicle as steps described in this manual; maintaining vehicle with
tools or methods not specified or recommended in this manual will cause
personnel injury or vehicle damage. Therefore, please consider ensuring
the safety of technicians and vehicle at first before performing maintenance.
z If it is necessary to replace parts, please replace with parts of the same or

similar size with original ones. It is forbidden to use inferior parts.
z In order to effectively avoid technician injury and vehicle damage and hid-
den danger caused by incorrect operation, it is very important to observe
Warning and Notes in this manual. It particularly needs to mention that
not all precautions on safety are included in Warning and Notes etc. in
this manual. Therefore, please fully realize that perform maintenance not
as regulations will cause dangerous consequences.
Contents
Brief introduction on Geely model FC Inspection ........................................................ 26

Basic parameters ................................................... 1 Drive belt .............................................................. 29
Replacement ................................................... 29
Maintenance period Valve clearance .................................................... 30
Regular maintenance items ................................... 4 Adjustment ...................................................... 30
Table on maintenance period at normal conditions5 Engine assembly ................................................. 36
Table on maintenance period at severe conditions .. 7 Replacement ................................................... 36
Timing chain assembly ....................................... 45
Engine control system Replacement ................................................... 45
EFI system ............................................................. 8 Camshaft ............................................................. 52
On-vehicle inspection ........................................ 8 Replacement ................................................... 52
Inspection .......................................................... 9 Crankshaft front oil seal assembly ..................... 60
Throttle body assembly ........................................ 13 Replacement ................................................... 60
Removing, installing and disassembling, assembling ... 13 Crankshaft rear oil seal assembly ...................... 62
Replacement ................................................... 62
Fuel Cylinder cover gasket components ..................... 63
Fuel system .......................................................... 14 Replacement ................................................... 63
Precautions ...................................................... 14
On-vehicle inspection ...................................... 16 Exhaust
Inspection ........................................................ 17 Exhaust pipe assembly ........................................ 65
Injection nozzle assembly .................................... 18 Removing, installing and disassembling, assembling ..... 65
Replacement ................................................... 18
Fuel pump assembly ........................................... 20 Cooling
Removing, installing and disassembling, assembling .... 20 Cooling system .................................................... 66
Fuel tank assembly ............................................. 21 On-vehicle inspection ...................................... 66
Removing, installing and disassembling, assembling .....21 Inspection ........................................................ 66
Cooling fan system .............................................. 68
Exhaust gas control On-vehicle inspection ...................................... 68
Exhaust gas control system ............................... 23 Inspection ........................................................ 68
On-vehicle inspection ...................................... 23 Water pump assembly ........................................ 69
Inspection ........................................................ 25 Replacement ................................................... 69
Temperature regulator components ................... 71
Engine mechanism Replacement ................................................... 71
Engine assembly .................................................. 26 Radiator with electronic fan assembly ................ 72
Replacement ................................................... 72 Front stabilizer bar ............................................... 96
Coolant ................................................................. 73 Overhaul .......................................................... 96
Replacement ................................................... 73 Front left lower control arm ball joint assembly .. 99
Replacement ................................................... 99
Lubrication
Lubricating system ............................................... 74 Rear suspension
On-vehicle inspection ...................................... 74 Rear suspension system .................................... 100
Oil filter assembly ................................................. 75 Table on trouble occurrence .......................... 100
Replacement .................................................... 75 Rear wheel alignment ......................................... 101
Oil pump assembly ............................................... 76 Adjustment ..................................................... 101
Replacement .................................................... 76 Rear strut assembly ........................................... 102
Overhaul ........................................................ 102
Ignition Handling ......................................................... 104
Ignition system ..................................................... 77 Rear stabilizer bar .............................................. 105
Inspection ........................................................ 77 Overhaul ........................................................ 105
On-vehicle inspection ...................................... 77 Rear shaft assembly ........................................... 106
Overhaul ........................................................ 106
Starting and charging
Starting system ..................................................... 79 Tire and wheel
Inspection ........................................................ 79 Wheel and tire system ....................................... 109
Charging system .................................................. 81 Inspection ...................................................... 109
Precautions ...................................................... 81
On-vehicle inspection ...................................... 82 Drive shaft
Alternator components .............................................. 84 Drive shaft ....................................................... 111
Replacement .................................................... 84 Notes ............................................................. 111
Starter components .............................................. 85 Malfunction phenomenon table .................... 111
Replacement .................................................... 85 Inspection on automobile ............................. 112
Front drive shaft ................................................. 113
Front suspension Overhaul ........................................................ 113
Front suspension system .................................... 86 Left front shaft hub assembly ............................ 123
Table on trouble occurrence ........................... 86 Change .......................................................... 123
Front wheel alignment ......................................... 87 Left front shaft hub bolt ...................................... 128
Adjustment ...................................................... 87 Change .......................................................... 128
Front absorber and helical spring ....................... 90 Left rear shaft hub and bearing assembly ........ 129
Overhaul .......................................................... 90 Change .......................................................... 129
Handling .......................................................... 93 Left rear shaft hub bolt ....................................... 131
Lower left control arm assembly ......................... 94 Change .......................................................... 131
Replacement ................................................... 94
Brake Transmission
Brake system ...................................................... 132 Disassemble assembly ................................... 165
Notes .............................................................. 132 Assemble the assembly .................................... 191
Remove malfunction ........................................... 133
Malfunction phenomenon table ..................... 133 Steering column
Brake liquid ......................................................... 135 Steering system .................................................. 192
Discharge the air in brake system ................. 135 Note ............................................................... 192
Brake pedal assembly ........................................ 136 Malfunction phenomenon table ..................... 192
Adjustment ..................................................... 136 Inspection on automobile ............................... 193
Change .......................................................... 137 Steering column system ..................................... 194
Vacuum booster assembly ................................. 138 Overhaul ........................................................ 194
Inspection on automobile ............................... 138
Change .......................................................... 138 Power steering
Front brake assembly ......................................... 141 Power steering system ...................................... 198
Overhaul ........................................................ 141 Note ............................................................... 198
Rear brake assembly ......................................... 144 Malfunction phenomenon table .................... 199
Overhaul ........................................................ 144 Inspection on automobile ............................. 200
Hydraulic pressure control unit (equipping with ABS) ... 148 Power steering oil pump assembly .................. 203
Inspection on automobile ............................... 148 Overhaul ........................................................ 203
Change .......................................................... 148 Power steering gear assembly ......................... 205
Speed sensor of front wheel .............................. 151 Overhaul ........................................................ 205
Change .......................................................... 151
Speed sensor of rear wheels ........................... 152 Air conditioner
Change .......................................................... 152 Air conditioning system ...................................... 213
Note ............................................................... 213
Parking brake Inspection on automobile ............................... 213
Parking brake system ......................................... 154 Inspection ...................................................... 214
Malfunction phenomenon table ..................... 154 Refrigerant .......................................................... 215
Adjustment ..................................................... 154 Inspection on automobile ............................... 215
Parking brake handle assembly ......................... 155 Change .......................................................... 221
Change .......................................................... 155 Refrigerant pipeline ............................................ 222
Parking front bake pull cable assembly ............ 156 Parts ............................................................... 222
Change .......................................................... 156 Control assembly, air conditioner control panel (AUTO A/C) ... 223
Parking rear brake pull cable assembly ........... 158 Overhaul ........................................................ 223
Change .......................................................... 158 Fan assembly ................................................... 224
Parking brake assembly .................................... 161 Overhaul ........................................................ 224
Overhaul ........................................................ 161 Air conditioner central heating core assembly .. 227
Overhaul ........................................................ 227
Compressor assembly ..................................... 234
Change .......................................................... 234 Adjustments .................................................. 287
Condenser Assembly ........................................... 236 Front fog light ..................................................... 289
Inspection on the automobile ....................... 236 Components ................................................. 289
Overhaul ........................................................ 236 Change .......................................................... 290
Adjustment .................................................... 290
Supplemental restraint system Side turning light ................................................ 291
Note .................................................................... 239 Components ................................................. 291
Malfunction treatment ......................................... 244 Rear combination light (LH) .............................. 292
Repair ................................................................. 247 Components ................................................. 292
Inspection ........................................................... 249 Change .......................................................... 293
Remove malfunction ........................................... 251 Rear fog light ...................................................... 294
Malfunction table ............................................ 251 Components ................................................. 294
Diagnosis of impacted automobile ................. 260 Change .......................................................... 295
Disassemble and assemble ............................... 261 Number plate light ............................................. 296
Electronic control unit of safety airbag (ECU) .. 261 Change .......................................................... 296
Safety airbag assembly at the side of driver .. 261 High brake light assembly ................................. 297
Safety airbag assemble at the side of passenger .... 263 Change .......................................................... 297
Scrap treatment for safety airbag .................. 264 Left combination switch ..................................... 298
Change .......................................................... 298
Safety belt
Safety belt .......................................................... 270 Wiper and cleaner
Note ............................................................... 270 Wiper and cleaner system ................................. 299
Treatment ....................................................... 270 Malfunction phenomena table ...................... 299
Subassembly ................................................. 273 Inspect the car ............................................... 299
Change .......................................................... 274 Inspect ........................................................... 300
Rear safety belt .................................................. 275 Right combination switch ................................. 302
Subassembly ................................................. 275 Change .......................................................... 302
Change .......................................................... 277 Wiper motor ....................................................... 303
Change .......................................................... 303
Light Wiper .................................................................. 305
Light System ....................................................... 279 Change .......................................................... 305
Notes .............................................................. 279 Cleaner nozzle ................................................... 306
The phenomena table .................................... 279 Adjustments .................................................. 306
Inspect the car ............................................... 281
Inspect ........................................................... 283 Audio system
Front combination light (LH) .............................. 286 Audio system ..................................................... 307
Subassembly ................................................ 286 Notes ............................................................. 307
Change .......................................................... 287 Radio assembly ................................................. 308
Replacement ................................................. 308
Left front door loudhailer .................................... 309 Panel / combination panel
Change .......................................................... 309 combination panel .............................................. 334
Left front small loudhailer .................................. 310 Trouble table .................................................. 334
Change .......................................................... 310 Vehicle inspection .......................................... 335
Rear loudhailer .................................................. 311 Inspection ...................................................... 339
Change .......................................................... 311 Panel .................................................................. 340
Outdoor antenna ............................................... 312 Preparation .................................................... 340
Change .......................................................... 312 Change .......................................................... 340
Combination instrument assembly ..................... 347
Circuitry Disassembly and assembly ........................... 347
Power supply ...................................................... 313
Components .................................................. 313 Chair
Front chair .......................................................... 348
Horn system Subassembly ................................................. 348
Horn system ....................................................... 316 Overhaul ........................................................ 349
Position .......................................................... 316 Rear chair (separating type) ............................... 352
Inspect ........................................................... 316 Overhaul ........................................................ 352
Rear chair (fixing type) ....................................... 354
Windshield/window glass/wing mirror Overhaul ........................................................ 354
Electric window control system .......................... 317
Position drawing ............................................ 317 Anti-stealing and door lock
Inspect the car ............................................... 317 Electric door lock control system ........................ 355
Malfunction phenomena table ....................... 319 Position of parts ............................................. 355
Inspect ........................................................... 319 Inspection on automobile ............................... 355
Front windscreen ................................................ 321 Malfunction phenomenon table ..................... 358
Change .......................................................... 321 Inspection ...................................................... 359
Rear ventilation window ..................................... 324 Electronic anti-stealing system ........................... 361
Change .......................................................... 324
Fog defrost system ............................................ 327 Electric sunroof
Position drawing ........................................... 327 Sunroof ................................................................. 362
Malfunction phenomena table ...................... 327 Overhaul ........................................................ 362
Inspect ........................................................... 328 Specification for sunroof function ...................... 364
Electric rearview mirror control system(option) . 329 Inspection for sunroof function ...................... 364
Inspect the vehicle ......................................... 329 Inspection for sunroof switch ........................ 365
Position drawing ........................................... 331 Position of parts ............................................ 365
Trouble table ................................................. 331 Malfunction phenomenon table .................... 365
INSPECT ....................................................... 332
Engine cover/automobile door Automobile control system
Engine cover ...................................................... 366 Ignition switch and anti-versa lock key warning switch . 394
Adjustment ..................................................... 366 Malfunction phenomenon table ..................... 394
Front automobile door ........................................ 367 Inspection ...................................................... 394
Subassembly ................................................. 367
Overhaul ........................................................ 369 Electrical schematic diagram .............................. 395
Adjustment ..................................................... 372
Rear automobile door ....................................... 373
Overhaul ........................................................ 373
Adjustment .................................................... 375
Trunk cover ......................................................... 377
Adjustment .................................................... 377
Torsion spring of trunk cover ............................. 378
Change .......................................................... 378
Exterior/inner trim board

Front bumper .................................................... 379
Subassembly ................................................ 379
Change .......................................................... 380
Rear bumper ...................................................... 381
Subassembly ................................................ 381
Change .......................................................... 382
Name plate ........................................................ 383
Change .......................................................... 383
Exterior seal tape of left front door glass (LH) ... 384
Change .......................................................... 384
Exterior seal tape of left rear door glass ........... 385
Change .......................................................... 385
Light fender ........................................................ 386
Change .......................................................... 386
Top left trim tape ................................................. 387
Replacement ................................................. 387
Left lower fender of automobile body (LH) ........ 388
Subassembly ................................................ 388
Change .......................................................... 389
Inner trim board of top ........................................ 390
Change .......................................................... 390
Brief introduction on Geely model FC Basic parameters
Brief introduction on Geely model FC

Basic parameters
Table 1 Complete vehicle basic parameters
Number Item name Unit Parameters
Length
Dimension parameters
Overall Width
dimension Height
Front wheel 15
Wheel track
Rear wheel 15
Wheel base 20
Front suspension 10
Rear suspension 10
Passenger number Person
Complete vehicle herb mass 30

Mass parameters
Max. total mass 30

No Front axle
Weight distribution
load Rear axle

Full Front axle
load Rear axle
Traverse ability
Min. turning diameter

Min. gound clearance
Approach angle (full load)
Departure angle (full load)
Front wheel camber
Front wheel alignment
parameters
Kingpin inclination angle

caster angle
Convergence of front wheels
Rear wheel camber
Front wheel Rear wheel
parameters
alignment
Convergence of rear wheels

Left wheel: inside/outside
steering
wheel
Right wheel:inside/outside
Luminous intensity of Candera
Head lamp light
high beam of head lamp

Left and Left lamp
right
optical axis
High beam
inclination Right lamp

Down Left lamp
inclination Right lamp
1
Table 2 Types and parameters of main assembly
Number Item name Unit Types and parameters

Model JL4G18
4-cylinderin-line, four-stroke, water-cooling, double over-head
Type camshaft, 16-valve, CVVT multipoint injection gasoline engine
Electric injection system model United Automotive Electronic Systems Co., Ltd. M7.9.7 electric injection system
Bore
Stroke
Engine
Delivery capacity
Compression ratio
Max. power / /
Max. torque . / /
Idling speed /
Ignition sequence
Min. fuel consumption / .
Type 5 gears synchronizer of constant mesh gear
1st gear
Each gear ratio
2nd gear
Transmission
3rd gear
4th gear
5th gear
Reverse gear
Main gear box ratio

Clutch type Dry single, diaphragm spring, constant pressure
Steering gear Rack-and-pinion steering gear with hydraulic power
Type Double pipeline, vacuum boosterwith ABS +EBD anti-lock system
Braking
system
Front brake Disc brake

Rear brake Disc brake
pension
Front suspension type Strut-type front independent suspension

Sus-
Rear suspension type Longitudinal swinging arm and anti-twist beam compound rear suspension
Radial Specification
Tire
tire Air pressure
Rim
Breakaway
Drive
Type
axle
Drive shaft BalI cage and tripot type constant velocity universal joint
Body structure Loaded all-metal body
Tail gas Catalytic converter Honeycomb cordierite carrier, noble metal catalyst
Air
Compressor type Swirl or swash plate compressor
condi-
tioning Nominal refrigerating capacity
system Refrigerant
2
Table 3 Main performance parameters of complete vehicle
Number Power performance Item name Unit Parameters Remarks

Max. vehicle speed
0-100 km/h accelerating time
Accelerating time from 30km/h to 100km/h at 4th gear
Min. stable vehicle speed at 4th gear

Max. climbing speed
performance
Slide Distance (full-load, initial speed 50km/h)

Economy
Fuel consumption with 4 operating modes

Average fuel consumption at specified operating mode
Dust sealing degree

mance
perfor-
Seal
Rain protection seal limit value

Weighted acceleration root of mean square
mance
perfor-
Ride
Equivalent mean value

Reduced comfort boundary
Reliability
Average mileage to first failure

Average mileage between failures
Efficient degree
3
Maintenance period-Regular maintenance items
Maintenance period
Regular maintenance items
Your precious automobile should be maintained according to maintenance period
at normal conditions (see table on maintenance period at normal conditions)
If your precious automobile is mainly driven under one or more of the following conditions, some
maintenance items must be performed more frequently (see table on maintenance period at severe
conditions).
A. Road conditions
1. Driving on rugged, muddy or melting snow road.
2. Driving on dusty road.
B. Driving conditions
1. Towing tail vehicle, equipped with camp frame or top storage racks.
2. Repeated on short-distance driving within 8 km and the temperature is below 0 .
3. Vehicles driven for long distance under idle speed or low speed over a long period of time,
such as police car, taxi or delivery truck.
4. Continuously driving at high speed for more than 2 hours frequently. (With 80% of max. ve-
hicle speed)
5. Vehicles driven with idle speed or low speed over a long period of time or frequently acceler-
ated or decelerated, such as training car of driving training class.
4
Maintenance period-Table on maintenance period at normal conditions
Table on maintenance period at normal conditions

Maintenance content:
I: Inspection and correction or replacement if necessary R: Replacement
Maintenance period mileage
(Odometer readings or 7.5 1 5 22.5 30 37.5 45 53.5 60 67.5 7 5 82.5 90 months
reading
operating months subject to
the first coming) 1000km
Engine basic elements
1. Valve clearance*1
2. Drive belt
3. Engine oil (APLSJ,SL or ILSAC) *2
4. Oil filter*2
5. Cooling and heating system hose and joint*3*4
6. Engine coolant*5*6
7. CVVT oil duct filter screen
8. Exhaust pipe and fixed mount
Ignition system
9. Spark plug
10. Battery
Fuel and exhaust gas control system
11. Fuel filter
12. Air filter core
13. Connecting conditions of fuel tank cover,

fuel pipe and fuel evaporation control valve*7
14. Activated carbon canister
Chassis and vehicle body
15. Brake pedal and parking brake
16. Brake pad and brake disc
17. Brake fluid
18. Brake Pipe and hose

19. Power steering oil
20. Steering wheel, steering linkage and gear box oil
21. Drive shaft dust cover

22. Ball joint and dust cap
23. Transmission oil
24. Front and rear suspension
25. Tire and tire pressure
26. All light, horn, wiper and washer
27. Air conditioner cleaning filter screen
Air conditioning system/ secondary refrigerant
5
Maintenance period-Table on maintenance period at normal conditions
Note: *1 Indicating that check valve noise and engine vibration condition, and adjust them if necessary.
*2
It is suggested that see operating modes on page 116 of operating instruction to perform.
*3
Indicating that check once every 20000km or 12 moths after 80000km or 48 months.
*4
Indicating that check water tank and condenser are blocked by leaves, dust or insects, and clean
hose connections.
*5
Replace at initial 60000km, and replace every 30000km in future.
*6
Only Geely genuine ultra-long engine coolant or equivalent high-quality ethylene glycol engine
coolant without silicate, amines, nitrite, borate and with long-life compound organic acid technology
are allowed to use, and coolant should be repeated several times until it is filled up.
*7
Indicating that check once every 20000km or 12 moths after 80000km or 48 months.
6
Maintenance period-Table on maintenance period at severe conditions
Table on maintenance period at severe conditions

According to the driving conditions listed below, maintenance should be performed to the items that
should be maintained more frequently (for other items not listed, please see Table on maintenance
period at normal conditions)
A-1: Driving on rugged, muddy or melting snow road
Inspection of brake pad and brake disc Every 5,000 km or 3 moths
Inspection of brake pipeline and hose Every 10,000 km or 6 moths
Inspection of ball joint and dust cover Every 10,000 km or 6 moths
Inspection of drive shaft dust cover Every 10,000 km or 12 moths
Inspection of the steering wheel, steering linkage and gear box oil Every 5,000 km or 3 moths
Check of front and rear suspension Every 10,000 km or 6 moths
A-2: Driving on dusty road
Replacement of engine oil Every 5,000 km or 6 moths
Replacement of engine oil filter Every 5,000 km or 6 moths
Inspection or replacement of air filter core I: Every 2,500 km or 3 moths
R: Every 10,000 km or 6 moths
Inspection of brake block and brake disc Every 5,000 km or 3 moths
Replacement of air conditioner cleaning filter screen Every 15,000 km
B-1: Towing tail vehicle, equipped with camp frame or top storage racks
Inspection of brake pad and brake disc Every 5,000 km or 3 moths
Inspection or replacement of transmission oil Every 60,000 km or 24 moths
Inspection of front and rear suspension Every 10,000 km or 6 moths
Screwing down the bolts and nuts of the chassis and vehicle body Every 10,000 km or 6 moths
B-2: Repeated on short-distance driving within 8 km and the temperature is below 0C
B-3: Vehicles driven for long distance under idle speed or low speed over a long period of time, such as police car, taxi or deliverytruck
.
Inspection of PCV valve and pipelines Every 5,000 km or 6 moths
Inspection of brake block and brake disc Every 5,000 km or 3 moths
B-4: Continuously driving at high speed for more than 2 hours frequently (With 80% of max. vehicle speed)
Replacement of transmission oil Every 40,000 km or 12 moths
B-5: Vehicles driven with idle speed or low speed over a long period of time or frequently accelerated or
decelerated, such as student car of driving training class.
Inspection of PCV valve and pipelines Every 3,000 km or 3 moths
7
Engine control system- EFI system
Engine control system

EFI system
On-vehicle inspection
1. Inspection of the voltage of power steering oil pres-
sure sensor
Measure the voltage between PS terminal and E2 terminal
with ohmmeter
Conditions Voltage (V)

Not turning steering wheel with
engine at idle speed
Turning steering wheel with
0-1.5
engine at idle speed
2. Inspection of stepping motor

(a) With engine running at idle speed, pull out the connection harness of stepping motor, and the change
of engine rotating speed indicates that the stepping motor operates normally.
(b) Pull out the connection harness of stepping motor, and measure the terminal current with universal
meter. When engine is running, there being impulse current output at the terminal indicates that there
is no trouble with ECU and stepping motor control system, and if idling is not stable at the moment
and deviates greatly from specified value, the stepping motor should be replaced. If there is no
impulse current output at the terminal, turn on air conditioner to test again, and still no impulse
current output indicates that there is trouble with ECU and stepping motor control system circuit.
(c) Check the malfunction of stepping motor circuit with diagnostic instrument.
8
Inspection
1. VVT control solenoid valve assembly (4G18-1006200)
(a) Resistance inspection
(1) Measure the resistance between terminals with ohmmeter
Resistance:
(b) Operation inspection

Connect battery positive (+) wire to No.1 terminal and negative (-) wire to No. 2 terminal, and check
valve operation.
Note: ensure that the valve is not stuck.
Hint: if there are foreign matters in the valve, the valve could not be closed tightly and will
thus result in slight pressure being lifted toward higher direction.
2. Throttle body components (4G18-1001240)

(a) Inspection of throttle body
(1) Throttle valve shaft should not swing.
(2) All channels should not be blocked.
(3) Throttle valve plate should rotate flexibly and act smoothly.
(4) When the throttle is at closed position, there should be no clearance between throttle stop bolts and
throttle lever.
Note: it is not allowed to adjust the throttle stop bolts.
3. Throttle position sensor (4G18-3600080)

(a) Resistance inspection
(1) Remove the wiring harness connectors of throttle posi-
tion sensor.
(2) Measure the resistance between 1# pin and 2# pin with

ohmmeter, resistance value: .
(3) Connect 2 terminals respectively to 1# pin and 3# pin,

and turn the throttle, the resistance value varies linearly
with the opening of throttle, but 2# pin and 3# pin are
contrary to this.
Note: pay attention whether there is great jump with

resistance value when observing resistance change.
9
4. Knock sensor (4G18-3600020)
Measuring method:
(Removing the joint) place digital universal meter at ohm gear, 1 Vibration block
and connect 2 terminals respectively to 1# pin and 2# pin, and 2 Housing
the resistance under normal temperature should be more than 3 Piezoelectric ce-
1M . Place digital universal meter at millivolt gear, and knock ramics
around knock sensor with a hand hammer, there should be voltage 4 Contact
signal output at the moment. 5 Electric connec-
tion
5. Water temperature sensor (4G18-3600040)

This sensor applies sealing NTC thermal resistor in temperature sensor, and resistance value varies with
ambient temperature, thus slight change of outside temperature could be measured. Measuring its out-
put resistance could reflect the temperature of contact media. Signals from A and C are sent to ECU,
and Signals from B and earth are sent to instrument.
Operating principle (Fig. 1):
Fig. 1
Note: A, B and C represent 3 pins of sensor, and see pin root for the mark.
10
Use digital universal meter to measure:

Resistance-temperature characteristics of temperature sensor
Temperature range( Resistance at A and C
Resistance at B
6. Intake air temperature sensor (4G18-3600090)
Intake air temperature sensor is a resistor with negative tem-

perature coefficient (NTC), resistance varies with intake air
temperature, and this sensor sends a voltage indicating change
of intake air temperature to controller.
Characteristic curve of
Simple measuring method: temperature sensor
(Removing the joint) place digital universal meter at ohm gear,

and connect 2 terminals respectively to 1# pin and 2# pin of
sensor, and rated resistance at 5%, and
other corresponding resistance values could be measured ac-
cording to the characteristic curve in above drawing. Analog
method could also be applied in measurement. Use an elec-
tric blower to blow air into the sensor (pay attention not to
keep them too near), and observe the change of resistance, Characteristic curve of intake air
which should decrease at the moment. temperature sensor NTC resistor
7. Stepping motor (4G18-3600070) Stepping motor of idle speed actuator
Schematic diagram and pins
11
Electrical
Pins: Pin A is connected to ECU No. 65 pin wiring
diagram
Pin B is connected to ECU No. 66 pin
on step-
Pin C is connected to ECU No. 67 pin ping motor
Pin D is connected to ECU No. 64 pin of idle
speed
actuator
Maintenance precautions:
1. It is not allowed to apply any force at axial direction with the purpose of pressing into or pulling out the
axle;
2. Before idle speed regulator with stepping motor is mounted into throttle body, its shaft must be at fully
retractive position;
3. Pay attention to clean and maintain bypass air passage frequently;
4. After removing battery or ECU, pay attention to self-teach stepping motor in time.
Self-teach method of M7 system: turn on ignition switch but not start engine immediately, and start it
after 5 seconds. If engine idle speed is found bad at the moment, it is
necessary to repeat the above steps.
Simple measuring method: (removing the joint) place digital universal meter at ohm gear, and connect
2 terminals respectively to Ad pin and BC pin of regulator, and rated resis-
tance at
12
Engine control system- Throttle body assembly
Throttle body assembly

Removing, installing and disassembling, assembling
1. Discharge coolant (see Page 73).
2. Remove air cleaner hose assembly.
3. Remove engine plastic hood components [4G18-1000310].
4. Remove throttle pull cable assembly.
5. remove throttle body assembly [4G18-1008240].
(a) Uncouple throttle position sensor joint and stepping motor joint.
(b) Disassemble ventilation hose.
(c) Remove 2 bolts and throttle control pull cable bracket.
(d) Remove 2 preheating water inlet and outlet hoses of throttle.
(e) Remove 2 bolts and 2 nuts, and remove throttle body from intake air manifold.
6. Remove stepping motor of throttle body [4G18-3600070].
Remove 3 screws and stepping motor.
7. Install stepping motor of throttle body.
Install stepping motor.
8. Install throttle body assembly.
(a) Install new seal gasket on intake air manifold.
(b) Install throttle body, 2 bolts and 2 nuts.
Torque:
9. Refill coolant.
10.Check there is leakage with coolant.
13
Fuel-Fuel system
Fuel
Fuel system
Precautions
1. Before repairing fuel system, uncouple battery negative (-) wire at first.
2. When operating on fuel system, do not smoke or repair near fire area.
3. Do not let gasoline come into contact with rubber or leather parts.
4. Take measures to prevent gasoline leaking.
(a) Uncouple electric fuel pump joint.
(b) Start engine and turn ignition switch to LOCK position
after the engine flames out.
(c) Uncouple battery negative (-) wire.
(d) Couple electric fuel pump joint.
5. Fuel system
(a) There will be a great amount of gasoline flowing out
when disassembling high-pressure fuel pipe,
therefore, it is required to observe the following
procedures.
(1) Take measures to prevent gasoline leaking.
(2) Disassemble fuel pipe.
(3) Completely discharge the oil in fuel pipe.
(4) Cover the fuel pipe with plastic bag to avoid pipe
damage and foreign matters entering.
(5) Place a container under the joint.
(b) When removing and installing injection nozzle, always

observe the following precautions.
14
Fuel-Fuel system
(1) It is not allowed to use o-ring repeatedly.

o-ring Correct
(2) When installing o-ring, always be careful to avoid dam-
aging o-ring.
(3) Before installing, coat o-ring with spindle oil or gasoline.
It is not allowed to coat with engine oil, gear oil or injection nozzle oil feed pipe
brake fluid. Wrong
oil feed pipe

(c) As shown in the diagram, install injection nozzle to oil feed
pipe and cylinder head.
Before installing, ensure that spindle oil and gasoline are
o-ring
coated at the contact position between o-ring and oil feed
pipe. washer
(d) When disassembling oil feed pipe, always observe the fol-
lowing precautions.
(1) Remove oil feed pipe clips.
(2) Remove oil feed hose.
(3) Cover oil inlet of fuel distribution pipe with plastic bag
to avoid foreign materials entering the fuel distribution
pipe.
6. Inspection of fuel leakage

(1) After completing maintenance, check there is leakage with the whole fuel system.
(2) Connect hand-held tester to diagnostic joint.
(3) Turn ignition switch to ON and turn main switch of hand-held tester to ON.
(4) Switch hand-held tester to function test state.
(5) For further details, please see hand-held tester operating instruction.
(6) If there is no hand-held tester, connect battery anode and cathode to electric fuel pump joint.
(7) Ensure that there is no leakage with all parts of electric fuel pump.
(8) Turn ignition switch to LOCK.
(9) Disassemble hand-held tester from diagnostic interface joint.
15
Fuel-Fuel system
1. Inspection of fuel pump function
(a) Connect hand-held tester to diagnostic joint.
(b) Turn ignition switch to ON and turn main switch of hand-
held tester to ON.
Note: do not start the engine.
(c) Switch hand-held tester to function test state.
(d) For further details, please see hand-held tester operating
instruction.
(e) If there is no hand-held tester, connect battery positive (+)
wire to P+ terminal and negative (-) wire to P- terminal.
2. Inspection of fuel pressure

(a) Preparation of inspection.
Purchase new fuel hose and take out fuel pipe joint.
(b) Take measures to prevent gasoline leaking.
(c) Disassemble fuel pipe clamp at fuel pipe joint of fuel rail
component.
(d) Disassemble fuel hose from fuel pipe of fuel rail component.
(e) As shown in the diagram, install special tool (pressure
gauge) with special tool and fuel pipe joint.
(f) Check there is fuel leakage.

(g) Start engine.
(h) Measure the fuel pressure at idle speed state.
Fuel pressure: 390~400Pa
(i) Take measures again to prevent gasoline leaking.
(j) After measuring the fuel pressure, remove special tool.
(k) Connect back fuel hose. Special
tool
(l) Install fuel hose fixing clip to fuel pipe joint.
(m)Check there is fuel leakage.
16
Fuel-Fuel system
Inspection
1. Fuel injector components [4G18-1112120]
(a) Check injection nozzle resistance.
(1) Measure the resistance between terminals with
ohmmeter.
Resistance:
Hint: if resistance is not within specification, replace in-
jection nozzle.
(b) Injection nozzle test.
Warning: there should be no sparks during testing.
(1) Purchase new fuel pipe and take out fuel hose joint.
(2) Install special tool and fuel hose joint to fuel pipe.
Note: Only after performing precautions could the
connection operation of fuel hose joint (fast-
joint mode) be allowed to perform.
Warning: before connecting fuel pipe joint (fast-joint
mode), please read precautions carefully
(3) Install o-ring to injection nozzle.

(4) Connect special tool (joint and hose) to injection nozzle, Special
tool
and hold down the injection nozzle to prevent fuel splash.
(5) Place injection nozzle into measuring cup. o-ring
Hint: install proper hose on injection nozzle to prevent Special
tool
gasoline injecting out of the cup.
(6) Connect special tool to injection nozzle joint.

(7) Connect special tool to battery for 15 seconds, and measure the injection volume with measuring
cup, each injection nozzle should be test for 2~3 times.
Injection volume:
Engine Injection volume Uneven volume between
each injection nozzle
Every 15 seconds or less
Hint: if injection volume is not within specification, replace

injection nozzle.
17
Fuel-Injection nozzle assembly
Injection nozzle assembly

Replacement
2. Remove engine plastic hood components.
3. Uncouple engine wire harness [4G18-3724100].
(a) Remove injection nozzle joint.
(b) Remove exhaust gas hose.
4. Remove fuel pipe assembly
(a) Loosen oil feed hose clips.
(b) Pull oil feed hose away from fuse distribution pipe.
Notes:
z Check there is dirt on fuel pipe and its joint before removing, and clean it off in the case of dirt.
z It is only allowed to remove with hands.
z Check there are foreign matters with the removed fuel pipe seal surface, and clean them off in the
case of foreign matters.
z Cover the fuel pipe with plastic bag to avoid pipe damage and foreign matters entering.
5. Remove fuel pipe assembly

Remove 2 bolts and oil feed pipe (together with injection nozzle).
6. Remove injection nozzle components.

Pull out 4 injection nozzles from oil feed pipe.
7. Install injection nozzle components.

Coat a thin layer of gasoline on o-ring and rotate left and right to push injection nozzle into oil feed pipe.
Notes:
z Be careful not to rotate o-ring.
z Check injection nozzle could rotate smoothly after it is installed, and if not replace with new o-ring.
8. Install fuel hose assembly.

Install fuel hose to oil feed pipe.
Notes:
z Check there are damage or foreign matters in the binding site of fuel pipe.
z After installing, pull the fuel pump with hands to check the fuel pipe is bound firmly with joint.
18
Fuel-Injection nozzle assembly
9. Install fuel rail component [4G18-1112110].

(a) Check injection nozzle o-ring and replace if there is damage.
(b) Install isolator on cylinder head.
(c) Install fuel rail component together with injection nozzle.
Torque:
(d) Install fuel pipe fixing clip.
Torque: m
10. Check the function of electric fuel pump and check there is fuel leakage.
19
Fuel - Fuel pump assembly
Fuel pump assembly

1. Take measures to prevent gasoline leaking
2. Remove rear seat cushion assembly
3. Remove rear floor repairing hole cover
4. Remove No. 2 fuel evaporation assembly
Notes:
z Check there is contaminant looked like dirt around the joint before operating and clean it off in the
case of contaminant.
z Be careful of the contaminant looked like dirt, because fast-joint depends on o-ring to seal fuel pipe
and joint.
z Do not perform this operation with tools.
z Do not bend or distort nylon hose.
z Cover the joint with plastic bag after removing the fuel hose.
z When the joint is stuck with fuel pipe, clip the hose with fingers and rotate carefully to release the
hose, and then remove it.
5. Remove fuel tank main fuel hose and oil return pipe assembly
Notes:
z Check there is contaminant looked like dirt around the joint before operating and clean it off in the
case of contaminant.
z Be careful of the contaminant looked like dirt, because fast-joint depends on o-ring to seal fuel pipe
and joint.
z Do not perform this operation with tools.
z Do not bend or distort nylon hose.
z Cover the joint with plastic bag after removing the fuel hose.
z When the joint is stuck with fuel pipe, clip the hose with fingers and rotate carefully to release the
hose, and then remove it.
6. Remove fuel pump assembly
(a) Screw off fuel pump tighten nut (plastic fuel tank) or remove
6 screws (iron fuel tank).
(b) Pull out fuel pump assembly.
Notes:
z Do not damage fuel pump filter screen.
z Be careful not to bend the measuring oil arm of fuel gauge
float unit.
7. Install fuel pump assembly
Torque: 8 N.m
8. Install rear floor repairing hole cover
Install rear floor repairing hole cover with butyl rubber cloth.
9. Check there is fuel leakage.
20
Fuel - Fuel tank assembly
Fuel tank assembly

1. Take measures to prevent gasoline leaking
(see Page 14)
2. Remove rear seat cushion assembly
3. Remove rear floor repairing hole cover
4. Remove No. 2 fuel evaporation assembly
5. Remove fuel tank main fuel hose and oil return pipe
assembly
6. Remove fuel pump assembly
7. Discharge fuel
8. Remove front floor bracket
9. Remove front exhaust pipe assembly
(a) Move away carpet and remove oxygen sensor joint.
(b) Remove front exhaust pipe assembly
10.Disassemble the vent pipe of fuel hose
11.Disassemble filler pipe from fuel tank
12.Remove No. 2 fuel evaporator hose assembly
Press fuel hose joint and then pull out the hose.
Notes:
Check there is contaminant that looked like dirt around the
joint before operating and clean it off in the case of
contaminant.
Be careful of the contaminant that looked like dirt, because
fast-joint depends on o-ring to seal fuel pipe and joint. Nylon pipe
Fuel pipe clip
Do not perform this operation with tools.
Do not bend or distort nylon hose. O-ring
Pipe
Cover the joint with plastic bag after removing the fuel hose.
When the joint is stuck with fuel pipe, clip the hose with
fingers and rotate carefully to release the hose, and then
remove it.
13.Disassemble fuel tank main fuel hose assembly
Clip the protrusion part of fixing ring and move lock claw toward
open direction, and then pull out the hose as shown in the
diagram.
Notes:
Check there is contaminant looked like dirt around the joint
before operating and clean it off in the case of contaminant.
21
Fuel - Fuel tank assembly
Be careful of the contaminant that looked like dirt, because

fast-joint depends on o-ring to seal fuel pipe and joint.
Do not perform this operation with tools.
Do not bend or distort nylon hose.
Cover the joint with plastic bag after removing the fuel hose.
When the joint is stuck with fuel pipe, clip the hose with
fingers and rotate carefully to release the hose, and then
remove it.
14. Remove fuel tank assembly
(a) Remove parking brake pull cable retaining clip.
(b) Place jack under fuel tank. Remove fuel tank band harness and fuel
tank assembly.
15. Remove fuel tank main fuel hose and oil return pipe
assembly
16. Remove No. 2 fuel evaporation hose assembly
17. Remove No. 1 fuel tank gasket
18. Remove No. 1 fuel tank protector
Remove rivet with electric drill and then remove fuel tank protector.
19. Install No. 1 fuel tank protector
Install fuel tank protector with rivet.
20. Install No. 1 fuel tank gasket
As shown in the diagram, install new fuel tank gasket.
21. Install fuel tank assembly
Torque: 39 N.m
22. Install front exhaust pipe assembly
Torque: 40 N.m
23. Install front floor bracket
Torque: 30 N.m
24. Install rear floor repairing hole cover
Install rear floor service hole cover with butyl rubber cloth.
25. Check fuel leakage (see Page 14)
26. Check gas leakage of exhaust system
22
Exhaust gas control - Exhaust gas control system
Exhaust gas control

Exhaust gas control system
1. Check oxygen sensor.
(a) Let the engine run at idle speed for 3 minutes to ensure oxygen sensor reaches operating tempera-
ture of 350
(b) Place digital universal meter at DC voltage gear, and connect 2 terminals respectively to (gray) pin
and (black) pin of sensor, and voltage should fluctuate
quickly between 0.1-0.9V at the moment.
Warning:
Perform inspection immediately after warming
up vehicle.
If voltage change could not be confirmed,
it is necessary to heat oxygen sensor again.
2. Check rotating speed after fuel cut off.

(a) Accelerate engine at least to 3500rpm.
(b) Check the operating noise of injection nozzle with listening device.
(c) When throttle is released, check the operating noise of injection nozzle recovers after stop.
3. Check fuel evaporation exhaust control system.

(a) Check the pipe clamps of connecting pipeline between
charcoal canister and carbon canister solenoid valve are
firmly clipped and check there is leakage.
(b) Check there is trouble with fuel evaporation exhaust con-
trol system with failure diagnostic instrument.
4. Visually check hose, joint and hot fin.

Check cracks, leakage and damage.
Hint: the disconnecting of engine oil level gauge, oil opening
cover and PCV hose may cause running failure of engine.
The cracks, looseness and not connecting at the intake
system between throttle and cylinder head will result in
redundant air entering and running failure of engine.
23
5. Check heater resistance of heated oxygen sensor.

(a) Uncouple oxygen sensor joint.
(b) Place digital universal meter at ohm gear, and connect 2 terminals respectively to 1# (white) pin and
2# (black) pin, and the resistance under normal temperature is 1 6
Oxygen sensor
Main relay
6. Check fuel tank cover.

Visually check fuel tank cover and gasket are distorted or damaged.
24
Inspection
1. Carbon canister assembly [4G18-1129020]
Carbonl canister assembly. Check the function of carbon can-
ister according to the following tables.
Standard:
Inspection Methods Standard

Close B hole and C hole and then
supply vacuum to A hole No leakage
Close C hole and then supply vacuum Air flown out

to A hole from B hole
Close C hole and then blow air Air flown out

into A hole from B hole
Blow air into A hole Air flown out from B hole
and C hole
2. Carbon canister control valve

(a) For carbon canister control valve, check the conduction be-
tween terminals.
Resistance:
(b) Check the control valve operates.
(1) Supply battery voltage to its terminal.
(2) Check air is flown as the arrow direction on valve body.
3. PCV valve assembly [4G18-1014110]

(a) Blow air into valve from cylinder side and check the air is Cylinder side
Clean hose
easy to get through.
Warning: do not suck against the valve, because the
gasoline left in the valve will make you be
injured.
(b) Blow air into valve from intake manifold side and check
the air is hard to get through.
Hint: if the function does not conform to the standard, PCV
valve should be replaced.
Intake manifold side
25
Engine mechanism - Engine assembly
Engine mechanism
Engine assembly
Inspection
1. Check coolant.
2. Check engine oil.
3. Check battery.
4. Check air filter assembly.
5. Check spark plug [4G18-3705113].
6. Check drive belt [4G18-1307107].
Hint: do not check belt tension, because automatic tensioner is applied.
7. Check ignition timing.

(a) Warm up engine.
(b) Connect timing lamp to engine.
(c) Check ignition timing at idle speed.

Ignition timing: before top dead center
Note: when checking ignition timing, place
transmission at neutral position.
Hint: After run the engine for 5 seconds with rotating K-line
speed of 1000-1300rpm, check the engine could

recover to idle running.
8. Check engine idle speed.

(a) Warm up engine and run it at idle speed.
(b) Read engine rotating number in data flow with diagnostic instrument.
(c) Check idle speed.
Idle speed: about 750-850rpm
Notes:
When checking idle speed, place cooling fan at OFF position.
Turn off all auxiliary devices and air conditioner.
26
9. Check compression pressure.

(a) Warm up engine.
(b) Remove ignition coil.
(c) Remove spark plug.
(d) Check cylinder compression pressure.
(1) Install cylinder compression pressure gauge on spark plug hole.
(2) Wide open throttle.
(3) Measure the pressure during crankshaft rotating.
Notes:
Ensure to use fully charged battery to make the rotating speed of engine reach or exceed 250rpm.
When measuring other items, please repeat steps (1) to (3).
Finish the measurement as soon as possible.
Compression pressure: 1080kPa
Min pressure: 1000kPa
Difference among cylinders: 100kPa
(4) If the compression pressure of one or more cylinders is too low, inject a small amount of engine oil
from spark plug hole into the cylinder with low pressure, and repeat steps (1) to (3) to check
pressure.
If the pressure increases after engine oil is injected, the piston ring of this cylinder or the
cylinder has been worn or scratched.
If the pressure is still too low, the valve may be stuck or not fully closed, or the cylinder head
gasket leaks.
10. Check CO/HC.

(a) Start engine.
(b) Keep the rotating speed of engine at 2500rpm for about 180 seconds.
(c) When the engine is idle running, insert the test bar of CO/HC gauge into exhaust pipe at least 40cm.
(d) Immediately check idle speed and CO/HC concentration at 2500rpm.
Hints:
Finish test within 3 minutes.
Perform the test under 2 analog states (idle speed and 2500rpm) according to measuring meth-
ods and sequences specified by Emission Regulations.
(e) If CO/HC concentration is not within specified value, perform trouble shooting according to the
following sequences.
(1) Check the function of oxygen sensor.
(2) See possible failure causes listed in the table below, and repair and correct if necessary.
27
CO HC Trouble occurrence Possible causes

1. Ignition system malfunction
Ignition timing incorrect
Spark plug too dirty, short circuit or clearance
Normal High Unstable idle speed incorrect
2. Valve clearance incorrect
3. Air inlet and exhaust valve leaky
4. Cylinder leaky
1. Vacuum leak:
PCV hose
Intake manifold
Low High Unstable idle speed
Throttle body
(HC readings not stable) Idle speed stepping motor
Vacuum booster and pipelines
2. Fire caused by too thin mixing ratio
1. Air filter core blocked
2. PCV valve blocked
3. EFI system malfunction
Fuel pressure regulator malfunction

Water temperature sensor malfunction
High High Unstable idle speed
Intake pressure sensor malfunction
(black smoke emission)
ECU malfunction
Injection nozzle malfunction
Throttle position sensor malfunction
28
Engine mechanism - Drive belt
Drive belt
Replacement
1. Remove engine right bottom shield.
2. Remove drive belt

Slowly turn drive belt tensioner clockwise to loosen it.
Then remove drive belt and put back drive belt tensioner slowly
and gently.
3. Install drive belt

Then install drive belt and put back drive belt tensioner slowly
and gently.
29
Engine mechanism - Valve clearance
Valve clearance
Adjustment
Mark Mark
2. Remove ignition coil components [4G18-3705110].
3. Remove cylinder head cover components [4G18-
1003130].
5. Turn crankshaft to cylinder 1 compression top dead
center position.
(a) Turn crankshaft pulley to align its groove with o mark on Mark Timing chain
timing chain hood. hood surface
(b) Check dot marks on camshaft timing sprocket and VVT
timing sprocket, and they should be in a line on timing chain
hood surface as shown in the diagram.
Hint: if not, turn crankshaft for one circle again
and align the above marks.
Groove
6. Check valve clearance.
(a) Only check the valves shown in the diagram.
(1) Measure the clearance between valve tappet and cam-
shaft with plug gauge.
(2) Record valve clearance measuring value exceeding
specification, and this value will be used to determine
valve tappet thickness that needs change.
Valve clearance (cold vehicle)
Intake air
Exhaust
(b) Turn crankshaft for one circle ), and cylinder 4 is

turned to compression top dead center position.
(c) Only check the valves shown in the diagram. Measure valve
clearance (see step (a)).
7. Remove drive belt

Then remove drive belt and put back drive belt tensioner slowly
and gently.
30
8. Remove right engine mounting assembly

(a) Remove PS oil pump reservoir and put it aside.
(b) Place wooden block between jack and engine, properly
place the jack, and then remove right engine mounting
assembly.
9. Remove drive belt tensioner device [4G18-
1300200].
Hint: operate the jack up and down to remove bolts.
10. Adjust valve clearance.
Note: do not turn crankshaft before installing chain
tensioner.
(a) Turn crankshaft to cylinder 1 top dead center position.
(b) Align the marks on timing chain and camshaft timing
sprocket.
Painting
(c) Remove 2 bolts and chain tensioner. mark
Fixing
(d) Fix camshaft with adjustable wrench and then loosen Loosening
the fixed bolts of exhaust camshaft timing sprocket.
Note: be careful not to damage valve lifter.
(e) As sequences shown in the diagram, loosen camshaft

bearing cover bolts on exhaust camshaft at several
times and remove the bearing cover at the same time.
(f) As shown in the diagram, remove exhaust camshaft

timing sprocket.
31
(g) As sequences shown in the diagram, loosen camshaft

bearing cover bolts on intake camshaft at several times
and remove the bearing cover at the same time.
(h) Hold timing chain with hands and then remove the
camshaft.
(i) As shown in the diagram, tie up the chain with bandage.

Note: be careful not to let anything fall into the
timing chain hood.
(j) Remove valve lifter.
(k) Measure the thickness of this valve lifter with

micrometer.
(1) Calculate the thickness of new valve tappet and
adjust valve clearance within specification.
Thickness of new valve lifter

Thickness of old valve lifter
easured valve clearance
:
Exhaust:
Hints: Timing remark
New valve tappet chosen should be near the value cal- chain link
culated as much as possible.
The thickness of valve tappet is from 5.06mm to 5.74mm,
and there is one specification every 0.02mm, therefore
there are totally 35 different dimensions to chose.
(m) As shown in the diagram, align alignment mark with tim-
Timing mark
ing mark on camshaft timing sprocket, and install timing
chain on the timing sprocket.
32
(n) Check intake side camshaft bearing cover forward re-

mark and figure, and tighten the bolts as sequences
shown in the diagram.
Torque:
Timing remark chain link

(o) Align alignment mark on the chain with timing mark on
camshaft timing sprocket, and place exhaust camshaft
in cylinder head.
Timing mark
(p) Temporarily lock fixed bolts.
(q) Check exhaust side camshaft bearing cover forward

remark and figure, and tighten the bolts as sequences
Torque:
(r) Install camshaft front bearing cover.
Torque:
Fixing
(s) Fix camshaft with adjustable wrench and then tighten
the fixed bolts of camshaft timing sprocket. Tightening
Torque:
33
(t) Check the matching marks on timing chain and cam-

Mark Mark
shaft timing sprocket, and then align the groove of crank-
shaft pulley with the timing mark on timing chain hood
as shown in the diagram.
(u) Install chain tensioner.
Mark
Timing chain
hood surface
Groove
(1) Check o-ring is clean, and buckle on the hook as

Lifting
Pressing
in
Hook
Pin
(2) Coat engine oil on the chain tensioner, and then

install it.
Note: when installing the chain temsioner, buckle
on the hook again if plunger has ejected.
Pressing in
(3) Turn crankshaft counterclockwise to separate the

hook from lock pin on the plunger.
Separation
Hook
Pin Turning
34
(4) Turn crankshaft clockwise, and check the sliding

parts are blocked by plunger.
Plunger
Pushing
Turning
Hint: if the plunger does not eject, press the chain ten-
sion rail toward chain tensioner with screwdriver
or fingers to separate the hook from lock pin and
make the plunger eject.
11.Install cylinder head cover components.

(a) Install cylinder head cover gasket on cylinder head cover.
(b) Eliminate all old sealant (FIPG) materials. Sealant
(c) Coat sealant on 2 positions shown in the diagram.
Notes:
Wipe off all the oil stains on junction plane.
After coating sealant, finish installation of cylinder head
cover within 3 minutes.
After installing, do not refill engine oil within 2 minutes.
(d) Install cylinder head cover components with 9 bolts, 2 seal washers and 2 nuts.
Evenly tighten bolts and nuts at several times.
Torque:
Short bolt:
Nut, long bolt etc.: m
12. Install drive belt tensioner device.

