Tehcnical Manual

Refit and Remove Manual
MG ZS EV
The Refit and Remove Manual provides the specification, system introduction, service procedure and adjustment
information of the new MG ZS EV vehicle.
After mastering the content of this manual and materials in the service bulletins of the SAIC Motor Passenger Vehicle
Co., the technicians of Authorised Repairers of SAIC Motor Passenger Vehicle Co. can provide better service for MG
ZS EV vehicle owners.
For relevant information about product brands, part numbers or special tools mentioned in this manual, we recommend
contacting SAIC Motor Passenger Vehicle Co.
SAIC Motor Passenger Vehicle Co.
All Rights Reserved.
Information is due in June, 2021.
Without prior written approval from SAIC Motor Passenger Vehicle Co., no part of the manual shall be reproduced,
stored in retrieval system or transmitted in any form or by any means (including but not limited to electronic, mechanical,
photocopy and recording). The statement above applies to all texts, illustrations and tables.
How to Use this Manual "Description" emphasizes the necessary features of certain
Overview diagnostic or service procedure. It is for the following
purposes:
To help you with the use of this Manual, we divided the Manual
into several chapters and sections. The title of each chapter • Clarify a procedure
is outside each page header, and the title of the corresponding • Provide additional information for the execution of
section is inside the page header. procedure
The contents of the chapter and section are at the beginning of • Provide internal reasons why to operate according to
the Manual, which are divided by chapters and sections. Page recommended procedures
numbers start with the first page of the text, which are outside • Provide information which can help to execute the
the footer of the page. procedures more effectively
All the repair operation steps must be arranged in the order • Present information that gives the technician the benefit
they normally appear in. The serial number in the illustration of past experience in accomplishing a procedure with
refers to the corresponding text. greater ease
The instructions for adjustment and repair operations include "Prompt" provides some help information.
the service tool number to be applied, and the corresponding Reference
illustration also reflects the use status of the tool. The
LH or RH in this manual is viewed from the rear of vehicle.
instructions for adjustment and repair operations also involve
wear limits, torque values, guide information and useful Operations involved in this manual do not include tests after
assembly details. Each adjustment or repair operation has an service. This is especially important after the component
unique repair operation number. related to safety is serviced or replaced.
The meanings of "Warning", "Note" and "Prompt" are as Dimensions

follows: Dimensions referenced here are based on design engineering
specifications. This manual includes all the available service
"Warning" requires you to take necessary measures or not
limits.
to take prohibited measures. If a "Warning" is neglected, the
following consequences may occur: The company will continuously improve the vehicle
• Serious injury to a technician specification, design and manufacturing. So there will be
some changes in vehicle frequently. Although we try our
• Serious injury to other technical staff in the work area
best to make the manual be correctly written, we cannot
• In case of improper vehicle repair, serious injury to the
guarantee there is no little error between the specification and
driver and/or passengers in the vehicle will be caused.
description in this manual as for the vehicle in any particular
"Note" requires to pay special attention to necessary measures situation.
or prohibited measures. If a "Note" is neglected, the following
consequences may occur:
• Damage to the vehicle
• Unnecessary vehicle repairs
• Unnecessary parts replacement
• Improper operation or performance of the system or
component under repair
• Damage to any system or component which is dependent
upon the proper operation or performance of the system
or component under repair
• Improper operation or performance of any system
or component which is dependent upon the proper
operation or performance of the system or component
under repair
• Damage to fasteners, basic tools, or special tools
• Leakage of coolant, lubricating oil or other main fluid
1.0 1
Notices of Service and Replacement
Components
In case of component replacement, use the recommended by
us only.
Special attention should be taken to the followings which are

all related with the service or replacement of components and
accessories:
• Use of other components rather than those

recommended by the SMC may weaken vehicle safety
factors and anti-corrosion measures.
• The torque value given in the manual must be used.
• The fasteners must be fitted at specified position. If the
performance of fasteners is reduced after removal, then
they must be replaced.
• If the components rather than those recommended by
SMC used, the guarantee clause of the vehicle will be
invalid.
All components recommended by SMC shall share the rights

given in the guarantee.
SMC dealers should only provide SMC recommended

components.
Special Tools
The use of special tool helps to prevent the possible
component damage.
Some operations herein cannot be performed without relevant

special tools.
The special tools herein can be available from the supplier

below:
Shanghai Runyue Industrial Development Co., Ltd
Address: Skirt Building, Lianhua Building, 159 Tianzhou Road,

Shanghai
Zip Code: 200233
Tel: 021-64853663
Fax: 021-64853639
1.0 2
Contents
General Information ........................... 1 Hose Assembly - Radiator to Electric
Water Pump................................................. 38
General Information .............................................1
Overflow Pipe Assembly ............................... 39
General Precautions .......................................... 1
PEB Coolant Sensor ..................................... 39
Safety Precautions .............................................. 2
PEB Water Pump.......................................... 40
Precautions for High Voltage............................... 3
Service Procedures-Battery .............................. 41
Environmental Precautions ................................. 4
Coolant - Drain and Refill ............................. 41
General Instructions for Assembly ...................... 6
Expansion Tank Cap - Pressure Test............... 42
Ball and Roller Bearings ...................................... 7
System Pressure Test .................................... 43
Oil Seals ............................................................ 8
Coolant Expansion Tank - Battery ................. 43
Junction and Mating Face .................................... 9
Hose Assembly - Electric Water Pump to
Locking Device................................................... 9 Traction Battery Heater................................ 44
Screw Threads ................................................. 10 Hose Assembly - Traction Battery Heater
Fastener Identification ...................................... 10 to Battery Chiller ......................................... 45
Flexible Pipe and Hose ..................................... 12 Hose Assembly - Battery Chiller to
Electrical Precautions ....................................... 13 Battery......................................................... 45
Supplementary Restraint System Traction Battery-side Hose Assembly ............ 46
Precautions...................................................... 14 Hose Assembly - Traction Battery to
SRS Component Replacement Strategy ............. 20 Battery Expansion Tank................................. 47
Air Conditioning System Precautions ................ 21 Hose Assembly - Battery Expansion Tank
to Water Pump ............................................ 48
Air Conditioning Compressor
Replacement .................................................... 23 Battery Chiller ............................................. 49
Lifting & Towing ..................................................24 Battery Chiller Expansion Valve..................... 50
Lifting Vehicle................................................... 24 Electric Water Pump .................................... 51
Roadside Assistance ......................................... 25 Service Procedures-Cooling Module.................. 52
Vehicle Identification Number ...........................26 Cooling Fan Assembly................................... 52
Vehicle Identification Number........................... 26 Cooling Fan Low-speed Resistor .................. 52
Position of Other Signs .................................... 27 Radiator Assembly ....................................... 53
Lubrication & Maintenance ................................28 Radiator Drain Valve..................................... 55
Capacity .......................................................... 28 Radiator Airflow Deflector - Upper .............. 55
Fluid ................................................................ 28 Radiator Airflow Deflector - Lower .............. 56
Lubricating Fluids ............................................. 29 Radiator Airflow Deflector - Left .................. 56
Radiator Airflow Deflector - Right ................ 57
Cooling System ................................. 31
Power and Control System .............. 59
Cooling System....................................................31
Specifications ................................................... 31 Power Drive System............................................59
Torque ......................................................... 31 Specifications ................................................... 59
Service Procedures-EDS ................................... 32 Torque ......................................................... 59
Coolant - Drain and Refill ............................. 32 Service Procedures........................................... 60
Expansion Tank Cap - Pressure Test............... 33 Power Electronic Box ................................... 60
System Pressure Test .................................... 34 Drive motor................................................. 62
Coolant Expansion Tank - PEB....................... 34 High Voltage Interlock Cover Plate................ 63
Hose Assembly - Electric Water Pump to Motor Rear End Cover Plate......................... 64
Charger ....................................................... 35 Axle Shaft Connecting Shaft .......................... 65
Hose Assembly - Charger to PEB .................. 36 Axle Shaft Oil Seal ........................................ 66
Hose Assembly - Drive Motor to Hose Fitting ................................................. 67
Radiator....................................................... 37 Axle Shaft Sealing Test .................................. 68
1.0 1
Contents
Special Tools .................................................... 70 Vehicle Control Unit..................................... 99
HV Battery Pack and Charging System ............71
Transmission .................................... 101
Specifications ................................................... 71
Torque ......................................................... 71 Shift Lock Control .............................................101
Service Procedures........................................... 72 Specifications ................................................. 101
Manual Service Disconnect ........................... 72 Torque ....................................................... 101
High-voltage Battery Pack ............................. 73 Service Procedures......................................... 102
Combined Charging Unit (CCU) ................... 74 Electronic Shifter ........................................ 102
Battery Heater ............................................. 75 Electrical Drive System ....................................104
Charging Port............................................... 76 Specifications ................................................. 104
Electric Vehicle Communication Controller Torque ....................................................... 104
(EVCC) ........................................................ 77 Service Procedures......................................... 105
Special Tools .................................................... 78 Oil - Drain and Refill................................... 105
HV Battery Pack Subsystem ..............................79 Electric Drive Transmission and
Specifications ................................................... 79 Suspension ................................................. 105
Torque ......................................................... 79 Differential Oil Seal - Left............................ 107
Service Procedures........................................... 80 Electric Drive Transmission
Disassembling............................................. 108
Precautions for High Voltage System
Disassembly ................................................. 80 Intermediate Shaft Assembly ....................... 112
General Description ..................................... 81 Differential Assembly .................................. 113
High Voltage Insulation Test .......................... 82 Electrical Park Module ................................ 114
Battery Pack Integrity Tests........................... 82 P Gear Unlocking ....................................... 115
Upper Cover................................................ 83 Electrical Park Motor Control Unit ............. 115
Insulation Cotton - 50.3kWh ........................ 84 Special Tools .................................................. 116
Flame Trap - 69.9kWh .................................. 85 HVAC System.................................. 117
BMS Module................................................. 85
HVAC System....................................................117
BMS Module Bracket .................................... 86
Specifications ................................................. 117
Wire Harness............................................... 86
Torque ....................................................... 117
Bus-bar ........................................................ 88
Service Procedures-General .......................... 118
CMU Module ............................................... 89
Odour Removal.......................................... 118
Battery Module ............................................ 90
Refrigerant Recovery and Recharging........... 118
EDM Module ................................................ 91
A/C Compressor Oil Balance...................... 120
Vent Value.................................................... 92
Air Conditioning System Seals..................... 120
Cooling Water Pipe ...................................... 92
Replacement of A/C System O-ring ............ 121
Temperature Sensor ..................................... 93
Service Procedures-Compressor and
Tray ............................................................. 94 Condenser..................................................... 122
GND Harness .............................................. 94 Compressor............................................... 122
Deflector ..................................................... 95 Compressor Bracket .................................. 123
Explosion Proof Value - 69.9kWh .................. 95 Condenser ................................................. 123
Pressure Switch - 69.9kWh ........................... 96 Service Procedures-Pipe ................................. 124
Baffle - 69.9kWh .......................................... 96 A/C Pipeline A - Compressor to
Special Tools .................................................... 97 Condenser ................................................. 124
Vehicle Control Unit ...........................................98 A/C Pipeline B - Compressor to
Condenser ................................................. 125
Specifications ................................................... 98
A/C Pipeline - Condenser to
Torque ......................................................... 98
Evaporator ................................................. 126
Service Procedures........................................... 99
2 1.0
Contents
A/C Pipeline - Evaporator to Electric Steering Column Lock .................... 151
Compressor............................................... 127 Steering Wheel Multifunction Switch ........... 152
A/C Pressure Sensor ................................. 128 Steering Wheel Combination Switch ........... 153
Service Procedures-Conditioner ..................... 129
A/C Box Assembly ..................................... 129 Suspension System.......................... 155
A/C Filter Element...................................... 130 Wheel Alignment ..............................................155
Evaporator Core Assembly ......................... 131 Specifications ................................................. 155
Expansion Valve.......................................... 132 Torque ....................................................... 155
Blower ...................................................... 133 Service Procedures......................................... 156
Blower Speed Regulation Resistor .............. 133 Wheel Alignment Check ............................ 156
A/C Drain Pipe........................................... 134 Wheel Alignment Adjustment .................... 156
Evaporator Core Temperature Front Suspension ...............................................157
Sensor ....................................................... 134 Specifications ................................................. 157
Temperature Damper Actuator................... 135 Torque ....................................................... 157
Circulation Damper Actuator ..................... 135 Service Procedures......................................... 158
Mode Damper Actuator ............................. 136 Front Low Control Arm Assembly .............. 158
Electric Heater ........................................... 136 Front Lower Control Arm Outer Ball
Electric Heater Temperature Sensor............ 137 Joint........................................................... 159
Service Procedures-Decompression Front Lower Control Arm Rear Bush........... 159
Valve.............................................................. 138 Front Shock Absorber Assembly ................. 160
Instrument Panel Air Duct .......................... 138 Full Frame Front Subframe .......................... 162
Air Outlet Temperature Sensor................... 138 Front Anti-roll Bar...................................... 166
Rear Face Air Duct..................................... 139 Front Anti-roll Bar Links ............................. 166
Body Relief Valve - Left ............................... 140 Front Wheel Hub Bearing Assembly............ 167
Body Relief Valve - Right ............................. 140 Front Steering Knuckle ............................... 167
Service Procedures-Control ........................... 141 Special Tools .................................................. 169
A/C Controller Assembly ........................... 141 Rear Suspension ................................................170
Interior Temperature Sensor....................... 141 Specifications ................................................. 170
Exterior Temperature Sensor ...................... 142 Torque ....................................................... 170
Solar Sensor .............................................. 142 Service Procedures......................................... 171
Steering System .............................. 143 Rear Shock Absorber Assembly ................. 171
Rear Suspension Spring Assembly .............. 171
Steering System ................................................143
Rear Wheel Hub ....................................... 172
Specifications ................................................. 143
Wheel Bracket ........................................... 172
Torque ....................................................... 143
Rear Torsion Beam Assembly ..................... 173
Service Procedures......................................... 144
Tyres and Wheels ..............................................174
Steering Rack Subassembly ......................... 144
Specifications ................................................. 174
Steering Rack Outer Tie Rod ..................... 145
Torque ....................................................... 174
Steering Rack Inner Tie Rod ....................... 146
Steering Rack Gaiter .................................. 146
Tires and Wheels ....................................... 175
Upper Steering Column Assembly ............... 147
Tyre Pressure Monitoring System ...................176
Intermediate Shaft ...................................... 148
Specifications ................................................. 176
Steering Column Trim Cover ...................... 148
Torque ....................................................... 176
Steering Wheel Positioning
Adjustment ................................................ 149 Service Procedures......................................... 177
Steering Wheel Assembly ........................... 150 Tyre Pressure Sensor .................................. 177
Steering Wheel Molding.............................. 151 TPMS Control ............................................ 177
1.0 3
Contents
Brake System................................... 179 Brake Module.....................................................210
Brake ..................................................................179 Specifications ................................................. 210
Specifications ................................................. 179 Torque ....................................................... 210
Torque ....................................................... 179 Service Procedures......................................... 211
Service Procedures......................................... 180 Brake Modulator ....................................... 211
Front Brake Pad ........................................ 180 Front Wheel Speed Sensor ........................ 212
Front Brake Disc ....................................... 181 Rear Wheel Speed Sensor ......................... 213
Front Brake Disc Guard Plate ..................... 182 Driveline/Axle.................................. 215
Front Brake Caliper Housing Assembly
................................................................. 182 Drive Axle ..........................................................215
Front Brake Caliper Bracket ....................... 183 Specifications ................................................. 215
Rear Brake Pad .......................................... 184 Torque ....................................................... 215
Rear Brake Disc ........................................ 185 Service Procedures......................................... 216
Rear Brake Disc Guard Plate ...................... 186 Right Front Drive Shaft Assembly ................ 216
Rear Brake Caliper Housing Assembly Left Front Drive Shaft Assembly .................. 217
................................................................. 187 Constant-velocity Joint Assembly ................ 219
Rear Brake Caliper Bracket ........................ 188 Constant-velocity Joint Assembly
Thickness and Circular Runout Check - Gaiter ........................................................ 220
Front Brake Disc ....................................... 189 Tripode Shaft Assembly............................... 220
Thickness and Circular Runout Check - Tripode Joint Assembly Sleeve ..................... 221
Rear Brake Disc ........................................ 190 Special Tools .................................................. 222
Reservoir Assembly ................................... 191
Brake Master Cylinder ............................... 192
Interior Fitting................................. 223
Vacuum Booster Assembly ......................... 193 Instrument Panel and Console.........................223
Vacuum Brake Hose Assembly .................... 194 Specifications ................................................. 223
Brake Lamp Signal Sensor ........................... 195 Torque ....................................................... 223
Brake Pedal ............................................... 195 Service Procedures......................................... 224
Brake Pedal Position Sensor ........................ 196 Instrument Panel End Cover Plate ............... 224
Accelerator Pedal ...................................... 197 Instrument Panel Body................................ 224
Master Cylinder Brake Hard Pipe ............... 197 Driver Side Lower Trim Panel
Assembly ................................................... 226
Front Left Brake Hard Pipe ........................ 198
Glove Box Assembly................................... 227
Front Right Brake Hard Pipe ...................... 199
Instrument Panel Lower Closure Panel
Connecting Pipe - ABS to Rear Brake
Assembly .................................................. 228
Pipe ........................................................... 200
Instrument Panel Side Air Outlet
Rear Left Brake Pipe ................................... 202
Assembly ................................................... 228
Rear Right Brake Pipe ................................. 203
Central Instrument Panel Air Outlet
Front Brake Hose ...................................... 204 Assembly ................................................... 229
Rear Brake Hose ....................................... 204 Central Control Panel and Switch of
Brake System Bleed ................................... 205 Instrument Panel ........................................ 230
Electric Vacuum Pump ................................ 206 Instrument Panel IPK Frame........................ 230
Special Tools .................................................. 207 Instrument Panel Beam Assembly ................ 231
Park Brake .........................................................208 Centre Console Heater Closing Plate
Assembly ................................................... 233
Specifications ................................................. 208
Centre Console Assembly .......................... 233
Torque ....................................................... 208
Centre Console Cup Holder ...................... 234
Centre Console Armrest Assembly ............. 235
Electronic Parking Brake Motor................... 209
4 1.0
Contents
Centre Console Upper Trim Panel Fixed Windows ..................................................259
Assembly ................................................... 235 Service Procedures......................................... 259
Centre Console Rear Panel Assembly........... 236 Windscreen ............................................... 259
Entertainment Panel Switch......................... 237 Rear Window............................................. 260
Interior Trim and Paneling ...............................238 Rear Quarter Window ............................... 261
Specifications ................................................. 238 Bumpers, Fascias and Grille .............................262
Torque ....................................................... 238 Specifications ................................................. 262
Service Procedures......................................... 239 Torque ....................................................... 262
A Pillar Upper Trim Panel............................ 239 Service Procedures......................................... 263
A Pillar Lower Trim Panel ........................... 239 Front Bumper Beam Assembly ................... 263
B/C Pillar Upper Trim Panel ........................ 240 Rear Bumper Beam Assembly .................... 264
B/C Pillar Lower Trim Panel ........................ 241 Front Bumper............................................. 264
D Pillar Upper Trim Panel ........................... 241 Rear Bumper.............................................. 266
D Pillar Lower Trim Panel ........................... 242 Exterior Trim and Paneling ..............................268
Roof Trim Panel Assembly - without Specifications ................................................. 268
Sunroof...................................................... 243
Torque ....................................................... 268
Roof Trim Panel Assembly - with
Sunroof...................................................... 244 Service Procedures......................................... 269
Carpet ....................................................... 245 Roof Rack Assembly ................................... 269
Sun Visor Assembly ................................... 245 Roof Molding Assembly .............................. 269
Interior Roof Handle ................................. 246 A/C Air Intake Grille Assembly ................... 270
Rear Parcel Shelf Assembly ......................... 246 Front Wheelhouse Liner Assembly.............. 271
Truck Side Trim Panel Assembly .................. 247 Rear Wheelhouse Liner Assembly ............... 272
Trunk Sill Trim Panel ................................... 247 Spoiler Assembly ........................................ 273
Tail Gate Interior Trim Panel ....................... 248 Bottom Deflector....................................... 273
Door Sill Trim Panel Assembly .................... 248 Mirrors................................................................275
Seat.....................................................................249 Specifications ................................................. 275
Service Procedures......................................... 250 Exterior Mirror Assembly ........................... 276
Front Seat Assembly ................................... 250 Exterior Rearview Mirror Glass .................. 276
Front Seat Interior Trim Panel ..................... 250 Exterior Mirror Cover................................ 277
Front Seat Exterior Trim Panel .................... 251 Manual anti-dazzle Interior Rearview
Mirror........................................................ 277
Front Seat Back Cover................................ 252
Roof.....................................................................278
Front Seat Cushion Cover .......................... 252
Specifications ................................................. 278
Front Seat Back Adjusting Handle................ 253
Torque ....................................................... 278
Front Seat Back Assembly ........................... 253
Front Seat Cushion Assembly...................... 254
Sunroof Assembly-Linear Style
Seat Headrest Guide Sleeve ........................ 254 Switch........................................................ 279
Rear Seat Cushion Assembly....................... 255 Sunroof Deflector Assembly-Linear Style
Rear Seat Cushion Cover and Foam ............ 255 Switch........................................................ 281
Rear Seat Back Latch .................................. 256 Front Sunroof Glass Panel-Linear Style
Rear Seat Back Assembly ............................ 256 Switch........................................................ 281
Rear Seat Back Cover and Foam.................. 257 Rear Sunroof Glass Panel-Linear Style
Switch........................................................ 282
Rear Seat Back Hinge Bracket ..................... 257
Sunroof Sunshade-Linear Style Switch........... 282
Exterior Fitting................................ 259
1.0 5
Contents
Sunroof Glass Panel Motor-Linear Style Rear Combination Lamp Assembly .............. 305
Switch........................................................ 283 Direction Indicator Lamp Bulb .................... 305
Sunroof Sunshade Motor-Linear Style Reverse Lamp Bulb ..................................... 306
Switch........................................................ 284
Rear Fog Lamp Assembly ............................ 306
Sunroof Harness-Linear Style Switch ........... 284
Rear License Plate Lamp Assembly .............. 307
Front Sunroof Drain Pipe ............................ 285
High-mounted Stop Lamp Assembly ............ 307
Rear Sunroof Drain Pipe ............................. 286
Light Sensor ............................................... 308
Panoramic Sunroof Outer Weatherstrip
................................................................. 286 Door Systems .................................. 309
Special Tools .................................................. 288
Door Panel & Accessories ................................309
Wipers and Washer ..........................................289
Specifications ................................................. 309
Specifications ................................................. 289
Torque ....................................................... 309
Torque ....................................................... 289
Front Door Adjustment.............................. 310
Wiper Blade Assembly................................ 290
Front Door and Hinge Assembly ................. 311
Window Wiper Arm .................................. 291
Driver Door Outer Handle and Lock
Window Wiper Linkage Assembly............... 291 Cylinder Assembly...................................... 312
Window Wiper Motor ............................... 292 Front Passenger Door/Rear Door Outer
Window Washer Reservoir Handle and Lock Cylinder Cover ................ 313
Assembly ................................................... 292 Driver Door Outer Handle Liner ................ 314
Window Washing Reservoir Filler Pipe Driver Door Lock Assembly ....................... 315
Assembly ................................................... 293
Rear Door Adjustment ............................... 316
Window Washer Pump Assembly ............... 293
Rear Door and Hinge Assembly .................. 317
Windshield Washer Pump Hose.................. 294
Rear Door Outer Handle Liner................... 318
Rear Windscreen Wiper Arm
Assembly ................................................... 294 Rear Door Lock Assembly .......................... 319
Rear Windscreen Wiper Motor .................. 295 Door Accessories ..............................................320
Rear Washer Pipe....................................... 296 Specifications ................................................. 320
Rear Windscreen Washer Nozzle ............... 297 Torque ....................................................... 320
Rain Sensor ................................................ 297 Service Procedures......................................... 321
Special Tools .................................................. 298 Front Door Window .................................. 321
Front Door Window Regulator................... 322
Lighting Systems ............................. 299 Front Door Window Regulator
Lighting...............................................................299 Control...................................................... 322
Service Procedures......................................... 299 Front Door Windowsill Inner
Weatherstrip.............................................. 323
Roof Console Assembly.............................. 299
Front Door Windowsill Outer
Front Reading Lamp Assembly..................... 300 Weatherstrip.............................................. 324
Front Reading Lamp Bulb ............................ 300 Front Door Window Slideway
Loadspace Lamp ......................................... 301 Weatherstrip.............................................. 324
Lamps .................................................................302 Front Door Glass Rail................................. 325
Specifications ................................................. 302 Rear Door Window ................................... 325
Torque ....................................................... 302 Rear Door Window Regulator.................... 326
Service Procedures......................................... 303 Rear Door Window Regulator
Headlamp Assembly.................................... 303 Control...................................................... 327
Side Direction Indicator Lamp..................... 303 Rear Door Windowsill Inner
Weatherstrip.............................................. 328
Headlamp Lighting Calibration .................... 304
Rear Door Windowsill Outer
Tail Lamp Assembly .................................... 304 Weatherstrip.............................................. 329
6 1.0
Contents
Rear Door Window Frame Exterior Trim Tailgate Gas Strut and Mounting
Panel.......................................................... 329 Bracket ...................................................... 351
Rear Door Window Slideway Tailgate Exterior Handle.............................. 352
Weatherstrip.............................................. 330 Tailgate Upper Trim Panel ........................... 353
Rear Door Glass Rail .................................. 330 Charger Filler Flap ............................................354
Power Window Switch - Driver Side ........... 331 Specifications ................................................. 354
Power Window Switch - Others ................. 331 Torque ....................................................... 354
Door Lock Switch ...................................... 332 Service Procedures......................................... 355
Door Molding .....................................................333 Charging Port Door Assembly ................... 355
Service Procedures......................................... 333 Body Control Module........................................356
Front Door Interior Trim Panel and Specifications ................................................. 356
Waterproof Membrane............................... 333
Torque ....................................................... 356
Front Door Interior Handle ........................ 334
Rear Door Interior Trim Panel and
Waterproof Membrane .............................. 335 Body Control Module (BCM) ..................... 357
Rear Door Interior Handle ......................... 336 Horn ...................................................................358
Specifications ................................................. 358
Body System .................................... 337 Torque ....................................................... 358
Fender ................................................................337 Service Procedures......................................... 359
Specifications ................................................. 337 Horn.......................................................... 359
Torque ....................................................... 337
Body Panel & Paint ......................... 361
Fender ...................................................... 338 Panel Repair.......................................................361
Front Module .....................................................339 Roof Panel ................................................. 361
Specifications ................................................. 339 Front Compartment Cover Panel ............... 362
Torque ....................................................... 339 Dash Panel ................................................. 363
Service Procedures......................................... 340 Bodyside Panel .......................................... 364
Front-end Module....................................... 340 Front Floor ................................................ 365
Bonnet ................................................................342 Rear Floor ................................................ 366
Specifications ................................................. 342 Door Panel Assembly ................................. 367
Torque ....................................................... 342 Front Compartment Cover Panel Assembly
................................................................. 368
Tailgate Sheet Metal Assembly ..................... 369
Hood Adjustment....................................... 343
Collision Repair .................................................370
Hood and Hinge Assembly .......................... 343
Body Material ............................................. 370
Bonnet Lock Assembly ............................... 344
Damage Diagnosis ..................................... 371
Bonnet Release Cable ................................. 345
Confirmation of Maintenance Scheme
Hood strut................................................. 346 ................................................................. 373
Hood Release Handle ................................. 346 Body Correction ........................................ 374
Tailgate ...............................................................347 Panel Repair ............................................... 376
Specifications ................................................. 347 Sheet Metal Replacement............................ 377
Torque ....................................................... 347 Paint and Coatings ............................................381
Service Procedures......................................... 348 Overview ................................................... 381
Tailgate Adjustment .................................... 348 Coating Process ........................................ 383
Tailgate and Hinge Assembly ....................... 348 General Film Coating Defects .................... 389
Tailgate Lock Catch Assembly ..................... 350 Seal .....................................................................393
Tailgate Lock Catch .................................... 351 Overview ................................................... 393
1.0 7
Contents
Sealing Performance Test ............................ 395 Steering Wheel Airbag................................ 472
Information of Sealant Positions ................. 396 Instrument Panel Airbag.............................. 472
Information of Gasket Positions ................. 409 Side Curtain Airbag .................................... 473
Corrosion Protection .......................................413 Airbag Control Module .............................. 474
Overview .................................................. 413 Front Passenger Airbag Disable
Anti-corrosion Products and Switch........................................................ 474
Construction.............................................. 416 Auxiliary Display Module ............................ 475
Welding Process ................................................422 Park Assistant System ......................................476
Welding Process Overview ......................... 422 Service Procedures......................................... 476
Welding Protection Measures...................... 423 Rear Ultrasonic Sensor ............................... 476
Welding Parts Remove................................ 424 Rear Camera.............................................. 476
OEM Welding Information ......................... 426 Around View Monitor (AVM) ...................... 477
Body Dimension ................................................450 360 Panoramic Front View Camera ............. 477
Point to Point Dimensional Information........... 450 360 Panoramic Side View Camera ............... 478
Bodyside and Roof Information .................. 450 360 Panoramic Rear View Camera .............. 478
Underbody Information ............................. 452 Rear Drive Assist System .................................479
Rear End Information ................................. 453 Service Procedures......................................... 479
Interior Information ................................... 454 Rear Distant Object Detection Module and
Front End Information ............................... 456 Sensor ....................................................... 479
Gap Information............................................. 457 Pedestrian Alert System...................................480
Body Side Information ............................... 457 Specifications ................................................. 480
Front End Information ................................ 458 Torque ....................................................... 480
Rear End Information.................................. 459 Service Procedures......................................... 481
Sunroof Information ................................... 461 Pedestrian Alert Control Module ................ 481
Pedestrian Alert Speaker............................. 481
Safety and Restraints ...................... 463 Vehicle Access....................................................482
Gateway..............................................................463 Specifications ................................................. 482
Service Procedures......................................... 464 Passive Entry and Passive Start Control
Gateway..................................................... 464 Module ...................................................... 483
Seat Belts ...........................................................465 Passive Entry and Passive Start Antenna -
Front ......................................................... 483
Specifications ................................................. 465
Passive Entry and Passive Start Antenna -
Torque ....................................................... 465 Middle........................................................ 484
Service Procedures......................................... 466 Passive Entry and Passive Start Antenna -
Front Seat Belt Assembly ............................ 466 Rear........................................................... 484
Front Seat Belt Buckle ................................ 467 Passive Entry and Passive Start Antenna -
Rear Seat Belt Assembly ............................. 467 Rear Bumper Fascia .................................... 485
Rear Seat Belt Buckle.................................. 468 Passive Entry and Passive Start Antenna -
Door Handle.............................................. 485
Rear Seat Middle Belt ................................. 468
Back Up Antenna........................................ 486
Supplementary Restraint Systems ..................470
Drive Assistant System.....................................487
Specifications ................................................. 470
Torque ....................................................... 470
Front View Camera Module ........................ 487
Front Detection Radar Module .................. 487
Airbag Front Impact Sensor ....................... 471
Special Tools .................................................. 489
Airbag Side Impact Sensor .......................... 471
8 1.0
Contents
Information and Front Door Harness ................................... 517
Entertainment ................................. 491 Rear Door Harness .................................... 518
Entertainment and Navigation ........................491 Centre Console Harness ............................ 518
Specifications ................................................. 491 Driver Seat Harness ................................... 519
Torque ....................................................... 491 Power Socket .....................................................520
Service Procedures......................................... 492 Service Procedures......................................... 520
Front Infotainment Control Module 12V Power Socket ...................................... 520
(FICM) ....................................................... 492 High Voltage Harness .......................................521
DAB Module .............................................. 493 Specifications ................................................. 521
Front Door Tweeter ................................... 493 Torque ....................................................... 521
Front Door Woofer ................................... 494 Service Procedures......................................... 522
Rear Door Woofer..................................... 494 High-voltage Power Distribution Unit
ECall Speaker ............................................. 495 (PDU) ........................................................ 522
Microphone................................................ 495 Combined Charging Unit High-voltage
Harness ..................................................... 523
Communication Module (TBOX)................. 496
Traction Battery High-voltage Harness
ECall Communication Module ..................... 496 ................................................................. 524
ECall Switch ............................................... 497 PDU to A/C Compressor to Power
Communication Module Antenna ................ 497 Electronic Box High-voltage Harness ........... 525
Roof Antenna............................................. 498 Heater High-voltage Harness ...................... 526
Displays and Gauges..........................................499 Heater High-voltage Harness 2.................... 528
Specifications ................................................. 499 Wireless Charging Of Mobile Phone ...............529
Torque ....................................................... 499 Specifications ................................................. 529
Service Procedures......................................... 500 Torque ....................................................... 529
Instrument Pack ......................................... 500 Service Procedures......................................... 530
Mobile wireless charging module ................. 530
Power & Signal................................. 501
Glossary List ......................................................531
Low Voltage Fusebox ........................................501
Specifications ................................................. 501
Torque ....................................................... 501
Front Compartment Fuse Box .................... 502
Battery Fuse Box & Management
System................................................................503
Specifications ................................................. 503
Torque ....................................................... 503
Positive Battery Cable................................. 504
Negative Battery Cable............................... 504
Battery....................................................... 505
Battery Sensor ........................................... 505
Battery Tray ............................................... 506
Battery Tray Bracket ................................... 506
Low Voltage Harness ........................................507
Instrument Harness .................................... 507
Body Harness............................................. 508
1.0 9
General Information
General Information Health Protection Precautions
General Precautions The following precautions should be observed at all times:
Dangerous Substances
• Wear protective clothing, including impervious gloves
Modern vehicles contain many materials or liquids which if not when practicable.
handled with care can be hazardous to both personal health • Avoid prolonged and repeated contact with lubricating
and the environment. oil.
Warning: Many liquids and other substances used in • Do not put oily rags in pockets.
vehicles are poisonous and should under no circumstances • Avoid contaminating clothes (particularly those next to
be consumed and should, as far as possible, be kept the skin) with lubricating oil.
from contact with the skin. These liquids and substances
• Overalls must be cleaned regularly. Discard heavily soiled
include acid, antifreeze, brake fluid, fuel, windscreen
clothing and oil impregnated footwear.
washer additives, lubricants, refrigerants and various
adhesives. • First aid treatment should be obtained immediately for
open cuts and wounds.
Warning: Always read any instructions that accompany,
• Apply barrier creams before each work period to help
are printed on the label, or are stamped on components
prevent lubricating oil from contaminating the skin.
very carefully. Follow the instructions and guideline
carefully in order to avoid damage and personal injury. • Wash with soap and water to ensure all lubricating oil is
removed (proprietary skin cleansers and nail brushes will
Synthetic Rubber
help).
Many O rings, seals, hoses, flexible pipes and other similar • Use moisturisers after cleaning; preparations containing
items which appear to be natural rubber, are in fact, made lanolin help replace the skin's natural oils which have been
of synthetic materials called Fluoroelastomers. Under normal removed.
operating conditions this material is safe and does not present
• Do not use petrol/gasoline, kerosene, diesel fuel,
a health hazard. However, if the material is damaged by fire
lubricating oil, thinners or solvents for cleaning skin.
or excessive heating, it can break down and produce highly
corrosive Hydrofluoric acid. • Where practicable, degrease components prior to
handling.
Contact with Hydrofluoric acid can cause serious burns on
• If skin disorders develop, obtain medical advice without
contact with skin. If skin contact does occur:
delay.
• Remove any contaminated clothing immediately. • Wear eye protection (e.g. goggles or face shield) if there
• Irrigate affected area of skin with a copious amount of is a risk of eye contamination. Eye wash facilities should
cold water or limewater for 15 to 60 minutes. be provided in close vicinity to the work area.
• Obtain medical assistance immediately.
Should any material be in a burnt or overheated condition,

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

Lubricating Fluids
Avoid excessive skin contact with used lubricating oils and
always adhere to the health protection precautions.
Warning: Avoid excessive skin contact with used
lubricating fluids. Used lubricating fluids contains
potentially harmful contaminants which may cause skin
cancer or other serious skin disorders.
Warning: Avoid excessive skin contact with mineral oil.
Mineral oils remove the natural fats from the skin, leading
to dryness, irritation and dermatitis.
1.0 1
General Information
Safety Precautions • Maintain absolute cleanliness when working with
Lift hydraulic components.
Caution: It is best to use the lift when working under the Cooling System Caps and Plugs
vehicle. Be sure to hold the wheels with chocks and apply When the cooling system is still hot, especially when it is
parking brake. overheated, take particular care if removing the expansion tank
Always use the recommended lifting points. cap, coolant drain pipe or bleed screws. To avoid the possibility
of burns, wait for the cooling system to cool down before
Always ensure that any lifting apparatus has sufficient load removal.
capacity for the weight to be lifted.
Ensure the lift is standing on level ground during lifting or

jacking.
Apply the parking brake and fit wedges to secure wheels.
Warning: Do not work on or under a vehicle supported

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

on the work bench area.
Always keep a clean and tidy work area.

Brake Shoes and Pads
Always fit the correct grade and specification of brake linings.
When renewing brake pads and brake shoes, always replace as
complete axle sets.
Brake Hydraulic System
Observe the following procedures when working on the brake
system:
• Apply two spanners to loosen or tighten brake pipes/tube

connectors.
• Ensure that hoses run in a natural curve and are not
twisted or deformed.
• Fit brake pipes securely in their retaining clips and ensure
that the pipe cannot contact a potential chafing point.
• Containers of brake fluids must be kept clean.
• Do not store brake fluid in an unsealed container,
otherwise it will absorb moisture in the air, which may
lower its boiling point, and in this condition it is likely to
cause danger in its use.
• Do not allow brake fluid to be contaminated by mineral
oil, or put new brake fluid in a container which has
previously contained mineral oil.
• Do not reuse brake fluid drained from the brake system.
• Always use clean brake fluid or a recommended
alternative to clean hydraulic components.
• After disconnecting brake pipes and hoses, immediately
fit suitable end caps or plugs to prevent the ingress of
dirt.
• Only use the correct brake fittings with compatible
threads.
1.0 2
General Information
Precautions for High Voltage Warning: Prior to opening any high voltage circuits the
Basic Requirements systems MUST be checked using a suitable multi meter
to ensure they carry no high voltage current. Where
Basic requirements for related precautions for high voltage in
there is need to work with the high voltage system
vehicle are as follows:
is essential that the correct 'make safe' procedure is
• ALWAYS ensure the correct PPE is worn when working followed - see Manual Service Disconnect procedure
on, or with HV components. in the Service Repair manual. After disconnecting the
• Unrelated and non qualified persons must be prevented Manual Service Disconnect (MSD), always wait 5 minutes
from coming into contact with the vehicle during repair. prior to commencing any checks for residual voltage etc.
• DO NOT touch any components that carry the high Caution: When removing or servicing any parts of the
voltage warning labels without the correct PPE or high voltage system it is essential that no liquids enter,
training. contaminate or are spilled on components, harnesses or
• If it is necessary to disassemble the relevant high-voltage connectors.
components, any personnel must have the correct high
voltage training and qualifications.
• When operating high-voltage components, the operator
must wear protective equipment and must also use
insulated gloves.
• When operating exposed high-voltage system
components, the operator must use a multimeter to
measure if there is high voltage, no operations should be
undertaken until the vehicle is made, and proven to be
safe and not subject to high voltage.
• Before carrying out any work on vehicles featuring
high voltage systems you must switch off the vehicle
power system/START/STOP Switch. If there is a need to
disassemble the high-voltage system, wait for 5 minutes
before proceeding.
• When disassembling or assembling electrical
components, the 12V power supply and the manual
service switch on the high-voltage battery pack must be
disconnected.
• After any removal and refitting of any high voltage
components it is necessary to ensure correct installation
and connection of all high-voltage components and
ensure their reliability before reconnecting the
high-voltage power.
• All high-voltage components MUST have a robust and
secure ground connection.
Warning: Only persons that hold the correct high voltage
training certificates and qualifications are allowed to work
on high voltage systems and components.
Warning: Non qualified staff are NOT permitted to
dismantle high voltage systems or components (including,
ESS, Electric Drive Transmission, PEB, PDU, EACP, PTC
units, HV harnesses, CCU, DCDC, Charging sockets etc).
1.0 3
General Information
Environmental Precautions • Never pour anything down a drain without first checking
Overview that it is environmentally safe to do so, and that it does
not contravene any local regulations.
This section provides general information which can help to
reduce the environmental impacts from the activities carried • Store liquids in a walled area.
out in workshops. • Make sure that taps on liquid containers are secure and
Emissions to Air cannot be accidentally turned on.
• Protect bulk storage tanks from vandalism by locking the
Many of the activities that are carried out in workshops emit
valves.
gases and fumes which contribute to global warming, depletion
of the ozone layer and/or the formation of photochemical • Transfer liquids from one container to another in an area
smog at ground level. By considering how the workshop away from open drains.
activities are carried out, these gases and fumes can be • Ensure lids are replaced securely on containers.
minimised, thus reducing the impact on the environment. • Have spill kits available near to points of storage and
Solvents handling of liquids.
Some of the cleaning agents used are solvent based and will Spill Kits
evaporate to atmosphere if used improperly, or if cans are Special materials are available to absorb a number of different
left unsealed. All solvent containers should be firmly closed substances. They can be in granular form, ready to use and
when not needed and solvent should be used sparingly. Suitable bought in convenient containers for storage. Disposal of used
alternative materials may be available to replace some of the spill-absorbing material is dealt with in 'Waste Management'
commonly used solvents. Similarly, many paints are solvent section.
based and the spray should be minimised to reduce solvent Land Contamination
emissions.
Lubricating oil, solvents, etc. can contaminate any soil that
Refrigerant they are allowed to contact. Such materials should never be
Discharge and replacement of refrigerant from air conditioning disposed of by pouring onto soil and every precaution must be
units should only be carried out by using the correct taken to prevent spillage reaching soil. Waste materials stored
equipment. on open ground could also leak, or have polluting substances
Diluent: washed off them that would contaminate the land. Always
store these materials in suitable robust containers.
• Keep lids on containers of solvents;
• Only use the minimum quantity;
Checklist
Always adhere to the following:
• Consider alternative materials;
• Minimise over-spray when painting. • Don't pour or spill anything onto the soil or bare ground.
Gases: • Don't store waste materials on bare ground.
• Use the correct equipment for collecting refrigerants; Local Issues
• Don't burn rubbish on site. A number of environmental issues will be of particular concern
Discharges to Water to residents and other neighbors close to the site. The
sensitivity of these issues will depend on the proximity of the
Lubricating oil, solvent, acids, hydraulic oil, antifreeze and other
site and the layout and amount of activity carried on at the
such substances should never be poured down the drain and
site.
every precaution must be taken to prevent spillage reaching
the drains. Car alarm testing, panel beating, hammering and other such
noisy activities should, whenever possible, be carried out
Handling of such materials must take place well away from the
indoors with doors and windows shut or as far away from
drains and preferably in an area with a kerb or wall around it, to
residential area as possible.
prevent discharge into the drain. If a spillage occurs, it should
be soaked up immediately. Having a spill kit available will make Be sensitive to the time of day when these activities are carried
this easier. out and minimise the time of the noisy operation, particularly
in the early morning and late evening.
Checklist
Another local concern will be the smell from the various
Always adhere to the following disposal and spillage prevention
materials used. Using less solvent, paint and petrol could help
instructions.
prevent this annoyance.
1.0 4
General Information
Local residents and other business users will also be concerned • Packaging: compact as much as possible and dispose of
about traffic congestion, noise and exhaust fumes, be sensitive in ordinary waste.
to these concerns and try to minimise inconvenience from • Asbestos material: keep separate and dispose of to
deliveries, customers and servicing operations. specialist contractor.
Checklist • Oily wastes (e.g. rags, used spill kit material): keep
Always adhere to the following: separate and dispose of to specialist contractor.
• Air filters: keep separate and dispose of to specialist
• Identify where the neighbors who are likely to be affected
contractor.
are situated;
• Rubber/plastics: dispose of in ordinary waste.
• Minimise noise, smells and traffic nuisance.
• Water pipes: dispose of in ordinary waste.
• Prevent waste pollution by disposing of waste in the
correct container. • Batteries: keep separate and dispose of to specialist
contractor.
• Have waste containers emptied regularly.
• Airbags - explosives: keep separate and dispose of to
Waste Management
specialist contractor.
One of the major ways that pollution can be reduced is by the
• Electrical components: send back to supplier for
careful handling, storage and disposal of all waste materials that
refurbishment, or disassemble and reuse any suitable
occur on sites. This means that it is necessary to not only know
parts. Dispose of the remainder in ordinary waste.
what the waste materials are, but also to have the necessary
documentation and to know local regulations that apply. • Catalysts: can be sold if kept separate from general
waste.
Handling and Storage of Waste
• Used spill-absorbing material: keep separate and dispose
They should be stored in such a way as to prevent the escape of to specialist contractor.
of the material to land, water or air.
They must also be segregated into different types of waste

e.g. oil, metals, batteries, used vehicle components. This will
prevent any reaction between different materials and assist in
disposal.
Disposal of Waste
Disposal of waste materials must only be to waste carriers who
are authorized to carry those particular waste materials and
have all the necessary documentation. The waste carrier is
responsible for ensuring that the waste is taken to the correct
disposal sites.
Dispose of waste in accordance with the following guidelines:
• Hydraulic fluid, anti-freeze and lubricating oil: keep

separate and dispose of to specialist contractor.
• Refrigerant: collect in specialist equipment and reuse.
• Detergents: safe to pour down the foul drain if diluted.
• Paint, thinners: keep separate and dispose of to specialist
contractor.
• Components: send back to supplier for refurbishment,
or disassemble and reuse any suitable parts. Dispose of
the remainder in ordinary waste.
• Small parts: reuse any suitable parts, dispose of the
remainder in ordinary waste.
• Metals: can be sold if kept separate from general waste.
• Tyres: keep separate and dispose of to specialist
contractor.
1.0 5
General Information
General Instructions for Assembly • Never inspect a component for wear or dimensional
Component Removal check unless it is absolutely clean; a slight smear of grease
can conceal an incipient failure.
Whenever possible, clean components and surrounding area
before removal. • When a component is to be checked dimensionally
against recommended values, use the appropriate
• Blank off openings exposed by component removal. measuring equipment (surface plates, micrometers,
• Immediately seal fuel, oil or hydraulic lines when dial gauges etc.). Ensure the measuring equipment is
apertures are exposed; use plastic caps or plugs to calibrated and in good serviceable condition.
prevent loss of fluid and ingress of dirt. • Reject a component if its dimensions are outside the
• Close the open ends of oilways exposed by component specified tolerances, or if it appears to be damaged.
removal with tapered hardwood plugs or conspicuous • A part may be refitted if its critical dimension is exactly
plastic plugs. to its tolerance limit and it appears to be in satisfactory
• Immediately a component is removed, place it in a condition. Use ‘Plastigauge' for checking bearing surface
suitable container; use a separate container for each clearances.
component and its associated parts.
• Clean bench and provide marking materials, labels and
containers before dismantling a component.
Dismantling
Observe scrupulous cleanliness when dismantling components,
particularly when brake, fuel or hydraulic system parts are
being worked on. A particle of dirt or a cloth fragment could
cause a serious malfunction if trapped in these systems.
• Blow out all tapped holes, crevices, oilways and fluid

passages with an air line. Ensure that any O-rings used
for sealing are correctly replaced or renewed, if disturbed
during the process.
• Use marking ink to identify mating parts and ensure
correct reassembly. Do not use a centre punch or
scriber to mark parts, they could initiate cracks or
distortion in marked components.
• Wire together mating parts where necessary to prevent
accidental interchange (e.g. roller bearing components).
• Attach labels to all parts which are to be renewed, and
to parts requiring further inspection before being passed
for reassembly; place these parts in separate containers
from those containing parts for rebuild.
• Do not discard a part due for renewal until after
comparing it with a new part, to ensure that its correct
replacement has been obtained.
Cleaning
Always use the recommended cleaning agent or equivalent.
Ensure that adequate ventilation is provided when volatile
degreasing agents are being used. Do not use degreasing
equipment for components containing items which could be
damaged by the use of this process.
General Inspection
All components should be inspected for wear or damage
before being reassembled.
1.0 6
General Information
Ball and Roller Bearings • In the case of grease lubricated bearings (eg. hub
Overview bearings) fill the space between bearing and outer seal
with the recommended grade of grease before fitting
When removing and installing bearings, ensure that the
seal.
following practices are observed to ensure component
serviceability. • Always mark components of separable bearings (eg.
taper roller bearings) when dismantling, to ensure
• Remove all traces of lubricant from bearing under
correct reassembly. Never fit new rollers in a used outer
inspection by cleaning with a suitable degreasant;
ring; always fit a complete new bearing assembly.
maintain absolute cleanliness throughout operations.
• Hold inner race of bearing between finger and thumb of
one hand and spin outer race to check that it revolves
absolutely smoothly. Repeat, holding outer race and
spinning inner race.
• Rotate outer ring gently with a reciprocating motion,
while holding inner ring; feel for any check or obstruction
to rotation. Reject bearing if action is not perfectly
smooth.
• Lubricate bearing with generous amounts of lubricant
appropriate to installation.
• Inspect shaft and bearing housing for discoloration or
other markings which indicate movement between
bearing and housing.
• Ensure that shaft and housing are clean and free from
burrs before fitting bearing.
• If one bearing of a pair shows an imperfection, it
is advisable to replace both with new bearings; an
exception could be if the faulty bearing had covered a
low mileage, and it can be established that damage is
confined to only one bearing.
• Never refit a ball or roller bearing without first ensuring
that it is in a fully serviceable condition.
• When hub bearings are removed or displaced, new
bearings must be fitted; do not attempt to refit the old
hub bearings.
• When fitting a bearing to a shaft, only apply force to the
inner ring of the bearing. When fitting a bearing into a
housing, only apply force to the outer ring of the bearing.
1.0 7
General Information
Oil Seals
General
Always renew oil seals which have been removed from their
working location (whether as an individual component or
as part of an assembly). NEVER use a seal which has been
improperly stored or handled, such as hung on a hook or nail.
• Carefully examine seal before fitting to ensure that it is

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

recess and press into position using great care, and if
possible a 'bell piece' to ensure that seal is not tilted. In
some cases it may be preferable to fit seal to housing
before fitting to shaft. Never let weight of unsupported
shaft rest in seal.
1.0 8
General Information
Junction and Mating Face Locking Device
General General
Fit joints dry unless specified otherwise. Always replace locking devices with one of the same design.
• Always use the correct gaskets as specified. Tab Washers

• When sealing compound is used, apply in a thin uniform Always release locking tabs and fit new locking washers. Do
film to metal surfaces; take care to prevent sealing not re-use locking tabs.
compound from entering oilways, pipes or blind tapped Locking Nuts
holes.
Always use a backing spanner when loosening or tightening
• If gaskets and/or sealing compound is recommended for
locking nuts, brake and fuel pipe unions.
use; remove all traces of old sealing compound prior to
reassembly. Do not use a tool which will damage the Roll Pins
joint faces and smooth out any scratches or burrs using Always fit new roll pins of an interference fit in the hole.
an oil stone. Circlips
• Prior to reassembly, blow through any pipes, channels or
Always fit new circlips of the correct size for the groove.
crevices with compressed air.
Keys and Keyways
Remove burrs from edges of keyways with a fine file and clean
thoroughly before attempting to refit key.
Clean and inspect key closely; keys are suitable for refitting only
if indistinguishable from new, as any indentation may indicate
the onset of wear.
Split Pins
Always fit new split-pins of the correct size for the hole in the
bolt or stud.
1.0 9
General Information
Screw Threads Fastener Identification
General Bolt Identification
Metric threads to ISO standards are used.
Damaged nuts, bolts and screws must always be discarded.

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

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

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

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

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

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

threads.
• Ensure threads are clean and free of oil and grease.
• Apply an approved locking agent.
1.0 10
General Information
An encapsulated bolt may be replaced with a bolt of equivalent also marked and some have the metric symbol M on the flat
specification provided it is treated with an approved locking opposite the strength grade marking.
agent.
When tightening a slotted or castellated nut, never loosen it
Self-locking Bolts and Screws to insert a split pin except where recommended as part of an
adjustment. If difficulty is experienced, alternative washers or
nuts should be selected, or the washer thickness reduced.
Where bearing preload is involved, nuts should be tightened in

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

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

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

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

one of the flats of the hexagon with the strength grade symbol
8, 12, or 14. Some nuts with a strength grade 4, 5 or 6 are
1.0 11
General Information
Flexible Pipe and Hose Hose Orientation and Connection
General
When removing and installing flexible hydraulic pipes and
hoses, ensure that the following practices are observed to
ensure component serviceability.
• Clean end fittings and the area surrounding them as

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

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

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

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

correct clip position. If no markings are provided, position the
clip directly behind the retaining lip at the end of the stub as
shown. Worm drive clips should be oriented with the crimped
side of the drive housing (2) facing towards the end of the hose,
or the hose may become pinched between the clip and the stub
pipe retaining lip. Worm drive clips should be tightened to 3
All flexible pipes are made up of two laminations, an armoured Nm unless otherwise stated. Ensure that hose clips do not foul
rubber outer sleeve and an inner viton core. If any of the adjacent components.
flexible pipes have been disconnected, it is imperative that the
Heat Protection
internal bore is inspected to ensure that the viton lining has
not become separated from the armoured outer sleeve. A Always ensure that heatshields and protective sheathing are
new pipe must be fitted if separation is evident. in good condition. Replace if damage is evident. Particular
care must be taken when routing hoses close to hot engine
Cooling System Hoses
components, such as the exhaust manifold and the Exhaust Gas
The following precautions MUST be followed to ensure that Recirculation (EGR) pipe. Hoses will relax and deflect slightly
integrity of cooling hoses and their connections to system
components are maintained.
1.0 12
General Information
when hot; ensure this movement is taken into account when Electrical Precautions
routing and securing hoses. General
The following guidelines are intended to ensure the safety of
the operator while preventing damage to the electrical and
electronic components fitted to the vehicle. Where necessary,
specific precautions are detailed in the individual procedures of
this manual.
Equipment
Prior to commencing any test procedure on the vehicle ensure
that the relevant test equipment is working correctly and any
harness or connectors are in good condition. It is particularly
important to check the condition of the lead and plugs of mains
operated equipment.
Polarity
Never reverse connect the vehicle battery and always ensure
the correct polarity when connecting test equipment.
High Voltage Circuits
Whenever disconnecting live HT circuits always use insulated
pliers and never allow the open end of the HT lead to contact
other components, particularly ECUs. Exercise caution when
measuring the voltage on the coil terminals while the engine is
running, high voltage spikes can occur on these terminals.
Connectors and Harnesses
The engine compartment of a vehicle is a particularly hostile
environment for electrical components and connectors:
• Always ensure electrically related items are dry and oil

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

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

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

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

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

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

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

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

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

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

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

do not rub it. Gently run large quantities of eye wash
over affected eye to raise the temperature. If an eye
wash is not available, cool clean water may be used to
flush the eye. After rinsing, cover the eye with a clean
pad and seek immediate medical care.
• If the air conditioning refrigerant liquid is splashed onto
the skin, rinse with large quantity of water to raise the
temperature. Take the same measures for skin contact
with the discharge. Wrap the contaminated skin in
blankets (or equivalents) and seek immediate medical
care.
• If inhalation of the air conditioning refrigerant vapour
cause persons to be unconscious, move them away from
the contaminated area to fresh air and apply artificial
respiration and/or oxygen and seek immediate medical
care.
1.0 21
General Information
Warning: Due to its low evaporating temperature, Air • Whenever the refrigeration system is opened, the
conditioning refrigerant must be handled with care. Air desiccant must be renewed immediately before refilling
conditioning refrigerant splashed on any part of the the refrigerant.
body will cause immediate freezing of that area. Also, • Use alcohol and a clean lint-free cloth to clean dirty
refrigerant cylinders and replenishment trolleys when connections.
discharging will freeze skin to them if contact is made.
• Ensure that all new parts fitted are marked for use with
Service Precautions air conditioning refrigerant.
Observe the following precautions when handling components A/C Oil
used in the air conditioning system: The A/C oil easily absorbs water and must not be stored for
• Air conditioning units must not be lifted by their hoses, long periods. Do not pour unused refrigerant oil back into the
pipes or capillary lines. container. Always use an approved A/C oil.
• Hoses and lines must not be subjected to any twist or When replacing components of the A/C system, drain the
stress; the efficiency of the system will be impaired by A/C oil from the component into a graduated container. On
kinks or restrictions. Ensure that hoses are correctly assembly, add the new component with the same quantity of
positioned and all clips and supports are utilized before A/C oil when draining.
tightening couplings.
Compressor
• Flexible pipes shall not be close to the hot component
A new compressor is sealed and pressurized with nitrogen gas.
(at least 100 mm) unless a heat shield is used.
When fitting a new compressor, slowly release the sealing cap;
• Completed assemblies must be checked for the A/C air leak noise can be heard when the seal is in poor condition.
pipe touching the metal panels. Noise due to any direct
contact between the A/C component and the panels Caution: Do not remove the cap(s) until immediately
shall be avoided. prior to connecting the air conditioning pipes to the
compressor.
• When tightening the connections of the A/C pipe,
tighten it to the specified torque with an appropriate Rapid Refrigerant Discharge
torque wrench. When tightening, an additional wrench If the air conditioning system is damaged in an accident, the
must be used to hold the support to prevent pipe from refrigerant will leak rapidly. Rapid discharge of the refrigerant
deformation. will also take away most of the A/C oil from the system.
• Before connecting any hose or tube, ensure that A/C oil While removing the compressor, drain the remaining A/C
is applied to the seat of the new O-ring, BUT NOT to oil, and maintain as per the instructions described in the air
the thread. conditioning section hereinl.
• All fittings of the A/C refrigeration system must be Precautions for Refrigerant Recovery, Refill and
stored under seal and shall be connected immediately Recycling
after removal of the sealing component. When refilling A/C refrigerant, drain and recover the
• Ensure components are at room temperature before refrigerant in the original system, then refill the refrigerant
uncapping, to prevent moisture in the air from entering and A/C oil required.
into the A/C.
Warning: Refrigerant must always be recycled before
• Component seal must not remain uncapped for more re-use to ensure that the purity of the refrigerant is high
than 15 minutes. In the event of a delay, the sealing enough for safe use in the air conditioning system.
component must be fitted.
Warning: Recycling should always be carried out with
• When disconnecting the A/C pipe, immediately cap
equipment which is design certified by Underwriter
the A/C pipe interface and prevent ingress of dirt and
Laboratory Inc. for compliance with SAE J1991. Other
moisture into the system.
equipment may not recycle refrigerant to the required
• Desiccant in the receiver/drier absorbs moisture. It must level of purity.
be positively sealed at all times. A receiver/drier that has
Warning: Refrigerant Recovery Recycling Recharging
been left uncapped must not be used, fit a new unit.
Station must not be used with any other type of
• The receiver/drier should be the last component
refrigerant.
connected to the system to ensure optimum dehydration
and maximum moisture protection of the system.
1.0 22
General Information
Warning: Refrigerant from domestic and commercial Air Conditioning Compressor Replacement
sources must not be used in motor vehicle air conditioning Replacement Instructions
systems.
A new compressor is supplied filled with a full charge of
Caution: The system must be evacuated immediately refrigerant oil. The new compressor must be drained and a
before recharging commences. Delay between evacuation calculated quantity of oil added before fitting. To calculate the
and recharging is not permitted. quantity of oil to be added, carry out the following procedure:
1. Remove the filler/drain plug from the old compressor.

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

Lifting Vehicle
Description
Before lifting the vehicle, note the followings:
• The vehicle shall be parked on a level and firm ground.

• Press the electronic parking brake system switch.
• Select P or N gear.
To avoid damage to the underbody parts, please follow the

procedures below:
Do not put the jack or axle bracket under the following

components:
Hydraulic Jack
• Body Structural Parts
The hydraulic jack to be used must have a bearing capacity of
• Bumper at least 1,500kg (3,300lbs).
• Brake Line Column Lifter
• Front Suspension Arm
• Steering Connecting Mechanism
• Rear Suspension Arm
• High-voltage Battery Module
• High-voltage Drive Motor
• Transmission Housing
• Rear Towing Eye
Lifting and Supporting the Vehicle
Front/Rear Supporting Point of the Vehicle
Put the head of the jack at the lifting point of the front/rear
door sill of the vehicle.
Caution: Do not jack or support the vehicle on any points Put the mat of the lifting arm of the lifter under the jacking
other than those indicated. Failure to comply is likely to point on the sill.
result in damage to the body or chassis components.
Warning: Always chock the wheels when jacking.

Warning: Do not commence work on the underside of the

vehicle until suitable safety supports have been positioned
under the sill reinforced brackets.
1.0 24
Lifting & Towing General Information
Roadside Assistance
Towing Vehicle
Towing Eye
Warning: DO not use a tow rope that is twisted - or the
towing hook may be unscrewed.
Vehicle Shipping
If the vehicle needs to be shipped, a special transporter is

recommended. Fix the vehicle on the transporter as follows:
The vehicle has a towing hole at the front and rear respectively
for fitting the towing eyes in the toolbox, and the toolbox is
placed under the trunk floor. Before fitting the towing eye,
remove the small cover on the bumper first, then screw the
towing eye through the hole into the threaded hole in the
bumper beam. Ensure the towing eye is fully tightened!
When your vehicle breaks down or has an accident, the towing

eyes can be used as towing points for towing. But they are not
designed for towing other vehicles. A soft rope can be used
for towing, however it is recommended to use a hard rod to
tow the vehicle.
• Before the vehicle is shipped, ensure that the electronic
Towing parking brake system (EPB) is enabled.
Warning: If, due to an electrical fault, potential
• Place the wheel chocks (1) as shown in the figure, and
safety hazards may exist, it is not allowed to put the
place the anti-slip rubber pads (2) around the wheels.
START/STOP Switch in ‘ON’ position.
• Fit the lashing strap (3) around the wheel and secure it
Warning: DO not suddenly start the towing car with great to the towing vehicle. Tighten the strap to secure the
acceleration or accelerate to avoid damaging the car. vehicle.
Suspension Towing
If your vehicle needs to be towed, the best way of towing is
suspension towing. The drive wheel shall be off the ground in
the suspension towing, or the transmission may be damaged.
The parking brake shall be released, the hazard warning lamp
shall be turned on, and passengers shall not stay in the vehicle
being towed.
1.0 25
General Information Vehicle Identification Number
Vehicle Identification Number

Vehicle Identification Number
Vehicle Identification Number (VIN)

Example：LSJW74U96MZXXXXXX
Figures Code Description
Manufacturer's
1–3 LSJ Identifier, LSJ = Saic
Motor
Vehicle Type, W7 =
4–5 W7
ZS1
Vehicle Body
Structure, 4 = Printed on the front floor of the right front seat.
6 4
2–compartment &
5–door
Engine
C = 1.3T/1.0T
7 C,U Gasoline Engine
U = 1.5L Gasoline
Engine
Occupant Restraint
System
9 = Safety belt,
driver and front-seat
8 9
passenger airbag &
Location of Vehicle Identification Plate
seat-side airbag , and
front & rear curtain The identification plate is located at the lower side of the
airbag right B pillar. For details, please refer to the specific vehicle
identification plate.
Check bit
(represented by any
9 6
figure from 0 to 9 or
letter X)
Year of Manufacturing
10 M
M = 2021
Plant, G = zhenzhou,
11 Z
henan
12–17 6 figures Serial number
VINThe VIN is also stamped in the following location:
On a plate behind the LH lower corner of the windshield.
1.0 26
Vehicle Identification Number General Information
Position of Other Signs
Drive motor number
Printed on the lower part of the drive motor housing, as shown
in the figure.
Electric Drive transmission

Printed on the upper rear part of the electric drive system
housing, as shown in the figure.
1.0 27
General Information Lubrication & Maintenance
Lubrication & Maintenance Fluid

Capacity Coolant
Liquid Capacity Please be sure to use the coolant recommended and approved
The following capacity values are merely approximate value for by SAIC Motor. Glycol (OAT) coolant is recommended.
the corresponding system. In emergency, a small amount of clean water may be filled in
Component/System Capacity the coolant reservoir. However, it should be noted that this
will weaken the freeze and corrosion protection function and
Electric drive transmission oil:
reduce the service life of the coolant. DO NOT refill the
Refill 0.9L cooling system with anti-freeze of different formulations.
Cooling System - Motor coolant: Adding additives that are not suitable for the vehicle to the
Refill 4.8L coolant may damage the parts that need to be cooled. It is
recommended to use additives approved by SAIC Motor.
Cooling System - Battery coolant:
Brake Fluid
Refill 5.6L
Use brake fluid DOT 4 only.
Brake fluid for brake system 0.75L
Windshield washer reservoir 4.0L
1.0 28
Lubrication & Maintenance General Information
Lubricating Fluids
Electric drive transmission Fluid
Failure to use the specified transmission fluid may result in
serious damage to the transmission.
Electric drive transmission
Refill with Shell E-Fluids E6 iX (SL2808) oil.
General Lubricating Grease
Use FN745/94 lubricating grease produced by.
Lock, Lock Body and Hinge
Do not apply any lubricating grease on the fixing end of the
torsion bar spring, however, Isoflex Topas L32CN lubricating
grease is recommended for its rotating end.
Washer Fluid
Use ZY-VIII washer fluid.
1.0 29
1.0 30
Cooling System Cooling System
Cooling System
Specifications
Torque
Description Value
Bolt-EDS coolant Expansion tank to body 4-6Nm
Bolt-Battery coolant Expansion tank to body 4-6Nm
Nut-Battery cooler pipe to body 4-6Nm
Bolts-Battery cooler to battery cooler bracket 7-10Nm
Nut-Air conditioning line to battery cooler TXV 7-10Nm
Nut-Battery cooler TXV to Battery cooler 7-10Nm
Bolt-Relay to front bracket 5–7Nm
1.0 31
Service Procedures-EDS 2. Prepare the coolant of specified concentration.

Coolant - Drain and Refill Fluid
Drain
3. Refill the cooling system, until the coolant level reaches
1. Disconnect the negative battery cable. between MIN and MAX marks on the expansion tank
2. Remove the manual service disconnect. and keeps still.
Manual Service Disconnect Remove 4. Fit the manual service disconnect.
3. Cover the expansion tank cap with a wet cloth, and Manual Service Disconnect Refit
unscrew the cap. 5. Connect the negative battery cable.
Warning: Since injury such as scalding could be caused by 6. It is required to rotate the water pump to bleed the air
escaping steam or coolant, do not remove the filler cap in the cooling system. See below for specific steps:
from the coolant expansion tank while the system is hot. 7. Connect the scan tool.
4. Remove the front bottom deflector. 8. Operate the electric drive system coolant refill/bleeding:
Bottom Deflector Remove VDS - Fast Channel - Others - Electric Drive System
Coolant Refill/bleeding.
5. Position a suitable container to collect the coolant.
9. Observe the flow of coolant in the tank (coolant flow
6. Unscrew the drain valve, and use a draining method
indicates that the pump is not idling).
to drain the coolant.
10. Keep the coolant flowing for 20 to 30 minutes. You can
add coolant when the coolant level in the expansion
tank is low during this process.
11. When the coolant level in the expansion tank does not
change, disconnect the scan tool.
12. Check whether the coolant level is between MIN and
MAX. If not, top up the tank with coolant or drain it to
be between MIN and MAX as required.
13. Close the expansion tank cap.
14. Fit the bottom deflector.
Bottom Deflector Refit
Refill
1. Close the coolant drain valve.
1.0 32
Expansion Tank Cap - Pressure Test
Check
1. Visually check the expansion tank cap for signs of
leakage.
2. Check the hose for any rupture and distortion trace,
and the tightness of the pipeline connection.
3. Open the coolant expansion tank cap.
Warning: Since injury such as scalding could be caused by

escaping steam or coolant, do not remove the filler cap
from the coolant expansion tank while the system is hot.
4. Fit the TEN00010 on the expansion tank cap.
6. Pressurize the expansion tank cap slowly to the

specified pressure, then check the pressure; if the
pressure range is maintained within 140-160KPa, the
expansion tank cap is normal.
7. Relieve the pressure through the relief valve on the
pressurizer.
5. Connect the T14001 pressure hose to the TEN00010.
8. Remove the T14001 pressure hose from the TEN00010.

9. Remove the expansion tank cap from the TEN00010
and replace it on the expansion tank.
1.0 33
System Pressure Test Coolant Expansion Tank - PEB

Check Remove
1. Check the hose for any rupture and distortion trace, 1. Drain the coolant.
and the tightness of the pipeline connection. Coolant - Drain
2. Open the coolant expansion tank cap. 2. Loosen the clamp (1), and disconnect the overflow pipe
Warning: Since injury such as scalding could be caused by assembly from the coolant expansion tank.
escaping steam or coolant, do not remove the filler cap 3. Loosen the clamp (2), and disconnect the hose assembly
from the coolant expansion tank while the system is hot. - radiator to electric water pump from the coolant
3. Fit the TEN00015 on the expansion tank. expansion tank.
4. Connect the T14001 pressure hose to the TEN00015.
5. Pressurize the system slowly to 140-160KP and check
for leakage.
Warning: Do not exceed the setting pressure value, or the

cooling system will be damaged.
4. Remove 1 bolt fixing the coolant expansion tank to the

body.
6. Visually check the electric drive unit and the cooling

system for signs of coolant leakage.
T14001.
5. Remove the coolant expansion tank - EDS.

Refit
1. Fix the coolant expansion tank to the body; fit 1 bolt,
tighten it to 4-6Nm, and check the torque.
2. Connect the hose assembly - radiator to electric water
pump to the coolant expansion tank, and secure it with
clamps.
3. Connect the overflow pipe to the coolant expansion
8. Disconnect the T14001 hose from the TEN00015. tank, and secure it with clamps.
9. Remove the TEN00015 from the expansion tank and 4. Refill the coolant.
fit the expansion tank cap. Coolant - Refill
1.0 34
Charger
Remove
1. Disconnect the negative battery cable.
2. Remove the manual service disconnect.
Manual Service Disconnect Remove
3. Drain the coolant.
Coolant - Drain
4. Loosen the clamp (1), and disconnect the hose assembly
- electric water pump to charger from the charger.
6. Loosen the clip, and remove the hose assembly -

electric water pump to charger.
Refit
1. Fit the hose assembly - electric water pump to charger,
and secure it with clips.
2. Connect the hose assembly - electric water pump to
charger to the electric water pump, and secure it with
clamps.
charger to the charger, and secure it with clamps.
4. Refill the coolant.
Coolant - Refill
- electric water pump to charger from the electric
water pump. 5. Fit the manual service disconnect.
Manual Service Disconnect Refit

6. Connect the negative battery cable.
1.0 35
Hose Assembly - Charger to PEB 6. Loosen the clamp (1), and disconnect the hose assembly
Remove - charger to PEB from the PEB.
Coolant - Drain
4. Disconnect the connector of the EDS coolant sensor.

charger to PEB.
Refit
1. Fit the hose assembly - charger to PEB, and secure
it with clips.
2. Connect the hose assembly - charger to PEB to the
PEB, and secure it with clamps.
5. Loosen the clamp (2), and disconnect the hose assembly 3. Connect the hose assembly - charger to PEB to the
- charger to PEB from the charger. charger, and secure it with clamps.
4. Connect the connector of the EDS coolant sensor.
Coolant - Refill
6. Fit the manual service disconnect.

1.0 36
Hose Assembly - Drive Motor to Radiator
Remove
Coolant - Drain
- drive motor to radiator from the radiator.
6. Loosen the clip, and remove the hose assembly - drive

motor to radiator.
Refit
1. Fit the hose assembly - drive motor to radiator, and
secure it with clips.
2. Connect the hose assembly - drive motor to radiator
to the drive motor, and secure it with clamps.
to the radiator, and secure it with clamps.
Coolant - Refill
- drive motor to radiator from the drive motor.

