Byd F5 PDF

BYD AUTO BYD Suri Maintenance & Repair Manual
Engine & Transmission
Contents
Chapter 1 BYD473Q Engine ............................................................................................................ 3
Part 1 Engine............................................................................................................................. 4
Section 1 Introduction ........................................................................................................ 4
Section 2 Cylinder Head ...................................................................................................11
Section 3 Cylinder Block .................................................................................................. 38
Part 2 Lubricating System ....................................................................................................... 57
Part 3 Intake Manifold and Exhaust System ........................................................................... 63
Part 4 Engine Cooling System ................................................................................................ 64
Part 5 Fuel and Exhaust System ............................................................................................ 67
Chapter 2 476ZQA Engine ............................................................................................................. 70
Part 1 Engine........................................................................................................................... 71
Section 1 Overview .......................................................................................................... 71
Section 2 Belt Driving Device .......................................................................................... 76
Section 3 Crankshaft Rear Oil Seal Component ............................................................. 78
Section 4 Timing Chain .................................................................................................... 80
Section 5 Detection of the Sparkplug and Cylinder Compression Pressure ................... 82
Section 6 Engine .............................................................................................................. 84
Part 2 Lubrication System ......................................................................................................119
Section 1 Schematic Diagram of Engine Lubrication Circuit ..........................................119
Section 2 Inspection of Oil Pressure ............................................................................. 120
Section 3 Engine Oil ...................................................................................................... 121
Section 4 Oil Sump ........................................................................................................ 122
Section 5 Oil Pump ........................................................................................................ 123
Part 3 Cooling System .......................................................................................................... 124
Section 1 Schematic Diagram of Engine Cooling System ............................................ 124
Section 2 Thermolator.................................................................................................... 125
Section 3 Water Pump ................................................................................................... 126
Part 4 Clutch.......................................................................................................................... 128
Section 1 Clutch Device................................................................................................. 128
Section 2 Flywheel ......................................................................................................... 131
Chapter 3 Transmission ............................................................................................................... 132
Section 1 Structural parameters .................................................................................... 133
Section 2 Service Guidelines ......................................................................................... 134
Section 3 Service of transmission ................................................................................. 136
Section 4 Differential ...................................................................................................... 165
Chapter 4 6T25 Manual Transmission ......................................................................................... 170
Section 1 Introduction of Transmission ......................................................................... 171
Section 2 Transmission Operating Mechanism ............................................................. 175
Section 3 Transmission mechanism .............................................................................. 179
1
Section 4 Transmission Assembly ................................................................................. 193

Chapter 5 BYD6DT25 Dual Clutch Transmission ........................................................................ 204
Section 1 Introduction of Transmission ......................................................................... 205
Section 2 Dual Clutch .................................................................................................... 207
Section 3 Operating Mechanism and Housing .............................................................. 216
Section 4 Gear and Drive Shaft ..................................................................................... 229
2
Chapter 1 BYD473Q Engine
Contents
Part 1 Engine .................................................................................................................................... 4

Section 1 Introduction ............................................................................................................... 4
Section 2 Cylinder Head .......................................................................................................... 11
Section 3 Cylinder Block ......................................................................................................... 38
Part 2 Lubricating System .............................................................................................................. 57
Part 3 Intake Manifold and Exhaust System .................................................................................. 63
Part 4 Engine Cooling System ....................................................................................................... 64
Part 5 Fuel and Exhaust System .................................................................................................... 67
3
Part 1 Engine
Section 1 Introduction
1.1 Main Technical Parameters
BYD473QB/QE engine uses the electronic fuel injection (EFI) system developed by our company
and it has advanced self-diagnosis function. The injection system uses the multi-point sequential
injection which features high power per liter, low fuel consumption, low noise, less pollution and
compact structure. Under any working conditions, BYD473QB/QE engine can operate with the
best performance and the complete vehicle equipped with this kind of engine can ensure reliable
safety, driving comfort, fuel economy and perfect environmental performance.
Main technical parameters of BYD473QB/QE Engine are listed in the following table.
Model BYD473QB BYD473QE
Type 4-stroke, water-cooled, inline, SOHC and EFI
Number of Cylinders 4
Cylinder Bore (mm) 73
Piston Stroke (mm) 88.9 89.4
Compression Ratio 10.2 10.6
Firing Order 1-3-4-2
Nominal Power (kW) 79 (5800r/min) 79 (5800r/min)
Max. Torque (Nm) 144 (4800 r/min) 144 (4650r/min)
Nominal Speed (r/min) 5800
Min.Spec Fuel Consumption (g/kW h) 245 236
Oil Pressure (kPa) 340~490 (3000r/min±50r/min)
Min. Stable Speed (idle speed (r/min) 780±50
Total Displacement (L) 1.488 1.497
Oil and Fuel Consumption Ratio (%) 0.26
Dimension (mm) 587×543×700 587×543×700
(length×width×height)
Net Weight (kg) 92 97
CO≤0.15% HC≤40ppm (780±50r/min)
Emissions at Idle Speed CO≤0.15% HC≤40ppm (2500±50r/min)
GB18285-2005
The vehicle uses 93# unleaded gasoline
Fuel
(GB17930-1999)
SG 10W/30 (All seasons in southern China and
Lubricant Oil spring, summer and autumn in northern China) SG
5W/30 (Winter in northern China) (GB11121)
Coolant Glycol Cooling Fluid
dry-type, single disc, diaphragm spring, constant
Type
pressure
Clutch Clutch plate assembly φ200×8.9 mm (Free State)
Dimensions (mm)
Clutch cover assembly φ255×40.4 mm
Weight (kg) 4.314
with synchromesh unit, five forward gears and one
Transmission Type
reverse gear 3
1st gear 3.308
2nd gear 1.826
Transmission Gear Ratio
3rd gear 1.207
4th gear 0.939
4
5th gear 0.730

reverse gear 3.231
Final Drive Ratio 4.471
Dimensions (mm) (length×width×height) 504×382×363mm
Lubricant Oil medium duty gear oils for vehicles (GL-4 SAE
80W/90)
1.2 Technical Specifications for Maintenance
Engine Cylinder Head

Measuring
Name Measuring Item Standard Value Overhaul Limit
Condition
Cylinder Warpage 0.08 mm
Head Height 119.9~120.1 mm
Axial Clearance 0.07~0.25 mm 0.5 mm
Oil Film Clearance
between Camshaft 0.025~0.046 mm 0.1 mm
and Bracket
Camshaft
Total Runout Max. 0.03 mm 0.04 mm
Intake 35.37 mm
Cam Lobe Height Variable Intake 30.565 mm
Exhaust 35.39 mm
Intake 0.18~0.22 mm
Clearance (cold state)
Exhaust 0.23~0.27 mm
Intake 5.470~5.485 mm 5.45 mm
Valve Tappet O.D.
Valve Exhaust 5.455~5.470 mm 5.42 mm
Clearance between Intake 0.025~0.060 mm 0.08 mm
Valve Tappet and
Exhaust 0.04~0.075 mm 0.11 mm
Guide
Intake 0.85~1.15 mm 1.60 mm
Width
Exhaust 1.25~1.55 mm 2.00 mm
Valve Seat
Valve Tappet Intake 46.1~46.5 mm 46.8 mm
Mounting Height Exhaust 46.2~46.6 mm 46.9 mm
Intake 50.5 mm
Valve Spring Free Length
Exhaust 57.2 mm
Intake 5.51~5.53 mm 5.55 mm
I.D.
Exhaust 5.51~5.53 mm 5.55 mm
Valve Guide
Intake 15.85~16.35 mm
Mounting Height
Exhaust 15.85~16.35 mm
Clearance between Intake 0.02~0.054 mm 0.08 mm
Rocker Arm Rocker Arm and
Exhaust 0.02~0.054 mm 0.08 mm
Rocker Shaft
Engine Cylinder Block

Measuring
Condition
Warpage Max.0.07 mm 0.10 mm
Cylinder Bore 73~73.019 mm 73.07 mm
Cylinder
Cylinder Bore Taper ---- 0.05 mm
Block
Cylinder Reboring
---- 0.25 mm
Limit
Distance from Bottom 72.955~72.975
Piston 72.945 mm
of Piston Skirt to mm
5
Piston O.D. 13 mm
Clearance with
0.035~0.054 mm 0.06 mm
Cylinder
First Air Ring 1.02~1.04 mm 1.07 mm
Piston Ring Groove Second Air 1.21~1.23 mm 1.25 mm
Width Ring
Multi-piece Oil
2.01~2.03 mm 2.05 mm
Ring
Clearance between First Air Ring 0.03~0.07 mm 0.15 mm
Piston Ring and Second Air 0.02~0.06 mm 0.13 mm
Groove Ring
First Air Ring 0.20~0.35 mm 0.6 mm
Piston Ring
Second Air 0.35~0.5 mm 0.65 mm
Piston Ring End Gap Ring
Multi-piece Oil
0.2~0.7 mm 0.8 mm
Ring
O.D. 17.996~18 mm
Clearance between
Piston Pin
Piston Pin and Piston 0.005~0.015 mm
Pin Bore
Clearance between
Pin and small-end hole 0.015~0.037 mm
of Connecting Rod
Diameter of small-end
17.963~17.981
hole of Connecting
mm
Connecting Rod
Rod Diameter of big-end
hole of Connecting Normal 43~43.015 mm
Rod
Installed on End
Clearance of 0.15~0.3 mm 0.4 mm
Crankshaft
Diameter of Main
49.937~49.955mm
Journal
Diameter of
39.940~39.955
Connecting Rod
mm
Journal
Connecting Rod/Main
Crankshaft 0.005 mm 0.01 mm
Journal Taper
Connecting Rod/Out
of Roundness of Main 0.005 mm 0.01 mm
Journal
End Clearance 0.1~0.35 mm 0.45 mm
Runout Max. 0.03 mm 0.04 mm
Oil Film Clearance
between Main Shaft 0.028~0.049 mm 0.055 mm
Crankshaft Bearing and Journal
Bearing Clearance between
Connecting Rod 0.022~0.050 mm 0.055 mm
Bearings
Engine Lubrication
Name Measuring Item Measuring Standard Value Overhaul Limit
6
Condition
Engine
4.0 L
overhaul
Replace oil,
including oil 3.3 L
Engine Oil Capacity
filter
Replace oil,
excluding oil 2.9 L
filter
Clearance between
0.075 mm~0.15
Internal and External 0.18 mm
mm
Rotor
Clearance between
0.06 mm~0.136
Oil Pump Pump Housing and 0.18 mm
mm
External Rotor
Clearance between
0.028 mm~0.065
Pump Housing and 0.085 mm
mm
External Rotor Shaft
Relief Valve, Oil idle speed Min. 30 kPa
Relief Valve Pressure when oil
3000 rpm/min Min. 300 kPa
temperature is 80°C
Engine Cooling
Measuring
Condition
Coolant volume Engine
4.7 L
(including engine, Overhaul
Radiator
heater, hoses and Coolant
3.6 L
radiator) Replacement
Reservoir Coolant Volume 0.4 L
Radiator
Opening Pressure 93 kPa~123 kPa
Cap
Functioning Just open 76°C~80°C
Thermolator Temperature Full open 90°C
Valve Lift at full-open 8 mm
ON 91~95°C
Thermo Switching
Subtract 3~8°C of the temperature
Switch Temperature OFF
when the switch is ON
1.3 BYD473QE/QB Tightening Torque Table of Gasoline Engine
Tightened Tightening Torque

Serial No. Bolt size
Parts/Components (Nm)
Cylinder Head Bolt and
1 Cylinder Head 29 and corner 130°
Gasket Unit
Main Bearing Cap Bolt and
2 Main Bearing Cap 25 and corner 40°
Gasket Unit
3 Connecting Rod Cap Connecting Rod Bolt 9.8 and corner 90°
4 Flywheel Flywheel Bolt 95
5 Sparkplug M14×1.25 20
6 Labyrinth Gland Bolt M6×12 12
7 Knock Sensor Bolt M8×30 25
8 Oil Pressure Switch R2 1/8 15
7
Cylinder Head
9 Bolt M10×1.25×12 30
Threaded Plug
Tensioning Link Plate Bolt
10 Tensioning Link Plate 22
Shaft
Camshaft Sprocket Bolt
11 Camshaft Sprocket 56
Assembly
12 Guide Link Plate Bolt M6×16 12
13 Tensioner Seat Bolt M6×30 12
Bolt M6×25 10
14 Oil Pump Assembly
Bolt M6×35 10
15 Water Pump Bolt M6×35 12
Bolt M6×12 10
16 Oil Collector
Nut M6 10
Bolt M6×30 12
17 Oil Sump Bolt M8×35 25
Bolt M6×50 12
Oil Filter 12
18 Oil Filter
Threaded Connecting Pipe 20
Welded Dipstick Tube
19 Bolt M6×12 10
Assembly
20 Water Outlet Tube Bolt M6×12 10
Bolt M8×50 25
21 Intake Manifold
Nut M8 25
Fuel Distributor
22 Bolt M6×12 10
Assembly
Intake Temperature Cross Recessed Pan Head
23 5
Pressure Sensor Screw M5×16
Bolt M6×30 12
24 Intake Valve Assembly
Bolt M6×35 12
25 Throttle Wire Bracket Bolt M6×12 12
Bolt M10×1.25×20 44
26 Exhaust Manifold
Bolt M10 44
Exhaust Manifold Heat
27 Bolt M6×25 10
Shield
Exhaust Manifold Bolt M8×20 25
28
Bracket Nut M8×25 25
29 Front Lambda Sensor M18×1.5-6e 45
30 Thermolator Cap Bolt M6×20 10
Camshaft Phase
31 Bolt M6×16 10
Sensor
Coolant Temperature
32 M12×1.5-6g 15
Sensor
33 Cylinder Head Cover Cylinder Head Cover Bolt Unit 12
34 Ignition Coil Bolt M6×25 10
Charcoal Canister
35 Bolt M6×12 10
Control Valve Bracket
Crankshaft Damper
36 Pulley Bolt and Gasket Unit 37 plus corner 90°
Pulley
37 Water Pump Pulley Bolt M6×12 14
Bolt M8×70 25
38 Generator
Bolt M8×25 25
39 Clutch Cover Hexagon Socket Head Cap 25
8
Assembly Screw
Bolt M12×1.25×60 65
40 Transmission Bolt M12×1.25×65 65
Bolt M12×1.25×95 65
41 Starter Bolt M10×1.25×45 44
Bolt M10×1.25×20 44
Intake Manifold Bolt M6×16 12
42
Bracket Assembly Intake Manifold Bracket Big
12
Gasket Bolt M6×30
Hexagon Fit Bolt 25
Bolt M8×50 25
43 Timing Cover Bolt M8×80 25
Bolt M6×30 10
Bolt M12×1.25×12 20
44 Clutch Baffle Bolt M6×12 10
Camshaft Thrust
45 Bolt M6×20 10
Cover
Camshaft Target Hexagon Socket-head Cap
46 34
Wheel Bolt
Cylinder Head
47 M16×1.5-6h 45
Threaded Plug
48 EGR Valve Seat M8 Nut 25
49 EGR Valve M8 Nut 25
50 OCV Valve Assembly Bolt M6×55 12
1.4 BYD473Q List of Different Elements of Gasoline Engine
Model
Part Number BYD473QB BYD473QE
Name
Cylinder Head Assembly Processing BYD473QA-1003400 BYD473QE-1003400
Crankshaft BYD473QB-1005021 BYD473QD-1005021
Rocker Arm Mechanism BYD473QA-1003060 BYD473QE-1003060
Camshaft Assembly BYD473QA-1006010 BYD473QE-1006010
Intake Manifold Assembly BYD473QA-1008020 BYD473QE-1008020
Intake Manifold Bracket BYD473QA-1003601 BYD473QE-1003601
Intake Manifold Stud BYD473QA-1003054 BYD473QE-1003054
Fuel Distributor Assembly BYD473QA-1121010 BYD473QE-1121010
Charcoal Canister Control Valve BYD473QA-1130020 BYD473QE-1026300
Charcoal Canister Control Valve Bracket BYD473QA-1130015 BYD473QE-1130015
Water Outlet Tube Welding Unit II BYD473QA-1303200 BYD473QE-1303200
Throttle Body BYD473QA-1132020 BYD473QE-1132110
Throttle Valve Position Sensor BYD473QA-3611030 BYD473QE-3611700
Knock Sensor BYD473QA-3611040 BYD473QE-3611400
Crankshaft Position Sensor BYD473QA-3611050 BYD473QE-3611200
Coolant Temperature Sensor BYD473QA-3611060 BYD473QE-3611100
Intake Air Temperature and Pressure
BYD473QA-3611070 BYD473QE-3611500
Sensor
9
Front Lambda Sensor BYD473QA-3611080 BYD473QE-1211100

Idle Stepper Motor BYD473QA-3611090 BYD473QE-1026200
Ignition Coil Assembly IB5-3705100 BYD473QE-3705010
Engine Harness Bracket Ⅹ IB5-1024217 IB5-4016214
Engine Harness Bracket Ⅻ None IB5-4016215
EGR Control Valve None BYD473QE-3615100
EGR Valve Seat None BYD473QE-1003501
EGR Valve Gasket None BYD473QE-1003507
EGR Valve Seat Gasket None BYD473QE-1003502
EGR Valve Stud None BYD473QE-1003506
EGR Valve Seat Branch Pipe None BYD473QE-1003505
Intake Manifold Transition Gasket None BYD473QE-1008021
Intake Manifold Gasket None BYD473QE-1008024
OCV Valve Unit None BYD473QE-1003700
Cylinder Head Threaded Plug None BYD473QE-1003055
Cylinder Head Threaded Plug Gasket None BYD473QE-1003056
EGR Backwater Hose None BYD473QE-1303016
10
Section 2 Cylinder Head

2.1 Valve Lash Control
Note: The valve can be adjusted only when the temperature of the cylinder head is below
38°C.
2.1.1 Remove the cylinder head cover.
2.1.2 Turn the crankshaft and place 1

cylinder piston on the top dead center
(TDC). Marker "UP" on the camshaft
sprocket should be on the top, and the
top dead center groove of the camshaft
sprocket should be aligned with the
upper edge of the cylinder head.
2.1.6 Tighten the adjusting lock nut and

recheck the clearance; if necessary,
repeat the procedure mentioned above.
2.1.7 Turn the crankshaft clockwise. Align

the top dead center groove of the No.3,
No.4, and No.2 pistons on the camshaft
sprocket with the upper edge of the
cylinder head successively; inspect the
2.1 3.Select appropriate feeler gauges for valve lash with a feeler gauge, and adjust
valves which need inspection. it if necessary.
BYD473QB Engine: intake valve
lash:0.25 mm ± 0.02 mm 2.1.8 Install the cylinder head cover.
exhaust valve lash: 0.29 mm ± 0.02 mm
BYD473QE Engine: intake valve lash:
0.20 mm ± 0.02 mm
exhaust valve lash: 0.25 mm, 0.02 mm
2.1 4 Insert a feeler gauge between the

adjusting screw and the end of the valve
lever, and then slide it back and forth;
slight resistance should be felt.
2.1.5 If the resistance is too big or small,

loosen the adjusting lock nut and rotate
the adjusting screw until appropriate
resistance can be felt when sliding the
feeler gauge back and forth.
11
2.2 Removal and Installation of

Crankshaft Damper Pulley
Removal
Remove bolts on the crankshaft damper pulley

using a ratchet wrench, an extension rod and a
19 mm sleeve.
Installation
2.2.1 Clean the crankshaft damper pulley (A), 2.3.3 Remove the idler unit.
crankshaft (B), bolt (C) and washer (D),
and lubricate them as shown in the
illustration below.
2.3.4 Turn the crankshaft damper pulley and

align its top dead center (TDC) marker with
the pointer.
2.2.2 Install the crankshaft damper pulley and
bolts on the crankshaft pulley and then
tighten bolts to 37 Nm with a torque
wrench and a 19mm sleeve. Don’t use an
impact wrench. If bolts on the pulley or the
crankshaft are new, tighten the bolts to 177
Nm and then loosen them and tighten
them to 37 Nm.
2.2.3 Tighten the bolts on the pulley to 90°.
2.3 Removal and Installation of Timing

Chain
Note: Keep the timing chain away from the

magnetic field. 2.3.5 Remove the water pump pulley.
Removal 2.3.6 Remove the cylinder head cover.
2.3.1 Remove the belt. 2.3.7 Remove the crankshaft damper pulley.
2.3.2 Remove the assembling bolt 1 on the
generator’s adjusting arm and then loosen 2.3.8 Remove the oil sump.
generator's assembling bolt 2.
12
2.3.9 Support the engine from the cylinder

block's bottom with a jack and a wood
block.
2.3.10 Keep the generator away from the

timing cover and remove the timing cover.
2.3.11 Apply engine oil on the surface of the

timing chain tensioner seat. Pry up holes
on the timing chain tensioner seat with a
screwdriver and remove bolt 1 and loosen 2.3.13 Remove the Chain tension plate and
bolt 2. the chain guide plate.
2.3.14 Remove the timing chain.
Installation

2.3.12 Remove the timing chain tensioner magnetic field.
seat.
2.3.14.1 Place the crankshaft on the top dead
center (TDC) Align the TDC marker on the
crankshaft sprocket with the pointer on the
oil pump.
13
2.3.14.5 Apply engine oil on the threads of the

chain tension plate bolts, and install the
2.3.14.2 Place No.1 piston on the top dead tensioning chain plate unit and guide chain
center. Marker "UP" on the camshaft plate unit.
sprocket should be on the top and the top
dead center groove of the camshaft
sprocket should be aligned with the upper
edge of the cylinder head.
2.3.14.6 Install the tensioner seat and then

2.3.14.3 Install the timing chain on the slightly tighten the bolt.
crankshaft sprocket and the color chip
should be aligned with TDC marker on the
crankshaft sprocket.
2.3.14.4 Install the timing chain on the

camshaft sprocket and the pointer should
be aligned with the three color chips. 2.3.14.7 Apply engine oil on the sliding surface
of the tensioner seat.
14
2.3.14.13 Install the timing cover.

2.3.14.8 Turn the tensioner seat clockwise to
press against the chain tension plate,
install the remaining bolts and tighten
them.
2.3.14.9 Check the crankshaft front seal of the

timing cover for any damage. If the oil seal
is damaged, replace the crankshaft front
seal.
2.3.14.10 Remove the old flange sealant on

the timing cover's mating surface, bolts
and bolt holes.
2.3.14.11 Clean the timing cover's mating

surface and dry it.
2.3.14.14 Install the oil sump.
2.3.14.12 Apply flange sealant evenly on the
mating surface of the timing cover and 2.3.14.15 Install the crankshaft damper pulley.
cylinder block as well as the inner thread
of each hole. 2.3.14.16 Install the cylinder head cover.
Note: 2.3.14.17 Install the water pump pulley.
Apply 2 mm~3 mm wide flange sealant 2.3.14.18 Install the idler unit.
along the dotted lines.
2.3.14.19 Install the generator’s adjusting arm
Apply 3 mm~4 mm wide flange sealant on assembling bolts.
the upper surface of the cylinder block on
the timing cover.
The parts should be installed within 4

minutes after the flange sealant is applied
on them. If not, clean the old residue,
reapply the flange sealant and install the
parts.
15
2.3.14.20 Install and adjust the belt. 34.5 mm -35.2 mm
2.4 Installation of Crankshaft Front Seal
Special tools needed: Guide rod for removal 2.5 Removal of Cylinder Head Cover
and installation
2.5.1 Remove the intake manifolds.
2.4.1 Using SST, tap a new oil seal into the
timing cover directly at the specified 2.5.2 Remove 4 ignition coils.
mounting height.
2.4.2 Measure the distance between the timing
cover’s surface (contacting surface with
the cylinder block) and the oil seal.
Oil seal mounting height 34.5 mm~35.2
mm
16
2.6 Removal of Cylinder Head
Note:
a Use a fender cover to avoid damaging

the paint.
b To avoid damage, hold the connectors

and carefully pull out the wire harness
connectors.
c To avoid damaging the cylinder head,

loosen the cylinder head bolts only 2.6.5 Remove heater hoses.
when the engine coolant temperature
is below 38°C (100°F).
d To avoid wrong connection, do mark

on all wire harnesses and hoses. Make
sure they do not contact with other
wires and hoses or interfere with other
parts.
e Keep the timing chain away from the

magnetic field.
2.6.1 Drain engine coolant.

2.6.6 Remove the belt.
2.6.2 Remove the air cleaner housing.
2.6.7 Remove the intake manifolds.
2.6.3 Remove inlet and outlet hoses of the
throttle body. 2.6.8 Remove the exhaust manifolds.
2.6.9 Remove the engine wire harness

connectors and harness retainers from the
cylinder head.
4 injector connectors
2.6.9.1 Engine coolant temperature sensor

connector
2.6.9.2 Camshaft phase sensor connector

2.6.4 Remove inlet and outlet hoses of the
radiator. 2.6.9.3 Oil pressure switch connector
2.6.9.4 Knock sensor
2.6.10 Remove the connected wire harnesses,

bolts and harness brackets.
2.6.11 Remove the water outlet tube

connecting pipe and the positive
crankcase ventilation (PCV) hose.
17
2.6.13 Remove the assembling bolts on the 2.6.22 Install the crankshaft damper pulley
generator's mounting bracket and loosen loosely.
the generator's assembling bolts.
2.6.23 Apply engine oil on the sliding surface
2.6.14 Remove the idler unit. of the timing chain tensioner seat through
the oil return hole on the cylinder head.
2.6.15 Turn the crankshaft damper pulley and
align its top dead center (TDC) marker with
the pointer.
2.6.16 Remove the water pump pulley.
2.6.17 Remove the crankshaft damper pulley.
2.6.18 Support the engine from the bottom of

the oil sump with a 300×300×25mm wood
block and a jack.
Note: Do not place the jack on the center

of the oil sump to avoid damaging it.
2.6.19 Remove the ground cable and then

remove engine front support.
2.6.20 Keep the engine away from the timing

cover and remove the timing cover. 2.6.24 Fix the crankshaft damper pulley and
put a socket wrench on the camshaft
sprocket bolt.
2.6.25 Turn the camshaft clockwise, press the

2.6.21 Make a reference marker on the chain tension plate, and install a M6 × 1.0
camshaft sprocket and the timing chain. mm bolt into the bolt hole of the cylinder
18
block through the chain tension plate.
2.6.26 Hold the camshaft with an open-end

wrench and remove the camshaft
sprocket.
The order of loosening the cylinder head

bolt unit.
2.6.29 Remove the cylinder head.

Camshaft Sprocket
Removal
2.6.27 Remove the bolt on the tensioning Note: Keep the timing chain away from the
chain guide plate. magnetic field.
2.7.2 Make a reference marker on the

camshaft sprocket and the timing chain.
2.7.3 Apply engine oil on the sliding surface of

the tensioner seat through the oil return
hole on the cylinder head.
2.6.28 Remove the cylinder head bolt unit. To

avoid warp age and deformation, loosen
the bolts by turning 1/3 circle each time in
order and repeat the procedure until all
bolts are loose.
19
Note: Hang the timing chain with a steel

wire.
2.7.4 Remove the sight glass cover.
Installation

magnetic field.
2.7.7.1 Align the reference marker and install

the timing chain on the camshaft sprocket;
install the camshaft sprocket on the
2.7.5 Remove the bolt M12×1.25×12 on the camshaft.
timing cover and the gasket, fix the
crankshaft damper pulley and put a socket
wrench on the camshaft sprocket bolt.
2.7.7.2 Hold the camshaft with an open-end

wrench and tighten the bolt.
2.7.6 Turn the camshaft clockwise, press the Specialized torque: 75 Nm

chain tensioning plate, and install a M6 ×
1.0 mm bolt into the bolt hole of the
cylinder block through the M12 bolt hole on
the timing cover and then the chain
tensioning plate.
2.7.7 Grip the camshaft with an open-end

wrench and remove the Camshaft
Sprocket Bolt Assembly.
20
2.7.7.5 Turn the camshaft clockwise, press the

timing chain tensioning plate and take out
the bolt M6×1.0mm.
2.7.7.6 Install the bolt M12×1.25×12 with a

new washer.
2.7.7.7 Install a new sight glass cover.
2.7.7.3 Apply engine oil on the sliding surface

of the tensioner seat through the oil return
hole of the cylinder head.
2.7.7.8 Install the cylinder head cover.
2.8 Replacement of Camshaft Target

Wheel (BYD473QB Engine)
Removal
2.8.1 Remove the air cleaner.
2.8.2 Remove connected wire harnesses,

bolts and harness brackets.
2.8.4 Remove the camshaft thrust cover.

2.7.7.4 Fix the crankshaft damper pulley and
sprocket bolt.
2.8.5 Fix the camshaft with an open-end

wrench and loosen the hexagon
socket-head cap bolt.
21
2.8.6.4 Install the cylinder head cover.

2.8.6 Remove the camshaft target wheel.
2.8.6.5 Install harness brackets, wire
harnesses, bolts and so on.
2.8.6.6 Install the air cleaner.
2.9 Inspection of Cylinder Head’s Warp

age
2.9.2 Inspect the camshaft.
2.9.3 Check the cylinder head for warp age.

Installation Measure the length of each side and the
length along the direction coming
2.8.6.1 Install the camshaft target wheel. through the center.
2.8.6.2 Hold the camshaft with an open-end 2.9.3.1 If the warp age is less than 0.08 mm,
wrench and then tighten the bolt to 34 Nm. the cylinder head needs no repair.
2.9.3.2 If the warp age is between 0.08 mm

and 0.2 mm, the cylinder head needs
repair
2.9.3.3 The overhaul limit for a 120 mm high

cylinder head is 0.2 mm.
2.9.3.4 Standard cylinder head height:119.9

mm~120.1 mm
2.8.6.3 Install the camshaft thrust cover using

a new O-ring seal.
22
2.10.4 Remove the rocker shaft hollow bolts

and then the rocker arm assembly.
Note: When disassembling the rocker arm,

remove the dowel pin first and then the
rocker arm from the rocker shaft's timing
chain side.
2.11 Disassembly and Assembly of

Rocker Arm and Rocker Shaft
BYD473QB Engine
2.10 Removal of Rocker Arm Assembly
Note:
2.11.1 To make sure each part is installed
2.10.2 Loosen the rocker arm adjusting in place, mark on each part when
screws. removing.
Rocker arm adjusting screws 2.11.2 Do remove or install the rocker
arms from the rocker shaft's timing
chain side.
2.11.3 Inspect the rocker shaft and the

rocker arm.
2.11.4 If the rocker arm is to be reused, it

must be installed on the former
position.
2.11.5 Before assembling, clean all parts

with the solvent, dry them and then
2.10.3 Turn 2 circles each time in the order as apply grease on all contact points.
the illustration shown and loosen the
rocker shaft hollow bolts.
23
BYD473QE Engine 2.11.8 Inspect the rocker shaft and the

rocker arm.
Note:
2.11.6 To make sure each part is installed 2.11.9 If the rocker arm is to be reused, it
in place, mark on each part when must be installed on the former
removing. position.
2.11.7 Do remove or install the rocker arm 2.11.10 Before assembling, clean all parts
from the rocker shaft's timing chain with the solvent, dry them and then
side. apply grease on all contact points.
2.12 Inspection of Rocker Arm and Rocker Shaft
2.12.1 Remove the rocker arm assembly.
2.12.2 Measure the diameter of the rocker

shaft of the first rocker arm.
24
2.12.3 Turn the I.D. dial gauge to 0 according

to the diameter of the axle.
2.12.5 Repeat the procedure for all rocker

arms and rocker shafts. If the clearance is
beyond the limit, replace the rocker shaft
and rocker arms whose clearance is
beyond the limit.
2.13 Removal of Camshaft
2.13.1 Remove the air cleaner.
2.12.4 Measure the rocker arm’s I.D. with an 2.13.2 Remove the camshaft sprocket.
I.D. dial gauge and check its out of roundness.
2.13.3 Remove the rocker arm assembly.
Clearance between the rocker arm and the
rocker shaft: 2.13.4 Remove the connected wire harness
bolts and wire harnesses.
Standard: 0.019 mm~0.058 mm
2.13.5 Disconnect the camshaft phase sensor
Overhaul limit: 0.08 mm connector and remove the camshaft phase
sensor.
2.13.6 Remove the camshaft thrust cover and

pull out the camshaft.
25
2.14.6 Support the camshaft with a V-block

and check its total runout.
2.14 Inspection of Camshaft
If the total runout is beyond the overhaul
2.14.1 Remove the camshaft sprocket. limit, replace the camshaft and recheck the
oil film clearance between the camshaft
2.14.2 Remove the rocker arm assembly. and seat hole.
2.14.3 Place the rocker shaft on the cylinder If the oil film clearance is still beyond the
head and tighten the bolts to the specified overhaul limit, replace the cylinder head.
torque.
Camshaft's total runout
Specified Torque: 29 Nm
Standard: Max. 0.03 mm
Apply engine oil on the bolts’ thread and
flange. Overhaul limit: 0.04 mm
2.14.4 Push the camshaft toward the back of

the cylinder head in place.
2.14.5 Hold the dial gauge's pointer against

the end of the camshaft and turn the dial
gauge to zero. Push the camshaft back
and forth and read the axial clearance.
If the axial clearance is beyond the

overhaul limit, replace the thrust cover and
make another inspection.
If it is still beyond the overhaul limit,

replace the camshaft.
Camshaft's axial clearance: 2.14.7 Measure the cam lobe height.

Standard: 0.07 mm~0.25 mm Standard cam lobe height:
Intake: 35.38 mm
Overhaul limit: 0.5 mm
Variable Intake: 30.565 mm
Exhaust: 35.39 mm
26
2.15 Removal of Valve, Valve Spring and C Overhaul limit: 5.42 mm

Valve Stem Seal
When removing the valve and valve spring,

mark to install them on the former position.
2.15.2 Remove the camshaft.
2.15.3 Using an appropriate sleeve and a

plastic hammer, tap the valve spring upper 2.17 Inspection of Valve Tappet and
seat slightly and loosen the valve collet.
Valve Guide Clearance
Remove the valve collet, valve spring,
valve and valve stem seal.
2.17.1 Remove the valve.
2.17.2 Slide the valve from the valve guide for

about 10 mm, then shake the valve tappet
(shaking method) on the normal thrust
direction, measure the I.D. of the valve
guide with an I.D. dial gauge, measure the
O.D. of the valve tappet with a micrometer
and thus the clearance between the two
can be calculated.
 If the measurement is beyond the

overhaul limit, use a new valve and
 If the measurement is within the

2.16 Inspection of Valve overhaul limit, reassemble with a new
valve.
Remove the valve If the measurement is still beyond the
overhaul limit after using a new valve, go
Measure the following items of the valve to step 3.
Intake valve: Clearance between intake valve tappet

and valve guide:
A Standard: 27.4 mm~27.6 mm
B Standard: 118.1 mm~118.7 mm
C Standard: 5.470 mm~5.485 mm
Clearance between exhaust valve tappet
C Overhaul limit: 5.44 mm and valve guide:
Exhaust valve: Standard: 0.10 mm~0.16 mm
A Standard: 22.9 mm~23.1 mm Overhaul limit: 0.22 mm
B Standard: 117.3 mm~117.9 mm
C Standard: 5.455 mm~5.470 mm
27
above operation.
2.18.3 Select appropriate and replaceable

valve guides and freeze them in a
refrigerator's freezing chamber for about 1
hour.
2.18.4 Heat the cylinder head to 150°C with a

platen heater or an oven. Monitor the
temperature with a thermometer. The
cylinder head's temperature should not be
over 150°C. Overheating may lead to
looseness of the valve seat.
2.17.3 Subtract the valve tappet O.D.

measured by a micrometer out of the guide
I.D. measured by a bore micrometer.
Measure along the valve tappet and valve
guide on three different locations. The
D-value of max. measurements and min.
measurements of the guide should not be
beyond the overhaul limit.
Clearance between intake valve tappet

and valve guide: 2.18.5 Start work from one side of the
camshaft and using a punch and an air
Standard: 0.02 mm~0.05 mm hammer, eject the valve guide towards the
direction of the combustion chamber for
Overhaul limit: 0.08 mm about 2 mm.
Clearance between exhaust valve tappet This could tap some carbon out and
and valve guide: makes the removal easier.
Standard: 0.050 mm~0.080 mm When holding the air hammer, keep it and
the valve guide paralleled to avoid
Overhaul limit: 0.11 mm damaging the punch.
2.18 Replacement of Valve Guide 2.18.6 Turn the camshaft over and tap out the
valve guide toward the cylinder head's
Special tools needed: camshaft side.
a Valve guide replacer
b Valve guide reamer
2.18.1 Inspect the clearance between the

valve tappet and the valve guide.
2.18.2 As shown in the figure below, use the

pneumatic valve guide punch which is
available on the market and modified in
accordance with the diameter of valve
guide. In most cases, using this special
tool and a regular hammer will finish the
28
2.18.7 If the valve guide cannot move, drill a

hole with an 8 mm drill and try again. Using
the drill is the last resort. If the valve guide
bursts, the cylinder may get damaged.
2.18.8 When necessary, take out one new

valve guide from the freezing chamber
each time.
2.18.9 Apply a thin layer of engine oil on the

outer surface of the new valve guide.
Install the valve guide from the cylinder
head’s camshaft side; using SST, tap the
valve guide to the specialized height. If 16
valve guides need to be installed, it may
2.18.12 Turn the reamer clockwise
be necessary to reheat the cylinder head.
continuously until it comes out of the valve
guide’s hole.
Valve guide's mounting height: 15.70
mm~16.30 mm
2.18.13 Clean valve guides thoroughly with
cleaner and water to remove all cuttings.
2.18.14 Check the clearance of a valve. Make

sure that there is no resistance when the
valve is sliding in the intake and exhaust
valve guides.
2.19 Overhaul of Valve Seat
2.19.1 Inspect the clearance between the

valve tappet and guide. If the valve guide
is worn, replace it when cutting the valve
seat.
2.19.2 Repair the valve seat in the cylinder

with a valve seat reamer.
2.18.10 Apply cutting oil on the reamer and the

valve guide.
2.18.11 Turn the reamer clockwise within the

range of the valve guide hole.
2.19.3 Cut a 45°seat carefully and only cut

away redundant material to make sure the
valve seat is smooth and concentric.
29
2.19.4 Mill the superior angle and under horn

according to the angle shown in the
illustration. Check the width of the valve
seat and make the corresponding
adjustment.
Inlet: 67.5° 2.19.7 As shown in the illustration, the valve

Outlet: 60° seat's surface with Prussian blue must be
aligned with the center of the valve seat.
2.19.7.1 If it is too high (close to the valve

tappet), it is necessary to ream it again
with a 67.5°reamer (inlet) or 60°
reamer (outlet) to make it lower and
then ream it again with a 45°reamer to
2.19.5 Ream again slightly with a 45°reamer
restore the valve seat's width.
to remove possible burr caused by other
reamers.
2.19.7.2 If it is too low (close to the edge
of the valve), it is necessary to ream it
Width of valve seat
again with a 30°reamer to make it
higher and then ream it again with a
Intake:
45°reamer to restore the valve seat's
width.
Note: Make sure that a 45°milling cutter is
used for the last milling.
Exhaust:
2.19.8 Insert the intake valve and exhaust
valve in the cylinder head and measure the
mounting height (A) of the valve tappet
Mounting height of intake valve tappet:
2.19.6 After adjusting the surface of the valve
seat, check the valve seat for smoothness:
Apply Prussian blue on the valve's surface,
and insert the valve in its former place in
the cylinder head. Then lift the valve and
Mounting height of Exhaust valve tappet:
push it against the valve seat. Repeat the
operation for several times.
Overhaul limit: 46.9mm
30
2.19.9 If the mounting height of the valve

tappet is beyond the overhaul limit, replace
the valve and make another inspection. If it
is still beyond the overhaul limit, replace
the cylinder head; because the valve seat
of the cylinder head is too deep.
2.20 Installation of Valve, Valve Spring

and Valve Stem Seal
Special tools needed:
a Valve tappet stem seal replacer

b Valve spring compressor
2.20.1 Apply a layer of engine oil on the valve 2.20.5 Install the valve spring. Orient the valve
tappet and install the valve into the valve spring with more winding toward the
guide. cylinder head.
2.20.2 Check whether it's smooth for the valve 2.20.6 Install the spring upper seat.
to move up and down.
2.20.7 Install the valve spring compressor.
2.20.3 Install the spring lower seat on the Press the spring and install the valve
cylinder head. collet.
2.20.4 Apply grease on the valve guide and

install a new valve stem seal with a valve
guide stem seal replacer.
Note: Exhaust valve stem seal is marked

as "EX" and intake valve stem seal as "IN"
and they are not exchangeable.
31
2.21.2 Install the camshaft phase sensor with

a new O-ring seal and connect the
camshaft phase sensor connector.
(BYD473QB Engine)
2.21.3 Install harness brackets and bolts.
2.21.4 Install the camshaft sprocket.
2.20.8 Tap each valve tappet 2 to 3 times 2.21.5 Install the rocker arm assembly.
slightly with a plastic hammer to make sure
that valves and valve collets are installed 2.21.6 Install the air cleaner.
in place. Only tap along the axial direction
of valve tappets to avoid deformation of 2.22 Installation of Rocker Arm
the valve tappets. Assembly
2.22.1 Install the rocker arm assembly with

dowel pins.
Note: When reassembling the rocker arm,

install the rocker arm from the rocker
shaft's timing chain side.
2.21 Installation of Camshaft
2.21.1 Install the camshaft on the cylinder

head and then the camshaft thrust cover
with a new O-ring seal.
2.22.2 Tighten each bolt by turning 2 circles

each time following the order shown in the
illustration. Specified Torque: 29 Nm.
32
Apply engine oil on the threaded and cylinder head.

flange part of the bolts.
2.23.6 Tighten the bolts on the cylinder head to
29 Nm following the order shown in the
illustration. Use a beam torque wrench to
tighten bolts and if a preset torque wrench
is used, make sure that bolts are tightened
slowly and do not over tighten them. If
noise occurs when tightening the bolt,
loosen it and tighten it again from the first
step.
2.22.3 Adjust the valve lash.
2.22.4 Install the cylinder head cover.
2.23 Installation of Cylinder Head
Install the cylinder head in the reverse order of

removal:
2.23.1 Clean the contacting surface of the

cylinder head and the cylinder block. 2.23.7 Tighten all bolts on the cylinder head to
130°.
2.23.2 Install the cylinder head gasket and
dowel pins on the cylinder head. Be sure 2.23.8 Install the assembling bolt on the timing
to use a new cylinder head gasket. chain's guide chain plate.
2.23.3 Make sure that the key slot of the

crankshaft is positioned upward.
2.23.9 Install the timing chain on the camshaft
2.23.4 Install the cylinder head on the cylinder sprocket, align the reference markers and
block. install the camshaft sprocket on the
camshaft.
2.23.5 Apply engine oil on the thread and the
bottom of the bolt head of all bolts on the
33
2.23.10 Fix the camshaft with an open-end

wrench and tighten the bolt.
Specified Torque: 56 Nm
2.23.13 Fix the crankshaft damper pulley and

sprocket bolt.
2.23.11 Install the crankshaft damper pulley

loosely.
2.13.12 Apply engine oil on the sliding surface

of the timing chain tensioner seat through
the oil return hole on the cylinder head.
2.23.14 Turn the camshaft clockwise, press

the timing Chain tension plate and take out
a bolt M6×1.0 mm.
Note:
When turning the camshaft, the torque
should not be over 56 Nm.
Don't turn the camshaft anticlockwise.
2.23.15 Check the crankshaft front seal for

damage. If the seal is damaged, replace
with a new one.
34
2.23.16 Remove the old flange sealant on the applied on them. If not, clean the old
timing cover's mating surface, bolts and residue, reapply the flange sealant and
bolt holes. install the parts.
2.23.17 Clean and dry the timing cover's

mating surface.
2.23.18 Apply flange sealant evenly on the

mating surface of the timing cover and the
cylinder block as well as the inner thread
of each hole.
Note:
2.23.20 Put the edge of the timing cover and
 Apply 2 mm~3 mm width flange the edge of the oil sump together and then
sealant along the dotted lines. install the timing cover on the cylinder
block.
 Apply 3 mm~4 mm width flange
sealant on the upper surface of the Note: When installing the timing cover,
cylinder block on the timing cover. don't slide the undersurface of the oil
sump's assembling surface.
2.23.19 Apply flange sealant evenly on the

mating surface of the timing cover and the
oil sump as well as the inner thread of
each hole.
Note:
 Apply 2 mm~3 mm width flange

sealant along the dotted lines.
 Apply 5.00 mm width flange sealant on

the shaded area.
 The parts should be installed within 4

minutes after the flange sealant is
35
2.23.21 Install the harness brackets.
2.23.22 Install the crankshaft damper pulley.
2.23.23 Install the cylinder head cover.
2.23.24 Install the water pump pulley.
2.23.25 Install the idler unit.
2.23.26 Install assembling bolts on the

generator's adjusting arm and adjusting
bracket. 2.23.34 Install the inlet and outlet hoses of the
radiator.
2.23.27 Install the belt and adjust the belt by
adjusting the adjusting bolt on the
generator.
2.23.28 Install the water outlet tube unit and

use a new water outlet tube O-ring.
2.23.35 Install the inlet and outlet hoses of the

throttle body.
2.23.29 Install the positive crankcase

ventilation (PCV) hose.
2.23 30 Install the harness brackets and

mounting bolts.
2.23.31 Install the exhaust manifold.
2.23.32 Install the intake manifold.
2.23.33 Install the heating hose. 2.23.36 Install the air cleaner.
2.23.37 After installation, check whether all

guides, hoses and connectors are installed
in place.
2.23.38 Check for fuel leakage. When the

ignition switch is switched ON (don't start
the starter), run the fuel pump for about 2
seconds and pressurize the fuel pipe.
Repeat the procedure 2 to 3 times and
36
then check the fuel pipe for leakage.
2.23.39 Refill the radiator with engine coolant

and bleed the air out of the cooling system
when the heater valve is open.
2.23.40 Inspect the idle speed.
2.23.41 Inspect the ignition timing.
2.24 Installation of Cylinder Head Cover
2.24.1 Clean the washer and groove of the

cylinder head cover thoroughly.
2.24.2 Install the cylinder head cover washer

into the groove of the cylinder head cover.
2.24.3 Make sure that the mating surface is

clean and dry.
2.24.4 Apply 3.0 m width flange sealant on the

mating area of the timing cover.
Note: The parts should be installed within

4 minutes after the flange sealant is
applied on them. If not, clean the old
residue, reapply the flange sealant and
install the parts.
2.24.5 When the cylinder head cover is

installed on the cylinder head, slide the
cylinder head cover back and forth slightly
to ensure that the cylinder head cover
washer is installed in place.
37
Section 3 Cylinder Block

Parts location (a)
38
Parts location (b)
39
3.1 Inspection of Axial Clearance of Connecting Rod and Crankshaft
3.1.1 Remove the oil pump.
3.1.2 Measure the connecting rod axial

clearance between the connecting rod and
the crankshaft with a feeler gauge.
Connecting rod axial clearance:
Standard value: 0.15 mm ~0.30 mm
3.1.5 If the axial clearance is beyond the

tolerance zone, replace the thrust plate
and make another inspection. If it is still
beyond the tolerance zone, replace the
crankshaft.
3.2 Replacement of Crankshaft Bearing

Shell
Inspection of Main Bearing Shell Clearance
3.2.1 Before inspecting the oil film between the

main bearing shell and the journal, remove
the crankshaft main bearing cap and the
3.1.3 If the connecting rod axial clearance is bearing shell first.
beyond the tolerance zone, install a new
connecting rod and make another 3.2.2 Clean each main journal and bearing
inspection. If it is still beyond the tolerance shell with a clean piece of maintenance
zone, replace the crankshaft. cloth.
3.1.4 Push the crankshaft away from the dial 3.2.3 Put a plastic clearance gauge between
gauge, place the dial gauge against the the two adjacent main journals.
crankshaft's end and turn it to zero. Then
pull back the crankshaft tightly against the 3.2.4 Reinstall the bearing shell and the
gauge: the reading should not exceed the crankshaft main bearing cap and tighten
overhaul limit. the bolt to 25 Nm +40°.
Crankshaft axial clearance: Note: Don’t turn the crankshaft during
inspection.
Standard value: 0.10 mm ~ 0.35 mm
3.2.5 Remove the crankshaft main bearing cap
Overhaul limit: 0.45 mm and the bearing shell again and measure
the widest area of the plastic clearance
gauge.
Oil film clearance between the main

bearing shell and the journal:
Standard value: 0.018 mm~0.036 mm
40
Location of Main Journal's Grouping

3.2.6 If the clearance measured by the plastic Codes
clearance gauge is too wide or too narrow,
remove the crankshaft and the upper 3.2.7.2 The main journal's grouping codes are
bearing shell. Install a complete and new stamped on the crankshaft.
bearing shell with the same grouping code
and inspect the clearance again. Don’t
adjust the clearance by filing, gap-filling,
grinding the bearing shell or bearing cap.
3.2.7 If the clearance measured by the plastic

clearance gauge is still not correct, try to
use a bigger or smaller bearing shell
(select the color above or below it in the
table), and then make another inspection.
If the clearance is still ont correct after
using an appropriate bearing shell, replace
the crankshaft and restart the inspection.
Selection of Main Bearing Shell
Location of Crankshaft Holes' Grouping

Codes
3.2.7.1 Grouping letters distinguishing 5 main Fifth gear

journals are stamped on the end of the journal
crankshaft. Write down the crankshaft
holes’ grouping codes. If the codes are
unreadable due to dirt and dust, clean the 3.2.7.3 Select a proper bearing shell for
parts only with the solvent or cleaner, replacement from the following table by
instead of the wire bush or scraper. using the grouping codes on the
crankshaft hole and crankshaft journal.
Note: Grouping codes are on the edge of

the main bearing shell.
Assembling table for main shaft hole, main

bearing shell and main journal
41
Main shaft hole becoming larger
Journal becoming larger
3.3 Replacement of Connecting Rod Bearing Shell
Inspection of Connecting Rod Bearing 3.3.6 Remove the connecting rod cap and the
Clearance bearing shell and then measure the widest
area of the plastic clearance gauge.
3.3.1 Inspect the oil film clearance between
the connecting rod bearing and the journal. Oil film clearance between the connecting
Remove the main bearing cap. rod bearing shell and the journal:
3.3.2 Remove the connecting rod cap and the
connecting rod bearing shell. Overhaul limit: 0.050 mm
3.3.3 Clean the crankshaft connecting rod

journal and the bearing shell with a clean
piece of maintenance cloth.
3.3.4 Place a plastic clearance gauge on the

connecting rod journal.
3.3.5 Reinstall the bearing shell and the

connecting rod cap and tighten the bolt.
Tightening Torque: 9.8 Nm + 90°corner.
Note: Don’t turn the crankshaft during

inspection. 3.3.7 If the clearance measured by the plastic
clearance gauge is too wide or too narrow,
remove the upper bearing shell. Install a
42
complete and new bearing shell with the

same grouping code and inspect the
clearance again. Don't adjust the
clearance by filing, gap-filling, grinding the
bearing shell or bearing cap.
3.3.8 If the clearance measured by the plastic

clearance gauge is still not correct, try to
use a bigger or smaller bearing shell
(select the color above or below it in the
table), and then make another inspection.
If the clearance is still not correct after Location of Connecting Rod Journal's
using an appropriate bearing shell, replace Grouping Codes
the crankshaft and restart the inspection.
3.3.8.3 Connecting rod journal's grouping
Selection of Connecting Rod Bearing Shell codes are stamped on the crankshaft.
3.3.8.1 Check each connecting rod for cracks Location of Connecting Rod Journal's
or thermal deterioration. Grouping Codes
Location of Connecting Rod Big End Hole

Code
3.3.8.2 The tolerance zone for each

connecting rod should be between 0 to
0.015 mm with an increment of 0.008 mm
according to the size of the big end hole on
the connecting rod. The range is indicated
by stamped numbers or bar codes. All
kinds of number and bar code
combinations can be found on the engine
(half of them are stamped on the bearing
cap and the other half are stamped on the
connecting rod).
If the codes are unreadable due to dirt and

dust, clean the parts only with the solvent
or cleaner, instead of the wire bush or
scraper.
3.3.8.4 Select a proper bearing shell for
replacement from the following table by
Standard hole size: 43.0 mm
using the codes on the big end hole and
connecting rod journal.
Note: Grouping codes are on the edge of

the bearing shell.
43
Assembling table of seat hole, connecting rod bearing shell and connecting rod journal
3.4 Removal of Oil Sump
3.4.1 Drain engine oil. 3.4.3 Remove the clutch baffle and then the 2
bolts (A) for tightening the transmission.
3.4.2 Move the dipstick tube.
44
3.4.4 Remove the bolt for tightening the oil

sump.
3.4.5 Place a straight screwdriver as shown in

the illustration and remove the oil sump
from the cylinder block.
3.5.7 Remove the main bearing cap.
3.5.8 Remove the connecting rod cap/bearing

shell and place them carefully in order.
3.4.6 Remove the oil sump and place it
carefully with its contacting surface with 3.5.9 Remove the crankshaft from the cylinder
the cylinder block upwards. block and make sure that it has no contact
with the cylinder block and don't damage
3.5 Removal of Crankshaft and Piston the journal.
3.5.1 Remove the engine.
3.5.2 Remove the transmission.
3.5.3 Remove the timing chain.
3.5.5 Remove the oil collector and then the oil

pump.
3.5.10 Remove the upper bearing shell from

the connecting rod and place it with the
corresponding bearing shell cap.
3.5.11 Observe the top of the cylinder liner's

inner wall carefully and if metal projection
or carbon deposit is found, remove it with a
3.5.6 Remove the main bearing cap bolt. To reamer following the instruction of the
avoid warpage and deformation, turn 1/3 reamer supplier. The projection may
circle each time to remove bolts in the damage the piston when the piston is
order shown in the following illustration. pulled out.
Repeat this procedure until all bolts are
loose.
45
3.6.2 Clean the pipeline of the crankshaft with

pipeline cleaner or an appropriate brush.
3.6.3 Clean the key slot and thread.
3.6.4 Measure the roundness at the

orthogonal part of the center of each
connecting rod journal and main journal.
The D-value of each journal's
measurement should not be beyond the
overhaul limit.
3.512 Tap out the piston with the hammer's Out of roundness of the journal:
wooden handle. Hold the piston by one
hand when tapping. Standard value: Max. 0.005 mm
3.513 Install the main bearing cap and bearing

shells on the cylinder block in the correct
order.
3.5.14 After removing all piston rings and the

connecting rod assembly, reinstall the
connecting rods and connecting rod caps.
3.5.15 Mark each piston/connecting rod

assembly with its cylinder number to
ensure they are installed in place.
Note: The marker on the connecting rod

indicates the dimension of the connecting
rod hole instead of its position in the
engine.
3.6 Inspection of Crankshaft
3.6.5 Measure the taper at the edge of each
Out of roundness and taper connecting rod and main journal. The
D-value of every journal's measurement
3.6.1 Remove the crankshaft from the cylinder should not be beyond the overhaul limit.
block.
46
Journal's taper:
Diameter of the piston:
Standard value: Max. 0.005 mm Standard value: 72.955 mm~72.975 mm
Verticality
3.6.6 Place the cylinder block on the surface

table.
3.6.7 Clean the bearing shell and install it on

No.1 and No.5 journals of the cylinder
block.
3.6.8 Lower the crankshaft and install it into

the cylinder block.
3.6.9 Measure all main journals' runout. Turn

the crankshaft for 2 rounds. The difference
between each journal's measurement
should not be beyond the overhaul limit.
Total runout of the crankshaft:
Standard value: Max. 0.03 mm
The diameter of the piston with an

enlarged dimension:
0.25: 73.205 mm~73.225 mm
3.7.4 Check the wear and measure the taper

from the direction of X and Y at 3 different
heights of each cylinder as shown in the
illustration. If the measurement of any
cylinder is beyond the overhaul limit of the
cylinder hole with an enlarged dimension,
replace the cylinder block. If the cylinder
3.7 Inspection of Cylinder Block and block needs reboring, see step 7 after
Piston reboring.
3.7.1 Remove the crankshaft and piston. Cylinder hole dimension:

3.7.2 Check the piston for deformation or Overhaul limit: 73.07 mm
cracks.
An enlarged dimension:
3.7.3 Measure the piston's diameter at the 0.25: 73.25 mm~73.269 mm
point shown in the illustration bellow the Reboring limit: Max. 0.25 mm
piston skirt.
47
Taper of the hole:
Limit: (difference of the 1st and 3rd

measurement) 0.05 mm
3.7.7 Measure the D-value between the

3.7.5 Grind the cylinder if it is scratched or cylinder hole diameter and piston diameter.
scraped. If the clearance is close to or beyond the
overhaul limit, check the piston and
3.7.6 Check the top of the cylinder block for cylinder for over wear.
warp age and deformation. As shown in
the illustration, do the measuring along the Clearance between the piston and the
cylinder block's edge and diagonal lines. cylinder:
Warp age of the engine: Overhaul limit: 0.05 mm
Standard value: Max. 0.05 mm
48
Cylinder's grinding 3.8.2 Remove the piston pin using SST.
Grinding is only necessary when the Inspection

cylinder hole is scratched or scraped.
3.8.2.1 Measure the diameter of the piston pin.
3.7.7.1 Measure the cylinder hole
Diameter of the piston pin:
If the cylinder block is to be reused, the
cylinder needs grinding and the cylinder Standard value: 17.996 mm~18.000 mm
hole needs to be measured again.
3.7.7.2 Using grinding oil and a fine grinding

stone (particle size 400), grind the cylinder
hole with a 60°checker plate. Only
grinding stones of particle size—400 or
finer stones such as Sunnen, Ammco or
the equivalent—can be used. A grinding
stone which is worn or broken should not
be used.
3.8.2.2 Turn the I.D. dial gauge to zero
according to the diameter of the piston pin.
3.7.7.3 After grinding, clean all metal particles

in the engine thoroughly. Clean the
cylinder hole with warm soap water. Dry it
and then apply engine oil on it immediately
to avoid rust. A solvent should not be used
because solvents could make metal
particles spread on the cylinder wall again.
3.7.7.4 If the scratch or scrape still exists after

the cylinder block is grinded to its repair
limit, rebore the cylinder block. The minor
vertical scratch and scrape are acceptable Replacement of Piston, Piston Pin and
as long as they are not deep enough to Connecting Rod
block a fingernail and they are shorter than
the cylinder hole. 3.8.2.3 Measure the clearance between the
piston pin and the small-end hole of
connecting rod.
3.8 Replacement of Piston, Piston Pin
and Connecting Rod Clearance between the piston pin and
small-end hole of connecting rod:
Disassembly
Standard value: -0.037 mm~-0.015 mm
3.8.1 Remove the piston from the cylinder
block.
49
3.8.2.4.2 Press the piston pin into the piston

with SST.
Replacement of Piston Ring

3.8.2.4 Inspect the D-value between the piston
pin diameter and the piston hole diameter. 3.8.2.4.2.1 Remove the piston from the
cylinder block.
Clearance between the piston pin and
piston hole 3.8.2.4.2.2 Remove the used piston ring using
a piston ring expander.
3.8.2.4.3 Clean all piston ring grooves

thoroughly with a split ring without a cutting
Reassembly angle or groove cleaner with a cutting
edge matching the piston ring groove.
3.8.2.4.1 Install the piston and connecting rod.
The arrow and the connecting rod marker The groove width of the first air ring is 1.0
should face the same direction. mm.
The groove width of the second air ring is

1.2 mm.
The groove width of the multi-piece oil ring

is 2.0 mm.
If necessary, the cutting edge can be

trimmed.
Don't use a wire brush to clean the groove

and don't deepen the groove with a
50
cleaner.
Note: If the piston is to be separated from

the connecting rod, don't install a new
piston ring.
3.8.2.4.4 Push a new piston ring into the

cylinder hole with a piston. The distance
from the piston ring to the bottom should
be 15 mm-20 mm.
3.8.2.4.5 Measure the close clearance of the

piston ring with a feeler gauge.
Standard close Overhaul limit

clearance
First air ring 0.20 mm~0.35 mm 0.79 mm
Second air ring 0.35 mm~0.50 mm 0.75 mm
Multi-piece oil 0.20~0.70 mm 0.80 mm
ring
If the measurement is beyond the

maximum close clearance, replace the 3.8.2.4.7 Turn the piston ring in the groove and
piston ring. make sure that there is no clamping
stagnation.
If the measurement is still beyond the
maximum close clearance after installing a 3.8.2.4.8 The direction of its end clearance
new piston ring, replace the cylinder block. should be as shown in the illustration when
installing the piston ring:
3.8.2.4.6 Install the first air ring (A) and the
second air ring (B) shown in the illustration.
Make sure that the surface with the marker
(C) made by the piston ring manufacturer
is upward when installing.
51
3.8.2.4 9 After installing a new piston ring,

measure the clearance of every groove.
Clearance of first air ring

3.8.2.4.9.4 Put the piston in the cylinder and
Overhaul limit: 0.17 mm tap it with the wooden handle of a hammer
(A) or the equivalent wooden bar. Before
Clearance of second air ring installing it into the cylinder hole, maintain
downward pressure on the piston ring
Standard value: 0.030 mm~0.055 mm compressor (B) to avoid the piston ring
Overhaul limit: 0.13 mm expanding.
Installation of Piston 3.8.2.4.9.5 Stop when the piston ring

compressor bounces and before pushing
If the crankshaft is installed the piston back into place, check whether
the connecting rod and the crankshaft
3.8.2.4.9.1 Set the crankshaft of each cylinder journal are aligned.
to the lower dead center successively.
3.8.2.4.9.6 Inspect the clearance of the
3.8.2.4.9.2 Remove the connecting rod cap, connecting rod bearing shell with a plastic
install the piston ring compressor and clearance gauge.
make sure that the bearing shell is firmly
installed in place. 3.8.2.4.9.7 Inspect the connecting rod bolt.
3.8.2.4.9.3 Orient the mark on the piston to the 3.8.2.4.9.8 Apply engine oil on the threads of
engine's timing chain side (front end). the bolt. Then install the connecting rod
cap with the bearing shell.
Tighten the bolt to 9.8 Nm + 90°corner.
If the crankshaft is not installed
52
bearing with a plastic clearance gauge.

3.8.2.4.9.8.1 Remove the connecting rod cap,
install the piston ring and make sure that 3.10.3 Inspect the connecting rod bolt.
the bearing shell is fixed in position.
3.10.4 Install a bearing shell on the cylinder
3.8.2.4.9.8.2 Orient the mark on the piston to block and the connecting rod.
the engine's timing chain side (front end).
3.10.5 Apply a layer of engine oil on the main
3.8.2.4.9.8.3 Put the piston in the cylinder and bearing shell and the connecting rod
tap it with the wooden handle of a hammer bearing shell.
(A) or the equivalent wooden bar.
3.10.6 Hold the crankshaft, place No.2 and
Before installing it into the cylinder hole, No.3 journals vertically and upward and
maintain downward pressure on the piston then put the crankshaft in the cylinder
ring compressor (B) to avoid the piston block.
ring expanding.
3.10.7 Install a thrust plate on No.4 journal of
3.8.2.4.9.8.4 Set all pistons to the top dead the cylinder block.
center.
3.9 Inspection of Connecting Rod Bolt
3.9.1 Measure the diameter of the connecting

rod bolt at point A and point B in the
illustration with a dial gauge.
3.10.8 Apply engine oil on the thread and

flange of the connecting rod bolt.
3.10.9 Put the connecting rod journal into No.1

and No.4 connecting rod. Align the
markers on the connecting rod and the
connecting rod cap and then tighten the
3.9.2 Calculate the difference of connecting rod cap and bolt by hand.
measurements at point A and point B.
3.10.10 Turn the crankshaft clockwise and fix
Diameter difference = diameter A - the journal between No.2 and No.3
diameter B. connecting rods. Align the markers on the
connecting rod and the connecting rod cap
Technical specification for diameter and then tighten the connecting rod cap
difference: 0~0.05 mm and bolt by hand.
3.9.3 If the diameter difference is beyond the 3.10.11 Tighten the connecting rod bolt to 9.8
tolerance zone, replace the connecting rod Nm.
bolt.
3.10.12 Tighten the connecting rod bolt to 90°
3.10 Installation of Crankshaft corner.
3.10.1 Inspect the clearance of the connecting 3.10.13 Install the crankshaft rear seal. Apply
rod bearing with a plastic clearance gauge. grease on the inner groove of the oil seal
before installing and then install the oil seal
3.10.2 Inspect the clearance of the main on the crankshaft.
53
3.10.14 Measure the distance between the flange of the main bearing cap bolts.
crankshaft and the oil seal.
3.10.21 Tighten the bearing cap bolts to 25 Nm
Mounting height of oil seal: 7 mm~8 mm in the order shown in the illustration.
3.10.22 Tighten the main bearing cap bolt to

40°corner.
3.10.23 Remove redundant flange sealant on

the cylinder block.
3.10.15 Install the main bearing cap and be 3.10.24 Install the dowel pin (A) and a new
aware of the marker's orientation. O-ring (B) on the oil pump (C), then align
the inner rotor with the crankshaft and
3.10.16 Remove the old flange sealant on the install the oil pump.
mating surface of the main bearing cap's
rear end.
3.10.17 Clean and dry the mating surface of

the main bearing cap's rear end.
3.10.18 Apply 3 mm width flange sealant along

the dotted lines.
Note: The parts should be installed within

install the parts.
3.10.25 Install the oil collector (D) with a new

washer (E).
3.10.26 Install the cylinder head.
3.10.27 Install the timing chain.

3.10.19 Place the main bearing cap on the
cylinder block. 3.10.28 Install the transmission.
3.10.20 Apply engine oil on the thread and 3.10.29 Install the engine.
54
Note: If the crankshaft or connecting rod

bearing shell is replaced, run the engine at
idle speed after reassembling until it
reaches normal operating temperature and
then run it for about 15 minutes.
3.11 Installation of Oil Sump
3.11.1 Remove the old flange sealant on the

oil sump's mating surface, bolt and bolt
hole.
3.11.2 Clean and dry the mating surface of the 3.11.5 Install oil sump A using dowel pin B and
oil sump and the cylinder block. a new O-ring.
3.11.3 Install a new crescent seal on the oil

sump.
3.11.4 Apply specialized flange sealant on the

oil sump's mating surface with the cylinder
block and the inner wall of the bolt hole.
3.11.6 Tighten bolts in 2 to 3 steps
Note: Apply 2 mm-3 mm width flange
sealant along the dotted line A in the Tightening torque: (refer to markers in the
following illustration. following illustration)
Apply 5.0 mm width flange sealant on the Marked as A: 25 Nm

shaded area B in the illustration.
Marked as B: 12 Nm
The parts should be installed within 4
minutes after the flange sealant is applied
on them. If not, clean the old residue,
reapply the flange sealant and install the
parts.
55
3.11.7 Install the clutch baffle and then tighten

the 2 bolts for fixing the transmission.
Tightening torque for each bolt is shown in
the illustration.
10 Nm
10. Nm
3.11.9 Wait for at least 30 minutes after

installation and then fill the engine oil.
3.11.8 Install dipstick tube (A) using a new

O-ring (B).Tightening torque shown in the
illustration.
56
Part 2 Lubricating System
1.1 Inspection of Oil Pressure Switch
1.1.1 Remove the oil pressure switch

connector (A) on the engine oil pressure
switch (B).
1.1.2 Inspect the continuity between the

positive terminal (C) and the engine
57
(grounding). The circuit should be Min. 340 kPa

continuous when the engine stops; the
circuit is open when the engine runs. 1.2.4 If the oil pressure is not within the range,
check the following items:
1.1.3 If the on-off action of the oil pressure
switch is abnormal, check the oil level; if Check the oil collector for blocking
the oil level is normal, check the oil
pressure; if the oil pressure is normal, Check the oil pump
replace the oil pressure switch.
1.3 Replacement of Engine Oil
1.2 Oil Pressure Test
1.3.1 Warm up the engine.
If the oil pressure warning light remains
ON when the engine is running, check the 1.3.2 Remove the drain bolt (A) and drain the
oil level; if the oil level is normal: engine oil.
1.2.1 Remove the oil pressure switch and

connect the oil pressure gauge and oil
pressure switch mounting hole together
using a specialized connector.
1.3.3 Reinstall the drain bolt using a new

washer (B).
1.3.4 Refill with new engine oil.
When replacing: 2.9 L;
When replacing (including oil filter): 3.3 L;

1.2.2 If the oil pressure gauge doesn't display
oil pressure when the engine starts, turn The engine is overhauled: 4.0 L.
the engine off. Troubleshoot before going
to the next step. 1.3.5 Keep the engine running for over 3
minutes and then check for oil leakage.
1.2.3 When the engine reaches the operating
temperature (the fan starts twice at least), 1.4 Replacement of Engine Oil Filter
the oil pressure should be:
1.4.1 Remove the oil filter using a wrench for
Oil temperature: 80°C oil filter removal.
Oil pressure:
1.4.2 Inspect the thread (A) and rubber seal (B)
Idle speed: Min.70 kPa; of the new oil filter, clean the oil sump base
and apply a thin layer of engine oil on the
When the engine runs at 3000r/min; rubber seal of the oil filter. Be sure to use
the oil filter with a built-in bypass system.
58
1.5.3 Tighten the oil filter screwed tube on the

oil sump to 20 Nm and then remove the oil
filter screwed tube nut.
1.4.3 Install the oil filter by hand.
1.4.4 Tighten the oil filter clockwise using SST

after the rubber seal is installed in place.
Tightening: 3/4 circle to 1 circle clockwise.
Tightening Torque: 12 Nm
1.4.5 After installation, fill the engine with

engine oil to the oil level required, keep the
engine running for over 3 minutes and then
check for oil leakage.
1.5 Replacing Screwed Tube of Oil

Filter
1.5.1 Remove the oil filter.
1.5.2 Install 2 M20×1.5 mm bolts (A) on the

new oil filter screwed tube. Hold the nut
using a wrench and then tighten the nut.
59
1.6 Overhaul of Oil Pump

Breakdown drawing
Removal Radial clearance between the internal

rotor and the external rotor:
a Remove the timing chain.
b Remove the oil collector (A) and then Standard: 0.075 to 0.15 mm
remove the oil pump (B). Overhaul limit: 0.18 mm
Inspection
a Remove the oil pump cap
b Inspect the radial clearance of the internal
rotor (A) and the external rotor (B).
If the radial clearance is beyond the

overhaul limit, the oil pump should be
replaced.
60
Overhaul limit: 0.18 mm.

c Inspect the radial clearance of the rotor (A)
and the pump housing (B). If the radial
clearance of the housing and the rotor is
beyond the overhaul limit, the oil pump
should be replaced.
Radial clearance of the pump housing and

the rotor:
e Check the internal rotor, external rotor and

the pump housing for scratch or other
damage, replace it if necessary.
f Install the oil pump cap.
Installation
Standard: 0.028~0.065 mm.
a Install the dowel pin (A) and a new O-ring
Overhaul limit: 0.085 mm. on the oil pump (C).
Then align the internal rotor and the

crankshaft and install the oil pump.
b Install the oil collector (D) using a new

washer (E).
c Install the timing chain.
d Inspect the radial clearance of the external

rotor (A) and the pump housing (B). If the
radial clearance of the housing and the
external rotor is beyond the overhaul limit,
the oil pump should be replaced.
Radial clearance between the pump

housing and the external rotor:
Standard: 0.06~0.136 mm.
61
1.7 Installation of Labyrinth Gland
1.7.1 Clean and dry the labyrinth gland's

mating surface, bolts and bolt holes. 1.8 Replacement of Oil Pressure
Switch
1.7.2 Apply 2 mm~3 mm width flange sealant
along the dotted line (A). 1.8.1 Disconnect the oil pressure switch
connector (A) and then remove the oil
Note: The parts should be installed within pressure switch (B).
15 Nm
install the parts.
1.8.2 Apply anaerobic adhesive on the

threaded part of the oil pressure switch,
then install the oil pressure switch and the
tightening torque is 15 Nm.
1.7.3 Install the labyrinth gland.
6×1.0 mm
12 Nm
62
Part 3 Intake Manifold and Exhaust System

1.1 Removal and Installation of Intake Manifold
Removal 1.1.10.2 Install the intake manifold bracket.

1.1.1 Remove the intake manifold cover.
1.1.10.3 If the inlet and outlet hoses of the
1.1.2 Remove the air cleaner. throttle body have been removed, they
must be installed in place.
1.1.3 Remove the breather pipe (A), brake
booster vacuum hose (B) and the positive 1.1.10.4 If the throttle body has been removed,
crankcase ventilation (PCV) hose (C)). install it in place using a new throttle valve
seal washer.
1.1.10.5 Install the charcoal canister control

valve connecting hose.
1.1.10.6 Install harness brackets and bolts.
1.1.10.7 Install the throttle valve wire and

adjust it.
1.1.10.8 Install the breather pipe, brake

booster vacuum hose and the positive
1.1.4 Remove the throttle wire. crankcase ventilation (PCV) hose.
1.1.5 Remove harness brackets and bolts. 1.1.10.9 Install the air cleaner.
1.1.6 Remove the charcoal canister control 1.1.10.10 Install the intake manifold cover.
valve connecting hose.
1.1.10.11 After installation, check whether all
1.1.7 Remove the throttle body when replacing guides, hoses and connectors are installed
the intake manifold. in place.
1.1.8 If the engine coolant has been drained, 1.1.10.12 If the engine coolant has been
remove the inlet and outlet hoses of the drained, refill the radiator with engine
throttle body. coolant. Open the heater valve when
refilling in order to bleed the air out of the
1.1.9 Remove the engine wire harness cooling system.
connectors and harness retainers and etc.
on the intake manifold.
1.1.10 Remove the intake manifold bracket Exhaust Manifold
and then remove the intake manifold.
1.2.1 Remove the exhaust manifold heat
Installation shield and the exhaust manifold bracket
and then remove the exhaust manifold.
1.1.10.1 Install the intake manifold with a new
intake manifold seal washer, tighten bolts 1.2.2 Install the exhaust manifold and tighten
and nuts in 2 to 3 steps in an intersectional bolts and nuts starting from the inside bolts
way starting from the inside bolts. The in 2 to 3 steps and in an intersectional way.
1.2.3 Install other parts in the reverse order of
removal.
63
Part 4 Engine Cooling System

Parts location
64
1.1 Inspection of Thermolator
If the thermolator turns on by itself in the

room temperature, replace the
thermolator.
Inspect the closed thermolator :
1.1.1 Hang the thermolator (A) in a container

with water and don't let the thermometer
(B) contact the bottom and inner wall of the
container.
1.2.3 Rotate the water pump pulley

anticlockwise and check whether the water
pump can turn freely.
1.2.4 Check the seal for leakage. It is normal

that the discharge orifice "leaks" a little.
1.1.2 Fill water, measure the temperature with

the thermometer and inspect the
temperature when the thermolator turns on
and is on.
1.1.3 Measure the lifting height when the 1.3 Replacement of Water Pump
thermolator is on.
Standard thermolator: 1.3.1 Remove the belt.
Lifting height: over 8.0 mm 1.3.2 Drain engine coolant.
Start to turn on: 76°C~80°C 1.3.3 Remove the water pump pulley.
Being on: 90°C 1.3.4 Remove the 5 bolts for tightening the
water pump and then remove the water
1.2 Inspection of Water Pump pump.
1.2.1 Remove the belt. 1.3.5 Inspect and clean the O-ring groove and
its mating surface with the cylinder block.
1.2.2 Remove the water pump pulley.
1.3.6 Install the water pump with a new O-ring
in the reverse order of removal.
1.3.7 Remove the overflowed engine coolant.

and open the heater valve when refilling in
order to bleed the air out of the cooling
system.
65
1.4 Replacement of Thermolator
Removal
1.4.1 Remove the thermolator cap (A) and

then remove the thermolator (B).
M6x 1.0 mm
10 Nm
4. Install the thermolator cap (D).

Installation Note: Refill the engine with coolant at least
30 minutes after installation.
1. Remove the used flange sealant on the
thermolator's mating surface, bolts and
bolt holes.
1.5 Replacement of Coolant
Temperature Sensor
2. Apply 2 mm~3 mm width flange sealant
along the dotted line (A). 1.5.1 Drain engine coolant.
1.5.2 Disconnect the coolant temperature

sensor connector and then remove the
coolant temperature sensor.
1.5.3 Install the coolant temperature sensor.
1.5.4 Remove the overflowed engine coolant.

3. Install the thermolator seal ring (A) on the and open the heater valve when refilling in
thermolator (B) and then install the order to bleed the air out of the cooling
thermolator with the pin (C) facing upward. system.
66
Part 5 Fuel and Exhaust System
Arrangement of Vacuum hoses:

BYD473QB Engine
Camshaft phase (CMP) sensor (EMS but

no such sensor in Delphi system)
The CMP sensor detects No.1 cylinder's

position and offers references for each
cylinder's injection successively.
BYD473QE Engine
Engine coolant temperature sensor (ECT)
The ECT sensor is a resistor varying with

the temperature (thermistor).The
PGM-FI System thermistor's resistance decreases when
the temperature of the engine coolant is
The Programmed Fuel Injection (PGM-FI) higher.
System is a multipoint sequential injection
system.
Crankshaft position (CKP) sensor
The CKP sensor detects engine speed and

makes sure of ignition timing and fuel
injection timing of each cylinder.
Idle Stepper Motor
67
The idle stepper motor (IMA) is a

carefully-chosen resistance device for
controlling the concentration of mixed gas
at idle speed.
System description:
Throttle body
Knock sensor
The knock control system can make the

knock lowest by adjusting the ignition
timing.
Positive Crankcase Ventilation (PCV)
System
The PCV valve inhales the piston's air

leakage into the intake manifold to avoid
releasing it into the atmosphere.
Throttle valve position (TP) sensor
The TP sensor is a potentiometer

connected to the throttle valve shaft. When
the throttle threshold varies, the sensor
changes the signal voltage to the Parts location of idle speed control system
ECM/PCM. TP sensor and the throttle
body must be replaced as a unit. Engine idle speed is controlled by the idle
stepper motor
a When the engine starts, keep the

solenoid valve on for a certain amount
of time. Increasing air quantity could
increase the idle speed.
68
quality of bypass air is controlled by

b When the temperature of the engine the temperature of the engine coolant.
coolant is low, open the solenoid valve
to achieve proper high idle speed. The
Parts location of the intake system d Pinch the PCV valve and intake manifold
slightly by the fingers or pliers at idle
The system supplies the engine with the speed and make sure a click sound occurs
air needed. When the air is inhaled into the from the PCV valve.
system, the resonance chamber in the
intake manifold can reduce noise. If no click sound is heard, check the PCV
valve retainer for cracks or damage. If the
retainer is ok, replace the PCV valve and
PCV system
c Check the connection parts of the PCV

valve (A) and hose (B) for leakage or
clamping stagnation.
69
Chapter 2 476ZQA Engine

Contents
Part 1 Engine .................................................................................................................................. 71

Section 1 Overview ................................................................................................................. 71
Section 2 Belt Driving Device.................................................................................................. 76
Section 3 Crankshaft Rear Oil Seal Component .................................................................... 78
Section 4 Timing Chain ........................................................................................................... 80
Section 5 Detection of the Sparkplug and Cylinder Compression Pressure .......................... 82
Section 6 Engine ..................................................................................................................... 84
Part 2 Lubrication System .............................................................................................................119
Section 1 Schematic Diagram of Engine Lubrication Circuit .................................................119
Section 2 Inspection of Oil Pressure..................................................................................... 120
Section 3 Engine Oil.............................................................................................................. 121
Section 4 Oil Sump ............................................................................................................... 122
Section 5 Oil Pump ............................................................................................................... 123
Part 3 Cooling System.................................................................................................................. 124
Section 1 Schematic Diagram of Engine Cooling System.................................................... 124
Section 2 Thermolator ........................................................................................................... 125
Section 3 Water Pump .......................................................................................................... 126
Part 4 Clutch ................................................................................................................................. 128
Section 1 Clutch Device ........................................................................................................ 128
Section 2 Flywheel ................................................................................................................ 131
70
Part 1 Engine
Section 1 Overview
The BYD476ZQA engine adopts the advanced technologies of exhaust gas turbocharging,
gasoline in-cylinder direct injection, hydraulic tappet, all-aluminum engine body, intake VVT,
etc., and has the characteristics of high power per liter, low fuel consumption, little noise, low
pollution, compact structure. The BYD476ZQA engine can operate at its optimum states in
various working conditions, and ensure the reliable safety, comfortable driving, best
economic efficiency and perfect environment-friendly performance of the loaded complete
vehicle.
1.1 Major Technical Parameters
1. The main specifications of BYD473QB/QE Engine are listed in the following table.
Parameters Model
BYD476ZQA
Items
Inline four-cylinder, water-cooled, dual-overhead camshaft,
Type 16-valve and 4-stroke electronically-controlled fuel injection
engine
Nominal power 113 KW (5200 r/min)
Maximum torque/rotating
240 N·m (1750 r/min-3500 r/min)
speed
Cylinder diameter × route 76.5 mm×81.4 mm
Engine displacement 1.497 L
Compression ratio 10:1
Valve structure Silent chain drive, dual-overhead camshaft, 16-valve
93# unleaded gasoline (GB17930-1999) or above used for
Type of fuel
vehicle
Mode of fuel supply Electronically-controlled direct fuel injection
Ignition sequence 1—3—4—2
Engine oil Special oil designated and approved by the Department
exhaust emission system Three-way catalytic converter
Supercharging Exhaust gas turbo-charging
Camshaft regulation Intake VVT
Cylinder block material Aluminum alloy
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2. Table of BYD476ZQA Engine Tightening Torque
Serial Tightened Parts/ Pieces/ Tightening

Bolt size
No. Components Set Torque (Nm)
20 Nm for the
first time
M11×1.5 internal
70 Nm for the
1 Cylinder head bolt dodecagonal lobular socket 10
second time
head bolt
90 ºrotation
angle
20 Nm for the
first time
M10×1.25 dodecagona
50 Nm for the
2 Main bearing cap bolt socket lobular socket flange 10
second time
bolt
90 ºrotation
angle
M8×1 dodecagonal lobular 30 Nm + 90 º
3 Connecting rod bolt 8
socket flange blot rotation angle
M10×1 internal dodecagonal 60 Nm + 90 º
4 Flywheel bolt 6
lobular socket head blot rotation angle
M14×1.5 dodecagonal 150 Nm + 180 º
5 Crank pulley bolt 1
lobular socket flange blot rotation angle
6 Sparkplug 4 25 Nm
7 Fuel pressure sensor M10×1 1 20 Nm
Fuel inlet fitting of the
8 M20×1.5 1 80 Nm
high-pressure fuel rail
Hex socket head blot M6×45 5 10 Nm + 90 º
9 Camshaft housing bolt
Hex socket head blot M6×65 10 rotation angle
M12×1.25-LH internal
50 Nm + 90 º
10 VVT component bolt dodecagonal lobular socket 1
rotation angle
flange blot
Exhaust camshaft 50 Nm + 90 º
11 M10×1.25 hex head bolt 1
sprocket rotation angle
M8 hex lobular socket
12 Oil pump sprocket 1 30 Nm
pan-head bolt
Exhaust manifold
13 M8 9 20 Nm
screw cap
Cylinder block
14 1 35 Nm
threaded plug I
Cylinder block 20 Nm
15 2
threaded plug II
Oil-return hole cover
16 M6×12 hex flange bolt 6 10 Nm
plate
Crankshaft rear oil
seal component
18 Cylinder block M14×1.5 1 35 Nm
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threaded plug
assembly
Fixing and supporting
plate assembly
Engine front lifting
hook
Engine rear lifting
hook
22 Exhaust manifold Stud 9 10 Nm
Camshaft rear end
cover
Intake fitting bolt M6 hex socket head cap
24 2 7 Nm
assembly screw
Three-way catalytic
25 6 20 Nm
converter screw nut
26 Intake manifold M8×35 hex socket head bolt 5 24 Nm
Exhaust manifold heat
shield
Semi-circular clamping Cross recessed pan-head
28 2 7 Nm
block tapping screw 63
Oil drain plug
29 1 25 Nm
assembly
30 Oil sump M6×20 hex flange bolt 20 10 Nm
31 Oil rule conduit tube M6×12 hex flange bolt 1 10 Nm
32 Oil collector M6×20 hex socket head bolt 2 10 Nm
33 Oil pump M8×50 hex flange bolt 3 24 Nm
M8×20 hex lobular socket
34 Oil cooler 5 24 Nm
head blot
Oil cooler water tube M6×20 hex socket head bolt 1 10 Nm
35
assembly M8×16 hex socket head bolt 1 24 Nm
PCV four-way
36 M6×20 hex socket head bolt 1 10 Nm
component
PCV breather tube
assembly I
38 Chain tension plate M8 chain plate fixing stud 1 20 Nm
39 Chain guide plate M8 chain plate fixing stud 3 20 Nm
Threaded tube for
40 1 35 Nm
mounting the oil filter
41 Oil filter 1 15 Nm
42 OCV valve M5×12 hex flange bolt 1 5 Nm
M8×50 hex flange bolt 7 24 Nm
43 Timing cover M8×20 hex flange bolt 3 24 Nm
Stud 1 10 Nm
44 Gas-oil separation M5×16 hex flange bolt 5 5 Nm
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device
Tension pulley
assembly
Hollow bolt M12×1.5 1 35 Nm
Supercharger oil inlet
46 Hollow bolt M10×1 1 30 Nm
pipe component
Supercharger oil M6×12 hex socket head bolt 2 10 Nm
47
return pipe component M6×16 hex flange bolt 2 10 Nm
Supercharger water Hollow bolt M12×1.5 1 35 Nm
48
inlet pipe component M6×12 hex flange bolt 1 10 Nm
Supercharger water Hollow bolt M12×1.5 1 35 Nm
49
outlet pipe component M6×12 hex flange bolt 2 10 Nm
50 Supercharger stud 6 10 Nm
Supercharger heat
shield
Solenoid valve for
Cross recessed pan-head
52 limiting supercharged 2 5 Nm
tapping screw 55
pressure
Cross recessed pan-head
53 Intercooler 6 7 Nm
tapping screw 63
54 High-pressure fuel rail
Oil inlet tube Screw nut M14×1.5 2 17 Nm
55
component M6×16 hex flange bolt 1 10 Nm
High-pressure fuel
pump
57 Throttle valve screw 4 7 Nm
58 Dual pipe component M8×12 hex flange bolt 1 24 Nm
Water inlet pipe
assembly for the
electrically-driven
water pump
Thermolator
component
61 Water pump pulley M8×12 hex flange bolt 3 24 Nm
M8×40 hex lobular socket
62 Water pump 5 24 Nm
head bolt
Motor-driven water M8×16 hex flange bolt 1 24 Nm
63
pump support M10×16 hex flange bolt 1 44 Nm
Motor-driven water
pump
Camshaft phase
sensor
66 Knock sensor M8×30 hex flange bolt 1 20 Nm
Intake air temperature Cross recessed pan-head
67 4 5 Nm
and pressure sensor tapping screw 55
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68 Generator M8×90 hex flange bolt 2 24 Nm

69 Ignition coil M6×30 hex flange bolt 4 10 Nm
70 Chain tensioner M6×35 hex flange bolt 2 10 Nm
71 Oil pressure switch 1 18 Nm
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Section 2 Belt Driving Device

2.1 Driving Belt
2.1.1 Disassembly of the driving belt
Rotate the tension pulleys

counterclockwise with a tool to loosen the
belt, and then disassemble the driving belt.
Right Wrong
2.1.3 Assembly of the Belt
Rotate the tension pulleys

counterclockwise with a tool, assemble the
belt in a winding manner shown in Figure
1.1, and then slowly loosen the tension
pulley to tension the belt slowly.
2.2 Belt Pulley and Driven Accessories
2.2.1 Crankshaft belt pulley
Disassembly of the crankshaft belt pulley:

position the flywheel with a special tool,
screw off the crankshaft belt pulley bolts
Figure 1.1
and take off the crankshaft belt pulley;
2.1.2 Inspection and adjustment of the belt
Appearance inspection of the driving belt
2.1.2.1 Visually inspect its appearance, and

change the belt if the wear is severe.
2.1.2.2 Inspection of the tension capacity
As Figure 1.1 shows, inspect the tension Installation of the crankshaft belt pulley:
pulleys with a tool, and replace the belt if position the flywheel with a special tool,
the tension pulley is in its ultimate state. screw up the crankshaft belt pulley bolt
with the tightening torque of a 150 Nm +
2.1.2.3 Inspection of the belt assemble 180ºrotating angle.
conditions
2.2.2 Electric generator
Reinstall the belt if any error in the
following figure occurs. Disassembly of the electric generator:
hold the generator gently by hand, screw
off the fixing bolts of the generator and
remove the generator;
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Installation of the electric generator: aim 2.2.5 Air conditioner compressor and tension
the mounting holes on the generator at pulley
those on the timing cover, and make sure
the belt pulley is facing the front end of the Disassembly: Unscrew the mounting bolts
engine, then gently hold the generator and of the air conditioner compressor and
screw down bolts A and B as shown in the remove the AC compressor, then screw off
following figure with a tightening torque of the tension pulley mounting bolts and
24 Nm. remove the tension pulley, after that,
unfasten the tension pulley support
2.2.3 Idler pulley mounting bolts and remove the tension
pulley support;
Disassembly of the idler pulley: screw off Installation:
the idler pulley bolts and take down the
idler pulley; 2.2.5.1 Install the tension pulley support on the
Installation of the idler pulley: train on the cylinder block and screw up the bolts
mounting holes on the timing cover and
then screw up the idler pulley bolt. 2.2.5.2 Assemble the tension pulley into the
support seat hole from the front end,
Tightening torque: 44 Nm making sure the Dowel pin on the
tension pulley is well matched and
positioned with the pinhole inside the
support, and then screw up the
mounting bolts from the back end with
Idler pulley a tightening torque of 44 Nm.
bolt
Dowel pin
pinhole
2.2.4 Water pump belt pulley
Disassembly of the water pump belt pulley:

unscrew the bolts of the water pump belt
pulley, and remove the water pump belt
pulley; Note: The compress surfaces between all
belt pulleys and the bolts must be clean
Assembly of the water pump belt pulley: and free from grease and other impurities.
Closely attach the belt pulley to the
mounting surface of the water pump, then
rotate and aim at the mounting holes, and
screw down the bolts with a tightening
torque of 24 Nm.
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Section 3 Crankshaft Rear Oil Seal Component

3.1 Disassembly of the Crankshaft Rear Oil Seal Component
3.1.1 Make sure the flywheel and oil sump are

already taken off before disassembling the
crankshaft rear oil seal component, making
sure the flywheel and oil sump are already
taken off;
Uniformly (1/2 circle maximum each time)

screw M6×35 bolts into three positions
pointed by the arrows in the right figure,
and then press out the crankshaft back end
cover component and the sensor wheel all
together.
Tightening torque: 30 Nm
3.2.2 Insert the Dowel pin on the positioning

tool into the pinhole of the signal wheel;
Pinhole
Dowel pin
3.2 Assembly of the Crankshaft Rear
Oil Seal Component
3.2.1 Screw the cylinder block threaded plug

components off the cylinder block, screw in
the crankshaft positioning tool, and fix the
crankshaft to the top dead centers of the
first and the fourth cylinders;
3.2.3 Fix the positioning tool and the crankshaft

rear oil seal component with three M6×20
bolts shown by arrows in the right figure;
Tightening torque: 3 Nm, and closely

attach the tool and crankshaft rear oil seal
component.
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Note: Clean the mounting surface of the

crankshaft with a piece of silk cloth before
installation, and do not apply any grease
on the surface;
The oil seal lip will be damaged if the seal

support ring, a protective tool for the oil
seal lip during transportation and assembly,
is removed early.
a= 0.5
3.2.4 As the figure shown, insert the dowel pin

into the threaded hole at the rear end of the
crankshaft, then screw up two hex socket
head bolts A to fix the positioning tool and
crankshaft rear oil seal component onto the
crankshaft;
Crankshaft Rotating
Speed Signal Wheel
3.2.6 Screw up the fixing bolts of the

crankshaft back end cover component
according to the sequence shown in the
figure.
Dowel pin
3.2.5 Carefully screw up the nuts shown in the

figure and take down the assembly tool.
Note: Check whether the dimensions

shown in the figure meet the requirement:
0.3 mm≤a≤0.7 mm
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Section 4 Timing Chain

4.1 Disassembly of the Timing Chain
4.1.1 Rotate the crankshaft clockwise to the shown in the figure, and lock the tensioner
adjacency of the top dead centers of the with a lock pin;
first and the fourth cylinders, and then
revolve the crankshaft 45 º. Then screw the
cylinder block threaded plug component off
the cylinder block, screw in the crankshaft
positioning tool, and rotate clockwise to fix
the crankshaft to the top dead centers of
the first and the fourth cylinders.
Positioning
Tool
Lock Pin
4.1.4 Disassemble the timing chain and other

accessories.
4.2 Assembly of the Timing Chain

4.1.2 Position the exhaust camshaft sprocket
4.2.1 Locate the crankshaft on top dead
and the chain tension with the positioning
centers of the first and the fourth cylinders
tool, and then unscrew the exhaust
with the crankshaft positioning tool. For
camshaft sprocket bolt as well as the VVT
details, refer to the first item in the
component bolt (left-handed thread);
disassembly of the timing chain;
4.2.2 Before the installation of the camshaft

housing, it is necessary to position the
camshaft to the top dead center for
compression of the first cylinder with the
camshaft positioning tool;
Positioning
Tool
4.1.3 Press the plunger towards the A direction
80
contacting with the chain. Install the chain

tensioner and apply a proper amount of oil
to the friction surface. Pull out the tensioner
lock pin (pointed out by the arrow) and
tension the chain;
4.2.3 Assemble the exhaust camshaft sprocket

onto the exhaust camshaft, screw the
exhaust sprocket bolt in the position 2mm
away from the abutted surface, keep the
sprocket rotating freely and prevent it from
falling off;
Assemble the VVT component onto the 4.2.5 Keep the camshaft at the top dead center
intake camshaft, screw the VVT of cylinder 1 and fix the exhaust camshaft
component bolt in the position 2mm away sprocket with the special tool shown in the
from the abutted surface, keep the figure. Then tighten the bolts of the VVT
sprocket rotating freely and prevent it from components and exhaust camshaft
falling off; sprocket to the specified torque.
Hang the timing chain guide plate in place, Tightening torque: 50 Nm+90ºrotating
and apply a proper amount of lubricating oil angle
to the part contacting with the chain. Hang
the timing chain onto the exhaust camshaft
sprocket, the VVT component sprocket and
the crankshaft sprocket with the guide
plate;
Positioning
Tool
Disassemble the special tool at the top

dead center of the camshaft and install the
camshaft back end cover. Protect the seal
ring of the camshaft back end cover.
Tighten the bolts to the specified torque.
Remove the camshaft positioning tool and

4.2.4 Hang the tensioning chain plate in place assemble the cylinder block threaded plug
and apply a proper amount of oil to the part component back to the original position
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Section 5 Detection of the Sparkplug and Cylinder Compression Pressure

The oil temperature shall be at least 30 º;
5.1 Disassembly and Assembly of the Sparkplug
Disconnect the ignition coil plug, screw off

four mounting bolts and remove the ignition coil;
Remove the sparkplug with the special wrench;

The installation is in the reverse order of the removal. The tightening toque of the sparkplug is
25 Nm, and the tightening torque of the mounting bolts of the ignition coil is 10 Nm.
5.2.2.5 Go onto the following steps if

5.2 Inspection of the Sparkplug dampness is found on the sparkplug.
5.2.1 As shown in the figure, measure the

electrical resistance with an ohmmeter and
check whether the resistance is greater
than 10 MΩ.
Go on to the fifth step if the resistance is

lower than 10 MΩ.
Ohmmeter
5.2.2.6 Check if there is any damage on

the threaded or insulated parts of the
sparkplug,
Ground 5.2.2.7 If any, change the sparkplug;

Connection
5.2.2.8 Check the sparkplug electrode gap;

5.2.2 Inspect the sparkplug with the simple
method below if an ohmmeter is not The range of the sparkplug electrode gap is
available. 1.0-1.2 mm.
5.2.2.1 Quickly speed the revolution of the Note: If the gap of a new sparkplug electrode
engine to 4000 r/min and leave at this needs adjusting, only the root part of the lateral
speed for five minutes; electrode can be adjusted rather than the head;
the adjustment of a used sparkplug is not
5.2.2.2 Remove the sparkplug; permitted.
5.2.2.3 Observe the sparkplug electrode;
5.3 Inspection of Compression Pressure
5.2.2.4 It shows the sparkplug is normal if
Pull out the plug from the fuel pump control
dryness on the electrode is detected;
unit before the inspection
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5.3.1 Heat the engine to the normal operating

temperature and then flame out; 5.3.5.5 Measure the compression pressure
of the cylinder;
5.3.2 Remove the connection plug of the
ignition coil of the first cylinder; 5.3.6 Take away the pressure gauge and install
the sparkplug with a tightening torque of 25
5.3.3 Remove the ignition coil of the first Nm;
cylinder;
5.3.7 Assemble the ignition coil;
5.3.4 Loosen the sparkplug of the first cylinder;
5.3.8 Connect connecting plug of the ignition
5.3.5 Check the compression pressure of the coil;
first cylinder;
Note: Following the steps of 2-7 and
5.3.5.1 Internally connect a pressure sequentially measure the compression
gauge to the sparkplug hole of the first pressure of the second and the third
cylinder; cylinders;
5.3.5.2 Ignite to run the engine; The measurement should be completed as

soon as possible.
5.3.5.3 Record the maximum reading
figure of the pressure gauge; If the compression pressure increases after
the oil is dropped, the piston, the piston
Item Compression ring or the cylinder wall may be worn and
Pressure MPa an overhaul is required;
(≥400r/min)
Standard Value 1.0-1.5 MPa If the compression pressure remains low, it
Maximum Limit of ≤0.3 MPa indicates the valve may be stuck or the
Pressure Difference sealing surfaces do not contact tightly, and
among Cylinders an overhaul is required; and if pressure of
adjacent cylinders is low, it indicates the
5.3.5.4 When the pressure inside the air cylinder head gasket may be damaged or
cylinder is too low or the pressure the cylinder head is deformed, thus an
difference among the cylinders greatly overhaul is required.
exceed the maximum limit, put a few
drops of oil into the cylinders through
the sparkplug hole and measure the
compression pressure of the cylinders
again.
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Section 6 Engine
6.1 Disassembly of the Engine
6.1.1 Disassembly of the driving belt

6.1.3.2 Take off the water pump and the water
See P4 for counterclockwise rotation of the pump gaskets.
tension pulley.
6.1.2 Disassembly of the front end pulley train
6.1.4 Disassemble the crankcase ventilation

device
6.1.4.1 Screw off the fixing bolt A, and remove

6.1.2.1 Screw off the mounting bolts of the idler the PCV breather tube assembly I;
pulley, and take down the idler pulley;
6.1.4.2 Screw off the fixing bolt B of the PCV
6.1.2.2 Screw off the engine mounting bolts, four-way component;
and take down the engine;
6.1.4.3 Remove the PCV breather tube
6.1.2.3 Secure the water pump pulley with a assembly II from the connector of the
pulley fixing tool, remove the mounting intake manifold;
bolts and take off the water pump pulley;
6.1.4.4 Pull out the four-way component from
the rubber sleeve of the intake fitting;
6.1.2.4 Screw off four mounting bolts of the air
conditioner compressor, and remove the 6.1.4.5 Pull out the camshaft housing
air conditioner compressor; connection hose and the one-way check
valve from the camshaft housing
6.1.2.5 Position the flywheel with a special tool connector;
and screw off the crankshaft belt pulley bolt
component. 6.1.4.6 And take off the camshaft housing
ventilation device.
6.1.3 Disassemble the water pump
6.1.3.1 Screw off five mounting bolts of the

water pump;
84
6.1.6.1 Screw off the tapping screw that fixes

the semi-circular clamping block, and then
remove the semi-circular clamping block;
6.1.6.2 Carefully unfasten the main intake pipe

from the throttle valve clamping seat and
then remove it.
6.1.5 Disassemble the fuel evaporate emission

control system
6.1.5.1 Pull out the charcoal canister vacuum

pipe component from the PCV four-way
component; 6.1.7 Disassemble the throttle valve
6.1.5.2 Take off the charcoal canister vacuum Screw off four throttle valve fixing bolts,
pipe component from the intake manifold; and then remove the throttle valve.
6.1.5.3 And then remove the charcoal canister Throttle Valve Mounting Screws
vacuum pipe component, charcoal canister
connection hose, and charcoal canister
control valve.
One-way Valve
6.1.8 Disassemble the intake manifold
6.1.8.1 Pinch off the clamp and pull out the

water inlet hose of the intercooler from the
intercooler water inlet;
6.1.8.2 Screw off five bolts for mounting the

Camshaft Housing Connection Hose intake manifold, and remove the intake
manifold.
6.1.6 Disassemble the main intake pipe
85
6.1.11.1 Screw off the fixing bolts and remove

the supercharger heat shield;
6.1.11.2 Screw off the fixing bolts and take off

the exhaust manifold heat shield.
6.1.9 Disassemble the oil inlet tube component
6.1.9.1 Screw off the support plate fixing bolts;
6.1.9.2 Screw off two union nuts, then take off

the oil inlet tube component.
Note: The oil inlet tube component must be 6.1.12 Disassemble the supercharger water
placed in a clean and dust-free sealed bag, outlet tube assembly
and the connection between the
high-pressure fuel pump and the fuel inlet 6.1.12.1 Screw off two support plate fixing
of the high-pressure fuel rail must be bolts;
sealed immediately with a clean cover.
6.1.12.2 Screw off the hollow bolts and remove
the pipe assembly.
Note: Two gaskets are required to be

replaced.
6.1.13 Disassemble the supercharger oil inlet

pipe component
6.1.13.1 Screw off the support plate fixing

bolts;
6.1.13.2 Screw off two hollow bolts, and

remove the pipe component.

replaced.
6.1.10 Disassemble the high-pressure fuel rail
6.1.14 Disassemble the supercharger water
6.1.10.1 Slowly screw off the five mounting inlet tube assembly
bolts of the high-pressure fuel rail;
6.1.14.1 Pinch off the clamp connected
6.1.10.2 Hold the high-pressure fuel rail with between the supercharger water inlet tube
both hands and remove it along the and the supercharger water inlet hose;
direction of the fuel injector.
6.1.11 Disassemble the heat shield
86
6.1.14.2 Screw off the support plate fixing

bolts;
6.1.14.3 Screw off the hollow bolts and remove

the pipe assembly.

replaced.
Note: The removed pipe should be placed

in a sealed and clean condition, and no
impurities are allowed in all connectors of
the supercharger pipes.
6.1.16 Disassemble the exhaust manifold
6.1.16.1 Screw off nine exhaust manifold

screw caps;
6.1.16.2 Remove the fixed plate I and II;
6.1.16.3 Slightly and vertically knock the

exhaust manifold with a rubber mallet in an
alternating way, until the exhaust manifold
is completely separated from the cylinder
block, and then slowly remove the exhaust
manifold.
6.1.15 Disassemble the supercharger and the

supercharger oil return pipe component
6.1.15.1 Screw off the two bolts connecting the

supercharger oil return pipe and the
cylinder block;
6.1.15.2 Screw off the three nuts connecting

between the supercharger and the exhaust
manifold;
6.1.15.3 Remove the supercharger and the

supercharger oil return pipe component.
6.1.17 Disassemble the water inlet pipe of the

motor-driven water pump
6.1.17.1 Screw off the bolts connected among

the water inlet pipe of the water pump, oil
sump and cylinder block;
87
6.1.17.2 Remove the water inlet pipe of the

motor-driven water pump.
6.1.20 Remove the timing chain
See P8 for details.
6.1.21 Remove the oil pump chain and the

tensioning plate
6.1.21.1 Remove the oil pump hood;

6.1.18 Remove the oil sump
6.1.21.2 As shown in the right figure, carefully
6.1.18.1 Unscrew twenty oil sump bolts; tighten the tensioning plate spring of the oil
pump chain to separate it from the stud,
6.1.18.2 Gently tap the oil sump downward then unscrew the tensioning plate stud A
with a rubber mallet to separate the contact and slowly loosen the spring to make the
surface of the oil sump and the cylinder chain loose;
block, and then remove the oil sump.
6.1.21.3 Unscrew the tensioning plate pin roll B
of the oil pump chain, and then remove the
chain tensioning plate and the tensioning
plate spring;
6.1.19 Remove the timing cover
6.1.19.1 As shown in the right figure, unscrew

the mounting bolts and nuts of the timing
cover;
6.1.19.2 Slightly tap the timing cover with a

rubber mallet to loosen it, and then 6.1.21.4 Position the oil pump sprocket with a
carefully pry the timing cover out from the special tool and carefully unscrew the oil
contact surface of the cylinder block, pump sprocket bolt;
cylinder head, camshaft housing and
timing cover with a slot type screwdriver.
88
6.1.21.5 Remove the oil pump sprocket,

crankshaft sprocket and oil pump chain. 6.1.24 Remove the camshaft housing and the
camshaft
6.1.22 Remove the high-pressure fuel pump
6.1.24.1 Unscrew the camshaft housing bolts
6.1.22.1 Unscrew two fixing bolts of the evenly in the order as shown in the figure
high-pressure fuel pump; 15-1;
6.1.22.2 Remove the high-pressure fuel pump 6.1.24.2 Remove the camshaft housing.
and the roller tappet.
Note: Please do not damage the O-ring
Roller Tappet
Check that the axial clearance of the

camshaft is 0.5 mm or less.
6.1.23 Remove the dual pipe component
6.1.23.1 Pinch off the clamp between the oil

cooler water outlet hose and the oil cooler
water pipe assembly, and the clamp
between the dual pipe component and the
supercharger water inlet hose;
6.1.23.2 Screw off the fixing bolts of the dual

pipe component and remove the dual pipe
component.
89
6.1.25 Remove the thermolator components

and the inlet pipe of water pump
6.1.25.1 Unscrew 4 mounting bolts of the

thermolator components;
6.1.25.2 Slowly pull out the inlet pipe of water

pump from the cylinder block. Do not
damage the O-rings. Then remove the
thermolator components and the inlet pipe
of water pump.
6.1.27.2 Remove the cylinder head and

cylinder head gaskets.
6.1.28 Remove the valve
6.1.28.1 Remove the valve collet, valve spring

upper seat and valve spring with the
special tools;
6.1.26 Remove the roller rocker arm and the Note: Place the removed valve collet, valve
hydraulic tappet spring upper seat and valve spring in the
cylinder order as well as intake and
6.1.26.1 Carefully take out the hydraulic tappet exhaust sequence.
and roller rocker arm.
Note: Place them in a clean and sealed

condition in the cylinder order as well as
intake and exhaust sequence
6.1.27 Remove the cylinder head Special Tool
6.1.27.1 Slowly and uniformly loosen and

6.1.28.2 Remove the valves
screw off the cylinder head bolts in the
order as shown in the figure 1-8, and then
remove the bolts and gaskets;
90
Note: Place the removed valves in the

cylinder order as well as intake and
exhaust sequence.
6.1.28.3 Remove the valve oil seal with needle

nose pliers.
6.1.29 Remove the motor-driven water pump
6.1.29.1 Unscrew two fixing bolts of the

motor-driven water pump support;
6.1.29.2 Remove the motor-driven water pump

support, motor-driven water pump,
three-way valves and related hoses.
6.1.31 Remove the oil cooler
6.1.31.1 Unscrew the fixing bolts of the oil

cooler water pipe assembly;
6.1.31.2 Unscrew five mounting bolts of the oil

cooler;
6.1.31.3 Remove the oil cooler, water pipe

assembly and gaskets.
6.1.30 Remove the tension pulley support
6.1.30.1 Unscrew three mounting bolts of the

tension pulley support;
6.1.30.2 Remove the tension pulley support.
6.1.32 Remove the labyrinth gland
Unscrew six bolts and remove the labyrinth

gland.
6.1.33 Remove the flywheel
6.1.33.1 Position the flywheel with a special

tool, and uniformly unscrew six flywheel
91
bolts;
6.1.33.2 Remove the flywheel and the clutch

baffle.
6.1.35.2 Carefully clean the connecting rod

bearing shell and journal;
6.1 34 Remove the crankshaft rear oil seal

component
See P6 for details.
6.1.35.3 Put a plastigauge on the connecting

rod journal;
6.1.35.4 Apply oil on the threads of the

connecting rod bolt and bearing shoulder,
and then install the connecting rod cap.
Screw in the bolts with a tightening torque
of 30 Nm.
Plastigauge
6.1.35 Inspect the connecting rod big end oil
film clearance
6.1.35.1 Unscrew two connecting rod bolts,

and then remove the connecting rod cap
and bearing shell;
6.1.35.5 Unscrew two connecting rod bolts,

and then remove the connecting rod cap
and lower bearing shell;
92
6.1.35.6 Measure the oil film clearance at the turns.

widest part of the plastigauge;
Standard oil film clearance: 0.02-0.06 mm

Maximum oil film clearance: 0.09 mm
Note: Do not turn the crankshaft when

measuring the oil film clearance;
The plastigauge must be completely
removed after measurement.
Assemble the removed connecting rod and

bearing shell;
Place the assembled piston connecting rod

assemblies in order depending on the
Replace the connecting rod bearing shell if cylinders;
the measured value is greater than the
maximum oil film clearance; 6.1.37 Measure the crankshaft end clearance
Replace the crankshaft if the measured Pry the crankshaft back and forth with a
value is still greater than the maximum oil screwdriver, and then measure the
film clearance after the bearing shell is crankshaft end clearance with a feeler
replaced. gauge.
Standard clearance: 0.07-0.18 mm,
6.1.35.7 Use the same method to measure the
oil film of other three connecting rods. Wear limit: 0.38 mm;
6.1.36 Remove the connecting rod Replace the thrust plate if the measured
value is greater than the maximum
Note: The connecting rod must be clearance;
replaced as a unit;
Replace the crankshaft if the measured
6.1.36.1 Screw off the connecting rod bolts, value is still greater than the maximum
and remove the connecting rod caps; clearance after the thrust plate is replaced.
6.1.36.2 Push the piston connecting rod

assembly and the upper connecting rod
bearing shell through the cylinder bore,
and then take them off from the top surface
of the cylinder block;
Note: Do not damage the surface of the

upper connecting rod bearing shell
6.1.36.3 Remove the piston connecting rod

assembly from the other three cylinders in
93
back and forth along the axis to loosen and

remove it.
6.1.38 Measure the oil film clearance of main 6.1.38.2 Clean the internal surface of main
journal bearing shell, the main bearing cap, the
main journal and the crankshaft;
Note: Do not turn the crankshaft during
measurement
6.1.38.1 Unscrew the main bearing cap bolts,

and then remove five main bearing caps;
6.1.38.3 Put a plastigauge on the crankshaft

main journal;
Plastigauge
Note: Loosen the main bearing cap bolts in

2 - 3 steps in the order as shown;
Remove and arrange the main bearing

caps and main bearing cap bolts in the
original order.
If it is difficult to remove the main bearing 6.1.38.4 Install the main bearing caps and
cap, lightly tap it back and forth with a screw in the bolts. Tighten the bolts in 2 – 3
rubber mallet to loosen it; steps in the order from 1 to 10 as shown to
a tightening torque of 50 Nm.
Hold the bolt with both hands as shown in
the figure, and shake the main bearing cap
94
Replace the crankshaft if the measured

value is still greater than the maximum
clearance after the main bearing shell is
replaced.
6.1.39 Remove the oil cooling nozzles
Unscrew the oil cooling nozzle bolts, and

remove the oil cooling nozzles in turns.
6.1.38.5 Unscrew the main bearing cap bolts of

1st gear, and remove the main bearing
caps and the main bearing shells;
6.1.38.6 Measure the oil film clearance at the

widest part of the plastigauge;
New oil film clearance: 0.03-0.18 mm
Wear limit: 0.20 mm 6.1.40 Remove the fixing and supporting plate
assembly
Note: The plastigauge must be completely
removed from the bearing journal after the Unscrew the fixing bolts, and remove the
measurement fixing and supporting plate assembly.
Fixing and Supporting

Replace the main bearing shell in the same Plate Assembly
set if the measured value is greater than
the maximum clearance;
Main Bearing Main Bearing Clearance 6.1.41 Remove the piston ring
Hole (Set No.) Shell (Set No.)
A A 0.024~ Remove the first air ring, second air ring
0.059 mm and the steel strip combination oil ring with
the piston ring expander.
B B 0.024~
0.059 mm
95
6.1.42 Remove the piston pin
6.1.42.1 Remove the wire ring for holes on one Note: Do not scratch the sealing surfaces
side from the notch with spring pliers; when removing the sealant.
6.1.42.2 Push the piston pin out of the other 6.2.3 Inspect the timing chain and oil pump
side carefully. chain
Inspect whether the timing chain and oil

pump chain are excessively worn or
cracked. If any, change the chain, and
detect the corresponding sprocket.
Note: Place the removed piston, piston ring,

piston pin, connecting rod and connecting
rod bearing shell in the cylinder order
6.2 Inspection of Engine

6.2.4 Inspect the VVT components and
6.2.1 Remove the residual sealant on the exhaust camshaft sprocket
sealing surfaces of the oil sump and
cylinder block with a scraper; Inspect whether the sprocket is worn or
damaged. If any, replace the camshaft
6.2.2 Remove the residual sealant on the sprocket.
sealing surfaces of the camshaft housing
and cylinder head with a scraper;
96
0.5 mm
6.2.7 Inspect the camshaft housing

6.2.5 Inspect the crankshaft sprocket
Carefully clean the intake and exhaust
Inspect whether the crankshaft is worn or camshaft holes of first, second and third
damaged. If any, replace the crankshaft gears
sprocket.
6.2.8 Inspect the camshaft
6.2 8.1 Inspect the axial clearance of the

camshaft:
6.2.6 Inspect the chain guide plate and chain a Install the camshaft on the camshaft
tensioning plate housing;
Inspect the wear degree of the chain guide b Slightly move the camshaft back and forth,
plate and chain tensioning plate, and and measure the axial clearance with a dial
replace the plates if the wear is greater gauge.
than 0.5 mm.
New axial clearance: 0.1-0.3 mm;
Wear limit: 0.5 mm.
Replace the camshaft housing if the

measured axial clearance exceeds the
wear limit;
97
Replace the camshaft if the camshaft thrust

surface is worn.
6.2.11 Repair the valve seat ring
6.2.11.1 Repair the valve seat ring again with a

45°reamer to make the width of the
sealing surface of the seat ring meet the
requirements;
6.2 9 Clean the valve
Note: Confirm the central position of the
Clean the carbon deposit on the valve with valve seat ring before repairing. Gradually
a brush. reduce the reamer force during repairing to
avoid damage to the surface quality of the
Note: Wear the protective glasses during seat ring sealing surface.
operation.
6.2.11.2 Inspect the assembly position of each

6.2.10 Inspect the valve spring valve, and repair the sealing surfaces of
the valve seat ring with a 45°reamer to
6.2.10.1 Inspect the verticality of the valve center the valve sealing surface on the
spring with the square and feeler gauge as seat ring sealing surface;
shown in the figure;
Width of the sealing tape: 1.5-1.8 mm
Maximum clearance: 1.5 mm;
6.2.11.3 Repair the 45°sealing surface with the
Replace the valve spring if the measured 30°and 60°reamer. Make sure the valve
value is greater than the maximum and the seat ring are completely sealed
and the width of sealing surface meets the
clearance.
requirements;
98
6.2.11.4 Uniformly coat the lapping compound

on the surface of valve and valve seat by
hand.
6.2.14 Clean the piston
6.2.14.1 Clean the carbon deposit on the

piston with a used piston ring or equivalent;
Note: Wear the protective glasses during

operation.
Do not scratch the piston surface
6.2.14.2 Remove the carbon deposit from the

6.2.12 Clean the cylinder block piston with special solvent.
Clean the contact surfaces between the

cylinder block and the timing cover,
cylinder head, oil sump as well as oil return
hole cover plate with an adhesive stick or
equivalent.
Note: Wear the protective glasses during

operation. Do not scratch the surface of
cylinder block, and do not allow any
impurity to drop into the water jacket of the
cylinder block.
6.2.13 Inspect the flatness of cylinder block