Torque: nut:
Bolt:
13. Install fixing bracket absorber on the left of engine.
Torque:
14. Check there is oil leakage.
35
Engine assembly
Replacement
3. Remove engine left bottom shield.
4. Discharge coolant.
5. Remove front wheels.
7. Remove battery.
8. Remove air filter assembly.
9. Remove air filter hose.
10. Remove battery tray.
11. Disassemble fuel hose assembly.
12. Remove throttle cable assembly.
13. Disassemble radiator hose inlet end.
14. Disassemble radiator hose outlet end.
15. Disassemble cold air pipe inlet hose.
16. Disassemble cold air pipe outlet hose.
17. Remove transmission control pull cable assembly.
18. Disassemble warm air water inlet hose [4G18-1300102].
19. Disassemble warm air water outlet hose [4G18-1300108].
20. Disassemble the hoses of all joints to connect vehicle body end.
21. Uncouple engine wire harness.
(a) Remove glove compartment door.
(b) Remove engine wire harness from engine ECU and junction block.
(c) Pull out engine wire harness.
(b) Remove engine wire harness from junction block of engine room.
(e) Remove vehicle body earth wire.
36
22. Remove drive belt.

Drive belt tensioner could turn belt tensioner clockwise to
loosen it.
23. Remove alternator mounting components [4G18-
3701100].
24. Remove compressor assembly.
25. Remove front chassis bracket.
26. Remove front exhaust pipe assembly.
27. Remove steering middle shaft assembly.
(a) Remove steering column seal hole cover.
(b) Make alignment mark on steering middle shaft.
(c) Remove 2 bolts and steering middle shaft.
Alignment
mark
(d) Remove steering column cover.
Lifting
Sliding out
28. Remove the nuts on left side of front shaft hub.

(a) Completely knock out the concave part of fixed nuts with
special tool and hammer.
Notes:
Completely knock out the concave part of fixed
nuts before removing the fixed nuts.
Do not damage thread of drive shaft.
Do not sharpen the sharp end of special tool.
Place the special tool in groove with its plane facing
Special tool
upward.
(b) Remove fixed nuts with socket wrench (30mm).
Hint: perform the same steps at another side.
29. Disassemble left side transversal lever assembly.

Disassemble transversal lever assembly from steering
knuckle with special tool.
Special tool
37
30. Disassemble left end front stabilizer link

assembly.
Fix bolts with hex socket wrench, and then remove nuts.
31. Disassemble lower left control arm assembly.
(a) As shown in the diagram, remove bolt and 2 nuts.
(b) Disassemble drive shaft from shaft hub with plastic

hammer.
32. Remove oil return pipe assembly.

After removing 3 retaining clips and 2 bolts of power steer-
ing oil reservoir, remove the oil return pipe from vehicle.
33. Remover engine assembly [4G18-1000000] and
transmission assembly.
(a) Erect engine hanger.
(b) Remove 4 bolts, 2 nuts and right engine mounting
assembly.
(c) Remove through bolt and nut, and then remove left
engine mounting assembly from vehicle.
(d) As shown in the diagram, remove 6 bolts.

(e) Carefully remove engine assembly and transmission
assembly from vehicle.
38
(f) As shown in the diagram, install front and rear hooks of

engine. Engine hook
Torque:
Hint: install engine hooks to front and rear sides of
engine.
(g) Lift engine assembly with chain pulley block and en-
gine lifting device.
34. Remove power steering pump assembly.
Front Rear
35. Remove sub frame together with side member.
(a) Remove front engine mounting assembly and rear en-
gine mounting assembly from engine assembly.
(b) Remove sub frame assembly.
36. Remove starter mounting components
[4G18-3708100].
37. Remove transmission assembly.
(a) Fix crankshaft with special tool, ant then remove 6 bolts.
(b) Remove transmission assembly.
38. Remove clutch assembly [4G18-1601000]
and flywheel components [4G18-1005120J].
(a) Fix crankshaft with special tool, ant remove clutch
assembly at first. Special tool
(b) Then remove flywheel components.
39. Remove throttlesupporting plate [4G18-1008202].
40. Remove intake manifold assembly [4G18-
1008200].
41. Remove exhaust manifold upper heat shield components [4G18-1008120].
42. Remove exhaust manifold assembly [4G18-1008100].
43. Remove fuel rail injector assembly [4G18-1112100].
44. Remove ignition coil installation components.
45. Remove oil level gauge tube components [4G18-1002140].
46. Remove temperature regulator assembly [4G18-1306100].
47. Disassemble warm air water outlet pipe components [4G18-1300100].
48. Remove oil pressure alerter [4G18-3757100].
Remove oil pressure alerter with SST.
49. Remove the hoses on all hose joint of engine.
Remove clips and hose.
50. Remove drive belt tensioner device.
51. Remove phase sensor [4G18-3600030].
39
52. Remove speed sensor [4G18-3600010].

53. Remove knock sensor.
Remove knock sensor with special tool.
54. Remove water temperature sensor.
Remove water temperature sensor with special tool.
55. Replace engine assembly.
56. Install water temperature sensor.
(a) Install new gasket to water temperature sensor.
(b) Install water temperature sensor with special tool.
Torque:
57. Install knock sensor.
Install knock sensor with special tool.
Torque: m
58. Install speed sensor.
Install speed sensor and harness clips.
Torque:
59. Install phase sensor.
Torque:
Torque: nut: m
Bolt: m
61. Install the hoses on all hose joint of engine.
Install clips and hose.
62. Install oil pressure alerter.
(a) Clean thread of oil pressure alerter and coat adhesive.
Adhesive: anaerobic pipe thread sealing adhesive 1545
(Kesaixin 1545)
(b) Install oil pressure alerter with special tool.
Torque:
63. Install warm air water outlet pipe components.

Install new gasket and warm air water outlet pipe
components.
Torque: nut: m
Bolt:
40
64. Install temperature regulator assembly.

(a) Check temperature regulator assembly o-ring.
(b) Install temperature regulator assembly as shown in the
diagram.
(c) Install engine water inlet pipe joint components.
Torque:
65. Install oil level gauge tube components.
66. Install ignition coil mounting components.
Torque: m
67. Install fuel rail injector assembly.
(a) Install isolator on cylinder head.
(b) Install fuel rail injector assembly.
Torque:
(c) Install fuel pipe retaining clip.
68. Install exhaust manifold gasket and exhaust
manifold assembly.
Torque:
69. Install exhaust manifold upper heat shield
components.
Torque:
70. Install intake manifold assembly.
Install new gasket and intake manifold assembly.
Torque: m
71. Install throttle supporting plate.
Torque:
72. Install flywheel components and clutch assembly.
(a) Fix crankshaft with special tool.
(b) Clean bolts and bolt holes.
(c) Coat bolts with adhesive.
Adhesive: thread locking sealant 1234 (Kesaixin 1234).
Special
tool
(d) Install flywheel components.

As sequences shown in the diagram, tighten bolts at
several times.
Torque: 88 5N m
(e) Install clutch assembly.
41
73. Install transmission assembly.

(a) Install transmission assembly.
Torque: bolt A:
Bolt B:
Bolt C:
(b) Install 6 bolts.
Torque:
74. nstall starter mounting components.
Torque: bolt:
Nut:
75. Install sub frame together with side member.
Install front mounting assembly and rear mounting
assembly.
Torque: front:
Rear:
76. Install power steering pump assembly.
Torque:
77. Install engine assembly together with

transmission assembly.
(a) Erect engine together with transmission assembly on
engine crane.
(b) Install engine assembly to vehicle.
(c) Temporarily install side member and 6 bolts.
(d) Install left engine mounting assembly.
Torque:
(e) Install right engine mounting assembly.
(f) Insert special tool into location hole on right side of sub
frame and vehicle.
(g) Temporarily lock bolt A at first, and then lock bolt B. Special
(h) Insert special tool into location hole on left side of sub tool
frame and vehicle.
(i) Temporarily lock bolt A at first, and then lock bolt B.
(j) Insert special tool into location hole on right side of sub
frame and vehicle, and then tighten bolts up to speci-
fied torque.
Torque: bolt A: m
Bolt B:
Special tool
42
(k) Insert special tool into location hole on left side of sub
frame and vehicle, and then tighten bolts up to speci-
fied torque.
Torque: bolt A:
Bolt B: m
(l) As shown in the diagram, tighten 2 bolts.
Torque:
Note: after installing sub frame, check the sub
frame is aligned with location hole on
vehicle.
78. Install compressor.
Torque:
79. Install lower left control arm assembly.
(a) Install drive shaft to steering knucle.
(b) Install lower left control arm.
Torque:
80. Install front left shaft hub nut.
(a) Install fixed nut with socket wrench (39mm).
Torque:
(b) Drive the cutout part of hub nut into groove with chisel.
81. Install left end front stabilizer link assembly.
Fix bolts with hex socket wrench.
Torque:
82. Install left side transversal lever assembly.
(a) Connect transversal lever assembly to steering knucle
and install new nuts.
Torque:
Note:
Do not coat lubricant on thread and conical surface.
After tightening nuts up to specified torque, con-
tinue turning nuts for 60and insert open pin.
(b) Insert new open pin.
83. Connect fuel hose assembly.
84. Install battery tray.
Torque:
43
85. Install alternator mounting components.

Torque: 12mm bolt head A:
14mm bolt head B:
86. Install drive belt.
87. Install engine wire harness and all hoses

not connected.
(a) Check and connect all joints of engine wire harness.
(b) Check and connect all hoses.
88. Install transmission control pull cable assembly
and valve control pull cable.
89. Install air filter assembly and its hose.
90. Install steering middle shaft assembly.
(a) Align alignment mark on steering middle shaft.
(b) Install 2 bolts.
Torque: m
(c) Install steering column cover.
91. Install front exhaust pipe assembly. Alignment
mark
92. Install front chassis bracket.
Torque:
93. Install battery and connect wire.
94. Install engine plastic hood components.
95. Install front wheel and engine bottom shield. Sliding in Pulling
96. Refill transmission lubricant.
97. Refill engine oil.
98. Refill coolant.
100. Check there is coolant leakage.
101. Check idle speed and ignition timing.
102. Check CO/HC.
44
Engine mechanism - Timing chain assembly
Timing chain assembly

Replacement
1. Remove engine left bottom shield.

3. Discharge coolant.
6. Remove power steering pump assembly.
7. Remove alternator assembly.
8. Uncouple engine wire harness.
(a) Remove ignition coil joint, PS fuel pressure switch joint,
fuel line control joint and speed sensor joint.
(b) Remove bolts and nuts of fixed earth wire and put aside
engine wire harness.
9. Remove ignition coil assembly.
10. Remove cylinder head cover components.
(a) Remove fuel pipe retaining clip and 2 PCV hoses from
cylinder head cover.
(b) Remove 9 bolts, 2 seal washers, cylinder head cover
components and gasket.
11. Remove right engine mounting assembly.

Special
(b) Place wooden block between jack and engine, prop-
tool
erly place the jack, and then remove right engine mount-
ing assembly.
12. Turn crankshaft to cylinder 1 compression top

dead center position.
13. Remove damping pulley components
[4G18-1005110].
Remove pulley bolts with special tool.
Special
Remove damping pulley components with special tool.
tool
45
14. Remove drive belt tensioner device.

15. Remove water pump components [4G18-1307110].
(a) Remove 6 bolts and water pump components.
16. Remove engine stabilizer bracket on engine cross
member.
17. Remove compressor.
18. Remove speed sensor.
19. Remove chain tensioner components
[4G18-1006160].
Note: do not turn crankshaft before installing chain
tensioner components.
20. Remove timing chain hood components
[4G18-1006140].
(a) Remove 11 bolts and nuts.
(b) Remove studs with star wrench.
(c) Pry open timing chain hood from timing chain hood pro-
trusion part between cylinder head and body with screw-
driver and remove it.
Note: be careful not to damage timing chain
hood, the contact surface of cylinder head and
body.
21. Remove crankshaft front oil seal assembly
[4G18-1006150].
Remove oil seal with screwdriver.
22. Remove speed sensor signal panel
[4G18-3600011A].
23. Remove chain tension rail components
[4G18-1006120].
24. Remove chain guide rail components
[4G18-1006130].
25. Remove timing chain [4G18-1006110].
Remove it with 2 screwdrivers.
Notes:
Place a piece of cloth to protect engine.
In the state of timing chain separating from timing
sprocket and turning camshaft, turn crankshaft 1/4
circle to avoid valve contacting with piston.
26. Install timing chain.

(a) Turn crankshaft to cylinder 1 compression top dead
center position.
(1) Turn camshaft from hexagon head part of
camshaft, and align dot marks on camshaft timing
sprocket.
46
(2) Use damping pulley bolts to turn crankshaft with its key
Toward port Set key
toward upward.
(b) Install timing chain on crankshaft timing sprocket and

align the chain link having yellow mark with timing mark Yellow
mark
of crankshaft timing sprocket.
Hint: there are 3 yellow chain links on the timing chain. Timing mark
(c) Install crankshaft timing sprocket with special tool.
Special tool
Color (yellow) mark

(d) Install timing chain on camshaft timing sprocket and
align the chain link having yellow mark with camshaft
timing sprocket.
Timing mark
27. Install chain guide rail components.

Torque: m
28. Install chain tension rail components.
Torque:
29. Install speed sensor signal panel.
Install signal panel with F mark toward forward.
47
30. Install crankshaft front oil seal assembly. Special

(a) Coat a little MP grease on oil seal lip. tool
(b) Gently knock new oil seal in with special tool and ham-
mer until the seal surface is parallel and level with the
edge of timing chain cover.
Note: do not let oil seal mouth contact with foreign
matters.
31. Install timing chain hood components.

(a) Eliminate all old seal materials from contact surface.
(b) As shown in the diagram, coat sealant on the edge Sealant width
(diameter 3.5mm-4.5mm).
Sealant: silicon rubber flange sealant 1596 (Kesaixin
1596).
Sealant
Chain cover
(c) Install timing chain hood with 12 bolts and nuts. groove
Torque:
Sealant Cylinder
concentration head groove
Notes:
Eliminate all grease on contact surface.
After coating sealant, finish installation of timing chain
hood within 3 minutes.
After installing, do not refill engine oil within 2 minutes.
32. Install chain tensioner components. Lifting

(a) Check o-ring is clean, and buckle on the hook as shown
in the diagram.
Entering
Hook
Pin
48
(b) Coat engine oil on the chain tensioner, and then install
it.
Torque:
Note: when installing the chain temsioner, buckle
on the hook again if plunger has ejected.
Pushing into
33. Install damping pulley.

(a) Align the key groove on the damping pulley with the
key on the crankshaft, and slide damping pulley in.
(b) Install damping pulley bolts with special tool. Special
Torque: tool
(c) Turn crankshaft counterclockwise to separate the hook

from lock pin on the plunger.
Separation
Hook
Pin
Turning
(d) Turn crankshaft clockwise, and check the chain ten-

sion rail is blocked by plunger.
Plunger
Pushing
into Turning
Hint: if the plunger does not eject, press the chain ten-
sion rail toward chain tensioner with screwdriver
or fingers to separate the hook from lock pin and
make the plunger eject.
49
34. Install speed sensor.

Torque:
35. Install engine fixing bracket
Torque:
36. Install water pump mounting components
[4G18-1307100].
(a) Install new o-ring on water pump.
(b) Install water pump with 6 bolts.
Torque: bolt A:
m

Torque: nut:
Bolt: m
38. Install right engine mounting assembly.

Torque:
39. Install cylinder head cover components.
(a) Install gasket to cylinder head cover.
(b) Eliminate all old seal materials.
(c) Coat sealant on 2 positions shown in the diagram.
Sealant: silicon rubber flange sealant 1596
(Kesaixin 1596).
Notes:
Eliminate all grease on contact surface.
After coating sealant, finish installation of cylinder
head cover within 3 minutes.
After installing, do not refill engine oil within 2
minutes.
(d) Install cylinder head cover and cable bracket with 9 bolts,
2 seal washers and 2 nuts.
Torque: nut:
Bolt: m
40. Install ignition coil mounting components.

Torque:
50

Torque: 12mm bolt head:
14mm bolt head: m
42. Refill coolant.

43. Check there is coolant leakage.
51
Engine mechanism - Camshaft
Camshaft
Replacement
1. Remove engine hood.
2. Remove ignition coil assembly.
3. Remove cylinder head cover assembly.
5. Turn crankshaft to cylinder 1 compression top dead
center position.
(a) Turn damping pulley to align its groove with o mark on Mark Mark
timing chain hood.
Mark Timing chain

(b) Check dot marks on camshaft timing sprocket and VVT
hood surface
timing sprocket, and they should be in a line on timing chain
hood surface as shown in the diagram.
Hint: if not, turn crankshaft for one circle (360 ) again
and align the above marks.
Groove

Slowly turn drive belt tensioner clockwise to loosen it.Then
remove drive belt and put back drive belt tensioner slowly and
gently.

place the jack, and then remove engine fixing bracket shock
absorber.
8. Remove drive belt tensioner assembly.
52
9. Remove camshaft.
Note: do not turn crankshaft before installing timing chain
tensioner.
(a) Turn crankshaft to cylinder 1 top dead center position.
(b) Make marks on timing chain and camshaft timing sprocket. Painting
(c) Remove 2 bolts and chain tensioner. mark
(d) Fix camshaft with variable wrench and then loosen the fixed Fixing
bolts of camshaft timing sprocket. Loosening
Note: do not damage valve lifter.
(e) As sequences shown in the diagram, loosen camshaft bear-

ing cover bolts on exhaust camshaft at several times and
remove the bearing cover at the same time.
(f) As shown in the diagram, remove exhaust camshaft tim-

ing sprocket.
(g) As sequences shown in the diagram, loosen camshaft bear-

ing cover bolts on intake camshaft at several times and
remove the bearing cover at the same time.
53
(h) Hold timing chain with hands and then remove intake
camshaft.
(i) As shown in the diagram, tie up the chain with bandage.

Note: be careful not to let anything fall into the timing
chain hood.
10. Check VVT driver assembly [4G18-1006300].

(a) Check locking state of timing sprocket.
Clip the camshaft with a jaw vice, and ensure VVT driver
is locked tightly.
Note: be careful not to damage intake camshaft.
(b) Release lock pin.
(1) As shown in the diagram, seal 5 oil ducts of intake
camshaft journal with vinyl rubber cloth.
Hint: there are 2 advance side oil ducts in the groove
of intake camshaft, and clog one of them with Delay side Advance
oil duct side oil
rubber block.
duct
(2) In opposite side of the groove, prick a hole on
vinyl rubber cloth of advance side oil duct surface
and delay side oil duct surface.
Close Close
Open Open
Vinyl rubber cloth Rubber block
(3) Send in 2 oil ducts (advance side oil duct and

Delay side Advance
delay side oil duct) with the surface rubber cloth side oil
oil duct
pricked under the pressure of 150Kpa. duct
Warning: cover the oil ducts with cloth to avoid
oil injecting out in pushing.
54
(4) Ensure whether the timing sprocket of VVT driver

will turn toward timing advance direction in de- Delay side Advance
creasing the pressure of timing delay oil duct. oil duct side oil
(5) When camshaft timing sprocket turns at max. duct
timing advance position, release the air pressure
Dropping
in timing delay side oil duct, and then release the
pressure
air in timing advance side oil duct.
Hint: camshaft timing sprocket will turn only af- Maintaining
pressure
ter the lock pin is released.
Warning: if the air pressure in timing advance side oil duct is released earlier than that
in timing delay side oil duct, VVT driver assembly will move suddenly toward
delay side, and the lock pin will be damaged.
(c) Check rotating is smooth.
Besides max. delay position, turn VVT driver assembly within rotating rang and check rotating is
smooth.
Warning: Perform inspection with hands but not with
compressed air.
(d) Check the fixing state of max. delay position.
Ensure camshaft timing sprocket assembly is fixed at Delay side Advance
oil duct side oil
max. delay position.
duct
11. Remove VVT driver assembly.
(a) Clip the camshaft with a jaw vice, and ensure VVT driver
is locked tightly.
Warning: be careful not to damage camshaft.
(b) As shown in the diagram, seal 5 oil ducts of camshaft
Close Close
journal with vinyl rubber cloth.
Hint: there are 2 advance side oil ducts in the Open Open
groove of camshaft, and clog one of them
with rubber block.
(c) In opposite side of the groove, respectively prick a hole
Vinyl rubber cloth Rubber block
on vinyl rubber cloth of advance side oil duct surface
and delay side oil duct surface.
(d) Send in 2 oil ducts (advance side oil duct and delay Advance
Delay side
side oil duct) with the surface rubber cloth pricked oil duct side oil
under the pressure of 150Kpa. duct
Warning: cover the oil ducts with cloth to avoid
oil injecting out in pushing.
(e) Ensure whether the timing sprocket of VVT driver will
turn toward timing advance direction in decreasing the
pressure of timing delay oil duct.
Hint: camshaft timing sprocket will turn toward
Delay side Advance
advance direction only after the lock pin is oil duct side oil
released. duct
(f) When camshaft timing sprocket turns at max. timing
advance position, release the air pressure in timing Dropping
pressure
delay side oil duct, and then release the air in timing
advance side oil duct. Maintaining
pressure
55
Warning: if the air pressure in timing advance side oil duct is released earlier than that in
timing delay side oil duct, VVT driver assembly will move suddenly toward
delay side.This will cause the damage of lock pin.
(g) Remove VVT drive fixed bolts.
Notes: Flange bolt
It is strictly forbidden to remove other 4 bolts.
Under the condition of repeating using camshaft
timing sprocket, release lock pin at first, and then
install sprocket.
Straight pin
12. Install VVT driver assembly.
13. Install camshaft.
Put VVT driver assembly together with intake camshaft.
(a) As shown in the diagram, gently make VVT assembly Straight pin
hold camshaft and turn it toward left until straight pin is
inserted into groove.
Warning: it is strictly forbidden to turn camshaft
timing sprocket toward timing delay side
(toward right). key
groove
(b) Check there is no clearance between sprocket flange

Timing remark
and camshaft. chain link
(c) Fix camshaft timing sprocket and then tighten flange
bolt.
Torque: 70 5N.m
Timing mark
(d) Check VVT driver assembly could move to timing

delay side and is locked at max. timing delay position.
(f) As shown in the diagram, align alignment mark with

timing mark on camshaft timing sprocket, and install
timing chain on the timing sprocket.
(g) Check forward mark and figure, and tighten bolts as
sequences shown in the diagram.
Timing remark chain link
Torque: 13 0.78N.m
(h) Align alignment mark on the chain with timing mark on Timing mark
camshaft timing sprocket, and place exhaust camshaft
in cylinder head.
56
(i) Temporarily tighten fixed bolts.
(j) Check forward mark and figure, and tighten bolts as

sequences shown in the diagram.
Torque: 0.78N.m
(k) Install camshaft front bearing cover.

Torque: 23 1.38N.m
Fixing
Tightening
(l) Fix camshaft with variable wrench and then tighten the
fixed bolts of exhaust camshaft timing sprocket.
Torque: 54 10.8N.m
Mark Mark
(m)Check the alignment marks on timing chain and cam-

shaft timing sprocket, and then align the groove of damp-
ing pulley with the timing mark on timing chain hood as
Mark
Timing chain hood
Groove
57
(n) Install chain tensioner components.

(1) Check o-ring is clean, and buckle on the hook as Lifting
shown in the diagram. Pressing
in
Hook
Pin
(2) Coat engine oil on the chain tensioner, and then

install it.
Torque: 9 1.8N.m
Pushing into
Note: when installing the chain temsioner,
buckle on the hook again if plunger has
ejected.
(3) Turn crankshaft counterclockwise to separate the

hook from lock pin on the plunger. Sepa-
rate
Hook
Pin
(4) Turn crankshaft clockwise, and check the sliding

parts are blocked by plunger.
Plunger
Pushing into Turning
Hint: if the plunger does not eject, press the ten-

sion rail toward chain tensioner with
screwdriver or fingers to separate the hook
from lock pin and make the plunger eject.
58
14. Adjust valve clearance.

15. Install cylinder head cover components.
(a) Install gasket to cylinder head cover.
(b) Eliminate all old sealant (FIPG) materials.
(c) Coat sealant on position shown in the diagram.
Sealant: silicon rubber flange sealant 1596 (Kesaixin
1596).
Notes:
Eliminate all oil on contact surface.
After coating sealant, finish installation of cylinder
head cover within 3 minutes.
After installing, do not refill engine oil within 2
minutes.
(d) Install cylinder head cover and harness bracket with 9
bolts, 2 oil seal washers and 2 nuts.
Evenly tighten bolts and nuts at several times.
Torque: nut: 29 5.8N.m
Bolt: 69 13.8N.m

Torque: nut: 29 5.8N.m
Bolt: 69 13.8N.m

Torque: 52N.m
59
Engine mechanism - Crankshaft front oil seal assembly
Crankshaft front oil seal assembly

Replacement
Slowly turn drive belt tensioner clockwise to loosen it. Then
remove drive belt and put back drive belt tensioner slowly and
gently.
place the jack, and then remove right engine mounting
assembly.
4. remove damping pulley.
(a) Remove pulley bolts with special tool.
Special
tool
(b) Remove damping pulley with special tool.
Special
tool
60
Engine mechanism - Crankshaft front oil seal assembly
5. Remove crankshaft front oil seal. Cut

(a) Cut oil seal lip with blade. position
(b) Prize out oil seal with flat screwdriver whose sharp end is
winded with tape.
Note: check crankshaft is damaged after removing oil
seal, and repair with abrasive paper (#400) if it
is damaged. Prizing out
6. Install crankshaft front oil seal.

(a) Coat a little MP grease on new oil seal lip.
Note: do not let oil seal lip contact with foreign
matters.
(b) Gently knock new oil seal in with special tool and hammer Special
until the seal surface is parallel and level with the end sur- tool
face edge of mounting hole.
Note: wipe off redundant grease on crankshaft.
7. Install damping pulley.

(a) Align the key groove on the pulley with the key on the
crankshaft, and slide pulley in.
Special
(b) Install pulley bolts with special tool. tool
Torque: m

Torque:
61
Engine mechanism - Crankshaft rear oil seal assembly
Crankshaft rear oil seal assembly

Replacement
1. Remove transmission assembly.
2. Remove clutch assembly and flywheel components.
Fix crankshaft with special tool, remove clutch assembly at
first, and then remove flywheel components.
3. Remove crankshaft rear oil seal.
(a) Cut oil seal mouth with blade.
(b) Prize out oil seal with flathead screwdriver whose sharp
end is winded with tape.
Note: check crankshaft is damaged after removing oil
seal, and repair with abrasive paper (#400) if it is
damaged. Special
tool
4. Install crankshaft rear oil seal [4G18-1002130].

(a) Coat a little MP grease on new oil seal lip.
Cut
Note: do not let oil seal lip contact with foreign position
matters.
(b) Gently knock new oil seal in with special tool and hammer
until the seal surface is parallel and level with the end sur-
face edge of mounting hole.
Note: wipe off redundant grease on crankshaft.
5. Install flywheel components and clutch assembly. Special

tool
(a) Fix crankshaft with special tool.
(b) Clean bolts and bolt holes.
(c) Coat bolts with adhesive.
Adhesive: thread locking adhesive 1234 (Kesaixin 1234)
(d) Install flywheel components.

As sequences shown in the diagram, tighten bolts at sev-
eral times.
Torque:
(e) Install clutch assembly.
6. Install transmission assembly.
62
Engine mechanism - Cylinder cover gasket components
Cylinder cover gasket components

Replacement
2. Remove timing chain assembly.
3. Remove camshaft.
As sequences shown in the diagram, evenly loosen at
several times, and remove 19 bearing cover bolts, and then
remove 9 bearing covers of intake camshaft and exhaust
camshaft.
4. Remove cylinder head assembly.

(a) Remove warm air water outlet pipe from cylinder head.
(b) As shown in the diagram, evenly loosen 10 cylinder head
bolts with 10mm dual hexagonal sleeves at several times,
and then remove 10 cylinder head bolts and plain washer.
Notes:
Be careful not to let washer fall into cylinder head.
Incorrect disassembling sequence will cause cylin-
der head warp or chap.
5. Remove cylinder head gasket components
[4G18-1003160].
6. Install cylinder head gasket components.
Put new cylinder head gasket on the cylinder body.
Notes:
Pay attention to installation direction.
Gently put down cylinder head to avoid damaging
cylinder head gasket.
7. Install cylinder head assembly.

Hint: Lock up cylinder head bolts as 2 steps.
(a) Coat a thin layer of engine oil at bolt thread and the bottom
of bolt head.
(b) As shown in the diagram, evenly tighten 10 cylinder head
bolts and plain washer with 10mm dual hexagonal sleeves
at several times.
Torque:
63
Engine mechanism - Cylinder cover gasket components
(c) Tighten each cylinder head bolt in turn again.

Torque: m
(d) Install heating air water outlet pipe components.

Torque:
8. Install camshaft.
(a) Coat engine oil on camshaft journal.
(b) Put 2 camshafts on cylinder head and with cylinder 1 cam-
shaft end toward the direction shown in the diagram.
(c) Check forward remarks and figures of all bearing cover, and
tighten the bolts as sequences shown in the diagram.
Torque:
Camshaft front bearing cover:
Camshaft bearing cover:
9. Check idle speed and ignition timing.

10. Check compression pressure.
11. Check CO/HC.
64
Exhaust - Exhaust pipe assembly
Exhaust
Exhaust pipe assembly
1. Remove oxygen sensor.
(a) Uncouple oxygen sensor joint.
(b) Remove oxygen sensor.
2. Remove exhaust pipe guard [64000051].
3. Remove front exhaust pipe together with three-way catalytic converter assembly
[64000042].
4. Remove middle exhaust pipe together with middle silencing device assembly [64000043].
5. Remove rear exhaust pipe together with rear silencing device assembly [64000044].
6. Install front exhaust pipe together with three-way catalytic converter assembly [64000042].
(a) Measure free length of compression spring with vernier caliper.
Free length: 43mm
Hint: if the free length does dot reach the standard value, it is necessary to replace compres-
sion spring.
(b) Gently knock silencing device inlet seal ring to exhaust manifold with hammer and wooden block until
the surfaces are parallel and level with each other.
Notes:
Gently knock gasket toward positive direction.
Do not repeat using the gasket that has been removed.
Do not push the gasket in by means of tightening
bolt connection.
(c) Install exhaust pipe. wooden
block
Torque: 43 N.m
7. Install oxygen sensor.
Torque: 44 N.m Gaskett
8. Install middle exhaust pipe together with middle si-
lencing device assembly [64000043].
Couple front intake pipe of middle exhaust pipe together with
middle silencing device assembly with outlet pipe of front ex-
haust pipe together with three-way catalytic converter using a Tail pipe side
new gasket.Torque: 43 N.m
9. Install rear exhaust pipe together with rear guard
assembly [64000044].
(a) Measure free length of compression spring with vernier Gasket
caliper.
Free length: 40mm
Hint: if the free length does dot reach the standard value, it is necessary to replace com-
pression spring.
(b) Install tail pipe to front pipe using a new gasket.
Torque: 43 N.m
10. Install front exhaust pipe guard [64000051].
11. Check there is gas leakage with exhaust system.
65
Cooling - Cooling syste
Cooling
Cooling system
1. Check there is leakage with cooling system.
Warning: when the temperature of engine and radiator is
high, do not remove radiator cap to avoid be-
ing scalded, because coolant and steam will
spurt under high pressure.
(a) Refill coolant to radiator, and install radiator cap tester.
(b) Preheat engine.
(c) Pump tester to make pressure go up to 118KPa, and check
the pressure falls.
Hint: if the pressure falls, check there is leakage with
hose, radiator or water pump, and check heater,
cylinder body and cylinder head if no external leak-
age is found.
2. Check engine coolant level in reservoir.

Engine coolant level should be between Low and Full mark line.
Hint: if the level is too low, check there is leakage and refill coolant to Full mark line.
3. Check engine coolant quality.
(a) Remove radiator cap.
Warning: when the temperature of engine and radiator is high, do not remove radiator cap to
avoid being scalded, because coolant and steam will spurt under high pressure.
(b) Check there is too much rust deposit around radiator cap or at outlet and check there is flake; there
should not be oil in the coolant.
Hint: if coolant is too dirty, it is required to replace coolant.
(c) Install back radiator cap.
Inspection
1. Temperature regulator
Hint: the figure on temperature regulator is the
opening temperature of valve.
66
Cooling - Cooling syste
(a) Immerse temperature regulator into water and heat

gradually.
(b) Check opening temperature of valve.
Opening temperature of valve: 80 84
Hint: if opening temperature of valve is not within
specified range, it is required to replace tempera-
ture regulator.
(c) Check opening of valve.
Opening of valve:
Temperature Degree of valve opening
Hint: if degree of valve opening is not within speci-

fied range, it is required to replace tempera-
ture regulator.
(a) When temperature regulator is at low temperature (below
), check valve is tightly closed.
Hint: if the valve could not be closed, it is required to
replace temperature regulator.
2. Radiator cap assembly
Notes:
If radiator is dirty, wash it with clean water.
Before using radiator cap tester, dampen relief valve
and pressure valve with coolant or water.
(a) Use radiator cap tester to slowly pump radiator cap
tester, and check the air is released by vacuum valve.
Pumping speed: 1 time /(3 seconds or more)
Note: pump radiator tester with constant speed.
Hints:
Pumping speed: 1 time /(3 seconds or more)
If air could not be released by vacuum valve,
please replace radiator cap.
(b) Pump tester and check opening pressure of relief valve.

Standard opening pressure: 74-108KPa
Min. opening pressure: 59KPa
Note: pumping speed means that the speed could be increased after the first time pumping
speed (to close vacuum valve).
Hints:
Pumping speed: 1 time within 1 second
Max. reading of tester is opening pressure.
If opening pressure is less than min. value, please replace radiator cap.
67
Cooling - Cooling fan system
Cooling fan system

1. Check cooling fan function at low temperature (below 95 ).
(a) Turn ignition switch to ON.
(b) Check cooling fan is stopped.
Hint: if it is not stopped, check cooling fan relay and water temperature sensor, or check the
joint or wire harness between them.
(c) Uncouple water temperature sensor joint.
(d) Check cooling fan runs.
If it does not run, check fuse, cooling fan relay, engine ECU and cooling fan, or check there is short
circuit between them.
(e) Connect back water temperature sensor joint.
2. Check cooling fan function at high temperature (above 95 ).
(a) Start engine and increase coolant temperature up to above
Hint: water temperature is the value measured by water temperature sensor on water outlet.
(d) Check cooling fan runs.
Hint: if it does not run, please replace water temperature sensor.
3. Check cooling fan.
(a) Uncouple cooling fan joint.
(b) Connect battery and ampere meter to cooling fan joint.
(c) Check cooling fan runs normally and check ampere meter reading.Standard current: 7 12A
(d) Connect back cooling fan joint.
Inspection
1. Electronic fan relay [67000064]
Terminal connected Specified
Conditions
by three-use meter conditions
Normal state Conduction

Supply battery voltage
to No. 1 and No. 2 Conduction
terminals
2. Electronic fan relay II [67000072]

Conditions

terminals
3. Cooling fan speed adjusting resistance assembly
[67000001]
Measure resistance between terminals with ohmmeter.
Resistance: at normal temperature: 1.3
68
Cooling - Water pump assembly
Water pump assembly

Replacement
2. Discharge engine coolant.
Slowly turn drive belt tensioner clockwise to loosen the belt;
then remove drive belt and put back drive belt tensioner slowly
to completely loosen the tensioner.
4. Remove alternator assembly.

(a) Remove rubber cover and nuts.
(b) Uncouple alternator joint.
(c) Remove 2 bolts and alternator.
5. Remove water pump assembly.

Remove 6 bolts, water pump and o-ring.
69
Cooling - Water pump assembly
6. Install water pump assembly.

(a) Install new o-ring on water pump.
(b) Install water pump with 6 bolts.
Torque: bolt A:
Bolt B:

Torque: 12mm bolt head:
14mm bolt head:
8. Refill engine coolant.

9. Check there is leakage with coolant.
70
Cooling - Temperature regulator components
Temperature regulator components

Replacement
Slowly turn drive belt tensioner clockwise to loosen the belt;
then remove drive belt and put back the tensioner slowly to
completely loosen it.
4. Remove alternator components.

5. Remove water inlet pipe.
6. Remove temperature regulator.
7. Install temperature regulator.
(a) Install new gasket to temperature regulator.
(b) As shown in the diagram, install temperature regulator with
inching valve toward upward.
8. Install water inlet pipe and joint.

Torque:
9. Install alternator installation components.

Torque: 12mm bolt head: m
14mm bolt head:

71
Cooling - Radiator with electronic fan assembly
Radiator with electronic fan assembly

Replacement
1. Discharge coolant (see Page 73).
2. Disassemble radiator water inlet hose [64000062].
3. Disassemble radiator water outlet hose [64000063].
4. Disassemble No.1 oil cooler inlet pipe (auto gear).
5. Disassemble No.1 oil cooler outlet pipe (auto gear).
6. Disassemble fixing clips of 2 wire harnesses from fan cover.
7. Remove mounting bracket assembly on radiator [64000058].
8. Remove radiator together with electronic fan assembly [64000057].
9. Remove electronic fan together with fan cover assembly [64000060].

(a) Screw off fixed nuts connecting electronic fan together with fan cover assembly with radiator.
(b) Uncouple fan motor joint.
(c) Remove 2 bolts of fan.
(d) Remove fan motor at the same time.
10. Replace and install as sequences opposite to the above.
11. Refill engine coolant (see Page 73).
12. Check there is leakage with coolant (see Page 66).
72
Cooling - Coolant
Coolant
Replacement
Warning: when the temperature of engine and radiator is high, do not remove radiator cap to
avoid being scalded, because coolant and steam will spurt under high pressure.
(a) Remove radiator cap.
(b) Open radiator drain valve and engine drain valve.
Engine drain valve
Radiator cap
Radiator drain valve

Drain pipe

(a) Lock 2 drain valves and pour coolant into radiator until it is full.
Hints:
Press radiator water inlet hose and outlet hose with hands several times.
If coolant level is too low, please refill coolant again.
(b) Screw down radiator cap.
(c) Pour coolant into expansion tank until the level is up to FULL mark line.
(d) Run engine with vehicle warning up until thermostat valve is opened.
Hint:During vehicle warning up, press radiator water inlet hose and outlet hose with hands
several times.
(e) Engine flames out until coolant temperature falls to cold. Then open radiator cap and check coolant
level.
(f) If coolant level is too low, please perform the above steps again.
(g) If coolant level is not too low, please adjust expansion tank coolant level.

(a) Refill engine coolant to radiator, and install radiator cap tester.
(b) Pressurize radiator to 118kPa, and check there is leakage.
73
Lubrication - lubricating system
Lubrication
Lubricating system
1. Check oil level.
During engine warming up and after it flames out for 5 minutes, check oil level, and the level should
be between two marks on oil dipstick at the moment.If oil level is too low, check there is leakage, and
refill oil up to upper mark on oil dipstick.
Note: oil level should not be above upper mark on oil
dipstick. Recommended viscosity (SAE)
2. Check oil quality.

(a) Check there is deterioration, water penetration, color
change or thinning with oil.
(b) If oil quality becomes poor, please replace with new oil.
Hint: oil grades: API, SH, SJ, SG grade oil or ILSAC Temperature range in forecasting next
multigrade oil. Recommended viscosity is oil replacement
shown as below.
The temperature increases from left to right.
3. Remove oil pressure alerter assembly.
(a) Uncouple oil pressure alerter joint.
Oil pressure alerter
4. Install oil pressure gauge. Oil pressure gauge

Install oil pressure gauge.
5. Warm up vehicle.
6. Check oil pressure.
Oil pressure:
7. Install oil pressure alerter.

(a) Coat adhesive on 2nd or 3rd circle thread of oil pressure
alerter. Adhesive
Adhesive: anaerobic pipe thread sealing adhesive
1545 (Kesaixin 1545).
Torque: m
(c) Connect oil pressure alerter joint.
8. Start engine and check there is leakage.
74
Lubrication - Oil filter assembly
Oil filter assembly

Replacement
Warning:
Long-term or repeat contacting mineral oil will cause decomposing of natural fat on skin, which
will result in dry and sensitive skin and skin rankling. Used oil has potential harm and may cause
carcinoma cutis.
When replacing engine oil, always wear protective clothes and gloves to avoid waste oil
penetrating, and reduce the frequency and time of skin contacting waster oil, and clean with
soapy water or clean water not with gasoline, thinner or solvent if skin contacts waste oil.
To protect environment, waste oil and oil filter must be abandoned at named place.
2. Discharge engine oil.
3. Remove oil filter assembly [4G18-1012100]. Special tool

Remove oil filter with special tool.
4. Install oil filter assembly.

(a) Check and clean oil filter junction plane.
(b) Coat oil seal of new oil filter with clean oil.
(c) Tighten oil filter with hands to the extent that oil seal
just touches fixing base.
3/4 circle
(d) Tighten oil filter for another 3/4 circle with special tool. Special tool
5. Install oil drain plug [4G18-1009101].

Clean oil drain plug, and install it back after replacing oil drain plug gasket.
Torque:
6. Refill engine oil.

75
Lubrication - Oil pump assembly
Oil pump assembly

Replacement
1. Remove timing chain assembly (see Page 45).
2. Remove oil pump assembly [4G18-1011100].

Remove 5 bolts, oil pump and oil pump gasket.
3. Install oil pump assembly.

(a) Install new gasket on cylinder body.
(b) Align the guide groove of oil pump drive rotor with the key
on crankshaft, and slide the oil pump in.
(c) Install oil pump with 5 bolts.
Torque:
76
Ignition - Ignition system
Ignition
Ignition system
Spark plug
Inspection cleane
1. Spark plug
(a) Clean spark plug.
Air pressure: below 588kPa.
Time: 20 s or less
(b) Check the damage condition of spark plug and insulator. If

there is something abnormal, please replace with new spark
plug.
Recommended spark plug specification:
Made in Xianghuoju Company: K6RTC
(c) Adjust electrode gap.

Electrode gap: 0.8mm
1. Phase sensor
(a) Turn on ignition switch but do not start engine, and place digital universal meter at DC voltage gear,
then connect 2 terminals respectively to 1# pin and 3# pin of sensor, and ensure the voltage is 12V.
(b) Start engine, and phase signal is read by 2# pin via vehicle oscilloscope.
2. Speed Sensor
(a) Remove speed sensor joint.
(b) Place digital universal meter at ohm gear, and connect 2 terminals respectively to 2# pin and 3# pin of
sensor, and the resistance at should be 8601/2 801/2.
(c) Connect speed sensor joint.
(d) Place digital universal meter at AC voltage gear, and connect 2 terminals respectively to 2# pin and 3#
pin of sensor, and start engine, there should be voltage output at the moment.(It is recommended to
check with vehicle oscilloscope)
77
Ignition - Ignition system
3. Inspection of ignition coil (including igniter) and spark test

(a) Check DTC.
Note: if there is display with DTC, perform trouble shooting according to DTC procedure.
(b) Check there is spark.
(1) Remove ignition coil (including igniter).
(2) Remove spark plug with 16mm spark plug sleeve.
(3) Install spark plug to each ignition coil (including igniter), and connect ignition coil joint.
(4) Uncouple joints of 4 injection nozzles.
(5) Earth spark plug.
(6) Check spark with engine running.
Notes:
Be sure to earth spark plug during checking.
When there is falling or collision with ignition coil,please replace with a new one
Running engine time for each time should not be more than 2 seconds.
If there is no spark, please perform test as the following steps.
(c) Install spark plug with 16mm spark plug sleeve.
Torque:
(d) Install ignition coil and igniter.
Torque:
4. Test procedure in the state of not spark
Spark test
Perform step 3
Replace bad spark plug with a good one, and perform spark test again.
Replace with a new spark plug
Replace with a new ignition coil (including igniter)
Replace all spark plugs with new ones, and perform spark plug again.
Spark plug is not good
Replace bad ignition coil (including igniter) with a new one.
78
Starting and charging - Starting system
Starting and charging

Starting system
Inspection
1. Starter installation components
Note: this test must be finished within 3 to 5 seconds to
avoid burning out coil.
(a) Remove nut at C terminal to uncouple wire of field coil.
(b) As shown in the diagram, connect battery wire to electro-
magnetic switch, and check drive pinion is pushed outside,
(pull-in coil and hold-in coil).
Terminal C
Terminal 50
(c) As shown in the diagram, uncouple negative wire from ter-

minal C after the above connections, and check drive pin-
ion is still at the state of being pushed outside.(Hold-in coil)
Terminal C
Terminal 50
(d) Push drive pinion toward armature side, and measure the
clearance between drive pinion end and stop ring.
Standard clearance: 1.0~5.0mm
(e) Uncouple negative wire from electromagnetic switch Terminal C

housing, and check drive pinion returns back to original
position toward inside.
Terminal 50
79
Starting and charging - Starting system
(f) Connect magnetic field coil wire to terminal C.

(h) Torque:
(i) Clamp starter with jaw vice.
(j) As shown in the diagram, connect battery with ampere
meter.
(k) Read current value displayed on ampere meter. Ampere
(l) Current value specification: 90 A or lower at 11.5 V. meter
Terminal 50 Terminal 30
2. Starter relay

Conditions

terminals
80
Starting and charging - Charging system
Charging system
Precautions
1. Check positive and negative wire of battery is con-
nected correctly.
2. When performing quick charge to battery, please

uncouple battery wire.
3. Do not test with high-pressure insulation resistance

tester.
4. do not uncouple battery wire during engine running.
81
1. Check battery voltage.
(a) If extinguishing time of engine is not more than 20 minutes
after driving, please turn on ignition switch and electric
equipment (head lamp, blower motor and rear window
defog line etc.) for about 60 seconds to eliminate surface
charging during driving.
(b) Turn ignition switch to OFF, and then switch off electric
equipment system.
(c) Measure the voltage between battery negative (-) terminal
and positive (+) terminal.
Standard voltage: 12.5~12.9V at 20 . Green White Black
Hint: if the voltage is lower than standard

specification, please charge battery.
(d) As shown in the diagram, check battery window.
Hints:
Green: OK
White: requiring charge
Black: replacing battery
2. Check battery joint, fusible link and slow fuse (100A).
(a) Check battery joint is loose or eroded.
(b) Check fast fuse and slow fuse (100A) are in conduction.
3. Check drive belt.
(a) Check belt is excessively worn or cable is broken etc.
Hints:
If any inferior part is found, please replace drive
belt.
It is allowable for the crack at the edge of drive belt
rib.
If there is block falling with belt rib, please replace with
new belt.
(b) Check the belt is correctly installed in guide groove.
Hint: Check with hands to ensure that the belt does
not slide out from the groove of pulley bottom.
4. Visually check alternator wire harness.
Check the condition of wire is perfect.
5. Listen to whether there is abnormal sound with alternator.
There should not be abnormal sound with alternator during engine running.
6. Check the circuit of charge alarm light.
(a) Turn ignition switch to ON, and check charge alarm light is on.
(b) Start engine, and charge alarm light should be off.
Hint: if the function of charge alarm light does not conform to the regulation, please perform
trouble shooting to the circuit of charge alarm light.
82
7. Check charging system circuit at no load.

(a) If there is battery/alternator tester, please connect tester
Ampere meter
to charging system circuit as manufacturer instruction. Uncoupling
(b) If there is no battery/alternator tester, please connect volt- terminal B wire
meter to charging system circuit as the following way.

z Uncouple wire on engine terminal B, and connect wire
on negative (-) test bar of ampere meter. Battery
z Connect positive (+) test bar of ampere meter to alter- Alternator
Voltmeter
nator terminal B.
z Connect positive (+) test bar of voltmeter to alternator
terminal B.
z Connect negative test bar of voltmeter to earth.
(c) Check charge system circuit.

(1) Check the readings of ampere meter and voltmeter with engine from idle speed to 2000rpm.
Standard current: 10A or less.
Standard voltage: 12.9~14.9V.
Hints:
If voltmeter reading is more than standard value, please replace with new voltage regulator.
If voltmeter reading is less than standard value, please check voltage regulator and alternator
as the following way.
(2) Earth terminal F, start engine and check voltage of
terminal B. Terminal F
Hints:
If voltmeter reading is more than standard value,
please replace with new voltage regulator.
If voltmeter reading is less than standard value,
please check alternator.
8. Check charging system circuit at load.

(a) Turn on high beam of front combination lamps with engine running at 2000rpm,and turn blower to
HI position.
(b) Check the reading of ampere meter.
Standard amperage: 30A or more.
Hints:
If amperage is less than standard value, please repair alternator.
If battery is under the state of full charge, amperage may be less than standard value sometimes.
83
Starting and charging - Alternator components
Alternator components
Replacement

Slowly turn drive belt tensioner clockwise to loosen the belt,
then remove drive belt and put back the tensioner slowly to
completely loosen it.
3. Remove alternator components.

4. Install alternator components.

Torque: 12mm head bolt : m
14mm head bolt :
84
Starting and charging - Starter components
Starter components
Replacement
1. Remove engine lower left shield.
2. Remove starter components.

(b) Uncouple starter joint.
(b) Remove nuts, and uncouple starter wire.
(c) Remove 2 bolts and starter.
3. Install Starter components.

Torque: bolt:
Wire harness:
85
Front suspension - front suspension system
Front suspension
Front suspension system
Table on trouble occurrence
This table could help you find out failure causes, and each figure in the table indicates the possible
sequence of failure causes, please check every part as the sequence, and replace if necessary.
Trouble occurrence Possible trouble part Pages to refer to

1. Tire (abrasion or improper tire pressure) 109
2. Wheel alignment (incorrect) 87
Deflection/single side 3. Steering linkage (looseness or abrasion) -
4. Shaft hub bearing (abrasion) 123
5. Suspension parts (abrasion) -
6. Steering gear (poor adjustment or breakage) -
1. Vehicle (overload) -
Bottoming 2. Spring (elastic fatigue) 90
3. Absorber (abrasion) 90
Swaying left and right/ 2. Stabilizer bar (bending or breakage) 96
shaking forward and backward 3. Absorber (abrasion) 90

2. Wheel (poor balance) 109
Front wheel shimmy 4. Wheel alignment (incorrect) 87
5. Ball joint (abrasion) 99
6. Shaft hub bearing (looseness or abrasion) 123
7. Steering linkage (looseness or abrasion) -
8. Steering gear (poor adjustment or breakage) -

Abnormal tire abrasion 2. Wheel alignment (incorrect) 87
3. Absorber(abrasion) 90
86
Front suspension - Front wheel alignment
Front wheel alignment

Adjustment
1. Inspection
(a) Check tire is worn and inflation pressure is proper.
Tire inflation pressure under normal temperature:
Tire size Front and rear kPa
*1 It is used under the condition of speed below 160 km/h.

*2 It is used under the condition of speed above 160 km/h.
(b) Check tire run-out with dial indicator.
Tire run-out: 3.0mm.
2. Measurement of vehicle height

Vehicle height:
(General road)
Front
Rear
(Coarse road)
Front
Rear
Measuring point:
A. Height for ground and front wheel center
B. Height for ground and bolt center in front of lower
control arm
C. Height for ground and fixed bolt center of rear axle beam
D. Height for ground and rear wheel center
Note: adjust vehicle height to standard value before checking front wheel alignment.
If vehicle height does not conform to regulations, please shake upward and downward or lift vehicle
body to adjust vehicle height.
3. Inspection of toe-in
Toe-in:
Toe-in
Front
(Total)
If toe-in is not within specification, please adjust left and

right levers of steering gear.
4. Adjustment of toe-in
(a) Remove dust cover fixing clip.
87
(b) Loosen lock nuts at the end of transversal lever .