1.0 37
Hose Assembly - Radiator to Electric Water 6. Loosen the clamp (2), and disconnect the hose assembly
Pump - radiator to electric water pump from the electric
Remove water pump.
Coolant - Drain
- radiator to electric water pump from the expansion
tank.

radiator to electric water pump.
Refit
1. Fit the pipeline assembly - radiator to electric water
pump, and secure it with clips.
pump to the electric water pump and secure it with
clamps.
5. Loosen the clamp, and disconnect the hose assembly -
pump to the radiator, and secure it with clamps.
radiator to electric water pump from the radiator.
pump to the expansion tank, and secure it with clamps.
Coolant - Refill

1.0 38
Overflow Pipe Assembly PEB Coolant Sensor
Remove Remove
1. Disconnect the negative battery cable. 1. Disconnect the negative battery cable.
2. Remove the manual service disconnect. 2. Remove the manual service disconnect.
Manual Service Disconnect Remove Manual Service Disconnect Remove
3. Drain the coolant. 3. Drain the coolant.
Coolant - Drain Coolant - Drain
4. Loosen the clamp (1), and disconnect the overflow pipe 4. Disconnect the connector of the EDS coolant sensor.
assembly from the expansion tank.
5. Loosen the circlip, and remove the EDS coolant sensor.

5. Loosen the clamp (1), and disconnect the overflow pipe Refit
assembly from the radiator.
1. Fit the EDS coolant sensor and secure it with circlips.
2. Connect the connector of the EDS coolant sensor.
Coolant - Refill

6. Loosen the clip and remove the overflow pipe assembly.

Refit
1. Fit the overflow pipe assembly and secure it with clips.
2. Connect the overflow pipe to the radiator, and secure
it with clamps.
3. Connect the overflow pipe to the expansion tank, and
secure it with clamps.
Coolant - Refill
1.0 39
PEB Water Pump

Remove
Coolant - Drain
4. Remove the EDS water pump bracket A(If Fitted).
EDS Water Pump Bracket A Remove(If Fitted)

- radiator to electric water pump from the electric 9. Remove the EDS water pump.
water pump.
Refit
1. Connect the connector of the EDS water pump.
- electric water pump to charger from the electric
water pump. 2. Fix the electric water pump bracket - small to the
electric water pump bracket - large, fit 1 bolt, tighten it
to TBD, and check the torque.
charger to the electric water pump, and secure it with
clamps.
pump to the electric water pump and secure it with
clamps.
5. Fit the EDS water pump bracket A(If Fitted).
EDS Water Pump Bracket A Refit(If Fitted)
Coolant - Refill
7. Disconnect the connector (1) of the EDS water pump.
8. Remove 1 bolt fixing the electric water pump bracket
- small to the electric water pump bracket - large, and Manual Service Disconnect Refit
remove the electric water pump bracket - small. 8. Connect the negative battery cable.
1.0 40
Service Procedures-Battery 7. Drain the battery coolant.
Coolant - Drain and Refill Refill
Drain 1. Connect the traction battery-side hose assembly to the
1. Disconnect the negative battery cable. high-voltage battery pack, and secure it with circlips.
2. Remove the manual service disconnect. 2. Prepare the coolant of specified concentration.
Manual Service Disconnect Remove Fluid
3. Remove the middle centre bottom deflector. 3. Refill the coolant, until the coolant level reaches
Bottom Deflector Remove between MIN and MAX marks on the expansion tank
and keeps still.
4. Cover the expansion tank cap with a wet cloth, and
unscrew the cap. 4. Connect the negative battery cable.
Warning: Since injury such as scalding could be caused by 5. Connect the scan tool.
escaping steam or coolant, do not remove the filler cap 6. Enter the forced output of BMS module, "High-voltage
from the coolant expansion tank while the system is hot. Battery Pack Coolant Pump Control", to operate the
5. Position a suitable container to collect the coolant. water pump.
6. Loosen the circlip, and disconnect the traction 7. If it is found that the coolant level in the expansion tank
battery-side hose assembly from the high-voltage does not drop, maybe the water pump is idling. It is
battery pack. considered to assist the T14001 with the pressurizer,
to force the coolant to flow into the water pump inlet.
8. Run the water pump for about 20–30 minutes, and
check the coolant level of the battery coolant expansion
tank. If required, fill the coolant to the level between
MIN and MAX.
9. Fit the battery coolant expansion tank cap.
10. Check the cooling system for leakage.
11. Fit the middle centre bottom deflector.

1.0 41
Expansion Tank Cap - Pressure Test

Check
1. Visually check the expansion tank cap for signs of
leakage.
2. Check the hose for any rupture and distortion trace,
Warning: Since injury such as scalding could be caused by

escaping steam or coolant, do not remove the filler cap
from the coolant expansion tank while the system is hot.
4. Fit the TAC00002 on the expansion tank cap.
6. Pressurize the expansion tank cap slowly to the

specified pressure, and check the pressure range, if the
pressure can be maintained at 35KPa, the expansion
tank cap is normal..
pressurizer.
5. Connect the T14001 pressure hose to the TAC00002.
8. Remove the T14001 pressure hose from the TAC00002.

9. Remove the expansion tank cap from the TAC00002
and replace it on the expansion tank.
1.0 42
System Pressure Test Coolant Expansion Tank - Battery
Check Remove
1. Check the hose for any rupture and distortion trace, 1. Drain the coolant.
Coolant - Drain
Warning: Since injury such as scalding could be caused by - traction battery to battery expansion tank from the
escaping steam or coolant, do not remove the filler cap coolant expansion tank.
from the coolant expansion tank while the system is hot. 3. Loosen the clamp (2), and disconnect the hose assembly
3. Fit the TAC00003 on the expansion tank. - battery expansion tank to water pump from the
4. Connect the T14001 pressure hose to the TAC00003. coolant expansion tank.
5. Pressurize the system slowly to 35KPa and check for

leakage.
Warning: Do not exceed the setting pressure value, or the

cooling system will be damaged.

body.
6. Visually check the electric drive unit and the cooling

system for signs of coolant leakage.
T14001.
5. Remove the coolant expansion tank - battery.

Refit
1. Fix the coolant expansion tank to the body; fit 1 bolt,
2. Connect the hose assembly - battery expansion tank to
water pump to the coolant expansion tank and secure
it with clamps.
8. Disconnect the T14001 hose from the TAC00003.
3. Connect the hose assembly - traction battery to
9. Remove the TAC00003 from the expansion tank and battery expansion tank to the coolant expansion tank
fit the expansion tank cap. and secure it with clamps.
Coolant - Refill
1.0 43

Traction Battery Heater
Remove
Coolant - Drain
2. Remove the CCU.
Coolant - Drain
3. Remove the front bottom deflector.
Coolant - Drain
- electric water pump to traction battery heater from
the traction battery heater.
electric water pump to traction battery heater.
Refit
1. Fit the hose assembly - electric water pump to traction
battery heater, and secure it with clips.
traction battery heater to the electric water pump and
traction battery heater to the traction battery heater
and secure it with clamps.
4. Fit the front bottom deflector.
Coolant - Drain
5. Loosen the clamp (1), and disconnect the hose assembly 5. Fit the CCU.
the electric water pump. Coolant - Drain
Coolant - Refill
1.0 44
Hose Assembly - Traction Battery Heater to Hose Assembly - Battery Chiller to Battery
Battery Chiller Remove
Remove 1. Drain the coolant.
Coolant - Drain
Coolant - Drain 2. Remove the front bottom deflector.
2. Remove the CCU.
Bottom Deflector Remove
3. Loosen the clamp (2), and disconnect the hose assembly - battery chiller to battery from the battery chiller.
- traction battery heater to battery chiller from the
battery chiller.
- traction battery heater to battery chiller from the
traction battery heater.
4. Loosen the clamp (2), and disconnect the hose

assembly - battery chiller to battery from the traction
battery-side hose assembly.
5. Remove the hose assembly - traction battery heater to

battery chiller.
Refit
1. Connect the hose assembly - traction battery heater
to battery chiller to the traction battery heater and
to battery chiller to the battery chiller and secure it
with clamps.
3. Fit the CCU.
Bottom Deflector Refit 5. Remove the hose assembly - battery chiller to battery.
4. Refill the coolant. Refit

1. Connect the hose assembly - battery chiller to battery
Coolant - Refill
to the traction battery-side hose assembly and secure
it with clamps.
to the battery chiller and secure it with clamps.

Coolant - Refill
1.0 45
Traction Battery-side Hose Assembly

Remove
Coolant - Drain
2. Remove the bottom deflector.
3. Remove the front subframe assembly.
Coolant - Drain
4. Loosen the clamp (2), and disconnect the traction
battery-side hose assembly from the hose assembly -
battery chiller to battery.
7. Loosen the clip and remove the traction battery-side
5. Loosen the clamp (1), and disconnect the traction hose assembly.
battery-side hose assembly from the hose assembly -
Refit
traction battery to battery expansion tank.
1. Fit the traction battery-side hose assembly and secure
it with clips.
2. Fix the traction battery-side hose assembly to the
body, fit 2 nuts, tighten them to 4-6Nm and check
the torque.
3. Connect the traction battery-side hose assembly to the
hose assembly - traction battery to battery expansion
tank, and secure it with clamps.
4. Connect the traction battery-side hose assembly to the
hose assembly - battery chiller to battery, and secure
it with clamps.
5. Fit the front subframe assembly.
6. Remove 2 nuts fixing the traction battery-side hose Coolant - Drain

assembly to the body. 6. Fit the bottom deflector.

Coolant - Refill
1.0 46
Hose Assembly - Traction Battery to Battery
Expansion Tank
Remove
Coolant - Drain
- traction battery to battery expansion tank from the
battery expansion tank.
5. Loosen the clip and remove the hose assembly -

traction battery to battery expansion tank.
Refit
1. Fit the hose assembly - traction battery to battery
expansion tank and secure it with clips.
battery expansion tank to the traction battery-side
hose assembly and secure it with clamps.
battery expansion tank to the battery expansion tank
4. Loosen the clamp (1), and disconnect the hose assembly and secure it with clamps.
- traction battery to battery expansion tank from the 4. Fit the front bottom deflector.
traction battery-side hose assembly.
Coolant - Refill
1.0 47
Hose Assembly - Battery Expansion Tank to

Water Pump
Remove
Coolant - Drain
Coolant - Drain
- battery expansion tank to water pump from the water
pump.
5. Loosen the clip and remove the hose assembly - battery

expansion tank to water pump.
Refit
1. Fit the hose assembly - battery expansion tank to water
pump, and secure it with clips.
water pump to the battery expansion tank and secure
it with clamps.
3. Connect the hose assembly - battery expansion tank
to water pump to the water pump and secure it with
clamps.
4. Loosen the clamp (2), and disconnect the hose assembly 4. Fit the front bottom deflector.
- battery expansion tank to water pump from the
battery expansion tank. Coolant - Drain
Coolant - Refill
1.0 48
Battery Chiller 10. Remove 2 bolts fixing the battery chiller to the body.
Remove

4. Recover the A/C system refrigerant.
Refrigerant Recovery and Refill

Coolant - Drain
6. Loosen the clamp (2), and disconnect the hose assembly 11. Loosen the clip and remove the battery chiller.
- traction battery heater to battery chiller from the Refit
battery chiller.
1. Fix the battery chiller to the body, fit 2 bolts, tighten
7. Loosen the clamp (1), and disconnect the hose assembly them to 7-10Nm and check the torque.
- battery chiller to battery from the battery chiller.
2. Fit a new seal ring on the A/C pipeline and apply clean
compressor oil.
3. Fix the A/C pipeline to the battery chiller expansion
valve, fit 1 bolt, tighten it to 7-10Nm, and check the
torque.
4. Connect the connector of the battery chiller.
to the battery chiller and secure it with clamps.
to battery chiller to the battery chiller and secure it
with clamps.
8. Disconnect the connector (2) of the battery chiller. Coolant - Refill

9. Remove 1 bolt (1) fixing the A/C pipeline to the battery 8. Refill the A/C system refrigerant.
chiller expansion valve, disconnect the pipeline, and Refrigerant Recovery and Refill
discard the seal ring.
Caution: Protect open connections to prevent
contamination.

1.0 49
Battery Chiller Expansion Valve

Remove

4. Disconnect the connector (2) of the battery chiller
expansion valve.
5. Remove 1 bolt (1) fixing the A/C pipeline to the battery
chiller expansion valve, disconnect the pipeline, and
discard the seal ring. Refit
1. Fit a new seal ring on the battery chiller expansion
valve and apply clean compressor oil.
contamination.
2. Fix the battery chiller expansion valve to the battery
chiller, fit 2 bolts, tighten them to 7-10Nm, and check
the torque.
compressor oil.
4. Fix the A/C pipeline to the battery chiller expansion
valve, fit 1 nut, tighten it to 7-10Nm, and check the
torque.
5. Connect the connector of the battery chiller expansion
valve.
6. Refill the A/C system refrigerant.

6. Remove 2 bolts fixing the battery chiller expansion 7. Fit the manual service disconnect.
valve to the battery chiller, remove the battery chiller
expansion valve, and discard the seal ring. Manual Service Disconnect Refit

contamination.
1.0 50
Electric Water Pump
Remove
Coolant - Drain
the electric water pump. 9. Remove the electric water pump.
6. Loosen the clamp (2), and disconnect the hose assembly Refit
- battery expansion tank to water pump from the 1. Fit the electric water pump.
electric water pump. 2. Fix the electric water pump bracket - small to the
electric water pump bracket - large, fit 1 bolt, tighten it
3. Connect the connector of the electric water pump.
electric water pump to the electric water pump and
traction battery heater to the electric water pump and
Coolant - Refill
7. Disconnect the connector (2) of the electric water 7. Fit the front bottom deflector.
pump. Bottom Deflector Refit
8. Remove 1 bolt (1) fixing the electric water pump
bracket - small to the electric water pump bracket -
large, and remove the electric water pump bracket - Manual Service Disconnect Refit
small. 9. Connect the negative battery cable.
1.0 51
Service Procedures-Cooling Module Cooling Fan Low-speed Resistor

Cooling Fan Assembly Remove
Remove Warning: Disconnect the battery to prevent operation of
1. Disconnect the negative battery cable. the cooling fan, which could cause personal injury.
3. Remove the radiator airflow deflector - upper. 2. Disconnect the connector (2) of the cooling fan.
3. Remove 1 screw (1) fixing the cooling fan speed
Radiator Airflow Deflector - Upper Remove
regulation resistor to the fan shroud.
4. Disconnect the connector (2) of the cooling fan.
4. Take about 5cm-long wire from the cooling fan speed

5. Disconnect 4 clips fixing the cooling fan to the radiator. regulation resistor and cut off the cooling fan speed
regulation resistor from the wire at this point.
5. After cutting off the cooling fan speed regulation
resistor, remove about 7cm-long insulated leather from
the remaining wire.
6. Remove the cooling fan speed regulation resistor.
Refit
1. Take a cooling fan speed regulation resistor to be fitted
and cover the heat-shrink tube onto the cooling fan
speed regulation resistor wire.
6. Remove the cooling fan assembly.

Refit
1. Align the cooling fan assembly to 4 slots on the radiator
and snap in to ensure that it is clamped in place.
2. Connect the connector of the cooling fan.
3. Remove the radiator airflow deflector - upper.
Radiator Airflow Deflector- Upper Refit

Manual Service Disconnect Refit 2. Insert the metal part with insulated leather wire
5. Connect the negative battery cable. removed into the double-head connector connected
with the cooling fan speed regulation resistor wire to
be fitted, and clamp them with crimping plier in the
T84001, with the tensile capacity of no less than 10 kg
1.0 52
for the joint and no looseness as the standard. Radiator Assembly
3. Cover the heat-shrink tube onto the double-head Remove
connector, and heat the heat-shrink tube with a proper 1. Drain the coolant.
source of heat, to make it shrink and bond to the wire.
Coolant - Drain
4. Fix the cooling fan speed regulation resistor on the fan
2. Remove the front bumper.
shroud, fit 1 self-tapping screw and tighten it, fasten the
wire with straps and ensure that the location of the Front Bumper Remove
wire and its coiled pipe sheath has no interference with 3. Remove the cooling fan assembly.
blade or hidden danger for interference due to change.
Cooling Fan Assembly Remove
4. Disconnect the connector (2) of the relay.
Manual Service Disconnect Refit 5. Remove 2 bolts (1) fixing the relay to the radiator
6. After the replacement is completed, start the vehicle assembly.
to inspect the operation of fan, if there is no big buzzer
during the operation, the speed regulation condition
resumes.
6. Loosen the clamp (1), and disconnect the overflow pipe

assembly from the radiator assembly.
- drive motor to radiator from the radiator assembly.
8. Loosen the clamp, and disconnect the hose assembly

- radiator to electric water pump from the radiator
assembly.
1.0 53
9. Remove 2 screws fixing the upper radiator shock pad 13. Remove the radiator assembly.
to the front-end module. Refit
1. Fit the new upper and lower radiator shock pads to
the radiator assembly.
2. Align the condenser with and fit it into 4 clips of the
radiator and ensure that it is clamped in place.
3. Fix the radiator assembly to the front-end module.
4. Fix the upper radiator shock pad to the front-end
module, fit 2 screws and tighten them.
pump to the radiator assembly, and secure it with
clamps.
to the radiator assembly, and secure it with clamps.
10. Move the radiator assembly backwards, to disengage
the fixing point of radiator assembly from the front-end 7. Connect the overflow pipe assembly to the radiator
module. assembly, and secure it with clamps.
11. Disconnect 4 clips fixing the condenser to the radiator. 8. Fix the relay to the radiator assembly, fit 2 bolts, tighten
them to 5–7Nm, and check the torque.
9. Connect the connector of the relay.
10. Fit the cooling fan assembly.
Cooling Fan Assembly Refit

11. Fit the front bumper.
Front Bumper Remove

Coolant - Refill
12. Remove the upper and lower radiator shock pads (1)
and (2).
1.0 54
Radiator Drain Valve Radiator Airflow Deflector - Upper
Remove Remove
1. Drain the coolant. 1. Disconnect the negative battery cable.
Coolant - Drain 2. Remove the manual service disconnect.

2. Remove the radiator drain valve. Manual Service Disconnect Remove
3. Remove 4 clips fixing the radiator airflow deflector -
upper to the radiator and condenser.
Refit
1. Fit the radiator drain valve.
2. Refill the coolant. 4. Remove the radiator airflow deflector - upper.
Coolant - Refill Refit

1. Fix the radiator airflow deflector - upper to the
radiator and condenser, and secure it with clips.

1.0 55
Radiator Airflow Deflector - Lower Radiator Airflow Deflector - Left

Remove Remove
1. Remove the front bumper. 1. Remove the front bumper.
Front Bumper Remove Front Bumper Remove

2. Remove 5 clips fixing the radiator airflow deflector - 2. Remove 1 clip fixing the radiator airflow deflector - left
lower to the front-end module. to the front bumper beam.
3. Remove the radiator airflow deflector - lower. 3. Remove 2 clips fixing the radiator airflow deflector -
Refit left to the front-end module.
1. Fix the radiator airflow deflector - lower to the
front-end module, and secure it with clips.
Front Bumper Refit
4. Remove the radiator airflow deflector - left.

Refit
1. Fix the radiator airflow deflector - left to the front-end
module, and secure it with clips.
2. Fix the radiator airflow deflector - left to the front
bumper beam, and secure it with clips.
Front Bumper Refit
1.0 56
Radiator Airflow Deflector - Right
Remove
Front Bumper Remove

2. Remove 1 clip fixing the radiator airflow deflector -
right to the front bumper beam.
3. Remove 2 clips fixing the radiator airflow deflector -

right to the front-end module.
4. Remove the radiator airflow deflector - right.

Refit
1. Fix the radiator airflow deflector - right to the
front-end module, and secure it with clips.
2. Fix the radiator airflow deflector - right to the front
bumper beam, and secure it with clips.
Front Bumper Refit
1.0 57
1.0 58
Power Drive System Power and Control System
Power Drive System
Specifications
Torque
Description Value
Bolt-PEB to TM 26-34Nm
Bolt-BUS—BAR to TM 14–16Nm
Bolt-Drive motor to EDU 19–25Nm
Bolt-High Voltage Interlock Cover Plate to Casing 7-10Nm
Bolt-Motor Rear End Cover Plate to Casing 7-10Nm
Bolt-Water Pipe Joint to Casing 7-10Nm
1.0 59
Power and Control System Power Drive System
Service Procedures
Power Electronic Box
Remove
ESS, Electric Drive Transmission, PEB, EAC, HV harnesses,
OBC, DCDC, Charging sockets etc).
Warning: Prior to opening any high voltage circuits the

systems MUST be checked using a suitable multi meter
is essential that the correct 'make safe' procedure is 7. Remove electric drive transmission and suspension.
followed - see Manual Service Disconnect procedure Electric Drive Transmission and Suspension
in the Service Repair manual. After disconnecting the Remove
Manual Service Disconnect (MSD), always wait 5 minutes 8. Release the buckles and velcro straps, remove the
prior to commencing any checks for residual voltage etc. upper section of the motor acoustic package cover.
Warning: Any qualified personnel working on high voltage 9. Remove high voltage interlock cover plate.
systems or components MUST wear the correct insulated
High Voltage Interlock Cover Plate Remove
personal protective equipment (PPE). All PPE must be
regularly checked and tested for condition and integrity. 10. Remove 3 bolts fixing the PEB assembly to the inside
of motor.
Caution: When removing or servicing any parts of the
11. Remove 4 bolts (4) fixing the PEB assembly to the
high voltage system it is essential that no liquids enter,
drive motor.
contaminate or are spilled on components, harnesses or
connectors.
1. Carry out high voltage battery isolation procedure - see

Manual Service Disconnect - HV Battery Management
System.

Coolant Drain and Refill

3. Loosen the clamp, disconnect the water inlet/outlet
pipes, and move them away.
4. Clean the coolant inside PEB and drive motor. 12. Remove the PEB assembly and discard the seal ring.
5. Loosen the harness clip, and disconnect the connector 13. Remove the PEB dampers from PEB.
(1) from front compartment harness to PEB and
Refit
connector (2) from front compartment harness to
1. Refit the PEB dampers.
drive motor.
2. Refit the new seal rings.
6. Disconnect the PEB high voltage harness connector
(3). 3. Fit the PEB assembly to the drive motor, fit 4 bolts,
tighten them to 26-34Nm, check the torque.
4. Carry out a sealing test for water seal integrity
Water Seal Integrity Test
5. Fix the PEB assembly to the inside of motor, fit 3 bolts,
tighten them to 14–16Nm, check the torque.
6. In a pollution-free environment with the ambient
temperature of 15°C to 45°C and the ambient humidity
of RH ≤ 75%, use the high-voltage insulation testing
equipment to perform the following operations:
1.0 60
a. Visually check if the PEB and high voltage harnesses 12. Connect the connectors from front compartment
are intact and free of defects; verify that the PEB harness to PEB and drive motor, and secure them
grounding wire is properly fitted. with clips.
b. Connect the positive terminal (red lead) of the 13. Fit the water inlet/outlet pipes and secure them with
high-voltage insulation testing equipment to the clamps.
terminal of PEB harness connector, position 1, 2, 14. Refill the coolant.
and 3 (U, V, W; any one of the three connectors);
connect the negative terminal (black lead) of the
testing equipment to the grounding wire (position 15. Fit the manual service disconnect.
4) of the PEB housing. Manual Service Disconnect Refit
17. Fit the front compartment trim cover(If Fitted).
Front Compartment Trim Cover Refit(If Fitted)

18. Program and encode the PEB. Refer to Service
Programming & Configuration Self-learning Manual,
"PEB Replacement".
mode，
Note: If the vehicle will not enter READY mode ，
please disconnect and reconnect the 12V battery and
retry.
c. Start the testing equipment, maintain a testing voltage

of 1,000Vdc and wait for stable test values.
d. Record the stable test values R1, R2 and R3.
e. If the test value R ≥ 5MΩ, the test is passed.
Otherwise, the parts need to be retested or
repaired.
7. Fit the high voltage interlock cover plate.
High Voltage Interlock Cover Plate Refit
8. Fit motor acoustic package cover.
9. Fit the electric drive transmission and suspension.
Electric Drive Transmission and Suspension
Refit
10. Connect the PEB high voltage harness connector.
11. Fix the harness to the motor, and secure it with clips.
1.0 61
Drive motor Electric Drive Transmission Disassembling

Remove 6. Remove axle shaft oil seal.
Axle Shaft Oil Seal Remove
7. Remove high voltage interlock cover plate.
OBC, DCDC, Charging sockets etc). High Voltage Interlock Cover Plate Remove
Warning: Prior to opening any high voltage circuits the 8. Remove axle shaft connecting shaft.
systems MUST be checked using a suitable multi meter Axle Shaft Connecting Shaft Remove
9. Remove the drive motor.
is essential that the correct 'make safe' procedure is Refit
followed - see Manual Service Disconnect procedure Warning: Prior to the refitting of ESS, EDS, HV harnesses,
in the Service Repair manual. After disconnecting the EACP, CCU/OBC, charge sockets etc. It is essential
Manual Service Disconnect (MSD), always wait 5 minutes that the 12V battery is disconnected and manual service
prior to commencing any checks for residual voltage etc. disconnect device is removed.
Warning: Any qualified personnel working on high voltage 1. Fit the retarder to the drive motor.
systems or components MUST wear the correct insulated Electric Drive Transmission
personal protective equipment (PPE). All PPE must be Disassembling-refit
regularly checked and tested for condition and integrity. 2. Fit the bolts fixing the drive motor to the EDU, tighten
Caution: When removing or servicing any parts of the them to 19–25Nm, and check the torque.
high voltage system it is essential that no liquids enter, 3. Fit the PEBassembly.
Assembly Refit
connectors.
4. Refit axle shaft oil seal.
Manual Service Disconnect - HV Battery Management Axle Shaft Oil Seal Refit
System. 5. Refit high voltage interlock cover plate.
Manual Service Disconnect Remove High Voltage Interlock Cover Plate Refit
2. Remove the Electric Drive Transmission. 6. Refit axle shaft connecting shaft.
Electric Drive Transmission and Suspension Axle Shaft Connecting Shaft Refit
Remove 7. Fit the Electric Drive Transmission.
3. Remove the PEBassembly.
Assembly Remove Refit
4. Remove the bolts fixing the drive motor to the retarder 8. Carry out a sealing test for water seal integrity.
housing, and disconnect the drive motor from the
Water seal integrity test
retarder.
9. Carry out a sealing test of dry chamber.
Sealing test of dry chamber


12. Fit the front compartment trim cover(If Fitted).
Front Compartment Trim Cover Refit(If Fitted)
5. Disassemble the E-Axis。
1.0 62
High Voltage Interlock Cover Plate 7-10Nm, and check the torque.
Remove 2. Carry out a sealing test of dry chamber.
3. Fit motor acoustic package cover.
OBC, DCDC, Charging sockets etc). 4. Fit front right drive axle shaft assembly.
Warning: Prior to opening any high voltage circuits the Front Right Drive Axle Shaft Assembly Refit
systems MUST be checked using a suitable multi meter 5. Fit the bottom deflector.
is essential that the correct 'make safe' procedure is 6. Fit the manual service disconnect.
followed - see Manual Service Disconnect procedure Manual Service Disconnect Remove
in the Service Repair manual. After disconnecting the
Manual Service Disconnect (MSD), always wait 5 minutes
prior to commencing any checks for residual voltage etc.
Warning: Any qualified personnel working on high voltage

regularly checked and tested for condition and integrity.

connectors.

3. Remove front right drive axle shaft assembly.
Front Right Drive Axle Shaft Assembly Remove
4. Release the buckles and velcro straps, remove the
upper section of motor acoustic package cover.
5. Remove 5 bolts fixing the high voltage interlock cover
plate to the housing and discard the gaskets.
Refit
1. Fit 5 bolts and new gaskets fixing the high voltage
interlock cover plate to the housing, tighten them to
1.0 63
Motor Rear End Cover Plate

Remove

followed - see Manual Service Disconnect procedure
in the Service Repair manual. After disconnecting the 5. Remove and discard the axle shaft connecting shaft
Manual Service Disconnect (MSD), always wait 5 minutes O-ring.


connectors.

2. Remove 6 bolts fixing the motor rear end cover plate 6. Remove the electronic rotor shaft small oil seal fixing
to the housing and discard the gasket. to the motor rear end cover plate.
3. Remove the axle shaft oil seal. Refit

Axle Shaft Oil Seal Remove 1. Use special tool TPT00094to fit the electronic rotor
4. Remove the axle shaft bearing hole circlip and pull out shaft small oil seal fixing to the motor rear end cover.
the axle shaft connecting shaft.
1.0 64
Axle Shaft Connecting Shaft
Remove

2. Fit a new axle shaft connecting shaft O-ring. in the Service Repair manual. After disconnecting the
3. Fit the axle to the motor rear end cover plate. Manual Service Disconnect (MSD), always wait 5 minutes
4. Fit the axle shaft bearing hole circlip.
5. Fit the axle shaft oil seal. Warning: Any qualified personnel working on high voltage
Axle Shaft Oil Seal Refit personal protective equipment (PPE). All PPE must be
6. Fit 6 bolts and new shims fixing the motor rear end regularly checked and tested for condition and integrity.
cover to the housing, tighten them to 7-10Nm, and
check the torque.
7. Carry out a sealing test of dry chamber. contaminate or are spilled on components, harnesses or
Sealing test of dry chamber connectors.
1. Remove motor rear end cover plate.

Motor Rear End Cover Plate Remove
2. Remove and discard the axle shaft connecting shaft
O-ring.
3. Remove and discard the axle shaft bearing inner ring

circlip.
1.0 65
Axle Shaft Oil Seal

Remove

4. Remove the axle shaft supporting ball bearing. in the Service Repair manual. After disconnecting the


connectors.
Refit Manual Service Disconnect Remove
1. Fit the axle shaft supporting ball bearing. 2. Remove the front right axle shaft assembly.
2. Fit a new axle shaft bearing inner ring circlip. Front Right Drive Axle Shaft Assembly Remove
3. Fit a new axle shaft connecting shaft O-ring. 3. Release the buckles and velcro straps, remove the
4. Fit the axle shaft connecting shaft assembly to motor upper section of motor acoustic package cover.
rear end cover plate, and fit the motor rear end cover 4. Remove 6 bolts fixing the motor rear end cover plate
plate. to the housing and discard the gasket.
Motor Rear End Cover Plate Refit 5. Remove the axle shaft oil seal.
Refit
1. Fit the axle shaft oil seal with special toolTPT00302 .
1.0 66
Hose Fitting
Remove

2. Fit 6 bolts fixing the motor rear end cover plate to in the Service Repair manual. After disconnecting the
the housing and tighten to 7-10Nm，and check the Manual Service Disconnect (MSD), always wait 5 minutes
torque. prior to commencing any checks for residual voltage etc.
3. Refit motor acoustic package cover. Warning: Any qualified personnel working on high voltage
4. Fit the front right axle shaft assembly. systems or components MUST wear the correct insulated
Front Right Drive Axle Shaft Assembly Refit
5. Carry out a sealing test of dry chamber.
connectors.


3. Disconnect the hose from the pipe fitting.
4. Remove 2 bolts fixing the pipe fitting to the housing

and discard the O-rings.
1.0 67
Axle Shaft Sealing Test

Water Seal Integrity Test

Refit in the Service Repair manual. After disconnecting the
1. Fit 2 bolts and new O-rings fixing the pipe fitting to Manual Service Disconnect (MSD), always wait 5 minutes
the housing, tighten them to 7-10Nm, and check the prior to commencing any checks for residual voltage etc.
torque. Warning: Any qualified personnel working on high voltage
2. Connect the hose to the pipe fitting. systems or components MUST wear the correct insulated
3. Carry out a sealing test for water seal integrity. personal protective equipment (PPE). All PPE must be
Water seal integrity test
Refill - PEB Cooling contaminate or are spilled on components, harnesses or
5. Fit the manual service disconnect. connectors.
Manual Service Disconnect Refit 1. Remove the manual service disconnect.

6. Connect the negative battery cable. Manual Service Disconnect Remove
3. Disconnect the water inlet/outlet hoses fromPEB.
4. Disconnect the water inlet/outlet hoses from motor.
5. Fit the special toolTEL00075，TEL00034 &
T14001to pipe fitting of PEB and motor.
6. Charge the system pressure to 2bar（Absolute

pressure, the pressure gauge display is 1bar）,hold the
pressure for 10 seconds and test for 10 seconds. The
system integrity is OK if the system pressure drop less
than 100Pa. Repair the dew point and do the test until
1.0 68
pass the test. plug the other hole in the plate and the hole at retarder
7. Connect water inlet/outlet hoses to PEB. housing. Use hand pressure to hold these in position.
8. Connect water inlet/outlet hoses to motor.

Sealing Test of Dry Chamber

systems MUST be checked using a suitable multi meter 10. Operate the pressure tester to apply a pressure of 0.25
to ensure they carry no high voltage current. Where bar (25kPa). The pressure should be monitored over
there is need to work with the high voltage system 30 seconds, if the pressure drop is less than 80Pa then
is essential that the correct 'make safe' procedure is the integrity is acceptable. Carry out any necessary
followed - see Manual Service Disconnect procedure repairs until the test is successful.
in the Service Repair manual. After disconnecting the 11. Remove special tools.
12. Refit plugs to retarder housing and high voltage
interlock cover plate.
Warning: Any qualified personnel working on high voltage 13. Fit the manual service disconnect.
regularly checked and tested for condition and integrity. 14. Connect the negative battery cable.

connectors.
1. Switch off the vehicle power/ignition and wait 5 minutes

before proceeding.
Caution: Please wait 5 minutes after the vehicle power
system has been switched off to allow any power stored
within the PEB capacitors to have been discharged.

4. Remove high voltage interlock cover plate.
High Voltage Interlock Cover Plate Remove
5. Remove ventilation plug from the plate.
6. Refit high voltage interlock cover plate.
High Voltage Interlock Cover Plate Refit
7. Remove ventilation plug from the retarder housing.
8. Use the white plug in special toolTPT00301plug up
one hole in the plate.
9. Use special toolTPT00301，TEL00036 and T14001,
1.0 69
Special Tools Tool Description Picture

Tool Description Picture Number
Number
Kit-pressure
Wheel drive TPT00301
test connector
TPT00094 shaft seal
installer
Manual service
The EDS drive TEL00036
device plug
TPT00302 shaft seal
installer
TEL00075 Pipe connector
Cooling system
TEL00034
leak test tool
Cooling system
T14001
pressure test kit
1.0 70
HV Battery Pack and Charging System Power and Control System
HV Battery Pack and Charging System
Specifications
Torque
Description Value
Bolt-Energy storage system to body 55–65Nm
Bolt-Energy storage system grounding to body 7–10Nm
Nut-Battery negative cable to CCU 11–15Nm
Bolt-CCU to CCU bracket 19–25Nm
-
Bolt-Battery Heater to body 7–10Nm
Bolt-Battery Heater grounding wire to body 7–10Nm
Bolt-Fast charge to PDU 13–17Nm
Bolt-The PDU bracket to PDU 5–7Nm
Nut-charger grounding wire to body 7–10Nm
Bolt-Charging Port to bracket 7–10Nm
Bolt-Electric Vehicle Communication Controller to battery 7–10Nm
tray
1.0 71
Power and Control System HV Battery Pack and Charging System
Service Procedures
Manual Service Disconnect
Remove
1. Ensure the START/STOP switch is OFF, remove keys
from the vehicle and place in a secure location at least 2
metres from the vehicle and wait 5 mins before carrying
out next step.

Warning: ALWAYS ensure the correct PPE is worn when

working on, or with HV components.
2. Remove the front compartment trim cover side cover
Refit
plate. 1. Remove the special tool TEL00052 of cover from the
manual service disconnect base.
2. Fit the manual service disconnect and secure it with
4. Raise the vehicle on a lift.
clips.
3. Fix the manual service cover plate to the bottom
deflector, fit and tighten 1 screw.
5. Remove 1 screw fixing the manual service cover plate
4. Lower the vehicle.
to the bottom deflector, and remove the manual service
cover plate.
6. Fit the front compartment trim cover side cover plate.
6. Loosen the clips and remove the manual service

disconnect from the high voltage battery pack.
7. Fit the special tool TEL00052 to the manual service

disconnect base.
1.0 72
High-voltage Battery Pack
Remove
1. Carry out high voltage battery isolation procedure -
see Manual Service Disconnect.

2. Remove the bottom battery protection plate.
Bottom Battery Protection Plate Refit

3. Drain the ESS coolant.

4. Disconnect the low voltage harness connector (1) from
the high voltage battery pack.
14. Slowly lower the high voltage battery pack on the high
5. Disconnect the high voltage harness connector (2) voltage battery pack carrier and remove it from the
from the high voltage battery pack. lifting station.
6. Disconnect the cooling water hoses (3) from the high Warning: DO NOT attempt to move the HV battery pack
voltage battery pack. carrier when it is in an extended state.
Refit
2. Slowly raise the high voltage battery pack by using
special tool TEL00050 of high voltage battery pack
carrier, and adjust the carrier to the proper position
for refit of high voltage battery pack.
3. Continue to raise the high voltage battery pack carrier
until the mounting surface of the high voltage battery
pack comes into contact with the body mounting
surface.
7. Disconnect the low voltage harness connector from
the pressure switch of high voltage battery pack. Warning: DO NOT attempt to move the HV battery pack
carrier when it is in an extended state.
8. Use a multimeter (DCV, the range is greater than 400V)
to measure if there is high voltage between terminals 4. Fix the high voltage battery pack to the body, fit 18
of high-voltage battery pack high voltage connectors, bolts, tighten them to 55–65Nm, check the torque.
between the terminals and the ground and between 5. Lower the high voltage battery pack carrier and remove
terminals in high-voltage connectors at the high voltage it from the lifting station.
harness end. If the voltage is zero, continue removing. 6. Fix the high voltage battery pack to the body, fit 2 bolts,
9. Remove 1 nut fixing the high voltage battery pack tighten them to 55–65Nm, check the torque.
grounding wire to the body. 7. Fix the high voltage battery pack grounding wire to the
10. Remove 2 bolts (1) fixing the high voltage battery pack body, fit 1 nut, tighten it to 7–10Nm, check the torque.
to the body. 8. Connect harness connectors to the high voltage battery
11. Place special tool TEL00050 of high voltage battery pack.
pack carrier under the high voltage battery pack on 9. Connect the cooling water hoses to the high voltage
the lifting station, and adjust the carrier to the proper battery pack.
position.
10. Refill the ESS coolant.
12. Slowly raise the high voltage battery pack carrier till it
Coolant Refill-ESS
reaches the bottom of the high voltage battery pack.
13. Remove 18 bolts (2) fixing the high voltage battery
pack to the body. Manual Service Disconnect Refit
12. FIt the bottom battery protection plate.
1.0 73
Bottom Battery Protection Plate Refit Combined Charging Unit (CCU)

13. Connect the negative battery cable. Remove
14. Program and encode the battery management system 1. Carry out high voltage battery isolation procedure -
(BMS). Refer to Service Programming & Configuration see Manual Service Disconnect.
Self-learning Manual, "BMS section". Manual Service Disconnect Remove
3. Remove the combined charging unit - 7KW.
a. Disconnect the low voltage harness connector (1)
from the combined charging unit.
b. Disconnect the high voltage harness connector (2)
c. Loosen the retaining clamp, and disconnect the
combined charging unit water inlet and outlet hoses
(3).
d. Remove 1 bolt (4) fixing the harness to the combined
charging unit.
e. Remove the combined charging unit grounding bolt
(5).
f. Remove 4 bolts fixing the combined charging unit to

the bracket, remove the combined charging unit.
4. Remove the combined charging unit - 11KW.

a. Disconnect the low voltage harness connector (1)
1.0 74
b. Disconnect the high voltage harness connector (2) Battery Heater
from the combined charging unit. Remove
c. Loosen the retaining clamp, and disconnect the 1. Carry out high voltage battery isolation procedure -
combined charging unit water inlet and outlet hoses see Manual Service Disconnect.
(3). Manual Service Disconnect Remove
d. Remove 1 bolt (4) fixing the harness to the combined 2. Drain the coolant.
charging unit.
e. Remove 4 bolts (5) fixing the combined charging unit 3. Remove the bottom deflector.
to the bracket.
4. Loosen the retaining clamps, and disconnect the water
inlet and outlet hoses.
5. Disconnect the low voltage harness connector (1).
6. Disconnect the high voltage harness connector (2).
7. Remove the grounding nut (4) of the battery heater.
8. Remove 4 bolts (3) fixing the battery heater assembly
to the body, and remove the battery heater assembly.
f. Remove the grounding bolt of the combined charging

unit, and remove the combined charging unit.
Refit
1. Fit the combined charging unit grounding bolt, tighten
it to 11–15Nm, check the torque.
2. Fix the combined charging unit to the combined
charging unit bracket, fit 4 bolts, tighten them to
19–25Nm, check the torque.
3. Fix the harness to the combined charging unit, fit 1 Refit
bolt, tighten it to , check the torque 1. Fix the battery heater assembly to the body, fit 4 bolts,
4. Fit the combined charging unit water inlet and outlet tighten them to 7–10Nm, check the torque.
hoses, and tighten them with clamps. 2. Fit the battery heater ground harness, fit 1 nut, tighten
5. Connect the harness connector to the combined it to 7–10Nm, check the torque.
charging unit. 3. Connect the harness connector.
6. Refill the coolant. 4. Connect the water inlet and outlet hoses and secure
them with clamps.
Coolant Refill-ESS
9. Program and encode the combined charging unit. Refer Manual Service Disconnect Remove
to Service Programming & Configuration Self-learning 7. Fit the manual service disconnect.
Manual, CCU section.
1.0 75
Charging Port
Remove
1. Carry out high voltage battery isolation procedure -
see Manual Service Disconnect.

Front Bumper Remove

4. Remove 2 bolts (2) and 2 nuts (3) fixing the charging
port assembly to the body.
10. Loosen the harness clips and remove the charging port
assembly.
Refit
1. Arrange the charging port harness in the front
compartment, and secure it with clips.
2. Fix the charging port harness in the PDU, fit 2 bolts,
3. Fix the upper PDU cover to the PDU assembly, fit 8
bolts, tighten them to 5–7Nm, check the torque.
4. Fix the charging port grounding wire to the body, fit 1
5. Disconnect the high voltage harness connector (1) from nut, tighten it to 7–10Nm, check the torque.
the charging port to the combined charging unit.
5. Fit 2 bolts fixing the harness bracket to the front right
6. Remove 1 nut (3) fixing the charging port grounding longitudinal beam, tighten them to 7–10Nm, check the
wire to the body. torque.
7. Remove 2 bolts (2) fixing the harness bracket to the 6. Connect the high voltage harness connector to the
front right longitudinal beam. combined charging unit.
7. Fix the charging port assembly to the body, fit 2 bolts
and nuts, tighten them to 7–10Nm, and check the
torque.
8. Connect the low voltage harness connector to charging
port.
Front Bumper Refit


8. Remove 8 bolts fixing the upper PDU cover to the

PDU assembly, and remove the upper PDU cover.
9. Remove 2 bolts fixing the charging port harness in the
PDU, and pull the charging port harness out of the
PDU.
1.0 76
Electric Vehicle Communication Controller
(EVCC)
Remove
Front Bumper Remove
3. Disconnect the harness connector (1).
4. Remove 2 bolts (2) fixing the communication controller
assembly to the front left longitudinal beam, and remove
the communication controller assembly.
Refit
1. Fix the communication controller to the front left
longitudinal beam, fit 2 bolts, tighten them to 7–10Nm,
check the torque.
2. Connect the harness connector of the communication
controller.
4. Programme and encode the electric vehicle
communication controller. Refer to Service
Programming & Configuration Self-learning Manual,
EVCC section.
Front Bumper Refit
1.0 77
Special Tools
Tool Description Picture
Number
Cover,MSD
TEL00052
Connector
TEL00050 Trolley,ess
1.0 78
HV Battery Pack Subsystem Power and Control System
HV Battery Pack Subsystem
Specifications
Torque
Description Value
Bolt-EDM Module to End Plate of Tray 5–7Nm
Bolt-Upper Cover to Tray 6–7Nm
Nut-Upper Cover to Tray 55–65Nm
Bolt-BMS Module to BMS Module Bracket 5–7Nm
Bolt-BMS Module Bracket to Tray 7.5–9.5Nm
Bolt-BMS Module Bracket to Tray 11–13Nm
Bolt-Bus-bar Bracket to Tray 5.5–7.5Nm
Bolt-Bus-bar to Battery Module 7.5–9.5Nm
Nut-Bus-bar to EDM Module 7.5–9.5Nm
Bolt-CMU Module to Battery Module 5.5–7.5Nm
Bolt-Battery Module to Tray 11–13Nm
Bolt-EDM Module to Tray 5–7Nm
Bolt-Water Pipe Bracket to Tray 5.5–7.5Nm
Bolt-GND Harness to Tray 7.5–9.5Nm
Nut-Energy storage system grounding to body 7–10Nm
Bolt-Deflector to Tray 9–12Nm
Bolt-Explosion Proof Valve to Tray 5.5–7.5Nm
Bolt-Pressure Switch to Tray 5.5–7.5Nm
Bolt-Plate to Tray 5–6Nm
1.0 79
Power and Control System HV Battery Pack Subsystem
Service Procedures Warning: Prior to opening any high voltage circuits the
Precautions for High Voltage System systems MUST be checked using a suitable multi meter
Disassembly to ensure they carry no high voltage current. Where
Basic Requirements there is need to work with the high voltage system
Basic requirements for related precautions for high voltage in
vehicle are as follows:
• ALWAYS ensure the correct PPE is worn when working Manual Service Disconnect (MSD), always wait 5 minutes
on, or with HV components. prior to commencing any checks for residual voltage etc.
• Unrelated and non qualified persons must be prevented
from coming into contact with the vehicle during repair.
• DO NOT touch any components that carry the high contaminate or are spilled on components, harnesses or
voltage warning labels without the correct PPE or connectors.
training.
• If it is necessary to disassemble the relevant high-voltage
components, any personnel must have the correct high
voltage training and qualifications.
• When operating high-voltage components, the operator
must wear protective equipment and must also use
insulated gloves.
• When operating exposed high-voltage system
components, the operator must use a multimeter to
measure if there is high voltage, no operations should be
undertaken until the vehicle is made, and proven to be
safe and not subject to high voltage.
• Before carrying out any work on vehicles featuring
high voltage systems you must switch off the vehicle
power system/START/STOP Switch. If there is a need to
disassemble the high-voltage system, wait for 5 minutes
before proceeding.
• When disassembling or assembling electrical
components, the 12V power supply and the manual
service switch on the high-voltage battery pack must be
disconnected.
• After any removal and refitting of any high voltage
components it is necessary to ensure correct installation
and connection of all high-voltage components and
ensure their reliability before reconnecting the
high-voltage power.
• All high-voltage components MUST have a robust and
secure ground connection.
Warning: Only persons that hold the correct high voltage
training certificates and qualifications are allowed to work
on high voltage systems and components.

ESS, Electric Drive Transmission, PEB, PDU, EACP, PTC
units, HV harnesses, CCU, DCDC, Charging sockets etc).
1.0 80
General Description Battery pack voltage potential hazard danger: The battery
General pack may be fully charged before high voltage disassembling.
A warning must be given when reconnecting the battery pack,
This Service Manual is intended for use by professionals and
otherwise severe personal injury or even death may be caused.
qualified technicians. Without proper training or without
suitable tools, injuries may be caused during repair. At the Manual service switch hazard danger: PPE must be worn
same time, it may cause damage to the battery pack or cause before removing the manual service switch. This will prevent
the battery pack to malfunction. potential hazards that could result in severe personal injury
or even death.
The high-voltage battery pack powers the vehicle. The
high-voltage battery pack management system is designed to Maintenance area hazards: Before repairing the battery pack,
detect and adjust cell voltage, current and temperature to the maintenance area must be set up, otherwise severe
ensure safe operation of the battery and maximum battery personal injury or even death may be caused.
life.
Manual service switch warning: To avoid unintentional fitting
The battery pack is consisted of 6 battery modules. Each and the risk of electric shock, the manual service switch must
of them are equipped with CMU for managing cell balancing, be stored in a safe place, otherwise severe personal injury or
voltage, temperature and charging. even death may be caused.
Safety Information Fasteners caution: If improper fasteners are used, the battery
You must read "Safety Information" section before repairing pack may be damaged; all used high voltage fasteners and
the battery pack. In order to reduce the risk of injury, you module pack fasteners must be replaced. Be sure to use the
must pay attention to the danger reminder, warning reminder correct part number, failure to follow the instructions may
and caution reminder in the manual before repair. Safety cause damage to the battery pack.
information includes both personal protective equipment Battery pack lifting caution: The weight of the battery pack
(PPE) requirements and work area requirements. must be evenly distributed on the length of the battery jack.
This manual contains various “Danger”, “Warning” and The battery pack upper cover must be fitted before lifting
“Caution” reminders. You must be aware of such reminders the battery pack. Failure to follow the instructions may cause
to reduce the risk of personal injuries or even death caused damage to the battery pack.
by battery pack repair. Electrostatic discharge caution: Electrostatic discharge
This manual is intended for use by trained personnel. Without can damage components, therefore, great care will be
proper training or without suitable equipment and tools, required when handling all electronic components. Personal
personal injuries may be caused to you and others electrostatic discharge must be performed before repairing all
electronic components. Failure to follow the instructions may
The “Danger”, “Warning” and “Caution” reminders are not
cause damage to the battery pack.
exhaustive, and the potential risks of failure to follow the
instructions in this manual may not be warned. Personal Protective Equipment (PPE)
Battery pack high voltage danger: The maximum voltage of PPE is used to protect the safety and health of the operator.
the battery pack can reach about 417V (battery pack type 1) PPE includes insulated gloves (higher than 1000 volts), insulated
or 438V (battery pack type 2). To avoid severe personal injury, shoes (higher than 1000 volts), face masks or safety goggles.
a buffer zone must be set before repair.
Before commencing any work, check that all PPE is fitted and
PPE danger: The high-voltage battery pack includes a variety worn correctly; do not use PPE that has been damaged, and
of high voltage components. High voltage insulated gloves perform the following checks before and after use:
and face masks must be worn when performing any repairs,
• Check PPE for aging and damage
• Check insulated rubber gloves for scratches, holes and
Battery pack reconnection danger: Reconnecting the battery tears
pack may result in systems receiving full battery voltage. A
• Check insulated safety shoes for holes, damage, nails,
warning must be given when reconnecting the battery pack,
metal parts, wear, or other problems.
Safe Work Area
Battery pack voltage danger: The battery high voltage must
be isolated before performing any movement and installation It is very important to provide a safe and effective controlled
procedures on the battery pack high-voltage system, otherwise work area when disassembling and repairing the battery pack.
severe personal injury or even death may be caused.
1.0 81
• The work area must be indoors and protected against Battery Pack Integrity Tests
rain, snow, sand and other substances. Airtight Integrity Test Procedure
• The work area should be separated from other areas to 1. After any maintenance that has required the battery
avoid contamination, such as metal powder, oil or other pack to be opened it is imperative that an airtight
substances. If necessary, use a plastic curtain to cover integrity test is carried out.
the work area. 2. Move the high-voltage battery pack to the work area.
• The work area should be approximately the size of a car 3. Fit special tool TEL00064 to low voltage connector
to ensure efficient work. socket (5).
• The floor of the work area must be kept dry and 4. Fit special tool TEL00091 to main HV connector
ventilated and free from rain or snow. socket (3).
• The work area should be set up with relevant warning 5. Fit special tool TEL00092 against the vent value. Fit
signs. DO NOT enter the work area without permission. 2 bolts provided in the tool and tighten to 5–7Nm,
check the torque (4).
6. Connect the barometer of TEL00036 (2) to the
air pipe on TEL00063 (1), and connect the other
end of barometer to another air pipe of special tool
TEL00063
7. Fit special tool TEL00063 to MSD socket.
High Voltage Insulation Test

Test Procedure
1. Before and after the repair work, the high voltage
insulation test should be conducted.
2. Move the high-voltage battery pack to the work area.
8. Use 4 heavy objects (each object is less than 10 kg)
3. Remove the upper cover.
which have a flat contact surface and put them on the
Upper Cover Remove upper cover of the battery pack.
4. Remove insulation cotton if needed. 9. Start the sealing test, release the compressed air into
5. Disconnect the HV sampling harness connectors from the battery pack through the special tool TEL00063
the EDM module to BMS module. slowly until the air pressure reaches 4.6kPa, turn off
6. Remove the positive and negative pole cover from EDM the valve on the barometer when the pressure value is
module. stable, monitor the gauge for 5 minutes to make sure
the pressure drop is no more than 0.25kPa.
7. Connect the positive terminal of the test equipment to
one pole of the EDM module and connect the negative Cooling System Integrity Test Procedure
terminal to the tray of high voltage battery pack. 1. After any repair work involving the water pipes or tray
Conduct the insulation test, set the insulation meter at of the battery, the sealing test of cooling system need
500V, the insulation resistance value should be greater to be conducted.
than or equal to 100MΩ. 2. Move the high-voltage battery pack to the work area.
8. Repeat the above process again using another pole of 3. Connect special tool TEL00034 to the water inlet and
the EDM. outlet respectively and fix with clamps.
4. Connect the pump used in special tool T14001 to one
of special tool TEL00034.
5. Use the pump to pressurise the pipework to 200kPa,
maintain for 4 minutes to make sure the pressure drop
1.0 82
is no more than 0.33kPa. Upper Cover
Remove
1. Remove the high-voltage battery pack.
High-voltage Battery Pack Remove
3. Remove any debris, dirt or stains from the surface of
high-voltage battery pack with a dry soft cloth.
4. Remove 2 hanging point nuts (1) fixing the high-voltage
battery pack upper cover to the tray.
5. Remove 2 bolts and gaskets (3) fixing the high-voltage

battery pack upper cover to the tray.
6. Remove 83 bolts (2) fixing the high-voltage battery
pack upper cover to the tray.
7. Remove the upper cover and scrap 4 seal rings located

in 2 hanging points and both sides of the hanging points.
8. Conduct the high voltage insulation test. If the test
result is in spec, move to the next step. If the test result
is out of the spec, start the troubleshooting process
with the DTC manual.
High Voltage Insulation Test
Refit
1. Clean the mating surface of high-voltage battery pack
tray and upper cover.
2. Check the seal ring on the upper cover for damage.
If necessary use 3M SZ1000 sealant to repair the
damaged part. The recommended ambient temperature
for repair is 10℃ – 25℃.
1.0 83
a. Material and tool: 3M SZ1000, two-component foam Insulation Cotton - 50.3kWh

sealant, pneumatic dispenser (recommended model Remove
is DP400-85-01), static mixing pipe (more than 18 1. Remove the high-voltage battery pack.
sections recommended), PET release film.
b. Depending on the size of the repair area, cut the
head of the rubber mixing tube in steps to the
appropriate diameter. 3. Remove the upper cover.
c. Install the two-component sealant and mixing pipe. t00237440-EN.xml

Connect the pneumatic dispenser to a source of 4. Remove the insulation cotton (1) on the BMS module
compressed air. and insulation cottons (2) on battery module.
d. Before the formal repair, test the mixing status of the

foam until it is uniform.
e. Apply the foam into the area to be repaired.
f. Place PET release film over the foam, making sure

that the strippable surface is facing the foam. Due to
the high viscosity of the adhesive, in order to ensure
the seamless bonding between the new foam and
the originals, a certain pressure can be applied to
the new foam through PET release film.
g. Peel the PET release film from the new foam until
the surface of the new foam is dry (at 23℃ - 25℃, Refit
about 10 - 15 minutes). 1. Refit the insulation cotton on the BMS module or
h. Wait for the new foam to cure completely and repair battery modules.
is completed. 2. Refit upper cover.
Note: The height of the foam strip where repaired may be t00237439-EN.xml
higher than originals due to the expansion of the foam. This 3. Refit the high-voltage battery pack.
should not affect the overall sealing performance. If it is
necessary to obtain a repair surface with a gentle transition to High-voltage Battery Pack Refit
the originals, a small amount of layered filling is recommended.
3. Fit 4 new seal rings to the hanging point and the

mounting points on both sides.
4. Fit the upper cover. Fit 83 bolts, tighten to 6–7Nm
and check the torque.
5. Fit 2 bolts and gaskets, tighten to 6–7Nm and check
the torque.
6. Fit 2 hanging point nuts, tighten to 55–65Nm and
check the torque.
7. Conduct an airtight integrity test.
Airtight Integrity Test

8. Refit the high-voltage battery pack.
High-voltage Battery Pack Refit
1.0 84
Flame Trap - 69.9kWh BMS Module
Remove Remove
1. Remove the high-voltage battery pack. 1. Remove the high-voltage battery pack.
High-voltage Battery Pack Remove High-voltage Battery Pack Remove

2. Move the high-voltage battery pack to the work area. 2. Move the high-voltage battery pack to the work area.
3. Remove the BMS module bracket. 3. Remove the upper cover.
BMS Module Bracket Remove Upper Cover Remove

4. Remove the flame trap upon the battery modules. 4. Remove the insulation cotton.
5. Disconnect the connectors from BMS module.
6. Remove 4 bolts (1) fixing BMS module to BMS module
bracket.
Refit
1. Refit the flame trap upon the battery modules.
2. Refit the BMS module bracket.
7. Remove BMS module. Place the BMS module in
BMS Module Bracket Refit
antistatic plastic bag after removal from pack to prevent
3. Refit the high-voltage battery pack. electrostatic breakdown.
High-voltage Battery Pack Refit Refit
1. Refit the BMS module to BMS module bracket.
2. Refit 4 bolts, tighten to 5–7Nm and check the torque.
3. Connect the connectors to BMS module.
4. Refit the insulation cotton upon the BMS module.
5. Refit upper cover.
Upper Cover Refit


7. Programme and encode the BMS module, refer to the
"Service Programming & Configuration Self-learning
Manual" - "Battery Management System (BMS)".
1.0 85
BMS Module Bracket Wire Harness

Remove Remove
1. Remove the high-voltage battery pack. 1. Remove the high-voltage battery pack.
High-voltage Battery Pack Remove High-voltage Battery Pack Remove

2. Move the high-voltage battery pack to the work area. 2. Move the high-voltage battery pack to the work area.
3. Remove BMS module. 3. Remove insulation cotton and flame trap.
BMS Module Remove Flame Trap Remove

4. Remove the harness clips fixing on BMS module bracket. 4. Main low voltage harness remove.
5. Remove 2 bolts (1) fixing BMS module bracket to the a. Disconnect the connector (1) to EDM module,
tray. Remove 2 bolts (2) fixing BMS module bracket connectors (2) to BMS module and connector (3)
to the tray and scrap. to temperature sensor.
6. Remove BMS module bracket.

b. Disconnect the clips on the BMS module bracket.
Refit Remove the main low voltage harness.
1. Refit the BMS module bracket to the tray.
5. Relay power harness remove.
2. Refit 2 bolts to fix the bracket, tighten to 7.5–9.5Nm
and check the torque. a. Disconnect the connector (4) to BMS module and
connector (5) to EDM module.
3. Refit 2 new bolts to fix the bracket, tighten to
11–13Nm and check the torque.
4. Refit the harness clips.
5. Refit BMS module.
Refit BMS Module

b. Disconnect the clips on the BMS module bracket.

Remove the relay power harness.
6. High voltage sampling harness remove.
a. Disconnect the connector (6) to BMS module and

connector (7) to EDM module.
1.0 86
b. Disconnect the clips on the BMS module bracket. b. Disconnect the clip or tie on the harness. Remove
Remove the high voltage sampling harness. the module sampling harness.
7. Communication harness remove 1. Refit
a. Disconnect the connector (8) to CMU module and 1. Module sampling harness refit.
connector (9) to BMS module. a. Connect the connectors at harness end to the CMU
module and battery module.
b. Use a new harness clip and secure the harness.
2. Communication harness refit 1.
a. Connect the connectors at harness end to the BMS

module and CMU module.
b. Use a new harness clip or tie and secure the harness.
3. Communication harness refit 2.
a. Connect the connectors at harness end to the both

CMU modules.
b. Disconnect the clips on the BMS module bracket. b. Use a new harness clip or tie and secure the harness.
Remove the communication harness.
4. High voltage sampling harness refit.
8. Communication harness remove 2.
a. Disconnect the connector (10) to CMU module and module and EDM module.
connector (11) to another CMU module.
5. Relay power harness refit.

module and EDM module.
6. Main low voltage harness refit.

module, EDM module and temperature sensor.
b. Disconnect the clip or tie on the harness. Remove 7. Refit flame trap and insulation cotton.
the communication harness. Flame Trap Refit
9. Module sampling harness remove. 8. Refit the high-voltage battery pack.
a. Disconnect the connector (12) to battery module High-voltage Battery Pack Refit
and connector (13) to CMU module .
1.0 87
Bus-bar
Remove
1. Remove the high-voltage battery pack.

3. Remove the all wire harnesses.
Wire Harness Remove

4. If the bus-bar is under BMS module bracket, remove
the BMS module bracket first.
BMS Module Bracket Remove b. Remove bus-bar.

5. Remove the cover on the mounting pole of the bus-bar.
8. Bus-bar remove-battery module to EDM module.
a. Remove 1 bolt (3) fixing the bus-bar to battery
module and 1 nut (4) fixing the bus-bar to EDM
module.
6. Bus-bar remove-battery module.
a. Remove 2 bolts (1) fixing the bus-bar to battery

module.
b. Remove 1 bolt (5) fixing the bus-bar bracket to tray.
b. Remove bus-bar.
c. Remove bus-bar and bus-bar bracket assembly. And
7. Bus-bar remove-module to module of battery. then remove the bus-bar from bracket.
a. Remove 2 bolts (2) fixing the bus-bar to battery 9. Refit the cover on the pole of the battery module.
modules. Refit
1. Clean up both ends of bus-bar.
2. Remove the cover from pole of battery module.
3. Bus-bar refit-battery module to EDM module.
a. Refit the bus-bar to bus-bar bracket.
b. Refit 1 bolt and fixing the bracket on tray, tighten to
5.5–7.5Nm and check the torque.
1.0 88
c. Refit 1 bolt and fixing the bus-bar to battery module, CMU Module
tighten to 7.5–9.5Nm and check the torque. Remove
d. Refit 1 nut and fixing the bus-bar to EDM module, 1. Remove the high-voltage battery pack.
tighten to 7.5–9.5Nm and check the torque. High-voltage Battery Pack Remove
4. Bus-bar refit-module to module of battery. 2. Move the high-voltage battery pack to the work area.
a. Refit the bus-bar to battery modules. 3. Remove the bus-bar upon the CMU module.
b. Refit 2 bolts and fixing the bus-bar to battery module, Bus-bar Remove
tighten to 7.5–9.5Nm and check the torque. 4. Remove 2 bolts (1) fixing CMU module on the battery
5. Bus-bar refit- battery module. module.
a. Refit the bus-bar to battery module.
b. Refit 2 bolts and fixing the bus-bar to battery module,

tighten to 7.5–9.5Nm and check the torque.
6. Refit the cover on pole of battery module.

7. If the bus—bar is under BMS module bracket, refit BMS
module bracket.
BMS Module Bracket Refit

8. Refit wire harnesses.
Wire Harness Refit

5. Remove CMU module.
Refit
1. Refit the CMU module to battery module.
2. Refit 2 bolts, tighten to 5.5–7.5Nm and check the
torque.
3. Refit bus-bar.
Bus-bar Refit
1.0 89
Battery Module surface.

Remove 2. Apply the thermal conductive adhesive evenly on the
1. Remove the high-voltage battery pack. surface of the tray according to the track shown in the
figure below. Recommend to use the pneumatic glue
gun with model DP400-85-01.
3. If the module pack is under BMS module bracket,
remove BMS module bracket.
BMS Module Bracket Remove
4. Remove the bus-bars from the battery module.
Bus-bar Remove
5. Remove the CMU module from battery module.
CMU Module Remove
6. Remove 8 bolts (1) fixing the battery module and
discard.
3. If a new module is to be fitted, it is necessary to charge

the new module to the same voltage level of other
modules in the battery pack first before refit.
4. Refit the battery module using special tool TEL00093
to the tray.
5. Refit 8 new bolts, tighten to 11–13Nm and check the
torque.
6. Refit CMU module.
CMU Module Refit

7. Refit bus-bars to battery module.
7. Use the hook on the special tool TEL00093 to hook
the hole on the left side of the battery module, use the Bus-bar Refit
lifting tool to lift the special tool TEL00093 slowly. 8. If the battery module is under BMS module bracket,
After the module is raised for a certain distance (about refit BMS module bracket.
5cm), press the tray down on both sides of the lifting BMS Module Bracket Refit
side of the battery module (operated by two people).
After one side of the battery module is separated from
the tray, remove the lifting tool. And then use special High-voltage Battery Pack Refit
tool TEL00093 to hook the two sides of the battery
module and lift it up (operated by two people), remove
the battery module and place it in a safe area.
Refit
1. Clean the tray surface and battery module bottom
1.0 90
EDM Module EDM module.
Remove 3. Refit 3 new vent values if the EDM module is a new one.
1. Remove the high-voltage battery pack. 4. Refit EDM module in the tray.
High-voltage Battery Pack Remove 5. Refit 13 bolts, tighten to 5–7Nm and check the torque.
2. Move the high-voltage battery pack to the work area. 6. Refit 4 bolts, tighten to 5–7Nm and check the torque.
3. Remove the wire harness between BMS module and 7. Connect cooling water pipe to water pipe fitting.
EDM module. 8. Refit temperature sensor.
Wire Harness Remove Temperature Sensor Refit
4. Remove BMS module bracket. 9. Refit the bus-bar between EDM module and battery
BMS Module Bracket Remove module.
5. Remove the bus-bar between EDM module and battery Bus-bar Refit
module. 10. Refit BMS module bracket.
Bus-bar Remove BMS Module Bracket Refit
6. Remove temperature sensor. 11. Refit wire harness between BMS module and EDM
Temperature Sensor Remove module.
7. Disconnect the cooling water pipe from water pipe Wire Harness Refit
fitting. 12. Refit the high-voltage battery pack.
8. Remove 4 bolts (1) fixing the EDM module to the tray.
9. Remove 13 bolts (2) fixing the EDM module to the

tray front end.
10. Remove the EDM module and scrap the seal ring.
Refit
1. Clean the contact surface of both EDM module and
front end of tray.
2. Refit the new seal ring to the contact surface of the
1.0 91
Vent Value Cooling Water Pipe

Remove Remove
1. Lift the vehicle. 1. Remove the high-voltage battery pack.
Vehicle Lifting High-voltage Battery Pack Remove

2. Remove the bottom deflector. 2. Move the high-voltage battery pack to the work area.
3. Drain the coolant from the battery pack. Use
compressed air (low pressure) to apply pressure to
3. Clean the vent valve and surrounding area.
the cooling pipe from the water inlet to blow out the
4. Remove the vent valve with tool and scrap. residual coolant in the pipeline. When there is no
coolant discharged from the water outlet, proceed to
the next operation.
4. Remove the wire harness fixed on the water pipe.
Wire Harness Remove
5. Water Inlet Pipe Remove
a. Disconnect the inlet water pipe from the water pipe
connection (1) on the EDM module.
b. Disconnect the cooling water pipe from cold plate
junction (2).
Refit
1. Clean the mounting surface of vent valve on the EDM
module.
2. Refit new vent value.
3. Refit bottom deflector.

c. Remove the water inlet pipe from bracket.

6. Water Outlet Pipe Remove
a. Disconnect the outlet water pipe from the water
pipe connection (3) on the EDM module.
b. Disconnect the cooling water pipe from cold plate
junction (4).
c. Remove the water outlet pipe from bracket.

7. Remove 1 bolt fixing the water pipe bracket to the tray.
1.0 92
Remove the water pipe bracket. Temperature Sensor
Refit Remove
1. Refit the water pipe bracket to the tray. Refit 1 bolt, 1. Remove the high-voltage battery pack.
tighten to 5.5–7.5Nm and check the torque. High-voltage Battery Pack Remove
2. Water outlet pipe refit. 2. Move the high-voltage battery pack to the work area.
a. Refit the water outlet pipe to pipe bracket. 3. Remove the insulation cotton.
b. Connect the water pipe and cold plate junction and 4. Disconnect the connector from main low voltage
make sure the junction is locked. harness.
c. Connect the water pipe and water pipe connection 5. Remove the temperature sensor from water pipe
on the EDM module and make sure the junction is connection.
locked.
3. Water inlet pipe refit.
a. Refit the water inlet pipe to pipe bracket.

b. Connect the water pipe and cold plate junction and
make sure the junction is locked.
c. Connect the water pipe and water pipe connection

on the EDM module and make sure the junction is
locked.
4. Refit the wire harness to the water pipe.
Wire Harness Refit Refit
5. Conduct the cooling system integrity test. 1. Refit the temperature sensor to the water pipe
connection.
Cooling System Integrity Test
2. Connect the temperature sensor to the main low
6. Refit the high-voltage battery pack. voltage harness.
High-voltage Battery Pack Refit 3. Refit insulation cotton.
1.0 93
Tray GND Harness

Remove Remove
1. Remove the high-voltage battery pack. 1. Lift the vehicle.
High-voltage Battery Pack Remove Vehicle Lifting

2. Move the high-voltage battery pack to the work area. 2. Remove the bottom deflector.
3. Remove battery module. Bottom Deflector Remove
Battery Module Remove 3. Remove 1 nut fixing the GND harness to body.
4. Remove temperature sensor. 4. Remove 1 bolt (1) fixing the GND harness to battery
pack.
Temperature Sensor Remove
5. Remove EDM module.
EDM Module Remove

6. Remove water pipes.
Water Pipe Remove

7. Remove baffle.
Baffle Remove
8. Remove tray of battery pack.
Refit
1. Clean the surface of cold plate.
5. Remove GND harness.
2. Refit baffle.
Refit
Baffle Refit
1. Refit the GND harness to battery pack.
3. Refit water pipes.
2. Refit 1 bolt, tighten to 7.5–9.5Nm and check the
Water Pipe Refit torque.
4. Refit EDM module. 3. Refit 1 nut, fixing the harness to body, tighten to
EDM Module Refit 7–10Nm and check the torque.
5. Refit temperature sensor. 4. Refit bottom deflector.
Temperature Sensor Refit Bottom Deflector Refit
6. Refit battery module. 5. Lower the vehicle.
Battery Module Refit

1.0 94
Deflector Explosion Proof Value - 69.9kWh
Remove Remove
1. Lift the vehicle. 1. Lift the vehicle.
Vehicle Lifting Vehicle Lifting

2. Remove 26 bolts (1) fixing the bottom deflector to the 2. Remove the bottom deflector if the explosion proof
battery pack. valve is at the back end of the battery.

3. Clean the explosion proof valve and surrounding area.
4. Remove 4 bolts fixing explosion proof valve to the tray.
3. Remove the deflector from the high-voltage battery

pack.
Refit
1. Clean the bottom surface of high-voltage battery pack.
5. Remove the explosion proof valve.
2. Apply the glue evenly to the specified positions on the
Refit
deflector (as shown in the figure below).
1. Clean the mounting surface of explosion proof valve
on the tray.
2. Refit the explosion proof valve to the tray.
3. Refit 4 bolts, tighten to 5.5–7.5Nm, check the torque.
4. Refit the bottom deflector if the explosion proof valve
is at the back end of the battery.

