AS22 Service Manual en 20180112（归档版）

Service Manual
MG RX5
This manual provides information on the specifications, the system introduction, the service procedures and the
adjustments for the MG RX5 Vehicle.
The technicians, worked for the servicing station authorized by SAIC Motor Passenger Vehicle Co., Ltd., can provide
better service for the owners of MG RX5 vehicle based on a profound understanding this manual and related updated
Service Bulletins.
You are suggested that please contact SAIC Motor Passenger Vehicle Co., Ltd., if you want to obtain related information
mentioned in this manual about the brand, the parts number, and special tools etc.
SAIC Motor Passenger Vehicle Co., Ltd.
Copy Right Reserved
All information received cutoff date is March 2017.
Any information contained in this manual are the property of the SAIC Motor Passenger Vehicle Co., Ltd.. No part of
this manual may be copied, stored in any retrieval system, or spread by any means (including but not limited in electronic,
mechanical, photocopying and recording) without written SMC authorization. This applies to all text, illustrations, and
tables (not limited in above) mentioned in this manual.
How To Use This Manual NOTE statements emphasize a necessary characteristic of
General a diagnostic or repair procedure. NOTE statements are
designed to do the following:
To assist in the use of this Manual, it is divided into sections
and sub-sections. The relevant sub-section title is given at the • Clarify a procedure.
header of each page. • Present additional information for accomplishing a
procedure.
There is a single Contents section at the front of the Manual,
which is divided by section and sub-section. The book is • Give insight into the reason or reasons for performing a
numbered from page 1. The page number is given at the procedure in the manner recommended.
bottom of each page. • Present information that will help to accomplish a
procedure in a more effective manner.
The individual actions of the repair operations must be
followed in the sequence in which they appear. Item numbers • Present information that gives the technician the benefit
in the illustrations refer to the relevant numbered text under of past experience in accomplishing a procedure with
the illustration. greater ease.
Adjustment and repair operations include reference to Service TIP: Gives helpful information.
tool numbers and the associated illustration depicts the tool in References
use. Adjustment and repair operations also include reference
References to the LH or RH side given in this Manual are made
to wear limits, relevant data, torque figures, and specialist
when viewing the vehicle from the rear. With the engine and
information and useful assembly details. Each adjustment or
gearbox assembly removed, the crankshaft pulley end of the
repair operation is given a unique Repair Operation number.
engine is referred to as the front.
WARNINGS, CAUTIONS, NOTES and TIPS have the
Operations covered in this Manual do not include reference
following meanings:
to testing the vehicle after repair. It is essential that work
When encountering a WARNING, you will be asked to take is inspected and tested after completion and if necessary a
a necessary action or not to take a prohibited action. If a road test of the vehicle is carried out. This is of particular
WARNING is not heeded, the following consequences may importance where safety related items are concerned.
occur: Dimensions
• Serious bodily injury or death to the technician.
The dimensions quoted are to design engineering specification.
• Serious bodily injury or death to other technicians in the Service limits are included where applicable.
workplace area.
Our company are constantly seeking to improve the
• Serious bodily injury to the driver and/or passenger(s) of
specification, design and production of their vehicles and
the vehicle, if the vehicle has been improperly repaired.
alterations take place accordingly. While every effort has been
CAUTION call special attention to a necessary action or to a made to ensure the accuracy of this Manual, it should not be
prohibited action. If a CAUTION is not heeded, the following regarded as an infallible guide to current specifications of any
consequences may occur: particular vehicle.
• Damage to the vehicle.
• Unnecessary vehicle repairs.
• Unnecessary component replacement.
• Improper operation or performance of the system or
component under repair.
• Damage to any systems or components which are
dependent upon the proper operation of the system or
component under repair.
• Improper operation or performance of any systems
or components which are dependent upon the proper
operation or performance of the system or component
under repair.
• Damage to fasteners, basic tools, or special tools.
• The leakage of coolant, lubricant, or other vital fluids.
1.0 1
Repairs and Replacements
Parts
When replacement parts are required it is essential that only
our company’s recommended parts are used.
Attention is particularly drawn to the following points

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

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

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

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

Shanghai
Post Code: 200233
Tel: 021-54234810
1.0 2
Contents
General Information ........................... 1 Intake/Exhaust Phase Modulator.................... 67
General Information .............................................1 Oil-gas Separator ......................................... 68
General Precautions ........................................... 1 Cylinder Head Check ................................... 69
Safety Instructions .............................................. 2 Crankshaft Check......................................... 73
Environmental Precautions.................................. 3 Connecting Rod Bearing Shell Check............. 76
General Fitting Instructions................................. 5 Piston Check................................................ 78
Ball and Roller Bearings ...................................... 6 Rear Crankshaft Oil Seal ............................... 80
Oil Seals ............................................................ 7 Front Crankshaft Oil Seal.............................. 81
Joints and Joint Faces .......................................... 8 Flywheel - Dual Clutch Automatic
Transmission ................................................ 81
Locking Devices ................................................. 8
Valve............................................................ 82
Screw Threads ................................................... 9
Valve Hydraulic Tappet Assembly................... 85
Fasteners Identification....................................... 9
Camshaft Cover ........................................... 86
Flexible Pipes and Hoses................................... 11
Camshaft - Intake or Exhaust ........................ 89
Fuel Handling Precautions................................. 12
Intake Manifold Gasket.................................. 90
Electrical Precautions ....................................... 13
Exhaust Manifold Gasket ............................... 92
Supplementary Restraint System
Precautions...................................................... 14 Oil Pump ..................................................... 93
SRS Component Replacement Policy................. 20 Engine Oil and Oil Filter................................ 94
Air Conditioning System Precautions ................ 21 Engine Oil Pressure Check............................ 95
Air Conditioning Compressor Oil Strainer .................................................. 96
Replacement .................................................... 23 Oil Pan......................................................... 96
Lifting & Towing...................................................24 Lower Crankcase ......................................... 97
Lifting Vehicle................................................... 24 Front Timing Cover ...................................... 99
Roadside Assistance ......................................... 25 Engine Timing Chain ................................... 102
Vehicle Identification Number ...........................26 Crankshaft Torsional Vibration
Vehicle Identification Number........................... 26 Damper ..................................................... 104
Position of Other Plates ................................... 27 Right Hydraulic Engine Suspension............... 105
Lubrication & Maintenance ................................28 Engine and Dual Clutch Automatic
Transmission .............................................. 106
Capacity .......................................................... 28
Cylinder Gasket ......................................... 110
Fluid ................................................................ 28
Turbocharger ............................................. 112
Lubricating Fluids ............................................. 29
Turbocharger Coolant Outlet Pipe .............. 115
Engine................................................. 31 Turbocharger Coolant Inlet Pipe.................. 116
Engine mechanical system-2.0T.........................31 Turbocharger Oil Return Pipe ..................... 118
Specifications ................................................... 31 Turbocharger Air Intake Hose..................... 119
Torque ......................................................... 31 Turbocharger Oil Inlet Pipe ......................... 119
Parameter .................................................... 34 Electronic Throttle Intake Pipe .................... 120
Description and Operation............................... 41 Intercooler Air Inlet Hose........................... 121
System Layout .............................................. 41 Oil Filter Module ........................................ 122
Description .................................................. 61 Special Tools .................................................. 123
Operation .................................................... 63 Engine mechanical system-1.5T.......................125
Service Procedures........................................... 65 Specifications ................................................. 125
Mechanical Vacuum Pump ............................. 65 Torque ....................................................... 125
Oil Control Valve ......................................... 65 Parameter .................................................. 127
CVVT Cover ................................................ 66 Description and Operation............................. 132
Thermostat Housing..................................... 66 System Layout ............................................ 132
1.0 1
Contents
Description ................................................ 149 Front Timing Cover .................................... 193
Operation .................................................. 151 Intake and Exhaust Valves............................ 194
Diagnostic...................................................... 153 Timing Chain.............................................. 195
Symptom - Engine Mechanical System........... 153 Camshaft Phase Regulation Actuator ........... 197
Engine Misfire Without Internal Timing Chain Tensioner .............................. 198
Noise......................................................... 154 Crankshaft Sprocket ................................... 198
Engine Misfire and Abnormal Noise Found Camshaft.................................................... 199
Below Internal Engine ................................. 156
Hydraulic Tappets ....................................... 200
Engine Misfire and Abnormal Noise Found
in Valve System........................................... 157 Intake Manifold ........................................... 201
Engine Misfire with Coolant Piston ........................................................ 202
Consumption ............................................. 158 Connecting Rod ......................................... 203
Engine Misfire With Excessive Oil Oil Pump ................................................... 205
Consumption ............................................. 159 Engine Oil Strainer ..................................... 206
Engine Noise at Start-up, but Only Lasting Front Crankshaft Oil Seal............................ 206
a Few Seconds............................................ 160
Rear Crankshaft Oil Seal ............................. 207
Upper Engine Noise, Regardless of Engine
Speed......................................................... 161 Vacuum Pump ............................................ 207
Lower Engine Noise, Regardless of Engine Seal-Vacuum Pump ..................................... 208
Speed......................................................... 162 Turbocharger ............................................. 209
Engine Noise Under Load ........................... 163 Turbocharger Fuel Inlet Pipe ....................... 210
Engine Unable to Start - Crankshaft Not Turbocharger Oil Return Pipe ..................... 211
Rotate ....................................................... 164 Turbocharger Water Inlet Pipe .................... 212
Ingress of Coolant into Combustion Turbocharger Water Return Pipe ................ 212
Chamber.................................................... 165
Water Outlet Assembly .............................. 213
Ingress of Coolant into Engine Oil ............... 166
Oil Cooler ................................................. 214
Engine Compression Pressure Test .............. 167
Cylinder Head Check ................................. 214
Cylinder Leak Test...................................... 167
Valve Mechanism Check.............................. 219
Oil Consumption Diagnosis ........................ 169
Piston Connecting Rod Check..................... 222
Engine Oil Pressure Diagnosis and
Test ........................................................... 170 Cylinder Block Check ................................. 225
Engine Oil Leak Diagnosis ........................... 171 Crankshaft Check....................................... 227
Crankcase Ventilation System Engine Oil Filter ......................................... 230
Inspection/Diagnosis ................................... 173 Special Tools .................................................. 231
Service Procedures......................................... 174 Engine Cooling System .....................................233
Powertrain Disassembly and Assembly - Specifications ................................................. 233
MT ............................................................ 174 Torque ....................................................... 233
Powertrain Disassembly and Assembly - Parameters................................................. 234
AT ............................................................. 177
Description and Operation............................. 236
Powertrain Mount ...................................... 180
System Layout ............................................ 236
Flywheel - MT ............................................ 181
Description ................................................ 242
Flywheel - AT ............................................. 182
Operation .................................................. 244
Cylinder Head ............................................ 183
Service Procedures-2.0T................................. 248
Cylinder Block............................................ 184
Coolant - Drain and Refill ........................... 248
Crankshaft ................................................. 185
Expansion Tank Cap - Pressure Test............. 249
Lower Crankcase ....................................... 187
System Pressure Test .................................. 250
Oil Pan....................................................... 189
Coolant Expansion Tank.............................. 251
Camshaft Cover ......................................... 191
Radiator Inlet Pipe ...................................... 252
Crankshaft Vibration Damper ..................... 192
2 1.0
Contents
Radiator Outlet Pipe................................... 252 Mechanical Water Pump ............................. 282
Heater Water Inlet Pipe.............................. 253 Special Tools .................................................. 284
Heater Water Outlet Pipe .......................... 254 Engine Fuel & Management System................285
Expansion Water Tank Outlet Pipe.............. 254 Specifications ................................................. 285
Engine Overflow Pipe A .............................. 255 Torque ....................................................... 285
Engine Overflow Pipe B .............................. 256 Description and Operation............................. 286
Cooling Fan Assembly................................. 256 System Layout ............................................ 286
Cooling Fan Low Speed Resistance.............. 257 Description ................................................ 287
Radiator Assembly...................................... 258 Service Procedures......................................... 288
Intercooler................................................. 259 Canister..................................................... 288
Radiator Airflow Deflector - Upper Underfloor Fuel Pipe - 2.0T ........................ 288
Left............................................................ 261 Underfloor Fuel Pipe-1.5T .......................... 289
Radiator Airflow Deflector - Lower Rubber Fuel Pipe ........................................ 291
Left............................................................ 261
Fuel Tank Heat Shield - AWD...................... 291
Radiator Airflow Deflector - Upper
Right.......................................................... 262 Fuel Tank - 2WD........................................ 292
Radiator Airflow Deflector - Lower Fuel Tank - AWD........................................ 293
Right.......................................................... 262 Fuel Pump - 2WD ...................................... 294
Transmission Outlet Hose........................... 263 Fuel Pump - AWD ...................................... 295
Transmission Inlet Hose .............................. 264 Fuel System - Pressure Release - 2.0T........... 296
Thermostat ................................................ 265 Fuel System - Pressure Release-1.5T............ 297
Clutch Water Pump.................................... 266 Fuel System - Pressure Test - 2.0T............... 297
Electronic Auxiliary Pump ........................... 267 Fuel System - Pressure Test - 1.5T............... 298
Service Procedures-1.5T................................. 268 Fuel Tank - Drain........................................ 299
Coolant - Drain and Refill ........................... 268 Fuel Tank Filler Pipe.................................... 299
Expansion Tank Cap - Pressure Test............. 269 Fuel Filter................................................... 300
System Pressure Test .................................. 270 Special Tools .................................................. 301
Coolant Expansion Tank.............................. 271 Engine Control System-2.0T ............................302
Radiator Inlet Pipe ...................................... 272 Specifications ................................................. 302
Radiator Outlet Pipe................................... 272 Torque ....................................................... 302
Heater Water Inlet Pipe.............................. 273 Description and Operation............................. 303
Heater Water Outlet Hose......................... 274 System Layout ............................................ 303
Engine Overflow Pipe ................................. 275 System Control Diagram............................. 304
Radiator Overflow Pipe .............................. 275 Description ................................................ 306
Cooling Fan Assembly................................. 276 Service Procedures......................................... 324
Coolant Fan Low Speed Resistor................. 277 Spark Plug .................................................. 324
Radiator Assembly...................................... 277 Ignition Coil ............................................... 324
1.5T Intercooler ......................................... 278 Engine Control Module (ECM) .................... 325
Radiator Airflow Deflector - Upper ECT Sensor................................................ 326
Left............................................................ 279 Intake Camshaft Position Sensor.................. 326
Radiator Airflow Deflector - Lower Exhaust Camshaft Position Sensor ............... 327
Left............................................................ 280
Oil Pressure Switch .................................... 327
Radiator Airflow Deflector - Upper
Right.......................................................... 280 Hot Film Meter (HFM)................................ 328
Radiator Airflow Deflector - Lower High-pressure Fuel Pump ............................ 328
Right.......................................................... 281 Fuel Rail Pressure Sensor ............................ 330
Thermostat ................................................ 281 Crankshaft Position Sensor ......................... 330
1.0 3
Contents
Intake Air Temperature/Manifold Absolute System Layout ............................................ 372
Pressure Sensor.......................................... 331 System Control Diagram............................. 373
Manifold Absolute Pressure/Temperature Description ................................................ 375
Sensor ....................................................... 331
Operation .................................................. 378
Knock Sensor............................................. 332
Service Procedures......................................... 379
Heated Oxygen Sensor - Front ................... 332
Alternator.................................................. 379
Heated Oxygen Sensor - Rear..................... 333
Auxiliary Drive Belt .................................... 380
Turbocharger Solenoid Valve ....................... 333
Starter Motor ............................................ 381
Fuel Rail ..................................................... 334
Automatic Tensioning Wheel - Auxiliary
Injector ...................................................... 335 Drive Belt .................................................. 381
Canister Solenoid ....................................... 336 Battery Negative Cable............................... 382
Special Tools .................................................. 337 Battery Positive Cable................................. 382
Engine Control System-1.5T ............................338 Battery....................................................... 383
Specifications ................................................. 338 Battery Sensor ........................................... 384
Torque ....................................................... 338 Special Tools .................................................. 385
Parameter .................................................. 339 Engine Electrical System-1.5T .........................386
Description and Operation............................. 342 Specifications ................................................. 386
System Layout ............................................ 342 Torque ....................................................... 386
System Control Diagram............................. 345 Description and Operation............................. 387
Description ................................................ 347 System Layout ............................................ 387
Service Procedures......................................... 358 Description ................................................ 388
Fuel Pump .................................................. 358 Operation .................................................. 390
Fuel Rail ..................................................... 359 Service Procedures......................................... 392
Fuel Injector............................................... 360 Alternator.................................................. 392
Spark Plug .................................................. 360 Starter Motor ............................................ 392
Engine Control Module (ECM) .................... 361 Auxiliary Drive Belt .................................... 393
Ignition Coil ............................................... 362 Auxiliary Drive Belt Tensioner..................... 393
Crankshaft Position Sensor ......................... 362 Engine Accessory Belt Abnormal Noise
Engine Coolant Temperature Sensor............ 363 Diagnosis ................................................... 393
Manifold Absolute Pressure Sensor.............. 363 Engine Accessory Belt Vibration
Camshaft Position Sensor ........................... 364 Diagnosis ................................................... 397
Camshaft Phase Adjustment Solenoid Accessory Belt Failure Diagnosis ................. 399
Valve.......................................................... 364 Drive Belt Tensioner Diagnosis.................... 400
Oil Pressure Sensor .................................... 365 Battery Negative Cable............................... 401
Knock Sensor............................................. 365 Battery Positive Cable................................. 402
Oxygen Sensor........................................... 366 Battery....................................................... 403
Canister Solenoid ....................................... 367 Engine Manifold & Exhaust
Turbocharger Electrically Controlled System-2.0T .......................................................404
Bypass Valve ............................................... 367 Specifications ................................................. 404
Turbocharger Relief Valve ........................... 368 Torque ....................................................... 404
Intake Air Temperature and Pressure Description and Operation............................. 405
Sensor ....................................................... 369 System Layout ............................................ 405
Special Tools .................................................. 370 Description ................................................ 408
Engine Electrical System-2.0T .........................371 Operation .................................................. 409
Specifications ................................................. 371 Service Procedures......................................... 410
Torque ....................................................... 371 Electronic Throttle Self-learning - UMC
Description and Operation............................. 372 System ....................................................... 410
4 1.0
Contents
Electronic Throttle - with Parking Cable Inspection and Adjustment -
Adjustment ................................................ 410 Dual Clutch Automatic Transmission ........... 439
Air Filter Assembly ..................................... 411 Gear Indicator............................................ 440
Air Filter Element ....................................... 412 Shift Lock Control-7 Speed Auto ....................441
Rear Muffler Assembly................................ 412 Specifications ................................................. 441
Catalytic Converter .................................... 413 Torque ....................................................... 441
Front Exhaust Pipe...................................... 414 Description and Operation............................. 442
Heat Shield - Rear Muffler........................... 415 System Layout ............................................ 442
Heat Shield - Exhaust Passage ..................... 415 Description ................................................ 443
Engine Manifold & Exhaust Service Procedures......................................... 444
System-1.5T .......................................................416 Shift Lever Knob......................................... 444
Specifications ................................................. 416 Shift Operating Control Mechanism
Torque ....................................................... 416 Assembly ................................................... 445
Description and Operation............................. 417 Gear Display .............................................. 446
System Layout ............................................ 417 Gear Cable ................................................ 447
Description ................................................ 420 Shift Lock Control-6MT....................................448
Operation .................................................. 421 Specifications ................................................. 448
Service Procedures......................................... 422 Torque ....................................................... 448
Electronic Throttle Self-learning - UMC Description and Operation............................. 449
System ....................................................... 422 System Layout ............................................ 449
Air Filter Assembly ..................................... 422 Service Procedures......................................... 450
Air Filter Element ....................................... 423 Shift Lever Knob and Sleeve Assembly -
Electronic Throttle ..................................... 423 Manual ...................................................... 450
Rear Muffler Assembly................................ 424 Shift Lever Assembly - Manual .................... 450
Three-way Catalytic Converter ................... 424 DCT360-6 Speed Auto......................................452
Front Exhaust Pipe...................................... 426 Specifications ................................................. 452
Heat Shield - Rear Muffler Assembly............ 427 Torque ....................................................... 452
Heat Shield - Exhaust Passage...................... 427 Parameters................................................. 453
Hose - Turbocharger to Intercooler ............ 428 Description and Operation............................. 454
Hose - Turbocharger Intercooler to System Layout ............................................ 454
Throttle Body ............................................ 428 System Control Diagram............................. 462
Transmission .................................... 431 Description ................................................ 465
Operation .................................................. 478
Shift Lock Control-6 Speed Auto ....................431
Specifications ................................................. 431
Dual Clutch Automatic Transmission ........... 488
Torque ....................................................... 431
TCM - Dual Clutch Automatic
Description and Operation............................. 432 Transmission .............................................. 491
System Layout ............................................ 432 Dual Clutch Automatic Transmission Fluid
Description ................................................ 433 - Drain and Refill ........................................ 491
Operation .................................................. 436 Dual Clutch Automatic Transmission Fluid
Service Procedures......................................... 437 - Fluid Level Check and Refill ...................... 492
Shift Lever Knob and Gear Display Panel - Differential Oil Seal - Transmission
Dual Clutch Automatic Transmission ........... 437 Housing ..................................................... 494
Shifter Assembly - Dual Clutch Automatic Differential Oil Seal -Clutch Housing ........... 494
Transmission .............................................. 438 Pressure Filter ............................................ 495
Shift Lever P Gear Emergency Unlocking - Parking Brake Cable Bracket ....................... 496
1.0 5
Contents
Parking Brake Cable Shaft Rocker Transmission Bearing Adjustive Shims
Arm........................................................... 496 Selection .................................................... 577
Oil Seal - Parking Brake Cable Shaft ............ 497 Transmission Failure Diagnosis .................... 580
Reverse Gear Shaft Sealing Cap ................... 498 Special Tools .................................................. 587
Special Tools .................................................. 499 Transmission-6MT .............................................591
DCT250-7 Speed Auto......................................500 Specifications ................................................. 591
Specifications ................................................. 500 Torque ....................................................... 591
Torque ....................................................... 500 Parameter .................................................. 592
Parameter .................................................. 501 Description and Operation............................. 594
Description and Operation............................. 502 System Layout ............................................ 594
System Layout ............................................ 502 Description ................................................ 602
System Control Diagram............................. 518 Operation .................................................. 604
Description ................................................ 519 Service Procedures......................................... 613
Operation .................................................. 527 Manual Transmission Assembly.................... 613
Service Procedures......................................... 547 Gear Shift Control Mechanism
Dry Dual-clutch Automatic Transmission Assembly ................................................... 615
Fluid - Drain and Refill ................................ 547 Manual Transmission Fluid - Drain and
Dry Dual Clutch Automatic Transmission Refill .......................................................... 617
Fluid - Check and Refill ............................... 548 Reverse Lamp Switch - Manual .................... 618
Dry Dual Clutch Automatic Transmission Left Differential Oil Seal - Manual ................ 618
Assembly ................................................... 550 Right Differential Oil Seal - Manual .............. 619
Dry Dual Clutch Automatic Transmission Manual Transmission Remove...................... 619
Harness ..................................................... 553
Differential Assembly .................................. 622
Transmission Control Module (TCM) - Dry
Dual Clutch Automatic Transmission ........... 554 Transmission Accessories and Release
Mechanism ................................................. 623
Transmission Electro-Hydraulic Control
Assembly ................................................... 555 Input Shaft Assembly................................... 625
Fork Position Sensor Assembly ................... 558 Output Shaft Assembly 1 ............................ 626
Input Speed Sensor Assembly...................... 558 Output Shaft Assembly 2 ............................ 629
Transmission Electro-Hydraulic Control Reverse Idler Shaft Assembly....................... 631
Assembly Harness ...................................... 559 Neutral Position Sensor .............................. 632
Dual Clutch Assembly - Dry Dual Clutch Special Tools .................................................. 633
Automatic Transmission.............................. 559 Cluth-6MT..........................................................635
Clutch Actuator Cylinder Assembly - Dry Specifications ................................................. 635
Torque ....................................................... 635
Shift Shaft Oil Seal - Transmission
Housing ..................................................... 563 Parameter .................................................. 636
Input Shaft Housing Oil Seal - Clutch Description and Operation............................. 637
Housing ..................................................... 564 System Layout ............................................ 637
Differential Oil Seal - Transmission Description ................................................ 638
Housing ..................................................... 564 Operation .................................................. 640
Differential Oil Seal - Clutch Housing........... 565 Service Procedures......................................... 641
Dry Dual Clutch Automatic Transmission Clutch Assembly......................................... 641
Disassembly ............................................... 566
Clutch Central Release Cylinder ................. 643
246R Input Shaft Oil Seal ............................ 573
Clutch Pipeline System Bleeding .................. 644
Input Shaft Assembly Disassembly ............... 574
Clutch Master Cylinder............................... 644
1267 Output Shaft Assembly ....................... 575
Special Tools .................................................. 646
345R Output Shaft Assembly ...................... 576
Power Transfer Unit -AWD ..............................647
Differential Assembly .................................. 576
6 1.0
Contents
Specifications ................................................. 647 Service Procedures......................................... 687
Torque ....................................................... 647 Refrigerant Recovery and Refill ................... 687
Parameters................................................. 648 Whether the Refrigerant Refilling is
Description and Operation............................. 649 Successful................................................... 688
System Layout ............................................ 649 Compressor............................................... 689
Description ................................................ 651 Compressor–1.5T ...................................... 690
Operation .................................................. 653 Compressor Bracket-1.5T........................... 691
Service Procedures......................................... 654 Evaporator ................................................. 691
PTU Assembly............................................ 654 Expansion Valve.......................................... 692
Right Oil Seal - PTU Assembly .................... 655 Condenser ................................................. 692
O Ring - PTU Assembly .............................. 656 A/C Pressure Sensor .................................. 693
Drain and Refill .......................................... 656 A/C Pipeline -
Compressor/Condenser ............................. 694
PTU Assembly Oil Check and Refill ............ 657
A/C Pipe A - Evaporator Compressor........... 695
Breather Plug ............................................. 657
A/C Pipe B - Evaporator Compressor........... 696
Special Tools .................................................. 658
A/C Filter Cover ........................................ 697
Final Drive Unit-AWD ......................................659
A/C Filter Element...................................... 698
Specifications ................................................. 659
A/C Box Assembly ..................................... 698
Torque ....................................................... 659
Blower....................................................... 699
Parameters................................................. 660
Heater Core .............................................. 700
Blower Speed Regulation Resistance............ 701
System Layout ............................................ 661
Left Floor Air Outlet Duct.......................... 701
System Control Diagram............................. 663
Right Floor Air Outlet Duct........................ 702
Description ................................................ 664
Left Body Relief Valve ................................. 702
Operation .................................................. 666
Right Body Relief Valve ............................... 703
Instrument Panel Vent for Air Distribution
Rear Axle Assembly.................................... 669 to Face....................................................... 703
Torque Control .......................................... 670 Left Instrument Panel Duct for
Harness - Torque Control .......................... 671 Defrost ...................................................... 704
FDU Input Shaft Oil Seal............................. 671 Right Instrument Panel Duct for
4WD Control Module (TCCM) .................. 672 Defrost ...................................................... 704
Right Oil Seal - Rear Axle Assembly ............ 673 Central Instrument Panel Duct for
Defrost ...................................................... 705
Left Oil Seal - Rear Axle Assembly .............. 673
HVAC System-ATC...........................................706
Drain and Refill - Rear Axle ........................ 674
Specifications ................................................. 706
FDUFluid Check and Refill.......................... 674
Torque ....................................................... 706
Breather Plug ............................................. 675
Special Tools .................................................. 676
System Layout ............................................ 707
HVAC System.................................. 677 System Control Diagram............................. 709
HVAC System....................................................677 Description ................................................ 710
Specifications ................................................. 677 Operation .................................................. 713
Torque ....................................................... 677 Service Procedures......................................... 715
Parameters................................................. 678 A/C Controller Assembly ........................... 715
Description and Operation............................. 679 A/C Panel................................................... 715
System Layout ............................................ 679 Evaporator Core Temperature
Sensor ....................................................... 716
Description ................................................ 681
Solar Sensor............................................... 716
Operation .................................................. 685
1.0 7
Contents
Exterior Ambient Temperature Specifications ................................................. 747
Sensor ....................................................... 717 Torque ....................................................... 747
Interior Ambient Temperature Parameter .................................................. 748
Sensor ....................................................... 717
Face Vent Temperature Sensor .................... 718
Description ................................................ 749
Feet Vent Temperature Sensor .................... 718
Blend Damper Servo Motor - Left ............... 719
Four-wheel Alignment................................. 752
Blend Damper Servo Motor - Right ............ 719
Front Suspension ...............................................754
Recirculation Damper Servo Motor............. 720
Specifications ................................................. 754
Mode Damper Servo Motor........................ 720
Torque ....................................................... 754
HVAC System-ETC...........................................721
Parameter .................................................. 754
System Layout ............................................ 721
System Layout ............................................ 755
Description ................................................ 758
Description ................................................ 724
Operation .................................................. 726
Front Lower Swing Arm Assembly .............. 760
Steering System .............................. 729 Front Lower Swing Arm Outer Ball
Joint........................................................... 761
Front Wheel Steering .......................................729
Front Lower Swing Arm Rear Bush ............. 761
Specifications ................................................. 729
Front Shock Absorber Assembly ................. 762
Torque ....................................................... 729
Front Subframe Assembly ........................... 763
Parameter .................................................. 729
Front Subframe Support Rod ...................... 765
Front Horizontal Stabilizer Bar.................... 765
System Layout ............................................ 730
Front Horizontal Stabilizer Bar
System Control Diagram............................. 732 Bushing ...................................................... 766
Description ................................................ 733 Front Horizontal Stabilizer Bar Connecting
Operation .................................................. 735 Rod ........................................................... 767
Service Procedures......................................... 736 Front Wheel Hub Assembly ........................ 767
Steering Gear Assembly.............................. 736 Special Tools .................................................. 769
Steering Gear Boot .................................... 737 Rear Suspension ................................................770
Steering Gear Outer Tie Rod ..................... 738 Specifications ................................................. 770
Steering Gear Inner Tie Rod ...................... 739 Torque ....................................................... 770
Steering Wheel Parameter .................................................. 771
Positioning/Adjustment ............................... 739 Description and Operation............................. 772
Steering Wheel Assembly ........................... 740 System Layout ............................................ 772
Steering Wheel Molding.............................. 741 Description ................................................ 775
Steering Column Shield............................... 741 Service Procedures......................................... 777
Upper Steering Column .............................. 742 Rear Upper Swing Arm Assembly................ 777
Intermediate Shaft ...................................... 744 Rear Lower Swing Arm Assembly................ 777
Steering Wheel Entertainment Rear Upper Swing Arm Bush....................... 778
Switch........................................................ 744
Rear Shock Absorber Assembly .................. 778
Shift Paddle Switch...................................... 745
Rear Suspension Spring Assembly................ 779
Steering Column Combination
Switch........................................................ 745 Rear Horizontal Stabilizer Bar ..................... 780
Rear Horizontal Stabilizer Bar Connecting
Suspension System.......................... 747 Rod ........................................................... 781
Wheel Alignment ..............................................747 Rear Horizontal Stabilizer Bar
Bushing ...................................................... 781
8 1.0
Contents
Rear Lower Swing Arm Bush ...................... 782 Right Front Brake Pipe ................................ 817
Rear Wheel Hub ........................................ 782 Brake Master Cylinder Pipe......................... 818
Rear Subframe Assembly............................. 784 Connecting Pipe from Brake Modulator to
Rear Subframe Assembly - AWD................. 785 Rear Brake Pipe.......................................... 818
Rear Lateral Push Rod Assembly ................. 787 Rear Brake Pipe.......................................... 819
Rear Lateral Push Rod Bushing .................... 787 Special Tools .................................................. 821
Trailing Arm Assembly ................................ 788 Park Brake .........................................................822
Rear Trailing Arm Bushing........................... 788 Specifications ................................................. 822
Special Tools .................................................. 790 Torque ....................................................... 822
Tyres and Wheels ..............................................791 Description and Operation............................. 823
Specifications ................................................. 791 System Layout ............................................ 823
Torque ....................................................... 791 System Control Diagram............................. 824
Service Procedures......................................... 792 Description ................................................ 825
Wheel........................................................ 792 Service Procedures......................................... 827
EPB Module................................................ 827
Brake System................................... 793 Parking Brake Cable.................................... 828
Brake ..................................................................793 Brake Module.....................................................829
Specifications ................................................. 793 Specifications ................................................. 829
Torque ....................................................... 793 Torque ....................................................... 829
Parameters................................................. 794 Description and Operation............................. 830
Description and Operation............................. 795 System Layout ............................................ 830
System Layout ............................................ 795 System Control Diagram............................. 831
Description ................................................ 796 Description ................................................ 832
Service Procedures......................................... 800 Service Procedures......................................... 837
Front Brake Pad.......................................... 800 Brake Modulator ........................................ 837
Front Brake Disc ........................................ 801 Front Wheel Speed Sensor ......................... 838
Front Brake Caliper Housing Rear Wheel Speed Sensor .......................... 839
Assembly ................................................... 802
Rear Brake Pad........................................... 803 Driveline/Axle.................................. 841
Rear Brake Disc ......................................... 804 Drive Axle ..........................................................841
Rear Brake Caliper Housing Specifications ................................................. 841
Assembly ................................................... 805 Torque ....................................................... 841
Thickness and Circular Runout Check - Description and Operation............................. 842
Rear Brake Disc ......................................... 806
System Layout ............................................ 842
Thickness and Circular Runout Check -
Front Brake Disc ........................................ 807 Description ................................................ 845
Pedal Assembly-MT .................................... 808 Service Procedures......................................... 846
Pedal Assembly - AT ................................... 809 Right Front Axle Shaft Assembly.................. 846
Brake Pedal Position Sensor ........................ 810 Right Rear Axle Shaft Assembly................... 847
Vacuum Booster Assembly.......................... 810 Left Front Axle Shaft Assembly ................... 848
Brake Lamp Signal Sensor............................ 811 Left Rear Axle Shaft Assembly..................... 849
Brake System Bleeding ................................ 812 Drive Shaft ................................................. 850
Brake Master Cylinder and Reservoir Constant Velocity Joint Assembly ................ 851
Assembly ................................................... 813 Constant Velocity Joint Assembly
Front Brake Hose ....................................... 814 Sleeve ........................................................ 852
Rear Brake Hose ........................................ 815 Tripod Joint Assembly ................................. 853
Left Front Brake Pipe.................................. 816 Tripod Joint Assembly Sleeve....................... 853
1.0 9
Contents
Special Tools .................................................. 854 Rear Seat Backrest Upholstery.................... 882
Rear Seat Back Foam .................................. 883
Interior Fitting................................. 855
Rear Seat Cushion ...................................... 883
Instrument Panel and Console.........................855 Rear Seat Cushion Upholstery .................... 884
Specifications ................................................. 855 Rear Seat Cushion Foam............................. 884
Torque ....................................................... 855 Door Trim ..........................................................885
Service Procedures......................................... 856 Specifications ................................................. 885
Driver Side Lower Trim Panel Torque ....................................................... 885
Assembly ................................................... 856
Glove Box Assembly................................... 857
Front Door Interior Trim Panel ................... 886
Instrument Panel Assembly ......................... 857
Front Door Waterproof Membrane ............ 887
Driver Side Instrument Panel Vent Trim
Panel Assembly........................................... 860 Front Door Inner Handle............................ 887
Passenger Side Instrument Panel Vent Trim Rear Door Interior Trim Panel .................... 888
Panel Assembly........................................... 860 Rear Door Waterproof Membrane.............. 889
Central Instrument Panel Vent Trim Panel Rear Door Inner Handle ............................. 889
Assembly ................................................... 861 Interior Trim and Paneling ...............................890
Panel Assembly - Fascia Closing Panel Specifications ................................................. 890
................................................................. 862
Torque ....................................................... 890
Instrument Panel Beam Assembly ................ 863
Centre Console Assembly .......................... 864
A Pillar Upper Trim Panel............................ 891
Centre Console Armrest Assembly ............. 865
A Pillar Lower Trim Panel ........................... 891
Centre Console Front Storage Box
Assembly ................................................... 866 B Pillar Upper Trim Panel ............................ 892
Centre Console Rear Panel Assembly........... 866 B Pillar Lower Trim Panel............................ 892
Centre Console Cup Holder D Pillar Upper Trim Panel ........................... 893
Assembly ................................................... 867 Doorsill Trim Panel..................................... 893
Insulation Pad of Engine Compartment Sun Visor and Bracket................................. 894
Heat Shield................................................. 868 Roof Interior Trim ...................................... 894
Front Insulation Pad.................................... 869 Roof Inner Handle ...................................... 895
Centre Console Four-key Switch................. 869 Luggage Compartment Side Trim
Entertainment Panel Switch......................... 870 Panel.......................................................... 896
Electronic Hand-brake Switch ..................... 871 Luggage Compartment Sill Trim Panel
Hazard Warning Lamp Switch ..................... 871 Assembly .................................................. 897
Seat.....................................................................872 Tail Gate Interior Trim Panel ....................... 897
Specifications ................................................. 872 Carpet ....................................................... 898
Torque ....................................................... 872 Exterior Fitting................................ 899
Fixed Windows ..................................................899
System Layout ............................................ 873
Description ................................................ 874
Rear Door Quarter Window ...................... 899
Windshield Assembly ................................. 899
Front Seat Assembly ................................... 876
Rear Window Assembly ............................ 900
External Trim Panel - Front Seat.................. 877
Bumpers, Fascias and Grille .............................901
Front Seat Cushion Assembly...................... 877
Specifications ................................................. 901
Front Seat Cushion Upholstery ................... 878
Torque ....................................................... 901
Front Seat Backrest Upholstery................... 879
Rear Seat (Including Centre Armrest)........... 880
Front Bumper............................................. 902
Rear Seat Back (with central armrest)........... 881
10 1.0
Contents
Rear Bumper.............................................. 903 Rear Sunroof Glass Panel ............................ 928
Front Bumper Beam ................................... 904 Sunroof Sunshade ....................................... 929
Rear Bumper Beam .................................... 905 Sunroof Glass Motor .................................. 930
Exterior Trim and Paneling ..............................906 Sunroof Sunshade Motor ............................ 930
Specifications ................................................. 906 Sunroof Harness......................................... 931
Torque ....................................................... 906 Sunroof Air Deflector................................. 931
Service Procedures......................................... 907 Left Front Sunroof Drain Pipe ..................... 932
Bottom Deflector....................................... 907 Right Front Sunroof Drain Pipe ................... 932
Front Wheelhouse Liner............................. 907 Left Rear Sunroof Drain Pipe ...................... 933
Rear Wheelhouse Liner .............................. 908 Right Rear Sunroof Drain Pipe .................... 933
A/C Air Intake Grille Side Corner ............... 908 Wipers and Washer ..........................................934
A/C Air Intake Grille Assembly ................... 909 Specifications ................................................. 934
Roof Rack Assembly ................................... 909 Torque ....................................................... 934
Roof Molding.............................................. 910 Description and Operation............................. 935
Spoiler Assembly ........................................ 910 System Layout ............................................ 935
Tail Gate Moulding ..................................... 911 System Control Diagram............................. 936
Doorsill Molding......................................... 911 Description ................................................ 937
Pedal Assembly........................................... 912 Operation .................................................. 939
Mirrors................................................................913 Service Procedures......................................... 941
Specifications ................................................. 913 Rain Sensor ................................................ 941
Torque ....................................................... 913 Wiper Arm Assembly ................................. 941
Description and Operation............................. 914 Wiper Motor and Linkage Mechanism........... 942
System Layout ............................................ 914 Windshield Wiper Motor ........................... 942
System Control Diagram............................. 915 Wiper Blade Assembly................................ 943
Description ................................................ 916 Washer Reservoir Spout Assembly.............. 943
Operation .................................................. 917 Washer Reservoir Assembly ....................... 944
Service Procedures......................................... 918 Washer Pump Assembly ............................. 944
Exterior Mirror Assembly ........................... 918 Rear Wiper Arm Assembly ......................... 945
Exterior Rearview Mirror Cover ................. 918 Rear Wiper Blade Assembly........................ 945
Exterior Rearview Mirrors Sealing Rear Window Wiper Rod Shaft Cap............ 946
Gaskets...................................................... 919 Rear Wiper Motor ..................................... 946
Automatic Anti-dazzle Interior Mirror Windshield Nozzle ..................................... 947
Assembly ................................................... 919
Rear Window Nozzle ................................. 947
Manual Anti-dazzle Interior Mirror
Assembly ................................................... 920 Windshield Nozzle Hose ............................ 948
Roof.....................................................................921 Windshield Washer Pump Hose.................. 948
Specifications ................................................. 921 Rear Window Washer Pump Hose.............. 949
Torque ....................................................... 921 Rear Window Nozzle Hose ........................ 950
Description and Operation............................. 922 Rear Window Washer Check Valve............. 950
System Layout ............................................ 922 Lighting Systems ............................. 951
Lighting...............................................................951
Description ................................................ 924
Specifications ................................................. 951
Operation .................................................. 925
Torque ....................................................... 951
Sunroof Assembly....................................... 926
System Layout ............................................ 952
Front Sunroof Glass Panel ........................... 928
1.0 11
Contents
Description ................................................ 954 Body Systems .................................. 985
Operation .................................................. 955 Door....................................................................985
Service Procedures......................................... 957 Specifications ................................................. 985
Instrument Panel Light Adjustment Switch Torque ....................................................... 985
................................................................. 957
Front Reading Lamp Assembly..................... 957
System Layout ............................................ 986
Rear Reading Lamp Assembly...................... 958
Front Reading Lamp Bulb ............................ 959
Operation .................................................. 988
Rear Reading Lamp Bulb ............................. 959
Glove Box Lamp Assembly.......................... 960
Front Door Adjustment ............................. 990
Trunk Lamp Assembly................................. 960
Front Door Assembly ................................. 991
Lamps .................................................................961
Driver Door Outer Handle......................... 992
Specifications ................................................. 961
Driver Door Outer Handle (with
Torque ....................................................... 961 PEPS) ......................................................... 992
Description and Operation............................. 962 Front Passenger Door Outer Handle........... 993
System Layout ............................................ 962 Front Passenger Door Outer Handle (with
System Control Diagram............................. 963 PEPS) ......................................................... 994
Description ................................................ 965 Front Door Hinge Assembly ....................... 995
Operation .................................................. 969 Front Door Lock Cylinder .......................... 996
Service Procedures......................................... 973 Front Door Lock Body Assembly ................ 997
Rear License Plate Lamp Bulb...................... 973 Front Door Outer Handle Liner.................. 998
Front Fog Lamp Bulb .................................. 973 Rear Door Outer Handle ........................... 999
Front Fog Lamp Assembly ........................... 974 Rear Door Outer Handle Liner..................1000
Headlamp Lighting Calibration (Low Beam Rear Door Adjustment .............................1001
and High Beam) .......................................... 974 Rear Door Assembly .................................1002
Headlamp Assembly.................................... 975 Rear Door Hinge Assembly........................1003
Integral High/Low Beam Bulb Rear Door Lock Body Assembly ................1003
(low-configuration headlamp)...................... 976
Front Door Window Slideway
Front Direction Indicator Lamp Bulb Weatherstrip.............................................1004
(low-configuration headlamp)...................... 976
Front Door Windowsill Inner
High Mounted Stop Lamp Assembly ............ 977 Weatherstrip.............................................1005
Rear Combination Lamp Assembly .............. 977 Front Door Windowsill Outer
Tail Lamp Assembly .................................... 978 Weatherstrip.............................................1006
Rear Combination Lamp Assembly Front Door Window Regulator..................1006
Bulb ........................................................... 978 Front Door Window .................................1007
Tail Lamp Assembly Bulb ............................. 979 Central Control Door Lock Switch ............1008
Position Lamp and Daytime Running Lamp Power Window Switch - Rear Door ...........1008
Source Module ........................................... 979
Power Window Switch - Driver Side ...........1009
Side Direction Indicator Lamp
Assembly ................................................... 980 Power Window Switch - Front Passenger
Side ..........................................................1009
Puddle Lamp Assembly ............................... 980
Rear Door Windowsill Outer
Headlamp Control Module.......................... 981 Weatherstrip.............................................1010
Headlamp Leveling Front Suspension Rear Door Windowsill Inner
Height Sensor ............................................ 981 Weatherstrip.............................................1010
Headlamp Leveling Rear Suspension Height Rear Door Window Slideway
Sensor ....................................................... 982 Weatherstrip.............................................1011
Light Sensor ............................................... 983 Rear Door Window Regulator...................1012
12 1.0
Contents
Rear Door Window ..................................1013 Description ...............................................1041
Front Closures .................................................1014 Operation .................................................1045
Specifications ................................................1014 Service Procedures........................................1047
Torque ......................................................1014 Body Control Module ................................1047
Service Procedures........................................1015 PMDC ...............................................................1048
Bonnet Assembly.......................................1015 Specifications ................................................1048
Bonnet Hinge Assembly .............................1016 Torque ......................................................1048
Bonnet Inspection and Adjustment ............1016 Description and Operation............................1049
Engine Hood Lock Body Assembly .............1017 System Layout ...........................................1049
Engine Hood Release Cable .......................1018 System Control Diagram............................1050
Bonnet Open Handle Assembly..................1019 Description ...............................................1051
Engine Hood Silencer.................................1019 Operation .................................................1052
Fender ......................................................1020 Service Procedures........................................1053
Upper Radiator Beam ................................1021 DC Converter with Electrical Power
Battery Tray ..............................................1024 Management..............................................1053
Battery Tray Bracket ..................................1024 Body Repair ................................... 1055
Rear Closures...................................................1025
Body Dimension ..............................................1055
Specifications ................................................1025
Point to Point Dimensional
Torque ......................................................1025 Information...................................................1055
Service Procedures........................................1026 Vehicle Side and Top Information................1055
Fuel Filler Door Assembly..........................1026 Bottom Plate Information ..........................1057
Oil Filler Flap Shutter Cable Rear End Information.................................1059
Assembly ..................................................1026
Internal Information...................................1061
Fuel Filler Door Open Handle....................1027
Front End Information ...............................1062
Tailgate Assembly ......................................1028
Gap Information............................................1063
Tailgate Lock Body Assembly......................1029
Body Side and Fuel Filler Cap
Tailgate Lock Catch ...................................1030 Information ...............................................1063
Tailgate Hinge Assembly.............................1030 Front End Information ...............................1064
Tailgate Air Spring and Mounting Rear End Information.................................1066
Bracket .....................................................1031
Sunroof Information ..................................1068
Tailgate Electric Prop Assembly ..................1032
Paint and Coatings ..........................................1069
Power Tailgate Controller ..........................1033
Summary...................................................1069
Power Tailgate Anti-pinching Stripe.............1034
Paint Process.............................................1071
Electric Suction Latch Assembly .................1035
Coating Flaw Identify .................................1075
Tail Gate Weatherstrip ..............................1035
Collision Repair ...............................................1078
Horn .................................................................1036
Description and Operation............................1078
Specifications ................................................1036
General Welding Protection
Torque ......................................................1036 Measures...................................................1078
Service Procedures........................................1037 Corrosion Protection ...............................1083
Horn.........................................................1037 Body Seal ..................................................1086
Body Control Module......................................1038 Diagnostic.....................................................1087
Specifications ................................................1038 Leak Test...................................................1087
Torque ......................................................1038 Service Procedures........................................1088
Description and Operation............................1039 Roof Panel ................................................1088
System Layout ...........................................1039 Engine Compartment Panel........................1089
System Control Diagram............................1040 Dash Panel ................................................1090
1.0 13
Contents
Side Wall Panel..........................................1091 System Layout ...........................................1121
Front Floor ...............................................1092 Description ...............................................1122
Rear Floor ................................................1093 Service Procedures........................................1125
Door Sheet Metal Assembly.......................1094 Gateway Module .......................................1125
Engine Hood Sheet Metal Assembly............1095 Seat Belts .........................................................1126
Tail Gate Panel Assembly ...........................1096 Specifications ................................................1126
Torque ......................................................1126
Safety and Restraints .................... 1097
Vehicle Access..................................................1097 System Layout ...........................................1127
Specifications ................................................1097 System Control Diagram............................1128
Torque ......................................................1097 Description ...............................................1129
Description and Operation............................1098 Operation .................................................1131
System Layout ...........................................1098 Service Procedures........................................1132
System Control Diagram............................1099 Front Seat Belt Height Regulator ................1132
Description ...............................................1101 Front Seat Belt Assembly ...........................1133
Service Procedures........................................1109 Front Seat Belt Buckle ...............................1134
Add and Disable a Key ...............................1109 Rear Seat Belt Assembly ............................1134
Passive Entry and Passive Start (PEPS) Rear Middle Seat Belt ................................1135
Control Module ........................................1110
Rear Seat Belt Buckle.................................1136
Passive Entry and Passive Start (PEPS)
Antenna - Front.........................................1110 Supplementary Restraint Systems ................1137
Passive Entry and Passive Start (PEPS) Specifications ................................................1137
Antenna - Middle.......................................1111 Torque ......................................................1137
Passive Entry and Passive Start (PEPS) Description and Operation............................1138
Antenna - Rear .........................................1111 System Layout ...........................................1138
Passive Entry and Passive Start (PEPS) System Control Diagram............................1139
Antenna - Rear Bumper Upholstery
................................................................1112 Description ...............................................1140
Passive Entry and Passive Start (PEPS) Operation .................................................1144
Antenna - Door Handle .............................1112 Service Procedures........................................1146
One-Touch Ignition Switch .........................1113 SAS System Diagnosis and Control
Mechanical Ignition Switch .........................1113 Module .....................................................1146
Alarm System..................................................1114 Collision Sensor ........................................1146
Specifications ................................................1114 Steering Wheel Airbag...............................1147
Torque ......................................................1114 Instrument Panel Airbag ............................1148
Description and Operation............................1115 Head Impact Protection Airbag
Module .....................................................1149
System Layout ...........................................1115
Park Assistant System ....................................1151
System Control Diagram............................1116
Specifications ................................................1151
Description ...............................................1117
Torque ......................................................1151
Operation .................................................1118
Service Procedures........................................1119
System Layout ...........................................1152
Low Frequency Immobiliser Receiver
coil ...........................................................1119 System Control Diagram............................1153
Spare Coil .................................................1119 Description ...............................................1154
Gateway............................................................1120 Operation .................................................1156
Specifications ................................................1120 Service Procedures........................................1158
Torque ......................................................1120 Control Unit (ECU) - Parking Distance
Control System .........................................1158
14 1.0
Contents
Rear Ultrasonic Sensor ..............................1158 Centre Console Power Socket ...................1206
Rear Camera.............................................1159
Self-learning/Programming .......... 1207
Information and Self-learning/Programming ............................1207
Entertainment ............................... 1161 Window Regulator and Sunroof
Entertainment and Navigation ......................1161 Initialization...............................................1207
Specifications ................................................1161 Power Liftgate Control Module
(PLCM) .....................................................1208
Torque ......................................................1161
Operations after Battery Power
Description and Operation............................1162 Resume.....................................................1209
System Layout ...........................................1162 Engine Control Module (ECM) ...................1210
System Control Diagram............................1163 TCM.........................................................1211
Description ...............................................1164 Transmission Control Module (TCM) -
Operation .................................................1169 7-speed.....................................................1215
Service Procedures........................................1170 SCU .........................................................1218
Player........................................................1170 TCCM ......................................................1219
A Pillar Tweeter.........................................1171 Air Conditioning System (HVAC) ...............1220
Front Door Full-range Speaker...................1171 EPS Module ..............................................1221
Rear Door Tweeter ...................................1172 EPB Module..............................................1222
Rear Door Full-range Speaker ....................1172 Stability Control System (SCS) ...................1223
Roof Antenna............................................1173 Steering Angle Sensor (SAS).......................1224
Radio Antenna Amplifier............................1173 Body Control Module (BCM) .....................1225
Antenna Coil.............................................1174 Communication Module (TBOX)................1226
Microphone...............................................1174 Gateway (GW)..........................................1227
Displays and Gages ..........................................1176 DHL .........................................................1228
Specifications ................................................1176 PEPS .........................................................1229
Torque ......................................................1176 Instrument Pack (IPK)................................1230
Description and Operation............................1177 SDM .........................................................1231
System Layout ...........................................1177 Entertainment Information Control Module
System Control Diagram............................1179 (FICM) ......................................................1232
Description ...............................................1180 PMDC ......................................................1233
Operation .................................................1187 PDC Module .............................................1234
Service Procedures........................................1188 Glossary List ....................................................1235
Instrument Pack ........................................1188
Fuse Box and Harness.....................................1189
Specifications ................................................1189
Torque ......................................................1189
Service Procedures........................................1190
Engine Compartment Fuse Box ..................1190
Battery Fuse Box .......................................1191
Body Harness............................................1191
Instrument Panel Harness ..........................1200
Driver Door Harness ................................1202
Front Passenger Door Harness ..................1203
Rear Door Harness ...................................1204
Centre Console Harness ...........................1205
Power Seat Harness...................................1205
1.0 15
General Information
General Information Health Protection Precautions
General Precautions The following precautions should be observed at all times.
Dangerous Substances
• Wear protective clothing, including impervious gloves
Modern vehicles contain many materials and liquids which if not where practicable.
handled with care can be hazardous to both personal health • Avoid prolonged and repeated contact with oils,
and the environment. particularly used engine oils.
Warning: Many liquids and other substances used in • Do not put oily rags in pockets.
vehicles are poisonous and should under no circumstances • Avoid contaminating clothes (particularly those next to
be consumed and should, as far as possible, be kept the skin) with oil.
from contact with the skin. These liquids and substances
• Overalls must be cleaned regularly. Discard heavily soiled
include acid, antifreeze, brake fluid, fuel, windscreen
clothing and oil impregnated footwear.
washer additives, lubricants, refrigerants and various
adhesives. • First aid treatment should be obtained immediately for
open cuts and wounds.
Warning: Always read carefully the instructions printed
• Apply barrier creams before each work period to help
on labels or stamped on components and obey them
prevent lubricating oil from contaminating the skin.
implicitly. Such instructions are included for reasons of
your health and personal safety. Never disregard them. • Wash with soap and water to ensure all oil is removed
(proprietary skin cleansers and nail brushes will help).
Synthetic Rubber
• Use moisturisers after cleaning; preparations containing
Many O-rings, seals, hoses, flexible pipes and other similar lanolin help replace the skin's natural oils which have been
items which appear to be natural rubber, are in fact, made removed.
of synthetic materials called Fluoroelastomers. Under normal
• Do not use petrol/gasoline, kerosene, diesel fuel, oil,
operating conditions this material is safe and does not present
thinners or solvents for cleaning skin.
a health hazard. However, if the material is damaged by fire
or excessive heating, it can break down and produce highly • Where practicable, degrease components prior to
corrosive Hydrofluoric acid. handling.
• If skin disorders develop, obtain medical advice without
Contact with Hydrofluoric acid can cause serious burns on
delay.
contact with skin. If skin contact does occur：
• Wear eye protection (e.g. goggles or face shield) if there
• Remove any contaminated clothing immediately. is a risk of eye contamination. Eye wash facilities should
• Irrigate affected area of skin with a copious amount of be provided in close vicinity to the work area.
cold water or limewater for 15 to 60 minutes.
• Obtain medical assistance immediately.
Should any material be in a burnt or overheated condition,

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

for leaks underneath the vehicle while a second operator
applies maximum brake pressure to the brakes (engine
running) and operates the steering.
Fuel System Hoses
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 fuel hoses 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 fuel adjacent components.
system hoses 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 hose must be fitted if separation is evident. in good condition. Replace if damage is evident. Particular
care must be taken when routing hoses close to hot engine
Cooling System Hoses
components, such as the exhaust manifold and the Exhaust Gas
The following precautions MUST be followed to ensure that Recirculation (EGR) pipe. Hoses will relax and deflect slightly
integrity of cooling hoses and their connections to system
components are maintained.
1.0 11
General Information
when hot; ensure this movement is taken into account when Fuel Handling Precautions
routing and securing hoses. General
Fuel vapour is highly flammable and in confined spaces is
also explosive and toxic. The vapour is heavier than air
and will always fall to the lowest level. The vapour can be
easily distributed throughout a workshop by air currents;
consequently, even a small spillage of fuel is potentially very
dangerous.
The following information provides basic precautions which

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

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

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

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

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

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

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

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

• Remove the component and support the disconnected
harness.
• When replacing the component keep oily hands away
from electrical connection areas and push connectors
home until any locking tabs fully engage.
1.0 13
General Information
Battery Disconnection Supplementary Restraint System Precautions
Before disconnecting the battery, disable the alarm system and General Precautions
switch off all electrical equipment. The SRS system contains components which could be
potentially hazardous to the service engineer if not serviced
Caution: To prevent damage to electrical components,
and handled correctly. The following guidelines are intended
always disconnect the battery when working on the
to alert the service engineer to potential sources of danger
vehicle's electrical system. The ground lead must be
and emphasise the importance of ensuring the integrity of
disconnected first and reconnected last.
SRS components fitted to the vehicle.
Caution: Always ensure that battery leads are routed
Warning: It is imperative that before any work
correctly and are not close to any potential chafing
is undertaken on the SRS system the appropriate
points.
information is read thoroughly.
Battery Charging
Always ensure any battery charging area is well ventilated and
that every precaution is taken to avoid naked flames and sparks.
Disciplines
Warning: The airbag module contains sodium azide which
Remove the handset prior to making any connection or is poisonous and extremely flammable. Contact with
disconnection in the system to prevent electrical surges water, acid or heavy metals may produce harmful or
caused by disconnecting ‘live' connections damaging electronic explosive compounds. Do not dismantle, incinerate or
components. bring into contact with electricity, before the unit has
Ensure hands and work surfaces are clean and free of grease, been deployed.
swarf, etc. Grease collects dirt which can cause electrical Warning: Always replace a seat belt assembly that has
tracking (shortcircuits) or high resistance contacts. withstood the strain of a severe vehicle impact, or if the
When handling printed circuit boards, treat with care and hold webbing shows signs of fraying.
by the edges only; note that some electronic components are Warning: Always disconnect the vehicle battery before
susceptible to body static. carrying out any electric welding on a vehicle fitted with
Connectors should never be subjected to forced removal or an SRS system.
refit, especially inter-board connectors. Damaged contacts can Caution: Do not expose an airbag module or seat belt
cause short-circuit and open-circuit fault conditions. pre-tensioner to heat exceeding 85℃.
Prior to commencing test, and periodically during a test, touch It should be noted that these precautions are not restricted
a good vehicle body earth to discharge static charge. Some to operations performed when servicing the SRS system,
electronic components are vulnerable to the static electricity the same care must be exercised when working on ancillary
that may be generated by the operator. systems and components located in the vicinity of the SRS
Electrical Multiplugs Lubricate components; these include, but are not limited to:
In order to prevent corrosion, Some multiplugs under bonnet • Steering system steering wheel airbag, rotary coupler.
and carpet is wiped special lubricate in factory. If these is • Front fascia passenger front airbag.
destroyed in maintaining, repair and replacing process, special
• Interior trim ICS Head Curtain Airbags（‘A'-post trim,
lubricate should be newly wiped
‘B'-post upper trim, grab handles, headlining above front
doors）; SRS Electronic Control Unit (ECU) (beneath
centre console); side impact crash sensors (under carpet
beneath front seats)
• Seats side (thorax) airbags; front seat belt pretensioner.
• Electrical system–SRS harnesses, link leads and
connectors.
Making the System Safe
Before working on, or in the vicinity of SRS components,
ensure the system is rendered safe by performing the following
procedures:
1.0 14
General Information
• Ensure the ECU is always installed correctly. SRS ECU.
SRS ECU There must not be any gap between the ECU
and the bracket to which it is mounted. SRS ECU
An incorrectly mounted ECU could cause the system to
malfunction.
• Do not supply power to the ECU are connected. SRS
before all SRS components SRS ECU before all SRS
components.
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
• Remove the handset from the docking station. correct torque.
• Disconnect both battery leads, earth lead first. Caution: Following seat belt pretensioner deployment,
• Wait 10 minutes for SRS ECU the SRS ECU back-up the seat belts can still be used as conventional seat
power circuit to discharge. belts, but will need to be replaced as soon as possible to
re-establish full SRS protection.
The SRS system uses energy reserve capacitors to keep
the system active in the event of electrical supply failure Caution: If the SRS component is to be replaced, the bar
under crash conditions. It is necessary to allow the capacitor code of the new unit must be recorded.
sufficient time to discharge (10 minutes) in order to avoid the SRS Component Testing Precautions
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.
Warning: The integrity of the SRS system is critical for

safety reasons. The SRS components are triggered using relatively low
Ensure the following precautions are always adhered to: operating currents, always adhere to the following precautions:
• Never install used SRS components from another vehicle Warning: Do not use a multimeter or other general
SRS or attempt to repair an SRS component. purpose test equipment on SRS system components
or accidental deployment may occur. Only use the
• Never use the SRS parts without a clear identification
recommended diagnostic equipment to diagnose system
SRS label.
faults.
• Never use an airbag or SRS ECU that has been dropped.
Warning: Do not use electrical test equipment on the SRS
• When repairing an SRS system only use SRS genuine new
harness while it is connected to any of the SRS system
parts.
components. It may cause accidental deployment and
• Never apply electrical power to an SRS component personal injury.
unless instructed to do SRS so as part of an approved
test procedure.
• Ensure the bolts are tightened to the correct torque.
Always use new fixings SRS when replacing SRS
components.
1.0 15
General Information
Handling and Storage
Warning: Store the airbag module with the deployment

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

belt pretensioner units, component failure could result.
Always observe the following precautions SRS with regards to
SRS system electrical wiring:
• Never attempt to modify, splice or repair SRS wiring.
1.0 16
General Information
• Never install electronic equipment (such as a mobile Never fit cover on seat which fitting side airbag.
telephone, two-way radio or in-car entertainment
Children under 12 years old should not sit in the front seat.
system) in such a way that it could generate electrical
interference in the airbag harness. Seek specialist advice Only genuine accessory parts are allowed to be installed.
when installing such equipment. Only authorised people can remove airbag modules, ECU, SRS
Note: SRS system wiring can be identified by a special system wiring harness and connectors. SRS ECU and SRS
yellow outer sleeve protecting the wires (black with yellow system wiring harness and connectors.
stripe protective coverings are sometimes used). If the airbag and seat belt pre-tensioner are deployed during an
accident, SRS ECU must be replaced and discarded.
Every SRS system on every car SRS 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.
Be careful to avoidtrapping or pinching the SRS wiring. Observe the following precautions:
Do not leave the connectors hanging loose or allow SRS
• Do not unlock and rotate the rotary coupler when it is
components to hang from their harnesses. Look for
possible points of chafing.
• Do not turn the road wheels when the rotary coupler is
• 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
Precautions for Vehicle Owners
vehicle. SRS components have additional warning labels
For the airbag to work effectively and protect vehicle owners, displayed on them to indicate that particular care is needed
follow the precautions listed below. when handling them. These include airbag modules, SRS
Driver and passengers must use seat belts correctly. Correctly ECU, seat belt pre-tensioners and the rotary coupler.
using the seat belts can protect the body and reduce injuries The following warning symbols may be displayed at various
in the event of an accident. locations on the vehicle:
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 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 SRS ECU on label on top of ECU
dependent on model year, legislation and market trends. • Rotary coupler – several labels on front face
Vehicle Recovery
Towing SRS Components Not Deployed
Normal towing procedures are unlikely to cause an airbag to
deploy. However, as a precaution, remove the handset from
the docking station and then disconnect both battery leads.
Disconnect the negative ‘-’ lead first.
Towing SRS Components Not Deployed
Once the driver＇s airbag has been deployed, the vehicle must
have a suspended tow. However, as a precaution remove the
handset from the docking station and then disconnect both
battery leads. Disconnect the negative ＇-＇ lead first.
SRS Components Deployed
Do not use rear facing child seat in front passenger seat of
vehicles fitted with passenger airbag. If a vehicle is to be scrapped and contains an undeployed airbag
module, the module must be manually deployed.
Rotary Coupler
Always observe the following precautions:
1. The need for caution when working SRS in close
proximity to SRS components. Warning: Only personnel who have undergone the
2. Refer to Workshop Manual for detailed instructions. appropriate training should undertake deployment of
airbag and seat belt pre-tensioner modules.
3. Ensure the wheels are in the straight ahead position
before removal and refitting. Warning: A deployed airbag or seat belt pre-tensioner is
very hot, DO NOT return to a deployed airbag module
until at least 30 minutes have elapsed since deployment.
1.0 18
General Information
Warning: Only use approved deployment equipment, Warning: Compliance with the following precautions
and only deploy SRS components in a well-ventilated MUST be ensured:
designated area. Ensure SRS components are not • Only use deployment equipment approved for the
damaged or ruptured before deployment. intended purpose.
Warning: Contact with chemicals from deployed and • Before commencing deployment procedure, ensure
damaged SRS components could present a health hazard, the deployment tool functions properly.
wear protective clothing when handling. DO NOT eat, • Deployment of airbag/pre-tensioner modules should
drink or smoke when handling SRS components. be performed in a well ventilated area which has
Warning: Deployment of airbag modules and seat belt been designated for the purpose.
pre-tensioners can cause injury to personnel in the close • Ensure airbag/pre-tensioner modules are not
vicinity of the deploying unit. In case of injury seek urgent damaged or ruptured before attempting to deploy.
medical advice. Possible sources of injury include: • Notify the relevant authorities of intention to deploy
• impact - due to inflating airbag or pretensioner airbag and pretensioner units.
operation causing component 'kick'. • When deploying airbag and seat belt pre-tensioner
• hearing - due to noise produced by deploying airbags units, ensure that all personnel are at least 15 metres
and seat belt pretensioner units. away from the deployment zone.
• burns - hot component parts and gases. • When deploying seat belt pretensioners in the
• irritation to eyes and lungs - from deploying gases or vehicle, ensure the pre-tensioner unit is fully secured
combustion residue. to its fixing point.
• When removing deployed airbag and seat belt
Warning: Ensure the SRS component to be deployed is
pre-tensioner modules, wear protective clothing.
securely fastened to its mounting.
Use gloves and seal deployed units in a plastic bag.
• Following deployment of any component of the SRS
system within the vehicle, all SRS components must
be replaced. DO NOT re-use or salvage any parts of
the SRS system.
• Do not lean over airbag modules or seat belt
pre-tensioner units when connecting deployment
equipment.
1.0 19
General Information
SRS Component Replacement Policy • SRS ECU
Impacts Which Do Not Deploy the Airbags or • Side impact crash sensors (both sides of vehicle)
Pre-tensioners
In addition, the following should be inspected for damage and
Check for structural damage in the area of the impact, paying
replaced as necessary:
particular attention to bumper armatures, longitudinals, crash
cans and bracketry. • Front seat belts (retractors, webbing, tongue latching, 'D'
loop and body anchorage points)
Impacts Which Deploy the Airbags or
Pre-tensioners • Rear seat belt buckles (webbing, buckle covers, tongue
latching and body anchorage)
The replacement and inspection policy is dependent on the
type and severity of the crash condition. SRS. The following • Front seat frame (if there is evidence of external or airbag
guidelines are the minimum that should be exercised as a result deployment damage to seat frame)
of the deployment of specific SRS components: • 'BC' 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 'BC' posts • Rear seat belt buckles (webbing, buckle covers, tongue
• Rear seat belt escutcheons in parcel shelf trim latching and body anchorage)
Side (Thorax) Airbags • 'BC' post upper finisher and fixings
If the side (thorax) airbags are deployed, the following parts • Door casing
must be replaced, on the side of the vehicle on which the • Seat belt automatic height adjusters on ‘B' post
deployment occurred: • Rear seat belt escutcheons in parcel shelf trim
• Seat (thorax) airbag module Rear Impacts
• Seat squab foam Rear impacts may cause the seat belt pretensioners to deploy.
• Seat squab cover If this occurs, all pretensioner units must be replaced. In
addition, the following components should be inspected for
• Front seat belt buckle pre-tensioners
damage and replaced as necessary:
1.0 20
General Information
• Front seat frames Air Conditioning System Precautions
• Seat belt automatic height adjusters on ‘B'- post General
• Front seat belts (retractors, webbing, tongue latching, 'D' The air conditioning system contains fluids and components
loop and body anchorage points) which could be potentially hazardous to the service engineer
• Rear seat belt buckles (webbing, buckle covers, tongue or the environment if not serviced and handled correctly. The
latching and body anchorage) following guidelines are intended to alert the service engineer
to potential sources of danger and emphasise the importance
• Rear seat belt escutcheons in parcel shelf trim
of ensuring the integrity of the air conditioning operating
• SRS ECU
conditions and components fitted to the vehicle.
Periodic Replacement of SRS Components
Where necessary, additional specific precautions are detailed
The performance of the propellants within airbags and in the relevant sections of this Manual which should be referred
pre-tensioners will deteriorate over a period of time. As a to prior to commencing repair operations.
result, it is essential that the airbags and pre-tensioners are
periodically replaced to maintain occupant safety. Airbags, The refrigerant used in the air conditioning system is HFC-134a
seat belt pre-tensioners and the rotary coupler should be (Hydrofluorocarbon) R134a.
replaced at 12 year intervals. Warning: Servicing must only be carried out by personnel
familiar with both the vehicle system and the charging and
testing equipment. All operations must be carried out in
a well ventilated area away from open flame and heat
sources.
Warning: R134a is a hazardous liquid and when handled

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

2. Invert the compressor and gravity drain the oil into a
calibrated measuring cylinder. Rotate the compressor
clutch to ensure the compressor is completely drained.
3. Record the quantity of oil drained, discard the oil.
4. Remove the filler/drain plug from the new compressor.
5. Invert the compressor and gravity drain the oil into a
calibrated measuring cylinder. Rotate the compressor
clutch to ensure the compressor is completely drained.
6. Add the same amount of oil drained from the old
compressor to the new compressor.
7. Discard the remaining oil drained from the new
compressor.
8. Fit and tighten the compressor filler/drain plug.
1.0 23
General Information Lifting & Towing
Lifting & Towing Warning: Do not work on or under a vehicle supported

Lifting Vehicle only by a jack.Always support the vehicle on safety stands.
Description Hydraulic Jack
Before lifting the vehicle, note the followings: The hydraulic jack to be used must have a bearing capacity of
at least 1500kg (3,300lbs).
• The vehicle shall be parked on a level and firm ground.
Warning: Do not commence work on the underside of the
• Put the hand brake in place.
vehicle until suitable safety supports have been positioned
• Select P or N gear. under the sill reinforced brackets.
To avoid damage to the underbody parts, please follow the Warning: Always chock the wheels when jacking.
procedures below:
Lifting and Supporting the Vehicle
Do not put the jack or axle bracket under the following Put the head of the jack at the lifting point of the front/rear
components: doorsill of the vehicle.
• Body Structural Parts Caution: Do not jack or support the vehicle on any other
• Bumper points than those indicated. Failure to comply is likely to
• Fuel Line result in damage to the body or chassis components.
• Brake Line Warning: Do not commence work on the underside of the
• Front Suspension Arm vehicle until suitable safety supports have been positioned
• Steering Connecting Mechanism under the sill reinforced brackets.
• Rear Suspension Arm Warning: Always chock the wheels when jacking.
• Fuel Tank Column Lifter
• Engine Oil Pan
• Transmission Housing
• Rear Towing Eye
Note: Jacking and supporting the front of the vehicle
should only be done under the customer front jacking
points and/or the jacking bracket on the front section of
the front subframe.
Front/Rear Supporting Point of the Vehicle
The jack of the vehicle is only applied to replace wheels in
emergency. Do not use it for other purposes.
Put the mat under the jacking point on the sill.
If use the jack to replace wheels, ensure that the jack is placed
on a solid level ground and under the supporting point near
the wheel to be removed. Note: the round head of the jack
must be in the corresponding slot on the baseplate.
1.0 24
Lifting & Towing General Information
Roadside Assistance Caution: A rear suspended tow must not be used for
Instructions for Roadside Assistance vehicles with an automatic transmission, as serious
damage will be caused to the transmission.
It is recommended that a rescue trailer or a two-wheel rescue
vehicle shall be used. In emergency, use a towing vehicle with Dual Clutch Automatic Transmission (2WD)
front towing point. Generally, vehicles with dual clutch automatic transmission
Front Towing Hook should be towed with the front wheels off the road (with front
wheels hanged up).
Caution: A rear suspended tow must not be used for
vehicles with an automatic transmission, as serious
damage will be caused to the transmission.
When the vehicles with dual clutch automatic transmission are

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

• The selector must be at ‘N'.
• The vehicle must not be towed at speeds greater than
30 km/h or for a distance exceeding 50 km.
• Do not tow if the gearbox or a drive shaft is faulty.
In the front of the vehicle, removable towing hook can be used
• Ensure the gear lever is in neutral and the parking
for rescue operation. The towing hook is usually kept in the
brake is released.
vehicle toolbox and should be put back after use. When fitting
the towing hook, the towing hook cover at the right side of • Remember that greater effort than normal will be
the front bumper shall be removed first, then screw the towing necessary to operate the brakes and steering if the
hook into the mounting position of the front bumper assembly vehicle is being towed without the engine running.
(bumper beam). Caution: Do not tow on four wheels if the gearbox or drive
Rear Towing Hook shafts are touching the body or frame.
Note: A vehicle with an automatic transmission cannot be

started by towing or pushing.
AWDVehicle
In the rear of the vehicle, removable towing hook can be used

for rescue operation. The towing hook is usually kept in the
vehicle toolbox and should be put back after use. When fitting
the towing hook, the towing hook cover at the right side of
For AWD vehicles, the vehicle shall be towed by wheel lift,
the rear bumper shall be removed first, then screw the towing
wheel trolley or flat-bed trailer with all wheels off the ground.
hook into the mounting position of the rear bumper assembly
(bumper beam). The rear towing hook can only be used to tow
light vehicles. The rear towing point of the vehicle equipped
with manual transmission can be used for rear towing.
1.0 25
General Information Vehicle Identification Number
Vehicle Identification Number

Vehicle Identification Number
Vehicle Identification Number (VIN)
For example, LSJA24W6XGSXXXXXX
Digit Code Description
1-3 LSJ Vehicle Manufacturer Code
4-5 A2 Model/Type
Vehicle Body Structural
6 4 Characteristics 4 =
2-compartment & 5-door
Engine
7 W
W=2.0T Gasoline Engine; Location of Vehicle Identification Plate
Passenger Protective Devices The identification plate is located at the lower side of the right
6 = Safety belt, driver and B pillar, for details, please refer to the specific vehicle plate.
8 6
front-seat passenger airbag &
seat-side airbag
Check bit, represented by any
9 X
figure from 0 to 9 or X
10 H Year of Manufacturing H = 2017
Assembly Plant S = Lingang
11 S
(Shanghai)
6 Digits = Production Sequential
12-17 XXXXXX
Number
VINAlso printed at the following locations:
The plane behind the lower left corner of the windshield.
Printed on the seat beam under the right seat.
1.0 26
Vehicle Identification Number General Information
Position of Other Plates
Engine Number
Printed on the left rear part of the cylinder block, as shown by
the arrow.
Dual Clutch Automatic Transmission Number

Printed on the top surface of the transmission housing, see the
figure below.
1.0 27
General Information Lubrication & Maintenance
Lubrication & Maintenance Fluid

Capacity Fuel
Liquid Capacity Following recommended oils must be applied:
The following capacity values are merely approximate value for For gasoline engines
the corresponding system. 95# and above gasoline RON is recommended. DO NOT use
Component/System Capacity gasoline containing methanol.
Fuel Tank: 55L Antifreeze Fluid
Engine Oil - 2.0T： The mixture with 50% water and 50% OAT shall be used.
The antifreeze containing organic acid technology (OAT)
Refill from Dry State 6.0L
preservative and summer coolant or ethylene-glycol-based
Replacement of the Engine Oil and Oil Filter 5.2L antifreeze (methanol not contained) are applied to protect
Engine Oil - 1.5T: the cooling system. Only the antifreeze with OAT antiseptic
can be used.
Do not use other types of antifreeze to supplement or refill
Replacement of the Engine Oil and Oil Filter 4.0L the cooling system. In emergency, if the antifreeze of this
Dual Clutch Automatic Transmission - 6 Speed: type is unavailable, the clean water can be used to fill the
cooling system. However, this may lower the frost protection
Refill 6.16L
capability. The correct antifreeze concentration must be
Refill from Dry State 7.63L recovered as soon as possible.
Manual Transmission – SCM250: When it is time for inspection specified in the Maintenance List,
Refill 2.2L drain the cooling system and clean it, then refill the cooling
system with appropriate coolant.
After refilling antifreeze, attach the warning label at a
Dual Clutch Automatic Transmission - 7 Speed:
prominent position of the vehicle to show the type of
Refill from Dry State 2.45L antifreeze used in the cooling system, so that correct antifreeze
Power Takeoff Lubrication Oil: can be used for next refill.
Concentration of Antifreeze Fluid
The overall antifreeze concentration shall not be less than 50%
FDU:
of the volume, meanwhile make sure the antisepsis property
Refill from Dry State 0.56L of the coolant. Antifreeze concentration more than 60% is not
Cooling System Coolant: recommended as it will weaken the cooling efficiency.
Engine - 2.0T 8.2L The antifreeze capacity recommended in the following table
shall provide frost protection at -37℃ - -40℃.
Engine - 1.5T 7.1L
Engine - 2.0T:
Brake Fluid for Brake System:
Concentration 50%
Capacity of Antifreeze Fluid 4.1L
Windshield Washer Reservoir 5.0L
Engine - 1.5T:
Concentration 50%
Capacity of Antifreeze Fluid 3.55L
Brake Fluid
Use brake fluid DOT4 only.
1.0 28
Lubrication & Maintenance General Information
Lubricating Fluids Engine Cover Lock Body
Overview Use FN745/94 grease produced by Fuchs.
The engine and other lubrication systems are filled with Lock, Lock Body and Hinge
high-performance lubricating fluid to extend the service life.
Do not apply any lubricating grease on the fixing end of the
Caution: Always use a high quality oil of the correct torsion bar spring, however, Krupp Isoflex Topas L32CN
viscosity range in the engine. The use of oil of the grease is recommended for its rotating end.
incorrect specification can lead to high oil and fuel
Washer Fluid
consumption and ultimately to damaged components.
Use QX-35 washer fluid.
The use of the engine oil of recommended specifications
containing additives may decrease the corrosive acid caused
by combustion and prevent formation of residues. These
residues may block the oil passage. Other engine oil additives
should not be used. Repair and maintenance must be carried
out within the specified interval.
Engine Oil
1.5T engine uses 5W–30 engine oil in compliance with
SN/GF-5 specification.
2.0T engine uses 5W–30 engine oil in compliance with ACEA

C3 specification.
The engine oil viscosity/temperature range refers to the

following table:
Transmission Fluid
Failure to use specified transmission fluid may result in serious
damage to the transmission.
Manual Transmission - 6MT
Refill or fill up with MTF94 oil.
Dual Clutch Automatic Transmission - 6 Speed
Refill or fill up with PENTOSIN FFL-2.
Dual Clutch Automatic Transmission - 7 Speed
Refill or fill up with DEXRON·DCT Fluid.
Power Takeoff and Rear Axle Assembly
Please refill with Idemitsu Apolloil Wide Gear LW 80W-90
GL5.
General Lubricating Grease
Use FN745/94 grease produced by Fuchs.
1.0 29
1.0 30
Engine mechanical system-2.0T Engine
Engine mechanical system-2.0T
Specifications
Torque
Description Value
Bolt - mechanical vacuum pump to cylinder head 13-15Nm
Bolt - VVT Control valves to CVVT housing 5–7Nm
Bolt - CVVT Housing to camshaft cover 9-11Nm
Stud- thermostat housing to cylinder block 3-5Nm
Bolt - thermostat housing to cylinder block 9-11Nm
Bolt - thermostat housing bracket to block and cylinder head 22-28Nm
Bolt - turbocharger bracket to turbocharger 40–45Nm
Bolt - turbocharger bracket to crankcase 50–60Nm
Bolt - auxiliary pump bracket and CAC hose bracket to 9–11Nm
cylinder head
Bolt - VVT unit to camshaft 40Nm+120°
Bolt -oil separator to camshaft cover 9–11Nm
Bolt - camshaft cover to cylinder head 9–11Nm
Nut - exhaust manifold to cylinder head 23–27Nm
Bolt -exhaust manifold heat shield to exhaust manifold 22–28Nm
Nut - intake manifold to cylinder head 23–27Nm
Spark plugs 15-20Nm
Bolt - piston cooling jets to crankcase 18–22Nm
Bolt - crankshaft trigger wheel to crankshaft 10–12Nm
Bolt - crankshaft retainer to cylinder block 9–11Nm
Bolt - connecting rod 25Nm+90°
Bolt - rear crankshaft oil seal 9–11Nm
Bolt - flywheel to crankshaft 20Nm+60°
Bolt - PAS bracket to cylinder head 23–27Nm
Bolt - chain guide rail upper to camshaft cover 9–11Nm
Bolt - cylinder head heat shield to camshaft cover 9–11Nm
Bolt - turbocharger outlet pipe to cylinder head heat shield 8–12Nm
bracket
Nut - turbocharger inlet pipe to camshaft cover Stud 8–12Nm
Bolt -oxygen sensor connector bracket to camshaft cover 8–12Nm
Bolt -camshaft inspect cover to camshaft cover and cylinder 5–7Nm
head
Bolt -low pressure tube bracket to camshaft cover 9–11Nm
Stud - camshaft cover to cylinder head 9–11Nm
Stud- inlet manifold to cylinder head 9–11Nm
Bolt- intake manifold bracket to intake manifold 22–28Nm
Stud- exhaust manifold to cylinder head 13–17Nm
Stud-turbocharger to exhaust manifold 8–12Nm
Bolt - oil pump to bedplate 23–27Nm
Bolt - oil pump procket to oil pump 68–72Nm
1.0 31
Engine Engine mechanical system-2.0T
Description Value
Plug - sump drain 20–25Nm
Oil filter 20–25Nm
Bolt -oil pick pipe to oil pump 9–11Nm
Bolt - oil pick pipe bracket to bedplate 13–17Nm
Bolt -oil pick pipe to oil pick pipe bracket 9–11Nm
Bolt - sump and chain bedplate 8–12Nm
Bolt-Air conditioner compressor to engine 19–25Nm
Bolt - transmission to engine 75–90Nm
Bolt - bearing cap to cylinder block 35Nm +90°+45°
Bolt - bedplate to cylinder block 23-27Nm
Bolt - engine lifting eye 22–28Nm
Bolt - timing chain cover to engine 80–90Nm
Idler -idler A to timing chain cover 32–38Nm
Bolt - timing chain cover to engine 23–27Nm
Bolt - timing chain cover to engine 9-11Nm
Bolt - sump to timing chain cover 9-11Nm
Idler -idler C to cylinder block 45–55Nm
Bolt - PAS pulley to PAS idler 14–16Nm
Bolt - water pump pulley to water pump 7.5–10.4Nm
Bolt - Fuel pipe fixed bracket to engine 19–25Nm
Bolt - oil pump chain tensioner to bedplate 20–24Nm
Bolt - chain guide rail and chain tensioner rail 20-24Nm
Bolt - timing chain tensioner to cylinder block 9–11Nm
Bolt - torsion vibration damper to crankshaft 85Nm+90°
Bolt - engine mounting to body 90–110Nm
Bolt -engine mounting to engine 50Nm+90°
Bolt - transmission mounting bracket 55–65Nm
Bolt - transmission mounting to transmission bracket 70Nm+90°
Nut- transmission mounting to transmission bracket 70Nm+90°
Bolt-compressor/condenser pipe to compressor 19-25Nm
Bolt - coolant outlet tube to twin clutch sportronic 7–10Nm
transmission
clamp- clamp to twin clutch sportronic transmission 7–10Nm
Bolt - cylinder head to cylinder block 45Nm+90°+90°
Bolt - PAS idler to PAS bracket 22–28Nm
Nut - turbocharger to exhaust manifold 28–32Nm
Bolt - turbocharger outlet oil tube to turbocharger 9–11Nm
Bolt - turbocharger outlet oil tube bracket to exhaust 22-28Nm
manifold
Bolt - turbocharger outlet oil tube to turbocharger inlet oil 9–11Nm
tube
Bolt - turbocharger inlet oil tube to turbocharger 18–22Nm
Nut - turbocharger outlet pipe to turbocharger 35–40Nm
1.0 32
Description Value
Nut - turbocharger inlet pipe to turbocharger 35–40Nm
Bolt -turbocharger heat shield to turbocharger 22–28Nm
Bolt - turbocharger outlet oil tube to crankcase 9–11Nm
Nut - turbocharger inlet oil tube to crankcase 18–22Nm
Bolt - CAC hose bracket to CAC hose 5.5Nm
Bolt - CAC hose bracket to intercooler 10–15Nm
Bolt - WAPU to cylinder block 22-28Nm
Bolt - coolant inlet pipe to WAPU 8–12Nm
Bolt - coolant inlet pipe to cylinder block 8–12Nm
1.0 33
Parameter
NLE - 2.0T Engine Assembly
Model 2.0 L gasoline engine, with 16 valves, dual overhead camshaft,
variable intake/exhaust cam timing
Cylinder arrangement 4-cylinder, in-line
Cylinder bore diameter Φ88mm
Stroke 82mm
Displacement 1.995 L
Ignition sequence 1-3-4-2
Compression ratio 10
Direction of rotation Clockwise when viewed from engine front end
Rated power 162kW / 5300r/min
Max. torque 350Nm / 2500-4000rpm
Idle speed 700 ± 50r/min
Max. engine speed 6500 rpm
Weight (excluding engine oil, A/C, clutch assembly) 153.2kg
1.0 34
Crankshaft
Cylinder block/skirt rack grade
Grade A Φ56.000-Φ56.005mm
Grade B Φ56.006-Φ56.011mm
Grade C Φ56.012-Φ56.019mm
Crankshaft main journal tolerance
Grade 1 Φ51.9810-Φ51.9879mm
Grade 2 Φ51.9880-Φ51.9939mm
Grade 3 Φ51.9940-Φ52.0000mm
Crankshaft connecting rod journal diameter Φ51.981-Φ52.000mm
Cylindricity 0.004
Quantity of main bearing shell 5 pieces for top and bottom respectively
Model The upper shell of the main bearing shell is provided with oil
hole and oil passage
Thrust washer Semi-washers are fitted on the left and right thrust washers of
the 4th main bearing seat, which fit the thrust surface
Thrust washer thickness 2.413-2.463mm
Crankshaft axial clearance 0.094-0.277mm
1.0 35
Cylinder Block and Piston

Cylinder block:
Cylinder block material Aluminum alloy
Cylinder liner type Precast cylinder liner
Cylinder liner diameter Φ88-Φ88.01mm
Connecting rod:
Model of connecting rod Fractured connecting rod, C70S6
Distance between central connecting rods 150.5
Type of piston pin Full floating type
Fitted connecting rod Clearance
Piston pin length 56.7-57mm
Connecting rod bearing shell:
Clearance 0.023-0.073mm
Piston:
Model Aluminum alloy piston
Piston diameter Φ87.965 ± 0.009mm
Tolerance in piston pin bore Φ23 (+0.005, +0.013) mm
0.5 ± 0.03 at 36
Max. ovality
0.7 ± 0.03 at 10
Piston ring:
Model 2 compression rings, 1 oil ring
Top compression ring Steel strip ring, ring height: 1.2 (–0.03, –0.01)
Secondary compression ring Cast iron ring, ring height: 1.2 (–0.03, –0.01)
Oil ring Two-piece oil ring, ring height: 2.0 (–0.03, –0.01)
Tolerance between piston ring and ring groove:
Top compression ring 0.04-0.08mm
Secondary compression ring 0.03-0.07mm
Oil ring 0.02-0.06mm
Gap between piston ring assembly notch:
Top compression ring 0.20-0.35mm
Secondary compression ring 0.40-0.60mm
Oil ring 0.20-0.40mm
Radial width of piston ring:
Top compression ring 3.1 ± 0.10mm
Secondary compression ring 3.6 ± 0.10mm
Oil ring 2.75 ± 0.15mm
1.0 36
Cylinder Head and Valve
Cylinder head:
Material Aluminum alloy
25*25 local flatness 0.0075mm
Cylinder head height: 137 ± 0.05mm
Flatness 0.08mm
Camshaft:
Model Assembled DOHC
Bearing 6th gear bearing
Drive Timing chain drive
Camshaft axial clearance: 0.07-0.22mm
Diameter of 1st gear journal: Φ31.957-Φ31.972mm
Camshaft journal
Diameter of 2-6 gear journal: Φ24.96-Φ24.98mm
Bearing clearance for 1st gear: 0.04-0.075mm
Bearing clearance
Bearing clearance for 2-6 gear: 0.02-0.061mm
Hydraulic tappet:
Model Hydraulic tappet, roller rocker
Hydraulic tappet OD Φ11.994 ± 0.006mm
Valve timing Timing information for initial assembly is as follows:
Intake valve:
ON 20°CA ATDC
OFF 80°CA ABDC
Max. lift 40°CA BBDC

Exhaust valve:
ON 64°CA BBDC
OFF 4°CA BTDC
Max. lift 56°CA ABDC

Valve stem diameter:
Intake valve Φ5.475 ± 0.0075mm
Exhaust valve Φ5.455 ± 0.0075mm

Gap between valve stem and valve guide:
Intake valve 0.0175-0.0445mm
Exhaust valve 0.0375-0.0645mm

Valve stem fit height A:
New intake valve 49.9-50.4mm
New exhaust valve 50.09-50.59mm
1.0 37
Valve head diameter:
Intake valve Φ34.2 ± 0.1mm

Valve thickness:
Intake valve 1.65 ± 0.15mm
Exhaust valve 1.75 ± 0.15mm

Intake valve length 113.4-113.9mm
Exhaust valve length 116.29-116.79mm
Valve surface angle - intake valve & exhaust valve 45°15′ ± 15′
Valve spring:
Free length 52.3mm
Mounting length 40.2mm
Assembly load 250N
Intake valve max. opening load 533N
Exhaust valve max. opening load 533N
1.0 38
Lubrication
Lubrication
Oil pump model External gear pump
Free length of pressure relief valve spring 45mm
Oil filter Full flow oil filter
Cutoff pressure of pressure relief valve at 1000r/min 0.5-0.6Mpa, oil (90°)
1.0 39
Spark plug
Spark plug
Supplier: NGK
Clearance: 0.7-0.8mm
Ignition coil manufacturer UAES
Primary resistance 0.453Ω ± 12%
Secondary resistance 9.64KΩ ± 12%
1.0 40
Description and Operation
System Layout
Engine Layout
1. 2.0T Engine
1.0 41
Cylinder Block Exploded View
1. Cylinder Block Assembly 6. Crankshaft Assembly

2. Transmission Locating Pin 7. Crankshaft Signal Wheel
3. Rear Crankshaft Oil Seal 8. Locating Pin - Engine
4. Locating Pin - A/C Compressor 9. Screw - Crankshaft Signal Wheel
5. Screw - Rear Crankshaft Oil Seal 10. Crankshaft Main Bearing Shell (Upper)
1.0 42
11. Crankshaft Thrust Washer 20. Piston Connecting Rod Assembly
12. Crankshaft Main Bearing Shell (Lower) 21. Connecting Rod Bearing Shell
13. Engine Oil Return Pipe 22. Crankshaft Key
14. Crankshaft Torsional Vibration Damper Button 23. Locating Pin - Timing Chain Cover
15. Cylinder Block Locating Pin 24. Piston
16. Bolt - Engine Skirt Rack 25. Plug - Cylinder Block Oil Passage
17. Bolt - Engine Skirt Rack 26. Cylinder Head Locating Pin
18. Piston Cooling Nozzle 27. Oil Check Valve
19. Bolt - Connecting Rod
1.0 43
Cylinder Head Exploded View
1. Engine Cylinder Head Assembly 4. Bolt - Camshaft Bracket

2. Bolt - Camshaft Access Hole Cover Plate 5. Bolt - Camshaft Bracket
3. Cylinder Head Oil Passage Blocked 6. Bolt - Exhaust Manifold
1.0 44
7. Cylinder Head Gasket 18. Intake Valve
8. Engine Vacuum Pump Assembly 19. Valve Stem Oil Seal
9. Cover Plate - Camshaft Access Hole 20. Valve Spring
10. Cylinder Head Locating Pin 21. Valve Spring Cover
11. Bolt - Cylinder Head 22. Valve Lock Clamp
12. Exhaust Camshaft 23. Engine Rocker Arm Assembly
13. Intake Camshaft 24. Valve Tappet Assembly
14. Bolt - Engine Vacuum Pump 25. Stud - Intake Manifold
15. Gasket - Engine Vacuum Pump 26. Cylinder Head Oil Passage Blocked
16. Stud - Camshaft Bracket 27. Locating Pin - Power Steering Pump Bracket
17. Exhaust Valve
1.0 45
Camshaft Cover Exploded View
1. Oil Separator Assembly 4. Bracket - Emission Control Valve

2. Bolt - Oil Control Valve Seat 5. Gasket - Oil Control Valve Seat
3. Bolt - Oil Separator Cover Plate 6. Bolt - Oil Control Valve
1.0 46
7. Oil Control Valve 12. Pipe Clip - Crankshaft Part Load Breather Hose
8. Machined Part of Oil Control Valve Seat 13. Crankshaft Full Load Breather Hose Assembly
9. Stud - Oil Control Valve Seat 14. Pipe Clip - Crankshaft Full Load Breather Hose
10. Bolt - Oil Control Valve Seat 15. Pipe - Oil Separator to Intake Manifold
11. Crankshaft Part Load Breather Hose Assembly
1.0 47
Ignition System/Fuel Injection System Exploded

View
1. Engine Low-pressure Fuel Pipe 3. Engine High-pressure Fuel Pump

2. Screw - Engine Fuel Pump 4. Sensor - Fuel Rail Fuel Pressure
1.0 48
5. High-pressure Fuel Pump Tappet 13. Bolt - Engine Low-pressure Fuel Pipe
6. Engine High-pressure Fuel Pipe 14. Nut - Engine Low-pressure Fuel Pipe
7. Fuel Rail 15. Bolt - Fuel Rail
8. Bolt - Fuel Rail 16. Locating Pin - Fuel Rail
9. Clip - Injector 17. Spark Plug Assembly
10. Injector Assembly 18. Ignition Coil Assembly
11. Injector Seal Ring 19. Screw - Ignition Coil
12. Fuel Pump Sound Insulator
1.0 49
Timing Chain System Exploded View
1. Bolt -Crankshaft Torsional Vibration Damper 13. Oil Pump Chain Tensioner
2. Bolt - Oil Pump Sprocket 14. Timing Chain Guide Rail
3. Crankshaft Torsional Vibration Damper 15. Timing Chain Guide Rail
4. Front Crankshaft Oil Seal 16. Bolt - Phase Modulator
5. Timing Chain Cover 17. Intake Phase Modulator
6. Bolt - Timing Chain Cover 18. Exhaust Phase Modulator
7. Bolt - Timing Chain Cover 19. Crankshaft Sprocket
8. Bolt - Timing Chain Cover 20. Timing Chain Assembly
9. Oil Filter Cap Assembly 21. Bolt - Timing Chain Guide Rail
10. Bolt - Timing Chain Tensioner 22. Timing Chain Guide Rail
11. Locating Pin - Timing Chain Guide Rail 23. Sprocket - Oil Pump
12. Timing Chain Tensioner Assembly 24. Chain - Oil Pump
1.0 50
Oil Cooling Module/Oil Pump/Oil Pan Exploded
View
1. Oil Level Indicator 3. Oil Pan Assembly

2. Oil Pump Assembly 4. Bolt - Oil Pan
1.0 51
5. Bolt - Oil Pan 14. Oil Pump Suction Pipe Bracket

6. Bolt - Oil Pan 15. Screw - Oil Pump Suction Pipe Bracket
7. Gasket - Oil Pan Drain Plug 16. Oil Filter Assembly
8. Drain Plug - Oil Pan 17. Bolt - Oil Filter
9. Oil Pump Connector 18. Seal Ring - Oil Filter Module
10. Bolt - Oil Pump 19. Seal Ring - Oil Filter Cover
11. Bolt - Oil Pump 20. Oil Filter Element
12. Oil Pump Suction Pipe Assembly 21. Oil Filter Cover Assembly
13. Screw - Oil Pump Suction Pipe
1.0 52
Water Pump/Thermostat Exploded View
1. Thermostat Assembly 12. Clip - Engine Cooling Water Pipe

2. Thermostat Housing Assembly 13. Water Pump Inlet Pipe Assembly
3. Nut - Thermostat Housing 14. Screw - Engine Cooling Water Pipe
4. Bolt - Thermostat Housing 15. Water Pump Inlet Pipe Assembly
5. Screw - Engine Cooling Water Pipe 16. O Ring - Water Pump Inlet Pipe
6. Bolt - Thermostat Housing Bracket 17. Water Pump Pulley
7. Bolt - Thermostat Housing Bracket 18. Bolt - Coolant Pump
8. Thermostat Housing Bracket 19. Screw - Water Pump Pulley
9. Seal Ring - Thermostat Housing 20. Thermostat Seal Ring
10. Bolt - Thermostat Housing 21. Engine Water Pump Assembly
11. Clip - Engine Cooling Water Pipe
1.0 53
Intake Manifold Exploded View
1. Intake Manifold Assembly 4. Bolt - Intake Manifold Bracket

2. Intake Manifold Gasket 5. Gasket - Throttle Body
3. Intake Manifold Bracket 6. Nut - Intake Manifold
1.0 54
7. Intake Manifold Gasket 11. Solenoid Solenoid Assembly
8. Throttle Body Assembly 12. Canister Solenoid Bracket
9. Screw - Throttle Body 13. Clamp - Canister Solenoid Pipe
10. Pipe Assembly - Canister Solenoid to Manifold 14. Bolt - Canister Solenoid Bracket
1.0 55
Exhaust Manifold Exploded View
1. Exhaust Manifold 4. Exhaust Manifold Gasket

2. Stud - Turbocharger 5. Exhaust Manifold Heat Shield
3. Nut - Turbocharger 6. Bolt - Exhaust Manifold Heat Shield
1.0 56
7. Gasket - Turbocharger 9. Exhaust Manifold Gasket
8. Nut - Exhaust Manifold Pipe 10. Bolt - Exhaust Manifold Heat Shield
1.0 57
Turbocharger Exploded View
1. Turbocharger Assembly 4. Gasket - Turbocharger Oil Return Pipe

2. Stud - Turbocharger Exhaust Pipe 5. Turbocharger Oil Return Pipe Assembly
3. Clip - Electronic Water Pump 6. Clip - Engine Cooling Water Pipe
1.0 58
7. Turbocharger Bracket 21. Electronic Water Pump Bracket
8. Bolt - Turbocharger Bracket 22. Bolt - Electronic Water Pump Bracket
9. Bolt - Turbocharger Bracket 23. Electronic Water Pump
10. Heat Shield - Turbocharger 24. Gasket - Turbocharger Coolant Pipe
11. Bolt - Turbocharger Heat Shield 25. Bolt - Turbocharger Coolant Pipe
12. Turbocharger Oil Inlet Assembly 26. Nut - Turbocharger Coolant Pipe Bracket
13. Bolt - Turbocharger Oil Return Pipe 27. Turbocharger Water Inlet Pipe Assembly
14. Bolt - Turbocharger Oil Return Pipe 28. Clip - Engine Cooling Water Pipe
15. Bolt - Turbocharger Oil Inlet Pipe 29. Cylinder Head Heat Shield
16. Turbocharger Water Oil Outlet Pipe Assembly 30. Bolt - Cylinder Head Heat Shield Bracket
17. Gasket - Turbocharger Oil Inlet Pipe 31. Bolt - Cylinder Head Heat Shield
18. Bolt - Turbocharger Oil Inlet Pipe Bracket 32. Bolt - Turbocharger Coolant Pipe Bracket
19. Cylinder Head Heat Shield Bracket 33. Bolt - Turbocharger Coolant Pipe
20. Electronic Water Pump Outlet Pipe Assembly 34. Gasket - Turbocharger Coolant Pipe
1.0 59
Accessory Belt Exploded View
1. Front Engine Belt 8. Bolt - Power Steering Pump Bracket

2. Screw - Tensioner 9. Bolt - Power Steering Pump Bracket
3. Auxiliary Belt Tensioner Assembly 10. Belt Idler Assembly
4. Belt Idler Assembly 11. Bolt - EPAS Idler
5. Pulley - Power Steering Pump 12. EPAS Idler
6. Power Steering Pump Bracket 13. Bolt - Power Steering Pump Pulley
7. Bolt - Power Steering Pump Bracket
1.0 60
Description The exhaust valve can remove the carbon deposit, and the
Overview valve stem with a machined side can remove the carbon deposit
at the end of the valve guide and in the combustion chamber
The NLE engine features inline 4-cylinder, 16-valve, DOHC,
and thus avoid valve seizing.
timing chain drive and direct injection system.
The metal cylinder gasket is of a multi-layer structure, the
It is composed of cylinder block, cylinder head, crankshaft,
cylinder opening adopts a pressing ring structure, which
connecting rod and camshaft, etc.The cylinder head is made
enhances sealing at cylinder opening; local rubber coat
of cast aluminum, and 10 high-strength bolts connect it to
technology is adopted to ensure the sealing performance.
the cast aluminum cylinder block through multiple layers of
cylinder gasket, so the whole strength is high and the structure Four oil orifices are arranged on both the front and rear of the
is reliable. camshaft head journal, which correspond to two oil circuits
Cylinder Block Components respectively.The oil circuits are two-way circuits. When the
front takes oil, the rear drains and vice versa.Oil enters the
The cylinder block is made of common cast aluminum
oil control solenoid valve via the oil ducts.The tail end of the
AlSi9Cu3, this provides high overall strength, reducing the
camshaft is equipped with a camshaft signal wheel to provide
likelihood of deformation.The cylinder liner is formed by
signals for camshaft position sensor.There is a tail groove on
cylinder hole honing.Y-shaped water passages are processed
the camshaft for controlling camshaft timing phase during
between two adjacent cylinders to ensure radiating effect of
assembly.
the cylinder block.
A phase modulator is fitted at the drive ends of the intake and
The aluminum alloy thermal expansion piston is fitted with full
exhaust camshafts, which is fixed by bolts.The phase modulator
floating piston pins, the clearance between the piston pin and
includes two hydraulic pressure chambers.The ECU controls
the connecting rod small end shall be appropriate, and the two
the duty cycle signal of the OCV valve according to the engine
ends of the piston pin is fixed by circlips.Each piston is provided
working condition, and the OCV valve adjusts the camshaft
with two compression rings and one oil ring.
phase and achieves an optimum distribution by controlling the
The forging steel connecting rod has the structure of the hydraulic pressure level in the two chambers.
H-section.The big end of the connecting rod moves on the
Two oil control valves are fitted on the housing of the camshaft
bearing shell of the crankshaft journal.The connecting rod
cover control valve, which are fixed by an O ring and a bolt
adopts forging+cracking process.
respectively.The control valve is a four-way proportioning
The crankshaft has four balance weights which are supported valve, which consists of an oil inlet, an oil return port and two
by five bearing shells.The end float is controlled by the thrust oil circuits connected with the phase modulator chamber.
washer on the top of the central main bearing shell.The radial Lower Crankcase Components
clearance of the bearing shell is optional, controlled by the
The lower crankcase assembly includes the lower crankcase
bearing shells of two different grades.The oil groove offered
and oil pump. The aluminum lower crankcase is designed into
in the upper half part of the main bearing shell supply oil to the
a shape that is suitable for accumulating oil around the oil
connecting rod big end bearing shell through the oil hole in the
strainer, the oil pump is fitted to the bottom of the crankcase.
crankshaft.
Oil passes through the oil strainer with screen, and it is then
Cylinder Head Components pressurized by the oil pump before returning to the oil strainer.
The cylinder head adopts 4-valve structure for each cylinder,
Clean oil is distributed to the main bearing and cylinder
the spark plug is mounted at the center of the combustion
head via main oil passage of the engine body to lubricate the
chamber. The overhead valve structure generates powerful
crankshaft, connecting rod and camshaft, etc.The mating face
whirlpool in the combustion chamber and allows the gas
of the lower crankcase and engine body are sealed by sealant
mixture to be distributed evenly, which facilitates spread of
and secured with bolts.
flame and improvement of the combustion condition, engine
Engine Accessories
power performance, fuel economy and emission performance.
The accessories are a single 6-ribbed belt drive system driven
One end of the camshaft drive roller rocker arm is supported
by crankshaft pulley: the system drives the water pump,
by the hydraulic tappet, and the other end is by the valve
alternator and A/C compressor, and tensions the belt via a
stem. The valve is driven by the moment of the rocker
damping tensioner.
arm.The hydraulic tappet can compensate the valve clearance
automatically.The valve stem oil seal is press-fitted on the
cylinder head oil seal seat and can be used as the valve spring
seat to support the valve spring.
1.0 61
Positive Crankcase Ventilation injector injects the fuel into the cylinder at a certain pulse
width, the rail pressure sensor provides rail pressure signal
The ventilation system redirects the exhaust gas escaped to
feedback for the ECU, and the ECU controls the rail pressure
the crankcase back into the intake system with the help of
by the high-pressure oil pump.The pressure of the NLE fuel
intake system vacuum level, then sends it to the cylinder for
injection system is up to 15MPa. ECU controls the spray form
combustion, so as to reduce the air pollution.
and fuel-injection quantity by controlling the rail pressure and
Oil and gas in the crankcase are separated via an oil separator fuel injection pulse width so as to meet the requirements for
in the camshaft cover, and oil flows back to the crankcase. injection under different conditions.
According to the different engine phrase，the separated gas Turbocharger
will enter into the intake pipe through part road breathe pipe，
The high temperature and high pressure gas exhausted from
or the separated gas through all road breathe pipe，then enter
the engine exhaust manifold contains a certain energy.For
into clean air pipe and turbo，then enter into intake pipe。
naturally aspirated engines, this energy is often wasted during
The oil separate inside is designed with labyrinth，whirlwind emissions.The turbocharger can use the exhaust gas as power
separate cell and PRV valve. the exhaust gas first enter into to improve the engine power (around 30%) and cylinder
the labyrinth to previous separate, then enter into whirlwind scavenging performance, this can effectively reduce NOx
separate cell to careful separate. the function of PRV valve emission.The turbine wheel and compressor impeller realize
is reduce the influence of the exhaust gas and the pressure rigid connection through the turbocharger shaft, and this
fluctuate in the intake pipe, and make the pressure steady. is called the turbocharger rotor.The turbocharger rotor is
High Pressure Common Rail & Direct Injection fixed in the turbocharger through the floating bearing (A
Gasoline System smaller friction resistance moment can be guaranteed when
the rotor rotates at high speed.).When the engine works, the
Comparing with PFI engine, the gasoline direct injection engine
exhaust gas impacts the turbine wheel at a certain angle with
avoids introducing moisture to the wall of the intake port, this
a high speed, which drives the turbocharger rotor to rotate
allows accurate calculation of the fuel, reduction of the HC
at high speed.The high-speed rotation of the compressor
emission level during cold start and improvement of the engine
impeller raises the pressure in the engine intake manifold, and
transient response speed.
pressurization is thus achieved during this process.By this way,
The gasoline in-cylinder direct injection (GDI) system includes: high pressure will allow more air with larger density to enter
High-pressure oil pump, high-pressure oil pipe, fuel rail, rail into the cylinder during intake process. This helps to improve
pressure sensor and injector. fuel combustion and engine performance.
The overhead cam drives the high-pressure oil pump to deliver Water cooling and oil cooing are used due to high temperature
high-pressure fuel to the fuel rail pump via the oil pipe, the of the gasoline engine turbocharger.
1.0 62
Operation
1. Cylinder Head Oil Passage 5. Main Oil Circuit

2. Cylinder Block Main Oil Circuit 6. Oil Filter
3. Crankshaft Cross Oil Circuit 7. Main Oil Circuit
4. Oil Pump
Lubricant Oil Circuit oil returns to the inlet side of the oil pump, and this helps
maintain the oil pressure within a certain working pressure
The lubrication system is a full-flow filtration, forced oil supply
range and ensure normal operation of the engine. The oil
system. Oil is drawn from the oil pan through the oil suction
from the oil pump outlet flows into the oil filter module
pipe by the oil pump, and the oil suction pipe is provided with
through the skirt rack and engine body oil circuit.
a strainer which can prevent impurities from entering the oil
pump. The oil filter module is directly fitted on the engine body, which
contains the oil cooler and oil filter. The oil cooler cools
The crankshaft uses a chain to drive the oil pump with a
the oil before delivering it into the oil filter, this oil filter is
pressure limiting valve. When the oil pressure achieves a
an environment-friendly filter, so you just need to replace the
certain value, the pressure limiting valve opens, the excess
1.0 63
filter element when doing maintenance. The oil filter is fitted The cylinder head includes 3 side oil circuits connected with
with a bypass valve, when the filter element is blocked, it will the engine body main oil circuit, one of them provides pressure
open and ensure free flow of the oil, but the element shall be for the VCT, and oil flows into the two horizontal oil circuits of
replace under this situation. standard length via the other two side circuits, the oil source
of each hydraulic tappet and camshaft journal is thus provided.
The oil then enters into the main oil circuit fitted with the
piston cooling nozzle which is used for cooling the piston and The turbocharger lubricant pipe and main engine oil circuit of
lubricating the connecting rod small end and piston pin. The oil the turbocharged engine are connected. Oil comes into the
lubricates the main bearing shell through the cross oil circuit, turbocharger before flowing back into the engine body cavity
and the cross oil circuit of the crankshaft delivers the oil from by the oil return pipe.
the main bearing shell to the connecting rod big end bearing
shell.
1.0 64
Service Procedures Oil Control Valve
Mechanical Vacuum Pump Remove
Remove 1. Disconnect the battery negative.
1. Remove the battery box. 2. Remove the engine cover.
Battery Remove 3. Disconnect the oil control valve connector.
2. Remove the engine hood.
3. Disconnect the vacuum pipe from the vacuum pump.
4. Release 2 bolts fixing the 2 oil control valves to the

CVVT cover and remove the oil control valves.
4. Remove 3 bolts fitting the vacuum pump to the cylinder

head to release the vacuum pump, and discard the
gasket.
Refit
1. Fix 2 oil control valves to the CVVT cover, fit 2 bolts,
tighten to 5–7Nm and check the torque.
2. Connect the oil control valve connector.
Refit
3. Fit the engine cover.
1. Fit new gaskets.
4. Connect the battery negative.
2. Pass 3 bolts through the mechanical vacuum pump to
fix the gasket to the mechanical vacuum pump.
3. Adjust the connecting parts of the mechanical vacuum
pump to level position, insert them into the camshaft
groove, fit 3 bolts, tighten to 13-15Nm and check
the torque.
4. Connect the vacuum pipe of mechanical vacuum pump.
5. Fit the engine hood.
6. Fit the battery.
Battery Refit
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CVVT Cover Thermostat Housing

Remove Remove
1. Disconnect the battery negative. 1. Disconnect the battery negative.
2. Remove the engine cover. 2. Remove the battery bracket.
3. Remove the oil control valve. Battery Bracket Remove
Oil Control Valve Remove 3. Drain the engine coolant.
4. Remove 9 bolts fixing the CVVT cover to the camshaft Coolant - Drain
cover, and remove the CVVT cover and gasket.
4. Remove the thermostat.
Caution: Mounting Position of Stud
Thermostat Remove
5. Remove the engine coolant temperature sensor.
Engine Coolant Temperature Sensor Remove
6. Remove 1 bolt (1) fixing the throttle air inlet pipe to
the bracket, and take away the throttle air inlet pipe.
7. Release the clamp and disconnect the cooling pipe of
the thermostat housing.
Refit
1. Clean the junction between the CVVT cover and the
camshaft cover.
2. Fit the gasket and ensure it is aligned with all holes.
3. Fix the CVVT cover to the camshaft cover, fit 9 bolts,
tighten to 9-11Nm, and check the torque.
8. Remove 2 bolts fixing the turbocharger bracket to

the cylinder block and turbocharger, and remove the
bracket.
4. Fit the oil control valve.
Oil Control Valve Refit

6. Connect the battery negative. 9. Remove 2 bolts fixing the thermostat housing bracket
to cylinder head and thermostat housing.
10. Remove 2 bolts and 2 nuts fixing the thermostat
housing to the engine cylinder block, remove the
thermostat housing and discard gasket.
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Intake/Exhaust Phase Modulator
Remove
1. Drain the engine oil.
Engine Oil - Drain
2. Remove the engine timing chain.
Engine Timing Chain Remove
3. Release the intake/exhaust phase modulator fastening
bolts.
4. Remove each 1 bolt securing intake/exhaust phase
modulator onto intake and exhaust camshafts and
discard them, distinguish the intake/exhaust phase
modulators and remove phase modulators.
11. Remove and discard 2 studs.
Refit
Refit
1. Fit the intake phase modulator to the front of the
1. Fit 2 new studs to the cylinder block, tighten to 3-5Nm
intake camshaft, fit new bolt to the phase modulator
and check the torque.
and pre-tighten it.
2. Fit new gaskets, fix the thermostat housing to engine
cylinder block, fit 2 bolts and 2 nuts and pre-tighten
them, then tighten to 9-11Nm in the diagonal sequence
3. Fix the thermostat housing bracket to the cylinder
head and thermostat housing, fit 2 bolts, tighten to
22-28Nm and check the torque.
4. Connect the cooling pipe of the thermostat housing
and secure it with clamps.
5. Fix the turbocharger bracket to the cylinder block
and turbocharger, fit 1 turbocharger bolt, tighten to
40–45Nm, then fit 1 cylinder block bolt, tighten to
50–60Nm and check the torque.
2. Fit the exhaust phase modulator to the front of the
6. Fix the throttle air inlet pipe to the bracket, fit 1 bolt,
exhaust camshaft, fit new bolt to the phase modulator
tighten to 9–11Nm, and check the torque.
and pre-tighten it.
7. Fit the engine coolant temperature sensor.
Engine Coolant Temperature Sensor Refit

8. Fit the thermostat.
Thermostat Refit
9. Refill the engine coolant.
Coolant - Refill
10. Fit the battery bracket.
Battery Bracket Refit

3. Tighten the phase modulator bolt with the tightening

torque of40Nm+120° (monitor if final torque is
140-200Nm), and check the torque.
4. Fit the engine timing chain.
Engine Timing Chain Refit
1.0 67
5. Fill the engine oil. Oil-gas Separator

Engine Oil - Refill
Remove
1. Disconnect the battery negative.
2. Remove the engine cover.
3. Release the clamp, and disconnect the breather pipe
from the oil-gas separator.
4. Remove 8 bolts fixing the oil-gas separator to the

camshaft cover to release the oil-gas separator.
5. Release the clamp, and remove the oil return pipe from
the oil-gas separator.
Refit
1. Clean the junction of the oil-gas separator.
2. Fit the oil return pipe to the intake manifold.
3. Adjust the angle of the oil return pipe, fit the big end of
the oil return pipe to the oil-gas separator and secure
with clamps.
4. Fix the oil-gas separator to the camshaft cover, fit 8
bolts, tighten to 9–11Nm, and check the torque.
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Cylinder Head Check
Remove
1. Remove the cylinder head.
Cylinder Head Remove
2. Remove 5 nuts fixing the intake manifold to the cylinder
head, remove the intake manifold and discard the
gasket.
5. Connect the vacuum pipe of the oil-gas separator and

secure with clamps.
3. Remove 4 bolts fixing the exhaust manifold heat shield

to the exhaust manifold to release the heat shield.
4. Remove and discard 8 nuts fixing the exhaust manifold

to the engine, remove the exhaust manifold and discard
the gasket.
5. Clear the dirt in the spark plug gap, and remove the
1.0 69
spark plug from the cylinder head. range, replace the cylinder head or camshaft.
6. Put the camshaft into the camshaft bearing seat of the 10. Remove 39 bolts fixing the camshaft cover to the
cylinder head. cylinder head in the sequence shown, and remove the
camshaft cover.
7. Apply engine oil to the camshaft journal evenly.
11. Identify the position of each camshaft carefully, and

8. Fix the camshaft cover to the cylinder head, fit 39 bolts,
remove the camshaft from the camshaft seat.
tighten to 9–11Nm in the sequence shown, and check
the torque. 12. With a viscous magnet, remove 16 roller rocker arms
and hydraulic tappet from the cylinder head, and keep
them in the mounting sequence.
9. Place the camshaft in the mounting position on the

cylinder head, fit a micrometer on the front end of the
camshaft along the thrust direction. When the camshaft 13. Measure the outside diameter of each tappet, and the
is moving forward or backward (in the axial direction), OD shall be Φ11.994±0.006mm; if it is out of the range,
measure the end clearance. The measurement shall replace it.
be within 0.07-0.22mm. If it is not within the specified 14. Ensure that the oil holes in each tappet are clean.
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15. Clean the surfaces of the camshafts and cylinder head
bearing.
16. Inspect the camshaft and replace if it is scratched, pitted
or excessively worn.
17. Fix the camshafts to the cylinder head, and place a
plastic gauge on each journal.
18. Then fit the camshaft cover and 39 bolts, tighten to
9–11Nm in the sequence shown, but do not rotate
the camshaft.
21. Compare the measured clearance with the standard

value. If the measured clearance exceeds the standard
value, and the camshaft journal is within the standard
value, renew the cylinder head and camshaft cover
assembly.
Parameter
22. Remove the valve.
Valve Remove
23. Clean the mating face of the cylinder head.
19. Remove 39 bolts fixing the camshaft cover to the
24. Check the cylinder head for damage. Pay special
cylinder head in the sequence shown, and remove the
attention to the gasket surface of the cylinder head.
camshaft cover.
25. Check the surface of the cylinder head for scratch, and
check the flatness of the cylinder head according to
the method shown, do the operation in a cross way. If
the flatness is not within the specified value (0.08mm),
replace the cylinder head.
20. Measure the widest part of the plastic gauge on each

journal and determine the matching clearance between
the journal of 1st gear/2-6 gear and the cylinder head.
26. Check the height of the cylinder head, if it is out of the

specified range (137±0.05mm), replace the cylinder
head.
27. Remove the carbon deposits and loose particles from
the valve guide, valve, valve seat and combustion
surface.
28. Measure the clearance between the valve stem (1) and
valve guide (2).
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Standard Value
Intake Valve 49.9-50.4mm
Standard Value Exhaust Valve 50.09-50.59mm
Intake Valve 0.0175–0.0445mm
Refit
Exhaust Valve 0.0375-0.0645mm 1. Clean the sealing area of the cylinder head and
29. Apply Prussian blue (or lead white) to the contact camshaft bracket. Treat the sealing surface with foam
surface of the valve seat and check the valve contact remover and plastic scraper, but never use any metal
surface condition. Check if the continuous contact is scraper. Clean the mating surface of the intake/exhaust
achieved throughout the circle. If continuous contact is manifolds.
not achieved, replace the valve. If the contact surface is 2. Blow the oil passage and coolant passage dry. Ensure
still abnormal in the following check, replace the entire clean oil will be supplied to the camshaft cover.
cylinder head. Tip: Please use SAIC MOTOR recommended solvent.
3. Fit the valves.
Valve Refit
4. Clean the mating surface of the exhaust manifold and
cylinder head.
5. Fit new gasket to the exhaust manifold, secure the
exhaust manifold on the engine, fit 8 gaskets and new
nut with high temperature antiwelding agent, then
tighten to 23–27Nm in the sequence shown and check
the torque.
30. Insert the valve into the valve guide of the cylinder head,
and check the matching height A of the valve stem.
6. Fix the exhaust manifold heat shield to the exhaust

manifold, fit 4 bolts, tighten to 22–28Nm, and check
1.0 72
the torque. Crankshaft Check
7. Fit the hydraulic tappet into the corresponding Remove
mounting bore on the cylinder head, and lubricate it 1. Remove the engine timing chain.
with clean engine oil.
8. Ensure the roller rocker arm holder is secure, align the
2. Remove the oil pump.
ball groove of the roller rocker arm with the plunger
ball head of the hydraulic tappet, and gently press the Oil Pump Remove
ball head into the ball groove. 3. When moving the crankshaft forward and backward
9. Fit the new intake manifold gaskets. sufficiently, measure the gap between the thrust bearing
10. Fix the intake manifold to the cylinder head, fit 5 nuts and the crankshaft with the dial gage. The standard gap
in the sequence as shown, tighten to 23–27Nm, and value is 0.094-0.277mm. If the measurement is not
check the torque. within the specified range, replace the thrust bearing
and make another measurement. If it remains out of
the standard limit, replace the crankshaft.
11. Adjust the clearance of every spark plug to 0.7-0.8mm.

12. Fit the spark plug and tighten it to 15-20Nm.
4. Remove the engine bearing ladder.
13. Fit the cylinder head.
Engine Bearing Ladder Remove
Cylinder Head Refit
5. Remove the lower bearing from the bearing seat bore
of the engine bearing ladder.
6. Remove the connecting rod bearing shell.
Connecting Rod Bearing Shell Remove

7. Remove the crankshaft.
8. Remove the upper main bearing and thrust washer
from the cylinder block.
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9. Remove and discard 3 bolts fixing the signal gear to the 12. Measure the cylinder diameter at different points of
crankshaft, and remove the signal gear. each cylinder with an inside micrometer, check for
wear, out-of-roundness and taper. The standard value
of the cylinder diameter is: Φ88-Φ88.01mm.
10. Remove 4 bolts fixing 4 piston cooling nozzles to the

cylinder block.
Refit
1. Clean the crankshaft, cylinder block, signal gear, skirt
rack and mating face of the main bearing, and ensure
there is no foreign material.
2. Clean the oil circuit, water channel and ensure there is
no foreign material.
3. Check the crankshaft and signal gear for damage or
burr.
4. Check the crankshaft bearing for any pit, groove (1),
severe scratch or discoloration (2). If any part of the
bearing is shiny and polished (3), this may indicate
misalignment.
11. Check the surface of the cylinder block for scratch,
and check the flatness of the cylinder block according
to the method as shown; check above in a cross way. If
the flatness is not the specified value (0.08mm), replace
the cylinder block.
1.0 74
the thickness of bearing shells are as follows:
a. Yellow = thin
b. Blue = medium
c. Red = thick
11. Use a piece of cloth without rough edges and
appropriate solvents to clean the sealing surface of the
cylinder block and bearing seat.
Tip: Please use SAIC MOTOR recommended solvent.
12. Press the upper main bearing into the bore of the
cylinder block bearing seat. Align the bearing with the
groove of the bearing seat bore, and ensure the oil
orifice is not covered.
5. Check the classification identification of the crankshaft

main journal from the flange of the crankshaft flywheel.
13. Clean and fit the new thrust washer to the two sides
of the cylinder block main bearing 4.
Tip: The oil groove surface of the thrust washer is the
6. Check the diameter of the main journal. surface contacting with the crankshaft thrust surface,
and never fit it reversely.
7. Check the corresponding classification identification on
the cylinder block and skirt rack. 14. Measure the inner diameter of the crankshaft main
bearing with an inside micrometer.
8. The selection order of the bearing starts with the
engine (from front to rear), with the timing chain cover
located at the first place.
9. Select the correct main bearing according to the group
number of the cylinder block/skirt rack and crankshaft,
see the table below.
Main Bearing Selection Table
Crankshaft
Main Journal 1 2 3
Grade
Main Bearing To
Upper Lower Upper Lower Upper Lower
Be Fitted
Cylinder A Red Blue Red Yellow Red Red
Block/ B Yellow Blue Yellow Yellow Yellow Red
Skirt
Rack C Blue Blue Blue Yellow Blue Red
Grade 15. Check the crankshaft main journal, refer to "Parameter"
10. The colours on the edge of bearing shells which indicate for details.
1.0 75
16. Fix 4 piston cooling nozzles to the cylinder block and Connecting Rod Bearing Shell Check
secure with the locating pin, fit 4 bolts, tighten to Remove
18–22Nm , and check the torque. 1. Remove the cylinder head.
17. Fix the signal gear to the crankshaft, fit 3 bolts, tighten
them to 10–12Nm, and check the torque.
2. Remove the engine bearing ladder.
18. Apply oil to the crankshaft main journal and inner
surface of the upper main bearing shell, and put the Engine Bearing Ladder Remove
crankshaft assembly (fitted with signal gear) into the 3. Use the TEN00123 to fix it to bearing 1, 5, and tighten
engine body. to 9–11Nm.
19. Use the TEN00123 to fix it to bearing 1, 5, and tighten
to 9–11Nm.
4. Rotate the crankshaft to allow each connecting rod bolt

to be easily removed.
20. Rotate the crankshaft to locate cylinder 1 and 4 at the 5. Remove and discard the connecting rod bolt. Remove
top dead centre. the shell cap of the connecting rod big end, mark it
21. Fit the connecting rod bearing shell. according to the original position and keep it in order.
Connecting Rod Bearing Shell Refit

22. Fit the lower bearing to the bore of the skirt rack
bearing seat.
23. Fit the engine skirt rack.
Engine Skirt Rack Refit

24. Fit the oil pump.
Oil Pump Refit

25. Fit the timing chain.

26. Place the ignition switch in "ON" position, perform
"Engine Control Module Reset Self-learning Value" with 6. Remove the half shell from the shell cap of the
VDS. connecting rod big end.
27. Wait for 2-5 seconds, turn off the ignition switch, then 7. Disconnect the connecting rod from the crankshaft, and
restart the vehicle. remove the other half of the shell from the connecting
rod.
Refit
1. Clean the crankshaft journal, connecting rod,
connecting rod big end shell cap and bearing shell, and
ensure there is no foreign material.
2. With no connecting rod bearing shell fitted, fit the
connecting rod cap and new connecting rod bolts, and
1.0 76
tighten them to 25Nm+90°. Measure the connecting
rod big end diameter with an inside micrometer. If the
limit value is exceeded, replace the connecting rod.
Tip: If the connecting rod shall be replaced, read

the group information on the connecting rod.
3. Respectively fit the two halves of the connecting rod
bearing shell with a special tool TEN00130 to the
connecting rod and the corresponding big end shell
cover.
8. Fit the connecting rod bolt, tighten to 25Nm+90° and

check the torque.
9. Rotate the crankshaft and ensure free rotation of the
crankshaft connecting rod.
10. Remove the special tool TEN00123.
11. Fit the engine skirt rack.
Engine Skirt Rack Refit
4. Apply lubricating oil to the connecting rod bearing shell Cylinder Head Refit
surface.
5. Locate the piston connecting rod assembly to the
crankshaft.
6. The raised letter "ZY" and "A"/"B"/"C" on the shell cap
shall face the front of the engine and be fitted to the
connecting rod.
Caution: The cylinder protrusion on the connecting

rod and the arrow on the piston shall both face the
front of the engine.
7. Check if the identification letter of each connecting rod

is on the same side.
1.0 77
Piston Check
Remove
1. Remove the cylinder head assembly.
Cylinder Gasket Remove

2. Remove the connecting rod bearing shell.
Connecting Rod Bearing Shell Remove
3. Push the piston to the top of cylinder bore.
Caution: Remove the carbon deposits on the top of the

cylinder bore first to avoid scratching the piston rings and
the piston.
4. The connecting rod shall not contact the inner wall of

cylinder bore. Push the piston assembly out of cylinder Piston Ring Opening
bore carefully. Standard Value (mm)
Clearance
Caution: Please carefully mark each piston and match Top Compression Ring 0.20-0.35
liner. Secondary Compression
0.40-0.60
5. Fit the connecting rod big end cap into the connecting Ring
rod, and lightly tighten the connecting rod bolt. Oil Ring 0.20-0.40
6. Remove and discard the used piston ring with an 4. Measure the side clearance between the piston ring and
expander (tool). the piston ring groove with a feeler gauge. If the limit
value is exceeded, replace the piston ring or piston.
Refit
1. Check the pistons for deformation and crack. Side Clearance between Standard Value (mm)
2. Clean the piston ring groove and purge the oil passage. Piston Ring and Ring
3. Measure the piston ring opening clearance. Use a Groove
cylinder block with qualified cylinder barrel, lubricate Top Compression Ring 0.04-0.08
the piston and piston ring with clean engine oil, insert
Secondary Compression 0.03-0.07
the piston ring into the middle of the cylinder block
Ring
with a piston, and measure the piston ring end clearance
with a clearance gauge. If the limit value is exceeded, Oil Ring 0.02-0.06
replace the piston ring. 5. Measure the piston diameter at the location 10mm
from the bottom of the skirt. The standard value is
Φ87.965±0.009mm.
1.0 78
6. Fit the spring of the piston oil ring.

7. With an expander, fit the piston ring in sequence (oil
ring, secondary compression ring and top compression
ring).
8. Ensure piston rings are free to rotate, the gap between
the two compression rings shall form an angle of 120°
and away from the piston thrust side.
13. Push the piston connecting rod assembly into the

cylinder liner until it is aligned with the upper surface
of the cylinder liner.
Caution: Do not push pistons below top face of cylinder

liner until big end bearings and caps are to be fitted.
Tip: It is recommended to replace the piston connecting
rod assembly as a set.
9. The oil ring gap and spring gap are arranged at 30°on 14. Fit the connecting rod bearing shell.
the opposite side of the piston pin axis.
Connecting Rod Bearing Shell Refit
10. Lubricate the cylinder liner opening, piston and piston
ring with engine oil, and ensure the piston ring gap is 15. Fit the cylinder head.
correctly positioned. Cylinder Head Gasket Refit
11. Fit the piston connecting rod assembly with piston ring
to the T10016.
12. Make the front mark on the piston face the front of the
engine, and fit the piston into the cylinder liner.
1.0 79
Rear Crankshaft Oil Seal

Remove
1. Remove flywheel - dual clutch automatic transmission.
Flywheel - Dual Clutch Automatic Transmission

Remove
2. Remove 6 bolts securing the rear crankshaft oil seal
onto the engine, then remove and discard the rear
crankshaft oil seal.
4. Align the TEN00128 and the real crankshaft oil seal,

fit 2 locating pins and 6 bolts, then tighten to 9–11Nm
in the sequence shown and check the torque.
Refit
1. Clean the working surface of the cylinder block and
crankshaft. Keep these surfaces clean and dry, free
from sealant.
2. Apply sealant of 3mm wide to the bracket of the rear
crankshaft oil seal.
5. Remove the TEN00128 and check oil seal lip for

rollup.
6. Fit the flywheel - dual clutch automatic transmission.
Flywheel - Dual Clutch Automatic Transmission

Refit
3. Fit the TEN00128 to the rear crankshaft oil seal and

prevent the lip from rolling up.
1.0 80
Front Crankshaft Oil Seal Flywheel - Dual Clutch Automatic Transmission
Remove Remove
1. Remove the crankshaft torsional vibration damper. 1. Remove the dual-clutch automatic transmission.
Crankshaft Vibration Damper Remove Dual-Clutch Automatic Transmission Remove

2. With a slotted screwdriver r or equivalent, remove the 2. Secure the flywheel with the special tool TEN00122
front crankshaft oil seal, and take care not to scratch to restrict the rotation of the crankshaft.
the ID of the hole on the front cover.
3. Remove and discard 8 bolts fixing the flywheel to the

Refit crankshaft.
1. Clean the operating surface of the crankshaft and oil

seal groove on the chain cover, and ensure there is no
foreign material.
2. Fit the front crankshaft oil seal into the corresponding
hole of the front lower cover (see the figure), press
the oil seal fully with the TEN00129, and the top of
the oil seal shall be 1.8-2.2mm from the plane of the
front cover.
4. Remove the flywheel from the crankshaft.

Refit
1. Use a saw to make two saw cuts on the bolt removed
from the flywheel at an angle of 45° to the bolt shank,
and clean the bolt hole in the crankshaft with the sawed
bolt.
2. Clean the flywheel and the rear flange face of crankshaft,
3. Fit the crankshaft pulley. and ensure there is no foreign material.
Crankshaft Pulley Refit 3. Fit the flywheel to the crankshaft with locating pins.
4. Fit the auxiliary drive belt. 4. Fit 8 bolts of the flywheel and pre-tighten the bolts.
Auxiliary Drive Belt Refit 5. Secure the flywheel with the special tool TEN00122
to restrict the rotation of crankshaft.
6. Tighten the flywheel bolt to 20Nm+60° in diagonal
sequence.
1.0 81
8. Fit the dual-clutch automatic transmission assembly. Valve

Dual-Clutch Automatic Transmission Refit
Remove
"Engine Control Module Reset Self-learning Value" with Cylinder Head Gasket Remove
VDS. 2. With a viscous magnet, remove 16 roller rocker arms
10. Wait for 2-5 seconds, turn off the ignition switch and and hydraulic tappet from the cylinder head, and keep
re-start the vehicle. them in the mounting sequence.
3. Remove 5 nuts fixing the intake manifold to the cylinder

head, remove the intake manifold and discard the
gasket.
4. Remove 3 bolts fixing the E-PAS idler support to

cylinder head, and remove the idler and its support.
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9. Remove the valve spring, valve spring cover and valve.

to the engine, remove the exhaust manifold and discard
the gasket.
10. Remove the valve oil seal and discard it.

Refit
1. Remove the carbon deposit on the valve guide, valve,
7. Clear the dirt in the spark plug gap, and remove the valve seat and combustion surface, and remove all loose
spark plug from the cylinder head. particles of the carbon deposit.
2. Check the valve spring:
8. Compress the valve spring with the valve spring tool,

take away the locking plate and release the valve spring,
then remove the valve spring tool.
1.0 83
Standard Value
Intake Valve 5.475±0.0075mm
Exhaust Valve 5.455±0.0075mm
Valve Seat Angle (a)
Intake Valve 45°15′±15′
Exhaust Valve 45°15′±15′
Valve Thickness (T)
Intake Valve 1.65±0.15mm
Exhaust Valve 1.75±0.15mm
4. Make sure that the tappet, valve, valve spring, spring

cover and locking clamp are clean.
5. Lubricate the valve and valve stem oil seal.
6. Fit the valve stem oil seal onto the valve guide with the
oil seal tool.
Valve Spring 7. Fit the valve, spring and spring cover, and fix the valve
spring tool to the valve and compression spring, and
Free Length 52.3 mm
fit the locking plate.
Mounting Height (mm) 40.2 mm 8. Repeat the above steps to fit the remaining valves.
Mounting Load 250N 9. Fit new gasket to the exhaust manifold, secure the
Load while the valve is open 250N exhaust manifold on the engine, fit 8 gaskets and new
nut with high temperature antiwelding agent, then
3. Check the parameter of the valve, if it is unacceptable, tighten to 23–27Nm in the sequence shown and check
replace the valve. the torque.
10. Fix the exhaust manifold heat shield to the exhaust

Standard Value
manifold, fit 4 bolts, tighten to 22–28Nm and check
Valve Head Diameter (D) the torque.
Intake Valve 34.2±0.1mm 11. Fix the E-PAS idler support to the cylinder head, fit 3
Exhaust Valve 28.3±0.1mm bolts, tighten to 23–27Nm and check the torque.
Valve Length (L) 12. Clean the mating surface of the intake manifold and
cylinder head and ensure there is no foreign material.
Intake Valve 113.4-113.9mm
13. Fit the new intake manifold gaskets.
Exhaust Valve 116.29-116.79mm
14. Fix the intake manifold to the cylinder head, fit 5 nuts
Valve Stem Diameter (D) in the sequence as shown, tighten to 23–27Nm, and
check the torque.
1.0 84
Valve Hydraulic Tappet Assembly
Remove
1. Remove the camshaft.
Camshaft Remove
2. Remove the rocker arm assembly of the valve actuator
and lay it aside in order.
15. Fit the hydraulic tappet into the corresponding

mounting bore on the cylinder head, and lubricate it
with clean engine oil.
16. Ensure the roller rocker arm holder is secure, align the
ball groove of the roller rocker arm with the plunger
ball head of the hydraulic tappet, and gently press the
ball head into the ball groove.
3. Remove the valve hydraulic tappet assembly and lay it
aside in order.
Cylinder Head Gasket Refit

Refit
1. Fit the valve hydraulic tappet assembly into the
corresponding mounting hole in the cylinder head, and
lubricate it with clean engine oil.
2. Ensure the rocker arm assembly holder of valve
actuator is secure, align the ball groove of valve actuator
rocker arm assembly with the plunger ball head of
hydraulic tappet, and gently press the ball head into the
ball groove.
1.0 85
Camshaft Cover
Remove
3. Remove 4 ball head bolts securing the engine hood.
4. Remove the dipstick.
Engine Oil Drain
6. Drain the cooling system.
Coolant - Drain
7. Remove the oil-gas separator.
3. Ensure the coaxiality of valve actuator rocker arm Oil-gas Separator Remove
assembly and the valve stem tip, and lubricate the
8. Remove the full load breather pipe from the
rocker arm roller with clean engine oil.
turbocharger intake pipe.
9. Remove the high-pressure oil pump.
High-pressure Oil Pump Remove
10. Remove 1 bolt and 1 nut fixing the low-pressure fuel
pipe clamp to the camshaft cover, and take away the
low-pressure fuel pipe.
4. Fit the camshaft.
Camshaft Refit
11. Remove the fuel rail.

Fuel Rail Remove
12. Remove overflow pipe A.
Overflow Pipe A Remove
13. Remove the ignition module.
Ignition Module Remove
14. Remove the cover of the CVVT.
CVVT Cover Remove
15. Remove the turbocharger control solenoid valve.
Turbocharger Control Solenoid Valve Remove
16. Remove the intake/exhaust camshaft position sensors.
Intake Camshaft Position Sensor Remove
Exhaust Camshaft Position Sensor Remove
17. Remove the mechanical vacuum pump.
1.0 86
18. Remove 3 bolts (1) fixing the observation hole cover
of the intake camshaft to the camshaft cover, remove
and discard the observation hole cover of the intake
camshaft.
19. Remove 1 bolt and 1 nut (2) fixing the harness bracket
of the front oxygen sensor to the camshaft cover, and
remove the harness bracket of the front oxygen sensor.
25. Remove 2 bolts fixing the heat shield bracket of the

cylinder head to the camshaft cover, and remove the
heat shield bracket.
20. Remove all harness clips from the engine and take away
the harness.
21. Remove 1 nut (1) fixing the turbocharger water inlet
pipe clamp to the stud of the camshaft cover.
22. Remove 1 bolt (2) fixing the turbocharger outlet pipe
clamp to the heat shield bracket of the cylinder head.
26. Remove 35 bolts fixing the camshaft cover to the

cylinder head in the sequence shown, and remove the
camshaft cover.
23. Remove the timing chain cover.
Timing Chain Cover Remove

24. Remove the remaining 4 bolts fixing the heat shield of
the cylinder head to the heat shield bracket and remove
the heat shield.
27. Remove 2 bolts fixing the upper guide rail of the timing
chain to the camshaft cover and remove the upper
guide rail.
1.0 87
Refit 8. Fix the heat shield of the cylinder head to the heat
1. Clean the mating surface of the front cover, camshaft shield bracket, fit 4 bolts, tighten to 9–11Nm and
cover and cylinder head and ensure there is no foreign check the torque.
material. 9. Fit the timing chain cover.
2. If any locating pin is missing, fit a new one to the Timing Chain Cover Refit
cylinder head.
10. Fix the turbocharger outlet pipe clamp to the heat
3. Apply engine oil to the camshaft journal evenly. shield bracket of the cylinder head, fit 1 bolt, tighten to
4. Apply sealant of 3mm wide to the camshaft cover (see 8–12Nm and check the torque.
the figure). 11. Fix the turbocharger inlet pipe clamp to the stud of
the camshaft cover, fit 1 nut, tighten to 8–12Nm and
check the torque.
12. Fix the oxygen sensor connector support to the
camshaft cover, fit 1 bolt and 1 nut, tighten to 8–12Nm,
13. Apply glue to the observation hole cover of the intake
camshaft according to the method shown.
5. Fix the upper guide rail to the camshaft cover, fit 2

6. Secure the camshaft cover on the cylinder head with 3
locating pins, then fix the solenoid valve bracket of the
turbocharger to the camshaft cover and fit 2 bolts.
7. Fix the heat shield bracket of the cylinder head to the
camshaft cover, fit 2 bolts and the remaining 35 bolts,
then tighten to 9–11Nm in the sequence shown and 14. Fix the observation hole cover of the intake camshaft
check the torque. to the camshaft cover, fit 3 bolts, tighten to 5–7Nm
Caution: Mounting position of the 2 studs. and check the torque.
15. Fit the mechanical vacuum pump.
Mechanical Vacuum Pump Refit
16. Fit the intake/exhaust camshaft position sensors.
Intake Camshaft Position Sensor Refit
Exhaust Camshaft Position Sensor Refit
1.0 88
17. Fit the turbocharger control solenoid valve. Camshaft - Intake or Exhaust
Turbocharger Control Solenoid Valve Refit
Remove
1. Fix the vehicle on lift.
18. Fit the cover of the CVVT.
CVVT Cover Refit
19. Fit the ignition module.
Engine Oil Drain
Ignition Module Refit
4. Remove the phase modulator.
20. Fit overflow pipe A.
Phase Modulator Remove
Overflow Pipe A Refit 5. Remove the camshaft cover.
21. Fit the fuel rail. Camshaft Cover Remove
Fuel Rail Refit 6. Identify the position of each camshaft carefully, and
22. Fit the high-pressure oil pump. remove the camshaft from the camshaft seat.
High-pressure Oil Pump Refit

23. Fix the low-pressure fuel pipe clamp to the camshaft
cover, fit 1 bolt and 1 nut, tighten to 9–11Nm, and
check the torque.
24. Fit the full load vacuum pipe to the turbocharger intake
pipe.
25. Fit the oil-gas separator.
Oil-gas Separator Refit

26. Fix all harness clips to the corresponding position of
the engine.
27. Fit 4 ball head bolts securing the engine hood, tighten
to 9–11Nm, and check the torque. Refit
28. Fill the engine oil. 1. Clean the camshaft.
2. Clean the bolt hole and pin of the camshaft cover.
Engine Oil Refill
3. Withe a micrometer, check the diameter of each
intake/exhaust camshaft journal, the journal diameter
30. Insert the dipstick.
of the 1st gear is Φ31.957-Φ31.972mm, that of the
31. Connect the battery negative. 2nd-6th gear is Φ24.96-Φ24.98mm.
4. Blow the oil gallery dry and lubricate the camshaft

bearing seat.
5. According to the camshaft thrust surface, put the
camshaft into the camshaft bearing seat on the cylinder
head.
1.0 89
6. Apply engine oil to the camshaft journal evenly. Intake Manifold Gasket
7. Fit the camshaft cover. Remove
Camshaft Cover Refit
8. Fit the intake/exhaust phase modulator.
3. Remove the full load vacuum pipe from the
Phase Modulator Refit
turbocharger intake pipe.
9. Fill the engine oil.
4. Remove the oil-gas separator.
Engine Oil Refill
Oil-gas Separator Remove
5. Remove the canister solenoid.
Canister Solenoid Remove

6. Disconnect the intake air temperature/manifold
absolute pressure sensors, and take away the harness.
7. Hold the red anti-looseness part to the right, until the

red anti-looseness part fits the right part, and remove
the vacuum pipe (1).
8. Release the clamp and remove the two vacuum hose
(2) from the intake manifold.
9. Remove the shield of the high-pressure oil pump.
1.0 90
10. Loosen the clamps and disconnect the intake pipe from 13. Remove 5 nuts fixing the intake manifold to the cylinder
the throttle body. head, remove the intake manifold and discard the
gasket.
11. Disconnect the connector of the throttle.

14. If necessary, remove 5 studs of the intake manifold.
12. Remove 1 bolt fixing the intake manifold bracket to

the intake manifold. Refit
1. Clean the mating surface of the intake manifold and
cylinder head and ensure there is no foreign material.
2. Fit 5 new studs to the cylinder head, tighten to
3. Fit the new intake manifold gaskets.
4. Fix the intake manifold to the cylinder head, fit 5 nuts,
tighten to 23–27Nm in the sequence shown, and
1.0 91
check the torque. Exhaust Manifold Gasket

Remove
2. Remove the turbocharger.
Turbocharger Remove
5. Fix the intake manifold bracket to the intake manifold,

fit 1 bolt, tighten to 22–28Nm and check the torque.
6. Connect the connector of the throttle body.
7. Connect throttle intake pipe to the throttle body and
secure with clamps.
8. Fit the shield of the high-pressure oil pump.
9. Connect the two vacuum hoses to the intake manifold,
and fix it with clamps.
to the engine.
10. Insert the vacuum hose into the red anti-looseness
part, until the step surface of the vacuum hose fits into
the red anti-looseness part.
11. Connect the connector of the intake air temperature
and manifold absolute pressure, and reset the harness.
12. Fit the canister solenoid.
Canister Solenoid Refit

13. Fit the oil-gas separator.
Oil-gas Separator Refit

14. Fit the full load vacuum pipe to the turbocharger intake
pipe.
5. Remove the exhaust manifold and discard the gasket.
6. Remove the exhaust manifold stud from the cylinder
head and discard it.
1.0 92
Refit Oil Pump
1. Clean the mating surface of the exhaust manifold and Remove
cylinder head. 1. Secure the vehicle on the lift.
2. Apply high temperature antiwelding agent to the 8 studs 2. Drain the engine oil.
of the exhaust manifold, fit the stud to the cylinder
Engine Oil Drain
head, tighten to 13–17Nm and check the torque.
3. Remove the oil strainer.
3. Fit new gasket to the exhaust manifold, secure the
exhaust manifold on the engine, fit 8 gaskets and new Oil Strainer Remove
nut with high temperature antiwelding agent, then 4. Lock the oil pump sprocket with the TEN00126, and
tighten to 23–27Nm in the sequence shown and check remove 1 bolt fixing the oil pump sprocket to the oil
the torque. pump.
Caution: The exhaust manifold gasket with black
coating faces the exhaust manifold.
5. Remove 4 bolts fixing the oil pump to the skirt rack,

and remove the oil pump and pipe connector - oil pump
4. Fix the exhaust manifold heat shield to the exhaust to skirt rack.
manifold, fit 4 bolts, tighten to 22–28Nm and check
the torque.
5. Apply high temperature antiwelding agent to the stud -
turbocharger to exhaust manifold, fit the small flange of
the exhaust manifold, tighten to 8–12Nm and check
the torque.
6. Fit the turbocharger.
Turbocharger Refit
Refit
1. Clean the oil pump, pipe connector - oil pump to skirt
rack and mating face of the skirt rack, and ensure there
is no foreign material.
2. Fit new pipe connector, apply a little oil to the pipe
connector - oil pump to skirt rack, and fit it into the
oil inlet on the skirt rack.
3. Fix the oil pump to the skirt rack, fit 4 bolts, tighten
to 23–27Nm in the sequence shown, and check the
torque.
1.0 93
Engine Oil and Oil Filter

Remove
2. Remove the oil filler cap.
3. Raise the vehicle on a lift.

4. Put the oil pan under the drain plug of the engine oil
pan, remove the drain plug and discard the seal washer.
Warning: Observe due care when draining engine oil as

the oil can be very hot.
4. Release the oil pump chain tensioner, fit the oil pump Warning: Avoid excessive skin contact with used engine
sprocket (the side with the timing identification shall oil. Used engine oil contains potentially harmful
face outward) to the oil pump chain, and turn the oil contaminants which may cause skin cancer or other
pump by hand and allow its D-hole to align with the serious skin disorders.
D-shaft of the oil pump, then release the oil pump chain
tensioner. After the operation, check if the chain is
properly pressed on the surface of the tensioner guide
plate (not the raised side edge).
5. With the TEN00126, lock the oil pump sprocket, fit
the oil pump sprocket bolt, tighten to 68–72Nm and
check the torque.
6. Fit the oil strainer.
Oil Strainer Refit

7. Refill engine oil.
Engine Oil Refill

6. Fit a new seal washer, fix the drain plug of the oil pan to
the oil pan, tighten to 20–25Nm and check the torque.
7. Protect the fuel line around the oil filter cover with a
clean cloth or equivalents.
8. Release the oil filter cover (1), and wait for few minutes
before removing it.
Warning: Never use an open-end wrench on the top

hexagon head of the oil filter cover.
9. Remove the oil filter (2) from the cover and discard it.
1.0 94
Engine Oil Pressure Check
Check
2. Remove the oil pressure switch.
Oil Pressure Switch Remove
3. Remove the seal ring from the oil pressure switch, and
fit it to the oil pressure gauge connector.
4. Fit and tighten the oil pressure gauge connector to the
original oil pressure switch.
S1113561 5. Connect the oil pressure gauge T10001 and T10002,
and tighten the connector.
10. Clean the oil filter housing in the engine cylinder block.
6. Check the engine oil, refill if necessary.
Refit
1. Fit a new oil filter and a new seal ring to the oil filter
8. Start and run the engine until the oil temperature
cover.
achieves 85-100°C.
2. With an appropriate wrench, fit the oil filter and oil
9. When the engine working condition achieves 1000
filter cover, tighten the oil filter cover until it is properly
RPM, the reading of the oil pressure gauge is 200Kpa.
located, and the torque shall be less than 20–25Nm.
10. Stop the engine, and disconnect the battery negative.
Caution: Excessive tightening of the oil filter
11. Release the connector of the oil pressure gauge and
cover may damage the cover and cause oil leak.
take away the pressure gauge to remove the connector.
Warning: Never use an open-end wrench on the top 12. Wipe off the spilled oil.
hexagon head of the oil filter cover.
13. Fit the oil pressure switch.
Oil Pressure Switch Refit
Capacity
14. Check and refill engine oil.
4. Fit the oil filler cap.
5. Start and run the engine until the oil pressure warning
lamp goes out.
6. Stop the engine, and check the engine oil level.
7. Check for any signs of leakage.
1.0 95
Oil Strainer Oil Pan

Remove Remove
1. Secure the vehicle on the lift. 1. Raise the vehicle on a lift.
2. Drain the engine oil. Warning: Do not work on or under a vehicle supported
Engine Oil Drain
3. Remove the oil pan.
Engine Oil Drain
Oil Pan Remove
3. Remove the front exhaust pipe.
4. Remove 1 bolt fixing the oil strainer to the oil strainer
Front Exhaust Pipe Remove
bracket.
4. Remove 3 bolts fixing the oil pan to the transmission.
5. Remove 1 bolt fixing the oil strainer bracket to the
skirt rack, and remove the oil strainer bracket.
6. Remove 2 bolts fixing the oil strainer to the oil pump,
and remove the oil strainer.
5. Unscrew 1 bolt fixing the air conditioning compressor

to the oil pan.
6. Remove 22 bolts fixing the oil pan to the engine skirt
rack, and note the mounting position of the two longest
Refit
bolts.
1. Clean the oil strainer and oil pump inlet, and ensure
Refit
1. Clean the mating face between the engine skirt rack
2. Fix the oil strainer to the oil pump, fit 2 bolts, tighten
and the oil pan, and ensure there is no foreign material.
to 9–11Nm, and check the torque.
2. Apply sealant (2.5mm in width) to the surface of the oil
3. Fix the oil strainer bracket to the skirt rack, fit 1 bolt,
pan component according to the route shown.
Caution: Ensure the sealant applied is continuous,
4. Fit 1 bolt fixing the oil strainer to the oil strainer
and complete the assembly within 5 minutes after
bracket, tighten to 9–11Nm, and check the torque.
application.
5. Fit the oil pan.
Oil Pan Refit
6. Engine Oil
Engine Oil Refill
3. Fit the oil pan to the skirt rack with the TEN00127,
1.0 96
fit 20 bolts and pre-tighten the bolt. Lower Crankcase
Remove
1. Remove the engine and dual clutch automatic
transmission.
Engine and Dual Clutch Automatic Transmission

Remove
3. Remove the oil strainer.
Oil Strainer Remove

4. Remove the crankshaft rear oil seal.
Rear Crankshaft Oil Seal Remove

4. Remove the oil pan locating tool (TEN00127).
5. Remove 16 bolts fixing the lower crankcase to cylinder
5. Fit the other 2 bolts. Tighten all bolts to 8–12Nm in block in the sequence shown.
the sequence shown and check the torque.
6. Remove the oil pump and pipe connector - oil pump

6. Fit 1 bolt fixing the A/C compressor to the oil pan, to lower crankcase.
7. Remove 10 main bearing bolts in the sequence shown
7. Fit 4 bolts fixing the oil pan to the transmission, tighten and discard the bolts.
them to 75–90Nm, and check the torque.
8. Fit the front exhaust pipe.
Front Exhaust Pipe Refit

9. Lower the vehicle.
Engine Oil Refill
8. Remove the lower crankcase, and remove the oil return

pipe from the lower crankcase.
1.0 97
9. Remove the crankshaft main bearing shell from the 7. Align the locating pin and secure the lower crankcase
lower crankcase, and arrange it in order. on the cylinder block.
8. Fit new bolts to the main bearing, tighten to 35Nm
+90°+45° in the sequence as shown, and check the
torque.
Caution: After application of the sealant, tighten
it to the specified torque within 15 minutes.
Refit
1. Clean the mating surface between the cylinder block
and the lower crankcase, and ensure there is no foreign
material.
2. Clean water and oil ducts, and ensure that there are
no foreign material. 9. Fit 12 bolts fixing the lower crankcase to the cylinder
3. Fit the crankshaft main bearing shell of the lower block, tighten to 23-27Nm in the sequence of 1-12 as
crankcase to the skirt rack in the original sequence. shown, and check the torque.
4. Apply fresh engine oil to the crankshaft main journal. Caution: After application of the sealant, tighten
it to the specified torque within 15 minutes.
5. Manually press the oil return pipe into the lower
crankcase, when the exposed section is appr. 10mm,
tap with a rubber hammer until the end of the pipe
touches the bottom.
6. Apply sealant (3.5mm in width) evenly to the mating
surface between the lower crankcase and the cylinder
block, see the figure.
10. Apply a small amount of oil to the pipe connector - oil
1.0 98
pump to skirt rack, and fit it into the oil inlet of the Front Timing Cover
lower crankcase. Remove
11. Fix the oil pump to the lower crankcase, fit 4 bolts, 1. Secure the vehicle on a lift.
tighten to 23–27Nm in the sequence of 13-16 as 2. Disconnect the battery negative.
shown, and check the torque.
3. Drain the engine coolant.
12. Fit the rear crankshaft oil seal.
Coolant - Drain
Rear Crankshaft Oil Seal Refit
13. Refit the oil strainer.
Engine Oil Drain
Oil Strainer Refit
5. Remove the auxiliary drive belt tensioner.
14. Fit the engine timing chain.
Auxiliary Drive Belt Tensioner Remove
6. Remove the front crankshaft oil seal.
15. Fit the engine and dual clutch automatic transmission.
Front Crankshaft Oil Seal Remove
Engine and Dual Clutch Automatic Transmission
7. Remove 2 bolts securing the thermostat housing
Refit
bracket.
8. Release the clip, and remove the fuel pipe from the fuel
pipe bracket.
9. Remove 1 bolt fixing the fuel pipe bracket to the engine,
and remove the fuel pipe bracket.
10. Fit the TEN00120 to the two sides of the engine,

tighten the bolt to 22–28Nm and check the torque.
11. Fix the engine with the T10007 and TEN00070.
1.0 99
12. Remove the engine suspension. 20. Tap the rear to remove the front timing cover as per
the position and sequence shown.
Engine Suspension Remove
13. Fix the water pump pulley with the TEN00009.
14. Remove 4 bolts fixing the water pump pulley to the
water pump, and remove water pump pulley.
15. Secure the PAS pump idler with the TEN00009.
Refit
1. Clean the engine cylinder block, oil pan and mating
face of the timing chain cover, and ensure there is no
foreign material.
2. Apply sealant (2.5mm in width) to the surface of the
16. Remove 3 bolts fixing the pulley to the PAS pump idler
timing chain cover component according to the route
assembly and remove the pulley.
shown.
17. Remove 1 bolt fixing idler C to the cylinder block and
Caution: Ensure the sealant applied is continuous,
remove idler C.
and complete the assembly within 5 minutes after
18. Remove 4 bolts connecting the oil pan and the timing
application.
chain cover.
19. Remove 23 M6 bolts, 2 M8 bolts, 3 M12 bolts and idler
A fixing the front timing cover to the engine in the
sequence of 7-29, 5-6, 4 and 1-3.
1.0 100
3. Apply sealant (2.5mm in width) to the mating face of 21. Fit the auxiliary drive belt tensioner.
the oil pan.
Auxiliary Drive Belt Tensioner Refit
4. Align the two locating pin holes of the timing chain
cover with the two locating pins, and fit them to the
mating face between the engine skirt rack and the Engine Oil Refill
cylinder head assembly. 23. Refill the engine coolant.
5. Fit 23 M6 bolts, 2 M8 bolts, 3 M12 bolts and idler A. Coolant - Refill
6. Tighten 3 M12 bolts to 80–90Nm in the sequence of

1-3, and check the torque.
7. Tighten idler A to 32–38Nm in the sequence of 4, and
check the torque.
8. Tighten 2 M8 bolts to 23–27Nm in the sequence of
9. Tighten 23 M6 bolts to 9-11Nm in the sequence of
10. Fit 4 bolts connecting the oil pan and the front timing
cover, tighten to 9-11Nm and check the torque.
11. Fix the idler C to the cylinder block, fit 1 bolt, tighten
12. Fix the PAS pump pulley to the EPAS idler assembly, fit
3 bolts, tighten to 14–16Nm and check the torque.
13. Secure the water pump pulley on the water pump, fit
4 bolts and tighten them to 7.5–10.4Nm, and check
the torque.
14. Fit the engine suspension.
Engine Suspension Refit
15. Remove the T10007 and TEN00070.
16. Remove the TEN00120.
17. Fix the fuel pipe bracket to the engine, fit 1 bolt, tighten
18. Fit the fuel pipe clip into the fuel pipe bracket, and
ensure it is properly located.
19. Fit the thermostat housing bracket, tighten the 2 bolts
to 22-28Nm and check the torque.
20. Fit the front crankshaft oil seal.
Front Crankshaft Oil Seal Refit
1.0 101
Engine Timing Chain

Remove
1. Secure the vehicle on a lift.
Engine Oil Drain

4. Remove the auxiliary drive belt.
Auxiliary Drive Belt Remove

5. Remove the timing chain cover.
Timing Chain Cover Remove

6. With an appropriate tool, lock the timing chain
9. Remove 2 bolts fixing the upper guide rail to the
tensioner, remove 2 bolts fixing the timing chain
cylinder head, and remove the upper guide rail.
tensioner to the cylinder block, and remove the timing
chain tensioner.
10. Remove the phase modulator.
7. Remove the tensioner rail from the chain guide rail bolt. Phase Modulator Remove
12. Remove 3 bolts (1) fixing the observation hole cover of
the intake camshaft to the camshaft cover, and remove
the observation hole cover of the intake camshaft.
8. Remove the chain guide rail and timing chain together.
13. Remove 3 bolts of the chain guide rail from the cylinder
head and cylinder block.
14. Remove the crankshaft timing sprocket.
1.0 102
15. Remove the bolt (1) of the oil pump chain tensioner.
16. Remove the oil pump chain tensioner.
17. Remove the bolt (2) of the oil pump chain tensioner.
3. Check the key slot and flat key of the crankshaft

assembly -sprocket, and ensure it is clean and free from
burrs.
4. Press the flat key into the key slot until it touches the
18. Remove the oil pump chain.
bottom of the key slot, and then the top of the key shall
be 2.5mm above the surface.
5. Fit the drive sprocket to the crankshaft.
6. Fit the oil pump chain.
7. Fix the bolt (2) of the oil pump chain tensioner to the
skirt rack, tighten to 20–24Nm and check the torque.
8. Fit the oil pump chain tensioner.
9. Pull the oil pump chain tensioner, fix the bolt (1) of the
oil pump chain tensioner to the skirt rack, tighten to
10. Fit the intake/exhaust phase modulator.
Phase Modulator Refit

19. Remove the oil pump sprocket. 11. Fix the upper guide rail to the cylinder head, fit 2 bolts,
20. Remove the flat key - sprocket. tighten to 9–11Nm, and check the torque.
Refit 12. Fit the 3 bolts of the chain guide rail to the cylinder
head, tighten to 20-24Nm and check the torque.
1. Rotate the crankshaft and allow the crankshaft to be
located at 90° CA before the acting TDC of cylinder 1, 13. Fit the timing chain to crankshaft sprocket, then fit the
and secure the crankshaft with the TEN00122. crankshaft sprocket into the front end of the crankshaft
(no need to push it to the end).
2. Turn the camshaft and fit the camshaft timing tool of the
TEN00124 into the tail groove of the intake/exhaust 14. Fit the timing chain and chain guide rail into the chain
camshafts. guide rail bolt, and push them to the end.
15. Fit the timing chain into the two phase modulators.
16. Fit the tensioner rail into the chain guide rail bolt and
push it to the end.
17. Fix the timing chain tensioner to the cylinder block, fit
2 bolts, tighten to 9–11Nm, and check the torque.
18. Adjust the timing chain and push the crankshaft
sprocket to the end.
19. Pull out the pin securing the timing chain tensioner.
1.0 103
Crankshaft Torsional Vibration Damper

Remove
1. Secure the vehicle on the lift.
3. Secure the flywheel with the TEN00122 to restrict
rotation of the crankshaft.
4. Remove the bolt securing the crankshaft torsional
vibration damper and discard the bolt and gasket.
20. Check the camshaft timing and the corresponding

reading according to the specification table.
21. Remove TEN00122, TEN00124.
22. Apply glue to the observation hole cover of the intake
camshaft according to the method shown.
5. Remove the crankshaft torsional vibration damper.
Caution: When removing the crankshaft torsional

vibration damper, do not damage the lip of the
front crankshaft oil seal.
6. Remove the flat key from the crankshaft - torsional
vibration damper.
Refit
23. Fix the observation hole cover of the intake camshaft 1. Check the flat key - crankshaft torsional vibration
to the camshaft cover, fit 3 bolts, tighten to 5–7Nm damper and key slot of the crankshaft assembly, and
and check the torque. ensure it is clean and free from burrs.
24. Fit the mechanical vacuum pump. 2. Press the flat key into the key slot until it touches the
Mechanical Vacuum Pump Refit bottom of the key slot, and then the top of the key shall
be 2.5mm above the surface.
25. Fit the timing chain cover.
3. Note the mounting position of the crankshaft flat
Timing Chain Cover Refit key, align the hub groove of the crankshaft torsional
26. Fit the auxiliary drive belt. vibration damper with the crankshaft key, and carefully
Auxiliary Drive Belt Refit fit the crankshaft torsional vibration damper to the
front of the crankshaft.
4. Fit new bolt, tighten to 85Nm+90° and check the
Engine Oil Refill torque.
28. Connect the battery negative. 5. Remove the TEN00122.
29. Place the ignition switch in "ON" position, perform 6. Fit the auxiliary drive belt.
"Engine Control Module Reset Self-learning Value" with
VDS. Auxiliary Drive Belt Refit
30. Wait for 2-5 seconds, turn off the ignition switch, then
restart the vehicle.
1.0 104
Right Hydraulic Engine Suspension
Remove
2. Remove the air filter assembly.
Air Filter Assembly Remove
bracket.
pipe bracket.
5. Remove 1 bolt fixing the fuel pipe bracket to the engine,
and remove the fuel pipe bracket.
8. Remove 2 bolts (1) fixing the engine suspension bracket

to the front wheel house panel and engine suspension.
9. Remove 3 bolts (2) fixing the engine suspension to the
engine.
10. Remove 2 bolts (3) fixing the engine suspension to
the front longitudinal beam and remove the engine
suspension.

Refit
1. Fit the engine suspension to the front longitudinal beam,
fit 2 bolts, tighten to 90–110Nm and check the torque.
2. Fit the engine suspension to the engine, fit 3 bolts,
tighten to 50Nm+90° and check the torque.
3. Fix the engine suspension bracket to the front wheel
house panel and engine suspension, fit 2 bolts, tighten
7. Fix the the power assembly with the T10007 and to 55–65Nm and check the torque.
TEN00070.
5. Remove the TEN00120 from the engine.
ensure it is properly located.
8. Fit the thermostat housing bracket, tighten the 2 bolts
9. Fit the air filter assembly.
1.0 105
Air Filter Assembly Refit Engine and Dual Clutch Automatic Transmission
10. Connect the battery negative. Remove
1. Secure the vehicle on the lift.
2. Remove the battery bracket.
Battery Bracket Remove
3. Recycle A/C refrigerant.
A/C Refrigerant Recycle
Engine Coolant Drain
5. Drain the dual clutch automatic transmission fluid.
Dual Clutch Automatic Transmission Fluid Drain
Engine Oil Drain
9. Release the fuel pressure.
Fuel System Pressure Relief
Warning: Fuel vapour is highly flammable and in confined
spaces is also explosive and toxic. Always have a fire
extinguisher containing foam, CO2, gas or powder close
10. Disconnect the fuel inlet hose from the low-pressure
fuel pipeline.
Caution: Always fit plugs to open connections to prevent
contamination.
11. Loosen the clamps, and disconnect the hose of the

activated carbon canister solenoid valve.
12. Loosen the clamps, and disconnect the throttle intake
pipe (intercooler hose) (3) from the intercooler.
13. Loosen the clamps and disconnect the intercooler
intake pipe from the intercooler.
14. Disconnect the vacuum pipe from the vacuum pump.
15. Disconnect the engine ECM connector.
1.0 106
16. Disconnect the connector of the engine harness and
body harness.
17. Remove the engine harness ground.
18. Loosen the clamp, disconnect the coolant hose from
the thermostat housing, and take away the hose.