(c) Evenly rotate end levers of left and right rack to
adjust toe-in.
Hint: try adjusting toe-in to medium value.
(d) Ensure that the end lever length of left rack equals that
of right rack.
(e) Tighten lock nuts at the end of transversal lever.
Torque: 74 5 N.m
(f) Install dust cover fixing clip.
Hint: ensure that the dust cover does not distort.
5. Inspection of turning angle
(a) Completely rotate steering wheel to the bottom and then Front
measure turning angle.
Turning angle:
(General road)
Inside wheel 38 o 45 2o
A: inside
Outside wheel: reference 32 o 50 B: outside
(Coarse road)
Inside wheel 39 o 05 2o
Outside wheel: reference 33 o10
If left and right inside wheels are not within specification, please check the end lever length of left rack
and right rack.
6. Inspection of camber, caster and steering shaft inclination
(a) Install camber-caster-kingpin gauge or erect wheel alignment tester.
(b) Check camber, caster and steering-axis inclination.
Camber, caster and steering shaft inclination:
(General road) Gauge
Wheel
alignment
Camber -0 31 45 tester
Left-right error 45
Caster 2 42 45
Left-right error 45
Steering shaft inclination 18 45
Left-right error 45
(Coarse road)
Camber - 0 18 45
Left-right error 45
Caster 2 30 45
Left-right error 45
Steering shaft inclination 10 52 45
Left-right error 45
If caster and steering axis inclination are not within specification, please adjust the caster and
then check parts of lower control arm is damaged or worn.
88
7. Adjustment of camber
Note: after adjusting the camber, please check toe-in.
(a) Remove front wheels.
(b) Remove 2 nuts under absorber.
If it is necessary to repeat using bolts or nuts, please coat
oil to thread of nuts.
(c) Clean nut absorber and attachment face of steering knucle.
(d) Temporarily install 2 nuts.
(e) Push or pull lower end of absorber in the direction that cam-
ber requires adjustment to adjust the camber.
(f) Tighten nut.
Torque: 153 10 N.m
(g) Install front wheels.
Torque: 103 10 N.m
(h) Check camber.
89
Front suspension - Front shock absorber and helical spring
Front absorber and helical spring

Overhaul
Hint: the following overhaul procedures only aim at left side (FL), and the overhaul procedures
of another side (RL) are the same as FL.
2. Separate front left stabilizer link assembly
[64000097].
Remove nuts, and disassemble stabilizer link from absorber.
Hint: if ball joint rotates with nuts, please fix bolts with
hexagonal wrench (6mm).
3. Remove front absorber and helical spring.

(a) Remove bolts, and disassemble brake hose and ABS speed
sensor wire harness bracket.
(b) Remove 2 nuts and bolts under absorber.
(c) Remove 3 nuts above absorber.

(d) Remove absorber and helical spring.
90
4. Fix front absorber and helical spring.

Install 2 nuts and 1 bolt to absorber bracket, and then fix it on
jaw vice.
5. Remove front left absorber assembly [61001036].

(a) Compress helical spring with special tool.
Note: do not use pneumatic wrench, or the special tool

will be damaged.
Special tool
(b) Remove cover from upper absorber bearing.
(c) Fix spring seat and remove nuts with special tool.
(d) Remove upper absorber bearing, dustproof seal ring, spring

seat, upper insulator, spring, limit block and lower insulator.
6. Check front left absorber assembly [61001036].

Press in and pull out absorber piston rod, and check there is
abnormal resistance or abnormal sound. If anything unusual
occurs, please replace absorber.
Note: When abandoning absorber, please refer to Page
86.
7. Install front left absorber assembly [61001036].
(a) Install lower insulator to absorber.
(b) Install limit block to piston rod.
(c) Compress helical spring with special tool.
will be damaged.
(d) Install helical spring to absorber. Special tool
Hint: install lower end of helical spring into notch of
absorber spring seat.
91
(e) As shown in the diagram, install upper insulator.

Outside
Outside
(f) Install spring seat to absorber with mark toward outside of

vehicle.
(g) Install new dustproof seal ring and upper absorber bearing.
(h) Fix upper shock absorber bearing with special tool, and
install new nuts.
Torque: 47 5 N.m
(i) Remove special tool.
(j) Install dust cover.
(k) Coat upper absorber bearing with grease. Grease

Note: do not coat grease on rubber surface of upper
shock absorber bearing.
8. Install front shock absorber and helical spring.

(a) Install 3 nuts above shock absorber.
Torque: 39 3 N.m
(b) Install 2 fixed bolts of shock absorber.
92
(c) Install 2 nuts to lower end of absorber.

Torque: 153 10 N.m
Hint: coat oil on thread of nuts.
(d) Install brake hose and ABS speed sensor wire harness
bracket with bolts.
Torque: 19 N.m
9. Install front left stabilizer link assembly [64000097].

Install stabilizer link with nuts.
Torque: 74 5 N.m
10. Install front wheels.

Torque: 103 10 N.m
11. Check and adjust front wheel alignment

(see Page 87).
Handling
1. Handle front left absorber assembly.
(a) Completely pull out absorber piston rod.
(b) As shown in the diagram, drill a small hole on cylinder body
between two lines with electric drill to make inside gas flow
out
Notes:
Iron chip may fly out during drilling, please be care-
ful in operating.
The gas is colorless, odorless and nontoxic.
93
Front suspension - Lower left control arm assembly
Lower left control arm assembly

Replacement
Hint: the replacement procedures of right side are the
same as that of left side.
2. Separate front left stabilizer link assembly
[64000097].
Remove nuts, and disassemble stabilizer link from shock
absorber.
hex wrench (6mm).
3. Separate right side front stabilizer link assembly
[64000097].
4. Remove fixed nuts of front left drive shaft (see Page
123).
5. Separate front left wheel speed sensor assembly [67000020].
6. Separate front left brake wheel pump assembly (see Page 141).
7. Remove front left brake assembly [64000134] (see Page 142).
8. Separate left side transversal lever assembly.
9. Separate lower left control arm assembly [64000091].
Remove bolts and 2 nuts, and separate lower control arm
from lower end ball joint.
10. Remove front left shaft hub assembly (see Page
123).
11. Remove lower left control arm assembly
[64000091].
Remove 2 bolts, nuts and lower control arm.
12. Temporarily lock up lower left control arm as-
sembly [64000091].
Install lower control arm, and temporarily lock up 2 bolts
and nuts.
13. Install front left shaft hub assembly (see Page
123).
14. Install lower left control arm assembly [64000091].
Connect lower control arm with ball joint with 2 bolts and nuts.
Torque: 142 10 N.m
15. Install left side transversal lever assembly. (See Page 123)
16. Install front left brake assembly. [64000134] (See Page 141)
94
Front suspension - Lower left control arm assembly
17. Install front left brake wheel pump bracket as-

sembly (see Page 141).
18. Install fixed nuts of front left drive shaft (see
Page 123).
19. Install front left stabilizer link assembly
[64000097].
Install stabilizer link with nuts.
Torque: 74 5 N.m
hex wrench (6mm).
20. Install front right stabilizer link assembly
[64000097].
Hint: the installation procedures of right side are the
21. Align suspension.
(a) Install front wheels and lay down vehicle from the lift.
Torque: 103 10 N.m
(b) Align suspension components by means of lifting ve-
hicle several times.
22. Completely lock up lower left control arm assem-
bly [64000091].
Completely tighten 2 bolts and nuts.
Torque: 137 10 N.m
23. Check and adjust front wheel alignment
(see Page 87).
24. Check ABS sensor signal.
95
Front suspension - Front stabilizer bar
Front stabilizer bar

Overhaul
1. Remove dust cap inside steering column (see Page 194).
2. Separate steering sliding shaft assembly (see Page 205)
4. Remove right engine bottom shield.
5. Remove left engine bottom shield.
6. Remove front left stabilizer link assembly

[64000097].
Remove 2 nuts and take down stabilizer link.
7. Remove front right stabilizer link assembly
[64000097].
Hint: the removal procedures of right side are the same
as that of left side.
8. Check front left stabilizer link assembly.
(a) As shown in the diagram, before installing nuts, shake joint
bolts forward and backward 5 times.
(b) Shake nuts continuously with torque wrench at the speed
of one circle per 2 4 s, and then read out torque value at
the 5th circle.
Rotating torque: 0.05~1.0 N.m
9. Separate left side transversal lever assembly (see Page 113).
10. Separate right side transversal lever assembly (see Page 113).
11. Separate oil pipe assembly (see Page 205).
12. Separate steering gear oil return pipe (see Page 205).
13. Separate lower left control arm assembly [64000091] (see Page 94).
14. Separate lower right control arm assembly [64000092] (see Page 94).
15. Remove sub frame assembly [64000087] (see Page 205).
96
16. Remove front stabilizer bar.

(a) Remove 4 bolts, bracket and bush.
(b) Remove stabilizer bar.
17. Install front stabilizer bar.

(a) Install bracket and bush with 4 bolts.
Hint: install bush to bush stop ring outside of Outside

stabilizer bar.
18. Install sub frame assembly [64000087]

(see Page 205).
Rear
Bush stop ring
side
19. Connect lower left control arm assembly [64000091] (see Page 94).
20. Connect lower right control arm assembly [64000092] (see Page 94).
21. Connect power steering oil pipe assembly (see Page 205).
22. Connect steering oil return pipe (see Page 205).
23. Connect left side transversal lever assembly (see Page 113).
24. Connect right side transversal lever assembly (see Page 113).
25. Install front left stabilizer link assembly

[64000097].
(a) Install front stabilizer link with 2 nuts.
Torque: 74 5 N.m
26. Install front right stabilizer link assembly
[64000097].
27. Install right engine bottom shield.
28. Install left engine bottom shield.
Torque: 103 10 N.m
97
30. Connect steering sliding shaft (see Page 205).
31. Check front wheel center line.
32. Install dust cover inside steering column.
33. Refill power steering oil (see Page 200).
34. Discharge air of power steering oil (see Page 200).
36. Check and adjust front wheel alignment (see Page 87).
98
Front suspension - Front left lower control arm ball joint assembly
Front left lower control arm ball joint assembly

Replacement
Hint: the replacement procedures of right side are the same as that of left side.
2. Remove front left shaft hub nuts (see Page 123).
3. Disassemble front left speed sensor assembly [67000020] (see Page 123).
4. Disassemble front left brake wheel pump assembly and brake block (see Page 141).
5. Remove front left brake assembly [64000134] (see Page 141).
6. Disassemble left side transversal lever assembly (see Page 123).
7. Disassemble lower left control arm assembly [64000091] (see Page 94).
8. Remove front left shaft hub assembly (see Page 123).
9. Remove lower left control arm ball joint assembly [64000093] (see Page 123).
10. Check lower left control arm ball joint assembly [64000093].
(a) As shown in the diagram, before installing nuts, shake
joint bolts forward and backward 5 times.
(b) Shake nuts continuously with torque wrench at the
speed of one circle per 2~4 s, and then read out torque
value at the 5th circle.
Rotating torque: 1.0~4.9 N.m
11. Install lower left control arm ball joint assembly

[64000093] (see Page 123).
12. Install front left shaft hub assembly
(see Page 123).
13. Install lower left control arm assembly [64000091] (see Page 123).
14. Install left side transversal lever assembly (see Page 123).
15. Install front left brake assembly [64000134] (see Page 141).
16. Install front left brake wheel pump assembly and brake block (see Page 141).
17. Install front shaft hub nuts (see Page 123).
Torque: 103 10 N.m
19. Check and adjust front wheel alignment (see Page 87).
99
Rear suspension - rear suspension system
Rear suspension
Rear suspension system
Table on trouble occurrence
This table could help you find out failure causes, and each figure in the table indicates the possible
sequence of failure causes, please check every part as the sequence, and replace if necessary.
Trouble occurrence Possible trouble part Pages to refer to

Wandering 2. Wheel alignment (incorrect) 101
3. Shaft hub bearing (abrasion) 129
1. Vehicle (overload) -
Bottoming 2. Spring (elastic fatigue) 102
Swaying left and right/ 1. Tire (abrasion or improper tire pressure) 109
shaking forward and 2. Rear stabilizer bar (bending or breakage) 105
backward 3. Absorber (abrasion) 102
Rear wheel shimmy 2. Wheel (poor balance) 109
4. Wheel alignment (incorrect) 101
Abnormal tire abrasion 2. Wheel alignment (incorrect) 101
100
Rear suspension - Rear wheel alignment
Rear wheel alignment

Adjustment
1. Check tire (see Page 109).
2. Measure vehicle height (see Page 87).
Note: adjust vehicle height to standard value before checking
vehicle tire alignment.
3. Inspection of toe-in
Toe-in:
(General road)
Toe-in
Front
(Total)
(Coarse road)
Toe-in
(Total)
If toe-in is not within specification, check and replace relevant suspension parts.
4. Inspection of camber
(a) Install camber-caster-kingpin gauge or erect wheel alignment tester.
(b) Check camber.
Camber:
(general road)
Camber 27 45
Left-right error
(Coarse road)
Camber
Left-right error
For camber could not be adjusted, therefore check suspension components are damaged or worn if
camber measuring value is not within specification, and replace parts if necessary.
101
Rear suspension - Rear strut assembly
Rear strut assembly

Overhaul
Hint:the following overhaul procedures only aim at left side (LH), and the overhaul procedures
of another side (RH) are the same as LH.
1. Remove rear wheels.
2. Remove rear left seat backrest assembly [68010078] (see Page 352).
3. Remove spare tire trim cover assembly.
4. Remove rear floor trim
5. Remove trunk left garnish [68000112].
6. Remove rear left strut assembly [64000098].
(a) Support rear shaft with a jack. Wooden
block
(b) Remove 2 nuts and bolts.
(c) Remove nuts, gasket and rear strut assembly.
7. Remove rear left strut assembly [64000098].

will be damaged.
Special tool
102
(b) Fix piston rod with a hexagonal wrench of 6mm, and remove
nuts.
(c) Remove bracket plate, washer, spring bracket, upper
separator, suspension pedestal, spring absorber and heli-
cal spring.
8. [64000098]
Press in and pull out absorber piston rod, and check there is
abnormal resistance or abnormal sound.
If anything unusual occurs, please replace absorber.
Note: When abandoning absorber, please refer to
Page 97.
9. Install rear left strut assembly [64000098].

Note: do not use pneumatic wrench, or the special Special

tool will be damaged. tool
(b) Install helical spring to absorber.
Hint: install lower end of helical spring into notch of

lower spring seat.
(c) Install spring absorber and suspension bracket.
(d) Encase upper separator into spring bracket.
(e) As shown in the diagram, it is the position of upper

separator encased into spring bracket.
(f) Install washer and bracket plate.
(g) Temporarily lock up new center nuts.
(h) Remove special tool.
(i) Check spring bracket direction again.
103
(j) Fix piston rod with a hexagonal wrench of 6mm, and tighten
nuts.
Torque: .m
10. Temporarily lock up rear strut assembly.

(a) Install rear strut, and temporarily lock up nuts and gasket.
(b) Install 2 nuts and bolts.

Torque:
11. Install real left seat backrest assembly [68010078].

(a) Lay down vehicle from the lift after installing rear wheels.
Torque:
(b) Align suspension components by means of lifting
vehicle several times.
13. Completely lock up rear strut assembly.
Completely tighten nuts.
Torque: .m
14. Check rear wheel alignment (see Page 101).
Handling
1. Handle rear left strut assembly [64000098].
(a) Completely pull out shock absorber piston rod.
(b) As shown in the diagram, drill a small hole on cylinder body
between two lines with electric drill to make inside gas flow
out.
Notes
Iron chip may fly out during drilling, please be care-

ful in operating.
The gas is colorless, odorless and nontoxic.
104
Rear suspension - Rear stabilizer bar
Rear stabilizer bar

Overhaul
1. Remove rear stabilizer bar assembly.
Remove 2 bolts, nuts and stabilizer bar.
2. Install rear stabilizer bar assembly.
Install 2 bolts, nuts and stabilizer bar.
Torque:
Hint: install the tag on balance bar toward rear right

side of vehicle.
Front
Tag
105
Rear suspension - Rear shaft assembly
Rear shaft assembly

Overhaul
1. Remove rear wheels.
2. Disassemble rear left brake caliper assembly
(see Page 144).
3. Disassemble rear right brake caliper assembly
(see Page 144).
4. Disassemble rear wheel speed sensor wire harness
(a) Uncouple sensor joint.
Special
(b) Remove 2 bolts and disassemble wire harness retaining tool
clip.
5. Remove rear left/right brake assembly [64000137/
64000139].
(See Page 144)
6. Remove rear stabilizer bar assembly (see Page 105).
7. Disassemble rear left/right strut assembly

(see Page 102).
8. Remove rear shaft assembly [64000120].
(a) Support rear shaft assembly with a jack.
(b) Remove 2 bolts, gasket and rear shaft.
106
9. Remove left side rear shaft gum cover assembly. Installation remark
(a) Inscribe 2 matching marks at the dent part of gum cover
and axle beam.
(b) Bend two parts of bush frame with chisel and hammer.
Hint: bend bush frame until it reaches the hook of spe- Dent
cial tool.
(c) Remove gum cover from axle beam with special tool. Special
tool
Bending part
Dent
Hint: if axle beam is damaged, please spray paint.
10. Remove right side rear shaft gum cover assembly.
Hint: the removal procedures of right side are the
11. Remove left side rear shaft gum cover assembly.

(a) Align the dent on new bush with the matching mark
previously making on axle beam, and then temporarily
encase gum cover into axle beam.
(b) Encase gum cover into axle beam with special tool.
Notes:
Rubber Special tool
The hook of special tool should be deeply and
port
actually inserted into gum cover.
Do not damage the rubber port of gum cover.
O Do not deform gum cover frame.
12. Install right side rear shaft gum cover assembly.
13. Temporarily lock up rear shaft assembly

[64000120].
(a) Support rear shaft with a jack.
(b) Install rear shaft, 2 bolts and gasket, and then tempo-
rarily lock up 2 nuts.
107
14. Temporarily lock up rear left strut assembly.

(a) Install rear left strut and gasket, and temporarily lock
up nuts.
(b) Perform to another side in the same way.
15. Install rear stabilizer bar assembly (see Page 105).

16. Install rear left/right brake assembly [64000137/64000139] (see Page 144).
17. Install rear wheel speed sensor wire harness.
Install wire harness and parking brake cable with 2 bolts and retaining clips.
Torque: (A) 5.4 N.m
(B) 5.0 N.m
18. Install rear left brake caliper assembly
(see Page 144).
19. Install rear right brake caliper assembly
(see Page 144).
(a) Lay down vehicle from the lift after installing rear wheels.
Torque:
(b) Align suspension components by means of lifting ve-
hicle with a jack several times.
21. Completely lock up rear shaft assembly
[64000120].
(a) Completely tighten bolts and pull on open pin.
Torque: m
22. Completely lock up rear left strut assembly.

(a) Completely tighten bolts.
Torque: m
23. Check rear wheel alignment (see Page 101).

108
Tire and wheel- wheel and tire system
Tire and wheel

Wheel and tire system
Inspection
1. Check tire.
(a) Check tire is worn and inflation pressure is proper.
Cold tire inflation pressure:
Tire size Front and rear kPa
*1 It is used under the condition of speed below 160 km/h.

(b) Check tire run-out with dial indicator.
Tire run-out:
2. Adjust tire position.
Hint: see adjusting position of tire shown in the dia-
gram whether there is spare tire or not.
Front
3. Check wheel balance.

(a) Check and adjust with off-the-car balancing machine.
(b) Check and adjust with in-the-car balancing machine if
necessary.
Unbalanced mass after adjusting:
4. Check axial clearance of front wheel bearing

(see Page 123).
5. Check end surface run-out of front wheel shaft hub
(see Page 123).
6. Check axial clearance of rear wheel bearing
(see Page 129).
7. Check end surface run-out of rear wheel shaft hub
(see Page 129).
8. Check front suspension is loose.
9. Check steering linkage is loose.
10. Check ball joint is loose.
109
Tire and wheel- wheel and tire system
11. Check the function of absorber is normal.

Check there is oil leakage.
Check liner clamp is worn.
Shake the front and rear of vehicle.
110
Drive shaft--Driveshaft
Drive shaft
Drive shaft
Notes
Note: if happening any malfunction, it is necessary to change the exterior joint assembly of trans-
mission shaft.
1. Check front drive shaft assembly.
Exterior joint assembly
58
Malfunction phenomenon table
Malfunction phenomenon Possible malfunction part Reference page
1. Steering connecting rod (loosened or abraded) -
Offset
2. Bearing of shaft hub (abraded) 123
1. Ball joint (abraded) 123
Shake of front wheels 2. Bearing of shaft hub (abraded) 123
3. Steering connecting rod (loosened or abraded) -
1. Inner joint (abraded) 113
Abnormal noise
2. Exterior joint (abraded) 113
111
Drive shaft--Drive shaft
Inspection on automobile
1. Check the bearing of front wheel hub
(a) Disassemble the front wheels.
(b) Disassemble front brake caliper assembly.
(c) Disassemble front brake.
(d) Check the axial clearance of bearing (referring to page 123)
(e) Check the terminal run-out of shaft hub (referring to page 123).
(f) Assemble front brake.
(g) Assemble front brake caliper assembly.
Torque: 106 10 Nm
(H) Assemble front wheel.
Torque: 103 10 Nm
2. Check the bearing of rear wheel hub.
(a) Disassemble rear wheels.
(b) Disassemble rear brake caliper assembly.
(c) Disassemble rear brake.
(d) Check the axial clearance of bearing (referring to page 129)
(e) Check the terminal run-out of shaft hub (referring to page 129).
(f) Assemble rear brake.
(g) Assemble rear brake caliper assembly.
Torque: 46 5 Nm
(H) Assemble rear wheel.
Torque: 103 10 Nm
112
Drive shaft--Front drive shaft
Front drive shaft

Overhaul
Hint: overhaul procedure for right side is same as the left
side.
1. Check the drive shaft (referring to page 111).
2. Discharge the oil in gearbox.
(a) Disassemble oil plug and gasket to discharge the oil in
gearbox.
(b) Change with a new gasket and assemble oil discharging
plug.
Torque: 45 5 Nm
3. Disassemble front wheels.
4. Disassemble fixing nut of drive shaft [64000083]
(a) Use special tool and hammer to unclench the concave part
special
of fixing nut. tool
(b) Disassemble the fixing nut.
5. Disassemble speed sensor assembly of left front

wheels (equipping with ABS) [67000020]
(a) Disassemble the bolt, and disassemble sensor wiring har-
ness and brake hose from the absorber.
(b) Disassemble the bolt, and disassemble speed sensor from

steering knuckle.
113
6. Disassemble left transversal lever assembly.

(a) Disassemble cotter pin and screw cap. special tool
(b) Use special tool to disassemble terminal assembly from

steering knuckle.
7. Disassemble left lower control arm assembly

[64000091]
Disassemble the bolt and two nuts, then disassemble lower
control arm from lower ball joint.
8. Disassemble wheel hub assembly of left front wheel.

Use plastic hammer to disassemble drive shaft from wheel hub.
Note: forbid damaging dust-proof cover and the rotator of
speed sensor.
9. Disassemble left front drive shaft assembly

[64000082]
(a) Disassemble the seal board of left front fender.
(b) Use special tool to disassemble front drive shaft assembly.
Note: do not damage oil seal.
10. Fix left front shaft hub assembly.

Note: if supporting automobile weight only with bearing,
shaft hub bearing will be damaged; for example, when
moving automobile in process of disassembling drive
special tool
shaft. So, if it is not necessary to support automobile
weight with shaft hub bearing, it is necessary to use
special tool to support.
11. Disassemble No.2 fixing clamp of inner joint dust-

proof cover of left front drive shaft.
(a) Single-contact fixing clamp type:
Use screw driver to disassemble No.2 fixing clamp of inner
joint dust-proof cover of left front drive shaft.
114
(b) Mesh clamp type:

Liking that shown in figure, use pliers to disassemble No.2
fixing clamp of inner joint dust-proof cover of left front trans-
Pliers clamp
mission shaft.
12. Disassemble fixing clamp of inner joint dustproof

cover of left front drive shaft.
Use screw driver to disassemble fixing clamp of inner joint
dust-proof cover.

Liking that shown in figure, use pliers to disassemble No.2
fixing clamp of inner joint dust-proof cover.
13. Disassemble inner joint dustproof cover of left front Pliers

drive shaft. clamp
Disassemble dustproof cover from left inner joint.
14. Disassemble inner joint of left front drive shaft.

(a) Remove old lubricating grease of inner joint.
Align the mark
(b) Make mark on inner joint and drive shaft.
Note: do not use punch to make mark.
(c) Disassemble inner joint assembly from drive shaft.
(d) Use clasp spreading pliers to disassemble the clasp.
115
(e) Make mark on transmission shaft and triangle joint. Copper stick
Note: do not use the punch to make mark. Align the mark
(f) Use copper stick and hammer to disassemble triangle joint.

Note: do not knock the stator position.
(g) Disassemble No.2 fixing clamp of inner joint dustproof cover
and fixing clamp of inner joint dustproof cover.
15. Disassemble the absorber of drive shaft (right trans-

mission shaft). Single-contact fixing
clamp type
Liking that shown in figure, use screw driver to disassemble
fixing clamp.
(b) Mesh clamp type.
Liking that shown in figure, use pliers to disassemble fixing
clamp.
(c) Disassemble dynamic absorber of drive shaft. Mesh clamp type
16. Disassemble No.2 fixing clamp of exterior joint

dustproof cover of left front drive shaft.
(a) Use screw driver to disassemble No.2 fixing clamp of exte-
rior joint dustproof cover.
17. Disassemble fixing clamp of exterior joint dustproof

(a) Use screw driver to disassemble fixing clamp of exterior
joint dustproof cover.
18. Disassemble fixing clamp of exterior joint dustproof

cover (B type and C type).
(a) Disassemble dustproof cover of exterior joint.
(b) Remove old lubricating grease of exterior joint.
116
19. Disassemble clasp of inner joint of left front drive

shaft.
Use screw driver to disassemble the clasp.
20. Disassemble dustproof cover of left front drive

shaft.
Use special tool and press to disassemble dustproof cover .
Special tool
21. Assemble dustproof cover of left front driveshaft.

Liking that shown in figure, use special tool and press to as-
semble left dustproof cover
Note: Dustproof cover should be assembled to its position
completely.
Do not damage dustproof cover lid.
22. Assemble the clasp of inner joint of left front drive
shaft.
Assemble new clasp.
23. Assemble exterior joint dustproof cover (B type and
C type).
(a) Twist ethylene adhesive tape on gear slot of exterior joint to
prevent damage.
(b) Assemble following parts on drive shaft by sequence.
(1) No.2 fixing clamp of exterior joint dustproof cover.
(2) Exterior joint dustproof cover
(3) Fixing clamp of exterior joint dustproof cover.
(c) Fill lubricating grease in exterior joint assembly.
Left and right driving shaft Capacity of lubricating grease

B type 125-135 grams
C type 190-200 grams
(d) Assemble exterior joint dustproof cover on exterior joint shaft. Special tool
24. Assemble No.2 fixing clamp of exterior joint
dustproof cover of left front drive shaft.
(a) AUMIGA fixing type.
Tighten big fixing clamp of exterior joint.
117
(1) Put big fixing clamp on dustproof cover firmly.

(2) Put special tool on big fixing clamp.
(3) Lock special tool to tighten big fixing clamp.
Note: do not tighten special tool too much.
(4) Use special tool to adjust the clearance of big fixing
Special
clamp. tool
Clearance: 0.8mm
25. Assemble fixing clamp of exterior joint dustproof

(a) AUMIGA fixing type. Special
Tighten small fixing clamp of exterior joint. tool
(1) Put small fixing clamp on dustproof cover firmly.
(2) Put special tool on small fixing clamp.
(6) Lock special tool to tighten small fixing clamp.
Note: do not tighten special tool too much.
(4) Use special tool to adjust the clearance of small fixing
clamp.
Clearance: 0.8mm
Special
tool
26. Assemble dynamic absorber of driveshaft (right

drive shaft).
(a) A type and C type
Liking that shown above, set up the distance of absorber:
A type and C type 440 2mm
118
(b) B type
Liking that shown above, set up the distance of absorber:
B type and C typ 470 2mm
27. Assemble fixing clamp of dynamic absorber of drive Single-contact fixing

clamp type
shaft.
Assemble new fixing absorber clamp on the absorber of drive
shaft, then fix the fixing clamp with screw driver.
(b) Mesh clasp type:
Assemble new fixing absorber clamp on the absorber of drive
shaft, then fix the fixing clamp with screw driver. Mesh clamp type
28. Assemble inner joint of left front drive shaft.

(a) Twist ethylene adhesive tape on gear slot of exterior joint to
prevent damage.
(b) Assemble following parts on drive shaft by sequence.
(1) No.2 fixing clamp of inner joint dustproof cover.
(2) Inner joint dustproof cover
(3) Fixing clamp of inner joint dustproof cover.
(c) Align the mark made before disassembly, and assemble

triangle joint in drive shaft.
(d) Assemble triangle joint assembly with copper stick and
hammer.
Note: do not knock the stator.
Align the
mark
119
(e) Use clasp spreading pliers to assemble the clasp.

(f) Fill lubricating grease in inner joint assembly.
Left transmis- Right trans-

Capacity of lubricating grease
sion shaft mission shaft
A type A type
180-190 grams
C type C type
B type B type 125-135 grams
Align the mark

(g) Align the mark before disassembly, and assemble inner joint
in drive shaft.
29. Assemble dustproof cover inner joint of left front

drive shaft.
Assemble inner joint dustproof cover to inner joint and drive
shaft.
30. Assemble fixing clamp of dustproof cover inner joint

of left front drive shaft.
Liking that shown in figure, use screw driver to assemble
fixing clamp of dust-proof cover inner joint .

Liking that shown in figure, use pliers to assemble fixing
clamp of inner joint dust-proof cover.
Pliers
clamp
31. Assemble No.2 fixing clamp of dust-proof cover in-

ner joint of left front drive shaft.
Liking that shown in figure, use screw driver to assemble
No.2 fixing clamp of dust-proof cover inner joint.
120
Driveshaft--Front drive shaft

Liking that shown in figure, use pliers to assemble No.2
fixing clamp of inner joint dust-proof cover.
Pliers
clamp
32. Check front drive shaft.

(a) Check whether there is any obvious clearance on exterior
joint.
(b) Check whether inner joint could slide smoothly in pushing
direction.
(c) Check whether there is any obvious clearance of inner joint
in radial direction.
(d) Check whether the dustproof cover is damaged.
Note: drive shaft assembly should keep moving on hori-
zontal position.
Hint: A size, please referring to following table.
Transmission shaft Left mm Right mm

A type 570.2 5 842.7 5
B type 570.2 5 847.3 5
C type 570.2 5 844.7 5
33. Assemble left front drive shaft assembly [64000082]

(a) Spread ATF on gear slot of inner joint shaft assembly.
(b) Put gear slot of drive shaft in integrated transmission, then
use copper stick and hammer to knock drive shaft to its
position.
Note:
z make the placket of clasp face the downside to
assemble.
z Be careful not to damage the seal oil
Hint: Whether the drive shaft contacts with gear shaft
could be felt by the sound or feeling in running process.
(c) Assemble seal board of left front swing board.
34. Assemble left front shaft hub assembly.
Assemble left front drive shaft assembly to left front hub assembly.
Note:
z Do not damage exterior joint dustproof cover.
z Do not damage the stator of speed sensor.
121
35. Assemble left lower control arm assembly [64000091]

(a) Assemble lower ball joint on lower suspension arm with the
bolts and screw caps.
Torque: 142 10 Nm
36. Assemble left transversal lever assembly.
(a) Assemble transversal lever terminal to steering knuckle with
screw cap.
Torque: 49 5 Nm
(b) Assemble new cotter pin.
Note: if hole position of cotter pin could not make a
line, lock the screw cap for 60.
37. Assemble speed sensor assembly of left front
wheels (equipping with ABS) [67000020]
(a) Assemble speed sensor absorber with bolts.
Torque: 49 5 Nm
(b) Assemble speed sensor on the steering knuckle with bolts.

Torque: 8 Nm
Note:
z Do not damage speed sensor.
z Prevent it from contacting with sundries.
z When assembling the sensor, the wiring harness
of sensor could not bend.
38. Assemble fixing nuts of drive shaft [68000083]

(a) Assemble fixing nuts.
Torque: 216 15 Nm
(b) Use chisel and hammer to knock the fixing nuts concave
and fix them.
39. Assemble front wheels.

Torque: 103 10 Nm
40. Add the oil in gearbox.
41. Check and adjust the oil in gearbox.
42. Check and adjust wheel alignment (referring to page
87)
43. Check the ABS speed sensor (equipping with ABS).
44. Test on road.
122
Driveshaft--Left front shaft hub assembly
Left front shaft hub assembly

Change
Hint: changing procedure for right side is same as the left
side.
1. Disassemble front wheels
2. Disassemble fixing nuts of left front drive shaft
[64000083]
(a) Use special tool and hammer to unclench concave part of
Special
fixing nuts. tool
(b) Disassemble fixing nuts.
3. Disassemble speed sensor assembly of left front

wheel [67000020]
(a) Disassemble the bolts, then disassemble the wiring har-
ness of sensor and brake hose.
(b) Disassemble the bolts, then disassemble speed sensor

from steering knuckle.
4. Disassemble left front brake caliper assembly

Disassemble two bolts to disassemble brake caliper bracket.
123
Drive shaft--Left front shaft hub assembly
5. Disassemble left front brake assembly [64000134] Special

tool
6. Disassemble left transversal lever assembly
(a) Disassemble cotter pin and nuts.
(b) Use special tool to disassemble transversal lever assembly
7. Disassemble left lower control arm assembly

[64000091]
Disassemble the bolt and two nuts, then disassemble lower
control arm from lower ball joint.
8. Disassemble left front shaft hub assembly.

(a) Use plastic hammer to disassemble transmission shaft from
shaft hub.
Note: do not damage the dustproof cover and the sta-
tor of ABS speed sensor.
(b) Disassemble two bolts and nuts, then disassemble steer-

ing knuckle with shaft hub.
9. Disassemble left front lower control arm ball head

assembly [64000093]
(a) Disassemble cotter pin and nut.
(b) Use special tool to disassemble ball head.

Special tool
10. Disassemble the clasp in left front shaft hub hole.

Use clasp pliers to disassemble the clasp.
124
11. Disassemble left front shaft hub assembly.

(a) Use special tool to disassemble shaft hub.
Special tool
(b) Use special tool to disassemble inner ring (exterior) seat

from shaft hub.
Special
12. Disassemble left front brake bottom board. tool
Disassemble three bolts, then take down the brake bottom
board.
13. Disassemble left front shaft hub bearing
(a) Put inner circle (exterior) on bearing. Special tool
(b) Use special tool and press to disassemble the bearing from
steering knuckle.
Special
tool
14. Assemble left front shaft hub bearing.

Use special tool and press to assemble the bearing on steer-
ing knuckle. Special
tool
15. Assemble left front brake bottom board.

Assemble bottom board with three bolts.
16. Assemble left front shaft hub assembly.

Use special tool and press to assemble shaft hub. Special
tool
17. Assemble the clasp of left front shaft hub hole.

Use the clasp pliers to assemble the clasp.
Special
tool
125
18. Assemble left front lower control arm ball head as-
sembly [64000093]
(a) Assemble lower ball head and locking nut.
Torque: 103 10 Nm
If hole position of cotter pin could not make a line, lock the
screw cap for 60 again.
19. Assemble left front shaft hub assembly

(a) Assemble two bolts and nuts, and assemble shaft hub as-
sembly on absorber.
Torque: 153 10 Nm
Note: when the bolts and nuts should be used again,
spread engine oil on the thread of nuts.
(b) Push the front shaft hub assembly to the outside of
automobile, then assemble transmission shaft assembly
in the gear slot of front shaft hub assembly.
Note:
Front shaft assembly could not be pushed to outside
too much.
z Do not damage the exterior joint dustproof cover of
drive shaft.
z Do not damage the stator of speed sensor.
20. Assemble left lower control arm assembly

[64000091]
Assemble lower control arm and ball head with two nuts and
bolts.
Torque: 142 10 Nm
21. Assemble left transversal lever assembly
(a) Connect transversal lever to steering knuckle.
(b) Assemble screw cap and new cotter pin.
Torque: 49 5 Nm
22. Assemble left front brake assembly [64000134]

23. Assemble front brake caliper assembly
(a) Assemble brake caliper assemble on steering knuckle with
two bolts.
Torque: 106 10 Nm
24. Assemble fixing nuts of left front drive shaft
[64000083]
Use torque wrench (30mm) to assemble new fixing nuts.
25. Disassemble left front brake branch pump assembly
26. Disassemble left front brake assembly [64000134]
27. Check the axial clearance of bearing
126
Use centimeter to check the axial clearance of shaft hub center.

Maximal value: 0.05 mm
If axial clearance exceeds the maximal value, it is necessary
to change the bearing.
28. Check the terminal face run-out of shaft hub.
Use centimeter to check the terminal run-out of exterior sur-
face of shaft hub.
Maximal value: 0.05 mm
If terminal run-out exceeds the maximal value, change the shaft
hub.
29. Assemble left front brake assembly [64000134]
30. Assemble left front brake branch pump assembly

Use two bolts to assemble brake branch pump assembly on
steering knuckle.
Torque: 106 10 Nm
31. Assemble speed sensor assembly of left front wheel

[67000020]
(a) Assemble wiring harness of speed sensor and brake hose
on the absorber with bolts.
Torque: 29 Nm
(b) Use the bolts to assemble speed sensor to steering knuckle.

Torque: 8.0 Nm
Note: Do not damage the speed sensor.
z Prevent it from contacting with sundries.
z When assembling the sensor, wiring harness of sen-
sor could not bend.
32. Assemble fixing nut of left front drive shaft

[64000083]
(a) Assemble new fixing nuts,
Torque: 216 15 Nm
(b) Use chisel and hammer to make fixing nut concave and fix
them.
Torque: 103 10 Nm
34. Check and adjust wheel alignment (referring to page
87).
35. Check the ABS speed sensor signal.
127
Drive shaft--Left front shaft hub bolt
Left front shaft hub bolt

Change
Hint: changing procedure for right side is same as left
side.
1. Disassemble front wheels
2. Disassemble left front brake branch pump assembly
3. Disassemble left front brake assembly [64000134]
4. Disassemble left front brake bottom board.
Disassemble three bolts, then disassemble the bottom board
5. Disassemble left front shaft hub bolt.

Use special tool and screw driver to disassemble shaft hub
bolt.
6. Assemble left front shaft hub bolt.

(a) Liking that shown in figure, assemble gasket and screw
cap on new shaft hub bolt.
(b) Use screw driver to fix and lock the screw cap to make the
bolt enter the hole.
7. Assemble left front brake bottom board.

Assemble three bolts, and assemble bottom board in steering
knuckle.
8. Assemble left front brake assembly.
9. Assemble left front brake branch pump assembly.
Torque: 106 10 Nm
Torque: 103 10 Nm
128
Drive shaft--Left rear shaft hub and bearing assembly
Left rear shaft hub and bearing assembly

Change
Hint: changing procedure for right side is same as left side.
1. Disassemble rear wheels.

2. Disassemble rear brake caliper assemble
Disassemble two bolts and take down brake caliper.
3. Disassemble the wiring harness of rear wheel speed

sensor (equipping with ABS).
Disassemble the joint of rear wheel speed sensor.
4. Disassemble left rear brake assembly [64000137]
5. Disassemble left rear shaft hub and bearing

assembly.
Disassemble four bolts, then take down lower shaft hub and
bearing assembly.
6. Disassemble rear wheel speed sensor assembly (equipping with ABS) [67000023]
(referring to page 52)
7. Assemble rear wheel speed sensor assembly (equipping with ABS) [67000023] (referring
to page 52)
8. Assemble left rear shaft hub and bearing assembly

Use four bolts to assemble left rear shaft hub and bearing
assembly
9. Assemble wiring harness of rear wheel speed sen-

sor (equipping with ABS).
Connect the joint of rear wheel speed sensor.
129
Drive shaft--Left rear shaft hub and bearing assembly
10. Check the axial clearance of bearing.

Put the centimeter besides shaft hub center, and check the
axial clearance of bearing.
Maximal value: 0.05mm
If axial clearance exceeds the maximal value, change the bearing
assembly.
11. Check the terminal face run-out of shaft hub.

Use centimeter to check the terminal run-out of exterior sur-
face of shaft hub.
Maximal value: 0.07m
If terminal run-out exceeds the maximal value, change the shaft
hub.
12. Assemble left rear brake assembly [64000137]
13. Assemble left rear brake branch pump assembly

Torque: 46 5 Nm
14. Assemble rear wheels

Torque: 103 10 Nm
15. Check the ABS speed sensor signal.
16. Inspection on road.
130
Drive shaft--Left rear shaft hub bolt
Left rear shaft hub bolt

Change
1. Disassemble rear wheels
2. Disassemble left rear brake caliper assemble
Disassemble two bolts and take down brake caliper.
3. Disassemble left rear brake assembly [64000137]

4. Disassemble left rear shaft hub bolt
(a) Screw the shaft to the position in figure, then use special
tool to disassemble shaft hub bolt.
Note: shaft hub bolt should be screwed to the position
in figure, or you could not change shaft hub bolt.
(b) Use special tool and screw driver to disassemble shaft hub
bolt.
5. Assemble left rear shaft hub bolt

(a) Liking that shown in figure, assemble new gasket and screw
cap on new shaft hub bolt.
(b) Use screw driver to fix and lock screw cap to make the bolt
enter hole.
6. Assemble left rear brake assembly [64000137]

7. Assemble left rear brake branch pump assembly
Use two bolts to assemble rear brake branch pump assembly.
Torque: 46 5 Nm
Torque: 103 10 Nm
131
Brake--Brake system
Brake
Brake system
Notes
z It is necessary to be very careful when changing any subassembly, for this will influence the perfor-
mance of brake system and incur the running becomes unsafe. It is necessary to use those parts with
same type or same grade when changing.
z When repairing brake system, it is very important to keep the surface of every part clean.
132
Brake--Remove malfunction
Remove malfunction
Use following table to help you find the reason of malfunction, the number in table indicates the preferred
sequence of possible reasons of malfunction. Please check every part by sequence, if necessary, change
this part.
1. Brake system (leaking oil). -
The height of brake pedal is too 2. Brake system (entering air). 135
low or brake pedal is loose. 3. Piston oil seal (abraded or damaged). 141, 144
4. Brake main pump (invalid) 138
5. Vacuum booster lever (adjusted badly) 138
1. Brake pedal free travel (too small). 136
2. Parking brake handle travel (adjusted badly). 154
3. Parking brake pull cable (lag). 156, 158
4. Brake block (damaged or distorted). 141, 144
Brake lag 5. Piston (locked). 141, 144
6. Piston (freezed). 141, 144
7. Tensility or return spring (invalid). 161
8. Vacuum booster lever (adjusted badly). 138
9. Vacuum boosting system (vacuum leakage). 138
10. Brake main pump (invalid). 138
1. Piston (locked). 141, 144
2. Brake block (oil dirt). 141, 144
Brake offset 3. Piston (freezed). 141, 144
4. Brake disk (scratched). 141, 144
5. Brake block (abraded or distorted). 141, 144
1. Brake system (leaking oil).
2. Brake system (entering air). 135
3. Brake block (abraded). 141, 144
Brake pedal is too hard to make power lack. 5. Brake block (oil dirt). 141, 144
6. Brake block (sclerosesed). 141, 144
8. Vacuum booster lever (adjusted badly). 138
9. Vacuum boosting system (vacuum leakage). 138
133

2. Assembled nut (loose). 141, 144
4. Support sheet of brake block (loose). 141, 144
Brake noise 5. Sliding pin (abraded). 141, 144
6. Brake block (oil dirt). 141, 144
7. Brake block(sclerosesed). 141, 144
8. Support pin or return spring (invalid). 161
9. Muffle gasket (damaged). 141, 144
10. Localizing spring (damaged). 161
134
Brake liquid
Discharge the air in brake system
Hint: if any part of brake system has been damaged or
you disbelieve whether there is any air in brake pipeline,
it is necessary to discharge the air in brake system
completely.
Note: do not make brake liquid spill on paint surface, if
having, wash it cleanly.
1. Add brake liquid in storage tank.

Brake liquid: DOT-4
2. Discharge the air in brake main pump.

Hint: if brake main pump or liquid storage tank is
disassembled, it is necessary to discharge the air in
brake main pump.
(a) Disassemble brake pipeline of brake main pump.
(b) Step down brake pedal slowly and keep this state.
(c) Plug oil hole with finger, then release brake pedal.
(d) Repeat (b) and (c) three times or four times.
3. Discharge the air in brake pipeline.

(a) Connect plastic pipe on exhaust bolt of brake branch pump.
(b) After stepping brake pedal several times, and step down
brake pedal, then release inflating bolt to discharge air.
(c) Lock exhaust bolt until brake liquid stops flowing out, then
release brake pedal.
(d) Repeat (b) and (c) until air is discharged completely.
(e) Repeat the procedure above, and release the air in brake
pipeline of every wheel.
Torque: 12.7-17.6 Nm
4. Check the brake liquid storage tank

Check the liquid level in storage tank, if necessary, add brake
liquid.
Brake liquid: DOT-4.
135
Brake pedal assembly

Adjustment Brake light switch
1. Check and adjust the height of brake pedal.
(a) Check the height of brake pedal.
Pedal distance from floor: 136.0-146.0mm
(b) Adjust the height of brake pedal.
(1) Disassemble lower trim board of panel.
(2) Disassemble switch joint of brake light.
(3) Loosen locking nut of brake switch, and disassemble
the switch of brake light. Push rod
(4) Loosen U-shaped clasp fixing nut of pedal lever.

(5) Turn pedal lever to adjust the height of pedal.
(6) Lock the fixing nut of lever.
2 N m
Torque: 26
(7) Assemble the switch of brake switch. Height of pedal
(8) Connect the switch joint of brake light.

(9) Press down the brake pedal for 5-15mm, and turn the switch of brake light to illuminate brake light,
then lock the nut.
(10) After assembling, press down the brake pedal for 5-15mm again, and confirm brake light has
illuminated.
2. Check the free travel of pedal.
(a) Extinguish the engine, and step brake pedal repeatedly until
there is no vacuum in vacuum booster.
(b) Press down pedal with hand until feeling the resistance,
then measure the distance of this section, liking that shown
in figure.
Free travel of pedal: 1-6mm.
If it is wrong, check the clearance of brake light switch.
Clearance of brake light switch: 0.5-2.4mm
If the clearance accords with the regulation, remove the
malfunction in brake system.
Free travel of
pedal
3. Check the distance from pedal to floor.

Release parking brake drag lever
When engine is running, step down brake pedal, then mea-
sure the distance from pedal to floor, liking that shown in figure,
Force 490 N on pedal, its distance from floor should be:
over 60mm.
If it is wrong, remove the malfunction in brake system.
Pedal distance
from floor
136
Change
Hint: after assembling, check and adjust the height, free travel of brake pedal and the height from
pedal to floor.
Brake pedal bracket
Brake pedal bushing
Brake pedal shaft

Locking shaft
Brake main pump lever pin
Brake pedal
Rubber gasket
Brake pedal
N.m: Regulated torque

Do not use the part repeatedly
Lithium soap base glycol lubricating grease
137
Brake--Vacuum booster assembly
Vacuum booster assembly

1. Check the vacuum booster
(a) Check the gas sealed performance. Good Bad
(1) Start the engine, and extinguish after one or two minutes,
then step and release brake pedal slowly several times.
Hint: if the first step is lowest, second and third step
rise gradually, and this shows the gas sealed per-
Third
formance of booster is normal.
Second
(2) Step down brake pedal when engine is running, then First
extinguish the engine.
Hint: if the distance from pedal to floor does not
change in 30 seconds, this shows gas seal perfor-
mance of booster is normal.
(b) Working inspection.
(1) When engine is at parking state, step brake pedal sev-
eral times to check brake pedal.
The height from floor should not change.
(2) Step down brake pedal, then start the engine.
Hint: if pedal drops a little, this shows working is
normal.
Con- Not con-

2. Check vacuum check valve duction duction
(a) Check vacuum check valve.
(1) Remove pipe clamp, and disassemble vacuum pipe.
(2) Disassemble vacuum check valve.
(3) Blow air to check: in the direction from booster to engine,
the check valve should ventilate, but its opposite direc-
tion should not ventilate.
(4) If finding any malfunction, change vacuum check valve.
Change
1. Discharge brake liquid
Note: do not spill the brake liquid on paint surface of automobile body, if having, wash it cleanly.
2. Disassemble air filter assembly [64000033]
3. Disassemble carbon canister assembly [4G18-1129020]
4. Disassemble brake main pump subassembly
138
5. Disconnect the U-shaped joint of brake main pump

lever
(a) Release fixing screw cap of lever U-shaped joint.
(b) Disassemble locking pin of U-shaped joint and lever pin of
brake main pump.
6. Disassemble left front wheel
7. Disassemble vacuum booster

(a) Use special tool and wrench to disassemble brake hose of
left front wheel.
(b) Disassemble the bolts, two screw caps and activated car-
bon canister bracket.
(c) Disassemble vacuum hose on vacuum booster.
(d) Disassemble four screw caps and U-shaped joint.
(e) Take out vacuum booster and gasket.
8. Assemble vacuum booster with brake pump assem-
bly [64000164]
(a) Assemble U-shaped joint on booster lever.
(b) Assemble new gasket and vacuum booster with four nuts.
Torque: 13 Nm
(c) Connect vacuum hose to vacuum booster.
(d) Use the bolts and nuts to assemble carbon canister bracket.
Torque: 5.4 Nm
(e) Use special tool and wrench to connect brake hose of left
front wheel.
Torque: 15 2 Nm
9. Assemble left front wheel

Torque: 103 10 Nm
139
10. Connect brake main pump

Assemble U-shaped joint pin in U-shaped joint and brake pedal, and assemble fixing clamp to U-shaped
joint pin.
11. Assemble brake main pump
12. Assemble carbon canister assembly [4G18-1129020]
13. Assemble air filter assembly [64000033]
14. Add brake liquid in liquid storage tank
15. Discharge the air in brake main pump
16. Discharge the air in brake system
17. Check and adjust the height of brake pedal
18. Check the pedal free travel
19. Check the height from pedal to floor
20. Check the liquid level in storage tank
21. Check whether the brake liquid leaks
140
Brake--Front brake assembly
Front brake assembly

Overhaul
2. Discharge brake liquid.
3. Disassemble brake branch pump assembly.

(a) Disassemble the bolts and gaskets of brake hose joint on
brake branch pump, then disassemble brake hose.
Hint: the gasket has two types: two sheets type or one
type.
(b) Fix sliding pin of cylinder body to disassemble two bolts.
4. Disassemble brake block of front wheels.
(a) Disassemble brake block with muffle gasket.
(b) Disassemble muffle gasket from every brake block.
5. Disassemble support sheet of brake block. Brake branch pump
6. Disassemble sliding pin of brake branch pump.
Disassemble sliding pin on branch pump bracket.
7. Disassemble dustproof cover on brake branch pump.
Disassemble two dustproof covers from brake branch pump
of disk.
8. Disassemble left front brake branch pump. Dustproof cover
Disassemble two bolts and brake branch pump bracket.
9. Disassemble dustproof cover of branch pump.
Use screw driver to disassemble oil seal loop and dustproof
cover.
10. Disassemble the piston of brake branch pump.