3. Refit the deflector to the bottom of battery pack within

10 minutes after applying the glue.
4. Refit 26 bolts, tighten to 9–12Nm and check the
torque.
1.0 95
Pressure Switch - 69.9kWh Baffle - 69.9kWh

Remove Remove
1. Lift the vehicle. 1. Remove the high-voltage battery pack.
Vehicle Lifting High-voltage Battery Pack Remove

2. Clean the pressure switch and surrounding area. 2. Move the high-voltage battery pack to the work area.
3. Remove 2 bolts fixing the pressure switch to the tray. 3. Remove the battery module beside the baffle.
Battery Module Remove

4. Remove 2 bolts (1) fixing the baffle to the tray.
4. Remove the pressure switch.

Refit
1. Clean the mounting surface of pressure switch to the 5. Remove the baffle.
tray.
Refit
2. Refit the pressure switch to the tray.
1. Refit the baffle to the tray.
3. Refit 2 bolts, tighten to 5.5–7.5Nm, check the torque.
2. Refit 2 bolts, tighten to 5–6Nm, check the torque.
3. Refit battery module.
Battery Module Refit
1.0 96
Number
Cooling system
Low voltage TEL00034
leak test tool
TEL00064 connector
plug 2
Main high Cooling system

T14001
voltage pressure test kit
TEL00091
connector 4-3
pin
Battery module
Pressure relief TEL00093 extraction
TEL00092 tool-3
valve plug 6
Manual service
TEL00036
device plug
MSD plug-low
TEL00063
voltage
1.0 97
Power and Control System Vehicle Control Unit
Vehicle Control Unit

Specifications
Torque
Description Value
Bolt-VCU to VCU bracket 7–10Nm
1.0 98
Vehicle Control Unit Power and Control System
Service Procedures
Vehicle Control Unit
Remove
2. Disconnect the harness connector (1) of the vehicle
control unit.
3. Remove 4 bolts (2) fixing the vehicle control unit to the
bracket, and remove the vehicle control unit.
Refit
1. Connect the harness connector of the vehicle control
unit.
3. Program and encode the vehicle control unit (VCU).
Refer to Service Programming & Configuration
Self-learning Manual, "VCU Replacement".
4. Fix the vehicle control unit to the bracket, fit 4 bolts,
1.0 99
1.0 100
Shift Lock Control Transmission
Shift Lock Control
Specifications
Torque
Description Value
Bolt-Electronic Shift Gear to Centre Console 3-7Nm
1.0 101
Transmission Shift Lock Control
Service Procedures
Electronic Shifter
Remove
1. Remove the centre console upper trim panel.
Centre Console Upper Trim Panel Remove

2. Remove the wireless charging module.
Wireless Charging Module Remove

3. Remove the centre console assembly.
Centre Console Assembly Remove
4. Remove the right armrest outer trim panel.
6. Remove 2 screws fixing the left armrest to the center
console.
5. Remove 3 screws fixing the right armrest to the center

console.
7. Remove 1 screw fixing the front storage box to the
center console.
8. Remove 4 screws fixing the electronic shifter to the

centre console.
1.0 102
Shift Lock Control Transmission
9. Disconnect the harness from the electronic shifter.
Refit
1. Connect the harness to the electronic shifter.
2. Fit 4 screws fixing the electronic shifter to the centre
console, tighten them to 3-7Nm, and check the torque.
3. Tighten 1 screw fixing the front storage box to the
center console.
4. Tighten 2 screws fixing the left armrest to the center
console.
5. Tighten 3 screws fixing the right armrest to the center
console.
6. Fit the right armrest outer trim panel.
7. Fit the centre console assembly.
Centre Console Assembly Refit

8. Fit the wireless charging module.
Wireless Charging Module Refit

9. Fit the centre console upper trim panel.
Centre Console Upper Trim Panel Refit

10. Program and encode the electronic shifter. Refer to
Module Self-learning and Programming Manual, “Shifter
Control Unit (SCU)”.
1.0 103
Transmission Electrical Drive System
Electrical Drive System

Specifications
Torque
Description Value
Bolt-Drain Plug 25-35Nm
Bolt-Filler Plug 30-40Nm
Bolt-Mount Bracket to Subframe 90-110Nm
Bolt-Rear Mount to EDU （63-77）Nm+（85-95）°
Bolt-Transmission Mount to EDU （63-77）Nm+（85-95）°
Bolt-Driving Motor Mount to EDU （63-77）Nm+（85-95）°
Bolt-Rear Mount to Mount Bracket （81-99）Nm+（85-95）°
Bolt-Transmission Mount to Subframe （81-99）Nm+（85-95）°
Bolt-Driving Motor Mount to Subframe （81-99）Nm+（85-95）°
Bolt-Electric Drive Transmission Upper Insulator to Casing 5-7Nm
Bolt-Bearing Support Plate to Casing 26-34Nm
Bolt-Park Brake Assembly to Casing 50Nm+90°
Bolt-Reducer Casing to Driving Casing 26-34Nm
Screw-Front Bearing Of Intermediate Shaft to Intermediate 65-75Nm
Shaft
Bolt-Electrical Park Module to Reducer 7-10Nm
Bolt-Electrical Park Motor Control Unit to Body 7-10Nm
1.0 104
Electrical Drive System Transmission
Service Procedures Electric Drive Transmission and Suspension
Oil - Drain and Refill Remove
Drain and Refill 1. Remove the compressor bracket.
1. Raise the vehicle on a lift. Compressor Bracket Remove
2. Remove the bottom deflector. 2. Remove 2 bolts fixing the electric drive transmission
Bottom Deflector Remove lower insulator to the electric drive transmission,
3. Place a suitable container under the electric drive separate the buckles with the upper insulator, and
transmission. remove the lower insulator.
4. Clean the area around the oil filler plug, remove the oil 3. Remove subframe and electric drive transmission.
filler plug and discard the seal gasket (1). Subframe Remove
5. Clean the area around the drain plug, remove the drain 4. Lift the electric drive transmission through the lifting
plug and discard the seal gasket (2). point.
6. Drain the transmission oil.

7. Clean the filler and the drain plug.
8. Place a new seal gasket on the drain plug, fit the drain
plug, tighten it to 25-35Nm, and check the torque.
9. Add transmission oil through the oil filler, the capacity
is:
·Drain and Refill 0.8±0.05L
·Fill from Dry State 0.9±0.05L
10. Place a seal gasket on the oil filler plug, fit the oil filler
plug, tighten it to 30-40Nm, and check the torque.
5. Remove and discard 3 bolts (1) fixing the transmission
Bottom Deflector Refit mount to the electric drive transmission.
12. Lower the vehicle. 6. Remove and discard 1 bolt (2) fixing the transmission
mount to the subframe.
1.0 105
7. Remove and discard 3 bolts (1) fixing the motor mount Refit
to the electric drive transmission. 1. Fit 4 bolts fixing the rear mount to the subframe,
8. Remove and discard 1 bolt (2) fixing the motor mount tighten them to 90-110Nm, and check the torque.
to the subframe. 2. Fit 4 new bolts fixing the rear mount bracket to the
electric drive transmission, tighten them to （ 63-77））
Nm+（（85-95））°, and check the torque.
3. Fit 3 new bolts fixing the transmission mount to the
electric drive transmission, tighten them to （ 63-77））
Nm+（（85-95））°, and check the torque.
4. Fit 3 new bolts fixing the motor mount to the electric
drive transmission, tighten them to （ 63-77））Nm+
（ 85-95））°, and check the torque.
5. Lift the electric drive transmission and slowly position
it to the subframe.
6. Fit 1 new bolt fixing the rear mount to the mount
bracket with 1 washer, tighten it to （81-99））Nm+
9. Remove and discard 4 bolts (1) fixing the rear mount （ 85-95））°, and check the torque.
bracket to the electric drive transmission.
7. Ensure that the pad of transmission mount is in right
10. Remove 1 bolt (2) and washer (3) fixing the rear mount position before fixing.
to the rear mount bracket, and discard the bolt.
8. Fit 1 new bolt fixing the transmission mount to the

11. Remove the electric drive transmission assembly slowly. subframe, tighten it to （ 81-99））Nm+（（85-95））°,
12. Remove 4 bolts fixing the rear mount to the subframe. and check the torque.
9. Ensure that the pad of motor mount is in right position
before fixing.
1.0 106
Differential Oil Seal - Left
Remove

2. Remove the front left axle shaft assembly.
Front Left Axle Shaft Assembly Remove
3. Remove the left differential oil seal and discard it.
10. Fit 1 new bolt fixing the motor mount to the subframe,
tighten it to （ 81-99））Nm+（（85-95））°, and check
the torque.
11. Fit the subframe and the electric drive transmission.
Subframe Mounting
12. Fit 2 bolts fixing the electric drive transmission lower
insulator to the electric drive transmission casing,
tighten them to 5-7Nm, and check the torque. Fasten
the buckles fixed with the upper insulator. Refit
13. Fit the compressor bracket. 1. Fit a new left differential oil seal with special tool
TPT00236.
Compressor Bracket Refit
14. Program, encode and perform a self-learning for the
power electronic box PEB and drive motor. Refer to
Module Self-learning and Programming Manual, “Power
Electronic Box (PEB)”.
15. Electrical Park Position Learning. Refer to Module
Self-learning and Programming Manual - “Vehicle
Control Unit (VCU)”.
2. Fit the front left axle shaft assembly.
Front Left Axle Shaft Assembly Refit

1.0 107
Electric Drive Transmission Disassembling

Remove
1. Remove electric drive transmission and suspension.

Remove
2. Remove the electrical park module.
Electrical Park Module Remove

3. Remove the electric drive transmission upper insulator.
4. Remove the differential oil seal - left and discard it.
Differential Oil Seal - Left Remove

5. Remove and discard the vent plug.
7. Remove the differential assembly.
6. Remove 16 bolts fixing retarder housing to drive motor

8. Remove 7 bolts fixing the bearing support plate to the
housing to separate the housings.
drive motor housing.
9. Remove the intermediate shaft assembly.

10. Remove and discard 4 bolts fixing the park brake
assembly to the retarder housing.
1.0 108
11. Remove and discard the differential cone bearing outer 14. Remove the intermediate shaft oil nozzle.
ring.
15. Remove and discard the differential cone bearing outer

12. Remove and discard the differential cone bearing outer ring fixing to the bearing support plate.
ring gasket.
Refit
13. Remove and discard the intermediate shaft bearing 1. Use special tools to TPT00128 fit the new differential
adjusting gasket. cone bearing outer ring to the bearing support plate.
1.0 109
8. Measure the distance Y2 from housing and case junction

surface to intermediate shaft bearing.
2. Fit the intermediate shaft assembly.

3. Fit 7 bolts fixing the bearing support plate to the drive
motor housing in the sequence as shown in the figure, Differential bearing adjusting shim selection requirement,
tighten them to 26-34Nm, and check the torque. interference: 0.1-0.15mm
Measure the clearance ( X
) (base surface of housing Shim thickness (mm)
shaft to bearing outer ring)
X=1.05 1.15
1.05＜X≤1.1 1.2
1.1＜X≤1.15 1.25
1.15＜X≤1.2 1.3
1.2＜X≤1.25 1.35
1.25＜X≤1.3 1.4
1.3＜X≤1.35 1.45
4. Fit the differential assembly, and place the cone bearing 1.35＜X≤1.4 1.5
outer ring to the differential. 1.4＜X≤1.45 1.55
5. Measure the distance X1 from housing and case 1.45＜X≤1.5 1.6
junction surface to differential cone bearing hole.
1.5＜X≤1.55 1.65
6. Measure the distance X2 from housing and case
junction surface to intermediate shaft bearing hole. 1.55＜X≤1.6 1.7
1.6＜X≤1.65 1.75
1.65＜X≤1.7 1.8
1.7＜X≤1.75 1.85
1.75＜X≤1.8 1.90
Intermediate shaft bearing adjusting shim selection

requirement, interference: 0-0.05mm
Measure the clearance ( X
) (base surface of housing Shim thickness (mm)
shaft to bearing outer ring)
1.4≤X＜1.45 1.45
7. Measure the distance Y1 from housing and case junction 1.45≤X＜1.5 1.5
surface to differential cone bearing. 1.5≤X＜1.55 1.55
1.0 110
1.55≤X＜1.6 1.6
1.6≤X＜1.65 1.65
1.65≤X＜1.7 1.7
1.7≤X＜1.75 1.75
1.75≤X＜1.8 1.8
1.8≤X＜1.85 1.85
1.85≤X＜1.9 1.9
1.9≤X＜1.95 1.95
1.95≤X＜2 2
2≤X＜2.05 2.05
15. Fit 16 bolts fixing the retarder housing to the drive
2.05≤X＜2.1 2.1 motor housing in the sequence as shown in the figure,
2.1≤X＜2.15 2.15 tighten them to 26-34Nm, and check the torque.
2.15≤X＜2.2 2.2
2.2≤X＜2.24 2.25
9. Fit differential bearing adjusting gasket.

10. Use special tools to TPT00128 fit the new differential
cone bearing outer ring to the housing.
16. Fit the new vent plug.

17. Fit the new differential oil seal - left.
Differential Oil Seal - Left Refit

18. Fit the electric drive transmission upper insulator.
19. Fit the electrical park module assembly.
11. Fit the intermediate shaft oil nozzle. Electrical Park Module Refit
12. Fit the intermediate shaft bearing adjusting gasket. 20. Fit electric drive transmission and suspension.
13. Fit 4 new bolts fixing the park brake assembly to the Electric Drive Transmission and Suspension
retarder housing, tighten them to 50Nm+90°, and Refit
check the torque.
14. Apply sealant to the motor side housing.
1.0 111
Intermediate Shaft Assembly Refit

Remove 1. Fit the spacer bushing.
1. Disassemble the electric drive transmission. 2. Fit a new intermediate shaft front bearing with special
Electric Drive Transmission Disassembling tool T34019.
2. Remove and discard 1 screw (2) fixing intermediate
shaft front bearing to intermediate shaft.
3. Remove and discard intermediate shaft front bearing
(1).
3. Fit 1 lock screw fixing the intermediate shaft front

bearing to intermediate shaft, tighten it to 65-75Nm,
4. Fit a new intermediate shaft rear bearing with special
tool T34003.
4. Remove the spacer bushing.
5. Fit 2 new oil pipe O-rings to the new oil pipe, and fit the
5. Remove and discard intermediate shaft rear bearing (1).
intermediate shaft oil pipe. (Knock in from left to right)
6. Remove and discard intermediate shaft oil pipe (2) and
6. Assemble the electric drive transmission.
2 O-rings on it. (Knock out from right to left)
Electric Drive Transmission Disassembling and
Refit
1.0 112
Differential Assembly special tool T24009.
Remove
1. Disassemble the electric drive transmission.
Electric Drive Transmission Disassembling
2. Remove and discard the differential front cone bearing
inner ring.
3. Assemble the electric drive transmission.
Electric Drive Transmission Disassembling and

Refit
3. Remove and discard the differential rear cone bearing

inner ring.
Refit
1. Fit a new differential rear cone bearing inner ring with
special tool T24009.
2. Fit a new differential front cone bearing inner ring with
1.0 113
Electrical Park Module Refit

Remove 1. it a new gear shift shaft oil seal with special tool
1. Disconnect the negative battery cable. TPT00140.
Manual Service Disconnect - HV Battery Management
System
3. Disconnect the harness from the electrical park
module.
2. Fit the connecting shaft sleeve.

3. Fit 3 bolts fixing the electrical park module to the
housing, tighten them to 7-10Nm, and check the
torque.
4. Connect the harness to the electrical park module.
4. Remove 3 bolts fixing the electrical park module to the 5. Fit the manual service disconnect.
housing, and remove the electrical park module.
5. Remove the connecting shaft sleeve (1).

6. Remove and discard the gear shift shaft oil seal (2).
1.0 114
P Gear Unlocking Electrical Park Motor Control Unit
1. After electrical park position learning, the vehicle will Remove
be placed in non-P gear, i.e. P Gear Unlocking. Refer 1. Disconnect the negative battery cable.
to Module Self-learning and Programming Manual - 2. Carry out high voltage battery isolation procedure - see
“Vehicle Control Unit (VCU)”. Manual Service Disconnect - HV Battery Management
After the vehicle starts: if EPB function is abnormal and System
SCU P gear command is received, the parking mechanism Manual Service Disconnect Remove
of electric drive transmission will enter P gear again; if the
3. Disconnect the harness (1) from the electrical park
EPB function is normal, the parking mechanism of the electric
motor control unit.
drive transmission will return to the non-P gear.
4. Remove 2 bolts (2) fixing the electrical park motor
control unit to the PDU bracket.
Refit
1. Fit 2 bolts fixing the electrical park motor control unit
to the PDU bracket, tighten them to 7-10Nm, and
check the torque.
2. Connect the harness to the electrical park motor
control unit.

1.0 115

Number
Replacer, inner
T24009 track of taper
Replacer, drive bearing
TPT00236
shaft oil seal
Replacer, Replacer park

TPT00140
outer track of shaft oil seal
TPT00128
tapered roller
bearing,differential
Remove upper
T34019 and lower arm
bush
Remover tailing
T34003
arm bush
1.0 116
HVAC System HVAC System
HVAC System
Specifications
Torque
Description Value
Bolt-Compressor to compressor bracket 19-25Nm
Nut-Air conditioner pipe A to Air conditioner pipe B 7-10Nm
Bolt-Air conditioner box assembly to body 4-6Nm
Nut-Air conditioner box assembly to body 4-6Nm
Bolt-Evaporator to expansion valve 19-25Nm
Bolt-Expansion valve to air conditioner case assembly 4-6Nm
1.0 117
Service Procedures-General Refrigerant Recovery and Recharging

Odour Removal Refrigerant Recycle
1. When the A/C is started under hot and humid 1. Connect the high pressure-side hose with a
conditions, a smell may be blown out from air vents. quick-disconnection connector to the high-pressure
The components that may produce the smell include: side maintenance connector of A/C system.
• Foreign objects or breeding micro-organisms in the A/C Tip: Only use refrigerant tanks that are designed for
filter; the specific charging station and use the recommended
refrigerant. DO NOT mix refrigerant types.
• Breeding micro-organisms on the A/C box housing;
2. Open the connector valve.
• Breeding micro-organisms on the evaporator;
3. Connect the low pressure-side hose with a
• Breeding micro-organisms on the air duct;
quick-disconnection connector to the low-pressure
2. In case of any smell, please observe the following steps side maintenance connector of A/C system.
for adour removal:
4. Open the connector valve.
• Replace the A/C filter; 5. Check the high pressure-side and low pressure-side
A/C Filter Element Replacement gauges on the filling station control panel and ensure
• Clean the A/C box housing; the A/C system is with pressure. There will be no
• Clean the evaporator; recyclable refrigerant in the system if there is no
• Clean the A/C air ducts. pressure.
3. The relevant cleaning fluid may be used during cleaning: 6. Open the high pressure-side and low pressure-side
valves.
• The solution containing 40% vinegar and 60% water;
7. Open the gas and liquid valves on the refrigerant tank.
• Proprietry cleanser, etc.
8. Drain refrigerant oil from the oil separator.
9. Close the oil drain valve.
10. Connect the filling station to a proper power outlet.
11. Connect the main power switch.
Caution: Reuse of the recycled lubricant is prohibited.
The recycled lubricant will damage the equipment.
Caution: A/C lubricant (PAG) could be recycled together

with refrigerant but the AC service equipment can
separate lubricant from refrigerant to calculate the
quantity of lubricant.
12. Start the recycle process. For more information about

the filling station, refer to manufacturer's instructions.
13. Wait 5 minutes, and then check the low pressure-side
pressure gauge on the control panel. If the A/C system
keeps vacuum, it is shown that recycle is completed.
Warning: Please ensure that the refrigerant tank being
used to reclaim the refrigerant has enough capactiy
to contain the removed refrigerant. DO NOT mix
reclamation tank types.
14. If the pressure of low side rises from zero, it is shown
that there is still refrigerant in the system. Recycle the
rest refrigerant. Repeat this step till the system can
keep vacuum for 2min.
Drain
1. Check if the high pressure-side and low pressure-side
hoses are connected to the A/C system. Open the high
pressure-side and low pressure-side valves on the filling
1.0 118
station control panel. 2. Open the high pressure-side valve on the control panel.
2. Open the gas and liquid valves on the refrigerant tank. 3. For more information about the filling station, refer to
manufacturer's instructions.
Caution: The evacuating procedure must be carried out
before recharging process. 4. Fill necessary amount of refrigerant to the A/C, and
ensure the measurement unit is correct, such as KG or
3. Start the vacuum pump and drain. The non-condensable lbs.
gases (mostly air) will exhaust automatically from the
5. Start to fill.
tank during the recycle. The sound of pressure release
may be heard. Refrigerant Refill Successful
4. Inspect the system for any leakage. For more 1. Close the high pressure-side valve on the filling station
information about the filling station, refer to control panel. The two valves shall be closed.
manufacturer's instructions. 2. Start the vehicle and A/C system.
Refill of A/C System Lubricating Oil 3. Keep the engine running until the readings on the high
Tip: Different types of compressor lubricants can not pressure-side and low pressure-side gauges are stable.
be mixed.
4. Compare the readings with system specification.
At the moment, it is necessary to refill the lubricating oil
5. Check the evaporator outlet temperature, ensure the
drained from A/C system during the recycle period.
operation of A/C system complies with the system
Note: specification.
• Tighten the lubricating oil cap at any time to prevent the 6. Keep the A/C running.
moisture or contaminates from entering the lubricating 7. Close the high pressure-side connector valve.
oil.
8. Disconnect the high pressure-side hose from the vehicle.
• This operation requires the A/C system is vacuum. DO
9. Open the low pressure-side valve on the control panel.
NOT open the lubricating oil filling valve under the
The system will suck the refrigerant from two hoses
positive pressure condition of A/C system. That will
quickly through the low pressure-side hose.
cause the lubricating oil flows back through the vent
10. Close the low pressure-side connector valve.
port of oil bottle.
11. Disconnect the low pressure-side hose from the vehicle.
• The oil level shall not be lower than the oil suction pipe
when filling or refilling the lubricating oil, otherwise the Refrigerant Refill Unsuccessful
air may enter into the A/C system. Sometimes the filled refrigerant is not fully transmitted to the
1. Apply the lubricating oil with a graduated bottle special A/C system. There are 2 causes for this situation:
for the system. 1. The pressure of filling station refrigerant tank is similar to
2. For more information about the filling station, refer that of the A/C system,
to manufacturer's instructions. Add proper amount of • thus lead to very slow oil transmission process.
A/C lubricating oil to the system. • For more information about the filling station, refer to
3. Close the valve when the oil filling volume reaches the manufacturer's instructions.
required value.
2. The refrigerant in refrigerant tank of filling station is not
Refill enough for full filling.
Caution: The evacuating procedure must be carried out • So you must recycle some filled refrigerant from the
before recharging process. vehicle. Then drain the A/C system and fill it again.
Refrigerant Refill
• For more information about the filling station, refer to
1. Close the low pressure-side valve on the control panel. manufacturer's instructions.
1.0 119
A/C Compressor Oil Balance Air Conditioning System Seals

Tip: Refrigerant oil in the A/C system must be balanced Remove
during the compressor replacement.
Tip: Check the oil level in the replacement compressor. 1. Remove the sealing washer from the A/C refrigerant
component.
1. Tip: The refrigerant oil in the A/C system must be
balanced during compressor replacement. Tip: Cap or tape the open A/C refrigerant components
2. If there is some compressor oil in the replaced immediately to prevent system contamination.
compressor, the oil must go through balance treatment 2. Inspect the sealing washer for signs of damage to help
according to the following conditions: determining the root cause of the failure.
a. Firstly, measure the oil volume in the replaced 3. Inspect the A/C refrigerant component for damage or
compressor, pour it out from the compressor intake burrs. Repair if necessary.
and exhaust ports, measure with a measuring cup 4. Discard the sealing washer.
and record the value.
Tip: DO NOT reuse sealing washers or rubber O-rings.
Refit
Tip: It is not necessary to lubricate flat type washers.
1. Inspect the new sealing washer for any signs of cracks,
cuts, or damage.
Do not use a damaged sealing washer.
2. Remove the cap or tape from the A/C refrigerant
components.
3. Using a lint-free, clean and dry cloth, clean the sealing
surfaces of the A/C refrigerant components.
4. Carefully install the new sealing washer onto the A/C
refrigerant components. The washer must completely
bottom against the surface of the fitting.
5. Assemble the remaining A/C refrigerant components.
Refer to the appropriate service procedure.
b. Pour out the oil from the new compressor, and add
the same volume of oil with that of the replaced
compressor.
1.0 120
Replacement of A/C System O-ring Refit
Remove 1. Inspect the new O-ring seal for any sign of cracks, cuts,
1. Disassemble the A/C refrigerant components. Refer to or damage. Replace if necessary.
the appropriate repair procedure. 2. Remove the cap or tape from the A/C refrigerant
2. Remove the O-ring seal from the A/C refrigerant components.
component. 3. Using a lint-free, clean and dry cloth, clean the sealing
3. Inspect the O-ring seal for signs of damage to help surfaces of the A/C refrigerant components.
determining the root cause of the failure. 4. Coat the new O-ring seal with a small amount of
4. Inspect the A/C refrigerant component for damage or mineral base 525 viscosity refrigerant oil.
burrs. Repair if necessary.
Tip: Never let any mineral-based 525 viscosity refrigerant
5. Cap or tape the A/C refrigerant components. on new O ring go into the cooling system.
Tip: Cap or tape the open A/C refrigerant components 5. Carefully put the new O-ring seal onto the A/C
immediately to prevent system contamination. refrigerant component.
Tip: DO NOT reuse O-ring seals.

6. The O-ring seal must be fully seated.
7. Assemble the A/C components.
Refer to the appropriate repair catalogue.
6. Discard the O-ring seal.
1.0 121
Service Procedures-Compressor and 9. Remove 3 bolts fixing the compressor to the

Condenser compressor bracket.
Compressor
Remove
5. Disconnect the low-voltage harness connector (3).
6. Loosen the harness clip (2) and disconnect the
high-voltage harness connector (1). 10. Remove the compressor assembly.
Refit
1. Fix the compressor to the compressor bracket, fit 3
blots, tighten them to 19-25Nm, and check the torque.
compressor oil.
3. Fix the A/C pipeline A - compressor to condenser to
the compressor, fit 1 nut and tighten it to TBD, and
check the torque.
compressor oil.
5. Fix the A/C pipeline - condenser to evaporator to the
compressor, fit 1 nut and tighten it to TBD, and check
7. Remove 1 bolt (1) fixing the A/C pipeline - condenser the torque.
to compressor to the compressor, disconnect the 6. Connect the high-voltage harness connector, and
pipeline, and discard the seal ring. secure it with clips.
Caution: Protect open connections to prevent 7. Connect the low-voltage harness connector.
contamination.
8. Remove 1 nut (2) fixing the A/C pipeline A - compressor
to condenser to the compressor, disconnect the
pipeline and discard the seal ring. 9. Refill the A/C system refrigerant.
Caution: Protect open connections to prevent Refrigerant Recovery and Refill

contamination. 10. Fit the manual service disconnect.

1.0 122
Compressor Bracket Condenser
Remove Remove
1. Disconnect the negative battery cable. 1. Drain the coolant.
2. Remove the manual service disconnect. Coolant - Drain
Manual Service Disconnect Remove 2. Remove the radiator assembly.
3. Remove the compressor. Cooling Fan Assembly Remove
Bottom Deflector Remove 3. Loosen 4 clips fixing the condenser to the radiator, and
4. Remove 3 bolts fixing the compressor bracket to the remove the condenser from the slot.
drive motor, and remove the compressor bracket.
Refit
Refit 1. Align the condenser with and fit it into 4 clips of the
radiator and ensure that it is clamped in place.
1. Fix the compressor bracket to the drive motor, fit 3
bolts, tighten them to TBD, and check the torque. 2. Fit the radiator assembly.
2. Fit the compressor. Radiator Assembly Refit
Bottom Deflector Refit 3. Refill the coolant.
3. Fit the manual service disconnect. Coolant - Refill
1.0 123
Service Procedures-Pipe condenser, and disconnect the pipeline and discard the
A/C Pipeline A - Compressor to Condenser seal ring.
Remove Caution: Protect open connections to prevent
1. Disconnect the negative battery cable. contamination.


Radiator Airflow Side Deflector - Right Remove
5. Loosen the compressor high-voltage harness clip (2).
8. Loosen the clip, and remove the A/C pipeline A -

compressor to condenser.
Refit
1. Fit the A/C pipeline A - compressor to condenser, and
compressor oil.
the A/C pipeline B - compressor to condenser, fit 1 nut
6. Remove 1 nut (2) fixing the A/C pipeline A - compressor
and tighten it to 7-10Nm, and check the torque.
to condenser to the compressor.
compressor oil.
contamination.
the compressor, fit 1 nut and tighten it to TBD, and
check the torque.
6. Fit the compressor high-voltage harness clip.
Radiator Airflow Side Deflector - Right Refit


7. Remove 1 nut fixing the A/C pipeline A - compressor
to condenser to the A/C pipeline B - compressor to
1.0 124
A/C Pipeline B - Compressor to Condenser
Remove


5. Remove 1 nut fixing the A/C pipeline B - compressor
to condenser to the condenser, disconnect the pipeline 8. Loosen the clip, and remove the A/C pipeline B -
and discard the seal ring. compressor to condenser.
Caution: Protect open connections to prevent Refit
contamination. 1. Fit the A/C pipeline B - compressor to condenser, and
compressor oil.
3. Fix the A/C pipeline B - compressor to condenser to
the A/C pipeline A - compressor to condenser, fit 1 nut
and tighten it to TBD, and check the torque.
4. Fix the A/C pipeline B - compressor to condenser
bracket to the front-end module, fit 1 nut and tighten it
compressor oil.
6. Fix the A/C pipeline B - compressor to condenser to
6. Remove 1 bolt (2) fixing the A/C pipeline B -
the condenser, fit 1 nut and tighten it to TBD, and
compressor to condenser bracket to the front-end
check the torque.
module.
7. Remove 1 nut (1) fixing the A/C pipeline B - compressor
to condenser to the A/C pipeline A - compressor to Bottom Deflector Refit
condenser, disconnect the pipeline and discard the seal 8. Refill the A/C system refrigerant.
ring.
Caution: Protect open connections to prevent 9. Fit the manual service disconnect.
contamination.
1.0 125
A/C Pipeline - Condenser to Evaporator

Remove


5. Disconnect the connector (1) of the A/C pressure
sensor. 8. Loosen the clip and remove the A/C pipeline -
6. Remove 1 nut (2) fixing the A/C pipeline - condenser condenser to evaporator.
to evaporator to the A/C pipeline - evaporator to Refit
compressor, disconnect the pipeline, and discard the
1. Fit the A/C pipeline - condenser to evaporator and
seal ring.
Caution: Protect open connections to prevent 2. Fit a new seal ring on the A/C pipeline and apply clean
contamination. compressor oil.
condenser, fit 1 nut and tighten it to TBD, and check
the torque.
compressor oil.
A/C pipeline - evaporator to compressor, fit 1 nut and
tighten it to TBD, and check the torque.
6. Connect the connector of the A/C pressure sensor.
Radiator Airflow Side Deflector - Right Refit

7. Remove 1 nut fixing the A/C pipeline - condenser to 8. Refill the A/C system refrigerant.
evaporator to the condenser, disconnect the pipeline,
and discard the seal ring.
contamination. Manual Service Disconnect Refit
1.0 126
A/C Pipeline - Evaporator to Compressor
Remove


5. Disconnect the connector (2) of the expansion valve
solenoid valve. 10. Remove the A/C pipeline - evaporator to compressor.
6. Remove 1 nut (1) fixing the A/C pipeline - evaporator Refit
to compressor to the A/C pipeline - condenser to
1. Fit the A/C pipeline - evaporator to compressor, and
evaporator, disconnect the pipeline and discard the
seal ring.
Caution: Protect open connections to prevent compressor oil.
contamination.
3. Fix the A/C pipeline - evaporator to compressor to the
7. Remove 1 bolt (4) fixing the A/C pipeline - evaporator compressor, fit 1 bolt and tighten it to TBD, and check
to compressor to the battery chiller, disconnect the the torque.
pipeline and discard the seal ring. 4. Fit a new seal ring on the A/C pipeline and apply clean
Caution: Protect open connections to prevent compressor oil.
contamination. 5. Fix the A/C pipeline - evaporator to compressor to the
A/C box, fit 1 bolt and tighten it to TBD, and check
8. Remove 1 bolt (3) fixing the A/C pipeline - evaporator
the torque.
to compressor to the A/C box, disconnect the pipeline
and discard the seal ring. 6. Fit a new seal ring on the A/C pipeline and apply clean
compressor oil.
7. Fix the A/C pipeline - evaporator to compressor to
contamination.
the battery chiller, fit 1 bolt and tighten it to TBD, and
check the torque.
compressor oil.
9. Fix the A/C pipeline - evaporator to compressor to the
A/C pipeline - condenser to evaporator, fit 1 bolt and
tighten it to TBD, and check the torque.
10. Connect the connector of the expansion valve solenoid
valve.
9. Remove 1 bolt (1) fixing the A/C pipeline - evaporator
to compressor to the compressor, disconnect the
pipeline and discard the seal ring. 13. Fit the manual service disconnect.
Caution: Protect open connections to prevent Manual Service Disconnect Refit

contamination. 14. Connect the negative battery cable.
1.0 127
A/C Pressure Sensor 5. Remove the A/C pressure sensor and discard the
Remove O-ring.
1. Disconnect the negative battery cable. Caution: Protect open connections to prevent
2. Remove the manual service disconnect. contamination.
Manual Service Disconnect Remove Refit

3. Recover the A/C system refrigerant. 1. Remove the plug, lubricate the new O-ring with clean
A/C lubricating oil, and fit the O-ring on the refrigerant
Refrigerant Recovery and Refill pressure sensor.
4. Disconnect the connector (1) of the A/C pressure 2. Connect the connector of the A/C pressure sensor.
sensor.


1.0 128
Service Procedures-Conditioner
A/C Box Assembly
Remove


4. Remove the instrument panel beam assembly.
Instrument Panel Beam Assembly Remove
5. Remove 1 bolt (3) fixing the pipeline assembly - 9. Remove 2 bolts (1) and 4 nuts (2) fixing the A/C box to
condenser to evaporator to the expansion valve, the dash panel.
disconnect the pipeline, and discard the seal ring.

contamination.
6. Remove 2 nuts fixing the A/C box assembly to the body.
10. Disconnect the A/C drain pipe.

11. Disconnect the connector of the A/C box.
12. Loosen the clip and remove the A/C box assembly.
Refit
7. Remove 1 nut (3) fixing the electric heater grounding 1. Fit the A/C box assembly and secure it with clips.
wire to the floor.
2. Connect the connector of the A/C box.
8. Disconnect the low-voltage harness connector (1)
3. Connect the A/C drain pipe properly.
of the electric heater first, then disconnect the
4. Fix the A/C box to the dash panel, fit 2 bolts, tighten
high-voltage harness connector (2) of the electric
them to 4-6Nm, and check the torque.
heater.
5. Fix the A/C box to the dash panel, fit 4 nuts, tighten
1.0 129
6. Connect the high-voltage harness connector of the A/C Filter Element

electric heater first, then connect the low-voltage Remove
harness connector of the electric heater. 1. Remove the glove box assembly.
7. Fix the electric heater grounding wire to the floor, fit
Glove Box Assembly Refit
and tighten 1 nut.
2. Loosen the clip, and remove the A/C filter cover.
8. Fix the A/C box assembly to the body, fit 2 nuts, tighten
compressor oil.
10. Fix the pipeline assembly - evaporator to compressor
to the expansion valve, fit 1 bolt and tighten it to
19-25Nm, and check the torque.
11. Fit the instrument panel beam assembly.
Instrument Panel Beam Assembly Refit


3. Take out the A/C filter element.
Refit
1. Fit the A/C filter element.
2. Fix the A/C filter cover to the A/C box, and secure
it with clips.
3. Fit the glove box assembly.
1.0 130
Evaporator Core Assembly 4. Loosen the clip and remove the electric heater.
Remove 5. Remove the screws and clips fixing the vent box to the
1. Remove the A/C box assembly. heater box, and remove the vent box.
A/C Box Assembly Remove 6. Remove the retaining clips and screws on the heater
box, and separate the heater housing.
2. Remove 2 screws (1) fixing the footwell air outlet on
the A/C box, and remove the footwell air outlet. 7. Remove the evaporator temperature sensor.
8. Remove the evaporator core assembly.
Refit
1. Insert the evaporator core assembly into the heater
box.
2. Fit the evaporator temperature sensor.
3. Fit the heater box and secure it with clips and screws.
4. Fix the vent box to the heater box and secure it with
clips and screws.
5. Fit the electric heater and secure it with clips.
6. Fix the electric heater to the A/C box, fit and tighten
3 screws.
3. Remove 3 screws (2) fixing the electric heater to the 7. Fix the footwell air outlet to the A/C box, fit and
A/C box. tighten 2 screws.
8. Fit the A/C box assembly.
A/C Box Assembly Refit

9. Perform a self-learning for the A/C servo motor. Refer
to Module Self-learning and Programming Manual, "A/C
Servo Motor Self-learning".
1.0 131
Expansion Valve
Remove

4. Remove 1 bolt (3) fixing the pipeline assembly -
evaporator to compressor to the expansion valve,
disconnect the pipeline, and discard the seal ring.

Refit
contamination.
1. Fit a new seal ring on the expansion valve and apply
clean compressor oil.
2. Fix the expansion valve to the A/C box, fit 2 bolts,
tighten them to 4-6Nm, and check the torque.
compressor oil.
4. Fix the pipeline assembly - evaporator to compressor
to the expansion valve, fit 1 bolt and tighten it to

5. Remove 2 bolts fixing the expansion valve to the A/C
box, remove the expansion valve, and discard the seal Manual Service Disconnect Refit
ring. 7. Connect the negative battery cable.

contamination.
1.0 132
Blower Blower Speed Regulation Resistor
Remove Remove
3. Remove the passenger side instrument panel lower 3. Remove the passenger side instrument panel lower
closure panel assembly. closure panel assembly.

4. Disconnect the connector (1) of the blower. 4. Disconnect the connector (1) from the blower speed
5. Remove 3 screws (2) fixing the blower to the A/C box, regulation resistor.
and remove the blower. 5. Remove 2 screws (2) fixing the blower speed regulation
resistor to the A/C box.
Refit
1. Fix the blower to the A/C box, fit and tighten 3 screws. 6. Remove the blower speed regulation resistor.
2. Connect the connector of the blower. Refit
3. Fit the passenger side instrument panel lower closure 1. Connect the connector to the blower speed regulation
panel assembly. resistor.
2. Fix the blower speed regulation resistor to the A/C
box, fit and tighten 2 screws.
3. Fit the passenger side instrument panel lower closure
Manual Service Disconnect Refit panel assembly.

1.0 133
A/C Drain Pipe Evaporator Core Temperature Sensor

Remove Remove
1. Disconnect the negative battery cable. 1. Remove the A/C box assembly.
2. Remove the manual service disconnect. A/C Box Assembly Remove
Manual Service Disconnect Remove 2. Remove 3 screws (2) fixing the electric heater to the
3. Remove the centre bottom deflector. A/C box, and remove the electric heater.

4. Remove the centre console heater closing plate
assembly.
Centre Console Heater Closing Plate Assembly

Remove
5. Loosen the clips and remove the A/C drain pipe.
Refit
1. Fit the A/C drain pipe and secure it with clips.
2. Fit the passenger side heater closing plate.

Refit
3. Remove the screws and clips fixing the vent box to the
3. Fit the centre bottom deflector. heater box, and remove the vent box.
Manual Service Disconnect Remove 4. Remove the retaining clips and screws on the heater
4. Fit the manual service disconnect. box, and separate the heater housing.
5. Remove the evaporator core temperature sensor.
Refit
1. Fit the evaporator core temperature sensor.
2. Fit the heater box and secure it with clips and screws.
3. Fix the vent box to the heater box and secure it with
clips and screws.
3 screws.

6. Perform a self-learning for the A/C servo motor. Refer
to Module Self-learning and Programming Manual, "A/C
Servo Motor Self-learning".
1.0 134
Temperature Damper Actuator Circulation Damper Actuator
Remove Remove
3. Remove the passenger side centre console heater 3. Remove the glove box assembly.
closing plate assembly.
Centre Console Heater Closing Plate Assembly Refit
Refit 4. Disconnect the connector of the circulation damper
4. Disconnect the connector (2) of the temperature actuator.
damper actuator. 5. Remove 3 screws fixing the circulation damper actuator
5. Remove 2 screws (1) fixing the temperature damper to the A/C box assembly.
actuator to the A/C box assembly.
6. Disconnect the circulation damper actuator from the

6. Disconnect the temperature damper actuator from the circulation damper linkage mechanism.
temperature damper linkage mechanism. 7. Remove the circulation damper actuator.
7. Remove the temperature damper actuator. Refit
Refit 1. Connect the circulation damper actuator and the
1. Connect the actuator and linkage mechanism of the circulation damper linkage mechanism.
temperature damper. 2. Fix the circulation damper actuator to the A/C box
2. Fix the temperature damper actuator to the A/C box assembly, fit and tighten 3 screws.
assembly, fit and tighten 3 screws. 3. Connect the connector of the circulation damper
3. Connect the connector of the temperature damper actuator.
actuator. 4. Fit the glove box assembly.
4. Fit the passenger side centre console heater closing
plate assembly.
Refit

7. To perform self-learning for the A/C controller,
please refer to Module Self-learning and Programming
Manual-"Air Conditioning Control Module (HVAC)".
1.0 135
Mode Damper Actuator Electric Heater

Remove Remove
3. Remove the driver side instrument panel lower closure 3. Remove the driver side lower trim panel assembly.
panel assembly. Driver Side Lower Trim Panel Assembly Remove
Centre Console Heater Closing Plate Assembly 4. Remove the centre console heater closing plate
Remove assembly.
4. Disconnect the connector (1) of the mode damper Centre Console Heater Closing Plate Assembly
actuator. Remove
5. Remove 2 screws (2) fixing the mode damper actuator 5. Disconnect the connector (2) of the driver side
to the A/C box assembly. footwell air outlet temperature sensor.
6. Remove 1 screw (1) fixing the driver side footwell air
outlet on the A/C box, and remove the driver side
footwell air outlet.
6. Disconnect the mode damper actuator from the mode

damper linkage mechanism.
7. Remove the mode damper actuator.
7. Lift the carpet, and remove 1 nut (3) fixing the electric
Refit heater grounding wire to the underbody.
1. Connect the mode damper actuator and the mode 8. Disconnect the low-voltage harness connector (1)
damper linkage mechanism. of the electric heater first, then disconnect the
2. Fix the mode damper servo motor to the A/C box high-voltage harness connector (2) of the electric
assembly, fit and tighten 3 screws. heater.
3. Connect the connector of the mode damper actuator.
4. Fit the driver side instrument panel lower closure panel
assembly.

Refit
7. To perform self-learning for the A/C controller,
please refer to Module Self-learning and Programming
Manual-"Air Conditioning Control Module (HVAC)".
9. Disconnect the connector (1) of the electric heater.
10. Remove 3 screws (2) fixing the electric heater to the
A/C box.
1.0 136
Electric Heater Temperature Sensor
Remove
3. Remove the passenger side centre console heater
closing plate assembly.

Remove
4. Disconnect the connector (1) of the electric heater
temperature sensor.
11. Remove the electric heater.
Refit
3 screws.
2. Connect the connector of the electric heater.
3. Connect the high-voltage harness connector of the
electric heater first, then connect the low-voltage
harness connector of the electric heater.
4. Fix the electric heater grounding wire to the body, fit
and tighten 1 nut.
5. Fix the driver side footwell air outlet to the A/C box,
fit and tighten 2 screw.
5. Loosen the clip and remove the electric heater
6. Connect the connector of the driver side footwell air
temperature sensor.
outlet temperature sensor.
Refit
7. Fit the centre console heater closing plate assembly.
1. Fit the electric heater temperature sensor and secure
it with clips.
Refit
2. Connect the connector of the electric heater
8. Fit the driver side lower trim panel assembly.
temperature sensor.
Driver Side Lower Trim Panel Assembly Refit 3. Fit the passenger side centre console heater closing
9. Fit the manual service disconnect. plate assembly.
Manual Service Disconnect Refit Centre Console Heater Closing Plate Assembly
10. Connect the negative battery cable. Refit

1.0 137
Service Procedures-Decompression Valve Air Outlet Temperature Sensor

Instrument Panel Air Duct Remove
Remove 1. Disconnect the negative battery cable.
1. Remove the upper fascia panel assembly. 2. Remove the manual service disconnect.
Upper Fascia Panel Assembly Refit Manual Service Disconnect Remove
2. Remove 6 screws fixing the instrument panel air duct 3. Remove the upper fascia panel assembly.
to the upper fascia panel assembly. Upper Fascia Panel Assembly Remove
4. Disconnect the connector of the instrument panel air
3. Remove the instrument panel air duct.

Refit
1. Fix the instrument panel air duct on the upper fascia 5. Disconnect the connector (2) of the footwell air outlet
panel assembly, fit 6 screws and tighten them. temperature sensor.
2. Fit the upper fascia panel assembly.

Upper Fascia Panel Assembly Refit
6. Loosen the clip, and remove the air outlet temperature

sensor.
Refit
1. Fit the air outlet temperature sensor and secure it with
clips.
2. Connect the footwell air outlet temperature sensor
connector.
3. Connect the connector of the instrument panel air
4. Fit the upper fascia panel assembly.
Upper Fascia Panel Assembly Refit
1.0 138
6. Connect the negative battery cable. Rear Face Air Duct
Remove

4. Remove the centre console rear panel assembly.

5. Remove 6 screws fixing the rear face air duct to the
centre console.
6. Remove the rear face air duct.

Refit
1. Fix the rear face air duct to the centre console, fit and
tighten 6 screws.
2. Fit the centre console rear panel assembly.
Centre Console Rear Panel Assembly Refit



1.0 139
Body Relief Valve - Left Body Relief Valve - Right

Remove Remove
1. Remove the rear bumper assembly. 1. Remove the rear bumper assembly.
Rear Bumper Assembly Refit Rear Bumper Assembly Refit

2. Loosen the clip and remove the body relief valve - left 2. Loosen the clip and remove the body relief valve - right
from the vehicle. from the vehicle.
Refit Refit
1. Fix the body relief valve - left and secure it with clips. 1. Fix the body relief valve - right and secure it with clips.
2. Fit the rear bumper assembly. 2. Fit the rear bumper assembly.
Rear Bumper Assembly Refit Rear Bumper Assembly Refit
1.0 140
Service Procedures-Control Interior Temperature Sensor
A/C Controller Assembly Remove
1. Disconnect the negative battery cable. 2. Remove the manual service disconnect.
2. Remove the manual service disconnect. Manual Service Disconnect Remove
Manual Service Disconnect Remove 3. Remove the steering column lower shield.
3. Remove the centre console assembly. Instrument Panel Beam Assembly Remove
Centre Console Assembly Remove 4. Remove 2 screws fixing the interior ambient
4. Disconnect the connector (2) of the A/C controller temperature sensor to the steering column lower
assembly. shield.
5. Remove 2 bolts (1) fixing the A/C controller assembly
to the instrument panel beam.
5. Remove the interior ambient temperature sensor.

Refit
6. Remove the A/C controller assembly. 1. Fit 2 screws fixing the interior ambient temperature
Refit sensor to the steering column lower shield, and tighten
them.
1. Fix the A/C controller assembly to the instrument
panel beam, fit and tighten 2 bolts. 2. Fit the steering column lower shield.
2. Connect the connector of the A/C controller assembly. Instrument Panel Beam Assembly Refit
3. Fit the centre console assembly. 3. Fit the manual service disconnect.
Centre Console Assembly Refit Manual Service Disconnect Refit

4. Fit the manual service disconnect. 4. Connect the negative battery cable.

6. To replace or refresh the A/C controller, please refer
to Module Self-learning and Programming Manual-"Air
Conditioning Control Module (HVAC)".
1.0 141
Exterior Temperature Sensor Solar Sensor

Remove Remove
3. Remove the front bumper. 3. Remove the instrument panel body assembly.
Front Bumper Remove Instrument Panel Beam Assembly Remove

4. Loosen the clips and remove the exterior ambient 4. Loosen the clip and remove the daylight sensor.
temperature sensor.
Refit
Refit 1. Fit the daylight sensor and secure it with clips.
1. Fit the exterior ambient temperature sensor and secure 2. Fit the instrument panel body assembly.
it with clips.
2. Connect the connector of the exterior ambient
temperature sensor.
3. Fit the front bumper. Manual Service Disconnect Refit
Front Bumper Refit

1.0 142
Steering System Steering System
Steering System
Specifications
Torque
Description Value
Bolts-Front subframe to body (81–99)Nm+（175–185）°
Bolt-Lower Tie Bar Bracket to Lower Tie Bar （81-99）Nm+（85-95）°
Bolts-Steering rack to front subframe 90–110Nm
Nut-Front anti-roll bar links to front anti-roll bar 55–65Nm
Bolts-Steering column intermediate shaft to Steering rack 20Nm+120°
Nuts-Steering rack outer tie rod 63-73Nm
Nuts-Steering rack outer tie rod to steering arm 28-32Nm
Steering rack inner tie rod-Steering rack inner tie rod to the 70-80Nm
steering rack
Bolts-ESCL to steering column 13-15Nm
Bolts- Steering column to fascia framework 19-25Nm
Bolts- Steering column to fascia framework 22Nm+45°
Bolts-Steering column intermediate shaft to upper steering 20Nm+120°
column
Bolts- Steering wheel to steering column 60–70Nm
Screw-Multi function 5–6Nm
1.0 143
Service Procedures
Steering Rack Subassembly
Remove
1. Remove and discard 1 bolt fixing the intermediate shaft
universal joint to the steering rack input shaft.
7. Support the electric drive system with the hydraulic

lifter.
8. Remove and discard 1 bolt (2) fixing the lower tie rod
to the lower tie rod bracket.
2. Disconnect the intermediate shaft universal joint from

the steering rack input shaft.
3. Remove the front&middle bottom deflectors.

4. Remove the steering rack outer tie rod.
Steering Rack Outer Tie Rod Remove

5. Remove and discard the nuts (on both sides) (2) fixing
the front anti roll bar connecting rod to the front anti
roll bar.
9. Support the front subframe assembly with the hydraulic

lifter.
10. Remove 6 bolts (2) fixing the front subframe assembly
to the body.
6. Remove and discard 2 bolts and nuts fixing the steering

rack to the front subframe.
11. Slowly lower the hydraulic lifter and keep the front
subframe assembly at a suitable distance from the body.
12. Gently take the steering rack subassembly out of the
vehicle.
1.0 144
Refit Steering Rack Outer Tie Rod
1. Ensure that the mounting position of the front subframe Remove
assembly is clean. 1. Remove the front wheels.
2. Lift the front subframe assembly to its mounting points Wheels Remove
on the body with the hydraulic lifter.
2. Remove and discard 1 nut (1) fixing the steering rack
3. Locate the front subframe assembly to the body, outer tie rod to the steering knuckle.
fit 6 bolts, and tighten them to (81–99)Nm+
3. Disconnect the steering rack outer tie rod from the
（ 175–185））°.
steering knuckle.
4. Lower the hydraulic lifter, and push it to the safety zone.
4. Mark the location of the locking nut, and loosen the
5. Locate the lower tie rod to the lower tie rod bracket, locking nut (2) fixing the steering rack outer tie rod to
fit a new bolt and tighten it to （ 81-99）） Nm+ the steering rack inner tie rod.
（ 85-95）） °.
7. Locate the steering rack assembly to the front
subframe, fit 2 new nuts and bolts in sequence (the
driver side first), and tighten them to 90–110Nm.
8. Locate the connecting rod of the front anti roll bar to
the front anti roll bar, fit a new nut and tighten it to
55–65Nm.
Caution: To prevent damage to components, use two

spanners when loosening or tightening unions.
9. Fit the steering rack outer tie rod.
Steering Rack Outer Tie Rod Refit

5. Unscrew the steering rack outer tie rod from the
10. Fit the front&middle bottom deflectors.
steering rack inner tie rod.
Bottom Deflector Refit Refit
11. Locate the intermediate shaft universal joint to the 1. Screw the steering rack outer tie rod to the mark
steering rack input shaft, fit 1 new bolt and tighten it position of the locking nut with the ball joint upward.
to 20Nm+120°.
2. Tighten the locking nut to 63-73Nm.
3. Locate the steering rack outer tie rod on the steering
knuckle, fit a new nut and tighten it to 28-32Nm.
4. Fit the front wheels.
Wheels Refit
5. Check the wheel alignment.
Wheel Alignment Check

6. Adjust the wheel alignment.
Wheel Alignment Adjustment

7. Perform a self-learning for the EPS module. Refer to
Module Self-learning and Programming Manual, "Electric
Power Steering (EPS) Module".
1.0 145
Steering Rack Inner Tie Rod Steering Rack Gaiter

Remove Remove
1. Remove the steering rack gaiter. 1. Remove the steering rack outer tie rod.
Steering Rack Gaiter Remove Steering Rack Outer Tie Rod Remove
2. Unscrew the steering rack inner tie rod from the 2. Remove and discard the outer gaiter clamp (1) of the
steering rack and disconnect the connection. steering rack.
3. Remove and discard the inner gaiter clamp (2) of the
steering rack.
3. Remove the steering rack inner tie rod.

Refit
1. Locate the steering rack inner tie rod to the steering 4. Unscrew the locking nut from the steering rack inner
rack and use a tool to tighten the steering rack inner tie rod and pull out the steering rack gaiter.
tie rod to 70-80Nm. Refit
2. Fit the steering rack gaiter. 1. Screw the locking nut and fit the steering rack gaiter
onto the steering rack. Ensure that the steering rack
Steering Rack Gaiter Refit
gaiter is located in the steering rack groove.
2. Fit the new inner gaiter clamp of the steering rack to
the steering rack gaiter, and secure it.
3. Fit the new outer gaiter clamp of the steering rack to
the steering rack gaiter, and secure it.
4. Fit the steering rack outer tie rod.
Steering Rack Outer Tie Rod Refit
1.0 146
Upper Steering Column Assembly
Remove
1. Disconnect the battery negative.
2. Remove the steering wheel combination switch.
Steering Wheel Combination Switch Remove
3. Remove the driver instrument panel lower trim panel.
Driver Instrument Panel Lower Trim Panel
Remove
4. Disconnect the EPS module connector.
7. Remove the upper steering column assembly.

8. Fix the upper steering column to the drilling machine,
drill a small hole in the retaining screw head of the
steering column lock, choose a broken screw extractor
with an appropriate diameter to rotate the screw out,
and do not damage adjacent parts.
9. Separate steering column lock and upper steering
column.
Refit
1. Fix the electronic steering column lock module on
5. Remove 1 bolt fixing the intermediate shaft on upper
steering column, refit 2 new bolts, tighten to 13-15Nm
steering column, and dispose it.
and twist off the bolt head.
2. Fix the upper steering column assembly on instrument
panel cross bream, refit 3 bolts in the order of
"below-left-right", tighten the top two bolts to
19-25Nmand the bottom bolt to 22Nm+45°.
3. Fix the intermediate shaft on upper steering column,
refit 1 new bolt, and tighten it to 20Nm+120°.
4. Connect the EPS module connector.
5. Connect the electronic steering column lock module
connector.
6. Refit the driver instrument panel lower trim panel.
Driver Instrument Panel Lower Trim Panel Refit

6. Remove 3 bolts fitting the steering column to the 7. Refit the steering wheel combination switch.
instrument panel beam assembly.
Steering Wheel Combination Switch Refit
8. Connect the battery negative.
9. Learn the electric power steering module. Refer to
Module Self-learning and Programming Manual - Electric
Power Steering (EPS) Module.
1.0 147
Intermediate Shaft Steering Column Trim Cover

Remove Remove
1. Maintain the vehicle wheel in the front to lock the 1. Slightly separate the upper trim cover from the lower
steering wheel. trim cover with a screwdriver.
2. Remove 1 bolt fixing the upper steering column to the 2. Remove the fixing buckle connecting the steering
intermediate shaft and discard it. column upper trim cover to fascia, and remove the
steering column upper trim cover.
3. Remove the steering column upper trim cover.
3. Remove 1 bolt fixing the intermediate shaft to the

steering rack and discard it.
4. Slightly separate the upper trim cover from the lower
trim cover with a screwdriver.
5. Remove 3 screws fixing the steering column lower trim
cover onto the steering column.
4. Remove the intermediate shaft.

Refit
1. Position the intermediate shaft on upper steering
column and steering rack.
2. Connect the intermediate shaft and upper steering 6. Release the steering column to the lowermost position,
column with a new bolt, and tighten to 20Nm+120°. and remove the steering column lower trim cover.
3. Connect the intermediate shaft and steering rack with Refit
a new bolt, and tighten to 20Nm+120°. 1. Position the steering column lower trim cover to the
steering column upper trim cover.
2. Turn the steering wheel left and right to the right
position, fit 2 screws fixing the steering column lower
trim cover to the combination switch and tighten them.
3. Fit 1 screw fixing the steering column lower trim cover
to the steering column and tighten it.
4. Fix the instrument panel IPK frame to the steering
column upper trim cover, and press the clip in place.
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5. Fix the steering column upper trim cover to the Steering Wheel Positioning Adjustment
steering column lower trim cover, and press the clip Adjustment
in place. 1. If the steering wheel is misaligned in a clockwise
direction:
a. Loosen the right locking nut.
b. Rotate the right inner tie rod shaft to the left one
hexagonal flat at a time.
c. Tighten the right locking nut to 63-73Nm.
d. Loosen the left locking nut.
e. Rotate the left inner tie rod shaft to the left one
f. Tighten the left locking nut to 63-73Nm.
2. If the steering wheel is misaligned in a anticlockwise

direction：
a. Loosen the left locking nut.
b. Rotate the left inner tie rod shaft to the right one
c. Tighten the left locking nut to 63-73Nm.

d. Loosen the right locking nut.
e. Rotate the right inner tie rod shaft to the right one
f. Tighten the right locking nut to 63-73Nm.
3. Repeat 1 or 2 until wheels face straight ahead and the

steering wheel is at central position.
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Steering Wheel Assembly 4. Connect the steering wheel harness connector.

Remove 5. Refit the steering wheel safety airbag.
Steering Wheel Airbag Refit
2. Remove the steering wheel safety airbag.
Steering Wheel Airbag Remove
3. Put the steering wheel in a centralised position, and
keep the vehicle wheel in a straight ahead position.
4. Disconnect the steering wheel harness connector.
5. Prevent the steering wheel from rotating and loosen
the bolt fixing the steering wheel on steering column,
and remove the bolt until the steering wheel is fully
loosened from the steering column.
6. Remove the steering wheel assembly from steering

column.
7. Stick tape along the edge of column lift lever
combination switch in order to retain the correct refit
position.
Refit
1. Remove the adhesive tape for steering column lifting
lever combination switch.
2. Ensure the wheels are in a straight and refit the steering
wheel on steering column according to the mark.
3. Fix the steering wheel on steering column, refit 1 bolt,
tighten to 60–70Nm and check the torque.
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Steering Wheel Molding Electric Steering Column Lock
Remove Remove
1. Disconnect the battery negative. 1. Remove the steering wheel combination switch.
2. Remove the steering wheel safety airbag. Steering Wheel Combination Switch Remove
Steering Wheel Airbag Remove 2. Remove the lower instrument panel assembly.
3. Disconnect the steering wheel harness connector. Driver Side Lower Trim Panel Assembly Remove
4. Release the clip slightly, and release the trim strip 3. Disconnect the connectors of the EPS module and
assembly from steering wheel. electric steering column lock.
5. Remove the steering wheel trim moulding.
Refit
1. Fix the steering wheel trim panel on steering wheel,
and tighten it.
2. Connect the steering wheel harness connector.
3. Refit the steering wheel safety airbag.
Steering Wheel Airbag Refit


to the upper steering column.
5. Remove and discard 3 bolts fixing the steering column

to the instrument panel beam assembly.
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Steering Wheel Multifunction Switch

Remove
2. Remove the steering wheel airbag.
Steering Wheel Airbag Remove
3. Disconnect the connector of the steering wheel
entertainment switch.
6. Remove the upper steering column assembly.

7. Fix the upper steering column assembly to the drilling
machine, drill small holes at the head of the bolts of
the steering column lock, and select the appropriate
tool to rotate the bolts out, so as not to destroy the
adjacent parts.
8. Separation of steering column lock and upper steering
column.
4. Pry off the clip, and remove the steering wheel
Refit multifunction switch.
1. Fix the steering column lock to the upper steering Refit
column, install new bolts, and tighten to13-15Nm.
1. Connect the harness connector at the back of the
2. Fix the upper steering column assembly on instrument steering wheel entertainment switch and fix the
panel cross bream, refit 3 bolts in the order of entertainment switch to the steering wheel.
"below-left-right", tighten the top two bolts to
2. Fit the steering wheel airbag.
19-25Nmand the bottom bolt to 22Nm+45°.
3. Fix the intermediate shaft to the upper steering column, Steering Wheel Airbag Refit
fit 1 new bolt and tighten it to 20Nm+120°. 3. Connect the negative battery cable.
4. Connect the connectors of the EPS module and
electric steering column lock.
5. Fit the lower instrument panel assembly.
Driver Side Lower Trim Panel Assembly Refit

6. Fit the steering wheel combination switch.
Steering Wheel Combination Switch Refit

7. Perform a self-learning for the ESCL module. Refer
to Self-learning and Programming Manual, "Electric
Steering Column Lock".
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Steering Wheel Combination Switch
Remove
2. Remove the steering column shield.
Steering Column Shield Remove
3. Pry off the retaining clip of the stalk switch trim panel
and remove the trim panel.
4. Remove 2 screws (3) fixing the wiper stalk switch to
the clock spring, remove the wiper stalk switch and
disconnect the harness connector.
5. Remove 2 screws (1) fixing the light stalk switch to
the clock spring, remove the light stalk switch and 3. Connect the harness connector of the clock spring.
disconnect the harness connector.
4. Fix the clock spring to the steering column, fit 1 screw,
6. Remove 2 screws (2) fixing the cruise control stalk tighten it to 5–6Nm, check the torque, and ensure the
switch to the clock spring, remove the cruise control combination switch assembly is not loose.
stalk switch and disconnect the harness connector.
5. Fit the steering wheel assembly.

7. Remove the steering wheel assembly.
Steering Wheel Assembly Refit
Steering Wheel Assembly Remove
6. Connect the harness connector of the stalk switch.
8. Fix the clock spring and bracket with tapes, ensure it
7. Fix the stalk switch to the clock spring, fit and tighten
will not move left and right and is always in the centre.
6 screws (4 screws for vehicles without cruise control
9. Remove 1 screw fixing the clock spring to the steering function).
column, disconnect the harness connector and remove
8. Fit the stalk switch trim panel and snap it into place.
the clock spring. Be careful not to damage the locating
tape. 9.
Refit 10. Fit the steering column shield.
1. Before fitting, ensure that the red locating pin of the Steering Column Shield Refit
clock spring is not removed or damaged and the front 11. Connect the negative battery cable.
wheels face the front. 12. Operate the electric power steering module (EPS).
2. Ensure the clock spring to be fitted is in the centre, if Refer to Module Self-learning and Programming Manual,
it is not, gently rotate the rotor counterclockwise to "Electric Power Steering Module (EPS)".
the end, then turn it clockwise for about 2.7 circles. 13. Check the system, rotate each lever of the combination
Align the connector clip with the Lock Pin position (this switch and check for correct operation.
location is the centre).
14. Check if the buttons of the entertainment switch on
the steering wheel for correct operation.
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1.0 154
Wheel Alignment Suspension System
Wheel Alignment
Specifications
Torque
Description Value
Nuts-Steering rack outer tie rod 63-73Nm
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Suspension System Wheel Alignment
Service Procedures Wheel Alignment Adjustment

Wheel Alignment Check 1. Observe the readings indicated on the test equipment,
Steering and vibration complaints are not always the result and adjust the four-wheel alignment data according to
of improper alignment. One possible cause is wheel and tire the requirements.
imbalance, and another possibility is tyre off-track due to 2. Front wheel toe-in adjustment:
worn or improperly manufactured tires. Definition of vehicle
a. Release the locking nut (2) of the steering outer tie
off-track: Vehicle off-track refers to the magnitude of the
rod.
force to be applied on the steering wheel to keep the vehicle
running in straight line when it runs at a constant high speed
on a typical straight road. Off-track is the vehicle deviation
from a straight path on a level road without pressure on the
steering wheel.
Before performing any adjustment affecting wheel alignment,

perform the following inspections and adjustments in order to
ensure correct alignment readings:
• Check tyres for proper air inflation or irregular wear.
• Check the radial runout of wheels and tyres.
• Check wheel bearings for excessive clearance or gap.
• Check ball joints and steering tie rod ends for looseness
or wear.
b. Adjust the steering outer tie rod to set the front
• Check control arms and stabilizer bar for looseness or
wheel alignment parameter to the specified value.
wear.
• Check the steering gear on the frame for looseness. c. Tighten the locking nut to 63-73Nm.
• Check struts/shock absorbers for wear, leakage or any d. For the other side, repeat the above steps.
noticeable noises.
• Check the vehicle trim height.
• Check the steering wheel for excessive drag or poor
returnability due to stiffness or corrosion of linkage
mechanism or suspension components.
Give consideration also to the condition of the equipment

being used for the alignment. Follow the equipment
Satisfactory vehicle operation may occur over a wide range of

alignment setting value. However, if the setting value exceeds
the service allowable specifications, correct the alignment to
the service recommended specifications.
Perform the following steps when measuring front and rear

wheel alignment angles:
1. Fit the alignment equipment according to the
2. Conduct up and down vibration for the front and rear
bumpers 3 times prior to checking the wheel alignment.
3. Measure the alignment angles and record the readings.
4. Adjust alignment angles to the specified value, if necessary.
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Front Suspension Suspension System
Front Suspension
Specifications
Torque
Description Value
Nuts-Front lower control arm rear bushing to front subframe （81–99）Nm+（175–185）°
Bolt-Front lower control arm front bushing to front subframe （81–99）Nm+（85–95）°
Nut-Front lower control arm ball joint to front steering 50-65Nm
knuckle
Nuts-Front lower control arm outer ball to front lower （81-99）Nm+（85-95）°
control arm
Nut-Front shock absorber top nut 65–75Nm
Nuts-Front shock absorber assembly to body 55-65Nm
Nut-Front anti-roll bar links to front damper 55-65Nm
Bolts-Front shock absorber assembly to steering knuckle 140-170Nm
Bolts-Front anti-roll bar to front subframe 55-65Nm
Bolt- Steering gear to subframe 70Nm+90°
Bolts-Right mount onto subframe 90-110Nm
Bolts-Front mount onto subframe （81–99）Nm+（85–95）°
Bolts-Rear mount bracket to subframe 90-110Nm
Bolts-Front subframe to body （135-165）Nm+（85-95）°
Bolt-ESS Water pump to Bracket 4–6Nm
Nut-EDS water pump bracket to body 7-10Nm
Nut-Steering outer tie rod to steering knuckle （ 28-32 ） Nm
Nut-Front anti-roll bar links to font anti-roll bar 55-65Nm
Bolts-Bumper to subframe 40–50Nm
Nut-front drive shaft 345–375Nm
Bolt- Steering column intermediate shaft to Steering 20Nm+120°
Bolts-Front anti-roll bar to front subframe 55-65Nm
Nut-Front anti-roll bar links to front anti-roll bar 55–65Nm
Nut-Front anti-roll bar links to front shock absorber assembly 50–65Nm
Bolts-Front wheel hub bearing assembly to front steering （63–77）Nm+（85–95）°
knuckle
Nut-drive shaft 225–275Nm
Bolts- Front wheel carrier to Front damper assembly 140–170Nm
Nuts-Steering outer tie rod to steering arm 28-32Nm
Bolts-Front Wheel speed sensor to steering arm 7–10Nm
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Suspension System Front Suspension
Service Procedures 4. Fit the front wheels.

Front Low Control Arm Assembly Wheels Refit
Remove
5. Check the four-wheel alignment parameters and
1. Remove the front wheels. perform adjustment if necessary.
Wheels Remove Four-wheel Alignment
2. Remove 1 nut and bolt fixing the front lower control
arm outer ball joint to the steering knuckle, discard the
nut and disconnect the connection.
3. Remove 1 bolt (1) fixing the front lower control arm

assembly front bushing to the front subframe and
discard it.
4. Remove 1 bolt and nut (2) fixing the front lower control
arm assembly rear bushing to the front subframe and
discard them.
5. Remove the front lower control arm assembly.

Refit
1. Locate the front lower control arm assembly rear
bushing to the front subframe, fit 1 new bolt and nut,
and tighten them to （ 81–99））Nm+（（175–185））°.
2. Locate the front lower control arm assembly front
bushing to the front subframe, fit 1 new bolt, and
tighten it to （ 81–99））Nm+（（85–95））°.
3. Locate the front lower control arm outer ball joint
to the steering knuckle, fit 1 bolt and 1 new nut and
tighten them to 50-65Nm.
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Front Lower Control Arm Outer Ball Joint Front Lower Control Arm Rear Bush
Remove Remove
1. Remove the front wheel. 1. Remove the front lower control arm assembly.
Wheels Remove Front Lower Control Arm Assembly Remove

2. Lift the vehicle to an appropriate height using the 2. Press the rear bush out from the front lower control
suitable jacking device. arm assembly by pressing machine and the special tool
3. Remove the front lower control arm assembly. TCH00116
Front Lower Control Arm Assembly Remove

4. Remove 3 bolts and nuts fixing the front lower control
arm outer ball joint to the front lower control arm.
Dispose the bolts and the nuts.
3. Remove the special tool from rubber bush.

Refit
1. Clean the concave notch of rubber bush.
2. Press the rubber bush into the front lower control
arm using the special tool TCH00116 and a pressing
5. Remove the outer ball joint.
machine.
Refit
1. Locate the front lower control arm outer ball joint to
the front lower control arm. Fit 3 new bolts and nuts
and tighten them to （ 81-99））Nm+（（85-95））°.
2. Refit the front lower control arm assembly.
Front Lower Control Arm Assembly Refit

3. Lower the vehicle to an appropriate height.
4. Refit the front wheel.
Wheels Refit
3. Remove the special tool from the bush.

4. Refit the front lower control arm assembly.
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Front Shock Absorber Assembly A/C Air Inlet Grille Assembly Remove
Remove 7. Remove 3 nuts fixing the front shock absorber to the
1. Remove the front wheels. body and discard them.
Wheels Refit
2. Disconnect the wheel speed sensor harness and brake
hose from the front shock absorber.
8. Remove the front shock absorber assembly.

9. Remove the dust cover at the top of the front shock
absorber.
10. Fix the spring compressor T32016and T32017to the
front shock absorber spring, ensure the adapter of the
spring compressor is properly fitted, and compress the
spring.
3. Support the steering knuckle and the brake disc with

hydraulic lifting device.
4. Remove 2 nuts and bolts (1) fixing the front shock
absorber assembly to the steering knuckle and discard
them. 11. Lock the top of the front shock absorber with an
5. Remove 1 nut (2) fixing the front anti-roll bar link to Allen wrench, remove and discard the top nut with
the front shock absorber and discard it. TCH00117 and an open-end wrench.
12. Remove the top mount assembly, bearing and upper
spring vibration isolator of the front shock absorber.
13. Remove the coil spring of front shock absorber and
lower spring vibration isolator.
14. Remove the bump stop and the dust cover.
15. Release the pressure of coil spring, loosen the adapter
from the spring compressor and remove the coil spring.
Refit
1. Check the front shock absorber strut and bearing for
any sign of crack or damage.
2. Check the dust cover and bump stop for any sign of
6. Remove the A/C air inlet grille assembly. aging or damage.
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3. Clean the front shock absorber strut and bump stop. 20. Check the wheel alignment.
4. Fit the bump stop and the dust cover to the front shock Four-wheel Alignment
absorber strut.
5. Fit the lower and spring vibration isolators and the
spring to the front shock absorber strut.
6. Apply T32016 and T32017 to compress the spring.
7. Ensure the correct relative position for installation, and

fit the bearing and the top mount assembly to the front
shock absorber strut.
8. Fit a new nut at the top of the front shock absorber.
9. Lock the top of the front shock absorber with an Allen
wrench and tighten the new nut to 65–75Nm with
TCH00117 and an open-end wrench.
10. Release the elasticity of the spring, loosen the adapter
of the spring compressor and take out the spring
compressor.
11. Fit the dust cover of the front shock absorber.
12. Clean the mating surfaces of the front shock absorber
assembly and the body.
13. Locate the front shock absorber assembly to the body,
fit 3 new nuts and tighten them to 55-65Nm.
14. Fit the A/C air inlet grille assembly.
A/C Air Inlet Grille Assembly Refit
15. Clean the front anti-roll bar link and locate it to the
front shock absorber assembly. Clamp the front
anti-roll bar link with a tool to lock the ball joint of the
link, fit 1 new nut and tighten it to 55-65Nm.
16. Locate the front shock absorber assembly to the
steering knuckle, fit 2 new bolts and nuts, and tighten
them to 140-170Nm.
17. Lower the hydraulic lifting device, and move it to the
safety zone.
18. Fit the front wheel speed sensor harness and brake
hose.
Wheels Refit
1.0 161
Full Frame Front Subframe

Remove
universal joint to the steering rack input shaft.
7. Remove the compressor bracket.