19. Remove 1 bolt fixing the oil cooler pipe clip to the
automatic transmission and remove the pipe clip.
20. Remove the bolt connecting the oil cooler pipe to the
automatic transmission, disconnect the pipe from the
automatic transmission and discard the seal ring.

contamination.

bracket.
pipe bracket. 26. Raise the vehicle on a lift.
23. Remove 1 bolt fixing the fuel pipe bracket to the engine, 27. Disconnect the harness from the dual clutch automatic
and remove the fuel pipe bracket. transmission and take away the harness.
1.0 107
33. Release the C-clip from the parking brake cable bracket,
and release the cable support.
28. Remove 2 nuts (3) fixing the air conditioning pipeline

to the compressor and release the air conditioning
pipeline from the compressor. 34. Remove the front subframe.
Caution: Always fit plugs to open connections to prevent Front Subframe Remove
contamination. 35. Lower the vehicle.
36. Remove the right engine hydraulic mount.
Right Engine Hydraulic Mount Remove
37. Remove 2 bolts and 1 nut fixing the transmission mount
to the transmission mount bracket.
29. Release the clamp, and disconnect cooling hose from

the oil filter module.
30. Remove the nut, disconnect the battery wire from the
starter motor and remove the battery wire.
38. Support the engine and dual clutch automatic

transmission with the hydraulic bracket.
40. Lift the vehicle, and remove the engine and dual clutch
automatic transmission.
Refit
1. Support the engine and dual clutch automatic
transmission with the hydraulic bracket.
2. Lower the vehicle, with assistance, put the engine and
dual clutch automatic transmission on the mounting
position of the engine compartment.
3. Fit the T10007 and TEN00070.
31. Place the shift lever in "P" gear.
4. Fix the transmission mount to the transmission mount
32. Disconnect the cable ball joint at the transmission side
bracket, fit 2 bolts, tighten to 70Nm+90°, fit 1 nut,
from the parking brake cable rocker arm.
tighten to 70Nm+90°, and check the torque.
1.0 108
5. Fit the right engine hydraulic mount. ensure it is properly located.
Right Hydraulic Engine Mount Refit 31. Fit the thermostat housing bracket, tighten the 2 bolts
6. Lift the vehicle and take away the hydraulic bracket. to 22-28Nm and check the torque.
7. Fit the front subframe. 32. Fit overflow pipe A.
Front Subframe Refit Overflow Pipe A Refit

8. Ensure the shift lever is in "P" gear. 33. Fit the air filter assembly.
9. Turn the shift rocker arm to the "P" mark on the Air Filter Assembly Refit
transmission housing, and ensure the shift rocker arm 34. Fill the engine oil.
is in "P" gear.
Engine Oil Refill
10. Fix the parking brake cable to the knob of the shift
rocker arm. 35. Fill the dual clutch automatic transmission fluid.
11. Connect the battery wire to the starter motor. Dual Clutch Automatic Transmission Fluid
12. Use a new O-ring, connect the A/C pipeline to the Refill
A/C compressor, fit the nut, tighten to 19-25Nm and 36. Fill the engine coolant.
check the torque.
Engine Coolant Refill
13. Connect the engine compartment harness to the
37. Fill the A/C refrigerant.
connector of the dual clutch automatic transmission.
A/C Refrigerant Refill
16. Remove the plug, fit a new seal to the oil cooler pipe, Battery Bracket Refit
and apply clean automatic transmission fluid to it. 39. Lower the vehicle from the lift.
17. Secure the oil cooler pipe to the automatic transmission,
fit 1 bolt respectively, tighten to 7–10Nm, and check
the torque.
18. Secure the oil cooler pipe clip to the automatic
transmission, fit 1 bolt, tighten to 7–10Nm, and check
the torque.
19. Connect the coolant hose to the thermostat housing,
20. Fit the engine harness ground.
21. Fit the connector of the engine harness and body
harness.
22. Connect the engine ECM connector.
23. Connect the vacuum pipe of the mechanical vacuum
pump.
24. Fit the intercooler intake pipe to the intercooler, and
fix it with clamps.
25. Fit the throttle intake pipe to the intercooler, and fix
it with clamps.
26. Connect the fuel breather hose to the activated carbon
canister solenoid valve and secure with clamps.
27. Connect the fuel inlet pipe to the low-pressure fuel
pipeline.
28. Remove the TEN00120.
1.0 109
Cylinder Gasket
Remove
2. Drain the engine cooling system.
Coolant - Drain
Engine Oil Drain


5. Remove the intake/exhaust camshafts.
Intake/Exhaust Camshaft Remove 11. Disconnect the intake air temperature/manifold

6. Remove the turbocharger. absolute pressure sensors, and take away the harness.
Turbocharger Remove
7. Remove the canister solenoid.
Canister Solenoid Remove

8. Disconnect the connector of the electronic throttle.
12. Hold the red anti-loose part to the right, until the
red anti-loose part fits the right part, and remove the
vacuum pipe (1).
13. Release the clamp and remove the two vacuum hose
(2) from the intake manifold.
9. Loosen the clamps and disconnect the throttle intake
pipe from the throttle.
14. Remove 3 bolts fixing the E-PAS idler assembly support

to cylinder head, and remove the support and E-PAS
10. Remove 1 bolt fixing the intake manifold bracket to idler assembly.
the intake manifold.
1.0 110
15. Remove 2 bolts fixing the electronic water pump 19. Remove the cylinder head gasket from the cylinder
bracket to the cylinder head, and remove the electronic block and discard it.
water pump and bracket.
Refit
16. Support the bottom of the engine with a bracket. 1. Clean the mating surface of the cylinder head and
17. Remove the T10007 and TEN00070. cylinder block, and ensure there is no foreign material.
2. Clean the passages of the engine oil and the coolant.
3. Apply a thin oil film on the threads and the underside
of the new bolt head of the cylinder head.
4. Check the surface of the cylinder head for scratch.
5. Fit new cylinder gasket onto the cylinder block and
note the "UP" mark.
6. With assistance, fit the cylinder head to the cylinder
block and carefully align it with the locating pins.
7. Carefully fit the cylinder head bolts, do not apply much
force to plug it or drop it into the bolt holes, and
tighten the bolt by hand.
8. Tighten cylinder head bolts to 45Nm+90°+90°
18. Remove and discard 10 bolts fixing the cylinder head to progressively in the sequence shown and check the
the cylinder block, and remove the cylinder head. torque.
1.0 111
Turbocharger
Remove
2. Drain the cooling system.
Coolant - Drain
Engine Oil Drain

4. Remove the three-way catalytic converter assembly.
Three-way Catalytic Converter Remove

9. Fix the electronic water pump bracket to the cylinder
bracket.
head, fit 2 bolts, tighten to 9–11Nm, and check the
6. Disconnect the pressure control hose (1), seal the
torque.
opening and ensure there is no foreign material in the
10. Fix E-PAS idler gear assembly bracket to the cylinder
turbocharger.
head, fit 3 bolts, tighten to 22–28Nm, and check the
7. Disconnect the connector (2) of the turbocharger.
torque.
8. Release the clamp, disconnect the turbocharger air
11. Fix the intake manifold bracket to the intake manifold,
inlet hose from the turbocharger, seal the opening and
fit 1 bolt, tighten to 22–28Nm, and check the torque.
ensure there is no foreign material in the turbocharger.
12. Connect throttle intake pipe to the throttle and secure
9. Release the clamp, disconnect the intercooler air inlet
with clamps.
hose (4) from the turbocharger, seal the opening and
13. Connect the electronic throttle connector.
14. Connect two vacuum hoses to the intake manifold, and
fix with clamps.
15. Insert the vacuum hose into the red anti-looseness
part, until the step surface of the vacuum hose fits into
the red anti-looseness part.
16. Connect the connector of the intake air
temperature/manifold absolute pressure sensor, and
reset the harness.
17. Fit the canister solenoid.
Canister Solenoid Refit

18. Fix the engine with T10007 and TEN00070.
19. Take away the bottom bracket.
20. Fit the intake/exhaust camshaft. 10. Remove overflow pipe A.
Intake/Exhaust Camshaft Refit Overflow Pipe A Remove

21. Fit the engine timing chain. 11. Remove the remaining 4 bolts fixing the heat shield of
the heat shield.
Engine Oil - Refill

23. Fill the engine cooling system.
Coolant - Refill
1.0 112
16. Remove 1 bolt (2) fixing the turbocharger coolant/water
outlet pipe clamp to the heat shield bracket.
17. Release the clamp, disconnect the turbocharger water
return hard pipe and turbocharger water return hose
connector, and take away the turbocharger water
outlet pipe.
18. Remove and discard the hollow bolt (2) fixing the
turbocharger oil inlet pipe to the turbocharger, and
take away and discard the two copper washers.
12. Remove and discard the hollow bolt fixing the

turbocharger coolant/water inlet pipe to the
turbocharger, and take away and discard the two
copper washers.
19. Remove 1 bolt (2) fixing the turbocharger oil inlet pipe
to the turbocharger oil return clamp, and take away the
turbocharger oil inlet pipe.
20. Remove 1 bolt (1) fixing the turbocharger oil return
pipe clamp to the exhaust manifold.
21. Remove 2 bolts fixing the turbocharger oil return pipe
to the turbocharger, and remove the turbocharger oil
13. Remove 1 nut (1) fixing the turbocharger coolant/water return pipe.
inlet pipe clamp to the stud of the camshaft cover. 22. Remove and discard 4 nuts fixing the turbocharger to
the exhaust manifold, remove the turbocharger and
discard the gasket.
14. Release the clamp, and disconnect the turbocharger

water inlet pipe from the electronic water pump outlet
pipe, and take away the turbocharger water inlet pipe. 23. Remove the 3 studs on the turbocharger.
15. Remove and discard the hollow bolt (1) fixing Refit
the turbocharger coolant/water outlet pipe to the 1. Apply high temperature antiwelding agent to the 3
turbocharger, and take away and discard the two new studs, fit the stud to the turbocharger, tighten to
copper washers. 8–12Nm and check the torque.
1.0 113
2. Use a new gasket, locate the turbocharger to the bolt, tighten to 40–45Nm, and check the torque.
exhaust manifold, fit the new nut with high temperature 21. Fit the three-way catalytic converter assembly.
antiwelding agent, tighten to 28–32Nm and check the
torque. Three-way Catalytic Converter Remove
3. Fix the turbocharger oil return pipe to the turbocharger, 22. Refill engine oil.
fit 2 bolts, tighten to 9–11Nm, and check the torque. Engine Oil Refill
4. Fix the turbocharger oil return pipe bracket to the 23. Refill the cooling system.
exhaust manifold, fit 1 bolt, tighten to 22-28Nm, and
Coolant - Refill
check the torque.
5. Fix the turbocharger oil inlet pipe to the turbocharger
oil return pipe clamp, fit 1 bolt, tighten to 9–11Nm,
6. Fit a new gasket, fix the turbocharger oil inlet pipe to
the turbocharger, fit 1 new hollow bolt, tighten to
18–22Nm, and check the torque.
7. Connect the turbocharger coolant/water outlet pipe to
the expansion tank outlet pipe, and fix it with clamps.
8. Fit a new gasket, fix the turbocharger coolant/water
outlet pipe to the turbocharger, fit 1 new hollow bolt,
shield bracket of the cylinder head, fit 1 bolt, tighten to
10. Connect the turbocharger coolant/water return hard
pipe to the turbocharger water return hose, and secure
with clamps.
inlet pipe to the turbocharger, fit 1 new hollow bolt,
12. Fix the turbocharger inlet pipe clamp to the stud of
check the torque.
13. Fix the heat shield of the cylinder head to the heat
shield bracket, fit 4 bolts, tighten to 9–11Nm and
check the torque.
Overflow Pipe A Refit

15. Connect the intercooler air inlet hose to the
turbocharger, and fix it with clamps.
16. Fit the turbocharger air inlet hose to the turbocharger,
17. Connect the turbocharger to the pressure control hose
at the exhaust gas port.
18. Connect the connector of the turbocharger.
19. Secure the turbocharger bracket on the cylinder body,
fit 1 bolt, tighten them to 50–60Nm, and check the
torque.
20. Fix the turbocharger bracket to the turbocharger, fit 1
1.0 114
Turbocharger Coolant Outlet Pipe
Remove
Coolant - Drain
3. Remove 3 bolts fixing the turbocharger heat shield to
the turbocharger, and remove the turbocharger heat
shield.
7. Remove 1 nut (1) fixing the turbocharger coolant/water

inlet pipe clamp to the stud of the camshaft cover.

the heat shield.
water inlet pipe from the electronic water pump outlet
pipe, and take away the turbocharger water inlet pipe.
turbocharger coolant/water outlet pipe to the
copper washers.

copper washers.
10. Remove 1 bolt (2) fixing the turbocharger coolant/water

outlet pipe clamp to the heat shield bracket of the
cylinder head.
11. Release the clamp, disconnect the turbocharger water
1.0 115
return hard pipe and turbocharger water return hose Turbocharger Coolant Inlet Pipe
connector, and take away the turbocharger water Remove
outlet pipe. 1. Disconnect the battery negative.
Refit 2. Remove the engine cover.
1. Connect the turbocharger coolant/water return hard 3. Drain the engine coolant.
pipe to the turbocharger water return hose, and secure
with clamps. Coolant - Drain
2. Fit a new gasket, fix the turbocharger coolant/water 4. Remove 3 bolts fixing the turbocharger heat shield to
outlet pipe to the turbocharger, fit 1 new hollow bolt, the turbocharger, and remove the turbocharger heat
tighten to 35–40Nm, and check the torque. shield.

shield bracket of the cylinder head, fit 1 bolt, tighten to
4. Connect the turbocharger water inlet pipe to the
electronic water pump outlet pipe, and fix it with
clamps.
inlet pipe to the turbocharger, fit 1 new hollow bolt,
check the torque.
7. Fix the heat shield of the cylinder head to the heat 5. Remove overflow pipe A.
shield bracket, fit 4 bolts, tighten to 9–11Nm and Overflow Pipe A Remove
check the torque.
8. Fit overflow pipe A. the cylinder head to the heat shield bracket and remove
Overflow Pipe A Refit the heat shield.
9. Fix the turbocharger heat shield to the turbocharger, fit
Coolant - Refill

copper washers.
1.0 116
Coolant - Refill
8. Remove 1 nut (1) fixing the turbocharger coolant/water

inlet pipe clamp to the stud of the camshaft cover, and
take away turbocharger water inlet pipe.

water inlet pipe from the electronic pump outlet pipe.
10. Remove the turbocharger water inlet pipe.
Refit
1. Connect the turbocharger water inlet pipe to the
electronic water pump outlet pipe, and fix it with
clamps.
2. Fix the turbocharger water inlet pipe to the
turbocharger, fit 2 new copper washers and 1 hollow
bolt, tighten to 35–40Nm, and check the torque.
check the torque.
4. Fix the heat shield of the cylinder head to the heat
shield bracket, fit 4 bolts, tighten to 9–11Nm and
check the torque.
Overflow Pipe A Refit

1.0 117
Turbocharger Oil Return Pipe

Remove
Engine Oil Drain
shield.

to the turbocharger, and remove the turbocharger oil
return pipe.
Refit
1. Fix the turbocharger oil return pipe to the turbocharger,
fit 2 bolts, tighten to 9–11Nm, and check the torque.
2. Secure the turbocharger oil return pipe on the cylinder
block, fit 2 bolts, tighten to 9–11Nm, and check the
torque.
3. Fix the turbocharger oil return pipe clamp to the
exhaust manifold, fit 1 bolt, tighten to 22-28Nm, and
bracket.
check the torque.
5. Secure the turbocharger bracket on the cylinder body,
fit 1 bolt, tighten them to 50–60Nm, and check the
torque.
6. Fix the turbocharger bracket to the turbocharger, fit 1
5. Remove 1 bolt (1) fixing the turbocharger oil return Engine Oil Refill
pipe clamp to the exhaust manifold. 9. Connect the battery negative.
to the turbocharger oil return pipe clamp.
7. Remove 2 bolt (3) fixing the turbocharger oil return
pipe to the cylinder block.
1.0 118
Turbocharger Air Intake Hose Turbocharger Oil Inlet Pipe
Remove Remove
1. Disconnect the full load breather pipe and turbocharger 1. Disconnect the battery negative.
vacuum pipe (1) from the turbocharger air inlet hose. 2. Drain the engine oil.
2. Release the clamp, disconnect the turbocharger air inlet
Engine Oil Refill
hose (2) from the turbocharger, seal the opening and
3. Release the clamp, disconnect the turbocharger air inlet
shield.
hose (3) from the air flow meter, and seal the opening
and ensure there is no foreign material.
4. Remove the alternator.
Refit Alternator Remove
1. Fit the turbocharger air inlet hose to the air flow meter, 5. Remove and discard the hollow bolt (2) fixing the
and secure with clamps. turbocharger oil inlet pipe to the turbocharger, and
2. Fit the turbocharger air inlet hose to the turbocharger,
3. Connect the full load breather pipe and vacuum pipe to
the turbocharger air inlet hose.

to the turbocharger oil return pipe clamp, and take
away the turbocharger oil inlet pipe.
to the cylinder block.
8. Remove and discard the hollow bolt (5) fixing the
turbocharger oil inlet pipe to the turbocharger, and
1.0 119
Electronic Throttle Intake Pipe

Remove
3. Remove the battery box.
Battery Remove
4. Remove the intake air temperature/manifold absolute
pressure sensor.
Intake Air Temperature/Manifold Absolute
Pressure Sensor Remove
5. Remove 1 bolt (1) fixing the throttle intake pipe to the
9. Remove the turbocharger oil inlet pipe. bracket.
Refit 6. Release the clamp, disconnect the throttle intake pipe

(intercooler hose) (2) from the throttle hard intake
pipe.
the cylinder block, fit 1 new hollow bolt, tighten to
18–22Nm, and check the torque. 7. Release the clamp, disconnect the throttle intake pipe
(intercooler hose) (3) from the intercooler to remove
2. Secure the turbocharger oil inlet pipe on the cylinder
the throttle intake pipe (intercooler hose).
block, fit 1 bolt, tighten to 18–22Nm, and check the
torque. 8. Release the clamp, disconnect the throttle intake pipe
(engine hose) (4) from the throttle hard intake pipe to
remove the throttle hard intake pipe.
and check the torque. 9. Release the clamp, disconnect the throttle intake pipe
(engine hose) (5) from the throttle to remove the
throttle intake pipe (engine hose).
the turbocharger, fit 1 new hollow bolt, tighten to
5. Fit the alternator.
Alternator Refit
Engine Oil Refill
Refit
1. Connect the throttle intake pipe (throttle hose) to the
throttle, make sure the rubber hose port is pushed to
the bottom of the throttle, and secure with clamps. Fit
the clamp into the round rubber groove and tighten
to 5.5Nm.
Tip: If it is improperly fitted, it may drop.
2. Connect the throttle intake pipe (engine hose) to the
throttle hard intake pipe and secure with clamps.
3. Connect the throttle intake pipe (intercooler hose) to
the throttle hard intake pipe and secure with clamps.
4. Connect the throttle intake pipe (intercooler hose)
1.0 120
to the intercooler, secure with clamps and tighten to Intercooler Air Inlet Hose
10–15Nm. Remove
5. Fix the throttle intake pipe to the bracket, fit 1 bolt, 1. Release the clamp, disconnect the intercooler air inlet
tighten to 9–11Nm and check the torque. hose (4) from the turbocharger, seal the opening and
6. Fit the intake air temperature and manifold absolute ensure there is no foreign material in the turbocharger.
pressure sensor.
Intake Air Temperature and Manifold Absolute

Pressure Sensor Refit
7. Fit the battery box.
Battery Refit
2. Remove the bottom deflector.
Bottom Deflector Remove

3. Release the clamp, and disconnect the intercooler
air inlet hose from the intercooler to remove the
intercooler air inlet hose.
Refit
1. Fit the intercooler air inlet hose to the intercooler, and
fix it with clamps.
2. Fit the bottom deflector.
Bottom Deflector Refit

3. Connect the intercooler air inlet hose to the
1.0 121
Oil Filter Module

Remove
Coolant - Drain
Engine Oil - Drain
4. Remove the right front drive shaft.
Right Front Drive Shaft Remove
5. Disconnect the connector (1) of the engine oil pressure
switch.
Refit
6. Remove the connector (2) of the clutch water pump.
7. Remove the ground wire (3).
and the oil filter module, ensure it is clean and smooth.
2. Fit a new gasket, fix the oil filter module to the cylinder
block, fit 4 bolts, tighten to 22-28Nm and check the
torque.
3. Fit a new O-ring to the water pump inlet pipe, apply
sealant to it, fit the water pump inlet pipe to the oil
filter module, fit 1 bolt, tighten to 8–12Nm and check
the torque.
4. Fix the water pump inlet pipe to the cylinder block, fit
1 bolt, tighten to 8–12Nm and check the torque.
5. Connect the hose to the oil filter module and secure
with clamps.
6. Fit the ground wire.
8. Release the clamp, and disconnect hose from the oil
7. Connect the oil pressure switch connector.
filter module.
8. Connect the clutch water pump connector.
9. Remove 1 bolt fixing the water pump inlet pipe to the
9. Fit the right front drive shaft.
cylinder block.
10. Remove 1 bolt fixing the water pump inlet pipe to the Right Front Drive Shaft Refit
oil filter module, disconnect the water pump inlet pipe 10. Fill the engine oil.
and discard the seal ring.
Engine Oil - Refill
11. Fill the engine coolant.
Coolant Refill
11. Remove 4 bolts fixing the oil filter module to the

cylinder block, remove the oil filter module and discard
the gasket.
1.0 122
Special Tools Tool Description Picture
Tool Description Picture Number
Number
Flywheel
TEN00122
Crankshaft locking tool
TEN00123
holding tool
Retainer oil
Connecting rod TEN00126
pump gear
TEN00130 bearing centring
tool
Engine oil
T10001 pressure test
Piston ring equipment
T10016
compressor
Protector Adaptor engine

T10002
sleeve oil pressure test
TEN00128
crankshaft rear
oil seal
Oil pan locating

Replacer TEN00127
pins
TEN00129 crankshaft front
oil seal
1.0 123
Tool Description Picture

Number
Lifting lug
TEN00120
double
Engine lift
T10007
bracket
TEN00070 Engine support
Retainer belt
TEN00009
wheel
Camshaft timing
TEN00124
locking tool
1.0 124
Engine mechanical system-1.5T
Specifications
Torque
Description Value
Bolt - transmission bracket to transmission bracket 70Nm+90°
Bolt - tie bar lower bracket to transmission 55-65Nm
Bolt -tie bar lower to tie bar lower bracket 90-110Nm
Bolt - A/C hose to compressor 19–25Nm
Bolt -battery bracket to body 40-50Nm
Bolt - transmission mounting to body 90–110Nm
Bolt - tie bar lower bracket to transmission 90-110Nm
Bolt - engine bracket to engine 58-62Nm
Nut- engine mounting to engine bracket 90-110Nm
Bolt- engine bracket to engine bracket 90-110Nm
Bolt - engine mounting to carling 90-110Nm
Bolt - engine mounting to body 55-65Nm
Bolt - flywheel to crankshaft 30Nm ＋ 70°
plug -cylinder head channel 53-67Nm
Bolt - cylinder head to cylinder block 30Nm+240°
plug -cylinder block channel 53-67Nm
plug - oil cylinder block 45-55Nm
Bolt- cooling jets to crankcase 8-12Nm
Bolt - knock sensor 15-25Nm
plug - oil press sensor 31-39Nm
Bolt - connecting rod 25Nm+75°
Bolt - oil deflector to lower crankcase 8-12Nm
Bolt -Oil Separator Drain Pipe to lower crankcase 8-12Nm
Bolt - main bearing cap to cylinder block 15Nm+ （ 176-184 ） °
Bolt - lower crankcase to cylinder block 8-12Nm
Bolt - crank sensor 8-12Nm
Bolt - A/C Compressor to engine 19–25Nm
Bolt - turbocharger outlet oil tube to crankcase 8-12Nm
Bolt - upper oil pan to lower crankcase 9-11Nm
Bolt - wiring harness connector to upper oil pan 8-12Nm
Bolt - lower oil pan to upper oil pan 9-11Nm
Bolt - engine to transmission 49–67Nm
Bolt - camshaft cover to cylinder head 14-16Nm
Bolt - PCV valves to camshaft cover 8-12Nm
Bolt - PCV valves to turbocharger connector 8-10Nm
Bolt -high pressure tube bracket to camshaft cover 8-12Nm
Bolt - torsion vibration damper to crankshaft 100Nm+(176-184)°
1.0 125
Description Value
Bolt - front cover to cylinder block 14-16Nm
Bolt - front cover to cylinder block 51-65Nm
Bolt - upper oil pan to front cover 8-12Nm
Bolt - fixed guide to cylinder block 8-12Nm
Bolt - pivot guide to cylinder block 21-29Nm
Bolt - chain guide rail upper to camshaft cover 8-12Nm
Bolt - VVT unit to camshaft 20Nm+90°
Bolt - timing chain tensioner to cylinder block 21-29Nm
Bolt- oil pump to lower crankcase 9-11Nm
Bolt- oil pump tensioner to lower crankcase 8-12Nm
Bolt- camshaft bearing cap to cylinder head 10-14Nm
Bolt - intake manifold to cylinder head 8-12Nm
Bolt - TMAP to inlet manifold 4-5Nm
Bolt -oil pick pipe to oil pump 8-12Nm
Bolt - mechanical vacuum pump to cylinder head 21-29Nm
Bolt-hose CAC to engine 7–10Nm
Nut - turbocharger to cylinder head 21-29Nm
Bolt - turbocharger outlet oil tube to turbocharger 9-11Nm
Bolt- turbocharger inlet pipe to turbocharger 31-39Nm
Bolt - turbocharger inlet oil tube to turbocharger 18-22Nm
Bolt -turbocharger heat shield to turbocharger 10-12Nm
Bolt- turbocharger outlet pipe to camshaft cover 8-12Nm
Bolt- turbocharger outlet pipe to turbocharger 31-39Nm
Bolt - outlet assembly to engine 10–14Nm
Bolt- oil cooler assembly to water pump 8-12Nm
Bolt - water pump to cylinder block 22-28Nm
Oil filter 26-34Nm
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Description Value
Plug - oil pan drain 21-29Nm
Parameter
1.5T Main Block
Model 1.5 turbocharger gasoline engine, with 16 valves, dual overhead
camshaft, variable intake/exhaust cam timing
Cylinder arrangement 4-cylinder, in-line
Cylinder bore diameter Φ74mm
Stroke 86.6mm
Displacement 1.490 L
Compression ratio 10.0:1
Ignition sequence 1-3-4-2
Direction of rotation Clockwise when viewed from engine front end
Rated power 124kW/5600rpm
Max. torque 250Nm/1700-4400rpm
Idle speed 680rpm
Max. speed of engine 6600rpm
Weight (excluding engine oil, PAS, A/C, clutch assembly) 116kg (excluding engine oil, A/C, clutch assembly, DIN
standard target weight)
Spark plug gap 0.60 - 0.70mm
1.5T Cylinder Block

Cylinder block
Cylinder block material Aluminum alloy
Type of cylinder liner Precast mushroom head cylinder liner
Cylinder liner diameter Primary: Φ74 ± 0.008mm
Other: Φ74 ± 0.011mm

Cylinder bore out-of-roundness 0.013mm
Surface flatness - top cylinder block - length: 25mm 0.025 mm
Surface flatness - top cylinder block - length: 150mm 0.05mm
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1.5T Crankshaft
Crankshaft
Connecting rod journal diameter Φ44 ± 0.008mm
Crankshaft axial gap 0.15 - 0.38mm
Primary: Φ51.875 ± 0.007mm
Crankshaft main bearing bore diameter
Other: Φ51.875 ± 0.011mm
Crankshaft main bearing clearance #1 bearing 0.011 - 0.070mm
Crankshaft main bearing clearance #2, 3, 4 and 5 bearing 0.012 - 0.067mm
Crankshaft main journal diameter Φ47 ± 0.008mm
Crankshaft main journal out-of-roundness 0.005mm
2, 3, 4 main journal runout for 1, 5 main journal 0.035mm
Quantity of main bearing shell 5 pieces each up and down
The upper shell of the main bearing shell is provided with oil
hole and oil groove, and upper main bearing shell 1 has the
Model coating, upper main bearing shell 4 is a flanged bearing shell
with thrust washers. The other three bearing shells share the
same model.
There is no single thrust washer, machined into a whole with
Thrust washer
the upper main bearing shell 4 to form the flanged bearing shell.
Thrust washer thickness 1.7275 - 1.7775mm
1.5 T Cylinder Head

Cylinder head
Material Aluminum alloy
Cylinder head height: 130.35 ± 0.125mm
Flatness 0.1mm
Valve seat cone angle - pressure relief surface Exhaust 50°, intake 56°
Valve seat cone angle - seat surface 90°
Valve seat cone angle - undercut surface 120°
Cylinder bore taper 0
Hydraulic tappet model Hydraulic tappet, directly driven by camshaft
Hydraulic tappet OD Φ11.993 ± 0.007mm
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1.5T Camshaft
Camshaft
Model Double overhead assembled camshaft
Bearing 6th gear bearing
Drive Timing chain drive
Camshaft journal diameter - journal 1 Φ30.935 - Φ30.960mm
Camshaft journal diameter - journal 2 - 6 Φ23.935 - Φ23.960mm
Camshaft thrust width 33.175 - 33.525mm
Camshaft axial clearance 0.40 - 0.66mm
Camshaft journal clearance 0.040 - 0.085mm
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1.5T Piston Connecting Rod
Piston and pin

Piston pin gap - connecting rod hole 0.007 - 0.020mm
Piston pin gap - piston pin hole 0.002 - 0.010mm
Piston pin diameter Φ17.997 - Φ18.000mm
Piston pin end gap 0.18 - 0.79mm
Piston diameter (38mm below the top piston) Φ73.957 - Φ73.971mm
Fit clearance between piston and cylinder 0.021 - 0.051mm
Piston pin hole diameter Φ18.002 - Φ18.010mm
Piston ring groove width - top 1.23 - 1.25mm
Piston ring groove width - secondary surface 1.23 - 1.25mm
Piston ring groove width - oil control surface 2.03 - 2.05mm
Piston ring
Model 2 compression rings, 1 oil ring
Top compression ring Steel tape ring, ring height: 1.2 (–0.03, –0.01) mm
Second compression ring Cast iron ring, ring height: 1.2 (–0.03, –0.01) mm
Oil ring Three-plate oil ring, ring height: 1.92 ± 0.07mm
Tolerance between piston ring and ring groove:
Top compression ring 0.03 - 0.08mm
Second compression ring 0.03 - 0.07mm
Oil ring 0.050 - 0.190mm

Piston ring gap clearance:
Top compression ring 0.25 - 0.4mm
Second compression ring 0.40 - 0.60mm
Oil ring 0.25 - 0.75mm

Connecting rod
Clearance between connecting rod bearing and crankshaft pin 0.013 - 0.068mm
Connecting rod bore diameter - bearing end Φ47.186 - Φ47.202mm
Connecting rod bore diameter - piston pin end (with a bushing) Φ19.007 - Φ19.017mm
Connection rod backlash 0.090 - 0.350mm
1.5T Lubrication
Lubrication system
Type of oil pump Vane type oil pump
Oil filter Full flow type
Engine oil pressure 200 - 480kPa
Oil capacity 4.5L
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1.5T Valve Timing
Valve timing
Intake valve:
ON 39°CA BTDC
OFF 30°CA ABDC
Max. lift 8.5

Exhaust valve:
ON 51°CA BBDC
OFF 1°CA BTDC
Max. lift 8.3

Gap between valve stem and valve guide:
Intake valve 0.025 - 0.065mm
Exhaust valve 0.035 - 0.075mm

Valve stem fit height:
New intake valve 104.64 ± 0.13mm
New exhaust valve 103.67 ± 0.13mm

Valve head diameter:
Intake valve Φ28 ± 0.13mm

Valve thickness:
Intake valve 1.79 ± 0.18mm
Exhaust valve 1.97 ± 0.18mm

Valve seat roundness 0.015mm
Intake valve length 104.64 ± 0.13mm
Exhaust valve length 103.67 ± 0.13mm
Distance (a) from valve seal lip to bottom of spring seat 16.9mm
Valve stem diameter (intake valve) Φ4.965 ± 0.01mm
Valve stem diameter (exhaust valve) Φ4.955 ± 0.01mm

Valve surface angle - intake valve and exhaust valve 46° ± 0.25°
Valve spring:
Free length 45.8mm
Mounting length 35mm
Assembly load 235N
Intake valve open load 425N
Exhaust valve open load 425N
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System Layout
SGE-1.5T Engine Layout
1. 1.5T Engine
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SGE-1.5T Cylinder Block Exploded View
1. Piston Ring 11. Lower crankcase Locating Pin

2. Connecting Rod Bearing Shell 12. Cylinder Block Water Jacket Plug
3. Bolt - Engine Connecting Rod 13. Engine Cylinder Block Oil Passage Hole Plug
4. Crankshaft Bearing Assembly 14. Crankshaft Assembly
5. Piston Cooling Nozzle Assembly 15. Crankshaft Torsional Vibration Shock Absorber Button
6. Bolt - Lower Crankcase 16. Piston Assembly (with Pin)
7. Bolt - Main Bearing Cover 17. Piston Pin Retaining Ring
8. Cylinder Block Assembly 18. Connecting rod assembly
9. Crankshaft Rear Oil Seal 19. Screw - Piston Cooling Nozzle
10. Engine Cylinder Block Core Hole Plug 20. Washer - Piston Cooling Nozzle
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21. Locating Pin - Transaxle 22. Crankshaft Signal Wheel
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SGE-1.5T Camshaft Cover Exploded View
1. Camshaft Cover Assembly 7. Bolt - Camshaft Position Actuator Solenoid Valve

2. Bolt - Camshaft Cover 8. Crankcase Pressure Regulating Valve Assembly
3. Stud - Camshaft Cover 9. Fixing Sleeve - Camshaft Cover Bolt
4. Locating Pin - Camshaft Cover 10. Bolt - Crankcase Pressure Regulating Valve
5. Camshaft Position Actuator Solenoid Valve Assembly 11. Crankcase Pressure Regulating Valve Assembly
6. O-ring - Camshaft Position Actuator Solenoid Valve 12. Fixing Sleeve - Crankcase Pressure Regulating Valve
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13. Crankcase Pressure Regulating Valve 19. Camshaft Cover Gasket

14. Crankcase Pressure Regulating Valve 20. Camshaft Cover Gasket
15. Oil Seal - Crankcase Pressure Regulating Valve 21. Gasket - Camshaft Position Actuator Solenoid Valve
16. Engine Vacuum Pump Oil Seal 22. Camshaft Position Sensor
17. Oil Filler Cap Assembly 23. Screw - Camshaft Position Sensor
18. Oil Filler Cap Seal Ring 24. Stub - Camshaft Cover
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SGE-1.5T Cylinder Head Exploded View
1. Engine Cylinder Head Assembly 8. Cylinder Head Plug

2. Camshaft Cover Check Valve 9. Exhaust Valve
3. Cylinder Head Oil Passage Plug 10. Intake Valve
4. Bolt - Camshaft Bearing Cover 11. Valve Spring Cap
5. Cylinder Head Plug 12. Valve Lock Clip
6. Cylinder Head Oil Passage Plug 13. Valve Spring
7. Cylinder Head Water Jacket Plug 14. Valve Stem Oil Seal
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15. Valve Stem Oil Seal 22. Screw - Front Engine Hoisting Bracket
16. Exhaust Camshaft Assembly 23. Engine Rocker Assembly
17. Intake Camshaft Assembly 24. Valve Tappet Assembly
18. Front Engine Hoisting Bracket 25. Cylinder Head Gasket
19. Rear Engine Hoisting Bracket 26. Cylinder Head Bolt
20. Rear Engine Hoisting Bracket 27. Cylinder Head Locating Pin
21. Screw - Rear Engine Hoisting Bracket
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SEG-1.5T Engine Oil Pump and Oil Filter Exploded
View
1. Oil Pump Assembly 7. Oil Pump Gasket

2. Oil Control Valve 8. Oil Pump Gasket
3. Bolt - Oil Pump 9. Fixing Sleeve - Oil Pump Bolt
4. Gasket - Oil Pump Suction Pipe 10. Locating Pin - Oil Pump
5. Sprocket - Oil Pump 11. Bolt - Oil Pump Suction Pipe
6. Bolt - Oil Pump Sprocket 12. Retainer - Oil Pump Flow Control Valve
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13. Oil Filter Assembly 14. Bolt - Oil Filter
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SGE-1.5T Oil Pan Exploded View
1. Oil Level Indicator Assembly 12. Fixing Sleeve - Oil Pan Bolt
2. O-ring - Engine Oil Scale 13. Oil Pan Assembly
3. Lower Crankcase Oil Baffle Assembly 14. Bolt - Oil Pan
4. Bolt - Lower Crankcase Oil Baffle 15. Oil Pan Drain Plug Assembly
5. Fixing Sleeve - Crankcase Oil Return Pipe Bolt 16. O-ring - Oil Pan Drain Plug
6. Oil Pan Assembly 17. Crankcase Oil Return Pipe Assembly
7. Oil Control Valve Harness Assembly 18. Bolt - Crankcase Oil Return Pipe
8. Locating Pin - Oil Pan 19. O-ring - Crankcase Oil Return Pipe
9. Bolt - Oil Pan 20. Bolt - Engine Harness
10. Bolt - Oil Pan 21. Fixing Sleeve - Lower Crankcase Oil Baffle Bolt
11. Bolt - Oil Pan 22. Sleeve - Lower Crankcase Oil Baffle Bolt
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SGE-1.5T Timing Chain System Exploded View
1. Timing Chain Assembly 16. Bolt - Timing Chain Cover

2. Timing Chain Guide Rail 17. Bolt - Timing Chain Cover
3. Bolt - Timing Chain Guide Rail 18. Plug - Timing Chain Cover Hole
4. Timing Chain Guide Rail 19. Timing Chain Cover
5. Bolt - Timing Chain Guide Rail 20. Bolt - Timing Chain Cover
6. Timing Chain Guide Rail 21. Oil Pump Chain Tensioner
7. Bolt - Timing Chain Guide Rail 22. Crankshaft Torsional Vibration Shock Absorber
8. Timing Chain Tensioner Assembly 23. Bolt - Crankshaft Sensor
9. Bolt - Timing Chain Tensioner 24. Timing Chain Fuel Injector Assembly
10. Fixing Sleeve - Timing Chain Tensioner Bolt 25. Fixing Sleeve - Timing Chain Track Bolt
11. Washer - Timing Tensioner 26. Bolt - Phase Modulator
12. Crankshaft Sprocket 27. Fixing Sleeve - Timing Chain Cover Bolt
13. Stub - Timing Chain Cover 28. Bolt - Oil Pump Chain Tensioner
14. Crankshaft Front Oil Seal 29. Chain - Oil Pump
15. Locating pin - Timing Chain Cover 30. Camshaft Position Actuator Assembly
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SGE-1.5T Intake Manifold Exploded View
1. Intake Manifold Assembly 5. Intake Manifold Gasket

2. Pipeline Assembly - Canister Solenoid to Manifold 6. Canister Solenoid Assembly
3. Bolt - Intake Manifold 7. Intake Manifold Cover Assembly
4. Bolt - Intake Manifold 8. Clip - Intake Manifold Noise Enclosure
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SGE-1.5T Turbocharger Exploded View
1. Turbocharger Assembly 6. Tube - Turbocharger Electrically Controlled Bypass Valve

2. Liner - Turbocharger to Turbocharger Outlet
3. Hose - Turbocharger Electrically Controlled Bypass Valve 7. Turbocharger Electrically Controlled Bypass Valve
to Release Valve Actuator 8. Bolt - Turbocharger Electrically Controlled Bypass Valve
4. Pipe Clamp - Turbocharger Electrically Controlled Bypass 9. Gasket - Turbocharger Electrically Controlled Bypass
Valve Tube Valve
5. Tube - Turbocharger Electrically Controlled Bypass Valve 10. Bolt - Turbocharger Relief Valve
to Turbocharger Inlet 11. Turbocharger Relief Valve
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12. Nut - Turbocharger Release Valve Actuator 28. Turbocharger Water Inlet Pipe Assembly
13. Crankcase Vent Pipe Joint Assembly 29. Gasket - Turbocharger Coolant Pipe
14. O-ring - Crankcase Vent Pipe Joint 30. Bolt - Turbocharger Water Inlet Pipe
15. Bolt - Crankcase Vent Pipe Joint 31. Turbocharger Oil Return Pipe Assembly
16. Nut - Turbocharger Release Valve Actuator Assembly 32. Liner - Turbocharger Oil Return Pipe
17. Fixed Pin - Turbocharger Release Valve Actuator Rod 33. Bolt - Turbocharger Oil Return Pipe
18. Turbocharger Heat Shield 34. Liner - Turbocharger Oil Return Pipe
19. Bolt - Turbocharger 35. Bolt - Turbocharger Oil Return Pipe
20. Nut - Turbocharger 36. Turbocharger Oil Inlet Pipe Assembly
21. Turbocharger Water Outlet Pipe Assembly 37. Bolt - Turbocharger Oil Inlet Pipe
22. Pipe Clamp - Turbocharger Water Outlet Pipe 38. Liner - Turbocharger Oil Inlet Pipe
23. Bolt - Turbocharger Water Outlet Pipe Bracket 39. Joint - Turbocharger Oil Inlet Pipe
24. Gasket - Turbocharger Coolant Pipe 40. Liner - Turbocharger Oil Inlet Pipe
25. Bolt - Turbocharger Water Outlet Pipe 41. Pipe Clamp - Turbocharger Oil Inlet Pipe
26. Pipeline - Turbocharger Water Outlet To Engine Outlet 42. Fixing Sleeve - Turbocharger Oil Return Pipe Bolt
27. Pipe Clamp - Turbocharger Water Outlet Pipe
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SGE-1.5T Water Pump and Thermostat Exploded View
1. Locating Pin - Coolant Pump 16. Thermostat and Housing Assembly

2. Front Water Pump Cover Assembly 17. Liner - Engine Water Pump
3. Oil Cooler Assembly 18. Liner - Engine Water Pump
4. Gasket - Oil Cooler 19. Liner - Turbocharger Cooling Pipe Connector
5. Bolt - Coolant Pump 20. Turbocharger Cooling Pipe Connector
6. Bolt - Water Pump Housing 21. Engine Water Outlet
7. Bolt - Water Pump Housing 22. Fixing Sleeve - Engine Water Outlet Bolt
8. Bolt - Engine Water Outlet 23. Bolt - Engine Water Outlet Pipeline
9. Bolt - Oil Cooler 24. Pipeline Assembly - Engine Water Outlet to Water Pump
10. Liner - Engine Water Outlet Pipe 25. Pipeline - Engine Water Outlet to Water Pump
11. Water Temperature Sensor Assembly 26. Pipe Clamp - Engine Water Outlet Pipeline
12. Bolt - Thermostat Housing 27. Pipe Clamp - Engine Water Outlet Pipeline
13. Thermostat Gasket 28. Gasket - Coolant Bypass Pipe
14. Fixing Sleeve - Water Pump Bolt 29. Bolt - Engine Water Outlet Pipeline
15. Fixing Sleeve - Engine Coolant Temperature Sensor 30. Engine Harness Bracket
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31. Engine Water Pump Assembly
1.0 147
SGE-1.5T Accessory Belt System Exploded View
1. Auxiliary Drive Tensioner Assembly 3. Front Engine Belt

2. Bolt-Tensioner
1.0 148
Description For the metal cylinder gasket in a multi-layer structure, the
Overview cylinder opening adopts a pressing ring structure, which
enhances sealing at cylinder opening.
The SGE engine features in-line 4-cylinder, 16-valve, DOHC,
timing chain drive and electronically-controlled multi-point There are four oil ducts at front bearing of the camshaft, one
direct injection fuel injection system. oil inlet duct, one oil return duct and two operating oil ducts.
Oil enters the oil control solenoid valve via the oil ducts. The
It is mainly composed of cylinder block, cylinder head,
tail end of camshaft is equipped with a camshaft signal wheel
crankshaft, connecting rod and camshaft. The cylinder head
to provide signals for camshaft position sensor. A stern notch
is made of cast aluminum material and connected with the
is formed in the exhaust camshaft for assembling mechanical
cylinder block through the multi-layer cylinder gaskets by
vacuum pump.
using 10 high-strength bolts.
Cylinder block A phase modulator is installed to the drive ends of the intake
and exhaust camshafts and fixed by bolts.
The cylinder block contains a upper cylinder block and lower
crankcase, this design improves the cylinder block stiffness, and Two phase modulator control valves are installed on the
reduces the manufacturing cost and vibration. camshaft cover lid control valve housing and fixed with an
O-ring and a bolt respectively. The control valve is a four-way
The upper cylinder block is made of aluminum alloy precision
proportioning valve, including an oil inlet, an oil return port
sand casting parts, with 4 cast-in-situ iron cylinder liners
and two oil ducts connected with the phase modulator
arranged in a straight line, high overall strength, and difficult
working chamber.
deformation.
Crankshaft
The lower crankcase assembly consists of lower crankcase
The crankshaft is a forged steel crankshaft with 8 balance
and oil pump. The oil pump is assembled to the bottom of
blocks, and supported by 5 bush bearings. The end float is
the crankcase, the oil passes through the oil strainer with a
controlled by the thrust washer on the top of the main bearing
strainer, pressurized through the oil pump to distribute clean
shell 4. The crankshaft vibration damper is used to control
oil free from impurities to the main bearing and cylinder head
torsional vibration.
via the main oil duct of engine body to lubricate crankshaft,
connecting rod, camshaft and other parts. The mating surface The main bearing journal is in a drilled type design, the upper
of the lower crankcase and engine block is sealed with sealant bearing is in a groove type design, and the oil groove offered
and fixed by bolts. in the upper half part of the main bearing shell supplies oil to
Cylinder head the connecting rod big end bearing shell through the oil hole
in the crankshaft.
The cylinder head adopts 4 valves per cylinder structure
Connecting Rod and Piston
with a spark plug mounted at the center of the combustion
chamber. Due to adoption of overhead valve structure, The aluminum alloy thermal expansion piston is provided
powerful whirlpool will be formed in the combustion chamber with a floating piston pin fit to the clearance of the small
to make the mixed gas evenly distributed, which is good for end of connecting rod, and both ends of the piston pin are
transmission of flame to improve combustion condition, so fixed and limited by circlips. Each piston is provided with two
as to enhance the power performance, fuel economy and compression rings and one oil ring.
emission performance of the engine.
The powder metallurgy connecting rod has an H-section
The camshaft drives the roller rocker, one end of the roller structure. The big end of connecting rod moves on the
rocker is supported by a hydraulic tappet, and the other end bearing shell of crankshaft journal. The connecting rod adopts
is supported by a valve stem end. The valve is driven by forging+cracking process.
swing arm torque. The valve clearance can be automatically Oil Pan
compensated by the hydraulic tappet. The valve stem oil seal
The oil pan consists of aluminum die casting (upper part of
is press-fitted on the cylinder head oil seal seat and can be used
oil pan) and iron die casting (lower part of oil pan). An oil
as the valve spring seat to support the valve spring.
pump control valve connector is installed at the upper part of
The exhaust valve is of a carbon deposit removal type, and the the oil pan, the upper part of the oil pan is fixed to the lower
valve stem with the side machined can clean the carbon deposit crankcase, connected and fixed to the transmission to provide
at the end of valve guide and in combustion chamber so as to additional structural support. The lower part of the oil pan is
prevent valve seizing. fixed to the upper part of the oil pan by bolts.
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Engine Accessories The fuel injection system mainly includes: high pressure fuel
pump, high pressure fuel pipe, fuel rail, rail pressure sensor,
The accessories are a single 5-ribbed belt drive system driven
fuel injector.
by crankshaft pulley: to drive the water pump, alternator and
A/C compressor, and tension the belt via a mechanical damping The high pressure oil pump driven by the overhead cam pumps
tensioner. high pressure fuel into the fuel rail through the fuel pipe, the
High pressure common rail and direct injection injector injects fuel in the rail into the cylinder at a certain
system pulse width, and the rail pressure sensor returns a signal of
pressure in the rail to ECU which controls the pressure in the
Comparing with PFI engine, the gasoline direct injection engine
fuel rail through the high pressure fuel pump. Fuel injection
avoids introducing moisture to the wall of the intake port, this
system pressure is up to 20MPa. ECU controls the spray form
allows accurate calculation of the fuel, reduction of the HC
and fuel-injection quantity by controlling the rail pressure and
emission level during cold start and improvement of the engine
fuel injection pulse width to meet the requirements of different
transient response speed.
conditions for injection.
1.0 150
Operation
1. Oil Filter 4. Tensioner

2. Oil Pump 5. Cylinder Head Main Oil Duct
3. Cylinder Block Main Oil Duct 6. Turbocharger
Lubrication channel in the cylinder head. The timing chain lubricant is
discharged into the oil pan directly. All other moving parts
The lubrication system is a full-flow filtration, forced oil supply
can be lubricated through gravity flow or splash-down. The
system. Oil is drawn from the oil pan through the oil strainer
engine oil switch is installed at the tail end.
by the oil pump, and the strainer is equipped with a screen
which can prevent impurities from entering the oil pump. Turbocharger
The oil pump with an oil pump control valve is driven by the It is high temperature and high pressure exhaust gas exhausted
crankshaft by using the chain. When the oil pressure achieves from the engine, and the exhaust gas has a certain energy.
a certain value, the oil pump control valve will be opened, the In a naturally aspirated engine, this part of energy is often
excess oil returns to the oil inlet side of the oil pump, this wasted with exhaust emissions. The turbocharger is an
helps to maintain the operating oil pressure within a certain exhaust-driven component, which provides compressed air
range and ensure the normal operation of the engine. (pressurized air) to the engine cylinder block, so as to increase
its volumetric efficiency, and the power source of exhaust gas
Pressure oil flows out from the oil pump outlet, then enters
turbocharger is mainly the exhaust gas. The turbine impeller
into the oil filter through the lower crankcase oil gallery, then
and the compressor impeller are in rigid connection through
into the main oil gallery of engine body, oil is distributed to
the turbocharger shaft, and this part is called the turbocharger
the crankshaft, piston cooling nozzle and timing chain cooling
rotor. The turbocharger rotor is fixed in the turbocharger
nozzle. The grooves around each upper main bearing supplies
through the floating bearing (which can guarantee a smaller
oil to the drilled crankshaft channel, and the connecting rod
friction resistance torque in rotor high-speed rotation).
bearing is supplied with oil by the channel connecting the main
When the engine operates, the exhausted gas impacts on the
journal and rod journal. The pressurized oil flows into the
turbocharger impeller at a certain angle at a high speed, so
cylinder head through the throttle hole of the cylinder head,
that the turbocharger rotor rotates at a high speed (up to tens
then enters into each oil supply hole of the camshaft. The cast
of thousands of revolutions per minute). Through high-speed
channel supplies oil to each hydraulic component adjuster, and
rotation of the compressor impeller, the compressor draws
the drilled channel supplies oil to the surface of each camshaft
air from the air filter and forces compressed air into the
bearing. The oil flows back to the oil pan through the cast
intake manifold through the intercooler, and the air pressure
1.0 151
in the intake manifold rises to achieve the pressurization The main channel PCV valve (check valve 1), installed in the
effect. So air will be exposed to greater pressure in the intake camshaft cover lid at the engine intake side, has the cut-off
process, so that more, denser air enters the cylinder. In this function, when the turbocharger starts operating, the valve
way, fuel can be combusted more adequately, and the engine body closes the channel to prevent gas backflow. When the
performance is improved. turbocharger does not operate, the gas in the crankcase enters
into the intake manifold through the valve.
High-pressure oil supplied from the engine provides lubrication
for the bearings, and returns to the oil pan through the oil Secondary PCV valve (check valve 2) is installed at the lateral
return pipe. The exhaust gas from the turbocharger goes into part of the camshaft cover lid at the engine intake side and
the three-way catalyst. The boost pressure is controlled by the connected to the turbocharger air inlet pipe and fresh air PCV
exhaust valve. The exhaust valve in the turbocharger provides valve through PCV pipes. When the crankcase pressure is
a bypass for the gas driven by the turbine, to limit the pressure greater than 1KPa, the secondary PCV valve starts operating,
into the engine when the output of the turbocharger exceeds the valve body opens the channel and supplies excessive
the engine volume flow. The pneumatic actuator controls the abnormal piston blow-by in the crankcase into the air inlet
exhaust valve and responds to the signals sent by the boost pipe through the PCV pipe to ensure crankcase pressure
control solenoid valve by bypassing excessive boost pressure balance.
of the turbocharger.
Turbo PCV valve (check valve 3) is installed at the top of the
Because of high temperature of the gasoline engine camshaft cover lid at the engine intake side, connected to the
turbocharger, the gasoline engine turbocharger is cooled by turbocharger air inlet through a hose, operates only under
water-cooling. crankcase pressurization condition, and it is used to introduce
Crankcase Ventilation separated dirty air into the turbocharger air inlet to ensure
crankcase pressure balance.
In the engine working process, a small amount of combustion
gas passes through the piston to enter the crankcase, which Fresh air PCV valve (check valve 4) is installed at the top of the
is called gas blow-by. Such gases mainly contain unburned camshaft cover lid at the engine exhaust side, and connected
hydrocarbon (HC), which will pollute engine oil and form to the turbocharger air inlet pipe and Secondary PCV valve
overlarge crankcase pressure at high engine speed, causing through PCV pipes. When the crankcase pressure is less than
oil leakage from seals and gaskets. The crankcase breather –1KPa, the fresh air PCV valve starts operating, the valve body
system is just used to bring such gases into the air intake opens the channel for introducing filtered fresh air into the
system from the crankcase. crankcase to ensure crankcase pressure balance.
1.0 152
Diagnostic Engine Misfires Without Internal Noise
Symptom - Engine Mechanical System Engine Misfire and Abnormal Noise Found Below
Internal Engine
Visual/Appearance Check
Engine Misfire and Abnormal Noise Found in
• Check if there is any aftermarket add-on device that may Valve System
affect engine operation. Engine Misfire With Coolant Consumption
Engine Misfire With Excessive Oil Consumption
• Check the easily accessible or visible system components Engine Noise at Start-up, but Only Lasting
for any obvious damage or failure that may cause the a Few Seconds
symptom. Upper Engine Noise, Regardless of Engine Speed
Lower Engine Noise, Regardless of Engine Speed
• Check if the oil level, oil viscosity and filter application Engine Noise Under Load
are correct. Engine Cannot Be Started - Crankshaft Cannot
• Confirm the exact operation conditions when failure Rotate
Ingress of Coolant Into Combustion Chamber
occurs. Record the specific factors, such as engine
Ingress of Coolant Into Engine Oil
speed, ambient temperature, engine temperature and Engine Compression Pressure Test
engine warm-up time. Cylinder Leakage Test
• Compare the engine sound with that of a normally Oil Consumption Diagnosis
operating engine to determine whether the current Oil Pressure Diagnosis and Test
Oil Leakage Diagnosis
situation is normal (if applicable).
Crankcase Ventilation System
Intermittent Failure Inspection/Diagnosis
Drive Belt Chirp, Squeal and Whine Diagnosis
Test the vehicle under the same conditions as reported by the
Drive Belt Rumbling and Vibration Diagnosis
customer to determine whether the system operates normally. Drive Belt Drop and Excessive Abrasion
Symptom List Diagnosis
Drive Belt Tensioner Diagnosis
Refer to the diagnostic procedures in the following list to
diagnose the symptom:
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Engine Misfire Without Internal Noise
Failure Cause Measure

Accessory Drive Belt Abnormal, Severely Cracked, Swelled or
Incomplete
Abnormal accessory drive system or parts may lead to DTCs Replace the drive belt.
for engine speed variation and engine misfire. The misfire DTC
may also occur when there is actually no misfire fault.
Wear, damage and misalignment of the accessory drive parts
or excessive pulley runout may result in engine misfire DTCs.
Check the component, repair or replace when necessary.
The misfire DTC may also occur when there is actually no
misfire fault.
Engine Flywheel Loose or Improperly Fitted
The misfire DTC may also occur when there is actually no Repair or replace the flywheel when necessary.
misfire fault.
Exhaust System Blockage
When exhaust airflow is seriously clogged, it will lead to

a significant reduction in engine performance, and a DTC Repair or replace as necessary.
may be set. Possible causes for the obstruction include
pipeline collapse or depression, muffler or catalytic converter
blockage.
Vacuum Hose Improperly Fitted or Damaged Repair or replace as necessary.
The seal between the intake manifold and the cylinder Replace the intake manifold, gaskets, cylinder heads or
head/throttle body is incorrect. throttle body if necessary.
Intake Manifold Absolute Pressure Sensor Damaged or
Improperly Fitted Repair or replace the intake manifold absolute pressure
sensor if necessary.
The seal ring of the intake manifold absolute pressure sensor
shall not be torn or damaged.
Intake Manifold Absolute Pressure Sensor Housing Damaged Replace the intake manifold.
Rocker Arm Worn or Loose
The end cap of the rocker arm bearing or needle bearing shall Replace the valve rocker arms, as required.
be in good condition and correct position.
Valve Stuck
Carbon deposits on the valve stem can cause the valve to close Repair or replace as necessary.
improperly.
Excessively Worn or Mis-aligned Timing Chain Replace the timing chain and sprockets as required.
Camshaft Lobe Worn Replace the camshaft and valve lash adjuster.
Oil Pressure Excessive • Perform the oil pressure test.
High oil pressure of the lubrication system may cause excessive Oil Pressure Diagnosis and Test
pump oil and compression pressure loss of the valve tappet. • Repair or replace the oil pump, as required.
Cylinder head gasket failure or cracked cylinder heads and • Check whether the spark plug is immersed in coolant.
cooling system passages of the engine cylinder block or other • Check the cylinder head, engine cylinder block or
damages. cylinder head gasket.
Coolant consumption may or may not cause engine overheat. • Repair or replace as necessary.
1.0 154
• Check the spark plugs for oil deposits.
• Check whether the cylinder compression pressure is
Piston Ring Worn lowered.
Oil consumption may but not necessarily result in engine Engine Compression Pressure Test
misfire. • Perform the cylinder leakage and compression test to
identify the failure cause.
• Repair or replace as necessary.
Crankshaft Variable Reluctance Rotor Damaged
Crankshaft variable reluctance rotor damage may cause

different symptoms depending on the severity and position of
the damage.
• For systems with the electronic communication, direct

ignition system or ignition coil (for each cylinder) and
a seriously damaged reluctance ring, the position of
the crankshaft may lose periodically, signal transmission
may stop and the position of the crankshaft will be
resynchronised. Replace the sensor or crankshaft if necessary.
• For systems with the electronic communication, direct

ignition system or ignition coil (for each cylinder) and
a slightly damaged reluctance ring, missing crankshaft
position and engine misfire will not occur. However,
DTC P0300 may be set.
• For systems with mechanical communication and high
voltage switch, a seriously damaged variable reluctance
ring may lead to additional pulse, which affects delivery
of the fuel and spark, until DTC P0300 or P0336 occurs.
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Engine Misfire and Abnormal Noise Found Below

Internal Engine
Accessory Drive Belt Abnormal, Severely Cracked, Swelled or
Incomplete
Abnormal accessory drive system or components may result

in engine speed change and the noise similar with that when Replace the drive belt.
the lower engine fails, which may also lead to misfire. The
misfire DTC may also occur when there is actually no misfire
fault.
Accessory drive component is worn, damaged, misaligned
or excessive pulley runout. A misfire DTC may be present Check the component, repair or replace when necessary.
without an actual misfire condition.
Engine Flywheel Loose or Improperly Fitted
The misfire DTC may also occur when there is actually no Repair or replace the flywheel when necessary.
misfire fault.
• Check the spark plug for oil deposit.
Crankshaft Thrust Bearing Worn
Excessive wear of the crankshaft thrust surface or thrust

bearing thrust surface can cause forward or backward Replace the crankshaft and bearings, as required.
movement of the crankshaft and misfire DTCs when no
misfire actually occurs.
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Engine Misfire and Abnormal Noise Found in
Valve System
Rocker Arm Worn or Loose
The rocker arm bearing end caps or needle bearings should be Replace the valve rocker arms, as required.
intact within the rocker arm assembly.
Valve Stuck
Carbon deposits on the valve stem can cause the valve to close Repair or replace as necessary.
improperly.
Excessively Worn or Mis-aligned Timing Chain Replace the timing chain and sprockets, as required.
Camshaft Lobe Worn Replace the camshaft and valve lash adjuster.
Stuck Valve Lifters Replace as required.
1. Confirm that the oil pressure is normal. If it is low, check
the bottom of the oil filter for oil return function.
Oil Pressure Diagnosis and Test
2. The noise source is identified as a specific camshaft
Camshaft Position Actuator Failure - Incorrect Oil Viscosity position actuator. Disconnect the electrical connector
or Contaminated Oil from the camshaft position actuator solenoid valve and
start the vehicle. If the noise disappears, repeat the
procedure and limit it to an independent actuator.
Camshaft Phase Adjustment Actuator
Replacement
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Engine Misfire with Coolant Consumption

Failure Cause Measures
• Check whether the spark plugs are saturated by coolant.
Cylinder head gasket failure or cracking or other damages to
• Perform a cylinder leakage test.
the cylinder heads and engine block cooling system passages.
• Inspect the cylinder heads and engine block for damage
Coolant consumption may or may not cause the engine to
to the coolant passages or cylinder head gasket failure.
overheat.
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Engine Misfire With Excessive Oil Consumption
Valve, Valve Guide or Valve Stem Oil Seal Worn
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Engine Noise at Start-up, but Only Lasting a Few

Seconds
Incorrect Oil Filter (without anti-return function) Fit a suitable oil filter.
• Drain the oil.
Incorrect Oil Viscosity
• Use the oil with correct viscosity.
Valve Lash Adjuster Leaks too Fast Replace the lash adjuster when necessary.
• Inspect the thrust bearing and crankshaft.
Crankshaft Thrust Bearing Worn
• Check if the oil filter bypass valve can work properly.
Damaged or Faulty Oil Filter Bypass Valve
Replacement
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Upper Engine Noise, Regardless of Engine Speed
• Perform the oil pressure test.
Low Oil Pressure Oil Pressure Diagnosis and Test
Rocker Arm Worn Replace the valve rocker arm.
Inspect the following components and repair or replace, as
required:
• Valve rocker arm
Improper Lubrication to Valve Rocker Arms • Valve lifter
• Oil filter bypass valve
• Oil pump and pump screen
• Engine block oil galleries
Valve Spring Broken Replace the valve spring.
Valve Lash Adjuster Worn or Dirty Replace the valve lash adjuster.
Timing Chain Stretched or Fractured or Sprocket Tooth
Inspect the timing chain and sprockets.
Damaged
Timing Chain Tensioner Worn, Damaged or Failed Replace the tensioner.
• Check the cam lobe of the engine.
Engine Cam Lobe Worn • Replace the camshaft and valve lash adjuster when
necessary.
required:
Valve Guide or Valve Stem Worn
• Valve
• Valve guide
Valve Stuck
required:
The valve is stuck in "ON" position due to possible carbon • Valve
deposit on the valve stem or valve seat.
• Valve guide
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• Repair or replace defective components as necessary.
Accessory drive component wear - Abnormal conditions, • Inspect the accessory drive system.
such as severe crack, swell or partial absence of the accessory
drive belt or system components misalignment occur • Repair or replace as necessary.
• Inspect the crankshaft balancer.

Crankshaft Balancer Loosened or Damaged
Detonation or Spark Knock Check if the ignition system can work properly.
• Inspect the torque converter bolts and flywheel.
Torque Converter Bolt Loosened
Flywheel Loosened or Damaged Repair or replace the flywheel.
• Check the oil pan.
Damaged Oil Pan Touching Oil Pump Screen - A damaged
oil pan may result in wrong location of the oil pump screen, • Check the oil pump screen.
preventing the oil from flowing to the oil pump properly.
• Check the oil pump screen.
Oil Pump Screen Loosened, Damaged or Blocked
• Inspect the piston and cylinder bore.
Large Gap Between Piston and Cylinder
• Repair when necessary.
• Inspect the piston, piston pin and connecting rod.
Excessive Piston Pin-to-Bore Clearance
Inspect the following components and repair, as required:
• Connecting rod bearing
Excessive Connecting Rod Bearing Clearance • Connecting rod
• Crankshaft
• Crankshaft journal
Excessive Crankshaft Bearing Clearance • Crankshaft bearing
Piston, Piston Pin and Connecting Rod Fitted Improperly - • Confirm that the piston, piston pin and connecting rod
When fitting the piston, ensure that the mark or dent on the are fitted properly.
top piston faces the front of the engine. Piston pins must be
centered in the connecting rod pin bore. • Repair when necessary.
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Engine Noise Under Load
Detonation or Spark Knock Confirm if the system can work properly.
• Inspect the torque converter bolts and flywheel.
Torque Converter Bolt Loosened
• Inspect the flywheel bolts and flywheel.
Flywheel Cracking, Automatic Transmission
• Connecting rod bearing
Excessive Connecting Rod Bearing Clearance
• Connecting rod
• Crankshaft
• Crankshaft bearing
Excessive crankshaft bearing clearance
• Cylinder block crankshaft bearing bore
Replacement
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Engine Unable to Start - Crankshaft Not Rotate

Failure Causes Measures
Remove the accessory drive belt.Rotate the crankshaft at the
Accessory drive system component stuck
balancer or flywheel position by hand.
Remove the spark plug and check if there is any fluid on it.
Cylinder blocked by hydraulic pressure • Check the cylinder head gasket for break.
• Coolant/antifreeze found in cylinder • Check the engine cylinder block or cylinder head for
• Oil found in cylinder cracking.
• Fuel found in cylinder • Check if the injector has got stuck.
• Check the cylinder wall for cracking.
Remove the torque convertor bolt.Rotate the crankshaft at
Automatic Transmission Torque Converter Stuck
the balancer or flywheel position by hand.
• Check the timing chain and gear.
Timing Chain or Gear Broken
• Check the balance shaft.
Balance Shaft Gets Stuck
Foreign material enters into cylinder
• Check the cylinder for damaged parts and/or foreign
• Valve broken
materials.
• Piston material
• Check if the cylinder wall falls off.
• Foreign materials
• Repair and replace the parts when necessary.
• Cylinder wall cracked
• Check the crankshaft and connecting rod bearings.
Crankshaft or Connecting Rod Bearing Gets Stuck • Check if the cylinder wall falls off.
• Check the connecting rod.
Connecting Rod Bent or Fractured
• Check the crankshaft.
Crankshaft Cracked
1.0 164
Ingress of Coolant into Combustion Chamber
Definition: Excessive white smoke or gas with coolant odour coming from the exhaust pipe may indicate coolant in the
combustion chamber. Coolant level low, cooling fan inoperative or thermostat failure may lead to "High Temperature" and
cause engine component damage.
1. A speed slower than normal may indicate coolant entering the combustion chamber.
Engine Cannot Be Started - Crankshaft Cannot Rotate
2. Remove the spark plugs and inspect for spark plugs saturated by coolant or coolant in the cylinder bore.
3. Check by performing a cylinder leakage test. During this test, excessive air bubbles within the coolant may indicate a
faulty gasket or damaged component.
4. Check by performing a cylinder compression pressure test. Two adjacent cylinders in the engine block with low
compression pressure may indicate a damaged cylinder head gasket.
Engine Compression Pressure Test
Replace the cylinder head gasket and components when
necessary.
Cylinder Head Gasket Failure
Cylinder Head Check
Cylinder Head Replacement
Replace the cylinder head and gasket.
Cylinder Head Warped
Cylinder Head Check
Cylinder Head Cracked Replace the cylinder head and gasket.
Cylinder Liner Cracked Replace components as necessary.
Cylinder Head or Block Porosity Replace components as necessary.
1.0 165
Ingress of Coolant into Engine Oil

Definition: Foamy or discolored oil or an engine oil overfill condition may indicate coolant entering the engine crankcase.
Coolant level low, cooling fan inoperative or thermostat failure may lead to "High Temperature" and cause engine component
damage. Contaminated engine oil and oil filter should be changed.
1. Inspect the oil for excessive foaming or an overfill condition. Oil diluted by coolant may not properly lubricate the
crankshaft bearings and may lead to component damage.
2. Check by performing a cylinder leakage test. During this test, excessive air bubbles in the cooling system may indicate a
faulty gasket or damaged component.
3. Check by performing a cylinder compression pressure test. Two adjacent cylinders in the engine block with low
compression pressure may indicate a damaged cylinder head gasket.
Engine Compression Pressure Test
Replace the cylinder head gasket and components when
necessary.
Cylinder head gasket failure
Cylinder Head Check
Cylinder Head Replacement
Replace the cylinder head and gasket.
Cylinder head warped
Cylinder Head Check
Cylinder head cracked Replace the cylinder head and gasket.
Cylinder liner cracked Replace components as necessary.
Cylinder head or block porosity Replace components as necessary.
1.0 166
Engine Compression Pressure Test • Valve clearance/adjustment improper
1. If the battery is not fully charged, charge it. • Piston wearing
2. Disable the ignition system. • Piston ring wearing
3. Disable the fuel injection system. • Cylinder hole wearing or damage
4. Remove all spark plugs. • Cylinder head cushion damaged
5. Place the ignition switch in "ON" position. • Cylinder head crack or damaged
6. Depress the accelerator pedal to keep the throttle fully • Engine cylinder crack or damaged
open. Warning: Before repairing any electrical parts, ignition
7. The compression pressure gauge gets started at and start switch must be turned to OFF or LOCK and all
zero position, and then starts the engine after 4 the electrical load must be turned off unless otherwise
compression/expansion strokes. specified in the procedure. Disconnect the cathode cable
8. Measure the compression pressure of each cylinder and of the battery to prevent the tool or equipment from
record the reading. contacting the exposed electrical terminal to generate
spark. Failure to follow the safety instructions may cause
9. If there is one cylinder with a too low compression
personal injury and/or damage to the vehicle or parts.
pressure, inject about 15 mL engine oil through the spark
plug hole into combustion chamber, and then remeasure 1. Disconnect the battery negative.
the compression pressure and record the reading. 2. Remove the spark plug.
10. The minimum compression pressure of any cylinder Spark Plug Remove
should be no less than 70% of the maximum value, 3. Turn the crankshaft, place the cylinder piston under test
and the pressure reading of any cylinder shall be no to the top dead center of compression stroke (TDC).
less than 690kPa. For example, if the maximum
4. Fit the cylinder head leakage tester or equivalent.
pressure of any cylinder is 1035 kPa, then the allowable
minimum pressure of other cylinders should be 725 kPa
(1035×70%=725).
• Normal - For each cylinder, the compression pressure

shall be augmented to its specified value in a rapid and
steady manner.
• Piston ring leakage - The compression pressure of the

first stroke is too low, and during the subsequent strokes,
the compression pressure increases but fails to reach
the normal level. Refill the engine oil, the compression
pressure will be notably increased.
• Valve leakage - The compression pressure of the first

stroke is too low, and the compression pressure will not 5. Apply the workshop compressed air pressure to
increase in the following strokes. Refill the engine oil, and cylinder head leakage tester, and make adjustment
the compression pressure will increase not much. according to the manufacturer's instructions.
• If the compression pressure of two adjacent cylinders Caution: The crankshaft balance tester bolt may be
is lower than the normal level, and the compression tightened to prevent the engine operation.
pressure will not increase by injecting oil to the cylinder,
6. Record the cylinder leakage value. If the cylinder leak
the cylinder head gasket may leak.
is more than 25%, it shall be deemed as excessive
Cylinder Leak Test leakage, and the component may need repair. In case of
Caution: To inspect the leakage of the excessive leakage, check for the following conditions:
cylinder/combustion chamber, leakage test may be • If the throttle body or intake hose sounds of air leakage,
required.If the leakage is serious, one or more faults may it indicates that the throttle may be worn, burnt or the
exist: throttle spring is cracked.
• Valve wearing or burnt
• If the exhaust system tail pipe sounds of air leakage, it
• Valve spring broken indicates that the exhaust valve may be worn, burnt or
• Valve tappet seized the exhaust valve spring is cracked.
1.0 167
• If the crankcase, dipstick conduit or oil filling pipe sounds • When there are bubbles in the cooling system, it indicates
of air leakage, it indicates that the piston ring is worn, that the cylinder head or cylinder head gasket may be
the piston is damaged, the cylinder bore is worn or damaged.
scratched, the engine cylinder block is damaged or the 7. Perform a leak test on the remaining cylinders and
cylinder head is damaged. record the values.
1.0 168
Oil Consumption Diagnosis According to local temperature, apply the recommended
Excessive oil consumption caused by non-leakage factors refers oil with a viscosity of SAE.
to the situation where an amount of 0.6 L engine oil or more • Continuous high speed driving and overuse
is consumed within 1000 km. The causes of excessive oil
• Crankcase ventilation system barrage or component
consumption are as follows:
failure
• Oil leak.
• Valve guide pipe or valve stem oil seal is worn, or the
Tighten the bolt, replace the gasket and oil seal when seals is deficient.
necessary. • The piston ring is broken, improperly fitted, worn or
• Oil level is incorrect or the oil dipstick reading is wrongly located, wait long enough to allow the piston
incorrect. ring to be in place. If necessary, replace the broken or
worn piston ring.
With the vehicle parked on level ground, wait long
• The piston is fitted or aligned improperly.
enough for oil return, and check the oil level.
• Engine oil viscosity is inadequate.
1.0 169
Engine Oil Pressure Diagnosis and Test

1. Park the vehicle on a level surface, wait long (2–3 Min)
enough to allow the oil to flow down and check if the
oil level is low.
Engine oil of recommended grade shall be refilled. Refill

the crankcase until the oil reaches the MAX mark on
the dipstick.
2. Warm up the engine, and confirm that there is no

indication of "too low pressure" or "no oil pressure" on
the vehicle instrument or indicator lamp.
Listen whether there is valve train noise or knock.
3. Check for the following conditions: 8. Fit the starter motor.

• The oil filer with return oil prevention function and the 9. Connect the battery negative cable.
O-ring on filter cylinder block side are normal. 10. Start the vehicle, the oil pressure must be 200-480KPa
• Oil diluted by water or unburnt fuel mixture at idle speed.
11. If the pressure of the engine oil is below the specified
• Oil viscosity not applicable to expected temperature
value, check the engine for one or more of the following
• Oil pressure transmitter incorrect or failed situations:
• Oil pressure gauge incorrect or failed • Oil filter and filter cylinder block side O-ring missing or
damaged
• Oil filter blockage
• Worn or contaminated oil pump.
• Oil bypass valve failure
• Oil pump to lower crankcase O-ring missing or damaged
4. Disconnect the battery negative cable.
5. Remove the starter motor. • Oil strainer loose, clogged or damaged
6. Remove the engine oil pressure sensor. • Oil strainer O-ring missing or damaged
7. Fit the special tools TEN00080 and T10001. • Oil pump pressure regulating valve failure
• Large bearing gap

Crankshaft check
• Oil passage cracked, porous or clogged
• Missing or improperly fitted oil passage plug
1.0 170
Engine Oil Leak Diagnosis
Step Operation Yes No

Definition: First determine the leakage position by visual inspection, then repair or replace parts, or reseal the gasket surface
to eliminate most of the oil leakage failures. Once the leak location is found, determine the causes of leakage. Repair the leak
source and solve the leak problem.
1. Run the vehicle until it reaches the normal operating
temperature.
2. Park the vehicle on a level surface, and place it on a
1 large piece of paper or other clean surfaces. Go to step 2 System OK
3. Wait for 15 Min .
4. Check for oil droplets.
Does oil droplet appear?

Can you identify the type of oil and approximate positions
2 Go to step 10 Go to step 3
of the leakage?
1. Visually check the suspected location. If the suspected
position is not readily observable, you can have the
aid of a small mirror.
2. Check the following positions for leakage:
3 • Sealing surface Go to step 10 Go to step 4

• Joint
• Cracking or damaged components

of the leakage?
1. Thoroughly clean the whole engine and surrounding
components.
2. Under the normal operating temperature, drive the
vehicle for several miles at different speeds.
3. Park the vehicle on a level surface, and place it on a
4 large piece of paper or other clean surfaces. Go to step 10 Go to step 5
4. Wait for 15 Min .
5. Identify the type of oil and the approximate positions
of the leakage.

of the leakage?
1. Visually check the suspected locations. If the suspected

• Joint
• Cracking or damaged components

of the leakage?
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1. Thoroughly clean the whole engine and surrounding
components.
2. Apply spray powder to the suspected locations.
3. Under the normal operating temperature, drive the
vehicle for several miles at different speeds.
6 Go to step 10 Go to step 7
4. Identify the type of oil,and determine the approximate
positions of the leakage according to the color change
of powder surface.

of the leakage?
1. Visually check the suspected locations. If the suspected

• Joint
• Cracking or damaged component

of the leakage?
Identify the type of oil and approximate positions of the
leakage with a high intensity invisible lamp assemblies.
8 Please refer to the manufacturer's instructions when Go to step 10 Go to step 9
you use the tool. Can you identify the type of oil and
approximate position of the leakage?
1. Visually check the suspected location. If the suspected
9 • Sealing surface Go to step 10 System is normal

• Joint
• Cracking or damaged component
Can you identify the type of oil and approximate position of

the leakage?
1. Check the engine for mechanical damage. Pay special
attention to the following positions:
• Fluid level higher than recommended value
• Oil pressure higher than recommended value
10 • Oil filter or pressure bypass valve clogged or got failure Go to step 11 System is normal
• Engine ventilation system clogged or got failure
• Improper tightening or damage to fastener
• Cracking or void in components
• Incorrect sealant or gasket
1.0 172
• Improper fitting of sealant or gasket
• Damage or wear of gasket or seal
• Damage or wear of sealing surface
2. Check whether the engine has been modified by the

user.
Is the engine mechanically damaged or modified by user?

Repair or replace all damaged or modified components.
11 Go to Step 1 -
Is the repair completed?
Crankcase Ventilation System

Inspection/Diagnosis
Symptoms Correction
Check for any of the following conditions:
• PCVHose or engine vent hose is blocked or kinked

External oil leakage
• PCVHose damage, incorrect or improper refit
• Large crankcase pressure
Check for any of the following conditions:
• PCVHose or engine vent hose is blocked or kinked

Unstable idle speed
• PCVHose leakage (damage)
• Vacuum hose wear or improperly fitted
High idle speed Check PCV hose for leakage (damage)
Silt in engine Check for blocked or kinked PCV hose or engine vent hose
1.0 173
Service Procedures
Powertrain Disassembly and Assembly - MT
Remove
Battery Box Bracket Remove


Engine Oil Drain
5. Drain the transmission fluid.
13. Remove the vacuum tube on the mechanical vacuum
Manual Transmission Fluid Drain pump.
6. Recycle A/C refrigerant. 14. Disconnect the low-pressure fuel pipe on the
high-pressure fuel pump.
15. Disconnect the connector of engine control module.
16. Disconnect the engine harness and body harness
connector, and remove and discard the harness clip
8. Loosen the clamps on both sides of the turbocharger from the body.
intake pipe, and remove the turbocharger intake pipe.
17. Remove 1 bolt fixing the engine ground wire to the
9. Loosen the clamp, and remove the throttle intake pipe. right beam, and loosen the engine ground wire.
10. Remove the harness clip from the battery box. 18. Disconnect the canister solenoid intake pipe.
11. Remove 6 bolts fixing 2 battery box brackets to the 19. Remove 2 shift cable ball joints (1).
front longitudinal member, and remove the 2 battery
20. Loosen the clips, release the external gear selection/shift
box brackets.
cable (2) from the cable bracket, and discard the plastic
clips.
12. Loosen the clamp, and disconnect the engine water

outlet pipe.
21. Disconnect the hydraulic clutch line, remove the lock
plate, and remove the hydraulic clutch hose.
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22. Disconnect the reverse lamp switch and neutral 31. Remove the engine mount.
position sensor harness, remove the clip and harness. Powertrain Mount Remove
23. Open the engine compartment fuse box cover, and 32. Remove 3 bolts fixing the transmission mount to the
disconnect the body harness and fuse box connector. transmission mounting bracket.
24. Raise the vehicle on the lift to a suitable position.
25. Remove the front subframe.
Front Subframe Remove
26. Remove 1 bolt fixing the lower tie bar to the lower tie
bar bracket, and remove the lower tie bar.
27. Remove 3 bolts fixing the lower tie bar bracket to the
transmission, and remove the lower tie bar bracket.
28. Remove the hold-down bolt securing the compressor
hose assembly to the compressor, and disconnect the
pipeline.
33. Support the bottom of the powertrain with a bracket.

34. Fix the engine to the bracket, remove the T10007 and
TEN00070, and remove the powertrain.
Refit
1. Fix the powertrain to the bracket, and place it at the
bottom of the vehicle.
2. Lower the vehicle, place the engine in the engine
compartment, and fix the engine with the T10007 and
TEN00070.
3. Fix the transmission mount to the transmission
mounting bracket, fit 3 bolts, tighten to 70Nm+90°
4. Fit the engine mount.
Powertrain Mount Refit
5. Remove the bracket.
7. Fix the lower tie rod bracket to the transmission, fit 3
bolts, tighten to 55-65Nm and check the torque.
8. Fix the lower tie bar to the lower tie bar bracket, fit 1
bolt, tighten to 90-110Nm and check the torque.
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9. Fix the compressor hose assembly to the compressor, Battery Bracket Refit
fit 1 hold-down bolt, tighten to 19–25Nm and check 34. Connect the battery negative.
the torque.
10. Fit the front subframe.
Front Subframe Refit
12. Open the engine compartment fuse box cover, and
connect the body harness and fuse box connector.
13. Connect the reverse switch and neutral position sensor
harness, and fix the harness clip.
14. Connect the hydraulic clutch line, and empty the air
in the clutch.
Clutch System Bleeding
15. Fit new plastic clips, and fit the external gear
selection/shift cable to the cable bracket.
16. Fit 2 shift cable ball joints.
17. Connect the canister solenoid intake pipe.
18. Fix the engine ground wire to the right beam.
19. Connect the engine harness and body harness
connector, and fix the harness clip to the body, and
then fix the harness to the harness clip.
20. Connect the connector of the engine control module.
21. Connect the low-pressure fuel pipe of the high-pressure
fuel pump.
22. Connect the vacuum tube on the mechanical vacuum
pump.
23. Connect the engine water outlet hose and fix it with
clamps.
24. Fix 2 battery box brackets to the front longitudinal
beam, fit 6 bolts, tighten to 40-50Nm, and check the
torque.
25. Fix the harness clip to the battery box.
26. Fit the throttle intake pipe and fix it with clamps.
27. Fit the turbocharger intake pipe, and fix it with clamps.
Air Filter Assembly Refit
Engine Oil Refill
30. Fill the transmission fluid.
Manual Transmission Fluid Refill
1.0 176
Powertrain Disassembly and Assembly - AT
Remove
Battery Bracket Remove

Engine Oil Drain

5. Drain the transmission fluid.
Automatic Transmission Fluid Drain 13. Remove the vacuum tube on the mechanical vacuum
6. Recycle A/C refrigerant. pump.
A/C Refrigerant Recycle 14. Disconnect the low-pressure fuel pipe on the
15. Disconnect the connector of engine control module.
16. Disconnect the engine harness and body harness
8. Loosen the clamps on both sides of the turbocharger connector, and remove and discard the harness clip
intake pipe, and remove the turbocharger intake pipe. from the body.
9. Loosen the clamp, and remove the throttle intake pipe. 17. Remove 1 bolt fixing the engine ground wire to the
10. Remove the harness clip from the battery box. right beam, and loosen the engine ground wire.
11. Remove 6 bolts fixing 2 battery box brackets to the 18. Disconnect the canister solenoid intake pipe.
front longitudinal member, and remove the 2 battery 19. Disconnect the transmission harness connector.
box brackets.
20. Disconnect the position sensor connector of the clutch

12. Loosen the clamp, and disconnect the engine water actuator master cylinder.
outlet pipe.
21. Disconnect the speed sensor connector.
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28. Remove 4 bolts fixing the lower tie bar bracket to the
transmission, and remove the lower tie bar bracket.
22. Remove the clip fixing the transmission harness to the

transmission and remove the harness.
31. Remove the engine mount.

Powertrain Mount Remove
32. Remove and discard 2 bolts and 1 nut fixing the
transmission mount to the transmission mounting
bracket.

disconnect the body harness and fuse box connector.
24. Raise the vehicle on the lift to a suitable position.

26. Remove the hold-down bolt securing the compressor
hose assembly to the compressor, and disconnect the
pipeline. 33. Remove 4 bolts fixing the transmission mount to the
body, and remove the transmission mount.
34. Support the bottom of the powertrain with a bracket.
35. Fix the engine to the bracket, remove the T10007 and
TEN00070, and remove the powertrain.
Refit
1. Fix the powertrain to the bracket, and place it at the
bottom of the vehicle.
2. Lower the vehicle, place the engine in the engine
compartment, and fix the engine with the T10007 and
TEN00070.
3. Fix the transmission mount to the body, fit 4 bolts,
27. Remove 1 bolt fixing the lower tie bar to the lower tie 4. Fix the transmission mount to the transmission
bar bracket, and remove the lower tie bar. mounting bracket, fit 2 new bolts, tighten to
1.0 178
70Nm+90°, fit 1 new nut, tighten to 70Nm+90° and 31. Fill the transmission fluid.
check the torque.
Automatic Transmission Fluid Refill
5. Fit the engine mount.
Powertrain Mount Refit
6. Remove the bracket.
8. Fix the lower tie bar bracket to the transmission, fit 4
bolts, tighten to 90-110Nm and check the torque. 34. Fit the battery bracket.
9. Fix the lower tie bar to the lower tie bar bracket, fit 1 Battery Bracket Refit
bolt, tighten to 90-110Nm and check the torque. 35. Connect the battery negative.
10. Fix the compressor hose assembly to the compressor,
fit 1 hold-down bolt, tighten to 19–25Nm and check
the torque.
connect the body harness and fuse box connector.
14. Connect the speed sensor connector.
15. Fit the position sensor connector of the clutch actuator
master cylinder.
16. Connect the transmission connector.
17. Connect the transmission harness connector, and fix
the harness clip to the transmission housing.
18. Connect the canister solenoid intake pipe.
19. Fix the engine ground wire to the right beam.
20. Connect the engine harness and body harness
connector, and fix the harness clip to the body, and
then fix the harness to the harness clip.
21. Connect the connector of the engine control module.
22. Connect the low-pressure fuel pipe of the high-pressure
fuel pump.
23. Connect the vacuum tube on the mechanical vacuum
pump.
24. Connect the engine water outlet hose and fix it with
clamps.
beam, fit 6 bolts, tighten to 40-50Nm, and check the
torque.
26. Fix the harness clip to the battery box.
27. Fit the throttle intake pipe, and fix it with clamps.
Engine Oil Refill
1.0 179
Powertrain Mount
Remove
3. Loosen the clamps, and remove the turbocharger air
intake pipe.
4. Fix the engine with the special tool T10007 and
TEN00070.
Refit
1. Fix the engine mounting bracket to the engine, fit 3
bolts, tighten to 58-62Nm and check the torque.
2. Fix the engine ground wire to the engine mounting
bracket and right longitudinal beam.
3. Fit the right engine mount to the engine mounting
bracket, fit 2 nuts and tighten to 90-110Nm; fit 1 bolt,
tighten to 90-110Nm and check the torque.
4. Fit the right engine mount to the right longitudinal
beam, fit 2 bolts, tighten to 90-110Nm and check the
5. Remove 2 nuts (1) fixing the right engine mount side torque.
bracket to the front wheelhouse liner and engine
5. Fix the right engine mount bracket to the front
mount.
wheelhouse panel and engine mount, fit 2 bolts and
6. Remove 2 nuts and 1 bolt (2) fitting the right engine tighten to 55-65Nm.
mount to the engine mounting bracket.
7. Remove 2 bolts (3) fitting the right engine mount to the
right longitudinal beam, and remove the right mount.

8. Remove the engine ground wire.

9. Remove 3 bolts fixing the engine mounting bracket to
the engine, and remove the engine mounting bracket.
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Flywheel - MT
Remove
2. Remove the clutch pressure plate and clutch driven
plate assembly.
Clutch Assembly Remove
3. Secure the crankshaft with the special tool TEN00135.
3. Fit the clutch pressure plate and clutch driven plate

assembly.
Clutch Assembly Refit

5. Place the ignition switch in "ON" position, and perform
"Engine Module Reset Self-learning Value" with VDS.
6. Wait for 2-5 seconds, turn off the ignition switch and
re-start the vehicle.
4. Remove 8 bolts securing the flywheel to the crankshaft,
then remove the flywheel and crankshaft position
sensor reluctor ring.
Refit
2. Fix the flywheel and the reluctor ring of crankshaft
position sensor to the crankshaft through locating pins,
fit 8 bolts, tighten to 30Nm＋＋70° in the sequence
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Flywheel - AT
Remove
2. Remove the dry dual-clutch automatic transmission.
Dry Dual-Clutch Automatic Transmission Remove
3. Fix the flywheel with the special tool TEN00135.
3. Fit the dry dual clutch automatic transmission.
Dry Dual Clutch Automatic Transmission Refit

4. Remove 8 bolts securing the flywheel to the crankshaft,
then remove the flywheel and crankshaft position
sensor reluctor ring.
Refit
2. Fix the flywheel and the reluctor ring of crankshaft
position sensor to the crankshaft through locating pins,
fit 8 bolts, tighten to 30Nm＋＋70° in the sequence
1.0 182
Cylinder Head
Remove
Engine Oil Drain

4. Remove the hydraulic tappet.
Hydraulic Tappet Remove

5. Remove the turbocharger.
Turbocharger Remove
6. Remove the intake manifold.
Intake Manifold Remove

7. Remove the high-pressure oil pump.
High-pressure Oil Pump Remove 13. Remove the spark plug.

8. Remove the thermostat housing.
Spark Plug Remove
Thermostat Remove 14. Remove the cylinder head oil gallery check valve.
9. Support the bottom of the engine with a bracket. 15. Remove the plug on the cylinder head.
10. Remove the lifting equipment. Refit
11. Remove 10 bolts fixing the cylinder head to cylinder 1. Fit the cylinder head plug, tighten to 53-67Nm and
block in the sequence shown. check the torque.
2. Fit the cylinder head oil gallery check valve.
3. Fit spark plugs.
Spark Plug Refit
4. Check and clean the cylinder head.
Cylinder Head Check

5. Fit a new cylinder gasket to the cylinder block with
locating pins.
6. Position the cylinder head to the cylinder block with
locating pin, fit 10 bolts and tighten to 30Nm+240° in
the sequence as shown, then check the torque.
12. Remove the cylinder head and discard cylinder gasket.
7. Fix the engine with fixing equipment.
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8. Take away the bottom bracket. Cylinder Block

9. Fit the thermostat housing. Remove
Thermostat Refit
10. Fit the high-pressure oil pump. Cylinder Head Remove
2. Remove the crankshaft.
High-pressure Oil Pump Refit
Crankshaft Remove
11. Fit the intake manifold.
3. Remove the oil pressure sensor.
Intake Manifold Refit
4. Remove the knock sensor.
12. Fit the turbocharger.
5. Remove 4 oil nozzles.
Turbocharger Refit 6. Remove 4 crankcase locating pins.
13. Fit the hydraulic tappet. 7. Remove 2 transmission locating pins.
Hydraulic Tappet Refit 8. Remove 2 cylinder head locating pins.
14. Fill the engine coolant. 9. Remove the plug - cylinder block oil duct.
Engine Coolant Refill 10. Remove the cylinder block water jacket plug.
Engine Oil Refill

Refit
1. Clean the cylinder block sealing mating surface, cooling
passage, oil passage, bearing seat, threaded hole and so
on, and ensure there is no foreign material.
2. Check the cylinder block.
Cylinder Block Check
3. Fit the cylinder block water jacket plug to the cylinder
block, tighten to 53-67Nm and check the torque.
4. Fit the plug - cylinder block oil passage to the cylinder
block, then tighten to 45-55Nm.
5. Fit 2 cylinder head locating pins.
6. Fit 2 transmission locating pins.
7. Fit 4 lower crankcase locating pins.
8. Fix 4 oil nozzles to the upper crankcase, fit and tighten
the bolt to 8-12Nm, then check the torque.
9. Fix the knock sensor to the cylinder block, fit bolts and
tighten to 15-25Nm, then check the torque.
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10. Fix the oil pressure sensor to the cylinder block, tighten Crankshaft
to 31-39Nm, then check the torque. Remove
11. Fit the crankshaft. 1. Remove the crankshaft sprocket.
Crankshaft Refit Crankshaft Sprocket Remove
12. Fit the cylinder head. 2. Remove the oil pump.
Cylinder Head Refit Oil Pump Remove
3. Remove 1 bolt fixing the crankcase oil return pipe to
the lower crankcase, and remove the crankcase oil
return pipe.
4. Remove 3 bolts fixing the crankshaft oil guide plate to
the lower crankcase, and remove the crankshaft oil
guide plate.
5. Rotate the crankshaft so that the piston rod assembly is

at the bottom dead center of the cylinder.
6. Remove 2 bolts fixing the connecting rod big end shell
cover to the connecting rod.
7. Remove the connecting rod big end shell cover, and
push the piston rod assembly to the top edge of the
cylinder.
8. Remove the lower crankcase.
Lower Crankcase Remove

9. Remove the main bearing shell from the lower
crankcase.
10. Remove the rear crankshaft oil seal.
11. Remove the crankshaft, and remove the other half
piece of main bearing shell from the cylinder block.
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10. Push the piston connecting rod assembly to the bottom

dead centre at the bottom of the cylinder liner, and
make the connecting rod big end fit the crankshaft
connecting rod journal.
11. Fit the bearing shell to the connecting rod big end
shell cover, fix the connecting rod big end shell cover
to the connecting rod big end, fit 2 bolts, tighten to
25Nm+75°, and check the torque.
Caution: Make the connecting rod big end shell cover

boss face the rear end of the engine; the alphabetic
signs "AA" at the side surface of the shell cover
must be on the same side.
Refit
and bearing base.
2. Check the crankshaft and main bearing shell.
3. Fix the main bearing shell and thrust bearing shell to the
cylinder block bearing seat, and ensure that the bearing
shell oil hole is aligned with the bearing seat oil hole.
Caution: Please fit the bearing 1 shell (with 12. Rotate the crankshaft to ensure free rotation of the
coating) and thrust bearing shell correctly. crankshaft connecting rod, without clamping stagnation.
13. Fix the crankshaft oil guide plate to the lower crankcase,
4. Apply clean engine oil to the bearing shell.
fit 3 bolts, tighten to 8-12Nm in the sequence shown,
5. Fit the crankshaft. and check the torque.
6. Clean the junction surface of the lower crankcase

14. Fix the crankcase oil return pipe to the lower crankcase,
bearing seat.
fit 1 bolt, tighten to 8-12Nm, and check the torque.
7. Fit the other half piece of main bearing shell to the
15. Fit the special tool TEN00144 into the crankshaft
lower crankcase bearing seat.
mounting hole at the rear end of the engine.
8. Fit the lower crankcase.
16. Fit the crankshaft rear oil seal to the rear end of
Lower Crankcase Refit the crankshaft with the TEN00143 through the
9. Rotate the crankshaft to locate the crankshaft TEN00144.
connecting rod journal at the bottom dead centre.
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Caution: The oil seal must be fitted in the correct Lower Crankcase
direction. The outward side shall be marked with Remove
"This Side Outwards". 1. Remove the flywheel.
Flywheel - MT Remove
Flywheel - AT Remove
2. Remove the crankshaft timing sprocket.
Crankshaft Timing Sprocket Remove
3. Remove the oil pump.
Oil Pump Remove
to the lower crankcase, and then disconnect.
5. Remove 3 bolts fixing the A/C compressor to the
engine, then remove the A/C compressor.
6. Remove 1 bolt fixing the crankshaft position sensor
17. Fit the oil pump. to the lower crankcase, and remove the crankshaft
Oil Pump Refit position sensor.
18. Fit the crankshaft sprocket.
Crankshaft Sprocket Refit

20. Wait for 2-5 seconds, turn off the ignition switch, then
restart the vehicle.

return pipe.
guide plate.
9. Remove 13 bolts fixing the lower crankcase to the

upper edge of the cylinder block.
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10. Remove 10 bolts fixing the crankshaft main journal in 4. Fit 13 peripheral bolts, tighten to 8-12Nm in the
the sequence shown, and remove the lower crankcase. sequence as shown, and check the torque.
Refit 5. Fix the crankshaft oil guide plate to the lower crankcase,
fit 3 bolts, tighten to 8-12Nm in the sequence as
1. Clean the mating surface between the lower crankcase
and cylinder block, and ensure that there is no foreign
material.
2. Apply sealant to the lower crankcase as illustrated.
6. Fix the crankcase oil return pipe to the lower crankcase,

7. Fix the crankshaft position sensor to the lower
3. Fix the lower crankcase to cylinder block with 2 locating crankcase, fit 1 bolt, tighten to 8-12Nm, and check
pins, fit 10 crankshaft main journal retaining bolts, the torque.
tighten to 15Nm+（（176-184））° in the sequence as
8. Fix the A/C compressor to the engine, fit 3 bolts,
9. Fix the turbocharger oil return pipe to the lower
1.0 188
crankcase, fit 2 bolts, tighten to 8-12Nm, and check Oil Pan
the torque. Remove
10. Fit the oil pump. 1. Disconnect the battery negative cable.
Oil Pump Refit 2. Drain engine oil.
11. Fit camshaft timing sprocket. Engine Oil Drain
Camshaft Timing Sprocket Refit 3. Remove the front exhaust pipe.
12. Fit the flywheel. Front Exhaust Pipe Remove
Flywheel - MT Refit 4. Remove 3 bolts fixing the oil pan to the transmission.
Flywheel - AT Refit 5. Remove 11 bolts fixing the lower part of the oil pan
to the upper assembly of the oil pan, and remove the
lower part of the oil pan.
6. Disconnect the external connector of oil pump control
valve.
7. Disconnect the internal connector of oil pump control
valve.
Caution: Oil must not be fed at the internal

connector; otherwise, the performance will be
affected, and the internal connection harness is
to be replaced!
8. Remove 1 bolt (3) fixing the internal connection
harness of oil pump control valve to the upper part of
the oil pan, remove and discard the internal connection
harness of oil pump control valve.
9. Remove 16 bolts fixing the upper part of the oil pan

to the lower crankcase, and remove the upper part of
the oil pan.
1.0 189
Caution: Oil must not be fed at the internal

connector; otherwise, the performance will be
affected, and the internal connection harness is
to be replaced!
6. Connect the external connector of oil pump control
valve.
7. Apply sealant to the lower part of the oil pan and lower
crankcase junction surface.
Refit
1. Clean all components and junction surfaces.
2. Apply sealant to the upper part of the oil pan and lower
crankcase junction surface.
8. Fix the lower part of the oil pan to the upper part of
the oil pan, fit 11 bolts, tighten to 9-11Nm in the
sequence as shown, and check the torque.
3. Fix the upper part of the oil pan to the lower crankcase
through locating pins, fit 16 bolts, tighten to 9-11Nm
in the sequence as shown, and check the torque.
9. Fit 3 bolts fixing the oil pan to the transmission and

tighten them to 49–67Nm.

Engine Oil Refill

12. Connect the battery negative cable.
4. Fix the internal connection harness of oil pump control
valve with a new seal ring to the oil pan, fit 1 bolt,
5. Connect the internal connector of oil pump control
valve.
1.0 190
Camshaft Cover
Remove
2. Remove the dipstick.
4. Remove the fuel injector.
Fuel Injector Remove
5. Remove the camshaft phase adjustment actuator
solenoid.
Camshaft Phase Adjustment Actuator Solenoid
Remove
6. Remove the camshaft position sensor.
Camshaft Position Sensor Remove
Mechanical Vacuum Pump Remove 16. Remove the camshaft cover and discard the seal gasket.
8. Remove the turbocharger water return pipe. Refit
Turbocharger Water Return Pipe Remove 1. Fit a new camshaft cover seal gasket.
9. Remove the harness clip fixed to the camshaft cover, 2. Locate the camshaft cover to the cylinder head, fit 18
and remove the harness. bolts and 2 studs, tighten to 14-16Nm in the sequence
10. Remove 1 bolt fixing the high pressure fuel pipe clip to shown, and check the torque.
the camshaft cover.
11. Remove 1 screw fixing the PCV tube assembly with
PCV valve and bolt joint to the turbocharger to
disconnect the assembly.
12. Remove the PCV tube assembly from the camshaft
cover and discard.
Caution: Remove this component only when replacement
is needed after check. Once removed, there will be
damage on PCV valve and it must be replaced.
13. Remove the PCV breather tube assembly.
14. Remove the bolts (1 for each) fixing the 2 PCV valve
assemblies to the camshaft cover.
3. Fix 2 PCV valve assemblies to the camshaft cover
respectively, fit 1 bolt individually, tighten to 8-12Nm
4. Fit the PCV breather tube assembly.
5. Fix a new PCV tube assembly with PCV valve and bolt
fitting to camshaft cover, fit 1 bolt, tighten to 8-12Nm,
6. Fix the PCV tube assembly connector to the
turbocharger, fit 1 screw 8-10Nm, and check the
torque.
7. Fix the high pressure pipe clamp to the camshaft cover,
8. Fix the harness staple bolt to the camshaft cover.
15. Remove 18 bolts and 2 studs fixing the camshaft cover
9. Fit the turbocharger water return pipe.
to the cylinder head in the sequence shown.
1.0 191
Turbocharger Water Return Pipe Refit Crankshaft Vibration Damper

10. Fit the mechanical vacuum pump. Remove
Mechanical Vacuum Pump Refit
11. Fit the camshaft position sensor.
Camshaft Position Sensor Refit
3. Remove the right front wheel.
12. Fit the camshaft phase adjustment actuator solenoid.
Wheel Remove
Camshaft Phase Adjustment Actuator Solenoid
Refit 4. Remove the right front wheelhouse liner.
13. Fit the fuel Injector. Front Wheelhouse Liner Remove
Fuel Injector Refit 5. Remove auxiliary drive belt.
14. Fit the engine hood. Auxiliary Drive Belt Remove

15. Fit the oil dipstick. 6. Fix the crankshaft shock absorber with a special tool
16. Connect the battery negative. TEN00135.
7. Remove 1 bolt fixing the crankshaft shock absorber

to crankshaft.
8. Pull out and remove the crankshaft shock absorber

with the special tool TEN00136.
1.0 192
Front Timing Cover
Remove
Engine Oil Drain
3. Remove the front crankshaft oil seal.
Front Crankshaft Oil Seal Remove
4. Remove the accessory belt tensioner.
Accessory Drive Belt Tensioner Remove
5. Remove the camshaft cover.
Camshaft Cover Remove
Refit
6. Remove the right engine mount.
1. Check whether the locating key is properly located on
Right Engine Hydraulic Mount Remove
the crankshaft.
7. Remove 3 bolts fixing the front cover to the upper oil
2. Check the mating surface between the crankshaft shock
pan.
absorber and crankshaft for scratch, if any, replace the
crankshaft shock absorber. 8. Remove 15 bolts fixing the front timing cover to the
cylinder block.
Tip: After reuse once, the crankshaft shock
absorber must be replaced.
3. Align the groove in the crankshaft shock absorber hub
with the key on the crankshaft, and carefully push the
crankshaft shock absorber to the crankshaft sprocket.
4. Fix the crankshaft shock absorber with a special tool
TEN00135.
5. Fit the crankshaft shock absorber bolt, tighten to
100Nm+(176-184)°, and check the torque.
6. Fit the auxiliary drive belt.
Auxiliary Drive Belt Refit

7. Fit the front right wheelhouse liner.
Refit
Front Wheelhouse Liner Refit
1. Clean the timing front cover mating surface to ensure
8. Fit the front right wheel.
Wheel Refit 2. Apply sealant to the front cover.

3. Position the timing front cover to the cylinder block

with 2 locating pins.
1.0 193
4. Fit 15 bolts respectively in the sequence shown, and Intake and Exhaust Valves
pretighten to 5Nm. Remove
2. Compress the valve spring with the valve remover.
Warning: The compressed valve spring exerts a great
tension on the valve spring compressor. A valve
spring that is not properly compressed by the
valve spring compressor or released from the valve
spring compressor can bounce from the valve spring
compressor by a great tension. Take care when
compressing or releasing the valve spring with
the valve spring compressor, and when removing or
fitting the valve stem key, or personal injury may
occur.
5. Tighten bolt 1 to 14-16Nm, and check the torque.
6. Tighten bolt 2 to 51-65Nm, and check the torque. Warning: Do not compress the valve spring to below
24.0mm. Exposure to the position between the valve
7. Tighten bolt 3 - 15 to 14-16Nm, and check the torque.
spring retainer and valve stem seal may cause
8. Fit 3 oil pan bolts, tighten to 8-12Nm and check the potential damage to the valve stem seal.
torque.
9. Fit the right engine mount.
Right Engine Hydraulic Mount Refit

10. Fit the camshaft cover.
11. Fit the accessory drive belt tensioner.
Accessory Drive Belt Tensioner Refit

12. Fit the front crankshaft oil seal.
Front Crankshaft Oil Seal Refit

Engine Oil Refill 3. Remove the locking clamp and release the valve spring,
14. Connect the battery negative. then remove the valve remover.
4. Remove the valve spring, valve spring cover and valve.
Caution: Mark immediately after removing the parts.
Mark the position, direction or orientation as
desired.
1.0 194
5. Remove the valve oil seal. Timing Chain
Remove
Engine Oil Drain
3. Remove the camshaft cover.
Camshaft Cover Remove

4. Remove the front timing cover.
Front Timing Cover Remove

5. Press the timing chain tensioner in place, and lock with
stop pin.
6. Remove 2 bolts securing the timing chain upper guide
Refit
rail to the cylinder head and then remove the timing
1. Check the valve mechanism. chain upper guide rail.
Valve Mechanism Check 7. Remove 1 bolt securing the tensioner guide rail to the
2. Ensure the valve, valve spring, spring cover and lock intake side of engine, and remove the tensioner guide
clamp are clean. rail.
3. Lubricate the valve and valve stem oil seal. 8. Remove 3 bolts securing the timing chain guide rail to
4. Fit the valve stem oil seal to the valve guide pipe. the exhaust side of engine and then remove the timing
chain guide rail.
5. Refit the valve, spring and spring cover, and fix the valve
removal tool to the valve and compression spring. 9. Remove the timing chain.
6. Compress the valve spring with valve removal tool, fit

the valve spring lock clamp, and then remove the valve
removal tool.
Cylinder Head Refit
10. Remove 1 bolt securing the oil nozzle to the cylinder

block, and remove the oil nozzle.
Refit
1. Secure the oil nozzle to the cylinder block, fit 1 bolt,
tighten to 8-12Nm and check the torque.
2. Rotate the intake/exhaust camshaft, locate the timing
marks at 12 o'clock position respectively, and fix with
the TEN00134.
1.0 195
Front Timing Cover Refit

13. Fit the camshaft cover.

Engine Oil Refill

3. Rotate the crankshaft, locate the timing marks at 6

o'clock position, and fix with the TEN00135.
Caution: Ensure that the timing chain ring is

aligned with the timing mark properly. The
actuator timing chain rings are in the same color,
while the color of the crankshaft sprocket timing
chain ring is unique.
5. Align the first timing chain ring with intake camshaft
timing mark.
6. Align the second timing chain ring with exhaust
camshaft timing mark.
7. Align the last timing chain ring with crankshaft sprocket
timing mark.
8. Fix the timing chain guide rail to engine exhaust side, fit
3 bolts, tighten to 8-12Nm, and check the torque.
9. Fix the tensioner guide rail to the engine intake side, fit
1 bolt, tighten to 21-29Nm, and check the torque.
10. Fix the timing chain upper guide rail to the cylinder
head, fit 2 bolts, tighten to 8-12Nm, and check the
torque.
11. Pull out the timing chain tensioner stop pin to tension
the timing chain system.
12. Fit the front timing cover.
1.0 196
Camshaft Phase Regulation Actuator 4. Fill the engine oil.
Remove Engine Oil Refill
Engine Oil Drain "Engine Module Reset Self-learning Value" with VDS.
3. Remove the timing chain. 7. Wait for 2-5 seconds, turn off the ignition switch and
Timing Chain Remove re-start the vehicle.
4. Lock the intake and exhaust camshafts with the special

tool TEN00134.
5. Remove 1 bolt fixing the intake camshaft phase

adjustment actuator to the camshaft, and remove the
intake camshaft phase adjustment actuator.
6. Remove 1 bolt securing the exhaust camshaft phase
regulation actuator to the camshaft, then remove the
exhaust camshaft phase regulation actuator.
Refit
1. Fix the exhaust camshaft phase adjustment actuator
to the camshaft, fit 1 bolt, tighten to 20Nm+90° and
check the torque.
2. Fix the intake camshaft phase adjustment actuator to
the camshaft, fit 1 bolt, tighten to 20Nm+90° and
check the torque.
Timing Chain Refit
1.0 197
Timing Chain Tensioner Crankshaft Sprocket

Remove Remove
1. Drain the engine oil. 1. Drain the engine oil.
Engine Oil Drain Engine Oil Drain
2. Remove the timing chain. 2. Remove the timing chain.

Timing Chain Remove
Timing Chain Remove
3. Remove the oil pan.
3. Remove 2 bolts fixing the timing chain tensioner to the
cylinder block, remove the timing chain tensioner, and Oil Pan Remove
discard the gasket. 4. Remove 1 bolt fixing the oil pump drive chain tensioner
to the cylinder block, and remove the oil pump drive
chain tensioner.
5. Loosen 4 oil pump bolts.
6. Tilt the oil pump, and remove the oil pump drive chain.
Refit
1. Fit a new gasket, fix the timing chain tensioner to the
cylinder block, fit 2 bolts, tighten to 21-29Nm, and
check the torque.
7. Remove the crankshaft sprocket and remove the
sprocket flat keys.
Timing Chain Refit
Engine Oil Refill
Refit
1. Fit the flat key to the crankshaft, and fit the crankshaft
sprocket to the crankshaft.
2. Tilt the oil pump, and fit the oil pump drive chain.
3. Tighten 4 oil pump bolts to 9-11Nm, and check the
torque.
4. Fix the oil pump drive chain tensioner to the cylinder
block, fit 1 bolt, tighten to 8-12Nm and check the
torque.
1.0 198
5. Fit the oil pan. Camshaft
Oil Pan Refit
Remove
Timing Chain Refit Engine Oil Drain
2. Remove the camshaft phase adjustment actuator.
Camshaft Phase Adjustment Actuator Remove
Engine Oil Refill
3. Loosen 12 intake camshaft and exhaust camshaft
bearing cap bolts (half circle for each).
4. Remove the bearing cover.
Caution: Observe the mark on the bearing cap. Mark

each bearing cap so as to identify its location.
5. Remove the intake/exhaust camshaft assembly.
Refit
1. Clean the camshaft seat, bearing cover, bearing cover
bolt and camshaft, and blow with compressed air.
2. Fit the exhaust camshaft and intake camshaft to the
camshaft seat. Ensure that the camshaft notch in the
front of the camshaft is at the 12 o'clock position.
3. Before fitting the camshaft cover, rotate the oil seal in
the camshaft bearing journal notch 1 so that the split
line is at about the 12 o'clock position.
4. Fit the bearing cap and pretighten by hand.
5. Fit the front bearing cap and pretighten by hand.
6. Tighten the exhaust camshaft and intake camshaft
bearing cover bolts to 10-14Nm in the sequence as
shown in increments of 3 circles, and check the torque.
1.0 199
Hydraulic Tappets
Remove
Engine Oil Drain
2. Remove the camshaft.
Camshaft Remove
3. Remove the valve drive rocker arm (2).
Caution:
1 The components must be orderly isolated, marked or
arranged to ensure that they are fitted in the original
positions, and take preventive measures to prevent parts
7. Fit the camshaft phase adjustment actuator. interchange.
2 Mark immediately after removing the parts. Mark the
Camshaft Phase Adjustment Actuator Refit
position, direction or orientation as desired.
4. Remove the valve hydraulic tappet (1).
Engine Oil Refill
Caution:
"Engine Module Reset Self-learning Value" with VDS. 1 The components must be orderly isolated, marked or
arranged to ensure that they are fitted in the original
positions, and take preventive measures to prevent parts
interchange.
2 Mark immediately after removing the parts. Mark the
position, direction or orientation as desired.
Refit
1. Clean the valve drive rocker arm, valve hydraulic
tappet and seat hole, and coat the surface with clean
lubricating oil.
2. Fit the valve hydraulic tappet into the seat hole in the
cylinder head.
3. Fit the valve drive rocker arm to the valve tip and valve
hydraulic tappet.
Caution: The used gap adjuster arm must be returned
to the initial position of the camshaft. If the
camshaft has been replaced, the gap adjuster arm
driven by the camshaft must also be replaced.
4. Fit the camshaft.
1.0 200
Camshaft Refit Intake Manifold
5. Fill the engine oil. Remove
Engine Oil Refill
2. Remove the electronic throttle.
Electronic Throttle Remove
3. Loosen the clamps, and disconnect the connecting hose
of the activated carbon canister solenoid valve.
4. Disconnect the connector of the activated carbon
canister solenoid valve.
5. Disconnect the intake manifold end hose of the
activated carbon canister solenoid valve.
6. Remove the harness fixed to the intake manifold.
7. Remove 1 screw fixing the manifold absolute pressure
and temperature sensor to the intake manifold, and
remove the sensor (1).
8. Remove the activated carbon canister solenoid valve
and hose (2).
9. Loosen two clips fixing the intake manifold cover

assembly to the intake manifold, and remove the intake
manifold cover assembly.
10. Remove 5 bolts fixing the intake manifold to the

cylinder head, remove the intake manifold and discard
the gasket.
1.0 201
Piston
Remove
1. Remove the connecting rod.
Connecting Rod Remove

2. Remove the piston ring (1) with an expander.
3. Remove 2 piston pin clamp springs (2).
4. Remove the piston pin (3).
5. Disconnect the piston from the connecting rod small
end, and remove the piston.
Caution: Mark immediately after removing the parts.

Mark the position, direction or orientation as
Refit desired.
1. Clean the mating face of intake manifold.
2. Fit a new intake manifold gasket, fix the intake manifold
to the cylinder head, fit 5 bolts, tighten to 8-12Nm in
the sequence shown, and check the torque.
Refit
1. Check the piston connecting rod.
Piston Connecting Rod Check
2. Fit the piston pin clamp spring of one side into the pin
3. Fix the intake manifold cover assembly to the intake hole clamp spring slot.
manifold, and fasten with clips.
3. Place the connecting rod small end to the inner side of
4. Fit the activated carbon canister solenoid valve and the piston pin boss, after application of lubricating oil,
hose to the intake manifold. fit the piston pin into the piston pin hole and connecting
5. Fix the manifold absolute pressure and temperature rod small end hole, and fit the piston pin clamp spring
sensor to the intake manifold, fit 1 screw, tighten to on the other side into the pin hole clamp spring slot.
4-5Nm, and check the torque.
Caution: The forward mark on the piston top shall
6. Fit the harness to the intake manifold. be consistent with that on the connecting rod.
7. Connect the intake manifold end hose of the activated
4. Fit the oil ring, the second gas ring and the first gas ring
carbon canister solenoid valve.
into the piston ring slot with an expansion tool from
8. Connect the connector of the activated carbon canister top to bottom.
solenoid valve.
Caution: The piston ring mark shall point to the
9. Connect the connecting hose of the activated carbon
piston top surface.
canister solenoid valve and secure with clamps.
10. Fit the throttle. 5. Refit the connecting rod.
Electronic Throttle Refit Connecting Rod Refit
1.0 202
Connecting Rod contact with the cylinder opening, and carefully push
Remove the piston assembly out from the cylinder liner.
1. Remove the cylinder head. Caution: Carefully align each piston and appropriate
Cylinder Head Remove cylinder liner.
2. Remove the oil pump. 12. Refit the connecting rod big end cap to the connecting
Oil Pump Remove rod, and gently tighten the connecting rod bolt.

return pipe.
guide plate.
Refit
1. Check the piston connecting rod.
Piston Connecting Rod Check
2. Ensure piston rings are free to rotate, the gap between
the two air rings shall form an angle of 180° and away
from the piston thrust side.
5. Rotate the crankshaft so that the piston rod assembly is
3. The notch of the oil ring and spring shall form an angle
at the bottom dead center of the cylinder.
of 120°.
6. Remove 2 bolts fixing the connecting rod big end shell
cover to the connecting rod. ∆ ∑ a ir rin g
π ∆ o il rin g
s p rin g
π ∆ o il rin g
∆ ∑ a ir rin g
4. Lubricate the cylinder liner opening, piston and piston

ring with engine oil, and ensure the piston ring gap is
7. Remove the connecting rod big end shell cover, then correctly positioned.
lower bearing shell. 5. Remove the connecting rod big end shell cover.
8. Disconnect the connecting rod big end from the 6. Fit the bearing shell to the connecting rod big end, and
crankshaft, and remove the bearing shell. apply engine oil.
9. Remove carbon deposit at the top of the cylinder liner 7. Fit the piston installer to the piston. Make the front
opening. mark on the piston face the front of the engine, and fit
10. Push the piston to the top of the cylinder liner. the piston into the cylinder liner.
11. Ensure that the connecting rod does not come into 8. Push the piston into the cylinder liner until it is aligned
1.0 203
with the upper surface of the cylinder liner. 15. Fix the crankcase oil return pipe to the lower crankcase,
9. Take away the piston installer. fit 1 bolt, tighten to 8-12Nm, and check the torque.
Caution: Before fitting the connecting rod big end 16. Fit the oil pump.
bearing bush and connecting rod big end cap, do Oil Pump Refit
not push the piston below the upper surface of the
cylinder liner.
Cylinder Head Refit
10. Rotate the crankshaft to locate the crankshaft
connecting rod journal at the bottom dead centre.
11. Push the piston connecting rod assembly to the bottom
dead centre at the bottom of the cylinder liner, and
make the connecting rod big end fit the crankshaft
connecting rod journal.
12. Fit the bearing shell to the connecting rod big end
shell cover, fix the connecting rod big end shell cover
to the connecting rod big end, fit 2 bolts, tighten to
25Nm+75°, and check the torque.
Caution: Make the connecting rod big end shell cover
boss face the rear end of the engine; the letter
"AA" at the side surface of the shell cover and that
of the connecting rod must be on the same side.
13. Rotate the crankshaft to ensure free rotation of the

crankshaft connecting rod, without clamping stagnation.
14. Fix the crankshaft oil guide plate to the lower crankcase,
fit 3 bolts, tighten to 8-12Nm in the sequence shown,
1.0 204
Oil Pump Strainer Refit
Remove 6. Fill the engine oil.
Engine Oil Refill
Engine Oil Drain
2. Remove the strainer.
Strainer Remove
3. Remove 4 bolts fixing the oil pump to the lower
crankcase.
4. Toggle the oil pump drive chain tensioner, tilt the oil
pump, and disconnect the drive chain from the sprocket.
5. Remove the oil pump, and discard the washer.

6. Loosen the clip, and remove the electronic flow control
valve of the oil pump.
Refit
1. Clean the mating surface between the oil pump and
the lower crankcase.
2. Fit the oil pump electronic flow control valve and fix
it with clips.
3. Toggle the oil pump drive chain tensioner, tilt the oil
pump, and fit the drive chain to the sprocket.
4. Fit a new washer, apply clean lubricating oil, fix the oil
pump to the lower crankcase, fit 4 bolts, tighten to
5. Fit the strainer.
1.0 205
Engine Oil Strainer Front Crankshaft Oil Seal

Remove Remove
1. Drain the engine oil. 1. Drain the engine oil.
Engine Oil Drain Engine Oil Drain

2. Remove the oil pan. 2. Remove the crankshaft shock absorber.
Oil Pan Remove Crankshaft Shock Absorber Remove
3. Remove 2 bolts securing the strainer onto the oil pump, 3. Remove the front crankshaft oil seal.
remove the strainer, and discard the O-ring.
Refit
Refit 1. Clean the mating surface of the oil seal and ensure that
1. Fit a new O-ring, fix the strainer onto the oil pump, fit it is free of foreign material.
2 bolts and tighten to 8-12Nm, and check the torque. 2. Fit the handle with the special tool TEN00141 and
2. Fit the oil pan. fit the front crankshaft oil seal with the special tool
TEN00142.
Oil Pan Refit
Engine Oil Refill
3. Fit the crankshaft shock absorber.
Crankshaft Shock Absorber Refit

Engine Oil Refill
1.0 206
Rear Crankshaft Oil Seal Vacuum Pump
Remove Remove
1. Disconnect the battery negative. 1. Remove 1 bolt fixing the throttle air inlet pipe to the
2. Drain the engine oil. cylinder head (4).
Engine Oil Drain

3. Remove the flywheel.
Flywheel - MT Remove
Flywheel - AT Remove
4. Remove the rear crankshaft oil seal.
2. Disconnect the vacuum tube on the mechanical vacuum

pump.
3. Remove 3 bolts fixing the vacuum pump to the cylinder
head, remove the vacuum pump, and discard the liner.
Refit
1. Clean the mounting hole of rear crankshaft oil seal.
2. Fit the special tool TEN00144 into the crankshaft
mounting hole at the rear end of engine.
3. Fit the handle with TEN00141 and fit the rear
crankshaft oil seal to the rear end of crankshaft with
TEN00143 through TEN00144.
Caution: The oil seal must be fitted in the correct
direction. The outward side shall be marked with
"This Side Outwards".
Refit
1. Clean the junction surface between the vacuum pump
and cylinder head.
2. Fit a new liner, position the vacuum pump by 2
locating pins to the cylinder head, fit 3 bolts, tighten to
21-29Nm in the sequence of 1-2-3 shown, and check
the torque.
Caution: Ensure that the vacuum pump transmission

gear is aligned with the camshaft end, and ensure
that the vacuum pump is flush with the cylinder
head before fitting the bolt.
4. Fit the flywheel.
Flywheel - MT Refit
Flywheel - AT Refit
Engine Oil Refill
1.0 207
Seal-Vacuum Pump
Remove
1. Remove vacuum pump。
Vacuum pump remove

2. Use screwdriver remove the seal of vacuum pump.
Caution: Use adhesive tape pack the head of the

screwdriver to protect the surface of the cylinder
head.
Refit
1. Use special tool TEN00141and hammer install the
seal to back of the cylinder head.
3. Connect the vacuum tube on the vacuum pump.
4. Fix the throttle air inlet pipe to the cylinder head, fit 1
2. Refit the vacuum pump.
Vacuum pump refit
1.0 208
Turbocharger
Remove
Engine Oil Drain

4. Remove the three-way catalytic converter.

5. Remove the A/C compressor.
A/C Compressor Remove 14. Remove the pipeline fixing the turbocharger oil inlet
6. Remove the turbocharger water return pipe. pipe to the engine, remove the turbocharger oil inlet
pipe.
Turbocharger Water Return Pipe Remove
to the engine, remove the turbocharger oil return pipe
Turbocharger Control Solenoid Valve Remove and discard the gasket.
8. Remove the turbocharger intake pipe. 16. Remove 2 bolts fixing the turbocharger oil return pipe
9. Loosen the clamps, and disconnect the intercooler to the turbocharger.
intake pipe from the turbocharger.
10. Remove 1 bolt fixing the PCV hose connector to the
turbocharger, and disconnect the PCV connector (1).
11. Remove 1 hollow bolt (2) fixing the turbocharger oil
inlet pipe to the turbocharger, and discard 2 copper
gaskets.
17. Remove 4 nuts fixing the turbocharger to the engine,

and remove the turbocharger and the turbocharger
heat shield.
12. Remove 1 hallow bolt fixing the turbocharger water

gaskets.
13. Remove 1 nut fixing the turbocharger water inlet
pipe to the rear of water pump, and remove the
turbocharger water inlet pipe.
Refit
1. Fix the turbocharger and the turbocharger heat shield
1.0 209
to the engine, fit 4 bolts, tighten to 21-29Nm in the Turbocharger Fuel Inlet Pipe
diagonal sequence, and check the torque. Remove
2. Fit a new gasket, fix the turbocharger oil return pipe to 1. Drain the engine oil.
the turbocharger, fit 2 bolts, tighten to 9-11Nm, and
Engine Oil Drain
check the torque.
2. Remove the A/C compressor.
3. Fit a new gasket, fix the turbocharger oil return pipe to
the engine, fit 2 bolts, tighten to 8-12Nm, and check A/C Compressor Remove
the torque. 3. Remove 3 bolts fixing the turbocharger heat shield to
4. Fix the turbocharger oil inlet pipe to the engine. the turbocharger, and remove the turbocharger heat
5. Fix the turbocharger water inlet pipe to the rear of shield.
water pump.
turbocharger, fit 2 new copper gaskets and 1 hollow
bolt, tighten to 31-39Nm, and check the torque.
7. Fix the turbocharger oil inlet pipe to the turbocharger,
fit 2 new copper gaskets and 1 hollow bolt, tighten to
8. Fix the PCV hose connector to the turbocharger, fit 1
bolt, tighten to 8-10Nm, and check the torque.
9. Connect the intercooler air inlet pipe to the
10. Fit the turbocharger intake pipe.
4. Remove 1 hollow bolt (2) fixing the turbocharger oil
11. Fit the turbocharger control solenoid valve.
Turbocharger Control Solenoid Valve Refit gaskets.
12. Fit the turbocharger water return pipe.
Turbocharger Water Return Pipe Refit

13. Fit the A/C compressor.
A/C Compressor Refit

14. Fit the three-way catalytic converter.
Three-way Catalytic Converter Refit

Engine Oil Refill


17. Connect the battery negative. 5. Remove the turbocharger oil inlet pipe clamp and
remove the turbocharger oil inlet pipe.
Refit
pipe connector and secure with the turbocharger oil
inlet pipe clamp.
2. Fix the turbocharger oil inlet pipe to the turbocharger,
fit 2 new copper gaskets and 1 hollow bolt, tighten to
3. Fix the three-way catalytic converter heat shield to the
turbocharger, fit 3 bolts, tighten to 10-12Nm, and
check the torque.
1.0 210
4. Fit the A/C compressor. Turbocharger Oil Return Pipe
A/C Compressor Refit
Remove
Engine Oil Refill Engine Oil Drain
2. Remove the three-way catalytic converter.
to the turbocharger.
to the engine, remove the turbocharger oil return pipe
and discard the gasket.
Refit
the engine, fit 2 bolts, tighten to 8-12Nm, and check
the torque.
the turbocharger, fit 2 bolts, tighten to 9-11Nm, and
check the torque.

Engine Oil Refill
1.0 211
Turbocharger Water Inlet Pipe Turbocharger Water Return Pipe

Remove Remove
1. Drain the engine coolant. 1. Drain the engine coolant.
Engine Coolant Drain Engine Coolant Drain

2. Remove the three-way catalytic converter. 2. Release the clamp, and disconnect the overflow pipe
(3) from the turbocharger water return pipe.
3. Remove 1 hollow bolt fixing the turbocharger water
water return pipe (5) from the water outlet assembly.
inlet pipe to the turbocharger, and discard 2 sealing
gaskets. 4. Release the clamp, and disconnect the turbocharger
water return pipe (4) from the bypass pipe assembly.
4. Remove 1 nut fixing the turbocharger water inlet
pipe to the rear of water pump, and remove the 5. Remove 1 hollow bolt (1) fixing the turbocharger water
turbocharger water inlet pipe. return pipe to the turbocharger, and discard 2 sealing
gaskets.
Refit
6. Remove 1 bolt (2) fixing the water return pipe bracket
1. Insert the turbocharger water inlet pipe into the quick
to the camshaft cover, and remove the turbocharger
connector at the back of water pump.
water return pipe.
turbocharger, fit 2 new gaskets and 1 hollow bolt,

Refit
1. Fix the turbocharger water return pipe to the
turbocharger, fit 1 hollow bolt and 2 new sealing
gaskets, and then pretighten.
2. Fix the water return pipe bracket to the camshaft cover,
fit 1 bolt and pretighten.
3. Connect the turbocharger water return pipe to the
bypass pipe assembly, and fix it with clamps.
water outlet pipe assembly, and fix it with clamps.
5. Connect the overflow pipe to the turbocharger water
return pipe, and fix it with clamps.
6. Screw the bracket bolt to 8-12Nm, and check the
torque.
7. Screw the hollow bolt to 31-39Nm, and check the
torque.
1.0 212
Water Outlet Assembly 8. Fill the engine coolant.
Remove Engine Coolant Refill
3. Disconnect the water temperature sensor connector
of water outlet assembly.
4. Remove 1 bolt fixing the throttle intake pipe to the
cylinder head.
5. Release the clamp, and disconnect the radiator water
inlet pipe (1) from the water outlet assembly.
6. Release the clamp, and disconnect the bypass pipe (2)
from the water outlet assembly.
7. Release the clamp, and disconnect 2 heater water pipes
(3) from the water outlet assembly.
water return pipe (4) from the water outlet assembly.
9. Remove 2 bolts (5) fixing the water outlet assembly
to the engine, remove the water outlet assembly and
discard the gasket.
Refit
1. Fit a new gasket, fix the water outlet assembly to the
engine, fit 2 bolts, tighten to 10–14Nm and check
the torque.
water outlet assembly, and fix it with clamps.
3. Connect 2 heater water pipes to the water outlet
assembly, and fix with clamps.
4. Connect the bypass pipe to the water outlet assembly,
5. Connect the radiator water inlet pipe to the water
outlet assembly, and fix it with clamps.
6. Fix the throttle intake pipe to the cylinder head, fit 1
bolt, tighten to 7–10Nm and check the torque.
7. Connect the water temperature sensor connector of
water outlet assembly.
1.0 213
Oil Cooler Cylinder Head Check

Remove Valve Check
1. Drain the engine coolant. 1. Remove the carbon deposition,engine oil and varnish
on the valve.Clean all carbon depositions on valve
head with a soft wire brush.Varnish can be removed by
soaking in parts soaking solvent or equivalent.。
Engine Oil Drain
Tip: DO NOT use a wire brush on any part of the valve
3. Remove the turbocharger intake pipe. stem.
4. Remove 4 bolts fixing the oil cooler to the water pump, Tip: DO NOT grind or condition the intake valve.If the
remove the oil cooler and discard the gasket. intake valve is out of specification, replace the valve.
2. Clean the valve guide pipe.
3. Check the valve stem for wear(4).
4. Check the valve lock plate groove for damage or
wear(5).If the valve is damaged or worn,replace it.
5. Check the valve conical surface for burnout or
cracking(1).If the component is damaged,check the
relevant piston and cylinder head areas for damage.
6. Check the valve stem for any burr or scratch.Burrs and
slight scratches can be removed by oil stone.
7. Use a V-shaped block to check the straightness of
valve stem and check the valve cover for bend or
deformation (3).Replace the bent or deformed valve.
Refit 8. Remove the deposit on the valve conical surface.Check
1. Clean the mating surface between oil cooler and water the valve conical surface for any damage.
pump, and ensure that there is no foreign material. 9. If there are damages on the conical surface,replace the
2. Fit a new gasket, fix the oil cooler to the water pump, valve.No machining of valve conical surface is allowed.If
fit 2 M6 bolts and 2 M8 bolts, tighten to 8-12Nm and the valve is worn or damaged,replace it.
22-28Nm respectively, and check the torque. 10. If the valve head is worn or the outer diameter and
3. Fit the turbocharger intake pipe, and fix it with clamps. chamfer (2) exceeds the specified value,replace the
4. Fill the engine oil. valve.
Engine Oil Refill Valve Mechanism Check
5. Fill the engine coolant. 11. Slightly stack up the valve onto valve seat.
12. If the valve stem end (6) is worn,replace the valve.
13. If there is no obvious wear,pitting,scratches or
deformation,measure and repair the valve to verify the
valve specification.
Valve Mechanism Check
1.0 214
Parameter
6. If the valve clearance is more than specified range and
the new valve stem with standard diameter also fails
to maintain the clearance within the specified range,
replace the cylinder head.
Tip: The abrasions at 10mm of the valve guide

bottom do not affect the normal operation.
Valve Spring Cleaning and Inspection
1. Clean the valve spring with solvent.
2. Dry the valve spring with compressed air.
Warning: Refer to "Warning of goggles".

3. Check the valve spring for any ruptured spring coil or
spring ring end.
4. Measure the valve spring tension with a blenometer.
Parameter
Valve Guide Measurement
1. Measure the clearance between valve stem (1) and
guide (2). The large clearance between valve stem
and guide may result in excessive oil consumption and
valve rupture. The insufficient clearance may result in
noise and valve stagnation, and may affect the normal
operation of engine assembly.
5. If the low load of valve spring is found, replace the

valve spring. Do not increase the spring load by using
spacer. If the spacer is used, the valve spring may be
compressed to the extreme before the camshaft cam
reached the top of lift.
2. Clamp the gauge to the cylinder head at the camshaft Valve Rocker Arm Cleaning and Check
cover guide rail. 1. Check the camshaft follower roller (1) for the
3. Locate the dial gauge so that the lateral movement followings:
(crossing with the cylinder head) of the valve stem can
• Flat spots
directly drive the dial gauge rod to move. Dial gauge
rod must contact to the side of the valve stem at the • Excessive scratch and spot corrosion
position a little higher than the valve guide. • Make sure the roller can freely rotate
4. Descend the valve head 0.064mm from the valve seat. 2. Inspect the connection part (2) at valve stem end of
5. To obtain the clearance reading for comparison with camshaft follower.
standard value, a slight pressure shall be applied during 3. Inspect the stationary hydraulic lash adjuster (SHLA)
the vertical movement of valve stem. pivot part of the camshaft follower (3).
1.0 215
• If the corrosion just occurs outside the area 4mm from

each combustion chamber (1), the cylinder head can be
reused.
• If the area between the valve seats is cracked (2), replace
the cylinder head.
• If the corrosion occurs inside the area 4mm from each
combustion chamber (3), replace the cylinder head.
4. Replace the camshaft follower when necessary.

Cylinder Head/Gasket Surface Cleaning and Check
1. Check the cylinder head gasket and mating face for
leakage,corrosion or blow-by.If the gasket is failed,
identify reasons based on following failures:
4. Clean the cylinder head. Remove all varnish, ash and
a. Incorrect installation carbon deposit on the exposed metal surface.
b. Cylinder head loose or warped Tip: DO NOT use a wire brush on any gasket sealing
surface.
c. Locating pin lost, not in original place or not fully
5. Clean the valve guide pipe.
located
6. Clean the bolt hole with a nylon mane brush.
d. Sealing area around coolant passage corroded
7. Remove the sealant residue in the plug hole.
e. Chip or debris found in cylinder head bolt hole
8. Check the cylinder head for thread damage or cylinder
f. Cylinder block bolt hole not drilled or tapped to a head stretched or damaged.
sufficient depth 9. Replace all suspected bolts.
g. Check the oil supply check valve 10. Clean all the surfaces of the cylinder head with
non-corrosive solvent.
2. Check the fuel injector hole, if necessary, clean the fuel
injector hole. 11. Blow-dry all the oil return holes with compressed air.
12. Remove all carbon deposits in the combustion chamber
with a nylon bristle brush.
13. Clear all the debris and sediments on the tappet
opening.
14. Check the cylinder head for crack. Check the area
between the valve seats and inside the exhaust port.
15. Check the top surface of the cylinder head for
corrosion, blister or blow-by hole.
Tip: DO NOT attempt to weld the cylinder head, replace
it.
16. Check all thread holes for damage. Thread inserts can
be used for thread repair.
3. Check the cylinder head gasket surface. 17. Check the sealing surface.
18. Check the plug of cylinder head, and confirm that the
1.0 216
oil hole is clean and free from debris. • Too many scratches or pitting
Cylinder Head Top Surface Cleaning and Check • Discoloration due to overheating
1. Check if the top surface of the cylinder head is smooth. • Deformation due to excessive wear (especially the
If the cylinder head exceeds the specified range, replace camshaft lobe)
the cylinder head. Processing the cylinder head is not
allowed.
Parameter
If the camshaft has any of abovementioned conditions, replace

the camshaft.
Camshaft Measurement
2. Make sure that the top surface of the cylinder head is 1. Position the camshaft to a suitable support to measure
clean and free from gasket material. whether the camshaft is worn or not.
3. Check if there is defect or scratch on the surface which
may affect the proper seal of cylinder head gasket.
4. Put the ruler on the top surface of cylinder head in
diagonal sequence.
5. Measure the clearance between the ruler and the top
surface of cylinder head along with 4 spots on the ruler
with a clearance gauge.
• If the twist is less than 0.05mm, then it is unnecessary to
repair the top surface of cylinder head.
• if the twist is between 0.05-0.20mm, or there is any
defect or scratch on the surface which may affect the
proper seal of cylinder head gasket, repair the top
surface of cylinder head. The maximum removable range 2. Measure the diameter and out-of-roundness of the
is 0.25mm. camshaft journal using an outer diameter micrometer.
• If material more than 0.25mm needs to be removed from
Parameter
the top surface of the cylinder head, replace the cylinder
head • If the diameter is less than specified value, replace the
camshaft.
Camshaft Check
• If the out-of-roundness is more than specified value,
1. Clean the camshaft with solvent.
replace the camshaft.
2. Check the camshaft oil supply hole (1) to camshaft
3. Measure the camshaft runout with a runout gauge .
position actuator for dust, debris or clogging.
3. Check threaded hole (2) for damage. Parameter
4. Check the camshaft position actuator locating notch (3)

for any damage or wear.
5. Check the camshaft seal groove (4) for damage.
6. Check the camshaft thrust surface (5) for damage.
7. Check the cam lobe (6) and journal (7) for followings:
1.0 217
4. Measure the camshaft thrust width for wear with a Camshaft Journal Clearance
depth micrometer. 1. Fit the camshaft bearing cap to the cylinder head
Parameter without fitting the camshaft.
2. Fit the camshaft cover bolts and tighten to 14-16Nm.
3. Measure the camshaft bearing bore diameter with the
inside micrometer.
4. Substract the camshaft journal from the camshaft
bearing bore diameter to obtain the running clearance.
If the running clearance exceeds the specified value and the

camshaft journal is within the specified value, replace the
cylinder head.
Parameter
5. After the measurement, remove the camshaft bearing
cap.
Camshaft Journal Positioning
5. Measure the camshaft thrust wall surface for runout
1. Ensure that the camshaft is maintainable.
with a runout gauge.
2. Check the cylinder head camshaft bearing surface for
Parameter
any defects or scratches that may hinder the correct
fit clearance of camshaft.Repair minor defects or
scratches.
3. Fit the camshaft to the cylinder head.
4. Fit the camshaft bearing cover.
5. Fit camshaft cover bolts and tighten to14-16Nm.
6. Ensure that the camshaft can rotate freely in the cylinder
head.If the camshaft can not rotate freely,replace the
cylinder head.
6. If damage to the camshaft or the wear condition is

more than specified value, replace the camshaft. Do
not allow to process the camshaft.
7. Measure the camshaft chamfering for wear with a
runout gauge.
1.0 218
Valve Mechanism Check
Overview of Valve Measurement and Finishing
• The proper service on valve is crucial to engine
performance.Therefore,all measurement procedures
must be followed to distinguish the parts exceeding the
specifications.
• If the measurement procedures indicate that the valve
or valve seat must be finished,it is essential to perform
measurement procedures after the finishing.
Measurement Procedure for Valve Seat Width
1. Measure the width of valve seat in the cylinder head
with a suitable gauge.
4. Measure the width of valve cone (1) with a suitable
gauge.
Tip: The minimum margin (a) between the valve seat

contact surface and the valve outside diameter
is 0.5mm. If the margin between the valve seat
contact surface and the valve is too small, the
valve seat must be finished to drive valve seat
contact surface out of margin.
2. Measure the length of valve with a vernier gauge.
Parameter
5. Compare the measured value with the specified value.
Parameter
6. If the valve seat width meets the requirements,
inspect the valve seat roundness according to the
"Measurement Procedure for Valve Seat Roundness".
7. If the valve seat width is out of the specification, grind
the valve seat according to the "Finishing Procedure for
3. Measure the valve stem diameter with a micrometer.
Valve and Valve Seat". Right valve seat width is vital to
Parameter provide right valve heat dissipating capacity.
Valve Seat Roundness Measurement Procedure
1.
1.0 219
Measurement Procedures for Valve Head OD and Caution: The minimum distance of removable trace of
Chamfer colorant to the valve outer diameter - margin (a)
1. Measure the outside diameter and chamfer (a) of valve shall be 0.5mm. If the removable trace of colorant
head with a suitable gauge. is very close to the margin, finish the valve seat
to allow the contact surface to disconnect from the
margin.
Caution: Never grind or adjust the intake valve.If the
intake valve exceeds the specification, replace it with
correct intake valve.
• If the valve cone and valve stem are not concentric,

discontinuous removable trace of colorant on the valve
cone will appear. Surface finishing or replacement shall
be made for the valve, and finishing of the valve seat shall
be done according to the "Finishing Procedure for Valve
and Valve Seat".
Parameter
3. If the outside diameter and chamfer of valve
head is within the specified range, test the valve
seat concentricity of valve (1) according to the
"Measurement Procedures for Valve to Valve Seat
Concentricity". After the concentricity measurement,
if valve seat finishing is done, recheck the outside
diameter and chamfer of valve head.
Measurement Procedure for Valve to Valve Seat
Concentricity
Caution: Finishing Procedures for Valve and Valve Seat
• Check the coaxiality of the valve and valve seat to Caution:
confirm the normal sealing of the valve and valve • If the width, roundness or coaxiality of the valve seat
seat. exceed the specified value, grind the valve seat to
• The valve conical surface and valve seat must be ensure enough radiating heat to prevent the carbon
measured to ensure the normal sealing of the valve. deposit on the seat.
1. Gently apply the blue colorant (1) to the valve cone (3). • If the valve seat needs to be adjusted, the valve
surface shall be adjusted unless new valve is used.
2. Fit the valve in the cylinder head.
1. Grind valve seat surface (a) until it meets specified
3. Apply sufficient pressure so that the valve seat can
value (2) of valve taper angle.
drive the valve to rotate, this can help to remove the
colorant. Parameter
4. Remove the valve from the cylinder head. 2. Grind valve relieving face until it meets specified value
5. Check the valve cone. (1) of valve taper angle, so that the valve seat face (a)
can be correctly positioned on the valve.
• If the valve cone and valve stem are concentric, provide
a suitable seal and continuous trace will appear around Parameter
the entire cone (2). 3. Grind valve seat undercut surface until it meets
specified value (3) of valve taper angle; decrease the
1.0 220
valve seat width (a) to meet the specified value. 9. If the height of valve stem is within the specified range,
test the concentricity of the valve seat according to
Parameter
the "Measurement Procedure for Valve to Valve Seat
Concentricity".
Measurement Procedure for Valve Stem Height
Caution: Measure the distance between the valve spring
seat and the valve spring seat to confirm the height of the
valve lever.
1. Insert the valve (1) into the valve guide of the cylinder
head (2).
4. If it exceeds the specified value, replace the intake valve.

Caution: Never grind or adjust the intake valve.If the
intake valve exceeds the specification, replace it with
correct intake valve.
5. If the exhaust valve being used is the original one,

grind it to reach the specified value. After the grinding,
measure the valve head outer diameter and chamfer
again according to the "Measurement Procedure for
Valve Head Outer Diameter and Chamfer". If it exceeds 2. Ensure the valve is secured properly on the valve seat
the specified value, replace the exhaust valve. Do not of the cylinder head.
grind new valves. 3. Fit the valve stem oil seal.
Parameter 4. Fit the valve spring seat and valve stem lock plate.
6. When grinding the valve and valve seat, remove as few 5. Measure the distance (a) from the valve seal lip to the
materials as possible. Grinding valve seat may lead to bottom of the spring seat.
the decrease of the valve spring pressure. Parameter
7. Fit the valve in the cylinder head. 6. If the height of the valve stem is above the maximum
• If an exhaust valve with surface finished is used, put value, fit a new valve and repeat the measurement.
the valve into the valve seat and grind it with fine Caution: Never grind the end of the valve lever.The end
abrasive agent. Valve and valve seat finishing shall ensure of the valve lever is hardened. The hardened surface will
a smooth surface and proper fitting, so just do basic be eliminated by grinding, then causing early wearing and
grinding works. Excessive grinding will leave groove on damage to the engine.
the valve cone and make proper location under high
temperature impossible. 7. If the height of the valve stem remains above the
maximum value, replace the cylinder head.
• Before final assembly, clean all residual abrasive agent on
valve and valve seat with solvents and compressed air, Caution: Never use the gasket to adjust the height of the
and keep the valve and valve seat clean. valve lever.If gasket is used to compress the valve spring
8. After the valve seat in cylinder head reaches the correct to the bottom before the cam salient reaches the max lift,
width, it is necessary to measure the height of valve the engine may be damaged.
stem again according to "Measurement Procedure for
Valve Stem Height".
1.0 221
Piston Connecting Rod Check Parameter

Piston Check
1. Clean the piston skirt and piston pin with cleaning
agent, do not clean any part of the piston with the wire
brush.
2. Clean the piston ring groove with ring groove cleaning
tool, ensure that the oil ring hole and groove are clean.
3. Dry the piston with compressed air.
Warning: Wear the goggles when using the compressed air
to avoid the damage to the eyes due to splashing dust and
particles.
4. Inspect the piston for the followings:
• Check the piston ring groove, piston skirt and piston pin
boss for cracks
• There are notches and burrs which may cause
obstruction in the piston ring groove
2. Measure the clearance from piston pin hole to piston
• Check the piston ring groove for bending or wear pin according to the following procedures:
• Check the piston pin retainer groove for burrs
a. Piston pin hole and piston pin must be free of any
• Piston top is corroded. varnish or wear.
• Check the piston skirt coating for wear or damage
b. Measure the piston pin within the position coming
• Check the piston pin bore or piston pin for wear into contact with the piston with an outer diameter
micrometer.
c. Measure the piston pin hole with an inner diameter
micrometer.
d. Subtract the piston pin diameter from the piston pin
bore diameter to obtain the clearance between the
piston pin bore and piston pin.
5. Replace pistons with any damage or excessive abrasion.

Piston Measurement
1. Measure the piston width according to the following
procedures:
a. Measure the width of the piston (1) at a point
38mm below the top of the piston with an outside
micrometer (2) at the thrust surface perpendicular
to the piston pin centerline. 3. Compare the results with the specified values of piston
pin diameter and clearance between piston pin and
b. Deduct the piston width from the cylinder diameter
piston pin bore.
to obtain the fit clearance, and compare the results
with the specified values of piston width and fit Parameter
clearance. 4. If the clearance is too large, identify the component
c. If the measured clearance is greater than the specified beyond the specification and replace it as needed.
value provided and the cylinder diameter is within 5. If any dimension of the piston exceeds the specification,
the specified range, replace the piston. the piston must be replaced.
1.0 222
6. If the new piston fails to meet the clearance
specification, the dimension of cylinder block may need
to be increased by 0.25mm. Only one piston and piston
ring with increased size are available for service.
Piston Ring Measurement
1. Measure the piston ring end clearance according to the
following procedures:
a. Position the piston ring in the cylinder bore, about

25mm from the top of the cylinder block. Locate
the piston ring with the piston head, and ensure the
piston ring is perpendicular to the cylinder bore.
b. Measure the piston ring end clearance with a feeler

gauge (1). Compare the measured value with the 3. For compression ring refit, there's a locating notch
specified value. near the end, which is used to identify the top surface,
make the notch upward.
Parameter
4. If the new piston ring is unable to reduce the clearance
c. If the clearance is greater than the provided to a proper specified value, fit a new piston.
specification, the piston ring must be replaced. 5. If the new piston fails to meet the clearance
d. Repeat this procedure to all piston rings. specification, the dimension of cylinder block may need
to be increased by 0.25mm. Only one piston and piston
ring with increased size are available for service.
Connecting Rod Check
1. Clean the connecting rod with solvent and dry it with
compressed air.

particles.
2. Remove the cap of the connecting rod and clean the
threads (3).
3. Remove and discard the connecting rod bearing, do not
reuse the connecting rod bearing used during engine
2. Measure the piston ring side clearance according to running.
the following procedures: 4. Check the piston pin bushing (4) for scratch or damage.
a. Rotate the entire piston ring (2) around the piston 5. Check the beam (1) of connecting rod for bend or
ring groove. If the blockage is caused by a distorted deformation.
piston ring, replace the piston ring. 6. Check the connecting rod cap (2) for any notch or
damage caused by any potential factors.
b. Position the piston ring on the piston, measure the
clearance from more than one locations with a
feeler gauge (1).
c. Compare the measured value with the specified value

of piston ring side clearance.
Parameter
d. If the clearance is greater than the specified value,

replace the piston ring.
1.0 223
7. Check the surface of the connecting rod bearing seat c. Subtract the piston pin diameter from the connecting
for scratch or wear. rod piston pin bore diameter to obtain the clearance
8. If slight scratch or wear occurs in the connecting rod between the piston pin and connecting rod bore.
hole, clean the connecting rod hole in circle direction
2. Compare the measured value of clearance with the
with a fine sandpaper.
specified value.
Caution: Do not scratch the connecting rod or
Parameter
connecting rod cap.
3. If the clearance is too large, replace the piston pin.
Connecting Rod Measurement
4. If the clearance is still too large, replace the connecting
1. When measuring the clearance between the piston pin
rod.
and the connecting rod hole, observe the following
5. Measure the inner diameter of connecting rod
procedures:
crankshaft bearing bore with an inner diameter
Caution: All components shall be measured at normal micrometer.
temperature.
6. Compare the measured value of bearing bore diameter
a. 2 measurements of the piston pin diameter shall with the specified value.
be performed with an outer diameter micrometer
Parameter
from the location where the piston pin comes into
7. If the bearing bore is beyond the specification, replace
contact with the connecting rod.
the connecting rod, and do not finish the connecting
rod.
b. Measure the connecting rod piston pin hole diameter

with an inner diameter micrometer.
1.0 224
1. Remove all the old thread sealant, lining material or
sealant.
2. Clean all the following areas with solvent:
• Sealing surface
• Cooling channel
• Oil gallery
• Bearing journal
3. Clean all the thread holes and through holes with
solvent.
4. Dry the engine cylinder block with compressed air. 2. Put the dial to zero at the spot to be tested of the
cylinder by setting the bore diameter gauge (1), and
measure the cylinder bore diameter. Before removing
the cylinder bore gauge from the cylinder, lock the dial
particles.
at the zero position. Set the zero position of cylinder
5. Inspect the crankshaft bearing journal for damage or
bore gauge to the same position when it has been
eccentricity.Crankshaft bearing journal can not be
removed from the cylinder, and measure the span of
repaired.If the crankshaft bearing journal is damaged,the
the cylinder bore gauge contact point with the external
cylinder block assembly must be replaced.
micrometer.
6. Check the primary camshaft drive chain tensioner
mounting surface of the engine cylinder block for burrs
or any defect that may reduce the sealing performance
of the new primary camshaft drive chain tensioner
gasket.
7. Check all sealing and meshing surfaces for damage,and
repair or replace the cylinder block assembly as
required.
8. Check all threaded holes and through-holes for damage
or excessive debris.
9. Check all bolts for damage.if damaged,replace the bolts
with new ones.
10. Check the cylinder wall for crack or damage, and the
cylinder liner cannot be repaired.If the cylinder liner is
damaged,the cylinder block assembly must be replaced. 3. The tiny vertical scratch caused by ring end will not
11. Check the engine cylinder block for cracks,and do not result in excessive oil consumption itself. DO NOT
repair any crack.If any crack is found,the cylinder block hone the cylinder to eliminate such scratch.
assembly must be replaced. 4. Compare the measured value with the specified value.
Cylinder Bore Diameter Measurement
Parameter
1. Measure the dimension of the location 37mm below the
5. If the cylinder bore exceeds the specified value, the
cylinder head gasket surface and measure the cylinder
dimension of cylinder block may need to be increased
bore diameter.
by 0.25mm. Only one piston and piston ring with
increased size are available for service.
Cylinder Bore Taper Measurement
1. Measure the cylinder bore along the thrust surface
perpendicular to the crankshaft centerline 10mm below
the top surface, and record the measured value (1).
2. Measure the cylinder bore along the thrust surface
1.0 225
perpendicular to the crankshaft centerline 100mm 5. Compare the measured value with the specified value.
below the top surface, and record the measured value
Parameter
(2).
6. If the cylinder exceeds the specified value, the
Top Surface Flatness Check
1. Make sure the engine cylinder block top surface is clean
without gasket material.
2. Check the surface for any defect or scratch that may
hinder correct sealing of cylinder head liner.
3. Place a ruler on the top surface of the cylinder block
diagonally.
4. Use a clearance gauge to measure the clearance
between the ruler and the top surface of the cylinder
3. Calculate the difference between two measured values, head at 4 points along the ruler.
which is the cylinder block taper.
Parameter
5. If the cylinder exceeds the specified value, the
Cylinder Bore Out-of-Roundness Measurement
1. Measure both the thrust and non-thrust cylinder bores
at the point 10mm below the top surface, and record
the measured value.
2. Calculate the difference between two measured values,
which indicates the out-of-roundness of the cylinder 5. If the distortion is less than 0.05mm,the top surface of
upper end. cylinder block does not need to be reconditioned.
3. Measure both the thrust and non-thrust cylinder bores 6. If the distortion is between 0.05 and 0.20mm,or there
at the point 100mm below the top surface, and record are any defect or scratch that may hinder the correct
the measured value. sealing of cylinder head liner,the top surface of cylinder
block needs to be reconditioned.
4. Calculate the difference between two measured values,
which indicates the out-of-roundness of the cylinder 7. If the top of the cylinder block needs to be
bottom. reconditioned,the maximum removable amount is
0.25mm.
8. If the removable amount on cylinder block top surface
is larger than 0.25mm,the cylinder block must be
replaced.
1.0 226
Crankshaft Check
Crankshaft check
Tip: Use care when handling the crankshaft.Avoid
damage to the bearing surfaces or the lobes of the
crankshaft position reluctor ring.Damage to the teeth of
the crankshaft position reluctor ring may affect on-board
diagnostic (OBD) II system performance.
1. Clean the crankshaft with solvent.
2. Thoroughly clean all oil ducts and check for blockage
or burr.
3. Dry the crankshaft with compressed air.

particles.
4. Visually check the crankshaft for damage.
Tip: Reluctor ring teeth should not have imperfections

on the rising or falling edges.Imperfections of the reluctor
ring teeth may effect OBD II system performance. 2. Measure the crankshaft runout.
5. Check the crankshaft journal for pitting or embedded a. Use a wooden V-shaped block, and support the
bearing material (1). crankshaft on the front and rear journals.
6. Check the crankshaft main journal for groove or b. Use an indicator (1) or equivalent shown in figure to
scratch (2). measure the runout of the front, rear intermediate
7. Check the connecting rod journal for scratch or wear crankshaft journals.
(3).
c. Measure the rear flange runout of the crankshaft
8. Check the crankshaft journal for wear. The journal shall with an indicator (1).
be smooth and free of scratch, wear or damage (4).
3. If the measured value is not within the specified range,

replace the crankshaft.
Parameter
Crankshaft Measurement Crankshaft Bearing Check
1. Measure the out-of-roundness of the crankshaft journal. Tip: If crankshaft bearing failure is due to other than
normal wear, investigate the cause.Inspect the crankshaft
or connecting rod bearing bores.
1. Check the crankshaft bearing for pits or grooves (1),
and the worn position shown in the bearing shell also
represents the sign of fatigue wear.
2. Check the crankshaft bearing for severe scratch or
discoloration (2).
3. Check the crankshaft bearing for embedded dust or
debris and other materials.
1.0 227
4. Check whether the crankshaft bearing is not properly • Bearing clearance can be calculated by measurements
seated as shown in the bright bearing section (3). based on Method A.
• If the lower part of the bearing is worn or damaged, both • The bearing clearance is directly obtained by Method B,
upper and lower parts shall be replaced. but no information on bearing runout will be given.
• Generally, if the lower part can be used, then the upper Method A
part can also be used. Tip: DO NOT mix inserts of different nominal size in
the same bearing bore.
1. With an angle of 90°, measure the diameter of the
crankshaft main journal from more than one point with a
micrometer (1), and calculate the average of measured
values.
2. Measure the taper and runout of the crankshaft main
journal.
3. Fit the bearing and the lower crankcase, and tighten the
bearing cap bolt to the specified torque value.
4. With an angle of 90°, measure the inner diameter (ID) of
the bearing from several points and average the measured
values.
5. Determine the clearance by deducting the measured
journal value from the measured bearing inner diameter.
6. Compare the clearance value with the standard value to
Crankshaft Bearing Selection determine whether the clearance is within the prescribed
Check the crankshaft main bearing bore as per following scope.
procedures.
Parameter
• Tighten the main bearing bolt torque to the specified
7. If it is out of the specified range, select another bearing.
angle value with an angle gauge.
8. Measure the inner diameter of the connecting rod along
• Measure the taper and roundness in the crankshaft main
the length of the connecting rod in the same direction
bearing with a runout gauge (1).
with an ID micrometer.
• Taper or roundness is not allowed.
Bearing Selection
Measure the bearing clearance so as to determine a correct

size of the bearing to be replaced. There are 2 methods for
measuring the bearing clearance. Method A is able to provide
more reliable results, so it is the preferred option.
1.0 228
Method B
1. Clean the used bearing.

2. Fit the used bearing.
3. Locate the plastic clearance gauge across the entire width
of the bearing.
4. Fit the bearing cap.
5. Fit the bearing cap bolt to the specified value.
Caution: Before connecting the bolt, use copper, lead
or leather hammers to knock the crankshaft bearing
cover into the cylinder hole, avoiding the damage to the
cylinder block or crankshaft bearing cover.Never use the
connection bolt to pull the crankshaft bearing cover into
the seat.Otherwise, the cylinder block or bearing cover
may be damaged.
6. Remove the bearing cap to release the plastic clearance

gauge from its original position. Whether the plastic of
the gauge is stuck to the journal or bearing cap is not
the key point.
DO NOT rotate the crankshaft.

7. According to the scale mark (1) printed on the plastic
clearance gauge component, measure the widest point of
the plastic clearance gauge.
8. Remove the plastic clearance gauge.
1.0 229
Engine Oil Filter

Remove
1. Open the engine oil filler cap.
2. Lift the vehicle with a hoist.
4. Place a suitable container under engine sump drain plug
(1), remove and discard the oil drain plug, and drain
the oil.
Warning: Observe due care when draining engine oil as
the oil can be very hot.
Warning: Avoid excessive skin contact with used engine
oil. Used engine oil contains potentially harmful
contaminants which may cause skin cancer or other
serious skin disorders.
5. Clean the area around the filter head, and place
a suitable container under the filter to collect the
possible spillage.
6. Remove and discard engine oil filter (2).
Refit
1. Clean the mating surface of the filter head.
2. Lubricate oil filter O-ring with clean engine oil.
3. Fit a new filter and tighten to 26-34Nm.
4. Fit a new oil drain plug and tighten to 21-29Nm.
5. Fill new oil to the correct level from the engine oil filler.
Capacity
Lubricating Fluid
6. Fit the oil filler cap.
9. Start and run the engine until the oil pressure warning
lamp goes out.
10. Stop the engine, and check the engine oil level.
11. Check for any signs of leakage.
1.0 230
Number
Crankshaft seal
transmission
TEN00144
Oil pressure side guide
TEN00080 bushing
gauge adapter
Crankshaft seal
Engine oil TEN00143 transmission
T10001 pressure test side installer
equipment
Crankshaft
Engine lift TEN00136 balancer 3-jaw
T10007 puller
bracket
Camshaft
TEN00134
TEN00070 Engine support locking tool
Crankshaft/balancer
TEN00135
holding tool
1.0 231

Number
Mechanical
TEN00141 vacuum pump
seal installer
Crankshaft seal
TEN00142 timing side
installer
1.0 232
Engine Cooling System Engine
Engine Cooling System
Specifications
Torque
Description Value
Bolt- expansion tank to body 4–6Nm
Screw-Cooling Fan Assembly 4.5-5Nm
Bolt-From front bumper impact bar to body in white 40–50Nm
Bolt-intercooler to platform 4–6Nm
Bolt- Wind scooper to body 3–5Nm
Bolt- oil cooling hose to AT 7–10Nm
Bolt-Thermostat to thermostat housing 9–11Nm
Bolt-Water pump to WAPU 13.5–16.5Nm
Bolt - water pump pulley to water pump 7.5-10.4Nm
Bolt - auxiliary pump bracket and CAC hose bracket to 9–11Nm
cylinder head
Bolt- thermostat housing to water pump 8-12Nm
Bolt - water pump to cylinder block 22-28Nm
Bolt - bypass pipe to water pump 8-12Nm
Bolt - bypass pipe to cylinder head 8-12Nm
1.0 233
Engine Engine Cooling System
Parameters
2.0T Engine
Model Temperature-controlled, pressure overflow backflow type
cooling system with forced circulation of water and OAT
mixture solution
Cooling Fan 9 Vanes, Temperature-Controlled Electric Axial Flow Type
Coolant Capacity:
Engine 8.2 L
Cooling Fan Switch
ON: Coolant temperature ≥ 95℃ or A/C ON request is received,
refrigerant pressure ≥ 0.22MPa
OFF: A/C OFF request is received, and coolant temperature <93℃
Cooling Fan Switch - After Engine Stop
ON: ≥102℃
Duration <100℃, turn off immediately; e.g. after 327s, ≥100℃, turn
off automatically.
Radiator Crossflow Type
Coolant Pump Clutch Water Pump, Radial Flow Impeller
Coolant Pump Drive Ratio 1.26
Thermostat Wax-type Component

Thermostat Operating Temperature:
∙Initial Activation 103℃
∙Full Open 115℃
∙Full Open Lift ≥ 8mm
Pressure-relief Valve of Expansion Tank Cap
∙High Pressure ON 140-160 KPa
∙Low Pressure ON 0-10 KPa
1.0 234
1.5T Engine
Model Temperature-controlled, pressure overflow backflow type
cooling system with forced circulation of water and OAT
mixture solution
Cooling Fan 9 Vanes, Temperature-Controlled Electric Axial Flow Type
Coolant Capacity:
Engine 7.1 L
Cooling Fan Switch
ON: Coolant temperature ≥ 95℃ or A/C ON request is received,
refrigerant pressure ≥ 0.22MPa
OFF: A/C OFF request is received, and coolant temperature <93℃
Cooling Fan Switch - After Engine Stop
ON: ≥102℃
Duration <100℃, turn off immediately; e.g. after 327s, ≥100℃, turn
off automatically.
Radiator Crossflow Type
Coolant Pump Mechanical, Radial Flow Impeller
Coolant Pump Drive Ratio 1: 1
Thermostat Wax-type Component

Thermostat Operating Temperature:
∙Initial Activation 97±2℃
∙Full Open 112℃
∙Full Open Lift ≥ 8mm
Pressure-relief Valve of Expansion Tank Cap
∙High Pressure ON 140-160 KPa
∙Low Pressure ON 0-10 KPa
1.0 235

System Layout
Engine Cooling System - (2.0L Turbocharged
Engine)
1.0 236
A = Radiator Outlet B = Radiator Inlet C = Engine Water Outlet D = Expansion Tank Water Outlet E = Electronic Water
Pump Inlet F = Heater Core Inlet Pipe G = Heater Core Water Outlet H = Oil Filter Module Water Inlet I = Engine Vent J =
Turbocharger Return Water Port
1. Condenser 9. Engine Overflow Pipe B
2. Radiator 10. Expansion Tank Outlet Pipe
3. Radiator Drain Valve 11. Heater Core Inlet Pipe
4. Intercooler 12. Heater Core Outlet Pipe
5. Cooling Fan 13. Radiator Inlet Pipe
6. Cooling Fan Speed Regulation Resistance 14. Engine Overflow Pipe A
7. Expansion Tank Cap 15. Radiator Outlet Pipe
8. Expansion Tank 16. Turbocharger Return Water Pipe
1.0 237
Engine Cooling System - (1.5L Turbocharged

Engine)
A = Radiator Outlet B = Radiator Inlet C = Engine Water Inlet D = Engine Water Outlet E = Engine Overflow Port F = Radiator
Overflow Port G = Heater Core Water Inlet H = Heater Core Water Outlet
1. Condenser 2. Radiator
1.0 238
3. Intercooler 9. Heater Core Water Inlet Pipe
4. Cooling Fan 10. Engine Overflow Pipe
5. Cooling Fan Speed Regulation Resistance 11. Radiator Overflow Pipe
6. Radiator Outlet Pipe 12. Expansion Tank
7. Radiator Inlet Pipe 13. Expansion Tank Cap
8. Heater Core Water Outlet Pipe 14. Radiator Drain Valve
1.0 239
Water Pump and Thermostat - (2.0L Turbocharged

Engine)
1. Clutch Water Pump 3. Thermostat Assembly

2. Electronic Water Pump
1.0 240
Water Pump and Thermostat - (1.5L Turbocharged
Engine)
1. Water Pump 2. Thermostat Assembly
1.0 241
Description motor. When the engine stops (at this stage, the clutch water
Overview pump does not work and the coolant does not recirculate),
after working for few minutes, the electronic water pump
The cooling system circulates the engine coolant in the loop
will recirculate the coolant in the turbocharger and eliminate
of engine and heater core. The coolant is the mixture of 50%
the heat accumulated in the turbocharger, this process can
water and 50% organic acid technique (OAT), which helps to
avoid coking and carbonization of the oil around the turbine
maintain the optimum operating temperature of the engine
bearing due to overheating after stalling of the engine, and
when the environment and engine working conditions are
thus protects the bearing and extends the service life of the
different.
turbocharger.
Caution: Engine coolant will damage paint finished
A sound can be heard when the electronic water pump works,
surfaces. If spilled, immediately rinse area with plenty of
this indicates the motor is in normal state.
water.
Cooling Water Pipe
The engine cylinder block is equipped with a "damping"
ladder-like cylinder liner. The thicker upper part of the cylinder The coolant pipe is connected with all components of the
liner forms the "wet" part, at the same time, the thinner lower cooling system, and the coolant flows to the component via the
part sliding and fitting into the cylinder block forms the "dry" coolant hose. The coolant hose is fixed to each component by
part. This thermal efficiency design exposes the upper part of spring clamps.
the cylinder liner to the coolant and dissipates heat directly Expansion Tank (2.0L turbocharged engine)
through its outer surface.
The injection molding coolant expansion tank with a pressure
To keep its optimum efficiency and corrosion resistance relief valve is fitted on the left frame. One of the overflow
performance, the coolant shall be replaced regularly. pipes connects the expansion tank with the short pipe of
Components of Cooling System the engine overflow port, the other connects the tee pipe of
the radiator inlet pipe. The hose under the expansion tank
Clutch Water Pump (2.0L turbocharged engine) connects the cooling system. When thermal expansion of the
The clutch water pump is a centrifugal impeller pump. The coolant occurs, the excess coolant in the cooling system will
water pump consists of the clutch, solenoid, spiral case, bearing flow back to the expansion tank through the overflow/return
and impeller. The clutch and impeller are fitted on the bearing, pipe; when the cooling system is short of coolant, the coolant
and the solenoid and bearing are fitted on the spiral case. The in the expansion tank will flow into the cooling system through
centrifugal force caused by impeller rotation drives the coolant the water inlet pipe.
to flow and provides pressure. The bearing is provided with
Expansion Tank (1.5L turbocharged engine)
grease, the two ends are sealed to prevent grease leak and
ingress of foreign material. The injection molding coolant expansion tank with a pressure
relief valve is fitted on the left frame. One of the overflow
The crankshaft turns the water pump via the drive belt pulley, pipes connects the expansion tank with the short pipe of the
which allows the coolant to circulate in the cooling system. engine overflow port, the other connects the connector at
When starting a cold engine, the clutch assembly works, the the top of the radiator. The hose under the expansion tank
water pump pulley rotates, and the water pump impeller connects the cooling system. When thermal expansion of the
does not turn, the engine coolant does not circulate, the coolant occurs, the excess coolant in the cooling system will
engine warm-up time is shortened and CO2 emission and fuel flow back to the expansion tank through the overflow/return
consumption are reduced. When the engine coolant achieves pipe; when the cooling system is short of coolant, the coolant
a curtain temperature, the clutch engages, the water pump in the expansion tank will flow into the cooling system through
impeller rotates and the coolant starts to circulate. the water inlet pipe.
Coolant Pump (1.5L turbocharged engine) Mechanical Thermostat

The coolant circulates through the coolant pump drive, and The electronic thermostat is a wax-type valve.
the coolant pump is fitted on the rear upper part of the engine When the coolant temperature is low, the wax-type
crankcase drive, which is sealed to the cylinder block by an O component of the thermostat is in solid state, and the
ring and driven by the crankshaft drive belt. thermostat valve switches off under the action of the spring,
Electronic Water Pump (2.0L turbocharged at this point, the cooling system is in a small circulation status,
engine) i.e. the coolant cannot enter into the radiator for circulation,
The electronic water pump is part of the engine cooling but it can flow to the heater core by the bypass circuit. When
system, which is driven by the impeller of the brushless the coolant temperature rises, the wax-type components start
1.0 242
melting into liquid state gradually followed by the increase of When the engine works at a low/medium load, increase of
volume, then the thermostat valve will open gradually under the engine water temperature can decrease oil viscosity,
the effect of the push rod, at this time, the cooling system is mechanical friction loss of the piston, etc and heat transfer
in a big circulation status. When the thermostat is fully open, loss and optimize combustion; when the engine works at a
the coolant flows through the radiator. high load/speed, decrease of the engine temperature allows
the engine to cool down rapidly. The thermostat keeps the
Electronic Thermostat
coolant temperature at an optimum level for engine operation.
The electronic thermostat is a wax-type valve with heating
elements which combine with the wax package.Indirect control Radiator and Cooling Fan
of the thermostat opening can be realized by controlling the The radiator is of aluminum crossflow type with injection
heat dissipation of the heating element according to the control moulding water tanks on both ends (for wet automatic
signal from the ECM. transmission model, automatic transmission oil cooler is
locate in the left water chamber of the radiator. The cooling
When the coolant temperature is low, the heating element
hose linked with the transmission connects the bushing of the
of the electronic thermostat does not work, the wax-type
transmission oil cooler by quick connectors). The radiator
component of the thermostat is in solid state, and the
supports the cooling fan assembly, A/C (A/C) condenser. The
thermostat valve switches off under the action of the spring,
top of the radiator is secured on the upper radiator beam by
at this point, the cooling system is in a small circulation status,
two bolts. The bottom of the radiator is located in the rubber
i.e. the coolant cannot enter into the radiator for circulation,
bushing supported by the upper radiator beam bracket. The
but it can flow to the heater core by the bypass circuit. When
plastic wind scooper behind the front bumper is used to guide
the coolant temperature rises, the heating element of the
the airflow through the radiator. The condenser fixed by two
electronic thermostat works, the wax-type components start
bolts is fitted on the upper side of the front radiator.
melting into liquid state gradually followed by the increase of
volume, then the thermostat valve will open gradually under The cooling fan assembly is fitted at the rear of the radiator.
the effect of the push rod, at this time, the cooling system is The cooling fan cools the radiator by intaking the air through
in a big circulation status. When the thermostat is fully open, the radiator.
the coolant flows through the radiator.
1.0 243
Operation
Coolant Flow
2.0L Turbocharged Engine
A= Cold; B= Hot
1.5L Turbocharged Engine
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A= Cold; B= Hot
Coolant Flow engine at the best temperature. When the thermostat is fully
The cooling system utilizes the heat conduction principle, open, all coolants flow through the radiator.
conducting heat from the engine components to the coolant. 2.0L Turbocharged Engine
When the engine is cold, keep the thermostat closed to
Coolant flows from the right top water chamber to the left
prevent the coolant from flowing through the radiator,
bottom water chamber and passes through the radiator, it is
however, a small amount of coolant may pass through the
cooled by the air flows by the radiator core before flowing
bypass, this helps to prevent the accumulated pressure from
back to the engine cylinder block via the thermostat.
getting too high. When the engine reaches the normal
operating temperature, the thermostat opens, the cool The coolant from the thermostat flows through the tee pipe,
coolant enters into the cylinder block through the hose at the and enters all the way into the heater core to meet the need of
bottom of the radiator,and the hot coolant will flow into the heating and into the turbocharger to satisfy the cooling demand
radiator through the hose at the top of the radiator, so that of the turbocharger.
the cool and hot coolant may be balanced to maintain the
1.0 245
Coolant entered into the turbocharger flows around the Cooling Fan Control Policy
bearing housing and comes into the expansion tank outlet pipe The cooling fan provides the corresponding control signal via
via the return pipe before flowing into the engine eventually. the ECM and realizes the control by the relay and speed
Meanwhile, the expansion tank will remove the air in the regulation resistor unit. The ECM utilizes the information
coolant. The excess coolant produced by thermal expansion provided by the ECT sensor, air conditioning pressure switch,
returns to the expansion tank through the overflow pipe of vehicle speed sensor and ATC to control the fan speed and
the cylinder head. The lower side of the expansion tank is engine coolant temperature.
provided with a hose connected with the cooling system, Cooling Fan ON
which returns coolant to the cooling system.
The ECM sends the cooling fan ON signal according to
1.5L Turbocharged Engine the coolant temperature and the pressure when the A/C is
Coolant flows from the right top water chamber to the left running.
bottom water chamber and passes through the radiator, it is Cooling Fan OFF
cooled by the air flows by the radiator core before flowing
With the engine running, check if the A/C is ON and if the
back to the engine cylinder block via the thermostat.
coolant temperature is below the specified value, then turn off
Coolant from the engine enters into the heater core through the cooling fan.
the heater core water inlet pipe, which meets the requirement
With the engine stationary, check coolant temperature and
for heating.
check if the corresponding cooling fan is ON/OFF.
Meanwhile, the expansion tank will remove the air in the
Cooling Fan Operation - In Failure Condition
coolant. The excess coolant produced by thermal expansion
returns to the expansion tank through the overflow pipe of When failure of the coolant temperature sensor, A/C pressure
the left top radiator and cylinder head. The hose under the switch and vehicle speed sensor occur, operate the cooling fan
expansion tank is connected with the heater core water outlet in accordance with the relevant fault strategy.
pipe through the tee pipe, which also connects the engine and Cooling Fan Relay Unit
compensates the engine cooling system. The cooling fan relay unit includes relay 1, relay 2 and relay 3.
The expansion tank cap with relief valve and vacuum valve The cooling fan relay unit is connected to the ECM by 2 wires,
isolates the cooling system from the ambient atmosphere, the the other 3 wires connects the internal relay winding to the
coolant expands when the temperature rises, and the pressure cooling fan. The cooling fan relay provides the 12V supply via
of the cooling system will increase accordingly. The increased the battery.
pressure raises the boiling point of the coolant, allowing the
engine to run at a higher, more efficient operating temperature When the cooling fan runs at low speed, ECM provides the
without the risk of coolant boiling. The pressurization of the ground for Pin 16 of the relay connector BY014.
cooling system is limited, so a pressure relief valve is provided When the cooling fan runs at medium speed, ECM provides
on the expansion tank cap. By this way, when the working the ground for Pin 14, 15 of the relay connector BY014.
pressure of the system exceeds the permissible maximum
When the cooling fan runs at high speed, ECM provides the
value, the excess pressure in the cooling system can be
ground for Pin 14, 15 and 16 of the relay connector BY014.
released.
The table below shows the specific cooling fan operation for
Warning: Since injury such as scalding could be caused by
low/high/medium fan speed.
escaping steam or coolant, do not remove the filler cap
from the coolant expansion tank while the system is hot. Relay 1 Relay 2 Relay 3 Cooling Fan
Gear
The engine coolant temperature signal is measured by the
OFF OFF OFF 0 (OFF)
ECT sensor. The ECM controls the cooling fan, etc, by
OFF OFF ON 1 (Low
monitoring the coolant temperature signal from this sensor.
Speed)
The ECM sends the engine coolant temperature signal to the
ON ON OFF 2 (Medium
HS CAN 1, the GateWay (gateway controller) forwards it to
Speed)
the HS CAN 3 and IPK controller, which is used to indicate
ON ON ON 3 (High
the coolant temperature and provide high temperature
Speed)
warning. If the coolant sensor fails or coolant temperature is
extremely high, the IPK will alert the driver by the warning
lamp and message.
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Warning: Keep clear of the cooling fan. The fan may start
automatically without warning, even after the engine is
turned off.
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Service Procedures-2.0T Refill

Coolant - Drain and Refill 1. Turn off the coolant/water drain valve under the
Drain radiator.
1. Remove the expansion tank cap. 2. Prepare the coolant of specified concentration.
Warning: Since injury such as scalding could be caused by Fluid
escaping steam or coolant, do not remove the filler cap 3. Open the expansion tank cap. Refill the expansion tank
from the coolant expansion tank while the system is hot. until the coolant reaches the neck of the expansion
tank and keeps still.
4. Ensure that the air conditioning is closed.
5. Start the engine and allow it to run at 1500~2500 RPM.
Refill the expansion tank as required to keep the level
just below the neck of the expansion tank. When the
coolant level reaches the neck of the expansion tank
due to thermal expansion, fit the expansion tank cap.
6. Continuously run the engine at the speed of 1500~2500
RPM until the cooling fan operates, and then run the
engine at idle speed until the cooling fan stops.
7. Turn off the engine and allow it to cool for 30 minutes.
8. Inspect the cooling system for any leak.
2. Secure a proper container to collect the coolant. 9. Check if the coolant level is between MIN and MAX. If
3. Raise the vehicle on a lift. not, open the expansion tank cap, refill the coolant to
the maximum level or keep it between MIN and MAX
4. Turn off the drain valve at the bottom of the engine
as required.
radiator.
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Expansion Tank Cap - Pressure Test TEN00010.
Check
1. Visually check the expansion tank cap for any leak.
2. Check the hose for signs of rupture and distortion and
the attachment strength of pipeline connection.
3. Open the coolant expansion tank cap.

from the coolant expansion tank while the system is hot.
6. Pressurize the expansion tank cap slowly to the

specified pressure, then check the pressure, if the
pressure range is maintained within 140-160KPa, the
expansion tank cap is normal.
7. Release pressure through the pressure relief valve on
the pressurization tool.
4. Fit the TEN00010 to the expansion tank cap.
8. Remove the T14001 pressure hose from the

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

Check
1. Check the hose for signs of rupture and twist and the
attachment strength of pipeline connection.
6. Visually inspect the engine and the cooling system for

signs of coolant leakage.
7. Release pressure through the relief valve on the
T14001.
3. Fit the TEN00015 to the expansion tank.

4. Connect the pressure hose of the T14001 to the
TEN00015.
5. Pressurize the system to the pressure of 140-160KPa
slowly and check whether there is any leakage.
Warning: Do not exceed the setting pressure value, or the

cooling system will be damaged.
8. Disconnect the T14001 hose from the TEN00015.
9. Remove the TEN00015 from the expansion tank and
fit the expansion tank cap.
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Coolant Expansion Tank hose (1).
Remove 5. Release the clamp and disconnect the expansion tank
1. Open the coolant expansion tank cap. outlet pipe (2).
6. Release the clamp and disconnect the cooling system
overflow hose (3).
2. Remove 2 bolts securing the coolant expansion tank

on the frame.
7. With the water pipe clips, clamp the expansion tank
outlet pipe to prevent coolant loss.
8. Remove the coolant expansion tank from the vehicle.
Refit
1. Fix the overflow pipe of the cooling system to the
expansion tank, and secure it with clamps.
2. Fit the expansion tank outlet pipe to the coolant
expansion tank and secure with clamps.
3. Fit the engine overflow pipe to the coolant expansion
tank and secure with clamps.
4. Secure the coolant expansion tank on the frame, fit 2
3. Prepare an appropriate container to collect the coolant bolts, and tighten to 4–6Nm.
dripping from the expansion tank. 5. Refill coolant to the specified level.
4. Release the clamp and disconnect the engine overflow 6. Fit the coolant expansion tank cap.
1.0 251
Radiator Inlet Pipe Radiator Outlet Pipe

Remove Remove
1. Drain the engine cooling system. 1. Drain the engine cooling system.
Cooling System Drain Engine Cooling System Drain

2. Release the clamp (3) securing the harness on the 2. Remove 2 bolts fixing the expansion tank to the body
radiator inlet pipe. and take away the expansion tank.
3. Loosen the clamps and disconnect the radiator inlet
pipe (2) from the radiator.
4. Loosen the clamps, disconnect the radiator inlet pipe
(1) from the thermostat housing and remove the
radiator inlet pipe.
3. Loosen the clamps and disconnect the radiator outlet

hose (2) from the radiator.
4. Release the clamp and disconnect the radiator outlet
hose (1) from the thermostat housing assembly.
5. Release the clamp and disconnect the radiator inlet

pipe (3).
5. Remove the radiator outlet hose from the vehicle.

Refit
1. Connect the radiator outlet pipe to the thermostat
Refit housing, and fix it with clamps.
1. Fix the radiator inlet pipe to the expansion water tank, 2. Connect the radiator outlet pipe to the radiator, and
and secure it with clamps. fix it with clamps.
2. Connect the radiator inlet pipe to the hard thermostat 3. Secure the coolant expansion tank on the frame, fit 2
pipe, and fix it with clamps. bolts, tighten them to 4–6Nm, and check the torque.
3. Connect the radiator inlet pipe to the radiator, and fix 4. Refill the engine cooling system.
it with clamps.
Engine Cooling System Refill
4. Fix the harness to the radiator inlet pipe.
5. Refill the engine cooling system.
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Heater Water Inlet Pipe
Remove
Cooling System Drain

2. Remove the electronic throttle intake pipe.
Electronic Throttle Intake Pipe Remove
3. Loosen the clamp and disconnect the heater core water
inlet pipe from the heater core (1).
4. Release the clamp and disconnect the heater core
water inlet pipe from the electronic pump (3).
6. Remove the heater core water inlet pipe from the

vehicle.
Refit
1. Fix the heater core water inlet pipe to the thermostat
and secure with clamps.
2. Fix the heater core water inlet pipe to the electronic
pump and secure with clamps.
3. Fix the heater core water inlet pipe to the heater core
4. Fit the electronic throttle intake pipe.
Electronic Throttle Intake Pipe Refit

water inlet pipe from the thermostat housing (3).
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Heater Water Outlet Pipe Expansion Water Tank Outlet Pipe

Remove Remove

2. Release the clamp and disconnect the heater core 2. Release the clamp (1) and disconnect the expansion
water outlet pipe from the heater core (2). tank outlet pipe from the expansion tank.
3. Release the clamp (2) and disconnect the expansion
tank outlet pipe from the engine.
4. Cut off the 2 straps (3) fixing the expansion outlet pipe
to the battery box.

water outlet pipe from the hard pipe of the oil filter
module assembly.
5. Release the clamp and disconnect the turbocharger

water outlet pipe.
4. Remove the heater water outlet pipe from the vehicle.

Refit
1. Fix the heater core water outlet pipe to the hard pipe of
6. Remove the expansion outlet pipe from the vehicle.
the oil filter module assembly, and secure with clamps.
Refit
2. Fix the heater core water outlet pipe to the heater
1. Fix the turbocharger water return hose to the
core and secure with clamps.
turbocharger hard return pipe, and secure with clamps.
2. Fix the expansion water tank outlet pipe to the engine,
Engine Cooling System Refill and secure it with clamps.
3. Fix the expansion water tank outlet pipe to the
expansion water tank, and secure it with clamps.
4. Fix the expansion water tank outlet pipe to the battery
box, and secure it with straps.
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Engine Overflow Pipe A 4. Remove 1 bolt (1) and 1 stud (2) fixing overflow pipe
Remove A to the engine.
Engine Cooling System Drain

2. Release the clamp and disconnect overflow pipe A from
the engine.
5. Remove the engine overflow pipe A from the vehicle.

Refit
1. Fix engine overflow pipe A to the engine, fit the bolt
and stud, and tighten them.
3. Release the clamp and disconnect the engine overflow 2. Connect engine overflow pipe B and A, and secure
pipe A and B (1). with clamps.
3. Fix engine overflow pipe A to the engine, and secure
it with clamps.
1.0 255
Engine Overflow Pipe B Cooling Fan Assembly

Remove Remove
1. Release the clamp and disconnect engine overflow pipe 1. Disconnect the battery negative.
A and B (1). 2. Disconnect the connector of the cooling fan low speed
2. Release the clamp and disconnect engine overflow pipe resistor.
B from the expansion tank (2).
3. Remove the front bumper assembly.

3. Remove engine overflow pipe B from the vehicle. Front Bumper Assembly Remove
Refit 4. Release 6 bolts (1) and 2 nuts (2) fixing the front
1. Connect engine overflow pipe B and expansion water anti-collision beam.
tank, and secure with clamps.
2. Connect engine overflow pipe B and A, and secure
with clamps.
3. Refill the expansion water tank with maximum coolant.
5. Release 2 bolts and 2 lock latches fixing the cooling fan

assembly to the upper radiator beam.
1.0 256
7. Move the cooling fan assembly slowly in the engine Cooling Fan Low Speed Resistance
compartment and remove it from the vehicle. Remove
Refit Warning: Disconnect the battery to prevent operation of
1. Fit the fan assembly to the vehicle. the cooling fan, which could cause personal injury.
2. Lower the vehicle. 1. Disconnect the battery negative.
3. Fix the cooling fan to the slot of the upper radiator 2. Remove the cooling fan assembly.
beam; fit 2 screws, tighten to 4.5-5Nm, and check Cooling Fan Assembly Remove
the torque. 3. Remove 1 screw securing the resistor on the wind
4. Fix the front bumper beam and upper radiator beam scooper to remove the resistor.
assembly to the body, connect them with bolts and nuts
respectively and tighten to 40–50Nm.
5. Fit the front bumper.
Front Bumper Assembly Refit

6. Disconnect the connector of the cooling fan low speed
resistor.
4. Measure about 5 cm lead at resistor end and cut the

resistor off the lead.
5. After cutting off the resistor, remove about 7 mm
insulation respectively from both ends of the remaining
lead.
Refit
1. Take a resistor to be fitted and cover the heat-shrink
tube on the lead of resistance.
2. Insert the metal part of the lead whose insulation

has been removed into the double end connector
connected to the lead of the resistance to be fitted, and
impact it with the terminal clamp in T84001, taking the
standard of at least 10 kg tension of the joint without
loosing.
3. Cover the heat-shrink tube on the double end
connector and heat it with proper heat supply to shrink
1.0 257
and agglutinate it with the lead. Radiator Assembly

4. Fix the resistor to the wind scooper with 1 self-tapping Remove
screw, fix the wire with tapes and ensure the wire and 1. Disconnect the battery negative.
the serpentuator bushing will not move or interfere 2. Drain the engine cooling system.
with the vane or cause any other interference.
5. Fit the cooling fan assembly.
3. Remove the coolant expansion tank.
Cooling Fan Assembly Refit
Coolant Expansion Tank Remove
6. After replacement, connect the battery negative and
start the engine to check the fan operation. If there is 4. Remove the front bumper assembly.
no high humming when the fan is running, resume the Front Bumper Assembly Remove
low speed operating condition. 5. Loosen the clamp, and disconnect the radiator water
inlet hose (3).
6. Loosen the clamp, and disconnect the radiator water

outlet hose (2).
7. Remove the cooling fan assembly.
Cooling Fan Assembly Remove

8. Prepare a proper container to collect the transmission
fluid.
9. Disconnect the transmission fluid cooling pipe at the
radiator side.
1.0 258
Intercooler
Remove
Front Bumper Assembly Remove


5. Loosen the clamps, and disconnect the air intake hose
from the intercooler.
10. Remove the upper radiator beam.
Upper Radiator Beam Remove

11. Remove the condenser from the radiator slot.
6. Loosen the clamps, and disconnect the air outlet hose

from the intercooler (3).
12. Remove the radiator from the vehicle.

Refit
1. Fit the radiator to the vehicle.
2. Fix the condenser to slot of the radiator groove.
3. Fit the upper radiator beam.
Upper Radiator Beam Refit

4. Fit the transmission oil cooler pipe.

6. Fit the radiator water outlet pipe.
7. Remove 2 bolts and 2 screws connecting the upper
7. Fit the radiator water inlet pipe.
radiator beam with radiator and intercooler.
8. Fit the front bumper assembly.

9. Refill transmission fluid.
Transmission Fluid Refill


1.0 259

10. Remove the intercooler from the slot of the upper
radiator beam and take out from the vehicle.
Refit
1. Fit the intercooler to the slot of upper radiator beam.
3. Tighten the front anti-collision beam bolt to 40–50Nm,
4. Fit the intercooler and radiator to the upper radiator
beam; fit 2 bolts and screws and tighten to 4–6Nm,
5. Fit the intercooler air intake hose to the intercooler,
8. Loosen 6 bolts (1) and 2 nuts (2) fixing the bumper
beam to the body.
6. Fit the intercooler air intake hose to the turbocharger,



1.0 260
Radiator Airflow Deflector - Upper Left Radiator Airflow Deflector - Lower Left
Remove Remove
1. Remove the front bumper assembly. 1. Remove the front bumper assembly.
Front Bumper Assembly Remove Front Bumper Assembly Remove

2. Remove 1 bolt (1) fixing the upper left radiator airflow 2. Remove 3 clips (2), (3) fixing the lower left radiator
deflector to the body. airflow deflector to the upper left radiator airflow
3. Remove 2 clips (2) fixing the upper left radiator airflow deflector and the upper radiator beam.
deflector to the lower left radiator airflow deflector.
3. Remove the upper left radiator airflow deflector from

4. Remove the upper left radiator airflow deflector from the vehicle.
the vehicle. Refit
Refit 1. Fit the lower left radiator airflow deflector to the
1. Fit the upper left radiator airflow deflector to the vehicle.
vehicle. 2. Fix the lower left radiator airflow deflector to the
2. Fix the upper left radiator airflow deflector to the lower upper left radiator airflow deflector and upper radiator
left radiator airflow deflector and tighten with clips. beam and tighten with clips.
3. Fix the upper left radiator airflow deflector to the body, 3. Fit the front bumper assembly.
fit 1 bolt, and tighten to 3–5Nm.
1.0 261
Radiator Airflow Deflector - Upper Right Radiator Airflow Deflector - Lower Right
Remove Remove

2. Unscrew 3 split pins fixing the air filter intake pipe and 2. Remove 3 clips (2), (3) fixing the right lower radiator
remove the air filter intake pipe. airflow deflector to the upper right radiator airflow
deflector and the upper radiator beam.
3. Remove the right lower radiator airflow deflector from
the vehicle.
Refit
1. Fit the lower right radiator airflow deflector to the
vehicle.
2. Fix the lower right radiator airflow deflector to the
upper right radiator airflow deflector and upper
radiator beam, and tighten with clips.
3. Remove 1 bolt (1) fixing the upper right radiator airflow

deflector to the body.
4. Remove 2 clips (2) fixing the upper right radiator airflow
deflector to the lower left radiator airflow deflector.

the vehicle.
Refit
1. Fit the upper right radiator airflow deflector to the
vehicle.
2. Fix the upper right radiator airflow deflector to the
lower right radiator airflow deflector and tighten with
clips.
body, fit 1 bolt, and tighten to 3–5Nm.
4. Fit the air filter intake pipe.
1.0 262
Transmission Outlet Hose clamp to the transmission.
Remove
1. Drain part of the transmission fluid.
3. Remove the battery box bracket.
4. Remove 1 clip (1) fixing the transmission outlet hose to
the radiator connector and disconnect the hose.
contamination.
7. Remove and discard the O-ring of the cooling hose.

8. Remove the transmission outlet hose from the vehicle.
Refit
1. Lubricate the new O-ring with clean transmission fluid
and fit it to the outlet cooling hose.
2. Insert the end of oil cooler pipe with pressure plate
into the corresponding interface of the transmission,
and insert the quick connector into the corresponding
interface of the radiator.
3. When inserting the transmission end, make sure that
5. Remove 1 bolt (2) fixing the transmission outlet hose the pipe is parallel with the interface, and press it into
to the transmission and disconnect the hose. the transmission with moderate force. After fitting the
quick connector of radiator oil cooler pipe, push the
dust cover to fit the connector of the radiator.
contamination.
4. Fix the transmission outlet hose clip to the transmission,
5. Fix the transmission outlet hose to the transmission, fit
1 bolt, tighten to 7–10Nm, and check the torque.
6. Fix the transmission outlet hose to the radiator
connector and secure with clips.
7. Fit the battery box bracket.
Battery Box Bracket Refit

8. Fit the coolant expansion tank.
Coolant Expansion Tank Refit

9. Add automatic transmission fluid.
6. Remove 1 bolt fixing the transmission outlet hose Transmission Fluid Check and Refill
1.0 263
Transmission Inlet Hose to the transmission.

Remove
1. Drain part of the transmission fluid.

4. Remove 1 clip (2) fixing the transmission inlet hose to
the radiator connector and disconnect the hose.

contamination.
7. Remove and discard the O-ring of the cooling hose.

8. Remove the transmission inlet hose from the vehicle.
Refit
1. Lubricate the new O-ring with clean transmission fluid.
2. Insert the end of oil cooler pipe with pressure plate
into the corresponding interface of the transmission,
and insert the quick connector into the corresponding
interface of the radiator.
3. When inserting the transmission end, make sure that
the pipe is parallel with the interface, and press it into
the transmission with moderate force. After fitting the
5. Remove 1 bolt (1) fixing the transmission inlet hose to quick connector of radiator oil cooler pipe, push the
the transmission and disconnect the hose. dust cover to fit the connector of the radiator.
4. Fix the transmission inlet hose clip to the transmission,
contamination.
5. Fix the transmission inlet hose to the transmission, fit 1
6. Fix the transmission inlet hose to the radiator
connector, fit the clip and secure it.

8. Fit the coolant expansion tank.
Coolant Expansion Tank Refit

9. Add automatic transmission fluid.
Transmission Fluid Check and Refill
6. Remove 1 bolt fixing the transmission inlet hose clamp
1.0 264
Thermostat 6. Release the clamp and disconnect the turbocharger
Remove water return pipe (3) from the thermostat cover.
1. Disconnect the battery negative. 7. Remove 3 bolts (1) fixing the thermostat cover to the
2. Drain the engine cooling system. thermostat housing.

3. Release the clamp and disconnect the engine water
outlet pipe (1) from the thermostat cover.
8. Remove the thermostat from the vehicle.

Refit
1. Fit the thermostat and ensure the seal ring is properly
fitted.
4. Release the clamp and disconnect the engine water
inlet pipe (1) from the thermostat cover. 2. Fix the the thermostat cover to the transmission
housing, fit 3 bolts, tighten to 9–11Nm, and check
the torque.
3. Connect the thermostat connector.
4. Fix the turbocharger water return pipe to the
thermostat cover and secure with clamps.
5. Fix the engine water inlet pipe to the thermostat cover
6. Fix the engine water outlet pipe to the thermostat
cover and secure with clamps.

5. Disconnect the connector (2) of the electronic
thermostat.
1.0 265
Clutch Water Pump

Remove
3. Remove the engine auxiliary drive belt.
Engine Auxiliary Drive Belt Remove

4. Remove the oil filter module assembly.
Oil Filter Module Remove

5. Remove 4 bolts securing the clutch water pump pulley
on the clutch water pump.
7. Remove the clutch water pump from the oil filter
module assembly.
Refit
1. Fit the clutch water pump to the oil filter module.
2. Fix the clutch water pump to the oil cooler module, fit
the harness bracket of clutch water pump connector, fit
6 bolts, tighten to 13.5–16.5Nm and check the torque.
3. Fit the oil filter module.
Oil Filter Module Refit
4. Secure the clutch water pump pulley on the clutch
water pump, fit 4 bolts, tighten to 7.5-10.4Nm and
check the torque.
6. Remove 6 bolts securing the clutch water pump on the 5. Refit the engine auxiliary drive belt.
oil cooler module and remove the harness bracket of
Engine Auxiliary Drive Belt Refit
the clutch water pump connector.

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Electronic Auxiliary Pump
Remove
4. Remove the battery.
Battery Remove
5. Disconnect the connector (1) of electronic auxiliary
water pump.
6. Release the clamp and disconnect the heater core water
inlet pipe from the electronic auxiliary water pump (3). Refit
7. Release the clamp and disconnect the turbocharger 1. Fix the electronic auxiliary water pump and its bracket
water inlet pipe from the electronic auxiliary water to the cylinder head, fit 2 bolts, tighten to 9–11Nm,
pump (2). and check the torque.
2. Connect the turbocharger water inlet pipe and the
electronic auxiliary water pump and tighten with
clamps.
3. Connect the heater core water inlet pipe and the
electronic auxiliary water pump and tighten with
clamps.
4. Connect the connector of electronic auxiliary water
pump.
5. Fit the battery.
Battery Refit

8. Remove 2 bolts securing the electronic auxiliary water
pump to the engine and remove the electronic auxiliary 7. Fit the engine hood.
water pump. 8. Connect the battery negative.
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Service Procedures-1.5T to keep the level just below the neck of the expansion
Coolant - Drain and Refill tank. When the coolant level reaches the neck of the
Drain expansion tank due to thermal expansion, screw the
expansion tank cap.
1. Remove the expansion tank cap.
6. Continuously run the engine at the speed of 1500~2500
RPM until the cooling fan operates, and then run the
engine at idle speed until the cooling fan stops.
7. Turn off the engine and cool it down for 30 minutes.
8. Check the cooling system for leakage.
9. Check the level of coolant whether it is between MIN
and MAX. If not, open the expansion tank cap and fill
the tank up with coolant or drain the coolant to MAX
as required.
2. Secure a proper container to collect the coolant.

3. Raise the vehicle on an elevator.
4. Open the drain valve at the bottom of the engine
cooling system radiator.

Refill
1. Close the coolant drain valve at the bottom of the
radiator.
2. Prepare the coolant of specified concentration.
Fluid
3. Open the expansion tank cap. Refill coolant to the
expansion tank until the coolant reaches the expansion
tank neck and keeps still.
4. Ensure that the air conditioner is turned off.
5. Start the engine and allow it to operate at the speed of
1500~2500 RPM. Refill the expansion tank as required
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Expansion Tank Cap - Pressure Test 6. Pressurize the expansion tank cap slowly to the
Check specified pressure, then check the pressure, if the
1. Visually check the expansion tank for signs of leakage. pressure range is maintained within 140-160KPa, the
expansion tank lid is normal.
the attachment strength of pipeline connection. 7. Release pressure through the relief valve on the
pressurizer.
8. Remove the T14001 pressure hose fromTEN00010.

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

TEN00010.
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System Pressure Test

Check
the attachment strength of pipeline connection.
8. Disconnect the T14001 hose from TEN00015.

9. Remove the TEN00015 from the expansion tank and
fit the expansion tank cap.
3. Fit the TEN00015 to the expansion tank.

4. Connect the T14001 pressure hose to the
TEN00015.
5. Pressurize the system to the pressure of 140-160KPa
slowly and check it for leakage.
Warning: Do not exceed the setting pressure value, or the

cooling system will be damaged.
6. Visually check the engine and the cooling system for

signs of coolant leakage.
7. Release pressure through the relief valve on the
T14001.
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Coolant Expansion Tank 7. Clamp the expansion tank with a water pipe clamp to
Remove prevent loss of coolant.
1. Open the coolant expansion tank cap. 8. Remove the coolant expansion tank from the vehicle.
Refit
1. Fix the cooling system overflow pipe to the expansion
tank, and fix with clamps.
2. Fit the expansion tank outlet port to coolant expansion
3. Fit the engine overflow pipe to the coolant expansion
tank and fix with clamps.
4. Fix the coolant expansion tank to the vehicle frame, fit
2 bolts, and tighten to 4–6Nm.
5. Supplement the coolant to standard level
6. Fit the coolant expansion tank cap.
2. Remove 2 bolts fixing the coolant expansion tank to

the vehicle frame.
3. Place a proper container to collect the coolant

overflowing from the expansion tank.
4. Loosen the clamp and disconnect engine overflow hose
(1).
5. Loosen the clamp and disconnect the expansion tank
outlet pipe (2).
6. Loosen the clamp and disconnect the cooling system
overflow pipe (3).
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Radiator Inlet Pipe Radiator Outlet Pipe

Remove Remove

2. Loosen the clamp, and disconnect the radiator water 2. Remove the 2 bolts fixing the coolant expansion tank
inlet (1) pipe from the radiator. to the vehicle frame and the expansion tank.
inlet pipe (2) from the thermostat housing and remove
the radiator water inlet pipe.

outlet hose from the radiator.
Refit
1. Connect the radiator water inlet pipe to the thermostat
hard pipe, and fix it with clamps.
2. Connect the radiator water inlet pipe to the radiator,

outlet hose from the thermostat housing assembly.
5. Remove the radiator water outlet pipe from the vehicle.
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Refit Heater Water Inlet Pipe
1. Connect the thermostat water outlet pipe to the Remove
thermostat housing assembly and fix it with clamps. 1. Drain the engine cooling system.
2. Connect the radiator water inlet pipe to the radiator Cooling System Drain
2. Remove the electronic throttle intake pipe.
3. Fix the coolant expansion tank to the vehicle frame;
fit two bolts and tighten to 4–6Nm, then check the Electronic Throttle Intake Pipe Remove
torque. 3. Loosen the clamp and disconnect the heater core water
4. Fill the engine cooling system. inlet pipe from the heater core (1).

inlet pipe from the engine (3).
5. Remove the heater core water inlet pipe from the

vehicle.
Refit
1. Fit the heater core water inlet pipe to the vehicle.
2. Fit the heater core water inlet pipe to engine, and fix
with clamp.
3. Fit the heater core water inlet pipe to the heater core,
and fix with clamp.

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Heater Water Outlet Hose 6. Remove the heater core water outlet pipe from the
Remove vehicle.
1. Drain the engine cooling system. Refit
Cooling System Drain 1. Fit the heater core water outlet pipe to the vehicle.
2. Remove the electronic throttle intake pipe. 2. Fit the heater core water outlet pipe to the expansion
Electronic Throttle Intake Pipe Remove
3. Fit the heater core water outlet pipe to the engine,
and fix with clamps.
outlet pipe from the heater core (2).
4. Fit the heater core water outlet pipe to the heater
core, and fix with clamps.


outlet pipe from the engine (4).

outlet pipe from the expansion tank (2).
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Engine Overflow Pipe Radiator Overflow Pipe
Remove Remove
1. Loosen the clamp and disconnect the connection (1) 1. Loosen the clamp, disconnect the connection (2)
between the radiator overflow pipe and the engine. between the radiator overflow pipe from the radiator.
2. Loosen the clamp and disconnect the connection (2) 2. Loosen the clamp, disconnect the connection (1)
between the radiator overflow pipe and the expansion between the radiator overflow pipe from the expansion
tank. tank .
3. Remove the engine overflow pipe from the vehicle. 3. Remove the radiator overflow pipe from the vehicle.
Refit Refit
1. Fit the radiator overflow pipe to the vehicle. 1. Fit the radiator overflow pipe to the vehicle.
2. Connect the radiator overflow pipe to the radiator and 2. Connect the radiator overflow pipe to the expansion
fix it with clamps. tank, and fix it with clamps.
3. Connect the radiator overflow pipe to the expansion 3. Connect the radiator overflow pipe to the radiator,
tank and fix it with clamps. and fix it with clamps.
4. Check the expansion tank coolant.
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Cooling Fan Assembly 7. Move the cooling fan assembly slowly in the engine
Remove compartment and remove it from the vehicle.
1. Disconnect the battery negative. Refit
2. Disconnect the connector of the cooling fan low speed 1. Fit the fan assembly to the vehicle.
resistor. 2. Lower the vehicle.
3. Fix the cooling fan to the slot of the upper radiator
beam; fit 2 screws, tighten to 4.5-5Nm, and check
the torque.
4. Fix the front bumper beam and upper radiator beam

6. Disconnect the connector of the cooling fan low speed
resistor.

4. Loose 6 bolt (1) and 2 nuts (2) fixing the front
anti-collision beam.
5. Release 2 bolts and 2 lock latches fixing the cooling fan

assembly to the upper radiator beam.
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Coolant Fan Low Speed Resistor Radiator Assembly
Remove Remove
Warning: Disconnect the battery to prevent operation of 1. Disconnect the battery negative.
the cooling fan, which could cause personal injury. 2. Drain the engine cooling system.
Expansion Tank Remove
3. Remove 1 screw securing the resistor on the wind
scooper to remove the resistor.
4. Measure about 5 cm lead at resistor end and cut the
resistor off the lead. 5. Loosen the clamp, and disconnect the radiator water
outlet pipe.
5. After cutting off the resistor, remove about 7 mm
insulation respectively from both ends of the remaining 6. Loosen the clamp, and disconnect the radiator water
lead. inlet pipe.
Refit 7. Remove the cooling fan assembly.
1. Take a resistor to be fitted and cover the heat-shrink Cooling Fan Assembly Remove
tube on the lead of resistance. 8. Remove the upper radiator beam.
2. Insert the metal part of the lead whose insulation
has been removed into the double end connector
connected to the lead of the resistance to be fitted, and 9. Remove the condenser from the radiator slot.
impact it with the terminal clamp in T84001, taking the 10. Remove the radiator assembly from the vehicle.
standard of at least 10 kg tension of the joint without Refit
loosing. 1. Fit the radiator to the vehicle.
3. Cover the heat-shrink tube on the double end
2. Fit the condenser into the radiator groove.
connector and heat it with proper heat supply to shrink
3. Fit the upper radiator beam.
and agglutinate it with the lead.
4. Fix the resistor to the wind scooper with 1 self-tapping Upper Radiator Beam Refit
screw, fix the wire with tapes and ensure the wire and 4. Fit the cooling fan assembly.
the serpentuator bushing will not move or interfere
with the vane or cause any other interference.
5. Fit the radiator water inlet pipe.
6. Fit the radiator water outlet pipe.
6. After replacement, connect the battery negative and
start the engine to check the fan operation. If there is
no high humming when the fan is running, resume the 8. Fit the coolant expansion tank.
low speed operating condition. Coolant Expansion Tank Refit
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1.5T Intercooler
Remove


5. Loosen the clamps, and disconnect the air intake hose
from the intercooler.
8. Loosen 6 bolts (1) and 2 nuts (2) fixing the bumper
beam to the body.
6. Loosen the clamps, and disconnect the air outlet hose

from the intercooler (3).
10. Remove the intercooler from the slot of the upper
radiator beam and take out from the vehicle.
Refit
1. Fit the intercooler into the slot of upper radiator beam.
3. Tighten the front anti-collision beam bolt to 40–50Nm,
4. Fit the intercooler and the radiator to the upper
radiator beam; fit 2 bolts and screws and tighten to
5. Fit the intercooler air intake hose to the intercooler,
7. Remove 2 bolts and 2 screws connecting the upper and fix it with clamps.
radiator beam with radiator and intercooler. 6. Fit the intercooler air intake hose to the turbocharger,
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10. Connect the battery negative. Radiator Airflow Deflector - Upper Left
Remove

2. Remove 1 bolt (1) fixing the upper left radiator airflow
3. Remove 2 clips (2) fixing the upper left radiator airflow
deflector onto the lower left radiator airflow deflector.

the vehicle.
Refit
1. Fit the upper left radiator airflow deflector to the
vehicle.
2. Fix the upper left radiator airflow deflector to the lower
left radiator airflow deflector and tighten with clips.
3. Fix the upper left radiator airflow deflector to the body,
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Radiator Airflow Deflector - Lower Left Radiator Airflow Deflector - Upper Right
Remove Remove

2. Remove 3 clips (2), (3) fixing the lower left radiator 2. Unscrew 3 split pins fixing the air filter intake pipe and
airflow deflector to the upper left radiator airflow remove the air filter intake pipe.

3. Remove the upper left radiator airflow deflector from deflector to the body.
the vehicle. 4. Remove 2 clips (2) fixing the upper right radiator airflow
Refit deflector to the lower left radiator airflow deflector.
1. Fit the lower left radiator airflow deflector to the
vehicle.
2. Fix the lower left radiator airflow deflector to the
upper left radiator airflow deflector and upper radiator
beam and tighten with clips.

the vehicle.
Refit
1. Fit the upper right radiator airflow deflector to the
vehicle.
lower right radiator airflow deflector and tighten with
clips.
4. Fit the air filter intake pipe.
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Radiator Airflow Deflector - Lower Right Thermostat
Remove Remove
1. Remove the front bumper assembly. 1. If it is the electronic thermostat, disconnect the battery
negative.
2. Remove 3 clips (2), (3) fixing the lower right radiator
airflow deflector to the upper right radiator airflow Engine Cooling System Drain
deflector and the upper radiator beam. 3. Remove the bottom deflector.

4. If it is the electronic thermostat, disconnect its
connector.
outlet pipe from the thermostat.
6. Remove 2 bolts fixing the thermostat housing to the
water pump.
7. Remove the thermostat, and discard the gasket.
3. Remove the lower right radiator airflow deflector from

the vehicle.
Refit
1. Fit the lower right radiator airflow deflector to the
vehicle.
2. Fix the lower right radiator airflow deflector to the
upper right radiator airflow deflector and upper
radiator beam, and tighten with clips.
Refit
1. Clean the mating surface between the thermostat
and water pump, and ensure that there is no foreign
material.
2. Fit a new gasket, fix the thermostat to the water pump,
fit 2 bolts, tighten to 8-12Nm, and check the torque.
3. Connect the radiator water outlet pipe to the
thermostat, and fix it with clamps.
4. If it is the electronic thermostat, connect its connector.

7. If it is the electronic thermostat, connect the battery
negative.
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Mechanical Water Pump

Remove

Engine Oil Drain

4. Remove the oil cooler.
Oil Cooler Remove

5. Remove the turbocharger water inlet pipe. 12. Remove 2 bolts fixing the water pump to the engine,
Turbocharger Water Inlet Pipe Remove remove the water pump, and discard the sealing gasket.
6. Loosen the clamp, and disconnect the bypass pipe (3)

from the water outlet assembly.
7. Loosen the clamp, and disconnect the bypass pipe from
the turbocharger water return pipe (1).
8. Remove 2 bolts (2) fixing the bypass pipe to the water
pump.
Refit
1. Clean the junction surface between the water pump
and the alternator, and ensure that there is no foreign
material.
2. Fix the water pump to the engine, fit 2 bolts, tighten to
3. Connect the hose to the thermostat housing and fix
9. Remove 1 bolt fixing the bypass pipe to the engine,
it with clamps.
remove the bypass pipe, and discard the sealing gasket.
4. Connect the electronic thermostat connector, and fix
10. Disconnect the electronic thermostat connector (2),
the harness.
remove the harness staple bolt (3), and remove the
harness. 5. Fit a new gasket; fix the bypass pipe to the water pump,
fit 2 bolts, tighten to 8-12Nm and check the torque.
11. Loosen the clamp, and disconnect the hose from the
thermostat housing (1). 6. Fix the bypass pipe to the engine; fit 1 bolt, tighten
to8-12Nm and check the torque.
7. Connect the bypass pipe to the water outlet assembly,
8. Connect the bypass pipe to the turbocharger water
return pipe, and fix it with clamps.
9. Fit the turbocharger water inlet pipe.
Turbocharger Water Inlet Pipe Refit
10. Fit the oil cooler.
Oil Cooler Refit
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Engine Oil Refill

12. Refit the engine auxiliary drive belt.
Engine Auxiliary Drive Belt Refit
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Special Tools
Number
Pressure test
TEN00010
connector, cap
Cooling system
T14001
pressure test kit
Pressure test
TEN00015 connector,
cooling system
Harness repair
T84001
kit
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Engine Fuel & Management System Engine
Engine Fuel & Management System
Specifications
Torque
Description Value
Fuel tank unit locking ring 75–85Nm
Bolt - fuel tank strap 22–28Nm
Bolt - fuel filler to body 5–7Nm
Nut - fuel filter to filter support bracket 7–10Nm
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Engine Engine Fuel & Management System

System Layout
Fuel System Layout - 2WD
1. Fuel Cap 5. Filter

2. Fuel Filler Pipe 6. Fuel Tank
3. Canister 7. Underfloor Fuel Pipe
4. Fuel Pump 8. Fuel Tank Strap
Fuel System Layout - AWD
1. Fuel Cap 6. Filter

2. Fuel Filler Pipe 7. Fuel Tank
3. Canister 8. Fuel Tank Strap
4. Primary Fuel Pump 9. Underfloor Fuel Pipe Assembly
5. Secondary Fuel Pump 10. Fuel Tank Heat Shield
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Description pump is located in the fuel tank, which soaks in the fuel and
Fuel System applies fuel to dissipate heat and lubricate. The battery supplies
power for the electric fuel pump via the fuel pump relay which
Fuel system is a loop-free and multi-point injection system
connects the electric fuel pump only when the power is on and
which is equipped with electromechanical fuel injectors. The
the engine operates. When the engine stops due to accident,
fuel drawn from the fuel tank is delivered to the fuel filter
the fuel pump will stop automatically.
outside the fuel tank. Then, the fuel is transmitted to the
engine high-pressure fuel pump through a single fuel pipe. Evaporative Emission System
ECM communicates with the following components of the fuel The evaporative emission system prevents the fuel evaporative
system: emission from entering into the air. The system contains a
canister filled with activated carbon particles, when the vehicle
• Fuel Pump is not in use, it can absorb hydrocarbon vapors. The canister
• Fuel Level Sensing Unit is near the left rear wheel. The pipeline connects to the fuel
• Canister Control Valve tank (air space above the fuel) and the canister. The capacity
of the canister pipe is limited, therefore, when the engine is
The fuel tank includes a fuel level sensing unit connected with
running, purification is achieved by sucking the fuel vapor into
the IPK. The instrument pack uses hybrid algorithm to measure
the cylinder. A pipe connects to the canister and the intake
the fuel in the fuel tank accurately.
manifold via the canister control valve. During ventilation, a
Electric Fuel Pump pipe is connected to the canister.
The electric fuel pump transfers the fuel from fuel tank to the
engine and provides sufficient fuel pressure and fuel. The fuel
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Service Procedures Underfloor Fuel Pipe - 2.0T

Canister Remove
Remove 1. Disconnect the battery negative cable.
1. Raise the vehicle on a lift. Warning: Fuel vapour is highly flammable and in confined
2. Pull the canister up from the fuel tank, and take away spaces is also explosive and toxic. Always have a fire
the canister (1). extinguisher containing foam, CO2, gas or powder close
2. Release the pressure of fuel system.
Fuel System - Pressure Release
3. Disconnect the canister breather hose from the
3. Disconnect the vent hose (2) from the canister.