6.2.15 Inspect the piston
surface
Measure the outside diameter of the piston
Inspect the flatness of the cylinder block
at the position which is perpendicular to the
upper surface with the straight edge and
piston pin hole and 10 mm above the
feeler gauge in the direction as shown in
piston bottom as shown in the figure;
the figure;
Standard size: 76.44 mm
Maximum flatness: 0.05 mm
Minimum size: maximum derivation 0.04
Repair limit: 0.10 mm
mm
Replace the cylinder block if the measured
Replace the piston if the measured value is
value is larger than the limit value.
lower than the minimum size.
99
6.2.16 Inspect the piston ring groove clearance
Insert a new piston ring into the piston ring 6.2.17.2 Measure the end gap of piston ring
groove, and inspect the clearance in the with a feeler gauge;
piston ring groove with a feeler gauge;
Standard End Gap
Standard Clearance (mm) First Air Ring 0.15-0.40 mm
Second Air Ring 0.40-0.60 mm
First Air Ring 0.065 ~ 0.095
Wear limit: 1.0 mm
Second Air
0.03 ~ 0.07 Replace the piston ring if the measured
Ring
value exceeds the maximum clearance;
Wear limit: 0.15 mm
Replace the cylinder block if the measured
Replace the piston if the measured value is still greater than the maximum
clearance is greater than the maximum clearance after the piston ring is replaced.
value.
6.2.17 Measure the end gap of piston ring 6.2.18 Inspect the crankshaft
6.2.17.1 Push a piston ring into the cylinder by 6.2.18.1 Measure the diameter of each main
45 mm with the piston, and then remove journal with a micrometer at the position as
the piston; shown in the right figure;
Size range: 53.963-53.978 mm;
If the measured value is not within the

range, inspect the oil film clearance of the
crankshaft.
100
6.3 Installation of Engine
6.3.1 Install the piston ring
6.3.1.1 Install the oil ring first;
6.3.1.2 Install the second and first air rings;
Note: Distinguish the cross section of the

first air ring from that of the second air ring;
the mark of the air ring should face the top
6.2.18.2 Measure the diameter of each of the piston;
connecting rod journal with a micrometer at
the position as shown in the figure below.
Standard size: 47.763-47.778 mm;

range, inspect the oil film clearance of the
connecting rod.
6.3.1.3 Adjust the opening direction of the

piston ring as shown in the figure
6.2.19 Inspect the crankshaft thrust plate
Measure the thickness of the crankshaft

thrust plate with a micrometer;
Standard thickness: 2.475-2.500 mm;

range, replace the crankshaft thrust plate.
6.3.2 Install the oil return hole cover plate
6.3.2.1 Clean the sealing surfaces of the oil

return hole cover plate and the cylinder
block;
101
6.3.2.2 Apply the sealant with the diameter of then tighten it;
Φ2.5-Φ3.5 mm on the position as shown in
the figure without breaking point; Tightening torque: 20 Nm
Note: After the sealant is coated, the part Oil Limiting Plug
must be installed within five minutes. If not,
remove the residual and apply the sealant
again.
6.3.3.3 Apply the pipe thread sealant on the

threaded plug I of the cylinder block and
install it on the cylinder block;
6.3.2.3 Tighten six bolts alternatively, and
install the oil return hole cover plate. Threaded plug I of
cylinder block
6.3.3 Install the oil cooling nozzle, oil limiting

plug and plug
6.3.3.1 Carefully clean the mounting surface of

the oil cooling nozzle, and tighten the bolts
with a tightening torque of 25 Nm.
6.3.4 Install the main bearing shell
6.3.4.1 Install the lower main bearing shell on

the main bearing cap;

bearing shell with a piece of silk cloth
before installation; Align the positioning lip
on the shell with the locked gap of the main
bearing cap;
6.3.3.2 Apply the pipe thread sealant on the

threaded plug II of the cylinder block and
102
6.3.5.2 Apply oil on the inner surface of the

upper main bearing shell, and then install
the crankshaft;
Locked Gap
Do not apply oil on the back of the bearing

shell and the mounting surface of the main
bearing cap. Oil Groove
6.3.4.2 Install the upper main bearing shell on 6.3.5.3 Apply oil on the lower main bearing
the main bearing support; shell, point the arrow on the main bearing
cap to the front of the engine, and install
Note: Clean the mounting surface of the the main bearing cap in the order of
bearing shell with a piece of silk cloth numerical markers from 1st to 5th gear.
before installation; Align the positioning lip
on the shell with the locked gap of the main
bearing support, and align the oil hole on
the shell with the oil hole of the main
bearing support;
6.3.5.4 Apply a little oil on the main bearing cap

bolts, and tighten the bolts in 3 steps in the
order from 10 to 1 as shown in the figure.
Step 1: 20 Nm
Do not apply oil on the back of the bearing
shell and the mounting surface of the main Step 2: 50 Nm
bearing support. The main bearing shell
should be selected and matched in groups. Step 3: 90 ºrotating angle (1/4 circle)
6.3.5 Install the crankshaft
6.3.5.1 Slide two thrust plates into the main

bearing support of third gear with the oil
groove on the thrust plate faces outward;
103
6.3.6.2 The connecting rod bearing shell on the

connecting rod cap;
6.3.5.5 Rotate the crankshaft after the
installation. The crankshaft should be Note: Clean the mounting surface of the
rotated freely without being stuck and the bearing shell with a piece of silk cloth
torque is 6 Nm or less. The axial play must before installation; do not apply oil on the
be within 0.04-0.19 mm after the crankshaft back of the bearing shell or the mounting
is assembled. surface of the connecting rod cap;
6.3.7 The connecting rod
6.3.7.1 Ensure the piston ring is installed

6.3.6 The connecting rod bearing shell correctly.
top compression ring
6.3.6.1 The connecting rod bearing shell on the scraper ring
connecting rod body;

bearing shell with a piece of silk cloth
before installation; Do not apply oil on the
back of the bearing shell or the mounting
surface of the connecting rod body; Align
the oil hole on the bearing shell with the oil
hole on the connecting rod body.
104
6.3.7. 4 On the lower connecting rod bearing

shell, make the 'BYD' mark face the front
end of the engine, and install the
connecting rod cap.
Note: Check that the threads of the

connecting rod bolts are not damaged;
Make sure 4 connecting rods are of the

6.3.7.2 l The friction surfaces shown in the same quality;
figure, and the other surfaces should be
clean and free of any impurity; Make sure the connecting rod body and the
connecting rod cap contact closely.
6.3.7.3 Install the piston connecting rod

assembly in the cylinder block with the
piston ring compressor. Note the arrow at
the exhaust side on the top of piston points
to the front end of the engine (the end of
6.3.7.5 As shown in the figure, apply a small
the crankshaft pulley);
amount of oil on the threads of connecting
rod bolts and the bolt bases. Make sure the
hold-down surfaces of the bolts are clean
and free of any impurity;
6.3.7.6 Alternatively tighten the connecting rod

bolts in 2 - 3 steps;
The tightening torque is 30 Nm
105
6.3.7.7 Mark on the connecting rod bolts with a

marker pen along the front end of the
engine;
Front end of the engine
Mark
6.3.9.2 Apply oil on the rod part of 26 mm from

the valve end;
6.3.7.8 Rotate the connecting rod bolts 90º

clockwise, and retighten the connecting rod
bolts;
6.3.7.9 The crankshaft should be rotated freely 6.3.9.3 Install the valve, valve spring and valve
after installation, and the torque should not spring upper seat;
exceed 10 Nm.
Note: The valve spring can be installed at
6.3.8 Install the crankshaft rear oil seal any direction as it has equal pitch.
component
See P6 for details

The special tool
6.3.9 Install the valve
6.3.9.1 Install the valve oil seal on the valve

guide with the special tool;
Note: MP lithium grease should be applied

on 16 new valve oil seals before the
installation.
106
6.3.9.4 Compress the valve spring with the

6.3.10 Install the cylinder head gaskets
special tool, install the valve collet at the
valve end and then loosen the valve spring
6.3.10.1 Vertically tap two positioning sleeves
carefully.
into the seat holes with a copper mallet;
6.3.10.2 Install the cylinder head gaskets on

the top of the cylinder block. The
positioning holes on the gaskets should be
aligned with the positioning sleeves, and
the wider end should face the front end of
the engine (crankshaft pulley end). At this
time, the oil holes and water holes of
cylinder block are aligned with the oil holes
and the water holes on the cylinder head
gaskets.
Note: The surface of cylinder head gasket

and the mating surface of cylinder block
and cylinder head should be clean and free
of grease and other foreign materials.
Special Tool
6.3.9.5 Gently tap the end of the valve stem

with a pin punch to fix the valve and the
valve collet securely.
6.3.11 Install the cylinder head
6.3.11.1 Align the positioning sleeve holes and
107
then slowly lower the cylinder head on the

cylinder block;
Note: The cylinder head should be lowered

gently to avoid damage to the cylinder
block gasket.
6.3.11.2 Install the cylinder head bolt gaskets

to the cylinder head bolts, and apply a
proper amount of oil on the cylinder head
bolts as shown in the figure;
6.3.12 Install the roller rocker arm component
6.3.12.1 Apply a proper amount of oil in the

positions as shown in the figure;
The contact surfaces of hydraulic tappet,

roller and valve end
6.3.11.3 Tighten the cylinder head bolts in two

steps in the order as shown in the figure;
Step 1: 20 Nm
Step 2: 70 Nm
6.3.11.4 Mark the cylinder head bolts with a

marker pen along the front end of the 6.3.12.2 Slowly install the roller rocker
engine; component into the plunger hole. Avoid
damage to the surface of the tappet.
6.3.11.5 Rotate the cylinder head bolts 90º
clockwise and tighten the bolts. Note: The roller rocker arm must be
correctly positioned at the end of the valve
stem.
108
6.3.13.3 Rotate the intake and exhaust

6.3.12.3 Install the sparkplug hole seal rings camshafts for 1 or 2 circles. They must be
and the OCV filter screen on the cylinder rotated freely without being stuck;
head.
6.3.13.4 Make sure the camshaft is positioned
at the compression top dead center of a
cylinder with the special tool, and prevent
the camshaft from dropping.
See P9 for details
6.3.14 Install the camshaft housing
6.3.14.1 Uniformly apply a thin layer of sealant

in the areas as shown in the figure.
6.3.13 Install the camshaft
Note: The sealant should not be applied
6.3.13.1 Apply a proper amount of oil in each thickly, or the excessive sealant may enter
bearing support of the camshaft housing; the oil hole, causing blockage of the oil
circuit.
6.3.14.2 Screw two studs into the cylinder

head. Carefully and vertically lower the
6.3.13.2 Insert the camshaft into the camshaft
camshaft housing with two studs passing
housing from rear to front. Note the journal
through, and align the positioning pins.
and cam should not be knocked and the
intake and exhaust camshafts should not
be inversely installed.
109
Note: The oil pump should rotate freely

without being stuck before it is installed.
6.3.14.3 Tighten the mounting bolts in two

steps in the order as shown in the figure; 6.3.15.2 Install the oil collector on the oil pump,
and uniformly tighten the bolts in several
Step 1: 10 Nm times.
Step 2: 90ºrotating angle
6.3.14.4 Install the camshaft phase sensor into
the corresponding seat hole, and tighten Note: Add a small amount of oil through the
the bolts with the specified torque; oil suction port of oil pump. Check if the
O-ring of oil collector is in good condition.
6.3.14.5 Install the front and rear lifting hooks

of the engine, and then tighten the bolts
with the specified torque;
6.3.16 Install the oil pump chain
6.3.14.6 Install the OCV solenoid valve into the
corresponding seat hole, and tighten the 6.3.16.1 Hang the oil pump chain on the oil
bolts with the specified torque; pump sprocket and crankshaft sprocket;
6.3.15 Install the oil pump and the oil collector
6.3.15.1 Align the positioning pin hole, install

the oil pump on the bottom surface of the
cylinder block and tighten the bolts;
110
rotated freely after installation. Apply oil on

the contact area between the tensioning
plate and the chain.
6.3.16.2 Install the oil pump sprocket and the

crankshaft sprocket in place on the
crankshaft and the camshaft sprocket. The
notch of oil pump sprocket should be 6.3.16.5 Place the tensioning plate spring in
aligned with that of the oil pump sprocket the correct position, tighten the retaining
shaft, and the notch of crankshaft sprocket bolts after tensioning the spring and then
should be aligned with that of the loosen the spring carefully;
crankshaft;
6.3.16.6 Install the oil pump hood.
6.3.16.3 Position the oil pump sprocket with
the special tool, and then screw up and
tighten the bolts;
6.3.17 Install the timing chain
See P8 for details
6.3.18 Install the timing cover
6.3.18.1 Press the crankshaft front oil seal into

6.3.16.4 Pass the tensioning plate pin roll the position shown in the right figure with
through the oil pump chain tensioning plate the special tool.
after the oil is applied on its outer, and then
tighten the tensioning plate pin roll;
Note: The tensioning plate should be
111
Special Tool
6.3.18.2 Install two oil-retaining seal rings of

the timing cover and the oil gas separator Connecting
in place, and then uniformly and Sleeve
alternatively tighten the bolts in two to three
times; 6.3.18.4 Install the timing cover in place with
the positioning pins, and uniformly and
alternatively tighten the bolts in two to three
times;
Note: Protect the oil seal lip with the

special tool before installing the front oil
seal into the connecting sleeve.
6.3.19 Install the oil sump
6.3.19.1 Remove the sealant from the bottom

of the cylinder block and the mounting
surface of the oil sump. Make sure the
surfaces are clean and free of any impurity;
6.3.19.2 Apply the flange sealant with the

diameter of Φ2.5-Φ3.5 mm on the inner
side of the oil sump joint surface without
breaking point;
6.3.18.3 Install the timing cover gasket with two

positioning pins. First install the O-ring into
the connecting sleeve and then install the
connecting sleeve on the crankshaft;
Note: The sealing surface should be clean

and free of grease.
Apply the sealant before installation.
6.3.19.3 Make sure the rear end surface of oil

sump is aligned with the rear end surface
of cylinder block with the special tool.
Install the oil sump in place. Uniformly and
alternatively tighten the bolts in several
times;
112
6.3.19.4 Tighten the oil drain plug. 6.3.21 Install the clutch
Tightening torque: 25 Nm 6.3.21.1 Install the clutch driven plate

assembly;
Note: Check the rubber seal gasket of the
oil drain plug before installation and make Insert the centering plug into the crankshaft
sure the gasket is complete and smooth. rear end bearing hole after passing through
the clutch driven plate assembly;
Note: The flat surface faces inwards and

the convex surface faces outwards.
6.3.20 Install the flywheel
6.3.20.1 Attach the flywheel to the mounting

surface of the crankshaft, carefully rotate it
to the correct position, and screw up the
flywheel bolt by hand for two to three 6.3.21.2 Install the clutch cover assembly
threads;
Align three positioning pins and install the
Note: The flywheel surface should be clean clutch pressure plate to the rear end of the
and free of the oil stain. flywheel;
6.3.20.2 Alternatively and uniformly tighten the Tighten six bolts in the order as shown in
flywheel bolts in several times. the figure to fix the clutch pressure plate on
the flywheel.
Tightening torque: 60 Nm+90ºrotating
angle Tightening torque: 25 Nm
Note: Check if the driven plate assembly is

centered after installation.
Gently shake the centering plug and

remove it after completing the above
operation.
113
tighten the bolts in several times;
6.3.22.3 Install the fuel inlet fittings on the

high-pressure fuel rails.
Note: Clean the sealant on the threads

before installation and apply the pipe
thread sealant again.
6.3.22 Install the high-pressure fuel rail
6.3.22.1 Fully press four fuel injectors into the

cylinder head;
6.3.23 Install the high-pressure oil pump
6.3.23.1 Clean the surface of the roller tappet

and apply a proper amount of oil. Then
push it into the camshaft housing;
Note: During the assembly, insert the

Note: Do not apply oil or grease on the packing locating block indicated by the arrow in the
ring as shown in the figure below. The seal ring, figure into the corresponding groove.
elastic part and packing ring shown in the
figure below can only be used once.
Seal Ring Elastic Part
Packing Ring
6.3.22.2 Place the high-pressure fuel rail

gasket on the mounting surface with the
positioning pin. Align the high-pressure fuel
rails with four fuel injectors, and press the
seal rings of the fuel injectors into the 6.3.23.2 Install the high-pressure oil pump in
high-pressure fuel rails. Then uniformly place, and tighten the bolts;
114
Note: Perform installation in the direction O-ring

as shown in the figure, and do not reverse
the installation direction.
6.3.23.3 Install the oil inlet tube component in

place. First screw in the union nuts for two
to three threads, and then screw in the
support plate bolts for two to three threads.
Tighten the union nuts, and then the
support plate bolts.
Tightening torque: Union nut 17 Nm Buckle
6.3.25 Install the sparkplug
6.3.25.1 Install the sparkplug in the cylinder

head and tighten it;
See P10 for details
6.3.25.2 Install the ignition coil on the camshaft

housing, and tighten the bolts;
6.3.25.3 Apply sealant on the threads of the oil

pressure switch, screw it into the mounting
base hole and tighten it;
6.3.24 Install the thermolator
6.3.24.1 Confirm the O-rings at both ends of
the oil inlet tube of the water pump are
6.3.25.4 Install the knock sensor in the
complete without damage. Install the water corresponding position at the intake side of
inlet tube of the water pump in the cylinder block with the plug part facing the
thermolator component through the
lower rear part of the engine with an angle
positioning groove; of 45º, and then tighten it;
6.3.24.2 Install the other end of the water inlet Tightening torque: 20 Nm
tube of the water pump into the cylinder
block, and then tighten the mounting bolts
of thermolator component.
6.3.24.3 Lock the water inlet tube of the water

pump with a buckle.
6.3.26 Install the motor-driven water pump
115
assembly and the water outlet hose of the

6.3.26.1 Install the motor-driven water pump oil cooler in place, and then tighten the
on the motor-driven water pump support, hoops.
and tighten the bolts;
6.3.26.2 Install the motor-driven water pump

support on the cylinder block, and tighten
the bolts;
Note: The mounting surface of the

motor-driven water pump should face the
front end of the engine, and do not reverse
the installation direction;
6.3.26.3 Install the dual pipe component and

the water inlet tube of motor-driven water
pump, and tighten the bolts;
6.3.26.4 Assemble the components shown in

the figure, and then tighten the hoops. 6.3.27.3 Screw the oil filter screwed tube into
the seat hole of timing cover, screw the oil
filter into the screwed tube, and tighten
them to the specified torque.
Note: Before installation, check that the

seal ring is complete and smooth without
wear. The seal ring is higher than the
flange end surface and a proper amount of
oil is applied on its surface.
6.3.27 Install the oil cooler
6.3.27.1 Install the oil cooler on the cylinder

block and tighten the bolts in several times;
Note: Make sure the sealing surface is free

of grease and other impurities before
installation;
6.3.28 Install the intake manifold
Check that the gasket surface is complete
without damage before installation; 6.3.28.1 Install the intake manifold in place,
and tighten the bolts alternatively in several
6.3.27.2 Install the water tube assembly of oil times;
cooler. Check that the O-ring at the oil
cooler end is complete without damage. Note: Check if four washers are complete
Tighten two bolts to install the water tube before installation.
116
6.3.28.2 Align the positioning pins to install the

throttle valve and throttle valve clamping
seat, and tighten the bolts;
6.3.28.3 Install the sealing strips, supporting

strip I and II of the intercooler in the
corresponding positions. Then install the
intercooler (Do not reverse the installation
direction) and tighten the screws.
6.3.28.4 Install the intake temperature

pressure sensor into the corresponding
seat hole of the intake manifold, and
tighten the screws.
Note: The wire harness plug should face

6.3.29.4 Install the intake fitting component (Do
the front end of the engine
not reverse the installation direction) and
then tighten the bolts;
6.3.29.5 Install the supercharge pressure

solenoid valve as shown in the figure (Do
not reverse the installation direction) and
tighten the bolts. Then install the
connection hose I, II and III in place.
6.3.29.6 Check that the O-rings on the intake

manifold and the turbocharger are
complete and smooth without damage.
Assemble the intake manifold and the
semi-circular clamping block, and tighten
the screws.
Note: Two gaskets must be installed for

6.3.29 Install the turbocharger each hollow bolt.
6.3.29.1 Install the exhaust manifold, exhaust Note: It is necessary to fill oil into the oil
manifold gasket, fixed plate I and II in place, inlet during installation if the turbocharger
and then tighten the screw cap; has been left for a long time.
6.3.29.2 Respectively install the turbocharger 6.3.30 Install the crankshaft housing ventilator
oil return pipe and the turbocharger. Then and the fuel evaporative emission control
install the turbocharger on the exhaust system
manifold and tighten the turbocharger nuts;
6.3.30.1 Install the PCV four-way components,
6.3.29.3 Install the supporting plate assembly, and tighten the bolts;
turbocharger water inlet tube, turbocharger
water return tube and turbocharger oil inlet Note: Check if the O-rings of PCV four-way
pipe, and then tighten the hollow bolts; components are complete and smooth
Note: It is necessary to fill the oil of more without damage.
than 5 ml into the turbocharger oil inlet
before installing the turbocharger oil inlet 6.3.30.2 Install the PCV breather tube I, II and
pipe. the intake fitting rubber sleeve;
117
Note: Check if the O-ring of the PCV

breather tube I is complete and smooth
without damage.
6.3.30.3 Install the charcoal canister control

valve, connection hose and vacuum pipe
component;
6.3.30.4 Install the camshaft housing

connection hose and one-way valve.
Note: Do not install the one-way valve
reversely.
Check Valve
Camshaft housing
connection house
118
Part 2 Lubrication System

Section 1 Schematic Diagram of Engine Lubrication Circuit
1st Gear Main Cylinder 1 Oil

Journal Cooling Nozzle
2nd, 3rd, 4th, 5th Gear Main Cylinder 2, 3, 4 Oil

Journal Cooling Nozzle
1st Gear
Camshaft
Journal
Exhaust
Side
2nd, 3rd Gear

Camshaft
Journal
1st Gear Camshaft

Journal Intake Side
Oil Collector
119
Section 2 Inspection of Oil Pressure

Warning: The oil temperature in the hot Engine Speed Oil Pressure
engine is very high, which can cause burns.
Perform operation after the engine is 2000 r/min Above 200 kPa
stopped and cooled down.
Note: The oil pressure may vary depending
2.1 Remove the oil pressure switch; on the oil viscosity and temperature;
If the pressure is not within the specified

range, find out the cause and perform the
repair or replacement as necessary.
2.4 Install the oil pressure switch
2.4.1 Stop the engine and cool it down;
2.4.2 Remove the oil pressure gauge and converter;
2.4.3 As shown in the figure, uniformly apply anaerobic

pipe thread sealant on the threads of oil pressure
switch;
2.4.4 Install the oil pressure switch;

2.2 Connect the oil pressure gauge to the oil
pressure switch mounting holes with a Tightening torque: 15 Nm
special adapter;
Note: Do not start the engine within one hour after
the oil pressure switch is installed;
1.0 ~ 2.0 mm
Sealant
Application
Area
4.0 ~ 6.0 mm
2.4.5 Connect the wire harness connector of oil

2.3 Start the engine and keep it running until pressure alarm;
the normal working temperature is reached
(≥80°C); 2.4.6 Start the engine and check for oil leakage.
Increase the engine speed until the
specified speed is reached, and check the
reading on the oil pressure gauge;
Oil pressure: 200-340 kPa (2000 r/min)
120
Section 3 Engine Oil
3.1 Engine Oil Inspection and then drain the oil into a suitable
container;
3.1.1 Park the vehicle on a level ground, and
stop the engine after it is started and the 3.2.3 Clean the drain plug. Check if the drain
normal working temperature is reached; plug gasket is complete and smooth, and
replace it if damaged. Tighten the drain
3.1.2 After five minutes, pull out the oil dipstick plug;
and observe the oil level and condition.
Check if the oil level is between A and B; Tightening torque: 25 Nm
Add or replace the oil if necessary 3.2.4 Install a new oil filter;
Check and clean the mounting surface of

the oil filter, gently screw the oil filter into
the filter base and turn it with the special
tool.
See P for details. The removal is in the

reverse order of installation.
3.2.5 Fill oil in the engine;
Oil filling quantity:
3.1.3 Insert the oil dipstick again. Item Filling

Quantity (L)
3.2 Engine Oil Replacement The oil filter is 4.0
replaced
Warning: Avoid burns as the oil The oil filter is not 3.8
temperature in the hot engine is very high; replaced
Waste oil may cause cancer, therefore 3.2.6 Tighten the oil filler cap;
wash the skin with soap and clean water
after replacement; 3.2.7 Start the engine and check for any oil
leakage;
For environment protection, the waste oil
and oil filter must be treated in the 3.2.8 Check the oil level, and add oil if
specified area. necessary.
3.2.1 Lift the vehicle horizontally with a lifter, or Engine oil grade: Special oil specified and
drive the vehicle onto a ditch; approved by BYD Auto Co., Ltd.
3.2.2 Remove the oil filler cap and drain plug,
121
Section 4 Oil Sump

4.1 Removal of oil sump
4.3.3 Slightly tap the oil sump with a rubber
4.1.1 Disconnect the negative battery terminal; mallet to loosen it, and remove the oil
sump with a remover if necessary.
4.1.2 Drain the engine oil;
4.4 Notes on installation of oil sump
4.1.3 Unscrew the oil sump mounting bolts.
4.4.1 Clean the bottom surface of cylinder
4.2 Installation of oil sump block and the mounting surface of oil sump,
and make sure no grease exists;
4.2.1 Perform installation in the reverse order
of removal; 4.4.2 Apply sealant around the inside of the oil
sump peripheral holes;
4.2.2 Start the engine and check for any oil
leakage. Diameter of sealant: Φ2.5-Φ3.5 mm
Note: The oil sump should be installed

within five minutes after the flange sealant
is applied. Otherwise it is necessary to
clean the residual and recoat new sealant.
The sealant must be dried for about thirty

minutes after the oil sump is assembled.
Then fill the engine oil;
4.4.3 Uniformly tighten the mounting bolts in

several times: Twenty M6 bolts for
connecting the cylinder block, timing cover
4.3 Notes on removal of oil sump and rear oil seal component, and two M10
bolts for connecting the transmission
4.3.1 Remove the oil sump bolts;
Tightening torque for drain plug: 25 Nm
4.3.2 Remove the sealant on the threads and
sealing surface;
122
Section 5 Oil Pump

5.1 Removal of Oil Pump
5.1.1 Make sure the oil sump has been

removed before the removal of oil pump; 5.1.4 Loosen the oil pump mounting bolts and
remove the oil pump.
5.1.2 Fix the oil pump sprocket with the special
tool, and loosen the fixing bolts; 5.2 Installation of Oil Pump
Note: Do not remove the oil pump sprocket The installation is in the reverse order of
bolts. removal;
5.2.1 Install the oil pump in place and tighten

the bolts;
5.2.2 Press the oil pump chain tensioning plate

in the direction indicated by the arrow as
shown in the figure with a screwdriver or
equivalent. Put the sprocket in the chain
and then on the oil pump shaft;
5.1.3 Press the oil pump chain tensioning plate
Note: Check if the sprocket is installed in
in the direction indicated by the arrow as
place on the oil pump shaft.
shown in the figure with a screwdriver or
equivalent. Unscrew the oil pump sprocket
5.2.3 Screw in the oil pump sprocket bolts,
bolts, and remove the sprocket from the oil
position the oil pump sprocket with the
pump and the chain;
special tool, and tighten the bolts;
5.2.4 Install the oil sump.
123
Part 3 Cooling System

Section 1 Schematic Diagram of Engine Cooling System
Water
Pump
Thermolator Motor- Intercooler

ll driven
Water
Pump
Turbocharger
124
Section 2 Thermolator
2.1 Removal of Thermolator
2.1.1 Disconnect the negative battery cable;
2.1.2 Drain the coolant;
2.1.3 Remove the thermolator cap.
Unscrew the thermolator cap bolts, and

remove two thermolators.
Thermolator I Thermolator II
2.2.2 Check the opening temperature and

full-open temperature of the thermolator.
Thermolat Thermolator
or I II
Opening 83 (+2/-1)
Temperature 95 (+2/-1)
(°C)
Full-open 98
Temperature 110
2.2 Inspection of Thermolator (°C)
2.2.1 Visually inspect whether the thermolator Full-open 7~10
meets the requirements; 7~10
Travel (mm)
Maximum 12
The mark on the thermolator indicates the 12
Travel (mm)
opening temperature. If the mark on the
thermolator does not match with the engine, Replace the thermolator if not as specified.
replace the thermolator.
Thermolator I: 83°C
Thermolator II: 95°C
125
Section 3 Water Pump

3.1 Removal of Water Pump
3.1.1 Drain the coolant; and see section 2 for

details.
3.1.2 Remove the driving belt; Refer to the

removal of driving belt for details
Rotate the tension pulley counterclockwise

(to the left) to the limit position with the
front end bolt so as to loosen the belt and
remove the driving belt.
3.2 Installation of Water Pump
The installation is in the reverse order of

removal;
3.2.1 Install the water pump
3.1.3 Remove the water pump pulley; See P5 3.2.1.1 Inspection before the installation
Unscrew three fixing bolts and remove the Rotate the water pump by hand and check
water pump pulley. if the water pump emits abnormal noise. If
3.1.4 Remove the water pump; any, replace the water pump assembly;
3.1.4.1 Screw off five mounting bolts of the Check if the water pump gaskets are
water pump; damaged. If any, replace the water pump
gasket;
3.1.4.2 Remove the water pump and the water
pump gaskets. Carefully clean the sealing surfaces of the
water pump and cylinder block and water
pump gasket;
126
3.2.1.2 Install the water pump and water pump

gaskets to the cylinder block, and then
tighten five bolts;
3.2.1.3 Install the water pump pulley, and

tighten three bolts;
3.2.1.4 Install the driving belt.
127
Part 4 Clutch
Section 1 Clutch Device

1.1 Removal of Clutch
1.1.1 Remove the starter; 1.1.3.1 Insert the centering plug into the
crankshaft rear end bearing hole after
passing through the clutch driven plate
assembly;

1.1.3.2 Screw off six fixing bolts as shown in

the figure, and remove the clutch.
1.1.2 Remove the transmission
Remove the bolts for connecting the 1.2 Inspection of Clutch
transmission to the cylinder block and oil
sump. 1.2.1 Inspect the clutch driven plate assembly
1.2.1.1 Measure the depth of rivet head on the

friction disc with a vernier caliper;
Minimum depth: 0.3 mm.
Replace the clutch driven plate assembly if

Connect the oil sump necessary.
1.1.3 Remove the clutch
128
1.2.1.2 Measure the circular run-out of the 1.2.3 Inspect the clutch cover assembly
friction disc with a magnetic stand dial
gauge and a deflection instrument; As shown in the figure below, check the
wear of the presure plate leaf spring with
The allowed maximum circular run-out is the vernier caliper;
0.8 mm.
Allowed maximum depth: 0.6 mm
Allowed maximum width: 0.5 mm
Replace the clutch cover assembly if the

measured value exceeds the allowed
maximum value.
Note: Do not allow the oil and other

impurities to drop on the surfaces of the
driven plate assembly and the flywheel.
Replace the clutch driven plate assembly if
necessary.
1.2.2 Inspect the flywheel
1.2.2.1 Measure the circular run-out of the rear

end surface of the flywheel with the
magnetic stand dial gauge;
The allowed maximum circular run-out is

0.1 mm.
Replace the flywheel if necessary.

1.3 Installation of Clutch
1.3.1 Install the clutch driven plate assembly;
Insert the centering plug into the crankshaft

rear end bearing hole after passing through
the clutch driven plate assembly;

129
Note: Check if the driven plate assembly is

centered after the installation;
Slightly shake the centering plug to remove

it after completing the above operation;
Make sure no oil stain is on the contact

surface of the flywheel and friction disc
before installation.
1.3.2 Install the clutch cover assembly
1.3.2.1 Align three positioning pins, and install

the clutch pressure plate to the rear end of
the flywheel;
1.3.2.2 Screw in and tighten six bolts in the

order as shown in the figure, and fix the
clutch pressure plate on the flywheel.
130
Section 2 Flywheel
2.1 Removal of Flywheel
2.1.1 Fix the flywheel with the special tool;

Tightening torque: 60 Nm+90ºrotating
2.1.2 Uniformly and alternatively unscrew the angle
flywheel bolts in several times, and then
remove the flywheel. 2.3 Inspection of Flywheel
Measure the axial circular run-out of the

flywheel with a magnetic stand dial gauge;
The allowed maximum axial circular

run-out: 0.1 mm.
Replace the flywheel if necessary.
2.2 Installation of Flywheel
2.2.1 Attach the flywheel to the crankshaft

mounting surface, and rotate it to the
correct position;
2.2.2 Screw in the flywheel bolts.
2.2.3 Position the flywheel with the special tool,

and then uniformly and alternatively tighten
the flywheel bolts in several times;
131
Chapter 3 Transmission
Contents
Section 1 Structural parameters............................................................................................ 133

1.1 Structural parameters of transmission................................................................... 133
Section 2 Service Guidelines ................................................................................................ 134
2.1 Service Materials ................................................................................................... 134
2.2 Auxiliary Materials Table ........................................................................................ 134
2.3 Service Regulations............................................................................................... 135
Section 3 Service of transmission ......................................................................................... 136
3.1 Disassembly of Transmission ................................................................................ 136
3.2 Inspection of reverse gear shaft fork clearance .................................................... 141
3.3 Inspection of shift lever clearance ......................................................................... 142
3.4 Disassembly and reassembly of manual gear shift assembly .............................. 143
3.5 Disassembly and reassembly of manual gear shift assembly (Note: Applicable for
transmissions with neutral switch assembly) ........................................................ 144
3.6 Inspection of gear shifting fork clearance.............................................................. 145
3.7 Disassembly and reassembly of gear shifting fork ................................................ 146
3.8 Inspection of main shaft assembly clearance ....................................................... 147
3.9 Disassembly of main shaft .................................................................................... 148
3.11 Reassembly of main shaft ..................................................................................... 150
3.12 Inspection of counter shaft assembly clearance ................................................... 151
3.13 Disassembly of counter shaft ................................................................................ 152
3.14 Inspection of counter shaft .................................................................................... 153
3.15 Reassembly of counter shaft ................................................................................. 154
3.16 Inspection of synchronizer gear sleeve and gear hub .......................................... 157
3.17 Inspection of synchronizer ring and gear .............................................................. 158
3.18 Replacement of main shaft bearing and oil seal ................................................... 159
3.19 Replacement of counter shaft bearing .................................................................. 160
3.20 Adjustment of main shaft meshing clearance ....................................................... 160
3.21 Reassembly of transmission ................................................................................. 161
Section 4 Differential ............................................................................................................. 165
4.1 Disassembly of differential .................................................................................... 165
4.2 Inspection of backlash ........................................................................................... 166
4.3 Removal and Installation of final drive driven gear ............................................... 166
4.4 Replacement of differential housing/vehicle speed sensor driving gear............... 166
4.5 Replacement of differential oil seal ....................................................................... 167
4.6 Replacement of differential adjusting shim ........................................................... 168
132
Section 1 Structural parameters

1.1 Structural parameters of transmission
BYD5T-14/BYD5T-14-1/BYD5T-14-4
Transmission model
/BYD5T-14-1A/BYD5T-14-4A/BYD5T-14-5A
Applicable Engine Model BYD473QE/BYD473QB
Type Manual 5-gear
Axial Distance (mm) 69-118
Overall Length (mm) 363
Dimensions (length × width × height) (mm) 363×515×382
Gear Ratio of Differential 16:10
1st gear 0.98
2nd gear 0.98
3rd gear 0.98
Transmission efficiency
4th gear 0.98
5th gear 0.98
Reverse 0.97
1st gear Φ74.9
2nd gear Φ74.9
Synchronizer ring
3rd gear Φ68.8
dimensions (mm)
4th gear Φ68.8
Synchronizer ring type
5th gear Φ62.8
Reverse Φ62.8
Gear shifting control Shift lever ratio 45.55/24.5
mechanism Select lever ratio 57.4/34.6
Gear ratio 19/23
Speed sensor
Type Electronic
SAE viscosity 80W-90 (Summer in northern China),
classification 75W-90 (Winter in northern China)
80W-90 or 85W-140 (All year round in
Gear Oil
southern China)
API classification GL-4
Oil volume (L) 1.6 L
Net weight (without clutch)
33
(kg)
Transmission model BYD5T-14-1A/BYD5T-14-4A/BYD5T-14-5A

Gears I II III IV V R
Gear ratio 43/13 42/23 35/29 31/33 27/37 31/13×42/31
Drive ratio 3.308 1.826 1.207 0.939 0.73 3.231
Final drive gear ratio 75/18
Final drive ratio 4.167
Total drive ratio 13.782 7.609 5.029 3.914 3.041 13.462
Transmission model BYD5T-14/BYD5T-14-1/BYD5T-14-4
Gears I II III IV V R
31/13
Gear ratio 43/13 42/23 35/29 31/33 27/37
X42/31
Drive ratio 3.308 1.826 1.207 0.939 0.73 3.231
Final drive gear ratio 76/17
Final drive ratio 4.471
Total drive ratio 14.787 8.164 5.396 4.2 3.262 14.443
133
Section 2 Service Guidelines

2.1 Service Materials
The materials listed in the following table are essential for maintaining the transmission.
Therefore, the materials should be prepared for use at any time. In addition, the washing
liquid and lubricant of specified type should be used.
2.2 Auxiliary Materials Table
No. Materials and Materials and type currently in use Position

type
1 Release fork
2 Release bearing
3 Front oil seal of input shaft
Lubricant 2 # sodium base grease Vehicle speed sensor
4
assembly
5 Gear selecting block
6 Differential oil seal
API grade GL-4 and above
75W-90 Winter in northern China
7 Gear Oil 80W-90 Summer in northern China Transmission assembly
80W-90 or 85W-140 (All year round
in southern China)
8 Sealant Loctite 587 Sealing plug
9 API grade GL-4 and above Input shaft needle bearing
Gear Oil 80W-90 Summer in northern China
10 Output shaft needle bearing
in southern China)
TONSAN TS1567F Contact surface of the
11 Sealant
transmission box
API grade GL-4 and above
Gear shifting fork and shift
12 Gear Oil 80W-90 Summer in northern China
lever assembly
in southern China)
TONSAN TS1567F Mounting surface of manual
13
gear shift assembly
Reverse shaft fork assembly
Sealant
bolts
14 TONSAN Kesaixin 1262
Reverse gear lock cam
assembly
134
2.3 Service Regulations
Prepare the parts kit and parts rack in

advance to store the removed and After servicing, disposable supplies
disassembled components. Put them in should be scrapped and replaced with
order and make markers if necessary to new ones.
avoid confusion and misplacement.
Use correct removal tools for
Be careful when serving the aluminum disassembly and assembly.
alloy parts to avoid damage to the
machined surface. Refer to this service manual as much as
possible during work.
Prepare sufficient auxiliary materials for
use in the process of servicing. If you encounter any difficult technical
problems during servicing, it is
For the bolts and other fastening parts recommended to consult our aftersales
with standard tightening torque technical service department.
requirements, tighten them with special
tools in accordance with the required
values.
135
Section 3 Service of transmission

3.1 Disassembly of Transmission
Disassembly diagram of front casing
(1) Differential assembly (13) Reverse gear shaft (24) Pull cable support
(2) Reverse gear lock cam (14) Idler gear assembly (25) Hexagon flange bolt
assembly (15) Mounting bolts (15 M8×45 (25 Nm)
(3) Mounting bolts (15 Nm) Nm) (26) Hexagon flange bolt
(4) Gear shifting fork (16) Reverse shaft fork M6×22 (10 Nm)
assembly assembly (27) Vehicle speed sensor
(5) Counter shaft assembly (17) Positioning pin assembly
(6) Main shaft assembly (18) Dust cover (28) O-ring
(7) Magnet assembly (19) Release arm (29) Vehicle speed sensor
(8) Slide bush (20) Release arm screw driven gear
(9) Cylindrical roller bearing (30 Nm) (30) Spring
(10) Oil guide plate 2 (21) Release arm spring (31) 8 mm washer
(11) 58 mm deep groove ball (22) Release bearing (32) Clamp spring
bearing (23) Differential right oil (33) 8 mm spring washer
(12) Main shaft oil seal seal (34) Fork shaft screw (25 Nm)
136
(35) Transmission front casing
Note: The matching condition of the vehicle speed sensor, neutral switch, front casing and rear
casing is listed below.
Transmission Vehicle speed Neutral Front casing Rear casing

model sensor switch
BYD5T-14 Available Unavailable 5T14-1701411 5T14-1701412
BYD5T-14-1 Available Available 5T14-1701411 5T14-1-1701412
BYD5T-14-4 Unavailable Available 5T14-4-1701411 5T14-1-1701412
BYD5T-14-1A Available Available 5T14-1701411 5T14-1-1701412
BYD5T-14-4A Unavailable Available 5T14-4-1701411 5T14-1-1701412
BYD5T-14-5A Available Unavailable 5T14-1701411 5T14-1701412
137
Disassembly diagram of rear casing
(1) Check bolt (22 Nm) (14) 72 mm washer

(2) Check spring (15) Drainage trough plate
(3) Steel ball (16) 80 mm washer
(4) 12 mm flat washer (17) Reversing light switch gasket
(5) Drain plug (39 Nm) (18) Reversing light switch assembly (30 Nm)
(6) 14 mm flat washer (19) Hexagon flange bolt
(7) Sealing plug (25 Nm) M6×20 (10 Nm)
(8) Hexagon flange bolt (20) Manual gear shift assembly
M8×40 (25 Nm) (21) Cylindrical pin
(9) Bolt M8 × 45 (25 Nm) (22) 20 mm flat washer
(10) Mounting support for high pressure steel (23) Oil filler plug (45 Nm)
pipe of clutch (24) Differential left oil seal
(11) Mounting support for oil tube of separation (25) Neutral switch assembly (35 Nm) (Note:
pump Applicable for transmissions with neutral
(12) Hexagon flange bolt switch assembly)
M6×8 (10 Nm)
(13) Oil deflector 1
Note: BYD5T-14-5A transmission has all the above components except the neutral switch
assembly
Note: Prop up the transmission front casing with two wood blocks thick enough to prevent the main
shaft from hitting the service stand.
138
3.1.1 Remove the neutral switch assembly (A)

(Note: Applicable for transmissions with
neutral switch assembly)
3.1.5 Remove the hexagon flange bolts M8 ×

40 (A), mounting support for the high
3.1.2 Remove the check bolt (A), 12 mm flat pressure steel pipe of clutch (B) and
washer, check spring, steel ball and hexagon flange bolts M8 × 45 (C)
reversing light switch assembly (B). alternatively.
3.1.3 Remove the manual gear shift assembly

(A) and the cylindrical pin (B).
3.1.4 Remove the drain plug, 14 mm flat

washer (A), oil filler plug, 20 mm flat
washer (B) and vehicle speed sensor (C).
Check if the O-ring (D) is broken, and
replace it when necessary.
139
3.1.5.1 Remove the sealing plug (A). 3.1.5.5 Remove the reverse shifting fork
assembly.
3.1.5.2 Open the counter shaft circlip (B) with
the circlip pliers, and then remove it
from the groove.
3.1.5.6 Remove the reverse gear lock cam

assembly.
3.1.5.3 Remove the transmission rear casing
(C) and positioning pin (D).
3.1.5.7 Wrap the main shaft spline with the

tape, and then remove the main shaft
3.1.5.4 Remove the idler gear assembly (A) assembly (A), counter shaft assembly
and reverse gear shaft (B). (B) and gear shifting fork assembly (C)
from the front casing.
140
3.2 Inspection of reverse gear shaft

fork clearance
3.2.1 Measure the clearance between the

reverse gear shaft fork assembly (B) and
the idler gear assembly (A) with the
3.1.5.8 Remove the fork shaft screw (E) and 8 feeler gauge (C). If the clearance
mm spring washer (F). exceeds the repair limit, go to step 2.
3.1.5.9 Remove the differential assembly (A) Standard: 1.50-1.90 mm

and magnet (B).
3.2.2 Measure the clearance of the reverse

gear shaft fork.
3.1.5.10 Remove the drainage trough plate (A),
oil deflector 1 (M) and 72 mm washer (B). 3.2.3 If the clearance does not meet the
standard, replace with a new reverse gear
shaft fork assembly.
3.2.4 If the clearance meets the standard,

replace with a new idler gear assembly.
141
3.3.2 Measure the shift lever assembly groove.
3.3.2.1 If the clearance does not meet the

standard, replace with a new shift lever
assembly.
3.3.2.2 If the clearance meets the standard,

replace with a new select lever
assembly.
Standard: 13.00-13.15 mm
3.3 Inspection of shift lever clearance
3.3.1 Measure the clearance between the shift

lever assembly (A) and the select lever
assembly (B) with a feeler gauge (C). If the
clearance exceeds the repair limit, go to
step 2.
142
3.4 Disassembly and reassembly of manual gear shift assembly
Before the reassembly, wash all the parts with solvent, and then apply lithium grease for all the
contact surfaces (A, B, C and D) after they are dry.
10 Nm
Vent pipe
assembly
Gear shifting
arm cover
143
3.5 Disassembly and reassembly of manual gear shift assembly (Note: Applicable
for transmissions with neutral switch assembly)
Before the reassembly, wash all the parts with solvent, and then apply lithium grease for all the
contact surfaces (A, B, C and D) after they are dry.
Hexagon flange bolt 10 Nm
Dust cover
Gear shifting shaft seal
144
3.6 Inspection of gear shifting fork clearance
Note: Replace the synchronizer hub if the

synchronizer gear sleeve is to be replaced. 3.6.3 Measure the clearance between gear
shifting fork (A) and the shift lever fork
3.6.1 Measure the clearance between the gear head (B). If the clearance exceeds the
shifting fork (A) and its synchronizer gear repair limit, go to step 2.
sleeves (B). If the clearance exceeds the
repair limit, go to step 2. Standard: 0.2-0.5 mm
Standard: 0.40-0.7 mm Repair limit: 0.62 mm
3.6.4 Measure the width of the shift lever fork

head.
3.6.2 Measure the thickness of the gear
shifting fork head. 3.6.4.1 If the width does not meet the standard,
replace with a new shift lever fork.
3.6.2.1 If the thickness does not meet the
standard, replace with a new gear shifting 3.6.4.2 If the width meets the standard,
fork. replace with a new gear shifting fork.
3.6.2.2 If the thickness meets the standard, Standard: 12.9-13.0 mm

replace with a new synchronizer gear
sleeve.
Standard:
1/2/3/4 gear shifting fork: 7.4-7.6 mm
5 gear shifting fork: 6.7-6.9 mm
145
3.7 Disassembly and reassembly of gear shifting fork
Before the reassembly, wash all the parts with solvents, and then apply lithium grease on all
the contact surfaces after they are dry.
146
3.8 Inspection of main shaft assembly clearance
Note: Replace the synchronizer hub if the synchronizer gear sleeve is to be replaced.
3.8.1 Prop up the bearing inner race with a 3.8.4 Measure the clearance between the 4th
proper tube seat (A), and then push it gear (A) and the distance ring (B) with a dial
down to the main shaft (B). gage (C). If the clearance exceeds the repair
limit, go to step 5.
3.8.2 Measure the clearance between the 2nd

gear and the 3rd gear with a feeler gauge
(E).
3.8.2.1 If the clearance exceeds the repair limit, 3.8.5 Measure the distance  on the distance
go to step 3. ring.
3.8.2.2 If the clearance meets the repair limit, 3.8.5.1 If the distance  does not meet the
go to step 4. standard, replace with a new distance ring.
Repair Limit: 0.40 mm 3.8.5.2 If distance  meets the standard, go to
step 6.
3.8.3 Measure the thickness of 3rd gear Standard: 24.03-24.08 mm
3.8.3.1 If the thickness of 3rd gear is less than

the repair limit, replace with a new 3rd gear.
3.8.3.2 If the thickness of 3rd gear meets the

repair limit, replace with a new 3rd / 4th gear
synchronizer hub.
3.8.6 Measure the thickness of 4th gear.
3.8.6.1 If the thickness is less than the repair

limit, replace with a new 4th gear.
3.8.6.2 If the thickness meets the repair limit,

then replace with a new 3rd / 4th gear
synchronizer hub.
147
3.8.9 Measure the thickness of 5th gear.

limit, replace with a new 5th gear.
3.8.7 Measure the distance between the
distance ring (A) and the 5th gear (B) with 3.8.9.2 If the thickness meets the repair limit,
a dial gage (C). If the distance exceeds the replace with a new 5th gear synchronizer
repair limit, go to step 8. hub.
Standard: 0.10-0.25 mm Standard: 28.88-28.93 mm
3.8.10 Measure the thickness of distance ring.

If the thickness does not meet the
standard, replace with a new distance ring.
Standard: 12-12.05 mm
3.8.8 Measure the distance  on the distance
ring.
3.8.8.1 If the distance  does not meet the

standard, replace with a new distance ring.
3.8.8.2 If the distance  meets the standard, 3.9 Disassembly of main shaft
go to step 9.
3.9.1 Remove the deep groove ball bearing,
Standard: 24.03-24.08 mm conical ring, main shaft distance ring,
reverse gear synchronizer ring and 5th
gear synchronizer gear sleeve.
3.9.2 Prop up the 5th gear (A) on a steel block,

and then press out the main shaft from the
5th gear synchronizer hub (B) as a puller
may damage the gear tooth.
148
A (Mounting surface of deep groove ball

bearing): 26.002-26.015 mm
B (Mounting surface of the 3rd/4th gear

distance ring): 29.008-29.021 mm
C (Mounting surface of needle bearing):

34.975-34.991 mm
D (Mounting surface of deep groove ball

bearing): 26.002-26.015 mm
E (Guiding shaft): 14.81-14.85 mm
Repair limit:
3.9.3 Prop up the 3rd gear (A) on a steel block,
and then press out the main shaft from the A: 25.95 mm
3rd/4th gear synchronizer hub (B) as a B: 28.95 mm
puller may damage the gear tooth. C: 34.92 mm
D: 25.95 mm
3.10.2 Prop up both ends of the main shaft to

inspect its circular run-out data. Rotate the
main shaft 2 turns during measurement. If the
data exceeds the repair limit, replace with a
new main shaft.
3.10 Inspection of main shaft
3.10.1 Inspect the gear surface and the

bearing surface for any wear or damage,
and then measure the main shaft at points
A, B,C, D and E. If any part of the main
shaft is less than the repair limit (except
point (E)), replace with a new main shaft.
Standard:
149
3.11 Reassembly of main shaft
Disassembly diagram
150
3.12 Inspection of counter shaft assembly clearance
3.12.1 Measure the clearance between the 1st

gear (A) and the counter shaft (B) with a
feeler gauge (C). If the clearance exceeds
the repair limit, go to step 2.
2.12.3 Measure the thickness of distance ring.

limit, replace with a new distance ring.
2.12.3.2 If the thickness meets the repair limit,

go to step 5.
3.12.2 Measure the thickness of 1st gear.
3.12.2.1 If the thickness of 1st gear is less

than the repair limit, replace with a new 1st
gear.
3.12.2.2 If the thickness of 1st gear meets the

repair limit, replace with a new 1st/2nd
synchronizer hub.
Repair limit: 26.79 mm 3.12.4 Measure the thickness of 2nd gear.
3.12.4.1 If the thickness of 2nd gear is less

than the repair limit, replace with a new
2nd gear.
3.12.4.2 If the thickness of 2nd gear exceeds

the repair limit, replace with a new 1st/2nd
synchronizer hub.
3.12.2.3 Measure the clearance between the
2nd gear (A) and the 3rd gear (B) with a
feeler gauge (C). If the clearance exceeds
the repair limit, go to step 4.
151
3.13 Disassembly of counter shaft
3.13.1 Clamp the counter shaft assembly to

the vise firmly with a wood block. 3.13.5 Prop up the 4th gear (A) on a steel
block (B), then press out the counter
shaft (E) from the 4th gear using the
press (C) and accessory (D).
3.13.2 Use the chisel (A) to pry the lock nut lug
(B) from the counter shaft groove.
3.13.3 Remove the lock nut (left-handed

thread) (A) and the spring washer (B).
3.13.6 Prop up the 3rd gear (A) on a steel
block (B), and then press out the
counter shaft (E) from the 3rd gear
using the press (C) and accessory (D).
3.13.4 Prop up the 5th gear (A) on a steel

block (B), and then press out the counter
shaft (E) from the ball bearing (F) using the
press (C) and accessory (D).
152
3.14 Inspection of counter shaft
3.14.1 Inspect the gear surface and the 3.14.2 Prop up both ends of the counter shaft
bearing surface for wear or damage, and to inspect its run-outs. Rotate the counter
then measure the counter shaft at points A, shaft for 2 turns during measurement. If
B and C. If any part of the counter shaft is the run-out exceeds the repair limit,
less than the repair limit, replace with a replace with a new counter shaft.
new counter shaft.
Standard: Repair limit: 0.05 mm
A (Ball bearing surface): 24.992-25 mm
B (Needle bearing surface): 37.989-38
mm
C (Needle bearing surface):
33.995-34.011 mm
Repair limit:
A: 24.942 mm
B: 37.939 mm
C: 33.945 mm
153
3.15 Reassembly of counter shaft
Disassembly diagram
Counter shaft distance ring
1st/2nd gear
synchronizer hub
1 st gear
Needle bearing
Needle bearing
Note: Refer to the disassembly diagram if necessary when performing the following steps.
154
3.15.1 Before the reassembly, wash all the

parts with solvents, and apply lithium
grease on all contact surfaces after they
are dry.
3.15.2 Install the needle bearing (A), 1st gear

of counter shaft (B) and 1st gear shock
absorber of counter shaft (C) onto the
counter shaft.
3.15.3 Install the 1st gear synchronizer ring (D)

and the 1st/2nd gear synchronizer spring
(E) onto the counter shaft.
3.15.6 Align the needle (C) on the 2nd gear
shock absorber of counter shaft with the
groove (D) on the 1st/2nd gear
synchronizer hub, and then install the
distance ring (A) and the 2nd gear shock
absorber of counter shaft (B).
3.15.4 Align the needle (A) on the 1st gear

shock absorber of counter shaft with the
groove (B) on the 1st/2nd gear
synchronizer hub, and then install the
1st/2nd gear synchronizer hub onto the
counter shaft.
3.15.7 Install the needle bearing (A) and 2nd
gear (B).
3.15.5 Install the 1st/2nd gear synchronizer

gear sleeve (A), 2nd gear synchronizer
spring (B) and 2nd gear synchronizer ring
(C) onto the counter shaft.
155
3.15.8 Install the 3rd gear (A) with special tools

and the press (B).
3.15.11 Install 5225 cylindrical roller bearing (A)

with special tools and the press (B).
3.15.9 Install the 4th gear (A) with special tools

and the press (B).
3.15.12 Install the deep groove ball bearing (A)

with special tools and the press (B).
3.15.10 Install the 5th gear (A) with special
tools and the press (B).
156
3.16.1 Check the gear teeth on all the

synchronizer hubs and gear sleeves for
any round corner, which is a sign of wear.
3.16.2 Install the synchronizer hub (A) into the

synchronizer gear sleeve (B), and check if
it can move freely. Make sure 3 sets of
long teeth (C) (with an interval angle of
120º) on the synchronizer gear sleeve fit
well with the groove (D) on the
synchronizer hub. Do not install the long
teeth into the slot (E) on the synchronizer
hub when installing the synchronizer gear
sleeve, as the spring coil may be
damaged.
Note: Replace the synchronizer hub if the

synchronizer gear sleeve is to be replaced.
3.15.13 Install 22 mm spring washer (A) and
lock nut (B) (left-handed thread).
3.15.14 Clamp the counter shaft assembly to

the vise firmly with a wood block.
3.15.15 Tighten the new lock nut to 110 Nm,

loosen it and then tighten it again to the
same torque. Put the lug of lock nut into
the groove.
3.16 Inspection of synchronizer gear

sleeve and gear hub
157
3.17 Inspection of synchronizer ring and

gear 3.17.4 Inspect the stress surface (D) of each
gear hub for any wear.
3.17.1 Inspect the inside of each synchronizer
ring (A) for any wear. 3.17.5 Inspect the conical surface (E) of each
gear hub for any wear or roughness.
3.17.6 Inspect the gear teeth on all the gears

(F) for any wear, scratch or crack.
3.17.7 Apply oil on the conical surface of each

gear (E), and install its synchronizer ring.
Rotate the synchronizer ring, and make
sure it does not slip.
3.17.8 Measure the clearance between each

gear (A) and its synchronizer ring (B) one
by one. Push the synchronizer ring against
the gear, and then measure the clearance.
If the measured value is less than the
repair limit, replace the synchronizer ring
and the gear.
Clearance between the synchronizer ring
and gear
Illustration of synchronizer ring gear teeth
Good Worn
Illustration of synchronizer gear sleeve
and gear teeth
Good Worn
3.17.2 Inspect the teeth (B) of each

synchronizer ring for any wear (round
corner).
3.17.3 Inspect the teeth (C) of each

synchronizer gear sleeve and the mating
teeth on each gear for any wear (round
corner).
158
3.18 Replacement of main shaft bearing

and oil seal
3.18.1 Remove the differential assembly.
3.18.2 Remove the deep groove ball bearing

(A) from the front casing (B) with special
tools.
3.18.5 Tap the new bearing into the

transmission casing from the side with
special tools.
3.18.3 Remove the oil seal (A). Be careful not

to damage the casing while removing
the oil seal.
3.18.4 Tap the new oil seal into the

transmission casing from the side with
special tools.
159
3.19 Replacement of counter shaft

bearing
3.19.1 Remove the cylindrical roller (A) and

then remove the engine oil deflector 2 (C)
with special tools.
3.20.2 Select a proper 72 mm adjusting shim

from the following table. Use the
measurement results in step 1 (See the
following examples).
Marker Thickness Marker Thickness

A 0.60 mm N 1.25 mm
B 0.65 mm O 1.30 mm
C 0.70 mm P 1.35 mm
D 0.75 mm Q 1.40 mm
E 0.80 mm R 1.45 mm
F 0.85 mm S 1.50 mm
G 0.90 mm T 1.55 mm
H 0.95 mm U 1.60 mm
3.20 Adjustment of main shaft meshing I 1.00 mm V 1.65 mm
clearance J 1.05 mm W 1.70 mm
K 1.10 mm X 1.75 mm
3.20.1 Measure the height (A) from the contact L 1.15 mm Y 1.80 mm
surface of front casing to 72 mm deep M 1.20 mm - -
groove ball bearing on the main shaft, and
then measure the depth (B) from the Basic formula: B-A-(0.10-0.18) = Gasket
contact surface of rear casing to the thickness
mounting hole of 72 mm deep groove ball
bearing on the main shaft. Make sure the 3.20.3 Install the selected 72 mm adjusting
proper clearance is left. shim (A) and oil deflector 1 onto the
rear casing (B).
160
3.21.4 Install the reverse gear lock cam

3.21 Reassembly of transmission assembly, and then apply sealant on the
threads of the mounting bolts.
Note: Before the reassembly, wash all the
parts with solvents, and apply lithium grease
15 Nm
on all contact surfaces after they are dry.
3.21.1 Install the magnet (A) and differential

assembly (B).
3.21.5 Install the reverse gear shaft fork

assembly, and then apply sealant on the
threads of the mounting bolts.
15 Nm
3.21.2 Install 8 mm spring washer (A) and fork

shaft screw (B).
3.21.6 Install the idler gear assembly (A) and

reverse gear shaft (B).
3.21.3 Wrap the main shaft spline (C) with the

adhesive tape, and then install the main
shaft and counter shaft (E) onto the gear 3.21.7 Select the proper 72 mm washer (A)
shifting fork assembly as an assembly. according to the measured value in the
section "Adjustment of main shaft meshing
161
clearance". Install the drainage trough

plate (B), engine oil deflector 1 (M) and 72
mm washer onto the transmission rear
casing.
3.21.10 Open the counter shaft circlip (B) with

circlip pliers, clamp it in the groove of the
counter shaft bearing and verify the
condition.
3.21.8 Remove the oil strain on the contact

surface of the transmission box. Apply
sealant on the contact surface, and make
sure the perimeter of the bolt hole has
been sealed to avoid oil leakage.
Note: If the parts are not installed within 5

minutes after the sealant was applied, the
sealant must be applied again. Fill the oil 3.21.11 Install the positioning pin (A).
in the transmission only when the sealant
is dried for at least 20 minutes after the
parts are assembled.
Sealant
3.21.9 Apply sealant on the threads of the 3.21.12 Install the hexagon flange bolt (A) M8
sealing plug (25 Nm) (A), and then install it × 40 (25 Nm), high pressure steel pipe
onto the transmission rear casing. mounting bracket of clutch (B) and
hexagon flange bolt (C) M8 × 45 (25 Nm).
162
3.21.13 Install the cylindrical pin (A) and

manual gear shift assembly (B).
10 Nm
3.21.13 Tighten the lock bolts alternatively.
3.21.14 Install the check bolt (A) (22 Nm), 12

mm flat washer, check spring, steel ball
and reversing light switch assembly (B)
(30 Nm).
3.21-14 Remove the oil strain on the contact

surface of the gear shifting arm cover, and
then apply sealant. (The width of the
sealant should be 2.5 mm±0.5 mm)
3.21.15 Install the neutral switch assembly (A)
(35 Nm). (Note: Applicable for
transmissions with neutral switch
assembly)
Sealant
163
3.21.16 Install the drain plug, 14 mm flat washer

(A), oil filler plug, 20 mm flat washer (B)
and vehicle speed sensor (C). Check if the
O-ring (D) is broken, and replace it when
necessary.
164
Section 4 Differential
4.1 Disassembly of differential
Disassembly diagram of differential
165
4.2 Inspection of backlash
4.2.1 Put the differential assembly on a 4.4 Replacement of differential

V-block, with half shaft installed on both housing/vehicle speed sensor
ends. driving gear
4.4 1 Check if the differential bearing is worn

abnormally and if it can rotate freely. The
bearing is in good condition if it can rotate
freely and there is no abnormal wear.
4.4.2 Remove the left and right bearings of the

differential from the differential housing
with the puller and bearing extractor.
4.2.2 Measure the backlash with a dial gage

while putting the gauge outfit on the tooth
surface of the planetary gear. Replace the
fault parts if the backlash does not meet
the following standard.
Standard: 0.05 mm - 0.25 mm.
4.3 Removal and Installation of final

drive driven gear
4.3.1 Remove the differential bolts

alternatively in several steps, and then
remove final drive driven gear from the
differential housing.
4.4.3 Remove and install the driving gear of
the vehicle speed sensor.
4.3.2 Install the final drive driven gear with the

bore upper chamfer facing the differential
housing, and tighten the bolts alternatively
in several steps. Note: Using the special tools, install the
left and right bearings of the differential
Tightening torque for the differential bolts: with the bearing dust cover facing
100 Nm. outwards.
166
4.5 Replacement of differential oil seal

4.5.4 Install the new oil seal to the
4.5.1 Remove the differential assembly. transmission casing with special tools.
4.5.2 Remove the left oil seal of differential
from the transmission rear casing;
4.5.3 Remove the right oil seal of differential

from the transmission front casing.
167
4.6 Replacement of differential adjusting

shim
If the differential housing, transmission
front casing or transmission rear casing is
replaced when servicing, a new 80 mm
adjusting shim should be selected.
4.6.1 Install the differential assembly into the

front casing.
4.6.4 Measure the clearance between the end

face of the differential left bearing and the
rear casing with a feeler gauge, then select
an 80 mm adjusting shim with the proper
thickness based on the measurement
result. Make sure to leave a proper
clearance between the adjusting shim and
outer ring of the differential left bearing.
4.6.2 Close the transmission rear casing, and Select a proper gasket from the following
tighten the assembly bolts around the table.
differential alternatively in several steps.
Standard clearance: 0 mm - 0.10 mm
4.6.3 Tap the differential assembly gently with

the special tool, and make sure the
differential assembly is properly installed in
the front casing.
168
Adjust the gasket thickness: K 1.20 mm L 1.25 mm
M 1.30 mm N 1.35 mm
Marker Thickness Marker Thickness
O 1.40 mm P 1.45 mm
A 0.70 mm B 0.75 mm
Q 1.50 mm - -
C 0.80 mm D 0.85 mm
E 0.90 mm F 0.95 mm 4.6.5 Remove and install the bolts and

transmission rear casing.
G 1.00 mm H 1.05 mm
4.6.6 Reinstall the transmission.
I 1.10 mm J 1.15 mm
169
Chapter 4 6T25 Manual Transmission

Contents
Section 1 Introduction of Transmission ................................................................................. 171

1.1 Structural Parameters ............................................................................................ 171
1.2 Service Guidelines................................................................................................. 172
1.3 General Requirements .......................................................................................... 172
Section 2 Transmission Operating Mechanism .................................................................... 175
2.1 Introduction of Manual Gear Shift Assembly ......................................................... 175
2.2 Service of Manual Gear Shift Assembly ................................................................ 175
2.3 Installation of Manual Gear shift Assembly ........................................................... 176
2.4 Introduction of Gear Shifting Fork Shaft Assembly ............................................... 178
2.5 Gear Shifting Fork Shaft Assemblies for Each Gear ............................................. 178
Section 3 Transmission mechanism ..................................................................................... 179
3.1 Transmission Sketch ............................................................................................. 179
3.2 Disassembly and Assembly of Main Shaft Components....................................... 179
3.3 Disassembly and Assembly of Counter Shaft 1 Components .............................. 180
3.4 Disassembly, Inspection and Assembly of Counter Shaft 2 Components ............ 185
3.5 Disassembly and Assembly of Differential Components....................................... 190
Section 4 Transmission Assembly ........................................................................................ 193
4.1 Construction of Transmission Assembly ............................................................... 193
4.2 Disassembly of Transmission Assembly ............................................................... 194
4.3 Service of Transmission Assembly ........................................................................ 196
4.4 Assembly of Transmission Assembly .................................................................... 200
170
Section 1 Introduction of Transmission

1.1 Structural Parameters
Transmission model BYD6T25/BYD6T25-1A

Applicable Engine Model BYD488QA/BYD476ZQA
Type 6-gear MT
Overall Length (mm) 375
Overall dimensions (length×width×height) (mm) 375×510×490
Maximum input torque ( Nm) 250
80W-90 (For summer in northern China),
Classification
Gear Oil 75W-90 (For winter in northern China)
Volume (L) 3.0
Weight (excluding clutch) (kg) 52
Transmission
BYD6T25-1A
model
2nd 4th
Gear 1st gear 3rd gear 5th gear 6th gear Reverse gear
gear gear
Gear ratio 49/13 48/23 45/34 42/43 39/40 35/43 36/13×23/14
Drive ratio 3.769 2.087 1.324 0.977 0.975 0.814 4.549
Final drive gear
72/17 72/22
ratio
Final drive ratio 4.235 3.273
Total drive ratio 15.962 8.838 5.607 4.138 3.191 2.664 14.89
Transmission
BYD6T25
model
2nd 4th
Gear 1st gear 3rd gear 5th gear 6th gear Reverse gear
gear gear
Gear ratio 47/13 48/22 47/32 46/40 43/36 39/40 34/13×23/14
Drive ratio 3.615 2.182 1.469 1.150 1.194 0.975 4.297
Final drive gear
71/18 71/23
ratio
Final drive ratio 3.944 3.087
Total drive ratio 14.258 8.606 5.794 4.536 3.686 3.01 13.265
171
Clean the joint surface of the box

1.2 Service Guidelines thoroughly and apply sealant.
The flange sealant should be applied
1.2.1 Prepare the parts kit and parts rack in uniformly and continuously so that it can
advance to store the removed and fully fill the sealing strip. It is recommended
disassembled components. Put them in that the sealant diameter is between 2
order and make markers if necessary to mm~3 mm.
avoid confusion and misplacement.
There should be no sealant in the threaded
1.2.2 Be careful when positioning the hole, ventilation hole or on the positioning
aluminum alloy parts to avoid damage to pin.
the machined surface.
1.3.3 Circlip
1.2.3 Prepare sufficient auxiliary materials for
use in the process of servicing. The circlip is a disposable product which
should be replaced after removal.
1.2.4 For the bolts and other fastening parts
with standard tightening torque Select the thickest circlip that can be fitted
requirements, tighten them with special into the circlip groove.
tools in accordance with the required 1.3.4 Nut and bolt
values.
1.3.4.1 Loosen or tighten the bolts or nuts on
1.2.5 After servicing, disposable supplies the transmission diagonally.
should be scrapped and replaced with new
ones. 1.3.4.2 Tighten the bolts or nuts in
accordance with the specified tightening
1.2.6 Use correct removal tools for torque.
disassembly and assembly.
1.3.4.3 For all the threaded holes with
1.2.7 Refer to this service manual as much as sealant, remove the residues from the
possible during work. holes with a thread tap before using them
1.2.8 Refer to the structural sketch of the again.
transmission when necessary. 1.3.5 Bearing
1.2.9 If you encounter any difficult technical 1.3.5 There is no need to lubricate the new
problems during servicing, it is bearings if they are supplied as a complete
recommended to consult our aftersales set.
technical service department.
1.3.5.2 The bearings on the same shaft must
1.3 General Requirements be replaced together and the bearings
from the same supplier should be used.
1.3.1 Oil seal and seal ring
1.3.5.3 The inner ring and outer ring of conical
The oil seal is a disposable product which bearing must be used in sets and cannot be
should be replaced after removal. exchanged.
Before installation, thoroughly clean the 1.3.6 Adjusting shim
mounting surface of the oil seal.
1.3.6.1 Measure the adjusting shim at several
Before installing the oil seal, check each positions with a micrometer and take the
part for crack, scratch and notch. If so, the average as the thickness of the adjusting
oil seal cannot be used. shim.
The new oil seal lip contains grease which 1.3.6.2 Check for any burr or damage.
should not be coated again.
1.3.6.3 Only install the adjusting shims without
Before removing and installing the part defects.
with a seal ring, check if the seal ring still
1.3.7 Synchronizer ring
functions. If not, replace it.
1.3.7.1 The removed synchronizer ring
1.3.2 Sealant
172
components should be placed in sets and oil.

installed in the original positions on the
1.3.8 Gear
synchromesh gear when reused.
1.3.8.1 Before installation, clean the gears to
1.3.7.2 Check if the conical surface of the
check for any sign of collision or defect.
synchronizer ring is worn and replace it
when necessary. 1.3.8.2 After assembly, check the gear
clearance and if the gear can rotate freely.
1.3.7.3 The coating of the synchronizer ring
should not be damaged. 1.3.9 Auxiliary materials
1.3.7.4 Before installation, lubricate the conical The materials should be prepared for use
surface of the synchronizer ring with gear at any time.
Auxiliary Material Table 1:
Model or
Fitting Position Grease application area
specification
Inner lip and outer ring of main shaft oil seal
Inner lip and outer ring of differential oil seal
Inner and outer rings of gear shifting shaft sleeve
Front box assembly
Counter shaft 1 front bearing outer ring
Counter shaft 2 front bearing outer ring No.2 lithium
Differential bearing outer ring grease (GB/T
Inner lip and outer ring of differential oil seal 7324-1984
Inner and outer rings of gear shifting shaft sleeve General lithium
Rear box assembly
Counter shaft rear bearing outer ring grease) or
Differential bearing outer ring verified
Inner and outer rings of shift lever oil seal equivalent
Shift lever shaft sleeve
Manual gear shift
Select lever bearing
assembly
Mating surface of gear shifting bracket assembly
and gear selecting fork head
Auxiliary Material Table 2:
Name, brand or
Part name Sealant application area specification of the
sealant
Gear shifting arm Flange sealant
Inside of the sealing surface edge
cover (Loctite 587 or verified
Front box Inside of the sealing surface edge equivalent)
Gear shifting steel ball
Bolt threads Thread sealant
assembly
(Loctite 567 or verified
Drain plug assembly Drain plug threads
equivalent)
Neutral switch Neutral switch threads
173
1.3.10 The transmission fasteners should be tightened to the specified tightening torque as
follows.
Tightening torque table:
Part Tightening
Quantity
Part Bolt size No./International torque
per unit
Standard No. (Nm)
Hexagon flange
M8×25 Q1840825T1F6 2 20
bolt
Drain plug
M18×1.5 BYD6T25-1701680 2 30
assembly
Reversing light
M12×1.5 BYD6T25-4113010 1 35
switch assembly
Gear shifting
steel ball M27×1.5 BYD6T25-1701620 1 45
assembly
Release bearing
assembly M7×1 BYD6T25-1601111 3 15
mounting bolts
Neutral switch M18×1.5 BYD5T19-1-3781100 1 35
Hex nut M8 GB/T 41 1 23
Assembly bolt M8×1.5 BYD6T25-1701601 20 40
Stud bolt M12×1.25 BYD6T25-1701604 3 35
Hexagon flange
M6×20 Q1840620T1F3 1 15
bolt
Hexagonal head
bolt and spring M8×20 Q1420820T1F6 1 20
washer assembly
Hexagonal head
bolt and spring M8×25 Q1420825T1F6 1 20
washer assembly
174
Section 2 Transmission Operating Mechanism

2.1 Introduction of Manual Gear Shift Assembly
2.1.1 Shift lever assembly
2.1.2 Gear shifting arm cover

The select lever shaft sleeve on the gear
shifting arm cover should not be removed.
It must be replaced together with the gear
shifting arm cover.
2.1.3 Split washer

It is a disposable product which should be
replaced with new parts after removal.
2.1.4 Gear selecting bracket assembly
2.1.5 Gear selecting fork head
2.1.6 Hex nut

2.1.7 Spring washer
2.1.8 Flat washer
2.1.9 Gear shifting bracket assembly
2.1.10 Vent pipe cap
2.1.11 Vent pipe
The vent pipe assembly should not be

blocked. 2.2 Service of Manual Gear Shift
During installation, align the flat key Assembly
opening.
Note: The parts in the dotted box as shown 2.2.1 Check if the gear shifting shaft (a) on the
in the right figure should not be further shift lever assembly 1 is worn.
disassembled.
2.2.2 Check the gear shifting oil seal
press-fitted in the gear shifting arm cover 2
for oil leakage or abnormal wear. Replace
it if there is any abnormity.
Note: The shift lever assembly 1 and the

gear shifting arm cover 2 cannot be
separated. They must be replaced as a
whole when necessary.
175
2.2.3 Check if the gear shifting fork head 5 can

slide freely when fitted with the gear
2.3 Installation of Manual Gear shift
selecting bracket assembly 4 and gear
shifting assembly 9. The No.2 lithium Assembly
grease (GB/T 7324-1994 General lithium
grease) or verified equivalent should be 2.3.1 Install the vent pipe and vent pipe cap
applied on the gear selecting fork head 5 Tap the vent pipe 3 gently into the gear
to ensure it can slide freely. Replace the shifting arm cover 2 with a tool and install
gear shifting fork head 5 if aging, breakage the vent pipe cap 4.
or plastic deformation occurs.
Note: The shift lever assembly 1 and the
gear shifting arm cover 2 cannot be
separated. They must be replaced as a
whole when necessary.
176
2.3.2 Install the gear selecting bracket 2.3.3 Install the gear shifting bracket assembly,
assembly 4 and gear selecting fork head flat washer, spring washer and hex nut in
5. turns to finish installation of the manual
Note: The No.2 lithium grease (GB/T gear shift assembly.
7324-1994 General lithium grease) or Note: The tightening torque for the hex nut
verified equivalent should be applied on is 18 Nm.
the gear selecting fork head 5.
The split washer 3 is a disposable product
which should be replaced with a new part
after removal.
177
2.4 Introduction of Gear Shifting Fork Shaft Assembly
The gear shifting fork shaft assemblies for

each gear are installed on the shaft as
shown in the right figure:
1 Counter shaft 1 assembly

2 1st/2nd gear shifting fork shaft assembly
3 3rd/4th gear shifting fork shaft assembly
5 5th/6th gear shifting fork shaft assembly
6 Reverse gear shafting fork assembly
7 Main shaft assembly
8 Reverse shaft assembly
9 End bearing stopper plate
10 T-tube assembly
11 Front box
12 Differential assembly
2.5 Gear Shifting Fork Shaft

Assemblies for Each Gear
A 3rd/4th gear shifting fork shaft assembly

B 5th/6th gear shifting fork shaft assembly
C 1st/2nd gear shifting fork shaft assembly
D Reverse gear shafting fork assembly
1 Vibration damper
2 Linear bearing
Note: The gear shifting fork shaft
assemblies for each gear should not be
further disassembled.
178
Section 3 Transmission mechanism

3.1 Transmission Sketch
1 Reverse idler gear shaft assembly

6 Final drive driven gear
7 Counter shaft 2nd gear assembly
8 Counter shaft 1st gear assembly
9 Counter shaft 4th gear assembly
10 Counter shaft 3rd gear assembly
13 Reverse idler gear
3.2.2 Disassembly of Main Shaft Components
3.2.2.1 Pull out the main shaft rear bearing

Remove the main shaft rear bearing circlip.
Place the press block and pressure piece
on the output shaft before installing the
puller.
Place the diffuser in the groove of main
shaft rear bearing circlip.
3.2 Disassembly and Assembly of Main

Shaft Components
3.2.1 Assembly Overview 3.2.2.2 Press out the main shaft 5th gear
to finish the disassembly of main shaft
1 Main shaft rear bearing outer circlip components.
2 Rear box
3 Rear bearing circlip
4 Main shaft rear bearing
5 Main shaft 5th gear
6 Main shaft
7 Main shaft front bearing
8 Front box
179
3.2.2.3 Install the main shaft rear bearing outer

circlip
Select the proper main shaft rear bearing

circlip A. After installation, use a feeler
gauge C to measure the clearance
between A and B and make sure it is less
than 0.05 mm.
3.2.2 Assembly of Main Shaft Components
3.2.2.1 Press out the main shaft 5th gear.

The groove in the gear must face upward
(indicated by the arrow in the right figure)
.
3.3 Disassembly and Assembly of

Counter Shaft 1 Components
3.3.1 Assembly Overview of Counter Shaft 1

Components
1 Front box
2 Oil deflector
3 Oil guide sleeve
4 Counter shaft 1 front bearing outer ring
5 Counter shaft 1 front bearing
6. Counter shaft 1
3.2.2.2 Press in the main shaft rear bearing. 7. 1st, 2nd and 4th gear needle bearing
The circlip groove should face upward 8 Counter shaft 2nd gear assembly
(indicated by A in the right figure). The 9 1st and 2nd gear synchronizer inner rings
bearing shoulder should face the main 10 1st and 2nd gear synchronizer middle
shaft 5th gear (indicated by B in the right steel rings
figure). 11 1st and 2nd gear synchronizer outer rings
Apply the grease before reassembly. 12 1st and 2nd gear synchronizer assembly
13 1st and 2nd gear synchronizer hub circlips
14 1st and 2nd gear synchronizer outer rings
15 1st and 2nd gear synchronizer middle
steel rings
16 1st and 2nd gear synchronizer inner rings
17 1st, 2nd and 4th gear needle bearings
18 Counter shaft 1st gear assembly
19 Counter shaft 1st gear snap-gauge
20 Counter shaft 1st gear snap-gauge outer
ring
21 1st, 2nd and 4th gear needle bearings
23 4th gear synchronizer ring
24 3rd and 4th gear synchronizer assembly
25 3rd/4th gear synchronizer hub circlips
180
26 3rd gear synchronizer outer ring

27 3rd gear synchronizer middle steel ring
28 3rd gear synchronizer inner ring
29 3rd gear needle bearing
30 Counter shaft 3rd gear assembly
31 Counter shaft rear bearing
32 Rear bearing circlip
33 Counter shaft rear bearing outer ring
34 Counter shaft adjusting shim
35 Rear box
3.3.2.4 Remove the 3rd/4th gear synchronizer

hub circlip.
3.3.2.5 Use a tool to remove the 3rd/4th

synchronizer assembly, counter shaft 4th
gear assembly, 4th gear synchronizer ring
and 4th gear needle bearing.
3.3.2 Disassembly of Counter Shaft 1

Components 3.2.6 Remove the counter shaft 1st gear
snap-gauge outer ring and counter shaft
3.3.2.1 Remove the oil guide sleeve. 1st gear snap-gauge.
3.3.2.2 Remove the bearing circlip at the rear 3.3.2.7 Remove the counter shaft 1st gear
end of the counter shaft. assembly.
3.3.2.3 Use a tool to remove the counter shaft 3.3.2.8 Remove 1st/2nd gear synchronizer
rear bearing and remove the counter shaft outer ring C, 1st/2nd gear synchronizer
3rd gear assembly, 3rd gear needle middle steel ring B and 1st/2nd gear
bearing, 3rd gear synchronizer outer ring, synchronizer inner ring A in turns.
3rd gear synchronizer middle ring and 3rd
gear synchronizer inner ring in turns.
181
Press the synchronizer ring assembly for

each gear onto the corresponding gear
cone and measure the clearance a with a
feeler gauge.
Repair
3.3.2.9 Press out the counter shaft 2nd gear Clearance a Standard size
limit
assembly and 1st/2nd gear synchronizer 1st/2nd gear
assembly. 0.75~1.25
synchronizer ring 0.5 mm
mm
assembly
3rd/4th gear
0.75~1.25
synchronizer ring 0.5 mm
mm
assembly
4th gear
1.0~1.7 mm 0.5 mm
synchronizer ring
3.3.3.5 Disassemble each gear synchronizer

assembly if necessary and check each
component for any abnormal wear.
1 Synchronizer spring
2 Slide block
3 Synchronizer gear sleeve
4 Synchronizer hub
3.3.3 Service of Counter Shaft 1 Components
3.3.3.1 Check each component for abnormal

wear and damage.
3.3.3.2 Turn each gear and bearing to check

for seizure or abnormal noise.
3.3.3.3 Check if each gear synchronizer can

be shifted to the corresponding gear
position easily.
3.3.3.4 Check the synchronizer ring for wear.
182
3.3.3.6 Install the synchronizer assembly.

Install the synchronizer gear sleeve to the
synchronizer gear hub. Align the gear
sleeve with the missing teeth of the gear
hub to make sure the slide block can be
installed properly.
The gear hub and gear sleeve should be

installed in the correct direction.
Insert the slide block and install the spring

at an angle of 120°with the angled end
placed into the hollow slide block.
The boss in the 1st/2nd gear synchronizer

hub should face downward (2nd gear
direction). The end with an identification
groove in the 1st/2nd synchronizer gear
sleeve should face upward (1st gear
direction).
The boss in the 3rd/4th gear synchronizer 3.3.4.2 Use a tool to press the 1st/2nd
hub should face upward (3rd gear synchronizer assembly into the
direction). The end with an identification corresponding position.
groove in the 3rd/4th synchronizer gear
sleeve should face upward (4th gear 3.3.4.3 Install the 1st/2nd gear synchronizer
direction). hub circlip of proper thickness.
3.3.4.4 Install the counter shaft 1st gear

snap-gauge and snap-gauge outer ring.
3.3.4 Assembly ofCounter Shaft 1 Components

3.3.4.5 Install the counter shaft 4th gear
3.3.4.1 Place the counter shaft 2nd gear needle bearing and counter shaft 4th gear
needle bearing, counter shaft 2nd gear assembly.
assembly and 1st/2nd gear synchronizer
ring assembly in the counter shaft. 3.3.4.6 Install the 4th gear synchronizer ring.
3.3.4.7 Press in the 3rd/4th gear synchronizer

assembly.
3.3.4.8 Install the 3rd/4th gear synchronizer

hub circlip of proper thickness.
183
distance a from the counter shaft 1 rear

bearing outer ring to the box joint surface;
3.3.5.2 Use a depth gage to measure the

distance a' from the installation position of
rear box counter shaft 1 rear bearing outer
ring to the box joint surface;
3.3.5.3 The thickness h of rear bearing

adjusting shim is calculated as follows:
h  a'a  (0.05～0.1)mm
Select the proper axial pre-tensioning

3.3.4.9 Install the 3rd gear synchronizer ring thickness (0.05~0.1 mm), and correct the
assembly. value h to the nearest shim thickness.
For example:
3.3.4.10 Press in the counter shaft rear If a is 197.10 mm;
bearing. If a' is 198.40 mm;
3.3.4.11 Select a proper counter shaft rear h  a'a  (0.05～0.1)mm =1.30+0.1=1.4
bearing circlip to finish the assembly of
counter shaft 1 components. 0 mm;
Therefore, the selected thickness of the

counter shaft 2 rear bearing adjusting shim
is 1.40 mm.
3.3.5 Selection of Counter Shaft 1 Rear

Bearing Adjusting Shim
The counter shaft 1 components must be

adjusted again if any of the following
components are replaced.
a Front box
b Rear box
c Counter shaft 1 rear bearing
d Counter shaft 1 front bearing
e Counter shaft 1
The counter shaft 1 assembly adjusting

shim is selected as follows:
3.3.5.1 Use a height gauge to measure the
184
3.4 Disassembly, Inspection and

Assembly of Counter Shaft 2
Components
3.4.1 Assembly Overview of Counter Shaft 2

Components
1 Front box
2 Counter shaft 2 front bearing outer ring
3 Counter shaft 2 front bearing
4 Counter shaft 2
5 Reverse gear synchronizer hub
6 Reverse gear synchronizer gear sleeve
(with reverse gear synchronizer ring)
7 Reverse gear needle bearing
8 Reverse gear assembly
9 Distance ring
10 Distance ring circlip
11 6th gear needle bearing
13 5th/6th gear synchronizer ring
14 5th/6th gear synchronizer assembly
15 5th/6th gear synchronizer hub circlip 3.4.2 Disassembly of Counter Shaft 2
16 5th gear needle bearing Components
17 5th/6th gear synchronizer ring
18 Counter shaft 5th gear assembly 3.4.2.1 Remove the rear bearing circlip.
19 Counter shaft rear bearing
20 Rear bearing circlip 3.4.2.2 Pull out the counter shaft 2 rear
21 Counter shaft rear bearing outer ring bearing with the combination tools.
22 Counter shaft adjusting shim
23 Rear box 3.4.2.3 Remove the counter shaft 5th gear
24 5th/6th gear synchronizer spring assembly, 5th gear needle bearing and
25 5th/6th gear synchronizer gear sleeve 5th/6th gear synchronizer ring in turns.
26 5th/6th gear synchronizer gear hub
27 Synchronizer slide block 3.4.2.4 Remove the 5th/6th gear synchronizer
hub circlip.
185
3.4.2.5 Clamp the snap-gauge at the bottom of 3.4.2.11 Press out the reverse gear
counter shaft 6th gear assembly, and synchronizer hub with the combination
press out the shaft with a pressure lever. tools.
Remove the 5th/6th gear synchronizer
assembly, 5th/6th gear synchronizer ring
and counter shaft 6th gear assembly in
turns.
3.4.2.6 Remove the distance ring circlip and

distance ring.
3.1.2.12 Pull out the counter shaft 2 front

bearing with the tools.
3.4.2.7 Clamp the snap-gauge at the bottom of

reverse gear assembly, and press out the
shaft with a pressure lever.
3.4.2.8 Remove the reverse gear assembly

and reverse gear needle bearing in turns.
3.4.2.9 Remove the reverse gear synchronizer

hub circlip.
3.4.2.10 Remove the reverse gear

synchronizer gear sleeve.
186
3.4.3 Service of Counter Shaft 2 Components
3.4.3.1 Check each component for abnormal

wear and damage.
3.4.3.2 Turn each gear and bearing to check

for seizure or abnormal noise.
3.4.3.3 Check if each gear synchronizer can

be shifted to the corresponding gear
position easily.
3.4.3.4 Check the wear condition of 5th/6th

gear synchronizer ring.
3.4.3.6 Install the synchronizer assembly.
Position the synchronizer ring on the
Install the synchronizer gear sleeve on the
corresponding gear cone horizontally, and
synchronizer gear hub, and align the
rotate it for 2 or 3 turns to make sure the
synchronizer gear sleeve with the missing
synchronizer ring contact with the gear
teeth of the synchronizer gear hub to make
cone. Using a feeler gauge, measure the
sure the slide block can be installed
clearance a between the synchronizer ring
properly.
and gear at several positions around the
circumference and record the values.
The synchronizer gear hub and
synchronizer gear sleeve should be
Clearance a Standard size Repair limit installed in the correct direction.
5th gear Insert the slide block and install the spring
synchronizer 1.0~1.7 mm 0.5 mm at an angle of 120°with the angled end
ring placed in the hollow slide block.
6th gear
synchronizer 1.0~1.7 mm 0.5 mm
ring
3.4.3.5 If necessary, disassemble each gear

synchronizer assembly and check each
component for any abnormal wear.
1 Synchronizer spring
2 Slide block
3 Synchronizer gear sleeve
4 Synchronizer hub
187
3.4.4 Installation of Counter Shaft 2

Components
3.4.4.1 Press in the counter shaft 2 front

bearing.
3.4.4.2 Press in the reverse gear synchronizer

hub.
3.4.4.3 Install the reverse gear synchronizer

gear sleeve, and select and fix the reverse
gear synchronizer hub circlip with proper
thickness in the circlip groove.
3.4.4.4 Install the reverse gear synchronizer

gear sleeve with reverse gear 3.4.4.10 Press in the 5th/6th gear synchronizer
synchronizer ring. assembly.
3.4.4.5 Install the reverse gear needle bearing 3.4.4.11 Select a 5th/6th gear synchronizer
and reverse gear assembly. hub circlip with proper thickness and fix it
in the circlip groove.
3.4.4.12 Install the 5th/6th gear synchronizer

ring, 5th/6th gear needle bearing and
counter shaft 5th gear assembly in turns.
3.4.4.6 Press in the distance ring.
3.4.4.7 Select a distance ring circlip with

proper thickness and fix it in the circlip
groove.
3.4.4.13 Press in the counter shaft rear
3.4.4.8 Install the 6th gear needle bearing and bearing.
counter shaft 6th gear assembly.
3.4.4.9 Install the 5th/6th gear synchronizer

ring.
188
3.4.5.2 Using a depth gauge, measure the

rear box counter shaft 2 rear bearing
outer ring to the joint surface of the box;
3.4.5.3 The thickness h of the rear bearing

adjusting shim is calculated as follows:
h  a'a  (0.05～0.1)mm
Select the proper axial pre-tensioning

thickness (0.05~0.1 mm), and correct the
value h to the nearest shim thickness.
For example:
3.4.4.14 Select a rear bearing circlip with
proper thickness and fix it in the circlip If a is 215.50 mm;
groove. If a' is 216.98 mm;
h  a'a  (0.05～0.1)mm =1.48+0.05≈1.

55 mm;
The selected thickness of the counter shaft

2 rear bearing adjusting shim should be
1.55 mm.
3.4.5 Selection of Counter Shaft 2 Rear Bearing

Adjusting Shim
The counter shaft 2 components must be

adjusted again if any of the following
components are replaced.
 Front box
 Rear box
 Counter shaft 2 rear bearing
 Counter shaft 2 front bearing
 Counter shaft 2
The counter shaft 2 assembly adjusting
shim is selected as follows:
3.4.5.1 Using a height gauge, measure the

distance a from the counter shaft 2 rear
bearing outer ring to the joint surface of
the box;
189
3.5 Disassembly and Assembly of Differential Components
3.5.1 Assembly Overview of Differential Components
1 Rear box 8 Differential bearing stopper plate

2 Differential adjusting shim 9 Front box
3 Differential bearing outer ring 10 Differential oil seal
4 Differential bearing 11 Differential side gear
5 Final drive driven gear (with differential 12 Differential planetary gear shaft
housing) 13 5X35 carbon steel spring pin
6 Differential bearing 14 Differential planetary gear
7 Differential bearing outer ring 15 Differential spherical washer
190
3.5.2 Disassembly of Differential Components 3.5.3.4 Install the differential planetary gear
shaft, and make sure to align it with the
3.5.2.1 Remove the differential bearing with carbon steel spring pin hole.
the tools.
3.5.3.5 Using a tool, tap the carbon steel

spring pin in place and deform the port to
3.5.2.2 Remove the carbon steel spring pin. prevent the carbon steel spring pin from
Tap it out from the other side with a tool. dropping out.
3.5.2.3 Take out the differential planetary gear

shaft.
3.5.2.4 Rotate 2 differential planetary gears for

180º, and then take out the differential
planetary gear and differential side gear in
turns.
3.5.2.5 Take out the differential spherical

washer.
3.5.3.6 Press the differential bearing in place

with a tool to finish the installation of
differential components.
3.5.3 Installation of Differential Components
3.5.3.1 Install the differential spherical washer

A. Make sure to align the holes of the
planetary gear and the side gear.
3.5.3.2 Install 2 differential side gears.
3.5.3.3 Rotate and install 2 differential

planetary gears with an angle of 180º.
191
3.5.4 Selection of Differential Bearing

Adjusting Shim
The differential must be adjusted again if

any of the following components are
replaced.
a Front box
b Rear box
c Differential housing
d Differential bearing
The differential adjusting shim must be

selected as follows:
3.5.4.1 Using a height gauge, measure the

distance a from the differential bearing
outer ring to the joint surface of the box;
3.5.4.2 Using a depth gauge, measure the

rear box differential bearing outer ring to
the joint surface of the box;
3.5.4.3 The thickness h of the differential

bearing adjusting shim is calculated as
follows:
h  a'a  (0.05～0.1)mm
Select the proper differential assembly

pre-tensioning thickness (0.05~0.1 mm),
and correct the value h to the nearest shim
thickness.
For example:
If a is 57.74 mm;
If a' is 58.80 mm;
h  a'a  (0.05～0.1)mm =1.06+0.7≈1.1

5 mm;
The thickness of the differential adjusting

shim should be 1.15 mm.
192
Section 4 Transmission Assembly

4.1 Construction of Transmission Assembly
1 Counter shaft 1 assembly 11 T-tube assembly

2 1st/2nd gear shifting fork shaft assembly 12 Front box
3 3rd/4th gear shifting fork shaft assembly 13 Release bearing unit
4 Counter shaft 2 assembly 14 Release bearing assembly mounting bolt
5 5th/6th gear shifting fork shaft assembly
6 Reverse shaft fork assembly
8 Reverse idler gear shaft assembly
9 End bearing stopper plate
10 T-tube assembly
11 Front box
12 Main shaft oil seal
13 Release bearing unit seal ring
14 Release bearing unit
15 Release bearing assembly mounting bolt
1 Hexagon flange bolt (M6 X 20)

2 Manual gear shift assembly
3 Rear box
4 Assembly bolt
5 Oil plug
6 Main shaft sealing cap
7 Main shaft rear bearing outer circlip
8 Sealing cap
9 Neutral switch
10 Gear selecting steel ball assembly
193
4.2 Disassembly of Transmission Assembly
4.2.1 Remove the sealing cap. 4.2.7 Remove the main shaft rear bearing
outer circlip with circlip pliers.
The sealing cap is a disposable product
and must be replaced before the 4.2.8 Pry out the circlip at the connection of
reassembly. the T-tube assembly and release bearing
unit, and then remove the T-tube
4.2.2 Remove the neutral switch with a assembly.
wrench.
4.2.9 Remove the release bearing assembly
4.2.3 Use M22 sleeve to remove the gear mounting bolts and release bearing
selecting steel ball assembly. assembly.
4.2.4 Remove the hexagon flange bolt

(M6×20).
4.2.5 Pull out the manual gear shift assembly

in direction indicated by the arrow.
Note: Make sure each gear shift fork is in
the neutral position before pulling out the
manual gear shift assembly.
4.2.10 Remove the assembly bolts (20 in

total).
4.2.6 Remove the main shaft sealing cap.

The main shaft sealing cap is a disposable
product and must be replaced before the
reassembly.
194
Note: The neutral switch assembly A and

1st/2nd lock pin assembly B (unlock) do
not interfere with the removal and
installation of the manual gear shift
assembly and transmission assembly.
4.2.13 Remove the main shaft, counter shaft 1

assembly, counter shaft 2 assembly and
reverse shaft assembly.
Note: Three persons are needed for
quicker removal.
The first person presses down the front
box with left hand while lifting the main
shaft assembly with right hand, and assists
the other 2 persons to lift the main shaft
assembly in the direction of arrow.
The second person holds the counter shaft
1 assembly, 1st/2nd gear shifting fork shaft
assembly and 3rd/4th gear shifting fork
shaft assembly with both hands, and lifts
the counter shaft 1 assembly in the
direction of arrow B.
The third person holds the reverse shaft

assembly and reverse shaft fork assembly
with the left hand, holds the counter shaft 2
4.2.11 Remove the rear box A in the direction assembly and 5th/6th gear shifting fork
indicated by the arrow. shaft assembly with the right hand, and
lifts the counter shaft 2 assembly in the
Note: The joint surface of the box is coated direction of arrow C.
with the flange sealant; therefore there
may be cohesive force on it during removal. 4.2.14 Take out the differential assembly and
The rear box must be placed upside down finish the disassembly of transmission
and do not damage the joint surface of the assembly.
box.
4.2.12 Using a tool, remove the neutral switch

assembly A and 1st/2nd lock pin assembly
B from the rear box.
195
4.3 Service of Transmission Assembly
4.3.1 Service of Front Box Accessories after removal.
4.3.1.1 Service the main shaft front bearing.

Grip the main shaft front bearing circlip
with pliers, and pull it out together with the
main shaft front bearing (with main shaft
front bearing circlip) using a pull rod.
Using the pressure lever A, press the new

gear shifting shaft sleeve into the front box.
Coat the bearing outer ring with grease

before installation. Clamp the main shaft
front bearing circlip in the circlip groove
before installation. Grip the main shaft
front bearing circlip with pliers and slowly
press it into the front box with a pressure
lever, until the main shaft front bearing
circlip opens automatically.
4.3.1.3 Service the end bearing.

Pull it out with the combination of pull rods.
4.3.1.2 Service the gear shifting shaft sleeve.

Pull it out with the combination of pull rods.
The gear shifting shaft sleeve is a Press it into the front box with the pressure
disposable product and must be replaced lever.
196
4.3.1.5 Service the differential oil seal and

main shaft oil seal.
Note: Check the oil seals for oil leakage and

abnormal oil seal lip wear. Check if the oil
seals are installed in place.
The oil seal is a disposable product and must

be replaced after removal.
4.3.1.4 Service the counter shaft 1 front

bearing outer ring, counter shaft 2 front
bearing outer ring and differential bearing
outer ring in the front box.
Pull them out with the pull rod and check
for obvious wear.
Note: The shim must be reselected after
replacement of the bearing outer ring.
Do not mix the counter shaft 1 front
bearing outer ring with the counter shaft 2 4.3.2 Service of Rear Box Accessories
front bearing outer ring as they have the
same appearance. Make markers on them 4.3.2.1 Service the 1st/2nd gear lock pin
and use them with the corresponding assembly.
bearing.
Remove the angle lever from the 1st/2nd
gear lock pin, and pry out the lock pin with
a screwdriver.
The 1st/2nd gear lock pin assembly is a

disposable product and must be replaced
before reinstallation.
Press the bearing outer ring into the front box.
Press it into the rear box with a special

pressure lever.
197
4.3.2.3 Service the gear shifting steel ball

assembly.
Tap out the gear shifting steel ball
assembly with a mandrel.
4.3.2.2 Service the gear shifting shaft sleeve.

Pull out the gear shifting shaft sleeve with
the pull rod and pressure plate.
Press the gear shifting steel ball assembly

into the rear box with the special pressure
lever.
Note: The gear shifting steel ball assembly

is a disposable product and must be
replaced before reinstallation.
Press the gear shifting shaft sleeve into

the rear box with the special tool.
4.3.2.4 Service the shift lever shaft sleeve.

Pull out the shift lever shaft sleeve with an
inner puller.
Coat grease on the out ring of shift lever

shaft sleeve before reuse.
198
4.3.3 Service of Other Components in

Press in the shift lever shaft sleeve with Transmission
the special tool.
4.3.3.1 Check the magnet. Take out the
Note: The shift lever shaft sleeve is a magnet and check for any obvious and
disposable product and must be replaced large particles of iron scurf. The amount
before reinstallation. and size of the particles on the magnet are
the primary basis to judge whether the
transmission is damaged. The magnet
must be wiped clean before reuse.
4.3.3.2 Replace the components in the main

shaft assembly. (For details, refer to
section 3.2 ―Disassembly and Assembly of
Main Shaft Components‖)
4.3.3.3 Replace the components in the counter

shaft 1 assembly. (For details, refer to
Counter Shaft 1 Components‖)
4.3.3.4 Replace the components in the counter

shaft 2 assembly. (For details, refer to
Counter Shaft 2 Components‖)
4.3.3.5 Replace the components in the

differential assembly. (For details, refer to
Differential Components‖)
4.3.3.6 Do not disassemble the reverse idler

4.3.2.5 Service the differential oil seal. gear shaft assembly. Replace it as a unit if
Note: Check the oil seals for oil leakage necessary.
and abnormal oil seal lip wear. Check if the
oil seals are installed in place. 4.3.3.7 Check each gear shift lever fork
assembly for any abnormal wear.
The oil seal is a disposable product and
must be replaced after removal.
199
4.4 Assembly of Transmission Assembly
4.4.1 Prepare the serviced front box assembly

with accessories.
Note: Press the differential bearing outer

ring, counter shaft 1 and 2 front bearing
outer rings into the front box. Do not mix
the counter shaft 1 front bearing outer ring
with the counter shaft 2 front bearing outer
ring.
4.4.6 Install the counter shaft 2 assembly,

5th/6th gear shifting fork shaft assembly
and reverse gear shifting fork assembly.
Note: Assemble the 5th/6th gear shifting
fork shaft assembly, reverse shaft fork
assembly and counter shaft 2 assembly
and put them in the corresponding
position.
4.4.2 Before assembly, remove the sealant

and oil from the joint surface of the box for
the application of new sealant.
4.4.3 Inspect the differential oil seal and main

shaft oil seal. The oil seals should be
installed in place without any abnormal
wear.
4.4.4 Place the clean magnet and positioning

pin in the corresponding positions.
Carefully clean the iron chips and oil on 4.4.7 Install the reverse shaft assembly.
the magnet before placing.
Note: Quicker installation can be achieved
4.4.5 Install the differential assembly. by 2 persons working together.
Note: The differential assembly should be One lifts up the counter shaft 2 assembly
rotated freely to ensure it can be installed together with the 5th/6th gear shifting fork
in place. shaft assembly and reverse shaft fork
assembly to a certain height with both
hands, and the other one installs the
reverse shaft assembly. When the reverse
shaft assembly is engaged with the
counter shaft 2 assembly, they should be
placed into the front box by 2 persons.
200
fork assembly and reverse shaft assembly

to a certain height with both hands.
The second person assists the first person
by lifting up the main shaft assembly to a
certain height.
The third person installs the counter shaft

1 assembly together with the 1st/2nd gear
shifting fork shaft assembly and 3rd/4th
gear shifting fork shaft assembly. When
the counter shaft 1 assembly is engaged
with the main shaft assembly, all the shafts
and gear shifting fork shaft assembly
should be placed into the front box by 3
4.4.8 Install the main shaft assembly. persons together.
by 2 persons working together.
One lifts up the counter shaft 2 assembly
together with the 5th/6th gear shifting fork
shaft assembly, reverse shaft fork
assembly and reverse shaft assembly to a
certain height with both hands, and the
other one installs the main shaft assembly.
When the main shaft assembly is engaged
with the counter shaft 2 assembly, they
should be placed into the front box by 2
persons.
4.4.10 Apply sealant on the joint surface of the

box as specified.
Note: The sealant should be applied

uniformly without breakpoint. For the
threaded hole and positioning pin, the
sealant should be applied to the position
close to the inside of the box.
4.4.9 Install the counter shaft 1 assembly,
1st/2nd gear shifting fork shaft assembly
and 3rd/4th gear shifting fork shaft
assembly.

by 3 persons working together.
The first person lifts up the counter shaft 2

assembly together with the 5th/6th gear
shifting fork shaft assembly, reverse shaft
201
4.4.11 Prepare the serviced rear box assembly 4.4.14 Install the assembly bolts.
with accessories.
Note: There are 20 assembly bolts in total,
Note: Press the differential bearing outer and their tightening torque is 25 Nm.
ring and its adjusting shim, counter shaft 1
rear bearing outer ring and its adjusting 4.4.15 Install the main shaft rear bearing outer
shim as well as counter shaft 2 rear circlip and main shaft sealing cap.
bearing outer ring and its adjusting shim
into the rear box together. 4.4.16 Install the mounting bolts of release
bearing unit and release bearing
4.4.11.1 For the selection of counter shaft 1 assembly.
rear bearing adjusting shim, refer to
section 3.3.5 ―Selection of Counter Shaft 1 Note: There are 3 mounting bolts for the
Rear Bearing Adjusting Shim‖ release bearing assembly, and their
4.4.11.2 For the selection of counter shaft 2
rear bearing adjusting shim, refer to section 4.4.17 Install the T-tube assembly.
3.4.5 ―Selection of Counter Shaft 2 Rear
Bearing Adjusting Shim‖
4.4.11.3 For the selection of differential

bearing adjusting shim, refer to section 3.5.4
―Selection of Differential Bearing Adjusting
Shim‖
4.4.12 Check the installation position and wear

condition of the differential oil seal.
4.4.13 Complete the assembly of the front and

rear boxes.
Note: Make sure to align the positioning

pins of the front and rear boxes during
assembly.
4.4.18 Install the manual gear shift assembly

and hexagon flange bolts.
Note: Put all the gear shift fork assembly in
the neutral position before installation of
the manual gear shift assembly.
There are 2 hexagon flange bolts (M6×20)
in total, and their tightening torque is 15
Nm.
4.4.19 Install the gear selecting steel ball

assembly and neutral switch assembly
(The tightening torque is 35 Nm).
4.4.20 Install the sealing cap.
Note: The sealing cap is a disposable

product and must be replaced before
reinstallation.
202
4.4.21 Tighten the oil drain plug assembly to

finish the assembly of transmission
assembly.
203
Chapter 5 BYD6DT25 Dual Clutch Transmission
Contents
Section 1 Introduction of Transmission ................................................................................. 205

1.1 Structural Parameters ............................................................................................ 205
1.2 Servicing Description ............................................................................................. 205
Section 2 Dual Clutch............................................................................................................ 207
2.1 Disassembly of Dual Clutch .................................................................................. 207
2.2 Repair Clutch Engaging Device ............................................................................ 208
2.3 Adjustment of Engaging Bearing 1 and 2 ............................................................. 210
2.4 Assembly of Dual Clutch ....................................................................................... 213
Section 3 Operating Mechanism and Housing ..................................................................... 216
3.1 Replacement of Transmission Oil ......................................................................... 216
3.2 Removal of Electric Hydraulic Control Module...................................................... 218
3.3 Installation of Electric Hydraulic Control Module................................................... 220
3.4 Disassembly and Assembly of Transmission ........................................................ 221
Section 4 Gear and Drive Shaft ............................................................................................ 229
204
Section 1 Introduction of Transmission
1.1 Structural Parameters
Transmission model BYD6DT25

Type DCT
1st gear 3.765
2nd gear 2.273
3rd gear 1.531
Gear ratio 4th gear 1.122
5th gear 1.176
6th gear 0.951
Reverse gear 4.170
1st gear 3-cone
2nd gear 3-cone
Synchronizer ring size 3rd gear 3-cone
(mm) 4th gear 2-cone
Synchronizer ring type 5th gear 1-cone
6th gear 1-cone
Reverse gear 1-cone
Dual clutch transmission Model Castrol MTF 95+EP+FM
gear oil Oil volume (L) 1.7
Total weight (kg) 72 kg
1.2 Servicing Description
1.2.1 Servicing Guidelines ones.
1.2.1.1 Prepare the parts kit and parts rack in 1.2.1.6 Use correct removal tools for
advance to store the removed and disassembly and assembly.
disassembled components. Put them in
order and make markers if necessary to 1.2.1.7 Refer to this service manual as much
avoid confusion and misplacement. as possible during work.
1.2.1.2 Be careful when servicing the 1.2.1.8 If you encounter any difficult technical
aluminum alloy parts to avoid damage to problems during servicing, it is
the machined surface. recommended to consult our aftersales
technical service department.
1.2.1.3 Prepare sufficient auxiliary materials
for use in the process of servicing. 1.2.2 Materials for Servicing
1.2.1.4 For the bolts and other fastening parts The materials listed in the following table
with standard tightening torque are essential for servicing the transmission
requirements, tighten them with special of this model. Therefore, they should be
tools in accordance with the required prepared for use at any time. In addition,
values. the washing liquid and lubricant of
specified models should be used.
1.2.1.5 After servicing, disposable supplies
should be scrapped and replaced with new
Auxiliary Material Table:
205
Materials and Materials and type currently in

No. Position
type use
Differential oil seal
Ball bearing
1 Grease
3# Lithium grease Main shaft oil seal
Taper bearing outer ring
6th gear shift lever bushing
Differential oil seal
Transmission assembly
API grade: GL-4
2 Gear oil Main shaft needle bearing
SAE viscosity:75W
Counter shaft needle bearing
Ball bearing
Mobilarma 524 or
3 Anti-rust oil Main shaft spline
Shell Ensis N Oil
Assembly Joint surface of transmission
4 Loctite 587
sealant front and rear boxes
1.2.3 Precautions 1.2.3.3 Install the clean parts only and take out
the original parts from their package only when
1.2.3.1 Do not allow the contaminants to enter they are to be installed.
the transmission when the transmission is
disassembled. 1.2.3.4 The transmission has two fuel supply
systems with one for gears and shafts and the
1.2.3.2 Put removed parts on a clean work other one for the electric hydraulic control
stand and cover them with a piece of clean module. Do not add any additives into oil.
and fibreless cloth to protect them from
contamination. 1.2.3.5 The engine oil drained should not be
used for refilling. Dispose the waste oil
properly.
206
Section 2 Dual Clutch

2.1 Disassembly of Dual Clutch
Special tools and servicing equipment needed
2.1.1 Mounting bracket-T1001-
2.1.2 Removal bracket-T1002
2.1.3 Cushion block-T1003-
2.1.4 Circlip pliers
2.1.5 Depth gauge
2.1.6 Vernier caliper
2.1.6.2 Fix the transmission with the dual

clutch facing upward.
2.1.6.3 Remove the circlip indicated by the

arrow from the damping disc.
a Tips
The clutch has self-regulating function.
Vibration will influence the self-regulating
device. Therefore do not drop the clutch
into the transmission when installing the
clutch. Even when the electric hydraulic
control module has been removed, taking
out the screwdriver underneath the
engaging level could also have a negative 2.1.6.4 Remove the damping disc with the
effect on the self-regulating device. circlip pliers and screwdriver.
2.1.6.1 Use the proper plugs to seal two

air outlets indicated by the arrows avoid
oil leakage.
207
2.1.6.5 Remove the main shaft 2 front circlip.

2.1.8 Turn the threaded rod of the mounting
bracket - T1001- in the direction of arrow
and pull out the dual clutch.
b Tips 2.1.9 Remove the clutch along with the

removal bracket.
2.1.6.5.1 The circlip may be fixed very
securely. In this case, the clutch and the
2.2 Repair Clutch Engaging Device
circlip contact with each other closely, so
the circlip is "stuck".
1 Connecting arm support
2.1.6.5.2 The clutch can be pressed down
2 Engaging bearing 2 sleeve thrust ring
slightly only when the circlip cannot be
removed from the circlip groove. Do not
3 Engaging bearing 2 sleeve
tap the clutch or shaft using a hammer!
4 Engaging bearing 1 sleeve pressure plate
2.1.6.5.3 Replace the circlip each time it is
removed.
5 Engaging bearing 1 sleeve
2.1.7 Fully turn the threaded rod of the
6 Connecting arm 2
mounting bracket -T1001- in the direction
of arrow, and install the mounting bracket
7 Hexagon flange bolt
-T1001- in the opposite direction to the
dual clutch.
a 2
b Replace them after removal
c 10 Nm
8 Connecting arm 1
9 Engaging bearing 1
208
10 Engaging bearing 1 gasket 2.2.3 Turn the lugs of the thrust ring indicated
by the arrows for 90°with respect to the
11 Engaging bearing 2 gasket connecting arm 2.
12 Engaging bearing 2 2.2.4 Pull out the sleeves of engaging bearing

1 and 2 together.
Removal of connecting arm 2, sleeves of

engaging bearing 1 and 2, engaging bearing 1
pressure plate
Disassembly and assembly of connecting arm
2.2.1 Remove the bolts indicated by the 1 and engaging bearing 1
arrows Disassembly
2.2.2 Remove the connecting arm 2 and
2.2.5 Pull the engaging bearing 1 in the
sleeves of engaging bearing 1 and 2.
direction of arrow A while pulling the engging
bearing 1 out of the connecting arm 1 locating
slot in the direction of arrow B.
Disassembly of connecting arm 2, sleeves of

engaging bearing 1 and 2
209
Assembly
2.2.6 Press the engaging bearing 1 downward

in the arrow direction until the sound of
engaging bearing 1 fixing clips entering the
connecting arm 1 locating slot is heard.
The position of engaging bearing must be

adjusted after the following operations are
performed
 Replace the electric hydraulic control

module of dual clutch transmission.
 Replace the connecting arm.
 Replace the engaging bearing.
 Replace the connecting arm holder.
If the following conditions are met, there is

no need to perform any adjustment after
removing and reinstalling all the above
parts.
2.3 Adjustment of Engaging Bearing 1  The tools used are in good condition.
and 2
 The mating surface of the transmission
Special tools and servicing equipment and the engine should be kept smooth
needed so as to better support the H plate.
a Gauge block-T1004-  The electric hydraulic control module
has been installed.
b H plate-T1005
Brief Description
Refer to the clutch clearance of
transmission for the position of engaging
bearing. In the BYD6DT25 dual clutch
transmission, both the transmission
engaging system and the transmission
itself have tolerance. The dual clutch also
has tolerance. Observe each tolerance
210
separately when performing adjustment. 2.1.3.5 The H plate -T1005 - should be kept in
this position in the following measurement.
The following contents will describe how to
determine all necessary dimensions on the 2.1.3.6 The depth gauge is placed on the main
transmission side so that a proper shaft.
adjusting shim can be selected. Then the
clutch tolerance can be determined by 2.1.3.7 Reset the depth gauge to zero
means of experience and the tolerance will
be used as a coefficient in the calculation 2.1.3.8 Measure the distance H
later. The thickness of adjusting shim is
determined by the tolerance of the
transmission side and the clutch.
2.3.1 Selection of Engaging Bearing 1

Adjusting Shim:
After assembling the engaging bearing 1,
measure the depth H from the circlip upper
surface to the joint surface of the engine
and transmission. Measure the depth Hd
from the tool -T1004- upper surface to the
joint surface of engine and then calculate
the thickness td of engaging bearing 1
adjusting shim based on the above
measurement results: td= (Hd+48-H) -
b Tips
50.08
2.1.3.9 Do not perform the measurement at
2.3.1.1 Install the clutch parts of engaging
the connection of circlip, or the circlip may
bearing 1
be disconnected, causing the incorrect
measurement.
2.3.1.2 Do not install the engaging bearing 1
and the adjusting shim.
2.1.3.10 Place the block gauge-T1004- on the
engaging bearing 1.
2.3.1.3 Install the main shaft 2 front circlip
indicated by the arrow
2.1.3.11 Press the block gauge-T1004- and
turn it at the same time.
The rotation condition of engaging bearing

can be observed so that the block gauge
-T1004- can be correctly installed on the
engaging bearing 1.
2.1.3.12 Place the depth gauge above the

main shaft.
2.1.3.13 Reset the depth gauge to zero.
2.1.3.14 Measure the distance Hd.