8. Remove the front, middle and bottom deflectors.
Front Bumper Remove
2. Remove the wheel centre trim cover, pry up the rear
9. Remove the front lower control arm assemblies (both
axle shaft nut locking device, and remove and discard
sides).
the axle shaft nuts (both sides).
10. Remove and discard 2 bolts fixing the bumper bar to
the full frame front subframe, and remove the bumper
bar.
3. Remove the front wheels (both sides).

Wheels Refit
11. Remove 1 nut fixing the front anti-roll bar link to the
Coolant Drain - PEB
front anti-roll bar and discard it (both sides).
- EDS to radiator from the EDS.
- CCU to EDS from the EDS.
12. Remove the nuts (both sides) fixing the steering rack
1.0 162
outer tie rod to the steering knuckle and discard them. electronic box and relevant harness clip.
13. Pull the wheel hub outward and disengage one end of 19. Disconnect the harness connector of the drive motor
axle shaft from the wheel hub (both sides). and relevant harness clip.
14. Disconnect the clip of EDS water pump harness
connector.
15. Remove 1 bolt fixing the EDS water pump to the EDS
water pump bracket, and set the EDS water pump
assembly to an appropriate position.
20. Remove 1 nut fixing the grounding wire to the

longitudinal beam.
16. Disconnect the clip of ESS water pump harness

connector.
17. Remove 1 bolt fixing the ESS water pump to the ESS
water pump bracket, and move the ESS water pump
to an appropriate position.
21. Disconnect the high voltage harness connector from

the PEB.
18. Disconnect the harness connector of the power
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22. Support the full frame front subframe assembly and 28. Remove and discard 1 bolt fixing the right mount to the
motor and mount assembly with hydraulic lifting device. full frame front subframe.
23. Remove 6 bolts fixing the full frame front subframe
assembly to the body.
29. Remove and discard 2 bolts and nuts fixing the steering
rack subassembly to the full frame front subframe, and
remove the steering rack subassembly.
24. Slowly lower the hydraulic lifting device, to disengage
the full frame front subframe assembly and motor and
mount assembly from the body.
25. Use a hoist to lift the motor and mount assembly at an
appropriate position.
26. Remove and discard 4 bolts fixing the rear mount
bracket to the full frame front subframe.
30. Remove and discard 4 bolts fixing the anti-roll bar to

the full frame front subframe, and remove the front
anti-roll bar.
27. Remove and discard 1 bolt fixing the left mount to the
full frame front subframe.
1.0 164
harness clip.
15. Locate the EDS water pump to the EDS water pump
bracket, fit 1 bolt and tighten it to 7-10Nm, and check
the torque.
16. Connect the clip of EDS water pump harness connector.
17. Pull the wheel hub outward to allow the axle shaft to
engage the wheel hub splines (both sides).
18. Locate the steering rack outer tie rod on the steering
knuckle, fit new nuts (both sides) and tighten them to
（ 28-32））Nm.
19. Locate the front anti-roll bar link to the front anti-roll
bar, fit 1 new nut (both sides) and tighten it to
31. Remove the full frame front subframe assembly. 55-65Nm.
Refit 20. Locate the bumper bar to the full frame front subframe,
1. Locate the front anti-roll bar to the full frame front fit 2 new bolts, and tighten them to 40–50Nm.
subframe, fit 4 new bolts, and tighten them to 21. Fit the front lower control arm assemblies (both sides).
55-65Nm.
2. Locate the steering rack subassembly to the full frame
front subframe, fit 2 new bolts and nuts, and tighten 22. Fit the front, middle and bottom deflectors.
them to 70Nm+90° . Front Bumper Remove
3. Fit 1 bolt fixing the right mount to the full frame front 23. Fit the compressor bracket.
subframe, tighten it to 90-110Nm, and check the
torque.
24. Connect the hose assembly - CCU to EDS to the EDS
4. Fit 1 bolt fixing the left mount to the full frame front
）Nm+（（85–95））°, and secure it with clamps.
subframe, tighten it to （ 81–99）
and check the torque. 25. Connect the hose assembly - EDS to radiator to the
EDS and secure it with clamps.
5. Fit 4 new bolts fixing the rear mount bracket to the
full frame front subframe, tighten them to 90-110Nm, 26. Refill the coolant.
and check the torque. Coolant Refill - EDS
6. Move away the hoist to a safe area. 27. Fit the front wheels (both sides).
7. Support the full frame front subframe assembly
Wheels Refit
and motor and mount assembly with hydraulic
lifting device, fit 6 bolts locating the full frame front 28. Fit the new axle shaft nut locking device and tighten
subframe assembly to the body, and tighten them to it to 345–375Nm.
（ 135-165））Nm+（（85-95））°. 29. Lock the nut to the front right axle shaft, and fit the
8. Lower the hydraulic lifting device, and move it to the wheel centre trim cover.
safety zone. 30. Locate the steering intermediate shaft to the steering
9. Connect the high voltage harness connector to the rack input shaft, fit 1 new bolt and tighten it to
PEB. 20Nm+120°.
10. Fit 1 nut fixing the grounding wire to the longitudinal

beam, and tighten it.
11. Connect the harness connector of the drive motor and
relevant harness clip.
12. Connect the harness connector of the power electronic
box and relevant harness clip.
13. Locate the ESS water pump to the ESS water pump
bracket, fit 1 bolt and tighten it to 4–6Nm.
14. Connect the ESS water pump harness connector and
1.0 165
Front Anti-roll Bar Front Anti-roll Bar Links

Remove Remove
1. Remove the front bottom deflector. 1. Remove the front wheel.
Front Bumper Remove Wheels Remove

2. Use a tool to lock the ball joint of the front anti-roll bar 2. Lift the vehicle to an appropriate height using a suitable
link, remove and discard the nuts (both sides) fixing jacking device.
the link to the anti-roll bar, and disconnect the anti-roll 3. Use a tool to block the front anti-roll bar links ball joint
bar from the link. to prevent it from turning. Remove 1 nut (1) fixing the
3. Remove 4 bolts fixing the front anti-roll bar to the full front anti—roll bar links to the front shock absorber
frame front subframe, and discard them. assembly and discard it.
4. Use a tool to block the front anti-roll bar links ball joint
to prevent it from turning. Remove 1 nut (2) fixing the
front anti—roll bar links to the front anti—roll bar and
discard it.
4. Take out the front anti-roll bar at an appropriate

position, and remove the bushing clamp and the bushing.
Refit
1. Fit the front anti roll bar bushing and clamp.
2. Locate the front anti-roll bar to the full frame front 5. Remove the front anti—roll bar links.
subframe, fit and pre-tighten 4 bolts, and tighten them Refit
to 55-65Nm in the sequence. 1. Locate the front anti-roll bar links to the front shock
3. Locate the front anti-roll bar link to the anti-roll bar, absorber assembly, refit 1 new nut, use a tool to block
use a tool to lock the ball joint of the link, fit new nuts the links ball joint to prevent it from turning and tighten
(both sides) and tighten them to 55–65Nm. it to 50–65Nm.
4. Fit the front bottom deflector. Caution: To prevent damage to components, use two
Front Bumper Remove spanners when loosening or tightening unions.
5. Check and adjust the four-wheel alignment parameters. 2. Locate the front anti-roll bar links to the front anti—roll
bar, refit 1 new nut, use a tool to block the links
Wheel Alignment
ball joint to prevent it from turning and tighten it to
55–65Nm.
Caution: To prevent damage to components, use two

spanners when loosening or tightening unions.
3. Lower the vehicle to an appropriate height.

4. Refit the front wheel.
Wheels Refit
1.0 166
Front Wheel Hub Bearing Assembly Front Steering Knuckle
Remove Remove
1. Remove the front wheels 1. Remove the front wheel hub assembly.
Wheels Remove Front Wheel Hub Assembly Remove
2. Pry up the locking device of the front drive half-axle 2. Remove 1 bolt fixing the front wheel speed sensor to
nut, and press down the brake pedal. Remove the front the steering knuckle.
drive half-axle nut and discard it.
3. Pull the front wheel speed sensor off the steering

3. Remove the front brake disc guard plate. knuckle.
Front Brake Disc Guard Plate Remove 4. Remove and discard 1 nut (1) fixing the ball head of
4. Remove 3 bolts that fasten the front hub assembly to steering gear outer tie rod to the steering knuckle.
the steering knuckle and discard them.
5. Disconnect the steering gear outer tie rod from the

5. Remove the front hub assembly. steering knuckle.
Refit 6. Remove 1 bolt and nut fixing the ball joint of front
lower swing arm assembly to the front steering knuckle,
1. Locate the front hub assembly on the steering knuckle,
discard the nut, and disconnect the connection.
（63–77）
install three new bolts, and tighten to（）Nm+
（ 85–95））°。
2. Install front brake disc guard plate.
Front Brake Disc Guard Plate Refit
3. Locate the front drive half axle on the front hub
assembly, install a new nut locking device, step on the
brake pedal, and tighten the nut to 225–275Nm。
4. Refit the front wheels
Wheels Refit
1.0 167
7. Remove and discard 2 bolts and nuts fixing the front

steering knuckle to the front shock absorber assembly,
then disconnect the connection.
8. Remove the front steering knuckle.

Refit
1. Locate the front steering knuckle to the front shock
absorber assembly, fit 2 new bolts and nuts, and tighten
them to 140–170Nm。
2. Locate the ball head of steering gear outer tie rod to
the steering knuckle, fit 1 new nut and tighten it to
28-32Nm。
3. Locate the front wheel speed sensor to the steering
knuckle, fit 1 bolt and tighten it to 7–10Nm。
4. Fit the front wheel hub assembly.
Front Wheel Hub Assembly Refit
1.0 168
Special Tools
Number
Remover and
TCH00116 relpace cap rear
lower arm bush
Coil spring
T32016
compressor
Adaptor
T32017 coil spring
compressor
Remover and
TCH00117 replacer front
damp big bolt
1.0 169
Suspension System Rear Suspension
Rear Suspension
Specifications
Torque
Description Value
Bolt-Rear shock absorber assembly to rear torsion beam 140–170Nm
Bolts-Rear shock absorber assembly to body 55–65Nm
Bolts-Rear wheel hub bearing assembly to wheel carrier （190-210）Nm+（85-95）°
Bolt-Rear wheel speed sensor to rear wheel support 7–10Nm
Nut-Rear wheel support to rear torsion beam 90-110Nm
Bolts-Rear damper to Rear torsion beam 140–170Nm
Bolts-Rear torsion beam to body 90–110Nm
Nuts-Rear wheel carrier to torsion beam 90–110Nm
1.0 170
Rear Suspension Suspension System
Service Procedures Rear Suspension Spring Assembly
Rear Shock Absorber Assembly Remove
Remove 1. Remove the rear wheels.
1. Remove the rear wheels. Wheels Remove
Wheels Remove 2. Raise the vehicle and support it securely, use a jack
2. Raise the vehicle on a lift and support the torsion beam. stand to support the torsion beam.
3. Remove and discard 2 bolts fixing the rear shock 3. Remove and discard the retaining bolts on both sides
absorber assembly to the upper body. under the shock absorber.
4. Remove and discard 1 bolt fixing the rear shock 4. Lower the torsion beam, and remove the spring and
absorber assembly to the torsion beam. upper&lower vibration isolators.
Refit
1. Fit and fasten the lower vibration isolator.
2. Fit the spring and upper vibration isolator, and raise
the torsion beam.
3. Pass the new bolt through the connecting bracket
under the shock absorber into the torsion beam, and
tighten it to 140–170Nm.
4. Fit the rear wheels.
Wheels Refit
5. Remove the jack stand and lower the vehicle.
5. Remove the rear shock absorber assembly.

Refit
1. Pass the new bolt through the connecting bracket
under the shock absorber into the torsion beam, and
tighten it to 140–170Nm.
2. Lower the vehicle to a height high enough to insert
the upper shock absorber stud into the corresponding
opening in the body, fit 2 new bolts and tighten them
to 55–65Nm.
Wheels Refit
1.0 171
Suspension System Rear Suspension
Rear Wheel Hub Wheel Bracket

Remove Remove
1. Remove the rear wheel. 1. Disconnect the negative battery cable.
Wheels Remove 2. Remove the rear brake disc guard.

2. Remove the rear brake caliper and the rear brake disc. Rear Brake Disc Guard Remove
Rear Brake Disc Remove 3. Disconnect the harness connector (1) of the rear wheel
speed sensor.
3. Remove the wheel hub bearing grease cap, and remove
the rear wheel hub bearing retaining bolt, discard the 4. Remove 1 bolt (2) fixing the rear wheel speed sensor
cap and the bolt. to the rear wheel bracket.
5. Remove and discard 4 nuts fixing the rear wheel

4. Remove the rear wheel hub bearing. bracket to the torsion beam.
Refit
1. Locate the rear wheel hub bearing assembly to the
rear spindle.
2. Fit 1 new rear wheel hub bearing assembly retaining
）Nm+（
bolt and tighten it to （ 190-210）（85-95））°.
3. Fit 1 new rear wheel hub bearing assembly grease cap.
4. Fit the rear brake caliper and rear brake disc.
Rear Brake Disc Refit

5. Fit the rear wheel.
Wheels Refit
6. Remove the rear wheel bracket.

Refit
1. Locate the rear wheel speed sensor to the rear wheel
bracket, fit 1 bolt and tighten it to 7–10Nm.
2. Connect the harness connector of the rear wheel
speed sensor.
3. Locate the rear wheel bracket to the torsion beam, fit
4 nuts and tighten them to 90-110Nm.
4. Fit the rear brake disc guard.
Rear Brake Disc Guard Refit

1.0 172
Rear Suspension Suspension System
Rear Torsion Beam Assembly
Remove
1. Remove the rear wheel hub assembly.
Rear Wheel Hub Remove
2. Remove the rear wheel speed sensor.
Rear Wheel Speed Sensor Remove
3. Remove 4 nuts fixing the rear brake disc guard plate
and rear spindle to the rear torsion beam.
4. Remove the rear brake disc guard plate and rear spindle.
5. Support the rear torsion beam assembly with the
hydraulic lifter.
6. Remove 8 bolts(1) fixing the rear torsion beam to the
body.
7. Remove the bolt (2) fixing the rear shock absorber to
the rear torsion beam, and disconnect the connection.
8. Slowly lower the hydraulic lifter.

9. Remove the rear suspension spring assembly, and
remove the rear torsion beam assembly.
Refit
1. Clean the junction surface of the rear torsion beam
assembly and the body.
2. Locate the rear torsion beam to its fixing points on the
body with the hydraulic lifter.
3. Locate the rear shock absorber to the rear torsion
beam, fit a new bolt and tighten it to 140–170Nm.
4. Locate the rear torsion beam to the body, fit 8 bolts
and tighten them to 90–110Nm.
6. Locate the rear spindle and rear brake disc guard plate
to the rear torsion beam, fit 4 nuts and tighten them
to 90–110Nm.
7. Fit the rear wheel speed sensor.
Rear Wheel Speed Sensor Refit
8. Fit the rear wheel hub assembly.
Rear Wheel Hub Assembly Refit
1.0 173
Suspension System Tyres and Wheels
Tyres and Wheels

Specifications
Torque
Description Value
Bolts-road wheel 120–130Nm
1.0 174
Tyres and Wheels Suspension System
Service Procedures wheel is seated firmly against the hub.
Tires and Wheels 5. Lower the vehicle.
Remove 6. Tighten 5 wheel bolts to 120–130Nm. For tightening
1. Take the position indicated by the arrow as the drawing order, please see the picture below (1 to 5).
point to remove the wheel trim cover.
7. Align the hollowed out part beside the valve mark on

2. Use the wheel bolt spanner to loosen each of the wheel the back of the wheel trim cover with the valve, and
bolts half a turn anti-clockwise. refit the wheel trim cover.
3. Place the vehicle on a suitable lift or jacking device,
raise to a suitable height.
4. Remove the 5 wheel bolts and put them in the tool tray.
5. Remove the wheels, extract the valve core assembly
and discard it, and remove the tyre from the rim with
a tyre changer.
Caution: Please pay special attention and take extra care
when working in the area of the tyre valve - this may
features an electronic transmitter device that can be easily
damaged.
Warning: Use a tyre changer to remove the tyre. Manual
tools or prybar could damage the road wheel or tyre.
Caution: Do not place the wheel face down on the ground Warning: If there is oil leakage between the wheel and the
to avoid scratching. brake disc or drum, it will cause the wheel bolts to become
loose and result in injury with the vehicle out of control.
Refit
Never use heat to remove a seized wheel. This will shorten
Caution: Please remove any corrosion from the surface of the life of the wheel, wheel bolts, hub and bearing. Wheel
the road wheel, drum and brake disc before refitting. If bolts must be tightened in correct sequence and to correct
wheel, disc and drum contact surfaces are not properly torque to avoid distortion of wheel, brake drum or disc.
cleaned, the wheel fixings could become loose and may
cause the wheel to fall off while the vehicle is moving. This
will cause the vehicle to go out of control, and could cause
injury.
1. Fit the new wheel valve assembly.
2. Fit the tyre onto the wheel using a suitable tyre changer
and inflate the tyre until the rim is in place. Ensure both
tyre beads are fully seated against the wheel rims.
3. Carry out a wheel dynamic balance using suitable tyre
balancing equipment.
4. Fit the wheel and tighten the wheel bolts until the
1.0 175
Suspension System Tyre Pressure Monitoring System
Tyre Pressure Monitoring System

Specifications
Torque
Description Value
Bolts-Tire pressure detection controller to the back panel 1.3–1.9Nm
of the central console
1.0 176
Tyre Pressure Monitoring System Suspension System
Service Procedures TPMS Control
Tyre Pressure Sensor Remove
Remove 1. Disconnect the negative battery.
1. Remove wheels. 2. Use tools to pry open the buttons that fix the back
Wheels Remove panel of the central console to the central console
assembly (as shown by the arrow).
2. Deflate the tyre.
3. Use the tyre changer to release the tyre from the rim
until the tyre pressure sensor can be seen.
4. Pull out the tyre pressure sensor and valve core
assembly.
3. Disconnect the TPMS controller electrical connector

(2).
4. Remove the two screws (1) that fix the tire pressure
monitoring controller to the back panel of the central
console.
5. Remove the tyre pressure sensor and valve core
assembly.
Refit
1. Fit the new tyre pressure sensor and valve core base
assembly to the hub. When fitting the tyre, ensure the
tyre will not touch the electronic module.
2. Inflate the tyre.
3. Rebalance the tyres.
4. Fit wheels.
Wheels Refit
5. Drive the vehicle at a speed of 40km/h for about
10 minutes until the tyre pressure value at the
corresponding position is correctly displayed in the 5. Remove the TPMS controller.
instrument display. Refit
1. Position the TPMS controller on the back panel of
the central console, install two screws, and tighten
to1.3–1.9Nm。
2. Connect the TPMS controller electrical connector.
3. Position the rear panel assembly of the central console
on the central console, and take the buckle in place.
5. Drive the vehicle at a speed of 40km/h(25mph) for
about 10 minutes until the tyre pressure value at the
corresponding position is correctly displayed in the
instrument display.
1.0 177
1.0 178
Brake Brake System
Brake
Specifications
Torque
Description Value
Bolts-Front brake caliper housing to brake caliper bracket 25–30Nm
Screw-Front brake disc to front wheel hub 7–10Nm
Bolts-Front brake caliper to steering hub assembly 190–210Nm
Bolts-Front brake disc protector to steering hub assembly 7–10Nm
Bolts-Front brake hose to front brake caliper housing 28–32Nm
Bolts-Brake caliper bracket to steering hub assembly 190–210Nm
Bolts-Rear brake caliper housing to rear brake caliper bracket 31–38Nm
Screw-Rear brake disc to rear wheel carrier 7–10Nm
Bolts-Rear brake caliper bracket to rear wheel bracket (81–99)Nm+(85–95)°
Bolts-Rear brake disc retaining to rear wheel bracket 7–10Nm
Bolts-Rear brake hose to rear brake caliper housing 28–32Nm
Bolt-Fluid reservoir to master cylinder 2.5–4.5Nm
Nuts- master cylinder to servo 21–29Nm
Nuts-Brake pipe to master cylinder 15–19Nm
Nuts- servo to pedal bracket 19–25Nm
Bolt-Brake light signal sensor to master cylinder 7–9Nm
Bolt- expansion tank to body 4–6Nm
Nuts-Brake pedal to front panel 19–25Nm
Bolts-Steering column intermediate shaft to upper steering 20Nm+120°
column
Nuts-Acceleration pedal to front panel 4–5Nm
Nuts-Brake pipe to ABS modulator 15–19Nm
Nuts-Brake pipe to brake hose pipe 15–19Nm
Nuts-Brake pipe to brake pipe 13–15Nm
Screw-Front bleeding screw 16–18Nm
Screw-Rear bleeding screw 9–13Nm
Bolts- EVP to bracket 7–10Nm
1.0 179
Brake System Brake
Service Procedures front brake pad in place.

Front Brake Pad Tip: Pedal travel may be longer than normal during first
Remove brake applications.
1. Remove the front wheels.
Wheels Remove
2. Remove the stop spring of the front brake caliper.
3. Remove the guide pin caps of the front brake caliper.
4. Remove and discard 2 guide pin bolts fixing the brake
caliper housing assembly to the front brake caliper
bracket.
5. Remove the front brake caliper housing assembly from

the front brake caliper bracket, and find the appropriate
position to fix it.
Caution: Do not tie or allow caliper to hang on brake
hose.
6. Remove the front brake pad from the brake caliper

bracket.
Refit
1. Clean up all dirt and corrosion contents from the edge
of the front brake disc.
2. Clean the front brake caliper housing and the front
brake caliper bracket, and check the front brake caliper
and seals for damage.
3. Locate the new front brake pad to the front brake
caliper bracket.
4. Use a tool to press the piston back into the brake
caliper housing.
5. Locate the front brake caliper housing assembly to the
front brake caliper bracket, fit 2 new guide pin bolts,
and tighten them to 25–30Nm.
6. Fit the guide pin caps of front brake caliper.
7. Fit the stop spring of front brake caliper.
Wheels Refit
9. Depress the brake pedal for several times to fit the
1.0 180
Brake Brake System
Front Brake Disc Wheels Refit
Remove
Wheels Remove
2. Remove and discard 2 bolts fixing the front brake
caliper assembly to the steering knuckle.
3. Lift the brake caliper assembly and find the appropriate

position to fix it.
4. Remove 1 countersunk head screw fixing the front
brake disc to the front wheel hub.
5. Remove the front brake disc assembly.

Refit
1. Clean the junction surface of the front brake disc and
the front wheel hub.
2. Locate the front brake disc to the front wheel hub, fit 1
countersunk head screw and tighten it to 7–10Nm.
3. Check the runout of the front brake disc.
Thickness and Circular Runout Check - Front
Brake Disc
4. Check the front brake pad, and replace it if necessary.
5. Fix the front brake caliper assembly to the steering
knuckle, fit 2 new bolts and tighten them to
190–210Nm.
1.0 181
Brake System Brake
Front Brake Disc Guard Plate Front Brake Caliper Housing Assembly
Remove Remove
1. Remove the front brake disc. 1. Remove the front wheels.
Front Brake Disc Remove Wheels Remove

2. Remove 3 bolts fixing the front brake disc guard plate 2. Put the cloth at the front brake hose fitting to absorb
to the steering knuckle. the spilled brake fluid.
3. Remove 1 bolt and gasket fixing the front brake hose
to the front brake caliper housing, discard the gasket
and disconnect the pipeline.
Caution: Before disconnecting or removing components,
ensure the immediate area around joint faces and
connections are clean. Plug open connections to prevent
contamination.
3. Remove the front brake disc guard plate.

Refit
1. Locate the front brake disc guard plate to the steering
knuckle, fit 3 bolts and tighten them to 7–10Nm.
2. Fit the front brake disc.
Front Brake Disc Refit

4. Remove the stop spring of the front brake caliper.
5. Remove the guide pin caps of the front brake caliper.
6. Remove and discard 2 guide pin bolts fixing the front
brake caliper housing to the front brake caliper bracket.
7. Remove the front brake caliper housing assembly.

Refit
1. Clean up all dirt and corrosion contents from the edge
of the front brake disc.
2. Locate the front brake caliper housing to the front
brake caliper bracket, fit 2 new guide pin bolts, and
tighten them to 25–30Nm.
1.0 182
Brake Brake System
3. Fit the guide pin caps of front brake caliper. Front Brake Caliper Bracket
4. Fit the stop spring of front brake caliper. Remove
5. Locate the front brake hose to the front brake caliper 1. Remove the front wheels.
housing, fit 1 bolt and new gasket, and tighten it to Wheels Remove
28–32Nm. 2. Remove the stop spring of the front brake caliper.
6. Take the cloth for absorbing spilled brake fluid away 3. Remove the guide pin caps of the front brake caliper.
and dispose of it.
4. Remove and discard 2 guide pin bolts fixing the front
7. Drain the brake system. brake caliper housing to the front brake caliper bracket.
Brake System Drain
8. Fit the wheels.
Wheels Refit
5. Remove the front brake caliper housing assembly, move

it to an appropriate position and fix it.
hose.
6. Remove the front brake pad from the brake caliper
bracket.
7. Remove and discard 2 bolts fixing the front brake
caliper bracket to the steering knuckle.
8. Remove the front brake caliper bracket.

Refit
1. Locate the front brake caliper bracket to the
steering knuckle, fit 2 new bolts and tighten them to
190–210Nm.
2. Clean the front brake caliper housing and the front
brake caliper bracket.
3. Fit the front brake pad to the front brake caliper
1.0 183
Brake System Brake
bracket. Rear Brake Pad

4. Remove the front brake caliper housing. Remove
5. Locate the front brake caliper housing to the front 1. Use the scan tool to release the electronic parking
brake caliper bracket, fit 2 new guide pin bolts, and brake.
tighten them to 25–30Nm. 2. Disconnect the negative battery cable.
6. Fit the guide pin caps of front brake caliper. 3. Remove the rear wheels.
7. Fit the stop spring of front brake caliper. Wheels Remove
8. Fit the front wheels. 4. Disconnect the parking motor harness connector.
Wheels Refit 5. Remove 1 bolt fixing the rear brake caliper housing
assembly to the rear brake caliper bracket.
6. Turn up the rear brake caliper housing and fix it. Be

careful not to damage the hoses or other components.
hose.
7. Remove the rear brake pad from the rear brake caliper
bracket.
Refit
1. Clean all dirt and corrosion contents from the edge of
the rear brake disc.
2. Clean the rear brake caliper housing and the rear brake
caliper bracket, and check the rear brake caliper for
damage.
3. Locate the rear brake pad spring to the rear brake
caliper bracket.
4. Locate the rear brake pad to the rear brake pad spring.
Let the inner and outer brake pads clamp the brake
disc and then release. Confirm that the inner and outer
brake pads can be returned, and there are visible gaps
between the brake pads and the brake disc.
Caution: Please replace the rear brake pad spring, if the
rear brake pad is replaced.
5. Use tools to press the rear brake caliper piston into the
rear brake caliper housing.
6. Turn down the rear brake caliper housing, locate it to
the rear brake caliper bracket and align them, fit 1 bolt
and tighten it to 31–38Nm.
1.0 184
Brake Brake System
7. Connect the parking motor harness connector. Rear Brake Disc
8. Fit the rear wheels. Remove
1. Use the scan tool to release the electronic parking
Wheels Refit
brake.
3. Remove the rear wheels.
rear brake pad in place.
Tip: Pedal travel may be longer than normal during first Wheels Remove
brake applications. 4. Disconnect the parking motor harness connector.
11. Connect the scan tool and carry out the 5. Remove and discard 2 bolts fixing the rear brake caliper
electronic parking brake system component assembly to the rear spindle.
replacement/adjustment routine.
6. Carefully pry up the rear brake caliper assembly with a

tool, and find an appropriate position to fix it.

hose.
7. Remove 1 countersunk head screw fixing the rear

brake disc to the rear wheel hub.
8. Remove the rear brake disc from the vehicle.

Refit
1. Clean the mating interface of the rear brake disc and
the rear wheel hub.
2. Locate the rear brake disc to the rear wheel hub, fit 1
3. Check the runout of the rear brake disc.
1.0 185
Brake System Brake
Thickness and Circular Runout Check - Rear Rear Brake Disc Guard Plate
Brake Disc Remove
4. Check the mounting surface and holes of the rear 1. Remove the rear wheel hub.
spindle and rear brake caliper assembly, remove the
Rear Wheel Hub Remove
foreign material or oil stain to ensure clean mounting
2. Remove 4 bolts fixing the rear brake disc guard plate
surface and holes.
to the rear spindle.
5. Use tools to press the rear brake caliper piston into the
rear brake caliper housing.
6. Locate the rear brake caliper assembly to the
rear spindle, fit 2 new bolts and tighten them to
(81–99)Nm+(85–95)°.
Caution: The bolt can only be used once, and it should be

replaced by a new one after the bolt is screwed (not only
screw down but also screw off).
7. Connect the parking motor harness connector.

Wheels Refit
3. Remove the rear brake disc guard plate from the
10. Connect the scan tool and carry out the
vehicle.
electronic parking brake system component
replacement/adjustment routine. Refit
1. Locate the rear brake disc guard plate to the rear
spindle, fit 4 bolts and tighten them to 7–10Nm.
2. Fit the rear wheel hub.
Rear Wheel Hub Refit
1.0 186
Brake Brake System
Rear Brake Caliper Housing Assembly 4. Take the cloth for absorbing spilled brake fluid away
Remove and dispose of it.
1. Remove the electronic parking brake motor. 5. Fit the electronic parking brake motor.
Electronic Parking Brake Motor Remove Electronic Parking Brake Motor Refit
2. Put the cloth at the rear brake hose fitting to absorb 6. Drain the brake system.
the spilled brake fluid.
Brake System Drain
3. Remove 1 bolt and gasket fixing the rear brake hose to
the rear brake caliper housing, and discard the gasket.
contamination.
4. Remove 2 bolts fixing the rear brake caliper housing

5. Remove the rear brake caliper housing assembly from

the vehicle.
Refit
1. Clean the rear brake components with brake cleaner.
2. Locate the rear brake caliper housing assembly to the
rear brake caliper bracket, fit 2 bolts and tighten them
to 31–38Nm.
3. Locate the rear brake hose to the rear brake caliper
housing, fit 1 bolt and new gasket, and tighten it to
28–32Nm.
1.0 187
Brake System Brake
Rear Brake Caliper Bracket 3. Locate the rear brake caliper bracket to the
Remove rear spindle, fit 2 new bolts and tighten them to
1. Use the scan tool to release the electronic parking (81–99)Nm+(85–95)°.
brake. 4. Fit the rear brake pad.
2. Disconnect the negative battery cable. 5. Remove the rear brake caliper housing assembly.
3. Remove the rear wheels. 6. Locate the rear brake caliper housing assembly to the
rear brake caliper bracket, fit 2 bolts and tighten them
Wheels Remove
to 31–38Nm.
4. Disconnect the parking motor harness connector.
5. Remove 2 bolts fixing the rear brake caliper housing
Wheels Refit
10. Connect the scan tool and carry out the
electronic parking brake system component
replacement/adjustment routine.
6. Carefully pry up the rear brake caliper housing assembly

with a tool, move it to an appropriate position and fix it.
hose.
7. Remove the rear brake pad.

8. Remove and discard 2 bolts fixing the rear brake caliper
bracket to the rear spindle.
9. Remove the rear brake caliper bracket.

Refit
1. Clean all dirt and corrosion contents from the edge of
the rear brake disc.
2. Clean the rear brake caliper housing and the rear brake
caliper bracket with brake cleaner.
1.0 188
Brake Brake System
Thickness and Circular Runout Check - Front 6. Fix the probe of the DTI to the location 10mm inward
Brake Disc from the edge of the front brake disc.
Check 7. Fit the front wheels.
Wheels Refit
Wheels Remove
8. Reset the DTI, turn the wheel for a full circle and
Warning: Do not work on or under a vehicle supported measure the front brake disc runout. The runout of the
only by a jack.Always support the vehicle on safety stands. front brake disc shall not exceed 0.05mm.
2. Remove and discard 2 bolts fixing the front brake 9. If the brake disc runout exceeds the limit:
caliper assembly to the steering knuckle.
a. Remove the front wheels.
b. Remove 1 countersunk head screw fixing the front

brake disc to the front wheel hub and remove the
front brake disc.
c. Clean the junction surface of the front brake disc

and the front wheel hub.
d. Fit the front brake disc to the front wheel hub, fit 1
e. Fit the front wheels.
f. Recheck the runout of the brake disc according to

the above procedures.
3. Remove the front brake caliper assembly and move it g. If the runout still exceeds the limit, replace the front
to an appropriate position to fix it. brake disc or front wheel hub.
4. Measure the thickness of the front brake disc as per 10. Remove the front wheels.
the four equal division points on the surface of front
Wheels Remove
brake disc with a micrometer, and the measurement
points are located 10mm inward from the edge of the 11. Remove the DTI and TCH00022 from the inner side
front brake disc. The thickness of the front brake disc of the front wheel hub.
shall be at least 23mm. If it exceeds the limit, the front 12. Fix the front brake caliper assembly to the front
brake disc must be replaced. steering knuckle, fit 2 new bolts and tighten them to
190–210Nm.
Caution: Brake discs must be renewed in pairs, unless one
disc requires renewal before 1000 miles (1500 km) from 13. Fit the front wheels.
new. Wheels Refit
front brake pad in place.
Tip: Pedal travel may be longer than normal during first

brake applications.
5. Fit the dial indicator (DTI) to the TCH00022, and fix

the TCH00022 to the inner side of the front wheel
hub through the bolt hole of the front brake caliper
assembly.
1.0 189
Brake System Brake
Thickness and Circular Runout Check - Rear

Brake Disc
Check
1. Use the scan tool to release the electronic parking
brake.
Wheels Remove

5. Remove and discard 2 bolts fixing the rear brake caliper 7. Fit the dial indicator (DTI) to the TCH00022, and fix
assembly to the rear spindle, remove the rear brake the TCH00022 to the inner side of the rear wheel
caliper assembly and move it to an appropriate position bracket through the bolt hole of the rear brake caliper
to fix it. assembly.
Caution: Do not tie or allow caliper to hang on brake 8. Fix the probe of the DTI to the location 10mm inward
hose. from the edge of the rear brake disc.
Wheels Refit
10. Reset the DTI, turn the wheel for a full circle and
measure the rear brake disc runout. The runout of the
rear brake disc shall not exceed 0.08mm.
11. If the rear brake disc runout exceeds the limit:
a. Remove the rear wheels.
b. Remove 1 countersunk head screw fixing the rear
brake disc to the rear wheel hub and remove the
rear brake disc.
c. Clean the junction surface of the rear brake disc and
the rear wheel hub.
6. Measure the thickness of the rear brake disc as per the
four equal division points on the surface of rear brake d. Locate the rear brake disc to the rear wheel hub, fit 1
disc with a micrometer, and the measurement points countersunk head screw and tighten it to 7–10Nm.
are located 10mm inward from the edge of the rear e. Fit the rear wheels.
brake disc. The thickness of the rear brake disc shall
f. Recheck the runout of the rear brake disc according
be at least 8mm. If it exceeds the limit, the rear brake
to the above procedures.
disc must be replaced.
g. If the runout still exceeds the limit, replace the rear
Caution: Brake discs must be renewed in pairs, unless one
brake disc or the rear wheel hub.
disc requires renewal before 1000 miles (1500 km) from
new. 12. Remove the rear wheels.
Wheels Remove
13. Remove the DTI and TCH00022 from the inner side
of the rear wheel hub.
14. Locate the rear brake caliper assembly to the
rear spindle, fit 2 new bolts and tighten them to
(81–99)Nm+(85–95)°.
Wheels Refit
1.0 190
Brake Brake System
17. Connect the negative battery cable. Reservoir Assembly
18. Depress the brake pedal for several times to fit the Remove
rear brake pad in place. 1. Disconnect the negative battery cable.
Tip: Pedal travel may be longer than normal during first 2. Unscrew the brake fluid reservoir cap, and drain the
brake applications. brake fluid.
19. Use the scan tool to adjust the electronic parking brake 3. Put the cloth under the brake master cylinder and
system. reservoir assembly to absorb the spilled brake fluid.
Caution: Brake fluid will damage paint finished surfaces.

If spilled, immediately remove fluid and clean area with
water.
4. Disconnect the harness connector (2) of the brake fluid

reservoir level sensor.
5. Remove 1 bolt (1) fixing the brake fluid reservoir to
the brake master cylinder.
6. Remove the brake fluid reservoir assembly.

Refit
1. Locate the brake fluid reservoir to the brake master
cylinder, fit 1 bolt, and tighten it to 2.5–4.5Nm.
2. Connect the harness connector of the brake fluid
reservoir level sensor.
3. Take the cloth for absorbing spilled brake fluid away
and dispose of it.
5. Drain the brake system.
Brake System Drain
1.0 191
Brake System Brake
Brake Master Cylinder 5. Fit the brake fluid reservoir assembly.

Remove Reservoir Assembly Refit
1. Remove the brake fluid reservoir assembly.
Reservoir Assembly Remove
2. Remove the brake lamp signal sensor.
Brake Lamp Signal Sensor Remove
3. Release 2 brake hard pipes (1) from the brake master
cylinder.
contamination.
4. Remove and discard 2 nuts fixing the brake master

cylinder to the vacuum booster.
5. Remove the brake master cylinder from the vehicle.

Refit
1. Locate the brake master cylinder to the vacuum
booster, fit 2 new nuts and tighten them to 21–29Nm.
2. Clean the brake hard pipe fittings.
3. Locate the brake hard pipe fittings to the brake master
cylinder, and tighten the fitting nuts to 15–19Nm.
4. Fit the brake lamp signal sensor.
Brake Lamp Signal Sensor Refit
1.0 192
Brake Brake System
Vacuum Booster Assembly pin and fasten it in place.
Remove 3. Connect the vacuum brake hose to the vacuum booster.
1. Remove the brake modulator. 4. Connect the harness connector of the vacuum sensor.
Brake Modulator Remove 5. Fit the brake master cylinder.
2. Remove the brake master cylinder. Brake Master Cylinder Refit
Brake Master Cylinder Remove 6. Fit the brake modulator.
3. Disconnect the harness connector of the vacuum
Brake Modulator Refit
sensor.
4. Disconnect the vacuum brake hose from the vacuum
booster (1).
Caution: The force to remove the hose shouldn’t too
heavy to damage the connector of vacuum hose.Do not
damage the connector and keep the connector away
from water when removing or fixing the hose with vacuum
sensor.
5. Remove the pin (2) fixing the vacuum booster to the

brake pedal.
6. Remove 4 nuts (1) fixing the vacuum booster to the
pedal bracket.
7. Remove the vacuum booster assembly from the vehicle.

Refit
1. Locate the vacuum booster assembly to the pedal
bracket, fit 4 nuts and tighten them to 19–25Nm.
2. Locate the vacuum booster to the brake pedal, fit the
1.0 193
Brake System Brake
Vacuum Brake Hose Assembly 3. Connect the vacuum brake hose to the vacuum booster.
Remove 4. Connect the harness connector of the vacuum sensor.
1. Remove the manual service disconnect. 5. Fit the manual service disconnect.
Manual Service Disconnect Remove Manual Service Disconnect Refit
2. Disconnect the harness connector of the vacuum
sensor.
3. Disconnect the vacuum brake hose from the vacuum
booster.
Caution: The force to remove the hose shouldn’t too
heavy to damage the connector of vacuum hose.Do not
damage the connector and keep the connector away
from water when removing or fixing the hose with vacuum
sensor.
4. Disconnect the vacuum brake hose from the electric

vacuum pump
5. Loosen the clip and remove the vacuum brake hose

assembly.
Refit
1. Arrange the vacuum brake hose properly and fit the clip.
2. Connect the vacuum brake hose to the electric vacuum
pump.
Caution: Keep the dust and foreign matter from vacuum
hose.If having trouble to fix vacuum hose ， please using
grease special for fixing vacuum hose to lubricate ， other
liquid or grease is prohibited.
1.0 194
Brake Brake System
Brake Lamp Signal Sensor Brake Pedal
Remove Remove
1. Disconnect the negative battery cable. 1. Remove the accelerator pedal.
2. Remove 1 bolt (2) fixing the coolant expansion tank Accelerator Pedal Remove
to the bracket.
2. Remove the driver side lower trim panel assembly.
Driver Side Lower Trim Panel Assembly Remove
3. Disconnect the harness connector (2) of the brake
pedal position sensor.
3. Remove the coolant expansion tank from the bracket.

lamp signal sensor.
5. Remove 1 bolt (1) fixing the brake lamp signal sensor
to the brake master cylinder. 4. Remove and discard 1 bolt fixing the intermediate shaft
universal joint to the steering column.
6. Remove the brake lamp signal sensor.

5. Disconnect the intermediate shaft from the steering
Refit
column.
1. Locate the brake lamp signal sensor to the brake master
6. Remove 5 nuts (1) fixing the brake pedal to the dash
cylinder, fit 1 bolt and tighten it to 7–9Nm.
panel.
2. Connect the harness connector of the brake lamp
7. Remove the pin (2) and disconnect the brake pedal
signal sensor.
from the vacuum booster.
3. Locate the coolant expansion tank to the bracket, fit 1
bolt and tighten it to 4–6Nm.
1.0 195
Brake System Brake
Brake Pedal Position Sensor

Remove
2. Disconnect the harness connector of the brake pedal
position sensor (2).
8. Loosen the harness clip fixed onto the pedal bracket

and remove the brake pedal assembly.
Refit
1. Locate the brake pedal assembly to the dash panel and
make it fit well with the vacuum booster, then fit the
harness clip onto the brake pedal bracket.
3. Loosen the fixing bolt and remove the brake pedal
2. Locate the vacuum booster push rod to the brake pedal position sensor.
and fit the pin by aligning the hole.
Refit
3. Fix the brake pedal to the dash panel, fit 5 nuts and
1. Locate the brake pedal position sensor to the pedal
tighten them to 19–25Nm.
bracket and fix the fixing bolt.
4. Locate the intermediate shaft universal joint to the
2. Connect the harness connector of the brake pedal
steering column, fit 1 new bolt and tighten it to
position sensor.
20Nm+120°.
5. Connect the harness connector of the brake pedal
4. Operate self-learning for the brake pedal position
position sensor.
sensor. Refer to Module Self-learning and Programming
Manual “Gate Way (GW) Self-learning”.
7. Fit the accelerator pedal.
Accelerator Pedal Refit
1.0 196
Brake Brake System
Accelerator Pedal Master Cylinder Brake Hard Pipe
Remove Remove
2. Disconnect the accelerator pedal harness connector 2. Remove 1 bolt (2) fixing the coolant expansion tank to
(1). the bracket, and remove the coolant expansion tank.
3. Remove and discard 3 bolts (2) fixing the accelerator
pedal assembly to the brake pedal.
3. Put the cloth under the brake modulator and master

cylinder to absorb the spilled brake fluid.
4. Remove the accelerator pedal assembly from the 4. Remove 2 fittings (1) fixing the brake hard pipe to the
vehicle. brake master cylinder.
Refit 5. Remove 2 fittings (2) fixing the brake hard pipe to the
1. Fix the accelerator pedal assembly to the brake pedal, brake modulator.
fit 3 new bolts and tighten them to 4–5Nm. Caution: Before disconnecting or removing components,
2. Connect the accelerator pedal harness connector. ensure the immediate area around joint faces and
3. Connect the negative battery cable. connections are clean. Plug open connections to prevent
contamination.
6. Remove the master cylinder brake hard pipe.

Refit
1. Locate 2 brake hard pipe fittings to the brake modulator,
and tighten the 2 fittings to 15–19Nm.
2. Locate 2 brake hard pipe fittings to the brake master
cylinder, and tighten the 2 fittings to 15–19Nm.
and dispose of it.
1.0 197
Brake System Brake
bolt and tighten it to 4–6Nm. Front Left Brake Hard Pipe

6. Drain the brake system. 1. Disconnect the negative battery cable.
2. Remove 1 bolt (2) fixing the coolant expansion tank to
Brake System Drain
the bracket, and remove the coolant expansion tank.
3. Put the cloth at the front left brake hard pipe fitting to
absorb the spilled brake fluid.
4. Remove the fitting nut (3) fixing the front left brake
hard pipe to the brake modulator, and disconnect the
pipe connection.

contamination.
5. Remove the fitting nut fixing the front left brake hard
pipe to the front left brake hose, and disconnect the
pipe connection.

contamination.
1.0 198
Brake Brake System
Front Right Brake Hard Pipe
Remove
6. Disconnect the front left brake hard pipe from the clip
on the body.
7. Remove the front left brake hard pipe from the vehicle.
Refit
1. Locate the front left brake hard pipe to the body and
fasten it with clips. 2. Remove the manual service switch.
2. Locate the front left brake hard pipe fitting to the Manual Service Disconnect Remove
front left brake hose, and tighten the fitting nut to 3. Remove the front bottom deflector.
15–19Nm.
3. Locate the front left brake hard pipe to the brake
modulator, and tighten the fitting nut to 15–19Nm. 4. Put the cloth at the front right brake hard pipe fitting to
absorb the spilled brake fluid.
and dispose of it. 5. Remove the fitting nut (2) fixing the front right brake
hard pipe to the brake modulator, and disconnect the
pipe connection.
6. Connect the negative battery cable. Caution: Before disconnecting or removing components,
Brake System Drain contamination.
6. Remove the fitting nut fixing the front right brake hard
pipe to the front right brake hose, and disconnect the
pipe connection.
contamination.
1.0 199
Brake System Brake
Connecting Pipe - ABS to Rear Brake Pipe

Remove

bracket, and remove the coolant expansion tank.
7. Disconnect the front right brake hard pipe from the

clip on the body.
8. Carefully pull the front right brake hard pipe out of
the vehicle.
Refit
1. Locate the front right brake hard pipe to the body and
fasten it with clips. 3. Place a suitable absorbent cloth under the brake
2. Locate the front right brake hard pipe fitting to the modulator to absorb the spilled brake fluid.
front right brake hose, and tighten the fitting nut to 4. Remove 2 fitting nuts fixing the connecting pipe from
15–19Nm. brake modulator to rear brake pipe to the brake
3. Locate the front right brake hard pipe to the brake modulator.
modulator, and tighten the fitting nut to 15–19Nm.
4. Take the cloth for absorbing spilled brake fluid away ensure the immediate area around joint faces and
and dispose of it. connections are clean. Plug open connections to prevent
5. Fit the front bottom deflector. contamination.
6. Fit the manual service switch.

Brake System Drain
5. Disconnect the brake modulator from the connecting

pipe, and plug the opening of the brake pipe and the
brake modulator to avoid any brake fluid loss and
contamination.
6. Remove the front, middle and bottom deflectors.

7. Disconnect the harness connector of the high-voltage
battery pack.
1.0 200
Brake Brake System
6. Remove the plug from the pipe fitting, locate the
connecting pipe fitting from brake modulator to rear
brake pipe to the brake modulator, and tighten the
fitting nut to 15–19Nm.
7. Take away the absorbent cloth and dispose of it.

10. Bleed the brake system.
8. Place a suitable absorbent cloth right under the brake Brake System Bleeding
pipe fitting to absorb the spilled brake fluid.
9. Remove 2 fitting nuts fixing the connecting pipe from
brake modulator to rear brake pipe to the rear brake
pipe.
contamination.
10. Disconnect the pipe fitting, and plug the opening of

the brake pipe for the avoidance of brake fluid loss or
contamination.
11. Disconnect the clip from the brake pipe.
12. Carefully pull the connecting pipe from brake modulator
to rear brake pipe out of the vehicle.
Refit
1. Locate the connecting pipe from brake modulator to
rear brake pipe to the body and secure it with clips.
2. Remove the plug from the pipe fitting, locate the
connecting pipe fitting from brake modulator to rear
brake pipe to the rear brake pipe, and tighten the fitting
nut to 13–15Nm.
3. Take away the absorbent cloth and dispose of it.
4. Connect the harness of the high-voltage battery pack.
5. Fit the front, middle and bottom deflectors.
1.0 201
Brake System Brake
Rear Left Brake Pipe Refit

Remove 1. Locate the rear left brake pipe to the clips on the body
1. Remove the high-voltage battery. and fasten it.
High-voltage Battery Pack Remove 2. Remove the plug from the pipeline, locate the rear
left brake pipe fitting to the rear left brake hose, and
2. Prepare an appropriate container to collect the spilled
tighten the fitting nut to 15–19Nm.
brake fluid.
3. Remove the plug from the pipeline, fix the connecting
3. Remove the fitting nuts fixing the connecting pipe from
pipe from brake modulator to rear brake pipe to the
brake modulator to rear brake pipe to the rear left
rear left brake pipe, and tighten the fitting nut to
brake pipe.
13–15Nm.
4. Take the container for collecting brake fluid away, and
clean it.
contamination. 5. Fit the high-voltage battery.

Brake System Bleeding

contamination.
5. Remove the fitting nut fixing the rear left brake pipe to
the rear left brake hose, and disconnect the pipeline.
contamination.
6. Disconnect the clip fixing the rear left brake pipe to

the body.
7. Carefully pull the rear left brake pipe out of the vehicle.
1.0 202
Brake Brake System
Rear Right Brake Pipe vehicle.
Remove Refit
1. Remove the high-voltage battery. 1. Locate the rear right brake pipe to the clips on the
High-voltage Battery Pack Remove body and fasten it.
2. Prepare an appropriate container to collect the spilled 2. Remove the plug from the pipeline, locate the rear
brake fluid. right brake pipe fitting to the rear right brake hose, and
tighten the fitting nut to 15–19Nm.
3. Remove the nut fixing the connecting pipe from brake
modulator to rear brake pipe to the rear right brake 3. Remove the plug from the pipeline, fix the connecting
pipe. pipe from brake modulator to rear brake pipe to the
rear right brake pipe, and tighten the fitting nut to
13–15Nm.
connections are clean. Plug open connections to prevent 4. Take the container for collecting brake fluid away, and
contamination. clean it.
5. Fit the high-voltage battery.

Brake System Bleeding

contamination.
5. Remove the fitting nut fixing the rear right brake pipe to
the rear right brake hose, and disconnect the pipeline.
contamination.
6. Disconnect the clip fixing the rear right brake pipe to

the body.
7. Carefully pull the rear right brake pipe out of the
1.0 203
Brake System Brake
Front Brake Hose Rear Brake Hose

Remove Remove
1. Raise the vehicle to the appropriate height. 1. Raise the vehicle to the appropriate height.
2. Put the cloth at the front brake hose fitting to absorb 2. Put the cloth at the rear brake hose fitting to absorb
the spilled brake fluid. the spilled brake fluid.
3. Remove the fitting nut (1) fixing the front brake hard 3. Remove the fitting nut (2) fixing the rear brake hard
pipe to the front brake hose, and disconnect the pipe pipe to the rear brake hose, and disconnect the pipe
connection. connection.
4. Remove the pin (2) fixing the front brake hose to the 4. Remove 1 bolt and washer (1) fixing the rear brake
body bracket. hose to the rear brake caliper housing, and discard
5. Remove 1 bolt and washer (3) fixing the front brake the washer.
hose to the front brake caliper housing, and discard Caution: Before disconnecting or removing components,
the washer. ensure the immediate area around joint faces and
Caution: Before disconnecting or removing components, connections are clean. Plug open connections to prevent
ensure the immediate area around joint faces and contamination.
contamination.
5. Loosen the rear brake hose pin, and remove the rear
brake hose.
6. Disconnect the front brake hose from the shock Refit
absorber strut.
1. Clean the brake pipeline fittings.
7. Remove the front brake hose.
2. Locate the rear brake hose to the body bracket, fit the
Refit pin and fasten it in place.
1. Clean the brake pipeline fittings. 3. Locate the rear brake hose to the rear brake caliper
2. Locate the front brake hose to the shock absorber housing, fit 1 bolt and new washer, and tighten it to
strut. 28–32Nm.
3. Locate the front brake hose to the front brake caliper 4. Locate the rear brake hard pipe fittings to the rear
housing, fit 1 bolt and new washer, and tighten it to brake hose, and tighten the fitting nut to 15–19Nm.
28–32Nm. 5. Take the cloth for absorbing spilled brake fluid away
4. Locate the front brake hose to the body bracket, fit the and dispose of it.
pin and fasten it in place. 6. Lower the vehicle.
5. Locate the front brake hard pipe fitting to the front 7. Bleed the brake system.
brake hose, and tighten the fitting nut to 15–19Nm.
Brake System Bleed
and dispose of it.
Brake System Bleed
1.0 204
Brake Brake System
Brake System Bleed
Drain
1. Refill the brake fluid reservoir to the MAX mark.
Caution: During the entire bleeding process, ensure the

new brake fluid level in the brake reservoir is between the
Min. and Max. position.
2. Remove the wheels.
Wheels Remove
3. Raise the vehicle to the appropriate height.
4. Remove the bleed screw dust cover at the rear right
brake caliper, and fit the hose onto the bleed screw.
Immerse the free end of the hose into the container 10. Lower the vehicle.
with fresh brake fluid. 11. Refill the brake fluid reservoir to the MAX mark.
12. Apply pressure to the brake pedal and check for
leakage.
13. Fit the wheels.
Wheels Refit
14. Test the vehicle on the road. Check the minimum travel
of the brake pedal when the brake is in effect.
5. Depress the brake pedal for several times and apply

stable pressure.
6. Release the bleed screw to separate the brake fluid and
air. Allow the pedal to return without any external
force.
7. Depress the brake pedal to the maximum travel
steadily, and allow it to return without any external
force. Repeat the operation for several times until the
air-free brake fluid flows into the container, then fix the
brake pedal to the maximum travel, tighten the front
bleed screw to 16–18Nm and the rear bleed screw
to 9–13Nm.
8. Remove the hose from the bleed screw and fit the
bleed screw dust cover.
9. Repeat the bleeding procedures for the remaining 3
brake calipers in the following sequence: rear left -
front right - front left.
1.0 205
Brake System Brake
Electric Vacuum Pump

Remove

3. Disconnect the electric vacuum pump harness from the
water temperature sensor harness connector.
4. Disconnect the vacuum brake hose from the electric
vacuum pump (1).
5. Remove 2 bolts (2) fixing the electric vacuum pump
to the bracket.
6. Take out the electric vacuum pump at the proper

position.
Refit
1. Locate the electric vacuum pump to the bracket, fit 2
bolts and tighten them to 7–10Nm.
2. Connect the vacuum brake hose to the electric vacuum
pump.
3. Connect the electric vacuum pump harness to the
water temperature sensor harness connector.
4. Lift the vehicle.
1.0 206
Brake Brake System
Special Tools
Number
Brake disc
TCH00022
runout test kit
1.0 207
Brake System Park Brake
Park Brake
Specifications
Torque
Description Value
Bolts-Rear EPB motor to caliper 10–13Nm
1.0 208
Park Brake Brake System
Service Procedures
Electronic Parking Brake Motor
Remove
1. Use a scan tool to perform an electronic parking brake
release.
Wheels Remove
5. Remove 2 bolts fixing the parking motor to the rear
brake caliper housing.
6. Remove the parking motor.

Refit
1. Locate the parking motor to the rear brake caliper
housing, fit 2 bolts and tighten them to 10–13Nm.
Wheels Refit
5. Perform a self-learning for the parking motor. Refer
to Module Self-learning and Programming Manual,
"Stability Control System Self-learning".
1.0 209
Brake System Brake Module
Brake Module
Specifications
Torque
Description Value
Bolts-ABS modulator to assembly 7–10Nm
Nuts-Brake pipe to ABS modulator 15–19Nm
Bolt- expansion tank to body 4–6Nm
Bolts-Front wheel speed sensor to steering bracket 7–10Nm
Bolt-Rear wheel speed sensor to rear wheel support 7–10Nm
1.0 210
Brake Module Brake System
Service Procedures
Brake Modulator
Remove
8. Disconnect the pipeline fitting, plug the opening of the

brake hard pipe for the avoidance of brake fluid drain
and contamination.

contamination.
3. Put the cloth under the brake modulator to absorb the
spilled brake fluid. 9. Remove 3 nuts fixing the brake modulator to the brake
4. Disconnect the harness connector from the brake modulator bracket.
modulator.
5. Remove 2 fitting nuts (2) fixing the master cylinder
brake hard pipe to the brake modulator.
10. Remove the brake modulator.

Refit
1. Fix the brake modulator to the brake modulator
6. Disconnect the pipeline fitting, plug the opening of the bracket, fit 3 nuts and tighten them to 7–10Nm.
brake hard pipe for the avoidance of brake fluid drain 2. Clean the oil outlet brake pipe fittings.
and contamination. 3. Remove the plug, connect the brake pipes to the brake
Caution: Before disconnecting or removing components, modulator by assembly mark, and ensure that the pipes
ensure the immediate area around joint faces and are connected to the correct ports. Tighten the brake
connections are clean. Plug open connections to prevent hard pipe fittings to 15–19Nm.
contamination. 4. Clean the oil inlet brake pipe fittings.
7. Mark the locations of 4 oil outlet pipes on the brake 5. Locate the master cylinder brake hard pipe fitting to
modulator for assembling, and remove the brake hard the brake modulator, and tighten the fitting nut to
pipe oil outlet pipe from the brake modulator in the 15–19Nm.
sequence of 1-4. 6. Connect the harness connector to the brake modulator.
1.0 211
Brake System Brake Module
and dispose of it. Front Wheel Speed Sensor

8. Locate the coolant expansion tank to the bracket, fit 1 Remove
bolt and tighten it to 4–6Nm. 1. Disconnect the negative battery cable.
9. Connect the negative battery cable. 2. Remove 1 bolt fixing the coolant expansion tank to the
10. Drain the brake system. bracket, and remove the coolant expansion tank.
Brake System Drain

11. Programme and encode the brake modulator. Refer
"Dynamic Stability Control System (SCS)".
3. Disconnect the harness connector of the front wheel

speed sensor.
4. Raise the vehicle on a lift to an appropriate height.

5. Remove 1 bolt fixing the front wheel speed sensor to
the steering knuckle.
6. Loosen the harness clip of the front wheel speed sensor

to remove the front wheel speed sensor.
1.0 212
Brake Module Brake System
Refit Rear Wheel Speed Sensor
1. Clean the contact surface of the front wheel speed Remove
sensor and the steering knuckle. 1. Disconnect the negative battery cable.
2. Fit the front wheel speed sensor harness to the clip and 2. Raise the vehicle on a lift to an appropriate height.
ensure that the harness route is correct. 3. Disconnect the harness connector (1) of the rear wheel
3. Locate the front wheel speed sensor to the steering speed sensor.
knuckle, fit 1 bolt and tighten it to 7–10Nm. 4. Remove 1 bolt (2) fixing the rear wheel speed sensor
4. Lower the vehicle. to the rear spindle.
5. Connect the harness connector of the front wheel
speed sensor.
5. Remove the rear wheel speed sensor.

Refit
1. Clean the contact surface of the rear wheel speed
sensor and the rear spindle.
2. Locate the rear wheel speed sensor to the rear spindle,
fit 1 bolt and tighten it to 7–10Nm.
3. Connect the harness connector of the rear wheel
speed sensor.
1.0 213
1.0 214
Drive Axle Driveline/Axle
Drive Axle
Specifications
Torque
Description Value
Bolts-Front lower arm bulb to Front wheel carrier 55–65Nm
Nuts-Front shock absorber assembly to front knuckle 140–170Nm
Nuts-Steering rack outer tie rod to steering arm 28–32Nm
Nuts-Front wheel hub 345–375Nm
1.0 215
Driveline/Axle Drive Axle
Service Procedures on front steering knuckle.

Right Front Drive Shaft Assembly
Remove
1. Lift the vehicle with a lift.
2. Pry up the locking device of the front drive half-axle
nut, and press down the brake pedal. Remove the front
drive half-axle nut and discard it.
6. Pull the hub outward and remove the right front drive
half-shaft assembly from the hub.
7. Prepare suitable containers to collect spilled liquids.
8. Use special toolsT30001 to separate right front drive
half axle from transmission.
3. Remove and discard 1 nut (1) fixing the ball head of

steering gear outer tie rod to the steering knuckle.
9. Remove right front drive shaft assembly. Remove the

drive half-shaft spring retaining ring and discard it.

Refit
1. Refit a new spring retaining ring on the right front drive
shaft.
5. Remove the nut fixing the lower arm outer ball joint 2. Clean the junctions between the right front drive shaft
1.0 216
end and hub/differential internal. Left Front Drive Shaft Assembly
3. Refit the right front drive shaft onto the differential and Remove
ensure they are fully engaged. 1. Lift the vehicle with a lift.
4. Connect front lower arm outer ball joint to steering 2. Pry up the locking device of the front drive half-axle
knuckle. Refit the new bolt and nut, and tighten them nut, and press down the brake pedal. Remove the front
to55–65Nm. drive half-axle nut and discard it.
5. Connect the front steering knuckle to the front shock
them to140–170Nm.
6. Locate the ball head of steering gear outer tie rod
to the steering knuckle, fit 1 new nut and tighten it
to28–32Nm.
assembly, install a new nut locking device, step on the
brake pedal, and tighten the nut to345–375Nm.
8. Lock the nut to the right front drive half axle.
9. Remove the container for collecting oil and clean it.
3. Remove and discard 1 nut (1) fixing the ball head of

steering gear outer tie rod to the steering knuckle.

5. Remove the nut fixing the lower arm outer ball joint
on front steering knuckle.
1.0 217
3. Refit the left front drive shaft onto the differential and
ensure they are fully engaged.
4. Connect front lower arm outer ball joint to steering
knuckle. Refit the new bolt and nut, and tighten them
to55–65Nm.
5. Connect the front steering knuckle to the front shock
them to140–170Nm.
6. Locate the ball head of steering gear outer tie rod
to the steering knuckle, fit 1 new nut and tighten it
to28–32Nm.
6. Pull the hub outward and remove the left front drive assembly, install a new nut locking device, step on the
half-shaft assembly from the hub. brake pedal, and tighten the nut to345–375Nm.
7. Prepare suitable containers to collect spilled liquids. 8. Lock the nut to the left front drive half axle.
8. Use special toolsT30001 to separate left front drive 9. Remove the container for collecting oil and clean it.
half axle from transmission.
9. Remove left front drive shaft assembly. Remove the

drive half-shaft spring retaining ring and discard it.
Refit
1. Refit a new spring retaining ring on the left front drive
shaft.
2. Clean the junctions between the left front drive shaft
end and hub/differential internal.
1.0 218
Constant-velocity Joint Assembly 6. the drive shaft assembly.
Remove Right Front Drive Shaft Assembly Refit
1. Remove the drive shaft assembly.
Right Front Drive Shaft Assembly Remove
2. Fix the drive shaft in a vice.
3. Loosen and scrap 2 clamps (1) and (2) of assembly
gaiter.
4. Slide the assembly gaiter along the drive shaft to check

the internal of constant-velocity joint.
5. Clamp the wire circlip of constant velocity universal
joint with nipper pliers.
6. Remove the constant velocity joint assembly from the

drive shaft. Remove the wire circlip from the drive
shaft and discard it.
1. Clean the drive shaft and gaiter.

2. a new spring collar onto the drive shaft.
3. Locate the new constant velocity joint assembly onto
the drive shaft, press the circlip in the groove with
the appropriate tool to completely push the constant
velocity joint into the drive shaft.
4. Apply grease onto the constant-velocity joint assembly.
5. Locate the gaiter on the constant-velocity joint, and
it with new clamps.
1.0 219
Constant-velocity Joint Assembly Gaiter Tripode Shaft Assembly

Remove Remove
1. Remove the constant-velocity joint assembly. 1. Remove the drive shaft assembly.
Constant-velocity Joint Assembly Remove Right Front Drive Shaft Assembly Remove
2. Remove the constant-velocity joint assembly gaiter 2. Fix the drive shaft in a vice.
from the drive shaft. 3. Loosen and scrap 2 clamps (1) and (2) of assembly
gaiter.
1. a new constant-velocity joint assembly gaiter onto
the drive shaft.
2. the constant-velocity joint assembly.
Constant-velocity Joint Assembly
4. Remove the tripode shaft assembly from the drive shaft.
1. Clean the drive shaft and tripode shaft assembly sheath.

2. 2 new clamp sets onto the drive shaft.
3. Locate a new tripode joint onto the drive shaft.
4. the new steel cable check ring onto the drive shaft.
5. Apply grease to the interior of the tripode shaft
assembly.
6. Fix the tripode shaft assembly gaiter onto the drive
shaft.
7. Fit the drive shaft assembly.
Right Front Drive Shaft Assembly Refit
1.0 220
Tripode Joint Assembly Sleeve
Remove
1. Remove the tripode shaft assembly.
Tripode Shaft Assembly Remove

2. Remove the tripode shaft assembly gaiter from the
drive shaft
Refit
1. Install the new tripode shaft assembly sheath on the
drive shaft.
2. Refit the new tripode shaft assembly gaiter.
Tripode Shaft Assembly Refit
1.0 221
Special Tools
Number
Remover drive
T30001
shaft
1.0 222
Instrument Panel and Console Interior Fitting
Instrument Panel and Console
Specifications
Torque
Description Value
Bolt-Instrument panel to fascia bracket 5–6.6Nm
Bolt-Front passenger airbag to facia bracket 6-8Nm
Bolt-Fascia bracket to body 19-25Nm
Bolt-A/C module ASSY to I/P tie bar 4–6Nm
Bolt- Steering column to facia bean 19–25Nm
1.0 223
Interior Fitting Instrument Panel and Console
Service Procedures Instrument Panel Body

Instrument Panel End Cover Plate Remove
Remove 1. Disconnect the negative battery cable. Wait for 10
1. Pry off the body weather strip at the instrument panel minutes until the SRS backup circuit is discharged.
end cover. 2. Pry off the clip, and remove the instrument panel lower
2. Pry off the clips of the instrument panel along the edge closure panel.
of the instrument panel end cover, and remove the 3. Remove the driver side lower trim panel assembly.
instrument panel end cover.
4. Remove the instrument panel side air outlet assembly.
Central Instrument Panel Air Outlet Assembly

Refit
5. Remove the central instrument panel air outlet
assembly.

Refit
6. Remove the steering column shield.
Steering Column Shield Remove

7. Remove the instrument pack.
3. Repeat the above steps to remove the instrument panel Player Refit
end cover on the other side. 8. Remove the player.
Refit
Player Refit
1. Extend the edge of the instrument panel end cover into
9. Remove the A pillar upper trim panel.
the body weather strips, align the clips of the end cover
with the hole of the instrument panel frame, push it A Pillar Upper Trim Panel Remove
hard to the end and clamp it in place. Press the body 10. Remove the glove box assembly.
weather strip tightly.
Glove Box Assembly Remove
2. Repeat the above steps to fit the instrument panel end
cover on the other side.
12. Remove 2 bolts fixing the instrument panel airbag
bracket to the instrument panel beam.
13. Remove 11 bolts fixing the instrument panel body

assembly to the instrument panel beam.
1.0 224
Refit
1. If the passenger airbag module has been removed, fit
2 screws fixing the passenger airbag module to the
instrument panel body and tighten them to ensure the
claws are fitted in place.
2. If the instrument air duct has been removed, fit 6
screws fixing the instrument panel air duct to the
instrument panel body, and tighten them.
3. If the solar sensor has been removed, first fix the solar
sensor to the instrument panel body, push in the solar
sensor to ensure that it is clamped in place.
4. Lift the instrument panel body assembly in the vehicle,
connect the harness connector, fit the harness clip,
align the locating pin of the instrument panel body with
the locating hole of the instrument panel beam, move
it forward to the end, and check the gap at the joint,
to ensure the connection is in place.
5. Fit 11 bolts fixing the instrument panel body to the
instrument panel beam, tighten them to 5–6.6Nm, and
check the torque.
6. Fit 2 bolts fixing the instrument panel airbag bracket to
the instrument panel beam, tighten them to 6-8Nm,
14. Pry off the harness clip fixing the instrument panel body
and disconnect the harness connector.
15. Adjust the steering wheel to the lowest position, and lift
out the instrument panel body assembly with assistance.
9. Fit the A pillar upper trim panel.
16. If necessary, pry off the clip of the solar sensor from
the back of instrument panel body, and push out the A Pillar Upper Trim Panel Refit
solar sensor. 10. Fit the player.
17. If necessary, remove 6 screws fixing the instrument Player Refit
panel air duct to the instrument panel body from 11. Fit the instrument pack.
the back of instrument panel body, and remove the
Instrument Pack Refit
instrument panel air duct.
12. Fit the steering column shield.
18. If necessary, remove 2 screws (1) and 9 claws (2) fixing
the passenger airbag module to the instrument panel Steering Column Shield Refit
body, and remove the passenger airbag. 13. Fit the central instrument panel air outlet assembly.
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Central Instrument Panel Air Outlet Assembly Driver Side Lower Trim Panel Assembly
Refit Remove
14. Fit the instrument panel side air outlet assembly. 1. Remove the left instrument panel end cover assembly.
Instrument Panel Side Air Outlet Assembly Instrument Panel End Cover Assembly Remove
Refit 2. Remove 1 screw fixing the driver side air outlet trim
15. Fit the driver side lower trim panel assembly. panel to the instrument panel body.

16. Fit the instrument panel lower closure panel, and snap
it into place.
17. Switch on the start switch, check if the SRS warning
lamp illuminates for several seconds, and then goes out.
3. Remove 2 screws fixing the bonnet release handle to

the driver side lower trim panel.
4. Remove 2 screws fixing the driver side lower trim panel

to the instrument panel body.
5. Pry off the retaining clip, disconnect the harness

connector and remove the driver side lower trim panel
assembly.
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6. If necessary, pry off the clip of light height adjustment Glove Box Assembly
switch, and push out the light height adjustment switch Remove
(1). 1. Open the glove box.
7. If necessary, remove 2 screws (2) fixing the eCall 2. Remove 2 stoppers of the glove box to disengage the
speaker to the driver side lower trim panel from the glove box from the glove box frame.
back of the driver side lower trim panel, and remove
the eCall speaker.
3. Loosen the clip of glove box damper, and remove the

glove box assembly.
Refit
Refit
1. If the light height adjustment switch has been removed,
1. Locate the glove box to the glove box frame, press
first fix the light height adjustment switch to the driver
the glove box stopper into the glove box frame, and
side lower trim panel, and push in the light height
tighten it.
adjustment switch to ensure it is clamped in place.
2. Fit the glove box damper.
2. If the eCall speaker has been removed, fit 2 screws
fixing the eCall speaker to the driver side lower trim 3. Close the glove box.
panel, and tighten them.
3. Connect the harness connector, fix the driver side
lower trim panel to the instrument panel, and snap it
into place.
4. Fix the driver side lower trim panel to the instrument
panel with 2 screws, and tighten them.
5. Fit 2 screws fixing the bonnet release handle to the
driver side lower trim panel, and tighten them.
6. Fit and tighten 1 screw fixing the driver side air outlet
trim panel to the instrument panel body.
7. Fit the left instrument panel end cover assembly.
Instrument Panel End Cover Assembly Refit
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Instrument Panel Lower Closure Panel Assembly Instrument Panel Side Air Outlet Assembly
Remove Remove
1. Remove the centre console heater closing plate 1. Remove the instrument panel end cover.
assembly.
Instrument Panel End Cover Assembly Remove
Centre Console Heater Closing Plate Assembly 2. Remove the central control panel and the switch of
Remove the instrument panel.
2. Remove 2 screws (1) fixing the driver side lower
Instrument Panel Central Control Panel and
closure panel to the instrument panel.
Switch Refit
3. Remove 2 screws (2) fixing the driver side lower
3. Remove 1 screw fixing the driver side air outlet trim
closure panel to the body, and remove the driver side
panel to the instrument panel body.
instrument panel lower closure panel.
4. Remove 2 screws (1) fixing the passenger side

instrument panel lower closure panel to the instrument 4. Pry off the clip along the edge of the instrument panel
panel. side air outlet, and remove the instrument panel side
5. Remove 2 clips (2) fixing the passenger side instrument air outlet.
panel lower closure panel to the body, and remove the
passenger side instrument panel lower closure panel.
Refit
1. Locate the passenger side instrument panel lower
closure panel assembly to the instrument panel body
assembly, fit 1 clip and 1 screw, ensure the clip is fitted
in place and tighten the screw.
2. Locate the driver side instrument panel lower closure
panel assembly to the instrument panel body assembly,
fit 1 clip and 1 screw, ensure the clip is fitted in place
and tighten the screw.
3. Fit and tighten 2 screws fixing the driver side instrument
panel lower closure panel assembly to the body.
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Refit Central Instrument Panel Air Outlet Assembly
1. Align the clip of the instrument panel side air outlet to Remove
the hole of the instrument panel body, push it hard to 1. Disconnect the negative battery cable.
the end, and clamp it in place. 2. Pry off the clip fixing the central air outlet to the
2. Fit and tighten 1 screw fixing the driver side air outlet instrument panel body from the edge of the central
trim panel to the instrument panel body. instrument panel air outlet, and remove the central
3. Fit the central control panel and switch of the instrument panel air outlet assembly.
instrument panel.