4. Disconnect the fuel tank hose (3) from the canister.
5. Disconnect the canister solenoid valve hose (4) from
the canister.
6. Remove the canister. 4. Raise the vehicle on a lift.
Caution: Always fit plugs to open connections to prevent 5. Disconnect the rubber fuel pipe and fuel inlet hose.
contamination.
Refit
1. Make sure all hose connections are clean.
2. Connect the fuel tank hose, canister solenoid hose and
vent hose to the canister.
3. Fit the canister to the fuel tank groove.
6. Disconnect the fuel pipe under the floor from the

canister.
7. Disconnect the fuel pipe under the floor from the filter.
8. Loosen the clip fixing the underfloor fuel pipe assembly
to the underbody.
9. Remove the underfloor fuel pipe assembly.
Refit
1. Fix the underfloor fuel pipe to the underbody.
2. Fit the clip of the underfloor fuel pipe.
3. Connect the underfloor fuel pipe and fuel filter.
4. Connect the underfloor fuel pipe and and canister.
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5. Connect the fuel inlet hose to the rubber fuel pipe. Underfloor Fuel Pipe-1.5T
6. Lower the vehicle. Remove
7. Connect the canister vent hose to the canister solenoid. 1. Disconnect the battery negative cable.
8. Connect the battery cable. Warning: Fuel vapour is highly flammable and in confined
2. Release the pressure of the fuel system.
3. Disconnect the connector (2) of the solenoid valve.
4. Disconnect the connection (1) between carbon
breathing hose and the canister solenoid.
5. Disconnect the fuel inlet hose from the high pressure

fuel pump.

7. Disconnect the connector (4) between fuel pipe and
carbon tank.
1.0 289
7. Connect the canister solenoid valve connector.

8. Connect the fuel inlet hose to the high-pressure fuel
pump.
8. Disconnect the fuel pipe from the fuel filter.
9. Loosen clamp fixing the underfloor fuel pipe assembly

to the underbody and remove it.
Refit
1. Fix the underfloor fuel pipe to chassis, and secure with
clamp.
2. Connect the fuel pipe and the filter.
3. Connect the fuel pipe and the fuel filter.
4. Connect the fuel pipe and the canister.
6. Connect the canister breathing hose to the canister
solenoid.
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Rubber Fuel Pipe Fuel Tank Heat Shield - AWD
Remove Remove
1. Disconnect the battery negative cable. 1. Lift the vehicle.
Warning: Fuel vapour is highly flammable and in confined 2. Remove the front exhaust pipe.
spaces is also explosive and toxic. Always have a fire Front Exhaust Pipe - Remove
3. Remove the drive shaft.
Drive Shaft - Remove
4. Remove screws securing the heat shield to the fuel tank.
3. Remove the clip on the fuel pipe bracket.
4. Disconnect the rubber fuel pipe and engine
6. Release the clip fixing the fuel pipe under the floor and
rubber fuel pipe.
5. Remove the fuel tank heat shield.
7. Disconnect the rubber fuel pipe and fuel inlet hose.

8. Remove the rubber fuel pipe.
Refit
1. Connect the rubber fuel pipe and fuel inlet hose.
2. Fit the clips fixing the underfloor fuel pipeline and
rubber fuel pipe.
Refit
4. Connect the rubber fuel pipe and engine high-pressure
oil pump. 1. Fit the heat shield to the fuel tank.
5. Fit the clips fixed on the fuel pipe bracket. 2. Refit the drive shaft.
6. Connect the battery cable. Drive Shaft Refit


1.0 291
Fuel Tank - 2WD

Remove

3. Drain the fuel system.
Fuel Tank - Drain

4. Remove the canister.
11. Remove the fuel tank. Remove the fuel pump first if
Canister Remove
necessary.
5. Loosen and discard clamps between the fuel tank filling
a. Release and remove the lock ring of the fuel pump
hose and the fuel tank, and take away the hose.
with the T18007.
Warning: The spilling of fuel is unavoidable during this
b. Take out the fuel pump unit with care and discard
operation. Ensure that all necessary precautions are
the seal.
taken to prevent fire and explosion.
6. Support the fuel tank securely. Refit
7. Remove 4 bolts fixing the steel strip of the fuel tank to 1. Fit a new seal to fuel tank and fit fuel pump, and take
the body, and take away the steel strip. Lower the fuel care not to damage the seal.
tank to access the top of the fuel tank. 2. Fit fuel pump lock ring with T18007, and tighten it to
75–85Nm.
3. Support the fuel tank securely with assistance.
4. Connect it to the connector of the fuel pump.
5. Connect the fuel supply pipe and fuel return pipe
between the fuel pump and the fuel filter.
6. Lift the fuel tank.
Caution: Take care not to trap any pipes or cables when

fitting fuel tank.
7. Raise the fuel tank assembly with a lift to the place

beneath the floor of the vehicle body seat, align the
steel strip fitting hole end to the vehicle welding nut
hole, fit with the fitting bolt and tighten it to 22–28Nm.
8. Lower the fuel tank.
8. Connect fuel filler pipe to the fuel tank, fit the hose
9. Disconnect the fuel supply pipe (1) and return pipe (2) connecting the fuel filler pipe and the fuel tank and
between the fuel pump and the fuel filter from the fuel secure it with new clamps.
pump.
9. Connect the fuel supply pipe and fuel return pipe
10. Disconnect the connector (3) of fuel pump. between the fuel pump and the fuel filter.
10. Fit the canister.
Canister Refit
12. Refill the fuel tank.
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Fuel Tank - AWD 9. Lower the fuel tank.
Remove 10. Disconnect the fuel supply pipe (1) and the fuel return
1. Disconnect the battery negative cable. pipe (2) connecting the fuel pump and the fuel filter
Warning: Fuel vapour is highly flammable and in confined from the fuel pump.
spaces is also explosive and toxic. Always have a fire 11. Disconnect the connector (3) of fuel pump.
Fuel System - Pressure Relief - 2.0T
Fuel System - Pressure Relief - SGE 1.5T
3. Drain the fuel system.
Fuel Tank - Drain
4. Remove the fuel tank heat shield.
Fuel Tank Heat Shield Remove
5. Remove the canister.
Canister - Remove
6. Loosen and discard the clamp securing the fuel filler
hose to the fuel tank, and take away the hose. 12. Remove the fuel tank. Remove the fuel pump first if
necessary.
a. Release and remove the lock ring of fuel pump with
T18007.
b. Take out the fuel pump unit with care and discard
the seal.
Refit
1. Fit a new seal to fuel tank and fit fuel pump, be careful
not to damage the seal.
2. Refit the fuel pump lock ring with T18007, and tighten
it to 75–85Nm.
3. Support the fuel tank securely with assistance.
Warning: The spilling of fuel is unavoidable during this 4. Connect it to the fuel pump connector.
operation. Ensure that all necessary precautions are 5. Connect the fuel supply pipe and return pipe between
taken to prevent fire and explosion. fuel pump and fuel filter.
7. Support the fuel tank securely. 6. Raise fuel tank.
8. Remove 4 bolts fixing the steel strap of the fuel tank to Caution: Take care not to trap any pipes or cables when
the body, and take away the steel strap. Lower the fuel fitting fuel tank.
tank to access the top of the fuel tank.
7. Raise the fuel tank assembly with a lifter to the place
beneath the floor of the vehicle body seat, align the
steel strap fitting hole end to the vehicle welding nut
hole, fit with the fitting bolt and tighten it to 22–28Nm.
8. Connect fuel filler pipe to fuel tank, fit the hose
connecting fuel filler pipe to fuel tank and secure it with
new clamps.
9. Fit Canister.
Canister Refit
10. Fit the fuel tank heat shield.
Fuel Tank Heat Shield Refit
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12. Fill the fuel tank. Fuel Pump - 2WD

13. Connect the battery negative cable. Remove


Fuel System - Pressure Relief

3. Remove the left rear seat.
Rear Seat - Remove
4. Pry the closing plate open with a screwdriver.

5. Cover the surrounding areas to prevent the overflow
of fuel.
6. Release the fuel supply pipe (1) and fuel return pipe (2)
from the fuel pump.
7. Disconnect the connector (3) of the fuel pump.
Caution: Before disconnecting any part of the fuel

system, it is imperative that all dust, dirt and debris is
removed from around components to prevent ingress of
foreign matter into fuel system.
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Warning: The spilling of fuel is unavoidable during this Fuel Pump - AWD
operation. Ensure that all necessary precautions are Remove
taken to prevent fire and explosion. 1. Disconnect the battery negative cable.
8. Release and remove the lock ring of fuel pump with Warning: Fuel vapour is highly flammable and in confined
T18007. spaces is also explosive and toxic. Always have a fire
9. Take out the fuel pump unit with care and discard the extinguisher containing foam, CO2, gas or powder close
seal. Warning: The spilling of fuel is unavoidable during this
Refit operation. Ensure that all necessary precautions are
1. Fit a new seal to the fuel tank and fit the fuel pump. taken to prevent fire and explosion.
Take care not to damage the seal. 2. Release the pressure of the fuel system.
2. Fit the fuel pump lock ring with T18007, and tighten it Fuel System - Pressure Relief
to 75–85Nm. 3. Remove the left rear seat.
Caution: Verify that the triangle mark on fuel pump is Rear Seat - Remove
aligned with the mark (three parallel line segments) on 4. Pry the closing plate open with a screwdriver.
fuel tank, and that the outer two line segments are not 5. Cover the surrounding areas to prevent the overflow
exceeded. of fuel.
6. Release the fuel supply pipe (1) and fuel return pipe(2)
from primary fuel pump.
7. Disconnect the connector of primary fuel pump (3).
8. Release and remove the lock ring of primary fuel pump
with T18007.
3. Connect the fuel supply pipe and fuel return pipe to 9. Take out the primary fuel pump unit with care and
the fuel pump connector. discard the seal.
4. Connect the connector of fuel pump. 10. Remove right rear seat.
5. Stick the closing plate with glue. Rear Seat - Remove
6. Recover the sound-proof material and carpet to original 11. Pry the closing plate open with a screwdriver.
location.
12. Cover the surrounding areas to prevent the overflow
7. Fit the rear seat. of fuel.
Rear Seat Refit 13. Release the fuel supply pipe (1) and fuel return pipe(2)
8. Connect the battery negative cable. from secondary fuel pump.
14. Disconnect the connector (3) of secondary fuel pump.
15. Release and remove the lock ring of secondary fuel
pump with T18007.
16. Take out the secondary fuel pump unit with care and
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discard the seal. Fuel System - Pressure Release - 2.0T

Refit Check
1. Fit a new seal to the fuel tank and fit the primary and 1. Release the fuel filler cap to release the vapor pressure
secondary fuel pump. Take care not to damage the seal. of the fuel tank.
2. Refit the fuel pump lock ring with T18007, and tighten Warning: Fuel vapour is highly flammable and in confined
it to 75–85Nm. spaces is also explosive and toxic. Always have a fire
Caution: Verify that the triangle mark on fuel pump is extinguisher containing foam, CO2, gas or powder close
aligned with the mark (three parallel line segments) on 2. Remove the fuel pump fuse from the engine
fuel tank, and that the outer two line segments are not compartment fuse box.
exceeded. 3. Place the ignition switch in "ON" position, and keep the
engine at idle mode until the engine stalls.
4. Place the ignition switch in "OFF" position, and restart
the engine with the ignition key (10 seconds), then
confirm if there is any fuel.
5. Secure the fuel filler cap.
3. Connect the fuel supply pipe and fuel return pipe to the
primary and secondary fuel pump connector.
4. Connect the connector of primary and secondary fuel
pump.
5. Stick the closing plate with glue.
6. Recover the sound-proof material and carpet to original
location.
7. Fit the rear seat.
Rear Seat Refit

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Fuel System - Pressure Release-1.5T Fuel System - Pressure Test - 2.0T
Check Check
1. Release the fuel filler cap to release the steam pressure 1. Place an absorptive cloth around the high-pressure fuel
in the fuel tank. pump, low-pressure fuel pipe and the interface of the
underfloor fuel pipe to collect the spilled fuel.
spaces is also explosive and toxic. Always have a fire Warning: Fuel vapour is highly flammable and in confined
extinguisher containing foam, CO2, gas or powder close spaces is also explosive and toxic. Always have a fire
2. Remove fuel pump fuse from the engine compartment extinguisher containing foam, CO2, gas or powder close
fuse box. Warning: The spilling of fuel is unavoidable during this
3. Place the ignition switch to ON position and keep the operation. Ensure that all necessary precautions are
engine idle until the engine stops. taken to prevent fire and explosion.
4. Place the ignition switch to OFF position, start the 2. Disconnect the high-pressure fuel pump, low-pressure
engine with the ignition key and keep for 10s to confirm fuel pipe and fuel supply pipe.
that the engine has no fuel.
5. Fix the fuel filler cap.
3. Connect the connector of the high-pressure fuel pump,

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

observe the readings on the fuel pressure gauge within
1 minute, if the readings are within the range of 5.3-6
bar, the fuel system is in normal state.
6. Stop the engine to disenable the fuel pump, if the
system pressure is below 3 bar after 20 minutes, there
is something wrong with the pressure maintaining
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performance of the system. In this case, check if the Fuel System - Pressure Test - 1.5T
pressure regulating valve of the fuel pump can work Check
properly. 1. Place cloths with strong absorptivity around the joint
7. Disconnect the high-pressure fuel pump, low-pressure of high-pressure fuel pump low-pressure fuel pipe and
fuel pipe and fuel supply pipe from the TCH00106. underfloor fuel pipe to collect the overflowing fuel.
8. Drain the fuel residue in the tool into the container. Warning: Fuel vapour is highly flammable and in confined
9. Connect the high-pressure fuel pump, low-pressure fuel spaces is also explosive and toxic. Always have a fire
pipe and fuel supply pipe. extinguisher containing foam, CO2, gas or powder close

2. Disconnect the high-pressure fuel pump low-pressure
fuel pipe from fuel supply pipe.
3. Respectively connect the high-pressure fuel pump
low-pressure fuel pipe and underfloor fuel pipe to the
master cylinder of TCH00107.
4. Fix TCH00107 to the fuel pressure gauge T18002.
5. Start the engine to allow the fuel pump to work,

observe the readings on the fuel pressure gauge within
a minute, if the readings are in the range of 5.3-6 bar, it
indicates that the fuel system is normal.
6. Stop the engine to make the fuel pump not run, if the
system pressure declines below 3 bar after 20 minutes,
it indicates that there is something wrong with system
pressure maintaining, so check the pressure regulating
valve of fuel pump for normal operation.
7. Respectively disconnect the high-pressure fuel pump
low-pressure fuel pipe and fuel supply pipe from
TCH00107.
8. Drain the remaining fuel in the tool to the container.
9. Connect the high-pressure fuel pump low-pressure fuel
pipe to fuel supply pipe.
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Fuel Tank - Drain Fuel Tank Filler Pipe
Drain and Refill Remove
Warning: The capacity of containers must be more than 1. Disconnect the battery negative cable.
adequate for the amount of fuel to be extracted or
drained. The container should be clearly marked with its
contents and placed in a safe storage area which meets
the requirements of local authority regulation.
2. Drain the fuel tank.
Warning: Proper fuel recovery equipment must be used,
Fuel Tank - Drain
and make sure the necessary protective measures have
taken to prevent fire and explosion. 3. Pull the fuel filler flap release handle under the
1. Remove the fuel filler cap from the fuel filler port. instrument panel at the driver side to open the fuel
filler flap.
2. With a fuel recovery device, drain the fuel into a sealed
container from the fuel tank. 4. Open the fuel tank filler cap.
5. Remove 3 bolts fixing the fuel tank filler to the body.
3. Please follow the manufacturer's instructions on the

connection and safe use of the fuel recovery device. 6. Remove the rear wheel house liner.
Warning: The capacity of containers must be more than Rear Wheel House Liner - Remove
adequate for the amount of fuel to be extracted or 7. Remove the muffler heat shield.
drained. The container should be clearly marked with its
contents and placed in a safe storage area which meets Rear Muffler Heat Shield - Remove
the requirements of local authority regulation. 8. Remove 2 nuts and 2 bolts fixing the fuel filling pipe
4. Refill the fuel tank. to the body.
9. Disconnect the canister vent hose.

10. Loosen and discard clamps between the fuel tank filling
hose and the fuel tank.
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Fuel Filter
Remove
Fuel System - Pressure Relief
4. Disconnect the connector of the fuel filter inlet pipe
and fuel return pipe from the fuel filter.
11. Remove the fuel tank filler pipe assembly.

Refit
1. Locate the fuel filling pipe, connect the fuel filling pipe
to the hose between the fuel filling pipe and the fuel
tank, and secure with clamps.
2. Connect the canister vent hose.
3. Fit 2 bolts and 2 nuts securing the fuel filling pipe to the
body, and tighten to 5–7Nm respectively.
4. Fit the head of the fuel filling pipe assembly to the oil
filler slot. Caution: Always fit plugs to open connections to prevent
contamination.
5. Fit the muffler heat shield.
Rear Muffler Heat Shield - Refit
6. Fit the rear wheel house liner.
Rear Wheel House Liner - Refit 5. Release 2 nuts securing the fuel filter bracket to remove
7. Fit 3 bolts fixing the fuel filler to the body, and tighten the fuel filter assembly.
to 5–7Nm. Refit
8. Refill the fuel tank. 1. Locate the ground terminal.
9. Fit the fuel tank filler cap. 2. Tighten 2 nuts of the fuel filter bracket to 7–10Nm.
10. Close the fuel filler flap. 3. Connect the connector of the oil inlet/return pipes to
11. Connect the battery negative cable. the fuel filter.
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Special Tools
Number
Wrench fuel
T18007
tank lock ring
Three-way pipe
TCH00106 of fuel pressure
gauge
Fuel pressure
T18002
test equipment
Three-way pipe
TCH00107 of fuel pressure
gauge
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Engine Engine Control System-2.0T
Engine Control System-2.0T

Specifications
Torque
Description Value
Spark plugs 15-20Nm
Bolt-Ignition coil 7-10Nm
nuts -ECM to body 7–10Nm
ECT sensor 14–18Nm
Bolt-CMP sensor to camshaft cover 9–11Nm
Oil pressure switch 14–18Nm
Screw-MAF to air dust 1.4–1.8Nm
Bolt -high fuel bump to camshaft cover 9-11Nm
Nut -low fuel line to high fuel bump 20-24Nm
Nut -high fuel line to high fuel bump 26-34Nm
Nut -high fuel line to fuel rail 26–34Nm
fuel rail pressure senso 30–35Nm
Bolt-CKP sensor 9–11Nm
Screw-MAP sensor to throttlebody inlet pipe 5–7Nm
Screw-T MAP sensor 5–7Nm
Bolt-Knock sensor 15–25Nm
Heated oxygen sensor 45–60Nm
Screw-turbocharger valve to bracket 2.5–3.5Nm
Bolt-fuel rail to camshaft cover 23-27Nm
Bolt -purge valve bracket to intake manifold 9–11Nm
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Engine Control System-2.0T Engine
System Layout
Fuel Control Layout
1. Intake Camshaft Position Sensor 6. Oil Pressure Switch

2. Exhaust Camshaft Position Sensor 7. Knock Sensor
3. Upstream Oxygen Sensor 8. Electronic Throttle
4. Coolant Temperature Sensor 9. Crankshaft Position Sensor
5. Downstream Oxygen Sensor 10. Intake Air Pressure Sensor
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System Control Diagram

Engine Control System Control Diagram
A ＝硬线
A ＝ Hard wire
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A ＝动力高速 CAN 总线； B ＝车身高速 CAN 总线

A ＝ PT High SpeedCAN ； B ＝ Body High SpeedCAN
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Description
Overview
The engine management system mainly consists of sensor,
microprocessor (ECM) and actuator, used for controlling
the air inflow, fuel injection quantity and ignition advance
angle when the engine is working. This engine uses BOSCH
MED17 ECM. MED17 engine electronic control system has
the main characteristics of: accurate measurement of fuel
injection quantity; generation of required injection pressure;
determination of injection starting point; direct and accurate
fuel injection into combustion chamber. The system must
also coordinate different torque requirements in turn, and
then adjust the engine functioning according to the final
requirement. Torque adjustment is the central task of the ECMPin Information of Harness Connector
engine management system, the most important torque Pin No. Description
requirement comes from the accelerator pedal controlled A01 Cylinder 4 Ignition
by the vehicle driver, and the engine management system
A02 Cylinder 2 Ignition
generates a specific torque according to the position of the
accelerator pedal; in addition, further torque requirements A03 Fuel Control Valve -
can also come from: transmission shift control, traction A04 Fuel Control Valve +
control system and electronic stability control system. The A05 Variable Valve Timing Valve
intentions of the engine management system control are to: (Exhaust)
enhance power performance, reduce fuel consumption and A06 —
exhaust pollution. A07 5V Power Supply
Engine Control Unit (ECM) A08 Sensor Ground
The engine control unit is the control centre of the fuel A09 —
injection system. It monitors continuously the information A10 Knock Sensor - Signal
from various sensors, controls various systems influencing
the vehicle performance. It also executes system diagnosis A11 —
function. It is able to identify the operation fault, reminds the A12 5V Power Supply
driver with malfunction indicator lamp (MIL) and stores the
A13 Sensor Ground
DTC at indication fault position to facilitate the repair of the
A14 Sensor Ground
service personnel.
A15 Clutch Water Pump
ECMHarness Connector End View
A18 Boost Pressure Control

Valve
A19 Electronic Throttle ＋
A20 Electronic Throttle -
A21 Intake Bleeder Valve
A22 GND
A23 Crankshaft Position Sensor
Signal
A24 Throttle Position Sensor 1
Signal
A25 Knock Sensor + Signal
A26 Sensor Ground
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A27 5V Power Supply K01 ECMGround 1
A28 — K02 ECMGround 2
A29 5V Power Supply K03 KL.87

A30 — K04 ECMGround 3
A31 Cylinder 1 Injection + K05 KL.87
A32 Cylinder 4 Injection + K06 KL.87
A33 Cylinder 1 Injection - K07 —
A35 Canister Control Valve K09 Starter Relay (High Side)
A36 Manifold Absolute Pressure K10 —
Sensor
K11 GND
A37 —
K12 —
A38 Intake Air Temperature
Sensor 2 Signal (Integrated K13 —
in TMAP) K14 —
Sensor Signal
K16 —
A40 Fuel Rail Pressure Sensor
Signal K17 —
A41 Throttle Position Sensor 2 K18 —
Signal
A42 — K19 Brake Lamp Switch
A43 — K20 A/C Request
A44 GND K21 Brake Switch
A45 — K22 P/N Signal
A46 Cylinder 3 Injection + K23 Oil Pressure Switch
A47 Cylinder 2 Injection + K24 —
A49 Cylinder 2 Injection - K26 Cooling Fan Relay 3
A50 Variable Valve Timing Valve K27 Cooling Fan Relay 1 and 2
(Intake) K28 Low-pressure Fuel Pump
A51 — Relay
A52 — K29 Downstream Oxygen

Sensor Heating
A53 Camshaft Position Sensor K30 KL.30
(Intake) Signal
K31 Starter Motor Relay (Low
A54 Camshaft Position Sensor Side)
(Exhaust) Signal
K32 —
A55 —
K33 Oxygen Sensor Ground
A56 Ambient Temperature
Sensor (Integrated with K34 —
HFM) K35 GND
A57 Coolant Temperature K36 —
Sensor Signal
K37 —
A58 Hot Film Air Flow Signal
(HFM) K38 —
K39 —
A59 GND —
K40
A60 Electronic Thermostat
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K41 — K79 Upstream Oxygen Sensor

Pump Current Signal
K42 Electronic Auxiliary Water K80 —
Pump Relay
K81 5V Power Supply
K43 —
K82 5V Power Supply
K44 Power HS CAN Low
K83 Accelerator Pedal Position
K45 Power HS CAN High Sensor 1 Signal
K46 — —
K84
K47 —
K85 ACC Wake-up Signal
K48 Starter Feedback Signal K86 —
K49 —
K87 KL.15
K50 — —
K88
K51 — K89 —
K52 GND K90 —
K53 — K91 —
K54 — K92 —
K55 — K93 —
K56 — K94 —
K57 —
The engine management system is composed of the following
K58 —
6 parts according to control principle:
K59 5V Power Supply
• External control
K60 A/C Pressure Sensor
• Air supply control
K61 Accelerator Pedal Position
Sensor 2 Signal • Ignition control
K62 Downstream Oxygen • Fuel supply control

Sensor Signal • Accessory 1 (heat management)
K63 — • Accessory 2 (external auxiliary)
K64 — External Control
K65 —
The external control of the engine mainly includes:
K66 —
• Main relay
K67 —
• Ignition switch
K68 —
• Battery
K69 Main Relay
• CANCommunication
K70 —
• Anti-theft system
K71 —
The external control refers to the power supply and
K72 A/C Compressor Relay
communication. One of the power supplies of the engine
K73 Upstream Oxygen Sensor
control unit (ECM) is directly connected to the power supply
Heating
through the fuse, this ensures ECM is in energized state.
K74 —
When the ignition switch is in "ON" or "START" position, the
K75 — engine control unit can activate the main relay or connect
K76 Upstream Oxygen Sensor with the ignition power supply.
Ground
The engine control unit can communicate with the controllers
Nernst Battery Voltage of other nodes on the network through the HS CAN and
ensure the performance of the system. It can also connect the
Trimming Resistance DLC and help the service personnel to carry out diagnosis.
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Main Relay Control • Electronic throttle body
ECMWhen an ignition signal is received, it will close the main • Accelerator pedal module
relay which provides power for the throttle, several sensors • Manifold absolute pressure sensor
and actuator. And the ECM monitors the voltage of the • Camshaft position sensor
system according to the relay voltage.
• Variable camshaft timing valve
Failure
• Air flow meter
The main relay may have failures under the following • Boost pressure control solenoid valve
conditions:
• Intake air pressure sensor
• The relay winding is short-circuited. • Intake bleeder valve
• The relay winding has a break circuit.
The gasoline direct injection system requires a complicated
• The relay winding has a high resistance. engine management system to fully satisfy the high fuel
• Relay contact is normally open. economy and high output power. In terms of gas mixture
• Relay contact is normally closed. formation, the two basic operating modes are somewhat
different:
• Relay contact has a high resistance.
• Relay harness has a break circuit. • Low Load Range
• Relay harness has a high resistance. In this range, the engine works in a highly delaminated
• Relay harness connected to the 12V power supply is and thin gas mixture so as to achieve the minimum
short-circuited. possible fuel consumption. Injection is postponed
until the ignition timing, and the purpose is to obtain
• Relay harness is short to ground.
the ideal condition of formation of two layers in the
• ECMNo ground access is provided.
combustion chamber: The first layer of combustible
Carry out the following inspections to check whether the main mixture is concentrated at the spark plug, and the
relay can work normally: outer second layer is an isolation layer formed by
air and residual exhaust gas. So the engine can run
• Sound inspection - place the ignition switch in "ON"
under a larger non-throttling condition and avoid air
position to check whether the fuel pump will work for
change loss. In addition, this also helps to avoid thermal
2s.
loss of the combustion chamber wall and improve the
• Check whether the fuel injector or ignition coil has thermodynamic efficiency.
enough power (apply multimeter to check the battery
voltage). • High-load range
If the above are detected, the main relay is OK. When the engine load and quantity of fuel injection rise,
the delaminated gas mixture gets increasingly rich, this
CANCommunication
can deteriorate the emission, especially the black smoke.
The engine management system applies HS CAN Therefore, when the engine works at a higher load, the
communication network for the communications between gas mixture in the cylinder shall be evenly distributed.
ECM and SCS, BCM, TCM, and diagnoses outputs through The fuel injects into the cylinder during the intake stroke
DLC. so that the fuel and air can mix evenly.
Anti-theft System To precisely control the air inflow, the manifold absolute
When the ignition switch is in "ON" position, the ECM and pressure sensor, intake air pressure sensor and air flow meter
BCM communicate through the CAN HS bus and verify are configured in the engine management system, and ECM
information mutually. After verification, the BCM allows the obtains the air inflow information through these sensors.
starter motor to work. When turning the key, the ECM After the air inflow information is obtained, on the one hand,
controls the ignition, fuel injection and engine start. If the ECM can control the turbocharging system through the intake
BCM cannot receive the verification information from the air discharge valve and boost control valve; on the other hand,
ECM, the starter motor will not work, and the engine will ECM can control the air intake and exhaust valves based on
not start. the signal from intake and exhaust camshaft position sensor
Engine Air Supply Control for optimal control on the air inflow.
The engine air supply control system includes:
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Electronic Throttle can perform direct pressure measurement through sensing

elements. It provides "load signal" for the controller according
The electronic throttle is composed of the throttle, throttle
to the pressurized intake manifold pressure measured. The
actuator (DC motor) and throttle position sensor, etc.
controller supplies the 5V power, and the boost pressure
ECMIt commands the DC motor to work and influences the sensor provides the 0-5V voltage feedback for the controller
opening of the throttle through the drive mechanism. The two based on different boost pressures. The intake air temperature
potentiometers function as position sensors which are fitted sensor 2 is an NTC sensor which measures the intake air
in reverse phase. When the position of the throttle changes, temperature. When the temperature rises, the resistance
the two resistances vary linearly, one increases and the other decreases. It also provides the 0-5V voltage feedback for the
decreases. When a +5V voltage is added, the position of the controller based on different intake air temperatures.
sensor will be transformed into a voltage output which varies
Camshaft Position (CMP) Sensor
with the resistance.
The camshaft position sensor is used in conjunction with the
These two potentiometers and the two potentiometers on
speed sensor, which provides the ECM with the camshaft
the accelerator pedal module used for monitoring the travel
phase information, i.e. identify the TDC of the compression
of the accelerator pedal form part of the whole electronic
stroke and the exhaust stroke of cylinder 1.
throttle control system monitoring function, which can provide
the redundancy protection expected by the system control. The camshaft position sensor is composed of a hall sensor
and a rotor made of steel plate. The hall sensor is fixed, and
Throttle Position Sensor
the rotor with a 36° arc boss is fitted on the camshaft. The
The throttle position sensor is used to provide throttle magnetic field inside the hall sensor will change when the boss
angle information for the ECM. The ECM can learn passes it, which leads to change of the output signal voltage. In
engine load information, operating conditions (such as this way, the two top dead centres are identified.
start, idle speed, reverse towing, part load, full load and
Failure
acceleration/deceleration) according to this information.
CMPThe sensor or magnetic ring may have failures or provide
Actually, the throttle sensor is an angle potentiometer
incorrect signals under the following conditions:
characterized by linear output. The potentiometer rotor arm
and throttle are fitted on the same shaft. When the throttle • CMPSensor gap fails to comply with the specifications.
rotates, the potentiometer rotor arm will slide into a specified • CMPSensor is contaminated by metallic debris.
location. Voltage signals output by the potentiometer are • CMPSensor hall-effect semiconductor is damaged.
proportional to the throttle position.
• CMPSensor magnetic field is too weak.
Accelerator Pedal Module
• CMPSensor harness has a break circuit.
The two potentiometers in the accelerator pedal module • CMPSensor harness is short-circuited.
act as sensors, their resistance varies with the position of
• CMPSensor harness has a high resistance.
the electronic accelerator pedal, and the ECM can response
precisely to the movement of the accelerator pedal, so it can • Magnetic ring is contaminated by metallic debris.
also monitor the motion of the accelerator pedal. • The accuracy of the magnetic ring is poor due to
mechanical damage.
Because both potentiometers are fitted in the same phase,
when the position of the accelerator pedal changes, their • Exhaust camshaft timing is incorrect.
resistance will increase or decrease linearly. When a +5V • Intake camshaft timing is incorrect.
voltage is added, the position of the pedal will be transformed Variable Camshaft Timing Valve
into a voltage output which varies with the resistance.
The engine control module outputs PWM signal to drive the
These two potentiometers and two potentiometers on the
solenoid. Change of the duty cycle may help to adjust the
electronic throttle used for monitoring the position of the
opening of the solenoid.
throttle form part of the monitoring function of the whole
electronic throttle control system, which can provide the Under low engine speed, the system can reduce fuel
redundancy protection expected by the system control. consumption and emission and improve the performance of
Temperature And Manifold Absolute Pressure the engine, especially torque characteristics.
(TMAP) ECMReceive signals from the CKP sensor and CMP sensor.
The temperature and manifold absolute pressure is fitted With these signals, the ECM determines the valve timing by
on the pipe between the compressor and the throttle. The consulting the control chart. Then the ECM operates the oil
pressure is measured by a piezoelectric type sensor which control valve on the cylinder head side. These solenoids adjust
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the valve timing by controlling the oil to flow into the phase of the exhaust pipe, then the exhaust gas flows into the
modulator and changing the position of the phase modulator turbocharger and the boost pressure rises at this stage.
relative to the camshaft. Manifold Absolute Pressure Sensor (MAP)
Hot Film Meter (HFM)
The manifold absolute pressure/temperature sensor is fitted
HFMIt works according to the hot film principle. HFMThere on the intake pipe. The pressure is measured by a piezoelectric
are two sensing elements in one film. One element stays type sensor which can perform direct pressure measurement
in ambient temperature (intake air temperature sensor 1), through sensing elements. It provides "load signal" for the
such as 25°C (77°F) while the other is heated to 200°C controller according to the MAP measured. The controller
(392°F), exceeding 225°C (437°F). The air passing by HFM supplies the 5V power, and the sensor provides the 0-5V
will generate a cooling effect on the hot film. The air flow voltage feedback for the controller based on the intake
which maintains the temperature difference of 200°C (392°F) pressure.
may provide precise and non-linear signal. Intake Bleeder Valve
HFMIt is combined with the NTC thermistor in the voltage The intake bleeder valve is mainly used to recirculate the
divider circuit. The resistance value of the thermistor pressurized air in the compressor in the turbocharging system
decreases with the increase of the intake air temperature. to the air intake pipe, so that the boost pressure rapidly
NTCThe thermistor current forms a voltage division circuit, decreases during engine surge and gear shift.
the variation of the reference voltage which controls the
ECMIt sends "ON/OFF" command to instruct the solenoid
voltage division circuit is transformed by the HFM into a
valve of the intake bleeder valve to work. When the solenoid
more stable frequency signal output for the ECM, and the
valve opens, the compressed air can circulate into the intake
ECM calculates the air flow and corrects the quantity of fuel
pipe, see the figure below:
injection by this frequency signal.
If the HFM fails, the ECM performs the alternative strategy.

If the HFM signal error occurs, the following symptoms may
occur:
• Hard start
• Engine stops after starting
• Emission control does not work
• Idle speed control does not work
• Engine performance degradation
If the NTC thermistor fails, the ECM defaults the set air
temperature to -5°C (23°F). If signal error of the NTC
thermistor occurs, one of the following symptoms can be
observed: 1. Compressor
2. Turbine
• Black smoke is caused by excessive oil supply
3. Intake bleeder valve
4. To intake
Boost Pressure Exhaust Control Solenoid Valve
5. To exhaust
The boost control solenoid valve uses the duty cycle
information from the ECM to adjust the boost pressure of Engine Ignition Control System
the turbocharger. The greater the duty cycle is, the higher the The engine ignition control system includes:
boost pressure will be.
• Ignition coil 1～4
When the engine works at medium load or small load, the • Crankshaft position (CKP) sensor
boost solenoid valve controls the diaphragm type bypass
• Knock sensor
valve to lead the exhaust gas from the exhaust pipe into the
bypass pipeline, and the boost pressure is extremely small at Ignition Coil
the moment; when the engine accelerates or works at high The ignition coil converts the battery low voltage DC to high
load and high speed, the boost solenoid valve controls the voltage and uses the spark by spark plug discharge to ignite the
diaphragm type bypass valve to reduce the bypass opening gas mixture in the cylinder. Each ignition coil contains a pair of
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coil windings around the laminated iron core, it also includes a Check if the ECM has received the signal from the CKP
primary resistance and secondary resistance. sensor by following operations:
There are four ignition coils fitted on the camshaft cover. They • Check the fuel pump during engine start, if the fuel pump
are fitted to each cylinder, and connected with the harness supplies fuel when the ignition starts, but does not work
through a connector. A spark plug is provided under each coil. yet, the ECM fails to receive the signal from the CKP
Failure sensor.
Knock Sensor
The ignition coil may have failures under the following
conditions: The knock sensor is used to provide the electronic controller
ECM with engine knock information for knock control.
• Primary winding has a break circuit.
• Primary winding is short-circuited. The knock sensor is a vibration acceleration sensor. It is fitted
on the engine cylinder block. The sensitive element of the
• The resistance of primary winding is out of tolerance.
sensor is a piezoelectric crystal. The vibration of the engine
• Secondary winding has a break circuit. block is transferred to the piezoelectric crystal through the
• Secondary winding is short-circuited. mass block in the sensor. The vibration of the mass block
• The circuit connecting secondary winding with primary can produce pressure which helps the piezoelectric crystal
winding is short-circuited. to generate voltage on both pole surfaces and transform the
• The resistance of secondary winding is out of tolerance. vibration signal into voltage signal output.
• Coil top insulation is mechanically damaged. Failure
Crankshaft Position (CKP) Sensor The knock sensor may have failures or provide incorrect signals
under the following conditions:
CKPThe sensor provides information of the engine speed
and crankshaft TDC, which is a hall-effect sensor and used in • The sensor has a break circuit.
conjunction with the pulse wheel. The pulse wheel is a tooth • Sensor ground is short-circuited.
plate, with 58 small teeth spaced at an interval of 6°on the
• Sensor circuit intermittently breaks.
magnetic ring and with 2 teeth absent. The pulse wheel is
• Knock sensor is improperly fitted.
fitted on the crankshaft, which rotates with the crankshaft.
When the tooth tips pass by sensor ends, the pulse wheel In case of knock sensor signal error, the following symptoms
made of steel magnetic materials cuts the magnetic force line may occur:
of the permanent magnets in the sensor and produces induced
• Failure code is stored.
voltage in the coil, which will be output as the speed signal.
• ECMFailure to inspect engine combustion knock.
Failure
• ECMRestore default settings.
CKPThe sensor or magnetic ring may have failures or provide
Engine Fuel Supply Control System
The engine fuel supply control system mainly includes:
• CKPSensor gap fails to comply with the specifications.
• Upstream oxygen sensor
• CKPSensor is contaminated by dust.
• Downstream oxygen sensor
• CKPSensor hall-effect semiconductor is damaged.
• Fuel injector 1 ~ 4
• CKPSensor magnetic field is too weak.
• Canister valve
• CKPSensor harness has a break circuit.
• Low-pressure fuel pump relay
• CKPSensor harness is short-circuited.
• Fuel control valve
• CKPSensor harness has a high resistance.
• Fuel rail pressure sensor
• Magnetic ring is contaminated by dust.
• The precision of magnetic ring is low due to erosion or The engine fuel supply control system is applied to control the
mechanical damage. fuel supply of the engine under different working conditions.
• The CKP sensor signal is distorted due to out-of-round MED-Motronic injection system stores the fuel to the fuel rail
flywheel or drive disk. according to the specific pressure, and the fuel is injected into
• The CKP sensor signal is changed due to crankshaft the combustion chamber by the electromagnetically controlled
radial movement. injector. And thus it can provide the following functions:
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• Free selection of injection starting point ensures that the three-way catalytic converters have a higher
• Variable system pressure efficiency in converting HC, CO and NOx in the exhaust.
Wide-range Oxygen Sensor (LSU) Its sensing element is a ceramic tube, the outside connects
the exhaust and the inside connects the atmosphere. When
The upstream oxygen sensor is a wide-range oxygen sensor
the temperature of sensing ceramic tube reaches 350℃, it
which can determine the oxygen concentration of the exhaust
has the property of solid electrolyte. With this property, the
within a wide range. The data provided by the sensor shows
concentration difference of oxygen can be converted into
the air/fuel ratio in the engine combustion chamber. It can
potential difference which forms electric signal outputs. If the
produce correct and continuous signal in the range from thick
gas mixture is rich, the concentration difference of oxygen
gas mixture to thin gas mixture.
inside and outside the ceramic tube is high, the potential
The wide-range oxygen sensor is a flat-plate type double-unit difference is high, a large amount of oxygen ions move from
current limiting sensor, which has a zirconia measuring unit. inside to outside and the output voltage is high (approximate
This unit is a combination of the Nernest concentration to 900mV); if the gas mixture is thin, the concentration
sensor and oxygen "pump battery" sensor (which is used for difference of oxygen inside and outside the ceramic tube is
transferring the oxyanion). Oxygen sensor must be heated to low, the potential difference is low, only a few of oxygen ions
350℃ before it produces effective signals. It has an integrated move from inside to outside and the output voltage is low
heater to reach the required temperature quickly. (approximate to 100mV).
Since the oxygen atom can be transfered with the current Failure
according to the polarity, the ECM controls the pump voltage
HO2SIt may have failures or provide incorrect signals under
of the pump battery to pump in or pump out appropriate
the following conditions:
amount of oxygen to the concentration sensor so as to
maintain the air/fuel ratio measured by concentration sensor • Contaminated by leaded fuel.
to be 1. When there is excessive air in the exhaust (thin), • Carbon or silicon deposit contaminant is found.
the oxygen is pumped out and the forward pump current • Impact damage/mechanical impact.
is formed. The more oxygen content, the bigger the pump
• External harness has a break circuit.
current; when the residual oxygen content in the exhaust is
low (rich), the pump battery pumps the oxygen in, and the • External harness connected to the 12V power supply is
pump current is reversal at this time. The oxygen sensor short-circuited.
transfers a current signal (change of oxygen concentration) • External harness is short to ground.
to the ECM, and the pump current is proportional to the • External harness has a high resistance.
oxygen concentration in the exhaust, therefore, the pump • Heating device has a break circuit.
current is a non-linearity measurement method for the excess
• Heating device is short-circuited.
air coefficient.
• ECMGround access for heating device is not available.
Failure
• Harness shielding is not connected to the ground.
The wide-range oxygen sensor may have failures or provide
Canister Control Valve
The canister control valve is applied to control the
• Impact damage/mechanical impact.
regeneration air flow of the fuel evaporation control system.
• External harness has a break circuit. The canister in the fuel evaporation control system absorbs
• External harness connected with the vehicle power is fuel vapor from the fuel tank till it cannot absorb any more.
short-circuited or the ground is short-circuited. ECMWhen the canister control valve opens, fresh air and
• Carbon or silicon deposit contaminant is found. saturated fuel steam in the canister form regeneration air flow
which will be reintroduced to the engine intake pipe.
• Exhaust system contains air.
Heated Oxygen Sensor The electronic controller changes the duty cycle of the
pulse signal transmitted to the canister control valve coil and
The downstream oxygen sensor is a heated oxygen sensor
controls the regeneration air flow based on different working
which measures the oxygen content in the engine exhaust
conditions of the engine. Moreover, the flow is also influenced
and determines if the oil and air are burnt completely. The
by the pressure difference on both ends.
electronic controller achieves the closed-loop control goal
(excess air coefficient λ = 1) according to the information and
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Failure • Relay harness has a break circuit.

The canister control valve may have failures under the following • Relay harness has a high resistance.
conditions: • Relay harness connected to the 12V power supply is
short-circuited.
• Electromagnetic winding has a break circuit.
• Electromagnetic winding is short-circuited.
• ECMFailure to provide a ground access.
• External harness connected to the 12V power supply is
short-circuited. Carry out the following inspections to check the fuel pump
• External harness is short to ground. relay for normal operation:
• External harness has a high resistance. • Sound inspection - place the ignition switch in "ON"
• ECMFailure to provide PWM signal. position to check whether the fuel pump will work for
2s.
• Mechanical problems occur in the valve.
• If there is no response, check the inertia switch and
Low-pressure Fuel Pump Relay
ensure it is not triggered accidentally. If there is no sign
The electric fuel pump transfers the fuel from the fuel tank to that the fuel pump is working, but the inertia switch is in
the engine and provides sufficient fuel pressure and fuel. "ON" position, remove the fuel pump relay and conduct
It is a DC motor driven vane pump, which is located in the fuel inspection.
tank and immersed in fuel. It utilizes fuel for heat dissipation Check if the ECM provides the ground access for the fuel
and lubrication. The battery supplies power to the electric fuel pump relay winding when the ignition switch is in "ON"
pump via fuel pump relay, which allows the electric fuel pump position (for 2s) and during starting. Remove the fuel pump
circuit to be switched on only when the relay is energized, relay, connect a multimeter between the 12V power supplied
starts and the engine operates. When the engine stops due to by the vehicle and the fuse box pin connected with fuel pump
accident, the fuel pump will stop automatically. pin 85, check the output according to the circuit diagram after
Failure the ignition is enabled.
If the fuel pump relay fails, the following symptoms will be As the ECM internal drive circuit consumes voltage, the
found: measured voltage may be lower than battery voltage.
At the time of startup Direct Fuel Injection System
• If the fuel system pressure falls to zero, the engine will The direct fuel injection system is composed of the
fail to ignite. high-pressure fuel pump, fuel pipe (fuel pump to fuel rail), fuel
rail assembly (including fuel rail, fuel rail pressure sensor, fuel
• If the fuel system pressure is lower than normal operating
injector) and low-pressure fuel pipe (before the high-pressure
pressure (0.38MPa), the engine may try to ignite, but fails
pump). The system operating pressure is 15MPa.
to operate normally.
• If the fuel system pressure is at a normal level, the engine
will ignite and run, but as the fuel pressure declines, it
will be off finally and fail to start again.
While driving
If the fuel pump relay fails during driving, the engine will lose
power and finally shuts down due to shortage of fuel.
The fuel pump relay may have failures under the following
conditions:
• Relay coil is short-circuited.

• Relay coil has a break circuit.
• Relay coil has a high resistance.
1. Rail Assembly
• Relay contact is normally open.
2. High Pressure Pump
• Relay contact is normally closed.
3. Pipe - Pump to rail
4. Pipe - Low pressure
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5. Sensor - Rail Pressure
6. Injector
High-pressure Fuel Pump
The function of the high-pressure fuel pump is to increase
the pressure of the low-pressure fuel to 15MPa, minimize the
pressure fluctuation in the fuel rail and prevent it from mixing
with the oil.
The working process goes like this: when the fuel pump
plunger goes down, the fuel pump is in the fuel suction stroke,
and the low-pressure fuel enters into the cavity of the fuel
pump plunger; the plunger starts to goes up after reaching the
BDC, and the pressurized fuel is delivered to the high-pressure
fuel rail. Blue = high-pressure oil circuit; red = direction of cam rotation;
black = direction of plunger motion
1. Inlet Fuel (from low-pressure fuel pump)

2. Outlet Fuel (to high-pressure fuel rail)
3. Cam
4. Fuel Control Valve
After solenoid valve activation, the fuel control valve starts

to close, it will be fully closed after a while, and the plunger
cavity is also fully closed at this point. The plunger keeps going
up, when the pressure in the plunger cavity continues to rise
(above rail pressure), the high-pressure fuel will be pumped
into the fuel rail.
Blue = high-pressure oil circuit; red = direction of cam rotation;

black = direction of plunger motion

3. Cam
Fuel Control Valve
ECMIt controls the high-pressure fuel flow by commanding
the fuel control valve to open/close.
During the former half of the rising of the high-pressure fuel

pump plunger, the fuel control valve is open, and the fuel
cannot generate pressure, so part of the fuel returns to the
low-pressure oil circuit by the fuel control valve. Blue = high-pressure oil circuit; red = direction of cam rotation;
black = direction of plunger motion.

3. Cam
4. Fuel Control Valve
Fuel Rail Pressure Sensor
The fuel rail pressure sensor is used to measure the pressure
in the fuel rail. It measures the pressure based on the
piezoelectric crystal resistance value, and sends a voltage
signal to ECM.
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Fuel Injector controller can correct the fuel injection and ignition. It is
a negative temperature coefficient (NTC) thermistor, its
According to the instructions of the ECM, the injector injects
resistance value is reduced as the temperature rises, but not a
fuel within the specified time, supplies the engine with fuel
linear relationship. The thermistor is mounted inside a copper
and atomizes it. ECMIt energizes the injector coil to form
heat sleeve.
magnetic force. When the magnetic force is strong enough
to overcome the resultant force of the return spring pressure, Failure
needle valve gravity and friction, the needle valve begins to rise, ECTThe sensor may have failures or provide incorrect signals
and the fuel injection process starts. When the fuel injection under the following conditions:
pulse ends, the pressure of return spring makes the needle
valve close again. • The system is lack of coolant due to leakage.
Failure • External harness has a break circuit.

• External harness is short to ground.
The fuel injector may have failures under the following
conditions: • External harness connected to the 5V power supply is
short-circuited.
• Nozzle is contaminated by dust or wax (flow is reduced).
• External harness has a high resistance.
• Nozzle offsets (injection is positioned incorrectly).
• ECMFailure to provide a ground access.
• Fuel filter blockage.
• ECTThe thermistor is damaged.
• Winding has a break circuit.
Clutch Water Pump (switch type water pump)
• Winding is short to ground.
The clutch water pump takes the structure of a clutch, when
• Winding connected to the 12V power supply is
starting a cold engine, the ECM controls the operation of the
short-circuited.
clutch solenoid and the rotation of the water pump pulley, and
• The resistance of winding is out of tolerance. if the water pump impeller does not turn, the engine coolant
• External harness has a break circuit. does not circulate, this shortens the engine warm-up time and
• External harness is short to ground. reduces CO2 emission and fuel consumption. Vehicles with
a turbocharger also contain an auxiliary electric water pump
• External harness connected to the 12V power supply is
relay which can pump the cooling water into the turbocharger
short-circuited.
and lower its temperature in some cases after the engine stops.
Accessory 1 (Heat Management)
Electronic Thermostat
The heat management portion mainly includes:
The electronic thermostat adjusts engine coolant temperature,
• A/C compressor relay ensures the coolant temperature can rise rapidly and prevents
• A/C pressure switch hot engine. When the engine works at a low/medium load,
• Coolant temperature sensor increase of the engine coolant temperature can decrease
oil viscosity, mechanical friction loss of the piston and heat
• Cooling fan
transfer loss and optimize combustion; when the engine works
• Clutch water pump at a high load/speed, decrease of the engine temperature can
• Electronic thermostat control cool the engine rapidly.
According to the coolant temperature, the engine opens or ECMIt gives PWM to command the electronic thermostat to
closes the cooling fan relay. work, when the paraffin and wax package of the heater core
When the driver presses the A/C option (switch) on the expand, the paraffin applies pressure to the push rod. The
instrument panel, the engine control unit turns on the upper side and housing of the push rod are fixed, so the push
A/C according to the current signal of the engine coolant rod pushes the whole core to move down reversely, and the
temperature sensor and engine speed, etc. interference fit between the copper cap and the main valve
drives the main valve to open. The opening of the electronic
Coolant Temperature Sensor
thermostat is proportional to the duty cycle of the PWM
The coolant temperature sensor is used to provide the signal.
information of the engine coolant temperature so that the
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• Brake switch
• Cruise control switch
• Cruise indicator lamp
• Automatic transmissionTCM
• ECM
• Electronic throttle
Cruise Control Switch
The cruise control switch is a handle switch which is used to
engage/disengage the cruise control system and adjust the set
speed.
The cruise control switch is connected with the GW which

1. Wax Package transmits network signal to the ECM, provides different
2. Push Rod voltage signals for the ECM by different switches and identifies
the current status of the cruise control.
3. Copper Cap
4. Main Valve
Cruise Indicator Lamp
5. Spring The indicator lamp indicates the status of the cruise control
system. The lamp is located on the instrument pack. When
6. Bracket
the cruise control system is on standby, the cruise indicator
Accessory 2 (External Auxiliary)
illuminates green; when the cruise control system is activated,
The external auxiliary portion mainly includes: the cruise indicator illuminates yellow.
• Alternator control input Standby
• Brake pedal switch When the handle is in "ON" position, and the vehicle is in an
• Brake lamp ideal state for driving, the cruise control system enters into
standby state.
Alternator Control Input
• Non-brake State
The ECM applies the alternator control input to control the
alternator to charge the battery while the engine works. • The road speed is within 40-200km/h.
• The engine is working and the vehicle speed is above 5
The alternator converts the mechanical energy from the
km/h.
engine into electric energy to charge the battery. Variation
of the engine load can significantly affect engine idle speed. • Engine speed is less than 6496 rpm.
To compensate the load and stabilize the idle speed, the • The transmission is not in "P" gear, "N" gear or "R" gear
ECM needs to acquire the torque/load information from the (for automatic transmission).
alternator. The alternator connects the power management • The TCS is not activated.
module PMDC by the LIN line, and the PMDC sends the
Activation
alternator load network signal to the ECM. ECMUse this
information to obtain the load which the engine applies to When it is in STANDBY, push the handle switch (SET button)
drive the alternator. to activate the cruise control system. The switch outputs the
signal to the ECM, the ECM operates the electronic throttle
Brake Lamp Switch
and generates the control required by the throttle.
The brake lamp switch is fixed to the brake pedal bracket.
ECMIt monitors the switch status and transfers the data When the cruise control system is activated, it sets the target
to TCM via the CAN bus, and the TCM controls the cruise speed by the handle +/-. After receiving the input
transmission clutch to open. When operating the brake pedal, information from the switch +/-, the ECM stores current
activate the brake switch. speed as set speed, operates the electronic throttle and
maintains the set vehicle speed.
Cruise Control System
Acceleration/Deceleration
The cruise control system can allow the vehicle to move
in a constant and comfortable speed without applying the When the cruise control system is activated,
accelerator pedal. Cruise control system involves: accelerate/decelerate with the handle +/-.
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Turn the switch +/- (less than 0.5s) to increase/decrease When one of the conditions for operating the cruise control
the vehicle set speed at the speed of 1km/h and system does not exist (e.g. applying the brake), the cruise
accelerate/decelerate to the new set speed. Turn and hold the control system pauses. If the vehicle speed drops below 70%
switch +/- to maintain the acceleration/deceleration until the of the set speed, such as driving uphill, the cruise control will
switch is released. On this point, the accelerated/decelerated also pause.
speed will be adopted as the new set speed.
If the vehicle speed continuously exceeds the cruise set speed,
The vehicle can also be accelerated by the accelerator pedal. such as depressing the accelerator pedal or driving downhill,
With the cruise control system activated, if release the the cruise control will pause.
accelerator pedal, the speed at that moment is the set speed; Cancellation
if turn the switch + , the higher vehicle speed will be used as
Turn the handle switch to "OFF" or place the ignition switch
the new set speed.
in "OFF" position to cancel the cruise control function. When
Resume/Pause
the cruise control function is canceled, the set speed in the
When the cruise control system is in standby, turn cruise control system is eliminated and the indicator lamp on
the RESUME switch to resume the system and the IPK turns off.
accelerate/decelerate to the set speed stored. Turn the
CANCEL switch to pause the cruise control system, i.e. shift
from activation to standby.
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Automated Stop/Start - Intelligent Fuel Saving
System
E le c tric rty S e n s o r
∏ ∆
G W
A ＝动力高速 CAN 总线； B ＝车身高速 CAN 总线； C=LIN 线； D= 硬线

A ＝ PT High Speed CAN ； B ＝ Body High Speed CAN ； C= LIN Line ； D= Hard Wire
Overview waiting for traffic lights), improve fuel economy and realize
stable and reliable vehicle start or stop.
The Automated Stop/Start - Intelligent Fuel Saving System can
automatically start or stop the vehicle at idle speed (such as
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After switching on the ignition switch, whether to enable the Note: When the vehicle will not be used for
Automated Stop/Start - Intelligent Fuel Saving System depends an extended period (more than 1 month), it is
on the ON/OFF status for last engine flameout. If the status is recommended to disconnect the battery negative
ON, the indicator lamp of the system illuminates. terminal. When connecting or disconnecting the
battery negative terminal, ensure the ignition
Press the main switch on the central channel to turn off the
switch is in "OFF" position. For vehicles with
Automated Stop/Start - Intelligent Fuel Saving System, at this
the Automated Stop/Start - Intelligent Fuel Saving
time, the switch indicator lamp is off, and the instrument
System, after the battery negative terminal is
display shows "Stop/Start System OFF".
reconnected, the battery shall be kept for at least
Note: Please turn off the Automated Stop/Start - 4 hours, and the engine will lose the automatic
Intelligent Fuel Saving System by pressing its main start/stop function before this operation.
switch when driving in water.
Note: If the vehicle is running continuously for
Automatic Engine Stop more than 100 hours, station the vehicle for at
With the Automated Stop/Start - Intelligent Fuel Saving System least 4 hours so that the battery state signal can
enabled, the engine will be automatically shut down when the return to normal state.
following driver's operations and vehicle status are detected Warning: Failure to follow the above instruction
after the vehicle is stopped, at this time, the indicator lamp of will impair the battery performance and the
the Automated Stop/Start - Intelligent Fuel Saving System on Automated Stop/Start - Intelligent Fuel Saving
the instrument is on: System.
• Vehicles with automatic transmission: the gear is in "D" Warning: To replace the vehicle battery, please
and the brake pedal is depressed, the gear shifts to "P/N" use the original accessories; otherwise, normal
gear when the engine automatically stops, and it is still in automatic stop/start of the engine cannot be
the automatic shutdown status when the brake pedal is guaranteed.
released.
Automatic Engine Start
• The vehicle speed signal on the instrument is normal, and
After stopping the vehicle, the engine will be automatically
the maximum vehicle speed before parking is more than
started when the following operations of the driver are
10km/h.
detected, and at this time the indicator lamp of the Automated
• There is no large steering operation when the vehicle
Stop/Start - Intelligent Fuel Saving System on the instrument
speed is less than 10km/h.
is off:
• Close the engine hood and the driver door, wear the
• Vehicles with automatic transmission: with the
driver seat belt.
transmission in D gear, release the brake pedal or with
The Automated Stop/Start - Intelligent Fuel Saving System will it in P/N gear, depress the brake/accelerator pedal, or
be prohibited and the engine will not stop automatically when shift to drive gear (R/D/S/W/Tiptronic).
the following situations occur:
Note: In some cases, the malfunction indicator lamp
• The engine does not reach the ideal operating on the instrument will illuminate in the process
temperature. of automatic engine start. This is caused by low
• Defrost function of the windshield is activated. voltage during the starting process, it does not
• The A/C determines that the temperature inside the mean actual faults.
vehicle does not meet the target value. Even if the driver does not have any operation, the engine
• Battery power is less than 65%, or battery temperature will also start automatically upon demands of the vehicle after
is not within the ideal range (0～60℃). automatic stop:
• Hard acceleration or deceleration exhausts the brake • Defrost function of the windshield is activated.
vacuum.
• Activate the air conditioner which detects that the
• Frequent work of the starter in a short period (more than temperature inside the vehicle does not meet the target
3 times/min). Automatic stop function will be disabled for value.
1 min after continuous operation for five times.
• Battery power is less than 65%.
• The vehicle is in "R" gear when parking or before parking.
• Brake vacuum is insufficient.
• At the place where the altitude is more than 3000m.
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• The vehicle speed exceeds its limits, such as slipping slope • Driver door is open.
of vehicle. • Engine hood is open.
• Press main switch of the Automated Stop/Start - • Automated Stop/Start - Intelligent Fuel Saving System is
Intelligent Fuel Saving System. closed.
Note: When the vehicle is in automatic start and • Automatic start fails upon unexpected flameout.
stop control, if flameout of the engine occurs, when
Warning: Never tie the seat belt or insert the
shifting to neutral gear, the engine will restart.
alternative steel into the buckle when the driver
Warning: When charging/discharging the battery leaves his seat, for this may cause the vehicle
with external device, or starting the engine with engine to start automatically.
external power, or supplying power for external
Warning: For vehicles with automatic transmission,
device with the vehicle, the negative cable must
when the driver leaves the vehicle, please shift
be connected with body ground rather than directly
to P/N gear even if the engine has been shut down,
connected with battery negative, otherwise, it
otherwise, the vehicle may move.
will result in inaccurate calculation of the
battery power and cause security problems when the Warning: The key must be removed to power off the
engine starts automatically. vehicle when the service personnel open the hood
to carry out static check.
Warning: Never remove the battery sensor from the
battery negative for several times, which will Warning: Even if the engine has been shut down, the
result in inaccurate calculation of the battery key must be removed to power off the vehicle for
power and cause security problems when the engine refueling.
starts automatically. Automated Stop/Start - Intelligent Fuel Saving
System Failure
In case of automatic shutdown or sudden flameout, the engine
could only be started with a key when one of the following When the Automated Stop/Start - Intelligent Fuel Saving
situations occurs: System fails, the instrument will show "Stop/Start Fail" and the
system will stop.
• The driver seat belt is unfastened.
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Symptom Item to be checked

The system is enabled, and the switch indicator lamp illuminates.
The vehicle speed displayed on the instrument is normal, the vehicle
stops and the previous drive speed exceeds 10km/h.
Vehicles with manual transmission: the vehicle is in "N" gear, and the
clutch pedal is released. Vehicles with automatic transmission: The shift
lever is in D position, and the brake pedal is depressed.
There is no large steering operation when the vehicle speed is less
than 10km/h.
Close the engine hood and driver door, fasten the driver seat belt.
Engine water temperature is high (at the 4th segment or above).
Check the specific disabling condition with a scan tool:
1. Front compartment open
2. Driver absent
3. Battery status disabled
The instrument does not show any
fault, and there is no automatic 4. Insufficient brake vacuum
engine stop. 5. A/C requirement
6. Hot starter
No Automatic
Stop 7. Diagnosis of N gear switch and clutch low switch unfinished
8. Diagnosis of clutch high switch unfinished
9. Diagnosis for stuck drive chain status relay unfinished
10. Engine status not meet stop condition (for example, engine
temperature, etc.)
11. TCM not allow automatic engine stop
12. BCM not allow automatic engine stop
13. High altitude
14. HHC does not allow automatic engine stop
15. Parking operation
16. Brake master cylinder pressure not meet stop condition
The instrument shows "stop/start
failure", and there is no automatic Use a scan tool to check EMS DTC and source of failure.
engine stop.
The instrument displays the MIL
(engine MIL, transmission MIL, ESP
Use a scan tool to check the DTC and source of failure.
MIL), and there is no automatic
engine stop.
After automatic The instrument does not show any Close the engine hood and driver door, fasten the driver seat belt.
engine stop, there fault, and there is no automatic
is no automatic engine start. Vehicles with manual transmission: shift to N gear.
engine start. The instrument shows "stop/start
failure", and there is no automatic Use a scan tool to check EMS DTC and source of failure.
engine start.
Accidental Stop Vehicles with manual transmission:
shift to gears other than N gear, Check N gear switch and its harness.
engine stops automatically.
Failure to turn off the intelligent
Check the main switch and harness of the Automated Stop/Start -
stop/start energy-saving system by
Intelligent Fuel Saving System.
button.
Vehicles with manual transmission:
Accidental Start shift to gears other than N gear, Check N gear switch and its harness.
engine starts automatically.
Test Mode If use the automatic stop function at this stage, please follow
the following procedures, and the battery status will not disable
After refitting the battery sensor to the battery, it shall be
the function for this operation:
conditioned for at least 4 hours so that the accurate battery
state information can be acquired. The engine will not stop 1. Reconnect the key, but do not start the engine.
automatically before completing this step.
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2. Depress the accelerator pedal and brake pedal to the 3. Repeat step 2.
maximum travel, hold the main switch of the Automated 4. With a scan tool, check if the status of the stop/start
Stop/Start - Intelligent Fuel Saving System for about 1s, test mode is ON.
then release both pedals.
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Service Procedures Ignition Coil

Spark Plug Remove
1. Disconnect the battery negative. 2. Remove the engine cover.
2. Remove the engine cover. 3. Disconnect the connector of the ignition coil (1).
3. Remove the ignition coil. 4. Remove 2 bolts (2) fixing the ignition coil to the engine.
Ignition Coil Remove
4. Clean the area around the spark plug. Remove the dust
around the spark plug with high pressure gas.
5. Remove 4 spark plugs with the spark plug socket.
5. Hold the rubber bush end of the ignition coil, and pull
out the ignition coil from the spark plug (if it is hard to
pull it out, rotate the ignition coil from left to right).
6. Repeat step 3 to 5 to remove other ignition coils.
Refit Refit
1. The gap of each new spark plug shall be within 1. Fit the ignition coil into the spark plug. When fitting the
0.70—0.80mm. ignition coil, align the hole of the ignition coil with the
bolt hole on the camshaft cover, and ensure the ignition
2. Fit the spark plug and tighten it to 15-20Nm.
coil is inserted into the spark plug. Fit 2 bolts, tighten
3. Fit the ignition coil. to 7-10Nm and check the torque.
Ignition Coil Refit 2. Connect the ignition coil connector.
4. Fit the engine cover. 3. Repeat step 1 and 2 to fit other ignition coils.
5. Connect the battery negative. 4. Fit the engine cover.
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Engine Control Module (ECM) 5. Perform self-learning for the electronic throttle.
Remove Electronic Throttle Self-learning
2. Remove 4 bolts fixing the ECM bracket to the firewall. "Engine Control Module Reset Self-learning Value" with
VDS.
3. Disconnect the connector from the ECM.

Caution: ECMWhen disconnecting the connector, do
not shake the connector forth and back or from side
to side, avoid applying force to one side only or
damaging the connector structure.
4. Remove 4 nuts fixing the ECM to the firewall.
Refit
1. Fix the ECM to the firewall, fit 4 nuts, tighten to
2. Fix the wire harness and connect it to ECM connector.
Caution: ECMWhen connecting the connector, align
the connector and insert the two ends with even
effort. Never tilt it or attempt to fit it by
applying force to one side only. If the connector
is damaged, replace the engine harness.
4. Perform the programming and encoding and mixed gas
self-learning for ECM.
Self-learning and Adjustment, Programming and
Encoding - ECM Replacement
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ECT Sensor Intake Camshaft Position Sensor

Remove Remove
2. Remove the coolant expansion tank cap to release the 2. Remove the engine cover.
pressure of the cooling system, and fit the cap. 3. Disconnect the connector of the intake camshaft
Warning: Injury (such as scald) can be caused by position sensor.
the spilled vapor or coolant, so do not open the 4. Remove 1 bolt fixing the intake camshaft position
expansion tank cap when the cooling system is still sensor to the cylinder block, and remove the sensor.
hot.
3. Remove the reservoir from the reservoir bracket.
4. Disconnect the ECT sensor connector.
Refit
1. Clean the mating surface of the intake camshaft position
sensor and cylinder block.
5. Prepare a proper container to collect the spilled 2. Fix the intake camshaft position sensor to the cylinder
coolant. block, fit 1 bolt, tighten to 9–11Nm, and check the
6. Remove the ECT sensor and discard the seal ring. torque.
Refit 3. Connect the connector of the intake camshaft position
1. Clean the thread of the coolant temperature sensor. sensor.
2. Fit the new seal washer to the coolant temperature 4. Fit the engine cover.
sensor. 5. Connect the battery negative.
3. Fit the engine coolant temperature sensor and tighten 6. Turn the ignition switch to ON position. Connect VDS
to 14–18Nm. and execute” ECM Adaption Reset ” .
4. Connect the connector of the ECT sensor. 7. Wait the 2-5 seconds, turn off the ignition switch, then
5. Fit the reservoir to the reservoir bracket. restart the vehicle .

7. Check the coolant level, refill if necessary.
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Exhaust Camshaft Position Sensor Oil Pressure Switch
Remove Remove
2. Remove the engine cover. 2. Remove the bottom deflector.
3. Disconnect the connector of the exhaust camshaft Bottom Deflector Remove
position sensor.
3. Place the oil sink under the switch to collect the spilled
4. Remove 1 bolt fixing the exhaust camshaft position oil.
sensor to the cylinder block, and remove the sensor.
4. Disconnect the connector of the engine oil pressure
switch.
5. Remove the oil pressure switch (1), and discard the
gasket.
Refit
1. Clean the mating surface of the exhaust camshaft
position sensor and cylinder block. Refit
2. Fix the exhaust camshaft position sensor to the cylinder 1. Clean the thread of the oil pressure switch.
block, fit 1 bolt, tighten to 9–11Nm, and check the 2. Fit the new seal ring to the oil pressure switch.
torque. 3. Fix the oil pressure switch to the oil filter module,
3. Connect the connector of the exhaust camshaft tighten the switch to 14–18Nm and check the torque.
position sensor. 4. Connect the oil pressure switch connector.
4. Fit the engine cover. 5. Remove the oil sink.
5. Connect the battery negative. 6. Fit the bottom deflector.
6. Turn the ignition switch to ON position. Connect VDS Bottom Deflector Refit
and execute” ECM Adaption Reset ” .
7. Wait the 2-5 seconds, turn off the ignition switch, then
8. Check the engine oil level, and refill if necessary.
restart the vehicle .
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Hot Film Meter (HFM) High-pressure Fuel Pump

Remove Remove
1. Disconnect the battery negative. Caution: Before removing the high-pressure system,
2. Disconnect the connector (1) of the air flow meter. allow the vehicle to cool.
3. Release the clamp and disconnect the turbocharger 1. Disconnect the battery negative.
intake pipe and air flow meter (2). 2. Remove the engine cover.
3. Remove the shield of the high-pressure oil pump.
4. Remove 2 screws fixing the air flow meter to the upper

air filter housing, and remove the air flow meter.
4. Place cloths with strong absorptivity around the
high-pressure fuel pump to collect the spilled fuel.


5. Unscrew the high-pressure pipe nut (1) on the
high-pressure fuel pump (one or two circles),
and release the nut completely after the fuel stop
overflowing.
6. Take away the cloth from the high-pressure fuel pump
Refit
and put it into a permissible container.
1. Fix the air flow meter to the upper housing of the air
Caution: Do not drip fuel onto the paint.
filter, fit 2 screws, tighten to 1.4–1.8Nm, and check
the torque. 7. Remove the high-pressure fuel pipe nut (2) from the fuel
2. Fit the turbocharger air inlet hose to the air flow meter, rail to release the high-pressure fuel pipe, and discard it.
and secure with clamps. Caution: Always fit plugs to open connections to prevent
3. Connect the connector of the air flow meter. contamination.
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and tappet.
3. Fit a new seal ring to the high-pressure fuel pump.
4. Fix the high-pressure fuel pipe to the camshaft cover, fit
2 bolts, tighten to 9-11Nm, and check the torque.
Caution: When tightening the fuel pump bolts, if

the 2 bolts of any equipment shall be tightened to
the specified torque or if no equipment needs to
tighten the bolts repeatedly one by one, then do
not tighten the bolt one after the other.
5. Connect the low-pressure fuel pipe to the high-pressure
fuel pump, tighten the nut to 20-24Nm and check
the torque.
8. Disconnect the connector of the high-pressure fuel
6. Connect the connector of the high-pressure fuel pump.
pump.
7. Replace the high-pressure fuel pipe with a new one,
9. Remove the low-pressure fuel pipe nut on the
for it is disposable.
8. Fix the high-pressure fuel pipe to the high-pressure
fuel pump and fuel rail, tighten 1 nut connecting the
high-pressure fuel pipe and the high-pressure fuel pump
to 26-34Nm, and tighten the other nut securing the
high-pressure fuel pipe and fuel rail to 26–34Nm, then
check the torque.
10. Remove 2 bolts fixing the high-pressure fuel pump to

the camshaft cover, remove the high-pressure fuel pump
and discard the seal ring of the high-pressure fuel pump.
11. Remove the high-pressure fuel pump and roller tappet.

Refit
1. Ensure the high-pressure fuel pump drive cam is located
on he BDC.
2. Evenly apply engine oil to the cam, fuel pump seat hole
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Fuel Rail Pressure Sensor Crankshaft Position Sensor

Remove Remove
Caution: Before removing the high-pressure system, 1. Disconnect the battery negative.
allow the vehicle to cool. 2. Remove the starter motor.
1. Disconnect the battery negative. Starter Motor Remove
2. Remove the engine cover. 3. Disconnect the connector of the crankshaft position
3. Disconnect the connector of the fuel rail pressure sensor.
sensor. 4. Remove 1 bolt (1) fixing the crankshaft position sensor
4. Place cloths with strong absorptivity around the fuel rail to the cylinder block, and remove the sensor.
pressure sensor to collect the spilled fuel.


5. Before removing the fuel rail pressure sensor, keep the
vehicle stationary for more than 2 hours, unscrew the
fuel rail pressure sensor (less than half circle) until the
fuel does not overflow.
Refit
1. Clean the mating surface of the crankshaft position
2. Fix the crankshaft position sensor to the cylinder block,
3. Connect the connector of the crankshaft position
sensor.
4. Fit the starter motor.
Starter Motor Refit

6. Take away the cloth from the fuel rail pressure sensor 6. Turn the ignition switch to ON position. Connect VDS
and put it into an permissible container. and execute” ECM Adaption Reset ” .
7. Wait the 2-5 seconds, turn off the ignition switch, then
restart the vehicle .
Refit
1. Fix the fuel rail pressure sensor to the fuel rail, tighten
to 30–35Nm and check the torque.
2. Connect the connector of the fuel rail pressure sensor.
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Intake Air Temperature/Manifold Absolute Manifold Absolute Pressure/Temperature Sensor
Pressure Sensor Remove
1. Disconnect the battery negative cable. 2. Disconnect the connector of the manifold absolute
2. Remove the engine cover. pressure sensor.
3. Disconnect the connector of the TMAP sensor. 3. Release 2 screws fixing the manifold absolute pressure
4. Release 2 screws fixing the TMAP sensor to the intake sensor to the throttle intake pipe and remove the
manifold and remove the sensor. sensor.
Refit Refit
1. Clean the mating face of the intake air 1. Clean the mating face of the manifold absolute pressure
temperature/manifold absolute pressure sensor sensor and throttle intake pipe.
and intake manifold. 2. Fit the manifold absolute pressure sensor to the
2. Fit the intake air temperature/manifold absolute throttle intake pipe and tighten the screw to 5–7Nm.
pressure sensor to the intake manifold and tighten the 3. Connect the connector of the manifold absolute
screw to 5–7Nm. pressure sensor.
3. Connect the connector of the intake air 4. Connect the battery negative.
temperature/manifold absolute pressure sensor.
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Knock Sensor Heated Oxygen Sensor - Front

Remove Remove
2. Raise the vehicle on a lift. 2. Remove the engine cover.
Warning: Do not work on or under a vehicle supported 3. Remove the front oxygen sensor connector from the
only by a jack.Always support the vehicle on safety stands. connector bracket of the front oxygen sensor.
3. Disconnect the knock sensor connector. 4. Disconnect the front oxygen sensor connector.
5. Remove the front oxygen sensor from the front
Warning: Exhaust components get extremely hot during
three-way catalytic converter with the TEN00011.
operation. Ensure exhaust components are sufficiently
cooled before handling. Warning: Exhaust components get extremely hot during
4. Remove 1 bolt (2) fixing the knock sensor to the operation. Ensure exhaust components are sufficiently
cylinder block, and remove the knock sensor. cooled before handling.
Refit Refit
1. Clean the mating surface of the knock sensor and 1. Clean the mating face of the front oxygen sensor and
cylinder block. front exhaust pipe.
2. Fix the knock sensor to the cylinder block, fit 1 bolt, 2. Apply high temperature antiwelding agent to the
tighten to 15–25Nm, and check the torque. thread of the front oxygen sensor, fit the front oxygen
3. Connect the knock sensor connector. sensor to the three-way catalytic converter with the
the TEN00011, tighten to 45–60Nm and check the
torque.
3. Connect the front oxygen sensor connector.
4. Fit the front oxygen sensor connector to the connector
bracket of the front oxygen sensor.
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Heated Oxygen Sensor - Rear Turbocharger Solenoid Valve
Remove Remove
2. Raise the vehicle on a lift. 2. Note the hose connection on the solenoid valve and
disconnect 3 hoses.
only by a jack.Always support the vehicle on safety stands. 3. Disconnect the connector of the solenoid valve.
3. Remove the bottom deflector. 4. Release 2 bolts fixing the turbocharger solenoid valve
to the bracket, and remove the solenoid valve.
4. Remove the rear oxygen sensor connector from the
connector bracket of the rear oxygen sensor.
5. Disconnect the rear oxygen sensor connector.
6. Remove the rear oxygen sensor from the front exhaust
pipe with the TEN00011.
cooled before handling.
Refit
1. Fix the solenoid valve to the bracket, fit 2 bolts, tighten
to 2.5–3.5Nm, and check the torque.
2. Connect the connector of the solenoid valve.
3. Connect 3 hoses to the solenoid valve correctly.
Refit
1. Clean the mating face of the rear oxygen sensor and
rear exhaust pipe.
2. Apply high temperature antiwelding agent to the thread
of the rear oxygen sensor. Fit the rear oxygen sensor
to the front exhaust pipe with the TEN00011, tighten
3. Connect the rear oxygen sensor connector.
4. Fit the rear oxygen sensor connector to the connector
bracket of the rear oxygen sensor.

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Fuel Rail and remove the high-pressure fuel pipe.

Remove Caution: Plug the connector disconnected to prevent
Caution: Before removing the high-pressure system, contaminants.
allow the vehicle to cool.
8. Disconnect the connector of the injector nozzle,
1. Disconnect the battery negative. high-pressure sensor, intake camshaft oil control valve
2. Remove the engine cover. and front oxygen sensor.
3. Remove the shield of the high-pressure oil pump. 9. Remove the engine harness clip from the fuel rail bolt.
4. Place cloths with strong absorptivity around the 10. Remove 7 bolts fixing the fuel rail to camshaft cover in
high-pressure fuel pump to collect the spilled fuel. the sequence shown.


5. Unscrew the high-pressure pipe nut (1) on the
high-pressure fuel pump (one or two circles),
and release the nut completely after the fuel stop
overflowing.
11. Remove the fuel rail assembly.

Refit
1. If the injector is disconnected from the fuel rail, replace
all seal rings and spring clips of the injector; if it is not
disconnected, replace the seal ring of the combustion
chamber only.
2. Fit the fuel rail, ensure the injector will not contact the
camshaft cover, fit 7 bolts and pre-tighten the bolt.
3. Tighten the bolts to 23-27Nm in the sequence shown
6. Take away the cloth from the high-pressure fuel pump Caution: When tightening the fuel rail bolt, if
and put it into a permissible container. the bolt of any equipment shall be tightened to
Caution: Do not drip fuel onto the paint. the specified torque or if there is no equipment,
tighten from outside bolt to inside bolt.
7. Remove the high-pressure fuel pipe nut on the fuel rail
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Injector
Remove
2. Remove the fuel rail assembly.
Fuel Rail Assembly Remove
3. Remove the spring clip from the fuel injector.
4. Remove the fuel injector with the TEN00121.
4. Fit the engine harness clip to the fuel rail bolt.

5. Connect the connector of the injector nozzle,
high-pressure sensor, intake camshaft oil control valve
and front oxygen sensor.
6. Replace the high-pressure fuel pipe with a new one,
for it is disposable.
7. Fix the high-pressure fuel pipe to the high-pressure
fuel pump and fuel rail, tighten 1 nut connecting the
high-pressure fuel pipe and the high-pressure fuel pump 5. Remove and discard the fuel injector seal ring.
to 26-34Nm, and tighten the other nut securing the 6. Fit the block cap to the end of each fuel injector.
high-pressure fuel pipe and fuel rail to 26–34Nm, then Refit
check the torque.
1. Remove the block cap from each fuel injector.
2. Clean the groove of the fuel injector and fuel rail.
3. Fit the fuel injector seal rings to the steering tool of
10. Connect the battery negative. the TEN00064, then fit the fuel injector seal rings to
the fuel injector with the TEN00064, and fit the fuel
injector seal rings in sequence.
4. Replace the spring clip, and fit the new clip to the
injector nozzle.
5. Fit the fuel injector to the fuel rail assembly.
Fuel Rail Assembly Remove
6. Fit the fuel rail assembly with injector to the cylinder
head.
1.0 335
Canister Solenoid 6. Connect the battery negative.

Remove
3. Disconnect the connector of the activated carbon
4. Loosen the clamps, and disconnect the two pipes
connecting the activated carbon canister solenoid valve.
5. Remove the activated carbon canister solenoid valve

from the bracket.
6. Remove 1 bolt fixing the bracket of the activated
carbon canister solenoid valve to the intake manifold
and remove the bracket.
Refit
1. Fix the activated carbon canister solenoid valve bracket
to the intake manifold, fit 1 bolt, tighten to 9–11Nm
2. Fit the activated carbon canister solenoid valve to the
bracket.
3. Connect the 2 pipes of the activated carbon canister
solenoid valve and secure them with clamps.
4. Connect the connector of the activated carbon canister
solenoid valve.
1.0 336
Special Tools
Number
Wrench O2
TEN00011
sensor
Injector remove
TEN00121
tool
Injector seal
TEN00064 installer and
sizer
1.0 337
Engine Control System-1.5T

Specifications
Torque
Description Value
Bolt-fuel pump to engine 21–29Nm
Bolt-fuel pump bracket to engine 19–25Nm
Nut-fuel rail 28–32Nm
Bolt-fuel rail assembly to injector 4–6Nm
Bolt-fuel rail assembly to engine 9–11Nm
Bolt-Spark Plug ASM 20Nm
nuts -ECM to body 7–10Nm
nuts and bolts -ECM bracket to body 8–10Nm
Bolt-coil to engine 8–12Nm
Bolt-crank sensor 8–12Nm
Bolt-MAP 4–6Nm
Bolt-CAM 8–12Nm
Bolt-the camshaft phase adjust the solenoid valve 8–12Nm
Bolt-oil pressure sensor 31–39Nm
Bolt-knock sensor 16–24Nm
Bolt-oxygen sensor 40–60Nm
Bolt-After oxygen sensor bracket to transmission 14-18Nm
Bolt-emissions control valve 4–6Nm
Bolt-emissions pressure relief valve 8–10Nm
Bolt-TMAP sensor 3–4Nm
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Parameter
Engine Management System - 1.5T
Emission standard GB V
Spark plug:
Manufacturer Federal-Mogul Corporation
Clearance 0.6-0.7 mm
Ignition coil:
Manufacturer Mitsubishi Electric
Model CSGE
Fuel injection system:
Model: Direct fuel injection system, returnless
Nozzle: 4x XL3
Operating pressure: 20 MPa
Static flow rate of nozzle: 9 g/s±5% @ 10MPa
1.0 339
Sensor -1.5T
Crankshaft position sensor
Manufacturer WODELL Technology co., Ltd

Camshaft position sensor:
Manufacturer Denso (China) Investment Co., Ltd, Shanghai Branch

Oxygen sensor
Manufacturer/model UMC LSF 4.2 TSP
Heating element (nominal value) 7W
Sensor voltage - high 1v
Sensor voltage - low 0v

Electronic throttle
Manufacturer Continental (Wuhu)

Coolant temperature sensor
Manufacturer/model INZI/NTC
TMAPSensor
Manufacturer Denso (China) Investment Co., Ltd, Shanghai Branch
Sensor supply voltage 5V+/-0.25V
1.0 340
Fuel System - 1.5T
System Direct fuel injection system, returnless
Fuel specification 92# above high-quality unleaded gasoline
Fuel rail Stainless steel tube structure
Nozzle: 4x XL3
Static flow rate of nozzle 9 g/s±5% @ 10MPa
Dynamic flow rate of nozzle 3.3 mg/pulse±5% @ 4MPa
Fuel pump (high pressure) Camshaft drive, fuel supply of fuel pump controlled by solenoid valve
Oil pressure 20MPa
Oil pressure adjustment High-pressure fuel pump solenoid valve adjusts the oil pressure by controlling
the fuel supply
1.0 341

System Layout
Sensor Layout
1. Knock Sensor 8. Front Oxygen Sensor

2. Screw - Knock Sensor 9. Front Oxygen Sensor Bracket Assembly
3. Oil Pressure Sensor 10. Clip - Oxygen Sensor
4. Manifold Absolute Pressure Sensor 11. Screw - Rear Oxygen Sensor Bracket
5. Screw - Manifold Absolute Pressure Sensor 12. Rear Oxygen Sensor
6. Crankshaft Sensor 13. Intake Air Temperature/Pressure Sensor
7. Screw - Crankshaft Sensor 14. Bolt - Intake Air Temperature/Pressure Sensor
1.0 342
Exploded View of Ignition Module Spark Plug
1. Ignition Coil Assembly 3. Spark Plug Assembly

2. Screw - Ignition Coil 4. Fixing Sleeve - Ignition Coil Bolt
1.0 343
Exploded View of Injector Fuel Rail
1. Fuel Rail 8. Bolt - Fuel Rail

2. Bolt - Engine Fuel Inlet Pipe Bracket 9. Engine Injector Harness
3. O-ring - Engine Fuel Pump 10. Engine High Pressure Fuel Pump
4. Engine Fuel Pump Tappet 11. Bolt - Engine Fuel Pump
5. Fuel Injector Assembly 12. Fixing Sleeve - Fuel Pump Bolt
6. Bolt - Fuel Injector Retaining Plate 13. Fuel Pump Silencer
7. Sensor - Fuel Rail Fuel Pressure 14. Engine High Pressure Fuel Pipe
1.0 344
Engine Control System Control Diagram
1.0 345
A ＝ HS CAN Bus ； B ＝ Medium Speed CAN Bus
1.0 346
Description
Overview
The engine management system mainly consists of sensor,
microprocessor (ECM) and actuator, used for controlling
the air inflow, fuel injection quantity and ignition advance
angle when the engine is working. This engine uses BOSCH
MED17 ECM. MED17 engine electronic control system has
the main characteristics of: accurate measurement of fuel
injection quantity; generation of required injection pressure;
determination of injection starting point; direct and accurate
fuel injection into combustion chamber. The system must
also coordinate different torque requirements in turn, and
then adjust the engine functioning according to the final
requirement. Torque adjustment is the central task of the Detailed Information List of Connector Pins
engine management system, the most important torque Pin No. Description
requirement comes from the accelerator pedal controlled A01 Cylinder 4 Ignition
by the vehicle driver, and the engine management system
generates a specific torque according to the position of the
accelerator pedal; in addition, further torque requirements A03 Fuel Control Valve -
can also come from: transmission shift control, traction A04 Fuel Control Valve +
control system and electronic stability control system. The A05 Variable Valve Timing Valve
intentions of the engine management system control are to: (Exhaust)
enhance power performance, reduce fuel consumption and A06 Sensor Ground
exhaust pollution. A07 5V Power Supply
Engine Control Unit (ECM) A08 Sensor Ground
The engine control unit is the control centre of the fuel A09 —
injection system. It monitors continuously the information A10 Knock Sensor -
from various sensors, controls various systems influencing
A11 Sensor Ground
the vehicle performance. It also executes system diagnosis
function. It is able to identify the operation fault, reminds the A12 5V Power Supply
driver with malfunction indicator lamp (MIL) and stores the A13 Sensor Ground
DTC at indication fault position to facilitate the repair of the A14 Sensor Ground
service personnel. A15 —
ECMWiring Harness Connector End View A16 Cylinder 1 Ignition
A18 Discarded Control Valve

A19 Electronic Throttle Control
+
A20 Electronic Throttle Control
-
A21 Intake Bleeder Valve
A22 Sensor Ground
A23 Engine speed sensor (Hall)
A24 —
A25 Knock Sensor +
A26 Sensor Ground
A27 5V Power Supply
1.0 347
A28 — K06 Main Relay Power 3

A29 5V Power Supply K07 —
A30 Throttle Digital SENT Signal K08 —
A31 Cylinder 1 Injection + K09 Starter Motor Relay
A32 Cylinder 4 Injection + K10 —
A33 Cylinder 1 Injection - K11 Sensor Ground
A35 Canister Control Valve K13 —
Sensor —
K15
A37 —
K16 —
A38 IAT sensor —
K17
A39 Intake Air Pressure Sensor —
K18
A40 Fuel Rail Pressure Sensor
K19 Brake Lamp Switch
A41 —
K20 A/C Request
A42 Alternator Load Signal
K21 Brake Switch
A43 —
K22 P/N Signal
A44 —
K23 —
A45 —
K24 —
A46 Cylinder 3 Injection + —
K25
A47 Cylinder 2 Injection +
K26 Cooling Fan Relay 3
A48 Cylinder 4 Injection -
K27 Cooling Fan Relay 1 and 2
A49 Cylinder 2 Injection -
K28 Low-pressure Fuel Pump
A50 Variable Valve Timing Valve Relay
(Intake)
K29 Downstream Oxygen
A51 Sensor Ground Sensor Heating
A52 Oil Control Valve K30 Continuous Power Supply
A53 Phase Position Sensor K31 Starter Motor Relay
(Intake) —
K32
A54 Phase Position Sensor
K33 Oxygen Sensor Ground
(Exhaust)
A55 Engine Oil Pressure Sensor K34 Oxygen Sensor Ground
A56 Ambient Temperature K35 Sensor Ground
Sensor
K36 —
A57 Water Temperature Sensor
K37 —
A58 Hot Film Air Flow Signal
(HFM7) K38 Speed Output to TCM
A59 Hot-film Air flow Meter K39 —

Sensor Ground K40 —
A60 Electronic Thermostat K41 —
K01 ECU Ground 1
K42 —
K02 ECU Ground 2
K43 Clutch Low Switch (only
K03 Main Relay Power 1 MT)
K04 ECU Ground 3 K44 CAN for Refresh Low
K05 Main Relay Power 2 K45 CAN for Refresh High
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K46 Neutral Switch (only MT) K84 Upstream Oxygen Sensor
— Signal
K47
K85 ACC Wake-up Signal
K48 Starter Feedback Signal
K86 —
K49 Reverse Gear Switch Signal
(only MT) K87 Ignition Switch
K50 Clutch High Switch (only K88 —
MT) —
— K89
K51
K90 —
K52 Sensor Ground
K91 —
K53 —
K92 —
K54 —
K93 —
K55 —
K94 —
K56 —
K57 — The engine management system is composed of the following
K58 — 6 parts according to control principle:
K59 5V Power Supply • External control
K60 A/C Pressure Sensor • Air supply control
K61 Accelerator Pedal Position • Ignition control
Sensor 2
• Fuel supply control
K62 Downstream Oxygen
Sensor • Accessory 1 (heat management)
K63 — • Accessory 2 (external auxiliary)
K64 — External Control
K65 — The external control of the engine mainly includes:
K66 — • Main relay
K67 —
• Ignition switch
K68 —
• Battery
K69 Main Relay • CANCommunication
K70 — • Anti-theft power supply
K71 — The external control refers to the power supply and
K72 A/C Compressor Relay communication. One of the power supplies of the engine
control unit (ECM) is directly connected to the power supply
Heating through fuse EF23 to ensure the ECM is in energized state.
— When the ignition switch is in "ON" or "IGN" position, the
K74
engine control unit can activate the main relay or connect
K75 —
with the ignition power supply.
K76 —
The engine control can communicate with controllers of
K77 —
other nodes on the network through CAN to ensure each
K78 — performance of the system. It can also connect the DLC and
K79 — help the service personnel to carry out diagnosis.
K80 — Main Relay Control
K81 5V Power Supply ECMWhen an ignition signal is received, it will close the main
K82 5V Power Supply relay which provides power for the throttle, several sensors
K83 Accelerator Pedal Position and actuator. And the ECM monitors the voltage of the
Sensor 1 system according to the relay voltage.
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Failure • Variable camshaft timing valve

The main relay may have failures under the following • Air flow meter
conditions: • Boost pressure control solenoid valve
• The relay winding is short-circuited. • Intake air pressure sensor
• The relay winding has a break circuit. • Intake bleeder valve
• The relay winding has a high resistance. The gasoline direct injection system requires a complicated
• Relay contact is normally open. engine management system to fully satisfy the high fuel
economy and high output power. In terms of gas mixture
• Relay contact is normally closed.
formation, the two basic operating modes are somewhat
different:
• Relay harness has a break circuit.
• Low Load Range
• Relay harness has a high resistance.
In this range, the engine works in a highly delaminated
• Relay harness connected to the 12V power supply is
and thin gas mixture so as to achieve the minimum
short-circuited.
possible fuel consumption. Injection is postponed
until the ignition timing, and the purpose is to obtain
• ECMNo ground access is provided. the ideal condition of formation of two layers in the
Carry out the following inspections to check whether the main combustion chamber: The first layer of combustible
relay can work normally: mixture is concentrated at the spark plug, and the
outer second layer is an isolation layer formed by
• Sound inspection - place the ignition key in "ON" position air and residual exhaust gas. So the engine can run
to check whether the fuel pump will work for 2s. under a larger non-throttling condition and avoid air
• Check whether the fuel injector or ignition coil has change loss. In addition, this also helps to avoid thermal
enough power (apply multimeter to check the battery loss of the combustion chamber wall and improve the
voltage). thermodynamic efficiency.
If the above are detected, the main relay is OK. • High-load Range
CANCommunication When the engine load and quantity of fuel injection rise,
The engine management system applies HS CAN the delaminated gas mixture gets increasingly rich, this
communication network for the communications between can deteriorate the emission, especially the black smoke.
ECM and ABS, BCM, TCM, and diagnoses outputs through Therefore, when the engine works at a higher load, the
DLC. gas mixture in the cylinder shall be evenly distributed.
The fuel injects into the cylinder during the intake stroke
Anti-theft Power Supply
so that the fuel and air can mix evenly.
When the ignition switch is in "ON" position, the ECM and
BCM communicate through the CAN HS bus and verify To precisely control the air inflow, the manifold absolute
information mutually. After verification, the BCM allows the pressure sensor, intake air pressure sensor and air flow meter
starter motor to work. When turning the key, the ECM are configured in the engine management system, and ECM
controls the ignition, fuel injection and engine start. If the obtains the air inflow information through these sensors.
harness connected to the anti-theft power pin of the ECM is After the air inflow information is obtained, on the one hand,
ECM can control the turbocharging system through the intake
disconnected, the engine anti-theft system will not work due
air discharge valve and boost control valve; on the other hand,
to lack of the 5V power, and the BCM cannot get verification
ECM can control the air intake and exhaust valves based on
information from the ECM, in this case, the starter motor
and engine do not work. the signal from intake and exhaust camshaft position sensor
for optimal control on the air inflow.
Engine Air Supply Control
Electronic Throttle
The engine air supply control system includes:
The electronic throttle is composed of throttle actuator,
• Electronic throttle body throttle driver (DC motor) and throttle position sensor, etc.
• Accelerator pedal module
ECMGive instructions to make the DC motor act and affect
• Manifold absolute pressure sensor the throttle opening through the drive mechanism; at the same
• Camshaft position sensor time, the throttle can give ECM a feedback signal indicating
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the current position of the throttle to realize throttle feedback • CMPSensor harness is short-circuited.
regulation. • CMPSensor harness has a high resistance.
Accelerator Pedal Module • Magnetic ring is contaminated by metallic debris.
The two potentiometers in the accelerator pedal module • The accuracy of the magnetic ring is poor due to
act as sensors, their resistance varies with the position of mechanical damage.
the electronic accelerator pedal, and the ECM can response • Exhaust camshaft timing is incorrect.
precisely to the movement of the accelerator pedal, so it can
• Intake camshaft timing is incorrect.
also monitor the motion of the accelerator pedal.
Variable Camshaft Timing Valve
Because both potentiometers are fitted in the same phase,
The engine control module outputs PWM signal to drive the
when the position of the accelerator pedal changes, their
solenoid. Change of the duty cycle may help to adjust the
resistance will increase or decrease linearly. When a +5V
opening of the solenoid.
voltage is added, the position of the pedal will be transformed
into a voltage output which varies with the resistance. Under low engine speed, the system can reduce fuel
These two potentiometers and two potentiometers on the consumption and emission and improve the performance of
electronic throttle used for monitoring the position of the the engine, especially torque characteristics.
throttle form part of the monitoring function of the whole
ECMReceive signals from the CKP sensor and CMP sensor.
electronic throttle control system, which can provide the
With these signals, the ECM determines the valve timing by
redundancy protection expected by the system control.
consulting the control chart. Then the ECM operates the oil
Intake Air Temperature/Pressure Sensor (TMAP) control valve on the cylinder head side. These solenoids adjust
The intake air temperature/pressure sensor is fitted on the valve timing by controlling the oil to flow into the phase
the pipe between the intercooler and the throttle. The modulator and changing the position of the phase modulator
pressure is measured by a piezoelectric type sensor which relative to the camshaft.
can perform direct pressure measurement through sensing Hot Film Meter (HFM)
elements. It provides "load signal" for the controller according
HFMIt works according to the hot film principle. HFMThere
to the pressurized intake manifold pressure measured. The
are two sensing elements in one film. One element stays in
controller supplies the 5V power, and the boost pressure
ambient temperature, such as 25℃ (77℉) while the other is
sensor provides the 0-5V voltage feedback for the controller
heated to 200℃ (392℉), exceeding 225℃ (437℉). The air
based on different boost pressures.
passing by HFM will generate a cooling effect on the hot film.
Camshaft Position (CMP) Sensor The air flow which maintains the temperature difference of
The camshaft position sensor is applied to cooperate with 200°C (392°F) may provide precise and non-linear signal.
the rotational speed sensor in the circumstances without the HFMIt is combined with the NTC thermistor in the voltage
electricity distributor, to provide ECM with the camshaft divider circuit. The resistance value of the thermistor
phase information, namely, identify the compression top dead decreases with the increase of the intake air temperature.
center and exhaust top dead center of the cylinder 1. NTCThe thermistor current forms a voltage division circuit,
The camshaft position sensor is composed of a hall sensor the variation of the reference voltage which controls the
and a rotor made of steel plate. The hall sensor is fixed, and voltage division circuit is transformed by the HFM into a
the rotor with a 36° arc boss is fitted on the camshaft. The more stable frequency signal output for the ECM, and the
magnetic field inside the hall sensor will change when the boss ECM calculates the air flow and corrects the quantity of fuel
passes it, which leads to change of the output signal voltage. In injection by this frequency signal.
this way, the two top dead centres are identified. If the HFM fails, the ECM performs the alternative strategy.
Failure If the HFM signal error occurs, the following symptoms may
occur:
CMPThe sensor or magnetic ring may have failures or provide
incorrect signals under the following conditions: • Hard start
• CMPSensor gap fails to comply with the specifications. • Engine stops after starting
• CMPSensor is contaminated by metallic debris. • Emission control does not work
• CMPSensor hall-effect semiconductor is damaged. • Idle speed control does not work
• CMPSensor magnetic field is too weak. • Engine performance degradation
• CMPSensor harness has a break circuit.
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If the NTC thermistor fails, the ECM defaults the set air
temperature to -5°C (23°F). If signal error of the NTC
thermistor occurs, one of the following symptoms can be
observed:
• Black smoke is caused by excessive oil supply

Boost Pressure Control Solenoid Valve
The boost control solenoid valve uses the duty cycle
information from the ECM to adjust the boost pressure of
the turbocharger. The greater the duty cycle is, the higher the
boost pressure will be.
When the engine works at medium load or small load, the

1. Compressor
boost solenoid valve controls the diaphragm type bypass
2. Turbine
valve to lead the exhaust gas from the exhaust pipe into the
bypass pipeline, and the boost pressure is extremely small at 3. Intake bleeder valve
the moment; when the engine accelerates or works at high 4. to intake
load and high speed, the boost solenoid valve controls the 5. to exhaust
diaphragm type bypass valve to reduce the bypass opening
Engine Ignition Control System
of the exhaust pipe, then the exhaust gas flows into the
turbocharger and the boost pressure rises at this stage. The engine ignition control system includes:
Manifold Absolute Pressure Sensor (MAP) • Ignition coil 1～4
The manifold absolute pressure sensor is fitted in front of the • Crankshaft position (CKP) sensor
intake manifold. The pressure is measured by a piezoelectric • Knock sensor
type sensor which can perform direct pressure measurement Ignition Coil
through sensing elements. It may provide the "load signal" to
The ignition coil converts the battery low voltage DC to high
the controller according to the measured manifold pressure;
voltage and uses the spark by spark plug discharge to ignite the
the controller provides a 5V voltage and feeds back a 0～5V
gas mixture in the cylinder. Each ignition coil consists of a pair
voltage to the controller depending on boost pressure.
of coil windings around laminated iron core.
Turbocharger Bleeder Valve
There are four ignition coils fitted on the camshaft cover. They
The intake bleeder valve is mainly used to recirculate the
are fitted to each cylinder, and connected with the harness
pressurized air in the compressor in the turbocharging system
through a connector. A spark plug is provided under each coil.
to the air intake pipe, so that the boost pressure rapidly
decreases during engine surge and gear shift. Failure
The ignition coil may have failures under the following
ECMIt sends "ON/OFF" command to instruct the solenoid
conditions:
valve of the intake bleeder valve to work. When the solenoid
valve opens, the compressed air can circulate into the intake • Primary winding has a break circuit.
pipe, see the figure below: • Primary winding is short-circuited.
• The resistance of primary winding is out of tolerance.
• Secondary winding has a break circuit.
• Secondary winding is short-circuited.
• The circuit connecting secondary winding with primary
winding is short-circuited.
• The resistance of secondary winding is out of tolerance.
• Coil top insulation is mechanically damaged.
Crankshaft Position (CKP) Sensor
CKPThe sensor provides information of the engine speed
and crankshaft TDC, which is a hall-effect sensor and used in
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conjunction with the pulse wheel. The pulse wheel is a tooth • Sensor ground is short-circuited.
plate, with 58 small teeth spaced at an interval of 6°on the • Sensor circuit intermittently breaks.
magnetic ring and with 2 teeth absent. The pulse wheel is
• Knock sensor is improperly fitted.
fitted on the crankshaft, which rotates with the crankshaft.
When the tooth tips pass by sensor ends, the pulse wheel In case of knock sensor signal error, the following symptoms
made of steel magnetic materials cuts the magnetic force line may occur:
of the permanent magnets in the sensor and produces induced • Failure code is stored.
voltage in the coil, which will be output as the speed signal.
• ECMFailure to inspect engine combustion knock.
Failure
• ECMRestore default settings.
CKPThe sensor or magnetic ring may have failures or provide Engine Fuel Supply Control System
The engine fuel supply control system mainly includes:
• CKPSensor gap fails to comply with the specifications.
• Upstream oxygen sensor
• CKPSensor is contaminated by dust.
• Downstream oxygen sensor
• CKPSensor hall-effect semiconductor is damaged.
• Fuel injector 1 ~ 4
• CKPSensor magnetic field is too weak.
• Canister valve
• CKPSensor harness has a break circuit.
• Low-pressure fuel pump relay
• CKPSensor harness is short-circuited.
• Fuel control valve
• CKPSensor harness has a high resistance.
• Fuel rail pressure sensor
• Magnetic ring is contaminated by dust.
• The precision of magnetic ring is low due to erosion or The engine fuel supply control system is applied to control the
mechanical damage. fuel supply of the engine under different working conditions.
• The CKP sensor signal is distorted due to out-of-round MED-Motronic injection system stores the fuel to the fuel rail
flywheel or drive disk. according to the specific pressure, and the fuel is injected into
• The CKP sensor signal is changed due to crankshaft the combustion chamber by the electromagnetically controlled
radial movement. injector. And thus it can provide the following functions:
Check if the ECM has received the signal from the CKP • Free selection of injection starting point
sensor by following operations: • Variable system pressure
• Check the fuel pump during engine start, if the fuel pump Heated Oxygen Sensor
supplies fuel when the ignition starts, but does not work The oxygen sensor is a heated oxygen sensor which measures
yet, the ECM fails to receive the signal from the CKP the oxygen content in the engine exhaust and determines if
sensor. the oil and air are burnt completely. The electronic controller
Knock Sensor achieves the closed-loop control goal (excess air coefficient λ =
1) according to the information and ensures that the three-way
The knock sensor is used to provide the electronic controller
catalytic converters have a higher efficiency in converting HC,
ECM with engine knock information for knock control.
CO and NOx in the exhaust.
The knock sensor is a vibration acceleration sensor. It is fitted
Its sensing element is a ceramic tube, the outside connects
on the engine cylinder block. The sensitive element of the
the exhaust and the inside connects the atmosphere. When
sensor is a piezoelectric crystal. The vibration of the engine
the temperature of sensing ceramic tube reaches 350℃, it
block is transferred to the piezoelectric crystal through the
has the property of solid electrolyte. With this property, the
mass block in the sensor. The vibration of the mass block
concentration difference of oxygen can be converted into
can produce pressure which helps the piezoelectric crystal
potential difference which forms electric signal outputs. If the
to generate voltage on both pole surfaces and transform the
gas mixture is rich, the concentration difference of oxygen
vibration signal into voltage signal output.
inside and outside the ceramic tube is high, the potential
Failure difference is high, a large amount of oxygen ions move from
The knock sensor may have failures or provide incorrect signals inside to outside and the output voltage is high (approximate
under the following conditions: to 900mV); if the gas mixture is thin, the concentration
difference of oxygen inside and outside the ceramic tube is
• The sensor has a break circuit.
low, the potential difference is low, only a few of oxygen ions
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move from inside to outside and the output voltage is low It is a DC motor driven vane pump, which is located in the fuel
(approximate to 100mV). tank and immersed in fuel. It utilizes fuel for heat dissipation
Failure and lubrication. The battery supplies power for the electric
low-pressure fuel pump via the low-pressure fuel pump relay
HO2SIt may have failures or provide incorrect signals under
which connects the electric low-pressure fuel pump circuit
the following conditions:
only when the power is on and the engine is starting or running.
• Contaminated by leaded fuel. When the engine stops due to accident, the fuel pump will stop
• Carbon or silicon deposit contaminant is found. automatically.
• Impact damage/mechanical impact. Failure

• External harness has a break circuit. If the low-pressure fuel pump relay fails, the following
• External harness connected to the 12V power supply is symptoms will be found:
short-circuited. At the time of startup
• External harness is short to ground. • If the low-pressure fuel system pressure falls to zero, the
• External harness has a high resistance. engine will fail to ignite.
• Heating device has a break circuit. • If the pressure of the low-pressure fuel system is lower
• Heating device is short-circuited. than normal operating pressure (0.38MPa), the engine
• ECMGround access for heating device is not available. may try to ignite, but it fails to operate normally.
• Harness shielding is not connected to the ground. • If the pressure of the low-pressure fuel system is normal,
the engine will ignite to operate, but will flame out finally
Canister Control Valve
with decrease in fuel pressure, and fails to restart.
The canister control valve is applied to control the
While driving
regeneration air flow of the fuel evaporation control system.
The canister in the fuel evaporation control system absorbs If the low-pressure fuel pump relay fails during driving, the
fuel vapor from the fuel tank till it cannot absorb any more. engine will lose power and be finally off due to shortage of
ECMWhen the canister control valve opens, fresh air and fuel.
saturated fuel steam in the canister form regeneration air flow
The low-pressure fuel pump relay may have failures under the
which will be reintroduced to the engine intake pipe.
following conditions:
The electronic controller changes the duty cycle of the
• Relay coil is short-circuited.
pulse signal transmitted to the canister control valve coil and
• Relay coil has a break circuit.
controls the regeneration air flow based on different working
conditions of the engine. Moreover, the flow is also influenced • Relay coil has a high resistance.
by the pressure difference on both ends. • Relay contact is normally open.
Failure • Relay contact is normally closed.
The canister control valve may have failures under the following • Relay contact has a high resistance.
conditions: • Relay harness has a break circuit.
• Electromagnetic winding has a break circuit. • Relay harness has a high resistance.
• Electromagnetic winding is short-circuited. • Relay harness connected to the 12V power supply is
• External harness connected to the 12V power supply is short-circuited.
short-circuited. • Relay harness is short to ground.
• External harness is short to ground. • ECMFailure to provide a ground access.
• External harness has a high resistance. Carry out the following inspections and check the
• ECMFailure to provide PWM signal. low-pressure fuel pump relay for normal operation:
• Mechanical problems occur in the valve. • Sound inspection - place the ignition key in "ON" position
Low-pressure Fuel Pump Relay to check whether the fuel pump will work for 2s.
The electric fuel pump transfers the fuel from the fuel tank to • If there is no response, check the inertia switch and
the engine and provides sufficient fuel pressure and fuel. ensure it is not triggered accidentally. If there is no sign
that the fuel pump is working, but the inertia switch is in
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"ON" position, remove the low-pressure fuel pump relay piezoelectric crystal resistance value, and sends a voltage
and conduct inspections. signal to ECM.
When the ignition key is in "ON" position (for 2s) and Fuel Injector
the vehicle is starting, check if the ECM provides the According to the instructions of the ECM, the injector injects
ground access for the relay winding of the low-pressure fuel fuel within the specified time, supplies the engine with fuel
pump. Remove the low-pressure fuel pump relay, connect a and atomizes it. ECMIt energizes the injector coil to form
multimeter between the 12V power supplied by the vehicle magnetic force. When the magnetic force is strong enough
and the fuse box pin connected with fuel pump pin 85, check to overcome the resultant force of the return spring pressure,
the output according to the circuit diagram after the ignition needle valve gravity and friction, the needle valve begins to rise,
is on. and the fuel injection process starts. When the fuel injection
As the ECM internal drive circuit consumes voltage, the pulse ends, the pressure of return spring makes the needle
measured voltage may be lower than battery voltage. valve close again.
Direct Fuel Injection System Failure
The direct fuel injection system is composed of the The fuel injector may have failures under the following
high-pressure fuel pump, fuel pipe (fuel pump to fuel rail), fuel conditions:
rail assembly (including fuel rail, fuel rail pressure sensor, fuel • Nozzle is contaminated by dust or wax (flow is reduced).
injector) and low-pressure fuel pipe (before the high-pressure
• Nozzle offsets (injection is positioned incorrectly).
pump). The system operating pressure is 20MPa.
• Fuel filter blockage.
High-pressure Fuel Pump
• Winding has a break circuit.
The function of the high-pressure fuel pump is to pressurize
• Winding is short to ground.
the low-pressure fuel and deliver high-pressure fuel to the
fuel pump through the high-pressure fuel pipe. Minimize the • Winding connected to the 12V power supply is
fluctuation of the fuel rail pressure and ensure it will not mix short-circuited.
with any oil. • The resistance of winding is out of tolerance.
The working process goes like this: when the fuel pump • External harness has a break circuit.
plunger goes down, the fuel pump is in the fuel suction stroke, • External harness is short to ground.
and the low-pressure fuel enters into the cavity of the fuel • External harness connected to the 12V power supply is
pump plunger; the plunger starts to goes up after reaching the short-circuited.
BDC, and the pressurized fuel is delivered to the high-pressure Accessory 1 (Heat Management)
fuel rail.
The heat management portion mainly includes:
Fuel Control Valve
• A/C compressor relay
ECMIt controls the high-pressure fuel flow by commanding
the fuel control valve to open/close. • A/C pressure sensor
• Coolant temperature sensor
For the front half of the rising part of the high-pressure fuel
pump plunger, if the solenoid valve is not energized, the • Cooling fan
fuel control valve is open, and the fuel cannot generate any • Electronic thermostat control
pressure, so part of the fuel returns to the low-pressure oil According to the coolant temperature, the engine opens or
circuit by the control valve. closes the cooling fan relay.
After solenoid valve activation, the fuel control valve starts When the driver presses the A/C option (switch) on the
to close, it will be fully closed after a while, and the plunger instrument panel, the engine control unit turns on the
cavity is also fully closed at this point. The plunger keeps going A/C according to the current signal of the engine coolant
up, when the pressure in the plunger cavity continues to rise temperature sensor and engine speed, etc.
(above rail pressure), the high-pressure fuel will be pumped
Coolant Temperature Sensor
into the fuel rail.
Fuel Rail Pressure Sensor The coolant temperature sensor is used to provide the
information of the engine coolant temperature so that the
The fuel rail pressure sensor is used to measure the pressure controller can correct the fuel injection and ignition. It is
in the fuel rail. It measures the pressure based on the a negative temperature coefficient (NTC) thermistor, its
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resistance value is reduced as the temperature rises, but not a Accessory 2 (External Auxiliary)
linear relationship. The thermistor is mounted inside a copper
The external auxiliary portion mainly includes:
heat sleeve.
• Alternator control input
Failure
• Brake pedal switch
ECTThe sensor may have failures or provide incorrect signals
• Brake lamp
under the following conditions:
Alternator load input
• The system is lack of coolant due to leakage.
The alternator load input refers to the feedback signal sent by
• External harness has a break circuit.
the alternator to the ECM according to the electrical condition
• External harness is short to ground. of the vehicle. Variation of the engine load can significantly
• External harness connected to the 5V power supply is affect engine idle speed. To compensate the load and stabilize
short-circuited. the idle speed, the ECM needs to acquire the torque/load
• External harness has a high resistance. information from the alternator.
• ECMFailure to provide a ground access. Brake Pedal Switch
• ECTThe thermistor is damaged. The brake switch is located on the pedal box in the driver
Cooling Fan compartment. ECMIt monitors the switch status and
transfers the data to TCM via the CAN bus, and the TCM
The ECM controls the 3 relays and the 3 cooling fan gears
controls the transmission clutch to open. When operating
by the two PINs. The ECM controls the cooling fan speed
the brake pedal, activate the brake switch.
based on the A/C request, engine coolant temperature, A/C
pressure, ambient temperature and vehicle speed. If the engine Cruise Control System
coolant temperature is still high after the engine stops, the The cruise control system can allow the vehicle to move
ECM will keep the cooling fan running for a while. in a constant and comfortable speed without applying the
Electronic Thermostat accelerator pedal. Cruise control system involves:
The electronic thermostat adjusts engine coolant temperature, • Brake switch

ensures the coolant temperature can rise rapidly and prevents • Cruise control switch
hot engine. When the engine works at a low/medium load,
• Cruise indicator lamp
increase of the engine coolant temperature can decrease
• Automatic transmissionTCM
oil viscosity, mechanical friction loss of the piston and heat
transfer loss and optimize combustion; when the engine works • ECM
at a high load/speed, decrease of the engine temperature can • Electronic throttle
cool the engine rapidly. Cruise control switch
ECMIt gives PWM to command the electronic thermostat to The cruise control switch is a handle switch which is used to
work, when the paraffin and wax package of the heater core engage/disengage the cruise control system and adjust the set
expand, the paraffin applies pressure to the push rod. The speed.
upper side and housing of the push rod are fixed, so the push
The cruise control switch is connected with the GW which
rod pushes the whole core to move down reversely, and the
transmits network signal to the ECM, provides different
interference fit between the copper cap and the main valve
voltage signals for the ECM by different switches and identifies
drives the main valve to open. The opening of the electronic
the current status of the cruise control.
thermostat is proportional to the duty cycle of the PWM
signal. Cruise Indicator Lamp
When the temperature of the engine coolant is above 97℃, The indicator lamp indicates the status of the cruise control
the thermostat starts to open step by step, the engine coolant system. The lamp is located on the instrument pack. When
enters into a systematic circulation (radiator) for cooling, it the cruise control system is on standby, the cruise indicator
then returns to the water pump inlet; when the temperature illuminates green; when the cruise control system is activated,
of the engine coolant reaches 112℃, the thermostat is fully the cruise indicator illuminates yellow.
open. When the temperature of the engine coolant is below Standby
97℃, the thermostat is closed, and the coolant directly comes
When the handle is in "ON" position, and the vehicle is in an
to the water pump inlet.
ideal state for driving, the cruise control system enters into
standby state.
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• Non-brake State The vehicle can also be accelerated by the accelerator pedal.
• The road speed is within 40 -200 km/h. With the cruise control system activated, if release the
accelerator pedal, the speed at that moment is the set speed;
• The engine is working and the vehicle speed is above
if turn the switch +, the higher vehicle speed will be used as
5 km/h.
the new set speed.
• Engine speed is less than 6496 rpm.
Resume/Pause
• The transmission is not in "P" gear, "N" gear or "R" gear
(for automatic transmission). When the cruise control system is in standby, turn
the RESUME switch to resume the system and
• The transmission is in the 3rd gear (for manual
accelerate/decelerate to the set speed stored. Turn the
transmission).
CANCEL switch to pause the cruise control system, i.e. shift
• The TCS is not activated. from activation to standby.
Activation
When one of the conditions for operating the cruise control
When it is in STANDBY, push the handle switch (SET button) system does not exist (e.g. applying the brake), the cruise
to activate the cruise control system. The switch outputs the control system pauses. If the vehicle speed drops below 70%
signal to the ECM, the ECM operates the electronic throttle of the set speed, such as driving uphill, the cruise control will
and generates the control required by the throttle. also pause.
When the cruise control system is activated, it sets the target If the vehicle speed continuously exceeds the cruise set
cruise speed by the handle +/-. After receiving the input speed by 16km/h (for more than 30s), such as depressing the
information from the switch +/-, the ECM stores current accelerator pedal or driving downhill, the cruise control will
speed as set speed, operates the electronic throttle and pause.
maintains the set vehicle speed.
Cancellation
Acceleration/Deceleration
Turn the handle switch to "OFF" or place the ignition switch
When the cruise control system is activated, in "OFF" position to cancel the cruise control function. When
accelerate/decelerate with the handle +/-. the cruise control function is canceled, the set speed in the
Turn the switch +/- (less than 0.5s) to increase/decrease cruise control system is eliminated and the indicator lamp on
the vehicle set speed at the speed of 1km/h and the IPK turns off.
accelerate/decelerate to the new set speed. Turn and hold the
switch +/- to maintain the acceleration/deceleration until the
switch is released. On this point, the accelerated/decelerated
speed will be adopted as the new set speed.
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Service Procedures 12. Remove 2 bolts fixing the fuel pump to the engine, and
Fuel Pump remove the high-pressure fuel pump and roller tappet.
Remove
Caution: Before removing the high-pressure system,
3. Place cloths with strong absorptivity around the fuel rail
high-pressure fuel pipe to collect the spilled fuel.

operation. Ensure that all necessary precautions are Refit
1. Ensure that the high-pressure fuel pump drive cam is at
4. Slowly loosen the high-pressure fuel pipe nut at the the bottom dead center.
high-pressure fuel rail end until the fuel flows out, and
2. Apply engine oil to the cam, fuel pump seat hole and
remove the nut when no fuel flows out.
tappet evenly.
5. Remove the cloth from the high-pressure fuel rail, and
3. Fix the fuel pump and roller tappet to the engine, fit 2
put it into a permissible container.
Caution: When tightening the fuel pump bolts, if
6. Remove the high-pressure fuel pipe nut of the there is any equipment, both bolts are to be
high-pressure fuel pump to remove and discard the tightened to the specified torque; if there is no
high-pressure fuel pipe. equipment, the bolts are to be repeatedly tightened
Caution: Always fit plugs to open connections to prevent in turn, and it is not allowed to tighten 1 bolt
contamination. after another.
7. Disconnect the connector of high-pressure fuel pump. 4. Fit the fuel pump sponge noise enclosure.
8. Remove the clip fixing the harness to the high pressure 5. Fix the high-pressure fuel pump protecting bracket
fuel-pump bracket, and remove the harness. to the engine cylinder block, fit 3 bolts, tighten to
9. Disconnect the low-pressure fuel pipe from the
high-pressure fuel pump. 6. Connect the low pressure oil pipe.
10. Remove 3 bolts fixing the high-pressure fuel pump 7. Locate the harness to the high-pressure fuel pump
protecting bracket to the engine cylinder block, and bracket, fix it with clips, and connect the connector of
remove the high-pressure fuel pump protecting bracket. high-pressure fuel pump.
8. Fix a new high-pressure fuel pipe to the fuel pump and
fuel rail, fit 2 nuts, and tighten to 28–32Nm.
11. Remove the fuel pump sponge noise enclosure.
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Fuel Rail
Remove
Caution: Before removing the high-pressure system,
3. Place cloths with strong absorptivity around the fuel rail
high-pressure fuel pipe to collect the spilled fuel.

Warning: The spilling of fuel is unavoidable during this 13. Remove 8 bolts fixing the fuel rail to the cylinder head,
operation. Ensure that all necessary precautions are and remove the fuel rail.
4. Slowly loosen the high-pressure fuel pipe nut at the
high-pressure fuel rail end until the fuel flows out, and
remove the nut when no fuel flows out.
5. Remove the cloth from the high-pressure fuel rail, and
put it into a permissible container.
6. Remove the connecting nut between the high-pressure

fuel pump and high-pressure fuel pipe, remove the
high-pressure fuel pipe, and discard the high-pressure
fuel pipe.

Refit
contamination.
1. Place the fuel rail assembly, and align the fuel injector
7. Disconnect the fuel rail harness from the engine and 8 bolts of fuel rail with their mounting holes. Press
harness. it down to allow the interface of the fuel injector to
8. Disconnect the connector of the fuel rail pressure totally engage with 4 fuel injectors until the mounting
sensor. surfaces of 8\4\2\6 bolts fit the cylinder heads.
9. Remove the fixing clip fixing the engine harness to the 2. Fit 8 bolts fixing the fuel rail to the fuel injectors,
fuel rail. tighten them to 4–6Nm, and check the torque.
10. Remove the ignition coil. 3. Tighten 8 bolts manually in the sequence of
Ignition Coil Remove 8-4-2-6/7-3-1-5. Tighten 8 bolts in the sequence of 1-8.
Tighten the bolt to half of the final torque at the first
11. Disconnect the connector on the fuel injector.
time, then further tighten to the final torque 9–11Nm,
12. Remove 8 bolts fixing the fuel rail to the fuel injector. and check the torque.
4. Connect the connector on the fuel injector .
5. Fit the ignition coil.
Ignition Coil Refit
6. Connect the fuel rail harness and engine harness.
7. Fix a new high-pressure fuel pipe to the fuel rail
and high-pressure fuel pump, fit 2 nuts, tighten to
8. Connect the connector of the fuel rail pressure sensor.
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Fuel Injector Spark Plug

Remove Remove
1. Remove the fuel rail assembly. 1. Remove the ignition coil.
Fuel Rail Assembly Remove Ignition Coil Remove

2. Remove 4 fuel injectors with the TEN00121 and 2. Clean the area around the spark plug. Remove the dust
TEN00140, and discard 16 fuel injector seal rings. around the spark plug with high pressure gas.
3. Remove 4 spark plugs with the spark plug socket.
Refit
1. Clean the groove of the fuel injector and fuel rail. Refit
2. Fit the fuel injector seal rings to the steering tool of 1. Identify the model of the original spark plug before
the special tool TEN00064, then fit the fuel injector fitting a new one. Spark plug of the same model shall
seal rings to the fuel injector with the special tool be selected for replacement.
TEN00064, and fit the fuel injector seal rings in 2. Fit the spark plug, tighten to 20Nm, and check the
sequence. torque.
3. Fit the ignition coil.
Ignition Coil Refit
3. Fix the fuel injector into the fuel injector seat hole in
the cylinder head, and fit it in place.
4. Fit the fuel rail assembly.
Fuel Rail Assembly Refit
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Engine Control Module (ECM) Self-learning and Adjustment, Programming and
Remove Encoding - ECM Replacement
1. Disconnect the battery negative. 6. Perform self-learning for the electronic throttle.
2. Remove 4 bolts securing ECM bracket to firewall. Electronic Throttle Self-learning
3. Disconnect the connector from the ECM.
Caution: When disconnecting the ECM connector,

avoid shaking the connector all round; avoid
applying the force on one side; avoid damaging the
connector structure.
4. Remove 4 nuts securing ECM to the body firewall.
Refit
1. Fix the ECM to the firewall, fit 4 nuts, tighten to
2. Fix the wire harness and connect it to ECM connector.
Caution: ECMWhen connecting the connector, align

the connector and insert the two ends with even
effort. Never tilt it or attempt to fit it by
applying force to one side only. If the connector
is damaged, replace the engine harness.
3. Fix the ECM bracket to the firewall, fit 4 bolts, tighten
5. Programme and encode ECM.
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Ignition Coil Crankshaft Position Sensor

Remove Remove
2. Disconnect 4 ignition coil connectors. 2. Raise the vehicle on the lift.
3. Remove 4 bolts fixing the ignition coil to the cylinder 3. Disconnect the electrical connector from the crankshaft
head. position sensor.
4. Remove 1 bolt fixing the crankshaft position sensor
to the cylinder block.
4. Hold the rubber bush end of the ignition coil, and pull
out the ignition coil from the spark plug (if it is hard to
pull it out, rotate the ignition coil right and left).
5. Remove the crankshaft position sensor.
Refit
1. Clean the mating surface of the crankshaft position
2. Secure the crankshaft position sensor to the cylinder
block, fit 1 bolt and tighten to 8–12Nm.
3. Connect the crankshaft position sensor connector.
6. Place the ignition switch in ON, and use VDS to
perform "ECM Adaption Reset".
7. Wait for 2-5 seconds, and turn off the ignition switch,
Refit then re-start the vehicle.
1. Fit 4 ignition coils to the spark plug, fit 4 fixing bolts,

2. Connect the ignition coil connector.
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Engine Coolant Temperature Sensor Manifold Absolute Pressure Sensor
Remove Remove
2. Remove the coolant expansion tank cap to release the 2. Disconnect the manifold absolute pressure sensor
pressure of the cooling system, and fit the cap. connector.
Warning: Since injury such as scalding could be caused by 3. Remove 1 screw fixing the manifold absolute pressure
escaping steam or coolant, do not remove the filler cap sensor to the manifold.
3. Disconnect the vacuum hose from the vacuum pump,
and remove the vacuum hose.
4. Loosen the clip of the coolant temperature sensor.
4. Remove the manifold absolute pressure sensor.

Refit
1. Fix the manifold absolute pressure sensor to the
manifold, fit 1 screw, and tighten to 4–6Nm.
5. Disconnect the coolant temperature sensor connector. 2. Connect the manifold absolute pressure sensor
connector.
6. Pull up and remove the coolant temperature sensor.
7. Prepare a proper container to collect the spilled
coolant.
Refit
1. Clean the coolant temperature sensor.
2. Check the sensor seal ring for aging, deformation,
fracture, etc., if any, the sensor assembly is to be
replaced.
3. Fit the coolant temperature sensor, and fix it with clips.
4. Connect the coolant temperature sensor connector.
5. Fit the vacuum hose to the vacuum pump.
7. Check the coolant level, refill if necessary.
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Camshaft Position Sensor Camshaft Phase Adjustment Solenoid Valve

Remove Remove
2. Disconnect the connectors from the intake/exhaust 2. Remove the engine hood.
camshaft position sensor respectively. 3. Disconnect the connectors of 2 camshaft phase
3. Remove 2 bolts securing the intake/exhaust camshaft adjustment solenoid valves.
position sensor to the cylinder block respectively, then 4. Remove 2 bolts used for fixing 2 camshaft phase
remove 2 camshaft position sensors. adjustment solenoid valves to the engine.
Refit 5. Remove 2 camshaft phase adjustment solenoid valves.

1. Clean 2 camshaft position sensors and the mating Refit
surface.
1. Fix 2 camshaft phase adjustment solenoid valves to the
2. Check the sensor sealing washer for aging, deformation, engine, fit 2 bolts, and tighten them to 8–12Nm.
crack, etc. If any, replace the sensor assembly.
2. Connect the connectors of 2 camshaft phase adjustment
3. Secure the intake and exhaust position sensors to the solenoid valves.
camshaft cover, fit 2 bolts and tighten to 8–12Nm.
4. Connect 2 camshaft position sensor connectors.
6. Place the ignition switch in ON, and use VDS to
perform "ECM Adaption Reset".
7. Wait for 2-5 seconds, and turn off the ignition switch,
then re-start the vehicle.
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Oil Pressure Sensor Knock Sensor
Remove Remove
2. Remove the starter motor. 2. Remove the starter motor.
Starter Motor Remove Starter Motor Remove
3. Disconnect the connector of the oil pressure sensor. 3. Disconnect the knock sensor connector.
4. Place the oil sink under the sensor to collect the spilled 4. Remove 1 bolt securing the knock sensor onto the
oil. cylinder block, and remove the knock sensor.
5. Remove the oil pressure sensor with the socket.
Refit
Refit 1. Clean the mating surface of the knock sensor and
1. Clean the thread of oil pressure sensor. cylinder block.
2. Fit new sealant to the oil pressure sensor, fit the oil 2. Fix the knock sensor onto the cylinder block, fit 1 bolt
pressure sensor to the engine, tighten the sensor to and tighten to 16–24Nm.
31–39Nm and check the torque. 3. Connect the knock sensor connector.
3. Connect the connector of oil pressure sensor. 4. Fit the starter motor.
4. Fit the starter motor. Starter Motor Refit
Starter Motor Refit 5. Connect the battery negative.
6. Check the engine oil level, and refill if necessary.
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Oxygen Sensor with the special tool 14-18Nm, tighten to 40–60Nm,

Remove and check the torque.
1. Disconnect the battery negative cable. 6. Connect the front oxygen sensor connector.
2. Disconnect the front oxygen sensor connector (1). 7. Connect the battery negative cable.
3. Remove the front oxygen sensor (2) from the three-way
catalyst with the special tool TEN00011.

5. Disconnect the rear oxygen sensor connector (1).
6. Remove 1 bolt fixing the rear oxygen sensor connector
bracket to the gearbox (2).
7. Remove the rear oxygen sensor (3) from the front

exhaust pipe with the special tool TEN00011.
Refit
1. Fit the rear oxygen sensor to the front exhaust
pipe with the special tool TEN00011, tighten to
2. Fit 1 bolt fixing the rear oxygen sensor connector
bracket to the gearbox, and tighten to 14-18Nm.
3. Connect the rear oxygen sensor connector.
5. Fit the front oxygen sensor to the three-way catalyst
1.0 366
Canister Solenoid Turbocharger Electrically Controlled Bypass
Remove Valve
Remove
2. Disconnect the connector of carbon canister solenoid 1. Disconnect the battery negative.
valve (1). 2. Disconnect the connector of the turbocharger
3. Disconnect the vacuum hose from the canister solenoid electrically controlled bypass valve (1).
(2). 3. Disconnect 3 hoses connected with the turbocharger
4. Disconnect the fuel breathing hose from the canister electrically controlled bypass valve (2).
solenoid (3). 4. Remove 1 bolt fixing the control valve to the
5. Remove the canister solenoid from the canister turbocharger, and remove the turbocharger electrically
solenoid bracket of the engine cylinder block. controlled bypass valve (3).
Refit Refit
1. Connect the fuel breather hose to the canister solenoid 1. Fix the turbocharger electrically controlled bypass valve
valve. to the turbocharger, fit 1 bolt, tighten to 4–6Nm, and
check the torque.
2. Connect the vacuum hose to the canister solenoid
valve. 2. Connect 3 hoses to the turbocharger electrically
controlled bypass valve.
3. Connect the canister solenoid valve connector.
3. Connect the connector of the turbocharger electrically
4. Fix the canister solenoid valve to the canister solenoid
valve bracket of the engine cylinder block.
1.0 367
Turbocharger Relief Valve the turbocharger.

Remove
2. Disconnect the turbocharger inlet pipe from the
turbocharger and remove the pipe.
7. Remove the turbocharger relief valve.

Refit
1. Fix the turbocharger relief valve to the turbocharger, fit
3 bolts, tighten to8–10Nm, and check the torque.
3. Disconnect the joint (1) of turbocharger to intercooler
2. Connect the connector of the turbocharger relief valve.
hose turbocharger from the turbocharger and remove
3. Connect a hose of the turbocharger electrically
the pipeline.
4. Remove the turbocharger to intercooler hose to the
turbocharger.
5. Fit the turbocharger inlet pipe to the turbocharger, and
fix it with clamps.
4. Disconnect a hose of the turbocharger electrically

controlled relief valve and remove the pipeline.
5. Disconnect the connector of the turbocharger relief

valve.
6. Remove 3 bolts fixing the turbocharger relief valve to
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Intake Air Temperature and Pressure Sensor
Remove
2. Remove 2 bolts fixing the expansion tank to the upper
radiator beam, remove the expansion tank.
3. Disconnect the connector of the intake air temperature
pressure sensor.
4. Remove 1 bolt fixing the intake air temperature and
pressure sensor to the hose from intercooler to engine,
and remove the intake air temperature and pressure
sensor.
Refit
1. Fix the air intake temperature and pressure sensor to
the hose from intercooler to engine, fit 1 bolt, and
tighten it to 3–4Nm.
2. Connect the connector of the intake air temperature
and pressure sensor.
3. Fix the expansion tank the battery bracket, fit 2 bolts,
tighten them o 4–6Nm, and check the torque.
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Special Tools
Number
Injector remove
TEN00121
tool
Fuel injector
TEN00140
remover
Injector seal
TEN00064 installer and
sizer
Wrench O2
TEN00011
sensor
1.0 370
Engine Electrical System-2.0T Engine
Engine Electrical System-2.0T
Specifications
Torque
Description Value
Bolt - Alternator to cylinder body 45–53Nm
Bolt -Harness bracket to Alternator 5–7Nm
Bolt - PAS bracket to cylinder head 23–27Nm
Bolt - Starter motor 75–90Nm
Nut- Battery lead to starter motor 11–13Nm
Bolt - Auto tensioner 23–28Nm
Bolt - Battery Negative Lead to Left Front W/H Panel 7–10Nm
Nut - Battery Top Fusebox to Engine Compartment Fusebox 5–7Nm
Nut - Battery Positive Cable to Battery Top Fusebox 5–7Nm
Nut-battery clip fit 2.5–3.5Nm
1.0 371
Engine Engine Electrical System-2.0T

System Layout
1. Starter 2. Alternator
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Control Diagram (Without Keyless Start)
A= 硬线 B= 动力高速 CAN 线 C= 车身高速 CAN 线 D=LIN 线

A=Hard Wire B=PT High Speed CAN C=Body High Speed CAN D=LIN Line
1.0 373
Control Diagram (With Keyless Start)
A= 硬线 B= 动力高速 CAN 线 C= 车身高速 CAN 线 D=LIN 线

A=Hard Wire B=PT High Speed CAN C=Body High Speed CAN D=LIN Line
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Description side of the alternator includes 6 semiconductor diodes, which
Overview are mounted on a heat sink for heat dispersion. 3 diodes are
located at the positive pole, the other 3 at the negative pole.
The starting system of the vehicle includes a 12V starter motor,
which can convert the electric energy into the mechanical The integrated circuit regulator is also located at the rear side
energy. of the alternator.
Starter Motor Battery
The starter motor is located at the left rear side of the engine, Battery Instruction
it is fixed to the threaded holes on the transmission housing
All vehicles have a 12V maintenance-free lead-acid battery
with 2 flange bolts. The mechanical energy of the pinion
equipped at the left side of the engine compartment, which is
drives the flywheel, the transmission ratio of them enlarges
fitted on the pressed steel bracket fixed on the transmission
the torque so as to provide sufficient torque.
suspension by the battery molding, and covered by the battery
Each of the starter motors is of the pre-engaged type, which heat shield. The battery terminals are a clamp-connected
includes a permanent magnet motor, an overdrive clutch and an column type.
solenoid valve. Both starter motors adopts the conventional
Warning: Battery fluid (electrolyte) contains sulphuric
configuration of pinion and in-line plunger motor with solenoid
acid. It may cause severe burns if it gets on your skin or
installed on it. The single connector on the starter motor
in your eyes. Wear protective clothing and a face shield.
provides connection for the engine locking device. The starter
If electrolyte gets on your skin or clothes, immediately
motor is directly connected to the positive pole of the battery
rinse it off with water. If electrolyte gets in your eyes,
through the 25mm² cable connecting to the copper stud.
immediately flush eyes with water for at least 15 minutes
Alternator and seek medical help.
The alternator at the right front of the engine is secured on The battery has three main functions. Firstly, the battery
the cylinder block by 3 bolts. The drive pulley is connected to provides energy for starting the engine. Secondly, the battery
the tail end of the rotor, which is driven by the drive belt of is used as the voltage regulator of the electrical system. Finally,
the crankshaft. The belt tension is maintained by the frictional when the electrical demand exceeds the alternator output, the
restriction tension pulley. The instrument pack is used in battery can provide energy within a certain period of time.
conjunction with a charging indicator lamp which will illuminate
Compared with the conventional batteries, the sealed batteries
when high/low voltage failure and mechanical fault occurs in the
have the following advantages:
alternator.
• Water does not need to be added throughout the life
The alternators includes a stator, a rotor, a rectifier and
time of the battery.
a regulator. By using the 12mm² cable, the alternator is
• It takes overcharge protection measures. If the voltage
connected to the battery and ground through the fuse.
exerted to the battery is too high, it will not accept
The stator includes a stator core, and a stator coil which has too much current like the conventional battery. On the
brackets supporting at both ends. The stator is made of the conventional battery, the battery will be still be charged
thin and soft iron sheet, its slot fits with the stator coil, and is at too high voltage, thus lead to air exhaust, causing liquid
fixed on the alternator housing. The stator has three sets of loss.
coils which are made of enamelled copper wires of large sizes.
• Compared with the conventional battery, self discharge
These 3 coil windings are connected in a "triangle connection"
is difficult for such battery. When the battery is not in
scheme, thus the tail end of each winding is connected to the
use for a long term, this is particularly important.
other 2 windings. The output current is provided from the
• For cigarette lighter and smaller appliances, it is more
other end of each winding. The stator core allows the magnetic
reliable to supply power.
flux from the rotor magnetic pole to flow through the stator
coil. Vehicles with a stop/start function are provided with the
H6 type maintenance-free lead-acid battery which is a valve
The rotor consists of an exciting winding which is wound on
regulated sealed lead-acid battery with absorbed glass mat
the iron core and fitted on the shaft. When the current flows
(AGM). Compared with the conventional flooded starting
through the exciting windings, both ends of the iron core at
battery, the AGM battery has a stronger charging acceptance
the north and south pole extend. The rotor is located in
capability, and better than the conventional starting battery
the stator, which is fitted on the bearing so as to guarantee
in terms of deep cycle discharging capability, cycle life, etc.,
stable rotation and enable it to support the high load in the
drive belt tension application. The rectifier located at the rear
1.0 375
which is more suitable for the occasions where the start/stop • During charging, when the battery temperature is higher
system needs to repeat the start for several times. than 40℃, stop charging and proceed after the battery
temperature drops to room temperature.
Battery Recharge
• Do not charge the battery at a temperature lower than
When the vehicle is not started, prolonged use of on-board
0℃.
electrical appliances and other abnormal uses, electric leakage
and long-time vehicle lay-off, or vehicle alternator charging When the battery voltage is lower than 11.0V, at the beginning
fault may cause charging failure and low battery, even failure of charging, the battery cannot be charged. For low batteries,
of vehicle start. The battery shall be charged. the sulfuric acid in the battery decreases greatly, the liquid is
almost pure water, and the battery internal resistance is very
Caution: When charging or Emergency Starting, the
high, but the sulfuric acid will increase with the process of
negative cable should be connected to the body earth
charging, and the charging current can resume gradually.
well, while not the negative pole.
Battery Test
Visual inspection before charging the battery:
The common battery tester in the aftermarket can be used to
• Batteries with a cracked housing or acid leaking battery
test the battery, for example, Midtronics series battery tester.
shall not be charged, check the reason before replacing
For AGM batteries, use testers with the function for testing
the battery. AGM batteries. Measuring data from the tester of incorrect
• Batteries with ruptured terminals shall not be charged, model cannot be used to determine the battery status.
check the reason before replacing the battery.
Battery Replacement
• Bulged battery due to overdischarge or overcharge shall
not be charged, it shall be replaced. Caution: When removing the battery, ensure that the
alarm is disarmed and that the ignition is switched off.
• Prior to charging, clean the terminals, and remove oxide
Always disconnect the negative terminal first and then
skin on the surface. For charging, apply butter to the post
the positive terminal. When refitting the battery, always
terminals to prevent electric corrosion.
fit the positive terminal first followed by the negative
Considerations in charging: terminal.
• Wear safety goggles. For battery replacement, please refer to "Battery -
• Charge in a well ventilated environment with room Remove/Refit" section.
temperature. When charging/discharging the battery with external device or
• Smoking is forbidden during charging, avoid the during jump start, take care not to connect the external cable
introduction of fire. directly to the battery negative, connect the external cable to
• When connecting the wire before charging, connect the a good ground point on the body.
positive wire first; when removing the wire after charging, Current Sensor
disconnect the negative wire first.
Models with the stop/start function are equipped with the
Battery recharge operation: battery current sensor which is widely used for measuring
DC, AC and pulse current. The sensor applies open-loop hall
• The positive pole of the charger connects the positive
effect technique, current can be measured just by connecting
pole of the battery, and do the same operation for the
the sensor to the battery negative cable, this simplifies the
negative pole. If the battery is not disconnected from the
procedures for installation and maintenance.
vehicle, the negative pole of the charger shall connect a
good body ground. The sensor output is the pulse width modulation (PWM)
• Ensure the battery terminal is clean and the charging output signal proportional to the primary current, which is
circuit is properly connected. powered by the single 5V voltage.
• For AGM valve-control batteries, use the charger with The output signal of the HAB 60–S current sensor used by
voltage/current limiting function to charge the battery, the vehicle is the standard PWM signal of 125 Hz, and the
and the constant voltage 14.1 - 14.8V and maximum linearity is 0.2%. The interference inside the vehicle is much
current limit is 25% of the rated capacity. For example, stronger, the PWM signal can control this interference.
the rated capacity is 70Ah, then the maximum current
This series product applies the ultrasonic seal welding, so it is
limit is 17.5A. When the charging current is less than 0.5A
waterproof and dustproof, which ensures the safe use of the
or the current is low, and no obvious change occurs for
engine compartment.
3 hours, the battery is fully charged.
1.0 376
End View and Pin Information of Current Sensor Pin No. Description
Harness Connector BY033
A Current Sensor 5V Power
Supply
B Ground
C Current Sensor PWM
Output
1.0 377
Operation voltage. Use the ground of the alternator to flash the warning
Starter Motor lamp and supply initial current to the alternator.
When the ignition key is in "ON" position, the engine locking When starting the engine, the rotor is rotating in the
device in the instrument pack will compare the code stored in stator, generating the 3-phase alternating current (AC).
the ignition key and that stored in the locking device. If these The generated alternating current is not suitable for the
codes match, the signal will be sent to the starter motor relay vehicle electrical system use, which must be rectified by the
in the engine compartment fuse box through BCM and ECM. semiconductor diodes of the rectifier. The diodes only allow
The starter motor relay supplies power to the starter motor the single direction current, to guarantee the output current
solenoid. The solenoid winding is powered on, allowing the is rectified. The diodes in the rectifier also prevents the
pinion to engage with the flywheel tooth ring. The engaging current from flowing from the battery to AC alternator when
lever will drive the pinion to engage with the flywheel tooth the output voltage of AC alternator is lower than the battery
ring. If the gear wheel is engaged incompletely, the flexible voltage.
connection will enable the solenoid to close the contact of the
The regulator has a power transistor, which is grounded
motor and battery power supply connection. Thus, the high
at the ground side of the magnetic field, acting as a quick
current may flow to the motor enabling the gear engagement.
switch of the magnetic field switch. Thus, it regulates the
The pinion rotates through the one-way clutch, turning the
voltage output according to the internal induced voltage, to
flywheel/starter tooth ring on the drive disc.
protect against the overcharge and the damage to the vehicle
Once the engine is started, the speed of the pinion will exceed electrical components caused by it. The output is restricted
the speed of the starter motor. If the ignition key is kept to approximately 14.2V, and it is protected by the over-voltage
in the ignition position, the one-way clutch will decrease its protection diodes. This voltage value allows the AC alternator
protection to the motor. When the ignition key is released, change the output voltage according to the charging condition
the power to the solenoid will be cut off, the switch contact of the battery, and charge the battery when the battery is low,
is open, the spring force will withdraw the pinion from the for example, operating the starter motor, and decreasing the
flywheel tooth ring. charging rate to zero when the battery is fully charged, so as
to avoid the overcharge.
When starting the engine, to allow the starter motor get the
maximum current, some electric load will be cut off when The alternator communicates with the DC converter with
the ignition key is moved to the ignition position. The power the power management (PMDC) via the LIN line. When the
supply of the headlamp, heated rear window (HRW), heating, output voltage of the alternator is lower than the battery
ventilation and air conditioning （HVAC) and blower motor voltage, the charging indicator illuminates. When the speed
will be switched off. When the engine start is complete, these of the rotor rises, the output voltage increases rapidly to
loads are to be reactivated respectively so as to the restrict increase the potential difference at the diode output side.
the battery discharge. With the increase of the voltage, when the output voltage of
the alternator is same with the battery voltage, the charging
After the following delays, the electric loads will be switched
warning lamp will turn off. Then the alternator generates
on again:
sufficient self-excited current via the diode in the magnetic
• HVACAfter the blower is stopped for 1s. field and begin to charge the battery.
• HRWAfter it is stopped for 1.5s. Failure
If the starting time exceeds 15s, the power supply of the starter The alternator may have failures or provide incorrect signals
motor will be cut off, all electric loads will be powered on again under the following conditions:
immediately.
• Internal regulator failure
Alternator
• Integrated diode component failure
Alternator uses the self-excited system, where many diodes • Stator winding open circuit
supply part of the current generated by the alternator for the
• Stator winding ground short circuit
rotors. Alternator can not supply the initial current required
for start-up of the charging procedure. Initial current is • Exciting winding short circuit
supplied by the battery power supply through ignition switch • Exciting winding open circuit
to activate the exciting winding to start up the charging • Mechanical failure
procedure. When the ignition switch is turned on, the
• External harness short circuit
charging warning lamp can also be used to supply the battery
• External harness break circuit
1.0 378
Service Procedures
Alternator
Remove

3. Remove the turbocharger intake hose.
Turbocharger Intake Hose Remove

Turbocharger Control Solenoid Valve Remove
5. Remove 3 bolts fixing the E-PAS idler assembly support
9. Remove the alternator.
to cylinder head, and remove the support and E-PAS
idler assembly. Refit
1. Clean the mating surface of the alternator and cylinder
block.
2. Locate the alternator to the cylinder block, fit 3 bolts
and tighten to 45–53Nm.
3. Locate the harness bracket, fit the bolts and tighten
to 5–7Nm.
4. Fit the connector of the alternator and engine harness.
5. Fix the E-PAS idler assembly support to the cylinder
head, fit 3 bolts, tighten to 23–27Nm，and check
the torque.
6. Fit the turbocharger control solenoid valve.
Turbocharger Control Solenoid Valve Refit

6. Remove the harness bracket bolt from the engine and 7. Fit the turbocharger intake hose.
take away the harness.
Turbocharger Intake Hose Refit

7. Loosen and remove the connector from the alternator.

8. Remove 3 bolts securing the alternator and cylinder
block.
1.0 379
Auxiliary Drive Belt

Remove
2. Raise the vehicle to a suitable height for operation.
3. Remove the liner of the right front wheel house.
Front Wheel House Liner Remove

4. Insert the TEN00119 into the 4 square holes
of the tensioner, and turn the torque wrench
counterclockwise to disconnect the tensioner from
the belt. 2. Fit the TEN00119 into the four holes of the tensioner,
Caution: The torque shall be less than 82Nm. turn it counterclockwise to release the tensioner,
and remove the locking pin. Ensure the belt of the
multi-wedge pulley on the position shown is stuck into
the groove, only put the belt of the wheel in the middle
of the pulley and mark "Qualified" with the marker.
Ensure the belt fitted is basically in the middle of the
tension pulley and a minimum margin of 2mm shall be
left on both sides of the tension pulley.
3. Take out the tool.
4. Fit the right from wheel house liner.
Right Front Wheel House Liner Refit

5. Keep the tension pulley at the position, and use an
appropriate pin to fit it into the hole on the rear panel
of the tension pulley.
6. Take out the belt.

Refit
1. In the sequence shown, fit the auxiliary drive belt into
each pulley groove, tension pulley and idler.
1.0 380
Starter Motor Automatic Tensioning Wheel - Auxiliary Drive
Remove Belt
Remove
2. Raise the vehicle to a suitable height for operation. 1. Remove auxiliary drive belt.
Warning: Do not work on or under a vehicle supported Auxiliary Drive Belt Remove
only by a jack.Always support the vehicle on safety stands. 2. Remove 2 bolts of the automatic tensioning wheel.
3. Disconnect the connector (1) from the starter motor.
3. Remove the automatic tensioning wheel of the auxiliary

4. Remove the nut, and disconnect the battery wire (2) drive belt.
from the starter motor. Refit
5. Unscrew 2 bolts fixing the starter motor and remove 1. Locate the automatic tensioning wheel to the cylinder
the starter motor. block, fit 2 bolts and tighten to 23–28Nm.
Refit
1. Clean the mating face of the starter motor and
transmission. Clean the pin and pin hole.
2. Locate the starter motor to the transmission housing,
fit and tighten 2 bolts to 75–90Nm.
3. Connect the battery wire to the starter motor, and
tighten nuts to 11–13Nm.
4. Fit the harness connector.
1.0 381
Battery Negative Cable Battery Positive Cable

Remove Remove
1. Disconnect the battery negative cable. 1. Disconnect the battery negative cable.
2. Loosen the bolt fixing the negative cable to the panel 2. Disconnect the battery positive cable. Release the
of left front wheelhouse. nuts on both ends of the positive transition cables and
remove the transition cable, and then disconnect the
nuts fixing the positive cable to the battery fuse box.
3. Remove the battery negative cable.

Refit
3. Raise the vehicle to a proper height with a lift.
1. Arrange the battery negative cable in the engine
compartment and ensure correct route. 4. Unscrew the nut fixing the battery cable to the starter
motor and loosen the fixing-points on the transmission.
2. Refit the bolt fixing the negative cable to the panel of
left front wheelhouse, and tighten to 7–10Nm.
3. Connect the negative cable to the battery negative
terminal.

6. Loosen the cable retaining clips and buckles, etc.
7. Remove the battery positive cable.
Refit
1. Arrange the battery positive cable in the engine
compartment and ensure correct route.
2. Tighten the nuts fixing the positive transition cable to
the both ends of the fuse box to 5–7Nm.
3. Tighten the nut fixing the positive cable to the battery
fuse box to 5–7Nm.
4. Close the upper fuse box cover.
5. Fix the cable retaining clips and buckles, etc.
7. Tighten the nut fixing the positive cable to the starter
1.0 382
motor to 11–13Nm. Battery
8. Lower the vehicle. Remove
9. Reconnect the battery cable terminal post and then 1. Disconnect the battery cable with the negative one
connect the negative. disconnected first.
2. Remove the battery fuse box.
Battery Fuse Box - Remove
3. Release the nuts of battery lock block and remove the
lock block.
4. Remove the battery sleeve.

5. Remove the battery from the battery tray.
Refit
1. Correctly place the battery onto the battery tray.
2. Refit the battery sleeve.
3. Apply mineral grease to clean both battery electrodes
of battery.
4. Refit the battery lock block. Pre-tighten 2 nuts of
battery lock block by hands at first until bolts reach out
from nuts about 11mm, tighten 2 nuts to 2.5–3.5Nm,
Warning: Keep the lock block at the horizontal when

screwing.
5. Refit the battery fuse box.
Battery Fuse Box - ReRefit

6. Connect the battery cable (first positive and then
negative).
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Battery Sensor
Remove
Battery Negative Cable - Remove

2. Remove the cable tie twining on the battery sensor,
disconnect the body harness connector.
3. Remove the battery sensor from the negative cable.

Refit
1. Engage the battery sensor into the negative cable in
place and fasten with cable tie after fixing with tapes
onto the negative cable.
2. Connect the body harness connector.
Battery Negative Cable - Refit
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Special Tools
Number
Accessory belt
TEN00119
remove tool
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Engine Electrical System-1.5T

Specifications
Torque
Description Value
Bolt-Alternator to fix bracket 19–25Nm
Nut-power line to Alternator 11–15Nm
Bolt - Starter motor 40–50Nm
Nut- Starter motor 40–50Nm
Nut-power line to Starter 11–15Nm
Bolt-tensioner to engine 49–67Nm
Bolt - Battery Negative Lead to Left Front W/H Panel 7–10Nm
Nut - Battery Top Fusebox to Engine Compartment Fusebox 5–7Nm
Nut - Battery Positive Cable to Battery Top Fusebox 5–7Nm
Nut- Battery lead to starter motor 11–13Nm
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System Layout
1. Generator 2. Starter
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Description conventional battery, the battery will be still be charged

Overview at too high voltage, thus lead to air exhaust, causing liquid
loss.
The starting system of the vehicle includes a 12V starter
motor which drives the engine to start combustion process • Compared with the conventional battery, self discharge
and convert electrical energy to mechanical energy. The is difficult for such battery. When the battery is not in
electric power system of the vehicle must be able to provide use for a long term, this is particularly important.
sufficient energy to ensure the starter motor can rotate the • For cigarette lighter and smaller appliances, it is more
crankshaft. reliable to supply power.
The charging system consists of the battery, alternator and Battery Recharge
related electrical elements.
When the vehicle is not started, prolonged use of on-board
The battery provides the energy for engine crankshaft rotation electrical appliances and other abnormal uses, electric leakage
and initial ignition. When the electrical demand exceeds the and long-time vehicle lay-off, or vehicle alternator charging fault
generator output, the battery can provide energy for a certain may cause charging failure and low voltage of battery, even
period of time. When generator voltage fluctuates, the battery failure of vehicle start. The battery shall be charged.
has the function of voltage stabilization.
Caution: When charging or Emergency Starting, the
The alternator obtains mechanical energy from the crankshaft negative cable should be connected to the body earth
during engine running and transforms it into electric energy well, while not the negative pole.
for operation of electrical elements of the vehicle and battery
Visual inspection before charging the battery:
charging. A charging indicator is fitted on the instrument
pack. It will be illuminated without output voltage from the • Replace the battery after identifying the cause for
alternator or with voltage lower than the battery voltage. broken battery cell case or no auxiliary charging of acid
permeable battery.
Battery
• Replace the battery after identifying the cause for no
Battery Instruction
auxiliary charging of battery with ruptured terminals.
All vehicles have a 12V maintenance-free lead-acid battery • The battery shall be replaced when auxiliary charging is
equipped at the left side of the engine compartment, impossible for a bulging battery due to overdischarging
which is fitted on the pressed steel bracket fixed on the or overcharging.
transmission mount by the battery retaining strap, and covered
• Prior to auxiliary charging, clean the terminals, and
by the battery heat shield. The battery terminals are a
remove oxide skin on the surface. For auxiliary charging,
clamp-connected column type.
apply butter to the post terminals to prevent electric
Warning: Battery fluid (electrolyte) contains sulphuric corrosion.
acid. It may cause severe burns if it gets on your skin or
Considerations in charging:
in your eyes. Wear protective clothing and a face shield.
If electrolyte gets on your skin or clothes, immediately • Wear safety goggles.
rinse it off with water. If electrolyte gets in your eyes, • Maintain environmental ventilation during charging, and
immediately flush eyes with water for at least 15 minutes charge at normal temperature.
and seek medical help. • Smoking is forbidden during charging, avoid the
The battery has three main functions. Firstly, the battery introduction of fire.
provides energy for starting the engine. Secondly, the battery • When connecting the cable before charging, connect
is used as the voltage regulator of the electrical system. Finally, the positive cable first; when removing the cable after
when the electrical demand exceeds the alternator output, the charging, disconnect the negative cable first.
battery can provide energy within a certain period of time.
Battery recharge operation:
Compared with the traditional batteries, the sealed batteries
• The charger positive connects to the battery positive,
have the following advantages:
and do the same operation for the battery negative. If the
• Water does not need to be added throughout the life battery is not disconnected from the vehicle, the charger
time of the battery. negative shall connect a good body ground.
• It takes overcharge protection measures. If the voltage • Ensure the battery terminal is clean and the charging
exerted to the battery is too high, it will not accept circuit is properly connected.
too much current like the conventional battery. On the
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• Chargers with a maximum voltage limit 16.0±0.1V and The measurement data of a tester of an unmatched model must
maximum current limit 25A are recommended for not be used as the basis for judging battery state.
constant voltage charging; when the charging current is
Battery Replacement
less than 2A, the battery is fully charged.
Caution: When removing the battery, ensure that the
• During charging, when the battery temperature is higher
alarm is disarmed and that the ignition is switched off.
than 40℃, stop charging and proceed after the battery
Always disconnect the negative terminal first and then
temperature drops to room temperature.
the positive terminal. When refitting the battery, always
• Do not recharge the battery when the temperature is
fit the positive terminal first followed by the negative
below 0℃.
terminal.
When the battery voltage is lower than 11.0V, at the beginning
For battery replacement, please refer to "Battery -
of charging, the battery cannot be charged. For low voltage of
Remove/Refit" section.
battery, the sulfuric acid in the battery decreases greatly, the
liquid is almost pure water, and the battery internal resistance When charging/discharging the battery with external device or
is very high, but the sulfuric acid will increase with the process during jump start, take care not to connect the external cable
of charging, and the charging current can resume gradually. directly to the battery negative, connect the external cable to
a good ground point on the body.
Battery Test
The common battery tester in the aftermarket can be used to

test the battery, for example, Midtronics series battery tester.
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Operation is fixed on the alternator housing. The stator has three sets
Starter Motor of coils, with insulating enamel coated on the copper wire.
Three coil windings are connected to a Star Connector, by
The starter motor is behind the engine, which is fixed to the
this way, the end of each winding is connected to the other
engine housing by 1 flange bolt and 1 nut.
two windings. The output current is provided from the other
Each starter motor applies the electromagnetic engagement end of each winding. The stator coil allows the magnetic flux
principle, which includes a series of harness motors, a one-way generated by the rotor pole to flow through the stator coil.
clutch and a whole coil. When the ignition switch is in "ON" Rotation of the rotor makes the coil generate AC.
position, the BCM sends a signal to provide voltage for the
The rectifier is behind the alternator, which converts the AC
starter relay coil. Prior to engine start, the BCM checks if
generated by the stator coil to DC required for the vehicle
correct feature code is received before accepting the START
electrical system. The rectifier includes 6 semiconductor
request.
diodes which are fitted on the cooling plate that is easy for
When the ignition switch is in the "ON" position, the coil will heat elimination. Three diodes are mounted on the front
supply power to connect the pinion and the flywheel gear ring. side, three on the back side, and the other two in the middle.
The pinion moves spirally around the motor reel, thus the When the output voltage of the alternator is lower than the
motor shaft can achieve the smooth connection through the battery voltage, the rectifier also prevents the current from
gear ring. On the starter motor, the motor drives the pinion flowing from the battery to the alternator.
through the transmission instead of the motor shaft directly.
The IC regulator is also behind the alternator, which
When starting the engine, the one-way clutch prevents motor controls the output voltage of the alternator to avoid battery
armature overspeed. The driver should not remove the key overcharge and controls the current of the rotor field to
from the start position so that the motor can keep running. prevent high input voltage in the vehicle electrical system.
After start-up of the engine, when the ignition switch is The set voltage of the regulator optimizes battery charging
released, solenoid coil will release energy to pull out the according to the temperature, sets a rated output voltage of
pinion from the gear ring. 14.5V and changes the output voltage according to battery
load and the required load for the vehicle electrical system.
Alternator
Transistors of the regulator can adjust the output voltage
The alternator is fitted on the front of the engine, which is
through the quick switch of the internal induced voltage. The
fixed to the bracket by 3 screws. The alternator can provide
regulator has an output terminal of the charging indicator
different installation methods for different auxiliary devices.
which can control the operation of the indicator. When the
The drive pulley fixed on the rotor uses the V-belt to drive
output voltage of the alternator is lower than the battery
the crankshaft. The location of the alternator is fixed, and the
voltage, the voltage indicator illuminates. The electrical load
belt tension is maintained by the automatic tensioning wheel
compensation signal is also provided by the regulator which
at the far end.
also provides the output data for the ECM, and the ECM
The alternators are similar in the structure, including a stator, adapts to a variety of electrical loads by adjusting the idle
a rotor, a rectifier and a regulator. The one-way output speed.
terminal is connected to the battery positive terminal by
When the alternator is operating at a low speed, the initial
a cable. The alternator is grounded through its bracket.
excitation current of the alternator provides excitation current
The three-pin connector provides a connection for charging
for the rotor via the brush which contacts the slip ring at the
indicator, ignition system battery power supply and ECM
shaft end. When the speed of the alternator increases, the
alternator charge signal.
alternator becomes self-excited.
The rotor is assembled on the shaft, which consists of a
Alternator applies a self-excited system, where the rectifier
magnetic field coil wound on the iron core. The iron core
diode supplies the rotor with part of the current generated
extends at both ends, forming the north and south poles of
by the alternator. Alternator can not supply the initial current
the coil magnetic line of force. The rotor is inside the stator
required for starting the charging procedure. The initial
and assembled with the bearing so as to operate smoothly,
current is supplied by the ignition switch of the battery input
also, when the drive belt applies load to one end of the rotor,
end and triggers the field winding to start up the charging
it provides support for the rotor.
procedure. When the ignition switch is ON, the battery
The stator includes a stator core and a stator coil which has voltage is also supplied through the charging warning lamp
brackets supporting at both ends. The stator is made of soft and grounds via the field winding of the alternator, so that the
iron sheet, which has a slot suitable for the stator coil and LED warning lamp illuminates.
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When the start-up of the engine rotates the rotors in the alternator output voltage is equal to the battery voltage, it
stator, three-phase alternating current will be generated. will go out. At this moment, the alternator can gain sufficient
When the rotor speed increases, the output voltage will rise self-excited current from the rectifier diode and begin to
quickly, and the potential difference of the diode output end charge the battery. If the charging warning lamp is still ON,
of the magnetic field will raise. When the voltage increases, the charging system fails and a check must be performed,
the charging warning lamp will darken gradually. When the otherwise, the battery will be damaged.
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Service Procedures Starter Motor

Alternator Remove
1. Disconnect the battery negative. 2. Remove the bottom deflector.
2. Remove the auxiliary drive belt. Bottom Deflector
Auxiliary Drive Belt Remove 3. Disconnect the harness connector of the starter
3. Disconnect the alternator harness connector. solenoid coil.
4. Remove 1 nut fixing the power cord to the alternator 4. Remove 1 nut fixing the battery wire to the starter, and
and take away the power cord. disconnect the battery wire.
5. Remove 3 bolts fixing the alternator to the alternator 5. Remove 1 bolt and 1 nut fixing the starter to the
mounting bracket. cylinder block.
6. Remove the alternator. 6. Remove the starter.

Refit Refit
1. Fix the alternator to the mounting bracket, fit 3 bolts, 1. Fix the starter to the engine block, fit 1 bolt, tighten to
tighten to 19–25Nm and check the torque. 40–50Nm and check the torque; fit 1 nut and then
2. Connect the power cord to the alternator, fit 1 nut, tighten it to 40–50Nm.
tighten to 11–15Nm and check the torque. 2. Connect the battery wire to the starter, fit 1 nut,
3. Connect the alternator to the engine harness tighten to 11–15Nm and check the torque.
connector. 3. Connect the starter connector.
4. Fit the auxiliary drive belt. 4. Fit the bottom deflector.
Auxiliary Drive Belt Refit Bottom Deflector

5. Connect the battery negative. 5. Connect the battery negative.
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Auxiliary Drive Belt Auxiliary Drive Belt Tensioner
Remove Remove
1. Disconnect the battery negative. 1. Remove the auxiliary belt.
2. Remove the bottom deflector. Auxiliary Drive Belt Remove
Bottom Deflector 2. Remove 1 bolt fixing the auxiliary belt tensioner to the
3. Insert the mounting tool into the square hole in the engine hood.
tensioner, wrench the torque spanner counterclockwise
to disconnect the tensioner from the belt.
3. Remove the auxiliary belt tensioner.

Refit
4. Take out the belt.
1. Fix the auxiliary belt tensioner onto the front engine
5. Allow the tensioner to return slowly, and take out the hood, fit 1 bolt, and tighten to 49–67Nm.
tool.
2. Fit the auxiliary belt.
Refit
1. Insert the installer into the square hole of the tensioner,
Engine Accessory Belt Abnormal Noise
and pull out the torque wrench counterclockwise. Diagnosis
2. Fit the auxiliary drive belt into each pulley groove and Diagnostic Aids
onto the tension pulley.
• Due to moisture on the drive belt or pulley, chirp or
3. Release the tensioner slowly, make sure the pulley shall squeal noise may be made intermittently. It may be
be basically located at the centre of each pulley after necessary to spray a small amount of water on the drive
refit, and a 2mm margin shall be kept on both sides of belt to reproduce the failure mentioned by the customer.
the tension pulley. If this symptom is reproduced on the drive belt after
4. Fit the bottom deflector. water spraying, this problem can be solved by cleaning
Bottom Deflector the belt.
5. Connect the battery negative. • If the noise is intermittent, it may be verified by changing
the load of accessory transmission components to
ensure its maximum efficacy. It is recommended to check
the following components: Overloaded air conditioning
system, power steering system with clamping hose or
improper oil, or malfunctioning alternator.
• Looseness or improper fit of body or suspension
components may cause chirp, squeal, or whine. Other
components of vehicle can also cause noise.
• The drive belt won't whine.
Test Description
The following numbers represents the step numbers in the
diagnostic table.
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2. The noise may have nothing to do with the engine. This

step intends to verify whether the engine makes a noise. If the
engine did not make a noise, this table is not further executed.
3. The noise may be the internal engine noise. Remove one

drive belt at a time, then operate the engine in a short time
to verify if the noise is associated with the drive belt. When
removing the drive belt, the water pump may not be capable of
operating normally and the engine may be overheated. After
the drive belt is removed, DTC may be set during engine
operation.
4. Check whether there are pillings on all drive pulleys. Pillings

refer to the small balls, pellets or line strings formed in the
drive belt slot by accumulation of rubber foam.
6. Pulley misalignment may be caused by improper fixing of

accessory drive components, improper fit of accessory drive
component pulley, or inward or outward bending of pulley
after repair. Test the misaligned pulley with a straight ruler in a
pulley groove passing through two or three pulleys. In case of
pulley misalignment, refer to "Accessory Drive Components"
for correct fit procedures of the corresponding pulley.
10. Check the fastener to eliminate the possibility of fit of

incorrect bolts, nuts, gaskets or washers.
12. Check of the pulley for bending shall include: check the
pulley for dent or other damages, so that when used to drive
the pulley on its back, the drive belt cannot be correctly located
in all the pulley grooves or on the smooth surface of pulley.
14. This test intends to verify whether the drive belt tensioner
is normally running. If the drive belt tensioner cannot run
normally, the correct belt tension for preventing drive belt
slippage is beyond the reach, leading to squeal.
15. This test intends to verify that the drive belt length
is moderate to ensure normal operation of the drive belt
tensioner. In addition, if the fitted drive belt length is
incorrect, there is no correct wiring, and the accessory drive
components will be rotated in the wrong direction.
16. Pulley misalignment may be caused by improper fixing of

accessory drive components, improper fit of accessory drive
component pulley, or inward or outward bending of pulley
after repair. Test the misaligned pulley with a straight ruler in a
pulley groove passing through two or three pulleys. In case of
pulley misalignment, refer to "Accessory Drive Components"
for correct fit procedures of the corresponding pulley.
17. This test intends to verify whether the diameter or width

of the pulley is correct. Compare the sizes of the pulleys by
using a known good vehicle.
19. If the drive belt is not damaged or slightly pills, perform

temporary repairs simply by replacing the drive belt.
Drive Belt Chirp, Squeal and Whine Diagnosis
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Step Action Yes No
Definition: The following shows that the drive belt chirps:
• The drive belt or pulley makes a sharp noise for each revolution.
• Chirp may occur in a cold, wet start, and will disappear once the vehicle reaches the normal operating temperature.
Definition: The following shows that the drive belt squeals:

• A loud, harsh noise is produced due to drive belt slippage. This is very rare in a drive belt containing multiple ribs.
• When the drive belt receives heavy load, for example, the air conditioning compressor engages and closes the throttle,
or sliding on a stuck pulley or malfunctioning accessory drive component, noise is generated.
Definition: The following shows that the drive belt whines:

• High-frequency and consecutive noise.
• The noise may be caused by the malfunction of the accessory drive component bearing.
Did you review the operations in the "Drive Belt Symptom" Symptom - Engine
1 Go to Step 2
and perform the necessary inspections? Mechanical System
Confirm that there is a chirp, squeal or whine noise.
2 Go to Step 3 Go to “Diagnostic Aids”
Does engine generate chirp, squeal or whine?
1. Remove the drive belt.
If the engine has more than one drive belt, one drive
belt is removed at one time and the following tests
shall be implemented when a drive belt is removed
3 at each time. Symptom - Engine Go to Step 4
Mechanical System
2. Make the engine operate for no more than 30-40s.
3. Remove the rest of belts to repeat this test when
necessary.
Does chirp, squeal or whine still exist?

If a chirp is diagnosed, check for serious pilling exceeding
1/3 belt groove depth.
4 Go to Step 5 Go to Step 6
If there is a squeal or whine, go to Step 13.
Does the belt groove have pilling?

Clean the drive belt pulleys using a suitable wire brush.
Inspect for misalignment of a pulley.
Are any of the pulleys misaligned?
Replace or repair any misaligned pulleys.
Inspect for a bent or a cracked bracket.
Did you find any bent or cracked brackets?
Replace any bent or cracked brackets.
Inspect for improper, loose or missing fasteners.
Did you find the condition?
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Step Action Yes No

1. Tighten any loose fasteners.
11 2. Replace incorrect or missing fasteners. Go to Step 20 Go to Step 12
Inspect for a bent pulley.
Inspect for an accessory drive component seized bearing or
a faulty accessory drive component.
13 If there is any whine and the failure still exists, go to Go to Step 20 Go to Step 14
"Diagnostic Aids".
Did you find and correct the failure?

Test the drive belt tensioner for operating correctly.
14 Drive Belt Tensioner Diagnosis Go to Step 20 Go to Step 15

Inspect if the length of the drive belt is correct.
Inspect if the pulley has a correct size.
Replace the bent pulley.
Replace the drive belt.
19 Drive Belt Replacement Go to Step 20 Go to “Diagnostic Aids”

Operate the system to verify the repair.
20 System OK Go to Step 3
Did you correct the condition?
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Engine Accessory Belt Vibration Diagnosis confused with an internal engine noise due to the similarity
Diagnostic Aids in the description. Remove only one drive belt at a time if
the vehicle has multiple drive belts. When removing the drive
• Accessory transmission components may affect engine
belt, the water pump may not be operating and the engine
vibration. Vibration from the operating engine may cause
may overheat. When the engine is running after the drive belt
a body component or another part of the vehicle to
is removed, the DTC may be set.
make a rumble. The reason for vibration includes but
not limited to excessive A/C refill and motor overload. 4. Inspecting the drive belts is to ensure that they are not
To help identify an intermittent or an improper condition, causing the noise. Small cracks across the ribs of the drive belt
vary the loads on the accessory drive components. will not cause the noise. Belt separation is identified by the
• The drive belt may have a rumbling condition that can not layer of the separated belt and may be seen at the edge of the
be heard or felt. Sometimes replacing the drive belt may belt or felt as a lump in the belt.
be the only method for repairing the symptom. 5. Small amounts of pilling is normal condition and acceptable.
• If replacing the drive belt, completing the diagnostic When the pilling is severe, the drive belt does not have a
table, and the noise is only heard when the drive belts are smooth surface for proper operation.
installed, there might be an accessory drive component
9. Inspection of the fasteners can eliminate the possibility that
with a failure. Varying the load on the different
a wrong bolt, nut , spacer, or washer is fitted.
accessory drive components may aid in identifying which
component is causing the rumbling noise. 11. This step should only be performed if the water pump is
Test Description driven by the drive belt. Inspect for a bent water pump shaft.
Also inspect the water pump bearings for smooth operation
The numbers below refer to the step numbers in the diagnostic and excessive play. Compare the water pump with a known
table. good water pump.
2. This test is to verify that the symptom is present during 12. Bent, cracked, or loose bracket of the accessory
diagnosis. Other vehicle components may cause a similar drive component may put extra tension on the accessory
symptom. component, which can cause it to vibrate.
3. This test is to verify that one of the drive belts is causing
the rumbling noise or vibration. Rumbling noise may be
Step Action Yes No
Caution: Refer " Note about belt oil".
Definition: The following situations are indications of drive belt rumbling:

• A low pitch tapping, knocking, or thumping noise heard at or just above the idler.
• Heard once per revolution of the drive belt or a pulley.
• Rumbling may be caused from:
– Pilling, the accumulation of rubber dust that forms small balls (pills) or strings in the drive belt pulley groove
– Drive belt separation
– A damaged drive belt
Definition: The following situations are indications of drive belt vibration:

• The vibration is engine-speed related.
• The vibration may be sensitive to accessory load.
Did you review the operations in the "Drive Belt Symptom" Symptom - Engine
1 Go to Step 2
and perform the necessary inspections? Mechanical System
Check and verify that the rumbling or vibration is related
2 to the engine. Go to Step 3 Go to “Diagnostic Aids”
Does the engine make the rumbling noise or vibration?
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Step Action Yes No

1. Remove the drive belt.
If the engine has more than one drive belt, one drive
belt is removed at one time and the following tests
shall be implemented when a drive belt is removed
3 at each time. Symptom - Engine Go to Step 4
Mechanical System
2. Make the engine operate for no more than 30-40s.
3. Remove the rest of belts to repeat this test when
necessary.
Does the rumbling or vibration still exist?

Check for worn, damaged, delaminated drive belt or
4 partially missing belt rib and debris. Go to Step 7 Go to Step 5
Did you find any of these conditions?
Inspect for severe pilling of more than 1/3 of the drive belt
5 pulley grooves. Go to Step 6 Go to Step 7
Did you find severe pilling?
1. Clean the drive belt pulleys using a suitable wire brush.
2. Reinstall the drive belts.
Drive Belt Replacement

Fit a new drive belt.
7 Drive Belt Replacement Go to Step 8 Go to Step 9
Did you complete the replacements?
Did you find any of these conditions?
Caution: Refer "Instruction about fastener".

2. Replace incorrect or missing fasteners.

Inspect for a bent water pump shaft.
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Accessory Belt Failure Diagnosis pulley bent inward or outward from a previous repair. Test
Diagnostic Aids for a misaligned pulley using a straight edge in the pulley
grooves across two or three pulleys. If a misaligned pulley is
• If the drive belt repeatedly falls off the drive belt pulleys,
found, refer to that accessory drive component for the proper
this is because of pulley misalignment.
installation procedure of that pulley.
• An extra load that is quickly applied on released by an
accessory drive component may cause the drive belt to 5. Inspecting the pulleys for being bent should include
fall off the pulleys. Confirm that the accessory drive inspecting for a dent or other damage to the pulleys that
component operates normally. would prevent the drive belt from not seating properly in all
of the pulley grooves or on the smooth surface of a pulley
• If the drive belt length is incorrect, the drive belt
when the back side of the belt is used to drive the pulley.
tensioner will not be able to keep the drive belt in an
appropriate tension. 6. Accessory drive component brackets that are bent or
• Excessive wear in drive belt is usually caused by improper cracked will let the drive belt fall off.
installation or use of the wrong belt. 7. Fastener check may eliminate the possibility of fitting wrong
• Minor misalignment of the drive belt pulleys will not cause bolts, nuts, spacers or washers. Missing, loose or wrong
excessive wear, but will probably cause the drive belt to fasteners may cause the pulley to misalign with the bracket
make a noise or to fall off. under load. Overtightening of fasteners may result in bracket
• Excessive misalignment of the drive belt pulleys will cause misalignment of the accessory parts.
excessive wear but may also make the drive belt fall off. 13.The purpose of this check is to check and confirm that the
Test Description drive belts are fitted correctly to all drive pulleys. Drive belt
abrasion may result from drive belt misalignment due to the
The numbers below refer to the step numbers in the diagnostic
pulley slot.
table.
14. If wide or narrow drive belt is fitted, wear may occur. The
2. The purpose of this inspection is to confirm the condition
drive belt ribs should match all of the grooves on all of the
of the drive belt. If the drive belt falls off, the drive belt may
pulleys.
be damaged. The drive belt may have been damaged, which
caused the drive belt to fall off. Check the belt for any cut, 15.The purpose of this check is to confirm that the drive belt
tear, missing belt rib or damaged belt layer. is not in contact with the engine parts or body parts during
engine operation. There should be sufficient clearance when
4. Misalignment of the pulleys may be caused from improper
the drive belt accessory drive components load varies. The
mounting of the accessory drive component, incorrect
drive belt should not come in contact with an engine or a body
installation of the accessory drive component pulley, or the
component when snapping the throttle.
Step Action Yes No
Caution: Refer " Note about belt oil".
Definition: The drive belt falls off from the pulley or cannot be correctly fitted to the pulley.
Definition: Outside edge of drive belt is worn due to incorrect mounting of the drive belt.
Did you review the operations in the "Drive Belt Symptom - Engine
1 Go to Step 2
Symptom" and perform the necessary inspections? Mechanical System
For excessive abrasion diagnosis, go to step 13.
If the diagnosis of the falling-off drive belt shall be carried

out, check whether the drive belt is damaged.

Fit a new drive belt.
3 Drive Belt Replacement Go to Step 4 System OK
Does the drive belt continue to fall off?
Did you find and repair the condition?
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Step Action Yes No

Inspect for a bent or dented pulley.
Did you find loose or missing fasteners?
Caution: Refer "Instruction about fastener".

8 Go to Step 9 System OK
2. Replace incorrect or missing fasteners.

Test the drive belt tensioner for operating correctly.
9 Drive Belt Tensioner Diagnosis Go to Step 11 Go to Step 10
Does the drive belt tensioner operate correctly?

Replace the drive belt tensioner.
10 Drive Belt Tensioner Replacement Go to Step 11 System OK

Inspect for failed drive belt idler and drive belt tensioner
11 pulley bearings. Go to Step 12 Go to “Diagnostic Aids”
Inspect the drive belt for the proper installation.
13 Drive Belt Replacement Go to Step 16 Go to Step 14
Does this failure occur?

Inspect for the proper drive belt.
Does this failure occur?
Inspect for the drive belt rubbing against a bracket, hose,
15 or harness. Go to Step 17 Go to “Diagnostic Aids”
Replace the drive belt.
16 Drive Belt Replacement Go to Step 17 -
Did you complete the replacements?

17 System OK -
Drive Belt Tensioner Diagnosis

1. Exert tension to the drive belt tensioner with a tool in
the direction as indicated by the arrow.
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Battery Negative Cable
Remove
2. Loosen the bolt fixing the negative cable to the panel
of left front wheelhouse.
2. The drive belt tensioner must return to the original

position automatically, if not, replace it.
Auxiliary Drive Belt Tensioner Replacement

3. Remove the auxiliary belt.
4. Check the tensioner pulley for abnormal sounds and
Refit
looseness.
1. Arrange the battery negative cable in the engine
5. If any, replace the belt tensioner.
Auxiliary Drive Belt Tensioner Replacement
2. Refit the bolt fixing the negative cable to the panel of
6. Fit the auxiliary belt. left front wheelhouse, and tighten to 7–10Nm.
Auxiliary Drive Belt Refit 3. Connect the negative cable to the battery negative
terminal.
1.0 401
Battery Positive Cable 7. Tighten the nut fixing the positive cable to the starter
Remove motor to 11–13Nm.
1. Disconnect the battery negative cable. 8. Lower the vehicle.
2. Disconnect the battery positive cable. Release the 9. Reconnect the battery cable terminal post and then
nuts on both ends of the positive transition cables and connect the negative.
remove the transition cable, and then disconnect the
nuts fixing the positive cable to the battery fuse box.

4. Unscrew the nut fixing the battery cable to the starter
motor and loosen the fixing-points on the transmission.

6. Loosen the cable retaining clips and buckles, etc.
7. Remove the battery positive cable.
Refit
1. Arrange the battery positive cable in the engine
2. Tighten the nuts fixing the positive transition cable to
the both ends of the fuse box to 5–7Nm.
3. Tighten the nut fixing the positive cable to the battery
fuse box to 5–7Nm.
4. Close the upper fuse box cover.
5. Fix the cable retaining clips and buckles, etc.
1.0 402
Battery
Remove
1. Disconnect the battery cable with the negative one
disconnected first.
Battery Fuse Box - Remove
3. Release the nuts of battery lock block and remove the
lock block.

5. Remove the battery from the battery tray.
Refit
1. Correctly place the battery to the battery tray.
3. Apply mineral grease to clean both battery electrodes
of the battery.

screwing.
Battery Fuse Box - Refit

negative).
1.0 403
Engine Engine Manifold & Exhaust System-2.0T
Engine Manifold & Exhaust System-2.0T

Specifications
Torque
Description Value
Bolt -Throttle body to inlet manifoldy 9Nm
Screw - air cleaner upper cap to air cleaner base 1.4–1.8Nm
Nut -Front pipe to Silencer 55–65Nm
Bolt -DPF to Turbo charge 55–65Nm
Nut -Front pipe to DPF 55–65Nm
Bolt -DPF bracket to engine 26–34Nm
Bolt -DPF to DPF bracket 26–34Nm
Bolt -turbocharger heat shield to turbocharger 22–28Nm
Bolt-Front pipe frame to engine oil pan 19–25Nm
Bolt -rear silencer Heat shield to body 4–6Nm
Nut -heat shield to body 4–6Nm
Bolt -heat shield to body 4–6Nm
1.0 404
Engine Manifold & Exhaust System-2.0T Engine
System Layout
Intake System Exploded View
1. Air Filter Assembly 2. Filter Element
1.0 405
3. Air Flow Meter 15. Pipe Assembly - Intercooler to Engine

4. Bolt－Air Filter 16. Bracket - Intercooler to Engine Pipe
5. Air Inlet Assembly 17. Bolt - Intercooler Outlet Pipe
6. Split Pin - Air Filter Inlet Pipe 18. Clamp - Intercooler to Engine Pipe
7. Hose - Air Filter to Booster 19. Clamp - Booster Hose to Intercooler
8. Clamp - Air Filter Outlet Pipe to Booster 20. Pipe Assembly - Intercooler to Engine
9. O Ring - Air Flow Meter 21. Pipe Assembly - Intercooler to Engine
10. Clamp - Air Filter Outlet Pipe to Air Flow Meter 22. Bolt - Intercooler Outlet Pipe
11. Screw - Air Flow Meter 23. Ring - Intercooler Outlet Pipe
12. Air Filter Ring 24. Clamp - Intercooler to Engine Pipe
13. Air Filter Ring 25. Clamp - Intercooler to Engine Pipe
14. Hose － Booster to Intercooler
1.0 406
Exhaust System Exploded View
1. Gasket - Front Exhaust Pipe 10. Exhaust Muffler Lug

2. Nut - Catalytic Converter 11. Rear Muffler Assembly
3. Three-way Catalytic Converter Assembly 12. Gasket - Exhaust System
4. Bolt - Front Exhaust Pipe Bracket 13. Gasket - Front Exhaust Pipe
5. Gasket - Front Exhaust Pipe 14. Bolt - Catalytic Converter Bracket
6. Front Exhaust Pipe Front Lug 15. Catalytic Converter Bracket
7. Front Exhaust Pipe Rear Lug 16. Front Oxygen Sensor
8. Front Exhaust Pipe Assembly 17. Rear Oxygen Sensor
9. Front Exhaust Pipe Assembly
1.0 407
Description bolts, gaskets and nuts. Five rubber lugs (the front two are
Air Filter made of silicone rubber) fix the exhaust system to the body,
which can damp slight vibration of the exhaust system and
The hose between the air filter and the turbocharger, between
decrease the vibration transferred to the body. The thermal
the turbocharger compressor and the intercooler, and
baffle can effectively reduce the heat transferred from the
between the intercooler and the throttle body is secured by
exhaust pipe to the body, and the tail pipe applies the stainless
the worm drive clamp. The air filter assembly is fixed to the
steel design.
body by the air filter bracket assembly.
Exhaust System
The exhaust system consists of a three-way catalytic converter
and a muffler. Adjacent pipelines are fixed together by welding
1.0 408
Operation of an absorption type, and a perforated pipe passes through the
Air Filter muffler, which minimizes the airflow limit. The rear muffler is a
reflective muffler which uses the internal hindered sound wave
Air enters into the front engine compartment and the intake
reflection to reduce the noise level.
pipe at the rear of the front bumper, and the impurities in the
air are filtered by the air filter element. Three-Way Catalytic Converter (TWC)
Air from the air filter is transferred to the turbocharger Warning: TWCs operate at very high temperatures;
compressor by the hose between the air filter and the therefore, extreme caution is necessary when handling
turbocharger, it is then delivered to the intercooler by the this component.
hose between the turbocharger and the intercooler. The Caution: For the TWC to work efficiently and to prevent
cooled fresh air is transmitted to the throttle by the hose premature failure do not run on leaded fuel and do not
between the intercooler and the throttle. allow unburnt fuel to pass through the exhaust system.
Exhaust Manifold and Exhaust System The primary combustion happens in the combustion chamber
The exhaust manifold introduces the combusted gas mixture and the exhaust gas enters into the TWC through the
from the 4 engine cylinders into the turbocharger through exhaust manifold. The TWC can operate effectively only if
its 4 passages, and the turbocharger turbine applies the gas its minimum working temperature is achieved. The exhaust
mixture from the engine to drive the turbocharger compress gas enters into an integral structure coated with Pt and Rh
to compress the inlet air. ACT can adjust the outlet air of the (catalyst), and two procedures (reduction and oxidation) are
volute bleeder valve according to different working conditions. performed here. The nitrogen oxide (NOx) is restored to
The ERCV can open the inlet/outlet return passage in the nitrogen, from which the oxide is combined with carbon
housing during braking and protect the turbocharger. monoxide (CO) to form carbon dioxide. The hydrocarbon
(HC) and CO will continue to react in the three-way catalytic
The exhaust from the engine enters into the exhaust system by
converter with the oxygen in the air, which forms water and
the turbocharger, it first passes through the three-way catalytic
CO2.
converter before flowing into the muffler. The front muffler is
1.0 409
Service Procedures Electronic Throttle - with Adjustment

Electronic Throttle Self-learning - UMC System Remove
Self-learning 1. Disconnect the battery negative.
1. Confirm if the vehicle speed is 0 km/h and the engine 2. Disconnect the connector of the throttle body.
speed is 0 r/min.
2. Connect the scan tool to the vehicle and access the
VDS.
3. Select "Diagnosis — ECM — Real-time Display",
ensure the battery voltage is above 10V, the accelerator
pedal opening is 0, the coolant temperature is within
5℃～100℃ and the intake air temperature is higher
than 5℃.
4. Check if the harness is properly connected and shows
no other faults, mainly including throttle fault.
5. Place the ignition switch in "ON" position, wait for 30s,
at this interval, do not do any other operations.
6. The self-learning is then completed.
3. Loosen the clamps and disconnect the throttle intake
pipe from the throttle body.

contamination.
4. Remove 4 bolts fixing the throttle body to the intake

manifold.
5. Remove the throttle body and discard the O ring.
1.0 410
Refit Air Filter Assembly
1. Clean the mating surface of the throttle body and intake Remove
manifold and ensure there is no foreign material. 1. Disconnect the battery negative.
2. Fit the O ring to the intake manifold. 2. Remove the air filter element.
3. Secure the throttle body on the intake manifold, fit 4 Air Filter Element Remove
bolts, tighten to 9Nm in diagonal sequence and check
3. Remove the air flow meter.
the torque.
4. Connect throttle intake pipe to the throttle body and Air Flow Meter Remove
secure with clamps. 4. Disconnect the air filter inlet pipe and air filter assembly.
5. Connect the connector of the throttle body.
7. Perform self-learning for the electronic throttle.
Electronic Throttle Self-learning
5. Release the lower air filter housing from the two

grommets and remove the air filter assembly.
Refit
1. Fix the lower air filter housing to the grommet.
2. Align the hole at the rear of the air filter inlet pipe with
the block at the rear side (junction) of the air filter,
align the mark and push to lock it.
3. Fit the air flow meter.
Air Flow Meter Refit

4. Remove the air filter element.
Air Filter Element Refit

1.0 411
Air Filter Element Rear Muffler Assembly

Remove Remove
1. Disconnect the battery negative. Warning: Exhaust components get extremely hot during
2. Disconnect the connector (1) of the air flow meter. operation. Ensure exhaust components are sufficiently
3. Release the clamp and disconnect the turbocharger
intake pipe and air flow meter (2). 1. Raise the vehicle on a lift.
4. Take away 4 screws (3) fixing the air filter cover. Warning: Do not work on or under a vehicle supported
2. Remove 2 nuts fixing the rear muffler assembly to the
front exhaust pipe and discard the flange gasket.
5. Release and open the cover to access the element of

the air filter.
Refit 3. Remove 3 rubber lugs fixing the rear muffler assembly
to the body.
1. Clean the inside of the air filter.
2. Refit the air filter element.
3. Fix the cover of the air filter to the housing of the air
filter, fit 4 screws, tighten to 1.4–1.8Nm, and check
the torque.
4. Fit the turbocharger air inlet hose to the air flow meter,
5. Connect the connector of the air flow meter.
Refit
1. Hang the rear muffler assembly on the rubber lug.
2. Fix the rear muffler assembly to the front exhaust pipe,
fit new flange gasket, tighten to 55–65Nm and check
the torque.
3. Lower the vehicle with the lift.
1.0 412
Catalytic Converter
Remove
2. Remove the front oxygen sensor.
Front Oxygen Sensor Remove
shield.
8. Remove 3 nuts fixing the catalytic converter to the

turbocharger.