2.3.1.3.4 Place the H plate -T1005- on the joint
surface of the transmission and the
engine.
a Tips
211
2.1.3.15 Determine which shim to be inserted

by referring to the following table.
Unit: mm
2.1.3.16 Measure the provided shims using a

vernier caliper, select the desired shim and
then install it.
Marker Thickness (Range for actual Marker Thickness (Range for actual shim
shim measurement) measurement)
100 1.0 (0.51~1.05) 160 1.6 (1.51~1.65)
115 1.15 (1.06~1.20) 175 1.75 (1.66~1.80)
130 1.3 (1.21~1.35) 190 1.9 (1.81~2.35)
145 1.45 (1.36~1.50)
Only 1 shim can be inserted during installation, 2.3.2.2 Check if the engaging bearing 2 is
instead of 2. correctly installed and if the groove
position is correct by turning.
2.3.2 Selection of Engaging Bearing 2

Adjusting Shim:
Similarly, assemble the engaging bearing

2 first, and then measure the depth Hx
from the tool -T1004- upper surface to the
joint surface of the engine and the
transmission. The thickness tx of engaging
bearing 2 adjusting shim can be calculated
by using the depth value H of circlip upper
surface measured in the previous step:
tx=34.35- (Hx+36-H)
2.3.2.1 Install the engaging bearing 2. 2.3.2.3 Install the gauge block -T1004- on the
engaging bearing 2.
Do not install the adjusting shim!
2.3.2.4 Place the depth gauge above the main
a The engaging bearing 2 can only be shaft.
installed in one position due to 4 grooves.
2.3.2.5 Reset the depth gauge to zero.
2.3.2.6 Measure the distance Hx.
212
2.4.1 Insert the connecting arm 2 and its

Determine which shim to be inserted by sleeve.
referring to the following table.
2.4.2 Make sure the connecting arm is
Unit: mm installed in the correct position.
Marker Thickness Marker Thickness 2.4.3 Fix the sleeve using 2 new bolts.
(Range for (Range for Tightening torque: 10 Nm
actual shim actual shim
measurement) measurement)
50 0.5 (0.21~0.55) 95 0.95 (0.86~1.0)
65 0.65 (0.56~0.7) 110 1.1 (1.01~1.15)
80 0.8 (0.71~0.85)
2.3.2.6 Measure the provided shims using a

vernier caliper, select the desired shim and
then install it.
b Only 1 shim can be inserted during

installation, instead of 2.
c Tips
2.3.2.7 For more accurate measurement,

place the depth gauge in the opposite position
twice and adopt the average value. In this Note that the sleeve of connecting arm and
case, the measured value is more accurate as all the mechanisms of engaging bearing
the shake caused by the engaging bearing can must be kept dry and free of the oil or
be minimized to avoid inaccurate grease.
measurement.
a Tips
2.4 Assembly of Dual Clutch
Before installation, the position of
Insert the plastic holder of the connecting arm. engaging bearing 1 and 2 must be adjusted
if the following operations have been
performed.
2.4.3.1 Replace the electric hydraulic

control module.
2.4.3.2 Replace the connecting arm.
213
2.4.3.3 Replace the engaging bearing.
2.4.3.4 Replace the connecting arm

holder.
2.4.3.5 The dual clutch can be installed

only after the engaging bearing is properly
adjusted!
2.4.4 If the above operations have not been

performed, insert the connecting arm 1
directly.
2.4.5 Check if the mounting positions of two

connecting arms are correct.
c The adjusting shim indicated by the arrow
must be installed on the two connecting arm
bearing.
b The engaging bearing 2 can only be

installed in one position due to 4 grooves
on the engaging bearing 2.
2.4.7 Insert the clutch into the transmission

shaft.
The clutch can be put in the transmission
with the help the removal bracket.
d Tips
2.4.7.1 The clutch is self-regulating. The

vibration will influence the self-regulating
device.
2.4.6 Check if the engaging bearing is installed Therefore do not allow the clutch to drop
correctly and if the mounting positions of into the transmission even when installing
the grooves are correct by turning the the clutch.
engaging bearing.
2.4.8 Install the mounting bracket -T1001- on
the transmission.
214
e Tips
2.4.8.1 Put a hand on the clutch while the

clutch is pressed. When slight vibration is
felt, it means the clutch is pressed to the
required position. In addition, the condition
when the clutch is pressed to the limit
position can also be felt.
2.4.9 Install the clutch circlip indicated by the

arrow
If the circlip cannot be installed, it means

the clutch is not pressed to the mounting
position. Reinstall the clutch.
2.4.10 Install the damping disc and damping

disc circlip.
215
Section 3 Operating Mechanism and Housing

3.1 Replacement of Transmission Oil
3.1.1 Replacement of Gear Oil
If the gear oil leaks from transmission, 3.1.1.3.2 Mark the mounting position of
check for leaking area. operating lever and remove it from the
gear shifting shaft.
3.1.1.1. Drain the remaining gear oil and
dispose it properly. 3.1.1.3.3 Remove the P gear cover plate.
3.1.1.2. Repair the leaking area. 3.1.1.3.4 Fill 1.7L gear oil through the opening.
3.1.1.3. Reinstall the drain plug. Tightening

torque: 30 Nm
3.1.1.3.1 Press the operating lever by hand

along the direction of pull cable seat
indicated by the arrow until the limit
position is reached. a Tips
3.1.2 Make sure the gear oil does not splash

out and fill the transmission with the exact
1.7L gear oil.
3.1.3 The gear oil should be added properly, or

the malfunction may be caused!
3.1.3.1 Install the P gear cover plate.
3.1.3.2 Install the gear shift operating lever

based on the position marked before.
Torque of P gear cover plate bolt 9 Nm
Tightening torque of gear shift operating

lever bolt15 Nm
216
Tips opening.
Replace the bolts on the gear shift Tips

operating lever each time.
Make sure the hydraulic oil does not
splash out. Fill the mechano-electronic unit
with the exact 1 L hydraulic oil and do not
fill too much or too little.
Or the malfunction may be caused!
b Install a new oil filling port bolt.
3.1.2 Replacement of Hydraulic System Oil
3.1.2.1 Discharging
The hydraulic oil is a long-life hydraulic oil

with no need for replacement.
It is not necessary to check the oil level in

the transmission.
Therefore, there is no oil level inspection

equipment.
If the hydraulic system oil leaks, check for

leaking area.
3.1.2.1.1 Remove the drain plug indicated by

the arrow.
3.1.2.1.2 Drain the remaining hydraulic oil and

dispose it properly.
3.1.2.1.3 Repair the leaking area.
3.1.2.1.4 Install a new drain plug in the

position shown by the arrow.
3.1.2.2 Filling
3.1.2.2.1 Remove the oil filling port bolt of the

electric hydraulic control module indicated
by the arrow.
3.1.2.2.2 Fill 1 L hydraulic oil through the
217
3.2 Removal of Electric Hydraulic Control Module
a Tips
3 2.1The clutch is self-regulating. Vibration

will influence the self-regulating device.
Even if the electric hydraulic control
module has been removed, pulling out the
screwdriver from the underneath of the
connecting arm suddenly may also have a
negative effect on the self-regulating
device.
3.2.1.1 Drain the gear oil and reinstall the drain

plug.
3.2.1.2 Pull out the exhaust hose and seal it

with an appropriate plug to avoid oil Instructions of detaching the clutch
leakage. connecting arm from the electric hydraulic
control module:
3.2.1.3 Remove the bolt -1- and remove the
cover plate -2- from the transmission. To take out the electric hydraulic control
module, two connecting arms must be
"pressed out" from the clutch push rod of
electric hydraulic control module. Or the
connecting arms will press on the clutch
push rod of electric hydraulic control
module and it is impossible to take out the
electric hydraulic control module.
b Tips
3.2.2 It is not allowed to connect the

screwdriver with the electric hydraulic
control module.
3.2.3 Careful press the two connecting

3.2.1.4 Detach the transmission input shaft arms out of the push rod.
speed sensor from the housing carefully
along the arrow direction using a
screwdriver.
218
3.2.9.1 Take out the electric hydraulic control

module.
3.2.3.1 Insert the screwdriver along the arrow
If the electric hydraulic control module
direction as shown in the figure.
cannot be removed:
3.2.3.2 Press the connecting arms out of the
In this case, the gear position adjuster is
push rod using the screwdriver and fix the
hooked on the upper left of the
connecting arms in the position. Do not
transmission housing.
take out the screwdriver and keep it
between the connecting arms and the
3.2.9.2 Put the electric hydraulic control
transmission housing during the whole
module in the transmission housing first
process.
and then fix it using a bolt.
c Tips
3.2.9.3 Put the electric hydraulic control
module in its original position.
3.2.4 Do not take out the screwdriver. Keep it
inserted during installation of the electric
3.2.9.4 Take out the electric hydraulic control
hydraulic control module.
module.
3.2.5 Do not damage the rubber seal cartridge
of clutch push rod.
3.2.6 Do not allow the connecting arms to hit

the housing!
3.2.7 Loosen the bolts alternatively (4 long

bolts and 3 short bolts)
d Tips
3.2.8 Do not remove all the bolts!

3.2.9 Do not remove the electric hydraulic
control module cover plate bolt.
219
and check if the gear shifting fork is stuck.

3.3 Installation of Electric Hydraulic If so, reinstall it after the cause has been
Control Module found out. If not, engage the gear shifting
fork to "neutral position".
3.3.1 Tips
Make sure all gear shifting forks are in N

"Neutral".
N-Neutral position of transmission
R-Reverse gear
1- 1st gear
2- 2nd gear
3- 3rd gear
4- 4th gear
5- 5th gear
3.3.2 Tips
6- 6th gear
3.3.2.1 Adjust the position of gear shift
adjuster and keep it in "neutral position" or
the transmission cannot be shifted
normally!
Please be aware that the 4 gear shift

adjusters protrude 25 mm -a-.
3.3.2.2 Do not damage the sensor when

prying the gear shift adjuster from the
electric hydraulic control module.
3.3.2.2.1 Use an appropriate plug to seal the vent hole

on the electric hydraulic control module to avoid oil
leakage.
3.3.2.2.2. Be aware of the gear selecting

piston rod.
3.3.2.2.3 Install the electric hydraulic control

module.
3.3.2.2.4 Tighten the bolts by hand.
- Check 4 gear shifting forks one by one. 3.3.3 Tips
Each gear shifting fork has 3 positions: 3.3.3.1 Replace with new bolts after removal.
"Engage a gear- Neutral - Engage a gear".
3.3.3.2 The tightening torque of the bolt is 10
- Engage each gear shifting fork to each Nm.
position once in order. Disengage all gears
220
3.3.3.3 Slowly take out the screwdriver for

holding the clutch engaging levers, and 3.4 Disassembly and Assembly of
install two clutch engaging levers on the Transmission
push rod.
Special tools and equipment needed
3.3.4 Tips
 Assembly bracket-T1006-
3.3.4.1 Do not release the clutch suddenly. If
the clutch engaging lever hit the electric  Disassembly bracket-T1007-
hydraulic control module, the
self-regulating function of the clutch may  Guide sleeve-T1008-
be damaged.
 Cover plate -T1009-
3.3.4.2 Install the transmission input shaft
speed sensor on the transmission  Guide pillar-T1010-
housing.
 Screwdriver
3.3.4.3 The sensor and its clamp plate must be
pressed tightly against the transmission  Circlip pliers
housing. If the sensor is loose, replace the
electric hydraulic control module.  Copper bar
3.3.5 Tips
3.3.5.1 Do not remove the seal cover from the

air outlet of electric hydraulic control
module if the transmission is not to be
installed immediately.
3.4.1 Disassembly of Transmission 3.4.1.2 Remove the main shaft rear circlip
using circlip pliers.
3.4.1.1 Remove the sealing cap using a
screwdriver.
221
3.4.1.3 Remove the bolts (20 in total) for

connecting the front and rear box
assembly.
3.4.1.3 Install the tools in place, turn the bolt

clockwise using an open-end wrench and
then remove the rear box.
b Tips
3.4.1.3.1 Turn the bolt with even force and do

not use too much strength to avoid
damage to the rear box.
a Tips
The sealing cap may influence the

disassembly. Align the screwdriver with the
center of sealing cap and tap it into the cap.
Do not tap too deeply to avoid damaging
the main shaft. Never use the removed
sealing cap.
3.4.1.2.1 Do not hit the main shaft rear bearing

when removing the main shaft rear circlip
using the circlip pliers.
3.4.1.2.2 Before disassembly, make sure the

clutch and the electric hydraulic control
module have been removed.
3.4.1.2.3 Make sure all the assembly

connecting bolts have been removed.
3.4.1.4 Remove the differential -5-.
c Tips
222
3.4.1.4.1 When removing the differential, lift

one side of the differential and pull it out. 3.4.2 Selection of Front Box Adjusting Shim
Use even strength, and do not use "too
much strength". Make sure the gear will 3.4.2.1 Selection of Counter Shaft 1 Front
not hurt your finger. Bearing Adjusting Shim:
3.4.1.5 Pull out the shift fork and counter shaft When the gear sleeve is in 2nd and 3rd
1 -4- together. gear, measure the height h2 and h3 from
the upper surface of the gear sleeve to the
3.4.1.6 Pull out the shift fork as well as the joint surfaces of the box. Based on the
counter shaft 2 -7- and reverse shaft -6- height, the thickness t1 of counter shaft 1
together. front bearing adjusting shim can be
determined: t1= {(48.2-h2) + (131.3-h3)}/2
d Tips
3.4.1.6.1 Shake the shaft slightly to make the

drive system loose when pulling out the
shaft. This can help pull out the shaft and
shift fork.
3.4.1.6.2 Take out the main shaft 1 -1-.
3.4.1.6.2.1 When removing the main shaft 1,

pull it upward along the centerline of
counter shaft 2. This can avoid damaging
the main shaft 2 oil seal.
3.4.1.6.3 Remove the main shaft 2 bearing

pressure plate bolt -3-
3.4.1.6.4 Remove the main shaft 2 -2-
3.4.1.6.4.1 Tap the front end of main shaft 2

slightly using a rubber hammer when
removing the main shaft 2.
Refer to the following table for shim selection
Marker Thickness Marker Thickness Marker Thickness
0.7 0.7 0.95 0.95 1.20 1.20

0.75 0.75 1.0 1.0 1.25 1.25
0.8 0.8 1.05 1.05 1.30 1.30
0.85 0.85 1.10 1.10 1.35 1.35
0.9 0.9 1.15 1.15
Counter shaft 1 front bearing adjusting shim Unit: mm
3.4.2.2 Selection of Counter Shaft 2 Front Bearing Adjusting Shim:
When the synchronizer gear sleeve is in the counter shaft 2 gear ring, measure the height h7
from the upper surface of 5th gear synchronizer gear sleeve to the joint surfaces of the box.
Based on the height, the thickness t2 of counter shaft 2 front bearing adjusting shim can be
determined: t2=127.45-h7
223
Refer to the following table for shim selection
Unit: mm
0.7 0.7 0.95 0.95 1.20 1.20
0.75 0.75 1.0 1.0 1.25 1.25
0.8 0.80 1.05 1.05 1.30 1.30
0.85 0.85 1.10 1.10 1.35 1.35
0.9 0.90 1.15 1.15 1.40 1.40
Unit: mm
0.7 0.7 0.95 0.95 1.20 1.20
0.75 0.75 1.0 1.0 1.25 1.25
0.8 0.8 1.05 1.05 1.30 1.30
0.85 0.85 1.10 1.10 1.35 1.35
0.9 0.9 1.15 1.15
3.4.2.3 Selection of Reverse Shaft Front 3.4.2.3.1 Install the special tools for of all the
Bearing Adjusting Shim: bearing outer rings in place in the front box
before adjusting the front box shim, or the
When the synchronizer gear sleeve is in shim adjustment accuracy will be affected.
reverse gear, measure the height hd from
the upper surface of synchronizer gear
sleeve to the joint surface of the box. 3.4.3 Selection of Rear Box Adjusting Shim
Based on the height, the thickness t3 of
reverse shaft front bearing adjusting shim The adjusting shims for the rear box
can be determined: t3=62.25-hd counter shaft, reverse shaft and differential
rear bearing are selected as follows:
First, install the adjusted front box

adjusting shim in the corresponding
position and install the shafts and
differential components to the front box.
Then measure the heights hf1 (for counter
shaft 1) , hf2 (for counter shaft 2), hd (for
reverse shaft) and hc (for differential) from
the shafts and the differential left bearing
outer ring end face to the joint surface of
the box. Then measure the depths Hf1 (for
counter shaft 1) , Hf2 (for counter shaft 2) ,
Refer to the following table for shim Hd (for reverse shaft) and Hc (for
selection
224
differential) from the rear box counter shaft,

reverse shaft and the machined surface of
differential mounting hole to the joint
surface of the box. Finally, the thickness of
each bearing adjusting shim of the rear
box can be calculated as follows:
tf1=Hf1-hf1+ (0.05~0.1);
tf2=Hf2-hf2+ (0.05~0.1);
td=Hd-hd+ (0.05~0.1);
tc=Hc-hc+ (0.05~0.1).
Refer to the table below for selection of tf1, tf2 and td shims;
Unit: mm
Unit: mm Marker Thickness Marker Thickness Marker Thickness
0.7 0.7 0.95 0.95 1.20 1.20
0.75 0.75 1.0 1.0 1.25 1.25
0.8 0.80 1.05 1.05 1.30 1.30
0.85 0.85 1.10 1.10 1.35 1.35
0.9 0.90 1.15 1.15 1.40 1.40
Refer to the attached table A.3 for selection of tc adjusting shim.
Unit: mm
0.8 0.8 1.05 1.05 1.30 1.30
0.85 0.85 1.1 1.1 1.35 1.35
0.9 0.9 1.15 1.15 1.40 1.40
0.95 0.95 1.20 1.20 1.45 1.45
1.0 1.0 1.25 1.25 1.50 1.50
3.4.3.1 Tips 3.4.3.1.3 After replacing the shaft and the

differential bearing, adjust the
Adjust the shim again in any of the corresponding shims.
following situations:
3.4.3.1.4 After the shaft has been
3.4.3.1.1 After replacing the rear box, disassembled, adjust the corresponding
adjust the shims of the rear box. shims of the front and rear box.
3.4.3.1.2 After replacing the front box, After adjusting the shim, assemble the rear
adjust the shims of the front box. box and rotate the shafts and differential.
When you feel the pre-tensioning force, it
225
means that the shim is adjusted

appropriately. If not, adjust again. 2.4.9.2 During installation, pull the differential
in the direction of arrow 3 to lift one
3.4.4 Installation of Transmission end of the differential. In this way, the
shaft and the fork can be installed
easily.
2.4.9.3 After installation, lift the main shaft 1

upward so that the gear can be
engaged in place. During rotation,
there is no clamping stagnation.
2.4.9.4 Lower the main shaft 1 slowly along

the axis of main shaft 2 to avoid
damaging the oil seal of the main shaft
2.
2.4.1 Install the assembly positioning pin and

the magnet.
2.4.2 Install the main shaft 2 in place.
2.4.3 Main shaft 2 bearing pressure plate bolts

(3) torque: 10 Nm.
2.4.4 Install the main shaft 1 in place.
2.4.5 Install the differential in place.

3.4.9.4.1 Place the cushion block indicated by
the arrow 1 under the main shaft.
2.4.6 Install the shift fork and the counter shaft
1 to the front box - arrow 3-.
b Tips
2.4.7 Install the shift fork, counter shaft 2 and
2.4.9.5 Insert the front end of main shaft 1 into
reverse gear shaft to the front box - arrow
the groove on the cushion block as
1-.
shown by the arrow 2.
2.4.8 Apply sealant on the joint surfaces of the
In this way, the rear box can be
front and rear box.
installed in place.
2.4.9 Rotate the differential and the entire drive 2.4.9.6 Make the joint surface of the
system has no clamping stagnation. transmission and the engine face
downward and place the transmission
a Tips on the "flat" bench, so as to make sure
the rear box can be installed in place.
2.4.9.1 During installation, place the fork rod
into the corresponding fork hole, and
then place the shaft in the
corresponding hole.
226
c Tips
3.4.9.8 Rotate the bolt with even force to

prevent the rear box from being
damaged.
3.4.9.8.1 Install the circlip indicated by the

arrow 1 in place using circlip pliers.
d Tips
3.4.9.9 If the circlip is not installed in place, it

means that the rear box is not installed
in place. Press the rear box downward
until the circlip is clamped in the
groove.
3.4.9.6.1 Install the assembly bracket in place.
3.4.9.7 After rotating the bolt counterclockwise,

press the rear box downward in place so that
the main shaft 1 rear bearing circlip groove
indicated by the arrow 2 should be exposed.
3.4.9.9.1 Install the new sealing cap assembly.
227
3.4.9.9.2 Install the assembly connecting bolts.
3.4.9.10 Front box assembly connecting bolts

M8X35 (14), torque: 25 Nm.
3.4.9.11 Rear box assembly connecting bolts

M8X50 (6), torque: 25 Nm.
228
Section 4 Gear and Drive Shaft

Counter shaft 2 and reverse shaft cushion
block- T1011 -.
Counter shaft 1 cushion block - T1012 -.
Main shaft 2 oil seal tool - T1013 -.
Pressing block - T1014 -
Synchronizer installation tool - T1015 -
5th gear distance ring installation tool -

T1016 -
Counter shaft conical bearing installation

tool - T1017 -
4th/6th gear distance ring installation tool -

T1018 -
 1st gear distance ring installation tool -

T1019 -
 Counter shaft 1 conical bearing installation

tool - T1020 -
 Snap-gauge - T1021 -
 Guide sleeve installation tool - T1022 -
 3rd gear distance ring installation tool –

T1023 -
229
4.1 Main Shaft 1
1 Gear oil guide sleeve;
2 Main shaft 1;
3 Main shaft 5th gear;
4 Main shaft 1 signal disc;
5 Main shaft 3th gear;
6 Main shaft distance ring;
7 Main shaft middle circlip;
8 Main shaft 1 rear needle bearing;
9 Main shaft 1 front needle bearing
230
4.1.2.3.1 Install the front and rear needle

Disassembly bearings of the main shaft 1.
4.1.1 Remove the front and rear needle

bearings of the main shaft 1.
4.1.2.3.2 Install the main shaft distance ring

and the main shaft middle circlip.
4.1.2 Remove the main shaft middle circlip and

the main shaft distance ring.
- Remove the gear oil guide sleeve.
4.1.2.3.3 Use the guide sleeve mounting tool -

T1022 - to install the gear oil guide sleeve.
Service
4.1.2.1 Check if the needle bearing has any

abnormity.
4.1.2.2 Check each gear for any sign of

collision and obvious tooth face damage.
4.1.2.3 Replace the damaged parts in time.
Assembly
231
4.2 Main Shaft 2
1 Main shaft 4th/6th gear roller bearing;
2 Main shaft 2;
3 Main shaft 2 bearing pressure plate;
4 Main shaft 2 bearing;
5 Main shaft 2 middle circlip;
6 Main shaft 2 oil seal assembly.
232
Disassembly Assembly
4.2.1 Remove the 4th/6th gear roller bearing 4.2.3.3.1 Install the main shaft 2 bearing
and the main shaft 2 oil seal. pressure plate and the main shaft 2
bearing.
Pay attention to the direction of pressure

plate indicated by the arrow.
4.2.2 Use the circlip pliers to remove the main

shaft 2 middle circlip.
4.2.3.3.2 Install the main shaft 2 middle circlip.
4.2.3 Use the snap-gauge - T1021 - to remove
the main shaft 2 bearing pressure plate 4.2.3.3.3 Use the tool - T1013 - to install the
and the main shaft 2 bearing. main shaft 2 oil seal.
Service
4.2.3.1 Check if the needle bearing has any

abnormity.
4.2.3.3.4 Install the 4th/6th gear roller bearing.
4.2.3.2 Check each gear for any sign of
collision and obvious tooth face damage.
4.2.3.3 Replace the damaged parts in time.
233
4.3 Counter Shaft 1
1 Counter shaft 1 front bearing 19 1st/3rd gear synchronizer inner ring;

2. Counter shaft 1; 20 1st/3rd gear middle steel ring;
3. 4th/6th gear needle bearing; 21 1st/3rd gear synchronizer outer ring;
4. Counter shaft 2nd gear assembly; 22 1st/3rd/reverse gear synchronizer circlip;
5 2nd gear synchronizer inner ring; 23 1st/3rd gear synchronizer gear sleeve;
6. 2th/4th gear synchronizer middle steel 24. 1st/3rd gear synchronizer hub;
ring; 25 1st gear needle bearing;
7 2nd gear synchronizer outer ring; 26 1st gear distance ring;
8 2nd/4th gear synchronizer circlip; 27 Counter shaft 1st gear assembly;
9 2nd/4th gear synchronizer hub; 28 Counter shaft 1st gear pressure plate;
10 2nd/4th gear synchronizer gear sleeve; 29 Counter shaft conical bearing;
11 Synchronizer slide block; 30 Counter shaft tightening screw.
12 4th gear synchronizer inner ring;
13 4th/6th gear distance ring;
14 Counter shaft 4th gear assembly;
15 3rd/4th gear distance ring retainer;
16 3rd gear distance ring;
17 3rd gear needle bearing;
18 Counter shaft 3rd gear assembly;
234
Disassembly shown and use a press to press the tool so

as to remove the 3rd distance ring, retainer,
4.3.1 Loosen and remove the counter shaft 4th gear and needle bearing.
tightening screw.
4.3.2 Clip the 1st gear of counter shaft 1

assembly onto the snap-gauge - T1021 as
shown.
Use a press to press the tool so as to
remove the counter shaft conical bearing
and pressure plate as well as the 1st gear
needle bearing.
4.3.2.1 Place the removed parts in good order.
4.3.4 Clip the 2nd gear of the counter shaft 1

shown and use a press to press the tool so
as to remove the synchronizer ring,
synchronizer and 2nd gear needle
bearing.
4.3.3 Clip the 3rd gear of the counter shaft 1

shown and use a press to press the tool so
as to remove the 1st/3rd gear synchronizer
and synchronizer ring as well as the
distance ring.
Service
4.3.4.1 Check if the 1st, 2nd and 3rd gear

inner rings are damaged.
4.3.1 Clip the 4th gear of the counter shaft 1 4.3.4.2 Check if the convex on the inner ring is
assembly onto the snap-gauge - T1021 as burnt.
235
4.3.4.3 Press the inner ring on the cone of the

shift gear and measure the clearance a
with a feeler gauge.
If a<0.3 mm, replace the synchronizer ring.
4.3.4.4 Check the outer rings of 1st, 2nd and

3rd gear synchronizer rings.
4.3.4.5 Press the synchronizer inner ring,

middle steel ring and outer ring on the
cone of the gear and measure the
clearance b with a feeler gauge.
If b<0.5 mm, replace the synchronizer ring.
Assembly
4.3.4.5.1 Install the 2nd gear assembly with

needle bearing.
4.3.4.5.9 Assemble the 1st/3rd and 2nd/4th
4.3.4.5.2 Install the inner ring, outer ring and gear synchronizers.
middle steel ring of the 2nd gear
synchronizer ring in the mounting position. 4.3.4.5.10 Install the synchronizer gear sleeve
on the synchronizer hub.
4.3.4.5.3 Install the inner ring A on the 2nd
gear. 4.3.4.5.11 Insert the synchronizer slide block,
and install the spring with an angle of 120°.
4.3.4.5.4 The flange indicated by the arrow 1
should face the middle steel ring B. The angled end of the spring must be
placed in the hollow slide block.
4.3.4.5.5 Install the middle steel ring B.
4.3.4.5.6 Engage the flange indicated by the

arrow 2 in the gear groove indicated by the
arrow 3.
4.3.4.5.7 Install the outer ring of synchronizer

ring C.
4.3.4.5.8 Engage the groove indicated by the

arrow 4 in the flange of inner ring A
indicated by the arrow 1.
4.3.4.5.12 Use the special tool - T1020 - to

install the counter shaft 1 front bearing
onto the shaft.
Be careful not to press the bearing holder.
236
4.3.4.5.13.2 Install the 2nd gear synchronizer

4.3.4.5.13 Install the 2nd needle bearing onto inner ring, middle ring and outer ring in
the shaft. place in turns.
a Place the shaft on the tool -T1012- to 4.3.4.5.13.3 Press the 2nd/4th gear
assemble the parts. synchronizer assembly on the shaft with
the tool -T1015. The flange of the
synchronizer outer ring must be in the
groove of the synchronizer. Pay attention
to the mounting direction of the
synchronizer.
4.3.4.5.13.4 Assemble the 4th gear

synchronizer ring assembly in the reverse
order of that for the 2nd gear.
Install the outer ring, middle ring and inner

ring in turns.
4.3.4.5.13.5 Press the 4th gear distance ring

onto the shaft with the tool -T1018 and
install the needle bearing.
Finally, install the gear. The gear must

rotate freely without stagnation.
4.3.4.5.13.1 Install the 2nd gear. It must rotate

freely without stagnation.
237
4.3.4.5.13.8 Press the 3rd gear distance ring

4.3.4.5.13.6 Install the 4th gear. The gear must

4.3.4.5.13.9 Install the 3rd gear. The gear

must rotate freely without stagnation.
4.3.4.5.13.7 Install the 3rd/4th distance ring
retainer.
4.3.4.5.13.10 Assemble the 1st/3rd gear

synchronizer ring on the shaft in the order
238
of inner ring, middle steel ring and outer

ring.
4.3.4.5.13.11 Press fit the 1st/3rd gear

synchronizer assembly with the tool
-T1015. The flange of synchronizer outer
ring must be in the groove of the
synchronizer.
4.3.4.5.13.12 The 1st/3rd gear synchronizer is

symmetrical and can be installed upside
down.
4.3.4.5.13.15 Install the 1st gear. The gear

4.3.4.5.13.13 Assemble the 1st/3rd gear 4.3.4.5.13.16 Install the counter shaft 1st gear
synchronizer ring assembly in place in the pressure plate and use the tool - T1018 -
order of outer ring, middle steel ring and to press fit the counter shaft conical
inner ring. bearing.
4.3.4.5.13.17 Tighten the counter shaft

tightening screw to the torque of 70 Nm.
4.3.4.5.13.14 Press the 1st gear distance ring

Finally, install the gear. The gear must

After assembly, check if the gears rotate
smoothly and can be shifted without
stagnation.
239
4.4. Counter Shaft 2
1. Counter shaft conical bearing 20 5th gear synchronizer gear sleeve;

2 Gear oil guide sleeve 21 5th gear distance ring;
3 Counter shaft 2; 22 5th gear needle bearing;
4 Reverse gear front end bearing 23 Counter shaft 5th gear assembly;
5 Reverse gear assembly; 24 Counter shaft 2 rear bearing;
6. Reverse gear rear end bearing; 25 Counter shaft tightening screw.
7 Counter shaft reverse gear needle bearing
8 5th/6th gear synchronizer circlip;
9 6th gear limit steel ring;
10 6th gear synchronizer hub;
11 6th gear synchronizer gear sleeve;
12 Synchronizer slide block;
13 5th/6th gear synchronizer ring;
14 4th/6th gear needle bearing;
15 4th/6th gear distance ring;
16 Counter shaft 6th gear assembly;
17 6th gear distance ring retainer;
18 Counter shaft 2 gear ring
19 5th gear synchronizer hub;
240
Disassembly
4.4.1 Loosen and remove the counter shaft

tightening screw.
4.4.2 Clip the 5th gear of counter shaft 2

assembly onto the snap-gauge - T1021-
as shown and press the tool -T1014- with
a press so as to remove the counter shaft
conical bearing and 5th gear as well as the
needle bearing.
a Place the removed parts in good order.

4.4.2.3 Clip the counter shaft reverse gear of
the counter shaft 2 assembly onto the
snap-gauge - T1021- as shown and press
the tool -T1014- with a press so as to
remove the 6th gear synchronizer ring,
synchronizer, counter shaft reverse gear
and needle bearing.
4.4.2.1 Clip the gear ring of the counter shaft 2

a press so as to remove the counter shaft
2 gear ring, 5th gear synchronizer and
synchronizer ring as well as the 5th gear
distance ring.
Service
4.4.2.4 Check if the convex on the inner ring is

burnt.
4.4.2.5 Check the outer rings of the 5th/6th

gear synchronizer rings.
4.4.2.6 Press the synchronizer ring on the

cone of the gear and measure the
clearance c with a feeler gauge.
If c<0.5 mm, replace the synchronizer ring.
Assembly
4.4.2.2 Clip the 6th gear of the counter shaft 2
4.4.2.6.1 Use the special tool - T1013- to
assemble the gear oil guide sleeve.
a press so as to remove the distance ring,
retainer, 6th gear and needle bearing.
241
4.4.2.6.4.1 Place the shaft on the tool -T1011-

and assemble the parts.
4.4.2.6.2 Use the special tool - T1017 - to

assemble the counter shaft bearing onto
the shaft.
4.4.2.6.5 Install the reverse gear rear end
Be careful not to press the bearing holder. bearing.
4.4.2.6.6 Press the 6th gear synchronizer

assembly on the shaft with the tool -T1015.
4.4.2.6.3 Install the reverse gear front end
bearing onto the shaft as shown in the Pay attention to the mounting direction of
figure. the synchronizer. During assembly, check
if the synchronizer is installed correctly.
4.4.2.6.4 Install the counter shaft reverse gear

needle bearing onto the shaft and install
the counter shaft reverse gear sleeve on it.
The gear must rotate freely without
stagnation.
242
4.4.2.6.7.2Finally, install the 6th gear. The

gear must rotate freely without stagnation.
4.4.2.6.7 Install the 6th gear synchronizer ring.
The flange of the synchronizer ring must
be in the groove of the synchronizer.
Install 1 into 2.
4.4.2.6.7.3 Assemble the 6th gear distance

ring retainer, 4th/6th gear distance rings,
needle bearings and counter shaft 2 gear
rings onto the shaft in turns. They should
4.4.2.6.7.1 Press the 6th gear distance ring be pressed to the position and the gear
onto the shaft with the tool -T1018 and must rotate freely without stagnation.
install the needle bearing. Finally, install
the gear. The gear must rotate freely
without stagnation.
243
4.4.2.6.7.4 Assemble the 5th/6th gear

synchronizer ring onto the shaft.
4.4.2.6.7.6 Install the 5th gear synchronizer

ring in place. The flange of the
synchronizer ring must be in the groove of
the synchronizer.
4.4.2.6.7.5 Press fit the 5th gear synchronizer

assembly with the tool -T1015. The flange
of the synchronizer ring must be in the
groove of the synchronizer.
4.4.2.6.7.7 Press the 5th gear distance ring

onto the shaft with the tool -T1020- and
install the needle bearing. Finally, install
the gear. The gear must rotate freely
without stagnation.
244
4.4 2.6.7.8 Use the tool -T1017- to install the 4.4.2.6.7.10 After assembly, check if the gears
counter shaft 2 rear bearing. rotate smoothly and can be shifted without
stagnation.
4.4.2.6.7.9 Tighten the counter shaft tightening

screw to the torque of 70 Nm.
245
Reverse Shaft
1 Counter shaft conical bearing;

2. Gear oil guide sleeve;
3. Reverse shaft;
4 Reverse gear needle bearing;
5 Reverse gear assembly;
6 Reverse gear synchronizer ring;
7 Reverse gear synchronizer circlip;
8 Reverse gear synchronizer hub;
9 Synchronizer slide block;
10 Reverse synchronizer gear sleeve;
11 Reverse shaft circlip;
12 Synchronizer circlip pressure plate;
13 P gear ratchet.
246
Disassembly
4.5.1 Clip the reverse shaft assembly onto the

snap-gauge –T1021- as shown. Press the
special remover –T1014- with a press to
remove the counter shaft conical bearing
and P gear ratchet. Place the removed
parts in good order.
Assembly
4.5.4 Use the special tool - T1022- to install

the gear oil guide sleeve into the reverse
shaft.
4.5.2 Take out the synchronizer circlip

pressure plate and remove the reverse
shaft circlip with outer circlip pliers.
4.5.5 Use the special tool - T1017 - to press

the counter shaft conical bearing onto the
reverse shaft.
4.5.3 Clip the remaining components onto the

press plate -T1021 as shown in the figure.
Remove the reverse gear synchronizer
assembly and reverse gear assembly with
a press. Place the removed parts in good
order.
247
4.5.8 Press the reverse gear synchronizer

assembly onto the reverse shaft spline in
place with the tool –T1015.
4.5.8.1 The flange of the synchronizer outer

ring must be in the groove of the
synchronizer. Pay attention to the
mounting direction of the reverse gear
4.5.6 Assemble the reverse gear needle synchronizer assembly.
bearing onto the reverse shaft and install
the reverse gear assembly on it. The gear
4.5.9 Select a reverse shaft circlip with proper

4.5.7 Place the reverse gear synchronizer ring
thickness. Use the outer circlip pliers to
onto the conical surface of reverse gear
install the reverse shaft circlip into the
assembly.
reverse shaft circlip groove.
4.5.7.1 To facilitate assembly and prevent the
conical bearing holder from being
damaged, place the components to be
assembled on the special tool.
248
4.5.12 Use the special tool - T1018 - to press

the counter shaft conical bearing onto the
reverse shaft.
4.5.10 Press the synchronizer circlip pressure
plate into the reverse gear synchronizer by
hand.
4.5.11 Use the special tool -T1019- to press 4.5.13 After assembly, check if the gears rotate
the P gear ratchet onto the reverse shaft smoothly and can be shifted without
spline in place. stagnation.
4.5.11.1 Pay attention to the direction of P

gear ratchet during installation.
249
Engine Management System

Content
Chapter 1 473QME1788 Management System Repair Manual ...................................................... 3
Part 1 Repair Requirements for Electronic Injection System ................................................... 6
Section 1 General Repair Requirements ........................................................................... 6
Section 2 Precautions during Repair ................................................................................. 6
Section 3 Summary of Repair Tools .................................................................................. 7
Section 4 Meaning of Abbreviations in Repair Manual ..................................................... 9
Part 2 Introduction of ME17 System ....................................................................................... 10
Section 1 System Operation ............................................................................................ 10
Section 2 Control Signal: Input/Output Signals of ME17 System ................................... 13
Section 3 Introduction of System Function ...................................................................... 14
Section 4 Introduction of System Diagnosis Function ..................................................... 16
Section 5 Description of Item Related Problems ............................................................. 17
Part 3 Structure, Theory and Trouble Analysis of ME17 System Components ..................... 18
Section 1 Layout of Engine Management System Components..................................... 18
Section 2 Intake Pressure/Temperature Sensor ............................................................. 20
Section 3 Electronic Throttle Valve Body Assembly ....................................................... 23
Section 4 Coolant Temperature Sensor .......................................................................... 24
Section 5 Knock Sensor .................................................................................................. 26
Section 6 Oxygen Sensor ................................................................................................ 29
Section 7 Crankshaft Position Sensor ............................................................................. 34
Section 8 Camshaft Position Sensor ............................................................................... 37
Section 9 Electronic Controller Unit ................................................................................. 39
Section 11 Injector ........................................................................................................... 46
Section 12 Ignition Coil .................................................................................................... 49
Section 13 Charcoal Canister Control Valve ................................................................... 51
Section 14 Fuel Distribution Pipe Assembly.................................................................... 55
Part 4 Diagnosis Flow for ME17 System in Accordance with Trouble Codes ........................ 56
Part 5 Diagnosis Flow for ME17 System in Accordance with Trouble Symptoms ................. 74
Section 1 The engine does not rotate or rotates slowly when starting ........................... 74
Section 2 The engine can rotate, but cannot be started successfully ............................. 75
Section 3 Hot starting is difficult ...................................................................................... 76
Section 4 Cold starting is difficult ..................................................................................... 76
Section 5 Engine is difficult to start at any time, but the engine speed is normal ........... 77
Section 6 Engine can be started normally, but idle speed unstable at any time ............ 78
Section 7 Engine can be started normally, but idle speed unstable during warming up 79
Section 8 Engine can be started normally, but idle speed unstable after warming up ... 80
Section 9 Engine can be started normally, but idle speed unstable or engine misfires
under some loads (for example, the air conditioning is on)............................................. 81
Section 10 Engine speed does not increase or the engine misfires during acceleration 81
1
Section 11 Response is slow during acceleration ........................................................... 82

Section 12 Engine power is low and performance is poor during acceleration .............. 83
Part 6 Instructions for BYD-ED400 Diagnostic Tester ............................................................ 85
Section 1 Preparation before Diagnosing the Vehicle with BYD-ED400 ........................ 85
Section 2 Instructions for Keyboard Operation................................................................ 87
Section 3 Function Introduction ....................................................................................... 88
Section 4 Precautions for Maintenance and Use of Diagnostic Tester ........................... 97
Part 7 Accessories .................................................................................................................. 98
Section 1 Components Installation Torque Specification Table...................................... 98
Section 2 Maintenance Procedures for Electronic Injection System .............................. 98
Chapter 2 BYD TB10 Engine Management System Repair Manual ........................................... 101
Section 1 Repair Requirements for Electronic Injection System................................... 103
Section 2 TB10 System Introduction ............................................................................. 106
Section 3 Structure, Theory and Trouble Analysis of TB10 System Components ....... 117
Section 4 Diagnosis Flow for TB10 System in Accordance with Trouble Codes .......... 161
Section 5 Diagnosis Flow for TB10 System in Accordance with Trouble Symptoms ... 192
Section 6 Instructions for Using Diagnostic Tester ....................................................... 210
Section 7 Attachment ..................................................................................................... 216
2
Chapter 1 473QME1788 Management System Repair Manual
Content
Part 1 Repair Requirements for Electronic Injection System ........................................................... 6
Section 1 General Repair Requirements .................................................................................. 6
Section 2 Precautions during Repair ........................................................................................ 6
Section 3 Summary of Repair Tools ......................................................................................... 7
Section 4 Meaning of Abbreviations in Repair Manual ............................................................. 9
Part 2 Introduction of ME17 System .............................................................................................. 10
Section 1 System Operation ................................................................................................... 10
Section 2 Control Signal: Input/Output Signals of ME17 System ........................................... 13
Section 3 Introduction of System Function ............................................................................. 14
Section 4 Introduction of System Diagnosis Function ............................................................ 16
Section 5 Description of Item Related Problems .................................................................... 17
Part 3 Structure, Theory and Trouble Analysis of ME17 System Components ............................ 18
Section 1 Layout of Engine Management System Components ............................................ 18
Section 2 Intake Pressure/Temperature Sensor .................................................................... 20
Section 3 Electronic Throttle Valve Body Assembly ............................................................... 23
Section 4 Coolant Temperature Sensor ................................................................................. 24
Section 5 Knock Sensor .......................................................................................................... 26
Section 6 Oxygen Sensor ....................................................................................................... 29
Section 7 Crankshaft Position Sensor .................................................................................... 34
Section 8 Camshaft Position Sensor ...................................................................................... 37
Section 9 Electronic Controller Unit ........................................................................................ 39
Section 11 Injector .................................................................................................................. 46
Section 12 Ignition Coil ........................................................................................................... 49
Section 13 Charcoal Canister Control Valve .......................................................................... 51
Section 14 Fuel Distribution Pipe Assembly ........................................................................... 55
Part 4 Diagnosis Flow for ME17 System in Accordance with Trouble Codes ............................... 56
Part 5 Diagnosis Flow for ME17 System in Accordance with Trouble Symptoms ........................ 74
Section 1 The engine does not rotate or rotates slowly when starting ................................... 74
Section 2 The engine can rotate, but cannot be started successfully .................................... 75
Section 3 Hot starting is difficult .............................................................................................. 76
Section 4 Cold starting is difficult ............................................................................................ 76
Section 5 Engine is difficult to start at any time, but the engine speed is normal .................. 77
Section 6 Engine can be started normally, but idle speed unstable at any time .................... 78
Section 7 Engine can be started normally, but idle speed unstable during warming up........ 79
Section 8 Engine can be started normally, but idle speed unstable after warming up .......... 80
Section 9 Engine can be started normally, but idle speed unstable or engine misfires under
some loads (for example, the air conditioning is on) .............................................................. 81
Section 10 Engine speed does not increase or the engine misfires during acceleration....... 81
Section 11 Response is slow during acceleration .................................................................. 82
3
Section 12 Engine power is low and performance is poor during acceleration...................... 83

Part 6 Instructions for BYD-ED400 Diagnostic Tester ................................................................... 85
Section 1 Preparation before Diagnosing the Vehicle with BYD-ED400................................ 85
Section 2 Instructions for Keyboard Operation ....................................................................... 87
Section 3 Function Introduction .............................................................................................. 88
Section 4 Precautions for Maintenance and Use of Diagnostic Tester .................................. 97
Part 7 Accessories.......................................................................................................................... 98
Section 1 Components Installation Torque Specification Table ............................................. 98
Section 2 Maintenance Procedures for Electronic Injection System ...................................... 98
4
Introduction
With the development of China's national economy, the automobile quantity is increasing
gradually and environmental regulations are becoming stricter. The combination of the
quantitative gasoline technique controlled by a closed loop and three-way catalytic converter may
reduce the emission of toxic substances by 92% or more, so it is an irreversible trend to replace
the carburetor with the electronically controlled gasoline injection technique. It marks the end of
the engine with a carburetor and the beginning of the engine with an electronically controlled
gasoline injection in the Chinese automobile industry.
The engine management system equipped in the BYD 473Q engine is the MOTRONIC system
provided by United Automotive Electronic Systems Co. Ltd. As the largest and most influential
provider of electronically controlled gasoline injection systems in China, United Automotive
Electronic Systems Co. Ltd. has been providing the Motronic series electronically controlled
injection system and other components introduced from Germany by BOSCH Company to
various automobile companies in China since 1996. Motronic is a trade name without a specific
meaning. The Motronic system has a technical feature which is a combination of engine
gasoline quantitative electronic control and an ignition timing electronic control system. Both
systems share a set consisting of a sensor, electronic control unit and power supply. It is
noticeable that the Motronic system has an ignition timing electronic control function which
naturally improves the engine performance.
As the other electronically controlled gasoline injection system, the Motronic system reduces the
vehicle emission significantly, but it makes things difficult for service personnel who are only
familiar with the engine with a conventional carburetor. The service personnel are familiar with the
structure of an engine with a carburetor. However, some electronic components replace the
familiar mechanical components in the engine with electronically controlled gasoline injection. In
the past, service personnel, or even the drivers could adjust the carburetor or distributor. But now
the data are stored in computer chips, general service personnel cannot repair the malfunction by
modifying the data with electronic instruments. A malfunction in the electronic components of the
system may not be visible from the appearance, and it should be detected with various
instruments. Therefore, service personnel do not know how to repair the engine with
electronically controlled gasoline injection. Based on this situation, we compiled the repair manual
with the aim of helping engineers in the engine plants or assembly plants to further understand
the electronic control system of the engine, and also to help local service personnel repair the
engine with electronically controlled gasoline injection.
The manual first of all introduces the composition and operation theory of the electronically
controlled gasoline injection system, and then it describes the construction and performance of
various components of the system in details.
In general, the diagnostic tester is an essential tool when repairing the electronically controlled
gasoline injection system. The diagnostic tester can recall the trouble information stored in the
ECU. To help the readers fully understand the meaning of each DTC, the manual lists the
conditions when the ECU sets a variety of trouble information. However some trouble cannot be
confirmed directly according to the recorded trouble information. The real trouble cause can be
found only after a series of analysis. Therefore, the repair manual uses more text to describe how
to find the real trouble according to the recorded trouble information.
The existence of electronic control components creates new engine trouble causes. In other
words, the same engine trouble may be caused by the mechanics and electronic components.
The real engine trouble cannot be detected with only the diagnostic tester. Therefore, the repair
manual helps find the trouble cause by describing the engine symptoms and combining the
electronic control system.
5
Part 1 Repair Requirements for Electronic Injection System

Section 1 General Repair Requirements
1.1 Only use the digital multimeter to check the electronically controlled injection system.
1.2 Use only the original components during repair, otherwise the normal operation of the
electronically controlled injection system cannot be guaranteed.
1.3 Only use lead free fuel during repair.
1.4 Please observe the repair diagnosis flow of specifications to perform repair.
1.5 Never disassemble the components of the electronically controlled injection system during
repair.
1.6 Be careful not to drop the electronic components (ECU, sensor, etc.) on the ground during
repair.
1.7 Effectively dispose of the waste during repair in consideration of environmental standards
and measures.
Section 2 Precautions during Repair

2.1 Do not remove any components or connectors of the electronically controlled injection
system from the mounting positions to avoid unexpected damage or prevent the moisture
and oil from entering the connectors, which would affect the normal operation of the
electronically controlled injection system.
2.2 When the connectors are disconnected and connected, be sure to turn the ignition switch to
OFF, or the electrical components may be damaged.
2.3 When simulating the thermal condition of trouble and performing other repairs which may
cause the temperature to rise, never allow the temperature of the electronic control unit to
exceed 80ºC.
2.4 The fuel supply pressure for the electronic injection system is high (about 350 kPa);
therefore the fuel lines use high-pressure resistant fuel pipes. The higher fuel pressure is
maintained in the fuel line even if the engine does not operate. So do not remove the fuel
pipes randomly during repair. When the fuel system needs to be repaired, release the
pressure of the fuel system before removing the fuel pipes. The pressure relief method is as
follows: Start the engine and keep it idling. Connect the diagnostic tester and enter
"Actuator Test". Turn off the fuel pump until the engine stalls. The removal of fuel pipes and
replacement of the fuel filter should be performed by professional service personnel in
well-ventilated places.
2.5 Do not energize the fuel pump when removing the power fuel pump from the fuel tank to
avoid generating electric sparks or causing fires.
2.6 Do not perform an operation test on the fuel pump in the dry state or in water, or its life time
may be reduced. Moreover, do not reverse the positive and negative terminals of the fuel
pump.
2.7 When checking the ignition system, perform the jump spark test only when necessary and it
should take a short time. Do not open the electronic throttle valve during testing, or a large
amount of unburnt gasoline will enter the exhaust pipe, damaging the three-way catalytic
converter.
2.8 The idling speed is adjusted only by the electronically controlled injection system without
manual adjustment. The throttle stop screw of the electronic throttle body assembly has
been adjusted in the factory, so the customers are not allowed to change its original
position.
2.9 Do not mix the positive and negative terminals when connecting the battery to avoid
damage to the electronic components. The system uses negative pole grounding.
2.10 Do not remove the battery cables when the engine is running.
2.11 When the welder is used on the vehicle, the positive and negative cables of the battery and
the electronic control unit should be removed.
2.12 Do not detect the input and output signals of components by piercing the wire sheath.
6
Section 3 Summary of Repair Tools

Tool Name:
Ignition Timing Light
Function:
Check the engine ignition timing, etc.
Tool Name:
Digital Multimeter
Function:
Check the characteristic parameters of the
electronically controlled injection system, such
as voltage, current and resistance.
Tool Name:
Vacuum Gauge
Function:
Check the pressure of the intake manifold.
Tool Name:
Cylinder Pressure Gauge
Function:
Check the pressure of each cylinder.
7
Tool Name:
Fuel Pressure Gauge
Function:
Check the pressure of the fuel system and
judge the operation of the fuel pump and fuel
pressure regulator in the fuel system.
Tool Name:
Exhaust Gas Analyzer
Function:
Check the exhaust emission of the vehicle to
help judge the trouble of the electronically
controlled injection system.
Tool Name:
Injector Washing Analyzer
Function:
Perform washing and analysis on the injector.
8
Section 4 Meaning of Abbreviations in Repair Manual

DG Crankshaft Position Sensor (Engine Speed Sensor)
DS-S-TF Intake Pressure/Temperature Sensor
ECU Electronic Control Unit (Computer)
EKP Fuel Pump
EMS Engine Management System
EV Injector
LSH Heated Lambda Sensor
KS Knock Sensor
KSZ Fuel Distribution Pipe Assembly
KVS Fuel Distribution Pipe
PG Camshaft Position Sensor (Phase Sensor)
TEV Charcoal Canister Control Valve
TF-W Coolant Temperature Sensor
ZSK Ignition Coil
9
Part 2 Introduction of ME17 System

Section 1 System Operation
1.1 System Overview: ME17-Motronic and actuator which control the intake air
Engine Management System amount, injection quantity and ignition
advance angle when the engine operates. The
The engine management system usually basic structure is shown in figure 2-1.
consists of a sensor, microprocessor (ECU)
Sensor Diagnosis ECU Diagnosis Actuator
Engine
Fig. 2-1 Composition of Engine Electronic Control System
In the electronic engine control (EEC) system, Once trouble is detected and confirmed, a
the sensor is used as the input part to DTC is stored and the "limp home" function is
measure various physical signals recalled. When the trouble is eliminated, the
(temperature, pressure, etc.) and convert normal value will be restored.
them to the proper electrical signals. The ECU
receives the signals input by the sensor, The major feature of the ME17 electronic
performs calculation according to the set engine control management system is to use
procedures and outputs the generated control the torque-based control strategy. The aim of
signal to the power-driven circuit. The the torque-based control strategy is to
power-driven circuit performs different actions combine various different control targets. This
by driving each actuator so that the engine is the only method to integrate various
can operate according to predetermined functions in different variants of the ECU
control strategy. Meanwhile, the trouble according to the engine and vehicle models.
diagnosis system of the ECU monitors the The basic components of the ME17 electronic
components or control function of the system. engine control (EEC) system are as follows:
Electronic controller (ECU) Electronic throttle body assembly

Intake pressure/temperature sensor Injector
Coolant temperature sensor Power fuel pump
Electronic throttle body assembly Fuel pressure regulator
Camshaft position sensor Fuel pump bracket
Crankshaft position sensor Fuel distribution pipe
Knock sensor Charcoal canister control valve
Oxygen sensor Ignition coil
The ME17-Motronic engine management Basic management function of the engine with
system is an electronically operated gasoline a physical model applied
engine control system which provides many
control features related to the operator and  Torque-based system structure
vehicle or device. The system combines the  Cylinder load determined by intake
open loop and closed loop (feedback) controls pressure sensor/air flow sensor
to provide various control signals for the  Improved mixture control function in static
operation of engine. and dynamic conditions
10
 Closed loop control these variables are processed first in the

 Cylinder by cylinder sequential fuel central torque demand coordinator module.
injection ME17 system puts the contradictory demands
 Ignition timing, including cylinder by in order, perform the most important demand
cylinder knock control and achieves the desired engine control
 Emission control function parameters through torque conversion
 Catalyst heating modules, such as injection time and ignition
 Charcoal canister control timing, etc. The performance of the control
 Idle control variable will not affect other variables. This is
 Limp home the feature of the torque-based control
system.
1.2 Torque structure: Torque control
based ME17 system When matching the engine, as the
torque-based control system has the variable
In the torque-based ME17 engine independence, the engine characteristic curve
management system, all the internal and and map are matched using only engine data
external demands of the engine are defined without the interference of other performance
by the engine torque or efficiency functions and variables. The repeated
requirements as shown in figure 2-2. By calibration is avoided, the matching process is
converting various demands of the engine to simplified and the matching cost is reduced.
the control variables of torque or efficiency,
Figure 2-2 Torque-based ME17 System Structure
11
Compared with the conventional M series The basic feature of the model-based engine
engine electronic injection management is independent and the calibration process is
system, the main features of ME17 system simplified;
are as follows: The sequential fuel injection with the camshaft
position sensor can help improve the
 The functional structure of the new emission;
torque-based engine is compatible with
other systems more easily and with Improve the driving performance by the
stronger expansibility; integrated coordination of various torque
requirements;
 The new modular software and hardware The system can be expanded according to
structures have stronger portability; future demands, such as future emissions
regulations or electronic throttle valve.
12
Section 2 Control Signal: Input/Output Signals of ME17 System

The main sensor input signals of the ECU in
the ME17 system include:
The desired actuator control signal is
2.1 Intake pressure signal generated after the above information is input
into the ECU, and the signal is magnified in
2.2 Intake temperature signal the output driver circuit and transferred to the
applicable actuator. The control signals
2.3 Electronic throttle angle signal include:
2.4 Coolant temperature signal 2.11 lectronic throttle valve opening
2.5 Engine speed signal 2.12 Injection timing and injection duration
2.6 Phase signal 2.13 Oil pump relay
2.7 Knock sensor signal 2.14 Charcoal canister control valve opening
2.8 Oxygen sensor signal 2.15 Ignition coil dwell angle and ignition
advance angle
2.9 Vehicle speed signal
2.16 Cooling fan relay
2.10 Air conditioning pressure signal
13
Section 3 Introduction of System Function

throttle valve opening increases, part of the
3.1 Start Control injected fuel will be absorbed by the oil film.
Therefore, additional fuel should be injected to
The charging capacity, injection and ignition compensate and prevent the mixture from
timing are controlled by using a special becoming thinner during acceleration. Once
calculation method during starting. In the the duty factor decreases, the additional fuel
beginning, the air in the intake manifold is contained in the oil film on the wall of the
static and the internal pressure display of the intake manifold will be released. So the
intake manifold is the atmospheric pressure. In injection duration must be reduced during
a similar process, the specific "injection timing" deceleration. Motoring or the towing working
is defined as the initial injection pulse. The fuel condition is a condition when the power
injection amount facilitates the formation of oil supplied by the engine at the flywheel is
film on the intake manifold and cylinder wall negative. In this case, the engine friction and
according to the changes of the engine pump loss can be used to decelerate the
temperature, therefore the mixture must be vehicle. When the engine is in motoring or
enriched before the engine reaches a certain towing working condition, the fuel is cut off to
speed. Once the engine starts, the system will reduce the fuel consumption and exhaust
reduce the cranking enrichment until the emission, and the most important is to protect
cranking enrichment is cancelled when the the three-way catalytic converter. Once the
starting is completed (600…700min-1). When speed decreases to a specified speed above
starting, the ignition angle changes with the the idle speed, the injection system will supply
engine temperature, intake temperature and fuel again. In fact, the ECU procedure has a
engine speed. range in which the speed can be restored.
They vary with the engine temperature and
3.2 Warm up and heating control of dynamic change of engine speed, and prevent
three-way catalytic converter the speed from decreasing to the specified
lowest threshold through the computer. Once
When the engine is started at low temperature, the injection system supplies the fuel again, it
the cylinder charge, fuel injection and will supplement the fuel using the initial
electronic ignition are adjusted to compensate injection pulse and rebuild an oil film on the
wall of the intake manifold. After the injection is
for the higher torque demands of the engine.
The process continues until the proper restored, the torque-based control system will
temperature threshold is reached. The most increase the engine torque slowly and stably
important thing is to quickly heat the three-way (stable transition).
catalytic converter in this stage, as the quick
transition to three-way catalytic converter 3.4 Idle control
operation will reduce the exhaust emission
significantly. In the working condition, the When idling, the engine does not provide
three-way catalytic converter should be heated torque to the flywheel. To ensure the stable
with exhaust by properly delaying the ignition operation of the engine at the lowest idle
advance angle. speed, the closed loop idle control system
must maintain the balance between the
3.3 Acceleration/deceleration and generated torque and engine "power
consumption". A certain amount of power must
motoring fuel cutoff control be generated when idling to meet various load
requirements. They come from the engine
Part of the fuel injected to the intake manifold crankshaft, valve mechanism and ancillary
will not reach the cylinder in time to be burned. components, such as the internal friction of
In contrast, it will form a layer of oil film on the the water pump.
wall of the intake manifold. According to the
load increase and extension of injection The torque-based ME17 system control
duration, the fuel stored in the oil film will strategy confirms the engine output torque
increase significantly. When the electronic
14
required to maintain the desired idle speed in modify the control variable in response to the
any working condition according to the closed input signals (1=thin mixture, 1=rich
loop idle control. The output torque increases mixture), and generate the correction factor as
as the engine speed decreases, and a multiplier to correct the injection duration.
decreases as the engine speed increases.
The system responds to the new "interference 3.6 Evaporative Emission Control
factors" by demanding larger torque, such as
ON/OFF of the air conditioning compressor or Due to the delivery of external radiation heat
the automatic transmission gear shift. When and oil return heat, the fuel in the fuel tank is
the engine temperature is low, the torque must heated and the fuel vapor is formed. The
be increased to compensate more internal vapor containing a large amount of HC cannot
friction loss and/or maintain higher idle speed. be discharged to the atmosphere due to the
The total of the output torque demands is limit of evaporative emission regulations. In
transferred to the torque coordinator, and the the system, the fuel vapor is collected in the
charge density, mixture content and ignition charcoal canister through the duct, and then
timing are calculated by the torque purged and burned in the engine at the proper
coordinator. time. The purge air flow can be achieved
through the charcoal canister control valve
3.5 Closed loop control controlled by the ECU. The control functions
when the  closed loop control system
The exhaust post-processing in the three-way operates.
catalytic converter is an effective method to
reduce the concentration of harmful 3.7 Knock Control
substances in the exhaust. The three-way
catalytic converter can reduce the The system detects the characteristic
hydrocarbons (HC), carbonic oxide (CO) and oscillation when the knock is detected by the
nitrogen oxides (NOx) by 98% or more, and knock sensor at the proper position of the
convert them to water (H2O), carbon dioxide engine, converts it to electronic signals and
(CO2) and nitrogen (N2). The high efficiency transfers them to the ECU for handling. The
can be reached only when the engine excess ECU uses a special processing algorithm to
air ratio  is about 1. The target of  closed detect the knock in each ignition cycle of each
loop control is to ensure the mixture cylinder. The closed loop control will be
concentration is within the range. triggered once the knock is detected. When
the knock danger is eliminated, the ignition of
The  closed loop control system can function the affected cylinder will gradually advance to
only when equipped with an oxygen sensor. the predetermined ignition advance angle
The oxygen sensor monitors the oxygen again.
content in the exhaust at the position of the
three way catalytic converter. The thin mixture The threshold of the knock control can adapt to
(1) will generate a sensor voltage of about different working conditions and different types
100 mV, and the rich mixture (1) will of fuel.
generate a sensor voltage of about 900 mV.
When =1, the sensor voltage will have a step
transition. The  closed loop control will
15
Section 4 Introduction of System Diagnosis Function

4.1 Record trouble information 4.2 Connection of diagnostic tester
The electronic control unit constantly monitors The system uses "K" line communication
the sensor, actuator, related circuits, fault protocol and an ISO 9141-2 standard
indicator, battery voltage and even the diagnostic plug as shown in figure 2-4. The
electronic control unit itself, and detects the standard diagnostic plug is securely
reliability of output sensor signals, actuator connected to the engine wire harness. Pin No.
drive signals and internal signals (for example, 4, 7 and 16 on the standard diagnostic plug
 closed loop control, coolant temperature, are used in the engine management system
knock control, idle speed control and battery (EMS). Pin No. 4 of the standard diagnostic
voltage control, etc.).Once the trouble is found plug is connected to the ground wire of the
in a cycle or some signal value is not reliable, vehicle. Pin No. 7 is connected to Pin No. 71
the electronic control unit will store the trouble of the ECU, i.e. engine data "K" line; Pin No.
information in the malfunction memory of RAM. 16 is connected to the battery positive.
The trouble information is stored in the form of
DTCs, and displayed in the order of trouble
occurrence.
Fig. 2-4 ISO9141-2 Standard Diagnostic Plug
The ECU communicates with the diagnostic

tester through "K" line and performs related
operations (For the functions and diagnostic
tester operation, refer to "ME17 Diagnostic
Tester Instructions").
Fig. 2-3 Schematic Diagram of
Electronically Controlled Injection System
Trouble Diagnosis
16
Section 5 Description of Item Related Problems

System features: Signal disc identification speed signal is used
Multi-point sequential injection system; (crankshaft position sensor);
The functional structure of the new Closed loop control of idle speed torque is
torque-based engine is more easily achieved;
compatible with other systems, and with Knock control (knock sensor KS-1-K);
stronger expansibility; Function to heat and protect the catalyst;
The new modular software and hardware Limp home function;
structures have stronger portability; Blink code function, etc.
The cylinder identification signal is used
(camshaft position sensor);
17
Part 3 Structure, Theory and Trouble Analysis of ME17 System

Components
Section 1 Layout of Engine Management System Components
473Q Engine
A: Electronic Throttle Body Assembly C: Intake Temperature/Pressure Sensor
18
E: Camshaft Position Sensor F: Ignition Coil

D: Coolant Temperature Sensor
G: Knock Sensor
H: Crankshaft Position Sensor
I: Front Oxygen Sensor J: Charcoal Canister Control Valve
K: Injection Nozzle L: Engine ECM
19
Section 2 Intake Pressure/Temperature Sensor

Diagram and Pin
Intake Pressure/
Temperature
Sensor
Fig. 3-1 Intake Pressure/Temperature Sensor Fig. 3-2 Circuit Diagram of Intake
Pressure/Temperature Sensor
Pin definition: 1# Ground;

2# Intake temperature signal output;
3# connected to 5 V power;
4# Intake pressure signal output.
Fig. 3-3 Connectors of Intake Pressure/Temperature Sensor
2.1 Installation Position formed. The active surface of the silicon chip
A sensor consisting of an intake manifold is subject to a pressure of nearly 0, and its
absolute pressure sensor and intake back is subject to an intake manifold absolute
temperature sensor is installed on the intake pressure introduced by a tube. The thickness
manifold. of the silicon chip is only several micrometers
(m), so the change of intake manifold
2.2 Operation Theory absolute pressure will cause the mechanical
The intake manifold absolute pressure sensor deformation of the silicon chip. The 4
consists of a silicon chip. A pressure piezoelectric resistors also deform and their
diaphragm is etched on the silicon chip. The resistance values change. The voltage signals
pressure diaphragm has 4 piezoelectric in linear relation with voltage will be generated
resistors which form a Wheatstone bridge as after the treatment of the signal processing
variable components. In addition to the circuit of the silicon chip.
pressure diaphragm, a signal processing
circuit is also integrated in the silicon chip. The intake temperature sensor is a resistor of
The silicon chip forms a closed reference negative temperature coefficient (NTC) which
space with a metal housing, with the absolute changes with the intake temperature. The
air pressure of the reference space close to 0. sensor will send a voltage signal indicating the
Thus a microelectronic mechanical system is intake temperature change to the controller.
1. Seal Ring
2. Stainless Bushing
3. PCB Plate
20
4. Sensor
5. Housing
6. Pressure Support
7. Welded Connection
8. Adhesive Connection
Fig. 3-4 Cross Section of Intake Manifold Absolute Pressure and Intake Temperature Sensor
2.3 Technical Parameters
2.3.1 Data Limit
Value
Items Unit
Min. Typical Max.
Withstand Voltage 16 V
Max. Allowed Pressure 500 kPa
Allowed Storage Temperature -40 +130 C
2.3.2 Performance Data
Value
Items Unit
Min. Typical Max.
Pressure Test Range 20 115 kPa
Operating Temperature -40 125 C
Operating Voltage 4.5 5.0 5.5 V
Current for US=5.0 V 6.0 9.0 12.5 mA
Load Current of Output Circuit -0.1 0.1 mA
Load Resistance to Ground or Battery 50 k
Response Time 0.2 ms
Weight 27 g
2.3.3 Transfer Function of Pressure Sensor Load capacity at 25C: 100mW
UA=(c1 pabs+c0)Us 2.3.5. Performance Data of Temperature

Sensor
In which, UA = Signal output voltage (V)
US = Power voltage (V) Operating temperature: -40/+125C
pabs = Absolute pressure (kPa) Rated voltage: Operates with resistance of 1
c0=-9.4/95 k at 5 V, or operates with the test current 1
c1=0.85/95(1/kPa) mA
From the above formula, under atmospheric Rated resistance at 20C: 2.5 k  5%
pressure, the signal output voltage of the Temperature-time factor 63 in air, v=6 m/s:
pressure sensor is close to the power voltage. 45 s
If the power voltage is 5 V, the signal output
voltage of the pressure sensor is about 4 V
2.4 Precautions for installation
when the electronic throttle valve is fully
The sensor is designed to be installed on the
opened.
surface of the intake manifold in the engine.
The pressure tube and temperature sensor
2.3.4. Data Limit of Temperature Sensor
are integrated in the intake manifold and
sealed with an O-ring.
Storage temperature: -40/+130C
21
voltage and current of the generator

If the sensor is properly installed in the vehicle are normal.
(extract pressure from the intake manifold, the
pressure tube tilts down, etc.), the condensate 2.5.4 Simple measurement method:
water will not be formed on the pressure
sensing components. Temperature sensor: (With the connector
removed) Turn the digital multimeter to the
The drilling and fixing of the intake manifold Ohms range, and connect two probes to Pins
must be performed according to the vendor No. 1 and 2 of the sensor respectively. The
drawing to ensure long-term tightness and rated resistance at 20ºC is 2.5kΩ±5%. The
corrosion resistance. other resistance values can be measured
according to the characteristic curve in figure
In addition to the influence of the main 3-5. The simulation can be used when
component connectors, the reliable contact of measuring. The specific method is to blow the
electrical connectors is also related to the sensor with a hair drier (Do not get too close)
material quality and dimension precision of the and observe the change of the sensor
connectors connected to the wire harness. resistance. At this time the resistance should
drop.
2.5 Trouble Symptoms and Judgment
Method Pressure sensor: (With the connector
connected) Turn the digital multimeter to DC
2.5.1 Trouble symptoms: misfiring, poor voltage range, connect the black probe to
idling, etc. ground and connect the red probes to Pins No.
3 and 4. Under the idling condition, Pin No. 3
2.5.2 General trouble cause: 1. Abnormal should have a reference voltage of 5 V, while
high voltage or reverse high current the voltage of Pin No. 4 is about 1.3 V (The
during use; 2. The vacuum specific values are not related to the models).
components are damaged during In the unloaded state, the voltage of Pin No. 4
repair. shows little change when the electronic
throttle valve is slowly opened. When the
2.5.3 Precautions for repair: Never impact electronic throttle valve is opened quickly, the
the vacuum components with voltage of Pin No. 4 can reach about 4 V
high-pressure air during repair. When immediately (The specific values are related
the sensor is replaced due to to the models) and then it decreases to about
malfunction, check if the output 1.5 V (The specific values are related to the
models).
Fig. 3-5 Characteristic Curve of Intake Temperature Sensor NTC Resistance
22
Section 3 Electronic Throttle Valve Body Assembly

Diagram and Pin
Pin definition:
1. Throttle position sensor 1;
2. 5 V power 2;
3. Positive terminal of electronic throttle
valve actuator;
4. Throttle position sensor 2;
5. Negative terminal of electronic throttle
valve actuator;
6. Throttle valve connected to ground.
Fig. 3-8 Connectors of Electronic Throttle

Fig. 3-6 Electronic Throttle Valve Body Valve Body Assembly
Assembly
Test Method
3.1. When a stable voltage of 4 V is supplied to

the motor of the electronic throttle valve
body, the electronic throttle valve can be
opened smoothly.
3.2 When the power of 5 V is supplied to the

sensor and the valve plate moves, the
Electronic Throttle Valve Body (Third voltage of pin No. 1 will increase and the
Party) voltage of pin No. 4 will decrease.
Fig. 3-7 Circuit Diagram of Electronic Throttle 3.3 Self-learning must be performed when the
Valve Body Assembly electronic throttle body assembly is
replaced (Wait for 1 min after the vehicle
is powered ON.
23
Section 4 Coolant Temperature Sensor

Diagram and Pin
4.2 Operation Theory

The sensor is a thermistor with a negative
temperature coefficient (NTC), and its
resistance will decrease with the increase of
coolant temperature, but not in linear relation.
The thermistor with a negative temperature
coefficient is installed on a copper surface as
shown in figure 3-12.
Fig. 3-9 Coolant Temperature Sensor
Coolant Temperature Sensor
Engine
ECM
Fig. 3-12 Cross Section of Coolant

Temperature Sensor
Fig. 3-10 Circuit Diagram of Coolant

Temperature Sensor
Resistance(R)
Temperature
Fig. 3-13 Characteristic Curve of Coolant

Pin definition: Pin A signal output; Temperature Sensor
Pin B in void;
Pin C connected to ground; Fig. 3-11
Connectors of Coolant Temperature
Sensor
4.1 Installation Position

The sensor is installed in the water outlet of
the engine.
24
4.3.1 Data Limit
Items Value Unit

Rated voltage Operated only by ECU
Rated resistance at 20C 2.55% k
Operating temperature range -30 to +130 C
Max. test current of sensor 1 mA
Allowed vibration acceleration 600 m/s2
4.3.2 Performance Data
No. Resistance (k) Temperature

Temperature Tolerance1C Temperature Tolerance0C (C)
Min. Max. Min. Max.
1 8.16 10.74 8.62 10.28 -10
2 2.27 2.73 2.37 2.63 +20
3 0.290 0.354 0.299 0.345 +80
4.4 Precautions for installation 4.5.3 Simple measurement method:

The coolant temperature sensor is installed on (With the connector removed) Turn the digital
the cylinder block, and the bronze heat multimeter to the Ohms range, and connect
conduction sleeve is inserted into the coolant. two probes to Pins A and C of sensor
The sleeve has thread, and the coolant respectively. The rated resistance at 20ºC is
temperature sensor can be easily screwed 2.5kΩ±5%, and the other resistance values
into the thread hole of the cylinder block with can be measured according to the above
the hexagon head on the sleeve. The characteristic curve. The simulation can be
maximum tightening torque is 20 Nm. used when measuring. The specific method is
to put the sensor working area in hot water
4.5 Trouble Symptoms and Judgment (The soak time should be sufficient) and
Method observe the change of sensor resistance. At
this time the resistance should drop to
4.5.1 Trouble symptom: Difficult to start. 300Ω-400Ω (The specific values depend on
4.5.2 General trouble cause: Human failure. the temperature of the hot water).
25
Section 5 Knock Sensor

Diagram and Pin
Pin: Pin No. 1 connected to Pin No. 19 of

ECU;
Fig. 3-14 Knock Sensor without Cable Pin No. 2 connected to Pin No. 20 of ECU.
Fig. 3-18 Connectors of Knock Sensor
The sensor is installed on the engine block.
The knock sensor is a vibration acceleration

Fig. 3-15 Knock Sensor with Cable sensor which is installed on the engine block.
One or more sensors can be installed. The
sensing component of the sensor is a
Knock Sensor piezoelectric element. The vibration of the
engine block is delivered to the piezo-electric
crystal through the mass block in the sensor.
The piezo-electric crystal generates voltage
Engine on two polar planes under the pressure
BCM generated by the vibration of the mass block,
and converts the vibration signal to voltage
signal output. The characteristic curve of its
frequency response is shown in the figure
below. The frequency of vibration signal
Fig. 3-16 Circuit Diagram of Knock Sensor caused by engine knocking is much higher
than that of the normal vibration signal of the
engine, therefore the knock and non-knock
signals can be distinguished after the signal of
the knock sensor is processed by the ECU.
Sensitivity
Fig. 3-17 Cross Section of Knock Sensor
Frequency
Fig. 3-19 Characteristic Curve of Knock

Sensor Frequency Response
26

(1) Data Limit
Items Value Unit

Min. Typical Max.
Operation temperature -40 +130 C
(2) Performance Data
Items Value Unit

Sensitivity of new sensor to 5 kHz signal 268 mV/g
Linearity between 3 to 15 kHz 15% of 5 kHz
Linearity when resonance occurs 15 to 39 mV/g
Variation during the entire life span -17% Max.
Main resonant frequency 20 kHz
Resistance 1 M
Impedance Capacitance 1200400 pF
Cable capacitance 28060 pF/m
Leak resistance 4.815% M
(Resistance between 2 output Pins of the
sensor)
Sensitivity variation caused by -0.06 mV/gK
temperature
27
5.4 Precautions for installation 5.5.1 Trouble symptom: poor acceleration.

5.5.2 General trouble cause: Various fluids
The knock sensor should be installed properly (for example, oil, coolant, brake fluid
so that the sensor can easily receive the and water) contact the sensor for a
vibration signals from all the cylinders. The long time so that the sensor is
optimal installation position of knock sensor corroded.
can be confirmed through the modal analysis 5.5.3 Precautions for repair: (Refer to
of the engine block. Do not allow the sensor to Precautions for installation)
contact various fluids for a long time, such as 5.5.4 Simple measurement method:
oil, coolant, brake fluid and water. No type of
washer is allowed during installation. The (With the connector removed) Turn the digital
metal surface of sensor must contact with the multimeter to the Ohms range, and connect
cylinder block. When routing the signal cable two probes to Pins 1 and 2 of the sensor
for the sensor, resonance of the signal cable respectively. Under normal temperature, its
should not occur to avoid breakage. Do not resistance should not be higher than 1MΩ.
supply high-voltage power between Pins No. 1 Turn the digital multimeter to Millivolts range,
and 2 of the sensor, or the piezoelectric and tap the areas around the knock sensor
element may be damaged. with a hammer. At this time the voltage signal
should be output.
Method
28
Section 6 Oxygen Sensor

Diagram and Pin
Fig. 3-20 Oxygen Sensor Fig. 3-21 Cross Section of Oxygen Sensor
1 Cable 2 Saucer Washer 3 Insulating Bushing 4 Protective Sleeve
5 Clamped Connector of Heating Element 6 Heating Rod
7 Contact Gasket 8 Sensor Base 9 Ceramic Probe 10 Protection Tube
Main relay of electronic injector Main relay of electronic injector
Front oxygen sensor Rear oxygen sensor
Fig. 3-22 Circuit Diagram of Front Oxygen Fig. 3-23 Circuit Diagram of Rear Oxygen
Sensor Sensor
Pin definition:
Front oxygen sensor: Pin No. 1 connected to main relay;
Pin No. 2 connected to Pin No. 73 of ECU;

Pin No. 4 connected to Pin No. 104 of ECU.
Fig. 3-24 Connectors of Front Oxygen Sensor
Rear oxygen sensor: Pin D connected to main relay;

Pin C connected to Pin No. 4 of ECU;
Pin B connected to Pin No. 21 of ECU;
Pin A connected to Pin No. 43 of ECU.
Fig. 3-25 Connectors of Rear Oxygen Sensor
6.1 Installation Position The sensing component of the oxygen sensor

is a ceramic tube with pores. The outside of
The sensor is installed in the exhaust pipe. the tube wall is surrounded by engine exhaust
and the inside is atmosphere. The sensing
6.2 Operation Theory ceramic tube wall is a solid electrolyte with an
electric heating tube inside as shown in figure
3-21.
29
The oxygen sensor is operated to convert the The concentration difference is converted to
difference of oxygen ion concentration inside potential difference so that the electrical signal
and outside of the sensing ceramic tube to is output. The variation range of the front
voltage signals and output them. When the oxygen sensor during idling is: 0-900 mV. If
temperature of the sensing ceramic tube the mixture is rich, the difference of oxygen
reaches 350ºC, it will have the characteristics ion concentration inside and outside the
of a solid electrolyte. Due to the special ceramic tube is high and the potential
material, the oxygen ion can penetrate the difference is too high. A large amount of
ceramic tube freely. With the characteristics, oxygen ions move from inside to outside and
the output voltage is high (close to 800
mV-1000 mV). If the mixture is thin, the
difference of oxygen ion concentration inside
and outside the ceramic tube is low and the
potential difference is too low. Few oxygen
ions move from inside to outside and the
output voltage is low (close to 100 mV). The
sudden change of signal voltage occurs
around the theoretical equivalent air-fuel ratio
(λ=1) as shown in figure 3-26.
Fig. 3-26 Characteristic Curve of Oxygen

Sensor at 600C
30
6.3.1. Data Limit
Value
Items Unit
Min. Typical Max.
Storage temperature -40 +100 C
Ceramic tube 200 850 C
Housing hexagon head 570 C
Operating
Metal retaining ring of
temperature 250 C
cable and connecting cable
Connector 120 C
Max. temperature
Exhaust at ceramic tube
allowed when the 930 C
heating end
component is
energized (Up to
Housing hexagon head 630 C
10 min each time,
the cumulative
time is up to 40 Metal retaining ring of
280 C
hours) cable and connecting cable
Temperature change rate permitted at the
100 K/s
ceramic tube end
Temperature of the ceramic components
permitted when there is condensate water on 350 C
the exhaust side
Random vibration
800 m/s2
(Peak value)
Allowed housing Harmonic vibration
0.3 mm
vibration (Vibration displacement)
Harmonic vibration
300 m/s2
(Vibration acceleration)
Absolute
Constant DC current at 350C A
value10
Max. constant AC current when the exhaust
20 A
temperature is 350C and f1Hz
Lead free fuel or the lead tolerance of upt to
Permitted fuel additive
0.15g/L
The tolerance and data must be confirmed
Oil consumption and combustion by the customer through appropriate tests.
Standard value: 0.7L/1000km
6.3.2. Performance Data

Items New After 250-hour bench test
Exhaust temperature for
350C 850C 350C 850C
performance data setup
Voltage (mV) of sensing
component when =0.97 840±70 710±70 840±80 710±70
(CO=1%)
Voltage (mV) of sensing
20±50 50±30 20±50 40±40
component when =1.10
31
Internal resistance (k) of sensing

 1.0 0.1 1.5 0.3
component
Response time (ms)
<200 <200 <400 <400
(600 mV to 300 mV)
Response time (ms)
<200 <200 <400 <400
(300 mV to 600 mV)
6.3.3. Electric Data of Sensor

Items Value Unit
Insulation resistance Indoor temperature, heating
30 M
between new sensor component powered off
heating component Exhaust temperature 350C 10 M
and sensor connector Exhaust temperature 850C 100 k
Rated voltage 12 V
Continuous operating voltage 12 to 14 V
Operating voltage which can maintain
up to 1% of total life span (exhaust 15 V
Power voltage at the
temperature 850C)
connector
Operating voltage which can maintain
up to 75 seconds 24 V
(Exhaust temperature 350C)
Test voltage 13 V
Heating power when the operating voltage is 13 V and heat
balance is reached (exhaust temperature is 350C and the 12 W
exhaust flow rate is about 0.7 m/s)
Heating current when the operating voltage is 13 V and heat
balance is reached (exhaust temperature is 350C and the 5 A
exhaust flow rate is about 0.7 m/s)
Fusible link of heating circuit 8 A
6.3.4. Service Life

The service life of the oxygen sensor is related to the lead content of gasoline as listed below.
Lead content of gasoline (g/L) Life (km)
0.6 30000
0.4 50000
0.15 80000
0.005(Lead free fuel) 160000
32
6.4 Trouble Symptoms and Judgment Method
Trouble symptom: poor idling, poor (With the connector removed) Turn the digital
acceleration, tail gas exceeds standard, high multimeter to the Ohms range, and connect
fuel consumption, etc. two probes to Pins 1 (C) and 2 (D) of the
sensor respectively. Under normal
6.4.1 l trouble cause: 1. Moisture in the temperature, its resistance is 8~10. (With
sensor. The temperature changes the connector connected). Under the idling
suddenly, and the probe is broken; 2. condition, when the operating temperature of
The oxygen sensor is "poisoned". (Pb, the oxygen sensor reaches 350ºC, turn the
S, Br, Si) digital multimeter to the DC voltage range and
6.4.2 Precautions for repair: Never use the connect two probes to Pins 3 (A) and 4 (B) of
cleaner, oily liquid or volatile solid on the sensor. At this time the voltage should
the oxygen sensor during repair. fluctuate quickly between 0.1~0.9 V.
6.4.3 Simple measurement method:
33
Section 7 Crankshaft Position Sensor

Diagram and Pin
1. Shielded Wire 2. Permanent Magnet 3. Sensor
Housing 4. Mounting Bracket
5. Magnet Core 6. Coil 7. Air Gap 8. 60-2 Gear Ring
Fig. 3-27 Crankshaft Position Sensor Fig. 3-30 Connectors of Crankshaft Position
Sensor
Crankshaft Position Sensor Pin definition: Pin No. 1 connected to Pin No.
15 of ECU;
Pin No. 2 connected to Pin No. 34 of ECU.
Engine
ECM
On the transmission housing
Fig. 3-28 Circuit Diagram of Crankshaft The crankshaft position sensor works with the
Position Sensor pulse wheel to provide the engine speed
information and crankshaft top dead center
information in the distributorless ignition
system. The crankshaft position sensor
consists of a permanent magnet and a coil
around the magnet. The pulse wheel is
installed on the crankshaft and rotates with
the crankshaft. When the tooth tip passes by
the end of the crankshaft position sensor, the
pulse wheel made of ferromagnetic material
cuts the magnetic field lines of the
permanent magnet in the crankshaft position
sensor and generates the induced voltage in
the coil as the speed signal.
Fig. 3-29 Cross Section of Crankshaft Position

Sensor
34
7.3.1. Data Limit
Value
Items Unit
Min. Typical Max.
Coil area -40 +150 C
Transition area Mixed Mixed C
Wire area -40 +120 C
Acceptable
Ambient temperature when not
temperature -40 +120 C
operated
for PUR wire
Long-term ambient
and -40 +120 C
crankshaft temperature when operated
position Short-term 150 hours +150 C
sensor (See ambient
the figure temperature 380 hours +140 C
below) when operated
150 hours +150 C
Entire service life 380 hours +140 C
of wire area 1,130
+130 C
hours
Coil area -40 +150 C
Transition area Mixed Mixed C
Acceptable Wire area -40 +130 C
temperature Storage temperature -20 +50 C
for H&S wire
Ambient temperature when not
and -40 +130 C
operated
crankshaft
Long-term ambient
position -40 +130 C
temperature when operated
sensor (See
Short-term ambient
the figure +150 C
temperature when operated
below)
Entire service life 500 hours +150 C
of wire area 200 hours +160 C
Vibration resistance of 20 to 71 Hz Acceleration40 m/s2
each plane in 168 hours 71 to 220 Hz Amplitude0.2 mm
Allowed magnetic intensity of external 2 kA/m
magnetic field in reversed direction
Insulation resistance (10 New Status 1 M
s, test voltage 100 V) End of usage 100 k
period
Withstand voltage (1 to 3 s, AC 1,200 V) Breakdown is not allowed
35
Fig. 3-31 Three Temperature Areas of Crankshaft Position Sensor

Value
Items Unit
Min. Typical Max.
Resistance between Pins 1 and 2 under the
731 860 989 
room temperature of 20C
Inductance 310 370 430 mH
Output voltage when the crankshaft speed is
1650 mV
416 rpm
7.4 Precautions for installation 7.5.2 General trouble cause: Human failure.
7.5.3 Precautions for repair: It should be
7.4.1 The crankshaft position sensor must installed by pressing it in, instead of
be removed from the packaging just hammering during repair.
before it is to be installed on the 7.5.4 Simple measurement method:
vehicle or test equipment.
7.4.2 The crankshaft position sensor should (With the connector removed) Turn the digital
be installed by pressing it in, instead multimeter to the Ohms range, and connect
of hammering. two probes to Pins 1 and 2 of the sensor
7.4.3 The bolt M612 is recommended for respectively. The rated resistance at 20ºC
fixing the crankshaft position sensor. should be 860Ω±10%. (With the connector
7.4.4 The tightening torque is 82 Nm. connected) Turn the digital multimeter to the
7.4.5 The air gap between the crankshaft AC voltage range, and connect two probes to
position sensor and tooth tip of pulse Pins 1 and 2 of sensor respectively. There is
wheel is 0.8 to 1.2 mm. voltage output when the engine is started.
(Check with an on-board oscilloscope)
Method
7.5.1 Trouble symptom: Unable to start.
Fig. 3-32 Test Oscillogram
36
Section 8 Camshaft Position Sensor

Diagram and Pin
Phase Sensor
Fig. 3-33 Camshaft Position Sensor Fig. 3-34 Circuit Diagram of Camshaft
Position Sensor
Pin definition: Pin No. 1 connected to 5 V power;

Pin No. 3 to ground;
Fig. 3-35 Connectors of Camshaft Position Sensor
8.1 Installation Position compressors top dead center and exhaust top
On the end cap of camshaft dead center of the crankshaft.
8.2 Operation Theory The sensor uses the Hall Theory in which
The sensor works with the inductive sensor of voltage is generated by the change of
the pulse wheel under the distributorless magnetic induction intensity.
condition and provides the crankshaft phase
information to the ECU to distinguish the
Hall Sensor Theory

When a current Is flows through a
semiconductor slice, a hall voltage UH will
be generated in the right-handed rotation
direction of the current which is in
proportion to the magnetic induction B
(vertical to the current Is) and the current
Is. The hall voltage is subject to the
change of magnetic induction intensity B.
Fig. 3-36 Hall Effect Theory

Rotation
direction
Phase signal
wheel
Output signal
Fig. 3-37 Schematic Diagram for Operation of Camshaft Position Sensor (1)
37
Fig. 3-38 Schematic Diagram for Operation of Camshaft Position Sensor (2)
Data Limit
Value
Items Unit
Min. Typical Max.
Ambient temperature -30 +130 C
Mounting clearance 0.5 1.5 mm
Supply voltage 4.5 24 V
8.4 Precautions for installation 8.5.2 General trouble cause: Human failure.
The sensor housing has only 1 hole for fixing. 8.5.3 Simple measurement method:
8.5 Trouble Symptoms and Judgment (With the connector connected) Turn on the
Method ignition switch, but do not start the engine.
Turn the digital multimeter to DC voltage
8.5.1 Trouble symptom: The emissions range, and connect two probes to Pins 1 and
exceed the standards and the fuel 3 of the sensor respectively. Make sure there
consumption increases. is a reference voltage of 5 V. When the engine
is started, check if the signal of Pin No. 2 is
normal with an oscilloscope.
38
Section 9 Electronic Controller Unit

On the cowl panel of the front compartment.
9.2.1 Function
• Multipoint sequential injection
• Ignition control
• Idle control
• Knock control
• Provide power supply for sensors
• Closed loop control with self-adaption
• Charcoal canister control valve control
• Air conditioner switch
• Engine malfunction indicator
• Fuel quantity correction
• Engine speed signal output
• Vehicle speed signal input
• Trouble self-diagnosis
• Receive the engine load signal, etc.
Fig. 3-39 ECU Profile and Pin Diagram
9.2.2 ECU Pin Definition:

Terminal Wire Standard
Terminal Definition Test Condition
No. Color Value
VEHICLE SIDE
Approx.
1 CAN bus interface Always
2.5 V
Ignition switch Less than
5 Main relay
ACC→ON 1V
6 Clutch switch
7 Accelerator pedal ground
14 Power steering switch Engine running —
15 Non-continuous power supply Ignition switch 10-14 V
39
ACC→ON
Ignition switch
16 Non-continuous power supply 10-14 V
ACC→ON
Approx.
17 CANL interface Always
2.5 V
18 Diagnosis K line Engine running
Ignition switch
20 Continuous power supply 10-14 V
ACC→ON
21 Rear oxygen sensor Engine running —
23 Braking switch
Medium voltage switch of air Ignition switch Less than
24
conditioner ACC→ON 1V
25 Braking light
28 Air conditioner switch Engine running —
29 Blower compensation Engine running —
30 Acceleration pedal sensor signal 2
31 High-speed radiator fan relay Engine running
32 Anti-theft input
34 Engine speed output Engine running —
Ignition switch
35 Ignition switch 10-14 V
ACC→ON
36 Accelerator pedal 2, 5 V power
37 Accelerator pedal 1, 5 V power
Less than
41 Oil pump relay Engine running
1V
43 Rear oxygen sensor ground
ACC→ON 1V
45 Acceleration pedal sensor signal 1
47 Analog signal sensor ground
ACC→ON 1V
48 Rear oxygen sensor heating Engine running —
Low-speed radiator fan and
56 Engine running —
condenser fan relay
58 Air conditioner control Engine running —
59 Accelerator pedal ground
ACC→ON 1V
63 Power Ground 2
ACC→ON 1V
64 Power Ground 1
ACC→ON 1V
ENGINE SIDE
65 Vehicle speed output
67 Injector of cylinder 2 Engine running —
69 Variable valve lift valve
71 EGR valve
73 Front oxygen sensor heating Engine running —
Positive terminal of electronic
75
throttle valve actuator
76 Ignition coil of cylinder 4 Engine running —
77 Throttle position sensor 1
40
78 Throttle position sensor 1

80 Front oxygen sensor ground
ACC→ON 1V
84 Sensor ground
ACC→ON 1V
Intake temperature/pressure sensor Ignition switch Less than
85
ground ACC→ON 1V
86 Throttle valve ground
ACC→ON 1V
Negative terminal of electronic
87
throttle valve actuator
89 Terminal B of knock sensor Engine running —
90 Terminal A of knock sensor Engine running —
91 Intake pressure sensor
ACC→ON 1V
93 Phase sensor
94 Charcoal canister control valve Engine running —
95 Phase sensor ground
ACC→ON 1V
Terminal A of crankshaft position
96 Always —
sensor
Terminal B of crankshaft position
97 Engine running —
sensor
98 5 V power of phase sensor
Ignition switch
101 Coolant temperature sensor —
ACC→ON
Ignition switch
102 Intake temperature sensor —
ACC→ON
103 EGR valve position input
104 Front oxygen Sensor Engine running —
5 V power of throttle valve position Ignition switch
107 5V
sensor ACC→ON
108 5 V power of phase sensor Engine running —
5 V power of intake
109
temperature/pressure sensor
111 Power Ground 4
ACC→ON 1V
112 Power Ground 3
ACC→ON 1V

Data Limit
Value
Items Unit
Min. Typical Max.
Normal operation 9.0 16.0 V
16.0 to
Battery Voltage Limited function 6.0 to 9.0 V
18.0
41
Some functions are

Limit value and time
maintained and trouble
for battery 26.0 V 60 s
diagnosis can be
overvoltage
performed
9.4 Precautions for installation Remove and store the ECU before
welding; 4. Never connect any circuit to
9.4.1 Discharge the static electricity during the connecting wire of the ECU.
installation
9.5.4 Simple measurement method:
9.4.2 Protect the Pins of connector
a (With the connector connected) Read the
9.5 Trouble Symptoms and Judgment engine malfunction record with the
Method diagnostic tester;
9.5.1 Trouble symptoms: Poor idling, poor b (With the connector removed) Check if the
acceleration, unable to start, high idle ECU connecting wire is in good condition
speed, emissions exceed standards, and if the ECU power supply and ground
difficult to start, air conditioner failure, circuit are normal;
injector control failure, misfire, etc.
c Check if the external sensor operates
9.5.2 General trouble causes: 1. Trouble is normally, the output signal is reliable and
caused by the internal parts burnout in the the circuit is in good condition;
ECU due to electric overload of external
devices; 2. The circuit board is corroded d Check if the actuator operates normally
as water enters the ECU. and the circuit is in good condition;
9.5.3 Precautions for repair: 1. Do not remove e Finally, replace the ECU and perform test.
Perform self-learning after ECU is
the ECU randomly during repair; 2.
Remove the battery terminal for more than replaced (Wait for 1 min after the vehicle
1 minute before the ECU is removed; 3. is powered on).
42
Section 10 Power Fuel Pump

Wiring 接主继
To Main
Diagram and Pin 配电盒
Box Relay
电器
30 86
Fuel Pump
燃油泵 Relay
继电器
87 85
Fuel Pump M
电动燃油泵 69
ECU
接地
Fig. 3-40 Power Fuel Pump Fig. 3-41 Circuit Diagram of Power Fuel
Pump
Pin definition:
Pin No. 1 connected to ground;
Pin No. 2 connected to combination instrument;
Pin No. 3 connected to combination instrument;
Pin No. 4 connected to fuel pump relay.
Fig. 3-42 Connectors of Power Fuel Pump
10.1 Installation Position The pump and motor are installed coaxially in
a closed housing. The gasoline is fully filled
In the fuel tank around the pump and motor in the housing
which are cooled and lubricated by fuel. The
10.2 Operation Theory battery supplies power to the oil pump relay
and the relay will energize the power fuel
The power fuel pump consists of a DC motor, pump only when the engine is started and
vane pump and end cap (Integrated with running. When the engine is stopped due to
return valve, relief valve and components an accident, the fuel pump will stop operating
resistant to electromagnetic interference) as automatically.
43
1. Fuel Pump End Cap

2. Motor
3. Oil Passage
4. Vane
Fig. 3-43 Cross Section of Power Fuel Pump
The maximum pressure at the outlet of the power fuel pump is determined by the relief valve
which is between 450 and 650 kPa. The overall pressure of the fuel system is determined by the
fuel pressure regulator which is usually 350 kPa.
The power fuel pump has different flow rates depending on the requirements of the engine, so do
not use the power fuel pump from other models.
10.3.1. Data Limit
Items Value Unit

Min. Typical Max.
Working voltage 8 14 V (DC)
System pressure 350 kPa
Outlet pressure 450 650 kPa
Ambient temperature -40 +80 C
(Suitable for storage and
transportation)
Allowed fuel temperature -30 +70 C
Allowed vibration acceleration 20 m/s2
10.3.2. Performance Data 10.4 Precautions for installation

The flow rate of the power fuel pump is The power fuel pump should be stored in the
proportional to the voltage under certain fuel closed original packing box. The permitted
supply pressures. maximum storage time is 6 months after it is
44
installed in the vehicle, and the maximum 10.5 Trouble Symptoms and Judgment
storage time is 4 years if it is used as a spare Method
part. The performance data of the fuel pump
should be rechecked by the manufacturer 10.5.1 Trouble symptoms: Loud operating
when the above time is exceeded. The fuel noise, poor acceleration, unable to
pump should be protected from the start (difficult to start), etc.
atmospheric effects when stored. The original 10.5.2 General trouble cause: Due to the use
packaging should not be damaged during of poor-quality fuel: 1. the insulation
storage. layer is formed by colloid
accumulation; 2. the fuel pump axle
Install a fuel inlet screen with mesh with the bushing and armature lock; 3. the
size of 60 or less or determined with the components of fuel level sensor are
customers when the fuel pump is installed. Do corroded.
not allow the fuel from the vent hole to spray 10.5.3 Precautions for repair:
on the fuel inlet screen, fuel pump bracket and
fuel tank wall. Be careful to transport the fuel 10.5.3.1 The power fuel pump has
pump. Protect the fuel inlet screen from any different flow rates depending on the
load or impact. The fuel pump must be requirements of engine. The fuel
carefully removed from the plastic packaging pump which has the same profile and
during installation. The protective cover can can be installed may be incorrect. The
be removed only when the fuel pump is to be part No. of the fuel pump used must
installed. Never remove the fuel inlet screen. be the same as the original during
The fuel pump may be damaged if foreign repair. Do not mix use of them;
objects enter the fuel pump inlet or screen.
10.5.3.2 To prevent the unexpected
Keep clean when the fuel pipes are installed. damage to the fuel pump, do not
The interior of fuel pipes should be clean. operate it in dry state for a long time;
Only use new fuel pipe clamps. Confirm the
correct position of fuel pipe clamps and 10.5.3.3 When the fuel pump needs to be
observe the methods recommended by the replaced, clean the fuel tank and pipe
manufacturer. lines and replace the fuel filter.
Do not hold the fuel pump by the fuel pipe or 10.5.4 Simple measurement method:
fuel inlet screen.
(With the connector removed) Turn the digital
To prevent damage to the fuel pump, do not multimeter to the Ohms range, and connect
operate the fuel pump under the dry state. Do two probes to Pins 1 and 4 of the fuel pump
not use a damaged fuel pump or a fuel pump respectively. The resistance between the two
dropped on the ground. Replace the fuel Pins is about 1 Ω.
pump in the fuel tank if it is dropped on the
ground. (With the connector connected) Connect the
fuel pressure gauge to the oil inlet pipe, start
If the fuel pump is returned, please send back the engine and observe if the fuel pump
the supply list, check list and package label operates; If it does not operate, check if there
with it. The returned fuel pump must be is power voltage at Pin No. 4 and if Pin No. 1
packed as specified. If the fuel pump has is grounded. If it operates, check if the fuel
been used, wash it with test solution and dry it pressure is about 350 kPa during idling.
in the air instead of blowing it dry. Depress the accelerator pedal until the engine
speed reaches 2,500 rpm, and check if the
fuel pressure is about 350 kPa.
45
Section 11 Injector
Diagram and Pin
To Main Relay
Injector
Injector
Injector
Injector
Fig. 3-44 Injector Fig. 3-45 Circuit Diagram of Injector
Fig. 3-46 Injector Connectors
Pin definition: The model uses 4 injectors and each injector has 2 Pins. Pin No. 1 of each injector
is connected to the main relay and Pin No. 2 is connected to the ECU.
Fig. 3-47 Cross Section of Injector
1. O-ring 2. Screen 3. Injector Body with Electric Connector 4. Coil 5. Spring 6. Valve Needle with Coil
Armature 7. Valve Seat with Nozzle Plate
11.1 Installation Position 11.2 Operation Theory
On the intake manifold close to the intake The ECU sends the electric pulse to the
valve injector coil to form a magnetic field force.
When the magnetic field force is higher than
46
the resultant force of the return spring

pressure, needle valve weight and friction
force, the needle valve begins to rise and the
injection process starts. When the injection
pulse is stopped, the pressure of return spring
will close the needle valve again.
11.3.1. Data Limit
Value
Items Unit
Min. Typical Max.
Storage temperature (original packaging) -40 +70 C
Permitted temperature of injectors in the
vehicle +140 C
(When not operated)
Operating Continuous -40 +110 C
temperature of Short time after hot
injectors
+130 C
start (about 3 minutes)
Permitted Continuous +70 C
temperature of fuel Short time (about 3
at the injector inlet +100 C
minutes)
Temperature where the deviation of fuel flow
-40 +45 C
rate from that at 20C reaches 5%
Leakage permission for O-ring within -35 to Fuel wetness is permitted in the O-ring area,
-40C but dripping is not permitted
Permitted maximum vibration acceleration
400 m/s2
(Peak value)
Power supply voltage 6 16 V
Insulation resistance 1 M
Acceptable internal fuel pressure 1100 kPa
Acceptable bending stress 6 Nm
Acceptable axial stress 600 N

Value
Items Unit
Min. Typical Max.
Working pressure (pressure difference) 350 kPa
Injector resistance at 20C 11 12 13 
LPG as the fuel in daily driving and the
11.3.3. Allowable Fuel gasoline is only used to start the vehicle. So
less gasoline is consumed. But the
The injector can only use the fuel which temperature of the fuel tank is very high due
complies with the National Standard of the to the continuous operation of the fuel pump.
People's Republic of China GB 17930-1999 If the gasoline is stored in the fuel tank of such
"Unleaded Gasoline for Motor Vehicles" and a vehicle, it will be oxidized easily, causing the
National Standard for Environmental injector blockage and even damage.
Protection GWKB 1-1999 "Hazardous
Materials Control Standard for Motor Vehicle 11.4 Precautions for installation
Gasoline ". Note that the gasoline will
deteriorate after stored for a long time. The 11.4.1 For easy installation, it is
taxies equipped with dual-fuel engine uses recommended to apply clean silicone-free
47
gasoline on the upper O-ring connected to the 11.4.5 The support washer of the O-ring
fuel distribution pipe. Do not allow the oil to should not be pulled out from the
contact the injector interior and nozzle. injector. Avoid damage to the inlet,
O-ring, support ring, nozzle plate and
11.4.2 Install the injector to the injector seat in electric connector of injector during
a direction perpendicular to the injector seat, installation. Do not use them if
and then fix the injector on the injector seat damaged.
with clips. Notes: 11.4.6 Perform a test on the tightness of the
fuel distribution pipe assembly after
11.4.2.1 The injector clips can be divided the injector is installed. It is acceptable
into an axial retaining clip and a radial when there is no leakage.
retaining clip according to the fixing 11.4.7 Remove the fault part by hand. First
method. Avoid mixing the use of them. remove the clips of the injector, and
then pull out the injector from the
11.4.2.2 For installation of axially fixed
injector seat.
injectors, make sure the center
Keep the injector clean after removal.
bayonet of the clip is fully clamped in
the injector slot, and the slots on both
sides of the clip are fully clamped on 11.5 Trouble Symptoms and Judgment
the outer edge hemming of the injector Method
seat.
11.5.1 Trouble symptoms: Poor idling, poor
11.4.2.3 When the injector must be fixed
acceleration, unable to start (difficult to
in axial and radial directions, the axial
start), etc.
and radial retaining clips should be
11.5.2 General trouble cause: The injector
used, and you must position the
fails to function due to the colloid
located block of the injector and dowel
accumulation in the injector caused by
pin of the injector seat in the proper
lack of maintenance.
slots on the retaining clip.
11.5.3 Precautions for repair: (Refer to
11.4.2.4 If the injector has two slots, be Precautions for installation)
careful not to confuse them. Refer to 11.5.4 Simple measurement method:
the installation position of the original
part. (With the connector removed) Turn the digital
multimeter to the Ohms range, and connect
11.4.3 The injector should be installed by two probes to Pins 1 and 2 of injector
hand. Never tap the injector with tools respectively. The rated resistance between
such as a hammer. the two Pins at 20ºC is 11~13 Ω.
11.4.4 The O-ring must be replaced when the
injector is removed and reinstalled. Do Advice: Thoroughly clean the injectors with a
not damage the sealing surface of the special washing analyzer for every 20,000 km.
injector.
48
Section 12 Ignition Coil

Diagram and Pin
Fig. 3-53 Ignition Coil Fig. 3-54 Ignition Coil Circuit
Pin definition:
Pin No. 1 connected to main relay;
Pin No. 2 connected to ground;
Pin No. 3 connected to ECU;
F:Ignition Coil
Fig. 3-55 Ignition Coil Connectors
12.1 Installation Position When a ground channel of primary winding is

connected, the primary winding is charged.
It is installed on the engine. Once the primary winding circuit is cut by the
ECU, the charging is stopped and a high
12.2 Operation Theory voltage is induced in the secondary winding to
discharge the sparkplug.
The ignition coil consists of primary winding,
secondary winding, iron core or housing.
49
Performance Data
Items Value Unit

Min. Typical Max.
Performance Working voltage 6 12 16 V
parameter Temperature range -40 140 ºC
12.4 Trouble Symptoms and Judgment 12.4.4 Simple measurement method:

Method
(With the connector removed) Turn the digital
12.4.1 Trouble symptom: Unable to start. multimeter to the Ohms range, and connect
two probes to two Pins of the primary winding
12.4.2 General trouble cause: Burnout respectively. The resistance at 20ºC should
caused by overcurrent, damage be 0.70-0.90 Ω.
caused by external force.
12.4.3 Precautions for repair: Never use the

"Short Circuit Ignition Test Method" to
test the ignition function during repair
to avoid damage to the electronic
controller.
50
Section 13 Charcoal Canister Control Valve

Diagram and Pin
Fig. 3-56 Charcoal Canister Control Valve

Fig. 3-57 Circuit Diagram of Charcoal Canister
Control Valve
Pin definition: Pin No. 1 connected to main relay;
Pin No. 2 connected to pin No. 94 of ECU.
Fig. 3-58 Connectors of Charcoal Canister Control Valve
On the vacuum connection line of charcoal canister to intake manifold
51
P is the difference of ambient pressure

Pu and intake manifold pressure Ps
Fig. 3-59 Cross Section of Charcoal Canister Control Valve
Fig. 3-60 Installation Diagram of Charcoal Canister Control Valve

1. From fuel tank 2. Charcoal canister 3. Atmosphere
4. Charcoal canister control valve 5. To intake manifold 6. Throttle valve
The charcoal canister control valve consists of the solenoid coil, armature and valve. A screen is
set at the inlet. On one hand, the air flow of the charcoal canister control valve is related to the
duty cycle of the electric pulse output to the charcoal canister control valve by the ECU. On the
other hand, it is also related to the pressure difference between the inlet and outlet of the
charcoal canister control valve. When there is no electric pulse, the charcoal canister control
valve will close.
The flow rates of different charcoal canister control valves are different when the duty cycle is
100% (i.e. under fully opened condition). Figure 3-61 shows two typical flow curves. Under the
pressure difference of 200 mbar, the flow rate of type A charcoal canister control valve is 3.0m3/h
when fully opened and the flow rate of type B is 2.0m3/h when fully opened as shown in the figure.
(The project is type B)
52
Type A
Type B
Flow
Pressure Difference
Fig. 3-61 Flow Diagram of Charcoal Canister Control Valve
13.3.1. Data Limit
Value
Items Unit
Min. Typical Max.
Working voltage 9 16 V
Overvoltage in 1 min 22 V
Min. starting voltage 7 V
Min. voltage drop 1.0 V
Allowed operation temperature -30 +120 C
Short-time allowed operating temperature +130 C
Allowed storage temperature -40 +130 C
Acceptable pressure difference between inlet
800 mbar
and outlet
8
Allowed switching cycles 10
Allowed vibration acceleration on the product 300 m/s2
Leakage rate when the pressure difference is
0.002 m3/h
400 mbar
Value
Items Unit
Min. Typical Max.
Rated voltage 13.5 V
Resistance at +20C 26 
Current under rated voltage 0.5 A
Frequency of control pulse 30 Hz
Type A 7 ms
Typical control pulse width
Type B 6 ms
Flow rate when the pressure Type A 2.7 3.0 3.3 m3/h
difference is 200 mbar and the
Type B 1.7 2.0 2.3 m3/h
duty cycle is 100%
53
13.4 Precautions for installation 13.5.1 Trouble symptom: Functional failure.
Refer to figure 3-60 for the connection of 13.5.2 General trouble cause: Corrosion or
charcoal canister control valve, charcoal poor tightness is caused as foreign
canister and intake manifold. materials enter the valve.
13.4.1 To avoid the transmission of 13.5.3 Precautions for repair: 1. The direction
solid-borne noise, it is recommended to of air flow must meet the requirements
hang the charcoal canister control valve during installation; 2. When the control
on the hose. valve is fault due to black particles in the
valve body and it needs to be replaced,
13.4.2 The direction of air flow must meet the please check the charcoal canister; 3.
requirements during installation. Prevent water or oil from entering the
valve during repair; 4. To avoid the
13.4.3 Proper measurements must be taken transmission of solid-borne noise, it is
(such as filtering and purging) to prevent recommended to hang the charcoal
foreign materials (such as particles) from canister control valve on the hose.
entering the charcoal canister control valve
from the charcoal canister or hose. 13.5.4 Simple measurement method:
13.4.4 It is recommended to install a proper (With the connector removed) Turn the digital
protective filter at the outlet of the charcoal multimeter to the Ohms range, and connect
canister (Mesh size50 m). two probes to two Pins of the charcoal
canister control valve respectively. The rated
13.5 Trouble Symptoms and Judgment resistance at 20ºC should be 22~30 Ω.
Method
54
Section 14 Fuel Distribution Pipe Assembly

Diagram 14.1 Installation Position
On the intake manifold
The fuel distribution pipe assembly, consisting

of fuel distribution pipe (KVS) and injector (EV)
is used to store and distribute the fuel.
Fig. 3-62 Fuel Distribution Pipe Assembly
Data Limit
Value
Items Unit
Min. Typical Max.
Operation temperature when the fuel distribution
-40 +120 C
pipe and O-ring are correctly connected
Max. operation temperature in 15 minutes under
+130 C
soaking status
Allowed maximum vibration acceleration (Peak
300 m/s2
value)
Refer to the performance parameters of 14.4.2 There should be no crack, scratch,

pressure regulating valve for system pressure groove, burr and rusting on the oil inlet
and refer to the performance parameters of pipe wall.
the injector for fuel requirements. The 14.4.3 Before assembling the fuel distribution
tightness requires no fuel leakage under the pipe assembly, lubricate the lower
operation pressure. O-ring of injector with clean lubricant.
14.4 Precautions for installation 14.5 Trouble Symptoms and Judgment

Method
14.4.1 The oil inlet pipe and rubber pipe are
connected with clamps. The clamp type must The tightness of the fuel distribution pipe can
match with the rubber pipe to ensure the be tested with the pressure drop method.
tightness between the oil inlet pipe and rubber When performing a test on the fuel distribution
pipe. pipe and O-ring of injector, the tested leakage
limit should be 1.5cm3/min or less under the
pressure of 4.5 bar.
55
Part 4 Diagnosis Flow for ME17 System in Accordance with

Trouble Codes
Description:
Diagnostic tips:
4.1 Perform the following maintenance after
the current steady state malfunction is 4.5.1 If the DTC cannot be cleared, it is a
confirmed, or the diagnosis failure may be steady state malfunction. If the
caused. malfunction is occasional, check the wire
harness connector for looseness.
4.2 The after-mentioned "multimeter" refers to
the digital multimeter. Never check the 4.5.2 After the above check, no abnormal
circuit of electronically controlled injection condition is found;
system with a pointer type multimeter.
4.5.3 Do not ignore the effect of car
4.3 When overhauling the vehicles with an maintenance, cylinder pressure and
anti-theft system, if "Replace the ECU" mechanical ignition timing imposed on the
appears in the column of "Follow-up Step", system during maintenance.
program the ECU after replacement.
4.5.4 Perform a test after the ECU is replaced.
4.4 When the DTCs P0171, P0172, P0335, If the DTC can be cleared, the trouble
P0336 and P1651 occur in the project, the area is the ECU. If the DTC still cannot be
engine malfunction indicator does not cleared, install the original ECU. Repeat
come on. the process and perform maintenance
again.
4.5 If a DTC indicates the circuit voltage is low,
the circuit may be short to ground. If a
DTC indicates the circuit voltage is high,
the circuit may be short to power supply. If
a DTC indicates the circuit is at fault, the
circuit may be open or has several circuit
malfunctions.
56
The repair methods for each DTC are as follows:
DTC: P0107 "Intake pressure sensor circuit voltage is low"
Test
No. Operation Steps Follow-up Step
Result
Connect the diagnostic tester and adapter, and then
1 Next step
position the ignition switch to "ON".
Check if the "Intake Pressure" in the data flow is about Yes Go to step 5
2 1,000 hpa (The specific value is related to the
atmospheric pressure). No Next step
Remove the connector of the intake pressure sensor Yes Go to step 5
from the wire harness, and check, using the
3
multimeter, if the voltage between Pins No. 3 and 1 of No Next step
the connector is about 5 V.
Repair or
Check if the circuits between Pins No. 17, 33 and 37 Yes replace wire
4 of the ECU and Pins No. 1, 3 and 4 of the sensor harness
connector are short to ground.
No Next step
Start the engine and keep it idling. When the
accelerator pedal is slowly depressed to the fully Yes Diagnostic tips
opened position, observe the change of "Intake
Pressure" value on the diagnostic tester. The
5
displayed value does not change greatly. When the
accelerator pedal is quickly depressed to fully opened Replace the
No
position, the displayed value should reach more than sensor
900 hpa immediately.
DTC: P0108 "Intake pressure sensor circuit voltage is high"

Test
Result
1 Next step
Check if the "Intake Pressure" in the data flow is about Yes Go to step 5
2 1,000 hpa (The specific value is related to the
atmospheric pressure). No Next step
Remove the connector of the intake pressure sensor Yes Go to step 5
from the wire harness, and check, using the
3
Repair or
4 of ECU and Pins No. 1, 3 and 4 of the sensor harness
connector are open or short to power supply.
No Next step
Start the engine and keep it idling. When the
accelerator pedal is slowly depressed to fully opened Yes Diagnostic tips
position, observe the change of "Intake Pressure"
value on the diagnostic tester. The displayed value
5
does not change greatly. When the accelerator pedal
is quickly depressed to the fully opened position, the Replace the
No
displayed value should reach more than 900 hpa sensor
immediately.
57
DTC: P0112 "Indicated temperature of intake temperature sensor is low"

Test
Result
1 Next step
Check if the "Intake Temperature" in the data flow is
equivalent to the temperature inside the intake pipe Yes Go to step 5
(The specific value is related to the engine
2
temperature).
Notes: If the displayed value is always -40ºC, the No Next step
circuit may be open.
Remove the connector of the intake temperature
sensor from the wire harness, and check if the Yes Next step
3 resistance between Pins No. 1 and 2 of the sensor is
in proportion to its temperature (Refer to the relevant Replace the
No
section in the repair manual). sensor
Remove the connector of the intake temperature Yes Go to step 5
sensor from the wire harness, and check, using the
4
Repair or
Check if the circuits between Pins No. 17 and 40 of Yes replace wire
5 the ECU and Pins No. 1 and 2 of the sensor connector harness
are open or short to power supply.
No Next step
Start the engine and keep it idling. Observe the Yes Diagnostic tips
change of "Intake Temperature" value on the
6
diagnostic tester. The displayed value should increase Replace the
with the rise of engine intake temperature. No
sensor
DTC: P0113 "Indicated temperature of intake temperature sensor is high"

Test
Result
1 Next step
Check if the "Intake Temperature" in the data flow is
equivalent to the temperature inside the intake pipe Yes Go to step 5
(The specific value is related to the engine
2
temperature).
Notes: If the displayed value is always -40ºC , the No Next step
Remove the connector of the intake temperature
3 resistance between Pins No. 1 and 2 of the sensor is
in proportion to its temperature (Refer to the relevant Replace the
No
Repair or
5 ECU and Pins No. 1 and 2 of the sensor connector harness
are short to ground.
No Next step
Start the engine and keep it idling. Observe the
6 Yes Diagnostic tips
change of "Intake Temperature" value on the
58

with the rise of engine intake temperature. No
sensor
DTC: P0117 "Indicated temperature of engine coolant temperature sensor is low"

Test
Result
1 Next step
Check if the "Coolant Temperature" in the data flow is Yes Go to step 5
equivalent to the engine temperature (The specific
2 value is related to the engine temperature).
Remove the connector of the coolant temperature
3 resistance between Pins A and C of the sensor is in
proportion to its temperature (Refer to the relevant Replace the
No
Repair or
No Next step
change of "Coolant Temperature" value on the
5
with the rise of engine coolant temperature. No
sensor
DTC: P0118 "Indicated temperature of engine coolant temperature sensor is high"

Test
Result
1 Next step
Check if the "Coolant Temperature" in the data flow is
Yes Go to step 5
equivalent to the engine temperature (The specific
2 value is related to the engine temperature).
Remove the connector of the coolant temperature
3 resistance between Pins A and C of the sensor is in
proportion to its temperature (Refer to the relevant Replace the
No
Repair or
No Next step
change of "Coolant Temperature" value on the
5
with the rise of engine coolant temperature. No
sensor
59
DTC: P0122 "Electronic throttle body assembly circuit voltage is low"