Switch Refit
4. Fit the instrument panel end cover.
3. Disconnect the harness connector and remove the

central instrument panel air outlet assembly.
4. If necessary, pry off the clip of the hazard warning lamp
switch from the back of the central air outlet of the
central instrument panel air outlet assembly and push
out the hazard warning lamp switch.
Refit
1. If the hazard warning lamp switch has been removed,
first fix the hazard warning lamp switch to the central
air outlet, push in the hazard warning lamp switch and
ensure it is clamped in place.
2. Connect the harness connector of the hazard warning
lamp switch, align the clip of the central air outlet
assembly with the hole of the instrument panel body,
push it hard to the end and clamp it in place.
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Central Control Panel and Switch of Instrument Instrument Panel IPK Frame
Panel Remove
1. Remove the right instrument panel end cover. 2. Remove the central control panel and the switch of
Instrument Panel End Cover Assembly Remove the instrument panel.
2. Remove the entertainment panel switch. Central Instrument Panel Air Outlet Assembly
Entertainment Panel Switch Remove Refit
3. Remove front infotainment control module (FICM). 3. Remove the steering column upper shield.
Front Infotainment Control Module (FICM)
Refit
Remove
4. Remove 1 screw fixing the driver side air outlet trim
4. Remove 5 screws fixing the instrument panel central
panel to the instrument panel body.
control panel to the instrument panel body.
5. Pry off the clip fixing the IPK frame to the instrument
5. Pry off the clip along the edge of the instrument
panel body, and remove the IPK frame.
panel central control panel, disconnect the harness
connector, and remove the instrument panel central
control panel.
6. If necessary, pry off the clip of the one-touch start
switch from the back of the instrument panel central
control panel and push out the one-touch start switch.
Refit
1. If the one-touch start switch has been removed, first
fix the one-touch start switch to the instrument panel
central control panel, and push in the one-touch start
switch to ensure it is clamped in place.
2. Connect the harness connector, locate the instrument
panel central control panel to the instrument panel,
and snap it into place. Refit
3. Fit 1 screw fixing the instrument panel central control 1. Align the clip of the instrument panel IPK frame to the
panel to the instrument panel body, and tighten it. hole of the instrument panel body, push it hard to the
end, and clamp it in place.
4. Fit the right instrument panel end cover.
2. Fit and tighten 1 screw fixing the instrument panel IPK
Instrument Panel End Cover Assembly Remove frame to the instrument panel.
3. Fit the steering column upper shield.
Steering Column Shield Refit
4. Fit the central control panel and switch of the
instrument panel.
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Central Instrument Panel Air Outlet Assembly Instrument Panel Beam Assembly
Refit Remove
5. Connect the negative battery cable. 1. Remove the instrument panel body assembly.

2. Remove the A/C air inlet grille.
A/C Air Inlet Grille Assembly Remove
3. Remove 3 bolts fixing the steering column assembly
to the instrument panel beam, remove the steering
column assembly and support it reliably.
4. Disconnect the harness connector, loosen the harness

clip, and remove 1 bolt (1) fixing the A/C box assembly
to the instrument panel beam.
5. Remove 9 bolts (2) fixing the instrument panel beam
assembly to the body, and remove the instrument panel
beam assembly with assistance.
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panel beam assembly, tighten them to 4–6Nm, and

check the torque.
7. Connect the harness connector, and fit the harness clip.
8. Fit 3 bolts fixing the steering column to the instrument
panel beam assembly, tighten them to 19–25Nm, and
check the torque.
9. Fit the A/C air inlet grille.
10. Fit the instrument panel body assembly.
6. If necessary, remove 2 bolts fixing the interconnected

T-BOX to the instrument panel beam, and remove the
interconnected T-Box.
7. If necessary, remove 2 bolts fixing the eCall T-BOX
to the instrument panel beam, and remove the eCall
T-Box.
8. If necessary, remove 2 bolts fixing the A/C control
module to the instrument panel beam, and remove the
A/C control module.
Refit
1. If the A/C control module has been removed, fit and
tighten 2 bolts fixing the A/C control module to the
instrument panel beam.
2. If the eCall T-BOX has been removed, fit 2 bolts fixing
the eCall T-BOX to the instrument panel beam and
tighten them.
3. If the interconnected T-BOX has been removed, fit and
tighten 2 bolts fixing the interconnected T-BOX to the
instrument panel beam.
4. With assistance, locate the instrument panel beam to
the correct position of the body.
5. Fit 9 bolts fixing the instrument panel beam assembly
to the body, tighten them to 19-25Nm, and check
the torque.
6. Fit 1 bolt fixing the A/C box assembly to the instrument
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Centre Console Heater Closing Plate Assembly Centre Console Assembly
Remove Remove
1. Remove 1 split pin fixing the centre console heater 1. Disconnect the negative battery cable.
closing plate assembly to the A/C box. 2. Remove the centre console heater closing plate
assembly.
Remove
3. Remove the instrument panel central control panel.
Switch Refit
4. Remove the electronic shifter.
Switch Refit
5. Remove 4 screws fixing the centre console assembly to
the instrument panel body.
2. Pry off the clip along the edge of the centre console 6. Move the front seat to a proper position, pry off the
heater closing plate and remove the centre console bolt cover, and remove 6 bolts fixing the centre console
heater closing plate assembly. to both sides of the bracket.
Refit
1. Align the clip of the centre console heater closing plate
to the hole of the centre console body, push it hard to
the end, and clamp it in place.
2. Locate the centre console heater closing plate to the
correct position, and press the locating pins in place.
7. Disconnect the harness connector, loosen the clip and

lift the centre console assembly out of the vehicle with
assistance.
Refit
1. With assistance, lift the centre console body assembly
in the vehicle, align the locating pin of the centre
console body with the locating hole of the instrument
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panel body, move it forward to the end, and check the Centre Console Cup Holder
gap at the joint between the front part of the centre Remove
console body and the lower part of the instrument 1. Remove the centre console assembly.
panel, to ensure the connection is in place.
Centre Console Rear Panel Assembly Remove
2. Connect the harness connector, and press the harness
clip. 2. Disconnect the backup antenna harness connect from
the bottom of the centre console, and remove 2 screws
3. Fit 4 screws fixing the centre console assembly to the
fixing the backup antenna to the centre console cup
instrument panel body, and press them in place.
holder.
4. Fit 6 bolts fixing the centre console to both sides of the
3. Disconnect the clip fixing the harness connector from
bracket, and tighten them.
the bottom of the centre console.
5. Fit the electronic shifter.
4. Open the centre console armrest, pry off the clip fixing
Instrument Panel Central Control Panel and the centre console cup holder to the centre console,
Switch Refit and remove the centre console armrest assembly.
6. Fit the instrument panel central control panel.

Switch Refit

Refit
Refit
1. Align the clip of the centre console upper trim panel
with the hole of the centre console body, push it hard
to the end, and clamp it in place.
2. Fit the centre console bottom harness clip.
3. Fit and tighten 2 screws fixing the backup antenna to
the centre console cup holder, and connect the harness
connector.
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Centre Console Armrest Assembly Centre Console Upper Trim Panel Assembly
Remove Remove
1. Remove the centre console rear panel assembly. 1. Disconnect the negative battery cable, and open the
centre console armrest.
2. Pry off the clip along the edge of the centre console
2. Pry off the retaining circlip and remove the shaft
cup holder, and lift up the centre console cup holder
connecting the centre console armrest and the centre
assembly without removing it.
console.
3. Pry off the clip along the edge of the centre console
3. Remove the centre console armrest assembly.
upper trim panel, disconnect the harness connector,
Refit
and remove the centre console upper trim panel.
1. Locate the centre console armrest on the centre
console.
2. Fit the shaft connecting the centre console armrest and
the centre console and fit the retaining circlip in place.
3. Fit the centre console rear panel assembly.
4. If necessary, remove 4 screws fixing the centre console

switch to the centre console upper trim panel from
the back of the centre console upper trim panel, and
remove the centre console switch.
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Refit Centre Console Rear Panel Assembly

1. If the centre console switch has been removed, fit and Remove
tighten 4 screws fixing the centre console switch to the 1. Pry off the clip along the edge of the centre console
centre console upper trim panel. rear panel assembly, disconnect the harness connector,
2. Connect the harness connector, align the clip of centre and remove the centre console rear panel assembly.
console upper trim panel with the hole of the centre
console body, push it hard to the end, and clamp it in
place.
3. Align the clip of the centre console cup holder with the
hole of the centre console body, push it hard to the
end and clamp it in place.
4. Put down the armrest, and connect the negative battery
cable.
2. If necessary, remove 2 screws fixing the rear USB

charging module to the centre console rear panel
assembly from the back of the centre console rear
panel, and remove the rear USB charging module.
3. If necessary, remove 2 screws fixing the TPMS to the
centre console rear panel assembly from the back of
the centre console rear panel, and remove the TPMS.
Refit
1. If the TPMS has been removed, fit 2 screws fixing the
TPMS to the centre console rear panel, and tighten
them.
2. If the rear USB charging module has been removed, fit
2 screws fixing the rear USB charging module to the
centre console rear panel, and tighten them.
3. Connect the harness connector, locate the centre
console rear panel assembly onto the centre console,
and snap it into place.
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Entertainment Panel Switch
Remove
2. Pry off the clip, loosen the harness connector and
remove the entertainment panel switch.
Refit
1. Connect the harness connector.
2. Fix the entertainment panel switch to the instrument
panel body, and snap it into place.
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Interior Fitting Interior Trim and Paneling
Interior Trim and Paneling

Specifications
Torque
Description Value
Bolt-Front seat belt retractor 35-45Nm
Screw-Compatment still trim to Body 2–2.7 Nm
Bolt-Grab handle to Handle bracket 5–7 Nm
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Interior Trim and Paneling Interior Fitting
Service Procedures A Pillar Lower Trim Panel
A Pillar Upper Trim Panel Remove
Remove 1. Remove the instrument panel end cover assembly.
1. Pull open the front door body side weatherstrips Instrument Panel End Cover Assembly Remove
located outside the A pillar upper trim panel.
2. Pull open the front door body side weatherstrips
2. Carefully pry off the clip of A pillar upper trim panel located outside the A pillar lower trim panel assembly.
assembly.
3. Pry off the front end clip of the door sill trim panel and
release the door sill trim panel from the lower end of
the A pillar lower trim panel assembly.
4. Pry off the clip of the A pillar lower trim panel assembly
and remove the A pillar lower trim panel assembly.
3. Disconnect the harness connector of the tweeter.

4. Remove the A pillar upper trim panel assembly.
Refit
1. Connect the connector of the tweeter.
2. Locate the A pillar upper trim panel to the body, and Refit
snap it into place. 1. Fit the A pillar lower trim panel assembly, and ensure
3. Press the front door body side weatherstrips located that the clip is fitted in place.
outside the A pillar upper trim panel tightly. 2. Insert the front end clip of the door sill trim panel into
the hole of the A pillar lower trim panel and ensure
that it is fitted in place.
3. Fit the instrument panel end cover assembly.

4. Fit the front door weatherstrips.
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B/C Pillar Upper Trim Panel 5. Fix the seat belt to the body, fit 1 bolt, tighten it to
Remove 35-45Nm, and check the torque.
1. Pull open the door weatherstrips on both sides of the 6. Fit the door sill trim panel assembly.
B/C pillar upper trim panel assembly. Door Sill Trim Panel Assembly Refit
2. Remove the door sill trim panel assembly.
7. Fit the door weatherstrips on both sides of the B/C
Door Sill Trim Panel Assembly Remove pillar upper trim panel assembly.
3. Remove 1 bolt from the lower fixing point of the front
seat belt.
4. Pry off the upper clip of the B/C pillar lower trim panel,
and separate the B/C pillar upper trim panel from the
upper part of the B/C pillar lower trim panel assembly.
5. Pry off the bolt cover of the B/C pillar upper trim panel,
and remove 1 bolt fixing the B/C pillar upper trim panel
to the body.
6. Pry off the fixing clip, remove the B/C pillar upper trim
panel and pull out the seat belt.
Refit
1. Pass the seat belt out of the hole of the B/C pillar upper
trim panel assembly.
2. Locate the B/C pillar upper trim panel assembly on the
B/C pillar, and snap it into place.
3. Fit and tighten 1 bolt fixing the B/C pillar upper trim
panel to the body, and fit the bolt cover.
4. Locate the B/C pillar lower trim panel to the lower end
of the B/C pillar upper trim panel, and snap it into place.
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B/C Pillar Lower Trim Panel D Pillar Upper Trim Panel
Remove Remove
1. Pull away the door weatherstrips on both sides of the 1. Remove the rear parcel shelf assembly.
B/C pillar lower trim panel assembly. Door Sill Trim Panel Assembly Remove
2. Pry off the clip at the connection between the door sill 2. Remove the D pillar lower trim panel.
trim panel and the lower end of the B/C pillar.
Door Sill Trim Panel Assembly Remove
3. Pry off the retaining clip of the B/C pillar lower trim
3. Remove the rear seat cushion assembly.
panel, and remove the B/C pillar lower trim panel
assembly.
4. Remove 1 bolts fixing the rear seat belt to the body.
5. Pry off the screw cover, and remove 3 screws fixing the
Refit D pillar upper trim panel to the body.
1. Locate the B/C pillar lower trim panel assembly on the

B/C pillar, and fit the clip in place.
2. Fit the retaining clip at the joint between the door sill
trim panel and the lower end of B/C pillar in place.
3. Fit the door weatherstrips on both sides of the B/C
pillar lower trim panel assembly.
6. Pry off the clip, remove the D pillar upper trim panel,
and pull the seat belt out of the hole in the D pillar
upper trim panel.
Refit
1. Pass the seat belt out of the hole of the D pillar upper
trim panel, locate the D pillar upper trim panel to the
body, and snap it into place.
2. Fit and tighten 3 screws fixing the D pillar upper trim
panel to the body, and press them into the screw cover.
3. Fit 1 bolt fixing the seat belt to the body, tighten it to
4. Fit the rear seat cushion assembly.
5. Fit the D pillar lower trim panel.
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6. Fit the rear parcel shelf assembly. D Pillar Lower Trim Panel
Remove
1. Pull open the rear door body side weatherstrips.
2. Carefully pry off the retaining clips on the D pillar lower
trim panel and remove the D pillar lower trim panel.
Refit
1. Fit the D pillar lower trim panel to the body, and ensure
that the clip is fitted in place.
2. Fit the rear door body side weatherstrip in place.
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Roof Trim Panel Assembly - without Sunroof A Pillar Upper Trim Panel Refit
Remove 8. Restore the seat adjustment and connect the negative
1. Disconnect the negative battery cable and put down battery cable.
the seat back.
3. Remove the sun visor assembly.
Sun Visor Assembly Remove
4. Remove the front reading lamp.
Front Reading Lamp Remove
5. Remove the inner roof handle.
Inner Roof Handle Remove
6. Remove the B/C pillar upper trim panel assembly.
B/C Pillar Upper Trim Panel Remove
7. Remove the D pillar upper trim panel assembly.
D Pillar Upper Trim Panel Assembly Remove
8. Loosen the retaining clips and carefully take out the
roof interior trim panel from the rear door of the
passenger side.
Refit
1. Locate the roof interior trim panel on the body, and
snap it into place.
2. Fit the D pillar upper trim panel assembly.
D Pillar Upper Trim Panel Assembly Refit
3. Fit the B/C pillar upper trim panel assembly.
B/C Pillar Upper Trim Panel Refit
4. Fit the inner roof handle.
Inner Roof Handle Refit
5. Fit the front reading lamp.
Front Reading Lamp Refit
6. Fit the sun visor assembly.
Sun Visor Assembly Refit
7. Fit the A pillar upper trim panel assembly.
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Roof Trim Panel Assembly - with Sunroof A Pillar Upper Trim Panel Refit
Remove 8. Restore the seat adjustment and connect the negative
1. Disconnect the negative battery cable and put down battery cable.
the seat back.
3. Remove the sun visor assembly.
Sun Visor Assembly Remove
4. Remove the front reading lamp.
Front Reading Lamp Remove
5. Remove the inner roof handle.
Inner Roof Handle Remove
6. Remove the B/C pillar upper trim panel assembly.
B/C Pillar Upper Trim Panel Remove
7. Remove the D pillar upper trim panel assembly.
D Pillar Upper Trim Panel Assembly Remove
8. Loosen the retaining clips and carefully take out the
roof interior trim panel from the rear door of the
passenger side.
Refit
1. Locate the roof interior trim panel on the body, and
snap it into place.
2. Fit the D pillar upper trim panel assembly.
D Pillar Upper Trim Panel Assembly Refit
3. Fit the B/C pillar upper trim panel assembly.
B/C Pillar Upper Trim Panel Refit
4. Fit the inner roof handle.
Inner Roof Handle Refit
5. Fit the front reading lamp.
Front Reading Lamp Refit
6. Fit the sun visor assembly.
Sun Visor Assembly Refit
7. Fit the A pillar upper trim panel assembly.
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Carpet Sun Visor Assembly
Remove Remove
1. Disconnect the negative battery cable. 1. Turn down the sun visor.
2. Remove the front seat assembly. 2. Pry up the sun visor screw cover, remove 2 screws
fixing the sun visor to the roof interior trim panel, and
Front Seat Assembly Remove
remove the sun visor from the sun visor bracket.
3. Remove the rear seat cushion assembly.


5. Remove the A pillar lower trim panel.
A Pillar Lower Trim Panel Remove

6. Remove the door sill trim panel.

7. Loosen the clip fixing the carpet, disconnect the
harness connector and remove the carpet.
3. Open the sun visor bracket screw cover, remove 1

screw fixing the sun visor bracket to the roof interior
trim panel, and remove the sun visor bracket.
Refit
1. Place the carpet in the vehicle, connect the harness
connector, and secure it with clips.
2. Fit the door sill trim panel.
Refit
Door Sill Trim Panel Assembly Refit
1. Fix the sun visor bracket to the roof interior trim
3. Fit the A pillar lower trim panel.
panel, fit 1 screw, tighten it to 2–2.7 Nm and check
A Pillar Lower Trim Panel Refit the torque.
4. Fit the centre console assembly. 2. Fix one end of the sun visor to the sun visor bracket
and the other end to the roof interior trim panel, fit
2 screws, tighten them to 2–2.7 Nm, and check the
torque. Fit the sun visor screw cover.
Rear Seat Cushion Assembly Refit 3. Reset the sun visor.
6. Fit the front seat assembly.
Rear Seat Cushion Assembly Refit

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Interior Roof Handle Rear Parcel Shelf Assembly

Remove Remove
1. Pry off 2 bolt covers of the interior roof handle. 1. Open the tail gate.
2. Remove 2 bolts fixing the interior roof handle to the 2. Remove 2 slings of rear parcel shelf on the tail gate.
body.
3. Lift the rear parcel shelf to disengage from the retaining

3. Remove the interior roof handle. slot, pull out and remove the rear parcel shelf.
Refit Refit
1. Locate the interior roof handle to the correct position. 1. Insert the tail end of the rear parcel shelf into the slot
of the D pillar upper trim panel, and push it into place.
2. Fit 2 retaining bolts, tighten them to 5–7 Nm and
check the torque. 2. Hang 2 slings on the tail gate.
3. Fit 2 bolt covers. 3. Close the tail gate.
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Truck Side Trim Panel Assembly Trunk Sill Trim Panel
Remove Remove
1. Remove the D pillar upper trim panel. 1. Open the tail gate.
Door Sill Trim Panel Assembly Remove 2. Remove the trunk carpet.
2. Remove the trunk sill trim panel. 3. Remove 2 screws fixing the trunk sill trim panel to the
body.
3. Pry off 2 clips fixing the trunk front trim panel to the
trunk side trim panel, and remove the trunk front trim
panel.
4. Pry off the clip, and remove the trunk sill trim panel.
Refit
1. Locate the trunk sill trim panel to the body, and snap
it into place.
4. Remove 2 bolts (1) and 1 clip (2) fixing the trunk side
trim panel to the body, and remove the trunk side trim 2. Fit 2 screws fixing the trunk sill trim panel to the body
panel. and tighten them.
3. Fit the trunk carpet.
4. Close the tail gate.
Refit
1. Locate the trunk side trim panel to the body, fit and
tighten 2 bolts, and snap it into place.
2. Locate the trunk front trim panel to the body, and snap
it into place.
3. Fit the trunk sill trim panel.

4. Fit the D pillar upper trim panel.
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Tail Gate Interior Trim Panel Door Sill Trim Panel Assembly
Remove Remove
1. Open the tail gate. 1. Pull open the front and rear door weatherstrips at the
2. Pry off the screw cover, and remove 2 screws fixing the door sill trim panel assembly.
tail gate interior trim panel to the tail gate. 2. Pry off the clip at the joint between the door sill trim
panel and the D pillar lower trim panel.
3. Pry off the clip, remove the door sill trim panel
assembly and pull out the seat belt.
3. Pry off the clip around the tail gate interior trim panel,
and remove the tail gate interior trim panel.
Refit
1. Locate the tail gate interior trim panel to the tail gate, Refit
and snap it into place. 1. Fit the seat belt into the door sill trim panel, and tighten
2. Fit and tighten 2 screws fixing the tail gate interior trim the back clip.
panel to the tail gate, and press them into the screw 2. Locate the door sill trim panel to the body, and snap
cover. it into place.
3. Close the tail gate. 3. Fit the clip at the joint between the door sill trim panel
and the lower end of the D pillar lower trim panel in
place.
4. Fit the front and rear door weatherstrips.
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Seat Interior Fitting
Seat
Specifications
Torque
Description Value
Bolt - front seat to body 40–50Nm
Screw - plate to seat 4–5Nm
Bolt - squab to cushion 31.5–37.5Nm
Bolt - seat lock to body 22Nm
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Interior Fitting Seat
Service Procedures Front Seat Interior Trim Panel

Remove 1. Move the front seat assembly to the most front
1. Remove the key from the ignition switch, and position, and remove 1 screw fixing the rear end of
disconnect the battery. Wait for 10min until the SRS interior trim panel onto the seat.
backup circuit is discharged, then start to operate. 2. Move the front seat assembly to the rearmost position,
2. Adjust the seat to the rearmost position. and remove 1 screw fixing the front end of interior
3. Remove 2 bolts fixing the front end of seat track onto trim panel onto the seat.
the floor and scrap them.
4. Adjust the seat to the most front position.
5. Remove 2 bolts fixing the rear end of seat track onto
the floor and scrap them.
3. Pry the clips fixing the seat interior trim panel onto the
seat and remove the interior trim panel.
Refit
1. Locate the seat interior trim panel on the seat and flap
6. Disconnect the left seat belt buckle harness connector clips. Ensure clips are refitted in place.
and the right airbag harness connector. 2. Move the seat, refit 2 screws fixing the interior trim
7. Lift the seats out from the vehicle. panel onto the seat, tighten to 4–5Nm and check the
torque.
Refit
3. Move the front seat assembly in place.
1. Ensure the seat track aligns with the body floor
correctly, and locate front seats on the vehicle.
2. Connect all harness connector clips of front seats.
3. Fix the seats onto the vehicle, fit 2 new bolts fixing the
rear end of seat track rail onto the floor, tighten to
40–50Nm and check the torque.
4. Move the seats backwards fully, fit 2 new bolts fixing
the front end of front seat track onto the floor, tighten
to 40–50Nm and check the torque.
1.0 250
Front Seat Exterior Trim Panel
Remove
1. Remove the front seat assembly.
2. manual seat:
a. Remove the front seat back adjusting handle.
Front Seat Back Adjusting Handle Remove
b. Insert the flat-blade tool into the inner side of front
seat height adjusting handle, pry the clips fixing the
height adjusting handle to the height adjusting handle
bracket, and remove the front seat height adjusting
handle. Refit
c. Remove 2 screws fixing the front seat height adjusting 1. Flap the clips fixing the seat exterior trim panel onto
handle to the seat exterior trim panel, pry retaining the seat, refit 2 screws fixing the exterior trim panel
clips and remove the exterior trim panel. onto the seat and refit the exterior trim panel.
2. manual seat：
a. Refit and fix the front seat height adjusting handle

（if equipped）.
b. Refit and fix the front seat back adjusting handle.
Front Seat Back Adjusting Handle Refit
3. power seat (if equipped ) : connect the power seat

harness connector , refit screws fixing the switch
assembly onto the exterior trim panel.
4. Refit the front seat assembly.
Front Seat Assembly Refit
3. power seat (if equipped ) :

a. Remove 2 screws (1) fixing the front seat height
adjusting handle to the seat exterior trim panel, pry
retaining clips and remove the exterior trim panel.
b. Disconnect the power seat harness connector (1) ,

remove 2 screws (2) fixing the switch assembly to
the seat exterior trim panel， remove the switch
assembly。
1.0 251
Front Seat Back Cover Front Seat Cushion Cover

Remove Remove
1. Remove the exterior trim panel. 1. Remove the exterior trim panel.
Front Seat Exterior Trim Panel Remove Front Seat Exterior Trim Panel Remove
2. Remove the interior trim panel. 2. Remove the interior trim panel.
Front Seat Interior Trim Panel Remove Front Seat Interior Trim Panel Remove
3. Remove the seat headrest guide sleeve assembly. 3. Remove C-rings and loosen the ties fixing the seat
4. Release the fixed clip and elastic clip of the seat back cover onto the cushion frame.
cover. 4. Loosen the cushion foam from the cushion frame, and
5. Put your hand into the foaming interior of the seat back, remove cushion foam and cover.
press the clip, and push the seat headrest guide sleeve. 5. Loosen the elastic tie and remove C-rings fixing the
cushion cover to the cushion foam. Mark the C-rings.
Refit
1. Insert the cushion foam into the cushion cover and fix
it with elastic belt and C-rings. Then check the fitting
between the cover and cushion foam.
2. Refit the cushion foam with cover onto the cushion
frame, and fix the cushion cover with tie and C-rings.
3. Refit the interior trim panel.
Front Seat Interior Trim Panel Refit

4. refit the exterior trim panel.
Front Seat Exterior Trim Panel Remove Refit

6. Mark the C-rings fixing the back cover to the foam,
and remove the cover and foaming after removing the
C-rings.
Refit
1. Insert the back cover into the back foam and fix it with
elastic belt and C-rings. Then check the fitting between
the cover and back foam.
2. Refit the back foam with the cover onto the back frame,
and fix the back cover with ties and clips.
3. Refit the seat headrest guide sleeve assembly.
4. Fix the back cover with a clip and an elastic clamp.
5. Insert the seat headrest into the guide. Press the
button and push down the pillow to adjust the seat
pillow to the appropriate position.
6. Refit the interior trim panel.

7. Refit the exterior trim panel.
Front Seat Exterior Trim Panel Remove Refit
1.0 252
Front Seat Back Adjusting Handle Front Seat Back Assembly
Remove Remove
1. Remove the front seat assembly. 1. Remove the front seat assembly.
Front Seat Assembly Remove Front Seat Assembly Remove

2. Pry up the front seat back adjusting handle along the 2. Press the left headrest guide sleeve button and remove
gap with a flat-blade tool. the headrest.
3. Pry up the inner edge of retaining circlip with the 3. remove the front exterior trim panel.
flat-blade tool, and remove the retaining circlip of front
Front Seat Exterior Trim Panel Remove
seat back adjusting handle.
4. Remove the front interior trim panel.
Front Seat Interior Trim Panel Remove

5. Loosen the hooks fixing the seat back covers to the
seat bottom.
6. Remove the bolts (4 on both sides in total) fixing the
back onto the cushion frame and remove the back.
4. Insert the flat-blade tool into the front seat back

adjusting handle from the edge, and slightly pry the
front seat back adjusting handle outwards.
Refit
1. Refit the front seat height adjusting handle onto the seat
height adjusting shaft, make sure it is refitted in place.
2. Refit retaining circlips onto the front seat height 7. Remove the front seat back assembly.
adjusting shaft, make sure they are refitted in place. Refit
3. Cover the front seat height adjusting handle trim cover. 1. Fix the back on the cushion frame, fit 4 bolts on both
4. Refit the front seat assembly. sides, tighten to 31.5–37.5Nm and check the torque.
2. Fix a seat back cover onto the seat with hooks.
3. Refit the front seat interior trim panel.

4. Refit the front seat exterior trim panel
Front Seat Exterior Trim Panel Refit

5. Locate the headrest onto the headrest mounting guide
correctly, and then insert it into the guide part. Press
the button, and push the headrest downwards in place.
1.0 253
Front Seat Cushion Assembly Seat Headrest Guide Sleeve

Remove Remove
1. Remove the front seat assembly. 1. Remove the front seat assembly.
Front Seat Assembly Remove Front Seat Assembly Remove

2. Remove the front seat belt buckle. 2. Press the headrest guide sleeve button, and pull up the
headrest to remove the headrest.
Front Seat Belt Buckle Remove
3. Loosen the retaining clips and elastic clamps of seat
3. Remove the front seat interior trim panel.
back cover.
Front Seat Interior Trim Panel Remove 4. Stretch out your hand into the seat back foam, press
4. Loosen the hooks fixing the seat back covers to the clamps on the lower end of headrest guide sleeve, and
seat bottom. push the headrest guide sleeve upwards.
5. Remove the bolts (4 on both sides in total) fixing the
back onto the cushion frame and remove the back.
Refit
1. Refit 2 seat headrest adjusting guide sleeves onto the
Refit seat back frame.
1. Locate the back on the cushion frame, fit 4 bolts on 2. Fix the back cover with clips and elastic clamps.
both sides, tighten to 31.5–37.5Nm and check the
3. Locate the headrest on the headrest mounting guide
torque.
part correctly, and then insert it to the guide part.
2. Locate a seat back cover on the seat, and fix it with Press the button and push the headrest downwards to
hooks. adjust the headrest to a proper position.
3. Refit the front seat interior trim panel. 4. Refit the front seat assembly.
Front Seat Interior Trim Panel Refit Front Seat Assembly Refit
4. Refit the front seat belt buckle.
Front Seat Belt Buckle Refit

5. Refit the front seat exterior trim panel.

1.0 254
Rear Seat Cushion Assembly Rear Seat Cushion Cover and Foam
Remove Remove
1. Uplift the rear seat cushion assembly, and loosen the 1. Remove rear seat cushions.
two front clips fixing the cushion and rear hooks.
Rear Seat Cushion Assembly Remove
2. Loosen the cable and J-clamp fixing the cushion covers
onto the seat frame.
3. Mark the layout positions of C-rings fixing the cushion
covers and foam, and remove the covers and foam.
Refit
1. Refit the cushion cover and fix it onto the cushion foam
with C-rings.
2. Fix the cushion cover and foaming onto the seat frame
with cable and J-clamp.
3. Refit the rear seat cushion assembly.

2. Remove rear seat cushions.
Refit
1. Move rear seat cushions to the compartment.
2. Refit and fix the rear seat cushion assembly by fastening
rear seat cushion clips correspondingly.
1.0 255
Rear Seat Back Latch Rear Seat Back Assembly

Remove Remove
1. Open rear doors, pull up the control lock knob on the 1. Remove rear seat cushions.
top of back and lay the rear seats to the folding position
to facilitate the remove of rear seat back latches.
2. Remove the rear middle seat belt.
2. Remove C Pillar Upper Trim Panel
Rear Middle Seat Belt Refit
BC Pillar Upper Trim Panel Remove
3. Pull up the control lock knob on the top of back and lay
3. Remove 3 screws fixing the rear seat back latches onto
the rear seats to the folding position.
the body and remove the rear seat back latches.
4. Uplift rear seat backs, and remove both sides of rear
seat back from the bracket. Move the rear seat backs
out from the vehicle.
Refit
1. Locate a rear seat back latch on the body, fit 3 bolts,
tighten to 22Nm and check the torque. Refit
2. Refit C Pillar Upper Trim Panel 1. Locate the right back of rear seats on the bracket and
BC Pillar Upper Trim Panel Refit refit it in place.
3. Adjust the rear seat to the original position. 2. Locate the left back of rear seats on the bracket and
refit it in place.
3. Refit the rear middle seat belt.
Rear Middle Seat Belt Refit

4. Pull up the control lock knob on the top of back and
upturn the rear seat backs to the backmost position.
5. Refit the rear seat cushion assembly.
1.0 256
Rear Seat Back Cover and Foam Rear Seat Back Hinge Bracket
Remove Remove
1. Remove rear seat backs. 1. Remove the rear seat back assembly.
Rear Seat Back Assembly Remove Rear Seat Back Assembly Remove
2. Remove seat headrest guide sleeve. 2. Remove 2 bolts connecting the rear seat back hinge
bracket with the body.
Seat headrest guide sleeves remove
3. Remove 1 screw fixing the back control lock knob and
disconnect the rear seat control knob from the cable.
Then remove the back control lock knob.
4. Pull out elastic clamps from seat covers.
5. Remove the retaining clips of rear seat back panel.
6. Remove C-rings fixing seat covers from the rear seat
back area.
7. Mark the layout positions of C-rings fixing the back
covers and foaming, and remove the C-rings, covers
and foaming.
Refit
1. Align the cover with the front side of back foam, and fix
3. Remove the rear seat back hinge bracket.
it with C-rings.
Refit
2. Refit backs onto the back frame, and fix the seat back
1. Locate the hinge bracket of rear seat backs on the bolt
panel to the back of back foam with clips.
holes on the body sheet metal, and refit it onto the
3. Fix the back cover to the back of the seat back with
body sheet metal.
C-rings and elastic clamps of the back cover.
2. Refit 2 bolts connecting the rear seat back hinge
4. Connect the rear seat control lock knob to cable, fit
bracket with the body and tighten up.
and tighten 1 screw to the control lock knob of rear
3. Refit the rear seat back assembly.
seats.
5. Refit seat headrest guide sleeves. Rear Seat Back Assembly Refit
Seat Headrest Guide Sleeve Refit

6. Refit the rear seat back.
Rear Seat Back Assembly Refit
1.0 257
1.0 258
Fixed Windows Exterior Fitting
Fixed Windows primer should not exceed the black area and the white
Service Procedures track line cannot be seen from the outside of the glass.
Windscreen 5. Apply glass adhesive to the glass with a gluer. Pay
1. attention to smooth application of adhesive at the
corners and avoid spillage.
Remove
6. Press the windscreen into the screen frame on the
1. Remove the A/C air inlet grille assembly.
body with suction cups. Insert the glass locating pins
Instrument Panel End Cover Assembly Remove into the roof mounting holes, adjust the glass in the X
2. Remove the front view camera module. and Y directions to ensure uniform gaps between the
upper end of the glass and the roof panel and between
the glass and the panels on both sides of body, and
3. Remove the rain sensor.
finally press the glass hard.
Instrument Panel End Cover Assembly Remove 7. Fix the upper end of the windscreen to the roof panel
4. Remove the manual anti-dazzle interior rearview with four tapes, to prevent the windscreen from sliding
mirror. down. In addition, keep the adhesive dry for 24 hours.
Instrument Panel End Cover Assembly Remove 8. Remove the tape, pour water on the windscreen
5. Remove the A pillar upper trim panel. assembly, and check for leak. If any leak is found, block
the leaking location with adhesive. If it still leaks,
Instrument Panel End Cover Assembly Remove remove the windscreen assembly and repeat the entire
6. Loosen the clip and disconnect the harness connector. repair procedure.
7. Put suitable coverings inside and outside the vehicle 9. Connect the harness connector, and snap it into place.
to prevent scratches. 10. Fit the A pillar upper trim panel.
8. Put 2 suction cups symmetrically on both sides of the
windscreen (outside).
11. Fit the manual anti-dazzle interior rearview mirror.
9. Pierce a through-hole in the adhesive, pass a cutting
wire through or use a cutter directly to cut the adhesive Instrument Panel End Cover Assembly Remove
on the glass and surroundings. 12. Fit the rain sensor.
10. Remove the windscreen with suction cups on both
sides aided by an assistant.
13. Fit the front view camera module.
11. To refit, remove the weatherstrips from the body, and
clean the adhesive from the original windscreen and Instrument Panel End Cover Assembly Remove
the vehicle body. 14. Fit the A/C air inlet grille assembly.
Refit Instrument Panel End Cover Assembly Remove
1. Clean the mounting position of the windscreen on the
body with a soft brush. The cleaning area is about
20mm in width. Using a suitable cleaning cloth to wipe
the cleanser area in the same direction with that of
cleanser coating. Do not wipe back and forth.
2. Evenly apply a thin layer of primer, about 15mm in
width, to the mounting position of the windscreen on
the body.
3. Clean the glass bonding surface with a soft brush. The
cleaned area should be larger than the primer track area
(about 15mm in width). Using a suitable cleaning cloth
to wipe the cleanser area in the same direction with
that of cleanser coating. Do not wipe back and forth.
4. On the back of the glass, apply glass primer along the
primer track and ensure the primer track area (about
15mm in width; the white line on the glass is the glue
track line) is completely covered by the primer, but the
1.0 259
Exterior Fitting Fixed Windows
Rear Window body with suction cups. Insert the glass locating pins
1. into the roof mounting holes, adjust the glass in the X
and Y directions to ensure uniform gaps between the
Remove
upper end of the glass and the roof panel and between
1. Disconnect the negative battery cable. the glass and the panels on both sides of body, and
2. Remove the rear window wiper motor. finally press the glass hard.
Instrument Panel End Cover Assembly Remove 8. Fix the upper end of the rear window to the roof panel
3. Remove the D pillar upper trim panel. with two tapes, to prevent the rear window from sliding
Instrument Panel End Cover Assembly Remove down, and keep the adhesive dry for 24 hours.
4. Remove the high-mounted stop lamp assembly. 9. Remove the tape, pour water on the rear window
assembly, and check for leak. If any leak is found, block
5. Pry off the clip, and remove the D pillar exterior trim remove the rear window glass assembly and repeat the
panel. entire repair procedure.
6. Put suitable coverings inside and outside the vehicle 10. Locate the D pillar exterior trim panel to the correct
to prevent scratches. position, and snap it into place.
7. Put 2 suction cups symmetrically on both sides of the 11. Fit the high-mounted stop lamp assembly.
rear window (outside).
8. Pierce a through-hole in the adhesive, pass a cutting
wire through or use a cutter directly to cut the adhesive 12. Fit the D pillar upper trim panel.
on the glass and surroundings. Instrument Panel End Cover Assembly Remove
9. Remove the rear window with suction cups on both 13. Fit the rear window wiper motor.
sides aided by an assistant.
10. To refit, clean the adhesive on the original rear window
and the vehicle body.
Refit
2. Clean the mounting position of the rear window on
the body with a soft brush. The cleaning area is about
20mm in width. Using a suitable cleaning cloth to wipe
the cleanser area in the same direction with that of
cleanser coating. Do not wipe back and forth.
width, to the mounting position of the rear window
on the body.
4. Clean the glass bonding surface with a soft brush. The
cleaned area should be larger than the primer track area
(about 15mm in width). Using a suitable cleaning cloth
to wipe the cleanser area in the same direction with
that of cleanser coating. Do not wipe back and forth.
5. On the back of the glass, apply glass primer along the
primer track and ensure the primer track area (about
15mm in width; the white line on the glass is the glue
track line) is completely covered by the primer, but the
primer should not exceed the black area and the white
track line cannot be seen from the outside of the glass.
6. Apply glass adhesive to the glass with a gluer. Pay
attention to smooth application of adhesive at the
corners and avoid spillage.
7. Press the rear window into the window frame on the
1.0 260
Fixed Windows Exterior Fitting
Rear Quarter Window
1.
Remove
1. Remove the D pillar upper trim panel.
2. Carefully cut the adhesive between the rear quarter
window and the vehicle body using a scraper and avoid
scratching the finishing coat.
3. Loosen the clip and remove the rear quarter window
from the vehicle.
4. Remove the adhesive on the rear quarter window and
frame with a blade.
Refit
1. Clean the inner side of the quarter window using a
cleaning cloth with cleanser. The cleaning width should
be approximately 20mm inward along the wrapped
edge. Wipe off excess solvent with another cleaning
cloth.
2. On the inner side of the quarter window, throughly
and evenly apply a thin layer of primer to the area
about 15mm inward along the wrapped edge to ensure
complete coverage of primed track area, while the
primer should not exceed the black area.
3. Clean the mounting position of the quarter window on
the body with a soft brush. The cleaning area is about
20mm in width.
width, to the mounting position of the rear quarter
window on the body.
5. Press hard to fit the rear quarter window into the rear
quarter window frame.
6. Secure the rear quarter window into the rear quarter
window frame with tapes, and keep the adhesive dry
for 24 hours.
7. Remove the tape, pour water on the rear quarter
window, and check for leak. If any leak is found, block
remove the rear quarter window and repeat the entire
repair procedure.
8. Fit the D pillar upper trim panel.
1.0 261
Exterior Fitting Bumpers, Fascias and Grille
Bumpers, Fascias and Grille

Specifications
Torque
Description Value
Bolt-From front bumper impact bar to body in white 40–50Nm
Screw-From front bumper impact bar to fend upper tie bar 7–10Nm
Bolt-Charging bracket to front module 7–10Nm
Bolt-From rear bumper impact bar to body in white 19–25Nm
Bolt-front bumper to front segment module 4–6Nm
Screw-rear bumper beam back to the body back buffer 2.7–3.3Nm
1.0 262
Bumpers, Fascias and Grille Exterior Fitting
Service Procedures beam onto the body, tighten them to 7–10Nm and
Front Bumper Beam Assembly check the torque.
Remove 4. Refit 2 bolts （1）fitting the charge door bracket to the
1. Disconnect the battery negative. front-end module and 2 nuts （2）to the front bumper
beam, tighten to 7–10Nm,and check the torque.
5. Refit radiator airflow side deflector.
Front Bumper Remove
Radiator Airflow SideDeflector - Left Refit
3. Remove the horn.
4. Remove radiator airflow side deflector. Radiator Airflow Side Deflector - Right Refit
6. Refit the horn.
Radiator Airflow Side Deflector - Left Remove
5. Remove 2 bolts （1）fitting the charge door bracket
to the front-end module and 2 nuts （2）to the front
bumper beam.
6. Remove 8 bolts (1) fixing the right and left sides of

front bumper beam onto the body and 6 screws (2)
onto the front module.
7. Remove the front bumper beam.

Refit
1. Position the front bumper beam to the body.
2. Refit 8 bolts fixing both sides of the front bumper beam
onto the body, tighten to 40–50Nm and check the
torque.
3. Refit 6 screws fixing both sides of the front bumper
1.0 263
Rear Bumper Beam Assembly Front Bumper

Remove 1.
1. Remove the rear bumper. Remove
Rear Bumper Assembly Remove 1. Disconnect the negative battery cable.
2. Remove 4 nuts fixing the rear bumper beam to the rear 2. Loosen the clip and remove the wheel brow.
end of the vehicle body（1）.
3. Remove 4 bolts fixing the rear bumper beam to the
rear end of the vehicle body（2）.
3. Remove 1 screw (1) fixing the front bumper to the

front left (right) fender.
4. Remove 6 screws (2) fixing the front bumper to the left
(right) front wheelhouse liner.
4. Remove the rear bumper beam from the body carefully.
Refit
1. Refit 4 nuts fixing both sides of the rear bumper beam
to the rear end of body, tighten to19–25Nm, and
check the torque.
2. Refit 4 bolts fixing both sides of the rear bumper beam
to the rear end of body, tighten to19–25Nm, and
check the torque.
3. Refit the rear bumper.
Rear Bumper Assembly Refit
5. Remove 2 bolts (1) fixing the front bumper to the

bottom deflector.
6. Remove 4 bolts (2) fixing the front bumper to the
front-end module.
1.0 264
7. Loosen 4 clips (1) fixing the front bumper cover plate
to the front bumper upper support.
8. Remove 4 bolts (2) fixing the front bumper cover plate
to the front bumper upper support.
14. If necessary, remove 4 bolts (1) fixing the front bumper

upper support to the front-end module, and remove
the front bumper upper support.
15. If necessary, remove 4 bolts (2) fixing the front bumper
9. Remove 2 bolts fixing the front bumper to the middle support to the front-end module, and remove
headlamp. the front bumper middle support.
Refit
10. With assistance, lift both sides of the front bumper
carefully and pull it outward, to remove the front 1. To remove the upper support, fix the upper support on
bumper assembly from brackets at both sides of the the front-end module, fit and tighten 4 bolts.
body. 2. To remove the middle support, fix the middle support
11. Remove the ambient temperature sensor on the front on the front-end module, fit and tighten 4 bolts.
bumper lower intake grille, disconnect the harness 3. To remove the mounting brackets on both sides of the
connector, and remove the front bumper. front bumper, fit the mounting brackets on both sides
12. If necessary, remove 3 screws fixing the front view of the front bumper.
camera assembly to the front bumper and remove the a. Fix the mounting brackets on both sides of the front
front view camera. bumper to the body, fit and tighten 2 bolts.
13. If necessary, remove the mounting brackets on both b. Fit the headlamp assembly.
sides of the front bumper. Headlamp Assembly Refit
a. Remove the headlamp assembly. 4. To remove the front view camera, fix the front view
Headlamp Assembly Remove camera to the front bumper, fit 3 screws, and tighten
them.
b. Remove 2 bolts fixing the mounting brackets on both
5. Fit the ambient temperature sensor on the air intake
sides of the front bumper to the fender, and remove
grille of the front bumper, and snap it into place.
the mounting brackets on both sides of the front
bumper. 6. With assistance, position the front bumper on the body,
connect the harness connector, and snap it into place.
1.0 265
7. Fit and tighten 2 bolts from the front bumper to the Rear Bumper
headlamp. 1.
8. Fix the front bumper cover plate to the upper support Remove
of the front bumper, fit and tighten 4 bolts and snap
1. Open the tail gate.
it into place.
2. Remove the tail lamp assembly.
9. Fit 4 bolts fixing the front bumper to the front-end
module, tighten them to 4–6Nm, and check the Tail Lamp Assembly Remove
torque. 3. Loosen the clip and remove the wheel brow.
10. Fix the front bumper to the bottom deflector, fit and
tighten 2 bolts.
11. Fit and tighten 6 screws fixing the front bumper to the
front left (right) wheelhouse liner.
12. Fit and tighten 1 screw fixing the front bumper to the
front left (right) fender.
13. Fit the wheel brow, and snap it into place.
4. Remove 1 screw (1) fixing the left (right) side of rear

bumper to the left (right) fender.
5. Remove 4 screws (2) fixing the left (right) side of rear
bumper to the rear left (right) wheelhouse liner.
6. Remove 2 screws fixing the rear bumper to the rear

bumper bracket.
1.0 266
7. Pry off part of the trunk weatherstrips, and remove 4 Tail Lamp Assembly Refit
screws fixing the rear bumper to the body. 9. Close the tail gate.
8. With assistance, loosen the retaining clip, remove the

rear bumper assembly and disconnect the harness
connector.
9. Remove 3 screws fixing the left and right side brackets
of the rear bumper to the body, and remove the side
bracket of the rear bumper.
Refit
1. Fix the left and right brackets of the rear bumper to
the body, fit and tighten 3 screws.
2. Connect the harness connector, locate the rear bumper
to the body with assistance, and snap it into place.
3. Fit 4 screws fixing the rear bumper to the body, tighten
them to 2.7–3.3Nm, check the torque, and fit the
trunk weatherstrips.
4. Fit and tighten 2 screws fixing the rear bumper to the
rear bumper bracket.
5. Fit and tighten 4 screws fixing the rear left (right)
wheelhouse liner to the rear bumper.
6. Fit and tighten 1 screw fixing the rear bumper to the
left (right) fender.
7. Fit the wheel brow, and snap it into place.
8. Fit the tail lamp assembly.
1.0 267
Exterior Fitting Exterior Trim and Paneling
Exterior Trim and Paneling

Specifications
Torque
Description Value
Screw-A/C air intake grille to body 1.5–2Nm
Bolt-A/C air intake grille to body 2–3Nm
1.0 268
Exterior Trim and Paneling Exterior Fitting
Service Procedures Roof Molding Assembly
Roof Rack Assembly Remove
Remove 1. Remove the roof rack assembly (if installed).
1. Remove the interior roof trim panel. Roof Rack Assembly Remove
Interior Roof Trim Panel (With Sunroof) Remove 2. Remove the roof molding (see Diagram A for the
Interior Roof Trim Panel (With Sunroof) Remove model with a roof rack; see Diagram B for the model
without a roof rack). Remove and scrap the mounting
2. Remove 4 nuts securing the roof rack onto the roof.
clip of roof molding if it comes off or is damaged.
3. Remove the binder close to the roof groove rack
mounting hole.
A
S 6913014
S 6 9 1 3 0 13 Refit
1. Wipe the molding mounting area on the vehicle body
4. Remove the roof rack.
surface.
Refit
2. Refit a new mounting clip of roof moulding into the
1. Raise the rack guide on one side over the roof roof groove if any clip comes off or is damaged.
horizontally, and align 4 bolts with the roof sheet metal
3. Refit the roof moudling.
mounting holes orderly from front to back.
4. Refit the roof rack assembly.
2. After confirming that all bolts are aligned with the
mounting holes, lower down the rack slowly and tear Roof Rack Assembly Refit
the protective film of the sealing washer up carefully to
allow the sealing washer to be in full contact with the
sheet metal.
3. Secure the roof rack onto the roof with 4 nuts.
4. Operate the same on the other side.
5. Fit the interior roof trim panel.
Interior Roof Trim Panel (Without Sunroof)

Refit

Refit
1.0 269
A/C Air Intake Grille Assembly

Remove
1. Pry up the clips of A/C intake grille side corner and
remove the A/C intake grille side corner.
Refit
1. Connect the windshield nozzle and hose.
2. Connect the windshield washer pump hose to the
windshield nozzle hose, and locate the A/C intake grille
2. Remove the windshield wiper arm assembly. on the body.
3. Refit 5 screws fixing the middle of A/C intake grille onto
Windshield Wiper Arm Assembly Refit
the body, tighten to 1.5–2Nm and check the torque.
3. Remove 5 screws (1), 2 bolts (2) on both sides and 4
4. Refit 4 clips and 2 bolts fixing the A/C intake grille to
clips (3) fixing the A/C intake grille onto the body.
both sides of the body, tighten to 2–3Nm and check
the torque.
5. Refit the windshield wiper arm assembly.
Windshield Wiper Arm Assembly Refit

6. Locate the A/C intake grille side corner, and flap clips
in place.
4. Disconnect the windshield washer pump hose with the

windshield nozzle hose.
5. Disconnect the windshield nozzle hose from the nozzle,

and remove the windshield nozzle and nozzle hose.
1.0 270
Front Wheelhouse Liner Assembly 4. Fit and tighten 4 clips and 1 bolt fixing the front left
1. wheelhouse liner to the body.
Remove 5. Fit and tighten 2 screws and 1 bolt fixing the front left
wheelhouse liner to the front bottom deflector.
1. Remove 6 screws (1) fixing the front left wheelhouse
liner to the front bumper. 6. Fit and tighten 6 screws fixing the front left wheelhouse
liner to the front bumper.
2. Remove 2 screws (2) and 1 bolt (3) fixing the front left
wheelhouse liner to the front bottom deflector. 7. Change the Step 5 to: Fit and tighten 3 screws fixing
the front right wheelhouse liner to the front bottom
3. Remove 1 bolt (4) and 4 clips (5) fixing the front left
deflector. Fit the front right wheelhouse liner as
wheelhouse liner to the body.
described above.
4. Remove 2 plastic nuts (6) fixing the front left
5. Remove 1 screw (7) fixing the front left wheelhouse
liner to the body.
6. Remove the front left wheelhouse liner.

7. Change the Step 2 to: Remove 3 screws fixing the front
right wheelhouse liner to the front bottom deflector.
Remove the front right wheelhouse liner as described
above.
Refit
1. Fix the front left wheelhouse liner to the body and align
it with the mounting hole.
2. Fit and tighten 1 screw fixing the front left wheelhouse
liner to the body.
3. Fit and tighten 2 plastic nuts fixing the front left
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Rear Wheelhouse Liner Assembly 5. Fit and tighten 6 screw fixing the rear left wheelhouse
1. liner to the body.
Remove 6. Change the Step 3 to: Fit 2 clips fixing the rear
left wheelhouse liner to the body. Fit the rear right
1. Remove 6 screws (1) fixing the rear left wheelhouse
wheelhouse liner as described above.
liner to the body.
2. Remove 4 plastic nuts (2) fixing the rear left wheelhouse
liner to the body.
3. Remove 1 clip (3) fixing the rear left wheelhouse liner
to the body.
4. Remove 4 screws (4) fixing the rear left wheelhouse
liner to the rear bumper.
5. Remove the rear left wheelhouse liner.

6. Change the Step 3 to: Remove 2 clips fixing the rear
right wheelhouse liner to the body. Remove the rear
right wheelhouse liner as described above.
Refit
1. Fix the rear left wheelhouse liner to the body and align
it with the mounting hole.
2. Fit and tighten 4 screws fixing the rear left wheelhouse
liner to the rear bumper.
3. Fit 1 clip fixing the rear left wheelhouse liner to the
body.
4. Fit and tighten 4 plastic nuts fixing the rear left
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Spoiler Assembly Bottom Deflector
1. Remove
Remove 1. Lift the vehicle.
1. Disconnect the negative battery cable. 2. Remove the bottom deflector - high-level configuration.
2. Open the tail gate, loosen the clip and remove the a. Remove 6 bolts (1) fixing the bottom deflector to the
high-mounted stop lamp cover plate. front bumper.
3. Pry off the spoiler bolt cover, remove 2 bolts (2) and 2 b. Remove 5 screws (2) and 1 bolt (3) fixing the bottom
nuts (1) fixing the spoiler to the body, and disconnect deflector to the left and right wheelhouse liners.
the high-mounted stop lamp harness connector (3).
c. Remove 10 bolts (4) fixing the bottom deflector
to the front subframe, and remove the bottom
deflector - high-level configuration.
4. Pry off the spoiler retaining clip, and remove the spoiler
assembly.
Refit 3. Remove the bottom deflector - low-level configuration.
1. Locate the spoiler assembly to the tail gate, and snap a. Remove 6 bolts (1) fixing the bottom deflector to the
it into place. front bumper.
2. Fit 2 nuts and 2 bolts fixing the spoiler assembly to the b. Remove 5 screws (2) and 1 bolt (3) fixing the bottom
body, and tighten them. deflector to the left and right wheelhouse liners.
3. Connect the harness connector of the high-mounted c. Remove 2 bolts (4) fixing the bottom deflector to the
stop lamp, and fit the bolt cover. front subframe, and remove the bottom deflector -
4. Fit the high-mounted stop lamp cover plate, and snap low-level configuration.
it into place.
Refit
1. Locate the bottom deflector to the body.
2. Fit the bottom deflector - low-level configuration.
a. Fit 2 bolts fixing the bottom deflector to the front
subframe, and tighten them.
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b. Fit 6 bolts fixing the bottom deflector to the front

bumper, and tighten them.
c. Remove 5 screws and 1 bolt fixing the bottom

deflector to the left and right wheelhouse liners, and
tighten them.
3. Fit the bottom deflector - high-level configuration.
a. Fit 10 bolts fixing the bottom deflector to the front

subframe, and tighten them.
b. Fit 6 bolts fixing the bottom deflector to the front

bumper, and tighten them.
c. Remove 5 screws and 1 bolt fixing the bottom

deflector to the left and right wheelhouse liners, and
tighten them.
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Mirrors Exterior Fitting
Mirrors
Specifications
Torque
Description Value
Nut-door mirror to front door 7–10Nm
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Exterior Fitting Mirrors
Service Procedures Exterior Rearview Mirror Glass

Exterior Mirror Assembly Remove
Remove 1. Push the upper end of an exterior mirror a little hard
1. Disconnect the battery negative. to make it tilt.
2. Remove the interior trim panel and waterproof 2. Grasp the back of mirror, and separate the rearview
membrane from the driver door. mirror glass from the rearview mirror motor hard.
Front Door Interior Trim Panel and Waterproof 3. Uplift the back of rearview mirror and disconnect the
Membrane Refit electrical connector. Then remove the exterior mirror
glass.
3. Remove the interior quarter trim panel from the front
door and uplift the front door sealing strip around this Refit
trim panel. 1. Connect the electrical connector.
4. Disconnect the exterior mirror assembly harness 2. Refit the exterior mirror glass and check whether it is
connector. refitted in place.
5. Remove 3 bolts fixing the exterior mirror assembly
onto the door, and remove the exterior mirror
assembly.
Refit
1. Locate this assembly into the corresponding locating
hole on the door in virtue of the locating pin on the
exterior mirror assembly, and flap the clips. Install 3
bolts, tighten to 7–10Nm and check the torque.
2. Connect the exterior mirror assembly harness
connector.
3. Refit the interior quarter trim panel and sealing strip of
front door.
4. Fit the interior trim panel and waterproof membrane
of the driver door.
Front Door Interior Trim Panel and Waterproof
Membrane Refit
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Mirrors Exterior Fitting
Exterior Mirror Cover Manual anti-dazzle Interior Rearview Mirror
Remove Remove
1. Remove the exterior mirror glass. 1. Knock down the interior rearview mirror assembly
with a rubber hammer to remove it from the base.
Exterior Mirror Glass Remove
2. Remove the clips fixing the cover onto the exterior
mirror assembly.
Refit
1. Locate the interior rearview mirror onto the mounting
bracket, and push it into the slot carefully to clamp it
3. Remove the exterior mirror cover.
in place.
Refit
1. Locate the exterior mirror cover on the exterior
mirror, and flap clips to place.
2. Refit the exterior mirror glass.
Exterior Mirror Glass Refit
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Exterior Fitting Roof
Roof
Specifications
Torque
Description Value
Bolt - sunroof to vehicle roof 7–9Nm
screw - sunroof glass to bracket 4.5–5.5Nm
-
Bolt-Top console to Roof 1.5–2Nm
stress-sunroof out seal to roof panel 60–70N
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Roof Exterior Fitting
Service Procedures
Sunroof Assembly-Linear Style Switch
Remove
1. Disconnect the battery negative terminal.
2. Remove the roof interior trim panel.
Interior Roof Trim Panel (With Sunroof) Remove

3. Disconnect 2 front drain pipes from sunroof assembly
(1).
4. Disconnect 2 rear drain pipes from sunroof assembly
(2).
3. Connect the sunroof motor connector.

4. Connect the drain tube to the sunroof assembly.
5. Check and adjust the flushness of the sunroof glass
according to the sunroof information.
Sunroof Information
7. Perform a self-learning for the sunroof glass motor:
Fully close the sunroof glass, slide the sunroof glass
switch forward to the 2nd position and hold in position
for 10 seconds. The sunroof will open a preset amount
and stop, it will then close automatically. During the
5. Disconnect the sunroof motor harness.
whole process, the switch must remain in the 2nd
6. Remove 18 bolts fixing the sunroof assembly onto the position.
body, with the assistance of a colleague, lower the roof
8. Perform a self-learning for the sunroof sunshade motor:
assembly and remove via the loadspace aperture.
Fully close the sunshade, slide the sunshade switch
forward to the 2nd position and hold in position for 10
seconds. The sunshade will open a preset amount and
stop, it will then close automatically. During the whole
process, the switch must remain in the 2nd position.
9. Operate the switch, and check the operation of the
glass and sunroof sunshade.
10. Refit the interior roof trim panel.
Refit
Grease Maintenance
1. Clean any dust and dirt from the sunroof glass panels
and the exposed sunroof surface as well as any
Refit
foreign materials from the glass run channel where the
1. With assistance, locate the sunroof assembly on the mechanical structure runs and the glass panel edges.
body, and prefit 18 bolts.
2. Remove the front and rear sunroof glass panels and place
2. Ensure that the front and rear locating holes of the them properly.
sunroof are completely aligned with two locating holes
3. Ensure there is no deformation inside the glass run
in the body, tighten 18 bolts to 7–9Nm, and check
channel groove and no damage or scratches on the
the torque.
surface coating.
4. Operate the sunroof to close, i.e., operate the mechanical
assembly of the sunroof to the front of the glass run
channel. Put the special tool TBO00061 into the front
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of glass run channel (1), rotate it for 90° (2), then push to increased friction between glass panel and wind-proof
the tool (3) toward the rear of guide rail, rotate it for net during closing of front glass panel.
90° (4) to clean out the foreign material and grease (5).
Clean the removed foreign material and grease from the
tool. Repeat the operation for over three times until less
foreign material and grease can be wiped off.
8. Fit the glass panel to the sunroof assembly. Sunroof

glass initialisation: fully close the sunroof glass, slide the
sunroof glass switch forward to the 2nd position and
hold in position for 10 seconds. The sunroof will open a
5. Completely open the sunroof, i.e., operate the mechanical preset amount and stop, it will then close automatically.
assembly of the sunroof to the rear of the glass run During the whole process, the switch must remain in the
channel, and remove foreign material and grease from the 2nd position.
front of glass run channel according to step 4: Insert the 9. Open and close the front sunroof glass panel at least 10
tool → Rotate the tool through 90° → Push the tool times to confirm if it works normally.
along the glass run channel → Rotate the tool through
90° → Remove the foreign material and grease. Clean
the removed foreign material and grease from the tool.
Repeat the operation for over three times until less
foreign material and grease can be wiped off.
6. Apply the after-sales special grease to the channel
(sectional view of channel is shown) where the mechanical
structure runs when the sunroof is opened and closed.
Make sure the grease is applied evenly at the red line
below. The special grease should be applied at a constant
speed and shape a uniform thickness with visible oily
reflection of light and without large caking.
7. Apply grease to the blocks at two corners of front glass

panel to prevent false triggering of anti-pinch function due
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Sunroof Deflector Assembly-Linear Style Switch Front Sunroof Glass Panel-Linear Style Switch
Remove Remove
1. Fully open the sunroof by sliding. 1. Open the sunroof sunshade.
2. Remove 5 screws fixing the sunroof deflector onto the 2. Fully tilt the sunroof glass to the open position.
sunroof. 3. Remove the both sunroof seals on the sunroof frame.
4. Remove the bolts fixing the front sunroof glass panel
onto the bracket (6 bolts on both sides in total).
3. Loosen the both retain clips of sunroof deflector and

remove the sunroof deflector.
5. Remove the front sunroof glass panel assembly. Do not

manually move both brackets refitting the glass panel.
Refit
1. Locate the front sunroof glass panel to the bracket,
prefit 6 screws.
2. Adjust the front sunroof glass panel to align to the
roof panel metal aperture, according to the sunroof
information, tighten the screws to 4.5–5.5Nm, and
check the torque.
Sunroof Information
3. Refit the sunroof seals.
Refit 4. Perform a self-learning for the sunroof glass motor:
1. Refit the sunroof deflector and fix it with clips. Fully close the sunroof glass, slide the sunroof glass
2. Fix the sunroof deflector onto the sunroof, fit 5 screws switch forward to the 2nd position and hold in position
and tighten up. for 10 seconds. The sunroof will open a preset amount
3. Close the sunroof glass.
position.
5. Operate the front sunroof glass panel to check for the
mounting.
6. Close the sunroof sunshade.
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Rear Sunroof Glass Panel-Linear Style Switch Sunroof Sunshade-Linear Style Switch
Remove Remove
1. Open the sunroof sunshade. 1. Fully open the sunroof glass and sunshade.
2. Fully tilt the front sunroof glass to the open position. 2. Slide the sunroof glass switch backward to the 2nd
3. Remove the both sunroof seals on the sunroof frame. position and hold in position for 10 seconds, the
sunshade will run to service position.
4. Remove the bolt fixing the rear sunroof glass panel to
the bracket (6 bolts on both sides in total). 3. Remove the roof interior trim panel.
Interior Roof Trim Panel (With Sunroof) Remove

4. Remove the rear sunroof glass panel.
Rear Sunroof Glass Panel-New State Remove

5. Remove 2 bolts fixing the sunshade assembly onto the
sunroof frame.
5. Pull the rear sunroof glass plate the front of the vehicle
for a certain distance, and then take out the rear
sunroof glass upward and remove it.
Refit
1. Locate the rear sunroof glass panel to the bracket,
prefit 6 screws.
6. Pry the clips at the bottom of the sunshade.
2. Adjust the rear sunroof glass panel according to the
sunroof information, tighten the screws to 4.5–5.5Nm,
Sunroof Information
3. Refit the sunroof seals.
4. Close the sunroof glass and sunshade.
7. Gently push the sunshade through the hole in the frame

by hand and remove the sunshade from the frame.
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Sunroof Glass Panel Motor-Linear Style Switch
Remove
2. For vehicles with front passenger air bag switch, pry
off the clip with tools and remove the roof console
assembly.
3. For vehicles without front passenger air bag switch,
open glass box, remove 2 screws fixing the roof console
assembly to the roof, pry off the clip with tools and
remove the roof console assembly.
4. Disconnect the sunroof glass panel motor connector.
5. Remove 3 screws fixing the sunroof glass panel motor
Remove
onto the sunroof assembly.
1. Position one side of the sunroof sunshade to the frame,
and then position the other side to the corresponding
position. Press both sides of the sunshade to make sure
that a clear "click" sound is heard to ensure that the
clips are installed in place
2. After locate the sunroof sunshade on the sunroof
frame, fit 2 bolts, tighten up.
6. Remove the sunroof glass panel motor.
process, the switch must remain in the 2nd position.
Refit
gsunroof sunshade. 1. Locate the sunroof motor, and engage the motor drive
gear into the sunroof cable.
6. Refit the rear sunroof glass panel.
2. Fix the sunroof glass panel motor to the sunroof, fit 3
Rear Sunroof Glass Panel-New State Refit
screws, tighten to and check the torque.
3. Connect the connector of the sunroof glass panel
Interior Roof Trim Panel (Without Sunroof) motor.
Refit 4. For vehicles without front passenger air bag switch, fix
the roof console assembly to the roof trim panel, fit 2
screws, tighten to1.5–2Nm and check the torque.
5. For vehicles with front passenger air bag switch, fix the
roof console assembly to the roof trim panel.
position.
8. Operate the front sunroof glass panel to check for the
mounting.
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Sunroof Sunshade Motor-Linear Style Switch Sunroof Harness-Linear Style Switch

Remove Remove
1. Disconnect the battery negative. 1. Disconnect the battery negative.
2. Remove the roof interior trim panel. 2. Remove the roof interior trim panel.
Interior Roof Trim Panel (With Sunroof) Remove Interior Roof Trim Panel (With Sunroof) Remove
3. Disconnect the sunroof sunshade motor connector. 3. Disconnect the sunroof harness and the roof harness.
4. Remove 3 screws securing the sunroof sunshade motor 4. Disconnect the sunroof switch connector.
onto the sunroof. 5. Disconnect the sunroof glass panel motor connector.
5. Remove the sunroof sunshade motor. 6. Disconnect the sunroof sunshade motor connector.
Refit
1. Locate the sunroof sunshade motor, and engage the
motor drive gear in the sunroof sunshade cable.
2. Fix the sunroof sunshade motor to the sunroof, fit 3
screws, tighten to and check the torque.
3. Connect the sunroof sunshade motor connector.
process, the switch must remain in the 2nd position. 7. Remove the clip fixing the sunroof harness to the
sunroof, and take away the sunroof harness.
sunroof sunshade. Refit
7. Refit the interior roof trim panel. 1. Fix the sunroof harness onto the sunroof and tighten
with clip.
2. Connect the sunroof sunshade motor connector.
Refit
3. Connect the sunroof glass panel motor connector.
4. Connect the sunroof switch connector.
5. Connect the sunroof harness and the roof harness.
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whole process, the switch must remain in the 2nd Front Sunroof Drain Pipe
position. Remove
8. Perform a self-learning for the sunroof sunshade motor: 1. Fold the seat back, lower the roof trim panel from the
Fully close the sunshade, slide the sunshade switch roof to a position low enough.
Roof Trim Panel Assembly - Sedan - Sunroof
Remove
process, the switch must remain in the 2nd position. 2. Disconnect the front sunroof drain pipe from the
sunroof drain casing pipe (1).
glass and sunroof sunshade. 3. Disconnect the front sunroof drain pipe end to the
drain pipe sleeve of the windscreen beam (2), and pull
out the drain pipe.
Refit
4. Disconnect the clip connecting the front sunroof drain

pipe to the A pillar.
5. Remove the front sunroof drain pipe.
Refit
1. Locate the front sunroof drain pipe to the A pillar, and
secure them with clips.
2. Connect the front sunroof drain pipe end to the drain
pipe sleeve of the windscreen beam.
3. Connect the front sunroof drain pipe to the sunroof
drain casing pipe.
4. Fit the roof trim panel assembly.