5. Remove 2 bolts (1) fixing the catalytic converter to 2
brackets of the catalytic converter.
6. Remove 2 bolts (2) fixing the two catalytic converter
brackets to the engine and remove the brackets. 9. Remove the catalytic converter and discard the gasket.
Refit
1. Fit a new gasket, fix the catalytic converter to the
turbocharger, fit 3 bolts, tighten to 55–65Nm, and
check the torque.
2. Fit a new gasket, fix the front exhaust pipe to the
catalytic converter, fit 3 bolts, tighten to 55–65Nm,
3. Fix 2 brackets of the catalytic converter to the engine,
fit the two bolts, tighten to 26–34Nm and check the
torque.
4. Fix the catalytic converter to 2 brackets of the catalytic
converter, fit the two bolts, tighten to 26–34Nm and
7. Remove 3 nuts fixing the front exhaust pipe to the check the torque.
catalytic converter and discard the exhaust pipe gasket. 5. Fit the bottom deflector.

7. Fit the front oxygen sensor.
Front Oxygen Sensor Refit

1.0 413
Front Exhaust Pipe

Remove
2. Remove the rear oxygen sensor.
Rear Oxygen Sensor Remove

3. Remove 3 nuts securing the front exhaust pipe on the
three-way catalytic converter and discard the flange
gasket.
6. Remove 2 rubber lugs securing the front exhaust pipe

to the body.
4. Remove 2 nuts fixing the rear muffler to the front

exhaust pipe and discard the flange gasket.
Refit
1. Hang the front exhaust pipe over the rubber lug.
2. Fix the front exhaust pipe to engine oil pan, fit 2 bolts
and tighten them to 19–25Nm, then check the torque.
3. Securing the front exhaust pipe on the rear muffler, fit
a new flange gasket and 2 nuts, tighten to 55–65Nm
4. Securing the front exhaust pipe on the three-way
catalytic converter, fit a new flange gasket and 3 nuts,
5. Fit the rear oxygen sensor.
5. Remove 2 bolts fixing the front exhaust pipe to the Rear Oxygen Sensor Refit
engine oil pan. 6. Connect the battery negative.
1.0 414
Heat Shield - Rear Muffler Heat Shield - Exhaust Passage
Remove Remove
Warning: Exhaust components get extremely hot during Warning: Exhaust components get extremely hot during
operation. Ensure exhaust components are sufficiently operation. Ensure exhaust components are sufficiently
cooled before handling. cooled before handling.
1. Remove the rear muffler. 1. Raise the vehicle on a lift.
Rear Muffler Remove Warning: Do not work on or under a vehicle supported
2. Remove 6 nuts fixing the thermal baffle (rear muffler) only by a jack.Always support the vehicle on safety stands.
to the body and remove the thermal baffle. 2. Remove 6 nuts and 1 bolt fixing the thermal baffle
(exhaust passage) to the body, and remove the thermal
baffle.
Refit
1. Fix the heat shield (rear muffler) to the body, fit 6 bolts,
Refit
1. Secure the heat shield (exhaust passage) on the body,
2. Fit the rear muffler.
fit 6 nuts, tighten to 4–6Nm, and tighten one bolt to
Rear Muffler Refit 4–6Nm, then check the torque.
1.0 415
Engine Manifold & Exhaust System-1.5T

Specifications
Torque
Description Value
screw-MAF 1.4-1.8Nm
screw-upper air cleaner to lower air cleaner 1.2–1.8Nm
Bolt-electronic throttle 8–12Nm
Nut-front vent-pipe to rear muffler 19–25Nm
Bolt-catalysts flange bracket to engine 19–25Nm
Nut-catalysts to flange bracket 19–25Nm
Nut-front vent-pipe to catalysts 19–25Nm
Bolt-catalysts fixing bracket to transmission 49–67Nm
Bolt-catalysts fixing bracket to catalysts 19–25Nm
Clamp-catalysts to V-clamp 13.5–16.5Nm
Bolt-shield asm-turbo 10–12Nm
Nut -heat shield to body 4–6Nm
Bolt -rear silencer Heat shield to body 4–6Nm
Clamp-hose-turbo to CAC 5–6Nm
Clamp-hose CAC to engine 5–6Nm
1.0 416
System Layout
Intake Air Layout
1. Hose - Turbocharger to Intercooler 9. Air Filter Intake Pipe Assembly

2. Clamp - Turbocharger to Intercooler Pipeline 10. Split Pin - Air Intake Pipe
3. Pipeline Assembly - Intercooler to Engine 11. Air Filter Assembly
4. Clamp - Intercooler to Engine Pipeline 12. Screw - Air Filter
5. Screw - Intercooler to Engine Pipeline 13. Filter Element
6. Clamp - Intercooler to Engine Pipeline 14. Liner - Air Filter
7. Pipeline Assembly - Intercooler to Engine 15. Liner - Air Filter
8. Pipeline Assembly - Intercooler to Engine 16. Air Filter Outlet Pipe Assembly
1.0 417
17. Clamp - Air Filter Outlet Pipe Assembly 19. Air Flow Meter
18. Clamp - Air Filter Outlet Pipe Assembly 20. Screw - Air Flow Meter
1.0 418
Exhaust Air Layout
1. Middle Exhaust Pipe Muffler Assembly (Four-Wheel 10. Clip - Front Exhaust Pipe
Drive) 11. Catalytic Converter Bracket
2. Middle Exhaust Pipe Front Lug 12. Bolt - Front Exhaust Pipe Bracket
3. Bolt - Front Exhaust Pipe Bracket to Oil Pan 13. Middle Exhaust Pipe Muffler Assembly (Two-Wheel
4. Nut - Exhaust Muffler Drive)
5. Nut - Catalytic Converter Bracket 14. Exhaust Rear Muffler Assembly
6. Catalytic Converter Sealing Gasket 15. Exhaust Muffler Lug
7. Bolt - Front Exhaust Pipe Bracket 16. Exhaust Muffler Lug
8. Front Exhaust Pipe Three-way Catalytic Converter 17. Gasket - Exhaust System
9. Catalytic Converter Bracket 18. Nut - Exhaust Muffler
1.0 419
Description Exhaust System

Air Filter It consists of a three-way catalytic converter and a muffler.
The hose (air filter to turbocharger) is between the air filter Adjacent pipelines are fixed together by welding bolts, gaskets
and the turbocharger; the hose (turbocharger to intercooler) and nuts. Five rubber lugs fix the exhaust system to the body
is between the turbocharger compressor and the intercooler; to buffer slight vibration of the exhaust system, and decrease
and the hose (intercooler to throttle body) is between the the vibration transferred to the body. The thermal baffle can
intercooler and the throttle body. Air filter assembly is fixed effectively reduce the heat transferred from the exhaust line
to the body with two rubber gaskets. to the body, and the tail pipe applies a stainless steel design.
1.0 420
Operation Three-Way Catalytic Converter (TWC)
Air Filter Warning: TWCs operate at very high temperatures;
Air enters into the front engine compartment and the intake therefore, extreme caution is necessary when handling
pipe at the rear of the front bumper, and the impurities in the this component.
air are filtered by the air filter element.
Caution: For the TWC to work efficiently and to prevent
Air from the air filter is transferred to the turbocharger premature failure do not run on leaded fuel and do not
compressor by the hose between the air filter and the allow unburnt fuel to pass through the exhaust system.
turbocharger, it is then delivered to the intercooler by the
The primary combustion happens in the combustion chamber
hose between the turbocharger and the intercooler. The
and the exhaust gas enters into TWC. TWCIt operates
cooled fresh air is transmitted to the throttle by the hose
effectively only when its minimum working temperature is
between the intercooler and the throttle.
achieved. The exhaust gas enters into an integral structure
Exhaust System coated with Pd and Rh (catalyst), and two procedures
The exhaust from the engine enters into the exhaust system by (reduction and oxidation) are performed here. The nitrogen
the turbocharger, it first passes through the three-way catalytic oxide (NOx) is restored to nitrogen, from which the oxide
converter before flowing into the muffler. The front muffler is is combined with carbon monoxide (CO) to form carbon
of an absorption type, and a perforated pipe passes through the dioxide. The hydrocarbon (CO) and CO will continue to
muffler, which minimizes the airflow limit. The rear muffler is a conduct combustion in the three-way catalytic converter with
reflective muffler which uses the internal hindered sound wave the oxygen in the air, which forms water and CO.
reflection to reduce the noise level.
1.0 421
Service Procedures Air Filter Assembly

Electronic Throttle Self-learning - UMC System Remove
Self-learning 1. Remove the air filter element.
1. Confirm if the vehicle speed is 0 km/h and the engine Air Filter Element Remove
speed is 0 r/min.
2. Pull up the lower housing of the air filter assembly
2. Connect the scan tool to the vehicle and access the and move the lower housing of the air filter assembly
VDS. from the mounting bracket, and then remove the lower
3. Select "Diagnosis — ECM — Real-time Display", housing of the air filter assembly from the mounting
ensure the battery voltage is above 10V, the accelerator bracket.
pedal opening is 0, the coolant temperature is within 3. Remove 2 tapping screws fixing the air flow meter to
5℃～100℃ and the intake air temperature is higher the upper housing of the air filter assembly, and remove
than 5℃. the air flow meter.
4. Check if the harness is properly connected and shows
no other faults, mainly including throttle fault.
5. Place the ignition switch in "ON" position, wait for 30s,
at this interval, do not do any other operations.
6. The self-learning is then completed.
4. Loose the clamp, disconnect the air filter assembly

outlet pipe, and remove the upper housing of air filter
assembly.
Refit
1. Fix the air flow meter to the upper housing of the
air filter assembly, fit 2 tapping screws, tighten to
1.4-1.8Nm and check the torque.
2. Connect the joint of the lower housing of the air filter
assembly to the air filter inlet pipe, and fit the lower
housing of the air filter assembly to rear bracket, and
then fit it to the front left bracket.
3. Fit the air filter element.
Air Filter Element Refit.
1.0 422
Air Filter Element Electronic Throttle
Remove Remove
2. Disconnect the air flow meter connector (1), and 2. Remove the engine hood.
disconnect the clips from the upper housing of the filter 3. Disconnect the throttle air inlet pipe from the throttle.
assembly, and remove the harness.
4. Disconnect the electronic throttle electrical connector .
3. Remove 4 screws (2) fixing the upper housing of
5. Disconnect the connecting hose connecting the canister
the filter assembly to the lower housing of the filter
solenoid valve to the electronic throttle.
assembly, and remove the upper housing of the filter
6. Remove 4 bolts fixing the electronic throttle to the
assembly.
intake manifold, and remove the electronic throttle and
discard the electronic throttle washer.
Refit
1. Fit a new electronic throttle gasket into the intake
manifold groove (ensure the cleanness of the sealing
surface).
Caution: Never insert any tool into the throttle hole to

prevent damage to the throttle plate.
2. Clean the junction surface between electronic throttle

and intake manifold, fix the electronic throttle to the
intake manifold, fit 4 bolts, tighten to 8–12Nm, and
check the torque.
3. Connect the electronic throttle connector.
Refit 4. Connect the connecting hose of the canister solenoid
valve to the electronic throttle.
1. Clean the inside of the air filter.
5. Connect the electronic throttle air inlet pipe.
2. Fit a new air filter element.
3. Fix the upper housing of the air filter assembly to the
lower housing of the air filter assembly, fit 4 screws, 7. Perform electronic throttle self-learning.
tighten to 1.2–1.8Nm. Electronic Throttle Self-learning
4. Connect the air flow meter connector, and fix the
harness to the upper housing of the air filter assembly.
1.0 423
Rear Muffler Assembly Three-way Catalytic Converter

Remove Remove
Warning: Exhaust components get extremely hot during 1. Disconnect the battery negative cable.
operation. Ensure exhaust components are sufficiently 2. Remove the front oxygen sensor.
Oxygen Sensor Remove
2. Remove 2 nuts (1) fixing the front exhaust pipe
assembly to the rear muffler assembly.
shield.
3. Fit 3 rubber lugs (2) fixing the rear muffler assembly
to the body.
4. Remove the clamp fixing the three-way catalytic

converter to the turbocharger air outlet, and
4. Remove the rear muffler assembly. disconnect it from the turbocharger.
5. Remove and discard the gasket. 5. Remove 2 bolts (1) fixing the three-way catalytic
Refit converter bracket to the catalytic converter.
1. Clean the flange face between the front exhaust pipe 6. Remove the bottom deflector.
assembly and rear muffler assembly. Bottom Deflector Remove
2. Fit a new liner to the flange face of the front exhaust 7. Remove 1 bolt (2) fixing the three-way catalytic
pipe assembly. converter mounting bracket to the transmission box,
3. Fit 2 nuts, tighten to 19–25Nm, and check the torque. and remove the bracket.
4. Fit 3 rubber lugs fixing the rear muffler assembly to
the body.
8. Remove 2 nuts fixing the front exhaust pipe to the

three-way catalytic converter, disconnect and discard
the gasket.
1.0 424
13.5–16.5Nm, and check the torque.
9. Fit the front oxygen sensor
Oxygen Sensor Refit

9. Remove 2 nuts fixing the three-way catalytic converter

to the flange bracket.
10. Remove the three-way catalytic converter assembly.

11. Remove 2 bolts fixing the flange bracket to the engine,
and remove the flange bracket.
Refit
1. Fix the flange support to the engine, fit 2 bolts, tighten
2. Fix the rear end of the three-way catalytic converter to
the flange support, fit 2 nuts, tighten to 19–25Nm,
3. Fit a new liner fixing the front exhaust pipe to the
three-way catalytic converter, fit 2 nuts, tighten to
4. Fix the three-way catalytic converter mounting bracket
to the gearbox body, fit 1 bolt, tighten to 49–67Nm,

6. Fix the mounting bracket to the three-way catalytic
converter, fit 2 bolts, tighten to 19–25Nm, and check
the torque.
7. Fit the front end of three-way catalytic converter
to the turbocharger, fix with clamps, tighten to
1.0 425
Front Exhaust Pipe front exhaust pipe and rear muffler assembly.
Remove 5. Insert the bolt of the front exhaust pipe flange face into
Warning: Exhaust components get extremely hot during the hole in the rear muffler assembly flange face, fit the
operation. Ensure exhaust components are sufficiently nut, but do not tighten in this step.
cooled before handling. 6. Tighten the nut connecting the front exhaust pipe to
1. Remove the bottom deflector. rear muffler assembly to 19–25Nm.
Bottom Deflector Remove 7. Connect the front exhaust pipe and the hook at the
2. Remove the rear oxygen sensor. bottom of the vehicle body with rubber lugs.
8. Fit the rear oxygen sensor.
Rear Oxygen Sensor Remove
3. Remove two nuts (1) fixing the middle muffler assembly Rear Oxygen Sensor Refit
to the front exhaust pipe, disconnect and discard the 9. Fit the bottom deflector.
gasket.
4. Remove 2 nuts fixing the front exhaust pipe to the front

catalytic converter, disconnect and discard the gasket.
5. Remove 2 rubber lugs fixing the front exhaust pipe to

the body, and remove the front exhaust pipe assembly.
Refit
1. Clean the flange face of the front exhaust pipe.
2. Fit a new liner to the flange face of the three-way
catalytic converter.
3. Align the hole in the front exhaust pipe flange face with
the bolt of the three-way catalytic converter flange face,
fit 2 nuts, tighten to 19–25Nm, and check the torque.
4. Fit a new gasket at the flange connection between the
1.0 426
Heat Shield - Rear Muffler Assembly Heat Shield - Exhaust Passage
Remove Remove
Warning: Exhaust components get extremely hot during 1. Remove the front exhaust pipe assembly.
Front Exhaust Pipe Remove
2. Remove 7 bolts fixing the front exhaust pipe assembly
1. Remove the rear muffler assembly.
thermal baffle to the floor panel and remove the front
Rear Muffler Assembly Remove exhaust pipe assembly thermal baffle.
2. Remove 7 nuts fixing the front exhaust pipe assembly
thermal baffle to the floor panel and remove the rear
muffler assembly thermal baffle.
Refit
1. Fix the front exhaust pipe assembly thermal baffle to
the floor panel, fit 7 bolts, and tighten to 4–6Nm.
Refit 2. Fit the exhaust pipe assembly.
1. Fix the rear muffler thermal baffle to the floor panel,
fit 7 nuts, and tighten to 4–6Nm.
2. Fit the rear muffler assembly.
Rear Muffler Assembly Refit
1.0 427
Hose - Turbocharger to Intercooler Hose - Turbocharger Intercooler to Throttle

Remove Body
Remove
1. Remove the intake air pressure/temperature sensor.
2. Loosen the clamp fixing the hose to the intercooler Intake Air Pressure/Temperature Sensor Remove
end, and disconnect the connection (2) between the 2. Remove the harness and overflow pipe fixed to the
hose and the intercooler. hose.
3. Loosen the clamp (1) fixing the hose to the intercooler,
and disconnect the hose from the intercooler.
4. Remove 1 bolt (2) fixing the hose assembly to the
engine.
3. Loosen the quick joint (1) fixing the hose to the

turbocharger end.
4. Remove the turbocharger to turbocharged intercooler
hose assembly.
Refit 5. Turn the clamp fixing the hose to the throttle, loosen
1. Position the hose into the engine compartment, and fit the quick joint, and disconnect the hose from the
the quick joint to the turbocharger. throttle.
2. Connect the other end of the hose to the intercooler,
fit the fixing clamp, tighten to 5–6Nm, and check the
torque.
6. Remove the hose assembly between the turbocharger

intercooler and the throttle.
Refit
1. Fix the hose assembly quick joint to the throttle, and
fix it with clamps.
2. Fix the hose to the engine, fit 1 bolt and tighten to
7–10Nm.
3. Connect the other end of the hose to the intercooler,
fit the clamp, and tighten to 5–6Nm.
4. Fit the harness and overflow pipe fixed to the hose
1.0 428
assembly.
5. Fit the intake air pressure/temperature sensor.
Intake Air Pressure/Temperature Sensor Refit
1.0 429
1.0 430
Shift Lock Control-6 Speed Auto Transmission
Shift Lock Control-6 Speed Auto
Specifications
Torque
Description Value
Nut - gear change mechanism to floor 19–25Nm
Bolt- park cable to floor 10–15Nm
1.0 431
Transmission Shift Lock Control-6 Speed Auto

System Layout
1. Automatic Transmission Shift Knob Bushing Assembly 6. Nut - Automatic Transmission Shift Control
2. Clamp Ring - Automatic Transmission Shift Knob 7. Bolt - Shift Cable to Body
3. Guide - PRND 8. Clip
4. Transmission Shift Display Module 9. Striker
5. Automatic Transmission Shift Control 10. Bushing - Automatic Transmission Shift Cable
1.0 432
Description It can be selected only when the vehicle is in stationary
Overview and the engine is idling.
Function of the shift control: • N: Neutral.
1. Collect the current position information of the shift lever. No torque passes to the wheel.
2. Output shift position signal. • D: Drive.
The shifter adopts HS CAN bus method to exchange the In this position, all 6 forward gears can be selected. It is
information with other external electronic control units. The the default position for common driving.
main object for data exchange is the transmission control
• S: sport mode, located between "+" (M+) and "-" (M-).
module (TCM). The position information (P, R, N, D/S, +, -)
• +/-: Tiptronic mode (M).
of the shift lever is obtained by reading the signal from the gear
position sensor, while the mode information (auto, sport) is Tiptronic Shift
obtained through the mode position sensor, and the position If the shift lever is shifted from "D" position to right side, the
or mode information collected is sent to the TCM via the system will automatically enter into "S" mode with different
CAN bus. shifting parameters. When the shift lever is moved forward or
The shifter drives the LED indicator on the shift panel to backward and then returned to "S/M" position, the Tiptronic
indicate the current gear and mode of the transmission, and mode is separated from "S" mode to provide manual shift
the corresponding LED indicator are provided on some control. Move the shift lever forward (+) to upshift and
positions ("P", "R", "N", "D/S", "+" (M+) and "-" (M-). When backward (-) to downshift. In addition, the shift paddle on
the ignition switch is in "ON" position, the program illuminates the steering wheel of some models also provides manual shift
the corresponding LED indicator according to the gear and control. To exit Tiptronic mode, return the shift lever to "D"
mode information of the transmission. position.
The lock-up solenoid valve is completely under the control

Shifter
of the BCM, when the conditions for unlocking are met, the
BCM will supply a 12V power to the solenoid valve directly,
then the solenoid valve can unlock.
Shift Lever Position
The operation positions of the shift lever are as follows:
The shifter assembly is composed of the SCU, control lever,

base, housing, parking cable and lock-up solenoid valve, etc,
and a locking pin hole of the "P" gear is set on the right housing.
Shifter base is fixed to the central body passage by 4 bolts.
1. Lock button draw bar

2. Shift lever
• P: Park.
3. P gear emergency unlock mechanism
The transmission is locked by the parking mechanism to
4. Lock-up solenoid valve
prevent the vehicle from sliding. Only when KL.15 is ON,
the brake pedal is depressed and the lock button on the 5. Housing
shift lever knob is pressed, can the shift lever be moved 6. Shifter base
from the position. 7. Gear position sensor (hall rotation angle/position)
• R: Reverse. 8. SCU(with 2 mode position sensors)
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Lock-up Solenoid Valve End View of Shifter End Connector

The shifter is equipped with a lock-up solenoid valve on the
shift lever, and the BCM controls it to unlock.
Shift Lever Locked in P Gear
SCU End View and Pin Information of Harness Connector
1. Lock-up solenoid valve

2. P gear locking pin hole
3. P gear emergency unlock mechanism
When the shift lever is in "P" position, the lock-up solenoid

valve is not activated, and the locking pin on the solenoid
valve is in the P gear locking pin hole on the shifter housing to
prevent the shift lever from being moved accidentally. When
the ignition switch is inserted and moved into position 2, the
shift lever is in "P" position and the brake pedal is depressed,
BCM energizes the lock-up solenoid valve, then the lock-up
solenoid valve is powered on and activated, and thus the
locking pin is removed from the P gear locking pin hole on the Pin No. Description
housing. Then press the lock button to move the shift lever 1 KL.30
out of the "P" gear. 2 KL.15
Shift Lever Released from P Gear in Emergency 3 Power HS CAN High
If the shift lever is in "P" gear, the power of the shift lever 4 GND
lock-up solenoid valve will be cut off, then the lock-up solenoid
valve will keep locking, and the shift lever cannot be moved. 5 Power HS CAN Low
Pull the emergency release mechanism to press the locking pin 6 Solenoid Valve (P gear unlocking)
out of the locking pin hole, and at the moment, the shift lever
7 Wake-up Signal Line
can be released in emergency from P gear.
8 —
9 —
10 —
11 —
12 —
Parking Cable
The shifter cable used for P gear prevents the vehicle from
sliding by using the parking mechanism in the transmission to
lock the parking gear on the differential housing. One end
of the parking brake cable is connected to the bottom of the
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shifter shift lever, and the other passes through the central passage and connects the rocker arm of the parking brake cable
shaft outside the transmission by bushings, bolts and nuts.
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Operation When the shift lever is away from P gear, it is possible to push
Gear Signal Collection the shift lever even if the solenoid is in the locking position;
however, when the shift lever is pushed back to P gear, it will
To ensure the reliable output of the gear signal, it adopts 2-way
be locked by the mechanism again. The following 3 conditions
redundancy design, and equips two gear position sensors in
shall be met to shift out P gear.
the inductive chip (the gear position sensors are Hall rotation
angle position sensor). If one of them has problem, SCU 1. The ignition key at KL15;
shall self-diagnose and save related DTC (DTC), however, the 2. Depress the brake pedal;
shifter is still able to provide normal gear signal. While the
3. BCM Delivers the signal showing the vehicle anti-theft
radially magnetized magnet fitted on the shift lever housing (at
is passed.
P gear emergency unlocking mechanism side) is rotating above
Pressure State Mode
the chip surface, the sensor in the chip shall induct the angle
position of the shift lever, and output the gear information to The power supply voltage has three states: normal, low and
SCU through chip processing, so as to judge the position of P, high.
R, N, D/S, and +/-.
Battery voltage is high:
The gear shift mode depends on the 2 mode (Hall) position
• Voltage is over 16V more than 1s, SCU records the fault;
sensors (S1, S2) welded on the back of SCU circuit board,
if less than 17.5V, it needs communication supporting.
judging the actual voltage value and calibrated voltage value of
the sensor to see whether the shift lever is under Auto mode Battery voltage is low:
or Sport mode. • Voltage is less than 9V more than 1s, SCU records the
Solenoid Control fault; if more than 6V, it needs communication supporting.
P Gear
When the shift lever is at P gear, it is impossible to push the shift

lever from P gear if the solenoid is located in locking position.
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Service Procedures Refit
Shift Lever Knob and Gear Display Panel - Dual 1. Place the shift lever in P position.
Clutch Automatic Transmission
2. Ensure the LOCK button of the shift lever knob is in
Remove
the correct position.
2. Pry off the shift lever knob sleeve.
3. Under inevitable situations or the LOCK button of the

shift lever knob is pressed accidentally, please perform
3. Pull up the sleeve, loosen the metal clamp from the the following procedures:
knob and discard it.
a. Remove the red limit lever of the new shift lever
knob.
b. Insert the limit lever into the bottom of the shift
lever knob.
4. Keep hands away from the LOCK button, pull up the

shift lever knob with care, and remove the knob and
sleeve assembly from the shift lever.
Caution: When removing, do not press the LOCK button
into the shift lever knob. c. Pull the limit lever outward to resume the LOCK
button of the shift lever knob for normal installation.
4. Locate a new metal clamp to the knob.
5. Insert the knob and sleeve into the second slot of the
shift lever.
6. Press the lock button, and check whether the lock
button can return naturally; it indicates that the fit
between the knob and the shift lever is correct if it
does.
7. Clamp the protruding part of the metal clamp with
calipers until the knob can not be pulled.
8. Embed the shift lever knob sleeve into the gear display
panel on the centre console.
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Shifter Assembly - Dual Clutch Automatic

Transmission
Remove

2. Place the shift lever in P position.
3. Disconnect the cable ball joint at the transmission side
4. Release the C-clip from the parking cable bracket, and
release the cable support.
Refit
1. Fix the shifter assembly to the central body passage, fit
4 nuts, tighten to 19–25Nm, and check the torque.
2. Connect the connector and secure the harness onto
the shifter.
3. Fix the parking brake cable to the underbody, fit 2
4. Fit the centre console assembly.
Centre Console Assembly Refit
5. Fit the shift lever knob and sleeve.
5. Remove the cable from the cable support.
Shift Lever Knob and Sleeve Refit
6. Remove the shift lever knob and sleeve.
6. Fit the cable ball joint at the transmission side to the
Shift Lever Knob and Sleeve Remove parking cable rocker arm.
7. Remove the centre console. 7. Locate the parking brake cable to its bracket and secure
with C-clip.
Centre Console Remove
8. Adjust the parking brake cable.
8. Remove 2 bolts fixing the parking brake cable to the
underbody. Parking Brake Cable Adjustment
9. Disconnect the shifter connector.

10. Remove 4 nuts fixing the shifter assembly to the central
body passage and take away the shifter assembly.
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Shift Lever P Gear Emergency Unlocking - Dual Parking Cable Inspection and Adjustment - Dual
Clutch Automatic Transmission Clutch Automatic Transmission
Unlocking Check
1. Pry up the centre console upper trim panel. 1. Place the shift lever in P position.
2. Press the unlocking lever as shown by the figure. 2. Release the cable regulating clip from the transmission
end.
3. Press the shift lever locking button and move the shift
lever from P gear to other positions. 3. Freely place the cable connecting with the transmission
end freely, making it have no contact with any other
Tip: If shift to P gear again, the shift lever
places.
will be locked again.
4. Move the shift lever from "P" to "D", then back to "P"
4. Locate the centre console upper trim panel onto the
position for several times, the shift lever should move
centre console and refit the clip properly.
smoothly.
Adjustment
Adjust the shift lever cable under the following conditions:
• The shift lever cable is disconnected.
• The engine and/or transmission is removed or fitted.
• The shifter assembly is removed or fitted.
• The parking shaft rocker arm is removed or fitted.
• The shift cable bracket is removed or fitted.
1. Release the cable regulating clip from the transmission.
2. Place the shift lever of the centre console in "P" gear.

3. Pull the parking shaft rocker arm of the transmission
towards the "P" mark on the transmission until it
cannot be moved, this can also push the transmission
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in "P" gear. Gear Indicator

Remove
2. Pry up the centre console upper trim panel.
4. Any of the following methods can be used to check

if "P" gear parking of the transmission is completely
locked:
• When both front two wheels cannot turn towards the 3. Disconnect the gear indicator rear connector, and
same direction after the vehicle is raised remove the gear indicator form the centre console
• Release the parking brake and service brake, the vehicle upper trim panel.
cannot be pushed or when it is pushed to move (the
moving distance shall not more than 20cm) a "click" can
be heard.
5. By this way, the parking pawl is completely engaged in
the tooth of the parking gear, this indicates that the
transmission is fully locked in "P" gear, then fit the cable
properly.
Caution: Parking pawl may not insert parking gear

completely in P range, if install shift cable in this situation,
incorrect gear range could result.
6. Reset and tighten the transmission cable regulating clip
to lock the cable.
Refit
1. Embed the gear indicator into the gear display panel.
2. Connect the gear indicator rear connector.
3. Fix the centre console upper trim panel onto the
centre console.
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Shift Lock Control-7 Speed Auto
Specifications
Torque
Description Value
Nut - gear change assembly to body 19–25Nm
Bolt - shift cable to body 12–15Nm
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System Layout
Shift Mechanism System Layout
1. Automatic Transmission Shift Knob Bushing Assembly 8. Shift Cable

2. Clamp Ring - Automatic Transmission Shift Knob 9. Bolt - Shift Cable
3. Guide - PRND 10. Shift Cable Bracket
4. Transmission Shift Display Module 11. Bolt - Shift Cable Bracket
5. Automatic Transmission Shift Mechanism 12. Gear Shift Rocker Arm
6. Striker 13. Nut - Gear Shift Rocker Arm
7. Nut - Shift Mechanism 14. Automatic Transmission Shift Mechanism Assembly
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Description Tiptronic Shift
Gear Shift Control Mechanism If the shift lever moves from "D" position to right side, the
The gear shift control mechanism mainly consists of a shift system will automatically use different shift parameters to
lever, a base, a gear shift lock-up solenoid valve, a gear shift enter into sport mode. Then move the shift lever to separate
cable, etc. The gear shift control mechanism base is fixed to the Tiptronic mode and sport mode, offering manual shift
the body central passage by 4 nuts. The inner latch of shift control. Move the shift lever towards "+" to upshift and
lever is engaged with the inner groove of base. towards "-" to downshift. In addition, the shift paddle on the
steering wheel also provides manual shift control. To exit
Tiptronic mode, return the shift lever to "D" position.
Gear Shift Lock-up Solenoid Valve
The transmission is equipped with a gear shift lock-up solenoid
valve located at the bottom of the shift lever. The operation of
the solenoid valve is determined by the BCM-controlled gear
shift lock-up relay in the passenger compartment fuse box.
When the shift lever is in P position, with the ignition switch

On and the brake pedal not applied, the lock-up solenoid
valve is not activated at the time. The lock tab of P gear lock
block contacts with the corresponding groove at the shift
lever bottom so as to prevent the accidental movement of
1. Shift Lever shift lever. The lock-up solenoid valve is activated only when
the brake pedal is depressed. Enable the solenoid valve to
2. Unlock Lever
make the solenoid valve push rod move towards the front of
3. Gear Shift Lock-up Solenoid Valve vehicle, so as to push the lock tab of P gear lock block away
Shift lever position operation is as follows: from the corresponding groove at the shift lever bottom.
Simultaneously, press the lock button on the shift lever knob
to allow the shift lever freely change to other positions from
P position.
Shift Lever Moving out of P Gear in Emergency
With the ignition switch on and the brake pedal depressed,
when the shift lever cannot be moved out of the P gear,
turn off the ignition switch, pull out the ignition key and
apply the parking brake, pry up the upper trim panel of the
centre console with an appropriate tool, unclench the P gear
emergency unlock button located at the left lower corner of
the gear shift mechanism with tool, move the shift lever to N
gear simultaneously, start the engine and shift to the required
gear.
• P: Lock the transmission to prevent vehicle slip. Gear Shift Cable
• R: Choose it only when the vehicle is still and the engine The gear shift cable connects the shift lever to the shift rocker
is idling. arm on the transmission. The outer cable is fixed to the
• N: No torque is transmitted to wheels. shift lever assembly end by a C-clip and fixed to the body and
• D: All 7 forward gears can be used in this position. This transmission end by two bolts respectively. The inner cable
is the default position for normal driving. at the shift control mechanism end is connected with the shift
• S: Sport mode. lever, and the inner cable at the transmission end is buckled to
the transmission shift rocker arm via a cable ball joint.
• +/-: Tiptronic.
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Service Procedures Refit

Shift Lever Knob 1. Place the shift lever in P position.
Remove 2. Locate a new metal clip to the knob.
1. Disconnect the battery negative. 3. Ensure the lock button of the shift lever knob is in the
2. Pry off the shift lever knob sleeve. correct position.
3. Pull up the sleeve, loosen the metal clamp from the 4. Under inevitable situations or the lock button of the
knob and discard it. shift lever knob is pressed accidentally, please perform
the following procedures:
a. Remove the red limit lever of the new shift lever
knob.
b. Insert the limit lever into the bottom of the shift
lever knob.
4. Keep hands away from the lock button, pull up the shift
lever knob with care, and remove the knob and sleeve
assembly from the shift lever.
Caution: When removing, do not press the lock button

into the shift lever knob.
c. Pull the limit lever outward to resume the lock
button of the shift lever knob for normal installation.
5. Locate a new metal clamp to the knob.
6. Insert the knob and sleeve into the second slot of the
shift lever.
7. Press the lock button, and check whether the lock
button can return naturally; it indicates that the fit
between the knob and the shift lever is correct if it
does.
8. Clamp the protruding part of the metal clamp with
calipers until the knob can not be pulled.
9. Embed the shift lever knob sleeve into the gear display
1.0 444
panel on the centre console. Shift Operating Control Mechanism Assembly
10. Connect the battery negative. Remove
1. Move the shift lever to "P" position.
3. Remove the shift lever knob.
Shift Lever Knob and Sleeve Assembly Remove

4. Remove the centre console assembly.
Centre Console Assembly Remove

5. Disconnect the gear shift cable at the tail end of gear
shift control mechanism.
6. Disconnect the gear shift control mechanism connector.
7. Remove 4 nuts fixing the gear shift control mechanism
to the central passage.
8. Remove the gear shift control mechanism.

Refit
1. Locate the gear shift control mechanism to the centre
passage.
2. Fix the gear shift control mechanism to the central
passage, fit 4 nuts, tighten to 19–25Nm, and check
the torque.
3. Connect the gear shift control mechanism connector.
4. Fit the shift cable to the gear shift control mechanism.
5. If cable adjustment is required, first ensure that the
transmission shift lever and shift rocker arm are in the
P position, push the clip backward (1), push the stop
block upward (2), adjust the gear selection cable to an
appropriate length, then thoroughly press down the
stop block (3), push the clip forward (4) to clamp the
gear selection cable joint.
1.0 445
Gear Display
Remove
2. Pry up the centre console upper trim panel.

7. Fit the shift lever knob and sleeve assembly.
Shift Lever Knob and Sleeve Assembly Refit

3. Disconnect the gear indicator rear connector, and
remove the gear indicator form the centre console
upper trim panel.
Refit
1. Embed the gear indicator into the gear display panel.
2. Connect the gear indicator rear connector.
3. Fix the centre console upper trim panel onto the
centre console.
1.0 446
Gear Cable to 12–15Nm, and check the torque.
Remove 4. Fit the shift cable to the gear shift control mechanism.
1. Move the shift lever to "P" position. 5. If cable adjustment is required, first ensure that the
2. Remove the battery box bracket. transmission shift lever and shift rocker arm are in the
P position, push the clip backward (1), push the stop
block upward (2), adjust the gear selection cable to an
3. Loosen the cable ball joint (1) from the gear appropriate length, then thoroughly press down the
selection/shift rocker arm, and loosen the C-clip (2) stop block (3), push the clip forward (4) to clamp the
fixing the gear selection/shift cable to the cable bracket. gear selection cable joint.
4. Remove the centre console assembly. 6. Fit the centre console assembly.
5. Disconnect the gear shift cable at the tail end of gear
shift control mechanism.
6. Remove 2 bolts fixing the gear shift cable to the body
floor.
7. Remove the gear shift cable from the vehicle.

Refit
1. Fix the gear shift cable to the jumper shifter cable
bracket on the automatic transmission with C-clip.
Caution: During clip installation, avoid pressure from
hand or tool to the nylon glove of cable, and check if the
nylon glove break off or not after installation.
2. Embed the cable ball joint into the shift rocker arm.
3. Fix the shift cable to the body floor, fit 2 bolts, tighten
1.0 447
Transmission Shift Lock Control-6MT
Shift Lock Control-6MT

Specifications
Torque
Description Value
Nut - gear change assembly to body 19–25Nm
Bolt - gear change cable to body 10–15Nm
1.0 448
Shift Lock Control-6MT Transmission
System Layout
Exploded View of Gear Shift Control Mechanism
1. Shift Lever Knob Handle and Sleeve Assembly 4. Nut - Shift Mechanism to Central Passage
2. Clip - Shift Lever Knob Handle 5. Bolt - Gear Selection/Shift Cable to Body
3. Manual Shift Control Mechanism and Gear Selection/Shift 6. Clip - Gear Selection/Shift Cable
Cable
1.0 449
Transmission Shift Lock Control-6MT
Service Procedures Shift Lever Assembly - Manual

Shift Lever Knob and Sleeve Assembly - Manual Remove
Remove 1. Remove the battery box bracket.
1. Pry up the shift lever sleeve. Battery Box Bracket Remove
2. Remove the shift lever knob and sleeve assembly.
Shift Lever Knob and Sleeve Assembly Remove
4. Locate the shift lever knob to 1st/2nd gear middle
position.
5. Align with the control lid and gear selection rocker
arm hole, insert the 1st/2nd gear lock pin of the
transmission (or use a Ф5mm elastic pin puncher), so
as to ensure the relative position between the gear
position of the shift control device and that of the
transmission control mechanism is fixed.
2. Loosen the metal clamp on the knob.
6. Align with the holes on the control mechanism device

and control lever, insert the 1st/2nd gear lock pin of
3. Pull up the shift lever knob with care, and remove the
the control mechanism (or use a Ф5mm elastic pin
knob and sleeve from the shift lever.
puncher), so as to ensure the relative position between
Refit
the gear position of the shift control mechanism device
1. Locate the trim ring to the knob, and screw the knob and that of the transmission control mechanism is fixed.
into sleeve.
2. Locate the clamp onto the knob.
3. Locate the knob and sleeve onto the shift lever of the
shifter.
4. Press the knob into the shift lever in place and secure
the clamp.
5. Embed the sleeve into the centre console upper trim
panel.
7. Remove 4 nuts fixing the shift mechanism assembly to

the body.
8. Loosen 2 bolts fixing the cable to the body.
1.0 450
Shift Lock Control-6MT Transmission
9. Loosen the cable ball joint (1) from the gear 8. Fit the centre console assembly.
selection/shift rocker arm, and loosen the clip (2) fixing
the gear selection/shift cable to the cable bracket.
9. Fit Shift Lever Knob and Sleeve Assembly.
Shift Lever Knob and Sleeve Assembly Refit
10. Remove the gear shift control mechanism assembly.

Refit
1. Locate the gear shift mechanism assembly to the body,
fit nuts and tighten to 19–25Nm.
2. Fit 2 bolts fixing the cable to the body and tighten to
10–15Nm.
3. Retain the gear selection/shift cable to the cable bracket
with clamps.
4. Make sure that the gear selection cable joint is in free
state (firstly push the top clip backward (1), then jack
up the block), connect the cable joint ball to the gear
selection/shift rocker arm.
Caution: During clip installation, avoid pressure from
hand or tool to the nylon glove of cable, and check if the
nylon glove break off or not after installation.
5. After adjusting the gear selection cable to a proper

length, firstly push the stop dog to the bottom (2), then
push the clip forward (3), thus the gear selection cable
joint is fastened.
6. After the gear selection/shift cable is fitted, pull out the

1st/2nd gear lock pin of the transmission.
7. Pull out the 1st/2nd gear lock pin of the gear shift
mechanism assembly.
1.0 451
Transmission DCT360-6 Speed Auto
DCT360-6 Speed Auto

Specifications
Torque
Description Value
Bolt - engine lifting eye 22–28Nm
Bolt - lower tie bar bracket to transmission 90–110Nm
Bolt - transmission bracket to transmission 55–65Nm
Bolt - flywheel to flywheel connecting plate 28–32Nm
Bolt - coolant outlet tube to twin clutch sportronic 7–10Nm
transmission
Bolt - TCM assembly to TCM bracket 7–10Nm
Bolt - TCM bracket to body 19–25Nm
Drain plug-transmission 57–63Nm
Check plug-transmission 57–63Nm
Filler plug-transmission 57–63Nm
Pressure filter cover 38–42Nm
Bolt - park rocker arm to transmission 38–42Nm
Bolt - park rocker arm to rocker 19–21Nm
1.0 452
DCT360-6 Speed Auto Transmission
Parameters
Type 6-speed Wet Type Dual Clutch Automatic Transmission
Gear 6 forward gears and 1 reverse gear (all gears are engaged by the synchronizer)
Speed Ratio 2WD AWD
1 3.25
2 1.88
3 1.206
4 0.897
5 1.029
6 0.795
R 4.434
Final Drive 1 4.278
Final Drive 2 2.852
Overall length 358.55mm
Centre Distance 197mm
Differential Head 72mm
Maximum Input Torque 360Nm
Maximum Input Rotation Speed 6800rpm
Total Mass 87.9kg 88.7kg
1.0 453

System Layout
Dual Clutch Automatic Transmission Assembly -
2WD
1. Dual Clutch Automatic Transmission - 2WD
1.0 454
Dual Clutch Automatic Transmission Assembly -
AWD
1. Dual Clutch Automatic Transmission - AWD
1.0 455
Dual Clutch Automatic Transmission Accessory

Layout - 2WD
1. Pressure Filter Cover 3. O Ring - Pressure Filter

2. Pressure Filter Element 4. Oil Filler Plug
1.0 456
5. Gasket - Oil Filler Plug 12. Gasket - Drain Plug
6. Parking Brake Cable Bracket 13. Drain Plug
7. Bolt - Parking Brake Cable Bracket 14. Vent Plug Cap
8. Parking Brake Cable Shaft Rocker Arm 15. R Gear Shaft Seal Cover
9. Bolt - Parking Brake Cable Shaft 16. Gasket - Oil Level Plug
10. Shift Shaft Oil Seal 17. Oil Level Plug
11. Axle Shaft Oil Seal
1.0 457
Dual Clutch Automatic Transmission Accessory

Layout - AWD
1. Pressure Filter Cover 3. O Ring - Pressure Filter

2. Pressure Filter Element 4. Oil Filler Plug
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5. Gasket - Oil Filler Plug 12. Gasket - Drain Plug
6. Parking Brake Cable Bracket 13. Drain Plug
7. Bolt - Parking Brake Cable Bracket 14. Vent Plug Cap
8. Parking Brake Cable Shaft Rocker Arm 15. R Gear Shaft Seal Cover
9. Bolt - Parking Brake Cable Shaft 16. Gasket - Oil Level Plug
10. Shift Shaft Oil Seal 17. Oil Level Plug
11. Axle Shaft Oil Seal
1.0 459
Dual Clutch Automatic Transmission Gear Shaft

Layout
1. Inner Input Shaft 11. 1st/3rd Gear Synchronizer Assembly

2. Parking Gear (integrated in the differential housing) 12. Outer Input Shaft Speed Signal Wheel
3. Differential 13. Inner Input Shaft Speed Signal Wheel
4. Outer Input Shaft 14. Reverse Gear Shaft
5. 1234 Output Shaft 15. 5th Gear Synchronizer Assembly
6. 2nd Gear Driven Gear Assembly 16. Output Shaft 5th Gear Assembly
7. 4th Gear Driven Gear Assembly 17. Output Shaft 6th Gear Assembly
8. 3rd Gear Driven Gear Assembly 18. 6th/Reverse Gear Synchronizer Assembly
9. 1st Gear Driven Gear Assembly 19. R Gear Driven Gear Assembly
10. 2nd/4th Gear Synchronizer Assembly 20. 56R Output Shaft
1.0 460
Differential Assembly Exploded View
1. Axle Shaft Oil Seal 8. Bolt - Differential Housing to Final Drive Driven Gear
2. Gasket - Differential 9. Planetary Gear Gasket
3. Tapered Bearing 10. Planetary Gear
4. Parking Gear 11. Axle Shaft Gear Shim
5. Differential Housing 12. Axle Shaft Gear
6. Planetary Shaft Pin 13. Planet Gear Shaft
7. Final Drive Driven Gear
1.0 461

Dual Clutch Automatic Transmission TCM Control
Diagram
A = Power HS CAN Bus; B = Body HS CAN Bus; C = Chassis HS CAN Bus
1.0 462
Hydraulic Control System
A= High Pressure Oil Circuit; B= Low Pressure Oil Circuit

1. Oil Pan 8. Fuel Injection Pipe (gear lubrication and cooling)
2. Suction Filter Assembly 9. Dual Clutch Cooling
3. Oil Pump 10. Pressure to Outer (Odd) Clutch
4. Pressure Filter 11. Pressure to Inner (Even) Clutch
5. Check Valve 12. Gear Control
6. Hydraulic Control Module Assembly
7. Transmission Oil Cooler (integrated in the left collecting
pipe of radiator)
1.0 463
Dual Clutch Automatic Transmission Solenoid

Valve, Sensor Control Diagram
A= Hard Wire
1.0 464
Description Clutch Disengagement State
Overview
The vehicle is equipped with 6-speed wet-type dual clutch
automatic transmission which possesses the high transmission
efficiency and durability of a manual transmission and the
comfortability of an automatic transmission that will not show
interruption of traction during shifting.
TCM It controls the system in a way similar with that used by

other ECUs equipped on the vehicle. It receives information
from the sensors or other control modules, calculates
according to the pulse spectrum information stored in the
TCM memory, and then outputs signals to the actuators or
other ECUs. The signal exchange with other control modules
is mainly conducted through the HS CAN bus. The diagnostic 1. Torsional Shock Absorber
test can be conducted through the Data Link Connector 2. C1 External Plate Bracket
(DLC). When the transmission has some faults, the TCM will
3. External (Odd) Clutch C1
store the related DTC which can be retrieved with the scan
tool. 4. C1 Internal Plate Bracket
5. C2 External Plate Bracket
Transmission Housing
6. Internal (Even) Clutch C2
The transmission housing assembly consists of the clutch
housing, main housing and end cap. The transmission housing 7. C2 Internal Plate Bracket
is made of cast aluminum, and the transmission assembly is 8. C1 Pressure Oil Cavity
connected to the engine with bolts. 9. C2 Pressure Oil Cavity
Dual Clutch and Shock Absorber Assembly 10. Pressure Oil Cavity for Lubricating Oil
The dual clutch and shock absorber assembly contains 2 parts: 11. C1 Return Spring
dual clutch module and torsional shock absorber. 12. C2 Return Spring
The dual clutch module consists of 2 wet-type multi-plate 13. Connecting External (Even) Input Shaft
friction clutches, its operation principle is as follows: 14. Connecting Internal (Odd) Input Shaft
Even gears are deployed on one part of the transmission, while 15. C1 Piston
odd gears are deployed on the other part. Before the gear 16. C2 Piston
shifting, the next gear is already locked on the unloaded part 17. Oil Pump Drive Wheel
of the transmission (pre-selected gear). Then, the clutch of
External (Odd) Clutch Engaged State and
pre-selected gear is engaged, meanwhile the clutch of loaded
Torque Transfer
gear is disengaged, so as to complete the torque transfer.
With inputted to the clutch from the flywheel, the torque in

the clutch is introduced from the external friction plate bracket
and applied to the internal plate clutch by the engagement of
the clutch, then transmitted to the corresponding input shaft.
One of the clutches always works in the force transmission
chain.
External clutch transfers the torque to the internal input shaft

connecting with 1st, 3rd, 5th and reverse gear. When the
external clutch is engaged, the hydraulic oil will fill into the
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oil cavity of the external clutch through the 1st oil inlet duct,
and push the piston to have the friction plates on the external
clutch compressed together.
The torque is transferred to the external input shaft through

the friction plate bracket. After the clutch is disengaged, the
return spring will push the piston back to its original position.
The torque is transferred to the internal input shaft through Flow Direction of Clutch Lubricating Oil
the friction plate bracket. After the clutch is disengaged, the
return spring will push the piston back to its original position.
Internal (Even) Clutch Engaged State and
Torque Transfer
The hydraulic oil fills into the lubricating oil cavity of the clutch
through the 3rd oil inlet duct; the optimum lubricating oil
distribution is achieved by the oil groove design, and the heat
generated will be taken away by the lubricating oil flowing
Internal clutch transfers the torque to the external input shaft through the friction plates of the clutch so as to cool the clutch.
connecting with 2nd, 4th, and 6th gear. When the internal Finally, the lubricating oil will flow out through the oil groove.
clutch is engaged, the hydraulic oil will fill into the oil cavity Torsional Shock Absorber
of the internal clutch through the 2nd oil inlet duct, and push The torsional shock absorber module is a rotary mechanical
the piston to have the friction plates on the internal clutch damping system, which is integrated with the dual clutch
compressed together. module, jointly forming the dual clutch and vibration shock
absorber assembly.
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Hydraulic Control Module Assembly pinion integrated with the output shaft is engaged with the
final drive driven gear of the differential assembly. When the
output shaft rotates, and the wheels swivel straight forward,
the torque will be applied to the whole assembly, and the
planetary gear does not rotate. The torque is transmitted to
the wheels through drive shaft. When the vehicle takes a turn,
the inner wheels will pass a shorter distance at a lower speed.
This drives the planetary gear to rotate, and the outer sun
gear offers a higher speed for outer wheels. Two driven shafts
transfer the torque to the differential, and the differential
transfers the torque to the wheels through the half axle.
Parking Mechanism
1. Valve Body Circuit Board

2. Solenoid Valve Body
3. Separator/Oil Seal
4. Actuator Valve Body
The hydraulic control module mainly consists of circuit board,

solenoid valve body, separator, actuator valve body and
solenoid valve etc. Its main function is:
• To control the engagement and disengagement of the dual

clutch
• To control the gear selection of the transmission
1. Parking Brake Cable Shaft Rocker Arm
• To provide cooling and lubrication for the transmission
2. Rocker Arm
gear shaft system and dual clutch
3. Locating Spring
Main Technical Parameters:
4. Guide Plate
• System operating temperature: -40～140℃; 5. Brake Pawl
Lubricating Oil 6. Parking Gear
The operating temperature of the transmission fluid is around 7. Pawl Return Spring
70～110℃. In addition to lubrication, cooling and cleaning,
8. Pawl Rotating Shaft
the main function of the transmission fluid is to control the
dual clutch and valve body through internal fluid pressure, Parking gear is fitted on the differential for reliable parking
therefore, the transmission fluid of high quality shall be used, and avoiding the occurrence of unnecessary rolling when the
and the fluid shall be clean. parking brake is not applied.
Differential The operating principle of the parking mechanism is as follows:
When the shift lever is moved to P position, the parking brake
The differential retains the final drive driven gear to the
cable shaft rocker arm drives the main guide plate through
differential housing with bolts, and the planetary shaft pin,
the lever to move along a straight line, and the main guide
planetary gear and half axle gear are supported by the
plate drives the pawl rolling through the roller to have the
differential housing. The differential assembly is supported by
pawl engaged with or separate from the parking gear, so as
bearings in the transmission housing. Parking gear is integrated
to achieve the purpose of locking or unlocking.
in the differential. The differential allows the wheels to rotate
at different speeds when the output torques are same. The
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Gear Shaft System Synchronizer
1. Internal (Odd) Input Shaft 1. Synchronizer Gear Bushing

2. Differential 2. Synchronizer Gear Hub
3. External (Even) Input Shaft 3. Key Assembly
4. 1234 Output shaft The Synchronizer consists of 3 parts: gear hub, key assembly
5. Reverse Gear Shaft and gear bushing. The gear hub is connected to the output
6. 56R Output Shaft shaft through the spline, and rotates together with the output
shaft. The key assembly is composed of housing, spring and
Input Shaft
steel balls. The key assembly is fitted in the gap of the gear
The input shafts include internal (odd) input shaft and external hub, under the action of the spring; the steel ball is pressed
(even) input shaft which are supported by bearing on the to the gear bushing and its spherical surface just embeds into
transmission housing. Among them, the solid one is the the groove of the gear bushing, which plays the role of neutral
internal input shaft, connecting to 1st, 3rd, 5th and reverse positioning. The spline teeth inside the gear bushing slides to fit
gear; and the hollow one is the external input shaft, which with the spline teeth outside the gear hub and the fork is stuck
is connected to 2nd, 4th and 6th gear. The internal (odd) on the gear bushing, so as to push the gear bushing to make
input shaft is connected to the external (odd) clutch, and the axial movement. After the gear bushing has engaged with the
external (even) input shaft is connected to the internal (even) synchronizer ring and driven ring gear, the gear shift process
clutch, both of them transmit the torque from the dual clutch is completed. With the help of synchronizer and synchronizer
module to the driven gear. ring, the impact and noise of engaging gears during the gear
Output Shaft shift is reduced, the service life of the gear is extended, and
There are 2 output shafts corresponding to the internal and the gear shift process becomes more smooth.
external input shafts, which is 1/2/3/4 output shaft and 5/6/R Synchronizer Ring
output shaft respectively. Two output shafts transmit the Different gears can generate a speed difference during shifting
torque to the differential through the driven gear. and the function of a synchronizer ring is to eliminate the
Reverse Gear Shaft speed difference between the shift gear to be engaged and the
The reverse gear teeth on the internal input shaft change the synchronizer gear bushing to make the shift more smooth.
rotating direction of the 56R output shaft by the engagement
with the idler pulley on the reverse gear shaft, that is, change
the direction of power transmission.
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Single Conical Synchronizer Ring Triple Conical Synchronizer Ring
1. Friction Ring 1. Inner Conical Ring

2. Conical Ring 2. Intermediate Ring
The one that 4th/ 5th /6th gear uses is a single conical 3. Outer Conical Ring
synchronizer ring. 4. Inner Friction Ring
Dual Conical Synchronizer Ring 5. Intermediate Friction Ring
6. Outer Friction Ring
The one that 1st /2nd gear uses is a triple conical synchronizer
ring. Compared to the single conical synchronizer ring, the
structure of triple conical synchronizer ring may increase the
friction surface significantly.
Gear Shift and Gear Selection
1. Outer Conical Ring

2. Intermediate Ring
3. Inner Conical Ring
4. Outer Friction Ring
5. Intermediate Friction Ring
The one that 3th /reverse gear uses is a dual conical

1. 6th/R Gear Fork
synchronizer ring.
2. 5th Gear Fork
3. 2nd/4th Gear Fork
4. 1st/3rd Gear Fork
5. Magnet
The figure illustrates the gear shift process by taking 5th gear
fork as an example, other gears are similar with it.
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The oil pump is an external double gear pump, its main

structure is a pair of mutually engaged gears. When the
gear rotates, the volume of the tooth gap where the gear
teeth at the suction chamber side are mutually disengaged
is gradually increasing, the pressure is reduced, and the fluid
flows into the tooth gap under the pressure difference. With
the gear rotation, the fluid in each tooth gap is brought to
the discharging chamber. The volume of the tooth gap where
the gear teeth at the discharging chamber side are engaged is
gradually decreasing, so as to discharge the fluid. With the
engine running, the pump discharges the fluid continuously.
The pump flow is directly related to the pump speed.

1. 5th Gear Fork Valve Body Piston Cylinder (in the Oil Filter
direction of shifting to N gear) The oil filter consists of a suction filter and a pressure filter.
2. 5th/N Gear Position Sensor
3. 5th Gear Fork Valve Body Piston Cylinder (in the
direction of shifting to 5th gear)
4. 5th Gear Fork
Inside the transmission, the hydraulically-operated fork is

controlled by the valve body piston cylinder to complete
the gear shift, and the fork shaft is connected to the fork.
During the gear shift, the transmission fluid in the valve body
is delivered into the oil cylinder at one side of the fork,
meanwhile there is no oil pressure in the oil cylinder at other
side of the fork, which allows the piston in the oil cylinder
push the fork to move, at the same time, the fork turns
synchronizer gear bushing to complete the gear shift.
The suction filter is fitted at the bottom of the transmission
After the gear is engaged, the pressure applied to the oil housing and connected with the gear pump. It filters the oil
cylinder disappear and the fork is locked in the current entering into the transmission hydraulic system at the suction
position by the set pin. end of the gear pump. The suction filter mainly consists of
There is a permanent magnet on each fork, the position sensor filter housing and filter net. Under the suction force of the oil
on the valve body control module can identify the precise pump, oil enters into the oil pump through the filter net and
location of each fork through the magnet. the suction filtration is completed in this process.
Oil Pump and Oil Filter

Oil Pump
1. Pressure Filter Cap

2. O-ring - Pressure Filter Cover
3. Pressure Filter Element
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4. O-ring - Pressure Filter Element 2. Fluid Level Pipe
The pressure filter is fitted on the top of the transmission The transmission is fitted with a fluid level pipe which can
housing, which is located in the oil duct between the pump be used to set the correct fluid level. During fluid level
and valve body and conducts fine filtration of the oil entering check, if fluid overflows as drops from the fluid level pipe,
into the proportional solenoid valve oil circuit. The pressure the transmission fluid level is correct. For correct fluid level
filter is mainly composed of the filter cover, bypass valve and setting, please refer to the "Service Guideline for Dual Clutch
filter element. Automatic",
Fluid Drain and Fluid Level Oil & Fluid
A baffle is provided on the main transmission housing, which

Sensor
ensures that the suction filter can suck enough fluid even when Satellite Sensor
the vehicle tilts. The baffle divides the transmission into two
fluid cavities, so the two cavities shall both be open when
draining the fluid thoroughly.
The satellite sensor assembly is fitted in the main housing and

is located next to the 1234 output shaft. The satellite sensor
assembly integrates the output shaft speed sensor, clutch
speed sensor (i.e., input speed sensor) and clutch temperature
1. Drain Plug
sensor.
2. Baffle
3. Drain Plug
Correct fluid level is significantly crucial for normal operation

of the transmission.
• Low fluid level: Oil pump will inhale air and result in low
oil pressure and transmission malfunction.
• High fluid level: A large number of bubbles produced by
the stir of the gear set will overflow from the vent pipe.
1. Satellite Sensor
2. 1234 Output Shaft Final Drive Driving Gear
3. Clutch Wheel Hub
The output shaft speed sensor operates based on the Hall

principle, the output speed of the transmission is determined
by detecting the output shaft final drive driving gear speed;
the clutch speed sensor determines the input speed of the
transmission by detecting the clutch wheel hub speed; and the
clutch temperature sensor measures the temperature of the
1. Drain Plug (Fluid Level Check)
lubricating oil flowing out of the plate clutch.
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Sensors can be divided into the following categories:

Pressure Sensor
There are 2 pressure sensors in total in the transmission
which are fitted on the valve body inside the transmission
respectively, and used for detecting the pressures of both odd
and even clutches in the dual clutch.
The oil temperature sensors are divided into 2 different

types, the inside of the solenoid temperature sensor is
a semiconductor thermistor which presents the negative
temperature coefficient characteristics, that is, the higher the
oil temperature, the smaller the resistance, or vice versa.
The pressure sensors are resistance strain gauge transducers,

when the oil pressure controlling the clutch engagement
changes, the deformation of resistance strain gauge will
occur with the oil pressure change, so that the voltage signal
generated by the sensor will increase along with the increased
oil pressure, and vice visa.
All 3 wires of the pressure sensor are connected with the ECU.
Among them, one is a power wire, one is a ground wire and
the other is the wire for signal of voltage to ground, which
varies with the oil pressure. TCM Measure the controlling
fluid pressure of the transmission clutch based on this voltage
change, so as to determine the current state of the dual clutch The valve body temperature sensor and clutch temperature
(engaged/disengaged). sensor are silicon temperature sensors which utilize
Temperature Sensor the diffused resistance principle, they have the positive
temperature coefficient characteristics, that is, the higher the
There are 3 temperature sensors mounted on the
oil temperature, the greater the resistance, or vice versa.
transmission, which are clutch temperature sensor, valve body
temperature sensor and solenoid valve temperature sensor. 2 wires of the oil temperature sensor are connected with
The clutch temperature sensor is integrated in the satellite TCM, among them, one is the ground wire, the other is the
sensor, and the valve body temperature sensor and solenoid wire for voltage to ground, which varies with the resistance
temperature sensor are located on the valve body. These value. TCM It measures the transmission hydraulic fluid
temperature sensors which contact with the transmission temperature based on this voltage change, so as to determine
fluid are used for detecting transmission temperature. the oil injection pulse width of the cooling lubricating oil etc,
together with the signals from other sensors.
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Position Sensor signal, so as to determine the transmission input, output
rotation speed and speed ratio, etc.
Solenoid Valve
There are 4 fork position sensors in total in the transmission.

They are fitted on the valve body inside the transmission
respectively and used for checking the positions of 4 forks. 1. Even Clutch Solenoid
The fork position sensors are the ones which adopts the
2. Odd Clutch Solenoid
PLCD principle, when the magnet fitted on the fork moves
3. Multi-way Solenoid 1
while the fork executes the gear shift action, the duty ratio
of the PWM signal generated by the sensor which are used 4. Main Oil Circuit Pressure Solenoid
to induce the magnet will increase or decrease along with 5. Multi-way Solenoid 2
the magnet position change, when the signal is normal, the 6. Lubricating Oil Circuit Pressure Solenoid
operating range of the duty ratio shall be 10%～90%.
7. Shift Solenoid 2
All 3 wires of the position sensor are connected with TCM, 8. Shift Solenoid 1
among which, one is a power wire, one is a ground wire and
the other is the wire for signal of PWM to ground, the duty Solenoids may be divided into 2 categories according to their
ratio will increase or decrease along with the magnet position operation: proportional solenoid and switch solenoid.
change. TCM It measures the positions of 4 forks based on Each solenoid is provided with an inner coil and a needle
this duty ratio signal, so as to determine the current gear and valve. The needle valve is activated by the voltage that passes
target gear of the transmission together with the signals from through the solenoid coil, and it opens or closes the hydraulic
other sensors. circuit. All solenoid valves are equipped with 2 pins, which
Speed Sensor are connected to TCM via the harness. Among them, one is
for power supply, and the other is for signal control. TCM It
There are totally 4 speed sensors in the transmission. They
outputs control signals to the solenoid based on the vehicle
are used for checking the rotation speed of the clutch, internal
driving condition and collected sensor signal.
input shaft, external input shaft and output shaft, among which
the clutch speed sensor and output shaft speed sensor are Main Oil Pressure and Lubricating Oil Pressure
integrated in the satellite sensor, and others are fitted on the Solenoid
valve body inside the transmission. All speed sensors are The transmission uses 1 main oil pressure solenoid and 1
Hall-effect sensors. When the target wheel starts to rotate, lubricating oil pressure solenoid which all pertain to current
the speed sensor begins to produce a series of pulse signals. pulse width modulation solenoids, and are fitted on the valve
The number of pulses increases with the increased vehicle body inside the transmission respectively.
speed, and the pulse signal frequency of the speed sensor
The main oil pressure solenoid is used to modulate the main
increases with the increased speed of detected component,
oil circuit pressure of the hydraulic system. The greater the
while the duty ratio keeps constant at any speed.
control current of the main oil circuit solenoid is, the smaller
2 wires of the speed sensor are connected with the TCM, the pressure of the main oil circuit is, and the smaller the
among which, one is the power wire, the other is the wire for control current is, the greater the pressure of the main oil
pulse signal to ground, whose frequency will increase as the circuit is.
rotation speed of the corresponding transmission component
The lubricating oil pressure solenoid is used to modulate the
increases, and the TCM measures the rotation speeds of
cooling lubricating oil pressure to the clutch. The greater the
different transmission shafts and clutches based on this pulse
control current of the lubricating oil pressure solenoid is, the
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smaller the flow volume entering into the clutch is, and the • OFF: Switch Solenoid Off
smaller the control current is, the greater the flow volume • ●: Current Pulse Width Modulation Solenoid Activated
entering into the clutch is.
Connecting Module and Harness Assembly
Clutch Solenoid Connecting Module and Harness Assembly
The transmission has 2 clutch solenoids, which pertain to 1. Connecting to Sensor Board
current pulse width modulation solenoids, and are fitted on
2. Connecting to Valve Body Circuit Board
the valve body inside the transmission respectively. They
are used to control and modulate the combined oil pressure 3. Connecting to Satellite Sensor
of odd and even clutches in the dual clutch respectively. 4. Connection TCM
The clutch solenoid controls the hydraulic pressure linearly End View and Pin Information of Valve Body
through the current size, that is, the hydraulic pressure will Module Harness Connector BY002
increase as the control current increases, or vice visa.
Shift Solenoid Value
The transmission has 2 shift solenoids, which pertain to
current pulse width modulation solenoids and are fitted on
the valve body inside the transmission respectively. 2 shift
solenoids and 2 multi-way solenoids participate in the control
on the shift oil pressure and 4 forks.
Multi-way Solenoid Value
The transmission has 2 multi-way solenoids, which pertain to
switch solenoids and are fitted on the valve body inside the
transmission respectively. 2 multi-way solenoids and 2 shift
solenoids participate in the control on 4 forks.
Solenoid Value Operation State Pin No. Description
Solenoid Valve 1 Odd Clutch Pressure Sensor Signal
Gear Gear Gear Multi Multi Odd Even
-way 1 -way 2 Clutch 2 Solenoid Temperature Sensor Signal
Shift 1 Shift 2 Clutch
P - - OFF OFF - - 3 Even Clutch Pressure Sensor Signal
R ● - OFF ON ● - 4 Valve Body Temperature Sensor Signal
N - - OFF OFF - - 5 Sensor Ground 2
1 - ● OFF OFF ● - 6 Sensor 5V Power Supply 2
2 ● - ON ON - ●
7 Even Input Shaft Speed Sensor Signal
3 ● - OFF OFF ● -
D 8 2nd/4th Gear Position Sensor Signal
4 - ● ON ON - ●
5 ● - ● - 9 6th/R Gear Position Sensor Signal
ON OFF
6 - ● OFF ON - ● 10 —
11 Multi-way Solenoid 2
• ON: Switch Solenoid On
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Pin No. Description Transmission Control Module (TCM)
12 Multi-way Solenoid 1
13 SubROM Chip Option
14 SubROM Read/Write
15 SubROM Clock
16 Main Oil Circuit Pressure Solenoid
17 Shift Solenoid 2
18 Shift Solenoid 1
19 Clutch Temperature Sensor Signal
20 Sensor 9V Power Supply 1
21 Sensor 9V Power Supply 2
22 Lubricating Oil Circuit Pressure Solenoid
TCM The TCM is located on the driver side fender and
23 Even Clutch Solenoid
connected to the transmission harness via 1 connector with a
24 Odd Clutch Solenoid
total of 81 pins.
25 Clutch Speed Sensor Signal
TCM Use an Electrically Erasable Read-Only Memory
26 Output Shaft Speed Sensor Signal
(EEPROM), so as to a new or replaced TCM may be used
27 Sensor Ground 1 for external configuration. EEPROM The TCM can also
28 Sensor Ground 1 update the new information and market-specific data. To
29 Sensor 5V Power Supply 1 input new information, the TCM must be configured with
a scan tool. EEPROM The TCM can be reconfigured for
30 Odd Input Shaft Speed Sensor Signal
many times as required, so as to meet the constantly changing
31 5th Gear Position Sensor Signal parameters and regulations.
32 1st/3rd Gear Position Sensor Signal
TCM It stores the signal values of the transmission sensor
33 —
and the actuator. These stored signals guarantee that the
Solenoid (Lubricating Oil Circuit Pressure transmission can always obtain the optimal performance. If
34 Solenoid, Main Oil Circuit Pressure Solenoid)
the battery voltage is too low, such as battery discharge, the
Power Supply 3
information will be lost. When the engine starts for the first
Solenoid (Even Clutch Solenoid, Shift Solenoid 2,
35 time after the battery is discharged or disconnected, TCM
Multi-way Solenoid 2) Power Supply 2
will restore to the default value. TCM The EEPROM inside
Solenoid (Odd Clutch Solenoid, Shift Solenoid 1,
36 allows the stored value to be rapidly accessed again.
Multi-way Solenoid 1) Power Supply 1
Input/Output
SubROM
The sensor signal enables TCM to monitor the transmission
SubROM is a memory chip located on the valve body of the state. TCM It processes the signals and compares them with
transmission and stores the relevant information such as the the data stored in the memory. If these signals are not in the
fork position of each gear, clutch meshing point, characteristic range of parameters stored by TCM, TCM will adjust the
curve of the solenoid etc. When replacing the TCM, it is operation of the transmission through the actuator, so as to
required to transmit these data in the SubROM into the new provide the optimal drive ability and other performances.
TCM with a scan tool.
TCM It also connects with the following units through the
CAN bus:
• ECM
• BCM
• ABS/SCS Regulator ECU
• Instrument Pack
• Diagnostic Socket
TCM It receives the input signals of throttle opening, engine

coolant temperature, engine speed, engine torque, etc. from
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ECM; TCM also receives the input signals of brake switch, outputs the torque control request, shift gear information
pressure sensor, clutch speed, oil temperature, valve body and failure warning information to the ECM and outputs
solenoid state, mode switch, etc. In addition, the TCM execution signal, etc. to the valve body solenoid.
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End View and Pin Information of TCM Harness
Connector BY001
Pin No. Description Pin No. Description

1 Ground 32-37 —
2 Ground 38 Shift Solenoid 2
3 Ground 39 Lubricating Oil Circuit Pressure Solenoid
4 KL.30 40-43 —
5 KL.30 44 Multi-way Solenoid 1
6 KL.15 45 Digital Output: P/N Hardwire
7 Sensor 9V Power Supply 1 46-48 —
8 Sensor 9V Power Supply 2 49 SubROM Read/Write Option
9 Odd Shaft Speed Sensor Signal 50-52 —
10 Even Shaft Speed Sensor Signal 53 Clutch Oil Temperature Sensor Signal
11 1st/3rd Fork Position Sensor Signal 54 Valve Body Oil Temperature Sensor Signal
12 2nd/4th Fork Position Sensor Signal 55 Instrument HS CAN Low
13 — 56 Instrument HS CAN High
14 KL.R 57 Odd Clutch Pressure Solenoid
15 Odd Clutch Pressure Sensor Signal 58 Even Clutch Pressure Solenoid
16 Even Clutch Pressure Sensor Signal 59 —
Solenoid Power Supply 2 (Even Clutch Solenoid, Shift
17 HS CAN Low 60
Solenoid 2, Even Multi-way Solenoid)
18 HS CAN High 61-62 —
19 Shift Solenoid 1 63 Multi-way Solenoid 2
20 Main Oil Circuit Pressure Solenoid 64 Sensor Ground 1
21-22 — 65 Sensor Ground 2
Solenoid Power Supply 1 (Odd Clutch
23 Solenoid, Shift Solenoid 1, Odd Multi-way 66-67 —
Solenoid)
24-25 — 68 SubROM Clock
26 Sensor 5V Power Supply 1 69 SubROM Chip Option
27 Sensor 5V Power Supply 2 70 —
28 Output Shaft Speed Sensor Signal 71 Sensor Ground 1
29 Engine Speed Sensor Signal 72 Oil Pan Oil Temperature Sensor Signal
30 5th/N Fork Position Sensor Signal 73-80 —
Solenoid Power Supply 3 (Main Oil Circuit Pressure
31 6/R Fork Position Sensor Signal 81
Solenoid, Lubricating Oil Circuit Pressure Solenoid)
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Operation shaft is driven by the outer (odd) clutch, while the outer input
Transmission Power Flow shaft is driven by the inner (even) clutch.
The delivery of torque in transmission is achieved via inner and The power flow of each gear is shown in the following diagram:
outer clutch. Each clutch drives an input shaft. The inner input
Data Note
1 Output Shaft 1st Gear Assembly 11 Inner (Even) Clutch

2 Output Shaft 2nd Gear Assembly 12 Inner Input Shaft
3 Output Shaft 3rd Gear Assembly A 5th Gear Synchronizer Assembly
4 Output Shaft 4th Gear Assembly B 6th/Reverse Gear Synchronizer Assembly
5 Output Shaft 5th Gear Assembly C 2nd/4th Gear Synchronizer Assembly
R Output Shaft Reverse Gear Assembly D 1st/3rd Gear Synchronizer Assembly
6 Reverse Gear Shaft E Input Shaft Bearing
7 56R Output Shaft FD Final Drive Driven Gear
8 1234 Output Shaft FD1 1234 Output Shaft Final Drive Driving Gear
9 Outer Input Shaft FD2 56R Output Shaft Final Drive Driving Gear
10 Outer (Odd) Clutch
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Shift Fork and Clutch State
Shift Fork Position Clutch

Gear
2nd/4th 1st/3rd Outer Inner
5th Gear 6th/R Gear
Gear Gear (Odd) (Even)
P M R R M O O
R M R R M C O
N M R R M O O
1 M M R L C O
2 M M R U O C
3 M M U R C O
D
4 U M L U O C
5 R U U M C O
6 R L M M O C
• O=Open
• C=Close
• L=Left
• R=Right
• M=Middle
• U=Unknow (depend on the current driving status)
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1st Gear
Solenoid Shift Fork Position
Gear Gear Shift Gear Shift Multiplexer Multiplexer Odd Even 6th/R 2nd/4th 1st/3rd
5th Gear
1 2 1 2 Clutch Clutch Gear Gear Gear
D 1 - ● OFF OFF ● - M M R L
Power Flow:
Engine - Outer (Odd) Clutch - Inner Input Shaft - 1st Gear -

1234 Output Shaft - Final Drive Gear - Differential- Drive Shaft
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2nd Gear
5th Gear
D 2 ● - ON ON - ● M M R U
Power Flow:
Engine - Inner (Even) Clutch - Outer Input Shaft - 2nd Gear -

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3rd Gear
5th Gear
D 3 ● - OFF OFF ● - M M U R
Power Flow:
Engine - Outer (Odd) Clutch - Inner Input Shaft - 3rd Gear -

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4th Gear
5th Gear
D 4 - ● ON ON - ● U M L U
Power Flow:
Engine - Inner (Even) Clutch - Outer Input Shaft - 4th Gear -

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5th Gear
5th Gear
D 5 ● - ON OFF ● - R U U M
Power Flow:
Engine - Outer (Odd) Clutch - Inner Input Shaft - 5th Gear -

56R Output Shaft - Final Drive Gear - Differential- Drive Shaft
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6th Gear
Gear Gear Gear Multiplexer Multiplexer Odd Even 6th/R 2nd/4th 1st/3rd
5th Gear
Shift 1 Shift 2 1 2 Clutch Clutch Gear Gear Gear
D 6 - ● OFF ON - ● R L M M
Power Flow:
Engine - Inner (Even) Clutch - Outer Input Shaft - 6th Gear -

56R Output Shaft - Final Drive Gear - Differential- Drive Shaft
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Reverse Gear
5th Gear
R ● - OFF ON ● - M R R M
Power Flow:
Engine - Outer (Odd) Clutch - Inner Input Shaft - Reverse Gear

Shaft - 56R Output Shaft - Final Drive Gear - Differential- Drive
Shaft
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Hydraulic Oil Circuit
Hydraulic system is mainly divided into two parts:
1. High pressure oil circuit, mainly in charge of gear shift of

transmission and clutch operation.
2. Low pressure oil circuit, mainly in charge of the
lubrication of the transmission gear, shaft, bearing and
clutch cooling.
Establishment and distribution of the hydraulic pressure: the

oil enters into the hydraulic system through the filter and
oil pump, the mainline pressure control valve controls the
mainline pressure range from 0 to 3.27MPa, the system oil
circuit is divided into two parts after flowing through the
mainline pressure modulator valve: high pressure oil circuit
and low pressure oil circuit.
The high pressure oil circuit takes charge of clutch and gear
shift control. The clutch solenoid adjust oil circuit pressure
range from 0 to 1.8MPa.
After a part of hydraulic oil flowing in the mainline pressure

control valve, the pressure is reduced within 0.57MPa. This oil
circuit is low pressure lubrication cooling oil circuit. The low
pressure oil circuit is divided into two parts after coming out of
the mainline pressure control valve, one part enters into the oil
cooler via the housing oil groove, returns to transmission after
cooling from oil cooler, and then connects with oil spray bar
and output shaft lubrication oil circuit after entering into the
transmission. The other part flows into the clutch lubrication
oil circuit after adjusted by the lube pressure valve, and then
flows back to the oil pan after the clutch is cooled down.
1.0 487
Service Procedures
Dual Clutch Automatic Transmission
Remove
2. Remove the battery tray.
Battery Tray Remove

3. Remove 1 bolt fixing the oil cooler pipe clip to the
automatic transmission and remove the pipe clip.
6. Fit the engine lug of the TEN00120 to the engine,

4. Remove the bolt connecting the oil cooler pipe to the

automatic transmission, disconnect the pipe from the
automatic transmission and discard the seal ring.

contamination.
5. Remove 2 central bolts connecting the engine cylinder

block to the transmission.
8. Remove and discard 2 bolts and 1 nut fixing the
transmission suspension to the transmission mounting
bracket.
1.0 488
9. Remove 4 bolts fixing the transmission suspension to 19. Support the transmission with a bracket.
the body, and remove the transmission suspension. 20. Remove the remaining 6 bolts connecting the engine
10. Raise the vehicle to a suitable position with the lift. to the transmission.
11. Disconnect the harness from the connector of the dual 21. With assistance, release the transmission and engine
clutch automatic transmission. from the locating pin, and put the transmission aside.
22. Lock the dual clutch module by securing the dual clutch
module with a panel.
23. Remove 4 bolts securing the automatic transmission
mounting bracket on the transmission, and remove the
bracket.
12. Drain the automatic transmission fluid.
Dual Clutch Automatic Transmission Fluid -

Drain

24. Remove 4 bolts fixing the lower tie rod bracket to the
14. Remove the PTU. transmission, and remove the lower tie rod bracket.
PTU Remove Refit
15. Remove the starter. 1. Clean the junction of the engine and transmission.
Starter Remove 2. Clean the locating pin and pin hole of the transmission
and engine.
16. Remove the parking brake cable bracket.
Parking Brake Cable Bracket Remove bolts, tighten to 90–110Nm and check the torque.
17. Rotate the flywheel to expose the bolts connecting 4. Fix the automatic transmission mounting bracket to
the flywheel with the flywheel plate from the starter the automatic transmission, fit 4 bolts, tighten to
mounting port. 55–65Nm and check the torque.
18. Remove and discard 6 bolts connecting the flywheel 5. Secure the automatic transmission holder on the
plate with the flywheel respectively. bracket, then lift and locate the bracket to the vehicle.
6. With assistance, align the front of the hydraulic torque
1.0 489
converter with the engine crankshaft hole, and align transmission.

the engine locating pin with the locating pin hole of the 17. Lower the vehicle.
automatic transmission and allow the transmission and
18. Fix the transmission suspension to the body, fit 4 bolts,
engine to fit together.
Caution: Take care not to damage the flywheel 19. Fix the transmission suspension to the transmission
connecting plate or clutch sealing cover when connecting mounting bracket, fit 2 new bolts, tighten to
engine and transmission, otherwise transmission failure 70Nm+90°, fit 1 new nut and washer, tighten to
could result! 70Nm+90°, and check the torque.
7. Fit 8 bolts connecting the engine and automatic 20. Fit the remaining 2 bolts connecting the automatic
transmission, tighten to 75–90Nm in diagonal transmission and engine, tighten to 75–90Nm, and
sequence, check the torque and mark with the marker. check the torque.
8. Rotate the crankshaft, align the hole on the flywheel 21. Remove the plug, fit a new seal to the oil cooler pipe,
with the bolt hole on the flywheel plate, fit 2 bolts and and apply clean automatic transmission fluid to it.
pre-tighten to 3–5Nm. 22. Secure the oil cooler pipe to the automatic transmission,
9. Rotate the crankshaft (appr. 120°), align the hole on fit 1 bolt respectively, tighten to 7–10Nm, and check
the flywheel with the bolt hole on the flywheel plate, fit the torque.
2 bolts and pre-tighten to 3–5Nm. 23. Secure the oil cooler pipe clip to the automatic
10. Rotate the crankshaft (appr. 120°) again, align the hole transmission, fit 1 bolt, tighten to 7–10Nm, and check
on the flywheel with the bolt hole on the flywheel plate, the torque.
fit 2 bolts and pre-tighten to 3–5Nm. 24. Fit the battery box.
11. Tighten 6 bolts to 28–32Nm in the sequence of
Battery Refit
1–5–3–4–2–6, and mark with the marker.
25. Refill automatic transmission fluid.
Caution: Take care to fit correct bolt securing flywheel
connecting plate to flywheel. If not, the longer bolt will Dual Clutch Automatic Transmission Fluid -
damage the clutch sealing cover, transmission failure Refill
could result! 26. Programme and encode the EEPROM.
Reset EEPROM Data to Default Value

27. Programme and encode the SubROM.
Read SubROM Data (all).

28. Test the automatic transmission sensor.
Automatic Transmission Sensor Test
12. Fit the parking brake cable bracket.

Parking Brake Cable Bracket Refit
13. Fit the starter.
Starter Refit
14. Fit the PTU (AWD).
PTU Refit
16. Connect the connector of the dual clutch automatic
1.0 490
TCM - Dual Clutch Automatic Transmission Dual Clutch Automatic Transmission Fluid -
Remove Drain and Refill
Drain
2. Remove the left front wheelhouse liner. 1. Remove the bottom deflector.
Front Wheelhouse Liner Remove Bottom Deflector Remove
3. Remove 2 bolts fixing the transmission control module 2. Place a suitable container below the transmission to
bracket to the body. collect the transmission fluid.
4. Disconnect the transmission control module connector. 3. Check the surrounding area of each oil plug for oil
leakage, and replace the faulty oil plug or sealing gasket
if necessary.
4. Clean 2 oil drain plugs (B, C) and their surrounding
areas.
5. Remove 4 screws fixing the transmission control

module to its bracket, and remove the transmission
control module.
5. Remove 2 oil drain plugs (B, C) and discard their the

sealing gaskets.
6. Drain the oil.
Warning: Observe due care when draining gearbox fluid

as the fluid can be very hot.
Refill
Caution: Only use appointed transmission oil. Do not add
any additives.
Caution: Do not reuse the drained transmission oil.
1. Fit new sealing gasket to the drain plugs (B and C),

tighten the drain plugs to 57–63Nm, and clean the oil
Refit
stains around the drain plug.
1. Fix the transmission control module to its bracket, fit 4
screws, tighten to 7–10Nm, and check the torque. Caution: Detect the flange surface quality of the oil plug,
and change for new plug if there is any knock marks or
2. Connect the transmission control module connector.
deformation.
3. Fix the transmission control module bracket to the
body, fit 2 bolts, tighten to 19–25Nm, and check the 2. Remove the oil plug (A) and discard its sealing gasket.
torque. 3. Lower the vehicle, clean the surrounding area of the oil
4. Refit the left front wheelhouse liner. filler, remove the oil filling plug and discard its sealing
gasket.
4. Fill the transmission fluid through oil filler with
TPT00059.
6. Programme and encode the TCM.
TCM Replacement
1.0 491

Fluid Level Check and Refill
Check
any additives.

2. Check the surrounding area of each oil plug for oil
if necessary.
5. Check the transmission fluid level. 3. Lift the vehicle to make wheels get off the ground.
4. Start the engine in P gear and keep it running at idle
Transmission Fluid Check and Refill
speed.
5. Depress the brake pedal, shift the gear according to the
following sequence: R-N twice, N-D twice (during the
gear shift, the brake pedal is always depressed). After
the completion of the gear shifts, shift to N gear.
6. Depress the brake pedal, shift to R gear, then release
the brake pedal, allow the wheels to rotate for about
10s; depress the brake pedal until the wheels stop
rotating, then release the brake pedal, allow the wheels
to rotate for about 10s again.
Warning: All the staff shall be away from the rotary parts
to avoid personal injury.
7. Connect a scan tool, ensure that the valve body
temperature is already between 35-45℃.
• If the valve body temperature is lower than 35℃, repeat

Step 6 until the valve body temperature is between
35-45℃;
• If the valve body temperature is higher than 45℃, turn
off the engine, repeat Steps 3, 4, 5 and 6 after it is
cooled down to room temperature, until the valve body
temperature is between 35-45℃;
8. Depress the brake pedal till the wheels are fully
stopped, shift to P gear, and keep the engine running
at idle speed.
9. Place a suitable container below the transmission,
remove the oil level plug (A) as illustrated.
10. Check for oil drops spilled from the oil filler.
• If the oil overflows, terminate the operation, close the

engine, clean the oil plug (A), fit a new sealing gasket and
tighten to 57–63Nm, then clean the oil stain around the
oil plug.

1.0 492
Caution: Detect the flange surface quality of the oil plug, 5. Fit the bottom deflector.
deformation.
• If no oil overflows, refill appropriate transmission fluid.

Dual Clutch Automatic Transmission Fluid
Refill
Refill
1. Lower the vehicle, clean the surrounding area of the oil
filler, remove the oil filling plug and discard its sealing
gasket.
2. Fill the transmission fluid through the oil filler with

TPT00059, until there are oil drops spilling from A,
then end the refilling and turn off the engine.
3. Clean the oil level plug (A), fit a new sealing gasket and
tighten to 57–63Nm, then clean the oil stain around
the oil plug.
Caution: Detect the flange surface quality of the oil plug,

deformation.
4. Fit the oil filler plug and a new sealing gasket, tighten to
57–63Nm, and clean the oil stains around the oil plug.
Caution: Detect the flange surface quality of the oil plug,

deformation.
1.0 493
Differential Oil Seal - Transmission Housing Differential Oil Seal -Clutch Housing
Remove Remove
1. Drain the dual clutch automatic transmission fluid. 1. Drain the dual clutch automatic transmission fluid.
Dual Clutch Automatic Transmission Fluid Drain Dual Clutch Automatic Transmission Fluid -
2. Remove the left drive shaft assembly. Drain
2. Remove the right drive shaft assembly.
Left Drive Shaft Assembly Remove
3. Insert the jaw at the front end of TPT00117 into Right Drive Shaft Assembly Remove
the steel ring frame of the oil seal, secure the jaw and 3. Insert the jaw at the front end of TPT00117 into
impact the oil seal with a ram. the steel ring frame of the oil seal, secure the jaw and
impact the oil seal with a ram.
4. Carefully remove the oil seal and discard it.

Refit 4. Carefully remove the oil seal and discard it.
1. Gently apply the specified dual clutch automatic Refit
transmission fluid around the lip with clean hands. 1. Gently apply the specified dual clutch automatic
2. Fit the new oil seal into the transmission housing with transmission fluid around the lip with clean hands.
TPT00118 and hammer. 2. Fit the new oil seal into the transmission housing with
TPT00118 and hammer.
Caution: Take care not to damage the oil seal.
3. Fit left drive shaft assembly.

3. Fit the right drive shaft assembly.
Left Drive Shaft Assembly Refit
4. Refill the transmission fluid and check the fluid level. Right Drive Shaft Assembly Refit
4. Refill the transmission fluid and check the fluid level.
Refill Dual Clutch Automatic Transmission Fluid -
Refill
1.0 494
Pressure Filter condition, and replace it if necessary.
Remove 4. Fit the O-ring to the pressure filter cap and check if it
Tip: Oil pressure filter and O ring of oil pressure filter is in right place, then apply transmission fluid to the
cover should replaced per 60,000 kilometers.
O-ring and the pressure filter cap threads.
1. Remove the throttle intake pipe.
5. Fit the pressure filter cap to the transmission housing
Throttle Intake Pipe Remove and pre-rotate until the O-ring connects with the flange
2. Remove 1 bolt fixing the oil cooler pipe clamp to the face of the transmission housing. If it is to be stuck
automatic transmission. during the pre-rotation, you shall stop the operation
and screw it out in reverse direction. Check the thread
or O-ring for damage, if any, replace it.
6. Tighten the pressure filter cap at a low, constant speed
(10s one circle) with a wrench to 38–42Nm. Torque
wrench with digital display or pointer is recommended
to use.
Warning: Take care to tighten the pressure filter cover
within specified value, if not transmission oil will spray
from transmission. The sprayed oil may result fire in hot
condition!
Caution: Do not use the pneumatic or electrical tool to

remove or fit pressure filter cover, otherwise the pressure
3. Unscrew the pressure filter cap, keep away from the filter cover will be damaged.
transmission oil cooler pipe, and take off the pressure 7. Mark on the mating face of the housing and pressure
filter cap. If need to replace the pressure filter cap, the filter cap with a marking pencil after tightening.
O-ring must be replaced synchronously.
8. Fit 1 bolt fixing the oil cooler pipe clip to the automatic
Caution: Do not use the pneumatic or electrical tool to transmission and tighten them to 7–10Nm, then check
remove or fit pressure filter cover, otherwise the pressure the torque.
filter cover will be damaged.
9. Fit the throttle air inlet pipe.
4. Pull out the pressure filter element slowly, handle with
Throttle Air Inlet Pipe Refit
care to allow the residual oil in the element to drop
back into the transmission instead of dropping on the
transmission housing.
Refit
1. Apply specified transmission fluid to the O-ring of
pressure filter element.
2. Insert the new pressure filter element in place through
the hole on the transmission housing and fit in place.
3. Check if the O-ring on the pressure filter cap is in good
1.0 495
Parking Brake Cable Bracket Parking Brake Cable Shaft Rocker Arm
Remove Remove
1. Place the shift lever in "P" gear. 1. Move the shift lever to "P" gear.
2. Disconnect the cable ball joint at the transmission side 2. Raise the vehicle on a lift.
3. Release the C-clip from the transmission cable bracket, only by a jack.Always support the vehicle on safety stands.
and release the cable support.
3. Disconnect the ball joint of the parking brake cable
from the rocker arm of the parking brake cable shaft.
4. Remove the parking brake cable from the parking brake

cable bracket.
4. Remove and discard 1 bolt fixing the rocker arm of the
5. Remove 2 bolts fixing the parking brake cable bracket parking brake cable shaft to the rocker arm shaft.
to the transmission housing to remove the parking
brake cable.
5. Remove the rocker arm of the parking brake cable shaft.

Refit
Refit
1. Ensure that the shift lever is in "P" gear.
1. Fix the parking brake cable bracket to the transmission
housing, fit 2 bolts, tighten to 38–42Nm, and check 2. Fix the rocker arm of parking brake cable shaft to the
the torque. rocker arm shaft, fit 1 new bolt, tighten to 19–21Nm,
2. Fit the cable ball joint at the transmission side to the
parking cable rocker arm. 3. Rotate the rocker arm of parking brake cable shaft
towards the "P" mark on the transmission housing, then
3. Locate the parking brake cable to its bracket and secure
rotate the front wheels or push the vehicle to move
with C-clip.
(displacement of the vehicle shall not exceed 20cm),
4. Adjust the parking cable.
until a "click" can be heard or the two front wheels
Parking Cable Adjustment cannot turn towards one direction. This indicates that
the parking pawl has snapped into the parking gear
teeth completely.
1.0 496
4. Fit the ball joint of parking brake cable to the rocker Oil Seal - Parking Brake Cable Shaft
arm knob of parking brake cable shaft. Remove
5. Check and adjust the parking brake cable. 1. Remove the starter motor.
Parking Brake Cable Check and Adjustment Starter Motor Remove
2. Remove the parking brake cable shaft rocker arm.
Parking Brake Cable Shaft Rocker Arm Remove
3. Pry up and discard the parking brake cable shaft oil seal
with TPT00141 carefully.
Refit
1. Place the guide of TPT00140 on the cable shaft.
2. Gently apply the specified dual clutch automatic
transmission fluid around the lip with clean hands.
3. Put the new oil seal into the guide of TPT00140.
4. Do not make the oil seal tilt, tap it in place with the
shaft handle of TPT00140.
5. Refit the parking brake cable shaft rocker arm.

Parking Brake Cable Shaft Rocker Arm Refit
6. Fit the starter motor.
Starter Motor Refit
1.0 497
Reverse Gear Shaft Sealing Cap

Remove
1. Remove the left front wheelhouse liner.
Front Wheelhouse Liner Remove

2. Knock out one hole on the middle part of the reverse
gear shaft seal cap with the punch and hammer.
4. Check if the reverse gear shaft seal cap is smooth.

5. Refit the left front wheelhouse liner.

6. After completing the installation, vehicle road test to
check if the oil leakage occurs to ensure the proper
installation.
3. Put one end of the nipper plier into the hole knocked
out on the reverse gear shaft seal cap, pry off and
discard the reverse gear shaft seal cap.
Refit
1. Clean the dust around the mounting hole housing of
reverse gear shaft seal cap.
2. Apply the transmission fluid to the new seal cap rubber
part, then push it into the transmission housing to
ensure that the outer metal coil of seal cap level with
the housing surface.
3. Refit the reverse gear shaft seal cap properly with the
special tool TPT00221.
1.0 498
Number
Replacer
TPT00118 driveshaft oil
Lifting lug seal
TEN00120
double
Remover park
TPT00141
Engine lift shaft oil seal
T10007
bracket
Replacer park
TPT00140
shaft oil seal
Replacer cover
Transmission TPT00221 assembly-reverse
TPT00059 fluid fill idler shaft
equipment
Remover
seal
1.0 499
DCT250-7 Speed Auto

Specifications
Torque
Description Value
Oil drain plug 7–14Nm
Oil over flow plug 7–14Nm
Tangential Bolt 30–35Nm
Bolt - closed on board to transmission 7.5–10.5Nm
Bolt -oxygen sensor bracket to transmission 22–28Nm
Bolt - bond strap to transmission 7.5–10.5Nm
Nut -transmission harness to TCM 8–10Nm
Bolt - TCM to transmission control codule 7.5–10.5Nm
Bolt - transmission control codule to transmission 7.5–10.5Nm
Bolt - shift fork position sensor to transmission control 7.5–10.5Nm
codule
Bolt - automatic transmission input speed sensor to 7.5–10.5Nm
transmission control codule
Bolt - transmission control module wiring harness to 7.5–10.5Nm
transmission control codule
Bolt - clutch actuator cylinder to clutch housing 12.5–14.5Nm
Bolt - clutch actuator cylinder position sensor wiring harness 7.5–10.5Nm
cover to clutch housing
Nut - shift arm to manual shift shaft 10–14Nm
Bolt - fluid trough to transmission housing 7.5–10.5Nm
Bolt - input shaft bearing retainer to transmission housing 7.5–10.5Nm
Bolt - output speed sensor to transmission housing 7.5–10.5Nm
Bolt - park pawl actuator bracket to transmission housing 7.5–10.5Nm
Bolt - park pawl actuator bracket to transmission housing 7.5–10.5Nm
Bolt - manual shaft detent lever spring to transmission housing 7.5–10.5Nm
Bolt - fluid trough to clutch housing 7.5–10.5Nm
Bolt - clutch housing to transmission housing 35–40Nm
Bolt - input shaft bearing retainer to clutch housing 7.5–10.5Nm
Bolt - input shaft bearing retainer to input shaft 40–50Nm
1.0 500
Parameter
Type 7-speed dry dual clutch automatic transmission
Transmission Arrangement Form Transverse Mount
Gear 7 forward gears and 1 reverse gear
Speed ratio: 2WD/AWD
·1 4.231
·2 2.476
·3 1.389
·4 0.929
·5 0.755
·6 0.714
·7 0.566
·R 3.882
·1267 output shaft final drive driving gear 4.563
·345R output shaft final drive driving gear 5.214
Maximum input torque 250Nm
Maximum input speed 7000 rpm
Gear Division P,R,N,D,W,Tiptronic
Housing Material Die-casting Aluminum
Transmission Net Weight (with Oil) 78kg
Lubricating Oil
• Model DEXRON®DCT Fluid

• Approximate Capacity 2.45 L
Hydraulic Oil
• Model Pentosin
• Approximate Capacity 1.90 L
1.0 501

System Layout
Drawing of Dry Dual Clutch Automatic
Transmission Assembly
1. Dry Dual Clutch Automatic Transmission - 2WD
1. Dry Dual Clutch Automatic Transmission -AWD
1.0 502
Diagram of Dry Dual Clutch Automatic
Transmission Refit
1. Transmission Mounting Bolt 4. Upper Closing Panel

2. Front Closing Panel 5. Bolt - Upper Closing Panel
3. Transmission Mounting Bolt
1.0 503
Layout of Dry Dual Clutch Automatic Transmission

Accessories
1. Bolt - Automatic Transmission Hydraulic Module and 14. Snap Ring

Control Module Assembly to Transmission Housing 15. Gear Hub Assembly - Clutch Driven Hub
2. Automatic Transmission Hydraulic Module and Control 16. Snap Ring
Module Assembly
17. Clutch Housing
3. Gasket - Hydraulic Module Assembly to Transmission
18. Differential Assembly
Housing
19. 1267 Output Shaft Assembly (Lower Intermediate Shaft)
4. Input Shaft Bearing Cover Bolt - Transmission Housing
20. 2/6 Gear Shifting Fork
5. 1357 Input Shaft Assembly
21. 1/7 Gear Shifting Fork
6. 246R Input Shaft Assembly
22. Washer - Clutch Housing to Transmission Housing
7. 35 Shifting Fork
23. Transmission Housing Assembly
8. 4R Shifting Fork
24. Automatic Transmission Breather Pipe Assembly
9. 345R Output Shaft Assembly (Upper Intermediate Shaft)
25. Automatic Transmission Breather Pipe
10. Bolt - Clutch Housing to Transmission Housing
26. Hydraulic Module Assembly Breather Pipe
11. Input Shaft Bearing Cover Bolt - Clutch Housing
27. Clamp between Breather Pipes
12. Dual Clutch Assembly
28. Breather Pipe to Intercooler Pipe Clamp
13. Input Shaft Bearing Gasket
1.0 504
Exploded View of Transmission Housing 1
1. Oil Filler Plug 4. Differential Half Axle Oil Seal

2. Oil Filler Plug O-ring 5. Oil Level Plug
3. Drain Plug
1.0 505
Exploded View of Transmission Housing 2
1. Transmission Housing Locating Pin 8. Bolt - 1267 Output Shaft Oil Guide Groove
2. Transmission Assembly Locating Pin 9. 1267 Output Shaft Oil Guide Groove
3. 1267 Output Shaft Rear Oil Nozzle 10. Bolt - Input Shaft Oil Nozzle
4. Outer Ring - 1267 Output Shaft Rear Cone Bearing 11. Input Shaft Oil Nozzle
5. Magnetic Steel 12. Outer Ring - 345R Output Shaft Rear Cone Bearing
6. Input Shaft Oil Nozzle 13. 345R Output Shaft Rear Oil Nozzle
7. Inner Ring - Differential Rear Cone Bearing
1.0 506
Exploded View of Clutch Housing 1
1. Outer Ring - 345R Output Shaft Front Cone Bearing 6. 1267 Output Shaft Front Oil Deflector
2. Gasket - Differential Front Cone Bearing 7. Gasket - 1267 Output Shaft Front Cone Bearing
3. Outer Ring - Differential Front Cone Bearing 8. Outer Ring - 1267 Output Shaft Front Cone Bearing
4. 345R Output Shaft Oil Guide Groove 9. 345R Output Shaft Oil Deflector
5. Bolt - 345R Output Shaft Oil Guide Groove 10. Gasket - 345R Output Shaft Front Cone Bearing
1.0 507
Exploded View of Clutch Housing 2
1. Bolt - Clutch Actuator Cylinder Harness Cover 5. Clutch Housing Oil Seal
2. Cover - Clutch Actuator Cylinder Position Sensor 6. Gasket - Clutch Actuator Cylinder
Harness 7. Locating Pin - Clutch Actuator Cylinder
3. Differential Half Axle Oil Seal 8. Clutch Actuator Cylinder Assembly
4. Bolt - Clutch Actuator Cylinder Assembly
1.0 508
Exploded View of Parking System
1. Transmission Internal Harness Assembly 10. Bolt - Parking Actuator Bracket

2. Parking Bracket Assembly 11. Pawl
3. Transmission Gearbox through Connector Assembly 12. Bolt - Transmission Output Speed Sensor
4. Shift Shaft Stop Pin 13. Transmission Output Speed Sensor
5. Shift Shaft Oil Seal 14. Return Spring - Pawl
6. Parking Control Lever Assembly 15. Pawl Shaft
7. Built-in Mode Switch 16. Guide Pin
8. Guide Pin Bracket 17. Shift Retaining Spring Assembly
9. Parking Pawl Support
1.0 509
Exploded View of Hydraulic Module and Control

Module Assembly
1. Bolt 6. Transmission Input Speed Sensor

2. Transmission Control Module 7. Bolt - Transmission Hydraulic Module Harness Assembly
3. Transmission Hydraulic Module Assembly 8. Bolt - Transmission Input Speed Sensor
4. Shifting Fork Position Sensor 9. Transmission Hydraulic Module Harness Assembly
5. Bolt - Shifting Fork Position Sensor
1.0 510
Exploded View of 1357 Input Shaft Assembly
1. Input Shaft Bearing Locking Bolt 4. Input Shaft Large Needle Bearing
2. Input Shaft Rear Ball Bearing Cover Assembly 5. Input Shaft Middle Needle Bearing
3. 1357 Input Shaft Assembly 6. Input Shaft Small Needle Bearing
1.0 511
Exploded View of 246R Input Shaft Assembly
1. 246R Input Shaft Assembly 3. Input Shaft Bearing Circlip

2. Input Shaft Front Ball Bearing Cover Plate Assembly 4. Input Shaft Oil Seal
1.0 512
Exploded View of 345R Output Shaft Assembly
1. Inner Ring - 345R Output Shaft Front Cone Bearing 2. 345R Output Shaft Assembly
1.0 513
Exploded View of 1267 Output Shaft Assembly
1. Inner Ring - 1267 Output Shaft Front Cone Bearing 2. 1267 Output Shaft Assembly
1.0 514
Exploded View of Differential Assembly
1. Outer Ring - Differential Rear Cone Bearing 3. Inner Ring - Differential Front Cone Bearing
2. Differential Assembly
1.0 515
Section View of Main Components
1. 345R Output Shaft Assembly 6. Differential Assembly

2. 3/5 Gear Shifting Fork 7. 1/7 Gear Shifting Fork
3. 246R Input Shaft Assembly 8. 2/6 Gear Shifting Fork
4. 4/R Gear Shifting Fork 9. 1267 Output Shaft Assembly
5. Dual Clutch Assembly 10. 1357 Input Shaft Assembly
1.0 516
Sensors of Electro-Hydraulic Control Assembly
1. Odd input shaft speed sensor 4. 4–R gear shift fork position sensor
2. 1–7 gear shift fork position sensor 5. Even input shaft speed sensor
3. 3–5 gear shift fork position sensor 6. 2–6 gear shift fork position sensor
1.0 517

Automatic Transmission Control Diagram
A = Hard Wire
A = Power HS CAN Bus; B = Diagnostic HS CAN Bus; C = Chassis HS CAN Bus; D = Body HS CAN Bus
1.0 518
Description Dual clutch automatic transmission uses the dual mass
Transmission Overview flywheel (DMF) for attenuating torque ripple caused by engine
ignition between engine crankshaft and transmission dry clutch
This transmission is a type of full-automatic, 7-speed
assembly. This design reduces the abnormal noise from gears.
electro-hydraulic control dry transmission with dual clutches,
and consists of 3 shafts. The maximum output torque of this Dry dual clutch automatic transmission acts within the
transmission is 250Nm, and the maximum input speed of this following gears:
engine is 7,000rpm.
Park (P): The front wheels are locked to avoid the moving
This transmission provides higher Overall Ratio (OAR) than of vehicle forward and backward. The transmission locks
the dual clutch design of a competitive product, so that the fuel the control system by shifting, and it is necessary to fully
economy is improved. Compared with the mechanical control depress the brake pedal before shifting from P position. For
of the competitive product, the design realizes extremely the purpose of safety, when the gear is placed in P position,
fast shifting time and quiet shift execution process. With this the parking brake shall also be applied.
design, the condition that the vehicle cannot drive because of a
Reverse (R): When the gear is placed in this position, the
certain part failure is avoided, which improves the robustness.
vehicle can drive in the opposite direction.
The start-stop function can shut down the engine when the
Neutral (N): When the gear is placed in this position, the
vehicle is parked, which improves the fuel economy also.
engine is allowed to be started or run during vehicle driving. If
The three-axle design realizes 7 forward gears and the reverse necessary, this gear can be selected when the vehicle is moving
gear. Automatic control of gear ratio is realized through to restart the engine. This gear can also be selected when the
the transmission control module (TCM) connected with vehicle is tracked.
the transmission. TCM receives and monitors the inputs
Drive (D): The maximum efficiency and fuel economy can be
of different electronic sensors and controls the gear shift in
achieved when the D gear is selected during normal driving.
proper time based on these information.
D gear allows the transmission to select any one of the 7
TCM controls the shift solenoid valve, and realizes shifting transmission ratios. Adjusting to low-speed gears or higher
between two intermediate shafts by executing the shifting fork transmission ratio can be achieved safely by releasing the
and synchronizer. Shift from even gear intermediate shaft to accelerator pedal or selecting low-speed gears under the
odd gear intermediate shaft by varying the torque, and vice manual mode.
versa. The operating process of DCT dual clutch transmission
Tiptronic: In this position, the driver is allowed to use the
is so much like two manual transmissions in one assembly.
manual shifting control system. When the gear shift lever is
TCM also controls the engagement and disengagement of dual
placed in this position, the driver can realize down-shift or
clutch assembly to realize the maximum fuel economy transfer
up-shift by moving the gear shift lever forward or backward.
of engine through a central slave clutch (CSC) without affecting
The shift paddle on the steering wheel of some models also
the vehicle performance. All the solenoids are integrated in a
provides manual shift control.
valve body assembly containing control module.
The dry dual clutch assembly is similar to the clutch of manual

transmission, and both clutches are normally open. The dry Dual Mass Flywheel (DMF), Dry Dual Clutch (DDC)
and Clutch Slave Cylinder (CSC)
dual clutch disc is not cooled by transmission oil, thus avoiding
additional oil loss. These dry friction components improves
the quality of automatic gear shifting for transmission during
engaging and releasing.
As same as the manual transmission, the dry dual clutch

automatic transmission is cooled by air, not liquid, therefore,
oil pump, pipelines, connectors, radiator, etc. are not needed
to cool the transmission.
There are two ways of separate oil in the transmission. In

which, a circuit of low-viscosity fluid flows in the control
valve body assembly, and the other circuit of fluid flows in
the transmission case to lubricate the gear, which is similar to
manual transmission.
1. Clutch Position Sensor
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2. Clutch Slave Cylinder Clutch Slave Cylinder

3. Dual Clutch Assembly
4. Dual Mass Flywheel
Dual Dry Clutch (DDC)
1. Anti-rotation Mechanism
2. C2 Bear
3. C2 Supporting Ring
1. C1 Pull Cover 4. C2 Magnetic Pole
2. C1 Diaphragm Spring 5. C1 O-ring
3. C1, C2 Pivot Pull Cover 6. Core Box Panel
4. C2 Diaphragm Spring 7. C1 Magnetic Pole
5. Pre-stressed Spring 8. Clutch Slave Cylinder Housing
6. C2 Pressure Plate 9. Clutch Position Sensor
7. C2 Driven Disc Functions of clutch slave cylinder are to:
8. Middle Pressure Plate
1. Control the two oil cylinders to realize the on and off
9. C1 Driven Disc of the clutch;
10. Shock Absorber Spring Bracket 2. The hydraulic control system controls the clutch C1
11. Support Gasket piston to realize engagement of C1 clutch so that the odd
12. C1 Pressure Plate input shaft can transfer torque; similarly, the hydraulic
control system also controls the clutch C2 piston to
13. Drive Disc
realize engagement of C2 clutch so that the even input
Functions of dual dry clutch are to: shaft can transfer torque;
1. Further absorb the torsional vibration from the dual mass 3. The oil cylinder position sensor judges the displacement
flywheel; of clutch diaphragm spring according to the displacement
2. The on-off of the two clutches are achieved by the action of piston.
of different pistons in clutch slave cylinder;
3. The two clutches are connected to the odd gear input
shaft and even gear input shaft separately by spline, and
selects the torque input shaft through the clutch.
1. Engine drives DMF primary cover plate
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2. DMF primary cover plate drives the secondary cover Electro-Hydraulic Control Assembly
plate through the spring
3. DMF secondary cover plate is connected firmly with the
clutch middle plate
4. With the action of hydraulic pressure, CSC pushes the
diaphragm spring
5. The diaphragm spring pushes the pressure plate and
driven plate to make the engine connect to the input
shaft smoothly
When the C1 piston of clutch slave cylinder acts with the

action of hydraulic oil, the diaphragm spring makes the clutch
C1 connected, then the power is transfered to the odd input
shaft from the clutch C1.
1. Transmission Control Module (TCM)
2. Accumulator
3. Penetration Harness (Transmission Body Side)
4. Actuator valve body
5. Solenoid
6. Penetration Harness (Harness Side)
7. Oil Pump
8. Solenoid Body
9. Body
10. Oil Pump Motor
1. Engine drives DMF primary cover plate

2. DMF primary cover plate drives the secondary cover
plate through the spring
3. DMF secondary cover plate is connected firmly with the
clutch middle plate
4. With the action of hydraulic pressure, CSC pushes the
diaphragm spring
5. The diaphragm spring pushes the pressure plate and
driven plate to make the engine connect to the input
shaft smoothly
When the C2 piston of clutch slave cylinder acts with the

action of hydraulic oil, the diaphragm spring makes the clutch 1. Slave Piston (4)
C2 connected, then the power is transfered to the even input 2. Clutch Slave Cylinder Seals
shaft from the clutch C2. 3. Valve Body Slave Piston (4)
4. Input Shaft Speed Sensor (2)
5. Position Sensor (4)
Electro-hydraulic control assembly mainly consists of the

following parts.
VB valve body assembly: By-pass valve;
SB valve body assembly: 9 solenoids;
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AB valve body assembly: 4 slave pistons, position sensors, input Instruction of Shifting
speed sensor;
Oil pressure establishment: Motor, oil pump, accumulator and

pressure filter;
Components of external wall: Harness, TCM, valve body cover

and connecting bolt.
Solenoid
1. External controller
2. Oil pump and motor
3. Body
4. Slave Piston
5. Accumulator
6. Solenoid
Solenoid Solenoid Solenoid Function 7. Gear shifting fork assembly

Name Type
S1 Pressure Control inlet pressure of S3
Valve
S2 Pressure Control inlet pressure of S4
Valve
S3 Flow Valve Control the position of
clutch C1
S4 Flow Valve Control the position of
clutch C2
S5 Pressure Control the shifting fork oil
Valve circuit pressure of 17 gear
and 35 gear 1. Magnet bracket
S6 Pressure Control the shifting fork oil 2. Linear bear
Valve circuit pressure of 2/6 gear 3. Track
and 4R gear
4. 3/5 gear shifting fork assembly
S7 Flow Valve Control the shifting fork 5. Lock pin
position of 1/7 gear and 3/5
6. 4/R gear shifting fork assembly
gear
7. Synchronizer assembly
S8 Flow Valve Control the shifting fork
position of 2/6 gear and 4/R Take the transmission in 3 gear for example, at this moment,
gear the solenoid S1 and S3 works, inputting high-pressure oil to the
C1 piston of CSC. The piston pushes the clutch C1 to engage.
S9 Pressure Control the logic of shifting
It is the odd shaft that transfers the torque at this moment;
Valve fork
otherwise, S5 and S7 moves the shifting fork by controlling the
piston, which makes the synchronizer is shifted to 3rd gear,
and then the transmission transfers power in the 3rd gear.
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Parking Mechanism gear the driver selects. The relation between the voltage
signal combination of Hall switch and the transmission gears is
shown in the following figure.
Gear PRNDL PRNDL PRNDL PRNDL PRNDL
S A B C P
P ON OFF ON OFF ON
R OFF ON OFF OFF ON
N ON ON OFF ON OFF
D OFF OFF ON ON OFF
W ON OFF ON ON OFF
Differential
1. Shift Retaining Spring Assembly Differential fixes the driven gear of main reducing gear to
differential housing with bolts, differential housing supports the
2. Bracket - parking paw actuator
planetary shaft pin, planetary gear and sun gear. The differential
3. Guider - parking control lever assembly is supported by bearings in the transmission housing.
4. Parking control lever assembly The differential allows the wheels to rotate at different speeds
5. IMS assembly when the output torques are same. The pinion integrated with
6. Manual shift shaft stop pin the output shaft is engaged with the final drive driven gear of
the differential assembly. When the output shaft rotates and
7. Parking Pawl Spring
the wheels moves forward in straight line, the torque will be
8. Parking Pawl Shaft applied to the whole assembly. The planetary gear does not
9. Parking Pawl rotate, and the torque is transfered to the wheel through the
10. Parking ratchet wheel drive shaft. When the vehicle turns, the inside wheels drive
for less distance with slow speed, this drives the planetary
The ratchet wheel mechanism mainly consists of shift retaining
gear to rotate, and the outer sun gear offers a higher speed
spring assembly, parking ratchet wheel, parking pawl, IMS
for outer wheels. Two driven shafts transfer the torque to
assembly, parking control lever assembly, guider, etc.
the differential, and the differential transfers the torque to the
The operating principle of parking mechanism: As shown in wheels through the half axle.
the figure above, for shifting to P gear, the shift cable pulls Transmission Control Module (TCM)
the build-in mode switch to make it rotate, and the parking
control lever is pulled to the left so as to embed the parking
pawl into the groove, then the parking is realized. The principle
of shifting from P gear to R gear: The parking control lever
moves to the right making the parking pawl get out of the
ratchet tooth groove with the action of parking pawl, and the
IMS transfers the R gear instruction to TCM, then shifting
from P gear to R gear is realized with TCM controlling the
transmission hydraulic system.
Transmission Internal Mode Switch (IMS)
The transmission internal mode switch (IMS) is multi-signal

Hall switch array which consists of 5 independent Hall
switches. The Hall switch is powered by the voltage of 8.59
~ 9.3V provided by transmission control module (TCM) TCM is fitted on the transmission case together with the
and transmits the voltage signal back to TCM through signal electro-hydraulic control assembly.
circuit. The Hall switch voltage signal is 0.70 ~ 0.96V (ON)
TCM uses an Electrically Erasable Read-Only Memory
or 1.68 ~ 2.38V (OFF). The voltage signal of each Hall switch
(EEPROM), therefore a new or replaced TCM may be used
is determined by the gear shift lever position. The TCM
for external configuration. EEPROM can also update the
receives the voltage signal combination of Hall switch and
new information and market-specific data for TCM. To input
search the relevant form in the TCM memory to judge which
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new information, TCM must be configured with a scan tool. the instruction shift, the TCM monitors the engine speed,
EEPROM can allow TCM to be reconfigured for many times transmission input shaft speed and output shaft speed to
as required, so as to meet the constantly changing parameters confirm if the gear shifting process is too fast (rigid) or too
and regulations. slow (soft), and adjusts the corresponding pressure control
solenoid signal to keep the set gear shifting feeling.
TCM stores the signal values of the transmission sensors
and the actuators. These stored signals guarantee that the The adaptive function is to automatically compensate the
transmission can always obtain the optimal performance. If shifting performance of all kinds of vehicle gear shifting system.
the battery voltage is too low, such as the battery discharges, The adaptive function is a continuous process, and this function
the information will be lost. When the engine starts for the will help to keep the optimal gear shifting performance during
first time after the battery is discharged or disconnected, the whole period of use.
TCM will restore to the default value. TCM 's EEPROM View of Transmission Control Module (TCM)
allows the stored value to be rapidly accessed again. Vehicle Harness Terminal Connector GB009 and
Pin Information
Input and Output
The sensor signal enables TCM to monitor the transmission
state. TCM processes the signals and compares them with the
data stored in the memory. If these signals are not in the range
of parameters stored by TCM, TCM will adjust the operation
of the transmission through the actuator, so as to provide the
optimal drive ability and other performances.
TCM also connects with the following units through the CAN
bus:
• ECM
• BCM
• ABS/SCS regulator ECU Pin No. Description
• Instrument Pack 1 Power Supply of Transmission Relay
• Data link connector 2 Run/Ignition State
3 HS CAN Low
TCM receives input signals of throttle opening from ECM,
engine coolant temperature, engine speed, engine torque, etc. 4 HS CAN High
from ECM; TCM also receives input signals of brake switch, 5 —
pressure sensor, clutch speed, oil temperature, solenoid state, 6 —
IMS, etc. In addition, TCM outputs torque control request, —
7
shift gear information and failure warning information to ECM
8 —
and outputs executive signal, etc. to the valve body solenoid.
9 —
Transmission Self-adaption
10 Engine Speed
The transmission compensates the normal wear of
11 Control of Transmission Relay
transmission components by pressure control system during
12 —
up-shift. When the joint components inside the transmission
is worn or changed after a period of time, the gear shifting 13 —
duration (duration required to engage the clutch) will increase 14 Transmission Wake-up
or decrease. To compensate these changes, the TCM adjusts 15 —
the target pressure of each pressure control solenoid so —
16
as to keep the originally calibrated gear shifting duration.
17 —
The automatic adjustment process is called as "Adaptive
Learning" which aims to ensure the consistent gear shifting 18 12V Power Supply
feeling and improve the durability of the transmission. During
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Transmission External Harness 15 —
16 —
17 Gear Shift Lever Signal P
18 Gear Shift Lever Signal Ground
View of Electro-hydraulic Control Assembly

Terminal and PIN Definition
1. Transmission External Harness

2. Transmission Control Module Harness Connector
3. P/N Signal Harness Connector
Pin No. Description
4. Clutch Slave Cylinder Harness Connector
1 Oil Pump Phase A
5. Transmission Case Penetration Harness Connector
2 Oil Pump Phase C
6. Transmission External Harness Ground Bolt
3 Oil Pump Phase B
View of Automatic Transmission Control Module
(TCM) Transmission External Harness Terminal 4 High-side Drive 2
Connector and PIN Definition 5 Current Control Output B
6 Current Control Output A
7 9V Power Supply B
8 26 Shifting Fork Position Sensor
9 Even Input Shaft Speed Sensor
10 Logic Solenoid Control
11 Transmission Main Oil Pressure\Oil
Temperature Sensor - Main Oil
Pressure Sensor
12 5V Power Supply A
Pin No. Description
13 Motor Ground
1 Ground
14 4R Shifting Fork Position Sensor
2 9V Power Supply A
3 9V Power Supply B
16 Current Control Output C
4 5V Power Supply A
17 Current Control Output D
5 Gear Shift Lever Signal A
18 —
6 Transmission Output Speed
19 5V Power Supply Ground
7 5V Power Supply Ground
20 High-side Drive 1
8 5V Power Supply B
9 Gear Shift Lever Signal B
22 Odd Input Shaft Speed Sensor
10 Odd Clutch Position Sensor
23 9V Power Supply A
11 5V Power Supply B Ground
24 Current Output Control F
12 Gear Shift Lever Signal S
25 Current Output Control E
13 Gear Shift Lever Signal C
14 Even Clutch Position Sensor
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26 Transmission Main Oil Pressure\Oil 27 Current Control Output G

Temperature Sensor - Oil Temperature
28 Current Control Output H
Sensor
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Operation
Transmission gear state
When the dry dual clutch automatic transmission is in different
gears, the operating states of the shifting fork, clutch and
solenoid are shown in the table below.
1/7 2/6 3/5 4/R
Gear Gear Gear Gear Clutch Clutch Soleno Soleno Soleno Soleno Soleno Soleno Soleno Soleno Soleno
Gear
Shifting Shifting Shifting Shifting C1 C2 -id S1 -id S2 -id S3 -id S4 -id S5 -id S6 -id S7 -id S8 -id S9
Fork Fork Fork Fork
P L M M R O O
R L M M R O C NA 1 NA 1 NA 1 NA 0 1
N M M M M O O
D1 L M M M C O 1 NA 1 NA 1 NA 1 NA 1
D2 M R M M O C NA 1 NA 1 NA 1 NA 1 0
D3 M M L M C O 1 NA 1 NA 1 NA 0 NA 0
D4 M M M L O C NA 1 NA 1 NA 1 NA 1 1
D5 M M L M C O 1 NA 1 NA 1 NA 1 NA 0
D6 M L M M O C NA 1 NA 1 NA 1 NA 0 0
D7 R M M M C O 1 NA 1 NA 1 NA 0 NA 1
NA: Solenoid state is irrelevant to the gear. L: Left shift fork; M: Middle shift fork; R: Right shift fork.
0, 1: Solenoid current (A) O: Clutch open; C: Clutch closed.
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Cold start - Energy accumulator not pressurized • Energy accumulator oil pressure is conveyed to 1/3/5/7 clutch
pressure solenoid S1 for shifting.
With the shift lever in P position and ignition switch connected,
the clutch and gear control actuator oil pump motor assembly • 2/4/6/R clutch pressure solenoid S2
are turned on, so that oil flows into the oil pump assembly,
• Energy accumulator oil pressure is conveyed to 2/4/6/R clutch
and the line pressure is supplied into the energy accumulator
pressure solenoid S2 for shifting.
circuit directly through the oil filter assembly.
• S7 and A37 oil circuit pressure solenoid S5
Build oil pressure and ready to shift
• Energy accumulator oil pressure is conveyed to S7 and A37
• Energy accumulator bypass valve
oil circuit pressure solenoid S5 for shifting.
• Energy accumulator oil is conveyed to the energy
• S8 and A6R oil circuit pressure solenoid S6
accumulator bypass valve, accumulator bypass ball, 1/3/5/7
clutch pressure solenoid S1, 2/4/6/R clutch pressure solenoids • Energy accumulator oil pressure is conveyed to S8 and A6R
S2, S7 and A37 oil circuit pressure solenoids S5, S8 and A6R oil circuit pressure solenoid S6 for shifting.
oil circuit pressure solenoid S6, and 1/3/5/7 and 2/4/6/R logic
• 1357/246R logic valve pressure control solenoid S9
valve pressure control solenoid S9. During cold start, the
energy accumulator oil pressure is not enough to move the Energy accumulator oil pressure is conveyed to 1357/246R
energy accumulator bypass valve from the release position. logic valve pressure control solenoid S9 for shifting.
• 1/3/5/7 clutch pressure solenoid S1
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P position - Engine Running • Main oil circuit pressure relief valve
When the shift lever is in the P position and the engine is Energy accumulator oil pressure overcomes the spring
running, the transmission control module (TCM) increases the resistance by moving the ball valve, and exhaust redundant oil
line pressure through the oil pump motor speed. After a cold circuit pressure.
start, following changes happen to the hydraulic and electric
• Energy accumulator bypass ball (#1)
system of the transmission.
Energy accumulator oil pressure moves off the ball valve, and
conveys enough oil circuit pressure to the control solenoid .
• Energy accumulator bypass valve
At this moment, the energy accumulator oil pressure is big
Enough energy accumulator oil pressure is conveyed to 1/3/5/7
enough to overcome the spring resistance of the energy
clutch pressure solenoid S1 for shifting.
accumulator bypass valve, and the accumulator bypass valve
is switched to the open state. Energy accumulator oil is • 2/4/6/R clutch pressure solenoid S2
conveyed to the accumulator bypass ball (#1), accumulator
Enough energy accumulator oil pressure is conveyed to 2/4/6/R
oil pressure and oil temperature sensor assembly, main oil
clutch pressure solenoid S2 for shifting.
circuit pressure relief valve, shift control actuator pressure
accumulator assembly, 1/3/5/7 clutch pressure solenoid S1, • S7 and A37 oil circuit pressure solenoid S5
2/4/6/R clutch pressure solenoids S2 and S7, A37 oil circuit Enough energy accumulator oil pressure is conveyed to S7 and
pressure solenoids S5 and S8, A6R oil circuit pressure solenoid A37 oil circuit pressure solenoid S5 for shifting.
S6, and 1357/246R logic valve pressure control solenoid S9.
• Gear shift control actuator pressure energy accumulator
assembly Enough energy accumulator oil pressure is conveyed to S8 and
A6R oil circuit pressure solenoid S6 for shifting.
Energy accumulator oil pressure overcomes the air pressure,
moves the accumulator piston, inhibits uneven pressure • 1357/246R logic valve pressure control solenoid S9
occurring in the accumulator oil circuit to control the oil Energy accumulator oil pressure is conveyed to 1357/246R
pressure supplied to the solenoid when each solenoid is logic valve pressure control solenoid S9 for shifting.
opened or closed.
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R Gear
Power flow in R position
When the shift lever is moved from the P position to R Then, S8/6R actuator oil is conveyed to A24 oil circuit flow
position, a command connects the 1/3/5/7 clutch pressure solenoid S8 and 2/4/6/R gear logic valve through #9 orifice.
solenoid S1, 2/4/6/R clutch pressure solenoid S2, 2/4/6/R
• A24 oil circuit flow solenoid S8
clutch flow solenoid S4, S8 and A6R oil circuit pressure
solenoid S6, and A24 oil circuit flow solenoid S8, and at Open A24 oil circuit flow solenoid S8, so that S8/6R actuator
the same time, the hydraulic and electrical system of the oil enters 24 actuator circuit. Then, 24 actuator oil is conveyed
transmission will have the following changes. to 2/4/6/R gear logic valve through #10 orifice.
Engage 2/4/6/R gear clutch • 2/4/6/R gear logic valve
• 2/4/6/R clutch pressure solenoid S2 24 actuator oil enters into the 4th gear circuit through 2/4/6/R
gear logic valve. S8/6R actuator oil enters into the reverse
Open 2/4/6/R clutch pressure solenoid S2, so that energy
circuit through 2/4/6/R gear logic valve. Both the 4th gear oil
accumulator oil enters the S2 signal circuit. Then, S2 signal
pressure and reverse gear oil pressure are conveyed to the 4R
flow is conveyed to 2/4/6/R clutch flow solenoid S4 through
gear shifting fork actuator piston assembly.
#12 orifice.
• 4R gear shifting fork actuator piston assembly
• 2/4/6/R clutch flow solenoid S4
With the reverse gear oil pressure greater than the 4th gear
Open 2/4/6/R clutch flow solenoid S4, so that S2 signal enters
oil pressure, move the 4th gear shifting fork actuator piston
into 2/4/6/R clutch circuit. Then, 2/4/6/R clutch oil is conveyed
assembly to the reverse gear position, so as to drive the 4R
to the clutch actuator cylinder assembly through #2 orifice.
gear shifting fork assembly, and the transmission is switched to
• Clutch actuator cylinder assembly reverse gear.
2/4/6/R clutch oil enters the clutch actuator cylinder assembly, Build oil pressure and ready to shift
then overcomes the spring force, moves the 2/4/6/R gear
clutch piston, and engages the 2/4/6/R gear clutch plate.
Open 1/3/5/7 clutch pressure solenoid S1, so that energy
Engage 4R gear shifting fork assembly
• S8 and A6R oil circuit pressure solenoid S6 flow is conveyed to 1/3/5/7 clutch flow solenoid S3 through
#13 and #20 orifices for shifting to the 1st gear.
Open S8 and A6R oil circuit pressure solenoid S6, so that
energy accumulator oil enters the S8/6R actuator circuit.
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N position － Engine running Release of 4R gear shifting fork assembly

When the shift lever is shifted to N position, the hydraulic • S8 and A6R oil circuit pressure solenoid S6
and electrical system operations are the same when it is in P
Command to close S8 and A6R oil circuit pressure solenoid
position. But if N position is selected after the vehicle runs to
S6, so that S8/6R actuator oil pressure is discharged from A24
the R position, a command closes the 1/3/5/7 clutch pressure
oil circuit flow solenoid S8 and 2/4/6/R gear logic valve.
solenoid S1, 2/4/6/R clutch pressure solenoid S2, 246R clutch
flow solenoids S4, S8 and A6R oil circuit pressure solenoid S6, • A24 oil circuit flow solenoid S8
and A24 oil circuit flow solenoid S8, and at the same time, the Command to close A24 oil circuit flow solenoid S8, so that
hydraulic and electrical system will have the following changes. 24 actuator oil pressure is discharged from 2/4/6/R gear logic
Release of 2/4/6/R gear clutch valve.
• 2/4/6/R clutch pressure solenoid S2 • 2/4/6/R gear logic valve
Command to close the 2/4/6/R clutch pressure solenoid S2, 4th gear oil pressure is discharged to 24 actuator circuit
so that S2 signal oil pressure is discharged from 2/4/6/R clutch through 2/4/6/R gear logic valve. Reverse gear oil pressure is
flow solenoid S4. discharged to 24 actuator circuit through 2/4/6/R gear logic
valve.
• 4R gear shifting fork actuator piston assembly
Command to close the 2/4/6/R clutch flow solenoid S4, so
that 2/4/6/R clutch oil pressure is discharged from the clutch Reverse gear oil pressure and 4th gear oil pressure are
actuator cylinder assembly. discharged from 4R gear shifting fork actuator piston assembly,
and at the same time, the 4R gear shifting fork actuator piston
• Clutch actuator cylinder assembly
assembly is moved to Neutral (N) position.
2/4/6/R clutch oil pressure is discharged from the clutch
actuator cylinder assembly, so that the spring moves the
2/4/6/R gear clutch piston, and the 2/4/6/R gear clutch plate
is released.
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D1 position
Power flow in D1 position
When the shift lever is moved from the N position to D S7/37 actuator oil is conveyed to A15 oil circuit flow solenoid
position, a command connects the 1/3/5/7 clutch pressure S7 and 1/3/5/7 gear logic valve through #7 orifice.
solenoid S1, 1/3/5/7 clutch pressure solenoid S3, S7, A37 oil
circuit pressure solenoid S5, and A15 oil circuit flow solenoid
S7. At the same time, the transmission hydraulic and electrical Open A15 oil circuit flow solenoid S7, so that S7/37 actuator
system will have the following changes, so as to start the oil enters 15 actuator circuit. Then, 15 actuator oil is conveyed
vehicle from the parking position. to 1/3/5/7 gear logic valve through #8 orifice.
Engage 1/3/5/7 gear clutch • 1/3/5/7 gear logic valve
• 1/3/5/7 clutch pressure solenoid S1 15 actuator oil enters into the 1st gear circuit through 1/3/5/7
gear logic valve. S7/37 actuator oil enters into the 7th gear
Open 1/3/5/7 clutch pressure solenoid S1, so that energy
circuit through 1/3/5/7 gear logic valve. Both the 1st gear oil
pressure and 7th gear oil pressure are conveyed to the 1/7 gear
flow is conveyed to 1/3/5/7 clutch flow solenoid S3 through
shifting fork actuator piston assembly.
#13 and #20 orifices
• 1/7 gear shifting fork actuator piston assembly
• 1/3/5/7 clutch flow solenoid S3
With the 1st gear oil pressure greater than the 7th gear
Open 1/3/5/7 clutch flow solenoid S3, so that S1 signal enters
oil pressure, move the1/7 gear shifting fork actuator piston
into 1/3/5/7 clutch circuit. Then, 1/3/5/7 clutch oil is conveyed
assembly to the 1st gear position, so as to drive the 1/7 gear
shifting fork assembly, and the transmission is switched to 1st
• Clutch actuator cylinder assembly gear.
1/3/5/7 clutch oil enters the clutch actuator cylinder assembly, Build oil pressure and ready to shift
then overcomes the spring force, moves the 1/3/5/7 gear clutch
• 2/4/6/R clutch pressure solenoid S2
piston, and engages the 1/3/5/7 gear clutch plate.
Open 2/4/6/R clutch pressure solenoid S2, so that energy
Engage 1/7 gear shifting fork assembly
• S7 and A37 oil circuit pressure solenoid S5 flow is conveyed to 2/4/6/R clutch flow solenoid S4 through
#12 orifice for shifting to the 2nd gear.
Open S7 and A37 oil circuit pressure solenoid S5, so that
energy accumulator oil enters the S7/37 actuator circuit. Then,
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D2 gear
Power flow in D2 gear
With the improvement of vehicle speed and running to the S9 signal flow is conveyed to 1/3/5/7 gear logic valve and 2/4/6/R
appropriate conditions, the transmission control module gear logic valve through #3 orifice.
(TCM) processes the input signals from the transmission
input and output shaft speed sensor, throttle position sensor
and other vehicle sensors to determine when the command Open S8 and A6R oil circuit pressure solenoid S6, so that
connects 2/4/6/R clutch flow solenoid S4, S8 and A6R oil energy accumulator oil enters the S8/6R actuator circuit.
circuit pressure solenoid S6 and A24 oil circuit flow solenoid Then, S8/6R actuator oil is conveyed to A24 oil circuit flow
S8 and 1357/246R logic valve pressure control solenoid S9, solenoid S8 and 2/4/6/R gear logic valve through #9 orifice.
and command 2/4/6/R gear clutch to engage. At the same • A24 oil circuit flow solenoid S8
time, command to close 1/3/5/7 clutch flow solenoid S3, S7,
A37 oil circuit pressure solenoid S5, and A15 oil circuit flow Open A24 oil circuit flow solenoid S8, so that S8/6R actuator
solenoid S7. At the same time, the transmission is shifted to oil enters 24 actuator circuit. Then, 24 actuator oil is conveyed
2nd gear. to 2/4/6/R gear logic valve through #10 orifice.
Engage 2/4/6/R gear clutch • 2/4/6/R gear logic valve
• 2/4/6/R clutch flow solenoid S4 The S9 signal flow is conveyed to the 2/4/6/R gear logic
solenoid, and overcomes the spring force to move the logic
Open 2/4/6/R clutch flow solenoid S4, so that S2 signal enters valve so that the 24 actuator oil enters the 2nd circuit
into 246R clutch circuit. Then, 2/4/6/R clutch oil is conveyed through the logic valve. S8/6R actuator oil enters the 6th
to the clutch actuator cylinder assembly through #2 orifice. circuit through 2/4/6/R gear logic valve. Both the 2nd gear oil
• Clutch actuator cylinder assembly pressure and 6th gear oil pressure are conveyed to the 2/6
2/4/6/R clutch oil enters the clutch actuator cylinder assembly,
then overcomes the spring force, moves the 2/4/6/R gear • 2/6 gear shifting fork actuator piston assembly
clutch piston, and engages the 2/4/6/R gear clutch plate. With the 2nd gear oil pressure greater than the 6th gear
Engage 2/6 gear shifting fork assembly oil pressure, move the 2/6 gear shifting fork actuator piston
assembly to the 2nd gear position, so as to drive the 2/6 gear
shifting fork assembly, and the transmission is switched to 2nd
Open 1357/246R logic valve pressure control solenoid S9, so gear.
that energy accumulator oil enters the S9 signal circuit. Then,
Release of 1/3/5/7 gear clutch
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• 1/3/5/7 clutch flow solenoid S3 • 1/3/5/7 gear logic valve

Command to close the 1/3/5/7 clutch flow solenoid S3, so S9 signal flow is conveyed to the 1/3/5/7 gear logic valve, and
that 1/3/5/7 clutch oil pressure is discharged from the clutch moves the logic valve according to spring force, which makes
actuator cylinder assembly. the oil pressure of 1st and 7th gear is discharged from the
1/3/5/7 gear.
1/3/5/7 clutch oil pressure is discharged from the clutch
actuator cylinder assembly, so that the spring moves the 1st gear oil pressure and 7th gear oil pressure are discharged
1/3/5/7 gear clutch piston, and the 1/3/5/7 gear clutch plate is from 1/7 gear shifting fork actuator piston assembly, and at the
released. same time, the 1/7 gear shifting fork actuator piston assembly
is moved to Neutral (N) position.
Release of 1/7 gear shifting fork assembly
Command to close S7 and A37 oil circuit pressure solenoid S5,
so that S7/37 actuator oil pressure is discharged from A15 oil Keep 1/3/5/7 clutch pressure solenoid S1 open, so that energy
circuit flow solenoid S7 and 1/3/5/7 gear logic valve. accumulator oil enters the S1 signal circuit. Then, S1 signal
#13 and #20 orifices for shifting to the 3rd gear.
Command to close A15 oil circuit flow solenoid S7, so that
15 actuator oil pressure is discharged from 1/3/5/7 gear logic
valve.
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D3 gear
With the improvement of vehicle speed and running to the Open A15 oil circuit flow solenoid S7, so that S7/37 actuator
appropriate conditions, the transmission control module oil enters 15 actuator circuit. Then, 15 actuator oil is conveyed
(TCM) processes the input signals from the transmission to 1/3/5/7 gear logic valve through #8 orifice.
• 1357 gear logic valve
and other vehicle sensors to determine when the command
connects 1/3/5/7 clutch flow solenoid S3, S7 and A37 oil circuit S7/37 actuator oil enters into the 7th gear circuit through
pressure solenoid S5 and A15 oil circuit flow solenoid S7, and 1/3/5/3 gear logic valve. 15 actuator oil enters into the 1st
command 1/3/5/7 gear clutch engagement. At the same time, gear circuit through 5/3/5/7 gear logic valve. Both the 3rd gear
command to close 2/4/6/R clutch flow solenoid S4, S8, A6R oil oil pressure and 5th gear oil pressure are conveyed to the 3/5
circuit pressure solenoid S6, and A24 oil circuit flow solenoid gear shifting fork actuator piston assembly.
S8. At the same time, the transmission is shifted to 3rd gear. • 3/5 gear shifting fork actuator piston assembly
Engage 1/3/5/7 gear clutch With the 3rd gear oil pressure greater than the 5th gear
• 1/3/5/7 clutch flow solenoid S3 oil pressure, move the 3/5 gear shifting fork actuator piston
assembly to the 3rd gear position, so as to drive the 3/5 gear
shifting fork assembly, and the transmission is switched to 3rd
gear.
Release of 2/4/6/R gear clutch
1/3/5/7 clutch oil enters the clutch actuator cylinder assembly,
then overcomes the spring force, moves the 1/3/5/7 gear clutch Command to close the 2/4/6/R clutch flow solenoid S4, so
piston, and engages the 1/3/5/7 gear clutch plate. that 2/4/6/R clutch oil pressure is discharged from the clutch
actuator cylinder assembly.
Engage 35 gear shifting fork assembly
actuator cylinder assembly, so that the spring moves the
S7/37 actuator oil is conveyed to A15 oil circuit flow solenoid
is released.
S7 and 1/3/5/7 gear logic valve through #7 orifice.
Release of 2/6 gear shifting fork assembly
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• S8 and A6R oil circuit pressure solenoid S6 • 2/6 gear shifting fork actuator piston assembly
Command to close S8 and A6R oil circuit pressure solenoid 2nd gear oil pressure and 6th gear oil pressure are discharged
S6, so that S8/6R actuator oil pressure is discharged from A24 from 2/6 gear shifting fork actuator piston assembly, and at the
oil circuit flow solenoid S8 and 2/4/6/R gear logic valve. same time, the 2/6 gear shifting fork actuator piston assembly
24 actuator oil pressure is discharged from 2/4/6/R gear logic • 2/4/6/R clutch pressure solenoid S2
valve.
Keep 2/4/6/R clutch pressure solenoid S2 open, so that energy
• 2/4/6/R gear logic valve accumulator oil enters the S2 signal circuit. Then, S2 signal
2nd gear oil pressure is discharged to 24 actuator circuit
#12 orifice for shifting to the 4th gear.
through 2/4/6/R gear logic valve. 2nd gear oil pressure is
discharged to 24 actuator circuit through 6/4/6/R gear logic
valve.
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D4 gear
With the improvement of vehicle speed and running to the • S8 and A6R oil circuit pressure solenoid S6
appropriate conditions, the transmission control module
Open S8 and A6R oil circuit pressure solenoid S6, so that
energy accumulator oil enters the S8/6R actuator circuit.
Then, S8/6R actuator oil is conveyed to A24 oil circuit flow
solenoid S8 and 2/4/6/R gear logic valve through #9 orifice.
connects 2/4/6/R clutch flow solenoid S4, S8 and A6R oil
circuit pressure solenoid S6 and A24 oil circuit flow solenoid • A24 oil circuit flow solenoid S8
S8, and command 2/4/6/R gear clutch engagement. At the Open A24 oil circuit flow solenoid S8, so that S8/6R actuator
same time, command to close 1/3/5/7 clutch flow solenoid oil enters 24 actuator circuit. Then, 24 actuator oil is conveyed
S3, S7, A37 oil circuit pressure solenoid S5, A15 oil circuit to 2/4/6/R gear logic valve through #10 orifice.
flow solenoid S7, and 1357/246R logic valve pressure control
solenoid S9. At the same time, the transmission is shifted to • 2/4/6/R gear logic valve
4th gear. When S9 signal oil pressure is discharged, the spring moves the
Engage 2/4/6/R gear clutch 2/4/6/R gear logic valve to the released position. 24 actuator
oil enters into the 4th gear circuit through 2/4/6/R gear logic
• 2/4/6/R clutch flow solenoid S4 valve. S8/6R actuator oil enters into the reverse circuit through
Open 2/4/6/R clutch flow solenoid S4, so that S2 signal enters 2/4/6/R gear logic valve. Both the 4th gear oil pressure and
into 246R clutch circuit. Then, 2/4/6/R clutch oil is conveyed reverse gear oil pressure are conveyed to the 4R gear shifting
to the clutch actuator cylinder assembly through #2 orifice. fork actuator piston assembly.
• Clutch actuator cylinder assembly • 4R gear shifting fork actuator piston assembly
2/4/6/R clutch oil enters the clutch actuator cylinder assembly, With the 4th gear oil pressure greater than the reverse gear
then overcomes the spring force, moves the 2/4/6/R gear oil pressure, move the 4th gear shifting fork actuator piston
clutch piston, and engages the 2/4/6/R gear clutch plate. assembly to the 4th gear position, so as to drive the 4R gear
shifting fork assembly, and the transmission is switched to 4th
Engage 4R gear shifting fork assembly
gear.
Release of 1/3/5/7 gear clutch
Command to close 1357/246R logic pressure control solenoid
• 1/3/5/7 clutch flow solenoid S3
S9, so that S9 signal oil pressure is discharged from 1/3/5/7 gear
logic valve and 2/4/6/R logic valve.
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Command to close the 1/3/5/7 clutch flow solenoid S3, so • 1/3/5/7 gear logic valve
that 1/3/5/7 clutch oil pressure is discharged from the clutch
When S9 signal oil pressure is discharged, the spring moves the
1/3/5/7 gear logic valve to the released position, so that the 3rd
• Clutch actuator cylinder assembly gear oil pressure and 5th gear oil pressure are discharged from
the 1/3/5/7 gear logic valve.
1/3/5/7 clutch oil pressure is discharged from the clutch
actuator cylinder assembly, so that the spring moves the • 3/5 gear shifting fork actuator piston assembly
1/3/5/7 gear clutch piston, and the 1/3/5/7 gear clutch plate is
3rd gear oil pressure and 5th gear oil pressure are discharged
released.
from 3/5 gear shifting fork actuator piston assembly, and at the
Release of 35 gear shifting fork assembly same time, the 3/5 gear shifting fork actuator piston assembly

so that S7/37 actuator oil pressure is discharged from A15 oil • 1/3/5/7 clutch pressure solenoid S1
circuit flow solenoid S7 and 1/3/5/7 gear logic valve.
Keep 1/3/5/7 clutch pressure solenoid S1 open, so that energy
• A15 oil circuit flow solenoid S7 accumulator oil enters the S1 signal circuit. Then, S1 signal
#13 and #20 orifices for shifting to the 5th gear.
15 actuator oil pressure is discharged from 1/3/5/7 gear logic
valve.
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D5 gear
With the improvement of vehicle speed and running to the • S7 and A37 oil circuit pressure solenoid S5
S7/37 actuator oil is conveyed to A15 oil circuit flow solenoid
S7 and 1/3/5/7 gear logic valve through #7 orifice.
connects 1/3/5/7 clutch flow solenoid S3, S7 and A37 oil
circuit pressure solenoid S5 and A15 oil circuit flow solenoid • A15 oil circuit flow solenoid S7
S7 and 1357/246R logic valve pressure control solenoid S9, Open A15 oil circuit flow solenoid S7, so that S7/37 actuator
and command 1357 gear clutch to engage. At the same time, oil enters 15 actuator circuit. Then, 15 actuator oil is conveyed
command to close 2/4/6/R clutch flow solenoid S4, S8, A6R oil to 1/3/5/7 gear logic valve through #8 orifice.
circuit pressure solenoid S6, and A24 oil circuit flow solenoid
S8. At the same time, the transmission is shifted to 5th gear. • 1/3/5/7 gear logic valve
Engage 1/3/5/7 gear clutch The S9 signal flow is conveyed to the 1/3/5/7 gear logic
solenoid, and overcomes the spring force to move the logic
• 1/3/5/7 clutch flow solenoid S3 valve so that the S7/37 actuator oil enters the 3rd circuit
Open 1/3/5/7 clutch flow solenoid S3, so that S1 signal enters through the logic valve. 15 actuator oil enters into the 1st
into 1/3/5/7 clutch circuit. Then, 1/3/5/7 clutch oil is conveyed gear circuit through 5/3/5/7 gear logic valve. Both the 3rd gear
to the clutch actuator cylinder assembly through #1 orifice. oil pressure and 5th gear oil pressure are conveyed to the 3/5
then overcomes the spring force, moves the 1/3/5/7 gear clutch With the 5th gear oil pressure greater than the 3rd gear
piston, and engages the 1/3/5/7 gear clutch plate. oil pressure, move the 3/5 gear shifting fork actuator piston
assembly to the 5th gear position, so as to drive the 3/5 gear
Engage 3/5 gear shifting fork assembly
• 1357/246R logic valve pressure control solenoid S9 gear.
Open 1357/246R logic valve pressure control solenoid S9, so Release of 2/4/6/R gear clutch
that energy accumulator oil enters the S9 signal circuit. Then,
S9 signal flow is conveyed to 1/3/5/7 gear logic valve and 2/4/6/R
gear logic valve through #3 orifice.
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Command to close the 2/4/6/R clutch flow solenoid S4, so • 2/4/6/R gear logic valve
that 2/4/6/R clutch oil pressure is discharged from the clutch
S9 signal flow is conveyed to the 2/4/6/R gear logic valve,
overcomes the spring force and moves the logic valve, which
• Clutch actuator cylinder assembly makes the oil pressure of 2nd and 6th gear is discharged from
the 2/4/6/R gear.
actuator cylinder assembly, which makes the spring move the • 4R gear shifting fork actuator piston assembly
Reverse gear oil pressure and 4th gear oil pressure are
is released.
discharged from 4R gear shifting fork actuator piston assembly,
Release of 4R gear shifting fork assembly and at the same time, the 4R gear shifting fork actuator piston
assembly is moved to Neutral (N) position.
Command to close S8 and A6R oil circuit pressure solenoid

S6, so that S8/6R actuator oil pressure is discharged from A24 • 2/4/6/R clutch pressure solenoid S2
• A24 oil circuit flow solenoid S8 accumulator oil enters the S2 signal circuit. Then, S2 signal
#12 orifice for shifting to the 6th gear.
24 actuator oil pressure is discharged from 2/4/6/R gear logic
valve.
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D6 gear
With the improvement of vehicle speed and running to the • A24 oil circuit flow solenoid S8
Open A24 oil circuit flow solenoid S8, so that S8/6R actuator
oil enters 24 actuator circuit. Then, 24 actuator oil is conveyed
to 2/4/6/R gear logic valve through #10 orifice.
connects 2/4/6/R clutch flow solenoid S4, S8 and A6R oil • 2/4/6/R gear logic valve
circuit pressure solenoid S6 and A24 oil circuit flow solenoid 24 actuator oil enters into the 4th gear circuit through 2/2/6/R
S8, and control 2/4/6/R gear clutch engagement. At the same gear logic valve. S8/6R actuator oil enters the 6th circuit
time, command to close 1/3/5/7 clutch flow solenoid S3, S7, through 2/4/6/R gear logic valve. Both the 2nd gear oil pressure
A37 oil circuit pressure solenoid S5, and A15 oil circuit flow and 6th gear oil pressure are conveyed to the 2/6 gear shifting
solenoid S7. At the same time, the transmission is shifted to fork actuator piston assembly.
6th gear.
Engage 2/4/6/R gear clutch
With the 6th gear oil pressure greater than the 2nd gear
• 2/4/6/R clutch flow solenoid S4 oil pressure, move the 2/6 gear shifting fork actuator piston
Open 2/4/6/R clutch flow solenoid S4, so that S2 signal enters assembly to the 6th gear position, so as to drive the 2/6 gear
into 246R clutch circuit. Then, 2/4/6/R clutch oil is conveyed shifting fork assembly, and the transmission is switched to 6th
to the clutch actuator cylinder assembly through #2 orifice. gear.
• Clutch actuator cylinder assembly Release of 1/3/5/7 gear clutch

2/4/6/R clutch oil enters the clutch actuator cylinder assembly, • 1/3/5/7 clutch flow solenoid S3
then overcomes the spring force, moves the 2/4/6/R gear Command to close the 1/3/5/7 clutch flow solenoid S3, so
clutch piston, and engages the 2/4/6/R gear clutch plate. that 1/3/5/7 clutch oil pressure is discharged from the clutch
Engage 2/6 gear shifting fork assembly actuator cylinder assembly.
• S8 and A6R oil circuit pressure solenoid S6 • Clutch actuator cylinder assembly
Open S8 and A6R oil circuit pressure solenoid S6, so that 1/3/5/7 clutch oil pressure is discharged from the clutch
energy accumulator oil enters the S8/6R actuator circuit. actuator cylinder assembly, so that the spring moves the
Then, S8/6R actuator oil is conveyed to A24 oil circuit flow 1/3/5/7 gear clutch piston, and the 1/3/5/7 gear clutch plate is
solenoid S8 and 2/4/6/R gear logic valve through #9 orifice. released.
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Release of 35 gear shifting fork assembly • 3/5 gear shifting fork actuator piston assembly
• S7 and A37 oil circuit pressure solenoid S5 3rd gear oil pressure and 5th gear oil pressure are discharged
same time, the 3/5 gear shifting fork actuator piston assembly
so that S7/37 actuator oil pressure is discharged from A15 oil
circuit flow solenoid S7 and 1/3/5/7 gear logic valve.
15 actuator oil pressure is discharged from 1/3/5/7 gear logic Keep 1/3/5/7 clutch pressure solenoid S1 open, so that energy
valve. accumulator oil enters the S1 signal circuit. Then, S1 signal
• 1/3/5/7 gear logic valve
#13 and #20 orifices for shifting to the 7th gear.
5th gear oil pressure is discharged to 15 actuator circuit
through 1/3/5/7 gear logic valve. 3rd gear oil pressure is
discharged to S7/37 actuator circuit through 1/3/5/7 gear logic
valve.
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D7 gear
With the improvement of vehicle speed and running to the Open S7 and A37 oil circuit pressure solenoid S5, so that
appropriate conditions, the transmission control module energy accumulator oil enters the S7/37 actuator circuit. Then,
(TCM) processes the input signals from the transmission S7/37 actuator oil is conveyed to A15 oil circuit flow solenoid
input and output shaft speed sensor, throttle position sensor S7 and 1/3/5/7 gear logic valve through #7 orifice.
connects 1/3/5/7 clutch flow solenoid S3, S7 and A37 oil circuit
pressure solenoid S5 and A15 oil circuit flow solenoid S7, and Open A15 oil circuit flow solenoid S7, so that S7/37 actuator
control 1/3/5/7 gear clutch engagement. At the same time, oil enters 15 actuator circuit. Then, 15 actuator oil is conveyed
command to close 2/4/6/R clutch flow solenoid S4, S8, A6R to 1/3/5/7 gear logic valve through #8 orifice.
oil circuit pressure solenoid S6, A24 oil circuit flow solenoid • 1/3/5/7 gear logic valve
S8, and 1357/246R logic valve pressure control solenoid S9.
At the same time, the transmission is shifted to 7th gear. When S9 signal oil pressure is discharged, the spring moves the
1/3/5/7 gear logic valve to the released position, which makes
Engage 1/3/5/7 gear clutch the S7/37 actuator oil enters the 7th gear circuit through the
• 1357 clutch flow solenoid S3 logic valve. 15 actuator oil enters into the 1st gear circuit
through 1/3/5/7 gear logic valve. Both the 7th gear oil pressure
and 1st gear oil pressure are conveyed to the 17 gear shifting
fork actuator piston assembly.
With the 7th gear oil pressure greater than the 1st gear oil
pressure, move the 1/7 gear shifting fork actuator piston
then overcomes the spring force, moves the 1/3/5/7 gear clutch
assembly to the 7th gear position, so as to drive the 1/7 gear
piston, and engages the 1/3/5/7 gear clutch plate.
Engage 17 gear shifting fork assembly gear.
• 1357/246R logic valve pressure control solenoid S9 Release of 2/4/6/R gear clutch
Command to close 1357/246R logic pressure control solenoid • 2/4/6/R clutch flow solenoid S4
S9, so that S9 signal oil pressure is discharged from 1/3/5/7 gear
Command to close the 2/4/6/R clutch flow solenoid S4, so
logic valve and 2/4/6/R logic valve.
that 2/4/6/R clutch oil pressure is discharged from the clutch
• S7 and A37 oil circuit pressure solenoid S5 actuator cylinder assembly.
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• Clutch actuator cylinder assembly When S9 signal oil pressure is discharged, the spring moves the
2/4/6/R gear logic valve to the released position, so that the
2/4/6/R gear clutch oil pressure is discharged from the clutch
2nd gear oil pressure and 6th gear oil pressure are discharged
actuator cylinder assembly, which makes the spring move the
from the 2/4/6/R gear logic valve.
2/4/6/R gear clutch piston, and the 2/4/6/R gear clutch plate is
released. • 2/6 gear shifting fork actuator piston assembly
Release of 2/6 gear shifting fork assembly 2nd gear oil pressure and 6th gear oil pressure are discharged
same time, the 2/6 gear shifting fork actuator piston assembly
Command to close S8 and A6R oil circuit pressure solenoid is moved to Neutral (N) position.
S6, so that S8/6R actuator oil pressure is discharged from A24
• 2/4/6/R clutch pressure solenoid S2
24 actuator oil pressure is discharged from 2/4/6/R gear logic
valve.
#12 orifice, so as to realize downshift.
• 2/4/6/R gear logic valve
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Service Procedures if necessary.
Dry Dual-clutch Automatic Transmission Fluid 10. Remove the drain plug (1), and drain the oil.
- Drain and Refill
Drain
1. Remove the transmission breather hose and
transmission electro-hydraulic control assembly
breather hose from the fixing groove of throttle intake
pipe.
2. Remove 1 bolt fixing the throttle intake pipe to the
engine.
Refill
any additives.
1. Fit the drain plug, tighten to 7–14Nm, and clean oil

3. Turn the buckle fixing the throttle intake pipe to stains around the drain plug.
the throttle end, loosen the quick connector, and
2. Remove the oil level plug (3), and discard it.
disconnect the throttle intake pipe.

4. Remove the throttle intake pipe.
4. Fill the transmission fluid into the transmission with the
5. Remove the transmission breather hose from the oil
special tool TPT00059 until oil starts to flow out from
filler plug.
the oil level access hole.
6. Remove the oil filler plug (2) and discard the O-ring
of the oil filler plug.
8. Place a suitable container below the transmission to
collect the transmission fluid.
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Dry Dual Clutch Automatic Transmission Fluid

- Check and Refill
Check
any additives.

leakage, replace the faulty oil plug as necessary.
2. Lift the vehicle to make wheels get off the ground.
3. Start the engine in P gear and keep it running at idle
speed.
4. Depress the brake pedal, shift the gear according to
5. Lift the vehicle.
the following sequence: R-N twice, N-D twice, D-W
6. Fit the new oil level plug, tighten to 7–14Nm and
twice (during the gear shift, the brake pedal is always
check the torque.
depressed). After the completion of the gear shifts,
7. Check the transmission fluid. shift to N gear.
Transmission Fluid Check 5. Depress the brake pedal, shift to R gear, then release
8. Fit a new filler plug O-ring to the filler plug, and fit the the brake pedal, allow the wheels to rotate for about
filler plug. 10s; depress the brake pedal until the wheels stop
9. Fit the transmission ventilation tube to the filler plug.
10. Fix the throttle intake pipe to the throttle.
11. Fix the throttle intake pipe to the engine, fit 1 bolt,
6. Depress the brake pedal, shift to W gear, then release
12. Fix the transmission breather hose and automatic
the brake pedal, allow the wheels to rotate for about
transmission hydraulic module breather hose to the
10s; depress the brake pedal until the wheels stop
throttle intake pipe.
7. Connect a scan tool, ensure that the valve body
temperature is already between 20-40℃.
• If the valve body temperature is lower than 20℃, repeat

Step 6 until the valve body temperature is between
20-40℃;
• If the valve body temperature is higher than 40℃, turn
off the engine, repeat Steps 3, 4, 5 and 6 after it is
cooled down to room temperature, until the valve body
temperature is between 20-40℃;
8. Depress the brake pedal until the wheels are fully
stopped, shift to P position, and turn off the ignition
switch.
9. Remove the oil level hole plug (3) and discard it, and
collect spilled oil with a graduated measuring cylinder.
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the filler plug (2).
10. Drain oil continuously for 5 minutes, and record the

color and volume of collected oil.
a. The new gearbox oil is amber, and becomes dark
brown black after driving for several kilometers.
b. If the drained oil is green, it indicates that the
automatic transmission hydraulic module has oil
leakage.
c. If the drained oil exceeds 200ml, the oil must be
refilled.
d. If no oil is drained from the oil level hole, the oil
must be refilled.
Refill
any additives.
1. Remove the filler plug, and discard the filler plug O-ring.
2. Fill the transmission fluid into the transmission with the
special tool TPT00059 until oil starts to flow out from
the oil level access hole.
3. Record the net weight of filled oil. If more than 200ml

of oil must be filled, check for external leakage.
4. Fit the new oil level plug (3), tighten to 7–14Nm, and
check the torque.
5. Fit a new filler plug O-ring to the filler plug, and tighten
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Dry Dual Clutch Automatic Transmission

Assembly
Remove
Caution: After removing the transmission assembly,
the breather plug shall face up, otherwise, leak
may occur!

4. Remove the hose - turbocharged intercooler to throttle
body.
11. Remove 2 bolts (1) fixing the catalytic converter
Hose - Turbocharged Intercooler to Throttle bracket to the catalytic converter.
Body Remove 12. Remove 1 bolt (2) fixing the catalytic converter bracket
5. Remove the shift cable ball joint (1) from the shift to the transmission, and remove the catalytic converter
rocker arm knob. bracket.
6. Release the C-clip from the cable bracket (2), remove
the shift cable fastener and remove the shift cable.
13. Remove 1 bolt fixing the upper closure plate to the

transmission, and remove the upper closure plate.
7. Remove the transmission harness.
Transmission Harness Remove

8. Disconnect the connector of the rear oxygen sensor,
and remove 1 bolt fixing the oxygen sensor connector
bracket to the transmission (1).
9. Remove the clip fixing the harness to the transmission
and remove the harness.
10. Disconnect the connector (2) of the TCM, and remove
the harness.
14. Rotate the crankshaft, remove the first tangential bolt,

then rotate to 120°, remove the second one, and finally
the third one.
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21. Drain the dry dual clutch automatic transmission fluid.
Drain
23. Remove the PTU assembly (AWD).
PTU Assembly Remove
24. Remove the starter.
Starter Motor Remove
25. Support the bottom of the transmission with a bracket.
15. Fix the engine with the T10007 and TEN00070. 26. Remove 3 bolts connecting the transmission to the
engine.
27. Move the transmission rightwards to disconnect it from
the engine.
28. Remove the transmission from the bracket.
29. Remove 4 bolts fixing the lower tie rod bracket to the
transmission, and remove the lower tie rod bracket.
Refit
1. Clean the mating face between the engine and the
transmission, and ensure that there is no foreign
material. Check the clearance (a) between the DMF
jaw and the cover plate, if it is less than 1.011mm or
greater than 3.668mm, replace the DMF assembly.
16. Remove 4 bolts between the upper transmission and Flywheel - AT
the engine.
17. Remove and discard 2 bolts (1) and 1 nut (1) fixing the
transmission suspension to the transmission.
18. Remove 4 bolts (2) fixing the transmission suspension
to the body, and remove the transmission suspension.
2. Clean the locating pin on the engine and the locating

pin hole of the transmission.
3. Confirm that the protective sleeve of the DMF bearing
is fitted, and check the DMF bearing and the input shaft
journal of the transmission for damage or wear. Make
replacements if necessary, clean the lube residue in
the DMF bearing and apply a little bit of grease before
Warning: Do not work on or under a vehicle supported fitting the transmission assembly.
Lubricant Brand Volume
Bottom Deflector Remove Mobil UNIREX N3 0.34g
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14. Fix the transmission mounting bracket to the
transmission housing, fit 3 bolts, tighten to 90–110Nm
15. Fix the transmission suspension to the transmission
mounting bracket, fit 2 new bolts, tighten to
70Nm+90°, fit 1 new nut, tighten to 70Nm+90° and
4. Secure the transmission on the bracket, rotate the
check the torque.
engine crankshaft to align the DMF jaw (1, 2, 3)
16. Fit 3 bolts between the upper transmission and the
with the dual-clutch block (1, 2, 3). Gently push the
engine, tighten to 49–67Nm and check the torque.
transmission until the transmission input shaft fits with
the DMF bearing; keep moving the transmission until 17. Remove the T10007.
the dual-clutch block enters into the DMF jaw. 18. When fitting, rotate the engine crankshaft to 360°, and
Caution: For the angle between the DMF jaw and the decrease the friction fit thrust between the DMF jaw
dual-clutch block, when assembling the transmission and the dual-clutch block. Measure the clearance (a)
to the engine, care shall be taken and avoid between the 1st jaw of the DMF and the cover plate,
impacts; otherwise, it may cause functional fault fit the 1st tangential bolt and pretighten to 5Nm; and
in the transmission! rotate the engine crankshaft to 120°, measure clearance
a, fit the 2nd tangential bolts and pretighten to 5Nm;
then rotate the engine crankshaft to 120°, measure
clearance a, fit the 3rd tangential bolts and pretighten
to 5Nm. The clearance shall be greater than 1.2mm,
otherwise, interference and flywheel damage may occur.
5. Rotate the transmission housing to align the locating

pin on the engine with the locating pin hole of the
transmission. Keep moving the transmission until the
mating face between the engine and the transmission
completely fits, fit 4 bottom bolts, tighten to 49–67Nm
and check the torque. 19. Rotate the crankshaft, tighten the 3 tangential bolts to
30–35Nm and check the torque; check if the 3 gaps
6. Remove the transmission bracket.
are greater than 1.2mm, otherwise, interference or
flywheel damage may occur.
bolts, tighten to 90–110Nm and check the torque.
20. Fix the upper closure plate to the transmission, fit 1
8. Fit the starter.
bolt, tighten to 7.5–10.5Nm and check the torque.
Starter Motor Refit
21. Fix the catalytic converter bracket to the catalytic
9. Fit the PTU assembly (AWD). converter, fit 2 nuts, tighten to 19–25Nm and check
PTU Assembly Refit the torque.
10. Fit the front subframe. 22. Fix the catalytic converter bracket to the transmission,
1.0 552
fit 1 bolt, tighten to 49–67Nm and check the torque. Dry Dual Clutch Automatic Transmission
23. Connect the connector of the TCM. Harness
Remove
24. Fix the harness to the transmission, and connect the
oxygen sensor connector. 1. Remove the battery box bracket.
25. Fix the oxygen sensor connector bracket to the Battery Box Bracket Remove
transmission, fit 1 bolt, tighten to 22–28Nm and check 2. Disconnect the transmission control module connector.
the torque.
26. Fit the transmission harness.
Transmission Harness Refit

27. Locate the shift cable to the cable bracket and fix with
C-clip.
28. Fit the shift cable ball joint to the shift rocker arm knob.
torque.

31. Refill the dry dual-clutch automatic transmission fluid. 3. Disconnect the cylinder position sensor connector of
Dry Dual Clutch Automatic Transmission Fluid the clutch actuator.
Refill 4. Disconnect the transmission gearbox through
32. Fit the hose - turbocharged intercooler to throttle body connector head connector.
Hose - Turbocharged Intercooler to Throttle

Body Refit
33. Connect the scan tool to the vehicle and access to SIPS.
34. Select "Programme and Encode - TCM (transmission
control module) - Replace", and operate according to
the instruction on the screen; upon the completion of
the update, the part selected to replace is "Transmission
Assembly", and click NEXT to operate according
to the instruction on the screen until the operation
is completed. Replacement operation includes the
refresh, configuration and self-learning options. For
self-learning, see "Transmission Control Module (TCM)
- 7 Speed Automatic Transmission Quick Self-learning" 5. Disconnect the transmission control harness connector.
for detail. 6. Remove 1 bolt fixing the ground wire to the
Transmission Control Module (TCM) - 7-speed transmission housing.
Automatic 7. Remove 1 nut fixing the transmission harness bracket
to TCM.
8. Remove the harness buckles from the transmission
housing, and remove the transmission harness.
1.0 553
Transmission Control Module (TCM) - Dry Dual

Clutch Automatic Transmission
Remove
3. Remove 2 bolts fixing the coolant expansion tank to the
frame, and then remove the coolant expansion tank.
Refit
Caution: Make sure the 2 connecting plugs are
aligned before connecting the connector. If they
are not aligned or they cannot be inserted by great
force, stop the connection. Check the PINs and
reconnect the connector.
1. Fix the transmission harness to the transmission
housing, and fix it with harness buckles. 4. Disconnect the transmission control module (TCM)
2. Fix the ground wire to the transmission housing, fit 1 connector.
bolt, tighten to 7.5–10.5Nm, and check the torque. 5. Remove 2 bolts fixing the transmission control
3. Fix the transmission harness bracket to the TCM, fit 1 module (TCM) to the upper part of transmission
nut, tighten to 8–10Nm, and check the torque. electro-hydraulic control assembly.
4. Connect the transmission control harness connector. 6. Lift the vehicle.
5. Connect the transmission gearbox through connector 7. Remove the bottom deflector.
head connector. Bottom Deflector Remove
6. Connect the master cylinder position sensor connector 8. Remove 2 bolts fixing the transmission control module
of the clutch actuator. (TCM) to the bottom of transmission electro-hydraulic
7. Connect the transmission control module connector. control assembly, and remove the transmission control
8. Fit the battery box bracket. module (TCM).
S1213102
Refit
1.0 554
1. Fix the transmission control module (TCM) to the Transmission Electro-Hydraulic Control
transmission electro-hydraulic control assembly, fit 2 Assembly
lower bolts, tighten to 7.5–10.5Nm and check the Remove
torque. Caution: After removing the transmission
2. Fit the bottom deflector. electro-hydraulic control assembly, the breather
plug shall face up, otherwise, leak may occur!
3. Lower the vehicle. 1. Keep the brake pedal depressed, start the engine,
engage into N gear, and stop the engine.
4. Fit 2 bolts fixing the transmission control module
(TCM) to the bottom of transmission electro-hydraulic 2. Use VDS to perform transmission accumulator
control assembly, tighten to 7.5–10.5Nm and check pressure relief. Refer to Transmission Control Module
the torque. (TCM) - 7-speed Automatic Transmission Accumulator
Pressure Relief for details.
5. Connect the transmission control module (TCM)
connector. Transmission Control Module (TCM) - 7-speed
Automatic
6. Fix the coolant expansion tank to the frame; fit 2 bolts,
tighten to 4–6Nm and check the torque. 3. Drain the dry dual clutch automatic transmission fluid.
Drain
the instruction on the screen; upon the completion 5. Remove the transmission control module (TCM).
of the update, the part selected to replace is "TCM", Transmission Control Module Remove
and click next step to operate according to the 6. Remove the hose - turbocharged intercooler to throttle
instruction on the screen until the operation is body.
completed. Replacement operation includes the Hose - Turbocharged Intercooler to Throttle
refresh, configuration and self-learning options. For Body Remove
self-learning, see "Transmission Control Module (TCM)
7. Disconnect the connectors, loosen the buckles,
- 7 Speed Automatic Transmission Quick Self-learning"
and move away harnesses from the transmission
for detail.
electro-hydraulic control assembly and control module.
Transmission Control Module (TCM) - 7-speed 8. Remove 12 bolts fixing the transmission
Automatic electro-hydraulic control assembly to the transmission
housing.
Caution: Do not remove 3 bolts fixing the controller
to the valve body actuator, otherwise, the
transmission electro-hydraulic control assembly
can be damaged.
9. Correctly fit the special tool TPT00203 to the

transmission electro-hydraulic control assembly (1) .
1.0 555
10. Remove the transmission electro-hydraulic control 3. Fix a new seal gasket to the transmission housing.
assembly along the vertical direction of the transmission 4. Locate the actuator piston to the middle position with
housing, and discard the sealing gasket. the TPT00200.
Caution: If the transmission electro-hydraulic
control assembly is not removed along the vertical
direction of the transmission housing, the 2 clutch
slave cylinder seals (1) may be damaged.
5. With the TPT00201, fix the shift fork to the N gear.
Refit
1. Clean the junction surface between transmission
electro-hydraulic control assembly and transmission
housing, and ensure that there is no foreign material.
2. Record the serial number of the electro-hydraulic 6. Fit the transmission electro-hydraulic control assembly
control assembly (PUN). to the transmission with the TPT00203.
Caution: If the transmission electro-hydraulic
control assembly is not fitted along the vertical
direction of the transmission housing, the clutch
slave cylinder seal may be damaged.
Caution: Before fitting the electro-hydraulic
control assembly, the shift actuator piston and
shift fork shall be in the N gear.
1.0 556
the operation is completed. Replacement operation
includes the refresh, configuration and self-learning
options. For self-learning, see "Transmission Control
Module (TCM) - 7 Speed Automatic Transmission
Quick Self-learning" for detail.
Transmission Control Module (TCM) - 7-speed

Automatic
16. When replacing electro-hydraulic control assembly
and transmission control module, select the part
"Electro-Hydraulic Control Assembly and Transmission
Control Module" to be replaced in step 15, and other
operations are same.
7. Fit 12 bolts fixing the transmission electro-hydraulic
control assembly, tighten to 7.5–10.5Nm in the
sequence shown, and check the torque.
8. Remove the TPT00203.

9. Reset the harnesses on the transmission
electro-hydraulic control assembly and control module,
connect the connector and fix it with clips.
10. Fit the hose - turbocharged intercooler to throttle body
Body Refit
11. Fit the transmission control module (TCM).
Transmission Control Module Refit
13. Refill the dry dual-clutch automatic transmission fluid.
Refill
the instruction on the screen; upon the completion
of the update, the part selected to replace is
"electro-hydraulic assembly", and click NEXT to
operate according to the instruction on the screen until
1.0 557
Fork Position Sensor Assembly Input Speed Sensor Assembly

Remove Remove
1. Remove the transmission electro-hydraulic control 1. Remove the transmission electro-hydraulic control
assembly. assembly.
Transmission Electro-hydraulic Control Transmission Electro-hydraulic Control

Assembly Remove Assembly Remove
2. Disconnect 4 shift fork position sensor connectors. 2. Disconnect 2 input speed sensor connectors.
3. Remove 4 bolts (1) securing 4 shift fork position 3. Remove 2 bolts (2) securing 2 input speed sensors onto
sensors onto the transmission electro-hydraulic control the transmission electro-hydraulic control assembly and
assembly, and remove shift fork position sensors. remove the input speed sensors.
Refit Refit
1. Fix 4 shift fork position sensors onto the transmission 1. Fix 2 input speed sensors onto the transmission
electro-hydraulic control assembly respectively, fit 4 electro-hydraulic control assembly respectively, fit 2
bolts, tighten to 7.5–10.5Nm, and check the torque. bolts, tighten to 7.5–10.5Nm, and check the torque.
2. Connect 4 shift fork position sensor connectors. 2. Connect 2 input speed sensor connectors.
3. Fit the transmission electro-hydraulic control assembly. 3. Fit the transmission electro-hydraulic control assembly.
Transmission Electro-hydraulic Control Transmission Electro-hydraulic Control

Assembly Refit Assembly Refit
1.0 558
Transmission Electro-Hydraulic Control Dual Clutch Assembly - Dry Dual Clutch
Assembly Harness Automatic Transmission
Remove Remove
1. Remove the transmission electro-hydraulic control 1. Remove the dry dual clutch automatic transmission
assembly. assembly.
Transmission Electro-Hydraulic Control Dry Dual Clutch Automatic Transmission

Assembly Remove Assembly Remove
2. Disconnect 2 connectors of input speed sensor and 4 2. Remove the snap ring, and remove the clutch driven
connectors of fork position sensor. hub.
3. Remove 1 bolt (3) fixing the harness of transmission
electro-hydraulic control assembly to the transmission
electro-hydraulic control assembly, and remove the
harness.
3. Fit the special tool TPT00199 to the clutch housing,

and the supporting feet shall be about 120° apart.
4. Press down the clutch assembly with the central
installer of the special tool TPT00199, keep pressing
Refit until enough space is set aside for removal of clutch
Caution: Make sure the 2 connecting plugs are retainer ring; once enough space required is obtained,
aligned before connecting the connector. If they reduce the centre bolt torque to 3Nm, tighten 3 screws
are not aligned or they cannot be inserted by great by hand, and fix the clutch in a compressed state.
force, stop the connection. Check the PINs and Caution: The torque applied to the centre bolt shall
reconnect the connector. not exceed 11.6Nm.
1. Fix the transmission electro-hydraulic control assembly 5. Remove the central installer of the special tool
harness on the transmission electro-hydraulic control TPT00199.
assembly, fit 1 bolt, tighten to 7.5–10.5Nm and check
6. Remove the snap ring and input shaft bearing shim, and
the torque.
remove the special tool TPT00199.
2. Connect 2 connectors of input speed sensor and 4
connectors of fork position sensor.
3. Fit the transmission electro-hydraulic control assembly.

Assembly Refit
7. Fix the special tool TPT00199 to the thread boss on

the clutch assembly at interval of 120°.
1.0 559
Gasket
Gasket Thickness/mm Measured Value a/mm
Grade
1.390 1.290 44.013 44.293 I4
1.110 1.010 44.294 44.570 I5
8. Fit the central installer of the special tool TPT00199

to the hollow shaft.
9. Align the central bolt of the special tool TPT00199
with the top groove in the installer and tighten, then
pull out the clutch assembly from the hollow shaft.
3. Remove the grease residue on the clutch assembly
spline, and apply a thin layer of new grease.
Grease Grade Volume
Klüber Microlube GNY202 About 0.5g
4. Fit the dual clutch assembly.

5. Fit the special tool TPT00199 to the clutch housing,
and the supporting feet shall be about 120° apart.
6. Press the clutch assembly into a hollow shaft with the
TPT00199, continue to press until enough space is
set aside for clutch retainer refit; once enough space
required is obtained, reduce the centre screw torque
10. Remove the special tool TPT00199 from the clutch by 3Nm, tighten 3 compression screws by hand, and fix
assembly. the clutch in a compressed state.
Refit Caution: The torque applied to the centre bolt shall
If the dual clutch assembly is renewed, please also not exceed 11.6Nm.
renew the clutch actuator assembly. 7. Remove the central installer of the TPT00199.
1. Check the original clutch retainer for damage, if there 8. Fit a new input shaft bearing shim to the even number
is no damage, continue to use it, if any, measure and input shaft.
select a new clutch retainer. 9. Fit the snap ring into the snap ring groove with snap
2. Measure from the clutch housing surface to the top of ring pliers.
the clutch retainer, and select a suitable gasket based
Caution: The angle between the opening of the
on the measured value (a).
installer and the clutch retainer is 180°;
Caution: Just measure the input shaft bearing shim otherwise, the clutch retainer may be damaged.
when replacing the clutch housing or input shaft.
10. Fix the TPT00199 to the thread boss on the clutch
Gasket assembly at interval of 120°.
Gasket Thickness/mm Measured Value a/mm
Grade 11. Fit the central installer of the special tool TPT00199
2.230 2.130 43.170 43.450 I1 to the hollow shaft.
1.950 1.850 43.451 43.731 I2 12. Align the central bolt of the TPT00199 with the top
groove in the installer and tighten, then pull the clutch
1.670 1.570 43.732 44.012 I3
assembly back to the right position.
1.0 560
Caution: The torque applied to the centre bolt shall Clutch Actuator Cylinder Assembly - Dry Dual
not exceed 11.6Nm. Clutch Automatic Transmission
Remove
1. Remove the dry dual clutch automatic transmission
assembly.
Assembly Remove
2. Fix the transmission to the fixed bracket with the
13. Remove the residual grease on the direct gear clutch

hub spline, apply a thin layer of new grease, and fit the
direct gear clutch hub to the clutch assembly.
Grease Grade Volume
14. Fit the clutch retainer ring.

15. Fit the dry dual clutch automatic transmission assembly.
3. Remove the transmission electro-hydraulic control
Dry Dual Clutch Automatic Transmission assembly.
Assembly Refit Transmission Electro-Hydraulic Control
Assembly Remove
Caution: Electro-hydraulic control assembly must
be removed before removing the clutch actuator
cylinder assembly, or the hydraulic oil in
electro-hydraulic control assembly will flow out
from the oil passage in the housing.
4. Remove the dual clutch assembly.
Dual Clutch Assembly Remove
5. Remove 2 bolts fixing the clutch actuator cylinder
position sensor harness cover to the clutch housing,
and remove the clutch actuator cylinder position
sensor harness cover.
6. Remove the clutch actuator cylinder position sensor
1.0 561
connector from the clutch housing. Transmission Electro-Hydraulic Control

7. Remove 3 bolts fixing the clutch actuator cylinder to Assembly Refit
the clutch housing and discard, and remove the clutch 8. Fit the dry dual clutch automatic transmission assembly.
actuator cylinder and discard the gasket.
Assembly Refit
Refit
If the clutch actuator cylinder assembly is to be
replaced with a new one, replace the dual clutch
assembly together.
1. Clean the contact surface between clutch actuator
cylinder and clutch housing.
2. Fix a new gasket to the clutch housing with a locating
pin.
3. Fix the clutch actuator cylinder to the clutch housing,
and fit 3 new bolts; first tighten to 9Nm in the
sequence of 1-2-3 as shown, then to 12.5-14.5Nm
in order, followed by 90° backward, then tighten to
12.5–14.5Nm and check the torque.
4. Fit the clutch actuator cylinder position sensor

connector to the clutch housing.
5. Fix the clutch actuator cylinder position sensor harness
cover to the clutch housing, fit 2 bolts, tighten to
7.5–10.5Nm and check the torque.
6. Fit the dual clutch assembly.
Dual Clutch Assembly Refit
1.0 562
Shift Shaft Oil Seal - Transmission Housing
Remove
1. Place the shift lever in "P" position.

4. Turn the clip fixing the hose to the throttle end, loosen
the quick joint, and disconnect the hose from the
throttle.
Refit
1. Clean the oil seal groove.
2. Fit a new oil seal to the transmission housing with the
installer of the special tool TPT00167.
5. Remove 1 bolt fixing the hose assembly to the engine,

and remove the hose.
3. Fix the shift rocker arm to the shift shaft according to

the mark position, fit 1 nut, tighten to 10–14Nm, and
check the torque.
4. Fit the shift cable to the shift rocker arm.
5. Fix the hose - turbocharger intercooler to throttle
body quick joint to the throttle, and fix it with clips.
6. Fix the hose - turbocharger intercooler to throttle
body to the engine, fit 1 bolt and tighten to 7–10Nm.
6. Remove the shift cable from the shift rocker arm. 7. Fit the battery box bracket.
7. Remove 1 nut fixing the shift rocker arm to the shift
shaft, mark the position of shift rocker arm, and remove
the shift rocker arm.
8. Remove the shift shaft oil seal with a remover of the
1.0 563
Input Shaft Housing Oil Seal - Clutch Housing Differential Oil Seal - Transmission Housing
Remove Remove
1. Remove the clutch actuator cylinder assembly. 1. Raise the vehicle on a lift.
Clutch Actuator Cylinder Assembly Remove Warning: Do not work on or under a vehicle supported
2. Remove the input shaft housing oil seal with special only by a jack.Always support the vehicle on safety stands.
tool TPT00195. 2. Drain the dry dual clutch automatic transmission fluid.

Drain
3. Remove the front axle left drive shaft.
Front Axle Left Drive Shaft Remove

4. Remove the differential oil seal and discard it.
Refit
2. Fit a new oil seal with special tools TPT00198 and
TPT00169.
Refit
2. Fit a new oil seal with the installer of the special tool
TPT00168.
3. Fit the front axle left drive shaft.

Front Axle Left Drive Shaft Assembly Refit
4. Fill the dry dual clutch automatic transmission fluid.

Refill
3. Fit the clutch actuator cylinder assembly.
Clutch Actuator Cylinder Assembly Refit
1.0 564
Differential Oil Seal - Clutch Housing
Remove

2. Drain the dry dual clutch automatic transmission fluid.

Drain
3. Remove the front axle right drive shaft (2WD).
Front Axle Right Drive Shaft Remove

4. Remove the power takeoff assembly (AWD).
4. Fit the power takeoff assembly (AWD).
Power Takeoff Assembly Remove
Power takeoff Assembly Refit
5. Remove the differential oil seal and discard it (2WD).
5. Fit the front axle right drive shaft (2WD).
6. Remove the differential oil seal and discard it (4WD)
with the special tool TPT00225. Front Axle Right Drive Shaft Refit
6. Fill the dry dual clutch automatic transmission fluid.
Refill
Refit
2. Fit a new oil seal (4WD) with the special tool
TPT00204.
3. Fit a new oil seal (2WD) with special tools TPT00198

and TPT00169.
1.0 565

Disassembly
Remove
assembly.

Assembly Remove
2. Fix the transmission to the fixed bracket with the
9. Remove the differential assembly.
3. Remove the transmission electro-hydraulic control

assembly.
Assembly Remove
4. Remove the clutch actuator cylinder assembly.
Clutch Actuator Cylinder Assembly Remove

5. Remove 5 fixing bolts (1) from the front ball bearing
cover plate of input shaft and discard.
6. Remove 18 bolts fixing the clutch housing to the
transmission housing (2). 10. Remove 1 bolt fixing the shift retaining spring to the
7. Remove the clutch housing (3), and discard the washer transmission housing, and remove the shift retaining
(4). spring.
8. Remove the magnetic steel (5) from the transmission

housing.
11. Disconnect the connector, and remove the transmission

internal harness assembly from the parking ratchet
bracket assembly (1).
1.0 566
12. Remove 2 bolts fixing the parking pawl bracket assembly 17. Fit the TPT00165 to the transmission housing.
to the transmission case, and remove the parking
bracket assembly of the parking pawl bracket (2).
13. Remove the parking lever (1), reset spring (2), pawl
shaft (3), and pawl (4). 18. With the TPT00165 as the handle, remove the
TPT00188 from the work bench together with the
transmission.
19. Support the transmission onto the work bench through
the supporting feet of the TPT00165.
20. Remove 3 input shaft bearing seat bolts.
21. Remove the special tool TPT00188.
14. Remove the parking control lever pin (1) and conduit
(2).
15. Remove 1 bolt fixing the parking control lever bracket
to the transmission housing, and remove the parking
control lever bracket (3).
16. Remove 1 bolt fixing the automatic transmission output
shaft sensor to the transmission housing, and remove 22. Remove 3 bolts fixing the special tool TPT00165 to
the automatic transmission output shaft sensor (4). the transmission housing, and remove the transmission
housing.
1.0 567
23. First remove 3/5 gear shifting fork (1) from the special
tool TPT00165, remove 4/R gear shifting fork (2), and
then remove 3/4/5/R output shaft (3).
24. First remove 1/7 gear shifting fork (4) from the special
tool TPT00165, remove 2/6 gear shifting fork (5), and
then remove 1/2/6/7 output shaft (6).
25. Remove the input shaft assembly (7) from the special
tool TPT00165.
29. Remove the differential cone bearing from the

transmission housing with a bearing extractor.
26. Remove the shift shaft stop pin from the special tool
TPT00189.
30. Remove the 3/4/5/R output shaft bearing outer race

from the transmission housing with the special tool
TPT00183, and remove 3/4/5/R output shaft oil
nozzle.
27. Remove the shift shaft position switch.

28. Remove 2 bolts fixing 1/2/6/7 output shaft oil guide
groove and input shaft oil guide groove to the
transmission housing, and remove 2 oil guide grooves.
31. Remove the input shaft oil nozzle from the transmission
housing.
1.0 568
32. Remove the 1/2/6/7 output shaft bearing outer race 35. Remove the 1/2/6/7 output shaft bearing outer
from the transmission housing with the special tool race from the clutch housing with the special tool
TPT00184 (left), and remove 1/2/6/7 output shaft oil TPT00185, and remove 1/2/6/7 output shaft oil nozzle.
nozzle.
36. Remove the differential front bearing outer race from

the clutch housing with the special tool TPT00187
33. Remove 1 bolt fixing the clutch housing side oil groove (2WD) or TPT00224 (AWD).
to the clutch housing, and remove the clutch housing
side oil groove.
34. Remove the 3/4/5/R output shaft bearing outer

race from the clutch housing with the special tool
TPT00183, and remove 3/4/5/R output shaft oil
nozzle.
1.0 569
Refit
1. Clean the transmission housing and clutch housing, and 5. Fit 3/4/5/R gear intermediate shaft oil nozzle to the
ensure that there is no foreign material. transmission housing with the TPT00198, TPT00190.
2. Fit 1/2/6/7 gear intermediate shaft oil nozzle to the

transmission housing with the TPT00198, TPT00192.
6. Fit 3/4/5/R gear main shaft bearing outer race to the

3. Fit 1/2/6/7 gear main shaft bearing outer race to the transmission housing with the TPT00198, TPT00179.
transmission housing with the TPT00198, TPT00180.
7. Fit the transmission left cone bearing to the transmission

4. Fit the input shaft oil nozzle to the transmission housing housing with the TPT00198, TPT00178.
with the TPT00198, TPT00191.
1.0 570
the parking pawl support assembly, and connect the
connector.
22. Fix the shift retaining spring to the transmission
housing, fit 1 bolt, tighten it to 7.5–10.5Nm, and
check the torque.
23. Fit the differential assembly.
24. Measure the adjusting shim of the transmission bearing
and select a proper shim.
Transmission Bearing Adjusting Shim

Measurement
25. Fit the differential main bearing outer race and gasket
to the clutch housing with the TPT00198, TPT00182
8. Fix 1/2/6/7 output shaft oil guide groove and input shaft (2WD) or TPT00223 (AWD).
oil guide groove to the transmission housing, fit 2 bolts,
tighten them to 7.5–10.5Nm, and check the torque.
9. Fit the shift shaft position switch to the transmission
housing, and fit the shift shaft stop pin.
10. Fix the shift shaft and shift fork to the TPT00165.
11. Fit the transmission housing into the shift shaft and
shift fork, fit it in place by corresponding to relevant
position, and fix the TPT00165 to the transmission
housing by 3 bolts.
Caution: Before fitting the transmission housing,

please adjust the position of rear ball bearing
cover plate of input shaft to align the threaded
hole in the rear ball bearing cover plate of input
shaft with the threaded hole in the transmission
housing.
12. Fit the TPT00188.
13. Fit 3 bolts of the rear ball bearing cover plate of the
input shaft to the transmission housing, tighten the
torque to 7.5–10.5Nm, and check the torque.
14. Use the TPT00165 as the handle, fit the TPT00188
to the work bench together with the transmission.
15. Remove the TPT00165.
16. Fix the automatic transmission output shaft sensor
to the transmission housing, fit 1 bolt, tighten to
7.5–10.5Nm and check the torque. 26. Fit 1/2/6/7 gear intermediate shaft oil nozzle to the
17. Fix the parking actuator support to the transmission clutch housing with the TPT00198, TPT00191.
housing, fit 1 bolt, tighten to 7.5–10.5Nm, and check
the torque.
18. Fit 2 parking lever pins and conduit.
19. Fit the parking lever, and fit the pawl shaft, pawl and
reset spring.
20. Fix the parking pawl support assembly to the
transmission housing, fit 2 bolts, tighten them to
21. Fit the transmission internal harness assembly to
1.0 571
27. Fit 1/2/6/7 gear main bearing outer race to the clutch 30. Fix the clutch housing side oil groove to the clutch
housing with the TPT00198, TPT00181. housing, fit 1 bolt, tighten to 7.5–10.5Nm, and check
the torque.
31. Fit the TPT00201 to the transmission housing.
28. Fit 3/4/5/R gear intermediate shaft oil nozzle to the

clutch housing with the TPT00198, TPT00190.
32. Fit the magnetic steel to a relevant position on the
33. Fit a new gasket, fix the clutch housing to the
transmission housing, fit 18 bolts, tighten to 35–40Nm,
34. Fix the front ball bearing cover plate of the input
shaft to the clutch housing, fit 5 new bolts, tighten to
Caution: Before fitting the clutch housing, please
adjust the position of the front ball bearing cover
plate of the input shaft to align the threaded hole
in the front ball bearing cover plate of the input
29. Fit 3/4/5/R gear main bearing outer race to the clutch shaft with the threaded hole in the clutch housing.
housing with the TPT00198, TPT00179. 35. Fit the clutch actuator cylinder assembly.
Clutch Actuator Cylinder Assembly Refit
Assembly Refit
Assembly Refit
1.0 572
246R Input Shaft Oil Seal
Remove
assembly.

Assembly Remove
2. Remove the clutch retainer ring, and remove the direct
gear clutch hub.
3. Remove the residual grease on the direct gear clutch

hub spline, apply a thin layer of new grease, and fit the
direct gear clutch hub to the clutch assembly.
Grease Grade Volume
4. Fit the clutch retainer ring.