Test
Result
1 Next step
Check if the "Absolute electronic throttle valve Yes Next step
2 opening" value in the data flow is between 4% and
10% (The specific value varies with the model). No Go to step 5
When the accelerator pedal is slowly depressed to the
fully opened position, check if the "Absolute electronic Yes Next step
3 throttle valve opening" in data flow increases to about
85-95% with the rise of throttle opening (The specific No Go to step 5
value varies with the model).
Repeat step 3 and check if the step transition occurs Replace the
Yes
4 during the change of "Absolute throttle valve opening" sensor
value in the data flow. No Next step
Remove the connector of the electronic throttle body Repair or
assembly from the wire harness, and check if the Yes replace wire
5 circuits between Pins No. 32, 35 and 16 of the ECU harness
and Pins No. 1, 2 and 3 of sensor connector are short
No Next step
to ground.
Replace the
Check if the voltage between Pins No. 1 and 2 of the Yes
6 sensor
connector is about 5 V with the multimeter.
No Diagnostic tips
DTC: P0123 "Electronic throttle body assembly circuit voltage is high"

Test
Result
1 Next step
Check if the "Absolute throttle valve opening" value in Yes Next step
2 the data flow is between 4% and 10% (The specific
value varies with the model). No Go to step 5
When the accelerator pedal is slowly depressed to the
fully opened position, check if the "Absolute throttle Yes Next step
3 valve opening" in data flow increases to about 85-95%
with the rise of throttle opening (The specific value No Go to step 5
varies with the model).
Repeat step 3 and check if step transition occurs Replace the
Yes
4 during the change of "Absolute throttle valve opening" sensor
value in the data flow. No Next step
Remove the connector of the electronic throttle body Repair or
assembly from the wire harness, and check if the Yes replace wire
5 circuits between Pins No. 32, 35 and 16 of the ECU harness
and Pins No. 1, 2 and 3 of the sensor connector are
No Next step
short to ground.
Replace the
Check, using the multimeter, if the voltage between Yes
6 sensor
Pins No. 1 and 2 of the connector is about 5 V.
No Diagnostic tips
60
DTC: P0130 "Front oxygen sensor signal circuit failure"
(Note: The following diagnosis flow is suitable for DTCs without P0135. If DTC P0135 occurs at
the same time, first repair the malfunction indicated by it and then perform maintenance
according to the following flow.)
Test
Result
1 Next step
Start the engine and keep it idling until the coolant
temperature reaches the normal value. Observe the Yes Diagnostic tips
2 change of "Oxygen sensor voltage" value on the
diagnostic tester. The displayed value should change No Next step
quickly between 100 mV~900 mV.
Repair or
No Next step
Perform
A. Check the intake system for severe air leakage; maintenance
Yes
B. Check the injector for blockage; according to
4 C. Check the sparkplug for excessive clearance; the diagnosis
D. Check the inlet valve guide for wear;
Others No Diagnostic tips
DTC: P0132 "Front oxygen sensor circuit voltage is high"

Test
Result
1 Next step
temperature reaches the normal value. Observe the Yes Diagnostic tips
2 change of "Oxygen sensor voltage" value on the
Repair or
are short to power supply.
No Diagnostic tips
DTC: P0134 "Front oxygen sensor signal failure"

61
Test
Result
1 Next step
Start the engine and keep it idling until the coolant Yes Diagnostic tips
temperature reaches the normal value. Observe the
2
change of "Oxygen sensor voltage" value on the
Repair or
are open.
No Diagnostic tips
DTC: P0135 "Front oxygen sensor heating circuit failure"

Test
Result
1 Position the ignition switch to "ON". Next step
Remove the connector of the oxygen sensor from the Yes Next step
wire harness, and check, using the multimeter, if the
2
voltage between Pins No. 1 and 2 of the connector is
about 12 V. No Go to step 4
Check, using the multimeter, if the resistance between Yes Next step
3 Pins No. 1 and 2 of the oxygen sensor at 20ºC is Replace the
No
between 8 and 10 Ω. sensor
Check if the circuits between Pin No. 48 of the ECU Repair or
and Pin No. 2 of the sensor connector, Pin No. Yes replace wire
4 B02-B18 of main relay and Pin No. 1 of the sensor harness
connector are open or short to power supply or
No Diagnostic tips
ground.
DTC: P0171 "Adaptive close-loop control of air-fuel ratio exceeds upper limit"
(Note: The following diagnosis flow is suitable for the condition when DTCs of the intake pressure
sensor, charcoal canister control valve and oxygen sensor do not occur at the same time. If they
occur at the same time, first repair the malfunctions indicated by them and then perform
maintenance according to the following flow.)
Test
Result
1 Next step
temperature reaches the normal value. Yes Next step
Observe the change of "Oxygen sensor voltage" value
2
on the diagnostic tester under all working conditions.
Check if the displayed value changes around 100 mV No Diagnostic tips
for a long time under some working conditions.
3 Connect the fuel pressure gauge to the oil inlet pipe of Yes Next step
62
the fuel system and check if the fuel pressure is about Overhaul the
No
350 kPa under all working conditions. fuel system
Repair or
No Next step
Perform
A. Check the intake system for severe air leakage; maintenance
Yes
B. Check the injector for blockage; according to
5 C. Check the sparkplug for excessive clearance; the diagnosis
D. Check the inlet valve guide for wear;
Others No Diagnostic tips
DTC: P0172 "Adaptive close-loop control of air-fuel ratio exceeds lower limit"
(Note: The following diagnosis flow is suitable for the condition when DTCs of the intake pressure
sensor, charcoal canister control valve and oxygen sensor do not occur at the same time. If they
occur at the same time, first repair the malfunctions indicated by them and then perform
maintenance according to the following flow.)
Test
Result
1 Next step
temperature reaches the normal value. Yes Next step
Observe the change of "Oxygen sensor voltage" value
2
on the diagnostic tester under all working conditions.
Check if the displayed value changes around 900 mV No Diagnostic tips
for a long time under some working conditions.
Connect the fuel pressure gauge to the oil inlet pipe of Yes Next step
3 the fuel system and check if the fuel pressure is about Overhaul the
350 kPa under all working conditions. No
fuel system
Repair or
4 the ECU and Pins No. 3 and 4 of sensor connector harness
No Next step
Perform
maintenance
A. Check the injector for dripping; Yes
according to
B. Check the exhaust pipe for air leakage; the diagnosis
5
C. Check if the ignition timing is correct;
Others
No Diagnostic tips
DTC: P0201 "Cylinder 1 injector circuit failure"
Test
Result
63

Remove the connector of cylinder 1 injector from the Yes Go to step 4
wire harness, and check if the voltage between Pin
2
No. 1 of the connector and the negative terminal of the No Next step
power supply is about 12 V with the multimeter.
Repair or
Check if the circuit between Pin No. 1 of the cylinder 1 Yes replace wire
3 injector connector and main relay is open or short to harness
ground.
No Go to step 2
Check if the resistance between Pins No. 1 and 2 of Yes Next step
4 the cylinder 1 injector at 20ºC is between 11 and 13 Ω Replace the
No
with the multimeter. injector
Check, using the multimeter, if the voltage between Yes Diagnostic tips
5 Pin No. 2 of the cylinder 1 injector connector and
negative terminal of power supply is about 3.7 V. No Next step
Repair or
6 injector connector and Pin No. 27 of the ECU is open harness
or short to power supply or ground.
No Diagnostic tips
Test
Result
2
voltage between Pin No. 1 of the connector and the No Next step
negative terminal of power supply is about 12 V.
Repair or
3 injector connector and the main relay is open or short harness
to ground.
No Go to step 2
4 Pins No. 1 and 2 of the cylinder 2 injector at 20ºC is Replace the
No
between 11 and 13 Ω. injector
5 Pin No. 2 of the cylinder 2 injector connector and the
Repair or
6 injector connector and Pin No. 6 of the ECU is open or harness
short to power supply or ground.
No Diagnostic tips
Test
Result
2 Remove the connector of cylinder 3 injector from the Yes Go to step 4
64

negative terminal of the power supply is about 12 V.
Repair or
Check, using the multimeter, if the circuit between Pin Yes replace wire
3 No. 1 of the cylinder 3 injector connector and main harness
relay is open or short to ground.
No Go to step 2
No
Pin No. 2 of the cylinder 3 injector connector and
5
negative terminal of power supply is about 3.7 V No Next step
.
Repair or
6 injector connector and Pin No. 7 of the ECU is open or harness
short to power supply or ground.
No Diagnostic tips
Test
Result
2
negative terminal of the power supply is about 12 V.
Repair or
3 injector connector and main relay is open or short to harness
ground.
No Go to step 2
No
5 pin No. 2 of the cylinder 4 injector connector and
Repair or
6 injector connector and pin No. 47 of the ECU is open harness
or short to power supply or ground.
No Diagnostic tips
DTC: P0230 "Fuel pump control circuit failure"
Test
Result
1 Position the ignition switch to "OFF". Next step
Remove the fuel pump relay, position the ignition
2 Yes Go to step 4
switch to "ON" and check if the voltage between the
65
power supply terminals of the fuel pump relay and

negative terminal of the power supply is about 12 V. No Next step
Repair or
Check if the circuit of the relay power supply terminal Yes replace wire
3 harness
is open or short to ground.
No Go to step 2
Replace the
Check, using the multimeter, if the voltage between Yes fuel pump
4 the control terminal of the fuel pump relay and relay
negative terminal of the power supply is about 3.7 V.
No Next step
Repair or
Check if the circuit between the relay control terminal
Yes replace wire
5 and Pin No. 69 of the ECU is open or short to power
harness
supply or ground.
No Diagnostic tips
DTC: P0325 "Knock sensor circuit failure"
Test
Result
Remove the connector of the knock sensor from the Yes Next step
2 Replace the
resistance between Pins No. 1 and 2 of the knock No
sensor
sensor is higher than 1 MΩ.
Repair or
Check if the circuits between Pins No. 1 and 2 of the Yes replace wire
3 knock sensor connector and Pins No. 19 and 20 of the harness
ECU are open or short to power supply or ground.
No Next step
Yes Diagnostic tips

Based on the specifications, replace the knock sensor,
4 road test the vehicle and run the engine to more than Check if it is
2,200 rpm. Check if the DTC P0325 reoccurs. No occasional
malfunction
DTC: P0335 "Crankshaft position sensor signal failure"
Test
Result
Remove the connector of the crankshaft position
sensor from the wire harness, and check, using the Yes Next step
2 multimeter, if the resistance between Pins No. 1 and 2
of the crankshaft position sensor is between 770 and Replace the
No
950 Ω. sensor
Check if the circuits between Pins No. 1 and 2 of the Repair or
crankshaft position sensor connector and Pins No. 15 Yes replace wire
3 harness
and 34 of the ECU are open or short to power supply
or ground. No Next step
Yes Diagnostic tips
4 Check if the flywheel signal disc is in good condition. Replace the
No
signal disc
66
DTC: P0336 "Crankshaft position sensor signal is irrational"
Test
Result
Remove the connector of the crankshaft position
sensor from the wire harness, and check, using the Yes Next step
2 multimeter, if the resistance between Pins No. 1 and 2
of the crankshaft position sensor is between 770 and Replace the
No
950 Ω. sensor
crankshaft position sensor connector and Pins No. 15 Yes replace wire
3 harness
and 34 of ECU are open or short to power supply or
ground. No Next step
Yes Diagnostic tips
4 Check if the flywheel signal disc is in good condition. Replace the
No
signal disc
DTC: P0340 "Camshaft position sensor signal failure"
Test
Result
1 Next step
Remove the connector of the camshaft position
sensor from the wire harness, and check, using the Yes Go to step 4
2 multimeter, if the voltage between pin No. 1 of the
camshaft position sensor connector and the negative No Next step
terminal of the power supply is about 5 V.
Repair or
Check if the circuit between pin No. 1 of the camshaft Yes replace wire
3 position sensor and pin No. 32 of ECU is open or harness
short to ground.
No Next step

camshaft position sensor connector and Pins No. 79 Yes replace wire
4
and 35 of the ECU are open or short to power supply harness
Yes Diagnostic tips
5 Check if the camshaft signal disc is in good condition. Replace the
No
signal disc
DTC: P0342 "Camshaft position sensor circuit voltage is low"
Test
Result
1 Next step
2 Yes Go to step 4
sensor from the wire harness, and check if the voltage
67
between pin No. 1 of the camshaft position sensor

connector and the negative terminal of the power No Next step
supply is about 5 V with the multimeter.
Repair or
3 position sensor and pin No. 32 of the ECU is open or harness
short to ground.
No Next step

4
Yes Diagnostic tips
No
signal disc
DTC: P0343 "Camshaft position sensor circuit voltage is high"
Test
Result
1 Next step
sensor from the wire harness, and check, using the Yes Go to step 4
camshaft position sensor connector and the negative No Next step
terminal of power supply is about 5 V.
Repair or
3 position sensor and pin No. 32 of the ECU is open or harness
short to ground.
No Next step

4
Yes Diagnostic tips
No
signal disc
DTC: P0443 "Charcoal canister control valve drive control circuit failure"
Test
Result
1 Next step
position the ignition switch the "ON".
Remove the connector of the charcoal canister control Yes Go to step 4
valve from the wire harness, and check, using the
supply is about 12 V.
68
Repair or
Check if the circuit between pin No. 1 of charcoal Yes replace wire
3 canister control valve and main relay is open or short harness
to ground.
No Go to step 2
4 Pins No. 1 and 2 of the charcoal canister control valve Replace the
at 20ºC is between 22 and 30 Ω. No
control valve
Repair or
Check if the circuit between pin No. 2 of the charcoal Yes replace wire
5 canister control valve and pin No. 46 of the ECU is harness
open.
No Diagnostic tips
DTC: P0444 "Charcoal canister control valve drive control circuit voltage is low"
Test
Result
1 Next step
Repair or
3 canister control valve and the main relay is open or harness
short to ground.
No Go to step 2
4 Pins No. 1 and 2 of the charcoal canister control valve Replace the
at 20ºC is between 22 and 30 Ω. No
control valve
Repair or
short to ground.
No Diagnostic tips
DTC: P0445 "Charcoal canister control valve drive control circuit voltage is high"
Test
Result
1 Next step
Repair or
3 canister control valve and the main relay is open or harness
short to ground.
No Go to step 2
4 Check, using the multimeter, if the resistance between Yes Next step
69
pin No. 1 and 2 of the charcoal canister control valve Replace the
No
at 20ºC is between 22 and 30 Ω. control valve
Repair or
short to power supply.
No Diagnostic tips
DTC: P0480 "Air conditioner condenser cooling fan relay control circuit failure"
Test
Result
Remove the air conditioner condenser cooling fan
relay, position the ignition switch to "ON" and check if Yes Go to step 4
2 the voltage between the power supply terminals of the
relay and negative terminal of the power supply is No Next step
about 12 V.
Repair or
Check if the power supply terminal circuit of the air Yes replace wire
3 conditioner cooling fan relay is open or short to harness
ground.
No Go to step 2
Check, using the multimeter, if the voltage between Replace the
Yes
the control terminal of the air conditioner cooling fan relay
4
relay and the negative terminal of the power supply is
about 3.7 V. No Next step
Repair or
Check if the circuit between the relay control terminal Yes replace wire
5 B02-B65 and pin No. 50 of the ECU is open or short to harness
power supply or ground.
No Diagnostic tips
DTC: P0506 "Idle speed is lower than target idle speed"
Test
Result
Yes Next step
Perform
Check if the electronic throttle valve operates necessary
2
normally. No overhauling
and
maintenance
Perform
A. Check if the pressure of the fuel supply system is Yes necessary
low; overhauling
3
B. Check the injector for blockage;
C. Check if the system exhaust is not smooth. No Diagnostic tips
DTC: P0507 "Idle speed is higher than target idle speed"
Test
Result
70

Yes Next step
Perform
Check if the electronic throttle body assembly necessary
2
operates normally. No overhauling
and
maintenance
Perform
A. Check the system for air leakage; Yes necessary
B. Check the injector for dripping; overhauling
3
C. Check if the pressure of the fuel supply system is
high. No Diagnostic tips
DTC: P0508 "Electronic throttle body assembly control circuit voltage is low"
Test
Result
1 Next step
Remove the connector of the electronic throttle body Yes Next step
assembly, and check, using the multimeter, if the
2 Repair or
resistance between Pins 3 and 5 of the electronic
throttle body assembly is about 10 Ω. No replace wire
harness
Repair or
Check if Pins 3 and 5 of the electronic throttle body Yes replace wire
3 harness
assembly connector are short to ground.
No Diagnostic tips
DTC: P0509 "Electronic throttle body assembly control circuit voltage is high"
Test
Result
1 Next step
2 Repair or
harness
Repair or
Check if Pins 3 and 5 of electronic throttle body Yes replace wire
3 harness
No Diagnostic tips
DTC: P0511 "Electronic throttle body assembly control circuit failure"
Test
Result
1 Next step
71
2 Repair or
harness
Repair or
Check if Pins 3 and 5 of the electronic throttle body Yes replace wire
3 harness
No Diagnostic tips
DTC: P0560 "System voltage signal is irrational"
Test
Result
Yes Next step
Check, using the multimeter, if the battery voltage is
2 Replace the
about 12 V. No
battery
Repair or
3 of ECU and pin B02-B18 of main relay are open or harness
short to ground.
No Next step
Start the engine and check if the charging voltage of Yes Next step
4 the generator is between 9 and 16 V within different Replace the
speed range. No
generator
Yes Diagnostic tips
Check if the ground point of the engine wire harness is Repair or
5
in good condition. No replace wire
harness
DTC: P0562 "System voltage is low"
Test
Result
Yes Next step
2 Replace the
about 12 V. No
battery
Repair or
Check the circuits between Pins No. 44, 45 and 63 of Yes replace wire
3 the ECU and pin B02-B18 of the main relay for high harness
resistance.
No Next step
4 the generator is between 9 and 16 V within different Replace the
speed ranges. No
generator
Yes Diagnostic tips
5
harness
DTC: P0563 "System voltage is high"
72
Test
Result
1 Position the ignition switch in "OFF". Next step
Yes Next step
2 Replace the
about 12 V. No
battery
3 generator is between 9 and 16 V within different Replace the
speed ranges. No
generator
Yes Diagnostic tips
4
harness
DTC: P0601 "Electronic control unit check code error"
Test
Result
1 Next step
Clear the DTC and reconfirm if the malfunction is a Yes Next step
2
steady state malfunction. No Normal system
3 Replace the ECU. Completed
DTC: P0602 "Electronic control unit diagnosis data ID code error"
Test
Result
1 Next step
Clear the DTC and reconfirm if the malfunction is a Yes Next step
2
steady state malfunction. No Normal system
3 Replace the ECU. Completed
73
Part 5 Diagnosis Flow for ME17 System in Accordance with

Trouble Symptoms
Perform preliminary check first before 5.3.6.4 Do not ignore the effect of car
troubleshooting in accordance with the engine maintenance, cylinder pressure, ignition
trouble symptoms: timing and fuel condition imposed on the
5.1 Make sure the engine malfunction system during maintenance;
indicator operates normally; 5.3.6.5 Perform test after the ECU is replaced.
5.2 Check that no diagnostic information is If the trouble symptom can be eliminated, the
recorded with a diagnostic tester; trouble area is ECU. If the trouble symptom
5.3 Make sure the trouble symptom still exists, install the original ECU. Repeat the
complained by the car owner exists, and process and perform maintenance again.
confirm the conditions when the trouble a The engine does not rotate or rotates
occurs. slowly when starting.
b The engine can rotate, but cannot be
Then check the appearance: started successfully.
5.3.1 Check the fuel line for any leakage; c Hot starting is difficult.
5.3.2 Check if the vacuum line is broken, d Cold starting is difficult.
kinked or correctly connected; e The engine is difficult to start at any time,
5.3.3 Check if the intake pipe line is blocked, but the engine speed is normal.
leaked, flattened or damaged; f The engine can be started normally, but
5.3.4 Check if the high-voltage wire of ignition the idle speed is unstable at any time.
system is broken or aging and if the g The engine can be started normally, but
ignition sequence is correct; the idle speed is unstable during warming
5.3.5 Check if the ground point of wire up.
harness is clean and secure; h The engine can be started normally, but
5.3.6 Check the connectors of the sensor and the idle speed is unstable after the
actuator for looseness or poor contact. warming up ends.
i The engine can be started normally, but
Important Tips: If the above symptoms occur, the idle speed is unstable or the engine
perform maintenance and repair for the misfires under some load (for example,
trouble; otherwise the subsequent the air conditioning is on).
troubleshooting and repair will be affected. g The engine can be started normally, but
Diagnostic tips: the idle speed is too high.
5.3.6.1 Make sure no malfunction is recorded k The engine speed does not increase or
for the engine; the engine misfires during acceleration.
5.3.6.2 Make sure the suspected trouble l The response is slow during acceleration.
symptom exists; m The engine power is low and performance
5.3.6.3 After the above check, no abnormal is poor during acceleration.
condition is found;
Section 1 The engine does not rotate or rotates slowly when starting
General trouble area: 1. Battery; 2. Cranking motor; 3. Wire harness or ignition switch; 4. Engine
mechanics.
General diagnosis flow:
No. Operation Steps Test Result Follow-up Step

Check if the voltage between two terminals of the Yes Next step
1 battery is about 8~12 V with the multimeter when Replace the
the engine is started. No
battery
74
Keep the ignition switch in "Start" position, and Yes Next step
check if the voltage at the positive terminal of Repair or
2
cranking motor is more than 8 V with the No replace wire
multimeter. harness
Repair or
Remove the cranking motor and check its operation Yes replace the
3 condition. Check if the open circuit exists or it is cranking motor
stuck due to poor lubrication.
No Next step
If the trouble only occurs in winter, check if the Use the proper
resistance of cranking motor is too high due to Yes
4 lubricant
improper selection of engine lubricant and gearbox
oil. No Next step
Overhaul the
Check if the cranking motor does not rotate or Yes internal engine
5 rotates slowly due to the high internal mechanical resistance
resistance of the engine.
No Diagnostic tips
Section 2 The engine can rotate, but cannot be started successfully

General trouble area: 1. Empty fuel tank; 2. Fuel pump; 3. Crankshaft position sensor; 4. Ignition
coil; 5. Engine mechanics.
Connect the fuel pressure gauge (to front of fuel Yes Next step
distribution pipe assembly oil inlet pipe), start the
1 Overhaul the
engine and check if the fuel pressure is about 350
kPa. No fuel supply
system
Yes Next step
Connect the diagnostic tester for electronically
controlled injection system and observe the "Engine Overhaul the
2 circuit of
Speed" value. Start the engine and check if the No
speed signal outputs. crankshaft
position sensor
Remove the ignition coil of one cylinder, connect
the sparkplug and position the plug electrode about Yes Next step
3 5 mm from the engine block. Start the engine and
check if there is blue and white high-pressure Overhaul the
No
spark. ignition system
Repair the
mechanical
Check each cylinder of the engine for insufficient Yes
4 malfunction of
pressure. engine
No Next step
Yes Diagnostic tips

Check if the power supply and ground connection
5
of related circuits are normal. Overhaul related
No
circuits
75
Section 3 Hot starting is difficult

General trouble area: 1. Fuel with water; 2. Fuel pump; 3. Coolant temperature sensor; 4.
Vacuum pipe of fuel pressure regulator; 5. Ignition coil.
1 Overhaul the
engine and check if the fuel pressure is about
350 kPa. No fuel supply
system
the sparkplug and position the plug electrode Yes Next step
2 about 5 mm from the engine block. Start the
engine and check if there is blue and white Overhaul the
No
high-pressure spark. ignition system
Remove the connector of coolant temperature Overhaul the
sensor, start the engine and check if the engine circuit or
Yes
can be started successfully. (Or connect a replace the
3 resistor of 300 ohms to the connector of coolant sensor
temperature sensor to replace the coolant
temperature sensor, and check if the engine can No Next step
be started successfully.)
Overhaul or
Yes
4 Check the power fuel pump for any damage. replace
No Next step
Replace the
Check the fuel condition to see if the trouble is Yes
5 fuel
caused immediately after the fuel is filled.
No Next step
Yes Diagnostic tips

Check if the power supply and ground
6
connection of related circuits are normal. Overhaul
No
related circuits
Section 4 Cold starting is difficult

General trouble area: 1. Fuel with water; 2. Fuel pump; 3. Coolant temperature sensor; 4. Injector;
5. Ignition coil; 6. Electronic throttle body assembly; 7. Engine mechanics.
1 Overhaul the
kPa. No fuel supply
system
76

check if there is blue and white high-pressure Overhaul the
No
spark. ignition system
sensor, start the engine and check if the engine can circuit or
Yes
be started successfully. (Or connect a resistor of replace the
3 2,500 ohms to the connector of coolant temperature sensor
sensor to replace the coolant temperature sensor,
and check if the engine can be started No Next step
successfully.)
Clean the
Lightly depress the accelerator pedal to see if the Yes electronic
4
engine can be started easily. throttle valve
No Next step
Remove the injector, and check the injector for any Replace the
Yes
5 leakage or blockage with the special washing faulty injector
analyzer. No Next step
Replace the
6 fuel
No Next step
Repair the
mechanical
7 malfunction of
pressure.
engine
No Next step
Yes Diagnostic tips

8
of related circuits are normal. Overhaul
No
related circuits
Section 5 Engine is difficult to start at any time, but the engine speed is
normal
General trouble area: 1. Fuel with water; 2. Fuel pump; 3. Coolant temperature sensor; 4. Injector;
5. Ignition coil; 6. Electronic throttle body assembly; 7. Inlet passage; 8. Ignition timing; 9.
Sparkplug; 10. Engine mechanics

Overhaul the
Check the air filter for blockage and check the inlet Yes
1 intake system
passage for air leakage.
No Next step
distribution pipe assembly oil inlet pipe), start the Overhaul the
2
engine and check if the fuel pressure is about 350 No fuel supply
kPa. system
77
Remove the ignition coil of one cylinder, connect Yes Next step
the sparkplug and position the plug electrode about
3 5 mm from the engine block. Start the engine and Overhaul the
check if there is blue and white high-pressure No
ignition system
spark.
Yes Next step
Check if the type and gap of sparkplug in each
4 Adjust or
cylinder are as specified. No
replace
Overhaul the
Remove the connector of coolant temperature circuit or
Yes
5 sensor, start the engine and check if the engine can replace the
be started successfully. sensor
No Next step
Clean the
Lightly depress the accelerator pedal to see if the Yes
6 throttle valve
engine can be started easily.
No Next step
Yes
Replace the
8 fuel
No Next step
Repair the
mechanical
9 malfunction of
pressure.
engine
No Next step
Yes Next step
Check if the ignition sequence and ignition timing of
10 Overhaul the
engine are as specified. No
ignition timing
Yes Diagnostic tips

11
No
related circuits
Section 6 Engine can be started normally, but idle speed unstable at any
time
General trouble area: 1. Fuel with water; 2. Fuel pump; 3. Sparkplug; 4. Electronic throttle body
assembly; 5. Inlet passage; 6. Ignition timing; 7. Engine mechanics.

Overhaul the
1 intake system
No Next step
Clean or
Yes
2 Check if the electronic throttle valve is stuck. replace
No Next step
78
Yes Next step

3 Adjust or
replace
Check the electronic throttle body assembly for Yes Clean
4
carbon deposit. No Next step
Yes
5 leakage, blockage or poor flow with the special faulty injector
washing analyzer. No Next step
Replace the
6 fuel
No Next step
Repair the
mechanical
Check if large pressure difference exists among Yes
7 malfunction of
each cylinder of the engine.
engine
No Next step
Yes Next step
8 Overhaul the
ignition timing
Yes Diagnostic tips

9
No
related circuits
Section 7 Engine can be started normally, but idle speed unstable during
warming up
General trouble area: 1. Fuel with water; 2. Coolant temperature sensor; 3. Sparkplug; 4.
Electronic throttle body assembly; 5. Inlet passage; 6. Engine mechanics.

Overhaul the
1 intake system
No Next step
Yes Next step
2 Adjust or
replace
Remove the electronic throttle body assembly and Clean related
Yes
3 check the electronic throttle body assembly for components
Overhaul the
Yes
4 sensor, start the engine and check if the engine idle replace the
speed is unstable during warming up. sensor
No Next step
Yes
79
Replace the
6 fuel
No Next step
Repair the
mechanical
7 malfunction of
engine
No Next step
Yes Diagnostic tips

8
No
related circuits
Section 8 Engine can be started normally, but idle speed unstable after
warming up
Electronic throttle body assembly; 5. Inlet passage; 8. Engine mechanics.

Overhaul the
1 intake system
No Next step
Yes Next step
2 Adjust or
replace
Yes
Overhaul the
Yes
No Next step
Yes
Replace the
6 fuel
No Next step
Repair the
mechanical
7 malfunction of
engine
No Next step
8 Yes Diagnostic tips
of related circuits are normal.
80
Overhaul
No
related circuits
Section 9 Engine can be started normally, but idle speed unstable or

engine misfires under some loads (for example, the air conditioning is
on)
General trouble area: 1. Air conditioning system; 2. Electronic throttle body assembly; 3. Injector.

Yes
Check if the engine output power increases with the
Yes Go to step 4
air conditioning on, which is to observe the change
2 of ignition advance angle, injection pulse width and
intake air volume with the diagnostic tester for No Next step
Connect the ECI system adapter and disconnect Yes Next step
the wire connected to pin No. 75 of electronic Overhaul the
3
control unit. Check the wire harness end for high No air conditioning
level signal with the air conditioning on. system
Yes Next step
Check if the pressure of air conditioning system,
No Overhaul the
4 magnetic clutch of compressor and air conditioning
air conditioning
compression pump are normal.
system
Yes
Yes Diagnostic tips

6
No
related circuits
Section 10 Engine speed does not increase or the engine misfires during
acceleration
General trouble area: 1. Fuel with water; 2. Intake pressure sensor and electronic throttle body
assembly; 3. Sparkplug; 4. Inlet passage; 5. Injector; 6. Ignition timing; 7. Exhaust pipe.

Overhaul the
Yes
1 Check the air filter for any blockage. intake system
No Next step
81
2 Overhaul the
kPa during acceleration. No fuel supply
system
Yes Next step
3 Adjust or
replace
Yes
Yes Next step
Overhaul the
Check if the intake pressure sensor, electronic
5 circuit or
throttle body assembly and their circuits are normal. No
replace the
sensor
Yes
Replace the
7 fuel
No Next step
Yes Next step
8 Overhaul the
ignition timing
Yes Next step
Check if the exhaust gas is discharged smoothly Repair or
9
from the exhaust pipe. No replace the
exhaust pipe
Yes Diagnostic tips

10
No
related circuits
Section 11 Response is slow during acceleration

assembly; 3. Sparkplug; 4. Inlet passage; 5. Injector; 6. Ignition timing; 7. Exhaust pipe.

Overhaul the
Yes
No Next step
2 Overhaul the
system
82
Yes Next step

3 Adjust or
replace
Yes
Yes Next step
Overhaul the
5 circuit or
replace the
sensor
Yes
Replace the
7 fuel
No Next step
Yes Next step
8 Overhaul the
ignition timing
Yes Next step
9
exhaust pipe
Yes Diagnostic tips

10
No
related circuits
Section 12 Engine power is low and performance is poor during

acceleration
assembly; 3. Sparkplug; 4. Ignition coil; 5. Inlet passage; 6. Injector; 7. Ignition timing; 8. Exhaust
pipe.

Check for the clutch slip, low tire pressure, brake Yes Repair
1 drag, incorrect tire size and incorrect four-wheel
No Next step
alignment.
Overhaul the
Yes
No Next step
3 Overhaul the
system
83

check if the intensity of high-pressure spark is Overhaul the
No
normal. ignition system
Yes Next step
5 Adjust or
replace
Yes
Yes Next step
Overhaul the
7 circuit or
replace the
sensor
Yes
Replace the
9 fuel
No Next step
Yes Next step
10 Overhaul the
ignition timing
Yes Next step
11
exhaust pipe
Yes Diagnostic tips

12
No
related circuits
84
Part 6 Instructions for BYD-ED400 Diagnostic Tester

BYD-ED400 diagnostic tester is the latest version of BYD which can troubleshoot all the existing
models of BYD AUTO CO. LTD. It can be updated online easily to support the diagnosis of new
systems in new models of BYD AUTO CO. LTD. It also features waveform display function, so it
can be used as a simple oscilloscope.
Section 1 Preparation before Diagnosing the Vehicle with BYD-ED400

1.1 Preparation and connection for connecting wire to the diagnostic socket of
vehicle diagnosis the vehicle.
1.1.1 Preparation for using BYD-ED400 Description: If the power supply of diagnostic
socket in the tested vehicle is insufficient or its
1.1.1.1. General test conditions power supply Pins are damaged, the power
supply can be obtained through one of the
1.1.1.1.1 Turn on the vehicle power supply following methods:
switch;
1.1.1.2.4 Cigarette lighter cable: Remove the
1.1.1.1.2 The batter voltage of vehicle should cigarette lighter. Insert one end of the
be between 11 and 14 V and the rated cigarette lighter cable into the cigarette
voltage of BYD-ED400 is 12 V. lighter hole, and connect the other end to
the power plug of BYD-ED400 test
1.1.1.2 Connection of BYD-ED400 mainline. The BYD-ED400 should be
turned off before the ignition switch is
The BYD-ED400 is connected as follows: turned off to avoid illicit shutdown.
1.1.1.2.1 Insert the diagnostic card into the 1.1.1.2.5 Double clamp power cable: Clamp
diagnostic card slot of BYD-ED400. Note the power clamp of double clamp power
the surface with "UPSIDE" faces upward cable on the positive and negative
and make sure the diagnostic card is terminals of battery, and insert the other
inserted in place. end into the power plug of BYD-ED400
test mainline.
1.1.1.2.2 Insert the end DB15 of BYD-ED400
diagnostic connecting wire into the "DATA 1.1.1.2.6 Extension adapter cable: Connect
I/O" of host. the end DB25 of extension adapter cable
to the "extension interface" of host,
1.1.1.2.3 Connect the interface OBDII on the connect the terminal DV of extension
other end of BYD-ED400 diagnostic adapter cable to the switch power jack of
85
special power adapter, and then insert the 1.2 Start the vehicle diagnosis
other end of power adapter into the
100-240 V AC power socket. When the above preparation is done, perform
the diagnosis with the diagnostic tester.
86
Section 2 Instructions for Keyboard Operation

2.1 Keyboard layout 2.2 Introduction of key function
The BYD-ED400 diagnostic tester is operated Number key 0-9: Menu selection; Number
through the membrane keys and simple input.
operation tips are provided on each displayed
page. The customer can also enter the Direction key ↑↓←→: The ↑ and ↓ keys are
"Operation Guide for Diagnostic Tester" for used to select the menu and the ← and →
basic operation modes which will not be keys are used to turn pages. When inputting
described below. numbers, pressing the ↑ key can increase by
1 and pressing the ↓ key can decrease by 1.
The membrane keys are arranged as follows: Pressing the ← key to backspace, which is to
delete the previous digit. When performing the
component operation test, the ← key is used
to turn off the component and the → key is
used to activate or turn on the component.
RST: System reset. Note: Be careful to use

the key. When using the key, press it for 1 to 2
seconds and then release.
ESC: Return to the parent directory; Exit the

current function page; Exit the current setting
items.
OK: Enter the next level directory; confirm the

performance of a function operation.
F1 and F2: F1 is used to display help; F2 is

used to print the current page. Both keys can
be used as auxiliary input function keys under
special conditions, for example inputting the
plus or minus. See the tips on corresponding
pages for details.
87
Section 3 Function Introduction

3.1 Instructions for display interface
The display interface for the host of diagnostic tester is divided into 3 main areas: title bar, info
bar and help bar. See the figure below.
Title bar
Please select a function
1. Model diagnosis
2. Diagnostic card programming
3. Diagnostic tester version information

4. Diagnostic tester setting
Info bar
5. Operation guide for diagnostic tester
Help bar
Press [] key to move up
Press [] key to move down
Press [OK] key to enter the sub-menu
Title bar -- Display the title information

Info bar -- Display area for main contents. Display the menus of each level and diagnosis
contents
Help bar -- Tips for current page operation and other auxiliary information
3.2 Program update
Insert the special diagnostic card into the

"card slot" of the hose correctly (The surface
printed with Up arrow should face upward and
the diagnostic card can prevent being inserted Downloading……
reversely), and then turn on the power supply.

The host will automatically detect the validity
of diagnostic card. If the card is valid, it will
continue to check if the versions of the
programs in the hose and diagnostic card are
the same. If the versions are different, the
host will automatically copy the program in the Precautions
card to the ROM of the host, and then run it. Do not use the RST key to reset the system!
Do not remove the diagnostic card during
This process is the intelligent update of downloading!
program in the hose.
The program update process is shown in Warning! During the program update, do
the right figure. The entire process takes not power off, reset the system with [RST]
about 1 to 2 minutes. and remove the diagnostic card. Otherwise
the program will fail to update, and the
system may break down. If the diagnostic
tester cannot be used due to such causes,
please send the hose and diagnostic card
to the BYD after-service department.
88
Description: The intelligent update of the Please select a model

program in the host occurs once only when
the versions of the programs in the host
and diagnostic card does not match.
3.3 Basic functions of diagnostic tester
The host of ED400 diagnostic tester mainly

has two functions: program update in the
diagnostic card and model diagnosis.
It also has some ancillary functions, such as
host setting of diagnostic tester. The following
will describe these functions with examples. If Press [] key to move up
the program in the host needs to be updated, Press [] key to move down
refer to the corresponding instructions for Press [OK] key to enter the sub-menu
Press [ESC] key to return to the previous menu
update.
3.3.1 Model diagnosis Description:

The instruction manual will demonstrate the
operation of engine management system 1. There is a box in front of each menu. If a
DELPHI-MT20U2 in F3 model. For the box is ticked, the current menu is selected.
operation of other systems, refer to the The same applies to below.
operation methods for the two systems.
2. The diagnosis for each module in the
Enter the "Model Diagnosis" on the main BYD-ED400 is similar, which can be
screen at power-On as shown in the right performed in two steps: First, select the
figure. The customer can select the models desired diagnosis system; second, select the
with ↑ and ↓ keys, and then press [OK] key to desired operation, such as reading the data
enter the diagnosis system of the model. flow and reading the trouble code.
Operation skills: On most menu selection
page, the customer can enter the menu by Select and enter the "F3" model on the model
directly pressing the number keys selection interface as shown in the under
corresponding to the numbers in front of the figure.
menu items. For example, if the customer
wants to diagnose the F3 model, the first Please select a model
method is to select the F3 model by pressing

the ↑ (or ↓) key and then press the [OK] key.
The second method is to press the [1] key
directly.

Press [] key to move down
Select and enter the "Engine Management

System" as shown in the figure below.
89
Please select a system
 1. Engine management system

 2. AMT system
 3. ABS system
 4. SRS system  1. Read computer version
2. Read DTCs
3. Clear DTCs
4. Read data flow
5. Component operation test
6. System Reset
Press [] key to move up Press [] key to move up

Press [] key to move down Press [] key to move down
Press [OK] key to enter the sub-menu Press [OK] key to enter the sub-menu
Press [ESC] key to return to the previous menu Press [ESC] key to return to the previous menu
Select and enter the "DELPHI-MT20U2" The "Title bar" displays ECU-MT20U2 which
system as shown in the under figure. is the abbreviation of the system of which the
customer is diagnosing the communication.
Please select a system
The "Info bar" lists all the operation types
supported by the ECU, such as reading the
version No. and data flow. [→] indicates the
operations that can be performed under the
current condition. Press the [OK] key to
perform the operation.
The "Help bar" displays the operation tips for

basic keys on the current page.
Description: Two methods can be used when

the customer wants to perform a diagnostic
function: First, press the ↑ (or ↓) key to change
the menu item indicated by [→], and then
press the [OK] key to perform. Second, press
the corresponding numbers directly to perform.
The display in the under figure will be shown The specific operations will not be described
when the BYD-ED400 diagnostic tester and below, and the customer can perform the
ECU communicate successfully. operations according to the tips on the screen.
3.3.1.1 Read the computer version
The computer version information is a set of

data defined by the manufacturer which is
used to identify some basic information, such
as Vehicle Identification Number. The display
of BYD-ED400 is shown in the under figure.
90
Computer Version Information DTC
1. P0122 (Intermittent): Throttle position

Vehicle identification number: sensor voltage is low
W0L000043MB541326 2. P0480 (Intermittent): No. 1 fan control circuit
Manufacturer hardware number: 90254861 GD failure (High speed)
System hardware number: DEL 3. P0481 (Current): No. 2 fan control circuit
010699999999AA failure (Low speed)
System software number: P0801AXZ01 4. P0685 (History): DTC not defined
Engine type: ABC123 5. P0230 (History): Fuel pump relay circuit
Test serial no.: SN12345678 failure
Programming date: 20020513
Press [F2] key to print the current page Press[←] key to turn to the previous page
Press [ESC] key to return Press[→] key to turn to the next page
Press [F2] key to print
Press [ESC] key to exit
Description: The information comes from the Trouble information consists of 4 parts. The
ECU. The specific contents vary with the ECU. first part is a serial number without meaning.
When the customer performs the maintenance The second part is the trouble code which is
operation, please send the information to the compiled according to related standards, for
relevant departments of BYD AUTO CO. LTD. example "P0122". The first letter "P" indicates
the engine malfunction and it forms a trouble
3.3.1.2 Read DTCs code with the last 4 numbers "0122". The third
part is in the bracket which indicates the
The function can display the trouble detected trouble conditions. There are three conditions
by the ECU in the form of specific code (DTC). such as "Current DTC", "History DTC" and
"Intermittent DTC". "Current DTC" indicates
 If the system is OK the trouble always exists and the DTC cannot
be cleared through the "Clear DTCs" function.
BYD-ED400 will display "System is OK" as "History DTC" indicates the trouble occurred
shown. in the past, but it has been repaired during the
diagnosis and the DTC can be cleared
DTC through the "Clear DTCs" function.
"Intermittent DTC" indicates the trouble is an
occasional malfunction which is caused by
poor contact and the DTC can be cleared
through the "Clear DTCs" function. The last
part is the complete description of trouble
System is OK information. If the trouble information is not
included in the BYD-ED400, it will display
"DTC Not Defined".
"Page: 1/2" on the upper right corner of the

screen indicates the received trouble
information is displayed in 2 pages and the
Press any key to return
current page is Page 1. The customer can
view other trouble information on Page 2 by
pressing [→] key as indicated in "Help bar".
Press [←] key to return to Page 1.
 If the system is faulty
The "Info bar" will list all the DTCs and 3.3.1.3 Clear DTCs
corresponding trouble information as shown in
the under figure.
91
The function is used to clear some history or The "Info bar" area is displayed in the right
intermittent DTCs recorded in the ECU. The figure. The current display is Page 1. The
display in the right figure will be shown if the customer can view other data by pressing ←
operation is successful. The customer is and → keys.
recommended to perform the operation for 2
to 3 times to ensure the DTCs are cleared  Graphical display mode
completely.
The graphical trend of two parameters can be
Clear DTCs displayed on each page under the graphical
display mode of BYD-ED400. The numbers in
the left of each graph are the maximum value,
median and minimum value from top to
bottom. The corresponding text will also be
displayed under the graph.
Trouble codes cleared
The graphical display achieves the dynamic
change by plotting the points from left to right
at regular time.
The top right corner of the "Info bar" will also

display "Page: 4/4" and the page can be
turned by the above method.
The graphical display has two modes.
3.3.1.4 Read data flow The first is to plot points as shown in the
under figure.
The BYD-ED400 diagnostic tester supports
two display modes: normal display mode and Data Flow
graphical display mode. The ED400 with
convenient graphical display is more
advanced than the previous diagnostic tester
designed by BYD AUTO Co., Ltd. The two
modes can be switched according to the key
tips of "Help bar" in BYD-ED400.
Oxygen sensor 1 voltage:
Data Flow
Battery voltage 11.9V Oxygen sensor 2 voltage:

Intake pressure 0 kPa
Intake temperature -40°C Press [1] key to switch the view mode
Press [2] key to switch the point plotting mode
Coolant temperature -1°C
Press [F2] key to print the current page
Ignition advance angle 7°C
Air conditioning pressure 0 kPa
Throttle sensor voltage 0 mV
Throttle valve opening 0% The second is to use bar graph as shown in
Vehicle speed 0 km/h the under figure.
Engine speed 750RPM
Press [1] key to switch the view mode

Press [2] key to switch the point plotting mode
 Normal display mode
92
Data Flow The switching parameters have two states: On

or Off. Therefore the customer can complete
relevant actions with simple operations.
The symbol "" indicates the parameters

being controlled currently. Meanwhile, the
customer's expected operation states will be
displayed on the right: On or Off. The
customer can select the items to be tested by
pressing the ↑ and ↓ keys. The current
switching parameters can be controlled by
pressing the ← and → keys. Press ← key to
perform Off operation and press → key to
Press [1] key to switch the view mode
Press [2] key to switch the point plotting mode perform On operation.
If the customer wants to give up the control of
currently selected item, select other test items
The two modes can be switched between simply by pressing the ↑ and ↓ keys, or exit
each other. Refer to the relevant tips in the the current page by pressing [ESC] key.
"Help bar" for details.
Component Operation Test
As the normal display mode, the current graph
in the graphical display mode can also be  Malfunction indicator: On
output through the miniprinter. Refer to the Fuel pump relay
tips of "Help bar" for detailed operation. Low speed fan
High speed fan
Air conditioning relay
3.3.1.5 Component Operation Test Gear communication self-learning
BLM self-learning
The component operation test on MT20U2 Fuel open loop
system can be controlled in 3 different ways Converter offline

Oxygen sensor
which are switching parameters, control
parameters and activated/deactivated
parameters as shown in the under figure.
Press [] and [] key to select test items
Press [] key to turn off; Press [] key to turn on
Component Operation Test Press [F2] key to print
3.3.1.5.2 Control parameters

 1. Switching parameters
2. Control parameters
The control parameters are some setting
3. Activated/deactivated parameters parameters. Some internal variables of ECU
can be changed by setting these parameters
so as to change the operation condition of the
engine.
The symbol "" indicates the items that can

be set by the customer currently. The
Press [] key to move down customer can select the parameter to be set
Press [OK] key to enter the sub-menu by pressing the ↑ and ↓ keys.
The second line of "Help bar" displays the

The operation methods for the parameters are setting range of current item, and the third line
different, which will be described below. displays the value input by the customer. The
fourth line indicates the customer can set the
3.3.1.5.1 Switching parameters current item by pressing the [OK] key.
93
When the customer inputs the value and Description: Be careful to perform the
presses the [OK] key, the fourth line will "component operation test". If you are not a
display the setting result. professional technician or service personnel,
do not use the function to avoid improper
operation and damage to the engine system.
If the customer wants to give up the control of
currently selected item, select other test items 3.3.1.6 System reset
simply by pressing the ↑ and ↓ keys, or exit
the current page by pressing [ESC] key. The system reset operation causes the ECU
to perform self-resetting once. If the system is
Component Operation Test reset successfully, the BYD-ED400 will
display "Reset Successfully".
 1. Charcoal canister purifying rate System Reset

2. Idling air control (Step)
3. Idling air control (Speed)
4. Ignition advance angle
Reset successfully
Input the numbers by pressing the number keys

after selecting the items with ↑ and ↓ keys [0-100]
0
Press [OK] key to set the input number
Activated/deactivated parameters
The control of activated/deactivated

parameters is similar to that of switching 3.3.2 Diagnostic card programming
parameters. The display interface is shown in
the under figure. Connect the terminal DB25 of special
extension cable to the "extension interface" of
Component Operation Test host, connect the terminal DB9 to the serial
port of computer and then connect the input
end of power adapter to the power input end
of extension cable. At last connect the power
adapter to the domestic mains supply network
 Injection nozzle 1: Activated
Injection nozzle 2
(AC 220V). The host will operate normally.
Injection nozzle 3 The schematic diagram for connection is
Injection nozzle 4 shown below.
Enter the function page of "Diagnostic Card

Programming" from the main interface. If the
host detects the diagnostic card is valid, the
display is as shown in the under figure.
Press [↑] and [↓] key to select the test items
Press [←] key to turn off; Press [→] key to turn on
Press [F2] key to print
Refer to the above operation mode of

"switching parameters" for detailed operation.
94
Diagnostic Card Programming
Diagnostic Card Programming
The card is valid. Do you want to program the

procedure? The host is ready. Please run the special
programming procedure
DTcard_Updata.exe...
Press [OK] key to continue

Press [ESC] key to cancel 1. Do not use the [RST] key to reset the system!
2. Do not remove the diagnostic card to avoid
system breakdown.
3. Make sure each connector is securely connected.
Enter the programming procedure by pressing

the [OK] key according to the tips in "Help bar". For using the programming software
Cancel the diagnostic card update and return DTcard_Updata.exe, refer to the help
to the main interface by pressing [ESC]. information for the software.
When programming the diagnostic card, two Warning: When programming, ensure the
conditions may occur depending on the PC entire process finishes naturally! Do not power
settings. off the host, reset the host by pressing the
[RST] key and remove the diagnostic card,
3.3.2.1 If the "Program File" is selected in the otherwise the diagnostic card will fail to
programming software, the diagnostic update and the diagnostic card may be
program of diagnostic card will be damaged. "Finish naturally" refers to the
updated. programming is finished by the host through
the special programming software
3.3.2.2 If the "Font File" is selected in the DTcard_Updata.exe and the screen displays
programming software, the font program "Programming Finished".
of diagnostic card will be updated. The
function is not commonly used. The 3.3.3 Diagnostic tester version information
desired simplified Chinese characters
(GB2312) font has been input in the Select and enter "Diagnostic Tester Version
diagnostic card in the factory. Information" from the main screen at
power-On. The screen will display the
Description: The diagnostic program and font software version, hardware version and
program are stored in two different areas of production date as shown in the under figure.
the diagnostic card. Therefore, the customer
must confirm which program needs to be
updated when updating the diagnostic card.
Press the [OK] key on the above interface and

the host will display "The host is ready. Please
run the special programming procedure
DTcard_Updata.exe..." as shown in the under
figure. At this time, the customer can run the
special programming software
DTcard_Updata.exe in the computer. The
diagnostic card can be updated after the
software is correctly configured and the
desired program file is selected.
95
Diagnostic Tester Version Information 3.3.5 Operation guide for diagnostic tester
Select and enter "Operation Guide for

Diagnostic Tester" from the main screen at
Software version number: 070507001.01
power-On. The screen display is as shown in
Hardware version number: ED300.001 the right figure. Here are some operation
Product serial number: 00000001 methods for the diagnostic tester. The specific
Production date: 2007.04.27 operation method will be simply displayed on
each page of "Help bar" area.
Operation Guide for Diagnostic Tester
Basic operations:
Press any key to return Press [↑] key to move up
Press [↓] key to move down
Press [←] key to turn to the previous page
Press [→] key to turn to the next page
Press the key to display the help information
The customer can confirm the program Press [ESC] key to return to the previous
menu
version depending on these contents and view
the program version status by accessing the Operation skills:
Enter the menu by pressing the number keys
website of BYD AUTO Co., Ltd. corresponding to the numbers in front of the
menu items
Description: The displayed contents are only
for reference. These contents will be
displayed when the host of diagnostic tester is
powered on.
3.3.4 Diagnostic tester setting
Select and enter "Diagnostic Tester Setting"

from the main screen at power-On. Some
operating conditions of the ED400 diagnostic
tester host can be set here, such as On and
Off of backlight, display font and data refresh
rate.
96
Section 4 Precautions for Maintenance and Use of Diagnostic Tester

4.1 Storage Environment BYD-ED400 host so as to save the power
and extend the service lift of screen.
4.1.1 The BYD-ED400 should be stored in a
flat, dry and comfortable place when not 4.3 Diagnostic card maintenance
used.
4.3.1 Never remove the diagnostic card when
4.1.2 Do not store the BYD-ED400 in direct the host is operating. Note that the
sunshine or close to the heating device. diagnostic card should not be put in a
place with intense magnetic field and
4.1.3 Do not put it near the stove or in a place electric field.
subject to fume, water or oil.
4.3.2 Do not turn on and off the BYD-ED400
4.1.4 Do not put it in a vibratory, dusty, wet or host frequently.
hot place.
4.3.3 When updating the program, do not use
4.1.5 Do not disassemble the host privately. the [RST] function of the host, remove the
When the host is dirty, wipe the main diagnostic card or remove the patchcord
case or screen with a wet soft cloth after to avoid update failure and system
it is wrung out. But note the host should breakdown.
be turned off and the power supply
should be cut off first. 4.4 Precautions for using diagnostic
tester
4.1.6 If the vehicle is not tested for a long time,
run the BYD-ED400 host at regular 4.4.1 The diagnostic tester is a precise
intervals to avoid moisture. electronic instrument. Do not strike it
when using.
4.2 LCD Maintenance 4.4.2 The host screen may flash when the
engine ignited. It is a normal
4.2.1 Do not put any objects on the host to phenomenon.
avoid damage to the internal
components caused by heavy load. 4.4.3 If the program does not run or the
4.2.2 Do not expose the screen in direct screen is disorderly after the screen
sunshine or under the ultraviolet lamp to flashes, remove the plug from the host.
extend the service life. Continue operation after reinserting
4.2.3 Do not put the product besides the the plug.
electrical devices which can generate
electromagnetic interference to avoid 4.4.4 Make sure the diagnostic tester and
affecting the display effect. diagnostic socket are well connected
4.2.4 The dust may attach on the surface of when testing to avoid the effect of
LCD screen due to static electricity. It is signal interruption on the test.
recommended to gently clean the screen
with the special wiping cloth for LCD 4.4.5 Be careful to connect the main cable
screen. Do not wipe with fingers to avoid and diagnostic socket. Tighten the
fingerprint. fastening screws to avoid
disconnection and damage to the
4.2.5 Do not wipe the screen with chemical interface during movement.
cleaner.
4.4.6 Hold the host handle when operating
4.2.6 When the BYD-ED400 is not used for a the BYD-ED400 to avoid damage to
long time, turn off the power supply of some interfaces or the host.
97
4.4.7 Hold the host securely when inserting 4.4.9 Be careful to operate the test to avoid
and removing the printer to prevent it impact. Remove the power cable
from dropping on the ground. when the tester is not in use.
4.4.8 Do not insert or remove the diagnostic 4.4.10 Put the cables and connectors back
card when the instrument is on! into the case when the BYD-ED400 is
Remove the diagnostic card after it is not in use to avoid missing.
ejected by pressing the ejector rob.
When inserting the diagnostic card, 4.4.11 Remove the plug while holding it,
align it with the socket and make sure instead of pulling the power cable.
it is inserted in place.
Part 7 Accessories
Section 1 Components Installation Torque Specification Table
No. Component Name Installation Torque (NM)
1 Intake Pressure/Temperature Sensor 3.3
2 Coolant Temperature Sensor 20 (Max)
3 Knock Sensor 20±5
4 Oxygen Sensor 50±10
5 Electronic Throttle Body Assembly 2±0.5
6 Crankshaft Position Sensor 8±2
7 Camshaft Position Sensor 8±0.5
8 Injector 6
(Phase 1) 2±1
9 Electronic Throttle Body Assembly
(Phase 2) 7±1
Section 2 Maintenance Procedures for Electronic Injection System

2.1 Family Cars
Description:
2.1.1 The maintenance procedures are for family cars;
2.1.2 The maintenance interval is determined by the odometer reading or the time interval,
whichever comes first;
2.1.3 The maintenance procedures are based on the assumption when the vehicle can be used
normally as designed, and should be strictly followed.
2.1.4 Mileage for inspection and replacement of sparkplug: Inspect the sparkplug when the
vehicle is driving for 13,000 km and 23,000 km. Replace it if it malfunctions; The
sparkplug must be replaced when the vehicle is driving for 33,000 km.
98
Mileage
10 20 30 40 50 60 70 80
Item x1000km
Month 3 6 9 12 15 18 21 24
Ignition Coil I I I I
Ignition Timing I I I I
Engine Idling I I I I
Fuel Tank I C
Gasoline Filter R R R R
Injector C* C* C* C*
Air Cleaner I R I R
Electronic Throttle Body
C C C C
Assembly
Emission Check I I I I
Diagnostic Tester Check I I I I
2.2 Taxi
Description:
2.2.1 The maintenance procedures are for taxies;
2.2.4 Mileage for inspection and replacement of sparkplug: Inspect the sparkplug when the
vehicle is driving for 13,000 km and 23,000 km. Replace it if it malfunctions; The
sparkplug must be replaced when the vehicle is driving for 33,000 km.
Mileage
20 40 60 80 100 120 140 160
Item x1000km
Month 3 6 9 12 15 18 21 24
Ignition Coil I I I I I I I I
Ignition Timing I I I I
Engine Idling I I I I
Fuel Tank C C
Gasoline Filter R R R R R R R R
Injector C* C* C* C* C* C* C* C*
Air Cleaner I R I R I R I R
Air Passage of Electronic
I C I C I C I C
Throttle Body Assembly
Electronic Throttle Body
I C I C I C I C
Assembly
Emission Check I I I I
Diagnostic Tester Check I I I I
Note: R-Replace
C-Clean
I-Inspect (Replace the malfunctioning components found during item inspection)
C*-It is recommended to use the special injector washing analyzer to clean and maintain the
injector
99
DTCs Table
DTC Malfunction
Description
Max. Min. Signal Irrational Type
Crankshaft position sensor signal
P0335 P0335 P0335 P0336
malfunction 33
Electronic throttle body assembly circuit
P0123 P0122 P0120 P0120
malfunction 31
Injector 1 control circuit malfunction P0201 P0201 P0201 P0201 31
λClosed loop control self-learning value
P0171 P0172 P0170 P0170
multiplication exceeds the limit 5
Oxygen sensor heater malfunction P0135 P0135 P0135 P0135 31
Fuel pump control circuit malfunction P0230 P0230 P0230 P0230 31
Knock zero test and diagnosis P0324 P0324 P0324 P0324 5
Knock offset diagnosis P0324 P0324 P0324 P0324 5
Knock test pulse diagnosis P0324 P0324 P0324 P0324 5
Knock sensor circuit malfunction P0325 P0325 P0325 P0325 31
Idle control speed deviates from target
P0507 P0506 P0505 P0505
speed 31
Intake pressure sensor malfunction P0108 P0107 P0105 P0106 31
Oxygen sensor malfunction P0132 P0131 P0134 P0130 31
Fan A control circuit malfunction P0480 P0480 P0480 P0480 31
Crankshaft position sensor malfunction P0335 P0335 P0335 P0336 33
Camshaft position sensor malfunction P0343 P0342 P0340 P0340 31
λClosed loop control self-learning value
P0171 P0172 P0170 P0170
addition exceeds the limit 5
Intake temperature sensor malfunction P0113 P0112 P0110 P0111 31
Charcoal canister control valve control
P0445 P0444 P0443 P0443
circuit malfunction 31
Water temperature sensor malfunction P0118 P0117 P0115 P0116 31
Power supply malfunction P0563 P0562 P0560 P0560 31
100
Chapter 2 BYD TB10 Engine Management System Repair

Manual
Content
Section 1 Repair Requirements for Electronic Injection System ................................................. 103
1.1 General Repair Requirements ........................................................................................ 103
1.2 Precautions During Repair .............................................................................................. 103
1.3 Recommended Service Tools ......................................................................................... 104
Section 2 TB10 System Introduction ............................................................................................ 106
2.1 System Operation ........................................................................................................... 106
2.2 Input/Output Signals of TB10 System............................................................................. 109
2.3 Introduction of System Function ..................................................................................... 110
2.4 Introduction of System Trouble Diagnosis Function ....................................................... 112
2.5 System Features ............................................................................................................. 115
Section 3 Structure, Theory and Trouble Analysis of TB10 System Components ...................... 117
3.1 Intake Pressure/Temperature Sensor............................................................................. 117
3.2 Coolant Temperature Sensor.......................................................................................... 120
3.3 Oxygen Sensor ............................................................................................................... 122
3.4 Crankshaft Position Sensor ............................................................................................ 125
3.5 Phase Sensor.................................................................................................................. 128
3.6 Knock Sensor .................................................................................................................. 130
3.7 High-pressure Fuel Pressure Sensor ............................................................................. 132
3.8 Accelerator Pedal Position Sensor ................................................................................. 134
3.9 Electronic Control Unit .................................................................................................... 138
3.10 Low Pressure Fuel Pump.............................................................................................. 143
3.11 High Pressure Fuel Pump ............................................................................................. 146
3.12 GDI Injection Nozzle ..................................................................................................... 147
3.13 OCV Solenoid ............................................................................................................... 150
3.14 Electronic Throttle Valve Assembly .............................................................................. 151
3.15 Turbocharger Air Circulation Valve ............................................................................... 152
3.16 Boost Pressure Limiting Solenoid ................................................................................. 153
3.17 Ignition Coil ................................................................................................................... 154
3.18 Power Water Pump ....................................................................................................... 156
3.19 Charcoal Canister Solenoid Valve ................................................................................ 157
3.20 Brake Vacuum Pump .................................................................................................... 159
Section 4 Diagnosis Flow for TB10 System in Accordance with Trouble Codes ........................ 161
Section 5 Diagnosis Flow for TB10 System in Accordance with Trouble Symptoms.................. 192
Section 6 Instructions for Using Diagnostic Tester ...................................................................... 210
6.1 Operation Panel of Diagnostic Tester ............................................................................. 210
6.2 Introduction of Key Function ........................................................................................... 210
6.3 Introduction of Diagnostic Tester Functions ................................................................... 210
6.4 Instructions for Using Diagnostic Tester ......................................................................... 211
101
Section 7 Attachment ................................................................................................................... 216

7.1 Periodic Maintenance Procedures for ECI System ........................................................ 216
7.2 Trouble Code Table ........................................................................................................ 217
7.3 Electrical Schematic Diagram ......................................................................................... 219
7.4 Definition of Fuses and Relays in Distribution Box ......................................................... 220
102
Section 1 Repair Requirements for Electronic Injection System
1.1 General Repair Requirements wire of the ignition system;
1.1.1 Only use the digital multimeter to 1.2.4 Do not remove any components or
check the electronically controlled connectors of electronically controlled
injection system; injection system from the mounting
positions to avoid unexpected damage
1.1.2 Please use the original components or prevent the water, oil and dirt from
during repair, otherwise the normal entering the connectors, affecting the
operation of electronically controlled normal operation of electronically
injection system cannot be ensured; controlled injection system.
1.1.3 Only use the lead free fuel during 1.2.5 When the connectors are
repair; disconnected and connected, be sure
to turn the ignition switch to OFF, or
1.1.4 Please observe the repair diagnosis the electrical components may be
flow of specifications to perform repair; damaged.
1.1.5 Never disassemble the components of 1.2.6 When simulating the thermal condition
electronically controlled injection of trouble and performing other repairs
system during repair; which may cause the temperature to
rise, never allow the temperature of
1.1.6 Be careful not to drop the electronic electronic control unit to exceed 80°C;
components (Electronic control unit ,
sensor, etc.) on the ground during 1.2.7 When overhauling the fuel system or
repair; electrical system, disconnect the
battery first. No smoke and open fire
1.1.7 Effectively dispose the waste during around. The fire extinguisher must be
repair in consideration of prepared;
environmental protection.
1.2.8 The fuel supply pressure for the
1.2 Precautions During Repair electronically controlled injection
system is high (about 600 kPa);
1.2.1 Before working on the engine therefore the fuel lines use the
compartment, turn off the engine, high-pressure resistant fuel pipes. The
remove the ignition key, pull the brake higher fuel pressure is maintained in
lever, switch the shift lever to N or P the fuel line even if the engine does
position and keep the children away not operate. So do not remove the fuel
from the engine; pipes randomly during repair. When
the fuel system needs to be repaired,
1.2.2 Avoid short circuit in the electrical release the pressure of fuel system
system, especially in the battery to before removing the fuel pipes. The
prevent battery explosion. pressure relief method is as follows:
Remove the fuel pump relay, start the
1.2.3 It is more dangerous to overhaul the engine and keep it idling until the
engine when it is started or running. engine stalls. The removal of fuel
Always take care to prevent the pipes and replacement of fuel filter
rotating components such as drive belt, should be performed by the
generator and radiator fan and professional service personnel in
high-voltage ignition system from well-ventilated places;
causing injury or even death to the
operator. Never touch the electrical 1.2.9 Do not energize the fuel pump when
103
removing the power fuel pump from Function: Read/clear the DTCs for the
the fuel tank to avoid generating electronically controlled injection system,
electric sparks, causing fires; observe the data flow and perform the
component operation test, etc.
1.2.10 Do not perform operation test on the
fuel pump in the dry state or water, or
its life time may be reduced. Moreover,
do not reverse the positive and
negative terminals of the fuel pump;
1.2.11 When checking the ignition system,

perform the jump spark test only when
necessary and it should take a short
time. Do not open the throttle valve
and disconnect the injector connector
during test, or large amount of unburnt 1.3.2 Tool Name: ECI system adapter
gasoline will enter the exhaust pipe,
damaging the three-way catalytic Function: Check the electric signal of each
converter; pin in the electronic control unit and the
circuit condition.
1.2.12 The idle speed is adjusted only by the
electronically controlled injection
system without manual adjustment
and the electronic throttle valve body
should be installed in place;
1.2.13 Do not mix the positive and negative

terminals when connecting the battery
to avoid damage to the electronic
components. The system uses
negative pole grounding;
1.2.14 Never ground the positive pole of 1.3.3 Tool Name: Ignition Timing Light
battery to avoid powering off the
electrical system of complete vehicle Function: Check the engine ignition timing,
and damage to the electronic etc.
components due to the burnout of
positive fuse;
1.2.15 Do not cut off the battery power when

the engine is running;
1.2.16 When the welder is used on the

vehicle, the positive and negative
cables of battery and the electronic
control unit should be removed;
1.2.17 Do not detect the input and output 1.3.4 Tool Name: Digital Multimeter
signals of components by piercing the
wire sheath. Function: Check the characteristic
parameters of electronically controlled
1.3 Recommended Service Tools injection system, such as voltage, current
and resistance.
1.3 Tool Name: BYD ED400 diagnostic tester
104
1.3.5 Tool Name: Vacuum Gauge 1.3.8 Tool Name: Exhaust Gas Analyzer
Function: Check the pressure of intake Function: Check the exhaust emission of
manifold. vehicle to help judge the trouble of
1.3.6 Tool Name: Cylinder Pressure Gauge

1.3.9 Tool Name: Injector Washing Analyzer
Function: Check the pressure of each Function: Perform washing and analysis
cylinder. on the injector;
1.3.7 Tool Name: Fuel Pressure Gauge
Function: Check the pressure of fuel

system and judge the operation of fuel
pump in the fuel system.
105
Section 2 TB10 System Introduction

2.1 System Operation
2.1.1 System Overview control signal to the power-driven circuit.

TB10 Engine Management System The power-driven circuit performs different
actions by driving each actuator so that the
The engine management system usually engine can operate according to
consists of sensor, controller (ECU) and predetermined control strategy. Meanwhile,
actuator which control the intake air the trouble diagnosis system of the ECU
amount, injection quantity and ignition monitors the components or control
advance angle when the engine operates. function of the system. Once a trouble is
The basic structure is shown in figure 2.1. detected and confirmed, a DTC is stored
and the "limp home" function is recalled.
Diag Diag When the trouble is eliminated, the normal
nosis nosis value will be restored.
Sensor Actuator
The TB10 engine electronic control
management system features the
in-cylinder direct injection and exhaust gas
Engine
turbocharging control and it also uses the
torque-based control strategy. The main
Fig. 2.1 Composition of Engine Electronic purpose of torque-based control strategy is
Control System to achieve perfect power distribution and
application and enable the complete
In the electronic engine control (EEC) vehicle to reach the excellent driving
system, the sensor is used as the input performance and efficiency by combining
part to measure various physical signals various different control targets.
(temperature, pressure, etc.) and converts
them to the proper electrical signals; ECU The structure of TB10 engine electronic
receives the signals input by the sensor, control system is as shown in figure 2.2.
perform calculation according to the set
procedures and outputs the generated
106
Fig. 2.2 Structure Figure of TB10 Engine Electronic Control System

The basic components of TB10 engine electronic control system are as follows:
Electronic Control Unit (ECU) Electronic Throttle Valve Body

OCV Solenoid High Pressure Injector
Intake Pressure/Temperature Sensor Low Pressure Fuel Pump and Module
Coolant Temperature Sensor High Oil Pressure Sensor
High Pressure Fuel Pump High Pressure Fuel Rail
Camshaft Phase Sensor Knock Sensor
Speed Sensor Charcoal Canister Solenoid Valve
Oxygen Sensor Ignition Coil
Turbocharger Air Circulation Valve Boost Pressure Limiting Valve
107
The TB10 engine management system is 2.1.1.1.16 Limp home

an electronically operated in-cylinder direct
injection system which provides many 2.1.1.17 CAN bus self-diagnosis;
control features related to the operator and
vehicle or device. The system combines 2.1.1.18 Support CAN communication of the
the open loop and closed loop (feedback) complete vehicle;
controls to provide various control signals
for the operation of engine. 2.1.1.2 Additional Functions
The main system functions are as follows: Burglar alarm function, engine anti-theft,
operative work with KEYLESS system
2.1.1.1 Basic management function of engine
with physical model applied 2.1.1.3 On-board Diagnosis (OBD) II
2.1.1.1.1 Torque-based system structure; A series of OBD II functions are used to

diagnose the management system of
2.1.1.1.2 The cylinder load is determined by functions.
the intake pressure sensor;
2.1.2 Torque Structure
2.1.1.1.3 Improved mixture control function in
the static and dynamic conditions; Torque control based TB10 system:
2.1.1.1.4 λClosed loop control; In the torque-based TB10 engine

management system, all the internal and
2.1.1.1.5 Cylinder by cylinder sequential direct external demands of engine are defined
fuel injection; by the engine torque or efficiency
requirements as shown in figure 2.3. By
2.1.1.1.6 Ignition timing, including cylinder by converting various demands of engine to
cylinder knock control; the control variables of torque or
efficiency, these variables are processed
2.1.1.1.7 Variable intake phase control; first in the central torque demand
coordinator module. TB10 system puts
2.1.1.1.8 Exhaust gas turbocharging control; the contradictory demands in order,
perform the most important demand and
2.1.1.1.9 Intake boost limiting circulation achieve the desired engine control
control; parameters through torque conversion
module, such as injection time and
2.1.1.1.10 The high pressure fuel pump ignition timing, etc. The performance of
boosts and adjusts the system the control variable will not affect other
mechanically to ensure high pressure variables. This is the feature of
common rail fuel pressure; torque-based control system.
When matching the engine, as the
2.1.1.1.11 Control the water pump cooling torque-based control system has the
system electronically; variable independence, the engine
characteristic curve and map are
2.1.1.1.12 Emission control function; matched only using engine data without
the interference of other performance
2.1.1.1.13 Catalyst heating; function and variables. The repeated
calibration is avoided, the matching
2.1.1.1.14 Charcoal canister purge control; process is simplified and the matching
cost is reduced.
2.1.1.1.15 Idle control;
108
(13) 32-bit central processing unit, 80 MHz

clock frequency, 768 k cache;
(14) Support higher emission regulations

(Higher than Chinese Phase IV), OBDII,
electronic throttle valve and cruise
control, etc.
2.2 Input/Output Signals of TB10

System
Fig. 2.3 Torque-based TB10 System Structure
The main sensor input signals of ECU in
Compared with the conventional engine
the TB10 system include:
load based engine electronic injection
management system, the main features of
2.2.1 Intake pressure signal (Before and
TB10 system are as follows:
after boosting)
(1) The functional structure of new
2.2.2 Intake temperature signal (Before and
torque-based engine is compatible with
after boosting)
other systems more easily with stronger
expansibility;
2.2.3 Electronic throttle angle signal
(2) The new modular software and hardware
2.2.4 Coolant temperature signal
structures have stronger portability;
2.2.5 Engine speed signal
(3) The basic feature diagrams of
model-based engine are independent
2.2.6 Camshaft phase signal
and the calibration process is simplified;
2.2.7 High pressure fuel rail pressure signal
(4) The sequential fuel injection with phase
sensor can help improve the emission;
2.2.8 Knock signal
(5) The system supports high pressure fuel
2.2.9 Generator feedback signal
rail and direct injection in gasoline
cylinder;
2.2.10 Accelerator pedal position signal
(6) Support the exhaust gas turbocharging
2.2.11 Clutch switch signal (Only for MT
control;
model)
(7) Support the VVT variable intake control;
2.2.12 Oxygen sensor signal
(8) Preset the exhaust temperature model
2.2.13 Air conditioning pressure signal
(9) and air-fuel ratio model and maximize
2.2.14 Brake booster pressure signal
the
2.2.15 The desired actuator control signal is
(10) system operation efficiency;
generated after the above information
is input into the ECU, and these
(11) The system integrates with the anti-theft
signals are magnified in the output
function and supports the push-button
driver circuit and transferred to the
start function; ;
applicable actuator. The control
signals include:
(12) Improve the driving performance by
integrated coordination of various torque
2.2.16 Electronic throttle valve opening
requirements;
109
2.2.17 Injection timing and injection duration When starting, the ignition angle changes
of high pressure injector with the engine temperature, intake
temperature and engine speed.
2.2.18 Time
2.3.2 Warming Up and Heating Control of
2.2.19 High pressure fuel pump control Three-way Catalytic Converter
signal
When the engine is started at low
2.2.20 Low pressure fuel pump control temperature, the cylinder charge, fuel
signal injection and electronic ignition are
adjusted to compensate the higher torque
2.2.21 Charcoal canister control valve demands of engine. The process
opening continues until the proper temperature
threshold is reached.
2.2.22 Ignition coil dwell angle and ignition The most important is to quickly heat the
advance angle three-way catalytic converter in the stage,
as the quick transition to three-way
2.2.23 Air conditioning compressor relay catalytic converter operation will reduce
the exhaust emission significantly. In the
2.2.24 Stepless fan control signal working condition, the three-way catalytic
converter should be heated with exhaust
2.2.25 Electronic water pump relay by properly delaying the ignition advance
angle.
2.2.26 Boost pressure limiting solenoid
2.3.3 Acceleration/Deceleration and Motoring
2.2.27 Air circulation valve Fuel Cutoff Control
2.2.28 Fuel pressure control valve Acceleration/deceleration: During

acceleration and deceleration, the
2.2.29 OCV solenoid torque-based model adjusts the fuel
injection amount and injection time and
2.2.30 Vacuum brake pump relay performs controls such as enrichment
during acceleration, leanness during
2.3 Introduction of System Function deceleration and fuel cutoff during
deceleration to ensure sensitive power
2.3.1 Start Control response.
The intake stroke injection is used during When the fuel cutoff during deceleration
starting. occurs under the motoring or towing
conditions, the power at the flywheel of
The fuel injection amount varies with the engine is negative. In this case, the
engine temperature. The "injection timing" engine friction and pump loss can be
is specified as the initial injection pulse. used to decelerate the vehicle. When the
The mixture must be enriched before the engine is in motoring or towing working
engine reaches a certain speed. condition, the fuel is cut off to reduce the
fuel consumption and exhaust emission,
Once the engine starts, the system will and the most important is to protect the
reduce the cranking enrichment until the three-way catalytic converter.
cranking enrichment is cancelled when
the starting is completed; After the engine Once the speed decreases to a specified
speed exceeds a limit value (for example speed above the idle speed, the injection
1,200 rpm), the injection timing will be system will supply fuel again. After the
changed to inject around the injection is restored, the torque-based
compressors top dead center. control system will increase the engine
110
torque slowly and stably (stable The target of λ closed loop control is to
transition). ensure the mixture concentration is within
the range.
2.3.4 Idle Control
The λ closed loop control system can
When idling, the engine does not provide function only when equipped with oxygen
torque to the flywheel. To ensure the sensor. The oxygen sensor monitors the
stable operation of engine at the lowest oxygen content in the exhaust at the
idle speed, the closed loop idle control position of three way catalytic converter.
system must maintain the balance The lean mixture (λ>1) will generate a
between the generated torque and engine sensor voltage of about 100 mV, and the
"power consumption". Certain amount of rich mixture (λ<1) will generate a sensor
power must be generated when idling to voltage of about 800 mV. When λ=1, the
meet various load requirements. They sensor voltage will have a step transition.
come from the engine crankshaft, valve The λ closed loop control will modify the
mechanism and ancillary components, control variable in response to the input
such as the internal friction of water signals (λ>1=thin mixture, λ<1=rich
pump. mixture), and generate the correction
factor as multiplier to correct the injection
The torque-based TB10 system control duration.
strategy confirms the engine output
torque required to maintain the desired 2.3.6 Evaporative Emission Control
idle speed in any working condition
according to the closed loop idle control. Due to the delivery of external radiation
The output torque increases as the heat and oil return heat, the fuel in the
engine speed decreases, and decreases fuel tank is heated and the fuel vapor is
as the engine speed increases. The formed. The vapor containing large
system responds to the new "interference amount of HC cannot be discharged to
factors" by demanding larger torque, such the atmosphere due to limit of
as ON/OFF of air conditioning evaporative emission regulations. In the
compressor and ON/OFF of the power system, the fuel vapor is collected in the
steering, etc. When the engine charcoal canister through the duct, and
temperature is low, the torque must be then purged and burned in the engine at
increased to compensate more internal the proper time. The purge air flow can be
friction loss and/or maintain higher idle achieved through the charcoal canister
speed. The total of output torque control valve controlled by ECU.
demands is transferred to the torque
coordinator, and the charge density, 2.3.7 High Pressure Fuel Pump Control
mixture content and ignition timing are
calculated by the torque coordinator. During the closed loop control of
high-pressure fuel pressure, the TB10
2.3.5 λ Closed Loop Control system adjusts the fuel pressure control
valve according to the preset MAP and
The exhaust post-processing in the performs closed loop correction via the
three-way catalytic converter is an high-pressure fuel rail pressure sensor to
effective method to reduce the match the current fuel pressure with the
concentration of harmful substance in the engine load.
exhaust. The three-way catalytic
converter can reduce the hydrocarbons The high pressure fuel pump is a
(HC), carbonic oxide (CO) and nitrogen mechanical pump which is driven by the
oxides (NOx) by 98% or more, and camshaft. The volume of fuel flowing into
convert them to water (H2O), carbon the high pressure fuel pump can
dioxide (CO2) and nitrogen (N2). The controlled by the fuel pressure control
high efficiency can be reached only when valve, thus achieving a stable fuel
the engine excess air ratio λ is about 1. pressure in the high pressure fuel rail;
111
The pressure limiting valve is integrated 2.3.11 Turbocharger Cooling System Control
in the high pressure fuel pump. When the
fuel pressure exceeds a preset value (for The heat is accumulated severely in the
example 200 bar), it will achieve turbocharger as it is exposed in the hot
mechanical pressure relief and send the environment for a long time. After the
fuel back to the low pressure fuel line. engine stops, the mechanical water pump
also stops to cool down the turbocharger
2.3.8 Boost Pressure Limiting Control for effective protection.
The torque model based TB10 system The system has the function to delay the
performs pulse width control on the boost power-off of electronic water pump. After
pressure limiting valve and adjusts the the engine stops, the electronic water
exhaust gas amount flowing through the pump will operate continuously for a while
turbo according to the current engine (for example, 8 min) to ensure the heat
speed and load demands. Therefore the dissipation and protection of
intake boost pressure is effectively turbocharger.
controlled to meet the demands of current
torque. 2.4 Introduction of System Trouble
Diagnosis Function
2.3.9 Boost Air Circulation Control
The on-board diagnosis system (OBD
When the boost pressure increases system for short) is integrated in the
suddenly due to rapid change of engine engine control system and monitors the
working conditions or other factors, TB10 faulty components affecting the exhaust
system will control the air circulation emission and the status of main engine
solenoid to enable the air continuity function. It can recognize, store and
before and after boosting and keep the display the trouble information through
pressure balance. the self-diagnosis malfunction indicator
lamp (MIL).
The control can effectively avoid
generating air noise and causing damage To ensure the durability of emission
to the impeller during fuel recovery, and it control performance during the use of
can also prevent the motoring brake or vehicle, China has clearly defined that "All
component damage caused by high the vehicles must be equipped with the
backpressure in the pressure cavity. on-board diagnosis (OBD) system which
can recognize the parts degradation or
2.3.10 Variable Intake Phase Control malfunction during the whole life cycle of
vehicle" in the "Limits and measurement
The torque model based system matches methods for emissions from light-duty
the current intake phase with the optimal vehicles (Chinese Phase IV)".
intake phase map according to the
current engine speed, load and OCV When repairing the vehicle with the OBD
solenoid control. Meanwhile, the intake system, the service personnel can locate
phase control and camshaft signal form the trouble area quickly and accurately
the closed loop control so as to ensure with the diagnostic tester, thus
the system control progress. significantly improving the repair
efficiency and quality.
The variable intake phase system can
effectively balance the fuel efficiency The OBD technique involves many
converted by the high and low speed of brand-new concepts. Some basic
engine and output performance to information about the OBD technique will
maximize the performance of complete be introduced first as so to better
vehicle. understand the follow-up contents.
112
2.4.1 Record Trouble Information control unit will store the trouble
information in the malfunction memory of
The electronic control unit constantly RAM. The trouble information is stored in
monitors the sensor, actuator, related the form of DTCs, and displayed in the
circuits, fault indicator, battery voltage order of trouble occurrence.
and even the electronic control unit itself,
and detects the reliability of output sensor The malfunctions can be divided into
signal, actuator drive signal and internal "steady state malfunction" and
signal (for example, λ closed loop control, "occasional malfunction" (caused by
coolant temperature, idle speed control temporary open circuit of wire harness or
and battery voltage control, etc.). Once poor contact of connectors) based on the
the trouble is found in a cycle or some occurrence frequency.
signal value is not reliable, the electronic
Fig. 2.4 Schematic Diagram of Electronically Controlled Injection System Trouble Diagnosis
2.4.2 Malfunction Indicators Description and MIL will turn off.

Control Strategy
2.4.2.3 When there is demand to illuminate
Malfunction indicator light (MIL): It the MIL in the malfunction memory or
indicates the components or system there is demand to illuminate the MIL
failure related to the emission as outside the ECU, the MIL will turn on.
specified by regulations. MIL is usually an
indicator light which can display on the 2.4.2.4 When there is demand to flash the MIL
dashboard and its shape meets the outside the ECU, due to fires or in the
requirements of regulation standards. malfunction memory, the MIL will flash
with the frequency of 1 Hz.
MIL is activated following the rules below:
SVS light: SVS light is a malfunction
2.4.2.1 When the ignition switch is turned on indicator set by the complete vehicle
(without starting), MIL will remain on. manufacturer for repairing the vehicle.
EOBD regulation does not clearly define
2.4.2.2 If there is no demand to illuminate the its shape and activation rules.
MIL in the malfunction memory 3
seconds after the engine is started, the SVS light control strategy is based on the
113
definition of complete vehicle diagnostic test device.

manufacturer. When the ignition key is
turned to ON, the operations of SVS light
are as follows under different modes:
2.4.2.4.1 Under normal mode, the

malfunction memory is empty
When the ignition switch is turned to

ON, the ECU will perform initialization
at once. The SVS light will turn off 2.4.4.2 Turn on the "ignition switch" or power
after being on for 4 seconds since the up the vehicle with push-start function.
initialization. If the engine is started
within the 4 seconds, the SVS light will
turn off immediately when the engine
speed is detected.
2.4.2.4.2 Under normal mode, the

malfunction has been stored in the
memory
2.4.4.3 Read the malfunction related
When the ignition switch is turn to ON, information (DTC, Freeze Frame, etc.);
the SVS light remains on. After the
engine is started, if the malfunction in Look up the repair manual to confirm the
the memory requires the SVS light to malfunction component and type, and
illuminate under the malfunction mode, formulate the maintenance plan
the SVS light will turn on in the according to the malfunction related
subsequent driving cycle; If the information and experience.
malfunction in the memory does not
require the SVS light to illuminate
under the malfunction mode, the SVS
light will turn off after the engine
speed is detected.
2.4.3 Four Malfunction Types
Type A malfunction: The signal exceeds 2.4.4.4 Repair the malfunction.

the upper limit of normal range.
Type B malfunction: The signal exceeds

the lower limit of normal range.
Type C malfunction: No signal.

Type D malfunction: The signal is
irrational.
2.4.4.5 Clear the malfunction memory; Run
2.4.4 Steps for Malfunction Overhauling
the vehicle in a proper way with the
requirements for malfunction diagnosis
For vehicles with OBD function, the
satisfied; Read the malfunction
following malfunction overhauling steps
information and make sure the
should be observed:
malfunction has been repaired.
2.4.4.1 Connect the diagnostic test device to
the diagnostic interface and power on the
114
2.4.5.1.3 Electronic throttle valve position

sensor signal voltage, coolant
temperature sensor signal voltage,
intake temperature sensor signal
voltage, intake pressure sensor signal
voltage.
2.4.5 Diagnostic Tester Connection
2.4.5.2 ECI System Status Display
The system uses "CAN" line
communication protocol and ISO 9141-2 Anti-theft system status, safety status,
standard diagnostic plug as shown in programming status, cooling system
figure 2.5. The standard diagnostic plug is status, steady working condition, dynamic
securely connected to the engine wire working condition, emission control status,
harness. Pin No. 4, 6, 14 and 16 on the oxygen sensor status, malfunction
standard diagnostic plug are used in the indicator status, emergent working
engine management system (EMS). Pin condition, air conditioning system status,
No. 4 of standard diagnostic plug is automatic transmission/torque request
connected to the ground wire of vehicle; status.
Pin No. 6 and 14 are connected to pin No.
101 and 109 of ECU, i.e. the engine data 2.4.5.3 Actuator Test Function
"CAN" line; Pin No. 16 is connected to the
battery positive. Malfunction indicator, fuel pump, air
conditioning relay, fan, ignition, injection
(single cylinder fuel cutoff).
2.4.5.4 Odometer Display
Driving range, driving time
2.4.5.5 Version Information Display

Fig. 2.5 ISO9141-2 Standard Diagnostic Plug
Vehicle Identification Number (VIN), ECU
hardware number, ECU software number.
The ECU can communicate with the
external diagnostic tester via the "CAN"
2.4.5.6 Malfunction Display
line and perform the following operations:
Intake pressure sensor, intake
(For the functions and diagnostic tester
temperature sensor, engine coolant
operation, refer to "BYD ED400
temperature sensor, electronic throttle
Diagnostic Tester Instructions")
valve position sensor, oxygen sensor,
oxygen sensor heating circuit, injector of
2.4.5.1 Engine Parameter Display
each cylinder, fuel pump, speed sensor,
phase sensor, charcoal canister control
2.4.5.1.1 Speed, coolant temperature,
valve, vehicle speed signal, idle speed,
electronic throttle valve opening,
system voltage, malfunction indicator.
ignition advance angle, intake boost
pressure, intake boost temperature,
vehicle speed, system voltage, 2.5 System Features
injection correction, charcoal canister
purge rate, oxygen sensor waveform, Multi-point sequential in-cylinder direct
etc. injection system;
2.4.5.1.2 Target speed, intake air flow, Engine function structure with torque as
fuel consumption, etc. variable;
115
Cylinder identification signal is used

(phase sensor);
The signal disc identification speed

signals of 60-2 teeth are used (speed
sensor);
The electronic throttle valve control is
used;
The closed loop control of idle speed

torque is achieved;
With function to heat and protect the

catalyst;
With Limp Home function;
With boost protection function;
With turbocharger power-off delay

function.
116
Section 3 Structure, Theory and Trouble Analysis of TB10 System

Components
3.1 Intake Pressure/Temperature Sensor
The TB10 system uses two intake

pressure/temperature sensors which
are intake pipe pressure/temperature
sensor and intake manifold
pressure/temperature sensor. The
range value of intake
pressure/temperature sensor is 30 kPa
to 40 kPa.
 Sensor diagram and electrical

schematic diagram:
Fig. 3-2 Electrical Schematic Diagram of

Intake Pipe Pressure/Temperature Sensor
Fig. 3-1 Intake Pressure/Temperature

Sensor Diagram

Intake Manifold Pressure/Temperature
Sensor
 Pin definition:
Ground
Output temperature signal
To 5 V power
Output pressure signal
117
3.1.1 Installation Position micrometers (μm), so the change of

absolute intake pressure will cause the
The intake pipe pressure/temperature mechanical deformation of silicon chip. 4
sensor is installed in the intake pipe in piezoelectric resistors also deform and
front of the electronic throttle valve which their resistance values change. The
is behind the turbocharger. voltage signals in linear relation with
voltage will be generated after the
The intake manifold pressure/temperature treatment of signal processing circuit of
sensor is installed in the intake pipe silicon chip. The intake temperature
behind the intercooler. sensing element is a resistor of negative
temperature coefficient (NTC) which
3.1.2 Operation Theory changes with the intake temperature. The
sensor will send a voltage signal
The intake pressure/temperature sensor indicating the intake temperature change
is consisted of absolute pressure sensing to the controller.
element and temperature sensing
element. The absolute pressure sensing
element consists of a silicon chip. A
pressure diaphragm is etched on the
silicon chip. The pressure diaphragm has
4 piezoelectric resistors which form a
Wheatstone bridge as variable
components. In addition to the pressure
diaphragm, the signal processing circuit is
also integrated in the silicon chip. The
silicon chip forms a closed reference
space with a metal housing, and the
absolute air pressure of the reference
space is close to 0. Thus a
microelectronic mechanical system is
formed. The active surface of silicon chip Fig. 3-4 Cross Section of Intake
is subject to a pressure of nearly 0, and Pressure/Temperature Sensor
its back is subject to an absolute intake
pressure introduced by a tube. The
thickness of silicon chip is only several
3.1.3 Technical Parameters
3.1.3.1 Data Limit
Parameter Value Unit

Power voltage 16 V
Pressure 500 kPa
Operation temperature -40/+130 C
3.1.3.2 Performance data of pressure sensor
Value
Parameter Unit
Min. Typical Max.
Pressure Test Range 10 250 kPa
Operation temperature -40 130 C
Power voltage 4.75 5.0 5.25 V
Power supply current for US=5.0 12.5 mA
V
118
3.1.3.3 Data limit of temperature sensor throttle valve.
Storage temperature: -40/+13 3.1.4.5 In addition to the influence of main

component connectors, the reliable
3.1.3.4 Performance data of temperature contact of connectors is also related to
sensor the material quality and dimension
precision of the connectors connected
Operating temperature: -40/+130°C to the wire harness. Therefore, the
connectors that are specified on the
Rated resistance at 20°C: 2.5 k ± 5% vendor drawing and comply with the
product specifications provided by the
3.1.3.5 Characteristic Curve of Temperature manufacturer must be used.
Sensor
3.1.4.6 The maximum diameter of set screws
in the mounting holes is 6 mm.
3.1.4.7 Use the gasket with the minimum

diameter of 10 mm or its diameter
equivalent to that of a screwhead.
3.1.4.8 The allowed maximum torque for

installing the set screws is 4.5 Nm.
Temperature T
3.1.5 Trouble Symptoms and Judgment
Method
Fig. 3-5 Characteristic Curve of Temperature 3.1.5.1 Trouble symptoms: misfire, poor idling,
Sensor R=f (T) etc.
3.1.4 Precautions for Installation General trouble cause: 1. Abnormal high
voltage or reverse high current during use;
3.1.4.1 The sensor must be installed on the 2. The vacuum components are damaged
surface of intake pipe in the engine. The during repair.
pressure tube and temperature sensor
are inserted into the intake pipe together 3.1.5.2 Precautions for repair: Never impact
and isolated from the atmosphere via the vacuum components with
O-ring. high-pressure air during repair. When
the sensor is replaced due to
3.1.4.2 The sensor must be installed in a malfunction, check if the output
correct way (extract pressure from the voltage and current of generator are
intake manifold, the pressure tube tilts normal.
down, etc.) to ensure the condensate
water will not accumulate in the 3.1.5.3 Simple measurement method:
pressure sensing components.
-- Temperature Sensor: (With the
3.1.4.3 The drilling and fixing of intake connector removed) Turn the digital
manifold must be designed according to multimeter to Ohms range, and connect
the vendor drawing to ensure long-term two probes to Pin No. 1 and 2 of sensor
tightness and corrosion resistance at the respectively. The rated resistance at
base of interface. 20°C is 2.5 kΩ±5%, and the other
resistance values can be measured
3.1.4.4 The back pressure may cause according to the above characteristic
measuring error; therefore the sensor curve. The simulation can be used when
should not be installed behind the measuring. The specific method is to
119
blow the sensor with a hair drier (Do not

get too close) and observe the change of
sensor resistance. At this time the
resistance should drop.
-- Pressure Sensor: (With the connector

connected) Turn the digital multimeter to
DC voltage range, connect the black
probe to ground and connect the red
Fig. 3-6 Coolant Temperature Sensor
probes to pin No. 3 and 4. Under the
Diagram
idling condition, pin No. 3 should have a
reference voltage of 5 V, and the voltage
of pin No. 4 is about 1.3 V (The specific
values are related to the models); Under
the unloaded state, the voltage of pin No.
4 has little change when the throttle
valve is slowly opened; When the throttle
valve is opened quickly, the voltage of
pin No. 4 can reach about 4 V
immediately (The specific values are
related to the models) and then it
decreases to about 1.5 V (The specific
values are related to the models).
3.2 Coolant Temperature Sensor
In the TB10 system, two coolant

temperature sensors of the same type are
installed at the engine water outlet and
radiator water outlet respectively.
 Sensor diagram and electrical schematic

diagram
Fig. 3-7 Electrical Schematic Diagram of Fig. 3-8 Electrical Schematic Diagram of
Engine Coolant Temperature Sensor Radiator Outlet Coolant Temperature
Sensor
 Pin definition:
120
3.2.1 Installation Position
The engine coolant temperature sensor is

installed on the engine coolant outlet, and
the radiator outlet coolant temperature
sensor is installed on the radiator water
outlet.
3.2.2 Operation Theory

Fig. 3-10 Schematic Diagram of Fluid Level
The coolant temperature sensor is a
thermistor with negative temperature 3.2.5.2 Insert the sensor into the mounting
coefficient (NTC), and its resistance will hole and fix it with special snap-fits. The
decrease with the increase of coolant allowed maximum torque for the plastic
temperature, but not in linear relation. part of sensor and bronze housing is 2
N.m. Therefore, do not twist the plastic
3.3.3 Characteristic Curve of Sensor part of the sensor during installation.
3.2.5.3 In the circuit powered by a voltage of 5

V, both terminals of the sensor should be
connected to the pull-up resister with
R≥1 kΩ to prevent the self-heating of
thermistor from affecting the
measurement results. No pull-up resister
or low resistance will cause the
measuring error, and even damage to
the sensor.

Method
 Trouble symptom: Difficult to start.
Fig. 3-9 Characteristic Curve of Coolant  General trouble cause: Human failure.
Temperature Sensor
 Simple measurement method: (With the
3.2.4 Performance Parameter connector removed) Turn the digital
multimeter to the Ohms range, and
3.2.4.1 Power: The allowed power at connect two probes to Pins No. 1 and 2
both ends is 0.075 W (25°C). of the sensor respectively. The rated
resistance at 25°C is 1.825-2.155 kΩ,
3.2.4.2 Operation temperature: and the other resistance values can be
-40°C~+130°C measured according to the above
3.2.5 Precautions for Installation characteristic curve. The simulation can
be used when measuring. The specific
3.2.5.1 The sensor should be installed in a method is to put the sensor working area
position where the flow rate of cooling in the hot water (The soak time should
water is high and the water temperature be sufficient) and observe the change of
can be correctly detected. Make sure the sensor resistance. At this time the
fluid level is at least 10 mm higher than resistance should drop to below
the bottom surface as shown in figure 300Ω-400Ω (The specific values depend
3-10 so that the sensor can detect the on the temperature of hot water).
correct cooling water temperature in a
short response time.
121
3.3 Oxygen Sensor
The upstream oxygen sensor and

downstream oxygen sensor used in the
system are of the same type.
 Sensor Diagram

Downstream Oxygen Sensor
 Pin definition:
Fig. 3-11 Oxygen Sensor Diagram
 Electrical Schematic Diagram
The upstream oxygen sensor is installed

in front of three way catalytic converter on
the exhaust pipe. The change times are 4
or more every 10 seconds and the
voltage variation range is 0 to 900 mV
during idling.
The downstream oxygen sensor is

installed at the rear of three way catalytic
converter on the exhaust pipe. The
voltage variation range is 0~1 V during
Fig. 3-12 Electrical Schematic Diagram of idling.
Upstream Oxygen Sensor
The LSF oxygen sensor used in the

system is planar type oxygen sensor
which is developed based on the LSH
(finger type oxygen sensor). LSF stacks
up each functional layer (such as internal
and external electrodes, heating
components) with the screen printing
technique to form a sheet. The core
element of oxygen sensor is ZrO2
122
electrolyte which can ionize the oxygen at If the mixture is thin, the difference of
high temperature to generate the oxygen oxygen ion concentration inside and
ion. Its structure is shown in figure 3-14. outside the ceramic tube is low and the
One side of ceramic tube leads to the potential difference is too low. Few
exhaust gas of exhaust manifold and the oxygen ions move from inside to outside
other side leads to the atmosphere. As and the output voltage is low (close to
the oxygen concentration at both sides 100 mV). The sudden change of signal
differs greatly, the potential difference (i.e. voltage occurs around the theoretical
signal voltage) will be generated between equivalent air-fuel ratio (λ=1) as shown
the inside and outside of tube wall when below.
the ionization occurs.
Sensor Voltage
1 Wire
2 Protective Sleeve
3 Planar Sensing Component
4 Wire
5 Sensor Base λ<1: Rich mixture (Insufficient oxygen)
6 Seal Ring λ>1: Lean mixture (Excessive oxygen)
7 Double Layer Protection Tube
Fig. 3-15 Characteristic Curve of Oxygen
Fig. 3-14 Structural Diagram of Oxygen Sensor Voltage at 600°C
Sensor
3.3.3 Communication with ECU
If the mixture is rich, the difference of
oxygen ion concentration inside and Parameter Condition Min. Max. Unit
outside the ceramic tube is high and the Working
Input voltage 0 1 V
potential difference is too high. Large voltage
amount of oxygen ions move from inside Reference Open
420 480 mV
to outside and the output voltage is high voltage circuit
(close to 800 mV-1000 mV);
123
(1) Electric Data of Sensor

Performance Measured Value Value Unit
Rated Rated resistance of cold heater for new sensor including 9 
resistance the cable and connector under the room temperature
Heater Rated voltage 12 V
power Continuous operating voltage 12 to 14 V
supply Maximum power supply voltage of system 16.5 V
(2) Service Conditions

Measured Value Value Unit
Min. Max.
Storage temperature -40 100 C
Exhaust temperature 150 930 C
(Recommended)
Operation Housing hexagon head 570 C
temperature
Cable and protective sleeve 250
Connector 120 C
Allowed fuel additive Lead free fuel or low lead fuel
Oil consumption and combustion Standard value: 0.7L/1000km
(3) Service life of leaded fuel sensor

Lead content of gasoline (g/L) Life (km)
0.6 20000
0.4 30000
0.15 60000
3.3.5 Precautions for Installation 3.3.5.1.4 The independent guiding tube is

usually regarded as the ideal mounting
3.3.5.1 Standards for Mounting Point point. If there is any doubt, perform the
Selection comparison test of tube heating
performance to demonstrate the fact.
Under the allowed operation temperature
of sensor, the mounting points of sensor 3.3.5.1.5 For the mounting points that cannot
should be selected following the rules be selected as specified, the system
below: calibration engineer will perform more
tests on the ceramic thermal shock and
3.3.5.1.1 Get close to the engine as much as take proper protective measures.
possible.
3.3.5.2 Recommended installation plan and
3.3.5.1.2 Tilt down the exhaust pipe so that the requirements
condensate water will not accumulate in
the upstream of mounting points. The 3.3.5.2.1 The oxygen sensor should be
exhaust pipe in front of the mounting installed with an angle of 10 degrees or
points should not have pits, bulges and more with the horizontal surface (The
sharp edges. electronic connector faces upward) so as
to prevent the condensate water from
3.3.5.1.3 The mounting points should not be accumulating between the housing and
positioned on the underside of exhaust ceramic part of sensor as shown in figure
pipe which will get wet first. 3-16.
124
changes suddenly, and the probe is

broken; 2. The oxygen sensor is
"poisoned". (Pb, S, Br, Si)
 Failure judgment:
Fig. 3-16 Installation Plan for Oxygen Sensor 3.3.6.1 Check with diagnostic tester
The engine malfunction indicator is
3.3.5.2.2 Recommended material for the turned on to indicate the malfunction in
thread of exhaust pipe: Heat resistant the engine system, and the diagnostic
stainless steel, such as X 5 CrNi 18 9 DIN tester should be used to diagnose the
17440 1.4301, 1.4303 SAE30304 or SAE malfunction.
30305 (American standard). Note the
thread of sensor must be covered Use the diagnostic tester specified by the
completely. assembly plant to communicate with the
electronically controlled injection system
3.3.5.2.3 The protection tube of sensor should ECU and read the trouble data in the
be inserted into the exhaust gas as much ECU so as to judge the oxygen sensor
as possible, but the hemming of protection failure.
tube should not face the hot exhaust gas
directly. Make sure the protection tube of 3.3.6.2 Simple inspection method for electrical
sensor does not contact the opposite side performance:
of exhaust pipe. When it is installed at the
connection of exhaust manifold and twin - (With the connector removed) Turn the
tube, the materials with minimum digital multimeter to Ohms range, and
deformation to high temperature should be connect two probes to the Pins at both
selected. terminals (+) and (-) of the sensor heater
respectively. Under normal temperature,
3.3.5.2.4 The tightening torque for the oxygen its resistance is 9 Ω.
sensor is 40 to 50 Nm. The following
specified mounting grease should be used: -- (With the connector connected) Under
BOSCH material No. 5964080112 (120 the idling condition, when the operating
g/tank) or 5964080145 (450 g/tank). The temperature of oxygen sensor reaches
other mounting greases will cause oxygen 350°C, turn the digital multimeter to DC
sensor poisoning. voltage range and connect two probes to
the ground signal pin and positive signal
3.3.5.2.5 During mass production, ensure the pin of sensor respectively. At this time
design of exhaust pipe system meets the the voltage should fluctuate quickly
geometric accuracy and airtight between 0.1~0.9 V.
requirements for installation.
-- Shake the oxygen sensor near your ear.
3.3.5.2.6 The tool needed for removal is the If the abnormal noise can be heard, the
wrench M22. After the removal, clean the internal ceramic probe may be broken.
mounting surface and make sure no oil
exists. 3.4 Crankshaft Position Sensor
3.3.6 Trouble Symptoms and Judgment The crankshaft position sensor is
Method integrated with an auxiliary seal ring as
shown in figure 3-17. The crankshaft
 Trouble symptom: poor idling, poor position sensor, seal ring and signal
acceleration, tail gas exceeds standard, wheel should be assembled as shown in
high fuel consumption, etc. figure 3-18.
 General trouble cause: 1. The moisture  Diagram of Sensor and Seal Ring
enters the sensor, the temperature
125
Fig. 3-17 Diagram of Crankshaft Position

Sensor and Seal Ring Fig. 3-18 Crankshaft Position Sensor,
Seal Ring and Signal Wheel
 Sensor and Signal Wheel
 Electrical Schematic Diagram installed on the crankshaft and rotates

with the crankshaft. The signal wheel
has 60 teeth with 2 missing teeth. When
the teeth on the signal wheel pass the
Hall sensor, the magnetic field in the
Hall sensor will change so that the
output signal voltage changes. The
ECU can recognize the top dead center
of each cylinder, calculate the crank
angle and obtain the engine speed
based on the pulse signal of each tooth
Fig. 3-19 Electrical Schematic Diagram of and missing-tooth signal.
Crankshaft Position Sensor
3.4.3 External Circuit Diagram of Sensor
 Pin definition:
On the surface of the signal wheel at

the crankshaft back end cap Fig. 3-20 External Circuit Diagram of
The crankshaft position sensor is a Hall

Effect sensor. The signal wheel is
126
3.4.4 Electrical Performance Parameter of Sensor
Parameter Min. Typical Max. Unit

Power supply voltage 4.2 5 17 V
Output voltage (High) 4.2 5 V
Speed 30 8000 rpm
3.4.5 Limiting Temperature of Sensor
Limiting temperature in 100 h: 160°C
Temperature range: -40°C-150°C
3.4.6 Pulse Signal Diagram of Crankshaft Teeth
Fig. 3-21 Pulse Signal Diagram of the Crankshaft Teeth
3.4.7 Trouble Symptoms and Judgment ignition switch, but do not start the
Method engine. Turn the digital multimeter to
DC voltage range, and connect two
3.4.7.1 Trouble symptom: The engine is probes to pin 1 and 3 of sensor
unable to start. respectively. Make sure there is a
reference voltage of 5 V. When the
3.4.7.2 General trouble cause: Human failure. engine is started, check if the signal of
pin No. 2 is normal with an
3.4.7.3 Simple measurement method: (With oscilloscope.
the connector connected) Turn on the
127
3.5 Phase Sensor
 Sensor Diagram
Camshaft end
The phase sensor is also a Hall Effect

sensor. The signal wheel is installed on
the camshaft and rotates with the
camshaft. The signal wheel has 2 small
teeth and 2 big teeth as shown in figure
3-24. When the teeth on the signal
wheel pass the Hall sensor, the
Fig. 3-22 Phase Sensor Diagram magnetic field in the Hall sensor will
change so that the output signal voltage
 Electrical Schematic Diagram of Sensor changes.
The compressors top dead center of

cylinder 1 can be determined by
combining the phase sensor signal and
crankshaft position sensor signal. In
addition, the phase sensor signal can
be used to adjust the feedback of
variable valve timing (VVT) so that the
intake phase is controlled more
accurately.

Phase Sensor
 Pin definition:
Fig. 3-24 Signal Wheel of Phase Sensor
128
3.5.3 Circuit Diagram and Electrical Performance Parameter of Sensor
Sensor
Parameter Symbol Status Min. Typical Max. Unit

Power supply
Vcc 4.5 5 12 V
voltage
Power supply
Icc Off 3 15 mA
current
Output voltage Vout On 0.5 V
3.5.4 Signal Diagram
In the above figure, OP (Operating Point) refers to the falling edge of electrical signal and RP
(Release Point) refers to the rising edge of electrical signal.
Fig. 3-25 Signal Diagram

Method
129
 Trouble symptom: The emissions exceed

the standards, the fuel consumption  Pin definition
increases, VVT cannot be normally
adjusted.
 General trouble cause: Human failure.
 Simple measurement method:
(With the connector connected) Turn on

the ignition switch, but do not start the
engine. Turn the digital multimeter to DC 1- Terminal A of knock sensor
voltage range, and connect two probes
to pin 1 and 3 of sensor respectively. 2- Terminal B of knock sensor
Make sure there is a reference voltage of
5 V. When the engine is started, check if
the signal of pin No. 2 is normal with an 3.6.1 Installation Position
oscilloscope.
3.6 Knock Sensor On the engine block between cylinder 2

and 3.
 Sensor Diagram
The knock sensor is enclosed in a

piezoelectric ceramics (Figure 3-28)
which has piezoelectric effect. When the
engine load, speed and water
temperature exceed the threshold and the
knock sensor does not record a
malfunction, the engine enters the knock
closed loop control .When the engine
knock occurs, the sensor will output a
voltage with higher amplitude and
frequency than that generated when no
knock occurs. It is output to the ECU after
Fig. 3-26 Knock Sensor Diagram
proper filtration and amplification.
 Electrical Schematic Diagram of Sensor
The ECU integrates the knock signal.
When the integral value within certain
crank angle exceeds the threshold, the
ECU determines the engine is in knocking
condition and reduces the ignition
advance angle by certain angle. If the
knock reoccurs in the next cycle, the
ignition advance angle will be reduced by
certain angle again until the engine knock
does not occur. Then the ignition advance
angle will be restored to the normal value
gradually.

Knock Sensor
130
Fig. 3-28 Structural Diagram of Knock Sensor

Frequency
3.6.3.1 Characteristic Curve

Fig. 3-29 Characteristic Curve
3.6.3.2 Data Limit

Items Value Unit
Min. Typical Max.
131
3.6.4 Precautions for Installation

 When the engine is running, the engine
malfunction indicator is turned on to
a When selecting the mounting points on indicate the malfunction in the engine
the engine, the requirements for system.
temperature range and vibration level
should be met.  Repair the short or open circuit in the wire
harness system.
b The planeness, perpendicularity and
surface fineness must be ensured and  Simple judgment method: Disconnect the
the operating requirements for the wire harness, turn the digital multimeter to
output signal of sensor must be met Ohms range and connect two probes to
when machining the mounting surface pin No. 1 and 2 of sensor respectively.
and mounting hole. Under normal temperature, its resistance
should not be higher than 1 MΩ. Turn the
c When selecting the mounting points, the digital multimeter to Millivolts range, and
sensor should not be exposed in the tap the cylinder block around the sensor
gasoline, antifreeze solution, oil or brake with a hammer. At this time the sensor
fluid. should output the voltage signal.
d The dimension of mounting screw is M8.
e The tightening torque for installation is 3.7 High-pressure Fuel Pressure Sensor
20±5 Nm.
3.6.4.2 The installation position of knock a Sensor Diagram
sensor should meet the following
requirements:
3.6.4.1 The knock sensor is usually installed

under the cylinder head gasket (about
2/3 of stroke), i.e. close to the
combustion chamber. (In some cases,
the knock sensor can be installed at the
lower position of engine cylinder wall
close to the suspension point of engine
to ensure the vibration of combustion
chamber can be preferably delivered to
the knock sensor.)
Fig. 3-30 High-pressure Fuel Pressure Sensor
3.6.4.2 Considering the heat resistance of Diagram
wire harness, the knock sensor must be b Electrical Schematic Diagram of Sensor
installed to the cold side of engine
(Intake side for counter flow type engine,
free side for U flow type engine).
3.6.4.3 The knock sensor must be installed

symmetrically to ensure the distance
between the knock sensor and each
cylinder is the same.

Method
Fig. 3-31 Electrical Schematic
 Poor acceleration occurs when the
engine is running. Diagram of High-pressure Fuel Pressure
132
Sensor 3.7.2 Operation Theory
c Pin definition There is a steel diaphragm inside the

high-pressure fuel pressure sensor. A
Wheatstone bridge is formed by the strain
1-Ground measurement elements on the pressure
2-Signal diaphragm. When there is fuel pressure in
3-Power the fuel rail, the deformation of diaphragm
supply will occur which is measured by the
Wheatstone bridge. The measured
deformation signal is in proportion to the
3.7.1 Installation Position fuel pressure. The integrated signal
processing circuit will process the signal
Fuel rail and output the fuel pressure signal the
ECU.
3.7.3.1 Operating characteristic
Parameter Symbol Value Unit

Min. Typical Max.
Fuel pressure range pn 0 14 MPa
20
26
Temperature range T -40 130 °C
Power supply voltage Us 4.75 5.00 5.25 V
3.7.3.2 Storage condition of sensor
Storage temperature: -30°C~+60°C;
Storage humidity: 0~80% rH;
Maximum storage time for new sensors:

5 years
3.7.3.3 Characteristic line
3.7.3.3.1 5 V characteristic line
The output voltage Uout of 5 V

characteristic line is shown in figure
3-32: Fig. 3-32 Output Voltage of Fuel Pressure
Function (5 V Characteristic Line)
3.7.3.3.2 V characteristic line
The output voltage Uout of 3.3 V

characteristic line is shown in figure 3-33:
133
3.7.4.7 The bolts should not be

contaminated by the fluid or other materials
during installation and transportation.
3.8 Accelerator Pedal Position Sensor
 Schematic Diagram of Sensor
Fig. 3-33 Output Voltage of Fuel Pressure

Function (3.3 V Characteristic Line)
3.7.4.1 The allowed maximum tightening

torque is 35 Nm;
3.7.4.2 Perform the installation according to

the provided parts drawing and make
sure no water is accumulated on the Fig. 3-34 Schematic Diagram of Accelerator
diaphragm; Pedal Position Sensor
3.7.4.3 The rotation direction of sensor a Electrical Schematic Diagram of Sensor
housing must be the same as that of fuel
pressure measuring port during
installation;
3.7.4.4 Tighten the fuel pressure sensor only

with the hexagon head on the sensor,
and the installer (such as socket wrench)
can be used only for the hexagon head;
3.7.4.5 The clearance between the hexagon

head and fuel rail of fuel pressure sensor
is specified as follows:
Thread Minimum clearance*, Port

Unit mm
M10×1 1.05 Conical
*Distance between the lower surface of

hexagon head and upper surface of fuel Fig. 3-35 Electrical Schematic Diagram of
rail Accelerator Pedal Position Sensor
3.7.4.6 Make sure the contaminant does not

enter or maintain in the fuel pressure
measuring port during installation;
 Pin definition
134
1- Accelerator pedal position sensor 2 power supply

2- Accelerator pedal position sensor 1power supply
3- Accelerator pedal position sensor signal 1
4- Accelerator pedal position sensor 1round
5- Accelerator pedal position sensor 1round
6- Accelerator pedal position sensor signal 2
3.8.1 Installation Position The ECU controls the idle speed,

acceleration and deceleration, and
The sensor is installed on the bearing interrupts the injection after receiving
seat of accelerator pedal. the signal from the accelerator pedal
position sensor.
The accelerator pedal position sensor

detects the position of accelerator pedal
and sends the signal to the ECU. The
accelerator pedal position sensor is a
contactless sensor with double
potentiometers. The circuit diagram of
potentiometer is shown in figure 3-36.
The ECU provides a voltage of 5 V to
the potentiometer. As 2 potentiometers
are installed in the same phase, the
resistance will increase or decrease
linearly when the position of electronic
accelerator pedal changes. 2
accelerator pedal position sensors send
2 voltage signals indicating the position Fig. 3-36 Circuit Diagram of Accelerator
of accelerator pedal to the ECU and the Pedal Position Sensor Potentiometer
sensor 1 voltage signal is 2 times of the
sensor 2 voltage signal. The ECU
calculates the torque demand expected
by the driver according to the signal and
controls the operation of electronic
throttle valve after the coordination in
the ECU.
135
Power supply voltage: UBi=5 V±10%; i=1, 2 Signal current: ISi, max≤50μA; i=1, 2
Power supply current: IBi≤10mA; i=1, 2 Short circuit protection: U=16 V; t=60 min
Nominal resistance:
Sensor 1 Sensor 2
Sensor resistance Rp1=1200±40% Rp2=1700±40%
Contact resistance and 1000±400≤RSi+RUi≤5000
dropping resistance (When operating for t>5 ms)
Limit value of sensor signal:
Sensor 1 Sensor 2
Minimum voltage 16.5 8.25
UAi/UBi*100/[%]
Maximum voltage <87.5 <43.75
UAi/UBi*100/[%]
Characteristic curve of sensor electrical signal:
Fig. 3-37 Characteristic Curve of Sensor Electrical Signal
3.8.4 Trouble Symptoms and Judgment sensor is faulty and should be

Method replaced.
a Trouble symptom: Difficult to start, 3.8.4.2 Check the power supply

unstable idling, poor acceleration. condition. Remove the connector at
the wire side from the accelerator
b Overhauling method: pedal position sensor and turn on
the ignition switch. Measure the
3.8.4.1 Turn on the ignition switch and voltages between pin 2 and 3, pin 2
fully depress the accelerator pedal and ground, pin 1 and 5 and pin 1
slowly. Without removing the and ground. All the voltages should
connector at the wire side, measure be higher than 4.5 V, otherwise the
the voltage between pin 3 and 4 of circuit or ECU may be faulty.
the sensor, pin 5 and 6 of the
sensor. Both voltages should 3.8.4.3 Check the wire harness
increase gradually and the sensor 1 condition. Turn off the ignition
voltage is always 2 times of the switch and remove the connector at
sensor 2 voltage. If the the wire side from the ECU.
requirements are not met, the Measure the resistance between the
136
Pins of the connector at wire side of

accelerator pedal position sensor
and the Pins of the connector at the
wire side of ECU, i.e. 1 and 97, 2
and 87, 3 and 8, 4 and 72, 5 and 48,
6 and 27. All the resistances should
not be higher than 1.5  (With
continuity). The resistance between
the wires should be ∞  (Without
continuity).
137
3.9 Electronic Control Unit
Electrical Schematic Diagram and Profile of Electronic Control Unit (ECU)
3.9.1 Electrical Schematic Diagram of Electronic Control Unit (ECU)
Fig. 3-38 Electrical Schematic Diagram of ECU
138
3.9.2 Profile
Fig. 3-39 Profile and Terminals of ECU
139

3.9.2.1.6 Boost control
At the battery side in the engine
compartment 3.9.2.1.7 Intake cam phase control
3.9.2 Operation Theory 3.9.2.1.8 Boost pressure protection Charcoal

canister control valve control Engine
3.9.2.1 Function malfunction indicator
3.9.2.1.1 Multi-point sequential in-cylinder 3.9.2.7.9 Fuel quantity correction

direct injection
3.9.2.7.10 Engine speed signal output
3.9.2.1.2 Ignition control
3.9.2.7.11 Vehicle speed signal input
3.9.2.1.3 Idle control
3.9.2.7.12 Trouble self-diagnosis
3.9.2.1.4 Provide power supply for sensors:
5V/100mA 3.9.2.7.13 Receive the engine load signal, etc.
3.9.2.1.5 λClosed loop control with

self-adaption
3.9.2.2 ECU Pin Definition:
Pin Connecting Point Type Pin Connecting Point Type

Fuel pressure control Upstream oxygen sensor
1 Output 62 Input
valve heating signal
2 Power Ground 1 Ground 63 Engine speed sensor Input
Non-continuous power Vehicle speed signal
3 Input 64 Input
supply 1 input
Electronic throttle valve
4 Output 65 Anti-theft input Input
motor control -
Intake pipe
5 Output 66 pressure/temperature Ground
motor control +
sensor ground
6 67
Coolant temperature
7 68 Ground
sensor ground
Radiator outlet coolant
Accelerator pedal position
8 Input 69 temperature signal Ground
sensor signal 1
ground
Intake pipe pressure High-pressure fuel
9 Input 70 Ground
sensor signal pressure sensor ground
Throttle position sensor
10 71 Ground
signal ground
Intake manifold Accelerator pedal
11 Input 72 Ground
temperature sensor position sensor 1 ground
Coolant temperature
12 Input 73
sensor at radiator outlet
Coolant circulation pump
13 Upstream oxygen sensor Input 74 Output
relay
14 Throttle position sensor 1 Input 75 Downstream oxygen Input
140
sensor heating signal

15 76 Engine speed output Output
16 77
17 78 Charcoal canister valve Output
18 Braking switch 2 Input 79 Stepless fan control Output
Electronic load 2 (Rear
19 Input 80
windshield heater switch)
CAN bus interface
20 81 OCV solenoid Output
CAN-H1
Turbocharger air
21 Output 82
circulation valve
Boost pressure limiting
22 Output 83
solenoid
23 84
24 85
25 86 Crankshaft sensor power Input
Accelerator pedal
26 87 position sensor 1 power Input
supply
Accelerator pedal position
27 Input 88 sensor power supply +5 Input
sensor signal 2
V
Intake manifold
Intake manifold pressure
28 Input 89 pressure/temperature Input
sensor
sensor power supply
High-pressure fuel
29 Input 90
pressure sensor
30 91
Engine coolant
31 Input 92
temperature sensor
Intake pipe gas
32 Input 93
temperature sensor
Intake pipe
Downstream oxygen
33 Input 94 pressure/temperature Input
sensor
sensor power supply
34 95 Sensor power supply 1 Input
35 Clutch switch Input 96 Sensor power supply 2 Input
Accelerator pedal
36 Braking switch 1 Input 97 position sensor 2 power Input
supply
Power assist steering
37 Input 98 Ignition signal 3 Input
switch
38 Engine feedback signal Input 99 Ignition signal 1 Input
CAN bus interface
39 100 Power Ground 2
CAN-L1
CAN bus interface
40 101 Input Output
CAN-L
41 Vehicle speed output Output 102 Main relay Output
42 103 Power Ground 3 Ground
43 Oil pump relay Output 104 Power Ground 4 Ground
44 Camshaft phase sensor Input 105 LIN line
141
Terminal B of knock
sensor
Terminal A of knock
sensor
47 Crankshaft sensor ground Ground 108 Power Ground 5 Ground
Accelerator pedal position CAN bus interface
48 Ground 109 Input Output
sensor 2 ground CAN-H
49 110
50 111
51 Electrical ground 1 Ground 112 Ignition switch Input
Continuous power
52 Throttle position sensor 2 Input 113 Input
supply
Intake manifold pressure
53 Ground 114 Injector 4 (Cylinder 4) Output
sensor signal ground
54 A/C request signal Input 115 Injector high side 1 Output
Upstream oxygen sensor
55 Ground 116 Injector high side 2 Output
ground
Downstream oxygen
sensor ground
Camshaft phase sensor
ground
Non-continuous power
58 Electrical ground 2 Ground 119 Input
supply 2
Electronic throttle valve Non-continuous power
59 Input 120 Input
motor control + supply 3
60 Input 121 Injector 2 (Cylinder 2) Output
motor control -
61 A/C permission signal Input
Note: The blank space is defined as N/A.
142
Parameter Limit
Items Value Unit
Min. Typical Max.
Battery Voltage 9.0 12 16.0 V
Operation Temperature -40 +105 C
Storage Temperature -40 +65 C
Product Quality 700 g
3.9.4 Precautions for Installation engine data CAN line;
3.9.4.1 Discharge the static electricity during 2. (With the connector removed) Check if
installation the ECU connecting wire is in good
condition and if the ECU power supply
3.9.4.2 Protect the Pins of connector and ground circuit are normal;
3.9.5 Trouble Symptoms and Judgment 3. Check if the external sensor operates
Method normally, the output signal is reliable and
the circuit is in good condition;
a Trouble symptoms: Poor idling, poor
acceleration, unable to start, high idle 4. Check if the actuator operates normally
speed, emissions exceed standards, and the circuit is in good condition;
difficult to start, air conditioner failure,
injector control failure, misfire, etc. 5 Replace the ECU and perform test;
b General trouble cause: 6. Self-learning must be performed after the

ECU is replaced (Wait for 1 min after the
1. The trouble is caused by the internal vehicle is powered ON.
parts burnout in ECU due to electric
overload of external devices; 3.10 Low Pressure Fuel Pump
2. The circuit board is corroded as the
water enters ECU. Diagram and Pin
c Precautions for repair:
3.9.4.1 Do not remove ECU randomly during

repair;
3.9.4.2 Remove the battery terminal for more

than 5 minutes before the ECU is
removed;
3.9.4.3 Properly store the ECU after removal;

Fig. 3-40 Power Fuel Pump
3.9.4.4 Never connect any circuit to the
connecting wire of ECU. Pin: The power fuel pump has two Pins which
are connected to the oil pump relay. The
d Simple measurement method:
symbols "+" and "-" are carved on the oil
pump housing besides the two Pins to indicate
1 (With the connector connected) Read the
the positive and negative terminals.
engine malfunction record with the
143
the relay will energize the power fuel

pump only when the engine is started and
running. The power fuel pump has
different flow rates depending on the
requirements of engine. For easy
production, the power fuel pumps with the
same structure adjust the motor speed by
adjusting the turns per coil so as to adjust
the flow rate. Therefore, do not use the
power fuel pump from other models.