Refit
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Rear Sunroof Drain Pipe Panoramic Sunroof Outer Weatherstrip

Remove Remove
1. Open the trunk. 1. Remove the front sunroof glass panel.
2. Fold the seat back, perform steps 3 to 12 in the "Roof Front Sunroof Glass Panel Remove
Trim Panel Assembly Remove" procedure. Lower the 2. Remove the rear sunroof glass panel.
roof trim panel from the roof to a position low enough.
Rear Sunroof Glass Panel Remove
Roof Trim Panel Assembly - Sedan - Sunroof 3. Peel off the sunroof outer weatherstrip from the roof,
Remove and remove the weatherstrip.
3. Remove the trunk side trim panel assembly.
Trunk Sill Trim Panel Remove

4. Disconnect the rear sunroof drain pipe from the
sunroof drain casing pipe (1).
5. Disconnect the rear sunroof drain pipe from the drain
pipe sleeve behind the bodyside outer panel (2).
Refit
1. The sheet metal surface of the frame to which the
weatherstrip is to be attached is required to be
oil-free, wax-free, water-free and dust-free, with a clean
surface. Use a lint-free wiping cloth to dip in alcohol
or isopropanol: water ≥50:50 alcohol or isopropanol
to clean the sheet metal.
6. Disconnect the clip connecting rear sunroof drain pipe
to the roof rail, D pillar and inner trunk. 2. After any solvent has completely evaporated, align the
seam of the new sunroof weatherstrip with the middle
7. Remove the rear sunroof drain pipe.
position of the sheet metal seam allowance on the rear
Refit of the top cover, peel off the backing paper near the
1. Locate the rear sunroof drain pipe to the roof rail, D seam, and stick the weatherstrip on the sheet metal for
pillar and inner trunk, and secure them with clips. preliminary positioning (it requires the temperature of
2. Connect the rear sunroof drain pipe to the drain pipe weatherstrip, sheet metal mounting surface ≥ 16 ℃).
sleeve behind the bodyside outer panel.
3. Connect the rear sunroof drain pipe to the sunroof
drain casing pipe.
4. Fit the trunk side trim panel assembly.
Trunk Sill Trim Panel Refit

Refit
6. Close the trunk.
3. Clamp the weatherstrip to the edge of the sheet metal

seam allowance in turn to pre-position the entire circle,
where the last quarter of the length is even on the
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longer straight side (please note that the weatherstrip
should not be stretched during this process).
4. Whilst maintaining a small angle, tear off the tape
backing paper from the outer sunroof weatherstrip
(slow the tearing speed at corners).
5. Useing skylight seal contact rollerTBO00060 to

completely roll along the same direction for 3 circles,
(Apply a firm force of 60–70N; ensure that the
weatherstrip is installed and bonded in place (the
direction of force must be perpendicular to the
weatherstrip installation surface).
6. After the assembly, make sure that the sunroof

weatherstrip is flush with the smooth surface of the
roof, not higher than the smooth surface of the roof,
and there is no gap at the middle joint point at the rear
of the roof, and no wrinkles at corners.
7. Install the rear glass panels of the sunroof.
Rear Sunroof Glass Panel Refit

8. Refit the front sunroof glass panel.
Front Sunroof Glass Panel Refit
9. After the sunroof installation, ensure that the sunroof
seal and the sunroof are properly matched, and there is
no extrusion deformation. The weatherstrip is installed
tightly and uniformly without distortion.
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Special Tools
Number
Grease removal
TBO00061
tool
Skylight seal
TBO00060
contact roller
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Wipers and Washer Exterior Fitting
Wipers and Washer
Specifications
Torque
Description Value
Nut-Front wiper arm to linkage spindle 28–32Nm
Bolt-Linkage spindle to body 7–10Nm
screw - from wipe motor to linkage spindle 28–32Nm
Bolt-Windshield washer to body 4–6Nm
Bolt-The washer bottle filler neck to right headlamp bracket 4–6Nm
Nut-Rear wiper arm to motor shaft 8–10Nm
Nut and Bolt-Rear wiper motor to tailgate 7–10Nm
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Exterior Fitting Wipers and Washer
Service Procedures 2. Put the wiper assembly back onto the windscreen, and
Wiper Blade Assembly check whether the wiper blade is fixed correctly onto
Remove the wiper arm.
Caution: When changing wiper blades it is essential that 3. Depress the wiper stalk switch to the single wipe
the wiper mechanism is placed in the service position and position and release it or turn the ignition switch from
that the wiper arms are raised away from the windscreen. position OFF to position ACC or ON/RUN/START, and
Ensure the arms are always held during any activity so the wiper will exit the service mode and automatically
as to avoid 'dropping' onto the windscreen and possibly go back to the original position.
causing damage such as cracking.
1. With the bonnet closed, and within 20 seconds of

switching the START/STOP Switch to the OFF position,
press the wiper stalk switch to the single wipe position
and release it; the wiper will automatically move to the
service position and stop at a mid-point the windscreen.
2. Lift the wiper arm away from the windscreen.
3. For the boneless wiper, press the retaining clip at both
sides while pulling the wiper blade outward, to remove
the wiper blade from the wiper arm.
4. For the bone wiper, rotate the wiper blade and press
the middle retaining clip , meanwhile pull the wiper
blade downward, to remove the wiper blade from the
wiper arm.
Refit
1. Slide the blade onto the wiper until the fixing clamp is
engaged. Refit the blade.
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Window Wiper Arm Window Wiper Linkage Assembly
Remove Remove
1. Remove the mounting shaft cover of the wiper arm. 1. Disconnect the battery negative.
2. Remove 2 nuts fixing the wiper arm to the linkage. 2. Remove the A/C air intake grille assembly.
A/C Air Intake Grille Assembly Remove
3. Remove 3 bolts (1) fixing the linkage mechanism onto
the body.
4. Disconnect the window wiper motor connector (2).
3. Remove the arm assembly from the linkage mechanism.

Refit
1. Fit the wiper arm onto the linkage mechanism.
2. Fit the nuts onto the shaft of linkage mechanism, tighten
to 28–32Nm, and check the torque. 5. Remove the wiper linkage assembly.
3. Refit the shaft cover of the wiper arm. Refit
1. Connect the window wiper motor connector.
2. Refit the windscreen wiper linkage assembly, fit 3
screws and tighten to 7–10Nm, and check the torque.
3. Fit the A/C air intake grille assembly.
A/C Air Intake Grille Assembly Refit

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Window Wiper Motor Window Washer Reservoir Assembly

Remove Remove
1. Disconnect the battery negative. 1. Disconnect the battery negative.
2. Remove the wiper linkage assembly. 2. Remove the window washer reservoir assembly.
Wiper Linkage Assembly Remove Window Washer Pump Assembly Remove
3. Remove 3 bolts (1) and 1 nut (2) securing motor onto 3. Remove the right front wheelhouse liner.
the linkage mechanism.
Front Wheelhouse Liner Refit
4. Remove the window washer reservoir filler pipe
assembly.
Window Washer Reservoir Filler Pipe Assembly

Remove
5. Remove 3 bolts fixing the washer reservoir to the body.
4. Remove the windshield wiper motor.

Refit
1. Fix the windshield wiper motor onto the linkage
mechanism, fit 3 bolts and 1 nut, tighten to 28–32Nm,
2. Window Wiper Linkage Assembly Refit
6. Remove the washer reservoir.
Window Wiper Linkage Assembly Refit
Refit
1. Fit 3 bolts fixing the washer reservoir to the body,
tighten to 4–6Nm, and check the torque.
2. Refit window washing reservoir filler pipe assembly.
Window Washer Reservoir Filler Pipe Assembly

Refit
3. Refit the window washer pump assembly.
Window Washer Pump Assembly Refit

4. Fit the right front wheelhouse liner.
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Window Washing Reservoir Filler Pipe Assembly Window Washer Pump Assembly
Remove Remove
1. Remove 1 bolt securing the washer reservoir nozzle 1. Disconnect the battery negative.
onto the right headlamp bracket. 2. Remove the front bumper.
Front Bumper Refit
3. Disconnect the washer pump connector (3).
4. Put one container under the washer reservoir.
5. Remove the washer pump from the washer reservoir.
6. Disconnect the rear window washer pump hose (2).
7. Disconnect the windshield washer pump hose (1), and
take away the washer pump.
2. Remove the washer reservoir nozzle and discard the

seal ring.
Refit
1. Fit the new seal ring to the washer reservoir nozzle.
2. Fit the washer reservoir nozzle onto the washer
reservoir.
3. Refit 1 bolt securing the washer reservoir nozzle onto
the right headlamp bracket, and tighten to 4–6Nm,
and check the torque. Refit
1. Fit the washer pump onto the washer reservoir.
2. Connect the windshield washer pump hose.
3. Connect the rear window washer pump hose.
4. Connect the washer pump connector.
5. Refill windscreen washer fluid.
Front Bumper Refit

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Windshield Washer Pump Hose Rear Windscreen Wiper Arm Assembly

Remove Remove
1. Remove the front bumper. Caution: Remove the nozzle to use the special tool,
otherwise the nozzle will be damaged.
Front Bumper Refit
2. Put one container under the washer pump. 1. Remove the rear windscreen washer nozzle.
3. Disconnect the windshield washer pump hose with the Rear Windscreen Washer Nozzle Remove
washer pump. 2. Remove 1 nut fixing the rear windscreen wiper arm
assembly to the rear wiper motor shaft.
4. Remove the A/C air intake grille assembly.

3. Remove the rear windscreen wiper arm assembly with
A/C Air Intake Grille Assembly Remove
special tool TBO00015.
5. Disconnect the windshield washer pump hose with the
windshield nozzle hose.
6. Remove the windshield washer pump hose.
Refit
1. Refit the new hose and connect it to the washer pump.
2. Route the new hose according to the used one and
twine it with strips.
3. Connect the windshield washer pump hose and the
nozzle hose.

5. Refill windscreen washer fluid.
Front Bumper Refit
Refit
1. Fix the rear windscreen wiper arm to the wiper motor
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shaft, fit 1 nut, tighten it to 8–10Nm, and check the Rear Windscreen Wiper Motor
torque. Remove
2. Fit the rear windscreen washer nozzle. 1. Disconnect the negative battery cable.
Rear Windscreen Washer Nozzle Refit 2. Remove the rear windscreen wiper arm assembly.
3. Ensure that the adhesive tape of the wiper blade is Rear Windscreen Wiper Arm Assembly Removal
fitted in its initial position properly and aligned with the 3. Remove the seal ring of rear wiper motor from the
locating dot of the wiper on the glass. wiper motor output shaft.
4. Remove the tail gate interior trim panel.
Tail Gate Interior Trim Panel Remove

5. Disconnect the harness connector (3) of the rear wiper
motor.
6. Remove 2 nuts (2) and 1 bolt (1) fixing the rear
windscreen wiper motor assembly to the tail gate.
7. Disconnect the rear windscreen washer pump hose
from the rear window washer nozzle.
8. Remove the rear windscreen wiper motor assembly.

Refit
1. Connect the rear windscreen washer pump hose to the
rear window washer nozzle.
2. Fit 2 nuts and 1 bolt fixing the rear wiper motor to
the tail gate, tighten them to 7–10Nm, and check the
torque.
3. Connect the harness connector of the rear wiper
motor.
4. Fit the tail gate interior trim panel.
Tail Gate Interior Trim Panel Refit

5. Fit the rear wiper motor seal ring.
6. Fit the rear windscreen wiper arm assembly.
Rear Windscreen Wiper Arm Assembly Refit

1.0 295
Rear Washer Pipe 3. Connect the rear washer pipe to the rear window
Remove motor.
1. Disconnect the negative battery cable. 4. Refill the windscreen washer fluid.
2. Remove the front bumper. 5. Fit the front bumper.
Front Bumper Refit Front Bumper Refit
3. Put a container under the washer pump. 6. Fit the right A pillar lower trim panel.
4. Disconnect the hose from the rear window washer A Pillar Lower Trim Panel Refit
pump.
7. Fit the right door sill trim panel assembly.

8. Fit the right trunk side trim panel.


5. Remove the right A pillar lower trim panel.

A Pillar Lower Trim Panel Refit
6. Remove the right door sill trim panel assembly.
7. Remove the right trunk side trim panel.
8. Remove the tail gate interior trim panel.
9. Disconnect the rear washer pipe from the rear wiper
motor.
10. Remove the rear washer pipe.

Refit
1. Fit a new water pipe to connect to the washer pump.
2. Route the new hose according to the used one and
twine it with straps.
1.0 296
Rear Windscreen Washer Nozzle Rain Sensor
Remove Remove
1. Remove the shaft cover of the rear wiper arm. 1. Disconnect the negative battery cable.
2. Lightly clamp the upper part of the nozzle with a proper 2. Pry open the rain sensor cover.
tool and remove the nozzle. 3. Disconnect the rain sensor harness connector.
Refit 4. Remove the rain sensor from the interior rearview

1. Insert the nozzle into the wiper motor shaft in the mirror base.
correct direction and tap to ensure that the nozzle is Refit
fitted in place and check if the washer fluid will inject in 1. Clean off any residual adhesive from the joint face
the correct direction. If adjustment is required, insert between the windshield and the rain sensor.
a needle into the nozzle and gently lever to adjust it 2. Fit and secure the rain sensor onto the interior
so that the washer fluid can be directly injected to the rearview mirror base with the clip.
center of the rear window.
3. Connect the harness connector of the rain sensor.
2. Fit the shaft cover of the rear wiper arm.
4. Fit the assembled rain sensor cover onto the interior
rearview mirror base with the clip.
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Special Tools
Number
Remover rear
TBO00015
wiper arm
1.0 298
Lighting Lighting Systems
Lighting 2. Clamp the roof console assembly onto the roof trim
Service Procedures panel.
Roof Console Assembly 3. Connect the negative battery cable.
Remove
Front Reading Lamp Assembly - with Sunroof
Switch
2. Pry off the clip and remove the roof console.
3. Disconnect the harness from the roof console.

Front Reading Lamp Assembly - without Sunroof
Switch
3. Disconnect the harness from the roof console.

Refit
Front Reading Lamp Assembly - with Sunroof
Switch
1. Connect the harness to the roof console.
2. Clamp the roof console assembly onto the roof trim
panel.
Front Reading Lamp Assembly - without Sunroof
Switch
1. Connect the harness to the roof console.
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Lighting Systems Lighting
Front Reading Lamp Assembly Front Reading Lamp Bulb

Remove Remove
1. Remove the roof console assembly. 1. Disconnect the battery negative cable.
Roof Console Assembly Refit 2. Using a suitable small screwdriver carefully pry off the
reading lamp lens.
2. Pry off the front reading lamp from the roof console.
3. Remove and discard the front reading lamp bulb.
Refit
Tip: Take care NOT to touch the glass with your fingers;
always use a cloth to handle the bulb. If necessary, clean
the glass with methylated spirits to remove fingerprints.
1. Refit the front reading lamp bulb.
2. Refit the front reading lamp lens.
3. Connect the battery negative cable.
Refit
1. Fix the front reading lamp assembly to the roof console
assembly.
2. Fit the roof console assembly.
Roof Console Assembly Refit
1.0 300
Lighting Lighting Systems
Loadspace Lamp
Remove
1. Disconnect the battery negative cable.
2. Pry out the loadspace lamp on the interior trim panel
of the loadspace using suitable tools.
3. Disconnect the connector and remove the loadspace
lamp assembly.
Refit
1. Connect the loadspace lamp connector.

2. Refit the loadspace lamp assembly.
1.0 301
Lighting Systems Lamps
Lamps
Specifications
Torque
Description Value
Bolt-Headlamp to body 3–5Nm
Screw-Headlamp alignment screw 0.1–0.5Nm
Nut-Tail lamp to body 3–5Nm
Nut-Rear grouped lamps to tailgate 2.7–3.3Nm
Bolt-Rear fog lamp to rear bumpers 1.5–2Nm
Nut-Center high mount stop lamp to spoiler 2.7–3.3Nm
1.0 302
Lamps Lighting Systems
Service Procedures Side Direction Indicator Lamp
Headlamp Assembly Remove
Remove 1. Disconnect the battery negative cable.
1. Disconnect the negative battery cable. 2. Remove the exterior mirror cover.
2. Remove the front bumper. Exterior Mirror Cover Remove
Front Bumper Remove 3. Remove 2 screws (1) securing the side direction
3. Remove 1 bolt (1) fixing the front reading lamp to the indicator lamp onto the exterior mirror.
fender, 1 bolt (2) fixing the front reading lamp to the 4. Disconnect the connector (2) and remove the side
front bumper bracket and 2 bolts (3) fixing the front direction indicator lamp.
reading lamp to the front-end module.
Refit
4. Disconnect the harness connector of the headlamp
1. Connect the side direction indicator lamp connector.
assembly.
2. Fix the side direction indicator lamp to the exterior
5. Remove the headlamp assembly.
mirror, fit 2 screws and tighten up.
Refit
3. Fit the exterior mirror cover.
1. Connect the harness connector of the headlamp.
Exterior Mirror Cover Refit
2. Align the headlamp assembly to the mounting point,
respectively fit 4 bolts, tighten them to 3–5Nm, and 4. Connect the battery negative cable.
check the torque.
Front Bumper Refit

5. Check the headlamp alignment.
Headlamp Alignment (Low Beam and High Beam)
1.0 303
Headlamp Lighting Calibration Tail Lamp Assembly

Adjustment Remove
Warning: Any mis-alignment caused by incorrect 1. Open the tail gate.
lamp fitment or deformed mounting brackets cannot 2. Disconnect the negative battery cable.
be corrected using the alignment screws, excessive
3. Remove the bolt cover of the tail lamp assembly.
adjustment toward the limits may break the lamps.
4. Remove 2 bolts fixing the tail lamp assembly to the
1. Turn the screw (Figure 1) to adjust the dipped beam in
body.
vertical direction, the torque is 0.1–0.5Nm.
2. Turn the screw (Figure 2) to adjust the dipped beam in
horizontal direction, the torque is 0.1–0.5Nm.
5. Release the tail lamp assembly and disconnect the

connector.
Refit
1. Connect the harness connector of the tail lamp, fit 2
bolts fixing the tail lamp assembly to the body, tighten
2. Fit the bolt cover of tail lamp.
4. Close the tail gate.
1.0 304
Rear Combination Lamp Assembly Direction Indicator Lamp Bulb
Remove Remove
2. Remove the access port cover of the tail gate interior 2. Remove the tail lamp assembly.
trim panel.
3. Turn the direction indicator lamp holder
counterclockwise and remove the holder.
3. Remove 3 nuts (1) fixing the rear right (left)

combination lamp assembly to the tail gate.
4. Disconnect the harness connector (2) from the rear 4. Remove the bulb from the bulb holder and discard it.
combination lamp. Refit
1. Fit the new bulb to the lamp holder.
2. Fit the lamp holder to the tail lamp assembly.
3. Fit the tail lamp assembly.
5. Remove the rear combination lamp assembly.

Refit
2. Fix the rear right (left) combination lamp assembly to
the tail gate, fit 3 nuts, tighten them to 2.7–3.3Nm,
3. Fit the access port cover of the tail gate interior trim
panel.
1.0 305
Reverse Lamp Bulb Rear Fog Lamp Assembly

Remove Remove
2. Remove the rear combination lamp assembly. 2. Remove the rear bumper assembly.
Tail Gate Interior Trim Panel Remove Rear Bumper Assembly Remove
3. Rotate the reverse lamp holder counterclockwise to 3. Disconnect the harness connector (1) of the rear fog
remove it. lamp assembly.
4. Remove 4 screws (2) fixing the rear fog lamp assembly
to the rear bumper.
4. Remove the bulb from the bulb holder.

Refit
always use a cloth to handle the bulb. If necessary, clean 5. Remove the rear fog lamp assembly.
Refit
1. Fit the bulb to the holder.
1. Fix the rear fog lamp assembly to the rear bumper, fit
2. Fix the reverse lamp holder to the rear combination
3 screws, tighten them to 1.5–2Nm, and check the
lamp assembly, tighten it clockwise and ensure it is fixed
torque.
in place.
2. Connect the harness connector of the rear fog lamp.
3. Fit the rear combination lamp assembly.
3. Fit the rear bumper assembly.
Rear Combination Lamp Assembly Refit
1.0 306
Rear License Plate Lamp Assembly High-mounted Stop Lamp Assembly
Remove Remove
1. Disconnect the battery negative cable. 1. Disconnect the battery negative cable.
2. Remove the rear bumper. 2. Remove the spoiler assembly.
Rear Bumper Assembly Refit Spoiler Assembly Refit
3. Disconnect the connector and remove the rear license 3. Remove 2 nuts securing the high-mounted stop lamp
plate lamp assembly. assembly to the spoiler.
Refit
1. Connect the harness connector and snap the license
plate lamp assembly into the rear bumper assembly.
2. Refit the rear bumper.

4. Remove the high-mounted stop lamp assembly.

Refit
1. Fix the high-mounted stop lamp to the spoiler, fit 2
nuts, tighten to 2.7–3.3Nm and check the torque.
2. Fit the spoiler assembly.
Spoiler Assembly Refit

1.0 307
Light Sensor
Remove
2. Remove the upper instrument panel body.
Instrument Panel Upper Body Remove
3. Disconnect the harness connector.
4. Pry up the retaining clip and remove the light sensor.
Refit
1. Connect the light sensor harness connector.
2. Clamp the light sensor into the upper instrument panel
body.
3. Fit the upper instrument panel body.
Instrument Panel Upper Body Refit

1.0 308
Door Panel & Accessories Door Systems
Door Panel & Accessories
Specifications
Torque
Description Value
Bolt - door hinge to door 22–28Nm
Bolt - door striker to body 19–25Nm
Bolt - door hinge to body 30–36Nm
Bolt - door checker to body 21–29Nm
Bolt-right door lock to doorknob scaleboard 2-2.5Nm
Screw -doorknob scaleboard to door 2-2.5Nm
Bolt - door lock to door 8–10Nm
Bolt - door hinge to body 30–36Nm
Screw - exterior handle backplate to door 2–2.5Nm
1.0 309
Door Systems Door Panel & Accessories
Service Procedures
Front Door Adjustment
Front Door Hinge Adjustment
1. Open the front door.
2. Place a suitable wooden block on a jack, and put the
jack under the door to support the front door.
3. Release 4 bolts securing the upper and lower door
hinges on the front door.
4. Close the door, and check if the rear of the door is

flush with the sheet metal of the body side panel and if
the door can open and close normally.
5. After the adjustment, open the door, fit 2 screws fixing
the strikers to the body, tighten them to 19–25Nm,
6. Close the door.
4. Carefully raise or lower the jack and adjust the front

door.
5. Pretighten the hinge bolts.
6. Take away the jack, close the door and check whether
the correction is good.
7. When the desired correction is achieved, tighten the
bolt fixing the hinge to the door to 22–28Nm and
check the torque.
Front Door Striker Adjustment
The front door striker is a latch with two screws. In many
cases, it is necessary to adjust the lock catch up, down or
inward and outward:
• Frame is damaged by collision
• New door sealing strip is fitted
• Customer complains of excessive wind noise
• It is difficult to open/close the door
Adjust the striker upward/downward or inward/outward
according to the following procedures:
1. The door must be positioned correctly.
3. Loosen 2 striker screws. Adjust the striker to align the
door pin, then pre-tighten the screws.
1.0 310
Front Door and Hinge Assembly
Remove
jack under the door to support the front door.
4. Remove and discard 1 bolt fixing the door check to
the body.
7. Remove the front door assembly.

8. Remove and discard 3 bolts fixing the upper hinge to
the body. Remove the front door upper hinge.
9. Remove and discard 3 bolts fixing the lower hinge to
the body. Remove the front door lower hinge.
5. With assistance, hold the door, then remove and

discard 4 bolts fixing the upper/lower hinges to the
door.
Refit
1. Fit 3 new bolts fixing the upper hinge to the body,
2. Fit 3 new bolts fixing the lower hinge to the body,
3. With assistance, locate the door to the vehicle body.
Caution: Please protect the paintwork by applying 4. Connect the connector port, and embed the rubber
masking tape where possible and using an assistant to ring into the mounting hole of the body.
help with the remove and refit process. 5. Fit 4 new bolts fixing the upper/lower hinges of the
6. With assistance, hold the door, remove the rubber front door to the door, tighten to 22–28Nm and
seal ring on the body, and pull out the connector to check the torque.
disconnect the harness connector. 6. Fit 1 new bolt fixing the door check to the body, tighten
7. Close the door and check if the door can be properly
opened or closed.
1.0 311
Driver Door Outer Handle and Lock Cylinder

Assembly
Remove
1. Open the driver door and fully lift the door window.
2. Remove the interior trim panel and waterproof
membrane from the driver door.
Membrane Refit
3. Release the clip between the left front door lock
cylinder link and the lock cylinder from the door cavity
to disconnect the lock cylinder link from the lock
cylinder.
Refit
1. Fix the rear bush of the outer handle, fit the front of
the driver door outer handle into the front mounting
hole of the door, and move the outer handle towards
the front vehicle to fix the driver door outer handle to
the liner of the outer handle.
2. Fully pull the rear of the driver door outer handle, fix
the front door lock cylinder to the outer handle liner
of the front door, tighten the screw to 2-2.5Nm and
check the torque.
3. Fit the lock cylinder cover.
4. Clamp the lock cylinder link into the clip of the door
lock cylinder.
4. Remove the cap of the lock cylinder screw at the end
of the front door to access the bolt fixing the door lock 5. Test if the door can work properly.
cylinder to the outer door handle liner. 6. Press the plug into the round hole on the door and
secure the plug clip firmly so that seal can be achieved.
7. Fit the interior trim panel and waterproof membrane
of the driver door.

Membrane Refit
8. Close the driver door.
5. Release the bolt, but do not remove it for it is clamped

inside.
6. Pull the rear of the front door outer handle, pry the
cover of the lock cylinder to remove the lock cylinder
assembly.
7. Move the outer handle towards the rear body, and pull
the rear of the handle outwards to disconnect it from
the outer handle liner of the driver door, then remove
it.
1.0 312
Front Passenger Door/Rear Door Outer Handle
and Lock Cylinder Cover
Remove
1. Open the door.
2. Remove the plug beside the door to access the plastic
slide valve fixing the door lock cylinder cover to the
outer door handle liner.
Refit
1. Fix the outer handle rear bush, fit the front of the outer
handle into the front door mounting hole, and move
the outer handle towards the rear vehicle to fix the
outer handle to the outer handle liner.
2. Fully pull the rear of the outer handle, and fit the outer
handle lock cylinder cover to the outer handle liner.
3. Use a hook to pull the plastic slide valve on the outer 3. Push the plastic slide valve towards the front vehicle
handle liner towards the rear body through the plug through the plug hole beside the door, fix the outer
hole beside the body, but do not remove the plastic handle lock cylinder cover, and confirm if it is properly
slide valve, because it is connected with the liner. clamped.
4. Check if the outer door handle can work properly.
5. Press the plug into the round hole on the door and
secure the plug clip firmly so that seal can be achieved.
6. Close the door.
4. Pull the rear of the outer handle to remove the lock

cylinder cover.
5. Move the outer handle towards the rear body, and pull
the rear of the outer handle outwards to disconnect it
from the outer handle liner, then remove it.
1.0 313
Driver Door Outer Handle Liner 3. Fit 1 screw fixing the outer handle liner to the door
Remove from the outside of the door, tighten the screw to
1. Open the front door. 2-2.5Nm and check the torque.
2. Ensure the front door window can be fully ascended. 4. Fix the front door outer handle link into the
corresponding slot of the lock.
3. Remove the front door interior trim panel and
waterproof membrane. 5. Fit the outer handle and lock cylinder assembly of the
front door.
Membrane Refit Driver Door Outer Handle and Lock Cylinder
Assembly Refit
4. Remove the outer handle and lock cylinder assembly of
the front door. 6. Try to open the door with the outer handle and lock
cylinder and ensure all parts are correctly fitted.
Assembly 7. Fit the front door interior trim panel and waterproof
membrane.
5. Remove 1 screw fixing the front door outer handle
liner to the door. Front Door Interior Trim Panel and Waterproof
Membrane Refit
8. Close the door.
6. Disconnect the front door outer handle link from the

front door outer handle liner.
7. Remove the outer handle liner assembly from the door

cavity.
Refit
1. Fit the front door outer handle liner assembly from
the cavity inside the front door, and locate it to the
mounting position on the outside door panel.
2. Fit the front door outer handle link to the front door
outer handle liner.
1.0 314
Driver Door Lock Assembly 4. Locate the lock assembly to the door panel from the
Remove door cavity, and tighten the bolt to 8–10Nm from top
1. Open the front door, and ensure the front door to bottom, and check the torque.
window is fully ascended. 5. Fix the front door outer handle link into the
2. Disconnect the battery negative. corresponding clip of the front door lock.
3. Remove the front door interior trim panel and 6. Fix the lock cylinder link into the corresponding clip of
waterproof membrane. the front door outer handle liner.
7. Check if the outer/inner handles of the front door can
work properly.
Membrane Refit
8. Fit the front door interior trim panel and waterproof
4. Remove 3 bolts fixing the door lock to the door.
membrane.

Membrane Refit
10. Close the front door.
5. Disconnect the harness connector of the door lock.

6. Release the clip (1) securing the lock cylinder link and
front door outer handle liner, and disconnect the lock
cylinder link.
7. Disconnect the lock cylinder link (2) and front door
outer handle link (3) from the lock, and remove the
lock assembly of the front door.
8. Disconnect the inner handle cable (4) from the lock
assembly.
Refit
1. Connect the inner cable of the front door to the front
door lock.
2. Connect the harness connector of the front door lock.
3. Fit the lock cylinder link to the lock.
1.0 315
Rear Door Adjustment

Rear Door Hinge Adjustment
1. Open the rear door.
jack under the door to support the rear door.
3. Loosen 4 bolts securing the upper/lower door hinges
of the rear door to the rear door.
4. Close the door, and check if the rear of the door is

flush with the sheet metal of the body side panel and if
the door can open and close normally.
5. Open the door after correction, tighten the screw
fixing the striker to the body to 19–25Nm, and check
the torque.
6. Close the door.
4. Correct the rear door with the jack.

5. Pretighten the hinge bolts.
6. Take away the jack, close the door and check whether
the correction is good.
7. When the desired correction is achieved, tighten the
bolt fixing the hinge to the door to 22–28Nm and
check the torque.
Rear Door Striker Adjustment
The striker of the rear door is a latch with two screws. In
many cases, it is necessary to adjust the lock catch up, down
or inward and outward:
• Frame is damaged by collision
• New door sealing strip is fitted
• Customer complains of excessive wind noise
• It is difficult to open/close the door
Following procedures shall be observed when adjusting the
door striker up and down or inward and outward:
1. The door shall be properly located.
2. Open the rear door.
3. Release 2 lock catch screws. Adjust the striker to align
it with the door latch, and pretighten the screws.
1.0 316
Rear Door and Hinge Assembly Caution: Please protect the paintwork by applying
Remove masking tape where possible and using an assistant to
1. Disconnect the battery negative terminal. help with the remove and refit process.
2. Open the rear door. 6. Remove the rear door assembly.

3. Remove and discard 1 bolt fixing the door check to 7. From the outside of the body, remove and discard 2
the body. bolts fixing the upper hinge to the body. Remove the
rear door upper hinge.
8. From the outside of the body, remove and discard 3
bolts fixing the lower hinge to the body. Remove the
rear door lower hinge.
4. Pry open the rubber ring on the body, and pull out the
connector to disconnect the connector interface.
Refit
1. Locate the rear door lower hinge to the body.
2. Fit 3 new bolts fixing the lower hinge to the body,
3. Locate the rear door upper hinge to the body.
4. Fit 2 new bolts fixing the upper hinge to the body,
5. With assistance, locate the door to the vehicle body.
6. Connect the connector port, and embed the rubber
ring into the body mounting hole.
5. With assistance, hold the outside of the door, then
7. Fit 4 new bolts fixing the upper and lower hinges of
remove and discard 4 bolts fixing the upper/lower
the rear door to the door, tighten to 22–28Nm and
hinges to the door.
check the torque.
8. Fit 1 new bolt fixing the door check to the body, tighten
9. Close the door and check if the door can be properly
opened or closed.
1.0 317
Rear Door Outer Handle Liner all parts are correctly fitted.
Remove 8. Fit the rear door interior trim panel and waterproof
1. Open the rear door. membrane.
2. Ensure the rear door window can be fully ascended. Rear Door Interior Trim Panel and Waterproof
3. Remove the rear door interior trim panel and Membrane Refit
waterproof membrane.
Rear Door Interior Trim Panel and Waterproof
Membrane Refit
4. Remove the rear door outer handle and the lock
cylinder cover assembly.
Rear Door Outer Handle and Lock Cylinder Cover
Remove
5. Remove 1 screw fixing the rear door outer handle liner
to the door.
6. Release the clip fixing the outer handle link to the lock.
7. Remove the outer handle liner assembly from the door
cavity.
8. Disconnect the rear door outer handle link from the
rear door outer handle liner.
Refit
1. Fix the rear door outer handle link into the
corresponding clip of the rear door outer handle liner.
2. Fit the outer handle liner assembly of the rear door
from the cavity inside the rear door, and locate it to the
mounting position on the outside door panel.
3. Fit the screw fixing the outer handle liner to the door
from the outside of the door, tighten the screw to
2–2.5Nm and check the torque.
4. Fix the rear door outer handle link into the
corresponding slot of the lock.
5. Secure the rear bush of the rear door outer handle.
6. Fit the rear door outer handle and the lock cylinder
cover.
Rear Door Outer Handle and Lock Cylinder Cover
Refit
7. Try to open the door with the outer handle and ensure
1.0 318
Rear Door Lock Assembly 5. Check if the rear door outer/inner handle can work
Remove properly.
1. Open the rear door. 6. Fit the rear door interior trim panel and waterproof
2. Ensure rear window glass can be fully ascended. membrane.
3. Remove the rear door interior trim panel and Rear Door Interior Trim Panel and Waterproof
waterproof membrane. Membrane Refit
Rear Door Interior Trim Panel and Waterproof 7. Close the door.
Membrane Refit
4. Pry the clip fixing the rear door outer handle link to
the lock so as to release the link.
5. Remove 3 bolts fixing the rear door lock, and take out
the door lock from the door cavity carefully.
6. Disconnect the lock body harness connector.

7. Carefully disconnect the inner handle cable end of the
rear door from the lock assembly to remove the lock
assembly.
Refit
1. Fit the rear door inner handle cable to the lock.
2. Connect the harness connector of the lock.
3. Locate the lock to the mounting position from the
door cavity, fit 3 bolts, tighten to 8–10Nm and check
the torque.
4. Connect the rear door outer handle link to the lock,
and secure the clip.
1.0 319
Door Systems Door Accessories
Door Accessories
Specifications
Torque
Description Value
Bolt - glass holder 7–10Nm
Bolt - window regulator guide rail to door 7–10Nm
Nut - window glass rail to door 7–10Nm
Bolt - glass to window regulator guide rail 7–10Nm
1.0 320
Door Accessories Door Systems
Service Procedures Front Door Windowsill Inner Weatherstrip Refit
Front Door Window 5. Fit the front door windowsill outer weatherstrip.
Remove
Front Door Windowsill Outer Weatherstrip Refit
2. Disconnect the battery negative terminal. membrane.
3. Remove the front door interior trim panel and
Membrane Refit
7. Connect the battery negative terminal.
Membrane Refit
8. Close the door.
Caution: Before taking down the panel, please raise the
glass so that the bolts is just in the mounting holes of the
door.
4. Remove the inner weatherstrip of the front door

windowsill.
Front Door Windowsill Inner Weatherstrip
Remove
5. Remove the outer weatherstrip of the front door
windowsill.
Front Door Windowsill Outer Weatherstrip
Remove
6. Remove 2 screws securing the glass and window
regulator.
7. Carefully remove the glass from the door window

frame.
Refit
1. Carefully place the glass between the inner panel and
outer panel through the window frame, and fit the slot
weatherstrip from the two sides.
2. Descend the glass slowly until it touches the slider of
the window regulator, fix the glass clip to the small
terrace of the slider and align the hole of the glass clip
with the regulator slider hole.
3. Fit 2 bolts fixing the front door window to the front
door window regulator , tighten to 7–10Nm and
check the torque.
4. Fit the front door windowsill inner weatherstrip.
1.0 321
Front Door Window Regulator Front Door Window Regulator Control

Remove Adjustment
1. Open the front door. 1. Open the front door.
2. Disconnect the battery negative terminal. 2. Disconnect the battery negative terminal.
3. Disassemble the front door window. 3. Remove the front door interior trim panel and
Front Door Window Remove
4. Remove 5 bolts fixing the glass regulator to the door Front Door Interior Trim Panel and Waterproof
panel. Membrane Refit

door.
4. Release 2 bolts securing the glass.
5. Disconnect the window regulator harness connector,

and remove the window regulator from the door cavity.
Refit
1. Fit the glass regulator into the front door cavity, fit 5
bolts securing the glass regulator on the door panel, 5. Release 5 bolts securing the window regulator.
tighten the bolt to 7–10Nm from top to bottom/left
to right and check the torque.
2. Connect the window regulator harness connector.
3. Fit the front door window.
Front Door Window Refit

5. Check if the window regulator can function and if the
window with the "one-button control" function can
work.
Note: In case of power off, the "one-touch" ascending

function may fail. To reset the function, press the switch to
ascend the window to the top, press and hold it for 3s, then 6. Adjust the glass so that it can mesh with the
press the switch to descend the window to the bottom, weatherstrip on both ends, and ensure the glass works
press and hold it for 3s to complete the self learning. The well.
"one-touch" ascending mode will be recovered.
7. Tighten 5 bolts of the window regulator to 7–10Nm
6. Close the front door. and check the torque.
8. Tighten the bolt of the glass to 7–10Nm and check
the torque.
9. Ascend/descend the glass to see if it can work properly
or if it is properly located.
membrane.
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Front Door Interior Trim Panel and Waterproof Front Door Windowsill Inner Weatherstrip
Membrane Refit Remove
11. Connect the battery negative terminal. 1. Open the front door.
12. Check if the window regulator can function and if the 2. Remove the front door interior trim panel.
window with the "one-button control" function can
work.
Membrane Refit
Note: In case of power off, the "one-touch" ascending 3. Pull up and remove the front door windowsill inner
function may fail. To reset the function, press the switch to weatherstrip.
ascend the window to the top, press and hold it for 3s, then
press the switch to descend the window to the bottom,
press and hold it for 3s to complete the self learning. The
"one-touch" ascending mode will be recovered.
Refit
1. Align the opening of the weatherstrip with the inner
door panel seam, and fit the front door windowsill
inner weatherstrip.
2. Fit the front door interior trim panel.

Membrane Refit
1.0 323
Front Door Windowsill Outer Weatherstrip Front Door Window Slideway Weatherstrip
Remove Remove
1. Open the front door. 1. Open the front door.
2. Remove the exterior rearview mirror assembly. 2. Disconnect the battery negative terminal.
Exterior Rearview Mirror Assembly Remove 3. Disassemble the front door window.
3. Uncover the door weatherstrip near the exterior Front Door Window Remove
rearview mirror assembly, and remove 2 screws 4. Remove the front door window slideway weatherstrip
securing the two ends of the outer weatherstrip of the carefully.
front door windowsill to door panel.
Refit
1. Fit the front door window slideway weatherstrip.
2. Fit the front door window.
Front Door Window Refit

4. Close the door.
4. Carefully pull the outer weatherstrip from the front to

the end of the door, and remove it.
Refit
1. Align the front door windowsill outer weatherstrip
with the door panel, then fit it to the revers of the
door panel.
2. Fit 2 screws securing the front door windowsill outer
weatherstrip to door panel and tighten the screw.
3. Fit the door weatherstrip on the exterior rearview
mirror assembly.
4. Fit the exterior rearview mirror assembly.
Exterior Rearview Mirror Assembly Refit

5. Close the front door.
1.0 324
Front Door Glass Rail Rear Door Window
Remove Remove
1. Open the door, and fully lift the window. 1. Disconnect the battery negative terminal.
2. Remove the front door interior trim panel and 2. Remove the rear door interior trim panel and
waterproof membrane. waterproof membrane.
Front Door Interior Trim Panel and Waterproof Rear Door Interior Trim Panel and Waterproof
Membrane Refit Membrane Refit
3. Remove 1 nut securing the glass rail on the inner door Caution: Before taking down the panel, please raise the
panel, and remove the glass rail of the front door. glass so that the bolts is just in the mounting holes of the
door.
3. Remove the rear door windowsill inner weatherstrip.

Rear Door Windowsill Inner Weatherstrip Remove
4. Remove the rear door windowsill outer weatherstrip.
Rear Door Windowsill Outer Weatherstrip Remove
5. Remove 2 bolts securing the glass and window
regulator.
Refit
1. Fit 1 nut securing the front door glass rail on the door
panel, tighten to 7–10Nm and check the torque.
membrane.
Membrane Refit
3. Close the door.
6. Carefully remove the glass from the door window
frame.
Refit
1. Place the glass between the inner panel and outer
panel through the door window frame, and fit the slot
weatherstrip from the two sides.
2. Descend the glass slowly until it touches the slider of
the window regulator, fix the glass clip to the small
terrace of the slider and align the hole of the glass clip
with the regulator slider hole.
3. Fit 2 bolts fixing the rear door window to the rear
door window regulator, tighten to 7–10Nm and check
the torque.
4. Fit the rear door windowsill outer weatherstrip.
Rear Door Windowsill Outer Weatherstrip Refit
5. Fit the rear door windowsill inner weatherstrip.
Rear Door Windowsill Inner Weatherstrip Refit
6. Fit the rear door interior trim panel and waterproof
membrane.
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Rear Door Interior Trim Panel and Waterproof Rear Door Window Regulator
7. Connect the battery negative terminal. 1. Open the rear door.
8. Close the rear door. 2. Disconnect the battery negative terminal.
3. Remove the rear door interior trim panel and
Membrane Refit
door.

Rear Door Windowsill Inner Weatherstrip Remove
5. Remove the rear door windowsill outer weatherstrip.
Rear Door Windowsill Outer Weatherstrip Remove
6. Remove the rear door window.
Rear Door Window Remove
7. Remove 3 bolts fixing the window regulator to the
door panel.
8. Disconnect the window regulator harness connector,

and remove the window regulator from the door
window frame.
Refit
1. Fit the glass regulator into the rear door cavity, fit 3
bolts securing the window regulator on the door panel,
tighten the bolt to 7–10Nm from top to bottom/left
to right and check the torque.
2. Connect the window regulator harness connector.
3. Fit the rear door glass.
Rear Door Glass Refit
4. Fit the rear door windowsill inner weatherstrip.
Rear Door Windowsill Inner Weatherstrip Refit
5. Fit the rear door windowsill outer weatherstrip.
Rear Door Windowsill Outer Weatherstrip Refit
1.0 326
membrane. Rear Door Window Regulator Control
Adjustment
Membrane Refit 1. Open the rear door.
7. Connect the battery negative. 2. Disconnect the battery negative.
8. Check if the window regulator can work. 3. Remove the rear door interior trim panel and
9. Close the rear door.
Membrane Refit
door.
4. Release 2 bolts securing the glass.
5. Release 3 bolts securing the window regulator.
6. Adjust the glass so that it can mesh with the

weatherstrip on both ends, and ensure the glass works
well.
7. Tighten the bolt of the window regulator to 7–10Nm
8. Tighten the bolt of the glass to 7–10Nm and check
the torque.
9. Ascend/descend the glass to see if it can work properly
or if it is properly located.
membrane.
1.0 327
Rear Door Interior Trim Panel and Waterproof Rear Door Windowsill Inner Weatherstrip
11. Connect the battery negative. 1. Open the rear door.
12. Check if the window regulator can work. 2. Remove the rear door interior trim panel and
Membrane Remove
Refit
1. Align the opening of the weatherstrip with the inner
door panel seam, and fit the rear door windowsill inner
weatherstrip.
membrane.

Membrane Refit
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Rear Door Windowsill Outer Weatherstrip Rear Door Window Frame Exterior Trim Panel
Remove Remove
1. Open the rear door. 1. Uncover the rear door weatherstrip on the rear door
2. Lift the door weatherstrip on the front of the rear window frame exterior trim panel.
door, remove 1 screw, and pull the outer weatherstrip 2. Pry the rear door triangle trim cover.
up to remove it. 3. Remove 3 screws securing the rear door window frame
exterior trim panel on the door, and remove the rear
door window frame exterior trim panel.
Refit
1. Align the rear door windowsill outer weatherstrip with
the door panel, then fit them to the revers of the door Refit
panel from the front to the end of the rear door, tighten 1. Position the rear door window frame exterior trim
1 screw and fit the door weatherstrip. panel on the door, fit the clip and 3 screws, then tighten
2. Close the rear door. them.
2. Fit the rear door triangle trim cover.
3. Fit the rear door weatherstrip on the rear door
window frame exterior trim panel.
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Rear Door Window Slideway Weatherstrip Rear Door Glass Rail

Remove Remove
1. Open the rear door. 1. Open the door, and fully lift the window.
2. Disconnect the battery negative terminal. 2. Remove the rear door interior trim panel and
3. Remove the rear door window. waterproof membrane.
Rear Door Window Remove Rear Door Interior Trim Panel and Waterproof
Membrane Refit
4. Remove the rear door window slideway weatherstrip
carefully. 3. Remove 2 nuts securing the glass rail on the inner door
panel, and remove the rear door glass rail.
Refit
1. Fit the rear door glass slot weatherstrip.
2. Fit the rear door glass.
Rear Door Glass Refit

4. Close the rear door.
Refit
1. Fit 2 nuts securing the rear door glass rail on the inner
door panel, tighten to 7–10Nm and check the torque.
membrane.

Membrane Refit
3. Close the door.
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Power Window Switch - Driver Side Power Window Switch - Others
Remove Remove
2. Pry off the screw cover. 2. Pry off the screw cover.
3. Remove 1 screw fixing the power window switch to 3. Remove 1 screw fixing the power window switch to
the door interior trim panel. the door interior trim panel.
4. Pry off the clip fixing the power window switch to the 4. Pry off the clip fixing the power window switch to the
door interior trim panel. door interior trim panel.
5. Disconnect the harness connector and remove the 5. Disconnect the harness connector and remove the
driver power window switch. power window switch.
Refit Refit
1. Connect the harness connector of the driver power 1. Connect the harness connector of the power window
window switch. switch.
2. Fix the power window switch to the door interior trim 2. Fix the power window switch to the door interior trim
panel, fit and tighten 1 screw. panel, fit and tighten 1 screw.
3. Fit the screw cover. 3. Fit the screw cover.
4. Connect the negative battery cable. 4. Connect the negative battery cable.
5. Perform a self-learning for the window regulator. Refer
"Window Regulator Initialisation Self-learning".
1.0 331
Door Lock Switch

Remove
2. Remove the driver side door interior trim panel.
Driver Side Door Interior Trim Panel Remove
3. Disconnect the harness connector of the door lock
switch.
4. Loosen the clip and remove the door lock switch.
Refit
1. Fit the door lock switch.
2. Connect the harness connector of the door lock
switch.
3. Fit the driver side door interior trim panel.
Driver Side Door Interior Trim Panel Refit

1.0 332
Door Molding Door Systems
Door Molding
Service Procedures
Membrane
Remove
2. Pry off the interior handle screw hole trim cover, and
remove 1 screw fixing the door interior handle to the
door.
6. Disconnect the interior handle cable assembly cable,

Remove the front door interior trim panel.
7. Remove 2 screws fixing the door trim panel mounting
bracket and take down the door trim panel mounting
bracket.
8. Remove the front door waterproof membrane from
the door sheet metal.
Refit
1. Pass the electrical interface through the corresponding
3. Pry off the door handle pull cup screw trim cover， location of the waterproof membrane, correspond the
remove 1 screw fixing the interior trim panel to the waterproof membrane locating hole with the door trim
door. panel mounting bracket, the upper edge is parallel with
the upper edge of the door sheet metal, and fit the
door waterproof membrane.
2. Fit 2 screws securing the door trim panel mounting
bracket and tighten screws.
3. Fit the interior handle cable assembly cable. Align the
new clip with the corresponding mounting hole of the
sheet metal. Fit the front door interior trim panel and
rear mirror trim panel on the door.
4. Connect the window regulator switch harness
connector, and fit the window regulator switch.
5. Fit 1 retaining screw securing the front door interior
trim panel pull cup on the door and tighten screw.
4. Pry off clips fixing the rear mirror trim panel to the 6. Fit 1 retaining screw securing the front door interior
door. trim panel on the door and tighten screw.
5. Pry off clips fixing the door trim panel to the door, 7. Connect the battery negative.
remove and discard the clip.
1.0 333
Door Systems Door Molding
Front Door Interior Handle Remove the front door interior trim panel.
Remove 7. Remove 3 screws fixing the front door interior trim
1. Disconnect the battery negative. panel to the trim panel.
door.
Refit
1. Locate the door interior handle to the front door
interior trim panel and secure with 3 screws.
3. Pry off the door handle pull cup screw trim cover，
2. Align the new clip with the corresponding mounting
remove 1 screw fixing the interior trim panel to the
hole of the sheet metal, fit the interior handle cable
door.
assembly cable, connect the harness connector and fit
the front door interior trim panel on the door.
3. Fit and tighten 1 retaining screw securing the front
door interior trim panel pull cup on the door. Fit the
door handle pull cup screw trim cover.
4. Fit and tighten 1 retaining screw securing the interior
handle on the door. Fit the interior handle trim cover.
4. Pry off clips fixing the rear mirror trim panel to the
door.
5. Pry off clips fixing the door trim panel to the door,
remove and discard the clip.
1.0 334
Door Molding Door Systems
Membrane
Remove
remove 1 screw fixing the rear door interior trim panel
to the door.

and disconnect the harness connector. Remove the
rear door interior trim panel.
8. Remove 2 screws fixing the door trim panel mounting
bracket and take down the door trim panel mounting
bracket.
9. Remove the front door waterproof membrane from
3. Pry off the door handle pull cup screw trim cover , the door sheet metal.
remove 1 screw fixing the rear door interior trim panel Refit
to the door. 1. Pass the harness connectors through the corresponding
positions of the waterproof membrane. Correspond
the waterproof membrane locating hole with the door
trim panel mounting bracket, the upper edge is parallel
with the upper edge of the door sheet metal, and fit the
door waterproof membrane.
2. Fit 2 screws securing the door trim panel mounting
bracket and tighten screws.
assembly cable, fit the front door interior trim panel
on the door.
4. Pry off the window regulator switch with tool carefully. connector. Fit the window regulator switch.
Disconnect the window regulator switch harness 5. Fit and tighten 1 retaining screw securing the front
connector, and remove the window regulator switch. door interior trim panel pull cup on the door. Fit the
5. Pry off clips fixing the triangular trim panel to the door. door handle pull cup screw trim cover.
6. Pry off clips fixing the door trim panel to the door, 6. Fit and tighten 1 retaining screw securing the interior
remove and discard the clip. handle on the door. Fit the interior handle trim cover.
1.0 335
Door Systems Door Molding
Rear Door Interior Handle

Remove
door.

Remove the rear door interior trim panel.
8. Remove 2 screws fixing the rear door interior trim
panel to the trim panel.
3. Pry off the door handle pull cup screw trim cover，
remove 1 screw fixing the interior trim panel to the
door.
Refit
1. Locate the door interior handle to the front door
interior trim panel and secure with 2 screws.
4. Pry off the window regulator switch with tool carefully. assembly cable, fit the rear door interior trim panel
Disconnect the window regulator switch harness on the door.
connector, and remove the window regulator switch.
5. Pry off clips fixing the triangular trim panel to the door. connector. Fit the window regulator switch.
6. Pry off clips fixing the door trim panel to the door, 4. Fit and tighten 1 retaining screw securing the rear door
remove and discard the clip. interior trim panel pull cup on the door. Fit the door
handle pull cup screw trim cover.
5. Fit and tighten 1 retaining screw securing the interior
handle on the door. Fit the interior handle trim cover.
1.0 336
Fender Body System
Fender
Specifications
Torque
Description Value
Bolt - fender to body 7–10Nm
Nut - fender to body 7–10Nm
Bolt-A/C air intake grille to body 2–3Nm
1.0 337
Body System Fender
Service Procedures to ensure a uniform gap. Then tighten 6 bolts fixing

Fender the fender to the body to 7–10Nm, and check the
Remove torque. And tighten 1 nut fixing the fender to the body
to 7–10Nm, and check the torque. Tighten 1 screw
1. Remove the headlamp assembly.
to 7–10Nm, and check the torque.
Headlamp Assembly Remove
4. Fit the acoustic pad of the fender.
2. Remove 1 screw each side fixing the A/C air inlet grille
5. Fit the front wheelhouse liner.
assembly to the fender.
6. Fit 1 screw fixing the A/C air inlet grille assembly to the
fender, tighten it to 2–3Nm, and check the torque.
7. Fit the headlamp assembly.
Headlamp Assembly Refit
3. Remove the front wheelhouse liner.

Front Wheelhouse Liner Remove
4. Remove 2 bolts (1) fixing the fender to the fender
bracket.
5. Remove 2 bolts (2) fixing the fender to the body.
6. Remove 1 bolt (3) fixing the fender to the body.
7. Remove the acoustic pad of the fender, and remove 1
nut (4) from the back.
8. Unscrew 1 fender mounting screw (5) at the side
corner of A/C air inlet grille.
9. Open the door, remove 1 bolt (6) fixing the fender to
the body, and remove the fender.
Refit
1. Locate and adjust the fender.
2. Fix the fender to the body, do not tighten the bolts.
3. Adjust the gap between the fender and adjacent panels
1.0 338
Front Module Body System
Front Module
Specifications
Torque
Description Value
Bolt-intercooler to platform 4–6Nm
Bolt - head lamp bracket to body 7–10Nm
Bolt - head lamp bracket to MFE 7–10Nm
Bolt-Air conditioner pipe A bracket to Front-end module 7-10Nm
Bolt-Headlamp to body 3–5Nm
1.0 339
Body System Front Module
Service Procedures
Front-end Module
Remove
1. Remove the front bumper beam assembly.
Front Bumper Beam Assembly Remove

2. Remove the 4 bolts fit the headlamp to the body.
7. Repeat the above steps to remove the upper mounting

panel of the left headlamp.
8. Disconnect the bonnet lock release cable assembly
from the lock assembly to remove the lock assembly.
Bonnet Lock Assembly Remove
9. Remove 2 screws connecting the front-end module
to the radiator shock pad to separate the front-end
3. Remove the bonnet strut rod assembly. module intercooler from the radiator, and remove the
4. Remove the bolt fixing the A/C Pipeline bracket to the front-end module.
front-end module.
Refit
5. Remove the window washing reservoir filler pipe 1. Fix the front-end module to the intercooler and
assembly radiator, fit 2 bolts fixing the front-end module to the
Window Washing Reservoir Filler Pipe Assembly radiator shock pad, tighten them to 4–6Nm, and check
Remove the torque.
6. Remove 1 bolt connecting the upper mounting panel of 2. Fit the bonnet lock assembly.
the right headlamp and the body and 2 bolts connecting Bonnet Lock Assembly Refit
the upper mounting panel of the right headlamp and 3. Fix the upper mounting panel of the right headlamp
the front-end module, and remove the upper mounting to the upper radiator beam and body, tighten 1 bolt
panel of the right headlamp. connecting the upper mounting panel of the right
headlamp and the body to 7–10Nm, and check the
torque. Tighten 2 bolts connecting the upper mounting
panel of the right headlamp and front-end module to
7–10Nm, and check the torque.
4. Repeat the above steps to fit the upper mounting panel
of the left headlamp.
1.0 340
Front Module Body System
5. Fit the windshield washer reservoir filler pipe assembly.
Windshield Washer Reservoir Filler Pipe

Assembly Refit
6. Refit the bolt fixing the A/C Pipeline bracket to the
front-end module, tighten to7-10Nm, and check the
torque.
7. Refit the bonnet strut rod assembly.
8. Fit the headlamp assembly, and fit 4 bolts, tighten
to3–5Nm, and check the torque.
9. Refit the front bumper beam assembly.
Front Bumper Beam Assembly Refit
1.0 341
Body System Bonnet
Bonnet
Specifications
Torque
Description Value
Nut - hood hinge to hood panel 19–25Nm
Bolt - bonnet hinge to body 19–25Nm
Bolt - hood latch to platform 7–10Nm
Bolt-From former bumper frame to body 3-4Nm
Screw - bonnet open handle 1.3–1.9Nm
1.0 342
Bonnet Body System
Service Procedures Hood and Hinge Assembly
Hood Adjustment Remove
Adjustment Warning: Take special attention to avoid vehicle damage
1. Mark the hood hinges outer profile with a and personal injury.
non-permanent marker. 1. Open and support the hood properly.
2. Loosen 4 nuts fixing the cover panel of the left and right 2. Remove the A/C intake grille assembly.
hinges to the engine hood. A/C Intake Grille Assembly Remove
3. Mark the hinges position relative to the hood for
positioning during installation.
4. Remove 4 nuts fixing the hood hinge on both sides to
the engine hood.
3. Adjust the hood to keep a uniform gap between the

hood and the front bumper upholstery, headlamp and
front fender, and keep it flush with the front bumper
upholstery, headlamp and front fender.
4. For gap information please refer to the "Body Size" of 5. With assistance, remove the engine hood.
the "Body Panel and Paint" section.
6. Mark the hinges position relative to the hood for
5. Tighten the nut of the hinge cover panel to 19–25Nm positioning during installation.
7. Remove the A/C intake grille assembly.
A/C Intake Grille Assembly Remove
8. Remove 4 bolts fixing the body hinge on both sides to
the front body.
9. Remove hinges on both sides.

Refit
Warning: Bonnet will drop under its own weight during
removal and refit, ensure panel is fully supported.
1. Locate the body hinge on both sides to the front body,
and align it with the position marked when removing.
1.0 343
Body System Bonnet
2. Fit 4 bolts fixing the body hinge on both sides to the Bonnet Lock Assembly
front body, tighten the bolt to 19–25Nm and check Remove
the torque. 1. Open and support the bonnet firmly.
3. With assistance, locate the engine cover to the 2. Remove 4 bolts （1）fitting front bumper cover to
vehicle， and align the hinge with the position marked the front-end module, remove 2 bolts （2）fitting
when removing. front bumper cover to the front bumper, loosen 4 clips
Caution: Take care not to damage the bonnet stub （3）, remove 2 bolts （2）fitting front bumper cover
threads when inserting into the hinge. to the headlamp, remove the front bumper cover.
4. Fit 4 nuts securing the hood and the hood hinge on

both sides, but do not tighten to the specified torque.
5. Check if the hood is properly located, and carefully
adjust the gap and surface difference between the hood
and the front fender to meet DTS (dimension technical
specification) requirements.
6. After adjustment, tighten 4 nuts to 19–25Nm and
check the torque.

8. Close the engine hood.
3. Mark the lock position on the front-end module bracket

so that proper location can be found for refit.
4. Remove 3 bolts fixing the bonnet lock to the front-end
module.
5. Disconnect the harness connector of the bonnet lock.

6. Disconnect the bonnet lock release cable assembly
from the lock assembly to remove the lock assembly.
1.0 344
Bonnet Body System
Bonnet Release Cable
Remove
1. Open the bonnet and support it with a rod firmly.
2. Remove the bonnet lock assembly
Bonnet Lock Remove
3. Release the bonnet release cable assembly from the
bonnet lock.
4. Loosen the clips fixing the bonnet release cables to the
upper mounting panel of left headlamp and the body
in sequence.
5. Release the bonnet release cable from the front
compartment.
Refit
6. Release the bonnet release cable assembly from the
1. Connect the lock end of the bonnet release cable release handle.
assembly and the lock assembly firmly, i.e. fit the
7. Pull out the bonnet release cable assembly from the
spherical end of the cable core wire into the hook slot
front compartment.
of the bonnet lock, put the core wire into the long slot
of the bonnet lock case, and align the circular groove of Refit
the main cable pipe connector with the mounting slot 1. Locate the front compartment cover release cable
of the lock case, then press it hard until it clicks. assembly in the front compartment, insert the flat
2. Locate the bonnet lock assembly to the front-end blade end through the hole in the front compartment
module, and align it with the position marked when bulkhead from the front compartment into the driver
removing. compartment, and fix it into the bulkhead hole with the
rubber seal ring of the cable assembly.
3. Fit 3 bolts fixing the lock assembly to the front-end
module, and do not tighten them to the specified 2. Insert the cylindrical end of the front compartment
torque at this step. cover release cable assembly into the cylindrical hole in
the release handle, place the core wire in the long slot
4. Close the bonnet, observe the relative position of the
of the handle, and align the cable sleeve connector with
lock and striker, adjust the lock and allow the striker to
the mounting slot of the release handle, then press it
enter into the lock tongue.
hard until it clicks.
5. Connect the harness connector of the bonnet lock.
6. After adjustment, tighten the 3 bolts to 7–10Nm, and
check the torque.
7. Refit 4 bolts fitting front bumper cover to the front-end
module, tighten to3-4Nm, and check the torque. Refit
4 clips firmly.
8. Refit 2 bolts fitting front bumper cover to the front
bumper, tighten to3-4Nm, and check the torque.
9. Refit 2 bolts fitting front bumper cover to the headlamp,
tighten to3-4Nm, and check the torque.
10. Close the bonnet.
3. Fix the front compartment cover release cable to the

front compartment and the upper mounting panel of
left headlamp in sequence.
4. Fit the front compartment cover lock assembly.
Front Compartment Cover Lock Assembly Refit
5. Pull the front compartment cover release handle in the
driver compartment, and check the opening effect of
the front compartment cover.
1.0 345
Body System Bonnet
Hood strut Hood Release Handle

Remove Remove
Warning: Take special attention to avoid vehicle damage 1. Lift the hood release handle.
and personal injury. 2. Remove 2 retaining screws fixing the hood release
1. Open and support the hood properly. handle.
2. Directly remove the hood strut.
Refit
Warning: Bonnet will drop under its own weight during
removal and refit, ensure panel is fully supported.
1. Fit the hood strut.
2. Close the engine hood.
3. Release the hood release handle to remove the release

handle.
Refit
1. Insert the cylindrical end of the hood release handle
into the cylindrical hole of the release handle, place the
core wire into the long slot of the handle, and align
the cable protection pipe end with the mounting slot
of the release handle, then press it hard until a "click"
sound is heard.
2. Align the two round mounting holes on the hood
release handle base with the two mounting holes on the
driver lower trim panel, and align the square protrusion
on the base with the square hole on the driver lower
trim panel and make two mounting surfaces fit with
each other.
3. Fit 2 self-tapping screws fixing the hood release handle
to the driver lower trim panel, tighten to 1.3–1.9Nm
1.0 346
Tailgate Body System
Tailgate
Specifications
Torque
Description Value
Bolt - Tailgate hinge to tailgate 7–10Nm
Nut - Tailgate hinge to body 26–34Nm
Bolt - Tailgate lock totailgate 19–25Nm
Bolt - tailgate striker to tailgate sill 19–25Nm
Bolt -Tailgate strut mounting bracket to body 7–10Nm
Bolt - Tailgate strut mounting bracket to tailgate 7–10Nm
Nut - Tailgate hand to tailgate 3.5–5Nm
1.0 347
Body System Tailgate
Service Procedures Tailgate and Hinge Assembly

Tailgate Adjustment Remove
Adjustment 1. Open the tailgate.
1. Mark the tailgate hinge outer profile with a 2. Disconnect the battery negative terminal.
non-permanent marker. 3. Release the coat hanger cable from the tailgate hook.
2. Loosen 4 bolts fixing the cover panel of the left/right 4. Remove the tailgate interior trim panel assembly.
hinges to the tailgate.
5. Disconnect the rear window wiper motor harness
connector.
6. Disconnect the tailgate lock body harness connector.
7. Disconnect the rear combination lamp harness
connector.
8. Release the interface of the tailgate window resistance
heater wire.
9. Release the harness sheath at both sides of the tailgate,
draw the harness out from the tailgate cavity.
3. Adjust the tailgate to keep a uniform gap between

the tailgate and the tail lamp and the rear bumper
upholstery, and keep it flush with the tail lamp and rear
bumper upholstery.
4. For gap information, please refer to the "Body Size" of
the "Body Panel and Paint" section.
5. Tighten the hinge cover panel bolt to 7–10Nm and
check the torque.
10. With assistance, remove 4 bolts fixing both hinges

to the tailgate. If it is required to refit the tailgate, a
reference position shall be marked on the hinge.
Warning: Due to physical size and weight of the tail gate.

Please ensure that the tail gate is supported correctly
before carrying out any repairs or modifications. Please
take care to minimise the risk of personal injury or damage
to the vehicle whilst work is carried out.
1.0 348
11. Carefully pry up the steel spring piece on left and right between the tailgate and the body side wall panel and
gas springs to pull the piston ball head socket from the quarter panel meet the DTS (dimension technical
tailgate ball head. Remove the tailgate assembly. specification) requirements. After adjustment, tighten
Warning: Due to physical size and weight of the tail gate. 4 bolts to the specified torque of 7–10Nm and check
Please ensure that the tail gate is supported correctly the torque.
before carrying out any repairs or modifications. Please 7. Press hard the ball head sockets of the gas spring
take care to minimise the risk of personal injury or damage pistons at both sides into the ball head of the tailgate
to the vehicle whilst work is carried out. side panel, till a "click" sound is heard, which indicates
12. Mark the tailgate hinge position on the vehicle body that they are fitted in place, and clamp the steel piece.
with a non-permanent marker. 8. Fit the harness into the tailgate cavity, and fit the
13. Release the roof interior trim panel at the tailgate end harness sheath at both sides of tailgate.
to access the nut fixing the tailgate hinge. 9. Release the interface of the tailgate window resistance
14. Remove 2 nuts securing the left and right tailgate hinges heater wire.
to the body. 10. Connect the rear combination lamp harness connector
.
11. Connect the tailgate lock body harness connector .
12. Connect the rear window wiper motor harness
connector.
13. Fit the tailgate interior trim panel.

14. Connect the coat hanger cable to the tailgate hook.

15. Remove the tailgate hinge assembly.
Refit
1. Locate the tailgate hinge assembly to the marked
mounting location on the body.
2. Fit 2 nuts fixing the left and right tailgate hinges to
the body, tighten the nut to 26–34Nm and check the
torque.
3. Fit the roof interior trim panel (at the tailgate end).
4. With assistance, locate the tailgate to the vehicle body
and align it with the relative mark.
5. Fit the bolt fixing the hinge to the tailgate, but do not
tighten it to the specified torque.
6. Check if the fit clearance and surface difference
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Tailgate Lock Catch Assembly in place.

Remove 6. Fit the interior trim panel of the tailgate.
1. Disconnect the battery negative terminal after
unlocking the tailgate.
2. Open the tailgate.
3. Remove the tailgate interior trim panel assembly.
4. Remove 2 bolts fixing the tailgate lock catch to the
tailgate.
5. Remove the tailgate lock catch sleeve.

6. Disconnect the lock catch harness connector.
7. Remove the tailgate lock body.

Refit
1. Locate the tailgate lock body to the tailgate sheet metal
through the tailgate cavity.
3. Fit 2 bolts fixing the tailgate lock body to the tailgate,
but do not tighten bolts.
4. Check and adjust the fit clearance and the surface
distance between the tailgate lock body and the
surrounding sheet metals, then tighten the lock body
retaining bolt to 19–25Nm and check the torque.
5. Push the tailgate lock body sleeve into the lock until a
"click" sound can be heard, which indicates it is fitted
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Tailgate Lock Catch Tailgate Gas Strut and Mounting Bracket
Remove Remove
1. Open the tailgate. 1. Open the tailgate, and when removing, make sure it is
2. Remove the trunk sill trim panel. securely supported.
Trunk Sill Trim Panel Refit Warning: Due to physical size and weight of the tail gate.
3. Mark the tailgate lock Striker relative to the quarter
panel.
4. Remove 2 screws fixing the tailgate lock Striker to the
quarter panel.
2. Carefully pry up the steel spring piece on both sides of
the left gas spring, and pull the ball head socket on the
end of piston from the tailgate ball head.
3. Then pull the ball head socket of the gas strut sleeve
from the ball head on the left body bracket.
4. Repeat steps 2-3 to remove the right gas strut.
5. Remove 2 bolts fixing the tailgate gas strut mounting
bracket to the body.
6. Remove 2 bolts securing the tailgate gas strut mounting
bracket to the tailgate, and remove the tailgate gas strut
mounting bracket.
5. Remove the tailgate lock Striker.

Refit
1. Pre-tighten the tailgate lock striker according to marks
of the tailgate lock striker and the quarter panel.
2. Open/close the tailgate repeatedly, check and adjust
the fit clearance and surface difference between the
tailgate and the surrounding sheet metals by moving the
bottom panel of the lock striker.
3. Make sure that the tailgate lock is fully locked.
4. Tighten the bolt securing the lock striker to the quarter
panel to the torque of 19–25Nm and check the torque. Refit
5. Refit the trunk sill trim panel.
1. Align the left gas spring mounting bracket with holes on
Trunk Sill Trim Panel Refit the trunk and the tailgate respectively.
2. Fit 2 screws securing the tailgate gas spring mounting
bracket to the body, tighten to 7–10Nm and check
the torque.
3. Fit 2 screws securing the tailgate gas spring mounting
bracket on the tailgate, tighten to 7–10Nm and check
the torque.
4. Align the ball head socket on the gas spring sleeve with
the ball head on the left bracket, and make sure the gas
spring piston is downward.
5. Hold the sleeve, push the ball head socket into the ball
head with thumb. If the two parts are fitted well, a
"crack" sound will be heard.
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Caution: To avoid damaging the airtightness of the air Tailgate Exterior Handle
spring, never hold the centre of the air spring and laterally Remove
apply force to it by hand. 1. Open the tailgate.
6. Align the ball head socket on the left gas spring piston 2. Disconnect the battery negative terminal.
end with the ball head on the tailgate interior panel. 3. Remove the tailgate interior trim panel.
Hold the end of the piston, push the ball head socket
into the ball head with thumb. If the two parts are Tail Gate Interior Trim Panel Remove
fitted well, a "crack" sound will be heard. 4. Disconnect the tailgate switch harness connector,
7. Refit the steel spring piece on both sides of the gas remove 3 nuts fixing the tailgate switch, and remove
spring ball head socket, and ensure it is properly located the tailgate switch.
in the spring piece slot.
8. Repeat steps 1-6 to fit the right tailgate gas spring.
9. Close the trunk lid.
Refit
1. Locate the tailgate switch on the tailgate, and connect
the tailgate switch harness connector. Install 3 nuts
fixing the tailgate switch, tighten to 3.5–5Nm and
check the torque.
2. Fit the interior trim panel of the tailgate.

4. Close the tailgate.
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Tailgate Upper Trim Panel
Remove
1. Open the tailgate.
2. Pry 2 clips on the tailgate upper trim panel, and remove
the tailgate upper trim panel.
Refit
1. Locate the tailgate upper trim panel on the tailgate, and
flap clips in place.
2. Close the tailgate.
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Body System Charger Filler Flap
Charger Filler Flap

Specifications
Torque
Description Value
Screw-Door of charging to front bumper 1.4–1.8Nm
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Charger Filler Flap Body System
Service Procedures
Charging Port Door Assembly
Remove
2. Turn off the ignition key and wait for more than 5 min
before removing.

3. Remove the front bumper assembly.

Front Bumper Remove
4. Remove 12 screws fixing the charging port door to the
front bumper, and remove the charging port door.
Refit
1. Fix the charging port door to the front bumper, fit 12
screws, tighten them to 1.4–1.8Nm, and check the
torque.
2. Fit the front bumper assembly.
Front Bumper Refit

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Body System Body Control Module
Body Control Module

Specifications
Torque
Description Value
Bolt-Body control module to Body 5–7Nm
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Body Control Module Body System
Service Procedures
Body Control Module (BCM)
Remove
1. Disconnect the battery negative cable.
2. Remove the glove box assembly.
Glove Box Assembly Remove

3. Disconnect the harness connector (1) of the BCM.
4. Remove 2 bolts (2) fixing the BCM to the vehicle body.
5. Remove the BCM.

Refit
1. Connect the harness connector of the BCM.
3. Programme and encode the BCM. Refer to Module
Self-learning and Programming Manual, "BCM
Self-learning".
4. Fix the BCM to the body, fit 2 bolts, tighten them to
5–7Nm, and check the torque.
5. Fit the glove box assembly
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Body System Horn
Horn
Specifications
Torque
Description Value
Bolt-Horn to body 19–25Nm
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Horn Body System
Service Procedures
Horn
Remove
Front Bumper Assembly Remove

3. Disconnect the tweeter/woofer harness connector (1).
4. Remove 2 nuts (2) fixing the tweeter/woofer to the
body.
5. Remove tweeter/woofer horns.