3. Remove 246R input shaft oil seal with the extractor of Dry Dual Clutch Automatic Transmission
the special tool TPT00166, and discard it. Assembly Refit
Refit
1. Fit the steering tool of the special tool TPT00166 to
1357 input shaft.
2. Fit a new 246R input shaft oil seal to 246R input shaft
through the steering tool with the installer of the
1.0 573
Input Shaft Assembly Disassembly

Remove
1. Disassemble the dual clutch automatic transmission.
Dual Clutch Automatic Transmission Disassembly

2. Remove 246R input shaft assembly from 1357 input
shaft assembly.
Refit
1. Fit 246R input shaft front ball bearing cover plate to
246R input shaft with the special tool TPT00170 .
3. Remove the needle bearing from 1357 input shaft

assembly.
4. Fix 1357 input shaft assembly to the bench clamp, and
remove the bolts from the input shaft.
5. Remove 1357 input shaft bearing with the bearing
extractor.
2. Measure the clearance (a) between 246R input shaft

front ball bearing cover plate and circlip slot, choose
a new circlip, then refit it.
Measured Circlip Circlip Grade
Dimensions (a) Thickness
2.04-2.059 2.00-2.02 R1
2.06-2.079 2.02-2.04 R2
2.08-2.099 2.04-2.06 R3
2.10-2.119 2.06-2.08 R4
6. Remove the snap ring, and remove 246R input shaft
bearing with the bearing extractor. 2.12-2.139 2.08-2.10 R5
2.14-2.159 2.10-2.12 R6
2.16-2.179 2.12-2.14 R7
2.18-2.199 2.14-2.16 R8
2.20-2.22 2.16-2.18 R9
1.0 574
1267 Output Shaft Assembly
Remove
1. Dismantle the dry dual clutch automatic transmission.

Dismantling
2. Remove 1267 output shaft bearing with bearing
remover.
3. Fix 1357 input shaft assembly to the vise, and fit 1357
input shaft rear ball bearing cover plate to 1357 input
shaft assembly with the special tool TPT00171.
4. Fit 1 bolt, tighten to 40–50Nm, check the torque, and
remove 1357 input shaft assembly.
5. Fit 3 needle bearings on 1357 input shaft.
6. Fit 246R input shaft assembly to 1357 input shaft
assembly. Refit
7. Assemble the dual clutch automatic transmission. 1. Fit 1267 output shaft bearing to 1267 output shaft
Dual Clutch Automatic Transmission Assembly assembly with the special tool TPT00171.
1.0 575
345R Output Shaft Assembly Differential Assembly

Remove Remove
1. Dismantle the dry dual clutch automatic transmission. 1. Dismantle the dry dual clutch automatic transmission.
Dry Dual Clutch Automatic Transmission Dry Dual Clutch Automatic Transmission
Dismantling Dismantling
2. Remove 345R output shaft bearing with bearing 2. Remove the right differential bearing with the bearing
remover. extractor.
Refit 3. Remove the outer ring of the left differential bearing

1. Fit 345R output shaft bearing onto 345R output shaft with the special tool TPT00186.
assembly with special tool TPT00173.
Refit
2. Fit the dry dual clutch automatic transmission. 1. Fit the differential left bearing outer race to the
differential with the special tool TPT00175.
2. Fit the differential right bearing to the differential with
1.0 576
the special tool TPT00176 (2WD) or TPT00222
(AWD).
Measuring Method
1. Clean the special tool, the connecting surface of clutch
housing and transmission case， bearing cups and so on.
2. Place the bearing cups removing from the clutch housing
separately on the 345R output shaft bearing, 1267 output
shaft bearing and differential shaft bearing.
3. Install two guide pins （14–13）into a transmission case
threaded hole approximately 180 degrees apart.
4. Place the shim selection gauges (14–10、14–11、14–12)
on the bearing cups.
5. Install a new gasket and the clutch housing through two
guide pins on the transmission case.
Caution: When the clutch housing is close to the

transmission case, align the upper tubes of shim
selection gauges to the bearing cup bases in the
Dry Dual Clutch Automatic Transmission Refit clutch housing.
Transmission Bearing Adjustive Shims Selection
Description
After the transmission is torn down , re-selection of
corresponding bearing adjustive shims is required to provide
appropriate preload if the transmission case , clutch housing,
1267 output shaft assembly, 345R output shaft assembly,
differential assembly, output shaft bearing or bearing cup,
differential bearing or bearing cup is replaced.
Special Tools
The tool for transmission bearing adjustive shims selection is
TPT00227，including totally 14 sub-tools. 14–1 to 14–9 are
spacer bolts with washers; 14–10 is shim selection gauge for
1267 output shaft bearing; 14–11 is shim selection gauge for 6. Install the spacers (14–1 to 14–9) evenly around the
345R output shaft bearing; 14–12 is shim selection gauge for clutch housing at every other bolt hole. Tighten the bolts
differential shaft bearing（available for both FWD and AWD in sequence to 30 Nm. Remove the guide pins.
transmissions ); 14–13 are two guide pins; 14–14 is a feeler
gauge.
spacers，
Caution: When installing the spacers ，the gasket is
placed on the clutch housing side.
7. Shift the forks into an even gear. Rotate the outer input
shaft to rotate the differential assembly 10 revolutions to
allow the bearings to seat into the cups.
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Caution: If the bearings are not properly seated Shim Shim Thickness
into the bearing cups, the shim selection will be Identification mm inch
inaccurate and the bearing pre-load will be set too Code
low. Low bearing pre-load will cause damage to the
U1 0.443 0.0174
transmission.
U2 0.494 0.0194
8. Place the feeler gauge (14–14) in the gap to determine
the proper shim. Continue trying different sizes of feeler U3 0.545 0.0215
gauge until the gauge will no longer fit into the gap. U4 0.596 0.0235
Record the largest blade gauge that fits into the gap. The
U5 0.647 0.0255
gap may not be even. Rotate the top of the gauge to even
out the gap. Take two gap measurements 180 degrees U6 0.698 0.0275
apart and average the two measurements U7 0.749 0.0295
9. Select the shim that is closest to the average as the
U8 0.800 0.0315
following tables.
U9 0.851 0.0335
1267 output shaft bearing shim
U10 0.902 0.0355
Shim Shim Thickness
U11 0.953 0.0375
Identification mm inch
Code U12 1.004 0.0395
L1 0.443 0.0174 U13 1.055 0.0415
L2 0.494 0.0194 U14 1.106 0.0435
L3 0.545 0.0215 U15 1.157 0.0456
L4 0.596 0.0235 U16 1.208 0.0476
L5 0.647 0.0255 U17 1.259 0.0496
L6 0.698 0.0275 U18 1.310 0.0516
L7 0.749 0.0295 U19 1.361 0.0536
L8 0.800 0.0315 U20 1.412 0.0556
L9 0.851 0.0335 U21 1.463 0.0576
L10 0.902 0.0355 Differential shaft bearing shim

L11 0.953 0.0375
Shim Shim Thickness
L12 1.004 0.0395 Identification mm inch
L13 1.055 0.0415 Code
L14 1.106 0.0435 D1 0.443 0.0174
L15 1.157 0.0456 D2 0.494 0.0194
L16 1.208 0.0476 D3 0.545 0.0215
L17 1.259 0.0496 D4 0.596 0.0235
L18 1.310 0.0516 D5 0.647 0.0255
L19 1.361 0.0536 D6 0.698 0.0275
L20 1.412 0.0556 D7 0.749 0.0295
L21 1.463 0.0576 D8 0.800 0.0315
D9 0.851 0.0335
345R output shaft bearing shim
D10 0.902 0.0355
D11 0.953 0.0375
1.0 578
Shim Shim Thickness
Identification mm inch
Code
D12 1.004 0.0395
D13 1.055 0.0415
D14 1.106 0.0435
D15 1.157 0.0456
D16 1.208 0.0476
D17 1.259 0.0496
D18 1.310 0.0516
D19 1.361 0.0536
10. Remove the spaces，bolts and washers.

11. Remove the clutch housing.
12. Remove the shim selection gauges.
Caution: The shim selection gauges may stick in the

clutch housing. Be careful not to drop the gauges.
13. Take off the bearing cups.
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Transmission Failure Diagnosis • No Symptom Found or Detected

Transmission Symptom Diagnosis 1. Dry Dual Clutch ATF Check
Note: Symptom table is used under the following conditions: Dry Dual Clutch ATF Check
2. Road Test
1. The scan tool can connect TCM normally;
Road Test
2. No DTC of TCM is detected;
3. Be familiar with the structure, principle and working Note: Road test is conducted only as a part of symptom
mode of the dry dual clutch automatic transmission. diagnosis.
For more information, please refer to "Description and Perform the road test and symptom diagnosis cooperatively.
Operation". Refer to "Symptom List".
The following test provides the method to test automatic
Appearance/Physical Inspection transmission state. The test can realize most driving
Check the accessible or visible system components for any conditions. The test is divided into the following several parts:
obvious damages or failures which may lead to such symptom.
1. Electrical Function Test
Intermittent failure
2. Upshift Control and Dual Clutch Engagement State
Electrical connection or harness failure may lead to 3. Some downshift actions when the accelerator is
intermittent failure. depressed
Symptom List 4. Manual Downshift
When diagnosing symptom, please refer to the following 5. Downshift by Coasting
diagnostic procedures: 6. Manual Shift Range Selection
• Fluid Diagnosis a. R Gear
1. Dry Dual Clutch ATF Check
b. Driver Shift Control
Dry Dual Clutch ATF Check
2. Fluid Leak Diagnosis Note: Complete the test in the order as shown. If the test is
not completed, correct assessment can not be made.
• Noise and Vibration Diagnosis
1. Low-speed Vibration Before the road test, each of the following items shall be
ensured:
2. Steering Noise
1. Engine is running normally
3. Clunk for Acceleration/Deceleration
2. Transmission fluid level is OK
4. "Click" During Steering
Dry dual clutch automatic transmission fluid
5. Neutral Noise for Engine Operation check
6. Noise in 1st Gear Only 3. Tyre pressure normal
7. Noise in 2nd Gear Only
During road test:
8. Noise in 3rd Gear Only
1. Conduct road test when road conditions allow
9. Noise in 4th Gear Only
2. Run the vehicle under controllable safety condition
3. Comply with all traffic rules
4. Check the scan tool parameter when conducting the test
5. Pay attention to the abnormal sound or smell
13. Noise in R Gear Only
6. The minimum transmission fluid temperature shall be
14. Noise in 4th/6th Gear
90℃.
15. Noise in 5th/7th Gear
Upon the road test, check the following items:
16. Noise in All Gears
• Shift Quality Diagnosis 1. Check if the transmission fluid level is proper.
Dry dual clutch automatic transmission fluid
1. Gear Slide
check
2. Gear Slide during Acceleration
2. Check for DTC generated during the road test. Refer to
3. Gear Slide during Coasting DTC troubleshooting manual for details.
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3. Check the scan tool for abnormal reading or parameter. the shift quality improves. If it does not improve,
4. Check for fluid leak. Please refer to "Fluid Leak refer to "Unsmooth Garage Shift"
Diagnosis". Shift delay may be caused by the following reasons:
Electrical Function Test a. Low engine idle speed - compare the actual engine
Conduct the procedure, make sure if the electronic idle speed and target idle speed;
components of transmission can perform normally. If such b. Transmission fluid level too low;
component is not checked, simple electrical failure will also
c. Transmission fluid temperature too low - read the
be diagnosed incorrectly.
real-time display parameter "Transmission Fluid
1. Connect the scan tool VDS; Temperature" with VDS;
2. Place the shift lever in P gear, and enable the EPB; d. Gear shift mechanism - if necessary, check and adjust
3. Start the engine; gear shift mechanism and cable;
4. Make sure the real-time display parameter can be Gear Cable - DCT 250 - Refit
obtained through VDS and can be displayed normally, and e. Unfinished or incorrect quick self-learning - perform
pay attention to the suspicious parameters: quick self-learning operation again, and observe if
a. Engine Speed the shift delay improves. If it does not improve, refer
to "1\R Gear Unsmooth Shift"
b. Odd Clutch Slipping Friction
6. Check the gear information in the real-time display
c. Even Clutch Slipping Friction
parameters from VDS.
d. Speed (in ABS Controller)
a. Depress the brake pedal, and enable electronic
e. Internal mode switch mode "A\B\C\P\S" position parking system;
sensor state
b. Shift the gear in the following order:
f. Transmission target gear P→R→N→D→R→D, and stop for 2 to 3s
g. General transmit speed ratio of transmission in each gear.
h. Brake pedal switch c. Stop the gear shift lever in "P" gear;
i. Engine coolant temperature d. Make sure the selected gear is same as the gear
displayed on the scan tool.
j. Transmission fluid temperature
7. Check the throttle position input information.
k. Ignition Voltage
5. Check the garage shift operation a. Depress the brake pedal, and enable electronic
parking system;
a. Depress the brake pedal, and enable electronic
parking system; b. Make sure the gear shift lever is in "P" gear;
b. Shift the gear in the following order: c. Depress or release the accelerator pedal to increase
P→R→N→D→R→D, and stop for 2 to 3s or decrease the engine speed, observe the "Throttle
in each gear. Position" parameter on the real-time display of the
scan tool VDS, and the value (percentage) shall
c. Check if the gear engages quickly (if the transmission
increase or decrease with the engine speed.
fluid temperature is higher than 20℃, the
transmission does not run sharply, and the gear If any one of the above tests is abnormal, after the road
engagement time is less than 2s). Note: Gear test, record the relevant test result for reference.
engagement is hardly felt in some cases. Upshift Control
The sharp gear engagement may be caused by the TCM calculates the upshift point based on two inputs: throttle
following reasons: position and speed. When TCM makes sure that the shift
a. High engine idle speed - compare the actual engine conditions are met, TCM controls the clutch action and shift
idle speed and target idle speed; fork position by transferring the current to the corresponding
solenoid valve, so as to realize gear shift process.
b. Some failure caused by DTCs leads to maximum
pipe pressure, and it prevent the clutch from sliding. Operate the following steps:
c. Unfinished or incorrect quick self-learning - perform 1. Check the following real-time parameters on the scan
quick self-learning operation again, and observe if tool:
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a. Engine speed 3. Release accelerator pedal and depress the brake pedal;
b. Speed 4. Monitor the real-time "General transmit speed ratio of
transmission" parameter on the scan tool, the parameter
c. Odd clutch slipping friction
will change after the "Target Gear" changes, and make
d. Even clutch slipping friction sure the downshift is normal.
e. Transmission target gear Manual Shift Range Selection
f. Internal mode switch mode "A\B\C\P\S" position R Gear
sensor state Perform the following test:
g. Brake pedal switch 1. Park the vehicle, and place the shift lever in R gear;
h. Engine coolant temperature 2. Accelerate the vehicle slowly, and keep the accelerator
i. Transmission fluid temperature pedal in 10%-15%;
2. Shift the shift lever to D gear. 3. Make sure if there is obvious skid, noise or vibration.
3. Depress the accelerator pedal to 15–20% and hold, so Driver Shift Control
as to accelerate the vehicle. Keep the accelerator pedal For the specific description related to driver shift control, refer
position steady. to User Manual. The driver shift control is used to enable the
4. Pay attention to any unsmooth, weak or slip shift, and transmission to make right response to the driver's instruction.
any noise or vibration. When the engine speed reaches to the maximum, TCM can
Shift down when accelerator is depressed shift up automatically, and prevent any downshift operation
which can lead to high engine speed.
1. Shift the shift lever to D gear;
2. Accelerate the vehicle by depressing the accelerator
pedal (5–15%) slightly, until it is shifted to the 3rd gear.
3. Depress the accelerator pedal quickly until the target
gear is displayed as the 2nd gear.
4. Make sure the transmission can shift down within 2s
when the accelerator pedal acts;
5. Repeat steps 2-4 when the speed is high, shift up to the
4th gear, depress the accelerator pedal and then shift
down to the 3rd gear.
down to the 4th gear.
9. Pay attention to any unsmooth, weak or slip shift, and
any noise or vibration.
Manual Downshift
Manual downshift test is not required. The vehicle is provided

with driver shift control system, and TCM can control the
transmission downshift automatically to prevent transmission
damage.
Downshift by Coasting
1. Place the shift lever in P gear;
2. Accelerate the vehicle to the 7th gear;
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Fluid Leak Diagnosis
Symptom Possible causes Correction

Fluid leak High fluid level Drain extra fluid
Axle shaft oil seal damaged Check the axle shaft oil seal, and replace when necessary.
Transmission vent plug blocked Check the vent plug and replace it when necessary.
The junction surface between the transmission Check the gasket between the transmission housing and
housing and clutch housing is poorly sealed or clutch housing, and replace it when necessary.
loose.
Low-speed vibration

Low-speed Drive shaft joint worn Check the drive shaft joint, and replace it when necessary.
vibration Differential gear worn Check the differential assembly, and replace the
differential assembly when necessary.
Steering noise

Steering noise Wheel bearing worn Check the front wheel bearing, and replace it when
necessary.
Differential gear worn Check the differential gear, and replace the differential
assembly when necessary.
Clunk for acceleration/deceleration

Clunk for Engine bracket loose Check the engine bracket, and tighten it when necessary.
acceleration Drive shaft joint spline worn Check the inside drive shaft joint, and replace it when
/deceleration necessary.
Differential side gear shaft spline worn Check the differential side gear shaft, and replace the
differential assembly when necessary.
"Click" during steering

"Click" Drive shaft outer ball joint worn Check the drive shaft ball joint, and replace it when
during necessary.
steering
Neutral noise for engine operation

Neutral noise The bolt from double mass flywheel (DMF) to the Check the tangent torque of the bolt from double mass
for engine clutch loose flywheel to the clutch
operation Double mass flywheel (DMF) centre bearing worn Check the bearing, and replace it when necessary.
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Noise in 1st gear only

Noise in 1st Wear, gap or scratch found in 1st gear constant Check the gear, and replace it when necessary.
gear only mesh gear
Wear, gap or scratch found in 1st/7th gear Check the gear synchronizer, and replace 1/2/6/7 output
synchronizer shaft assembly when necessary.
Noise in 2nd gear only

Noise in 2nd Wear, gap or scratch found in 2nd gear constant Check the gear, and replace it when necessary.
gear only mesh gear
Wear, gap or scratch found in 2nd/6th gear Check the gear synchronizer, and replace 1/2/6/7 output
Noise in 3rd gear only

Noise in 3rd Wear, gap or scratch found in 3rd gear constant Check the gear, and replace it when necessary.
gear only mesh gear
Wear, gap or scratch found in 3rd/5th gear Check the gear synchronizer, and replace 3/4/5/R output
Noise in 4th gear only

Noise in 4th Wear, gap or scratch found in 4th gear constant Check the gear, and replace it when necessary.
gear only mesh gear
Wear, gap or scratch found in 4th/R gear Check the gear synchronizer, and replace 3/4/5/R output

gear only mesh gear
Wear, gap or scratch found in 3rd/5th gear Check the gear synchronizer, and replace 3/4/5/R output

Noise in 6th Wear, gap or scratch found in 6th constant mesh Check the gear, and replace it when necessary.
gear only gear
Wear, gap or scratch found in 2nd/6th gear Check the gear synchronizer, and replace 1/2/6/7 output
1.0 584

gear only mesh gear
Wear, gap or scratch found in 1st/7th gear Check the gear synchronizer, and replace 1/2/6/7 output
Noise in R gear only

Noise in R Wear, gap or scratch found in R gear constant Check the gear, and replace 1/2/6/7 output shaft assembly
gear only mesh gear or 3/4/5/R output shaft assembly when necessary.
Wear, gap or scratch found in 4th/R gear Check the gear synchronizer, and replace 3/4/5/R output
Noise in 4th and 6th gear

Noise in Input shaft gear worn or damaged Check if the gear and bearing of the even input shaft is
4th/6th Gear damaged, and replace them if necessary.
Noise in 5th and 7th gear

Noise in Input shaft gear worn or damaged Check is the gear and bearing of odd input shaft is
5th/7th Gear damaged, and replace them if necessary.
Noise in all gears

Noise in all Low fluid level Add appropriate fluid.
gears Wheel bearing worn or damaged Check the wheel bearing, and replace it when necessary.
Shift sliding rail guide bearing loose Check the shift sliding rail guide bearing.
Wear, gap or scratch found in Check the components, and replace the components if
1st/2nd/3rd/4th/5th/6th/7th/R gear necessary.
Differential assembly is worn, and with gap and Check the differential assembly, and replace the
scratch. differential assembly when necessary.
Taper ball bearing is worn or scratched. Check if the ball bearing is scratched or dent is found, and
replace it when necessary.
Gear slide

Gear slide Transmission mount loose Tighten or replace the transmission mount.
Worn or bent shifting fork Check the shifting fork, and replace it when necessary.
Transmission internal gear shift mechanism failure Remove the transmission, and repair it when necessary.
1.0 585
Gear slide during acceleration

Gear slide Gear 1 spline lock on 1st/7th gear synchronizer Check the spline lock, and replace it if necessary.
during canine tooth worn or damaged
acceleration Gear 7 spline lock on 1st/7th gear synchronizer Check the spline lock, and replace it if necessary.
canine tooth worn or damaged
Gear 2 spline lock on 2nd/6th gear synchronizer Check the spline lock, and replace it if necessary.
Gear 6 spline lock on 2nd/6th gear synchronizer Check the spline lock, and replace it if necessary.
Gear 3 spline lock on 3rd/5th gear synchronizer Check the spline lock, and replace it if necessary.
Gear 5 spline lock on 3rd/5th gear synchronizer Check the spline lock, and replace it if necessary.
Gear 4 spline lock on 4th/R gear synchronizer Check the spline lock, and replace it if necessary.
Gear R spline lock on 4th/R gear synchronizer Check the spline lock, and replace it if necessary.
1st/2nd/3rd/4th/5th/6th/7th/R gear spline lock Check the spline lock, and replace it if necessary.
worn or damaged
Transmission internal gear shift mechanism failure Remove the transmission, and repair it when necessary.
Gear Slide during Coasting

Gear Slide Fork sliding rail worn, damaged or missing Check the fork sliding rail, and replace it when necessary.
during Transmission internal gear shift mechanism failure Remove the transmission, and repair it when necessary.
Coasting
Unsmooth Garage Shift

Unsmooth Clutch position sensor (CPS) reading abnormal Replace clutch actuator cylinder assembly
Garage Shift 2/4/6/R even input shaft idle speed greater than Check the dual clutch assembly, and replace it when
250RPM necessary
1. Clutch middle plate bearing drags, and hot
clutch may lead to such condition.
2. The even clutch driven plate deforms because
of overheating, and it leads to drag
1/3/5/7 odd input shaft idle speed greater than Check the 1/3/5/7 odd input shaft, double mass flywheel,
250RPM dual clutch assembly, and replace them when necessary
1. Double mass flywheel needle bearing drags,
and such condition may occur after the
bearing damage.
2. The odd clutch driven plate deforms because
of overheating, and it leads to drag
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Number
Shift Fork
Transmission TPT00201 Neutral
TPT00059 fluid fill Alignment Plate
equipment
Dual Clutch
TPT00199 Assembly
Engine lift Remover/Installer
T10007
bracket
Transmission
TPT00188
Holding Fixture
Manual Shift
Powerpack TPT00167 Shaft Seal
TPT00203 Installing Remover/Installer
Guided Pins
Clutch Housing
Powerpack TPT00195
Seal Remover
TPT00200 Actuator Piston
Neutral Gauge
1.0 587
Tool Description Picture Tool Description Picture

Number Number
Transmission
Clutch Housing Gearset
TPT00168 TPT00165
Seal Installer Assembly
Fixture
Manual Shift
Oil Seal Installer
TPT00198 TPT00189 Shaft Fixing Pin
Handlebar
Remover/Installer
345R Output
Driving Shaft
TPT00169 TPT00183 Shaft Bearing
Seal Installer
Cup Remover
1267 Output
Pressure cap Shaft left
TPT00225 TPT00184
test tool Bearing Cup
Remover
Driving 1267 Output

Shaft Seal Shaft Right
TPT00204 TPT00185
Installer-PTU Bearing Cup
side-AWD Remover
1.0 588
Number Number
Right
345R Output
Differential
TPT00187 TPT00190 Shaft Oil Dam
Bearing Cup
Installer
Remover
Right
345R Output
Differential
TPT00224 TPT00179 Shaft Bearing
Bearing Cup
Cup Installer
Remover-AWD
1267
Output Shaft
Left Differential
TPT00192 Transmission TPT00178
Bearing Installer
Case Side Oil
Dam Installer
1267 Output Right

Shaft Left Differential
TPT00180 TPT00182
Bearing Cup Bearing Cup
Installer Installer
1267 Output
Shaft Clutch Right
Housing Side Differential
TPT00191 TPT00223
Oil Dam and Bearing Cup
Input Shaft Oil Installer-AWD
Dam Installer
1.0 589

Number Number
1267 Output
Left Differential
Shaft Right
TPT00181 TPT00186 Bearing Cup
Bearing Cup
Remover
Installer
Even Input Left Differential

TPT00166 Shaft Seal TPT00175 Bearing Cup
Remover/Installer Installer
Even Input Shaft Right

TPT00170 Right Retainer TPT00176 Differential
Installer Bearing Installer
Odd Input Shaft

Left Retainer Right
and 1267 Differential
TPT00171 TPT00222
Output Shaft Bearing
Right Bearing Installer-AWD
Installe
345R Output
Thrust Washer
TPT00173 Shaft Bearing TPT00227
Selection Gauge
Installer
1.0 590
Transmission-6MT Transmission
Transmission-6MT
Specifications
Torque
Description Value
Bolt - transmission bracket to transmission 90–110Nm
Bolt - release bearing 23–27Nm
Bolt - gear shift lever cover to transmission housing 25–30Nm
Drain plug 30–40Nm
Filler plug 30–40Nm
Reverse lamp switch 23–27Nm
Bolt - transmission housing 23–27Nm
Bolt - final drive gear 90–100Nm
Plug 30–40Nm
Bolt - release bearing 10–14Nm
Interlock pin 15–20Nm
Bolt - gear selection/shift bracket 19–25Nm
Bolt - reverse idler gear shaft to transmission bottom housing 23–27Nm
Bolt - reverse idler gear shaft to transmission side housing 33–37Nm
Bolt - neutral position sensor 8–12Nm
1.0 591
Transmission Transmission-6MT
Parameter
SCM250 6-speed Manual Transmission
Model:
Matched with 1.5T Engine
Speed ratio:
·1st Gear 4.385
·2nd Gear 2.348
·3rd Gear 1.351
·4th Gear 1.049
·5th Gear 0.946
·6th Gear 0.756
·Reverse Gear 3.72
·Main Reduction 3.632/4.059

Transmission Center Distance 79/95mm
Maximum input torque 250（1st215）Nm
Maximum input speed 6800rpm
Mass (without oil) 48Kg
Lubricating Oil MTF 94
Transmission Standard Oil Capacity:
·Drain and Refill 2.2L
·Refill in Dry State 2.5 L

Maximum Transmission Boundary Dimension
·Length 349.6mm
·Width 512.6mm
·Height 406.8mm
Locking bolt
Spring Pin
Shift fork shaft bushing 15x15
Input shaft oil seal
Cone Bearing
Differential half axle oil seal
Oil deflector
List of Disposable Assembly Parts:
Driven Shaft Front Bearing
Gear selection/shift shaft needle bearing
Spring pin (5x26)
Gear selection/shift shaft oil seal
Gear selection/shift shaft bushing
Circlip
Gear selection/shift shaft linear bearing
1.0 592
Gear shift control pin
Oil plug washer
1.0 593

System Layout
Transmission Assembly Layout
1. Flange Bolt 2. Closing Panel
1.0 594
Transmission Assembly and Accessories
1. Bolt - Gear Selection/Shift Bracket 8. Locating Pin

2. Gear Selection/Shift Bracket 9. Reverse Lamp Switch/Interlock Pin Washer
3. Oil Level Plug Washer 10. Reverse Lamp Switch
4. Oil Level Plug 11. Interlock Pin
5. Oil Plug 12. Oil Plug Washer
6. Neutral Position Sensor 13. Transmission Assembly
7. Bolt - neutral position sensor
1.0 595
Transmission Gear Shift Operating Mechanism and

Housing
1. Gear Shift Rocker Arm Welding Assembly 20. 1st/2nd Gear Fork
2. Spring Pin 21. Shift Fork Shaft 1
3. Gear Selection/Shift Shaft Oil Seal 22. 5th/6th gear fork
4. Gear Selection/Shift Shaft Sleeve 23. Reverse Gear Fork
5. Gear Shift Cover 24. Shift Fork Shaft 2
6. Gear Selection Rocker Arm Assembly 25. 3rd/4th Gear Fork
7. Bolt 26. Locating Pin
8. Circlip 27. Ventilation cap
9. Gear Selection/Shift Shaft Linear Bearing 28. Clutch Housing
10. Gear Selection/Shift Shaft 29. Oil Nozzle
11. Gear Shift Control Pin 30. Input Shaft Oil Seal
12. Neutral Position Sensor Signal Block 31. Bolt
13. Gear Selection/Shift Sleeve 32. Magnetic Steel
14. Gear Selection Rocker Arm Shaft Sleeve 1 33. Transmission Main Case
15. Inner Gear Selection Rocker Arm Assembly 34. Bearing Cover
16. Gear Selection Rocker Arm Shaft Sleeve 2 35. Sealing Washer
17. Gear Shift Cover Locating Pin 36. Inner Hexagon Bolt
18. Shift Fork Shaft Bushing 37. Gear Selection/Shift Shaft Needle Bearing
19. Spring Pin
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Input Shaft Assembly
1. Input Shaft Front Bearing 3. Locking Bolt

2. Input Shaft Rear Bearing 4. Input Shaft Assembly
1.0 597
Output Shaft 1 Assembly
1. Output Shaft 1 7. 5th Gear Needle Bearing and Inner Ring

2. 1st Gear Needle Bearing and Inner Ring 8. Output Shaft 5th Gear Assembly
3. Output Shaft 1st Gear Assembly 9. 5th/6th Gear Synchronizer Assembly
4. 1st/2nd Gear Synchronizer Assembly 10. Output Shaft 6th Gear Assembly
5. 2nd Gear Needle Bearing and Inner Ring 11. 6th Gear Needle Bearing and Inner Ring
6. Output Shaft 2nd Gear Assembly 12. Output Shaft 1 Assembly
1.0 598
Output Shaft 2 Assembly
1. Output Shaft 2 Front Bearing 7. Output Shaft 3rd Gear Assembly

2. Output Shaft 2 8. 3rd/4th Gear Synchronizer Assembly
3. Reverse Gear Needle Bearing 9. Output Shaft 4th Gear Assembly
4. Output Shaft Reverse Gear Assembly 10. 4th Gear Needle Bearing And Inner Ring
5. Reverse Gear Synchronizer Assembly 11. Output Shaft 2 Assembly
6. 3rd Gear Needle Bearing And Inner Ring
1.0 599
Reverse Idler Gear Shaft Assembly
1. Thrust Bearing 5. Reverse Idler Shaft

2. Reverse Idler Gasket 6. Inner Hexagon Flat Head Bolt
3. Reverse Idler Needle Bearing 7. Bolt
4. Reverse Idler
1.0 600
Differential Assembly
1. Differential Axle Shaft Oil Seal 8. Planetary Shaft

2. Cone Bearing 9. Spring Pin
3. Adjusting Washer 10. Axle Shaft Gear Gasket
4. Main Reduction Gear 11. Axle Shaft Shaft Gear
5. Differential Housing 12. Bolt
6. Planetary Gear Gasket 13. Differential Assembly
7. Planetary Gear
1.0 601
Description set pin will lock the radial motion of the sleeve through sleeve
Overview groove.
This vehicle is equipped with a 6-speed manual transmission. Reverse Gear Switch
The shift lever is located at the center console of the The reverse lamp plunger switch is fitted on the transmission
passenger compartment, it provides the driver with 7 choices rear housing.
for variable speed position, namely, 1st gear, 2nd gear, 3rd *
Neutral Position Sensor
gear, 4th gear, 5th gear, 6th gear and reverse gear. The gears
of all positions are engaged by the synchronizer. The drive
shaft is fitted in the differential assembly at the rear of the
transmission, and it is used to transmit the driving force to the
wheel. The transmission housing is made of cast aluminum,
and is connected to the engine cylinder block with bolts. The
transmission input shaft and output shaft are supported by
bearings. The transmission clutch case is equipped with an oil
filler plug, and there is an oil drain plug at the lower rear side
of the transmission main housing, both of them are sealed
with an aluminum washer. The transmission is filled with
lubricating oil so as to lubricate the internal components in a
splashing manner.
Gear Shift and Gear Selection For the vehicle equipped with intelligent Stop/Start fuel saving
system function, the neutral position sensor is fixed on the
Gear selection is realized by manipulating the shift lever fitted
control seat of the transmission, and identifies whether the
at the center console of the passenger compartment. Both
transmission is in neutral position by detecting the gear
cables have one end connected to the bottom of the shift
selection/shift shaft position in a non-touch manner. With the
lever, and the other end connected to the gear selection
neutral position as the centre, the area within 8° range both
rocker arm and gear shift rocker arm fitted outside the
left and right sides is defined as the neutral area, and the area
transmission through the connector ring assembly. In the
outside this range will be considered as non-neutral area.
transmission case,the fork shaft is connected with the fork,
turn an appropriate synchronizer to shift to the forward gear The operating temperature of the sensor is: -40~140℃.
or the reverse gear. Sensor Harness End Connector EB076
Interlock Mechanism
Definition of Sensor PINs
1: Power (12V)
2: N1 (neutral signal 1)
1. Reverse Lamp Switch
2. Interlock pin 3: N2 (neutral signal 2)
3. Locating pin 4: Ground
4. Pocket Differential
The interlock pin cooperates with the set pin to restrict the Differential with traditional design fixed the driven gear of main
sleeve motion. When a gear is selected, the sleeve position is reducing gear to differential housing with bolts, differential
restricted by the interlock pin in the axial direction, and the housing supports the planetary shaft pin, planetary gear and
1.0 602
sun gear. The differential assembly is supported by bearings in
the transmission housing.
1.0 603
Operation of other forward gears are the same as that of the 1st gear.
Transmission Assembly When the shift lever is moved to reverse gear position, the
reverse gear wheel is engaged with the reverse idler gear to
Drivetrain changes the speed and direction of rotation through
change the rotation direction of the output shaft.
the engagement between different gears of the input shaft and
Neutral Position Sensor *
output shaft, thereby generating 7 forward gears of different
speed ratio and 1 reverse gear. The gear wheels of all other The neutral signal adopts independent 2-way redundancy
gears are constantly engaged. If the 1st gear is selected, design, to guarantee the safety and reliability of the output
the synchronizer gear ring is pressed by the synchronizer signal (N1, N2). Through hardwires, the N1 signal is inputted
gear bushing so as to contact with the conical ring of the to BCMand the N2 signal to ECM. When the transmission is
corresponding gear selected. In this way, the speeds of both in neutral position, N1 is a low level signal (Lo), while N2 is a
synchronizer hub and gear are synchronized. Ensure that the high level one (Hi); and it is vice versa when the transmission
taper head on the gear selection/shift sleeve can select the is engaged at a gear other than neutral.
gear accurately and the gears are remained in the correct
High level is an approximate value that battery voltage
work position. After being transmitted from the engine to
subtracts 2V, and low level is about 0~1.5V.
the transmission input shaft through the clutch,the torque is
transmitted to the output shaft pinion and main reduction N1 N2
driven gear and then to the drive shaft through the selected N gear Lo Hi
gear. The operation of the 2nd, 3rd, 4th, 5th, 6th and reverse Gear other than
gears is the same with that of the 1st gear. When the reverse Hi Lo
Neutral
gear is selected, the reverse gear tooth (integrated with the
input shaft) is engaged with the output shaft reverse gear ECMECMalso monitors some faults of neutral position
tooth and reverse idler gear, hence, the rotation direction of sensor, it is supposed to confirm whether there are faults
the driven shaft is changed and the reverse gear is achieved. in sensor through the real-time display parameter "Error
Occurrence - Neutral Switch Sensor" on ECM, and meanwhile,
Gear Shift and Gear Selection
ECM may also set DTC P081D.
When the shift lever is moved to the 1st gear position, the
shift lever will control the gear selection/shift rocker arm Refer to Diagnosis Manual - Engine - Engine Fuel and Control
through the cable. The gear selection rocker arm rotates System - Diagnose Information and Procedure for details
and moves the gear selection/shift shaft through the torque Differential
of the cable, and the gear selection/shift taper head on the The differential allows the wheels to rotate at different speeds
gear selection/shift shaft moves along with it and locates at when the output torques are the same. The pinion integrated
the groove of the 1st/2nd shift fork, at this time, the gear with the output shaft is engaged with the final drive driven gear
selection/shift taper head shall be completely separated from of the differential assembly. When the output shaft rotates, and
the groove of 3rd/4th taper head. One end of the interlock the wheels swivel straight forward, the torque will be applied
pin will lock 1st/2nd gear. Then the gear shift rocker arm to the whole assembly, and the planetary gear does not rotate.
rotates the gear selection/shift shaft through the torque of the The torque is transmitted to the wheels through drive shaft.
cable, and the gear selection/shift sleeve rotates along with the When the vehicle takes a turn, the inner wheels will pass a
gear selection/shift shaft, one side of the gear selection/shift shorter distance at a lower speed. Thus it drives the planetary
taper head turns 1st/2nd gear taper block to drive the gear to rotate, and the outer sun gear offers a higher speed for
operation of 1st/2nd gear synchronizer so as to achieve the outer wheels.
gear selection/shift function of the 1st gear. The operations
1.0 604
Power Sequence
1. Differential Assembly 7. Input Shaft

2. Output Shaft 1st Gear Assembly 8. Output Shaft 2
3. Output Shaft 2nd Gear Assembly 9. Output Shaft 4th Gear Assembly
4. Output Shaft 5th Gear Assembly 10. Output Shaft 3rd Gear Assembly
5. Output Shaft 6th Gear Assembly 11. Output Shaft Reverse Gear Assembly
6. Output Shaft 1 12. Reverse Gear Assembly
1.0 605
1st gear
1.0 606
2nd gear
1.0 607
3rd gear
1.0 608
4th gear
1.0 609
5th gear
1.0 610
6th Gear
1.0 611
R Gear
1.0 612
Service Procedures
Manual Transmission Assembly
Remove

3. Remove the hose - turbocharged intercooler to throttle
body.

Body Remove
4. Disconnect the connector from the reverse lamp
switch. 8. Remove 2 bolts (1) fixing the catalytic converter
bracket to the catalytic converter.
9. Remove 1 bolt (2) fixing the catalytic converter bracket
to the transmission, and remove the catalytic converter
bracket.
5. Disconnect the neutral position sensor connector.
10. Disconnect the connection between central release

cylinder pipeline assembly and hose.
6. Loosen the cable ball joint (1) from the shift rocker arm
of the manual transmission.
7. Loosen the clip (2), and then remove the shift cable
from the cable bracket.
12. Remove 3 upper bolts connecting the engine and the

13. Remove 4 bolts between the upper transmission and
the engine.
14. Remove 2 bolts and 1 nut fixing the transmission
1.0 613
suspension to the transmission.
28. Remove 4 bolts fixing the lower tie rod mounting

bracket to the transmission, and remove the lower tie
15. Remove 4 bolts fixing the transmission suspension to
rod mounting bracket.
the body, and remove the transmission suspension.

18. Drain the manual transmission fluid.
Manual Transmission Fluid Drain


20. Remove the starter.
Starter Motor Remove Refit

21. Support the manual transmission with a jack. 1. Clean the mating surface between the engine and
the transmission, and ensure that there is no foreign
22. Remove 4 lower bolts connecting the engine and the
material.
2. Clean the locating pin on the engine and the locating
23. Support the bottom of the transmission with a bracket.
pin hole of the transmission.
24. Remove 3 bolts connecting the transmission to the
engine.
25. Move the transmission rightwards to disconnect it from
4. Fix the transmission mounting bracket to the
the engine.
transmission, fit 4 bolts, tighten to 90–110Nm and
26. Remove the transmission from the bracket. check the torque.
27. Remove 4 bolts securing the transmission mounting 5. Fix the transmission to the bracket.
bracket on the transmission, and remove the bracket.
6. With assistance, adjust the transmission and align the
locating pin on the engine with the locating pin hole
of the transmission.
Caution: For the angle between the flywheel plate
and the clutch, take care not to incur any collision
when assembling the transmission to the engine;
otherwise, it may cause functional fault in the
transmission!
7. After the mating surface between the engine and the
1.0 614
transmission completely fits, fit 4 bottom bolts, tighten Gear Shift Control Mechanism Assembly
to 49–67Nm, and check the torque. Remove
8. Remove the transmission bracket. 1. Remove the battery box bracket.
9. Fit the starter. Battery Box Bracket Remove
Starter Motor Refit 2. Ensure that the shift lever is in neutral position.
10. Fit the front subframe. 3. Loosen the cable ball joint (1) from the gear
selection/shift rocker arm of the manual transmission.
4. Loosen the clip (2), and then remove the gear
selection/shift cable from the cable bracket.
14. Fix the transmission suspension to the transmission,
fit 2 new bolts, tighten to 70Nm+90°, fit 1 nut and
washer, tighten to 70Nm+90°, and check the torque.
15. Fit 3 bolts between the upper transmission and the
engine, tighten to 49–67Nm and check the torque.
16. Remove the T10007.
17. Connect the central release cylinder pipeline assembly
and hose, and tighten bolts to 23–27Nm.
5. Remove the reverse lamp switch, set pin and interlock
18. Fix the catalytic converter bracket to the catalytic
pin.
converter, fit 2 nuts, tighten to 19–25Nm, and check
the torque. Transmission Accessories and Release Mechanism
Remove
19. Fix the catalytic converter bracket to the transmission,
fit 1 bolt, tighten to 49–67Nm and check the torque. 6. Remove the bolts fixing the gear selection/shift control
mechanism assembly to the case, and remove the
20. Locate the shift cable to the cable bracket and fix with
control mechanism assembly.
C-clip.
7. Knock out the coiled spring pin fixing the gear
21. Fit the shift cable ball joint to the shift rocker arm knob.
selection/shift shaft to the control cover with a
22. Connect the connector of the neutral position sensor. punching tool and discard, then remove the gear shift
23. Connect the reverse lamp switch connector and fix rocker arm.
the harness clip.
24. Fit the hose - turbocharged intercooler to throttle body

Body Refit
torque.
27. Refill the manual transmission fluid.

8. Pull the gear selection/shift shaft out of the control
cover, remove the gear selection/shift shaft oil seal at
the top of the control cover and discard.
9. Knock out the gear selection rocker arm pin in the
control cover with tools, discard it and separate the
1.0 615
external gear selection rocker arm shaft and the

external gear selection rocker arm.
3. Fit the gear selection/shift shaft oil seal into the shaft
hole at the top of the control cover with TPT00120.
10. Remove the gear selection rocker arm shaft oil seal in
the side of the control cover and discard.
11. Knock out the locating pin on the gear selection/shift
shaft sleeve with a punching tool, discard it and separate
the gear selection/shift shaft sleeve and the gear
selection/shift shaft.
Refit
1. Fit 2 linear bearings into the gear selection/shift shaft
sleeve with TPT00119.
4. Fit the gear selection rocker arm shaft oil seal into the
side rocker arm shaft hole of the control cover with
TPT00121.
2. Insert the gear selection/shift shaft into the gear

selection/shift shaft sleeve, and knock in the elastic pins
with TPT00136 for fixation.
5. Fit the gear selection rocker arm shaft and shaft sleeve
into the case, and the shaft end transmission case linear
bearing.
6. Fit the gear selection/shift shaft bushing (A) into the
gear selection/shift shaft hole of the control cover with
TPT00124; fit the rocker arm shaft outer curling
bushing (B) into the rocker arm shaft hole of the
control cover with TPT00122; fit the rocker arm shaft
1.0 616
inner curling bushing (C) into the rocker arm shaft hole Manual Transmission Fluid - Drain and Refill
of the control cover with TPT00131. Drain

2. Put a proper container under the transmission.
3. Clean the surrounding area of oil drain plug (2), remove
the oil drain plug and discard the sealing gasket.
7. Clean the mating surface of the control cover and the

rear case, and apply sealant evenly.
8. Fit the gear shift rocker arm and control cover into the
case and tighten the bolts to 25–30Nm.
9. Remove the reverse lamp switch, set pin and interlock
pin.
Transmission Accessory and Release Mechanism

4. Drain the transmission oil.
Refit
5. Clean the oil drain port.
10. Insert a new coiled spring pin into the gear shift rocker
arm shaft head for fixation. 6. Place the new sealing gasket on the oil drain plug, fit the
oil drain plug and tighten to 30–40Nm.
11. Connect the cable joint ball to the gear selection/shift
rocker arm. Refill
12. Fit the battery box bracket. 1. Clean the surrounding area of oil filler plug (1), remove
the oil filler plug and discard the sealing gasket.
2. Fill the transmission oil in the transmission with a

proper tool through the oil filler.
·Drain and Refill 2.2 L
Refill from Dry State 2.5 L
3. Place the new sealing gasket on the oil filler plug, fit the
oil filler plug and tighten to 30–40Nm.
1.0 617
Reverse Lamp Switch - Manual Left Differential Oil Seal - Manual

Remove Remove
1. Disconnect the battery negative cable. 1. Raise the vehicle on a lift.
2. Remove 2 bolts fixing the coolant expansion tank to the Warning: Do not work on or under a vehicle supported
vehicle frame, and then remove the coolant expansion only by a jack.Always support the vehicle on safety stands.
tank.

3. Remove the left drive shaft assembly.
Left Drive Shaft Assembly Remove

4. Remove the differential oil seal and discard it.
Caution: Do not damage the oil seal groove.

Refit
2. Fit the new oil seal with TPT00130.
3. Disconnect the reverse lamp switch connector.
3. Fit the left drive shaft assembly.

Left Drive Shaft Assembly Refit
4. Fill the manual transmission oil.
4. Remove reverse lamp switch.
Manual Transmission Oil Refill
Refit
1. Clean the mating surface of components.
2. Fit the reserve lamp switch to the transmission and
tighten to 23–27Nm, check the torque.
3. Connect the reserve lamp switch connector.
4. Fix the coolant expansion tank to the vehicle frame; fit
2 bolts and tighten to 4–6Nm and check the torque.
1.0 618
Right Differential Oil Seal - Manual Manual Transmission Remove
Remove Remove
1. Raise the vehicle on a lift. 1. Raise the vehicle on a lift.
Warning: Do not work on or under a vehicle supported Warning: Do not work on or under a vehicle supported
only by a jack.Always support the vehicle on safety stands. only by a jack.Always support the vehicle on safety stands.
2. Drain the manual transmission fluid. 2. Drain the manual transmission fluid.
Manual Transmission Fluid Drain Manual Transmission Fluid Drain

3. Remove the right drive shaft assembly. 3. Remove the manual transmission assembly.
Right Drive Shaft Assembly Remove Manual Transmission Assembly Remove

4. Remove the differential oil seal and discard it. 4. Remove the gear shift control mechanism assembly.
Caution: Do not damage the oil seal groove. Gear Shift Control Mechanism Assembly Remove
Refit 5. Remove the transmission accessories and release
1. Clean the oil seal groove. mechanism.
2. Fit the new oil seal with TPT00130. Transmission Accessories and Release Mechanism
Remove
6. Place the transmission inverted, and remove the rear
case bearing cover plate bolts.

Right Drive Shaft Assembly Refit
4. Fill the manual transmission oil.
7. Remove the housing connecting bolts.
Manual Transmission Oil Refill
8. Remove the housing reverse connecting bolts.
1.0 619
9. Separate the transmission housing. Refit

1. Fit the oil deflector to the clutch housing.
2. Fit the differential tapered bearing outer ring on the
clutch housing and transmission with the TPT00128.
10. Remove the reverse idle gear assembly.
Reverse Idler Gear Assembly Remove

11. Hold out the shaft and fork assembly.
3. Fit the input shaft oil seal into the clutch housing with
TPT00127.
12. Remove the differential assembly.
4. Fit the gear selection/shift shaft linear bearing on the

transmission housing with the TPT00138.
1.0 620
5. Fit the fork shaft bushing on the clutch housing and 8. Fit the reverse idle gear assembly.
transmission housing with the TPT00123.
Reverse Idler Gear Assembly Refit
9. Apply sealant to the clutch housing. Assemble the
transmission housing together with the clutch housing
with set pins.
10. Fit the housing connecting bolts and tighten to
23–27Nm.
11. Place the transmission inverted, fit the reverse
connecting bolts of the housing and tighten to
23–27Nm.
12. Fit the bearing cover plate bolts and tighten to
25–30Nm.
13. Fit the transmission accessory and release mechanism.
Transmission Accessory and Release Mechanism

6. Fit the differential oil seal on the clutch housing and
Refit
14. Fit the shift control mechanism assembly.
7. Fit the shaft assembly, fork assembly and differential
assembly into the clutch housing with TPT00126. Shift Control Mechanism Assembly Refit
15. Fit the manual transmission assembly.
Manual Transmission Assembly Refit

1.0 621
Differential Assembly
Remove


3. Remove the manual transmission assembly.
Manual Transmission Assembly Remove

4. Dismantle the manual transmission assembly.
Manual Transmission Assembly Dismantling

8. Remove the planet shaft, planet gear, axle shaft gear
5. Pull out the inner ring of the tapered bearing with and gasket.
T32001, and take out the gasket.
Refit
1. Fit the planet gear, axle shaft gear, planet gear gasket
and axle shaft gear gasket.
2. Rotate the planet gear and axle shaft gear until the
planet shaft holes of the planet gear and differential
case are aligned.
3. Fit the planet shaft.
4. Fit the planet shaft pin.
5. Fit the driven gear of final drive, and tighten connecting
bolts to 90–100Nm.
6. Fit the conical bearing inner ring with TPT00128.
7. Check the thickness of adjusting gasket, and determine
whether to replace it according to the check result.
6. Remove the planet shaft pins with punching tools.
0.95
1.00
1.05
1.10
1.15
1.20
1.25
8. Assemble the manual transmission assembly.
Manual Transmission Assembly Assembling

7. Unscrew the bolts and remove the driven gear of final
drive. Manual Transmission Assembly Refit
1.0 622
Transmission Accessories and Release
Mechanism
Remove



4. Remove the bolts fixing the gear selection/shift cable
bracket, and remove the gear selection/shift cable 7. Remove the interlock pin.
bracket.
8. Remove the set pin on the case.

5. Remove the plug on the control cover.
6. Remove the reverse lamp switch.

9. Remove the bolts fixing the gear shift control
mechanism, and remove the control mechanism
assembly.
1.0 623
5. Fit the interlock pin and tighten to 15–20Nm.

6. Fit the reverse lamp switch and tighten to 23–27Nm.
7. Fit the shift control cover oil plug, and tighten to
30–40Nm.
8. Fit the gear selection/shift cable bracket and tighten the
bolts to 19–25Nm.

10. Invert the transmission, and remove the central release

cylinder and release bearing.
11. Remove the oil filler plug and oil plug gasket.
12. Remove the oil drain plug and oil plug gasket.
Refit
1. Fit the oil filler plug and oil drain plug and oil plug gasket
2. Fit the central release cylinder and release bearing and
tighten the bolts to 10–14Nm.
3. Fit the shift control cover on the transmission case, and
tighten bolts to 25–30Nm.
4. Fit the set pins on the housing and tighten.
1.0 624
Input Shaft Assembly
Remove




8. Remove and discard the input shaft sleeve.
5. Remove and discard the locking bolt and rear bearing.
9. Remove the input shaft 3rd/5th gear.

6. Remove the rear bearing baffle.
10. Place the input shaft inverted, remove and discard the
7. Remove the input shaft 4th/6th gear. input shaft front bearing.
Refit
1. Fit the new front bearing on the input shaft with
TPT00133.
1.0 625
Output Shaft Assembly 1

Remove




2. Fit the input shaft 3rd/5th gear.
5. Remove the locking bolt and the rear bearing of output
3. Fit the new input bearing bushing.
shaft 1 and discard them.
4. Fit the input shaft 4th/6th gear.
6. Remove the output shaft 6th gear needle bearing inner
5. Fit the bearing baffle assembly.
ring with a puller.
6. Fit the new input shaft rear bearing.


7. Remove the output shaft 6th gear and needle bearing

and discard them.
8. Remove the output shaft 6th gear synchronizer gear

ring and synchronizer gear bushing.
1.0 626
9. Place the output shaft assembly 1 to the hydraulic 4. Fit the output shaft 1st/2nd gear synchronizer assembly.
press panel, and press output shaft 1 downward with
hydraulic press to separate the shaft from the gear set.
Refit
1. Fit the front bearing inner race to output shaft 1 with
the TPT00131.
5. Fit the output shaft 2nd gear spacer, new needle bearing
and 2nd gear.
2. Place the output shaft 1 inverted, use TPT00134 to

fit the 1st gear needle bearing inner race to the output
shaft 1.
6. Fit the 5th gear needle bearing inner race to output

shaft 1 with the TPT00132.
3. Fit the new output shaft 1st gear needle bearing and
1st gear.
1.0 627
7. Fit the new output shaft 5th gear needle bearing and 10. Fit the new rear bearing on output shaft 1 with the
5th gear. TPT00132.
8. Fit the output shaft 5th/6th gear synchronizer assembly.
9. Assemble the 6th gear needle bearing inner race, the

new needle bearing and the 6th gear together first; fit 3
parts to output shaft 1 with the TPT00131.
1.0 628
Output Shaft Assembly 2 TPT00131.
Remove
4. Dismantle the manual transmission.
Manual Transmission Dismantling
5. Remove the locking bolt and the rear bearing of output
shaft 2 and discard them. 2. Place output shaft 2 inverted, and fit a new output shaft
6. Remove the output shaft 4th gear needle bearing inner reverse gear needle bearing and reverse gear.
ring with a puller.
7. Remove the output shaft 4th gear and needle bearing
and discard them.
3. Fit the reverse gear synchronizer assembly.
8. Remove the output shaft 3rd/4th gear synchronizer

assembly.
4. Fit the 3rd gear needle bearing inner ring into output
shaft 2 with TPT00132, and fit a new needle bearing.
9. Place the output shaft assembly 2 on the hydraulic

press panel, and press output shaft 2 downward with
hydraulic press to separate the shaft from the gear set.
Refit
1. Fit the front bearing inner ring to output shaft 2 with
1.0 629
5. Fit the output shaft 3rd gear. 8. Fit the new rear bearing on output shaft 2 with
TPT00132.
Transmission Assembly Assembling
6. Fit the output shaft 3rd/4th gear synchronizer assembly.
7. Assemble the 4th gear needle bearing inner ring, the

new needle bearing and the 4th gear together first; fit
the 3 parts to output shaft 2 with TPT00131.
1.0 630
Reverse Idler Shaft Assembly
Remove



4. Place the transmission inverted, and remove the rear
case bearing cover plate bolts.
7. Separate the transmission housing.
5. Remove the housing connecting bolts.

8. Remove the bolts fixing the reverse idler gear shaft to
the clutch housing.
6. Remove the housing reverse connecting bolts.
9. Remove the reverse idler gear shaft, reverse gear,

gasket, needle bearing and thrust bearing in sequence.
1.0 631
Neutral Position Sensor

Remove
2. Disconnect the connector from the neutral position
sensor.
3. Loosen 1 bolt fixing the sensor to the transmission
control seat and slowly remove the sensor by rotating
it.
Refit
1. Fit the thrust bearing, needle bearing, gasket, reverse
gear and reverse idler shaft on the clutch housing in
sequence.
2. Tighten the bolts in the reverse idler shaft hole to
23–27Nm.
3. Tighten the bolts at the side of the reverse idler shaft
to 33–37Nm .
4. Apply sealant to the clutch housing. Assemble the Refit
transmission housing together with the clutch housing 1. Clean the mating surface of the transmission.
with set pins.
2. Apply transmission oil to the O-ring of the neutral
5. Fit the housing connecting bolts and tighten to position sensor.
23–27Nm.
3. Press the neutral position sensor into the transmission
6. Place the transmission inverted, fit the reverse control seat hole by hand and tighten the retaining
connecting bolts of the housing and tighten to screw to 8–12Nm.
23–27Nm.
Caution: Do not refit the neutral position sensor by
7. Fit the bearing cover plate bolts and tighten to
knocking.
25–30Nm.
8. Fit the manual transmission assembly. 4. Connect the sensor connector.
1.0 632
Number
Replacer, oil
TPT00121
Engine lift seal, select shaft
T10007
bracket
Replacer, bush,
TPT00124 shift and select
TEN00070 Engine support shaft
Replacer, outer
Replacer,needle
TPT00122 bush, select
roller bearing,
TPT00119 shaft
shift and select
shaft
Replacer, inner
Supporter, shift TPT00131 bush, select
TPT00136 and select shaft shaft
barrel
Replacer, oil
Replacer, oil TPT00130
seal, drive shaft
TPT00120 seal, shift and
select shaft
1.0 633

Number Number
Replacer,
outer track of
TPT00128 T32001 Puller universal
tapered roller
bearing,differential
Replacer, oil Replacer, inner

TPT00127 TPT00133
seal, input shaft track of bearing
Replacer, rear
Replacer, ball bearing and
TPT00138 bearing, shift TPT00134
inner track of
and select shaft roller bearing
Replacer, inner
Replacer, bush , TPT00132 track of bearing,
TPT00123
selector fork output shaft
Sleeve, lock
TPT00126
bolt, shaft
1.0 634
Cluth-6MT Transmission
Cluth-6MT
Specifications
Torque
Description Value
Bolt - clutch cover to flywheel 25Nm
Bolt - clutch slave cylinder 7–10Nm
Bolt - clutch hose bracket 7–10Nm
Nut - concentric slave cylinder hose to pipe 15–19Nm
Breath plug 10Nm
1.0 635
Transmission Cluth-6MT
Parameter
Model Dry Single Disc, Hydraulic Booster Clutch
Diameter of driven plate: 240mm

Diameter of pressure plate 240mm
Thickness of driven plate:
New 7.3—7.9mm
Service limit 6.5mm

Depth of rivet:
New 1.2mm (above the rivet head)
Service limit 0.2mm (above the rivet head)

Wear loss of driven plate:
New 0.8mm
1.0 636
System Layout
Clutch System Layout
1. Clutch Master Cylinder 11. Bolt - Clutch Hose Bracket

2. Clamp - Brake Fluid Reservoir Hose 12. Manual Transmission
3. Clutch Master Cylinder Hose 13. Central Release Cylinder Pipeline Assembly
4. Clip - Clutch Hard Pipeline 14. Plug - Central Release Cylinder Pipeline Assembly
5. Clutch Hard Pipeline 15. Rubber Plug
6. Clutch Master Cylinder Hose 16. Central Release Cylinder
7. Clutch Master Cylinder Pipeline Assembly Bracket 17. Bolt - Central Release Cylinder
8. Bolt - Clutch Master Cylinder Pipeline Assembly Bracket 18. Bolt - Clutch Cover Assembly
9. Clutch Hose Bracket 19. Clutch Cover Assembly
10. Clamp - Clutch Hose 20. Driven Plate
1.0 637
Description 4. Support ring

Overview 5. Leaf spring
This is a three-piece diaphragm clutch with self-adjusting The clutch cover assembly is composed of the diaphragm
function, equipped with a hydraulic clutch release system. spring, pressure plate and cover. The pressure plate is made
This system consists of two main parts, a master cylinder and of cast iron and has a smooth plane machined to connect the
a central release cylinder. driven plate. There are 3 pull rings on the outer ring of the
Clutch Hydraulic System pressure plate, which is then connected to the housing through
a spring. The spring is composed of three quenched and
The master cylinder of the clutch is directly fitted on the pedal
tempered steel sheets. When the clutch pedal is depressed, it
box in the passenger compartment, and the push rod is fixed
will pull the pressure plate away from the driven plate. Clutch
to the clutch pedal box by master cylinder fastening clips.
housing is punched by steal plate.
The clutch pipeline is connected to the master cylinder with a
The diaphragm spring is a cast ring with 18 release fingers in
rotary connector, and this kind of connector is useful for refit
its inner ring. There are two round support rings fitted on
and adjustment. The other end of the pipeline is connected
the housing so that the diaphragm spring can rotate between
to the central release cylinder with quick connector. The
them. The diaphragm spring is not directly connected to the
pipeline is of a flexible type for easy refit and also can buffer
pressure plate. When the release bearing applies stress on the
the replacement and vibration generated by the engine.
release finger of the diaphragm spring, the diaphragm spring
The cylinder connecting piece fitted on the manual will rotate around the support ring to leave the pressure plate.
transmission case, and the central release cylinder coaxial And meanwhile, the spring of the pressure plate connected to
with the transmission input shaft form a release mechanism, the housing will also be away from the driven plate.
the clutch pipeline from the cylinder connecting piece is
Driven Plate
connected to the pipeline of the master cylinder through the
quick connector.
Clutch Mechanical System
The vehicle with manual transmission is equipped with double
mass flywheel. The clutch cover assembly is fitted on the
flywheel with three locating pins and is fixed with six bolts.
Clutch Cover Assembly
1. Driven plate body

2. Friction plate
3. Spline hub
The driven plate is fitted between the flywheel and the

pressure plate. Its feature is that the spline hub engages the
spline on the transmission input shaft. The friction plate is
composed of two discs, which are riveted on each side of the
1. Diaphragm spring driven plate body. The rivets are fitted in the notches in the
2. Clutch cover friction plate as well as that at the other side to protect the
3. Pressure plate pressure plate and flywheel from damage.
1.0 638
Clutch Master Cylinder Sensor Fit a permanent magnet to the clutch master cylinder piston.
The magnet produces different magnetic field strength for
different sensor varied with the piston motion.
According to the different working states of the clutch master

cylinder, the sensor shall output at most 3 signals:\
• Digital signal: Clutch top-position switch, applied to the
constant speed cruise system.
• PWMSignal: Apply to supply the electronic parking
brake
• Digital signal: Clutch bottom-position switch, applied to
supply the engine Stop/Start system
For the engine Stop/Start system (Such as equipments), clutch

bottom-position switch relative to clutch top-position switch
The clutch master cylinder sensor is fitted to the master and PWM signal is independent and used to redundancy
cylinder for detecting the position of the clutch master check.
cylinder piston.
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Operation The diaphragm spring rotates around the support ring on the
Hydraulic Operation pressure plate housing, and applies pressure on the pressure
plate, and the pressure plate will overcome the resistance of
When the clutch pedal is depressed, the piston moves in the
the leaf spring, move towards the flywheel and apply stress on
master cylinder. The piston drives the fluid in the master
the driven plate.
cylinder to move along the clutch pipeline. This pressure is
applied on the piston of the central release cylinder and the The pressure on the driven plate applied by the pressure plate
piston will move under the action of hydraulic pressure. increases the frictional force between the driven plate and
flywheel. When the clutch pedal is released, the frictional
When the clutch pedal is released, the release finger of the
force will increase, the rotational motion of flywheel is
diaphragm spring returns to its original position, which pushes
transmitted to the driven plate, and then it is transferred to
the fluid in the central release cylinder to flow back, allowing
the transmission input shaft.
the master cylinder piston to return to its original position.
Mechanical Operation When the pedal is fully released, the force on the pressure
plate applied by the diaphragm spring will press the driven plate
When the clutch pedal is depressed, the push rod pushes the
on the flywheel, making no skidding between them.
piston to move. The pressure produced by the piston motion
Clutch Master Cylinder Sensor
is transferred to the central release cylinder, the central release
cylinder pushes the release finger of the diaphragm spring, The clutch master cylinder sensor mainly supply 2 switch signal:
and the diaphragm spring will rotate around the support ring
• Clutch top-position switch (CTS) signal:
on the pressure plate housing. Following the deformation of
the diaphragm spring, its pressure on the pressure plate will When the clutch pedal is depressed, the clutch starts
disappear. Three leaf springs will pull the pressure plate away to work. The clutch position sensor supply a clutch
from the driven plate. high-position switch (CTS) signal for EMS; the signal
applies to the constant speed cruise; its travel is 3–7mm
Disappearance of the pressure on the driven plate applied by
(From the top).
the pressure plate reduces the frictional force between the
driven plate and flywheel. The driven plate will skid on the • Clutch bottom-position switch (CBS) signal:
flywheel and can not transmit the power of the flywheel to When the clutch pedal achieves the maximum travel, the
the transmission input shaft. clutch disengages completely. The clutch position sensor
When the clutch pedal is released, the stress on the central supply a CBS signal for the BCM; this signal will be used
release cylinder will disappear. Disappearance of this pressure by the stop/start system; its travel is 19-25mm (From the
allows the diaphragm spring to return to its original position, top).
the release finger goes back to its original position, pushing
the fluid back to the master cylinder from the central release
cylinder.
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Service Procedures
Clutch Assembly
Remove

2. Restrict the flywheel with T10028.
Thickness of driven plate (compressed) A
New driven plate 7.3mm

Service limit value 6.5mm
4. Measure the depth of rivets, replace driven plate if the

depth is less than the service limit.
Depth of rivet B
3. Gradually loosen and remove 6 bolts fixing the clutch
cover assembly to the flywheel. New driven plate 1.2mm
4. Remove the clutch housing assembly and take out the Service limit value 0.2mm
driven plate.
5. Check the pressure plate for any sign of wear or
damage. Check the drive plate for any sign of overheat
(with color from deep yellow to blue) and replace it
if necessary.
Caution: Renew a clutch pressure plate which has been
accidentally dropped.
6. Check the surface levelness of pressure plate at 4

separate points with a square edge gauge and feeler
gauge. Replace the pressure plate if deformation
exceeds the service limit value.
Refit
1. Visually check the diaphragm finger for wear or
irregular height.
2. Check the clutch driven plate for any sign of wear or
oil contamination. Replace the driven plate if necessary.
3. Measure the thickness of clutch plate, replace driven
plate if the thickness is less than the service limit.
Deformation of pressure plate
Service limit 0.15mm
7. Check the central release cylinder for any sign of wear

or damage and replace it if necessary.
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8. Clean the pressure plate, flywheel, locating pins and

pin holes.
9. Check the flywheel for any sign of scratch or other
damages. Replace it if it is scratched or damaged.
Refit
1. Lubricate the central release cylinder with designated
lubricating grease.
2. Apply specified lubricating grease to the spline of the
clutch driven plate.
3. When fixing the driven plate to the pressure plate, pay
attention to the refit direction.
4. Align the driven plate with the pressure plate with
7. Fit 6 bolts fixing the pressure plate to the flywheel and
T22001.
screw them manually.
8. Lock the flywheel with T10028 and tighten the bolts
gradually to 25Nm in diagonal sequence.
9. Remove the aligning tool T22001 for the driven plate.
5. Make sure that the driven plate is aligned with the

center of the pressure plate.
6. Fit the clutch assembly into the flywheel with T22001.
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Clutch Central Release Cylinder
Remove
1. Drain the brake fluid from the brake fluid reservoir.
Caution: Brake fluid will damage paint finished surfaces.

If spilled, immediately remove fluid and clean area with
water.
2. Loosen the hose clip, and unscrew the bolt fixing the
hose to the release cylinder pipeline assembly.
3. Unscrew the bolt fixing the release cylinder pipeline
assembly to the transmission case.
4. Remove the manual transmission assembly. 3. Fit the manual transmission assembly.
Manual Transmission Assembly Remove Manual Transmission Assembly Refit
5. Disconnect the quick connector between the release 4. Fix the central release cylinder pipeline bracket to the
cylinder pipeline assembly and the central release transmission case, and tighten bolts to 7–10Nm.
cylinder and remove the release cylinder pipeline 5. Connect the central release cylinder pipeline assembly
assembly. and hose, and tighten bolts to 15–19Nm, and then
6. Remove the bolts fixing the central release cylinder to tighten with hose clips.
the transmission case, and take off the central release 6. Fill the brake fluid to reservoir up to the MAX mark.
cylinder.
7. Bleed the clutch pipeline system.
Clutch Pipeline System Bleeding
Refit
1. Fix the central release cylinder to the manual
transmission case, and tighten the nuts to 7–10Nm.
2. Fit the central release cylinder pipeline assembly to the
central release cylinder quick joint and fasten.
Caution: . Before installation, please ensure the

gasket of quick joint is all right and properly
installed.
1.0 643
Clutch Pipeline System Bleeding Clutch Master Cylinder

Bleeding Remove
Bleed the air that enters into hydraulic system when 1. Drain the brake fluid from the brake fluid reservoir.
disconnecting the pipeline for repair. During the air bleeding,
the brake fluid in the brake fluid reservoir must be maintained Note: Brake fluid will damage painted surfaces. Soak
between MIN and MAX mark. up any spillage with an absorbent cloth immediately and
Warning: Do not allow brake fluid to come into contact wash the area with a mixture of car shampoo and water.
with eyes or skin. 2. Loose the clamp, disconnect the clutch master cylinder
Caution: Do not reuse the brake fluid drained from the hose from the reservoir.
clutch pipeline system.
1. Unscrew the bleed plug dust cover from the cylinder

connector. Connect a plastic hose to the bleed plug,
and insert the other end of the hose into the glass
container half-filled with fresh brake fluid.
3. Remove the fixing pin, disconnect the master from the

hard pipe.
2. Press the clutch pedal to the maximum stroke and hold,

so as to ensure the maximum system pressure.
3. Loosen the bleed plug, remove the air in the fluid, the
system pressure will drop at this time.
4. Tighten the bleed plug firstly to avoid the suck-back
of the fluid.
5. Release the brake pedal to the maximum stroke steadily,
allowing it return to its original position without any
external force. Supplement with sufficient brake fluid.
6. Repeat the operation in the above sequence for several 4. Remove the driver side lower trim panel assembly.
times until the brake fluid without any air flows into the Driver Side Lower Trim Panel Assembly Remove
container, then fix the brake pedal to the maximum
5. Release the fixing clamp of the master cylinder push rod
stroke, tighten the bleed plug to 10Nm.
from the clutch pedal and disconnect the connection.
7. Remove the hose from the bleed plug, and fit the bleed
plug anti-dust cover.
8. Refill brake fluid to the MAX mark.
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6. Disconnect the connector of clutch master cylinder

position sensor.
7. Remove the clutch master cylinder front the dash panel.
Refit
1. Connect the clutch master cylinder position sensor.
2. Locate the master cylinder to the dash panel and make
sure the seal ring is fitted in place.
3. Fix the master cylinder push rod clip to the clutch pedal.
4. Connect the master with hard pipe, and fix it with lock
pin.
5. Fit the driver side lower trim panel assembly.
Driver Side Lower Trim Panel Assembly Refit

6. Connect the clutch master cylinder hose with the fluid
reservoir, and fix it with clamp.
7. Bleed the clutch pipeline system.
Clutch Pipeline System Bleeding

8. Fill the brake fluid to reservoir up to the MAX mark.
1.0 645
Special Tools
Number
Flywheel
T10028
locking tool
Aligner, clutch
T22001
plate
1.0 646
Power Transfer Unit -AWD Transmission
Power Transfer Unit -AWD
Specifications
Torque
Description Value
Bolt -PTU to transmission 70–80Nm
Bolt -PTU bracket to engine 42–48Nm
Bolt -PTU bracket to PTU 42–48Nm
Bolt -intermediate driving shaft to PTU 26–34Nm
Drain plug-PTU 29–34Nm
Filler plug-PTU 29–34Nm
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Transmission Power Transfer Unit -AWD
Parameters
Description PTU Assembly
Overall length 375mm
Total Width 228mm
Total Height 270mm
Weight (with oil) 19.9Kg
Speed Ratio 2.224
Lubricant Model Idemitsu Apolloil Wide Gear LW 80W-90 GL5
Maximum Output Torque 1,000Nm
1.0 648
System Layout
PTU Assembly
1. PTU Assembly
1.0 649
PTU Assembly Accessory Drawing
1. Breather Plug 7. Filler Plug Gasket

2. O Ring - PTU 8. Bolt - PTU to Transmission
3. Oil Seal - Right Front Axle Shaft 9. Bracket - PTU
4. Drain Plug 10. Bolt - PTU Bracket
5. Oil Filler Plug 11. PTU Assembly
6. Drain Plug Gasket
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Description the spline and accelerate and steer the torque (90°) by the
Overview of Power Transfer Unit Assembly two-stage gear in the PTU, by this way, it transfers the torque
to the intermediate drive shaft.
The function of the power transfer unit (PTU) is to take part
of torque from the transmission differential housing through PTU Assembly Cutaway View
1. Housing 5. Gasket
2. Bearing 1 - Intermediate Gear 6. Adjusting Socket
3. Hyperbolic Gear (large) 7. Oil Seal
4. O-ring 8. Lock Nut
1.0 651
9. Output Flange 16. Oil Seal

10. Bearing 1 - Output Shaft 17. Housing
11. Housing Socket 18. Bearing 1 - Input Shaft
12. Bearing 2 - Output Shaft 19. Input Gear
13. Hyperbolic Gear (small) 20. Bearing 2 - Input Shaft
14. Bearing 2 - Intermediate Gear 21. O-ring
15. Intermediate Gear
The power transfer unit assembly consists of the housing, gear (large) to rotate. The intermediate gear rotation and
housing cover, housing sleeve, input gear, intermediate gear, the drive half shaft of the right front wheel rotate towards
hyperbolic gear (large), hyperbolic gear (small), output flange, opposite direction. The hyperbolic gear combination changes
bearing and oil seal, etc. The input shaft connects the the rotation direction (90°) and transfers the torque. The
transmission differential housing, which drives the drive half hyperbolic gear (small) transfers the power to the drive shaft
shaft of the right front wheel to rotate. The input gear through the output flange.
engages the intermediate gear and drives the hyperbolic
1.0 652
Operation
PTU Assembly Power Flow
1. Torque is input from the differential housing spline of the

transmission.
2. Primary Gear Acceleration
3. Secondary Hyperbolic Gear Acceleration and 90°Steering
4. Torque is output from the flange
1.0 653
Service Procedures
PTU Assembly
Remove

2. Drain the dual clutch automatic transmission fluid.

Drain
3. Remove the drive shaft of the right front wheel.
Right Front Wheel Drive Shaft Remove
4. Remove 6 bolts connecting the power takeoff and the 8. Remove 3 bolts connecting the power takeoff and the
drive shaft to disconnect the drive shaft. upper transmission.
5. Remove 2 bolts (1) fixing the power takeoff bracket 9. Support the power takeoff with a bracket, move the
to the power takeoff. power takeoff to the right to remove it.
6. Remove 2 bolts (2) fixing the power takeoff bracket to Caution: Do not invert the power takeoff.
the engine, and remove the bracket. Refit
1. Clean the mating face of the power takeoff and
automatic transmission.
2. Clean the locating pin and pin hole of the power takeoff.
3. Secure the power takeoff on the bracket, then lift and
locate the bracket to the vehicle.
4. Align the locating pin of the power takeoff with the pin
hole of the automatic transmission and allow the power
takeoff and automatic transmission to fit together.
5. Fit 5 bolts fixing the power takeoff to the transmission,
tighten them to 70–80Nm and check the torque.
6. Fit the power takeoff bracket to the engine, fit 2 bolts,
7. Remove 2 bolts connecting the power takeoff and the 7. Fit 2 bolts fixing the power takeoff to the power takeoff
lower transmission. bracket, tighten to 42–48Nm, and check the torque.
8. Secure the drive shaft on the power takeoff, fit 6 new
9. Fit the drive shaft of the right front wheel.
Right Front Wheel Drive Shaft Refit
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10. Fill the dual clutch automatic transmission fluid. Right Oil Seal - PTU Assembly
Remove
Refill 1. Drain the dual clutch automatic transmission fluid.
11. Lower the vehicle. Dual Clutch Automatic Transmission Fluid -
Drain
2. Remove the right drive shaft assembly.
Right Drive Shaft Assembly Remove

3. Remove the oil seal at the right side of the power
takeoff.
4. Carefully remove the oil seal and discard it.

Refit
1. Gently apply the specified dual clutch automatic
transmission fluid around the lip with clean hands.
2. Fit the new oil seal into the transmission housing with
the special tool TPT00214 and hammer.
Right Drive Shaft Assembly Refit

4. Fill the dual clutch automatic transmission fluid.

Refill
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O Ring - PTU Assembly Drain and Refill

Remove Drain
1. Drain the automatic transmission fluid. 1. Raise the vehicle on a lift.
Dual Clutch Automatic Transmission Fluid - Warning: Do not work on or under a vehicle supported
Drain only by a jack.Always support the vehicle on safety stands.
2. Remove the power takeoff. 2. Put a proper container under the PTU.
Power Takeoff Remove 3. Clean the surrounding area of oil filler plug, remove the
oil filler plug and discard the seal gasket.
3. Remove and discard the O-ring seal.
4. Clean the surrounding area of the drain plug, remove
the drain plug and discard the seal gasket.
Refit
1. Fit the new O-ring seal onto the power takeoff.
5. Drain the PTU oil.
Caution: The O-ring seal must be put into the groove Refill
without being twisted.
1. Clean the filling port and drain plug.
2. Fit the power takeoff.
2. Fit a new seal gasket to the drain plug, and tighten the
Power Takeoff Refit drain plug to 29–34Nm.
3. Refill automatic transmission fluid. 3. Refill PTU oil of a specified volume into the PTU
through the filling port.
Refill Drain and Refill 0.52L (Volume for refill after
10min's horizontal drain)
Refill from Dry State 0.55-0.63 L
4. Fit a new seal gasket to the oil filler plug, and tighten
the oil filler plug to 29–34Nm.
1.0 656
PTU Assembly Oil Check and Refill Breather Plug
Check and Refill Remove
1. Raise the vehicle on a lift. 1. Remove the power takeoff assembly.
Warning: Do not work on or under a vehicle supported Power Takeoff Assembly Remove
only by a jack.Always support the vehicle on safety stands. 2. Remove the breather plug cover with the pincher.
2. Check the surrounding area of each oil plug/oil seal for 3. Remove and discard the breather plug with the special
oil leakage, replace the faulty oil plug or seal gasket, tool TPT00177 and the impact puller in TPT00117.
oil seal as necessary.
3. Put a proper container under the PTU.
4. Clean the area around the oil filler plug, remove the oil
filler plug and seal gasket, and discard the seal gasket.
5. If the oil level port has oil drop overflows, finish
the operation and turn off the engine; if no oil drop
overflows there, refill appropriate oil.

6. Refill the PTU oil into the PTU through the filling port
until the oil overflows.
the oil filler plug to 29–34Nm. Refit
1. Clean the mounting position of the breather plug to
ensure that there is no foreign material.
2. Refit the new breather plug to the power takeoff
assembly with the special tool TPT00194 and hammer.
3. Fit the power takeoff assembly.
Power takeoff Assembly Refit
1.0 657
Special Tools
Number
Front right
wheel drive
TPT00214
shaft oil seal
presser-PTU
Vent-plug
TPT00177 Sleeve-PTU
and FDU
Remover
seal
Vent-plug
TPT00194 Presser-PTU
and FDU
1.0 658
Final Drive Unit-AWD Transmission
Final Drive Unit-AWD
Specifications
Torque
Description Value
Bolt -FDU assy to rear subframe 120–140Nm
Bolt -EMCD to FDU assy 17.7–24Nm
nut -intermediate driving shaft to FDU assy 55–61Nm
Bolt -connector bracket to FDU assy 6.9–8.8Nm
Bolt -TCCM to fix bracket 8–10Nm
Drain plug-FDU 29–34Nm
Filler plug-FDU 29–34Nm
1.0 659
Transmission Final Drive Unit-AWD
Parameters
Description Rear Axle Assembly
Overall length 520mm
Total Width 340mm
Total Height 180mm
Weight (with oil) 24.2Kg
Speed Ratio 2.214
Lubricant Model Idemitsu Apolloil Wide Gear LW 80W-90 GL5
Maximum Input Torque 1,000Nm
Torque Manager:
Operating Voltage 12V
Maximum Operating Current 2.1A
1.0 660
System Layout
Rear Axle Assembly
1. Rear Axle Assembly
1.0 661
Rear Axle Assembly Accessory Drawing
1. Oil Seal - Rear Axle Shaft 9. Buffer Washer

2. Drain Plug 10. Input Shaft Oil Seal
3. Oil Filler Plug 11. Torque Control Harness
4. Gasket - Drain Plug 12. Bracket - Torque Control
5. Gasket - Oil Filler Plug 13. Screw - Torque Control Bracket
6. Electromagnetic Torque Control 14. Bolt - Rear Axle Housing
7. Bolt - Torque Control 15. Rear Axle Assembly
8. Vent Plug
1.0 662
Four-wheel-drive System Control Diagram
A = Hard Wire; B = Power HS CAN Bus; C = Chassis HS CAN Bus; D = Body HS CAN Bus
1.0 663
Description 1. Main Clutch

Overview of Rear Axle Assembly 2. Pressure Plate
The rear axle assembly (FDU) is a power transmission device 3. Armature
used for the city SUV with transverse engine/transmission, 4. Guide Clutch
which is composed of the electromagnetic torque control
5. Electromagnet
(EMCD) and the rear axle differential. The FDU can
6. Cam
provide the following functions: 1) Uses deceleration of the
hyperbolic gear set increase to increase the torque transferred 7. Reaction
from the intermediate drive shaft, provides 90°steering and 8. Magnetic Force
distributes the torque to the two half shafts of the rear axle; 9. Gravity
2) Compresses the internal friction plate by changing the input
10. Cam Thrust
current, controls the output torque of the rear axle and the
speed difference between the front axle and the rear axle; 3) 11. Input
Controls the speed difference between the left half shaft and 12. Output
the right half shaft of the rear axle by the differential. The working principle of the torque control:
1. The magnetic field from the electromagnet current

causes the armature to compress the guide clutch.
2. The resistance of the guide clutch can produce rotation
torque in the slope device of the two-way ball.
3. The rotating force drives the ball to roll up along the
opposite slope and thus moves the front cam forward;
4. The cam thrust is transferred by compressing the
pressure plate of the main clutch;
5. The rotation torque of the external panel (input)
transferred to the internal panel (output) is proportional
to the current.
6. The electronic control unit (TCCM) controls the
1. Rear Axle Differential
clutch torque by adjusting the current according to the
2. Electromagnetic Torque Control applicable vehicle input and control algorithm.
Electromagnetic Torque Control (EMCD)
Technical Features
The electromagnetic torque control developed by GKN
• The auto mode applies a closed clutch lubrication system.
Driveline is an active control coupler between the axle
wheels, which is used for the auto mode and AWD system. • The steel guide clutch with special grooves has
The EMCD is a most compact electronic coupler with all undergone heat treatment, so it has a high durability and
functions, which is fitted between the axles and used for the low resistance.
powertrain. • Maximum Current: 3.0 A
Advantages
• Improved traction and maneuverability

• Compact design structure
• Low energy consumption
• Light weight and reliable performance
4WD Control Module (TCCM)
The 4WD control module (TCCM) is under the driver seat.
The TCCM adjusts the operating current of the torque
control and controls the torque transferred to the rear axle
according to the applicable vehicle input and control algorithm.
1.0 664
17:—
18:—
End View and Pin Information of 4WD Control

Module (TCCM) Harness Connector BY151
1: Ground
2:—
3: Lock Mode Button
4:—
5:—
6:—
7:—
8: Power HS CAN High
9: Power HS CAN Low
10: KL.30
11: Torque Control Coil＋
12: Torque Control Coil-
13: Wake-up Line Signal
14:—
15:—
16:—
1.0 665
Operation
4WD Power Flow Chart
1.0 666
Rear Axle Assembly Power Flow Chart
1. The flange inputs torque by the intermediate drive shaft. 7. The torque is transferred to the half shaft gear through
2. The torque is transferred to the housing inside the the planetary gear.
EMCD via the flange spline. 8. The torque is output by the spline of the half shaft gear.
3. The clutch transfers the torque from the housing inside Description of 4WD Function
the EMCD to the spindle of the EMCD.
The 4WD system improves the off-road performance,
4. The torque is transferred from the spindle spline of the maneuverability, driving stability and safety of the vehicle by
EMCD to the input shaft of the FDU. controlling the driving force distribution of the four wheels.
5. The torque is transferred to the differential housing The system controls the rational distribution of the engine
through the hyperbolic gear set. torque over the four wheels according the driver's intention,
6. The torque is transferred to the planetary gear through vehicle state and actual road condition. The 4WD mode
the differential pin shaft. includes auto mode and lock mode. The auto mode is used
on common paved roads, and the lock mode is only used by
the driver in trouble. In lock mode, the 4WD system will
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limit the vehicle speed, when the vehicle speed is higher than powers on the vehicle after 1min, the 4WD system will enter
60km/h, the 4WD system will automatically shift to the auto into the auto mode.
mode, when the vehicle speed is less than 60km/h, the the 4WD Indicator Lamp
4WD system will not resume the lock mode.
Lock Mode ON Indicator Lamp - Green
SN. Characteristic Remark When the lock mode is applied, the indicator lamp (green)
illuminates; when the auto mode is applied, the indicator lamp
1 Auto Mode Shift between 2WD and
turns off.
4WD is automatically
done according to the
vehicle state and actual 4WD Failure Indicator Lamp - Yellow
road condition.
When the 4WD system fails, the 4WD Failure indicator lamp
2 Lock Mode Locked in 4WD Mode (yellow) will illuminate. Place the ignition switch in "ON"
The 4WD system completes all operations for the power-on position, the indicator lamp (yellow) illuminates and will go out
initialization and one fault self-test within 200ms when the after few seconds.
power mode of the vehicle shifts from OFF to Wake-up.
In some cases, the 4WD system may fail, then the 4WD
Under different conditions, the TCCM detects that the
Failure indicator lamp (yellow) will illuminate for a short
vehicle is unstable or is about to lose stability, it will improve
while. For example, when driving on rough roads, the speed
the dynamic characteristic of the vehicle by controlling the
difference between the front wheel and the real wheel will
torque distribution of the front and rear axles.
exist for a long time, this causes the clutch in the middle of
Lock Mode Button the 4WD system to be hot. In this case, the 4WD system
Turn the ignition switch to "ON" position, press the lock disconnects temporarily the torque transfer of the rear axle,
mode button to activate the lock mode, and the indicator and illuminates the 4WD Failure indicator lamp (yellow).
lamp illuminates (green); press the button again to enter into Normally, the vehicle will resume the 4WD mode after a
the auto mode and the indicator lamp turns off. After the short while and the indicator lamp will go out. Therefore,
lock mode is activated, the vehicle powers off, if powers on if the 4WD Failure indicator lamp (yellow) illuminates for a
the vehicle within 1min, the lock mode will be maintained; if short time, no service is required for this condition.
1.0 668
Service Procedures Caution: Do not invert the rear axle assembly.
Rear Axle Assembly
Remove
3. Drain the rear axle assembly lubricating oil.
Rear Axle Assembly Lubricating Oil - Drain
4. Remove the left/right drive shaft.
Left Drive Shaft Remove
Right Drive Shaft Remove
5. Remove the rear horizontal stabilizer bar. Refit
1. Position the rear axle assembly on the hydraulic bracket,
Rear Horizontal Stabilizer Bar Remove
lift the bracket and put the rear axle assembly on the
6. Remove 3 bolts and nuts fixing the rear drive shaft to
mounting position, fit 4 bolts, tighten to 120–140Nm
the rear axle assembly, and discard the nut.
2. Take away the hydraulic bracket.
3. Connect the connector of the torque control.
4. Fit the rear horizontal stabilizer bar.
Rear Horizontal Stabilizer Bar Refit

5. Fit the left/right drive shaft.
Left Drive Shaft Refit

Right Drive Shaft Refit
6. Fit the rear drive shaft.
Rear Drive Shaft Refit

7. Refill rear axle assembly oil.
7. Disconnect the external connector of the torque Rear Axle Assembly Oil - Refill
manager and take away the harness clip. 8. Lower the vehicle.
10. With the VDS, perform the self-test function
of the 4WD system according to the path ("Fast
Track→Other→4WD Control Module Self-test") and
interface prompt.
8. Place a hydraulic bracket under the rear axle assembly.

9. Remove 4 bolts fixing the rear axle assembly to the
rear subframe, remove the rear axle assembly, lower
the bracket and move the rear axle assembly to the
workbench.
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Torque Control 7. Remove and discard the input shaft oil seal.
Remove Refit
1. Disconnect the battery negative. 1. Refit the input shaft oil seal with the special tool
2. Raise the vehicle on a lift. TPT00213 and a hammer.
Warning: Do not work on or under a vehicle supported 2. Refit the new buffer washer
only by a jack.Always support the vehicle on safety stands. 3. Clean the mating face of the torque manager and rear
3. Remove 3 bolts fixing the drive shaft to the flange and axle assembly.
take away the drive shaft. 4. Apply sealant to the mating face of the rear axle
assembly housing.
5. Fix the torque manager to the rear axle assembly, fit 6
bolts, tighten to 17.7–24Nm in sequence and check
the torque.
4. Disconnect the external connector of the torque

control.
6. Connect the external connector of the torque manager.

7. Fix the drive shaft to the flange, fit 3 bolts, tighten them
10. With the VDS, perform the self-test function
of the 4WD system according to the path ("Fast
interface prompt.
5. Remove 6 bolts fixing the torque control to the rear
axle assembly, and remove the torque control.
6. Remove and discard the buffer washer.
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Harness - Torque Control FDU Input Shaft Oil Seal
Remove Remove
1. Remove the torque control. 1. Disconnect the battery negative.
Torque Control Remove 2. Drain rear axle assembly oil.

2. Remove 1 bolt fixing the connector bracket to the Rear Axle Assembly Oil Drain
torque control and remove the bracket. 3. Remove the torque control.
Torque Coupler Remove

4. Remove and discard the buffer washer.
5. Remove and discard the input shaft oil seal.
3. Disconnect the external connector of the torque

control.
4. Remove the harness and insulating plug from the torque
control housing.
Refit
1. With the TPT00213 and hammer, fit the input shaft
oil seal.
Refit
1. Fit the harness and insulating pug to the torque coupler
housing.
2. Align the notch of the new buffer washer with the
2. Connect the internal connector of the torque coupler.
notch on the housing and fit the washer properly.
3. Fix the connector bracket to the torque coupler, fit 1
3. Fit the torque coupler.
bolt, tighten to 6.9–8.8Nm, and check the torque.
4. Fit the torque coupler. Torque Coupler Refit
4. Refill rear axle assembly oil.
Torque Coupler Refit
5. With the VDS, perform the self-test function Rear Axle Assembly Oil Refill
of the 4WD system according to the path ("Fast 5. Connect the battery negative.
interface prompt.
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4WD Control Module (TCCM) 6. Programme and encode TCCM.

Remove Self-learning and Adjustment, Programming and
1. Disconnect the battery negative. Encoding - TCCM Replacement
2. Remove the front seat assembly.
Front Seat Assembly Remove
3. Cut the carpet along with the tear of carpet with a
scissor.
Caution: Do not cut off the harness under the carpet.
4. Disconnect the connector (1) of four-wheel drive

control module (TCCM).
5. Remove 2 bolts (2) fixing the four-wheel drive control
module (TCCM) to the bracket, and remove the
four-wheel drive control module (TCCM).
Refit
1. Fix the four-wheel drive control module (TCCM) to
the bracket, fit 2 bolts, tighten to 8–10Nm, and check
the torque.
2. Connect the connector of four-wheel drive control
module (TCCM).
3. Pave the carpet.
4. Fit the front seat assembly.
Front Seat Assembly Refit

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Right Oil Seal - Rear Axle Assembly Left Oil Seal - Rear Axle Assembly
Remove Remove
2. Drain the rear axle assembly lubricating oil. 2. Drain the rear axle assembly lubricating oil.
Rear Axle Assembly Lubricating Oil - Drain Rear Axle Assembly Lubricating Oil - Drain
3. Remove the right rear drive shaft. 3. Remove the left rear drive shaft.
Right Drive Shaft Remove Left Rear Drive Shaft Remove

4. Remove the oil seal and discard it. 4. Remove the oil seal and discard it.
Refit Refit
1. Clean the oil seal groove. 1. Clean the oil seal groove.
2. With the TPT00212 and hammer, fit the new oil seal 2. With the TPT00212 and hammer, fit the new oil seal
to the rear axle assembly. to the rear axle assembly.
3. Fit the right rear drive shaft. 3. Fit the left rear drive shaft.
Right Rear Drive Shaft Refit Left Rear Drive Shaft Refit
4. Refill rear axle assembly oil. 4. Refill rear axle assembly oil.
Rear Axle Assembly Oil - Refill Rear Axle Assembly Oil - Refill
5. Lower the vehicle. 5. Lower the vehicle.
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Drain and Refill - Rear Axle FDUFluid Check and Refill

Drain Check and Refill
2. Put a proper container under the rear axle assembly. 2. Check the surrounding area of each oil plug/oil seal for
3. Clean the surrounding area of oil filler plug, remove the oil leakage, replace the faulty oil plug or seal gasket,
oil filler plug and discard the seal gasket. oil seal as necessary.
4. Clean the surrounding area of the drain plug, remove 3. Put a proper container under the rear axle assembly.
the drain plug and discard the seal gasket. 4. Clean the area around the oil filler plug, remove the oil
filler plug and seal gasket, and discard the seal gasket.
5. If the oil level port has oil drop overflows, finish
the operation and turn off the engine; if no oil drop
overflows there, refill appropriate oil.

6. Refill the rear axle assembly oil through the filling port
until the oil overflows.
5. Drain rear axle assembly oil.

Refill
1. Clean the filling port and drain plug.
2. Fit a new seal gasket to the drain plug, and tighten the
drain plug to 29–34Nm.
3. With an appropriate and clean funnel, refill the rear
axle assembly with oil through the filling port until the
oil reaches the specified value.
Drain and Refill 0.51L (Volume for refill after
10min's horizontal drain)
Refill from Dry State 0.53-0.59 L
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Breather Plug
Remove
1. Remove the rear axle assembly.
Rear Axle Assembly Remove

2. Remove the breather plug cover with the pincher.
3. Remove and discard the breather plug with the special
tool TPT00177 and the impact puller in TPT00117.
Refit
1. Clean the mounting location of the vent plug and
ensure it is free from foreign material.
2. With the TPT00194 and hammer, fit a new vent plug
to the rear axle assembly.
3. Fit the rear axle assembly.
Rear Axle Assembly Refit
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Special Tools
Number
Input shaft
TPT00213 oil seal
presser-FDU
Rear wheel
drive shaft
TPT00212
oil seal
presser-FDU
Vent-plug
TPT00177 Sleeve-PTU
and FDU
Remover
seal
Vent-plug
TPT00194 Presser-PTU
and FDU
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HVAC System HVAC System
HVAC System
Specifications
Torque
Description Value
Bolt-Air conditioner compressor to engine 19–25Nm
Bolt-compressor/condenser pipe to compressor 19-25Nm
Bolt - PAS to PAS bracket 22–28Nm
Blot- A/C Compressor to engine 19–25Nm
Bolt-Expansion valve to evaporator 5.5Nm
Nut-Air conditioner pipe to expansion valve 18–22Nm
Nut-Air conditioner pipe to condenser 19–25Nm
Nut-evaporator/compressor pipe A to 7 - 10 Nm
evaporator/compressor pipe B
Bolt-heater assembly to body 5Nm
Bolt-Blow to heater case 1.2Nm
Bolt-Heater water pipe to heater case 1.2Nm
Bolt-front seat belt to ‘BC’ post 30–35Nm
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Parameters
Parameters
Type of Refrigerant HFC-R134a

Volume of Refrigerant 560±20 g
Compressor:
Displacement: 8–161 cm³/r
Speed
∙Minimum Speed 600 r/min
∙Maximum Speed 9200 r/min
Lubricant: SP10
Refill Amount (New) 130±10 ml
Evaporator Temperature Sensor:
∙Compressor ON ≥5℃
∙Compressor OFF Off after 60s @ ≤3.5℃ or Off immediately @ ≤2℃
Pressure Sensor:
Pressure Protection:
∙High Pressure Protection ON When pressure ≥3.14 Mpa, the switch disconnects.
∙Low Pressure Protection ON When pressure ≤0.196 Mpa, the switch disconnects.
Amount of lubricating oil for replacement of air conditioning system components (parameters including oil
recovered):
Total amount of lubricant 130±10 ml

Compressor replacement Remaining lubricant in the original compressor
Condenser replacement 30 ml
Evaporator Replacement 40 ml
Replace one or more pipes 30 ml
Note: 1. large leak, cracked hose, impact or open relief valve can cause sudden loss of the refrigerant. Refrigerant leak
or slow leak will not cause this degree of fluid loss. When replacing components which cause a huge loss of refrigerant,
add an appropriate amount of fluid to specific components. 2.If the lost fluid of the components exceeds the specified
value, add as per the amount of loss.
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System Layout
Heating and Ventilation Components
1. Instrument Panel Air Duct - Right 6. Rear Seat Footwell Air Duct - Left
2. Internal Circulation Inlet 7. Instrument Panel Air Duct - Left
3. Instrument Panel Air Duct - Face 8. Front Window Air Duct - Left
4. Rear Seat Footwell Air Duct - Right 9. Windshield Air Duct
5. Rear Central Air Duct 10. Front Window Air Duct - Right
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A/C Cooling System
1. Low Pressure Service Connector 5. Evaporator and TXV

2. A/C Pipe 6. Condenser
3. A/C Pressure Sensor 7. Compressor
4. High Pressure Service Connector
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Description A/C Air Duct
Overview
HVAC: HVAC is used to control the interior air temperature,
humidity, cleanliness and airflow in an optimum state, provide
a comfortable ride for the occupant and relieve travel fatigue;
meanwhile, it creates a good working condition for driver and
plays an important role in ensuring safe driving.
According to the setting on the control panel, the blower

provides power source, and the fresh air or interior air filtered
by the A/C filter passes through the A/C box before being
heated or cooled, it then blows to the windshield or passenger
through the air duct.
HVAC: it consists of the ventilation, refrigeration, heating

and control unit. It includes the A/C filter assembly, A/C The A/C air duct uses air as the transmission medium, which
box assembly (heater core, evaporator, etc.), air duct, A/C consists of the instrument panel central air duct, instrument
controller, negative ion generator, control panel, etc. panel Defrost air duct, front Feet air duct, rear Feet air duct
According to models, the vehicle will be provided with one of and centre console air duct.
the two air conditioning systems, i.e. ETC or ATC: A/C Box Assembly
• In the ETC system, functions such as air recirculation, air
The A/C box assembly heats and distributes the fresh air or
temperature, air distribution and blower speed, etc are
recirculating air according to the mode selected on the control
selected manually.
panel. The A/C box assembly is below the instrument panel.
• The ATC monitors and regulates the temperature, The A/C box includes the blower, A/C air filter, heater core,
blower speed and air distribution automatically. The evaporator core and control damper. The passage in the A/C
automatic mode provides an optimum system control box assembly introduces air into the A/C box and divides it into
and does not need any manual interference. Manual three parts, air is delivered to the "face", "feet" and "defrost"
mode allows to ignore the automatic running of a single vents respectively. A fresh recirculating air damper is provided
function for the purpose of fulfilling individual needs. on the A/C box assembly housing, which makes adjustments
Ventilation and uses the interior air or exterior air as the recirculating
air. The drain outlet at the bottom of the box body directs
Ventilation: A/C filter, A/C air duct, A/C box (housing, damper,
condensed water from the box body to the lower side of the
damper actuator, blower) and air outlet.
vehicle.
A/C Air Filter
The damper is in the A/C box, which controls the inlet air,
The A/C air filter is used to improve the quality of the air outlet air temperature and position of the outlet air.
flowing into the interior of the vehicle and filter fine particles,
Recirculation damper: the damper actuator drives the
such as dust and pollen, etc.
recirculation damper to open and close the fresh and
The A/C air filter is fitted on the A/C box assembly, it shall be recirculating air inlets so as to control the inlet air.
checked on a regular basis, and if necessary, replace it.
Temperature damper: the damper actuator drives the
temperature damper to vary the mixing ratio of the cold/warm
air so as to control the temperature of the A/C outlet air.
Mode damper: the damper actuator drives the mode damper

to vary the air passing through the A/C box and air duct so
as to meet the user's different needs, such as, face air, feet air,
windscreen air, etc.
Blower
The blower is the power source for the whole ventilation

system, use the blower to drive interior air circulation or
introduce fresh air into the interior vehicle.
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The blower is inside the A/C box assembly. Control of the Heating
blower air volume can be realized by using the button on the
It provides heat for the A/C heating.
control panel to control the blower speed regulation resistor
of the A/C box assembly. Heater Core
Air Outlet The heater core heats the air supplied to each distribution
outlet. The heater core mounted in the A/C box assembly
The air outlet helps the warm air and ventilating air to pass
is an aluminum unidirectional flat-tube heat exchanger. Two
through the passenger compartment.
aluminum pipes are mounted on the heater core, they pass
The air outlet is located at both sides of the luggage through the engine compartment wall to connect the heater
compartment, which allows the air in the passenger core assembly with the engine coolant circulating system.
compartment to be discharged to the hidden area between When engine runs, coolant constantly flows through the
the body and the rear bumper. The air outlet is an effective heater core under the action of coolant pump.
check valve and each consists of a grille covered by soft Refrigerant System
rubber dampers. The damper can open or close automatically
A/C Schematic
according to the pressure difference between the passenger
compartment and the external environment.
A/C System Schematic
A= Liquid Coolant; B= Gas Coolant

1. Evaporator 6. Filter
2. TXV 7. Desiccant
3. A/C Pressure Sensor 8. Condenser
4. High Pressure Service Connector 9. A/C Compressor
5. Cooling Fan 10. Low Pressure Service Connector
The refrigeration system transfers heat from the vehicle to the pressure/temperature modes. In each pressure/temperature
outside atmosphere and provides the A/C box assembly with mode, the state of the refrigerant changes. During this process,
dehumidified cool air. The system comprises a compressor, a the refrigerant absorbs and releases maximum heat. The low
condenser, TXV, A/C pipes and an evaporator. The system pressure/temperature mode starts with the TXV, through the
is a closed loop which applies R134a refrigerant as the heat evaporator to the compressor, in the TXV, the refrigerant
transfer medium. Add A/C oil to the refrigerant to lubricate decreases in pressure and temperature, then it changes from
the internal components of the compressor. moderate temperature liquid to low temperature vapour in
the evaporator before absorbing heat from the ambient air of
To accomplish the transfer of heat, the refrigerant is
the evaporator. The high pressure/temperature mode starts
circulated around the system where it passes through two
with the compressor, through the condenser to the TXV,
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the pressure and temperature of the refrigerant increase as and changes the refrigerant from a vapour to liquid. The
it passes through the compressor, then it releases heat to condenser cools and liquifies the refrigerant before it enters
the atmosphere via the condenser and changes from high the modulator. In the modulator, most of the remaining gas in
temperature vapour to moderate-high temperature liquid. the refrigerant is separated. The refrigerant uses the desiccant
and filter to remove moisture and particles before entering
Compressor
into the secondary cooler. The refrigerant is further cooled
as it flows through the secondary cooler, this results in the
refrigerant from the condenser outlet to the evaporator is
almost 100% converted into liquid.
Thermostatic Expansion Valve (TXV)
TXV and Evaporator
1. High Pressure Compressor Harness Interface

2. Inlet Port
3. Outlet Port
4. Low Pressure Connector
The compressor fitted on the engine is a variable displacement

compressor. The compressor is driven by the electromagnetic
clutch and pulley. The compressor circulates the refrigerant
within the system by compressing the low pressure/low
temperature vapour from the evaporator and loading it into
the condenser as high pressure/high temperature vapour.
Condenser 1. Evaporator
2. O-ring
3. TXV
4. Bolt
The TXV regulates the flow of the refrigerant and matches

the refrigerant flow with the heat load of the air passing
through the evaporator core. The TXV is mounted on the
inlet and outlet ports of the evaporator. The valve consists of
an aluminum housing containing inlet and outlet passages. A
metering valve is fitted in the inlet passage and the metering
valve is controlled by a temperature sensitive tube connected
to a diaphragm. The top of the diaphragm is filled with
refrigerant and senses evaporator outlet pressure and the
The condenser transfers the refrigerant heat into the ambient tube senses evaporator outlet temperature. By regulating the
air and changes the coolant vapour from the compressor opening of the thermostatic expansion valve, the force can be
into liquid. The condenser also removes moisture and balanced, this keeps a proper temperature for the evaporator
solid impurities from the refrigerant with its drying module outlet and balances the refrigerant flow and the thermal load
and functions as a reservoir for liquid refrigerant so as to of the air.
accommodate changes of heat load in the evaporator.
With the impact effect and/or cooling fan, the air passing
through the heat exchanger absorbs heat from the refrigerant
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Thermostatic Expansion Valve The temperature and pressure of the refrigerant from the
evaporator drive the diaphragm and temperature sensitive
tube to move and regulate the metering valve opening, by
this way, the temperature and pressure control the volume of
the refrigerant flowing through the evaporator. The warmer
the air flowing through the evaporator core, the more heat
available to evaporate refrigerant, and this allows more
refrigerant to pass through the metering valve.
Evaporator
The evaporator is in the air inlet of the heater assembly and
absorbs heat from the exterior or recirculated inlet air. Low
pressure and low temperature refrigerant changes from liquid
to vapour in the evaporator, absorbing large quantities of heat
during this process.
1. Film
A/C Pipeline
2. Housing
Aluminum A/C pipelines connect the system components
3. Metering valve together with O rings refitted between the connections to
4. Inlet passage to the evaporator ensure a secure seal. To maintain a similar flow velocity in the
5. Outlet passage from the evaporator system, the diameter of the refrigerant lines may vary so as to
6. Thermo-sensitive tube suit the two pressure/temperature modes. Fit the pipelines
with larger diameters under low pressure/temperature
The liquid coolant flows from the metering valve to the condition and those with smaller diameters under high
evaporator. The metering valve reduces the pressure and pressure/temperature condition, and incorporate the
temperature of the refrigerant, changes the solid stream of refrigerant refilling port into the A/C pipelines so as to
refrigerant into a fine spray and improves the evaporation facilitate system service.
effect. As the refrigerant passes through the evaporator,
it absorbs heat from the ambient air flowing through the
evaporator core. The increase of the temperature causes the
refrigerant to vaporize and increases its pressure.
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Operation 2. If the refrigerant pressure is below or above the pressure
Overview limit, the ECM sends commands for disengaging the A/C
compressor clutch.
To run the cooling system, the A/C ECU shall communicate
with the ECM. The ECM controls the engagement of the 3. If the refrigerant pressure is greater than the specified
compressor clutch and the speed of the engine cooling fan. value, the ECM sends commands for adjusting the cooling
The A/C ECU also controls the blower speed of the heater, fan speed and operating the cooling fan at high/low speed
intake air, air temperature and air distribution. according to the pressure value.
Blower Control Pressure protection of the pressure switch:

The blower control module connects the blower power High Voltage Low Voltage
Protection Protection
output terminal to different ground terminals, the appropriate
operating voltages are thus produced. The blower control MPa ≥3.14 ≤0.196
module can only provide the blower with the battery voltage
Thus, if the A/C pressure is lower than or exceeds one of the
and allow it to operate at maximum speed.
closing pressure thresholds, the ground path of the ECM will
Intake
be disconnected. This causes the ECM to disengage the A/C
When pressing the circulation control switch, the switch will compressor clutch.
ground the control panel. Then the circulation control motor
The compressor is lubricated by oil suspended in the
turns the control damper of the heater assembly to close the
refrigerant, so operation of the compressor shall be prevented
fresh air inlet and open the circulating air inlet. Press the
if the refrigerant/lubricant in the system are minimum due to
circulation control switch again, the circulation control motor
minimum refrigerant pressure.
turns the circulating air ground to the fresh air ground. Then
the circulation control motor turns the control damper of When the refrigerant pressure increases to a value that
the heater assembly to open the fresh air inlet and close the indicates additional condensing is required, the ECM grounds
circulating air inlet. the cooling fan relay unit and requests for the corresponding
cooling fan speed.
The circulation control motor shifts the damper to external
circulation mode. Failure
Air Temperature If the sensor fails, the driver may notice that the A/C system
does not operate at all or it stops after running for a period of
The blend damper servo motor of the fan heater on the fan
time.
heater assembly is controlled by turning the temperature knob
switch on the control panel. The blend damper changes the The sensor may have the following faults:
ratio of air flowing through the fan heater bypass and the • Low refrigerant pressure due to leak or wrong
heater core body. The ratio varies between "all bypass without refrigerant refilled
heater" and "all heater without bypass" so as to fit the position • High refrigerant pressure due to wrong refrigerant
of the knob switch. refilled
Air Distribution • Internal wire is short circuit.
Use the 4 air distribution switches on the control panel to • External wire is open.
operate the mode damper servo motor and turn the air • External wire is short to the 12V power supply.
distribution damper in the heater assembly so that air can
• Ground of the sensor is missing.
be introduced into the corresponding air outlet around the
passenger compartment. Compressor
A/C Pressure Sensor When the engine is running and A/C is off, the clutch is
de-energized, the pulley and the drive belt freewheel. Balance
The A/C pressure sensor monitors the pressure of the A/C
the vapour pressure in the compressor housing, the spring
system and sends signals to the ECM. The ECM controls
between the carriage and the swash plate fixes the swash plate
the cooling fan speed and protects the compressor, etc. The
with a minimum angle of inclination so as to reduce the load
pressure sensor performs the following operations:
during the start-up of the system.
1. If the specified refrigerant pressure is met, the ECM sends
commands for engaging the A/C compressor clutch. When the A/C is requested, the clutch is energized and the
pulley turns the shaft. The lug plate and the swash plate turn
with the shaft, and the angled swash plate allows the piston
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to produce reciprocating movement. Vapour from the inlet A/C Compressor Clutch Relay
pressure chamber is drawn into the cylinders, compressed,
A 12V power supply is supplied to the A/C compressor clutch
and discharged into the outlet pressure chamber, producing
via the engine compartment fuse. When the main relay is
a flow around the refrigerant circuit. The flow rate in the
energized, the relay coil of the A/C compressor clutch can be
compressor depends on the piston stroke, which is controlled
activated. The relay coil ground is controlled by the ECM,
by the inclination angle of the swash plate. The inclination
which completes the ground when an A/C On request message
angle of the swash plate is set by the servo pressure and the
is received.
compressor inlet pressure acted on the piston in its intake
stroke. When the relevant intake pressure exceeds the servo Failure
pressure, the piston moves along its cylinder to increase the If the A/C compressor clutch relay fails, the followings will
angle of inclination, piston stroke and flow rate. Similarly, when occur:
the relevant intake pressure drops below the servo pressure, • The clutch does not engage the compressor pulley (visual
the piston moves along its cylinder to decrease the angle of check).
inclination, piston stroke and flow rate.
• High intake air temperature.
When starting, the compressor inlet pressure is relatively
The A/C compressor clutch relay may have the following
low. In the control valve, the baffle plate and push rod keep
malfunctions:
the ball valve open. This allows the restricted flow of the
outlet pressure enter into the swash plate chamber through • Relay coil is short-circuited.
the ball valve and the minimum inclination angle of the swash • Relay coil is open.
plate is maintained. When the refrigerant flows through • Relay coil has a high resistance.
the evaporator and absorbs heat (i.e. when the heat load • Relay contact is disconnected.
increases), the vapour pressure entered into the compressor
• Relay contact is closed.
will increase. In the control valve, the increased inlet pressure
will move the baffle plate and the push rod to switch off the • Relay contact has a high resistance.
ball valve. When the pressure of the swash plate chamber • Relay wire is open.
decreases and the intake pressure increases, the piston will • Relay wire has a high resistance.
move the swash plate in its intake stroke to increase the
• Relay wire is short to the 12V power supply.
inclination angle, piston stroke and the flow rate in the
• Relay wire is short to ground.
compressor. When the heat load of the evaporator decreases,
the pressure of the vapour entered into the compressor • ECM does not provide ground.
will reduce to open the control valve. This will increase the If the A/C compressor clutch does not engage, but the A/C
pressure of the swash plate chamber, and thus reduces the switch is in "On" position, remove the compressor clutch relay
inclination angle of the swash plate and the flow rate in the and conduct a test.
compressor.
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Service Procedures Drain
Refrigerant Recovery and Refill 1. Check whether the high-pressure side and low-pressure
Refrigerant Reccovery side hoses are connected to the air conditioning
1. Connect the high-pressure side hose with a quick system. Open the high/low-pressure side valves on the
disconnection interface to the high-pressure service refilling station control panel.
side connector of the air-conditioning system. 2. Open the gas and liquid valves on the refrigerant
Tip: Use refrigerant tank designed only for service reservoir.
station. Overcharging restraint system is designed based Caution: The evacuating procedure must be carried out
on this kind of refrigerant tank. The tank valve is also before recharging process.
designed for the restraint system.
3. Start the vacuum pump and start the drain process.
2. Open the interface valve. In the process of recirculation, non-condensable gases
3. Connect the low-pressure side hose with a quick (mostly air) will be automatically exhausted from the
disconnection interface to the low-pressure service reservoir. A sound of pressure release may be heard.
side connector of the air-conditioning system. 4. Check the system for leak. For information about the
4. Open the interface valve. refilling station, refer to the manufacturer's instructions
5. Check the high-pressure side and low-pressure side for use.
gauges on the control panel of the refilling station, A/C Lubricating Oil Refill
and ensure there is pressure in the A/C. If there is no At this time, the lubricating oil discharged from the air
pressure, there is recoverable refrigerant in the system. conditioning system during recovery must be supplemented.
6. Open the valves for the high-pressure side and
Note:
low-pressure side.
• Always keep the lubricating oil bottle cap tight to prevent
7. Open the gas and liquid valves on the refrigerant
moisture or contaminants from entering the lubricating
reservoir.
oil.
8. Drain the refrigerant in the oil separator.
• This operation requires a vacuum air conditioning
9. Close the drain valve. system. It is forbidden to open the lubricating oil filling
10. Connect the refilling station to the appropriate power valve when the air conditioning system is at positive
socket. pressure. This will result in backflow of lubricating oil
11. Connect the main power switch. through the bottle air vent.
Caution: Reuse the recycled lubrication is prohibited. The • An oil level lower than the suction pipe is prohibited
recycled lubrication will damage the equipment. when refilling or supplementing lubricating oil; otherwise,
air will enter the air conditioning system.
Caution: Part of A/C lubrication (PAG) could be recycled
together with refrigerant but service station can separate 1. Use the special polyether type lubricating oil (contained
lubrication from refrigerant to calculate the quantity of in graduated bottle) for R-134a system.
lubrication. 2. For information about the refilling station, refer to the
manufacturer's instructions for use. Add an appropriate
12. Start the recovery. For information about the refilling
amount of lubricating oil to the A/C system.
station, refer to the manufacturer's instructions for use.
3. When the oil refilled reaches the required point, close
13. Wait for 5min before checking the low-pressure side
the valve.
gauge on the control panel. If the air conditioning
system is capable of keeping vacuum, the recovery is Refill
completed. Caution: The evacuating procedure must be carried out
before recharging process.
Warning: If warning indicator illuminates, it means the
tank is overfull and service station will stop, install a new 1. Close the low-pressure side valve on the control panel.
empty tank to continue this process. The different type 2. Open the high-pressure side valve on the control panel.
of tank is prohibited using.
3. For information about the refilling station, refer to the
14. If the pressure at the low-pressure side starts to manufacturer's instructions for use.
rise from 0, there remains refrigerant in the system.
4. Refill refrigerant of the required amount into the air
Recover the residual refrigerant. Repeat this step until
conditioner, and ensure the unit of measurement is
the system can keep vacuum for 2 minutes.
1.0 687
correct, for example, kg or lb. Whether the Refrigerant Refilling is Successful

5. Start refill. Refrigerant Refill Completion
1. Close the high-pressure side valves on the refilling
station control panel. Both valves shall be closed.
2. Start the vehicle and air conditioning system.
3. Keep the engine running until the readings on the
high-pressure side pressure gauge and the low-pressure
side pressure gauge are stable.
4. Compare the readings with the system specifications.
5. Check the outlet temperature of the evaporator, and
ensure that the air conditioning system operation
conforms to the system specifications.
6. Keep the air conditioner running.
7. Close the high-pressure side interface valve.
8. Disconnect the high-pressure side hose from the
vehicle.
9. Open the valves of the high/low-pressure side on
the control panel. The system will quickly suck in
refrigerant from two hoses through the low-pressure
side hose.
10. Close the low-pressure side interface valve.
11. Disconnect the low-pressure side hose from the
vehicle.
Refrigerant Refill Failure
Sometimes, the refrigerant is not completely refilled into the
air conditioning system. There are two reasons:
1. The pressure of the refrigerant reservoir in the refilling
station is close to that of the A/C system,
• which leads to slow oil delivery.
• For information about the refilling station, refer to the

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

of the refilling station.
• Therefore, part of the refrigerant refilled must be

recovered from the vehicle, then drain the air conditioning
system before refilling.
• For information about the refilling station, refer to the

manufacturer's instructions for use.
1.0 688
Compressor Refit
Remove 1. Fix the A/C compressor to the engine, fit the bolts,
1. Disconnect the battery negative. tighten to 19–25Nm in the sequence of A–B–C, and
2. Recover the air conditioning refrigerant. check the torque.
A/C Refrigerant Recovery

5. Remove 3 bolts fixing the steering pump idler to the
bracket.
2. Remove the plug, fit a new seal ring to the A/C pipeline,
and coat with clean compressor oil.
3. Fit the A/C pipe to the compressor, fit the nut, tighten
4. Connect the connector of compressor clutch.
5. Fit the turbocharger solenoid valve.
6. Remove the turbocharger solenoid valve. Turbocharger Solenoid Valve Refit

6. Fix the steering pump idler to the bracket, fit 3 bolts,
Turbocharger Solenoid Valve Remove
7. Disconnect the connector (2) of the compressor clutch.
7. Fit the engine auxiliary drive belt.
8. Remove 2 nuts (3) fixing the A/C pipe to the
compressor and release the A/C pipe from the Engine Auxiliary Drive Belt Refit
compressor. 8. Lower the vehicle.
Caution: Always fit plugs to open connections to prevent 9. Refill the A/C refrigerant.
contamination. A/C Refrigerant Refill
9. Remove and discard the O-ring of the A/C pipe. 10. Connect the battery negative.
10. Remove 3 bolts (1) securing the A/C compressor and
engine.
11. Slowly move the compressor in the engine

compartment to remove it.
1.0 689
Compressor–1.5T 5. Fit bottom air deflector.

Remove Bottom Deflector Refit
6. Refill the air conditioning system refrigerant.
2. Recycle the air conditioning system refrigerant.
Air Conditioning System Refrigerant Refill
Recycling of Air Conditioning System
Refrigerant
4. Disconnect the connector (2) of compressor
electromagnetic clutch.
5. Remove one bolt (1) securing the hose assembly to the
compressor, and disconnect the connection.
6. Remove 3 bolts fixing the compressor to the

compressor bracket.
7. Move the compressor slowly in the engine compartment

and remove it.
Refit
1. Fit the compressor to the vehicle.
2. Fix the compressor to the compressor bracket, fit 3
screws, tighten it to 19–25Nm, and check the torque.
3. Fix the hose to the compressor, fit 1 nut, tighten it to
4. Connect the connector of compressor electromagnetic
clutch.
1.0 690
Compressor Bracket-1.5T Evaporator
Remove Remove
1. Remove the compressor assembly. 1. Remove the heater assembly.
Compressor Assembly Remove Heater Assembly Remove

2. Remove 3 bolts fixing the compressor bracket to the 2. Remove the heater core.
engine.
Heater Core Remove
3. Remove the expansion valve.
Expansion Valve Remove

4. Remove the blower assembly.
Blower Assembly Remove

5. Remove the screw and clip fixing the guide pipe of the
intake air to the heater.
6. Remove the screw and clip securing the vent box and
heater, and remove the vent box.
7. Remove the clip and screw securing the heater, and
disconnect the heater box.
8. Remove the evaporator assembly.
3. Remove the compressor bracket from the vehicle.
Refit
Refit
1. Fit the evaporator to the heater assembly.
1. Secure the compressor bracket to the engine, fit 3
2. Fit the heater box and secure with clips and screws.
bolts and tighten them to 19–25Nm.
3. Secure the vent box on the heater box, and secure
2. Fit the compressor assembly.
with screws and clips.
Compressor Assembly Refit 4. Fix the guide pipe of the intake air to the heater box,
and secure with screws.
5. Refit the blower assembly.
Blower Assembly Refit

6. Refit the heater core.
Heater Core Refit

7. Refit the expansion valve.
Expansion Valve Refit

8. Refit the heater assembly.
Heater Assembly Refit
1.0 691
Expansion Valve Condenser

Remove Remove
1. Recover the A/C refrigerant. 1. Disconnect the battery negative.
A/C Refrigerant Recovery 2. Recycle the A/C system refrigerant.
2. Remove 1 nut fixing the A/C hard pipe to the TXV and A/C System Refrigerant Recycle
disconnect the pipe. 3. Remove the cooling fan assembly.
contamination.
5. Remove 1 nut (2) securing the A/C hard pipe assembly
(condenser) on the condenser.
contamination.
6. Remove the nut (1) securing the A/C pipe (

compressor/condenser) on the condenser.
contamination.
3. Remove and discard the O ring.

4. Remove 2 bolts fixing the TXV to the A/C box and
remove the TXV.
contamination.
7. Remove the upper radiator beam.

8. Remove the condenser from the radiator slot.
5. Remove and discard the O ring.

Refit
1. Renew the O ring, and fit it to the evaporator core pipe.
2. Fit the TXV bracket to the evaporator core, fit 2 bolts,
tighten to 5.5Nm and check the torque.
3. Renew the O ring, and fit it to the air conditioning
hard pipe assembly.
4. Fit the A/C hard pipe assembly to the TXV, fit 1 nut,
5. Refill the A/C refrigerant. Refit
A/C Refrigerant Refill 1. Fix the condenser to the radiator groove.
1.0 692
2. Fit the upper radiator beam. A/C Pressure Sensor
Upper Radiator Beam Refit
Remove
3. Secure the compressor exhaust hose to the condenser,
fit 1 nut, tighten it to 19–25Nm, and check the torque. 2. Recover the air conditioning refrigerant.
4. Secure the A/C tube assembly - condenser on the A/C Refrigerant Recovery
condenser, fit 1 nut, tighten to 19–25Nm, and check 3. Disconnect the connector of the A/C pressure sensor.
the torque.

7. Refill the A/C system refrigerant.
A/C System Refrigerant Refill

4. Remove the A/C pressure sensor from the A/C high

pressure pipe and discard the O ring.

contamination.
Refit
1. Lubricate the new O ring with clean A/C oil.
2. Fit the O ring to the A/C pressure sensor.
3. Fit the A/C pressure sensor to the A/C high-pressure
pipe and secure it.
4. Connect the connector of the A/C pressure sensor.
5. Refill the A/C refrigerant.

1.0 693
A/C Pipeline - Compressor/Condenser 2. Secure the A/C pipeline - compressor/condenser on

Remove the compressor, fit the nut, tighten to 19-25Nm, and
1. Recycle the A/C refrigerant. check the torque.
3. Replace a new O-ring, and fit it to the A/C pipeline -
A/C System Refrigerant Recycle
compressor/condenser.
4. Secure the A/C pipe - compressor/condenser on the
Front Bumper Assembly Remove condenser, fit the nut, tighten to 19–25Nm, and check
3. Remove the nut (1) securing the A/C pipeline the torque.
- compressor/condenser on the condenser, and 5. Fit the front bumper assembly.
disconnect the pipeline from the condenser.
contamination. 6. Fill the A/C refrigerant.
4. Remove the O-ring from the evaporator/compressor

pipeline and discard it.
5. Remove the nut (3) fixing the A/C pipeline -
compressor/condenser on the compressor, disconnect
the pipeline from the compressor, and remove the A/C
pipeline - compressor/condenser.
contamination.
6. Remove the O-ring from the A/C pipeline -

compressor/condenser and discard it.
Refit
1. Replace a new O-ring, and fit it to the A/C pipeline -
compressor/condenser.
1.0 694
A/C Pipe A - Evaporator Compressor (evaporator/compressor) to 7 - 10 Nm, and check
Remove the torque.
1. Recover the air conditioning refrigerant. 3. Remove the plug, fit a new seal ring to the A/C pipeline,
A/C Refrigerant Recovery
4. Secure A/C pipe A (evaporator/compressor) on the
2. Remove the nut (3) fixing A/C pipe A
compressor, fit the nut, tighten to 19-25Nm and check
(evaporator/compressor) to the compressor,
the torque.
and disconnect the pipe from the compressor.
5. Refill the A/C refrigerant.
contamination. A/C Refrigerant Refill
3. Remove the O ring from the evaporator/compressor

pipe and discard it.
4. Remove the nut connecting A/C pipe A
(evaporator/compressor) and A/C hard pipe,
and disconnect the pipe.
contamination.
5. Remove the O ring from the evaporator/compressor

pipe and discard it.
6. Remove the pipe from the vehicle.
Refit
1. Remove the plug, fit a new seal ring to the A/C pipeline,
2. Tighten the nut connecting A/C pipe B
(evaporator/compressor) and A/C pipe A
1.0 695
A/C Pipe B - Evaporator Compressor

Remove
1. Recycle A/C refrigerant.
4. Remove the turbocharger intake hose.
Turbocharger Intake Hose Remove
5. Disconnect the connector of the A/C pressure sensor.
10. Remove and discard the O-ring of the pipe.

11. Remove the nut (2) securing A/C pipe B
(evaporator/compressor) on the condenser.

contamination.

7. Remove the nut fixing the A/C hard pipe assembly to
the thermal expansion valve, and disconnect pipeline
connection.
contamination. 12. Remove and discard the O-ring of the pipe.
13. Remove 2 clips securing the A/C hard pipe assembly
on the body.
8. Remove and discard the O-ring of the pipe.

9. Remove the nut connecting A/C pipe A
(evaporator/compressor) and A/C pipe B 14. Remove A/C pipe B (evaporator/compressor) from
(evaporator/compressor), and disconnect the pipe. the vehicle.
Caution: Always fit plugs to open connections to prevent Refit

contamination. 1. Fit A/C pipe B (evaporator/compressor) to the vehicle.
1.0 696
2. Fit A/C pipe B (evaporator/compressor) to the body, A/C Filter Cover
and secure with clips. Remove
3. Remove the plug, fit a new seal ring to the A/C pipe, 1. Remove the glove box assembly.
Glove Box Assembly Remove
4. Secure A/C pipe B (compressor/condenser) on the
2. Loose the clip securing the filter cover onto the A/C
condenser, fit the nut, tighten to 19–25Nm and check
box and remove A/C filter cover.
the torque.
5. Remove the plug, fit a new seal ring to the A/C pipe,
6. Tighten the nut connecting A/C pipe B
(evaporator/compressor) and A/C pipe A
(evaporator/compressor) to 7 - 10 Nm, and check
the torque.
7. Remove the plug, fit a new seal ring to the A/C pipe,
8. Secure A/C pipe B (evaporator/compressor) on the
thermostatic expansion valve, fit 1 nut, tighten to
Refit
1. Refit the filter cover onto the A/C box assembly and
10. Connect the connector of the A/C pressure sensor. secure with clips.
11. Fit the turbocharger intake hose. 2. Fit the glove box assembly.
Turbocharger Intake Hose Refit Glove Box Assembly Refit


1.0 697
A/C Filter Element A/C Box Assembly

Remove Remove
1. Remove the A/C filter cover. 1. Disconnect the battery negative.
A/C Filter Cover Remove 2. Drain the engine cooling system.

2. Remove the A/C filter element. Engine Cooling System Drain
3. Recycle the A/C system refrigerant.
A/C System Refrigerant Recycle

4. Remove the nut fixing the A/C hard pipe assembly
to the thermal expansion valve, then disconnect the
pipeline.

contamination.
Refit
1. Refit the new A/C filter element.
2. Refit the filter cover onto the A/C box assembly and
secure with clips.
3. Refit the A/C filter cover.
A/C Filter Cover Refit
5. Remove 2 clamps (1) and (2) fixing hoses to the air

heater assembly, then disconnect the pipeline.
6. Remove the instrument panel beam.
Instrument Panel Beam Remove

7. Disconnect the harness connector of A/C box assembly.
8. Remove 2 screws fixing the A/C box assembly to the
firewall sheet metal.
1.0 698
Blower
Remove
2. Disconnect the blower connector (1).
3. Remove 1 screw (2) securing the blower on the heater
assembly.
9. Remove the A/C box assembly from the vehicle.

Refit
1. Fit the A/C box assembly to the vehicle.
2. Fix the A/C box assembly to the front firewall sheet
metal, fit 2 bolts and tighten to 5Nm, then check the
torque.
4. Pry the clip (1) open and turn it clockwise to remove
3. Connect the connector of A/C box assembly.
the blower from the vehicle.
4. Fit the instrument panel beam assembly.
Instrument Panel Beam Assembly Refit
5. Fix the hose to the heater assembly and secure with
clamps.
6. Remove the plug, fit a new seal washer to the A/C pipe,
and apply clean compressor oil.
7. Fit the A/C tube assembly to the thermostatic
expansion valve, fit 1 nut, tighten to 18–22Nm and
check the torque.
9. Fill the engine cooling system. Refit
1. Turn the blower counterclockwise to secure it on the
heater, and fix the clips.
2. Secure the blower on the heater assembly, fit 1 screw,
11. Perform a self-learning for the A/C servo motor. tighten to 1.2Nm and check the torque.
Self-learning and Adjustment, Programming and 3. Connect the connector of the blower.
Encoding - A/C Servo Motor Self-learning 4. Connect the battery negative.
1.0 699
Heater Core Refit

Remove 1. Fit the heater core to the A/C box.
1. Remove the A/C box assembly. 2. Fix the feet vent duct to the A/C box, fit 2 screws and
A/C Box Assembly Remove tighten up.
2. Remove 1 screw securing the heater core pipeline on 3. Secure the heater core on the A/C box assembly and
the A/C box, and release the pipe clamp. tighten with clips.
4. Fix the heater core pipeline clamp to the A/C box, fit 1
screw, tighten to 1.2Nm, and check the torque.
5. Refit the A/C box assembly.
A/C Box Assembly Refit
3. Release the clip securing the heater core on the A/C

box assembly.
4. Remove 2 screws fixing the feet vent duct to the A/C

box.
5. Remove the heater core from the A/C box assembly.
1.0 700
Blower Speed Regulation Resistance Left Floor Air Outlet Duct
Remove Remove
1. Disconnect the battery negative. 1. Remove the driver seat assembly.
2. Disconnect the connector of the blower speed Driver Seat Assembly Remove
regulation resistance.
2. Remove 1 bolt securing the front seat belt to the
3. Remove 2 screws fixing the blower speed regulation vehicle body.
resistance to the A/C box assembly.
3. Pry off the doorsill trim panel clip and remove the
doorsill trim panel.
4. Remove the left A pillar lower trim panel.
A Pillar Lower Trim Panel Remove

5. Turn over the driver carpet.
6. Remove 2 nuts (1) fixing the left floor vent duct to the
floor.
4. Remove the blower speed regulation resistance from

the A/C box.
Refit
1. Secure the blower speed regulation resistance on the
A/C box, fit 2 screws and tighten the screw.
2. Connect the connector of the blower speed regulation
resistance.
7. Remove the left floor vent duct.
Refit
1. Refit the left floor air outlet duct to the vehicle.
2. Fix the left floor air outlet duct to the floor, fit 2 nuts
and tighten up.
3. Place the driver carpet again.
4. Refit the left A pillar lower trim panel.
A Pillar Lower Trim Panel Refit

5. Refit 1 bolt connecting the doorsill trim panel and the
front seat belt, tighten to 30–35Nm, and check the
torque.
6. Fit the driver seat.
Driver Seat Assembly Refit
1.0 701
Right Floor Air Outlet Duct Left Body Relief Valve

Remove Remove
1. Remove the passenger seat assembly. 1. Remove the rear bumper assembly.
Front Seat Assembly Remove Rear Bumper Assembly Remove

2. Remove 1 bolt securing the front seat belt to the 2. Loose the clip and remove the left body relief valve
vehicle body. from the vehicle.
4. Remove the right A pillar lower trim panel.

5. Turn over the passenger carpet.
6. Remove 2 nuts (2) fixing right floor air outlet duct to
the floor.
Refit
1. Secure the left body relief valve onto the vehicle and
tighten with clips.
2. Fit the rear bumper assembly.
Rear Bumper Assembly Refit
7. Remove the right floor air outlet duct.

Refit
1. Fit the right floor air outlet duct to the vehicle.
2. Fix the right floor air outlet duct to the roof panel, fit
2 screws and tighten up.
3. Place the passenger carpet again.
4. Refit the right A pillar lower trim panel.

5. Refit 1 bolt connecting the doorsill trim panel and the
front seat belt, tighten to 30–35Nm, and check the
torque.
6. Refit the passenger seat assembly.
1.0 702
Right Body Relief Valve Instrument Panel Vent for Air Distribution to
Remove Face
1. Remove the rear bumper assembly.
Remove
1. Remove the instrument panel assembly.
Rear Bumper Assembly Remove
2. Loose the clip and remove the right body relief valve Instrument Panel Assembly Remove
from the vehicle. 2. Remove 9 screws securing the instrument panel duct
for distribution to face onto the A/C box assembly.
Refit
1. Secure the right body relief valve onto the vehicle and 3. Remove the instrument panel duct for distribution to
tighten with clips. face .
2. Fit the bumper assembly. Refit
1. Refit the instrument panel duct for distribution to face
Rear Bumper Assembly Refit
onto the vehicle.
2. Locate the instrument panel duct for distribution to
face onto the A/C box assembly, then fit 9 screws and
tighten up.
3. Fit the instrument panel assembly.
Instrument Panel Assembly Refit
1.0 703
Left Instrument Panel Duct for Defrost Right Instrument Panel Duct for Defrost
Remove Remove
1. Remove the instrument panel assembly. 1. Remove the instrument panel assembly.
Instrument Panel Assembly Remove Instrument Panel Assembly Remove

2. Remove the instrument panel duct for distribution to 2. Remove the instrument panel duct for distribution to
face. face.
Instrument Panel Duct for Distribution to Face Instrument Panel Duct for Distribution to Face
Remove Remove
3. Remove 2 screws fixing the left instrument panel duct 3. Remove 2 screws fixing the right instrument panel duct
for defrost to the A/C box assembly. for defrost to the A/C box assembly.
4. Remove the left instrument panel duct for defrost. 4. Remove the right instrument panel duct for defrost.
Refit Refit
1. Refit the left instrument panel duct for defrost onto 1. Refit the right instrument panel duct for defrost.
the vehicle. 2. Fix the right instrument panel duct for defrost onto the
2. Fix the left instrument panel duct for defrost onto the A/C box assembly, then fit 2 screws and tighten up.
A/C box assembly, then fit 2 screws and tighten up. 3. Refit the instrument panel duct for distribution to face.
3. Refit the instrument panel duct for distribution to face.
Instrument Panel Duct for Distribution to Face
Instrument Panel Duct for Distribution to Face Refit
Refit 4. Refit the instrument panel assembly.
1.0 704
Central Instrument Panel Duct for Defrost
Remove
Instrument Panel Assembly Remove

2. Remove the instrument panel duct for distribution to
face.

Remove
3. Remove 7 screws fixing the central instrument panel
duct for defrost to the A/C box assembly.
4. Remove the central instrument panel duct for defrost.

Refit
1. Refit the central instrument panel duct for defrost.
2. Fix the central instrument panel duct for defrost onto
the A/C box assembly, then fit 7 screws and tighten up.
3. Refit the instrument panel duct for distribution to face.

Refit
1.0 705
HVAC System HVAC System-ATC
HVAC System-ATC
Specifications
Torque
Description Value
Bolt-Controller to cross member dash 2–4Nm
Screw-A/C control panel to IPK 1.2–2Nm
Bolt-Blend flap servo motor to heater case 1.2Nm
Bolt-Fresh recirculated air flap servo motor to heater case 1.2Nm
Bolt-Distribution flap servo motor to heater case 1.2Nm
1.0 706
HVAC System-ATC HVAC System
System Layout
A/C Control Panel *
1. AC On/Off Touch Button

2. System On/Off Touch Button
3. Air Recirculation Mode Touch Button
4. Air Distribution Mode Touch Button
5. Air Volume Up Touch Button
6. Right Zone Temperature Control Touch Button
7. AUTO Touch Button
8. DUAL Touch Button
9. Left Zone Temperature Control Touch Button
10. Air Volume Down Touch Button
1.0 707
A/C Control System
1. A/C Pressure Sensor 5. Blower Speed Resistance

2. Vent Temperature Sensor 6. Evaporator Core Temperature Sensor
3. Auto Temperature Control Module 7. Exterior Ambient Temperature Sensor
4. Auto Temperature Control Panel * 8. Solar Sensor
1.0 708
A=Body Can B=PT Can C=Hardwire
1.0 709
Description Air Volume Regulation Touch Button

Overview Activated only when the system is on. Provide manual blower
The ATC automatically monitors the inside and outside speed control:
temperature, and adjusts the outlet air temperature, blower • One press of the air speed up/down button, the blower
speed and air distribution. The automatic mode provides speed will change accordingly within Level 1 to Level 8.
an optimum system control mode and does not need any
Fresh/Recirculated Air Button
manual interference. Manual mode allows to ignore the
automatic running of a single function for the purpose of Activated only when the system is on. Provide manual
fulfilling individual needs. selection of the air inlet source. When selecting the
recirculated air mode by manual control, the indicator on the
Control Panel - Automatic Temperature Control
display will illuminate.
The control of the switch is realized by touching the
AUTOTouch Button
entertainment display. These switches have the following
functions: Set the desired target temperature, then press the AUTO
button to enter into the automatic regulation mode. In auto
Air distribution switch: mode, the ATC ECU will automatically control the interior
Activated only when the system is on. Provide manual air air temperature and air distribution.
distribution control:
Close the system:
• When a switch is pressed every time, the air distribution
Press the system OFF button, the system (excluding the
will change, and the change range is only face, face and
display) is off; press the button again to start the system.
feet, only feet, feet and windscreen/front side window
defrost, only windscreen/front side window defrost. Sensor
Temperature Control: Air Duct Temperature Sensor
Activated only when the system is on. The air duct temperature sensor is a 2-wire negative
temperature coefficient thermistor. The sensor operates
• Every turn of the temperature button will increase or
within the temperature range of −40 to +85°C. Sensor is
decrease the corresponding set temperature by 1℃, and
installed inside the distribution duct and is used to measure
the temperature ranges between 16℃ and 28℃.
the air temperature which flow through the air hose. HVAC
• If the temperature drops at 18℃, the screen displays LO
system control module uses these numeric values to calculate
(maximum cooling).
the location of the mixed air damper.
• If the temperature rises at 26℃, the screen displays HI
Evaporator Temperature Sensor
(maximum heating).
The evaporator temperature sensor is a 2-wire negative
Heated rear window (HRW) switch:
HRWIt works only when the engine is running. When within the temperature range of −40 to +85°C. The sensor
operating the HRW switch, a message will be sent to the is in the evaporator, which is used to measure the evaporator
ATC ECU through the hard wire. This will make the HRW temperature. If the temperature is less than 3°C, then turn
relay energized and closed to supply power to the HRW. off the compressor to prevent evaporator from freezing.
HRWThe function is timed (unless it is turned off manually),
otherwise the rear window heater will stop automatically at A/C Refrigerant Pressure Sensor
the following time: The A/C refrigerant pressure sensor is a 3-wire piezoelectric
• For initial start, it turns off after the heating operation pressure sensor. This sensor applies the 5V reference voltage,
lasts for 15min, and it starts to work again within 5min, low level reference voltage and signal circuit to work. The
then it stops automatically after the heating operation A/C pressure signal can be within 0.2 – 4.8V. When the air
lasts for 8min. conditioning refrigerant pressure is low, its signal values will
approach to 0V. When the air conditioning refrigerant pressure
A/C On/Off Touch Button
is high, its signal values will approach to 5V. The engine control
Press the A/C switch to switch on the air conditioner. The module (ECM) converts the voltage signal to a pressure value.
A/C icon on the display illuminates. Press the switch again to When the pressure is low/high, the engine control module will
switch off the A/C. not allow the ETC compressor to work.
1.0 710
Interior Temperature Sensor ATC Harness Connector
The interior temperature sensor is aNTC sensor which End View and Pin Information of ATC Harness
provides the air temperature input of the passenger Connector FA037
compartment forATC ECU. The sensor is fitted on the
one-button start trim panel.
Solar Sensor
This sensor assembly provides the following information:

• Sunlight intensity
• Passenger temperature
The solar sensor is connected to the ground and a 12V timing

power supply through the HVAC control module. The timing
power supply provides power supply for the electronic devices
of the sensor and it is used as the clock generator of the solar
sensor microcontroller.
The sensor identifies data and transfers the measured value of

Pin No. Description
the sunlight intensity through the pulse signal. When the timing
power input rises, the solar sensor microcontroller will change 1 KL30
channels and output the newly measured signal intensity value 2 KL31
to the HVAC control module. The signal voltage changes 3 Sensor Ground_1
within 0 - 4V.
4 Reserved
The passenger compartment temperature sensor is a negative 5 HS CAN High 5V Power Supply_1
6 HS CAN Low
depending on signals and low level reference voltage circuit.
7 LIN_1
When the air temperature increases, the sensor resistance
will decrease. The sensor signal voltage changes within 0 - 5V. 8 Solar Sensor_L
9 Solar Sensor_R
Bright or high intensity light causes the rise of interior air
temperature. The HVAC compensates for the increased 10 Ambient Temperature Sensor
temperature by diverting additional cool air into the vehicle. 11 —
Ambient Temperature Sensor 12 —

13 —
The ambient temperature sensor is fixed on the front inlet
grille. ATC ECUUse the signal of the sensor to modify climate 14 —
control algorithm, so as to compensate the surrounding air 15 —
temperature. 16 Blower Control
17 Integrated Heat Indication Sensor
18 Integrated Heat Sensor Ground
19 Integrated Heat Indication Solar
Sensor
20 Integrated Heat Indication
Reference Sensor
1.0 711
ATCEnd View and Pin Information of Harness ATCEnd View and Pin Information of Harness
Connector FA072 Connector FA073

1 Blower Feedback 1 ＋ 1 —
2 Blower Feedback 1 - 2 —
3 Temperature Damper Actuator＋ 3 —
4 Temperature Damper Actuator－ 4 —
5 Temperature Damper Actuator 5 —
Feedback —
6
6 —
7 Temperature Damper Actuator 2
7 Mode Damper Actuator＋＋
8 Mode Damper Actuator－ 8 Temperature Damper Actuator 2 -
9 Mode Damper Actuator Feedback 9 Temperature Damper Actuator
— Feedback 2
10
10 —
11 —
11 —
12 Evaporator Temperature Sensor
12 Face Temperature Sensor 2
13 Face Temperature Sensor 1
13 —
14 Feet Temperature Sensor 1
14 —
15 —
15 —
16 5V Power Supply_2
16 —
17 Fresh/Recirculation Damper
Actuator＋ 17 —
18 Fresh/Recirculation Damper 18 —
Actuator－ —
19
19 —
20 —
20 Sensor Ground_2
1.0 712
Operation In the defrost mode, the ATC ECU sets the intake air supply
Overview as fresh air, the blower as the most effective speed and the air
distribution as the windshield and front window.
ATCThe system is a closed loop control system, and its
purpose is to realize a comfortable climate in the passenger ATC ECUThe output signal directly manipulates the rear
compartment. For this purpose, the system will maintain the window heater.
following two states:
While pressing the fresh/recirculated air switch, the
• Temperature distribution from floor to roof. fresh/recirculated air damper shall determine whether the air
• Average temperature in the passenger compartment. source is the fresh air outside the vehicle or the recirculated
air already in the passenger compartment. ATC ECUThis
The purpose of the system is to use the following inputs to
damper is controlled at the following two positions:
realize a temperature distribution of high floor temperature
and a low roof temperature: • Fresh Air Side
• Set the temperature of the passenger compartment • Recirculated Air Side

according to the selection of the user. Air Volume Control
• Interior Temperature Blower Speed Regulation Resistor
• Ambient Temperature The blower speed regulation resistor controls the speed of
• Evaporator Temperature the blower motor by decreasing or increasing voltage values
• Face Vent Temperature of the blower motor ground. The HVAC control module
• Feet Vent Temperature provides low voltage pulse width modulation (PWM) signal
for the blower motor control processor through the blower
The ATC ECU processes these inputs and obtains the motor speed control circuit. When the required blower
following outputs: speed increases, the HVAC control module will increase the
• Blower Speed time for adjusting the speed signal to the ground. When the
• Position of Blend Damper Servo Motor required blower speed decreases, the HVAC control module
will shorten the time for adjusting the speed signal to the
• Position of Mode Damper Servo Motor
ground.
• Position of Internal/External Recirculation Damper Servo
Motor Blower Control
The sensor and control panel switch input information into the The blower speed can be controlled by manual selection or
ATC ECU, then the ATC ECU outputs it into the heater auto control. Use the following inputs to calculate the blower
assembly. ATC ECUIt connects the ECM through a gateway speed:
controller. • Ambient Temperature
When the system is powered on for the first time, the ATC • Temperature Difference of External Control Circuit
ECU continues to use the control output used when the • Set Temperature
system is powered off last time. If the condition changes, • Battery Voltage
or initiate the system in a different mode, change the control
• Blower Feedback Voltage
output immediately to produce the desired new setting.
The blower relay and power tube are used to run the blower
When the system operates in the automatic and defrost
at one of the 8 speeds. The blower relay is powered by the
modes, it is possible to manually set the intake air supply,
battery and grounded via the ATC ECU, the ATC ECU
blower speed and air distribution, and ignore the automatic
adjusts the voltage of the blower motor via the power tube
control. The air temperature is automatically controlled in all
to control the blower speed.
running modes.
Inlet Control
In the automatic mode, the ATC ECU manipulates the system
The internal recirculation switch is integrated into the HVAC
to warm or cool the passenger compartment, so as to establish
control. The position of the selected internal recirculation
and maintain the selected temperature on the control panel, at
switch is sent to the HVAC control module by the LAN bus.
the same time guides the air flow to the outlets that make the
The HVAC control module controls the intake air with the
passengers feel most comfortable.
intake actuator and internal recirculation actuator. Under
internal recirculation mode, intake damper is closed while
the internal recirculation damper is open so as to circulate
1.0 713
air inside the vehicle. Under external recirculation mode, • Pressure sensor to ECM ground
intake damper is open, then internal recirculation damper is • The evaporator temperature is above 5℃.
closed so as to introduce the exterior air into the vehicle.
• The engine is not under hard acceleration.
The internal recirculation can be activated only when the
defrost mode is not enabled. When starting the defrost mode, • The engine coolant temperature is not too high.
internal recirculation actuator will open internal recirculation • There is no engine running problem.
damper, and intake actuator will open intake damper, and If one of the permitted conditions no longer exists, the ECM
exterior air will circulate to the windshield to avoid fogging. will de-energize the compressor clutch relay and disengage the
Temperature Control compressor clutch until the permitted condition is restored.
To determine the required amount of heating and cooling A/C Pressure Sensor
for passenger compartment, the ATC ECU uses the sensor The A/C pressure sensor monitors the pressure of air
input and the selected temperature on the control panel to conditioning system, and send the signal to the ECM.
calculate the target temperature at the air outlet of the heater ECMExecute such orders as cooling fan speed, protecting
assembly on the driver side and front passenger side. Then, compressor, etc. The pressure sensor performs the following
the ATC ECU sends a signal to the servo motor and requests operations:
it to control the blend damper on the heater assembly so
that the damper can move to an appropriate position. The
commands for engaging the A/C compressor clutch.
target temperature will be updated continuously, and in the
automatic mode, the target temperature will be used for 2. If the refrigerant pressure is below or above the pressure
further calculation of the blower speed and air distribution. limit, the ECM sends commands for disengaging the A/C
compressor clutch.
The average temperature in the passenger compartment
3. If the refrigerant pressure is greater than the specified
is regulated according to the ambient temperature. If
value, the ECM sends commands for adjusting the cooling
the ambient air temperature is too low, raise the average
fan speed and operating the cooling fan at high/low speed
temperature in the vehicle. If the ambient air temperature is
according to the pressure value.
too high, slowly raise the average temperature in the vehicle.
Pressure protection of the pressure switch:
The signal provided by the solar sensor serves as a
compensation for the control algorithm so that a comfortable High Voltage Low Voltage
Protection Protection
temperature in the passenger compartment can be reached
even if there is sunshine. The compensation is effective only MPa ≥3.14 ≤0.196
when air distribution is set to face or face/feet mode because
Thus, if the A/C pressure is lower than or exceeds one of the
the passengers can well feel the compensation for these
closing pressure thresholds, the ground path of the ECM will
positions.
be disconnected. This causes the ECM to disengage the A/C
Air Distribution Control compressor clutch.
To control the air distribution in the passenger compartment, The compressor is lubricated by oil suspended in the
the ATC ECU sends a signal to the servo motor and allows it refrigerant, so operation of the compressor shall be prevented
to control the distribution damper of the heater assembly so if the refrigerant/lubricant in the system are minimum due to
that it can move to an appropriate location. minimum refrigerant pressure.
Compressor Control
When the refrigerant pressure increases to a value that
Compressor Control indicates additional condensing is required, the ECM grounds
When it detects that the request has changed to compressor the cooling fan relay unit and requests for the corresponding
ON, the ECM will energize the compressor clutch relay to cooling fan speed.
supply battery power to the compressor clutch, provided that
the following conditions exist:
1.0 714
Service Procedures A/C Panel
A/C Controller Assembly Remove
1. Disconnect the battery negative. 2. Pry off the instrument panel upper trim assembly,
2. Remove the A/C control panel. disconnect the connector and remove the instrument
panel upper trim assembly.
A/C Control Panel Remove
3. Remove 2 bolts securing the A/C controller assembly
to the instrument panel beam.
3. Remove 4 screws fixing the A/C panel to the instrument

4. Disconnect the connector of the A/C controller

assembly.
4. Remove the A/C panel.

Refit
5. Remove the A/C controller assembly. 1. Secure the A/C panel onto the upper instrument panel
trim, fit 4 screws and tighten to 1.2–2Nm, and check
Refit
the torque.
1. Connect the connector of A/C controller assembly.
2. Connect the connector, locate the instrument panel
2. Secure the A/C controller assembly on the instrument upper trim assembly onto the instrument panel, press
panel beam, fit 2 bolts, tighten to 2–4Nm, and check the clip and ensure it is fitted in place.
the torque.
3. Refit the A/C panel.
A/C panel Refit

5. Programme and encode the A/C controller assembly.

Encoding - A/C Controller Replacement
1.0 715
Evaporator Core Temperature Sensor Solar Sensor

Remove Remove
2. Disconnect the evaporator core temperature sensor 2. Release the clip securing the solar sensor onto the
connector. instrument panel.
3. Turn the evaporator core temperature sensor 90° and 3. Disconnect the solar sensor connector and avoid to fall
remove it. down below the instrument panel.
Refit 4. Remove the solar sensor.

1. Turn the evaporator core temperature sensor 90° and Refit
fix it onto the A/C box.
1. Connect the solar sensor connector.
2. Connect the evaporator core temperature sensor
2. Fix the solar sensor onto the instrument panel and
connector.
tighten with clips.
1.0 716
Exterior Ambient Temperature Sensor Interior Ambient Temperature Sensor
Remove Remove
2. Remove the exterior ambient temperature sensor from 2. Remove the driver side lower trim panel assembly.
the retaining clip and take out from the lower bumper
Driver Side Lower Trim Panel Assembly Remove
air intake grille.
3. Remove the central instrument panel vent trim
3. Disconnect the exterior ambient temperature sensor
assembly.
connector and remove the sensor.
Central Instrument Panel Vent Trim Assembly
Remove

5. Remove the 5 screw fixing the one-touch start
trim panel to the instrument panel, pry off the clip,
disconnect the connector and press the one-touch
start trim panel.
6. Remove 2 screws fixing the interior temperature
sensor to the one-touch start trim panel.
Refit
1. Connect the exterior ambient temperature sensor.
2. Put the exterior ambient temperature sensor into the
lower bumper air intake grille and secure onto the clip.
7. Remove the interior temperature sensor.

Refit
1. Fix the interior temperature sensor to the one-touch
start trim panel, fit and tighten screws.
2. Connect the interior temperature sensor, fix the
one-touch start trim panel to the instrument panel, fit
5 screws and tighten up.
3. Refit the centre console assembly.

4. Refit the central instrument panel vent trim assembly.
Central Instrument Panel Vent Trim Assembly
Refit

1.0 717
Face Vent Temperature Sensor Feet Vent Temperature Sensor

Remove Remove
1. Remove the instrument panel assembly. 1. Disconnect the battery negative.
Instrument Panel Assembly Remove 2. Remove the passenger side heater closure panel.
2. Disconnect the connector of face vent temperature 3. Disconnect the feet vent temperature sensor.
sensor.
3. Remove the face vent temperature sensor from the
A/C box.
4. Remove the feet vent temperature sensor form the

heater.
Refit
Refit 1. Fit the feet vent temperature sensor onto the heater.
1. Fit the face vent temperature sensor onto the A/C box. 2. Connect the feet vent temperature sensor connector.
2. Connect the face vent temperature sensor. 3. Fit the heater closure panel at the passenger side.
3. Fit the instrument panel assembly. 4. Connect the battery negative.
1.0 718
Blend Damper Servo Motor - Left Blend Damper Servo Motor - Right
Remove Remove
2. Remove the driver side lower trim panel assembly. 2. Remove the passenger side heater lower closure panel.
Driver Side Lower Trim Panel Assembly Remove 3. Disconnect the blend damper servo motor connector.
3. Disconnect the blend damper servo motor connector. 4. Remove 2 screws securing the blend damper servo
(1) motor onto the A/C box assembly.
4. Remove 2 screws (2) fixing the blend damper servo

motor to the A/C box assembly.
5. Disconnect the blend damper servo motor from the

blend damper linkage mechanism.
5. Disconnect the blend damper servo motor from the 6. Remove the blend damper servo motor.
blend damper linkage mechanism. Refit
6. Remove the blend damper servo motor. 1. Connect the blend damper servo motor and blend
Refit damper linkage mechanism.
1. Connect the blend damper servo motor and blend 2. Fix the blend damper servo motor to the A/C box
damper linkage mechanism. assembly, fit 2 screws, tighten to 1.2Nm, and check
the torque.
2. Fix the blend damper servo motor to the A/C box
assembly, fit 2 screws, tighten to 1.2Nm, and check 3. Connect the blend damper servo motor connector.
the torque. 4. Refit the passenger heater lower closure panel.
3. Connect the connector of blend damper servo motor. 5. Connect the battery negative.
4. Fit the driver side lower trim panel assembly. 6. Perform a self-learning for the A/C servo motor.
Driver Side Lower Trim Panel Assembly Refit Self-learning and Adjustment, Programming and
5. Connect the battery negative. Encoding - A/C Servo Motor Self-learning
6. Perform a self-learning for the A/C servo motor.

Encoding - A/C Servo Motor Self-learning
1.0 719
Recirculation Damper Servo Motor Mode Damper Servo Motor

1. Remove
1. Disconnect the battery negative. 2. Remove 3 screws (1) securing the mode damper servo
motor onto the A/C box assembly.

3. Remove 2 screws (2) securing the recirculation damper
servo motor onto the A/C box assembly.
3. Disconnect the connection between the motor and the

mode damper linkage mechanism.
4. Remove the mode damper servo motor.
Refit
4. Disconnect the connection between the motor and the
1. Connect the motor and the mode damper linkage
fresh air/recirculation damper linkage mechanism.
mechanism.
5. Remove the recirculation damper servo motor.
2. Fix the mode damper servo motor to the A/C box
Refit
assembly, fit 2 screws, tighten to 1.2Nm, and check
1. Connect the motor and fresh air/recirculation damper the torque.
linkage mechanism.
2. Fix the recirculation damper servo motor to the A/C
box assembly, fit 2 screws, tighten to 1.2Nm, and
check the torque. Self-learning and Adjustment, Programming and


1.0 720
HVAC System-ETC HVAC System
HVAC System-ETC
System Layout
A/C Control Panel
1. Temperature Control Switch

2. Defrost/Defog Button
3. AC On/Off Button
4. Air Recirculation Button
5. Heated Rear Window Button
6. Air Volume Control Button
7. Windscreen and Feet Mode Button
8. Feet Mode Button
9. Face and Feet Mode Button
10. Face Mode Button
1.0 721
HVAC System HVAC System-ETC
A/C Control System
1. A/C Pressure Sensor

2. Electrical Temperature Control Module
3. Electrical Temperature Control Panel
4. Blower Speed Resistance
5. Evaporator Temperature Sensor
1.0 722
A=Body Can B=PT Can C=Hardwire
1.0 723
Description When the A/C on/off button is pressed, the A/C gives request
Overview to activate the refrigeration system, meanwhile the indicators
on the button illuminate, and all functions are restored to the
In the electronic temperature control system, functions such as
state before the system is turned off. Press the button again to
air recirculation, air temperature, air distribution and blower
turn off the refrigeration system and the indicator goes out.
speed, etc are selected manually. ETCThe control system
consists of the following components: Air Volume Control Knob
• ETC ECU Activated only when the system is on. Manual blower speed
• A/C pressure sensor control is provided: rotate the air volume control knob
• Evaporator temperature sensor clockwise/counterclockwise to increase/decrease the air
volume.
• Power tube
Fresh/Recirculated Air Button:
The input signals of the sensor and control panel switch are
processed by the ETC ECU, and then the ETC ECU outputs Activated only when the system is on. Provide manual
the corresponding control signal. ETC ECUIt communicates selection of the air inlet source. When selecting the
with the ECM trough the gateway controller and controls recirculated air mode by manual control, the indicator on the
the high/low speed of the compressor clutch and cooling fan. display will illuminate.
ETC ECUIt directly receives the evaporator temperature and When the auto mode is selected and the ambient temperature
determines when to disconnect or connect the compressor is lower than 5℃, the rear window heater will start
clutch so that frost on the evaporator surface can be avoided. automatically.
Control Panel - Electronic Temperature Control
Close the system:
The temperature control knob and air volume control knob
Press the system OFF button, the system (excluding the
are incremental rotary switches, and the rest of the switches
display) is off; press the button again to start the system.
on the control panel are not the self-locking switches. These
switches have the following functions: Sensor
Air distribution switch: Evaporator Temperature Sensor
Activated only when the system is on. Provide manual air The evaporator temperature sensor is a 2-wire negative
distribution control: temperature coefficient thermistor. The sensor operates
within the temperature range of −40 to +85°C. The sensor
• When a switch is pressed every time, the air distribution
is in the evaporator, which is used to measure the evaporator
will change, and the change range is only face, face and
temperature. If the temperature is less than 3°C, then turn
feet, only feet, feet and windscreen/front side window
off the compressor to prevent evaporator from freezing.
defrost, only windscreen/front side window defrost.
A/C Refrigerant Pressure Sensor
Temperature Control Knob:
The A/C refrigerant pressure sensor is a 3-wire piezoelectric
Activated only when the system is on. Rotate the
pressure sensor. This sensor applies the 5V reference voltage,
temperature control knob clockwise/counterclockwise to
low level reference voltage and signal circuit to work. The
increase/decrease the air outlet temperature.
A/C pressure signal can be within 0.2-4.8V. When the air
Heated rear window (HRW) switch: conditioning refrigerant pressure is low, its signal values
HRWIt works only when the engine is running. When will approach to 0V. When the air conditioning refrigerant
operating the HRW switch, a message will be sent to the pressure is high, its signal values will approach to 5V. The
ETC ECU through the hard wire. This will make the HRW engine control module (ECM) converts the voltage signal to
relay energized and closed to supply power to the HRW. a pressure value. When the pressure is low/high, the engine
HRWThe function is timed (unless it is turned off manually), control module will not allow the ETC compressor to work.
otherwise the rear window heater will stop automatically at ETC Harness Connector
the following time: ETCEnd View and Pin Information of Harness
• For initial start, it turns off after the heating operation Connector FA037
lasts for 15min, and it starts to work again within 5min,
then it stops automatically after the heating operation Pin No. Description
lasts for 8min. 1 KL30
A/C On/Off Button 2 KL31
1.0 724
3 — 19 —
4 — 20 Sensor Ground_2
5 HS CAN High 5V Power Supply_1
6 HS CAN Low
7 LIN_1
8 —
9 —
10 —
11 —
12 —
13 —
14 —
15 —
16 —
17 —
18 —
19 —
20 —
ETCEnd View and Pin Information of Harness

Connector FA072
Pin No. Description

1 Blower Feedback 1 ＋
2 Blower Feedback 1 -
3 Temperature Damper Actuator＋
4 Temperature Damper Actuator－
5 Temperature Damper Actuator
Feedback
6 —
7 Mode Damper Actuator＋
8 Mode Damper Actuator－
9 Mode Damper Actuator Feedback
10 —
11 —
12 Evaporator Temperature Sensor
13 —
14 —
15 —
16 5V Power Supply_2
Actuator＋
Actuator－
1.0 725
Operation the blend damper on the heater assembly so that the damper
Overview can move to an appropriate position. The target temperature
will be updated continuously, and in the automatic mode, the
The sensor and control panel switch input information into the
target temperature will be used for further calculation of the
ETC ECU, then the ETC ECU outputs it into the heater
blower speed and air distribution.
assembly. ETC ECUIt connects the ECM through a gateway
controller. Air Distribution Control
Air Volume Control To control the air distribution in the passenger compartment,
the ETC ECU sends a signal to the servo motor and allows it
Blower Speed Regulation Resistor
to control the distribution damper of the heater assembly so
The blower speed regulation resistor controls the speed of that it can move to an appropriate location.
the blower motor by decreasing or increasing voltage values
Compressor Control
of the blower motor ground. The HVAC control module
provides low voltage pulse width modulation (PWM) signal Compressor Control
for the blower motor control processor through the blower When it detects that the request has changed to compressor
motor speed control circuit. When the required blower ON, the ECM will energize the compressor clutch relay to
speed increases, the HVAC control module will increase the supply battery power to the compressor clutch, provided that
time for adjusting the speed signal to the ground. When the the following conditions exist:
required blower speed decreases, the HVAC control module • Pressure sensor to ECM ground
will shorten the time for adjusting the speed signal to the
• The evaporator temperature is above 5℃.
ground.
• The engine is not under hard acceleration.
Blower Control
• The engine coolant temperature is not too high.
The blower speed can be controlled by manual control. • There is no engine running problem.
The blower relay and power tube are used to run the blower If one of the permitted conditions no longer exists, the ECM
at one of the 7 speeds. The blower relay is powered by the will de-energize the compressor clutch relay and disengage the
battery and grounded via the ETC ECU, the ETC ECU compressor clutch until the permitted condition is restored.
adjusts the voltage of the blower motor via the power tube
A/C Pressure Sensor
to control the blower speed.
Inlet Control The A/C pressure sensor monitors the pressure of air
conditioning system, and send the signal to the ECM.
The internal recirculation switch is integrated into the HVAC ECMExecute such orders as cooling fan speed, protecting
control. The position of the selected internal recirculation compressor, etc. The pressure sensor performs the following
switch is sent to the HVAC control module by the LAN bus. operations:
The HVAC control module controls the intake air with the
intake actuator and internal recirculation actuator. Under
commands for engaging the A/C compressor clutch.
internal recirculation mode, intake damper is closed while
the internal recirculation damper is open so as to circulate 2. If the refrigerant pressure is below or above the pressure
air inside the vehicle. Under external recirculation mode, limit, the ECM sends commands for disengaging the A/C
intake damper is open, then internal recirculation damper is compressor clutch.
closed so as to introduce the exterior air into the vehicle. 3. If the refrigerant pressure is greater than the specified
The internal recirculation can be activated only when the value, the ECM sends commands for adjusting the cooling
defrost mode is not enabled. When starting the defrost mode, fan speed and operating the cooling fan at high/low speed
internal recirculation actuator will open internal recirculation according to the pressure value.
damper, and intake actuator will open intake damper, and
Pressure protection of the pressure switch:
exterior air will circulate to the windshield to avoid fogging.
High Voltage Low Voltage
Temperature Control Protection Protection
To determine the required amount of heating and cooling for MPa ≥3.14 ≤0.196
passenger compartment, the ETC ECU uses the selected
temperature on the control panel to calculate the target Thus, if the A/C pressure is lower than or exceeds one of the
temperature at the air outlet of the heater assembly on the closing pressure thresholds, the ground path of the ECM will
driver side and front passenger side. Then, the ETC ECU be disconnected. This causes the ECM to disengage the A/C
sends a signal to the servo motor and requests it to control compressor clutch.
1.0 726
The compressor is lubricated by oil suspended in the
refrigerant, so operation of the compressor shall be prevented
if the refrigerant/lubricant in the system are minimum due to
minimum refrigerant pressure.
When the refrigerant pressure increases to a value that

indicates additional condensing is required, the ECM grounds
the cooling fan relay unit and requests for the corresponding
cooling fan speed.
1.0 727
1.0 728
Front Wheel Steering Steering System
Front Wheel Steering
Specifications
Torque
Description Value
Bolt- Steering gear to front subframe 100Nm+45°
Nut-Steering outer tie rod to steering arm 40–50Nm
Bolt- Steering column to steering import shaft 20Nm+120°
Nut- Steering outer tie rod to steering gear 65–75Nm
Steering inner tie rod- Steering inner tie rod to steering gear 100–110Nm
Bolt- Steering wheel to steering column 60–70Nm
Screw-Steering column lock to steering column 11–14Nm
Bolt - Steering column to facia framework 19–25Nm
Bolt - Steering column to facia framework 26–34Nm
Bolt（New）-Steering column intermediate shaft to upper 20Nm+120°
steering column
Screw- Multi-Function Column Switch Assemble to steering 7.5–8.5Nm
column
Parameter
Type Column Electric Power Steering System
Steering Column Four-way Adjustable Energy-absorbing Steering Column
Model
Diameter of Steering Wheel 374mm
Revolution of Steering Wheel 2.7
Transmission Ratio 53.4mm/R
1.0 729
Steering System Front Wheel Steering

System Layout
Steering System Component Layout
1. Steering Column Assembly 4. Steering Gear Assembly

2. Steering Motor 5. Steering Wheel
3. EPS Control Module
1.0 730
Steering Gear Assembly Layout
1. Steering Gear Assembly 6. Nut - Outer Tie Rod to Steering Knuckle

2. Steering Gear Inner Tie Rod 7. Steering Gear Bolt
3. Steering Gear Boot Assembly 8. Steering Gear Nut
4. Nut-Inner Tie Rod Lock 9. Seal
5. Steering Gear Outer Tie Rod
1.0 731

EPS Control Diagram
A = Hard Wire; B = Chassis HS CAN Bus; C = Power HS CAN Bus; D = Body HS CAN Bus
1.0 732
Description Torque Sensor
Overview The torque sensor is integrated in the steering column, which
The motor provides auxiliary torque for the EPS. According measures the size and direction of the torque acted by the
to motor arrangement, the EPS can be divided into: steering driver on the steering wheel, as well as the size and direction
column-assist type, pinion-assist type and rack-assist type. The of the steering wheel angle. It is the control signal of the EPS.
motor of the steering column-assist EPS is fixed at one side When reconnecting the battery after disconnection, initialize
of the steering column, which connects the steering column the steering wheel angle, for specific procedures, please refer
through the reducing mechanism and directly drives the to the "Electronic Power Assisted Steering (EPS) Module"
power-assisted steering of the steering shaft. The motor and under the "Self-learning and Adjustment, Programming and
reducing mechanism of the pinion-assist EPS are connected Coding" section.
with the pinion, which directly drive the power-assisted Reducing Mechanism
steering of the pinion. The motor and reducing mechanism of
The reducing mechanism of the EPS is connected with the
the rack-assist EPS directly drive the rack to provide power.
motor, the function of the mechanism is to decrease the speed
Different types of EPS have the same basic principle: The and increase the torque, which applies a mechanism of worm
torque sensor is connected with the steering shaft (pinion and gear.
shaft) together, when the steering shaft rotates, the torque
End view and pin information of EPS module
sensor starts to operate, turns the relative rotational harness connector BY009
displacement generated by the input shaft and output shaft
under the action of the torsion bar into an electric signal
and transmits the signal to ECU, and ECU determines the
direction of rotation of the motor and the power-assist current
based on the signals from the speed sensor and torque sensor
to complete real-time control power steering. Therefore, it
can easily provide different powers for the motor at different
speeds and ensure the vehicle is flexible at low speed and
stable at high speed. The setting of the EPS steering behavior
provides a high degree of freedom.
EPS
The EPS is composed of the following components:
1. EPS Module
Pin No. Description
2. Steering Motor
1 KL.30
3. Torque Sensor
2 Ground
4. Steering Reducing Mechanism
EPS Module End view and pin information of EPS module
harness connector BY035
The function of the electronic control unit (ECU) is to
conduct logical analysis, make calculations and give commands
to control the motor according to the signal from the torque
sensor and vehicle speed sensor. Furthermore, the ECU
is also configured with safety protection and self-diagnosis
functions, the ECU determines if the system is in normal state
by the motor current, alternator voltage and engine working
condition, etc. If the system fails, the power will be cancelled
automatically and the ECU will carry out fault diagnosis and
analysis.
Steering Motor
The function of the motor is to output an appropriate auxiliary
torque according to the instruction of the ECU, which is the
power source of the EPS. The permanent magnet brushless
DC motors are widely used in this application.
1.0 733
Pin No. Description 3 Chassis CAN Low

1 Wake-up 4 —
2 Chassis CAN High
1.0 734
Operation The EPS module responds to the alteration of the torque
While operating the steering gear by using the EPS module sensor signal and voltage signal from the motor rotation sensor
to control the power steering motor, the EPS can reduce by controlling the current of the steering motor. The EPS
the power for vehicle steering. The EPS module also uses module controls the PWM motor drive circuit to drive the
the combination of the torque sensor, motor rotation sensor, 3-phase motor.
battery voltage circuit and serial data circuit to perform the The EPS module can calculate the internal system
system functions. The EPS module will monitor the vehicle temperature and protect the EPS from high temperature
speed and engine speed information through the serial data damage. In order to reduce the high system temperature, the
circuit to determine the magnitude of power for vehicle EPS module will decrease the directive current flowing to the
steering. Under low speed mode, the larger force should be power steering motor, that is, reduce the steering power. The
provided for steering in the parking operation. At high speed, EPS module can detect faults of the EPS. When failure of the
use lower power to improve road feel and direction stability. EPS is detected, the steering warning lamp on the instrument
The EPS module determines the desired force by using the will illuminate.
combination of torque sensor, motor position sensor, speed The EPS module is provided with the "active return" function,
and system temperature input. The EPS module continuously when the driver's hands leave the steering wheel, control of the
monitors the torque of the torque sensor and locates current return speed can improve the driving feel and safety greatly.
signal. With the rotation of the steering column and steering
The EPS module is also configured with the "end protection"
shaft, monitor the steering input and output shaft by torque
function which can decrease the auxiliary torque and avoid
signal circuit, then use the EPS module to calculate the torque.
noise, overheat and damage of the mechanical parts before the
The EPS module handles the voltage signal from the motor
maximum travel of the steering gear rack is achieved.
position sensor and the location current signal from the torque
sensor, by this way, it detects and calculates the angle of the
steering wheel.
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Service Procedures
Steering Gear Assembly
Remove
1. Remove front wheels.
Wheel Remove
2. Remove and discard the bolt fixing the universal joint
to the power steering gear.
8. Carefully draw the steering gear from the vehicle.

Refit
1. Fit the steering gear to the vehicle.
2. Fit the steering gear to the subframe, fit new bolt/nut
and tighten to 100Nm+45°.
3. Fix the outer tie rod of the steering gear on both sides
to the front wheel hub, fit 1 new nut respectively and
tighten to 40–50Nm.
3. Loosen the universal joint from the power steering gear.
4. Secure the universal joint on the input shaft of the
power steering gear, fit 1 new bolt and tighten to
5. Remove the nut fixing the outer tie rod of the steering 20Nm+120°.
gear on both sides to the wheel hub, and discard the
5. Fit the wheels.
nut. Fit a M10 nut to the outer tie rod and align it with
the outer tie rod. Wheel Refit
6. With the T38008, release the outer tie rod of the 6. Check the alignment parameters of the front wheels.
steering gear from the wheel hub on both sides, and Four-wheel Alignment
remove the M10 nut from the outer tie rod.
7. Perform a self-learning for the EPS module.

Coding - EPS Module Self-learning
7. Release 2 bolt and nuts fixing the steering gear to the

subframe.
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Steering Gear Boot 3. Fix the outer boot clamp of the steering gear to the
Remove steering gear boot.
1. Raise the vehicle on a lift. 4. Fit the lock nut of the steering gear inner tie rod and
2. Remove the outer tie rod of the steering gear. tighten to 65–75Nm.
5. Fit the outer tie rod of the steering gear.
Steering Gear Outer Tie Rod Remove
3. Remove the lock nut (1) from the steering gear inner Steering Gear Outer Tie Rod Refit
tie rod. 6. Lower the vehicle.
7. Check the alignment parameters of the front wheels.
Four-wheel Alignment

4. Remove the outer boot clamp (1) of the steering gear,

and discard the clamp.
5. Remove the inner boot clamp (2) of the steering gear,
and discard the clamp.
6. Remove the steering gear boot (3) from the steering
gear.
7. Check the inner/outer tie rods of the steering gear

for obvious corrosion or contamination. If no obvious
corrosion or contamination, continue the repair. If
obvious corrosion or contamination is found, replace
the steering gear.
Refit
1. Fit the steering gear boot to the steering gear. Ensure
that the steering gear boot is located in the fitting
groove.
2. Fit the inner boot clamp of the steering gear to the
steering gear boot.
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Steering Gear Outer Tie Rod 3. Tighten the lock nuts to 65–75Nm.
Remove 4. Fit the wheels.
Wheel Refit
Warning: Do not work on or under a vehicle supported 5. Lower the vehicle.
Wheel Remove
3. Release the lock nut (1) from the outer tie rod of the
steering gear. Self-learning and Adjustment, Programming and
4. Remove nuts (2) fixing the outer tied rod of the
steering gear to the steering arm.
5. Fit M10 nut to the outer tie rod ball joint of the steering
gear and align it with the pin end.
6. With the T38008, release the outer tie rod ball joint of
the steering gear from the wheel hub on both sides,
and remove the M10 nut from the ball jiont.
7. Remove the outer tie rod of the steering gear from

the power steering gear, and mark the position of the
lock nuts.
Refit
1. Fit the outer tie rod of the steering gear to the marked
location of the lock nut with the ball joint up.
2. Connect the outer tie rod of the steering gear to the
steering arm, fit new nuts and tighten to 40–50Nm.
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Steering Gear Inner Tie Rod Steering Wheel Positioning/Adjustment
Remove Use the steering tie rod to position/adjust the steering wheel,
and do not remove the steering wheel.
1. Remove the steering gear boot.
Check
Steering Gear Boot Remove
1. Ensure correct tyre pressure and maintain the vehicle
2. Place the wrench on the housing surface of the steering in unladen mass condition.
gear inner tie rod.
2. Shake the vehicle back and forth to release the stress
3. Remove the bolt fixing the inner tie rod of the steering for steering and suspension.
gear to the steering gear, and remove the inner tie rod.
3. Please apply the four-wheel aligners recommended
by our company when measuring the alignment
parameters.
4. Select the average value of the three readings.
5. Check if the front wheel alignment parameter is within
the specified tolerance range.
Adjustment
1. Mark the position of the steering tie rod as a reference.
2. Release the lock nut of the right/left steering tie rod.
Caution: To avoid possible joint damage always use a
spanner to hold steering rack outer tie rod when loosening
or tightening steering rack outer tie rod lock nut.
Refit 3. Adjust the steering tie rod and acquire correct
1. Fix the inner tie rod of the steering gear to the steering alignment parameters of the front wheels.
gear and tighten the nut to100–110Nm. Tip: When rotating one side of the steering rack outer tie
2. Fit the steering gear boot. rod lock nut outward or inward, the other side should
Steering Gear Boot Refit be rotated in the same amount of threads outward or
inward.
3. Fit the outer tie rod of the steering gear.
Steering Gear Outer Tie Rod Refit


4. Recheck the alignment parameters of the front wheels.

5. Tighten the lock nuts of the left/right steering tie rod.
6. Ensure that the cover of the power steering gear is not
tightened or deformed.
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Steering Wheel Assembly

Remove
1. Remove the steering wheel airbag.
Steering Wheel Airbag Remove

2. Put the steering wheel in the centre and allow the
wheel to be in the front.
3. Disconnect the steering wheel entertainment switch
harness connector (1).
4. With the steering wheel stopped, loosen the bolt (2)
fixing the steering wheel to the steering column, until
the steering wheel is fully loosened from the steering
column splines, remove the bolt.
3. Fix the steering wheel to the steering column, fit 1 bolt,
4. Connect the steering wheel entertainment switch
connector.
5. Fit the steering wheel airbag.
Steering Wheel Airbag Refit
5. Remove the steering wheel assembly from the steering

column.
6. Stick tape along the edge of steering column stalk
combination switch to keep it in the correct mounting
position.
Refit
1. Remove the tape on the combination switch of steering
column stalk.
2. Ensure that the wheel is in the front, and fit the steering
wheel to the steering column according to the mark.
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Steering Wheel Molding Steering Column Shield
Remove Remove
1. Remove the steering wheel airbag. 1. With a screwdriver, gently disengage the upper trim
cover with the lower trim cover.
2. Remove 3 screws securing the steering column lower
2. Gently pry the clip open, release the molding from the
trim cover onto the steering column.
steering wheel(3).
Refit
1. Fix the steering wheel molding assembly onto the
steering wheel and tighten up.
3. Release the steering column to the lowermost position

and remove the steering column lower trim cover.
Refit
1. Release the steering column lever and move the
steering column to the upper position.
2. Fix the steering column lower trim cover onto the
steering column, fit 3 screws and tighten up.
3. Place the steering column upper trim cover onto the
steering column, and secure onto the lower trim cover.
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Upper Steering Column

Remove
2. Remove the steering wheel assembly.
Steering Wheel Assembly Remove
3. Remove the driver instrument panel lower closure
panel.
Driver Instrument Panel Lower Closure Panel

Remove
4. Release the steering column to the lowermost position.
5. Disconnect the connector of EPS module.
7. Loosen the steering column adjustment handle, and
remove the steering column lower trim cover.
8. Remove the combination switch.
Combination Switch Remove
9. Remove 1 bolt fixing the intermediate shaft to the
upper steering column, and discard it.
6. Remove 3 screws fixing the steering column lower trim

cover to the steering column.
10. Latch the adjustment handle tightly to prevent the

column from falling off.
Warning: DO NOT release the locking lever when moving

or assembling ， or upper steering column may be pulled
out of lower steering column and steering colunm may be
broken.
11. Remove 3 bolts fitting the steering column to the
instrument panel beam assembly.
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steering column, fit 3 screws and tighten closely.
8. Connect the connector of EPS module.
9. Fit the driver instrument panel lower closure panel.

Refit
10. Fit the steering wheel assembly.
Steering Wheel Assembly Refit
12. Programme and encode the electric power steering
module.

Encoding - EPS Replacement
13. If the upper steering column drops off during handling
or assembly, re-install the drop-off part and ensure
when the intermediate shaft lower fork teeth mark is in
the 9 o'clock position, the steering shaft teeth is in the
6 o'clock position. Check whether the left and right
steering wheel strokes are the same after assembly, or
re-assembly is needed.
12. Remove the upper steering column assembly.

13. 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.
14. Separate steering column lock and upper steering
column.
Refit
1. Position the steering column lock to the upper steering
column.
2. Attach with new mounting screw, tighten to 11–14Nm,
and twist off the screw head.
3. Fix the steering column to the instrument panel
beam assembly, fit 3 bolts, tighten the upper bolts to
19–25Nm and the lower bolts to 26–34Nm.
4. Connect the intermediate shaft and the upper
steering column with new locking bolts, and tighten
to 20Nm+120°.
5. Fit the combination switch.
Combination Switch Refit

6. Release the steering column lever and move the
steering column to the upper position.
7. Fix the steering column lower trim cover to the
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Intermediate Shaft Steering Wheel Entertainment Switch

Remove Remove
1. Maintain the vehicle wheel in the front to lock the 1. Disconnect the battery negative.
steering wheel. 2. Remove the steering wheel airbag.
panel.
3. Disconnect the steering wheel entertainment switch
Driver Instrument Panel Lower Closure Panel connector.
Remove
4. Gently pry off the clip, release the molding and switch
3. Remove 1 bolt fixing the upper steering column to the assembly from the steering wheel.
intermediate shaft and discard it.
5. Remove 4 screws securing the steering wheel switch
on the molding.
6. Remove the steering wheel entertainment switch.
Refit
1. Fix the steering wheel entertainment switch onto the
steering wheel molding, and tighten with 4 screws.
2. Connect the harness connector at the back of the
steering wheel entertainment switch and fix the
steering wheel molding onto the steering wheel.

4. Remove 1 bolt fixing the intermediate shaft to the
steering gear and discard it.
5. Remove the intermediate shaft.

Refit
1. Connect the intermediate shaft and the upper steering
column with the new locking bolt and tighten to
20Nm+120°.
2. Connect the intermediate shaft and the steering engine
with the new locking bolt and tighten to 20Nm+120°.

Refit
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Shift Paddle Switch Steering Column Combination Switch
Remove Remove
1. Remove the steering wheel entertainment switch. 1. Disconnect the battery negative.
Steering Wheel Entertainment Switch Remove 2. Remove the steering wheel assembly.
2. Remove 4 screws securing left/right shift paddle switch Steering Wheel Assembly Remove
onto the steering wheel. 3. Fix the clock spring with tapes, ensure it will not move
3. Disconnect the harness connector on the back of the towards left and right (relative to the combination
switch. switch bracket) and is always in the centre.
4. Remove the shift paddle switch. 4. Remove the steering column shroud.
Refit Steering Column Shroud Remove
1. Connect the harness connector on the back of the 5. Remove the trim panel fixed by clips between the
shift paddle switch. lever switches of cruise control and direction indicator
2. Connect the left/right shift paddle switch to the back lamp/high beam lever.
of the steering wheel respectively, and tighten with 4 6. Remove 6 screws (4 screws for vehicles without cruise
screws. control) fixing the lever switch to the steering column.
3. Fit the steering wheel entertainment switch.
Steering Wheel Entertainment Switch Refit
7. Disconnect the 5 harness connectors of the clock

spring, wiper/washer lever switch, direction indicator
lamp/high beam and cruise control lever switches (if
equipped).
8. Remove the wiper/washer lever switch, direction
indicator lamp/high beam and cruise control lever
switches (if equipped) respectively.
9. Release the retaining screw to remove the clock spring
from the steering column, and take care not to damage
the tape.
Refit
Caution: If the peg on a new rotary coupler is broken, or
if you suspect that the rotary coupler has been dropped
or mishandled, discard the coupler.
1. Before fitting, ensure the red locating pin of the clock

spring is not removed or damaged and the front wheels
face the front.
2. Ensure the clock spring to be fitted is in the centre, if
not, gently rotate the rotor counterclockwise to the
end, then turn it clockwise for about 2.7 circles. Align
the connector clip with the Lock Pin position (this
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location is the centre). 11. Check the system, rotate each lever of the combination
switch and check if it can work.
12. Check if the button of the entertainment switch on the
steering wheel can work.
3. Fit the clock spring to the steering column and connect

the harness connector.
4. Connect the harness connectors of the lever switch of
the direction indicator lamp/high beam, wiper/washer
and cruise control (if equipped) respectively, and fix
it to the combination switch bracket with 6 screws
(vehicles without cruise control use 4 screws).
5. When fitting a new combination switch assembly to the
steering column, ensure the front wheels face the front,
place the combination switch assembly right above the
steering column, fit it into the steering column as an
assembly and locate it by turning from side to side.
6. Tighten the screw under the combination switch
bracket to 7.5–8.5Nm and ensure the combination
switch assembly will not loose.
7. Fit the steering column shroud.

Steering Column Shroud Refit
8. Fit the steering wheel assembly.
Steering Wheel Assembly Refit
10. Perform the self-learning for the angle sensor.
Self-Learning and Adjustment, Programming and
Encoding - Steering Angle Sensor
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Wheel Alignment Suspension System
Wheel Alignment
Specifications
Torque
Description Value
Nut- steering rod outer ball joint 65–75Nm
Bolts- rear upper arm assembly to rear subframe 110±11Nm
Nut- lateral rod assembly to rear subframe 100±10Nm
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Suspension System Wheel Alignment
Parameter
Four-wheel Alignment Parameter
Front Wheel
Wheel Camber - unloaded state -0°14′ ± 45′
Kingpin Caster - unloaded state 4°57′ ± 45′
Kingpin Inclination 12°45′ ± 45′
Total Toe-in - unloaded state 0°8′ ± 12′

Rear Wheel
Wheel Camber - unloaded state –0°60′ ± 45′
Toe-in 0°12′ ± 12′
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Description
Description of Camber Angle
The camber angle refers to the wheel deviation angle from the
vertical direction when observed from the front of the vehicle.
When the wheel top tilts outward, the camber is positive (+).
When the wheel top tilts inward, the camber is negative (-).
How it tilts depends on the deviation angle from the vertical
direction. The value of the vehicle camber angle can affects the
direction control and tire wear.
• Large positive camber angle will cause early wear of the
outside of the tire and excessive wear of the suspension
parts.
When the positive caster angle is small, it is hard to turn
• Large negative camber angle will cause early wear of the at higher speed and the wheel returnability decreases after
inside of the tire and excessive wear of the suspension turning. If the positive caster angle of one of the wheels is
parts. larger than others, the wheel will tilt to the center of the
• If the difference between the camber angles of the two vehicle. In this case, even a minimum positive caster angle can
sides is 1° or above, the vehicle will deviate to the side lead to deviation.
with a larger positive camber angle. Description of Runout
Vehicle runout refers to the magnitude of the force to be
applied on the steering wheel to keep the vehicle running in
straight line when it runs in a constant high speed on a typical
straight way.
Tip: Vehicles will tend to lead/pull in the direction of the
road slope as part of normal operation.
Runout generally can be caused by the following factors:

• Slopes
• Change of tire structure
• Wheel alignment (left/right caster angle difference and
camber difference of front wheels)
• Unbalanced steering gear
Description of Caster Angle
• Wrong calibration of the EPS steering position/torque
The caster angle is the front/rear inclination of the highest sensor
point of the steering axis when viewed from the side of
Description of Steering Memory
the vehicle. The rear inclination is positive, and the front
inclination is negative. The caster angle affects direction It refers to the situation where vehicle runout can occur in
control during steering, but does not affect tire wear. Vehicle the direction where the driver just steered. In addition, after
height has a great impact on the caster angle, so it is important turning to the opposite direction, vehicle runout still can occur
to keep the vehicle at the height designed. Overload, fatigue in this direction.
or loose rear spring will affect the caster angle. When rear Description of Scrub Radius
vehicle is lower than the designed body height, the front
Theoretically, the scrub radius shall be kept as small as possible.
suspension moves towards the direction with a bigger positive
Generally, the steering axis inclination (SAI) crosses with the
caster angle. When rear vehicle is higher than the designed
centerline of the tire and the wheel below the road, which
body height, the front suspension moves towards the direction
forms a positive scrub radius. In sliding column structure,
with a smaller positive caster angle.
the steering axis inclination (SAI) is much larger than the long
arm/short arm suspension system. This allows the steering
axis inclination (SAI) to cross with the wheel camber angle
above the road, which forms a negative scrub radius. A better
directional stability can be achieved by smaller scrub radius.
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If aftermarket add-on wheels are fitted, the vehicle will offset If the thrust angle is negative (-) (the right vehicle moves
excessively, which can cause a substantial increase of the scrub backwards and/or left vehicle moves forwards), the trust angle
radius. The newly fitted wheel may cause further deviation of will also move to zero angle.
the tire centerline from the spindle. This can cause increase of Description of Toe
the scrub radius.
Toe is the measurement by which the front of a wheel
A larger scrub radius may cause severe shimmy when the points inward or outward, compared to a true straight-ahead
tire impacts uneven roads. Four-wheel drive vehicles which position. When the wheel points inward, the toe is positive
are fitted with large wheels, use the steering damper to (+). When the wheel points outward, the toe is negative (-).
compensate the increased scrub radius. Conventional Toe is a fraction of a degree. The function of the toe is to keep
methods shall not be used directly to measure the scrub the wheels rolling in parallel. The toe can also compensate the
radius. The scrub radius is geometrically designed by the small offset from the wheel support system when the wheel
engineer during the design of the suspension system. moves forward. In other words, if set the wheels to positive
Description of Thrust Angle wheel toe when the vehicle is still, then the wheels at both
sides will roll in parallel when the vehicle is running. Improper
The front wheels locate the vehicle or do turning work. The
toe will lead to early tire abrasion and unsteady rotation angle.
rear wheel controls the track of the vehicle, which relates to
the thrust angle (3). The thrust angle is the driving track of the
rear wheels. Theoretically, the thrust angle is geometrically
consistent with the body centerline (3).
The toe angle of the left rear wheels shown is positive which
causes the thrust line (1) to deviate from the center. The
deviation from the centerline here is known as the thrust angle.
Description of Torque Steering

In the event of sudden or hard acceleration, the vehicle will
deviate from one direction. During deceleration, the vehicle
will deviate from the other direction.
If the thrust angle is wrong, the driving track of the vehicle

may appear to be that of a dog, and the steering wheel cannot
return or the driver may wrongly think the axle curves. Check
the thrust angle when aligning the wheels.
If the thrust angle is positive, the thrust line points to the right
vehicle (RHS).
If the thrust angle is negative, the thrust line points to the left
vehicle (LHS).
If the thrust angle exceeds the specified value, change of the

relation between the axle and the body can change the reading
For a specific vehicle, the following factors can cause obvious
of the thrust angle.
torque steering:
If positive (+) value is out of the specified range (right vehicle • Tires with a smaller right front diameter can generate
moves forwards and/or left vehicle moves backwards), the a right guide torque. Check the brand, structure or
trust angle will move to zero angle. dimension of the front tires. If the tires are similar,
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exchange the front tires at both sides and retest the as the inclination of the axle. The higher transaxle
vehicle. The tire and wheel assembly can greatly affect surface (see the left of the figure) has a maximum down
the calibration of the torque steering. axle inclination.
• The pressure of the right front and left front tires differs Description of Sway
significantly.
When applying force manually on the steering wheel, the
• The difference between the left axle angle and the vehicle in the straight-line direction uncontrollably drifts or
right axle angle (front view) may cause obvious steering deviates to one side, this is referred to as the sway. When
deviation. Deviation may happen on the side with the vehicle is too sensitive to external disturbance (such as
maximum inclination angle, i.e. the location where the rough roads and side wind, it will sway, and the situation can
axle slopes down from the differential to the wheel. The be worsened by poor returnability of the steering mechanism.
axle tilts down from the differential. Tilt between the
transaxle surface and the level surface can be considered
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Service Procedures
Check
1. Only equipment approved by the manufacturer can be
used for four-wheel alignment.
2. The equipment must be calibrated according to the
manufacturer's requirements.
3. Ensure that the vehicle data input into the equipment
is correct.
4. Check the ball joint of the steering tie rod/front lower
swing arm and wheel bearing for wear. Replace or
repair it if necessary.
3. Rear Wheel Camber Adjustment:
5. Check and adjust the tyre pressure.
6. Raise the vehicle on a four-wheel aligner. a. Release the nut (1) inside the rear lower swing arm.
7. Ensure that the vehicle is in unladen mass condition. b. With a spanner, rotate the eccentric bolt until the
rear wheel camber falls in the specified range.
Vehicle Lifting
8. Ensure that the wheel mounting clamp has been c. Tighten the lock nut to 110±11Nm with another
adjusted to a correct specification and has been fixed wrench.
firmly to the vehicle. d. For the other side, repeat the above steps.
9. Ensure that the camera is fitted and aligned properly. .
10. Align the wheels according to the manufacturer's
instruction. Lower the vehicle and keep the vehicle
suspension in normal state.
11. Ensure that the steering wheel is positioned in the
centre.
Adjustment
1. Observe the readings indicated on the test equipment,
and adjust the four-wheel alignment data according to
the requirements.
General Precautions
2. Front Wheel Toe-in Adjustment:
a. Release the lock nut (1) of the steering tie rod.