(a) Put a cloth or similar thing between piston and branch pump.
(b) Use compressed air to disassemble piston from branch
pump.
Warning: when using compressed air, do not put your
finger at the front of piston.
Note: you could not be splashed by brake liquid.
11. Disassemble oil seal of piston.
Use screw driver to disassemble oil seal of piston from branch
pump.
12. Disassemble exhaust bolt of branch pump.
141
13. Check the brake branch pump and piston

Check whether there is rust or scratch in cylinder of branch
pump and piston.
14. Check the thickness of brake block
Use rule to measure the thickness of brake block.
Standard thickness: 11.00mm
Minimal thickness: 1.0mm
15. Check support sheet of brake block
Confirm the support sheet could rebound enough without any distortion, crack or abrasion, and it has
removed rust, dust and sundries completely.
16. Check the thickness of brake disk
Use centimeter to measure the thickness of brake disk.
17. Disassemble front brake disk
(a) Make a mark on corresponding position of brake disk and shaft hub.
(b) Disassemble brake disk.
18. Assemble brake disk
Hint: choose the position with minimal terminal run-out quantity to assemble brake disk.
19. Check the terminal run-out of brake disk
(a) Lock the brake disk temporarily with shaft hub nut.
Torque: 103 10 Nm
(b) Use centimeter to measure the terminal run-out of brake
disk on the position with 10mm apart from the exterior edge
of brake disk.
Maximal run-out quantity: 0.05mm
(c) If terminal run-out of brake disk exceeds or equals to maxi-
mal value, firstly, check the axial clearance of bearing, then
check the terminal run-out of shaft hub, if they are both
normal, adjust the terminal run-out of brake disk to eligible
value or use turning motor to turn terminal surface of brake
disk.
20. Lock exhaust bolt temporarily
Lock exhaust bolt temporarily on front brake branch pump.
21. Assemble oil seal of piston
(a) Spread lithium soap base glycol lubricating grease on new oil seal of piston.
(b) Assemble oil seal of piston on brake branch pump.
Note: do not force piston to assemble in branch pump compulsively.
22. Assemble piston of front brake branch pump
(a) Spread lithium soap base glycol lubricating grease on the piston.
(b) Assemble piston on brake branch pump.
Note: do not force piston to assemble in branch pump compulsively.
142
23.Assemble dustproof cover of branch pump..

(a) After spreading lithium soap base glycol lubricating grease
on new dustproof cover of branch pump, assembling it in
brake branch pump.
Hint: dustproof cover should be assembled in branch
pump firmly.
(b) Use wrench to assemble fixing loop.
Note: do not damage dustproof cover.
24. Assemble brake branch pump bracket.
Use two bolts to assemble brake branch pump bracket.
Torque: 106 10 Nm
25. Assemble dustproof cover of brake branch pump
bracket.
(a) Spread lithium soap base glycol lubricating grease on new
dustproof cover.
(b) Assemble two dustproof covers in front brake branch pump
bracket.
26. Assemble sliding pin of front brake branch pump.
(a) Spread lithium soap base glycol lubricating grease on the
surface of sliding part and sliding pin.
(b) Assemble two sliding pins in front brake branch pump
bracket.
27. Assemble support sheet of brake block.
28. Assemble brake block.
Note: when changing brake block, muffle gasket should be changed with brake block at the same
time.
(a) Spread brake lubricating grease on both sides of every muffle gasket.
(b) Assemble muffle gasket on every brake block.
(c) When assembling inner brake block, abrasion indicator should face the upside.
Note: do not attach oil dirt or lubricating grease on the surface of brake block and brake disk.
29. Assemble brake branch pump assembly.
(a) Use two bolts to assemble brake branch pump.
Torque: 34 3Nm
(b) Use joint bolt to assemble new gasket and brake hose.
Torque: 30 3Nm
Hint: Gasket has two types: two sheets type and one type.
Bracket soft pipe should be assembled in localizing hole of branch pump firmly.
31. Discharge the air in brake main pump.
33. Check the liquid level of storage tank.
34. Check whether the brake liquid leaks.
Torque: 103 10 Nm
143
Brake--Rear brake assembly
Rear brake assembly

Overhaul
Hint: overhaul procedure for right side is same as the left side.
3. Disassemble brake block of rear wheels.
(a) Disassemble fixing clamp of anti-vibration spring.
(b) Disassemble two guide pins of brake block and brake block
with muffle gasket.
(c) Take down muffle gasket from every brake block.
4. Disassemble left rear brake branch pump.
(a) Disassemble the joint, bolt and gasket of brake hose of brake
branch pump, then disassemble brake hose.
Hint: gasket has two types: two sheets type and one
sheet type
(b) Disassemble two bolts and brake branch pump.
5. Disassemble the bushing of brake branch pump.
Disassemble two bushings from brake branch pump.
6. Disassemble dustproof bushing of rear brake.

Disassemble three dustproof bushings.
7. Disassemble dustproof cover of branch pump.
Use screw driver to disassemble fixing loop and dustproof cover.
8. Disassemble the piston of brake branch pump.

(a) Put a cloth or similar thing between the piston and branch
pump.
(b) Use compressed air to disassemble piston from branch
pump.
Warning: when using compressed air, do not put your
fingers at the front of piston.
Note: do not let brake liquid splash on you.
9. Disassemble oil seal of piston.
144
Use screw driver to disassemble oil seal of piston from brake

branch pump.
Note: do not damage cylinder wall and slot.
10. Disassemble exhaust bolt of branch pump.
11. Check whether there is any dust or scratch on
branch pump and piston.
12. Check the thickness of brake block.
Use rule to measure the thickness of brake block.
13. Check the thickness of brake disk.
Use centimeter of exterior diameter to measure the thickness
of disk.
14. Disassemble rear brake disk.
(a) Make a mark on disk and shaft hub.
(b) Disassemble disk.
15. Assemble brake disk.
Hint: choose the position with minimal terminal run-out
to assemble brake disk.
16. Check the terminal run-out of disk.
(a) Lock the disk temporarily with screw cap of shaft hub.
Torque: 103-10 Nm
(b) Use centimeter to measure the terminal run-out of brake
disk on the position with 10mm apart from the exterior edge
of brake disk.
Maximal run-out quantity: 0.15mm
(c) If terminal run-out of brake disk exceeds or equals to maxi-
mal value, firstly, check the axial clearance of bearing, then
check the terminal run-out of shaft hub, if they are both
normal, adjust the terminal run-out of brake disk to eligible
value or use turning motor to turn terminal surface of brake
disk.
17. Lock exhaust bolt of rear brake branch pump
temporarily.
Lock exhaust bolt to rear brake branch pump temporarily.
18. Assemble oil seal of piston.
oil seal of piston.
(b) Assemble oil seal of piston to brake branch pump.
145
19. Assemble piston of Rear brake branch pump

piston.
(b) Assemble piston on brake branch pump.
Note: do not force piston to assemble in branch pump
compulsively.
20. Assemble dustproof cover of branch pump.
dustproof cover of branch pump.
(b) Assemble dustproof cover in brake branch pump.
Hint: dustproof cover should be assembled in branch
pump firmly.
(c) Use screw driver to assemble fixing loop.
Note: do not damage dustproof cover.
21. Assemble dustproof bushing of rear brake. Brake branch pump
surface of three dustproof bushings.
(b) Assemble three dustproof bushings in brake branch pump.
Dustproof cover
Dustproof cover
Brake branch pump

22. Assemble the bushing of brake branch pump
bracket.
Assemble two bushings of brake branch pump bracket.
23. Assemble brake branch pump.

(a) Assemble branch pump with two bolts.
Torque: 47 4Nm
(b) Assemble new gasket and brake hose with joint bolt.
Torque: 30 3Nm
Hint:
z Gasket has two types: two sheets type and one
sheet type.
z Brake soft pipe should be assembled in localizing
hole of branch pump firmly.
146
24. Assemble rear brake block.

Note: when changing brake block, the inside of muffle gasket should be changed together.
(a) When assembling muffle gasket on every brake block, it is necessary to spread brake lubricating
grease on the inside of muffle gasket.
(b) When assembling inner brake block, abrasion indicator should face upside.
Note: do not attach any oil dirt or lubricating grease on the surface of brake block and brake
disk.
(c) Assemble two guide pins of brake block.
(d) Assemble fixing clamp of anti-abrasion spring.

26. Discharge the air in brake main pump (referring to page 135).
27. Discharge the air in brake pipeline (referring to page 135).
28. Check the liquid level in storage tank.
29. Check whether brake liquid leaks.
30. Assemble rear wheels.
Torque: 103 10Nm
147
Brake--Hydraulic pressure control unit
Hydraulic control unit (equipping with ABS)

1. Connect handle tester
(a) Connect handle tester to DLC3.
(b) Start the engine and make it run at idling speed.
(c) Handle tester should choose Active test module.
Hint: details could refer to operating instruction for handle tester.
2. Check the function of hydraulic .
(a) Start the motor relay, and check hydraulic motor should have working sound.
(b) Stop the motor relay.
(c) Step brake pedal for 15 minutes, and check brake pedal should not be stepped down.
(d) Start the motor relay, and check brake pedal should not have any pulse.
Note: Time when motor relay locates ON could not exceed 5 seconds, when it is necessary to
operate continually, interval time should be over 20 seconds.
(e) Stop the motor relay and release brake pedal.
3. Check the function of right front wheel.
Note: forbid making electromagnetic valve be ON in following situations.
(a) Make following operation when brake pedal is stepped down.
(b) Make electromagnetic valve SFRH and SFRR be ON at the same time, and check the brake pedal
should not be stepped down.
(c) Make electromagnetic valve SFRH and SFRR be OFF at the same time, and check the brake pedal
should be able to be stepped down.
(d) Make electromagnetic valve SFRH and SFRR be ON at the same time, and check whether the brake
pedal could return.
(e) Make motor relay be OFF and release brake pedal.
4. Check the function of other wheels.
Check the electromagnetic valves of other wheels by same procedure.
Hint:
Left front wheel: SFLH,SFLR
Right rear wheel: SRRH,SRRR
Left rear wheel: SRLH, SRLR
Change
Note: do not leave brake liquid on paint surface of automobile body, if having, wash it cleanly.
2. Disassemble right front wheel.
148
3. Disassemble gasket of right wheel wing.

4. Disassemble hydraulic control unit and bracket.
(a) Disassemble the joint and bolt.
(b) Turn the locking bolt of joint of hydraulic control unit, and
disassemble the joint.
(c) Use special tool to disassemble the brake oil pipe on hy-
draulic control unit.
(d) Use label to mark the name of every oil pipe, and tie it on
oil pipe. Connect the front
of main cylinder Connect the back
of main cylinder
Connect 2#
brake pipe
Connect the front left

Connect the front right
Connect 2#
brake pipe
(e) Disassemble screw caps, two bolts and hydraulic control

unit and bracket.
5. Disassemble hydraulic control unit assembly.
Disassemble three bolts and hydraulic control unit from the bracket.
6. Assemble hydraulic control unit assembly.
Assemble three bolts and hydraulic control unit on the bracket with three bolts.
Torque: 4.7 Nm
149
7. Assemble hydraulic control unit and bracket.

(a) Assemble hydraulic control unit and bracket with screw cap
and two bolts.
Torque: 19 Nm
(b) Liking that shown in figure, use special tool to assemble

brake oil pipe on correct position of hydraulic control unit.
Torque: 15 2 Nm Connect the front
(c) Connect the joint of hydraulic control unit. of main cylinder Connect the back
of main cylinder
Connect 2#
brake pipe
Connect the front left

Connect the front right
(d) Assemble bolt and connect the joint. Connect 2#
brake pipe
8. Assemble gasket of right front wing.

9. Assemble right front wheel.
11. Discharge the air in main pump.
13. Check the liquid level of brake liquid.
14. Check whether brake liquid leaks.
15. Use handle tester to check the hydraulic control
unit.
150
Brake--Speed sensor of front wheel
Speed sensor of front wheel

Change
Hint: the process for changing right side is same as the
left side.
2. Disassemble gasket of left front wing.
3. Disassemble speed sensor of left front wheel.
(a) Disassemble resinous clamp and speed sensor wiring har-
ness from fixing clamp of automobile body.
(b) Disassemble the sensor joint.
(c) Disassemble two bolts of fixing clamp of sensor wiring har-
ness from automobile body and absorber.
(d) Disassemble bolt and left front sensor.

Note: do not attach any sundries on top of sensor.
4. Assemble speed sensor of left front wheel.

(a) Use bolt to assemble left front sensor.
Torque: 8.0 Nm
Note: do not attach any sundries on top of sensor.
(b) Use two bolts to assemble fixing clamp of sensor wiring

harness on automobile body and absorber.
Bolt A: 9.0 Nm
Bolt B: 29 Nm
(c) Connect the joint of speed sensor.

(d) Connect resinous clamp and speed sensor wiring harness
on automobile body and fixing clamp.
5. Assemble gasket of left front wheel wing.
Torque: 103 10 Nm
7. Check the signal of ABS speed sensor.
151
Brake--Speed sensor of rear wheels
Speed sensor of rear wheels

Change
Hint: the process for changing right side is same as the
left side.
2. Disassemble wiring harness of speed sensor of rear
wheel.
Disassemble the joint of speed sensor of rear wheel.
3. Disassemble left rear disk brake branch pump

assembly.
4. Disassemble rear brake disk.
5. Disassemble left rear shaft hub and bearing assem-
bly (referring to page 129).
6. Disassemble speed sensor of rear wheel.
(a) Fix rear shaft hub on pliers with soft gasket.
Note: when changing shaft hub assembly, it is neces-
sary to shake intensively to make it break off.
Special
(b) Use punch pin and hammer to knock out two pins. tool
(c) Use special tool and two bolts (M12*1.5) to disassemble
speed sensor of rear wheel from rear shaft hub. Bolt
Bolt
Note:
z If sensor stator is damaged, change the shaft hub
assembly.
Special tool
z Do not scratch the surface of shaft hub and speed
sensor.
7. Assemble speed sensor of rear wheels.

(a) Wash contacting surface of rear shaft hub and new speed
sensor of rear wheels.
(b) When sensor is assembled in shaft hub, it is necessary
to assemble sensor joint facing lower position of
automobile.
152
Brake--Speed sensor of rear wheels
(c) Use special tool and press to assemble speed sensor of

Special
rear wheels to rear shaft hub. tool
Note:
z Do not use hammer knock directly in speed sensor
of rear wheels.
z Insure no sundries are attached on the supervising
part of speed sensor of rear wheels
z Press speed sensor of rear wheels straightly and
slowly.
8. Assemble left rear shaft hub and bearing assembly

(referring to page 129).
9. Assemble brake disk.
10. Assemble left rear brake branch pump.
11. Assemble wiring harness of speed sensor of rear
wheels.
Torque: 103 10 Nm
13. Check and adjust wheel alignment.
14. Check the signal of ABS speed sensor.
153
Parking brake--Parking brake system
Parking brake
Parking brake system
Use following table to find the reason of malfunction, the number in table indicates the preferred se-
quence of possible reason. Please check each part by sequence, if necessary, change this part.

1. Travel of parking brake handle (adjusted badly). 154
2. Pull cable of parking brake (attached). 156, 158
Brake lag 3. Clearance of parking brake shoe (adjusted badly). 161
4. Friction plate of parking brake shoe (damaged or distorted). 161
5. Tension or return spring (damaged). 161
Adjustment
1. Disassemble rear wheels
2. Adjust the clearance of parking brake shoe
Torque: 103 10 Nm
4. Check the travel of parking brake handle.
Pull up the parking brake handle and calculate the sound num-
ber of handle.
When parking brake handle locates 196N: 6-9 sounds.
5. Adjust the travel of parking brake handle
(a) Disassemble upper trim board of central box.
(b) Disassemble central box.
(c) Release locking screw cap, then rotate adjusting screw cap
until handle travel accords with the specification. Lock the screw cap
(d) Tighten locking screw cap.
Torque: 5.0 Nm
(e) Assemble central box.
Adjust the
(f) Assemble trim board on central box. screw cap
154
Parking brake--Parking brake handle assembly
Parking brake handle assembly

Change
1. Disassemble trim board on central box.
2. Disassemble parking brake hole cover.
3. Disassemble central box.
4. Disassemble parking brake handle assembly.
(a) Disassemble locking screw cap and adjusting screw cap.
(b) Disassemble the joint of parking brake switch.
(c) Disassemble two bolts and parking brake handle.
5. Disassemble parking brake switch assembly.

Disassemble the screw and parking brake switch.
6. Assemble parking brake switch assembly.
Assemble parking brake switch assembly with screw.
7. Assemble parking brake pull cable.
(a) Connect parking brake pull cable to handle and assemble adjusting screw cap and locking screw cap.
(b) Assemble parking brake handle with two bolts.
Torque: 13 Nm
(c) Connect the joint of parking brake switch.
8. Check the travel of parking brake handle (referring to page 154).
9. Adjust the travel of parking brake handle (referring to page 154).
155
Parking brake--Parking front bake pull cable assembly
Parking front brake pull cable assembly

Change
1. Disassemble upper trim board on box.
3. Disassemble central box.
4. Disassemble parking brake handle assembly.
5. Disassemble front bottom board bracket.
6. Disassemble front exhaust pipe with Three-Way
Catalytic Converter assembly.
(a) Disassemble the joint of oxygen sensor.
(b) Disassemble four bolts, compressed spring and front ex-
haust pipe with Three-Way Catalytic Converter assembly.
7. Disassemble heat insulation board of front exhaust

pipe.
Disassemble there screw caps and heat insulation board of
front exhaust pipe.
8. Disassemble parking front brake pull cable
assembly.
9. Assemble parking front brake pull cable assembly.
10. Assemble heat insulation board of front exhaust
pipe.
Assemble heat insulation board of front exhaust pipe with there
screw caps.
Torque: 5.4 Nm
11. Assemble front exhaust pipe with Three-Way Cata-
lytic Converter assembly.
(a) Assemble two new gaskets and front exhaust pipe with
Three-Way Catalytic Converter assembly with four com-
pressed springs and bolts.
Torque: 43 3 Nm
(b) Connect the joint of oxygen sensor.
156
Parking brake--Parking front bake pull cable assembly
12. Assemble front bottom board bracket.

13. Assemble parking brake handle assembly.
14. Check the travel of parking brake handle (referring
to page 154).
15. Adjust the travel of parking brake handle (referring
to page 154).
157
Parking brake--Parking rear brake pull cable assembly
Parking rear brake pull cable assembly

Change
Hint: the changing procedure for left rear brake pull cable is same as parking right rear brake
pull cable.
2. Disassemble rear brake disk brake branch pump bracket assembly(LH).
3. Disassemble brake disk.
4. Disassemble support lever of parking brake shoe (LH).
5. Disassemble adjustor of parking brake shoe.
6. Disassemble parking brake inner shoe assembly (LH).
7. Disassemble parking brake exterior shoe assembly (LH).
8. Disassemble parking brake shoe lever (LH).
9. Disassemble left rear brake pull cable assembly.

Disassemble the bolt and parking left rear brake pull cable assembly from brake back board.
10. Disassemble front bottom board bracket.

11. Disassemble front part exhaust pipe.
12. Disassemble heat insulation board.
13. Disassemble parking left rear brake pull cable assembly.
(a) Disassemble fixing clamp of rear wheel speed sensor wiring
harness.
(b) Disassemble four bolts and parking left rear brake pull cable
from automobile.
(c) Disassemble left rear brake pull cable from parking brake
balancer, then disassemble parking left rear brake pull cable.
14. Assemble parking left rear brake pull cable

assembly.
(a) Connect parking left rear brake pull cable on parking brake
pull cable balancer.
(b) Assemble parking left rear brake pull cable with four bolts.
Torque: 5.4 Nm
(c) Connect resinous clamp of speed sensor wiring harness of
158
rear wheel to fixing clamp.
15. Assemble No.2 clapboard.

16. Assemble front part exhaust pipe assembly.
17. Assemble front bottom board bracket.
18. Connect parking left rear brake pull cable assembly.
Assemble parking left rear brake pull cable assembly to brake
back board with bolt.
Torque: 7.8 Nm
19. Spread high temperature lubricating grease.
20. Assemble support lever of parking brake shoe (LH).
21. Assemble parking brake exterior shoe assembly
(LH).
22. Assemble parking brake inner shoe assembly (LH).
159
23. Assemble parking brake shoe adjustor.

24. Assemble drag lever of parking brake shoe (LH).
25. Check the assembly of parking brake.
26. Assemble rear brake.
27. Adjust the clearance of parking brake shoe.
28. Connect brake branch pump bracket assembly.
Torque: 103 10 Nm
30. Check the travel of parking brake lever.
31. Adjust the travel of parking brake lever.
32. Check whether exhaust system leaks.
160
Parking brake--Parking brake assembly
Parking brake assembly

Overhaul
Hint: overhaul process for right side is same as the left
side.
1. Disassemble left rear wheel.
2. Disassemble left rear brake branch pump bracket
assembly.
3. Disassemble left rear brake.
Hint:
z Make mark on disk and shaft hub.
z If disk is not easy to disassemble, adjust shoe until
wheel could rotate freely.
4. Check the inner diameter of brake drum.

Use centimeter or other measures with same grade to mea-
sure inner diameter of brake drum.
Standard inner diameter: 173mm
Maximal inner diameter: 174mm
5. Disassemble support lever of parking brake shoe

(LH).
(a) Use needle-nosed pliers to disassemble two springs on
upside of shoe.
(b) Disassemble support lever of parking brake shoe.
6. Disassemble parking brake shoe adjustor.

(a) Use needle-nosed pliers to disassemble return spring.
(b) Disassemble left parking brake shoe adjustor.
161
7. Disassemble parking brake shoe assembly (LH).

Use special tool to disassemble parking brake shoe, localiz-
ing spring, pin and brake exterior shoe.
Special tool
8. Disassemble parking brake shoe assembly (LH).

(a) Use special tool to disassemble parking brake shoe, localiz-
ing spring, pin and brake inner shoe.
Special
(b) Disassemble parking brake lever, then disassemble parking tool
brake inner shoe.
9. Check the thickness of friction plate of parking
brake shoe
Use ruler to measure the thickness of friction plate of shoe.
Maximal thickness: 1.0mm
10. Check whether the contact between brake drum and
friction plate of parking brake shoe is applicable.
Spread chalk on inner diameter of brake drum, then mesh it
with shoe friction plate. If the contact between brake shoe and
brake drum is not applicable, use brake drum to abrade and
repair shoe or change brake shoe assembly.
11. Disassemble lever of parking brake shoe (LH).
Use needle-nosed pliers to disassemble parking brake pull cable,
then disassemble lever of parking brake shoe.
12. Spread high temperature lubricating grease.
Spread high temperature lubricating grease on brake back
board of contacting part of shoe.
13. Assemble parking drag lever (LH).
Use needle-nosed pliers to connect parking brake pull cable to
lever of left parking brake shoe.
14. Assemble parking brake inner shoe assembly (LH).
(a) Spread high temperature lubricating grease on contacting
part between parking brake shoe and lever.
(b) Use special tool to assemble parking brake shoe with park- Special
tool
ing shoe, localizing spring and pin.
162
15. Assemble parking brake exterior shoe assembly

(LH).
Use special tool to assemble parking brake shoe with parking
shoe, localizing spring and pin.
Special
tool
16. Assemble parking brake shoe adjustor.

(a) Spread high temperature lubricating grease on adjusting
bolt.
(b) Assemble parking brake shoe adjustor.
(c) Use needle-nosed pliers to assemble return spring.
17. Assemble support lever of parking brake shoe (LH).

(a) Spread high temperature lubricating grease on contacting
surface between shoe support lever and tension spring.
(b) Assemble support lever of parking brake shoe.
(c) Use needle-nosed pliers to assemble upper two tension

springs.
163
18. Check the assembly of parking brake system.

Check every part after assembly.
Note: do not attach oil dirt or lubricating grease on contacting surface between shoe friction
sheet and brake drum.
Left Right
Front Front
19. Assemble the brake

20. Adjust the clearance of parking brake shoe.
(a) Lock screw cap of shaft hub temporarily. Increase the
clearance
(b) Disassemble hole plug, then use screw driver to turn the
adjustor until brake drum is locked by shoe.
(c) Return the adjustor for 8 gears.
(d) Check whether shoe has lag.
(e) Assemble hole plug. Decrease the
clearance
21. Assemble rear disk type brake branch pump assem-
bly (LH).
Torque: 103 10Nm
23. Check the travel of parking brake drag lever.
24. Adjust the travel of parking brake drag lever.
164
TransmissionDisassemble assembly
Transmission
Disassemble assembly
Connecting bolt of cover
Cover
Stop disc spring of output shaft bearing
Fastening bolt of shift cover

Support cover of rear shaft of output shaft
Connecting bolt
Firstly, loosen the connecting bolt of cover, and take out cover and stop disc spring of output shaft
bearing, secondly, put special wrench whose surface has four cylindrical column heaves in four holes
of support cover of rear shaft of output shaft and screw it out; lastly, loosen fastening bolt of shift cover,
take out shift cover assembly, and loosen connecting bolt of transmission to take out transmission
shell.
165
Take out interlocking pin with magnetic stick
Take out clip spring of fork shaft, liking that shown in figure.
Clamp the upside of fork shaft which is protected by some

cloths and take it out, liking that shown in figure.
Take out reverse gear and reverse gear shaft
Disassemble two bolts and swing arm bracket of reverse gear,

liking that shown in figure.
166
Disassemble interlocking pin with magnetic stick and take out

fork shaft and fork.
Disassemble bolt and fork shaft liking that shown in figure.
Disassemble clip spring liking that shown in figure.
Take out fork by disassembling clip spring.
167
Disassemble lubricating oil pipe.
Take our bushing liking that shown in figure.
Take our oil seal.
Take our exterior ring of tapered shaft with special tool liking
that shown in figure.
Disassemble oil guide cover.
168
Check the axial clearance of third gear with clearance gauge,

its standard value is: 0.10.35 mm.
Third gear
Check the axial clearance of fifth gear liking that shown in

figure, its standard value is: 0.10.50 mm.
Five gear
Check the radial clearance of forth gear and fifth gear liking
that shown in figure, its standard value is less than 0,058mm.
169
Put input shaft assembly into position with pressure machine

liking that shown in figure, at the same time, hold the lower
end of input shaft to disassemble gear cover, gear hub and
five gear.
Check the axial clearance of forth gear, its standard value is:
0.10.55mm.
Third gear
Take down clip spring used by shaft with clip spring wrench.
Take out fixing ball with magnetic stick, and take down the
gear and third-and-forth synchronous gear loop.
170
Take down clip spring with clip spring wrench.

Note: do not hurt its surface.
Take down synchronizer assembly, synchronous loop and third

gear with pressure machine liking that shown in figure.
Note: hold lower end of shaft with hand to make it stand.
Take down radial ball bearing with pressure machine, and

hold lower end of shaft with hand to make it stand.
Disassemble synchronizer assembly liking that shown in

figure.
171
Take our elastic cylindrical pin from shift swing lever with pin
taker and hand hammer liking that shown in figure.
Note: do not hurt its surface.
Take down clip spring liking that shown in figure.
Disassemble interlocking bracket, shift swing lever, spring and

A gasket liking that shown in figure.
Disassemble shift swing lever and connecting bolt.
Disassemble clip spring liking that shown in figure, and dis-

connect it.
172
Disassemble shift guide shaft and dust-proof cover from shift

cover, and take down gasket liking that shown in figure.
Take out the shift cover oil seal with wrench liking that shown
in figure
Take out the other oil seal on shift cover with same method.
173
Take down tapered bearing on differential shell liking that

shown in figure.
Note: put column end surface in bearing into position
reliably.
Take down cylindrical bearing of speedmeter driving wheel

side liking that shown in figure.
Take down driving gear of speedmeter
Disassemble by sequence the fastening bolts of differential.
Take out elastic cylindrical pin with pin taker, and take out
second planetary gears and gaskets, two axle shaft gears
and gaskets and planetary gear shaft by sequence.
174
Check the radial run-out of input shaft liking that shown in

figure, maximal diameter is 0.03mm.
Check the distance from back surface of synchronous loop to

gear end surface with clearance gauge, the minimal value
should be 0.8mm, if the minimal distance could not reach this
value, it is necessary to change synchronous loop.
Check the distance between gear cover and shift fork with
clearance gauge, its maximal value is 0.35mm, or it is neces-
sary to change gear cover or shift fork.
Measure the minimal diameter of abrasion surface A of input

shaft with micrometer, its value is 33.985mm, and the mini-
mal diameter of surface B is 30.985mm, if the value exceeds
this scope, it is necessary to change input shaft.
175
1 gear 2 gear
Measure axial clearance of 1 gear and 2 gear with thickness
gauge,
1 gear: 0.10.35mm
2 gear: 0.10.35mm
Measureradial clearance of 1 gear and 2 gear liking that shown

in figure, the maximal flop value is 0.056mm.
Take down tapered bearing liking that shown in figure

Note:
1. Hold the lower end of shaft to prevent it falling.
2. Clamp inner ring of bearing to make it reliable.
Disassemble tapered bearing on the other end with same

method.
176
Disassemble spring clamp loop on output shaft liking that

shown in figure.
Take down forth and fifth gear wheel with pressure machine.
Note: hold the lower end of shaft to prevent it falling.
Move first and second gear to first gear.
Disassemble third gear with pressure machine, and hold the

lower end of shaft to prevent it falling, at this time, disassemble
roller bearing, synchronous loop and second gear.
Disassemble clip spring with clamp spring pliers, and do not

hurt bearing surface of shaft.
177
Measure the round flop liking that shown in figure, its maxi-
mal allowed flop value is 0.03, if exceeding this value, it is
necessary to change the output shaft.
Check the axial clearance between the back surface of syn-

chronous loop and end surface of gear splines with clear-
ance gauge, its minimal value is 0.8mm, if the clearance is
less than this value, it is necessary to change the synchro-
nous loop.
Check the clearance between gear cover fork slot and fork
with clearance gauge, its maximal value is 0.35mm, if exceed-
ing this value, it is necessary to change fork.
Check the abrasion and damaged situation of output shaft,

and measure the exterior diameter of bearing platform with
micrometer, its minimal value is 33.985mm, if measured re-
sult is less than this value, it is necessary to change the out-
put shaft.
Assemble first gear and synchronous loop liking that shown

in figure.
178
Press first and second gear synchronizer assembly in input

shaft with pressure machine, its direction likes that shown in
figure.
Use new clip spring used for shaft to replace that one which
has been stretched.
Note: do not hurt the shaft surface.
Assemble synchronous ring, roller bearing and second gear.
Press third gear in output shaft with pressure machine liking

that shown in figure, its direction likes that shown in figure.
Use pressure machine to press forth and fifth gear in output

shaft with the method in figure, its direction likes that shown
in figure.
179
Press bearing in input shaft with pressure machine liking that

shown in figure.
Note: adjust to bearing inner ring and put it into position
Assemble roller bearing, third gear and third gear synchro-

nizer loop liking that shown in figure, and assemble synchro-
nizer assembly by the direction in figure.
180
Assemble a new clip spring on input shaft.
Assemble roller bearing, and assemble third and forth

ssynchronizer assemble by the direction in figure, at this time,
assemble forth gear on input shaft.
Assemble fixting ball liking that shown in figure, and assemble

fifth gear stop gasket in input shaft by this ball.
181
Assemble clip spring with same method.
Assemble roller bearing, fifth gear, fifth gear synchronous loop

with same method above.
Assemble synchronizer assembly with pressure machine by

the direction in figure.
Press radial ball bearing in with pressure machine.
182
Press a new clip spring in input shaft by the direction in figure.
Press front tapered bearing in output shaft with method in

figure.
Note: make sure the bearing inner ring has been put into
position.
Press rear tapered bearing in output shaft with method above.

Note: make sure the bearing inner ring has been put into
position.
183
Press shift cover oil seal in with the method in figure, and the
distance from oil seal end surface to oil seal hole end surface
is 2.0-2.5mm after pressing it in.
Press in the other oil seal liking that shown in figure, and the
distance from oil seal end surface to oil seal hole end surface
is 0-0.5mm after pressing it in.
Assemble the gasket on shift guide shaft, and assemble dust-

proof cover in shift guide shaft, then assemble them on shift
cover.
Press a new clip spring on shift reverse shaft liking that shown
in figure.
184
Assemble two new fork shaft clip spring, and assemble inter-
locking pin in the position in figure.
Assemble two new fork shaft clip springs liking that shown in
figure.
Assemble first and second gear fork on fork shaft, and put
fork shaft in first and second gear cover, then assemble first
and second guide block, at the same time, tighten the bolts,
the torque is 16Nm.
Press elastic cylindrical pin in guide block liking that shown in

figure.
185
Assemble lubricating oil pipe liking that shown in figure.
Press a new fork shaft clip spring in third and forth gear fork
shaft liking that in figure.
Assemble reverse gear block and fork shaft clip spring liking
that shown in figure.
Assemble third and forth gear fork shaft in clutch shell body,
and assemble third and forth shift fork in gear cover slot and
tighten them.
Bolt torque is 16Nm
186
Assemble interlocking pin in reverse gear block liking that

shown in figure.
Assemble two connecting bolts on reverse gear swing arm

bracket liking that shown in figure, their torque is 17Nm, and
put the head of reverse gear block in corresponding hole of
reverse gear swing arm bracket.
Put the head of reverse gear swing arm in the slot between
those reverse gear shafts liking that shown in figure.
Assemble reverse gear fork, spring and fifth reverse gear guide
block on fifth reverse fork shaft, and put fifth reverse gear
pulling fork in fifth gear cover, then assemble them in clutch
shell.
187
Spread seal fastening glue on the bolts, and connect trans-

position swing lever and transposition swing lever shaft with
transposition cover with bolts, bolt torque is 16Nm
Assemble A gasket, spring, interlocking bracket and shift swing

lever on shift reverse shaft by the sequence in figure, then
press elastic cylindrical pin in the hole of shift swing lever, at
the same time, the distance from its end surface to hole should
be 0-0.5mm after pressing it in.
Press in a new clamp spring liking that shown in figure.
Take out oil with the method in figure, and assemble a new oil
seal in transmission shell body.
188
Assemble two axle shaft gears and their gaskets in differen-

tial shell by sequence, then screw two planetary gears and
their gaskets in differential shell, and put planetary gear shaft,
lastly, assemble a new elastic cylindrical pin liking that shown
in figure.
Assemble differential gear ring by the direction in figure, and

screw connecting bolts of differential.
Assemble speedmeter driving gear by the direction in figure.
189
Assemble chosen adjusting gasket in transmission shell.
Spread seal glue on joint surface of shell body liking that shown
in figure.
Screw corresponding bolts liking that shown in figure, its torque

is 29Nm.
Spread anti-loose fastening glue on connecting bolts of re-

verse shaft, and use a new gasket to cover on the bolt, then
tighten reverse shaft on transmission shell, its torque is 29Nm
Assemble shift fixing assemble on transmission shell, its torque

is 37Nm
190
TransmissionAssemble the assembly
Transmission
Assemble the assembly
Connecting bolt of end cover
Stop disc spring of output

shaft bearing
End cover
Support cover of output

rear shaft
Screw support cover of output rear shaft in differential shell until reaching screwing torque that is
40Nm, then put stop disc spring of output shat bearing in support cover of output rear shaft by the
direction in figure, lastly, press down end cover and tighten connecting bolts of end cover, their
torque is 12Nm
191
Steering
Steering column--Steering
column--Steering system
system
Steering column
Steering system
Note
1. Notes that are necessary for steering system:
(a) It is necessary to change parts correctly, for they will influence the performance of steering system to
make running danger.
2. Notes that are necessary for SRS airbag:
(a) MR7180 assembles with SRS (auxiliary protection system) such as safety airbag at the side of driver
and safety airbag at the side of passenger.
Maintenance does not accord with correct repair step, this might incur SRS explodes suddenly in
repair term to make heavy accident. Before repairing auxiliary protection system (including
disassembling, assembling, check or change parts), it is necessary to read the notes in SRS chapter
(auxiliary protection system).

Following table could help you find the reason of malfunction. And the number in table is only used for indicat-
ing possible preferred sequence. Please check each part by sequence, if necessary, change this part.
Malfunction phenomenon Possible malfunction part Referred page

1.Tyre (tyre pressure is wrong). 109
2.Power steering oil level (low). 200
3.Driving belt (loose). -
4.Wheel alignment (wrong). 87
Steering is heavy 5.Steering system joint (abraded). -
6.Lower control arm ball joint (abraded). 99
7.Steering column (bent). -
8.Power steering oil pump. 203
9.Power steering gear. 205
Return is bad 2.Wheel alignment (wrong). 87
1.Steering system joint (abraded). -
2.Lower control arm ball joint (abraded). 99
Clearance is too big. 3.Middle shaft, sliding fork (abraded). -
4.Front wheel bearing (abraded). 123
2.Steering system joint (abraded). -
Abnormal noise
3.Power steering oil pump. 203
192
Steering
system
Inspection on automobile Maximal free

clearance
1. Check the free clearance of steering wheel
(a) Park the automobile, and the front wheels are towards the
front.
(b)Turn the steering wheel to left and right with your fingers
lightly, and check the free clearance.
Maximal free clearance: 30mm
193
Steering
system
Steering column system

Overhaul
1. Put the front wheels towards the front.
2. Disassemble safety airbag assembly at the side of

driver (equipping with SRS) [67000179]
Note: if disconnecting airbag joint when ignition switch
locates at ON position, checking number will record it. planetary
screw shell
(a) Put the front wheels towards the front. screws
(b) Use planetary sleeve wrench to loosen two planetary
screws until the concave slot around the screw contacts
the screw shell.
(c) Pull out airbag assemble from steering wheel, and
disassemble airbag joint.
(d) Disassemble the terminal.
Warning:

When storing safety airbag assembly at the side
of driver, it is necessary to put the surface of
airbag assembly towards the upside.

Do not disassemble airbag assembly.
Note: when disassembling airbag assembly, pay
attention not to pull airbag wiring harness.
airbag joint
Wrong Correct
3. Disassemble steering wheel assembly [67100001]

(a) Disassemble the fixed screw cap of steering wheel.
(b) Make corresponding marks on steering wheel and main
shaft assembly. Align the mark
(c) Use special tool to disassemble steering wheel.
4. Disassemble upper/lower decoration plate of

steering column [64000128/64000129]
5. Disassemble left combination switch assembly

[67000078] (referring to page 298)
194
Steering
system
6. Disassemble right combination switch assembly

7. Disassemble helix cable assembly (equipping with

SRS)
Note: do not disassemble helix cable or spread lubricat-
ing grease.
8. Disassemble the middle connecting plate of lower
panel [68100006] (referring to page 340)
9. Disassemble dust-proof cover in steering column.

Disassemble two screw caps, then take down dust-proof cover
in steering column.
10. Disassemble steering shaft assembly

(a) Disconnect joint and fixed clap of wiring harness.
(b) Loosen three fixed bolts of steering column assembly.
11. Disassemble the clamp of ignition switch [68000020]

(a) Use central punch to make hole on the central part be-
tween two tapered bolts.
(b) Use 3-4 mm aiguille to drill two bolts.
(c) Use bolt screwdriver to disassemble two bolts, then take
Bolt screwer
down ignition switch clamp.
12. Disassemble electronic anti-stealing loop assem-

bly (assembling with enter illumination system)
[67000009].
195
Steering
system
13. Disassemble ignition switch key tank assembly

(a) Put ignition switch key tank on ACC position.
(b) Pull down stop pin and pull out key tank assembly with
right-angled screwdriver.
14. Disassemble ignition switch assembly

Disassemble two screws, and take down ignition switch
assembly.
15. Assemble ignition switch with locking core and key

assembly [68000019]
Assemble ignition switch with locking core and key assembly
with two screws.
16. Assemble ignition switch key tank assembly
(a) Make sure ignition switch key tank assembly locates at
ACC position.
(b) Assemble ignition switch key tank.
17. Steering locking function
(a) When taking out the key, check whether steering locking
organization is locked.
(b) When inserting the key, and turning to ACC, check whether
the steering locking organization is released.
18. Assemble electronic anti-stealing loop assembly
[67000009]
19. Assemble ignition switch clamp [68000020]
20. Assemble steering shaft assembly

(a) Assemble steering column assembly with three bolts.
Torque: 21 2 Nxm
196
Steering
system
(b) Align the mark on sliding yoke and middle shaft.

(c) Assemble B bolt and tighten A bolt.
Torque: 35 3 Nxm
Hint: When changing new sliding yoke, it is neces-
sary to adjust the front wheel at the front, and
Align the mark
make the bolt hole surface of sliding yoke face
the back (liking that shown in figure), then as-
semble the bolt.
21. Adjust front wheel at the front.
22. Assemble helix cable assembly (equipping with

SRS) [67000121]
23. Put the helix cable assembly at central position

(equipping with SRS)
(a) Check whether the front wheel faces the front.
(b) Turn helix cable counter-clockwise with hand until it could
not turn.
(c) Then turn helix cable 2.5 clockwise and align the mark.
Hint: helix cable could turn left or right from central
position for 2.5 rounds.
24. Assemble steering wheel assembly [67010001]
(a) Align the mark on steering wheel and main shaft assembly.
(b) Assemble the fixed screw cap of steering wheel.
(c) Connect the joint. Align the
mark
25. Assemble safety airbag assembly at the side of driver [67010011]

Warning:
z Forbid using SRS parts on other automobiles, when changing any part, it is necessary to use new
product.
z If safety airbag assembly at the side of driver once dropped or exterior shell and joint has crack,
concave or other distortions, it is necessary to change with new product.
z When assembling the airbag assemble at the side of driver, it is necessary to pay attention to airbag
wiring harness could not interrupt other parts or be clamped by other parts.
(a) Connect the end. planetary
screw shell
(b) Connect the joint of airbag. screws
(c) After assembling the safety airbag assembly at the side
of driver, insure planetary screw of concave slot contacts
with screw shell.
(d) Use planetary screwdriver to tighten two screws.
Torque: 8.8 Nxm
26. Check the central point of steering wheel
27. Check SRS warning light (equipping with SRS)
197
Power steering--Poser steering system
Power steering
Power steering system
Note
1. Notes for steering system:
It is necessary to change parts correctly, for they will influence the performance of steering system to incur
running danger.
2. Notes for SRS airbag system
MR7180 equips with SRS (auxiliary protection system), such as safety airbag at the side of driver and
safety airbag at the side of passenger, if repairment does not accord with correct sequence, it might incur
SRS explodes suddenly in repairing term to make heavy accident. Before repairing (including disassem-
bling or assembling, checking or changing parts), it is necessary to read the notes in chapter SRS (auxiliary
protection system) carefully.
198

Use following table to help you find the reason of malfunction, the number in table only show the possible
preference sequence of malfunction, please check each part by sequence, if necessary, change this part.

3.Driving belt (loose). -
4.Wheel alignment(wrong). 87
Steering is heavy 5.Steering system joint (abraded). -
6.Lower control arm ball head (abraded). 99
8.Power steering oil pump 203
9.Power steering gear 205
Return is bad 2.Wheel alignment (wrong) 87
3.Steering column (bent) -
1.Steering system joint (abraded) -
2.Lower control arm ball head (abraded) 99
Clearance is too big 3.Middle shaft, sliding fork (abraded) -
4.Front wheel bearing (abraded) 123
1.Power steering oil level (low) 200
2.Power steering joint (abraded) -
Abnormal noise
3.Power steering oil pump 203
199
1. Check driving belt
(a) Check whether the belt has been abraded too much with eyes, and rope is broken.
If finding any defect, change the driving belt.
Hint: Some light crack at the side of belt rib could be approved, but if belt has any crack from
its rib, it is necessary to change.
2. Exhaust air of power steering system
(a) Check the oil level.
(b) Lift up automobile body, and support it with bracket.
(c) Turn steering wheel.
(1) Turn steering wheel slowly from left and right to bottom for several times when engine extinguishes.
(d) Lay down the automobile.
(e) Start the engine to make it run at idling speed for several minutes.
(f) Rotate steering wheel.
(1) Keep engine at idling speed, and turn the steering wheel from left or right to bottom and keep this
state for 2-3 seconds, then turn it to the other direction for 2-3 seconds.
(2) Repeat (1) for several times.
(g) Engine extinguishes. Normal Abnormal
(h) Check whether there is any foam or emulsification
phenomenon.
If there is any foam or emulsification phenomenon and
it is necessary to exhaust air second time, it is necessary
to check whether the system has any leakage.
(i) Check the oil level.
3. Check the oil level

(a) Keep automobile horizontal.
(b) Extinguish the engine, and check the oil level of oil stor-
age tank.
If oil level is too low, add oil.
Power steering oil: automatic transmission oil
DEXRON II or III
Hint: check whether the oil level is in the HOT mark
scope of oil storage tank, if oil is cool, check the
oil level is in COLD mark scope. Normal Abnormal
(c) Start the engine, and keep it at idling speed.
(d) Turn steering wheel from left bottom to right bottom for
several times to make oil temperature increase.
Oil temperature: 80C
200
(e) If there is any foam or emulsification phenomenon, it is necessary to exhaust air in power steering
system. 5mm

(f) Keep the engine at idling speed, and measure the oil
level of oil storage tank.
(g) Engine extinguishes.
(h) After waiting for several minutes, measure the oil level
of oil storage tank again.
Maximal increased height of oil level: 5mm
If finding any problem, it is necessary to exhaust
the air in power steering system.
(i) Check the oil level.
4. Check steering oil pressure.
(a) Disassemble oil pressure supply pipe from power steering gear. (referring to page 205)
(b) Connect special tool liking that shown in figure.
Note: when checking, the valve of special tool should be opened.
(c) Exhaust the air in power steering system.
(d) Start the engine, and keep it at idling speed.
(e) Turn steering wheel from left bottom to right bottom for several times to make oil temperature
Accessory
Special tool
Power steering
gear
Out
In
Oil pressure supply pipe
Accessory
increase.
Oil temperature: 80C Oil tank
(f) Keep the engine at idling speed, and close the valve of
special tool, then observe the reading of special tool. Power Close
steering
Minimal oil pressure: 6400kPa gear
Note:
Pump
y The closing time of oil pressure meter valve could not Special tool
201
Power steering--Power steering system
exceed 10 seconds.
y Do not make oil temperature become too high. Oil tank
(g) When engine is running at idling speed, open the valve
completely. Power Open
steer-
(h) Measure the 1.000 rpm and 3.000 rpm oil pressure of
ing
engine. gear
Pump
Oil pressure difference: 490 kPa or less
Special tool
Note: do not turn the steering wheel.
(i) When engine is running at idling speed, open the valve

completely, and turn the steering wheel to bottom. Oil tank
Turn the steering wheel
Minimal oil pressure: 6,400kPa to the bottom position
Note: Power Open
y Do not keep the wheel locate at bottom for over 10 steering
gear
seconds.
Pump
y Do not make oil temperature become too high.
Special tool
(j) Disassemble the special tool.
(k) Connect oil pressure supply pipe with power steering gear
(l) Exhaust the air in power steering system.
5. Check the steering force

(a) Put the steering wheel at central position.
(b) Disassemble safety airbag assembly at the side of driver.
(c) Start engine, and make it run at idling speed.
(d) Measure the steering force of two directions.
Steering force (reference): 5.5 Nxm
Hint: before diagnosing, it is necessary to consider
the tyre type, tyre pressure and contacting sur-
face at first.
(e) Tighten fixed screw cap of steering wheel.
Torque: 50 5 Nxm
(f) Assemble the safety airbag assembly at the side of driver.
202
Power steering--Power steering oil pump assembly
Power steering oil pump assembly

Overhaul
1. Disassemble front wheel
2. Disassemble right bottom defender board [68000004]
3. Disassemble driving belt.

Special tool
4. Disassemble oil storage tank to the No. 1 oil pipe
of power steering pump
Disassemble fixed clamp, and take down the oil storage tank
to the No. 1 oil pipe of power steering pump.
5. Disassemble in-out oil pipe assembly of power
steering gear [64000131]
(a) Use special tool to disassemble in-out oil pipe assembly.
(b) Disassemble the bolts and disconnect the fixed clamp of
in-out oil pipe.
6. Disassemble rear bracket of power steering pump
Disassemble the bolt and rear bracket of power steering pump.
7. Disassemble power steering oil pump assembly
[64000132]
(a) Disconnect the joint of oil pressure switch.
(b) Disassemble two bolts, two screw caps, then take down
the power steering oil pump assembly.
8. Assembly power steering oil pump assembly

(a) Assemble power steering oil pump assembly with two
bolts and two screw caps.
Torque: 37 Nxm
(b) Connect the joint of oil pressure switch.
Note: the joint could not contact any oil.
9. Assemble the rear bracket of power steering oil pump assembly

Assemble rear bracket of power steering oil pump assembly with bolts.
Torque: 37 Nxm
Hint: Insure the stop lever of bracket has contacted the body of power steering pump, then
tighten the bolt.
203
Power steering--Power steering oil pump assembly
10. Connect the in-out oil pipe assembly of power Special

tool
steering gear [64000131]
(a) Assemble fixed clamp of in-out oil pipe with bolt.

Torque: 7.8 Nxm
(b) Connect in-out oil pipe with special tool.
Torque: 41 Nzxm
Hint:
z Use torque wrench whose lever length is 345 mm.
z Special tool should be parallel with torque wrench,
only this could make practical torque value.
11. Connect the N0. 1 oil pipe of oil storage tank to power steering oil pump assembly.
Connect oil pipe with fixed clamp.
12. Assemble driving belt.
13. Assemble front wheel.

Torque: 103 10 Nxm
14. Add power steering oil.
15. Exhaust the air in power steering system.
16. Check whether there is any oil leakage.
17. Assemble right bottom defender board of engine [68000004].
204
Power steering--Power steering gear assembly
Power steering gear assembly

Overhaul
1. Make front wheel face the front
2. Disassemble safety airbag assembly at the side of driver

(equipping with SRS) [6701011]
3. Disassemble steering wheel assembly [67010001].
4. Disassemble dust-proof cover in steering column

[64000123].
Disassemble two screw caps, then take down the dust-proof
cover.
5. Disassemble steering sliding shaft assemble

(a) Make mark on sliding yoke and steering middle shaft.
(b) Loosen A bolt and disassemble B bolt, then disassemble
sliding shaft.
Align the mark
6. Disassemble front wheel
7. Disassemble right bottom defender board [68000004].
8. Disassemble left bottom defender board [68000003].
9. Disconnect left end terminal of transversal lever

(a) Disassemble cotter pin and screw cap.
(b) Use special tool to disassemble the left end terminal of
transversal lever from steering knuckle. Special tool
Hint: disassemble the other with same method.
10. Disassemble right end terminal of transversal lever.
11. Disassemble in-out oil pipe assembly of power

steering gear [64000131].
(a) Use special tool to disassemble in-out oil pipe assembly
of power steering gear.
Special tool
205
(b) Disassemble the screw and disconnect the fixed clamp of

in-out oil pipe assembly of power steering gear.
12. Disassemble linking lever assembly of front stabi-

lizer bar [64000097].
(a) Use socket head wrench (5mm) to fix bolt, then disas-
semble screw cap.
(b) Disassemble the left linking lever of front stabilizer liking
lever assembly.
13. Disassemble the coupling bolt and nut of left/right

lower control arm ball head and control arm.
Disassemble one bolt and two nuts, and disassemble control
arm from left steering knuckle.
14. Disassemble engine cover assembly
15. Support engine assembly.
16. Disassemble auxiliary automobile bracket assem-

bly [64000087]
(a) Disassemble two bolts, then disassemble side rail from
right front engine suspension.
(b) Disassemble two bolts, then disassemble carling from au-
tomobile body.
(c) Disassemble the bolt and three nuts, then disassemble

engine rear suspension from auxiliary automobile bracket.
(d) Use gearbox jack to support auxiliary automobile bracket.
(e) Disassemble four bolts and auxiliary automobile bracket
assembly with steering gear.
17. Disassemble exterior dust-proof cover of steering

column.
206
18. Disassemble steering middle shaft.