Refit
1. Fix the tweeter/woofer to the body, fit 2 nuts, tighten
Front Bumper Assembly Refit

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Panel Repair Body Panel & Paint
Panel Repair
Roof Panel
1. Roof Panel - Sunroof

2. Sunroof Reinforcement Assembly
3. Roof Front Beam Assembly
4. Roof 1st Intermediate Beam
5. Roof 2nd Intermediate Beam
6. Roof 3rd Intermediate Beam
7. Roof Rear Beam Assembly
8. Roof Panel - Without Sunroof
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Body Panel & Paint Panel Repair
Front Compartment Cover Panel
1. Left Dash Panel Side Panel Assembly

2. Right Dash Panel Side Panel Assembly
3. Front Left Wheelhouse Liner Assembly
4. Front Right Wheelhouse Liner Assembly
5. Left Front Longitudinal Beam Assembly
6. Right Front Longitudinal Beam Assembly
7. Left Front Bumper Mounting Bracket Assembly
8. Right Front Bumper Mounting Bracket Assembly
9. Washer Fluid Reservoir Bracket Assembly
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Dash Panel
1. Dash Panel Upper Panel Assembly

2. Dash Panel Lower Panel Assembly
3. Dash Panel Upper Beam Assembly
4. Dash Panel Assembly
5. Dash Panel Lower Beam Assembly
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Bodyside Panel
1. Bodyside Outer Panel

2. A Pillar Reinforcement Panel Assembly
3. B/C Pillar Closing Panel Assembly
4. Rear Bodyside Inner Panel Assembly
5. A Pillar Upper Closing Panel Assembly
6. Drain Channel Extension Panel Assembly
7. Fender Bracket
8. Fender Bracket
9. Fender Bracket
10. Front Bodyside Outer Panel
11. Middle Bodyside Outer Panel
12. Rear Bodyside Outer Panel
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Front Floor
1. Right Doorsill Inner Panel Assembly

2. Front Floor Assembly
3. Left Doorsill Inner Panel Assembly
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Rear Floor
1. Rear Floor Assembly

2. Rear End Panel Assembly
3. Rear Seat Plate Assembly
4. Heel Board Beam Assembly
5. Left Rear Longitudinal Beam Assembly
6. Right Rear Longitudinal Beam Assembly
7. Rear Floor Beam Assembly
8. Spare Tyre Compartment Assembly
9. Rear Left Wheelhouse Assembly
10. Rear Right Wheelhouse Assembly
11. Rear Left Wheelhouse Support Plate Assembly
12. Rear Right Wheelhouse Support Plate Assembly
13. Rear Left Door Sill Extension Panel
14. Rear Right Door Sill Extension Panel
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Door Panel Assembly
1. Front Door Assembly

2. Rear Door Assembly
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Front Compartment Cover Panel Assembly
1. Front Compartment Cover Panel Assembly
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Tailgate Sheet Metal Assembly
1. Tailgate Sheet Metal Assembly
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Body Panel & Paint Collision Repair
Collision Repair
Body Material
According to the strength requirement for different location of the body, different high strength steel sheet and ultra high
strength steel sheet (hot forming steel sheet) are used on the vehicle, the specific location of different materials is as follows:
Only repair specified by the manufacturer's Service Manual is permitted, use the modernized inverter technology to repair
the extra high strength steel sheet and hot forming steel sheet.
When repairing the galvanized steel sheet, observe the following points:
• Thoroughly remove the paint coat and zinc coating before grinding, grind with great care;
• Before spot welding, the paint for spot welding shall be applied between the contact surfaces for welding (use brush or
spray);
• The electrode will absorb the particle on the surface, so the tip of the electrode shall be cleaned on a regular basis.
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Collision Repair Body Panel & Paint
Damage Diagnosis Characteristics of body damage:
Damage detection • Characteristics of front collision damage
During the damage detection, it is required to visually estimate
the collided position, determine the collision direction and
magnitude of collision force, and check the possible damage.
For the vehicle damaged in an accident, it is required to ask
about the speed at the moment when the accident takes place,
and the position, direction and angle to the crash or rollover
to grasp the impact form, position, angle, etc of the collided
vehicle and intuitively determine the position damaged by the
collision and the area that may be affected. A comprehensive
inspection can also be conducted to the vehicle in combination • Characteristics of middle collision damage
with test drive and measuring equipment to confirm whether
the underbody is deformed, whether the body suffers from
overall damage and overall skew, whether the door can be
opened smoothly, etc to determine the extent of damage and
repair method.
1. Visual inspection to the vehicle
• Characteristics of rear collision damage
2. Visual inspection to the specific position
Measurement of the damaged position

Accurate measurement is one of the procedures required to
successfully perform a variety of collision repairs. For the
integral body, the measurement is even more important for
successful damage repair, because most of the steering and
suspension systems are fitted on the vehicle body while some
suspension systems are designed according to the assembly
requirements. To guarantee the correct steering and driving
operation performance of the vehicle, the fit tolerance of the
key processing dimensions should be controlled within the
Identify all damaged positions
allowed range.
After a vehicle is collided, beyond the deformation damage
The measurement work should be carried out in conjunction
from the collided position, its entire body, including frame,
with the disassembly work, or it will be unable to accurately
suspension, motor and other parts, may also be deformed.
identify all the damages. To facilitate the body maintenance
During the detection, it is required to check all damages of
and thorough damage inspection while avoid unnecessary
the related parts along the collided route system till there has
damage caused by the maintenance to the disassembled
been no trace of damage and those to the surrounding area.
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parts, it is required to disassemble the related parts. The • Verify all measuring results repeatedly.
disassembly should follow the principle to minimize damage
and destruction of the parts.
Selection of measuring point
• Screw hole and process hole for parts installation;
• Lap point of body steel plates;
• Machining gap or raised impression on steel plate.
Measuring methods:
• Distance measuring method: it is the simplest and most
practical measuring method employing a steel tape to
measure the distance from each component to the datum
point.
• Centering gauge method: measure with the centering

gauge.
• Three-dimensional coordinate measuring method:
measure the three-dimensional coordinate data of the
selected measuring point, and then compare them with
the original vehicle data to determine the body damage.
• Electronic measuring: more accurate and more effective.
Main reasons accounting for the measuring error of
body size:
The error caused by accuracy of the measuring tool or

equipment itself;
The error caused by human factors:
• Failure to accurately locate position of the measuring

point;
• Failure to select a correct measuring method;
• Failure to use the measuring tool and equipment in a
correct manner.
Precautions for measurement:
• Adjust the body to the horizontal position before the
measurement;
• Mark measuring points on the body to prevent messing
up the points during the measurement;
• Conduct the measurement in an accurate manner;
• Repeat the measurement for several times;
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Confirmation of Maintenance Scheme
Underbody correction
When the car is severely damaged, involving deformation of
the underbody, there is no need to replace the body and
it is required to conduct underbody correction in the first
place. Completion of the underbody correction can guarantee
three-dimensional position of the underbody and overall
position of the body, determine placement position of the
motor assembly and front suspension, and restore positioning
angle of the wheel and positioning of other assemblies. The
body panel metal repair should be carried out after completion
of the underbody correction.
Correction of body and its covering part
When the body and its covering part only suffer from
repairable depressed deformation and minor damage in a
collision, there will be no need for part replacement while
it is required to adopt a correction method to restore their
original shapes.
Panel replacement
For a certain position of the body or a part suffering from
multiple breakages, when the damage/corrosion has reached a
certain degree, making the repair meaningless or the required
technical standards and functional requirements unable to be
reached after repair, the damaged panel should be replaced.
Body replacement
When it is determined as that the body is irreparable, because
the car is seriously damaged, making the entire body almost
smashed up, the underbody severely deformed, and the two
sides, roof, front compartment cover, and trunk deck almost
completely destroyed, the vehicle body can be replaced as
required by the user. Remove all serviceable assemblies and
parts from the damaged car, and then conduct thorough check
and repair to the principal assemblies of motor, etc. Replace
the body assembly with a new one and all the parts requiring
substitution, and then conduct re-assembly in accordance with
the vehicle assembly process.
Partial replacement of body
When the vehicle is partially damaged in a collision, for
example, when the front/rear fender, door, front compartment
cover, or trunk deck is damaged, partial replacement can be
employed to the body to achieve the purposes of trouble
saving, time saving, and cost saving.
Replacement of body pillar
When the body pillar, front windshield pillar, or front/rear wall
pillar is beyond repair after being seriously damaged, it can
only be replaced. Only after the deformation of a large area is
restored can a regular pillar of the same shape can be installed
as a substitute.
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Body Correction
The purpose of body correction is to recover the correct
position and size of the sheet metal by eliminating the
deformation (plastic deformation) and residue stress caused
by collisions.
Introduction of Correcting Equipment
The correcting equipment shall provide the following features:
• The equipment shall have high-strength body positioning
device and fixture. Correction/Drawing Method
• It shall have a service puller with various shapes and Drawing Sequence
different functions that can meet the repair requirements Note the method and procedure for drawing: during drawing,
for different locations. draw for a little while, then release the chain, unload and make
• Be able to perform multipoint and comprehensive measurements. Operate from inside to outside.
correction/drawing. 1. Take length as the priority. Draw the vehicle in the
• Be able to accurately measure and detect the deviation longitudinal direction along the centreline of the vehicle.
and repair error for each reference point. 2. Then correct the width. Correct the vehicle in the
Operation Process for Correcting Equipment horizontal direction.
Regardless of the type of the equipment used, its operation is 3. Finally correct the height.
broadly divided into the following 4 steps: Stress Elimination
1. Get on the vehicle. Eliminate the stress during drawing;
2. Position, clamping. • Knock the raised location beside the deformed region
3. Drawing. and the back;
4. Measurement. • Knock the welding location of the deformed region;
Auxiliary fixture: • Knock the ridge of the deformed region;
• Prevent motion of the vehicle; • Knock the reinforcement of the deformed region;
• Force caused by even and disperse drawing;
The high-strength integral body is susceptible to heat, so

do not attempt to complete the correction/drawing just by
Auxiliary support:
operation of one step. Generally, follow the cyclic process:
• Prevent secondary damage to the body due to drawing; draw - keep balance - draw - keep balance. If some bodies
• Focus the drawing force on the damaged location, and are tightly folded after an impact, and there is a risk of metal
improve the efficiency of the drawing operation; damage, then heat it. When heating, only heat the corner
• Prevent moment resulted from drawing; or the location where the two panels are tightly connected.
Heating is merely a means to eliminate metal stress, not a
method to be used to soften some location.
Note: Do not service the body by heating oxygen-acetylene.
Apply tensile force to the predetermined location, recover the

size and shape of the damaged steel sheet carefully and slowly,
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completely eliminate the stress of the curved steel sheet to
achieve accurate repair of the body.
Note: overstretch shall be avoided during body correction.

The only solution to overstretch is to replace the damaged
sheet metals.
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Panel Repair obvious defect that can be sensed by a touch are not allowed.
Panel Repair Method Especially for large scale repair, ensure the integrity, streamline
feature, continuity and fineness of the continuous surface.
Puller Method for Sheet Metal Repair (Meson
Machine) Sufficient Strength and Rigidity
The puller traction method for sheet metal repair is introduced The body of the original design has sufficient strength and
in recent years, for this method, a number of flat gasket pullers rigidity, the body repaired shall ensure sufficient strength and
is welded according to the size of the damaged sheet metals, rigidity. The vibration noise of the body repaired shall be within
the flat gasket puller is a traction medium, insert the wire into the permissible range, abnormal vibration noise shall not occur.
the medium, and draw the wire with a manual or mechanical Ensure the body has no any fatigue damage within the certain
manner, apply force to the damaged sheet metals through distance, the entire body shall have the specified rigidity, make
the medium so that it can be drawn outwards and resume sure the body panels is able to maintain its shape in use.
its position and shape, especially for larger deformation,
bilayer structure, inaccessible location, corner transition and
door pillar, etc, the puller traction method provides a more
convenient method for repair.
Heat Shrinkage Method
Local heat shrinkage is a commonly used method for sheet

metal repair. Deformation of the sheet metals refers to tensile
deformation of the related position, use heat shrinkage method
to eliminate tensile stress and resume the shape.
Hammer and Jacking Block Method
The hammer and jacking block method is a conventional

method for sheet metal repair. The metaler holds the hammer
with one hand and the jacking block with the other hand or
uses other tools to strike the sheet metal for repair. The
manual work of the sheet metal requires the metaler to have
the appropriate skill and experience, good repair skill cannot
be obtained overnight, repair of the sheet metal includes
repair of the deformed surface and correction of the shape
line.
Technical Requirement for Panel Repair
No matter which method is used to repair the body surface,
the specified technical requirement shall be met, and the
performance and appearance quality of the vehicle shall be
resumed.
Shape Recovery
For repair, the shape of the large smooth structure and the
wedge structure of the local transition shall be recovered.
When it is hard to recover the shape, change the original shape
in an appropriate way, the shape shall be symmetrical, beautiful,
firm and durable.
Integrity and Fineness of Continuous Surface
Most of the car bodies are produced by mould stamping, which

have the integrity and fineness of the surface. For repair,
the streamline surface shall have a continuous transition; the
transition point of the surface shall have a smooth transition;
the external surface repaired shall be as bright as a new surface,
ripple, wrinkle, dent, knock mark, scratch and visible defect or
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Sheet Metal Replacement
The process for sheet metal replacement is as follows:
1. Preparation before cutting new/old sheet metals.

2. Remove damaged sheet metals.
3. Position, adjustment and cutting of new parts.
4. Treatment and corrosion prevention before welding.
5. Final position and welding of the panel.
6. Treatment after Welding
7. Accessory installation and inspection after operation
Principle for Sheet Metal Replacement
Thin Panel Replacement
3. Indicate the actual cutting position on the old body parts
Thin panel replacement is made for aesthetic purpose and shall
(reserve 15mm paper adhesive tape), and indicate the
follow the requirements below:
location for welding spot elimination.
1. Cutting is performed on the shortest position 15mm Welding Information Provided by
from the foam, damage to the foam by welding shall be Manufacturer
avoided;
Position of the foam
2. When replacing the A pillar and rear fender, please
remove the windshield;
3. Do not cut locations including any reinforcement.
Thick Panel Replacement
Thick panel replacement is made for strength purpose and shall
follow the requirements below:
1. Do not cut the energy absorption area;

2. No cutting is allowed within 50mm from the front/rear of
the position for laser welding;
3. Cutting is performed on the shortest position 15mm
4. Indicate the actual cutting position on the new body
from the foam, damage to the foam by welding shall be
parts, and paste the paper adhesive tape.
avoided;
Position of the foam Damaged Sheet Metals Remove
4. Do not cut locations including any reinforcement; 1. Position the welding spot.
5. To ensure welding penetration, the size of the cutting 2. Grind the welding spot.
seam shall be equal to the thickness of a panel.
Preparation before cutting new/old sheet metals
1. Remove all sealer residues with hot air gun to reduce the
toxic fumes generated due to heat during welding.
2. Straighten the existing panel side seams with form block
and hammer.
3. Carry out rough cut and remove the welding spot.
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3. Mark the punch position for welding the plug hole.

Treatment and corrosion prevention before
welding
1. New body parts: grind the location for welding and
sealant application to remove the paint film.
2. Grind the location for welding and sealant application to
remove the old paint film, burr and rust (20mm from
the welding joint), but do not grind the cross section of
the joint.
4. Remove the damaged sheet metals.

Position, adjustment and cutting of new parts
1. Position the new panel on the body and adjust its position
and size.
• Compare the hole;
3. Clean the location for welding and sealant application on

the new parts and body, and wait for 5-10min to volatilise
the detergent.
4. Paint zinc spray to the welding junction of the new parts
and body that does not need sealant, and control the
thickness of the zinc spray.
5. Apply structure sealant: before application, remove and
discard the sealant (10cm), to ensure uniform bond of the
panel, welding shall be finished within the time specified
• Adjust the clearance; by the structure sealant, or bond of the panel will be
affected.
Final position and welding of the panel.
Adjusting Panel Refit
1. Confirm the position of the ridge;
• Adjust the difference between the high surface and the low
surface;
2. Cut the new/old panel by overlap, take care not to cut

the reinforcement inside the body, remove the new panel,
and cut the excess old panel section by section. 2. Compare the hole;
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3. Adjust surrounding clearance; Caution: Use arms not exceeding 300 mm in length.
2. Fit the resistance spot welding arm and test equipments

with test silicon slice so as to meet the operation
requirements. If there is no monitoring device, the weld
strength can be tested by checking welding pool pull wires
around the metal under tensile force during the stretch.
4. Adjust the difference between the high surface and the

low surface.
Position of gas shielded welding
1. Select a gas ratio of 80% argon, 20% CO2.
2. To ensure the accuracy of the position, positioned
welding shall be performed on both sides of the ridge Welding Sequence
instead of on the ridge, and the distance of the positioned
• Welding sequence: to decrease the possibility of strength
welding shall be above 30mm.
reduction due to welding shunt, it is recommended
Trial Welding before Spot Welding that you begin with the direct welding, and follow
1. Select an electric welding arm for resistance spot welding the sequence shown below, the distance between the
and shape the electrode head with nozzle finisher. Finish welding spots shall be 25mm.
the nozzle, making its diameter equal to 2 times the
welding thickness and plus another 3.0mm.
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Welding Requirement • Gas shielded welding - butt welding.

• If the resistance spot welding has been used in
production, a new resistance spot welding must be done
at any other feasible position. During spot welding, to
ensure the quality of the welding, test coupons of the
same metal gauge and material are recommended for
peeling test. If condition permits, the welding quality
monitor can be used to ensure welding quality. If the
satisfactory spot welding can not be achieved, plug weld
welding must be used.
Treatment after Welding

Process for Corrosion Prevention
1. Use P36 disc polisher or belt polisher to grind or finish
all welding locations, and clean the location.
• Length of the welding rod holder of hand spot welding

gun must be no more than 300mm.
• Single sided spot welding is not allowed;
• Neither braze welding nor gas welding is allowed unless
it is specified in production.
• Gas shielded welding - plug welding: when welding the
region with 3 layers or more than 3 layers of panel or
the welding nozzle is close to the restricted area, and
resistance spot welding is impossible, use the hole made 2. Paint anti-corrosion primer which can prevent corrosion
by the cutter for spot welding, or punch or drill a hole to and improve the adhesion of the sealant.
perform the MAG plug welding. The diameter of the hole 3. Apply sealant, fill the seam between the panels to realise
for plug welding of the structural component is 8mm, the leak prevention purpose.
and that for plug welding of the covering component is Position of the foam
5mm, the ratio of the welding spot for plug welding to
4. Deliver the vehicle to the painter for painting.
the manufacturer's welding spot is 1:1.
5. Apply wax to the cavity before fitting the accessory.
Information of Cavity Wax Application
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Paint and Coatings Body Panel & Paint
Paint and Coatings
Overview
The purpose of automotive painting is to provide an excellent
appearance, decoration, gloss protection, colour protection,
corrosion resistance and a longer service life, so it has
distinctive features:
• Automotive painting is a high-level protective painting,

the coating shall have a superb corrosion resistance,
weather resistance, acid/alkali resistance, inclusion
resistance and an extensive adaptability, etc.
• Automotive painting (mainly refers to body painting) is
a high-level decorative painting, and careful design, good
working environment and conditions are required for Function of Each Coating
providing the coating with good decoration. Vehicle 1. Zinc Coating: with a good function of
decoration mainly relies on painting, the quality of the anti-corrosion/anti-rust, good paint adhesion,
painting has a direct influence on the commercial value decorative performance and forming property.
of the vehicle. 2. Zinc Phosphate Coating: the first paint that is directly
• Automotive painting is the most typical industrial applied to the treated workpiece surface and is the base
painting, it requires reasonable and effective for the whole coating. Its characteristics are as follows:
pretreatment method, drying method and process
• It shall have a good adhesion to the treated surface of
preparation.
the workpiece, and the primer film formed shall have an
• Automotive painting is a multi-coating painting system, excellent mechanical strength;
and the painting quality and process control of each
coating is of great importance. • It shall serve as a corrosion inhibitor, and the primer
coating shall have an excellent corrosion resistance, water
Coating Introduction
resistance and chemical resistance;
Coating Composition
• It shall well fit the intermediate coating or top coat;
During manufacture, paint application consists of the corrosion
resistant coating (zinc coating) of the raw material, zinc • It shall have a good workability.
phosphate coating, electrocoating, intermediate coating and 3. Electrocoating: enhance cavity corrosion resistance;
top coat. improve the uniformity and leveling of the paint film
thickness; raise the quality of the paint film, painting
efficiency and paint utilization efficiency.
4. Putty Coat: used for the object surface with primer
precoat so as to fill the pit, weld seam, scratch, rust hole,
etc. on the object surface. until the surface becomes
smooth.
5. Intermediate Coating: it is the last intermediate coat
before applying the top coat, its binder content is
between the primer and the top coat, and the paint film is
bright and semi-bright. It provides the following functions:
• Enhance the adhesion between the primer and the top
coat;
Aftermarket paint repair is composed of the primer coat, putty • Increase the total thickness of the coating and improve the
coat, intermediate coating, pigmented paint coating and varnish film build;
coating. • Improve the corrosion resistance and weather resistance
of the primer/top coat;
• Repair minor defects on the substrate surface;
• Raise the decoration performance of the top coat.
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Body Panel & Paint Paint and Coatings
6. Top Coat: top coat is used for the final coating of 7. In order to thoroughly clean the area of exposed metal
the multi-coatings, it directly affects the decoration due to damage of the painted surface, the cleaning area
performance, weather resistance, gloss protection, shall be larger than the original damaged area.
colour protection, chemical resistance, contaminant 8. Use phosphate to eliminate the dust, contaminant, etc on
resistance and appearance of the vehicle. the exposed metal, and offer a good repair environment
Classification of Top Coat for the new coating.
The classification of the top coat by colour effect is as follows:
• Pure pigmented paint: containing resin, pigment and
additive only.
• Metallic paint: containing metal powder, with better gloss
and saturation.
• Pear paint: comparing with the metallic paint, instead
of using metallic paint, it uses mica powder coated with
titanium dioxide and ferrum dioxide to improve the
texture and gloss of the paint film.
By application procedure, it can be classified into the following

processes:
• Single-process: a system that uses one type of paint to
form a complete surface coating. Single-process pure
pigmented paint and metallic paint are included.
• Double-process: a system that uses two different types of
paints to form a complete surface coating, generally, the
pigmented paint is applied before the finishing varnish is
painted. Double-process pure pigmented paint, metallic
paint and pearl paint are included.
• Three-process: usually, a layer of primer is required for
this system, then a layer of pearl paint, and finally a layer of
finishing varnish, the combination of these three coatings
forms a complete surface coating. Three-process pearl
paint and coloured varnish are included.
Principle of Paint Repair
The following principles must be followed when repairing the
painted surface:
1. Use the certified jointing sealant to seal the inner and

outer jointing.
2. Repair all damaged parts of the sealant under the vehicle
body.
3. Use two-pack paint to repair the system and it shall be
consistent with the original production parts.
4. Apply the inner wax to the entire inner surface without
paint finishing.
5. Steam cleaner or high pressure cleaner must be used to
clean the vehicle thoroughly before paint repair.
6. Clean the local part needing requirement with warm and
water soluble cleaning solution, then thoroughly clean it
with solvents. Painting must be done immediately after
this operation.
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Coating Process
The automobile coating process is generally divided into two
sections: One is the metal surface treatment before coating,
also known as pretreatment technology; the other is the
coating application process.
Surface Pretreatment
The surface pretreatment mainly consists of:
1. Surface cleaning: The mud, dirt and other foreign objects
on the complete vehicle should be cleaned thoroughly
during coating operation, particularly pay attention to the
dirt at the door frame, trunk, front compartment cover
apertures and wheelhouse, if not cleaned up, the new
painted film may be splotchy.
• Chemical soluble substance treatment: Apply the

degreasing agent to the surface with a piece of special
cleaning cloth, and then wipe off the degreasing agent and
removed residues, such as grease, with another clean and
dry cloth.
• Treatment of water and floating dust: Use a piece of

clean and dry dust-sticking cloth to absorb the water and
floating dust, then blow it dry with a high pressure air gun.
2. Coating Identification and Damage Assessment:
• Coating identification: It is important to identify the

category of the coating on the body panels in repainting Precautions for mechanical polishing:
process. If it is not correctly identified, the serious
a. Do not use the electric sander to make cross
problems may occur during finish application. If one
sanding on surfaces with large curve radian and high
vehicle has not been resprayed up to now, the category of
projection or very low dent;
the coating can be identified based on its model manual,
but the category of body coating must be identified when b. Do not use the electric sander to sand the corners,
repaired if the body has been resprayed. wrinkle gaps, welding seams, sticking joints or the
area that has been applied with plastic sealant.
• Damage evaluation: Evaluating the damage properly is one
of the critical factors to determine the repair cost and c. The sander can only be activated to sand when
ensure the coating quality. The repair scope can only be contacting with the panel surface, do not apply
determined after the proper damage evaluation, then the pressure, or deep scratches will be made, and also
scope of each treatment process, transition area, the area the sander should be aligned with edge line to be
to be covered and the parts to be removed, etc. can sanded before it is activated;
be defined, which will lay the foundation for the correct d. To avoid the panel deformation caused by
implementation of subsequent processes and satisfactory overheating, do not place the sander in the same
repair quality. The evaluation methods for film damage position for a long time;
include visual, touch and ruler evaluations:
e. Do not make the well painted surface around the
3. Old film removal: Examine the body coating carefully after sanded area contact with the coarse sand abrasive,
washing the body to find the damage signs on the film, it is better to protect the perfect coating with tapes.
such as bubbles, cracks, peeling, rust and some damages Sanding operation: The refined processing to the surface
resulted from paint baking, make-up, gas welding and other experienced rough sanding is aimed to obtain a more flat
repairs. For the above damages, the old film must be surface. Align the front of the rotating grinding wheel with
wholly or partially removed based on the degree of old the sanding surface, and get the rear part away from the
film damage and the quality requirement after repainting. surface a little. Keep this angle and move the sander up
The #P80 - P180 abrasive papers are recommended to and down to sand, the covered area between each grinding
make out the feather edges (not less than 3 mm). crack is better to be 50% - 60%.
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Panel replacement: Use #P280 - P320 abrasive paper to

carry out dry sanding over the electrophoretic primer
layer of the new part.
4. Grease and rust removal from metal surface:
• Remove the rust spots from the surface. The methods

used to remove the rust from metal include: manual
rust removal (polishing, sanding, high pressure water,
etc.), mechanical, chemical and ultrasonic rust removals.
Different rust removal methods are selected depending
on the rust conditions.
• Clean the metal surface again.
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Each Coating Application • Wear the respirator, select the proper type of abrasive
paper, then sand the surface together with hard sanding
When you perform coating repairs over the panels which have
pad. The rail sander can also be used, but be careful not
been experienced surface pretreatment, please refer to the
to sand the surrounding areas. When the sanding pad is
detailed process as below:
used, it should sand in the horizontal direction and move
1. Primer Spraying from up to down gradually.
• Cover the surrounding of the repaired area; • Use the air blow gun to clean the repairing surface;
• Wipe the surface to be sprayed with a piece of soft cloth
soaked with detergent, while wipe the detergent left on
the surface with another clean and soft cloth;
• Blow the surface with compressed air;
• Spray the anti-corrosive primer and let it dry;
• Wipe the surface with a piece of soft cloth soaked with

detergent, while dry the surface with another clean cloth;
3. Surfacer Application
• Cover the surrounding of the repairing area and prepare
to spray the surfacer, the periphery of the covered area
should be longer than the area to be sprayed by more than
2. Putty application (not required when replacing new parts) 10cm;
• Mix the putty and curing agent in the proportion defined • Wipe the surface to be sprayed with a piece of soft cloth
in the instructions; soaked with detergent, while wipe the detergent left on
the surface with another clean and soft cloth;
• Use a clean putty mixing plate; only mix the amount of
putty to be used by this time; • Blow the surface with compressed air;
• Fill up the sanding scratches and air pores, then apply the • Mix the surfacer, curing agent and diluent in the
putty thoroughly; proportion defined in the instructions;
• Firstly, spray a layer of surfacer lightly and let it dry for 5
minutes, then spray it wet twice;
• Let it dry for 5 minutes after application, and bake it with

an infrared baked lamp according to the requirement in
putty instructions; • When the paint film flows level for 10 – 15 minutes, the
film can be cured with an infrared baked lamp;
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• Spray the sanding indication layer on the surface, so that • Wipe the area to be repaired with a piece of soft cloth
it is easy to find the uneven locations when sanding. soaked with detergent, while dry it with another clean
cloth;
• Cover the surrounding of the repairing area, and start to
paste the papers from the inside of the repairing area, be
careful not to tear the masking papers;
• Blow the panel to be sprayed and the complete vehicle
with compressed air, be careful not to tear the masking
papers, finally wipe the surface with dust-sticking cloth;
• To prevent the dust, particles and other impurities from
entering into the paint, pour the mixed paint into the gun
tank with the help of screen;
• Try to spray to check the air pressure, the amount of
sprayed paint, sector pattern and atomization;
• Sand the surface roughly with #P240 - P400 abrasive paper, • Wet spray two layers of colorant, the leveling between
then sand it finely with #P600 - P800 paper; each layer takes 5 - 10 minutes;
• For the aluminum paint, make a virtual sprayed layer finally
to ensure the aluminum powder is distributed evenly;
5. Varnish Application
• After spraying the colored paint layer, let it dry for about
15 minutes (the colorant layer totally loses the gloss), and
spray the varnish: firstly, wet spray a layer of varnish and
let it dry for 5 – 10 minutes; next, wet spray the second
varnish layer, let it dry for 15 minutes and carry out heating
and baking; (Note: Do not turn off the ventilation system
installed in the spraying booth during the phase of drying
after spraying)
• Heat and cure the film at the specified product
• Remove the masking paper along the periphery of temperature within the set time. Or, dry it forcibly for 15
repairing area, then blow the inside and outside surfaces minutes using a far infrared baked lamp;
of this area with compressed air to remove the abrasive • After heating and curing, the further treatment (e.g.
dust and water thoroughly; sanding, polishing) can only be done when the film is
4. Finish Application cooled down completely.
• Check the color code, and find out the color formulation 6. Polishing and Waxing
according to the codes; • #P1500 or P2000 abrasive papers can be used to polish
• Polish the body surface around the repairing area to obtain the defects on the coating, such as dust spots and sags,
the exact color matching; when the film is completely cooled down.
• Check the difference between the mix color and the • Grind the sanded area using slack waxes together with
original body color with the assistance of daylight stage wool wheels. At the start of grinding, the rotating speed
lamp or in the sunlight; of polishing machine should not be too high but increase
slowly;
• Spray the color test board under the same conditions with
the vehicle to be sprayed (dilution rate, spray distance, air • Perform the polishing with fine wax and sponge wheel;
pressure, amount of sprayed paint, temperature, dry time, • Replace with a clean sponge wheel and remove the swirl
etc.); marks left by polishing with polishing wax to allow the
• Let the test board dry for 15 minutes, then bake the board coating to restore its original gloss.
at the specified temperature within the set time. Note • Examine the accuracy of color mixture at the spraying area
that do not overheat the test board when heating and in the lamp light, and then move it to outdoor and check
curing; it under sunlight.
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7. Cosmetic and Cleaning
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8. Information for Various Brands of Paint

Recommended Paint Manufacturer and Product Model
PPG Sherwin-Williams Akzo Nobel
P565-895 E2G973 Sikkens #680 Primer Grey
P565-9850 GBP988-AR Protective green primer
Primer
P565-9085 UPO7299 Sikkens universal plastic primer
UPO7226-3 Alloy primer 1K 1CF/EF
P551-1050 18380221 Sikkens Kombi Filler
Putty P551-1052 Alloy putty
P551-1057
Middle P565-510/511 P30 Sikkens Autosurfacer® Classic
coating P565-5601/5605/5607 P50 Rapid
primer
P190-376 CC645HS Sikkens Autoclear® Plus HS
P190-6850 HPC15 Sikkens Autoclear® Xcel
P190-6060 CC939 Autoclear® II Clearcoat
ClearcoatP190-6208+P210-6863 CC931 Autoclear® Rapid
P190-588AP210-790/938/939 CC930 Autoclear® Mat Clearcoat
P190-588+P210-760/790 CC655
Finishing NEXA Autocolor 2K (oil paint) Ultra 7000 (oil paint) Sikkens (oil paint)
coat Aquabase plus (water paint) AWX (water paint) Sikkens Autowave (water paint)
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General Film Coating Defects • Low product temperature, low spraying pressure, slow
Paint Film Defects Caused by Application and gunning speed, short distance to spray gun, thicker film;
Treatments • Large caliber of spray gun, poor atomization of spray gun;
Particles • Slow solvent evaporation rate and low paints' viscosity;
The phenomenon that bumps in the film coatings are spread • Short distance between spray gun and workpiece, slower
over the whole or local surface in granular form. gunning speed, thicker spraying coatings;
Analysis of Possible Causes: • Insufficient flash-off intervals between layers;
• Poor air cleanliness and impurities in the painting Preventive Measures:

environment, such as dust;
• Improve the painting environment, control the
• Workers wear dirty clothes or the fibers contained in appropriate ambient temperature, humidity and wind
the materials are easy to fall out, substrates that are not speed.
properly handled have bumps, the vehicle body is not
• Choose the correct solvent and pay attention to select
cleaned thoroughly, etc.
the dissolving capacity and evaporation rate of the
• The painting pressure is insufficient, atomization is poor, solvent;
the spray gun is not cleaned up and an improper screen
• Strictly control the viscosity and the temperature for
is selected;
coating application;
• The pigments or flashing materials in the paints are
• Reduce the amount of paints from spray gun, and increase
badly dispersed, the paints are unfiltered or filtered
the gun distance and gunning speed;
improperly, the paints become deteriorated and show
• Full flash-off between layers;
abnormal signs, such as separate out, flocculation.
• The film is moved out of the baking booth before drying Defect treatments: For the slightly local varnish sagging, it
the surface to dust-free. can be sanded to eliminate the sagging defects before being
polished if this defect exists; or if the sagging defect is more
Preventive Measures:
severe or it appears on the surfacer layer and the color paint
• Ensure that the spraying environment is clean; layer (finally revealed on the layer of varnish), the sagging must
• Ensure that the objects to be painted and workers are be sanded thoroughly and make the spraying again.
cleaned thoroughly before entering the baking booth; Pin Holes/Eyes
• Ensure the paints' performance, the deteriorated and The blisters or solvent bubbles appear on the film and there are
poorly dispersed paints are not applicable; small needle holes on the top of them, which are referred to as
• Set the optimal parameters for paints' application and use pin holes (the solvent contained in the film coatings evaporates
the spray gun to spray after the paints being filtered. rapidly during the surface drying, its left trace forms hole );
these pin holes are known as defects that the holes are still
Defect treatments: The tiny dirty spots can be polished after
visible on the surface after spraying the finish due to some holes
removed by abrasive paper; if the impurity particles are large
on the substrate are not filled up. They are easily generated at
or the dirty spots on the surfaces of primer and even surfacer
the corners of workpieces.
can only be ground to the extent that the spots disappear
completely, perform the spraying again. Analysis of Possible Causes:
Sags • Pin hole: The paints are mixed with impurities, for
example water enters into the solvent based coating; the
Upon the liquid paint is sprayed onto the workpiece surfaces,
painted objects have dirt on their surfaces; the flash-off
some wet film surface runs down, creating unevenly stripes
intervals between layers is insufficient during application;
and sags, which are thin on the top and thick on the bottom,
the continuous spraying is too thick; the temperature
resulting in the local thicker film on vertical surface. It can
rises up suddenly and the surface is dried rapidly when
be divided into sinking, sagging and running depending on the
stoving.
shapes of sags.
• Pin eyes: The uneven locations on the original workpiece
Analysis of Possible Causes: surface are not filled up;
• The painted workpieces' surface is too cold;
Precautions and Improvements:
• Low application environment temperature, slow wind
speed and high solvent vapor content in the ambient air; • Set appropriate temperature and humidity for
application. Wind speed and other conditions;
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• Mix the paint and solvent in proportion to ensure the • The substrate is not flat or the finish coating is sprayed
proper fluidness; to the surfacer surfaces without having the orange skin
• It should be heated up slowly to avoid the rapid solvent ground smooth;
evaporation. • The ambient temperature is high, the wind speed is fast
• Full flash-off intervals between layers; and the substrate temperature is high;
• The diluent volatilizes rapidly, the paint has high viscosity
Defect treatments: The defects should be completely ground
and the film is too thin;
to remove the pin holes and pin eyes, then repaint it.
• The distance from spray gun is too far, the gunning speed
Blistering is too fast, the spraying pressure is low and the amount
Part of the film coating floats off the painted surface or prime of paint out of spray gun is little;
coat and is filled with liquid or gas, which is about 1-5mm in
diameter or floats off in large pieces. If there is some water
under the film, the vapor generated by evaporation of water • Grind the intermediate coating completely smooth
will plump up the film to form blister when the temperature according to the process requirements;
rises up. • Control the ambient temperature and wind speed (0.2 -
Analysis of Possible Causes: 0.6m/s);
• Use the diluent suitable for that temperature, and
• The ambient humidity is high and the film is dried
adjust the paint viscosity as per the paint manufacturers'
naturally after spraying, resulting in moisture infiltrating
product instructions.
into the film;
• Adjust the gun pressure, then regulate the gun to
• The substrate is not dried properly, the drying time is
proper distance and reduce the gunning speed as per the
short between coatings, the heating and drying are too
manufacturers' instructions;
fast;
• Spray the appropriate layers to ensure that the film get
• Grind the putty while adding water and the putty absorbs
the desired thickness;
water;
•
• There is oil or water in the compressed air lines;
Defect treatments: Only perform the grinding and polishing if
the defect of orange skin is slight; the orange skin should be
• Grind the dry putty; ground to completely removed and then be resprayed if the
• Ensure that the previous coating has met the defect is serious.
requirements for cleanness and dryness before spraying; Sanding Scratches
• Reduce the humidity in the painting and spraying room;
The sanding scratches left by sanding substrate are visible
• Use the curing agent and diluent suitable for environment on the film after spraying the paint. Sometimes, the sanding
temperature, make it dry as soon as possible once the scratches on the substrate will extend due to the erosion
spraying is completed to prevent the moisture from caused by solvent contained in the film, the upper film would
infiltrating into the film. be subsided gradually after a period, resulting in the sanding
Defect treatments: Once blisters appear on the film surface, scratches more and more obvious.
this surface should be ground to remove the blistering Analysis of Possible Causes:
defects completely, then respray it depending on the surface
• If the improper abrasive papers are used to sand the
conditions.
substrate, the sanding scratches will be wide and unable
Orange Skin to be covered and filled up by upper film;
The orange skin is used to describe the leveling property of • If the lower film is sanded and sprayed with upper film
the film: When you observe the film surface against the light, over it before it isn't totally dry, it is easy to make the
you can see different ripples of 1 - 5mm presenting on the sanding scratches to extend due to the erosion caused by
film surface, and the brightness and plumpness vary in different solvent in the upper film and form the sanding scratches
ripple areas, such texture on the film surface, which is similar defect;
to orange peel, is known as orange skin.
• The diluent that has high solubility for upper paint or too
Analysis of Possible Causes: slow to dry has been misused.
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• When you select the abrasive paper number to make Defect treatments: Once the putty marks appear, those areas
sanding, you should observe the principle that the should be sanded, and apply the putty again and respray the
abrasive paper number should not be jumped by 2 levels surfacer and finish.
each replacement;
Lifting
• Ensure that the lower film is totally dry before sanding;
The lower-layer paint is single-component, or even if it is
• Select the correct upper film solvent as per the product two-component, it is not dry and cured completely (including
instructions; improper amount of curing agent is used), when the paint
Defect treatments: For slight sanding scratches, they can be is sprayed above it, the solvent contained in upper film will
removed or made less obvious by sanding and polishing as they erode the lower film, causing the uplift and shrinks present on
have been filled up by paint; For the sanding scratches that the lower film surface.
are more obvious, they cannot be removed by sanding and Analysis of Possible Causes:
polishing, it should be resprayed after removing the scratches.
• The lower film is not totally dry;
Putty Marks
• The lower film becomes deteriorated;
A putty mark means the defect that trace is left along the edges
• The continuous spraying of surfacer or finish results in
of putty application areas after spraying the surfacer or finish.
too thick surface, or the used curing agent and diluent
Analysis of Possible Causes: are too slow to dry, or the diluent with high solubility
is used, or the flash-off intervals between layers are too
• The feather edges are improperly treated before putty
short when spraying the surfacer or finish, or the low
application;
air temperature during the spray causes the infiltration
• The putty is mixed with curing agent in improper
and erosion of solvent contained in the surfacer or
proportion;
finish, resulting in the lifting occurred at the putty edges,
• The next action is taken before the putty is completely one-component putty or surfacer edges.
dry (sanding, spraying the surfacer, etc.);
• The putty is not flat enough, the feather edges do not
meet the standard, and it is higher or lower than the old • For the film not totally dry, it must be sanded and sprayed
surrounding coatings or metal; with the next layer paint after it is completely dry. If
it cannot be totally dry due to the improper adding of
• The curing agent and diluent mixed in the surfacer or
curing agent, it needs to respray the paint mixed with
finish are dried slowly, or the flash-off intervals between
proper curing agent after film removal.
layers are too short when spraying the surfacer or finish,
and the solvent penetrates and erodes the putty, resulting • For the deteriorated film, shown as chalking, cracking,
in the edges expanded and extended. loss of gloss, they must be removed totally and resprayed
with two-component surfacer or finish;
• Use the correct mating curing agent and diluent, and
• The width of the feather edges must be 20 - 30mm ensure the flash-off interval between layers is enough.
and the surface is smooth without steps before putty
• Use the two-component putty and surfacer.
application;
Defect treatments: When the lifting defect appears, it should
• Adding the curing agent in proper proportion according
be sanded to remove any defects at the lifting area, if the lifting
to the product instructions;
is severe, the film that has lifting should also be sanded and
• Make sure to perform the sanding and spray the surfacer
removed completely, then spray the two-component surfacer
when the putty is totally dry.
and finish.
• Use the correct curing agent and diluent, and ensure the
Paint Film Defects Caused by Operating
flash-off interval between layers is enough. Environment and Treatments
• The periphery of putty must be sanded to be qualified. Paint film defects caused by external corrosive
Not only the putty, but also the extended old materials
surrounding coatings should be sanded when you sand
Defect phenomenon: The film defects occur when the film
the putty edges to allow the putty together with the
is affected by the acidic and alkaline materials as well as
surroundings to form flat surface.
industrial fall-outs, such as asphalt, oil, battery electrolyte,
bird droppings, sap, acid rain, pollen, dust produced by steel
plant and black carbon from boiler stack. It generally appears
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as uplift, discolor and even cracking and peeling caused by the

contaminants infiltrating into the film.
Defect treatments: If the film defect is tiny, it can be

recovered only by polishing the surface damage; if the film has
been discolored, the defective areas should be sanded until
eliminating the defect, then respray it.
Water Spots
Defect phenomenon: When the rainwater on the film surface
or the tap-water left by car washing is heated to evaporate, a
white ring drop mark will be left on the water-drop area and
cannot be removed by common cleaning methods.
Causes: As the water contains mineral substances, such as

calcium, when the water is heated to evaporate, some warm
water will infiltrate into the softened film with heat, and the
left mineral substances infiltrate into the coating.
Defect preventions and treatments: Try not to wash the car

under the sunlight, and wipe the water drops off the vehicle
surface after washing to avoid evaporation caused by heating.
It should only be polished when water spots appear.
Stone-crash Damages
Defect phenomenon: Some small stones may hit the film and
cause the film peeling during vehicle traveling, the area where
the film is peeled off usually form the surface with sharp and
jagged edges, sometimes a small indentation will appear in the
middle of this area. The front edges of the front compartment
cover or the roof is usually damaged by stones.
Defect treatments: When the stone-crash damages occur,

the film on the defective area must be removed and sanded
to feather edges, and filled up with putty or surfacer, then
continue to apply the surfacer and finish; if the area hit by
stones is rusted, the rust must be removed thoroughly.
When new original parts are sprayed, if the finish is directly

sprayed onto the electrophoretic coating without spraying
surfacer, and when the plastic parts are sprayed, if the surfacer
and finish are not added with softening agent depending on the
plastic hardness, the stone crash protection for the film will
be reduced and the film is easy to hit off by stones and sands.
Discolor/Chalking/Loss of gloss
Defect phenomenon: As the vehicle exposes to the ultraviolet
rays, the pigment deterioration of the film causes color fading,
the resin deterioration causes yellowing, the film peels off as
powder and loses gloss.
Defect treatments: Color fading is a representation of film

aging, it is usually shown up together with chalking and full loss
of gloss. Once any one of these defects occurs, the defective
film must be sanded and removed thoroughly, then respray the
two-component surfacer and finish.
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Seal Body Panel & Paint
Seal Clean the affected seam, re-process the exposed metal area
Overview with proper etch primer;
Process Area of Underbody Seal Coat proper sealant at the required places;
Underbody areas and doorsill outer panels should be Process the affected area with acid-etch primer (chassis sealant
processed with plastisol PVC underbody sealer. This sealer is also acceptable), and apply proper colour paint film.
shall not be reused. When repairing the sealer for the
After reassembly or refit of parts, if the seam is plugged, then
underbody areas, the underbody sealer upon delivery should
apply paste seam sealant to such seam. Blockage of the seam
be removed and returned to the proper breakpoint. Expose
may occur after panel repair. In this case, apply sealant and
the clean metal surface, and the current sealing edge shall also
paint before final assembly. If the inlet is of proper size, apply
fit firmly to the panels.
seam sealant to the two sides of the joint to be repaired. If the
Use new chassis sealant between the primer and the spray can be only done to one side (such as compartment),
intermediate primer. If necessary, use the seam sealant before then use cavity wax to process the affected compartment
applying the chassis sealant. Before coating the chassis sealant, beam.
fit the plugs and insulating ring on the disk type floor (except
Seams which require sealant when assembling in the plant is
the part for wax spray). Refit the heat-fusible plugs damaged in
described in the figure below.
repair with heat blower or replace them with rubber insulating
ring. Caution: Look through all the joints near the fixed areas.
If necessary, all the combined ,fixed or replaced areas
Before using new chassis sealant, cover the suspension, wheel,
should be sealed. These areas can’t be ruined. Sealing
tyre, power unit, exhaust system and brake system (including
could protect from waters and wind noises and so on.
all mounting points).
Before the final inspection, it is necessary to look through
Seam Sealant all the sealed areas.
For factory assembly, apply PVC sealant treated by baking to
special joint weld and sheet metal edge. This kind of material
is not suitable for repair, so approved special sealant shall be
used for aftersales service.
Seam sealant is used after the primer and before the

intermediate primer and outer coat. The spray of the seam
sealant must be smooth and continuous, and the spray line
depends on the type of the seam. If the sealant is coated by
brush, pay special attention to the coverage area required for
the weld. At the places needing sealant formation, use cloths
dipped in the solvent oil to complete the required operations.
Remember to seal all the seams to be processed after each

repair. The area away from the joggled joints often distorts
when the vehicle is damaged. Thus, sealant for these places will
frequently occur in the following repair and correction. Check
all the welds around the area to be repaired to see whether it
is damaged, then process the damages as required, then coat
new sealant. Specific steps are as follows:
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Body Panel & Paint Seal
Application of PVC sealant:

Operation
Process Implementation effect section view Application location
method
Mating faces for fitting the parts, welds
Sealant with appearance requirement; such as
Elimination tail lamp, side body and roof joint, visible
location after assembly
PVC Welds without appearance requirement
sealant Sealant or assembly requirement (covered weld,
Application with a width < 50mm); such as seam of
interior floor, underbody
Sealant Edge of four doors and two covers (thickness:
Injection 1-2.5mm, width: 5-9mm)
Plug
Plug type One-component plug Two-component plug
Workshop Painting workshop or general assembly Painting workshop
workshop
Material EPDM, TPE, PA6, TEEE, etc. (PA6-GF) + hot melt adhesive, metal sheet + hot melt
TPE + hot melt adhesive, etc
Sealing 30mm water column, 10min, no water leak 500mm water column, 10min, no water leak
Performance
Application 4 doors, side body, etc Floor, spare tyre compartment, etc
Location
Remark Seals holes with no direct connection with Used to seal holes directly connecting passenger
passenger compartment or waterproof holes compartment and external horizontal holes
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Sealing Performance Test damaged, aged or displaced. Meanwhile, align the door with
Overview the seal.
Process of the leaking problem needs to combine techniques, Note: Check the colour of the water around the leak. If
experiences and instincts to take proper and effective the water is dirty, the leak is from under the vehicle. If the
measures. Do not come to conclusions fast only by naked water is clean, it is from above.
eyes.
When a leaking spot is found, the methods below are
Test Tool and Instrument necessary for resolution of the leak problem:
When checking and correcting the leaking problems, the below 1. Replace all of the damaged, displaced and aged door hole
tools and instruments are recommended to use: seal and weatherstrip.
1. Garden Sprayer (manual) 2. Check all the body seals and ensure it is fixed on the
2. Wet/Dry Vacuum Cleaner fixing flange/fixing face correctly. If necessary, the simitar
can be used.
3. Dry, Absorbent Cloth
3. Blow the body weld seam to be processed with
4. Battery Torch
compressed air and/or hot blower when necessary.
5. Mirror
4. If necessary, apply sealant to the outside of the connector
6. Weatherstrip Locating Tool
to prevent water.
7. Trim Panel Remover
5. When correcting leakage of the windshield and
8. Small Wooden or Plastic Wedges weatherstrip (or polish between the upper glass and
9. Dry Compressed Air Supply the body directly), try not to remove the glass. Use
10. Hot Blower qualified materials at proper places (such as glass to the
weatherstrip or glass to the body).
11. Sealer Applicators
Initial Door Seal Replacement
12. Ultrasonic Leak Detector
The initial seals for both front and rear doors are stuck on the
When checking for leak, at least the following parts should be
specified positions. Always comply with the regulations below
checked:
when replacing the weatherstrip:
• Front Inner Space;
• Clean the position where the door weatherstrip is
• Rear Seat Space; located. Do not clean the doors with paint diluent agent.
• Storage Compartment or Luggage Compartment • The ideal temperature for sticking the weatherstrip is
Test Method and Measure 25℃ (77℉). For either the door or the weatherstrip,
The operators at the fittings center can judge from where to when the temperature is less than 18℃ (64℉), it is hard
check the leakage by information offered by the customers. to stick the weatherstrip.
The next step is to find the leaking spot after the leaking place • Do not apply too much force to stick the weatherstrip,
is founded. this will make disassembly or re-installation much easier.
If the weatherstrip shall be refitted, do not touch the
For the first case, an easy and effective method is the common
contact face or stain it.
garden sprayer. Nozzle of this extruding garden sprayer ought
to be adjusted, so that water can be sucked into the nozzle
directly and spray out proper spray. At the dark corners, a
mirror or battery torch cab be used (the test light using supply
voltage is not available).
The test order is very important. Begin from the lowest point
and go up gradually, this can avoid blocking off the other leaking
place when an area is being checked. If the test is begun from
the windscreen, any water flowing into the pumping chamber
may drop on the pedal by baffle insulating ring. Even though, it
may be judged wrongly that seal of the windscreen fails.
Another part for leaking check is to visually observe whether

the door hole sealer, insulating ring or weather strip is
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Information of Sealant Positions

Body Seal Identification
1. Between Panels - Bolted Connection 7. Riveting Joints - Type (a)

2. Panel Edges - Bolted Connection 8. Riveting Joints - Type (b)
3. Between Panels - Spot Welding 9. Riveting Joints - Type (c)
4. Panel Edges - Spot Welding 10. Panel Gaps - Type (a)

5. Between Panels - Bonding 11. Panel Gaps - Type (b)
6. Panel Edges - Bonding 12. Lap Joints
Sealant Information • Plug thumb glue to the following red dot position. For
any place not specifically described in the figure below,
After the panel is welded or replaced for repair, it is required
brushing glue is applied.
to use PVC sealant to seal the weld seam and the new
panel according to the following construction principles
and the instructions on gluing position given by the original
manufacturer to guarantee the repair quality:
• PVC brushing glue requirements: cover the weld seam
to make the surface smooth and even without fillets, and
the width < 50mm.
• PVC tube glue requirements: cover the weld seam to
make the surface smooth and even, the width is within
5-9mm and the thickness within 1-2.5mm.
• PVC frictioning glue requirements: cover the weld seam
to make the surface smooth and even without pinholes
or bubbles.
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Front Compartment
1.0 397
Floor Panel
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Dash Panel
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Bodyside Panel
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1.0 401
Front Door
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Rear Door
1.0 403
Front Compartment Cover
1.0 404
Tail Gate
1.0 405
1.0 406
Foam Part Position Information
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1.0 408
Information of Gasket Positions
Damping mats are used at the underbody panel, dash panel, rear end panel, rear wheelhouse and central passage. When
making panel repairs or replacements in these areas, it is required to tailor new gaskets according to the size of original ones
and paste them as the following instructions:
• Clean the positions on the panel where new gaskets are to be pasted.
• Follow the size requirements in the figure below.
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Gasket Pasting Position Information
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Gasket Size Information
1.0 412
Corrosion Protection Body Panel & Paint
Corrosion Protection to steam clean these areas, apply a new coating of wax or
Overview underbody protection as soon as possible.
Factory Treatments Maintenance Checks
During production, vehicle bodies are treated with the Carry out the following operations to check bodywork for
following anti-corrosion materials: corrosion:
• A galvanized steel sheet is used. • With the vehicle on a lift, carry out visual check of
• Phosphate rust protection primer dip coat/electro-coat. underbody sealer for damage.
• Stone crash protection coating. • With the vehicle lowered, inspect exterior paintwork for
damage and body panels for corrosion.
• A coating of underbody protection which is sprayed onto
the underside of the main floor, rear floor and the rear Note: If the vehicle is dirty, it will need to be washed prior
wheel arches; to inspection of bodywork.
• An application of cavity wax which is sprayed into the sill The checks described above are intended to be visual only. It
panels, bodyside extensions and the lower areas of the is not intended that the operator should remove trim panels,
door panels; finishers, rubbing strips or sound-deadening materials when
• A coat of protective wax is applied to areas of the wheel checking the vehicle for corrosion and paint damage.
arch not covered by the liners. 1. With the vehicle on a lift, and using an inspection or spot
Whenever body repairs are carried out, ensure the lamp, visually check for the following:
anti-corrosion materials in the affected area are repaired or • Corrosion damage and damaged paintwork, condition of
renewed as necessary using the approved materials. underbody sealer on front and rear lower panels, sills and
Precautions During Body Repairs and Handling wheel arches;
Take care when handling the vehicle in the workshop. • Damage to underbody sealer. Corrosion in areas adjacent
Underbody sealers, seam sealers, underbody wax and body to suspension mountings and fuel tank fixings.
panels may be damaged if the vehicle is carelessly lifted.
Note: In case no exposure of metal, the little bubble on
When fitting accessories, ensure that the vehicle's corrosion underbody sealing material can be neglected.
protection is not affected, either by breaking the protective
Pay special attention to signs of damage caused to panels
coating or by introducing a moisture trap.
or corrosion protection material by incorrect jack
Do not screw self-tapping screws directly into body panels. Fit positioning.
suitable plastic inserts to the panel beforehand. Always ensure
that the edges of holes drilled into panels, chassis members Warning: It is essential to follow the correct jacking and
and other body parts are protected with a suitable zinc rich lifting procedures.
or acid etch primer, and follow with a protective wax coating
brushed onto the surrounding area. 2. With the vehicle lowered, visually check for evidence
Do not attach painted metal surfaces of any accessory directly of damage and corrosion on all visible painted areas, in
to the vehicle's bodywork unless suitably protected. Where particular the following:
metal faces are bolted together always interpose a suitable • Front edge of front compartment cover;
interface material such as weldable zinc rich primer, extruded
• Visible flanges of front compartment;
strip, or zinc tape.
• Lower body and door panels.
Due to the high temperatures generated by steam cleaning
equipment, there is a risk that certain trim components could Rectify any bodywork damage or evidence of corrosion
be damaged and some adhesives and corrosion prevention found during inspection as soon as is practicable, both to
materials softened or liquefied. Adjust the equipment so that minimise the extent of the damage and to ensure the
the nozzle temperature does not exceed 90℃(194℉). Take long term effectiveness of the factory-applied corrosion
care not to allow the steam jet to dwell on one area, and keep prevention treatment. Where corrosion has become
the nozzle at least 300 mm from panel surfaces. evident and is emanating from beneath a removable
component (e.g. trim panel, window glass, seat, etc.),
DO NOT remove wax or lacquer from underbody or
remove the component as required to permit effective
underbonnet areas during repairs. Should it be necessary
rectification.
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Body Panel & Paint Corrosion Protection
Underbody Protection Repairs 8. Remove masking from component mounting faces, and
touch-in where necessary.
Whenever body repairs are carried out, ensure that full sealing
and corrosion protection treatments are reinstated. This After refitting mechanical components, including hoses and
applies both to the damaged areas and also to areas where pipes and other fixtures, mask off the brake discs and apply
protection has been indirectly impaired, as a result either of a coat of approved underbody wax. The underbody wax must
accident damage or repair operations. be reinstated following all repairs affecting wheel arch panels.
The wax is applied over paints and underbody sealers. Remove
Remove corrosion protection from the damaged area before
old underbody wax completely from a zone extending at least
straightening or panel repair. This applies in particular to panels
200 mm beyond the area where new underbody sealer is to
coated with wax, PVC underbody sealer, sound deadening
be applied.
pads, etc.
Note: Where repairs include the application of finish
Warning: DO NOT use oxy-acetylene gas equipment to
paint coats in the areas requiring underbody wax, carry
remove corrosion prevention materials. Large volumes of
out paint operations before applying wax.
fumes and gases are liberated by these materials when
they burn. Cavity Wax Injection
Note: The device used for removing strong corrosion After repairs, always treat areas with an approved cavity
protection sealer can provide several speeds and wax. In addition, treat all interior surfaces which have been
efficiency. The scraper (not pneumatic chisel) disturbed during repairs whether they have been treated
driven by compressed air provides a relatively in production or not. This includes all cavities and door
quiet mechanical method by using a very rapid interiors. It is permissible to drill extra holes for access where
reciprocating motion. Move the operating edge of necessary, provided these are not positioned in load-bearing
the tool along with the workpiece surface to remove members. Ensure that such holes are treated with a suitable
the sealing material. zinc rich primer, brushed with wax and then sealed with a
rubber grommet.
The most common method of removal is by means of a hot
air blower with integral scraper. One of the most efficient Before wax injection, ensure that the cavity to be treated is free
methods is the rapid cutting 'hot knife'. This tool uses a wide from any contamination or foreign matter. Where necessary,
blade and is able to be used easily in profiled sections where clear out any debris using compressed air.
access is otherwise difficult. Ensure that cavity wax is applied AFTER the final paint process
Use the following procedure when repairing underbody and BEFORE refitting any trim components.
coatings: During application, ensure that the wax covers all flange and
1. Remove existing underbody coatings. seam areas and that it is adequately applied to all repaired areas
of both new and existing panels.
2. After panel repair, clean the affected area with a solvent
wipe, and treat bare metal with an etch phosphate It should be noted that new panel assemblies and complete
material. body shells are supplied without wax injection treatment.
3. Re-prime the affected area. Ensure that such treatment is carried out after repairs.
Caution: DO NOT, under any circumstances, apply Effective cavity wax protection is vital. Always observe the
underbody sealer directly to bare metal surfaces. following points:
4. Replace all heat-fusible plugs which have been disturbed. • Complete all paint refinish operations before wax
Where such plugs are not available use rubber grommets application.
of equivalent size, ensuring that they are embedded in • Clean body panel areas and blow-clean cavities if
sealer. necessary before treatment.
5. Mask off all mounting faces from which mechanical • Maintain a temperature of 18℃ (64℉) during application
components, hoses and pipe clips, have been removed. and drying.
Underbody sealer must be applied before such • Check the spray pattern of injection equipment.
components are refitted.
• Mask off all areas not to be wax coated and which could
6. Brush sealer into all exposed seams. be contaminated by wax overspray.
7. Spray the affected area with an approved service • Remove body fixings, such as seat belt retractors, if
underbody sealer. contamination is at all likely.
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• Move door glasses to fully closed position before treating
door interiors.
• Treat body areas normally covered by trim before
refitting items.
• Check that body and door drain holes are clear after the
protective wax has dried.
• Keep all equipment clean, especially wax injection
nozzles.
1.0 415
Anti-corrosion Products and Construction Caution: Do not force the lance into access holes when
Equipment and Supplier using this attachment.
Cavity Waxing Machine and Technology 1100 mm movable nylon spray gun pipe: the elastic nylon
spray gun shares the same type with the rigid spray gun, but
it provides a stronger penetrability, it can be used to spray the
inaccessible vessel of the curved section or nozzle. The main
disadvantage of the elastic nylon spray gun is that it cannot
precisely position the internal compartment. When spraying,
spray outwards by the stroke of the spray gun. When pulling
the spray gun out, retract it slowly and ensure the integrity of
the finished spray. Do not pull the spray gun out with a rush.
Ensure the nylon pipe of the spray gun is away from the edge
and located in the hole so that wear of the nylon pipe can be
avoided and the service life of the nylon pipe can be prolonged.
Ensure the spray operation is stopped before removing the
nozzle from the port. To assist in the completion of this step,
1. Air Inlet use red paint to mark the rear of the nozzle (30 mm).
2. Flow Control (adjust spray mode) Hook Nozzle of Movable Spray Gun
3. Pressure Cup (1L) Max. Pressure 140 PSI (9.7 bar, 9.84 The spray gun with rigid hook nozzle provides a forward
kg/cm³) spray, its conical spray is characterised by long range and good
4. Spray Gun Connector dispersion. The combination of these two features provides a
good capability of orientation and a good effect on the short
5. Nozzle Connection of Spray Gun Pipe
and narrow locations to be sprayed, besides, it can also be
6. Retractable Spray Gun Pipe used for direct spray of the inner wheel arc, etc.
7. Rigid Hook Rod (forward, conical spray)
When using, place the smooth area at the end of the spray gun
8. Movable nylon spray gun pipe (1100 mm), 360° spray to form an angle of 180° with the location to be sprayed. For
9. Rigid spray gun pipe (1100 mm), 360° spray locations hidden in a box or hole, this helps to finish the spray
For repair, if the waxing area is scratched, handle it again. successfully.
Compressed air spray guns with the integral pressure cup and For general spray, arch the nozzle, and move from one end
replaceable spray gun pipe shall be used. to the other as required, and ensure complete spray of the
According to the configuration of the add-on device, please surface.
strictly observe the following in use: Note: Always clean gun after use with appropriate solvent
• When handling the film area, use the rigid or movable to maintain efficiency.
spray gun to give a 360° spray to ensure a maximum Recommended Equipment
coverage; 3M Schutz Pistol Spray Gun 08996 for Body: The pistol spray
• For restricted openings, use a hook nozzle to provide gun is constructed of the housing and machined light alloy,
a more directional spray (narrow inside or short which is fitted by 3M bolts to the Schutz container.
compartment);
3M Pneumatic Cartridge Pistol Spray Gun 08012: The direct
• Wax is directly sprayed to the bottom surface through feed pneumatic gun is used for the 3M cartridge product. It has
the smaller spray pipe of the spray gun, disconnect the a good performance in smooth spray, and an adjusting valve for
liquid. additional control is provided.
1100 mm rigid spray gun: the nozzle of the rigid spray gun gives 3M pneumatic pistol spray gun-08006/7: direct feed pneumatic
a forward conical spray of 360° circumference. Though the guns are used for the 3M product sealed in bags (spray gun
wax film is sprayed by a single stroke, it can affect all surfaces 08006 is used for products of 200 ml and 310 ml in bags, and
of the compartment, internal and external spray can provide spray gun 08007 is used for products of different models in
effective and complete wax coverage for the long/straight bags, including products of 600 ml).
structure and compartment. By visual inspection, the rigid
spray pipe also provides position accuracy for handling the Other applicable spray guns: heavy pistol 08013.
shapely location.
1.0 416
3M glue gun 08190: this model is used for 3M structure gluing • The cutting surface or damaged coating of the sheet
08120. metal panel requires zinc spray;
3M cavity wax film glue gun 08997: This machine can load • Zinc shall be sprayed on the contact surface of the
a tank of 1L, it is equipped with a hose of 750 mm. The welding to prevent rust of the spot welding.
approved system can be obtained from the 3M surface repair
coefficient. The Cooper Greux falcon preliminary spray gun
(airtight) is used for spraying transit wax, which has a 5L
container with a complete manual pump and achieves effective
spray without compressed air or additional operation. Use
of the nozzle, spray gun, hose length and a trigger valve
with complete filter can facilitate the application. Other
applications include general service, wax spray liquid and paint
spray. The operation may use heavy materials. All components
can be replaced and configured with different nozzles.
SATA Schutz gun UBE: the SATA gun is used for retreatment of
the bottom vehicle coated with protective paint, the spray gun
is in the special one-way container (1L). Thread parts (inner
thread of the gun) conform to the standard of most of the
Schutz product packages.
Specification of UBE:
Air consumption 7 ft3/min (200 litres/min) @
45 lbf.in2
Weight: 23.3 oz (220 grams)
SATA HKD1 waxing machine: used for retreatment of cavity

wax. SATA HKD1 device consists of the following parts:
high quality forging, gun with 1L pressure feed container,
retractable nylon spray gun pipe, 1100 mm steel pipe and hook
pipe. The replacement quick connector of the standard parts
can be used to transfer the pipe. Each spray gun is provided
with a complete nozzle machined for spray purpose, which is
applicable for the compartment to be treated.
Note: Always clean gun after use with appropriate solvent

to maintain efficiency.
Contact information of 3M supplier
3M (China) Co. Limited
Address: No. 38 building, Maxdo Centre, No. 8 Xing Yi Road,

Shanghai, China
Zip Code: 200336
Tel: 86 21 62753535
Website: www.3M.com
Zinc Spray
For locations needing MIG/MAG welding or spot welding, apply
the primer rich in zinc to the area near the connector surface,
and do not process the welding area.
Zinc spray is used for the following two situations:
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Information of Cavity Wax Application

Doorsill
1.0 418
Door and Luggage Compartment Lid
Spray cavity wax from the process hole inside the door and luggage compartment lid to cover the internal sheet metal and
frame with a layer of protective film. Most of the cavity wax deposit is at the bottom of the sheet metal cavity, and it will be
finally drained from the hole at the bottom.
1.0 419
1.0 420
Chassis Adhesive
Function of chassis adhesive:
• Improve the stone-chipping resistance of the underbody;
• Improve the corrosion resistance of the underbody sheet
metal;
• Improve the seam sealing performance of the underbody
sheet metal;
• Improve the sound insulation performance of the
underbody.
Caution: Ensure that suspension units, wheels, tyres,
power unit, exhaust and brakes (including all mounting
points) are shielded prior to application of fresh
underbody sealer.
Operation procedures for chassis adhesive:
1. Cleaning: to ensure the maximum viscosity of the
product, the underbody surface shall be clean and free
from any dirt, oil stain, grease or wax residue.
2. Inspection: before operation, thoroughly inspect the
underbody for any potential damage or rust. Key location:
wheel arch, lower side, seam and overlap joint.
3. Dust elimination: eliminate the rust spot on the
underbody with a shovel or wire brush. Pay particular
attention to the inaccessible locations, for example,
wheel frame, overlap or seam.
4. Check the type of the underbody coating: check the type
of the underbody coating and select a suitable product.
5. Read use instruction: before operation, please carefully
read the instruction on the package of the product and
view the technical data sheet. Read the safety instruction
in the Material Safety Data Sheet carefully so that you
can minimize some potential risk and hazard and achieve
the optimum effect.
6. Use cross spray technique: spray the rust prevention
product at a distance of around 30cm, spray in the
horizontal direction first, then spray the stiffener of the
base plate from a proper angle (cross spray technique).
To achieve an optimum thickness (1.5mm) of the wet
film, at least three sprays shall be done.
7. Drying time: a specific drying time shall be defined, the
coating material shall adhere to the underbody firmly and
permanently. Different solutions and different coating
thicknesses may require different drying time. Products
with high volatile solution require 2hr drying time at least.
8. Clean spray gun: use spray gun detergent to clean the
spray gun immediately after use.
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Body Panel & Paint Welding Process
Welding Process Resistance spot welding

Welding Process Overview The resistance spot welding is the most common method for
Characteristics of welding process: welding the integral body. This method can be used for the
non-deformable thin steel sheet on the body which requires a
• It is applicable to any shape and can be used to connect
high welding strength. Suitable for roof, window, doorsill and
the integral body, and the vehicle body integrity can be
external components, etc. The quality of the resistance spot
maintained after welding;
welding depends on the voltage, current, pressure time and
• Mass reduction can be achieved due to lack of the
thickness of the metal panel to be welded, etc, the details are
connecting parts;
as follows:
• Good sealing performance for air and water;
• Material and cleanness of the weldment: the location
• High production efficiency; between the weldments or the contact point between
• The welding connector strength is affected by the skill the weldment and the electrode shall be clean;
level of the operator; • Electrode pressing force: insufficient force can cause
• Excessive heating may cause surrounding panels spatter on the contact point; excessive force can
deformation. generate large current, but it will lead to small welding
spot diameter and penetration due to increase of the
For modern vehicles, the body welding repair usually adopts
heat distribution zone;
MAG shielded arc welding, resistance spot welding and
soldering. For the body panel welding repair, an optimum • Welding current: the welding spot diameter and welding
welding method that will not reduce the original strength and strength increase with the current, and large current
durability of the body shall be applied depending on the specific and small pressure may also lead to spatter between the
situations, spot welding or inert gas welding is preferred. panels; the spatter will be otherwise minimized;
MAG Shielded Arc Welding • Welding time: long welding time will cause much heat,
large diameter and deep penetration of the welding spot.
MAG shielded arc welding is mainly used for welding high However, prolonged welding time will lead to electrode
strength, low alloy steel body and aluminum casting, etc. impress and thermal deformation rather than increase of
Advantages of the MAG shielded arc welding include: the welding spot.
• Easy operation; • Arrangement of the welding spot: the gap and margin
• This method can melt the base metal completely, low of the welding spot (distance between the spot and the
current can be used to weld thin metal, which can panel edge) is also crucial for determining the welding
diminish damage to the adjacent area strength; spot strength. Welding spot gap decrease can improve
• Stable and controllable arc; the weldment connection strength, but the effect is
• Suitable for welding locations with gap and misalignment; actually limited. Excessive gap may cause the welding
current to transfer through the last welding spot or
• Temperature and duration of the welding is controllable,
leak, then the added welding spot will not strengthen
short heating time of the welding zone reduces fatigue
the connection strength of the weldment any more, and
and deformation of the base metal.
it will have an adverse impact, therefore, the gap of the
Typical welding locations and methods: welding spot shall be beyond the area of current leak.
• Butt welding. Fit two adjacent metal edges together, fit Correct welding sequence shall be applied for the resistance
mutually along the two metal panels or weld the butted spot welding, continuous welding in one direction is generally
edge; not allowed, when the electrode tip is hot and discolours, stop
• Overlap welding. Weld two overlapping metal panels; welding and allow it to cool down. To avoid crack due to stress
• Plug welding. Punch a hole on one or several exterior concentration, do not weld the boundary of the corner.
workpieces, arc passes through the hole before entering
into the interior workpiece, and the hole is filled with the
melting metal;
• Spot welding. When the wire feed timing pulse is
triggered, current will be introduced into the two metal
panels to be welded.
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Welding Process Body Panel & Paint
Welding Protection Measures
Electronic Control Unit
Before welding repair is operated, in consideration of the
electronic control unit (ECU) refitted on the vehicle, the
following protection measures must be followed. The plentiful
heat and sharp vibration produced during these operations
may damage the electronic control unit.
When disconnect or remove the airbag control module

SDM, pay special attention to the following proper protection
measures.
Protection Measures for Assistant Protection
System
Implement and remove or replace any item related to the
assistant protection system (SRS), be especially careful and
comply with proper protection measures.
Equipments
When starting any test on the vehicle, ensure that the
related test equipments work normally and all harnesses and
connectors are in good state. This is especially important to
the electronic control unit.
Seat Belt Rivet Joint
Seat belt rivet joint is crucial for safety. When repairing
these areas, it is important to follow the following design
specifications. Note: High strength low alloy steel (HSLA)
can be used at the installation position for seat belts.
Try best to use the original production assembly, including rivet

joints of seat belts, or the layout of cutting line should not
interfere with the original rivet joints of seat belts.
Carefully check the welding quality of the jointing for seat belts
rivet joints within 250mm, including the spot welding spacing.
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Welding Parts Remove

1. Expose the resistance spot welding. Use a rotary bowl
grinder or a wire brush installed into the air drill, or
manual wire brush for the spot welding is not obvious.
3. Location for laser welding: use grinder and grinding disk.
Caution: In wheel arch areas it may be necessary to soften

underbody coating, using a hot air gun, prior to exposing
spot welds.
2. The drill or clamping platoon welder for spot welding can

be used to remove the welding spot.
4. CO2-MAG Arc Welding Location
5. Rivet Junction
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6. Big panel cutting • d. Overlap cutting

• a. Cutting by edge of steel panel
Caution: On certain panel joints MIG welds and braze

• b. Plastic sample panel cutting should be removed using a sander where possible, before
cutting out the panel bulk.
7. Separate the electric welding point with hammers, base

plate chisels and pincers, and remove the penal scraps.
• c. Dimension measurement
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OEM Welding Information

Welding Identification
—2 layers of welding
—3 layers of welding
—MAG welding/CMT welding
Welding Information of Main Parts

Front Compartment
Structure
A— Front Longitudinal Beam Assembly

B— Front Wheelhouse Panel Assembly
C— Dash Panel Lower Beam Assembly
D— Dash Panel Upper Beam Assembly
E— Dash Panel Assembly
F— Dash Panel Lower Panel Assembly
G— Dash Panel Upper Panel Assembly
H— Dash Panel Side Panel Assembly
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Welding
1. Weld the front left and right wheelhouse panel (B) assembly with the left and right front longitudinal beam assembly (A),
and then weld the dash panel lower beam assembly (C) with the dash panel upper beam assembly (D);
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2. Weld the dash panel assembly (E), dash panel lower panel assembly (F) and dash panel upper panel assembly (G) with
the front longitudinal beam frame assembly;
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3. Finally, weld the dash panel side panel assembly (H).
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Rear Floor
Structure
A— Rear Longitudinal Beam Assembly

B— Heel Board Beam Assembly
C— Rear Floor Beam Assembly
D— Rear Seat Plate Assembly
E— Spare Wheel Compartment Assembly
F— Rear Wheelhouse Assembly
G— Rear Wheelhouse Support Plate Assembly
H— Rear Door Sill Extension Panel
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Welding
1. Weld the heel board beam assembly (B) and rear floor beam assembly (C) with the left and right rear longitudinal
beam assembly (A);
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2. Weld the rear seat plate assembly (D) and spare wheel compartment assembly (E) with the rear longitudinal beam
frame assembly;
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3. Finally, weld the rear wheelhouse assembly (F), rear wheelhouse support plate assembly (G) and rear door sill extension
panel (H).
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Lower Body
Structure
A— Front Compartment Assembly

B— Front Floor Assembly
C— Rear Floor Assembly
D— Door Sill Inner Panel Assembly
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Welding
1. Weld the front compartment assembly (A), front floor assembly (B) and rear floor assembly (C) with the door sill
inner panel assembly (D).
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Bodyside
Structure
A— Bodyside Outer Panel

B— Drain Channel Extension Panel Assembly
C— A Pillar Upper Closing Panel
D— Fender Bracket
E— Fender Bracket
F— Fender Bracket
G— A Pillar Reinforcement Panel Assembly
H— B/C Pillar Closing Panel Assembly
I— Rear Bodyside Inner Panel Assembly
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Welding
1. Weld the bodyside outer panel (A), drain channel extension panel assembly (B), A pillar upper closing panel (C), fender
brackets (D, E and F) into the bodyside outer panel assembly;
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2. Weld the rear bodyside inner panel assembly (H), A pillar reinforcement panel assembly (I) and B/C pillar closing panel
assembly (J) with the bodyside outer panel assembly.
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Sunroof Panel
Structure
A— Roof Panel-Sunroof
B— Sunroof Reinforcement Panel Assembly
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Welding
1. Weld the roof panel - sunroof (A) and the sunroof reinforcement panel assembly (B).
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Body In White Assembly

Structure
A— Bodyside Panel Assembly

B— Rear End Panel Assembly
C— Front Roof Beam Assembly
D— Rear Roof Beam Assembly
E— Sunroof Panel Assembly
F— Roof Panel-Without Sunroof
G— Middle Roof No.1 Beam
H— Middle Roof No.2 Beam
I— Middle Roof No.3 Beam
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Welding
1. Weld the bodyside panel assembly (A) and rear end panel assembly (B) onto the lower body assembly;
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2. Then weld the front roof beam assembly (C) and the rear roof beam assembly (D);
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3. For body in white assembly with sunroof, weld the sunroof panel assembly (E) onto the vehicle body;
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4. For body in white assembly without sunroof, weld the roof beams (G, H and I) onto the vehicle body, and then weld the
roof panel - without sunroof (F).
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Body Panel & Paint Body Dimension
Body Dimension
Point to Point Dimensional Information
Bodyside and Roof Information
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Body Dimension Body Panel & Paint
Note: All dimensions are to hole/slot centres.
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Underbody Information
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Rear End Information
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Interior Information
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1.0 455
Front End Information
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Gap Information
Body Side Information
Note: “//” represents parallel requirement, It means the difference between maximum clearance and minimum
clearance should be within the required range.
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Front End Information
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Rear End Information
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Sunroof Information
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Gateway Safety and Restraints
Gateway
Specifications
Torque
Description Value
Bolt-getaway to fasic bracket 6–8Nm
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Safety and Restraints Gateway
Service Procedures
Gateway
Remove
2. Remove driver side lower trim panel.
Driver Side Lower Trim Panel Remove

3. Disconnect the gateway module connector (1).
4. Remove 2 nuts (2) fixing the gateway module to the
bracket.
5. Remove the gateway module assembly.