4. Rear Wheel Toe-in Adjustment:
b. Adjust the steering tie rod and adjust the front wheel
a. Release the nut (2) fixing the front end of the rear
alignment parameter to the specified value.
horizontal push rod assembly to the rear subframe.
c. Tighten the lock nuts to65–75Nm
b. Rotate the eccentric bolt 2 with a wrench until the
d. For the other side, repeat the above steps. rear wheel toe-in is within the specified range.
c. Tighten the lock nut to 100±10Nm.
d. Repeat the above steps for the other side.
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1.0 753
Suspension System Front Suspension
Front Suspension
Specifications
Torque
Description Value
Bolts- front lower arm to front subframe 110±10Nm
Bolts- FR Lower arm rear to front subframe 90Nm ＋ 120°
.Nut- front knuckle to front lower arm 95±10Nm
Bolt - ASM-FR sensor to bodywork 7–10Nm
Nut- front lower arm ball joint to front lower arm 140Nm ＋ 45°
Nut- front strut damper top mounting 65–75Nm
Nut- front damper to body 55–65Nm
Bolts - front damper to hub 90–110Nm
Nuts- anti-roll bar links to damper 40–50Nm
Bolts- front anti-roll bar to front subframe 55–65Nm
Bolt- Steering gear to front subframe 100Nm+45°
Bolt- front subframe to body 90Nm ＋ 180°
Bolts- front subframe brace 80±10Nm
Nuts- anti-roll bar links to anti-roll bar 55–65Nm
Bolts- front knuckle asm to bearing 70Nm ＋ 90°
Bolts- front knuckle asm to front damper 140–170Nm
Bolt-Front wheel speed sensor to wheel carrier 7–10Nm
Screw-Front brake pan to bearing 7–10Nm
Bolt-Front brake caliper assembly to front knuckle 190–210Nm
Parameter
Model The front suspension is an independent McPherson shock
absorber. This shock absorber and the fork type lower swing
arm are outside the front subframe, which provides the front
suspension with the anti-dive and anti-squat features.
Diameter of Front Horizontal Stabilizer Bar 23mm
Data of Front Coil Spring:
• Total Coils • 5.8
• Effective Coils • 4.84
• Diameter of Wire • Appr. 13.2mm
• Free Length: • Appr. 353mm
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Front Suspension Suspension System
System Layout
Front Suspension Layout
1. Macpherson Front Shock Absorber Assembly (2) 5. Front Lower Swing Arm Assembly (2)
2. Front Horizontal Stabilizer Bar Connecting Rod (2) 6. Front Horizontal Stabilizer Bar
3. Front Subframe Assembly 7. Front Horizontal Stabilizer Bar Bushing/Clamp (2)
4. Front Wheel Hub Assembly (2) 8. Front Subframe Support Rod (2)
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Front Suspension Exploded View
1. Front Shock Absorber Coil Spring 8. Front Lower Swing Arm Rear Bush
2. Front Shock Absorber Strut 9. Front Lower Swing Arm
3. Front Horizontal Stabilizer Bar Connecting Rod 10. Front Lower Swing Arm Bush and Bracket Assembly
4. Front Horizontal Stabilizer Bar 11. Front Steering Knuckle
5. Front Horizontal Stabilizer Bar Bushing 12. Front Wheel Hub Bearing Assembly
6. Front Stabilizer Bar Mounting Bracket 13. Front Drive Shaft Nut
7. Front Lower Swing Arm Ball Head
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Macpherson Front Shock Absorber Exploded View
1. Front Shock Absorber Strut 5. Nut - Top of Front Shock Absorber

2. Front Spring 6. Anti-rust Cap
3. Front Bumper Block 7. Front Dust Shield
4. Top Plate 8. Bearing
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Description Front Shock Absorber

Overview The front shock absorber is maintainable, which has a
Front suspension includes: compression stroke of 100mm and a rebound stoke of 70mm.
The front shock absorber is a dual barrel type structure,
• 2 McPherson dampers
can be inflated and fuelled. This type of structure allows the
• 2 fork type front lower swing arms movement of shock absorber piston inside the inner cylinder.
• Front Horizontal Stabilizer Bar There is an oil drain hole on the inner cylinder between
• 2 Front Horizontal Stabilizer Bar Connecting Rods the inner and outer cylinder. This structure minimizes the
• Front Subframe cavitation and eliminates the influence of the piston motion
due to the damaged outer cylinder. The lower part of
• Front Wheel Hub, Hub Bearing Assembly
front shock absorber is attached to the front wheel hub,
According to the damper transmission ratio (1:1), the design of and secured with locking bolts. The base of front shock
the front suspension shall feature the anti-dive and anti-squat. absorber is fixed on the front wheel hub, to ensure the
The layout and design of the damper minimizes the wheel correct orientation of front shock absorber. The front shock
camber loss as a result of lateral force and improves the absorber strut is integrated with the upper mounting support
handling performance and steering response capability. by nuts. There is a hexagonal slot at the front shock absorber
Front Subframe strut, when fastening the nut of the front shock absorber
strut, the hexagonal slot can prevent rotation of the front
The front subframe is stamped and welded with the
shock absorber strut. The spring seat at a certain angle is
high-strength steel, which features light weight and high
combined with the shock absorber body, which is also used as
structural strength. The geometric dimension of all key
the connection point of the front horizontal stabilizer bar link.
positions is accurately controlled during manufacture, this
There are 2 welding brackets near the bottom of the shock
ensures proper location of the front suspension and steering
absorber cylinder, where are used for fitting the front brake
components. The front subframe is assembled on the vehicle
hose and ABS sensor harness respectively.
body through 4 supporting points, the front subframe provides
mounting locations for all components of the front suspension Coil Spring
except top damper, engine and transmission. The coil spring is made of silicon, chromium, alum alloy
materials, which is connected with the shock absorber strut.
The rear supporting plate of the front subframe between the
The top of the coil spring is under the bearing seat, and the
rear supporting point of the front subframe and the body can
bearing is in the upper mounting support. The lower coil
increase the rigidity of the front subframe. The arrangement
spring is directly fitted on the spring support which combines
of the supporting points can prevent the front subframe
with the shock absorber body. The front coil spring may vary
from moving under lateral force, this will cause unnecessary
depending on the engine model used in the vehicle and vehicle
steering.
configuration. Different front coil spring can be identified by
McPherson Dampers
the color code applied to the coil.
The 2 McPherson dampers control the damping effect of the Upper Mounting Support Assembly
front suspension. Each damper includes a vibration absorption
The upper mounting support is composed of the support
unit, a coil spring and an upper mounting support assembly.
frame, vulcanized rubber, upper/lower gasket and 3 bolts.
The coil spring is between the damper spring seat and upper
Vulcanize rubber on the steel frame, and press a gasket into
mounting support assembly, which remains in the compressed
the upper/lower sides respectively. Press the top bearing into
state. Vibration isolator at both ends of the spring reduces
the base under the upper mounting support. The mounting
noises delivered to the vehicle body from the front suspension.
bearing is in clearance fit with the base. If necessary, replace
Under the upper mounting support assembly is installed a
the bearing. The upper mounting support is an integrated
bearing, when the steering system work, the bearing allows
component, so it cannot be replaced as an individual part, the
coil spring rotation. A dust shield is fitted between the limiting
upper mounting support assembly shall also be replaced.
buffer block of the compression stroke and the damper, which
protects the damper strut from contamination or damage. The Front Lower Swing Arm
coil spring shaft deviates from the damper shaft, during turning, The front lower swing arm is a fork type arm. The swing arm is
this arrangement can provide lateral load compensation and made of two stamped and welded steel plates, which connects
enhance the damping effect. the front steering knuckle and the front subframe. The front
lower swing arm is fitted with a ball pin which contains a
rotatable pin. The pin is between the front steering knuckle
1.0 758
and the swing arm, which is fixed by two bolts and lock nuts to subframe by using two polytetrafluoroethene (PTFE) sleeves,
the steering knuckle. When the wheel turns and bounces, the and the PTFE sleeves are secured with bolts and front
steering knuckle drives the pin to rotate around the center of horizontal stabilizer bar anchorage brackets. The PTFE sleeve
the ball. During driving, the ball pin can transfer force to the has a low friction, and does not need extra lubrication, which
vehicle through the swing arm. The front lower swing arm allows the static front horizontal stabilizer bar to rotate freely
and subframe are connected by the front/rear bushes. Two and give rapid response to the overturn input. The washer
pairs of bolts/nuts fit the front bush to the front subframe outside each sleeve on the front horizontal stabilizer bar
through the bush bracket. The rear bush is fitted into the can prevent the lateral movement of the front horizontal
subframe bracket by a pair of bolt/nut. The force from the stabilizer bar. The two ends of the front horizontal stabilizer
vehicle wheel is transferred to the swing arm by the ball pin bar is connected to the cylinder of the front shock absorber
before the front/rear bushes transfer it to the subframe. In by its connecting rod. This arrangement allows the front
addition to transferring force, the flexibility of the bush also horizontal stabilizer bar to act in an approximate ratio of
allows the swing arm to sway up and down, it can absorb the 1:1 with the wheel travel and provides the maximum lateral
vibration from the ground and its rigidity can provide a good stability performance. For each front horizontal stabilizer bar,
stability. The axis of the front and rear bushes is in the same the end of the connecting rod is fitted with a ball joint which
straight line. The swing arm rotates around the axis of the can increase the response speed and efficiency. The upper ball
front and rear bushes, which guides the motion track of the joint and the axis line of the connecting rod are at an angle
vehicle wheel and helps the wheel to move in accordance with of 90°, which is fitted on the connecting rod and connected
the scheduled track. The ball pin and front/rear bushes of the directly by lock nuts with the welded bracket on the front
swing arm are replaceable. shock absorber cylinder. The lower ball joint and the axis
line of the connecting rod are at an angle of 90°, which is
Caution: Do not jack the vehicle under the front or rear
fitted on the connecting rod and connected with the front
lower arm as damage or misalignment may occur.
horizontal stabilizer bar by lock nuts. The connecting rod
Front Horizontal Stabilizer Bar and Connecting must be connected to the rear ball joint of the front horizontal
Rod
stabilizer bar, and the locking surface of lock nut shall face
The steel front horizontal stabilizer bar of solid spring passes the inside of the vehicle. The ball joint on the connecting
through the connecting rod of the stabilizer bar transversely rod of the front horizontal stabilizer bar is not repairable, if
and connects the shock absorber strut bracket. The diameter any one of the ball joints should be replaced, the connecting
of the front horizontal stabilizer bar is 23mm. The front rod assembly of the front horizontal stabilizer bar shall be
horizontal stabilizer bar is connected to the rear of front renewed.
1.0 759
Service Procedures height sensor to the front lower swing arm, fit 2 bolts
Front Lower Swing Arm Assembly and tighten to 7–10Nm.
Remove 6. Fit the wheels.
1. Raise the vehicle on a lift. Wheel Refit
2. Remove the corresponding front wheel. 7. Check and adjust the parameters for wheel alignment.
Wheel Remove
3. For vehicles with DHL, remove 2 bolts fixing the DHL
8. For vehicles with DHL, perform a self-learning for the
front suspension height sensor to the front lower swing
null voltage of the DHL height sensor.
arm.
4. Remove and discard the nut (3) fixing the outer ball Self-learning and Adjustment, Programming and
joint of the front lower swing arm to the front wheel Coding - Height Sensor Null Voltage Self-learning
hub.
5. Loosen the outer ball joint of the front lower swing
arm from the front wheel hub.
Warning: Do not jack the vehicle under the front or rear
6. Remove and discard the bolt and nut (1), (2) fixing the
front bush of the front lower swing arm to the front
subframe.
7. Remove the outer ball joint from the front wheel hub.
8. Remove and discard the bolt (4) fixing rear bush bracket
assembly of the front lower swing arm to the subframe.
9. Remove the front lower swing arm assembly.
Refit
1. Locate the front lower swing arm to the subframe, fit
the bolt, but do not tighten it at this step.
2. Tighten 2 bolts securing the bracket assembly of the
front lower swing arm bush to 110±10Nm.
3. Fit the rear bush nut of the front lower swing arm and
tighten to 90Nm＋＋120°.
4. Connect the outer ball joint of the front lower swing
arm to the front wheel hub. Fit the bolt and tighten the
front wheel hub to 95±10Nm.
Caution: Nuts and bolts must be tightened with weight of
vehicle on suspension.
5. For vehicles with DHL, fix the DHL front suspension
1.0 760
Front Lower Swing Arm Outer Ball Joint Front Lower Swing Arm Rear Bush
Remove Remove
Caution: This ball joint boot kit should only be used if the 1. Remove the front lower swing arm assembly.
boot is damaged during a service. It must not be used if
Front Lower Swing Arm Assembly Remove
the vehicle has been driven with a damaged boot.
2. With the pressing device and TCH00098, press the
1. Remove the front lower swing arm assembly. rear bush of the front lower swing arm out of the front
Front Lower Swing Arm Assembly Remove lower swing arm assembly.
2. Remove and discard 3 bolts and nuts (1) fixing the front
lower swing arm outer ball joint sheath to the front
lower swing arm outer ball joint.
Refit
1. Clean the junction of the front lower swing arm, front
lower swing arm bush and bracket assembly.
Refit 2. Clean the junction of the front lower swing arm and the
1. Connect the new outer ball joint of the front lower rear bush of the front lower swing arm.
swing arm to the the front lower swing arm with 3 3. With the pressing device and TCH00098, press the
bolts. rear bush of the front lower swing arm into the front
2. ＋45°.
Fit the nut and tighten to 140Nm＋ lower swing arm assembly.
3. Fit the front lower swing arm assembly.
Front Lower Swing Arm Assembly Refit
Front Lower Swing Arm Assembly Refit
1.0 761
Front Shock Absorber Assembly 12. Fix the spring compressor T32016 and T32017 to the
Remove front shock absorber spring.
2. Remove wheels on both sides.
Wheel Remove
3. Release the wheel speed sensor harness and brake hose
from the front shock absorber. Release the harness and
brake hose (1), (2) from the clip.
13. Ensure the adapter of the spring compressor is properly

fitted, and compress the spring.
14. Lock the top of the front shock absorber with an Allen
wrench, remove and discard the top nut.
15. Remove the upper mounting support assembly of front
shock absorber.
4. Remove nuts fixing the steering gear outer rod to the 16. Remove the spring vibration isolator.
knuckle and discard them. Then disconnect the steering
17. Remove the coil spring of front shock absorber.
gear outer rod from the knuckle.
18. Remove the front bumper block and front dust shield
5. Release the nut (1) fixing the front horizontal stabilizer
of the front shock absorber.
bar to the front shock absorber.
19. Release the pressure of coil spring, loosen adapter from
spring compressor and remove coil spring.
Refit
1. Check the front shock absorber strut and bearing for
any sign of crack and damage.
2. Check the front shock absorber dust shield and the
front buffer block for any sign of aging or damage.
3. Clean the front shock absorber strut and bumper block.
4. Fit the front bumper block and dust shield of the front
shock absorber to the front shock absorber strut.
5. Fit the coil spring of front shock absorber to front
shock absorber strut.
6. Remove the bolt (3) fixing front shock absorber
6. Locate the spring compressor to the front shock
assembly to front wheel hub, and discard it.
absorber, apply T32016 and T32017 to compress
7. Remove the front shock absorber from the front wheel spring.
hub.
7. Ensure correct relative position of installation, fit the
8. Remove the top A/C intake grille. upper erection support of front shock absorber and
A/C Air Intake Grille Remove the vibration isolator of front shock absorber spring to
9. Remove 3 nuts (4) fixing the front shock absorber to front shock absorber shaft.
the body, and then discard. 8. Fit the nut at the top of the front shock absorber.
10. Remove the spring and the front shock absorber 9. Lock the front shock absorber strut with hexagonal
assembly. socket spanner and tighten the nuts to 65–75Nm.
11. Remove the anti-rust cap at the top of the front shock 10. Release the elasticity of the spring, loosen the adapter
absorber. of the spring compressor and take out the spring
1.0 762
compressor. Front Subframe Assembly
11. Fit the anti-rust cap of the front shock absorber. Remove
12. Clean the conjunction plane between front vibration 1. Remove the front wheels.
absorber and spring assembly and the vehicle body. Front Wheels Remove
13. Locate the front shock absorber and spring assembly to 2. Raise the vehicle on a lift.
the vehicle body, fit and tighten new nuts to 55–65Nm.
3. For vehicles equipped with DHL (dynamic headlamp
14. Fit the front shock absorber assembly into the front leveling), remove 2 bolts fixing the headlamp leveling
wheel hub, fit and tighten new bolts and nuts to front suspension height sensor to the front subframe.
90–110Nm.
4. For AWD vehicles, remove the intermediate drive shaft.
15. Fit the front A/C intake grille.
Intermediate Driving Shaft Remove
Front A/C Intake Grille Refit
5. Remove the left/right drive shaft.
16. Clean the connecting rod of the front horizontal
stabilizer bar and fit it into the front shock absorber Left Drive Shaft Remove
assembly. With an open-end wrench, clamp the Right Drive Shaft Remove
connecting rod of the front horizontal stabilizer bar to
6. Remove the front exhaust pipe.
lock the ball joint of the front horizontal stabilizer bar,
fit the nut and tighten to 40–50Nm. Front Exhaust Pipe Remove
17. Fit front brake hose and front wheel ABS sensor 7. Remove the front lower swing arm.
harness to front shock absorber bracket. Front Lower Swing Arm Remove
18. On the right: fix front brake pad wearing sensor 8. Remove the bolt and nut (1) fixing the front lower tie
harness to front shock absorber bracket. rod to the transmission.
19. Fit the wheels.
Wheel Refit
21. Check the wheel alignment parameters.
22. For vehicles with DHL (dynamic headlamp leveling),
perform a self-learning for the null voltage of the DHL
height sensor.
Self-learning and Adjustment, Programming

and Encoding - Height Sensor Null Voltage
Self-learning
9. Remove the bolt (2) fixing the lower tie rod to the
front subframe, and remove the lower tie rod.
10. Remove 2 nuts fixing the steering gear and front wheel
hub.
11. Remove 2 bolts (1) fixing the connecting rod of the
horizontal stabilizer bar to the front shock absorber.
1.0 763
＋180°
the bolt.90Nm＋
8. Tighten the bolt securing the front subframe support
rod on the front subframe to 80±10Nm.
9. Tighten the bolt fixing the lower engine tie rod to the
engine bracket.
10. Tighten the nut fixing the steering gear and front wheel
hub to 40–50Nm.
11. Tighten the nut fixing the connecting rod of the
horizontal stabilizer bar to the front shock absorber
assembly to 40–50Nm.
12. Remove 2 bolts (2) fixing the left/right support rods of Front Lower Swing Arm Assembly Refit
the front subframe to the body. 13. Fit the front exhaust pipe.

14. For AWD vehicles, fit the intermediate drive shaft.
Drive Shaft Refit

15. Fit the left/right drive shafts.

16. For vehicles with DHL (dynamic headlamp leveling), fix
the DHL front suspension height sensor to the front
subframe, fit 2 bolts and tighten to 7–10Nm.
17. Fit the front wheel.
13. Support the front subframe assembly with the hydraulic Wheel Refit
lifting equipment, remove 4 bolts (1) fixing the front 18. Connect the battery negative cable.
subframe to the body and remove the subframe.
19. Check the parameters for four-wheel alignment.
14. Remove 4 bolts fixing the horizontal stabilizer bar to
the front subframe.
20. For vehicles with DHL (dynamic headlamp leveling),
15. Remove 2 bolts fixing the steering gear to the subframe.
perform a self-learning for the null voltage of the DHL
Refit
height sensor.
1. Fit the horizontal stabilizer bar bush to the horizontal
Self-learning and Adjustment, Programming
stabilizer bar, tighten 4 bolts fixing the horizontal
and Encoding - Height Sensor Null Voltage
stabilizer bar bracket to the front subframe to
Self-learning
55–65Nm.
2. Fit the bolt fixing the steering gear to the front
subframe, and tighten to 100Nm+45°.
3. Locate the front subframe assembly to the hydraulic
lifting equipment.
4. Clean the mounting location on the front subframe
assembly.
5. Locate the subframe to the body according to the
mounting mark on the body.
6. Locate the subframe support rod to the front subframe,
fit 4 new bolts to the subframe.
7. Evenly tighten 4 mounting bolt of the front subframe,
align the washer with the subframe bushing and tighten
1.0 764
Front Subframe Support Rod Front Horizontal Stabilizer Bar
Remove Remove
1. Raise the vehicle on a lift. 1. Remove two front wheels.
2. Remove the screw (2) fixing the subframe support rod Wheel Remove
to the body. 2. Raise the vehicle on a lift.
3. Remove and discard the nut (2) fixing the front
horizontal stabilizer bar to the connecting rod of the
front horizontal stabilizer bar.
4. Fix the wheel hub aside, so that there is enough space
for removing the horizontal stabilizer bar.
3. Take away the bolt (1) fixing the subframe support rod
to the subframe, and remove the subframe support rod.
Refit
1. Locate the subframe support rod to the subframe, fit
the bolt and tighten to 80±10Nm.
2. Locate the subframe support rod to the body, fit the 5. Remove and discard 4 bolts (1), (2) securing the front
bolt and tighten to 90Nm＋＋180°. horizontal stabilizer bar on the front subframe.
6. Remove the front horizontal stabilizer bar.

Refit
1. Locate the front horizontal stabilizer bar to the
subframe and adjust it.
2. Fit the front horizontal stabilizer bar bush and locate it
to the support.
Caution: Anti roll bar bushes have a special coating and
must not be lubricated.
3. Fit the bush bracket of the front horizontal stabilizer

bar. Fit new bolt to the bush bracket and tighten to
55–65Nm in sequence.
4. Align the connecting rod of the front horizontal
stabilizer bar, fit new nut securing the connecting rod
1.0 765
of the front horizontal stabilizer bar on the the front Front Horizontal Stabilizer Bar Bushing
horizontal stabilizer bar, and tighten to 55–65Nm. Remove
Caution: Nuts and bolts must be tightened with weight of 1. Remove front wheels.
vehicle on suspension. Wheel Remove
3. Remove and discard 4 bolts fixing the bracket and
bushing of the front horizontal stabilizer bar to the
front subframe.
4. Remove the bracket and bushing of the front horizontal
stabilizer bar.
Refit
1. Fit the bush to the front horizontal stabilizer bar and
locate it to the support.
Caution: Anti roll bar bushes have a special coating and

must not be lubricated.
2. Fit the bush bracket.

3. Fit new bolt to the bush bracket and tighten each bolt
to 55–65Nm in sequence.
4. Check whether the tightening force of each bolt is
correct.
Caution: Failure to carry out this procedure can result in

bolts being incorrectly tightened.
1.0 766
Front Horizontal Stabilizer Bar Connecting Rod Front Wheel Hub Assembly
Remove Remove
2. Remove front wheels. 2. Remove front wheels.
Wheel Remove Front Wheels Remove
3. Remove and discard the nut (2) fixing the connecting 3. Remove the front left/right drive shafts.
rod of the front horizontal stabilizer bar to the front Left Drive Shaft Remove
horizontal stabilizer bar.
Right Drive Shaft Remove
4. Release the harness of the ABS speed sensor from the
bracket. Remove the clip from the bracket and release
the brake hose.
5. Remove 2 bolts (1), (2) fixing the brake caliper to the
front wheel hub. Release the brake caliper from the
front wheel hub and fix it aside.
4. Disconnect the connecting rod of the front horizontal

stabilizer bar from the front horizontal stabilizer bar.
5. Remove the nut (1) fixing the connecting rod of the
front horizontal stabilizer bar to the front shock
absorber.
Caution: To prevent damage to components, use two

spanners when loosening or tightening unions. Caution: Don’t tie brake caliper on brake hose.
6. Remove the connecting rod of the front horizontal 6. Remove the countersunk bolts securing the front brake
stabilizer bar from the front shock absorber. disc and the front wheel drive flange.
Refit
1. Fit the connecting rod of the front horizontal stabilizer
bar to the front shock absorber, and tighten the nut
to 40–50Nm.

spanners when loosening or tightening unions.
2. Connect the connecting rod of the front horizontal

stabilizer bar to the front horizontal stabilizer bar, fit
new nuts and tighten to 55–65Nm.

spanners when loosening or tightening unions.
3. Fit the two front wheels. 7. Remove the front brake disc.
Wheel Refit 8. Remove nuts fixing the steering gear outer rod to the
9. Remove screws fixing the ABS speed sensor, release
the sensor and put it aside.
10. Remove nuts and bolts fixing the outer ball joint of
1.0 767
the front lower swing arm to the front wheel hub and 11. Clean the mating surface of the front wheel ABS speed
discard the bolt and nut. sensor and front wheel hub.
11. Remove the bolts fixing front shock absorber assembly 12. Lubricate the junction between the front wheel ABS
to front wheel hub, and discard them. sensor and the front wheel hub with appropriate grease.
12. Remove the outer ball joint of the front lower swing Capacity
arm.
13. Fit the front wheel ABS sensor to front wheel hub with
13. Remove the front wheel hub from the front shock screws and tighten to 7–10Nm.
absorber.
14. Fit the front brake disc to front drive flange, fit
14. Remove and discard 4 bolts fixing the wheel hub countersunk head screws and tighten them to
bearing assembly to the front knuckle. Remove the 7–10Nm.
wheel hub bearing assembly.
15. Loosen front brake caliper assembly and locate it
to front brake disc. Fit the bolts fixing the front
brake caliper to the front wheel hub and tighten to
190–210Nm.
16. Secure the front brake hose to front shock absorber
bridging bracket and fix it with pipe clamp.
17. Fix the front wheel ABS sensor harness to the front
shock absorber strut. Fix the front brake hose and
front wheel ABS sensor harness to the pipe clamp.
18. Fit the left/right drive shaft.

Tip: Do not remove protective cover from bearing until
19. Fit the wheels.
hub is about to be fitted.
Tip: Do not store hub bearings near magnetic fields or Wheel Refit
iron filings as damage may occur. 20. Lower the vehicle.
Refit 21. Check the wheel alignment parameters.
1. Clean the junction between front wheel hub bearing
Four Wheel Alignment Check
assembly and front steering knuckle.
2. Clean the junction between front steering knuckle and
front shock absorber.
3. Clean the junction between front steering knuckle and
front lower rocker arm ball joint.
4. Fit a new bolt securing the wheel hub bearing assembly
and front steering knuckle, and tighten to 70Nm＋＋90°.
5. Connect the front steering knuckle and front shock
absorber assembly with bolts.
6. Check the ball joint sheath of the front lower swing
arm for any damage and connect the front wheel hub
to the front lower rocker arm assembly.
7. Fix front shock absorber assembly to front wheel hub
with new nut and tighten to 140–170Nm.
8. Fix front lower rocker arm assembly to front wheel hub
with new nut and tighten to 95±10Nm
9. Clean the junction between the steering tie rod and
the steering arm.
10. Connect the steering tie rod to the steering arm, fit
new lock nuts and tighten to 40–50Nm.
1.0 768
Special Tools
Number
Remove and
replacer front
TCH00098
lower arm small
bus
Coil spring
T32016
compressor
Adaptor
T32017 coil spring
compressor
1.0 769
Suspension System Rear Suspension
Rear Suspension
Specifications
Torque
Description Value
Bolts- rear upper arm assembly to rear subframe 110±11Nm
Nut- rear upper arm assembly to rear wheel carrier 90Nm+90°
Nut- rear lower arm assembly to rear subframe 100±10Nm
Nut- rear lower arm assembly to rear wheel carrier 155±15Nm
Bolts- rear damper to body 55–65Nm
Bolts- rear damper to rear wheel carrier 75–90Nm
Bolt-wheel to hub 120–130Nm
Nut- lateral rod assembly to rear subframe 100±10Nm
Nuts- rear anti-roll bar links to anti-roll bar 45–55Nm
Nut- rear anti-roll bar links to rear lower arm assembly 7–11Nm
Bolts- rear anti-roll bar to rear subframe 55–65Nm
Bolts- rear wheel carrier 180Nm ＋ 180°
Bolts- rear bearing to rear wheel carrier 70Nm ＋ 90°
Nut-front drive shaft 350–370Nm
Screw-Rear brake pan to bearing 7-10Nm
Bolt-Rear brake caliper assembly to rear knuckle 55 Nm+30°
Bolts- rear subframe to body 90Nm+90°
Nut- lateral rod assembly to rear wheel carrier 130Nm+90°
Bolts- rear blade arm assembly to rear wheel carrier 60±5Nm
Bolts- rear blade arm assembly yo rear body 100±10Nm
Bolt - ASM-FR sensor to bodywork 7–10Nm
Nuts- rear trailing arm bush to rear trailing arm 155±10Nm
1.0 770
Rear Suspension Suspension System
Parameter
Model The coil spring, inflatable pillar shock absorber and four
connecting rods are at the rear subframe.
Rear Upper Swing Arm High Strength Steel
Diameter of Rear Horizontal Stabilizer Bar 20mm
Rear Coil Spring Data:
Total Coils 7.65
The diameter of wire 12.5mm
Free Length: 341mm
1.0 771

System Layout
Rear Suspension Layout
1. Rear Shock Absorber Assembly (2) 6. Rear Wheel Hub Assembly (2)
2. Rear Lower Swing Arm Assembly (2) 7. Rear Upper Swing Arm Assembly (2)
3. Rear Subframe Assembly 8. Rear Trailing Arm Assembly (2)
4. Rear Horizontal Stabilizer Bar Connecting Rod (2) 9. Rear Lateral Push Rod Assembly (2)
5. Rear Suspension Coil Spring Assembly (2) 10. Rear Horizontal Stabilizer Bar Assembly
1.0 772
Rear Suspension Exploded View
1. Rear Shock Absorber Assembly (2) 8. Rear Lateral Push Rod Assembly (2)
2. Rear Lower Swing Arm Assembly (2) 9. Rear Coil Spring Assembly (2)
3. Rear Wheel Bracket (2) 10. Rear Horizontal Stabilizer Bar Assembly (2)
4. Rear Wheel Hub Bearing Assembly (2) 11. Rear Horizontal Stabilizer Bar Connecting Rod (2)
5. Rear Subframe Assembly (2) 12. Rear Horizontal Stabilizer Bar Bushing (2)
6. Rear Lower Swing Arm Assembly (2) 13. Rear Horizontal Stabilizer Bar Mounting Bracket (2)
7. Rear Trailing Arm Assembly (2) 14. Rear Horizontal Stabilizer Bar Bushing and Bracket
1.0 773
Rear Shock Absorber Assembly Exploded View
1. Rear Shock Absorber Strut 5. Rear Top Plate

2. Rear Bumper Block 6. Upper Gasket
3. Cushion - Piston Rod Step 7. Rear Dust Shield
4. Cover - Bumper Block 8. Nut
1.0 774
Description and upper mounting support are secured by a lock nut and
Overview rebound gasket. The upper mounting support is connected
with the body by two bolts. The rebound gasket is between
Rear suspension includes:
the lock nut of the rear shock absorber strut and the upper
• 2 Shock Absorbers
mounting support. The bumper block is on the rear shock
• 2 Coil Springs absorber strut, which slows down the shock absorber when
• 2 Upper Swing Arms the maximum compression stroke is achieved.
• 2 Lower Swing Arms Coil Spring
• 2 Trailing Arms The coil spring made of chrome steel is between the body
• 2 Rear Lateral Push Rods and the rear lower swing arm, and each spring is between the
• Rear Horizontal Stabilizer Bar (if fitted) upper and lower spring vibration isolator which can reduce
the noise delivered to the body from the suspension. Every
• 2 Connecting Rods of Rear Horizontal Stabilizer Bar (if
vibration isolator is directly connected with the spring. The
fitted)
lower vibration isolator is fitted in a flat hole of the rear lower
• Rear Subframe swing arm, when removing, pull it out from the flat hole. The
The trailing arm provides the rear suspension with the cut hole of lower vibration isolator is used for drainage, when
characteristic of anti-lift control, and the horizontal upper fitting, align it with the corresponding hole of the rear upper
and lower swing arms allow the rear suspension to control swing arm.
the wheel camber. The compact layout of the rear Rear Upper Swing Arm
suspension allows the vehicle to have lower and wider luggage
The rear upper swing arm is an unrepairable structural part,
compartment floor, and the rear suspension does not interfere
which is welded with a sleeve by stamping the hot rolled steel
with the luggage compartment.
plate into a U punching sheet. The inside of the rear upper
Rear Subframe control arm is fitted with a rubber bushing which is connected
The rear subframe assembly includes 2WD and AWD. The rear with the rear subframe by a bolt and a nut. The outside of
subframe assembly has a frame structure, which is connected the rear upper control arm is open, which is connected to the
with the body by a 4-point hard connection and is fitted with rear wheel bracket by a bolt and a nut. The punching sheet of
locating pin. the rear upper control arm is also provided with the mounting
hole of the wheel speed sensor which is connected by a clip.
The rear subframe provides mounting location for the rear
upper/lower control arms, rear lateral push rod and stabilizer Rear Lower Swing Arm
bar, etc. The 4WD rear subframe provides mounting point for The rear lower swing arm is stamped from hot rolled steel
the transmission through the 4 press-fit bushings. In addition, plate, the box type part welded through the upper side and
it also supplies mounting hook and bracket for the exhaust lower side loads the spring and connects the connecting rod
pipe and EPB cable. The rear subframe assembly can transfer of the stabilizer bar. The inside of the rear lower swing arm
the load of the suspension components to the lower vehicle is fitted with a rubber bushing which is connected to the rear
body and weaken the impact from the collision with the body subframe by an eccentric bolt, an eccentric gasket and a nut,
structure. and the eccentric bolt can be used to adjust the four-wheel
Rear Shock Absorber alignment toe-in of the rear axle. The outside of the rear lower
swing arm is connected to the rear wheel bracket by a bolt and
The rear shock absorber is not repairable. The rear shock
a nut.
absorber has a compression stroke of 120mm and a rebound
stroke of 80mm. The rear shock absorber is a dual barrel type Caution: Do not jack the vehicle under the front or rear
structure, can be inflated and fuelled. This type of structure lower arm as damage or misalignment may occur.
allows the movement of shock absorber piston inside the inner Rear Lateral Push Rod
cylinder with a oil hole which is between the inner and outer
The rear lateral push rod is an unrepairable structural part
cylinder. This structure minimizes the cavitation and eliminates
which is welded by two sleeves and one hollow link, and the
the influence of the piston motion due to the damage of outer
two sleeves are fitted with a rubber bushing respectively. The
cylinder. There is a non-repairable bushing at the lower part
inside of the rear lateral push rod is connected with the rear
of the shock absorber, which is connected to the trailing arm
subframe by an eccentric bolt, an eccentric gasket and a nut,
extension bar by bolts. This fitting position can provide a
and the eccentric bolt can be used to adjust the camber and
1:1 mechanical lever ratio for the rear shock absorber and
toe-in of the rear axle for four-wheel alignment. The outside
enhance vibration control. The rear shock absorber strut
1.0 775
of the rear lateral push rod is connected with the rear wheel the horizontal stabilizer bar is 19mm. The horizontal stabilizer
bracket by a bolt, a gasket and a nut. bar is connected to the rear side of the subframe by two
Trailing Arm polytetrafluoroethene (PTFE) sleeves, and the PTFE sleeves
are secured with bolts and clamping plate. The PTFE sleeve
The rear trailing arm is stamped by high strength steel, which
has a low friction, and does not need extra lubrication, which
is a single piece, has the shape of a blade and is used for
allows the static horizontal stabilizer bar to rotate freely and
transferring the driving force and brake force of the rear wheel
give rapid response to the overturn input. The end of the
to the body. The front of the trailing arm is fitted with a welded
rear horizontal stabilizer bar is connected with the trailing
pipe for fitting the rubber bushing which is connected with
arm by the unrepairable connecting rod of the rear horizontal
the blade arm bracket by a bolt and a nut, and the bracket
stabilizer bar, and each connecting rod of the rear horizontal
is connected to the body by 4 bolts. The rear of the trailing
stabilizer bar connects the rear horizontal stabilizer bar by
arm is connected to the rear wheel bracket by 3 bolts. Since
the ball joint and the lower cross arm by the upper/lower
different ways are used to tighten the bolt, the body bolt can
rubber bushings. The ball joint can improve the response
be reused while the wheel bracket bolt cannot be reused. In
speed to vehicle overturn and efficiency. When connecting
order to relieve the longitudinal impact of the rear axle, the
each connecting rod to the rear horizontal stabilizer bar, the
longitudinal structure of the rubber bushing applies a hollow
ball joint shall be outside the mounting surface of the rear
design. If the bushing shall be replaced, carefully observe and
horizontal stabilizer bar, while the nut is on the inside.
make a mark for future installation.
Horizontal Stabilizer Bar and Connecting Rod
The horizontal stabilizer bar made of solid spring steel is
directly connected to the wheel hub bracket. The diameter of
1.0 776
Service Procedures Rear Lower Swing Arm Assembly
Rear Upper Swing Arm Assembly Remove
Remove 1. Remove the rear suspension spring assembly.
1. Raise the vehicle on a lift. Rear Suspension Spring Assembly Remove
2. Remove the rear wheel. 2. Release the nut (1) fixing the lower swing arm assembly
Wheel Remove of the rear suspension to the rear subframe, and
3. Remove the clip securing the harness on the rear upper remove the lower swing arm assembly.
swing arm assembly.
Refit
4. Remove the bolt (4) and nut fixing the rear upper swing 1. Fit the bolt fixing the rear lower swing arm to the rear
arm assembly to rear wheel bracket, and discard the subframe, pre-tighten the bolt by hand, but do not
nut. tighten it.
5. Remove the bolt and nut (3) fixing the rear upper swing 2. Fit the rear suspension spring assembly.
arm assembly to rear subframe, and discard the nut. Rear Suspension Spring Assembly Refit
Refit 3. Tighten the nut securing the rear lower swing arm
1. Locate the upper swing arm of the rear suspension to assembly and subframe to 100±10Nm.
the subframe, fit the bolt, but do not tighten it at this 4. Tighten the nut securing the rear lower swing arm
step. assembly and wheel bracket to 155±15Nm.
2. Locate the upper swing arm of the rear suspension to 5. Four-wheel Alignment Check and Adjustment
the wheel bracket, fit the bolt, but do not tighten it
at this step. Four-wheel Alignment
3. Tighten the nut fixing the upper swing arm of the rear
suspension to the rear subframe to 110±11Nm.
4. Tighten the nut fixing the upper swing arm of the rear
suspension to the wheel bracket to 90Nm+90°.

5. Secure the harness on the upper swing arm clip of the

rear suspension.
6. Fit the rear wheels.
Wheel Refit
1.0 777
Rear Upper Swing Arm Bush Rear Shock Absorber Assembly

Remove Remove
1. Remove the rear upper swing arm assembly. 1. Raise the vehicle on a lift.
Rear Upper Swing Arm Assembly Remove 2. Remove the rear wheels.
2. With the TCH00100 and hydraulic machine, press Wheel Remove
the bushing. 3. Remove the bolt (2) fixing the rear shock absorber to
the wheel bracket.
3. Remove the tool from the rubber bushing.

Refit 4. Remove 2 bolts fixing the rear shock absorber to the
body, remove the shock absorber and discard the nut.
1. Clean the groove of the rubber bushing.
2. With the TCH00100 and hydraulic machine, press
the new rubber bushing into the rear upper swing arm
(see the figure).
Caution: Ensure the rubber end of the bush is located fully

in the special tools. Use a hydraulic press to install bush.
5. Lock the piston of the shock absorber with a wrench.

Remove and discard the shock absorber nut.
6. Remove the rebound limit disc, mounting support,
bumper block/limit disc of the compression stroke and
dust shield. Mark the original location of the rebound
limit disc of the rear shock absorber.
3. Remove the tool from the ball joint sheath.
4. Fit the rear upper swing arm assembly.
Rear Upper Swing Arm Assembly Refit
1.0 778
Rear Suspension Spring Assembly
Remove
2. Remove the rear wheels.
Wheel Remove
3. Support the rear lower swing arm through the spring
seat of the rear lower swing arm.
Caution: Do not jack the vehicle under the front or rear

4. Remove the bolt (3) securing the rear lower swing arm
and wheel bracket, and release the rear lower swing
arm.
Refit
1. Fit the dust shield, bumper block/limit disc of the
compression stroke, mounting support and rebound
limit disc, and ensure the rebound limit disc of the rear
shock absorber is located on the original position. 5. Remove the rear suspension spring assembly.
2. Fit the bolt at the top of the rear shock absorber strut
3. Clean the mating face of the rear vibration absorber
assembly and body.
4. Fit the rear shock absorber assembly to the wheel
bracket, but do not tighten it at this step.
5. Stretch the rear vibration absorber assembly and locate
it to the mating face of the vehicle body.
6. Fit the nuts fixing the rear vibration absorber assembly
to the vehicle body and tighten to 55–65Nm.
7. Tighten the nut securing the rear vibration absorber
assembly and wheel bracket to 75–90Nm.
6. Remove the upper/lower vibration isolators (1), (2) of
8. Fit the rear wheels. the rear suspension spring assembly.
Wheel Refit Refit
9. For vehicles with DHL, perform a self-learning for the 1. Clean the mating face of the rear lower swing arm and
null voltage of the DHL height sensor. spring.
Self-learning and Adjustment, Programming and 2. Locate the rear suspension spring assembly on the
Coding - Height Sensor Null Voltage Self-learning rear lower swing arm, and ensure the bulge on the
lower vibration isolator of the rear suspension spring is
aligned with the rear lower swing arm.
3. Support the rear lower swing arm and fit the upper
vibration isolator of the rear suspension spring into the
lug of the rear subframe.
1.0 779
4. Fit the bolts fixing the rear lower swing arm to the Rear Horizontal Stabilizer Bar
wheel bracket, but do not tighten temporarily. Remove
5. Fit the rear wheels and tighten bolts to 120–130Nm. 1. Raise the vehicle on a lift.
6. Tighten the bolt securing the rear lower swing arm and 2. Remove and discard 4 bolts (1) fixing the rear horizontal
wheel bracket to 155±15Nm. stabilizer bar to the rear subframe, and remove the
bushing and clip of the rear stabilizer bar.


Coding - Height Sensor Null Voltage Self-learning
3. Lock the connecting rod of the rear horizontal

stabilizer bar with an open-end wrench and prevent
rotation of the ball joint. Remove the nuts fixing the
rear horizontal stabilizer bar to the connecting rod
of the rear horizontal stabilizer bar. Remove the rear
Refit
1. Align the connecting rod of the rear horizontal stabilizer
bar, fit bolts and nuts, but do not tighten them.
2. Fit 2 bushings of the rear horizontal stabilizer bar.
3. Fit the mounting bracket of the rear horizontal stabilizer
bar. Fit new bolts and tighten each bolt to 100±10Nm
in sequence.
4. Lock the connecting rod of the rear horizontal stabilizer
bar with an open-end wrench and prevent rotation of
the ball joint, then tighten the nut to 45–55Nm.
1.0 780
Rear Horizontal Stabilizer Bar Connecting Rod Rear Horizontal Stabilizer Bar Bushing
Remove Remove
2. Remove and discard the nut fixing the connecting rod 2. Remove and discard 4 bolts (1) fixing the bracket of
of the rear horizontal stabilizer bar to the rear lower the rear horizontal stabilizer bar to the subframe, and
swing arm, and keep the gasket and bushing. remove the bracket.
3. Remove the nut fixing the connecting rod of the rear 3. Remove the bushing of the rear horizontal stabilizer bar.
horizontal stabilizer bar to rear horizontal stabilizer Refit
bar, remove the connecting rod and keep the other 2 1. Fit the bushing of the rear horizontal stabilizer bar.
gaskets and 1 bushing.
2. Fit the bracket of the rear horizontal stabilizer bar, fit
Refit new bolts and tighten to 55–65Nm.
1. Fit 1 bushing and 1 gasket on the connecting rod of the 3. Lower the vehicle.
rear horizontal stabilizer bar to the rear lower swing
arm, and fit the bolt on the other end of the connecting
rod into the rear horizontal stabilizer bar.
2. Fit the nut fixing the connecting rod of the rear

horizontal stabilizer bar to the rear horizontal stabilizer
bar, and tighten to 45–55Nm.
3. Fit the other 2 gaskets and bushings into the connecting
rod of the rear horizontal stabilizer bar, fit the nut fixing
the connecting rod of the rear horizontal stabilizer bar
to the rear lower swing arm and tighten the nut to
7–11Nm until the thread can be seen.
1.0 781
Rear Lower Swing Arm Bush Rear Wheel Hub

Remove Remove
1. Remove the rear lower swing arm assembly. 1. Raise the vehicle on a lift.
Rear Lower Swing Arm Assembly Remove 2. Remove wheels.

2. With the TCH00101 and hydraulic machine, press Wheel Remove
the ball joint sheath. 3. Remove and discard 2 bolts fixing the rear brake caliper
assembly to the rear wheel bracket.
4. Secure the rear brake caliper assembly on the frame.
5. Remove the countersunk head screws fixing the rear
brake disc to the wheel hub.
6. Remove the rear brake disc from the vehicle.
7. For 2WD vehicles, remove the grease cap of the rear
wheel hub from the rear wheel hub assembly and
discard the cap.
3. Remove the tool from the ball joint sheath.

Refit
the new rubber bushing into the rear upper swing arm
(see the figure).
8. For 2WD vehicles, remove and discard the countersunk

head bolt securing the rear wheel bracket and real
wheel hub assembly.
9. For 4WD vehicles, remove and discard the rear drive
shaft nut.
3. Remove the tool from the rubber bushing.
Caution: Ensure the rubber end of the bush is located fully

in the special tools. Use a hydraulic press to install bush.
4. Fit the rear lower swing arm assembly.

Rear Lower Swing Arm Assembly Refit
10. For 4WD vehicles, remove and discard 4 bolts fixing

the rear wheel hub assembly to the wheel bracket.
11. Remove the rear wheel hub bearing assembly.
Caution: Do not store hub bearings near magnetic fields

or iron filings as damage may occur.
1.0 782
Refit 12. Fit the rear wheels.
1. Clean the half shaft. Wheel Refit
2. Check the wheel bracket and bearing, and ensure the
mating face between the parts is free from foreign
material and scratch.
3. Fit the wheel bracket and rear wheel hub bearing
assembly to the half shaft.
Caution: Do not remove protective cover from bearing

until hub is about to be fitted.
4. Insert the bolt for 2WD vehicles into the internal

spindle thread of the hub bearing assembly, and tighten
the bolt to 180Nm＋＋180°.
5. For 2WD vehicles, use the magnet in the front of
the TCH00083 to absorb the the grease cap and
put it into the flange hole of the bearing, knock the
TCH00083 with a hammer, apply uniform force when
fitting, the grease cap shall not tilt. After assembly,
check if the part fits well.
6. For 4WD vehicles, insert the bearing assembly into the
wheel bracket and ensure the thread hole is aligned
with the through-hole of the wheel bracket. Insert 4
fillister head bolts from the inside of the wheel bracket,
and pre-tighten the 4 bolts, then tighten the bolt to
70Nm＋＋90° in the diagonal sequence.
7. For 4WD vehicles, fit the new rear drive shaft nut and
tighten it to 350–370Nm.
8. Keep the mating face between the rear brake disc and
the wheel hub clean.
9. Fix the rear brake disc to the wheel hub, fit 1
countersunk head screw, tighten to 7-10Nm and check
the torque.
10. Check the mounting surface and hole of the wheel
bracket and rear brake caliper assembly, remove the
foreign material or oil stain and ensure the mounting
surface and hole are clean.
11. Fix the rear brake caliper assembly to the rear wheel
bracket, fit 2 bolts and tighten to 55 Nm+30°.
1.0 783
Rear Subframe Assembly

Remove
2. Remove two rear wheels.
Wheel Remove
3. Remove the rear exhaust pipe (muffler).
Rear Exhaust Pipe - Muffler Remove

4. Disconnect 2 connectors of the ABS vehicle speed
sensor and brake pad wear sensor.
and rear wheel bracket.
5. Remove the clip (1), (2) fixing the EPB cable to the
subframe.
13. Support the subframe with the hydraulic lifting

equipment.
14. Remove 4 subframe bolts and keep the washer properly.
15. Lower the rear subframe with the hydraulic lifting
equipment.
16. If the subframe has been removed, do not attempt to
repeat the operation.
17. Remove the nut and bolt fixing the lateral push rod to
the subframe, and do the same operation for the other
side.
6. Prepare a container to collect the spilled liquid. 18. Remove the nut fixing the connecting rod of the
7. Disconnect the left brake hose from the body bracket. rear horizontal stabilizer bar to the rear lower swing
arm, and keep the gasket and bushing. Do the same
8. Repeat the above steps for the other side.
operation for the other end.
9. Remove the rear suspension spring assembly.
19. Remove the bolt securing the rear lower swing arm and
Rear Suspension Spring Assembly Remove subframe, and release the rear lower swing arm. Do
10. Remove the bolt (4) securing the rear upper swing arm the same operation for the other end.
and rear wheel bracket assembly. 20. Remove the bolt securing the rear upper swing arm and
11. Remove and discard the bolt (1) securing the lateral subframe, and release the rear upper swing arm. Do
push rod and rear wheel bracket assembly. the same operation for the other end.
21. Remove 4 bolts and 2 brackets fixing the rear horizontal
stabilizer bar to the subframe, and release the rear
1.0 784
Refit Rear Subframe Assembly - AWD
1. Fit the bolts fixing the rear upper swing arm to the Remove
subframe, but do not tighten temporarily. Do the same 1. Raise the vehicle on a lift.
operation for the other end. 2. Remove two rear wheels.
2. Fit the bolts fixing the rear lower swing arm to the
Wheel Remove
subframe, but do not tighten temporarily. Do the same
operation for the other end. 3. Remove the rear exhaust pipe (muffler).
3. Fit the bolts fixing the rear lateral push rod to the Rear Exhaust Pipe - Muffler Remove
subframe, but do not tighten temporarily. Do the same 4. Remove the rear axle assembly.
Rear Axle Assembly Remove
4. Clean mating face of the subframe and body.
5. Disconnect 2 connectors of ABS vehicle speed sensor
5. Locate the subframe on the body with a hydraulic lifting and brake pad wear sensor.
equipment.
6. Fit the bolt and gasket fixing the subframe to the body,
and tighten the bolt to 90Nm+90°.
7. Fit two rear suspension spring assemblies.
Rear Suspension Spring Assembly Refit

8. Fit the bolt fixing the lower swing arm to the wheel
bracket, and tighten to 155±15Nm.
9. Fit the bolt fixing the upper swing arm to the wheel
bracket, and tighten to 90Nm+90°.
10. Fit the bolt fixing the rear lateral push rod to the wheel
11. Tighten the nut fixing the rear horizontal stabilizer bar
and the connecting rod of the rear horizontal stabilizer 6. Remove the clip (1), (2) fixing the EPB cable to the
bar to 45–55Nm. subframe.
12. Locate the rear horizontal stabilizer bar on the rear

subframe, secure with bushing and bracket and tighten
the bolt to 55–65Nm. Fit 2 gaskets and bushing into
the connecting rod of the rear horizontal stabilizer
bar, fit the nut fixing the connecting rod of the rear
horizontal stabilizer bar to the rear lower swing arm
and tighten the nut to 7–11Nm until the thread can
be seen.
13. Connector the ABS and brake lining alarm connector.
14. Fit the clip fixing the EPB cable to the subframe.
15. Fit the rear exhaust pipe (muffler).
Rear Exhaust Pipe - Muffler Refit 7. Place a container to collect the spilled liquid.
16. Check the four-wheel alignment parameters and align 8. Disconnect the left brake hose from the body bracket.
the four wheels.
9. Repeat the above steps for the other side.
Four-wheel Alignment 10. Remove the rear suspension spring assembly.
Rear Suspension Spring Assembly Remove

11. Remove the bolt (4) fixing the rear upper swing arm
and the rear wheel bracket assembly, and discard.
12. Remove the bolt (1) fixing the lateral push rod and the
rear wheel bracket assembly, and discard.
1.0 785

2. Fit the bolts fixing the rear lower swing arm to the
3. Fit the bolts fixing the lateral push rod to the subframe,
but do not tighten temporarily. Do the same operation
for the other end.
4. Clean mating face of the subframe and body.
5. Locate the subframe on the body with a hydraulic lifting
equipment.
6. Fit the bolt and gasket fixing the subframe to the body,
and tighten the bolt to 90Nm+90°.
7. Fit two rear suspension spring assemblies.
and rear wheel bracket.
Rear Suspension Spring Assembly Refit
8. Fit the bolt fixing the lower swing arm to the wheel
9. Fit the bolt fixing the upper swing arm to the wheel
10. Fit the bolt fixing the connecting rod to the wheel
11. Fit the rear axle assembly.
Rear Axle Assembly Refit

12. Tighten the nut fixing the rear horizontal stabilizer bar
and the connecting rod of the rear horizontal stabilizer
14. Support the subframe with the hydraulic lifter. bar to 45–55Nm.
15. Remove 4 subframe bolts and keep the washer properly. 13. Locate the rear horizontal stabilizer bar on the rear
subframe, secure with bushing and bracket and tighten
16. Lower the subframe with hydraulic lifter.
the bolt to 55–65Nm. Fit 2 gaskets and bushing into
17. If the subframe has been removed, do not attempt to the connecting rod of the rear horizontal stabilizer
repeat the operation. bar, fit the nut fixing the connecting rod of the rear
18. Remove the nut and bolt fixing rear lateral push rod to horizontal stabilizer bar to the rear lower swing arm
subframe, and take the same operation at other side. and tighten the nut to 7–11Nm until the thread can
19. Remove the nut fixing the connecting rod of the be seen.
rear horizontal stabilizer bar to the rear lower swing 14. Connector the ABS and brake lining alarm connector.
arm, and keep the gasket and bushing. Take the same 15. Fit the clip fixing the EPB cable to the subframe.
operation at other side.
16. Fit the rear exhaust pipe (muffler).
20. Remove the bolt fixing rear lower swing arm to
subframe, and release the rear lower swing arm. Take Rear Exhaust Pipe - Muffler Refit
the same operation at other side. 17. Check the four-wheel alignment parameters and align
21. Remove the bolt fixing the rear upper swing arm and the four wheels.
subframe, and release the rear upper swing arm. Take Four-wheel Alignment
the same operation at other side.
22. Remove 4 bolts and 2 brackets fixing the rear horizontal
stabilizer bar to the subframe, and release the rear
Refit
1. Fit the bolts fixing the rear upper swing arm to the
1.0 786
Rear Lateral Push Rod Assembly Rear Lateral Push Rod Bushing
Remove Remove
1. Raise the vehicle on a lift. 1. Remove the rear lateral push rod assembly.
2. Remove the rear wheels. Rear Lateral Push Rod Assembly Remove
Wheel Remove 2. With the special tool TCH00100, press the rear
3. Remove the eccentric bolt and nut (2) fixing the rear lateral push rod bushing with the hydraulic machine as
lateral push rod assembly to the rear subframe, discard shown in the figure.
the nut and remove the washer.
Refit
4. Remove and discard the bolt and nut (1) fixing the rear
lateral push rod assembly to the rear wheel bracket.
5. Remove the rear lateral push rod.
the new rubber bushing into the rear lateral push rod
Refit (see the figure).
1. Fit the bolt and nut fixing the rear lateral push rod
assembly to the rear wheel bracket, but do not tighten
the bolt and nut.
2. Fit the bolt, washer and nut fixing the rear lateral push
rod assembly to the rear subframe, and tighten the nut
to 100±10Nm.
3. Tighten the nut securing the rear lateral push rod
assembly and rear wheel bracket to 130Nm+90°.
4. Perform four-wheel alignment.
5. Fit wheels.
3. Fit the rear lateral push rod assembly.
Rear Lateral Push Rod Assembly Refit
1.0 787
Trailing Arm Assembly Rear Trailing Arm Bushing

Remove Remove
1. Raise the vehicle on a lift. 1. Remove the rear trailing arm assembly.
2. Remove the rear wheels. Rear Trailing Arm Assembly Remove
Wheel Remove 2. Remove the bolt fixing the cover plate of the rear
3. For vehicles with DHL, remove 1 nut fixing the DHL trailing arm to the rear trailing arm.
front suspension height sensor to the rear trailing arm,
and disconnect the height sensor.
4. Remove 3 bolts (2) securing the trailing arm and wheel
bracket.

the ball joint sheath.
5. Remove 4 bolts (1) securing the trailing arm assembly

and body.
Refit
1. Fit the bolt and nut fixing the trailing arm to the wheel
2. Tighten 4 bolts securing the trailing arm and body to
100±10Nm.
3. For vehicles with DHL, fix the DHL front suspension
height sensor to the rear trailing arm, fit 1 nut and
4. Remove the tool from the rear trailing arm bushing.
Caution: In the refit process, please check the rear
suspension height sensor control arm, make sure the Refit
direction of control arm point to vehicle head (arrow 1. Clean the groove of the rubber bushing.
direction indicated on diagram). 2. With the TCH00102 and hydraulic machine, press
4. Fit the rear wheels. the new rubber bushing into the rear trailing arm (see
the figure).
Wheel Refit

1.0 788
3. Connect the bolt and nut securing the rear welded

trailing arm assembly and bracket, and tighten to
155±10Nm.
4. Fit the rear trailing arm assembly.
Rear Trailing Arm Assembly Refit
1.0 789
Special Tools
Number
Remove and
TCH00100 replacer rear
upper arm bush
Remove and
TCH00101 replacer rear
lower arm bush
Rear bearing
TCH00083
cap replacer
Remove and
replacer rear
TCH00102
trailing arm
bush
1.0 790
Tyres and Wheels Suspension System
Tyres and Wheels
Specifications
Torque
Description Value
Bolt-wheel to hub 120–130Nm
1.0 791
Suspension System Tyres and Wheels
Service Procedures
Wheel
Warning: Do not use silicone lubricant on the or wheel rim
or tyre edge. Clean tyre edge before removing. Use 50%
non-silicone lubricant and 50% water based lubricant to
these areas prior to refitting.
Remove
1. Remove the wheel trim cover assembly with a
screwdriver.
2. Remove the wheel bolt cap with the special tool.
3. With wheel wrench, rotate the bolt of each wheel
counterclockwise (half circle).
4. Place the vehicle on the lift and lift to a certain height. Warning: If there is oil leakage between the wheel and the
brake disc or drum, it will cause the wheel bolts to become
5. Remove the wheel bolts and place them in the tool tray.
loose and result in injury with the vehicle out of control.
6. Remove wheels.
Never use heat to remove a seized wheel. This will shorten
7. Pull out the wheel valve assembly, and remove the tyre the life of the wheel, wheel bolts, hub and bearing. Wheel
from the rim with the tyre changer. bolts must be tightened in correct sequence and to correct
Warning: Use a tyre changer to remove the tyre. Manual torque to avoid distortion of wheel, brake drum or disc.
tools or prybar could damage the road wheel or tyre. 7. Fit the wheel bolt cap.
Caution: Do not place the wheel face down on the ground 8. Fit the wheel trim cover assembly.
to avoid scratching.
Refit
Caution: Please clean the corrosive on the surface of the
road wheel, drum and brake disc before refitting. If wheel,
disc and drum contact surfaces are not properly cleaned,
the wheel bolts could become loose and may cause the
wheel to fall off while the vehicle is moving. This will cause
the vehicle to go out of control, and could cause injury.
1. Fit a new wheel valve assembly.

2. Fit the new tyre with a tyre changer and charge the
tyre until the rim is in place. Ensure that the locating
ring at the outside of the tyre bead is around the wheel
rim flanges. This method can ensure the tyre bead is
properly fitted.
3. Use a tire dynamic balancer to measure the wheel
dynamic balance, match it and fit new wheel balance
weights.
4. Fit the wheel and tighten the wheel bolts until the
wheel is firmly secured on the hub.
6. Tighten 5 wheel bolts to 120–130Nm. For tightening
order, please see the figure below (1 to 5).
1.0 792
Brake Brake System
Brake
Specifications
Torque
Description Value
Bolt-Front brake caliper shuck assembly to bracket 25–30Nm
Screw-Front brake pan to bearing 7–10Nm
Bolt-Front brake caliper assembly to front knuckle 190–210Nm
Bolt-Front Brake hose to front brake caliper 28–32Nm
Bolt-Rear brake caliper shuck assembly to bracket 30–33Nm
Screw-Rear brake pan to bearing 7-10Nm
Bolt-Rear brake caliper assembly to rear knuckle 55 Nm+30°
Bolt-Rear Brake hose to rear brake caliper 28–32Nm
Bolt-Clutch pedal to bracket 19–25Nm
Bolt-Brake pedal to bracket 19–25Nm
Nut -Brake pedal to bracket 19–25Nm
Bolt-Brake lamp switch to bracket 7–10Nm
Screw- Front bleeding screw 16-18Nm
Screw- Rear bleeding screw 9-13Nm
Bolt-Fluid reservoir to master cylinder 2.5-4.5Nm
Nut - master cylinder to servo 19–25Nm
Brake pipe 15-19Nm
Brake pipe connector 15-19Nm
Brake pipe to brake pipe 13–15Nm
1.0 793
Brake System Brake
Parameters
Model
Diameter of Brake Disc
Front 312mm
Rear 282mm
Minimum Thickness of Front Brake Disc
New (Nominal Value) 25mm
Service Limit 23mm
Minimum Thickness of Rear Brake Disc
New (Nominal Value) 12mm

Service Limit 10mm
Maximum Runout of Brake Disc (Equipped with Wheel) 0.025mm
Minimum Thickness of Front Brake Pad
New (Nominal Value) 13.5mm
Wear Limit 2mm
Minimum Thickness of Rear Brake Pad
New (Nominal Value) 10.5mm
Wear Limit 2mm
1.0 794
Brake Brake System
System Layout
Brake Hydraulic System Layout
1. Front Brake Caliper Assembly 7. Rear Brake Caliper Assembly

2. Front Brake Vent Disc 8. Rear Brake Disc backplate
3. Brake Modulator 9. Rear Brake Hose
4. Vacuum Booster 10. Rear Brake Disc
5. Brake Master Cylinder 11. Front Brake Disc backplate
6. Brake Fluid Reservoir
1.0 795
Brake System Brake
Description the vacuum booster in the diagonal way. The brake system
General also contains the antilock brake system (ABS) and electronic
brake force distribution (EBD).
The brake system consists of the front/rear disc brakes which
are controlled by the dual-circuit hydraulic brake system with
Hydraulic System Schematics
1. Brake Master Cylinder/Vacuum Booster Assembly 5. Front Brake

2. Brake Pedal 6. Secondary Hydraulic Circuit
3. Brake modulator 7. Primary Hydraulic Circuit
4. Rear Brake
Under normal operating conditions, the displacement of the in the brake modulator. The ECU also controls the alarm
brake pedal is boosted and delivered by the vacuum booster device on the IPK, which provides the status information of
assembly to the brake master cylinder assembly. The brake each function for the driver.
master cylinder assembly converts the movement of the brake Brake Pedal and Brake Lamp Switch
pedal into hydraulic pressure. The primary and secondary
The brake pedal is fitted on the shaft of the brake pedal
hydraulic circuit pipes deliver the hydraulic pressure to the
mounting bracket located on the dash panel, and the brake
brake through the brake modulator. The primary circuit
booster input rod is connected to the brake pedal with rod
supplies pressure to the left front and right rear brakes, and
pin and U-clip. It is located at the end of the brake pedal,
the secondary circuit supplies pressure to the right front and
which is used to control the Hall-Effect brake lamp switch on
left rear brakes. The vacuum of the vacuum booster assembly
the brake pedal mounting bracket. The brake lamp switch
is obtained through a vacuum pipeline and check valve from
provides two brake pedal status outputs: one is connected to
the engine intake manifold.
the BCM, the other is connected to the ECM.
For the functions of the ABS and EBD, the brake modulator
The brake lamp switch contains an inner sensor located in the
adjusts the hydraulic pressure of the brake and controls the
external mounting slide valve. To ensure the correct fitting
speed of one wheel or that of the two wheels on the same
orientation of the inner sensor, the inner sensor is fitted in the
axle. These functions are controlled by the ECU integrated
1.0 796
Brake Brake System
mounting slide valve in a key connection mode, the mounting vacuum booster assembly failure, the hydraulic system still has
slide valve is also fitted to the brake pedal mounting bracket in the brake function, but greater pedal braking force is required
a key connection mode, and the mounting slide valve and the due to lack of vacuum booster.
sensor make the inner sensor maintain its correct position in
The vacuum booster assembly is connected to the dash panel
the slide valve with mutually matched saw teeth. When brake
with 4 studs. The brake master cylinder assembly is connected
is released, the end on the brake pedal is against the tail end of
to two fixing bolts at the front end of the vacuum booster
the sensor, when the brake pedal is depressed, the end of the
assembly. The vacuum booster assembly consists of a round
pedal is far away from the sensor and causes a change in the
casing with double diaphragms, a center plate, a control valve
sensor output voltage.
assembly, an input push rod, an output push rod and a filter.
Brake Lamp Signal Sensor The input push rod is connected to the brake pedal, and the
The brake lamp signal sensor is a hall effect sensor which output push rod is located in the main piston of the brake
works with the permanent magnet ring on the brake master master cylinder. A rubber protective sleeve is fitted to the
cylinder piston. The outside housing of the brake master control valve assembly at the point where the control valve
cylinder where the sensor locates is driven by the magnet protrudes from the rear housing. There is a hole in the front
ring. The working mechanism of the sensor is to change the housing connected to the vacuum tube from the engine, and
hall voltage based on the change of the distance between the a check valve is fitted on the vacuum tube. The control valve
permanent magnet ring and the sensor hall element. When assembly consists of a valve body with a vacuum valve, a piston,
pressing the brake, the piston motion drives the magnet ring a vacuum valve spring and an input push rod spring. The
to move through the brake lamp signal sensor, this generate vacuum valve body is provided with a vacuum hole. The piston
the magnetic flux required for signal switch. When releasing controls the air inlet hole between the vacuum valve and the
the brake, the return force from the spring drives the piston piston. The reaction disc and the proportional disc separate
with the permanent magnet ring to its original position. the piston from the output push rod. A guide tube is fitted
on the front diaphragm in the front of the valve body, which is
Brake Pedal Position Sensor
supported in the bushing on the center plate. The nozzle end
The brake pedal position sensor is fitted on the brake pedal of the guide tube is provided with a return spring. The double
bracket, which is used to detect the driver's action on the brake diaphragms and the center plate divide the internal space of the
pedal. The brake pedal position sensor provides an analog round casing into 4 mutually sealed chambers. The chambers
voltage signal to the GW, which will increase when the brake in front of the diaphragm are connected together through the
pedal is depressed. fixed channel on the control valve assembly. The chambers
Vacuum Booster Assembly behind the diaphragms are connected together through the
inside of the secondary diaphragm at the fixing bolt.
The vacuum booster assembly provides boost during braking
to reduce the pedal force required for braking. In case of the
1.0 797
Brake System Brake
Brake Master Cylinder Assembly
1. Secondary Pressure Chamber 8. Primary Piston

2. Secondary Piston 9. Primary Spring
3. Secondary Oil Inlet 10. Primary Pressure Chamber
4. Brake Fluid Reservoir Port 11. Secondary Centre Valve
5. Brake Master Cylinder 12. Valve Pin
6. Primary Oil Inlet 13. Secondary Spring
7. Primary Centre Valve
When the brake pedal is depressed, the brake master cylinder fluid reservoir. A permanent magnet is provided on the float
assembly produces hydraulic pressure so that the brake in the fluid reservoir, which keeps the brake fluid level switch
operates. The assembly is fitted in front of the vacuum in the OFF state when the brake fluid level is at a suitable
booster assembly, which contains a pump body with a total height. When the brake fluid level is low, the float sinks and
of two pistons in the front and rear sections. The rear piston causes the reed switch to turn ON.
produces brake pressure for the primary circuit, and the front Front Brake
piston produces brake pressure for the secondary circuit. The
The front brake consists of a single-piston sliding brake caliper
brake fluid reservoir is fitted at the top of the master cylinder.
assembly fitted to the hub, and a brake disc with ventilation
The fluid reservoir is partitioned inside to feed liquid for every
device. When the hydraulic pressure is transmitted to the
brake circuit independently, thus avoiding the condition that
brake caliper, the piston stretches outward, forcing the inner
neither the primary brake circuit nor the secondary brake
brake pad to press against the brake disc. The brake caliper
circuit can operate due to one brake fluid leakage. If one
housing under reaction slides along the guide pin to drive the
brake circuit is out of order, the remaining brake circuits can
outer brake pad to come into contact with the brake disc.
still effectively operate, but the brake pedal travel and the
braking distance of the vehicle will increase. If the brake fluid Rear Brake
level in the fluid reservoir is too low, turn on the brake fluid The brake brake consists of a single-piston sliding brake caliper
level switch, cut off the circuit between the brake modulator assembly fitted to the hub, and a brake disc with ventilation
regulator and the instrument panel so that the brake warning device. The inside of the brake disc is protected by a guard
lamp illuminates. The brake fluid level switch contains a reed plate. The EPB cable on the rear brake caliper assembly applies
switch located in the plastic sheath at the downside of the brake force to the rear wheel. When the hydraulic pressure is
1.0 798
Brake Brake System
transmitted to the brake caliper, the piston stretches outward, to drive the outer brake pad to come into contact with the
forcing the inner brake pad to press against the brake disc. The brake disc.
brake caliper housing under reaction slides along the guide pin
1.0 799
Brake System Brake
Service Procedures front brake pad.

Front Brake Pad Tip: Pedal travel may be longer than normal during first
Remove brake applications.
2. Remove wheels.
Wheel Remove
3. Remove the stop spring of the front brake pad from the
front brake caliper housing.
4. Remove the dust shield from the bolt of the front brake
caliper housing.
5. Remove 2 guide pin bolts (1) securing the brake caliper
housing assembly on the front brake caliper bracket.
6. Remove the front brake caliper housing assembly from

the front brake caliper bracket.
Caution: Do not tie or allow caliper to hang on brake
hose.
7. Remove the front brake pad from the brake caliper

bracket.
Refit
1. Remove all dirts and corrosives from the edge of the
front brake disc.
2. Clean the front brake caliper housing and front brake
caliper bracket. Check the front brake caliper and seals
for damage.
3. Fit the brake pad to the brake caliper bracket.
4. Secure the front brake caliper housing assembly on the
front brake caliper bracket, fit 2 guide pin bolts, tighten
5. Fit the dust shield to the bolt of the front brake caliper
housing.
6. Secure the stop spring of the front brake pad.
7. Fit the wheels.
Wheel Refit
9. Press the brake pedal for several times so as to fit the
1.0 800
Brake Brake System
Front Brake Disc 6. Fit the wheels.
Remove Wheel Refit
2. Remove wheels.
Wheel Remove
3. Remove 2 bolts (2) fixing front brake caliper assembly
to the steering knuckle.
4. Lift the brake caliper assembly and secure it on the

frame.
5. Remove the countersunk screws securing the front
brake disc and the front wheel drive flange.
6. Remove the front brake disc assembly.

Refit
1. Ensure the cleanness of the mating surface between the
front brake disc and the front wheel drive flange.
2. Fit the front brake disc to the front wheel drive flange,
fit the countersunk head screw, tighten 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, replace it if necessary.
5. Fit the brake caliper assembly to the steering knuckle, fit
2 bolts, tighten to 190–210Nm and check the torque.
1.0 801
Brake System Brake
Front Brake Caliper Housing Assembly caliper bracket and align them. Fit 2 bolts, tighten to
Remove 25–30Nm and check the torque.
1. Raise the vehicle on a lift. 3. Fit the dust shield to the bolt of the front brake caliper
2. Remove wheels. housing.
Wheel Remove 4. Fit the stop spring clip of the front brake caliper into
the front brake caliper housing.
3. Place a suitable container under the vehicle to collect
the spilled fluid. 5. Connect the front brake hose to the front brake caliper
housing, tighten the connector to 28–32Nm and check
4. Remove 1 bolt and washer (1) fixing the brake hose to
the torque.
the front brake caliper housing, and disconnect hose.
6. Bleed the brake system.
Caution: Before disconnecting or removing components,
ensure the immediate area around joint faces and Brake System Bleeding
connections are clean. Plug open connections to prevent 7. Fit the wheels.
contamination.
Wheel Refit
5. Remove the front brake caliper stop spring from the

front brake caliper housing.
6. Remove 2 dust shields from the bolt of the front brake
caliper housing.
7. Remove 2 bolts (1) securing the front brake caliper
housing on the front brake caliper bracket.
8. Remove the brake caliper housing assembly.

Refit
1. Remove all dirts and corrosives from the edge of the
front brake disc.
2. Fix the front brake caliper housing to the front brake
1.0 802
Brake Brake System
Rear Brake Pad 4. With the TCH00015 and TCH00105, press the rear
Remove brake caliper piston into the rear brake caliper housing,
1. Release the parking brake cable. rotate the piston of the left assembly clockwise and
that of the right assembly counterclockwise.
Parking Brake Cable Full Release
3. Remove wheels.
Wheel Remove
4. Release the clip to remove the EPB cable.
5. Fit the brake pad spring to the brake pad, use the
direction shown by the figure below.
5. Remove 2 bolts securing the rear brake caliper housing

assembly on the rear brake caliper bracket.
6. Fit the brake pad to the rear brake housing assembly.

7. Align the rear brake caliper housing with the rear brake
caliper bracket, fit 2 bolts, tighten to 30–33Nm and
check the torque.
6. Fix the rear brake caliper housing assembly to the 8. Fit the stop spring clip rear brake caliper into the rear
vehicle frame and avoid damaging the hose and other brake caliper housing.
components. 9. Fit the EPB cable to the rear brake caliper bracket and
Caution: Do not tie or allow caliper to hang on brake secure with clips.
hose. 10. Fit the wheels.
7. Remove the rear brake pad from the rear brake caliper Wheel Refit
housing. 11. Lower the vehicle.
Refit 12. Press the brake pedal for several times so as to fit the
1. Remove all dirts and corrosives from the edge of the front brake pad.
rear brake disc. Tip: Pedal travel may be longer than normal during first
2. Clean the rear brake caliper housing and rear brake brake applications.
caliper bracket with brake cleaner. 13. Adjust the parking brake cable.
3. Check the rear brake caliper and rear brake caliper
Parking Brake Cable Adjustment
piston seal rings for any damage.
1.0 803
Brake System Brake
Rear Brake Disc brake caliper piston into the rear brake caliper housing,
Remove rotate the piston of the left assembly clockwise and
1. Release the parking brake cable. that of the right assembly counterclockwise.

3. Remove wheels.
Wheel Remove
4. Remove and discard 2 bolts fixing the rear brake caliper
assembly to the rear wheel bracket.
5. Check the mounting surface and hole of the wheel

bracket and rear brake caliper assembly, remove the
foreign material or oil stain and ensure the mounting
surface and hole are clean.
6. Fix the rear brake caliper assembly to the rear wheel
bracket, fit 2 new bolts and tighten to 55 Nm+30°.
Caution: The bolt can only be used once, and it should be

5. Secure the rear brake caliper assembly on the frame. replaced by a new one after the bolt is screwed (not only
6. Remove the countersunk head screws fixing the rear screw down but also screw off).
brake disc to the wheel hub. 7. Fit the wheels.
Wheel Refit
7. Remove the rear brake disc from the vehicle.

Refit
1. Keep the mating face between the rear brake disc and
the wheel hub clean.
2. Fix the rear brake disc to the wheel hub, fit 1
countersunk head screw, tighten to 7-10Nm and check
the torque.
3. Check the runout of rear brake disc.
Thickness and Circular Runout Check - Rear
Brake Disc
4. With the TCH00015 and TCH00105, press the rear
1.0 804
Brake Brake System
Rear Brake Caliper Housing Assembly
Remove
1. Release the parking brake cable.

3. Remove wheels.
Wheel Remove
4. Release the clip to remove the EPB cable.
7. Remove the rear brake caliper housing assembly from

the vehicle.
Refit
1. Clean the brake components.
Warning: Do not use compressed air to clean brake

components. Dust from friction materials can be harmful
if inhaled.
2. Align the rear brake caliper housing with the rear brake
caliper bracket, fit 2 bolts, tighten to 30–33Nm and
5. Remove and discard the bolt and washer (1) securing check the torque.
the brake hose and brake caliper. 3. Fix the rear brake hose to the brake caliper, fit 1 bolt
Caution: Before disconnecting or removing components, and washers and tighten to 28–32Nm.
ensure the immediate area around joint faces and 4. Fix the EPB cable to the rear brake caliper bracket and
connections are clean. Plug open connections to prevent secure with clips.
contamination. 5. Bleed the brake system.
Brake System Bleeding

6. Fit the wheels.
Wheel Refit
6. Remove 2 bolts securing the rear brake caliper housing

assembly on the rear brake caliper bracket.
1.0 805
Brake System Brake
Thickness and Circular Runout Check - Rear b. Remove the countersunk head screws fixing the rear
Brake Disc brake disc to the rear wheel hub and take down the
Check rear brake disc.
1. Raise the vehicle on the lift. c. Ensure cleanness of the mating face between the rear
Warning: Do not work on or under a vehicle supported brake disc and the rear wheel hub flange.
only by a jack.Always support the vehicle on safety stands. d. Fit the rear brake disc into the rear wheel hub, fit the
2. Remove wheels. countersunk head screw and tighten to 7-10Nm.
Wheel Remove e. Fit the wheels.
3. Remove 2 bolts fixing the rear brake caliper assembly f. Recheck the runout of the rear brake disc according
to the rear steering knuckle, remove the rear brake to the above detailed procedures.
caliper assembly and put it aside.
g. If the runout still exceeds the limit, replace the rear
Caution: Don’t tie brake caliper on brake hose. brake disc or rear wheel hub.
4. Measure the thickness of the rear brake disc along 10. Remove wheels.
the four average points at the surface of the rear
brake disc with differential gauge/micrometer, and the Wheel Remove
measurement points are inward, 10mm away from the 11. Remove the DTI and TCH00022 from the inside of
margin of the rear brake disc. The thickness of the rear the rear wheel hub.
brake disc shall be at least 10.0mm. If it exceeds the 12. Fit the rear brake caliper assembly into the trailing
limit, the rear brake disc must be replaced. arm, fit the bolt, tighten to 55 Nm+30° and check
Caution: Brake discs must be renewed in pairs, unless one the torque.
disc requires renewal before 1000 miles (1500 km) from 13. Fit the wheels.
new. Wheel Refit
14. Depress the brake pedal for several times so as to
adjust the rear brake pad.
5. Fit the dial indicator (DTI) to the TCH00022, and fix

the TCH00022 to the inside of the rear wheel hub
through the bolt hole of the rear brake caliper assembly.
6. Fix the probe of the DTI to the location inward, 10mm
away from the margin of the rear brake disc.
7. Fit the wheels.
Wheel Refit
8. Reset the DTI, turn the wheel for a full circle and
measure the runout of the rear brake disc. The runout
of the rear brake disc shall not exceed 0.025mm.
9. If the runout of the rear brake disc exceeds limits:
a. Remove wheels.
1.0 806
Brake Brake System
Thickness and Circular Runout Check - Front c. Ensure the cleanness of the mating surface between
Brake Disc the front brake disc and the front wheel hub flange.
Check
d. Fit the front brake disc to the front wheel hub, fit the
1. Raise the vehicle on a lift. countersunk head screw, tighten to 7–10Nm and
Warning: Do not work on or under a vehicle supported check the torque.
e. Fit the wheels.
2. Remove wheels.
f. Recheck the runout of the brake disc according to
Wheel Remove the above procedures.
3. Remove 2 bolts fixing the front brake caliper assembly
g. If the runout still exceeds the limit, replace the front
to the front wheel hub, remove the front brake caliper
brake disc or front wheel hub.
assembly and secure it on the frame.
4. Measure the thickness of the front brake disc along 10. Remove wheels.
the four average points at the surface of the front Wheel Remove
brake disc with differential gauge/micrometer, and the 11. Remove the DTI and special tool from the inside of
measurement points are inward, 10mm away from the the front wheel hub.
margin of the front brake disc. The thickness of the
12. Fit the brake caliper assembly to the front steering
front brake disc shall be at least 23.0mm. If it exceeds
knuckle, fit 2 bolts, tighten to 190–210Nm and check
the limit, the front brake disc must be replaced.
the torque.
Caution: Brake discs must be renewed in pairs, unless one
13. Fit the wheels.
disc requires renewal before 1000 miles (1500 km) from
new. 14. Depress the brake pedal for several times to adjust the
front brake pad.
5. Fit the dial indicator (DTI) to the special tool, and fix it
to the inside of the front wheel hub through the bolt
hole of the front brake caliper assembly.
6. Fix the probe of the DTI to the location inward, 5mm
away from the edge of the front brake disc.
7. Fit the wheels.
Wheel Refit
8. Reset the DTI, allow the wheel to turn for a full circle
and measure the brake disc runout. The runout of the
front brake disc shall not exceed 0.025mm.
9. If the brake disc runout exceeds the limit:
a. Remove wheels.
b. Remove the countersunk head screws fixing the front
brake disc to the front wheel hub and remove the
front brake disc.
1.0 807
Brake System Brake
Pedal Assembly-MT
Remove
2. Remove the driver side lower cover plate assembly.
3. Disconnect the accelerator pedal assembly connector
(1).
4. Remove 3 nuts (2) fixing the accelerator pedal assembly
to the dash panel.
9. Remove the brake pedal assembly from the vehicle.

10. Remove the clutch master cylinder and clutch pedal
from the vehicle.
Clutch Master Cylinder Remove
5. Remove the accelerator pedal assembly from the

vehicle.
6. Remove the clips and rod pins fixing the vacuum
booster to the brake pedal.
11. Disconnect the clutch pedal from the master cylinder,

and remove the clutch pedal assembly.
7. Remove 4 nuts (1) fixing the brake pedal to the body

dash panel.
8. Remove 1 bolt (2) fixing the brake pedal to the body
dash panel.
Refit
1. Connect the clutch master cylinder and clutch pedal
assembly.
2. Fit the clutch master cylinder and clutch pedal assembly
to the vehicles, fit 3 bolts and tighten to 19–25Nm.
Clutch Master Cylinder Refit
1.0 808
Brake Brake System
3. Fit the brake pedal to the vehicle. Pedal Assembly - AT
4. Fix the brake pedal assembly to the dash panel of the Remove
body, then fit 1 bolt and tighten to 19–25Nm. 1. Disconnect the battery negative.
5. Fix the brake pedal assembly to the dash panel of the 2. Remove the driver side lower cover plate assembly.
body, then fit 4 nuts and tighten them to 19–25Nm.
6. Fix the vacuum booster to the brake pedal, fit the rod
3. Remove the brake pedal position sensor.
pin and tighten it with clips.
7. Fit the accelerator pedal to the vehicle. Brake Pedal Position Sensor Remove
8. Fix the accelerator pedal assembly to the dash panel, 4. Disconnect the accelerator pedal assembly connector
then fit 3 nuts and tighten them to 19–25Nm. (1).
9. Connect the accelerator pedal assembly connector. 5. Remove 3 nuts (2) fixing the accelerator pedal assembly
to the dash panel.
10. Fit the driver side lower cover plate assembly.
6. Remove the accelerator pedal assembly from the
Driver Side Lower Trim Panel Assembly Refit vehicle.
11. Connect the battery negative. 7. Remove the clips and rod pins fixing the vacuum
booster to the brake pedal.
8. Remove 4 nuts (1) fixing the brake pedal to the body
dash panel.
9. Remove 1 bolt (2) fixing the brake pedal to the body
dash panel.
10. Remove the brake pedal assembly from the vehicle.
Refit
1. Fit the brake pedal to the vehicle.
2. Fix the brake pedal assembly to the dash panel of the
body, then fit 1 bolt and tighten to 19–25Nm.
3. Fix the brake pedal assembly to the dash panel of the
body, then fit 4 nuts and tighten them to 19–25Nm.
4. Fix the vacuum booster to the brake pedal, fit the rod
pin and tighten it with clips.
5. Fit the accelerator pedal to the vehicle.
6. Fix the accelerator pedal assembly to the dash panel,
then fit 3 nuts and tighten them to 19–25Nm.
7. Connect the accelerator pedal assembly connector.
8. Fit the brake pedal position sensor.
Brake Pedal Position Sensor Refit

1.0 809
Brake System Brake
Brake Pedal Position Sensor Vacuum Booster Assembly

Remove Remove
2. Remove the driver side lower cover plate assembly. 2. Remove the battery box bracket.
Driver Side Lower Cover Panel Assembly Remove Battery Box Bracket Remove
3. Disconnect the connector (2) of brake pedal position 3. Remove the brake master cylinder and fluid reservoir
sensor. assembly.
4. Remove 1 bolt (1) securing the brake pedal position Brake Master Cylinder and Fluid Reservoir
sensor to the pedal bracket. Assembly Remove
4. Disconnect the vacuum sensor connector (1) of the
vacuum pump.
5. Disconnect the vacuum tube (2) 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.
5. Remove the brake pedal position sensor from the body.

Refit
1. Refit the brake pedal position sensor to the vehicle.
2. Fix the brake pedal position sensor to the pedal bracket,
3. Connect the connector of brake pedal position sensor.

5. Connect the battery negative. 6. Remove the driver side lower cover plate assembly.
6. Perform the zero position learning for the brake pedal Driver Side Lower Cover Panel Assembly Remove
position sensor. 7. Remove the clips and pin rods fixing the vacuum
Self-learning and Adjustment, Programming booster to the brake pedal.
and Encoding - Brake Pedal Position Sensor Zero 8. Remove 4 nuts (1) fixing the vacuum booster to the
Position Learning lower dash panel.
9. Remove the vacuum booster assembly from vehicle.
Refit
1. Fix the vacuum booster to the lower dash panel, fit 4
nuts and tighten them to 19–25Nm.
2. Locate the push rod of vacuum booster to the brake
pedal, and secure it with the rod pin and clip.
4. Connect the vacuum hose to the vacuum booster.
Caution: Keep the dust and foreign matter from vacuum
hose.If having trouble to fix vacuum hose ， please using
1.0 810
Brake Brake System
grease special for fixing vacuum hose to lubricate ， other Brake Lamp Signal Sensor
liquid or grease is prohibited. Remove
5. Connect the vacuum sensor connector of the vacuum 1. Disconnect battery earth lead.
booster. 2. Disconnect the connector (2) of the brake signal sensor.
6. Fit the brake master cylinder and fluid reservoir
assembly.
Brake Master Cylinder and Reservoir Assembly

Refit
7. Drain the brake system.
Brake System Drain


3. Remove the clips and bolts fixing the brake lamp signal
sensor to the brake master cylinder, and remove the
lock catches.
Refit
1. Fix the Brake Lamp Signal Sensor to the brake master
cylinder with clips, fit bolts and tighten them.
2. Connect the connector of the brake signal sensor.
3. Connect battery earth lead.
1.0 811
Brake System Brake

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.

3. Remove the bleed screw dust cover at the right rear
brake caliper, and fit the hose into the bleed screw.
Immerse the free end of the hose into the container
with fresh brake fluid.

10. Refill the brake fluid reservoir to the MAX line.
11. Apply the brake and check for leakage.
12. Test the vehicle on the road. Check the minimum
stroke of the brake pedal when the brake is functioning.
VDS Bleeding
1. Place the ignition switch in "RUN" position (2).
2. Connect the brake fluid filling/bleeding machine to the
brake fluid reservoir and adjust the refill pressure to
2Bar.
3. Connect diagnostic tool and access the VDS.
4. Depress the brake pedal for several times and apply 4. Select "Routines - Other - ABS/SCS Brake Bleeding",
stable pressure. and operate as per the instructions on the screen.
5. Release the bleed screw to separate the brake fluid and 5. If the operation fails, please operate as per the
air. Allow the pedal to return without any external instructions on the screen.
force.
6. Press the brake pedal to the maximum stroke steadily,
and allow it to return without any external force.
Repeat the operation for several times until the brake
fluid without any air flows into the container, then fix
the brake pedal to the maximum stroke, tighten the
front bleed screw to 16-18Nm and the rear bleed
screw to 9-13Nm, then check the torque.
7. Remove the hose from the bleed screw, fit the bleed
screw dust cover.
8. Repeat the draining procedures for the remaining 3
brake calipers in the following order: left rear, left
front, right front.
1.0 812
Brake Brake System
Brake Master Cylinder and Reservoir Assembly
Remove
3. Put the cloth under the brake master cylinder and fluid
reservoir assembly to absorb the spilled fluid.
Caution: Brake fluid will damage paint finished surfaces.

If spilled, immediately remove fluid and clean area with
water.
4. Disconnect the connector from the brake fluid level

switch. 8. Remove the brake master cylinder and fluid reservoir
assembly.
9. Remove 1 bolt fixing brake fluid reservoir to the master
cylinder, and remove the reservoir.
Refit
1. Fix the brake fluid reservoir to the master cylinder, fit 1
bolt, tighten to 2.5-4.5Nm and check the torque.
2. Fit the brake master cylinder and reservoir assembly
to the vehicle.
3. Clean the brake hard pipe connector.
4. Fix the brake master cylinder to the vacuum booster,
fit 2 new nuts and gaskets, tighten to 19–25Nm and
check the torque.
5. Release 2 hard brake pipes from the brake master 5. Fit 2 brake hard pipes to the brake master cylinder,
cylinder. tighten the connector nut to 15-19Nm and check the
Caution: Before disconnecting or removing components, torque.
ensure the immediate area around joint faces and 6. Connect the signal sensor connector of the brake lamp
connections are clean. Plug open connections to prevent (if any).
contamination. 7. Connect the connector of the brake fluid level switch.
9. Drain the brake system.
Brake System Drain

6. Disconnect the connector (2) from the brake lamp

signal sensor (if any).
7. Remove 2 nuts and gasket (1) securing the master
cylinder on the vacuum booster and discard them.
1.0 813
Brake System Brake
Front Brake Hose

Remove
2. Remove wheels.
Wheel Remove
3. Remove 1 bolt and washer fixing the brake hose to
the front brake caliper housing, and discard the bolt
and washer.

ensure the immediate area around joint faces and
connections are clean. Plug open connections to prevent
contamination.
7. Remove the front brake hose from the vehicle.
Refit
1. Clean the connector of the brake pipe.
2. Fit the front brake hose to the vehicle.
3. Fix the front brake hose and its bracket to the front
shock absorber, fit 1 bolt and tighten it.
4. Connect the front brake hose to the brake pipe, secure
with nuts and tighten the nut to 15-19Nm.
5. Fix the front brake hose to the body and secure with
clips.
6. Fix the front brake hose to the front brake caliper
housing, fit new bolts and washers and then tighten the
4. Remove the clip (1) fixing the front brake hose to the bolt to 28–32Nm.
body. 7. Bleed the brake system.
5. Remove the nut (2) connecting the brake hose and Brake System Bleeding
brake pipe.
8. Fit the wheels.
Wheel Refit
contamination.
6. Remove 1 bolt fixing the front brake hose and its

bracket to the front shock absorber.
1.0 814
Brake Brake System
Rear Brake Hose 8. Lower the vehicle.
Remove
2. Remove wheels.
Wheel Remove
3. Remove 1 bolt and washer (1) fixing the rear brake
hose to the rear brake caliper housing, and discard the
bolt and washer.
contamination.
4. Remove the clip (2) fixing the rear brake hose to the
body.
5. Remove the nut (3) connecting the rear brake hose and
brake pipe, and disconnect them.
contamination.
6. Remove the rear brake hose from the vehicle.

Refit
1. Clean the brake components.
2. Fit the rear brake hose to the vehicle.
3. Connect the rear brake hose to the brake pipe, secure
with nuts and tighten the nut to 15-19Nm.
4. Fix the rear brake hose to the body and secure with
clips.
5. Fix the rear brake hose to the rear brake caliper
housing, fit new bolts and washers and then tighten the
bolt to 28–32Nm.
7. Fit the wheels.
Wheel Refit
1.0 815
Brake System Brake
Left Front Brake Pipe and tighten the nuts to 15-19Nm.

Remove 5. Bleed the brake system.
Brake System Bledding
2. Remove wheels.
6. Fit the wheels.
Wheel Remove
Wheel Refit
3. Put a cloth under the brake modulator to absorb the
spilled oil.
4. Remove the nut (2) fixing the left front brake pipe to
the brake modulator, and disconnect the pipe.
5. Remove the nut connecting the brake hose and brake

pipe.
contamination.
6. Remove the clip fixing the front brake hose to the body.
7. Remove the left front brake pipe from the vehicle.

Refit
1. Fit the left front brake pipe to the body pipe clip.
2. Connect the left front brake hose to the brake pipe,
secure with nuts and tighten the nut to 15-19Nm.
3. Fix the left front brake hose to the body and secure
with clips.
4. Fix the left front brake pipe to the brake modulator,
1.0 816
Brake Brake System
Right Front Brake Pipe
Remove
2. Remove wheels.
Wheel Remove
spilled oil.
4. Remove the nut (3) fixing the right front hard brake
pipe to the brake modulator, and disconnect the pipe.
7. Remove the right front brake pipe from the body.

Refit
1. Fit the right front brake pipe to the body pipe clip.
2. Connect the right front brake hose to the brake pipe,
secure with nuts and tighten the nut to 15-19Nm.
3. Fix the right front brake hose to the body and secure
with clips.
4. Fix the right front brake pipe to the brake modulator,
and tighten the nuts to 15-19Nm.
5. Remove the nut (2) connecting the right front brake
hose and brake pipe. Brake System Bleeding
Caution: Before disconnecting or removing components, 6. Fit the wheels.
ensure the immediate area around joint faces and Wheel Refit
contamination.
6. Remove the clip fixing the right front brake hose to

the body.
1.0 817
Brake System Brake
Brake Master Cylinder Pipe Connecting Pipe from Brake Modulator to Rear
Remove Brake Pipe
1. Put a cloth under the brake modulator and master
Remove
cylinder to absorb the spilled oil. 1. Raise the vehicle on a lift.
2. Disconnect 2 oil inlet brake pipes (1) from the brake 2. Put a cloth under the brake modulator to absorb the
modulator. spilled oil.
3. Disconnect 2 oil outlet brake pipes (2) from the master 3. Remove the 2 nuts (1) and (4) fixing the pipe connecting
cylinder. the brake modulator with the rear brake pipe to the
brake modulator.
4. Disconnect the brake pipe, plug the opening of the
brake caliper and the brake pipe to avoid brake fluid
loss and contamination.
contamination.
Refit
1. Fix the brake pipe to the brake master cylinder, and
tighten the nuts to 15-19Nm.
2. Fix the brake pipe to the brake modulator, and tighten
the nuts to 15-19Nm.

5. Remove the pipe connecting the brake modulator to
the rear brake pipe and the nut of the rear brake pipe.
6. Disconnect the brake pipe, plug the opening of the

brake caliper and the brake hose to avoid brake fluid
loss and contamination.
contamination.
1.0 818
Brake Brake System
7. Remove the pipe connecting the brake modulator and Rear Brake Pipe
the rear brake pipe from the vehicle. Remove
Refit 1. Raise the vehicle on a lift.
1. Clean the connector of the brake pipe. 2. Remove wheels.
2. Remove the pipe connecting the brake modulator to Wheel Remove
the rear brake pipe, and fit it to the vehicle.
3. Remove the pipe connecting the brake modulator to
3. Connect the pipe connecting the brake modulator to the rear brake pipe and the nut of the rear brake pipe.
the rear brake pipe, and tighten the nuts to 15-19Nm.
4. Fix the pipe connecting the brake modulator with the
rear brake pipe to the brake modulator, and tighten the
nuts to 15-19Nm.

4. Disconnect the brake hose, plug the opening of the

brake hose to avoid brake fluid loss and contamination.
contamination.
5. Disconnect the connector of the fuel filter inlet/outlet

pipe from the fuel filter.
contamination.

6. Disconnect the oil return pipe.

7. Remove the rear subframe assembly.
Rear Subframe Assembly Remove
1.0 819
Brake System Brake
8. Remove the nut (3) connecting the left rear brake hose the fuel filter.
with the brake pipe, and disconnect them. 8. Connect the pipe connecting the brake modulator
Caution: Before disconnecting or removing components, to the rear brake pipe, fit the nut and tighten to
ensure the immediate area around joint faces and 13–15Nm.
connections are clean. Plug open connections to prevent 9. Fit the wheels.
contamination.
Wheel Refit
9. Remove the nut connecting the right rear brake hose

with the brake pipe, and disconnect them.
contamination.
10. Remove the rear brake pipe from the body pipe clip.
Refit
1. Clean the connector of the brake pipe.
2. Fix the rear brake pipe to the body pipe clip.
3. Connect the right rear brake hose with the brake pipe,
fit the nut and tighten to 15-19Nm.
4. Connect the left rear brake hose with the brake pipe,
fit the nut and tighten to 15-19Nm.
5. Fit the rear subframe assembly.
Rear Subframe Assembly Refit
6. Connect the oil return pipe.
7. Connect the connector of the oil inlet/return pipes to
1.0 820
Brake Brake System
Special Tools
Number
Replacement
TCH00015 brake rear
caliper piston
Adapter -
replacement
TCH00105
brake rear
caliper piston
Brake disc
TCH00022
runout test kit
1.0 821
Brake System Park Brake
Park Brake
Specifications
Torque
Description Value
Bolt-Electric brake control module to bracket 7–10 Nm
1.0 822
Park Brake Brake System
System Layout
Parking Brake
1. EPB Module 3. EPB Switch

2. Parking Brake Cable Assembly
1.0 823

EPB Control Diagram
A = Chassis HS CAN Bus; B = Body HS CAN Bus; C = Power HS CAN Bus; D = Hard Wire
1.0 824
Description • Release the EPB switch or depress the accelerator pedal
Electronic Parking Brake (EPB) to cancel the brake process.
Description of Electronic Parking Brake (EPB) • During dynamic deceleration of the EPB, the EPB can
prevent the rear wheel from being locked by the clamp
The EPB is comprised of the EPB switch, EPB module and 1
force of the EPB actuator.
EPB motor. The EPB switch on the center console facilitates
EPB moduleEPB Harness Connector BY036
the driver's operation. Under the condition of power
shortage, the electronic parking brake can not be engaged or
released. The EPB module is on the right rear body, which is
connected with the body harness by a harness connector. The
EPB motor is integrated in the EPB module, fit the EPB cable
to the rear wheel and apply brake force on the rear wheel.
Connect the EPB.
When the vehicle is static or the ignition switch is off, the

electronic parking brake can be applied at any time. When
leaving the vehicle or parking, the parking brake must be
applied.
• Pull the EPB switch (button) up until the indicator lamp

on the EPB switch comes on.
• If the indicator lamp on the EPB switch and the IPK Pin No. Description
illuminates, the EPB is activated. A1 —
• If the indicator lamp on the IPK illuminates, the EPB
P
A2 Chassis HS CAN Low
fails, please contact the local after-sales service center
A3 Chassis HS CAN High
immediately.
A4 —
Disable the EPB manually
B1 —
• Connect the ignition switch
B2 —
• Press the EPB switch, depress the brake pedal or
B3 —
slightly depress the accelerator pedal when the engine is
working. B4 —
• If the indicator lamp on the switch/IPK goes out, the C1 —

EPB is disabled. C2 Analogue Brake
Aux Start C3 Brake Signal Input
The EPB automatically judges the intention of the driver, and C4 EPB Indicator Lamp
release the parking brake automatically. For hill start, the EPB D1 —
can judge engine torque output and prevent slip. D2 Switch Ground
When you fasten the seat belt, place the ignition switch D3 Release Signal Input
in "ON" position, engage a gear and slightly depress the D4 —
accelerator pedal to start the vehicle, the electronic parking E1 —
brake will close automatically. For manual transmission, the
E2 —
clutch must be depressed completely before starting so that
the system can identify and release the parking brake. E3 —
E4 —
ECD
F1 —
During driving, when in any emergency, such as the vehicle can
F2 —
not be stopped by stepping on the pedal, decelerate by pulling
up and holding the EPB switch. F3 —
F4 —
• Pull the EPB switch up and hold to realize emergency
brake. Continuous acoustic alarm can be heard during G1 —
emergency brake. G2 Ground
1.0 825

G3 Wake-up 1 Switch Ground
G4 KL.30 2 Release Signal Input
H1 — 3 Indicator
H2 Ground 4 KL.30
H3 — 5 Ground
H4 KL.30 6 Brake Signal Input
EPB Harness Connector CE003 7 Analogue Brake

8 —
1.0 826
Service Procedures 8. Connect the battery negative.
EPB Module 9. Programme and code the EPB module.
Remove
1. Release the parking brake cable. Coding - EPB Module Replacement
Self-learning & Adjustment, Programming &
Coding - Parking Brake Cable Full Release
3. Remove wheels.
Wheel Remove
5. Remove the rear wheel house liner.
Rear Wheel House Liner Remove
6. Disconnect the connector (1) of the EPB module.
7. Disconnect the left/right parking brake cables from the
parking brake cable on the EPB module side.
8. Remove the clip (2) fixing the parking brake cable
assembly on the EPB module side to the rear axle, and
remove parking brake cable on the EPB module side.
9. Remove 3 nuts (2) securing the EPB module on the
bracket.
10. Remove the EPB module from the vehicle.

Refit
1. Secure the EPB module on the bracket, fit 3 nuts and
tighten to 7–10 Nm.
2. Fix the parking brake cable on the EPB module side to
the rear axle, and secure with clips.
3. Fix the left/right parking brake cables to the parking
brake cable on the EPB module side.
4. Connect the connector of the EPB module.
5. Fit the rear wheel house liner.
Rear Wheel House Liner Refit
7. Fit the wheels.
Wheel Refit
1.0 827
Parking Brake Cable

Remove
1. Release the parking brake cable. 。

Coding - Parking Brake Cable Full Release
2. Remove the wheel.
Wheel Remove
4. Disconnect the parking brake cable on the EPB module
side and the left/right parking brake cables (2).
7. Remove the clip (1) fixing the left parking brake cable
to the rear axle.
8. Remove the clip (3) fixing the right parking brake cable
to the rear axle.
5. Remove the clip (2) fixing the left parking brake cable
to the rear brake shoe assembly.
9. Remove the parking brake cable.

Refit
1. Fix the right parking brake cable to the rear axle and
secure with clips.
2. Fix the right parking brake cable to the rear brake shoe
assembly and secure with clips.
3. Fix the left parking brake cable to the rear axle and
secure with clips.
4. Fix the left parking brake cable to the rear brake shoe
6. Remove the clip fixing the right parking brake cable to assembly and secure with clips.
the rear brake shoe assembly. 5. Fit the left/right parking brake cables to the parking
brake cable on the EPB module side.
7. Fit the wheels.
Wheel Refit

Coding - Parking Brake Cable Adjustment
1.0 828
Brake Module Brake System
Brake Module
Specifications
Torque
Description Value
Bolt-SCS/ABS to bracket 7–10Nm
Bolt-bracket to body 19-25Nm
Brake pipe 15-19Nm
Bolt-Front wheel speed sensor to wheel carrier 7–10Nm
Screw-Front wheel speed sensor bracket to body 7-10Nm
Bolt-Rear wheel speed sensor to wheel carrier 7–10Nm
1.0 829
Brake System Brake Module

System Layout
Brake Module System Layout
1. TPMS Failure & Low Tire Pressure Warning Lamp 8. Rear Wheel Speed Sensor Assembly
2. ABS Warning Lamp 9. Front Wheel Speed Sensor Assembly
3. Brake System Malfunction Indicator Lamp 10. Brake Master Cylinder
4. SCS ON/Malfunction Indicator Lamp 11. Brake Fluid Reservoir
5. SCS OFF Indicator Lamp 12. Brake Fluid Level Indicator Switch
6. EPB Status/Self-lock Indicator Lamp 13. Vacuum Booster
7. EPB Malfunction Indicator Lamp 14. Brake Modulator
1.0 830
Brake Module Control Diagram
A = Hard Wire; B = Power HS CAN Bus; C = Body HS CAN Bus ; D = Chassis HS CAN Bus
1.0 831
Description controls the regulator action, ECU can control the HCU
Brake Modulator according to the status of various system components, and
allow it to convert under different operation conditions
The brake modulator can assist the driver to well control
(including normal braking, pressure-maintaining braking,
the driving and stability under all driving conditions and
decompression braking and boost braking).
ensure maximum vehicle safety. The brake modulator is a
maintenance free 4-channel component and consists of a Hydraulic Control Unit (HCU) Schematic
combinational hydraulic regulator (HCU) and a ECU which Diagram
Brake Hydraulic System Schematic Diagram
Here is the operation principle of the brake pressure regulation 5. Check Valve
for one of the four channels (Other channels work on the same 6. Isolating Solenoid Valve
principle).
7. System Inlet Solenoid Valve
8. Check Valve
9. Electric Pump
10. Check Valve
11. Wheel Cylinder Inlet Solenoid Valve
12. Low Pressure Accumulator
13. Check Valve
14. Wheel Cylinder Outlet Solenoid Valve
15. Brake Cylinder
Normal Braking
Under normal braking, all components of the brake pressure
regulation device are de-energized, the brake fluid flows
1. Oil Cup through the isolation valve and wheel cylinder inlet solenoid
2. Vacuum Booster valve to the wheel cylinder, and the brake pressure regulation
3. Brake Master Cylinder device will not impact the normal braking, Illustrated as the
following chart.
4. Overflow Valve
1.0 832
Boost Stage Decompression Stage

When the ABS/SCS system requires to increase the wheel When it needs to reduce the wheel cylinder brake pressure,
cylinder brake pressure, the System Inlet Solenoid Valve 7 is the system inlet solenoid valve 7 and wheel cylinder inlet
powered on, the Isolation Solenoid Valve 6 is powered off, the solenoid valve 11 will be cut off, the isolating solenoid valve 6
Electric Pump 9 begins to operate, the brake fluid flows into and the system outlet solenoid valve 14 will open, the brake
the Wheel Cylinder 15, and the brake pressure increases. See fluid flows into the low pressure accumulator 12 to relieve the
the following figure. Among them, the Overflow Valve 4 plays hydraulic impact caused by the high pressure brake fluid, the
the role of safety protection; if the brake pressure exceeds electric pump 9 begins to operate, the brake fluid in the wheel
the maximum system safety pressure limitation when boosting cylinder will return to the master cylinder, and the wheel
brake pressure, the Overflow Valve 4 will be turned on and cylinder pressure reduces, Illustrated as the following chart.
allow the brake fluid flow back to the Brake Master Cylinder
3.
The above processes continue in the operation of the

ABS/SCS system until the vehicle is regulated to the optimum
Pressure-maintaining Stage driving condition.
When it needs to maintain the wheel cylinder brake pressure,
End View of SCS modulator Connector BY003 and ABS
both the wheel cylinder inlet and outlet solenoid valves 11
modulator Connector BY023
and 14 will be cut off, the wheel cylinder disconnects with
external pipeline, and the wheel cylinder internal pressure
remains unchanged, Illustrated as the following chart.
1.0 833
Pin No. Pin Function

29 Left Rear Wheel Speed
Sensor Signal
Sensor Ground
31 Diagnosis
32 Brake Fluid Level Switch
33 Right Rear Wheel Speed
Sensor Ground
34 Right Rear Wheel Speed
Sensor Signal
35 —
Detailed Pin Information of SCS Connector 36 Left Front Wheel Speed

Sensor Signal
37 Left Front Wheel Speed
1 KL.30 Sensor Ground
2 KL.30 38 —
3 —
Detailed Pin Information of ABS Connector
4 SCS Switch
5 —
1 KL.30
6 Wake-up
2 Brake Fluid Level Switch
7 Vehicle Speed
3 Vehicle Speed
8 —
4 —
9 —
5 —
10 Power CAN Low
6 Wake-up
11 Power CAN High
7 —
12 —
8 —
13 Pump Motor Ground
9 —
14 —
10 Chassis CAN Low
15 — 11 Chassis CAN High
16 — 12 —
17 Vacuum Sensor Power Supply 13 Ground
18 Chassis CAN Low 14 —
19 Chassis CAN High
15 —
20 Hill Descent Control Switch
16 —
21 Vacuum Sensor Signal
17 —
22 —
18 —
23 Vacuum Sensor Ground
19 —
24 —
20 —
25 KL.30
21 —
26 Right Front Wheel Speed
Sensor Ground 22 —
27 Right Front Wheel Speed 23 —

Sensor Signal 24 —
28 — 25 KL.30
1.0 834
Pin No. Pin Function trailing arm, and are extremely close to the inner sealing device
26 Right Front Wheel Speed of each relevant wheel bearing. Rotating together with the
Sensor Ground wheels, the sealing device includes a magnetic element with 48
27 Right Front Wheel Speed pairs of magnetic poles, when the wheels rotate, the magnetic
Sensor Signal poles in the sealing device generates voltage fluctuation in
28 Vacuum Sensor Power Supply the ABS sensor, the voltage fluctuation is converted into
square wave signal and output to the ABS modulator. The
Sensor Signal signal frequency is proportional to wheel speed. In actual
use, each ABS sensor has a wire in the engine compartment
Sensor Ground or luggage compartment, which connects the sensor to the
vehicle harness.
31 Diagnosis
Yaw Sensor
32 Vacuum Sensor Signal
33 Right Rear Wheel Speed The yaw sensor is integrated in the SCS, which measures
Sensor Ground vehicle rotation around the vertical axis and vehicle slip and
34 Right Rear Wheel Speed transmits the corresponding data to the SCSECU, the ECU
Sensor Signal compares the signals from the yaw sensor and the steering
35 Vacuum Sensor Ground angle sensor and determines the forthcoming situation, and
then takes corresponding control. The Yaw Sensor adopts the
Sensor Signal whole micro-structure method to process two relative thick
oscillating components (quality film) from the crystal, the two
Sensor Ground components take antiphase oscillation at a resonant frequency
determined by quality and the coupling spring. Each oscillating
38 —
component has a miniaturized formal microstructure capacity
End View of SAS Connector FA028 accelerated speed sensor. When the sensor chip rotates
around its vertical axis in yaw rate Ω, the Coriolis acceleration
which is perpendicular to the oscillating direction on the
crystal surface is recorded. The accelerations are proportional
to the product by the yaw rate and the current maintained
constant oscillating speed.
Tyre Pressure Monitoring
The indirect tyre pressure monitoring system monitors the
tyre pressure by comparing the speed difference between the
tyres through the wheel speed sensor of the SCS system.
The SCS uses the wheel speed sensor to determine if the
Detailed Pin Information of SAS Connector wheel is locked and if the antilock brake is required. When
Pin No. Pin Function the tyre pressure is low, the weight of the vehicle will cause
decreased tyre diameter, and this may result in change of
1 —
the vehicle speed, which can trigger the alarm system. After
2 Ground replacing/charging the tyre, the TPMS shall be reset. After
3 Wake-up activated reset, the TPMS will undergo a self-learning, the status of the
self-learning can be viewed by the VDS.
4 —
Auto Hold
5 Chassis CAN High
When the engine is working, and where regular or long-time
6 Chassis CAN Low
stop is required (for example, waiting for traffic lights, stopping
Wheel speed sensor on a hill or driving in the stop and go traffic), the auto hold
function can help the driver to stabilize the vehicle.
The wheel speed sensors are active sensors (i.e. they receive
the power supply from the ABS modulator), and they transmit After the vehicle stops, the driver do not need to depress
the wheel speed signal to the ABS modulator. The sensors the brake pedal, the auto hold function can lock the vehicle
are mounted in each front wheel hub and each rear suspension automatically.
1.0 835
When the driver depresses the accelerator pedal to start the the button indicator lamp will turn off. In this case, the EPB
vehicle, the auto hold function releases the brake immediately may activate automatically to control the vehicle.
and the vehicle moves according the inclination of the road.
Generally, the auto hold has three statuses: OFF, STANDBY
If the working condition of the auto hold changes when the and ACTIVE.
vehicle is stationary, the auto hold will close automatically and
1.0 836
Service Procedures
Brake Modulator
Remove
1. Disconnect battery earth lead.
spilled oil.
3. Disconnect the connector from the brake modulator.
4. Disconnect 2 oil inlet brake pipes (1) from the brake
modulator.
9. Remove 2 bolts securing the brake modulator on the

mounting bracket.
5. Cover the brake pipe connector and prevent brake

fluid loss and pollution.
6. Record 4 positions of the oil outlet pipe on the brake
modulator for assembly, then disconnect the brake pipe
oil outlet pipe from the top of the brake modulator.
10. Remove the brake mounting bracket from the body.
Refit
1. Connect the connector disconnected from the brake
modulator.
2. Fit the brake modulator to the bracket.
3. Fix the brake modulator to the mounting bracket, fit 2
4. Fix the under mounting bracket of brake to the body,
fit 1 bolt, tighten to 19-25Nm and check the torque.
5. Clean the hard brake pipe connector.
6. Connect the oil inlet and outlet brake pipes to the brake
modulator, ensure that the pipelines are connected to
7. Cover the brake pipe connector and prevent brake the right port. Tighten the connector of the brake pipe
fluid loss and pollution. to 15-19Nm and check the torque.
8. Remove 1 bolt fixing the under mounting bracket of 7. Bleed the brake system.
brake to the body.
Brake System VDS Bleeding
9. Programme and code the brake modulator.

Coding - SCS Replacement
1.0 837
Front Wheel Speed Sensor

Remove
1. Disconnect battery earth lead.
Wheel Remove
3. Disconnect the connector of the front wheel speed
sensor.
4. Remove 1 bolt fixing the front wheel speed sensor

bracket to the front suspension arm.
5. Remove 1 bolt fixing the front wheel speed sensor to
the steering knuckle.
3. Fix the front wheel speed sensor to the steering

knuckle, fit 1 bolt and tighten to 7–10Nm.
4. Fix the front wheel speed sensor bracket to the front
suspension arm, fit 1 bolt and tighten to 7-10Nm.
5. Connect the connector of the front wheel speed sensor.
6. Fit the front wheel.
Wheel Refit
6. Remove the front wheel speed sensor.

Refit
1. Clean the contact surface between the wheel speed
sensor and the steering knuckle.
2. Fit the front left/right wheel speed sensor to the vehicle
according to the alignment of the harness as following.
Caution: If the trend of the harness is incorrect, it may

intervene with the drive shaft, and there is risk that the
wiring harness is worn to break.
1.0 838
Rear Wheel Speed Sensor fit 1 bolt and tighten to 7–10Nm.
Remove 5. Connect the connector of the rear wheel speed sensor.
1. Disconnect battery earth lead. 6. Lower the vehicle.
2. Raise the vehicle on a lift. 7. Connect battery earth lead.
3. Disconnect the connector (2) of the rear wheel speed
sensor.
4. Remove 1 bolt (1) fixing the rear wheel speed sensor
to the wheel bracket.
5. Remove the clip fixing the rear wheel speed sensor to

the rear suspension arm.
6. Remove the rear wheel speed sensor.
Refit
1. Clean the contact surface between the wheel speed
sensor and the steering knuckle.
2. Fit the rear wheel speed sensor to the vehicle (2WD:
the alignment of harness is shown in the following
figure).
Caution: Harness must bu located between shock

absorber and lower arm, and should not be fixed on the
other side of the lower arm, otherwise the harness will
intervene with swivel hub.
3. Fix the rear wheel speed sensor to the rear suspension

arm and secure with clips.
4. Fix the rear wheel speed sensor to the wheel bracket,
1.0 839
1.0 840
Drive Axle Driveline/Axle
Drive Axle
Specifications
Torque
Description Value
Bolt-intermediate shaft support bearing bracket to engine 42–48Nm
.Nut- front knuckle to front lower arm 95±10Nm
Nuts- anti-roll bar links to anti-roll bar 55–65Nm
Nut-front drive shaft 350–370Nm
Bolts- rear damper to rear wheel carrier 75–90Nm
Nut- rear upper arm assembly to rear wheel carrier 90Nm+90°
Bolts- rear blade arm assembly to rear wheel carrier 60±5Nm
Nut- lateral rod assembly to rear wheel carrier 130Nm+90°
Bolt-propshaft to axle 55–61Nm
Bolt-propshaft to body 55–65Nm
Bolt-propshaft to PTU 26–34Nm
1.0 841
Driveline/Axle Drive Axle

System Layout
Right Front Drive Shaft Exploded View
1. Right Alxe Shaft Assembly - Front Wheel 5. Right Outer Joint Assembly Service Kit - Front Wheel
2. Right Inner Joint Sleeve Service Kit - Front Wheel 6. Intermediate Shaft Assembly - Front Wheel
3. Right Inner Joint Assembly Service Kit - Front Wheel 7. Bolt
4. Right Outer Joint Sleeve Service Kit - Front Wheel 8. Bolt
1.0 842
Left Front Drive Shaft Exploded View
1. Left Alxe Shaft Assembly - Front Wheel 4. Left Inner Joint Sleeve Service Kit - Front Wheel
2. Left Outer Joint Assembly Service Kit - Front Wheel 5. Left Inner Joint Assembly Service Kit - Front Wheel
3. Left Outer Joint Sleeve Service Kit - Front Wheel
Rear Drive Shaft Exploded View
1. Alxe Shaft Assembly - Rear Wheel 3. Outer Joint Sleeve Service Kit - Rear Wheel
2. Outer Joint Assembly Service Kit - Rear Wheel 4. Inner Joint Sleeve Service Kit - Rear Wheel
1.0 843
5. Inner Joint Assembly Service Kit - Rear Wheel

Drive Shaft Assembly Drawing
1. Drive Shaft Assembly 4. Gasket

2. Bolt 5. Bolt
3. Bolt 6. Nut
1.0 844
Description resistance. The counter shaft and the tripod joint form an
The drive shaft is a rigid shaft with the tripod joint assembly assembly. The constant velocity joint assembly is a cage type,
and the constant velocity joint assembly, one integral shaft with which is connected to the counter shaft by splines, and is fixed
roller bearing and bearing support are fixed to the rear end of with a steel wire snap ring. The constant velocity joint is filled
the engine block, and the other is located at the left side and with lubricating grease and is protected by the rubber sleeve.
is connected with the differential. There are three pins with The drive shaft is also equipped with the shock absorption ring.
ball gaskets on the tripod joint assembly to reduce the sliding
1.0 845
Service Procedures cylinder body.

Right Front Axle Shaft Assembly
Remove
2. Remove the front splasher assembly.
Front Wheelhouse Liner - Remove
3. Pry up the nut locking device of the front drive shaft,
depress the brake pedal, remove and discard drive shaft
nut.
11. Disconnect the right front drive shaft assembly from

the differential.
Refit
1. Clean the connection of the right front axle shaft end,
wheel hub and inner differential.
2. Fit the right front axle shaft to the differential and
ensure full engagement.
3. Clean the contact surface of the axle shaft bracket and
4. Remove nuts fixing the steering gear outer rod to the cylinder block.
knuckle and discard them. Then disconnect the steering 4. Fit the bolt fixing the axle shaft bracket to the cylinder
gear outer rod from the knuckle. block and tighten to 42–48Nm.
5. Remove the nuts fixing the connecting rod of the 5. Remove the ball joint T32003 of the front lower swing
horizontal stabilizer bar to the horizontal stabilizer bar arm.
and release the connecting rod.
6. Pull the wheel hub outward, allow the right front axle
6. Remove the nut fixing the front wheel hub to the front shaft to engage the wheel hub spline, fit the wheel hub
lower swing arm. to the outer ball joint of the lower swing arm.
7. Fit the nut fixing the wheel hub to the lower swing arm,
and tighten to 95±10Nm.
8. Ensure full engagement of the ball joint pin of the lower
swing arm and wheel hub, and the bolt is in the groove
of the ball joint connector.
9. Ensure the steering tie rod ball joint and steering arm
are clean, and the rubber shield is not damaged.
10. Fit the steering tie rod to the steering arm, and tighten
the nuts to 40–50Nm.
11. Ensure the contact surface of the horizontal stabilizer
bar and horizontal stabilizer bar connecting rod is clean.
12. Locate the connecting rod of the horizontal stabilizer
7. Remove the front lower swing arm outer ball joint with bar to the horizontal stabilizer bar, fit the nuts and
T32011. tighten to 55–65Nm.
8. Be careful not to damage the outer ball joint rubber 13. Fit the new axle shaft nut and tighten to 350–370Nm.
bushing of the front lower swing arm. 14. Lock the nut to the right front axle shaft.
9. Pull the wheel hub outward and remove the right front 15. Fit the front wheel fender assembly.
drive shaft assembly from the wheel hub.
Front Wheelhouse Liner - Refit
10. Remove 3 bolts fixing the drive shaft support to the
1.0 846
16. Lower the vehicle. Right Rear Axle Shaft Assembly
Remove
1. Raise the vehicle.
2. Remove the fender board assembly of the rear wheel.
Rear Wheel House Liner - Remove
3. Pry up the nut locking device of the right rear axle
shaft, depress the brake pedal, remove and discard axle
shaft nut.
4. Remove the bolt and nut fixing the rear lateral push
rod to the wheel bracket, and release the rear lateral
push rod.
5. Remove 3 bolts fixing the rear blade trailing arm to the
wheel bracket, and release the rear blade trailing arm.
6. Remove the bolt and nut fixing the rear upper swing
arm to the wheel bracket, and release the rear upper
swing arm.
7. Remove the bolt and nut fixing the shock absorber to
the wheel bracket, and release the shock absorber.
8. Pull the wheel hub outward to remove the right rear
axle shaft assembly from the wheel hub.
9. Disconnect the right rear axle shaft assembly from the
differential with the T30001.
10. Remove the right rear axle shaft assembly.
11. Remove and discard the axle shaft circlip.
Refit
1. Fit the circlip into the axle shaft.
2. Clean the end of the axle shaft, mounting location of
the wheel hub and junction of the differential.
3. Fit the right rear axle shaft to the differential and ensure
full engagement.
4. Pull the wheel hub outwards and allow the axle shaft
to engage the wheel hub.
5. Fix the shock absorber to the wheel bracket, fit the nut
6. Fix the rear upper swing arm to the wheel bracket, fit
the nut and tighten to 90Nm+90°.
1.0 847
7. Fix the rear blade trailing arm to the wheel bracket, fit Left Front Axle Shaft Assembly
3 bolts and tighten to 60±5Nm. Remove
8. Fix the rear tie rod to the wheel bracket, fit the nut and 1. Lift the vehicle.
tighten to 130Nm+90°. 2. Remove the front wheel fender assembly.
9. Fit the new axle shaft nut and tighten to 350–370Nm.
Front Wheelhouse Liner - Remove
10. Lock the nut to the right rear axle shaft.
3. Pry up the nut locking device of the front wheel drive
11. Fit the fender board assembly of the rear wheel. shaft, depress the brake pedal, remove and discard
Rear Wheel House Liner - Refit drive shaft nut.
4. Remove nuts fixing the steering gear outer rod to the

5. Remove the nuts fixing the connecting rod of the
horizontal stabilizer bar to the horizontal stabilizer bar
and release the connecting rod.
6. Remove the nut fixing the front wheel hub to the front
lower swing arm.
7. Remove the front lower swing arm outer ball joint with
T32011.
8. Be careful not to damage the outer ball joint rubber
bushing of the front lower swing arm.
9. Pull the wheel hub outward and remove the left front
drive shaft assembly from the wheel hub.
10. Separate the left front drive shaft from the differential
with T30001.
1.0 848
11. Remove the left front drive shaft assembly. Left Rear Axle Shaft Assembly
12. Remove and discard the drive shaft circlip. Remove
1. Raise the vehicle.
2. Remove the fender board assembly of the rear wheel.
Rear Wheel House Liner - Remove
3. Pry up the nut locking device of the left rear axle shaft,
depress the brake pedal, remove and discard axle shaft
nut.
4. Remove the bolt and nut fixing the rear tie rod to the
wheel bracket, and release the rear tie rod.
5. Remove 3 bolts fixing the rear blade trailing arm to the
wheel bracket, and release the rear blade trailing arm.
Refit
1. Fit the circlip into the left front drive half shaft.
2. Clean the end of the drive half shaft, mounting location
of the wheel hub and junction of the differential.
3. Fit the left front drive half shaft to the differential and
ensure full engagement.
4. Remove the outer ball joint T32003 of the front lower
swing arm.
5. Pull the wheel hub outward, allow the left front drive
half shaft to engage the wheel hub, and fit the wheel
hub into the outer ball joint of the lower swing arm. 6. Remove the bolt and nut fixing the rear upper swing
6. Fit the nut fixing the wheel hub to the lower swing arm, arm to the wheel bracket, and release the rear upper
and tighten to 95±10Nm. swing arm.
7. Ensure full engagement of the lower swing arm outer 7. Remove the bolt and nut fixing the shock absorber to
ball joint and the wheel hub, and the bolt is located at the wheel bracket, and release the shock absorber.
the groove of the outer ball joint connector. 8. Pull the wheel hub outward to remove the left rear axle
8. Ensure the contact surface of the horizontal stabilizer shaft assembly from the wheel hub.
bar and horizontal stabilizer bar connecting rod is clean. 9. Disconnect the left rear axle shaft assembly from the
9. Locate the connecting rod of the horizontal stabilizer differential with the T30001.
bar to the horizontal stabilizer bar, fit the nuts and 10. Remove the left rear axle shaft assembly.
11. Remove and discard the axle shaft circlip.
10. Ensure the steering tie rod and steering arm are clean,
Refit
and the rubber shield is not damaged.
1. Fit the circlip into the axle shaft.
11. Fit the steering tie rod into the steering arm and tighten
2. Clean the end of the axle shaft, mounting location of
the nuts to 40–50Nm.
the wheel hub and junction of the differential.
12. Fit the new drive half shaft nut and tighten to
3. Fit the left rear axle shaft to the differential and ensure
350–370Nm.
full engagement.
13. Lock the nut to the left front drive half shaft.
4. Pull the wheel hub outwards and allow the axle shaft
14. Fit the front wheel fender assembly.
to engage the wheel hub.
Front Wheelhouse Liner - Refit 5. Fix the shock absorber to the wheel bracket, fit the nut
15. Lower the vehicle. and tighten to 75–90Nm.
6. Fix the rear upper swing arm to the wheel bracket, fit
the nut and tighten to 90Nm+90°.
1.0 849
7. Fix the rear blade trailing arm to the wheel bracket, fit Drive Shaft
3 bolts and tighten to 60±5Nm. Remove
8. Fix the rear tie rod to the wheel bracket, fit the nut and 1. Lift the vehicle.
tighten to 130Nm+90°. 2. Support the drive shaft with the jack.
9. Fit the new axle shaft nut and tighten to 350–370Nm. 3. Remove 6 bolts fixing the drive shaft to the power
10. Lock the nut to the left rear axle shaft. takeoff.
11. Fit the fender board assembly of the rear wheel.
Rear Wheel House Liner - Refit

4. Remove 2 bolts fixing the drive shaft to the body.
5. Remove 6 bolts fixing the drive shaft to the rear axle.
6. Slowly lower the jack and remove the front drive shaft
assembly.
Refit
1. Place the new drive shaft assembly on the jack and
1.0 850
slowly lift it to an appropriate position. Constant Velocity Joint Assembly
2. Fit 6 bolts fixing the drive shaft to the rear axle, and Remove
tighten to 55–61Nm. 1. Remove the drive shaft assembly.
3. Fit 2 bolts fixing the drive shaft to the body, and tighten Right Drive Shaft Assembly
to 55–65Nm. 2. Fix the drive shaft with the vise.
4. Fit 6 bolts fixing the drive shaft to the power takeoff, 3. Release and discard 2 clamps of the assembly sheath.
5. Remove the jack.
4. Glide the assembly sheath along the drive shaft so as to

see the inside of constant velocity universal joint.
5. Clamp the wire circlip of constant velocity universal
joint with nipper pliers, and remove the constant
velocity joint assembly from the drive shaft.
6. Remove the wire circlip from the drive shaft and discard
it.
Refit
1. Clean the drive shaft and its sleeve.
2. Fit new circlip to the drive shaft.
3. Locate the new constant velocity joint assembly to the
drive shaft, press the circlip into the groove with an
appropriate tool and fully push the constant velocity
joint into the drive shaft.
4. Apply grease to the constant velocity joint assembly.
5. Locate the sleeve to the constant velocity joint and fix
it with new clamps.
6. Fit the drive shaft assembly.
1.0 851
Right Drive Shaft Assembly Constant Velocity Joint Assembly Sleeve

Remove
1. Remove the constant velocity joint assembly.
Constant Velocity Joint Assembly

2. Take off the constant velocity joint assembly sleeve
from the drive shaft.
3. Take off the constant velocity joint steel ring and
discard it.
Refit
1. Clean the drive shaft.
2. Fit the new constant velocity joint assembly sleeve and
2 new clamps to the drive shaft.
3. Fit the constant velocity joint assembly.
Constant Velocity Joint Assembly
1.0 852
Tripod Joint Assembly Tripod Joint Assembly Sleeve
Remove Remove
1. Remove the drive shaft assembly. 1. Remove the constant velocity joint assembly sleeve.
Right Drive Shaft Assembly Constant Velocity Joint Assembly Sleeve

2. Fit the drive shaft clip to the vise. 2. Remove the drive shaft shock absorption ring.
3. Loosen and discard 2 clamps. 3. Loosen two sleeve clips of the tripod joint assembly
and remove the tripod joint assembly sleeve from the
drive shaft.
4. Remove the intermediate shaft of drive shaft.

5. Remove and discard the wire circlip of the drive shaft
4. Discard the tripod joint assembly sleeve.
intermediate shaft.
Refit
6. Remove the tripod joint from the drive shaft
intermediate shaft. 1. Clean the drive shaft and the tripod joint assembly.
Refit 2. Apply grease to the interior of the tripod shaft assembly.
1. Clean the drive shaft and tripod joint assembly sleeve. 3. Refit the new tripod joint assembly sleeve onto the
drive shaft and fix it with new clamps.
2. Fit 2 new clamps to the drive shaft.
4. Lubricate and fit the drive shaft shock absorption ring.
3. Locate the new tripod joint to the drive shaft.
5. Make sure that the position of the drive shaft shock
4. Fit the new wire snap ring to the intermediate shaft of
absorption ring is correct.
the drive shaft.
6. Clean the drive shaft and the constant velocity joint
5. Apply grease to the interior of the tripod joint assembly.
assembly sleeve.
6. Fix the tripod joint assembly sleeve to the drive shaft.
7. Refit the constant velocity joint assembly sleeve.
7. Fit the drive shaft assembly.
Constant Velocity Joint Assembly Sleeve
Right Drive Shaft Assembly
1.0 853
Special Tools
Number
Lever front
T32011 lower arm ball
joint
Protector -
T32003 front lower arm
ball joint
Remover drive
T30001
shaft
1.0 854
Instrument Panel and Console Interior Fitting
Instrument Panel and Console
Specifications
Torque
Description Value
Bolt-Fasic Main to Fasic Bracket 19–25 Nm
Bolt-Fasic Bracket to Body 19–25 Nm
Nut-T-box to cross car beam 7–10Nm
Nut-GW module to instrument panel beam 7–8Nm
Bolt-Console Main to Console front bracket 1.6–2.0Nm
Bolt-Console Main to Console rear bracket 3.0–4.0Nm
Screw-front console switch assembly to console panel 1.0–1.4Nm
Screw-EPB switch to console assembly 1.0–1.4Nm
1.0 855
Interior Fitting Instrument Panel and Console
Service Procedures
Driver Side Lower Trim Panel Assembly
Remove
1. Carefully pry out 4 clips (2) fixing the left instrument
panel end cap to the instrument assembly with a
flat-bladed tool starting from the access port (1).
Refit
1. Fix the driver lower trim panel to the instrument panel,
and fit the clip properly.
2. Fix the release handle of front engine hood to the
driver lower trim panel, fit 2 screws and tighten up.
3. Fix the oil filler cap release handle to the driver lower
2. Carefully pull out the left instrument panel end cap trim panel, fit 2 screws and tighten up.
from the door weatherstrip covering the edge of left 4. Carefully extend the edge of left instrument panel
instrument panel end cap. Take care to protect the end cap into the bottom of door weatherstrips, fit
cover from scratch. the left instrument panel end cap and press the door
3. Remove 2 retaining screws of the oil filler cap release weatherstrips tightly.
handle.
4. Remove 2 retaining screws of the front engine hood
release handle.
5. Pry open the driver lower trim panel clip and remove
the driver lower trim panel.
1.0 856
Glove Box Assembly Instrument Panel Assembly
Remove Remove
1. Open the glove box. 1. Disconnect the battery negative.
2. Remove 2 limits for the glove box. 2. Remove the centre console assembly.
3. Remove the steering wheel assembly.
Steering Wheel Assembly Remove
4. Remove the steering column shroud.
Steering Column Shroud Remove
5. Remove the instrument pack.
Instrument Pack Remove
6. Remove the driver side air outlet trim panel.
Driver Side Air Outlet Trim Panel Remove
7. Remove the driver side lower trim panel.
3. Remove the damper cable. Driver Side Lower Trim Panel Assembly Remove
4. Remove the glove box. 8. Carefully pry out 4 clips (2) fixing the left instrument
Refit panel end cap to the instrument assembly with a
flat-bladed tool starting from the access port (1).
1. Refit the glove box onto the right location of the
instrument panel. 9. Carefully pull out the left instrument panel end cap
from the door weatherstrip covering the edge of left
2. Refit the damper cable.
instrument panel end cap. Take care to protect the
3. Refit 2 limits for the glove box. cover from scratch.
4. Close the glove box. 10. Remove the 5 screws fixing the switch trim panel of the
exterior mirror to the instrument panel, pry the clip,
disconnect the connector and remove the switch trim
panel of the exterior mirror.
11. Remove the player.

Player Remove
12. Remove the A/C controller.
A/C Controller Assembly Remove
13. Remove the 5 screws fixing the one-button start trim
panel to the instrument panel, pry the clip, disconnect
the connector and remove the one-button start trim
panel.
1.0 857
19. Disconnect the passenger side airbag harness

connector.
20. Remove 2 bolts securing the passenger side airbag
bracket.
14. Remove the glove box.

15. Remove the glove box lamp.
Glove Box Lamp Assembly Remove
21. Remove the left/right A pillar upper trim panel.
16. Use a flat blade tool to start with the access hole (1),
carefully pry the 4 clips (2) fixing the right end cap of A Pillar Upper Trim Panel Remove
the instrument panel to the instrument panel assembly. 22. Remove the 6 bolts securing the instrument panel to
the instrument panel beam.
17. Carefully pull the right end cap of the instrument panel
out of the door sealing strip covering the edge of the
23. Move the instrument panel assembly, disconnect the
end cap, take care not to scratch it.
connector of the solar/temperature sensor and remove
18. Remove 15 screws and 7 bolts fixing the lower the harness clip of the instrument panel.
instrument panel to the instrument panel, pry the clip
24. With assistance, remove the instrument panel from
and remove the lower instrument panel.
the vehicle.
Refit
1. With assistance, fit the instrument panel into the
vehicle.
2. Connect the connector of the solar/temperature
sensor and fix the harness clip.
3. Position the instrument panel on the instrument panel
beam, and ensure the heater pipe and vent pipe are
correctly embedded into the heater assembly.
4. Fit 6 bolts fixing the instrument panel to the instrument
panel beam, tighten to 19–25 Nm and check the
torque.
1.0 858
5. Fit the left/right A pillar upper trim panel. 20. Fit the steering column shroud.
A Pillar Upper Trim Panel Refit Steering Column Shroud Refit
6. Fit 2 bolts securing the passenger side airbag bracket. 21. Fit the steering wheel assembly.
7. Connect the passenger side airbag connector. Steering Wheel Assembly Refit
8. Fix the lower instrument panel to the instrument panel, 22. Fit the centre console assembly.
fit 15 screws and 7 bolts and tighten them.
9. With great care, extend the edge of the right end cap
of the instrument panel into the bottom of the door 23. Connect the battery negative.
sealing strip, fit the right end cap of the instrument
panel and press the door sealing strip tightly.
10. Fit the glove box lamp.

Glove Box Lamp Refit
11. Fit the glove box.
Glove Box Assembly Refit
12. Connect the connector, fix the one-button start trim
panel to the instrument panel, fit the clip and 5 screws,
then tighten them.
13. Fit the A/C controller.
A/C Controller Refit
14. Fit the player.
Player Refit
15. Connect the connector, fix the switch trim panel of the
exterior mirror to the instrument panel, fit the clip and
5 screws, then tighten them.
16. Carefully extend the edge of left instrument panel
end cap into the bottom of door weatherstrips, fit
the left instrument panel end cap and press the door
weatherstrips tightly.
17. Fit the driver side lower trim panel.
Driver Side Lower Trim Panel Refit
18. Fit the driver side air outlet trim panel.
Driver Side Air Outlet Trim Panel Refit
19. Fit the instrument pack.
Instrument Pack Refit
1.0 859
Driver Side Instrument Panel Vent Trim Panel Passenger Side Instrument Panel Vent Trim
Assembly Panel Assembly
Remove Remove
1. Pry off the retaining clip of the driver side vent trim 1. Pry off the instrument panel upper trim assembly,
panel assembly. disconnect the connector and remove the instrument
2. Remove 3 screws securing the driver side vent onto

the driver side vent trim panel assembly. 2. Remove 6 screws fixing the passenger air outlet trim
panel assembly to the instrument panel upper trim
assembly, and remove the passenger air outlet trim
panel assembly.
3. Pry off the clip and remove the driver side vent.
Refit
1. Refit the driver side vent onto the driver side vent trim
3. Remove 3 screws fixing the passenger air outlet to the
panel and ensure the clip is fitted in place.
passenger air outlet trim panel assembly.
2. Fit 3 screws and tighten up.
3. Locate the driver side vent trim panel assembly onto
the instrument panel, press the clip and ensure it is
fitted in place.
4. Pry off the clip and remove the passenger air outlet.
1.0 860
Refit Central Instrument Panel Vent Trim Panel
1. Refit the passenger side vent onto the passenger side
Assembly
vent trim panel and ensure the clip is fitted in place. Remove
2. Fit 3 screws and tighten up. 1. Pry off the instrument panel upper trim assembly,
disconnect the connector and remove the instrument
3. Fix the passenger side vent trim panel onto the
instrument panel upper trim assembly, fit 6 screws and
tighten up. 2. Remove 4 screws (1) fixing 2 central vents on the
central control panel, pry off the clip and remove 2
central vents.
upper trim assembly onto the instrument panel, press
the clip and ensure it is fitted in place. 3. Remove 4 screws (2) fixing the A/C control panel to
the central panel, and remove the A/C control panel.
(if equipped)
4. Remove 4 screws (2) fixing the A/C control panel

and the entertainment control panel to the central
panel, and remove the A/C control panel and the
entertainment control panel. (if equipped)
5. Remove 2 screws (3) fixing the slot to the central panel,

and remove the slot. (if equipped)
6. Remove 13 screws fixing the central panel to the
instrument panel upper trim, and remove the central
panel.
1.0 861
Panel Assembly - Fascia Closing Panel

Remove
1. Remove 2 screws (1) securing lower closing panel for
passenger to the instrument panel assembly .
Refit
1. Fix the central panel to the instrument panel upper
trim, fit 13 screws and tighten up.
2. Fix the slot to the centre panel, fit 2 screws and tighten
up. (if equipped)
3. Fix the A/C control panel and entertainment control
2. Remove 2 bolts (2) securing lower closing panel for
panel to the central panel, fit 4 screws and tighten up.
passenger to the air-condition blower.
(if equipped)
3. Remove the lower closing panel.
4. Fix the A/C control panel to the central panel, fit 4
Refit
screws and tighten up. (if equipped)
1. Fix the lower closing panel for passenger to the
5. Fit the 2 central vents to the central control panel and
instrument panel assembly by 2 screws and tighten up.
ensure the clip is fitted in place.
2. Fix the lower closing panel for passenger to the
6. Fit 4 screws and tighten up.
air-condition blower by 2 bolts and tighten up.
upper trim assembly onto the instrument panel, press
the clip and ensure it is fitted in place.
1.0 862
Instrument Panel Beam Assembly
Remove

2. Remove the instrument panel harness.
Instrument Panel Harness Remove
3. Remove the steering column from the instrument panel
beam.
Steering Column Assembly Remove

4. Remove 2 nuts (at passenger side) fixing the
communication module to the instrument panel beam,
then remove the communication module. 7. Remove the wiper motor and linkage mechanism.
Wiper Motor and Linkage Mechanism Remove
8. Remove 2 bolts fixing the instrument panel frame to
the launder.
5. Remove 2 bolts (at driver side) fixing the gateway to

the instrument panel beam, then remove the gateway.
9. Remove the instrument panel beam assembly out of

the vehicle with assistance.
Refit
1. Remove the instrument panel beam assembly into the
vehicle with assistance.
2. Position the instrument panel beam assembly.
3. Fit 2 bolts in the gutter, tighten to 19–25 Nm and
check the torque.
4. Fit the wiper motor and linkage mechanism.
Wiper Motor and Linkage Mechanism Refit
5. Fit 9 retaining bolts, tighten to 19–25 Nm and check
6. Remove 9 bolts securing the instrument panel frame. the torque.
6. Fix the communication module to the instrument panel
beam, fit 2 nuts, tighten to 7–10Nm and check the
torque.
7. Fix the gateway to the bolt of instrument panel beam,
fit 2 nuts, tighten to 7–8Nm and check the torque.
8. Fit the steering column to the instrument panel beam.
Steering Column Assembly Refit
9. Fit the instrument panel harness.
1.0 863
Instrument Panel Harness Refit Centre Console Assembly

10. Fit the instrument panel assembly. Remove
2. Remove the centre console front storage box assembly.
Centre Console Front Storage Box Assembly
Remove
3. Remove 2 screws (1) fixing both heater cover plates
and take down the heater cover plates on both sides.
4. Remove retaining bolt trim covers on both sides of
centre console, and remove 6 retaining bolts (2).
5. Remove 2 retaining screws on the front of centre

console.
6. Disconnect the centre console harness connector to

remove the centre console.
Refit
1. Connect the centre console harness connector.
2. Locate the centre console into the vehicle.
3. Fit 2 bolts fixing the front part of centre console to the
instrument panel lower body, tighten to 1.6–2.0Nm,
4. Fit 2 bolts fixing both sides of centre console onto the
centre console front bracket, tighten to 1.6–2.0Nm,
5. Fit 4 bolts fixing both sides of centre console to the
1.0 864
centre console rear bracket, tighten to 3.0–4.0Nm, Centre Console Armrest Assembly
and check the torque. Remove
6. Refit the heater cover plates of both sides, fit 2 bolts 1. Remove the centre console rear panel assembly.
and tighten up.
Centre Console Rear Panel Assembly Remove
7. Fit the centre console front storage box assembly.
2. Remove 6 screws securing the centre console armrest
Centre Console Front Storage Box Assembly onto the centre console.
Refit
3. Remove the centre console armrest assembly.

Refit
1. Refit the centre console armrest and tighten 6 fastening
bolts.
2. Refit the centre console rear panel assembly.
1.0 865
Centre Console Front Storage Box Assembly Centre Console Rear Panel Assembly
Remove Remove
1. Pry off the shift panel assembly clip. 1. Pry off the centre console rear panel assembly clip.
2. Remove 2 bolts securing the centre console front
storage box onto the centre console.
2. Disconnect the 12V power supply connector.

3. Remove the rear panel assembly.
3. Pry off the centre console front storage box clip, 4. If it's required to replace the new centre console rear
disconnect the connector and remove the USB port. vent, remove 4 screws fixing the rear vent to the centre
4. Remove the centre console front storage box. console rear panel assembly and remove the rear vent.
Refit
1. Connect the connector, locate the centre console front
storage box onto the centre console and press the clip
in place.
2. Refit 2 retaining bolts and tighten up.
3. Locate the shift panel assembly, and press the clip in
place.
Refit
1. Fix the rear vent onto the centre console rear panel
assembly, fit 4 screws and tighten up.
2. Connect the 12V power supply connector.
3. Locate the centre console rear panel assembly onto the
centre console, and fit the clip in place.
1.0 866
Centre Console Cup Holder Assembly Centre Console Rear Panel Assembly Remove
Remove 4. Locate the centre console harness to the bottom of
1. Disconnect the battery negative. centre console and secure with clips.
2. Remove the centre console assembly. 5. Connect the harness connector.
Centre Console Assembly Remove 6. Refit the centre console assembly.
3. Disconnect the harness connector. Centre Console Assembly Refit
4. Release the clip securing the harness to the bottom of 7. Connect the battery negative.
centre console.
5. Remove the centre console harness.
6. Remove the centre console rear panel assembly.
Centre Console Rear Panel Assembly Remove
7. Remove 6 screws fixing the rear vent duct to the
bottom of centre console, and remove the rear vent
duct.
8. Remove 4 screws the centre console cup holder

assembly to the bottom of centre console, then remove
the centre console cup holder assembly.
Refit
1. Fix the centre console cup holder assembly to the
bottom of centre console, then fit 4 screws and tighten
up.
2. Fix the rear vent duct to the bottom of centre console,
fit 6 screws and tighten up.
3. Remove the centre console rear panel assembly.
1.0 867
Insulation Pad of Engine Compartment Heat Body Harness Refit

Shield
11. Refit the instrument panel assembly.
Remove
1. Open the engine hood and disconnect the battery
negative. 12. Connect the battery negative and close the engine
hood.
3. Remove the body harness.
Body Harness Remove
4. Remove the vacuum booster.
Vacuum Booster Assembly Remove
5. Remove the ABS control unit.
ABS Regulator Remove
6. Remove the clamp and disconnect the heater water
inlet pipe from the heater.
7. Remove the clamp and disconnect the heater water
outlet pipe from the heater.
8. Remove 1 bolt fixing the A/C pipe to the expansion
valve.
9. Disconnect the left body harness connector (control
module side).
10. Disconnect 3 clips securing the left body harness on
the body.
11. Remove 4 nuts securing the insulation pad of the engine
compartment heat shield on the front body.
12. Remove the insulation pad of the engine compartment
heat shield.
Refit
1. Fit the insulation pad of the engine compartment heat
shield.
2. Fit 4 nuts securing the insulation pad of the engine
compartment heat shield on the front body.
3. Connect 3 clips securing the left body harness on the
body.
4. Connect the left body harness connector (control
module side).
5. Fit 1 bolt fixing the A/C pipe to the expansion valve.
6. Fit the clamp and connect the heater water outlet pipe
to the heater.
7. Fit the clamp and connect the heater water inlet pipe
to the heater.
8. Fit the ABS control unit.
ABS Regulator Refit
9. Fit the vacuum booster.
Vacuum Booster Assembly Refit
10. Fit the body harness.
1.0 868
Front Insulation Pad Centre Console Four-key Switch
Remove Remove
1. Remove the heater assembly. 1. Disconnect the battery negative cable.
Heater Assembly Remove 2. Pry up the centre console upper trim panel molding
assembly.
2. Remove the instrument panel harness.
3. Remove 2 screws securing the centre console four-key
Instrument Panel Harness Remove
switch to the centre console upper trim panel molding
3. Remove the brake pedal bracket. assembly.
Pedal Assembly Remove 4. Disconnect the harness connector on the back of the
switch and remove the switch.
Pedal Assembly - MT Remove
Refit
4. Remove the main carpet.
1. Refit the centre console four-key switch from its back
Carpet Remove onto the centre console upper trim panel molding
5. Remove 7 nuts securing the front insulation pad. assembly, fit 2 tapping-screws on the left and right sides
and tighten to 1.0–1.4Nm, and check the torque.
2. Refit the harness to the back of the centre console
four-key switch.
3. Refit the centre console upper trim panel molding
assembly.
6. Remove the front insulation pad.

Refit
1. Lay the front insulation pad to the corresponding
position of vehicle body, and put the locating hole into
the locating pin.
2. Fix the front insulation pad to the vehicle body with
6 nuts.
3. Fit the main carpet.
Carpet Refit
4. Fit the brake pedal.
Pedal Assembly Refit
Pedal Assembly - MT Refit

5. Refit the instrument panel harness.
Instrument Panel Harness Refit

6. Fit the A/C box.
Heater Assembly Refit
1.0 869
Entertainment Panel Switch 5. Connect the battery negative cable.

Remove
2. Pry off the instrument panel upper trim assembly,
3. For vehicles with single knob cap (1), remove the knob
cap separately from the front of entertainment panel
switch at first.
4. Remove 2 screws (3) fixing the entertainment panel
switch (2) to instrument panel upper molding assembly.
5. Remove the entertainment panel switch.

Refit
1. Refit the entertainment panel switch from the back
onto the instrument panel upper trim assembly, fit 2
self-tapping screws on the left and right sides, tighten
to 1.0–1.4Nm, and check the torque.
2. Refit the harness to the back of entertainment panel
switch.
3. For vehicles with knob caps, align any one clip of knob
caps with any one mounting slope, then fit knob caps
from the front of entertainment panel until you hear a
sound of "click" after correct installation.
4. Refit the instrument panel upper molding assembly.
1.0 870
Electronic Hand-brake Switch Hazard Warning Lamp Switch
Remove Remove
2. Remove the centre console assembly. 2. Pry off the instrument panel upper trim assembly,
3. Disconnect the harness connected to the back of the
3. Disconnect harness connector at the back of the hazard
switch.
warning lamp switch.
4. Remove 2 self-tapping screws on the front end of the
4. Release the clip, and remove the switch from the front
switch.
of the upper molding assembly.
5. Loosen the clip on the rear end of the switch and
Refit
remove the electronic hand brake switch.
1. Connect the harness to the back of the hazard warning
Refit
lamp switch.
1. Refit the electronic hand brake switch from the back
2. Refit the switch to the instrument panel upper trim
into the centre console assembly mounting hole, and
assembly in a positive way and fasten with clips.
tighten the clip at the rear end of the switch.
3. Refit the instrument panel upper trim assembly.
2. Refit 2 screws to the front end of switch, tighten to
1.0–1.4Nm, and check the torque. 4. Connect the battery negative cable.
3. Connect the harness to the harness connector on back

of the switch.

1.0 871
Interior Fitting Seat
Seat
Specifications
Torque
Description Value
Bolt - front seat to body 40–50Nm
Bolt - squab to cushion 40–50Nm
Bolt - squab to cushion 40–50Nm
Screw - rear seat to body 40–50Nm
1.0 872
Seat Interior Fitting
System Layout
Power Seat Motor Layout
1. Seat Back Regulator Motor 3. Seat Horizontal Motor

2. Seat Height Adjuster Motor
1.0 873
Description 1. Seat Longitudinal Position Adjusting Handle

Front Seat Assembly 2. Seat Height Adjusting Handle (if equipped)
The configuration of the front seat assembly may vary 3. Seat Back Adjusting Handle
according to vehicle configuration and seat exterior, for
Manual seats can be adjusted by the handle according to
example, 4 way manual seat (forward/backward adjustment,
individual needs.
seat back inclination adjustment); 6 way manual/power
seat (forward/backward adjustment, seat back inclination The front/rear position of the seat can be adjusted by the
adjustment, seat height and optional lumbar support handle in the front of the seat. Lift the handle and pull it
adjustment); fabric of high quality, PU or leather, optional side to the desired position. Release the longitudinal position
airbag. adjusting handle to lock the seat to the selected position. The
2nd adjusting handle is located in the front of the trim panel
Manual Seat
outside the seat cushion, which can adjust the seat height.
Lift or press the height adjusting handle repeatedly to raise
or lower the seat. The 3rd adjusting handle is located in
the rear of the height adjusting handle, which can adjust the
backrest inclination. Pull up the seat back adjusting handle to
release the back. Then the back can be moved back and forth
according to the need. Release the back adjusting handle to
lock the seat back to the selected position.
1.0 874
Power Seat Seat Headrest
1. Seat Lumbar Support Adjusting Handle (if equipped) The seat headrest has 3 adjustable heights. When adjusting the
2. Seat Back Adjusting Switch headrest from a low position to a high one, pull the headrest
3. Seat Longitudinal Position/Height Adjusting Switch directly upward, and gently press the headrest downward after
(4-channel switch) it reaches the desired position to make sure that it is locked in
position. To remove the headrest, hold the left guide button
The power driver seat can be adjusted by the driver seat switch
of the headrest, and pull the headrest upward to remove it.
assembly on the trim panel outside the seat cushion according
When adjusting the headrest from a high position to a low one,
to the individual needs. This seat can be moved back/forth, and
press the left guide button, and press the headrest downward,
the height and angle of the back inclination can also be adjusted
release the button after it reaches the desired position, and
electrically.The power of the power seat is provided by the
gently press the headrest downward to make sure that it is
BCM fuse 19 (30A). The axial motion of the seat is controlled
locked in position.
by the driver seat switch assembly on the trim panel outside
Rear Seat Assembly
the seat cushion. The switch assembly contains a 2-channel
switch which controls the forward/backward inclination of the
seat back and a 4-channel switch which controls the height
and forward/backward location of the seat. Each motor can
receive a 12V power supply from the switch box and connect
the ground. The power will enter into the selected motor and
drive it to work according to different requirements. When
the seat achieves its maximum position for any direction, the
thermal protection cut-off switch will protect the motor by
cutting off the power supply automatically.
A rotary handle is fitted on the lower side of the exterior

driver seat back, which is used for adjusting the lumbar
support of the seat back. Rotation the lumbar support handle
will pull the cable connected with the ribbed lumbar support.
1. Rear Seat Back Assembly Control Button
When pulling the cable, the lumbar support will deviate from
its original position and adjust the push-out height. 2. Central Armrest
The rear seat of the vehicle is an independent seat, the height

of the headrest is adjustable; the inclination of the rear seat
back assembly can be adjusted to a certain angle by pulling the
control button of the rear seat back assembly, when it reaches
the desired position, release the control button and ensure it
is engaged.
1.0 875
Service Procedures
Front Seat Assembly
Remove
Warning: Refer to "Warning of airbag system".
1. Adjust the seat to the rearmost location.
2. Remove 2 bolts from the front of the seat guide rail
and discard the bolts.
7. Remove the seat from the vehicle.

Refit
1. Ensure the seat guide rail is properly aligned with the
body floor, and locate the front seat to the vehicle.
2. Connect the seat belt buckle and the plug of the side
airbag module connector and power seat harness
connector (if equipped), etc.
3. Adjust the seat to the forefront. 3. Fix the seat to the vehicle, fit 2 new bolts to the rear
4. Remove 2 bolts from the back of the seat guide rail of the seat guide rail, tighten the bolt to 40–50Nm
and discard the bolts. and check the torque.
4. Fully move the seat backward.
5. Fit 2 new bolts to the front of the seat guide rail, tighten
the bolt to 40–50Nm and check the torque.

6. Disconnect the seat belt buckle and the plug of the
side airbag module connector and power seat harness
connector (if equipped), etc.
1.0 876
External Trim Panel - Front Seat Front Seat Cushion Assembly
Remove Remove
1. Remove the front driver seat assembly. 1. Remove the front seat.
Front Seat Assembly Remove Front Seat Assembly Remove

2. Remove the screw fixing the external panel to the seat. 2. Remove the exterior trim panel.
Exterior Trim Panel - Front Seat Remove
3. Remove 1 screw fixing the internal panel to the seat.
3. Release the clip fixing the the external panel to the

seat, and remove the external panel.
4. Remove the height adjusting handle and back adjusting 4. Remove the clip fixing the internal panel to the seat,
handle from the external trim panel (manual seat). and take away the internal panel.
5. Remove 3 screws fixing the combination switch to the 5. Release the clip securing the seat back upholstery.
external panel and take away the external panel (power
seat).
6. Remove the bolts (totally 4 for both sides) fixing the

seat back to the seat cushion frame, and take away the
Refit seat back.
1. Fit the combination switch to the outside panel and
fasten with screws.
2. Fix the outside panel to the seat with the clips and
screws.
3. Fit the front driver seats.
1.0 877
Front Seat Cushion Upholstery

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

2. Remove the C-ring and release the strap fixing the seat
cushion upholstery to the seat cushion frame.
3. Release the seat cushion foam from the seat cushion
frame and remove the foam and upholstery.
4. Release the elastic belt and remove the C-ring fixing
the seat cushion upholstery to the seat cushion foam.
Refit
1. Locate the seat back and cushion, fit 4 bolts, tighten to
2. Fix the seat back upholstery to the seat cushion frame
with clips.
3. Refit the interior panel and press into the clip, fasten it
with 2 screws.
4. Fit the exterior trim panel.
Exterior Trim Panel - Front Seat Refit

5. Refit the front seat.
Front Seat Assembly Refit 5. Remove the seat cushion upholstery.

Refit
1. Fit the seat cushion foam into the seat cushion
upholstery and secure it with elastic band and C-ring,
and check the fit between the upholstery and cushion
foam.
2. Fit the seat cushion foam with upholstery to seat
cushion frame, and secure the seat cushion upholstery
with strap and C-ring.
3. Fit the seat back and 4 bolts, tighten to 40–50Nm,
4. Connect the seat back harness connector.
5. Fix the seat back upholstery to the seat cushion frame
with clips.
6. Refit the interior trim panel and press into the clip,
fasten it with 2 screws.
7. Refit the front seat belt buckle.
Front Seat Belt Buckle Refit

8. Fit the exterior trim panel.
1.0 878
Front Seat Backrest Upholstery
Remove
1. Remove the front seat.

2. Remove the headrest by pressing guide sleeve button
on both sides.
3. Release and remove 2 headrest guide sleeves.
8. Remove the bolts (totally 4 for both sides) fixing the

seat back to the seat cushion frame, and take away the
seat back.
4. Remove the exterior trim panel.
Exterior Trim Panel - Front Seat Remove

5. Remove 1 screw fixing the internal panel to the seat.
9. Release the strap of the back upholstery.

10. Mark the location of the C-ring, remove the C-ring and
upholstery.
6. Remove the clip fixing the internal panel to the seat,

and take away the internal panel.
7. Release the clip securing the seat back upholstery.
Refit
1. Fit the seat back upholstery over back foam and secure
it with elastic band and C-ring, and check the fit
between the upholstery and back foam.
2. Fix the strap of the back upholstery.
3. Locate the seat back and cushion, fit 4 bolts, tighten to
1.0 879
4. Fix the seat back upholstery to the seat cushion frame Rear Seat (Including Centre Armrest)
with clips. Remove
5. Refit the interior panel and press into the clip, fasten it 1. Remove the rear seat leg cap, and remove the front 2
with 2 screws. bolts (1) fixing the rear seat to the body.
6. Fit the exterior trim panel. 2. Slightly lift the rear seat cushion, and remove 2 bolts (2)
fixing the rear seat to the central body mounting hole.
7. Fit the headrest guide pipe.
8. Fit the headrest.
9. Refit the front seat.
3. Remove 1 bolt fixing the central belt of rear seat to

the underbody.
4. Pull up the control lock knob at the top of seat back to

put the rear seat back to the "FOLD" position.
5. Remove the rear 2 bolts fixing the rear seat to the body.
6. Remove the rear seat from the vehicle.
1.0 880
Refit Rear Seat Back (with central armrest)
1. Place the rear seat (folded) to the mounting position Remove
of the body seat, and locate it with the locating pin of 1. Remove the rear seat.
the mounting leg.
Rear Seat (with central armrest) Remove
2. Fix the mounting hole at the rear side of the seat to
2. Remove the rear seat headrest.
the floor, fit 2 bolts, tighten to 40–50Nm, and fit the
screw from inside to outside, then check the torque. 3. Remove 1 screw securing the exterior bracket cover
of the rear seat.
3. Stick the fastening tape on the seat back cover to the

4. Remove the bracket cover of rear seat.
tape of the trunk carpet.
5. Remove the bolt securing the rear seat back and
4. Lift the rear seat back upward to the rearmost position
cushion.
and lift the seat cushion to the highest location by
pulling the control lock knob at the top of the seat back.
5. Fix the 2 bolts to the floor through the mounting hole
in the central seat, tighten the bolts to 40–50Nm,
from inside to outside, and check the torque.
6. Put the seat cushion down and keep it level, place the
front mounting leg of the seat on the body mounting
hole and secure with locating pins.
7. Fix the 2 bolts to the floor through the front mounting
hole of the seat, tighten the bolts to 40–50Nm, and
check the torque.
8. Fit the rear seat leg cap to the front mounting leg of
the rear seat.
6. And repeat the operation for the other side of seat
back.
7. Remove the rear seat back assembly.
Refit
1. Place the rear seat cushions and backrests properly.
2. Refit bolts connecting the rear seat backrests and
cushions and tighten up.
3. Refit the rear seat backrest and cushion connecting
bracket trim cover and the screws securing the trim
cover.
4. Refit the rear seat.
Rear Seat (Including Centre Armrest) Refit

5. Fit the rear seat headrest.
1.0 881
Rear Seat Backrest Upholstery upholstery.

Remove
1. Pry off the cover of the rear part of the rear seat
central armrest.
2. Remove 1 screw fixing the central armrest of the rear
seat to the mounting bracket.
Refit
1. Align the upholstery with the front of back foam and
secure with C-rings.
2. Fit the seat back to the seat back frame.
3. Fix the seat back panel to the back foam with clips.
3. Fold the central armrest of the rear seat, push the
4. Fix the seat back upholstery to the seat back with
armrest down to allow the guide pin and locating pin
C-rings.
outside the armrest from the mounting bracket.
5. Fix the elastic clip of the seat back upholstery.
4. Pull the central armrest of the rear seat outwards.
6. Connect the rear seat control lock knob and cable, fit
5. Remove the rear seat back.
1 bolt and tighten it to the rear seat back control lock
Rear Seat Back Remove knob.
6. Release and remove 2 headrest guide sleeves. 7. Fit the headrest guide pipe and fix with clips.
7. Remove 1 screw securing the seat back control lock 8. Fit the rear seat back.
knob, disconnect the seat back control lock knob and
Rear Seat Back Refit
cable from the rear seat and remove the control lock
knob. 9. Refit the guide pin and locating pin inside the rear seat
middle armrest, and refit the outer guide pin to the
guide slot.
10. Refit 1 outer fixing bolt and refit the trim cover.
8. Pull out the elastic clip from the upholstery.

9. Release the clip securing the rear seat back panel and
remove it.
10. Remove the C-ring securing the rear seat back
upholstery.
11. Mark the location of the C-ring securing the seat
back upholstery and foam, and remove the C-ring and
1.0 882
Rear Seat Back Foam Rear Seat Cushion
Remove Remove
1. Remove the backrest upholstery. 1. Remove the rear seat backrest.
Rear Seat Backrest Upholstery Remove Rear Seat Backrest (Including Centre Armrest)
2. Remove the backrest foam. Remove
Refit 2. Remove the rear seat cushion.
1. Fit the backrest foam. Refit
2. Fit the backrest upholstery. 1. Put the rear seat cushion and backrest in right place.
2. Fit the rear seat backrest.
Rear Seat Backrest Upholstery Refit
Rear Seat Backrest (Including Centre Armrest)
Refit
1.0 883
Rear Seat Cushion Upholstery Rear Seat Cushion Foam

Remove Remove
1. Remove the rear seat cushion. 1. Remove the cushion upholstery.
Rear Seat Remove Rear Seat Cushion Upholstery Remove

2. Mark the distribution positions for seat cushion 2. Remove the cushion foam.
upholstery and foam fixing C-ring and take off them. Refit
1. Mount the seat cushion foam.
2. Mount the seat cushion upholstery.
Rear Seat Cushion upholstery Refit
3. Take off the upholstery from the seat cushion.

Refit
1. Refit the seat cushion upholstery and secure it onto the
seat cushion foam with the C-rings.
2. Fix the seat cushion upholstery onto the seat frame
with cables and J-clamps.
3. Fit the rear seat cushion.
Rear Seat Cushion Refit
1.0 884
Door Trim Interior Fitting
Door Trim
Specifications
Torque
Description Value
Bolt-Door inside trim to Body 2–2.4 Nm
1.0 885
Interior Fitting Door Trim
Service Procedures tighten to 2–2.4 Nm and check the torque.

Front Door Interior Trim Panel 6. Fix the interior handle to the door, fit 1 screw, tighten
Remove to 2–2.4 Nm and check the torque.
1. Disconnect the battery negative. 7. Connect the battery negative.
2. Remove the interior handle screw hole trim cover, and
remove 1 screw fixing the interior door handle to the
door.
3. Carefully pry off the trim cover of door handle pull cup
screw by the removing hole, and remove 1 screw fixing
the interior trim panel to the door.
4. Carefully release 9 clips fixing the door trim panel to

the door, remove the clip and discard.
5. Disconnect the electrical connector.
6. Release the door lock cable of the inner handle.
7. Remove the front door interior trim panel.
8. Refit the front door trim panel atmosphere lamp.
Refit
1. Refit the atmosphere lamp to the front door trim panel.
2. Refit the door lock cable.
3. Connect the electrical connector.
4. Align the new clip with the corresponding sheet metal
mounting hole, and refit the front door trim panel to
the front door.
5. Fix the interior trim panel to the door, fit 1 screw,
1.0 886
Front Door Waterproof Membrane Front Door Inner Handle
Remove Remove
1. Remove the front door interior trim panel. 1. Remove the front door interior trim panel.
Front Door Interior Trim Panel Remove Front Door Interior Trim Panel Remove
2. Remove the front door waterproof membrane from 2. Remove 3 screws securing the front door interior
the door sheet metal. handle onto the trim panel.
Refit
1. Take out the electric sockets from the relevant
position in waterproof membrane, keep the waterproof
membrane locating hole aligned with the sheet metal
boss, remain the edge of the upper end parallel with
the interior belt line, and refit the door waterproof
membrane.
2. Refit the front door interior trim panel.
Front Door Interior Trim Panel Refit
3. Remove the front door interior handle from the

interior door trim panel.
Refit
1. Locate the interior door handle onto the front door
interior trim panel and secure it with screws.
1.0 887
Interior Fitting Door Trim
Rear Door Interior Trim Panel 6. Fix the interior door handle to the door, fit 1 screw,
Remove tighten to 2–2.4 Nm and check the torque.
1. Disconnect the battery negative. 7. Refit the rear door handle pull cup screw trim cover.
2. Remove the triangle window trim cover. 8. Refit the rear door interior handle screw trim cover.
3. Remove the interior handle trim cover, and remove 1 9. Refit the triangle window trim cover.
screw fixing the interior door handle to the door. 10. Connect the battery negative.
4. Remove the rear door interior handle trim cover, and

remove 1 screw fixing the rear door interior trim panel
to the door.
5. Carefully release 10 clips fixing the door trim panel to

the door, remove and discard the clip.
6. Disconnect the electrical connector.
7. Remove the tweeter.
8. Release the door lock cable of the inner handle.
9. Remove the rear door interior trim panel.
Refit
1. Connect the electrical connector.
2. Refit the door lock cable.
3. Refit the tweeter.
4. Align the new clip with the corresponding sheet metal
mounting hole, and refit the rear door trim panel to
the rear door.
5. Fix the interior trim panel to the door, fit 1 screw,
tighten to 2–2.4 Nm and check the torque.
1.0 888
Rear Door Waterproof Membrane Rear Door Inner Handle
Remove Remove
1. Remove the rear door interior trim panel. 1. Remove the rear door interior trim panel.
Rear Door Interior Trim Panel Remove Rear Door Interior Trim Panel Remove
2. Remove the rear door waterproof membrane from the 2. Remove 5 screws securing the door handle base onto
door sheet metal. the trim panel.
Refit
1. Take out the electric sockets from the relevant
position in waterproof membrane, keep the waterproof
membrane locating hole aligned with the sheet metal
boss, remain the edge of the upper end parallel with
the interior belt line, and refit the door waterproof
membrane.
Rear Door Interior Trim Panel Refit
3. Remove the rear door interior handle from the interior

door trim panel.
Refit
1. Fix the interior door handle onto the rear door interior
trim panel and tighten with screws.
1.0 889
Interior Fitting Interior Trim and Paneling
Interior Trim and Paneling

Specifications
Torque
Description Value
Bolt-‘BC’upper post trim to Body 1.5–2.2 Nm
Bolt-‘D’upper post trim to Body 1.5–2.2 Nm
Bolt-Grab handle to Handle bracket 5–7 Nm
Bolt-Compatment trim to Body 1.5–2.2 Nm
Bolt-front seat belt‘D’loop to front seat belt height adjuster 30–35Nm
Bolt-Compatment still trim to Bodyy 1.5–2.2 Nm
Bolt-Gate low trim to Body 1.5–2.2 Nm
Boult-Gate middle trim to Body 1.5–2.2 Nm
1.0 890
Interior Trim and Paneling Interior Fitting
Service Procedures A Pillar Lower Trim Panel
A Pillar Upper Trim Panel Remove
Remove 1. Carefully pry off the front door body side weatherstrip
1. Carefully pry off the front door body side weatherstrip outside the A pillar lower trim panel assembly.
outside the A pillar upper trim panel assembly. 2. Remove the doorsill trim panel assembly.
2. Pry off the A pillar upper trim panel assembly clip. Doorsill Trim Panel Assembly Remove
3. Disconnect the tweeter connector. 3. Remove the blank cover on the A pillar lower trim
4. Remove the A pillar upper trim panel assembly. panel assembly (only driver side with blank cover) .
Refit 4. Pry off the A pillar lower trim panel assembly clip and
1. Connect the tweeter connector. remove the A pillar lower trim panel assembly.
2. Locate the A pillar upper trim panel assembly onto the Refit
vehicle body and press the clip in place. 1. Locate the A pillar lower trim panel assembly onto the
3. Fit the front door body side weatherstrip of the A pillar vehicle body and press the clip in place.
upper trim panel assembly. 2. Refit the blank cover on the A pillar lower trim panel
assembly (only driver side with blank cover) .
3. Refit the doorsill trim panel assembly.
Doorsill Trim Panel Assembly Refit
4. Fit the front door body side weatherstrip of the A pillar
lower trim panel assembly.
1.0 891
B Pillar Upper Trim Panel B Pillar Lower Trim Panel

Remove Remove
1. Pry off the clips between the B pillar upper and lower 1. Pry off the door weatherstrips on both sides of B pillar
trim panel assembly. lower trim panel assembly.
2. Pry off the bolt trim cover plate fixed on the B pillar 2. Pry off the clips between B pillar lower trim panel
upper trim panel and remove the bolt. assembly and the doorsill trim panel assembly as well as
B pillar upper trim panel assembly.
3. Pry off the clip, and remove the B pillar lower trim
panel assembly.
3. Remove 1 bolt securing the front seat belt onto the

vehicle body.
Refit
1. Fix the B pillar lower trim panel assembly onto the B
pillar in place.
2. Refit the door weatherstrips at the B pillar lower trim
panel assembly.
4. Pry off the clip of B pillar upper trim panel assembly.

5. Pull out the seat belt from the hole of the B pillar upper
trim panel assembly and remove it.
Refit
1. Pass in the seat belt through the hole of B pillar upper
trim panel assembly.
2. Locate the B pillar upper trim panel assembly onto the
B pillar and press the clip in place.
3. Fit 1 bolt of B pillar upper trim panel assembly and
tighten to 1.5–2.2 Nm, and check the torque.
4. Refit the bolt trim cover.
5. Fix the front seat belt onto the vehicle body, fit 1 bolt,
1.0 892
D Pillar Upper Trim Panel Doorsill Trim Panel
Remove Remove
1. Pry off the tailgate and the body weatherstrip at the 1. Pry off the clips between the trunk side trim panel and
outside of D pillar. the doorsill trim panel.
2. Remove the trunk cover assembly. 2. Remove 1 bolt securing the front seat belt onto the
3. Remove the trunk side trim panel. vehicle body.
Trunk Side Trim Panel Remove
4. Remove the trunk lamp.
Trunk Lamp Remove

5. Remove 1 bolt securing the D pillar upper trim panel
assembly to the D pillar.
Refit
1. Locate the doorsill trim panel to the vehicle body, and
press the clip in place.
2. Fix the front seat belt onto the vehicle body, fit 1 bolt,
6. Pry off the clip, and remove the D pillar upper trim tighten to 30–35Nm, and check the torque.
panel assembly. 3. Fit the clips between the trunk side trim panel and
7. Pass out the seat belt through the hole of D pillar upper doorsill trim panel.
Refit
1. Pass in the seat belt through the hole of D pillar upper
2. Locate the D pillar upper trim panel assembly to the D
pillar and press the clip properly.
3. Fit 1 retaining bolt, tighten to1.5–2.2 Nm, and check
the torque.
4. Refit the trunk lamp.
Trunk Lamp Refit

5. Fit the trunk side trim panel.
Trunk Side Trim Panel Refit

6. Fit the trunk cover assembly.
7. Refit the tailgate and the body weatherstrip at the
outside of D pillar.
1.0 893
Sun Visor and Bracket Roof Interior Trim

Remove Remove
1. Disconnect the battery negative cable. 1. Remove the front reading lamp.
2. Open the sun visor downward. Front Reading Lamp Remove
3. Remove the sun visor screw cover and 2 screws fixing 2. Remove the rear reading lamp.
the sun visor to the roof interior trim panel. Rear Reading Lamp Remove
3. Remove the sun visor and bracket.
Sun Visor and Bracket Remove
4. Remove the door weatherstrips at column and so on.
5. Remove the inner roof handle.
Inner Roof Handle Remove
6. Remove the A pillar upper trim panel assembly.
A Pillar Upper Trim Panel Assembly Remove
7. Remove the B pillar upper trim panel assembly.
B Pillar Upper Trim Panel Assembly Remove
8. Remove the D pillar trim panel assembly.
D Pillar Trim Panel Assembly Remove
4. Disconnect the harness plug.
9. Release buckles securing the roof interior trim.
5. Remove the sun visor from the sun visor bracket.
6. Open the sun visor bracket screw cover and remove 1
screw fixing the sun visor bracket to the roof interior
trim panel.
10. Unplug the connector of vanity mirror lamp (if

equipped).
11. Recline two front seats backward, then put down rear
seats.
7. Remove the sun visor bracket. 12. Remove the interior roof trim panel from the tailgate
Refit carefully.
1. Fix the sun visor bracket onto the interior roof trim Refit
panel, fit 1 fastening screw and tighten up. 1. Open the tailgate, move the interior roof trim panel
2. Connect the harness plug. into vehicle to seat it with roof panel. Fix the front part
3. Fix the one end of the sun visor bracket onto the sun of interior roof trim panel to the body with sun visor
visor, the other end onto the interior roof trim panel, bracket and insert the locating pins at the rear of the
fit 2 fastening screw and tighten to 2–2.7 Nm. interior roof trim panel into the sheet metal hole, while
press two rear clips into the roof beam hole, then fix
4. Fit the sun visor screw trim cover.
the left front part of interior roof trim panel to the
5. Reset the sun visor.
body with sun visor bracket.
2. Plug the connector of vanity mirror lamp (if equipped).
3. Fit the A pillar upper trim panel assembly.
1.0 894
A Pillar Upper Trim Panel Assembly Refit Roof Inner Handle
4. Fit the B pillar upper trim panel assembly. Remove
1. Pry off 2 screw trim covers on the inner roof handle.
B Pillar Upper Trim Panel Assembly Refit
2. Remove 2 screws securing the inner roof handle onto
5. Fit the D pillar trim panel assembly.
the vehicle body.
D Pillar Trim Panel Assembly Refit
6. Fit weatherstrips at the column.
7. Fit the roof inner handle.
Roof Inner Handle Refit

8. Fit the sun visor and bracket.
Sun Visor and Bracket Refit

9. Fit the front reading lamp.
Front Reading Lamp Refit

10. Fit the rear reading lamp.
Rear Reading Lamp Refit
3. Disconnect the rear reading lamp connector on the

inner roof handle.
Refit
1. Put the inner roof handle to correct position.
2. Fit 2 fastening screws with torque of 5–7 Nm.
3. Fit the upper screw blank cap.
1.0 895
Luggage Compartment Side Trim Panel 30–35Nm and check the torque.
Remove 5. Refit the rear seat.
1. Remove the trunk carpet assembly.
Rear Seat Refit
2. Remove the storage compartment of trunk.
6. Fit the trunk sill trim panel assembly.
3. Remove the trunk sill trim panel.
Trunk Sill Trim Panel Assembly Refit
Trunk Sill Trim Panel Remove
7. Fit the storage compartment of trunk.
4. Remove the rear seat.
8. Fit the trunk carpet assembly.
Rear Seat Remove
9. Close the trunk lid.
5. Remove 1 bolt (1) fixing the seat belt to D pillar.
6. Release 2 bolts (2) securing the trunk side trim panel
to the body.
7. Pry off the clip and remove the trunk side trim panel.
8. If you need to remove the trunk side trim panel tray,
pry off 4 spring clips connecting the tray to trunk side
trim panel and remove the tray.
Refit
1. If the trunk side trim panel tray has been removed, put
it into the mounting position of trunk side trim panel at
first and press the spring clip properly.
2. Locate the trunk side trim panel into the trunk and
press the clip properly.
3. Fit 2 bolts, tighten to 1.5–2.2 Nm and check the
torque.
4. Fix the seat belt to D pillar, fit 1 bolt, tighten to
1.0 896
Luggage Compartment Sill Trim Panel Assembly Tail Gate Interior Trim Panel
Remove Remove
1. Open the luggage compartment lid. 1. Open the tailgate, and disconnect the battery negative.
2. Remove the luggage compartment sealing strip. 2. Pry off the upper trim panel of tailgate interior and
3. Take out the carpet assembly of the luggage remove it.
compartment. 3. Remove 2 screws fixing the centre trim panel of tailgate
4. Take out the luggage compartment storage box. interior to the tailgate, and remove the centre trim
panel.
5. Remove the 2 screws securing the luggage compartment
sill trim panel assembly to the vehicle body.
S 4353002
4. Remove 4 screws fixing the lower trim panel of tailgate
6. From the lower end, pull the sill trim panel assembly of interior to the tailgate, and remove the lower trim
the luggage compartment upward by hand, and push it panel.
out towards the location of the compartment.
Refit
1. Position the luggage compartment sill trim panel
assembly to the correct position, fit two screws with
the torque of 1.5–2.2 Nm.
2. Fit the luggage compartment storage box.
3. Fit the carpet assembly of the luggage compartment.
4. Fit the luggage compartment sealing strip.
5. Close the luggage compartment lid.
Refit
1. Remove 4 screws fixing the lower trim panel of tailgate
interior to the tailgate, tighten to 1.5–2.2 Nm, and
check the torque.
2. Remove 2 screws fixing the centre trim panel of tailgate
interior to the tailgate, tighten to 1.5–2.2 Nm, and
check the torque.
3. Fit the upper trim panel of tailgate interior, and align to
the clip to press it.
5. Perform the self-learning for the power tailgate, if
equipped.
Power Tailgate Self-learning
1.0 897
Carpet
Remove
2. Remove the rear seat cushions.
Rear Seat Cushions Remove
3. Remove the doorsill trim panel.
Doorsill Trim Panel Remove

4. Remove the left/right A pillar lower trim panels.

5. Remove the front seats.
Front Seats Remove

6. Remove the centre console.
Centre Console Remove

7. Remove the carpet.
Refit
1. Put the carpet into the vehicle.
2. Fit the floor centre console.
Centre Console Refit

3. Refit the front seats.
Front Seats Refit

4. Fit the left/right A pillar lower trim panels.
5. Refit the doorsill trim panel.
Front Doorsill Trim Panel Refit
6. Fit the rear seat cushions.
Rear Seat Cushions Refit

1.0 898
Fixed Windows Exterior Fitting
Fixed Windows Windshield Assembly
Service Procedures Remove
Rear Door Quarter Window 1. Remove the A/C air intake grille assembly.
Remove
A/C Air Intake Grille Assembly Remove
1. Remove the D pillar upper trim panel.
2. Remove the interior mirror.
D Pillar Upper Trim Panel Remove
Automatic Anti-dazzle Interior Mirror Remove
2. Carefully cut off the adhesive between the rear quarter
window and the vehicle body using the scraper and Manual Anti-dazzle Interior Mirror Remove
avoid to scratch the finishing paint. 3. Put suitable coverings to the interior molding and body
3. Remove the rear quarter window from the vehicle. to protect from scratch.
4. Remove the adhesive on the rear quarter window and 4. Put 2 suckers symmetrically on both sides of windscreen
frame with blade. (outer side).
Refit 5. Drill a through hole on the adhesive, thread the cutting

line or use cutters directly to cut the adhesive on the
1. Thoroughly clean the mounting position of the rear
glass and surroundings.
triangle window and area around the triangle window
on the body with cleaner. 6. Remove the windshield with suckers on both sides
aided by an assistant.
2. Apply the glass primer to the assembly area of the body
and area around the rear triangle window. 7. If need to reinstall, remove the weatherstrip from
the body, and clean the adhesive on the original front
3. Apply the adhesive to the rear triangle window and
windshield and body.
press the rear triangle window into its frame.
Refit
4. Fix the rear triangle window to the rear triangle
window frame with tapes, and keep the adhesive dry 1. Thoroughly clean the mounting position of the
for 24 hours. windshield and the windshield on the body with cleaner.
5. Remove the tape. 2. Apply the glass primer to the body assembly area
around the windshield.
6. Pour the water on the rear triangle window, and check
for leak. If any leak is found, dry the rear triangle 3. Apply the adhesive to the windshield assembly, and
window and block the leaking location with adhesive. press the windshield into the windshield frame with
If it still leaks, remove the rear triangle window and suction cups.
repeat all service procedures. 4. Fix the windshield to the windshield frame with tapes,
7. Fit the D pillar upper trim panel. and keep the adhesive dry for 24 hours.
5. Remove the tape.
D Pillar Upper Trim Panel Refit
6. Pour the water on the windshield assembly, and check
for leak. If any leak is found, dry the windshield
assembly and block the leaking location with adhesive.
If it still leaks, remove the windshield assembly and
repeat all service steps.
7. Fit the A/C air intake grille assembly.
A/C Air Intake Grille Assembly Refit

8. Fit the interior mirror.
Automatic Anti-dazzle Interior Mirror Refit
Manual Anti-dazzle Interior Mirror Refit
1.0 899
Exterior Fitting Fixed Windows
Rear Window Assembly defogger.

Remove 9. Connect the battery negative.
1. Disconnect the battery negative. 10. Perform the self-learning for the power tailgate, if
2. Disconnect the rear window defogger connector. equipped.
3. Remove the rear wiper motor.

Rear Wiper Motor Remove
4. Put suitable coverings to the interior trim and vehicle
body to protect from scratch.
5. Put 2 suckers symmetrically on both sides of rear
window (outer side).
6. Drill a through hole on the adhesive, thread the cutting
line or use cutters directly to cut the adhesive on the
glass and surroundings.
7. Remove the rear window with suckers on both sides
aided by an assistant.
8. If need to reinstall, clean the adhesive on the original
rear window and vehicle body.
Refit
1. Thoroughly clean the mounting position of the rear
window and the rear window on the body with cleaner.
2. Apply the glass primer to the body assembly area
around the rear window.
3. Apply the adhesive to the rear window assembly, and
press the rear window into the rear window frame
with suction cups.
4. Fix the rear window to the rear window frame with
tapes, and keep the adhesive dry for 24 hours.
5. Remove the tape.
6. Pour the water on the windshield assembly, and check
for leak. If any leak is found, dry the windshield
assembly and block the leaking location with adhesive.
If it still leaks, remove the windshield assembly and
repeat all service steps.
7. Fit the rear wiper motor.
Rear Wiper Motor Refit
8. Connect the electrical connector of the rear window
1.0 900
Bumpers, Fascias and Grille Exterior Fitting
Bumpers, Fascias and Grille
Specifications
Torque
Description Value
Bolt-From front bumper to fend upper tie bar 3–5Nm
Bolt-From rearbumper to wheel casing 2–3Nm
Bolt-From front bumper to bottom wind scooper 4–6Nm
Bolt-From rear bumper to body in white 3–4Nm
Bolt-From rearbumper to wheel casing 3–4Nm
Bolt-From front bumper impact bar to fend upper tie bar 7–10Nm
Bolt-From rear bumper impact bar to body in white 19–25Nm
1.0 901
Exterior Fitting Bumpers, Fascias and Grille
Service Procedures
Front Bumper
Remove
2. Remove the fender flares.
6. With assistance, lift both sides of the front bumper

carefully and pull it outward to remove the front
bumper from the brackets at both sides of the body.
7. Remove the ambient temperature sensor from the
lower air inlet grille of the front bumper.
3. Remove 5 bolts fixing the front bumper to the upper 8. Disconnect left and right front fog lamps and front
radiator beam. camera harness (if equipped), and remove the front
bumper.
9. If it is necessary to replace with a new bumper, remove
the front fog lamp and front camera (if equipped).
Front Fog Lamp Assembly Remove
Refit
1. Fit the front fog lamp to the front bumper and the front
camera of panoramic image (if equipped).
Front Fog Lamp Assembly Refit

2. Connect the connector of front fog lamps on both
sides and the front camera.
3. With assistance, fit the front bumper assembly to the
body, and fit it into the bracket under the headlamp
4. Remove 3 screws fixing the front bumper to the left
and on the fender bracket.
(right) wheelhouse liner.
4. Fit 5 bolts fixing the front bumper to the upper radiator
beam, tighten to 3–5Nm, and check the torque.
5. Remove 4 screws and 2 clips fixing the front bumper to
the wheelhouse shield, tighten to 2–3Nm, and check
the torque.
6. Fit 5 bolts fixing the bottom of the front bumper,
7. If using the original bumper, clean the residual adhesive
on the bumper, fender and fender flare, paste new 3M
adhesive to the undeformed fender flare, and refit the
fender flare with clips.
5. Remove 5 bolts(1), 4 screws(2) and 2 retaining clips(3)

fixing the front bumper to the bottom deflector.
1.0 902
Rear Bumper lamps.
Remove 8. Remove the rear bumper and disconnect the reverse
1. Disconnect the battery negative. radar harness connector.
2. Open the tailgate. Refit
3. Remove the rear fender flare. 1. With assistance, locate the rear bumper to the vehicle.
2. Connect 4 connectors of the reverse radar.
3. Push the rear bumper slightly in place to allow the
bumper on each side to engage with the bumper
bracket.
4. Fit 2 screws and 3 split pins connecting the rear bumper
and the underbody, tighten the screws to 3–4Nm, and
check the torque.
5. Remove 2 screws securing the left (right) rear bumpers
and left (right) rear wheelhouse liners, tighten to
6. Fit the taillamp assembly on both sides.
Rear Taillamp Assembly Refit

4. Remove 2 screws securing the left (right) rear bumpers
7. If using original rear bumper, clean the residual adhesive
and left (right) rear wheelhouse liners.
on the rear bumper and fender flare, paste new 3M
adhesive to the undeformed fender flare, and refit the
fender flare with clips.
8. Close the tailgate.
5. Remove 3 plastic split pins and 2 screws fixing the rear

bumper assembly to the underbody.
6. Remove the rear tail lamp assembly on both sides.

Rear Tail Lamp Assembly Remove
7. Disconnect the connectors of the left/right rear fog
1.0 903
Exterior Fitting Bumpers, Fascias and Grille
Front Bumper Beam

Remove
1. Remove the front bumper.