(a) Make mark on middle shaft and steering small gear shaft. Align the mark
(b) Disassemble bolt and steering middle shaft.
19. Disassemble power steering gear assembly

[64000133].
(a) disassemble four bolts, and disassemble power steering
gear from beam.
20. Fix power steering gear assembly [64000133]. Special tool

(a) Use special tool to insure power steering gearbox assem-
bly is clamped on pliers.
Hint: affix ethylene glue on special tool before using.
Ethylene
adhesive
tape
21. Disassemble left transversal lever ball head.
(a) Make mark on transversal lever ball head and gear end.
(b) Loosen fixed nut, then disassemble transversal lever ball
head and fixed nut.
Hint: disassemble the other side with same method.
22. Disassemble right transversal lever ball head.

Align the mark
23. Check left transversal lever ball head.
(a) Insure the left transversal lever ball head is clamped on
pliers.
(b) Assemble nut on bolt.
(c) Shake the bolt of joint front and back for 4-5 times.
(d) Use torque wrench to rotate screw cap continually at the
speed of 2-4 s/r, then read the torque at fifth rotate.
Rotating torque: 0.49-3.43 N.m
Hint: check the other side with same method.
207
24. Check right transversal lever ball head.
25. Disassemble No.2 dust-proof cover of steering gear.

(a) Use pliers to disassemble fixed clamp.
(b) Use pliers to disassemble iron wire.
Note: do not hurt dust-proof cover.
Hint: make mark on RH and LH dust-proof cover.
Hint: disassemble the other side with same method.
26. Disassemble No.1 dust-proof cover of steering gear.
27. Disassemble terminal lever of steering gear.

(a) Use right-angled screwdriver and hammer to unclench claw
gasket.
Note: avoid knocking steering gear.
(b) Use wrench(22mm) to fix steering gear, then use special

Special
tool to disassemble gear terminal lever.
tool
Note: use special tool by the direction in figure.
Hint: Make mark on RH and LH gear terminal lever.
28. Assemble the parts of steering gear terminal lever.

(a) Assemble new claw gasket, and assemble gear terminal
Special tool
lever temporarily.
Hint: Align pliers claw of gasket with steering gear
concave slot. Length of
lever
(b) Use wrench to fix steering gear, and use special tool to
tighten gear terminal lever.
Torque: 62 Nxm Wrench
Note: use special tool by the direction in figure.
Hint: use torque wrench whose lever length is 380mm.
(c) Use copper stick and hammer to concave gasket.

Note: do not hurt the steering gear.
208
29. Assemble steering No.2 dust-proof cover.

(a) Insure steering gear hole is not plugged by lubricating
grease.
Hint: if hole is plugged, the pressure in dust-proof
cover when steering wheel turns after combin-
ing will change.
(b) Assemble dust-proof cover, fixed clamp and new iron wire.
Note: do no t hurt or bend dust-proof cover.
(c) After coiling dust-proof cover with iron wire for two circles,
turn it for several circles to fix it.
(d) Liking that shown in figure, bend iron wire to rotating di-
rection to prevent it from hurting dust-proof cover.
Hint: assemble the other side with same method.
30. Assemble No.1 dust-proof cover of steering gear.
31. Assemble left ball head of transversal lever .

(a) Screw locking cap and transversal lever ball head in gear
terminal lever until aligning the mark.
(b) After adjusting front wiring harness, tighten the screw cap
Align the mark
Torque: 74 5 Nxm
Hint: assemble the other side with same method.
32. Assemble right ball head of transversal lever .
33. Assemble power steering gear assembly [64000133].

(a) Assemble power steering gear assembly on beam with
four bolts.
Torque: 58 Nxm
209
34. Assemble steering middle shaft.

(a) Align the mark of steering middle shaft and steering small Align the mark
gear shaft.
(b) Assemble the bolt.
Torque: 35 Nxm
35. Assemble exterior dustproof cover of steering

column.
36. Assemble auxiliary bracket assembly (64000087).

(a) Use special tool to align the right side of auxiliary bracket
with the hole of body, then lock the A bolt and B bolt
temporarily.
Special
(b) Use special tool to align the left side of auxiliary bracket
tool
with the hole of body, then lock the A bolt and B bolt
temporarily.
(c) Use special tool to align the left side of auxiliary bracket
with the hole of body, then lock the A bolt and B bolt.
Torque:
A bolt: 157 10 Nxm
B bolt: 113 10 Nxm
(d) Use special tool to align the right side of auxiliary bracket Special tool
with the hole of body, then lock the A bolt and B bolt.
Torque:
A bolt: 157 10 Nxm
B bolt: 113 10 Nxm
(e) After connecting with engine with one bolt and three screw
caps, hang it to auxiliary bracket.
Torque: 52 N.m 5 Nxm
(f) Assemble carling to body with two bolts.

Torque: 39 3 Nxm
(g) Assemble the front suspension of engine to carling with
two screw caps.
Torque: 52 5 Nxm
210
37. Connect the bolts and nuts of left/right control arm

and control arm ball head.
Torque: 142 10 Nxm
Hint: connect the other side with same method.
Connect left lower control arm to steering knuckle with
bolt and two nuts.
38. Connect linking lever assembly of left/right front

stabilizer bar [64000097].
Use socket head wrench (5mm) to fix bolt, then connect sta-
bilizer linking lever with screw cap.
Torque: 74 5 Nxm
39. Connect the in-out oil pipe assembly of power steer-

ing gear [64000131].
(a) Connect the in-out oil pipe fixed clamp of power steering
gear with bolt.
Torque: 7.8 Nxm
(b) Use special tool to connect the in-out oil pipe assembly of
power steering gear.
Torque: 41 Nxm
Hint:
z Use the torque wrench whose lever length is
345mm.
z Special tool should be parallel with torque wrench,
only this could make practical torque value.
Length of lever
40. Connect the ball head at the left side of transversal
lever.
(a) Connect the ball head at the left side of transversal lever
with screw cap.
Torque: 49 5 Nxm
Note: if cotter pin hole could not be aligned , tighten
the screw cap for 60 again.
211
41. Connect the ball head at the right side of transver

sal lever .
42. Assemble right bottom defending board of engine

[68000004].
43. Assemble left bottom defending board of engine

[68000003].
44. Assemble front wheel

Torque: 103 10 Nxm
45. Connect steering slide shaft assembly.
(a) Align the mark between steering middle shaft and sliding
shaft.
(b) Assemble B bolt.
Torque: 35 3 Nxm
(c) Tighten the A bolt.
Torque: 35 3 Nxm
46. Assemble inner dustproof cover of steering column [64000123].
Assemble inner dustproof cover of steering column with two screw caps.
47. Make front wheel face the front
Hint: lift up front wheel shaft.
48. Assemble helix cable assembly (equipping with SRS).
49. Assemble steering wheel assembly [67010001].

(a) Align the mark between steering wheel and main shaft of steering column.
(b) Lock the fixed screw cap of steering wheel temporarily.
50. Add power steering oil (referring to page 200).
51. Exhaust the air in power steering system (referring to page 200).
52. Check the central point of steering wheel.

(a) Check the central point of steering wheel.
(b) Lock the fixed screw cap of steering wheel.
Torque: 50 Nxm
53. Assemble safety airbag assembly at the side of driver (equipping with SRS) [67010011].
54. Check whether there is oil leakage.
55. Check the engine cover assembly.
56. Adjust the engine cover assembly.
57. Check and adjust the front wheel alignment (referring to page 87).
212
Air conditioner--Air conditioning system
Air conditioner
Air conditioning system
Note
1. Do not dispose Refrigerant in sealed space or near
flame.
2. Wear glasses to protect your eyes.
3. Do not let liquid Refrigerant contact with your eyes

or skin.
If liquid Refrigerant contacts with your eyes or skin:
(a) Wash the contacted part with much water.
Warning: do not knead your eyes or skin.
(b) Spread clean Vaseline on your skin.
(c) Go to doctor or hospital for special cure.
4. Forbid heating it or making it expose the flame.
5. Forbid dropping the Refrigerant tank or shake it

intensively. wrong correct
6. Do not operate compressor when Refrigerant is lack.

If the Refrigerant in cooling system is lack, it will incur com-
pressor burned out for lacking lubrication. So it is necessary
to avoid.
7. Do not open the high pressure valve of filling instru-
ment package when compressor is working.
If opening the valve at this time, Refrigerant will flow back into
refrigerant tank to incur the tank will break. So only the low
pressure valve could be opened or closed.
8. Do not fill Refrigerant too much.
Too much refrigerant will make many problems such as lack
cooling degree, oil consumption, too hot engine and so on.
1. Check the No.1 pressure switch.
(a) Control for electromagnetic clutch: Low-pressure High-pressure
side Con- side
Check the function of pressure switch.
duction
(1) Assembly filling instrument package.
(2) Connect the anode lead of OUM meter to No. 4 termi-
nal and connect cathode lead to No. 1 terminal. Not Not
conduction conduction
(3) Liking that shown in figure. When refrigerant pressure
is changed, check the conduction between terminals.
213
Air conditioner--Air conditioning system
If the function does not accord with the regulation, it is

necessary to change pressure switch.
(b) Control for cooling fan:
Check the function of pressure switch.
(1) Connect the anode lead of OUM meter to No. 2 termi-
nal and connect cathode lead to No. 3 terminal.
(2) Liking that shown in left figure. When refrigerant pres-
sure is changed, check the conduction between
Not conduc- Conduc-
terminals. tion tion
If the function does not accord with the regulation, it is
necessary to change pressure switch.
Inspection
1. No.1 thermal resistor
(a) Check the resistance between No.1 terminal and No.2 ter-
minal of No.1 heat sensitive resistance at different
temperatures, liking that shown in figure.
Resistance:
2200
Resistance
1155
1100
88
66
44
22
--2255 --1155 --55 55 1155 2255 3355 4455 5555 6655 7755 8855
Temperature
If resistance does not accord with the regulation, it is necessary to change heat sensitive resistance.
214
Air conditioner--Refrigerant
Refrigerant
1. Inspection of refrigerant quantity
Observe the visible window on high pressure liquid pipe.
Testing condition:

Engine runs at the speed of about 1500 rpm.

Fan speed is controlled at HI position.

A/C switch turns to ON.

Temperature control turns to MAX. COOL position. View window

Automobile doors are opened.
Item Phenomenon Refrigerant quantity Verify

There is air bubble on window. Lack (1)Use leakage measurer to check whether there is any leakage,
1 if necessary, repair it.
(2)Add refrigerant until air bubble disappears.
2 There is no air bubble on window. Without, full or too full Referring to item 3 and 4.
There is no temperature difference on Without or little (1)Use leakage measurer to check whether there is any leakage, if necessary, repair it.
3 outlet and inlet of compressor (2)Add refrigerant until air bubble disappears.
There is obvious temperature difference Applicable or too much Referring to item 5 and 6.
4 on outlet and enter of compressor.
Window becomes clear after air Too much (1)Reclaim refrigerant.
5 conditioner is closed. (2)Exhaust air and supply applicable clean refrigerant.
After air conditioner is closed, refrigerant Applicable -
6 makes bubble, then becomes clear.
* When environment temperature is normal and refrigerant is enough, it is normal when there is no
bubble in window.
2. Use filling instrument package to check the refrigerant pressure.
This is a type to use filling pressure meter to check the malfunction position. In following situations, read
the meter.
Testing condition:
z Switch is set up at inner air cycle, and the inlet temperature is 30-50C.
z Engine runs at the speed of 1500 rpm.
z Set up the speed control switch of fan at HI position.
z Temperature control switch is set up at COOL position.
z A/C switch turns to ON.
z Automobile door is opened completely.
Hint: please pay attention to that the show of meter might change little for environment tem-
perature changes.
215
(1) Refrigerant system with normal function.

Meter reading
Low pressure end:
0.15-0.25Mpa
High pressure end:
1.37-1.57Mpa
(2) Water in cooling system.
Situation: too cold periodically, then lose cooling degree.
Phenomenon Possible reason Diagnose Method

When cooling system is Water vapor enters refrigerant z Dryer locates at full humidity (1)Change the condenser.
working, the pressure in low system, and freezes on the ex- state. (2)Remove water in pipeline
pressure end changes to pansion valve, the system z Water vapor of refrigerant with method of taking out
vacuum or normal periodically. stops cycle in short time, when freezes on the outlet orifice vacuum repeatedly.
ice melts, it returns to normal of expansion valve to ob- (3)Fill applicable new
again. stacle freezing cycle. refrigerant.
(3) Lack refrigerant
State: lack refrigerant

z The pressure of high and low Some part of refrigerant system z Refrigerant in system lacks. (1)Check it with leakage
pressure end is low. leaks. z Cooling degree is not measurer, if necessary, re-
z There is air bubble on enough. pair it.
window. (2)Fill refrigerant to applicable
z Refrigerant leaks. quantity.
(3)If meter pressure reading is
0, after checking and repair-
ing leaking position, take out
vacuum.
216
(4) Refrigerant cycle is poor
State: cooling degree is not enough

z The pressure of high and low z Refrigerant flow in adjuster z Adjuster is obstructed. z Change the condenser.
pressure end is low. is obstructed by impurity.
z The pipeline from condenser
to expansion valve frosts.
(5) Refrigerant does not have any cycle.
State: not cool (sometime cool)

z Low pressure side is z Refrigerant flow in cool- Refrigerant does not flow. (1)Check the expansion
vacuum, and pressure at ing system is obstructed valve.
high pressure side is low. by water vapor or dust. (2)Remove the dirt in ex-
z The pipeline of front and z Refrigerant flow is ob- pansion valve with high
rear end of expansion structed by expansion pressure air.
valve or adjuster frosts or valve. (3)Change condenser.
dews. (4)Take out vacuum and fill
applicable refrigerant.
(5)If this is caused by ex-
pansion valve leakage,
change the valve.
217
(6) Refrigerant is too much or the radiating fin of condenser is bad
State: cooling degree is not enough.

z The pressure of high and z Too much refrigerant in z Filled refrigerant is too (1)Clean the condenser.
low pressure end is high. system incurs this. much. (2)Check the function of
z There is no bubble on z Heat dispersion of con- z Heat dispersion of con- cooling fan.
window when engine denser is bad. denser is bad
heat
dis- (3)If those two items above
speed decreases. persion sheet of con- are normal, check the re-
denser is obstructed or fan frigerant quantity. Fill
engine has malfunction. applicable refrigerant.
(7) Air enters cooling system
State: cooling degree is not enough.
Note: if cooling system is

opened, and it does not
take out vacuum when
filling refrigerant, this
state will happen.

z The pressure of high and Air enters cooling system. z There is air in cooling (1)Check whether the Re-
low pressure end is high. system. frigerant oil is too dirt or
z Pipeline of low pressure
z It does not take out lack.
end is too hot to contact.
z There is bubble on vacuum completely. (2)Take our vacuum and fill
window. new refrigerant.
218
(8) Expansion valve is bad
State: cooling degree is not enough

z The pressure of high and low Expansion valve has z Refrigerant in low pressure Check the expansion valve.
pressure end is high. malfunction. pipeline is too much.
z Pipeline of low pressure end z Open degree of expansion
frosts or dews heavily. valve is too big.
(9) Not cool
State: not cool

z The pressure of low pressure There is inner leakage in z Compressor is bad. Repair or change the
end is too high. compressor. z Expansion valve leaks or compressor.
z The pressure of high pres- sliding part is damaged.
sure end is too low.
219
Reading of filling meter (referred value)
Pressure of low pressure side
Fan HI phase
Blower LO phase
Pressure of high
pressure side
220
Change
1. Reclaim HFC-134a (R134a)
(a) Turn A/C switch to ON.
(b) Keep the engine speed at 1000 rpm, and rotate cooling compressor for 5 to 6 minutes to make
refrigerant cycle, this could collect the Refrigerant oil in each part in cooling compressor as possible.
(c) Extinguish the engine.
(d) Drain the refrigerant.
2. Fill refrigerant
(a) Use vacuum pump to take out vacuum.
(b) Fill the refrigerant HFC-134a (R134a)
Standard quantity: 660 10g
Filling quantity of refrigerant

Increase 100g
Applicable
filling scope
Pressure at Too much filling refrigerant

the high
pressure side
Bubble
disappearing
point
Refrigerant quantity
Auxiliary condenser system
3. Heat the engine
4. Check whether the refrigerant leaks.
221
Air conditioner--Refrigerant pipeline
Refrigerant pipeline
Parts
Refrigerant low
pressure hose

Pipeline

nut
Refrigerant high
pressure hose
Refrigerant liquid pipe
. : Regulated torque
222
Air conditioner--Control assembly, air conditioner control panel (AUTO A/C)
Control assembly, air conditioner control panel

(AUTO A/C)
Overhaul
1. Disassemble central wind outlet trim board of panel.
2. Disassemble decoration panel assembly of shift

organization. [68000076]
3. Disassemble central storage box.
4. Disassemble control panel assembly of air

conditioner. [67000148]
Fixing claw
5. Disassemble control assembly and control panel
assembly of air conditioner.
(a) Disassemble ten screws.
(b) Disconnect four fixed claws and disassemble control as-
sembly and control panel of air conditioner.
6. Disassemble control box of air conditioner.
Disconnect flat linking wire and disassemble control box of
air conditioner.
7. Disassemble electric circuit board of air conditioner

control module.
(a) Disassemble two screws.
(b) Disassemble electric circuit board from air conditioner con-
trol box.
8. Disassemble control panel wiring of air conditioner.

(a) Disassemble two screws.
(b) Disassemble control panel wiring of air conditioner from
air conditioner control box.
9. Disassemble control box assembly of air conditioner.
10. Disassemble switch bulb of air conditioner control

panel.
11. Disassemble control button assembly.
12. Disassemble NO.2 warm control button
223
Air conditioner--Fan assembly
Fan assembly
Overhaul
1. Disassemble left/right front door pedal trim board.
2. Disassemble front lower inner trim board at the left/

right side.
3. Disassemble storage box assembly at the right side

of panel.
4. Disassemble engine ECU.

(a) Disassemble two fixed clamps and engine ECU cover.
(b) Disassemble two screws and disconnect engine ECU.
5. Disassemble panel assembly.

(a) Disassemble the bolts and screws from panel.
(b) Disassemble the screws and air conduct.
Fixing claw
6. Disassemble fan assembly.

(a) Disassemble fixed clamp and turn over the carpet.
Carpet
(b) Disassemble fixed claw and disconnect joint plug.
224
Locking point
Fixing claw
(c) Disconnect joint and fixed clamp.
Fixing clamp
(d) Disassemble servo motor assembly joint of in-out air cycle

flow choke.
(e) Disassemble three screws and bolts.

(f) Disconnect fixed claw and disassemble electric engine of
fan.
(g) Disassemble fan assembly.
Fixing claw
225
7. Disassemble servo motor assembly of indoor cycle

flow choke.
Disassemble two screws and servo electric engine assembly
of indoor cycle flow choke.
8. Disassemble fan motor assembly.

Disassemble three screws and fan electric engine assembly.
9. Disassemble fan motor control assembly (automatic

air conditioner).
Disassemble two screws and fan electric engine control
assembly.
226
Air conditioner--Air conditioner central heating core assembly
Air conditioner central heating core assembly

Overhaul
1. Disassemble radiator cover.
2. Reclaim HFC-134a(R134a)
low pressure
3. Disconnect refrigerant No.1 low pressure hose.
hose
Note:
after disassembling the pipeline, it is necessary to cover
the joint to prevent humidity or dust from entering in
system.
4. Disconnect refrigerant liquid pipe A.
Hint: disconnect liquid pipe A with the method being liquid pipe A
same as No.1.
5. Disconnect water outlet hose of heating.

(a) Slide out fixed clamp and disassemble water outlet hose
of heating.
6. Disconnect water intake hose of heating.

Slide out fixed clamp and disassemble water intake hose of
heating.
7. Disassemble cathode wire of battery.
8. Make front wheels face the front.

driver.
10. Disassemble steering wheel.
11. Disassemble combination instrument cover

[68000077].
12. Disassemble combination instrument assembly

[68000081].
13. Disassemble ventilation orifice assembly at the left

side of panel [68010010].
14. Disassemble ventilation orifice assembly at the right

side of panel [68010011].
227
15. Disassemble central ventilation orifice assembly of panel [68010012].
16. Disassemble right storage box assembly of lower panel [68010008].
17. Disassemble inner trim board assembly of right front column [68010017].
18. Disassemble inner trim board assembly of left front column [68010014].
19. Disconnect the joint of safety airbag assembly at the side of passenger.
20. Disassemble upper panel assembly [6801004].
21. Disassemble upper/lower trim board of steering pipe [64000128/64000129].
22. Disassemble left combination switch assembly [67000078].
23. Disassemble right combination switch assembly [67000079].
24. Disassemble air spring assembly of right storage box [68000082].
25. Disassemble decoration panel assembly of shift organization [68000076].
26. Disassemble air conditioner control panel assembly [67000148].
27. Disassemble the assemble bracket of CD machine.
28. Disassemble ventilation pipe assembly of evaporator [67000149].
29. Disassemble air conditioner control assembly.
30. Disassemble parking brake lever hole cover.
31. Disassemble auxiliary panel assembly.
32. Disassemble step trim board of right front door [68010021].
33. Disassemble step trim board of left front door [68010020].
34. Disassemble lower inner trim board of right defender [68010016].
35. Disassemble lower inner trim board of left defender [68010015].
36. Disassemble central linking board of lower panel [68010006].
37. Disassemble lower panel assembly [68010005].
38. Disconnect steering column assembly [64000122].

(a) Disassemble three bolts.
(b) Disassemble steering column from panel framework body.
228
39. Disassemble lower mounting bracket of panel frame-

work [68000074].
(a) Disassemble the screw and disconnect wiring harness.
(b) Disassemble the screw cap, bolt and lower assemble
bracket of panel framework.
40. Disassemble panel framework body assembly

[68000070].
(a) Disassemble three bolts and disconnect panel junction box
and joint fixed plug.
(b) Release fixed clamp from panel framework body and dis-
connect the wiring harness.
(c) Disassemble five bolts and panel framework body
assembly.
41. Disassemble wind outlet of Defogger.

Release five fixed claws and disassemble wind outlet of de-
fogger
Fixing claw
42. Disassemble control cable assembly of air mixing

flow choke (manual air conditioner).
(a) Disassemble pull cable from fixed clamp.
(b) Disassemble control cable of air mixing flow choke.
Fixing clamp
43. Disassemble engine ECU.

Disassemble two bolts and disconnect engine ECU.
44. Disassemble air conditioner group assembly.
Disassemble two screw caps, screws, bolts and air condi-
229
tioner group assembly.
45. Disassemble air conditioner central heating core

assembly.
(a) Disassemble the screw and pull out wind leading pipe.
(b) Disassemble two screws.
(c) Disconnect fixed claw and disassemble air conditioner
central heating core assembly.
Fixing claw
Fixing claw
46. Disassemble servo motor of module state flow

choke (automatic air conditioner).
Disassemble three screws and servo motor of module state
flow choke.
230
47. Disassemble servo motor of air mixing flow choke

(automatic air conditioner).
Disassemble two screws and servo motor of air mixing flow
choke.
48. Disassemble air conditioner pipeline.

(a) Disassemble two screws and extending cover.
(b) Use planetary wrench (5.0mm) to disassemble two plan-
etary bolts and air conditioner pipeline.
(c) Disassemble two O-shape loops from air conditioner
pipeline.
49. Disassemble expansion valve.

(a) Disassemble expansion valve from air conditioner group.
(b) Disassemble two O-shape rings from air conditioner
pipeline.
50. Disassemble No.1 air conditioning heat sensitive

resistance.
51. Disassemble evaporator.

(a) Disassemble six screws and air conditioning group parts.
(b) Pull out evaporator.
52. Disassemble central heating core.

Disconnect fixed claw and central heating water pipe defend-
ing cover, then pull out central heating core.
Fixing
claw
231
53. Assemble expansion valve.

(a) Spread Refrigerant oil on two O-shape loops and assemble
it on expansion valve.
Refrigerant oil: ND-OIL No. 8 or other products with
same grade.
(b) Assemble expansion valve on evaporator.
54. Assemble air conditioner pipeline.

(a) Spread Refrigerant oil on two O-shape loops and assemble
it on air conditioner pipeline.
Refrigerant oil: ND-OIL No. 8 or other products with
same grade.
(b) Use planetary wrench (5.0mm) to assemble air conditioner
pipeline with two planetary bolts.
Torque: 3.5 Nxm
(c) Assemble two screws and extending cover.
55. Assemble panel framework body assembly
Assemble panel strengthening beam and five bolts.
56. Assemble lower assemble bracket of panel

framework.
Assemble lower assemble bracket of panel framework, screw
cap and bolt.
232
57. Assemble control cable of air mixing flow choke

(manual air conditioner).
(a) Connect control cable of air mixing flow choke to air condi-
tioner control assembly.
(b) Set up drag arm at MAX>COOL position.
(c) Assemble inner pull cable terminal to control lever.
(d) Press down lightly the fixed clamp of pull cable by the ar-
row direction in left figure, then assemble exterior pull cable
to fixed clamp.
Hint: Operate temperature control lever, check whether the control lever keep silent and does
not return at the position of MAX.COOL and MAX.HOT.
(e) Disassemble control cable of air mixing flow choke from air conditioner control assembly.
58. Assemble upper panel assembly.
59. Assemble air conditioner control assembly.
60. Assemble helix cable.
61. Assemble steering wheel.
62. Check whether the steering wheel position is right.
63. Check horn button assembly.
64. Assemble horn button assembly.
65. Check SRS warning light.
66. Assemble refrigerant No.1 low pressure hose.

(a) Spread Refrigerant oil on new O-shape loop and assemble
it on hose. Connection Clearance Wrong
(b) Assemble refrigerant No.1 low pressure hose and fixed

clamp.
Hint: After installation, check the fixed situation of
pipeline fixed clamp claw.
67. Assemble refrigerant liquid pipe A.
(a) Spread Refrigerant oil on new O-shape loop and assemble it on hose.
(b) Assemble refrigerant liquid pipe A and fixed clamp.
Hint: After installation, check the fixed situation of pipeline fixed clamp claw.
68. Add cooling water.
69. Heat the engine.
70. Check whether the cooling water leaks.
71. Fill the refrigerant, regulated quantity: 660 10g.
233
Air conditioner--Compressor assembly
Compressor assembly
Change
1. Disassemble radiator cover.
2. Reclaim HFC-134a(R134a)
3. Disconnect refrigerant No.1 low pressure hose.
(a) Disassemble the bolt from compressor and electromag-
netic clutch assembly and disconnect refrigerant low pres-
sure hose.
(b) Disassemble O-shape loop from refrigerant low pressure
hose.
Note: after disassembling the pipeline, it is necessary
to cover the joint to prevent humidity or dust from
entering in system.
4. Disconnect refrigerant No.1 high pressure hose.
(a) Disassemble the bolt from compressor and electromag-
netic clutch assembly and disconnect refrigerant high pres-
sure hose.
(b) Disassemble O-shape loop from refrigerant high pressure
hose.
Note: after disassembling the pipeline, it is necessary
to cover the joint to prevent humidity or dust from
entering in system.
5. Disassemble right bottom defending cover of engine.
6. Disassemble driving belt.
7. Disassemble compressor and electromagnetic

clutch.
(a) Disconnect the joint.
(b) Disassemble three screws and electromagnetic clutch.
8. Check the Refrigerant oil.
When upgrading compressor assembly, it is necessary to reclaim the refrigerant in system at first.
Refrigerant oil quantity added by new compressor should be calculated by following formula.
Refrigerant oil standard quantity of new compressor:
(Inner Refrigerant oil quantity of new compressor:60 10ml)-(Inner discharged Refrigerant oil quantity
of old compressor)=(Refrigerant oil quantity consumed by the system when changing)
Note:
z When checking the Refrigerant oil quantity, please refer to the notes on page 206.
z For there is some Refrigerant oil in automobile pipeline, if some Refrigerant oil is not discharged
when assembling new compressor, this will incur the Refrigerant oil in system is too much to make
the system heat exchange become bad and air conditioning become invalid.
234
Air conditioner--Compressor assembly
z If Refrigerant oil quantity in the disassembled old com-

pressor is too little, check whether the system leaks Re-
frigerant oil.
z Only could use 100PG Refrigerant oil.
9. Assemble compressor and electromagnetic clutch.
(a) Assemble compressor, electromagnetic clutch and three
bolts.
Torque: 24.5 Nm
(b) Connect the joint.
10. Assemble driving belt.
11. Assemble refrigerant No.1 high pressure hose.

(a) Disassemble the cover on pipeline joint.
(b) Spread Refrigerant oil on new O-shape loop and assemble
it on No.1 refrigerant high pressure hose.
Refrigerant oil: 100PG
(c) Connect No.1 refrigerant high pressure hose to compres-
sor and electromagnetic clutch and assemble the bolts.
Torque: 9.8 Nm
12. Assemble refrigerant No.1 low pressure hose.
(a) Disassemble the cover on pipeline joint.
(b) Spread Refrigerant oil on new O-shape loop and assemble
it on No.1 refrigerant low pressure hose.
Torque: 23 Nm
(c) Connect No.1 refrigerant low pressure hose to compres-
sor and electromagnetic clutch and assemble the bolts.
Torque: 9.8 Nm
13. Fill the refrigerant (referring to page 221).
Regulated quantity: 660 10g
14. Heat the engine.
235
Air conditioner--Condenser Assembly
Condenser Assembly
Inspection on the automobile
1. Check the Condenser Assembly.
(a) If the radiating fins of condenser assembly are dirty, wipe it with water and blow it to dry with com-
pressed air.
Notice: Do not damage the radiating fin.
(b) If the radiating fin is curved, repair it with gad screw driver or pliers.
2. Check whether the Condenser leaks.
(a) Use leakage detector to check whether the Refrigerant leaks at the joint of the pipelines.
(b) If it leaks, check the fastening torque of joint part.
Overhaul
1. Disassemble the radiator cover assembly.
2. Recycle the HFC-134a(R134a)
3. Disassemble the Refrigerant liquid pipe A.

(a) Disassemble the bolt from the condenser assembly and
disconnect the Refrigerant liquid pipe A.
(b) Disassemble the O-shape ring from the Refrigerant liquid
pipe.
Notice: The pipeline should be covered immediately
to prevent damp or dust from getting into the system.
4. Disassemble the Refrigerant NO.1 high pressure
hose.
(a) Disassemble the bolt and the Refrigerant NO.1 high pres-
sure hose from the condenser assembly.
(b) Disassemble the O-shape ring from the Refrigerant high
pressure hose.
Notice: The pipeline should be covered immediately
to prevent damp or dust from getting into the system.
5. Disassemble the condenser assembly.

(a) Disassemble those two bolts and the bracket on water tank.
236
(b) Disassemble two bolts.

(c) Pull the component on the top of water tank assembly back
to disassemble the condenser assembly.
6. Disassemble the drier

(a) Use 10mm hexagon wrench to disassemble the cover and
filter core from regulator.
Inner hexagon
socket wrench
Adjuster
(b) Disassemble two O-shape rings from the cover.
(c) Use the acutilingual pliers to disassemble the drier.
7. Assemble the drier.

(a) Use the acutilingual pliers to assemble the drier.
(b) Put the O-shape ring in the cover.
(c) Spread freezing lubricant at the connecting part between
the O-shape ring and the cover.
(d)Use the 10mm hexagon wrench key to assemble the cover
to condenser assembly.
Torque: 12.3 Nm
8. Assemble condenser assembly.
9. Assemble Refrigerant NO.1 high pressure hose.

(a) Disassemble the cover from the tie in of the pipe.
(b) Daub enough Refrigerant oil to lubricate at the connecting
part between the O-shape ring and the cover.
(c) Use the bolt to connect Refrigerant high pressure hose
with condenser assembly.
Torque: 5.1 Nm
237
10. Assemble the Refrigerant liquid pipe A.

(a) Disassemble the cover from the pipeline joint.
(b) Assemble the O-shape ring to the Refrigerant liquid pipe
A.
(c) Spread enough Refrigerant oil to lubricate at the conencting
part between the O-shape ring and the cover.
(d) Use the bolt to connect the Refrigerant liquid pipe A with
condenser assembly.
Torque: 5.4 Nm
11. Fill with Refrigerant.
Regulated quantity: 660 10g
12. Warm the engine.
13. Check whether the Refrigerant leaks.
238
Supplemental restraint system--Note
Supplemental restraint system

Note
Warning:
This product is the SRS (supplemental restraint system) equipped by JILI YUANJIN vision type automobile, when
the automobile frontal face is impacted heavily, this product could reduce the possible hurt for driver and passen-
ger at the front seat, but this product could not replace the safety belt. For SRS is supplemental restraint safety
system, the driver should tie safety belt. This product is single-point electronic dual-airbag system whose charac-
teristic is that all sensors and control circuits are assembled in control box and gas maker is protechny. At the
same time, this product accords with the enterprise standard Automobile safety airbag equipment (Q/JL001
2001) to product.
In repairing process, if it does not accord with correct operation sequence to operate, SRS might happen the
accidental explosion to make heavy accident. If repair does not accord with correct procedure, even if repair does
not incur accident, SRS might disable when automobile happens accident, for example, it could not explode by
the requirement. So, when making repair (including disassembling, assembling, checking or changing any part),
it is necessary to operate by correct sequence regulated by repair manual.
It is necessary to confirm following works before repairing: 1. Put the ignition switch at OFF state. 2. Disconnect
the cathode connection of battery, and make repair after waiting for 60s. In addition, disassembled cathode
should be twisted by insulating tape to insulate. (Capacitor in ECU could keep some electric power after battery
is cut off to unfold safety airbag in some time. So, when making maintenance, if it does not wait for some time
before operating, it might incur heavy hurt accident for wrong expansion of safety airbag.)
Do not put the parts of SRS directly under the insulation of hot air or flame.
Note:
When making repair, please make malfunction diagnosis by the flash light and malfunction diagnosing device
according with the method regulated in this operation manual at first, at the same time, it is necessary to check
whether there is any malfunction code before disassembling battery wire.
Forbid disassembling or repairing at any non-appointment repair station
Do not assemble any safety lever or bumper at the front of automobile, this will influence the performance of this
airbag.
People for repairing, disassembling and assembling should be trained specially.
When disassembling steering wheel assembly, it is necessary to make steering wheel right, only this could disas-
semble steering wheel assembly and make helix cable locate correct position, or it will damage helix cable assembly.
ECU matches with the technical parameter of electric system, forbid using the SRS parts of other automobiles, at
the same time, it is necessary to use new product to replace any part.
When repairing automobile (especially electric welding), it is necessary to close key switch, and it is best to cut off
the anode of battery.
After unfolding airbag, safety airbag assembly and helix cable assembly should be changed completely.
When disassembling or carrying airbag assembly, trim cover should face the upside; safety airbag assembly
could not superpose directly to avoid make wrong explosion and make any accident.
The inner malfunction of controller (ECU) could not repair, if it happens any malfunction, change it.
Safety airbag assembly should be stored in the environment whose temperature is lower than 40C, relative humid-
ity is lower than 75% and is apart from electromagnetic interruption.
Forbid disassembling the airbag assembly and gas generator in it.
Forbid connect AC or DC with over 20V with ECU to avoid damage.
239
Special tools and measurers which any safety airbag repairing position should have:
Number Name and type of tool Function

a 5S hexagon wrench Disassemble airbag subassembly on steering wheel
b Socket wrench 18S Assemble and disassemble big nut on steering column
c 14S socket wrench Assemble and disassemble ECU and safety airbag assembly
at the side of passenger on automobile body.
d Numeric multi-meter DT 992 type Used for electric measurement on wiring harness
e Electric detonator tester Used for resistance measurement of electric ignition device
QJ992 type of airbag subassembly.
Changeable subassembly which safety airbag repairing position should have:

a. Safety airbag assembly at the side of driver;
b. Safety airbag assembly at the side of passanger;
c. Helix cable assembly.
d. ECU assembly;
e. Steering wheel.
I. Safety airbag joint
Helix Safety airbag at

cable the side of driver
Airbag controller
Short
Safety airbag at the
wiring
side of passenger
harness
No. Item Applicable

(1) Terminal dual-locking organization
(2) Airbag anti-explosive organization Joint 3, 4, 7, 8
(3) Checking organization of electric circuit connection
(4) Inadequacy connection protection organization Joint 4
(5) Joint dual-locking organization Joint 2
(6) Joint dual-locking organization Joint 6, 7, 10
1. All safety airbag joints should be yellow to be easy to distinguish the joints on other automobile parts,
this could guarantee the safety performance and reliability of safety airbag joint, each kind of joint has
special function and design.
240
(1) Terminal dual-locking organization: Locking block

Each joint should be dual-locking organization and combines
with joint body and locking block. This design is caused by Body
the reason that dual-locking device (locking block and fixed
sheet) could fix the terminal to prevent it from releasing.
(2) Airbag anti-explosive organization
Each joint has a short circuit sheet, when the joint is
Mother Father
disassembled, short circuit sheet will connect the terminal joint joint
of device power supply with that terminal of igniter.
When connecting the joint When disconnecting the joint
Short circuit spring sheet

Short circuit spring sheet
Body
Contact with father terminal
Body
Terminal
Short circuit spring sheet ON
Detonator Detonator
Joint Short circuit spring sheet Closed circuit
(3) Joint dual-locking organization:

The joint equipping with this organization (male joint and female joint) is locked by dual-locking device
to increase the reliability of connection.
If one time lock is not firm, convex block will interrupt and stop the locking of twice lock.
Twice lock
Convex block
lock
One time lock lock
One time lock is not firm Twice lock is firm Dual-lock could lock
(twice lock is stopped) (Twice lock could lock) completely
241
(4) Joint locking organization:

Lock the locking clasp of joint to fasten the connection of joint.
2. When the automobile front face is impacted, and generated force is bigger than the standard pre-set,
airbag will work automatically. The sensor in safety airbag controller will feel the impact, at the same
time, it will judge the generation of impact by inner arithmetic to make ignition electric current. Electric
current will flow in gas generator to make explosive function, then two gas generators in airbag at the
side of driver and passenger will make gas to increase quickly inner pressure of airbag and rush out
the trim cover of steering wheel and instrument panel. After airbag charging is closed, the gas ejects
from the gas outlet at the side or at the back of airbag.
II. Disassemble the connecting joint of lower helix cable and wiring harness of steer-
ing wheel.
1. Put your finger on sliding block.
2. Move the sliding block to release the clasp.
3. Pull out the male joint.
Liking that shown in figure: some joints of wiring harness use the female joints in the right part of figure,
some designs of helix cable is similar with the joints in the left part.
Sliding block Sliding block
Disconnect completely
III. Connect the connecting joint of lower helix cable and wiring harness of steering wheel.
1. Liking that shown in figure, align locking part of male joint and sliding block of female joint in same
direction to avoid mutual friction.
242
2. Confirm inserting it until locking, after assemble, pull it to check whether it is locked (when locking,
confirm exterior joint returns to former position, at the same time, assembling sound could hear).
Hint:
When moving the sliding block, do not contact it.
Pay attention to do not distort the release board, if release board is distorted, it is neces-
sary to change it with new helix cable.
Sliding block Sliding block
IV. Assemble ECU joint

Limit switch
Figure 1 Figure 2 Figure 3
1. Press down limit switch in figure 1.

2. Dial white switch along the black line in figure 2, dial it to bottom liking that shown in figure3.
Hint: you will hear the assembling sound that shows it is put to position when white switch is
put into position.
V. Connect airbag wiring harness and short wiring harness at the side of passenger.
Figure 3 Figure 4
1. Insert the connector in figure 3 in the part in figure, after assemble it into its position, you will hear hint
sound.
243
Supplemental restraint system--Malfunction treatment
Malfunction treatment
1. Basic procedure of malfunction diagnosis
After assembling new electronic control unit of safety airbag system, indicating light of safety airbag
system will extinguish forever after flashing for 5 seconds when ignition switch is at state of ON, this
shows airbag system works normally. At this time, the system does not need to repair, it is necessary
to make system diagnosis and repair when showing any situation except this.
If indicating light of safety airbag system does not illuminate when ignition switch is at the state of ON,
check the related circuits of indicating light, then operate it to make it enter working state.
Warning light illuminate Scanning ECU by connecting Find the malfunction Deal with Clean the code
and does not extinguish diagnostic instrument malfunction
2. Inspection for indicating light of safety airbag

(1) When set the ignition switch at ON position, confirm whether the indicating light illuminates.
(2) After illuminating for five seconds, confirm whether indicating light extinguishes forever.
(3) If starting ignition switch for five seconds, indicating light does not extinguish (flash or illuminate for long
time), confirm the position of system malfunction with special diagnostic tool according to the flash
situation of indicating light.
3. System diagnosis
Safety airbag controller (KD4.1) will implement a series of cycle diagnostic testing to check whether the
function of airbag system has been prepared completely. This test will prevent restraint system from
exploding wrongly and insure the necessary explosion in impact. If finding any malfunction, safety airbag
controller (KD4.1) will store a applicable malfunction code and turn on indicating light to indicate a mal-
function state to be easy to maintain.
4. Malfunction judgment
(1) Malfunction category
System malfunction could be divided into three categories: power supply malfunction, subassembly
assembling malfunction and ECU inner malfunction.
a. Power supply malfunction
Normal working voltage of ECU is 9-18 V, related working voltage is 12 V. When automobile key is
turned to ACC gear, ECU connects power and begins to self-check, indicating light extinguishes
after illuminating for five seconds, this shows there is not any malfunction in ECU and exterior
subassembly, they could work normally. When automobile power voltage is less than 9V or higher
than 18V, ECU will self-check again. If self-checking could pass, ECU works normally, and indicat-
ing light extinguishes; if self-checking could not pass, it is necessary to self-check again, this self-
checking could be made six times, if indicating light illuminates all the time after six times, there is
some malfunction in power supply.
b. Assembling malfunction of airbag subassembly
Assembling malfunction of airbag subassembly is that malfunction which only needs to change or
repair airbag subassembly without needing to change ECU, including the situation that airbag
subassembly is not connected completely. If happening this malfunction when connecting power
supply, indicating light will flash N times at first, then it will illuminate all the time until malfunction is
removed. If happening impact in malfunction term, ECU could explode the channel of good part
and record every malfunction when exploding.
c. Inner malfunction of controller
Inner malfunction is the malfunction happening in ECU body, when happening this malfunction,
ECU could not explode airbag, and will record the impacting acceleration.
Note: common repairer could not repair this inner malfunction, if happening this malfunction,
it is necessary to change ECU.
(2) Malfunction state display
244
Malfunction display of SRS could confirm originally by the flash of indicating light, detailed information
could be gained by malfunction diagnostic tool.
a. Safety airbag indicating light is driven by ECU, all malfunction displays are finished by ECU. After
working voltage is supplied for safety airbag controller (KD4.1) by battery, safety airbag controller
(KD4.1) illuminates indicating light to check SRS. To notify driver that there are some malfunctions
in system, indicating light will illuminate for long time after working voltage is supplied. If existing
SRS does not have any malfunction, indicating light will close after illuminating for five seconds
after ignition on. In original phase, safety airbag controller (KD4.1) does not prepare to check the
impact and stop the unfold until the wire of safety airbag controller (KD4.1) is reliable.
After ignition switch is turned to ON gear, the display type of indicating light when there is no any
malfunction in SRS is:
Ignition switch ON
Assembling malfunction information of subassembly could see follow table 1.

Table1: Assembling malfunction information indicating table for airbag subassembly
Number Malfunction type Slow flash times (N times) Remark

1 Igniter at the side of driver happens short circuit 3
2 Igniter at the side of driver happens open circuit 4
3 Igniter at the side of driver connects grounding 5 or wrong explosion
of airbag subas-
4 Igniter at the side of driver connects battery 6
sembly will make
5 Igniter at the side of passenger happens short circuit 7 big hurt for human,
6 Igniter at the side of passenger happens open circuit 8 its warning rea-
7 Igniter at the side of passenger connects grounding 9 sons should be di-
vided detailedly.
8 Igniter at the side of passenger connects battery 10
9 Safety belt at the side of driver happens pre-tightening malfunction 11
10 Safety belt at the side of passenger happens pre-tightening malfunction 12
12 Impact output interface happens malfunction
Schematic drawing for slow flash indicating light
Illuminate
Extinguish
245
Inner malfunction information could see following table 2.