Refit
1. Connect the gateway module connector.
3. Programme and encode the gateway module. Refer
“Gateway Module Replacement”.
4. Fix the gateway module to the instrument panel beam,
fit 2 nuts, tighten them to 6–8Nm, and check the
torque.
5. Fix driver side lower trim panel.
Driver Side Lower Trim Panel Fix
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Seat Belts Safety and Restraints
Seat Belts
Specifications
Torque
Description Value
Bolt-front seat belt retractor to ‘BC’ post 35–45Nm
Bolt-front seat belt to body 35–45Nm
Bolt-rear seat belt‘D’loop to body 35–45Nm
Bolt-front seat belt buckle 43–53Nm
Bolt-rear seat belt retractor to body 35–45Nm
Bolt-rear seat belt buckle to rear seat 35-45Nm
Bolt-rear seat belt double buckle 35–45Nm
Bolt-rear middle seat belt to seat 35–45Nm
Bolt-rear seat belt to body 35–45Nm
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Safety and Restraints Seat Belts
Service Procedures fit 1 bolt, tighten it to 35–45Nm, and check the torque.
Front Seat Belt Assembly 4. Fix the D-ring of the front seat belt to the body, fit 1
Remove bolt, tighten it to 35–45Nm, and check the torque.
1. Remove the key from the ignition switch, and 5. Fit the door sill trim panel.
disconnect the battery positive and negative (disconnect
the ground wire first). Wait for 10min until the SRS
backup circuit is discharged. 6. Fit the B/C pillar lower trim panel.
2. Remove the Bpillar upper trim panel. B/C Pillar Lower Trim Panel Refit
BC Pillar Upper Trim Panel Remove 7. Connect the battery negative. Perform a system check,
3. Remove the B pillar lower trim panel. turn the ignition switch, check whether the SRS
warning lamp is illuminated for several seconds, and
B/C Pillar Lower Trim Panel Remove
then goes out.
4. Remove 1 bolt fixing the D-ring of the front seat belt
to the body.
5. Remove the end cover of the seat belt, and remove 1

bolt (1) fixing the front seat belt to the underbody.
6. Disconnect the connector of the seat belt pretensioner.
7. Remove 1 bolt fixing the front seat belt retractor to
the body.
8. Remove the front seat belt assembly.

Refit
1. Fix the front seat belt retractor to the body, fit 1 bolt,
tighten it to 35–45Nm, and check the torque.
2. Connect the electrical connector of the pre-tensioner.
3. Fix the fixed end of the front seat belt to the underbody,
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Front Seat Belt Buckle Rear Seat Belt Assembly
Remove Remove
1. Remove the front seat assembly. 1. Remove the key from the ignition switch, and
disconnect the battery positive and negative (disconnect
the ground wire first). Wait for 10min until the SRS
2. Remove 1 bolt securing the front seat belt buckle onto
backup circuit is discharged, then start to operate.
the seat.
2. Remove the rear seat cushion.
3. Remove the three bolts (1) that fasten the D-ring of the
side seat belt of the rear seat to the body of the car.
4. Remove a bolt (2) that secures the side seat belt coiler
of the rear seat to the body of the car, and take out
the retractor
3. Disconnect the front seat belt buckle harness clip.

4. Remove the front seat belt buckle.
Refit
1. Fix the front seat belt buckle onto the seat, fit 1 bolt
and tighten to 43–53Nm, then check the torque.
2. Connect the front seat belt buckle harness clip.
3. fit the front seat assembly.
5. Remove the rear seat belt assembly.
Front Seat Assembly Refit Refit
1. Fix the rear seat side belt retractor onto the body, fit 3
bolt and tighten to 35–45Nm then check the torque.
2. Fix the rear seat side belt D ring onto the body, fit 1
bolt and tighten to 35–45Nm, then check the torque.
3. Fit the C pillar upper trim panel.
BC Pillar Upper Trim Panel Refit
4. Fit the rear seat cushion.
5. Connect the negative battery. Check the system, rotate
the ignition switch, and check whether the SRS warning
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Safety and Restraints Seat Belts
Rear Seat Belt Buckle Rear Seat Middle Belt

Remove Remove
1. Remove the rear seat cushion assembly. 1. Remove the rear seat cushion assembly.
Rear Seat Cushion Assembly Remove Rear Seat Cushion Remove

2. Remove 1 bolt securing the rear seat belt single buckle 2. Remove 1 bolt fixing the rear seat middle seat belt
to the rear floor (1) and 1 bolt securing the rear seat onto the floor.
belt double buckle to the rear floor (2), then remove
the rear seat belt buckle.
3. Lift the rear seat back cover, and remove 1 bolt fixing
the rear seat middle retractor onto the rear seat back
Refit frame.
1. Fix the rear seat belt single buckle onto the floor, fit 1
bolt, tighten it to 35-45Nm, and check the torque.
2. Fix the rear seat belt double buckle onto the rear floor,
fit 1 bolt, tighten it to 35–45Nm, and check the torque.
4. Move the rear seat back foam, and take out the rear
seat middle retractor.
5. Pass the middle seat belt webbing through the rear
middle seat belt decorative frame and remove the rear
seat middle belt assembly.
Refit
1. Pass the rear middle seat belt webbing through the rear
middle seat belt decorative frame.
2. Fix the rear middle seat belt onto the rear seat back
frame, fit 1 bolt, tighten to 35–45Nm, and check the
torque.
3. Reset the rear seat back foam.
4. Reset the rear seat back cover assembly, and secure
with hooks.
5. Fix the rear middle seat belt onto the floor, fit 1 bolt,
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tighten it to35–45Nm, and check the torque.
6. Fit the rear seat cushion.
Rear Seat Cushion Refit
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Safety and Restraints Supplementary Restraint Systems
Supplementary Restraint Systems

Specifications
Torque
Description Value
Bolt-Front impact sensor to Body 7-10Nm
Bolt-Side impact sensor to Body 7-10Nm
Screw- side curtain 7–9Nm
Bolt-SDM to Body 7-10Nm
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Supplementary Restraint Systems Safety and Restraints
Service Procedures Airbag Side Impact Sensor
Airbag Front Impact Sensor Remove
1. Disconnect the negative battery cable. 2. Remove the door sill trim panel assembly.
2. Remove 1 bolt (2) fixing the front impact sensor to the Door Sill Trim Panel Assembly Remove
body.
3. Disconnect the harness connector (1) and remove the
4. Lift the carpet, and remove 1 bolt (2) fixing the side
front impact sensor.
impact sensor to the body.
Refit
5. Remove the airbag side impact sensor.
Refit
2. Fix the front impact sensor to the body, fit 1 bolt,
2. Fix the side impact sensor to the body, fit 1 bolt, tighten
it to 7-10Nm, and check the torque.
3. Fit the door sill trim panel assembly.

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Steering Wheel Airbag Instrument Panel Airbag

Remove Remove
Warning: It is imperative that before any work 1. Disconnect the negative battery cable. Wait for 10
is undertaken on the SRS system the appropriate minutes until the SRS backup circuit is discharged.
information is read thoroughly. 2. Remove the instrument panel body assembly.
1. Disconnect the negative battery cable. Wait for 10
minutes until the SRS backup circuit is discharged.
3. Remove 2 screws (1) fixing the passenger's front airbag
2. Adjust the steering wheel to the lowest position.
module to the instrument panel body.
3. Adjust the depth of the steering wheel and pull it
4. Remove 9 claws (2) fixing the passenger's front airbag
outwards to the end.
module to the instrument panel, and remove the
4. Pry off and remove the upper trim cover of the steering passenger's front airbag module.
column to spare room for removing the airbag lock ring.
5. Rotate the steering wheel to expose the airbag lock
ring.
6. Carefully pry off 3 lock rings from the lower part of the
steering wheel with a flat-bladed screwdriver to release
3 PINs fixing the airbag to the steering wheel.
Refit
1. Fit 9 claws fixing the passenger's front airbag module
to the instrument panel.
2. Fit 2 screws fixing the passenger's front airbag module
to the instrument panel.
7. Disconnect the airbag connector, and remove the
steering wheel airbag. Instrument Panel Beam Assembly Refit
Refit 4. Connect the negative battery cable. Perform a system
check, press the start switch, check if the SRS warning
1. Connect the driver airbag connector.
2. Place the driver airbag in the steering wheel mounting
position, with the three protruding PINs of the airbag
aligned with the three concave holes in the steering
wheel.
3. Push the driver airbag into the steering wheel until
a click can be heard.
4. Fix the steering column upper trim cover to the lower
trim cover, and press the clip in place.
5. Restore the steering wheel.
6. Connect the negative battery cable. Perform a system
check, press the start switch, check if the SRS warning
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Side Curtain Airbag the roof trim panel.
Remove 5. Fit the roof handle bracket.
Warning: It is imperative that before any work
Roof Interior Handle Refit
is undertaken on the SRS system the appropriate
information is read thoroughly.
1. Disconnect the battery. Wait for 10min until the SRS A Pillar Upper Trim Panel Refit
backup circuit is discharged, then start to operate. 7. Fit the B pillar upper trim panel.
2. Remove the A pillar upper trim panel. B/C Pillar Lower Trim Panel Refit
A Pillar Upper Trim Panel Remove 8. Fit the C pillar upper trim panel.
3. Remove the B pillar upper trim panel. BC Pillar Upper Trim Panel Refit
B/C Pillar Upper Trim Panel Remove 9. Repeat the step below to fit the curtain airbag on the
4. Remove the C pillar upper trim panel. other side.
10. Connect the battery negative. Perform a system check,
C Pillar Upper Trim Panel Remove
turn the ignition switch, check whether the SRS
5. Remove the roof handle bracket.
warning lamp is illuminated for several seconds, and
Roof Interior Handle Remove then goes out.
6. Pry the roof trim panel on one side.
7. Release the hook to disconnect the curtain airbag
connector.
8. Remove the clip (1) securing the curtain airbag front
tether.
9. Remove 2 bolts securing the curtain airbag gas
generator bracket (2).
10. Remove 5 bolts (3) securing the curtain airbag.
11. Remove the side curtain airbag.

12. Repeat the above steps to remove the right curtain
airbag.
Refit
1. Fix the curtain airbag to the roof, fit the clip, fit 5 bolts,
2. Fit 2 bolts securing the curtain airbag gas generator
bracket, tighten to 7–9Nm and check the torque.
3. Fix the curtain airbag front tether to the A pillar, fit
the hook and tap the clip.
4. Connect the side curtain harness connector, tap down
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Airbag Control Module Front Passenger Airbag Disable Switch

Remove Remove
1. Disconnect the negative battery cable, wait for 1. Disconnect the negative battery cable.
10 minutes until the SRSECU internal circuit is 2. Open the glove box.
discharged.
3. Disconnect the harness connector, loosen the clip, and
2. Remove the centre console assembly. remove the front passenger airbag disable switch.
4. Remove 3 bolts (2) fixing the airbag control module
to the body.
Refit
2. Fix the front passenger airbag disable switch to the
glove box frame, and snap it into place.
5. Remove the airbag control module. 3. Close the glove box.
Refit 4. Connect the negative battery cable.
1. Fix the airbag control module to the body, fit 3 bolts,
tighten them to 7-10Nm, and check the torque.
4. Programme and encode the airbag control module
(SDM). Refer to Module Self-learning and Programming
Manual, "SDM Replacement".
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Auxiliary Display Module
Remove
3. Disconnect the harness connector.
4. Remove 11 screws (if any) fixing the roof console upper
cover to the roof console, and remove the roof console
upper cover.
5. Remove 2 screws fixing the auxiliary display module
to the roof console.
6. Remove the auxiliary display module.

Refit
1. Fix the auxiliary display module to the roof console, fit
2 screws and tighten them.
2. Fix the roof console upper cover to the roof console,
fit 11 screws (if any) and tighten them.
4. Fit the roof console.
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Safety and Restraints Park Assistant System
Park Assistant System Rear Camera

Service Procedures Remove
Rear Ultrasonic Sensor Warning: Rear View Camera must be disassembled after
Remove the exhaust has cooled.
Warning: Rear PDC Sensor must be disassembled after the 1. Disconnect the battery negative cable.
exhaust has cooled. 2. Lift the vehicle.
1. Disconnect the battery negative cable. 3. Disconnect the connector (1).
2. Lift the vehicle. 4. Press the rear camera clip (2), push it outwards to
3. Remove the ultrasonic sensor from the rear bumper. remove the rear camera.
4. Disconnect the ultrasonic sensor connector, and
remove it.
Refit
1. Fit the camera to the rear bumper.
Refit 2. Connect the harness connector.
1. Connect the ultrasonic sensor connector. 3. Lower the vehicle.
2. Clamp the ultrasonic sensors into the rear bumper. 4. Connect the battery negative cable.
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Park Assistant System Safety and Restraints
Around View Monitor (AVM) 360 Panoramic Front View Camera
Remove Remove
2. Remove the driver side lower closure panel. 2. Remove the front bumper assembly.
Front Seat Assembly Remove Front Bumper Remove
3. Remove 2 bolts (2) fixing the AVM to the PEPS bracket. 3. Remove 3 screws fixing the front camera trim panel
4. Disconnect the harness connector (1) and remove the to the front bumper.
AVM.
4. Remove the 360° panoramic front view camera.

Refit
1. Connect the harness connector of the camera.
Refit
3. Programme and encode the 360° panoramic view
camera. Refer to Module Self-learning and Programming
3. Programme and encode the around view monitor Manual, “360 Panoramic View Camera Calibration”.
(AVM). Refer to Module Self-learning and Programming
4. Fix the trim panel of the 360° panoramic front view
Manual, “Around View Monitor (AVM)” and “360
camera to the front bumper, fit 3 screws and tighten
Panoramic View Camera Calibration”.
them.
4. Fix the AVM to the PEPS bracket, fit 2 bolts, tighten
5. Fit the driver side lower closure panel. Front Bumper Refit
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Safety and Restraints Park Assistant System
360 Panoramic Side View Camera 360 Panoramic Rear View Camera
Remove Remove
2. Remove the side direction indicator lamp. 2. Disconnect the harness connector.
Side Direction Indicator Lamp Remove 3. Release the retaining clip and remove the 360°
panoramic rear view camera.
3. Remove 2 screws fixing the camera to the exterior
rearview mirror and disconnect the connector.
Refit
4. Remove the 360° panoramic side view camera. 1. Connect the harness connector.
Refit 2. Connect the negative battery cable.
1. Connect the camera connector. 3. Programme and encode the 360° panoramic view
2. Connect the negative battery cable. camera. Refer to Module Self-learning and Programming
3. Programme and encode the 360° panoramic view Manual, “360 Panoramic View Camera Calibration”.
camera. Refer to Module Self-learning and Programming 4. Align the locating point of the camera with the
Manual, “360 Panoramic View Camera Calibration”. mounting hole and press down to engage.
4. Fix the 360° panoramic side view camera to the
exterior rearview mirror, fit 2 screws and tighten them.
5. Refit the side direction indicator lamp.
Side Direction Indicator Lamp Refit
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Rear Drive Assist System Safety and Restraints
Rear Drive Assist System
Service Procedures
Rear Distant Object Detection Module and
Sensor
Remove
2. Remove the rear bumper.

3. Remove 2 bolts (2) fixing the right (left) rear distant
object detection module and bracket to the body.
5. Loosen the clip, and remove the rear distant object

detection module.
Refit
1. Connect the harness connector of rear distant object
detection module.
3. Programme and encode the rear distant object
detection module (). Refer to Module Self-learning and
Programming Manual, "Rear Driver Assist System () ".
4. Fix the rear distant object detection module to the
bracket, and secure it with clips.
5. Fix the rear distant object detection module and
bracket to the rear bumper, fit and tighten 2 bolts.
6. Fit the rear bumper.
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Safety and Restraints Pedestrian Alert System
Pedestrian Alert System

Specifications
Torque
Description Value
Nut-Pedestrian Alert Control Module to body 5–7Nm
Bolt-Speaker—PED alert to Body 4–6Nm
1.0 480
Pedestrian Alert System Safety and Restraints
Service Procedures Pedestrian Alert Speaker
Pedestrian Alert Control Module Remove
1. Disconnect the negative battery cable. 2. Remove the front bumper.
2. Remove the passenger side assembly. Front Bumper Remove
Front Seat Assembly Remove 3. Disconnect the harness connector (1).
3. Disconnect the harness connector (1). 4. Remove 3 bolts (2) fixing the pedestrian alert speaker
4. Remove 2 nuts (2) fixing the pedestrian alert module to to the vehicle body, and remove the pedestrian alert
the body. And remove the pedestrian alert module. speaker.
Refit Refit
1. Fix the pedestrian alert module to the body, fit 2 nuts, 1. Fix the pedestrian alert speaker to the body, fit 3 bolts,
tighten them to 5–7Nm, and check the torque. tighten them to 4–6Nm, and check the torque.
2. Connect the harness connector. 2. Connect the harness connector.
3. Fit the passenger side seat assembly. 3. Fit the front bumper.
Front Seat Assembly Refit Front Bumper Refit

4. Connect the negative battery cable. 4. Connect the negative battery cable.
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Safety and Restraints Vehicle Access
Vehicle Access
Specifications
Torque
Description Value
Bolt -PEPS Module Assembly to Body 7–9Nm
Bolt-Back up antenna to Console 1.4–1.8Nm
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Vehicle Access Safety and Restraints
Service Procedures Passive Entry and Passive Start Antenna - Front
Passive Entry and Passive Start Control Module Remove
1. Disconnect the negative battery cable. 2. Remove the A/C controller assembly.
2. Remove the driver side lower trim panel assembly. A/C Controller Assembly Remove
Driver Side Lower Trim Panel Assembly Remove 3. Disconnect the antenna harness connector, loosen the
3. Disconnect the harness connectors (1) of the PEPS clip and remove the antenna - front.
module.
4. Remove 2 bolts (2) fixing the PEPS module assembly to
body, and remove the PEPS module assembly.
Refit
1. Align the antenna locating point with the mounting hole
Refit and press down to engage.
1. Connect the harness connector of the PEPS module. 2. Connect the antenna harness connector.
2. Connect the negative battery cable. 3. Fit the A/C controller assembly.
3. Programme and encode the PEPS module. Refer to A/C Controller Assembly Refit
Service Programming & Configuration Self-learning
Manual, PEPS replacement.
4. Fix the PEPS module to body, fit 2 bolts, tighten them
to 7–9Nm， check the torque.
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Passive Entry and Passive Start Antenna - Middle Passive Entry and Passive Start Antenna - Rear
Remove Remove
2. Remove the centre console assembly. 2. Lift up and remove the rear seat cushion assembly.
Centre Console Assembly Remove 3. Disconnect the antenna harness connector.
3. Disconnect the antenna harness connector and remove 4. Remove the antenna - rear.
the antenna - middle.
Refit
Refit 1. Connect the antenna harness connector.
1. Align the antenna locating point with the mounting hole 2. Fit the antenna in the mounting hole and press down
and press down to engage. to engage.
2. Connect the antenna harness connector. 3. Fit and secure the rear seat cushion assembly by fitting
3. Fit the centre console assembly. the rear seat cushion clips in place.
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Vehicle Access Safety and Restraints
Passive Entry and Passive Start Antenna - Rear Passive Entry and Passive Start Antenna - Door
Bumper Fascia Handle
Remove Remove
1. Disconnect the negative battery cable. 1. For vehicles equipped with PEPS module, the outer
2. Remove the rear bumper. door handle antenna and switch units (HSU) are
respectively fitted in the driver side door outer handle
Rear Bumper Remove
and the front passenger side door outer handle, so the
3. Disconnect the antenna harness connector and remove door handle antenna can be replaced by replacing the
the antenna - rear bumper fascia. door handle assembly.

Assembly Remove
Front Passenger Side Door Outer Handle and

Lock Cylinder Remove
Refit
1. Fit the passive entry and passive start antenna - door
handle.

Assembly Refit
Front Passenger Side Door Outer Handle and

Lock Cylinder Refit
Refit
1. Align the antenna locating point with the mounting hole
and press down to engage.
2. Connect the antenna harness connector.
Rear Bumper Refit

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Back Up Antenna
Remove
3. Disconnect the back up antenna connector.
4. Remove 2 screws fixing the back up antenna to the
centre console.
5. Rotate the back up antenna to remove it.
Refit
1. Fit the back up antenna to the mounting position,
slightly turn it to secure it.
2. Connect the connector of the backup antenna.
3. Fit the backup antenna with 2 screws, tighten them to
1.4–1.8Nm, check the torque.

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Drive Assistant System Safety and Restraints
Drive Assistant System Front Detection Radar Module
Service Procedures Remove
Front View Camera Module 1. Disconnect the negative battery cable.
Remove 2. Remove the front bumper lower trim cover and the
1. Disconnect the negative battery cable. front detection radar cover.
2. Remove the interior rearview mirror cover. 3. Disconnect the harness connector (1) of the front
detection radar.
3. Disconnect the harness connector of the front view
camera module. 4. Remove 3 plastic clips (2) fixing the front detection
radar to the bracket.
4. Loosen the clip with a tool, and remove the front view
camera module.
Caution: Immediately place suitable covers over the view

point holes in the camera and bracket to avoid the entry
of moisture or debris.
5. Remove the front detection radar.

Refit
1. Locate the front detection radar to the bracket.
2. Connect the harness connector of the front detection
radar.
Refit
1. Fit the front view camera module and secure it with
clips. 4. Move the vehicle onto the wheel aligner.
5. Align 3 locating lugs (1) of special tool TEL00051 with
Caution: After removal of the protective covers please
3 locating grooves (2) on the front detection radar, and
ensure the refit operation is completed within 10 seconds
fix the special tool to the front detection radar with the
so as to avoid contamination of debris or moisture.
2 clamping jaws of special tool TEL00051.
2. Connect the harness connector of the front view
camera module.
3. Fit the interior rearview mirror cover.
5. Operate self-learning for the front view camera module.
Refer to Module Self-learning and Programming Manual
“Front View Camera Module (FVCM) Self-learning”.
6. Operate self-learning for the front detection radar in

vertical direction.
a. Place the radar calibration level on the wheel aligner
and carry out a zero point calibration.
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Safety and Restraints Drive Assistant System
b. Place the radar level after zero point calibration on

the appropriate position of special tool TEL00051.
Adjust the adjusting bolt on the lower right of the
front detection radar until the radar calibration level
value is -2degrees (pointing slightly downwards).
c. Remove the radar calibration level and special

toolTEL00051.
7. Operate self-learning for the front detection radar in

horizontal direction. Refer to Module Self-learning
and Programming Manual, “Front Detection Radar
Self-learning”. If necessary, adjust the adjusting bolt on
the upper left of the front detection radar according
to the prompts.
8. Fit the front bumper lower trim cover and the front
detection radar cover.
1.0 488
Drive Assistant System Safety and Restraints
Special Tools
Number
Front radar
TEL00051 alignment spirit
level
1.0 489
1.0 490
Entertainment and Navigation Information and Entertainment
Entertainment and Navigation
Specifications
Torque
Description Value
Screw-Duo-cone speaker to front door 1–2Nm
Screw-Duo-cone speaker to rear door 1–2Nm
Bolt-T-box to cross car beam 7–10Nm
Bolt-Antenna to Instrument Panel 1.3–1.9Nm
Screw-Communications antenna 3-4Nm
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Information and Entertainment Entertainment and Navigation
Service Procedures screws, tighten them to 1.4-1.8Nm, and check the

Front Infotainment Control Module (FICM) torque.
Remove 7. Fit the entertainment panel switch.
1. Disconnect the negative battery cable. Entertainment Panel Switch Refit
2. Remove the entertainment panel switch.
Entertainment Panel Switch Remove

3. Remove 2 screws fixing the FICM to the instrument
panel.
4. Disconnect the harness connector, loosen the clip and

remove the FICM.
5. Remove 6 screws fixing the display to the FICM, and
remove the FICM and the display.
Refit
1. To replace high configuration entertainment mainframe,
report SN code to TCMP.
4. Program and encode the front infotainment control
module (FICM). Refer to Module Self-learning and
Programming Manual - "Front Information Control
Module (FICM)".
5. After confirming that the FICM can work normally, fix
the display to the FICM, fit 6 screws and tighten them.
6. Fix the FICM assembly to the instrument panel, fit 2
1.0 492
DAB Module Front Door Tweeter
Remove Remove
2. Pull open the DAB module service access under the 2. Remove the A pillar upper trim panel.
driver seat.
3. Loosen the harness clip from the DAB module retaining
3. Loosen the retaining clip and remove the front tweeter.
nut.
4. Remove 2 nuts fixing the DAB module to the body.
Refit
1. Push the tweeter into the A pillar upper trim panel and
ensure the clips are fully engaged.
DAB module.
Refit
1. Connect the harness connector. A Pillar Upper Trim Panel Refit
2. Fix the DAB module to the body, fit 2 nuts and tighten 3. Connect the negative battery cable.
them to TBD, and check the torque.
3. Fix the harness clip to the DAB module retaining nut.
4. Recover the service access.
1.0 493
Front Door Woofer Rear Door Woofer

Remove Remove
2. Remove the front door interior trim panel. 2. Remove the rear door interior trim panel.
Front Door Interior Trim Panel Remove Rear Door Interior Trim Panel Remove
3. Disconnect the harness connector (1) of the woofer. 3. Disconnect the harness connector (1) of the woofer.
4. Remove 3 screws (2) fixing the woofer to the front 4. Remove 3 screws (2) fixing the woofer to the rear door.
door.
5. Remove the rear door woofer.

5. Remove the front door woofer.
Refit
Refit
1. Fix the rear door woofer to the rear door, fit 3 screws,
1. Fix the front door woofer to the front door, fit 3 tighten them to 1–2Nm, and check the torque.
screws, tighten them to 1–2Nm, and check the torque.
2. Connect the harness connector of the woofer.
2. Connect the harness connector of the woofer.
3. Fit the rear door interior trim panel.
Rear Door Interior Trim Panel Refit
Front Door Interior Trim Panel Refit
1.0 494
ECall Speaker Microphone
Remove Remove
2. Remove the driver side lower trim panel. 2. Remove the roof console.
Driver Side Lower Trim Panel Remove 3. Disconnect the harness connector.
3. Remove 2 screws fixing the eCall speaker to the trim 4. Loosen the retaining clip and remove the microphone.
panel, and remove the eCall speaker.
Refit
Refit 1. Fix the microphone to the roof console.
1. Fix the eCall speaker to the trim panel, fit 2 screws 2. Connect the harness connector.
and tighten them. 3. Fit the roof console.
2. Fit the driver side lower trim panel. 4. Connect the negative battery cable.
Driver Side Lower Trim Panel Refit
1.0 495
Communication Module (TBOX) ECall Communication Module

Remove Remove
2. Remove the glove box assembly. 2. Remove the glove box assembly.
Glove Box Assembly Remove Glove Box Assembly Remove
3. Remove 2 bolts (1) fixing the communication module 3. Remove 2 bolts (1) fixing the eCall communication
to the instrument panel beam. module to the instrument panel beam.
4. Disconnect the harness connector (2) of the 4. Disconnect the harness connector (2) of the eCall
communication module and remove the communication communication module and remove the eCall
module. communication module.
Refit Refit
1. Report SN code and ICCID code to TCMP. 1. To replace the eCall communication module, you
2. Connect the harness connector of the communication need to enter the following path "Diagnosis -TAC
module. Q&A -AVN/TBOX/FICM Replacement Inquiry" in
SAIC Self-Service System (SNW) and input relevant
information. It needs to confirm that the status is
4. Program and encode the TBOX. For details, please
submitted.
refer to Module Self-Learning and Programming Manual
2. Connect the harness connector of the eCall
- Communication Module (TBOX).
communication module.
5. Fix the communication module to the instrument panel
beam, fit 2 bolts, tighten them to 7–10Nm, and check
the torque. 4. Programme and encode the eCall TBOX. For details,
please refer to Module Self-Learning and Programming
Manual - ECall Communication Module (ECall TBOX).
5. Fix the eCall communication module to the instrument
panel beam, fit 2 bolts, tighten them to 7–10Nm, and
check the torque.
1.0 496
ECall Switch Communication Module Antenna
Remove Remove
2. Remove the roof console. 2. Remove the instrument panel body assembly.
3. Disconnect the harness connector. Instrument Panel Body Assembly Remove
4. Loosen the retaining clip and remove the eCall switch. 3. Disconnect the harness connector.
4. Remove 4 screws fixing the communication antenna on
the instrument panel, and remove the communication
module antenna.
Refit
1. Fix the eCall switch to the roof console.
3. Fit the roof console.
Refit
1. Fix the communication module antenna to the
instrument panel, fit 4 screws, tighten them to
1.3–1.9Nm, and check the torque.
Instrument Panel Body Assembly Refit

1.0 497
Roof Antenna
Remove
2. Remove the roof trim panel assembly.
Roof Trim Panel Assembly - without Sunroof
Remove
Roof Trim Panel Assembly - with Sunroof Remove

3. Disconnect the harness connector (1) of the roof
antenna.
4. Remove 1 bolt (2) fixing the roof antenna to the body,
and remove the roof antenna.
Refit
1. Fix the roof antenna to the body, fit 1 bolt, tighten it
to 3-4Nm, and check the torque.
2. Connect the harness connector of the roof antenna.

Refit
Roof Trim Panel Assembly - with Sunroof Refit

1.0 498
Displays and Gauges Information and Entertainment
Displays and Gauges
Specifications
Torque
Description Value
Bolt-Clusters to Instrument Panel 1.3–1.9Nm
1.0 499
Information and Entertainment Displays and Gauges
Service Procedures
Instrument Pack
Remove
2. Remove the instrument panel IPK frame assembly.
Instrument Panel IPK Frame Assembly Remove

3. Remove 2 screws fixing the instrument pack to the
instrument panel.

instrument pack.
Refit
3. Program and encode the instrument pack (IPK). Refer
to Module Self-learning and Programming Manual -
"Instrument Pack (IPK)".
4. Fix the instrument pack to the instrument panel, fit 2
screws, tighten them to 1.3–1.9Nm, and check the
torque.
5. Fit the instrument panel IPK frame assembly.
Instrument Panel IPK Frame Assembly Refit
1.0 500
Low Voltage Fusebox Power & Signal
Low Voltage Fusebox
Specifications
Torque
Description Value
Bolt-Front fuse box pedestal to Body 7–10Nm
Nut-Harness to front fuse box 7–10Nm
1.0 501
Power & Signal Low Voltage Fusebox
Service Procedures check the torque.

Front Compartment Fuse Box 5. Fit the fuse box upper cover.
Remove 6. Connect the negative battery cable.
2. Loosen the clips and remove the upper cover of the
front compartment fuse box.
3. Remove 2 nuts fixing the harness and cable to the front
compartment fuse box.
4. Loosen the clip fixing the front compartment fuse box

to the fuse box base and lift the front compartment
fuse box.
5. Disconnect the harness connector, and remove the
front compartment fuse box.
6. Remove 3 nuts fixing the fuse box base to the body and
remove the fuse box base.
Refit
1. Fix the front compartment fuse box base to the body,
fit 3 nuts, tighten them to 7–10Nm, and check the
torque.
2. Connect the harness connector to the back of the front
3. Fix the front compartment fuse box to the fuse box
base with clips.
4. Fix the harness and bracket to the front compartment
fuse box, fit 2 nuts, tighten them to 7–10Nm, and
1.0 502
Battery Fuse Box & Management System Power & Signal
Battery Fuse Box & Management System
Specifications
Torque
Description Value
Nut-Battery positive cable to fuse box 7–10Nm
Nut-Battery positive cable to battery 4–6Nm
Nut-Battery negative cable to body 7–10Nm
Nut-Battery negative cable to EBS 7–10Nm
Bolt-Battery clip to battery tray 19–25Nm
Nut-EBS to clamp 4.5–7.5Nm
Nut-EBS to battery 4.5–7.5Nm
Bolt-Battery tray to body 19–25Nm
Bolt-Battery tray bracket to body 19–25Nm
1.0 503
Power & Signal Battery Fuse Box & Management System
Service Procedures Negative Battery Cable

Positive Battery Cable Remove
Remove Caution: Always use a second ‘locking spanner’ to prevent
1. Disconnect the negative battery cable. damage to the battery sensor.
2. Remove the upper cover of the front compartment 1. Hold the negative battery terminal with an open-end
fuse box. wrench (1) to fix the EBS. Remove 1 nut (2) fixing the
3. Open the cover of the positive terminal, loosen 1 nut negative battery cable to the battery sensor.
(1) fixing the positive battery cable to the terminal, and 2. Remove 1 nut (3) fixing the negative battery cable to
remove the cable. the body.
4. Remove 1 nut (2) fixing the positive battery cable to 3. Loosen the harness clip and remove the negative
the front compartment fuse box, and remove the cable. battery cable.
5. Remove 1 nut (3) fixing the body harness to the positive
battery cable, and remove the harness.
Refit
Caution: Always use a second ‘locking spanner’ to prevent
6. Remove the positive battery cable. damage to the battery sensor.
Refit 1. Fit the harness clip and fix the negative battery cable.
1. Fix the body harness to the positive battery cable, fit 2. Fix the negative battery cable to the body, fit 1 nut,
and tighten 1 nut. tighten it to 7–10Nm, and check the torque.
2. Fix the positive battery cable to the front compartment 3. Hold the negative battery terminal with an open-end
fuse box, fit 1 nut, tighten it to 7–10Nm, and check wrench to fix the EBS, fit the nut fixing the negative
the torque. battery cable to the EBS, tighten it to 7–10Nm, and
3. Fix the positive battery cable to the positive terminal, check the torque.
tighten the nut to 4–6Nm, and check the torque.
4. Fit the cover of the positive terminal.
5. Fit the upper cover of the front compartment fuse box.
1.0 504
Battery Fuse Box & Management System Power & Signal
Battery Battery Sensor
Remove Remove
1. Loosen 1 nut (1) fixing the battery sensor to the Caution: Always use a second ‘locking spanner’ to prevent
negative terminal, and remove the sensor. damage to the battery sensor.
2. Open the cover of the positive battery terminal, loosen 1. Hold the negative battery terminal with an open-end
1 nut (2) fixing the positive battery cable to the battery wrench (1) to fix the EBS.
terminal, and remove the cable.
2. Remove 1 nut (4) fixing the negative battery cable to the
3. Remove the battery bandage. battery sensor, and remove the negative battery cable.
4. Remove 1 bolt (3) fixing the battery retaining plate to 3. Disconnect the harness connector (3) of the battery
the battery tray, and remove the battery retaining plate. sensor.
4. Loosen the nut (2) fixing the battery sensor to the
negative terminal.
5. Remove the battery assembly.

Refit
Caution: Always use a second ‘locking spanner’ to prevent 5. Remove the battery sensor.
damage to the battery sensor. Refit
1. Fix the battery to the battery tray. Caution: Always use a second ‘locking spanner’ to prevent
2. Fix the battery with the retaining plate, fit 1 bolt, damage to the battery sensor.
tighten it to 19–25Nm, and check the torque. 1. Clamp the EBS negative terminal to the negative
3. Fit the battery bandage. battery terminal, and rotate the EBS to the bottom
4. Fix the positive battery cable to the battery terminal, fit and adjust it.
1 nut, tighten it to 4–6Nm, and check the torque. 2. Tighten the negative terminal nut to 4.5–7.5Nm, and
5. Close the cover of the positive battery terminal. check the torque.
6. Fix the EBS to the negative terminal, tighten it to 3. Connect the battery sensor connector.
4.5–7.5Nm, and check the torque. 4. Fit the negative battery cable onto the EBS connecting
7. Perform "Write Battery ID" for the battery sensor. post, hold the negative battery terminal with an
Refer to Module Self-learning and Programming Manual. open-end wrench, fit 1 nut, tighten it to 7–10Nm, and
check the torque.
5. Perform "Write Battery ID" for the battery sensor
(EBS). Refer to Module Self-learning and Programming
Manual.
1.0 505
Power & Signal Battery Fuse Box & Management System
Battery Tray Battery Tray Bracket

Remove Remove
1. Remove the battery. 1. Remove the battery tray.
Battery Remove Battery Tray Remove

2. Remove 5 bolts fixing the battery tray to the battery 2. Remove 3 bolts fixing the battery tray bracket and
tray bracket. bandage to the left front longitudinal beam.
3. Loosen the clip from the battery tray and remove the 3. Loosen the harness clip, and remove the battery tray
battery tray. bracket and bandage.
Refit Refit
1. Arrange the harness to the battery tray and secure it 1. Fix the battery tray bracket and bandage to the left
with clips. front longitudinal beam, fit 3 bolts, tighten them to
2. Fix the battery tray to the body, fit 5 bolts, tighten 19–25Nm, and check the torque.
them to 19–25Nm, and check the torque. 2. Fix the harness clip to the battery tray bracket.
3. Fit the battery assembly. 3. Fit the battery tray.
Battery Refit Battery Tray Refit
1.0 506
Low Voltage Harness Power & Signal
Low Voltage Harness side).
Service Procedures 5. Fit the driver side A pillar lower trim panel.
Instrument Harness A Pillar Lower Trim Panel Refit
Remove
Instrument Panel Body Assembly Refit
2. Remove the instrument panel body assembly.
Instrument Panel Body Assembly Remove
3. Remove the driver side A pillar lower trim panel.
A Pillar Lower Trim Panel Remove
4. Disconnect the connector (1) from the body harness
(drive side).
5. Disconnect the harness connector (2) from the EPS
control unit.
6. Disconnect the harness connector from the

7. Loosen the harness clip, and remove the instrument

panel harness.
Refit
1. Fix the instrument panel harness to the instrument
panel beam, and secure it with clips.
2. Connect the harness connector to the communication
module.
3. Connect the harness connector to the EPS control unit.
4. Connect the connector to the body harness (driver
1.0 507
Power & Signal Low Voltage Harness
Body Harness
Remove
Front Bumper Remove
4. Remove the radiator airflow deflector - upper left.
Radiator Airflow Deflector - Upper Remove
5. Remove the battery tray.
Battery Tray Remove
13. Disconnect the harness connector (1) of the left
6. Remove the front compartment fuse box. headlamp.
Front Compartment Fuse Box Remove 14. Disconnect the harness connector (2) of the front left
7. Disconnect the low voltage harness connector (1) of impact sensor.
the charging port. 15. Disconnect the harness connector (3) of the cooling
8. Disconnect the harness connector (2) of the bonnet fan relay.
lock. 16. Disconnect the harness connector (4) of the cooling
fan motor.
9. Disconnect the harness connector of the forward

detection radar.
17. Remove the A/C air inlet grille.
A/C Air Inlet Grille Assembly Remove

18. Disconnect the harness connector of the front wiper
motor.
10. Disconnect the harness connector (1) of the left horn.

11. Disconnect the harness connector (2) of the electric
vehicle communication controller module assembly.
12. Disconnect the outer ground terminal (3) of the front
left longitudinal beam. 19. Remove the coolant expansion tank.
1.0 508
Coolant Expansion Tank - PEB Remove 32. Disconnect the harness connector (1) of the right horn.
20. Remove the brake modulator. 33. Disconnect the harness connector (2) of the pedestrian
Brake Modulator Remove alert speaker.
21. Disconnect the ground terminal (1) behind the front 34. Disconnect the harness connector (3) of the
compartment fuse box. windscreen washer pump.
22. Disconnect the harness connector (2) of the front left

wheel speed sensor.
23. Disconnect the harness connector (3) of the brake fluid
level sensor.
push rod stroke sensor.
25. Disconnect the harness connector (5) of the vacuum
sensor.
35. Disconnect the harness connector (1) of the A/C

pressure switch.
36. Loosen the ground terminal (2) below the A/C pressure
switch.
26. Loosen the ground terminal on the lower right side of

the brake fluid tank.
27. Disconnect the harness connector (1) of the expansion
valve.
28. Disconnect the harness connector (2) of the battery
chiller.
29. Disconnect the harness connector (3) of the front right
wheel speed sensor. 37. Disconnect the low-voltage harness connector (1) of
the combined charging unit.
38. Open the combined charging unit harness cover (2),
remove 1 bolt fixing the body harness to the combined
charging unit, and remove the body harness.
30. Disconnect the harness connector of the right

headlamp.
31. Disconnect the harness connector of the front right
impact sensor.
1.0 509
39. Disconnect the harness connector of the water drive motor.

temperature sensor.
46. Disconnect the harness connector of the power

40. Disconnect the low-voltage harness connector (1) of electronic box.
the high-voltage PDU.
41. Disconnect the harness connector (2) of the electrical
park motor control module.
47. Disconnect the harness connector (1) of the parking

mechanism.
48. Disconnect the low-voltage harness connector (2) of
42. Remove the bottom deflector assembly. the electric A/C compressor.
Bottom Deflector Assembly Remove

water pump.
vacuum pump.
49. Remove the A/C box assembly.
A/C Box Assembly Remove

50. Remove the carpet.
Carpet Remove
51. Disconnect the harness connector (1) of the passive
45. Disconnect the low-voltage harness connector of the
1.0 510
entry and passive start module.
52. Disconnect the harness connector (2) of the around
view monitor (AVM).
53. Disconnect the harness connector (3) of the gateway.
54. Disconnect the harness connector (4) of the vehicle
control unit.
55. Disconnect 2 ground terminals (5) below the passive
entry and passive start module.
56. Disconnect the body harness from the instrument panel
harness (6) (driver side).
62. Remove the interior rearview mirror base.

63. Disconnect the harness connector (1) of the front view
camera module.
64. Disconnect the harness connector (3) of the top USB
module.
65. Disconnect the harness connector (if equipped) (2) of
the rain sensor.
57. Disconnect the harness connector of the brake pedal

position sensor.
58. Disconnect the harness connector of the accelerator
pedal position sensor.
66. Disconnect the harness connector of the sensing and

diagnostic module.
59. Disconnect the body harness from the driver door

harness.
60. Remove the roof trim panel assembly.

Remove
Roof Trim Panel Assembly - with Sunroof Remove

61. Disconnect the harness connector (if equipped) of the 67. Disconnect the ground terminal behind the sensing and
sunroof motor. diagnostic module.
68. Disconnect harness connector (1) of the pedestrian
alert control module.
1.0 511
69. Loosen the ground terminal (2) above the pedestrian 76. Remove the tail gate interior trim panel.
alert control module.
Tail Lamp Assembly Remove
78. Remove the rear parcel shelf assembly.
Rear Parcel Shelf Assembly Remove

79. Disconnect the harness connector (1) of the rear seat
belt buckle.
80. Disconnect the harness connector (2) of the passive
entry and passive start - trunk.
70. Disconnect the harness connector (1) of the DAB

module.
71. Loosen the ground terminal (2) above the DAB module.
81. Disconnect the harness connector of the top antenna.
72. Disconnect the body harness from the rear door

harnesses on both sides (1).
73. Disconnect the harness connectors (2) from the front
seat belt pretensioners on both sides.
74. Disconnect the harness connectors (3) from the side
impact sensors on both sides.
82. Loosen the ground terminal on the right side of the

top antenna.
83. Disconnect the harness connector of the left rear seat
belt pretensioner.
75. Remove the trunk side trim panel assembly.

Trunk Side Trim Panel Assembly Remove
1.0 512
84. Loosen the ground terminal (1) below the left tail lamp. 92. Disconnect the harness connector (1) from the BCM.
85. Disconnect the harness connectors (2) of the rear 93. Disconnect the harness connector (2) of the eCall
window heating elements on both sides. communication module.
86. Disconnect the harness connectors (3) of the rear 94. Loosen the ground terminal (3) below the BCM.
combination lamps on both sides. 95. Remove 2 bolts (4) fixing the passenger compartment
87. Disconnect the harness connector (4) of the rear wiper fuse box to the body, and remove the harness.
motor.
88. Disconnect the harness connector (5) of the tail gate
release switch.
96. Disconnect the body harness from the passenger door

harness.
97. Remove the rear bumper.
89. Disconnect the harness connector of the tail gate lock. Rear Bumper Remove
90. Disconnect the harness connector (1) of the right rear 98. Disconnect the harness connector of the passive entry
seat belt pretensioner. and passive start - rear bumper antenna.
91. Loosen the ground terminal (2) above the right rear
seat belt pretensioner.
99. Disconnect the harness connector of the backward
1.0 513
drive assistance detection radar on both sides. Refit

1. Arrange the body harness inside the body and secure
it with clips.
2. Connect the low-voltage harness connector of the
high-voltage battery pack.
3. Connect the harness connectors of the rear parking
brakes on both sides.
4. Connect the harness connectors of the rear wheel
speed sensors on both sides.
6. Connect the harness connector of the backward drive
assistance detection radar on both sides.
7. Connect the harness connector of the passive entry
and passive start - rear bumper antenna.
Rear Bumper Refit
101. Disconnect the harness connectors (1) of the rear
wheel speed sensors on both sides. 9. Connect the body harness to the passenger door
harness.
102. Disconnect the harness connectors (2) of the rear
parking brakes on both sides. 10. Fit and tighten 2 bolts fixing the passenger compartment
fuse box to the body.
11. Tighten the ground terminal below the BCM.
12. Connect the harness connector of the eCall
13. Connect the harness connector to the BCM.
14. Tighten the ground terminal above the right rear seat
belt pretensioner.
15. Connect the harness connector of the right rear seat
belt pretensioner.
16. Connect the harness connector of the tail gate lock.
17. Connect the harness connector of the tail gate release
switch.
103. Disconnect the low-voltage harness connector of the
18. Connect the harness connector of the rear wiper
motor.
19. Connect the harness connectors of the rear
combination lamps on both sides.
20. Connect the harness connectors of the rear window
heating elements on both sides.
21. Tighten the ground terminal below the left tail lamp.
22. Connect the harness connector of the left rear seat
belt pretensioner.
23. Tighten the ground terminal on the right side of the
top antenna.
24. Connect the harness connector of the top antenna.
104. Loosen the harness clip, and remove the body harness and passive start - trunk.
assembly. 26. Connect the harness connector of the rear seat belt
buckle.
1.0 514
27. Fit the rear parcel shelf assembly. unit.
Rear Parcel Shelf Assembly Refit 52. Connect the harness connector of the gateway.
28. Fit the tail lamp assembly. 53. Connect the harness connector of the around view
monitor (AVM).
Tail Lamp Assembly Refit
and passive start module.
Tail Gate Interior Trim Panel Refit
55. Fit the carpet.
30. Fit the trunk side trim panel assembly.
Carpet Refit
Trunk Side Trim Panel Assembly Refit
31. Connect the harness connectors of the impact sensors
on both sides.
32. Connect the harness connectors of the front seat belt
electric A/C compressor.
pretensioners on both sides.
58. Connect the harness connector of the parking
33. Connect the body harness to the rear door harnesses
mechanism.
on both sides.
59. Connect the harness connector of the power electronic
34. Tighten the ground terminal above the DAB module.
box.
35. Connect the harness connector of the DAB module.
36. Tighten the ground terminal above the pedestrian alert drive motor.
control module.
61. Connect the harness connector of the electric vacuum
37. Connect the harness connector of the pedestrian alert pump.
control module.
62. Connect the harness connector of the electric water
38. Tighten the ground terminal behind the sensing and pump.
diagnostic module.
39. Connect the harness connector of the airbag control
module.
64. Connect the harness connector of the electrical park
40. Connect the harness connector (if equipped) of the
motor control module.
rain sensor.
41. Connect the harness connector of the top USB module.
high-voltage PDU.
42. Connect the harness connector of the front view
66. Connect the harness connector of the water
camera module.
temperature sensor.
43. Fit the interior rearview mirror base.
67. Fit 1 nut fixing the body harness to the combined
44. Connect the harness connector of the sunroof motor charging unit, tighten it, and close the cover.
(if equipped).
45. Fit the roof trim panel assembly. combined charging unit.
Roof Trim Panel Assembly - without Sunroof 69. Tighten the ground terminal below the A/C pressure
Refit switch.
Roof Trim Panel Assembly - with Sunroof Refit 70. Connect the harness connector of the A/C pressure
46. Connect the body harness to the driver door harness. switch.
47. Connect the harness connector of the accelerator 71. Connect the harness connector of the windscreen
pedal position sensor. washer pump.
48. Connect the harness connector of the brake pedal 72. Connect the harness connector of the pedestrian alert
position sensor. speaker.
49. Connect the body harness to the instrument panel 73. Connect the harness connector of the right horn.
harness (driver side). 74. Connect the harness connector of the front right
50. Tighten 2 ground terminals below the passive entry and impact sensor.
passive start module. 75. Connect the harness connector of the right headlamp.
51. Connect the harness connector of the vehicle control 76. Connect the harness connector of the front right wheel
1.0 515
speed sensor. Front Bumper Refit

77. Connect the harness connector of the battery chiller. 103. Fit the manual service disconnect.
78. Connect the harness connector of the expansion valve. Manual Service Disconnect Refit
79. Tighten the ground terminal of the lower right brake 104. Connect the negative battery cable.
fluid tank.
80. Connect the harness connector of the vacuum sensor.
81. Connect the harness connector of the brake push rod
stroke sensor.
82. Connect the harness connector of the brake fluid level
sensor.
83. Connect the harness connector of the front left wheel
speed sensor.
84. Tighten the ground terminal behind the front
85. Fit the brake modulator.
Brake Modulator Refit
86. Fit the coolant expansion tank.
Coolant Expansion Tank - PEB Refit
87. Connect the harness connector of the front wiper
motor.
88. Fit the A/C air inlet grille assembly.
89. Connect the harness connector of the cooling fan
motor.
90. Connect the harness connector of the cooling fan relay.
91. Connect the harness connector of the left front impact
sensor.
92. Connect the harness connector of the left headlamp.
93. Tighten the outer ground terminal of the front left
longitudinal beam.
94. Connect the harness connector of the electric vehicle
communication controller module assembly.
95. Connect the harness connector of the left horn.
96. Connect the harness connector of the forward
detection radar module.
97. Connect the harness connector of the bonnet lock.
98. Connect the low voltage harness connector of the
charging port.
99. Fit the front compartment fuse box.
Front Compartment Fuse Box Refit
100. Fit the battery tray.
Battery Tray Refit
101. Fit the radiator airflow deflector - upper left.
Radiator Airflow Deflector - Upper Refit
1.0 516
Front Door Harness Front Door Interior Trim Panel Refit
Remove 9. Connect the harness connectors of the front door and
1. Disconnect the negative battery cable. the body, and fit the rubber seal rings.
2. Pry off the rubber seal ring on the body side and 10. Connect the negative battery cable.
disconnect the connector between the front door
harness and the body harness.
3. Remove the front door interior trim panel.
Front Door Interior Trim Panel Remove
4. Tear off the front door waterproof membrane.
5. Disconnect the harness connector (1) of the exterior
rearview mirror.
6. Disconnect the harness connector (2) of the front door
window regulator motor.
7. Disconnect the harness connector (3) of the front
door woofer.
8. Disconnect the harness connector (4) of the front door
handle antenna.
9. Disconnect the harness connector of the front door

lock motor.
10. Loosen the harness clip and remove the front door
harness.
Refit
1. Arrange the front door harness to the door and secure
it with clips.
2. Connect the harness connector of the front door lock
motor.
3. Connect the harness connector of the front door
handle antenna.
woofer.
6. Connect the harness connector of the exterior
rearview mirror.
7. Fit the front door waterproof membrane.
1.0 517
Rear Door Harness Centre Console Harness

Remove Remove
2. Pry off the rubber seal ring on the body side and 2. Remove the centre console assembly.
disconnect the connector between the rear door
harness and the body harness.
3. Disconnect the harness connector (if equipped) (1) of
3. Remove the rear door interior trim panel.
the wireless charging module.
Rear Door Interior Trim Panel Remove 4. Disconnect the harness connector (2) of the passive
4. Tear off the rear door waterproof membrane. entry and passive start - centre console antenna.
5. Disconnect the harness connector (1) of the rear door 5. Disconnect the harness connector (3) of the backup
window regulator motor. antenna.
6. Disconnect the harness connector (2) of the rear door 6. Disconnect the TPMS harness connector (4).
woofer. 7. Disconnect the centre console harness from the USB
charging module harness (5).
7. Disconnect the harness connector of the rear door

lock motor.
8. Loosen the harness clip, and remove the centre console
8. Loosen the harness clip and remove the front door harness.
harness. Refit
Refit
1. Arrange the centre console harness to the centre
1. Arrange the rear door harness to the door and secure console and secure it with clips.
it with clips.
2. Connect the centre console harness to the USB
2. Connect the harness connector of the rear door lock charging module harness.
motor.
3. Connect the harness connector of the TPMS.
3. Connect the harness connector of the rear door
4. Connect the harness connector of the backup antenna.
woofer.
4. Connect the harness connector of the rear door
and passive start - centre console antenna.
6. Connect the harness connector (if equipped) of the
5. Fit the rear door waterproof membrane.
wireless charging module.
6. Fit the rear door interior trim panel.
Rear Door Interior Trim Panel Refit
7. Connect the harness connectors of the rear door and
the body, and fit rubber seal rings.
1.0 518
Driver Seat Harness
Remove
2. Remove the front seat exterior trim panel.
Front Seat Exterior Trim Panel Remove
3. Remove the front seat back cover.
Front Seat Back Cover Remove

4. Disconnect the harness connector of the front seat
adjustment switch.
5. Disconnect the harness connector from the driver seat
upward/downward adjustment motor.
6. Disconnect the harness connector from the front seat
forward/backward adjustment motor.
7. Disconnect the harness connector from the front seat
back adjustment motor.
8. Loosen the harness clip, and remove the seat harness.
Refit
1. Arrange the harness to the seat and secure it with clips.
2. Connect the harness connector to the front seat back
adjustment motor.
3. Connect the harness connector to the front seat
forward/backward adjustment motor.
4. Connect the harness connector to the driver seat
upward/downward adjustment motor.
5. Connect the harness connector of the front seat
adjustment switch.
6. Fit the front seat back cover.
Front Seat Back Cover Refit

7. Fit the front seat exterior trim panel.

1.0 519
Power & Signal Power Socket
Power Socket Refit

Service Procedures 1. Locate the bezel of the power socket to the trim panel,
12V Power Socket and snap it into place.
Remove 2. Clip the power socket into the bezel and snap it into
1. Disconnect the negative battery cable. place.
2. Pry off the clip and remove the upper trim panel. 3. Connect the harness connector behind the power
3. Loosen the clip, pry off the power socket trim panel socket, fit the power socket trim panel, and snap it into
and disconnect the harness connector behind. place.
4. Fix the upper trim panel to the centre console, and
snap it into place.
4. Loosen the clip fixing the power socket to the bezel,

and remove the power socket.
5. Loosen the clip fixing the bezel and remove the bezel
of the power socket.
1.0 520
High Voltage Harness Power & Signal
High Voltage Harness
Specifications
Torque
Description Value
Screw-PDU to body 18–25Nm
Screw-PDU Upper Cover to PDU 5–7Nm
Screw-HV harness and bracket to body 7–10Nm
Nut-HV harness and bracket to body 7–10Nm
Bolt-The PDU bracket to PDU 5–7Nm
1.0 521
Power & Signal High Voltage Harness
Service Procedures 3. Fix the PDU upper cover to the PDU, fit 8 bolts,
High-voltage Power Distribution Unit (PDU) tighten them to 5–7Nm, and check the torque.
Remove 4. Connect the high and low voltage harness connectors.
1. Turn off the start switch, remove key and store safely 5. Fit the harness and pipe clips fixing to the PDU.
at least 2 metres from the vehicle. 6. Fit the manual service disconnect.
Caution: Please wait 5 minutes after the vehicle power Manual Service Disconnect Refit

5. Disconnect the high-voltage harness connector (2).
6. Remove 8 bolts (3) fixing the PDU upper cover to the
PDU, and remove the PDU upper cover.
7. Remove 7 bolts (1) fixing the high-voltage harness to

the PDU, and pull out the high-voltage harness.
8. Remove 4 bolts (2) fixing the PDU to the body, and
remove the PDU assembly.
Refit
1. Fix the PDUassembly to the body, fit 4 bolts, tighten
2. Fix the high voltage harness into the PDU, fit and
tighten 7 bolts.
1.0 522
Combined Charging Unit High-voltage Harness 6. Loosen the clip, and remove the combined charging
Remove unit high-voltage harness.
Warning: Staff that do not hold the necessary high voltage Refit
certification are NOT permitted to dismantle high voltage Warning: Before completing the maintenance of the HV
systems or components (including, ESS. TM, PEB, PDU, system: ESS, Electric Drive Transmission, PEB, PDU, HV
EACP, HV harnesses, CCU, ESS PTC, Charging sockets harness, EACP, Electric Heater, CCU, ESS heater，charge
etc). socket (including all connectors), make sure the negative
Warning: Prior to opening any high voltage circuits the cable of the 12V battery and manual service disconnect
systems MUST be checked using a suitable multi meter switch are disconnected.
to ensure they carry no high voltage current. Where 1. Fix the harness to the bracket and secure it with clips.
there is need to work with the high voltage system 2. Connect the combined charging unit high-voltage
is essential that the correct 'make safe' procedure is harness connector to the PDU.
followed - see Manual Service Disconnect procedure 3. Connect the high-voltage harness connector to the
in the Service Repair manual. After disconnecting the combined charging unit.
systems or components MUST wear the correct insulated 5. Connect the negative battery cable.

connectors.
1. Turn off the start switch, remove key and store safely
at least 2 metres from the vehicle.



4. Disconnect the high-voltage harness connector (1)
5. Disconnect the combined charging unit high-voltage
harness connector (2) from the PDU.
1.0 523
Traction Battery High-voltage Harness

Remove
Warning: Staff that do not hold the necessary high voltage
certification are NOT permitted to dismantle high voltage
systems or components (including, ESS. TM, PEB, PDU,
EACP, HV harnesses, CCU, ESS PTC, Charging sockets
etc).

followed - see Manual Service Disconnect procedure 7. Remove the centre bottom deflector.
in the Service Repair manual. After disconnecting the Bottom Deflector Remove
8. Remove 1 bolt (1) and 1 nut (2) fixing the high-voltage
harness and bracket to the body.
Warning: Any qualified personnel working on high voltage 9. Disconnect the high-voltage harness connector (3)
systems or components MUST wear the correct insulated from the high-voltage battery pack, and remove the
personal protective equipment (PPE). All PPE must be main high-voltage harness.

connectors.


3. Remove the manual service disconnect. Refit
Manual Service Disconnect Remove Warning: Before completing the maintenance of the HV
4. Remove 8 bolts (3) fixing the PDU upper cover to the system: ESS, Electric Drive Transmission, PEB, PDU, HV
PDU, and remove the PDU upper cover. harness, EACP, Electric Heater, CCU, ESS heater，charge
socket (including all connectors), make sure the negative
cable of the 12V battery and manual service disconnect
the PDU, and pull out the high-voltage harness.
switch are disconnected.
1. Arrange the high voltage harness to the underbody and
the body.
the dash panel, and secure it with clips.
2. Fix the high-voltage harness and bracket to the body,
fit 1 bolt and 1 nut, tighten them to 7–10Nm and
7–10Nm respectively, and check the torque.
3. Connect the high voltage harness connector to the
4. Fit the centre bottom deflector.
5. Fix the high-voltage harness to the body, fit 2 bolts,
tighten them to 7–10Nm, and check the torque.
1.0 524
6. Fix the high voltage harness into the PDU, fit and PDU to A/C Compressor to Power Electronic
tighten 3 bolts. Box High-voltage Harness
7. Fix the PDU upper cover to the PDU, fit 8 bolts, Remove
tighten them to 5–7Nm, and check the torque. Warning: Staff that do not hold the necessary high voltage
8. Fit the manual service disconnect. certification are NOT permitted to dismantle high voltage
Manual Service Disconnect Refit EACP, HV harnesses, CCU, ESS PTC, Charging sockets
9. Connect the negative battery cable. etc).



connectors.



4. Remove 8 bolts (3) fixing the PDU upper cover to the
PDU, and remove the PDU upper cover.
5. Disconnect the high-voltage harness connector (1).
1.0 525
6. Remove 2 bolts (2) fixing the high-voltage harness to Heater High-voltage Harness
the PDU, and pull out the high-voltage harness. Remove
7. Remove 1 bolt (3) fixing the high-voltage harness to Warning: Staff that do not hold the necessary high voltage
its bracket. certification are NOT permitted to dismantle high voltage
etc).

8. Loosen the harness clip and remove the high-voltage Warning: Any qualified personnel working on high voltage
harness. systems or components MUST wear the correct insulated
Refit personal protective equipment (PPE). All PPE must be
Warning: Before completing the maintenance of the HV
system: ESS, Electric Drive Transmission, PEB, PDU, HV Caution: When removing or servicing any parts of the
harness, EACP, Electric Heater, CCU, ESS heater，charge high voltage system it is essential that no liquids enter,
socket (including all connectors), make sure the negative contaminate or are spilled on components, harnesses or
cable of the 12V battery and manual service disconnect connectors.
1. Arrange the high-voltage harness to the body and at least 2 metres from the vehicle.
2. Fix the high-voltage harness to its bracket , fit 1 bolt,
tighten it to 7–10Nm, and check the torque.
3. Fix the high voltage harness into the PDU, fit and
tighten 2 bolts. 2. Disconnect the negative battery cable.
4. Connect the high-voltage harness connector. 3. Remove the manual service disconnect.
5. Fix the PDU upper cover to the PDU, fit 8 bolts, Manual Service Disconnect Remove
tighten them to 5–7Nm, and check the torque. 4. Remove the centre console heater closing plate
6. Fit the manual service disconnect. assembly.
Manual Service Disconnect Refit Centre Console Heater Closing Plate Assembly
5. Disconnect the low-voltage harness connector (1) of
the electric heater.
6. Disconnect the high-voltage harness connector (2) of
the electric heater.
1.0 526
7. Disconnect the PTC high-voltage harness connector

from the PDU.
8. Lift the carpet, pry off the rubber ring, loosen the
harness clip, and pull out the PTC high-voltage harness.
Refit
system: ESS, Electric Drive Transmission, PEB, PDU, HV
harness, EACP, Electric Heater, CCU, ESS heater，charge
socket (including all connectors), make sure the negative
cable of the 12V battery and manual service disconnect
1. Arrange the heater high voltage harness to the body
and secure it with clips.
2. Restore the carpet.
3. Connect the heater high-voltage harness connector to
the PDU.
4. Connect the high-voltage harness connector to the
electric heater.
5. Connect the low-voltage harness connector to the
battery heater.
Refit
1.0 527
Heater High-voltage Harness 2

Remove
Warning: Staff that do not hold the necessary high voltage
certification are NOT permitted to dismantle high voltage
etc).

followed - see Manual Service Disconnect procedure 6. Loosen the harness clip and remove the harness from
in the Service Repair manual. After disconnecting the the traction battery electric heater.
Manual Service Disconnect (MSD), always wait 5 minutes Refit
Warning: Any qualified personnel working on high voltage system: ESS, Electric Drive Transmission, PEB, PDU, HV
systems or components MUST wear the correct insulated harness, EACP, Electric Heater, CCU, ESS heater，charge
personal protective equipment (PPE). All PPE must be socket (including all connectors), make sure the negative
regularly checked and tested for condition and integrity. cable of the 12V battery and manual service disconnect
high voltage system it is essential that no liquids enter, 1. Fix the high-voltage harness of the traction battery
contaminate or are spilled on components, harnesses or electric heater to the front compartment and secure
connectors. it with clips.
2. Connect the high-voltage harness connector of the
traction battery electric heater.
3. Connect the high-voltage harness of the traction
battery electric heater at the PDU.

4. Disconnect the harness connector from the traction
battery electric heater at the PDU.
5. Disconnect the high voltage harness connector from

the traction battery electric heater.
1.0 528
Wireless Charging Of Mobile Phone Power & Signal
Wireless Charging Of Mobile Phone
Specifications
Torque
Description Value
Bolt-Wireless Device to Trim 1.4–1.8Nm
1.0 529
Power & Signal Wireless Charging Of Mobile Phone
Service Procedures
Mobile wireless charging module
Remove
1. Disconnect the negative battery.
2. Remove the center control upper trim panel.

3. Pry open the clip and remove the cover of wireless
charging module.
4. Remove the four screws that secure the wireless
charging module to the center console.

wireless charging module.
Refit
1. Fix the wireless charging module of the mobile phone
to the center console, install 4 screws, and tighten
to1.4–1.8Nm，And check the torque.
2. Fix the cover of wireless charging module of mobile
phone to the center console and snap in the clip.
3. Install the center control upper trim panel.

4. Connect the negative battery.
1.0 530
Glossary List
Name Description
BCM Body Control Module

BMS Battery Management System
DTI Dial Test Indicator
EBS Electrical Battery Sensor
ECU Electronic Control Unit
EPS Electric Power Steering
ESCL Electronic steering column
lock
ESS Energy Storage System
HSLA High Strength Low Alloy
ICS Inflatable Curtain Structure
IPK Instruments Pack Kit
PDU Power Distribution Unit
PEB Power Electrical Box
PEPS Passive Entry Passive Start
PVC Polyvinyl Chloride
SDM Sensing Diagnostic Module
SRS Supplementary Restraint
System
TBOX Telematics BOX
VCU Vehicle Control Unit
VDS Vehicle Diagnostic System
VIN Vehicle Identification
Number
1.0 531

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SAIC Motor Passenger Vehicle Co.

All Rights Reserved.

Information is due in June, 2021.

The meanings of "Warning", "Note" and "Prompt" are as Dimensions

Special attention should be taken to the followings which are

• Use of other components rather than those

All components recommended by SMC shall share the rights

SMC dealers should only provide SMC recommended

Some operations herein cannot be performed without relevant

The special tools herein can be available from the supplier

Shanghai Runyue Industrial Development Co., Ltd

Address: Skirt Building, Lianhua Building, 159 Tianzhou Road,

Zip Code: 200233

Should any material be in a burnt or overheated condition,

Decontaminate and dispose of gloves immediately after use.

Ensure the lift is standing on level ground during lifting or

Apply the parking brake and fit wedges to secure wheels.

Warning: Do not work on or under a vehicle supported

Do not leave tools, lifting equipment, spilt oil, etc. around or

Always keep a clean and tidy work area.

• Apply two spanners to loosen or tighten brake pipes/tube

They must also be segregated into different types of waste

Dispose of waste in accordance with the following guidelines:

• Hydraulic fluid, anti-freeze and lubricating oil: keep

• Blow out all tapped holes, crevices, oilways and fluid

• Carefully examine seal before fitting to ensure that it is

• Grease outside diameter of seal, place square to housing

• Always use the correct gaskets as specified. Tab Washers

Damaged nuts, bolts and screws must always be discarded.

Always ensure that replacement bolts are at least equal in

Castellated nuts must not be loosened to accept a split-pin,

Do not allow oil or grease to enter blind threaded holes. The

Encapsulated bolts and screws have a microencapsulated

Unless a specific repair procedure states otherwise,

• Remove loose adhesive from the bolt and housing

Where bearing preload is involved, nuts should be tightened in

Self-locking bolts and screws, i.e. nylon patched or trilobular

Nylon patched bolts and screws have a locking agent

DO NOT fit non self-locking fasteners in applications where a

A nut with an ISO metric thread is marked on one face or on

• Clean end fittings and the area surrounding them as

Clean hose externally and blow through with airline.

• Absolute cleanliness must be observed with hydraulic Hose Clip

After any work on hydraulic systems, carefully inspect

Markings (1) are usually provided on the hose to indicate the

• Always ensure electrically related items are dry and oil

Having confirmed a component to be faulty:

• off the START/STOP Switch and disconnect the battery.

Caution: Ensure SRS components are not contaminated

Caution: Torque wrenches should be regularly checked for

Caution: Following seat belt pretensioner deployment,

Warning: Store the airbag module with the deployment

Caution: Do not apply grease or cleaning solvents to seat

• Never attempt to modify, splice or repair SRS wiring.

Modifying the vehicle structure or SRS system is strictly not

Never fit any accessory that obstructs or impairs the operation

Do not place any object on the steering wheel or instrument

A The need for caution when working in close proximity to

Side (Thorax) Airbags • ‘B' post upper finisher and fixings