Power Fuel Pump
In the fuel tank
The power fuel pump consists of a DC

motor, vane pump and end cap
(Integrated with return valve, relief valve
and components resistant to
electromagnetic interference) as shown in Fig. 3-42 Cross Section of Power Fuel Pump
the figure below. The pump and motor
are installed coaxially in a closed housing.
The gasoline is fully filled around the
pump and motor in the housing which are
cooled and lubricated by fuel. The battery
supply power to the oil pump relay and
(1) Data Limit
Value
Items Unit
Min. Typical Max.
Working voltage 12 V (DC)
System pressure 6 Bar
Ambient temperature
(Suitable for storage and -40 +80 C
transportation)
Allowed fuel temperature -30 +70 C
144
The power fuel pump should be stored in If the fuel pump is returned, please send
the closed original packing box. The back the supply list, check list and
allowed maximum storage time is 6 package label with it. The returned fuel
months after it is installed in the vehicle, pump must be packed as specified. If the
and the maximum storage time is 4 years fuel pump has been used, wash it with
if it is used as spare part. The test solution and dry it in the air instead of
performance data of fuel pump should be blowing it dry. For safety, the fuel pump
rechecked by the manufacturer when the with fuel is not accepted.
above time is exceeded. The fuel pump
should be protected from the atmospheric 3.10.5 Trouble Symptoms and Judgment
effects when stored. The original Method
packaging should not be damaged during
storage. 3.10.5.1 Trouble symptoms: Loud operating
noise, poor acceleration, unable to start
The power fuel pump is used only in the (difficult to start), etc.
fuel tank. Install a fuel inlet screen with
mesh size of 60 μ or less or determined 3.10.5.2 General trouble cause: Due to the
with the customers when the fuel pump is use of poor-quality fuel: 1. the insulation
installed. Do not allow the fuel from the layer is formed by colloid accumulation;
vent hole to spray on the fuel inlet screen, 2. the fuel pump axle bushing and
fuel pump bracket and fuel tank wall. Be armature lock; 3. the components of fuel
careful to transport the fuel pump. Protect level sensor are corroded.
the fuel inlet screen from any load or
impact. The fuel pump must be removed 3.10.5.3 Precautions for repair:
from the plastic packaging carefully
during installation. The protective cover 3.10.5.4 The power fuel pump has different
can be removed only when the fuel pump flow rates depending on the
is to be installed. Never remove the fuel requirements of engine. The fuel pump
inlet screen. The fuel pump may be which has the same profile and can be
damaged when the foreign objects enter installed may be improper. The part No.
the fuel pump inlet or screen. of fuel pump used must be the same as
the original during repair. Do not mix use
Keep clean when the fuel pipes are of them;
installed. The interior of fuel pipes should
be clean. Only use new fuel pipe clamps. 3.10.5.4.1 To prevent the unexpected
Confirm the correct position of fuel pipe damage to the fuel pump, do not
clamps and observe the methods operate it in dry state;
recommended by the manufacturer.
3.10.5.4.2 When the fuel pump needs to be
Do not hold the fuel pump at the fuel pipe replaced, clean the fuel tank and pipe
or fuel inlet screen. lines and replace the fuel filter.
To prevent damage to the fuel pump, do 3.10.5.5 Simple measurement method:

not operate the fuel pump under the dry Connect the fuel pressure gauge to the oil
state. Do not use the damaged fuel pump inlet pipe, start the engine and observe if
or the fuel pump dropped on the ground. the fuel pump operates. If the fuel pump
Replace the fuel pump in the fuel tank if it does not operate, check for power
is dropped on the ground. voltage at the pin "+". If it operates, check
if the fuel pressure is about 600 kPa
Do not apply force on the inlet plate. during idling.
There should be no mechanical stress at
the caulking. The fuel pump must be fixed
as specified.
145
3.11 High Pressure Fuel Pump
Diagram
Fig. 3-43 High Pressure Fuel Pump Diagram Fuel Pump

Fig. 3-44 Cross Section of High Pressure
On the side of cylinder head
The high pressure fuel pump is driven by

a 4-point cam on the intake camshaft and
each lift is 3.5 mm. The fuel pump is also
used to transmit the fuel to the
high-pressure fuel system under the
non-injection condition.
The pressure limiting valve is integrated

in the high pressure fuel pump and it can
protect the components from high fuel
pressure when it is expanded under hot
temperature or malfunctions.
146
Performance Data
Items Value Unit
Min. Typical Max.
System pressure 2 15 MPa
Fuel supply pressure (Absolute) 0.65 0.9 MPa
Storage humidity 0 80 %
Ambient temperature for operation -40 +100 °C
Fuel temperature at oil inlet -40 +80 °C
Dry running 0 10 Min
Flow control valve Resistance 0.5 Ω
Insulation 10 MΩ
resistance
3.11.4 Precautions for Installation b General trouble cause: Due to the use of
poor-quality fuel
a The clean engine oil without silicone
must be used to lubricate the hole with c Precautions for maintenance:
a diameter of 35 mm in the fuel pump
flange before installing the fuel pump; 3.11.5.1 Use the specified fuel and fuel
additive;
b The parting plane is not allowed in the
seal area; 3.11.5.2 Fill the fuel before the volume
indicator light is turned on to reduce the
c The fuel pump supporting surface must effect of fuel deposits on the entire
be fully supported at the flange end. engine system;
d All the dropped parts must be 3.11.5.3 Release the fuel pressure when it is
discarded; \ necessary to replace the fuel pump.
e The fuel pump must be installed as 3.12 GDI Injection Nozzle

follows:
Diagram and Pin
3.11.4.1 Position the cam at the bottom
dead center;
3.11.4.2 Press the fuel pump to the bottom

dead center (The required maximum
force is 1 kN);
3.11.4.3 Tighten the fuel pump with specified

torque. Otherwise the piston may be
broken.
Fig. 3-45 MM GDI Injection Nozzle Fig.
Method
a Trouble symptoms: Poor idling, unable

to start (difficult to start), hunting during
idling, etc.
147
3-46 Circuit Diagram of Electromagnetic

Injector Gas Sealing
Pin: Ring
Each injector has 2 Pins. The pin with a

positive sign at the housing side is Fig. 3-48 Cross Section of Electromagnetic
connected to the output terminal, and the Injector
other Pins are connected to pin No. 117, 121,
118 and 114 of ECU respectively. 3.12.1 Installation Position
Close to intake valve end.
The ECU sends the electric pulse to the

injector coil to form magnetic field force.
When the magnetic field force is higher
than the resultant force of return spring
pressure, needle valve weight and
friction force, the needle valve begins to
rise and the injection process starts.
When the injection pulse is stopped, the
pressure of return spring will close the
needle valve again.
3.12.3.1 Data Limit

Items Value Unit
Min. Typical Max.
Storage temperature (original packaging) -40 +70 C
Storage humidity 20 70 %
Operating temperature of injectors -40 +140 C
Allowed temperature of fuel at the -30 +80 C
injector inlet
Fuel pressure 2 12 MPa
Power supply voltage 6 16 V
3.12.3.2 Allowed fuel
The injector can only use the fuel which
148
complies with the National Standard of 3.12.4.2.4 If the injector has two slots, be
the People's Republic of China GB careful not to confuse them. Refer to the
17930-1999 "Unleaded Gasoline for installation position of original part.
Motor Vehicles" and National Standard
for Environmental Protection GWKB 3.12.4.3 The injector should be installed by
1-1999 "Hazardous Materials Control hand. Never tap the injector with tools
Standard for Motor Vehicle Gasoline", such as hammer.
and the detergent should be added in the
gasoline. Note that the gasoline will 3.12.4.4 The O-ring must be replaced when
deteriorate after stored for a long time. the injector is removed and reinstalled.
The temperature of fuel tank is very high Do not damage the sealing surface of
due to the continuous operation of fuel injector.
pump. If the gasoline is stored in the fuel
tank of such vehicle, it will be oxidized 3.12.4.5 The support washer of O-ring should
easily, causing the injector blockage and not be pulled out from the injector. Avoid
even damage. damage to the inlet, O-ring, support ring,
nozzle plate and electric connector of
3.12.4 Precautions for Installation injector during installation. Do not use
them if damaged.
3.12.4.1 Do not mix use of the injector
connectors. 3.12.4.6 Perform test on the tightness of fuel
distribution pipe assembly after the
3.12.4.2 For easy installation, it is injector is installed. It is acceptable
recommended to apply clean when no leakage exists.
silicone-free oil on the upper O-ring
connected to the fuel distribution pipe. 3.12.4.7 Remove the fault part by hand. First
Do not allow the oil to contact the remove the clips of injector, and then
injector interior and nozzle. pull out the injector from the injector seat.
Keep the injector clean after removal.
3.12.4.3 Install the injector to the injector seat
in a direction perpendicular to the 3.12.5 Trouble Symptoms and Judgment
injector seat, and then fix the injector on Method
the injector seat with clips.
3.12.5.1 Trouble symptoms: Poor idling, poor
Notes: acceleration, unable to start (difficult to
start), etc.
3.12.4.2.1 The injector clips can be divided into
axial retaining clip and radial retaining 3.12.5.2 General trouble cause: The injector
clip according to the fixing method. fails to function due to the colloid
Avoid mixing use of them. accumulation in the injector caused by
lack of maintenance.
3.12.4.2.2 For installation of axially fixed
injectors, make sure the center bayonet 3.12.5.3 Precautions for repair: (Refer to
of clip is fully clamped in the injector slot, Precautions for installation)
and the slots on both sides of clip are
fully clamped on the outer edge Advice: Clean the injectors with a special
hemming of injector seat. washing analyzer at regular intervals.
3.12.4.2.3 When the injector must be fixed in

axial and radial directions, the axial and
radial retaining clips should be used and
position the located block of injector and
dowel pin of injector seat in the proper
slots on the retaining clip.
149
signal, the engine ECU calculates the

3.13 OCV Solenoid optimal intake valve timing, controls the
position of oil control valve and enables
Diagram and Pin the VVT controller to generate the
advance, delay or holding actions so as
to change the valve timing.
In addition, the engine ECU detects the

actual valve timing based on the signals
from the camshaft position sensor and
crankshaft position sensor so as to
perform the feedback control as much as
possible and achieve the predetermined
valve timing.
Fig. 3-49 OCV Solenoid
Fig. 3-50 Electrical Schematic Diagram
On the valve-chamber cover and face the

intake camshaft.
Based on the crankshaft position sensor,

intake pressure signal, throttle position
sensor, camshaft position sensor, water
temperature sensor and vehicle speed
1) Parameter Limit
Items Value Unit

Min. Typical Max.
Working voltage 11 15.5 V
Maximum axial force 200 N
2) Performance Parameters
Items Value Unit
Coil resistance (20°C) 8 Ω

Insulation resistance 25 MΩ
150
the valve timing is improper due to

3.13.4 Precautions for Installation slippage of the timing belt.
3.13.4.1 The engine may not operate normally 3.14 Electronic Throttle Valve Assembly
after the VVT valve body is removed
and repaired. The valve body assembly Diagram and Pin
must be replaced if it malfunctions.
3.13.4.2 When the oil with higher viscosity

(15W40 or higher) is used, the VVT may
not operate if the engine is in low
temperature. It is recommended to use
the oil with viscosity lower than 10W30.
3.13.4.3 The internal precision of VVT valve Fig. 3-51 Electronic Throttle Valve
body and OCV solenoid is very high. If
the non-original oil and oil filter are used,
the engine VVT system may operate
abnormally.

Method
a Trouble symptoms: 1. Engine hunting 2.

Excessively advanced timing 3.
Excessively delayed timing Fig. 3-52 Pin Definition
b General cause:
3.13.5.1 If aluminum skimmings block the
movement of solenoid and the oil flows The electronic throttle valve is installed on
directly into the oil chamber of the the intake pipe of engine.
camshaft without control, the
misalignment of camshaft will be caused 3.14.2 Operation Theory
for a long time. As the ignition timing at
low speed is different from that at high The position of throttle butterfly valve is
speed and the air pressure flow away controlled by the motor. The positioning
from the minor gap, the intake pressure control module in the engine control unit
will be insufficient; controls the motor rotation. Two
non-contact position sensors are installed
3.13.5.2 The OCV slide valve is stuck in the in the product to constantly monitor the
advance position. The variable valve position of butterfly valve. Base on the
timing actuator is stuck in the advance signal value output by the product and its
position; The timing belt is too loose or change rate, the system judges the
the valve timing is improper due to engine load and dynamic change. Under
slippage of the timing belt; the power-off condition, the butterfly valve
is kept in the original position by the
3.13.5.3 The engine oil pressure is low; The return spring and torque ring. The
OCV slide valve is stuck in the delay components include the throttle valve,
position; The variable valve timing gear drive and return structure, DC motor
actuator is stuck in the delay position; and sensor connector.
The oil passage between the oil switch
and OCV or between the OCV and
variable valve timing actuator may block
or leak; The timing belt is too loose or
151
Performance Parameters
Items Value Unit

Min. Typical Max.
Operation temperature -40 +140 °C
Check the tightness at the connection as

specified during installation.
Perform the self-learning after

replacement (Wait for 1 min after the
vehicle is power on).

Method
a Trouble symptoms: Difficult to start, Fig. 3-53 Turbocharger Air Circulation Valve
unstable idling, poor acceleration or " backfire",
abnormal exhaust emission
b General cause: The throttle body is faulty

due to dirt caused by lack of maintenance.
c Troubleshooting:
3.14.5.1 Check the accelerator pedal position

sensor signal
3.14.5.2 Check the circuit connection
3.14.5.3 Clean the throttle body and check the

throttle valve shaft and throttle valve motor Fig. 3-54 Electrical Schematic Diagram
3.14.5.4 Check the throttle body for air 3.15.1 Installation Position
leakage
In the intake pipe at the compressor side
3.14.5.5 Check the ignition and injector
operation. The abnormal operation of 3.15.2 Operation Theory
engine will also cause the electronic
throttle valve body to loss control, The turbo is driven by the exhaust gas.
resulting in the failure illusion. When the accelerator pedal is released
during driving (for example, during gear
3.15 Turbocharger Air Circulation Valve shifting or sudden braking), the throttle
valve will close and the turbo vane
Diagram and Pin (compressor impeller) will rotate
continuously under the inertia effect. At
this time, the air pressure inside the
intake pipe (between the throttle valve
152
and turbo) will increase quickly due to the

cut-off by the throttle valve and
continuous boosting by the vane. To
protect the pressurization system, the
intake bypass valve will open when the
pressure reaches a limit value to transmit
the surplus air (pressure) to the area
between the filter and turbo.
Items Value
Unit
Min. Typical Max.
Fuel temperature 205 °C
Ambient
-40 +160 °C
temperature
Working voltage 8 12 16 V
All the pipe lines should be connected

securely without leakage and aging
during installation.

Method
3.15.5.1 Trouble symptom: The clear "cluck"

sound from the engine can be heard.
Fig. 3-55 Boost Pressure Limiting Solenoid
3.15.5.2 General cause: The turbocharger air
circulation valve is damaged
3.15.5.3 Simple measurement: Measure the

resistance of the wire connectors with
a multimeter and the resistance
should meet the technical
requirements. Otherwise, replace the
wire connector. If the resistance
meets the requirements, check the
power supply voltage of wire
connectors.
3.16 Boost Pressure Limiting Solenoid
Diagram and Pin

Fig. 3-56 Electrical Schematic Diagram
On the accessory of engine block to
153
receive three-way air pressure diagnostic tester is 3 or less.
3.16.2 Operation Theory 3.16.5 Trouble Symptoms and Judgment

Method
The boost pressure limiting solenoid is
controlled rhythmically by the engine 3.16.5.1 Trouble symptoms: No previous back
controller. It controls the control pressure feeling during acceleration, the fuel
of pressure sensor in the exhaust consumption increases, the exhaust
turbocharger and exhaust gas valve. Part temperature increases
of the exhaust gas is led by the solenoid
to pass the turbo and enter the exhaust 3.16.5.2 General cause: The opening pressure
equipment. The turbo power and boost of actuator is too low due to stuck
pressure can also be adjusted by the exhaust bypass valve
solenoid. The actual boost pressure is
close to the atmosphere pressure during 3.16.5.3 Repair method: Correctly set the
idling. opening pressure value of actuator,
and strictly follow the installation
3.16.3 Technical Parameters requirements to install the
turbocharger.
Value
Items Unit 3.17 Ignition Coil
Min. Typical Max.
Fuel
205 °C Diagram and Circuit Diagram
temperature
Ambient
-40 +140 °C
temperature
Working
8 12 16 V
voltage
3.16.4.1 Strictly follow the installation

requirements;
3.16.4.2 After installation, start the vehicle and

keep it idling for 5 to 10 minutes. Never Fig. 3-57 Single-spark Ignition Coil
depress the accelerator pedal immediately
after the vehicle is started; Check the engine
oil pressure after installation.
Pin 3
3.16.4.3 Make sure the intake air is clean and

Pin 2
replace the air filter at regular intervals;
3.16.4.4 Always check the oil volume to avoid

bearing failure and stuck rotating parts due to Pin 1
lack of oil;
3.16.4.5 Replace the oil and oil filter at regular Fig. 3-58 Circuit Diagram of Single-spark
intervals; Ignition Coil
3.16.4.6 Check the flexibility of bypass valve Note: The system has four ignition coils.
regulator lever at regular intervals. Each ignition coil is connected to a
cylinder and the ignition sequence is
3.16.4.7 When the ignition switch is turned on 1-3-4-2.
and the engine is idling, the duty cycle of
boost pressure limiting valve displayed on the Pin definition:
154
d Ignition coil of cylinder

a Ignition coil of cylinder
Low pressure side: The primary winding
Low pressure side: The primary winding pin of No. 3 coil is connected to the
pin of No. 1 coil is connected to the ignition switch; The primary winding pin of
ignition switch; The primary winding pin of No. 4 coil is connected to pin No. 106 of
No. 1 coil is connected to pin No. 99 of ECU; High pressure side: Two secondary
ECU; High pressure side: Two secondary winding terminals are connected to the
winding terminals are connected to the sparkplug of engine No. 4 cylinder
sparkplug of engine No. 1 cylinder through the distributor respectively;
through the distributor respectively;
b Ignition coil of cylinder
On the valve-chamber cover of engine
Low pressure side: The primary winding
pin of No. 2 coil is connected to the 3.17.2 Operation Theory
ignition switch; The primary winding pin of
No. 2 coil is connected to pin No. 107 of The ignition coil consists of primary
ECU; High pressure side: Two secondary winding, secondary winding, iron core
winding terminals are connected to the and housing. When a ground channel of
sparkplug of engine No. 2 cylinder primary winding is connected, the primary
through the distributor respectively; winding is charged. Once the primary
winding circuit is cut by ECU, the
c Ignition coil of cylinder charging is stopped and a high voltage is
induced in the secondary winding to
Low pressure side: The primary winding discharge the sparkplug. Each cylinder
pin of No. 3 coil is connected to the has an ignition coil which is installed
ignition switch; The primary winding pin of above the sparkplug. The individual
No. 3 coil is connected to pin No. 98 of ignition eliminates the high-voltage wires
ECU; High pressure side: Two secondary and the power consumption during
winding terminals are connected to the ignition is further reduced.
sparkplug of engine No. 3 cylinder
through the distributor respectively;
1) Performance Data
Basic Function Parameter Value Unit

Rated voltage 14 V
Wire resistance 150±50 mΩ
2) Parameter Limit
Items Value Unit

Min. Typical Max.
Allowed operation -30 +120 °C
temperature
155
3.17.4.1 The ignition coil is installed on the

engine with a recommended installation
torque of 8 Nm±2 Nm to avoid damage to
the plastic housing;
3.17.4.2 There should be no sharp metal

edge around the installation area of ignition
coil. The installation clearance between the
high-voltage output area and surrounding
metal surface should be at least 2 mm;
3.17.4.3 Make sure the high-voltage

extension rod and sparkplug are connected Fig. 3-60 Electrical Schematic Diagram of
securely during installation; otherwise the Power Water Pump
high-voltage leakage and poor ignition may
occur easily.

Method
3.17.5.1 Trouble symptom: Unable to start.
3.17.5.2 General trouble cause: Burnout

caused by overcurrent, damage
caused by external force.
3.17.5.3 Precautions for repair: Never use

the "Short Circuit Ignition Test
Method" to test the ignition function
during repair to avoid damage to the
electronic controller.
3.18 Power Water Pump
Diagram and Pin Fig. 3-59 Power Water Pump
Pin definition:
Pin No. 1 is negative terminal of power

supply
Pin No. 3 is positive terminal of power

supply
Pin No. 2 is N/A.
On the engine coolant circulation pipe
156
3.18.2 Operation Theory 3.18.4.2 All the components should be

installed correctly and properly;
When the water pump is turned on, the
impeller rotates at high speed in the 3.18.4.3 Applicable media: Automotive
pump body (Fully fill the fluid in the antifreeze, water;
pump body before turning on the water
pump). The fluid in the pump body 3.18.4.4 There is no foreign object inside the
rotates with the impeller and it is tossed pump body and the water inlet and
out from the outlet under the centrifugal outlet are equipped with the dust
force. The speed of tossed fluid cover.
decreases gradually in the diffusion
chamber of pump body. After the fluid is 3.18.5 Trouble Symptoms and Judgment
tossed out, it will form a vacuum low Method
pressure zone at the center of impeller.
The fluid in the liquid pool flows into the a Trouble symptoms: The water
water pump via the suction pipe under temperature is too high, the water
the atmospheric pressure. The capacity temperature increases too rapidly
of pump body diffusion chamber is
limited and the pressure increases b Repair:
gradually with the increase of tossed
fluid. At last the fluid will be discharged 3.18.5.1 Check if the pumping pressure of
from the outlet of water pump. This is the water pump meets the
how the fluid is drawn in from the liquid requirements;
pool and then discharged from the
outlet of water pump continuously. 3.18.5.2 Check the water pump for leakage;
3.18.3 Technical Parameters 3.18.5.3 Check if the drive end of the water
pump is connected securely;
1) Performance Data
3.18.5.4 Check the water pump for blockage
Basic
Performance Value Unit
3.19 Charcoal Canister Solenoid Valve
Parameter
Diagram and Pin
Rated power 24 W
Rated voltage 12 V
Working current 2 A
2) Parameter Limit
Items Value Unit Fig. 3-61 Charcoal Canister Control Valve

Min. Typical Max
Working 9 16 V
voltage
3.18.4.1 Appearance: The outer surface of

injection molding should be smooth and
have no obvious defects. The metal parts
should not have rusting;
157
difference of pressure at both valve

ends.
The active carbon filter in the charcoal

canister collects the fuel vapor from the
fuel tank, and the air flow sent to the
engine intake pipe is measured by the
charcoal canister solenoid valve. The
active carbon filter is controlled by the
pulse output by the electronic controller,
and the operation duration and
frequency should match with the engine
working condition.
Fig. 3-62 Circuit Diagram of Charcoal
Canister Control Valve
Pin: The charcoal canister control valve only

has two Pins with one connected to pin No.
201 at the output terminal of main relay and
the other one connected to pin No. 78 of
ECU.
On the vacuum line of the charcoal

1. From fuel tank
canister to intake manifold
2. Charcoal canister
3. Atmosphere
The charcoal canister in the evaporative
emission control system absorbs the
4. Charcoal canister control valve
fuel vapor from the fuel tank until the
fuel vapor is saturated. The electronic
5 To intake manifold
controller opens the charcoal canister
solenoid valve, and the fresh air forms
6. Throttle valve
the regenerative air flow with the
saturated fuel vapor in the charcoal
 P is the difference between ambient
canister. The air flow will be introduced
pressure Pu and intake manifold
into the engine intake pipe. There is
pressure Ps
solenoid coil inside the valve.
Depending on the engine working
conditions, the electronic controller
Fig. 3-63 Installation Diagram of Evaporative
changes the duty cycle of pulse signal
Emission Control System and Charcoal
sent to the solenoid coil so as to change
Canister Control Valve
the valve opening. Moreover, the valve
opening is also affected by the
158
(1) Data Limit
Items Value Unit

Min. Typical Max.
Allowed operation temperature -30 +120 C
Allowed storage temperature -40 +130 C
Acceptable pressure difference between 800 mbar
inlet and outlet
Allowed switching cycles 108
(2) Performance Data
Items Value Unit
Min. Typical Max.
Rated voltage 13.5 V
Resistance at +20C 26 
Current under rated voltage 0.5 A
3.19.5.2 General trouble cause: Corrosion
3.19.4 Precautions for Installation or poor tightness is caused as the
foreign materials enter the valve.
3.19.4.1 Refer to figure 3-63 for the
connection of charcoal canister 3.19.5.3 Precautions for repair:
solenoid valve, charcoal canister and
intake manifold. 3.19.5.3.1 The direction of air flow must
meet the requirements during
3.19.4.2 To avoid the transmission of installation;
solid-borne noise, it is recommended
to hang the charcoal canister control 3.19.5.3.2 When the control valve is fault
valve on the hose. due to black particles in the valve body
and it needs to be replaced, please
3.19.4.3 The direction of air flow must meet check the charcoal canister;
the requirements during installation.
3.19.5.3.3 Prevent the water or oil from
3.19.4.4 Proper measures must be taken entering the valve during repair;
(such as filtering and purging) to
prevent the foreign materials (such as 3.19.5.3.4 To avoid the transmission of
particles) from entering the charcoal solid-borne noise, it is recommended to
canister solenoid valve from the hang the charcoal canister solenoid
charcoal canister or hose. valve on the hose or install the rubber
boot.
 It is recommended to install a proper
protective filter at the outlet of charcoal 3.20 Brake Vacuum Pump
canister (Mesh size <50μm).
Diagram
Method
3.19.5.1 Trouble symptom: Functional

failure.
159
The engine control unit judges if the

vacuum pressure can drive the brake
booster based on the voltage signal
from the pressure sensor.
Operation theory: l
To achieve all the brake pressure as

quickly as possible, the brake booster
needs certain amount of vacuum. The
throttle valve opening is large in the
homogeneous thin inflatable mode;
Fig. 3-64 Brake Vacuum Pump therefore there is less vacuum in the
intake manifold. If the brake pedal is
3.20.1 Installation Position depressed continuously several times,
the vacuum intensity in the brake
The sensor is installed on the pipe line booster will not perform effective
between the intake manifold and brake braking.
booster. It is used to measure the
pressure in the pipe line or the brake
booster.
Items Value Unit

Min. Typical Max.
Rated voltage 12 V
Working current 5 8 A
Starting current >10 A
Operation °C
-30 90
temperature
Storage °C
-40 120
temperature
Weight 1100 g
3.20.4 Precautions for Installation 3.20.5.2 Repair:
Check the vacuum pipe for leakage 3.20.5.2.1 Replace the vacuum pipe if it is
after replacement; Check the brake aging or leaking
operation after the engine is started and
operated for 5 minutes. 3.20.5.2.2 Replace the vacuum pump after it
is damaged.
Method
3.20.5.1 Trouble symptoms: The engine

shaking and occasional unstable idling
occur after the brake pedal is
depressed continuously
160
Section 4 Diagnosis Flow for TB10 System in Accordance with Trouble

Codes
Description: 4.3.1 01 Read the current powertrain
4.1 The after-mentioned "multimeter" refers diagnosis data
to the digital multimeter. Never check
the circuit of the electronically 4.3.2 02 Read the freeze frame data
controlled injection system with a
pointer type multimeter. 4.3.3 03 Read the system diagnosis DTC
related to emissions
4.2 When overhauling vehicles with an
anti-theft system, if "Replace the ECU" 4.3.4 04 Clear and reset the emission related
appears in the column of "Follow-up diagnosis information
Step", program the ECU after
replacement. 4.3.5 05 Read the oxygen sensor monitoring
and test result
4.3 The ECM mentioned in the trouble codes
is ECU. 4.3.6 06 Read the test result of specific
monitoring system OBD
Diagnostic tips:
4.3.7 07 Read the DTCs monitored by OBD
4.3.1 Do not ignore the effect of car system during current or previous driving
maintenance, cylinder pressure and cycle
mechanical ignition timing imposed on
the system during maintenance; 4.3.8 08 Components test, but not
mandatory
4.3.2 If the DTC still exists after checking the
wire harness and sensor in accordance 4.3.9 09 Read the vehicle and software
with the repair tips, replace the ECU identification number (Change them after
and perform test. the diagnostic tester is developed
completely)
If the DTC can be cleared, the trouble
area is ECU. If the DTC still cannot be It is noticeable that the scan tools and
cleared, install the original ECU. Repeat diagnostic testers may be different in
the process and perform maintenance terms of design and usage, but the read
again. contents must belong to one of the
above mode.
Description of scan tool or diagnostic tester
modes: The DTCs can be displayed and output
The OBD system can provide much under mode 3 after the trouble is
trouble diagnosis related information confirmed; All the DTCs that exist in the
which is very valuable for overhauling current driving cycle or occurred in the
the electronically controlled injection previous driving cycle will be displayed
system. According to the definition in and output under mode 7.
the international automobile standard
ISO/DIS15031-5, the related information The following are the DTCs meaning,
of the OBD system is available at 9 relevant diagnostic strategy, possible
different services/modes through the trouble causes and trouble treatment
diagnostic tools meeting the measures used in the current TB10
requirements of ISO/DIS15031-4. system which can be used for reference
when repairing the vehicles.
The main functions of each mode are as The after-mentioned ECU Pins are only
follows: for reference.
161
DTC: P0010 Camshaft control valve control circuit is open
Step 1: Read DTCs with the diagnostic tester

Read the result: P0010 Camshaft control valve control circuit is open
Service tips:
The following malfunctions may exist
a The signal circuit of OCV solenoid (Camshaft control valve) is open. Measure the
resistance between the ECU and pin No. 2 of control valve signal line with the
multimeter.
DTC: P0016 Intake phase deviation is large

Read the result: P0016 Intake phase deviation is large
Service tips:
a The camshaft control valve body is faulty or blocked. Check the camshaft control valve.
b The camshaft valve timing is incorrect. Check if the valve timing is correct and if the
timing chain is "jumping teeth".
DTC: P0030 Front oxygen heating control circuit is open

Read the result: P0030 Front oxygen heating control circuit is open
Service tips:
a The circuit between pin No. 2 of front oxygen sensor and ECU pin is open. Measure the
resistance of circuit between the ECU and pin No. 2 of front oxygen sensor with the
multimeter.
b The circuit between pin No. 1 of front oxygen sensor and main relay is open. Measure
the resistance of circuit between the pin No. 1 of front oxygen sensor and main relay with
the multimeter.
c The internal circuit between pin No. 1 and 2 of front oxygen sensor is open. Measure the
resistance between the pin No. 1 and 2 of front oxygen sensor with the multimeter.
162
DTC: P0031 Front oxygen heating control circuit voltage is low

Read the result: P0031 Front oxygen heating control circuit voltage is low
Service tips:
a The circuit between the front oxygen sensor and ECU pin is short to ground. Measure the
resistance of circuit between the ECU pin and ground with the multimeter.
DTC: P0032 Front oxygen heating control circuit voltage is high

Read the result: P0032 Front oxygen heating control circuit voltage is high
Service tips:
a The circuit of ECU pin is short to the circuit of pin No. 1 of upstream oxygen sensor.
Measure the resistance of circuit between the ECU pin and pin No. 1 of upstream oxygen
sensor.
b The circuit of ECU pin is short to other power supply circuits. Measure the voltage of pin
No. 2 of oxygen sensor connector with the multimeter.
DTC: P0033 Turbocharger bypass valve control circuit is open

Read the result: P0033 Turbocharger bypass valve control circuit is open
Service tips:
a The circuit between the bypass valve signal circuit and ECU pin is open. Measure the
resistance between the ECU pin and bypass valve signal circuit with the multimeter.
DTC: P0034 Turbocharger bypass valve control circuit voltage is low

Read the result: P0034 Turbocharger bypass valve control circuit voltage is low
Service tips:
a The bypass valve signal circuit is short to ground. Measure the resistance between the
ECU pin and ground with the multimeter.
163
DTC: P0035 Turbocharger bypass valve control circuit voltage is high

Read the result: P0035 Turbocharger bypass valve control circuit voltage is high
Service tips:
a The bypass valve signal circuit is short to the power supply. Measure the voltage of ECU
pin with the multimeter.
DTC: P0036 Rear oxygen heating control circuit is open

Read the result: P0036 Rear oxygen heating control circuit is open
Service tips:
a The circuit between the ECU pin and pin No. 2 of rear oxygen sensor is open. Measure
the resistance of circuit between the ECU and pin No. 2 of rear oxygen sensor.
b The circuit between pin No. 1 of rear oxygen sensor and main relay is open. Measure the
resistance of circuit between the pin No. 1 of rear oxygen sensor and main relay.
c The circuit between pin No. 1 and 2 of rear oxygen sensor is open. Measure the
resistance between the pin No. 1 and 2 of rear oxygen sensor.
DTC: P0037 Rear oxygen heating control circuit voltage is low

Read the result: P0037 Rear oxygen heating control circuit voltage is low
Service tips:
a The circuit between the pin No. 2 of rear oxygen sensor and ECU pin is short to ground.
Measure the resistance between the ECU pin and ground with the multimeter.
DTC: P0038 Rear oxygen heating control circuit voltage is high

Read the result: P0037 Rear oxygen heating control circuit voltage is low
Service tips:
a The circuit of ECU pin is short to the circuit of pin No. 1 of rear oxygen sensor. Measure
the resistance of circuit between the ECU pin and pin No. 1 of rear oxygen sensor with
164
the multimeter.
b The circuit of ECU pin is short to other power supply circuits. Check if the voltage of ECU
pin is normal with the multimeter.
DTC: P0089 Fuel pressure control valve control circuit failure

Read the result: P0089 Fuel pressure control valve control circuit failure
Service tips:
a The circuit between the control valve signal circuit and ECU pin is open. Measure the
resistance between the ECU pin and pin No. 2 of fuel pressure control valve with the
multimeter.
b The circuit between the control valve signal circuit and ECU is short to ground. Measure
the resistance between the ECU pin and ground with the multimeter.
c The circuit between the control valve signal circuit and ECU is short to the power supply.
Measure the voltage of ECU pin with the multimeter.
DTC: P0097 Boost gas temperature sensor circuit voltage is low

Read the result: P0097 Boost gas temperature sensor circuit voltage is low
Service tips:
a The sensor signal circuit connected to the ECU pin is short to ground. Measure the
resistance between the sensor signal circuit of ECU pin and ground with the multimeter.
DTC: P0098 Boost gas temperature sensor circuit voltage is high

Read the result: P0098 Boost gas temperature sensor circuit voltage is high
Service tips:
a The sensor signal circuit connected to the ECU pin is short to the power supply. Check if
the voltage of the sensor signal circuit of ECU pin is normal with the multimeter.
DTC: P0106 Intake pressure sensor signal rationality failure

Read the result: P0106 Intake pressure sensor signal rationality failure
165
Service tips:
The malfunctions have been confirmed. The following malfunctions may exist
a The sensing element in the pressure sensor leaks
b The pressure sensor is damaged
c The installation position of pressure sensor leaks
d The characteristic of pressure sensor offsets
DTC: P0107 Intake pressure sensor circuit voltage is low

Read the result: P0107 Intake pressure sensor circuit voltage is low
Service tips:
DTC: P0108 Intake pressure sensor circuit voltage is high

Read the result: P0108 Intake pressure sensor circuit voltage is high
Service tips:
DTC: P0111 Intake temperature sensor signal is irrational

Read the result: P0111 Intake temperature sensor signal is irrational
Service tips:
The intake temperature sensor is damaged and should be replaced.
DTC: P0112 Intake temperature sensor circuit voltage is low

Read the result: P0112 Intake temperature sensor circuit voltage is low
166
Service tips:
DTC: P0113 Intake temperature sensor circuit voltage is high or open circuit

Read the result: P0113 Intake temperature sensor circuit voltage is high or open circuit
Service tips:
DTC: P0116 Coolant temperature sensor signal is irrational

Read the result: P0117 Coolant temperature sensor signal is irrational
Service tips:
a The coolant temperature sensor is damaged and should be replaced.
DTC: P0117 Coolant temperature sensor circuit voltage is low

Read the result: P0117 Coolant temperature sensor circuit voltage is low
Service tips:
DTC: P0118 Coolant temperature sensor circuit voltage is high

Read the result: P0118 Coolant temperature sensor circuit voltage is high
Service tips:
167
DTC: P0121 Throttle position sensor A voltage is incorrect

Read the result: P0121 Throttle position sensor A voltage is incorrect
Service tips:
a The electronic throttle valve position sensor is faulty and the electronic throttle valve
assembly should be replaced.
DTC: P0122 Throttle position sensor A voltage is low

Read the result: P0122 Throttle position sensor A voltage is low
Service tips:
a The sensor 1 signal circuit connected to the ECU pin is short to ground. Measure the
resistance between the sensor 1 signal circuit of ECU pin and ground with the multimeter.
b The electronic throttle valve assembly should be replaced.
DTC: P0123 Throttle position sensor A voltage is high

Read the result: P0123 Throttle position sensor A voltage is high
Service tips:
The sensor 1 signal circuit connected to the ECU pin is short to the power supply. Check if the
voltage of the sensor 1 signal circuit of ECU pin is normal with the multimeter.
DTC: P0131 Front oxygen sensor signal is short to low voltage

Read the result: P0131 Front oxygen sensor signal is short to low voltage
Service tips:
168
DTC: P0132 Front oxygen sensor signal is short to high voltage
Trouble cause description: The ECU measures the voltage of upstream oxygen sensor circuit
after the engine is started. When the signal voltage is higher than 1.5 V for a long time, the front
oxygen sensor circuit voltage is high.

Read the result: P0132 Front oxygen sensor signal is short to high voltage
Service tips:
a The signal circuit connected to the ECU pin is short to the pin No. 1 of oxygen sensor.
Measure the resistance between the signal circuit connected to the ECU pin and Pin No.
1 of the oxygen sensor connector with the multimeter.
b The signal circuit connected to the ECU pin is short to other power supply circuits.
Measure the voltage of signal circuit connected to the ECU pin.
DTC: P0133 Front oxygen sensor response is slow
Trouble cause description: The air-fuel ratio of fuel-air mixture switches between the rich and lean
states under normal conditions. Accordingly, the amplitude of oxygen sensor signal will jump
constantly. When the oxygen sensor is aging, the sensitivity to perceive the mixture decreases
and the signal fluctuation period will become long. The ECU will calculate the average period of
signal according to the relevant algorithm. If the period is longer than the preset threshold, the
sensor is judged to be aging.

Read the result: P0133 Front oxygen sensor response is slow
Service tips:
a The sensor is aging and should be replaced.
DTC: P0134 Front oxygen sensor circuit is open
Trouble cause description: The ECU measures the voltage of upstream oxygen sensor circuit
after the engine is started. When the signal voltage always changes between 0.4 and 0.6 V, the
system judges the front oxygen sensor circuit is open.

Read the result: P0134 Front oxygen sensor circuit is open
Service tips:
a The circuit between the oxygen sensor and ECU pin is open. Measure the resistance of
169
circuit between the ECU connector and pin No. 4 of oxygen sensor connector with the
multimeter.
b The oxygen sensor connector is not well connected. Check the connector.
DTC: P0135 Upstream oxygen sensor heater failure
Instructions for diagnosing oxygen sensor heater: The system confirms if the heater output is
correct by measuring the resistance of sensor heater. The heated sensor may be damaged by
the condensate under some unfavorable conditions, especially during the cold starting.
Therefore, the main sensors of the catalytic converter are directly heated after the engine is
started. The secondary sensors of the catalytic converter will be heated only when the theoretical
temperature in the catalytic converter is higher than 308°C.

Read the result: P0135 Upstream oxygen sensor heater failure
Service tips:
a The upstream oxygen sensor heater malfunctions. Replace the oxygen sensor.
DTC: P0137 Rear oxygen sensor circuit voltage is low

Read the result: P0137 Rear oxygen sensor circuit voltage is low
Service tips:
a The signal circuit connected to the ECU pin is short to ground. Measure the resistance
between the signal circuit connected to the ECU pin and the ground with the multimeter.
DTC: P0138 Rear oxygen sensor circuit voltage is high
Trouble cause description: The ECU measures the voltage of downstream oxygen sensor circuit
after the engine is started. When the signal voltage is higher than 1.5 V for a long time, the rear
oxygen sensor circuit voltage is high.

Read the result: P0138 Rear oxygen sensor circuit voltage is high
Service tips:
a The signal circuit connected to the ECU pin is short to the pin No. 1 of the oxygen
sensor. Measure the resistance between the signal circuit connected to the ECU pin and
Pin No. 1 of the oxygen sensor connector with the multimeter.
b The signal circuit connected to the ECU pin is short to other power supply circuits.
170
Measure the voltage of signal circuit connected to the ECU pin with the multimeter.
DTC: P0140 Rear oxygen sensor circuit is open
Trouble cause description: The ECU measures the voltage of downstream oxygen sensor circuit
after the engine is started. When the signal voltage always changes between 0.4 and 0.6 V, the
system judges the rear oxygen sensor circuit is open.

Read the result: P0140 Rear oxygen sensor circuit is open
Service tips:
a The circuit between the oxygen sensor and ECU pin is open. Measure the resistance of
circuit between the ECU connector and pin No. 4 of oxygen sensor connector with the
multimeter.
b Poor contact occurs at the relevant Pins of ECU or oxygen sensor connectors. Check the
connectors.
DTC: P0141 Rear oxygen sensor heater failure
Instructions for diagnosing oxygen sensor heater: The system confirms if the heater output is
correct by measuring the resistance of sensor heater. The heated sensor may be damaged by
the condensate under some unfavorable conditions, especially during the cold starting.
Therefore, the main sensors of the catalytic converter are directly heated after the engine is
started. The secondary sensors of the catalytic converter will be heated only when the theoretical
temperature in the catalytic converter is higher than 308°C.

Read the result: P0141 Rear oxygen sensor heater failure
Service tips:
a The downstream oxygen sensor heater malfunctions. Replace the oxygen sensor.
DTC: P0192 Fuel pressure sensor circuit voltage is low

Read the result: P0192 Fuel pressure sensor circuit voltage is low
Service tips:
171
a The signal circuit connected to the ECU pin is short to ground. Measure the resistance
between the signal circuit connected to the ECU pin and the ground with the multimeter.
DTC: P0193 Fuel pressure sensor circuit voltage is high

Read the result: P0193 Fuel pressure sensor circuit voltage is high
Service tips:
a The sensor signal circuit connected to the ECU pin is short to the power supply. Measure
the voltage of the signal circuit connected to the ECU pin with the multimeter.
DTC: P0201 No. 1 injector control line open-circuit error
The results are:
P0201 No. 1 injector control line open-circuit error
Service tips:
a The circuit between the pin No. 2 of injector connector and ECU pin is open. Measure the
resistance of circuit between the ECU connector and pin No. 2 of injector connector with
the multimeter.
b Poor contact occurs at the relevant Pins of ECU or injector connectors. Check the
connectors.
DTC: P0221 Throttle position sensor signal is irrational

Read the result: P0221 Throttle position sensor signal is irrational
172
Service tips:
a The electronic throttle valve position sensor is faulty and the electronic throttle valve
assembly should be replaced.
DTC: P0222 Throttle position sensor B circuit voltage is low

Read the result: P0222 Throttle position sensor B circuit voltage is low
Service tips:
resistance between the sensor 2 signal circuit of ECU pin and ground with the
multimeter.
DTC: P0223 Throttle position sensor B circuit voltage is high

Read the result: P0223 Throttle position sensor B circuit voltage is high
Service tips:
a The sensor 2 signal circuit connected to the ECU pin is short to the power supply. Check
if the voltage of the sensor 2 signal circuit of ECU pin is normal with the multimeter.
DTC: P0226 Pedal position sensor signal is irrational

Read the result: P0226 Pedal position sensor signal is irrational
Service tips:
a The sensor itself is faulty and the sensor should be replaced.
DTC: P0227 Pedal position sensor 1 circuit voltage is low

Read the result: P0227 Pedal position sensor 1 circuit voltage is low
Service tips:
173
resistance between the sensor 1 signal circuit of ECU pin and ground with the
multimeter.
DTC: P0228 Pedal position sensor 1 is short to high voltage

Read the result: P0228 Pedal position sensor 1 is short to high voltage
Service tips:
a The sensor 1 signal circuit connected to the ECU pin is short to the power supply.
Measure the voltage of the signal circuit connected to the ECU pin with the multimeter.
DTC: P0236 Boost pressure sensor signal is irrational

Read the result: P0236 Boost pressure sensor signal is irrational
Service tips:
a The sensing element in the boost pressure sensor leaks, the pressure sensor is
damaged, the installation position of pressure sensor leaks and the characteristic of
pressure sensor offsets.
DTC: P0237 Boost pressure sensor circuit voltage is low

Read the result: P0237 Boost pressure sensor circuit voltage is low
Service tips:
DTC: P0238 Boost pressure sensor circuit voltage is high

Read the result: P0238 Boost pressure sensor circuit voltage is high
Service tips:
a The sensor signal circuit connected to the ECU pin is short to the power supply. Measure
the voltage of the signal circuit connected to the ECU pin with the multimeter.
174
DTC: P0261 The voltage at the low side of No. 1 injection nozzle is low

The results are:
P0261 The voltage at the low side of No. 1 injection nozzle is low
Service tips:
a The low side circuit connected to the ECU pin is short to ground. Measure the resistance
between the circuit connected to the ECU pin and the ground with the multimeter.
DTC: P0262 The voltage at the low side of No. 1 injection nozzle is high
DTC: P0265 The voltage at low side of No. 2 injection nozzle is high
The results are:
P0262 The voltage at the low side of No. 1 injection nozzle is high
Service tips:
a The low side circuit connected to the ECU pin is short to the power supply. Measure the
voltage of the circuit connected to the relevant ECU pin with the multimeter.
175
DTC: P0263 Short circuit between the low and high side circuits of No. 1 injection nozzle

The results are:
P0263 Short circuit between the low and high side circuits of No. 1 injection nozzle
Service tips:
a There is short circuit between Pins No. 1 and 2 of the injection nozzle. Measure the
resistance between Pins No. 1 and 2 of the injector with the multimeter.
DTC: P0300 One or multi-cylinder misfire
DTC: P0301 Cylinder 1 misfire
Trouble cause description: The misfire refers to when the engine cannot release the ignition
energy effectively in the cylinder due to the ignition system (ignition failure). The injection quantity
deviation (concentration deviation of mixture), low cylinder compression pressure and other
reasons will cause the combustion in the cylinder to interrupt or disable the fuel combustion. The
misfire may cause the emissions to exceed the standards or damage the catalytic converter due
to overheat. For the OBD diagnostic test, the system will judge the misfire occurance when the
misfire times exceed the set value.
The results are:
P0300 One or multi-cylinder misfire
P0301 Cylinder 1 misfire
176
Service tips:
a The injector should be cleaned.
b The inlet passage should be cleaned.
c The ignition system malfunctions. Check and replace the sparkplug and ignition coil on
the misfired cylinder, and check if the ignition coil circuit is open.
DTC: P0335 No signal from crankshaft sensor circuit
Trouble cause description: The ECU monitors the signals from the crankshaft position sensor and
phase sensor after the engine is started. If the signals from the phase sensor can be received
continuously, but the signals from the crankshaft position sensor cannot be received, the system
judges no signal is output from the crankshaft sensor circuit.

Read the result: P0335 No signal from crankshaft sensor circuit
Service tips:
a The circuit between the crankshaft position sensor and ECU is open. Measure the
resistance of circuit between the crankshaft position sensor and ECU with the multimeter.
b There is open circuit inside the crankshaft position sensor. Measure the internal
resistance of crankshaft position sensor with the multimeter.
c Poor contact occurs at the Pins of ECU or sensor connectors. Check the connectors.
DTC: P0336 Crankshaft sensor signal is irrational

Read the result: P0336 Crankshaft sensor signal is irrational
Service tips:
a The crankshaft sensor is damaged. Replace the sensor.
DTC: P0340 No signal from camshaft sensor

Read the result: P0340 No signal from camshaft sensor
177
Service tips:
a The circuit between the camshaft sensor and ECU is open. Measure the resistance of
circuit between the camshaft sensor and ECU with the multimeter.
b There is open circuit inside the camshaft sensor. Measure the internal resistance of
camshaft sensor with the multimeter.
c Poor contact occurs at the Pins of connector. Check the connector.
DTC: P0341 Camshaft sensor signal is irrational
Trouble cause description: The camshaft sensor (phase sensor) uses the Hall elements to induce
a trigger wheel which rotates with the camshaft so as to monitor the camshaft position. The phase
signals received by the ECU should alternate regularly between the high level and low level. If the
ECU only detects the slow alternation between the high level and low level or irregular alternation,
the camshaft sensor signals are regarded as irrational.

Read the result: P0341 Camshaft sensor signal is irrational
Service tips:
a The camshaft sensor is damaged. Replace the sensor.
DTC: P0351 No. 1 ignition coil control circuit is open
The results are:
P0351 No. 1 ignition coil control circuit is open
Service tips:
178
a The circuit between the pin No. 2 of ignition coil connector and ECU pin is open.
Measure the resistance of circuit between the ECU connector and pin No. 2 of ignition
coil connector with the multimeter.
b The circuit between the ignition coil and main relay is open. Measure the resistance of
circuit between pin No. 3 of the ignition coil connector and main relay with the multimeter.
c Poor contact occurs at the relevant Pins of ECU or ignition coil connectors. Check the
connectors.
DTC: P0444 Charcoal canister solenoid valve control circuit is open

Read the result: P0444 Charcoal canister solenoid valve control circuit is open
Service tips:
a The circuit between the pin No. 2 of charcoal canister solenoid valve connector and ECU
pin is open. Measure the resistance of circuit between the ECU connector and pin No. 2
of charcoal canister solenoid valve connector with the multimeter.
b The circuit between the charcoal canister solenoid valve and main relay is open.
Measure the resistance of circuit between pin No. 1 of the charcoal canister solenoid
valve connector and main relay with the multimeter.
c Poor contact occurs at the relevant Pins of ECU or charcoal canister solenoid valve
connectors. Check the connectors.
d The circuit between pin No. 1 and 2 of the charcoal canister solenoid valve is open.
Measure the resistance of circuit between pin No. 1 and 2 of the charcoal canister
solenoid valve connector with the multimeter.
DTC: P0458 Charcoal canister solenoid valve control circuit voltage is low

Read the result: P0458 Charcoal canister solenoid valve control circuit voltage is low
Service tips:
a The circuit between pin No. 2 of the charcoal canister solenoid valve connector and ECU
is short to ground. Measure the resistance between the circuit connected to the ECU pin
and the ground with the multimeter.
DTC: P0459 Charcoal canister solenoid valve control circuit voltage is high

Read the result: P0459 Charcoal canister solenoid valve control circuit voltage is high
179
Service tips:
a The circuit connected to the ECU is short to the circuit of pin No. 1 of charcoal canister
solenoid valve. Measure the resistance of circuit between the ECU pin and pin No. 1 of
charcoal canister solenoid valve with the multimeter.
DTC: P0476 Boost pressure limiting solenoid control circuit is open

Read the result: P0476 Boost pressure limiting solenoid control circuit is open
Service tips:
a The circuit between the pin No. 2 of boost pressure limiting solenoid connector and ECU
pin is open. Measure the resistance of circuit between the ECU connector and pin No. 2
of boost pressure limiting solenoid connector with the multimeter.
b The circuit between the boost pressure limiting solenoid and main relay is open. Measure
the resistance of circuit between pin No. 1 of the boost pressure limiting solenoid
connector and main relay with the multimeter.
c Poor contact occurs at the relevant Pins of ECU or boost pressure limiting solenoid
d The circuit between pin No. 1 and 2 of the boost pressure limiting solenoid is open.
Measure the resistance of circuit between pin No. 1 and 2 of the boost pressure limiting
solenoid connector with the multimeter.
DTC: P0477 Boost pressure limiting solenoid control circuit voltage is low

Read the result: P0477 Boost pressure limiting solenoid control circuit voltage is low
Service tips:
a The circuit between pin No. 2 of the boost pressure limiting solenoid and ECU is short to
ground. Measure the resistance between the circuit connected to the ECU pin and the
ground with the multimeter.
DTC: P0478 Boost pressure limiting solenoid control circuit voltage is high

Read the result: P0478 Boost pressure limiting solenoid control circuit voltage is high
180
Service tips:
a The circuit connected to the ECU is short to the circuit of pin No. 1 of boost pressure
limiting solenoid. Measure the resistance of circuit between the ECU pin and pin No. 1 of
boost pressure limiting solenoid with the multimeter.
DTC: P0480 Stepless fan control line is open

Read the result: P0480 Stepless fan control line is open
Service tips:
a The circuit between the stepless fan and ECU pin is open. Measure the resistance of
circuit between the ECU connector and stepless fan with the multimeter.
b Poor contact occurs at the relevant Pins of ECU or boost pressure limiting solenoid
DTC: P0562 System voltage is low
DTC: P0563 System voltage is high
The results are:
P0562 System voltage is low
P0563 System voltage is high

Service tips:
The system voltage is low as the following malfunctions may exist
a The generator cannot generate electricity due to damage or the battery leaks.
b The field circuit of generator is open.
The system voltage is high as the following malfunctions may exist
a The voltage is high as the generator regulator has been damaged so that it cannot
control the generated energy.
DTC: P0620 AC generator load failure
181
Read the result: P0620 AC generator load failure
Service tips:
a The circuit between the generator and ECU is faulty (open circuit or low voltage). Check
the circuit.
b The generator is faulty. Replace the generator.
DTC: P0627 Fuel pump control circuit is open
DTC: P0628 Fuel pump control circuit voltage is low
DTC: P0629 Fuel pump control circuit voltage is high
The results are:
P0627 Fuel pump control circuit is open
P0628 Fuel pump control circuit voltage is low
P0629 Fuel pump control circuit voltage is high
Service tips:
The open circuit occurs as the following malfunctions may exist
a The circuit between the fuel pump relay control circuit connected to the ECU and fuel
pump relay is open. Measure the resistance of the fuel pump relay control circuit
connected to the ECU with the multimeter.
b The circuit between the relay and main relay is open. Measure the resistance of circuit
between the relay and main relay with the multimeter.
c The solenoid coil of relay is open. Measure the internal resistance of relay with the
multimeter.
Low voltage error occurs as the following malfunctions may exist
pump relay is short to ground. Measure the resistance of circuit between the fuel pump
relay control circuit connected to the ECU and the ground with the multimeter.
High voltage error occurs as the following malfunctions may exist
pump relay is short to the power supply. Measure the voltage of the fuel pump relay
control circuit connected to the ECU with the multimeter.
DTC: P0633 ECM and anti-theft system authentication failure
182

Read the result: P0633 ECM and anti-theft system authentication failure
Service tips:
a The intelligent key authentication fails due to the internal malfunction in the intelligent
key. Check the intelligent key.
b The ECM is faulty. Replace the ECM.
DTC: P0645 Air conditioning permission control circuit is open
DTC: P0646 Air conditioning permission control circuit voltage is low
DTC: P0647 Air conditioning permission control circuit voltage is high
The results are:
P0645 Air conditioning permission control circuit is open
P0646 Air conditioning permission control circuit voltage is low
P0647 Air conditioning permission control circuit voltage is high
Service tips:
The open circuit occurs as the following malfunctions may exist
a The air conditioning permission control circuit connected to the ECU is open. Measure
the resistance of the air conditioning permission control circuit connected to the ECU with
the multimeter.
a The air conditioning permission control circuit connected to the ECU is short to ground.
Measure the resistance of the circuit between the air conditioning permission control
circuit connected to the ECU and the ground with the multimeter.
a The air conditioning permission control circuit connected to the ECU is short to the power
supply. Measure the voltage of the air conditioning permission control circuit connected
to the ECU with the multimeter.
DTC: P0691 Stepless fan control line voltage is low
DTC: P0692 Stepless fan control line voltage is high
183
The results are:
P0691 Stepless fan control line voltage is low
P0692 Stepless fan control line voltage is high
Service tips:
a The stepless fan control line connected to the ECU is short to ground. Measure the
resistance of the circuit between the stepless fan control line connected to the ECU and
the ground with the multimeter.
a The stepless fan control line connected to the ECU is short to the power supply. Measure
the voltage of the stepless fan control line connected to the ECU with the multimeter.
DTC: P1601 Stepless fan motor rotor locked or short circuit

Read the result: P1601 Stepless fan motor rotor locked or short circuit
Service tips:
a The stepless fan is locked. Check if there is any foreign object blocking the fan.
b The fan motor rotor is locked. Check if the motor is stuck.
c There is short circuit in the motor. Check the internal resistance of the motor.
DTC: P1602 Stepless fan over-temperature protection or electronic error

Read the result: P1602 Stepless fan over-temperature protection or electronic error
Service tips:
a The fan motor is damaged. Replace the motor or fan.
DTC: P1611 ECM internal failure 1
184
The results are:
P1611 ECM internal failure 1
Service tips:
a ECM internal failure. Replace the ECM.
DTC: P1621 Intercooler system failure
Trouble cause description: As the intercooler system cannot operate normally, the intake air
temperature is very high after passing the intercooler. At this time, the intake temperature of
intake manifold is close to the intake temperature after boosting so that the engine performance is
reduced. When the ECU detects the difference between both temperatures is small, the
intercooler system is regarded as faulty.

Read the result: P1621 Intercooler system failure
Service tips:
a The coolant flow is blocked by the foreign objects or dirt inside the intercooler.
b The coolant cannot be circulated normally inside the intercooler due to the thermostat
failure in the intercooler cooling system. Check the thermostat.
DTC: P2088 Camshaft control valve control circuit voltage is low
185

Read the result: P2088 Camshaft control valve control circuit voltage is low
Service tips:
a The circuit between the camshaft control valve control signal pin and ECU is short to
DTC: P2089 Camshaft control valve control circuit voltage is high

Read the result: P2089 Camshaft control valve control circuit voltage is high
Service tips:
a The circuit between pin No. 2 of camshaft control valve and ECU is short to the circuit of
pin No. 1 of camshaft control valve. Measure the resistance of circuit between the ECU
pin and pin No. 1 of camshaft control valve with the multimeter.
b The circuit between pin No. 2 of camshaft control valve and ECU is short to other power
supply circuits. Check if the voltage of pin No. 2 of camshaft control valve is normal with
the multimeter.
DTC: P2100 Throttle motor control circuit is open

Read the result: P2100 Throttle motor control circuit is open
Service tips:
a The circuit between the throttle motor control circuit and ECU pin is open. Measure the
resistance between the ECU connector and throttle motor control circuit with the
multimeter.
b Poor contact occurs at the relevant Pins of ECU or throttle motor control circuit
DTC: P2102 Throttle motor control circuit voltage is low

Read the result: P2102 Throttle motor control circuit voltage is low
Service tips:
a The circuit between the throttle motor control circuit and ECU is short to ground. Measure
186
the resistance between the circuit connected to the ECU pin and the ground with the
multimeter.
DTC: P2103 Throttle motor control circuit voltage is high

Read the result: P2103 Throttle motor control circuit voltage is high
Service tips:
1) The throttle motor control circuit is short to the power supply. Measure the voltage of the
circuit connected to the ECU pin with the multimeter.
DTC: P2118 Throttle valve adjustment failure or control circuit is open

Read the result: P2118 Throttle valve adjustment failure or control circuit is open
Service tips:
a The throttle body is damaged and should be replaced.
b There is short circuit between the positive and negative terminals of throttle motor
control. Measure the resistance between the positive and negative terminals of throttle motor
control with the multimeter.
c The voltage of throttle motor control positive terminal is too high. Measure the voltage
between the positive and negative terminals of throttle motor control with the multimeter.
DTC: P2119 Mechanical failure in throttle body

Read the result: P2119 Mechanical failure in throttle body
Service tips:
a The throttle body is damaged and should be replaced.
DTC: P2121 Pedal position sensor signal is irrational

Read the result: P2121 Pedal position sensor signal is irrational
187
Service tips:
a The pedal position sensor is faulty and should be replaced.
DTC: P2122 Pedal position sensor 2 circuit voltage is low

Read the result: P2122 Pedal position sensor 2 circuit voltage is low
Service tips:
a The circuit between the pedal position sensor 2 signal circuit and the ECU is short to
DTC: P2123 Pedal position sensor 2 circuit voltage is high

Read the result: P2123 Pedal position sensor 2 circuit voltage is high
Service tips:
a The pedal position sensor 2 signal circuit is short to the power supply. Measure the
voltage of the circuit connected to the ECU pin with the multimeter.
DTC: P2147 The voltage at the high side of No. 1 injection nozzle is low
DTC: P2150 The voltage at the high side of No. 2 injection nozzle is low

The results are:
P2147 The voltage at high side of No. 1 injection nozzle is low
P2150 The voltage at high side of No. 2 injection nozzle is low
Service tips:
a The high side circuit connected to the ECU pin is short to ground. Measure the
resistance between the circuit connected to the ECU pin and the ground with the
multimeter.
DTC: P2148 The voltage at high side of No. 1 injection nozzle is high
DTC: P2151 The voltage at high side of No. 2 injection nozzle is high
The results are:
188
P2148 The voltage at high side of No. 1 injection nozzle is high
P2151 The voltage at high side of No. 2 injection nozzle is high
Service tips:
a The high side circuit connected to the ECU pin is short to the power supply. Measure the
voltage of the circuit connected to the ECU pin with the multimeter.
DTC: P2184 The circuit voltage of coolant temperature sensor at radiator outlet is low

Read the result: P2184 The circuit voltage of coolant temperature sensor at radiator outlet is
low
Service tips:
a The circuit between the signal circuit of the coolant temperature sensor at radiator outlet
is short to the ground. Measure the resistance between the circuit connected to the ECU
pin and the ground with the multimeter.
DTC: P2185 The circuit voltage of the coolant temperature sensor at radiator outlet is high

Read the result: P2123 Pedal position sensor 2 circuit voltage is high
Service tips:
a The circuit between the signal circuit of the coolant temperature sensor at the radiator
outlet is short to the power supply. Measure the voltage of the circuit connected to the
ECU pin with the multimeter.
DTC: P2227 Atmospheric pressure sensor signal is irrational

Read the result: P2227 Atmospheric pressure sensor signal is irrational
Service tips:
a The atmospheric pressure sensor integrated in the ECU is faulty. Replace the ECU.
DTC: P2228 Atmospheric pressure sensor circuit voltage is low
DTC: P2229 Atmospheric pressure sensor circuit voltage is high
189
The results are:
P2228 Atmospheric pressure sensor circuit voltage is low
P2229 Atmospheric pressure sensor circuit voltage is high
Service tips:
a The atmospheric pressure sensor circuit integrated in the ECU is faulty. Replace the
ECU.
DTC: P2300 No. 1 ignition coil control circuit voltage is low
The results are:
P2300 No. 1 ignition coil control circuit voltage is low
Service tips:
a The circuit connected to the ECU pin is short to ground. Measure the resistance between
the circuit connected to the ECU pin and the ground with the multimeter.
DTC: P2301 No. 1 ignition coil control circuit voltage is high
The results are:
P2301 No. 1 ignition coil control circuit voltage is high
190
Service tips:
a The circuit connected to the ECU pin is short to the power supply. Measure the voltage of
the circuit connected to the ECU pin with the multimeter.
DTC: P2600 Cooling water pump control circuit is open

Read the result: P2600 Cooling water pump control circuit is open
Service tips:
a The cooling water pump signal circuit connected to the ECU is open. Measure the
resistance between the ECU pin and cooling water pump signal circuit with the multimeter.
DTC: P2602 Cooling water pump control circuit voltage is low

Read the result: P2602 Cooling water pump control circuit voltage is low
Service tips:
a The cooling water pump signal circuit connected to the ECU is short to the ground.
Measure the resistance between the circuit connected to the ECU pin and the ground
with the multimeter.
DTC: P2603 Cooling water pump control circuit voltage is high

Read the result: P2603 Cooling water pump control circuit voltage is high
Service tips:
a The cooling water pump signal circuit connected to the ECU is short to the power supply.
Measure the voltage of the circuit connected to the ECU pin with the multimeter.
DTC: U0121 Communication failure between ECM and ABS system
DTC: U0164 Communication failure between ECM and air conditioning controller
DTC: U0168 Communication failure between ECM and keyless system
191
The results are:
U0121 Communication failure between ECM and ABS system
U0164 Communication failure between ECM and air conditioning controller
U0168 Communication failure between ECM and keyless system
Service tips:
a Check if the relevant systems are faulty and if the communication lines are short or open.
Section 5 Diagnosis Flow for TB10 System in Accordance with Trouble

Symptoms
Perform preliminary check first before 5.3.6 Check the booster appearance for any
troubleshooting in accordance with the scratch; Check if the turbine shaft
engine trouble symptoms: components can rotate freely; Check
the impeller for any damaged due to
5.1 Make sure the engine malfunction impact;
indicator operates normally;
5.3.7 Check the turbine housing and related
5.2 Check that no diagnostic information is pipe connectors for any exhaust gas
recorded with a diagnostic tester; leakage and check the intake system
for any leakage;
5.3 Make sure the trouble symptom
complained by the car owner exists, 5.3.8 Check if the ground point of wire
and confirm the conditions when the harness is clean and secure;
trouble occurs.
Then check the appearance: 5.3.9 Check the connectors of the sensor
and actuator for looseness or poor
5.3.1 Check the fuel pipe line for any contact.
leakage;
Important Tips: If the above symptoms
5.3.2 Check if the vacuum line is broken, occur, perform repair for the trouble
kinked or correctly connected; symptoms, otherwise the subsequent
troubleshooting and repair will be
5.3.3 Check if the intake pipe line is blocked, affected.
leaked, flattened or damaged;
Diagnostic tips:
5.3.4 Check the appearance of ignition coil
for any bulges and scorification and 5.3.9.1 Make sure no malfunction is
check if the ignition sequence is recorded for the engine;
correct;
5.3.9.2 Make sure the trouble symptom
5.3.5 Check the cooling system pipe line for exists;
any blockage or leakage;
5.3.9.3 After the above check, no abnormal
192
condition is found;
5.3.9.5.6 The engine can be started normally,
5.3.9.4 Do not ignore the effect of car but the idle speed is unstable at any
maintenance, cylinder pressure, time.
ignition timing and fuel condition
imposed on the system during 5.3.9.5.7 The engine can be started normally,
maintenance; but the idle speed is unstable during
warming up.
5.3.9.5 Perform test after the ECU is
replaced. 5.3.9.5.8 The engine can be started normally,
but the idle speed is unstable after the
If the trouble symptom can be warming up ends.
eliminated, the trouble area is ECU. If
the trouble symptom still exists, install 5.3.9.5.9 The engine can be started normally,
the original ECU. Repeat the process but the idle speed is unstable or the
and perform maintenance again. engine misfires under some load (for
example, the air conditioning is on).
The repair manual lists the following 14
common malfunctions, and general 5.3.9.5.10 The engine can be started
diagnosis flows are provided only for normally, but the idle speed is too high.
reference:
5.3.9.5.11 The engine speed does not
5.3.9.5.1 The engine does not rotate or increase or the engine misfires during
rotates slowly when starting. acceleration.
5.3.9.5.2 The engine can rotate, but cannot 5.3.9.5.12 The response is slow during
be started successfully. acceleration.
5.3.9.5.3 Hot starting is difficult. 5.3.9.5.13 The engine power is low and
performance is poor during
acceleration.
5.3.9.5.4 Cold starting is difficult.
5.3.9.5.14 The vehicle pauses from time to
5.3.9.5.5 The engine is difficult to start at time and shakes during acceleration or
any time, but the engine speed is driving at constant speed.
normal.
193
5.4 The engine does not rotate or rotates slowly when starting.
General trouble area: 1. Battery; 2. Cranking motor; 3. Wire harness or ignition switch; 4.
Fuses or relays in front compartment wiring box and instrument wiring box; 5. Engine
mechanics.
Test
Result
Check if the voltage between two terminals of the Yes Next step
1 battery is about 8-12 V with the multimeter when Replace the
the engine is started. No
battery
Keep the ignition switch in "Start" position, and Yes Next step
check if the voltage at the positive terminal of
2 Repair or replace
cranking motor is more than 8 V with the No
multimeter. wire harness
Repair or replace
Remove the cranking motor and check its Yes the cranking
3 operation condition. Check if the open circuit motor
exists or it is stuck due to poor lubrication.
No Next step
Remove the positive and negative terminals of the Replace the
Yes
battery and check the fuses in the front relevant fuses
compartment wiring box (F1/5, F1/9, F1/18,
F1/22-1, F1/23-2) and the fuses in the instrument
4 wiring box (F2/3, F2/14, F2/22, F2/23, F2/24,
F2/25, F2/26) for continuity with the multimeter. No Next step
Confirm if the fuses have been blown. (For details
on the wiring box fuses and relay, refer to the
attachment 7.4)
When the engine is turned on, check the relays in Repair or replace
the instrument wiring box (K2-1, K2-4, K2-6) for Yes the relevant
5 actuation; When the engine is started, check the relays
relay in the instrument wiring box (K2-7) for
actuation. No Next step
If the trouble only occurs in winter, check if the Use the proper
resistance of cranking motor is too high due to Yes
6 lubricant
improper selection of engine lubricant and gearbox
oil. No Next step
Overhaul the
Yes internal engine
Check if the cranking motor does not rotate or resistance
7 rotates slowly due to the high internal mechanical
resistance of the engine. Repeat the above
No
procedures
194
5.5 The engine can rotate, but cannot be started successfully.
General trouble area: 1. Empty fuel tank; 2. High pressure fuel pump; 3. Low pressure fuel
pump; 4. Speed sensor; 5. Ignition coil; 6. Fuses or relays in front compartment wiring box
and instrument wiring box; 7. Engine mechanics.

Connect the fuel pressure gauge (to the high Yes Next step
pressure fuel rail inlet), start the engine and
1
check if the fuel pressure is about 600 kPa Overhaul the fuel
during idling. No
supply system
Connect the diagnostic tester for the Yes Next step
electronically controlled injection system and Overhaul or replace
2
check if the pressure of the high pressure fuel No the high pressure fuel
pump is about 65 bar. pump
Remove the injector, and check the injector for Clean or replace the
Yes
3 any leakage or blockage with the special injector
Connect the diagnostic tester for electronically Yes Next step
controlled injection system and observe the
4 Overhaul the speed
"Engine Speed" value. Start the engine and No
check if the speed signal outputs. sensor circuit
Remove the ignition coil and injection nozzle
connector from one cylinder, connect the Yes Next step
sparkplug and position the plug electrode about
5
5 mm from the engine block. Start the engine Overhaul the ignition
and check if there is blue and white No
system
high-pressure spark.
Remove the positive and negative terminals of Replace the relevant
Yes
the battery and check the fuses in the front fuses
compartment wiring box (F1/9, F1/18) and the
fuses in the instrument wiring box (F2/3, F2/14,
6
F2/23, F2/24, F2/25, F2/26) for continuity with
No Next step
the multimeter. Confirm if the fuses have been
blown. (For details on the wiring box fuses and
relay, refer to the attachment 7.4)
When the engine is turned on, check the relays Repair or replace the
Yes
7 in the instrument wiring box (K2-1, K2-4, K2-6) relevant relays
for actuation. No Next step
Repair the
Check each cylinder of the engine for Yes mechanical
8 malfunction of engine
insufficient pressure.
No Next step
Connect the ECI system adapter, turn on the
ignition switch and check if the continuous Yes Diagnostic tips
power supply, ignition switch, non-continuous
9 power supply and pin power supply are normal;
Check if the Pins of ignition ground, electronic Overhaul related
No
ground 1 and power ground 1 are grounded circuits
normally.
195
5.6 Hot starting is difficult.
General trouble area: 1. Fuel with water; 2. High pressure fuel pump; 3. Low pressure fuel
pump; 4. Coolant temperature sensor; 5. Ignition coil.

Connect the fuel pressure gauge (to the Yes Next step
high pressure fuel rail inlet), start the engine
1
and check if the fuel pressure is about 600 Overhaul the fuel
kPa during idling. No
supply system
Remove the ignition coil and injection
nozzle connector from one cylinder, connect Yes Next step
the sparkplug and position the plug
2
electrode about 5 mm from the engine Overhaul the
block. Start the engine and check if there is No
ignition system
blue and white high-pressure spark.
Remove the connector of coolant Overhaul the circuit
temperature sensor, start the engine and Yes or replace the
check if the engine can be started sensor
successfully. (Or connect a resistor of 300
3 No Next step
ohms to the connector of coolant
temperature sensor to replace the coolant
temperature sensor, and check if the engine No Next step
can be started successfully.)
Check the fuel condition to see if the trouble Yes Replace the fuel
4
is caused immediately after the fuel is filled. No Next step
Connect the ECI system adapter, turn on
the ignition switch and check if the power Yes Diagnostic tips
supply of pin No. 113, 112, 3, 119 and 120
5
is normal; Check if the pin No. 51, 58, 2, Overhaul related
100, 103, 104 and 108 are grounded No
circuits
normally.
196
5.7 Cold starting is difficult.
pump; 4. Coolant temperature sensor; 5. Injector; 6. Ignition coil; 7. Electronic throttle valve;
8. Engine mechanics.
Yes Next step

Connect the fuel pressure gauge (to the high
1 pressure fuel rail inlet), start the engine and check if Overhaul the
the fuel pressure is about 600 kPa during idling. No fuel supply
system
connector from one cylinder, connect the sparkplug Yes Next step
2 and position the plug electrode about 5 mm from
the engine block. Start the engine and check if Overhaul the
No
there is blue and white high-pressure spark. ignition system
sensor, start the engine and check if the engine can Yes circuit or replace
be started successfully. (Or connect a resistor of the sensor
3 2,500 ohms to the connector of coolant temperature
sensor to replace the coolant temperature sensor,
No Next step
and check if the engine can be started
successfully.)
Clean the
4 throttle valve
No Next step
Yes
Check the fuel condition to see if the trouble is Yes Replace the fuel
6
caused immediately after the fuel is filled. No Next step
Repair the
mechanical
7 malfunction of
pressure.
engine
No Next step
ignition switch and check if the power supply of pin Yes Diagnostic tips
8 No. 113, 112, 3, 119 and 120 is normal; Check if
the pin No. 51, 58, 2, 100, 103, 104 and 108 are Overhaul related
No
grounded normally. circuits
5.8 The engine is difficult to start at any time, but the engine speed is normal.
pump; 4. Coolant temperature sensor; 5. Injector; 6. Ignition coil; 7. Electronic throttle valve
assembly; 8. Inlet passage; 9. Ignition timing; 10. Sparkplug; 11. Engine mechanics.
197
Follow-up
No. Operation Steps Test Result
Step
Overhaul the
Check the air filter for blockage and check the inlet Yes intake
1 system
No Next step
Yes Next step

system
Yes Next step
connector from one cylinder, connect the sparkplug
3 and position the plug electrode about 5 mm from Overhaul the
the engine block. Start the engine and check if No ignition
there is blue and white high-pressure spark. system
Yes Next step
4 Adjust or
replace
Overhaul the
Yes
5 sensor, start the engine and check if the engine can replace the
be started successfully. sensor
No Next step
Clean the
6 throttle valve
No Next step
Replace the
Remove the injector, and check the injector for any
Yes faulty
7 leakage or blockage with the special washing
injector
analyzer.
No Next step
Replace the
8 fuel
No Next step
Repair the
mechanical
9 malfunction
pressure.
of engine
No Next step
Yes Next step
Check if the ignition sequence and ignition timing of Overhaul the
10
engine are as specified. No ignition
timing
Connect the ECI system adapter, turn on the Diagnostic
Yes
ignition switch and check if the power supply of pin tips
11 No. 113, 112, 3, 119 and 120 is normal; Check if Overhaul
the pin No. 51, 58, 2, 100, 103, 104 and 108 are No related
198
5.9 The engine can be started normally, but the idle speed is unstable at any time.
General trouble area: 1. Fuel with water; 2. Injector; 3. Sparkplug; 4. Electronic throttle body
assembly; 5. Inlet passage; 6. Ignition timing; 7. Sparkplug; 8. Engine mechanics.
Follow-up
Step
Overhaul the
1 system
No Next step
Yes Next step
2 Adjust or
replace
Check the electronic throttle body for carbon Yes Clean
3
deposit. No Next step
Replace the
Yes faulty
4 leakage, blockage or poor flow with the special
injector
washing analyzer.
No Next step
Replace the
5 fuel
No Next step
Repair the
mechanical
6 malfunction
of engine
No Next step
Yes Next step
7
timing
Yes
199
5.10 The engine can be started normally, but the idle speed is unstable during warming up.
Electronic throttle valve; 5. Inlet passage; 6. Engine mechanics.

Follow-up
Step
Overhaul the
1 system
No Next step
Yes Next step
2 Adjust or
replace
Clean
Check the electronic throttle body for carbon Yes related
3
deposit. components
No Next step
Overhaul the
Yes
No Next step
Replace the
Yes faulty
injector
washing analyzer.
No Next step
Replace the
6 fuel
No Next step
Repair the
mechanical
7 malfunction
of engine
No Next step
Yes
200
5.11 The engine can be started normally, but the idle speed is unstable after the warming up
ends.
Electronic throttle valve; 5. Inlet passage; 8. Engine mechanics.
Follow-up
Step
Overhaul the
1 system
No Next step
Yes Next step
2 Adjust or
replace
Clean
Yes related
3 Check the throttle body for carbon deposit.
components
No Next step
Overhaul the
Yes
No Next step
Replace the
Yes faulty
injector
washing analyzer.
No Next step
Replace the
6 fuel
No Next step
Repair the
mechanical
7 malfunction
of engine
No Next step
Yes
201
5.12 The engine can be started normally, but the idle speed is unstable or the engine misfires
under some load (for example, the air conditioning is on).
General trouble area: 1. Air conditioning system; 2. Electronic throttle valve; 3. Injector.
Follow-up
Step
Clean
1
deposit. components
No Next step
Check if the engine output power increases with the
Yes Go to step 4
air conditioning on, which is to observe the change
2 of ignition advance angle, injection pulse width and
intake air volume with the diagnostic tester for No Next step
Yes Next step
Connect the ECI system adapter and disconnect
Overhaul the
the wire connected to pin No. 54 of electronic
3 air
control unit. Check the wire harness end for high No
conditioning
level signal with the air conditioning on.
system
Yes Next step
Check if the pressure of air conditioning system, Overhaul the
4 magnetic clutch of compressor and air conditioning air
No
compression pump are normal. conditioning
system
Replace the
Yes faulty
injector
washing analyzer.
No Next step
Yes
202
5.13 The engine can be started normally, but the idle speed is too high.
General trouble area: 1. Electronic throttle body assembly; 2. Vacuum pipe: 3. Coolant
temperature sensor; 4. Ignition timing.
Follow-up
Step
Replace the
Check if the electronic accelerator pedal signal is Yes accelerator
1
output normally. pedal
No Next step
Overhaul the
Check the intake system and connected vacuum Yes intake
2 system
pipe line for air leakage.
No Next step
Clean
3
deposit. components
No Next step
Overhaul the
Yes
4 sensor, start the engine and check if the idle speed replace the
of engine is too high. sensor
No Next step
Yes Next step
Overhaul the
5 Check if the ignition timing of engine is as specified.
No ignition
timing
Yes
203
5.14 The engine speed does not increase or the engine misfires during acceleration.
General trouble area: 1. Fuel with water; 2. Intake pressure sensor; 3. Sparkplug; 4.
Electronic throttle body assembly; 5. Inlet passage; 6. Idle speed regulator; 7. Injector; 8.
Ignition timing; 9. Exhaust pipe; 10. Turbocharger.
Follow-up
Step
Overhaul the
Yes intake
1 Check the air filter for any blockage. system
No Next step
Yes Next step

system
Yes Next step
3 Adjust or
replace
Clean
4
deposit. components
No Next step
Yes Next step
Overhaul the
5 circuit or
throttle body and their circuits are normal. No
replace the
sensor
Replace the
Yes faulty
injector
analyzer.
No Next step
Replace the
7 fuel
No Next step
Yes Next step
8
timing
Yes Next step
9
exhaust pipe
Yes Next step
ignition switch and check if the power supply of pin
204
Diagnostic
Yes
tips
Check the turbocharger operation for insufficient Overhaul the
11 boosting or air leakage. turbocharger
pipe line or
No
replace
related
components
5.15 The response is slow during acceleration.
General trouble area: 1. Fuel with water; 2. Intake pressure sensor; 3. Sparkplug; 4.
Electronic throttle body assembly; 5. Inlet passage; 6. Injector; 7. Ignition timing; 8. Exhaust
pipe; 9. Turbocharger.
Follow-up
No. Test Result
Operation Steps Step
Overhaul the
Yes intake
1 Check the air filter for any blockage. system
No Next step
Yes Next step

system
Yes Next step
3 Adjust or
replace
Clean
Yes related
4 Check the throttle body for carbon deposit.
components
No Next step
Yes Next step
Overhaul the
Check if the intake pressure sensor circuit is
5 circuit or
normal. No
replace the
sensor
Replace the
Yes faulty
injector
analyzer.
No Next step
Replace the
7 fuel
No Next step
Yes Next step
8
timing
9 Check if the exhaust gas is discharged smoothly Yes Next step
205
from the exhaust pipe, and check the turbocharger Repair or

No
for air leakage or insufficient boosting. replace
Yes
206
5.16 The engine power is low and performance is poor during acceleration.
General trouble area: 1. Fuel with water; 2. Intake pressure sensor; 3. Sparkplug; 4. Ignition
coil; 5. Electronic throttle body; 6. Inlet passage; 7. Injector; 8. Ignition timing; 9. Exhaust pipe;
10. Turbocharger.

Check for the clutch slip, low tire pressure, Yes Repair
1 brake drag, incorrect tire size and incorrect
No Next step
four-wheel alignment.
Overhaul the
Yes
No Next step
pressure fuel rail inlet), start the engine and
3
during idling. No
supply system
sparkplug and position the plug electrode
4
about 5 mm from the engine block. Start the Overhaul the
engine and check if there is blue and white No
ignition system
Check if the type and gap of sparkplug in Yes Next step
5
each cylinder are as specified. No Adjust or replace
Clean related
Check the electronic throttle valve for carbon Yes
6 components
deposit.
No Next step
Yes Next step
Check if the intake pressure sensor, throttle Overhaul the
7
position sensor and their circuits are normal. No circuit or replace
the sensor
Remove the injector, and check the injector Replace the faulty
Yes
8 for any leakage or blockage with the special injector
9
Yes Next step
Check if the ignition sequence and ignition
10 Overhaul the
timing of engine are as specified. No
ignition timing
Yes Next step
Check if the exhaust gas is discharged
11 Repair or replace
smoothly from the exhaust pipe. No
the exhaust pipe
ignition switch and check if the power supply Yes Next step
12 of pin No. 113, 112, 3, 119 and 120 is normal;
Check if the pin No. 51, 58, 2, 100, 103, 104 Overhaul related
No
and 108 are grounded normally. circuits
207
Yes Diagnostic tips

Check the turbocharger operation for
13 insufficient boosting or air leakage. Overhaul the
circuit or replace
No
the related
components
5.17 The vehicle pauses from time to time and shakes during acceleration or driving at constant
speed.
General trouble area: 1. The fuel or tire does not meet the technical requirements; 2. The air
filter and inlet passage is blocked; 3. Excessive carbon is deposited in the electronic throttle
body; 4. Low fuel pressure or no fuel pressure; 5. Ignition coil; 6. Sparkplug; 7. Injector; 8.
Ignition timing; 9. Exhaust pipe; 10. Turbocharger; 11. Charcoal canister blocked or charcoal
canister solenoid valve failure; 12. Sensors and circuits failure.

Check if the fuel, tire pressure, tire size and Yes Replace or repair
1 four-wheel alignment meet the technical
No Next step
requirements.
Replace the air
Check the air filter for blockage and check if Yes filter and clean the
2 excessive carbon is deposited in the inlet inlet passage
passage.
No Next step
Clean or replace
Check if excessive carbon is deposited in the Yes
3 the throttle valve
electronic throttle valve.
No Next step
pressure fuel pump inlet), start the engine and
4
during idling. No
supply system
sparkplug and position the plug electrode
5
about 5 mm from the engine block. Start the Overhaul the
engine and check if there is blue and white No
ignition system
Check if the type and gap of sparkplug in Replace the
Yes
6 each cylinder are not as specified and if sparkplug
excessive carbon is deposited. No Next step
Remove the injector, and check the injector Replace the faulty
Yes
7 for any leakage or blockage with the special injector
8
Yes Next step
Check if the ignition sequence and ignition
9 Overhaul the
timing of engine are as specified. No
ignition timing
10 Check if the exhaust gas is discharged Yes Next step
208
smoothly from the exhaust pipe. Repair or replace

No
the exhaust pipe
Check the turbocharger operation for Yes Diagnostic tips
11
insufficient boosting or air leakage. No Next step
Replace the
Check if the charcoal canister cannot operate Yes
12 charcoal canister
normally due to blockage.
No Next step
Turn on the ignition switch and switch the Yes Next step
charcoal canister solenoid valve to On or Off Repair or replace
13 with the diagnostic tester. Check if the the charcoal
No
charcoal canister solenoid valve can be canister solenoid
operated based on demands. valve
Yes Next step
Check if the intake pressure sensor, throttle Overhaul the
14
position sensor and their circuits are normal. No circuit or replace
the sensor
ignition switch and check if the power supply Yes Next step
15 of pin No. 113, 112, 3, 119 and 120 is normal;
Check if the pin No. 51, 58, 2, 100, 103, 104 Overhaul related
No
and 108 are grounded normally. circuits
209
Section 6 Instructions for Using Diagnostic Tester

With the BYD ED400 diagnostic tester developed by BYD AUTO Co., Ltd. as an example, the
section describes how to diagnose and analyze the TI electronically controlled injection system
using a diagnostic tester. The displayed contents and functions may vary with the new models
and program update which the customers should pay attention to.
The values and related contents in the section are only for reference and the actual measurement
by the diagnosis program should prevail.
6.1 Operation Panel of Diagnostic key to backspace which is to delete the

Tester previous digit. When performing the
component operation test, the ← key is
6.1.1 The LCD is on the left of the panel which used to turn off the component and the →
is used to display a variety of diagnostic key is used to activate or turn on the
information. component.
6.1.2 The operation buttons are on the right of RST: System reset. Note: Be careful to
the penal as follows: use the key. When using the key, press it
for 1 to 2 seconds and then release.
ESC: Return to the parent directory; Exit

the current function page; Exit the current
setting items.
OK: Enter the next level directory.

Confirm the performance of a function
operation.
F1 and F2: F1 is used to display help; F2

is used to print the current page. Both
keys can be used as auxiliary input
function keys under special conditions, for
example inputting the plus or minus. See
the tips on corresponding pages for
details
6.3 Introduction of Diagnostic Tester

Functions
6.3.1 Self diagnosis
It mainly includes reading and clearing

6.2 Introduction of Key Function DTCs;
Number key 0-9: Menu selection; Number 6.3.2 System parameter display
input.
Direction key ↑↓← →:The ↑ and ↓ keys It mainly displays the main parameters,
are used to select the menu and the ← test items and sensor signal voltage;
and → keys are used to turn pages;
When inputting numbers, pressing the ↑ 6.3.3 System status
key can increase by 1 and pressing the ↓
key can decrease by 1. Pressing the ← It mainly displays the status of 10 items
210
such as programming status, cooling

system, steady working condition,
dynamic working condition, emission
control, oxygen sensor, idling,
malfunction indicator, emergency
operation and air conditioning;
6.3.4 Actuator test
It mainly tests the function of 6 times such

as malfunction indicator, fuel pump, air
conditioning relay, fan control, ignition
test and single cylinder fuel cutoff;
6.3.5 Odometer
It mainly displays the vehicle driving

range and driving time;
6.3.6 Version information
It mainly displays the vehicle 6.4.4 Select the model diagnosis;

identification number (optional), ECU
hardware number, ECU software 6.4.5 Enter the diagnosis model selection
number. interface;
6.4 Instructions for Using Diagnostic 6.4.6 Select the model to be diagnosed (such
Tester as G6);
6.4.1 Connect the diagnostic cable; 6.4.7 Enter the diagnosis system selection
interface;
6.4.2 Power on the vehicle by pressing the
push-start button;
6.4.3 Enter the diagnosis function selection

interface;
211
6.4.8 Select the engine management system;
6.4.9 Enter the engine management system

selection interface;
6.4.10 lect the "TI engine management

system";
1. Read
2. Read
3. Clear
4. Read 6.4 10.3 If the system is faulty
5. Component”
The "Info bar" will list all the DTCs and
corresponding trouble information as
shown below.
DTC
1. PO106: Intake pressure sensor

signal is irrational
2. PO107 Intake pressure sensor
circuit voltage is low
3. .PO108 Intake pressure sensor
circuit voltage is high
4. PO111 Intake temperature sensor
signal is irrational
5. PO685 DTC is not defined
6.4 10.1 Read the computer version
The computer version information is a set

of data defined by the manufacturer
which is used to identify some basic Press｛←｝ key to turn to the previous page
Press｛→｝key to turn to the next page
information, such as Vehicle Identification Press｛F2｝key to print
Number. Press {ESC} key to exit
6.4.10.2 Read DTCs Trouble information consists of 4 parts. The

first part is a serial number without meaning.
The function can display the trouble
The second part is the trouble code which is
detected by the ECU in the form of compiled according to related standards, for
specific codes (DTCs). Refer to the example "P0122". The first letter "P" indicates
related industrial standards for the coding the engine malfunction and it forms a trouble
specification of trouble codes.
code with the last 4 numbers "0122". The third
part is in the bracket which indicates the
If the system is OK
trouble conditions. There are three conditions
such as "Current DTC", "History DTC" and
BYD-ED400 will display "System is OK"
"Intermittent DTC". "Current DTC" indicates
as shown below.
the trouble always exists and the DTC cannot
be cleared through the "Clear DTCs" function.
"History DTC" indicates the trouble occurred
212
in the past, but it has been repaired during the speed.

diagnosis and the DTC can be cleared
through the "Clear DTCs" function. The display is as shown below after
"Intermittent DTC" indicates the trouble is an successful communication. The current
occasional malfunction which is caused by display is Page 1. The customer can view
poor contact and the DTC can be cleared other data by pressing ← and → keys.
through the "Clear DTCs" function. The last
part is the complete description of trouble
information. If the trouble information is not
included in the BYD-ED400, it will display
"DTC Not Defined". In this case, contact the
BYD aftersales service for feedback.
"Page: 1/2" on the upper right corner of the

screen indicates the received trouble
information is displayed in 2 pages and the
current page is Page 1. The customer can
view other trouble information on Page 2 by
pressing [→] key as indicated in "Help bar".
Press [←] key to return o Page 1
10.3 Clear DTCs
The function is used to clear some history

or intermittent DTCs recorded in the ECU.
The display in the right figure will be 6.4 10.5 Component Operation Test
shown if the operation is successful. The
customer is recommended to perform the The component operation test can be
operation for 2 to 3 times to ensure the controlled in 2 modes which are switching
DTCs are cleared completely. parameters and control parameters. See
the figure below. The operation methods
for the parameters are different, which will
be described below.
6.4 10.4 Read data flow
The function is used to present various

data status of engine to the customers,
including current engine speed, vehicle
213
a Switching parameters
The customer can press the [OK] key to
The switching parameters have two enter and set the relevant items.
states: On or Off. Therefore the customer
can complete relevant actions with simple
operations.
The symbol "" indicates the parameters

being controlled currently. Meanwhile, the
customer's expected operation states will
be displayed on the right: On or Off (The
display status is "Unknown" when no
operation is performed). The customer
can select the items to be tested by
pressing the ↑ and ↓ keys. The current
switching parameters can be controlled
by pressing the ← and → keys. Press ←
key to perform Off operation and press →
key to perform On operation.
If the customer wants to give up the

control of currently selected item, select With the charcoal canister control valve
other test items simply by pressing the ↑ setting as an example, the display is as
and ↓ keys, or exit the current page by shown below after entering the setting
pressing [ESC] key. interface.
b Control parameters
The control parameters are some setting In the "Info bar" shown above, the first
parameters. Some internal variables of line is the setting value input by the
ECU can be changed by setting these customer, and the second line is the
parameters so as to change the operation range of setting value. The input value
condition of the engine. should not exceed the specified range, or
the operation may fail.
The symbol "" indicates the items that
can be set by the customer currently. The Description: Be careful to perform the
customer can select the parameter to be "component operation test". If you are not
set by pressing the ↑ and ↓ keys. a professional technician or service
214
personnel, do not use the function to

avoid improper operation and damage to
the engine system.
215
Section 7 Attachment
7.1 Periodic Maintenance Procedures for ECI System
Description:
7.1.1 The periodic maintenance procedures are for family cars;
Mileage
10 15 20 25 30 35 40 45 50 55 60
Item x 1000km
Month 12 18 24 30 36 42 48 54 60 66 72
Ignition Coil I I I
Sparkplug I R I R I R
Ignition Timing I I I
Engine Idling I I I
Fuel Tank I
Gasoline Filter R R
Injector C* C* C*
Oil Filter R R R R R R
Air Cleaner I R I R I R
Electronic Throttle
C C C C C C
Valve Body
Emission Check I I I I I I
Diagnostic Tester
I I I
Check
Oxygen Sensor
I I I I I I
Check
Three Way Catalytic
I I I I I I
Converter Check
R-Replace
C-Clean
I-Inspect (Replace the malfunctioning components found during item inspection)
C*-It is recommended to use the special injector washing analyzer to clean and maintain the
injector
216
7.2 Trouble Code Table
TB10 Trouble Code Table

No. DTC Malfunction Description
1 P0010 Camshaft control valve control circuit is open
2 P0016 Intake phase deviation is large
3 P0030 Front oxygen heating control circuit is open
4 P0031 Front oxygen heating control circuit voltage is low
5 P0032 Front oxygen heating control circuit voltage is high
6 P0033 Turbocharger bypass valve control circuit is open
7 P0034 Turbocharger bypass valve control circuit voltage is low
8 P0035 Turbocharger bypass valve control circuit voltage is high
9 P0036 Rear oxygen heating control circuit is open
10 P0037 Rear oxygen heating control circuit voltage is low
11 P0038 Rear oxygen heating control circuit voltage is high
12 P0089 Fuel pressure control valve control circuit failure
13 P0097 Boost gas temperature sensor circuit voltage is low
14 P0098 Boost gas temperature sensor circuit voltage is high
15 P0107 Intake pressure sensor circuit voltage is low
16 P0108 Intake pressure sensor circuit voltage is high
17 P0112 Intake temperature sensor circuit voltage is low
18 P0113 Intake temperature sensor circuit voltage is high
19 P0117 Coolant temperature sensor circuit voltage is low
20 P0118 Coolant temperature sensor circuit voltage is high
21 P0121 Throttle position sensor is irrational
22 P0122 Throttle position sensor A circuit voltage is low
23 P0123 Throttle position sensor A circuit voltage is high
24 P0131 Front oxygen sensor circuit voltage is low
25 P0132 Front oxygen sensor circuit voltage is high
26 P0134 Front oxygen sensor circuit is open
27 P0137 Rear oxygen sensor circuit voltage is low
28 P0138 Rear oxygen sensor circuit voltage is high
29 P0140 Rear oxygen sensor circuit is open
30 P0192 Fuel pressure sensor circuit voltage is low
31 P0193 Fuel pressure sensor circuit voltage is high
32 P0201 No. 1 injector control line open-circuit error
36 P0221 Throttle position sensor signal is irrational
37 P0222 Throttle position sensor B circuit voltage is low
38 P0223 Throttle position sensor B circuit voltage is high
39 P0226 Pedal position sensor signal is irrational
40 P0227 Pedal position sensor 1 circuit voltage is low
41 P0228 Pedal position sensor 1 circuit voltage is high
42 P0236 Boost pressure sensor signal is irrational
43 P0237 Boost pressure sensor circuit voltage is low
217
44 P0238 Boost pressure sensor circuit voltage is high

45 P0261 The voltage at low side of No. 1 injector is low
46 P0262 The voltage at low side of No. 1 injector is high
47 P0263 Short circuit between low and high side circuits of No. 1 injector
57 P0300 One or multi-cylinder misfire
58 P0301 Cylinder 1 misfire
62 P0335 No signal from crankshaft sensor circuit
63 P0336 Crankshaft sensor signal is irrational
64 P0340 No signal from camshaft sensor
65 P0341 Camshaft sensor signal is irrational
66 P0351 No. 1 ignition coil control circuit is open
70 P0444 Charcoal canister solenoid valve control circuit is open
71 P0458 Charcoal canister solenoid valve control circuit voltage is low
72 P0459 Charcoal canister solenoid valve control circuit voltage is high
73 P0476 Boost pressure limiting solenoid control circuit is open
74 P0477 Boost pressure limiting solenoid control circuit voltage is low
75 P0478 Boost pressure limiting solenoid control circuit voltage is high
76 P0480 Stepless fan control line is open
77 P0562 System voltage is low
78 P0563 System voltage is high
79 P0620 AC generator load failure
80 P0627 Fuel pump control circuit is open
81 P0628 Fuel pump control circuit voltage is low
82 P0629 Fuel pump control circuit voltage is high
83 P0633 ECM and anti-theft system authentication failure
84 P0645 Air conditioning permission control circuit is open
85 P0646 Air conditioning permission control circuit voltage is low
86 P0647 Air conditioning permission control circuit voltage is high
87 P0691 Stepless fan control line voltage is low
88 P0692 Stepless fan control line voltage is high
89 P1601 Stepless fan motor rotor locked or short circuit
90 P1602 Stepless fan over-temperature protection or electronic error
218
91 P1611 ECM internal failure 1

99 P1621 Intercooler system failure
100 P2088 Camshaft control valve control circuit voltage is low
101 P2089 Camshaft control valve control circuit voltage is high
102 P2100 Throttle motor control circuit is open
103 P2102 Throttle motor control circuit voltage is low
104 P2103 Throttle motor control circuit voltage is high
105 P2118 Throttle valve adjustment failure or control circuit is open
106 P2119 Mechanical failure in throttle body
107 P2121 Pedal position sensor signal is irrational
108 P2122 Pedal position sensor 2 circuit voltage is low
109 P2123 Pedal position sensor 2 circuit voltage is high
110 P2147 The voltage at high side of No. 1 injector is low
111 P2148 The voltage at high side of No. 1 injector is high
112 P2150 The voltage at high side of No. 2 injector is low
113 P2151 The voltage at high side of No. 2 injector is high
114 P2184 The circuit voltage of coolant temperature sensor at radiator outlet is low
115 P2185 The circuit voltage of coolant temperature sensor at radiator outlet is high
116 P2227 Atmospheric pressure sensor signal is irrational
117 P2228 Atmospheric pressure sensor circuit voltage is low
118 P2229 Atmospheric pressure sensor circuit voltage is high
119 P2300 No. 1 ignition coil control circuit voltage is low
120 P2301 No. 1 ignition coil control circuit voltage is high
127 P2600 Cooling water pump control circuit is open
128 P2602 Cooling water pump control circuit voltage is low
129 P2603 Cooling water pump control circuit voltage is high
130 U0121 Communication failure between ECM and ABS system
131 U0164 Communication failure between ECM and air conditioning controller
132 U0168 Communication failure between ECM and keyless system
7.3 Electrical Schematic Diagram
Refer to the relevant schematic diagram of wire harness for different models. When
troubleshooting and repairing, be sure to refer to the schematic diagram.
219
7.4 Definition of Fuses and Relays in Distribution Box
Schematic diagram of front compartment distribution box
220
Specifications and usage of relays in the front compartment distribution box:
221
Position Definition Specification Position Definition Specification

Front blower Front fog light
K1-1 30 A K1-4 20 A
relay relay
Compressor Daytime running
K1-2 20 A K1-5 20 A
relay light relay
Rear
K1-3 defroster 30 A
relay
Specifications and usage of fuses in the front compartment distribution box:
No. Specification Usage No. Specification Usage

Horn, braking
F1/1 10 A High beam RH F1/14 20 A
light
F1/2 10 A High beam LH F1/15 40 A Rear defroster
Door lock,
F1/3 10 A Low beam LH F1/16 40 A MICU constant
voltage
F1/4 10 A Low beam RH F1/17 25 A ABS
No. 2 ignition
F1/5 10 A F1/18 40 A EMS
switch
F1/6 15 A Side lamp F1/19 40 A ABS
F1/7 7.5 A MCU F1/20 40 A Power seat
F1/8 20 A Reserved F1/21 40 A Blower
F1/9 15 A EMS F1/22-1 125 A Main fuse
Electronic
F1/10 20 A Front fog light F1/22-2 50 A
cooling fan
Daytime running Door window
F1/11 15 A F1/23-1 50 A
light motor
F1/12 7.5 A Compressor F1/23-2 50 A Ignition switch
F1/13 15 A Steering light
222
Schematic diagram of instrument wiring box
Specifications and usage of relays in the instrument wiring box:
Position Definition Specification Position Definition Specification

Main relay II of Power window
K2-1 30 A K2-5 30 A
electronic injector relay
K2-2 A/T relay 30 A K2-6 Oil pump relay 20 A
Cigarette lighter
K2-3 20 A K2-7 Starter relay 20 A
relay
Main relay I of
K2-4 30 A K2-8 Flasher relay
electronic injector
223
Specifications and usage of fuses in the instrument wiring box:
Position Definition Position Definition Position Definition

Main relay I of
Oxygen sensor (7.5
F2/1 Door latch (20 A) F2/12 F2/23 electronic
A)
injector (15 A)
Door light, interior Steering shaft lock Fuel pump
F2/2 F2/13 F2/24
light (7.5 A) unlocked (7.5 A) motor (15 A)
Control module Main relay II of
F2/3 constant power F2/14 IG2 power (10 A) F2/25 electronic
(10 A) injector (15 A)
Audio system
Power skylight (20
F2/4 constant power F2/15 F2/26 EMS (15 A)
A)
(15 A)
Cigarette lighter Left front window Reserved (10
F2/5 F2/16 F2/27
(15 A) motor (20 A) A)
Rear fog light (7.5 Right rear window Washer motor
F2/6 F2/17 F2/28
A) motor (20 A) (15 A)
Rearview
Right front window mirror
F2/7 Seat heater (20 A) F2/18 F2/29
motor (20 A) defroster (7.5
A)
Left front power Left rear window Reserved fuse
F2/8 F2/19 F2/30
seat (25 A) motor (20 A) (15 A)
Power for
Reserved fuse (25 Auxiliary power
F2/9 F2/20 F2/31 switch 2nd
A) supply (7.5 A)
gear (7.5 A)
Right front power Motor control
F2/10 F2/21 F2/32 SRS (15 A)
seat (25 A) module (15 A)
Reserved fuse (20 Front wiper
F2/11 F2/22 Starter (20 A) F2/33
A) power (30 A)
224
Electrical System
Contents
Chapter 1 Combination Instrument .................................................................................................. 5
1 Parts Location ........................................................................................................................ 6
2 System Diagram .................................................................................................................... 7
3 Information sheet ................................................................................................................... 8
4 System overview .................................................................................................................... 9
5 Diagnosis process ............................................................................................................... 12
6 Diagnosis Trouble Code Table ............................................................................................ 13
7 Problem Symptoms Chart.................................................................................................... 14
8 Terminal Diagnosis .............................................................................................................. 17
9 Removal ............................................................................................................................... 51
10 Installation .......................................................................................................................... 52
Chapter 2 Lighting System ............................................................................................................. 53
1 Position of the Assembly ..................................................................................................... 54
2 System Diagram .................................................................................................................. 58
3 System overview .................................................................................................................. 62
7 Overall Diagnosis Procedure ............................................................................................... 72
8 Assembly & disassembly ...................................................................................................122
Chapter 3 Multimedia System ...................................................................................................... 128
1 Parts Location .................................................................................................................... 129
2 System Diagram ................................................................................................................ 131
3 System Description ............................................................................................................ 132
4 How to Troubleshoot.......................................................................................................... 134
5 Problem Symptoms Chart..................................................................................................136
6 ECU terminals .................................................................................................................... 138
7 Power Supply Circuit of the Multimedia Machine .............................................................. 162
8 Disassembly and Assembly of the Door Speakers ........................................................... 186
9 Assembly and Disassembly of the Front High Pitch Speakers ......................................... 187
10 Assembly and Disassembly of the Middle Pitch Speakers ............................................. 187
11 Assembly & disassembly of exterior power amplifier ...................................................... 188
12 Removal and Installation of the USB & AUX Interface ................................................... 188
13 Assembly and Disassembly of the Rear High Pitch Speakers........................................ 189
14 Assembly and Disassembly of the Mega Bass Speakers ............................................... 189
15 Removal and Installation of the Antenna Amplifier ......................................................... 190
16 Disassembly & Assembly of the Exterior Antenna .......................................................... 190
Chapter 4 Audio System .............................................................................................................. 192
1 Parts Location .................................................................................................................... 193
2 System Diagram ................................................................................................................ 196
1

4 How to Proceed with Troubleshooting ............................................................................... 199
5 Malfunction Symptoms Table ............................................................................................ 201
6 ECU Terminals................................................................................................................... 202
7 Overall Diagnosis Procedure ............................................................................................. 205
8 Removal and Installation of the CD Unit ........................................................................... 227
9 Removal and Installation of the Door Speakers ................................................................ 227
10 Removal and Installation of the Front High Pitch Speakers............................................ 228
11 Removal and Installation of the USB&AUX Interface ..................................................... 228
Chapter 5 Multi-functional display ................................................................................................ 230
1 Parts Location .................................................................................................................... 231
2 System Diagram ................................................................................................................ 232
6 ECU terminals .................................................................................................................... 237
7 Diagnosis Trouble Code Table .......................................................................................... 239
8 Removal ............................................................................................................................. 246
9 Installation .......................................................................................................................... 246
Chapter 6 Power seat control system .......................................................................................... 247
1 Position of the Assembly ...................................................................................................248
2 System Diagram ................................................................................................................ 249
3 Diagnosis process ............................................................................................................. 250
6 Seat electrical adjustment fails. ......................................................................................... 252
7 Driver seat adjustment fails ............................................................................................... 254
8 Driver seat horizontal adjustment fails .............................................................................. 256
9 Driver seat pan adjustment fails ........................................................................................ 260
10 Seat back adjustment fails ............................................................................................... 264
11 Driver seat height adjustment fails .................................................................................. 268
Chapter 7 Power Window............................................................................................................. 272
2 System Diagram ................................................................................................................ 275
3 System overview ................................................................................................................ 276
5 Problem Symptoms Table .................................................................................................279
6 Terminal Diagnosis ............................................................................................................ 280
7 Overall Diagnosis Flow ...................................................................................................... 282
8 Front-left window lifter switch block power distribution ..................................................... 282
Chapter 8 Power outer rear view mirror ....................................................................................... 313
2
2 System Diagram ................................................................................................................ 315

3 System overview ................................................................................................................ 316
6 ECU terminals .................................................................................................................... 320
7 Disassembly....................................................................................................................... 335
8 Assembly ........................................................................................................................... 335
Chapter 9 Power sun roof ............................................................................................................ 336
1 System overview ................................................................................................................ 337
Chapter 10 Washing of Windshield Wiper ................................................................................... 345
1 Position of the Components .............................................................................................. 346
2 System Diagram ................................................................................................................ 347
5 Malfunction Symptom Table .............................................................................................. 351
6 Overall Diagnosis Process ................................................................................................ 352
7 Removal and installation of the front wiper assembly ....................................................... 363
8 Removal and installation of the washing motor .................................................................364
Chapter 11 Rear LOGO assembly ............................................................................................... 365
1 System overview ................................................................................................................ 366
3 LOGO has no light when the sidelamp is on. ....................................................................367
Chapter 12 Cruise control system ................................................................................................ 370
2 System overview ................................................................................................................ 371
Chapter 13 Tire pressure monitoring system ............................................................................... 379
1 Parts Location .................................................................................................................... 380
2 System Diagram ................................................................................................................ 382
6 ECU terminals .................................................................................................................... 387
Chapter 14 Parking System ......................................................................................................... 395
2 System overview ................................................................................................................ 398
3
5 DTC table ........................................................................................................................... 402

8 Auxiliary parking system module disassembly & assembly .............................................. 437
9 Sensor assembly & disassembly ....................................................................................... 438
Chapter 15 Accessories ............................................................................................................... 439
2 System overview ................................................................................................................ 442
5 Cigarette lighter assembly & disassembly......................................................................... 458
4
Chapter 1 Combination Instrument

1 Parts Location ........................................................................................................................ 6
2 System Diagram .................................................................................................................... 7
3 Information sheet ................................................................................................................... 8
4 System overview .................................................................................................................... 9
6 Diagnosis Trouble Code Table ............................................................................................ 13
9 Removal ............................................................................................................................... 51
10 Installation .......................................................................................................................... 52
5
1 Parts Location
Combination
Instrument
6
2 System Diagram
Supplemental
Lighting System restraint system
Oil level sensor Multimedia System
Combination
Power generating
Instrument
system Multi-display
Parking brake
switch
Combination Switch
Oil Pressure Switch
Brake fluid level