Table 2: ECU inner malfunction information indicating table
Number Malfunction type Fast flash type Remark
1 Electronic acceleration offset malfunction Short, short, short and long 0001
2 Electronic acceleration self-checking malfunction Short, short, long and short 0010
3 SCM inner RAM is wrong Short, short, long and long 0011
4 Inner parameter is wrong Short, long, short and short 0100
5 Inner malfunction or acceleration storage space is full and ignition record has been made. Short, long, short and long 0101
6 Mechanical safety sensor happens malfunction Short, long, long and short 0110
7 Increased pressure is wrong Short, long, long and long 0111
8 Ignition driving function is wrong Long, short, short and short 1000
9 Voltage of ignition voltage F12 and F13 is wrong Long, short, short and long 1001
10 Other parts are wrong Long, short, long and short 1010
Schematic drawing for fast flash indicating light
Schematic drawing for short, short, long and short malfunction

If happening the situations above, it is necessary to turn off key switch of automobile at first, then turn on key
switch and start it again, if information hint could not be removed, it is necessary to change ECU.
246
Supplemental restraint system--Repair
Repair
a. In using process, if happening any malfunction of power supply, it shows the voltage of power supply
is less than 9V or higher than 18V, or the battery is damaged, at this time, it only needs to charge or
change the battery.
b. Use special malfunction diagnostic tool to test.
Malfunction codes approved by safety airbag controller (KD4.1)
Number Malfunction specification Remove

1 Ignition circuit 1 (safety airbag at the side of driver), the resistance is too high or open circuit. OK
2 Ignition circuit 1 (safety airbag at the side of driver), the resistance is too low or short circuit. OK
3 Ignition circuit 1 (safety airbag at the side of driver), connects with the grounding OK
4 Ignition circuit 1 (safety airbag at the side of driver), connects with power supply OK
5 Ignition circuit 2 (safety airbag at the side of passenger), the resistance is too high or open circuit. OK
6 Ignition circuit 2 (safety airbag at the side of passenger), the resistance is too low or short circuit. OK
7 Ignition circuit 2 (safety airbag at the side of passenger), connects with the grounding OK
8 Ignition circuit 2 (safety airbag at the side of passenger), connects with power supply. OK
9 Ignition circuit 3 (pre-tension safety belt at the side of driver), the resistance is too high or open circuit. OK
10 Ignition circuit 3 (pre-tension safety belt at the side of driver), the resistance is too low or short circuit. OK
11 Ignition circuit 3 (pre-tension safety belt at the side of driver), connects with the grounding OK
12 Ignition circuit 3 (pre-tension safety belt at the side of driver), connects with the power supply OK
13 Ignition circuit 4 (pre-tension safety belt at the side of passenger), the resistance is too high or open circuit. OK
14 Ignition circuit 4 (pre-tension safety belt at the side of passenger), the resistance is too low or short circuit. OK
15 Ignition circuit 4 (pre-tension safety belt at the side of passenger), connects with the grounding OK
16 Ignition circuit 4 (pre-tension safety belt at the side of passenger), connects with power supply OK
17 Voltage of power supply is too high OK

18 Voltage of power supply is too low OK
19 Malfunction of indicating light connects with power supply or bulb is short circuit. OK
20 Malfunction of indicating light connects with the grounding or filament is open circuit. OK
No (change safety airbag
21 Lack/wrong calculation rule parameters
controller (KD4.1))

22 Front impact has been recorded
controller (KD4.1))
23 Communication malfunction OK

24 Inner malfunction
controller (KD4.1))
25 Impact output (oil pump) pin connects with the grounding OK
26 Impact output (oil pump) pin short connects with power supply OK
27 Impact output (central control door lock) pin connects with the grounding OK
28 Impact output (central control door lock) pin connects with power supply OK
29 Pre-tension safety belt ignites independently OK, but most is five times
30 Pre-tension safety belt ignites six times independently
controller (KD4.1))
247
Supplemental restraint system--Repair
there are some malfunctions, indicating light will indicate them. If exterior malfunctions are historical,
after they are removed, indicate will disappear.
one displayed or historical malfunction is only set up again by server. Inner malfunction or impact
record of safety airbag controller (KD4.1) could not be set up again, in this situation, it is necessary to
change safety airbag controller (KD4.1).
(3) micro controller, independent indicating light illuminates.
Microprocessor having obvious malfunction state could not work, so it could not control the work of indicat-
ing light. In this situation, indicating light will illuminate directly by applicable circuit without considering the
micro-processor, liking that shown in following:
The battery providing electricity for safety airbag controller (KD4.1) disables: indicating light illumi-
nates by the automatic light driving function.
Inner working voltage loses: indicating light illuminates usually.
New setup caused by the unsuccessful watchdog trigger: indicating light flashes
Micro-processor does not work: indicating light illuminates usually
Insert of connecter of safety airbag controller (KD4.1) is wrong: indicating light illuminates usually by
short circuit stick.
Take example to specify diagnostic step:
If finding indicating light of safety airbag illuminates usually, even if it extinguishes at last, you could check
by follow step. First is to check the part happening malfunction with diagnostic tool.
Then make by the checking step for corresponding position.
a. If scan result is inner malfunction or safety airbag has exploded, at this time, change the ECU directly.
b. Malfunction has been removed.
248
Supplemental restraint system--Inspection
Inspection
I. The inspection for airbag module at the side of
driver could be divided into three situations:
Automobile is not impacted, automobile is impacted but
airbag does not explode, and automobile is impacted and
airbag explodes.
1. Automobile is not impacted:
a. Make malfunction diagnostic inspection,
b. Check the safety airbag assembled on steering wheel
with your eyes,
including following items mainly:
Check whether the airbag has any cut, small crack or the surface and concave slot of airbag has
obvious changed color.
2. Automobile is impacted but airbag does not explode:
b. Check the disassembled safety airbag with your eyes, including following items mainly:
Check whether wiring harness has any cut, crack or joint has any flaw,
Check whether steering wheel has distorted,
Check whether the plug and wiring harness of helix cable has been damaged, the loudspeaker wiring
harness plug and wiring harness has been damaged or distorted,
Check whether contacting board of steering wheel loudspeaker button has been distorted (if it has
been distorted, it is necessary to change with new safety airbag module, forbid repairing it),
Interruption situation could happen between safety airbag module and steering wheel lower defend-
ing cover, and when new airbag module is assembled on steering wheel, its surrounding clearance
must be even (Assemble and disassemble of driver airbag module should accord with correct step to
work).
3. Automobile is impacted and airbag explodes:
Check whether the plug and wiring harness of helix cable has been damaged, the loudspeaker wiring
harness plug and wiring harness has been damaged or distorted,
Check whether wiring harness has any cut, crack or joint has any flaw,
Check whether steering wheel has distorted,
Interruption situation could happen between safety airbag
module and steering wheel lower defending cover, and
when new airbag module is assembled on steering wheel,
its surrounding clearance must be even (Assemble and
disassemble of driver airbag module should accord with
correct step to work)
II. The inspection for airbag module at the side of

passenger could be divided into three situations:
Change the
Automobile is not impacted, automobile is impacted but wiring harness
airbag does not explode, and automobile is impacted and of airbag
Safety airbag module at
airbag explodes.
the side of passenger
249
Supplemental restraint system--Inspection
1. Automobile is not impacted:

b. Check the safety airbag assembled on panel framework with your eyes, including following items
mainly:
Check whether the airbag has any cut and small crack, the surface and concave slot of airbag has
obvious changed color, and connecting bolts are loosened.
Check whether wiring harness has any cut, crack or joint has any flaw.
Check whether connecting bolt between airbag module and panel framework has been loosened, weld-
ing part of assemble bracket has any crack or distortion, and Assemble and disassemble of passenger
airbag module should accord with correct step to work.
3. Automobile is impacted and airbag explodes:
Check whether panel has any distortion and crack;
Check whether wiring harness of safety airbag has any cut, crack or the joint has any flaw;
If there is any crack on connector between panel and safety airbag, it is necessary to change it with
new product;
When new airbag module is assembled on its position, its surrounding clearance should be even
(Assemble and disassemble of passenger airbag module should accord with correct step to work).
III. Inspection for safety airbag controller could be divided into two situations: automobile
is not impacted, and automobile is impacted but airbag does not explode.
1. Automobile is not impacted: make system inspection.
a. Make system inspection.
b. Check safety airbag controller with your eyes:
Whether the bracket has any concave, crack, distortion and so on;
Whether zincification layer of bracket is damaged;
Whether the exterior casing of controller has any crack, concave or distortion;
Whether the joint is damaged, the terminal is distorted, or wiring harness is bitten.
IV.Inspection for wiring harness.
a. Make system inspection.
b. Check whether all wiring harnesses of safety airbag (SRS) has been damaged or lead wire are exposed,
joint has been damaged, and terminal has any distortion or crack.
Hint: wiring harness of safety airbag combines with the wiring harness of whole automobile,
but the wiring harness of safety airbag is yellow.
250
Supplemental restraint system--Remove malfunction
Remove malfunction
Malfunction table
Number Malfunction removing item Specification
1 Indicating light of safety airbag system does not illuminate Warning circuit of safety airbag system happens malfunction
2 Indicating light of safety airbag system illuminates usually Warning circuit of safety airbag system happens malfunction or
there is exterior malfunction
Malfunction Test state Possible reason

l The voltage disappears (fuse is cut off)
Indicating light of Warning circuit of safety
safety airbag l Combination instrument happens malfunction
airbag system happens
system does not l Wiring harness between instrument package
malfunction
illuminate and ECU unit has malfunction
1. Indicating light of safety airbag system does not illuminate

Diagnostic procedure
When making first malfunction test, we advise shaking wiring harness and plug to test whether there is
discontinuous bad contact in wire, if having this problem, please verify whether the connection of plug, terminal
and wiring harness is correct and is not damaged, if it is not this problem, please make by next step.
(1) Check other wiring harnesses and indicating lights of instrument package
a. Set ignition switch at ON position,
b. Are other warning indicating lights illuminating?
If illuminating: set ignition switch on LOCK position, then make next operation.
If not: check the power supply system and grounding system of instrument package (fuse), then
make step 5.
(2) Check the bulb
Warning: wrong treatment for safety airbag system parts will incur safety airbag and pre-
tension safety belt are opened accidentally, this might happen heavy accident. Please read
service warning of safety airbag system before disposing safety airbag parts.
a. Set ignition switch at LOCK position,
b. Cut off cathode wire of battery and keep this state for 60 seconds at least,
c. Disassemble combination instrument,
d. Measure whether corresponding two pins of indicating light of safety airbag could conduct,
Yes: make next step,
No: change the bulb of indicating light.
(3) Check the wiring harness connection between ECU unit and instrument package .
b. Cut off cathode wire of battery,
c. Cut off the plug of instrument package ,
d. Check whether corresponding circuit of indicating light could conduct,
No: change the wiring harness, then make step 5.
251
2. Indicating light of safety airbag system illuminates usually

Malfunction Test state Possible reason
Power supply of battery is lack
ECU has inner malfunction
Indicating light of combination meter safety airbag has
Indicating light of Indicating light of safety malfunction
safety airbag sys- airbag system illumi- Plug connection of ECU has malfunction
tem illuminates nates usually Plug of combination meter contacts badly
usually Power supply fuse of ECU is cut off or contacts badly
Plug terminal of ECU contacts badly
Wiring harness between plug terminal and grounding of
ECU contacts badly
Safety airbag circuit at the side of driver or passenger
has malfunction.
When starting to check, firstly, use special diagnostic tool and ECU to make diagnostic communication to
find the reason of malfunction, if communication could not implement, make following inspection:
(1) Check the battery
a. Measure the voltage of battery
b. Is the voltage higher than 9V?
Yes: make next operation,
No: Power supply of battery is lack, check the charging/discharging system, then make step 5.
(2) Check the conduction of wiring harness between ECU and combination meter.
b. Cut off cathode of battery,
c. Open the defending board of central channel,
d. Disconnect the connector of instrument package ,
e. Connect the cathode of battery,
f. Set ignition switch at ON position,
g. Check whether the terminal voltage of corresponding connector of instrument is 12V (connecting
wire of power supply and instrument)
No: check the circuit part, then make step 5 after repairing it.
h. Set ignition switch at LOCK position,
i. Check whether the corresponding terminal of instrument connector conducts with corresponding
terminal of diagnostic interface (diagnose two ends of K wire),
No: repair or change the wiring harness, then make step 5.
j. Guarantee cathode of battery is cut off and keep this state for one minutes at least, cut off connec-
tor of ECU.
k. Disconnect the plug of instrument package,
l. Check whether it conducts between ECU plug voltage, K wire, airbag indicating light terminal and
plug of instrument package ?
No: change the wiring harness, then make the step 5.
m. Disassemble the ECU to check whether the terminal is good, and the short circuit stick is broken.
Yes: change the ECU,
No: connect the ECU connector again, then make next operation.
252
(3) Confirm the malfunction will not happen again after repairing,
b. Cut off cathode of battery, and keep this state for one minutes at least,
c. Connect all ECU plugs,
d. Connect the subassembly plug of safety airbag at the side of driver,
e. Connect the subassembly plug of safety airbag at the side of passenger,
f. Connect the plug of pre-tension safety belt at the side of driver and passenger,
g. Connect the plug of helix cable,
h. Connect the cathode of battery,
i. Set ignition switch at ON position,
j. Does the indicating light of safety airbag work correctly?
Yes: malfunction has been removed, and the repair procedure should be explained for customers,
No: Check the malfunction state again, then if malfunction happens again, repeat from step 1.
3. Inner malfunction
Inner malfunction of safety airbag system unit

Warning
Test condition Test condition for this malfunction is the malfunction code which does not happen
before checking, DTC makes the inspection, it might incur wrong operation to hurt
human or system when making this inspection, so it is necessary to make preparation
before the inspection.
Inner circuit of electronic control unit of safety airbag system has malfunction.
Possible reason Inner malfunction in safety airbag system unit
Operation Change the safety airbag system unit, referring to the disassembling and assembling of
safety airbag system and safety airbag system unit.
4. Malfunction of power supply
Power voltage of electronic control unit of safety airbag system is too low.
Warning
Test condition for this malfunction is the malfunction code which does not happen
Test condition
before checking, DTC makes the inspection, it might incur wrong operation to hurt
human or system when making this inspection, so it is necessary to make preparation
before the inspection.
The voltage of safety airbag system unit and the grounding connector pin is less than
9V.
Possible reason The voltage of battery is too low.

The wiring harness between battery and electronic control unit of safety airbag system
has malfunction.
253
(1) Check the battery
Is the voltage higher than 9V?
No: The voltage of battery is too low, check the charging/discharging system.
Refer to chapter 1, Inspection of battery, charging system
(2) Check the wiring harness between battery and safety boox.
Disassemble fuse panel to set ignition switch at ON position without loosening connector.
Measure whether the voltage of related two pins of fuse panel is more than 9V?
Yes: make next step
No: check and repair the wiring harness.
(3) Check the wiring harness between fuse panel and the connector of safety airbag system unit.
Warning:
If the treatment is wrong, safety airbag assembly might be triggered to unfold to make heavy
human hurt, so, before the treatment, it is necessary to read repairing warnings carefully.
Refer to repairing warning of safety airbag system.
b. Loosen the cathode cable of battery and keep this state for one minute at least,
c. Disassemble the shell body of steering column,
d. Loosen the connector of helix cable,
e. Disassemble glove box (with safety airbag assembly at the side of passenger),
f. Loosen the connector of safety airbag assembly at the side of passenger,
g. Disassemble left inner trim board,
h. Loosen the connectors of all safety airbag system units,
i. Assemble cathode cable of battery, and set the ignition switch at ON position, then measure
whether the voltage of safety airbag system unit and grounding connector pin is more than 9V?
No: change the wiring harness.
j. Set the ignition switch at LOCK position,
Loosen the cathode cable of battery and keep this for one minute at least.
k. Disassemble left inner trim board,
l. Cut off the conversion connector of safety airbag system unit,
m. Assemble cathode cable of battery, and set the ignition switch at ON position, then measure
whether the voltage of safety airbag system unit and grounding connector pin is more than 9V?
Yes: malfunction diagnosis ends,
No: change the wiring harness.
254
5. Malfunction at the side of driver

Malfunction of safety airbag at the side of driver (resistance is too big or too small,
short circuit, grounding and so on)
Warning
If the treatment is wrong, safety airbag assembly might be triggered to unfold to make
Test condition heavy human hurt, so, before the treatment, it is necessary to read repairing warnings
carefully. Refer to repairing warning of safety airbag system.
The resistance between connector pins of safety airbag system unit is not in regulated
scope.
Related wiring harness of driver airbag in safety airbag system happens short circuit or
open circuit.
Safety airbag assembly at the side of driver has malfunction.
Helix cable has inner malfunction.
Possible reason Connector of the circuit between helix cable and electronic control unit of safety airbag
system has malfunction.
Wiring harness between helix cable and electronic control unit of safety airbag system
happens open circuit or short circuit.
Connector of driver gas generator in safety airbag system is not inserted well.
(1) Check helix cable
Warning
If the treatment is wrong, safety airbag assembly might be triggered to unfold to make heavy
human hurt, so, before the treatment, it is necessary to read repairing warnings carefully.
Is every related part of helix cable normal? (Whether the relationship between pins is normal,
whether there is any unnecessary short circuit, open circuit and other phenomenon)
Normal: make next step
Abnormal: change the helix cable
Refer to safety airbag system, disassembling and assembling of helix cable
(2) Confirm whether the malfunction is on safety airbag assembly at the side of driver or other parts.
a. Change it with a good safety airbag assembly at the side of driver,
b. Assemble the cathode cable of battery,
c. Set ignition switch at ON position,
d. Is there the display of malfunction code? Could it be removed?
Yes: change the safety airbag assembly at the side of driver
Refer to safety airbag system, disassembling and assembling of safety airbag assembly at
the side of driver.
No: make next step
(3) Check the connector of helix cable wiring harness
a. Set ignition switch at LOCK position.
c. Disassemble shell body of steering column,
d. Loosen connector of helix cable,
e. Is the connector of helix cable normal? (Whether the relationship between pins is normal, whether
there is any unnecessary short circuit, open circuit and other phenomenon)
Abnormal: change the helix cable
Refer to safety airbag system, disassembling and assembling of helix cable
255
(4) Check the wiring harness between helix cable and electronic control unit of safety airbag system
c. Disassemble glove box (with safety airbag assembly at the side of passenger),
d. Loosen the connector of safety airbag assembly at the side of passenger,
e. Disassemble left inner trim board,
f. Loosen the connectors of all safety airbag system units,
g. Check the wiring harness between connector pole of safety airbag system unit and helix cable
connector pin.The wiring harness between safety airbag system at the side of passenger unit con-
nector pin and helix cable connector pin has following situation:
Earth
Short connection with power supply
Short circuit
h. Are the wiring harnesses above normal?
i. Normal: malfunction diagnosis ends, assemble all parts
j. Abnormal: change the wiring harness.
6. Malfunction at the side of passenger
Malfunction of safety airbag at the side of passenger (resistance is too big or too
small, short circuit, grounding and so on)
Warning
If the treatment is wrong, safety airbag assembly and pre-tension safety belt might be
Test condition triggered to unfold to make heavy human hurt, so, before the treatment, it is necessary
to read repairing warnings carefully. Refer to repairing warning of safety airbag system.
The resistance between connector pin 13 and pin 14 of safety airbag system unit is not
in regulated scope.
The wiring harness between connector pin 13 and pin 14 of safety airbag system unit
happens short circuit.
Safety airbag assembly at the side of passenger has malfunction.

Connector between safety airbag assembly at the side of passenger and electronic con-
Possible reason trol unit of safety airbag system has malfunction.
Connector between safety airbag system unit and grounding position has malfunction.
The circuit between safety airbag assembly at the side of passenger and electronic
control unit of safety airbag system happens open circuit or short circuit.
Circuit between safety airbag system unit and grounding position happens open circuit
or short circuit.
Safety airbag system unit has malfunction.
(1) Check the connector of safety airbag assembly at the side of passenger
If the treatment is wrong, safety airbag assembly and pre-tension safety belt might be triggered to
unfold to make heavy human hurt, so, before the treatment, it is necessary to read repairing
warnings carefully.
256

c. Disassemble glove box,
d. Loosen the connector of safety airbag assembly at the side of passenger,
e. Is the connector of safety airbag assembly at the side of passenger normal?
Normal: make next step,
Abnormal: change the wiring harness
(2) Confirm malfunction reason is on safety airbag assembly at the side of passenger or on other parts.
a. Connect a good assembly on connector pin A and B of safety airbag assembly at the side of
passenger,
b. Connect the cathode cable of battery,
c. Set the ignition switch at ON position,
d. Is there the display of malfunction code? Or could the malfunction code be removed?
No: make next step
Yes: change the safety airbag assembly at the side of passenger.
Refer to safety airbag system, disassembling/assembling of safety airbag assembly at the side of
passenger.
(3) Check the wiring harness between safety airbag assembly at the side of passenger and electronic
control unit of safety airbag system.
c. Disassemble the shell body of steering column,
d. Loosen the connector of helix cable,
e. Loosen the connector of safety airbag assembly at the side of passenger and driver,
f. Disassemble left inner trim board,
g. Loosen the connectors of all safety airbag system units,
h. Check the circuit between connector pin of safety airbag system electronic control unit and the
circuit between connector pin of safety airbag assembly at the side of passenger, and the circuit
between connector pin of safety airbag system unit and safety airbag assembly at the side of
passenger has following situation:
Earth
Open circuit
i. Are the wiring harnesses above normal?
Normal: malfunction diagnosis ends
Abnormal: change related wiring harness.
257
7. Malfunction of pre-tension safety belt

Malfunction of pre-tension safety belt (resistance is too big or too small, short circuit,
grounding and so on)
Warning
Test condition triggered to unfold to make heavy human hurt, so, before the treatment, it is necessary
to read repairing warnings carefully.
If having pre-tension safety belt
The resistance between connector pin 1, 2 or pin 3, 4 of safety airbag system unit is
not in regulated scope.
The wiring harness between connector pin 1, 2 or pin 3, 4 of safety airbag system unit
happens short circuit.
The wiring harness between connector pin 1, 2 or pin 3, 4 of safety airbag system unit
happens open circuit, if there is not safety airbag at the side passenger.
Safety belt pre-tension has malfunction.
Connector between safety belt pre-tension and electronic control unit of safety airbag
Possible reason system has malfunction.
Connector between safety belt pre-tension and grounding position has malfunction.
The circuit between safety belt pre-tension and electronic control unit of safety airbag
system happens open circuit or short circuit.
or short circuit.
(1) Check the connector warning of safety belt pre-tension
If the treatment is wrong, pre-tension safety belt might be triggered to unfold to make heavy hu-
man hurt, so, before the treatment, it is necessary to read repairing warnings carefully.
a. Set the ignition switch at the LOCK position,
c. Disassemble B column defending board
d. Loosen the safety belt pre-tension connector
e. Is the safety belt pre-tension connector normal?
Abnormal: change the wiring harness
(2) Confirm malfunction reason is on pre-tension safety belt or on other parts.
a. Connect a good pre-tension safety belt on safety belt pre-tension connector,
b. Connect cathode cable of battery,
c. Set ignition switch at ON position,
d. Could the malfunction code be removed?
No: make next step,
Yes: change pre-tension safety belt.
Refer to safety airbag system, disassembling/assembling of pre-tension safety belt.
(3) Check the wiring harness between the pre-tension safety belt at the side of passenger and electronic
control unit of safety airbag system
c. Loosen the connector of safety belt pre-tension module,
258
d. Loosen the connectors of all safety airbag system units,

e. Check whether the connector between electronic control unit of safety airbag system and the
circuit between connector of safety belt pre-tension have following situations:
Earth
Open circuit
f. Are the wiring harnesses above normal?
Normal: malfunction diagnosis ends
Abnormal: change related wiring harness.
8. Malfunction of impact output
Malfunction of safety airbag assembly at the side of passenger (resistance is too big
or too small, short circuit, grounding and so on)
Warning
Resting condition triggered to unfold and tighten to make heavy human hurt, so, before the treatment, it
is necessary to read repairing warnings carefully.
Connector between impact output circuit and electronic control unit of safety airbag sys-
tem has malfunction.
Possible reason Connector between safety airbag system unit and grounding position has malfunction.
The circuit between impact output circuit and electronic control unit of safety airbag
system happens open circuit or short circuit.
or short circuit.
(1) Check whether this airbag controller has impact output function
a. Set ignition switch at LOCK position
b. Loosen the cathode cable of battery and keep this state for one minute at least
(2) Check whether the connection of impact output connector is good,
(3) Check whether the impact output connecting wire is earth or is short connecting with other wires,
(4) Check whether impact output connecting wire is open circuit,
(5) Check whether the central control door lock control system or electric injection control system of
engine has been changed,
Note: If repairing it by the steps above and requirements, indicating light or diagnostic tool
could display the mistakes before repairing all the time, please do not change it by
yourself, you should contact with the manufacturer as soon as possible avoid wrong
explosion or no explosion when using airbag.
259
Diagnosis of impacted automobile

No matter whether the safety airbag has been unfolded, the inspection and maintenance for impacted auto-
mobile should be made by following sequence.
1. Check the ECU diagnostic signal.
(1) Connect the diagnostic joint of diagnostic tool,
(2) Use diagnostic tool to read the diagnostic result.
2. Repair sequence
Note: For the impact, when power supply of battery is lack, diagnostic tool could not communicate
with ECU, at this time, it is necessary to check and maintain the wiring harness of panel or use
exterior power supply.
(1) When safety airbag has been unfolded,
Following parts should be changed with new ones
a. Safety airbag assembly at the side of passenger
b. ECU
c. Safety airbag assembly at the side of driver
d. Pre-tension safety belt at the side of driver and passenger
Check the following parts, if they are abnormal, change them with new ones
a. Helix cable
b. Steering wheel, steering column, combination switch
Assembling state for steering wheel of safety airbag assembly at the side of driver
a. Check whether there is any abnormal noise in steering wheel, its action is flexible and clearance is
normal.
b. Check whether the joint of wiring harness is damaged or terminal is distorted.
260
Supplemental restraint system--Disassemble and assemble
Disassemble and assemble

Electronic control unit of safety airbag (ECU)
1. Note (referring to chapter 1)
2. Disassembling sequence:
(1) Disassemble the cover board at the side of central channel (or disassemble auxiliary panel).
(2) Disassemble the connector connecting with safety airbag ECU.
(3) Disassemble the ECU.
3. Assembling sequence
(1) Check the ECU assembly, and make arrow direction on hint card point to running direction of automobile.
(2) Assemble the connector connecting with safety airbag ECU, the connector should be locked firmly (if
you hear a light sound KA when press the connector, this shows it has been locked).
a. Fix the special bolt used by controller assembly on assembling position of central channel, and
confirm it has been assembled firmly.
b. Assemble the cover board at the side of central channel (or assemble auxiliary panel).
c. Connect the cathode of battery.
4. Main notes of assembling operation:
(1) When assembling ECU assembly, pay attention to that ECU assembly could not be impacted.
(2) Inspection after the assembling
a. Set the ignition switch at ON position.
b. Indicating light illuminates at 7 second, and continues to extinguish.
c. If it does not extinguish, it is necessary to check and remove malfunction.
Note: if ECU could not be assembled correctly, safety airbag will not work normally.
5. Inspection: referring to chapter 2.
6. Removing malfunction: referring to chapter 3.
Safety airbag assembly at the side of driver

1. Note (referring to chapter 1).
2. Use the flash or malfunction diagnostic tool to test malfunction (referring to chapter 1
and 3).
3. Place the steering wheel and front wheels correctly
and make them face the front, and take out ignition
switch key, then do not operate it in 60 seconds af-
ter disassembling the cathode of battery.
driver:
(1) Guarantee the wheels face the front.
(2) Use 5s hexagon socket-head wrench to loosen the two plan-
etary bolts.
(3) Pull out the safety airbag assembly at the side of driver
from upside of steering wheel.
261
(4) Disassemble the joint of loudspeaker and airbag wiring

harness.
(5) Take down safety airbag module at the side of driver.
Note: Disassembled safety airbag assembly at the side
of driver should make its bottom surface face
the upwards, and it should be stored in clean
and dry environment.
5. Check the safety airbag assembly at the side of
driver.
6. Disassemble steering wheel:
Disassemble assembling screws to take down steering wheel
from the middle position.
Note: For the mesh of spline and column is too tight, steer-
ing wheel is hard to disconnect from the column, at
this time, pay attention to do not disassemble the
steering wheel compulsively, it is necessary to
screw the screws on column, then lift the steering
wheel up (for steering wheel connects with helix
cable at its bottom, if disassembling steering wheel
compulsively, helix cable will be damaged).
7. Disassemble the lower cover of combination switch
Disassemble three screws and lower cover of combination
switch.
8. Disassemble helix cable:
(1) Slide the upper cover of combination switch.
(2) Disassemble airbag joint from helix cable.
(3) Disassemble three fixed claws and helix cable.
Note: disassembled helix cable should be stored in
clean and dry environment.
9. Check the helix cable:
(1) When assembling new helix cable, check whether the yel-
low fixed clamp on helix cable is good, if yellow clamp drops,
Fixed claw
please adjust by the requirement on hint card of helix cable,
insure helix cable could turn left and right for 2.5 circles on
its existing fixed position.
(2) If finding following situations, it is necessary to change the
helix cable with new one.
a. There are some scratches or cracks on joint.
b. There are cracks, concaves or flaws on wiring harness
of helix cable.
10. Remove malfunction (referring to chapter 3).
11. Make the wheels face the front.
Note: it is necessary to make the front wheels face the
front, or the wires in helix cable might break in steer-
ing process.
12. Assemble helix cable:
(1) Inspection before assembling (referring to item 9).
(2) Set the steering light switch at middle position.
The pin of steering light switch may be broken, so it must
be confirmed whether the pin is at central position.
262
(3) Make three fixed claws mesh steering column.

When changing with new helix cable, it is necessary to disassemble yellow clamp before assembling.
(4) Insert the plug of airbag wiring harness in the plug of helix cable and make this connection firm.
(5) Connect the lower cover of combination switch.
(6) Connect the upper cover of combination switch with the
lower cover with special bolts firmly.
13. Set the helix cable at middle position
a. Check whether ignition switch locates OFF state.
b. Check whether the cathode end of battery has been
disassembled.
Note: do not operate in 60 seconds after disassembling
cathode end.
c. Turn helix cable anticlockwise with hand until it could not
be turned.
d. Then turn the helix cable clockwise for 2.5 circles to align
the mark.
14. Assemble steering wheel Align the
(1) Inspection before assembling: mark
Steering wheel
Connecting wiring harness
Safety airbag assembly at the side of driver
(2) Tighten the assembling screws at both sides.
(3) Connection of battery terminal -.
(4) After assembling, use malfunction diagnostic tool or malfunction indicating light to check
and confirm the malfunction has been removed.
Safety airbag assemble at the side of passenger

1. Note (referring to chapter 1).
2. Use the flash or malfunction diagnostic tool to test the malfunction (referring to chapter
1 and 3).
3. Disconnect the connection of cathode of battery, and do not operate in 60 seconds after
disconnecting.
4. Disassemble the glove box.
5. Disassemble the joint of safety airbag at the side of passenger, and do not damage
airbag wiring harness carefully.
6. Disassemble the safety airbag assembly at the side of passenger.
a. Disassemble three connecting bolts from the bracket of safety airbag assembly at the side of passenger.
b. Take down the safety airbag assembly from panel.
7. Check the safety airbag assembly at the side of passenger (referring to chapter 2).
8. Assemble airbag assembly.
a. Check whether the connection between safety airbag module and airbag short wiring harness is firm.
b. Firstly, insert the module in assembling position from the upside of panel, secondly, align the assem-
bling hole of small bracket on module with the assembling hole on framework of panel, at the same
time, the module cover and panel clearance should be even, and the barb on module should be con-
nected to its position.
9. After assembling, use malfunction diagnostic tool or malfunction indicating light to
check and confirm the malfunction has been removed.
263
Supplemental restraint system--Scrap treatment for safety airbag
Scrap treatment for safety airbag

Hint:
When scraping a automobile with SRS or disposing safety airbag module, it is necessary to explode the airbag by
following steps at first.
If there is any abnormal phenomenon when exploding airbag, please contact with our service store or automobile
factory in time.
Note:
Forbid exploding the safety airbag module that does not explode by yourself.
When exploding the airbag, it will make much big explosive sound, so it is necessary to operate this out of the
automobile, please do not make this operation influence the life of near habitants to avoid their complaints.
When exploding the airbag, use the battery as power supply whose voltage is (121)V.
When exploding the airbag, operator should be apart from the exploded module and he should confirm there is
not anyone in the scope of 10m at least.
When disposing the exploded airbag module, it is necessary to wear glove and safety glass.
When airbag is exploded, the temperature of airbag module is too high, and a lot of gas with peculiar smell will
be produced, so do not make any treatment for exploded airbag in 30 minutes after exploding it.
Please wash your hands with water after finishing those operations above.
Do not sprinkle water on exploded airbag module.
When scraping a automobile, the safety airbag module assembled on automobile should be exploded.
I. Scrap the safety airbag module on automobile

1. Treatment before exploding:
(1) Park the automobile on flat place.
(2) Disassemble the cathode and anode of battery and disassemble the battery from automobile.
Note: do not work until disassembling the cathode and anode of battery for 60 seconds.
(3) Safety airbag assembly should be unfolded by following sequence.
2. Safety airbag assembly at the side of driver
(1) Disassemble three screws and lower cover of combination switch.
(2) Disassemble the lower end of helix cable and the joint connecting with panel wiring harness.
(3) Connect the conversion wiring harness of safety airbag with one wiring harness with over 10 m used
for unfolding, and the connecting part should be twisted with insulation adhesive tape to insulate and
prevent from wrong unfolding for static.
Note: take down the joint of helix cable from panel wiring harness, the joint of helix cable
will be short circuit automatically, this will prevent from exploding the safety airbag
assembly at the side of driver for static to make heavy accident.
(4) Connect conversion wiring harness of safety airbag on yel-
low joint of helix cable, then lead it out of automobile with Cover of automobile body
unfolding wiring harness (see following figure).
(5) Close all windows and doors, and assemble automobile
cover.
(6) Cut off the joint of wiring harness used for unfolding of safety
airbag assembly at the side of driver at the place apart from Wiring harness for explosion
the automobile, then connect it with two ends of battery
taken from automobile to make it explode (see following
figure).
264
(7) Safety airbag assembly at the side of driver after explosion should be scraped by the scrap main points.
Note: Firstly, confirm whether there are people on automobile and near the automobile, do
not operate until confirming none there.
After the safety airbag at the side of driver is unfolded, its gas generator temperature is
high, do not make any treatment until putting it for over 30 minutes to wait for it be-
comes cool.
If safety airbag assembly at the side of driver could not be unfolded, it is necessary to
contact with local appointed repairing station.
3. Safety airbag assembly at the side of passenger.

(1) Disassemble the glove box.
(2) Disassemble the connector between airbag short wiring harness and airbag wiring harness.
(3) Connect the conversion wiring harness of safety airbag with one wiring harness with over 10 m used
for unfolding, and the connecting part should be twisted with insulation adhesive tape to insulate and
prevent from wrong unfolding for static.
(4) Connect conversion wiring harness of safety airbag on yellow joint of helix cable, then lead it out of
automobile with unfolding wiring harness (see following figure).
(5) Close all windows and doors, and assemble automobile

cover. Cover of automobile body
airbag assembly at the side of driver at the place apart from
the automobile, then connect it with two ends of battery
taken from automobile to make it unfold (see following figure). Wiring harness for explosion
(7) Safety airbag assembly at the side of driver after explosion

should be scraped by the scrap main points.
Note: Firstly, confirm whether there are people on automobile and near the automobile, do not
operate until confirming none there.
After the safety airbag at the side of driver is unfolded, its gas generator temperature is
high, do not make any treatment until putting it for over 30 minutes to wait for it be-
comes cool.
If safety airbag assembly at the side of driver could not be unfolded, it is necessary to
contact with local appointed repairing station.
2. Only scrap airbag module

1. Explosion of safety airbag assembly at the side of driver.
(1) Prepare a battery as detonating power (121)V.
(2) Disassemble safety airbag assembly at the side of driver, and connect the airbag short wiring harness
on gas generator.
Warning: when storing safety airbag module at the side of driver, it is necessary to keep upper
surface face upwards.
265
(3) Fix the module on wheel.

a. Assemble two bolts with gasket on two assembling holes
of safety airbag module at the side of driver.
Size of bolt: L 35.0 mm
M 6.0 mm
Note: tighten the bolts with hand until they could
not be turned in. But they could not be
screwed too tightly.
b. Use maintenance electric wire used for automobile to

fix safety airbag module at the side of driver on wheel.
Section area of nude wire part of wiring harness is more
than 2 mm2. If the wiring harness is too thin, it might
break for the shake when airbag explodes. This is very
dangerous.
c. Use three wiring harnesses, and the wiring harness

should twist the bolts at the two sides of airbag assem-
bly twice at least. Tighten the wiring harness twisted on
fixed bolts to avoid them loosen, if wiring harness loosen,
they might incur airbag assemble loosens for shake
when airbag explodes. This is very dangerous.
d. Place the airbag module upwards, and bind the con-

necting bolts at the two sides of airbag module in wheel
hub bolt holes of wheel. Adjust the fixed position of airbag
module to make the joint hang in the wheel hub hole of
wheel. Wiring harness should be tightened. The metal
surface of airbag assembly must face the downside to
prevent wiring harness from breaking for airbag
explosion, explosive force will throw airbag to air to hurt
human or surrounding things. Airbag explosion will leave
track for surrounding things, so used wheel should be
scraped.
(4) Place wheel on flat ground, and connect the one end of Safety airbag assembly
wiring harness used for unfolding with airbag short wiring
harness, and connect the other end with short circuit.
Wiring harness for explosion
266
(5) Fix three scraped old tyres without wheel hub on the fixed
tyre of safety airbag assembly at the side of driver. The Old tire
terminal end of unfolding wiring harness is 10m apart from without hud
wheel of fixed airbag at least.
Width: 185mm
Inner diameter: 360mm
Wiring harness
for explosion
airbag assembly at the side of driver at the place apart from
the automobile, then connect it with two ends of battery.
Wiring harness
for explosion
(7) Treatment for explosive module.

Disassemble the safety airbag module at the side of driver
from wheel, and put it in ethane plastic bag, then bind the
bag for treatment with other parts.
2. Explosion of safety airbag assembly at the side of passenger.

(1) Prepare a battery as detonating power (121)V.
(2) Disassemble safety airbag assembly at the side of passenger, and connect the airbag short wiring
harness on gas generator.
Warning: when storing safety airbag module at the side of driver, it is necessary to keep upper
surface face upwards.
(3) Fix the module on wheel.

a. Assemble three bolts with gasket on two assembling
holes of left, middle and right support pin of safety airbag
module at the side of passenger.
Size of bolt: L 35.0 mm
M 8.0 mm
Note: screw the bolts with hand, but they could not
Left and
be screwed too tightly, 2/3 L of bolts should right small
expose. bracket
267
b. Use maintenance electric wire used for automobile to fix

safety airbag module at the side of driver on wheel.
Section area of nude wire part of wiring harness is more
than 2 mm2. If the wiring harness is too thin, it might
break for the shake when airbag explodes. This is very
dangerous.
c. Use four wiring harnesses, and the wiring harness should

twist the fixed bolts and small bracket of airbag assem-
bly twice at least. Tighten the wiring harness twisted to
avoid them loosen, if wiring harness loosen, they might
incur airbag assembly loosens for shake when airbag
explodes. This is very dangerous.
d. Place the airbag module upwards, and bind the wiring

harnesses at the two sides of airbag module in wheel
tightly. After twisting the tyre twice with the wiring har-
ness twisted on middle small bracket, bind it on tyre.
After twisting the tyre twice with the wiring harness
twisted on left and right small bracket, bind it on tyre.
Adjust the fixed position of airbag module to make the
joint hang in the wheel hub hole of wheel. Then fix the
wiring harness getting through the center of left and right Safety airbag assembly
small bracket on tyre to prevent the module from shak-
ing left and right, and the wiring harness twisted on bolts
of small bracket is fixed on tyre to prevent airbag mod- Wiring harness for explosion
ule from shaking front and back.
(4) Place the wheel on flat ground, and connect one end of
wiring harness used for unfolding with airbag short wiring
harness, and connect the other end with short circuit. The
terminal end of unfolding wiring harness is 10m apart from Tyre
wheel of fixed airbag at least. (over five)
268
(5) Put two tyres at least under the tyre fixed with airbag
assembly, and put two tyres at least on the tyre fixed with
airbag assembly, at the same time, top tyre should have
wheel hub. Use two wiring harnesses to bind tyre tightly, if
shake is produced when airbag explodes, airbag module
will break off to make danger.
Width: 185mm
Inner diameter: 360mm
(6) Cut off the joint of wiring harness used for unfolding of safety Special Battery
airbag assembly at the side of driver at the place apart from tool
Safety airbag
the automobile, then connect it with two ends of battery. assembly at the
side of passenger
Over 10m
(7) Treatment for explosive module.

Disassemble the safety airbag module at the side of driver
from wheel, and put it in ethane plastic bag, then bind the
bag for treatment with other parts.
269
Safety belt--Front safety belt
Safety belt
Note
Hint:
When scraping a automobile equipping with safety belt pre-tension crimper, or disposing the safety belt
(equipping with safety belt pre-tension crimper), firstly, it is necessary to make by following steps.
If happening any abnormal phenomenon, please consult with GEELY automobile company.
When disposing a impacted automobile, and its safety belt pre-tension crimper did not explode, its treatment
step is same as the Treatment step 1-(e).
Warning:
Forbid disposing the safety belt pre-tension crimper that does not work.
When exploding the safety belt pre-tension crimper, it will produce big explosive noise, so this opera-
tion should be made out of automobile and in environment where will not influence near habitants.
When exploding the safety belt pre-tension crimper, it is necessary to use SRS airbag exploding
special tool, at the same time, the environment implementing this operation should be apart from
electronic interruption.
When exploding the safety belt pre-tension crimper, the environment implementing this operation
should be 10m apart from safety belt pre-tension crimper assembly.
When exploding the safety belt pre-tension crimper, safety belt will be very hot, please do not dispose
it in 30 minutes after explosion.
When disposing exploded safety belt pre-tension crimper, it is necessary to wear glove and safety
glass.
After finishing this operation, it is necessary to wash your hand with water.
Do not sprinkle water on exploded safety belt pre-tension crimper.
Treatment
1. Safety belt pre-tension crimper when scraping Battery
automobile.
Hint: prepare a battery as the power to explode safety Special
tool
belt pre-tension crimper.
(a) Confirm the function of special tool

Warning: when exploding safety belt pre-tension
crimper, it is necessary to use regulated special
tool: SRS airbag exploding tool. Special
tool
270
(1) Connect special tool with battery,

Connect the red clamp of special tool with the anode of
battery (+), and black clamp with the cathode of battery Battery
(-).
Hint: Do not connect the yellow joint with safety Special
belt pre-tension crimper. tool
(2) Confirm the function of special tool.

Press working switch of special tool, then the LED on Special
switch should illuminate. tool
Warning: if working switch is not pressed, LED
illuminates, then special tool might have
malfunction, at the this time, do not use the
special tool.
(b) Disassemble the joint of safety belt pre-tension crimper.
(1) Disassemble panel trim board of front door,
(2) Disassemble panel trim board of rear door.
(3) Disassemble lower fixed bolts and trim cover of safety
belt.
(4) Disassemble lower inner trim board of middle column.
(5) Liking that shown in figure, disassemble the joint of safety
(c) Assemble special tool
(1) Assemble lower fixed bolts and trim cover of safety belt.
(2) Connect two special tools with lower fixed bolts and trim
cover of safety belt..
Note: to avoid damaging the joint and wiring har-
ness of special tool, do not lock the twice lock
of dual-lock organization. Special Special
tool tool
(3) Move the special tool apart from the front end of auto-
mobile for 10m at least.
(4) Close all doors and windows.
Note: do not damage wiring harness of special tool.
(5) Connect the read clamp of special tool with the anode
of battery (+), and black clamp with the cathode of bat-
tery (-).
Over 10m
271
(d) Explode safety belt pre-tension crimper.

(1) Confirm there is no one in automobile and in 10m scope apart from automobile.
(2) Press down working switch of special tool and explode safety belt pre-tension crimper.
Hint: when LED of working switch of special tool illuminates, safety belt pre-tension crimper will
explode charged gas at the same time.
(e) Treatment for safety belt pre-tension crimper.
Hint: when scraping automobile, it is necessary to explode safety belt pre-tension crimper,
then it could be scraped with automobile.
2. Only treatment for safety belt pre-tension crimper (Treatment type for exploding front
seat safety belt).
Note:
when only exploding safety belt pre-tension crimper,
Battery
forbid using the automobile belonging to customer to
explode safety belt pre-tension crimper.
When exploding safety belt pre-tension crimper, it is
Special
necessary to accord with following step. tool
(a) Disassemble safety belt.
Hint: cut off safety belt at its position closing to
shrinker.
(b) Confirm the function of special tool.
(c) Assemble special tool.
(1) Connect two joints of special tool to the joint of safety
Note: to avoid damaging the joint and wiring har- Special Special
ness of special tool, do not lock the twice lock tool tool
of dual-lock organization.
(2) Place the safety belt pre-tension crimper on ground, and

cover it with tyre.
Note: Place the safety belt pre-tension crimper lik-
ing that shown picturey.
(3) Place th special tool above 10mm away from tire
Note: do not damage special tool and wiring har-
ness carefully. Special Special
tool tool
(d) Explode safety belt pre-tension crimper.

(1) Connect red fixed clamp of special tool to the anode of
battery (+), black fixed clamp to cathode of battery (-).
(2) Confirm there is not anyone in 10m apart from the tyre
binding safety belt pre-tension crimper.
(3) Press down working switch of special tool to explode
safety belt pre-tension crimper.
Hint: when LED of working switch of special tool Over 10m
illuminates, safety belt pre-tension crimper
will explode at the same time.
272
(e) Treatment for safety belt pre-tension crimper.

(1) Disassemble the tyre and special tool.
(2) Put safety belt pre-tension crimper in plastic bag, then
bind the bag for treatment with other parts.
Subassembly
41
Q184C1020
Trim cover of safety belt

upper fixed bolt
Lower inner defending

board of middle column
Front safety belt

crimper assembly
41
Q184C1020
Trim board of pedal

of rear door
41 Trim cover of safety belt
Q184C1020 lower fixed bolt
Front safety belt

locker assembly
Trim board of pedal of
41
front door
Q184C1020
N.m : Regulated torque
273
Change
Hint:
When assembling, please work by the sequence that is reverse with disassembling sequence,
if necessary, assembling instruction could be got.
Changing procedure for left side and right side is same.
Refer to subassembly drawing of front safety belt on page 273.
1. Disassemble cathode wire of battery.
2. Disassemble left front safety belt locker assembly [68010040].
(a) Disassemble driver seat assembly (referring to page 349).
(b) Disassemble safety belt locker assembly in side of driver seat gasket (referring to page 349).
(c) Only driver side: disassemble fixed clamp from gasket bracket of driver seat.
(d) Disassemble the bolts and safety belt locker assembly in side of front seat.
3. Disassemble trim board of pedal of left front door [68010020].
4. Disassemble trim board of pedal of left rear door [68010022].
5. Disassemble sealed part of doorframe of left front
door [68010055].
6. Disassemble sealed part of doorframe of left rear
door [68010059].
7. Disassemble lower inner trim board of left middle
column [68010018].
8. Disassemble left front safety belt crimper assembly
[68010044].
(a) Use right-angled screwdriver to disassemble trim cover of
upper fixed bolt of safety belt.
Hint: use adhesive tape to twist its top end before using.
(b) Disassemble the bolts and crimper assembly.
(c) Use right-angled screwdriver to disassemble trim cover of
upper fixed bolt of safety belt.
Hint: use adhesive tape to twist its top end before using.
(d) Disassemble the bolts and lower fixed bolts of floor safety belt.
(e) Disconnect the joint of crimper liking that shown in figure.
Note: when disassembling the safety belt, it is necessary to turn the ignition switch to LOCK
position, and disconnect the cathode of battery for 90 seconds, then it could start to work.
(f) Disassemble the bolts and crimper.
9. Assemble left front safety belt crimper assembly.
(a) Check the inclining angle when ELR starts to lock.
(1) Confirm whether safety belt could be pulled out if the angle exceeds 45.
Note: do not disassemble the crimper.
(b) Use the bolts to assemble crimper.
Torque: 41 Nm
(c) Use two bolts to assemble fixed seat of side shoulder belt
and safety belt.
Torque: 41 Nm
(d) Check the lock of ELR.
(e) After safety belt is assembled on automobile, check whether
the safety belt could be locked when it is pulled out quickly.
10. Assemble left front inside safety belt clamp.
Torque: 41 Nm
274
Safety belt--Rear safety belt
Rear safety belt

Subassembly
1. Inner trim board assembly of left rear column 6. Rear platform with sun blind assembly
[68010026] [68010032]
2. Inner trim board assembly of right rear column 7. Plastic clamp of column trim board [68000089]
[68010027] 8. Rear safety belt crimper assembly [68010048]
3. Backrest assembly of rear row seat [68010076] 9. Middle waistband of rear row safety belt with
4. Step bolt M8*20 of hexagon flange face locker assembly[68010043]
[68000203] 10. High mount brake light assembly [67010008]
5. Cushion assembly of rear row seat [68010074]
1
10
7
2
3
8
41
41
4
9
41
5 41
N.m : Regulated torque
275
1. Inner trim board assembly of left rear column 7. Step bolt of hexagon flange face [68000203]
[68010026] 8. Combination part of hexagon bolt with flat big
2. Inner trim board assembly of right rear column washer M10*1.25*22 [Q1401022]
[68010027] 9. Cushion assembly of rear row seat [68010074]
3. Left backrest assembly of rear row seat 10. Rear safety belt crimper assembly [68010048]
[68010078] 11. Middle waistband of rear row safety belt with
4. Right backrest assembly of rear row seat locker assembly [68010043]
[68010079] 12. Rear shelf with sun shade assembly
5. Combination part of Hexagon head bolt and flat [68010032]
washer M6*14 [Q1400614] 13. High mount brake light [68010008]
6. Backrest assembly of rear row seat [68010076]
1
13
12
3 6
5
8
4
8 41
7
5
41
10
41
41
41
1 1
9
276
Change
Hint:
When assembling, please work by the sequence that is reverse with disassembling sequence,
if necessary, assembling instruction could be got.
Changing procedure for left side and right side is same.
Refer to subassembly drawing of front safety belt on page 275.
1. Disassemble cushion assembly of rear row seat.
2. Disassemble Right backrest assembly of rear row seat [68010079]
3. Disassemble left backrest assembly of rear row seat [68010078]
4. Disassemble cushion assembly of rear row seat [68010074]
5. Disassemble backrest assembly of rear row seat [68010076]
6. Disassemble high mount brake light assembly [68010008]
7. Disassemble inner trim board assembly of right rear column [68010027]
8. Disassemble inner trim board assembly of left rear column [68010026]
9. Disassemble rear platform with sun blind assembly [68010032]
(a) Use special disassembling tool to disassemble three fixed clamps.
(b) Pull out safety belt from the clearance, then disassemble rear platform with sun blind assembly.
10. Disassemble rear safety belt crimper assembly [68010048]

(a) Disassemble the bolts and safety belt clamps.
(b) Disassemble the bolts and rear safety belt crimper assembly.
11. Disassemble middle waistband of rear row safety belt with locker assembly. [68010043]
(a) Disassemble the bolts and middle waistband of rear row safety belt with locker assembly.
277
12. Assemble middle waistband of rear row safety belt Protuberant

with locker assembly [68010043] part
(a) Use the bolts to assemble middle waistband of rear row
safety belt with locker assembly.
Torque: 41 Nm
Note: insure the clamp part does not press the protu-
berant part of floor.
Protuberant
part
13. Assemble rear safety belt crimper assembly.

(a) Check the inclining angle when ELR starts to lock.
(1) Confirm whether safety belt could be pulled out if the
angle exceeds 45.
Note: do not disassemble the crimper.
(b) Use the bolts to assemble rear safety belt crimper assembly.
Torque: 41 Nm
(c) Use the bolts to assemble floor side clamp.
Torque: 41 Nm
(d) Check the lock of ELR.
(1) After safety belt is assembled on automobile, check
whether the safety belt could be locked when safety belt
is pulled out quickly.
278
Light--Light System
Light
Light System
Notes
1. Notes for changing the front combination bulb
(a) When the surface of halogen bulbs (the bulb of front assembled headlamp and front fog light) touches
oil, their working life will be shorten. When it lights, it becomes hot.
(b) Because of pressured gas in halogen bulbs (the bulb of front assembled headlamp and front fog
light), the bulb may explode and pieces of broken glass disperse around. So deal with it carefully.
(c) If the time after disassembling the bulb from lamp carrier is too long, the mirror may be polluted by
dirties or hydrosphere. You should prepare a new bulb,then replace it.
(d) Replace it with the lamp of same wattage.
(e) Assemble the changing bulb on the lamp carrier firmly, or it may bring mirror mirage or water intrusion.
(f) Do not touch the black of the top of glass, or it may shorten its working life.
The phenomena table

1. front combination lights and tail light
Phenomena Possible part Reference pages
1.bulb -
Only one front combination light 2.fuse -
lights 3.wiring harness
1.fuse -
2.relay -
Low beam headlights do not light
3.left combination switch -
(all)
4.wiring harness -
1.fuse -
2.relay -
distance lights do not light (all)
3.left combination switch
4.wiring harness -
Distance light do not light (one 1.bulb -
side) 2.wiring harness -
1.left combination switch -
Flare does not light 2.flare
3.wiring harness -
Front combination lights are too 1.bulb -
dark 2.wiring harness -
Only one rear combination light 1.bulb -
lights 2.wiring harness -
1.bulb -
Rear combination lights do not light 2.wiring harness -
(front combination lights are normal) 3.left combination switch -
4.wiring harness -
Rear combination lights do not light 1.fuse -
(front combination lights are abnormal) 2.relay -
279
Light--Light System
2. Fog light System
phenomena Possible part Reference pages

1.(front fog light)fuse
The light control switch switches on,
2.fog light relay
the front fog lights do not light (front
3.fog light switch
combination lights are normal)
4.wiring harness
Lamp switch turn to HEAD. front fog
lights do not light (front combination light 1.other parts
do not light) 2.wiring harness
1.bulb
Only one front fog light do not light
2.wiring harness
1.fuse
Rear fog lights do not light (front
2.rear fog light switch
combination lights are normal)
3.wiring harness
(front fog lights are normal)
4.bulb
1.other parts
Rear fog lights do not light (front fog 2.wiring harness
lights do not light) 3.bulb
4.front fog light switch
5.rear fog light switch
3. Turning and emergency warning light system
phenomena Possible parts Reference pages

1. (meter) fuse
Emergency warning light and turn 2. (turn) fuse

light does not light 3. ignition switch
4. flasher assembly
5. wiring harness
Emergency warning light does 1. Emergency warning light switch

not light (turning light is normal) 2. wiring harness
Turn light does not light 1. turn light switch

(Emergency warning light is normal 2. wiring harness
1. turn light switch

Side turning light does not light
2. wiring harness
(warning light is normal)
3. bulb
1. turn light switch

One side of turning light does not
2. wiring harness
light
3. bulb
One side of turning light does not 1. turn light switch

light 2. wiring harness
1. bulb
Only one bulb does not light 2. wiring harness
280
Light--Light System
4. Room lights system
phenomena Possible parts Reference pages

All lights do not light 1. (room light) fuse
When driver cap side door opens, 1. driver cap side door control switch
the light does not light 2. wiring harness
3. bulb
When right front door opens, the 1. right front door control switch
light does not light 2. wiring harness
3. bulb
When right rear door opens, the 1. right rear door control switch
light does not light 2. wiring harness
3. bulb
When left rear door opens, the light 1. left rear door control switch
does not light 2. wiring harness
3. bulb
Only one light can light 1. bulb
After all doors are closed, illuminat- 1. Door-control switch
ing lamp will not flame out gradually. 2. Wire harness
After all doors closed, the head lamp 1. ignition switch
does not light in 15 seconds, when 2. fuse
turn ignition switch to ACC or ON. 3. light relay
4. wiring harness
1. (door) fuse
2. (meter) fuse
Driver side light or passenger cap 3. light relay
side light do not light 4. driver side door control switch
5. bulb
6. wiring harness
When Driver side door opens, 1. driver side door control switch
driver side light does not light 2. wiring harness
3. bulb
When Passenger side door opens, 1. passenger side door control switch
passenger side light does not light 2. wiring harness
3. bulb
Inspect the car

1. inspect turning flasher wiring
(a) Disassemble joint from turning flasher and inspect wiring
harness side joint as following table.
281
Light--Light System
Avometer terminals condition regular situations

7-earth normal conduction
1-earth turn light switch ON battery voltage
1-earth turn light switch ON no voltage
4-earth normal battery voltage
(b) Connect joint to directional switch and inspect from wiring harnesss side joint as following table:
Avometer terminals condition regular situation

2-earth warning light switch OFF ON 0V 0 9Vevery min 60 to 120 times
2-earth turn light switch (right) OFF ON 0V 0 every min 60 to 120 times
3-earth warning light switch OFF ON 0V 0 9Vevery min 60 to 120 times
3-earth turn light (left) switch OFF ON 0V 0 9Vevery min 60 to 120 times
5-earth turn light(left) switch OFF ON over 9V 0V
6-earth turn light(right) switch OFF ON over 9V 0V
8-earth warning light switch OFF ON over 9V 0V
2. Inspect rear fog light switch

Wiring
(a) inspect rear fog light wiring harness side
(1) Disassemble the joint from switch sides and inspect the
joint from wiring harness as following table.
Avometer terminals condition regular situation

2-earth light control switch OFF ON 0V 10-14V
3-earth normal 10-14V
5-earth light control switch OFF ON not conduction conduction
6-earth front fog light switch OFF ON not conduction conduction
(b) Inspect function of rear fog light.