2. Remove 1 bolt (1) fixing the upper left radiator airflow
3. Remove 3 clips (2), (3) fixing the lower left radiator
airflow deflector to the upper left radiator airflow
8. Remove the right radiator airflow deflector from the

vehicle.
9. Remove the harness clip on the front bumper beam.
10. Remove 6 bolts (1) and 2 nuts (2) fixing the front
bumper beam to the body.
4. Remove the left radiator airflow deflector from the

vehicle.
5. Unscrew 3 split pins fixing the air filter intake pipe and
remove the air filter intake pipe.
11. Remove 5 screws (3) fixing the front bumper beam to

the upper radiator beam.
12. Remove the front bumper beam.
Refit
1. Connect the front bumper beam and upper radiator
beam with screws, and tighten to 7–10Nm.
deflector to the body. 3. Fix the upper right radiator airflow deflector to the
7. Remove 3 clips (2), (3) fixing the right lower radiator
airflow deflector to the upper right radiator airflow 4. Fit 3 clips (2), (3) fixing the lower right radiator airflow
deflector and the upper radiator beam. deflector to the upper right radiator airflow deflector
and the upper radiator beam.
6. Fit 3 clips (2), (3) fixing the lower left radiator airflow
deflector to the upper right radiator airflow deflector
1.0 904
7. Fit the harness clip to the front bumper beam. Rear Bumper Beam
8. Fit the front bumper. Remove
1. Remove the rear bumper.
Rear Bumper Remove
2. Remove the harness clip fitted on the rear bumper
beam.
3. Remove 4 bolts (1) and 2 nuts (2) securing the rear
bumper beam to the rear end of the vehicle body.
4. Carefully remove the rear bumper beam from the rear

end of the vehicle body.
Refit
1. Secure the rear bumper beam to the rear end of
the vehicle body, connecting with bolts and nuts
2. Refit the harness clip onto the rear bumper beam.
3. Refit the rear bumper.
Rear Bumper Refit
1.0 905
Exterior Fitting Exterior Trim and Paneling
Exterior Trim and Paneling

Specifications
Torque
Description Value
Bolt-From under flow duct to front wheel casing 2–3Nm
Bolt-From front wheel casing to front bumper 2–3Nm
Bolt-From front wheel casing to front bumper and sill 2.5–3.5Nm
Bolt-From rear wheel casing to rear bumper 2–3Nm
Bolt-A/C air intake grille to body 2–3Nm
Bolt-A/C air intake grille to body 1.5–2.3Nm
Nut-Stern door spoiler to Body 5–7 Nm
Bolt-Gate upper trim to Body 1.5–2.2 Nm
Nut-From tailgate trim to tailgate 2–4Nm
1.0 906
Exterior Trim and Paneling Exterior Fitting
Service Procedures Front Wheelhouse Liner
Remove 1. Raise the vehicle on a lift.
1. Raise the vehicle on the elevator. 2. Remove the front wheels.
2. Remove 4 self-tapping screws securing the bottom Wheel Remove
deflector with front wheelhouse.
3. Remove front wheel eyebrow and front fender board
3. Remove 3 bolts connecting the bottom deflector and (if any).
front subframe.
4. Remove 5 split pins fixing the front wheel house liner
4. Remove 5 bolts connecting the bottom deflector and to the left of the front bumper.
front bumper to take out the bottom deflector.
5. Remove 2 screws fixing the front wheel house liner
to the bottom deflector.
6. Remove 2 nuts fixing the front wheel house liner to
the body fender.
7. Remove 4 self-tapping screws connecting the front
wheel house liner to the front section of the sill
molding.
8. Remove the front wheel house liner.
Refit
1. Lift the wheel house, pass the split pin through the
wheel house and fix it to the mounting point on the
BIW.
2. Fix the wheel house to the corresponding position on
Refit
the bottom deflector, fit 2 screws, tighten to 2–3Nm
1. Insert the bottom deflector to the lower revers of and check the torque.
front bumper, and fit 5 screws from the middle to both
3. Fix the flanging of the wheel house, front bumper and
sides in sequence.
fender, fit the self-tapping screw, 7 screws and split
2. Fit 3 bolts from left to right in sequence to connect the pin connecting the flanging of the wheel house, front
bottom deflector with front subframe. bumper and fender, tighten to 2–3Nm and check the
3. Fit 4 self-tapping screws connecting the bottom torque.
deflector with front wheelhouse. 4. Fit 4 self-tapping screws connecting the wheel house,
4. Lower the vehicle. bottom of the front bumper and front of the sill
molding, tighten to 2.5–3.5Nm and check the torque.
5. Fit front wheel eyebrow and front fender board (if any).
6. Fit the front wheels.
Wheel Refit
1.0 907
Rear Wheelhouse Liner A/C Air Intake Grille Side Corner

Remove Remove
1. Raise the vehicle on the elevator. 1. Pry off the clip of A/C intake grille side corner.
2. Remove the rear wheel.
Wheel Remove
3. Remove rear wheel eyebrow and rear mudguard (if
any).
4. Remove the screws and cotter pins fixing on the wheel
house revers, wheel trim and rear bumper revers.
5. Remove the rear wheel house liner.
Refit
1. Lift the wheel house liner, pass the split pin through
the wheel house and fix it to the mounting point on
the BIW.
2. Connect the rear wheel house, wheel house flanging,
2. Remove the A/C intake grille side corner.
wheel trim and rear bumper, fit the self-tapping screw
and split pin, tighten to 2–3Nm and check the torque.
Refit
1. Locate the A/C air intake grille side corner and press
3. Fit rear wheel eyebrow and rear fender (if any).
the clip in place.
4. Fit the rear wheel.
Wheel Refit
1.0 908
A/C Air Intake Grille Assembly Roof Rack Assembly
Remove Remove
1. Remove the A/C intake grille side corner. 1. Remove the interior roof trim panel.
A/C Intake Grille Side Corner Remove Interior Roof Trim Panel Remove
2. Remove the windscreen wiper arm assembly. 2. Remove 4 nuts securing the roof rack to the roof.
Windscreen Wiper Arm Assembly Remove 3. Remove the binder close to the mounting hole of roof
groove rack.
3. Remove 8 bolt securing the A/C intake grille to the
body.
4. Remove the roof rack.
4. If need to replace a new A/C intake grille, disconnect Refit

the windshield nozzle hose from the nozzle and remove 1. Raise the rack guide on one side over the roof
them. horizontally, and align 4 bolts with the roof sheet metal
Refit mounting holes orderly from front to back.
1. Connect the windshield nozzle and hose. 2. After confirming that all bolts are aligned with the
mounting holes, lower down the rack slowly and tear
2. Connect the windscreen washer hose, locate the A/C
the protective film of the sealing washer up carefully to
air intake grille to the body.
allow the sealing washer to be in full contact with the
3. Fit 2 bolts on both sides and tighten to 2–3Nm, fit 6
sheet metal.
central bolts and tighten to 1.5–2.3Nm, and check
3. Secure the roof rack onto the roof with 4 nuts.
the torque.
4. Operate the same on the other side.
4. Fit the windscreen wiper arm assembly.
5. Fit the interior roof trim panel.
Windscreen Wiper Arm Assembly Refit
Interior Roof Trim Panel Refit
5. Fit the A/C intake grille side corner.
A/C Intake Grille Side Corner Refit
1.0 909
Roof Molding Spoiler Assembly

Remove Remove
1. Remove the roof rack assembly (if equipped). 1. Open the tailgate and remove the tailgate weatherstrip.
Roof Rack Assembly Remove 2. Pry off 2 screw blank caps on the tailgate interior upper
trim panel, and release 2 screws securing the tailgate
2. Remove the roof molding, if the clips of the roof
interior upper trim panel to the tailgate.
molding comes off or get damaged, remove and discard
the clips. 3. Remove the tailgate interior upper trim panel.
4. Remove 6 fastening nuts of the spoiler assembly.
Refit
1. Wipe the molding mounting area on the vehicle body 5. Cut off the adhesive on the connection between the
surface. spoiler and the tailgate with the knife carefully. Pay
attention to protect the painting surface and remove
2. If the roof molding mounting clips come off or get
the spoiler assembly.
damaged, use the specified glue to fix new mounting
clips of the roof molding into the roof groove. Refit
3. Fit the roof molding. 1. Clean the residual adhesive tape on the spoiler and
tailgate.
4. Fit the roof rack assembly (if equipped).
2. Stick a round of 3M adhesive tape on the joint face
Roof Rack Assembly Refit between the spoiler and tailgate.
3. Place the spoiler to the corresponding mounting
position of the tailgate outer plate.
4. Open the tailgate, fit 6 fastening nuts, tighten to 5–7
Nm, and check the torque.
5. Fit 2 screws securing the tailgate upper interior trim
panel with the torque of 1.5–2.2 Nm, fit 2 screw caps
of the tailgate upper interior trim panel.
1.0 910
Tail Gate Moulding Doorsill Molding
Remove Remove
1. Open the tailgate and remove the tailgate trim panel 1. Remove 4 fastening screws securing the doorsill
molding to the side of front/rear wheelhouse.
Tailgate Interior Trim Panel Remove
2. Remove 7 split pins of the doorsill molding.
2. Remove the nuts fastening the tailgate molding.
3. Disconnect the rear camera or rear license plate lamp
harness connector.
4. Pull out the clips and remove the tailgate molding.
Refit
1. Locate the tailgate molding onto the tailgate and secure
with clips.
2. Secure the tailgate molding with nuts to 2–4Nm.
3. Connect the rear camera or license plate lamp harness
connector.
4. Refit the tailgate trim panel.
Tailgate Interior Trim Panel Refit

3. Remove the doorsill molding.
Refit
1. Position the doorsill molding.
2. Refit 7 split pins of the doorsill molding.
3. Refit 4 retaining screws on the side of front/rear
wheelhouse.
1.0 911
Pedal Assembly 6. Fasten the brake pedal assembly and the body bracket
Remove with 6 bolts.
1. Remove 4 screws (1) securing the pedal to the front 7. Fix the brake pedal assembly to the front and rear
and rear wheelhouses. wheelhouse with 4 screws.
2. Remove 6 bolts (2) securing the pedal onto the vehicle 8. Complete the installation.
body bracket.
3. Remove the pedal assembly.
4. Remove 9 bolts (3) securing the vehicle body bracket
onto the vehicle body.
5. Remove the vehicle body bracket.
3 1
S 6453001
Refit
1. Tear apart the body patch (if any).
2. Pry off 2 plugs at the illustrated position on the
underbody (if any).
3. Clean the black adhesive (shaded part in diagram) on
the contact surface between the bracket and the body,
especially on the contact surface between the rear
bracket and the body.
S 6453002
4. Fasten the body bracket to the body with bolts, fit the
bracket with the boss near the front of vehicle.
5. Open the door, fix the brake pedal assembly to the
body bracket. Visually check if the clips of brake pedal
assembly align with the body holes and adjust. Then
press the clips into the body holes from centre to both
sides in sequence.
1.0 912
Mirrors Exterior Fitting
Mirrors
Specifications
Torque
Description Value
Nut-door mirror to front door 7–10Nm
Nut-interior mirror to backet of mirror 1.6–2.0Nm
1.0 913
Exterior Fitting Mirrors

System Layout
Exterior Mirror Layout
1. Left Exterior Rearview Mirror Assembly b Master Light Switch（without leveling）

2. Right Exterior Rearview Mirror Assembly
3. a Master Light Switch（with leveling）
1.0 914
A=Power HS CAN Bus ； B=Body HS CAN Bus ； C=LIN Bus ； D=Hard Wire
1.0 915
Description Exterior Mirror Adjustment Switch

Overview
The power exterior mirror assembly is fitted on all models
as a standard configuration. Each exterior mirror assembly is
controlled by the circular control switch of the master light
switch.
Exterior Mirror Assembly
The left and right exterior mirror assemblies are available
in a vehicle, but the basic structures are the same. The
exterior mirror assembly housing is a plastic mould, with
exterior mirror glass steering gear, glasses, side direction
indicator lamps, puddle lamps (if equipped) and 360° camera
(if equipped) placed inside. The exterior mirror assembly
comprises 3 bolts and 2 locating pins fixing it on the front
The exterior mirror adjustment switch is located on the driver
door, and the 3 bolts are all visible only when the front door
exterior mirror adjustment switch trim panel.
pillar trim panel is removed.
The exterior mirror adjustment switch has a round adjustment
The exterior mirror assembly is non-serviceable part and shall
switch which can operate the folding, vertical and horizontal
be replaced together as an assembly. The exterior mirror glass,
regulating motors in the exterior mirror assembly. Toggling the
exterior mirror sealing gasket, exterior mirror cover and side
round adjustment switch which can be adjusted and rotated in
direction indicator lamp assembly are serviceable parts.
four directions can fold and rotate open the rearview mirror.
Exterior Mirror Heater There are two LED on each side above it, namely L and R and
Heating the exterior mirror glass is to avoid appearance of mist one of them can be selected by rotating counterclockwise or
or fog on the mirror. The heating element is located at the clockwise. When the width lamp or headlamp is illuminated,
back side of the mirror, which works when the rear window LED flashes.
is heated. The heating element is connected with the door Exterior Mirror Adjustment Switch
harness by two terminals behind the mirror.
The exterior mirror assembly system has no diagnosis
information. Its faults can be judged by detecting power supply,
grounding connection, harness continuity and the working
condition of switches.
1.0 916
Operation commands to DDSP switch through LIN wires to activate
Exterior Mirrors exterior mirror folding motor, thus realizing power folding or
unfolding function of exterior mirror.
Exterior mirror glass steering gear includes 2 bidirectional
motors (vertical motor and horizontal motor), providing Exterior Mirror Adjustment
vertical and horizontal movement of rearview mirror glass.
MLSConnect the vertical motor and horizontal motor with
Vertical motor is responsible for upward and downward
the hard wire, and operate the control switch on MLS to
movement, while horizontal motor is responsible for leftward
adjust the glass up, down, left or right, thereby realizing the
and rightward movement.
adjustment of the exterior mirror.
According to different configurations, some exterior mirrors Automatic Anti-dazzle Function
are equipped with 1 fold motor to realize power folding or
During driving, the strong light from the interior mirror may
unfolding function.
affect the driver. The auto anti-dazzle function can solve
The major operation of exterior mirrors includes: this problem and avoid unnecessary consequences from this
• Exterior Mirror Heating visual impact. But the anti-dazzle function is disabled during
• Exterior Mirror Folding (power) reversing, i.e, when the shift lever is in R gear and the engine
is running, BCM provides reversing signals to the interior
• Exterior Mirror Adjustment
mirror. When the rearview mirror detects this input, it
Exterior Mirror Folding (power) disables the auto anti-dazzle function, this helps the driver
BCMReceive the exterior mirror folding or unfolding request observe the object behind the vehicle by the reflectivity of the
signal sent by control switch on MLS, and deliver operation rearview mirror during reversing.
1.0 917
Service Procedures Exterior Rearview Mirror Cover

Exterior Mirror Assembly Remove
Remove 1. Remove the exterior mirror glass.
1. Disconnect the battery negative. 2. Remove 2 clips securing the cover onto the exterior
2. Release 2 clips securing the front door interior triangle mirror assembly.
trim panel on the door, and remove the trim panel.
Front Door Interior Trim Panel Assembly Remove

4. Disconnect the exterior mirror assembly harness
connector.
5. Remove 3 bolts securing the exterior mirror assembly
on the door, and remove the exterior mirror assembly.
3. Prop up the exterior mirror cover outwards with a

flat-blade screwdriver.
Refit
1. With the locating pins on the exterior mirror assembly,
position the assembly to the corresponding locating
hole on the door, fit and tighten 3 bolts to 7–10Nm.
2. Connect the exterior mirror assembly harness
connector.
3. Fit the front door interior triangle trim panel. Refit
4. Fit the front door interior trim panel.
1. Refit the cover onto the exterior mirror assembly.
Front Door Interior Trim Panel Assembly Refit 2. Fit the exterior mirror glass and check if it is fitted in
5. Connect the battery negative. place.
1.0 918
Exterior Rearview Mirrors Sealing Gaskets Automatic Anti-dazzle Interior Mirror Assembly
Remove Remove
1. Remove the exterior mirror assembly. 1. Disconnect the battery negative.
Exterior Mirror Assembly Remove 2. Push the cover down to disconnect it from the roof,
and remove the cover. (if equipped)
2. Remove the exterior mirror sealing gasket.
Refit
1. Refit the exterior mirror sealing gasket.
2. Install the exterior mirror assembly.
Exterior Mirror Assembly Refit
3. Pry out the multi-function sensor cover in vehicle

towards two sides from the interface and remove the
cover. (if equipped)
4. Remove 1 screw securing the automatic anti-dazzle

interior mirror to the interior mirror bracket.
5. Push the automatic anti-dazzle interior mirror upwards

and remove it from the windshield base.
1.0 919
Manual Anti-dazzle Interior Mirror Assembly

Remove
1. Knock down the interior mirror assembly with rubber
hammer with care to remove it from the base.
6. Disconnect the automatic anti-dazzle interior mirror.

Refit
1. Insert the interior mirror into the windshield base.
2. Refit and tighten screws to 1.6–2.0Nm, and clamp the
roof harness connector with interior mirror connector. Refit
3. Clip the cover onto the interior mirror, and push 1. Locate the interior mirror onto the mounting bracket
upwards to come into contact with the roof. and push it into the slot with care to fit in place.
1.0 920
Roof Exterior Fitting
Roof
Specifications
Torque
Description Value
Bolt - sunroof to vehicle roof 7–9Nm
screw - sunroof glass to bracket 4.5–5.5Nm
screw - sun shade to sunroof 1.8–2.2Nm
screw - motor to sunroof 3.15–3.85Nm
1.0 921
Exterior Fitting Roof

System Layout
Sunroof Assembly Structure Chart
1. Sunroof Front Glass Panel 9. Sunroof Flex Molding

2. Sunroof Rear Glass Panel 10. Sunroof Harness
3. Sunroof Sealing Strip 11. Right Rear Sunroof Drain Pipe
4. Sunroof Sunshade 12. Left Rear Sunroof Drain Pipe
5. Sunshade Motor 13. Sunroof Drain Pipe Valve
6. Sunroof Frame Assembly 14. Right Front Sunroof Drain Pipe
7. Glass Panel Motor 15. Left Front Sunroof Drain Pipe
8. Sunroof Deflector 16. Sunroof Drain Pipe Protector
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A=Hard Wire B=Body HS CAN Bus C=LIN Bus
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Description Input and Output of the Motor and Drive Unit

Overview The sunroof glass ECU and its motor are powered by fuse 13.
The sunroof system has one-touch slide opening/closing The system ground can be used for the operation of the ECU,
function. All operations on the sunroof system are completed motor and switch. The switch ground signal and two control
by the knob switch. signals of the sunroof are input by the switch.
Sunroof Assembly The sunroof sunshade ECU and its motor are powered by
The sunroof assembly consists of a front sunroof glass panel, a fuse 17. The system ground can be used for the operation of
rear glass panel, a sunshade, a frame assembly between the roof the ECU, motor and switch. The switch ground signal and
and the interior roof panel, a deflector (on the frame assembly two control signals of the sunroof sunshade are input by the
between the roof and the interior roof panel), 4 drain gutters, switch.
a sunroof motor and sunshade motor. Front Sunroof Glass Operation - Mechanical
Method
The frame assembly is composed of the front frame, guide rails
on both sides and a drain gutter on the beam. The mechanical method is used in unexpected situations only,
for example, when low battery and motor malfunction causes
The sunroof deflector is designed with a knife-edge shape, failure of the sunroof motor, this method can be used to open
which includes the formed leaf spring fitted on the front of and close the sunroof, but the operation shall be performed
the guide rail. slowly.
The sunroof glass is made of safety glass. The front and rear 1. Remove the front reading lamp assembly.
sunroof glass panels are fixed on the sunroof assembly by 6 Front Reading Lamp Assembly - With Sunroof
screws. Switch Remove
The sunroof sunshade is in the slot on the inner edge of the 2. Insert an Allen hexagon wrench into the hole
front frame side rail, the scroll of the sunshade is behind the (appr. 40mm) under the cover, turn the sunroof
frame. The operation of the sunroof sunshade is controlled by counterclockwise to open it.
a motor.
The sunroof assembly is provided with a drainage control

system. Water can be introduced into the drain pipe through
the drain gutter, and then enters into each wheel house via
the drain pipe.
Sunroof Switch
The sunroof switch controls the lifting and slide of the sunroof
glass assembly and the operation of the sunshade.
Sunroof Glass
The rotation of the switch controls the contacts inside the

switch and transfers the signal output to the motor and drive
unit of the sunroof assembly. The sunroof electronic control
unit (ECU) analyzes signals and powers the motor to drive the 3. Fit the front reading lamp assembly.
sunroof glass panel to move in the required direction. Front Reading Lamp Assembly - With Sunroof
Switch Refit
Sunroof Sunshade
It is activated when the system is running, press the control

switch of the sunroof sunshade to open or close the sunshade.
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Operation Anti-pinch Function
Operation of Sunroof Assembly When being closed by automatically sliding, the sunroof glass
Sunroof Switch Operation and sunshade will stop movement and automatically open after
encountering an obstacle to allow to remove the obstacle. In
The sunroof control unit drives the sunroof motor to open,
case of low battery, the anti-pinch function is ineffective.
tilt or close by sliding according to the input command from
the sunroof switch, and drives the sunshade motor to open or Initialization of Sunroof Assembly
close by sliding. Sunroof operation will be influenced by power failure when
Entertainment Display Operation sunroof glass or sunshade is in motion, and it is necessary to
initialize after power on.
The entertainment display transmits an operation command to
BCM through body HS CAN bus, the command will then be Window Initialization:
transmitted to the sunroof control unit by BCM through LIN Close the window, pull down the sunroof window switch
bus, at last, the driver motor will open, tilt or close the sunroof and hold it for approximate 10 seconds, and the window
and sunshade by sliding. will automatically open by sliding for a distance during which
Mechanical Key Operation the switch shall keep being pulled down and then close
automatically.
When the driver door is locked with the mechanical key and
the locking operation maintains for more than 2 seconds, the Sunshade initialization:
lock signal will be transmitted to the sunroof control unit by Close the sunshade, press the close button of sunshade and
BCM via LIN bus to drive the sunroof motor to close, and all hold for 10 seconds, and the sunshade will automatically open
windows will be closed simultaneously. by sliding for a distance during which the switch shall keep being
pulled down and then close automatically.
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Service Procedures 2.3 Totally remove the front and rear glass panels of the sunroof
Sunroof Assembly assembly, and place properly.
Remove 2.4 Ensure there is no deformation for the guide rail groove
1. Disconnect the battery negative cable. cavity, and no damage and scratch on surface coating.
2. Remove the interior roof trim panel. 2.5 Move the sunroof to Off state, put the special tool into
Interior Roof Trim Panel Remove the guide rail (1), rotate it for 90° (2); then push the tool (3)
toward the rear of guide rail to clean out the foreign material
3. Disconnect the connection of 4 drain tubes from the
and grease (4), and remove the grease for the whole guide rail.
sunroof assembly.
4. Remove 18 bolts securing the sunroof assembly onto
the vehicle body, and remove the sunroof assembly by
help.
2.6 Clean the removed foreign material and grease from the
tool, fully open the sunroof, and repeat step 2.4 to remove the
foreign material and grease from the front of guide rail. Put
Refit the tool in → Move to the front of guide rail, then rotate the
tool for 90° → Push the tool toward the rear of guide rail →
1. Locate the sunroof assembly onto the vehicle body by
Remove the foreign material and grease.
help, and tighten the bolts to 7–9Nm, and check the
torque. 2.6 Put the grease application tool into the guide rail, rotate
2. Connect the drain tube to the sunroof assembly. for 90°, and apply grease evenly on the surface of the whole
guide rail.
3. Refit the interior roof trim panel.
2.7 Apply the special grease as least as oily reflection can be
Interior Roof Trim Panel Refit
seen, but a large bump on the surface is not allowed as most.
2.8 Apply grease on the blocks at two corners of front glass
Grease Maintenance and Troubleshooting
panel.
1. Tool Preparation
1.1 Fit the special grease removal/application tool to the front

part of the special grease package, and ensure it is fitted in
place.
1.2 After using, clean the special grease removal/application

tool for further use.
2. Clean Panoramic Sunroof and Remove, Apply Special

Grease
2.1 Totally remove the front and rear glass panels of the sunroof
assembly, and place properly.
2.2 Clean the dust and dirt on the sunroof glass panel and
the exposed surface. Clean the foreign material on the guide
rail on which the mechanical structure is running and the glass 2.9 Make sure that the special grease is applied evenly in the
panel edge. guide rail groove cavity, fit the glass panel back to the sunroof
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assembly, run the sunroof glass panel for 10 times to confirm it
works normally. Sunroof clean and maintenance is completed.
3. Instructions after the Roof with Panoramic Sunroof

Exposed to the Sun
3.1 Totally remove the front and rear glass panels of the sunroof
assembly, and place properly. Ensure there is no deformation
for the guide rail groove cavity, and no damage and scratch on
surface coating.
3.2 Loosen the bolts connecting the sunroof frame and the
roof, adjust the sunroof frame to the middle position, i.e., align
with the position of front drain gutter and rear drain gutter
relative to the locating holes in the roof.
• Front Drain Gutter Locating Hole 3.5 Apply the lateral force of sunroof centre outward on the
guide rail in serious conditions, move the guide rail outward
and then tighten the connecting bolt.
• Rear Drain Gutter Locating Hole
3.6 Fit the glass panel back to the sunroof assembly, run the
sunroof glass panel for 10 times to confirm it works normally.
3.3 Tighten the retaining bolts of front and rear drain gutter
after aligning to appropriate position.
3.4 After ensuring the sunroof can work normally, tighten the
bolts fixing the sunroof guide rail and the roof on by one.
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Front Sunroof Glass Panel Rear Sunroof Glass Panel

Remove Remove
1. Open the sunroof sunshade. 1. Remove the front sunroof glass panel.
2. Open the sunroof by sliding slightly. Front Sunroof Glass Panel Remove
3. Remove the sunroof flex molding. 2. Remove the bolt securing rear sunroof glass panel onto
4. Remove the screw securing the front sunroof glass the bracket (6 bolts on both sides in total).
panel onto the bracket (6 screws on both sides in total). 3. Take off the rear sunroof glass panel.
Refit
1. Fix the rear sunroof glass panel onto the bracket, fit 6
screws, tighten to 4.5–5.5Nm and check the torque.
2. Refit the front sunroof glass panel.
Front Sunroof Glass Panel Refit
5. Remove the front sunroof glass panel assembly and do

not move manually to refit the brackets on both sides
of 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 allow it to keep
consistent with the roof sheet metal radian, tighten the
screws to 4.5–5.5Nm, and check the torque.
3. Refit the sunroof flex molding.
4. Initialize the sunroof glass motor.
Sunroof Glass Motor Initialization
5. Operate the front sunroof glass panel to check for the
mounting.
6. Close the sunroof sunshade.
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Sunroof Sunshade 7. Remove 2 screws (3) fixing the sunroof sunshade
Remove assembly to the sunroof.
1. Remove the roof interior trim.
Roof Interior Trim Remove
2. Remove the front sunroof glass panel.
Front Sunroof Glass Panel Remove
3. Remove the bolt fixing the rear sunroof glass panel to
the bracket (6 bolts on both sides in total).
8. Slide the sunroof sunshade backwards to remove.

Refit
1. Fix the sunroof sunshade to the sunroof assembly, fit 2
bolts, tighten to 1.8–2.2Nm and check the torque.
2. Refit the sunroof sunshade limit block to the sunshade
and tighten up.
4. Remove the rear sunroof glass panel. 3. Fix the sunroof weatherstrip to the sunroof and fit 2
5. Remove 2 screws fixing the sunroof weatherstrip on screws and tighten up.
the sunroof. 4. Operate the sunroof sunshade to check for the
mounting.
5. Fix the rear sunroof glass panel to the bracket, fit 6
6. Refit the front sunroof glass panel.
Front Sunroof Glass Panel Refit

7. Fit the roof interior trim.
Roof Interior Trim Refit
6. Release the clip and remove the sunroof sunshade limit

block.
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Sunroof Glass Motor Sunroof Sunshade Motor

Remove Remove
1. Close the front sunroof glass panel and disconnect the 1. Disconnect the battery negative cable.
battery negative. 2. Remove the roof interior trim.
2. Remove the front reading lamp assembly.
Front Reading Lamp Assembly - with Sunroof 3. Disconnect the sunroof sunshade motor connector (1).
Switch
4. Remove 3 screws (2) securing the sunroof sunshade
3. Disconnect the sunroof glass panel motor connector motor onto the sunroof.
(2).
4. Remove 3 screws (1) fixing the sunroof glass motor
to the sunroof assembly.
5. Take out the sunroof glass panel motor.
Refit
1. Locate the sunroof motor, and engage the motor drive
gear into the sunroof cable.
2. Fix the sunroof glass panel motor to the sunroof, fit 3
3. Connect the connector of the sunroof glass panel
motor.
4. Fit the front reading lamp assembly.
5. Remove the sunroof sunshade motor.
Front Reading Lamp Assembly Refit
Refit
1. Locate the sunroof sunshade motor, and engage the
6. Learn the sunroof glass motor by oneself.
motor drive gear in the sunroof sunshade cable.
Sunroof Glass Motor Initialization 2. Fix the sunroof sunshade motor to the sunroof, fit 3
screws, tighten to3.15–3.85Nmand check the torque.
3. Connect the sunroof sunshade motor connector.

6. Perform a self-learning for the sunroof sunshade motor.
Sunroof Sunshade Motor Initialization
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Sunroof Harness Sunroof Air Deflector
Remove Remove
1. Remove the roof interior trim. 1. Open the sunroof by sliding.
Roof Interior Trim Remove 2. Remove 5 screws securing the sunroof deflector onto
the sunroof.
2. Disconnect the sunroof harness and the roof harness.
3. Disconnect the sunroof switch connector.
4. Disconnect the sunroof glass panel motor connector
(2).
3. Release the clip securing the sunroof deflector and

remove the deflector.
Refit
1. Refit the sunroof deflector and secure with clips.
5. Disconnect the sunroof sunshade motor connector (1).
2. Fix the sunroof deflector onto the sunroof, fit 5 screws
6. Remove the clip fixing the sunroof harness to the
and tighten up.
sunroof, and take away the sunroof harness.
Refit
1. Fix the sunroof harness onto the sunroof and tighten
with clip.
2. Connect the sunroof sunshade motor connector.
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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Left Front Sunroof Drain Pipe Right Front Sunroof Drain Pipe
Remove Remove
1. Remove the roof interior trim. 1. Remove the roof interior trim.
Roof Interior Trim Remove Roof Interior Trim Remove

2. Remove the left A pillar upper trim panel. 2. Remove the right A pillar upper trim panel.
A Pillar Upper Trim Panel Remove A Pillar Upper Trim Panel Remove
3. Remove the driver side lower trim panel assembly. 3. Disconnect the right front sunroof drain pipe from the
sunroof drain gutter (1).
4. Remove the right front sunroof drain pipe (2) from the
4. Disconnect the left front sunroof drain pipe from the
clip.
sunroof drain gutter (1).
5. Remove the left front sunroof drain pipe (2) from the
clip.
Refit
1. Fit the right front sunroof drain tube to the clip.
Refit 2. Fit the right front sunroof drain tube onto the sunroof
drain gutter.
1. Fit the left front sunroof drain pipe to the clip.
3. Refit the right A-pillar upper trim panel.
2. Fit the left front sunroof drain pipe to the sunroof drain
gutter. A Pillar Upper Trim Panel Refit
3. Fit the driver side lower trim panel assembly. 4. Fit the roof interior trim.
Driver Side Lower Trim Panel Assembly Refit Roof Interior Trim Refit
4. Fit the left A pillar upper trim panel.
A Pillar Upper Trim Panel Refit

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Left Rear Sunroof Drain Pipe Right Rear Sunroof Drain Pipe
Remove Remove
1. Remove the roof interior trim. 1. Remove the roof interior trim.
Roof Interior Trim Remove Roof Interior Trim Remove

2. Remove the left D pillar upper trim panel. 2. Remove the right D pillar upper trim panel.
Left D Pillar Upper Trim Panel Remove Right D Pillar Upper Trim Panel Remove
3. Remove the left trunk trim panel. 3. Remove the right trunk trim panel.
Left Trunk Trim Panel Remove Right Trunk Trim Panel Remove
4. Disconnect the left rear sunroof drain pipe from the 4. Disconnect the right rear sunroof drain pipe from the
sunroof drain gutter (1). sunroof water chute.
5. Remove the left rear sunroof drain pipe (2) from the 5. Remove the right rear sunroof drain pipe from the clip.
clip .
6. Remove the right rear sunroof drain pipe.

6. Remove the left rear sunroof drain pipe. Refit
Refit 1. Refit the right rear sunroof drain tube.
1. Refit the left rear sunroof drain pipe. 2. Fix the right rear sunroof drain tube to the clip.
2. Fix the left rear sunroof drain pipe to the clip. 3. Fit the right rear sunroof drain pipe to the sunroof
3. Fit the left rear sunroof drain pipe to the sunroof water drain gutter and tighten it.
chute and tighten it. 4. Refit the right trunk trim panel.
4. Refit the left trunk trim panel.
Right Trunk Trim Panel Refit
Left Trunk Trim Panel 5. Refit the right D pillar upper trim panel.
5. Refit the left D pillar upper trim panel.
D Pillar Upper Trim Panel Refit 6. Fit the roof interior trim.
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Exterior Fitting Wipers and Washer
Wipers and Washer

Specifications
Torque
Description Value
Nut - wiper arm to linkage spindle 8–10Nm
screw - linkage spindle to bodywork 7–10Nm
screw - from wipe motor to linkage spindle 28–32Nm
screw - filler neck of washer reservoir to bracket of headlamp 4–6Nm
Bolt- wiper container to bodywork 4–6Nm
Nut -rear wiper arm to motor shaft 8–10Nm
screw -rear wiper motor to tailgate 7–10Nm
1.0 934
Wipers and Washer Exterior Fitting
System Layout
Wiper Exploded View
1. Windshield Wiper Linkage/Motor Assembly 7. Rear Window Wiper Motor

2. Windshield Wiper Motor 8. Rear Window Wiper Nozzle
3. Driver Side Wiper Arm Assembly 9. Rear Window Wiper Shaft Cap
4. Driver Side Wiper Blade Assembly 10. Rear Window Wiper Arm Assembly
5. Front Passenger Side Wiper Arm Assembly 11. Rear Window Wiper Blade Assembly
6. Front Passenger Side Wiper Blade Assembly
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A=Chassis HS CAN Bus ； B=Body HS CAN Bus ； C=Power HS CAN Bus D=Hard Wire ； E=LIN Bus
1.0 936
Description switch is off, the wiper will finish a complete wipe cycle at low
Overview speed until the motor stops.
The wiper and washer is controlled by the body control Low Speed Wipe
module (BCM), which will operate after receiving the When the switch is turned on and locked in the low speed
command from the driver. All wiper functions are controlled position, the wiper will wipe continuously at low speed.
by the wiper/washer lever switch assembly on the right side
High Speed Wipe
of the steering wheel. The wiper and washer system includes:
When the switch is turned on and locked in the high speed
• Front Wiper Motor
position, the wiper will wipe continuously at high speed.
• Front Wiper Linkage Mechanism
Auto Wipe (With Rain Sensor)
• Two Arms and Blades of Front Wiper
The activation/deactivation and the optimum wipe speed of the
• Two Windshield Washer Nozzles of Front Wiper
auto wipe function is determined by the BCM according to the
• Washer Reservoir, Windshield Washer Pump signal transmitted by the rain sensor through the LIN bus. The
• Rear Wiper Motor rain sensor sends a status signal to the BCM every 10 seconds
• Rear Wiper Lever and Blade through the LIN and informs the BCM that the rain sensor is
in normal state.
• Rear Window Washer Nozzle
• Wiper Lever Switch Intermittent Wipe
The intermittent wipe is controlled by the BCM. When the
The wiper can be operated when the ignition switch is on. All
switch is in the intermittent position, the BCM starts single
wiper functions will be suspended at the moment of engine
low speed wipe operation. The wiper blades are kept in the
starting.
stop position between two wiper actions until the selected
Wiper/Washer Lever Switch delay period comes to an end. Use the 4-bit rotary switch
The wiper lever switch consists of a 5 gear toggle switch and located at the end of the wiper lever to select the length of
a rotary switch. The switch of intermittent wipe, low/high delay. If a longer delay time is reselected during intermittent
speed wipe and "OFF" position are locked, while the switch operation, this delay time will be executed for the next wipe
of single wipe and programmed wipe/wash are unlocked. Use operation. If a shorter delay time is reselected during this
the rotary switch to select intermittent delay. period, this delay time will be executed immediately. After the
intermittent wipe is selected, if the programmed wipe/wash
Functions of Wiper
function is required, the programmed wipe/wash operation
The wiper system supports the following functions: starts immediately, and the intermittent wipe function will
• Programmed Wash/Wipe restart after the programmed wipe/wash operation comes to
an end and the motor reaches the stop position.
• Single Wipe
• Low Speed Wipe Speed-sensitive Intermittent Wipe
• High Speed Wipe When the switch is in intermittent, low speed or high speed
position, the BCM will adjust the interval of intermittent wipe
• Auto Wipe (With Rain Sensor)
according to the vehicle speed. ABS ECU monitors the wheel
• Intermittent Wipe (adjusted according to speed delay
speed signal and transmits it to the BCM through HS CAN
adjustment)
bus.
Programmed Wash/Wipe
If the wiper switch is in the intermittent position, the BCM
When pulling the lever switch towards the steering wheel, adjusts the selected delay time by comparing vehicle speed with
the washer will operate immediately. After a short interval, the resistance corresponding to the intermittent delay rotary
the wiper will work with the washer. After the lever switch switch.
is released, the wiper will keep wiping for 3 times. After
several seconds, the wiper will wipe once more to eliminate When the wiper switch is ON and locked in low speed, and
the washing fluid on the windshield. the vehicle speed is less than 8 km/h, the BCM will activate
the intermittent wipe function, and the set rotary switch will
Single Wipe determine the appropriate delay time.
After the wiper/washer lever switch is pressed and quickly
When the wiper switch is ON and locked in high speed, and
released, the wiper completes a low speed wipe cycle. If the
the vehicle speed is less than 8 km/h, then the wiper will work
switch is on all the time, the wiper will quickly run, when the
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at low speed. When the vehicle speed is above 8 km/h, the clean the windshield at any mode and decrease noise and wind
wiper will resume the speed-sensitive intermittent wipe. resistance.
Wiper Washer
The wiper motor is below the air inlet grille at the bottom of The washer system consists of the washer reservoir, washer
the windshield, which is fitted to a linkage mechanism on the reservoir neck, washer pump, washer nozzle, check valve, hose
support between the inner and outer compartment walls. and hose connector.
The motor is a DC motor which drives the worm gear through The washer reservoir is located in the left wheel house, with a
the worm attached to the motor spindle. The outside of the capacity of about 6 liters. The engine compartment is provided
worm gear is connected to the linkage which can drive the with a filler neck with seal cap which can be used to refill the
wiper arm attached to the worm gear box at the end of the washer reservoir. A washer pump is also provided below the
linkage. washer reservoir.
The wiper arm is fitted to the output shaft of the linkage. Each When the washer pump is enabled, it will pump the fluid
wiper arm has a pivot between the arm and arm mounting in the washer reservoir into the washer nozzle under the
point. A spring is connected to both ends of the pivot to apply action of pressure. The check valve of the tailgate washer
appropriate pressure to the wiper blade on the windshield. can prevent fluid from flowing back to the washer reservoir
through the nozzle and hose, and thus ensures the washer is
The blade of the boneless wiper is fixed to the wiper arm
instant available.
by clips, which can rotate freely around the mounting point
of the wiper arm. This structure ensures that the wiper can
1.0 938
Operation Single Wipe
Overview When a valid single wipe request from the front wiper is
The front/rear wipers and washers are controlled by the BCM. received, BCM will control the front wiper to work at low
When the BCM receives an ON signal from the washer/wiper speed. If the single wipe request is valid, the wiper will keep
lever switch connecting with the hard wire, it drives the washer working at low speed.
pump and wiper motor to work. The bidirectional washer Programmed Wash/Wipe
pump provides washer fluid for the front and rear windows,
With the ignition switch in the ON position and the front wiper
the front washer pump is indirectly controlled by the BCM,
switch enabled, the BCM controls the front wiper to work at
and the rear washer pump is directly controlled by the rear
low speed, enables the washer pump and triggers the internal
window washer switch.
counter. When the counter value achieves the set value, the
Front Wiper/Washer BCM closes the relay, and the front wiper starts to work.
The front wiper includes the BCM, washer/wiper lever switch When the driver release the washer/wiper lever, the washer
and two relays. One of the relay (1) is used to turn on/off the pump and front wiper stop.
wiper, and the other (2) is used to control the wiper speed. Caution: During engine start, the windshield washer
When the BCM receives signals from the washer/wiper lever is disabled.
switch, it drives the front wiper to work by closing the two
Front Wiper Stop
wiper relays in the engine compartment fuse box.
With the ignition switched to ON posiition, turn the wiper
The switches for single wipe, intermittent wipe, low/high speed
switch of the washer/wiper lever to "OFF" position, the wiper
wipe form a closed circuit with the BCM through relay 1 or 2.
relay disconnects immediately and the front wiper then stops
When the ignition switch is in the 1st/2nd gear, the output promptly.
status of the front wiper is as follows:
If turn off the ignition switch when the wiper is working, the
Relay Switch Status wiper relay will remain closed, even if the washer/wiper lever
Front Wiper is in "OFF" position, when the wiper shifts to the "RESET"
Switch 1 Switch 2
Mode position at low speed, the relay disconnects automatically and
Stop 0 0 the wiper stops working.
Single Wipe 1 0 Front Wiper Failure Protection
Auto Wipe 1 0
When the front wiper is enabled, the BCM monitors the
Low Speed Wipe 1 0 position signal of the front wiper switch. If the ignition switch
High Speed Wipe 1 1 is in "OFF" position, but the switch of the front wiper remains
0 = Disconnected 1 = Closed in the original status, the relay of the front wiper will also
disconnect automatically.
High Speed Wipe
Rear Wiper/Washer
When choosing high speed mode for the front wiper, the BCM
will send a signal to the wiper relay. When relay 2 closes, When a valid request from the rear wiper switch is received,
the power supply bypasses the resistor for deceleration and BCM will control the corresponding relay to work.
connects the motor directly, at this stage, the wiper works at Intermittent Wipe
high speed.
When the ignition switch is in the ACC/ON position, if the
Low Speed Wipe BCM detects that the rear wiper switch is activated, it controls
When choosing low speed wipe mode, the BCM sends a signal the rear wiper to work at low speed, enables the washer pump
to the wiper relay. The power supply passes through relay 1 and triggers the internal counter. When the counter value
before connecting with the motor by a resistor. The resistor achieves the set value, the BCM closes the relay, and the rear
reduces the power, so the wiper works at low speed. wiper starts to work.
Auto Wipe Programmed Wiper

When auto wipe mode is selected, the BCM determines the When the rear wiper switch is activated, the washer pump is
activation/deactivation and the optimum wipe speed according enabled, and the BCM monitors the status of the rear wiper
to the signal from the rain sensor. The rain sensor sends a switch and counts. If the switch is not released, the BCM will
signal to the BCM every 10 seconds and informs the BCM activate the rear wiper relay, then the rear wiper keep working.
that the rain sensor is in normal state.
1.0 939
R Gear Wipe Rear Window Washer/Wiper Failure

When the ignition switch is in the ACC position, and If the tailgate is open, the wiper/washer of the rear window
the front washer/wiper lever switch is in high speed/low will be disabled for any mode.
speed/intermittent mode, if the shift lever is in R gear, the
If the BCM detects that the tailgate is open when the rear
BCM will apply the rear wiper relay automatically after several
wiper is working, the rear wiper will be disabled immediately.
seconds and activate the rear wiper, this does not affect the
After the tailgate is closed, the rear wiper returns to normal
front wiper.
state after appr. 5s' delay, this provides enough time for the
user to take his hands away from the wash/wipe area.
1.0 940
Service Procedures Wiper Arm Assembly
Rain Sensor Remove
Remove 1. Remove the mounting shaft cover of the wiper arm.
2. Remove the rain sensor cover by left and right halves
respectively.
2. Remove the nuts securing the wiper arm onto the

linkage mechanism.
3. Remove the arm assembly from the linkage mechanism.
3. Disconnect the rain sensor harness connector. Refit
4. Remove the rain sensor from the interior mirror base. 1. Fit the wiper arm onto the linkage mechanism.
Refit 2. Fit the nuts onto the shaft of linkage mechanism, tighten
1. Refit and secure the rain sensor onto the interior to 8–10Nm, and check the torque.
mirror base with the clip. 3. Refit the shaft cover of the wiper arm.
2. Connect the rain sensor harness connector.
3. Refit the left and right halves of rain sensor cover
together.
4. Refit the assembled rain sensor cover onto the interior
mirror base with the clips from top to bottom.
1.0 941
Wiper Motor and Linkage Mechanism Windshield Wiper Motor

Remove Remove
1. Disconnect the battery negative. 1. Disconnect the battery negative cable.
2. Remove the A/C air intake grille assembly. 2. Remove the wiper motor and linkage mechanism
assembly.
3. Remove 3 bolts fixing the linkage mechanism to the Wiper Motor and Linkage Mechanism Assembly
body. Remove
3. Remove 3 bolts (1) and 1 nut (2) securing motor onto
the linkage mechanism.
4. Disconnect the connector of the windshield wiper

motor.
5. Remove the windshield wiper linkage and motor 4. Remove the windshield wiper motor.
assembly. Refit
Refit 1. Fix the windshield wiper motor onto the linkage
1. Connect the windscreen wiper motor. mechanism, fit 3 bolts and 1 nut, tighten to 28–32Nm,
2. Refit the windscreen wiper linkage and motor assembly,
fit 3 screws and tighten to 7–10Nm, and check the 2. Refit the wiper motor and linkage mechanism assembly.
torque. Wiper Motor and Linkage Mechanism Assembly
3. Fit the A/C air intake grille assembly. Refit
A/C Air Intake Grille Assembly Refit 3. Connect the battery negative cable.
1.0 942
Wiper Blade Assembly Washer Reservoir Spout Assembly
Remove Remove
1. Lift the wiper arm away from the windscreen. 1. Remove 1 bolt securing the washer reservoir nozzle
2. Press the button on the wiper arm, and pull the upper onto the left headlamp bracket.
end of the wiper blade outward to disengage from the
wiper arm.
3. Remove the wiper blade from the wiper arm.
Refit
1. Put the fitting on new wiper blade into the slot of the
wiper arm.
2. Push the wiper blade towards the wiper arm until the
wiper blade is fully embedded.
3. Put the wiper assembly back onto the windscreen, and
check whether the wiper blade is fixed correctly onto
the wiper arm.
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 left headlamp bracket, and tighten to 4–6Nm, and
check the torque.
1.0 943
Washer Reservoir Assembly Washer Pump Assembly

Remove Remove
2. Remove the washer pump. 2. Remove the front bumper.
Washer Pump Assembly Remove Front Bumper Assembly Remove
3. Remove the left front wheelhouse liner. 3. Disconnect the washer pump connector (2).
Front Wheelhouse Liner Remove 4. Put one container under the washer reservoir.
4. Remove the washer reservoir spout. 5. Remove the washer pump from the washer reservoir.
6. Disconnect the hose of the rear window washer pump
Washer Reservoir Spout Assembly Remove
(3).
5. Remove 4 bolts fixing the washer reservoir to the body.
7. Disconnect the hose of the windshield washer pump
(1), and take away the washer pump.
6. Remove the washer reservoir.

Refit Refit
1. Fit 4 bolts fixing the washer reservoir to the body,
1. Fit the washer pump onto the washer reservoir.
2. Connect the windshield washer pump hose (1).
2. Refit the washer reservoir spout.
3. Connect the rear window washer pump hose (3).
Washer Reservoir Spout Assembly Refit
4. Connect the washer pump connector (2).
3. Refit the washer pump assembly.
5. Refill windscreen washer fluid.
Washer Pump Assembly Refit 6. Fit the front bumper.
4. Fit the left front wheelhouse liner.
Front Wheelhouse Liner Refit 7. Connect the battery negative cable.
1.0 944
Rear Wiper Arm Assembly Rear Wiper Blade Assembly
Remove Remove
1. Pry off the rear window wiper arm shaft cover and 1. Raise the wiper blade from the rear window.
remove it. 2. Pull the connection of wiper blade and wiper arm and
2. Remove the 1 nut securing the rear window wiper arm take out the wiper blade from the wiper arm and
assembly to the rear window. remove it.
Refit
1. Insert the wiper blade into the connection with wiper
arm.
2. Put the wiper arm onto the rear window.
3. Remove the rear window wiper arm assembly.

Refit
1. Fit the rear window wiper arm onto the wiper motor
shaft.
2. Fit the nuts onto the shaft, tighten to 8–10Nm, and
check the torque.
3. Refit the rear wiper arm mounting shaft cover.
4. Ensure that the wiper blade is fitted to the correct
initial position and is aligned with the dot on the black
edge of the glass.
1.0 945
Rear Window Wiper Rod Shaft Cap Rear Wiper Motor

Remove Remove
1. Pry off the rear window wiper arm shaft cover and 1. Disconnect the battery negative.
remove it. 2. Remove the rear window wiper arm assembly.
Refit
Rear Wiper Arm Assembly Remove
1. Fit the rear window wiper arm shaft cover.
3. Remove the seal ring of rear wiper motor from the
wiper motor output shaft.
4. Remove the tailgate trim panel.
Tailgate Interior Trim Panel Remove

5. Disconnect the electrical connector (3) and rear
washer water pipe.
6. Remove 2 nuts (1) and 1 screw (2) fixing the rear
window wiper motor assembly to the tailgate.
7. Remove the rear window wiper motor assembly.

Refit
1. Fit the rear window wiper linkage mechanism assembly
with 2 nuts and 1 screw, and tighten them to 7–10Nm.
2. Connect the electrical connector and rear washer
water pipe.
Tailgate Interior Trim Panel Refit

4. Fit the seal ring and rear window wiper arm assembly.
Rear Wiper Arm Assembly Refit

equipped.
1.0 946
Windshield Nozzle Rear Window Nozzle
Remove Remove
1. See "A/C Air Intake Grille Assembly Remove". 1. Take off the rear wiper arm mounting shaft cover.
Refit 2. Remove the nozzle.
1. See "A/C Air Intake Grille Assembly Refit".
Refit
1. Refit the nozzle and adjust the angle.
2. Refit the rear wiper arm mounting shaft cover.
1.0 947
Windshield Nozzle Hose Windshield Washer Pump Hose

Remove Remove
1. Remove the A/C air intake grille assembly. 1. Remove the front bumper.
A/C Air Intake Grille Assembly Remove Front Bumper Assembly Remove
2. Disconnect the windshield nozzle hose form the nozzle. 2. Put the container under the washer pump.
3. Disconnect the hose from the windshield washer pump.
3. Remove the hose.

Refit 4. Remove the A/C air intake grille assembly.
1. Connect the windshield nozzle hose.
5. Disconnect the windshield washer pump hose from the
A/C Air Intake Grille Assembly Refit windshield nozzle hose.
6. Remove the 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. When laying the pipeline to the upper seal ring, cut off
the used hose passed through the seal ring and use the
new one instead.
1.0 948
Rear Window Washer Pump Hose
Remove
2. Put the container under the washer pump.
3. Disconnect the hose from the rear window washer
pump.
4. Connect the washer pump hose and the nozzle hose.

A/C Air Intake Grille Assembly Refit


Tailgate Trim Panel Remove
5. Disconnect the hose of the rear window washer pump
from the check valve.
6. Remove the hose of the rear window washer pump.

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 rear window washer pump hose to the
check valve.
Tailgate Trim Panel Refit
1.0 949
Rear Window Nozzle Hose Rear Window Washer Check Valve

Remove Remove
1. Remove the tailgate trim panel. 1. Remove the tailgate trim panel.
Tailgate Trim Panel Remove Tailgate Trim Panel Remove

2. Disconnect the rear window nozzle hose. 2. Disconnect the check valve.
3. Remove the check valve.
3. Remove the rear window nozzle hose.

Refit Refit
1. Connect the rear window nozzle hose. 1. Refit the check valve and connect the pipeline.
2. Refit the tailgate trim panel. 2. Refit the tailgate trim panel.
Tailgate Trim Panel Refit Tailgate Trim Panel Refit
1.0 950
Lighting Lighting Systems
Lighting
Specifications
Torque
Description Value
Nut-Microphone to roof 1.5–2Nm
Bolt-Grab handle to Handle bracket 5–7 Nm
1.0 951
Lighting Systems Lighting

System Layout
Interior Lighting Layout
1. Vanity Mirror Lamp (if fitted) 5. Rear Reading Lamp

2. Front Reading Lamp with Sunroof Switch 6. Luggage Compartment Lamp
3. Front Reading Lamp 7. BCM
4. Glove Box Lamp
1.0 952
A=LIN Bus ； B=Hard Wire
1.0 953
Description Front reading lamp assembly includes 3 switches and 2 bulbs.

Overview The front reading lamp of high-configuration model is equipped
with sunroof switch. The assembly is fixed with 2 screws, and
The interior lighting system is controlled by the BCM at the
secured on the roof interior trim panel with 2 spring clamps.
left front side panel.
The front reading lamp of low-configuration model is fixed on
Interior lighting system includes: roof interior trim panel with spring clamps.
• Front Reading Lamp The front reading lamp bulb applies the single filament bulb.
• Rear Reading Lamp The front reading lamp lens is subtransparent, this can ensure
• Glove Box Lamp (if equipped) even interior illumination.
• Vanity Lamp (if equipped) When replacing the bulb, remove the lamp lens, slightly pull
• Trunk Lamp the bulb to remove it; and push it into the lamp holder to fit it.
Front Reading Lamp Assembly Rear Reading Lamp

The rear reading lamp assembly is in the centre of rear handle
of roof, and is fixed on the roof interior trim panel.
Trunk Lamp
The truck lamp is on the left interior trim panel of the trunk.
The outside is a plastic case which includes the lens and lamp
clamp. When the trunk is open, the trunk lamp will be lighted
up automatically.
Glove Box Lamp ( if equipped )
Glove box lamp is in the hole of upper right side of the glove
box, when the cover opens, the glove box lamp will be lighted
up automatically.
Vanity Lamp ( if equipped )
• Front Reading Lamp - with Sunroof Switch
The vanity lamp is on the roof interior trim of the sun visor,
with the translucent lens, carefully pry off the lens and remove
the bulb.
When opening the vanity mirror cover, the vanity lamp

illuminates.
Bulb Specification
Bulb Bulb Type Voltage Power
Front Interior W5W 12V 5W
Lamp
Rear Interior W5W 12V 5W
Lamp
Glove Box Lamp C10W 12V 10W
• Front Reading Lamp - without Sunroof Switch Trunk Lamp C10W 12V 10W
The front reading lamp is in the central roof interior trim panel
above the windshield.
1.0 954
Operation lamp switch is pressed, the interior lamp will be
Overview disabled at once.
BCM receives signals of the interior lighting system. When Manual Mode PWM Control:
the BCM receives the activation signal from the reading lamp,
Press the master switch on the front reading lamp
door or tailgate, it will illuminate the corresponding lamp inside
assembly to turn on/off the front/rear reading lamps.
the vehicle. When the BCM detects that the headlamp is
When the interior lamp is turned on/off manually, the
on or the light is dim by the solar/light sensor (if fitted), the
auto delay function will be cancelled. In this mode, if you
BCM controls the backlight of the instrument panel and some
lock the door with the remote control or mechanical key,
switches.
the auto mode PWM control function will resume.
BCM controls the operation range of the interior lighting
Manual shift between control modes:
system:
In auto mode, long press the interior lamp switch for
1. Interior Door Lighting Controlled by PWM
more than 5s to cancel the auto mode; and when the
Press the roof lamp switch to illuminate the corresponding auto mode is disabled, long press the interior lamp switch
lamp. Interior lamps include the front/rear reading lamps, for more than 5s to activate the auto mode.
switch backlight and LED indicator lamp. The interior
2. The interior door lighting delay power control includes:
lamp illuminated will turn off at the time of engine
start-up, but it will resume automatically afterwards. a. Front Reading Lamp
The interior door lighting system can be controlled by b. Rear Reading Lamp
auto mode or manual mode. c. Left/Right Vanity Mirror Lamp (if equipped)
Auto Mode PWM Control:
d. Glove Box Lamp (if equipped)
No need to press the switch, the BCM will control the
Delay Control (if equipped)
working status of the interior lamp according to the
signal received. BCM controls the interior lighting system by the relay. The
interior lamp includes reading lamp, vanity mirror lamp (if
The interior lamp will illuminate automatically under the
equipped) and glove box lamp (if equipped). Under the
following conditions:
following situations, the BCM controls the delay of the
a. When pressing the UNLOCK button on the remote front/rear reading lamps by disconnecting the delay relay.
key, use the mechanical key or PEPS module (if fitted)
• Ignition Switch in 1st Gear
to unlock the door, the front/rear reading lamps
illuminate gradually. If the door is not opened within • When the UNLOCK button on the remote key is
30s, the front/rear reading lamps will dim gradually. pressed, and the door is unlocked by the PEPS module
(if equipped) or mechanical key.
b. After the ignition switch is off, the reading lamp will
illuminate gradually. If the door is not opened within The delay function may fail under the following conditions:
30s, the reading lamps will dim gradually. • 15min since the ignition is OFF
c. If the interior lamps illuminate, all doors are in a • When the LOCK button on the remote key is pressed,
closed state. When the ignition switch is shifted to and the door is locked by the PEPS module (if equipped)
other gears from the 1st gear, the interior lamps will or mechanical key
dim gradually in 30s. • When the vehicle is in the anti-theft state
d. When you press the LOCK button on the remote • When the vehicle is locked externally
key or lock the doors with the mechanical key/PEPS • When the ignition switch in "START" position
module (if equipped), the interior lamps will dim
LEDInterior Backlight Illumination Control
gradually.
When the width lamp is enabled or the BCM determines
e. When all doors are in the closed state and the
that the signal of the solar/light sensor (if equipped) is for
ignition switch is in the 1st gear, the interior lamps
night driving, the LED and backlight on the instrument panel
will dim gradually.
illuminate. It also provides LED backlight illumination for
Note: In auto mode PWM control, once the impact the ignition switch (if equipped), entertainment system, cigar
sensor is triggered, the interior lamp will lighter, rearview mirror control button, passive start ignition
illuminate immediately, and when the interior switch (if equipped), upper/lower centre console switch,
1.0 955
auxiliary A/C instrument panel, HMI (front panel) and hazard The illumination of the LED backlight can be controlled by
warning lamp, etc. adjusting the steering wheel control button.
1.0 956
Service Procedures Front Reading Lamp Assembly
Instrument Panel Light Adjustment Switch Remove
Remove Front Reading Lamp Assembly - with Sunroof
Switch
2. Pry off the clips of the instrument panel left end panel, 1. Disconnect the battery negative.
and remove the panel. 2. Remove 2 nuts fixing the roof console assembly to the
3. Put the hand from the instrument panel left end into roof.
the back of the light adjustment switch, release the
switch clip and push it outwards.
4. Disconnect the light adjustment switch harness
connector and remove the switch.
Refit
1. Connect the light adjustment switch electrical
connector and push the switch into the mounting hole,
and ensure the clips are fully engaged.
2. Fit the instrument panel left end plate.
3. Pry off the clip and remove the roof console.

4. Pry off the front reading lamp assembly with tools.
5. Disconnect the connector of front reading lamp and
remove the lamp assembly.
Front Reading Lamp Assembly - without Sunroof

Switch
2. Pry off the front reading lamp assembly with tools.
1.0 957
Rear Reading Lamp Assembly

Remove
2. Remove trim covers of 2 screws on the inner roof
handle.
3. Remove 2 screws securing the inner roof handle onto
the vehicle body.
5. Pry off the rear reading lamp assembly with tools
carefully.
3. Disconnect the connector and remove the front reading

lamp assembly.
Refit
Front Reading Lamp Assembly - with Sunroof
Switch
1. Fit the front reading lamp assembly to the roof console.
2. Connect the reading lamp connector.
3. Fix the roof console assembly to the roof, fit 2 bolts,
tighten to1.5–2Nm and check the torque.
Front Reading Lamp Assembly - without Sunroof 6. Disconnect the connector and remove the rear reading
Switch lamp.
1. Connect the connector of front reading lamp assembly. Refit
2. Fit the reading lamp assembly to the roof trim panel. 1. Connect the rear reading lamp assembly connector.
3. Connect the battery negative. 2. Clamp the rear reading lamp assembly onto the roof
interior trim panel.
3. Put the inner roof handle to correct position.
4. Fit 2 fastening screws with torque of 5–7 Nm.
5. Fit the upper screw blank cap.
1.0 958
Front Reading Lamp Bulb Rear Reading Lamp Bulb
Remove Remove
2. Pry off the front reading lamp lens with tools. 2. Pry off the rear reading lamp lens with tools.
3. Remove front reading lamp bulb. 3. Remove rear reading lamp bulb.
Refit Refit
Tip: Take care NOT to touch the glass with your fingers; Tip: Take care NOT to touch the glass with your fingers;
always use a cloth to handle the bulb. If necessary, clean always use a cloth to handle the bulb. If necessary, clean
the glass with methylated spirits to remove fingerprints. the glass with methylated spirits to remove fingerprints.
1. Refit the front reading lamp bulb. 1. Refit the front reading lamp bulb.
2. Refit the front reading lamp lens. 2. Refit the front reading lamp lens.
3. Connect the battery negative cable. 3. Connect the battery negative cable.
1.0 959
Glove Box Lamp Assembly Trunk Lamp Assembly

Remove Remove
2. Pry off the glove box lamp assembly with tools. 2. Pry off the trunk lamp with tools.
3. Disconnect the connector and remove the glove box 3. Disconnect the connector and remove the trunk lamp
lamp assembly. assembly.
Refit Refit
1. Connect the glove box lamp connector. 1. Connect the trunk lamp connector.
2. Install the glove box lamp assembly. 2. Refit the trunk lamp assembly.
3. Connect the battery negative cable. 3. Connect the battery negative cable.
1.0 960
Lamps Lighting Systems
Lamps
Specifications
Torque
Description Value
Bolt-Front fog lamp to front bumper 2.7–3.3Nm
Screw-Headlamp lighting calibration 0.1–0.5Nm
Bolt - head lamp to bodywork 3–5Nm
Nut-CHMSL to spoiler 2.7–3.3Nm
Nut-rear grouped lamp to tail gate 2.7–3.3Nm
Screw- tail lamp to bodywork 3–5Nm
Screw-DHL module to body 6–8Nm
Bolt -Front suspension height sensor to body 7–10Nm
Bolt - ASM-RR height sensor to bodywork 7–10Nm
1.0 961
Lighting Systems Lamps

System Layout
Exterior Lighting Layout
1. Bulb Front Lamp（if fitted） 9. License Plate Lamp

2. Full LED Front Lamp（if fitted） 10. Rear Grouped Lamp
3. Front Fog Lamp（if fitted） 11. Tail Lamp
4. Hazard Warning Lamp Switch 12. Rear Fog Lamp
5. Headlamp Levelling Front Suspension Height Sensor（if 13. Direction Indicator Lamp/High Beam Lever Switch
fitted） 14. Ground Lamp（if fitted）
6. Dynamic Headlamp Levelling Control Module（if fitted） 15. Side Direction Indicator Lamp
7. eadlamp Levelling Rear Suspension Height Sensor(if 16. BCM
fitted）
8. High-mounted Stop Lamp
1.0 962
Exterior Lighting Control Diagram
A=Chassis HS CAN Bus ； B=Diagnostic HS CAN Bus ； C=Power HS CAN Bus ； D=Body HS CAN Bus ； E=Hard Wire
1.0 963
Dynamic Headlamp Leveling (DHL) Control

Diagram
A=Power HS CAN Bus ； B=Body HS CAN Bus ； C=Chassis HS CAN Bus ； D=LIN Bus ； E=Hard Wire
1.0 964
Description Headlamp - Low Configuration
Overview
The exterior lighting system includes external lamps, which
are controlled by the master light switch and auto light control
sensor. Exterior lighting system includes:
• Headlamp
• Tail Lamp
• Rear Combination Lamp
• Rear License Plate Lamp
• Side Direction Indicator Lamp
• Puddle Lamp (If equipped) 1. Front Direction Indicator Lamp (Bulb)
• High-mounted Stop Lamp 2. Daytime Running Lamp/Position Lamp (LED)
• Front Fog Lamp (if equipped) 3. High/Low Beam (Bulb)
• Rear Fog Lamp The headlamp is fixed on the upper radiator beam by
Master Light Switch (MLS) screws. There are two types of headlamps: low-configuration
headlamp and high-configuration headlamp.
The low-configuration headlamp assembly includes the

high/low beam, daytime running lamp/position lamp and
front direction indicator lamp. The bulb of the high/low
beam and front direction indicator lamp is a halogen bulb,
the front direction indicator lamps are LED lamps. The
high-configuration headlamp assembly includes the high/low
beam, daytime running lamp/position lamp and front direction
indicator lamp. The high-configuration headlamps are LED
lamps. The rear of the headlamp assembly is protected by a
seal rubber cover to prevent water and dust.
• Master Light Switch Tail Lamp
Headlamp
Headlamp - High Configuration
1. Brake Lamp (Bulb)

2. Rear Direction Indicator Lamp (Bulb)
1. High Beam (LED) 3. Position Lamp (LED)
2. Low Beam (LED)
The tail lamp is fixed on the body with screws. The tail lamps
3. Front Direction Indicator Lamp (LED) only have bulb lamps.
4. Daytime Running Lamp/Position Lamp (LED)
The bulb tail lamp assembly includes the brake lamp, position
lamp and rear direction indicator lamp. The brake lamp bulb
1.0 965
is above the tail lamp assembly, rear direction indicator lamp Front Fog Lamp (if equipped)
bulb is under the tail lamp assembly. The position lamp is in
The front fog lamp is on the front bumper and each front fog
the centre of the tail lamp assembly.
lamp includes a halogen bulb.
Rear Combination Lamp Rear Fog Lamp
The rear fog lamp is on the rear bumper. The rear fog lamp bulb
extends from the lens gap of the rear fog lamp and illuminates
the area around the lens.
Dynamic Headlamp Leveling (if equipped)
The dynamic headlamp leveling (DHL) is an intelligent system.
The main function of the system is to provide an optimum road
illumination for the driver.
End View and Pin Information of DHL Module
1. Position Lamp (LED)

2. Reverse Lamp (Bulb)
The rear combination lamp is fixed to the tailgate by nuts,

which only has bulb lamp.
The bulb rear combination lamp assembly consists of the

position lamp and reverse lamp, the reverse lamp bulb is under
the rear combination lamp, the LED position lamp is in the
middle upper part of the rear combination lamp.
Rear License Plate Lamp
The two rear license plate lamps are inside the lower molding
Pin No. Description
of the tailgate.
1 —
Side Direction Indicator Lamp
2 —
The bulb of the side direction signal lamp is integrated in the
3 —
exterior rearview mirror.
4 —
Direction Indicator Lamp/High Beam Lever Switch
5 LIN Signal
The direction indicator lamp/high beam lever switch is located
6 CAN L
at the left side of the steering column, which controls the
following components: 7 CAN H
8 —
• Fog Lamp
9 —
• Left Direction Signal Lamp
10 —
• Right Direction Signal Lamp
11 Front Height Sensor Ground
• Headlamp Flash
12 Rear Height Sensor Ground
• Low Beam/High Beam Switching
13 Front Height Sensor Signal
High-mounted Stop Lamp (CHMSL)
14 Rear Height Sensor Signal
The high-mounted stop lamp is above the rear window, which
15 Wake-up Enable
is an LED lamp and fixed by 3 nuts to the spoiler.
16 —
Puddle Lamp (If equipped)
17 Front Height Sensor Power
The puddle lamp is on the exterior mirror.
18 Rear Height Sensor Power
1.0 966
19 — 3 —
20 — 4 Front Height Sensor Signal
End View and Pin Information of DHL Module 5 Front Height Sensor Power
Harness Connector BY114 6 —
End View and Pin Information of DHL Rear Height

Sensor Harness Connector BY116
Pin No. Description

1 —
2 — Pin No. Description
3 — 1 Rear Height Sensor Ground
4 — 2 —
5 — 3 —
6 — 4 Rear Height Sensor Signal
7 GND 5 Rear Height Sensor Power
8 KL.30 6 —
9 —
Bulb Specification
10 —
Bulb Type Voltage Power
End View and Pin Information of DHL Module Low Beam and HB3L 12V 60W
Harness Connector BY115 High Beam (Low
Configuration)
Front direction PY21W 12V 21W
indicator
lamp (Low
Configuration)
Front Width LED
Lamp/Daytime
Running Lamp
Front Fog Lamp H8 12V 35W
Side Direction LED
Indicator Lamp
Puddle Lamp LED
Rear Fog Lamp LED
Rear Width Lamp LED
Pin No. Description Reverse Lamp W16W 12V 16W
1 Front Height Sensor Ground License Plate W5W 12V 5W
Lamp
2 —
1.0 967
Brake Lamp W21W 12V 21W

Rear Direction WY21W 12V 21W
Indicator Lamp
1.0 968
Operation The emergency brake lamp can be activated only when the
Overview vehicle speed exceeds 50km/h. After the emergency brake
lamp is activated, when the activation signal of the ABS/hard
Exterior Lighting Control and Monitor
brake disappears (more than 2s), the emergency brake lamp
BCM controls the following exterior lamps: will be disabled. After the emergency brake lamp is activated,
• High Beam Headlamp when the activation signal of the ABS/hard brake disappears
• Front Fog Lamp (if fitted) and the vehicle speed is less than 2km/h, the emergency brake
• Side Direction Indicator Lamp lamp will be extinguished after a 5s' illumination.
• Puddle Lamp (if fitted) When the vehicle speed is less than 10km/h for 1s, if the
BCM monitors and controls the following emergency brake lamp is extinguished, the hazard warning
exterior lamps: lamp will be activated automatically; when the vehicle speed
remains above 10km/h, if the emergency brake lamp stops
• Direction Indicator Lamp/Hazard Warning Lamp (Bulb
flashing, the hazard warning lamp will not be activated
Monitoring)
automatically even if the vehicle speed is already below
• Brake Lamp (including High-mounted Stop Lamp) 10km/h. When the hazard warning lamp is activated, the
• Low Beam Headlamp (Bulb Monitoring) hazard warning lamp will be extinguished by pressing the
• Rear Fog Lamp hazard warning lamp switch, keeping the vehicle speed above
• Width Lamp (License Plate Lamp) 20km/h for 5s or powering on the vehicle.
• Reverse Lamp When the SCS cannot receive any activation signal for the
• Daytime Running Lamp (if fitted) hard brake, the BCM can illuminate the emergency brake lamp
as per the acceleration signal of the SCS.
Auto Lamp Control (if fitted)
Brake Lamp Activation Request from Other
When the master light switch is in "AUTO" position, the
Systems
lamplight sensor of the solar and lamplight integrated sensor
When the BCM receives the brake lamp activation request
will turn on/off the headlamp automatically according to the
from the EPB and SCS, the BCM will illuminate the brake
intensity of the outside light (visible light). When the master
lamp according to the valid signal.
light switch is in other positions, the priority of the switch
command is higher than that of the request signal from the Brake Lamp Illumination Control (if fitted)
solar and lamplight integrated sensor. When the BCM detects that the daytime mode or width lamp
Brake Lamp is turned off, the BCM will drive the brake lamp to output
100% PWM. When the BCM detects that the night mode or
When the brake pedal is not used, the tang of the brake pedal
width lamp is turned off, the BCM will drive the brake lamp
leans against the sensor end and is in idle state. When the
to output 80% PWM.
brake pedal is depressed, the tang moves away from the sensor,
which causes change of the sensor output voltage. For some Direction Indicator Lamp
models, the brake lamp switch has two pedal status inputs, one When the ignition switch is in the 1st gear and the direction
signal is sent to the BCM, the other is sent to the ECM; some indicator lamp switch is turned on, the BCM flashes the
models may only transmit the signal directly to the ECM by the corresponding direction indicator lamp by identifying the
hard wire. switch status of the direction indicator lamp. Then the
Emergency Brake Lamp Control direction indicator lamp flashes and provides the current
status of the direction indicator lamp for the driver by acoustic
The brake lamp will flash under the following conditions:
warning.
1. The brake pedal inputs activation signal.
Front Fog Lamp (if fitted)
2. ABS or SCS sends the corresponding activation signal.
According to the switch signal of the front fog lamp on the
When the emergency brake is activated, if the hazard warning
master light switch, the BCM closes and opens the relay and
lamp is working, the emergency brake lamp will not flash.
allows the front fog lamp to work. It also sends the ON/OFF
If the activated hazard warning lamp causes failure of the status of the front fog lamp to the IPK, the main display area of
emergency brake lamp, the emergency brake lamp will not the message centre on the IPK displays "Front Fog Lamp ON"
flash again after the hazard warning lamp is cancelled unless (if fitted), and this message will disappear after few seconds.
the above conditions are met. When the width lamp is activated, the front fog lamp can be
turned on by pressing the front fog lamp switch. In order to
1.0 969
provide maximum current for the starter motor, the front fog automatically. Accidental activation of the hazard
lamp will be died out at the time of engine start, and it will warning lamp during impact can be cancelled by pressing
resume later. the hazard warning lamp switch for more than 5s.
Rear Fog Lamp • When the security system is activated and the engine is
running, once a door is opened, the hazard warning lamp
When the ignition switch is in the 2nd gear, the low beam
will flash for 15s, after the door is closed, the warning
headlamp or front fog lamp is turned on, activation of the rear
will be cancelled immediately.
fog lamp switch can illuminate the rear fog lamp. The BCM
Low Beam Headlamp
sends the ON/OFF status of the rear fog lamp to the IPK by
receiving the activation signal of the rear fog lamp. The main When the master light switch is turned to the low beam
display area of the message centre on the IPK shows "Rear Fog position, the BCM closes the low beam relay and illuminates
Lamp ON" (if fitted), and this message will disappear after few the low beam headlamp.
seconds. When the rear fog lamp switch, low beam headlamp
High Beam Headlamp
or front fog lamp switch is turned off, the rear fog lamp is died
out. If the rear fog lamp is already activated at the time of When the ignition switch is in ON position, the BCM closes
engine start, it will remain ON. the high beam relay and illuminates the high beam headlamp by
identifying the status of the light stalk switch. When the high
Puddle Lamp (if fitted)
beam is enabled, the blue indicator lamp on the IPK illuminates.
When the vehicle unlocks, the lamplight sensor of the solar and
Width Lamp
lamplight integrated sensor (if fitted) will turn on the puddle
lamp automatically according to the intensity of the outside When turning the master light switch to the width lamp or low
light (visible light). The puddle lamp goes out automatically beam headlamp, the width lamp illuminates.
after working for 30s. The master light switch is in the "AUTO" position (if fitted),
Hazard Warning Lamp when the BCM receives the "Outside Illumination Intensity
Low" signal from the solar and lamplight integrated sensor (if
Hazard warning lamps include the front, rear and side direction
fitted), it will illuminate the width lamp automatically. When
indicator lamps.
the BCM receives the identified status signal of the TPMS (if
Hazard warning switch is marked with hazard triangle which fitted), the BCM will flash the width lamp. When the ignition
is a touch switch. The switch has a hazard triangle, which will switch is off, and the master light switch is in the width lamp
flash when the hazard lamps are activated. When the width position, the width lamp will be extinguished within 20min.
lamps or headlamps are on, the triangle will have a reduced
Reverse Lamp
brightness and remain flashed. The hazard warning lamps can
be activated manually regardless of the present position of the When the ignition switch is in the ON position, and the ECM
ignition switch. (MT) or TCM (AT) detects that the shift lever is in the "R"
gear, it will send reverse signal to the BCM through the CAN
Operation Priority of Direction Indicator Lamp and Hazard
bus. Once the BCM judges the signal is valid, it illuminates the
Warning Lamp
reverse lamp immediately. When the BCM detects that the
If the direction indicator lamp switch is turned on when the signal is invalid (the ignition switch is not in the ON position
hazard warning lamp is working, the direction indicator lamp or the shift lever is not in the "R" gear), it turns off the reverse
will take place of the hazard warning lamp to be illuminated. lamp.
Then, the hazard warning lamp will still flash after the direction
When the ignition switch is in the 2nd gear position, if the
indicator lamp or ignition switch is went out.
BCM receives a fault signal of the "R" gear switch, the reverse
If the hazard warning lamp switch is turned on when the lamp will remain on.
direction indicator lamp is working, the hazard warning lamp
Note: For vehicles with automatic transmission, to
will take place of the direction indicator lamp to be illuminated.
avoid shifting to "R" gear and illuminating the
The direction indicator lamp will resume after the hazard
reverse lamp accidentally, when the BCM detects
warning lamp is turned off.
that the shift lever is in "R" gear, it will hold
The hazard warming lamp can be activated automatically under it there for more than 1s before illuminating the
the following situations: reverse lamp.
• In case of impact, when the BCM monitors an
impact signal, it will activate the hazard warning lamp
1.0 970
Additional Functions 30s, the time will be reset, the maximum duration will be within
Battery Save Mode (if fitted) 5 min.
If the master light switch remains in the width lamp position Daytime Running Lamp
after the ignition switch is off, the battery electric protection BCM controls the daytime running lamp through 2 different
system will turn off the exterior lamp automatically after a HSDs. When the direction indicator lamp flashes, the
while so as to avoid unnecessary battery discharge. corresponding daytime running lamp is disabled; when the
Follow Me Home (if fitted) direction indicator lamp is disabled, the daytime running lamp
illuminates. BCM configure the front fog lamp and use it as
When the driver turns off the ignition switch and is about to
the daytime running lamp.
leave the vehicle, the Follow Me Home function can control
the timed illumination of the low beam headlamp and/or rear Lamps of Security System
fog lamp (optional) to illuminate the area around the vehicle. If Lamps of the security system consists of the low beam
the door is opened after the Follow Me Home function timer headlamp and high beam headlamp.
is working, the timer will repeat the operation.
If the BCM receives a valid request signal of the outside lock,
The Follow Me Home function can be set by auto mode and and the vehicle is in the security system, locked or completely
manual mode. The BCM can identify the status of the Follow in the anti-theft state, it controls the direction indicator lamp
Me Home function according to the activation signal of this to give 3 flashes.
function.
If the anti-theft function of the security system is disabled, the
• Auto mode: When the master light switch is in "AUTO" direction indicator lamp gives 1 flash.
position (if fitted), and the outside illumination is
deficient, the vehicle will enter into the Follow Me Home If the vehicle is not fully locked (engine cover, tailgate and door
mode automatically after the vehicle power is off. are open), the direction indicator lamp will not flash.
• Manual mode: After the ignition switch is off, pull the light Auto Lamp Control Illumination(if fitted)
stalk switch to the high beam, the system enters into the
When the master light switch is in "AUTO" position for night
Follow Me Home mode. driving, the following lamps illuminate:
With the Follow Me Home activated, pull the high beam • When the ignition switch is off, the low beam headlamp
headlamp lever or shift the ignition switch to disable the does not illuminate.
Follow Me Home.
• When the ignition switch is in the ACC position, the park
When enabled ignition switch, alternator failure or battery lamp illuminates.
overdischarge is detected, the Follow Me Home function
• When the ignition switch is in the ON position, the low
cannot work normally.
beam headlamp illuminates.
Find My Car Operation of Emergency Mode
This function helps the driver to quickly locate his car with BCM possesses a completely independent microprocessor.
the body lamp during night driving. This function can be During data processing or peripheral equipment failure and low
activated or cancelled by the combination switch menu on the battery, the BCM can ensure normal operation of the vehicle
entertainment and navigation interface, and the duration of security system.
the illumination (0-300s) can also be set according to individual
needs (increase at an increment of 30s). Direction indicators The following functions can be used in emergency mode:
and horns will operate based on setting. • When the ignition switch is in the 2nd gear, the low beam
Press the LOCK bottom on the remote key, the vehicle headlamp and width lamp illuminate no matter whether
locating mode will be enabled. the master light switch is enabled.
• With the ignition switch in the 2nd gear and the brake
The vehicle locating function can be disabled by shifting the
pedal depressed, the brake lamp will be enabled.
ignition switch, overdischarging the battery or receiving a valid
LOCK/UNLOCK request from the remote key. After reset, the emergency mode will be activated for 2.5s, this
allows the low beam headlamp to illuminate when the ignition
License Plate Lamp (if fitted)
switch is in the 2nd gear. However, the direction indicator
After the ignition switch is off, the license plate lamp can be
lamp, high beam headlamp, front fog lamp, rear fog lamp and
activated (appr. 30s) by pressing the tailgate UNLOCK button
CAN bus or LIN bus will not work in emergency mode.
on the remote key. If press the UNLOCK button again within
1.0 971
Dynamic Headlamp Leveling (DHL) based on the vehicle speed and signal inputs from the high
speed sensor, etc. The DHL system can provide an optimum
The DHL system is an intelligent system which can realize
road illumination for the driver.
headlamp leveling automatically. It controls headlamp leveling
1.0 972
Service Procedures Front Fog Lamp Bulb
Rear License Plate Lamp Bulb Remove
Remove .
1. Disconnect the battery negative cable. Front fog lamp bulb must be disassembled after the engine
has cooled.
2. Remove the tailgate molding.
Tailgate Outer Molding Remove 2. Remove the bottom deflector.
3. Remove the rear license plate lamp bulb from the
socket and discard the bulb.
3. Rotate the bulb holder counterclockwise to remove.
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. Fit the new rear license plate lamp bulb into the socket,
and then fit the socket to the lamp assembly.
2. Refit the tailgate molding.
Tailgate Outer Molding Refit

4. Pull the bulb out of the bulb holder.

Refit
Tip: Take care NOT to touch the glass with your fingers;
1. Fit the bulb to the holder.
2. Rotate the bulb holder clockwise to fit it to the front
fog lamp assembly.

1.0 973
Front Fog Lamp Assembly Headlamp Lighting Calibration (Low Beam and
Remove High Beam)
Check
Halogen Headlamp
1. Unload the cargo in the vehicle and keep the vehicle
empty.
3. Remove 4 bolts securing the front fog lamp assembly
2. Turn on the low beam and allow the beam to fall on the
onto the front bumper.
screen 10m away from it.
3. Adjust the headlamp, and the height of the cut-off line or
central height of the low beam shall be 0.7H-0.9H (H =
890mm).
4. The halogen headlamp high/low beam bulb is a bulb which
needs to adjust the low beam only.
5. For requirements on beam illumination location, please
refer to GB 7258-2012 Safety Specifications for Motor
Vehicles Operating on Roads.
LED Headlamp
1. Unload the cargo in the vehicle and keep the vehicle
empty.
2. Turn on the low beam and allow the beam to fall on the
4. Remove the front fog lamp assembly.
screen 10m away from it.
Refit
3. Adjust the headlamp, and the height of the cut-off line or
1. Refit the front fog lamp assembly onto the front central height of the low beam shall be 0.7H-0.9H (H =
bumper. 878mm).
2. Fit 4 screws securing the front fog lamp assembly onto 4. Turn on the high beam and allow the beam to fall on the
the front bumper and tighten to 2.7–3.3Nm. screen 10m away from it.
3. Fit the front bumper assembly. 5. Adjust the headlamp, ensure the central height of the
Front Bumper Assembly Refit high beam on the screen is 0.85H-0.95H (H = 860mm),
4. Connect the battery negative cable. it shall not be lower than the cut-off line or centre of
the low beam.
6. For requirements on beam illumination location, please
refer to GB 7258-2012 Safety Specifications for Motor
Vehicles Operating on Roads.
Adjustment
Warning: The light deflection caused by the bracket
deformation or wrong lamp fixing position can't be
corrected by adjusting and the excessive adjustment will
break the lamp.
Halogen Headlamp
1. Adjusting screw (1) is the composite dimming point,
turn the adjusting screw to adjust the low beam in both
horizontal and vertical direction with the torque of
0.1–0.5Nm.
2. And turn the screw (2) to adjust the low beam in vertical
direction, the torque is 0.1–0.5Nm.
1.0 974
Headlamp Assembly
Remove
3. Remove 4 bolts securing the headlamp to the body.
LED Headlamp
1. Turn the screw (1) to adjust the low beam in horizontal
2. Turn the screw (4) to adjust the low beam in vertical
3. Turn the screw (2) to adjust the high beam in horizontal
4. Disconnect the connector from the headlamp assembly.
4. Turn the screw (3) to adjust the high beam in vertical
direction, the torque is 0.1–0.5Nm. 5. Remove the headlamp assembly.
Refit
1. Connect the headlamp connector.
2. Fit the headlamp assembly.
3. Align the headlamp assembly with the mounting point,
fit the bolt and tighten to 3–5Nm.
6. Check if the headlamp is aligned.
Headlamp Lighting Calibration (Low Beam and

High Beam)
1.0 975
Integral High/Low Beam Bulb (low-configuration Front Direction Indicator Lamp Bulb
headlamp) (low-configuration headlamp)
Remove Remove
2. Counterclockwise turn the high/low beam bulb cover 2. Counterclockwise turn the front direction indicator
to an appropriate position and remove the bulb cover. lamp bulb cover to an appropriate position, and remove
3. Turn the high/low beam lamp holder counterclockwise the bulb cover.
and remove the lamp holder.
3. Turn the front direction indicator lamp holder

counterclockwise and remove the holder.
4. Remove the bulb from the bulb holder and discard it.
Refit 4. Remove the bulb from the bulb holder and discard it.
Tip: Take care NOT to touch the glass with your fingers; Refit
always use a cloth to handle the bulb. If necessary, clean Tip: Take care NOT to touch the glass with your fingers;
the glass with methylated spirits to remove fingerprints. always use a cloth to handle the bulb. If necessary, clean
1. Fit the bulb to the bulb holder.
1. Fit the bulb to the bulb holder.
2. Fit the bulb holder to the headlamp assembly.
2. Fit the bulb holder to the headlamp assembly.
3. Fit the high and low beam bulb covers.
3. Fit the front direction indicator bulb cover.
1.0 976
High Mounted Stop Lamp Assembly Rear Combination Lamp Assembly
Remove Remove
1. Disconnect the battery negative cable. 1. Disconnect the battery negative.
2. Pry off the tailgate upper trim panel. 2. Pry off the rear combination lamp cover with an
3. Remove the spoiler assembly. appropriate tool.
3. Remove 2 nuts fixing the rear combination lamp
Spoiler Assembly Remove
assembly to the tailgate.
4. Remove 3 nuts securing the high mounted stop lamp
onto the spoiler assembly and take down the lamp.
4. Loosen the clip fixing the rear combination lamp

harness to the tailgate.
Refit
5. Remove the tailgate outer molding.
1. Fix the high mounted stop lamp onto the spoiler
assembly, fit 3 nuts, tighten to 2.7–3.3Nm, and check Tailgate Outer Molding Remove
the torque. 6. Disconnect the connector and remove the rear
2. Refit the spoiler assembly. combination lamp assembly.
Refit
Spoiler Assembly Refit
1. Refit the rear combination lamp assembly onto the
3. Fit the tailgate upper trim panel.
tailgate and secure with nuts to 2.7–3.3Nm.
2. Connect the connector and fix the rear combination
lamp harness onto the tailgate with clips.
3. Refit the tailgate outer molding.
Tailgate Outer Molding Refit

4. Refit the rear combination lamp cover.
1.0 977
Tail Lamp Assembly Rear Combination Lamp Assembly Bulb

Remove Remove
2. Remove plugs securing the tail lamp assembly screws. 2. Pry off the rear combination lamp cover with an
3. Remove 2 bolts securing the tail lamp assembly onto appropriate tool.
the vehicle body. 3. Remove the rear combination lamp holder.
4. Release the tail lamp assembly and disconnect the 4. Remove the bulb from the lamp holder and discard
connector. the bulb.
5. Remove the tail lamp assembly and discard 2 bolt Refit
sealing washers. Tip: Take care NOT to touch the glass with your fingers;
Refit the glass with methylated spirits to remove fingerprints.
1. Fit 2 new sealing washers onto the tail lamp assembly.
1. Fit the new lamp bulb into the holder, and then fit the
2. Connect the tail lamp connector and fit the tail lamp holder to the lamp assembly.
assembly. 2. Refit the rear combination lamp cover.
3. Fix the tail lamp assembly to 3–5Nm with nuts, and
check the torque.
4. Fit the plug of mounting hole.
1.0 978
Tail Lamp Assembly Bulb Position Lamp and Daytime Running Lamp
Remove Source Module
1. Remove the tail lamp assembly.
Remove
1. Remove the left headlamp assembly.
Tail Lamp Assembly Remove
2. Rotate the rear direction indicator holder Headlamp Assembly Remove
counterclockwise and remove it (2). 2. Turn over the left headlamp assembly, and remove
3. Rotate the brake lamp holder counterclockwise and 3 screws securing the source module onto the left
remove it (1). headlamp assembly.
4. Remove the bulb from the lamp holder and discard 3. Disconnect the control module and headlamp
the bulb. connector and remove module assembly.
Refit Refit
Tip: Take care NOT to touch the glass with your fingers; 1. Connect the source module and left headlamp
always use a cloth to handle the bulb. If necessary, clean connector.
2. Secure the source module onto the left headlamp
1. Fit the new lamp bulb into the holder, and then fit the assembly, fit 3 screws and tighten up.
holder to the lamp assembly.
Caution: Please ensure seal ring fixed correctly when refit
2. Refit the tail lamp assembly.
AFS slave ECU, if there is water leakage, it may cause
Tail Lamp Assembly Refit headlamp damage.
Headlamp Assembly Refit
1.0 979
Side Direction Indicator Lamp Assembly Puddle Lamp Assembly

Remove Remove
2. Remove the exterior mirror cover. 2. Remove the exterior mirror glass.
Exterior Mirror Cover Remove 3. Pry off the puddle lamp (2) with tools.
3. Remove 2 bolts securing the side direction indicator 4. Disconnect the connector (1), and remove the puddle
lamp to the exterior mirror. lamp.
4. Disconnect the connector and remove the side

direction indicator lamp.
Refit
1. Connect the puddle lamp connector.
Refit 2. Refit the puddle lamp.
1. Connect the side direction indicator lamp connector. 3. Fit the exterior mirror glass.
2. Fix the side direction indicator lamp to the exterior 4. Connect the battery negative cable.
mirror, fit 2 bolts and tighten up.
3. Fit the exterior mirror cover.
Exterior Mirror Cover Refit

1.0 980
Headlamp Control Module Headlamp Leveling Front Suspension Height
Remove Sensor
Remove
2. Remove the Passive Entry and Passive Start (PEPS) 1. Disconnect the battery negative.
control module. 2. Raise the vehicle on the elevator.
Passive Entry and Passive Start (PEPS) Control 3. Disconnect the connector from the headlamp leveling
Module Remove front suspension height sensor.
3. Disconnect the connector of dynamic headlamp leveling 4. Remove 4 bolts securing the headlamp leveling front
control module. suspension height sensor to right front subframe and
right front lower swing arm.
4. Remove 2 bolts fixing the dynamic headlamp leveling
control module to the body.
5. Remove the headlamp leveling front suspension height

sensor.
5. Remove the dynamic headlamp leveling control module
from the body.
Refit
Refit 1. Fix the DHL front suspension height sensor to the right
front subframe and right front lower swing arm, fit 4
1. Fix the dynamic headlamp leveling control module to
bolts and tighten to 7–10Nm.
the body, fit 2 bolts and tighten to 6–8Nm.
2. Connect the connector of the DHL front suspension
2. Connect the electrical connector of dynamic headlamp
height sensor.
leveling control module.
3. Lift down the vehicle.
4. Programme and encode the dynamic headlamp leveling
(DHL) control module. 5. Perform height sensor null voltage self-learning.
Self-learning and Adjustment, Programming and Self-learning and Adjustment, Programming and
Encoding - DHL Module Replacement Coding - Height Sensor Null Voltage Self-learning
5. After replacement, disconnect the battery negative and

fit the passive entry and passive start (PEPS) control
module.
Passive Entry and Passive Start Control Module
Refit
1.0 981
Headlamp Leveling Rear Suspension Height 4. Connect the battery negative.

Sensor 5. Perform height sensor null voltage self-learning.
Remove
2. Raise the vehicle on the elevator.
3. Disconnect the electrical connector from the headlamp
leveling rear suspension height sensor.
4. Remove 3 bolts securing the headlamp leveling rear
suspension height sensor to the body and right rear
trailing arm.
5. Remove the headlamp leveling rear suspension height

sensor.
Refit
1. Fix the DHL rear suspension height sensor to the body
and right rear trailing arm (note the curved surface of
the sensor bracket shall fit the trailing arm), fit 3 bolts
Caution: In the refit process, please check the rear

suspension height sensor control arm, make sure the
direction of control arm point to vehicle head (arrow
direction indicated on diagram).
2. Connect the electrical connector of the DHL rear

suspension height sensor.
3. Lift down the vehicle.
1.0 982
Light Sensor
Remove
2. Release the clip securing the light sensor onto the
instrument panel.
3. Disconnect the light sensor connector and avoid to fall
down below the instrument panel.
4. Remove the light sensor.

Refit
1. Connect the light sensor connector.
2. Fix the light sensor onto the instrument panel and
tighten with clips.
1.0 983
1.0 984
Door Body Systems
Door
Specifications
Torque
Description Value
Bolt - door hinge to door 42–48Nm
Bolt - door striker to body 19–25Nm
Bolt-body- checker 21–29Nm
Screw - exterior handle backplate to door 2–2.5Nm
Bolt - door hinge to body 30–36Nm
Bolt - door lock to door 8–12Nm
Bolt - door striker 15–21Nm
Bolt - door checker to body 19–25Nm
Bolt - door lock 8–12Nm
Bolt - glass holder 7–10Nm
Bolt-From weather-strip to door inner panel 1–2Nm
Bolt - window regulator guide rail to door 7–10Nm
1.0 985
Body Systems Door

System Layout
1. Window Regulator Motor of Front Passenger 6. Window Regulator Motor of Rear Passenger
2. Front Passenger Window Switch 7. Left Front Door Handle
3. Window Regulator Motor of Rear Passenger 8. Driver Window Switch
4. Rear Passenger Window Switch 9. Driver Window Regulator Motor
5. Rear Passenger Window Switch 10. Remote Key
1.0 986
Door Body Systems
A=Hard Wire ； B=LIN
1.0 987
Body Systems Door
Operation in the ascending channel of the window, the window will stop
Power Window before the obstacle and return to the bottom automatically.
Control of the window regulator can be achieved by the Heat Protection and Self-learning
following operations: Heat Protection
• Use the switch of the DDSP to control power window Window regulator motors without the "one-button control"
regulator and disable the rear power window. and "anti-pinch" functions realize heat protection function
• Use the front/rear passenger side switch to control the through the opening and closing of the temperature-sensitive
regulator of the corresponding power window. patch. When consecutive and repeated operation of the
• Apply the mechanical key to lock/unlock the driver door window regulator switch within a short period of time causes
(if equipped) and hold the operation for several seconds, a hot motor, the temperature-sensitive patch will disconnect,
then all windows will close/open (if equipped). this can cut off the power of the regulator motor and realize
heat protection for the regulator motor. Then, the switch of
Window Regulator Switch
the power window will become disabled temporarily, please
DDSP wait for a short time, after the motor becomes a little bit
DDSPIt sends control command to the motor of the four cold, it will recontrol the function of the window regulator.
windows through the BCM, including such request signals
Window regulator motors with the "one-button control"
as open, quick move to memory location to close, manual
and "anti-pinch" functions has a motor control module
lock/unlock, one-button lock/unlock, etc. The DDSP is fitted
which realizes the ascending/descending, anti-pinch and heat
with the rear window disable switch, when the disable switch
protection functions of the window by receiving the command
is activated, the rear passenger window switch will be disabled.
signal from the BCM. Consecutive and repeated operation
Independent Passenger Window Switch of the power window with the "one-button control" and
The independent passenger window switch controls the "anti-pinch" functions within a short period of time can cause
regulator of the corresponding passenger window through the BCM to determine that the window regulator motor is
the BCM. When the rear passenger window is disabled, the too hot and that the heat protection is required, in this case,
switch of the rear passenger window cannot ascend/descend the switch of the power window will be disabled, and the
this window. regulator motor will stop, in 30 seconds, the BCM will resume
the function of the regulator motor to ascend/descend the
Window Regulator Control Mode
window. If consecutive and repeated operation of the window
Manual Mode regulator then occurs again, for the purpose of protecting
Press/lift the window switch to perform manual mode. The the regulator motor and allowing it to cool thoroughly, the
window will continue ascending/descending until the switch is window regulator motor will be disabled for 30s, and the
released. switch of the power window will be disabled again. Within
One-button Control the 30min's waiting time, do not disconnect the battery cable,
otherwise, the time for disabling the switch of the power
The driver window switch is provided with one-button control
window will be extended due to failure of the motor control
function.
module to count the time.
• One-button unlock: press the driver window switch of
Driver Power Window Self-learning
the DDSP to the 2nd gear and then release it to descend
the window to the bottom. If recharge the battery, disconnect the connector, or if the
• One-button lock: lift the driver window switch of the battery cannot work, the message centre of the IPK will show
DDSP to the 2nd gear and then release it to ascend the the relevant icon and text and request a self-learning for the
window to the top. driver power window. Before self-learning, ensure the battery
can provide sufficient power.
The passenger window switch is provided with one-button
control function. Procedures for self-learning:
• One-button unlock: short press and then release the 1. Place the ignition switch in the 1st/2nd gear;
passenger window switch to descend the window to the 2. Press the power window switch until the window is wide
bottom. open;
Anti-pinch Function 3. Lift the power window switch until the window is fully
closed;
The driver window is provided with anti-pinch function. When
the one-button lock function is applied, if there is any object
1.0 988
Door Body Systems
After completion of the above procedures, self-learning of the Synchronization of Window Regulator System
driver power window is finished.
If the vehicle is locked by the mechanical key, or if the vehicle
is locked by the remote control emitter for more than 2s, all
windows will close, including the sunroof.
1.0 989
Body Systems Door
Service Procedures
Front Door Adjustment
Front Door Hinge Adjustment
1. Open the front door.
2. Put the wood block on the jack, and put the jack under
the door to support the front door.
3. Unscrew 2 bolts securing the upper and lower door
hinges to the door side.
4. Close the door, and check if the rear of the door is

flush with the panel of the body side panel and if the
door can open and close normally.
5. After the adjustment, open the door, and tighten the
screws to 19–25Nm, and check the torque.
6. Close the door.
4. Use a jack to support the vehicle and adjust the door.

5. Pre-tighten the hinge bolts.
6. Take away the jack, close the door and check if the
adjustment is proper.
7. When the desired adjustment is achieved, tighten the
hinge bolts to 42–48Nm, and check the torque.
Front Door Striker Adjustment
Front door striker is a latch with two screws. In most cases,
it is necessary to adjust the striker upward/downward or
inward/outward:
• Frame damage resulting from a collision.
• Fit a new door weatherstrip.
• The customer complains that the wind noise is too loud.
• It is difficult to open or close the door.
Adjust the lock catch 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, and then pre-tighten the screws.
1.0 990
Door Body Systems
Front Door Assembly
Remove
the door to support the front door.
4. Remove the bolt fixing the door check to the body,
and discard the bolt.
7. Remove the front door assembly.

Refit
1. Position the door to the body with the help of an
assistant.
2. Connect the connector plug, and insert the rubber seal
ring into the mounting hole of the body.
3. Fit the set bolts between the upper and lower hinges
of the front door and the door side, and tighten the
torque to 42–48Nm and check the torque.
4. Fit the set bolts between the door check and the body
5. With the help of an assistant, hold the door, then side, and tighten the torque to21–29Nm and check
remove and discard 2 bolts fixing the upper/lower the torque.
hinges to the door. 5. Close the door and check if the door can be properly
opened or closed.
Caution: Please protect paint from scratch when

removing or refitting the door assembly.
6. With the help of an assistant, hold the door, remove

the rubber seal ring on the body, and pull out the
connector to disconnect the harness connector plug.
1.0 991
Body Systems Door
Driver Door Outer Handle Driver Door Outer Handle (with PEPS)
Remove Remove
1. Open the driver door. 1. Open the driver door and ascend the door window
2. Remove the driver door lock cylinder. fully.
Front Door Lock Cylinder Remove
3. Remove the driver door plug to access the screw fixing
3. Move the outer handle toward the rear of vehicle
the outer handle cover to the outer handle liner.
body, then pull the rear end of the handle outwards
to separate it from the driver door outer handle liner
and remove.
4. Release the screw, but do not remove as it is clamped

inside.
Refit 5. Pull up the rear end of outer handle and remove the
outer handle cover.
1. Insert the front of driver door outer handle into the
front door mounting hole, and move the outer handle 6. Remove the driver door interior trim panel.
towards the rear vehicle. Front Door Interior Trim Panel Remove
2. Fit the rear gasket of outer handle. 7. Remove the driver door waterproof membrane.
Caution: Ensure door handle gaskets are fitted correctly. 8. Disconnect the antenna harness connector of driver
outer handle from the door cavity.
3. Insert the rear of outer handle into the liner slot of
outer handle.
4. Fix the front door lock cylinder to the outer handle
liner of front door, and tighten the screws.
5. Press the plug into the round hole on the door and
secure the plug clip firmly so that seal can be achieved.
9. Move the outer handle towards the rear body, and pull
the rear part of handle outwards to disconnect the
outer handle from the liner, then remove it.
6. Close the door and check if the outer handle can work
properly.
1.0 992
Door Body Systems
Front Passenger Door Outer Handle
Remove
1. Open the front passenger side door.
2. Remove the cap beside the front passenger door.
Refit
1. Thread the antenna through the front handle mounting
hole of the door from the outside and connect the
harness connector.
2. Fit the front of driver door outer handle into the front
3. Loosen the screw fixing the outer handle cover to the
mounting hole of the door, and move the outer handle
outer handle plate， but do not remove it for it is
towards the rear vehicle.
clamped inside.
3. Refit the rear gasket on the outer handle.
4. Lightly pull the rear end of the outer handle to remove
4. Fit the rear of driver door outer handle into the slot the outer handle cover.
of the outer handle liner.
5. Lightly pull the outer handle towards the rear of vehicle,
5. Fully lift the rear of driver door outer handle, fix and pull out the rear end of the outer handle, then pull
the driver door outer handle cover to the door out its front end to remove the outer handle.
outer handle liner, tighten the screw to the torque of
2–2.5Nm, and check the torque.
6. Check if the door handle can work properly.
secure the plug clip firmly so that seal can be achieved.
8. Refit the driver door waterproof membrane.
9. Refit the driver door interior trim panel.

11. Close the driver door.
Refit
1. Refit the front end of the outer handle into the front
mounting hole of the door, and move the outer handle
towards the rear vehicle.
2. Refit the rear shim of the front passenger side door
outer handle.
3. Refit the rear end of the handle, and move it towards
the front of the body.
4. Refit the front door lock cylinder to the outer handle
plate, tighten the screw to2–2.5Nm, and check the
torque.
5. Check if the outer handle of the front passenger side
1.0 993
Body Systems Door
door can work properly. Front Passenger Door Outer Handle (with PEPS)
6. Press the plug into the round hole on the door and Remove
secure the plug clip firmly so that seal can be achieved. 1. Open the front passenger door and ascend the door
window fully.
3. Remove the front passenger door plug to access the
screw fixing the outer handle cover to the outer handle
liner.

inside.
5. Pull up the rear end of outer handle and remove the
outer handle cover.
6. Remove the door interior trim panel.
Front Door Interior Trim Panel Remove

7. Remove the door waterproof membrane.
8. Disconnect the antenna harness connector of door
outer handle from the door cavity.
9. Move the outer handle towards the rear body, and pull
the rear part of handle outwards to disconnect it from
the outer handle liner, then remove it.
1.0 994
Door Body Systems
Front Door Hinge Assembly
Remove
1. With assistance, remove the front door assembly.
Front Door Assembly Remove
2. From the outside of the body, remove 2 bolts (1) fixing
the upper/lower hinge to the body, and discard the
bolts.
10. Remove the passenger door outer handle and remove

the outer handle antenna.
3. Remove the A pillar lower trim panel.

4. Remove the instrument panel beam assembly.
Instrument Panel Beam Assembly Remove
5. From the inside of A pillar, remove 2 bolts (2) fixing
the upper/lower hinge of the front door to the body,
Refit and discard 2 bolts. Remove the upper/lower hinge of
the front door.
1. Thread the antenna through the front handle mounting
hole of the door from the outside and connect the Refit
harness connector. 1. Locate the upper hinge of front door to the body A
2. Fit the front of front passenger door outer handle into pillar.
the front mounting hole of the door, and move the 2. Fit a new bolt fixing the upper hinge to the body from
outer handle towards the rear vehicle. the inside of A pillar, tighten to the specified torque of
3. Fit the rear gasket on the door outer handle. 30–36Nm, and check the torque.
4. Fit the rear of outer handle into the slot of outer 3. Locate the lower hinge of front door to the body A
handle liner. pillar.
5. Fully lift the rear of the door handle, fix the outer 4. Fit a new bolt fixing the lower hinge to the body from
handle cover to the door outer handle liner, tighten the inside of A pillar, tighten to the specified torque of
the screw to the torque of 2–2.5Nm, and check the 30–36Nm, and check the torque.
torque. 5. Fit 2 new bolts fixing the upper and lower hinges to
6. Check if the door outer handle can work properly. the body from the outside of A pillar, tighten to the
specified torque of 30–36Nm, and check the torque.
secure the plug clip firmly so that seal can be achieved. 6. Fit the instrument panel beam assembly.
8. Refit the door waterproof membrane. Instrument Panel Beam Assembly Refit
9. Refit the door interior trim panel. 7. Fit the A pillar lower trim panel.
Front Door Interior Trim Panel Refit A Pillar Lower Trim Panel Refit
10. Connect the battery negative. 8. Fit the front door assembly.
11. Close the passenger door. Front Door Assembly Refit
1.0 995
Body Systems Door
Front Door Lock Cylinder

Remove
1. Open the left front door.
2. Remove the left front door interior trim panel.
3. Release the clip connecting the lock cylinder link to the
lock cylinder of left front door from the door cavity to
disconnect the lock cylinder link from the lock cylinder.
Refit
1. Insert the lock cylinder into the lock cylinder housing.
2. Pull up the rear end of front door exterior handle and
locate the front door lock cylinder assembly to the
front door mounting hole. Tighten the screw.
3. Connect the lock cylinder linkage and the lock cylinder
from the door cavity, and engage the clip tightly.
4. Fit the left front door interior trim panel.
4. Remove the cap of lock cylinder screw at the end of Front Door Interior Trim Panel Refit
front door to access the screw fixing the door lock 5. Press the screw plug into the round hole at the side of
cylinder to the outer door handle liner. the door, and make sure that the clips on the plug are
fully engaged for good sealing.

inside.
6. Lift the rear of front door outer handle to remove the
lock cylinder cover and the lock cylinder assembly.
7. Disconnect the lock cylinder cover from the lock
cylinder.
1.0 996
Door Body Systems
Front Door Lock Body Assembly
Remove
2. Ensure the front door window glass is fully ascended.

5. Remove the front door waterproof membrane.
6. Loosen the clip (1) fixing the front door outer handle
connecting rod and the lock body, and the clip (2) fixing
the front door lock cylinder connecting rod and the
front door outer handle liner (if equipped). 10. Disconnect the lock cylinder link from the lock, and
remove the front door lock assembly.
Refit
1. Connect the inner cable of the front door to the front
door lock.
2. Connect the harness connector of front door lock.
3. Fit the lock cylinder link to the lock.
4. Locate the lock assembly to the door sheet metal from
the door cavity, and tighten the screws to the torque of
8–12Nm from top to bottom, and check the torque.
5. Insert the front door outer handle link into the
corresponding clip of the front door lock.
6. Insert the lock cylinder link into the corresponding clip
7. Remove 3 screws fixing the door lock to the door.
of the front door outer handle liner (if any).
7. Fit the front door waterproof membrane.

9. Check if the outer and inner handles of the front door
can work properly.
11. Close the front door.
8. Disconnect the harness connector (1) of the door lock.

9. Disconnect the inner cable from the lock (2).
1.0 997
Body Systems Door
Front Door Outer Handle Liner

Remove
2. Ensure the front door window glass is fully ascended.

4. Remove the front door waterproof membrane.
5. Remove the front door outer handle.
Driver Door Outer Handle Remove (with PEPS)
Driver Door Outer Handle Remove

6. Remove the rear gasket of the front door outer handle.
Refit
7. Remove screws fixing the front door outer handle liner
1. Refit the front door outer handle link to the front door
to the door.
outer handle liner.
2. Fit the front door outer handle liner assembly through
the front door cavity, and locate it to the mounting
position on the door outer panel.
3. Fit the screw fixing the outer handle liner to the door
from the outside of door with the tightening torque of
4. Insert the front door outer handle link into the
corresponding lock slot.
5. Insert the lock cylinder link (if any) into the
corresponding slot of the front door outer handle liner.
6. Fit the front door outer handle.
Driver Door Outer Handle (with PEPS) Refit

8. Loosen the clip (1) fixing the front door outer handle
connecting rod and the lock body, and the clip (2) fixing Driver Door Outer Handle Refit
the front door lock cylinder connecting rod and the 7. Try to open the door with the outer handle and lock
front door outer handle liner (if equipped). cylinder (if any) and ensure all parts are correctly fitted.
9. Remove the outer handle liner assembly from the door

cavity.
10. Separate the front door outer handle connecting rod
from the liner, then remove the front door outer
handle liner.
1.0 998
Door Body Systems
Rear Door Outer Handle properly.
Remove
1. Open the rear door.
2. Remove the cap at the side of the rear door.
3. Loosen the screw fixing the outer handle cover to
the outer handle plate, but do not remove it for it is
clamped inside.
4. Pull the rear end of the outer handle to remove the

outer handle cover.
5. Lightly pull the outer handle towards the rear of vehicle,
and pull out the rear end of the outer handle, then pull
out its front end to remove the outer handle.
Refit
1. Fit the front of the rear door outer handle into the
front mounting hole of the door, and move the outer
handle towards the rear vehicle.
2. Fit the rear shim of the outer handle.
3. Fit the rear of the rear door outer handle into the plate
of the outer handle.
4. Fix the outer handle cover to the outer handle plate,
tighten the screw to 2–2.5Nm and check the torque.
5. Press the cap into the round hole on the door and
secure the cap clip firmly so that seal can be achieved.
6. Close the door and check if the outer handle can work
1.0 999
Body Systems Door
Rear Door Outer Handle Liner Rear Door Interior Trim Panel Refit
Remove
2. Ensure the rear door window glass is fully ascended.
Rear Door Interior Trim Panel Remove
4. Remove the rear door waterproof membrane.
5. Remove the rear door outer handle.
Rear Door Outer Handle Remove
6. Remove the rear gasket from rear door outer handle.
7. Remove the screw fixing the rear door outer handle
liner to the door.
8. Release the clip fixing the outer handle link to the lock
end.
9. Remove the outer handle liner assembly from the door
cavity.
10. Disconnect the rear door outer handle link from the
rear door outer handle liner.
Refit
1. Insert the rear door outer handle link into the clip of
rear door outer handle liner.
2. Fit the rear door outer handle liner assembly from the
rear door cavity, and locate it to the mounting position
on the door outer panel.
3. Fit the screw fixing the outer handle liner to the door
from the outside of door with the tightening torque of
4. Insert the rear door outer handle link into the
corresponding lock slot.
5. Refit the rear door outer handle.
Rear Door Outer Handle Refit
6. Try to open the door with the outer handle and ensure
all parts are correctly fitted.
7. Fit the rear door waterproof membrane.
8. Fit the rear door interior trim panel.
1.0 1000
Door Body Systems
Rear Door Adjustment
Rear Door Hinge Adjustment
the door to support the rear door.
3. Loosen 2 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 panel of the body side panel and if the
door can open and close normally.
5. After the adjustment, open the door, and tighten the
screws to 15–21Nm, and check the torque.
6. Close the door.
4. Use a jack to support the vehicle and adjust the door.

5. Pre-tighten the bolt fixing the hinge to the door.
6. Take away the jack, close the door and check if the
adjustment is proper.
7. When the desired adjustment is achieved, tighten the
hinge bolts to 42–48Nm, and check the torque.
Rear Door Lock Catch Adjustment
Rear door striker is a latch with two screws. In most cases,
it is necessary to adjust the striker upward/downward or
inward/outward:
• Frame damage resulting from a collision.
• Fit a new door weatherstrip.
• The customer complains that the wind noise is too loud.
• It is difficult to open or close the door.
Adjust the lock catch 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, and then pre-tighten the screws.
1.0 1001
Body Systems Door
Rear Door Assembly tighten to19–25Nm, and check the torque.

Remove 5. Close the door and check if the door can be properly
1. Disconnect the battery negative. opened or closed.
2. Open the rear door. 6. Connect the battery negative.
the door to support the rear door.
4. Remove the bolt fixing the door check to the body,
and discard the bolt.
5. Prize up the rubber seal ring on the body, and pull out
the connector to disconnect the connector interface.
6. With the help of an assistant, hold the outside of
the door, then remove and discard 2 bolts fixing the
upper/lower hinges to the door.
Caution: Please protect paint from scratch when

removing or refitting the door assembly.
7. Remove the rear door assembly.
Refit
1. With assistance, locate the door to the vehicle body.
2. Connect the connector port, and embed the rubber
seal ring into the mounting hole of the body.
3. Fit 2 new bolts fixing the upper and lower hinges of
the rear door to the door, tighten to 42–48Nm and
check the torque.
4. Fit new bolts fixing the door checker to the body,
1.0 1002
Door Body Systems
Rear Door Hinge Assembly Rear Door Lock Body Assembly
Remove Remove
1. With assistance, remove the rear door assembly. 1. Open the rear door.
Rear Door Assembly Remove 2. Ensure the rear window glass is fully ascended.
2. From the outside of the body, remove 2 bolts (1) fixing 3. Remove the rear door interior trim panel assembly.
the upper/lower hinge to the body, and discard the Rear Door Interior Trim Panel Assembly Remove
bolts. 4. Carefully remove the waterproof membrane.
3. Remove the B pillar lower trim panel. 5. With a flat blade screwdriver, carefully remove the clip
B Pillar Lower Trim Panel Remove fixing the outer handle link to the lock of rear door
and release the link.
4. From the inside of B pillar, remove 1 bolt (2) fixing the
upper hinge of rear door to the body, and discard the 6. Remove 3 bolts fixing the rear door lock, and take out
bolt. Remove the upper hinge of rear door. the door lock from the door cavity carefully.
5. From the inside of B pillar, remove 1 bolt (2) fixing the
lower hinge of rear door to the body, and discard the
bolt. Remove the lower hinge of rear door.
7. Disconnect the lock harness connector.

8. Carefully disconnect the inner handle cable end of the
rear door from the lock assembly to remove the lock
assembly.
Refit
1. Locate the lower hinge of rear door to the body B pillar.
2. Fit a new bolt fixing the lower hinge to the body from
the inside of B pillar, tighten to the specified torque of
3. Locate the upper hinge of rear door to the body B pillar.
4. Fit a new bolt fixing the upper hinge to the body from
the inside of B pillar, tighten to the specified torque of
5. Fit the B pillar lower trim panel.
B Pillar Lower Trim Panel Refit

6. Fit 2 new bolts fixing the upper and lower hinges to
the body from the outside of B pillar, tighten to the Refit
specified torque of 30–36Nm and check the torque. 1. Fit the inner cable of the rear door to the lock.
7. Fit the rear door assembly. 2. Connect the lock harness connector.
Rear Door Assembly Refit 3. Locate the lock to the mounting position from the door
cavity, fit 3 screws and tighten to torque 8–12Nm.
Check the torque.
4. Connect the rear door outer handle release rod and
lock, and secure the clip.
1.0 1003
Body Systems Door
5. Fit the rear door waterproof membrane. Front Door Window Slideway Weatherstrip
6. Fit the rear door interior trim panel. Remove
7. Check if the outer/inner handle of rear door can work
properly. Front Door Interior Trim Panel Remove
Caution: Before taking down the panel, please raise the
glass so that the bolts is just in the mounting holes of the
door.
3. Carefully remove the front door waterproof membrane

from the door sheet metal.
4. Remove the inner weatherstrip of front door
windowsill.
5. Remove the outer weatherstrip of front door
windowsill.
Front Door Windowsill Outer Weatherstrip
Remove
6. Remove 2 screws securing the glass to the window
regulator.
7. Carefully remove the glass from the door window

frame.
8. Remove the front door window chute weatherstrip
carefully.
Refit
1. Refit the front door window chute weatherstrip.
1.0 1004
Door Body Systems
2. Carefully place the glass between the inner panel and Front Door Windowsill Inner Weatherstrip
outer panel through the window frame, and fit the Remove
chute weatherstrip from both sides. 1. Open the front door.
3. Descend the glass slowly until it touches the slider of 2. Remove the front door interior trim panel.
the glass regulator, fix the glass clip to the small terrace
of the slider and align the hole of the glass clip with the Front Door Interior Trim Panel Remove
slider hole of the regulator. 3. Pull up and remove the front door windowsill inner
4. Fit 2 screws fixing the front door glass to the front weatherstrip.
door glass regulator, tighten to 7–10Nm, and check
the torque.
5. Fit the inner weatherstrip of front door windowsill.
6. Fit the outer weatherstrip of front door windowsill.
Front Door Windowsill Outer Weatherstrip Refit

Refit
1. Align the weatherstrip opening with the door inner
sheet metal seam allowance, and fit the front door
windowsill inner weatherstrip.
1.0 1005
Body Systems Door
Front Door Windowsill Outer Weatherstrip Front Door Window Regulator

Remove Remove
1. Open the front door. 1. Open the front door.
2. Push the door side weatherstrip aside. 2. Disconnect the battery negative.
3. Remove 1 screw securing the front door windowsill 3. Remove the front door interior trim panel.
outer weatherstrip to the door sheet metal. Front Door Interior Trim Panel Remove
door.
4. Carefully remove the front door waterproof membrane

5. Remove the inner weatherstrip of front door
windowsill.
6. Remove the outer weatherstrip of front door
windowsill.
Remove
4. Remove the exterior mirror assembly.
regulator.
Exterior Mirror Assembly Remove
5. Carefully pull the outer weatherstrip up from the front
to the end of door in order and remove it.
Refit
1. Align the front door windowsill outer weatherstrip
with the door sheet metal, then fit it onto the revers of
door sheet metal from A pillar to B pillar.
2. Refit the exterior mirror assembly.
Exterior Mirror Assembly Refit

3. Fit 1screw securing the front door windowsill outer
weatherstrip to the body, tighten to 1–2Nm, and
check the torque.
8. Remove the front door glass.
4. Fit the door weatherstrip to the door.
9. Remove 5 bolts fixing the glass regulator to the door
5. Close the front door.
sheet metal.
10. Carefully remove the glass regulator from the door

cavity.
1.0 1006
Door Body Systems
Refit Front Door Window
1. Fit the glass regulator into the front door cavity, fit 5 Remove
bolts securing the glass regulator on the door sheet 1. Open the front door.
metal, tighten the bolts to 7–10Nm from top to 2. Disconnect the battery negative.
bottom and from left to right, and check the torque.
2. Carefully place the glass between the inner panel and
outer panel through the window frame, and fit the Front Door Interior Trim Panel Remove
chute weatherstrip from both sides. Caution: Before taking down the panel, please raise the
3. Descend the glass slowly until it touches the slider of glass so that the bolts is just in the mounting holes of the
the glass regulator, fix the glass clip to the small terrace door.
of the slider and align the hole of the glass clip with the 4. Carefully remove the front door waterproof membrane
slider hole of the regulator. from the door sheet metal.
4. Fit 2 screws fixing the front door glass to the front 5. Remove the inner weatherstrip of the front door
door glass regulator, tighten to 7–10Nm, and check windowsill.
the torque.
6. Remove the outer weatherstrip of the front door
5. Fit the front door waterproof membrane. windowsill.
Front Door Interior Trim Panel Refit Remove
7. Connect the battery negative. 7. Remove 2 screws securing the glass to the window
8. Check if the glass regulator can work properly, and regulator.
check if the window with "one-touch up" function can 8. Carefully remove the glass from the door window
operate normally. frame.
Note: In case of power off, the "one-touch" ascending Refit
function may fail; To reset the function, press the switch 1. Carefully place the glass between the inner panel and
to ascend the window to the top, press and hold it for outer panel through the window frame, and fit the
5s to complete the self learning, then the "one-touch" chute weatherstrip from both sides.
ascending mode will be recovered. 2. Descend the glass slowly until it touches the slider of
of the slider and align the hole of the glass clip with the
slider hole of the regulator.
3. Fit 2 screws fixing the front door glass to the front
door glass regulator, tighten to 7–10Nm, and check
the torque.
5. Fit the inner weatherstrip of front door windowsill.
6. Fit the outer weatherstrip of front door windowsill.
Front Door Windowsill Outer Weatherstrip Refit

1.0 1007
Body Systems Door
Central Control Door Lock Switch Power Window Switch - Rear Door
Remove Remove
1. Remove the driver door trim panel assembly. 1. Remove the rear door trim panel.
Driver Door Trim Panel Remove Rear Door Trim Panel Remove
2. Disconnect the connector harness at the back of the 2. Disconnect the harness connector on the back of the
door lock switch. switch.
3. Release the clip and remove the door lock switch from 3. Release 4 clips securing the rear window switch onto
the front of the door trim panel. the door trim panel.
Refit 4. Remove the rear window switch from the back of the
1. Refit the door lock switch to the driver interior door door trim panel.
trim panel from the frontal direction, and secure it with Refit
the clip. 1. Connect the connector at the back of rear door power
2. Connect the harness to the harness connector on the window switch to the rear door harness.
back of the door lock switch. 2. Fit the rear door power window switch onto the rear
3. Refit the driver door trim panel. door interior trim panel and secure it.
Driver Door Trim Panel Refit 3. Fit the rear door interior trim panel.
1.0 1008
Door Body Systems
Power Window Switch - Driver Side Power Window Switch - Front Passenger Side
Remove Remove
1. Remove the driver door trim panel. 1. Remove the right front door interior trim panel.
Driver Door Trim Panel Remove Front Door Interior Trim Panel Remove
2. Disconnect the harness connector on the back of the 2. Carefully release 6 clips securing the front passenger
switch. power window switch onto the front door interior
3. Release 6 clips securing driver door window switch trim panel handle.
onto the door trim panel. 3. Disconnect the harness connector from the back of the
4. Remove the window switch from the back of the door front passenger power window switch.
trim panel. 4. Remove the front passenger power window switch.
Refit Refit
1. Connect the harness to the connector on back of the 1. Connect the connector at the back of front passenger
driver door window switch. power window switch to the right front door harness.
2. Refit the door window switch from the back of door 2. Fit the front passenger power window switch onto the
trim panel and secure with 6 clips. front door interior trim panel and secure it.
3. Refit the driver door trim panel. 3. Refit the right front door interior trim panel.
Driver Door Trim Panel Refit Front Door Interior Trim Panel Refit
5. Check if the window glass regulator can work. During
assembly/disassembly, the "one-button up/down" and
"anti-pinch" functions may fail, in this case, perform
Driver Power Window Switch Self-learning
1.0 1009
Body Systems Door
Rear Door Windowsill Outer Weatherstrip Rear Door Windowsill Inner Weatherstrip
Remove Remove
1. Open the rear door. 1. Open the rear door.
2. Gently pull up the outer weatherstrip from the front to 2. Remove the rear door interior trim panel.
end of the rear door and remove it.
Refit
3. Remove the inner weatherstrip of rear door windowsill.
1. Align the rear door windowsill outer weatherstrip with
the door sheet metal, then fit them onto the flanging
of door sheet metal from the front to end of the rear
door.
2. Close the rear door.
Refit
1. Align the weatherstrip opening with the door inner
sheet metal seam allowance, and fit the rear door
windowsill inner weatherstrip.
2. Refit the rear door interior trim panel.
1.0 1010
Door Body Systems
Rear Door Window Slideway Weatherstrip the glass regulator, fix the glass clip to the small terrace
Remove of the slider and align the hole of the glass clip with the
1. Open the rear door. slider hole of the regulator.
2. Disconnect the battery negative. 4. Fit 2 screws fixing the rear door window to the rear
door window regulator, tighten to 7–10Nm, and check
the torque.
Rear Door Interior Trim Panel Remove 5. Refit the rear door waterproof membrane.
Caution: Before taking down the panel, please raise the 6. Fit the rear door interior trim panel.
door.
4. Carefully remove the rear door waterproof membrane
6. Remove the outer weatherstrip of rear door windowsill.
7. Remove 2 screws securing the window to the window
regulator and remove the rear door window.
8. Remove the rear door window chute weatherstrip

carefully.
Refit
1. Refit the rear door window chute weatherstrip.
2. Place the glass between the inner panel and outer panel
through the door window frame, and fit the chute
weatherstrip from both sides.
3. Descend the glass slowly until it touches the slider of
1.0 1011
Body Systems Door
Rear Door Window Regulator metal, tighten the bolts to 7–10Nm from top to
Remove bottom and from left to right, and check the torque.
1. Open the rear door. 2. Place the glass between the inner panel and outer panel
2. Disconnect the battery negative. through the door window frame, and fit the chute
Caution: Before taking down the panel, please raise the of the slider and align the hole of the glass clip with the
glass so that the bolts is just in the mounting holes of the slider hole of the regulator.
door.
4. Fit 2 screws fixing the rear door window to the rear
4. Carefully remove the rear door waterproof membrane door window regulator, tighten to 7–10Nm, and check
from the door sheet metal. the torque and refit the rear door window.
5. Remove the inner weatherstrip of rear door windowsill. 5. Fit the inner weatherstrip of rear door windowsill.
6. Remove the outer weatherstrip of rear door windowsill. 6. Fit the outer weatherstrip of rear door windowsill.
7. Remove 2 screws securing the glass to the window 7. Fit the rear door waterproof membrane.
regulator. 8. Fit the rear door interior trim panel.

9. Check if the window regulator can work.

frame.
9. Remove 5 bolts fixing the glass regulator to the door
sheet metal.
10. Carefully remove the glass regulator from the door

window frame.
Refit
1. Fit the glass regulator into the rear door cavity, fit 5
bolts securing the glass regulator on the door sheet
1.0 1012
Door Body Systems
Rear Door Window
Remove

door.

4. Remove the outer weatherstrip of rear door windowsill.
5. Carefully remove the rear door waterproof membrane
regulator.
frame.
Refit
1. Place the glass between the inner panel and outer panel
through the door window frame, and fit the chute
of the slider and align the hole of the glass clip with the
slider hole of the regulator.
3. Fit 2 screws fixing the rear door window to the rear
door window regulator, tighten to 7–10Nm, and check
the torque.
4. Refit the rear door waterproof membrane.
5. Refit the outer weatherstrip of rear door windowsill.
6. Refit the inner weatherstrip of rear door windowsill.
7. Fit the rear door interior trim panel.
1.0 1013
Body Systems Front Closures
Front Closures
Specifications
Torque
Description Value
Bolt - hood latch safety to hood panel 7–10Nm
Nut - hood hinge to hood panel 19–25Nm
Bolt - hood hinge to body 26–34Nm
Bolt - hood hinge to body 26–34Nm
Bolt - hood latch to platform 7–10Nm
Screw - hood open handle 1.3–1.9Nm
Bolt - fender to body 7–10Nm
Screw-front bumper bracket to body 2–2.5Nm
Bolt - head lamp to bodywork 3–5Nm
Bolt-intercooler to platform 4–6Nm
Bolt-From front bumper impact bar to fend upper tie bar 7–10Nm
Bolt - head lamp bracket to body 7–10Nm
Bolt - head lamp bracket to MFE 7–10Nm
Bolt- wiper container to bodywork 4–6Nm
Bolt - battery bracket to body 19–25Nm
Bolt-battery tray bracket to body 40–50Nm
1.0 1014
Front Closures Body Systems
Service Procedures 5. After adjustment, tighten the 4 nuts to 19–25Nm,
Bonnet Assembly check the torque and close the bonnet.
Remove
Warning: Take special attention to avoid vehicle damage
and personal injury.
1. Open and support the bonnet properly.
2. Remove 4 nuts fixing the bonnet hinges to the bonnet.
3. With the help of an assistant, remove the bonnet.

4. Remove the bonnet safety lock from the bonnet.
Refit
Warning: Bonnet will drop under its own weight during
removal and refit, ensure panel is fully supported.
1. Secure the bonnet safety lock on the bonnet with bolts,
tighten the bolts to 7–10Nm and check the torque.
2. With the help of an assistant, position the bonnet to
the body.
Caution: DO NOT damage the thread on the bolt when
inserting the bolt into the fit hole.
3. Fit 4 nuts securing the bonnet hinges to the bonnet on

both sides, but do not tighten the nuts.
4. Check if the bonnet is properly positioned, and
adjust the clearance and surface difference between
the bonnet and the front fender. It shall meet DTS
(dimension technical specification) requirements.
1.0 1015
Bonnet Hinge Assembly Bonnet Inspection and Adjustment

Remove Inspections
Warning: Take special attention to avoid vehicle damage Inspect the positioning of the bonnet:
and personal injury. 1. The curve from the bonnet to the front fender must
1. Mark the hinge relative to the bonnet for positioning be unblocked;
during installation. 2. The gap between the bonnet and the front fender must
2. With assistance, remove the bonnet. be uniform;
3. The front rake of the bonnet must be kept level with
Bonnet Assembly Remove
the front fender.
3. Remove 4 bolts fixing the hinges to the body side on
Adjustment
both sides.
1. Mark the profile of the bonnet hinges with a non
permanent marker.
2. Loosen the nuts securing the hinges to the bonnet.
4. Remove the hinges on both sides.

Refit
1. Locate the hinges to the body on both sides, and align
it with the position marked when removing. 3. Adjust the bonnet and align it with the front fender.
2. Fit 4 bolts fixing the hinges to the body on both sides , 4. Tighten the nut on the bonnet hinge to19–25Nm, and
tighten the bolts to 26–34Nm, and check the torque. check the torque.
3. With assistance, fit the bonnet. 5. Loosen the bolts securing the hinges to the body.
6. Adjust the position of the bonnet at lateral and
Bonnet Assembly Refit
front/rear direction to align the bonnet with the front
Warning: Bonnet will drop under its own weight during fender, and the front corner of the bonnet should be
removal and refit, ensure panel is fully supported. horizontal with the front fender.
7. Tighten the hinge bolts (body side) to 26–34Nm, and
check the torque.
1.0 1016
Engine Hood Lock Body Assembly upper radiator beam bracket, aligning it with the
Remove location marked at the time of removal.
1. Open and support the engine hood properly. 3. Fit 3 bolts fixing the lock body assembly to the upper
2. Remove the front bumper assembly. radiator beam bracket, and do not tighten the bolt to
the specified torque at this step.
4. Close the engine hood, observe the relative location of
3. Mark the lock location on the upper radiator beam lock and lock catch, and adjust lock body location until
bracket so that proper location can be found for the lock catch drops into tab smoothly.
installation.
5. After adjustment, tighten the 3 bolts to the specified
4. Remove 3 bolts (1) fixing the engine hood lock to the torque of 7–10Nm, and check the torque.
upper radiator beam.
5. Disconnect the harness connector (2) of engine hood
lock. Front Bumper Assembly Refit
7. Close the engine hood.
6. Separate the engine hood cable assembly from the lock

body assembly to remove the lock body assembly.
Refit
1. Connect the engine hood release cable assembly lock
end to lock body assembly firmly, that is, place the ball
end of cable core wire in the stopper hook slot of
engine hood lock body and place the core wire in the
elongated slot in the engine hood lock case. Align the
circular slot on the main cable protection pipe end with
the mounting slot on the lock case, and press it hard
until a "click" sound is heard.
2. Locate the engine hood lock body assembly to the
1.0 1017
Engine Hood Release Cable completed.

Remove
1. Open the engine hood and support it with a rod firmly.
2. Remove the engine hood lock body assembly.
Engine Hood Lock Body Assembly Remove
3. Release the clips of engine hood release cable assembly
from the engine compartment in proper order.
3. Refit the engine hood lock body assembly.
Engine Hood Lock Body Assembly Refit

4. Pull the engine hood open handle inside the driver
compartment to check if the engine hood can work
properly.
4. Release the engine hood release cable assembly from

the end of engine hood lock body.
5. Release the engine hood release cable assembly from

the open handle.
6. Drag the engine hood release cable assembly from the
engine compartment.
Refit
1. Locate the release cable assembly of the engine hood
to the engine compartment, fit the flat blade end to the
driver compartment through the bulkhead hole of the
front engine compartment, and secure it in the bulkhead
hole with the rubber seal ring of the cable assembly.
2. Insert the cylindrical end of the engine hood release
cable assembly into the cylindrical hole of the open
handle, place the core wire into the long slot of the
handle, and align the cable pipe connector with the
mounting slot of the open handle, then press it hard
till a "click" can be heard, then the connection is
1.0 1018
Bonnet Open Handle Assembly Engine Hood Silencer
Remove Remove
1. Pull up the bonnet open handle. 1. Open and support the engine hood properly.
2. Remove 2 self-tapping screws fixing the bonnet open 2. Remove 12 staple bolts securing the silencer to hood
handle assembly to the instrument panel lower closing and take down the hood silencer.
plate.
Refit
3. Pull the bonnet release cable assembly out of the open 1. Align holes of silencer with those of hood.
handle to remove the release handle assembly. 2. Press 12 new staple bolts into holes.
Refit
1. Align the 2 circular mounting holes on the bonnet
opener handle assembly base with the 2 mounting holes
on the instrument panel, and align the quadrate salience
with the quadrate hole on the instrument panel, and
make the two fitting surfaces snug.
2. Secure the opener handle to the instrument panel with
2 self-tapping screws, the torque is 1.3–1.9Nm, and
check the torque.
3. Fit one side of the cable assembly column shape end to
the bonnet opener handle assembly.
1.0 1019
Fender
Remove

Refit
1. Locate and adjust the fender.
2. Fix the fender to the body, do not secure the bolts.
3. Adjust the gap between the fender and adjacent panels
and ensure uniform gap. Then tighten 6 bolts securing
the fender to body to 7–10Nm, and check the torque.
Meanwhile, tighten 1 screw and 1 nut fixing the fender
4. Remove the headlamp assembly. to the body to the same torque range.
5. Remove 2 screws fixing the front bumper mounting 4. Fit the side corner of A/C intake grille.
bracket, then remove the front bumper mounting
A/C Intake Grille Side Corner Refit
bracket.
5. Fit the acoustic pad of fender.
6. Fit sill molding.
Sill Molding Refit

7. Fit the front wheelhouse liner.
8. Fit the front bumper bracket. Tighten 2 screws securing
the front bumper bracket to the body to 2–2.5Nm,
11. Align the headlamp assembly mounting point, fit bolts
6. Remove the front wheelhouse liner. and tighten to 3–5Nm, then check the torque.
Front Wheelhouse Liner Remove
7. Remove sill molding. Front Bumper Assembly Refit
Sill Molding Remove

8. Remove the acoustic pad of fender.
9. Remove the A/C intake grille side corner.
A/C Intake Grille Side Corner Remove

10. Remove 6 bolts (1), 1 nut (2) and 1 screw (3) connecting
fender to body, then remove the fender.
1.0 1020
Upper Radiator Beam upper mounting panel of the left headlamp.
Remove
8. Remove 2 bolts (1) connecting the upper mounting

panel of the left headlamp and the body and 2 bolts
(2) connecting the upper mounting panel of the left
headlamp and the upper radiator beam, and remove the
upper mounting panel of the left headlamp.
4. Remove the headlamp assembly.
5. Remove 3 split pins fixing the air filter inlet pipe to the
upper radiator beam.
9. Remove 2 bolts (1) connecting the upper mounting

panel of the right headlamp and the body and 2 bolts
(2) connecting the upper mounting panel of the right
headlamp and the upper radiator beam, and remove the
6. Remove 2 bolts fixing the coolant expansion tank to upper mounting panel of the right headlamp.
the upper mounting panel of the left headlamp.
10. Remove 3 bolts (1) fixing the engine hood lock to the
7. Remove 1 bolt fixing the washer reservoir neck to the upper radiator beam.
1.0 1021
11. Disconnect the harness connector (2) of the engine

hood lock.
19. Remove the 5 screws (3) connecting the front bumper

beam and upper radiator beam to disconnect the front
12. Separate the engine hood cable assembly from the lock bumper beam.
body assembly to remove the lock body assembly. 20. Disconnect 2 connectors of the front impact sensor in
13. Remove 1 bolt (1) fixing the upper left radiator airflow the upper radiator beam, and disconnect the clip fixing
deflector to the body. the harness of the front impact sensor to the upper
radiator beam.
14. Remove 3 clips (2), (3) fixing the lower left radiator
airflow deflector to the upper left radiator airflow
21. Remove 2 bolts (1) and 2 bolts (2) connecting the upper
radiator beam, radiator and intercooler, and remove
the upper radiator beam
15. Remove the left radiator airflow deflector from the
vehicle.
16. Repeat step 13～15, remove the right radiator airflow
deflector.
17. Remove the harness clip on the front bumper beam.
18. Remove 6 bolts (1) and 2 nuts (2) fixing the front
bumper beam to the body.
Refit
1. Fix the upper radiator beam to the intercooler and
radiator, fit bolts, tighten to 4–6Nm and check the
1.0 1022
torque. Front Bumper Assembly Refit
2. Connect 2 connectors of the front impact sensor in the
upper radiator beam, and fix the harness clip of the
front impact sensor to the upper radiator beam.
3. Connect the front bumper beam and upper radiator
beam with screws, and tighten the screw to 7–10Nm.
6. Fit 3 clips (2), (3) fixing the lower left radiator airflow
deflector to the upper right radiator airflow deflector
7. Repeat step 5～6, fit the right radiator airflow deflector.
8. Fit the harness clip to the front bumper beam.
9. Fit 3 bolts fixing the lock body assembly to the upper
radiator beam bracket, and do not tighten the bolt to
the specified torque at this step.
10. Close the engine hood, observe the relative location of
lock and lock catch, and adjust lock body location until
the lock catch drops into tab smoothly.
11. After adjustment, tighten the 3 bolts to the specified
torque of 7–10Nm, and check the torque.
12. Fix the upper mounting panel of the right headlamp
to the upper radiator beam and body, tighten 2 bolts
connecting the upper mounting panel of the right
headlamp and the body to 7–10Nm, tighten 2 bolts
connecting the upper mounting panel of the right
headlamp and the upper radiator beam to 7–10Nm
13. Fix the upper mounting panel of the left headlamp
to the upper radiator beam and body, tighten 2
bolts connecting the upper mounting panel of the
left headlamp and the body to 7–10Nm, tighten 2
bolts connecting the upper mounting panel of the left
headlamp and the upper radiator beam to 7–10Nm
14. Fix the washer reservoir bolt to the upper mounting
panel of the left headlamp, tighten the bolt to 4–6Nm
15. Secure the coolant expansion tank on the frame, fit 2
bolts, and tighten to 4–6Nm.
16. Fix the air filter inlet pipe to the upper radiator beam
and fit 3 split pins.
18. Align the headlamp assembly mounting point, fit bolts
and tighten to 3–5Nm, then check the torque.
1.0 1023
Battery Tray Battery Tray Bracket

Remove Remove
1. Disconnect the battery negative and positive. 1. Remove the battery tray.
2. Release 2 nuts, and remove the battery lock block. Battery Tray Remove
2. Remove 3 bolts fixing the battery tray bracket to the
vehicle body and remove one of brackets.
3. And then remove another battery tray bracket.

4. Remove the battery assembly.
5. Remove 4 bolts fixing battery tray , and remove the
battery tray. Refit
1. Fix the battery tray bracket to the vehicle body and
tighten bolts to 40–50Nm. And check the torque.
2. Refit the battery tray.
Battery Tray Refit
Refit
1. Refit the battery tray, screw 4 bolts fixing the battery
tray, tighten the torque to 19–25Nm, and check the
torque.
2. Refit the battery assembly.

screwing.
negative).
1.0 1024
Rear Closures Body Systems
Rear Closures
Specifications
Torque
Description Value
Bolt - Fuel filler door to body 7–10Nm
Screw - hood open handle 1.3–1.9Nm
Bolt - Tailgate hinge to body 26–34Nm
Bolt - tailgate latch to tailgate 19–25Nm
Bolt - tailgate striker to tailgate sill 19–25Nm
Nut - Tailgate hinge to body 26–34Nm
Bolt - Spigot-gas strut to body 19–25Nm
Bolt - Electromagnetism striker to tailgate sill 19–25Nm
1.0 1025
Body Systems Rear Closures
Service Procedures Oil Filler Flap Shutter Cable Assembly

Fuel Filler Door Assembly Remove
Remove 1. Pull the open handle of the fuel filler on the lower
1. Pull up the open handle of the fuel filler door under shield of the driver side instrument panel, and open
the driver side instrument panel assembly to open the the fuel filler flap.
fuel filler door. 2. Release the open cable assembly of the fuel filler flap
2. Release the fuel filler cap connecting wire from fuel from the open handle of the fuel filler flap (see the
filler door, as shown in figure 1. arrow).
3. Remove 2 bumper blocks from fuel filler door.
4. Unscrew 2 bolts connecting the fuel filler door to the
body, as shown in figure 2, and remove the fuel filler
door assembly.
3. Remove the side trim panel of left trunk.

4. Remove the left front seat belt tab cover.
5. Remove the sill trim panel of left door.
Refit
6. Remove the left A pillar lower trim panel.
1. Locate the fuel filler door to the body, take care to
adjust the gap around the fuel filler door to avoid the A Pillar Lower Trim Panel Remove
interference with side panel. 7. Lift the carpet at the left side to expose the cable
2. Refit the bolt, tighten to 7–10Nm, and check the assembly, and release the cable from the electrical
torque. harness clips.
3. Fit the fuel filler door bumper block.

4. Stuck the fuel filler cap connecting wire into the fuel
filler door, and close fuel filler door.
8. Disconnect the shutter from the body, and draw the

shutter manual cable assembly of the fuel filler flap from
the fuel filler flap.
1.0 1026
Fuel Filler Door Open Handle
Remove
1. Pull the fuel filler door open handle.
2. Remove 2 self-tapping screws fixing the fuel filler flap
open handle assembly to the instrument panel lower
closing plate.
Refit
1. Fit the small end of the shutter manual cable assembly
to the trunk through the fuel filler flap and the hole
on the side panel, push the shutter into the hole along
the hole axis till it clicks and clips at both sides of the
shutter are completely stuck into the side panel.
2. Pass the cable assembly into the rear of compartment
3. Release the fuel filler door release cable from the open
through the left side of trunk, fix the cables to electrical
handle to remove the fuel filler door open handle
harness clips along the direction from left compartment
assembly.
door sill edge to instrument panel in turn, and finally
Refit
clamp the cylindrical end of cable assembly into the gap
of open handle at the bottom of instrument panel. 1. Insert the cylindrical end of the fuel filler door release
cable assembly into the cylindrical hole of the open
3. Pull the open handle of the fuel filler flap on the lower
handle, place the core wire into the long slot of the
shield of the driver side instrument panel assembly, and
handle, and align the cable pipe connector with the
check the connection of shutter manual cable assembly.
mounting slot of the open handle, then press it hard
4. Arrange the carpet at the left compartment.
until it clicks.
5. Refit the left A pillar lower trim panel.
2. Align the two round mounting holes on the base of
A Pillar Lower Trim Panel Refit the fuel filler door open handle assembly with the
6. Refit the left door sill trim panel. two mounting holes on the lower closure plate of the
instrument panel, and align the square protrusion of the
7. Refit the left front seat belt tab cover.
base with the square hole on the lower closure plate
8. Refit the side trim panel of left trunk. of the instrument panel. The two mounting surfaces
Trunk Side Trim Panel Refit shall fit.
9. Close the fuel filler flap. 3. Fit 2 self-tapping screws fixing the open handle of the
fuel filler door to the instrument panel, tighten the
screw to 1.3–1.9Nm, and check the torque.
1.0 1027
Tailgate Assembly Refit

Remove 1. Locate the tailgate to the body with assistance, and
1. Open the tailgate. align it with the mark.
2. Disconnect the battery negative. 2. Fit the bolt fixing the tailgate hinge to the tailgate, but
3. Remove the tailgate lower trim panel. do not tighten it to the specified torque.
Tailgate Trim Panel Remove Warning: As the large weight of the tailgate, operations
4. As indicated by the arrow, release the harness sheath should be performed after the safety feature is set, and
at both sides of tailgate, and disconnect the harness take extra care to prevent the vehicle from damaging and
connector. personal injury.
3. Press the ball head socket of the gas spring pistons at
both sides into the ball head of the tailgate side panel
till a 'click' sound is heard, which indicates that they are
fitted in place. Fit the steel piece.
Caution: Oil seals are waxed and must not be lubricated

prior to fitting.
4. Check the fit clearance and surface difference between

the tailgate and the side body panel and back panel
and ensure they meet the DTS (dimension technical
specification) requirements. After adjustment, tighten
the bolt to the specified torque of 26–34Nm, and
check the torque.
5. With assistance, remove 4 bolts fixing the hinges on 5. Refit the tailgate trim panel.
both sides to the tailgate. If it is required to refit the
tailgate, a reference position shall be marked on the
hinge.
equipped.
Warning: As the large weight of the tailgate, operations

should be performed after the safety feature is set, and
take extra care to prevent the vehicle from damaging and
personal injury.
6. With assistance, carefully pry off the clips of gas spring
pistons at both sides of tailgate, pull out the ball head
socket of piston from the ball head of tailgate, and
remove the tailgate assembly.
personal injury.
1.0 1028
Tailgate Lock Body Assembly Tailgate Trim Panel Refit
Remove 7. Connect the battery negative.
1. Disconnect the battery negative after unlocking the 8. Perform the self-learning for the power tailgate, if
tailgate. equipped.
2. Open the tailgate.
3. Remove the lower trim panel assembly of the tailgate.
4. Remove 2 bolts fixing the tailgate lock to the tailgate.
5. Remove the tailgate lock sleeve.

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

Refit
1. Locate the tailgate lock to the tailgate sheet metal
through the tailgate cavity.
2. Connect the harness connector.
3. Fit 2 bolts fixing the tailgate lock to the tailgate, but
do not tighten the bolts.
4. Check and adjust the fit clearance and the surface
difference between the tailgate lock and the surrounding
sheet metals, then tighten the lock bolt to 19–25Nm,
5. Push the tailgate lock sleeve into the lock until a "click"
sound can be heard, which indicates it is fitted in place.
6. Fit the lower trim panel of tailgate.
1.0 1029
Tailgate Lock Catch Tailgate Hinge Assembly

Remove Remove
1. Open the tailgate. 1. Open the tailgate.
2. Remove the trunk sill trim panel. 2. Remove the tailgate assembly.
Trunk Sill Trim Panel Remove Tailgate Assembly Remove
3. Mark the tailgate lock catch relative to the quarter 3. Mark the position of tailgate hinge on the vehicle body
panel. with a non-permanent marker.
4. Remove 2 screws securing the tailgate lock catch onto 4. Release the roof interior trim panel at tailgate end to
the quarter panel. access to the nut fixing the tailgate hinge.
5. Remove the nut fixing the hinge assembly to the body
from the inside of body (the hinge bolt indicated
corresponds to the nut fitted from the inside of body)
to remove the tailgate hinge assembly.

personal injury.
5. Remove the tailgate lock catch.

Refit
1. Pre-tighten the tailgate lock catch according to marks
of tailgate lock catch and rear 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 lock catch.
3. Make sure that the tailgate lock is fully locked, and 6. Remove the tailgate hinge assembly.
check if the electrical signal of tailgate lock is correct. Refit
4. Tighten the bolt securing the lock catch to the rear 1. Locate the tailgate hinge assembly to the marked
panel to the torque of 19–25Nm, and check the mounting location on the body.
torque.
2. Fit the nut fixing the tailgate hinge to the body, tighten
5. Refit the trunk sill trim panel. the nut to 26–34Nm, and check the torque.
Trunk Sill Trim Panel Refit 3. Fit the roof interior trim panel (at tailgate end).
4. Fit the tailgate assembly.
Tailgate Assembly Refit

equipped.
1.0 1030
Tailgate Air Spring and Mounting Bracket 6. Refit the steel spring piece on both ball head sockets
Remove of the gas spring, and ensure it is properly located in
1. Open the tailgate, and when removing, make sure it is the spring piece slot.
securely supported. 7. Repeat step 1-6, fit the right gas spring of the tailgate.

personal injury.
2. Carefully pry up the steel spring piece on both sides of
left gas spring to pull the piston ball head socket from
the tailgate ball head.
3. Then pull the ball head socket of gas spring sleeve from
the ball head of left body bracket.
4. Repeat step 2-3 to remove the right gas spring.
5. Finally, remove the screw fixing the tailgate inner panel
and brackets on both sides of body respectively and
remove the tailgate gas spring mounting bracket.
Refit
1. Respectively align the left gas spring mounting bracket
with the hole on the trunk and the hole on the tailgate.
2. Tighten the gas spring ball heads respectively with the
torque of 19–25Nm.
3. 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.
4. 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.
Caution: To avoid damaging the airtightness of the air

spring, never hold the centre of the air spring and laterally
apply force to it by hand.
5. Align the ball head socket on the left gas spring piston
with the ball head on the tailgate inner panel. Hold
the end of piston, push the ball head socket into the
1.0 1031
Tailgate Electric Prop Assembly 5. Connect the harness connector of tailgate electric
Remove brace rod assembly.
1. Open the tailgate, and when removing, make sure it is 6. Refit the left D pillar upper trim panel.
securely supported. D Pillar Upper Trim Panel Refit
Warning: As the large weight of the tailgate, operations 7. Connect the battery negative.
8. Perform the self-learning for the power tailgate.
personal injury. Power Tailgate Self-learning
3. Remove the left D pillar upper trim panel.
4. Disconnect the harness connector of tailgate electric
brace rod assembly.
5. Carefully pry up the steel spring piece on both sides of

left gas spring to pull the piston ball head socket from
the tailgate ball head.
6. Then pull the ball head socket of gas spring sleeve from
the ball head of left body bracket.
Refit
1. 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.
2. Hold the sleeve, push the ball head socket into the
Caution: To avoid damaging the airtightness of the air
spring, never hold the centre of the air spring and laterally
apply force to it by hand.
3. Align the ball head socket on the left gas spring piston
with the ball head on the tailgate inner panel. Hold
the end of piston, push the ball head socket into the
4. Refit the steel spring piece on both ball head sockets
of the gas spring, and ensure it is properly located in
the spring piece slot.
1.0 1032
Power Tailgate Controller 4. Connect the battery negative cable.
Remove 5. Perform the self-learning for the power tailgate.
1. Open the tailgate, and when removing, make sure it is
securely supported.
personal injury.
3. Remove the left D pillar upper trim panel.
4. Release the clip fixing the power tailgate controller to
the body.
5. Disconnect the harness connector of the power tailgate

controller.
6. Take out the power tailgate controller from the

chamber.
Refit
1. Connect the power tailgate controller harness
connector .
2. Refit the clip of the power tailgate controller into the
corresponding hole of the vehicle body.
3. Refit the left D pillar upper trim panel.
Left D Pillar Upper Trim Panel
1.0 1033
Power Tailgate Anti-pinching Stripe Tailgate Trim Panel Refit

Remove 4. Repeat the steps 1-3, and refit the right tailgate
1. Open the tailgate, and when removing, make sure it is anti-pinch strip.
securely supported. 5. Connect the battery negative cable.
personal injury.
3. Remove 4 clips fixing the anti-pinch strip at the left
tailgate to the tailgate.
4. Remove the upper left trim panel of tailgate.

5. Disconnect the harness connector of the tailgate
anti-pinch strip.
6. Remove the anti-pinch strip at the left tailgate.
7. Repeat the step 3-6, and remove the anti-pinch strip

at the right tailgate.
Refit
1. Refit 4 clips securing the left tailgate anti-pinch strip
to the tailgate.
2. Connect the tailgate anti-pinch strip harness connector.
3. Refit the upper left tailgate trim panel.
1.0 1034
Electric Suction Latch Assembly Tail Gate Weatherstrip
Remove Remove
1. Open the tailgate. 1. Open the tailgate, and make sure it is securely
2. Disconnect the battery negative. supported during removal.
3. Remove the trunk sill trim panel. 2. Pull out the tailgate weatherstrip carefully and remove
it down.
Refit
4. Mark the electric lock catch relative to the rear panel.
1. Open the tailgate, and when removing, make sure it is
5. Disconnect the harness connector of the electric lock securely supported.
catch .
2. Align the tailgate weatherstrip connector with the left
6. Remove 2 bolts fixing the electric lock catch to the headlamp mounting area of the rear body close to the
rear panel. edge of sheet metal centre and insert the weatherstrip
into the edge.
3. Insert the weatherstrips into the edge from the
connector position in both the clockwise and
counterclockwise directions from top to bottom
respectively.
4. Tap the weatherstrip in place with the rubber hammer.
equipped.
Refit
1. Pre-tighten the electric lock catch assembly according
to marks of the electric lock catch assembly and rear
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 lock catch.
3. Make sure that the electric lock is fully locked, and
check if the electrical signal of electric lock is correct.
4. Tighten 2 bolts securing the electric lock catch to the
rear panel to the torque of 19–25Nm, and check the
torque.
5. Refit the trunk sill trim panel.
Trunk Sill Trim Panel Refit
6. Perform the self-learning for the power tailgate.
1.0 1035
Body Systems Horn
Horn
Specifications
Torque
Description Value
Bolt-hororn bracket to the front rail 7–10Nm
1.0 1036
Horn Body Systems
Service Procedures
Horn
Remove
3. Disconnect the connector (1) of tweeter/woofer.
4. Remove the bolt (2) securing the tweeter/woofer onto
the front wheelhouse front connector.
Refit
1. Fix the horn onto the front wheelhouse front
connector, fit 1 bolt, tighten to 7–10Nm, and check
the torque.
2. Connect the connector of the horn.
1.0 1037
Body Systems Body Control Module
Body Control Module

Specifications
Torque
Description Value
Screw-BCM to front left body panel 5–7Nm
1.0 1038
Body Control Module Body Systems
System Layout
1.BCM Module
1.0 1039
A=Diagnostic HS CAN Bus；B=Chassis HS CAN Bus；C=Power HS CAN Bus；D=Body HS CAN Bus；E=LIN Bus
1.0 1040
Description Pin No. Description
Mounting Location:
1 KL.30
BCM is in left front panel of A pillar. 2 Right Low Beam Output
BCM includes the low power mode microprocessor, flash 3 Right Daytime Running Lamp/Puddle Lamp
memory, electrically erasable programmable read-only
4 KL.30
memory (EEPROM), CAN, LIN transceiver and power
supply in low power mode. It has discrete input and output 5 GND
terminals which control most of the body functions. It 6 KL.30
interacts with other primary electrical systems through the
7 Left Daytime Running Lamp Output
high speed CAN bus, and interacts with the secondary
electrical systems through the LIN bus. Its power mode 8 —
master control module (PMM) provides power for most of
the electrical components. BCM End View and Pin Information of Harness
Connector BY085
The BCM communicates directly with the following
components through the body HS CAN bus:
• Power liftgate control module (PLCM)

• PMDC (DC converter with power management) (2.0T)
• ACM (A/C)
• FICM (entertainment system)
• IPK (instrument pack)
• PEPS (passive entry and passive start control module)
• GW (GATEWAY)
With LIN bus, the body control module directly

communicates with the following parts:
• SR (sunroof) Pin No. Description

• SS (sunshade) 1 KL.30
• IMMO (low frequency immobiliser coil) 2 —
• RS (rain sensor)
3 —
• DDSP(driver door combination switch)
4 Left Low Beam Output
• PWL (power window regulator motor)
5 GND
BCM End View and Pin Information of Harness
Connector BY084 6 Unlock 0utput
7 —
8 GND
9 KL.30
10 Driver Door Unlock Output
11 KL.30
12 Luggage Compartment Unlock Output
13 Door Lock Output
14 —
1.0 1041
BCM End View and Pin Information of Harness 24 Left Seat Heater Relay Coil End Output
Connector BY086
25 —
26 —
27 —
28 —
29 —
30 —
31 Left Position Lamp Output
32 Right Position Lamp Output

Connector BY087
Pin No. Description

1 Front Wiper Stop Position Feedback
2 —
3 KL.15 Relay Coil End Output
4 Starter Relay Coil End Output (Only for
start/stop system)
5 Horn Relay Coil End Output
6 —
7 —
8 Right Seat Heater Relay Coil End Output
9 Rear Window Heater Output Pin No. Description
10 Rear Window Washer Pump Relay Coil End 1 Left Front Window Up Output
Output 2 Left Front Window Down Output
11 Front Windshield Washer Pump Relay Coil End 3 Right Front Window Up Output
Output 4 Right Front Window Down Output
12 Rear Wiper Motor Relay Coil End Output 5 Right Rear Window Up Output
13 Front Wiper Motor Speed Relay Coil End 6 Right Rear Window Down Output
Output
7 Left Rear Window Up Output
14 Front Wiper Motor Enable Relay Coil End
Output 8 Left Rear Window Down Output
15 Front Fog Lamp Relay Coil End Output 9 —
16 Master Light Relay Coil End Output 10 High Mounted Stop Lamp Output
17 High Side Drive Output 11 License Plate Lamp Output
18 — 12 Interior Roof Lamp PWM Output
19 Engine Hood Input 13 —
20 — 14 —
21 — 15 —
22 — 16 —
23 — 17 —
1.0 1042
18 — 10 Luggage Compartment Lamp Output
19 — 11 —
20 — 12 —
21 — 13 LIN3
22 Right Brake Lamp Output 14 —
23 Right Rear Direction Indicator Lamp/Right 15 —
Width Lamp Output 16 Left Rear Window Down Switch Input
24 Right Front Direction Indicator Lamp Output 17 Clutch Switch Input
25 Right Position Lamp Output 18 Left Rear Window Auto Switch Input
26 Reverse Lamp Output 19 Left Rear Window Up Switch Input
27 Left Brake Lamp Output 20 Neutral Gear Switch Input
28 Rear Fog Lamp Output 21 —
29 Left Position Lamp Output 22 Left Rear Door Status Input
30 Left Front Direction Indicator Lamp Output 23 Luggage Compartment Door Status Input
31 Left Rear Direction Indicator Lamp/Left Width 24 Right Rear Window Down Switch Input
Lamp Output
25 LIN5
32 Interior Roof Lamp Delay Relay Output
26 —
BCM End View and Pin Information of Harness 27 Right Front Window Auto Switch Input
Connector BY088
28 Reverse Gear Switch Input
29 Right Rear Window Auto Switch Input
30 Right Rear Window Up Switch Input
31 Right Front Window Down Switch Input
32 Right Front Window Up Switch Input
33 Right Rear Door Status Switch Input
34 Right Front Door Status Switch Input
35 Driver Door Lock Input
36 —
37 —
Pin No. Description 38 —
1 — 39 LIN1
2 — 40 —
3 — 41 Luggage Compartment Release Switch Input
4 — 42 Left Front Door Status Switch Input
5 — 43 Left Front Door Unlock Input
6 — 44 —
7 — 45 —
8 Atmosphere Lamp 46 Washer Fluid Level Alarm Input
9 P Gear Lock Output 47 —

48 —
1.0 1043
49 Rear Wiper Motor Stop Position Switch Input 19 —

50 Brake Pedal Switch Input 20 Hazard Warning Lamp Switch Input
51 MS CAN High 21 —
52 MS CAN Low 22 Light Sensor Ground
23 —
Connector FA026 24 —
25 IGN Switch Run Input/Start Signal Input
26 One-button Start ACC Indicator Output
27 GND
28 Front Fog Lamp Switch Signal
29 Master Light Switch Input
30 —
31 —
32 —
33 —
34 —
Pin No. Description
35 —
1 —
36 —
2 —
37 One-button Start ST/RUN Indicator Output
3 —
38 Light Sensor Request Signal
4 —
39 —
5 Central Lock Switch Input
40 Rear Washer Switch Input
6 —
41 Front Wiper Switch Input 2
7 Master Light Switch Input
42 Front Wiper Intermittent Wipe Switch Input
8 Direction Indicator Lamp Switch Input
43 Rear Wiper Switch Input
9 —
44 Front Washer Switch Input
10 Private LIN
45 One-button Start Switch Input
11 —
46 —
12 KL.50
47 Front Wiper Switch Input 1
13 Central Unlock Switch Input
48 Horn Switch Input
14 Headlamp Washer Pump Coil Input
49 Door Status LED Lamp Output
15 —
50 Light Sensor Power Supply
16 —
51 ACC Wake-up Signal
17 —
52 —
18 —
1.0 1044
Operation With the aftermarket diagnostic tool, the MG Authorised
Overview Repairer can change the configuration of the vehicle load
management from transportation mode to normal mode.
When the ignition switch is enabled, the BCM will wake up the
security system, lighting system and diagnostic system. When Normal Mode
the ignition switch is in the ACC position, the BCM allows the The normal mode is the default setting, in this mode, the
washer/wiper and power window system to operate. When vehicle can function properly.
the ignition switch is in the START/RUN position, the fuel
Sleep Status
system starts to work, and the BCM communicates with other
ECUs through the CAN bus and LIN bus. When the IGN switch is off, and the CAN bus and LIN bus
are disabled, if the battery is still connected, then the BCM
Load Management
will stay in the sleep (standby) status and be ready to receive
BCM can manage the load of some electric appliances by the signal from the CAN bus and LIN bus.
configuration and ensure low battery power consumption
Wake-up Status
during storage and transportation or idle time.
In sleep mode, perform one of the following operations to
Production Mode
wake up the BCM.
It refers to the mode configured for the BCM during vehicle
• Receive the activation signal of the hazard waring lamp
assembly.
switch.
Transportation Mode
• Receive the activation signal of the direction indicator
After assembly, programme the BCM to use transportation lamp switch.
mode during transportation. This can avoid severely low • Receive the LOCK signal of the interior lock.
battery when delivering the vehicle to the MG Authorised
• Receive the UNLOCK signal of the interior lock.
Repairer. The transportation mode may have restrictions on
some functions of the electric component, as follows: • Receive the activation signal of the driver door switch.
• Receive the activation signal of the passenger door
• The rear fog lamp does not work unless the engine is
switch.
running.
• Receive the activation signal of the engine hood switch.
• The front fog lamp does not work (if fitted) unless the
engine is running. • Receive the activation signal of the tailgate switch.
• The high beam headlamp does not work unless the engine • Receive the activation signal of the tailgate release switch.
is running. • Receive the activation signal of the driver door LOCK
• The low beam headlamp does not work unless the engine switch.
is running. • Receive the activation signal of the driver door UNLOCK
• The reverse lamp does not work unless the engine is switch.
running. • The ignition switch is in the 1st gear.
• The park lamp does not work unless the engine is • The ignition switch is in the 2nd gear.
running. • Signal of Depressed Brake Pedal
• The direction indicator lamp does not work unless the • SSB Data (PEPS)
engine is running. • Activation Signal of Interior Lamp Switch
• The daytime running lamp does not work (if fitted) unless • LIN Wire Wake-up Signal
the engine is running.
• CAN Wire Wake-up Signal
• The auto lamp does not work (if fitted) unless the engine
• Wake-up Signal of Local Hard Wire
is running.
• Valid RF Signal
• "Follow Me Home" and "Find My Car" functions cannot
be realized. Load Management
• The backlight of the hazard warning lamp does not work At the moment when the engine is started, to ensure the
unless the engine is running, but the function of the starter motor can obtain the maximum current required,
hazard warning lamp is in normal state. the power of some electric loads shall be disconnected. For
• When the engine is not operated, the window can be example, disconnect the power of the HRW, intelligent
ascended, but the descending operation is prohibited. stop/start energy saving system DISABLE switch, front fog
1.0 1045
lamp (if fitted), high beam headlamp, reverse lamp, horn and The diagnostic socket can exchange information between
interior lamp, etc. the BCM and the aftermarket diagnostic tool. The closure
panel of the driver side instrument panel is above the driver's
Diagnosis
leg and is made according to the ISO standard. There is a
BCM monitors all the information inputs and outputs, if any special diagnostic bus between the gateway and the TBOX.
faults are detected, the corresponding DTC will be stored in The diagnostic bus allows to read the diagnostic information
the fault record. BCM can detect the short and open circuits with the scan tool and programme some functions.
as well as wrong CAN and LIN bus signals. When a fault
is detected, the BCM will close the corresponding functions.
When the fault is eliminated, the corresponding function will
be activated when the function is requested next time.
1.0 1046
Service Procedures
Body Control Module
Remove
2. Remove the driver side lower trim panel assembly.
Remove
3. Disconnect the connector of the BCM.
4. Remove 3 screws fixing BCM to the right front panel
of body.
5. Remove BCM.
Refit
1. Connect the connector of the BCM.
3. Programme and encode the BCM.

Encoding - BCM Replacement
4. Fix BCM to the left front panel of body, fit 3 screws
and tighten to 5–7Nm, and check the torque.
Refit
1.0 1047
Body Systems PMDC
PMDC
Specifications
Torque
Description Value
Blot-PMDC to body 7–10Nm
1.0 1048
PMDC Body Systems
System Layout
1. PMDC (under the driver seat)
1.0 1049
Body Systems PMDC
A = Power HS CAN Bus; B = Chassis HS CAN Bus; C = Body HS CAN Bus; D = LIN; E = Hard Wire
1.0 1050
PMDC Body Systems
Description 10 LIN Bus
Mounting position 11 —
The PMDC module is under the driver seat (below the carpet), 12 Current Sensor Power
which performs power management and DC conversion. 13 —
End View and Pin Information of PMDC Harness 14 Current Sensor Ground
Connector BY031 15 Battery -
16 —
17 KL.15
18 —
19 KL.50
20 —
21 —
22 —
23 Power Management Module (PMG)
Ground
24 —
25 —
26 —
Pin No. Description
27 Power Management Module (PMB)
1 Output Voltage 1 Power
2 Output Voltage 2 28 —
3 DC-DC Power Input 2 29 Current Signal
4 DC-DC Power Input 1 30 —
5 DC-DC Ground 2 31 —
6 DC-DC Ground 1 32 Battery ＋
7 Body HS CAN Low 33–38 —
8 Body HS CAN High
9 —
1.0 1051
Body Systems PMDC
Operation is low, apply electrical load limit mode, and the hazard
Function level will be displayed on the instrument.
Power Management DC conversion
• Battery status detection: this function detects real-time The DC converter module includes boost mode and bypass
battery status and collects information involving the mode.
voltage, current and temperature of the battery. After • Boost mode: it is enabled when the stop/start is
the vehicle is locked, it can determine battery status activated and the battery is in good state. During start,
by the self wake-up signal of less than 1s every hour. the stop/start mode ensures normal operation of the
If high power consumption is detected, the PMDC will IPK, entertainment system and A/C by providing a stable
continue detecting the discharge current of the battery. voltage (appr. 12V) for some electric equipment that
After the vehicle is unlocked, the PMDC reports the ensures ride comfort.
battery status and acquires vehicle working condition by
• Bypass mode: it is enabled when the boos mode is
the CAN, and it also communicates with the LIN bus
disabled, which can directly use the input voltage of the
of the alternator and has it prepared for starting. During
PMDC as an output voltage.
start, the PMDC continues detecting the action of the
battery. To ensure quick response, the PMDC will enter Self-learning
into the specific start detection mode when the start The PMDC detects real-time battery status and collects
signal is valid. information involving the voltage, current and temperature
• Intelligent charge control: it can improve charge of the battery. When the battery negative is reconnected
efficiency by calculating the charge voltage of the after disconnection or when the battery is replaced, vehicles
alternator and adjusting the alternator output voltage with the intelligent stop/start energy saving system shall be
automatically according to the battery status and fuel stationary for at least 4hr so that the PMDC can acquire
efficiency. The charge indicator lamp on the instrument stable and accurate battery status information and meet the
panel provides status information of the alternator for operation requirement of the intelligent stop/start energy
the user. During start, no alternator status will be saving system. Failure to observe the above requirements
displayed; when the engine is working, if overvoltage, can lead to failure of the intelligent stop/start energy saving
undervoltage or mechanical fault occurs in the alternator, system before the PMDC can acquire any accurate battery
the power controller requests the instrument to display status information.
the fault.
• Load management: this function manages the load
according to vehicle load and power. When the battery
1.0 1052
PMDC Body Systems
Service Procedures
DC Converter with Electrical Power
Management
Remove
2. Search for the preset cutting mark on the carpet near
the sliding rail on the right of driver seat.
3. Cut the carpet along the mark.
4. Disconnect the connector (1) from PMDC.
5. Remove 2 bolts (2) securing PMDC to the body.
6. Remove PMDC.
Refit
1. Connect the connector of the PMDC.
3. Programme and code the PMDC.

Coding - PMDC Replacement
4. Fix the PMDC to the body, fit 2 bolts, tighten to
5. Resume the carpet, and try not to damage the cotton
felt of the carpet for the felt can prevent depression
of the carpet.
1.0 1053
1.0 1054
Body Dimension Body Repair
Body Dimension
Point to Point Dimensional Information
Vehicle Side and Top Information
Location From To Length (mm)

A-Y Front Door Hinge Mounting Front Door Lock Catch Mounting Hole 1012
Hole
B-Y Front Door Hinge Mounting Front Door Lock Catch Mounting Hole 986
Hole
C-Y Front Door Hinge Mounting Front Door Lock Catch Mounting Hole 1063
Hole
D-Y Front Door Hinge Mounting Front Door Lock Catch Mounting Hole 1038
Hole
E-Y Fender Mounting Hole Front Door Lock Catch Mounting Hole 1013
F-Y Fender Mounting Hole Front Door Lock Catch Mounting Hole 1080
G-Z Rear Door Hinge Mounting Rear Door Lock Catch Mounting Hole 989
Hole
H-Z Rear Door Hinge Mounting Rear Door Lock Catch Mounting Hole 962
Hole
I-Z Rear Door Hinge Mounting Rear Door Lock Catch Mounting Hole 1086
Hole
J-Z Rear Door Hinge Mounting Rear Door Lock Catch Mounting Hole 1062
Hole
1.0 1055
Body Repair Body Dimension
K-L Sunroof Mounting Hole Sunroof Mounting Hole 770

K-M Sunroof Mounting Hole Sunroof Mounting Hole 1440
L-M Sunroof Mounting Hole Sunroof Mounting Hole 817
Note: All dimensions are to hole/slot centres.
1.0 1056
Bottom Plate Information

A Front Subframe Mounting Front Subframe Mounting Hole - RH 550
Hole - LH
B Front Longitudinal Beam Front Longitudinal Beam Mounting Hole - RH 738
Mounting Hole - LH
C Fuel Tank Mounting Hole - LH Fuel Tank Mounting Hole - RH 712
D Trailing Arm Mounting Hole - Trailing Arm Mounting Hole - RH 1309
LH
E Trailing Arm Mounting Hole - Trailing Arm Mounting Hole - RH 1272
LH
F Rear Subframe Mounting Rear Subframe Mounting Hole - RH 707
Hole - LH
G Rear Suspension Shock Rear Suspension Shock Absorber Column 1172
Absorber Column Mounting Mounting Hole - RH
Hole - LH
H Rear Suspension Shock Rear Suspension Shock Absorber Column 1173
Absorber Column Mounting Mounting Hole - RH
Hole - LH
I Rear Subframe Mounting Rear Subframe Mounting Hole - RH 1034
Hole - LH
a Main Standard Hole Front Subframe Mounting Hole 733
1.0 1057
b Main Standard Hole Front Longitudinal Beam Mounting Hole 1357

c Main Standard Hole Fuel Tank Mounting Hole 1844
d Main Standard Hole Trailing Arm Mounting Hole 2422
e Main Standard Hole Trailing Arm Mounting Hole 2604
f Main Standard Hole Rear Subframe Mounting Hole 2804
g Main Standard Hole Rear Suspension Shock Absorber Column 2904
Mounting Hole
h Main Standard Hole Rear Suspension Shock Absorber Column 3011
Mounting Hole
i Main Standard Hole Rear Subframe Mounting Hole 3113
1.0 1058
Rear End Information

A-Z Tail Lamp Mounting Hole - LH Tail Lamp Mounting Hole - RH 1526
B-Y Tail Lamp Mounting Hole - LH Tail Lamp Mounting Hole - RH 1196
C-X Tail Lamp Mounting Hole - LH Tail Lamp Mounting Hole - RH 1196
D-W Rear Bumper Bracket Rear Bumper Bracket Mounting Hole - RH 1474
Mounting Hole - LH
E-V Rear Bumper Bracket Rear Bumper Bracket Mounting Hole - RH 1358
Mounting Hole - LH
F-U Mounting Hole of Rear Mounting Hole of Rear Bumper Anti-collision 1014
Bumper Anti-collision Beam Beam - RH
- LH
G-T Rear Bumper Mounting Hole Rear Bumper Mounting Hole - RH 780
- LH
H-S Rear Bumper Mounting Hole Rear Bumper Mounting Hole - RH 722
- LH
I-R Mounting Hole of Rear Mounting Hole of Rear Bumper Anti-collision 1100
- LH
J-Q Mounting Hole of Rear Mounting Hole of Rear Bumper Anti-collision 900
- LH
1.0 1059
1.0 1060
Internal Information

A-C Airbag ECU Anchor Point Gear Shit Mechanism Anchor Point 138
A-D Airbag ECU Anchor Point Gear Shit Mechanism Anchor Point 163
A-E Airbag ECU Anchor Point Gear Shit Mechanism Anchor Point 470
B-C Airbag ECU Anchor Point Gear Shit Mechanism Anchor Point 112
B-D Airbag ECU Anchor Point Gear Shit Mechanism Anchor Point 69
B-F Airbag ECU Anchor Point Gear Shit Mechanism Anchor Point 400
1.0 1061
Front End Information

A-Z Front Suspension Shock Front Suspension Shock Absorber Mounting 1240
Absorber Mounting Hole - Hole - RH
LH
B-Y Front Suspension Shock Front Suspension Shock Absorber Mounting 1052
LH
C-X Front Suspension Shock Front Suspension Shock Absorber Mounting 1241
LH
D-W Fender Mounting Hole - LH Fender Mounting Hole - RH 1491
E-V Fender Mounting Hole - LH Fender Mounting Hole - RH 1477
F-U Fender Mounting Hole - LH Fender Mounting Hole - RH 1471
G-T Bumper Beam Mounting Hole Bumper Beam Mounting Hole - RH 921
- LH
H-S Bumper Beam Mounting Hole Bumper Beam Mounting Hole - RH 1095
- LH
1.0 1062
Gap Information
Body Side and Fuel Filler Cap Information
Location Detailed Description Gap Dimension (mm) Outer Profile (mm)

A Fender to Front Door 4.0±0.7/0.5 0±1.0/0
B Front Door to Rear Door 4.0±0.7/0.5 0±1.0/0
C Rear Door to Rear Side Panel 4.0±0.7/0.5 0±1.0/0
D Rear Door to Rear Fender 4.0±1.0/1.0 N/A
Flare
E Fender to Sill Trim Panel 2.0±1.0 N/A
F Sill Trim Panel to Front Door 6.0±1.5 N/A
G Sill Trim Panel to Rear Door 6.0±1.5 N/A
H Oil Filler to Rear Side Panel 3.0±0.75//0.75 -0.5±0.5
I Oil Filler to Rear Side Panel 3.0±0.75//0.75 0±0.5
Note: “//” represents parallel requirement, It means the difference between maximum clearance and minimum
clearance should be within the required range.
1.0 1063
Front End Information

A Headlamp to Grille 2.5±1.2 N/A
B Engine Hood to Headlamp (6.5-5.0)±1.0 N/A
C Headlamp to Front Bumper 2.0±1.0//1.0 N/A
D Front Fog Lamp to Front Bumper 2.0±0.8//0.8 N/A
E Lower Grille to Front Bumper 1.0±0.5 N/A
1.0 1064

A Fender to Front Bumper 0+0.5/0 0±0.5//0.5
B Front Bumper to Front Fender 0.3±0.3 N/A
Flare
C Fender to Front Fender Flare 0.3±0.3 N/A
D Engine Hood to Fender 3.5±0.75//0.75 0±0.5
E Engine Hood to Fender 3.5±0.75//0.75 -1.0±0.5
F Fender to A Pillar 2.5±0.5 0±1.0//1.0
G Headlamp to Fender 2.0±1.0//1.0 N/A
H Headlamp to Fender 1.5±1.0//1.0 0±1.0//1.0
1.0 1065
Rear End Information

A Tail Lamp A to Rear Side Panel 1.5±0.9//0.9 -1.0±0.8//1.0
B Tail Lamp B to Tailgate Molding 1.5±1.0//1.0 1.0±1.0//0.8
C Tail Lamp B to Tailgate 1.5±0.8//0.8 N/A
D Tail Lamp A to Rear Bumper 1.5±0.8//0.8 N/A
E Tail Lamp A to B 4.0±1.2//1.0 0±1.0
F Rear Bumper to Rear Side Panel 0+0.5/0 0±0.5//0.5
G Rear Fender Flare to Rear Bumper 0.3±0.3 N/A
1.0 1066

A Tailgate to Rear Bumper 6.0±1.2//1.0 N/A
B Tailgate Molding to Tailgate 1.0±0.5 N/A
C Rear Window to Rear Side Panel 4.0±1.0//1.0 -4.3
D Rear Window to Tailgate 3.0±1.0//1.0 -3.0±1.0//1.0
1.0 1067
Sunroof Information

A Sunroof to Roof 0 -1.7±0.7
B Sunroof to Roof 0 (-1.7-0.5)±1.0
C Sunroof to Roof 0 0.5±0.7
1.0 1068
Paint and Coatings Body Repair
Paint and Coatings
Summary
The purpose of automobile coating is to make the car have a
good appearance, decor, color and luster as well as enhancing
its corrosion resistance and service life:
• Automobile painting belongs to advanced protective

coating. It must have excellent corrosion resistance,
weather resistance, acid resistance and alkali resistance,
as well as a wide range of adaptability.
• Automotive painting also belongs to the senior
decorative painting category. It must be carefully
designed to have a suitable coating environment and
condition to make the coating have a good decorative Role of Each Coating
function. The automobile decoration mainly depends on 1. Galvanized layer: with sound anticorrosive, antirust
the coating, which depends on the coating quality, and function, painting quality, decorative and shaping
directly affects the commodity value of the automobile. performance.
• Automotive painting is the most typical form industrial 2. Zinc phosphate layer: directly sprayed on surface of
coating, and must undergo a reasonable and efficient pretreated parts, it is the basis of the whole coating. It
pretreatment method, drying method and process must have the following characteristics:
preparation.
• Good adhesion to the surface of pretreated parts, and
• The automotive coating system contains multiple the formed paint film should have excellent mechanical
coatings, each coating’s quality and process control are strength.
particularly important.
• Must be an anti - corrosion agent, having excellent
Introduction of Each Coating
corrosion resistance, water resistance and chemical
Coating Composition resistance;
The production coating process contains a galvanized layer,
• Highly compatible with the intermediate coating or
phosphate layer, electrophoretic layer, buffer layer, topcoat
topcoat.
layer and a final varnish layer.
• Good construction performance.
3. Electrophoretic layer: Improves the anticorrosive

performance of the cavity, the uniformity of coating
thickness, leveling property, the quality of coating film and
the coating efficiency as well as the coating utilization.
4. Putty layer: Used on the pre primed surface to fill surface
pits and defects, welding seams and scratches, until a
smooth surface is formed.
5. Buffer layer: the final middle coating before the topcoat.
Its paint content varies between the primer and topcoat,
and the film is in a bright and semi bright state. It has
the following functions:
• Enhance the adhesion of topcoat;

The coating repair process contains primer, putty layer, buffer
layer, topcoat layer and a final varnish layer. • Increase the total coating thickness, and improve the
fullness;
• Improve corrosion resistance and weather resistance of

the bottom primer;
• Fill small defects on the surface of the base material;
• Improve the decorative performance of the topcoat.
1.0 1069
Body Repair Paint and Coatings
6. Topcoat layer: as the final layer of automobile painting, 7. Treating the bare metal with phosphate to remove all
it directly affects the decoration, weatherability, gloss, the dust and other objects, and provide a good repair
chemical resistance, contamination resistance and overall environment.
appearance of the car.
Classification of Topcoat
According to the color effect, it can be divided into the
following categories:
• Ordinary paint: just contained with resins, pigments and
additives.
• Metallic paint: paint with added metal powder, enhancing
gloss and fullness.
• Pearl paint: Compared with metallic paint, pearl paint
uses titanium dioxide and ferric oxide coated mica
pigments to replace metal powder, so as to further
enhance the texture and glossiness of the coating.
According to the spraying process, it can be divided into the

following categories:
• Single-process: forming a complete coating with the
same paint, including the single-process ordinary paint
and double-process metallic paint.
• Double-process: forming a complete coating with two
kinds of paint. Generally, the topcoat is sprayed first, and
then the varnish. including the double-process ordinary
paint, double-process metallic paint and double-process
pearl paint.
• Three-process: Generally, the topcoat is sprayed first,
then the pearl paint and last the varnish. The three layer
paint is combined to form the complete coating. An
example would be the three-process pearl paint.
Principles of Coating Repair
Please follow the following principles in the process of coating
repair:
1. Using the certified sealant to seal the inner and outer

seams.
2. The paint repair system should be consistent with the
original production parts.
3. Apply the cavity wax to all the inner surfaces that have
not been painted.
4. The vehicle must be washed thoroughly with a steam
cleaner or a high pressure washer before paint repairing.
5. Thorough cleaning of the area to be repaired with gentle
and water soluble cleaning solution, then conducting the
painting work immediately.
6. In order to ensure that the exposed metal area is
thoroughly cleaned, the clean areas should be bigger than
the original damaged area.
1.0 1070
Paint Process
The automotive painting process, generally can be divided into
two parts:
1. Surface treatment of metal before painting, also called the
pre-treatment technology;
2. Spray process of each coating.
Pre-Treatment of Panel Surface
Surface pretreatment mainly includes the following work:
1. Surface cleaning：thoroughly clean the dirt, and foreign
substances on the vehicle, pay particular attention to the
door frame, luggage compartment, engine hood gap and
the dirt at the wheel cover, if not, the new paint on the
paint film may be stained.
• Chemical materials treatment: Apply degreasing agent on

the surface, then with a clean dry cloth wipe off the agent
and removed grease with another clean dry cloth.
• Water and dust treatment: suck the moisture and dust

using a clean and dry cloth, and then dry it with high
pressure gun.
2. Coating identification and damage assessment:
• Coating identification: identifying coating types on the

body panels is very important in the coating process.
Without proper identification, serious problems will
cause. If a vehicle has never been repainted, the type of Notes of mechanical sanding:
coating can be determined according to the vehicle's user
a. Can not cross sanding high curvature，convex and
manual, but for a repainted body, the body coating type
concave surface;
must be determined in the repair process.
b. Can not sand the corner, fold seam, weld seam,
• Damage assessment：Correct assessment of damage is
adhesive or scraped sealant area with electric driven
one of the key factors to determine the maintenance
sanding machine;
cost and coating quality. After the correct assessment of
the damage，you can determine the repair scope, and c. Please do not start the sanding machine until the
then determine the transition area, parts that need to be machine reaches contact with the panel surface. Align
covered or removed, lay the foundation for the following the edge of the sanding area, and do not overexert at
correct implementation and the satisfactory repair quality. this time, otherwise, a deep trench will form.
Damage assessment methods include the visual method,
d. In order to prevent the heat deformation of the metal
touch method and ruler evaluation method:
panels, please do not stop the sanding machine in a
3. Removal of old coating: After the body is cleaned, check position for a long time;
the body paint carefully, looking for signs of coating
e. Do not let the rough sanding material reach contact
damage, such as bubbles, cracks, corrosion, exfoliation
with the fine area，it is best to cover the fine area
and other damage that are caused by baking or welding
with adhesive tape to prevent any damage.
repair. For these damages, the old coating must be
removed, Clearance rate is decided by the extent of Fine sanding operation：A fine processing of the rough
the old paint film damage and the quality requirements sanded surface to obtain a more even surface. Keep the
of new painting, and determine whether to conduct a front part of the rotating sanding wheel contact with the
full or part clearance. It is recommended to use P80～ panel and the rear part away from the panel. Keep this
P180 sandpaper to sanding out the feathered edge (the angle and move the sanding machine up and down, the
feathered edge not less than 3 cm). overlap part between each sanding mark being kept in
50%～60% is optimal.
1.0 1071
Replace new panel: using P280 ～ P320 sandpaper for

sanding the electrophoretic primer of new panel.
4. Degreasing and derusting of panel surface:
• Remove any rust on the surface. Metal rust removing

methods mainly includes: Manual derusting method
(sanding, polishing and high pressure water flushing) 、
mechanical derusting, chemical derusting and ultrasonic
derusting. Under different corrosion conditions, different
derusting methods should be conducted.
• Clean the panel surface again.