Gateway
switch
Start CAN
7
3 Information sheet
Sending Transmission
Receiving node Information
node type
 Front-left door status
 Front-right door status
 Rear-left door status
 Rear-right door status
Combination  Driver safety belt switch signal
BCM CAN
Instrument  Complete vehicle status
 Trunk signal
 Smart key system warning light
signal
 Buzzer control signal
Combination
SRS  Fault indicator light drive signal CAN
Instrument
 High beam switch signal
Combination Combination  Front fog lamp switch signal
CAN
Switch Instrument  Rear fog lamp switch signal
 Sidelamp
Combination
Multi-display  Dimming gear position signal CAN
Instrument
Combination
Multimedia System  Parking braking switch signal CAN
Instrument
 (MIL) emissions fault signal
 Coolant temperature
 Vehicle speed signal
 Revolution speed of the engine
 EBD fault signal
Combination  ABS fault signal
Gateway CAN
Instrument  Engine speed signal
 Vehicle speed signal
 Service warning light
 Gear position signal
 Instant fuel quantity
 ESP
Power
Combination
generating  Charging system lamp Hard wire
Instrument
system
Lighting Combination  Left turn signal indicator
Hard wire
System Instrument  Right turn signal indicator
Combination Interior Light
 Backlight drive signal Hard wire
Instrument System
8
4 System overview
The combination instrument is an electromechanical
combination instrument located in front of the driver
and above the steering column. It includes mounting
parts and electrical connections. The circuits of all
combination instruments compose a wire harness,
which is connected to the back of the combination
instrument housing by via a connector. The dial and
the indicator light of the combination instrument are
arranged behind a whole transparent mask. The
transparent mask adopts a light shield, which
protects the instrument surface from light and
reflection, thus reducing glare.
Metering gages:
Name Description
Speedometer Based on the wheel speed sensor, ABS converts wheel speed signals
into vehicle speed signals, and transmits data to the combination
instrument via the CAN.
Tachometer Engine ECM sends rotation speed signals to the combination
instrument via the CAN line.
Thermometer of Engine ECM sends engine coolant temperature signal to combination
engine coolant instrument via the CAN line.
Fuel meter This combination instrument collects the oil level signal collected by
the oil level sensor via the hard wire.
Alarms and indicators:
Name Icon Operational logic

Turn signal The instrument collects the steering signal of the
light indicator combination switch via the hard wire.
High beam When the combination instrument high beam shows the
indicator "ON" CAN message, the high beam is lit up and stays on.
When receiving high beam "OFF" CAN message, the high
beam is off. The indicator works simultaneously with the
high beam.
Sidelamp Receives the sidelamp switch signal from the combination
indicator switch (CAN)
Rear fog light Receives the rear fog lamp switch signal from the
indicator combination switch (CAN)
Indicator light Receives safety belt switch signal from the BCM (CAN)
of driver seat
safety belt
SRS failure Receives safety air bag fault signal from the supplemental
warning restraint system
indicator
9
Warning light Receives the charging system fault information from the
of charging charging system (hard wire)
system
ABS failure Receives the ABS system fault message from the gateway
warning and light up the indicator. CAN breakage ON.
indicator
Warning light Receives parking signals from the parking brake switch
for parking (hard wire); Receive the brake level signals from the brake
brake failure level switch (hard wire); The combination instrument
acquires "EBD fault" signals (CAN)
EPS failure Receives EPS failure signals (CAN)
warning (red)
indicator
SVS warning Receives complete vehicle status signal from BCM
lamp
Warning light Reads key message from intelligent key system (CAN)
for intelligent
key system
Theft deterrent (red) When the vehicle is asleep, the indicator is lit up and kept
indicator on; after a period of time, it starts flickering, which means
the vehicle has fallen asleep.
Front The combination instrument acquires the mode signal of
headlamp the front headlamp regulating unit (CAN)
regulating
indicator
(reserved)
Cruise master Operates the cruise button on the steering wheel. The
indicator instrument receives messages from the gateway and turns
(reserved) the ON/OFF the indicator.
Cruise control The instrument receives the gateway signal and turns
indicator ON/OFF the indicator to show whether the vehicle is in
(reserved) cruise mode.
Indicator of Receives status of doors and trunk from the BCM (CAN)
door and trunk
condition
Main warning Receives failure message and prompt (except backlight
light regulation, doors and trunk status)
Warning light Receives engine failure signal (CAN) CVTK wire from the
of engine gateway
failure
ESP failure Receives ESP failure signal from the ESP system (CAN)
warning
indicator
ESP OFF Receives the ESP system OFF signal (CAN)
warning lamp
10
Tire pressure Receives tire pressure failure signals from the tire pressure
failure warning monitoring system (CAN)
light (reserved)
Combination instrument lighting is realized via the

adjustable LED on the back. The instrument can be
lit up in this way to achieve necessary visibility.
Each indicator of the combination instrument is lit up
by a special LED. Each LED is welded as a whole to
the circuit board on the back of the combination
instrument housing. The connection circuits connect
the combination instrument to the vehicle’s electrical
system. These connection circuits are integrated in
the vehicle wire harness, and are fixed at different
positions, in different directions and different ways.
11
5 Diagnosis process
1 Vehicle taken to the workshop
Next
2 Customer problem analysis and symptom check
Next
3 Check battery voltage
Standard voltage:
11 to 14 V
If the voltage is below 11 V, recharge or replace the
battery before going to the next step.
Next
4 Refer to the malfunction symptom table for diagnosis
Result
Result Proceed to
Symptom isn't listed in problem symptoms table A
Symptom is listed in problem symptoms table B
B Go to step 5
5 Overall diagnosis
Next
6 Adjustment, repair or replacement
Next
7 Confirmation test
Next
12
6 Diagnosis Trouble Code Table
DTC code Detection Item Trouble Area See Page

B2342 Instrument internal failure Combination instrument
B2343 Clock malfunction Combination instrument
U1101 Communication interruption Combination instrument
between the instrument and the Combination switch
combination switch Gateway
between the instrument and the SRS
SRS Gateway
U0146 Communication interruption
Combination instrument
between the instrument and the
Gateway
gateway
between the instrument and BCM
BCM Gateway
B2344 Fuel gauge input device open Combination instrument
circuit failure Wire harness or connector
B2345 Fuel gauge input device short Combination instrument
circuit failure Wire harness or connector
B243D Message switching button input Combination Instrument
device short circuit failure Wire harness or connector
B234A CAN bus receives coolant Gateway
temperature signal error
B234B CAN bus receives vehicle speed Gateway
signal error
B234C CAN bus receives rotational Gateway
speed signal error
Outside temperature sensor Wire harness or connector
B2A22 open
Outside temperature sensor Wire harness or connector
B2A23 short
13
7 Problem Symptoms Chart

Tips:
Use the table below to help determine the cause of
malfunctions. The potential causes of the faults are
listed in order of probability. Check the suspected
area in order. Repair or replace faulty parts or
perform adjustments as necessary.
Symptom Suspected Area See Page
The whole instrument Power circuit

doesn't work. Combination instrument
Long/short mileage
adjustment failure
Instrument backlight
adjustment failure
Vehicle backlight
Wire harness
adjustment failure
Other modules
Wheel Speed Sensor
ABS
Malfunctioning of the
Gateway
speedometer
CAN communication
ECM
Malfunctioning of the
Gateway
speedometer
CAN communication
Oil level sensor
Fuel gauge malfunction Combination instrument
Wire harness or connector
Coolant temperature sensor
ECM
Coolant thermometer
Gateway
malfunction
CAN communication
Instrument steering Combination switch

indicator OFF Combination instrument
14

Oil level sensor
Low-fuel warning indicator
malfunction
CAN communication
High beam indicator OFF Combination switch
Parking brake switch
Parking brake indicator
malfunction
BCM
Safety system indicator
malfunction
CAN communication
Driver's safety belt lock switch
BCM
Malfunctioning of driver's
seat safety belt indicator
CAN communication
SRS system
Malfunctioning safety air
bag failure indicator
CAN communication
BCM
Vehicle door and luggage
compartment open Combination instrument
indicator malfunction
CAN communication
Combination switch
Malfunctioning of rear fog
lamp indicator
CAN communication
Combination switch
Malfunctioning of front fog
lamp indicator
CAN communication
ABS system failure
Malfunctioning of ABS
malfunction indicator
CAN communication
Oil pressure switch
Engine oil pressure
indicator malfunction
15
I-KEY ECU
Intelligent key system key BCM
position indicator
malfunction Combination instrument
CAN communication
Combination switch
Malfunctioning of sidelamp
indicator
CAN communication
Generator
Malfunctioning of charging
system indicator
ECM
Engine failure indicator
malfunction (considering Combination instrument
CVT)
CAN communication
ECM
BCM
SVS indicator malfunction
CAN communication
Gear shift mechanism
TCU
Abnormal display of gear
Gateway
positions
CAN communication
Wheel speed sensor
Mileage display Combination instrument

malfunction Gateway
CAN communication
16
8 Terminal Diagnosis
1. Check pins of the combination instrument
(a) Lead wire from the back of the combination

instrument connector G16.
(b) Inspect each terminal of the connector.
Terminal No. Terminal Specified

Wire Color Condition
(Symbol) Description Condition
G16-4-vehicle P-vehicle body
B-CAN H Always 2.5~3.5 V
body ground ground
G16-5-vehicle V-vehicle body
B-CAN L Always 1.5~2.5 V
body ground ground
G16-8-vehicle B/W-vehicle body Resistance
Fuel signal input Power ON
body ground ground signal
G16-9-vehicle B/Y-vehicle body Fuel signal
Always Less than 1 Ω
body ground ground ground
G16-11-vehicle B-vehicle body
Ground Always Less than 1 Ω
body ground ground
G16-12-vehicle B-vehicle body
Ground Always Less than 1 Ω
body ground ground
G16-15-vehicle G/B-vehicle body Coolant level
ON position Less than 1 Ω
W-vehicle body Backlight Less than 1 Ω
G16-18vehicle
ground adjustment key + Press this key
body ground
signal
Br/W-vehicle body Backlight Press this key Less than 1 Ω
G16-19-vehicle
ground adjustment key +
body ground
signal
G16-20-vehicle Y/W-vehicle body Mileage switch Press this key Less than 1 Ω
body ground ground key - signal
R-vehicle body Backlight Turn on the
G16-21-vehicle
ground brightness sidelamp and Voltage signal
body ground
adjusting output adjust the
17
backlight
brightness.
G16-22-vehicle Br-vehicle body Steer right status
Steer right 11~14 V
G/O-vehicle body The hand brake
G16-23-vehicle ground is pulled on or
Parking signal Less than 1 Ω
body ground the brake fluid
level is too low.
Buoy sinks
G16-24-vehicle G/R-vehicle body Brake fluid level
(brake fluid level Less than 1 Ω
too low)
Sit down and
Passenger' safety fasten the Vacant
G16-27-vehicle R/B-vehicle body safety belt.
belt signal
body ground ground
acquisition No one is
Less than 1 V
seated.
Br/W-vehicle body Information switch
G16-28-vehicle
ground button signal Always Less than 1 V
body ground
ground
G16-33-vehicle R/L-vehicle body Steer left status 11~14V
Steer left
Y/R-vehicle body Flameout Less than 1 Ω
G16-34-vehicle ground Engine oil
body ground pressure signal More than 10
Start the engine
kΩ
Engine
G16-35-vehicle Y/L-vehicle body Charging system malfunction
Voltage signal
body ground ground warning signal (output voltage
too low)
L/W-vehicle body Less than 8.2
Press "OK".
ground kΩ
Message switch
G16-37-G16-28
button input Press "up" About 23.2 kΩ
Press "Down" About 50.2 kΩ
G16-38-vehicle Y-vehicle body
IG1 Power ON 11~14 V
body ground ground
G16-39-vehicle W/R-vehicle body
Battery Always 11~14 V
body ground ground
Seated, without
Passenger safety fastening the Less than 1 V
G16-40-vehicle L-vehicle body safety belt
belt indicator
body ground ground
control No one is
Vacant
seated.
18
The whole Instrument doesn't work.
Circuit Diagram
Battery
Power supply
for switch 2nd
Power Supply
gear
Battery
Combination Instrument
19
Inspection Procedures
1 Inspect fuse
(a) Using a multimeter, check whether there is

continuity between the switch 2nd gear
power supply F2/31 and BCM power fuse
F2/3 fuse.
OK: Yes
NG Replace fuse
OK
2 Inspect wire harness
(a) Disconnect combination instrument connector

G16.
(b) Check each terminal of the wire harness side

connector.
Standard Voltage
Specified
Tester Connection Condition
Condition
G16-38-vehicle
Power ON 11 to 14 V
body ground
G16-39-vehicle
Always 11 to 14 V
body ground
Standard Resistance
Specified
Condition
G16-11-vehicle Less than 1
Always
body ground Ω
G16-12-vehicle Less than 1
Always
body ground Ω
NG
Replace wire harness or connector
OK
3 Replace the Combination Instrument
20
Malfunctioning of the speedometer

Circuit Diagram
Gateway Controller
Body
network
Shielding
layer
System
Check Procedures
1 Use the diagnostic unit to check diagnostic trouble codes (DTCs).
(a) Connect the diagnostic tester to DLC port and

read DTCs of systems.
21
Result Proceed to
DTC is output A
No DTC is output C
ABS System
Result Proceed to
DTC is output B
No DTC is output C
Enter "CAN Diagnosis" for inspection
Enter "ABS System" for inspection
22
Malfunctioning of the speedometer
Circuit Diagram
Gateway Controller
Shielding
layer
Body network
Combination
Instrument
Adapter
system
Check Procedures

Result Proceed to
DTC is output A
No DTC is output C
23
ECM system
Result Proceed to
DTC is output B
No DTC is output C
Enter "ECM System" for inspection
24
Fuel gauge malfunction
Circuit Diagram
Oil level
sensor
Check Procedures
1 Check the oil level sensor
(a) Disconnect the oil level sensor connector K11.
(b) Measure the resistance between the two

terminals of the sensor.
Standard Resistance
Specified
Condition
K11-2-K11-3 Always 40-250 Ω
NG Change the oil level sensor
OK
25
2 Inspect Harness or Connector

G16.
(b) Disconnect the oil level sensor connector K11.
(c) Check each terminal of the wire harness side

connector.
Standard Resistance
Tester Specified
Condition
Connection Condition
G16-8-K11-3 Always Less than 1 Ω
G16-9-vehicle
body ground
NG
OK
26
Coolant temperature sensor malfunction
Circuit diagram (473 QE)
Gateway Controller
Shielding
layer
Adapter
Coolant N/A
temperature
sensor
Combination
Instrument
27
Circuit Diagram (476ZQA)
Gateway Controller
Shielding
layer
Body
network
Adapter
Coolant temperature
sensor
Combination
Instrument
28
Check Procedures
Result Proceed to
DTC is output A
No DTC is output C
ECM system
Result Proceed to
DTC is output B
No DTC is output C
Enter "engine system" for inspection
29
High beam indicator malfunction
Circuit Diagram
Combination
Instrument
Combination
Switch
Check Procedures
1 Check the work condition of the high beam lamp
(a) Place the combination switch at high beam to
see whether the high beam works well.
NG
Enter "light system" for inspection

OK

read DTC of the combination instrument
30
system.
Result Proceed to
DTC is output A
No DTC is output B
31
Vehicle door open indicator malfunction

Circuit Diagram
Front door Rear door Front lock Rear door

lock motor lock motor motor door lock motor
LH LH RH RH
(Door light signal)
Check Procedures
1 Check the work condition of the door lamp
(a) Open doors and check whether door lamps are

on.
NG
32
OK

system.
Result Proceed to
DTC is output A
No DTC is output B
33
Malfunctioning of Rear Fog Lamp Indicator
Circuit Diagram
Combination
Instrument
Combination Switch
Check Procedures
1 Check the work condition of the rear fog lamp
(a) Place the combination switch at rear fog lamp to

see whether it works well.
NG
34
OK

system.
Result Proceed to
DTC is output A
No DTC is output B
35
Malfunctioning of Front Fog Lamp Indicator

Circuit Diagram
Combination
Instrument
Combination
Switch
Check Procedures
1 Check the work condition of the front fog lamp
(a) Set the combination switch to front fog lamp to
see whether it works well.
NG

OK
36

read the DTC of the combination instrument
system.
Result Proceed to
DTC is output A
No DTC is output B
37
Malfunctioning of Sidelamp Indicator

Circuit Diagram
Combination
Instrument
Combination
Switch
Check Procedures
1 Check the work condition of the sidelamp
(a) Set the combination switch to sidelamp to see

whether it works well.
NG
OK
(a) Connect the diagnostic tester to the DLC port

and read the DTC of the combination
38
instrument system.
Result Proceed to
DTC is output A
No DTC is output B
39
Engine oil pressure indicator malfunction

Circuit Diagram
Combination
Instrument
Engine oil pressure sensor

(closed: engine stops
open: engine runs)
Check Procedures
1 Check the engine oil pressure switch
(a) Disconnect the engine oil pressure sensor A36
connector.
(b) Check the resistance between the engine oil

pressure sensor terminal and the body ground.
Standard Resistance
Specified
Condition
Flameout Less than 1 Ω
A36-1-vehicle
body ground Start the
More than 10 kΩ
engine
NG
Change the engine oil pressure switch
OK
40

G16.
(b) Disconnect the engine oil pressure sensor A36

connector.

connector.
Standard Resistance
Tester Specified
Condition
G16-34-A36-1 Always Less than 1 Ω
G16-34-vehicle
Always More than 10 kΩ
body ground
NG
OK
41
Steering indicator malfunction

Circuit Diagram
Battery
distributor box
Steer warning
Dashboard
light
Right
steering
lamp relay
Left
steering
lamp relay
Right
steering
light
Left
steering
light
Combination Instrument Multiplex

integration
control module
42
Check Procedures
1 Check the work condition of the steering lamp
(a) Place the combination switch at the steer gear

to see whether the steering light works well.
NG
OK

G16.
(b) Disconnect G37 connector.

connector.
Standard Resistance
Specified
Condition
G37-7-G16-33 Always Less than 1 Ω
NG
OK
43
Malfunctioning of Charging System Indicator

Circuit Diagram
Combination
Instrument
Generator
Note: A16-473 A37-476
Check Procedures
1 Check the engine
(a) Lead wire from the back to measure the output

voltage of the engine
Standard Voltage
Tester Specified
Condition
A16-2-vehicle Engine
11 to 14 V
body ground running
A37-2-vehicle Engine
11 to 14 V
body ground running
44
NG
Check or change the engine
OK

G16.
(b) Disconnect engine A16 and A37 connectors.

connector.
Standard Resistance
Tester Specified
Condition
NG
OK
45
Parking brake indicator malfunction

Circuit Diagram
Combination
Instrument
Parking brake
switch: (Close:
Pulled)
Check Procedures
1 Check the brake fluid
(a) Check whether there is enough brake fluid.
NG Add brake fluid
OK
2 Inspect on the Parking Braking Switch
(a) Lead wire from the back and measure G32 pin
resistance.
Standard Resistance
Specified
Condition
G32-1-vehicle Pull the Less than 1
body ground hand brake Ω
NG
46
Change parking brake switch
OK

G16.
(b) Disconnect the parking brake switch G32

connector.

connector.
Standard Resistance
Specified
Condition
G16-23-G32-1 Less than 1
Always
Ω
NG
OK
47
Driver's safety belt indicator malfunction

Circuit Diagram
Driver's
safety belt
latch switch
(close:
locked)
Combination
Instrument
Check Procedures

system.
Result Proceed to
DTC is output A
No DTC is output B
A
48
2 Check the driver seat safety belt latch switch
(a) Lead wire from the back and check the

performance of the driver seat safety belt latch
switch KJ08.
Standard Resistance
Tester Specified
Condition
Safety belt is More than
fastened. 10 kΩ
KJ08-1-KJ08-2
Safety belt Less than 1
isn't fastened. Ω
NG
Change safety belt latch switch
OK
3 Inspect harness or connector
(a) Disconnect the safety belt latch KJ08 connector.
(b) Disconnect K2F connector.

connector.
Standard Resistance
Specified
Tester connection condition
condition
K2F-14-KJ08-1 Always Less than 1 Ω
KJ08-1-KJ08-2 Always Less than 1 Ω
NG
OK
4 Replace the combination instrument
49
Instrument control module internal

DTC B2342
error
Inspection Procedure
1 Replace the combination instrument
Next
50
9 Removal
1. Disconnect battery negative.
2. Remove the steering wheel regulating

rod and press the steering wheel
vertically.
3. Remove the upper protective plate

rubber cushion of the combination
instrument
4. Remove the upper protective plate of

the combination switch (c) Disconnect the interior temperature
sensor connector and take out the inner plate
5. Remove the interior plate of the of the combination instrument housing.
combination instrument housing.
6. Disassemble the combination instrument.
(a) Remove 2 set screws.
(a) Remove the three tapping screws of the
combination instrument with a crosshead
screwdriver.
(b) Remove the interior plate of the

combination instrument housing.
(b) Take out the combination instrument and

disconnect the connector.
51
10 Installation
1. Install the combination instrument
(a) Connect the instrument connector and

align the positioning hole with the
corresponding point.
(b) Install the three set screws with a

crosshead screwdriver.
(c) Install the two set screws with a

3. Install the upper protective plate of the

combination switch
4. Install the upper protective plate rubber

cushion of the combination switch
5. Lift the steering wheel vertically and press

2. Install the combination instrument the regulating rod.
interior plate.
6. Connect battery negative and do testing.
(a) Connect the front room temperature
sensor connector.
(b) Align the combination instrument inner

hood and press it with strength. Make sure
all bayonets are well installed.
52
Chapter 2 Lighting System

1 Position of the Assembly ..................................................................................................... 54
2 System Diagram .................................................................................................................. 58
3 System overview .................................................................................................................. 62
7 Overall Diagnosis Procedure ............................................................................................... 72
53
1 Position of the Assembly
Turn light RH
Turn light LH
Right front Left front

fog light fog light
Front right combination light

and support assembly
-Low-beam lamp
Front right combination light -High-beam lamp
and support assembly -Position lamp
-Low-beam lamp -Turn light
-High-beam lamp
-Position lamp
-Turn light
54
Trunk light
High braking lamp
Left plate light
Right plate light
Right
combination
rear lamp
-Position lamp
-Braking light
-Rear fog light
-Reversing light
-Turn light
Left combination
rear lamp Reflex
-Position lamp Reflector
-Braking light
-Rear fog light
-Reversing light
-Turn light
Reflex
Reflector
55
Dress-up mirror light (right)
Atmosphere lamp
(rear right)
Front interior Rear interior

light assembly light assembly
Atmosphere lamp
(front right)
Front right
door light
Atmosphere
lamp (front left) Atmosphere lamp
(rear left)
Front left
door light
Dress-up mirror
light (left)
56
Storage tank light
Emergency Warning
Light Switch
Braking Light
Switch
Storage light
switch
Clutch pedal
switch
Left foot Right foot light
light
Headlamp
Adjusting Switch
57
2 System Diagram
Left high beam High beam

relay
Right high beam
Left low beam Low beam

relay
Right low beam
Front left side Sidelamp

light Relay
relay
control
module
Front right side
light
Rear left side light
Rear right side

light
Left plate light
Right plate light
Left atmosphere
lamp
Right atmosphere
lamp
Right feet light
Left feet light
All backlights
Left front fog light Front fog

light relay
Right front fog

light
58
Combination
Switch
Front door lock LH

signal Multiplex
integration
Front left door control
light module
Rear door lock LH

signal
Rear left door light
Front door lock

RH signal
Front right door

light
Rear door latch

RH signal
Rear right door

light
Trunk light
Trunk light switch
59
Braking
Light
Switch
Multiplex
integration
control
module
Left braking
light
Right braking
light
High braking
lamp
Rear left fog

light
Rear right fog

light
Left reversing
light
Right reversing
light
Outer left rear view

mirror foot light
Outer right rear view

mirror foot light
60
Front turn light Left steering

LH lamp relay
Rear turn light Multiplex

LH integration
control
Turn light LH module
Flash relay
Front turn light

RH
Rear turn light

RH
Right
Turn light RH steering lamp
relay
Emergency
Warning Light
Switch
Left regulating
motor Headlamp
Adjusting
Switch
Right regulating
motor
61
3 System overview
The light system provides illumination for night
driving. Outside lights mainly include front
lights, reversing lights, plate light, fog light.
Inside lights mainly include indoor lights, door
lights and switch backlights. Different lights are
installed to meet different illumination needs.
They are served with their own control switch,
lines and fuse to form the light system. The
light system also provides a signal indication
function by generating light signals to warn
other cars and passengers in order to ensure
driving safety. It includes the steering signal,
braking signal, danger warning signal, outline
signal and reversing signal.
Besides lighting, the vehicle also has functions

of automatic lighting and high beam delayed
power-off, so the lighting system is more
convenient and user-friendly.
Automatic lighting: Switch the combination

switch to AUTO. BCM will turn the light
automatically on or off based on the external
illumination intensity collected by the
illumination intensity sensor, and it turns on
sidelamps or headlamps based on the
intensity.
Headlamp delayed power-off: When the
headlamp is on and the vehicle power is
switched from ON to OFF, the headlight will
not turn off immediately. The engine hood
distributor box conducts timing automatically,
keeping the headlight on for another 10
seconds. Then the light relay is disconnected
and the headlamp is turned off.
62
4 Diagnosis process
1 Vehicle brought to workshop
Analysis of failure described by the user: Ask the

user about car condition and the environment when
the fault occurs.
Next
2 Inspect Battery Voltage
Standard voltage:
11 to 14 V
battery before proceeding to the next step.
Next
3 Table of Reference Symptoms of Malfunctions
Result Proceed
The fault is not recorded in A
the fault symptom table
The fault is recorded in the B
fault symptom table
B Go to Step 5
4 Overall Analysis and Diagnosis

(a) Overall functional inspection
(b) ECU terminal inspection (see ECU terminal

inspection)
(c) Check with diagnostic tester
Next
(a) Adjust, repair or replace lines or parts
Next
63
6 Confirmation test
Next
7 End
64

Front lighting system
Malfunction Description Possible Location of Malfunction

Low-beam light is off (one side) Left low-beam light fuse or right low-beam light fuse
Bulb
Low-beam light circuit
Low-beam light is off (both sides) Left low-beam light fuse and right low-beam light fuse
Bulb
Control circuit of combination switch
Relay control module
High-beam light is off (one side) Left high-beam light fuse or right high-beam light fuse
Bulb
High-beam light circuit
High-beam light is off (both sides) Left high-beam light fuse and right high-beam light
fuse
Bulb
Front light is dim (brightness not 1. Battery Voltage
enough) 2. Low-beam light bulb
3. High-beam light bulb
4. Wire harness
Passing light doesn't work (high-beam 1. Control circuit of combination switch
light and low-beam light are ok) 2. Relay control module
Front fog light system

Front fog light fuse
When the side light turns on or the
Front fog light circuit
high-beam light turns on, the front fog light
does not turn on (both sides)
BCM
Bulb
Only one foglight does not turn on
Wire harness
Rear fog light system

If the rear foglight is turned on when the Rear fog light circuit
high-beam light, the low-beam light and the Control circuit of combination switch
front foglight have been turned on, the rear BCM
foglight does not turn on
65
Only one rear fog light does not turn on 1. Bulb

2. Wire harness
Steering and emergency alarming system

1.Steering/emergency alarming light fuse
When operating the left/right steering switch
2.Flash relay
or pressing the emergency alarming switch,
3. Steering light/emergency alarming light circuit
the steering light does not work
4. BCM
When pressing the emergency alarming
1. Emergency alarming switch circuit
switch, it does not work (when steering, it
2. BCM
works normally)
When operating the left/right steering, the
1. Combination switch control circuit
steering light does not work (danger alarm
2. BCM
works normally)
1. Control circuit of combination switch
2. Steering light/emergency alarming light circuit
The steering lights on one side don't turn on
3. Flash relay
4. BCM
Only one or several steering lights don't turn 1. Bulb
on. 2. Wire harness
Braking light system

The braking lights don't turn on (both
Speaker/ braking light fuse
high-level and left/right braking lights do not
Braking light circuit
work)
LED light
Only one braking light does not turn on
Wire harness
Side light and plate light system

1. Front side light fuse
2.Control circuit of combination switch
Neither the side light nor the plate light turns
3. Internal side light relay
on
4. Position light/plate light circuit
5.Relay control module
Only one or several side lights or plate lights 1. LED light or bulb
do not turn on 2. Wire harness
Reversing light system

1. Reversing light switch circuit
When operating the reversing gear, no
2. Reversing light circuit
lights turn on
3. BCM
1. Bulb
Only one reversing light remains off
2. Wire harness
66
Ground lighting system

The vehicle enters anti-burglary status.
1. Ground light circuit
When you approach the vehicle with the
2. BCM
key, the ground lights don't turn on.
1. LED
Only one ground light remains off
2. Wire harness
Interior light system

Indoor lighting fuse
Door lamp doesn't turn on. Door lamp circuit
BCM
Front side light fuse
None of the backlights can be switched on. Sidelight relay
Door light switch circuit
Interior light doesn't turn on. Interior light assembly circuit
Interior light assembly
Manual headlamp adjustment (non-flagship)

Headlamp Adjusting Switch
Manual headlamp adjustment doesn't work. Left (right) adjusting motor
Wire harness
67
1 Engine hood distributor box
(a) Lead wire from connectors behind the engine

hood distributor box
(b) Inspect distribution box terminals.
Terminal No. Wire Terminal Description Option Normal Value

Color
B1I-1-body ground V B-CAN L Always 1.5-2.5 V
B1I-2-body ground P B-CAN H Always 2.5-3.5 V
B1I-3 -- N/A -- --
B1I-4-body ground Br/Y Inner siren relay -- --
B1I-5-body ground W/B Relay control -- --
module
B1I-6-body ground G/Y Clock spring -- --
B1I-7-body ground W Headlamp signal Combination Less than 1 V
switch headlamp
gear
B1I-8-body ground G/W Wiper signal Combination Less than 1 V
switch wiper gear
B1I-9-body ground Y Power ON Under gear ON 11-14 V
B1I-10-body R/B Sidelight relay Combination 11-14 V
ground switch sidelight
gear
C1H-1 -- N/A -- --
68
C1H-2-body G/B Engine compartment -- --

ground cover switch
C1H-3-body L/B Front fog light relay Combination Less than 1 V
ground control module switch turns on the
front fog light
C1H-4 -- N/A -- --
C1H-5-body R/G Right high-beam Turn on the 11-14 V
ground power supply high-beam
C1H-6 -- N/A -- --
C1H-7-body L/R Horn relay -- --
ground
C1H-8-body L/R Horn relay -- --
ground
C1H-9-body R/B Sidelight relay Combination 11-14 V
gear
C1H-10-body R/B Sidelight relay Combination 11-14 V
gear
C1H-11-body W/G Right low-beam Turn on the 11-14 V
ground power supply low-beam light
C1H-12 -- N/A -- --
C1H-13-body W/R Left low-beam power Turn on the 11-14 V
ground supply low-beam light
C1H-14-body R/Y Left high-beam Turn on the 11-14 V
ground power supply high-beam
Dashboard distributor box
69
(a) Lead wire behind connectors of the

dashboard distribution box.
(b) Inspect distribution box terminals.
Terminal No. Wire Terminal Description Option Normal

Color Value
G2Q-1-body R/Y Rear fog light fuse Turn on the rear fog light 11-14 V
ground
G2Q-2 -- N/A -- --
G2Q-3-body R/W Rear fog light power Turn on the rear fog light 11-14 V
ground supply
G2Q-4-body W/G Right turn light Turn on the right turn light 11-14 V
ground control signal
G2Q-5-body R/Y Greeting light drive Approach the vehicle with 11-14 V
ground the key
G2Q-6-body G/W Start Button Turn to ACC or ON 11-14 V
ground Position
G2Q-9-body Y/G Door lamp control Turn the front right door Less
ground lamp on than 1
V
G2P-12-body G/R Left turn light control Turn on the left turn light 11-14 V
ground signal
G2P-14-body G Reversing light Reverse gear 11-14 V
ground power supply
G2P-21-body W/R Braking light signal Tread the brake pedal 11-14 V
ground
Combination Switch
(a) Lead wire behind the combination switch

connector G24.
(b) Check the combination switch terminals

Terminal No. Wire Terminal Option Normal Value
Color Description
G24-1-body P B-CAN H Always 2.5-3.5 V
ground
G24-2-body V B-CAN L Always 1.5-2.5 V
ground
70
G24-3-body B Ground connection Always Less than 1 V

ground
G24-4-body W Headlamp signal Turn on the Less than 1 V
ground headlamp
G24-5-body W/R Battery ACC position 11-14 V
ground
G24-6-body Y Power ON ON position 11-14 V
ground
G24-7 -- N/A -- --
G24-8-body G/W Wiper HI position Set the Less than 1 V
ground signal combination
switch to HI
position
71
7 Overall Diagnosis Procedure

Circuit Diagram
Power supply for switch 2nd gear Relay control module
Power
Supply
Combination Switch
1 Check the trouble codes

(a) Insert the diagnostic unit into Port DLC3
(b) Clear DTC
(c) Read DTC of the combination switch.
72
DTC Implication
B24A0-00 Circuit malfunction of "OFF"
position of lighting master switch
B24A1-00 Circuit malfunction of "TALL"
B24A2-00 Circuit malfunction of "AUTO"
B24A4-00 Circuit malfunction of dimmer
switch
B24A5-00 Circuit malfunction of turn signal
switch
B24AA-00 Internal error of combination
switch control device
B24AC-00 Circuit malfunction of "ON"
B24AE-00 Circuit malfunction of "ON"
position of rear fog lamp switch
OK:
No output of trouble code
NG
Replace combination switch
OK
2 Check the fuse
(a) Using a multimeter, check the dashboard

distributor box fuse F2/3 and F231 for
continuity.
OK:
continuity in the fuse
NG Replace fuse
OK
3 Check wire harness ( combination switch power supply wire harness)
(a) Disconnect coupler G24 of combination

switch
(b) Switch power supply to "ON".
(c) Check voltage of terminal.
73
Terminal Wire Color Normal

Condition
G24-5-body W/R 11-14 V
ground
G24-6-body Y 11-14 V
ground
G24-3-body B Less than
ground 1V
NG Replace wire harness
OK
4 Check the combination switch

(a) Keep on the coupler G24 of combination
switch.
(c) Lead wire from rear end of G24 and check

the terminal value
Terminal Wire Option Normal

Color Conditio
n
G24-4-body W Combination Less
ground switch at than 1 V
headlamp
position
G24-1-body P Always 2.5-3.5 V
ground
G24-2-body V Always 1.5-2.5 V
ground
NG Replace combination switch
OK
5 Check CAN communication

(a) Disconnect G24 connector.
(b) Disconnect battery negative
(c) Using a multimeter, measure the resistance

between the terminals.
74
Terminal Resistance
G24-1-G24-2 About 60 Ω
NG Check CAN communication
OK
6 Check wire harness ( combination switch - relay control module)
(a) Disconnect combination switch connector

G24
(b) Disconnect relay control module B1I

connector
(c) Measure the resistance between terminals of

wire harness.
Terminal Wire Normal

Color Condition
G24-4-B1I-7 W Less than 1 Ω
G24-8- B1I-8 G/W Less than 1 Ω
OK
7 Circuit is ok.
75

Circuit Diagram
Battery
Right
Left low low
beam Internal
beam
low-beam
light relay
low-beam light
low-beam light
circuit
Front right
Front left
1 Check the fuse

distributor box fuse F1/3 and F1/4 for
continuity.
OK:
Continuity in the fuse
NG Replace fuse
OK
2 Check Low beam relay
76
(a) Pull out the low-beam relay KT1-6 from the

relay control module
(b) Inspect relay
OK:
Relay is ok.
NG Change low beam relay
OK
3 Examine the bulb
(a) Disconnect the bulb connector (left low-beam

C20, right C22)
(b) Apply voltage to both ends of the bulb and

check the bulb.
Terminal Normal Condition

C20-2-battery(+) Front left low-beam
C20-1-battery(-) light on
C22-2-battery(+) Front right low-beam
NG Change bulb
OK
4 Check wire harness (relay control module - low-beam light)
(a) Disconnect the bulb connector (left low-beam

C20, right C22)
(b) Disconnect relay control module C1H

connector
Left low beam

Color Condition
C20-2-C1H-13 W/R Less than 1 Ω
Right low beam

Color Condition
77
C22-2-C1H-11 W/G Less than 1 Ω
Ground connection

Color Condition
C20-1-body B Less than 1 V
ground
ground
OK
5 Replace the relay control module
78

Circuit Diagram
Battery
Internal high-beam
Left high Right
light relay circuit

beam high
beam
high-beam light
Front left
Front right
high-beam
light
1 Check the fuse

distributor box fuse F1/1 and F1/2 for
continuity.
OK:
NG Replace fuse
OK
2 Check high beam relay
(a) Pull out the high-beam relay KI1-7 from the

79
(b) Inspect relay

OK:
Relay is OK.
NG Change high beam relay
OK
3 Examine the bulb
(a) Disconnect the bulb connector (left

high-beam C12, right C13)

check the bulb.

C12-2-battery(+) Front left high-beam
C13-2-battery(+) Front right high-beam
NG Change bulb
OK
4 Check wire harness (relay control module - high-beam light)

(b) Disconnect relay control module C1H

connector
Left high beam

Color Condition
C12-2-C1H-14 R/Y Less than 1 Ω
Right high beam

Color Condition
C13-2-C1H-5 R/G Less than 1 Ω
Ground connection
80

Color Condition
ground
ground
OK
81
Front fog light circuit

Circuit Diagram
Battery
Front fog light
Engine hood
distributor
box
Front fog Engine hood

light distributor
relay box
Right Left front

front fog fog light
light
Relay
control
module
82
1 Check the fuse

distributor box fuse F1/8 for continuity.
OK:
NG Replace fuse
OK
2 Examine the front fog light relay
(a) Pull out the front fog light relay KC-1 from the
(b) Inspect relay
OK:
Relay is OK.
NG Change front fog light relay
OK
3 Examine the bulb


check the bulb.
C03-2-battery(+) Bulb on
C03-1-battery(-)
C16-1-battery(-)
NG Change bulb
OK
4 Check wire harness (front fog light relay - front fog light)
(a) Disconnect the bulb connector (left C03, right

C16)
83
(b) Disconnect the relay connector C1F.
Left front fog light

Color Condition
C03-2-C1F-16 L Less than 1 Ω
Right front fog light

Color Condition
C16-2-C1F-16 L Less than 1 Ω
Ground connection

Color Condition
C03-1body ground B Less than 1 V
OK
5 Examine the relay control module
(a) Change a new relay control module.
OK:
System is OK
OK
84
Rear fog light circuit

Circuit Diagram
Rear
right
Rear fog
left fog light
light
1 Check the rear fog light bulb
(a) Disconnect the rear fog light bulb connector

(left K24 and right K14)

check the bulb.

K24-5-battery(+) Bulb on
K24-6-battery(-)
85
K14-5-battery(+) Bulb on
K14-6-battery(-)
NG Change bulb
OK
2 Check the wire harness (BCM - rear fog light)
(a) Disconnect the bulb connector (left K24 and

right K14)
(b) Disconnect the BCM connector G2Q.
Rear left fog light

Condition
K24-5-G2Q-3 R/W Less than 1 Ω
Rear right fog light
Condition
K14-5-G2Q-3 R/W Less than 1 Ω
Ground connection
Condition
K24-6-body B Less than 1 Ω
ground
ground
OK
3 Replace BCM
86
Steering/emergency alarming light circuit

Circuit Diagram
Thunder
Multiplex integration
control module
Right turn signal

Left turn signal
Dashboard power
distribution
Steer
warning light
Flash
light
relay
distribution box
Instrument
Rear
Engine turn
Multiplex Engine
distribut light
integration distribut
or box RH
control or box
module
Rear
turn
light
RH
Front
turn Front
light turn
LH light
RH
Multiplex Window control

integration module
control module Combination Outer rear view
Instrument mirror system
87
Emergency
Warning
Light
Switch
Right
steering
lamp
relay
Turn
light RH
Multiplex
integration
control Multiplex
Combination integration
instrument module
G16-22 G2Q-4 control
module
G2P-12
88
1 Check the fuse

distributor box fuse F1/13 for continuity
OK: Continuity in the fuse
NG Replace fuse
OK
2 Check flash relay
(a) Change a new flash relay and check whether

it functions well.
OK OK. End
NG
3 Inspect turn light bulb
(a) Disconnect the bulb connectors (front left

C07, front right C18, rear left K24, rear right
K14, left side T05 and right side U05.)
(b) Apply voltage to both ends of the bulb (take

front left turn light for example). Check the
bulb.
C07-1-battery(-)
NG Change bulb
OK
4 Check wire harness ( front compartment distribution box - BCM)
(a) Disconnect the front compartment

distribution box B1E and disconnect the
dashboard distribution box G2N.
(b) Check the resistance between the terminals.
89

Condition
B1E-2-G2N-36 R/L Less than 1 Ω
OK
5 Check the wire harness (BCM - turn light)
(a) Disconnect the bulb connectors (front left

C07, front right C18, rear left K24, rear right
K14, left side T05 and right side U05.)
(b) Disconnect the front compartment

distribution box connectors K2F, T2K and
G2N.
Front turn light LH

Color Condition
C07-2-G2N-36 R/L Less than 1 Ω
Front turn light RH

Color Condition
C18-2-G2N-44 Br Less than 1 Ω
Turn light LH

Color Condition
T05-1-T2K-12 R/L Less than 1 Ω
Turn light RH

Color Condition
U05-1-G2N-26 Br Less than 1 Ω
Rear turn light LH

Color Condition
K24-3-K2F-4 R/L Less than 1 Ω
90
Rear turn light RH

Color Condition
K14-3-K2F-1 Br Less than 1 Ω
Ground connection

Color Condition
ground
K24-6-body B Less than 1 V
ground
T05-7-body B Less than 1 V
ground
U05 -7-body B Less than 1 V
ground
K14-6-body B Less than 1 V
ground
OK
5 Replace BCM
91
Emergency Warning Light Switch Circuit
Circuit Diagram
Battery
distributor box
Dashboard
Emergency Warning
Steer warning light
Light Switch
1 Check Emergency Warning Light Switch
(a) Disconnect emergency warning light switch

connector G44.
(b) Examine the switch
Terminal Option Normal Condition

G44-3-G44-2 Switch is Less than 1 Ω
pressed
Switch is Larger than 10 kΩ
bounced up
OK:
The switch is ok.
NG
Change Emergency Warning Light Switch
92
OK
2 Check wire harness
(a) Disconnect emergency warning light switch

connector G44.
(b) Disconnect the BCM connector G2P.

Color Condition
G44-2-G2P-12 G/R Less than 1 Ω
G44-3-body B 11-14 V
ground
OK
3 Replace BCM
93
Braking light circuit

Circuit Diagram
Horn, brake
Brake
switch
(closed
pedal
pressed
Right braking light
High braking light

Left braking light
94
1 Check the fuse

OK:
NG Replace fuse
OK
2 Examine the braking light switch
(a) Disconnect the braking light switch connector

G18.
(b) Examine the switch
Terminal Option Normal

Condition
G18-2-G18-1 Tread the pedal Less than 1
Ω
Release the More than
pedal 10 kΩ
OK:
Switch is ok.
NG
Replace the braking light switch
OK
3 Check the braking light
(a) Disconnect the brake connectors (left K14,

right K24 and high braking light KJ12)
(b) Apply voltage to both ends of the braking

light (take the high braking light for example)
and check the work status.
Notice: Don't mix up the positive and negative

terminals.
95

KJ12-1-battery(+) Braking light on
KJ12-2-battery(-)
NG Replace the braking light
OK
4 Check the wire harness (braking light switch - front compartment distribution box)
(a) Disconnect the braking light switch connector

G18.
(b) Disconnect the front compartment distributor

box connector B1D.

Condition
G18-2-B1D-1 R Less than 1
0 Ω
NG
Replace wire harness
OK
5 Check the wire harness (braking light switch - braking light)
(a) Disconnect the braking light connectors (left

K24, right K14 and high braking light KJ12)
(b) Disconnect the braking light switch connector

G18.
(c) Measure the resistance between the

terminals.
High braking lamp

Color Condition
G18-1- KJ12-1 W/B Less than 1 Ω
Left braking light
96

Color Condition
G18-1-K24-1 W/B Less than 1 Ω
Right braking light

Color Condition
G18-1-K14-1 W/B Less than 1 Ω
Ground connection

Color Condition
ground
ground
KJ12-2-body B Less than 1 Ω
ground
OK
6 End
97
Position lamp/plate light circuit
Battery
Front
position
light
Internal
side light
relay
Front right side light
Rear right side light

Front left side light
Right plate light

Left plate light
98
Circuit Diagram
1 Check the fuse

OK:
NG Replace fuse
OK
2 Examine the sidelight relay
(a) Pull out the side light relay KI1-5 from the
(b) Check the relay.
OK:
NG Replace the sidelight relay
OK
3 Check the position light and the plate light
(a) Disconnect the position light and plate light

connectors C04, C17, K24, K14, K09 and
K13.

left plate light for example). Check the bulb.

K09-2-battery(+) Plate light on
K09-1-battery(-)
NG Change bulb
OK
99
4 Check wire harness (relay control module - position light/plate light)
(a) Disconnect the position light and plate light

connectors C04, C17, K24, K14, K09 and
K13.
(b) Disconnect the front compartment

distribution box connectors C1H and B1I.
(c) Measure the resistance between the

terminals.
Front left side light

Color Condition
C1H-10-C04-2 R/B Less than 1 Ω
Front right side light
Color Condition
C17-2-C1H-9 R/B Less than 1 Ω

Color Condition
K24-2-B1I-10 R/B Less than 1 Ω
Rear right side light
Color Condition
Left plate light
Color Condition
Right plate light
Color Condition
Ground connection
Color Condition
C04-1-body ground B Less than 1 Ω
C17-1-body ground B Less than 1 Ω
K24-1-body ground B Less than 1 Ω
100

OK
101
Reversing light circuit

Circuit Diagram
Right reversing light
Left reversing light
1 Check the reversing light
(a) Disconnect the reversing light connector (left

K24 and right K14)

left reversing light for example). Check the
work status.

K24-2-battery(+) Reversing light on.
K24-6-battery(-)
NG Change the reversing light
102
OK
2 Inspect the BCM
(a) Disconnect the BCM connector G2P.
(b) Switch power supply to "ON" and R gear.
(c) Check the output of the terminal.

Condition
G2P-14-body G 11-14 V
ground
NG Replace BCM
OK
3 Inspect the Wiring (Reversing light-BCM)
(a) Disconnect the reversing light connector (left

K24 and right K14)
(b) Disconnect the BCM connector G2P.

Left reversing light
Color Condition
K24-2-G2P-14 G Less than 1 Ω
Right reversing light
Color Condition
K14-4-G2P-14 G Less than 1 Ω
Ground connection
Color Condition
OK
4 Replace BCM
103
Ground light circuit

Circuit Diagram
Lights and CAN

module
Auxiliary power
supply 40A
Indoor lighting
Right ground light
Left
ground
light
1 Check the fuse

OK:
NG Replace fuse
OK
2 Check the ground light
104
(a) Disconnect the ground light connectors U05

and T05.

left ground light for example). Check the work
status.

T05-6-battery(+) Ground light on
T05-11-battery(-)
OK:
NG Replace BCM
OK
3 Inspect the wire harness (ground light-BCM)
(a) Disconnect the ground light connectors U05

and T05.
(b) Disconnect BCM connectors G2N, T2K, T2J

and G2Q.
Left ground light

Condition
T05-6-T2K-9 W/L Less than 1 Ω
T05-11-T2J-17 R/L Less than 1 Ω
Right ground light
Condition
U05-6-G2N-22 W/L Less than 1 Ω
U05-11-G2Q-5 R/Y Less than 1 Ω
OK
4 Replace BCM
105
Door lock signal control circuit

Circuit Diagram
Front door Rear door Front door Rear door

lock motor lock motor lock motor lock motor
LH LH RH RH
Check Procedure
1 Check the door lock feeding switch
(a) Disconnect the door lock connectors T01,

V05, U02 and W02.
(b) Examine the switch (take front left door

switch for example)

Condition
106
T01-6-T01-5 Latch Larger than 10

closed kΩ
Latch open Less than 1 Ω
NG Change door lock
OK
2 Check the wire harness (door lock - BCM)
(a) Disconnect the door lock connectors T01,

V05, U02 and W02.
(b) Disconnect BCM connectors G2P, K2H and

K2E.
Front door lock LH

Color Condition
T01-6-K2E-13 G Less than 1 Ω
Front door lock RH

Color Condition
U02-6-K2H-14 Lg/R Less than 1 Ω
Rear door lock LH
Color Condition
V05-6-K2E-14 G/Y Less than 1 Ω
Rear door lock RH
Color Condition
W02-6-K2H-8 G/W Less than 1 Ω
OK
3 Replace BCM
107
Door lamp circuit

Circuit Diagram
Lights and CAN module

Auxiliary power supply
40A
Indoor
lighting
Front right
door light
door light
Front left
Trunk light
108
Check Procedure
1 Check door lights
(a) Disconnect door lights T04, UO4 and K15.

left ground light for example). Check the work
status.

T04-2-battery(+) Door light on
T04-1-body ground(-)
NG Change door light
OK
2 Check wire harness BCM
(a) Disconnect the BCM connectors G2Q and

T2J.
(b) Check the output of the terminal.

Condition
T2J-7-body ground Front left door Less than
open 1V
G2Q-9-body ground Front right Less than
door open 1V
NG Replace BCM
OK
3 Check wire harness (door light - BCM)
(a) Disconnect door light connectors T04, UO4

and K15.
(b) Disconnect BCM connectors G2Q, G2N, T2K,

T2J and K2F
Front left door light

Terminal Wire Normal Condition
Color
T04-2-T2K-9 W/L Less than 1 Ω
109
T04-1- T2J-7 Y/L Less than 1 Ω
Front right door light

Color
U04-1-G2N-22 W/L Less than 1 Ω
U04-2-G2Q-9 Y/G Less than 1 Ω
OK
4 Replace BCM
110
BYD AUTO
light
switch
Reading
Reading light switch
Circuit Diagram
Emergency rescue
switch backlight
Emergency rescue
indicating light
Self-inspection & fault

indicating light
Rear interior light

Indoor lighting
40A
Dress-up light
Front interior light and atmospheric light circuit
Left sun screen switch
Dress-up light Right sun screen switch

BYD Suri Maintenance & Repair Manual
111
Check Procedure
1 Check the fuse
(a) Using a multimeter, check the distributor box

fuses F1/16 and F2/2.
OK:
NG Replace fuse
OK
2 Check wire harness(power supply)
(a) Disconnect the interior light connectors P03

and P04.
(b) Check the voltage of the wire harness

terminal.

Color Condition
P03-8-body R/B 11-14 V
ground
P04-2-body R/B 11-14 V
ground
OK
3 Check the interior light
(a) Disconnect the interior light connectors P03

and P04.
(b) Apply voltage to corresponding terminals and

check the work status.
Front interior light

Condition
Front interior light OFF Front interior
112
on ON light on
P03-4-battery(-)
Rear interior light

Condition
P04-2-battery(+) OFF Rear interior
P04-3-battery(-) light on
ON
OK
4 Inspect the BCM
(a) Disconnect the BCM connector P2I
(b) Lead wire behind P2I
(c) Check the voltage of the wire

harness terminal.

Condition
P2I-4-body Any door is Less than 1 V
ground open.
P2I-4-body Any door is Less than 1 V
ground open.
NG Replace BCM
OK
5 End
113
Atmospheric light and foot light circuit

Circuit Diagram
Left Right
foot foot Front left Front right latch
light light latch atmospheric
atmospheric light
light
Rear left Rear right

door latch door latch
atmospheric atmospheric
light light
Instrument 6#
body ground
Instrument 4# Instrument 3#
body ground body ground
114
Check Procedure
1 Check the backlight
(a) Vehicle switched to ACC and combination

switch switched to side light position.
OK:
All backlights are on. Both foot lights and
atmospheric lights are on. If none of them
is on, check the vehicle backlights.
NG:
Some lights cannot be turned on.
OK Circuit is ok.
NG
2 Check the problematic bulb (LED light)
(c) Disconnect the problematic bulb.
(d) Apply power to both ends of the bulb with 12

V regulated power supply. Since it is LED,
don't mix the positive and negative up.
OK:
Bulb on
NG Change bulb
OK
3 Inspect Power Supply Wiring
(c) Disconnect the problematic bulb connector.
(d) Measure the wire harness side voltage with a

multimeter.
OK:
Voltage is normal.
OK
4 Circuit is ok.
115
Headlamp adjustment doesn't work.

Circuit Diagram

Exterior light system

Right regulating
Left
regulating
motor
motor
Combination
Instrument
G16-22
116
Check Procedure
1 Check the Power Supply of the Headlamp Adjusting Switch
(a) Lead wire behind headlamp adjusting switch

G45 connector.
(b) Check the voltage of each terminal.

Condition
G45-1-body Side light ON 11-14 V
ground
G45-3-body Side light ON 11~14 V
ground
G45-2-body Always Less than
ground 1Ω
NG Go to step 5
OK
2 Examine the headlight adjusting switch
(a) Adjust the gear of the headlight regulating

switch
(b) Check the output voltage of terminals G45-5

and G45-5.

G45-4-body ground Terminal voltage varies
with the headlamp
adjusting switch gear
G45-5-body ground The voltage is basically
consistent with 4-pin.
NG
Replace the headlight regulating switch
OK
3 Check the power supply of the regulating motor
(a) Lead wire behind the left regulating motor

terminals C31-1 and C31-3.
117
(b) Lead wire behind the right regulating motor

terminals C23-1 and C23-3.
(c) Check voltage of these terminals.

Condition
C31-1-body R/B 11-14 V
ground
C31-3-body B Less than 1
ground Ω
C23-1-body R/B 11-14V
ground
C23-3-body B Less than 1
ground Ω
OK Go to step 5
NG
4 Check wire harness
(a) Lead wire behind the engine hood distributor

box B1I-10 terminal
(b) Take out the lead from the back end of the
dashboard distribution box G2N-35 terminal.
(c) Check voltage of the two terminals.

Condition
B1I-10-body Side light 11~14 V
ground ON
G2N-35-body Side light 11~14 V
ground ON
OK
Change the problematic distribution box.
(d) Disconnect the front compartment distributor

box connector B1I.
(e) Disconnect the G2N connector for the

(f) Disconnect headlamp adjusting switch G45
118
connector.
(g) Disconnect left regulating motor C31

connector.
(h) Disconnect the right regulating motor C23

connector.
(i) Check continuity of each terminal of the wire

harness side connector.

Color
G2N-35-G45-1 R/B Less than 1 Ω
G2N-35-G45-3 R/B Less than 1 Ω
B1I-10-C31-1 R/B Less than 1 Ω
B1I-10-C23-1 R/B Less than 1 Ω
G45-5-C31-2 Y Less than 1 Ω
G45-4-C23-2 L/W Less than 1 Ω
C31-3-body B Less than 1 Ω
ground
C23-3-body B Less than 1 Ω
ground
NG
Replace or repair wire harness
OK
5 Change the regulating motor
119
Auto light doesn't work.
Circuit Diagram
Combination
Gateway
switch
Illumination intensity
sensor
Check Procedure
1 Check whether the manual headlamp is on.
(a) Switch the power supply to ON position.
(b) Adjust the combination switch to sidelamp

position and headlamp position manually to
see whether the sidelamp and the headlamp
can be turned on.
OK: Headlamp and sidelamp can be turned on and

off manually, which means RCM relay circuit and
CAN communication are OK.
120
NG
Check "combination switch circuit"
OK
2 Check illumination intensity sensor
(a) Change an illumination intensity sensor
(b) Check whether the auto light works well.
OK: Auto light works well.
OK
Illumination intensity sensor failure
NG
3 Check wire harness (Illumination intensity sensor - BCM)
(a) Disconnect the illumination intensity sensor

wire connector (wire harness end number)
GJ08.
(b) Disconnect BCM G2Q connector.
(c) Check voltage between these terminals.

Color Condition
G2Q-8-GJ08-6 Gr/L Less than 1 Ω
G2Q-7-GJ08-5 L/O Less than 1 Ω
GJ08-5-body L/O Larger than 10
ground kΩ
GJ08-6-body Gr/L Larger than 10
ground kΩ
OK
4 Replace combination switch
121
8 Assembly & disassembly
Front combination light
Take left combination light for example.

Disassembly
1. Remove front bumper
2. Remove front left combination light 2. Install front bumper
(a) Remove the upper two bolts and the Front fog light
one on the lateral side, as well as the
one on the water tank post with size-10
socket wrench Take the front left turn light as an example
Disassembly
(b) Disconnect all connectors on the left
combination light. 1. Remove the front fog light trim panel.
(c) Remove the rear left combination light. 2. Remove front bumper
3. Remove front left fog light
(a) Disconnect the connector.
(b) Use two tapping screws.
Assembly
1. Install the left combination front light
(d) Connect all connectors on the left

combination rear light.
(e) Insert the left combination rear light into (c) Take off the front left fog light from the
appropriate positions. front.
(f) Place four set bolts.
Assembly
122
1. Install the front left fog light. (b) Disconnect the connector.
(a) Align the front left fog light with the Remove the rear left combination light
mounting hole.
(b) Insert 2 screws.
(c) Connect the connector.
2. Install front bumper
3. Install the front fog light trim panel.
1. Install the left combination rear light.
(a) Insert the left combination rear light

into appropriate positions.
(b) Install 3 set nuts.
Combination rear lamp
Take left combination light for

example.
Disassembly
1. Remove the left armor of the trunk. 2. Left armor of the trunk.
2 Remove the left combination rear light.
(a) Remove 3 set bolts with 10# socket

wrench.
123
High braking lamp Trunk light
Disassembly Disassembly
1. Remove the rear shelf (a) Press the snap-fits on both sides.
2. Remove the high braking lamp (b) Remove the trunk light.
(a) (c) RDisconnect the connector.

emove two tapping screws with a
(b) M
ove the two snap-fits according to the
diagram and remove the high braking
light.
Assembly
(a) Connect the connector.
Assembly
(a) Insert the high braking light into the shelf

directly.
(b) Install 2 set screws.
Insert the trunk light into the mounting point

directly.
ve the trunk light.
(d) ess the snap-fits on both sides.
Plate lamp
Disassembly
1. Remove the inner trim plate of the trunk.
2. Remove the plate light.

124
(b) Eject the snap-fit from the inside of the b Connect the connector.
trunk cover.
(c) Remove the plate light from the mounting
hole with the trim strip of the rear plate
Front interior light
light on.
Disassembly
(a) Open the spectacle case and pry the

installation bolt plug with a small straight
screwdriver.
(b) Remove the two assembling bolts in the

spectacle case.
(c) Separate the light from the ceiling with

two hands outside the interior light.
Assembly (d) Disconnect the connector.
1. Install the plate light.
(a) Insert the plate light from the mounting

hole of the rear plate and other ones with
the trim strip on.
(b) Connect the connector.
Plate lamp
Disassembly
Assembly
1. Remove the inner trim plate of the trunk.
Assemble in the reverse order.
2. Remove the plate light.
(d) Disconnect the connector. Side steering light
(e) Eject the snap-fit from the inside of the
trunk cover.
Please refer to assembly & disassembly of
(f) Remove the plate light from the
power outer rear view mirror.
mounting hole with the trim strip of the
rear plate light on.
Outer rear view mirror foot light
Assembly
Please refer to assembly & disassembly of
1 Install the plate light. power outer rear view mirror.
a Insert the plate light from the mounting

hole of the rear plate and other ones with the
trim strip on.
125
Storage tank light
Disassembly
(a) Remove the storage tank.
(b) Remove the two tapping screws of the

storage tank light support on the lower
body of the dashboard with a crosshead
screwdriver.
(c) Remove the storage tank light and

support
(d) Disconnect the connector
(e) Rotate the storage light

counterclockwise. Assembly
(f) Remove the storage light from the Assemble in the reverse order.
support.
Dress-up light
Disassembly
(a) Open the sun screen and you can see
the dress-up light.
(b) Pry the dress-up mirror right snap-fit

with a straight screwdriver (to the right
of the driver's side and to the left of the
passenger's side) and remove the
dress-up mirror light.
(c) Disconnect the connector.
Assembly
The assembly is in reverse order of

disassembly.
126
Foot light 1. Remove front left door protective plate.
2. Remove the door latch protective panel

Both the left foot light and the right foot light
from the front left door protective plate.
are arranged on the sound-proof panel
below the dashboard and are assembled in
3. Remove the atmosphere lamps
the same way. Take the right foot light for
example.
(a) Press the atmosphere lamp bayonet
and pry it according to the diagram.
Disassembly
(b) Remove the atmosphere lamp from the
(a) Remove dashboard lower acoustic
door latch protective plate.
panel RH
(b) Disconnect the connector.
(c) Rotate the right foot light

counterclockwise and remove the foot
light upward in the same way as the
storage tank light. You can refer to the
picture of the storage tank light.
Assembly
The assembly is in reverse order of Assembly

disassembly.
The assembly is in reverse order of
disassembly.
Atmosphere lamps
All of the four atmosphere lamps are

arranged on the protective plate of the door
latch and installed in the same way. We take
the front left atmosphere lamp for example.
Disassembly
127
Chapter 3 Multimedia System

1 Parts Location .................................................................................................................... 129
2 System Diagram ................................................................................................................ 131
6 ECU terminals .................................................................................................................... 138
7 Power Supply Circuit of the Multimedia Machine .............................................................. 162
8 Disassembly and Assembly of the Door Speakers ........................................................... 186
9 Assembly and Disassembly of the Front High Pitch Speakers ......................................... 187
10 Assembly and Disassembly of the Middle Pitch Speakers ............................................. 187
11 Assembly & disassembly of exterior power amplifier ...................................................... 188
13 Assembly and Disassembly of the Rear High Pitch Speakers........................................ 189
14 Assembly and Disassembly of the Mega Bass Speakers ............................................... 189
16 Disassembly & Assembly of the Exterior Antenna .......................................................... 190
128
1 Parts Location
High Pitch
Speaker RH
Middle Pitch
Speaker
High Pitch
Speaker LH
Multimedia
Machine
129
130
2 System Diagram
Steering
switch
Exterior
antenna
Multimedia Machine
Printed Printed
antenna antenna
Right
rearview
mirror
camera
Backup
camera
USB & AUX

Interface
Speaker Exterior
amplifier
131
3 System Description (b) Disc cleaning

If dirt is on the disc surface, wipe it with a
soft dry cloth such as an eyeglass cleaner
Warning: from the inside to the outside in radial
direction.
The DVD player unit operates via a laser, so
radioactive leaks may cause injury, please Tips:
always operate in accordance with the
instructions.  Do not use a lens cleaner, because it may
affect the DVD machine.
This multimedia system integrates digital  Pressing on the CD by hand or rubbing the
imaging and a series of other functions. CD with a hard cloth may scratch the CD
Whether playing CDs, watching TV or listening surface.
to AM/FM radio, this system can best satisfy
your requirements. 3. MP3/WMA File Playing
1. Main Components: (a) Playable MP3 files
(b) Playable WMA files
 Multimedia Machine (c) File name
 Central Control Panel
 On-board phone (1) 0nly files with extension of ".mp3" or ".wap"
 Multi Steering Wheel can be recognized and played.
 Exterior Power Amplifier (2) Save files with an extension of ".mp3" or
 Speakers (two high pitch speakers, three ".wap".
middle pitch speakers [front and rear],
four-door speakers and mega bass speakers) Tips:
 On-board television module If any file other than MP3 or WMA is saved
 Glass-printed antenna and antenna with extension of ".mp3" or ".wma", it will be
feeding recognized and played as an mp3 file or wma
 Antenna Amplifier file, and may generate noise and even
damage the speaker.
 External antenna (including GPS antenna
and TV antenna)
4. Description of the Radio
2. DVD machine overview
(a) Radio frequencies
Radio frequencies:
The DVD machine uses the laser to read
AM: 522 KHz~1620 KHz
digital signals recorded on the disc, and
FM: 87.5 MHz~108.0 MHz
sends the signals to other media
Tips:
components to play.
The scope of FM and AM varies greatly.
Tips:
Sometimes AM can be received clearly while
FM (stereo) cannot. FM (stereo) has a very
 Do not remove any part of the unit. small service area, and is easily disturbed by
 Don't insert anything other than a 12cm statics or other substances (such as noise).
standard CD into the unit.
(a) Usable discs
Discs in formats of DVD Video, DVD Audio,

CD Digital Audio, CD-TEXT, MP3 or WMA
132
Dolly
interference
FM (Stereo)
FM (Non-Stereo)
(2) Multipath interference
Multipath interference is due to the reception

of two signals from the same source of
(b) Radio reception issues transmission-one received directly from the
source of transmission, and the other reflected
Tips: back by buildings, high mountains and other
Apart from stereo, other issues, such as obstacles.
"phase modulation", "multi-channel" and
"sound attenuation", are not caused by Signal
electronic noises but due to the transmission Attenuation
and reception of signals themselves.
PM
Ionosphere
(3) Signal Attenuation
Signal attenuation is the reduction of wave

energy of signals due to the deflection and
(1) PM deviation of some signals caused by huge
obstacles (buildings and mountains, etc.)
AM radio broadcast is easily subject to between the source of transmission and the
interference by electromagnetic waves and radio. High-frequencies are more easily
other factors. Therefore, phase modulation blocked, while low-frequency signals can pass
(PM) is created. System overviewly, phase the obstacles more easily.
modulation happens at night. The vehicle
receives two signals from the same source of
transmission-one signal is reflected through
the ionosphere, and the other is directly
received from the source of transmission.
133
4 How to Troubleshoot
Tips:
 Use the following procedure to troubleshoot the
multimedia system.
 *: Using the intelligent detecter.
Next
2 Customer problem analysis and symptom check
Next
3 Inspect battery voltage
Standard voltage:
11 to 14 V
Next
4 Check CAN communication system*
(a) Using the intelligent detecter to check for

normal function of the can communication
system.
Result
Result Proceed to
No output of CAN communication system DTC A
CAN communication system DTC output B
Go to CAN communication system
5 Inspect DTC*
Result
Result Proceed to
No DTC is output A
DTC is output B
134
B Go to step 8
6 Problem symptoms chart
Result
Result Proceed to
Fault is not listed in problem symptoms table A
Fault is listed in problem symptoms table B
B Go to step 8
7 Overall analysis and troubleshooting*
(a) ECU terminals

Next
Next
9 Confirmation test
Next
End
135

Tips:
Malfunctions. The potential causes of the faults are
area in the order. Repair or replace faulty parts or
Multimedia System:
Reference
Symptom Suspected area
page
Power circuit of CD unit
The system cannot be switched on
Multimedia machine
Steering switch
Steering switch does not function Multimedia machine
Wire harness
Speakers
Exterior power amplifier
Speakers are silent
Multimedia machine
Wire harness
Check wire harness
Amplifier cannot be detected Exterior power amplifier
Multimedia machine
Speakers
Noise exists or sound quality is poor Multimedia machine
Multimedia machine
Silent only in DVD Mode Exterior power amplifier
Wire harness
Speaker circuit
Multimedia machine to external power
Poor sound quality (Sound volume is amplifier circuit
too low) in all modes
Multimedia machine
Lighting system (See Lighting System)
Central control panel backlighting
Multimedia machine
does not illuminate
Wire harness
The radio cannot receive any signal Go to "The radio cannot receive signals
(or signal reception is very poor) (or signal reception is very poor)"
The Disc cannot be Inserted or Disc
136
Ejected Multimedia machine

Wire harness
TV glass printed antenna
Exterior antenna
Poor TV signals or unclear images
Multimedia machine
Wire harness
Go to "Disc playing skips"
Disc playing skips
Multimedia machine
Multimedia machine
Display screen is black Central control panel
Wire harness
Multimedia machine
Touch screen not working Central control panel
Wire harness
GPS SD card
Multimedia machine
GPS image jitter or blurring
Exterior antenna
Wire harness
Incorrect GPS locations on the GPS SD card

screen Multimedia machine
137
6 ECU terminals
1. Inspect the multimedia machine terminal
(a) Lead wire from the rear end of the G29

connector for multimedia unit.
(b) Measure the resistance or voltage
between each terminal of the connector.
Standard voltage or resistance
Terminal No. Specified

Wire color Terminal description Option
(Symbol) condition
G29-1 -- N/A -- --
G29-2 -- N/A -- --
G29-3-body Y/R
ACC power supply ACC gear 11 to 14 V
ground
G29-4-body
W/G Battery Always 11-14 V
ground
G29-5 -- N/A -- --
G29-6 -- N/A -- --
G29-7-body B Always Less than 1
body ground-
ground Ω
G29-8-body Y/G Power source of antenna ACC gear 11-14 V
138
ground
G29-9 -- N/A -- --
G29-10 -- N/A -- --
Standard voltage or resistance (interior power amplifier)

(Symbol) condition
G/Y Front door speaker RH -- --
G29-1
positive
G/B Front door speaker LH -- --
G29-2
positive
G29-3-body Y/R
ACC power supply ACC gear 11-14 V
ground
G29-4-body
W/G Battery Always 11-14 V
ground
Gr Front door speaker RH -- --
G29-5
negative
Lg Front door speaker LH -- --
G29-6
negative
G29-7 B body ground- Always Less than 1 Ω
G29-8-body Y/G ACC gear 11-14 V
Power source of antenna
ground
G29-9 -- N/A -- --
G29-10 -- N/A -- --
(c) Lead wire from the rear end of the G30
connector of the multimedia unit.
(d) Measure the resistance or voltage


(Symbol) condition
G30-1-body B Rear door speaker RH -- --
ground positive
G30-2-body W Rear door speaker LH -- --
ground positive
G30-3-body Y Rear door speaker RH -- --
ground negative
G30-4 -- N/A -- --
G30-5 -- N/A -- --
G30-6-body Rear door speaker LH -- --
L
ground negative
139
(e) Lead wire from the rear end of the G31

(f) Measure the resistance or voltage


(Symbol) condition
G31-1-body W/L Front-right camera -- --
ground signal
Backup W Backup
camera camera
signal Backup camera signal signal
G31-3-body W/B Backup camera video -- --
ground ground
G31-4 -- --
G31-5-body With power ON,
B/Y 11-14 V
ground Backup camera power shift to Gear R
G31-6-body Front-right camera Power ON, 11-14 V
L
ground power front-right imaging
G31-7 -- -- -- --
G31-8 -- -- -- --
G31-9-body B Front-right camera -- --
ground signal shielding ground
G31-10-body -- Front-right camera -- --
ground signal shielding layer
G31-11-body -- Backup camera signal -- --
ground shielding layer
G31-12 -- -- -- --
G31-13 -- -- -- --
G31-14 -- -- -- --
G31-15-body Backup camera power Less than 1
B Always
ground ground Ω
G31-16-body G Front-right camera Less than 1
Always
ground power ground Ω
G31-17 -- -- -- --
G31-18 -- -- -- --
(g) Lead wire from the rear end of the G51

(h) Measure the resistance or voltage
140

Wire color Option
(Symbol) description condition
G51-1-body Always Less than 1 Ω
R
ground AUX ground
G51-2-body -- --
L
ground AUX right channel
G51-3-body -- --
W
ground AUX left channel
G51-4-body AUX detection No AUX external Less than 1 Ω
G
ground signal equipment
G51-5-body -- AUX signal shield -- --
ground ground
G51-6-body Always 2.5 V
V
ground CAN_L
P
ground CAN_H
G51-8-body Steering wheel -- --
Sb
ground switch signal
G51-9-body -- --
L
ground WAKE
G51-10-body Br
ground USB ground
G51-11-body B ACC position 5V
ground USB power supply
G51-12-body -- --
Y
ground DP_U
G51-13-body -- --
Gr
ground DM_U
G51-14-body USB signal shield -- --
--
ground ground
G51-15 -- N/A -- --
G51-16 -- N/A -- --
G51-17 -- N/A -- --
G51-18 -- N/A -- --
G51-19 -- N/A -- --
G51-20 -- N/A -- --
G51-21 -- N/A -- --
G51-22 -- N/A -- --
Connected with
G51-23-body external power
L Always Less than 1 Ω
ground amplifier signal
ground
141
G51-24-body Front-left audio -- --

Y/O
ground output-
G51-25-body Front-left audio -- --
Y/L
ground output+
G51-26-body Front-right audio -- --
Y/G
ground output-
G51-27-body L/W Front-right audio -- --
ground output+
G51-28-body L/O Rear-right audio -- --
ground output+
G51-29-body Rear-right audio -- --
Gr
ground output-
G51-30-body DVD audio output -- --
B
ground shielding ground

(Symbol) condition
G51-1-body Always Less than
R
ground AUX ground 1Ω
G51-2-body -- --
L
ground AUX right channel
G51-3-body -- --
W
ground AUX left channel
G51-4-body No AUX external Less than
G
ground AUX detection signal equipment 1Ω
G51-5-body -- AUX signal shield -- --
ground ground
V
ground CAN_L
P
ground CAN_H
G51-8-body Steering wheel -- --
Sb
ground switch signal
G51-9 -- N/A -- --
G51-10-body Br Less than
Always
ground USB ground 1Ω
G51-11-body B ACC position 5V
ground USB power supply
G51-12-body -- --
Y
ground DP_U
G51-13-body -- --
Gr
ground DM_U
142
G51-14-body USB signal shield -- --

--
ground ground
(i) Lead wire from the rear end of the G55

connector of the multimedia unit.
(j) Measure the resistance or voltage
Terminal No.
Wire color Terminal description Option Specified condition
(Symbol)
G55-1 -- N/A -- --
G55-2 -- N/A -- --
G55-3 -- N/A -- --
G55-4-body Steering wheel Always, switch Corresponding
G/R
ground audio switch signal pressed switch resistance
G55-5-body Br Steering wheel Always, switch Corresponding
ground audio switch signal pressed switch resistance
G55-6 -- N/A -- --
If the result is not as specified, there may

be a malfunction on the wire harness.
2. Exterior power amplifier terminal
(a) Lead wire behind the exterior power

amplifier K26 connector.


Wire color Option
K26-1-body
Y-body ground Power (+) Always 11-14 V
ground
K26-2-body Y-body ground Power (+) Always 11-14 V
143
ground
K26-3-body ACC power
R/L-body ground ACC 11-14 V
ground supply
K26-4-body Less than 1
B-body ground Battery ground Always
ground Ω
ground Ω
K26-6-body
ground
K26-7-body
ground
K26-8-body -- --
P-body ground CAN_H
ground
K26-9-body -- --
V-body ground CAN_L
ground
K26-10-body -- -- -- --
ground
ground Ω
ground Ω
(c) Lead wire behind the exterior power

(d) Measure the resistance or voltage


(Symbol) condition
K27-1-body ground G/Y Front speaker RH positive -- --
K27-2-body ground Gr Front speaker RH negative -- --
K27-3-body ground B Rear speaker RH positive -- --
K27-4-body ground Y Rear speaker RH negative -- --
K27-5-body ground W Rear speaker LH positive -- --
K27-6-body ground L Rear speaker LH negative -- --
(e) Lead wire behind the exterior power

(f) Measure the resistance or voltage

144

(Symbol) condition
K28-1-body Front speaker LH -- --
G/B
ground positive
K28-2-body Front speaker LH -- --
Lg
ground negative
K28-3-body Middle loudspeaker -- --
B/W
ground positive
K28-4-body Middle loudspeaker -- --
L
ground negative
K28-5-body -- -- --
L
ground
K28-6-body -- -- --
W
ground
K28-7-body Rear mega bass -- --
L/W
ground speaker positive
K28-8-body Rear mega bass -- --
L/B
ground speaker negative
K28-9-body -- -- --
Lg
ground
K28-10-body -- -- --
G/Y
ground
(g) Lead wire behind the exterior power

(h) Measure the resistance or voltage


Wire color Option
K37-5-body -- --
L/O Audio signals
ground
K37-9-body -- --
Y/L Audio signals
ground
K37-10-body -- --
Y/O Audio signals
ground
K37-11-body -- --
Y/G Audio signals
ground
K37-12-body Audio signals -- --
L/W
ground
K37-13-body Audio signals -- --
Gr
ground
K37-14-body L Rear mega bass -- --
145
ground speaker positive

K37-15-body -- --
Screen ground
ground

146

1 On-vehicle Inspection
(a) Switch power supply to the ACC position.

(b) Check whether the multimedia unit has been
switched on (whether there is an indication on
the display).
(c) Check for the functions of the buttons on the
operation panel and touch screen.
OK: There is an indication on the display and button
response is normal.
OK System is OK
NG
2 Inspect Power Supply Circuit of the Multimedia Machine
(a) See page "multimedia unit power source

circuit”
OK: The circuit is normal.
OK
3 Replace the Multimedia Machine
147
Steering switch does not function
1 Inspect the Steering Switch
(a) Temporarily replace a normal steering switch to

check its effectiveness.
OK: Steering wheel switch works well.
OK Replace the steering switch
NG
2 Inspect the Circuit from the Steering Switch to the Multimedia Unit
(a) See page "The circuit from the steering switch

to the multimedia unit".
OK
148
Speakers give out no sounds in all modes

1 Adjust Sound Volume Setting
(a) Increase sound volume to the maximum and

reset sound effects.
Next
2 Inspect Speakers
(a) Switch on the multimedia machine and adjust

the mode to audio output (such as: DVD disc,
TV, AUX, AM and FM).
(b) Inspect whether each speaker is functional.
Result of the Inspection Proceed

No sound from some speakers A
No sound from all speakers B
See page "The Circuit from Speakers to Exterior

Power Amplifier".
B
3 Inspect Power Supply for the Exterior Amplifier
(a) See page "exterior power amplifier power

circuit”
OK
4 Inspect Exterior Amplifier
(a) Temporarily replace the multimedia unit with a

normal one and check whether the
malfunctioning has been removed.
OK: Malfunctioning removed.

OK
Replace the Exterior Power Amplifier
NG
149
5 Inspect the Circuit from Exterior Amplifier to Multimedia Machine
(a) See page "Circuit from Exterior Amplifier to

Multimedia Machine”

OK
150
Noise exists or sound quality is poor

(a) Make sure there is no external electromagnetic

interference around and compare with other
vehicles of the same model to check whether
the sound effects are the same.
Abnormal: The sound effects are the same.
OK System is OK
NG
2 Inspect Speakers
(a) Inspect whether the sound effect of each

speaker is normal.
Result Inspection Proceed

Sound effects of some
A
speakers are abnormal
Sound effects of all speakers
B
are abnormal
A
Replace the speakers with the abnormal sound
effects
B
(a) Temporarily replace the multimedia unit with a

normal one and check whether the
malfunctioning has been removed.
OK: Malfunctioning removed.

OK
Replace the Exterior Power Amplifier
NG
151
4 Inspect the Circuit from the Exterior Amplifier to Multimedia Machine
(a) See page "Circuit from Exterior Amplifier to

Multimedia Machine”
OK: Circuit is ok.
OK
152
Silent only in DVD Mode

(b) Switch on the multimedia system and adjust it

to the DVD mode to check whether there are
sounds.
(c) Adjust the mode to other modes with audio

output to check whether there are sounds.

There are no sounds for the
DVD mode but there are A
sounds for other modes
There are no sounds for the
B
DVD mode or other modes
B
See page "No Sounds from Speakers in All
Mode"
A
153
Poor sound quality (Sound volume is too low) in all modes

(a) Turn on the multimedia machine and adjust the

sound effect.
OK: Sound effect recovers.
OK System is OK
NG
2 Compare Sound Effects with a Vehicle of the Same Model
(a) Compare the vehicle with another one of the

same model and configuration with normal
sound effects to check the difference in sound
effects.
OK: No big difference in effect
OK System is OK
NG
3 Replace the Exterior Power Amplifier
154
The Disc cannot be Inserted or Ejected
1 Inspect the Disc
(a) Make sure the disc format is correct.

(b) Inspect whether the disc is deformed, corroded
or cracked.
OK: Disc is OK.
NG The disc is damaged
OK
2 Replace the Disc
(a) Replace a normal disc to see whether it can

be inserted and ejected normally.
OK: The disc can be inserted and returned
normally.
OK Disc is damaged.
NG
3 Inspect the Connectors Behind the Multimedia Unit for any Looseness
(a) Disconnect and reconnect the connectors

behind multimedia unit once and check
whether malfunctioning has returned to
normal.
OK: The disc can be taken out.
OK Connectors loose
NG
155
Poor TV signals or unclear images

(a) Redo auto search for stations and check image

and sound qualities.
OK: Image and sound qualities return to normal.
OK System is OK
NG
2 Compare TV Effects with a Vehicle of the Same Model

same model and configuration with normal TV
effects to check the difference in sound effects.
OK: Difference in sound effects is not big.
OK System is OK
NG
3 Check Exterior Antenna
(a) Temporarily replace the exterior antenna with a

normal one and check whether TV effects have
returned to normal.
OK Change Exterior Antenna
NG
4 Inspect the Circuit from TV Module to Multimedia Machine
(a) See page "The circuit from TV module to

multimedia unit".

OK
156
Disc playing skips

1 Cleaning the Disc
(a) Wipe it with a soft cotton cloth from the inside to

the outside in a radial direction.
Notice: Don't wipe the disc with a hard cloth or

corrosive cleaning agent.
(b) Insert the disc again and check whether the

skips occur
OK: Skip doesn't occur any more.
OK
There is dirt on the surface of the CD/DVD.
NG
2 Inspect the Disc
(a) Inspect whether the disc is scratched or leaks

light.
OK: The disc is not scratched and doesn't leak light.

OK
CD/DVD damaged, replace with another one

NG
157
Display screen is black

(a) Power on and off repeatedly to check whether

there is image display.
OK: Malfunction does not recur
OK System is OK
NG
2 Inspect the Temperature and Humidity in the Driver's Compartment
(a) Inspect whether the humidity in the driver's

compartment is too high, whether temperature
change is drastic or the temperature is too high
or too low.
Notice: Too high humidity may easily cause a short

circuit of the LCD.
OK: Temperature and humidity are agreeable.

NG
Adjust the humidity and temperature to an

appropriate level.
OK
3 Return to Power Supply Circuit of the Multimedia Machine
(a) See page "multimedia unit power source

circuit”
OK: Circuit is ok.

OK
158
Touch screen not working

(a) Switch on and off the multimedia machine

repeatedly and try to press on different buttons
on the touch screen.
OK: Touch screen recovers.
OK System is OK
NG
159
The radio cannot receive any signal (or signal reception is

very poor)
Tips:
Inspect the signal reception capability of the radio at
a place far from high buildings. If the radio is far
from radio stations or near high-voltage power
transmission lines in mountainous areas or of
buildings, the signal reception capability of the radio
is inevitably poor.
1 Inspect the Auto Search Function

(b) Switch the radio to AM and check whether the
search function is normal.
OK: Auto search functions well
OK
Replace the Multimedia Machine
NG
2 Inspect Whether There Is Interference from Other Equipment
(a) Check whether there are other interfering

devices at work, such as wipers and
glass-frame risers.
OK: There are interfering electric devices at
work.
OK
Influence from other electric devices
NG
3 Inspect the Radio (Multimedia Machine)
(a) Unplug the radio feeder.
(b) With other connectors to multimedia unit

connected, switch power supply to the ACC
position.
(c) Turn on the multimedia unit and switch to AM

mode.
160
(d) Insert a screwdriver or a wire into the antenna

socket of the radio to check whether there are
noises.
OK: There is noise.

NG
OK
4 Change the Radio Antenna and Amplifier
161
7 Power Supply Circuit of the Multimedia Machine

Circuit Diagram
Audio-Visual
System
Auxiliary Power Supply

Dashboard
Wire
Harness
Adapter
Batter
yy Multimedia Machine
162
Audio-Visual
System

Dashboard
Wire
Harness
Adapter
Battery Multimedia Machine

(Interior power amplifier)
1 Check the fuse
(a) Use a multimeter to check whether the audio

system is good.
(b) Exterior power amplifier: F4/2, F4/12; interior
power amplifier: F2/4, F2/20
OK: The fuses are good.
NG Replace fuse
OK
163
2 Inspect distribution box
(a) Lead wire behind the dashboard distribution

box connector G2N (interior power amplifier)
and connector G01
(b) Check voltage of terminal.
Standard Voltage
Specified
Tester Connection Option
Condition
G2N-10-body
ground
Always 11-14 V
G01-G12-body
ground
G2N-37-body
ground Power up to
11-14 V
G01-G02-body ACC position
ground
NG
Replace dashboard distributor box
OK
3 Inspect the Harness or Connector
(a) Disconnect dashboard distributor box

connectors G2N and G01.
(b) Disconnect the multimedia host G29 connector.
(c) Check the resistance between each terminal of

the wire harness side connector.
Standard Resistance
Specified
Condition
G2N-10-G29-4
G01-G12- G29-4
G2N-37-G29-3
G01-G02-G29-3
G29-7-body
ground
164
NG
OK
4 Circuit is ok.
165
Power Supply Circuit of the Power Amplifier

Circuit Diagram

40A
Audio-Visual System
Battery Battery Battery Battery

1 Check the fuse
(a) Check, using a multimeter, whether amplifier

fuses F4/2 and F1/16 are good.
NG Replace fuse
OK
166
(a) Lead wire behind the dashboard distribution

box connectors K2E and G01
(b) Check voltage of terminal.
Standard Voltage
Specified
Condition
K2E-15 - body
Always 11 to 14 V
ground
G01-G02-body ACC power
11 to 14 V
ground supply
NG
OK
(a) Disconnect dashboard distributor box

connectors K2E and G01.
(b) Disconnect the exterior power amplifier K26

connector.

Standard Resistance
Specified
Condition
K2E-15-K26-1 Always Less than 1 Ω
G01-G02-K26-3 Always Less than 1 Ω
K26-4-body ground Always Less than 1 Ω
167
NG
OK
4 Circuit is ok.
168
Circuit from Speaker to Exterior Power Amplifier

Circuit Diagram
Rear
Rear Right
Door Middle
Speaker Pitch
LH Speaker
169
Rear Mega Bass Speaker

Rear Door Speaker RH
Middle loudspeaker
Rear
Right
Middle
Pitch
Speaker
170
Exterior Power Amplifier
Dashboard
Dashboard Wire
Wire Harness
Harness Adapter
Adapter
Front
High
Front Door Pitch
Speaker RH Speaker
RH
171
1 Inspect Speakers
Tips: The inspection methods for all the speakers

are the same. We take the front door LH as an
example.
(a) Remove the front door speaker LH T07

connector.
terminals of the speaker.
Standard Resistance
Tester Specified
Option
1-2 Always About 4 Ω
NG Replace Speakers
OK
(a) Disconnect connectors V07, K29, K30, W01,

G52, K31, T07, T02, U07 and U03 of the
speaker and disconnect connectors K27 and
K28 of the exterior power amplifier.
(b) Measure the resistance between each terminal

of the wire harness side connector.
Standard Resistance
Tester Specified
Option
V07-1-K27-6 Always Less than 1 Ω
V07-2-K27-5 Always Less than 1 Ω
K29-1-K27-6 Always Less than 1 Ω
W01-1-K27-4 Always Less than 1 Ω
W01-2-K27-3 Always Less than 1 Ω
172

K31-2-K28 -7 Always Less than 1 Ω
T07-1-K28-2 Always Less than 1 Ω
U07-1-K27-2 Always Less than 1 Ω
NG
OK
3 Replace the Exterior Power Amplifier
173
Circuit from Speaker to Interior Power Amplifier

Circuit Diagram
Multimedia machine (Interior power amplifier)

distributor box
Dashboard
Rear Door Speaker LH

Front High Pitch
Rear High Pitch

Speaker RH
Speaker LH
Speaker RH
Front Door
174
1 Inspect Speakers
Tips: The inspection methods for all the speakers

are the same. We take the front door LH as an
example.
(a) Remove the front door speaker LH T07

connector.

Standard Resistance
Specified
Condition
1-2 Always About 4Ω
NG Replace Speakers
OK
(a) Remove the speakers T07, U07, V02, W01

connectors and the multimedia unit G29, G30
connectors.

Standard Resistance
Tester Specified
Option
U07-1-G29-5 Always Less than 1 Ω
T07-1-G29-6 Always Less than 1 Ω
V02-1-G30-6 Always Less than 1 Ω
W01-1-G30-3 Always Less than 1 Ω
NG
175
OK
3 Change multimedia machine (Interior power amplifier)
176
BYD AUTO
Circuit Diagram
Control Switch of
Steering Wheel Audio Clock spring
Steering wheel side

camera control switch Clock spring
Multimedia Machine
Steering wheel vehicle

phone control switch Clock spring
Circuit from Steering Switch to Multimedia Unit
177
(a) Disconnect connectors G55 and G51 of the

multimedia machine

Standard Resistance
Tester Specified
Option
Do not push any
G55-4-G55-5 ∞
button
Less than
G55-4-G55-5 Push VOL+
1Ω
G55-4-G55-5 Push VOL- About 8.2 kΩ
About 23.2
G55-4-G55-5 Push CH+
kΩ
About 50.2
G55-4-G55-5 Push CH-
kΩ
About 132.2
G55-4-G55-5 Push MODE
kΩ
Do not push any
G55-5-G51-8 ∞
button
About 4.64
G55-5-G51-8 Press VIEW
kΩ
Press the
About 9.84
G55-5-G51-8 reversing camera
kΩ
switch OFF
G55-5-G51-8 Press HOOK About 1 kΩ
Press on-board
About 3.16
G55-5-G51-8 phone control
kΩ
switch OFF
NG
Replace the steering switch
OK
2 Check wire harness or connector (steering wheel switch - multimedia machine)
(a) Disconnect connectors X993 and X994 of the

steering wheel and connectors G51 and G55 of
178
the multimedia machine
(b) Check the resistance between each terminal of

Standard Resistance
Tester Specified
Option
X993-3-G51-8 Always Less than 1 Ω
NG
Replace wire harness and clock spring
OK
3 Go to the Next Step of the Procedure
179
Circuit from Exterior Amplifier to Multimedia Machine

Circuit Diagram
Shielding
layer
Shielding
layer
Shielding
layer
Exterior power amplifier Multimedia machine
ne
1 Inspect the multimedia machine terminal
(a) Lead wire from the rear end of the G51


Standard Resistance
Specified
Condition
G51-30-body
ground
NG
OK
2 Inspect the Wire Harness (Multimedia Machine-Exterior Power Amplifier)
180
(a) Disconnect connector G51 of the multimedia

machine
(b) Disconnect connector K37 of Exterior Power

Amplifier

Standard Resistance
Tester
Option Specified Condition
Connection
NG
OK
3 Go to the Next Step of the Procedure
181
GPS cannot receive satellite.

1 Inspect the Multimedia Machine (GPS module)
(a) Click to enter map view.
(b) Click "view number of satellites"
OK: e.g. "three satellites received"

NG
OK
2 Check Exterior Antenna And Antenna Feed Wire Harness
(a) Check continuity between exterior antenna and

antenna feed wire harness
OK
2 Change or repair the exterior antenna
182
Amplifier cannot be detected

Circuit Diagram
Multimedia Machine
Screen
Battery ground
Battery
Lights and CAN

module auxiliary
power supply40A
Screen
Audio-Visual Dashboard ground
System Wire
Audio-Visual Harness
System Adapter
Battery Battery Battery Battery Screen

ground
Exterior amplifier
1 Inspect Power Supply for Exterior Amplifier
(a) Lead wire behind the exterior power amplifier

K26 connector.
(b) Check the voltage of each terminal.
Standard Voltage
183
Specified
Condition
K26-1-body ground Always 11 to 14 V
OK Go to Step 3
NG
2 Check fuse and distribution box
(a) Check whether audio system fuses F2/4 and

F4/12 are OK.
OK: The fuses have continuity
NG Replace fuse
(b) Lead wire behind connectors G01 and G2E of

the distribution box.
(c) Check the voltage of each terminal.
Standard Voltage
Specified
Condition
G01-G12-body
Always 11 to 14 V
ground
K2E-15-body
Always 11 to 14 V
ground
NG
Change the distribution box
OK
Change the wire harness or the connector (Dashboard distributor box - exterior power amplifier)
3 Check whether the audio wire is well connected.
(a) Re-plug the exterior power amplifier connector

and the connector G29 of the multimedia
machine.
184
(b) Check whether it's recovered.
OK: Recovered
OK Connectors loose
NG
(a) Temporarily replace it with a normal exterior

amplifier
(b) Check whether it's recovered.
OK: Recovered
OK
Exterior power amplifier is damaged and needs to
be replaced.
NG
185
Assembly & Disassembly of

the Multimedia Machine
Disassembly
1. Remove combination instrument head

cover
2. Remove the dashboard middle cover

2. Install the dashboard center cover plate.
3. Disassembly of the Multimedia Machine
3. Install the combination instrument head
(a) Remove 2 set bolts. cover.
(b) Disconnect the connector behind the

multimedia unit. 8 Disassembly and Assembly
of the Door Speakers
(c) Remove the Multimedia Machine
We take the front door LH as an example.
Disassembly
1. Remove the Front Door Shield Inner LH
2. Remove the Front Door Speaker LH
(b) Disconnect the connector and remove the

Installation speaker.
1. Install the Multimedia Machine
(a) Connect the multimedia unit connector.
(b) Set the multimedia unit to the

dashboard.
(c) Install 2 set bolts.
Assembly
1. Install the Front Door Speaker LH
186
(a) Align the front door speaker LH with the

installation holes.
Assembly
2. Install the Front Door Shield Inner LH
1. Install the Front High Pitch Speaker LH
9 Assembly and Disassembly
of the Front High Pitch
Speakers (b) Install 2 screws.
(c) Install the front door guard plate LH.

We take the front high pitch speaker LH as an
example
Disassembly
1. Remove the Front High Pitch Speaker LH
(a) Remove the front door guard plate LH.
(c) Remove 2 screws with a cross

screwdriver.
(d) Remove the speaker.

of the Middle Pitch Speakers
Disassembly
1. Remove the middle loudspeaker hood
(a) Use a screwdriver to pry open the hood.
187
2. Remove the middle pitch loudspeaker Assembly
(a) Remove the two screws with a crosshead 1. Install the exterior power amplifier
screw driver.
(a) Align the exterior power amplifier with the
(b) Disconnect the connector and remove the mounting hole;
middle pitch speaker.
(b) Mount 4 bolts.
11 Assembly & disassembly of

exterior power amplifier 2. Install the carpet left electrical hood
12 Removal and Installation of the

Disassembly
USB & AUX Interface
1. Remove the carpet left electrical hood
Disassembly
2. Remove the exterior amplifier
(a) Remove 4 set bolts. 1. Pry up the back of the USB & AUX
interface with a straight screwdriver.
2. Disconnect the connector.
(c) Take off the exterior power amplifier.
3. Remove the USB & AUX interface.
188
Assembly
Assembly
1. Install the rear middle pitch speaker LH
1. Connect the connector.
(a) Align the rear middle pitch speaker LH
2. Snap the USB & AUX interfaces into the with the mounting holes.
secondary dashboard.
(b) Insert the bolts.

of the Rear High Pitch 2. Install the carrier
Speakers
Disassembly
of the Mega Bass Speakers
We take the rear middle pitch speaker LH as
an example Disassembly
1. Remove carrier
1. Remove the carrier
2. Remove the rear middle pitch speaker LH
2. Disassembly of the Mega Bass Speakers
(a) Remove the bolts with 8# socket wrench.
(a) Remove the 6 bolts with 8# socket
(b) Disconnect the connector. wrench.
(c) Remove the rear middle pitch speaker LH (b) Disconnect the connector.
189
(c) Remove the antenna amplifier.
(c) Remove the mega bass speaker.
Assembly
Assembly
1. Install the Antenna Amplifier
1. Assembly of the Mega Bass Speakers
(a) Align the antenna amplifier with the
installation hole.
(a) Align the mega bass speaker with the
mounting holes.
(b) Install 1 set nut.
(b) Replace the 6 bolts.
(c) Connect the connector. 2. Install C Pillar Left Protector
15 Removal and Installation of the 16 Disassembly & Assembly of the

Antenna Amplifier Exterior Antenna
Disassembly Disassembly
1. Remove the C Pillar Left Protector 1. Remove the ceiling
2. Remove the Antenna Amplifier 2. Disassembly of the Exterior Antenna
(a) Remove a bolt with a 10# socket wrench. (a) Remove a nut with a 22# socket wrench.
(b) Disconnect the connector. (b) Disconnect the connector of the exterior
antenna
190
(c) Take out the antenna from the outside (b) Install 1 set nut
Assembly
2. Assembly of the ceiling
1. Assembly of the Exterior Antenna
(a) Insert the exterior antenna into the

mounting hole.
191
Chapter 4 Audio System

1 Parts Location .................................................................................................................... 193
2 System Diagram ................................................................................................................ 196
4 How to Proceed with Troubleshooting ............................................................................... 199
5 Malfunction Symptoms Table ............................................................................................ 201
6 ECU Terminals................................................................................................................... 202
8 Removal and Installation of the CD Unit ........................................................................... 227
9 Removal and Installation of the Door Speakers ................................................................ 227
10 Removal and Installation of the Front High Pitch Speakers............................................ 228
192
1 Parts Location
High Pitch Speaker

RH
High Pitch CD Unit

Speaker LH
193
USB & AUX

Rear Door Interface
Speaker RH
Front Door
Speaker RH
Rear Door Speaker

LH
Front Door
Speaker LH
194
Printed
Antenna
Antenna Amplifier
195
2 System Diagram
Steering Switch
Printed Antenna CD
Antenna Amplifier Unit
USB & AUX

Interface
Speaker
196
3 System Description 1 If dirt is on the disc surface, wipe it with a soft

dry cloth such as eyeglass cleaner from the
inside to the outside in radial direction.
Warning:
Tips:
The CD player unit operates by the laser, so
radioactive leaks may cause injury. Please
 Pressing on the CD by hand or rubbing the
operate in accordance with the instructions. CD with a hard cloth may scratch the CD
surface.
This audio system integrates digital imaging
2. Description of the Radio
and a series of other functions, and it turns
your car into a small moving AV theater.
Whether playing CDs or listening to AM/FM (a) Radio frequency bands
radio, this system can best satisfy your
Radio wavebands:
requirements.
AM: 522KHz~1620KHz
Main Components:
FM: 87.5MHz~108MHz
 CD Unit
 Central Control Panel
(b) The radio spectrums for AM and FM are
 Multi Steering Wheel
 Speakers (two front high pitch speakers, quite different. Sometimes, AM radio can be
received very clearly, but FM radio cannot, for
two front door speakers, two rear door
the radio spectrum for FM is very narrow. FM
speakers)
is more inclined to the reception of sounds with
 Glass Printed Antenna
narrower bandwidths such as noises.
 Antenna Amplifier
 Antenna Feeder
1. CD Unit Overview
(a) The CD player uses the laser to read digital

signals recorded on the CD/DVD, and sends
the signals to other media components to play.
FM (Stereo)
Tips:
FM (Non-Stereo)
 Do not remove any part of the unit.
 Do not insert anything but the CD/DVD into
the unit.
(b) Usable CD/DVD

(c) Radio reception issues
Tips:
 Apart from stereo, other issues, such as
"phase modulation", "multi-channel" and
"sound attenuation", are not caused by
electronic noises but by the transmission and
(c) CD/DVD cleaning
reception of signal.
Tips:
(1) PM
 Do not use lens cleaner, because it may AM radio broadcast is easily interfered by
affect the unit. electromagnetic waves and other factors.
197
Therefore, phase modulation (PM) is created.

System overviewly, phase modulation (3) Signal Weakening
happens at night. The vehicle receives two
signals from the same source of Signal weakening is the reduction of signal
transmission--one is reflected through the wave energy due to the deflection and
ionosphere, and the other is directly received deviation of some signals, caused by huge
from the source of transmission. obstacles (buildings and mountains, etc.)
between the source of transmission and the
PM
radio. High-frequencies are more easily
blocked, while low-frequencies can pass the
obstacles more easily.
Ionosphere
Signal Weakening
(2) Multipath interference

Multipath interference is due to the reception
of two signals from the same source of
transmission--one received directly from the
source of transmission, and the other is
reflected back by buildings, high mountains or
other obstacles.
Multipath Interference
198
4 How to Proceed with

Troubleshooting
Tips:

audio system.
 Using the intelligent detecter.

Next
2 Customer Problem Analysis and Symptom Inspection
Next
Standard voltage:
11 to 14 V
Next
4 Inspect CAN communication system*
(b) Using the intelligent detecter to inspect for

system.
Result
Result Proceed to
CAN communication system DTC is not output A
CAN communication system DTC is output B
5 Inspect DTC*
Result
Result Proceed to
199
No DTC is output A
DTC is output B
B Go to step
6 Fault Symptoms Table
Result
Result Proceed to
Fault is not listed in fault symptoms table A
Fault is listed in fault symptoms table B
B Go to step 8
7 Overall Analysis and Troubleshooting*
(b) Data List / Active Test
(c) ECU Terminals

Next
8 Adjustment, Repair or Replacement
Next
9 Confirmation Test
Next Completed
200
5 Malfunction Symptoms Table

Tips:

Malfunctions. The probability of the fault causes are
listed in a diminishing order. Inspect the suspected
area in the order. Repair or replace the faulty parts
or perform adjustments if necessary.
Audio System:
Reference
Symptoms Suspected Area
page
Power circuit of CD unit -
CD unit -
Steering switch -
Steering switch does not function CD unit -
Wire harness -
Speakers -
Speakers are soundless CD unit -
Wire harness -
Speakers -
Noises exist or sound quality is poor.
CD unit -
CD unit -
Soundless only in CD Mode
Wire harness -
Poor sound quality (Sound volume is Speaker circuit -
too low) in all modes CD unit -
Lighting system (See Lighting System) -
Central control panel backlighting
CD unit -
does not illuminate
Wire harness -
The radio cannot receive any signal Go to "The radio cannot receive signals -
(or signal reception is very poor) (or signal reception is very poor)"
CD/DVD -
CD/DVD cannot be inserted or
CD unit -
ejected
Wire harness -
Go to "CD/DVD playing skips" -
CD/DVD playing skips
CD unit -
CD unit (whether the connectors behind -
the display are connected well)
Display screen is Black
Central control panel -
Wire harness -
USB & AUX circuit -
USB or AUX interface cannot play
CD unit -
the music
Wire harness -
201
6 ECU Terminals
1 Inspect the ECU Terminals of CD Unit
(i) Wire the rear end of the G29 connector of

CD unit.
(j) Measure the resistance or voltage
between the terminals of the connector on
the wiring side.
Standard Voltage or Resistance

Wire Color Terminal Description Condition
(Symbol) Condition
G29-1-Body Sound signal (FR)
G/Y- Body Ground
Ground
G29-2- Body Sound signal (FL)
G/B- Body Ground
Ground
G29-3- Body Level 1 power supply Power up to
Y/R- Body Ground 11 to 14 V
Ground (+12V) ACC position
G29-4- Body Constant voltage
W/G- Body Ground Always 11 to 14 V
Ground (storage battery)
G29-5- Body Sound signal (FR)
Gr- Body Ground
Ground
G29-6- Body Sound signal (FL)
Lg- Body Ground
Ground
G29-7- Body Battery ground Less than
B- Body Ground Always
Ground 1Ω
G29-8- Body Power source of Switch to radio
Y/G- Body Ground 11 to 14 V
Ground antenna mode
G29-9- Body Backlight brightness
R- Body Ground
Ground control wire
G29-10- Body Power source of
R/B- Body Ground Sidelamps on 11 to 14 V
Ground backlight
If the result doesn't meet the specification,

there may be a fault in the wire harness.
(k) Wire the rear end of the G30 connector of

CD unit.
(l) Measure the resistance or voltage
202
the wiring side.

(Symbol) Condition
G30-1- Body Sound signal (RR)
B- Body Ground
Ground
G30-2- Body Sound signal (RL)
W- Body Ground
Ground
G30-3- Body Sound signal (RR)
Y- Body Ground
Ground
G30-4- Body Steering wheel key
G/R- Body Ground
Ground signal
G30-5- Body Signal ground for Less than
Br- Body Ground Always
Ground steering wheel 1Ω
G30-6- Body Sound signal (RL)
L- Body Ground
Ground

(m) Wire the rear end of the G31 connector of

CD unit.
(n) Measure the resistance or voltage
the wiring side.
G31-1- Body AUX shield
- Body Ground
Ground ground wire
G31-2- Body AUX left audio
W- Body Ground
Ground signal
AUX detection Plug the
G31-3- Body
G- Body Ground signal external audio About 3.3 V
Ground
device in AUX
G31-4- Body USB shield
- Body Ground
Ground ground wire
G31-5- Body USB signal wire
Y- Body Ground
Ground
G31-6- Body Signal ground for
R- Body Ground Always Less than 1 Ω
Ground AUX
G31-7- Body AUX right audio
L- Body Ground
Ground signal
G31-8- Body CAN-L
V- Body Ground Always 2.5 V
Ground
G31-9- Body P- Body Ground CAN-H Always 2.5 V
203
Ground
G31-10- Power Supply
B- Body Ground Always 11 to 14 V
Body Ground
G31-11- USB signal wire
Gr- Body Ground
Body Ground
G31-12- Signal ground for
Br- Body Ground Always Less than 1 Ω
Body Ground USB

204

The System Cannot be Switched on
1 On-Vehicle Inspection
(b) Inspect whether the CD unit has been switched

on (whether there is an indication on the
display).
(c) Check whether the buttons on the operation

panel and touch screen function.
OK: There is indication on the display and button
response is normal.
Normal Normal system
Abnormal
2 Inspect the Power Supply Circuit of CD Unit
(a) Refer to "CD unit power source circuit".

Next
3 Inspect the CD Unit
(a) Temporarily replace with a normal CD unit.
(b) Repeat the inspection in Step 1.
OK: There is indication on the display and button

response is normal.
OK
4 Replace the CD unit
205
Steering Switch does not Function

(a) Temporarily replace with a normal CD unit to

check their function.
OK: Steering switch is in normal function
OK Replace the CD unit
NG
(a) Temporarily replace with a normal steering

switch to check their function.
OK: Steering switch is in normal function.

OK Replace the steering switch
NG
3 Inspect the Circuit from Steering Switch to CD Unit
(a) Refer to "The circuit from steering switch to CD

unit".
Next
Completed
206
Speakers are Soundless in All Modes

1 Adjust Sound Volume Setting
(a) Increase sound volume to the maximum and

reset sound effects.
Next
2 Inspect Speakers
(a) Switch on the audio system and adjust the

mode to audio output (such as AUX, AM, FM).
(b) Inspect whether each speaker functional.

Some speakers are soundless A
All speakers are soundless B
Refer to "The Circuit from Speakers to CD Unit".
207
Noises exist or Sound Quality is Poor

(a) Make sure there is no external electromagnetic

interference around and compare with other
vehicles of the same model to inspect whether
the sound effects are the same.
OK: The sound effects are the same.

OK Normal system
NG
2 Inspect Speakers
(a) Inspect whether the sound effect of each

speaker is normal.

Sound effects of some
A
speakers are abnormal
Sound effects of all speakers
B
are abnormal
Replace the speakers with abnormal sound

effects
(a) Temporarily replace the CD unit with a normal

one and inspect whether fault has been
cleared.
OK: Fault Cleared.
OK
208
Soundless Only in CD Mode

(b) Switch on the audio system and adjust it to the

CD mode to inspect whether it sounds.
(c) Adjust the mode to other modes with audio

output to inspect whether it sounds.

Soundless in CD mode but
A
normal in other modes
Soundless in both the CD
B
mode and other modes
Refer to "No Sounds from Speakers in All Mode"
209
Sound Quality is Poor (Sound Volume is Too Low) in All

Modes
(a) Switch on audio system and adjust the sound

effects.
OK: Sound effects return to normal.
OK System Normal
NG
2 Compare Sound Effects with a Vehicle of the Same Model

same model and configuration with normal
sound effects to inspect difference in sound
effects.
OK: Difference in sound effects is not big.

OK System Normal
NG
210
CD/DVD cannot be Inserted or Ejected

1 Inspect the CD/DVD
(a) Make sure the CD/DVD format is correct.
(b) Inspect whether the CD/DVD is deformed,

corroded or cracked.
OK: The CD/DVD is normal.

NG CD/DVD is damaged
OK
2 Replace the CD/DVD
(a) Replace with a normal CD/DVD to see whether

it can be inserted and ejected normally.
OK: The CD/DVD can be inserted and ejected
normally.
OK CD/DVD is damaged
NG
3 Inspect the Connectors Behind the CD Unit for any Looseness
(a) Disconnect and reconnect the connectors

behind CD unit once, and check whether fault
has been cleared.
OK: The CD/DVD can be ejected.

OK Connectors loose
NG
211
CD/DVD Playing Skips

1 Clean the CD/DVD
(a) Wipe it with a soft cotton cloth from inside to

outside in radial direction.
Note: Do not wipe the CD/DVD with hard cloth or

corrosive cleaner.
(b) Insert the disc again and inspect whether the

skips occur
OK: Skips do not occur.
OK
There is dirt on the surface of CD/DVD.
NG
2 Inspect the CD/DVD
(a) Inspect whether the CD/DVD is scratched or

leaks light.
OK: The CD/DVD has no scratches and light leaks.
OK
CD/DVD is damaged, replace with another one
NG
212
CD Display Screen is Black

(a) Power on and off repeatedly to inspect whether

image is displayed.
OK: The malfunctions disappear.
OK System Normal
NG
2 Inspect the Temperature and Humidity in the Driver's Compartment
(a) Inspect whether the humidity in the driver's

compartment is too high, or temperature
change is drastic, and, whether the
temperature is too high or low.
Note: High humidity may easily cause short

circuit of the LCD.
OK: Temperature and humidity are suitable.

NG
Adjust the humidity and temperature to an
appropriate level.
OK
3 Go to power circuit of CD unit
(a) Refer to "CD unit power source circuit".

OK
213
The Radio cannot Receive Any Signal (or Signal Reception is

very Poor)
Tips:
Inspect the signal reception capability of the radio at
a place far from high buildings. If the radio is far
from radio stations or near transmission lines of
high-voltage power in mountainous areas or of
buildings, the signal reception capability of the radio
is inevitably poor.
1 Inspect the Auto Search Function
(b) Switch the radio to AM and inspect whether the

search function is normal.
OK: The auto search function is normal.

NG
2 Inspect Whether There Is Interference from Other Equipment
(a) Inspect whether there are other interfering

devices at work, such as engine, wipers and
glass-frame risers.
OK: There are interfering electric devices at work.
OK
Influence from other electric devices
NG
3 Inspect the Radio (CD Unit)
(a) Unplug the radio feeder.

(b) With other connectors to CD unit connected,
switch power supply to the ACC position.
(c) Switch on the audio system and turn to the AM
mode.
(d) Insert a screwdriver or a wire into the antenna
socket of the radio to inspect whether there are
noises.
OK: There are noises.
NG
214
Replace the CD unit
OK
4 Inspect the Radio Antenna Amplifier
215
Power Circuit of CD Unit

Circuit Diagram
Audio-Video System
Dashboard
Wire
Harness
Adapter
CD Unit
1 Inspect the Fuses
(b) Use a multimeter to inspect whether the audio

system fuses F2/4, F2/20 are in continuity.
NG Replace the fuse
OK
216
2 Inspect the Distribution Box
(c) Wire the rear end of the dashboard distribution

box G2N connector.
(d) Measure the voltage of each terminal.
Standard Voltage
Specified
Condition
G2N-10- Body
Always 11 to 14 V
Ground
G2N-37- Body Power up to
11 to 14 V
Ground ACC position
NG
OK
(a) Disconnect the G2N connector of the

(b) Disconnect the G29 connector of CD unit.
(c) Measure the resistance between each terminal

Standard Resistance
Tester Specified
Condition
G2N-10-G29-4 Always Less than 1 Ω
G2N-37-G29-3 Always Less than 1 Ω
G29-7- Body
Ground
NG
Replace harness or connector
217
OK
4 The Circuit is Normal
218
BYD AUTO
Front Door
Speaker RH
Circuit Diagram
Front Door Dashboard

Speaker LH Distribution Box
Circuit from Speakers to CD Unit
CD Unit
Rear Door
Speaker LH
Rear Door
Speaker RH
219
1 Inspect Speakers
Tips:
The inspection methods for all the speakers are the
same (connector may be different). We take the
front door LH as an example.
(a) Remove the T07 connector of front door

speaker LH
Standard Resistance
Specified
Condition
1-2 Always About 4 Ω
NG
Replace Speakers
OK
2 Inspect Wire Harness or Connector
(a) Remove the speakers' T07, U07, V02, W01

connectors and the G29, G30 connectors of CD
unit.
Standard Resistance
Tester Specified
Condition
NG
220
OK
3 The Circuit is Normal
221
Circuit from Steering Switch to CD Unit

Circuit Diagram
Control
Switch of
Steering
Wheel
Audio
Clock
Spring
CD Unit
(a) Remove the multimedia machine G30

connector.

Standard Resistance
Tester Specified
Condition
Do not push
G30-4-G30-5 ∞
any button
Less than 1
G30-4-G30-5 Push VOL+
Ω
G30-4-G30-5 Push VOL- About 8.2
222
kΩ
About 23.2
G30-4-G30-5 Push CH+
kΩ
About 50.2
G30-4-G30-5 Push CH-
kΩ
About 132.2
G30-4-G30-5 Push MODE
kΩ

NG
2 Inspect the Clock Spring
(a) Remove the G25, X991 connector of clock

spring.

Standard Resistance
Specified
Condition
Less than 1
G25-7-X991-7 Always
Ω
Less than 1
G25-8-X991-8 Always
Ω
NG Replace the c
OK
(a) Remove the G25 connector of clock spring and

G30 connector of the multimedia machine.
Standard Resistance
Specified
Condition
Less
G25-4-G30-7 Always
than 1 Ω
223
Less
G25-5-G30-8 Always
than 1 Ω
NG Replace harne
OK
4 Replace the Steering Switch
224
USB & AUX Circuit

Circuit Diagram
CD Unit
(a) Switch to AUX mode.
(b) Wire the rear end of the CD unit G31 connector

and measure the voltage of each pin of CD unit.
Standard Voltage
Specified
Condition
G31-12-Body Less than 1
Always
Ground V
G31-6-Body Less than 1
Always
Ground V
G31-10-Body
Always About 5 V
Ground
225
NG Replace the
OK
2 Inspect Wire Harness or Connector
(a) Disconnect USB&AUX G43 connector and CD

unit G31 connector.

Standard Resistance
Tester Specified
Condition
G43-1-Vehicle
Body Ground
G43-6-Vehicle
Body Ground
NG
OK
3 Replace USB & AUX Interface
226
8 Removal and Installation of

the CD Unit
Removal
1. Remove the Combination Instrument

Head Cover
2. Remove the Dashboard Middle Cover

2. Install the Dashboard Middle Cover
3. Remove the CD Unit
3. Install the Combination Instrument Head
(a) Remove 2 set bolts. Cover
(b) Disconnect the connector behind CD unit.

(c) Take down the CD unit.
the Door Speakers
We take the front door LH as an example
Removal
2. Remove the Front Door Speaker LH
(b) Disconnect the connector and take down

the speaker.
Installation
1. Install the CD Unit
(a) Connect the CD unit connector.
(b) Set the CD unit into dashboard.
(c) Install 2 set bolts.
Installation
1. Install the Front Door Speaker LH
(a) Align the front door speaker LH with the

installation holes.
227
(b) Install 2 screws.
(c) Install the front door guard plate LH.
2. Install the Front Door Inner Shield LH

the Front High Pitch Speakers
We take the front high pitch speaker LH as an
example
Removal
the USB&AUX Interface
1 Remove the Front High Pitch Speaker LH
Removal
(e) Remove the front door guard plate LH.
(f) Disconnect the connector. 1. Remove the USB&AUX Interface
(g) Remove 2 screws with cross screwdriver. (a) Pry up the backside of USB&AUX
interface with a straight screwdriver.
(h) Take down the speaker.
(c) Take down the USB&AUX interface.
Installation
2. Install the Front High Pitch Speaker LH Installation
(a) Connect the connector. 1. Remove the USB&AUX Interface
228
(b) Snap the USB & AUX interfaces into the

secondary dashboard
Installation
1. Install the Antenna Amplifier
(a) Align the antenna amplifier with installation

hole.
(b) Install 1 set nut.
the Antenna Amplifier
Removal (c) Connect the connector.
1. Remove the C Pillar Guard Plate
2. Remove the Antenna Amplifier
(a) Remove 1 bolt with 10# socket wrench.
(c) Take down the antenna amplifier.
2. Install the C Pillar Guard Plate
229
Chapter 5 Multi-functional display

1 Parts Location .................................................................................................................... 231
2 System Diagram ................................................................................................................ 232
6 ECU terminals .................................................................................................................... 237
8 Removal ............................................................................................................................. 246
9 Installation .......................................................................................................................... 246
230
1 Parts Location
Multi-functional
display
231
2 System Diagram
Combination
Instrument
Multimedia
Machine
Multi-
functional
display
232
3 System Description
The vehicle is provided with a multi-functional
display which is arranged in the middle of the
dashboard protective plate, not blocking the driver's
view. The driver can acquire basic information of the
current vehicle from the display, and take
corresponding measures.
The multi-functional display mainly includes:
 Time display
 Exterior temperature display (CD host)
 Interior temperature display (DVD host)
 Reversing radar display
 Front-row seats safety belt indicator
233
Tips:
 Follow procedures below to troubleshoot the
multi-functional display.
 Using the intelligent detecter.