(1) Turn the ignition switch to ON.
(2) Inspect rear fog lights situation when every switch works, just as following table.
Situation rear fog light working situations

Light switch OFF ON, front fog light switch OFF rear fog light does not light
Light switch OFF ON, front fog light switch ON, rear fog light switch ON rear fog light lights
3. Inspect lighting system function

Clues on: key aperture lamp and room light.
282
Light--Light System
(a) Turn the ignition switch to OFF and open all doors, then lock driver cap side door.
(b) Unlock the drives side door and open any door, then inspect whether room light lights. Close the door
and inspect whether room light lights off in 15 seconds.
(c) Turn ignition switch to ON, then open any door to inspect whether room light lights off immediately.
(d) Turn ignition switch to OFF.
(e) Open or close any door to light room light. Turn ignition switch to ON before room light turns off(about
15seconds) to inspect whether room light turns off immediately.
(f) Turn ignition switch to OFF.
(g) Open or close any door to light room light. Lock driver cap side door before room light turns off(about
15seconds) to inspect whether room light turns off immediately.
Inspect
1. Front combination headlight dimmer switch
assembly
(a) Inspect the conduction of light control switch
(1) Inspect switch on every positions, the conduction among
terminals as following table.
Switch positions Avometer terminals regular situations

OFF - not conduction
Position light 12-6 conduction
Lamp 12-6 conduction
Lamp 7-10 conduction
(b) Inspect conduction of front assembled dimmer switch

(1) Inspect switch on every parts, the conduction among terminals as following table.

Flasher 11-10 conduction
Low beam light 9-10 conduction
Distant light 7-10 conduction
(c) Inspect the conduction of turning light switch

(1) Inspect switch on every positions, the conduction among terminals as following table.

Turn right 4-5 conduction
neutral - not conduction
turn left 4-3 conduction
283
Light--Light System
(d) Inspect conduction of front fog light switch

(1) Inspect switch on every positions, the conduction among terminals as following table.
Switch positions Avometer terminals regular situation

OFF 1-2 not conduction
ON 1-2 conduction
2. Interior rear top light assembly [67010006]

(a) Inspect the conduction of interior rear top light
(1) Inspect switch on every position, the conduction among
terminals as following table.
Standard:
Switch positions Avometer terminals regular situation

OFF - not conduction
DOOR 1-2 conduction
ON 2-bodywork earth conduction
3. Room front top light assembly [67010007] (equipped

with electric sunroof [67010009])
(a) Inspect the conduction of room front roof light
(1) Inspect the conduction between terminal 1 and terminal
2,when switch works.
Standard:
ON: conduction 2 1
OFF: not conduction
4. Room front top light assembly [67010005](do not

equipped with electric sunroof)
(a) Inspect the conduction of room front roof light
(1) Inspect the conduction between terminal 1 and terminal
2,when switch works.
Standard:
ON: conduction
OFF: not conduction
5. Trunk lighting assemble [67000106]
(a) Inspect the conduction among terminals.
Standard: conduction
6. Inspect the B door pillar control switch assembly
[67000075]
284
Light--Light System
(a) Inspect the conduction of B pillar control switch assembly

(1) Inspect the conduction between terminal 1 and bodywork earth, when switch works.
Standard:
ON (when press the switch): conduction
OFF (when un-press the switch): not conduction
7. Inspect the C door pillar control switch assembly [67000076]
(a) Inspect the conduction of C pillar control switch assembly
(1) Inspect the conduction between terminal 1 and bodywork earth,when switch works.
Standard:
8. Trunk light switch assemble [67000073]
(a) Inspect the conduction of Trunk light switch
Standard:
9. Front fog light relay [67000071]
(a) Inspect the conduction of front fog light relay
(1) Inspect the conduction among terminals
Standards:
Avometer terminals regular situations
1-2 conduction
3-5 not conduction
(2) Supply battery voltage(10-14V) to terminal1 and terminal2, then inspect the conduction between
terminal 3 and terminal 5.
Standard: conduction
1
10. Inspect rear fog light switch of instrument block
left switch units [67010003].
(a) Inspect batterys positive wire connects to terminal 1,nega-
tive connects to terminals 7.
(b) Connect a 3.4W test bulb from batterys positive wire to
terminal 3.
(c) Inspect lighting switch, indicator light of assembled instru-
ments and test bulb should light. If it does not accord with
regularizations, replace the switch.
11. Inspect door light assembly [67000107]
Inspect the conduction among terminals.
If the conduction does not accord with regularizations, replace
the switch.
285
Light--Front fog light joint
Front combination light (LH)

Subassembly
Radiator cover
assembly
Front fog light

joint Left front combination
light units
Front combination
light bulb Light
seat cap
Bulb joint
Bulb
Bulb
Ultrasonic sensor joint
Front combination
light bulb
Front combination light

bulb joint
Front bumper Front fog light joint
286
Change
Notes:
z Assemble according to the opposite of disassemble. Instructions comes when necessary.
z The replace procedure are the same on the left and right side.
z Referring to the drawing of front combination light on page 286.
1. Disassemble Radiator cover assembly (reference to page 380)
2. Disassemble left front tyre lining (reference to page 380)
3. Disassemble right front tyre lining (reference to page 380)
4. Disassemble front bumper (reference to page 380)
5. Disassemble left front combination light assembly [67000102]
(a) Disassemble three bolts Pin
(b) Disassemble four joints
(c) Pull combination light ahead
(d) Disassemble two light seat cap and four bulbs.
Adjustments
1. Adjust front combination light focus only
(a) Parking car should accord to the following situations:
z Front combination light around does not be distorted or damaged.
z Park the car on flat road.
z Tyre pressure limits to the regular number value
z The driver is on driving seat and the car is ready to go(gasoline tank in full)
z The car weaves fore-and-aft for many times.
(b) Inspect front combination light focus
(1) Prepare for thicker white paper
(2) Arise the paper plumb at the distance of 300cm from headlight.
(3) Make sure centerline of the car makes 90 degree angle with papers surface as following drawing.
(4) Draw a level line (H line) on the paper which headlight can irradiate.
(5) Draw a plumb line (V line) on the paper to across centerline of the car.
(6) Draw two level lines (V RH and V LH) in the area where two side lights can irradiate.
(7) Draw a level line(connect the middle signal of two low beam headlight) to the area where headlight
can irradiates.
Clues on: H RH and H LH lines are 0.57 lower than level line(H line)of light.
(8) Start the engine.
(9) Turn the front assembled switch to ON.
287
(10) Inspect front combination light whether it irradiates on the area as drawing.
(11) If not, adjust light on vertical line or level line.
Distant Low
light beam
light
wire wire
wire wire
wire wire
H RH and
H LH wire
1209.0 939.8
Numbers for approach sequence
Clues on:
z Adjust the focus between lights of RH and LH as the drawing.
z The value of low beam focal length is reference value for it is impossible to adjust at
level direction.
(c) Adjust vertical direction Adjusting bolt A

Use the adjustable bolt A to make the headlight focus limits
to the regular.
(d) Adjust level direction
Use the adjustable bolt B to make the headlight focus limits
to the regular.
Adjusting bolt B
288
Front fog light

Components
Front fog light joint
Left front fog light unit
Bulb
289
Change
Notes:
z Assemble according to the opposite of disassemble.
Instructions comes when necessary.
z The replace procedure are the same, left and right side.
z Referring to the drawing of front combination light on
page 286
1. Replace front fog light bulb
(a) Disassemble front fog light seal cap
(b) Press front fog light bulb spring
(c) Disassemble the bulb
Adjustments
1. Adjust front fog light optic axis
(a) Tyre pressure limits to regular number values.
(b) Start the engine.
(c) Adjust fog light optic axis by turning the optic axis adjust-
able button on the vertical direction.
290
Light--Side turning light
Side turning light

Components
Side turning light
291
Light--Rear combination light
Rear combination light (LH)

Components
Bulb
Left rear combination light
292
Light--Rear combination light
Change
Notes:
z The replace procedure are the same on the left and right side.
z Referring to the drawing of front combination light on page 286
1. Disassemble left rear combination light assembly [67000108]
(a) Disassemble three bolts and rear combination light.
(b) Disassemble two bulbs
293
Light--Rear fog light
Rear fog light

Components
Left rear fog light
Rear fog light joint
Bulb
294
Light--Rear fog light
Change
Notes:
z The replace procedure is the same on the left and right side.
z Referring to the drawing of front combination light on page 286
1. Disassemble rear fog light.
(a) Disassemble two bolts.
(b) Disassemble rear fog light by using vice screw driver
295
Light--Number plate light
Number plate light

Change
1. Disassemble key aperture of trunk cover and bracket
2. Disassemble number plate light of trunk cover
3. Disassemble number plate light assemble [68000097]
(a) Disassemble the joints.
(b) Disassemble number plate light using vice screw driver. Fixing
Clues on: Before using vice screw driver, its cusp claw
should enwind adhesive tape.
(c) Disassemble the bulb.
296
Light--High brake light assembly
High brake light assembly

Change
1. Disassemble high brake light assembly [67010008]
(a) Loosen two fixed jaw just as drawing.
(b) Loosen two fixed jaw and disassemble high brake light
assembly as the drawing, then take the joint apart.
Fixing claw
297
Light--Left combination switch
Left combination switch

Change
1. Disassemble decorative board under steering column [67000129]
2. Disassemble left combination switch assembly [67000078]
(a) Take the joint apart.
(b) Loosen fixed jaw and pull left combination switch assembly.
Fixing
claw
298
Wiper and cleaner--Wiper and cleaner system
Wiper and cleaner

Wiper and cleaner system
Malfunction phenomena table
The underside table can help you to eliminating malfunction in wiring. It sorts as possibilities of malfunctions
reasons.
Malfunction Component names Reference pages
1. ignition switch -
2. ignition relay -
Wiper and cleaner do not work. 3. (wiper) fuse (central power distribution box) -
4. right assembled switch 302
5. wiring harness
Wiper does not work on LO, HI or MIST. 2. wiper generator 303
3. wiring harness
Wiper does not work on INT 2. wiper generator 303
3. wiring harness
1. (washer) fuse (central power distribution box) -
Washer generator does not work 2. wiper switch -
3. wiper generator -
4. wiring harness -
When cleaner switch ON, wiper does not 1. right assembled switch 302
work. 2. washer generator 303
3. wiring harness -
Wiper cleaner can not spout 1. cleaner hose and nozzle -
z Right assembled switch on HI, wiper 1. right assembled switch *1 302
blade will touch the bodywork. 2. wiring harness -
z When right combination switches are OFF, washer will
not return to original position or stop position is incorrect.
*1:inspect set position of wiper arm and wiper blade.
Inspect the car

Inspect the function of cleaner generator
(1) Add some rinsing to wiper water tank, then disassemble
cleaner generator joint.
(2) Connect battery wire with cleaner generator joint terminal2,
negative wire with terminal1,then inspect whether cleaner
generator works.
Notes: Be quick(in 20 seconds) to do this test to pre-
vent cleaner generator coil from burning.
If its function does not in accord with regulations, replace
cleaner generator.
299
Inspect
1. Inspect the conduction of right combination
switch [67000079]
(a) Inspect the conduction of every terminal of joints.
Right combination switch

Switch positions terminals connect with avometer regular situations
MIST SWL-WIG Conduction
OFF AS-SWL Conduction
INT AS-SWL/SWL-WIG Conduction
LO SWL-WIG Conduction
HI SWH-WIG Conduction
Sprinkler switch
Switch position terminals connect with avometer regular situations

OFF - Not conduction
ON WIG-WS conduction
(b) Inspect intermittent function of wiper.

(1) Connect voltmeter positive wire with joint terminal SWL, connect negative to terminal EW.
(2) Connect battery positive wire with joint terminal WIG, connect negative to terminal EW.
(3) Turn right assembled switch to INT.
(4) Connect battery positive wire with terminal AS for 5 seconds.
(5) Connect battery negative with terminal AS for 5 seconds actuate intermittent relay and check the
voltage between terminal SWL and terminal EW .
(c) Inspect the function of cleaner

(1) Turn right assembled switch to OFF.
(2) Connect battery positive wire with joint terminal WIG, connect negative to terminal EW.
(3) Connect voltmeter positive wire with joint terminal WS, connect negative to terminal EW.
(4) Switch on cleaner switch and inspect its going.
300
2. Inspect the function of generator

(a) low speed:
Connect battery positive wire with joint terminal SWL, connect negative to terminal ES. Inspect whether
generator work at low speed.
If its function does not in conformity with regulations, replace wiper.
(b) high speed
Connect battery positive wire with joint terminal SWH, connect negative to terminal WS. Inspect
whether generator work at high speed.
If its function does not in conformity with regulations, replace wiper.
(c) Free stop position
(1) Connect battery positive wire with joint terminal SWL, connect negative to terminals ES to make
generator work at low speed. Disassemble terminal SWL

lead to make generator stop except stop position.
(2) Connect terminal SWL with terminal AS
(3) Connect battery positive wire with joint terminal SWL to
make generator work at low speed again. Inspect gen-
erator whether stop at the stop position.
Free stop
If its function does not in conformity with regulations, position
replace wiper.
301
Wiper and cleaner--Right combination switch
Right combination switch

Change
1. Disassemble the lower trim board of the steering
gear
2. Disassemble right combination switch assembly
[67000079] Fixing
claw
(a) Disassemble the joints.
(b) Press fixed jaw to separate meshing then disassemble right
combination switch assembly.
Notes: Do not overly press fixed jaw, or it may de
damaged.
302
Wiper and cleaner--Wiper generator
Wiper generator
Change
1. Disassemble wiper arm cap.
2. Disassemble auxiliary wiper arm assembly
[68000059]
Disassemble screw cap and auxiliary wiper arm assembly.
3. Disassemble main wiper arm assembly [68000057]
Disassemble screw cap and main wiper arm assembly.
4. Disassemble generator cap to fire barrier seal.
Separate eight fixed buckles to disassemble the seal from gen-
erator cap to fire barrier.
Fixing clasp
5. Disassemble ventilation cover on passenger side.

Disassemble five fixed jaws so as to disassemble ventilation
cover on passenger side.
Fixing
claw
6. Disassemble ventilation cover on driver side.

Disassemble five fixed jaw so as to disassemble ventilation
cover on driver side.
Fixing
claw
7. Disassemble wiper connecting rod assembly

[68000053]
(a) Disassemble the joint.
(b) Disassemble the bolt.
(c) Slide wiper connecting rod assembly to passenger side to Pin
separate meshing of rubber pin so as to disassemble wiper

connecting nod.
303
Wiper and cleaner--Wiper generator
8. Disassemble wiper generator

(a) Separate two connecting rod caps of shaft pins.
(b) Separate two star- bolts so as to disassemble wiper

generator.
9. Assemble wiper generator

(a) Daub MP grease to connecting rod caps of wiper generator.
(b) Use two Star-bolts to assemble wiper generator to wiper
connecting rod.
Torque: 5.39 N.m
10. Assemble wiper connecting rod assembly

[68000053]
(a) Meshing wiper connecting rod rubber pin
(b) Use two bolts to assemble wiper connecting rod. Assembly starting and
stopping position
Torque:5.5 N.m
(c) Connect the joints.
11. Assemble assistant wiper arm assembly [68000059]

(a) Use steel brush to clean small tooth slot of wiper pivot.
(b) Use bolt cap to fix wiper arm on passenger side to make
wiper blade at the position as drawing.
Torque: 20.5 N.m
12. Assemble main wiper arm assembly [68000057] Assembly starting and
(a) Use steel brush to clean small tooth slot of wiper pivot. stopping position
(b) Use bolt cap to fix wiper arm on driver side to make wiper
vane at the position as drawing.
304
Wiper and cleaner--Wiper
Wiper
Change
1. Disassemble left wiper shelf.
Disassemble left wiper shelf from left wiper arm.
Note: Do not bend wiper arm adown when disassemble
wiper shelf.
2. Disassemble wiper blade
Disassemble wiper blade from wiper shelf.
3. Disassemble wiper blade fixed branch vane.
4. Assemble wiper blade fixed branch vane.
Note: Be careful, do not assemble front and rear branch
blade by mistake.
5. Assemble wiper blade

Put the head of wiper blade(on big end side) on the direction of
wiper arm connecting shaft side, when you assemble left wiper
blade.
Note: Pull the wiper blade into wiper shelf completely.
305
Wiper and cleaner--Cleaner nozzle
Cleaner nozzle
Adjustments
1. Inspect cleaner nozzle
When engine works, inspect whether wiper water blast spurt in the area of wind shield bias as the drawing.
Adhesives strip
306
Audio system--Audio system
Audio system
Audio system
Notes
1. Observe notes for disposal and operation
(a) Please explain to customers: when take batterys negative terminal off, the memory broadcasting
station on the audio AM/FM set on the radio will be deleted. So, before taking battery s negative
terminal off ,note the stations information according to your need. After taking back negative terminal,
set former station again.
(b) Before disassemble/assemble the radio, inspect and take cassette and CD out in.
Clues on: the malfunction of disassemble/assemble the radio is because the tape or CD can
not take out. Do not take it out by force. Drive the car to the service station.
(c) Do not touch the audio film of loudhailer
2. Refer to instructions about using and maintaining audio system
307
Audio system--Radio assembly
Radio assembly
Change
1. Disassemble the CD machine assembly (referring to page 342)
2. Disassemble radio assembly
(a) Disassemble four bolts as the drawing.
(b) Take the joint apart, then disassemble radio assembly.
308
Audio system--Left front door loudhailer
Left front door loudhailer

Change
1. Disassemble left front door control panel assembly
[68000142]
2. Disassemble left front door inner guard board as-
sembly [68010049]
3. Disassemble left front door water screen assembly
[68000140]
4. Disassemble left front door loudhailer assembly
[67000127]
(a) Disassemble three rivets.
(b) Disassemble the joint, then disassemble left front loudhailer.
5. Diasassemble left front door loudhailer assembly
[67000127]
(a) Use three new rivets to assemble new left front door
loudhailer assembly.
6.Replace right front door loudhailer,just as upper
method
309
Audio system--Left front small loudhailer
Left front small loudhailer

Change
1. Disassemble left front door control panel assembly
[68000142]
2. Disassemble left front door inner guard board as-
sembly [68010049]
3. Disassemble left front door water screen assembly
[68000140]
4. Disassemble left front door small loudhail cover
assembly [67000131]
5. Disassemble left front door small loudhailer assem-
bly [67000129]
(a) Disassemble maintenance hole cap, then take the joint apart.
(b) Disassemble two nuts and left front small loudhailer
assembly.
310
Audio system--Rear loudhailer
Rear loudhailer
Change
1. Disassemble rear platform sun blind assembly [68010032] (referring to page 277)
2. Disassemble rear loudhailer assembly [67000133]
Disassemble eight tapping screws and two loudhailers.
311
Audio system--Outdoor antenna
Outdoor antenna
Change
1. Disassemble battery negative wire
2. Put the front tyre forward
3. Disassemble safety airbag assembly at the side of the driver
4. Disassemble steering wheel
5. Disassemble integration instrument cap
6. Disassemble integration instrument
7. Disassemble panel NO.3 air outlet
8. Disassemble panel NO.1 air outlet
9. Disassemble panel center air outlet trim board
10. Disassemble glove box
11. Disassemble right front pillar trim board
12. Disassemble left front pillar trim board.
13. Disassemble the joint of the safety airbag at the side of the passenger
14. Disassemble panel
15. Disassemble right front door trim board.
16. Disassemble right side trim board.
17. Disassemble antenna assembly [67000136]
(a) Take removable antenna pillar plug apart from radio.
18. Assemble antenna assembly [67000136]
19. Assemble panel
20. Assemble helix cable.
21. Assemble steering wheel
22. Inspect steering wheel whether it dead against the center.
23. Inspect horn button.
24 Assemble horn button
25. Inspect SRS warning light
312
Circuitry--Power supply
Circuitry
Power supply
Components (For reference only)
engine room assistant

fuse box
Engine room main

fuse box
Center power
distribution
313
1. ST startup system 20. left distance headlight

2. HEAD MAIN light system 21. right distantce headlight
3. spare 22. left low beams
4. ECU instrument travel 23. right low beams
computer (Aldine)
5. horn
6. turn light, alarm light
7. charging system
8. air condition system
9. electric injection system
10. audio system, air condition,
instrument, room light, trunk
light, door light
11. AM2 startup system
12. spare safety
13. spare safety
14. spare safety
15. spare safety
16. electric chair (Aldine)
17. electric fan
18. ABS system
19. ABS system
314
24. spare light

25. OBD discharge test system 39. brake light
26. rear fog light 40. electric sunroof
27. Anti-burglary 41. instrument system, air condition
28. DOOR center control, light con- system, defrost system, Re-
trol system verse Radar, rear light, turn light.
29. Defrost load 42. CIG air condition system, audio
30. spare system, electric rear view mirror,
31. spare cigarette lighter
32. eletric injection system, safety 43. washer
airbag system, anti-burglary 44. spare
system, instrument system 45. wiper
33. spare 46. spare
34. spare 47. center control, light control
35. spare system, anti-burglary system,
36. front fog light ABS system
37. AMI ignition system 48. air condition system
38. TAILposition light, number plate 49. rear defrost system
50. electric glass operator
315
Horn--system
Horn system
Horn system
Position
Horn (alt)
Horn (undertone)
Inspect
1. Inspect the relay
(a) Inspect Whether horn relay (mark: HORN)is conduct
Condition avometer connection terminal regular situations

Normal 1-2 conduction
Supply battery voltage 3-5 conduction
to Terminal 1 and 2
If the conduction situation does not accord with regulations, re-

place the relay.
316
Windshield/bodywork glass/wing mirror--Electric window control system
Windshield/window glass/wing mirror

Electric window control system
Position drawing (For reference only)
Right front door electric

window generator
Electric window Electric window
switch switch
Electric window
main switch Right front door electric
window lift
Left front door electric
window lift Right rear door electric
windows lift
Right rear door electric

window generator
Left front door electric

window generator
Electric window
switch
Left rear door electric
window lift
Left rear door electric

window generator
Inspect the car

1. Inspect electric window
(a) Inspect basic function (manual operation function)
(1) Turn the ignition switch to ON
(2) Inspect the window whether it descends when you press electric window switch. Pull the switch up
and inspect whether it ascends.
(3) Inspect the window whether it descends when you press electric window switch of every door. Pull
the switch up and inspect whether it ascends.
317
(4) Inspect other windows whether they can not actuate except window of driver seat room, when the
electric window switch locked.
2. Inspect automation function
(a) inspect basic function
(1) Turn the ignition switch to ON
(2) Inspect whether driver seat window automatic descends completely, when you press electric win-
dow main switch.
(3) Inspect whether driver seat window stop descending when driver seat window automatic descends
and press the main switch.
3. Inspect electric window main switch assembly

(a) Inspect operations
(1) Disassemble the joint of driver seat electric window main
switch and inspect the voltage and conduction among
terminals.
Avometer terminals conditions regular situations

16-earth(input +B signal) turn ignition switch from OFF to ON 0V 10-14V
11-earth always conduction
12-earth always conduction
15-earth(input IG signal) turn ignition switch from OFF to ON 0V10-14V
If the voltage and conduction do not accord with the regulations, the input side of electric window main
switch may have malfunction.
(b) Inspect the joint terminal voltage when connect the joint.
Avometer terminals conditions regular situations
4-earth turn the ignition switch to ON, turn Driver seat
0Vover 9V
(output P/W.UP) Main switch from OFF to UP (manual operation)
9-earth turn the ignition switch to ON, turn Driver seat
0Vover 9V
(output P/W.DOWN) Main switch from OFF to DOWN (manual operation)
turn the ignition switch to ON, turn Off Driver seat
9-earth
window driver seat Main switch to DOWN 0Vover9V0V
(output P/W.DOWN)
(auto Operation) windows open completely.
If the voltage does not accord with the regulations, electric window main switch may have malfunction.
(c) Inspect whether AUTO headlamp(LED) lights when connect the joint, turn the ignition switch from
OFF to ON.
318

Phenomena impossible positions wiring harness
Electric window does not Work(all)(electric 1. POWER fuse(center power distribution box) -
door lock does Not work) 2. window shift main relay (center Distribution box) -
3. wiring harness -
1. ignition switch -
Electric window does not work(all) (electric 2. left front door control Panel assembly 319
door lock is normal) 3. wiring harness -
4. electric window generator 320
Automation system does Not work 1. left front door control panel assembly 319
2. electric window generator (driver seat) 320
1. left front control panel assembly 319
Only one window can not Move 2. electric window switch 320
3. electric window generator 320
4. wiring harness -
1. left front door control panel assembly 319
Electric window system Does not work
2. wiring harness -.
Inspect
1. Inspect left front door control panel assembly
[68000142]
Action switch, inspect the conduction among joint terminals.
Notes: Whether it works good or bad ,it can judged by
basic function. Becauce the conduction can not inspect
by ascending or descending drivers electric window main
switch.
Electric window does not locked
right front, avometer right rear, avometer Left rear, avometer
Switch position situations
terminal terminal terminal
UP 4-15, 6-10 9-15, 7-10 3-15, 1-10 Conduction
OFF 4-10, 6-10 9-10, 7-10 3-10, 1-10 Conduction
DOWN 6-15,4-10 7-15, 9-10 1-15, 3-15 Conduction
Electric window locked
right front, avometer right rear, avometer Left rear, avometer

Switch position situations
terminal terminal terminal
UP 4-15 9-15 3-15 Conduction
OFF 4-6 7-9 1-3 Conduction
DOWN 6-15 7-15 1-15 Conduction
If the conduction does not limit to regulations, replace electric window main switch.
319
2. Inspect electric window switch assembly

Active switch, inspect the conduction among the joint terminals.
Switch position avometer terminals situations

UP 4-5, 2-3 conduction
OFF 4-5, 1-3 conduction
DOWN 2-5, 1-3 conduction
If the conduction does not limit to regulations, replace electric

window main switch.
3. Inspect left rear electric window motor assembly.
(a) Inspect the function of left rear electric window assembly.
(1) Inspect whether the motor works calmly.
Battery terminals working direction

Battery anode lead-terminal 5 main driving axis working
Battery cathode lead-terminal 4 as clockwise
Battery anode lead-terminal 4 main driving axis working
Battery cathode lead-terminal 5 as anticlockwise
4. Inspect electric window shift relay [67000061]

Check the conduction of relay (mark: P/W)
If the conduction does not limit to regulations, replace relay.
Conditions avometer regular situations

Always 1-2 conduction
To that between terminal 1 3-5 conduction
and terminal 2
320
Windshield/bodywork glass/wing mirror--Front windscreen
Front windscreen
Change
Clues on: Please assemble as the disassembly opposite sequence. Assemble directions could
be got when necessary.
1. Disassemble right front pillar trim board assembly [68010017] (referring to page 390)
2. Disassemble left front pillar trim board assembly [68010014] (referring to page 390)
3. Disassemble inner rear mirror assembly [67010013] (referring to page 390)
4. Disassemble right sun shade [68010085] (referring to page 390)
5. Disassemble left sun shade [68010084] (referring to page 390)
6. Disassemble interior front headlamp assembly [67010075] (referring to page 390)
7. Disassemble passenger handle (referring to page 390)
8. Disassemble sun shade pothook [68010086] (referring to page 390)
9. Disassemble top interior trim board
Disassemble top interior trim board
10.Disassemble top left trim tape [68000128]
11. Disassemble top right trim tape [68000129]
12. Disassemble front windscreen sealed trim board [68000062]
(a) Use blade to cut trim tape as the drawing.
Note: Do not cut the bodywork.
(b) Disassemble rudimental trim type.
13. Disassemble front windscreen assembly [68000061]

(a) Use a steel wire to drill through windows and bodywork.
(b) Tie something like wood block at both the end of steel wire.
Clues on: Stick adhesive tape on the bodywork at work
to prevent paintwork from scraping.
Clues on: When separate window, do not damage
paintwork and interior trim board. When disassemble
front windscreen,put a plastic board between steel wire
and panel to prevent scratching the panel.
(c) Pull steel wire along front windscreen around, remove
agglutinant.
(d) Disassemble front windscreen.
Note: When cut front windscreen down, leave aggluti-
steel wire
nant as much as possible on the bodywork.
14.Clean front windscreen assembly [68000061]
Use white gasoline to clean front windscreen around.
15. Assemble windscreen orientation plastic button
321
Assemble two orientation block on the windscreen as the

drawing.
A: 40mm
B: 8mm
16. Assemble front windscreen in board sealed tape
[68000063]
Stick sealed tape with double faced adhesive tape on both
sides.
a: 7mm
b: 22.5mm
c: 45mm
d: 5mm
17. Assemble front windscreen assembly [68000061]
(a) Put front windscreen at the right position.
(b) Inspect the contacting part of front windscreen brim whether
it is flat
(c) Mark signal between bodywork and glass.
(d) Disassemble front windscreen .
(e) Use blade to remove granulation area.
Note: leave agglutinant as much as possible on the
bodywork.
(f) Use duster cloth with cleaner to clean the agglutinant on Bond
the incision.
Clues on: When all the agglutinant has been removed Bond
completely, clean the bodywork.
(g) Use brush to daub M priming paint on the o contacting part
of bodywork.
Notes:
z Dry M priming paint for three minutes.
z Do not daub M priming paint on the agglutinant.
z Opened M priming paint can not use for the next
322
time.
(h) Use brush or sponge to daub G priming paint on the front
windscreen brim and contacting interface.
(i) When daub other areas beside regulations, use clean duster
cloth to clean before priming paint gets dry.
Notes:
z Use G priming paint over three minutes.
z Opened G priming paint can not use for the next
time.
(j) Cut a hole on glue canister sharp mouth
(k) Put the glue canister in the sealed glue jet gun.
(l) Daub agglutinant on the front windscreen.
A: 12mm
B: 8mm
18.Assemble front windscreen sealed trim tape
[68000062]
Assemble the new trim tape in the bodywork manually.
19. Inspect water leakage and repair
(a) Actualize water leakage after hardening.
(b) Use agglutinant to seal leak position.
323
Windshield/bodywork glass/wing mirror--Rear ventilation window
Rear ventilation window

Change
Clues on: Please assemble by the sequence opposite with disassembling sequence. Assemble
directions could be got when necessary.
1. Disassemble the step trim board of left rear door [68010022] (referring to page 390)
2. Disassemble the step trim board of right rear door [68010024] (referring to page 390)
3. Disassemble left rear door frame sealed tape [68010059]
4. Disassemble right rear door frame sealed tape [68010060]
5. Disassemble rear seat cushion
6. Disassemble rear seat back assembly (fixed) [68010076] (referring to page 354)
7. Disassemble rear seat right back assembly (fixed) [68010079] (referring to page 352)
8. Disassemble rear seat left side back assembly (separate) [68010078](referring to page
352)
9. Disassemble left rear pillar interior trim board assembly [68010026] (referring to page
390)
10. Disassemble right rear pillar interior trim board assembly [68010027] (referring to page
390)
11. Disassemble high brake light assembly [68010008]
12. Disassemble rear platform front-below trim board [68010034]
13. Disassemble rear wind window sealed trim tape [68000104]
(a) Use blade to cut the trim tape as the drawing.
Notes: Do not damage the bodywork by blade.
(b) Disassemble rudimental trim tape.
14. Disassemble rear ventilation window assembly
[68000103]
(a) Use a steel wire to drill through windows and bodywork.
(b) Tie something like wood block at both the end of steel wire.
Clues on: Stick adhesive tape on the bodywork at work
to prevent paintwork from scraping.
Notes: When separate window, do not damage
paintwork and interior and exterior trim board.
(c) Pull steel wire along front windscreen around, removal
agglutinant.
(d) Disassemble front windscreen.
steel wire
Note: When cut front windscreen down, leave aggluti-
nant as much as possible on the bodywork.
15. Clean rear ventilation window assembly [68000103]
Use white gasoline to clean rear ventilation window around.
16. Assemble windscreen orientation plastic button
[68000064]
Assemble two orientation block on the rear windscreen as the
324
figure.
A: 40mm
B: 8mm
17. Assemble rear ventilation window inboard sealed
tape [68000105]
Stick sealed tape with double faced adhesive tape on both
sides.
18. Assemble rear ventilation window assembly
[68000103]
(a) Put rear ventilation window at the right position.
(b) Inspect the contacting part of rear ventilation window brim
whether it is flat.
(c) Mark signal between bodywork and glass.

(d) Disassemble rear ventilation window
(e) Use blade to remove coarseness area.
Note: leave agglutinant as much as possible on the
bodywork.
(f) Use duster cloth with cleaner to clean the agglutinant on
the cutting surface.
Clues on: When all the agglutinant has been removed
Bond
completely, clean the bodywork.
(g) Use brush to daub M priming paint on the contacting part
of bodywork.
Notes:
z Dry M priming paint for three minutes.
z Do not daub M priming paint on the agglutinant. Bond
z Opened M priming paint can not use for the next
time.
(h) Use brush or sponge to daub G priming paint on the front
windscreen brim and contacting interface.
(i) When daub other areas beside regulations, use clean duster
325
cloth to clean before priming paint gets dry.

Clues on:
z Use G priming paint over three minutes.
z Opened G priming paint can not use for the next
time.
(j) Cut a hole on glue canister sharp nose.
(k) Put the glue canister in the sealed glue jet gun.
(l) Daub agglutinant on the front windscreen.
A: 12mm
B: 8mm
C: 6.5mm
D: 13mm
19. Disassemble rear seat back assembly (fixed)
20 Disassemble rear right side back assembly
(separate) [68010079] (referring to page 352)
21. Disassemble rear seat left side back assembly (separate) [68010078] (referring to page
352)
326
Windshield/bodywork glass/wing mirror--Fogbroom system
Fog defrost system

Position drawing
Demist wire
Demist (Defrost)switch

Malfunction components name reference pages
1. DEF main relay
2. DEF-IP fuse
All demists (defrosts) do not work 3. DEF-m fuse
4. demist switch
5. wiring harness
Rear ventilation window Demist (defrost) 1. demist wire
do not work 2. wiring harness
electric rear mirror defrost dose not work 1. electric rear mirror
327
Windshield/bodywork glass/wing mirror--Fogbroom system
Inspect
1. Inspect the relay
Inspect the conduction of rear window demist(defrost) relay
(mark: DEF)
If the conduction does not accord with the regulations, replace
relay.
Conditions avometer terminals regular situations
Always 1-2 conduction
between terminal1 and 3-5 conduction
Terminal2
328
Windshield/bodywork glass/wing mirror--Electric rearview mirror control system
Electric rearview mirror control system(option)

Inspect the vehicle
1. Inspect Electric retractable rearview mirror function
(a) Turn the ignition switch to ACC
(b) Inspect operating electric retractable rearview mirror function, when it at different positions.
(1) When retractable switch at steering position and left/right rearview mirror at steering position either,
press retractable switch, inspect left and right rearview mirrors whether they remove from steering
position to retraction position and stop at it. steering position retractable
(2) When retractable switch at steering position and left/ position
right rearview mirror at steering position either, if any one
of the rearmirrors can be pushed back by hand, then
press retractable switch to retractable position, inspect Electric
left and right rearview mirrors whether they remove from retract-
able
steering position to retraction position and stop at it. operation
(3) When retractable switch at retractable position and left/
right rearview mirror at steering position either, if any one
of the rearmirrors can be pushed back to steering posi-
tion by hand, then press retractable switch to retract- steering position retractable
position
able position , inspect whether rearview mirrors move to
restricted position only in steering position and stop at
it. Handle
Electric operation
retract-
able
operation
(4) When retractable switch at retractable position and left/

right rearview mirror at retractable position either, inspect
steering position retractable
left and right rearview mirrors whether they remove from
position
retraction position to steering position and stop at it.
Electric Electric
retract- retract-
able able
(5) When retractable switch at retractable position and left/ operation operation
right rearview mirror at retractable position either, if any
one of the rearmirrors can be pushed back to steering
position by hand, then press retractable switch to steer-
steering position retractable
ing position, inspect whether rearview mirrors move from
position
restricted position to steering position and stop at it.
Electric Handle
retract- operation
able o
peration
329
(c) When operating left and right rearview mirrors, inspect whether ignition switch works when turn it to
OFF.
(1) When operating left and right rearview mirrors, turn ignition switch to OFF and inspect rearview
mirrors function whether they stop.
(2) Turn ignition switch to ACC again, inspect whether rearview mirrors work
Clues on: Turn ignition switch to OFF, if you press retractable switch and turn ignition
switch to ACC, then left and right rearview mirrors will move to opposite position.
(d) Inspect whether rearview mirrors work when restricted by others.
(1) When left and right rearview mirrors move to retractable position or steering position, restrict left
and right rearview mirrors manually, inspect retraction stops.
(2) Press retractable switch again, inspect whether it works.(at the opposite direction of stop position)
330
Positions
Electric rear view mirrors

switch
Left rear view mirrors
Right rearview mirrors
Trouble table
Trouble Components name Reference page
1. (accessory) fuse -
rearview mirrors do not work 2. rearview mirror switch 332
3. wiring harness -
1. rearview mirror switch 332
rearview mirrors work abnormally
2. wiring harness -
331
Left and right

INSPECT adjusting switch Folding switch
(optional)
1. Inspect rear view mirrors switch
Inspect conduction of rearview mirror.
(1) Adjust left or right for side of the switch.
Rearview
Inspect conduction of rearview mirror on left side mirror
switch
Switch positions Avometer terminals Regular situations

ON - Not conduction
Up 5-8, 6-7 Conduction
Down 5-7, 6-8 Conduction
Left 4-8, 6-7 Conduction
Right 4-7, 6-8 Conduction
Replace the switch if it does not accord with the regulations.

(2) Adjust right side of left and right switch.
Inspect conduction of rearview mirror on right side

ON - Not conduction
Up 3-8, 6-7 Conduction
Down 3-7, 6-8 Conduction
Left 2-8, 6-7 Conduction
Right 2-7, 6-8 Conduction
Replace the switch if it does not accord with the regulations.

(3) Inspect conduction of retracting switch

Position of driving 8-9, 7-10 Conduction
Position of retracting 8-10, 7-9 Conduction
Replace the switch if it does not accord with the regulations,

2. Inspect rear rear view mirror
(a) Inspect motor function of rearview mirror
(b) Inspect function of electric retracted motor
Battery terminals Positions of rearview mirror
Positive wire (+) -A
Turn left
Negative wire (-) -B
Positive wire (+) -B
Turn right
Negative wire (-) -A
Positive wire (+) -C
Turn up
Negative wire (-) -B
Positive wire (+) -B
Turn down
Negative wire (-) -C
332
Notes:
z When repeat the same inspection, cut off the voltage of battery, then inspect again with
same steps.
z When supply battery voltage, the rearview mirror will not retract even if trying to move the
crust of rearview mirror.
Outer rearview mirror assembly L
Positions of rearview mirror Connection style Actuated style

Connect wire G to positive
A (position of driving) Not actuated
Connect wire D to negative
B (between position of driving Connect wire D to positive, connect wire G to negative A-B-C
and retracting) Connect wire G to positive, connect wire D to negative C-B-A
Connect wire D to positive
C (position of retract) Not actuated
Connect wire G to negative
Outer rearview mirror assembly R

Positions of rearview mirror Connection style Actuated style
Connect wire D to positive Not actuated
A (position of driving)
Connect wire G to negative
B (between position of driving Connect wire G to positive, connect wire D to negative A-B-C
and retracting) Connect wire D to positive, connect wire G to negative C-B-A
Connect wire G to positive
C (position of retract) Not actuated
Connect wire D to negative
Replace the rearview mirror if actuation does not accord with regulations.
L terminal L terminal
connecting wire connecting
wire
assembly L assembly R
333
Panel/combination instrument--combination instrument
Panel / combination instrument

combination instrument
Trouble table
Lightening:
Phenomenon Possible parts of trouble Reference pages

1. combination instrument assembly -
All lights fail
2. joint or harness -
Only one light fails 1. combination instrument assembly -
Indicator light:

1. harness or joint -
Trouble light fails 2. engine ECU -
Charge light fails 2. engine ECU -
Brake system light fails 2. ABS ECU -
3. combination instrument assembly 335
ABS light fails 2. ABS ECU -
SRS lights fails 2. airbag sensor assembly -
Door light fails 2. door control switch -
low fuel level light fails 2. fuel level light switch 335
low Oil pressure light fails 2. oil pressure light switch 335
3. harness or joint 335
334
Indicator light:
Turning light fails 2. turn light and safety warning light system -
Distant light fails 2. left combination switch -
Instrument:

Revolution counter, petrol guage and
2. (panel) safety fuse -
engine water thermometer fail
petrol guage fails or works abnormally 2. Fuel guage sensor 335
Vehicle inspection
1. inspect speed counter
(1) Use speedometer tester to inspect allowed error of speedometer and action of speedometer
Reference: Km/h
speed indicated by speedometer actual speed

20km/h 17-23km/h
40km/h 35-40km/h
60km/h 55-60km/h
80km/h 75-80km/h
100km/h 95-100km/h
120km/h 114-120km/h
140km/h 133-140km/h
160km/h 152-160km/h
Notes: tyre wear or tyre pressure too high or too low will increase error.
(2) Inspect speedometer needle offset
Reference: below 0.5km/h
335
2. Inspect output signal of vehicle speed.

(1) When vehicle run at 10km/h, inspect voltage between ter- A1 A20
minal10 and terminal A1 of combination instrument assembly.
Standards: the voltage pulsates repeatedly between
0V to 5V for thirteen times.
Notes: Inspect the ignition switch on connects the
joint
3. Inspect speed gauge
(1) Connect a test tachometer. then startup the engine.
Notes:
z Tachometer terminals polarity connects oppositely will damage interior transistors and
LEDs.
z When move or disassemble tachometer. do not drop on the ground or knock the surface.
(2) Compare indicted value test tachometer and combination instrument tachometer.
Standard indicted value (rmp) permitted values (rpm)

700 630-770
1,000 (900-1,100)
2,000 (1,850-2,250)
3,000 2,850-3,150
4,000 (3,800-4,200)
5,000 4,750-5,250
6,000 (5,700-6,300)
7,000 6,650-7,350
4. Inspect fuel gauge

The fuel gauge has the function of sensor detection (that is
failure treatment of oil level tachometer)that is when fuel gauge
indictor is at E position, if low oil level warning light doesnt
light, first should judge whether there have open-loop trouble of
fuel sensor or wiring harness. When sensor fails, fuel indictor
should stop at current position. But if failing time is over 20
seconds, the indictor will return to E position quickly, the in-
strument will at wire break detection. If the normal situation of
detection panel is over 20 seconds, indicator will return to normal.
DC 13.5V, 25C
(1) Disassemble the joint of fuel meter
(2) Turn ignition switch to ON, inspect indictor position of fuel guage.
Indictor position: F
(3) Connect short terminal1 and terminal2 of wiring harness sides. Turn ignition switch to ON, inspect
indictor position of fuel guage.
Indictor position: F
5. Inspect low fuel level indictor
336
(1) Disassemble fuel meter joints or break wire, when indictor is at E, fuel indictor does not light.
(2) Jumper a 300-330 resistor from the corner of terminal1 and termianl2, turn ignition switch to ON,
indictor is at E line, the indictor light lights.
6. Inspect generator water thermometer .

(1) Disassemble joint of generator water thermometer
(2) Turn ignition switch to ON, inspect indictor position of gen- 1 2 3
erator water thermometer.
Indictor position: COOL
(3) Earth 2 terminal of the wiring harness side joint to inspect
indictor position of generator water thermometer.
Indictor position: HOT
7. Inspect untied indictor light of driver seat belt.
(1) Turn ignition switch to ON, Inspect untied indictor light of driver seat belt lights.
(2) Tie the seat belt, inspect untied indictor light seat belt lights off.
(3) Disassemble the joint of safe belt button switch, earth the terminals of wiring harness
(4) Turn ignition switch to ON, inspect untied indictor light seat belt lights on.
8. Inspect low oil pressure indictor
(1) Disassemble the joint of oil pressure switch.
(2) Turn ignition switch to ON.
(3) Earth terminals of wiring harness sides, inspect low oil pressure indictor.
Low oil pressure indictor: light
9. Inspect oil pressure switch
(1) disassemble joints of oil pressure switch,
(2) Inspect the conduction of oil pressure switch terminals and earth.
Generator extinguishes: conduction
Generator works: not conduction
10. Inspect light warning buzzer

(a) Inspect the function of light warning buzzer
Clues on: light warning buzzer works together, only key
reminding buzzer works. Light switch
Key warning
(1) Front combination light switch switches to ON, extract the switch
key, open driver seat door, inspect light warning buzzer. Pull out the key
Audio buzzer: Audio for 10 seconds in the night to cut Open driver door
lamp power, in the day cut the lamp instantly. Buzzer
(2) When buzzer works, do any one of the followings, inspect whether buzzer stop buzzing.
z Turn front combination switch to OFF.
z Close driver seat door.
z Insert the key.
337
(b) Inspect light warning buzzer function

A1 A20
(1) Disassemble combination instrument.
(2) Connect battery positive wire to terminal A5 and nega-
tive to terminal A1 and A2.
tive to terminalA17,inspect buzzer.
Audio buzzer: long buzzes
(4) When buzzer works, connect battery positive wire to ter-
minal A4,inspect whether buzzer stop working.
11. Inspect key buzzer Key warning

switch
(a) Inspect when key buzzer and light warning buzzer works Key switch
together, only key buzzer works. 1G gear
Pull out the key
(1) Insert the key, when driver seat door opens, turn ignition
Open driver door
switch to OFF (LOCK or ACC). inspect key buzzer works
1HZ discontinuously. Buzzer
(b) inspect key buzzer function

(1) Disassemble combination instrument.
tive to terminal A1 and A2. B8 B1
(3) Connect battery negative wire to terminal A17 and B8,
inspect buzzer which should work discontinuously.
(4) When buzzer works, connect battery positive wire to ter-
minal A4,inspect whether buzzer stop working.
12. Inspect brake system indictor
(a) Inspect parking brake system indictor
(1) Disassemble the joint of parking brake switch, and earth terminals of wiring harness side joints.
(2) Turn ignition switch to ON, inspect brake system indictor light lights.
(b) Inspect brake oil level indicator light
(1) Disassemble the joint of brake oil level indicator light, connect terminal of wiring harness side
joints.
(2) Turn ignition switch to ON, inspect brake system indicator light lights.
338
Panel/combination instrument-combination instrument
13. Check the switch of indicating light of brake liquid level.