Each Coating Operation
Please refer to the following the process when coating the • After scraping ， wait for 5 minutes, and then use the
treated panel: infrared baking lamp in accordance with the putty specified
1. Spray primer temperature to bake the putty;
• Cover the surrounding area; • Wear a dust mask, and select the appropriate type of
sandpaper with a hard grinding sanding pad. A rail sanding
• Wipe the surface with a soft cloth soaked with detergent,
machine also can be used for sanding. Be careful not
at the same time, wipe off the residual detergent with
to sand the surrounding area to avoid damage. When
another clean soft cloth;
sanding with the sanding pad, it should be sanded along
• Blowing the surface again with compressed air; the horizontal direction, and from the top end gradually
moving downward;
• Spray anti-corrosion primer, and then air dry;
• Use an air blowing gun to clean the repair surface;
2. Putty operation（replacement part not need）

• Wipe with a soft cloth soaked with detergent, and dry
• Reference to the putty specification given ratio to mix the
with another piece of clean cloth.
putty and curing agent;
3. Buffer layer operation
• Using a clean putty mixing plate, make sure that the
amount each time mixed just for one time using; • Cover the surrounding area to prepare for spraying with
the primer, the covered area should be 10 cm further than
• First fill sandpaper marks and gap, and then overall
the area to be sprayed;
scraping;
• Wipe the surface with a soft cloth soaked with detergent,
at the same time, wipe off the residual detergent with
another clean soft cloth;
• Blowing the surface again with compressed air;
• Mixing the buffer primer, curing agent and solvent
according to the specification gave ratio;
1.0 1072
• First, lightly spray once, and wait 5 minutes, then spray a • Check the color code, and then retain the color schemes
second time; according to the code.
• Polish the surface of the body around the repair area to

obtain an accurate color scheme.
• Use of daylight mode stage lights or more broad daylight

to check for any difference between the allocated color
and the body original color.
• Under the same conditions （ dilution ratio, spraying

distance, air pressure, paint volume, temperature, drying
time）spray the color test board.
• After drying the test board in clean air for 15 minutes,

bake in accordance with the specified temperature and
time. Note: do not let the test board overheat in the
heating and curing process。
• After the coating film is left to set for 10 - 15 minutes, the
infrared lamp can be used for curing; • Wipe the panel that will be repaired with a soft cloth
soaked with detergent, and dry it with another piece of
• Apply sanding indicator on the surface to find the uneven
clean cloth.
place;
• Cover the surrounding area starting from the inside of the
repaired area. Avoid tearing the paper in the process.
• Use compressed air to blow the panel and the entire car
that to be sprayed. Be careful not to damage the masking
paper, and finally, wipe the surface with a dust catcher
cloth.
• In order to prevent any foreign particles mixing with paint,

please add the mixed paint to the gun tank with a filter
screen.
• Spray mildly to check the pressure, spray volume,

fan-shaped and atomization condition.
• Then spray once and wait 5～10 minutes， then spray the
• First, rough sand surface with P240 – P400 sandpaper, and second time.
then fine sand with P600 – P800 sandpaper.
• Silver paint can be sprayed a third time to ensure an
uniform distribution of silver.
5. Varnish operation
• After the topcoat layer has been sprayed, please dry it in

the air for 15 minutes, then spray the varnish. Firstly, wet
spray varnish once, and dry it in air for 5～10 minutes;
then spray the second time. After dry it in air for 15
minutes , then heat and bake. （ Note: After spraying,
the ventilation system of the spraying room must not be
closed.）
• Curing the coating film according to the product's

specified temperature and time.
• Remove the cover paper, then use compressed air to • After the coating film has cured, do not engage in any
blow the inner and outer surface of the repaired area, further processes (such as sanding or polishing) until the
thoroughly removing debris and moisture; film has completely cooled.
4. Topcoat operation 6. Polish and wax
1.0 1073
• After the coating film has completely cooled down, you • Check the accuracy of the color in the light, and then
can use P1500 or P2000 sandpaper to sanding dust point, check it out in the sunlight.
flow and other defects on the surface.
7. Facial and clean.
• Use crude wax with a wool wheel for grinding the surface. Recommend paint brand information
• Use fine wax with sponge wheel for polishing.
• Change a clean sponge wheel, and use polishing wax to

polish the polishing traces, to restore the coating original
luster.
Recommend paint brand information
PPG Sherwin-Williams Akzo Nobel
P565-895 E2G973 Priming Filler 680 Grey
P565-9850 GBP988-AR Primer Surfacer EP
Primer
P565-9085 UPO7299 Sikkens 1K All Plastics Primer
UPO7226-3 Washprimer 1K 1CF/EF
P551-1050 18380221 Kombi Filler
Putty P551-1052 Polykit IV Set
P551-1057
Buffer P565-510/511 P30 Autosurfacer Classic
layer P565-5601/5605/5607 P50 Autosurfacer Rapid
P190-376 CC645HS Autoclear Plus HS (HSR)
P190-6850 HPC15 Autoclear Xcel SET
P190-6060 CC939 Autoclear II
Varnish P190-6208+P210-6863 CC931 Autoclear Rapid
P190-588AP210-790/938/939 CC930 Autoclear Mat
P190-588+P210-760/790 CC655
NEXA Autocolor 2K（Oily paint） Ultra 7000（Oily paint） Sikkens（Oily paint）

Topcoat Aquabase plus（Water-based paint） AWX（Water-based paint） Sikkens Autowave（Water-based
paint）
1.0 1074
Coating Flaw Identify • The diameter of spray gun is too large, the atomizing of
Coating Flaw Caused by Operation and Treatment spray gun is not up to standard;
Method • Solvent evaporation rate is too slow, the paint viscosity
Particles is low, so will not adhere;
Bulges are granularly distributed on the whole or local surface • The distance between spray gun and part is too close
of coating. and the speed of spray is too slow causing the coating to
become too thick;
Possible reasons analysis:
• Insufficient time left for drying between multiple layers;
• poor air conditions of the spraying environment;
preventive measures:
• dirty clothing, bulge caused by substrate, unclean car
body; • Improve spraying environment, by monitoring the
• spray pressure deficiency, poor atomization, unclean temperature, humidity and wind speed;
spray gun, unsuitable filter screen; • Choose an appropriate solvent, noting the dissolving
• uneven dispersion of pigment or flash material, coating ability and volatilization rate;
is not filtrated or filter effect is not up to standard, • Strictly control coating construction viscosity and
paint deterioration, precipitation, flocculation and other temperature;
anomalies. • Reduce paint amount of spray gun at the same time,
• The film surface not being dry enough before moving out increase the distance and gun speed;
from the baking house. • Conduct full flash dry between each layer.
preventive measures: Defect treatment method ： For slight and partial varnish
• Ensure the spray environment is clean and not flow，polish after the defect is removed. If the flow is heavy,
contaminated; e.g. if the flow mark shown in the varnish layer is in the buffer
layer or topcoat layer, the flow mark should be polished off
• Ensure the part to be coated and worker are not
completely then re-sprayed upon.
contaminated before entering the drying house;
• Ensure the quality of coating by not using bad or poorly Pinhole
dispersed coating; Blisters or solvent bubbles that appear on the coating, and the
• Setting the optimum construction parameters of the bubble tip appear needle holes are called pinholes. If little holes
coating. The paint should be filtered before added to on the part surface are not filled, so then they are still visible
the spray gun. after spraying, these holes are called needle hole.
Defect treatment method：Small dirt spots can be treated by Possible reasons analysis:
sanding and polishing; If the impurity are large, or there are • Pinhole：coatings have been mixed with impurities, e.g.
dirty spots in topcoat layer or buffer layer, the spots should be solvent based paint mixed with water; dirt is on the
wiped off and re-sprayed upon. coated surface; drying time is insufficient between layers;
Flow Mark continuous spraying too thick; when the temperature of
drying too fast, or when the surface is drying too fast.
If after spraying liquid coating on the surface of parts, and some
wet coating drips down, causing the coating thickness to be • Needle hole：surface roughness is not filled.
uneven, you can determine the category of damage：according preventive measures:
to the shape of the flow marks it can be divided into sinking,
• Set appropriate coating temperature, humidity and wind
sagging, flow, etc.
speed;
• Mix according to the ratio of paint and solvent to ensure
• The surface temperature of the part is too low; proper mobility;
• The environment temperature and wind speed is low and • Heat slowly to avoid rapid evaporation of solvent;
the solvent vapor content in ambient air is high; • Ensure sufficient time for a full flash dry between each
• The product temperature、 spray pressure is low、the layer.
speed of spraying is slow、the distance of spray gun is
Defect treatment method：Pinhole and needle hole should be
close or the coating is too thick;
wiped off, then re-sprayed upon.
1.0 1075
Bubbles • Use suitable temperature diluent, adjust coating viscosity

A section of the coating where the diameter is 1–5mm float according to the product description;
from the surface or primer and liquid or gas fill in the coating. • Adjust spray gun pressure, adjust the gun to the
If there is water under the coating, the water vapor produced appropriate distance, reduce spraying speed;
by the evaporation of water will be the top of the coating when • Spray a suitable number of times, and ensure the
the temperature rises, then lead to foaming. thickness of coating.
Possible reasons analysis: •
• The environment temperature is high, and the coating Defect treatment method：polish surface when the orange
is naturally dryed after spraying, leading to the peel is not heavy; but when it is heavy, the orange peel should
environmental moisture penetrating into the coating. be sanded off completely, then re-sprayed upon.
• The substrate has not been fully dryed, the drying time Coating Flaw Caused by Environment and
is short between layers, and heating is too fast; Treatment Method
• Putty absorbs moisture from environment; Coating defects caused by external corrosive
• Oil, water, etc. is in compressed air pipelines. substances
Defect phenomenon: the coating is subject to acid, alkali and
preventive measures:
industrial settlement, such as asphalt, engine oil, battery acid,
• Dry grinding putty； bird droppings, acid rain, pollen, dust produced by steel making
• Ensure that the coating is clean and dry before spraying; plant, carbon black from the boiler chimney, which will lead to
the defect of coating.
• Reduce the humidity of coating room;
• Use suitable curing agents and diluent for ambient Defect treatment method: When the coating defects are not
temperature, and dry as soon as possible after spraying, heavy, as long as you are polishing the coating surface, you can
to avoid moisture penetrating into the coating layer. restore the status quo; if the colour of the coating has altered,
you will need to polish the defected parts until it is eliminated,
Defect treatment method ： Once blister appear on the
then re-spray upon.
coating surface, it will need to be polished to completely
remove the foaming defects, then re-sprayed according to the Water spots
surface conditions. Defect phenomenon: After evaporation of rain water on the
Orange Peel surface of coating or the tap water used for car washing, the
water droplets form a white ring, which can not be removed
Orange Peel is used to describe the levelling property of
by common cleaning methods.
coating: when facing the light, it can be seen when the surface
of the coating is 1 - 5mm of different levels, and the brightness Cause of production: when the water is heated and
and the fullness of different ripple areas are different. evaporated, part of the water heated to soften the coating,
and calcium and other minerals in the water enter into the
coating surface.
• The substrate is not smooth enough, or the spray
Defect prevention and treatment method: try not to wash
topcoat is sprayed when the orange peel texture of
the car under the broad daylight, after the car is washed
buffer surface is not polished smoothly enough;
wipe off the water droplets as soon as possible, to avoid heat
• The environment and substrate temperature is too high, evaporation; if there is water spot forming, polishing must be
the wind speed is too fast; carried out.
• Diluent volatility too high, the coating viscosity is too Stone strike damage
high, coating is too thin;
Defect phenomenon: in the process of moving vehicles, there
• The distance of spray gun is too far, the speed of spraying
may be some small pebbles that hit the coating, leading to
is too fast, the spray pressure is low, the paint amount of
coating coming off and forming a sharp or jagged surface; stone
the spray gun is too low.
damage often occurs at the front edge of the hood or roof of
preventive measures: a vehicle.
• Polish smoothly according the process requirements; Defect treatment method: when stone strike damage occurs,
• Control environment temperature and wind speed the coating of the defect area must be polished off , and the
（0.2–0.6m/s）; side of the feather is worn out, fill with putty or buffer, then
1.0 1076
spray topcoat; if stone hit parts are already rusty, the rust must
be must be completely removed.
When spraying the original parts of the plant, spray topcoat

directly on electrophoretic paint without buffer, and when
spraying plastic parts, do not add softener according to
the plastic soft in buffer and topcoat, all lead to decreasing
anti-stone strike ability of coating.
Fade/powder/lost light
Defect phenomenon: due to exposure to ultraviolet
light, deterioration of coating lead to color fading, resin
deterioration leads to yellow color, the coating is powdery
and loses its luster.
Defect treatment method: discoloration is often associated

with powder, complete loss of light at the same time, once
there is any one of them, the detect coating should be polished
completely and re-sprayed with buffer and the topcoat.
1.0 1077
Body Repair Collision Repair
Collision Repair in its place. The number of plug welds must match exactly
Description and Operation the number of spot welds which have been removed.
General Welding Protection Measures • Where holes are left in an existing panel after removal of
Overview the spot welds, a single MIG plug weld will be made in
each hole as appropriate.
For ease of reference, the diagrams on the following pages
Electronic Control Unit
show only the type of weld used in repair where it varies from
that used in production. The Electronic Control Units （ECU）fitted to vehicles make
it advisable to follow suitable precautions prior to carrying out
The replacement welds in the welding diagrams are denoted
welding repair operations.
by the following symbols:
Harsh conditions of heat and vibration may be generated
during these operations which could cause damage to the
units.
In particular, it is essential to follow the appropriate

precautions when disconnecting or removing the
Supplementary restraint system Diagnostic Module.
Supplementary Restraint System Precautions
Any work undertaken which involves the removal or
replacement of any item of the Supplementary Restraint
System （SRS）, requires extreme caution and adherence
to the appropriate precautions.
Equipment
A.= Single/Multiple thickness plug welds Prior to commencing any test procedure on the vehicle, ensure
that the relevant test equipment is working correctly and any
B.= MIG seam weld
harness or connectors are in good condition.
When carrying out welding operations the following criteria
This particularly applies to electronic control units.
must be observed:
Seat Belt Anchorages
• Where resistance spot welds have been used in
production, these must be reproduced with new Seat belt anchorages are safety critical. When making repairs in
spot welds in replacement where possible. All such these areas, it is essential to follow design specifications. Note
reproduction spot welds must be spaced 30 mm apart. that High Strength Low Alloy （HSLA）steel may be used
for seat belt anchorages.
• When spot welding, it is recommended that test coupons
of the same metal gauges and materials are produced to Where possible, the original production assembly should be
carry out peel tests to ensure that welding equipment used, complete with its seat belt anchorages, or the cut line
being used can produce a satisfactory joint. Plug welds should be so arranged that the original seat belt anchorage is
must be used if a satisfactory spot weld cannot be not disturbed.
produced. All welds within 250 mm of seat belt anchorages must be
• The electrode arms on hand-held spot welding guns must carefully checked for weld quality, including spacing of spot
not exceed 300 mm in length. welds.
• Single-side spot welding is not acceptable. Panel Replacement Procedure
• Gas welding and brazing are not acceptable. This procedure is designed to explain the basic panel removal
• Where 3 metal thicknesses or more are to be welded and replacement method. The main criterion in removal and
together it is imperative to use MIG plug welds to ensure replacement of body panels is that the original standard is
joint strength. maintained as far as possible. While individual repairs will differ
• MIG plug welds must be used in repair joints where there in detail, this procedure has been devised placing emphasis on
is no access for a resistance spot welder. To replace each ease of repair and the elimination of unnecessary work.
production spot weld, an 8mm (approx.) hole must be Body panels are being increasingly manufactured in high
drilled and/or punched, and a MIG plug weld then made strength steels to meet design requirements for safety and
weight saving. As panels in high strength steels cannot be
1.0 1078
Collision Repair Body Repair
visually identified, and as they are more sensitive to excess
heat than panels manufactured from low carbon steel, it is
advisable that the following procedure be observed at all
times.
Remove Panel
1. Expose resistance spot welds. For those spot welds
which are not obviously visible, use a rotary drum sander
or wire brush fitted to an air drill, or alternatively a hand
held wire brush.
4. Cut away the bulk of the panel as necessary using an air

saw.
Caution: In wheel arch areas it may be necessary to soften

underbody coating, using a hot air gun, prior to exposing
spot welds.
2. Cut out welds using a cobalt drill.
Caution: On certain panel joints MIG welds and braze

should be removed using a sander where possible, before
cutting out the panel bulk.
5. Separate spot welded joints and remove panel remnants

using hammer, bolster chisel and pincers.
3. Alternatively, use a clamp-type spot weld remover.
Prepare Old Surfaces

1. Remove any remaining sealant using a hot air gun to
minimise the risk of toxic fumes caused by heat generated
during welding.
1.0 1079
Warning: Care must be taken to avoid excessive heat

build-up when using the hot air gun.
2. Clean all panel joint edges to a bright smooth finish, using

a belt-type sander.
2. Cut new and existing panels as necessary to form butt,

joggle or brace joint as required, Remove all clamps and
metal remnants.
3. Straighten existing panel joint edges using a shaping block

and hammer.
3. Prepare new panel joint edges for welding by sanding to

a bright finish. This must include inner as well as outer
faces.
Prepare New Surfaces

1. Mark out bulk of new panel and trim to size, leaving
approximately 50 mm overlap with existing panel. Offer
up new panel/section, align with associated panels (e.g.
new body side panel aligned with door and boot lid) and
clamp it properly
4. Apply suitable weld-through primer, to panel joint

surfaces to be welded, using brush or aerosol can.
1.0 1080
5. Apply correct sealant or adhesive, as applicable, to panel Caution: Use arms not exceeding 300 mm in length.
joint surfaces.
2. Fit resistance spot welding arms and test equipment

Offer up and Align for satisfactory operation, using test coupons. Where
Offer up new panel and align with associated panels. monitoring equipment is not available, verify weld
strength by checking that metal around the weld puddle
Clamp into position using welding clamps or other clamps. pulls apart under tension during pulling.
Where a joggle or brace joint is being adopted, make a set in
the original panel joint edge or insert a brace behind the joint.
Caution: In cases where access for welding clamps is

difficult, it may be necessary to use tack welds.
1. Select arms for resistance spot welding and shape

electrode tips using a tip trimmer. Tips should be dressed
so the diameter is equal to twice the thickness of the
metal to be welded plus 3.0 mm.
3. Use a resistance spot welder where access permits. Try

to ensure weld quality by using a welding monitor where
possible.
1.0 1081
4. MIG tack weld butt joints and re-check alignment and 7. Always use MIG plug welds where excessive metal
panel contours where necessary, Ensure that a gap is thickness or limited access makes resistance spot welding
maintained to minimise welding distortion, by inserting a impractical. Make plug welds either by using holes left
hacksaw blade as an approximate guide. by the spot weld cutter, or through holes punched and
drilled for the purpose, approximately 8mm diameter.
5. Dress MIG tack welds using a sander with 36 grit disc,

or a belt-type sander where access is limited. 8. Dress all welds using either a sander with 36 grit disc, or
a belt-type sander and/or wire brush. When dressing
welds ensure an area as small as possible is removed to
protect the zinc coating.
6. MIG seam weld butt joints.
1.0 1082
Corrosion Protection Adjust the equipment so that the nozzle temperature does not
Factory Treatments exceed 90℃(194℉). Take care not to allow the steam jet to
dwell on one area, and keep the nozzle at least 300 mm from
During production, vehicle bodies are treated with the
panel surfaces.
following anti-corrosion materials:
DO NOT remove wax or lacquer from underbody or
• A PVC-based underbody sealer which is sprayed onto
underbonnet areas during repairs. Should it be necessary
the underside of the main floor, rear floor and the rear
to steam clean these areas, apply a new coating of wax or
wheel arches;
underbody protection as soon as possible.
• An application of cavity wax which is sprayed into the sill
Maintenance Inspection
panels, side member extensions and the lower areas of
the door panels; Carry out the following operations to check bodywork for
• A coat of protective wax is applied to areas of the wheel corrosion:
arch not covered by the liners. • With the vehicle on a lift, carry out visual check of
Whenever body repairs are carried out, ensure the underbody sealer for damage.
anti-corrosion materials in the affected area are repaired or • With the vehicle lowered, inspect exterior paintwork for
renewed as necessary using the approved materials. damage and body panels for corrosion.
Precautions During Body Repairs and Handling Note: If the vehicle is dirty, it will need to be washed prior
Take care when handling the vehicle in the workshop. to inspection of bodywork.
Underbody sealers, seam sealers, underbody wax and body The checks described above are intended to be visual only. It
panels may be damaged if the vehicle is carelessly lifted. is not intended that the operator should remove trim panels,
finishers, rubbing strips or sound-deadening materials when
Proprietary Anti-Corrosion Treatments
checking the vehicle for corrosion and paint damage.
The application of proprietary anti-corrosion treatments, in
1. With the vehicle on a lift, and using an inspection or spot
addition to the factory-applied treatment, could invalidate the
lamp, visually check for the following:
Corrosion Warranty and should be discouraged. This does not
apply to homologated compatible, preservative waxes which • Corrosion damage and damaged paintwork, condition of
may be applied on top of existing coatings. underbody sealer on front and rear lower panels, sills and
Fitting Approved Accessories wheel arches;
When fitting accessories, ensure that the vehicle's corrosion • Damage to underbody sealer. Corrosion in areas adjacent
protection is not affected, either by breaking the protective to suspension mountings and fuel tank fixings.
coating or by introducing a moisture trap. Note: In case no exposure of metal, the little bubble on
Do not screw self-tapping screws directly into body panels. underbody sealing material can be neglected.
Fit suitable plastic inserts to the panel beforehand. Pay special attention to signs of damage caused to panels
or corrosion protection material by incorrect jack
Always ensure that the edges of holes drilled into panels,
positioning.
chassis members and other body parts are protected with
a suitable zinc rich or acid etch primer, and follow with a
Warning: It is essential to follow the correct jacking and
protective wax coating brushed onto the surrounding area.
lifting procedures.
Do not attach painted metal surfaces of any accessory directly
to the vehicle's bodywork unless suitably protected. Where 2. With the vehicle lowered, visually check for evidence
metal faces are bolted together always interpose a suitable of damage and corrosion on all visible painted areas, in
interface material such as weldable zinc rich primer, extruded particular the following:
strip, or zinc tape.
• Front edge of bonnet.
Steam Cleaning and De-waxing
• Visible flanges in engine compartment.
Due to the high temperatures generated by steam cleaning
• Lower body and door panels.
equipment, there is a risk that certain trim components could
be damaged and some adhesives and corrosion prevention Rectify any bodywork damage or evidence of corrosion
materials softened or liquefied. found during inspection as soon as is practicable, both to
minimise the extent of the damage and to ensure the
1.0 1083
long term effectiveness of the factory-applied corrosion Underbody sealer must be applied before such
prevention treatment. components are refitted.
Where corrosion has become evident and is emanating 6. Brush sealer into all exposed seams.
from beneath a removable component (e.g. trim panel, 7. Spray the affected area with an approved service
window glass, seat etc.), remove the component as underbody sealer.
required to permit effective rectification. 8. Remove masking from component mounting faces, and
Underbody Protection Repairs touch-in where necessary.
Whenever body repairs are carried out, ensure that full sealing After refitting mechanical components, including hoses and
and corrosion protection treatments are reinstated. This pipes and other fixtures, mask off the brake discs and apply
applies both to the damaged areas and also to areas where a coat of approved underbody wax.
protection has been indirectly impaired, as a result either of
Note: Where repairs include the application of finish
accident damage or repair operations.
paint coats in the areas requiring underbody wax, carry
Remove corrosion protection from the damaged area before out paint operations before applying wax.
straightening or panel beating. This applies in particular Underbody Wax
to panels coated with wax, PVC underbody sealer, sound
The underbody wax must be reinstated following all repairs
deadening pads etc.
affecting wheel arch panels. The wax is applied over paints and
Warning: DO NOT use oxy-acetylene gas equipment to underbody sealers.
remove corrosion prevention materials. Large volumes of
Remove old underbody wax completely from a zone extending
fumes and gases are liberated by these materials when
at least 200 mm beyond the area where new underbody sealer
they burn.
is to be applied.
Note: The device used for removing strong anti-corrosion
Cavity Wax Injection
sealant can provide several speeds and efficiency. The
scraper (not pneumatic chisel) driven by compressed air After repairs, always treat areas with an approved cavity
provides a relatively quiet mechanical method by using a wax. In addition, treat all interior surfaces which have been
very rapid reciprocating motion. Move the operating edge disturbed during repairs whether they have been treated in
of the tool along with the workpiece surface to remove the production or not. This includes all box members, cavities
sealing material. and door interiors. It is permissible to drill extra holes for
access where necessary, provided these are not positioned in
The most common method of removal is by means of a hot
load-bearing members.
air blower with integral scraper. One of the most efficient
methods is the rapid cutting 'hot knife'. This tool uses a wide Ensure that such holes are treated with a suitable zinc rich
blade and is able to be used easily in profiled sections where primer, brushed with wax and then sealed with a rubber
access is otherwise difficult. grommet.
Use the following procedure when repairing underbody Before wax injection, ensure that the cavity to be treated is free
coatings: from any contamination or foreign matter. Where necessary,
clear out any debris using compressed air.
1. Remove existing underbody coatings.
Ensure that cavity wax is applied AFTER the final paint process
2. After panel repair, clean the affected area with a solvent
and BEFORE refitting any trim components.
wipe, and treat bare metal with an etch phosphate
material. During application, ensure that the wax covers all flange and
3. Re-prime the affected area. seam areas and that it is adequately applied to all repaired areas
of both new and existing panels.
Caution: DO NOT, under any circumstances, apply
underbody sealer directly to bare metal surfaces. It should be noted that new panel assemblies and complete
body shells are supplied without wax injection treatment.
4. Replace all heat-fusible plugs which have been disturbed.
Ensure that such treatment is carried out after repairs.
Where such plugs are not available use rubber grommets
of equivalent size, ensuring that they are embedded in Effective cavity wax protection is vital. Always observe the
sealer. following points:
5. Mask off all mounting faces from which mechanical • Complete all paint refinish operations before wax
components, hoses and pipe clips, have been removed. application.
1.0 1084
• Clean body panel areas and blow-clean cavities if
necessary before treatment.
• Maintain a temperature of 18℃ (64℉) during application
and drying.
• Check the spray pattern of injection equipment.
• Mask off all areas not to be wax coated and which could
be contaminated by wax overspray.
• Remove body fixings, such as seat belt retractors, if
contamination is at all likely.
• 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. Areas treated with cavity wax are shown in the
following figures.
1.0 1085
Body Seal can be plugged. Under this case, the sealant and paint can
Process Area of Under Body Seal be coated after assembly. If the inlet is of proper size, coat
the two sides of the repaired joints with jointing sealant. If
Underfloor areas and sill outer panels should be processed
the spray coating can be only operated to one side (such as
with plasticizing PVC underfloor glue. This glue is not
compartment), then use cavity cere to process the affected
applicable to repeated use. When repairing the sealant for the
compartment beam.
underfloor areas, the underfloor glue upon delivery should be
peeled off and returned to the proper breakpoint. Do expose The jointing sealed with sealant when assembling is described
the clean metal surface, and the current sealing edge should in detail as below.
also be obedient to the panels.
Caution: Look through all the joints near the fixed areas.
Use new underpan glue between the primer and the second If necessary, all the combined ,fixed or replaced areas
primer. If necessary, use the jointing sealant before applying should be sealed. These areas can’t be ruined. Sealing
the underpan glue. Before coating the underpan glue, do firstly could protect from waters and wind noises and so on.
fit the plugs and insulating ring on the disk type floor (except Before the final inspection, it is necessary to look through
for the part for cere spraying). Refit the heat-fusible plugs all the sealed areas.
damaged in repair with heat blower or replace them with
rubber insulating ring.
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.
Jointing Sealant
When the welding special joints during the assembly, it applies
a kind of PVC sealant processed by thermofixation. This kind
of material is not suitable for repair, so the approved jointing
sealant should be used for check.
Jointing sealant is used after the primer spraying and before the
second primer and the outer coat spraying. Jointing sealant
must be sprayed smoothly and continuously, and the spraying
line depends on the jointing type. If the sealant is coated
by brush, pay special attention to keep the due cover area
for welding. At the places needing sealant formation, cloths
dipped in the solvent oil can be used to complete the required
operations.
Do seal all the jointing need to process after each repair.

The area away from the joggled joints often distorts when
the vehicle is damaged. Thus, in the following repair and
alignment, the sealant at this place is often met. Check all
the jointing around the repaired area to see whether it is
damaged, then process the damages as required, then coat
new sealant. Specific steps are as follows:
Clean the affected jointing, re-process the exposed metal area

with proper etch primer;
Coat proper sealant at the required places;
Process the affected area with acid-etch primer (underpan glue

is also available), coating proper color paint film.
After the re-assembly or refit of parts is completed, if the

jointing is plugged, then paste jointing sealant can be used to
apply such jointing. After the panels are finished, the jointing
1.0 1086
Diagnostic For example, if testing started at the level of the windscreen,
Leak Test any water cascading into the plenum chamber could leak
Overview through a bulkhead grommet and into the footwells. Even at
this point it could still be wrongly assumed that the windscreen
Where water leakage is involved, always adopt a logical
seal was at fault.
approach to the problem using a combination of skill,
experience and intuition. Do not reach a conclusion based Another important part of identifying a water leak is by
only on visual evidence, such as assuming that a wet footwell visual examination of door aperture seals, grommets and
is caused by a leak emanating from the windscreen. It will weatherstrips for damage, deterioration or misalignment,
often be found that the source of the leak is elsewhere. Use together with the fit of the door itself against the seals.
of the correct procedure will increase the chance of locating Note: Check the colour of the water around the leak. If
a leak, however obscure it may seem. the water is dirty, the leak is from under the vehicle. If the
Tools and Equipment water is clean, it is from above.
The following tools and equipment are recommended for the Sealing
purpose of detection and rectification of water leaks: When the point of the leak has been detected, it will then be
1. Garden sprayer (hand-operated) necessary to rectify it using the following procedure:
2. Wet/dry vacuum cleaner 1. Renew all door aperture seals and weatherstrips which
3. Dry, absorbent cloths have suffered damage, misalignment or deterioration
4. Battery torch 2. Check all body seals to ensure that they are correctly
5. Small mirror located on their mounting flanges/ faces using a lipping
tool if necessary
6. Weatherstrip locating tool
3. Dry out body seams to be treated using compressed air
7. Trim panel remover
and/or a hot air blower as necessary
8. Small wooden or plastic wedges
4. Apply sealant on the outside of the joint wherever
9. Dry compressed air supply possible to ensure the exclusion of water
10. Hot air blower 5. When rectifying leaks between a screen glass and it's
11. Sealer applicators weatherstrip (or in the case of direct glazing, between the
12. Ultrasonic leak detector glass and bodywork), avoid removing the glass if possible.
During leak detection, the vehicle should be considered in Apply the approved material at the appropriate location
three basic sections: (i.e. glass to weatherstrip or glass to body)
Primary Door Seal Replacement
• The front interior space.
• The rear passenger space. The primary door seals on the front and rear doors are bonded
into position. It is imperative that the following points are
• The loadspace or boot.
adhered to when replacing a seal:
Testing
• The area of the door where the seal is to be bonded
From the information supplied by the customer it should be
must be thoroughly cleaned. Do not use paint thinners
possible for the bodyshop operator to locate the starting point
for cleaning the door.
from which the leak may be detected. After the area of the
• The ideal temperature of the seal and door when bonding
leak has been identified, find the actual point of entry into the
is 25℃(77℉). The seal will not bond properly if either
vehicle.
the door or seal is below 18℃ (64℉).
A simple and effective means in the first instance is an ordinary
• When initially fitting the seal, apply only a light pressure,
garden spray with provision for pressure and jet adjustment,
this allows the seal to be removed and repositioned if
which will allow water to be directed in a jet or turned into a
necessary. If repositioning the seal, do not touch or allow
fine spray. Use a mirror and a battery-powered torch (NOT a
the contact surfaces to be contaminated in any way.
mains voltage inspection lamp) to see into dark corners.
The sequence of testing is particularly important. Start at the

lowest point and work slowly upwards, to avoid testing in one
area while masking the leak in another.
1.0 1087
Service Procedures
Roof Panel
1. Sunroof Panel 10. Screw - Sunroof Assembly

2. Front Roof Beam Assembly 11. Sunroof Glass Outer Weatherstrip
3. Sunroof Window Reinforcement Assembly
4. Roof Middle Second Beam
5. Rear Roof Beam
6. Roof Panel
7. Roof Middle Third Beam
8. Roof Middle Fourth Beam
9. Roof Middle First Beam
1.0 1088
Engine Compartment Panel
1. Front Wheelhouse Inner Longitudinal Beam Assembly -

LH
2. Front Wheelhouse Inner Longitudinal Beam Assembly -
RH
3. Tower Cover Plate Front Assembly - LH
4. Tower Cover Plate Front Assembly - RH
5. Front Longitudinal Beam Assembly - LH
6. Front Longitudinal Beam Assembly - RH
7. Front Longitudinal Beam Closure Plate Assembly - LH
8. Front Longitudinal Beam Closure Plate Assembly - RH
9. Front Subframe Mounting Bracket Assembly - LH
10. Front Subframe Mounting Bracket Assembly - RH
11. Front Subframe Rear Mounting Bracket Assembly - LH
12. Front Subframe Rear Mounting Bracket Assembly - RH
13. Headlamp Front Mounting Bracket Assembly
14. Bolt - Headlamp Bracket
1.0 1089
Dash Panel
1. Dash Panel Lower Beam Assembly

2. Dash Panel Lower Panel Assembly
3. Dash Panel Upper Panel Assembly
1.0 1090
Side Wall Panel
1. Side Outer Panel 9. Fender Bracket

2. Side Wall Reinforcement Assembly 10. Front Outer Frame Assembly
3. B/C Pillar Upper Closure Panel Assembly 11. Side Outer Panel (Front)
4. Side Wall Rear Extension 12. Side Outer Panel (Centre)
5. Drain Groove Extension Assembly 13. Side Outer Panel (Rear)
6. Rear Side Panel and Rear Wheelhouse Panel Welding
Assembly
7. Oil Filler Housing Assembly
8. Fender Bracket
1.0 1091
Front Floor
1. Front Floor Assembly

2. A Pillar Closure Panel Assembly - RH
3. A Pillar Closure Panel Assembly - LH
4. Doorsill Inner Panel Assembly - RH
5. Doorsill Inner Panel Assembly - LH
6. Front Doorsill Inner Reinforcement Assembly
7. Bolt - Front Floor Reinforcement
1.0 1092
Rear Floor
1. Rear Floor Assembly 11. Lower Rear Beam Assembly

2. Quarter Panel Assembly
3. Rear Floor Frame Assembly
4. Rear Seat Support Assembly
5. Rear Wheelhouse Assembly - LH
6. Rear Wheelhouse Assembly - RH
7. Rear Wheelhouse Extension - LH
8. Rear Wheelhouse Extension - RH
9. Rear Longitudinal Beam Assembly - LH
10. Rear Longitudinal Beam Assembly - RH
1.0 1093
Door Sheet Metal Assembly
1. Front Door Assembly

2. Rear Door Assembly
1.0 1094
Engine Hood Sheet Metal Assembly
1. Engine Hood Sheet Metal Assembly
1.0 1095
Tail Gate Panel Assembly
1. Tailgate Sheet Metal Assembly
1.0 1096
Vehicle Access Safety and Restraints
Vehicle Access
Specifications
Torque
Description Value
Nut-PEPS module to body 7–9Nm
1.0 1097
Safety and Restraints Vehicle Access

System Layout
1. PEPS Module 6. LF antenna-Rear Bumper Skin

2. Outer Door Handle Antenna and Switch(HSU) 7. Outer Door Handle Antenna and Switch(HSU)
3. Spare Coil 8. Remote Key
4. LF Antenna-Central（behind center console bracket） 9. LF Antenna-Front(A/C Box Assembly)
5. LF antenna-Rear（on rear seat beam）
1.0 1098
Vehicle Access and Safety Control Diagram
A = Chassis HS CAN Bus; B = Power HS CAN Bus; C = Diagnostic HS CAN Bus; D = Body HS CAN Bus; E = RF Signal; F = LIN
Bus; G = Hard Wire
1.0 1099
PEPS Control Logic Diagram
A = Body HS CAN Bus; B = LIN Bus; C = Power HS CAN Bus; D = RF Signal; E = Hard Wire
1.0 1100
Description • Valid LOCK request from the driver door LOCK switch
Overview is received.
The security system is achieved by the RF signal from the When the security system enters into the complete anti-theft
remote key or by operating the mechanical key. The RF signal status, the BCM will allow the direction indicator lamp to give
receiver receives demodulation signals and checks signals, the three flashes.
BCM decodes them and releases the relevant operation signal
Complete Anti-theft Status to Partial Anti-theft
in the CAN bus. Status
Operation of the Security System In the complete anti-theft system, if a valid UNLOCK request
The security system includes the following three parts: of the tailgate is received, the BCM opens the tail gate and the
security system enters into the partial anti-theft status.
1. Peripheral system:
Partial Anti-theft Status
• Engine hood, door and tailgate RELEASE switch
If the error lock is caused by area 1 only (for example, open
• ACC/ON switch
engine hood), area 2 and 3 will enter into the complete
• Central lock (LOCK/UNLOCK) switch anti-theft status.
2. Acoustic alarm: vehicle horn If the error lock is caused by area 2 only (for example, 1 door
3. Visible alarm: hazard warning lamp or more doors are open), area 1 and 3 will enter into the
complete anti-theft status.
The security system is divided into three independent areas,
and each area includes many discrete input signals (see the table If the error lock is caused by area 3 only (for example, open
below). When the security system is working, any intrusion tail gate), area 1 and 2 will enter into the complete anti-theft
into these areas can trigger the alarm. status.
Safe Area Discrete Signal Partial Anti-theft Status to Complete Anti-theft
1 (Front) • Engine Hood Release Switch Status
When each safe area is in the security system, the vehicle will
• Driver Door Release Switch
enter into the complete anti-theft status.
• Front Passenger Door Release
Switch For partial locks caused by error lock due to open door, when
the security system enters into the anti-theft status, it can be
• Left Rear Door Release Switch
2 disabled after being enabled within 5 seconds, and the alarm
(Middle/Inside) • Right Rear Door Release Switch will not be triggered.
• Driver Door Key Unlock (timed for
If the partial lock is caused by several areas, when the relevant
15s)
door/cover of these areas are closed, these areas will enter
• Central Lock LOCK/UNLOCK into the complete anti-theft status. The entire security system
Switch enters into the complete anti-theft status only when all the
3 (Rear) • Tailgate Release Switch areas enter into this status.
Complete Anti-theft Status Error Lock Alarm
When the three areas of the security system are closed, if a With the door (engine hood, tail gate) open, and the ignition
LOCK request from the remote control, mechanical key, PEPS, switch in the 1st, 2nd/3rd gear or the engine running, when
etc is received, the security system formally enters into the using the mechanical key or remote key to lock the vehicle
complete anti-theft status. Once the security system enters from outside and when using the PEPS LOCK request (if any),
into the complete anti-theft status, it will monitor all activated the BCM will activate the horn to send an acoustic alarm (appr.
safe areas all the time. When the switch of area 2 or 3 is 30ms) to indicate error lock.
enabled, if you attempt to lock the system from outside, the Disabling Security System
vehicle enters into the partial lock status and gives an error
Any of the following operations will cause the BCM to disable
lock alarm.
the security system:
BCMIt will monitor the following outside LOCK request
• A valid UNLOCK request from the remote key is
signals:
received.
• A valid LOCK request from the remote key is received.
• A valid LOCK request from the PEPS module is received.
1.0 1101
• A valid UNLOCK request from the PEPS module is Description of Passive Entry and Passive Start
received. (PEPS)
• A valid UNLOCK request from the driver door switch is Overview
received.
For vehicles with PEPS, the traditional key is replaced by the
Caution: If the driver door UNLOCK switch is stuck intelligent key, the operation of the PEPS is achieved by LF/RF
or the switch circuit is short-circuited, the (wireless) communication between the intelligent key and the
emergency key will not be used to disable the vehicle.
alarm; while the remote key will not be affected. • Passive entry: no action is required for the intelligent key.
When the security system is disabled, the BCM will allow the You just need to take the intelligent key with you, and you
direction indicator lamp to give one flash. can enter into your vehicle by simply pressing the button
on the door handle and pulling the handle.
Unlock Triggered by Impact Sensor
• Passive start: it is not necessary to insert/pull out the key,
When the impact sensor senses an impact, it will send an you just put the intelligent key in the vehicle and press the
UNLOCK request, and then the door will unlock automatically start-stop button (SSB) to start/stop the vehicle.
except in the case of external locking.
The PEPS includes: the PEPS ECU, intelligent key, interior
Automatic Relock
LF antenna, exterior door handle antenna/switch (HSU), rear
After being unlocked with the remote key, the vehicle will bumper skin LF antenna.
automatically return to the previous locked state if there is no Mounting Location
operation within 30 seconds. In the automatic relock status, if
• PEPS ECU: under the instrument panel (front passenger
the ignition switch is in the "AUX"position or a valid key exists,
side).
then the current timing of the relock timer is canceled, and the
automatic relock function is canceled. • Exterior door handle antenna/switch (HSU): inside the
front door exterior door handle.
Auto Lock
• 3 LF antennas inside the vehicle: fitted on the A/C
If the driver door is closed and the vehicle is unlocked, when box assembly, rear of the centre console bracket and
the vehicle speed reaches a certain value (preset), the door centreline of the rear seat beam respectively.
will lock automatically.
• Rear bumper skin LF antenna: on the centreline of the
Auto Unlock rear bumper skin bracket.
With the vehicle in an internally locked state, turn the End View and Pin Information of PEPS Module
ignition switch to the "OFF" state, then the vehicle unlock Harness Connector BY126
automatically.
Door Lock Controlled by Interior Centre Console
Switch
With the driver door closed and the impact sensor disabled,
press the centre console LOCK button to lock all doors, and
the main zone of the message centre on the IPK shows "Door
Locked".
When the door is internally locked, press the centre console

UNLOCK button to unlock all doors, and the main zone of
the message centre on the IPK shows "Door Unlocked".
When an impact occurs and the impact sensor is triggered,

the door unlocks automatically. The door cannot be relocked
Pin No. Description
within the current ignition cycle even if the centre console
LOCK button is pressed. When it is externally locked, the 1 KL.30
centre console button does not work. 2 —
3 ACC State Signal
4 IGN State Signal
1.0 1102
5 Body HS CAN Low 10 Reference Signal of SSB
6 Body HS CAN High 11 Tail Gate Switch
7 — 12 —
8 — 13 —
9 — 14 Front LF Antenna Signal - High
10 — 15 Rear LF Antenna Signal - Low
11 — 16 Rear LF Antenna Signal - High
12 —
End View and Pin Information of PEPS Module
13 SSB Signal Harness Connector BY128
14 —
15 —
16 GND
End View and Pin Information of PEPS Module

Pin No. Description

1 —
Left Front Door Handle Antenna
2
Signal - Low
3
Signal - High
Pin No. Description
Rear Bumper Skin Antenna Signal
1 — 4
- Low
2 — 5 —
3 — Right Front Door Handle Antenna
6
4 — Signal - Low
7
Signal - High
6 Front LF Antenna Signal - Low
7 Middle LF Antenna Signal - Low 8
- High
8 Middle LF Antenna Signal - High
9 —
1.0 1103
End View and Pin Information of PEPS Module Pin No. Description
1
Signal - Low
2
Signal - High
End View and Pin Information of HSU Harness

Connector PD005
Pin No. Description

1 —
2 —
3 —
4 LIN
5 — Pin No. Description
1
7 — Signal - Low

2
Signal - High
9 GND
10 — End View and Pin Information of LF Antenna Harness
Connector FA040
End View and Pin Information of HSU Harness
Connector DD005
Pin No. Description

1 Front LF Antenna Signal - Low
2 Front LF Antenna Signal - High
1.0 1104
End View and Pin Information of LF Antenna Harness End View and Pin Information of Rear Bumper Skin
Connector BY062 Antenna Harness Connector BY130

1 Middle LF Antenna Signal - Low Rear Bumper Skin Antenna Signal
1
2 Middle LF Antenna Signal - High - Low
End View and Pin Information of LF Antenna Harness 2
- High
Connector BY153
Operation of Passive Entry and Passive Start
(PEPS)
In the vicinity of the closed door and in the driver
compartment, the PEPS can detect and identify the intelligent
key.
Function of LIN Bus in PEPS
LIN bus interface is used for the communication between

the PEPS ECU and the BCM. When the vehicle is stopped
and locked, the CAN bus is in the sleep state, in this case,
there is a need to quickly wake up the CAN bus and establish
communication between the PEPS ECU and BCM, which
shall be accomplished by the LIN bus. When pressing the
exterior door handle antenna/switch (HSU), the PEPS ECU
Pin No. Description
communicates with the RF signal receiver and identifies the
1 Rear LF Antenna Signal - Low intelligent key. After authentication, it sends an UNLOCK
2 Rear LF Antenna Signal - High request to the BCM.
Function of CAN Bus in PEPS
The PEPS communicates with other ECUs through the CAN

bus.
Identifier/Intelligent Key
The intelligent key is a hand-held electronic device which is

powered by the lithium battery. Each vehicle is provided with
2 matching intelligent keys. Once the match is finished, the
intelligent key can perform LF/RF communication in the PEPS.
As long as the lithium battery provides power, the intelligent
key can receive LF signal and communicate with the BCM to
lock/unlock the vehicle.
1.0 1105
The intelligent key detects the 125kHz LF electromagnetic field Exterior Door Handle Antenna/Switch (HSU)
signal from the vehicle LF antenna and exterior door handle
Exterior door handle antenna/switch (HSU) is an assembly of
antenna/switch (HSU). The intelligent key sends an RF signal
the LF antenna and switch. It connects the PEPS ECU, the
within the 433MHz ISM band and gives a response when it
PEPS ECU generates current for the LF antenna to form the
appears in the coverage area of the LF antenna.
magnetic field. The PEPS ECU reads the status of the switch
Function of Intelligent Key in PEPS (i.e. detects the action of the operator). The PEPS ECU and
HSU are connected by stranded wires.
The PEPS shall have an intelligent key.
Effect of Intelligent Key on Vehicle Access Function of Exterior Door Handle
Antenna/Switch (HSU) in PEPS
• PEPS mode (passive entry): the intelligent key receives
The LF antenna is used to generate an LF electromagnetic
the LF signal and sends the RF signal to complete the
induction area near the door so that the operator can
authentication and match in the LF coverage area.
lock/unlock the door switch. Only when a matching intelligent
• Remote key entry mode: when pressing the button on
key is detected in the LF antenna coverage area, and the
the key, the authentication code transmitted by the RF
LOCK/UNLOCK request received matches the status of the
signal will be used as the LOCK/UNLOCK request for
door lock, can the lock and unlock operation be performed.
the door or tailgate.
After the operator finishes the operation of the HSU, the PEPS
• Exhaustion mode of the intelligent key lithium battery:
ECU will transmit current to the HSU LF antenna to generate
the intelligent key is provided with a mechanical key
the electromagnetic field signal. The operator's intelligent key
matching the vehicle lock, use the mechanical key to
can detect/receive the electromagnetic field signal and give a
lock/unlock the vehicle.
response to the BCM by the RF signal, and the PEPS validates
Effect of Intelligent Key on Vehicle Start the legality of the key and unlock the door eventually, this
• PEPS mode (passive start): the intelligent key receives ensures access of the legal user.
the LF signal and sends the RF signal to complete the
HSU coverage area:
authentication and match.
• Low battery mode of the intelligent key: the intelligent HSU coverage area: calculate the radiation (appr. 1.5m) by the
key shall be close to the spare coil (i.e. icon at the centre of the door handle surface.
bottom of the cup holder), see the "Key Addition and LF Antenna
Disable" section. Then, use the BCM to perform the
The independent LF transmitter consists of 3 internal LF
authentication of the intelligent key in the transponder
antennas and 1 antenna of the rear bumper skin. To ensure
mode.
the intelligent key can receive the signal in the coverage area,
In order to inform the operator to replace the battery in the transmitter generates the LF magnetic field signal of the
a timely manner, the intelligent key applies the RF signal 125kHz band.
transmitted to the IPK by the BCM, and the general
Function of LF Antenna in PEPS
information screen will indicate "Low Key Battery, Please
Replace!". The LF antenna transmits LF signal in the PEPS and
communicates with the intelligent key.
Once the button on the intelligent key is pressed, this
operation will be regarded as the default RF request signal of Internal LF Antenna
the remote key. When the button is pressed for more than The internal LF antenna is necessary for the PEPS, which sends
20s, the intelligent key will stop transmitting the RF signal until the LF signal to the intelligent key, and the intelligent key sends
the button is released and pressed again. the authentication information via the RF signal to BCM. After
Intelligent Key/Identifier Management the authentication, the engine can be started.
The system permits to handle 4 identifiers at one time. The internal LF antenna can also be used to search the
intelligent key in the driver compartment and determine if the
For delivery, in principle, 2 matching intelligent key are vehicle can be locked, this prevents the operator from leaving
provided, and the intelligent key can be added or deleted the intelligent key in the vehicle when locking the vehicle.
during the subsequent aftersales diagnosis. Intelligent key Although the vehicle cannot be locked when it is detected that
addition and deletion is the task of the BCM, and the BCM the intelligent key is in the driver compartment, it is necessary
will inform the PEPS ECU that a new key is added or an old to alert the operator that the current security system is
key is deleted. vulnerable. As a matter of fact, the internal LF antenna is used
1.0 1106
to search the valid intelligent key in the vehicle. Therefore, The authorised operator requires to complete the following
the radiation area of the antenna shall cover the entire area start requests:
inside the vehicle. If the valid intelligent key can receive the • Manual transmission: depress the clutch.
signal from the internal LF antenna and give a response, then
• Automatic transmission: when the transmission shift
intelligent key is in the driver compartment.
lever is in "P" gear or "N" gear, depress the brake pedal.
LF Antenna of Rear Bumper Skin
Press the SSB to start the engine. When the engine is running,
In the passive entry system, the antenna of the rear bumper within a certain vehicle speed, press the SSB to stop the engine.
skin is used to separately open the tail gate. However, it
Spare Coil
cannot be used for the passive start. The function of the rear
bumper skin antenna is to send the LF signal to the intelligent The spare coil is under the cup holder at the passenger side,
key near the tail gate, and the intelligent key returns the signal which is an electronic coil. The intelligent key communicates
to the BCM. So, the radiation range of the antenna shall with the BCM by the spare coil. BCMIt provides 125kHz
be a smaller area near the luggage compartment. After the modulating current, when the intelligent key is near the
necessary authentication is completed, the tail gate will open. 125kHz electromagnetic field generated by the LF antenna, it
When the key is outside the vehicle, the radiation area of the obtains power from the electromagnetic induction area and
bumper skin antenna is 1m above the ground, the radius is starts to communicate with the special electronic component
within the 1.0 m range. in the BCM. The communication allows the intelligent key to
be authenticated. If the battery of the intelligent key is low,
If the intelligent key in the vehicle makes a response to the
it can still communicate with the spare coil, this is because
antenna of the rear bumper skin (i.e. the LF signal from the
the intelligent key can obtain power from the electromagnetic
internal antenna and the antenna of the rear bumper skin
radiation of the spare coil.
detects the intelligent key), then the intelligent key cannot
open the tailgate or unlock the vehicle. In this case, if the Function of Spare Coil in PEPS
valid intelligent key gives a response to the signal from the If the intelligent key is unable to supply the power required
antenna of the rear bumper skin, the intelligent key is near the for routine key authentication due to low battery, then shift
tailgate. Once the tailgate switch is pressed and the operation to transponder mode. Position the intelligent key near the
is authorised, the BCM releases the tailgate switch. activated spare coil (i.e. the image/text identification at the
SSB bottom of the cup holder at the passenger side), the system
will identify and authenticate the key.
The start-stop button (SSB) is on the instrument panel of
the driver compartment, it is used for requesting the engine If the battery of the intelligent key is full and able to receive
to start and stop. When the engine does not start, different and transmit the LF signal of the internal antenna, no need to
power modes (ACC, IGN) can be selected. The SSB is use the transponder mode, under this situation, the spare coil
integrated with the backlight control, it provides the operator will not be activated.
with the power mode and indicate whether the conditions for If the PEPS does not detect and authenticate the intelligent key
starting the engine is met by changing the inner yellow and after the SSB is pressed, the spare coil will be activated.
green LED lamps.
The spare coil is also used for key match on the production line,
The SSB has two identical parts. aftersales key addition and deletion. The key authentication
The first part connects the BCM, and the second part lasts for hundreds of milliseconds.
connects the PEPS ECU. The PEPS ECU will monitor PEPS ECU
the second part, the BCM receives the power status CAN
information from the PEPS ECU and determines whether The PEPS ECU includes the system software controlling the
to handle it. Unless an error occurs, these two parts work operation of the PEPS.
together. The PCB circuit board of the PEPS ECU contains the
Function of SSB in PEPS interface circuit of all PEPS components and the interface used
to communicate with other vehicle controllers.
The SSB is used to start/stop the engine or shift the vehicle
status to ACC or ON and indicates the power status of the BCMPeripheral Equipment
vehicle. The RF signal from the intelligent key is received by the RF
The SSB is used for the passive start system, and it does not receiver embedded in the BCM, in the PEPS mode, the BCM
work for the passive entry system. matches and authenticates the current intelligent key. The
1.0 1107
function of the PEPS is achieved by the quick communication and achieves the authentication of the intelligent key and
between the PEPS ECU and the BCM. the function of the passive entry. BCMThe door status is
transmitted to the PEPS ECU by the CAN bus. In order to
BCMFunction in PEPS
give a response to the action of the user, the BCM predicts
The PEPS ECU communicates with the BCM through
the user's intention by informing the PEPS ECU of the change
the CAN bus and LIN bus, the LIN bus provides quick
of the door status.
wake-up signal and communication information for the BCM
1.0 1108
Service Procedures be placed beyond the valid range. It is recommended to
Add and Disable a Key place them outside the vehicle.
Keys Addition • For vehicles with "one-touch start" function: ensure that
• For vehicles without "one-touch start" function: ensure the key to be reserved should be placed in the marked
that the key to be added is put into the ignition switch position inside the centre console cup holder as shown.
and turned to ON position. Keys not to be added should Keys to be deleted should be placed beyond the valid
be placed beyond the valid range. It is recommended to range. It is recommended to place them outside the
place them outside the vehicle. vehicle.
• For vehicles with "one-touch start" function: ensure that Perform the keys deletion.
the key to be added should be placed in the marked
position inside the centre console cup holder as shown. Encoding - Keys Deletion
Keys not to be added should be placed beyond the valid For vehicles with PEPS function, in case the remote key low
range. It is recommended to place them outside the battery, the valid distance of radio frequency signal will greatly
decrease. To ensure the normal function of the vehicle, the
vehicle. remote key is suggested to be placed in the marked position
inside the centre console cup holder.
Caution: If the key is in wrong position and

orientation, it may not be recognized.
Perform the operation of adding the keys.
Encoding - Keys Addition
Keys Deletion
• For vehicles without "one-touch start" function: ensure
that the key to be reserved is put into the ignition switch
and turned to ON position. Keys to be deleted should
1.0 1109
Passive Entry and Passive Start (PEPS) Control Passive Entry and Passive Start (PEPS) Antenna
Module - Front
Remove Remove
2. Remove the glove box assembly. 2. Remove A/C panel.
Glove Box Assembly Remove A/C Panel Remove
3. Disconnect the connector (1) of PEPS module. 3. Disconnect the connector from the antenna.
4. Remove 3 nuts (2) securing PEPS module onto the
vehicle body.
4. Pull out gently at the side of connector to separate the

locating pin of antenna from the mounting hole, then
pull the antenna towards the connector to move it out.
5. Remove PEPS module.
5. Remove the antenna.
Refit
Refit
1. Fix the PEPS module to the body, fit 3 nuts, tighten to
7–9Nm and check the torque. 1. Align the antenna locating point with the mounting hole
and press down to engage.
2. Connect the PEPS module connector.
2. Connect the antenna connector.
3. Refit the A/C panel.
4. Programme and encode the PEPS.
Self-learning and Adjustment, Programming A/C panel Refit
and Encoding - PEPS Replacement 4. Connect the battery negative.
5. After replacement, refit the glove box assembly.
1.0 1110
Passive Entry and Passive Start (PEPS) Antenna Passive Entry and Passive Start (PEPS) Antenna
- Middle - Rear
Remove Remove
2. Release the clip fixing the rear panel assembly of the 2. Fold the rear seats and lift the luggage compartment
center console to the center console assembly. carpet.
3. Remove the rear panel assembly of the center console. 3. Disconnect the connector from the antenna.
4. Disconnect the connector of the antenna.
4. Pull out gently at the side of connector to separate the

5. Slightly pull the connector outward to release the locating pin of antenna from the mounting hole, then
locating pin of the antenna from the mounting hole, pull the antenna towards the connector to move it out.
then pull the antenna towards the connector to 5. Remove the antenna.
disconnect it. Refit
6. Remove the antenna. 1. Align the antenna locating point at the mounting hole
Refit and press down to engage.
1. Align the antenna locating point at the mounting hole 2. Lay the luggage compartment carpet, and recover the
and press down to engage. rear seats.
2. Connect the connector of the antenna. 3. Connect the connector of the antenna.
3. Refit the centre console rear panel assembly. 4. Connect the battery negative.
1.0 1111
Passive Entry and Passive Start (PEPS) Antenna Passive Entry and Passive Start (PEPS) Antenna
- Rear Bumper Upholstery - Door Handle
Remove Remove
1. Disconnect the battery negative. For vehicles with PEPS module, door outer handle antenna
and switch (HSU) are fitted inside the driver outer door and
2. Raise the vehicle to proper height. passenger outer door handles respectively. Replace the door
3. Disconnect the connector from the antenna. handle antenna by replacing the door handle assembly.
Door Outer Handle Remove

Refit
Door Outer Handle Refit
4. Remove the antenna fixed on rear bumper mounting

bracket.
Refit
1. Align the antenna locating point at the mounting hole
of rear bumper mounting bracket and press down to
engage.
2. Connect the connector of the antenna.
1.0 1112
One-Touch Ignition Switch Mechanical Ignition Switch
Remove Remove
1. Disconnect the battery negative cable. 1. Remove the steering column shroud.
2. Remove the instrument panel molding assembly. Steering Column Shroud Remove
3. Disconnect the harness connector at the back of 2. Remove 2 bolts fixing the steering column lock
one-touch ignition switch. assembly to the steering column.
4. Release 2 clips securing the one-touch ignition switch
onto the instrument panel molding assembly and
remove the one-touch ignition switch.
Refit
1. Fix the one-touch ignition switch onto the instrument
panel molding assembly with 2 clips.
2. Connect the connector at the back of the one-touch
ignition switch.
3. Fit the instrument panel molding assembly.
3. Disconnect the harness connector of immobiliser coil.

4. Release 2 clips fixing the ignition lock cylinder to the
steering column and remove the mechanical ignition
switch lock cylinder.
Refit
1. Refit the mechanical ignition lock cylinder to the
steering column lock assembly, and tighten with 2 clips.
2. Connect the immobiliser coil harness connector to the
steering column lock assembly.
3. Refit the steering column lock assembly to the steering
column and tighten with 2 bolts.
4. Fit the steering column shroud.
Steering Column Shroud Refit
1.0 1113
Safety and Restraints Alarm System
Alarm System
Specifications
Torque
Description Value
Nut-Spare coil to console 1.3–1.9Nm
1.0 1114
Alarm System Safety and Restraints
System Layout
1. LF Anti-theft Coil(If Fitted) 2. Spare Coil(If Fitted)
1.0 1115
A=RF Signal ； B=Power HS CAN Bus ； C=Body HS CAN Bus ； D=LIN Bus ； E=Hard Wire
1.0 1116
Overview 1 -
The vehicle is equipped with an immobiliser system connecting 2 KL.30
with the engine control module. It sends a characteristic value 3 -
with transceiver for verification. Once matched, start the
4 -
engine. When supplying, the key sends characteristic value to
low-frequency immobiliser coil (if fitted)/spare coil (if fitted), 5 Ground
and transmits to BCM through LIN serial data circuit. 6 LIN
Mounting Location Spare coil (if equipped): End View and Pin Information
• Low-frequency immobiliser coil (if fited): fit at ignition of Harness Connector CE008:
switch lock cylinder.
• Spare coil (if fitted): fit at passenger side cup holder
bottom, i.e, the interior of centre console assembly.
Low-frequency immobiliser coil (if fitted): End View
and Pin Information of Harness Connector FA039:
Pin No. Description

1 LIN
2 KL.30
3 Ground
1.0 1117
Operation the radio frequency transceiver sends a signal including

The theft-deterrent system function is provided by BCM, its characteristic value. BCM receives this signal, and
ECM, and any modules storing and reporting environment compare this value with the value stored in the memory.
identifiers. Once the two values matched, BCM will send pre-disabled
• Low-frequency immobiliser coil: when ignition key password to ECM via serial data circuit. If the characteristic
is inserted into the ignition lock cylinder and the value of radio frequency transceiver is incorrect, BCM will
ignition switch is placed in ON position, the radio send the fuel disable password to ECM.
frequency transceiver in the key is energized through When ECM receives the pre-disabled password from BCM,
the low-frequency immobiliser coil on the ignition lock ECM will verify this password. ECM sends the check
cylinder. At the moment, the radio frequency transceiver password back to BCM via serial data circuit. ECM and
sends a signal including its characteristic value. BCM BCM will calculate the check password.
receives this signal, and compare this value with the
If BCM calculation result matches with ECM calculation
value stored in the memory.
result, ECM will allow to start the vehicle.
• Spare coil: for vehicles with "one-touch start" function,
when the smart key is positioned in the transmitter slot,
1.0 1118
Service Procedures Spare Coil
Low Frequency Immobiliser Receiver coil Remove
Remove 1. Disconnect the battery negative cable.
1. Disconnect the battery negative cable. 2. Remove the centre console assembly.
2. Remove the lower steering column shroud. Centre Console Assembly Remove
Steering Column Shroud Remove 3. Disconnect the spare coil connector.
3. Disconnect the low frequency immobiliser coil 4. Remove 2 screws securing the spare coil to the centre
connector and remove the clips securing the low console.
frequency immobiliser coil onto the instrument panel
beam.
4. Remove the low frequency immobiliser coil from the
steering column lock.
Refit
1. Fix the low frequency immobiliser coil on steering
column lock. Allow 2 clips of the coil to fit in the
relevant adapters of the steering column lock.
2. Fit the lower steering column shroud.
Lower Steering Column Shroud Refit
3. Connect the low frequency immobiliser coil connector.
4. Fit the clips on the low frequency immobiliser coil 5. Slightly turn the coil and take it away.
connector onto the instrument panel beam holes. Refit
1. Fit the spare coil into the mounting position, and slightly
turn it to fasten.
2. Connect the spare coil connector.
3. Fit the spare coil and 2 screws on its both sides
respectively, tighten them to 1.3–1.9Nm, and check
the torque.
1.0 1119
Safety and Restraints Gateway
Gateway
Specifications
Torque
Description Value
Nut-GW module to instrument panel beam 7–8Nm
1.0 1120
Gateway Safety and Restraints
System Layout
1.GW Module
1.0 1121

Mounting Location 1 Starter Relay Drive
The gateway is in the front of the closure panel under the driver 2 KL.15 Power Relay Converter Drive
side instrument panel. 3 —
Overview 4 —
The gateway is responsible for the transmission of most of the 5 GW Power 2

functional control signal, which communicates with the TBOX 6 —
via the CAN bus, with the cruise control switch by the hard 7 —
wire and with the RPND (remote control RPND display) by —
8
the LIN bus. The gateway can be used to diagnose the vehicle
9 —
signal.
10 —
With the HS CAN bus, the gateway communicates and
11 Diagnosis CAN High
interacts with the following parts:
12 Diagnosis CAN Low
• Engine Control Module ECM
13 Gateway LIN 5
• Transmission Control Module TCM
14 —
• Shift Control Unit SCU
15 Power CAN Low
• Transfer Case Control Module TCCM
16 Power CAN High
• Airbag Control Module SDM
17 —
• SCS/ABS
18 —
• Parking Assist Control System PDC
19 Body CAN Low
• Electronic Parking Brake EPB
20 Body CAN High
• Steering Angle Sensor SAS
21 Passive Entry and Passive Start
• Front Camera Module FVCM
22 Ignition Switch Crank/BCM Start
• Electronic Power Steering System EPS
23 Gateway Ground 2
• Instrument Pack IPK
24 —
• Power Tailgate PLCM
25 —
• HVAC Module HVACM
26 Cruise Control Switch Ground
• Entertainment Control Module FICM
27 —
• Passive Entry and Passive Start PEPS —
28
• Body Control Module BCM —
29
End View and Pin Information of Gateway Harness
30 Cruise Control Switch 1 Signal
Connector FA004
31 —
33 5V Power Supply
34 —
35 —
36 Ignition Switch Run
37 —
38 Stop/Start OFF Switch Status
39 —
40 —
1.0 1122
End View and Pin Information of Gateway Harness 1. Network Signal Route
Connector FA005 2. Primary Node for Network Management
3. Primary Node for Vehicle Power Mode Management
4. Switch Test
5. Vehicle Configuration Information
Network Signal Route
The gateway is responsible for establishing different CAN
networks, connecting the LIN network, transmitting signals
from the source CAN/LIN network to the target CAN/LIN
network according to network design requirements and
achieving information exchange and share between several
networks. Besides, the gateway shall support the TBOX to
perform remote diagnosis for the vehicle.
Primary Node for Network Management
Pin No. Description As the primary node for network management, the gateway
1 Chassis CAN Low performs the following demands for network management:
2 Chassis CAN High • When the ignition key is in the "ACC", "RUN" or
3 — "CRANK" position, all networks shall communicate.
4 — • When turning the ignition key to "OFF" position from
5 — "ACC" or "RUN" position, the network communication
shall delay at least for 30s, this time can be configured by
6 Passive Entry Accessory
the diagnosis. If the vehicle speed is not 0, the gateway
7 Ignition Switch Accessory/BCM Accessory requires to maintain network communication; when the
8 — vehicle speed signal is 0, the gateway shall maintain the
9 KL.R Power Relay Drive communication for 10s.
10 GW Power 1 • The gateway performs the VCT network management
11 Accessory Wake-up strategy on the CAN 3 and CAN 5. As the primary
node for network management, in CAN 3 and CAN 5,
12 Wake-up Enabled
the gateway can be woken up for communication by using
13 —
the network wake-up method from the node.
Primary Node for Vehicle Power Mode
15 — Management
16 — • The gateway is the primary node for vehicle power
17 — mode management. The gateway determines the status
18 — of the vehicle power mode according to the status of the
19 Gateway Ground ignition key or the hard wire input of the gateway ignition
key status provided by the BCM and PEPS. The gateway
20 —
sends the status of the vehicle power mode to the CAN
21 — or LIN network. Each CAN or LIN module requires
22 — to receive the status signal of the power mode from
23 — the gateway, the CAN/LIN module enables/disables the
— corresponding function in accordance with the status
24
signal of the power mode.
Definition • The gateway shall raise/lower the corresponding high side
The gateway mainly connects several CAN/LIN networks drive according to the status of the vehicle power mode.
and establishes signal/frame route between networks. It also The KL.R high side drive, Ignition high side drive and
provides hard wire I/O interface and achieves some control KL.15 switch high side drive are the relay control. When
functions. The main functions are as follows: it is raised, the corresponding relay closes.
1.0 1123
KL.15 ACC/ Wake-up gateway collects the state information of the shift mode
KL.R IGN
Vehicle Switch Wake-up Enable switch and sends the signal to the transmission control
High High
Power High High High unit.
Side Side
Mode Side Side Side • Cruise Switch: the gateway collects the state information
Drive Drive
Drive Drive Drive of the cruise switch and sends the signal to the engine
OFF Low Low Low Low Low control unit.
ACC High Low Low High High • Brake Pedal Sensor Signal Acquisition: the gateway
RUN High High High High High collects the signal of the brake pedal sensor and sends
CRANK Low High Low Low High the percentage signal of the brake pedal position to the
• Vehicle Voltage Detection: the gateway acquires the transmission control unit and voltage control unit. To
battery voltage, determines the status of the battery identify the position of the brake pedal, the gateway
voltage, and sends the voltage signal to the network. needs to perform a self-learning for the zero position
voltage output of the brake pedal.
Switch Test
Vehicle Configuration Information
• Shift Paddle Switch: the vehicle is provided with 2 shift
paddle switches, one is on the shift lever, and the other When the vehicle is offline, the gateway configures the
is on the steering wheel. The gateway collects the state vehicle configuration information online, the configuration
information of the shift paddle switch and sends the signal information is stored in the EEPROM of the gateway. The
to the transmission control unit. gateway sends the vehicle configuration information according
to the configuration information of the EEPROM.
• Shift Mode Switch: shift mode switch consists of the
"Snow" mode switch and "Sport" mode switch, and the
1.0 1124
Service Procedures
Gateway Module
Remove
2. Remove the driver side lower trim panel assembly.
Remove
3. Disconnect the connector (1) from the gateway.
4. Remove 2 nuts (2) securing the gateway to the
instrument panel beam.
5. Remove the gateway.

Refit
1. Connect the gateway connector.
3. Programme and encode the gateway.

Encoding - GW Replacement
4. Fix the gateway to the bolt of instrument panel beam,
fit 2 nuts, tighten to 7–8Nm and check the torque.
Refit
1.0 1125
Safety and Restraints Seat Belts
Seat Belts
Specifications
Torque
Description Value
Bolt-front seat belt height adjuster 30–35Nm
Bolt-front seat belt retractor to ‘BC’ post 30–35Nm
Bolt-front seat belt‘D’loop to front seat belt height adjuster 30–35Nm
Bolt-front seat belt buckle 35–45Nm
Bolt-rear seat belt retractor to body 30–35Nm
Bolt-rear seat belt‘D’loop to body 30–35Nm
Bolt-rear seat belt to body 30–35Nm
Bolt-rear middle seat belt to body 30–35Nm
Bolt-rear seat belt buckle 40–50Nm
1.0 1126
Seat Belts Safety and Restraints
System Layout
Seat Belt Layout
1. Rear Seat Belt Assembly 6. Front Seat Belt Retractor with Pretensioner
2. Rear Seat Belt Retractor 7. Driver Seat Belt Buckle (with Alarm Function)
3. Rear Seat Belt Buckle 8. Seat Belt Not Tied Warning Lamp
4. Rear Seat Central Belt 9. Front Seat Belt Height Adjuster Assembly
5. Front Seat Belt Assembly
1.0 1127

Seat Belt Control Diagram
A= Chassis HS CAN Bus; B= Diagnostic HS CAN Bus; C= Body HS CAN Bus; D= Power HS CAN Bus; E= Hard Wire
1.0 1128
Description Front Seat Belt
Front Seat Belt Pretensioner
The retractor of the front seat belt is fitted on the body, in the
In case of collision, the front seat belt pretensioner is tightened cavity at the bottom of the B pillar lower trim panel. Pull the
to ensure that the occupants are securely kept in their seats. belt webbing from the retractor, and fix it to the mounting
The seat belt pretensioner unit is fixed by bolts to the seat belt point under the B pillar with the manual height adjustment
retractor assembly in the B pillar. The connector of the seat device on the upper part of B pillar.
belt pretensioner is a 2-pin connector which is connected with Seat Belt Height Regulator Assembly
the body harness.
The height adjustment device is fixed above the B pillar
In case of collision, the seat belt pretensioner is controlled by bolts. The belt webbing is fixed to the seat belt height
by the signal from the SRS ECU. The retractors of the two regulator assembly by D rings, and the seat belt can be fixed
pretensioners are positioned and work in the same way. Each in the optimal position under different conditions through the
pretensioner unit is provided with an initiator and a propulsion up-and-down sliding of the seat belt height regulator assembly.
generator which act on the rotor of the seat belt retractor. The belt buckle assembly is fitted to the bracket inside the
Warning: Once the pre-tensioner has been operated, it seat cushion.
cannot be reset. The gas generator will be exhausted. The
unit must be replaced.
Seat Belt
The seat belt provides the most basic protection for all
occupants. The restraint system also provides further
protection for the front occupants through the airbag module
and the pretensioner seat belts. The front seats are all
fitted with appropriate retractors and hip-shoulder belts.
Emergency locking retractors (ELR) are used for the vehicle.
Rear Seat Belt Assembly
The retractor is provided with an additional lock mechanism
which includes a webbing sensor and an automotive sensor.
If the webbing is suddenly pulled, the webbing sensor will
immediately start the lock mechanism. If the vehicle suddenly
slows down or tilts at a large angle, the automotive sensor
will start the lock mechanism.
The retractor will lock in case of impact, so the front seat belt
retractor are equipped with load limiters. If the load limit has
exceeded the critical level, the load limiter loosens the seat
belt webbing and reduces the load acting on the occupants.
1.0 1129
The retractor of the rear seat belt on both sides is fixed by Seat Belt Alarm Indicator
bolts to the white body behind the trunk side trim panel. The
belt webbing on both sides can be pulled out from the retractor
through the trim of the D pillar trim panel, the other end of the
webbing is secured on the mounting point of the body floor;
and the middle seat belt retractor of the rear seat is fixed on
the frame of the rear seat foam. Pull the webbing of the middle
seat belt out of the seat retractor shaft, fix the other end of
the webbing to the body floor under the rear seat cushion.
With 2 bolts, fix the left seat belt buckle and the middle seat
belt buckle of the rear seat on the floor under the rear seat
cushion respectively. The left belt buckle of the rear seat is
located at the occupant's right hip.
The right belt buckle of the rear seat and the belt of the middle
The belt buckle of the front seat is integrated with the seat
seat form one assembly which is fixed by one bolt between the
belt not tied warning switch, which is connected to the
right rear seat and the middle rear seat. The belt of the middle
instrument pack through the SRS ECU. If the occupant does
passenger seat goes from the passenger's right shoulder to the
not fasten the seat belt when the vehicle is in motion, the seat
buckle of the left hip.
belt alarm will be triggered. The warning message comprises
an acoustic alarm and an illuminating warning lamp on the
instrument panel. Some vehicle specifications specify that: to
prevent unnecessary warning when there is no passenger on
the seat, a pressure sensor shall be fitted within the foam of
the passenger seat. If there is a passenger on the seat, but the
pressure sensor is not activated, then the seat belt warning
will not be triggered even if the occupant does not fasten the
seat belt.
1.0 1130
Operation actuates the rotor of seat belt inertial retractor to
SRS ECUtriggers the operation of pre-tensioning seat belt: tighten the seat belt and increase the tension, so that
the passengers can be restricted on the seat in the event
• For the front seat belt, the initiator and propulsion of the collision.
generator in the seat mounting lock catch assembly
1.0 1131
Service Procedures 5. Check the system, rotate the ignition switch, and check
Front Seat Belt Height Regulator whether the SRS warning lamp illuminates for 6s, and
Remove then goes out.
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
backup circuit is discharged, then start to operate.
2. Remove the B pillar upper trim panel.
B Pillar Upper Trim Panel Remove
3. Remove 1 bolt fixing the front seat belt D ring to the
height adjuster.
4. Remove 1 bolt securing the front seat belt height

adjuster to the body.
5. Remove 2 hooks of front seat belt height adjuster from

the mounting hole of B pillar, and remove the front seat
belt height adjuster.
Refit
1. Insert 2 hooks under the front seat belt height adjuster
into the mounting hole of B pillar.
2. Fix the front seat belt height adjuster to the body, fit 1
bolt, tighten to 30–35Nm, and check the torque
3. Fix the front seat belt D ring to the height adjuster.
4. Refit the B pillar upper trim panel.
B Pillar Upper Trim Panel Refit
1.0 1132
Front Seat Belt Assembly
Remove
1. Remove the key from the ignition switch, and
2. Remove the seat belt tab cover, and remove 1 bolt
fixing the front seat belt to the lower trim panel of
the B pillar.
8. Remove the front seat belt assembly.

Refit
1. Locate the front seat belt retractor to the body, refit 1
bolt and tighten to 30–35Nm.
2. Connect the electrical connector of the pre-tensioner.
3. Fix the front seat belt D ring to the height adjuster, fit 1
bolt and tighten to 30–35Nm.
4. Refit the B pillar upper trim panel.
3. Remove the B pillar lower trim panel. B Pillar Upper Trim Panel Refit
5. Refit the B pillar lower trim panel.
B Pillar Lower Trim Panel Remove
4. Remove the B pillar upper trim panel. B Pillar Lower Trim Panel Refit
6. Locate the fixing end of front seat belt to B/C pillar
lower trim panel, fit 1 bolt and tighten to 30–35Nm.
5. Remove 1 bolt fixing the front seat belt D ring to height
7. Refit the front seat belt tab cover.
adjuster.
8. Check the system, rotate the ignition switch, and check
whether the SRS warning lamp illuminates for 6s, and
then goes out.
6. Disconnect the seat belt pretensioner connector.

7. Remove 1 bolt fixing the front seat belt retractor to
the body.
1.0 1133
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
2. Unscrew 1 bolt securing the front seat belt buckle to
the seat.
Rear Seat (Including Centre Armrest) Remove
3. Remove 1 bolt (1) fixing the rear seat belt to the D
pillar lower trim panel.
3. Remove the front seat belt buckle.

Refit
1. Fix the front seat belt buckle to the seat, fit 1 bolt and
4. Remove the D pillar upper trim panel.
2. Refit the front seat assembly.
5. Remove 1 bolt (2) securing the rear seat belt D ring
to the body.
6. Remove the trunk side trim panel.
7. Remove 1 bolt (3) fixing the rear seat belt retractor to
the body and remove the retractor.
8. Remove the rear seat belt assembly.
Refit
1. Locate the rear seat belt retractor to the body, refit
the bolt and tighten to 30–35Nm.
2. Locate the rear seat belt D ring to the body, refit 1 bolt
3. Fit the trunk side trim panel.
4. Fit the D pillar upper trim panel.
5. Locate the rear seat belt to the D pillar lower trim
panel, fit 1 bolt and tighten to 30–35Nm.
whether the SRS warning lamp illuminates for 6s, and
then goes out.
1.0 1134
Rear Middle Seat Belt 5. Fit the rear seat back upholstery assembly.
Remove Rear Seat Back Upholstery Assembly Refit
1. Remove the rear seat (including centre armrest)
6. Fix the rear middle seat belt to the floor, fit 1 bolt,
assembly.
tighten to30–35Nm and check the torque.
Rear Seat (Including Centre Armrest) Remove 7. Fit the rear seat (including centre armrest)
2. Remove 1 bolt fixing the rear middle seat belt to the
floor.
3. Remove the rear seat back upholstery assembly.

Rear Seat Back Upholstery Assembly Remove
4. Remove the rear seat backboard.
5. Remove 1 bolt fixing the rear middle seat belt retractor
to the rear seat back frame.
6. Remove the rear seat back foam and take out the rear
middle seat belt retractor.
7. Pass the middle seat belt web through the rear seat
belt decorative frame and remove the rear middle seat
belt assembly.
Refit
1. Pass the rear middle seat belt web through the rear
seat belt decorative frame.
2. Fix the rear middle seat belt to the rear seat back frame,
3. Reset the rear seat back foam.
4. Fit the rear seat backboard.
1.0 1135
Rear Seat Belt Buckle

Remove
Rear Seat (Including Centre Armrest) Remove

2. Remove 2 bolts securing 2 buckles of rear seat belt to
the rear floor, then remove the rear seat belt buckles.
Refit
1. Secure 2 buckles of rear seat belt onto the rear floor,
fit 2 retaining bolts, and tighten to 40–50Nm.
1.0 1136
Supplementary Restraint Systems Safety and Restraints
Supplementary Restraint Systems
Specifications
Torque
Description Value
Nut-SDM 7–10Nm
Bolt- front impact sensor 7–10Nm
Bolt-side impact sensor 7–10Nm
Screw-front passenger airbag to instrument panel 1.4–1.8Nm
Bolt-front passenger airbag to facia bracket 6–8Nm
Bolt - side curtain 7–9Nm
1.0 1137
Safety and Restraints Supplementary Restraint Systems

System Layout
Airbag Layout
1. RightCurtain Airbag 7. BCM

2. Left Seat side Airbag 8. Front Impact Sensor
3. Side Impact Sensor 9. SRS Warning Lamp
4. SDM 10. Communication Module
5. Driver Airbag 11. Passenger Airbag
6. GW
1.0 1138
Airbag Control Diagram
A= Chassis HS CAN Bus; B= Diagnostic HS CAN Bus; C= Body HS CAN Bus; D= Power HS CAN Bus; E= Hard Wire
1.0 1139
Description and severity of the impact so as to make sure the airbag can
Overview efficiently operate.
The SRS can enhance the passive protection for the passenger If the front impact severer than the preset trigger value is
when severe impact occurs. This system is usually built on the detected, the SRS ECU will send the signal to activate the
basis of the appliance of the standard restraint system (seat front airbag module and seat belt pretensioners.
belts).
When fitting the side airbag and side curtain airbag, two side
The SRS includes the following components: impact sensors shall be fitted to monitor the side impact
condition. If the side impact severer than the default trigger
• The supplementary restraint system ECU (SRS ECU)
value is detected, the SRS ECU will send the signal to activate
• Driver Airbag Module the corresponding side airbag and side curtain airbag module.
• Front Passenger Airbag Module And the seat belt pretensioner will be activated.
• Seat Side Airbag Module (if equipped) If the rear impact severer than the preset trigger value is
• Head Curtain Airbag Module (if equipped) detected, the SRS ECU will send the signal to activate the
• Seat Belt Pretensioner (if equipped) seat belt pretensioner.
• Front Impact Sensor (if equipped) Caution: It is important that the SRS ECU is correctly
• Side Impact Sensor (if equipped) mounted and is fitted in the designated location and
• Rotary Coupler orientation to ensure correct operation.
• SRS Warning Lamp (in the instrument pack) ECUMonitoring

• Seat Belt Not Tied Warning Lamp (in the instrument While energized, the SRS ECU monitors the preparation of
pack) the SRS module. After start-up, it shall perform the continuous
monitoring. SRS ECUIt monitors the status of the following
SRS ECUIt connects the vehicle diagnostic socket through
modules:
the HS CAN bus.
The supplementary restraint system ECU (SRS • SRS ECUInternal Accelerometer
ECU) • SRS ECUMicro-processor
• Side Impact Sensor (if equipped)
• Front Impact Sensor (if equipped)
• Driver Side Airbag Module
• Passenger Side Airbag Module
• Side Airbag Module (if equipped)
• Side Curtain Airbag Module (if equipped)
• Seat Belt Pretensioner (if equipped)
• Diagnosis Count
If any system failure is detected, the SRS warning lamp will

illuminate to warn the driver.
The recommended diagnostic device can be used to inquire

SRS ECUdetermines the affected range of the front impact, the SRS system malfunction. The diagnostic information
side impact or rear impact through the internal and external read includes the current malfunction information, frequency
impact sensor (if equipped), so as to control the operation of of the occurrence of malfunction and the duration of each
the SRS. malfunction.
SRS ECUIt is fitted on the central passage beneath the centre Power Supply and Backup Situation
console, which is secured with three nuts. SRS ECUIt is The power supply provides the operating voltage for the SRS
connected to the body harness through two connectors. ECU through a special system fuse on the BCM.
SRS ECUIt monitors the impact state around the vehicle In case of a power failure, check the connection status of
through the internal accelerometer and the external sensors. the fuse and harness of the BCM and SRS ECU. When the
SRS ECUIt can use these input data to distinguish the type ignition switch is in the "Ⅱ" position, the SRS is activated.
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SRS ECUIt contains a capacitor which can save a certain Warning: Do not use a multimeter or other general
amount of electricity, this ensures that the corresponding purpose test equipment on SRS system components
trigger device and ignition circuit can still work within a certain or accidental deployment may occur. Only use the
period of time in case of an impact and interruption of regular recommended diagnostic equipment to diagnose system
power supply. faults.
SRS ECU End View and Pin Information of SRS ECU End View and Pin Information of
Harness Connector BY079 Harness Connector BY142

1 HS CAN Low 1 —
2 HS CAN High 2 GND
3 Passenger Seat Belt Buckle Switch 3 —
4 Driver Seat Belt Buckle Switch 4 —
5 — 5 —
6 Ground/Right Impact Sensor Low 6 —
7 Right Impact Sensor High 7 Ground/Right Front Impact Sensor Low
8 Left Impact Sensor High 8 —
9 Ground/Left Impact Sensor Low 9 —
10 Wake-up Signal 10 Ground/Front Left Impact Sensor Low
11 KL.15 11 Front Right Impact Sensor High
12 KL.30 12 Left Front Impact Sensor High
13 Driver Airbag Low 13 —
14 Driver Airbag High 14 —
15 Passenger Airbag High 15 —
16 Passenger Airbag Low 16 —
17 Left Side Airbag Low 17 —
18 Left Side Airbag High 18 —
19 Right Side Airbag High 19 —
20 Right Side Airbag Low 20 —
21 Driver Pretensioner Low 21 Right Curtain Airbag Low
22 Driver Pretensioner High 22 Right Curtain Airbag High
23 Passenger Pretensioner High 23 Left Curtain Airbag High
24 Passenger Pretensioner Low 24 Left Curtain Airbag Low
Side Impact Sensor

For vehicles with side airbag module, the side impact sensor
is beside the body sill frame, which is fixed to the body by
screws. The sensor is designed with a mounting position for
1.0 1141
correct installation of the sensor, and each sensor includes Front Passenger Airbag Module
an electronic circuit and a sensing unit. The side impact
Warning: After replacing the vehicle windscreen the
sensor sends an acceleration signal to the ECU, and the ECU
Passenger Restraint System may not be capable of normal
determines whether to trigger through calculation.
operation for 24 hours.
Caution: The side impact crash sensors must be fitted in
Warning: If a new airbag module shows any sign of
the correct orientation. Ensure the fixing screws do not
damage, do not use.
damage the sensors or sensor harness when refitting the
front seats.
Front Impact Sensor
The front impact sensor is in the front the engine
compartment, which is fixed to the radiator bracket by
screws. The sensor is designed with a mounting position for
correct installation of the sensor, and each sensor includes
an electronic circuit and a sensing unit. The front impact
sensor sends an acceleration signal to the ECU, and the ECU
determines whether to trigger through calculation.
Driver Airbag Module 1. Airbag Housing
2. Airbag Cover
3. Airbag Connector
4. Gas Generator
The front passenger airbag module is on the glove box in the

instrument panel, just in front of the passenger seat. The airbag
module is fixed on the instrument panel by bolts.
The front passenger airbag module is triggered by the

control signal from the SRS ECU. The folding airbag and
gas generator module are in the module. When severe front
impact is detected by the SRS ECU, the gas generator will
be triggered, making the nylon bag inflate rapidly.
Side Airbag (if equipped)
1. Airbag Cover
2. Housing
damage, do not use.
3. Gas Generator
4. Airbag Connector
The driver airbag module is fitted on the steering wheel by

three protruding PINs and one airbag module connector.
When fitting the driver airbag module, push the airbag module
towards the steering wheel firmly to embed the wire spring
around the airbag module into the opening of the 3 PINs.
The electrical connection between the driver airbag module

and the SRS ECU is done by the rotary coupler, which
connects the steering wheel by a connector.
The driver airbag module is triggered by the control signal from

the SRS ECU. The folding airbag and gas generator module
are in the module. When severe front impact is detected by 1. Airbag Housing
the SRS ECU, the gas generator will be triggered, making the
2. Airbag Connector
nylon bag inflate rapidly.
3. Retaining Bracket
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The seat side airbag is fitted at the outside of the seat bracket Caution: Do not try to remove the connector at the
below the seat upholstery. It can protect the rib, pelvis and module end, it is a permanent connection.
upper visceral organs in case of side impact. If the side impact Head Side Curtain Airbag Module (if equipped)
is severe enough to deploy the seat side airbag, the control
signal from the SRS ECU will trigger the seat side airbag.
damage, do not use.
The seat side airbag module connector is a 4-pin connector,
which is below the seat cushion and connected to the SRS
ECU through the body harness.
1. Retaining Clip The head side curtain airbag module is in the interior trim
2. Airbag Connector panels above the front and rear doors. The airbag housing
and gas generator are fixed on one bracket in the middle of
3. Mounting Point
the airbag module. The cable at the front is under the A pillar.
4. Gas Generator Assembly
The airbag is fixed by plastic clips, which ensures the airbag can
5. Side Curtain Airbag disconnect from the body after the airbag is inflated. The head
The head side curtain airbag is provided to ensure all side curtain airbag module is connected with the SRS ECU
occupants' heads will not touch the body and intruded external through the body harness.
objects will not hurt the occupants' bodies in case of collision.
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Operation driver/passenger front airbags and seat belt pretensioner

Overview are activated (side airbag may also be triggered).
With the ignition switch in "Ⅱ" position, the SRS will be Warning Lamp Check
activated. With the ignition switch in "ON" position, the SRS When the ignition switch is turned on, the SRS warning lamp
warning lamp illuminates for about 6s, then goes out, this shall illuminate, then check the lamp. If no failure occurs in the
indicates that the system is in normal condition. SRS, the warning lamp shall go out after about 6s to monitor
Front Impact the subsequent ignition cycles.
If the front impact is severe and exceeds the threshold set in System Continuity Fault
the SRS ECU, the front airbag module and front pretensioning With the ignition switch ON, if any of the following faults
seat belt will work. occurs in the system, the SRS warning lamp will illuminate.
When the accelerometer and front impact sensor in the SRS • SRS ECU Failure
ECU detect any impact, the ECU will produce current to
• Harness Failure
trigger the front airbag module:
• Ground Connection Failure
• The driver side front airbag module is activated to expand
• Open Circuit
the airbag.
• Airbag Module Failure
• The passenger side front airbag module is activated to
• Seat Belt Pretensioner Failure
expand the airbag.
If the system detects any failure during driving, the warning
When the front airbag is fully expanded, it will release the gas
lamp will also illuminate to indicate failure of the SRS system.
immediately from the passage port and provide the passenger
When the warning lamp illuminates, the SRS may not work
moving forward with gradual deceleration, this reduces the risk
when any impact occurs.
level of injury to the occupants.
With the ignition switch ON, the diagnosis function of the SRS
SRS The ECU can determine the type and severity level of the
ECU will monitor the SRS. If any fault is detected, the SRS
impact. If the front impact detected by the sensor is severe,
ECU will store a related DTC in a nonvolatile memory and
the SRS ECU will send an ignition signal to the front airbag
output a signal to illuminate the SRS warning lamp. The failure
module and seat belt pretensioner.
information in the memory can be read with the scan tool.
Side Impact
Low Voltage
Normal operation of the side seat airbag and head curtain
When the voltage is not within the specified range, the
airbag depends on whether the severity level of the side impact
malfunction indicator lamp will illuminate. The DTC is stored
detected by the side impact sensor and acceleration sensor
in the memory.
in the SRS ECUexceeds the threshold for triggering the
side impact sensor. When the SRS ECU detects severe side Intermittent Failure
impact, it will activate the side airbag, curtain airbag module When intermittent failure occurs, the warning lamp
and seat belt pretensioner. The triggered gas generator can illuminates, and it will be disabled after the failure is eliminated.
produce a large quantity of gas to expand the airbag. The The warning lamp will not illuminate in the next ignition unless
expanded airbag will eject from the seat upholstery, similarly, the failure occurs again, but the DTC is still stored in the SRS
if the head curtain airbag module is triggered, the airbag will ECU memory.
eject from the interior trim panel above the door to protect
Permanent Failure
the passenger from head injury. The fully expanded airbag will
release excess gas and reduce the risk of passenger injury. For a permanent failure, the SRS lamp will illuminate when
the test is conducted, and it will remain on in every subsequent
Front Impact with Angle
ignition cycle until the cause of the failure is solved. In addition,
When a front impact with angle happens, whether the airbag the diagnosis system will also record the information of the
and seat belt pretensioner work depends on the speed and failure occurred.
angle of the impact. There are several conditions:
Additional information provided by the "scan tool" for
• The impact is below the threshold of the impact sensor
diagnostic socket includes:
in the SRS ECU, and no airbag or seat belt pretensioner
is activated. • SRS ECU DTC
• The speed and angle of the impact exceed the • Version Levels of Hardware and Software
triggering threshold of the front impact sensor, and the • Vehicle Identification Number (VIN) Data
1.0 1144
SRS The ECU records fault information in the memory, and diagnostic socket below the closure plate of the driver side
the information can be read by connecting the scan tool to the instrument panel.
1.0 1145
Service Procedures Collision Sensor

SAS System Diagnosis and Control Module Remove
1. Disconnect the battery negative. Wait for 10min until 2. Remove the side impact sensor.
the internal circuit of SRS ECU is discharged, then
a. Remove the B pillar lower trim panel.
start to operate.
B Pillar Lower Trim Panel Remove
b. Disconnect the electrical connector of side impact
Centre Console Assembly Remove sensor.
3. Disconnect the connector of SAS system diagnosis and
c. Remove 1 bolt fixing the side impact sensor assembly
control module.
to B pillar.
4. Remove 3 nuts fixing the SAS system diagnosis and
control module to the body.
d. Remove the side impact sensor.

3. Remove the front impact sensor.
5. Remove the SAS system diagnosis and control module.
a. Open the engine hood, locate the front impact sensor
Refit
in front of engine compartment.
1. Fix the airbag control module to the body, fit 3 nuts
b. Remove 1 bolt fixing the front impact sensor to the
radiator bracket.
2. Connect the electrical connector of airbag control
module.
4. Programme and encode the airbag control module
(SDM).
Encoding - SDM Replacement

6. Turn the ignition switch to ON position, and check if
the SRS warning lamp illuminates for 6s and then goes
out.
c. Disconnect the front impact sensor connector and
remove it.
Refit
1. Refit the front impact sensor
a. Connect the front impact sensor connector.
b. Fix the front impact sensor to the radiator bracket,
fit 1 bolt and tighten to 7–10Nm.
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2. Refit the side impact sensor. Steering Wheel Airbag
a. Fix the side airbag sensor assembly to B pillar, fit 1
Remove
bolt and tighten to 7–10Nm. Warning: It is imperative that before any work
b. Connect the electrical connector of side impact
sensor.
1. Disconnect the battery negative. Wait for 10min until
c. Fit the B pillar lower trim panel. the SRS backup circuit is discharged, then start to
B Pillar Lower Trim Panel Refit operate.
2. Adjust the steering wheel to the lowest position.
3. Adjust the depth of the steering wheel so that it can be
pulled outwards to the limit position.
4. Pry off the upper trim cover of steering column to
spare the room to remove the airbag lock ring.
5. Rotate the steering wheel to show the airbag lock ring.
6. Pry open three lock rings from the lower part of the
steering wheel with a flat-bladed screwdriver to release
three PINs fixing the airbag to the steering wheel.
7. Disconnect the airbag connector.

8. Remove the steering wheel airbag.
Refit
1. Connect the driver airbag connector.
2. Place the driver airbag in the steering wheel mounting
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 till a click
can be heard.
4. Fix the steering column upper trim cover to the lower
trim cover, and press the clip properly.
5. Restore the steering wheel.
whether the SRS warning lamp illuminates for 6s first,
and then goes out.
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Instrument Panel Airbag 4. Connect the airbag module connector.

Remove 5. Fit the instrument panel assembly.
1. Disconnect the battery negative. Wait for 10min until
the SRS backup circuit is discharged, then start to
6. Connect the battery negative and positive.
operate.
7. Turn on the ignition switch, and check if the SRS
warning lamp illuminates for 6s and then goes out.
3. Disconnect the passenger airbag module connector.
4. Remove 2 bolts fixing the passenger front airbag
module bracket to the instrument panel frame.
5. Remove 2 screws fixing the passenger front airbag

module to the instrument panel.
6. Remove 9 clamping jaws fixing the passenger front
airbag module to the instrument panel, and remove the
passenger front airbag module.
Refit
1. Fix the passenger front airbag module to the instrument
panel, and fit 9 clamping jaws.
2. Fit 2 screws 1.4–1.8Nm fixing the passenger front
airbag module to the instrument panel, and check the
torque.
3. Fix the passenger airbag module bracket to the
instrument panel frame, fit 2 bolts, tighten to 6–8Nm,
1.0 1148
Head Impact Protection Airbag Module
Remove
1. Disconnect the battery negative, and wait for 10
minutes until the SRS backup circuit is discharged.
2. Remove the roof interior trim, column interior trim
and rear quarter trim panel.
Trunk Side Trim Panel Remove Refit

3. Separate the curtain airbag connector with the hook Tip: If the airbag module is to be replaced, the bar code
from the new module must be recorded.
released.
1. Fix the curtain airbag to the roof, fit 4 retaining bolts
4. Remove the roof handle bracket.
and tighten to 7–9Nm, then check the torque.
5. Remove 2 bolts fixing the curtain airbag gas generator
bracket.
S 4730001
2. Fix the curtain airbag front drawstring to A pillar, fit 1

retaining bolt and tighten to 7–9Nm, then check the
6. Unscrew 1 clip fixing the curtain airbag front drawstring. torque.
S 4730002
7. Remove 4 bolts fixing the curtain airbag. 3. Fix the curtain airbag bracket to the mounting position,
fit 2 retaining bolts and tighten to 7–9Nm, then check
the torque.
4. Fit the handle bracket.
5. Connect the curtain airbag connector.
1.0 1149
6. Fit the roof interior trim, column interior trim and rear
quarter trim panel.
B Pillar Upper Trim Panel Refit

whether the SRS warning lamp illuminates for 6s first,
and then goes out.
1.0 1150
Park Assistant System Safety and Restraints
Park Assistant System
Specifications
Torque
Description Value
Nut-parking distance control module 4–6 Nm
1.0 1151
Safety and Restraints Park Assistant System

System Layout
Parking Aid Control System Layout
1. IPK 5. Parking distance control module

2. FICM 6. Gateway
3. Rear camera 7. Body Control Module (BCM）
4. Rear ultrasonic sensors
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Parking Aid Control System Control Diagram
A = CH HS CAN ； B = Hard wired ； C = BO HS CAN
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Overview 1 Left Rear Middle Sensor
Rear Obstacle Detection 2 Right Rear Middle Sensor
During reversing, if the vehicle has to go through obstructions 3 Right Rear Sensor
on the road, the parking distance control system will 4 Wake-up Signal
send a warning to the driver. The system consists of the 5 —
ultrasonic sensors fitted on the rear bumper, PDC ECU, IPK,
6 Sensor Power Supply
entertainment mainframe and the speaker controlled by the
entertainment mainframe. When the vehicle is in reverse gear, 7 KL.30
the PDC ECU uses the ultrasonic sensor to monitor the 8 Rear Left Sensor
area around the rear bumper, if an object is detected within 9 Sensor ground
the monitoring area, the acoustic alarm in the instrument pack
10 Chassis HS CAN High
or the speaker controlled by the entertainment mainframe
11 Chassis HS CAN Low
will issue a warning. The system is able to detect relatively
hard solid objects and objects like wire fence. 12 —
13 —
If the rear camera is provided, the image of the vehicle rear
area will be displayed on the navigation display. 14 —
Ultrasonic Sensor 15 —
16 GND
The ultrasonic sensors are fixed on the rear bumper. All the
sensors share the same structure, with the colour matching Acoustic Alarm
the vehicle.
The acoustic alarm in the instrument pack and the speaker
The detection range of the sensors on the rear bumper is the controlled by the entertainment mainframe can send an audible
area 1500mm away from the rear bumper. alarm to inform the driver of the system status and presence
The PDC control module (PDC ECU) of obstacles in the monitoring area.
PDC ECUis located in the back of the trim panel of the left Rear Camera (if equipped)
luggage compartment. It connects the sensor by the harness,
when the system is activated, the PDC ECU outputs signal
to the sensor and acoustic device and receives the distance
information from the sensor.
PDC ECUEnd View and Pin Information of Harness
Connector BY104
The rear camera is between the two license plate lamps

under the tailgate, it can provide the driver with real-time
image around the rear of the vehicle and facilitate the reverse
operation.
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End View and Pin Information of Rear Camera Pin No. Description
Connector BY083
1 Camera Power Supply
2 GND
3 Video Signal
4 Signal Ground
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Operation the vehicle, until the distance from the vehicle reaches about
Overview 300mm and the audible alarm becomes consecutive alarm.
When the ignition switch is in the "II" position and the reverse If a draw bar is provide, the ECU will detect the towing
gear is selected, the system runs. ECUWhen the reverse gear hook/draft ball from the input information of the sensor, and
is selected, activate the system after around 1 second delay. in order to compensate the towing hook/draft ball, delay the
system activation to prevent invalid warning when the shift
After the ECU receives the information that the reverse
lever moves between the drive gear and park gear.
gear is selected, it starts the ultrasonic sensor, then outputs
signals into the speaker makes the speaker generate an audible Detection Range
warning ("beep"), which shows that the system is activated.
Then, the ECU receives the distance reading information
from the ultrasonic sensor and determines whether there is
any object in the detection range. If no object is detected
within the detection range, it will not issue any audible alarm;
if there are objects detected, the ECU outputs signals into
the speaker to produce a repetitive audible alarm.
From the detection range margin, about 1500mm away from The relationship between the alarm level, obstacle and the
the rear vehicle, the frequency of the alarm increases with acoustic alarm is shown in the following table:
the decrease of the distance between the detected object and
SN. Alarm Level Distance (mm) Warning Period (msec)
1 00 = No >1500
Obstacle
2 01 = Range 1 0-300
3 02 = Range 2 300-450
4 03 = Range 3 450-600
5 04 = Range 4 600-750
6 05 = Range 5 750-900
7 06 = Range 6 900-1050
8 07 = Range 7 1050-1200
9 08 = Range 8 1200-1350
10 09 = Range 9 1350-1500
Caution: Blind spots, areas where the sensor cannot Self-diagnosis

detect obstructions, may occur if obstructions are present
Every time when the system is activated, the PDC ECU and
at distances of around 200 mm from the sensors.
sensor will perform a self-diagnosis. PDC ECUThey also
perform a short circuit or break circuit check for the system
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circuit. If a fault is detected and the fault exists for more than
3s, the PDC ECU will send an acoustic alarm (3s).
Failure Mode Warning Period Acoustic Alarm
Left Sensor 3s Acoustic Alarm + "Beep"
Middle Sensor 3s Acoustic Alarm + "Beep, beep"
Right Sensor 3s Acoustic Alarm + "Beep, beep,

beep"
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Service Procedures Rear Ultrasonic Sensor

Control Unit (ECU) - Parking Distance Control Remove
System 1. Disconnect the battery negative cable.
Remove
2. Remove the rear bumper.
Rear Bumper Remove
2. Remove the left interior trim panel of trunk.
3. Disconnect the ultrasonic sensor connector.
3. Disconnect the connector of the parking aid control
module.
4. Remove 2 nuts fixing the parking aid control module to
the left inner panel of trunk and remove the parking
aid control module .
4. Remove the ultrasonic sensor from its retaining bracket.

Refit
1. Snap the ultrasonic sensor in its bracket on the rear
bumper.
2. Connect the ultrasonic sensor connector.
Refit 3. Fit the rear bumper.
1. Fix the parking aid control module to the left inner Rear Bumper Refit
panel, fit 2 nuts and tighten to 4–6 Nm. 4. Connect the battery negative.
2. Connect the electrical connector of parking aid control
module.
4. Programme and encode the parking aid control module
(PDC).

Encoding - PDC Replacement
5. Fit the left interior trim panel of the trunk.
1.0 1158
Rear Camera
Remove
2. Remove the tailgate molding.
Tailgate Molding Remove
3. Disconnect the connector.
4. Remove rear camera.
Refit
1. Refit rear camera to rear license plate trim panel.
2. Connect the connector.
3. Refit the tailgate molding.
Tailgate Molding Refit

1.0 1159
1.0 1160
Entertainment and Navigation Information and Entertainment
Entertainment and Navigation
Specifications
Torque
Description Value
Screw-CD player to instrument panel 2–2.5Nm
Screw-Multi-range speaker to front door 7–10Nm
Screw-Multi-range speaker to rear door 7–10Nm
Screw-Roof antenna to vehicle body 3–4Nm
Bolt-Radio antenna amplifier to vehicle body 7–8.4Nm
Bolt-Antenna coil to tailgate 7–8.4Nm
Nut-Microphone to roof 1.5–2Nm
1.0 1161
Information and Entertainment Entertainment and Navigation

System Layout
Entertainment and Navigation Layout
1. Entertainment Control Panel 8. Front Door Full-range Speaker

2. Navigation Player； 9. A Pillar Tweeter
3. Microphone 10. Gateway
4. Antenna 11. Body Control Module
5. Rear Door Tweeter 12. Audio Control Button on Steering Wheel
6. Rear Door Full-range Speaker 13. Instrument Pack
7. USB Port
1.0 1162
Entertainment and Navigation System Control
Diagram
A= Body HS CAN；B= Hard Wire；C=LIN；D= Chassis HS CAN
1.0 1163
Description 2. The navigation mainframe with high configuration is

Overview provided with an 8 inch screen, which supports the
navigation, radio, USB, bluetooth phone, video function,
According to vehicle configuration and optional assembly,
etc.
there are two types of entertainment mainframes available for
installation: Entertainment Mainframe with Low Configuration
1. The entertainment mainframe with low configuration

supports the radio, USB, bluetooth phone function, etc.
1. Numeric Button 1 8. ] Button

2. Numeric Button 2/ Random Button 9. ] Button
3. Numeric Button 3/ Cycle Button 10. [MENU] Button
4. [ON/OFF] Button / [VOL] Knob 11. Numeric Button 6/ Next Folder
5. Bluetooth Telephone 12. Numeric Button 5/ Previous Folder
6. [SRC] Button 13. Numeric Button 4/ Information Button
7. USB Port
1.0 1164
Navigation Mainframe With High Configuration
1. SRC Button 4. Button

2. Button 5. Mute Button
3. ON/OFF Button/VOL Knob
1.0 1165
Audio Control Button on Steering Wheel

The audio device can be controlled by the remote switches
mounted on the steering wheel. These function buttons allow
the most common functions in the ICE system to be used in
a much more convenient manner.
Antenna
The antenna of the entertainment system may vary depending
on the configuration of the vehicle.
The entertainment mainframe with low configuration is

provided with the rear window printed antenna.
Screen
The navigation mainframe with high configuration is provided
The screen shows the audio information and relevant with the shark fin antenna without network antenna.
information.
Full Range Speaker
The full range speaker is inside the four doors. Secure the
speaker on the door panel with 3 screws.
Connector of Entertainment Mainframe with Low

Configuration
End View and Pin Information of Harness Connector
FA088 (Entertainment Mainframe with Low
Configuration)
Tweeter
Two tweeters are on the left/right A pillar, and the other two
are on the two rear doors. The tweeters on the A pillar are
fixed to the A pillar trim panel by clips, and the tweeters on
the rear door is fixed to the rear door inner handle assembly
by clips.
1.0 1166
Pin No. Description Harness Connector of Navigation Mainframe with
High Configuration
1-5 —
6 Right Front Sound Channel +
FA011 (Navigation Mainframe with Medium
7 Left Front Sound Channel + Configuration)
8-9 —
10 KL.30
11 KL.R
12 Reverse gear
13-15 —
16 Right Front Sound Channel -
17 Left Front Sound Channel -
18-19 —
20 GND

FA098 (Entertainment Mainframe with Low
Configuration)
Pin No. Description
A1 Audio Right Rear +
A2 Audio Right Front +
A3 Audio Left Front +
A4 Audio Left Rear +
A5 Audio Right Rear -
A6 Audio Right Front -
A7 Audio Left Front -
A8 Audio Left Rear -
B9 —
B10 —
B11 —
Pin No. Description
B12 —
1 AM/FM Signal
B13 —
2 GND
B14 —
B15 KL.30
B16 GND
C1 —
C2 —
C3 Steering Wheel Button Signal
Ground
C4 Steering Wheel Button Signal 1 +
C5 —
C6 —
C7 —
C8 —
C9 —
C10 Steering Wheel Button Signal 2 +
1.0 1167
Pin No. Description End View and Pin Information of Harness

— Connector FA021 (Navigation Mainframe with High
C11
Configuration)
C12 —
D1 —
D2 USB Power Supply
D3 —
D4 TT0SYS
D5 —
D6 —
D7 —
D8 USB Ground
D9 —
D10 —
D11 —
D12 — Pin No. Description
1 USB Power Supply
End View and Pin Information of Harness
Connector FA012 (Navigation Mainframe with High 2 USB Data -
Configuration) 3 USB Data +
4 —
5 USB Ground
End View and Pin Information of Radio Antenna

Harness Connector FA017 (Navigation Mainframe
with High Configuration)
Pin No. Description

1 USB Power Supply
2 USB Data -
3 USB Data +
4 —
5 USB Ground Pin No. Description
FM1 AM/FM Signal
FM2 GND
End View and Pin Information of Navigation Antenna

Harness Connector FA068 (Navigation Mainframe
with High Configuration)
Pin No. Description

GPS1 GPS Signal
GPS2 GND
1.0 1168
Operation For details of the operation of the entertainment system,
The entertainment system is operable only when the remote please refer to "User Manual" and "Navigation Manual".
key is inserted or the ignition switch is ON.
1.0 1169
Service Procedures 5. Programme and encode the FICM.

Player Self-learning and Adjustment, Programming and
Remove Encoding - FICM Replacement
2. Pry off the instrument panel upper trim assembly,
3. Remove the entertainment host.
a. Remove 4 bolts fixing the radio (low configuration)

to the instrument panel, disconnect the connector
and remove the radio.
b. Remove 4 bolts fixing the 8-inch navigation

mainframe (medium configuration) to the instrument
panel, disconnect the connector and remove the
entertainment host.
Refit
1. Connect the connector of the entertainment host.
2. Fit 4 screws fixing the entertainment host to the
instrument panel, tighten to 2–2.5Nm and check the
torque.
3. Refit the upper trim panel connector of the instrument
panel and fit the upper trim panel assembly of the
instrument panel.
1.0 1170
A Pillar Tweeter Front Door Full-range Speaker
Remove Remove
2. Remove the A pillar upper trim panel. 2. Remove the front door interior trim panel.
A Pillar Upper Trim Panel Remove Front Door Interior Trim Panel Remove
3. Disconnect the electrical connector from the tweeter. 3. Disconnect the front door full-range speaker connector.
4. Release the clip securing A pillar tweeter to A pillar 4. Unscrew 3 screws securing the full-range speaker onto
upper trim panel and remove A pillar tweeter. the front door, and remove the full-range speaker.
Refit Refit
1. Clamp the A pillar tweeter into A pillar trim panel and 1. Fix the front door full-range speaker onto the front
ensure the clips are fully engaged. door, fit 3 screws and tighten to 7–10Nm.
2. Connect the tweeter connector. 2. Connect the full-range speaker connector.
3. Fit the A pillar upper trim panel. 3. Refit the front door interior trim panel.
A Pillar Upper Trim Panel Refit Front Door Interior Trim Panel Refit
4. Connect the battery negative. 4. Connect the battery negative.
1.0 1171
Rear Door Tweeter Rear Door Full-range Speaker

Remove Remove
2. Remove the rear door interior trim panel. 2. Remove the rear door interior trim panel.
Rear Door Interior Trim Panel Remove Rear Door Interior Trim Panel Remove
3. Disconnect the rear door tweeter connector. 3. Disconnect the rear door full-range speaker connector.
4. Release the clips of the rear door tweeter to remove 4. Unscrew 3 screws securing the rear door full-range
the tweeter from the rear door inner handle assembly. speaker onto the rear door, and remove the full-range
speaker.
Refit
1. Place the rear door tweeter into the rear door inner Refit
handle assembly. 1. Fix the rear door full-range speaker onto the rear door,
2. Connect the rear door tweeter connector. fit 3 screws and tighten to 7–10Nm.
3. Refit the rear door interior trim panel. 2. Connect the rear door full-range speaker connector.
3. Refit the rear door interior trim panel.
4. Connect the battery negative. Rear Door Interior Trim Panel Refit
1.0 1172
Roof Antenna Radio Antenna Amplifier
Remove Remove
2. Remove the roof interior trim. 2. Remove the tailgate upper trim panel.
Roof Interior Trim Remove Tailgate Trim Panel Remove
3. Disconnect the roof antenna connector. 3. Disconnect the harness connector.
4. Remove 1 bolt securing the roof antenna onto the 4. Remove 1 bolt securing the antenna amplifier onto the
vehicle body and take off the roof antenna. vehicle body.
Refit 5. Remove the radio antenna amplifier.

1. Fix the roof antenna onto the vehicle body, fit 1 bolt, Refit
tighten to 3–4Nm, and check the torque. 1. Connect the antenna amplifier connector.
2. Connect the roof antenna connector. 2. Fix the antenna amplifier onto the vehicle body, fit 1
3. Fit the roof interior trim. bolt, tighten to 7–8.4Nm, and check the torque.
Roof Interior Trim Refit 3. Fit the tailgate upper trim panel.
4. Connect the battery negative. Tailgate Trim Panel Refit

1.0 1173
Antenna Coil Microphone

Remove Remove
1. Disconnect the battery negative. Microphone (high configuration)
2. Remove the tailgate lower trim panel. 1. Disconnect the battery negative.
Tailgate Trim Panel Remove 2. Remove 2 nuts fixing the roof console assembly to the
roof.
3. Disconnect the harness connector.
4. Remove 1 bolt securing the coil onto the tailgate.
3. Pry off the clip and remove the roof console.

4. Disconnect the connector.
5. Release the clip securing the microphone to the roof
5. Remove the antenna coil. console and remove 2 microphones.
Refit
2. Fix the antenna coil onto the tailgate, fix 1 bolt, tighten
to 7–8.4Nm, and check the torque.
3. Fit the lower tailgate trim panel.
Microphone (low configuration)

2. Pry off the microphone assembly.
1.0 1174
3. Disconnect the microphone connector.
4. Remove the microphone from the microphone assembly.
Refit
Microphone (high configuration)
1. Fix the microphone to the roof console.
2. Connect the connector.
3. Fix the roof console to the roof, fit 2 nuts, tighten to
1.5–2Nm and check the torque.
Microphone (low configuration)
1. Embed the microphone into the slot of microphone
cover.
2. Connect the microphone connector.
3. Refit the microphone assembly.
1.0 1175
Information and Entertainment Displays and Gages
Displays and Gages

Specifications
Torque
Description Value
Screw-Instrument pack to instrument panel 1.3–1.9Nm
1.0 1176
Displays and Gages Information and Entertainment
System Layout
Instrument Pack Layout
1. Speedometer 18. Front Fog Lamp Indicator (if any)

2. TPMS Warning (if any) 19. ECO Driving Mode Indicator (if any)
3. ABS Warning 20. Intelligent Start-Stop Energy-Saving System Malfunction
4. Brake System Warning Warning (if any)
5. EPS/SAS Warning 21. Intelligent Start-Stop Energy-Saving System Status
Indicator (if any)
6. Seatbelt unfastened Warning
22. Airbag Warning
7. Direction indicator (left)
23. Low Fuel Warning
8. SCS/TC Warning
24. Immobiliser System Warning
9. Message Center
25. Side Lamps Indicator
10. Low Oil Pressure Warning
26. Rear Fog Lamp Indicator
11. Direction indicator (right)
27. Main Beam Indicator
12. Tachometer
28. Engine Coolant Temperature Warning
13. Alternator Malfunction Warning
29. SCS/TC Off Warning
14. Engine Emissions Malfunction Warning
30. HDC ON/Malfunction Indicator (if any)
15. Check Engine/Drive by Wire Warning
31. TCCM System Indicator (if any)
16. Transmission Overheating Warning
32. EPB / Automatic Parking Status Indicator
17. Dipped Beam Indicator
1.0 1177
33. EPB Malfunction Warning 34. Cruise Control Indicator (if any)
Instrument Unit Layout
1. Instrument Pack
1.0 1178
A= Chassis HS CAN ； B= Power HS CAN ； C=Body HS CAN ； D= Hard Wire
1.0 1179
Description Transmission Receiving

Overview Signal Name
Component Component
The instrument pack is connected to the body harness by SASMalfunction
connectors and connected to the instrument panel assembly by SAS Instrument Pack
State
4 screws. The instrument pack is an enclosed (one-piece) unit
TPMSStatus SCS Instrument Pack
and can not be dismantled for maintenance. The control switch
of the trip computer can be used to operate the function of HDC Status SCS Instrument Pack
the trip compute or make some personalized settings. For SCSStatus SCS Instrument Pack
specific operations, please refer to the "Message Centre" in
TCStatus SCS Instrument Pack
this section.
SCSMode SCS Instrument Pack
Communication Signal
TCMode SCS Instrument Pack
The instrument pack receives/sends messages via the HS
CAN. Nodes of the HS CAN include PMDC, ECM, PEPS, EBDStatus SCS Instrument Pack
BCM, etc. The IPK uses the gateway to receive the HS CAN Brake Fluid State SCS Instrument Pack
signal from the ECM, TCM, SCU, SDM, SCS, EPS, SAS,
High Beam State BCM Instrument Pack
DHL, EPB, PDC, etc. The signals received and sent by the
instrument pack are shown below. Left/Right
Direction
Transmission Receiving BCM Instrument Pack
Signal Name Indicator Lamp
Component Component
State
System Power
Gateway Instrument Pack Key Battery Low
Mode BCM Instrument Pack
State
Wheel Speed
ABS /SCS Instrument Pack Anti-theft Alarm
Pulse Signal BCM Instrument Pack
Status
ABSMalfunction
ABS Instrument Pack Tailgate Open
Indicator Lamp BCM Instrument Pack
State
Seat Belt
TCCMMalfunction
(Driver/Passenger) SDM Instrument Pack TCCM Instrument Pack
State
Status
EPBOperation
Airbag Warning EPB Instrument Pack
SDM Instrument Pack State
Lamp
Auto Hold State SCS Instrument Pack
Door Status BCM Instrument Pack
EPBFailure EPB Instrument Pack
Cruise Control
ECM Instrument Pack
State Engine Speed ECM Instrument Pack
Engine Start by Key ECM Instrument Pack

Malfunction ECM Instrument Pack Depress Clutch
Indicator Lamp BCM Instrument Pack
Request
Engine Emission Depress Brake
Malfunction ECM Instrument Pack BCM Instrument Pack
Pedal Request
Indicator Lamp
Key is Not
Oil Pressure State ECM Instrument Pack Detected, Please
BCM Instrument Pack
Stop/Start Depress Brake
ECM Instrument Pack
Status/Disabled Pedal
Stop/Start Failure ECM Instrument Pack Restart after

Closing Driver ECM Instrument Pack
EPSMalfunction
EPS Instrument Pack Door
State
1.0 1180
Transmission Receiving Transmission Receiving
Signal Name Signal Name
Component Component Component Component
Restart after FCW State FVCM Instrument Pack
Fastening Seat ECM Instrument Pack LDW State FVCM Instrument Pack
Belt
Select N Gear to Harness Connector
ECM Instrument Pack
Restart State Location Diagram of IPK Harness Connector
Stop/Start Switch
ECM Instrument Pack
State
HHCStatus SCS Instrument Pack
Lock State BCM Instrument Pack
Request for
Pressing SSB to BCM Instrument Pack
Stop Engine
Request for
Removing BCM Instrument Pack
Intelligent Key
Request for
Moving Shift Lever BCM Instrument Pack 1. IPK Harness Connector
to PARK Gear
End View and Pin Information of IPK Harness
Intelligent Key Connector FA029
BCM Instrument Pack
Not Detected Pin No. Description
Request for 1 KL.30
Positioning
BCM Instrument Pack 2 KL.31
Intelligent Key
in Spare Coil 3 —
Intelligent Key 4 —
BCM Instrument Pack
Detected Inside 5 KL.15
Ignition Relay 6 Alternator (if any)
BCM/ PEPS Instrument Pack
Failure
7 —
SSB Failure PEPS Instrument Pack
8 —
Width Lamp State BCM Instrument Pack
9 —
Front/Rear Fog
BCM Instrument Pack 10 —
Lamp State
Daytime Running 11 —
BCM Instrument Pack
Lamp State 12 —
Washer Fluid 13 —
BCM Instrument Pack
Level State 14 —
DHL State DHL Instrument Pack 15 —
Battery Aging 16 —
PMDC Instrument Pack
State
17 —
Clutch
TCM Instrument Pack 18 —
Overheating State
19 —
20 —
1.0 1181
Pin No. Description Engine Coolant Temperature Warning

21 —
The IPK informs the driver of the high/low engine
22 Fuel Sensor + coolant temperature by receiving the signal from the ECM.
23 Fuel Sensor - Engine Malfunction Warning
Output Signal of Auto Hold State
24
Switch The IPK informs the driver that the EMS failure
25 — seriously affects the engine performance by receiving the signal
from the ECM.
26 Body HSCANHigh
Engine Emission Malfunction Warning
27 Body HSCANLow
28 — The IPK informs the driver that the EMS failure
Input Signal of Trip Computer Control affects the engine performance and emission by receiving the
29 signal from the ECM.
Switch
Trip Computer Control Switch Alternator Malfunction Warning
30
Ground
The IPK informs the driver of the alternator failure
31 —
by receiving the signal from the ECM.
32 —
By receiving the signal from the PMDC, the IPK informs the
The instrument pack mainly includes the following driver that the system will restrict or turn off some electrical
display functions: equipment when the battery is low.
Tachometer Low Oil Pressure Warning

The tachometer indicates the engine speed in revolutions per
By receiving the signal from the ECM, the IPK informs
minute (X1000). The HS end of the tachometer scale range
the driver that the current oil pressure is low, which may cause
features a red sector to warn the driver that the excessive
serious damage to the engine.
engine speed may result in engine damage. When the ignition
switch is in position 2, the instrument pack uses the HS CAN Intelligent Start-Stop Energy-Saving System
bus to receive the engine speed signal from the ECM. Status Indicator (if any)
Speedometer
By receiving the signal from the ECM, the IPK tells the
The speed indicated by the speedometer refers to the number driver if the current intelligent stop/start energy saving system
of kilometers travelled per hour (km/h). The maximum controls the engine.
indication of the speedometer is 240km/h.
Intelligent Start-Stop Energy-Saving System
ABS ECUCalculation of the vehicle speed can be achieved by Malfunction Warning (if any)
collecting the wheel speed pulse signal. The instrument pack
receives signals from the ABS ECU via the HS CAN bus. By receiving the signal from the ECM, the IPK
Fuel Gauge informs the driver of the failure of the intelligent stop/start
energy-saving system.
The fuel level of the fuel tank is indicated by the number of the
bar segments illuminated. EPSFault/SASMalfunction Warning
When the fuel level of the fuel tank is low, the low fuel level
By receiving the signal from the EPS/SAS, the IPK
warning lamp illuminates, with the drop of the fuel, the low fuel
informs the driver of the failure state of the EPS/SAS.
level warning lamp flashes.
TPMSWarning (if any)
Warning Lamps and Indicators
Cruise Control Indicator (if any)
By receiving the state signal of the TPMS from the
SCS, the IPK informs the driver of low tyre pressure or TPMS
The IPK informs the driver of the state of the current
failure.
cruise control system by receiving the signal from the ECM.
1.0 1182
ABSMalfunction Warning Front Fog Lamp Indicator (if any)
The IPK informs the driver of the ABS failure by By receiving the signal from the BCM, the IPK
receiving the signal from the SCS. reminds the driver that the front fog lamp illuminates.
HDC ON/ Malfunction (if any) Direction Indicator
The IPK informs the driver of the state of the current By receiving the signal from the BCM, the IPK
HDC by receiving the HDC signal from the SCS. reminds the driver that the direction indicator lamp illuminates.
If the hazard warning lamps are enabled, both direction
SCS/TCWarning
indicator lamps will flash together.
By receiving the signal from the SCS, the IPK tells Immobiliser System Warning
the driver if the SCS/TC fails.
The IPK receives the signal from the BCM, if the
If this lamp flashes during driving, it indicates the system is
engine immobiliser system cannot identify the key in the
operating to assist the driver.
ignition switch, this lamp illuminates.
SCS/TCOFF Warning
When the BCM receives an RF signal of low battery from the
remote key, the lamp flashes.
By receiving the signal from the SCS, the IPK informs
the driver of the OFF state of the SCS/TC. When the door is not closed, and the alarm is triggered, the
lamp flashes.
Brake System Malfunction Indicator
EPBStatus/Auto Hold Status Indicator
By receiving the signal from the SCS, the IPK informs
The IPK receives the signal from the EPB/SCS. If the
the driver of brake failure (such as lack of brake fluid) or EBD
lamp becomes red, the EPB is applied; if the red lamp flashes,
failure.
the EPB is not tight or it is in the process of dynamic braking.
Seat Belt Unfastened Warning
When the auto hold is operating to assist the driver, the green
indicator lamp illuminates.
By receiving the signal from the SDM, the IPK
reminds the driver or front passenger to tie the seat belt. EPBSystem Malfunction Warning
Airbag Warning
The IPK receives the signal from the EPB, if the lamp
remain ON or illuminates during driving, the EPB fails or it is
By receiving the signal from the SDM, the IPK
in the diagnosis state.
reminds the driver of the SRS failure.
4WD Indicator Lamp (if any)
Main Beam Indicator
By receiving the signal from the BCM, the IPK The IPK uses the signal from the TCCM to indicate
reminds the driver that the high beam illuminates. the status of the 4WD.
Dipped Beam Indicator (if any) Low Fuel Warning
By receiving the signal from the BCM, the IPK The instrument receives the signal from the fuel
reminds the driver that the low beam illuminates. sensor, when the fuel level is low, the lamp illuminates. When
the fuel level keeps going down and causes an emergency
Side Lamps Indicator situation, the lamp flashes. After the fuel tank is refilled, the
indicator will go out.
By receiving the signal from the BCM, the IPK
ECO Indicator (if any)
reminds the driver that the width lamp illuminates.
Rear Fog Lamp Indicator The instrument makes calculations and determines if
the vehicle is in the ECO mode according to the current engine
By receiving the signal from the BCM, the IPK speed, vehicle speed, instantaneous fuel consumption.
reminds the driver that the rear fog lamp illuminates.
1.0 1183
Transmission Overheating Warning Lamp Gear Display
With the ignition switch in ON position, it displays the current

By receiving the signal from the TCM, the IPK informs shift lever position (P, R, N, D, 1, 2, 3, 4, 5, 6, 7, S) of the
the driver that the transmission is hot. automatic transmission. If it displays "EP", it indicates the
Trip Computer Control Switch automatic transmission has a failure.
Total Mileage
With the ignition switch in ON position, it displays the total

driving mileage of the car.
Next Maintenance
Record the remaining distance before next maintenance.
Whenever the ignition is switched to ON position, the
message centre will first display the value for next maintenance
for about 3s, then it will switch to other displays.
• Press the left/right button on the right of steering wheel General Message
to switch the trip computer items The general message provides the followings:
• Press the up/down button on the right of steering wheel
1. Warning Message
to adjust the trip computer items.
2. Trip Computer Message
• Press OK button the right of steering wheel to confirm
3. Setting
or long press OK button to reset.
Message Centre
Warning Message
For the following warning messages, when a failure is detected,
the message display shows the warning icon, but the warning
indicator will not illuminate.
Icon Action
Before leaving or driving the
vehicle, close all doors, engine
hood and tailgate.
Reminds the driver to
slow down.
Reminds the driver to adjust the

steering wheel to the left.
Reminds the driver to adjust the

steering wheel to the right.
The message centre provides the followings:
Trip Computer
1. Digital Clock The trip computer comprises the following messages:
2. Temperature
1. Trip 1
3. General Message
2. Driving Time 1
4. Mileage
3. Average Speed 1
5. Gear Display
4. Average Fuel 1
Digital Clock
5. Trip 2
It displays the current time in digital form. 6. Driving Time 2
Temperature 7. Average Speed 2
It displays the current ambient temperature in digital form. 8. Average Fuel 2
9. Range to Empty
10. Instantaneous Fuel Consumption
1.0 1184
Trip 1 Average Speed 2
Displays the distance travelled this journey. The value will It displays the average vehicle speed since last reset. Long press
be automatically reset one hour after power off, or by long the OK button to reset.
pressing OK button on the right of steering wheel to reset.
Average Fuel 2
It displays the average fuel consumption since last reset. Long

press the OK button to reset.
Note: Average fuel consumption is related to driving

habits, road condition, load, tyre pressure, the
Driving Time 1 quality of oil, etc.
Displays the distance travelled this journey. The value will Range to Empty
be automatically reset one hour after power off, or by long This function automatically calculates and displays the mileage
pressing OK button on the right of steering wheel to reset. which the car can run before the fuel tank becomes empty, and
this mileage will change after refueling.
Average Speed 1
Displays the distance travelled this journey. The value will "Range to Empty" is calculated based on current fuel
be automatically reset one hour after power off, or by long consumption and the remaining fuel in the tank.
pressing OK button on the right of steering wheel to reset. Instantaneous Fuel Consumption
The option displays the current fuel consumption when the

engine is working.
Average Fuel 1
Displays the distance travelled this journey. The value will

be automatically reset one hour after power off, or by long Settings
pressing OK button on the right of steering wheel to reset.
On the trip computer interface, press the upper/lower button
on the right steering wheel to enter the following interface.
Note: Average fuel consumption is related to driving

habits, road condition, load, tyre pressure, the
On this display interface, press the OK button on the right
quality of oil, etc.
steering wheel or long press the trip computer button at the
Trip 2 top of the steering wheel lever switch to enter into the setting
It displays the mileage since last reset. Long press the OK mode.
button to reset. The following setting options are available:
Drving Time 2 • Illumination Level
It displays the time since last reset. Long press the OK button • Speed Limit Alarm
to reset. • Tyre Pressure Reset
• ECO Mode
• Exit
1.0 1185
Illumination Level In this interface, long press OK button will initialize the
system. If successful, the message centre display will show OK.
If unsuccessful, the message centre display will show NOK.
If this situation appears, please consult an MG Authorised
Repairer.
Note: ‘Tyre Pressure Reset’ should be made upon

In this interface, long press OK button on the right of steering each tyre replacement or inflation.
wheel, the illumination level will flash. Press the up/down
ECO Mode Setting
button to adjust the illumination level. There are 3 brightness
levels in total.
Note: This option can only be accessible when the

side lamps is on.
Speed Limit Alarm
In this interface, long press OK button on the right of steering In the ECO mode setting interface, long press OK button
wheel, the displayed speed value will flash. Press the up/down on the right of steering wheel to set ECO mode. Press the
button to modify the setting speed as required. The set range is up/down button on the right of steering wheel to select ON
OFF～30～220 km/h.OFF indicates that the speed limit alarm or OFF to turn on/off the ECO mode.
function is off. If the vehicle speed exceeds the set value, the Exit
set value will flash, accompanied with an audible warning.
Tyre Pressure Reset
In this interface, long press OK button on the right of steering

wheel to exit.
1.0 1186
Operation Preview Mode
Operation Mode Place the ignition switch in 2nd gear position, or press the trip
The specific function of the instrument pack available at a given computer control switch to activate the instrument pack from
time depends on the position of the ignition switch. the sleep mode. Operating the trip computer control switch
may activate some functions of instrument pack, e.g. the total
The instrument pack obtains the status information of ignition driving mileage, accumulated mileage and digital clock.
switch via CAN network or input signals of hard wire.
Activation Mode
Sleep Mode
All functions can be activated and operate. Such as: CAN
The instrument pack is fully in sleep mode, with minimum
signal transmission, instrument warning lamp, engine speed
quiescent current.
tachometer, speedometer and self-check system.
Standby Mode
Some functions can be achieved normally.
1.0 1187
Service Procedures Self-learning and Adjustment, Programming and

Instrument Pack Encoding - IPK Replacement
Remove 4. Ensure the instrument pack can work properly and fix
1. Disconnect the battery negative. the instrument pack to the instrument desk, fit 4 screws
2. Remove the air outlet trim panel of driver instrument and tighten to 1.3–1.9Nm, and check the torque.
panel. 5. Fix the instrument pack frame to the instrument panel,
fit 2 screws and tighten up.
Driver Instrument Panel Air Outlet Trim Panel
Remove 6. Fit the upper shield of steering column.
3. Pry off the instrument panel upper trim assembly, 7. Connect the connector, locate the instrument panel
disconnect the connector and remove the instrument upper trim assembly onto the instrument panel, press
panel upper trim assembly. the clip and ensure it is fitted in place.
8. Refit the air outlet trim panel of driver instrument
panel.
Driver Instrument Panel Air Outlet Trim Panel

Refit
4. Pry off the upper shield of steering column.

5. Remove the 2 bolts fixing the instrument pack frame to
the instrument panel and remove the instrument pack
frame and the upper shield of steering column.
6. Remove 4 screws securing the instrument pack to the

instrument desk.
7. Disconnect the instrument pack connector.
8. Remove the instrument pack.
Refit
1. Connect the instrument pack connector.
3. Programme and encode the instrument pack.
1.0 1188
Fuse Box and Harness Information and Entertainment
Fuse Box and Harness
Specifications
Torque
Description Value
Nut-Engine bay fuse box house to left front longitudinal 5–7Nm
Nut-Battery anode to battery fusebox 7–10Nm
Nut-Body harness to battery fusebox 3.5–5.5Nm
Nut-Alternator to battery fusebox 5–7Nm
1.0 1189
Information and Entertainment Fuse Box and Harness
Service Procedures
Engine Compartment Fuse Box
Remove
2. Release the clip fixing the upper fuse box cover to the
fuse box and remove the upper fuse box cover.
Refit
1. Secure the engine compartment fuse box base to the
body, fit 3 bolts , tighten to 5–7Nm, and check the
torque.
2. Connect the harness connector to the back of engine
compartment fuse box.
3. Remove 1 nut fixing battery positive cable to the engine 3. Secure the engine compartment fuse box to the fuse
fuse box and remove the harness. box lower cover with 5 clips.
4. Release 5 clips fixing the engine compartment fuse 4. Fix the positive battery cable to the fuse box, fit 1 nut,
box to the fuse box lower cover and lift the engine tighten to 7–10Nm, and check the torque.
compartment fuse box. 5. Secure the fuse box upper cover to the engine
compartment fuse box with 2 clips.
5. Disconnect the harness connector at the back of

engine compartment fuse box and remove the engine
compartment fuse box.
6. Remove 3 bolts fixing the fuse box base to the body
and remove the fuse box base.
1.0 1190
Battery Fuse Box Body Harness
Remove Remove
2. Remove the upper cover of battery fuse box. 2. Remove the front bumper assembly.
3. Remove the bolt (1) fixing the battery fuse box to the Front Bumper Assembly Remove
battery positive.
4. Remove the nut (2) fixing the alternator cable to the
battery fuse box, and take away the cable. Air Filter Assembly Remove
4. Remove the engine compartment fuse box.
5. Remove 3 nuts (3) fixing the body harness to the
battery fuse box, and take away the cable. Engine Compartment Fuse Box Remove
5. Remove the battery fuse box assembly.
Battery Fuse Box Remove

6. Disconnect the connector of the TCM to the body
harness.

Refit
1. Locate the battery fuse box on the battery.
2. Locate 3 terminals of body harness to the battery
fuse box in the principle of "maximum line diameter 7. Disconnect the connector of the EBS battery current
matching with maximum fuse limit", and ensure the sensor.
color of fuse consistent with that of harness, fit 3 nuts,
tighten to 3.5–5.5Nm and check the torque.
3. Refit the engine cable to the battery fuse box, fit 1 nut
4. Fix the battery cable to the battery fuse box, fit 1 bolt
5. Fit the upper cover of battery fuse box.
8. Disconnect the connector of the front fog lamp (1) and

daytime running lamp (2).
1.0 1191
9. Disconnect the connector of the horn. 15. Disconnect the connector of the ambient temperature
sensor.
10. Disconnect the connector of the windshield washer

motor and washer fluid level sensor. 16. Release the ground point of the right headlamp.
11. Disconnect the connector of the cooling fan motor. 17. Release the ground point of the left front longitudinal
12. Disconnect the front impact sensor connector. beam.
18. Disconnect the connector of the ECM to the body
harness.
19. Release the ECM ground point under the ECM.
20. Disconnect the engine harness connector.
21. Disconnect the connector of the windshield wiper
motor.
22. Disconnect the connector of the wiper reservoir level
sensor.
23. Disconnect the connector of the A/C pressure switch.
13. Disconnect the connector of the engine hood release

switch.
14. Disconnect the connector of the headlamp.
1.0 1192
24. Disconnect the connector of the SCS ECU. 28. Disconnect the connector from the brake fluid level
switch.
25. Release the ground point of the lower SCS ECU.

26. Disconnect the connector of the vacuum sensor. 29. Raise the vehicle to a suitable height for operation.
30. Disconnect the connector of the front chassis height
sensor.
27. Disconnect the connector of the brake lamp switch.
31. Disconnect the connector of the front wheel speed

sensor.
1.0 1193
32. Disconnect the left/right connectors of the fuel tank 37. Disconnect the connector (1) of the EPB ECU.
harness.
33. Disconnect the connector (2) of the rear wheel speed
sensor.
38. Release the ground point under the EPB.

34. Disconnect the connector of the torque transfer device.
panel.

Remove
41. Remove the glove box assembly.
42. Remove the carpet.
Carpet Remove
43. Disconnect 5 connectors of the BCM to the body
harness.
35. Remove the rear wheelhouse liner.
Rear Wheelhouse Liner Remove

36. Disconnect the connector of the rear chassis height
sensor.
1.0 1194
44. Disconnect the connector of the brake pedal position 49. Disconnect 2 connectors of the headlamp control
sensor. module.
45. Disconnect the connector of the accelerator pedal 50. Disconnect the connector of the A pillar body harness
sensor. to instrument panel harness.
51. Release the ground point under the A pillar.
52. Disconnect the connector of the DC converter with
power management (PMDC).
53. Disconnect the connector of the TCCM.
54. Disconnect the connector of the front door harness.
55. Remove the A pillar upper trim panel.
A Pillar Upper Trim Panel Remove
56. Disconnect the connector of the A pillar tweeter.
46. Disconnect the connector of the EPS and EPS ECU

to the body harness.
47. Release the ground point of the lower EPS.
48. Disconnect 4 connectors of the PEPS control module.
1.0 1195
57. Remove the roof interior trim.

58. Disconnect the connector of the sunroof motor.
65. Disconnect the connector of the shift control.

66. Disconnect the airbag harness connector on the
instrument panel harness.
67. Disconnect 2 connectors of the airbag control module.
59. Disconnect the rain sensor.
68. Release 2 ground points of the lower airbag control
60. Disconnect the connector of the front view camera.
module.
(If equipped)
69. Disconnect the connector of side impact sensor.
61. Disconnect the connector of the side curtain airbag.

70. Disconnect the connector of the seat belt pretensioner
from the lower part of the left/right B/C pillar.
71. Disconnect the connector of the rear door harness.
72. Disconnect the connector of the rear window heating
element of the left/right D pillars.
62. Disconnect the connector of the radio antenna.

63. Disconnect the connector of the GPS antenna. (If
equipped)
64. Disconnect the PEPS antenna - middle connector.
1.0 1196
73. Disconnect the connector of high mounted stop lamp. 80. Disconnect the connector of the rear auxiliary power
socket.
81. Disconnect the connector of the power tailgate control
module. (If equipped)
74. Open the tailgate.

75. Remove the trunk sill trim panel.
82. Disconnect the connector of the tail lamp.
76. Remove the interior trim panel of the trunk.
Trunk Interior Trim Panel Remove
78. Disconnect the connector of the rear window wiper
motor.
83. Release the ground point of the tail lamp.

84. Disconnect the connector of the left/right trunk lamps.
85. Disconnect the connector of the 4 parking distance
control sensors on the rear body.
86. Disconnect the connector of the rear fog lamp.
79. Disconnect the connector of the PDC ECU on the 87. Remove the rear bumper assembly.
left of the trunk. Rear Bumper Assembly Remove
88. Disconnect the PEPS antenna - rear bumper upholstery
connector.
1.0 1197
9. Connect the connector of the left/right trunk lamps.

10. Fit the ground point of the tail lamp.
11. Connect the connector of the tail lamp.
12. Connect the connector of the rear auxiliary power
socket.
13. Connect the connector of the power liftgate control
module. (If equipped)
14. Connect the connector of the PDC ECU on the left
of the trunk.
15. Connect the connector of the rear window wiper
motor.
16. Fit the tailgate trim panel.
89. Disconnect the connector (2) of the tailgate release
switch (1) and motor. Tailgate Trim Panel Refit
17. Fit the interior trim panel of the trunk.
Trunk Interior Trim Panel Refit

18. Fit the trunk sill trim panel.
Trunk Sill Trim Panel Refit
20. Connect the connector of high mounted stop lamp.
21. Connect the connector of the rear window heating
element of the left/right D pillars.
22. Connect the rear door harness connector.
23. Connect the connector of the seat belt pretensioner
under the B/C pillar.
90. Disconnect the connector (3) of the rear license plate 24. Connect the connector of the side impact sensor.
lamp. 25. Fit 2 ground points of the lower airbag control module.
91. Disconnect the connector (4) of the rear view camera. 26. Connect 2 connectors of the airbag control module.
(If equipped)
27. Connect the airbag harness connector on the
92. Loosen the clip and rubber grommet fixing the harness instrument panel harness.
from the body.
28. Connect the connector of the shift control.
93. Take away the body harness.
29. Connect the PEPS antenna - middle connector.
Refit
30. Connect the connector of the GPS antenna. (If
1. Locate the harness to the body, secure with clips, and equipped)
make sure all clips are secured in right position.
31. Connect the connector of the radio antenna.
2. Connect the connector of the rear camera. (If
32. Connect the connector of the side curtain airbag.
equipped)
33. Connect the connector of the sunroof motor.
3. Connect the connector of the rear license plate lamp.
34. Connect the connector of the front view camera. (If
4. Connect the connector of the tailgate release switch
equipped)
and motor.
35. Connect the connector of the rain sensor.
5. Connect the PEPS antenna - rear bumper skin
connector. 36. Fit the roof interior trim.
6. Fit the rear bumper assembly. Roof Interior Trim Refit
Rear Bumper Assembly Refit 37. Connect the connector of the A pillar tweeter.
7. Connect the connector of the rear fog lamp. 38. Fit the A pillar upper trim panel.
8. Connect the connector of the 4 PDCs on the rear body. A Pillar Upper Trim Panel Refit
1.0 1198
39. Connect the front door harness connector. sensor.
40. Connect the connector of the TCCM. 72. Connect the connector of the windshield wiper motor.
41. Connect the connector of the PMDC (DC converter 73. Connect the connector of engine harness.
with power management). 74. Fit the ECM ground point under the ECM.
42. Fit the ground point under A pillar. 75. Connect the connector of the ECM and body harness.
43. Connect the connector of A pillar body harness and 76. Fit the ground point of the left front longitudinal beam.
77. Fit the ground point of the right headlamp.
44. Connect 2 connectors of the headlamp control module.
78. Connect the connector of the ambient temperature
45. Connect 4 connectors of the PEPS module. sensor.
46. Fit the ground point under the EPS. 79. Connect the connector of the headlamp.
47. Connect the body harness connector of the EPS and 80. Connect the connector of the engine hood touch
EPS ECU. switch.
48. Connect the connector of the accelerator pedal sensor. 81. Connect the connector of the front impact sensor.
49. Connect the connector of the brake pedal position 82. Connect the connector of the cooling fan motor.
sensor.
83. Connect the connector of the windshield washer
50. Connect 5 connectors of the BCM and body harness. motor and washer fluid level sensor.
51. Fit the carpet. 84. Connect the connector of the horn.
Carpet Refit 85. Connect the connector of the front fog lamp and
52. Fit the glove box assembly. daytime running lamp.
86. Connect the connector of the EBS battery current
sensor.
87. Connect the connector of the TCM and body harness.
88. Fit the battery fuse box assembly.
Refit
Battery Fuse Box Refit
54. Raise the vehicle to a suitable height for operation.
89. Fit the engine compartment fuse box.
only by a jack.Always support the vehicle on safety stands. Engine Compartment Fuse Box Refit
55. Fit the ground point under the EPB. 90. Fit the air filter assembly.
56. Connect the connector of the EPB ECU. Air Filter Assembly Refit
57. Connect the connector of the rear height sensor. 91. Fit the front bumper assembly.
58. Fit the rear wheelhouse liner. Front Bumper Assembly Refit
Rear Wheelhouse Liner Refit 92. Connect the battery negative.
59. Connect the connector of the torque coupler.
60. Connect the connector of the rear wheel speed sensor.
61. Fit the left/right connectors of the fuel tank harness.
62. Connect the connector of the front wheel speed sensor.
63. Connect the connector of the front height sensor.
65. Connect the connector of the brake fluid level switch.
66. Connect the connector of the brake lamp switch.
67. Connect the connector of the vacuum sensor.
68. Fit the ground point under the SCS ECU.
69. Connect the connector of the SCS ECU.
70. Connect the connector of the A/C pressure switch.
71. Connect the connector of the wiper reservoir level
1.0 1199
Instrument Panel Harness

Remove
3. Disconnect the connector of passenger compartment
fuse box.
4. Disconnect the connector between BCM and the
7. Disconnect the connectors of wiper/washer lever

switch and the clock spring.
5. Disconnect 2 gateway connectors.
8. Disconnect the connector of blower motor.
6. Disconnect the connectors of direction indicator

lamp/high beam lever switch, cruise control lever switch
and angle sensor.
9. Disconnect the connector of recirculating air damper

servo motor.
10. Disconnect the connector of face vent temperature
sensor.
11. Disconnect the connector of blower speed regulation
module.
1.0 1200
12. Disconnect the connector of evaporator temperature 17. Disconnect the connector of feet distribution outlet
sensor. temperature sensor.
13. Disconnect the connector of the mode damper servo 18. Disconnect the connector of the passenger airbag.
motor. 19. Disconnect the connector of the communication
module assembly.
14. Disconnect the connector of body harness airbag.

15. Disconnect the connector at front of PEPS interior 20. Disconnect 3 body harness connectors.
antenna.
21. Release the ground point.
22. Release the clip fixing the harness to the instrument
panel beam.
23. Take down the instrument panel harness.
Refit
1. Fix the instrument panel harness to the instrument
panel beam and attach with clips.
2. Fit the grounding contact.
3. Connect 3 connectors of body harness.
4. Connect the connector of communication module
S8213002 assembly.
5. Connect the connector of passenger side airbag.
16. Disconnect the connector of the blend damper servo
motor. 6. Connect the connector of 'feet' distribution outlet
temperature sensor.
7. Connect the connector of blend damper servo motor.
8. Connect the connector at the front of PEPS internal
antenna.
1.0 1201
9. Connect 2 connectors of automatic temperature Driver Door Harness

control unit. Remove
10. Connect the connector of the body harness airbag. 1. Disconnect the battery negative.
11. Connect the connector of mode damper servo motor. 2. Disconnect the driver door harness and the body
12. Connect the connector of evaporator temperature harness connector.
sensor. 3. Remove the front left door waterproof membrane.
13. Connect the connector of blower speed regulation Front Door Waterproof Membrane Remove
module.
4. Disconnect the exterior mirror connector.
14. Connect the connector of 'face' distribution outlet
5. Disconnect the window regulator motor connector.
temperature sensor.
6. Disconnect the front door woofer connector.
15. Connect the connector of mode damper servo motor.
16. Connect the connector of blower motor assembly.
17. Connect the connectors of wiper/washer stalk switch
and clock spring.
18. Connect the connectors of direction indicator
lamp/high beam lever switch, cruise control lever switch
and angle sensor.
19. Connect 2 connectors of the gateway.
20. Connect BCM to the connector of the instrument
panel harness.
21. Connect the connector of passenger compartment
fuse box.
22. Fit the instrument panel assembly. 7. Disconnect the door handle antenna connector.
8. Disconnect the front door lock connector.
1.0 1202
9. Release the clip fixing the harness to the door. Front Passenger Door Harness
10. Remove the driver door harness. Remove
Refit 1. Disconnect the battery negative.
1. Locate the harness to the door and fix it with clips. 2. Disconnect the front passenger door harness and the
2. Connect the front door lock connector. body harness connector.
3. Connect the door handle antenna connector. 3. Remove the front right door waterproof membrane.
4. Connect the front door woofer connector. Front Door Waterproof Membrane Remove
5. Connect the window regulator motor connector. 4. Disconnect the exterior mirror connector.
6. Connect the exterior mirror connector. 5. Disconnect the window regulator motor connector.
7. Connect the driver door harness and the body harness 6. Disconnect the front right door woofer connector.
connector.
8. Fit the front left door waterproof membrane.
Front Door Waterproof Membrane Refit

7. Disconnect the door handle antenna connector.
8. Disconnect the front door lock connector.
1.0 1203
9. Release the clip fixing the harness to the door. Rear Door Harness
10. Remove the front passenger door harness. Remove
Refit 1. Disconnect the battery negative.
1. Locate the harness to the door and fix it with clips. 2. Disconnect the rear door harness from the body
2. Connect the front door lock connector. harness connector.
3. Connect the door handle antenna connector. 3. Remove the rear door waterproof membrane.
4. Connect the window regulator motor connector. Rear Door Waterproof Membrane Remove
5. Connect the exterior mirror connector. 4. Disconnect the rear door tweeter connector.
6. Connect the front right door woofer connector. 5. Disconnect the rear door woofer connector.
7. Fit the front right door waterproof membrane. 6. Disconnect the window regulator motor connector.
Front Door Waterproof Membrane Refit 7. Disconnect the rear door lock connector.
8. Connect the front passenger door harness and the

body harness connector.
8. Release the clip fixing the harness to the door.

9. Remove the rear door harness.
Refit
1. Locate the harness to the door and fix with clips.
2. Connect the body harness connector.
3. Connect the rear door lock body connector.
4. Connect the window regulator motor connector.
5. Connect the rear door tweeter connector.
6. Connect the rear door woofer connector.
7. Refit the rear door waterproof membrane.
Rear Door Waterproof Membrane Refit

1.0 1204
Centre Console Harness Power Seat Harness
Remove Remove
2. Remove the centre console assembly. 2. Disconnect the connector of driver power seat
combination switch.
3. Disconnect the connector of seat vertical adjuster
3. Disconnect the harness connector.
motor.
4. Release the clip securing the harness onto the centre

4. Disconnect the connector of seat leveling adjuster
console.
motor.
5. Take away the centre console harness.
Refit
1. Locate the centre console harness onto the centre
console and secure with clips.

5. Disconnect the connector of seatback adjuster motor.
6. Disconnect the connector of body harness.

7. Release the clip fixing the harness to the seat.
1.0 1205
8. Remove the seat harness. Centre Console Power Socket

Refit Remove
1. Locate the harness onto the seat and secure with clips. 1. Disconnect the battery negative.
2. Connect the body harness connector. 2. Remove the centre console front storage box assembly.
3. Connect the seat backrest regulating motor connector. Centre Console Front Storage Box Assembly
4. Connect the seat level regulating motor connector. Remove
5. Connect the seat vertical regulating motor connector. 3. Remove the centre console power socket from the
6. Connect the driver power seat combination switch centre console front storage box assembly.
connector. Refit
7. Connect the battery negative. 1. Insert the cigar lighter socket from the front part of
centre console front storage box and fasten with clips.
2. Refit the centre console front storage box assembly.
Centre Console Front Storage Box Assembly

Refit
1.0 1206
Self-learning/Programming Self-learning/Programming
Self-learning/Programming
Window Regulator and Sunroof Initialization
Window Regulator Initialization
For window regulators with "one-button up" and "anti-pinch"
functions, when the power is off in the process of window
regulator operation, these functions will be disabled; when
power on, these function can be resumed by initialization of the
regulator. After power on, if it fails to initialize, the instrument
pack message centre will display the warning icon and warning
information "Please Initialize the Driver Window" to remind
you of window regulator initialization. Raise the window to the
upmost by pressing the switch briefly and consecutively, then
press and hold the switch for approximate 5 seconds, window
functions of "one-touch up" and "anti-pinch" will be resumed.
Sunroof Initialization
Sunroof operation will be influenced by power failure when
sunroof glass or sunshade is in motion, and it is necessary to
initialize after power on.
Window Initialization:
Close the window, pull down the sunroof window switch

and hold it for approximate 10 seconds, and the window
will automatically open by sliding for a distance during which
the switch shall keep being pulled down and then close
automatically.
Sunshade Initialization:
Close the sunshade, press the close button of sunshade and

hold for 10 seconds, and the sunshade will automatically open
by sliding for a distance during which the switch shall keep being
pulled down and then close automatically.
1.0 1207
Power Liftgate Control Module (PLCM)

Power Liftgate Self-learning
If any of the followings occur, perform the power liftgate
self-learning:
• Replace power liftgate control module

• Replace relevant components of power liftgate: liftgate
lock, liftgate interior trim panel, liftgate sheet metal,
liftgate glass, liftgate weatherstrip, liftgate lock catch, rear
wiper, rear wiper motor, liftgate brace rod and hinge.
When performing the diagnostic procedure, the following

conditions must be met:
1. Place the ignition switch in "ON" position

2. Place the shift lever in "P" position
3. The engine does not start and the vehicle stops on the
flat ground (the ground inclination does not exceed 11°)
4. The liftgate is fully closed
5. PLCM module and relevant actuator operate normally
Perform the diagnostic procedure with the scan tool:
1. Connect the scan tool to the vehicle and accessVDS

2. Select "Fast Channel - Learn Value/Adjust - Power Liftgate
Self-learning", and follow the instructions on the screen.
PLCM Module Replacement
After replacing the power liftgate control module, the
following operation must be performed:

2. Place the shift lever in "P" position
3. The engine does not start and the vehicle stops on the
flat ground (the ground inclination does not exceed 11°)
4. The liftgate is fully closed
5. Connect the scan tool to the vehicle and accessSIPS
6. Select "Programme and Encode - PLCM - Replace" and
follow the instructions on the screen
Replacement operation includes the refresh, configuration, and

setting (diagnostic procedure for power liftgate self-learning)
options.
1.0 1208
Operations after Battery Power Resume
After battery power resume, the following operations shall be
performed to resume some functions of the vehicle back to
normal.
Electronic Parking System Resume
When the battery power is resumed after battery run down or
battery supply disconnected, the EPB malfunction indicator in
the instrument pack will illuminate, and the electronic parking
system shall not be normally started or stopped.
At this time, you need to depress the brake pedal, press EPB
switch and then pull EPB switch up, repeat such operations
till EPB malfunction indicator is extinguished, then electronic
parking system is back to normal.
Electric Power Steering Module Angle Initialization
After battery power resume, the electric power steering
(EPS) warning lamp will illuminate yellow. After completing
the initialization operations, the warning lamp goes out.

Encoding - Electric Power Steering Module Angle
Initialization
Start-Stop Function Resume
For a vehicle with intelligent Start-Stop energy-saving system,
after the battery negative terminal is reconnected, the battery
needs to be left for at least 4 hours, and the engine will lose
the automatic start-stop function before that.
Dynamic Stability Control/Traction Control
System Recovery
When the battery is resumed after it runs out or is
disconnected, the IPK will display the Dynamic Stability
Control/Traction Control Warning lamp, and the Dynamic
Stability Control/Traction Control System cannot work.
In this case, please initialize EPS. Move the steering wheel to the
leftmost position and then move it to the rightmost position.
And Flameout the vehicle. Then restart. Run the vehicle to
above 20 km/h. And move the steering wheel to left 45°, then
to right 45°. The lamp would go off and the Dynamic Stability
Control/Traction Control System resumes.
1.0 1209
Engine Control Module (ECM)

Mixed Gas Self-learning
For models with intelligent Start/Stop function, when
the following conditions occur, the intelligent Start/Stop
energy-saving system function will lose, and the adaptive
function of mixed gas shall be performed to restore the
Start/Stop function.
1. ECMResume the power after a power-off, including
disconnection of the battery, ECM connector, etc.
2. ECMAfter using SIPS to update the software or
calibration.
3. After using VDS to clear ECM DTCs.
The following steps are recommended to complete the engine
mixed gas self-learning in a quick manner: After warming
the engine, keep it at idle speed for about 3-5 minutes, then
depress and hold the acceleration pedal to enable the vehicle
to drive at an even speed of 30-70km/h for about 20 minutes,
then the self-learning of the intelligent Start/Stop energy-saving
system is completed.
Caution: Never use the cruise function to stabilize

vehicle speed to perform the self-learning of the
intelligent Start/Stop energy-saving system.
With VDS, read "Start/Stop - Mixed Gas Self-Learning
Uncompleted" parameter on the real-time display, when this
flag bit shifts from "ON" to "OFF", the adaptive process of
the mixed gas is completed. Upon completion, drive for 3
automatic engine stop cycles to reconfirm the effect of the
self-learning.
ECM Replacement
The following steps must be performed after replacing ECM:

2. Select "Programme and Encode - ECM - Replace", and
follow the instructions on the screen.
Replacement operation includes the refresh, configuration

and anti-theft match options. If the interface gives failure
prompt during replacement, please follow the interface
prompt.
3. Perform self-learning for the electronic throttle.

Electronic Throttle Self-learning
4. Perform mixed gas self-learning for vehicles equipped

with intelligent Start/Stop function.
"Engine Control Module Reset Self-learning Value" with
VDS.
1.0 1210
TCM
Diagnostic Routine Implementation Condition
Clutch Clutch
Reset Shift Fork
Pressure/Current Engagement Transmission
EEPROMData Read SubROM Position
Curve Point Sensor Test
to Default Value Self-learning
Self-learning Self-learning
Refresh software × × × × × ×
Replacement
TCM √ √ × √ √ ×
Replacement
new √ √ × × × ×
transmission
Replacement old
transmission √ √ × √ √ ×
Replacement
pressure sensor × × √ × × √
Replacement
TCM and new √ √ × × × ×
transmission
Replacement
TCM and old √ √ × √ √ ×
transmission
Severe impact
occurs during
vehicle start、
severe impact
occurs during × × × × √ ×
vehicle shifting
or the respond
is too long
Note: 3. Can’t reset the EEPROM to default value after clutch

engagement point self-learning.
• The new transmission refers to the new manufacture
transmission which we get from the supplier. After operation successful, must let the vehicle power down
• Execute the order of the above routine: sequentially from normally(must not disconnect battery).
left to right. Perform this diagnostic procedure, the operation shall be held
Reset EEPROM Data to Default Value for about 3s.
The EEPROM is part of the TCM memory, the data stored 1. Connect the scan tool to the vehicle and access the VDS.
in the EEPROM will not change when the software and 2. Select "Fast Track - Learn Value/Adjustment - Reset
calibration is updated. After the diagnostic procedure is EEPROM Data to Default Value", and operate as per
completed, restore the EEPROM data to a reasonable range the instructions on the screen.
so as to avoid wrong data is used by the TCM software.
Caution: The operation shall be done before the
After replacement of the following parts, perform the "SubROM data" is read.
diagnostic procedures for resetting the EEPROM data to
Read SubROM
default value:
The SubROM is an external memory of the transmission
• Transmission
valve, the diagnostic procedure sends the SubROM data to the
• TCM EEPROM of the TCM.These data are related to shift fork
When performing the diagnostic procedure, the following position, clutch engagement point and solenoid characteristic
conditions must be met: curve, etc.
1. The ignition switch is in "ON" position. After replacement of the following parts, perform the
diagnostic procedures for read SubRom:
2. Turn off the engine.
• Transmission
1.0 1211
• TCM Caution: During clutch pressure/current curve

self-learning, to ensure a stable engine torque
output, do not shift the A/C between ON/OFF state.
After self-learning, drive for a while to check the effect of the
1. The ignition switch is in "ON" position.
self-learning. If the vehicle performance is lowered, repeat the
self-learning.
After operation successful, must let the vehicle power down Shift Fork Position Self-learning
normally(must not disconnect battery).
Shift fork position self-learning will store the correct position
Caution: After replacement of the dual clutch information of the shift fork to the TCM.
automatic transmission or TCM, apply the scan tool
After replacement of the following parts, perform the
to read the shift data and valve characteristic
diagnostic procedures for shift fork position self-learning
data stored in the SubROM of the transmission
valve. The original data stored in the TCM only • Transmission (The operation is not needed when replace
apply to the original TCM, not apply to the new a totally new transmission)
transmission. • TCM
The diagnostic procedure shall last for about 5s. When performing the self-learning, the following conditions
1. Connect the scan tool to the vehicle and access the VDS. must be met:
2. Select "Fast Track - Learn Value/Adjustment - AT Control 1. The engine is working for more than 5min.
Module SubROM Data Reading - Reading SubROM Data 2. The vehicle is in P gear and the vehicle speed is 0.
(All)", and operate as per the instructions on the screen.
3. TCM has no identified DTC
Clutch Pressure/Current Curve Self-learning
After operation successful, must let the vehicle power down
Correct pressure/current curve value of the odd/even clutch normally(must not disconnect battery).
can be stored to the TCM by self-learning of the clutch
pressure/current curve. The self-learning shall last for about 1min. During the
operation, forced actions of the shift fork will cause vehicle
After replacement of the following parts, perform the vibration. This is a normal situation.
diagnostic procedures for clutch pressure/current curve
self-learning: 1. Connect the scan tool to the vehicle and access the VDS.
2. Select "Fast Track - Learn Value/Adjustment - AT
• Pressure sensor
Self-learning - Shift Fork Position Self-learning", and
When performing the self-learning, following conditions must operate as per the instructions on the screen.
be met:
After self-learning, drive for a while to check the effect of the
1. The engine is working for more than 5min. self-learning. If the vehicle performance is lowered, repeat the
2. The vehicle is in P gear and the vehicle speed is 0. self-learning.
3. TCM has no identified DTC. Clutch Engagement Point Self-learning
4. Valvebody temperature: 35–70℃. Clutch engagement point self-learning will store the correct
engagement point information of the odd/even clutch to the
After operation successful, must let the vehicle power down
TCM.
Perform the diagnostic procedures for clutch engagement
The self-learning shall last for about 1min, during the operation,
point self-learning under the following conditions:
the forced actions of the clutch will cause vehicle vibration, this
is a normal situation. When a part is replaced:
1. Connect the scan tool to the vehicle and access the VDS. • Transmission (The operation is not needed when replace
2. Select "Fast Track - Learn Value/Adjustment - AT a totally new transmission)
Self-learning - Clutch Pressure/Current Curve • TCM
Self-learning", and operate as per the instructions on the
Poor Vehicle Performance:
screen.
• Severe impact occurs during vehicle start.
• Severe impact occurs during vehicle shifting.
1.0 1212
• The respond is too long. 1. The ignition switch is in "ON" position.
When performing the diagnostic procedure, the following 2. Engine running
conditions must be met: 3. The vehicle speed is 0.
1. The engine is working for more than 5min. 4. The vehicle is in P gear.
2. The vehicle is in P gear and the vehicle speed is 0. 5. TCM has no identified DTC
3. TCM has no identified DTC The diagnostic procedure shall last for about 20s.
4. The A/C is always ON/OFF (do not shift between 1. Connect the scan tool to the vehicle and access the VDS.
ON/OFF).
2. Select "Fast Track - Other - AT Sensor Test", and operate
5. Clutch Temperature: 45–70℃. as per the instructions on the screen.
6. Engine coolant temperature: 90–140℃.
When the operation is completed successfully, the scan tool
7. Outside Temperature: 5–35℃ will prompt its completion.
8. Do not depress the accelerator pedal. TCM Replacement
9. Engine speed (when engine idles) is less than 1200rpm.
After replacement of the TCM, perform the following
10. Is engine torque stable:Yes. operations:
After operation successful, must let the vehicle power down 1. Connect the scan tool to the vehicle and access the SIPS.
2. Select "Programming and Coding — TCM
The self-learning shall last for about 1min, during the operation, —Replacement", and operate as per the instructions on
the forced actions of the clutch will cause vehicle vibration, this the screen.
is a normal situation.
The procedures for replacement already include procedures
1. Connect the scan tool to the vehicle and access the VDS. for update, configuration and setting (diagnostic procedures
2. Select "Fast Track - Learn Value/Adjustment - AT for resetting EEPROM to default value and reading SubROM
Self-learning - Clutch Meshing Point Self-learning", and data (all)).
operate as per the instructions on the screen. If the operation fails during replacement, please operate as
Caution: During clutch meshing point self-learning, per the instructions on the screen. If resetting EEPROM to
to ensure a stable engine torque output, do not default value or reading SubROM data (all) fails only, apply the
shift the A/C between ON/OFF state. VDS to reset the EEPROM to default value; if the operation
is successful, perform the diagnostic procedures for reading
After self-learning, check the self-learning effect: SubROM data (all).
1. Place the gear lever to D position on flat road, release
Self-adaption Procedures
electronic parking brake and service brake, with the
accelerator pedal undepressed, the vehicle should start Caution: With the use of the transmission, the dual
off within 1 second while engine speed has no obviously clutch is constantly worn, this will resulting in
decline. the decline of the shifting performance. In order
to improve the performance of the vehicle, we need
2. Step on brake pedal, it should not shock obviously when
do the self-adaption procedures.
switch the shift lever from N gear to D gear and N gear
to R gear . Warm-up
If the vehicle performance is lowered, repeat the self-learning. Start the engine, make sure the clutch valve body temperature
Transmission Sensor Test within the range of 40-100 degrees.
The diagnostic procedure can be used to determine if the signal Vehicle torque Map self-adaption operation
of the transmission sensor is normal by comparing the signal
• Odd clutch
from the TCM and the actual feedback from the sensor.
1. Shift to 3/5 gear in M mode (suggest use M5), then
After replacement of the following parts, perform the adjustment the throttle opening slowly until the
diagnostic procedures for transmission sensor test. rotational speed of the engine above to 1500rpm,
• Pressure sensor and then stable running at 10% - 15% of the throttle
opening. If the speed is too high you can slow down
When performing the diagnostic procedure, the following to guarantee the safety, if the speed is too low, you
1.0 1213
can operation in accordance with the above method,

but you should to ensure the throttle is about 10%
- 15%, driving stability for more than 150 seconds in
3/5 gear.
2. Operation like step 1, ensure the throttle is about
20%-25%, driving stability for more than 150 seconds
in 3/5 gear.
in 3/5 gear.
4. Operation like step 1, ensure the throttle is over
50%, driving stability for more than 150 seconds in
3/5 gear.
After the above 4 steps, the odd clutch torque Map

adaptive to complete.
• Even clutch
1. Shift to 4/6 gear in M mode (suggest use M6), then
adjustment the throttle opening slowly until the
rotational speed of the engine above to 1500rpm,
and then stable running at 10% - 15% of the throttle
opening. If the speed is too high you can slow down
to guarantee the safety, if the speed is too low, you
can operation in accordance with the above method,
but you should to ensure the throttle is about 10%
- 15%, driving stability for more than 150 seconds in
4/6 gear.
in 4/6 gear.
in 4/6 gear.
4. Operation like step 1, ensure the throttle is over
50%, driving stability for more than 150 seconds in
4/6 gear.
After the above 4 steps, the even clutch torque Map

adaptive to complete.
Caution: To ensure safety driving and self-learning

effect, suggest to operate on a straight
expressway.
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Transmission Control Module (TCM) - 7-speed
Scenario and Function Matrix
Scenario Function A Function B Function C Function D Function E/F
ECU Software
- ① - - ②
Update
ECU Replacement - - ① - ②
ECU & PowerPack
① - ② - ③
Replacement
PowerPack
① - ② - ③
Replacement
Transmission
Assembly - - ① - -
Replcement
Transmission
Mechanical Box
- - - ① ②
Repair or
Replcement
Driveability
- - - ① ②
Improvement
A.Transmission Accumulator Pressure Relief B.ECU Software Refresh

Function Description Function Description
• This function will relieve the hydraulic fluid pressure of • This function is used for updating the internal application
transmission accumulator, to facilitate the safe removal or calibration softwares of ECU, and modifying the
of PowerPack. corresponding control features.It also includes the
"Transmission Fast Learn” function.
Scenario
Scenario
• Before PowerPack Replacement
• Before ECU & PowerPack Replacement • ECU Software Update
Conditions Conditions
• Confirm that there is no transmission hydraulic fluid • Switch shift lever to P.

related failure and the internal mode switch is correctly • ON Ignition ON.
fitted. • Engine Off.
• Switch shift lever to P. • Vehicle Speed is 0.
• ON Ignition ON.
Software Path
• Engine Off.
• SIPS > Programme and Encode > TCM > Refresh
• Vehicle Speed is 0.
Result verification
Software Path
• Confirm that the application and calibration software
• VDS > TCM > Diagnosis > Forced Output>Transmission
versions of ECU are correct.
Accumulator Pressure Relief
C.Transmission Component Replacement
Result verification
Function Description
• Check if the diagnostic software parameter
This is a function combination, which contains the following
"Transmission Fluid Accumulator Pressure" is below
sub-functions.Please select the operation according to the
500kPa.
scenario prompted by the software.
• ECU Software Refresh
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• Write SoloData into ECU • The engine is in idle state, and the devices which may
• Write VIN into ECU increase the engine load are turned off.
• Update Sever Relation Infomation • Confirm that the engine speed is 600 - 800 rpm, and the
coolant temperature is less than 130℃.
• Transmission Fast Learn
• Confirm that the transmission fluid temperature is -10
Scenario
to 100℃, and the transmission accumulator pressure is
• After PowerPack Replacement greater than 3000kPa.
• After ECU Replacement • Shift the gear in the order: P→R→D→P, repeat three
• After Transmission Assembly Replacemen times, and finally shift it to P gear to exhaust the air in
the clutch.
• After ECU & PowerPack Replacement
Software Path
Conditions
• Vehicle Diagnostic System (VDS)>Fast Channel>Learning
• Switch shift lever to P.
Value Adjustment>TCM Fast Learning
• ON Ignition ON
Result verification
• Engine Off
• Vehicle Speed is 0. • The transmission warning icon and message on the
instrument disappear.
Software Path
• The vehicle can conduct gear shift and drive normally.
• SIPS > Programme and Encode > TCM > Replace
Exception Handling
Result verification
• After the software prompts successful execution, if the
• Confirm that the server binding relationship is consistent transmission still can not engage in R/D gear, please
with the actual vehicle. disconnect the negative battery cable for 10 minutes,
• Confirm that the application and calibration software and then re-connect it and try again.
versions of ECU are correct. • If the software prompts that the execution fails, please
• The transmission warning icon and message on the check if the execution conditions are met, and if there is
instrument disappear. any assembly fault in the transmission housing mechanical
• The vehicle can conduct gear shift and drive normally. parts or electro-hydraulic control assembly.
D.Transmission Fast Learn E.Transmission Adaptive Value Learn
Function Description Function Description
• This function is used to complete the learning of • This function is used to automatically trigger the learning
transmission housing internal clutch and fork control procedure of transmission internal adaptive value in
solenoid initial positions,so that the transmission can different working conditions,to improve the vehicle
work normally. driveability.
Scenario Scenario
• After Transmission Mechanical Box Repair or The function will be triggered automatically in the following
Replcement scenarios:
• Driveability Improvement • Dramatic changes in ambient temperature results in

performance reduction.
Conditions
• Long term mechanical wear of transmission results in
• Confirm that there is no failure on the following systems performance reduction.
of the vehicle: power supply, braking, engine speed or
throttle, transmission sensor actuator. The following scenario needs to be simulated to trigger this
function:
• The vehicle is in stationary state, release the accelerator
pedal and keep the brake pedal depressed. • Transmission Mechanical Box Repair or Replacement.
• Place the shift Lever in P position, and apply the parking • ECU Replacement or Reprogramming.
brake. • Driveability Improvement.
Conditions
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• Confirm that the vehicle can conduct the gear shift during Result verification
driving and no DTC is set.
• Check if various parameters shown by the software are
• The initial temperature of odd and even gear clutch is less displayed as "Stable".
than 60℃.
• Clutch Temperature Region Comparison Table:
• Execute 10 driving cycles (each cycle contains one static
and one dynamic process as shown below), refer to the Clutch Temperature Temperature Range (℃)
zone bit in Function F for specific execution times. Region
• f conditions permit, repeat the cycle at small(<20%), Region2 60-75
medium (20-50%), large (50%)throttle in the dynamic
Region3 75-95
process.
Region4 95-115
Static Triggering
• Place the shift lever in P position, and keep Exception Handling

• The brake pedal depressed. • If various parameters shown by the software are not
• The engine is in idle state. displayed as "Stable", execute "E.Transmission Adaptive
Value Learning" again.
• Shift the gear in the order: P→D→P, and stop in P gear
for 10 seconds.
Dynamic Triggering
• Place the shift lever in D position, and the vehicles starts

off.
• Depress the accelerator pedal until the vehicle is driving
at 7th gear (vehicle speed is about 70 km/h), release the
accelerator pedal, slightly depress the brake pedal until
the vehicle comes to a standstill.
• The vehicle is stationary, shift to P gear and wait for 10
seconds.
Result verification
• Execute the function "F. Transmission Adaptive Value

Learning State"
F.Check Transmission Adaptive Value Learn State
Function Description
• This function is used to check the learning state of

transmission adaptive value, so as to judge if the vehicle
has driveability issues.
Scenario
• Completion of transmission adaptive value learn

• Troubleshooting of vehicle driveability issues
Software Path
• SIPS > Programme and Encode > TCM >State
Conditions
• Switch shift lever to P.

• ON Ignition ON
• Engine Off
• Vehicle Speed is 0.
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SCU
SCU Replacement
After replacement of the SCU, perform the following
operations:
1. Connect the scan tool to the vehicle and access the SIPS.
2. Select "Programming and Coding — SCU
—Replacement", and operate as per the instructions on
the screen.

for update and configuration.
If the operation fails during replacement, please operate as per

the instructions on the screen.
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TCCM
TCCM Self-test
This function is used to check the TCCM and solenoid valve
of the torque control. When self-test is enabled, the clutch is
activated and the torque can be transferred. The duration of
the self-test shall be less than 3s.


2. Engine is stopped.
3. Clutch slip speed <5 r/min, vehicle speed <5 km/h.
Perform this diagnostic procedure with the scan tool, the

operation shall be held for about 3s.
1. Connect the scan tool to the vehicle and access the VDS.
2. Select "Routines - other - TCCM On-Demand self Test",
and operate as per the instructions on the screen.
TCCM Replacement
After replacement of the TCCM, perform the following
operations:
2. Select "Programming and Coding — TCCM —Replace",


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Air Conditioning System (HVAC)

A/C Servo Motor Self-learning
Perform self-learning for the A/C servo motor under the
following situations:
1. Replace the A/C controller.
2. Replace the A/C box assembly.
3. Replace the servo motor of the blend damper/mode
damper.
1. Place the ignition switch in "ON" position.
Use the scan tool to perform the diagnostic procedure:
2. Select "Fast Track - Learn Value/Adjustment - A/C Servo
Motor Self-learning", and operate as per the instructions
on the screen.
A/C Controller Replacement
After replacement of the A/C controller, perform the following
operations:
2. Select "Programming and Coding — HVAC
the screen.
The procedures for replacement already include update,

configuration and setting (diagnostic procedures for A/C
servo motor self-learning).

the instructions on the screen. If A/C servo motor self-learning
fails only, use the VDS to repeat the diagnostic procedures.
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EPS Module The procedures for replacement already include update,
EPS Module Angle Initialization configuration and setting (diagnostic procedures for EPS
module self-learning).
When the vehicle power is connected after disconnection,
initialize the angle of the EPS module. If the operation fails during replacement, please operate as the
instructions on the screen. If EPS module self-learning fails
1. Return the steering wheel.
only, use the VDS to repeat the diagnostic procedures.
2. Fully turn the steering wheel to the left.
4. Fully turn the steering wheel to the right.
EPS Module Self-learning
This diagnostic procedure is used for EPS self-learning, this
provides active return and end stop functions for the steering
system.
Perform steering wheel angle self-learning for the EPS module

under the following situations:
• Replace the steering column assembly.

• Replace the upper steering column.
• Replace the steering column intermediate shaft.
• Replace the steering gear boot.
• Replace the inner tie rod of the steering gear.
• Replace the outer tie rod of the steering gear.
• Replace the steering gear assembly.

1. Start the engine and wait for 5s.

2. Engine speed is above 500r/min.
3. Battery voltage is within 9-16V.
4. EPS is in normal state.
5. Vehicle is stationary.
6. The steering wheel is in the center.
Perform the diagnostic procedure:
1. Connect the diagnostic tool to the vehicle and access

the VDS.
2. Select "Routines - Reset Adaptions- EPS Calibration",
and operate as the instructions on the screen.
EPS Replacement
After replacement of the EPS, perform the following
operations:

the SIPS.
2. Select "Programming and Coding — EPS
—Replacement", and operate as the instructions on the
screen.
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EPB Module
Before removing any part, fully release the parking brake cable
under any of the following situations:
• Replace the EPB module.

• Replace the parking brake cable.
• Replace the rear brake caliper.
• Replace the rear brake pad.
• Replace the rear brake disc.
Parking Brake Cable Full Release - Recommended
Method
VDS of the scan tool is recommended for full release of 3. Insert the Allen hexagon wrench into the hole (appr.
the parking brake cable. Before use of the VDS, ensure the 40mm) under the cover, and turn clockwise until the
following conditions are met: parking brake cable is fully released.
2. EPB switch is pressed for 5s. Under any of the following situations, make adjustments and
record the original position of the parking brake cable after
3. Make sure the engine is stationary and the vehicle speed
any part is fitted, otherwise, the EPB module cannot work:
is 0.
4. EPB module and relevant actuator are in normal state. • Replace the EPBModule
• Replace the parking brake cable.
• Replace the brake caliper housing assembly.
• Replace the brake pad.
2. Select "Fast Track - Learn Value/Adjustment - Parking
• Replace the brake disc.
Brake Cable Full Release", and operate as per the
instructions on the screen. Perform the diagnostic procedure:
3. Fully release the parking brake cable as per the 1. Connect the scan tool to the vehicle and access the VDS.
instructions on the screen. 2. Select "Fast Track - Learn Value/Adjustment - Parking
Parking Brake Cable Full Release - Mechanical Method Brake Cable Adjustment", and operate as per the
Generally, this method is not recommended for release of the instructions on the screen.
parking brake cable, it is only used in unexpected situations, 3. Normal operation of the EPB is achieved by adjusting the
for example, low battery and EPB failure, when the EPB fails, parking brake cable as per the instructions on the screen.
fully release the parking brake cable manually. EPB Module Replacement
1. Remove the rear wheel house liner. After replacement of the EPB, perform the following
Rear Wheel House Liner Remove operations:
2. Turn the white emergency release cover counterclockwise 1. Connect the scan tool to the vehicle and access the SIPS.
with the socket.
2. Select "Programming and Coding — EPB
the screen.

for update, configuration and setting (diagnostic procedures
for adjusting parking brake cable).
If the operation fails during replacement, please operate as

per the instructions on the screen. If parking brake cable
adjustment fails only, use the VDS to repeat the diagnostic
procedures.
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Stability Control System (SCS) SCS Replacement
SCS Pressure Sensor Self-learning After replacement of the SCS, perform the following
This function is used to perform self-learning for the SCS operations:
module after replace the SCS.
When performing the diagnostic procedure, the following the SIPS.
conditions must be met: 2. Select "Programming and Coding — SCS —
1. Place the ignition switch in "ON" position, but do not Replacement", and operate as per the instructions on
start the engine. the screen.
2. The vehicle speed is 0. The procedures for replacement already include procedures
for update, configuration and setting (diagnostic procedures
for SCS pressure sensor/yaw sensor self-learning).
the VDS.
the instructions on the screen. If SCS pressure sensor/yaw
2. Select "Routines - Reset Adaptions - SCS Pressure sensor self-learning fails only, use the VDS to repeat the above
Sensor Calibration", and operate as per the instructions procedures.
on the screen.
Yaw Sensor Self-learning
This function is used to perform self-learning for the yaw
sensor after replace the SCS module.

1. Place the ignition switch in "ON" position, but do not

start the engine.
2. The vehicle speed is 0.
3. SCS modulator and relevant actuator are in normal state.

the VDS.
2. Select "Routines - Reset Adaptions - Yaw Sensor
Self-learning", and operate as per the instructions on the
screen.
ABS/SCS Bleeding
This option can be used to bleed the module and pipe.

1. Place the ignition switch in "ON" position.
2. Connect the brake fluid filling/drain machine to the brake
fluid reservoir and adjust the refill pressure to 2Bar.
Bleed the ABS/SCS according to the following instructions:

1. Connect the diagnostic tool to the vehicle and access the
VDS.
2. Select "Routines - Other - ABS/SCS Brake Bleeding", and
operate as per the instructions on the screen.
If the operation fails, please operate as per the instructions on

the screen.
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Steering Angle Sensor (SAS)

SAS Reset Self-learning/Zero Position Self-learning
If any of the followings occur, perform the SAS reset

self-learning/zero position self-learning:
• After the clock spring or combination switch is touched,

removed or replaced


2. Maintain the vehicle speed at 0, return the steering wheel
and keep it still, then check if the front wheels face right
ahead
3. SASModule and relevant actuator operate normally
1. Connect the scan tool to the vehicle and access to the
VDS.
2. Select "Fast Channel - Learn Value/Adjust - SAS Reset
Self-learning", and follow the instructions on the screen.
3. Select "Fast Channel - Learn Value/Adjust - SAS Zero
Position Self-learning", and follow the instructions on the
screen.
SASReplacement
The following operations shall be done after the clock spring
or combination switch is replaced:

SIPS.
2. Select "Programme and Encode - SAS - Replace", and
3. After the operation, the system will automatically
complete the corresponding self-learning operations of
the SAS.
Replacement operation includes the refresh, configuration,

setting (diagnostic procedures for the SAS reset self-learning
and zero position self-learning) options.
If the interface gives failure prompt during replacement,

please follow the interface prompt. If the interface only
gives failure prompt of the SAS reset self-learning and zero
position self-learning, then use the VDS to perform the SAS
reset self-learning, after the operation is successfully done,
perform the diagnostic procedures for the SAS zero position
self-learning.
1.0 1224
Body Control Module (BCM)
BCMPower Mode Adjustment
After renew the BCM, in order to prevent failure of some
functions controlled by the BCM, please check the power
mode of the BCM and ensure it is in the normal mode.

VDS.
2. Select "Fast Channel - PDI - Adjust BCM Power Mode"
and follow the instructions on the screen to shift the
power mode of the BCM.
BCM Replacement
After replacing the BCM, please perform the following
operations:

SIPS.
2. Select "Programme and Encode - BCM - Replace" and
Replacement operation includes the refresh, configuration,

setting (immobiliser match, keys addition and the power mode
of the BCM to normal mode) options.
If the interface gives failure prompt during replacement, please

follow the interface prompt. If it only prompts the failure of
the BCM power mode, repeat this diagnostic routine with the
VDS.
Keys Addition
SIPS.
2. Select "Programme and Encode - BCM - Add Keys" and
3. Use the new key to start the vehicle and ensue it can
start, lock or unlock the vehicle successfully.
Keys Deletion
SIPS.
2. Select "Programme and Encode - BCM - Delete Keys"
and follow the instructions on the screen.
3. After the key is successfully deleted, please read the key
information again and ensure the key is deleted.
1.0 1225
Communication Module (TBOX)

TBOX Replacement
After replacing the TBOX, the following operations must be
performed:

2. Select "Programme and Encode - TBOX - Replace", and
Replacement operation includes the module refresh,

configuration, anti-theft and activation.

follow the interface prompt.
TBOX Restart
When you need to restart the TBOX, follow the operations
below:
1. Connect the scan tool to the vehicle and access to VDS.

2. Select "Fast Channel - Learn Value/Adjust - TBOX
Restart", and follow the instructions on the screen.
1.0 1226
Gateway (GW) sensor or gateway power mode adjustment, perform above
Zero Position Self-learning of Brake Pedal Position diagnostic procedure again with VDS.
Sensor
If any of the followings occur, perform the zero position
self-learning of brake pedal position sensor:
• Replace the gateway

• Replace the brake pedal position sensor
• Replace the brake pedal assembly
• Update the gateway application
When performing the self-learning, the following conditions

must be met:
1. The ignition is placed in "ON" position, and ensure the

engine is shut off.
2. Do not depress the brake pedal.
Perform the diagnostic procedure with the scan tool

VDS.
2. Select "Fast Channel - Learn Value/Adjust - Brake Pedal
Sensor Zero Position Self-learning", and follow the
instructions on the screen. Do not touch brake pedal
during self-learning while it can be gently stepped several
times during the vehicle starting, then go on self-learning
after complete release.
Adjustment of Gateway Power Mode
The gateway power mode must be checked after replacing with
new gateway to ensure it is in normal mode.
VDS.
2. Select "Fast Channel - PDI - Gateway Power Mode
Adjustment", and operate according to the description
on the screen, which can fulfill the switching of gateway
power modes.
GW Replacement
After replacing the gateway, the following operation must be
performed:

SIPS.
2. Select "Programme and Encode - GW - Replace" and
The replacement operation includes the refresh, configuration

and setting (diagnostic procedures for zero position
self-learning of brake pedal position sensor and the adjustment
of gateway power mode to normal mode) options.

follow the interface prompt. If the interface only gives failure
prompt of zero position self-learning of brake pedal position
1.0 1227
DHL
DHL Axle Sensor Zero Position Learning
DHL axle sensor zero position learning shall be performed
under the following situations:
• DHL module is replaced.

• Axle Sensor is replaced.
• Suspension components (front/rear shock absorber,
front lower swing, front subframe, rear suspension
spring and rear trailing arm) are replaced.
• DHL function fails or performance deteriorates.


2. The engine is stationary and the vehicle is on a level
ground.
3. DHL module and relevant actuator are in normal state.
Use the diagnostic tool to perform the procedure.

the VDS.
2. Select "Routines - Reset Adaptions - DHL Axle Sensor
Zero Position Learning", and operate as per the
instructions on the screen.
DHL Module Replacement
After replacement of DHL module, perform the following
operations:
1. Park the vehicle on a level ground.

the SIPS.
3. Select "Programming and Coding — DHL — Replace",
The procedures for replacement already include reprogram,

configuration and setting (diagnostic procedures for height
sensor null voltage self-learning).
If the operation fails during replacement, please operate

as per the instructions on the screen. If DHL axle sensor
zero position learning fails only, use the VDS to repeat the
diagnostic procedures for DHL axle sensor zero position
learning.
1.0 1228
PEPS
PEPS Set Power Mode
After replacement of the PEPS, check the power mode of the
PEPS and ensure it is in normal condition.
1. Connect the diagnostic tool to the vehicle and access the
VDS.
2. Select "Routines - PDI - PEPS Set Power Mode", and shift
the power mode of the PEPS by the instructions on the
screen.
Caution: Once the power mode of the PEPS is adjusted

to normal mode, it cannot be shifted to other modes.
If shift the power mode at this step, the VDS will
display "CAN NOT Change the PEPS to other mode".
PEPS Replacement
After replacement of the PEPS, perform the following
operations:

the SIPS.
2. Select "Programming and Coding — PEPS —Replace",
The procedures for replacement already include reprogram,

configuration and setting (diagnostic procedures for matching
anti-theft data and adjusting PEPS power mode).
If the operation fails during replacement, please operate as

per the instructions on the screen. If failure of PEPS power
mode adjustment occurs only, apply the VDS to repeat the
operation.
1.0 1229
Instrument Pack (IPK)

IPK Replacement
After replacing the new instrument pack, the following
operations must be conducted:

2. Select "Programme and Encode - IPK - Replace", and
Replacement operations include the refresh and configuration.

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SDM
SDM Replacement
After replacement of the SDM, perform the following
operations:

the SIPS.
2. Select "Programming and Coding — SDM — Replace",

for reprogram, configuration and setting (lock module).

1.0 1231
Entertainment Information Control Module

(FICM)
FICM Replacement
After replacing the new entertainment host, the following
operations must be conducted:
1. Connect the scan tool to the vehicle and access to SIPS;

2. Select "Programme and Encode - FICM - Configuration",
and follow the instructions on the screen.
If the interface gives failure prompt during configuration, please

1.0 1232
PMDC
PMDC Self-learning
Vehicles with intelligent stop/start energy saving system shall
be stationary for at least 4hr so that the PMDC can acquire
stable and accurate battery status information and meet the
operation requirement of the intelligent stop/start energy
saving system.
PMDC self-learning shall be carried out under the following

situations:
• The battery negative is reconnected after disconnection.

• The battery is replaced.
Caution: Failure to observe the above requirements

can lead to failure of the intelligent stop/start
energy saving system before the PMDC can acquire
any accurate battery voltage information.
PMDC Replacement
After replacement of the PMDC, perform the following
operations:
2. Select "Programming and Coding — PMDC
the screen.


1.0 1233
PDC Module
PDC Replacement
After replacement of the PDC, perform the following
operations:
1. Connect diagnostic tool to the vehicle and access the

SIPS.
2. Select "Programming and Coding — PDC — Replace",

for reprogram and configuration.

1.0 1234
Glossary List Name Description
Name Description ETC Electronic Temperature
A/C Air Conditioning Control
ABS Anti-lock braking system FDU Final Drive Unit
AC Alternating current GPS Global Positioning System
ACM Air conditioning Module HC Hydro Carbons
AGM Absorbed Glass Mat HFM Hot film air mass
ATC Automatic Temperature HHC Hill Hold Control
Control HO2S Heated Oxygen Sensor
AUTO Automatic HRW Heated Rear Window
AWD All Wheel Drive HS High Speed
BCM Body Controller Module HSLA High Strength Low Alloy
CAN Controller area network HVAC Heating, Ventilation and Air
CHMSL Centre High Mounted Stop Conditioning
Lamp HVACM Heating，Ventilation and Air
CKP Crankshaft Position Conditioning Module
CMP Camshaft Position Hz Hertz
CO Carbon Monoxide ICE In Car Entertainment
CO2 Carbon Dioxide ICS Inflatable Curtain Structure
DC-DC Direct Current to Direct IPK Instrument Cluster
Current Converter ISO International Organization
DDSP Driver’s Door Switch Pack for Standardization
DTC Diagnostic Trouble Code L litre
DTI Dial Test Indicator LED Light Emitting Diode
EBD Electronic Braking-force LIN Local Interconnect Network
Distribution MIG Metal Inert Gas
EBS Electrical Battery Sensor MIL Malfunction Indicator Lamp
ECM Engine Control Module MLS Master Light Switch
ECT Engine Coolant Temperature Min minute
ECU Electronic Control Unit NOx Oxides of Nitrogen
EEPROM Electronic Erasable NTC Negative Temperature
Programmable Read Only
Coefficient
Memory
OAT Organic Acid Technology
ELR Emergency Locking
PCV Positive Crankcase
Retractor
Ventilation
EMCD Electric Magnetic Control
PDC Parking Distance Control
Device
EMS PLCD Permanentmagnetic Linear
Engine Management System
Contactless Displacement
EPB Electronic Parking Brake
PTU Power Transfer Unit
EPS Electric Power Steering
PVC Polyvinyl Chloride
PWM Pulse Width Modulation
1.0 1235
Name Description
RON Research Octane Number
SAE Society of Automotive
Engineers
SAS Steering Angle Sensor
SCS Stability Control System
SCU Shifter Control Unit
SDM Sensing Diagnostic Module
SIPS SAIC Integrated Program
System
SRS Supplementary Restraint
System
TC Traction Control
TCCM Transfer Case Control
Module
TCM Transmission Control
Module
TDC Top Dead Centre
TMAP Temperature, Manifold
Absolute Pressure
TPMS Tyre Pressure Monitoring
System
TWC Three-way Catalyst
TXV Thermostatic Expansion
Valve
VDS Vehicle Diagnostic System
VIN Vehicle Identification
Number
kPa Kilo Pascal
km kilo metre
mL milliliter
1.0 1236

AS22 Service Manual en 20180112（归档版）

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AS22 Service Manual en 20180112（归档版）

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Service Manual

SAIC Motor Passenger Vehicle Co., Ltd.

Copy Right Reserved

All information received cutoff date is March 2017.

Attention is particularly drawn to the following points

• Safety features and corrosion prevention treatments

SMC Dealers are obliged to supply only SMC recommended

Some operations in the manual cannot be carried out properly

Special tools can be obtained from the following supplier.

Shanghai Runyue Industrial Development Co., Ltd

Address: Skirt Building, Lianhua Building, 159 Tianzhou Road,

Post Code: 200233

Should any material be in a burnt or overheated condition,

Decontaminate and dispose of gloves immediately after use.

Ensure the vehicle is standing on level ground prior to lifting

Apply the parking brake and chock the wheels.

Warning: Do not work on or under a vehicle supported

Do not leave tools, lifting equipment, spilt oil, etc. around or

• Ensure that hoses run in a natural curve and are not

They must also be segregated into different types of waste

• Blow out all tapped holes, crevices, oilways and fluid

• Carefully examine seal before fitting to ensure that it is

• Grease outside diameter of seal, place square to housing

• Always use the correct gaskets as specified. Tab Washers

Damaged nuts, bolts and screws must always be discarded.

Always ensure that replacement bolts are at least equal in

Castellated nuts must not be loosened to accept a split-pin,

Do not allow oil or grease to enter blind threaded holes. The

Encapsulated bolts and screws have a microencapsulated

Unless a specific repair procedure states otherwise,

• Remove loose adhesive from the bolt and housing

Where bearing preload is involved, nuts should be tightened in

Self-locking bolts and screws, i.e. nylon patched or trilobular

Nylon patched bolts and screws have a locking agent

DO NOT fit non self-locking fasteners in applications where a

A nut with an ISO metric thread is marked on one face or on

• Clean end fittings and the area surrounding them as

Clean hose externally and blow through with airline.

• Absolute cleanliness must be observed with hydraulic Hose Clip

After any work on hydraulic systems, carefully inspect

Markings (1) are usually provided on the hose to indicate the

The following information provides basic precautions which

Always have a fire extinguisher containing FOAM, CO2, GAS

Always disconnect the vehicle battery before carrying out

Whenever fuel is being handled, drained or stored, or when

Warning: Do not remove fuel system components while

Warning: Do not remove fuel system components while

The capacity of containers must be more than adequate for

• Always ensure electrically related items are dry and oil

Having confirmed a component to be faulty:

• Switch off the ignition and disconnect the battery.

Caution: Ensure SRS components are not contaminated

Caution: Torque wrenches should be regularly checked for

Warning: The integrity of the SRS system is critical for

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

Do not place any object on the steering wheel or instrument

A The need for caution when working in close proximity to