Next
2 Customer Problem Analysis and Symptom Check
Next
Standard voltage:
11 to 14 V
Next

(a) Using the intelligent detecter to check for
system.
Result
Result Proceed to
B
5 Inspect DTC*
Result
Result Proceed to
No DTC is output A
DTC is output B
234
B Go to step 8
Result
Result Proceed to
B Go to step 8
(a) Data List / Active Test

(b) ECU terminals
Next
Next
9 Confirmation test
Next
Completed
235

Tips:
malfunctions. The potential causes of the faults are
Multi-functional display:
Symptom Suspected Area Reference page
Multi-functional display Power supply of the multi-functional display -

doesn't work. Multi-functional display -
236
6 ECU terminals
1. Check multi-functional display pins
(a) Measure voltage and resistance according

to values in the table below.
Standard Voltage
(Symbol) Condition
He03-1-body W/G-body Battery power
Always 11 to 14 V
ground ground supply
He03-3-body P-body
B-CAN-H Always 2.5 to 3.5 V
ground ground
He03-4-body V-body
B-CAN-L Always 1.5 to 2.5 V
ground ground
He03-9-body Y-body Switch to gear
Gear ON 11 to 14 V
ground ground ON
He03-11-body Y/R-body Switch to gear
Gear ACC 11 to 14 V
ground ground ACC
Standard Resistance
He03-2-body Less than 1
B-body ground Group Always
ground Ω
He03-8-body Less than 1
B-body ground Group Always
ground Ω

(b) Re-connect the connector He03.
(c) Measure voltage according to values in the
table below.
Standard Voltage
237
Less than 1
He03-16-body Passenger safety Indicator OFF
R/L V
ground belt indicator
Indicator ON 11 to 14 V

be something wrong with BCM.
238

DTC code Detection Item Trouble Area Reference page
B1990-00 Clock malfunction 1. Multi-functional display
U0164-00 Out of touch with the air 1. Multi-functional display
conditioning system 2. Air Conditioning System
U0245-00 Out of touch with 1. Multi-functional display
multimedia 2. Multimedia System
U0155-00 Out of touch with 1. Multi-functional display
combination meter 2. Combination Instrument
239
DTC B1900-00 Clock malfunction
1 Replace multi-functional display
Next
Completed
240
DTC U0164-00/U0245-00/U0155-00 Communication malfunction
Circuit Diagram:
Multi-functional display
Connect with 1#CAS

adapter
1 Inspect CAN line
(a) Disconnect the multi-functional display He03

connector.
(b) Check the voltage of the wire harness terminal.
Standard Voltage
Specified
Condition
He03-3 -body 2.5 to 3.5 V
Always
ground
He03-4-body 1.5 to 2.5 V
Always
ground
NG
241
OK
2 Jump to the corresponding system to check communication failure
Next
Completed
242
Power supply of the multi-functional display

Circuit Diagram
Audio system
Auxiliary Power
Supply Adapter
Audio system
Multi-functional display
243
1 Inspect fuse
(a) Check whether the fuse has continuity with a

multimeter (TI*F4/12,473*F2/4).
OK: The fuse has continuity
NG Replace fuse
OK
(a) Lead wire behind the dashboard distribution box

connectors G2N-10 and G2N-37.
(b) Check the voltage of terminal.
Standard Voltage
Specified
Condition
G2N-10 -body ground Always 11 to 14 V
G2N-37- body ground Gear ACC 11 to 14 V
NG
OK
(a) Disconnect the G2N connector for the

(b) Disconnect the multi-functional display He03

connector.
(c) Measure the resistance or voltage between the

terminals of the wire harness side connector.
Standard Voltage
244
Specified
Condition
G2N-10-He03-1 Always 11 to 14 V
G2N-37-He03-11 Gear ACC 11 to 14 V
Standard Resistance
Specified
Condition
He03-8-body Less than 1 Ω
Always
ground
He03-2-body Less than 1 Ω
Always
ground
NG
OK
Completed
245
8 Removal
1. Disassemble the body on the dashboard

and disconnect the multi-functional
display connector
2. Disassemble the multi-functional display
(a) Remove the two screws between the

multi-functional display and the middle
cover.
(b) Remove the multi-functional display
9 Installation
1 Install the multi-functional display
(a) Fix the multi-functional display on the

middle cover and install two screws.
2. Connect the connector and install the

upper body of the dashboard
246
Chapter 6 Power seat control system

2 System Diagram ................................................................................................................ 249
6 Seat electrical adjustment fails. ......................................................................................... 252
7 Driver seat adjustment fails ............................................................................................... 254
8 Driver seat horizontal adjustment fails .............................................................................. 256
9 Driver seat pan adjustment fails ........................................................................................ 260
10 Seat back adjustment fails ............................................................................................... 264
11 Driver seat height adjustment fails .................................................................................. 268
247
Seat back
adjustment
motor
Seat height
adjustment motor
Seat horizontal
adjustment motor
Seat pan
adjustment motor
Adjusting switch of
motor-driven seat
248
2 System Diagram
Seat horizontal
adjustment motor
Adjusting switch of
motor-driven seat
Seat pan
adjustment motor
Seat back
adjustment motor
Seat height
adjustment motor
249
3 Diagnosis process
Next

Standard voltage value:
11 ~ 14 V
If the voltage is lower than 22 V, please recharge
or replace the storage battery before the next step.
Next
Result Proceed
Symptom is not listed in A
problem symptoms table
Symptom is listed in B
problem symptoms table
B Go to Step 5
4 Overall Diagnosis
Next
Next
6 Confirmation test
Next
7 Completed
250

Problem Symptom Possible Location of Malfunction
Seat electrical adjustment 1. Fuse (F1/20)
fails. 2. Wire harness
1. Fuse
Driver seat adjustment fails
2. Wire harness
1. Seat horizontal adjustment motor
Driver seat horizontal 2. Adjusting switch of motor-driven seat
adjustment fails
3. Wire harness
1. Seat pan adjustment motor
Driver seat pan adjustment
2. Adjusting switch of motor-driven seat
fails
3. Wire harness
1. Seat back adjustment motor
Seat back adjustment fails 2. Adjusting switch of motor-driven seat
3. Wire harness
1. Seat height adjustment motor
Driver seat height
2. Adjusting switch of motor-driven seat
adjustment fails
3. Wire harness
251

6 Seat electrical adjustment fails.
Circuit Diagram:
Battery
Power seat
Adjusting switch of motor-driven seat
Inspection Procedures:
1 Inspect fuse
(a) Check whether the power seat F1/20 fuse
has continuity with a multimeter
OK: The fuse has continuity
NG Replace fuse
OK
(a) Disconnect B2B connector.

(b) Inspect the voltage of the wiring side.
252
Wire Normal
Terminal Condition
Color Condition
B2B-3-body
L Always 11-14 V
ground
NG
Change the wire harness (front compartment -

dashboard distributor box)
OK
3 Completed
253
7 Driver seat adjustment fails
Circuit Diagram:
Power seat
Driver power seat

adjustment switch
1 Inspect fuse
(a) Check whether the power seat F2/8 and
F2/10 fuses have continuity with a multimeter
OK: The fuses have continuity
NG Replace fuse
OK
254

(a) Disconnect the driver power seat adjustment
switch connector
(b) Measure the wire harness side voltage or

resistance
Wire Normal
Terminal Condition
Color Condition
Driver power
seat
adjustment
W/R Always 11-14 V
switch
4-pin-body
ground
Driver seat
waist
adjustment
R Always 11-14 V
switch
10-pin-body
ground
Driver power
seat
adjustment Less than
B Always
switch 1Ω
2-pin-body
ground
Driver power
seat
adjustment Less than
B/W Always
switch 1Ω
8-pin-body
ground
NG
Replace the corresponding wiring harness
OK
3 Completed
255
8 Driver seat horizontal adjustment fails

Circuit Diagram:
Power seat
Driver
power
seat
adjustme
nt switch Forward Backward
Seat horizontal adjustment motor
1 Output voltage of driver power seat adjustment switch
(a) Lead wire from the back and measure the
256
output voltage of the driver seat

adjustment switch
Normal
Terminal Condition
Condition
Driver power Horizontal
seat adjustment backward
switch 7-pin- adjustment or
± (11-14) V
Driver power horizontal
seat adjustment forward
switch 11-pin adjustment
OK Go to step 4
NG
2 Check the driver power seat adjustment switch

(a) Disconnect the driver seat adjustment switch
connector
(b) Check continuity between terminals.
The following terminals refer to the terminals of the

driver seat adjustment switch. The seat is adjusted
horizontally.
Normal
Terminal Condition
Condition
Backward
10-11 horizontal Less than 1 Ω
adjustment
Backward
adjustment
Forward horizontal
10-7 Less than 1 Ω
adjustment
Forward horizontal
11-8 Less than 1 Ω
adjustment
Seat pan adjustment
Normal
Terminal Condition
Condition
10-3 Upward adjustment Less than 1 Ω
Downward
10-9 Less than 1 Ω
adjustment
Downward
3-8 Less than 1 Ω
adjustment
Seat back adjustment
Normal
Terminal Condition
Condition
Tilt forward
4-6 Less than 1 Ω
adjustment
257
Tilt forward
12-2 Less than 1 Ω
adjustment
Tilt backward
4-12 Less than 1 Ω
adjustment
Tilt backward
6-2 Less than 1 Ω
adjustment
Seat height adjustment
Normal
Terminal Condition
Condition
Downward
4-5 Less than 1 Ω
adjustment
Downward
1-2 Less than 1 Ω
adjustment
NG
Change the driver power seat adjustment

switch
OK

(a) Disconnect the seat horizontal adjustment
motor connector
Normal
Terminal Condition
Condition
Horizontal
backward
1-2 adjustment or ± (11-14) V
horizontal forward
adjustment
NG
Replace wire harness (switch-motor)
OK
4 Check seat horizontal adjustment motor

(a) Disconnect the seat horizontal adjustment
motor connector.
(b) Provide the motor with a battery to check the

motor's performance.
258

2-battery(+) Driver seat horizontal
1-battery(-) backward adjustment
1-battery(+) Driver seat horizontal
2-battery (-) forward adjustment
OK NG
Change seat horizontal adjustment motor
5 Completed
259
9 Driver seat pan adjustment fails

Circuit Diagram:
Power seat
Driver power
seat
adjustment Upward Downward
switch
Seat pan adjustment motor
output voltage of the driver seat adjustment
switch
260
Normal
Terminal Condition
Condition
Driver power Horizontal
seat adjustment upward
± (11-14) V
Driver power horizontal
seat adjustment downward
switch 9-pin adjustment
OK Go to step 4
NG

connector

horizontally.
Normal
Terminal Condition
Condition
Backward horizontal
10-11 Less than 1 Ω
adjustment
Backward horizontal
7-8 Less than 1 Ω
adjustment
Forward horizontal
10-7 Less than 1 Ω
adjustment
Forward horizontal
11-8 Less than 1 Ω
adjustment
Seat pan adjustment
Normal
Terminal Condition
Condition
Downward
10-9 Less than 1 Ω
adjustment
Downward
3-8 Less than 1 Ω
adjustment

Normal
Terminal Condition
Condition
Tilt forward
4-6 Less than 1 Ω
adjustment
Tilt forward
12-2 Less than 1 Ω
adjustment
261
Tilt backward
4-12 Less than 1 Ω
adjustment
Tilt backward
6-2 Less than 1 Ω
adjustment
Normal
Terminal Condition
Condition
Downward
4-5 Less than 1 Ω
adjustment
Downward
1-2 Less than 1 Ω
adjustment
NG

switch
OK

(a) Disconnect the seat pan adjustment motor
connector.
Normal
Terminal Condition
Condition
Upward adjustment or
1-2 ± (11-14) V
backward adjustment
NG
OK Replace wire harness (switch-motor)
4 Check seat pan adjustment motor

(a) Disconnect the seat pan adjustment motor
connector.

1-battery(+) Driver seat pan
2-battery(-) upward adjustment
2-battery(+) Driver seat pan
1-battery(-) downward adjustment
262
NG
Change seat pan adjustment motor
OK
5 Completed
263
10 Seat back adjustment fails

Circuit Diagram:
Power seat
Driver
power seat
adjustment
switch
Tilt Tilt
forward backward
Seat pan adjustment

motor
264
switch
Normal
Terminal Condition
Condition
Driver power
seat adjustment Tilt backward
± (11-14) V
Driver power tilt forward
seat adjustment adjustment
switch 2-pin
OK Go to step 4
NG

connector

horizontally.
Normal
Terminal Condition
Condition
Backward
Less than 1
10-11 horizontal
Ω
adjustment
Backward
Less than 1
7-8 horizontal
Ω
adjustment
Forward horizontal Less than 1
10-7
adjustment Ω
Forward horizontal Less than 1
11-8
adjustment Ω
Seat pan adjustment
Normal
Terminal Condition
Condition
Less than 1
10-3 Upward adjustment
Ω
9-8 Upward adjustment Less than 1
265
Ω
Downward Less than 1
10-9
adjustment Ω
3-8
adjustment Ω
Normal
Terminal Condition
Condition
Tilt forward Less than 1
4-6
adjustment Ω
Tilt forward Less than 1
12-2
adjustment Ω
Tilt backward Less than 1
4-12
adjustment Ω
Tilt backward Less than 1
6-2
adjustment Ω
Normal
Terminal Condition
Condition
Less than 1
Ω
Less than 1
Ω
4-5
adjustment Ω
1-2
adjustment Ω
NG

switch
OK

(a) Disconnect the seat back adjustment motor
connector.
Normal
Terminal Condition
Condition
Tilt forward
adjustment or tilt
1-2 ± (11-14) V
backward
adjustment
OK
266
NG
Replace wire harness (switch-motor)
4 Check seat back adjustment motor

(a) Disconnect the seat back adjustment motor
connector.

2-battery(+) Driver seat back tilt
1-battery(-) forward adjustment
1-battery(+) Driver seat back tilt
2-battery(-) backward adjustment
NG
Check seat back adjustment motor
OK
5 Completed
267
11 Driver seat height adjustment fails

Circuit Diagram:
Power seat
Driver power
seat
adjustment
switch
Down Upward
ward
Seat height adjustment motor
268
switch
Normal
Terminal Condition
Condition
Driver power
Upward
seat adjustment
adjustment
switch 4-pin-
or ± (11-14) V
Driver power
downward
seat adjustment
adjustment
switch 2-pin
OK Go to step 4
NG

connector

horizontally.
Normal
Terminal Condition
Condition
Backward
adjustment
Backward
adjustment
Forward horizontal
10-7 Less than 1 Ω
adjustment
Forward horizontal
11-8 Less than 1 Ω
adjustment
Seat pan adjustment
Normal
Terminal Condition
Condition
10-9 Downward Less than 1 Ω
269
adjustment
Downward
3-8 Less than 1 Ω
adjustment
Normal
Terminal Condition
Condition
Tilt forward
4-6 Less than 1 Ω
adjustment
Tilt forward
12-2 Less than 1 Ω
adjustment
Tilt backward
4-12 Less than 1 Ω
adjustment
Tilt backward
6-2 Less than 1 Ω
adjustment

Normal
Terminal Condition
Condition
Downward
4-5 Less than 1 Ω
adjustment
Downward
1-2 Less than 1 Ω
adjustment
NG

switch
OK

(a) Disconnect the seat height adjustment motor
connector.
Normal
Terminal Condition
Condition
Upward Upward
adjustment or adjustment or
± (11-14) V
downward downward
adjustment adjustment
NG
OK Replace wire harness (switch-motor)
270
4 Check seat height adjustment motor

(a) Disconnect the seat height adjustment motor
connector.


Driver seat
1-battery(+)
downward
2-battery(-)
adjustment
2-battery(+) Driver seat upward
1-battery(-) adjustment
NG
Check seat height adjustment motor
OK
5 Completed
271
Chapter 7 Power Window

2 System Diagram ................................................................................................................ 275
3 System overview ................................................................................................................ 276
7 Overall Diagnosis Flow ...................................................................................................... 282
8 Front-left window lifter switch block power distribution ..................................................... 282
272
Rear-right door window lifter assembly

Rear-right door window lifter motor
Front-right door window lifter assembly

Front-right door window lifter motor
Rear-left door window lifter assembly

Rear-left door window lifter motor
Front-left door window lifter assembly

Front-left door window lifter motor
273
Rear-right door window lifter switch and

trim panel assembly
- Rear-right door window lifter switch
Front-right door window lifter switch block

and trim panel assembly
- Front-right door window lifter switch
Rear-left door window lifter switch and trim

panel assembly
- Rear-left door window lifter switch
Front-left door window lifter switch block and

trim panel assembly
- Front-left door window lifter switch
- Front-left door window control main switch
274
2 System Diagram
Power window
Dashboard
distributor
relay
box
Front- right window Front-right window

lifter switch lifter motor
Front-left
window
lifter Rear-right window Rear-right window
switch lifter switch lifter motor
block
Rear-left window Rear-left window

lifter switch lifter motor
Front-left window
lifter motor
275
3 System overview
In the power window system, windows can be The power window motor adopts the latest
regulated through the switch on the door trim processes, technologies and materials, such
panel. On the driver's seat, windows are as water sealing design. Gas-permeable
regulated through the main switch on the membranes are adopted (After temperature
front-left door window lifter switch trim panel. rises during motor running, there may be a
The locking switch of the power window is on pressure gap inside and outside the motor,
the front door trim panel on the driver's side. It which breaks the seal at the weakest point. At
enables the driver to disable all passenger this time, the motor needs a respiratory unit to
window switches. The power window system balance the pressure gap so that there is no
works only when the start button is at ON. By impact to the weakest point. The
using of automatic window lowering (AUTO), gas-permeable membrane just plays this role.
the window on the driver's side can be lowered It can balance the pressure gap via gas and
to the bottom. During operation, press the block the fluid outside the motor, so that the
switch of the window on the driver's side in motor can meet requirements of water
lowering direction towards another position. sealing.); Polymer PTC over-current protector
Then automatic lowering is started. Press the is adopted for overheat protection of the motor,
switch again in any direction to stop the which can protect the motor from being burnt
window and cancel automatic lowering. Some more quickly and effectively due to external
functions and features of the power window faults (such as switch fault); Special design is
system rely on electronic module control. adopted for the motor rotating shaft to reduce
These electronic modules are integrated in the noise. Wear-resistant and shock-damping
front-left door window lifter switch block. materials are adopted to ensure that there is
no noise of metal impact or friction when the
Power window system consists of the following motor is running at a high speed; In terms of
components: motor power wire connection, terminal
 Window lifter switch interface is adopted to replace the power lead
 Window lifter motor wire, thus avoiding faults caused by lead wires,
such as poor contact; DC bipolar PM structure
Power window delay: Close the front door. is adopted, dual-way turning. An overheat
Within 10 minutes after vehicle power is protector is arranged inside so there is no
switched from ON to OFF, the window control need of protection in outer circuit. After
switch can still work. Light on the switch electrifying the motor, it will rotate under the
backlight to regulate the door window: Once magnetic field force. Then low-speed big
any front door is opened, delay will be torque got on the output gear through a big
disabled. worm gearbox. When the motor is stuck or the
circuit fails, the overheat protector can cut off
Remote controlled window raising/lowering the power supply in time to protect the motor.
function:
(1) At OFF gear, press and hold the unlocking

button on the remote controlling key and the
four windows will be lowered automatically.
Release the button and the window will stop
lowering.
(2) At OFF gear, press and hold the locking

button on the remote controlling key and the
four windows will be raised automatically.
Release the button and the window will stop
rising.
276
4 Diagnosis process

the fault occurs.
Next
Standard voltage:
11 to 14 V
Next
Result Proceed to
The fault is not recorded in the A
fault symptom table
The fault is recorded in the fault B
symptom table
B Go to Step 5
(d) Overall functional inspection

(e) ECU terminal inspection (see ECU terminal
inspection)
(f) Check with diagnostic tester
Next
(b) Adjust, repair or replace lines or parts
277
Next
6 Confirmation test
(a) After adjustment, repair or changing lines or

parts, make sure there is no failure. If failure
doesn't occur again, simulate conditions and
environment when the failure occurs for the first
time and do the test again.
Next
7 Completed
278
5 Problem Symptoms Table

The whole window control system doesn't Front-left window lifter switch block power
work. distribution
Window lifter motor power circuit
Only the front-left window lifter can work. Front-left window lifter switch block
Other lifters cannot. Wire harness
The front-left window switch cannot control the 1. Fuse
front-left window. 2. Front-left window motor
3. Front-left window switch
4. Wire harness
The front-right window switch cannot control 1. Fuse
the front-right window. 2. Front-right window motor
3. Front-right window switch
4. Wire harness
The rear-left window switch cannot control the 1. Fuse
rear-left window. 2. Rear-left window motor
3. Rear-left window switch
4. Wire harness
The rear-right window switch cannot control 1. Fuse
the rear-right window. 2. Rear-right window motor
3. Rear-right window switch
4. Wire harness
The front-left window switch block cannot 1. Front-left window switch
control the front-right window, but the 2. Wire harness
front-right window switch can control the
front-right window.
control the rear-left window, but the rear-left 2. Wire harness
window switch can control the rear-left
window.
control the rear-right window, but the rear-right 2. Wire harness
window switch can control the rear-right
window.
Only the front-left window lifter can work. Front-left window lifter switch block
Other lifters cannot. Wire harness
279
1. Inspect front window switch LH
(a) Remove the front-left window switch T03
connector.
between the terminals of the wire harness
side connector.
OK:
Terminal No. Wire Terminal Description Condition Normal
Color Value
T03-1-Body ground G/R Front-left window motor Always 11 ~ 14 V
power supply (battery)
T03-14Body Y Power ON Switch power supply 11~14 V
ground to the ON position.
T03-19-Body W/R Battery Always 11 ~ 14 V
ground
T03-8-Body ground W/G Power window relay Always 11 ~ 14 V
T03-9-Body ground B Ground Always Less than
1V
T03-10-Body W/B Ground Always Less than
ground 1V
Tips:
If the test results are not consistent with the normal
value, it's likely that there is something wrong with
the corresponding wire harness.
(c) Connect the connector T03 and measure

the panel end terminal voltage from the
lead wire at the rear end.
OK:
Terminal No. Wire Terminal Description Condition Normal
Color Value
T03-11-Body R/B Front-left window raising Switch the power 11~14 V
ground power supply supply to ON position
and pull the front-left
door switch upward.
280
T03-23-Body R/Y Front-left window Switch the power 11~14 V

ground lowering power supply supply to ON position
and press the front-left
door switch
downward.
T03-2-Body ground L/W Front-right window -- --
lowering power supply
T03-16-Body L/R Front-right window raising -- --
ground power supply
T03-15-Body Br Rear-left window lowering -- --
ground power supply
T03-21-Body Br/W Rear-left window raising -- --

ground power supply
T03-20-Body Br/Y Rear-right window -- --
ground lowering power supply
T03-22-Body L/O Rear-right window raising -- --
ground power supply
T03-17-Body V CAN_ L Always 1.5 V~2.5
ground V
T03-18-Body P CAN _H Always 2.5 V~3.5
ground V
T03-4-Body ground W Front-rear door unlock Front-rear door Less than
signal unlocked 1V
Tips:
If the test results are not consistent with the normal

value, it's likely that there is something wrong with
the switch.
281
7 Overall Diagnosis Flow

8 Front-left window lifter switch block power distribution
Description:
The window control system power supply is drawn out from the dashboard distributor box.
Circuit Diagram
Battery
Window Control
System
Switch 2nd gear

Power Supply MICU Power Supply
7.5A Front-left
Power
window
window
motor
relay
Front-left window lifter switch block
282
1 Inspect power supply
(a) Disconnect connector T03, and measure the

wire harness side voltage.
Terminal Wire Condition Normal
Color Condition
T03-14-Bod Y Power ON 11-14 V
y ground
T03-19-Bod W/R Battery 11-14 V
y ground
T03-9-Body B Always Less than
ground 1V
T03-10-Bod W/B Always Less than
y ground 1V
NG
Change the distribution box or the wire harness
OK
2 Front-left window lifter power supply is ok.
283
Window lifter motor power circuit
Circuit Diagram
Battery
Window Control
System
Front-left Power
window motor window
relay
Rear-right Front-right Rear-left
window window window
motor motor motor
1 Inspect fuse
(a) Check the fuse. Measure the resistance of the

fuse with a multimeter at both ends of the fuse.
Terminal Result
F1/23-1 both ends Less than 1 Ω
F2/16both ends Less than 1 Ω
284
NG Replace fuse
OK
2 Check the front-left window lifter motor power supply
(a) Disconnect the front-left electrical door/window

control switch T03 connector.

Color Condition
T03-1-Body G/R Battery 11-14 V
ground
OK
285
3 Check the output voltage signal of the relay
(a) Measure the output voltage of the distribution

box.
Color Conditi
on
K2H-10-Body -- Power ON, 11-14 V
ground window lock
switch on
K2E-12-Body -- Power ON, 11-14 V
ground window lock
switch on
G2N-41-Body -- Power ON, 11-14 V
ground window lock
switch on
OK Power supply circuit is OK
NG
4 Inspect relay
(a) Remove the electrical window relay from the

(b) Apply voltage on the control end and check

whether the relay is pickup.
Terminal Result
1 - Battery positive Continuity in 3 and 5
2 - Battery negative
286
NG Replace relay
OK
5 Check the relay control module
(a) Measure the panel end output by leading wire

from the rear end

Color Condition
T03-8- W/G Power ON, Less than 1
Body window lock V
ground switch open
NG
Change the front-left window lifter switch block
OK
(a) Disconnect connector T03, and measure the

wire harness voltage.

Color Condition
T03-8-T2J-2 W/G Always Less than
1Ω
OK
7 Circuit is ok.
287
Only the front-left window lifter can work. Other lifters cannot.
Circuit Diagram
Battery
Window Control
System
Motor
Window
Relay
Front-right Rear-left Rear-right
motor motor motor
1 Check front-left window lifter switch block
(a) Measure T03-8 terminal voltage by leading

wire from the rear end.

Color Condition
T03-8- W/G Power ON Less than
Body Window 1V
ground control lock
switch
bounced up.
NG
Change the front-left window lifter switch block
288
OK

control switch T03 connector and disconnect
the connector T2J.
(b) Measure the resistance of the wire harness.

Color Condition
T03-8-T2J-2 W/G Always Less than
Ω
OK
3 Check the power window relay
(a) Remove the electrical window relay from the

(b) Apply voltage on the control end and check
whether the relay is pickup.
Terminal Result
1 - Battery positive Continuity in 3 and 5
NG Replace the power window relay
OK
4 End
289
The front-left window switch cannot control the front-left

window.
Description:
When the engine is working or the start button is at ON position, the front-left window lifter switch
block (front-left window switch) can control the front-left, front-right, rear-left and rear-right
windows. The front-left window has four gears: ① Stop; ② Up I; ③ Down I; ④ Down II (AUTO).
Circuit Diagram:
Battery
Window control Front-left

system window
motor
Front-left
window
lifter motor
Front-left window switch
1 Inspect fuse
(a) Measure the resistance of the fuse with a

multimeter at both ends of the fuse F2/16
Terminal Result
NG Replace fuse
OK
290
2 Check the front-left window lifter motor power voltage

control switch T03 connector.

Color Condition
T03-1-Body G/R Always 11-14 V
ground
NG
Replace wire harness (distribution box -

front-left switch)
OK
3 Check the front-left window lifter motor
(a) Remove the front-left door/window motor T06

connector.
(b) Apply voltage to both ends of the motor with a
battery, and inspect the operation of the motor.
Terminal Result
Battery positive-T06-2
Battery Window goes up
negative-T06-1
Battery positive-T06-1
Battery Window goes down
negative-T06-2
NG Change a motor
OK
291
4 Check front-left window lifter control switch
(a) Lead wire from the rear end of the front-left

control switch and measure the output voltage
of the panel end
Terminal Test condition Normal

Value
T03-11-T03-23 Power ON 11-14 V
Switch bounced up
T03-23-T03-11 Power ON 11-14 V
Switch pressed
NG
Change front-left window lifter control switch
OK
(a) Remove the front-left window switch T03

connector.
(b) Remove the front-left window motor T06
connector.
Color Condition
T03-11-T06-2 R/B Always Less than
1Ω
T03-23- R/Y Always Less than
T06-1 1Ω
NG
OK
6 End
292
The front-right window switch cannot control the front-right

window.
Description:
When the engine is working or the start button is at ON position, and the window lock switch is
bounced up, the front-right window switch can control the front-right window. The front-right
window switch has three gears:  Stop;  Up;  Down.
Circuit Diagram:
Battery
Window Control Power

System Window
Relay
motor motor motor
Front-left window lifter switch

block
Front-right window switch
Front-right
window lifter
motor
293
1 Check front-right window lifter control switch power supply
(a) Disconnect front-right control switch U01

terminal.
(b) Switch the power supply to ON position and
check the voltage of the wire harness terminal.
Color Conditio
n
U01-9-Body G/B Power ON, 11-14 V
ground window lock
switch open
U01-6-Body B Always Less
ground than 1 V
OK Go to step 4
NG
2 Check the output power supply of the relay
(a) Open the dashboard distribution box to

measure the output voltage of the relay.
Color Condition
G2N-41- -- Power ON, 11-14 V
Body window lock
ground switch open
NG
Jump to "Window lifter motor power circuit"
OK
294
3 Check the wire harness (distribution box - front-right window lifter switch)
(a) Disconnect front-right control switch U01

terminal and measure the resistance of the wire
harness
Color Condition
U01-9-G2N-41 G/B Always 11-14 V
OK
4 Check front-right window lifter switch
(a) Change a new front-right window lifter switch.

(b) Operate the switch to check whether the
front-right window lifter works normally.
NG:
It works normally.
NG
Replace front-right window lifter switch
OK
295
5 Check the front-right door motor
(a) Remove the front-right door/window motor U06

connector.
Battery positive-U06-2 Window goes up
Battery negative-U06-1
Battery positive-U06-1 Window goes
Battery negative-U06-2 down
NG
Replace the front-right door motor
OK
6 Check the wire harness (front-right window lifter switch - front-right door motor)
(a) Disconnect connectors U06 and U01.

Color Value
U01-7-U06-1 R/L Always Less than
1Ω
U06-2- U01-5 R Always Less than
1Ω
OK
7 End
296
The rear-right window switch cannot control the rear-right

window.
Description:
bounced up, the rear-right window switch can control the rear-right window. The rear-right window
switch has three gears:  Stop;  Up;  Down.
Circuit Diagram:
Battery
Window Control
System Power
Window
Relay
motor motor motor
Rear-right window
switch
Rear-right
window lifter
motor
297
1 Check rear-right window lifter control switch power supply
(a) Disconnect the rear-right control switch terminal

W03.
Color Conditio
n
W03-4-Body Y/L Power ON, 11-14 V
ground window lock
switch open
W03-5-Body B Always Less
ground than 1 V
OK Go to step 4
NG

Color Condition
K2H-10-Body -- Power 11-14 V
ground ON,
window
lock
switch
open
NG
OK
3 Check the wire harness (distribution box - rear-right window lifter switch)
(a) Disconnect the rear-right control switch terminal

W03 and measure the resistance of the wire
harness.
298

Color Condition
W03-4- K2H-10 Y/L Always 11-14 V
OK
4 Check the rear-right window lifter switch of the wire harness
(a) Change a new rear-right window lifter switch.

(b) Operate the switch to see whether the rear-right
window lifter works normally.
NG:
It works normally.
NG
Replace rear-right window lifter switch
OK
5 Check the rear-right window motor
(a) Remove the rear-right window motor connector

W04.

Battery positive-W04-1 Window goes up
Battery negative-W04-2
Battery positive-W04-2 Window goes down
Battery negative-W04-1
NG Replace rear-right door motor
299
OK
Check the wire harness (rear-right window lifter switch - rear-right door/window
6
motor)
(a) Disconnect connectors W03 and W04.

Color Value
W03-3-W04-2 L/B Always Less than
1Ω
W03-6- W04-1 R/W Always Less than
1Ω
OK
7 End
300
The rear-left window switch cannot control the rear-left

window.
Description:
bounced up, the rear-left window switch can control the rear-left window. The rear-left window
switch has three gears:  Stop;  Up;  Down.
Circuit Diagram:
Battery
Window Control
Power
System
Window
Relay
motor motor motor
Rear-left window switch
Rear-left
window lifter
motor
301
1 Check rear-left window lifter control switch power supply
(a) Disconnect the rear-left control switch terminal

V03.
Color Condition
V03-4- Y/L Power ON, 11-14 V
Body window lock
ground switch open
V03-5- B Always Less than
Body 1V
ground
OK Go to step 4
NG

Color Condition
K2E-12- -- Power ON, 11-14 V
Body window lock
ground switch open
NG
OK
302
3 Check the wire harness (distribution box - rear-left window lifter switch)
(a) Disconnect the rear-left control switch terminal

V03 and measure the resistance of the wire
harness.
Color Condition
V03-4- Y/L Always 11-14 V
K2E-12
OK
4 Check the rear-left window lifter switch of the wire harness
(a) Change a new rear-left window lifter switch.

(b) Operate the switch to see whether the rear-left
window lifter works normally.
NG:
It works normally.
NG
Replace rear-left window lifter switch
OK
5 Check the rear-left door/window motor
(a) Remove the rear-left door/window motor

connector V03.

Battery positive-V03-6 Window goes up
Battery negative-V03-3
Battery positive-V03-3 Window goes
Battery negative-V03-6 down
303
NG Replace rear-left door motor
OK
6 Check the wire harness (rear-left window lifter switch - rear-left door/window motor)
(a) Disconnect connector V03.

Wire Normal
Terminal Condition
Color Value
Less than
V03-3-V04-2 L/B Always
1Ω
Less than
V03-6- V04-1 R/W Always
1Ω
OK
7 End
304
The front-left window switch cannot control the front-right,

rear-left and rear-right windows.
Description:
bounced up, the front-left window switch can control the front-right, rear-left and the rear-right
windows. The button on the front-left window switch that controls the front-right, rear-left and
rear-right windows has three gears:  Stop;  Up;  Down.
Circuit Diagram:
Power window relay
Front-left window lifter switch

block
Front-right
window motor
Front-right
window switch
Front-right
window lifter
motor
305
Power window
relay
Front-left window lifter

switch block
Rear-left
window motor
Rear-left
window switch
Rear-left
window lifter
motor
306
Power window
relay
Front-left window lifter

switch block
Rear-left
window motor
Rear-right window switch
Rear-right
window
lifter motor
307
(a) Check the control function of the front-right,

rear-left and rear-right window switches on
corresponding windows.
A: None of them works well.
B: Some don't work well.
C: All of them can work well.
A
Check the power supply of the window control
system.
B
Jump to the corresponding window lifter circuit
for inspection
OK
(a) Disconnect connectors and measure the

resistance of harness.
Front-right

Color Value
T03-2-U01-2 L/W Always Less than
1Ω
T03-16-U01-1 L/R Always Less than
1Ω
Rear-right

Color Value
T03-20-W03-1 Br/Y Always Less than
1Ω
T03-22-W03-2 L/O Always Less than
1Ω
Rear-left
308

Color Value
T03-15-V03-1 Br Always Less than
1Ω
T03-21-V03-2 Br/W Always Less than
1Ω
OK
3 Change the front-left window lifter switch block
309
Window lock switch doesn't work.
Description:
When the engine is working or the start
button is switched to ON position, and when
the window lock switch is bounced up, the
front-right, the rear-right and the rear-left
window switches can control the
corresponding lifters independently. The
front-left switch can also control the
front-right, rear-right and the rear-left window
lifters. When the window lock switch is
pressed, the front-right, rear-right and
rear-left window switches don't work, and the
front-left switch cannot control the front-right,
rear-left and rear-right window lifters.
1 Change the front-left window lifter switch block
Preparation of Tools
Gloves A pair
Wrench Size-10 socket wrench and ratchet wrench
Straight screwdriver One piece
Crosshead Screwdriver One piece
310

Assembly & disassembly of
window lifter
Disassembly
2. Remove front-left door window lifter switch
4. Disconnect the window lifter connector.
5. Remove the rear-left door window
a Switch on the rear-left window lifter and
adjust the height of the window. You can
see the window mounting point from the
two holes in the diagram. (a) Take out the window lifter assembly.
Assembly
b Remove 2 set nuts with the Size-10 socket 1. Install window lifter assembly.
wrench. (a) Put the window lifter assembly into the
door plate, aligned with the mounting
hole.
(b) Install seven set bolts.
a Remove the front-left window guide rail.

b Remove the window.
6. Remove front-left window lifter.
a Remove 7 set nuts with the Size-10 socket
wrench.
2. Install the window.
(a) Place the glass into the door plate and
prepare the window mounting hole.
311
(b) Install the window guide rail.

(c) Install the two set bolts of the window.

(c) Remove the window control switch.
3. Connect the connector of the window lifter.

4. Install door inner shield. Assembly
5. Install front-left door window lifter switch 1. Install front-left window control switch
6. Connect battery negative. (a) Secure the connector
(b) Align the window control switch with the
Assembly & disassembly of mounting point and press it down.
front-left window control switch
Disassembly
2. Remove front-left window control switch
(a) Prize the front-left window control switch
according to the diagram with a
screwdriver.
2. Connect battery negative.
312
Chapter 8 Power outer rear view mirror

2 System Diagram ................................................................................................................ 315
3 System overview ................................................................................................................ 316
6 ECU terminals .................................................................................................................... 320
7 Disassembly....................................................................................................................... 335
8 Assembly ........................................................................................................................... 335
313
Right power outer rear Left power outer rear

view mirror assembly view mirror assembly
BCM 2# Switch Block

Power outer rear view
mirror folding switch
mirror regulating switch
314
2 System Diagram
Right motor outer rear

view mirror assembly

mirror switch
Left power outer rear

view mirror assembly
315
3 System overview
The power outer rear view mirror system can
be controlled by the electrical switch on the
dashboard to the left of the driver's seat. When
the power outer rear view mirror is hit, the
housing will be unfolded to some extent in the
direction of force, so as to protect the rear view
mirror from damage. If the mirror is hit and
crashed, fragments will not leave the mirror
holder, so it's quite safe.
Main functions of the rear view mirror:
Mirror adjustment: The driver can get the best

view by moving the mirror vertically and
horizontally.
Manual folding: Use the switch to fold or unfold
the outer rear view mirror, and improve the
vehicle trafficability and protection of the outer
rear view mirror.
Auto folding:
(1) At OFF position, press the remote locking
button and the door is locked; BCM will
drive the power outer rear view mirror to
be folded automatically;
(2) At OFF position, press the remote
unlocking button and the door is unlocked.
BCM will drive the power outer rear view
mirror to be unfolded.
Camera monitoring: The camera on the right

outer rear view mirror can get the view of the
dead corner on the right, supporting vehicle
parking.
Outer rear view mirror foot lighting: The left

side is for greeting guests and the right side
provides light to the right outer rear view mirror
camera.
Main components:
 Rear view mirror assembly
 Control switch
 BCM
316
4 Diagnosis process
Next
2 Customer Problem Analysis and Symptom Check
Next
Standard voltage:
11 to 14 V
Next
4 Inspect DTC*
Result
Result Proceed to
No DTC is output A
DTC is output B
B Go to step 8
Result
Result Proceed to
B Go to step 8
317
6 Overall analysis and troubleshooting
(c) ECU terminals

Next
Next
8 Confirmation test
Next
End
318
Symptom Suspected Area Reference Page

Cigarette lighter fuse
The whole system doesn't
Power outer rear view mirror switch MI-322
work.
Wire harness
Power outer rear view mirror switch
Only the left power outer
rear view mirror cannot be Left power outer rear view mirror assembly MI-325
regulated.
Wire harness
Only the right power outer
rear view mirror cannot be Right power outer rear view mirror assembly MI-328
regulated.
Wire harness
Power outer rear view BCM

MI-331
mirror cannot be folded. Power outer rear view mirror assembly
Wire harness
Refer to the air conditioning system
mirror electrical defrost
maintenance manual
fails.
319
6 ECU terminals
1. Inspect dashboard distributor box
(a) Wire the rear end of the dashboard

distributor box.
(b) Measure the voltage or resistance of each
terminal.
Wire
Terminal No. Terminal Description Condition Normal Value
Color
Power ON, outer rear
Power outer rear view view mirror switched to Less than 1 V
G2P-16-body
L/R mirror folding switch folded
ground
signal
Power ON, outer rear 11-14 V
320
view mirror switched to

unfolded
view mirror switched to 11-14 V
Power outer rear view folded
G2P-17-body
Sb mirror folding switch
ground Power ON, outer rear
signal
view mirror switched to Less than 1 V
unfolded
G2X-37-body Power outer rear view
L view mirror switched to 11-14 V
ground mirror folding power
folded
G2Q-11-body Power outer rear view
G view mirror switched to 11-14 V
ground mirror unfolding power
unfolded
321
The whole system doesn't work.
Circuit Diagram
Electric exterior rearview mirror

regulating switch

(b) Measure the wire harness side voltage.
Normal
Terminal Wire Color
Condition
G41-8-body
Y/R 11-14 V
ground
NG
Check or replace the power supply harness
OK
322
2 Check the ground wire

(d) Measure the wire harness side voltage.
Wire Normal
Terminal
Color Condition
G41-7-body
B Less than 1 V
ground
NG
Check or replace the ground wire harness
OK
3 Check the power outer rear view mirror switch

(b) Measure the resistance between terminals of
the power outer rear view mirror switch
Select the left side outer rear view mirror (turn the
switch to L)
Test condition
Terminal Normal Value
(switch)
G41-8-G41-5 Leftward Less than 1Ω
G41-5-G41-7 Rightward Less than 1Ω
G41-8-G41-4 Upward Less than 1Ω
G41-4-G41-7 Downward Less than 1Ω
Between any Larger than 10
No direction
terminals KΩ
Select the right side external rear view mirror (turn

the switch to R)
Test condition
(switch)
323

No direction
terminals KΩ
NG
Change the power outer rear view mirror switch
OK
4 The power supply is OK. End.
324
Only the left power outer rear view mirror cannot be regulated.
Circuit Diagram

regulating switch
Left Up+
Right Down+
Front-left door outer rear view mirror

the power outer rear view mirror switch with a
multimeter.
(c) Select the left side outer rear view mirror (turn
the switch to L)
Test condition
(switch)
325

No direction
terminals KΩ
NG
OK
2 Check the left power outer rear view mirror assembly
(a) Disconnect the left power outer rear view mirror

connector T05.
(b) Electrify pins of the left outer rear view mirror

and check the mirror adjustment performance.

T05-9-Battery(+)
Move the mirror leftward
T05-4-Battery(-)
T05-9-Battery(+)
Move the mirror upward
T05-3-Battery(-)
NG
Change the left power outer rear view mirror

assembly
OK
Check the wire harness (power outer rear view mirror switch - left power outer rear
3
view mirror)

connector T05.
(b) Disconnect the power outer rear view mirror
switch connector G41.
326
(c) Check the voltage between terminals using a

multimeter.
Wire
Color
G41-5-T05-4 R/Y Less than 1 Ω
G41-4-T05-3 W/R Less than 1 Ω
G41-6-T05-9 G/W Less than 1 Ω
OK
4 End
327
Only the right power outer rear view mirror doesn't work.
Circuit Diagram

regulating switch
Left+ Up+
Right + Down+
Right power outer rear view mirror

assembly
(a) Disconnect the power outer rear view mirror

connector G41.
(b) Check the voltage between terminals using a
multimeter.
328
(c) Select the right side external rear view mirror

(turn the switch to R)
Test condition
(switch)
G41-8-G41-2 Leftward Less than 1 Ω
G41-7-G41-6 Leftward Less than 1 Ω
G41-2-G41-7 Rightward Less than 1 Ω
G41-8-G41-6 Rightward Less than 1 Ω
G41-8-G41-3 Upward Less than 1 Ω
G41-6-G41-7 Upward Less than 1 Ω
G41-3-G41-7 Downward Less than 1 Ω
G41-8-G41-6 Downward Less than 1 Ω
No direction
terminals KΩ
NG
OK
2 Check the right power outer rear view mirror assembly
(a) Disconnect the right power outer rear view

mirror assembly connector U05.
(b) Electrify pins of the right outer rear view mirror

and check the mirror adjustment performance.

U05-9-Battery(+) Move the mirror
U05-4-Battery(-) leftward
U05-9-Battery(+) Move the mirror
U05-3-Battery(-) upward
NG
329
Replace front door latch assembly LH
OK
Check the wire harness ( power outer rear view mirror switch - right power outer
3
rear view mirror)

connector U05.
switch connector G41.
multimeter.
Wire
Color
G41-2-U05-4 L/B Less than 1 Ω
G41-3-U05-3 W/L Less than 1 Ω
G41-6-U05-9 G/W Less than 1 Ω
OK
4 End
330
Power outer rear view mirror cannot be folded.
Circuit Diagram
Left power outer Right power

rear view mirror outer rear view
assembly mirror assembly
Folding Unfolding Folding Unfolding
Electric exterior rearview

mirror regulating switch

connector G41.
(b) Using a multimeter, measure the resistance
Test condition
(switch)
G41-9-G41-7 pressed Less than 1 Ω
G41-9-G41-8 bounced up Less than 1 Ω
331
NG
OK
2 Check the wire harness (power outer rear view mirror switch - BCM)
(a) Disconnect the BCM connector G2P.
(b) Connect connector G41.
(c) Switch the power supply to ON position.
(d) Measure the voltage of wire harness side.

Wire Test Normal
Terminal
Color condition Condition
G2P-17-body
Sb 11-14 V
ground Switch is
G2P-16-body pressed Less than
L/R
ground 1V
G2P-17-body Less than
Sb Switch is
ground 1V
bounced
G2P-16-body up
L/R 11-14 V
ground
OK
3 Inspect the BCM
(a) Disconnect the BCM connectors G2X and

G2N.
(b) Connect connector G2P.
Wire Test Normal

Terminal
Color condition Condition
332
G2X-2-body
O 11-14 V
ground Switch is
G2N-34-body pressed Less than
G
ground 1V
G2X-2-body Less than
O Switch is
ground 1V
bounced
G2N-34-body up
G 11-14 V
ground
NG Replace BCM
OK
4 Check the power outer rear view mirror assembly

connectors T05 (left) and U05 (right).
(b) Supply power to the terminal pins.

T05-8-Battery(+)
T05-2-Battery(-) Rear view mirror
U05-2-Battery(+) folded
U05-8-Battery(-)
T05-8-Battery(-)
T05-2-Battery(+) Rear view mirror
U05-2-Battery(-) unfolded
U05-8-Battery(+)
NG
Change the power outer rear view mirror.
OK
5 Check the wire harness (BCM - power outer rear view mirror)
(a) Disconnect the BCM connectors G2X and

G2N.
connectors T05 (left) and U05 (right).
(d) Left power outer rear view mirror
333
Wire
Color
G2X-2-T05-8 O Less than 1 Ω
G2N-34-T05-2 G Less than 1 Ω
(e) Right power-driven external rearview mirror

Wire
Color
G2X-2-U05-8 O Less than 1 Ω
G2N-34-U05-2 G Less than 1 Ω
NG
Replace the corresponding wiring harness
OK
6 End
334
7 Disassembly 8 Assembly
Take the left outer rear view mirror assembly 1. Left outer rear view mirror assembly
for example. (a) Align the left outer rear view mirror
1. Remove the front-left door trim plate assembly with the mounting hole.
2. Remove the Front High Pitch Speaker LH (b) Align the front door speaker LH with the
trim plate mounting holes.
(a) Disconnect the connector. (c) Install 3 set screws.
(b) Remove 3 bolts with 10# socket wrench. (d) Connect the connector.
(c) Remove the outer rear view mirror
assembly.
2. Remove the Front High Pitch Speaker LH

trim plate
3. Remove the front-left door trim plate
335
Chapter 9 Power sun roof

1 System overview ................................................................................................................ 337
336
1 System overview
The sun roof system is panoramic. The sun
roof control motor assembly opens, closes,
raises and lowers the sun roof by controlling
the forward/backward turning of the motor.
337
2 Diagnosis process

fault occurs.
Next
Standard voltage:
11 to 14 V
Next
Result Proceed
The fault is not recorded in the A
fault symptom table
fault symptom table
B Go to Step 5
(g) Overall functional inspection

(h) ECU terminal inspection
(i) Check with diagnostic tester
Next
(c) Adjust, repair or replace lines or parts
338
Next
6 Confirmation test
(b) After adjustment, repair or changing lines or

Next
7 End
339

Symptom of Malfunction Possible Location of Malfunction
The sun roof cannot slide or 1. Sun roof power supply
incline. 2. Sun roof motor
3. Sun roof switch
4. Wire harness
Sun roof fails in either sliding or 1. Sun roof switch
inclining. 2. Wire harness
340
Description:
If the sun roof doesn't work completely, maybe the problem lies in the power supply.
Battery
Sun roof
Window Control
System
Sun roof control

module
Check Procedures
1 Inspect fuse

distributor box fuses F1/23 and F2/15.
Normal:
The fuse works well.
341
NG Replace fuse
OK
(a) Take out the lead from the back end of the
dashboard distribution box G2X-19 terminal.
(b) Check the voltage of terminal.
Terminal Test Normal
Condition Value
G2X-19-body Always 11~14 V
ground
NG
OK
(a) Disconnect the ceiling wire harness connector

P02.
(b) Lead wire from the rear end of G2X-19.

Value
G2X-19-P02-2 G Less than 1
Ω
OK
4 Circuit is ok.
342
Sun roof switch
Circuit Diagram

40 A
Indoor lighting
Sun roof switch
Check Procedures
1 Inspect fuse

distributor box fuses F1/16 and F2/31.
Normal:
NG Replace fuse
OK
343
(a) Disconnect the sun roof switch connector P03.

(b) Measure the resistance or voltage between the
Terminal Test Normal Value
Condition
P2I-14-P03-9 Always Less than 1Ω
P03-9-body Always 11~14 V
ground
P03-1-body Always Less than 1Ω
ground
OK
3 This part is ok.
344
Chapter 10 Washing of Windshield Wiper
1 Position of the Components .............................................................................................. 346

2 System Diagram ................................................................................................................ 347
5 Malfunction Symptom Table .............................................................................................. 351
7 Removal and installation of the front wiper assembly ....................................................... 363
8 Removal and installation of the washing motor.................................................................364
345
1 Position of the Components
Wiper motor
Right
combination
switch
Washing motor
346
2 System Diagram
Combination Switch
Front cabin
distribution Washing motor
box
Wiper motor
347
Wiping and washing system for front
windshield is mainly composed of wiper arm
assembly, mechanical linkage for wiper, wiping
brush, wiper motor, washing pump, washing
water pot, washing duct and nozzles. The
system provides various functions, including
spot wiping, intermittent wiping, slow wiping
and fast wiping. This system is intended to
ensure the visual field for the driver by
providing convenient, secure and reliable
facility.
348
4 Diagnosis process
Next
2 Customer Problem Analysis and Symptom Inspection
Next
Standard voltage:
11 to 14 V
Next
Result
Result Proceed to
B Proceed to step 6
5 Overall Diagnosis
Next
Next
7 Confirmation test
349
Next
8 Completed
350
5 Malfunction Symptom Table

Wiping and washing system for front windshield
Symptom of Malfunction Possible Location of Malfunction

Failure of wiping and washing system 1. Combination Switch
1. Fuse
2. Circuit of front windscreen wiper motor
Failure of front wiping motor
4. Relay control module
Failure of the wiping motor at a certain 1. Combination Switch
gear(normal at other gears) 2. Relay control module
1. Front wiper motor
Reset of front wiping motor disabled 2. Relay control module
3. Wiring
1. Fuse
2. Circuit of front washing motor
Failure of front washing motor
4. Relay control module
351
6 Overall Diagnosis Process

Wiping circuit of combination switch
Circuit Diagram
MICU Power Power supply for switch 2nd gear

Supply
High and low wiper
Battery
Combination Switch
Signal Signal 3rd gear 2nd gear

switch switch
for for 4th gear 1st gear
washing wiping
Ground
Cigar lighter system
Multiplex integration control module
352
Inspect Procedure
1 Inspect the trouble codes
(a) Insert the diagnostic unit into Port DLC3

(b) Clear trouble code
(c) Read combination switch trouble code
Trouble code Implication

Circuit malfunction of "OFF"
B24A0-00
position of lighting main switch
Circuit malfunction of "TALL"
B24A1-00
Circuit malfunction of "AUTO"
B24A2-00
B24A4-00 Circuit fault of dimmer switch
Circuit fault of turn signal
B24A5-00
switch
Internal error of combination
B24AA-00
switch control device
Circuit malfunction of "ON"
B24AC-00
Circuit fault of "ON" position of
B24AE-00
rear fog lamp switch
Normal:
No output of trouble code
Abnormal
Normal
2 Inspect the fuse
(a) Inspect fuse F2/3 or F2/31 of the dashboard

distributor box for continuity with a multimeter.
Abnormal:
Abnormal Replace the fuse
Abnormal
3 Inspect wire harness(Wire harness of power supply for combination switch)
353
(a) Disconnect connector G24 of combination

switch.
(c) Measure the voltage of terminals.
Normal
Terminal Wire Color
Condition
G24-5 - Body
W/R 11-14 V
ground
G24-6 - Body
Y 11-14 V
ground
G24-3 - Body Less than 1
B
ground V
Abnormal Replace wire harness
Abnormal
4 Inspect the combination switch
(a) Keep on connector G24 of combination switch

(c) Wire the rear end of G24 and measure the
terminal value.
Wire Normal
Terminal State
Color Condition
G24-8 - Combination
Less than
Body G/W switch to "HI"
1V
ground position
G24-1 -
Body P Always 2.5 V
ground
G24-2 -
Body V Always 2.5 V
ground
Abnormal
Normal
354
5 Inspect CAN communication

(b) Disconnect battery negative pole
(c) Measure the resistance between the terminals
with a multimeter.
Terminal Resistance
G24-1-G24-2 56-64 Ω
Abnormal Inspect CAN communication
Normal
6 Inspect wire harness ( combination switch-relay control module)
(a) Disconnect connector G24 of combination

switch.
(b) Disconnect connector B1I of relay control
module
wire harness.
Terminal Wire Color Normal Condition
G24-4-B1I-7 W less than 1 Ω
G24-8- B1I-8 G/W less than1 Ω
Normal
Go to false list for next step, or replace relay control module, or inspect relay control
7
module
355
wiper motor circuit

Circuit Diagram
Wiper
Switch Motor
relay of relay of
internal internal
wiper wiper
Wiper
reset
Wiper
motor
356
Inspect Procedure
1 Inspect the fuse
(a) Inspect fuse F2/33 of dashboard distributor box

with a multimeter.
Normal:
Abnormal Replace fuse
Normal
2 Inspect wire harness(power supply)
(a) Disconnect B1I connector of relay control

module.
Normal
Terminal Wire Color
Condition
B1J-3 - Body
Gr 11-14 V
ground
Normal
3 Inspect relay KI1-2
(a) Pull out the relay KI1-2 from the relay control
module.
(b) Check the relay terminal

Normal
Terminal State
Condition
Battery voltage applied less than1
3-5
to terminals 1 and 2 Ω
Battery voltage not
More
3-5 applied to terminals 1
than10 KΩ
and 2
Battery voltage applied More than
3-4
to terminals 1 and 2 10 KΩ
Battery voltage not less than
3-4
applied to terminals 1 1Ω
357
and 2
Abnormal Replace relay
Normal
4 Inspect relay KI1-2
module.
(b) Inspect the relay terminal
Normal
Terminal State
Condition
Battery voltage applied Less than
3-5
to terminals 1 and 2 1Ω
Battery voltage not
More than
10 KΩ
and 2
Battery voltage applied More than
3-4
to terminals 1 and 2 10 KΩ
Battery voltage not
Less than
1Ω
and 2
Abnormal Replace relay
Normal
5 Inspect the front wiper motor
(a) Disconnect the connector B01 of front wiper

motor.
(b) Power on the corresponding terminal of motor

and inspect operation condition of the motor.
Normal
Terminal State
Condition
2 - Battery
Running of
positive
-- the motor in
4-Battery
a low speed.
negative
1 - Battery Running of
positive -- the motor in
4 - Battery a high speed
358
negative
The motor not
More than
3-4 stops in idle
10 KΩ
position
The motor stops Less than 1
3-4
in idle position Ω
Abnormal
Replace the front wiper motor
Normal
6 Inspect wire harness(Front wiper-relay control module)
(a) Disconnect the connector B01 of front wiper

motor.
(b) Disconnect B1I connector of relay control
module.
(c) Measure the resistance between terminals.
Wire
Color
B01-2-B1J-4 L Less than 1 Ω
B01-1- B1J-5 Y Less than 1 Ω
B01-3- B1J-1 W Less than 1 Ω
B01-4 - Body
B More than 10 KΩ
ground
Normal
359
Circuit of the washing motor
Circuit Diagram
Motor
relay of
internal
washer Washing
motor of
the front
window
360
Inspect Procedure
1 Inspect the fuse
(a) Inspect fuse F2/28 of dashboard distributor box

with a multimeter.
Normal:
Abnormal Replace the fuse
Normal
2 Inspect wire harness(power supply)
(a) Disconnect B1E connector of relay control

module.
B1E-8-IG1 Y/G 11-14 V
Normal
3 Measure relay KI1-3
module.
(b) Measure the relay terminal.
Normal
Terminal Wire Color
Condition
Battery voltage
3-5 applied to Less than 1 Ω
terminals 1 and 2
Battery voltage not
More than 10
3-5 applied to
KΩ
terminals 1 and 2
Abnormal Replace the relay
361
Normal
4 Inspect the front washing motor
(a) Disconnect C19 connector of the front washing

motor.
(b) Fill the washing water pot with required
washing solution (to specified scale).
State Normal Condition

1 - Battery positive Eruption of washing
2 - Battery negative solution
Abnormal
Replace the washing motor
Normal
5 Inspect the wire harness ( combination switch-relay control module)
(a) Disconnect connector C19 of the front wiper

motor.
(b) Disconnect C1F connector of the relay control
module.
(c) Measure the resistance between terminals.
Wire
Color
C19-1-C1F-20 Y/G Less than 1 Ω
C19-2 - Body
B More than 10 KΩ
ground
Abnormal
Replace the wire harness
Normal
362
7 Removal and installation of Installation

the front wiper assembly 1. Install the front wiper assembly
(a) Align the front wiper assembly with the
Removal mounting hole.
1. Remove the left and right wiping arms
(b) Install four bolts.
(a) Remove two decorating hats.
(c)Connect the connector.
(b) Remove two retaining nuts.

2. Install the front vent cover
3. Install the left and right wiping arms
(a) Insert the wiping arm into the set bolt.
(b) Install two retaining nuts.
2. Remove the front vent cover

3. Remove the front wiper assembly
(a) Remove four bolts with a 10# sleeve.
(c) Remove the front wiper assembly. (c) Install two decorating hats of the wiping
arm.
363
8 Removal and installation of Installation

the washing motor 1. Install the washing motor
(a) Put the washing motor into the washing
Removal water pot.
1. Remove the front bumper assembly
2. Install the washing water pot
2. Disconnect the washing hose (a) Put the washing water pot into installation
position.
3. Remove the washing water pot
(b) Install three bolts.
(a) Disconnect the connector of motor.
(b) Remove one snap.
(c) Fix a snap.

(c) Remove three bolts with a 10# sleeve.
(d) Remove the washing water pot.
3. Connect the washing pipe

4. Install the front fuse
4. Remove the washing motor
(a) Remove washing motor from the washing
water pot.
364
Chapter 11 Rear LOGO assembly
1 System overview ................................................................................................................ 366

3 LOGO has no light when the sidelamp is on. ....................................................................367
365
1 System overview
The rear LOGO assembly is arranged at the
rear part of the vehicle. It is obvious in
darkness and can be a reminder for vehicles
behind.
Symptom of Malfunction Location which might cause fault

1. Rear LOGO assembly
2. Combination Switch
LOGO has no light when the
3. Engine hood distributor box
sidelamp is on.
4. Dashboard distributor box
5. Wire harness
366
3 LOGO has no light when the sidelamp is on.

Circuit Diagram:
Sidelamp
小灯
K2F-12
R/B
0.85
1 K40
Rear LOGO后Logo灯
light
3 K40
K7
367
1 Check the sidelamps
(a) Check whether other sidelamps can be lit up,

such as the position lamp and the entire car
backlight.
NG: Other sidelamps cannot be lit up either.
NG
Please turn to the lighting system to check

sidelamps.
OK
(a) Lead wire from rear part of the dashboard

distribution box K2F-12 and check the
voltage of the two terminals.
(b)
Connection
Condition Normal Value
terminal
K2F-12-body Sidelamp is
11~14 V
ground on.
NG
OK
3 Check the rear LOGO.
(a) Disconnect the rear LOGO lamp connector

K40.
(b) Electrify terminals according to the table below
to check lighting performance of LOGO.
Connection terminal Normal Value

K40-1 - battery (+)
LOGO in red light
K40-3 - battery (-)
NG Change the rear LOGO.
OK
4 Replace wire harness
368
Removal Assembly
(a) Disconnect the negative electrode of the (a) Align the LOGO with the mounting holes
storage battery and install it.
(b) Prize the LOGO carefully with a (b) Connect the negative electrode of the
screwdriver. storage battery
369
Chapter 12 Cruise control system

2 System overview ................................................................................................................ 371
370

Engine ECU
Cruise instruction:
Cruise switch:
2 System overview
The vehicle is provided with a cruise control
system. Fixed speed cruise control enables
you to keep the speed higher than 40 km/h
without treading on the accelerator pedal.
This function is enabled when the car runs on
a straight and smooth highway.
371
3 Diagnosis process
Next
2 Fault symptom confirmation
Next
3 Check circuit connection
Next
Next
5 Confirmation test
Next
Completed
372
Symptom Suspected Area
Cruise switch
Wheel Speed Sensor
Cruise control fails. Communication error
Harness or connector
Throttle Valve Position Sensor
Speed cannot be set during cruise.

Electronic throttle actuator
ECM
Throttle Valve Position Sensor
Cruise control speed is incorrect

Electronic throttle actuator
ECM
Braking Light Switch

Cruise cancel fails.
ECM
Wheel Speed Sensor

The vehicle jitters (speed is unstable)
ECM
373
Cruise control system circuit
Circuit Diagram
Electronic
throttle
valve
body
374
Steering wheel
cruise switch
Clock spring
(off: padel pressed)

Braking light switch
375
Check Procedures
1 Check whether cruise control works.
(a) Check whether engine startup and running

function well.
(b) Check whether you can enter cruise control

mode during running.
Situation Go to
The car cannot run normally. A
The car can run normally, but you
B
cannot enter cruise control mode.
You can enter cruise control mode,
C
but there are other faults.
A
Please check the engine management system.
C Go to step 4
2 Check the steering wheel switch.
(a) Disconnect the clock spring connector and

check the connection resistance of the cruise
control switch according to the table below.
Connection Normal
Condition
terminal Value
Press the cruise About 1000
10 - 11
switch Ω
Press the cruise About 3160
10 - 11
closing switch Ω
NG
Replace the steering wheel switch.
OK
376
3 Check whether the car speed signal is ok.
(a) Read ABS DTC with a diagnostic tester to

check whether there is vehicle speed
malfunction.
Normal:
No vehicle speed malfunction
NG Please examine ABS system
OK
4 Examine the braking light switch
(a) Disconnect the braking light switch connector.

Lead wire from the rear end of the switch and
check the connection between pins.
Tips:
Tread the brake pedal (or press the cruise switch) to

cancel cruise mode.
Connection
Condition Normal Value
terminal
Tread the
1-2 Less than 1 Ω
brake pedal
Tread the
3-4 More than 1 MΩ
brake pedal
Release the
1-2 More than 1 MΩ
brake pedal
Release the
3-4 Less than 1 Ω
brake pedal
NG Replace the braking light switch
OK
5 Check the Throttle Valve Position Sensor
(a) Read the electronically controlled injection

system data stream by using of a diagnostic
tester.
(b) Tread the accelerator pedal when the engine is

on and check whether the throttle openness
changes normally.
377
Normal:
The throttle openness changes with the
compression of the pedal.
NG
Change the electronic throttle valve body.
OK
6 Change the electronic throttle valve body.
(a) You may read the electronically controlled

injection system data stream by using of a
diagnostic tester when the car is running.
(b) Manipulate the cruise switch when the car is

running to see whether the throttle openness
changes normally.
Normal:
Throttle openness changes with times for
which the cruise switch is pressed.
NG
Change the electronic throttle valve body.
OK
7 Check whether it's recovered.
NG
Change the engine control module.
OK
8 End
378
Chapter 13 Tire pressure monitoring system
1 Parts Location .................................................................................................................... 380

2 System Diagram ................................................................................................................ 382
6 ECU terminals .................................................................................................................... 387
379
1 Parts Location
Tire pressure monitoring module
Tire pressure
monitoring and
control module
Tire pressure
monitoring module
380
Seal Ring
Plastic
gasket
Metal gasket
Hex nut
Protective
cap
381
2 System Diagram
UHF 433.92MHZ
Tire
pressure
monitoring
module
Tire Tire
Power ON pressure pressure

monitoring
monitoring module
and
Display CAN control Tire
pressure
unit module monitoring
module
Tire
pressure
monitoring
module
382
1. Tire pressure monitoring module
Arranged inside the tire, it measures the
tire pressure and transmits information via
wireless transmission. Integrated with the
valve, it can be divided into the monitoring
module body and the valve.
2. Tire pressure monitoring and control

module
It receives and processes the tire pressure
information sent from the tire monitoring
module, and sends signals to instruments
via CAN cable.
3. Principle of tire pressure monitoring

system
The tire pressure monitoring system
measures parameters of the tire, such as
pressure and acceleration by using of the
pressure sensors in each tire. It sends data
acquired to the receiving module via radio
frequency transmission and the receiving
module demodulates, analyzes and
processes the data into CAN signals, and
sends CAN signals to instruments. In this
way, tire information is displayed digitally in
a real-time manner. When the pressure of
any tire exceeds the normal range, alarm
can be given to the driver through sound or
light or visually to guarantee travel safety.
383
Tips:

tire pressure monitoring system.
 *: Using the intelligent detecter.
Next
2 Customer problem analysis and symptom inspection
Next
Standard voltage:
11 to 14 V
Next
(b) Using the intelligent detecter to check for

system.
Result
Result Proceed to
The CAN communication system DTC is output B
5 Inspect DTC*
384
Result
Result Proceed to
No DTC is output A
DTC is output B
B Go to step 8
Result
Result Proceed to
B Go to step 8
(e) ECU terminals

Next
Next
9 Confirmation test
Next
End
385

Tips:

Malfunctions. The potential causes of the faults are
Tire pressure failure warning light:
Symptom Suspected Area Reference page

Fuse -
Tire pressure failure
Tire pressure monitoring and control module -
warning light not on
Harness or connector -
Fuse -
Tire pressure failure
Tire pressure monitoring and control module -
warning light always on
Harness or connector -
386
6 ECU terminals
1 Check the pin of the tire pressure
monitoring and control module
(d) Measure voltage and resistance according

to values in the table below.
Standard Voltage
Terminal Specified
Terminal No. (Symbol) Wire Color Condition
Description Condition
W/R-Vehicle Body
K35-1 - Body ground Power ON (IG1) Always 11 to 14 V
Ground
P-Vehicle Body
K35-6 - Body ground CAN-H Always About 2.5 V
Ground
V-Vehicle Body
K35-12 - Body ground CAN-L Always About 2.5 V
Ground
Standard Resistance
Terminal Specified
Terminal No. (Symbol) Wire Color Condition
Description Condition
B-Vehicle Body
K35-7 - Body ground Battery ground Always Less than 1 Ω
Ground

387

DTC code Detection Item Trouble Area See page
C1000 Front-left tire pressure monitoring Front-left tire pressure
module RF communication failure monitoring module
C1001 Front-right tire pressure monitoring Front-right tire pressure
C1002 Rear-left tire pressure monitoring Rear-left tire pressure
C1003 Rear-right tire pressure monitoring Rear-right tire pressure
C1004 Pressure exceeding the range of Front-left tire pressure
the front-left tire pressure monitoring module
monitoring module Front-left wheel tire pressure
C1005 Pressure exceeding the range of Front-right tire pressure
the front-right tire pressure monitoring module
monitoring module Front-right wheel tire
pressure
C1006 Pressure exceeding the range of Rear-left tire pressure
the rear-left tire pressure monitoring module
monitoring module Rear-left wheel tire pressure
C1007 Pressure exceeding the range of Rear-right tire pressure
the rear-right tire pressure monitoring module
monitoring module Rear-right wheel tire pressure
C1008 Front-left tire pressure monitoring Front-left tire pressure
module ID not registered monitoring module
C1009 Front-right tire pressure monitoring Front-right tire pressure
C100A Rear-left tire pressure monitoring Rear-left tire pressure
C100B Rear-right tire pressure monitoring Rear-right tire pressure
C100D Left front wheel monitoring module Left front wheel monitoring
low battery module battery
C100E Right front wheel monitoring Right front wheel monitoring
module low battery module battery
C100F Left rear wheel monitoring module Left rear wheel monitoring
C1010 Right rear wheel monitoring module Right rear wheel monitoring
U0155 Out of touch with combination Communication
meter
388
DTC U0155 Out of touch with combination meter
Circuit diagram
Adapter
Tire pressure monitoring

and control module
1 Inspect CAN line
(c) Disconnect the connector of the tire pressure

monitoring and control module K35.
(d) Check the wire harness side voltage.
Standard Voltage
Specified
Condition
K35-6 - Body ground Always 2.5 V
K35-12 - Body ground Always 2.5 V
OK
2 Go to the corresponding system to check communication failure
Next
End
389
Tire pressure monitoring and control module power circuit

Circuit diagram
Tire pressure monitoring

and control module
1 Inspect fuses
(b) Use a multimeter to check whether fuses

F2/28 are good.
OK
(d) Disconnect the connector of the tire pressure

monitoring and control module K35.
(e) Disconnect floor harness K2E connector.
(f) Measure the resistance or voltage between the

390
Standard Voltage
Tester Connection Specified

Condition
Condition
K2E-2 - body ground Power ON 11 to 14 V
K35-1 - Body ground Power ON 11 to 14 V
Standard Resistance
Specified
Condition
Less than
K35-7 - Body ground Always
1Ω
Abnormal
OK
End
391
Tire pressure matching procedures
392

Tire pressure monitoring and
control module disassembly
1. Remove the trim panel of right C column
2. Remove tire pressure monitoring and

control module
a Disconnect the connector.
b Remove a bolt with 10# socket wrench.

Tire pressure monitor module
c Remove tire pressure monitoring and
control module disassembly
1. Disassembly preparation: Sleeve torque

wrench and tire disassembling machine;
2. Tire pressure monitor module

disassembly
(a) Screw out the protective cap to deflate the

tire;
(b) After making sure that the tire has been

deflated completely, use the sleeve torque
Tire pressure monitoring and wrench to remove the hex nut at 4 N/m.
Remove the metal gasket and the plastic
control module assembly gasket. Push the valve gently with hands
so that the valve assembly drops into the
1. Install the tire pressure monitoring and tire;
control module
(c) Place the tire on the tire disassembly
a Align the tire pressure monitoring and machine. Adjust the gap between the
control module with the mounting hole. wheel rim edge and the pressure plate to
10~20 mm. Tread the pedal to separate
b Install a set bolt. the tire from the rim;
c Connect the connector. (d) Place the tire on the workbench of the tire
disassembly machine and chuck the rim.
2. Install the trim panel of right C column Remove the tire from the edge by using of
the tire remover. Remove the valve
assembly in the tire and place it at
designated position;
393
the plastic gasket and the metal gasket.

Finally, lock the hex nut with strength of
4.0±0.6 Nm.
Note:
(c) Place the rim on the tire disassembly
Protective caps, valve cores, hex nuts, metal machine, as shown in the figure below:
gaskets and valve assemblies should be used rotate the rim clockwise and adjust the
repeatedly, so they should be well protected position of the rim to keep the mounting
during disassembly and then kept at head of the tire disassembly machine at
designated position; 12'o clock. The monitoring module must be
within the section line. Apply lubricant on
Plastic gaskets and seal rings are the hub and the tire, sleeve the rim with the
consumables and should be replaced when lower tire edge, rotate the rim and install
they're installed next time (unless otherwise the whole lower tire edge on the rim. Make
stipulated). sure that the tire edge doesn't touch the
monitoring module during installation
Tire pressure monitor module

assembly
1. Preparation: Sleeve torque wrench, tire
disassembly machine, balancing machine,
balance block, inflation gun and pressure
gauge;
2. Tire monitoring module installation
(a) Place the hub on the workbench of the

tire disassembly machine and fix it with a
jaw;
(b) Put the valve assembly through the rim

mounting hole and sleeve the valve with
(d) .
394
Chapter 14 Parking System

2 System overview ................................................................................................................ 398
5 DTC table ........................................................................................................................... 402
8 Auxiliary parking system module disassembly & assembly .............................................. 437
9 Sensor assembly & disassembly ....................................................................................... 438
395
Backup camera
assembly
Rear-right
angle sensor
Rear-left angle
sensor Right-reverse
Left-reverse sensor
sensor
396
Auxiliary
parking
system
module
Front-right Front-left
corner corner
probe probe
397
2 System overview
Vehicle parking system consists of parking  When there is mud or snow on the
auxiliary system and parking imaging system. sensor (The sensor can be resumed
Parking auxiliary system is a vehicle after foreign matters have been
monitoring system that imitates bat's flight flushed by water.)
detection principles. Ultrasonic wave sensors  The vehicle is exposed to sunshine
are arranged at the tail or head of the vehicle or extremely low temperature
to send or receive signals, and feedback  The sensor may suffer wrong
information to the controller. The controller detection in any of the following
calculates the distance of the tested obstacle circumstances
according to the return time, and gives  When the vehicle is on uneven road,
different audio warning and indicator warning gravel pavement or grassland
based on the distance to remind the driver of  When there is horn of other vehicles,
the distance between the obstacle and the engine sound of motorcycles and air
vehicle, thus making reversing and parking brake sound of large vehicles
more convenient and safer;
 Vehicles in heavy rain or with water
stain
The parking imaging system is a new
technology. The wide angle camera on the
 Vehicles incline greatly
body takes photo of the view not easily  When there is mud or snow on the
observed during parking. The multimedia sensor
displayer corrects and displays images for the  The vehicle has a towing hook
driver. Meanwhile, the driver can switch views  When another vehicle with a sensor
through the switching button on the steering approaches
wheel to choose the image needed, thus  When the vehicle runs to high or
facilitating parking. right-angle curbs
(b) Due to the shape, features or material
1. Composition of the parking system: of the obstacle, the sensor may fail to
 Auxiliary parking system module detect the following items:
 Sensors (six, 2 at the front and 4 at the  Linear objects, such as wires or
back) ropes
 No.2 switch block (parking auxiliary  Objects that absorb sound saves,
switch) such as cotton and snow, etc.
 Multimedia Machine (flagship/luxury)  Objects with sharp edges
 Reversing light switch  Object too low
 Dashboard distributor box  Object too high or upper part
 Camera (front-right camera and backup projecting
camera)  When the sensor is impacted or
 Steering wheel switch (imaging switch) collided greatly
2. Notes for the parking auxiliary system:  When the vehicle is too close to the
(a) Sensor detection may fail functioning step, the system cannot measure the
well in any of the following situations: distance between the bottom step
 When there is mud or snow on the and the vehicle tail, thus causing
sensor (The sensor can be resumed damage to the fender.
after foreign matters have been (c) Notes for the parking imaging system:
flushed by water.)  Don't hit the camera by hard objects,
 When the sensor is blocked by or the camera may be damaged.
hands  Don't wipe the lens with hands or
 When the temperature outside is low hard cloth, or the lens may be
and the sensor fails due to icing, the scratched, thus affecting imaging.
scope of detection may change in Use fresh water or cleaning agent to
any of the following circumstances. clean the lens.
398
(d) If the vehicle is parked where the

temperature changes greatly, the imaging
effect may be affected.
(e) The image may be unclear in any of the
following circumstances:
 Expose of the camera to sunshine or
light may cause unclear imaging.
 Surrounding area is too dark.
 Ambient temperature is too high or
too low.
399
3 Diagnosis process
Tips:
 Troubleshooting Procedures Are As Follows
 Use the diagnostic unit for analysis for Step 4.

fault occurs.
Next
Standard voltage:
11 to 14 V
Next
Result Proceed
The fault is not recorded in A
the fault symptom table
fault symptom table
B Go to Step 5
(j) Overall functional inspection

(k) ECU terminal inspection (see ECU terminal
inspection)
(l) Check with diagnostic tester
Next
400
(d) Adjust, repair or replace lines or parts
Next
6 Confirmation test
(c) After adjustment, repair or changing lines or

Next
7 End
401

Symptom of Malfunction Location which might cause fault
1. No.2 switching group
The whole parking auxiliary system doesn't 2. Auxiliary parking system module
work. 3. Sensor (probe)
4. Wire harness
The buzzer makes no sound (sensor gives
2. Auxiliary parking system module
alarm)
3. Wire harness
Buzzer gives sound abnormally (sensor works
well)
3. Wire harness
Position alarm confusion/absent (buzzer 2. Sensor
works normally) 3. Auxiliary parking system module
4. Wiring
1. Steering wheel switch block
Steering wheel switch block cannot switch
2. DVD host
parking screen
3. Wiring
1. Backup camera power
No display of reverse image (blue screen) 2. Camera
3. Wire harness
1. Wire harness
Reverse image confusion 2. Camera
3. Multimedia Machine
1. Front-right camera power
No display of front-right image (blue screen) 2. Camera
3. Wire harness
1. Wire harness
Front-right image confusion 2. Camera
3. Multimedia Machine
No display of lead wire 1. Multimedia Machine
5 DTC table
DTC Implication Fault Area
B1B00-00 Front-left corner sensor cannot work well. Front-left corner sensor fails
B1B01-00 Front-right corner sensor cannot work well. Front-right corner sensor fails
B1B02-00 Rear-left corner sensor cannot work well. Rear-left corner sensor fails
B1B03-00 Rear-right corner sensor cannot work well. Rear-right corner sensor fails
B1B04-00 Left reverse sensor cannot work well. Rear-left reverse sensor fails
B1B05-00 Right reverse sensor cannot work well. Rear-right reverse sensor fails
402
1. Check auxiliary parking system module
(a) Lead wire from the back end of parking

auxiliary system module K17 connector and
check voltages or resistances of terminals.
Connection terminal Wire Color Terminal Condition Normal Value
Description
K17-1 - Body ground P CAN_H Always 2.5V~3.5V
K17-2 - Body ground -- N/A -- --
K17-3 - Body ground -- N/A -- --
K17-4-Body ground -- N/A -- --
K17-5-Body ground G Reverse gear Shift to reverse Signal
signal
K17-11-Body ground W/R Signal ground Always Less than 1 Ω
K17-12-Body ground Y Right-reverse Obstacle Detection signal
sensor detected
K17-13-Body ground Br/W Rear-left corner Obstacle Detection signal
sensor detected
K17-14-Body ground L Signal ground Always Less than 1 Ω
K17-15-Body ground R Rear-right Obstacle Detection signal
corner sensor detected
K17-16-Body ground G Signal ground Always Less than 1 Ω
K17-17-Body ground V CAN_L Always 1.5 V~2.5 V
K17-19-Body ground V/W Power Supply Power ON, press 11-14 V
parking auxiliary
switch
403

K17-28-Body ground G/W Left-reverse Obstacle Detection signal
sensor detected
K17-29-Body ground Br Front-left corner Obstacle Detection signal
sensor detected
K17-30-Body ground B Body ground Always Less than 1 V
K17-31-Body ground B/L Front-right Obstacle Detection signal
corner sensor detected
K17-32-Body ground B Body ground Always Less than 1 V
404
7 Overall Diagnosis Process

1 Diagnosis Using the Diagnostic Unit
(a) If a fault is found, go to abnormal.

(b) If no fault is found, go to next.
Abnormal
Go to corresponding fault for inspection
Next
2 Inspect the BCM
(a) Shift to R and observe whether the reverse light

is on. If not, go to abnormal. If so, go to next.
Abnormal Go to the light system
Next
3 Go to power circuit for inspection
405
DTC B1B00-00 Front-left corner sensor cannot work well.
Circuit diagram
Auxiliary parking
system module
Front-left
corner sensor
406
1 Check front-left corner sensor
(a) Replace it by a front-left corner sensor that can

work normally.
(b) Clear DTC with a diagnostic tester. Check
whether the trouble occurs again.
Normal:
No trouble
Normal
The sensor fails. Replace it by another one.
Abnormal
(a) Disconnect the auxiliary parking system

module connector K17.
(b) Disconnect front-left corner sensor connector

C25.

multimeter.
Terminal Wire Normal Resistance

Color Value
K17-14-C25-1 L Less than 1 Ω
K17-29-C25-2 Br Less than 1 Ω
Abnormal
Normal
3 Replace auxiliary parking system module
407
DTC B1B01-00 Front-right corner sensor cannot work well.
Circuit diagram
Auxiliary parking
system module
Front-right
corner sensor
1 Check front-right corner sensor
(a) Replace it by a front-right corner sensor that

can work normally.

Normal:
No trouble
Normal
Abnormal
408

(b) Disconnect front-right corner sensor connector

C24.

multimeter.
Terminal Normal
Wire Color Resistance
Value
K17-16-C24-1 Y/G(G24Termin Less than 1
al wire color G) Ω
K17-31-C24-2 B/L Less than 1
Ω
Normal
409
DTC B1B02-00 Rear-left corner sensor cannot work well.
Circuit diagram
Auxiliary parking
system module
Rear-left corner
sensor
1 Check rear-left corner sensor
(a) Replace it by a rear-left corner sensor that can

work normally.
Normal:
No trouble
Normal
Abnormal
410

(b) Disconnect rear-left corner sensor connector

R02.

multimeter.

Color Value
K17-11-R02-1 W/R Less than 1 Ω
K17-13-R02-2 Br/W Less than 1 Ω
Abnormal
Normal
411
DTC B1B03-00 Rear-right corner sensor cannot work well.
Circuit diagram
Auxiliary parking
system module
Rear-right
corner sensor
1 Check rear-right corner sensor
(a) Replace it by a rear-right corner sensor that

can work normally.
Normal:
No trouble
Normal
Abnormal
412

(b) Disconnect rear-right corner sensor connector
R04.
multimeter.

Color Value
K17-15-R04-2 R Less than 1 Ω
Normal
413
DTC B1B04-00 Left reverse sensor cannot work well.
Circuit diagram
Auxiliary parking
system module
Left-reverse
sensor
1 Check left-reverse sensor
(c) Replace it by a left-reverse sensor that can

work normally.
(d) Clear DTC with a diagnostic tester. Check
Normal:
No trouble
Normal
Abnormal
414

(b) Disconnect rear-right corner sensor connector
R01.
multimeter.
Terminal Wire Color Normal Resistance
Value
K17-28-R01-2 G/W Less than 1 Ω
Abnormal
Normal
415
DTC B1B05-00 Right reverse sensor cannot work well.
Circuit diagram
Auxiliary parking
system module
Right-reverse
sensor
1 Check right-reverse sensor
(a) Replace it by a right-reverse sensor that can

work normally.
Normal:
No trouble
Normal
Abnormal
416

(b) Disconnect right-reverse sensor connector
R03.
multimeter.
Terminal Wire Color Normal Resistance
Value
K17-12-R03-2 Y Less than 1 Ω
Normal
417
Circuit diagram
Power supply for

switch 2nd gear
Dashboard
Wire Harness
Adapter
Reversing radar
switch
Auxiliary parking system module
1 Inspect fuses
(a) Check dashboard distributor box fuse F2/31

with a multimeter.
(b) Tips: The fuse is related to many systems, such
as window control, light and combination switch.
Therefore, we can check other systems first. If
none of them works, it's very likely that the fuse
is broken.
Normal:
418
Normal
2 Check the power switch
(a) Disconnect the reversing radar switch

connector G48.
(b) Switch the power to ON position.
(c) Check the terminal voltage using a multimeter.

Condition
G48-1-Body R/G 11-14 V
ground
Abnormal
Wire harness maintenance (dashboard wire

harness-reversing radar switch)
Normal
3 Check reversing radar switch
(a) Disconnect the reversing radar switch

connector G48 and press the reversing radar
switch.
(b) Operate the reversing radar switch and check

the resistance between terminals.
Terminal Condition Normal

Condition
pressed
Abnormal
Replace reversing radar switch
Normal
4 Check the power supply of the auxiliary parking system module
419

(b) Press the parking auxiliary switch
(c) Measure the wire harness voltage.

Condition
K17-19-Body V/W 11-14 V
ground
Abnormal
Replace reversing radar switch
Normal
5 Check the grounding of the auxiliary parking system module

(b) Measure the wire harness voltage.

Color Condition
K17-30-Body B Less than 1 V
ground
K17-32-Body B Less than 1 V
ground
Abnormal
Wire harness maintenance (grounding wire)
Normal
420
The sensor works well and the buzzer gives no alarm/ buzzer
gives alarm abnormally.
Circuit diagram
Auxiliary parking Multi-functional display

system module
Adapter
1 Check multi-functional display
(a) Replace it by a multi-functional display that can

work normally.
the multi-functional display.
Normal:
No trouble
Normal
Multi-functional display fails. Replace it by

another one.
Abnormal
421

(b) Check the terminal voltage using a multimeter.

Condition
K17-1-Body P 2.5V~3.5 V
ground
K17-17-Body V 1.5V~2.5 V
ground
K17-1-K17-17 -- 56-64 Ω
Normal
2 Check auxiliary parking system module
(a) Change it with an auxiliary parking system

module that works normally.

whether the fault occurs again.
Normal:
No trouble
Normal
Auxiliary parking system fails, so replace the

auxiliary parking system module.
Normal
3 End
422
Position alarm confusion/absent (buzzer works normally)
Circuit diagram
Auxiliary parking Multi-functional display

system module
Adapter
1 Check sensor installation
(b) Check whether sensors are installed correctly

and whether they are deformed.
Normal:
Sensors are installed correctly.
Normal
Correct the position of the sensor
Normal
423
2 Read DTCs with the Diagnostic Unit

(a) Connect the diagnostic tester to DLC3
diagnostic interface.
(b) Clear DTC.
(c) Read DTC of the parking auxiliary system.
Normal:
There is DTC output.
Normal
Check according to corresponding DTC
Abnormal
3 Check multi-functional display
(a) Replace it by a multi-functional display that can

work normally.
(b) Check whether the fault occurs again
Normal:
No trouble
Normal
Replace multi-functional display
Abnormal
4 Check auxiliary parking system module

Normal:
No trouble
424
Normal
Replace auxiliary parking system module
Abnormal

module and the multi-functional display
connectors K17 and He03.

Condition
K17-1-Body P 2.5 V~3.5 V
ground
K17-17-Body V 1.5 V~2.5 V
ground
K17-1-K17-17 -- 56-64 Ω
He03-4-Body V 2.5 V~3.5 V
ground
He03-3-Body P 1.5 V~2.5 V
ground
He03-3- He03-4 -- 56-64 Ω
Normal
6 End
425
Parking auxiliary information of parking image interface on

multimedia host is wrong or not displayed.
Circuit diagram
Auxiliary parking DVD host

system module
Adapter
1 Check the display of parking auxiliary switch in No.2 switch block
(a) Check whether parking auxiliary switch is

displayed normally.
Normal:
Sensors are installed correctly.
Abnormal Solve the trouble first.
Normal
426


Color Condition
K17-1-Body P 2.5 V~3.5 V
ground
K17-17-Body V 1.5 V~2.5 V
ground
K17-1-K17-17 -- 56-64 Ω
Abnormal
Normal
3 Check auxiliary parking module

Normal:
No trouble
Normal
Replace auxiliary parking system module
Abnormal
4 Check DVD host
(a) Replace it by a DVD host that can work

normally.
427
Normal:
No trouble
Normal Check DVD host
Normal
5 End
428
The parking auxiliary screen cannot be switched by the

steering wheel switch.
Circuit diagram
DVD host
Clock spring
Steering wheel
side camera
control switch
1 Check the switch signal
(a) Disconnect DVD host connectors G51 and

G55.
(b) Operate the switch and check the wire harness

terminal resistance.

Condition
Press OFF Press VIEW 4.64 kΩ
Press OFF 9.84 kΩ
429
Abnormal Replace DVD host
Normal
2 Examine the switch
(a) Remove the steering wheel switch.

(b) Disconnect the steering wheel connector X993.
(c) Operate the switch and check the wire harness
terminal resistance.
Condition
X993-3-X993-4 Press VIEW 4.64 kΩ
Press OFF 9.84 kΩ
Abnormal
Replace the steering wheel switch.
Normal
(a) Disconnect DVD host and steering wheel

switch connectors G51, G55 and X993.

wire harness.

Condition
G51-8-X993-3 Sb Less than 1 Ω
G55-5-X993-4 Br Less than 1 Ω
Abnormal
Normal
4 End
430
No display of reverse image (blue screen)
Circuit diagram
DVD host
Shielding
layer
Video ground Shielding

layer
Backup camera
(a) Disconnect the backup camera connector K33.
Connection Test condition Normal

terminal Condition
K33-1-Body With power ON, 11~14 V
ground shift to Gear R
K33-2-Body Always Less than 1
ground V
Abnormal
431
Normal
2 Check the signal line
(a) Disconnect the backup camera connector K33.

wire harness.
Connection Wire Normal

terminal Color Condition
K33-1-G31-5 B/Y Less than 1 Ω
K33-2-G31-15 B Less than 1 Ω
Abnormal
Normal
3 Examine the camera
(a) Change a normal camera to check whether the

reverse image can be recovered.
Normal:
Reverse image is OK.
Normal
4 Replace a camera
432
No display of front-right image (blue screen)
Circuit diagram
DVD host
Shielding
layer
Shielding
layer
Screen ground
Front-right camera
(a) Disconnect the backup camera connector U08.
Connection Test condition Normal

terminal Condition
U08-1-Body With power ON, 11~14 V
ground shift to Gear R
U08-4-Body Always Less than 1
ground V
Abnormal
433
Normal
(a) Disconnect the backup camera connector U08.

wire harness.
Connection Wire Normal Condition

terminal Color
U08-1-G31-6 L Less than 1 Ω
U08-4-G31-16 G Less than 1 Ω
Abnormal
Normal

front-right image can be recovered.
Normal:
Front-right image is OK.
Abnormal
Replace DVD host
Normal
4 Replace a camera
434
Front-right image confusion
Circuit diagram
DVD host
Shielding
layer
Shielding
layer
Screen ground
Front-right camera
(a) Change a new set of signal lines and check

whether the screen is recovered.
Normal:
The screen is OK.
Abnormal
Change the camera.
Normal
435

front-right image can be recovered.
Normal:
Reverse image is OK.
Normal
3 Replace a camera
436
8 Auxiliary parking system (c) Connect the connectors.
module disassembly &

assembly
Disassembly
2. ECU is below the passenger seat. Move
the seat forward to the limit and you can
see the parking auxiliary module.
2. Connect No.2 switch block connector

and install the dashboard lower-left
backplate body.
3. Remove the auxiliary parking system

modul

module connector.
(b) Remove the two set bolts with No.10

ratchet wrench.
(c) Remove the auxiliary parking system

module
Assembly
assembly
(a) Place the auxiliary parking system
module at the designated position.
(b) Install the two set bolts with No.10
ratchet wrench.
437
9 Sensor assembly & Assembly

1. Install the front sensor.
disassembly (a) Install the sensor from outside in the
Disassembly direction of arrow.
2. Remove the front grid.
3. Remove the front bumper.
4. Disconnect the sensor connector and
remove the bumper completely.
(b) Push the sensor support according to the

diagram.
5. Remove the front sensor
(a) Remove the sensor support according to
the diagram.
2. Connect the connector and install the front

bumper.
3. Install the front grid.
(b) Rotate the sensor in the direction shown in
the diagram and remove the sensor from
outside.
438
Chapter 15 Accessories

2 System overview ................................................................................................................ 442
5 Cigarette lighter assembly & disassembly......................................................................... 458
439
Internal rearview mirror

- Direction display circuit
Cigarette
lighter
440
Siren
Bass electric horn
High tone horn
441
2 System overview
Accessories mainly include the cigarette
lighter, the electrical horns, the siren, the inner
rear view mirror direction display and the
onboard power supply, etc.
442
3 Diagnosis process
Next
Next
Standard voltage:
11 to 14 V
Next
4 Inspect DTC*
Result
Result Proceed to
No DTC is output A
DTC is output B
B Go to step 8
Result
Result Proceed to
443
B Go to step 8
(f) ECU terminals

Next
Next
8 Confirmation test
Next
End
444
4 Fault symptoms table

Fuse
Cigarette lighter
Cigarette lighter doesn't work. Cigarette lighter relay (some with relays OT-446
while some not)
Siren
MCU
The siren does not work. OT-454
BCM
Electric Horn
Only one horn does not work OT-449
Fuse
Horn relay
Horn switch
No electric horns work OT-451
Clock spring
Electric Horn
Horn relay
Horn switch
Horn keeps honking. OT-451
Clock spring
Fuse
Inner rear view mirror doesn't
Internal rearview mirror -
show direction.
Fuse
There is no output of onboard Cigarette lighter relay

-
power supply. Onboard power supply interface
445
Cigarette lighter doesn't work.

Circuit diagram
Indoor light Indoor light
control control Lights, cad module
ACC Power Supply and auxiliary
power supply
Cigarrette lighter
Cigarrette lighter
Cigarette
lighter
relay
Cigarette lighter
Cigarrette lighter
Note: *1-473 *2-476QZA *3-476QZA+DCT
446
1 Inspect fuses
(a) Check whether the cigarette lighter fuses

F2/5(*1, *2) and F4/1(*3) are through by using
of a multimeter.
Normal
(a) Lead wires from the rear end of G2N-12 and

G01-1 and check the voltage of the terminal.
Connection Normal
Test condition
terminal Value
G2N-12-Body ACC power
11~14 V
ground supply
G01-1-Body ACC power
11~14 V
ground supply
Abnormal
Normal
(a) Disconnect the cigarette lighter G22 connector,

turn on the small light and check voltage or
resistance of terminals of wire harness end
connector.
Connection Normal
Wire Color
terminal Value
G22-2-Body
W/R 11~14 V
ground
G22-1-Body Less than
B
ground 1Ω
G22-3-Body
R/B 11-14 V
ground
447
Abnormal
Normal
4 Replace the cigarette lighter
448
Only one horn does not work
Circuit diagram
Battery
Horn, braking light
Internal electric
horn relay
fanfare horn
fanfare horn
Right bass
Left bass
449
1 Examine the electric horn
(a) Remove the electric horn that doesn't work.
(b) Power the two pins of the electric horn with a

battery to check whether the horn honks.

C09-1-battery(+) The electric horn
C09-2-battery(-) honks.
C27-1-battery(+) The electric horn
C27-2-battery(-) honks.
Abnormal
Replace the electric horn that doesn't honk.
Normal
(a) Disconnect engine distributor box C1H

connector and the left bass horn C09
connector.

of the wire harness.
Wire
Color
C1H-7-C09-1 L/R Less than 1 Ω
C1H-8-C27-1 G/R Less than 1 Ω
C08-5-Body ground B Less than 1 Ω
C14-1-Body ground B Less than 1 Ω
Normal
3 Replace engine distributor box
450
No electric horns work
Circuit diagram
Battery
Horn, brake
Clock
spring
Internal horn
relay Horn
switch
Left bass Right bass

fanfare fanfare
horn horn
451
1 Examine the electric horn
(a) Check whether the fuses of the horn and the

braking light F1/14 are through with a
multimeter.
Normal:
The fuse is through.
Normal
2 Examine the horn switch signal
(a) Disconnect the front compartment distributor

box connector B1I.
(b) Check the resistance between B1T-6 terminal
and the body ground.
Connection Normal
Test condition
terminal Value
Less than 1
Horn pressed
B1I-6-Body Ω
ground More than
Horn not pressed
10 kΩ
Abnormal
3 Examine engine distributor box
(a) Lead wires from the rear end of engine

distributor box terminals C1H-7 and C1H-8 and
check the voltage of the two terminals.
Test Normal
Connection terminal
condition Value
C1H-7-Body ground Horn
11~14 V
C1H-8-Body ground pressed
C1H-7-Body ground Horn not Less
452
C1H-8-Body ground pressed than 1 V
Abnormal
Replace engine distributor box
Normal
4 Replace wire harness (front cross bearer wire harness)
453
The siren does not work.
Circuit diagram
Battery
Horn,
braking light
Inner siren
relay
Siren
454
1 Inspect fuses
(c) Check whether the fuses of the horn and the

braking light F1/14 are through with a
multimeter.
Normal:
The fuse is through.
Abnormal
Replace fuse
Normal
2 Inspect siren
(b) Disconnect the siren K20 connector and power

the siren with a battery. Check whether the
siren works.

1-battery(+)
Siren honks.
2-battery(-)
Abnormal Replace siren
Normal
3 Check alarm status
(b) Keep the vehicle in alarm status (e.g.: switch

the vehicle to power OFF, close all doors, the
back door and the front compartment hatch,
lock the car with the electronic intelligent key
and enter anti-burglary status. Then open the
door with the mechanical key and the car
enters alarm status.)
(c) Check whether any steering lamp flickers.
Normal:
There are flickering steering lamps.
Abnormal
455
Normal
4 Inspect CAN communication line
(b) Disconnect the front compartment distributor

box B1I connector and the dashboard
distributor box B2D connector.

Connection Wire
Normal Value
terminal Color
B1I-1-B2D-11 V Less than 1 Ω
B1I-2-B2D-12 P Less than 1 Ω
Abnormal
Normal
5 Examine engine distributor box
(c) Lead the wire from the rear end of engine

distributor box B1I-4 terminal and check the
voltage of the terminal.
Connection Normal
Test condition
terminal Value
B1I-4-Body
In alarm status 11~14 V
ground
B1I-4-Body Not in alarm Less than 1
ground status V
Abnormal
Normal
456
(c) Disconnect the front compartment distributor

box B1I connector and the siren K20 connector.
(d) Check the resistance between each terminal of

Connection
Wire Color Normal Value
terminal
B1I-4-K20-1 Br/Y 11~14 V
K20-2-Body
B Less than 1 V
ground
Abnormal
Normal
7 End
457
5 Cigarette lighter assembly & disassembly

Disassembly
1. Remove the cigarette lighter
(a) Disconnect the connector on the cigarette

lighter.
Assembly
1. Install the cigarette lighter
(a) Place the cigarette lighter in the hole.
(b) Rotate the cigarette lighter housing as

shown in the diagram.
(b) Assemble the cigarette lighter housing

with the cigarette lighter.
(c) Remove the cigarette lighter housing.
(c) Connect the cigarette lighter connector.
(d) Remove the cigarette lighter
458
Intelligent Key, Air Conditioner and Airbag
Content
Chapter 1 Anti-theft system ............................................................................................................ 3

1 Parts location ............................................................................................................ 4
2 System diagram .......................................................................................................... 6
3 System overview ....................................................................................................... 7
4 Diagnosis flow ......................................................................................................... 10
5 Problem symptoms table ........................................................................................ 12
6 ECU terminals ......................................................................................................... 13
7 Removal and installation of siren ............................................................................ 29
Chapter 2 Central locking ............................................................................................................. 30
1 Parts location .......................................................................................................... 31
2 System diagram ...................................................................................................... 33
3 System overview ..................................................................................................... 35
4 Diagnosis flow ......................................................................................................... 36
6 ECU terminals ......................................................................................................... 39
7 Removal and installation of front door lock LH ....................................................... 56
Chapter 3 Intelligent Key System ................................................................................................. 58
1 Parts Location ......................................................................................................... 59
2 System Diagram ..................................................................................................... 61
3 System Overview .................................................................................................... 62
4 Diagnosis Flow ....................................................................................................... 63
5 Trouble Code Table ................................................................................................. 66
6 ECU terminals ......................................................................................................... 68
7 On-vehicle Inspection ............................................................................................. 70
8 Removal and Installation of Start Button ................................................................ 96
9 Removal and Installation of I-Key ECU .................................................................. 97
10 Removal and Installation of High-frequency Reception Module ............................ 98
11 Removal and Installation of Interior Detection Antenna (Rear) .............................. 99
12 Removal and Installation of Exterior Detection Antenna (Front Door LH) ............. 99
Chapter 4 Remote Driving System ............................................................................................. 100
1 Parts Location ....................................................................................................... 101
2 System Diagram ................................................................................................... 103
3 System Overview .................................................................................................. 104
4 Diagnosis Flow ..................................................................................................... 105
5 Problem Symptoms Table ..................................................................................... 107
Chapter 5 Steering Shaft Lock ....................................................................................................114
1 Parts Location ........................................................................................................ 115
2 System Diagram ....................................................................................................116
3 System Overview ...................................................................................................117
1
4 Diagnosis Flow ........................................................................................................ 118

5 Diagnostic trouble code chart ................................................................................ 119
6 Terminal Diagnosis ............................................................................................... 120
7 Overall Diagnosis Flow ......................................................................................... 121
8 Removal and Installation ...................................................................................... 131
Chapter 6 Gateway Controller .................................................................................................... 132
1 Parts Location ....................................................................................................... 133
2 System Diagram ................................................................................................... 134
3 System Overview .................................................................................................. 135
4 Diagnosis Flow ..................................................................................................... 135
7 Removal ................................................................................................................ 151
8 Installation ............................................................................................................. 151
Chapter 7 Air Conditioning System ............................................................................................ 152
1 Parts Location ....................................................................................................... 154
2 System Diagram ................................................................................................... 156
3 System Overview .................................................................................................. 157
4 Diagnosis Flow ..................................................................................................... 161
6 ECU terminals ....................................................................................................... 165
7 On-vehicle Inspection ........................................................................................... 168
8 Removal and Installation of A/C Panel ................................................................. 219
9 Removal and Installation of A/C Case .................................................................. 220
10 Removal and Installation of A/C Compressor ....................................................... 221
11 Removal and Installation of Solar Sensor ............................................................ 221
Chapter 8 SRS System .............................................................................................................. 223
1 Parts Location ....................................................................................................... 224
2 System Overview .................................................................................................. 228
3 Safety Regulations for Repairing Supplemental Restraint System ...................... 231
4 Diagnosis Flow ..................................................................................................... 233
5 Diagnostic Trouble Code Chart ............................................................................ 235
6 Problem Symptoms Chart .................................................................................... 236
7 ECU terminals ....................................................................................................... 237
8 Entire System does not Operate .......................................................................... 240
9 Special Tool ........................................................................................................... 299
Chapter 9 Electrical Schematic Diagram ................................................................................... 305
Section 1 Instruction for Repair Manual .............................................................................. 306
Section 2 Electrical Equipment Layout ............................................................................... 307
Section 3 Relay and Fuse Layout ....................................................................................... 310
Section 4 Low Voltage Wire Harness Layout ...................................................................... 329
Section 5 Complete Vehicle Ground Position Layout ......................................................... 374
Section 6 Electrical Schematic Diagram ............................................................................. 381
2
Chapter 1
Anti-theft system
Content
1 Parts location ............................................................................................................ 4
2 System diagram .......................................................................................................... 6
3 System overview ....................................................................................................... 7
4 Diagnosis flow ......................................................................................................... 10
6 ECU terminals ......................................................................................................... 13
7 Removal and installation of siren ............................................................................ 29
3
1 Parts location
Instrument panel
distribution box
4
Trunk lid switch
Siren
Front
compartment
distribution
box
5
2 System diagram
Front door lock LH Trunk light switch (trunk

signal lid lock inspection)
Front door lock RH

signal Anti-theft indicator
Front door latch RH

Start button
detection
Rear door lock LH Front window switch LH

signal
Front door latch LH
detection
Rear door latch LH
detection
Engine hood switch
Rear door lock RH
signal MCU
Anti-theft siren
Rear door latch RH
detection
Meter
6
3 System overview - The alarm function is not operating
3.1 Anti-theft system overview - The anti-theft system is not operating
3.1.1 When the vehicle is in the armed  Arming preparation state

state, any attempt to forcibly enter the
vehicle, to reconnect the battery terminals - The preparation state before the system
disconnected or to open any door, engine goes into the armed state
hood or trunk lid without the key, will cause
the horn and anti-theft siren of the vehicle to - The anti-theft system is not operating
sound and the hazard warning indicator to
flash as an alarm.  Armed state
3.1.2 The anti-theft system has 4 states: - The anti-theft system is operating
disarmed state, arming preparation state,
armed state and alarm state.  Alarm state
 Disarmed state – Alarm system is operating
Alarm methods and duration:
Blinking
Theft warning indicator blinks
Frequency: 30 times/min
Blinking
Frequency: 85 times/min
Alarm methods Hazard warning indicator blinks Continues for 25 seconds and
5-second pause, in this cycle for 25
seconds
Sounding
Anti-theft siren sounds
Frequency: 150~200 times/min
Alarm duration Approximately 300 seconds
3.2 State switching conditions
Tips:
After locking doors, the system enters the

arming preparation state immediately.
The state switching conditions are as follows:
7
Disarmed state
Condition Condition
3 1
Arming preparation state
Condition
2
Condition 5 Armed state
Condition
4
Condition 6
Alarm state
8
Condition Event
In the disarmed state with all doors closed, the arming preparation
state can be entered by performing the following operations:
 Lock by wireless operation
 Lock by sensitive switch
Condition 1 (arming  Automatic lock
preparation state  When the engine hood or trunk lid is not closed, lock them by
entered) wireless operation or sensitive switch and then both of them are
detected to be closed.
 When the trunk lid is opened by wireless operation or sensitive
switch in rear end of the vehicle, the vehicle turn from armed state
to disarmed state, and the trunk lid is detected to be closed
After entering the arming preparation state, the anti-theft indicator will
Condition 2 (armed
be turned on and last for 10 seconds, and after that the armed state
state entered)
will be entered with the anti-theft indicator blinking.
In the arming preparation state, perform the following operations to
cancel;
 Open any door
Condition 3 (arming  Open any door latch
preparation state  Open the engine hood or trunk lid
canceled)  Press the start button and detect the key in the vehicle
 Open the trunk lid by wireless operation
Tips: After canceling the arming preparation state, the anti-theft
indicator will be turned off
In the armed state, an alarm will be triggered (turn light flashes,
frequency: 85 times/min, continues for 25 seconds, 5-second pause,
in this cycle for 10 times)if the following signals are detected;
 Any door is open(except when the door is opened by wireless
Condition 4 (alarm
operation or sensitive switch)
cycled)
 Open any door latch
 Open the engine hood or trunk lid
 IG1 voltage is detected
 Reconnect the battery after it is disconnected
In the armed state, perform the following operations to cancel:
 Unlock by wireless operation or sensitive switch
Condition 5 (armed  Press the start button and detect the key in the vehicle
state canceled)  Open the trunk lid by wireless operation
Tips: The anti-theft indicator will be turned off after canceling the
armed state; and the vehicle turned to the disarmed state
In the alarm state, perform the following operations to cancel:
Condition 6 (alarm  Open a lock by wireless operation/sensitive switch
state canceled)  Press the start button. And detect the key in the vehicle
 Open the trunk lid by wireless operation
9
4 Diagnosis flow
Next
Next
Standard voltage:
11 to 14 V
Next
4 Inspect DTC*
Result
Result Proceed to
No DTC is output A
DTC is output B
B Go to step 8
5 Problem symptoms table
Result
Result Proceed to
B Go to step 8
10
ECU terminals
Next
Next
9 Confirmation test
Next
End
11

Symptom Suspected area See page
BCM power source
Door lock signal
Latch button switch
Arming preparation state can not be
Trunk lid switch TD-15
entered
Engine hood switch
BCM
CAN communication line
Armed state can be entered but no alarm
sounds when any door(including the
BCM -
engine hood and trunk lid) is forcibly
opened
Siren
BCM
Siren does not sound while anti-theft
MCU TD-26
system is in warning operation
Each door latch
Armed state can be entered when any
door (including the engine hood and trunk Engine hood switch TD-19
lid) is open
Trunk lid switch
BCM
Warning light (turn light) does not operate Turn light relay
while anti-theft system is in warning TD-23
operation Turn light
12
6 ECU terminals
a Inspect dashboard distributor box
Disconnect the dashboard distributor box

connector G2Q, G2P, G2T and the left floor butt
joint connector LH K2E, K2H.
Measure the wire harness side signals.
Wire Terminal
Terminal No. Condition Normal value
color description
Front door lock RH locked More than 10 kΩ

Front door latch RH
G2Q-14 Br/W Front door lock RH
position detection Less than 1 V
unlocked
Rear door lock LH locked More than 10 kΩ

Rear door lock LH
G2P-3 W Rear door lock LH
detection Less than 1 V
unlocked
13
Rear door lock RH locked More than 10 kΩ

Rear door lock RH
G2P-2 B/R Rear door lock RH
detection Less than 1 V
unlocked
Front door lock LH
K2E-13 G Less than 1 V
signal Front door LH closed
Rear door lock LH
K2E-14 G/Y Less than 1 V
signal Rear door LH closed
Front door lock RH
K2H-14 Lg/R Less than 1 V
signal Front door RH closed
Rear door lock RH
K2H-8 G/W Less than 1 V
signal Rear door RH closed
G2T-5 V B-CAN Always Approx. 2.5 V
G2T-6 P B-CAN Always Approx. 2.5 V
K2E-5 - Module ground Always Less than 1 V
B
Body ground
G2P-8 - Module ground Always
B Less than 1 V
Body ground
b Inspect front window switch LH
(a) Wire the rear end of the terminal T03-4 of

front window switch LH, and measure this
terminal’s voltage.
Terminal No. Wire color Terminal description Condition Normal Value

Front door latch LH Front door LH
T03-4 W Less than 1 V
position detection unlocked
14
Arming preparation state can not be entered
Circuit diagram
Front window switch LH
Engine
Left front hood
door lock switch
motor (closed:
engine
hood
open)
Rear door Rear door lock

lock motor motor RH
RH Front door
locks
motor RH
Trunk lid Trunk
light
open motor switch
(closed:
trunk
lid open,
light on)
Front door Rear door lock Front door Front door

locks motor motor LH locks motor locks motor
LH RH RH
15
Inspection procedures
1 Inspect if each door lock can be locked
(a) Operate the intelligent key or central locking

main switch to see if each door lock can be
locked normally
NG Refer to "Central lock"
OK
2 Inspect if each door is closed
(a) Inspect if each door (including engine hood,

trunk lid) is closed.
NG Close each door
OK
3 Inspect button switch latch of each door

main switch to unlock/lock each door lock
(b) Inspect if the lock position feedback of each

door lock is correct
Front door latch LH
Normal
Terminal Test condition
value
T03-4 - Body Front door lock Less than 1
ground LH unlocked Ω
T03-4 - Body Front door lock More than
ground LH locked 10 kΩ
Rear door latch LH
Normal
value
G2P-3 - Body Rear door lock Less than 1
ground LH unlocked Ω
G2P-3 - Body Rear door lock More than
16
Front door latch RH
Normal
value
G2Q-14 - Body Front door lock Less than 1
ground RH unlocked Ω
G2Q-14 - Body Front door lock More than
ground RH locked 10 kΩ
Rear door latch RH
Normal
value
NG
Replace the corresponding latch
OK
4 Inspect engine hood switch and trunk lid switch
(a) Inspect the operation of engine hood switch

and trunk lid switch
Engine hood switch
Normal
value
C1H-2 - Body Engine hood Less than
ground open 1Ω
C1H-2 - Body Engine hood More than
ground closed 10 kΩ
Trunk lid switch
Normal
value
G2P-20 - Body Less than 1
Trunk lid open
ground Ω
G2P-20 - Body Trunk lid More than
17
NG
Replace the corresponding switch
OK
5 Inspect CAN line
(a) Disconnect the front window switch LH and

MCU connector.
(b) Measure the voltage of CAN line.
Wire
Terminal Normal value
color
T03-17 - Body ground V Approx. 2.5 V
T03-18 - Body ground P Approx. 2.5 V
B1I-1 - Body ground V Approx. 2.5 V
B1I-2 - Body ground P Approx. 2.5 V
NG Replace CAN line
OK
6 Replace BCM
18
Armed state can be entered when any door (including the

engine hood and trunk lid) is open
Circuit diagram
Front window switch LH
Front door Engine hood switch

locks motor (closed: engine hood
LH open)
Rear door lock

motor LH Rear door lock
motor RH
Trunk lid open Trunk Front door

motor light locks motor
switch RH
(closed:
trunk lid
open,
light on)
Front door Rear door l Front door Rear door lock

locks motor ock motor locks motor motor RH
LH LH RH
19
1 Inspect button switch latch of each door

main switch to unlock/lock each door lock
(b) Inspect if the lock position feedback of each

door lock is correct
Front door latch LH
Normal
value
T03-4 - Body Front door lock Less than
ground LH unlocked 1Ω
T03-4 - Body Front door lock More than
Rear door latch LH
Normal
value
G2P-3 - Body Rear door lock Less than
ground LH unlocked 1Ω
Front door latch RH
Normal
value
G2Q-14 - Front door lock Less than 1
Body ground RH unlocked Ω
G2Q-14 - Front door lock More than
Body ground RH locked 10 kΩ
Rear door latch RH
Normal
value
20
NG
Replace the corresponding latch
OK
2 Inspect engine hood switch and trunk lid switch
(a) Inspect the operation of engine hood switch

and trunk lid switch
Engine hood switch
Normal
value
C1H-2 - Body Engine hood Less than 1
ground open Ω
C1H-2 - Body Engine hood More than
Trunk lid switch
Normal
value
G2P-20 - Less than 1
Trunk lid open
Body ground Ω
G2P-20 - More than
Trunk lid closed
Body ground 10 kΩ
NG
Replace the corresponding switch
OK
21
3 Inspect CAN line
(a) Disconnect the front window switch LH

connector T03 and MCU connector B1I.
(b) Measure the voltage of CAN line.
Wire Normal
Terminal
color value
T03-17 - Body Approx. 2.5
V
ground V
T03-18 - Body Approx. 2.5
P
ground V
Approx. 2.5
B1I-1 - Body ground V
V
Approx. 2.5
B1I-2 - Body ground P
V
NG Replace CAN line
OK
4 Replace BCM
22
Warning light (turn light) does not operate while anti-theft

system is in warning operation
Circuit diagram
Battery
Right turn Turn/warning light

signal
Flasher
contact
Emerge
ncy
warning
switch
Turn light
relay RH
Turn light
RH
Engine
distribut
or box
Rear turns
light RH
Front turn
light RH
Multiplex Multiplex
integration integration
control control
Combination meter module module
23
4 Inspect turn light
(a) Press down emergency warning light switch or

place the combination switch to turn position
(ON), and observe if the turn light operates
normally
NG Refer to "Lighting system"
OK
5 Inspect if turn light relay operates normally
(a) Perform lock/unlock operation with the

intelligent key or card key, and observe if the
turn light operates normally
OK Go to step 6
NG
6 Inspect power supply of turn light relay
(a) Disconnect connector G37, and measure the

Normal
Terminal Wire color
value
G37-6 - Body ground W/B 11-14 V
OK
24
7 Inspect turn light relay
(a) Remove relay KG-6 and KG-5 from the relay

block, and inspect the operation of the relays.
Terminal Normal condition
1 - Battery positive
3, 5 Continuity
1, 2 Continuity
Battery disconnected
3, 5 No continuity
NG Replace turn light relay
OK
8 Inspect wire harness (BCM - turn light, turn relay - turn light)
(a) Disconnect the connector G2Q, G37, G2N and

GJ10
(b) Measure the resistance of the wire harness
Terminal Wire color Normal Value

G2Q-4 - G37-10 W/G Less than 1 Ω
G2Q-4 - G37-5 W/G Less than 1 Ω
G37-7 - G2N-40 R/L Less than 1 Ω
G37-2 - G2N-26 Br Less than 1 Ω
G37-2 - GJ10-5 Br Less than 1 Ω
OK
9 Replace BCM
25
Siren does not sound while anti-theft system is in warning

operation
Circuit diagram
Battery
Horn
braking
light
Inner
siren
relay
Siren
26
1 Inspect turn light
(a) Using a multimeter, inspect the continuity of the

engine distributor box fuse F1/14
NG Replace fuse
OK
2 Inspect siren
(a) Disconnect the siren connector K20
(b) Apply 12 V to the 2 terminals of the siren, and

observe if the siren sounds
NG Replace siren
OK
3 Inspect wire harness (relay - siren)
(a) Measure the resistance of the wire harness
Wire Normal
Terminal Condition
color value
Less
K20-1 - B1I-4 Br/Y Always
than 1 Ω
K20-2 - Body Less
B Always
ground than 1 Ω
OK
4 Inspect siren relay
(a) Inspect the operation of the relay

1 - Battery positive 3, 4 Continuity
2 - Battery negative 3, 5 No continuity
Battery disconnected 3, 4 No continuity
27
3, 5 Continuity
NG Replace relay
OK
5 Inspect relay socket
(a) Remove the siren relay and inspect if the

voltage of the relay socket (corresponding with
relay 1# pin) is 11-14 V
NG
OK
6 Inspect CAN line
(a) Disconnect the connector and inspect the

voltage of the CAN line
Wire Normal
Terminal
color condition
B1I-1 - Body ground V Approx. 2.5 V
B1I-2 - Body ground P Approx. 2.5 V
NG Replace CAN line
OK
7 Replace engine distributor box
28
7 Removal and installation of siren
Removal
7.1 Turn power switch to OFF Installation
7.2 Disconnect battery negative
7.3 Remove siren 1 Install siren
(a) Remove the trunk garnish inner LH (a) Connect the siren connector
(b) Disconnect the siren connector (b) Install the siren to the fixing position
(c) Using the 10# wrench, remove 2 set nuts (c) Install 2 set bolts with a wrench.
(d) Remove the siren from the sheet metal 2 Install trunk inner garnish LH
29
Chapter 2 Central locking
Contents
1 Parts location .......................................................................................................... 31
2 System diagram ...................................................................................................... 33
3 System overview ..................................................................................................... 35
4 Diagnosis flow ......................................................................................................... 36
6 ECU terminals ......................................................................................................... 39
7 Removal and installation of front door lock LH ....................................................... 56
30
1 Parts location
Rear door lock

assembly RH
Trunk lid lock

Front door assembly
locks
assembly RH
Front door window

lifter switch block RH
- Front door central
locking switch RH
Rear door lock

assembly LH
Front door locks

assembly LH
Front door window
lifter switch block LH
- Front door central
locking switch LH
31
Instrument panel
distribution box
32
2 System diagram
Front door lock LH signal
Front door lock RH

signal
Rear door lock LH signal
Rear door lock RH signal
Trunk light switch
Front door locks motor

LH
-- Door lock motor

RH
-- Door lock motor
-- Door lock position
switch
CAN line
33
Rear door lock motor

LH
-- Door lock motor
switch
Rear door lock motor

RH
-- Door lock motor
switch
Trunk lid lock motor

-- Door lock motor
switch

LH
switch
Front window control switch

LH
CAN line
34
3 System overview
The central locking system is a system to control the
unlock/lock operation of the power door locks by
BCM (the body control module), and it has 3 types
of operation methods as follow:
3.1 Press down the door lock main switch on the

front window lifter switch block LH or central
locking switch on the front door RH, and an
unlock/lock signal will be sent to the BCM. BCM
receive and process the switch signal, and then
drive the corresponding door lock motor to
perform the unlock/lock operation.
3.2 Open/lock a door with the mechanical key, and

an unlock/lock signal will be sent to the BCM by
the key cylinder switch. BCM receive and
process the switch signal, and then drive the
relevant door lock motor to perform the
unlock/lock operation.
3.3 Open/lock a door with the wireless key, and an

unlock/lock signal will be sent to the BCM by the
I-key ECU. BCM receive the signal and then
drive the corresponding door lock motor to
perform the unlock/lock operation.
35
4 Diagnosis flow
Next
Next
Standard voltage:
11 to 14 V
Next battery before going to the next step.
4 Inspect DTC*
Result
Result Proceed to
No DTC is output A
DTC is output B
B Go to step 8
Result
Result Proceed to
B Go to step 8
36
ECU terminals
Next
Next
8 Confirmation test
Next
End
37
Symptom Suspected area See page

Door locks cannot be BCM
unlocked/locked by neither wireless DL-11
key nor central locking main switch CAN communication
Front window control switch LH

Door locks cannot be
unlocked/locked by central locking CAN communication DL-13
main switch only
Gateway controller
Front door lock LH
Only front door LH cannot be
BCM DL-15
unlocked/locked
Front door lock motor RH
Only front door RH cannot be
BCM DL-49
unlocked/locked
Rear door lock motor LH
Only rear door LH cannot be
BCM DL-51
unlocked/locked
Rear door lock motor RH
BCM
Only rear door RH cannot be
Wire harness or connector DL-53
unlocked/locked
BCM
38
6 ECU terminals
1. Inspect dashboard distributor box
(d) Wire the rear end of the dashboard

distributor box.
(e) Measure the voltage or resistance of each

terminal.
Wire
Terminal No. Terminal Description Condition Normal value
color
G2P-2 - Body Rear door latch RH
B/R Rear door RH locked Less than 1 V
ground position
G2P-3 - Body Rear door latch LH
W Rear door LH locked Less than 1 V
ground position
G2Q-14 - Body Br/W Front door latch RH Front door lock RH Less than 1 V
39
ground position
G2P-20 - Body
L/B Trunk light switch Trunk lid open Less than 1 V
ground
G2N-7 - Body Front door latch RH Front door RH
Y/B 11-14 V
ground lock power supply locked
Front door latch RH
G2N-8 - Body Front door RH
Y unlocked power 11-14 V
ground unlocked
supply
Wire
Terminal No. Terminal description Condition Normal value
color
K2H-4 - Body Rear door latch RH lock Rear door RH
Y/B 11-14 V
ground power supply locked
K2H-11 - Body Rear door latch RH Rear door RH
Y/R 11-14 V
ground unlock power supply unlocked
K2E-1 - Body Rear door latch LH lock Rear door LH
Y/B 11-14 V
ground power supply locked
K2E-8 - Body Rear door latch LH Rear door LH
Y 11-14 V
ground unlock power supply unlocked
Wire Normal
Terminal No. Terminal description Condition
color value
T2K-2 - Body Front door latch LH
Y/G Front door LH unlocked 11-14 V
ground unlocked power supply
T2K-8 - Body Front door latch LH lock
Y/B Front door LH lock 11-14 V
ground power supply
40
Door locks cannot be unlocked/locked by neither wireless key

nor central locking main switch
Circuit diagram
Gateway controller
Front window control

switch LH
41
1 Inspect CAN communication
(a) Disconnect battery negative.
(b) Disconnect the BCM connector G2T.

between the terminals of the wire harness.
Terminal Normal
G2T-5 - G2T-6 56-64 Ω
(d) Measure the wire harness side voltage.
Normal
Terminal Wire color
condition
G2T-5 - Body
V Approx. 2.5 V
ground
G2T-6 - Body
P Approx. 2.5 V
ground
NG Replace CAN line
OK
2 Replace BCM
42
Door locks cannot be unlocked/locked by central locking main

switch only
Circuit diagram
Gateway controller
Front window
control switch LH
43
1 Inspect front door lock main switch LH
(a) Connect the diagnostic tester to the DLC3.
(b) Clear the trouble codes.
(c) Read the trouble codes of the door multiplex

controller.
DTC Meaning
Key cylinder switch malfunction
B2240-00
of driver side door lock
Main switch malfunction of driver
B2241-00
side door lock
Button switch malfunction of
B2242-00
driver side door lock
NG
Replace front window control switch LH

OK
2 Inspect CAN communication of front window control switch LH
(a) Disconnect the front window control switch LH

connector T03.

between the terminals of the wire harness.
Terminal Normal
T03-17 - T03-18 56-64 Ω
(c) Measure the wire harness side voltage.
Terminal Wire color Normal condition

T03-17 - Body
V Approx. 2.5 V
ground
T03-18 - Body
P Approx. 2.5 V
ground
NG Replace CAN line

Normal
3 Replace front window control switch LH
44
Only front door LH cannot be unlocked/locked

Circuit diagram
Gateway controller
Front window control switch LH
Front door latch

Front door locks
LH position
motor LH
45
1 Inspect front door latch LH
(a) Disconnect the front door latch LH connector

T01.
(b) Apply voltage between the 2 terminals of the

motor, and inspect the operation of the motor.
Terminal Normal
Battery positive - T01-4 Door lock motor
Battery negative - T01-3 locked
Battery positive - T01-3 Door lock motor
Battery negative - T01-4 unlocked
NG
Replace front door lock assembly LH
OK
2 Inspect front door latch LH position detection

T01.
(b) Measure the resistance between terminal 1 and

2.
Normal
Terminal Condition
condition
T01-2 - Front door lock More than 10
T01-1 LH locked kΩ
T01-1 - Front door lock
Less than 1 Ω
T01-2 LH unlocked
NG
Replace front door latch assembly LH
OK
46
3 Inspect wire harness (front door latch LH - BCM)
Disconnect the BCM connector T2K.
Disconnect the front door lock LH connector T01.
Measure the resistance between terminals of wire

harness side.