(1) Disassemble the cover and filter screen of liquid storage tank of brake main pump.
(2) Disassemble the joint.
(3) Check the conduction between switch side joints.
Float (switch is OFF): not conduction
(4) Use siphon and other tools to absorb brake liquid in storage tank.
(5) Check the conduction between switch side joint terminals.
Sink (switch is ON): conduction
(6) Pour brake liquid into storage tank.
Inspection
1. Check the switch of indicating light of brake liquid level.
Check the conduction between switch side joint terminals.
Float ((switch is OFF): not conduction
Sink (switch is ON): conduction
2. Check parking brake switch.
Check the conduction between switch side joint terminals.
When switch pin is released: conduction
When switch pin is pressed: not conduction
339
Panel/combination instrument-- panel
Panel
Preparation
1. Automobile prepares to equip with SRS airbag and safety belt pre-tension crimper.
Parking disassembling and assembling works in this chapter might influence SRS airbag. Before imple-
menting these works, it is necessary to read the notes in SRS chapter.
Change
1. Schedule for bolt, screw and screw cap
Note: when using screw driver to unclench fixing clasp or fixing clamp, it is necessary to wrap
the needled top of wrench with adhesive tape.
Hint: when disassembling or assembling panel, if necessary, use the figure and code in following
table to choose bolt, screw and screw cap.
mm
Code Shape Code Shape Code Shape
=4.8 =4.8 =6
=13 =19 =20
< > < > < >
2204813 2754819 1740620
=4.8 =6 =6
=9.5 =16 =20
< > < > < >
2754895 1400616 1400620
2. Preparation
3. Disassemble leading wire of battery cathode
4. Turn front wheel to face the front
340

driver [67010011] (Referring to page 261)
6. Disassemble steering wheel assembly [67010001]
7. Disassemble Combination instrument cover
[68000077]
(a) Disassemble fixing clamp.
(b) Use screw driver to unclench three fixing clamps and four
3 Fixing clamp
fixing clasps, then disassemble Combination instrument.
4 Fixing clasp
Hint: before using screw driver, it is necessary to wrap
its needled top with adhesive tape.
8. Disassemble Combination instrument assembly
[67000081]
(a) Disassemble A screw.
(b) Liking that shown in figure, unclench two fixing clamps.
(c) Disassemble the joint, then disassemble Combination in-
strument assembly.
9. Disassemble panel left ventilation hole assembly

[68010010]
Use disassembling tool for trim tape to disassemble panel left
ventilation hole assembly.
Hint: before using screw driver, it is necessary to wrap its
needled top with adhesive tape.
10. Disassemble panel right ventilation hole assembly
[68010011] 4 Fixing clasp
11. Disassemble front ashtray

12. Disassemble shift organization trim board assem-
bly [68000076]
(a) Use screw driver to unclench six fixing clamps.
(b) Disassemble the joint, then disassemble shift organization
trimmain board.
6 Fixing clamp
341
13. Disassemble air conditioner control panel assem-

bly [67000148]
(a) Use screw driver to unclench four fixing clamps and four
fixing clasps, then disassemble air conditioner control panel
assembly.
(b) Disassemble the joint.
4 Fixing clamp
4 Fixing clasp
14. Disassemble CD machine assembly [67000126]

(a) Disassemble two E self tapping screws and two F bolts.
8 Fixing
clamp <F>
(b) Use screw driver to unclench eight fixing clamps, then dis-
assemble DVD assembly and panel central ventilation hole
assembly.
(c) Disconnect panel central ventilation hole assembly.
8 Fixing
15. Disassmble lower panel right storage box assem-
clamp
bly [68100008]
(a) Disassemble A screw and gas spring on storage box.
(b) Bend upper part of storage box to release gas spring.
(c) Pull put storage box upwards.
16. Disassemble right front pillar inner trim board as-

sembly [68010017]
< >
(a) Unclench two fixing clamps.
(b) Pull out right front pole inner trim board upwards.
17. Disassemble left front pole inner trim board assem-
bly [68010014]
18. Disassemble the joint of safety airbag assembly at
the side of passenger (referring to page 263)
Fixing clamp
2 Fixing clasp
342
19. Disassemble upper panel assembly [68010004]

(a) Disassemble D bolt and two A screws.
(b) Use disassembling tool for trim tape to unclench six fixing clamps.
(c) Disassemble upper panel assembly.
6 Fixing clamp
5 Fixing clasp
20. Disassemble upper/lower trim board of steering column [64000128/64000129]

21. Disassemble left combination switch assembly [67000078] (referring to page 298)
22. Disassemble right combination switch assembly [64000079] (referring to page 302)
23. Disassemble gas spring
Unclench fixing clamp, then disassemble gas spring.
gas
spring
24. Disassemble evaporator ventilation pipe assembly

[67000149]
Disassemble four fixing clamps and evaporator ventilation pipe
assembly.
343

Use screw driver to unclench four fixing clamps, then disas-
semble parking brake hole cover.
4 Fixing
clasp
26. Disassemble auxiliary panel assembly [68010002]

(a) Disassemble two L bolts, two C bolts and auxiliary panel L
assembly.
27. Disassemble right front door pedal trim board

[68010021]
Use screw driver to unclench three fixing clamps, then disas-
semble right front door pedal trim board.
28. Disassemble left front door pedal trim board

[68010020]
3 Fixing
clasp
29. Disassemble lower inner trim board of right de-
fender [68010016]
(a) Disassemble plastic nuts of lower inner trim board of right
defender.
(b) Unclench fixing clamp, then disassemble lower inner trim
board of right defender liking that shown in figure.
30. Disassemble lower inner trim board of left defender

Fixing
[68010015] clamp
31. Disassemble connecting board at the middle of

panel [68010006]
(a) Use screw driver to unclench four fixing clamps, then open
the connecting board at the middle of panel.
(b) Disassemble connecting board at the middle of panel.
344
Panel/combination instrument--panel
32. Disassemble lower panel assembly [68010005]

(a) Disassemble the joint of indoor temperature sensor.
(b) Disassemble machine cover locking pull cable with handle assembly.
(c) Disassemble six D bolts.
(d) Disassemble six fixing clamps and panel lower board.
<D> <D>
<D>
<D>
<D>
<D>
33. Disassemble left storage box of lower panel [68010007]

34. Assemble upper panel assembly [68010004]
Assemble upper panel assembly with D bolt and two A screws.
D bolt: 18 Nm
35. Assemble CD machine assembly [67000126]
(a) Assemble pedal central ventilation hole assembly on CD machine assembly.
345
Panel/combination instrument--panel
(b) Assemble CD machine assembly and panel central ventila-

tion hole assembly.
4 Fixing
clamp
36. Assemble helix cable assembly (referring to page

261)
Fixing
37. Assemble steering wheel assembly [67010001] clamp
38. Check the central position of steering wheel.
39. Check the safety airbag assembly at the side of
driver [67010011] (referring to page 249)
40. Assemble the safety airbag assembly at the side of
driver [67010011]
41. Check the warning light of SRS airbag
346
Panel/combination instrument--Combination instrument assembly
Combination instrument assembly

Disassembly and assembly
1. Disassemble Combination instrument cover [68000077]
(b) Use screw driver to unclench three fixing clamps and four fixing clasps, then disassemble combination
penal cover.
2. Disassemble Combination instrument assembly
[68000081]
(a) Disassemble the screw.
(b) Liking that shown in figure, unclench two fixing clamps.
(c) Disassemble the joint, then disassemble Combination
instrument.
347
Chair--Front chair
Chair
Front chair
Subassembly
Head pillow assembly
Head pillow bracket
Chair backrest
gasket
Chair backrest
bracket
Exterior cover of
chair backrest
With waist support:
Waist support
adjustment assembly
Exterior cover of
chair gasket Clamp
With waist support:
Inner trim cover of Adjusting lever of
front chair gasket waist support lever Rear cover of chair
Clamp
sliding rail
Declining adjust-
ment releasing
handle
Inner safety belt
clamp of front chair
Chair
gasket
Front cover of chair

sliding rail
Chair front and rear
adjusting handle
Chair gasket bracket
auxiliary assembly Chair vertical
adjusting button
Exterior trim cover
Lower trim cover of
of front chair
N.m: Regulated torque gasket front chair gasket
348
Chair--Front chair
Overhaul
Hint:
z When assembling, please work by the sequence opposite with disassembling sequence, but
when it has items that need to pay special attention, it will add special specification.
z This overhaul procedure is the disassembling procedure for left side, and the procedure for
right side is same.
1. Disassemble driver chair assembly [68010061]
(b) Use screw driver to disassemble left lower trim board of driver
chair [68010062].
(c) Use screw driver to disassemble right rear lower trim board
of driver chair [68010065].
(d) Use screw driver to disassemble right front lower trim board
of driver chair [68010064].
(e) Disassemble the joint.
(f) Disassemble four bolts and front chair.
Note: Do not damage automobile body.
2. Disassemble front chair pillow assembly [68010066]

3. Disassemble chair vertical adjusting button
Disassemble fixing clamp and chair vertical adjusting
button.
4. Disassemble declining adjustment releasing handle.

Use screw driver to disassemble declining adjustment releas-
ing handle.
349
Chair--Front chair
5. Disassemble lower trim cover of front chair gasket.
6. Disassemble inner trim cover of front chair gasket.

Disassemble the screw and inner trim cover of front chair gasket.
7. Disassemble left front safety belt locker assembly

[68010040]
(a) Cut off fixing clasp.
(b) Disassemble the bolt and left/right front safety belt locker
assembly.
8. Disassemble chair backrest assembly.
(a) Disassemble the clasp.
(b) Over turn exterior cover of chair backrest , then disassemble the clasp.
(c) Disassemble four bolts and chair backrest assembly.
9. Disassemble exterior cover of chair backrest .
(a) Disassemble head pillow bracket.
(b) Disassemble fixing clamp and adjusting lever of waist support lever.
(c) Disassemble the clamp, then disassemble exterior cover of chair backrest with gasket.
(d) Disassemble the clamp, then disconnect exterior cover of chair backrest with chair backrest gasket.
(e) Disassemble two screws and waist support lever.
10. Disassemble exterior cover of chair gasket.
(a) Disassemble fixing clamp, then disassemble exterior cover of chair backrest with gasket.
(b) Disassemble the clamp, then disconnect exterior cover of chair backrest with chair backrest gasket.
11. Disassemble chair gasket bracket assembly.
12. Disassemble chair front and rear adjusting handle.
Use screw driver to disassemble chair front and rear adjusting handle.
Hint: before using screw driver, it is necessary to wrap its needled top with adhesive tape.
13. Assemble chair gasket bracket assembly.
Use four bolts to assemble chair gasket bracket on chair adjustment assembly.
Torque: 20 Nm
14. Assemble exterior cover of chair gasket.
(a) Use new clamp to assemble exterior cover of chair gasket in chair gasket.
350
Chair--Front chair
(b) Use new clamp to assemble chair gasket on chair gasket Locking loop pliers
bracket.
Hint:
z Do not damage or dirty exterior cover of chair
gasket.
z When assembling clamp, it is necessary to prevent
exterior cover of chair gasket from crinkling.
15. Assemble exterior cover of chair backrest .

(a) Use new clamp to assemble exterior cover of chair backrest
Locking loop pliers
in chair gasket.
(b) Use new clamp to assemble chair backrest on chair
backrest bracket.
Hint:
z Do not damage or dirty exterior cover of chair
backrest .
z When assembling clamp, it is necessary to prevent
exterior cover of chair backrest from crinkling.
16. Assemble chair backrest assembly.

(a) Use four bolts to assemble chair backrest assembly.
Torque: 45 Nm
(b) Over turn exterior cover of chair backrest to assemble clamp.
(c) Assemble the clamp.
17. Assemble left front safety belt locking assembly [68010040]
(a) Use the bolt to assemble left front safety belt locking assembly.
Torque: 42 Nm
(b) Assemble fixing clasp.
18. Assemble driver chair assembly.
(a) Assemble driver chair.
Note: do not damage automobile body.
(c) Assemble four bolts.
Torque: 47 Nm
(d) Assemble right front lower trim board, right rear lower trim board and left lower trim board of driver chair.
351
Chair--Rear chair (separating type)
Rear chair (separating type)

Overhaul
Hint:
When assembling, please work by the sequence opposite with
disassembling sequence, but when it has items that need to
pay special attention, it will add special specification.
1. Disassemble rear row chair cushion assembly.
Pull rear row chair cushion assembly upwards, then disas-
semble it.
Note: when disassembling, it is necessary to hold the
A: 100mm
bracket at two sides of fixing clasp, then pull it upwards
to prevent it from distorting.
2. Disassemble rear chair head pillow assembly
[68010077]
3. Disassemble rear row chair backrest assembly.
4. Make the backrest face the front, then disassemble
four fixing clamps.
5. Disassemble four bolts and rear chair backrest
assembly.
6. Disassemble rear row chair right backrest assem-
bly [68010079]
Disassemble the bolt and rear row chair right backrest
Fixing
assembly. clasp
7. Disassemble rear row chair left backrest assembly
[68010078]
Disassemble two bolts and central backrest hinge.
8. Disassemble exterior cover of rear row backrest
(small).
(a) Disassemble fixing clamp, then disassemble rear row chair
gasket cloth.
(b) Disassemble fixing clamp, then disassemble head pillow Fixing
bracket. clasp
(c) Disassemble exterior cover of rear row backrest with gasket.

(d) Disassemble the clamp, then disconnect exterior cover of
rear row backrest with gasket.
9. Disassemble exterior cover of rear row backrest (big).
(a) Disassemble central handrail hinge trim cover.
(b) Disassemble the bolt and central handrail.
(c) Disassemble fixing clamp, then disassemble rear row chair gasket cloth.
(d) Disassemble the clamp, then disassemble head pillow bracket.
(e) Disassemble exterior cover of rear row backrest with gasket.
352
Chair--Rear chair (separating type)
(f) Disassemble the clamp, then disconnect exterior cover of

Locking loop pliers
rear row backrest with gasket.
10. Disassemble exterior cover of rear row chair
cushion.
Disassemble the clamp, then disconnect exterior cover of cush-
ion with gasket.
11. Assemble exterior cover of rear row chair cushion.
Use new clamp to assemble exterior cover of rear row chair
cushion in gasket.
Hint:
z Do not damage or dirty exterior cover of cushion.
z When assembling clamp, it is necessary to prevent exterior cover of cushion from crinkling.
12. Assemble exterior cover of rear row chair backrest (big).
Hint:
13. Assemble exterior cover of rear row chair backrest (small).
Use new clamp to assemble exterior cover of rear row chair backrest in gasket.
Hint:
14.Assemble rear backrest central hinge assembly.
Use two bolts to assemble central hinge assembly.
Torque: 20 Nm
15. Assemble rear chair backrest side hinge assembly.
Use two bolts to assemble two side hinge assemblies.
16. Assemble rear row chair left backrest assembly [68010078]
Use the bolt to assemble left backrest assembly.
Torque: 8.0 Nm
17. Assemble rear row chair right backrest assembly [68010079]
Use the bolt to assemble right backrest assembly.
Torque: 8.0 Nm
18. Assemble rear row chair backrest assembly.
Use four bolts to assemble backrest assembly.
Torque: 18 Nm
353
Chair--Rear chair (fixing type)
Rear chair (fixing type)

Overhaul
Hint: When assembling, please work by the sequence
opposite with disassembling sequence, but when it has
items that need to pay special attention, it will add special
specification.
1. Disassemble rear row chair cushion assembly.
Pull rear row chair cushion assembly upwards, then disas-
semble it.
Note: when disassembling, it is necessary to hold the
A: 100mm
bracket at two sides of fixing clasp, then pull it upwards
to prevent it from distorting.
2. Disassemble rear row chair backrest assembly
[68010076]
Disassemble three bolts and rear row chair backrest assembly.
3. Disassemble rear chair head pillow assembly
[68010077]
4. Disassemble exterior cover of rear row chair
backrest. Locking loop pliers
(a) Disassemble head pillow bracket.
(b) Disassemble the clamp, then disconnect exterior cover of
rear row chair backrest with gasket.
5. Disassemble exterior cover of rear row chair cushion.
Disassemble the clamp, then disconnect exterior cover of cush-
ion with gasket.
6. Assemble exterior cover of rear row chair cushion.
cushion in gasket. Locking loop pliers
Hint: Do not damage or dirty exterior cover of cushion.
When assembling clamp, it is necessary to prevent exterior
cover of cushion from crinkling.
7. Assemble exterior cover of rear row chair backrest.
backrest in gasket.
Hint: Do not damage or dirty exterior cover of cushion.
When assembling clamp, it is necessary to prevent exterior
cover of cushion from crinkling.
8. Assemble rear row chair backrest assembly
[68010076]
Torque: 8.0 Nm
354
Anti-stealing and door lock--Electric door lock control system
Anti-stealing and door lock

Electric door lock control system
Position of parts (only for reference)
Door control switch of electric
window main switch assembly
(Used for handle operation)
Door control switch of left front
door locker assembly
(Used for key operation)
Door control light switch
Left rear door locker

assembly
Right front door

locker assembly
Right rear door

locker assembly
1. Basic inspection for electric door locker.
(a) Press middle control switch to locker closing side, and check the all doors should be locked; then
press middle control switch to locker opening side, and check all doors should be opened.
(b) Insert key in door locker and turn it anticlockwise, and check all doors should be locked; then turn the
key clockwise, and check all doors should be opened.
(c) Check the keeping protection function of the key.
Note: When checking the keeping protection function of the key, it is necessary to open elec-
tric window at the side of driver to prevent its function from losing and lock the key in
automobile.
(1) Insert key in ignition switch.
(2) Open the door, and press middle control switch on the door at the side of driver to locker closing
side, at this time, door locker could not close.
(3) Open the door, and press locker button on the door at the side of driver to locker closing side, at
this time, door locker could not close.
(4) After pressing locker button upwards for over two seconds, and locking driver door; when driver
door is closed and key is not used to lock, check whether all doors could open automatically.
355
(d) Check security function:

(1) When closing all doors, open the driver window to operate door control switch out of automobile.
(2) Take down the key, open driver door, then close the door and lock (not use key). In this situation
above, check that door could not open locker even if door control switch (handle operation) is
pressed to locker opening side out of automobile.
(3) Take down the key, close and use the key to lock driver door. In this situation above, check that
door could not open locker even if door control switch (handle operation) is pressed to locker
opening side out of automobile.
(4) Take down the key, close and use remote control key to lock driver door. In this situation above,
check that door could not open locker even if door control switch (handle operation) is pressed to
locker closing side out of automobile (only applicable for the automobile equipping with remote
control door locker control system).
Hint:
z In following situation, check whether security has been canceled.
z Ignition switch is turned to ON.
z Use key operation to open the driver door locker.
z After door locker is pressed to opening side by hand, door control switch (handle
operation) is pressed to locker opening side.
z Use remote control locker control to open the door (only applicable for the automobile
equipping with remote control door locker control system).
2. Electric window main switch assembly
Operate door control switch by hand to check its conduction.
Position of switch Terminal connected by avometer Regulated situation
LOCK 5-1 or 5-3 Conduction

UNLOCK 8-1 or 8-3
3. Check panel junction box assembly.

(a) Check 25A DOOR fuse.
(b) Check conformity relay.
(1) Disassemble F, G, H and I joint on instrument junction
box.
(2) Check the voltage and conduction of every terminal of
joint.
356
Power supply (+) Grounding wire Power supply (+)
Sunroof
Power supply Power supply

Power supply (-) (+) (+)
1G2 out 1G2 in
Power supply (+) Power supply (+) Power supply (+) Power supply (+)
Rain wiper Brake light Anti-steal
Power supply Power supply Power supply Power supply Power supply
(+) (+) (+) (-) (+)
Rear fog light
Power supply (+)
Power supply (+)
Instrument
357

Malfunction phenomenon Possible malfunction part Referred page
Door locker control system does not work 1. DOOR fuse (panel J/B) -
(all). 2. Wiring harness -
Door locking/unlocking malfunction (use 1. Electric window main switch (door control switch) 359
handle operation and key operation) 2. Wiring harness -
1. Door at the side of driver assembly (door control switch) 359
Door locking/unlocking malfunction (use
2. Wiring harness -
key)
3. Door locker connecting rod is loosen -
1. Anti-versa lock supervising switch 359
Malfunction of key keeping protection func-
2. Door control light switch -
tion
3. Wiring harness -
Only one door locker does not work 1. Door locker electric motor 359
2. Wiring harness -
358
Inspection
1. Check driver sear door locker assembly.
(a) Liking that shown in figure, check the conduction of every
terminal of door key switch.

LOCK 2-4 Conduction
Close
OFF - Not conduction
UNLOCK 1-2-3 Conduction
If the conduction does not accord with the regulation, change

the switch. Open
(b) Liking that shown in figure, supply battery voltage to terminal, Close
and check the function of door locker.
Open
Condition Function
Supply battery anode to No. 6 terminal, cathode to No.5 terminal Open
Supply battery anode to No. 5 terminal, cathode to No.6 terminal Close
If the function does not accord with the regulation, change

the door locker assembly.
359
2. Check front passenger seat door locker assembly

Liking that shown in figure, supply battery voltage to terminal, Close
Open
Condition Function
If the function does not accord with the regulation, change the
door locker assembly.
3. Check the left rear and right rear door locker assembly.
Close Open
Liking that shown in figure, supply battery voltage to terminal,
Condition Function
If the function does not accord with the regulation, change the
door locker assembly.
360
Anti-stealing and door lock--Electronic anti-stealing system
Electronic anti-stealing system

Electronic anti-stealing system consists of anti-stealing controller, anti-stealing loop and transmitter. One
end of loop covers ignition locker core, the other end connects with anti-stealing controller, and the other end
of controller connects with engine ECU, at the same time, transmitter is assembled in key. Memory of
transmitter stores only mark (code) showing the legal identity of automobile owner, transmitter, anti-stealing
controller and electric injection ECU constitutes a multi-layer effective electronic anti-stealing system verified
by password.
If customer key loses, anti-stealing ECU is changed or engine ECU is changed, it is necessary to match
again in repairing station. When automobile leaves the factory, safety password is delivered directly to
owner for keeping with the type of secrecy. If it is necessary to make a new key, change anti-stealing
controller and make other operations, owner should bring the safety password with the automobile to repair
in repairing station. Repairing station should keep repairing (make new key, change anti-stealing controller
and so on) record for inquiring in future.
361
Electric sunroof (optional)--Sunroof
Electric sunroof (optional)

Sunroof
Overhaul
Hint: when assembling, please work by the sequence which is opposite with disassembling
sequence; but when it has items that need to pay special attention, it will add special specification.
1. Disassemble inner trim board of top (referring to page 390).
2. Disassemble the glass of sunroof.
(a) Use planetary wrench to disassemble planetary screw.
(b) Pull the glass upwards to disassemble it.
3. Disassemble waterproof adhesive tape of sunroof.
4. Disconnect connection of wiring harness.
5. Disassemble shell body of sunroof.
(a) Disassemble four drain hoses.
(b) Liking that shown in figure, disassemble four bolts and six screw caps, then disassemble shell body.
Bolt
Screw cap
6. Disassemble trim sun shade of sunroof.

(a) Disassemble the screw and stopper.
(b) Disassemble trim sun shade of sunroof.
362
Electric sunroof (optional)--Sunroof
7. Use screw driver (twisted by adhesive tape) to align

the sunroof driving pull cable with right mark. Assembly mark
8. Assemble sunroof shell body assembly.
(a) Bolt.
Torque: 5.5 Nm
(b) Screw cap.
Torque: 5.0 Nm
9. Assemble the glass of sunroof.

(a) Check the phase difference between sunroof waterproof ad-
hesive tape and top gasket.
Front end and rear end: 01.5mm
Rear corner: 01.5mm
0-1.5mm
(b) Adjustment
Use T25 planetary wrench to loosen the screw to adjust
the sunroof on correct position, then lock the screw.
10. Inspection for water leakage.

(a) After the adjustment, check whether the sunroof leaks water.
(b) If sunroof leaks water, adjust it again.
363
Electric sunroof (optional)--Sunroof system
Sunroof system
Specification for sunroof function
1. Operation category
Spot contact: press the keystroke one time, then release immediately (the time is less than 0.3 seconds).
Long press: press the key stroke for long time (the time is more than 0.3).
2. Specification for function.
Anti-clamping function: spot contact the keystroke to make the sunroof could face 10 Kg resistance in the
process of closing from any position, at this time, electric motor turns oppositely, and the sunroof returns
turn-up or opening state.
Automatic closing function: when the key is pulled out from ignition locker, at this time, the sunroof is not
at closing state, it will close automatically in three seconds.
Inspection for sunroof function

1. Inspection for sliding opening function.
(1) Turns ignition switch to ON, when spot contacting sunroof Front
switch keystroke 2, the sunroof will start automatic sliding
opening work, and it does not stop until it is at complete
opening state. If spot contacting it in running process, or
pressing keystroke 1 or 2 for long time, sunroof glass will
Rear
stop running immediately.
(2) Turns ignition switch to ON, when pressing keystroke 2 for
long time, the sunroof will start automatic sliding opening work, and it does not stop until it is at
complete opening state. If releasing keystroke 2 in running process, the sunroof glass will stop running
immediately.
2. Inspection for sliding closing function.
(1) Turns ignition switch to ON, if the sunroof is at opening state, when spot contacting sunroof switch
keystroke 1, the sunroof will automatically slide to closing state. If spot contacting it or pressing
keystroke 1 or 2 for long time in running process, sunroof glass will stop running immediately.
(2) Turns ignition switch to ON, if the sunroof is at opening state, when pressing sunroof switch keystroke
1 for long time, the sunroof will automatically slide to closing state. If releasing keystroke 1 in running
process, sunroof glass will stop running immediately.
3. Inspection for turn-up opening function
(1) Turns ignition switch to ON, if the sunroof is at closing state, when spot contacting sunroof switch
keystroke 1, the sunroof will automatically move to turn-up opening state. If spot contacting it again or
pressing keystroke 1 or 2 for long time in running process, sunroof glass will stop running immediately.
(2) Turns ignition switch to ON, if the sunroof is at closing state, when pressing sunroof switch keystroke
1 for long time, the sunroof will automatically slide to turn-up opening state. If releasing keystroke 1 in
running process, sunroof glass will stop running immediately.
4. Inspection for turn-up closing function
(1) Turns ignition switch to ON, if the sunroof is at turn-up opening state, when spot contacting sunroof
switch keystroke 2, the sunroof will automatically move to closing state. If spot contacting it again or
pressing keystroke 1 or 2 for long time in running process, sunroof glass will stop running immediately.
(2) Turns ignition switch to ON, if the sunroof is at turn-up opening state, when pressing sunroof switch
keystroke 2 for long time, the sunroof will automatically slide to closing state. If releasing keystroke 2
in running process, sunroof glass will stop running immediately.
364
Electric sunroof (optional)--Sunroof system
Inspection for sunroof switch

(a) Check the function of switch. Disassemble front top light,
and disassemble the joint of front top light, then check the
joint at the side of switch liking that shown in figure.
Terminal connected by avometer Condition Regulated situa-
Spot contact or press
2-4 keystroke 2 for long time tion
2-5 Spot contact or press Conduction
keystroke 1 for long time
Conductiion
Position of parts
Shell body of sunroof

Motor of sunroof
Switch of sunroof

1. Ignition switch. -
2. Control switch of sunroof. -
Sunroof system does not work
3. 25A, 15# fuse. -
4. Wiring harness -
1. Control switch of sunroof. -
Sunroof system works abnormally
2. Wiring harness -
365
Engine cover/automobile door--Engine cover
Engine cover/automobile door

Engine cover
Adjustment
1. Check engine cover assembly.
Check whether the clearance of engine cover is in regulated
value shown in table.
2. Adjust engine cover assembly.

(a) Adjust engine cover assembly by loosening the hinge bolt at
the side of engine cover.
Torque: 13 Nm
(b) Adjust engine cover assembly by turning the gasket.
(c) Adjust engine cover assembly by loosening three bolts of

engine cover locker.
Torque: 7.0 Nm
366
Engine cover/automobile door--Front automobile door
Front automobile door

Subassembly
4 33
5 24
6
23
7 8
9
25
26
10
14
27
28 15 1 1 18
29 16
17
30
31
26
27 20
32 13
12
19
22
21
367
Marked Number of parts Name of parts Specification Amount

number
1 68000147 Right front glass assembly 1

2 68000162 Seal tape of right front glass leading slot 1
3 68000149 Right front glass leading slot assembly 1
4 Q1860610 Hexagon flange face bolt M6 10 1
5 68000159 Exterior seal tape of right front door glass 1
6 67000157 Right exterior electric rearview mirror assembly 1
7 Q32006 Hexagon flange face nut M6 3
8 68000153 Right front door locker organization assembly 1
9 Q2580816 Inner hexagon floriated raised countersunk head screw M6 18 3
1 1 JQ2756316 Combination part of hexagon head self-tapping screw with flat gasket ST6.3 16 1
1 2 67000123 Right front door glass lift assembly 1
1 3 Q1860610 Hexagon flange face bolt M6 10 6
14 68000145 Right front door board bracket 1
1 5 Q2716319 Cross slot plate head self-tapping screw ST6.3 19 2
1 6 67000132 Right front small speaker cover assembly 1
1 7 68000144 Right front door control panel assembly 1
1 8 Q2714216 Freerson plate head self-tapping screw ST4.2 16 1
1 9 68010050 Right front door inner defending board assembly 1
20 Q2204816 Combination part of cross slot plate head self-tapping screw with flat washer ST4.8 16 1
2 1 67000107 Door light assembly 1
22 68000141 Right front door defender water curtain assembly 1
23 68000160 Right front door seal tape assembly 1
24 62000479 Right front door assembling assembly 1
25 62000025 Right front door upper hinge assembly 1
26 62000024 Hexagon flange face bolt (with step) M8 20 2
28 68000163 Front door limiter assembly 2
29 JQ1840816T1F31 Hexagon flange face bolt M8 16 2
30 Q1400616 Combination part of hexagon head bolt with flat washer M8 16 2
3 1 62000027 Right front door lower hinge assembly 1
32 68010052 Right side door inner handle assembly 2
33 68000151 Right front door exterior handle assembly 1
368
Overhaul
Hint:
z When assembling, please work by the sequence which is opposite with disassembling
sequence; but when it has items that need to pay special attention, it will add special
specification.
z Overhaul procedure for right side is same as the left side.
z Please refer to subassembly figure of front door on page 360.
1. Disassemble left front door control panel assembly [68000142]
(b) Use screw driver to disassemble left front door control panel assembly.
Hint: before using screw driver, it is necessary to wrap its needled top with adhesive tape.
(c) Disassemble the joint.
2. Disassemble left front door inner defending board assembly [68010049]

(b) Without equipping with door control light: use screw driver to disassemble door inner defending board
assembly.
(c) Equipping with door control light: use screw driver to disassemble door inner defending board assembly,
then disassemble the joint again.
(d) Equipping with door control light: use screw driver to disassemble door control light.
3. Disassemble left door inner handle assembly [68010051]

(a) Disassemble inner handle, and disassemble two pull cables from inner handle.
4. Disassemble repairing hole cover of left front door
5. Disassemble left front small loudhail cover assembly [67000131]
6. Disassemble left exterior electric rearview mirror

assembly [67000155]
(b) Disassemble three screw caps and left exterior electric
rearview mirror.
7. Disassemble exterior seal tape of left front door glass
[68000158]
369
8. Disassemble left front glass assembly [68000146]

Hint: insert the cloth in door steel board to prevent it from
scratching the glass.
(a) Turn the door glass until the bolts happens in repairing
hole.
(b) Disassemble two bolts and door glass.
Note: do not damage the door glass.
Hint: pull the door glass upwards to disassemble it.
9. Disassemble seal tape of left front glass guide slot
[68000161]
10. Disassemble left front door glass lift assembly
[67000122]
(b) Disassemble six bolts and glass lift.
11. Spread lubricating grease on automobile body.
12. Disassemble left front door window glass guide
slot assembly [68000148]
Disassemble the screw and door framework rear lower bracket.
13. Disassemble left front door locker organization as-
sembly [68000152]
(b) Disassemble connecting rod from exterior handle.
(c) Disassemble the bolt and screw.
(d) Use planetary socket wrench (T30) to disassemble three
planetary screws and door locker.
(e) Disassemble two screws and left front door locker organi-
zation driver.
Spread MP lubricating grease on sliding and turning parts of
lift assembly.
15. Disassemble left front door exterior handle pedestal.
(a) Use planetary socket wrench to disassemble the screw
and door key tank.
(b) Disassemble exterior handle from exterior handle pedestal.
(c) Use planetary socket wrench to disassemble the screw
and left front door exterior handle pedestal.
16. Assemble left front door locker organization assembly [68000152]
(a) Use two screws to assemble left front door locker organization driver.
(b) Use planetary socket wrench (T30) to assemble three planetary screws and front door locker assembly.
Torque: 5.0 Nm
(c) Assemble the bolts and screws.
(d) Connect connecting rod to exterior handle.
(e) Connect the joint.
370
17. Assemble left front door glass lift assembly [67000122]

(a) Use six bolts to assemble left front door glass lift.
Torque: 8.0 Nm
(b) Assemble electric window lift and door glass.
(c) Connect electric window switch to wiring harness and turn ignition switch to ON.
(d) Operate UP and DOWN several times by hand repeatedly.
(e) Check whether the AUTO UPAUTO DOWN of automatic operation is normal.
Hint:
z When it is set up again, anti-clamping protection function does not work.
z After implementing AUTO UP operation to close window completely, if automobile window
could not be operated downwards, it is necessary to set up the lift again.
(f) Check the function of electric window.
18. Check the function of electric window

19. Assemble repairing hole cover of left front door
Hint:
z When assembling repairing hole cover, pull out con-
necting rod and joint from repairing hole cover.
z After assembling repairing hole cover, connecting rod
and joint could not be bent or concaved.
z After assembling repairing hole cover, it is necessary
to confirm the affixing situation of adhesive tape.
371
Adjustment
Hint: the working procedure for right side is same as left side.
1. Check the clearance of left front door
(a) Check whether following data is in standard value.
At the side of At the side of

2. Adjust the clearance of left front door. automobile door
automobile body
(a) Use special tool to loosen hinge bolt at the side of automo-
bile body to adjust the door.
Torque: 26 Nm
(b) Loosen hinge bolt at the side of automobile body to adjust
the door.
Torque: 26 Nm At the side of At the side of
automobile body automobile door
(c) Loosen lightly fixing screw of locking pedestal and use plas-
tic hammer to knock lightly locking pedestal to adjust its
position.
(d) Lock fixing screw of locking pedestal again.
Torque: 23 Nm
372
Engine cover/automobile door--Rear automobile door
Rear automobile door

Overhaul
Hint:
sequence; if necessary, it will have assembling instruction..
z Overhaul procedure for right side is same as the left side.
1. Disassemble left rear door control panel assembly [68000176]
Use screw driver to disassemble left rear door control panel assembly.
2. Disassemble left rear door inner trim board assem- Fixing
clasp
bly [68010057]
(a) Disassemble three screws.
(b) Disconnect the fixing clamp, then pull inner trim board up-
wards to disassemble it.
3. Disassemble left door inner handle assembly

[68010051]
Disassemble inner handle and two pull cables from inner handle.
4. Disassemble left rear door repairing hole cover.
Disassemble repairing hole cover.
5. Disassemble exterior seal tape of left rear door glass
Fixing
[68000196] clasp
6. Disassemble seal tape of left rear glass guide slot
[68000199]
(a) Disassemble seal tape of left rear glass guide slot.
7. Disassemble left rear door window glass guide slot
assembly [68000187]
Disassemble two bolts and comparting pillar of rear window.
8. Disassemble left rear door triangle glass [68000181]
(a) Disassemble left rear door triangle glass.
Note: do not damage the glass.
(b) Disassemble corner window waterproof rubber from the glass.
9. Disassemble left rear glass assembly [68000179]
Hint: insert the cloth in the door steel board to prevent the glass from scratching.
(a) Drop the door glass.
(b) Incline door glass and disassemble the roller pole of lift from glass leading slot to disassemble door
glass.
10. Disassemble left rear door lift assembly [67000124]
(b) Disassemble four bolts and window lift.
373

Spread MP lubricating grease on sliding and turning parts of
door locker.
12. Disassemble left rear door exterior handle pedestal.
(a) Use planetary socket wrench to disassemble the screw
and left rear door exterior handle cover.
(b) Disassemble exterior handle.
(c) Use planetary socket wrench to disassemble the screw
and left rear door exterior handle pedestal.
13. Assemble left rear door locker organization assem-
bly [68000191]
(a) Assemble left rear door locker organization driver and two
screws.
(b) Use planetary socket wrench to assemble left rear door
locker organization assembly and three screws.
Torque: 5.0 Nm
(c) Assemble the bolt.
(d) Connect the joint.
14. Assemble left rear door glass lift assembly
[67000124]
Torque: 5.5 Nm
15. Assemble left rear door repairing hole cover.
(a) Assemble repairing hole cover on door steel board.
Hint:
z When assembling repairing hole cover, pull out
connecting rod and joint from repairing hole cover. Adhesive
tape
z After assembling repairing hole cover, connecting
rod and joint could not be bent or concaved.
z After assembling repairing hole cover, it is neces-
sary to confirm the affixing situation of adhesive
tape.
374
Adjustment
Hint: working procedure for right side is same as the left side.
1. Check the clearance of left rear door.
375
2. Adjust the clearance of left rear door. At the side of At the side of
(a) Loosen hinge screw cap at the side of automobile body to automobile body automobile door
adjust the door.

Torque: 26 Nm
(b) Loosen hinge screw cap at the side of automobile door to
adjust the door.
Torque: 26 Nm
At the side of At the side of

automobile body automobile door
(c) Loosen lightly fixing screw of locker pedestal, and use plastic
hammer to knock lightly the locker pedestal to adjust its
position.
(d) Lock the fixing screw of locker pedestal again.
Torque: 23 Nm
376
Engine cover/automobile door--Trunk cover
Trunk cover
Adjustment
1. Check the clearance of trunk cover.
2. Adjust the clearance of trunk cover.

(a) If you want to make front and rear, left and right adjustment,
please loosen the bolt at first.
(b) If the front end of trunk cover needs to adjust vertically, please
increase or decrease the number of washers between hinge
and trunk cover.
Torque: 7.0 Nm
(c) Use the hammer and copper stick to knock lightly the locker
pedestal to adjust.
Torque: 5.5 Nm
377
Engine cover/automobile door--Torsion spring of trunk cover
Torsion spring of trunk cover

Change
Hint:
sequence; if necessary, it will have assembling instruction.
z Changing procedure for right side is same as the left side.
z For torsion spring is disassembled, trunk cover does not have any tension, at this time, when
opening and closing trunk cover, it is necessary to support it with hand to prevent trunk cover
from closing for other resistances.
z Torsion spring I of trunk cover locates the upper end, and Torsion spring II of trunk cover
locates the lower end, so it is necessary to work from left side to right side when assembling;
but it is necessary to work by opposite sequence when disassembling.
1. Disassemble torsion spring of trunk cover
[68000100]
(a) Disassemble torsion spring I from middle bracket.
(b) Assemble special tool at the side of hinge.
special tool
(c) Push the special tool downwards, then pull trunk cover hinge
upwards from torsion spring I.
(d) Raise the special tool slowly, then use the special tool to
disassemble torsion spring I from the bracket.
(e) Disassemble torsion spring I from the bracket.

(f) Implement the work at the other side with same method.
2. Assemble torsion spring I of trunk cover [68000100]

(a) When assembling torsion spring I, it is necessary to as-
semble it on fixing clamp stably.
378
Exterior/inner trim board--Front bumper
Exterior/inner trim board

Front bumper
Subassembly
Inner gasket of
right front wheel
Fixing pedestal of
radar probe Inner gasket of
left front wheel
Radiator cover
assembly
Radar probe head
Radar probe head Fixing pedestal of

radar probe head
Front bumper
Equipping with fog light
Front fog light assembly
379
Exterior/inner trim board--Front bumper
Change
Hint:
z Please refer to subassembly figure of front bumper on page 379.
1. Disassemble radiator cover assembly [68000094]
(a) Disassemble the bolt and radiator cover assembly.
2. Disassemble inner gasket of left front wheel [68000225]
(a) Use disassembling tool for fixing clamp to disassemble two fixing clamps.
(b) Disassemble the screw and a part of inner gasket of left front wheel.
Hint: Disassemble the fixing clamp of screw and inner gasket of left front wheel in the scope of
front bumper which could be disassembled.
3. Disassemble inner gasket of right front wheel [68000228]
4. Disassemble front bumper [68000005]
(a) Disassemble four screws and two fixing clamps.
(b) Disassemble fixing clasp and front bumper.
(c) Equipping with fog light: disassemble two joints of fog light.
(d) Equipping with radar probe head: disassemble two radar probe heads (luxury type).
5. Disassemble reversing radar probe head assembly.
(a) Disassemble two fixing pedestals of radar probe head and two radar probe heads.
6. Disassemble left front fog light assembly [67000098]
(a) Disassemble fixing clasp and left front fog light assembly.
7. Disassemble right front fog light assembly [67000099]
380
Exterior/inner trim board--Rear bumper
Rear bumper
Subassembly
Left decoration of
luggage cas Right decoration of trunk
Rear trim board of

trunk
Trim board of right

rear wheel
Equipping with radar:

fixing pedestal of radar
probe head
Trim board of left

Equipping with
rear wheel
reversing radar:
reversing radar
probe head
Equipping with
reversing radar:
reversing radar
probe head
Rear bumper
Mudguard of left Mudguard of right

rear wheel rear wheel
381
Change
Hint:
z Please refer to subassembly figure of rear bumper on page 381.
1. Disassemble trunk carpet assembly [68000114]
2. Disassemble rear trim board of trunk [68000118]
(a) Use two fixing clasps.
(b) Use disassembling tool for trim tape to disassemble rear
trim board of trunk.
3. Disassemble left decoration of trunk [68000112]
(a) Use disassembling tool for fixing clamp to disassemble
fixing clamp and a part of left decoration of trunk.
Hint:
Disassemble the fixing clasp and left decoration of trunk in the scope of screw cap used for
fixing rear bumper and trunk which could be disassembled.
4. Disassemble right decoration of trunk [68000113]
5. Disassemble mudguard of left rear wheel [68000223]
(a) Disassemble two screws and mudguard of left rear wheel.
6. Disassemble mudguard of right rear wheel [68000224]
7. Disassemble trim board of left rear wheel [68000230]
(a) Use screw driver to disassemble fixing clasp from rear bumper.
(b) Use disassembling tool for fixing clasp to disassemble fix-
ing clasp.
(c) Disassemble trim board of left rear wheel.
Hint: Disassemble trim board of left rear wheel in the
scope of screw used for fixing rear bumper which could
be disassembled.
8. Disassemble trim board of right rear wheel [68000231]
9. Disassemble rear bumper [68000012]
(a) Use screw driver to disassemble two fixing clasps.

(b) Disassemble four screw caps and two screws.
(c) Disassemble fixing clasp and rear bumper.
(d) Equipping with radar probe head: disassemble four joints of
radar probe head.
10. Disassemble reversing radar probe head assembly.
(a) Disassemble fixing pedestal of radar probe and radar probe.
11. Disassemble left rear fog light assembly [67000100]
(a) Disassemble fixing nut and left rear fog light assembly.
12. Disassemble right rear fog light assembly [67000101]
382
Nameplate
Change
1. No.2 nameplate of trunk cover 2 1
2. No.3 nameplate of trunk cover 3. No.6 nameplate of trunk cover
C h i n a -
Geely
4. Nameplate of front wing board
383
Exterior/inner trim board--Exterior seal tape of left front door glass
Exterior seal tape of left front door glass (LH)

Change
Hint:
z Changing procedure for right side is same as left side.
1. Disassemble exterior seal tape of left front door
glass [68000158]
(a) Affix protective adhesive tape to the lower part of exterior
seal tape of left front door glass.
(b) Use disassembling tool or scraper for trim tape to disas-
semble exterior seal tape of left front door glass.
protective
Hint: before using scraper, the needled top of scraper adhesive tape
should be twisted with adhesive tape.
384
Exterior/inner trim board--Exterior seal tape of left rear door glass
Exterior seal tape of left rear door glass

Change
Hint:
1. Disassemble exterior seal tape of left rear door glass
[68000196]
(a) Affix protective adhesive tape to the lower part of exterior
seal tape of left rear door glass.
(b) Use disassembling tool or scraper for trim tape to disas-
semble exterior seal tape of left rear door glass.
Protective
Hint: before using scraper, the needled top of scraper adhesive tape
should be twisted with adhesive tape.
385
Exterior/inner trim board--Light fender
Light fender
Change
1. Disassemble locker core and pedestal of trunk.
2. Disassemble number plate light defender [68000107]
Disassemble four screw caps, then disassemble the defender.
2 Fixing clamp
3. Assemble rear logo assembly [61000019]
(a) Use white gasoline to clean the assembling surface of logo.
(b) Use heating light to heat defender and logo.
(c) Assemble the logo.
Note:do not heat logo excessively
386
Exterior/inner trim board--Top left trim tape
Top left trim tape

Change
Hint:
1. Disassemble top left trim tape [68000128]
(a) Use protective adhesive tape to affix around the trimtape.
(b) Use disassembling tool for trim tape to release the front and
rear fixing clamp of trim tape, then disassemble top left trim
tape.
Note:
z Do not disassemble fixing clamp.
z If fixing clamp is damaged when disassembling,
change it with new one.
2. Assemble top left trim tape [68000128]

Note: when only changing fixing clamp.
(a) Disassemble adhesive tape remaining on the surface of
body affixed trim tape, then use white gasoline to clean the
surface.
(b) Use heating light to heat the assembling surface of fixing
clamp and automobile body.
Automobile body: 40-60C.
Trimtape: 20-30C.
Note: do not heat the trim tape and body too much.
(c) Put the fixing clamp on the position shown in figure, then
press it into position with hand.
(d) After pressing the fixing clamp into position for over 30
minutes, then assemble top left trimtape.
Hint:
z Surface induration time: 30 minutes.
z Complete induration time: 24 hours.
387
Exterior/inner trim board--Left lower fender of automobile body
Left lower fender of automobile body (LH)

Subassembly
Lower fender
Mudguard of
left front wheel
Fixing clasp
388
Exterior/inner trim board--Left lower fender of automobile body
Change
Hint:
When assembling, please work by the sequence which is opposite with disassembling sequence;
if necessary, it will have assembling instruction..
Changing procedure for right side is same as the left side.
Please refer to the subassembly figure of body left lower fender on page 388.
1. Disassemble mudguard of left front wheel [68000221]
(a) Disassemble three screws and mudguard of left front wheel.
2. Disassemble body left lower fender [68000049]

(a) Use disassembling tool for fixing clamp to disassemble eight
fixing clamps.
(b) Disassemble the screw.
(c) Use disassembling tool for trim tape to disassemble body
left lower fender.
389
Exterior/inner trim board--Inner trim board of top
Inner trim board of top

Change
Hint:
z Changing procedure for right side is same as the left side.
1. Disassemble trim board of right front door pedal [68010021]
(a) Use screw driver to disassemble trim board of right front
door pedal.
Hint: before using screw driver, its needled top should
be twisted by adhesive tape.
(b) Use same method to disassemble the trim board at the
other side.
2. Disassemble stop trim board of left front door
[68010020]
3. Disassemble stop trim board of right rear door
[68010024]
(a) Use screw driver to disassemble trim board of right rear door
pedal.
other side.
4. Disassemble trim board of left rear door pedal
[68010022]
5. Disassemble lower inner trim board at the front of
right fender [68010016]
(a) Disassemble fixing clamp. Fixing
(b) Use screw driver to disassemble right trim board. clamp
(C) Use same method to disassemble the trim board at the
other side.
6. Disassemble lower inner trim board at the front of
left fender [68010015]
7. Disassemble inner fender assembly of right front door [68010050]
8. Disassemble inner fender assembly of left front door [68010049]
9. Disassemble inner trim board assembly of right rear
door [68010058]
10. Disassemble inner trim board assembly of left rear
door [68010057]
11.Disassemble lower inner trim board assemblyco
(a) Pull out lower inner trim board assembly of right stand pole
to disassemble it.
other side.
12. Disassemble lower inner trim board assembly of
390
left pillar [68010018]

13. Disassemble upper inner trim board assembly of
right pillar [68010025]
(a) Disassemble the bolt and upper fixing bolt trim cover of front
Fixing
safety belt.
clamp
(b) Use screw driver to disassemble upper inner trim board of
right stand pole.
(C) Use same method to disassemble the trim board at the
other side.
14. Disassemble upper inner trim board assembly of
left pillar [68010023]
15. Disassemble rear row chair cushion (referring to
page 352).
16. Disassemble rear row chair backrest (fixing type)
Fixing
(referring to page 354). clamp
17. Disassemble rear row chair right backrest assem-
bly (referring to page 352).
18. Disassemble rear row chair left backrest assembly
19. Disassemble inner trim board of right rear pillar
assembly [68010027] Fixing
clamp
(a) Use screw driver to disassemble inner trim board of right
rear pillar assembly.
other side.
20. Disassemble inner trim board of left rear pillar as-
sembly [68010026]
21. Disassemble inner trim board of right front pillar
assembly [68010017]
(a) Use screw driver to disassemble inner trim board of right
front pillar assembly.
other side.
22. Disassemble inner trim board of left front pillar as-
sembly [68010014]
23. Disassemble inner rear view mirror assembly [67010013]
(a) Use screw driver to disassemble trim cover of inner rearview
mirror pedestal.
(b) Disassemble two screws and inner rearview mirror assembly.
391
24. Disassemble right sun shade assembly [68010085]

(a) Liking that shown in figure, use screw driver to unclench the
trim cover of fixing pedestal, then pull down the trim cover.
(b) Liking that shown in figure, use screw driver to release fixing
claw and disassemble sun shade.
(c) Use same method to disassemble the trim board at the Fixing
other side. clamp
25. Disassemble left sun shade assembly [68010084]

26. Disassemble indoor front top light assembly
[67010005]
Use screw driver to disassemble front top light cover, and dis-
assemble fixing screw with cross wrench, then disconnect the
joint.
Hint: before using screw driver, its needled top should be
twisted by adhesive tape.
27. Disassemble indoor rear top light assembly
[67010006]
(a) Disassemble two screws and indoor light, then disconnect
the joint.
28. Disassemble passenger hand rail [68010088]

(a) Use screw driver to disassemble trim cover of handrail.
(b) Disassemble two screws and passenger handrail.
392
29. Disassemble the pothook of sun shade [68010086]

Turn the pothook of sun shade to left for 90, then disassemble
it.
30. Disassemble fixing pedestal of rear window sun

blind.
Use screw driver to turn the fixing pedestal of sun blind for 90,
then disassemble it.
31. Disassemble trim tape of top sunroof [67010010]
32. Disassemble inner trim board of top [68010035]
(a) Use screw driver to disassemble inner trim board of top.
(b) Disassemble three fixing clamps and inner trim board of
top.
(c) Take out inner trim board of top from rear door. Fixing
clamp
33. Assemble inner trim board of top [68010035]

(a) Liking that shown in figure, align the mark, then fix the wir-
ing harness of top with adhesive tape.
(b) Use three fixing clamps to assemble inner trim board of top.
34. Assemble the pothook of sun shade [68010086]

Turn the pothook of sun shade to make fixing claw proturde,
then assemble sun shade.
35. Assemble rear row chair left backrest assembly
Adhesive
[68010078] tape
36. Assemble rear row chair right backrest assembly
[68010079]
37. Assemble rear row chair backrest assembly
[68010076]
393
Automobile control system--Ignition switch and anti-versa lock key warning switch
Automobile control system

Ignition switch and anti-versa lock key warning switch
Phenomenon Possible malfunction part Reference page
Ignition switch could not insert on any 1. Ignition switch 394
position 2. Circuit of power supply -
Inspection
1. Check the ignition switch.
Check the conduction of ignition switch joint and terminal

LOCK - Not conduction
ACC 1-3 Conduction
ON 1-2-3, 5-6 Conduction
START 1-2, 4-5-6 Conduction

the switch.
2. Check the anti-versa lock key warning switch.

OFF (key does not insert) - Not conduction
ON (key inserts) 1-2 Conduction

the switch.
394
Electrical schematic diagram--Ignition switch/starting/charging
Ignition switch/starting/charging
395
Electrical schematic diagram--Electric injection control of engine
Electric injection control of engine
396
Electrical schematic diagram--Anti-locking brake system ABS Brake distribution EBD
Anti-locking brake system ABS Brake distribution EBD
397
Electrical schematic diagram--Electric glass lifter
Electric glass lifter
398
Electrical schematic diagram--Electric sunroof Electric chair
Electric sunroof Electric chair
399
Electrical schematic diagram--Wiper and water injection Brake light
Wiper and water injection Brake light
400
Electrical schematic diagram--Electric rearview mirror
Electric rearview mirror
401
Electrical schematic diagram--Reversing radar system
Reversing radar system
402
Electrical schematic diagram--Safety airbag system
Safety airbag system
403
Electrical schematic diagram--Air conditioning system Defrosting system
Air conditioning system Defrosting system
404
Electrical schematic diagram--Door control system Anti-stealing system Central control system Light system
Light system
Door control system Anti-stealing system Central control system
405
Electrical schematic diagram--Adjustment for headlight height Speaker cigar lighter Sound system
Adjustment for headlight height Speaker cigar lighter Audio system
406
Electrical schematic diagram--Combination instrument
Combination instrument
407
Electrical schematic diagram--Self-diagnosis Chip anti-stealing system
Self-diagnosis Chip anti-stealing system
408

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Preface

We start to compile FC Automobile Maintenance Manual, which is divided into 27 sec-

Geely International Corporation

In order to avoid personnel injury and vehicle damage caused by dangerous

z If it is necessary to replace parts, please replace with parts of the same or

Brief introduction on Geely model FC Inspection ........................................................ 26

Exterior/inner trim board

Brief introduction on Geely model FC

Complete vehicle herb mass 30

Max. total mass 30

load Rear axle

Min. turning diameter

Kingpin inclination angle

Convergence of rear wheels

high beam of head lamp

inclination Right lamp

Table 2 Types and parameters of main assembly

Number Item name Unit Types and parameters

Main gear box ratio

Front brake Disc brake

Front suspension type Strut-type front independent suspension

Table 3 Main performance parameters of complete vehicle

Number Power performance Item name Unit Parameters Remarks

Min. stable vehicle speed at 4th gear

Slide Distance (full-load, initial speed 50km/h)

Fuel consumption with 4 operating modes

Dust sealing degree

Rain protection seal limit value

Equivalent mean value

Average mileage to first failure

Table on maintenance period at normal conditions

12. Air filter core

13. Connecting conditions of fuel tank cover,

17. Brake fluid

18. Brake Pipe and hose

21. Drive shaft dust cover

Table on maintenance period at severe conditions

Engine control system

Conditions Voltage (V)

2. Inspection of stepping motor

(b) Operation inspection

2. Throttle body components (4G18-1001240)

3. Throttle position sensor (4G18-3600080)

(2) Measure the resistance between 1# pin and 2# pin with

(3) Connect 2 terminals respectively to 1# pin and 3# pin,

Note: pay attention whether there is great jump with

4. Knock sensor (4G18-3600020)

5. Water temperature sensor (4G18-3600040)

Operating principle (Fig. 1):

Use digital universal meter to measure:

Temperature range( Resistance at A and C

6. Intake air temperature sensor (4G18-3600090)

Intake air temperature sensor is a resistor with negative tem-

(Removing the joint) place digital universal meter at ohm gear,

7. Stepping motor (4G18-3600070) Stepping motor of idle speed actuator

Schematic diagram and pins

Throttle body assembly

(b) When removing and installing injection nozzle, always

(1) It is not allowed to use o-ring repeatedly.