T2K-8 -
Y/B Less than 1 Ω
T01-4
T2K-2 -
Y/G Less than 1 Ω
T01-3
OK
4 Inspect wire harness (front door latch LH - front window control switch LH)
(a) Disconnect the front window control switch LH

connector T03.
(b) Disconnect the latch connector T01 of front

door lock LH.

wire harness side.

T03-4 -
W Less than 1 Ω
T01-1
T03-9 -
B Less than 1 Ω
T01-2
OK
47
5 Inspect wire harness (front door latch LH ground wire)

T01.
(b) Measure the voltage between the terminals.

T01-2 -
Body B Less than 1 V
ground
OK
6 Replace BCM
48
Only front door RH cannot be unlocked/locked

Circuit diagram
Front door
locks motor
RH
49
1 Inspect front door lock motor RH
(a) Disconnect the front door lock motor RH

connector U02.
(b) Inspect the operation of the motor.
Terminal Normal
Battery positive - U02-3 Door lock motor
Battery negative - U02-4 locked
Battery positive - U02-4 Door lock motor
Battery negative - U02-3 unlocked
NG
Replace front door lock motor assembly RH
OK
2 Inspect wire harness (front door lock motor RH - BCM)
(a) Disconnect the BCM connector G2N.
(b) Disconnect the front door lock RH connector

U02.
(c) Measure the resistance between the terminals.
Wire
color
G2N-7 - U02-3 Y/B Less than 1 Ω
G2N-8 - U02-4 Y Less than 1 Ω
OK
3 Replace BCM
50
Only rear door LH cannot be unlocked/locked

Circuit diagram
Rear door
lock motor
LH
51
4 Inspect rear door lock motor LH
(a) Disconnect the rear door lock motor LH

connector V05.
Terminal Normal
Battery positive - V05-4
Door latch locked
Battery negative - V05-3
Battery positive - V05-3
Door latch unlocked
Battery negative - V05-4
NG
Replace rear door lock motor LH
OK
5 Inspect wire harness (rear door latch LH - BCM)
(a) Disconnect the BCM connector K2E.
(b) Disconnect the rear door lock LH connector

V05.

K2E-1 -
Y/B Less than 1 Ω
V05-4
K2E-8 -
Y Less than 1 Ω
V05-3
OK
6 Replace BCM
52
Only rear door RH cannot be unlocked/locked
Circuit diagram
Rear door
lock motor
LH
53
1 Inspect rear door lock motor RH
(a) Disconnect the rear door lock motor RH

connector W02.
Terminal Normal
Battery positive - W02-3
Door latch locked
Battery negative - W02-4
Battery positive - W02-4 Door latch
Battery negative - W02-3 unlocked
NG
Replace rear door lock motor RH
OK
2 Inspect wire harness (rear door lock motor RH - BCM)
(a) Disconnect the BCM connector K2H.
(b) Disconnect the rear door lock motor RH

connector W02.

K2H-4 -
Y/B Less than 1 Ω
W02-3
K2H-11 -
Y/R Less than 1 Ω
W02-4
OK
3 Replace BCM
54
Arming preparation state cannot be entered after locking

Description
After locking, the arming preparation state cannot be entered if the trunk lid or engine hood is not
closed, and also if the latch locks signals of the door locks are not detected by the BCM.
For details, refer to anti-theft system
55
7 Removal and installation of front door lock LH
Removal
1. Disconnect battery negative
2. Remove door inner shield
3. Remove window lifter assembly

(refer to power window)
4. Remove key cylinder

6 Remove door lock assembly
a Open the key cylinder set screw cover.
a Remove 2 set screws inside the door
b Loosen the set screw with a cross handle with a cross screwdriver.
screwdriver.
b Remove 3 fixing points of the door lock

assembly with an Allen wrench.
c Take out the key cylinder of the door lock.
c Disconnect the snap-fit connection and
take down the door lock assembly.
Installation
1 Install door lock assembly
a Place the door lock to the installation

position, and align it with the installation
point.
5 Remove door handle
b Install the 3 set screws with an Allen
a Push the door handle in the direction wrench.
shown in the figure and take it down.
56
c Fix the door handle. 4 Install window lifter assembly.
5 Install door inner shield.
6 Connect battery negative.
Removal and installation of

central locking main switch
Central locking main switch is integrated into
the front door window lifter switch LH. Refer
to the removal and installation of front door
2 Install door handle. window lifter switch LH.
a Place the door handle in the installation

hole, and firmly push the door handle to
the installation position in the direction
shown in the figure.
b Fix the door handle.
3 Install key cylinder
a Align the key cylinder with the flat groove

inside the door lock and insert it.
b Fix the mounting screws with an Allen

wrench.
57
Chapter 3
Intelligent Key System
Contents
1 Parts Location ......................................................................................................... 59
2 System Diagram ..................................................................................................... 61
3 System Overview .................................................................................................... 62
4 Diagnosis Flow ....................................................................................................... 63
5 Trouble Code Table ................................................................................................. 66
6 ECU terminals ......................................................................................................... 68
7 On-vehicle Inspection ............................................................................................. 70
8 Removal and Installation of Start Button ................................................................ 96
9 Removal and Installation of I-Key ECU .................................................................. 97
10 Removal and Installation of High-frequency Reception Module ............................ 98
11 Removal and Installation of Interior Detection Antenna (Rear) .............................. 99
12 Removal and Installation of Exterior Detection Antenna (Front Door LH) ............. 99
58
1 Parts Location
Steering
shaft lock Start button
59
Interior detection
antenna (rear)
High-frequency
reception
module
Intelligent key Interior

system controller detection
antenna
(luggage
compartment)
Interior detection
antenna (middle)
Interior detection
antenna (front)
60
2 System Diagram
Intelligent key
High-frequency Detection antenna

reception module
Start button (card Sensitive switch

reader)
Steering Gateway
shaft lock
Unlock driver
Start button
Braking light switch

Door lock motor
Clutch pedal switch
61
3 System Overview
For controlling the door lock, apart from a Note:
traditional mechanical key and an electronic
intelligent key, the vehicle is also equipped a Do not leave the key at hot places.
with an electronic intelligent key system. When
carrying the electronic intelligent key, the b Do not hit the key with hard objects. Do
driver can open a door, unlock the steering not throw it or let it fall to hard ground.
shaft lock, and start the engine, etc. without
doing anything (like pressing a button, etc.) to c Keep the key far away from magnetic
the vehicle's key. fields.
The whole system is controlled by a Body d With doors locked and armed state
Control Module (BCM). When the on-board activated, please keep the key far away
antenna detects the key within a certain from the vehicle if the vehicle is not used,
detection range, it will validate the key and because the vehicle's card auto-search
send operation signals to related ECUs for function will consume battery power.
respective actions, to finish the work of whole
system. e The electronic intelligent key system may
fail in the following conditions
The detection system, composed of 6
detection antenna assemblies (4 in the vehicle, f The key battery is low.
2 out of the vehicle) and a high-frequency
reception module, is used to detect keys within g There is strong magnetic fields or electric
the effective range in the vehicle and a certain fields (such as a TV tower) near the
range outside the vehicle. detection system.
h They key is covered with a metal object.
i The key is placed together with cell

phones.
j The electronic intelligent key system of

another vehicle nearby is also operating
at the same time.
k If the key cannot be detected even it is

within the detection range; please bring
the key close to the magnetic card
antenna.
62
4 Diagnosis Flow
Next
Next
Standard voltage:
11 to 14 V
Next
4 Inspect DTC*
Result
Result Proceed to
No DTC is output A
DTC is output B
B Go to step 8
Result
Result Proceed to
B Go to step 8
63
ECU terminals (see page IK-10)

Next
Next
8 Confirmation test
Next
End
64
Problem Symptoms Table

Electronic intelligent key
All remote control functions of electronic High-frequency receiver
intelligent key do not operate (with the valid
I-key ECU
key in possession and within the remote
control range) BCM
Front door handle sensitive switch LH
Remote control functions are normal but the
front door sensitive switch LH does not Front door handle detection antenna LH
respond when operated (with the valid key in I-key ECU
possession and within the detection range)
Front door handle sensitive switch RH
front door sensitive switch RH does not Front door handle detection antenna RH
respond when operated (with the valid key in I-key ECU
possession and within the detection range)
Rear sensitive switch
rear sensitive switch does not respond when Rear detection antenna
operated (with the valid key in possession and I-key ECU
within the detection range)
Interior detection antennas (front, middle and
Interior detection antennas do not recognize rear)
the key (with the valid key in possession and
I-key ECU
within the detection range)
Start button
Start button does not operate properly in
Intelligent key
power-off mode
65
5 Trouble Code Table

DTC Malfunction Description Trouble Area
Malfunction of intelligent key
B2270-00 I-key ECU
system controller
Detection antenna loop Front door handle detection antenna LH
malfunction of front door handle
B2271-00 I-key ECU
LH
Front door handle detection antenna RH
Detection antenna loop
B2272-00 malfunction of front door handle I-key ECU
RH
Front door handle sensitive switch LH
Normal close malfunction of
B2274-00 front door handle sensitive I-key ECU
switch LH
Front door handle sensitive switch RH
B2275-00 front door handle sensitive I-key ECU
switch RH
Rear detection antenna
Trunk (rear detection) antenna
B2276-00 I-key ECU
malfunction (reserved)
Rear sensitive switch
B2277-00 trunk (rear detection) sensitive I-key ECU
switch (reserved)
Card reader (start button)
B2278-00 Start button
malfunction
Interior detection antenna (front)
Loop malfunction of front interior
B227C-00 I-key ECU
detection antenna
Module malfunction of
B227A-00 High-frequency receiver
high-frequency receiver
Password for steering shaft lock
B227B-00 Steering shaft lock
unmatched
Interior detection antenna (middle)
Loop malfunction of middle I-key ECU
B227D-00
interior detection antenna
Loop malfunction of rear interior Interior detection antenna (rear)

B227E-00
detection antenna I-key ECU
66

B227F-00 No.1 key malfunction No.1 key
B2280-00 No.2 key malfunction No.2 key
B2281-00 No.3 key malfunction No.3 key
67
6 ECU terminals
6.1 Inspect I-key ECU
6.1.1 Wire the rear end of the I-key ECU G49

connector.
6.1.2 Measure the resistance or voltage between
each terminal of the connector.
Terminal No. Wire Color Terminal Description Condition Normal Value

G49-1 - G49-9 R-B Battery positive Always 11 ~ 14 V
Power supply for start
G49-2 - G49-9 Br/B-B ---- ----
button
Date input with start button
G49-3 - G49-8 Br/W-Sb ---- ----
in power-off mode
Interior key detection
G49-4 - G49-14 W-O ---- ----
antenna (middle)
G49-5 - G49-15 Gr-G/Y ---- ----
antenna (rear)
Exterior key detection
G49-6 - G49-17 V/W-L/Y ---- ----
antenna (front door RH)
Clock output with start
G49-7 - G49-8 Br/Y-Sb ---- ----
button in power-off mode
G49-8 - Body Signal ground for start
Sb Always Less than 1 Ω
ground button
G49-9 - Body
B Body ground Always Less than 1 Ω
ground
G49-10 - Body
B Body ground Always Less than 1 Ω
ground
Exterior key detection
G49-11 - G49-16 L/W-V/B ---- ----
antenna (front door LH)
Power supply for
G49-12 - G49-9 G-B high-frequency reception
module of key
G49-13 - G49-18 Y-L ---- ----
antenna (front)
G49-19 - G49-20 Y/L-R Rear key detection ---- ----
68
antenna
G49-21 ---- N/A ---- ----
G49-22 ---- N/A ---- ----
(a) Wire the rear end of the I-key ECU G50

connector.
(b) Measure the resistance or voltage between

each terminal of the connector.
Wire
Color
Front door
Door handle switch
G50-1 - G50-8 G/W-R/G sensitive switch Less than 1 Ω
(front door LH)
LH pressed
Front door
Door handle switch
G50-2 - G50-9 R/W-G/R sensitive switch Less than 1 Ω
(front door RH)
RH pressed
Rear sensitive
G50-3 - G50-10 R-Gr Rear sensitive switch Less than 1 Ω
switch pressed
G50-4 ---- N/A ---- ----
High-frequency data
G50-5 - G50-7 G/L-Sb ---- ----
signal
G50-6 - Body
V CAN_L Always Approx. 2.5 V
ground
G50-12 - Body
P CAN_H Always Approx. 2.5 V
ground
Signal ground for
G50-7 - Body high-frequency
Sb Always Less than 1 Ω
ground reception module of
key
High-frequency signal
G50-11 - G50-7 L/W-Sb ---- ----
monitor
69
1 Inspect central locking
(a) Perform the unlock or lock operation with a

mechanical key or central locking switch.
(b) Inspect if the operation is normal.
NG
Proceed to central locking system
OK
2 Inspect key
(a) Operate the system with a card key and

electronic intelligent key respectively, and
inspect if the system operation is ok.
OK:
The system operation can be ok with one
of the keys.
OK The key is damaged.
NG
3 Inspect if there are magnetic fields nearby.
(a) Bring the key close to door outside detection

antenna (0.7-1.0 m). Pay attention to the height
and direction of the key so as to align it with the
detection antenna.
(b) Operate the key or sensitive switch, and

inspect the operation of the system.
Measurement Proceed to
Operates normally A
Operate abnormally B
There is magnetic field interference nearby.
4 Refer to the problem symptoms table for diagnosis
70
DTC B2270-00 Intelligent key controller malfunction
1 Replace intelligent key controller
Detection antenna loop malfunction

DTC B2271-00
of front door handle LH
Schematic Diagram
Detection antenna of exterior magnetic

card - Front door LH
71
(a) Disconnect the front door handle LH TJ02

connector.
(b) Disconnect the I-key ECU G49 connector.

connector.
Normal
Terminal Wire Color
Condition
G49-11 -
L/W Less than 1 Ω
TJ02-1
G49-16 -
V/B Less than 1 Ω
TJ02-2
NG
OK
2 Inspect detection antenna
(a) Temporarily replace a front door handle LH

(with detection antenna and sensitive switch).
(b) Bring the key close to the detection antenna,

and press down the front door sensitive switch
LH.
(c) Inspect if the unlock/lock operation is working.
OK:
The unlock/lock operation is working
NG Replace me-key ECU
OK
3 Replace front door handle LH (with detection antenna and sensitive switch)
72
Detection antenna loop malfunction

DTC B2272-00
of front door handle RH
Schematic Diagram
Detection antenna of exterior magnetic card - Front door RH
73
(a) Disconnect the front door handle RH UJ03

connector.

connector.
Normal
Terminal Wire Color
Condition
G49-6 - UJ03-2 V/W Less than 1 Ω
G49-17 -
L/Y Less than 1 Ω
UJ03-1
NG
OK
(a) Temporarily replace a front door handle RH

(with detection antenna and sensitive switch).

and press down the front door sensitive switch
RH.
OK:
NG Replace I-key ECU
OK
3 Replace front door handle RH (with detection antenna and sensitive switch)
74
Normal close malfunction of front

DTC B2274-00
door handle sensitive switch LH
Schematic Diagram
Front
door
sensitiv
e switch
LH
75
1 Inspect front door sensitive switch LH
(a) Disconnect the front door handle LH TJ02

connector.

female connector.
Normal
Terminal Condition
Condition
TJ02-5 - Sensitive
Less than 1 Ω
TJ02-6 switch pressed
Sensitive
TJ02-5 - More than 10
switch
TJ02-6 kΩ
released
NG
Replace front door handle LH (with sensitive
switch)
OK
(a) Disconnect the I-key ECU G50 connector.
(b) Disconnect the front door handle LH TJ02

connector.

connector.
Normal
Terminal Wire Color
Condition
G50-8 -
R/G Less than 1 Ω
TJ02-6
G50-1 -
G/R Less than 1 Ω
TJ02-5
NG
OK
3 Replace I-Key ECU
76
Normal close malfunction of front door

DTC B2275-00
handle sensitive switch RH
Schematic Diagram
Front door
sensitive
switch LH
77
1 Inspect front door sensitive switch RH
a Disconnect the front door handle RH UJ03

connector.
b Measure the resistance between terminals
of female connector.
Normal
Terminal Condition
Condition
UJ03-6 - Sensitive
Less than 1 Ω
UJ03-5 switch pressed
Sensitive
UJ03-6 - More than 10
switch
UJ03-5 kΩ
released
NG
Replace front door handle RH (with sensitive

switch)
OK
(b) Disconnect the front door handle RH UJ03

connector
(c) Measure the resistance between terminals

of connector.
Normal
Terminal Wire Color
Condition
G50-9 - UJ03-5 G/R Less than 1 Ω
G50-2 - UJ03-6 R/W Less than 1 Ω
NG
OK
3 Replace I-key ECU
78
Trunk (rear detection) antenna

DTC B2276-00
malfunction
Schematic Diagram
Detection antenna of exterior magnetic card -

Trunk
79
(a) Disconnect the rear detection antenna K18

connector.
(b) Disconnect the I-Key ECU G49 connector.

connector.
Normal
Terminal Wire Color
Condition
G49-19 - K18-1 Y/L Less than 1 Ω
G49-20 - K18-2 R Less than 1 Ω
NG
OK
(a) Temporarily replace a rear detection antenna

and press down the rear sensitive switch.
OK:
NG Replace I-Key ECU
OK
3 Replace rear detection antenna
80
DTC B2278-00 Card reader (start button) malfunction

Schematic Diagram
Start button
81
1 Inspect start button
(a) Temporarily replace the start button with a new

or normally functioning one.
(b) Inspect if the start button operates normally in

power-off mode.
OK:
Cranking is ok
NG
OK
(a) Disconnect the start button G27 connector.

G27-14 -
Br/B Less than 1 Ω
G49-2
G27-9 - G49-3 Br/W Less than 1 Ω
G27-8 - G49-8 Sb Less than 1 Ω
G27-10 -
Br/Y Less than 1 Ω
G49-7
NG
OK
3 Replace I-Key ECU
82
Loop malfunction of front interior

DTC B227C-00
detection antenna
Schematic Diagram
Detection antenna of interior magnetic card -

Front
83
(a) Disconnect the front interior detection antenna

G28 connector.

connector.

G49-13 -
Y Less than 1 Ω
G28-1
G49-18 -
L Less than 1 Ω
G28-2
NG
OK
(a) Temporarily replace a front interior detection

antenna
(b) Bring the key close to the front detection

antenna, and perform the power-up or cranking
operation.
(c) Inspect if the power-up or cranking operation is

ok.
OK:
The power-up or cranking operation is ok
OK
3 Replace front interior detection antenna
84
High-frequency reception module

DTC B227A-00
malfunction
Schematic Diagram
High-frequency reception module
85
(a) Disconnect the high-frequency reception

module K19 connector.
(b) Disconnect the I-key ECU G49 and G50

connectors.

of the wire harness.
Normal
Terminal Wire Color
Condition
K19-5 - G49-12 G Less than 1 Ω
K19-3 - G50-5 G/L Less than 1 Ω
K19-1 - G50-7 Br Less than 1 Ω
K19-2 - G50-11 L Less than 1 Ω
NG
OK
2 Replace high-frequency reception module
86
Password for steering shaft lock

DTC B227B-00
unmatched
1 Match the password of steering shaft lock
Match the password with a diagnostic tester
87
Loop malfunction of middle interior

DTC B227D-00
detection antenna
Schematic Diagram

Middle
88
(a) Disconnect the middle interior detection

antenna G33 connector.

connector.
Normal
Terminal Wire Color
Condition
G49-14 -
O Less than 1 Ω
G33-1
G49-4 -
W Less than 1 Ω
G33-2
NG
OK
(a) Temporarily replace a middle interior detection

antenna
(b) Bring the key close to the middle detection

operation.

ok.
OK:
OK
3 Replace middle interior detection antenna
89
Loop malfunction of rear interior

DTC B227E-00
detection antenna
Schematic Diagram

Rear
90
(a) Disconnect the rear interior detection antenna

K16 connector.

connector.

K16-1 -
G/Y Less than 1 Ω
G49-15
K16-2 -
Gr Less than 1 Ω
G49-5
NG
OK
(a) Temporarily replace a rear interior detection

antenna
(b) Bring the key close to the rear detection

operation.

ok.
OK:
OK
3 Replace rear interior detection antenna
91
DTC B227F-00 No.1 key malfunction
1 Rematch No.1 key
DTC B2280-00 No.2 key malfunction
1 Rematch No.2 key
DTC B2281-00 No.3 key malfunction
1 Rematch No.3 key
92
I-Key ECU power source circuit

Circuit Diagram
Battery
Horn, braking light
Battery Battery
Note: *1 - 473 Electronic injection system *2 - 476QZA System *3 - 476QZA+DCT
93
1 Inspect fuses
(a) Using a multimeter, inspect the horn and

braking light fuses F1/14 and F4/11 of the
engine distributor box.
OK:
There is continuity in the fuse.
NG Replace fuse
OK
(b) Measure the resistance or voltage between the

Wire Normal
Terminal Condition
Color Condition
G49-1 -
R-B Always 11-14 V
G49-9
OK
NG
(a) Disconnect the engine distributor box B1D

connector and I-key ECU G49 connector.
(b) Inspect the resistance between each terminal

Wire Normal
Terminal Condition
Color Condition
B1D-10 - Less than
R/W-R Always
G49-1 1Ω
G49-9 -
Less than
Body B Always
1Ω
ground
94
G49-10 -
Less than
Body B Always
1Ω
ground
OK
4 Circuit normal
95

Start Button Installation
Removal 1 Install start button
1 Disconnect battery negative a Install the start button directly into the
dashboard assembly.
2 Remove dashboard assembly
b Connect the connector.
3 Remove start button
a Disengage the 2 claws as the figure

shown.
b Force out the start button.
2 Install dashboard assembly
3 Connect battery negative.
96

I-Key ECU
Removal
1 Disconnect battery negative
2 Remove the accessory meter glove box,
and after that an I-key ECU fixed on the
tubular beam can be seen
Installation
1 Install I-Key ECU
(a) Install I-Key ECU on the deputy

dashboard.
(b) Install a bolt.
3 Remove I-Key ECU
a Remove a bolt with 10# socket wrench.
b Disconnect the connector.
c Take down I-Key ECU.
2 Install glove box
3 Connect battery negative
97

High-frequency Reception
Module
Removal
1 Remove C-pillar inner garnish LH and the
high-frequency receiver can be seen
2 Remove high-frequency receiver
(a) Remove one bolt with a 10# socket Installation

wrench.
(b) Disconnect the connector. 1 Install high-frequency reception module
(c) Take down the high-frequency reception
module. a Align the high-frequency reception module
with the installation hole.
b Install a 10# bolt.
c Connect the connector.
2 Install C-pillar inner garnish LH
98

Interior Detection Antenna
(Rear)
Removal
1 Remove carrier
2 Remove interior detection antenna (rear)
a Using a flat-head screwdriver, pry up the

snap fit of the detection antenna.
b Disconnect the connector and take down the

detection antenna. 12 Removal and Installation of
Exterior Detection Antenna
(Front Door LH)
Tips: Replace the door outside handle
assembly if damaged.
Removal
1 Remove front door protector assembly LH
2 Remove front door outside handle assembly

LH
For the details of the removal and installation,

Installation refer to section 4 of "Body, Interior and
Exterior".
1 Install interior detection antenna
Installation
a Install the detection antenna into the rear 1 Install front door outside handle assembly
carrier. LH
b Connect the connector. 2 Install front door protector assembly LH
2 Install carrier
99
Chapter 4
Remote Driving System
Contents
1 Parts Location ....................................................................................................... 101
2 System Diagram ................................................................................................... 103
3 System Overview .................................................................................................. 104
4 Diagnosis Flow ..................................................................................................... 105
100
1 Parts Location
Start button
Steering shaft
lock
101
Interior detection
antenna (rear)
High-frequency
reception
module
Interior
Intelligent key detection
system controller antenna
(luggage
compartment)
Interior detection
antenna (middle)
Interior detection
antenna (front)
102
2 System Diagram
Steering
angle
sensor
Gateway
P position
controller
CAN line
103
3 System Overview
Remote driving is used to start the vehicle,
move it forward and backward, turn right and
left, and take control of it to move at a low
speed (less than 0.7 km/h) for a certain
distance, by using the remote control key
within the visible range (within 10 m around
the vehicle).
Notice:
3.1 Remote driving buttons are only

available when the remote driving mode
is activated after remote start.
3.2 Remote driving buttons cannot be

operated at the same time.
3.3 The maximum control time of the

forward/backward/left/right turning is 60
s.
3.4 The maximum available distance range

of the remote driving is 10 m - 20 m.
104
4 Diagnosis Flow
Next
Next
Standard voltage:
11 to 14 V
Next
4 Inspect DTC*
Result
Result Proceed to
No DTC is output A
DTC is output B
B Go to step 8
Result
Result Proceed to
B Go to step 8
105
Next
Next
8 Confirmation test
Next
End
106

Remote Start is Unavailable
CAN communication malfunction
Remote Forward or Backward is Electronic intelligent key

Unavailable CAN communication malfunction
Remote Steering is Unavailable
CAN communication malfunction
107
Remote Start is Unavailable

Circuit Diagram
Gateway
108
1 Inspect key
(b) Long time press the remote start button on the

key.
OK:
The power indicator on the key flashes.
NG Replace key or battery
OK
2 Inspect start system
(c) Bring the key into the vehicle, depress the

brake pedal and press down the start button.
OK:
The start button indicator turns green and
the engine can be started.
NG Inspect start system
OK
3 Depot repair is suggested
109
Remote Forward/Backward is Unavailable
Circuit Diagram
P position Gateway
controller
110
1 Inspect key
(a) Long time press the forward/backward button

on the key.
OK:
OK
2 Inspect driving system
(a) Bring the key into the vehicle, depress the

brake pedal and press down the start button to
start the vehicle.
(b) Put into gear and drive.
OK:
The vehicle can be driven normally.
NG Check driving system
OK
111
Remote Left/Right Turning is Unavailable
Circuit Diagram
Gateway
Steering
angle sensor
112
1 Inspect key
(a) Long time press the left/right turning

button on the key.
OK:
OK
2 Inspect steering system
(c) Bring the key into the vehicle, depress the

brake pedal and press down the start button to
start the vehicle.
(d) Turn the steering wheel to the left and right.
OK:
The steering wheel can be turned easily.
NG Check steering system
OK
113
Chapter 5
Steering Shaft Lock
Contents
1 Parts Location ........................................................................................................ 115
2 System Diagram ....................................................................................................116
3 System Overview ...................................................................................................117
4 Diagnosis Flow ........................................................................................................ 118
5 Diagnostic trouble code chart ................................................................................ 119
114
1 Parts Location
Steering shaft lock
115
2 System Diagram
Steering
shaft lock
116
3 System Overview
As a part of the anti-theft system, the steering
shaft lock plays an important role in the system.
It drives the latch by a motor to lock the
steering column, so the steering wheel cannot
be rotated and theft prevention function is
achieved.
Operation:
Steering shaft lock sends an unlock/lock signal

to the steering shaft lock controller by the
intelligent key system controller and BCM, and
then performs an unlock/lock operation by the
motor. Steering shaft lock control module will
determine whether the unlock/lock command
is successfully performed based on signal
from the hall sensor, and then send the
information back to the intelligent key system
and BCM to finish other commands.
117
4 Diagnosis Flow
NEXT

Standard voltage value:
11 ~ 14 V
NEXT
3 Refer to the problem symptoms table for diagnosis
Result Proceed to
Symptom is not listed in problem
A
symptoms table
Symptom is listed in problem
B
symptoms table
B Go to step 5
4 Overall Diagnosis
NEXT
NEXT
6 Confirmation test
NEXT
7 End
118
5 Diagnostic trouble code chart

DTC Meaning Trouble Area
Sensor power supply
B22D0-00
abnormal
B22D1-00 Sensor signal abnormal
B22D2-00 Relay abnormal Shaft lock internal malfunction
B22D3-00 Memory abnormal
B22D4-00 Memory data lost
B22D5-00 Memory not initialized
Power supply voltage
B22D6-00
abnormal Steering shaft lock power supply abnormal
B22D7-00 Power-on abnormal
There is electricity on the No Lockup Pin (Pin 5) of
B22D8-00 "No Lockup" abnormal
the steering shaft lock when power supply is OFF.
B22D9-00 Unlock time out Shaft lock internal malfunction or power supply
B22DA-00 Lockup time out abnormal
B22DB-00 Recovery illegal Shaft lock internal malfunction
B22DC-00 Matching failed Failure in matching with intelligent key
Lost communication with
U0214-00
intelligent key system Communication malfunction
U0140-00
body control module
119
(a) Disconnect the connector G21.
(b) Measure the voltage or resistance between

each terminal of the wire harness side
connector.
Normal:
Terminal No. Wire Terminal Condition Normal Value

Color Description
G21-1 - Body
B Ground Always Less than 1 V
ground
Moment when carrying a
G21-2 - Body
Y Power supply key with power off and 11 ~ 14 V
ground
pressing the start button
G21-3 - Body
P B-CAN_H Always Approx. 2.5 V
ground
G21-4 - Body
Gr Hall power supply ---- ----
ground
G21-5 - Body ACC signal power
Y/R ACC power supply 11 ~ 14 V
ground supply
G21-6 - Body
V B-CAN_L Always Approx. 2.5 V
ground
(c) Reconnect the connector G21.
120

B22D0-00/ B22D1-00/
B22D2-00/ B22D3-00/ Steering shaft lock
DTC
B22D4-00/ B22D5-00/ internal malfunction
B22DB-00
1 Replace steering shaft lock
Tips: The whole steering column can be replaced.

NEXT
2 Match with I-KEY system (refer to "Matching Abnormal" in this section)
121
B22D6-00/ Steering shaft lock power supply

DTC
B22D7-00 abnormal
Schematic Diagram:
Power supply
Steering shaft lock
1 Inspect power supply voltage

a Disconnect the connector G21, and measure the
Wire Normal
Terminal Condition
Color Condition
Carry a legal
key with power
off and press
G21-2- remote control 0  11~14
Y-B
G21-1 or sensitive V0
switch to lock
while all doors
are closed.
OK
Replace steering shaft lock
122
NG
2 Inspect output voltage of the BCM

(a) Wire the rear end of the BCM and measure
the voltage of the terminal G2P-30.
Wire Normal
Terminal Condition
Color Condition
Carry a legal
key with power
off and press
G2P-30 - 0
remote control
Body ---- 11~14 V
or sensitive
ground 0
switch to lock
while all doors
are closed.
NG
Replace BCM
OK

(a) Disconnect the dashboard distributor box
connector G2P.
(b) Disconnect the steering shaft lock connector
G21.
Wire Normal
Terminal Condition
Color Condition
G2P-30 - Less than 1
Y Always
G21-2 Ω
G21-1 - Less than 1
B Always
Body ground Ω
NG
OK
123
DTC B22D8-00 "No Lockup" abnormal
Schematic Diagram:
Battery
To dashboard
distributor box
50A
Auxiliary
Relay power
supply
ACC power supply
Steering shaft lock
124
1 Inspect input voltage

(a) Turn the power switch off
(b) Disconnect the connector G21, and measure
the wire harness side voltage
Wire Normal
Terminal Condition
Color Condition
G21-5 - Body Less than
Y/R OFF
ground 1V
NG
OK
End
2 Inspect output voltage of dashboard distributor box

(b) Disconnect the connector G2N, and measure

Wire Normal
Terminal Condition
Color Condition
G2N-37 - Less than
---- OFF
Body ground 1V
If the output voltage of this terminal is normal, the

wire harness between the dashboard distributor box
and steering shaft lock is short (short to the power
supply circuit)
OK Repair or replace wire harness

(distributor box - shaft lock)
NG
3 Inspect input voltage of dashboard distributor box

(b) Disconnect the connector G2A, and measure
Wire Normal
Terminal Condition
Color Condition
G2A-4 - Body Less than
---- OFF
ground 1V
125

dashboard distributor box is short
OK Replace or repair dashboard

distributor box
NG
4 Inspect output of ACC relay


Wire Normal
Terminal Condition
Color Condition
G37-2 - Body Less
W/R OFF
ground than 1 V

wire harness between the dashboard distributor box
and relay block is short (short to the power supply
circuit)
OK Replace or repair wire harness
NG
5 Inspect ACC relay
(a) Remove the ACC relay from the relay block

(b) Inspect the operation of the relay

3, 4 continuity
3, 4 no continuity
3, 5 continuity
NG Replace ACC relay
OK
6 Inspect output voltage of BCM
126
(b) Disconnect the connector G2P, and measure

Wire Normal
Terminal Condition
Color Condition
G2P-9 - Less than 1
L/R OFF
Body ground V
OK Replace or repair wire harness

(BCM - relay)
NG
7 Replace BCM
127
DTC B22D9-00/ B22DA-00
1 Inspect "Steering Shaft Lock Power Supply"
The steering shaft lock power supply is abnormal
NG Go to "Steering Shaft Lock Power

Supply Abnormal"
OK
128
DTC U0214-00 Communication malfunction

Schematic Diagram:
Steering shaft lock
1 Inspect CAN line

(a) Disconnect the connector G21
(b) Measure the wire harness side voltage
Wire Normal
Terminal Condition
Color Condition
G21-3 - Body Approx. 2.5
P Always
ground V
G21-6 - Body Approx. 2.5
V Always
ground V
NG
OK
2 End
129
DTC B22DC-00 Matching abnormal
Note: If the steering shaft lock is replaced, do rematch it with the I-K ECU as the matching process
below:
Owner contacts the 4S shop
4S shop confirms the owner's

identity
Remove and replace the steering

shaft lock with a special tool
Using a tester, match the steering

shaft lock with the keyless system
controller
End
Fig. 3 Flowchart for replacement of steering shaft lock
130
8 Removal and Installation
8.1 Steering column
For the removal and installation of steering

column, refer to "Chassis"
131
Chapter 6
Gateway Controller
Content
1 Parts Location ....................................................................................................... 133
2 System Diagram ................................................................................................... 134
3 System Overview .................................................................................................. 135
4 Diagnosis Flow ..................................................................................................... 135
7 Removal ................................................................................................................ 151
8 Installation ............................................................................................................. 151
132
1 Parts Location
Gateway
controller
133
2 System Diagram
Multimedia
system
Air conditioner
Combination
Diagnostic meter
interface
Airbag
Vehicle speed Anti-lock
signal brake
system Steering shaft
lock
Gear position Transmissi
signal on module Body control
module 2
Speed/coolant Electronic Intelligent key

temperature, injector system
etc
Power Reversing radar
Gateway
assists
steering
controller
Body control
module 1
Electronic
parking
system Combination
switch
Parking
assist Door multiplex
controller controller
Steering On-board
Gear television
position angle
signal sensor
Multi-display
Sun roof
Tire pressure
monitoring
system
CAN line
134
3 System Overview
Several networks exist in the vehicle need to
communicate with each other, and the gateway is
such an intermediate to sustain the communication.
The gateway controller has the following three main

functions:
1 Message routing:
Forwarding messages, and diagnosing the state of

bus messages;
2 Signal routing:
Mapping signals between different messages;
3 Network management:
Network state monitoring and statistics,

troubleshooting and sleep wakeup, etc.
4 Diagnosis Flow
Next
Next
Standard voltage:
11 to 14 V
Next
4 Problem Symptom Confirmation
Next
5 Inspect gateway and peripheral circuit
Next
135
6 Inspect major node terminal resistance of each network
Next
End
Inspect gateway controller pin
Disconnect the gateway controller connector G07.
Measure the voltage and resistance between each

terminal of the wire harness.
Standard Voltage
(Symbol) Condition
G07-5 - Body R/W Battery positive Always 11 to 14 V
ground
G07-7 - Body R/G IG1 power supply Power 11 to 14 V
ground ON
Standard Resistance
G07-1 - Body B Signal ground Always Less than 1 Ω
ground
Reconnect the connector G07. Wire the rear end of

the connector and measure the voltage of each
terminal.
Standard Voltage
G07-4 - Body P B-CANH1 Always 2.5 to 3.5 V
ground
G07-6 - Body P F-CANH Always 2.5 to 3.5 V
ground
G07-8 - Body P B-CANH2 Always 2.5 to 3.5 V
136
ground
G07-9 - Body V B-CANL2 Always 1.5 to 2.5 V
ground
G07-10 - Body V B-CANL1 Always 1.5 to 2.5 V
ground
G07-11 - Body B Shielded wire Always Less than 1 V
ground
G07-12 - Body V F-CANL Always 1.5 to 2.5 V
ground
137
Gateway and Peripheral Circuit

Circuit Diagram:
Battery
Gateway Power
network
Shielding
layer
Gateway controller
Start Body
netwo netwo
rk rk
Multiplex integration 1#CANS Adapter

control module ESC system
Note: *3--476QZA+DCT
138
Measure the voltage and resistance between each

terminal of the wire harness side connector.
Standard Voltage

Condition
(Symbol) Condition
G07-5 - Body
Always 11 to 14 V
ground
G07-7 - Body
Power ON 11 to 14 V
ground
Standard Resistance
Condition
(Symbol) Condition
G07-1 - Body
ground
OK Go to step 3
NG
139
Wire the rear end of the dashboard distributor box

connector G2N-32 and B2C-11.
Measure the voltage between two terminals and

body ground respectively.
Standard Voltage

Condition
(Symbol) Condition
G2N-32 - Body
Power ON 11 to 14 V
ground
B2C-11 - Body
Always 11 to 14 V
ground
NG Distributor box malfunction
OK
Wire harness malfunction (dashboard distributor box - gateway controller)
140
3 Inspect CAN communication line
Disconnect the gateway controller connector G07

and TCU connector A47, and then measure the
resistance between each terminal of the wire
harness side connector.
Standard Resistance

Condition
(Symbol) Condition
G07-6 - A47-11 Always Less than 1 Ω
G07-12 - A47-12 Always Less than 1 Ω
G07-6 - G07-12 Always More than 10 kΩ
NG
The main line of the power network is open or

short, and the wire harness should be replaced

and engine distributor box connector B1I, and then
measure the resistance between each terminal of
Standard Resistance

Condition
(Symbol) Condition
B1I-2 - G07-4 Always Less than 1 Ω
B1I-1 - G07-10 Always Less than 1 Ω
G07-4 - G07-10 Always More than 10 kΩ
141
NG
The main line of the comfort network is open or


and Keyless ECU connector G50, and then
measure the resistance between each terminal of
Standard Resistance

Condition
(Symbol) Condition
G07-8 - G50-12 Always Less than 1 Ω
G07-9 - G50-6 Always Less than 1 Ω
NG
The main line of the start network is open or

OK
4 Replace gateway controller
142
Major node of B-CAN1

Circuit Diagram:
Gateway controller
Body
netw
ork
Adapter
143
1 Inspect gateway terminal resistance
Measure the resistance between pin 4 and pin 10

on the panel end.
Standard Resistance

Condition
(Symbol) Condition
4 - 10 Always Approx. 120 Ω
NG
Replace gateway controller
OK
2 Inspect terminal resistance of engine distributor box
Disconnect the engine distributor box connector

B1I.
Measure the resistance between pin 1 and pin 2 on

the panel end.
Standard Resistance

Condition
(Symbol) Condition
1-2 Always Approx. 120 Ω
NG Replace engine distributor box
OK
3 Inspect dashboard distributor box
144
Disconnect dashboard distributor box connectors

B2D and G2N.
Measure the resistance between each pin on the

panel end.
Standard Resistance

Condition
(Symbol) Condition
B2D-11 - G2N-39 Always Less than 1 Ω
B2D-12 - G2N-38 Always Less than 1 Ω
B2D-11 - B2D-12 Always More than 1 MΩ
NG
OK
145
4 Inspect wire harness of B-CAN 1 main line
Disconnect the engine distributor box connector

B1I.
Measure the resistance between each terminal of

Standard Resistance

Condition
(Symbol) Condition
G07-10 - B1I-1 V Less than 1 Ω
G07-4 - B1I-2 P Less than 1 Ω
G07-10 - G07-4 V-P More than 1 MΩ
OK
End
146
Major node of B-CAN2
Circuit Diagram:
Gateway controller
Measure the resistance between pin 8 and pin 9 on

the panel end.
Standard Resistance

Condition
(Symbol) Condition
8-9 Always Approx. 120 Ω
NG Replace gateway controller
OK
147
6 Inspect terminal resistance of Keyless ECU
Disconnect the Keyless ECU connector G50.

on the panel end.
Standard Resistance

Condition
(Symbol) Condition
NG Replace Keyless ECU
OK
7 Inspect wire harness of B-CAN 2 main line
Disconnect the Keyless ECU connector G50.

Standard Resistance

Condition
(Symbol) Condition
G07-8 - G50-12 P Less than 1 Ω
G07-9 - G50-6 V Less than 1 Ω
G07-8 - G07-9 P-V More than 1 MΩ
OK
End
148
Major node of F-CAN

Circuit Diagram:
Power
network
Gateway controller

on the panel end.
149
Standard Resistance

Condition
(Symbol) Condition
NG Replace gateway controller
OK
2 Inspect ECM terminal resistance
Disconnect the TCU connector A47.

on the panel end.
Standard Resistance
Condition
(Symbol) Condition
NG Replace ECM
OK
3 Inspect wire harness of H-CAN main line
Disconnect the TCU connector A47.

Standard Resistance

Condition
(Symbol) Condition
G07-12 - A47-12 V Less than 1 Ω
G07-6 - A47-11 P Less than 1 Ω
G07-12 - G07-6 V-P More than 1 MΩ
OK
End
150
7 Removal 8 Installation
1 Remove glove box
8.1Install gateway controller
2 Remove gateway controller
a Align the gateway controller with the
a Disconnect the connector. installation hole.
b Remove a bolt with 10# socket wrench. b Install a set bolt.
c Take down the gateway controller. c Connect the connector.
8.2Install glove box
151
Chapter 7
Air Conditioning System
Contents
1 Parts Location ....................................................................................................... 154
2 System Diagram ................................................................................................... 156
3 System Overview .................................................................................................. 157
4 Diagnosis Flow ..................................................................................................... 161
6 ECU terminals ....................................................................................................... 165
7 On-vehicle Inspection ........................................................................................... 168
8 Removal and Installation of A/C Panel ................................................................. 219
9 Removal and Installation of A/C Case .................................................................. 220
10 Removal and Installation of A/C Compressor ....................................................... 221
11 Removal and Installation of Solar Sensor ............................................................ 221
152
Condenser and
Pressure bracket assembly
switch
Outside Compressor
temperature assembly
sensor
153
1 Parts Location
Mode control motor
154
155
2 System Diagram
156
3 System Overview
3.1 Overview
Air conditioning system of this vehicle is a

single evaporator type automatic air
conditioning, which is used in
middle/high-grade car. The system mainly
consists of components such as
compressor, condenser, HVAC assembly,
refrigeration line, heater water pipe, air
duct and A/C controller. It has 4 functions
including cooling, heating,
defrosting/defogging and smog ventilating.
This system uses the residual heat of the
engine coolant for heating, and vapor
compression refrigeration cycle for cooling.
The refrigerant is R134a and the control
method is button-controlled type. The
mode, air mix and internal/external
circulation dampers of the automatic air
conditioning case are all controlled by the
motor.
3.2 Operation of refrigeration system
A scroll compressor driven by the engine

sucks the gaseous refrigerant out of the
evaporator and forces it into the condenser.
The high-pressure gaseous refrigerant is
liquefied while passing through the
condenser, and the heat released out is
carried away by the air outside of the
vehicle. The high-pressure liquid
refrigerant lowers its pressure by the
restriction effect of the expansion valve,
and the low-pressure liquid refrigerant is
gasified in the evaporator to exchange the
heat (absorb the heat). The cooled air near
the evaporator is blown into the cabin by
the blower. The gaseous refrigerant is
sucked away by the compressor and
pumped into the condenser again. In this
way, the refrigerant is circulated within a
closed system, and the heat in the cabin is
continuously discharged outside of the
vehicle, so the air temperature inside the
cabin can be kept to a suitable
temperature.
157
Medium-temperature Low-temperature and

and high-pressure low-pressure liquid
liquid 1500-1800 kPa Drying Expansion 200-500 kPa10°-20°
70°-80° bottle valve
Heat from
Heat from Condenser Evaporator the air to
the the
refrigerant refrigerant
to the air
High-temperature and Medium-temperature

high-pressure gas Compressor
and low-pressure gas
80°-90° 5°-10°
3.3 Operation of heating system
The heating system is water-heated and the

heat source is engine coolant. The heating
system mainly consists of the heat exchanger,
heater water pipe, blower, air duct, control
mechanism, etc. The heating unit housing is
integrated with the evaporator housing, and
the refrigeration system is shared by the
blower, air duct, etc.
When the engine is operating, the coolant

heated by high temperature (generated by the
combustion in engine cylinder) enters the heat
exchanger through the heater water inlet pipe
by the water pump in the engine cooling
system. The air blown out by the blower
transfers the heat from the heated coolant to
the cabin or windshield in order to increase the
temperature in the cabin and to defrost. The
coolant cooled in the heat exchanger is
pumped back through the heater water outlet
pipe and circulated in this way. Therefore, the
heating function of the heater achieved.
158
High-tempera
Engine
ture coolant
Heat is
transferred
Heat to the air
Low-temperature exchanger
coolant
Water pump Medium-temp

erature
coolant
3.1 Fan control logic 3.11 When the A/C is ON, the fan will operate
at low speed; When the temperature of
3.2 473 fan control logic: the engine water outlet is above 98°C or
the
Fans are divided into radiator fan and
condenser fan. The speeds of the fans 3.12 Temperature of the radiator water outlet is
cannot be adjusted; above 80°C, the fan will operate at low
speed.
Operation condition of radiator fan:
HI operation condition:
3.3 When the A/C is ON, the radiator fan will
operate; 3.13 When the A/C is ON and the A/C
pressure is above 1.77 Mpa, the fan will
3.4 When the temperature of the engine operate at high speed;
coolant is above 93°C, the radiator fan will
operate. 3.14 When the temperature of the engine
water outlet is above 106°C or the
Operation condition of condenser fan: temperature of the radiator water outlet is
above 86°C, the fan will operate at high
3.5 When the A/C is ON and A/C pressure is speed.
above 1.77 Mpa, the condenser fan will
operate; Note: Before a HI operation, the fan must
operate at low speed for 2 seconds.
3.6 When the temperature of the engine
coolant is above 100°C, the condenser fan 3.15 Precautions when servicing air
will operate. conditioning system
3.7 476 fan control logic: 3.16 The maintenance of the air conditioning
system must be carried out by professional
Fans are double-pole speed governing technicians.
type, and can operate at high and low
speed. 3.17 The work area should be ventilated
LO operation condition: before servicing. Do not handle refrigerant
159
in an enclosed area or near an open flame. protection is divided into temperature

Do wear an eyeshade during servicing protection of evaporator (low temperature
until it is completed. protection 0-2°C) and excess temperature
protection of compressor (high
3.18 Do not get liquid refrigerant in your eyes temperature protection 130±5°C).
or on your skin. If liquid refrigerant gets in
your eyes or on your skin, wash the area 3.24 Note that the O-ring on the opening line
with cold water and pay attention to the must be replaced when servicing. Do coat
following precautions: Do not rub your the seal ring with refrigeration before
eyes or skin. Apply clean petroleum jelly to assembly and then install it according to
the skin. Go to hospital or see a physician the specified torque.
immediately for professional treatment.
3.25 When servicing, operate strictly
3.19 Do not operate compressor without according to the technical requirements
enough refrigerant in refrigerant system. (charge volume, refrigeration oil model,
The compressor may be damaged when torque requirement, etc.). Inspect and
the refrigerant is not enough and the oil repair the A/C according to the
lubrication is insufficient in system. Do requirements to ensure a normal operation
avoid this. as well as long useful life of the air
conditioning system.
3.20 Do not open the high pressure valve of
the pressure gauge while the compressor 3.26 Plug the port with a plug or cover as soon
is operating. Open and close the low as the line is removed, because the
pressure valve only. refrigeration oil has strong water
absorbability. Do not let the moisture or
3.21Be sure to use special refrigerant. Do not dust entering the refrigeration system.
misuse lubricants of other brands or mix
them with each other (different brands and 3.27 When draining the excessive refrigeration
models). in the system, do not drain it too fast so as
not to draw the compressor oil out of the
3.22 The refrigerant charge volume of the system.
Surui air conditioning system is 600 g and
the total amount of refrigeration oil is 120 3.28 Periodically clean the air strainer to
ml. When the total amount of refrigeration ensure excellent air regulating quality.
oil is bellow 110 ml because of seepage,
there is a possibility of compressor 3.29 Inspect if surfaces of the condenser fins
excessive wear, and the service shop are dirty. Do not wash them with steam or
should refill the refrigeration oil if high-pressure water gun so as not to
necessary. damage the condenser fins. Scrub them
with a soft brush.
3.23 The air conditioning pressure is protected
by tri-state pressure switch. The pressure 3.30 Avoid excessive refrigerant. Excessive
switch will be turned off when the pressure refrigerant may lead to poor cooling.
is excessively high or low. Temperature
160
4 Diagnosis Flow
Next
Next
Standard voltage:
11 to 14 V
Next
4 Inspect DTC*
Result
Result Proceed to
No DTC is output A
DTC is output B
B Go to step 8
A
Result
Result Proceed to
B Go to step 8
A
(a) ECU terminals (refer to page AC-12)

Next
161
Next
8 Confirmation test
Next
End
162

A/C controller/panel power supply circuit
All functions of air
conditioning system do not A/C controller AC-37
operate
Pressure switch
Request permission circuit
Only refrigeration system Compressor fuse
does not operate (blower AC-43
operates normally) Compressor relay
Compressor
Refrigeration system does Each sensor (room and outside temperature AC-16,
not operate normally sensor) AC-18
(deviations in actual
A/C controller -
temperature and set
temperature) Wire harness and connector -
Blower fuse
Blower relay
Blower
Blower does not operate AC-28
Governor module
A/C controller
Blower governor module
Wind speed of blower cannot
be adjusted (blower operates A/C controller AC-28
normally)
Outlet mode control motor
Outlet mode adjustment is
A/C controller AC-22
abnormal
Wire harness and connector
Air mix control motor
Temperature adjustment is
abnormal
Circulation control motor
Internal/external circulation
adjustment does not operate
Rear defroster wire fuse
Rear defroster does not
Rear defroster wire relay AC-46
operate
Rear defroster wire
163

Fuse
Relay
Condenser/radiator fan
Fan AC-39
malfunction
ECM
Wire harness
Trouble Code and Self Diagnosis Trouble Code Chart
Diagnostic Trouble See

Detection Item Trouble Area
Codes (DTC) Page
11 (B2A20) Room temperature sensor open circuit Room temperature
AC-16
12 (B2A21) Room temperature sensor short circuit sensor circuit
13 (B2A22) Outside temperature sensor open circuit Outside temperature

Ac-18
14 (B2A23) Outside temperature sensor short circuit sensor circuit
Evaporator temperature sensor open

15 (B2A24) Evaporator
circuit
temperature sensor AC-20
Evaporator temperature sensor short circuit
16 (B2A25)
circuit
Outlet mode control
17 (B2A2A) Outlet mode control motor malfunction AC-20
motor circuit
Air mix control motor
18 (B2A2B) Air mix control motor malfunction AC-25
circuit
Master controller controlled blower
20 (B2A2D) Blower circuit AC-28
malfunction
Forwarding signals (including
permission, water temperature and
21 (U0155) CAN communication CA
vehicle speed) of gateway not received
by A/C controller
High/low pressure
22 (B2A2F) Pressure malfunction AC-32
signal malfunction
Coolant temperature
24 (B2A28) Water temperature malfunction ES
sensor circuit
Vehicle speed signal
25 (B2A29) Vehicle speed malfunction BC
circuit
35 Solar sensor open
Solar sensor circuit ES
36 Solar sensor short
Hard line permission malfunction for Permission
40 -
electronic injector condition not met
164
6 ECU terminals
6.1 Inspect A/C control module
6.1.1 Wire the rear end of the A/C control

module connector G47.
6.1.2 Inspect each terminal of the connector.
Terminal No. Wire Color Terminal Description Condition Normal Value

LOW-level terminal of CAN
G47-1 V Always Approx. 2.5 V
bus
HIGH-level terminal of CAN
G47-2 P Always Approx. 2.5 V
bus
Output terminal of blower
G47-3 L/B A/C ON Voltage signal
governor signal
Power supply of A/C
G47-4 ON position 5V
pressure sensor
Compressor
G47-5 L/Y A/C permission signal Less than 1 V
ON
Power defroster Rear defroster
G47-6 Y 11 ~ 14 V
compensation ON
G47-7 ---- Reserved ---- ----
Signal feedback terminal of
G47-8 P/B air mix damper actuator A/C ON Voltage signal
motor
G47-9 ---- N/A ---- ----
Signal input terminal of
G47-10 Br evaporator temperature A/C ON Voltage signal
sensor
Signal input terminal of
G47-11 G/B A/C ON Voltage signal
room temperature sensor
G47-12 ---- N/A ---- ----
G47-13 B Ground Always Less than 1 Ω
A/C blower relay output
G47-14 B/Y Blower ON Less than 1 V
terminal
165
G47-15 ---- N/A ---- ----

G47-19 ---- N/A ---- ----
G47-20 ---- N/A ---- ----
Positive input terminal of 12
G47-21 R/B V power supply of side light Side light ON 11 ~ 14 V
switch
Negative input terminal of
G47-22 R illumination power supply of Always Less than 1 Ω
side light
Turn the power
switch ON, if
High/low pressure signal
G47-23 Y/L the refrigerant 11 ~ 14 V
input terminal
line pressure is
normal
Input terminal of A/C
Compressor
G47-24 L/B request signal sent from AC 11 ~ 14 V
ON
module to engine ECU
G47-25 ---- N/A ---- ----
G47-26 G/W Blower feedback signal Blower ON Voltage signal
Feedback input terminal of
G47-27 R/L A/C ON Voltage signal
mode damper motor
G47-28 ---- N/A ---- ----
Signal input
terminal of
G47-29 Temperature
outside A/C ON
Sb signal
temperature
sensor
Solar sensor signal input Light intensity
G47-30 O A/C ON
terminal signal
Magnetic clutch relay output Compressor
G47-31 Y/R Less than 1 V
terminal of compressor ON
G47-32 ---- N/A ---- ----
G47-33 B Ground Always Less than 1 Ω
Power supply input (positive
G47-34 – Temperature
P/L - G - negative) for air mix 11 ~ 14 V
G47-16 adjustment
damper servo motor
G47-35 ---- N/A ---- ----
Power supply input (positive
G47-36 – Outlet mode
W/L – Y/G - negative) for mode 11 ~ 14 V
G47-17 adjustment
damper actuator motor
Internal/external
Internal/external circulation
G47-37 – circulation
R/G-R/W actuator motor control 11 ~ 14 V
G47-18 mode
(positive - negative)
adjustment
166
+5 V power supply output

G47-38 R/Y terminal Approx. 5 V
A/C ON
+5 V power supply output
G47-39 Gr A/C ON Approx. 5 V
terminal
IG2 power supply input
G47-40 B/Y Power ON 11 ~ 14 V
terminal
167
1 Directly inspect
Tips:
When air conditioning system does not operate or

operates abnormally, this will be reflected in
appearance. By a direct inspection (see, touch and
hear), trouble areas can be diagnosed accurately
and corrected easily and quickly.
(a) Carefully observe the line for damage and the

condenser surface for cracks or oil. If there is
oil on a certain area of the condenser,
evaporator or its line, confirm if there is a
leakage. Leaking areas can be especially
inspected with a soap bubble method are as
follows:
 Connector of each line and connection of

valve;
 Hose and hose connector;
 Compressor oil seal, gasket, etc.;
 Scratched or deformed surface of such

as condenser and evaporator;
(b) Inspect the electrical wires. Carefully check for

an open circuit in related line connection.
NG
Replace or repair corresponding component
OK
2 Inspect for a malfunction by hand-feel
Inspect the high pressure terminal of A/C refrigerant

system
Turn the A/C switch ON, and touch the high

pressure terminal line and components of air
conditioning system by hand when the refrigerant
compressor operates for 10~20 min. From the
compressor outlet, condenser and dryer to the
expansion valve inlet, the temperature felt by hand
should turn from hot to warm.
168
If there is an extra hot spot in the center portion, it

indicates the heat radiation performance is poor;
If these components are cool, it indicates that there
may be a malfunction in the A/C refrigerant system,
such as blockage, no refrigerant, compressor does
not operate or operates abnormally.
Inspect the low pressure terminal of the A/C

refrigerant system
Turn the A/C switch ON, and touch the low pressure
terminal line and components of the air conditioning
system by hand when the refrigerant compressor
operates for 10~20 min. From the evaporator to the
compressor inlet, the temperature felt by hand
should turn from cool to cold.
If it is not cool or frost exists on certain area, there

are abnormalities in the refrigeration system.
Inspect the temperature difference on both

terminals of the compressor outlet
Turn the A/C switch ON, and touch both terminals of
the compressor inlet and outlet by hand when the
refrigerant compressor operates for 10~20 min.
There should be an obvious temperature difference
between the high and low pressure terminals of the
compressor.
If the temperature difference is not obvious or not

exist, the refrigeration may be run out or seriously
insufficient.
Inspect line
Inspect if the wire harness connectors are
connected well by hand. There should be no
looseness or heat in each connector of the air
conditioning system line.
If the connectors are loose or the connector surface
temperatures felt by hand are very high (hot), it
indicates that there are poor contacts in the
connectors, causing the air conditioning system
inoperative or abnormal.
NG
OK
3 Inspect malfunctions by listening
(a) Carefully listen for abnormal noises or
169
operating sounds from the compressor to

determine if the malfunction, such as no
cooling or poor cooling in air conditioning
system, is caused by the compressor or
compressor control circuit.
NG
OK
Use a tester or refer to problem symptoms table
170
11
DTC Room temperature sensor open circuit
(B2A20)
12
DTC Room temperature sensor short circuit
(B2A21)
Circuit Diagram
Room
temper
ature
sensor
171
1 Inspect room temperature sensor
(a) Disconnect the connector G53 of room

temperature sensor, and remove the room
temperature sensor.
(b) Measure the resistance according to the table

below.
Standard Value
Lower Upper
Terminal Condition
Limit (kΩ) Limit (kΩ)
-25°C 126.4 134.7
-10°C 54.60 57.65
0°C 32.25 33.69
1-2 10°C 19.68 20.35
20°C 12.37 12.67
30°C 7.95 8.14
50°C 3.51 3.66
NG
Replace room temperature sensor
OK
2 Inspect wire harness (room temperature sensor - AC ECU)
Disconnect the connector G53 of front room

temperature sensor.
Disconnect the AC ECU connector G47.
Measure the resistance between the terminals.
Standard Value
Normal
Terminal Wire Color
Condition
G53-2 - G47-11 G/B Less than 1 Ω
G53-1 - Body
B Less than 1 Ω
ground
G53-1 - G53-2 -- More than 10 kΩ
172
NG
OK
3 Replace A/C controller (AC ECU)
173
13 Outside temperature sensor open

DTC
(B2A22) circuit
14 Outside temperature sensor short
DTC
(B2A23) circuit
Circuit Diagram
Engine hood
distributor box
Outside
temperature
sensor
Engine hood
distributor box
174
4 Inspect outside temperature sensor

(a) Disconnect the connector C10 of outside
temperature sensor, and remove the outside
temperature sensor.

below.
Standard Value
Lower Upper
Terminal Condition
-25°C 126.4 134.7
-10°C 54.60 57.65
0°C 32.25 33.69
1-2 10°C 19.68 20.35
20°C 12.37 12.67
30°C 7.95 8.14
50°C 3.51 3.66
NG
Replace outside temperature sensor
OK
5 Inspect wire harness (outside temperature sensor – AC ECU)
(a) Disconnect the connector C10 of outside

temperature sensor.
(b) Disconnect the AC ECU connector G47.
Standard Value
Wire Normal
Terminal
Color Condition
C10-1 – G47-29 P-Sb Less than 1 Ω
C10-2 – Body R/B Less than 1 Ω
175
ground
More than 10
C10-1 – C10-2 -
kΩ

NG
OK
176
15 Evaporator temperature sensor open

DTC
(B2A24) circuit
16 Evaporator temperature sensor short
DTC
(B2A25) circuit
Circuit Diagram
Evapo
rator
temper
ature
sensor
177
1 Inspect evaporator temperature sensor

(a) Disconnect the connector X981 of evaporator
temperature sensor, and remove the
evaporator temperature sensor.

below.
Lower Upper
Terminal Condition
-20°C 14.82 16.38
0°C 5.081 5.559
10°C 3.101 3.359
1-2 15°C 2.466 2.644
20°C 1.946 2.106
30°C 1.276 1.354
40°C 0.845 0.897
NG
Replace evaporator temperature sensor
OK
2 Inspect wire harness (evaporator temperature sensor - AC ECU)
(a) Disconnect the air conditioning system

connector G47.
(b) Disconnect the connector X981 of evaporator

temperature sensor.
Measure the resistance between the terminals.
Standard Value
Wire
Color
G47-10 - X981-2 Br Less than 1 Ω
X981-1 - Body
B Less than 1 Ω
ground
X981-1 - X981-2 -- More than 10 kΩ
178
OK
179
17
DTC Outlet mode control motor malfunction
(B2A2A)
Circuit Diagram
Outlet
mode
damper
control
motor
180
1 Inspect operation of outlet mode control motor

(a) Disconnect the connector X984 of outlet mode
control motor, and do not remove the motor.
(b) Test the mode motor.
Notice:
 Mode control motor may be damaged by

incorrect power supply and ground.
Please follow the operation instruction
carefully.
 Disconnect the battery immediately

when the mode motor stops

X984-4 - Battery The mode control motor
positive should be operated freely
X984-5 - Battery and stopped at the face
negative vent.
Install the connector
X984-5 - Battery upside down. The mode
positive control motor should be
X984-4 - Battery operated smoothly and
negative stopped at the front
defroster.
OK Go to step 4
NG
2 Inspect mechanism (linkage and damper)
(a) Remove the mode motor, and inspect the

motion stability of the linkage and damper of
mode control motor.
Result Proceed to
Linkage and damper
A
move freely
Linkage and damper are
B
stuck or seized
Replace outlet mode control motor
181
3 Repair or replace it if necessary
4 Inspect wire harness (AC ECU - mode motor)

(a) Disconnect the A/C controller connector G47.
(b) Disconnect the mode motor connector X984.
(c) Measure the resistance of the wire harness.
Standard Value
Wire Normal
Terminal
Color Condition
X984-2 - G47-38 R/Y Less than 1 Ω
X984-3 - G47-27 R/L Less than 1 Ω
X984-4 - G47-36 W/L Less than 1 Ω
X984-5 - G47-17 Y/G Less than 1 Ω
OK
5 Inspect wire harness (mode motor - body ground)
(a) Disconnect the mode motor connector X984.
Standard Value
Wire Normal
Terminal
Color Condition
X984-1 - Body
B Less than 1 Ω
ground

OK
182
6 Inspect for short circuit to GND in wire harness
(a) Disconnect the connector G47 and measure

the resistance between each wire harness side
terminal and ground.
Normal
Terminal Wire Color
Condition
G47-27 - Body
R/L More than 10 kΩ
ground
G47-38 - Body
R/Y More than 10 kΩ
ground
G47-17 - Body
Y/G More than 10 kΩ
ground
G47-36 - Body
W/L More than 10 kΩ
ground
OK
7 Inspect AC ECU
(a) Wire the rear end of the A/C controller

connector G47.
(b) Turn the A/C on, and measure the output value.
Normal
Terminal Condition
Condition
G47-38 - Body
A/C ON Approx. 5 V
ground
FACE Approx. 0.2 V
G47-27 - Body FOOT/DEF Approx. 3.1 V

ground FACE/FOOT Approx. 1.1 V
FOOT Approx. 2.5 V
G47-36 - Outlet mode
11 ~ 14 V
G47-17 adjustment
Replace A/C controller (AC ECU)
OK
8 End
183
18
DTC Air mix motor malfunction
(B2A2B)
Circuit Diagram
Air mix
damper
motor
184
1 Inspect operation of air mix control motor

(a) Disconnect the connector X982 of air mix
control motor, and do not remove the motor.
(b) Test the air mix control motor
Notice:
 Air mix control motor may be damaged

by incorrect power supply and ground.
Please follow the operation instruction
carefully.

when the air mix control motor stops.

X982-4 - Battery
The air mix control motor
positive
should be operated freely
X982-5 - Battery
and stopped at MAX COLD.
negative
Install the connector upside
X982-5 - Battery
down. The air mix control
positive
motor should be operated
X982-4 - Battery
smoothly and stopped at
negative
MAX HOT.
OK Go to step 4
NG
2 Inspect mechanism
(a) Remove the air mix motor.
(b) Inspect if the air control linkage and damper

move freely.
Result Proceed to
Linkage and damper
A
move freely
Linkage and damper
B
are stuck or seized
185
Replace air mix control motor
4 Inspect wire harness (air mix control motor - AC ECU)

control motor.
(b) Disconnect the AC ECU connector G47.
(c) Measure the resistance of the wire harness.
Standard Value
Wire Normal
Terminal
Color Condition
X982-2 - G47-39 Gr Less than 1 Ω
X982-3 - G47-8 P/B Less than 1 Ω
X982-5 - G47-16 P/L Less than 1 Ω
X982-4 - G47-34 G Less than 1 Ω
NG
OK
5 Inspect wire harness (air mix motor - body ground)

control motor.
Standard Value
Normal
Terminal Wire Color
Condition
X982-1 - Body
B Less than 1 Ω
ground
NG

OK
186
(a) Disconnect the connector G47 and measure

the resistance between each wire harness side
terminal and ground.
Standard Value
Wire Normal
Terminal
Color Condition
G47-39 - Body
Gr More than 10 kΩ
ground
G47-8 - Body
P/B More than 10 kΩ
ground
G47-16 - Body
G More than 10 kΩ
ground
G47-34 - Body
P/L More than 10 kΩ
ground
NG
OK
7 Inspect A/C controller (AC ECU)

connector G47.
(b) Turn the A/C on, and measure the output value.
Standard Value
Condition
Normal
Terminal (temperature
Condition
adjustment)
G47-39 -
A/C ON Approx. 5 V
Body ground
32°C Approx. 0.9 V
G47-8 - Body
25°C Approx. 1.9 V
ground
18°C Approx. 4.1 V
G47-16 - Temperature
11 ~ 14 V
G47-34 adjustment
Replace A/C controller (AC ECU)
OK
187
8 End
188
20
DTC Blower malfunction
(B2A2D)
Circuit Diagram
Battery Power ON
Blower
Blower
Blower
relay
Blower
governor
module
189
1 Inspect fuses
(a) Using a multimeter, inspect F1/21 and F4/6 of

dashboard distributor box for continuity.
OK:
Continuity
NG Replace fuse
OK
2 Inspect blower
(a) Wire from the rear side to connect the jumper
wire NO.1 of connector G42 with the body
ground.
(b) Turn the power switch on, and inspect the

operation of the blower.
NG:
The blower does not operate
Go to step 6
NG
OK
Inspect wire harness (blower - governor module/AC ECU, governor module - AC ECU,
3
governor module - blower relay)
(a) Disconnect the blower connector G42,
governor module connector G38 and AC ECU
connector G47.
Standard Value

G38-4 -
L/Y Less than 1 Ω
G42-1
G38-1 - Body
B Less than 1 Ω
ground
G38-4 -
L/Y Less than 1 Ω
G47-26
190
G42-1 -
G/W Less than 1 Ω
G47-26
NG
OK
4 Inspect A/C controller (AC ECU)

connector G47.
(b) Measure the output of terminal.
Normal
Terminal Condition
Condition
Turn the
The voltage
blower on, and
G47-3 - Body changes
adjust the
ground between 1.9
volume from
and 2.3 V
low to high
NG Replace A/C controller
OK
5 Replace blower governor module
6 Inspect blower power signal
(a) Disconnect the blower connector.
Standard Value
Wire Normal
Terminal Condition
Color Condition
G42-2 - Body Power
W/L 11 ~ 14 V
ground ON
OK Replace AC blower
191
NG
7 Inspect blower relay
(a) Remove the blower relay from the engine hood

distributor box.
(b) Inspect the blower relay.
(c) Inspect the terminals.
Standard Value

3, 5 Continuity
1, 2 Continuity
3, 5 No continuity
NG Replace blower relay
OK
Inspect wire harness (blower - relay, relay - dashboard distributor box, relay - body
8
ground)
(a) Disconnect the blower connector G42.
(b) Disconnect the connectors B1E, B2D and B1D
(c) Measure the resistance of the wire harness
Standard Value
Wire
Color
G42-2 - B1D-4 W/L Less than 1 Ω
B1E-10 - G47-14 B Less than 1 Ω
B1E-15 - B2D-14 B/Y Less than 1 Ω
NG
OK
9 End
192
DTC 22 (B2A2F) Line pressure malfunction
Circuit Diagram
Compressor
1 Inspect fuse
(a) Using a multimeter, inspect the fuse F1/12 of

front compartment distributor box for continuity.
OK:
Continuity
NG Replace fuse
OK
2 Inspect power supply signal of air conditioning pressure switch
(a) Disconnect the connector B03 of air

conditioning pressure switch.
193
(b) Measure the voltage of the wire harness

terminal.
Standard Value
Normal
Terminal Wire Color
Condition
C1F-3 - Body
R 11 ~ 14 V
ground
NG
Repair or replace wire harness
OK
3 Inspect air conditioning pressure switch
(a) Disconnect the connector B03 of air

conditioning pressure switch.
Standard Value
Normal
Terminal Condition
Condition
Refrigerant
B03-1 -
pipe line Less than 1 Ω
B03-4
pressure is OK
NG Go to step 8
OK
4 Inspect AC ECU pressure signal
(a) Connect the connector B03 of air conditioning

pressure switch
(b) Disconnect the AC ECU connector G47
(c) Measure the voltage of the wire harness

terminal.
Standard Value
Normal
Terminal Wire Color
Condition
G47-23 - Body
R 11 ~ 14 V
ground
194
NG
OK
5 Inspect refrigerant pressure
(a) Using a pressure gauge, inspect the A/C

refrigerant pressure.
Low pressure side: 0.15~0.25 MPa;
High pressure side: 1.47~1.67 MPa

NG
Refill or adjust refrigerant
OK
6 Replace pressure switch
195
Internal/External Circulation Adjustment does not Operate
Circuit Diagram
Circulation
control
motor
196
1 Inspect internal/external circulation control motor
(a) Disconnect the internal/external circulation

motor connector.
(b) Test the internal/external circulation control

motor.
Notice:
 Internal/external circulation control motor

may be damaged by incorrect power
supply and ground. Please follow the
operation instruction carefully.

when the internal/external circulation
control motor stops.

The internal/external
X985-5 - Battery circulation control motor
positive should be operated freely
X985-1 - Battery and stopped when the
negative external circulation (Fresh)
is switch is pressed
OK Go to step 4
NG
2 Inspect mechanism
(a) Remove the internal/external circulation control

motor
(b) Inspect if the air control linkage and damper

move freely
Result Proceed to
Linkage and damper move
A
freely
Linkage and damper are
B
stuck or seized
197
Replace the internal/external circulation control

motor
(a) Disconnect the AC ECU connector G47
(b) Measure the resistance between the wire

harness terminal and ground
Normal Value
G47-37 - Body
R/G More than 10 kΩ
ground
G47-18 - Body
R/W More than 10 kΩ
ground
NG
OK
5 Inspect wire harness (AC ECU - circulation motor)
(a) Disconnect the AC ECU connector G47.
(b) Disconnect the circulation motor connector

X985.
(c) Measure the resistance of the wire harness

terminal.
Standard Value
Normal
Terminal Wire Color
Condition
G47-18 - X985-1 G/W Less than 1 Ω
G47-37 - X985-5 Lg/R Less than 1 Ω
NG
OK
6 Replace AC ECU
198
A/C Controller Power Supply Circuit
Circuit Diagram
Power ON Power ON
Note: *3--476QZA+DCT
199
1 Inspect fuses
(a) Using a multimeter, inspect the fuse F2/4 or

F4/6 of dashboard distributor box for continuity.
OK:
Continuity
NG Replace fuse
OK
(a) Disconnect the A/C controller (AC ECU)

connector G47.
(b) Measure the voltage of terminals.
Standard Value
Wire Normal
Terminal Condition
Color Condition
G47-40 -
B/Y Power ON 11 ~ 14 V
Body ground
G47-33 - Less than
B Always
Body ground 1Ω
NG
OK
3 Power supply circuit is OK
200
Inspection of Condenser Fan and Radiator Fan
Circuit Diagram
Battery Battery
Condenser Radiat
fan or fan Conde
Radiat
nser or fan
fan relay
relay
Dashboard
distributor
box
Conde Radiat
nser or fan
fan motor
motor
Reserved
201
1 Inspect fuses
(a) Using a multimeter, measure the fuse F1/11 or

F1/10 for continuity
OK:
Continuity
NG Replace fuse
OK
2 Inspect fan
(a) Disconnect the fan connectors C02 and C15.
(b) Inspect the operation of the fan.
Standard Value
Normal
Terminal Condition
Condition
Fan moves
C02-2 - Battery (+)
-- smoothly at
C02-1 - Battery (-)
low speed
Fan moves
C15-2 - Battery (+)
-- smoothly at
C15-1 - Battery (-)
high speed
NG Replace fan
OK
3 Inspect wire harness (fan relay - main relay)
(a) Disconnect the connector B1E.
(b) Measure the voltage of the wire harness

terminal.
Standard Value
Wire Normal
Terminal Condition
Color Condition
B1E-16 -
Body G Power ON 11 ~ 14 V
ground
202
NG
OK
4 Inspect fan relays
(a) Remove relays K1-4 and K1-5, then inspect the

operation of the relays
Standard Value

3, 5 Continuity
1, 2 Continuity
3, 5 No continuity
NG Replace relays
OK
5 Inspect wire harness (fan - relay, fan - body ground, relay - ECM)
(a) Disconnect connectors C02, C15, C1F, B1E

and A10.
(c) Fan – Relay
Standard Value
Wire Normal
Terminal Condition
Color Condition
C15-2 - Less than 1
L/Y Always
C1F-14 Ω
C02-2 - Less than 1
L/W Always
C1F-16 Ω
Fan - Body ground
Standard Value
Wire Normal
Terminal Condition
Color Condition
203
C15-1 - Body Less than

B Always
ground 1Ω
C02-1 - Body Less than
B Always
ground 1Ω
Relay – ECM
Standard Value
Wire Normal
Terminal Condition
Color Condition
B1E-16 -
Less than
A10-4 G Always
1Ω
(473)
OK
6 Replace ECM
204
Only cooling function does not operate
Circuit Diagram
Power ON
Battery
Compressor
Dashbo
ard
Compre distribut
ssor or box
clutch
relay
Compre
ssor
clutch
A/C A/C
request permission
205
1 Inspect "High/Low Voltage Circuit Malfunction"
(a) Go to next step after troubleshooting the

high/low voltage circuit malfunction.
Next
2 Inspect A/C request signal
3 Inspect "Evaporator Temperature Sensor Circuit"
(a) Go to next step after troubleshooting the

evaporator circuit malfunction.
Next
4 Inspect fuses
(a) Using a multimeter, inspect fuses F1/12 and

F4/6 for continuity
OK:
Continuity
NG Replace fuse
OK
5 Inspect compressor relay
(a) Remove the relay K1-2, and inspect the

operation of the relay
Standard Value

3, 5 Continuity
1, 2 Continuity
3, 5 No continuity
Replace relay
206
OK
6 Inspect compressor
(a) Disconnect the connector A47.
(b) Connect the terminal A47-1 to the battery

positive terminal with a jumper wire, and then
connect and disconnect the negative terminal
repeatedly. Carefully listen for a clicking sound
from the compressor.
NG:
No sound
NG
Repair or replace compressor
OK
Check wire harness (compressor - relay, relay - AC ECU, relay - dashboard

7
distributor box)Inspect wire harness
(a) Disconnect connectors A47, C1F, B1E and
G47.
(c) Compressor – Relay
Standard Value
Wire Normal
Terminal Condition
Color Condition
A47-1 - Less than
L/R Always
C1F-2 1Ω
(d) Relay - AC ECU
Standard Value
Wire Normal
Terminal Condition
Color Condition
G47-31 - Less than
R Always
B1E-11 1Ω
NG
207
OK
8 Replace AC ECU and control panel assembly
208
Power Defroster does not operate
Circuit Diagram
209
1 Inspect operation
(a) Turn the defroster on, and inspect the operation
Result Proceed to
Both rear and mirror
Step 2
defrosters do not operate
Only rear defroster does not
Step 9
operate
Only mirror defroster does not
Step 16
operate
2 Inspect fuse

dashboard distributor box for continuity.
OK:
Continuity
NG Replace fuse
OK
3 Inspect defroster compensation signal
Tips:
If there is no compensation and the defroster still

functions normally, but the defrosting efficiency may
be lowered.
(a) Wire the rear end of the A/C control panel

connector G47.
Standard Value
Normal
Terminal Condition
Condition
G47-6 - Body Defrosting More than 9
ground function enabled V
NG Replace AC ECU
210
OK
4 Inspect wire harness (A/C control panel - ECM)
(a) Disconnect the A/C control panel connector

G47.
(b) Disconnect the ECM connector A01.
Normal Value

G47-6 -
Y Less than 1 Ω
A01-19
OK
5 Inspect MCU
(a) Disconnect the connector B1E of front

compartment distributor box.
(b) Measure the resistance between the terminals.
Standard Value
Normal
Terminal Condition
Condition
B1E-14 - Body Turn power Less than 1
ground defroster ON V
OK End
211
NG
6 Inspect CAN wire harness (MCU - AC ECU)
(a) Disconnect the A/C control panel connector

G47.
(b) Disconnect the connector B1I of front

(c) Inspect the connection of the wire harness.
Standard Value
Normal
Terminal Wire Color
Condition
G47-2 - B1I-2 P Less than 1 Ω
G47-1 - B1I-1 V Less than 1 Ω
OK
7 Replace AC ECU
(a) Temporarily replace the AC ECU with a

normally operating one, and inspect if the
malfunction recurs.
OK:
Malfunction does not recur
NG Replace MCU
OK
8 Replace AC ECU
9 Inspect fuse
(a) Inspect the fuse F1/15 of the front compartment

distributor box for continuity.
OK:
Continuity
212
NG Replace fuse
OK
10 Inspect rear defroster heater relay
(a) Remove the rear defroster heater relay.
(b) Inspect the relay.
Standard Value

3, 5 Continuity
1, 2 Continuity
3, 5 No continuity
NG
Replace rear defroster heater relay
OK
11 Inspect wire harness (front compartment distributor box - body ground)
(a) Disconnect the connector B1E of front

compartment distributor box
Standard Value
Test Normal
Terminal
Condition Condition
B1E-15 - Body
Power ON 11 ~ 14 V
ground
NG
Replace wire harness (BCM - MCU)
OK
12 Inspect front compartment distributor box (relay socket)
(a) Remove rear defroster heater relay K1-3.
213
(b) Inspect the relay socket.
Standard Value
Normal
Terminal Test Condition
Condition
88 - Body
Battery 11 ~ 14 V
ground
86 - Body
Power ON 11 ~ 14 V
ground
Power ON,
85 - Body
turn power Less than 1 V
ground
defroster on
NG
Replace front compartment distributor box
OK
13 Inspect rear defroster wire
(a) Disconnect the rear defroster wire connector.
(b) Using a multimeter, measure the resistance of

the wire.
Standard Value

X931-1 - Body
Approx. 1.2 Ω
ground
NG Repair rear defroster wire
OK
14 Inspect wire harness (front compartment distributor box - rear defroster wire)
(a) Disconnect the connector B1D of front

(b) Disconnect the rear defroster wire connector.
Standard Value
214
Normal
Terminal Wire Color
Condition
B1D-2 -
B/Y Less than 1 Ω
X931-1
OK
15 End
16 Inspect fuse

dashboard distributor box.
OK:
There is continuity in the fuse
NG Replace fuse
OK
17 Inspect outer rear view mirror defroster heater relay
(a) Remove the outer rear view mirror defroster

heater relay from the front compartment
distributor box.
(b) Inspect the relay.
Standard Value

3, 5 Continuity
3, 5 No continuity
NG
Replace outer rear view mirror defroster heater

relay
OK
Inspect wire harness (dashboard distributor box - outer rear view mirror defroster
18
heater relay)
215
(a) Disconnect the connector G37 of dashboard

wire harness.
(b) Turn the power switch ON, and measure

terminal voltage.
Standard Value
Normal
Terminal Wire Color
Condition
G37-11 - Body
Y/R 11 ~ 14 V
ground
G37-13 - Body
B/Y 11 ~ 14 V
ground
OK
Inspect wire harness (dashboard distributor box - outer rear view mirror defroster
19
heater relay)
(a) Disconnect the connector G37 of dashboard
wire harness.
(b) Turn the power switch ON, and measure

terminal voltage.
Standard Value
Wire Test Normal

Terminal
Color Condition Condition
G37-15 -
Turn power Less than
Body B
defroster ON 1V
ground
OK
20 Inspect outer rear view mirror defroster heater relay socket
(a) Remove the outer rear view mirror defroster

heater relay from the relay block.
(b) Inspect the relay socket.
216
Standard Value
Test Normal
Terminal
Condition Condition
88 - Body ground Battery 11 ~ 14 V
86 - Body ground Power ON 11 ~ 14 V
Power ON,
Less than 1
85 - Body ground turn power
V
defroster on
NG
Replace outer rear view mirror defroster heater

relay socket
OK
21 Inspect outer rear view mirror defroster wire
(a) Disconnect the rear defroster wire connector

(such as outer rear view mirror LH).
(c) Outer rear view mirror LH
Standard Value

T05-5 - T05-10 Approx. 6.5 Ω
(a) Outer rear view mirror RH
Standard Value

U05-5 - U05-10 Approx. 6.5 Ω
NG Replace defroster wire
OK
Inspect wire harness (outer rear view mirror defroster heater relay - rear defroster
22
wire)
(a) Disconnect the relay connector G37.
217
(b) Disconnect outer rear view mirror defroster wire

connectors (T05 for LH, U05 for RH).
(d) Outer rear view mirror LH
Standard Value
Wire Normal
Terminal
Color Condition
T05-5 - G37-12 O Less than 1 Ω
T05-10 - Body
B Less than 1 Ω
ground
(a) Outer rear view mirror RH
Standard Value
Normal
Terminal Wire Color
Condition
U05-5 - G37-12 O Less than 1 Ω
U05-10 - Body
B Less than 1 Ω
ground
Abnormal
OK
23 End
Preparation of Tools
Crosshead screwdriver 1
10# T-type socket or ratchet wrench 1
Flat-head screwdriver
218
8 Removal and Installation of b Using a flat-head screwdriver, remove the

snap-fits around itc Remove the A/C
A/C Panel panel, and disconnect the rear panel
connector
Removal
8.1 Turn power switch off
8.3 Remove combination instrument head

cover
8.4 Remove dashboard center cover plate (it

is ok to not remove but pry up its lower
part only) Installation
1 Install A/C panel
8.5 Remove center console trim strip
Put the A/C panel into the fixing position,
8.6 Remove gear shift mechanism cover and connect the rear panel connector
plate
2 Install cigarette lighter box (using a
8.7 Remove cigarette lighter box crosshead screwdriver to fix the 2 tapping
screws)
8.8 Remove A/C panel
3 Install gear shift mechanism cover plate
a Using a crosshead screwdriver, remove
4 Install center console trim strip
the 2 set screws
5 Install dashboard center cover plate
6 Install combination instrument head cover
219
9 Removal and Installation of fixing points between the A/C case and
cowl panel
A/C Case
Removal
9.1 Turn power switch off
9.3 Recover refrigerant
9.4 Remove dashboard upper body

(removes A-pillar upper protector LH/RH,
disconnect each connector and remove
the service bolt, ground point, etc.
between the airbag and tubular beam) c Tools: crosshead screwdriver, flat-head
screwdriver, 10# socket, 13# socket with
9.5 Remove sub dashboard ratchet and T-type bar
9.10 Disconnect steering column

9.6 Remove dashboard lower body
9.11 Take the tubular beam out of the cab
9.7 Disconnect each connection point
together with the case
between tubular beam and body
9.8 Disconnect each line on A/C case Installation

(refrigerant line/heater water pipe/outlet
water pipe) 1 Put the tubular beam into the correct
position of the cab together with the case
9.9 Remove fixing points (a bolt and a nut) 2 Connect steering column
between A/C case and cowl panel 3 Install A/C Case
a Install the A/C case to the fixing position

and connect each connector and line
b Install the 2 fixing points between the A/C

case and cowl panel
4 Connect each line on the A/C case
5 Install each connection point between
tubular beam and body
6 Install dashboard lower body
7 Install sub dashboard
8 Install dashboard upper body
9 Charge refrigerant
a Disconnect each connector on the A/C 10 Connect battery negative
b Using a ratchet wrench, remove the 2
220
10 Removal and Installation of 2 Install the 2 lines on the compressor

A/C Compressor
Removal 3 Charge refrigerant
1 Turn power switch off 4 Connect battery negative
2 Disconnect battery negative 11 Removal and Installation of

3 Recover refrigerant from compressor
Solar Sensor
and refrigeration line
Removal
4 Disconnect the 2 lines on the
compressor 1 Turn power switch off
5 Remove compressor 3 Remove dashboard body
4 Remove solar sensor
a Loosen belt tension bolts (3 in total)
(a) Disconnect solar sensor connector
b Remove the compressor belt
(b) Using a flat-head screwdriver, pry the
c Disconnect the compressor connector snap-fits on both sides
d Using 10# ratchet wrench, remove the 4 (c) Remove the solar sensor from the lower
set bolts part.
Installation
1 Install compressor
a Place the compressor on the fixing

position Installation
b Using 10# ratchet wrench, install the 4 set 1 Install solar sensor to fixing position
bolts 2 Connect solar sensor connector
3 Put dashboard body into fixing position
c Connect the compressor connector 4 Install dashboard body
221
12 Removal and Installation of fixing position, and connect the room

temperature sensor connector
Room Temperature Sensor 2 Install the dashboard lower protector LH to
Removal the fixing position, and snap the snap-fits
1 Turn power switch off around it
2 Disconnect battery negative 3 Install the dashboard lower acoustic panel
3 Remove dashboard lower acoustic panel LH to the fixing position, and snap the
LH snap-fits around it. Using a crosshead
4 Remove dashboard lower protector screwdriver, install the 2 set screws
assembly LH 4 Connect battery negative
5 Remove room temperature sensor
a Remove the dashboard lower acoustic
panel LH. Using a crosshead screwdriver, Outside Temperature Sensor
remove the 2 set screws. Carefully remove
the snap-fits around it and remove the Removal
acoustic panel
1 Turn power switch off
3 Remove front bumper
4 Remove outside temperature sensor
a Disconnect the outside temperature

sensor connector
b Using a flat-head screwdriver carefully
pries the snap-fits on both sides and
removes the outside temperature sensor
b Remove the dashboard lower protector

assembly LH. Carefully remove the
snap-fits around it and remove the protector
c Disconnect the room temperature sensor
connector
d Using a flat-head screwdriver, pry the
snap-fits on both sides. Remove the room
temperature sensor from behind
Installation
1 Install outside temperature sensor
(a) Install the outside temperature sensor to

the fixing position, and snap the snap-fits
(b) Connect the outside temperature sensor
connector
Installation
2 Install front bumper
1 Install the room temperature sensor to the 3 Connect battery negative
222
Chapter 8
SRS System
Contents
1 Parts Location ....................................................................................................... 224
2 System Overview .................................................................................................. 228
3 Safety Regulations for Repairing Supplemental Restraint System ...................... 231
4 Diagnosis Flow ..................................................................................................... 233
5 Diagnostic Trouble Code Chart ............................................................................ 235
6 Problem Symptoms Chart .................................................................................... 236
7 ECU terminals ....................................................................................................... 237
8 Entire System does not Operate .......................................................................... 240
9 Special Tool ........................................................................................................... 299
223
1 Parts Location
Curtain Shield
Airbag RH
Front collision Curtain Shield

sensor RH Side collision Airbag LH
sensor RH
Rear collision
sensor LH
Rear collision
sensor RH
Front collision
sensor LH
Side collision
sensor LH
224
225
Driver airbag (DAB) Passenger airbag

(PAB)
SRS electronic
control unit
226
Driver airbag
Front collision sensor
(DAB)
LH
Passenger airbag
Front collision sensor (PAB)
RH
Side collision sensor Curtain Shield

LH Airbag LH
Curtain Shield
Rear side collision Airbag RH
sensor LH
Front seat side

airbag LH
Rear side collision
sensor LH Front seat airbag
RH
Rear side collision

sensor RH Front seat belt
pretension LH
PAB switch Front seat belt

pretension RH
Collision unlock signal
Combination
instrument
227
2 System Overview equipped)

8 Curtain shield airbag module (if equipped)
9 Front occupant airbag module (airbag
Vehicle safety is classified into active safety inflator)
system and passive safety system. The active 10 Seat belt warning sensor (if equipped)
safety refers to the ability to predict danger,
such as the view of windshield, lighting system
and reflector; the ability to avoid danger in
advance, such as steering system, braking
system, anti-slip regulation and stability control
system. The passive safety refers to the ability
to avoid or reduce the injury to the occupant,
such as seat belt and airbag.
The Supplemental Restraint System (SRS)

described in this section is a passive, inflatable
and supplementary protection system. Vehicle
equipped with this system can be identified
quickly by the mark "SRS-AIR-BAG".
Airbag ECU is installed in the central axis,
under the center console panel. Even when
the battery voltage is too low or the power
supply is cut off due to a collision, airbag ECU
can still operate continuously more than 100
ms.
Driver airbag (DAB) is installed in the steering

wheel center pad and cannot be disassembled.
DAB includes the gas generator, airbag, pad,
support and other accessories. The function of
the DAB is designed to receive an ignition
The driver airbag mark is stamped on the
signal from the airbag ECU, initiate the gas
steering wheel center pad and the passenger
generator to generate a lot of gas, which
airbag mark on the dashboard above the glove
inflate the airbag and form an air cushion to
box. In addition, vehicle equipped with
protect the occupant.
Supplemental Restraint System can be
identified by an airbag malfunction indicator
The clock spring, installed on the combination
light in the combination instrument (as shown
switch, consists of the spiral cable, rotor, case,
in the left figure). The airbag malfunction
wire harness and other accessories. The rotor
indicator light in the combination instrument
and steering wheel will be rotated as a unit
comes on for approximately 5 seconds as a
when turning the steering wheel. There is a
self-check of this system every time the power
long enough spiral cable wound around the
switch is turned on.
case, therefore, even when the rotor is rotated
clockwise or counterclockwise 2.5 turns from
The supplemental restraint system consists of
the neutral position, the reliability of the wire
the following main components:
harness connection will not be affected.
1 Front collision sensor
Front occupant airbag (PAB) is installed above
2 SRS ECU
the glove box. The components and function of
3 SRS warning lamp
the PAB are the same as those of the DAB.
4 Clock spring
Front collision sensor LH is installed to the
5 Driver airbag module (airbag inflator)
inside of longitudinal beam LH of front
6 Side collision sensor (if equipped)
compartment. Front collision sensor RH is
7 Front seat side airbag module (if
228
installed to the inside of longitudinal beam RH

of front compartment. The function of the front
collision sensors is designed to send a
collision signal to the SRS ECU. Depending on
this signal, ECU can determine whether it is
necessary to send out an ignition signal and
collision unlock signal.
Airbag wire harnesses are used to connect

SRS ECU, DAB, PAB, SAB, CAB, clock spring
and dashboard wire harness, etc. The airbag
wire harnesses include the airbag module
drive line, warning lamp line, collision unlock
line and complete vehicle communication bus,
etc. The function of the airbag wire harnesses Seat belt: It is the main active protection
is designed to send a signal among airbag equipment used to protect the passengers. In
ECU, airbag module and complete vehicle, to the event of a sudden braking, collision or
ensure a reliable communication. The airbag roll-over, it can force the occupant securely on
wire harnesses can be identified by their the seats, restrain the position of the driver or
yellow cables or connectors. occupant, avoid or reduce injury to the
occupant during a secondary collision caused
Airbag malfunction indicator light is located in by the inertia force. To obtain maximum
the combination instrument. When there is a safety from the supplemental restraint system,
malfunction in the self diagnosis circuit of the occupant must wear the seat belt.
SRS ECU, the airbag malfunction indicator Seat belt lock striker signals from combination
light will come on to inform the driver of a instrument: Monitor the driver seat belt
malfunction in the supplemental restraint
system. Under normal conditions, when the
power switch is turned ON, the indicator Child safety protection lock (CPLS): The doors
should be illuminated for 5s and then turned cannot be opened from inside the vehicle by
off. the rear seat occupant when the CPLS is set.
They must be opened from the outside. This
Other items used to assist the supplemental helps avoid the risk of sudden opening of the
restraint system are as follows: door caused by children's disoperation or car
collision.
Steering wheel lower protector: It is a molded
structural member, located on the backside of Tillable front headrest: Avoid injury to the neck
the steering column opening cover, integrated of occupant during a collision.
with the dashboard and can protect the knees
of the driver during a collision. Laminated safety glass (LSG): Avoid injury
caused by glass splinter during a collision.
Console box assembly LH: It is a structural
reinforcement and can protect the knees of the Collision avoidance and energy absorbing
driver during a collision. body and accessories: Include energy
absorbing bumper, cushion, impact door beam,
Console box assembly RH: It is a structural etc.
reinforcement, hidden in the glove box door,
integrated with this door and can protect the Supplemental restraint system:
knees of the front seat passenger during a
collision. This supplemental restraint system is
developed and made by BYD Corporation and
its operation is shown in the left figure.
229
(G) measured by the collision sensor in the

Collision range SRS ECU. When a front collision is serious
enough, an operation signal will be sent to the
inflators of the 2 airbag modules by the micro
processor in the SRS ECU to deploy the
airbags. The clock spring on the top of the
steering column keeps a continuous circuit
between the fixed steering column and driver
Power supply airbag (DAB) inflator and turns as the rotation
of the steering wheel. When the airbags are
deployed during a front collision of the vehicle,
knee bars will operate in cooperation with seat
belts and restrain the driver and front seat
Safety Initiator passenger on the proper positions. The keen
sensor bars can also absorb and dissipate the impact
energy of the driver and front seat passenger
to the construction of the dashboard. When
the SRS ECU detects that there is a
Deceleration malfunction in any airbag component and
sensor airbag system circuit, it will store a trouble
code or DTC in the memory, and send the
information to the combination instrument to
The operation of the airbag depends on the turn on the airbag malfunction indicator light. A
collision angle and severity of the vehicle. The malfunction diagnostic tester is required to
collision operating angle designed for the correctly test components of the airbag system,
supplemental restraint system uses a collision read or clear trouble codes, perform repairs,
angle within 30°ahead of the body center line etc.
as standard. Rather than the vehicle speed,
the deployment of the airbag depends on the
deceleration rate calculated from the gravity
230
3 Safety Regulations for Warning labels are attached to the SRS

Repairing Supplemental parts and the related positions in the
vehicle. Follow the instructions on the
Restraint System labels while performing the operation.
3.1. Overview Before repairs, remove the airbag ECU if
vibrations may be applied to the vehicle
Failure to carry out service operations in during servicing other systems or parts of
the correct sequence could cause the the vehicle.
airbag to unexpectedly deploy during
servicing the supplemental restraint
system, leading to a serious accident.
Furthermore, if a mistake is made during
service operations, the airbag may fail to
deploy when required. Therefore, before
servicing, be sure to read the following
precautions carefully and follow the correct
operation procedures.
Right Wrong
3.2. Precautions:
Never test any circuit of the supplemental

restraint system with electrical test Remove and store parts such as airbag
equipment, unless instructed by the repair ECU, DAB, PAB, SAB, CAB and clock
manual. spring if the painting work may affect them
by high temperature (more than 93°C).
When installing the airbag ECU, make
sure it is installed in the correct direction so During servicing of SRS, the airbag
that it can operate normally. Before module should be installed to the vehicle
installation, inspect it for cracks, as soon as it is taken out of the transport
deformation or rust. container. If a stop operation is required,
put the airbag module back into the
Never use SRS parts removed from other transport container. Do not leave the
vehicles when replacing parts, with new airbag module in an unattended place.
parts. Always place the airbag module with
deployment surface facing upward.
Never disassemble, repair or install parts
such as the DAB, PAB, and SAB, CAB and
SRS ECU for reuse or other purpose.
Never expose parts such as the DAB, PAB,

SAB, CAB and SRS ECU directly to hot air
or flames. Wrong
Right
If the vehicle has been involved in a minor
collision where the airbag does not deploy,
the SRS should be inspected. Before starting a special service operation,
turn the power switch off, remove the
If parts such as the DAB, PAB, SAB, CAB battery negative ground wire, and wait for
and SRS ECU are dropped on the ground more than 90s. Failure to do so may cause
or subjected to any vibration or impact, or if the airbag to unexpectedly deploy. In
any cracks, dents or other defects are addition, insulate the removed negative
found on the cases, supports or ground wire with insulation tape as shown
connectors, replace them with new parts. in the figure.
231
If the dashboard is damaged after the

airbag has deployed, replace it.
Negative (-)
terminal Activation prevention mechanisms are
provided for connectors of airbag ECU,
clock spring, DAB, PAB, SAB and CAB, to
prevent accidental airbag activation.
Do not connect the airbag module with the

circuit immediately after servicing the SRS.
An electrical inspection should be
When the battery negative ground wire is performed first. Connect the airbag module
removed, the DTCs of other systems will after it is proved to be normal.
be lost. So be sure to make a record of the
status in other systems before removing The normal useful life of the airbag is 10
the battery negative ground wire. years, beyond which time the airbag and
the label must be replaced.
Before starting work with an electric welder
anywhere on the vehicle, be sure to The airbag inflator contains sodium aside
disconnect the SRS to avoid deployment. and niter. These materials are poisonous
and inflammable. If exposed to the acid,
While testing, use a voltmeter/ohmmeter water or heavy metal, harmful and irritant
with high impedance (minimum 10 kΩ/V) gas (easy to form sodium hydroxide in a
instead of a test light, a common voltmeter wet place) or combustible compound will
or ohmmeter. Do not use an ohmmeter on be produced. The airbag contains
the DAB, PAB, SAB or CAB. pressurized argon gas, please do not
attempt to disassemble the airbag,
Before and after replacing any parts, be damage the inflator of the airbag, puncture
sure to perform a system self-diagnosis or burn the airbag, allow the airbag to
operation to over check for normal function contact with the electric or store it in a
of the system. place with ambient temperature more than
93°C.
232
4 Diagnosis Flow
Tips:
a Perform malfunction diagnosis in accordance

with the flow
Customer problem analysis: Ask the customer

about the vehicle conditions and the environment
present when the problem occurred.
Next
Standard voltage:
11 to 14 V

Next
3 On-vehicle inspection
Self-diagnosis of SRS malfunction indicator light

circuit in combination instrument:
(a) Turn the power switch on, and enter the SRS
system self-diagnosis.
(b) Observe the illumination condition of the

malfunction indicator light.
Result Proceed to
Illuminated for 5 seconds OK
and then goes off
Remains on NG
OK System is OK
NG
233
4 Diagnose with a malfunction diagnostic tester
(a) Connect the malfunction diagnostic tester to

Handheld tester the malfunction diagnostic interface
(b) Read the diagnostic trouble code (DTC) by

following the prompts on the diagnostic tester
Result Proceed to
DTC is output A
No DTC is output B
B Go to step 5
Go to overall diagnosis flow and repair corresponding trouble area according to

5
diagnostic trouble code chart.
Next
6 Go to overall diagnosis flow directly
Next
7 End
234
5 Diagnostic Trouble Code Chart
DTC Malfunction Description

B1600-00 Driver front airbag disconnected
B1601-00 Short to GND in driver front airbag
B1602-00 Power supply short in driver front airbag
B1610-00 Assistant driver front airbag disconnected
B1611-00 Short to GND in assistant driver front airbag
B1612-00 Power supply short in assistant driver front airbag
B1620-00 Driver side airbag disconnected
B1621-00 Short to GND in driver side airbag
B1622-00 Power supply short in driver side airbag
B1630-00 Assistant driver side airbag disconnected
B1631-00 Short to GND in assistant driver side airbag
B1631-00 Power supply short in assistant driver side airbag
B1640-00 Driver seat belt pretension disconnected
B1641-00 Short to GND in driver seat belt pretension
B1642-00 Power supply short in driver seat belt pretension
B164A-00 Assistant driver seat belt pretension disconnected
B164B-00 Short to GND in assistant driver seat belt pretension
B164C-00 Power supply short in assistant driver seat belt pretension
B1654-00 Front collision sensor LH disconnected
B1655-00 Short to GND in front collision sensor LH
B165D-00 Front collision sensor RH disconnected
B165E-00 Short to GND in front collision sensor RH
B1666-00 Side collision sensor LH disconnected
B1667-00 Short to GND in side collision sensor LH
B166F-00 Side collision sensor RH disconnected
B1670-00 Short to GND in side collision sensor RH
B1676-00 Rear side collision sensor LH disconnected
B1677-00 Short to GND in rear side collision sensor LH
B167A-00 Rear side collision sensor RH disconnected
B167B-00 Short to GND in rear side collision sensor RH
B168D-00 SRS ECU malfunction
U1004 Short to GND in CAN
U1005 Power supply short in CAN
235
U0146 Lost communication with gateway

B1693-00 Bad ground wire connection
B1694-00 Power supply voltage too low
B1695-00 Power supply voltage too high
B1696-00 SRS ECU malfunction
B169A-00 SRS ECU malfunction
B169D-00 SRS ECU malfunction
B169E-00 SRS ECU malfunction
B169F-00 SRS ECU malfunction
B16A1-00 SRS ECU malfunction
B16AC-00 SRS ECU malfunction
B16AD-00 SRS ECU malfunction
B16AE-00 Ignition encryption
B1704-00 Driver side curtain shield airbag disconnected
B1705-00 Short to GND in driver side curtain shield airbag
B1706-00 Power supply short in driver side curtain shield airbag
B170D-00 Assistant driver side curtain shield airbag disconnected
B170E-00 Short to GND in assistant driver side curtain shield airbag
B170F-00 Power supply short in assistant driver side curtain shield airbag
B17FF-00 Pulse speed malfunction
U0155 Lost communication with combination meter

Problem Symptom Trouble Area
Entire system does not Fuse
operate SRS ECU
Wire harness
236
7 ECU terminals
Inspect ECU terminals of SRS system (plate end
connector)
(a) Wire the rear end of the connector K21 for SRS
ECU and measure the voltage or resistance of
each terminal.
Terminal No. Wire Terminal Description Test Condition Normal

Color Value
K21-1 ---- N/A ---- ----
K21-2 ---- N/A ---- ----
K21-3 ---- N/A ---- ----

K21-4 ---- N/A ---- ----
K21-5 ---- N/A ---- ----
K21-6 ---- N/A ---- ----
K21-7 ---- N/A ---- ----
K21-8 ---- N/A ---- ----
K21-9 - K21-10 O/R-Y/B Front seat belt pretension LH ---- ----

(low - high)
K21-11 - V/R-V/B Front seat belt pretension RH ---- ----
K21-12 (high - low)
K21-13 - Y/B-Y/R Curtain shield airbag RH (low - ---- ----
K21-14 high)
K21-15 - L/R-L/B Curtain shield airbag LH (high - ---- ----
K21-16 low)
K21-17 - G/B-P Side collision sensor RH ---- ----
K21-18 (positive - negative)
K21-19 - R-Y/R Side collision sensor LH ---- ----
237
K21-21 ---- N/A ---- ----
K21-22 ---- N/A ---- ----
K21-23 ---- N/A ---- ----
K21-24 - G/Y-L/Y Rear side collision sensor LH ---- ----

K21-26 - Lg/Y-L/Y Rear side collision sensor RH ---- ----
K21-28 ---- N/A ---- ----
K21-29 ---- N/A ---- ----
K21-30 ---- N/A ---- ----
K21-31 ---- N/A ---- ----
K21-32 ---- N/A ---- ----
(b) Wire the rear end of the connector G36 for SRS
ECU and measure the voltage or resistance of
each terminal.
Terminal No. Wire Color Terminal Description Test Condition Normal Value
G36-1 - Body R/B Power ON Power ON 11 V - 14 V
ground
G36-2 - G36-13 L/W-Br/W Front collision sensor ---- ----
LH (low - high)
G36-3 - G36-14 G/B-P- Front collision sensor ---- ----
RH (low - high)
G36-4 ---- N/A ---- ----
G36-5 ---- N/A ---- ----
G36-6 ---- N/A ---- ----
G36-7 ---- N/A ---- ----
G36-8 - Body V CAN_L Always 1.5 V - 2.5 V

ground
G36-9 - Body P CAN_H Always 2.5 V - 3.5 V
ground
G36-11 - Body W/B Signal ground Always Less than 1 Ω
ground
G36-12 - Body W/B System ground Always Less than 1 Ω
ground
G36-15 ---- N/A ---- ----
G36-16 ---- N/A ---- ----
238
G36-17 - G36-18 L/B-L/R Front seat side airbag ---- ----

LH (low - high)
G36-19 - G36-20 Y/R-Y/B Front seat side airbag ---- ----
RH (high - low)
G36-21 - G36-22 W/L-G/R Assistant driver airbag ---- ----
(low - high)
G36-23 - G36-24 Y/R-Y/B Clock spring (driver ---- ----
airbag)
239
8 Entire System does not Operate

Circuit Diagram
Power ON
240
1 Inspect fuse
(a) Using a multimeter, measure the continuity of

fuse F2/32
NG Replace fuse
OK
2 Inspect dashboard distributor box
(a) Inspect the voltage of dashboard distributor box

terminal G2S-1.
Terminal Wire Measurement Normal

Connection Color Condition Value
G2S-1 - R/B ACC 11 ~ 14
Body V
ground
NG
OK
(a) Disconnect the connector G2S of dashboard

distributor box.
(b) Disconnect the connector G36 of SRS ECU.

Terminal Wire Normal Value

Connection Color
G2S-1 - G36-1 R/B Less than 1 Ω
G36-12 - Body W/B Less than 1 Ω
ground
G36-11 - Body W/B Less than 1 Ω
ground
241
NG
OK
4 Inspect SRS ECU
242
B1694-00, Power Supply Voltage too Low or

DTC
B1695-00 High
Circuit Diagram
1#Ignition switch
Relay Combination
instrument
Voltage regulator
Gene
rator Rectifier
Field coil
Battery
Engine
assembly Transmission assembly
243
1 Inspect generator
(a) Disconnect the connector A1B, and measure

the terminal voltage.
Terminal Wire Color Measurement Normal

Connection Condition Value
A1B - Body B Starting 11-14V
ground engine
NG Repair or replace engine
OK
2 Inspect IG1 relay
(b) Remove KG-1 relay.
(c) Apply battery voltage to terminals 1 and 2, and

inspect for continuity between terminals 3 and
5.
Terminal Condition Normal Value

3-5 Battery voltage Less than 1 Ω
applied to
terminals 1 and 2
3-5 Battery voltage not More than 10
applied to kΩ
terminals 1 and 2
NG Replace IG1 relay
OK
3 Replace power supply wire harness
244
DTC B1693-00 Bad ground wire connection

Circuit Diagram
Power ON
(a) Before the inspection of the wire harness,

inspect the ground points and the ground of the
SRS ECU case for looseness. Make sure they
are in good connection before going to the next
step.

the resistance between the wire harness
terminal and body ground.
245

G36-11 - W/B Always Less
Body ground than 1 Ω
G36-12 - W/B Always Less
Body ground than 1 Ω
OK
5 Replace ECU (internal malfunction of ECU)
246
DTC B1600-00 Driver front airbag disconnected

Circuit Diagram
Clock
spring
Driver
airbag
1 Inspect if driver airbag connector is securely connected
(a) Disconnect and reconnect the driver airbag

connector (make sure the connector is securely
connected).
(b) Turn the power switch on. Clear the trouble

code with the diagnostic tester and wait for at
least 20 seconds.
(c) Turn the power switch off.
(d) Turn the power switch on and read the trouble

code with the diagnostic tester.
Result Proceed to
Trouble code does not A
reoccur
247
Trouble code reoccurs B
System is OK (poor connector connection or

disconnected)
Inspect driver airbag wire harness for short to GND or power supply (If this occurs,
2
this malfunction will also be displayed)
(a) Disconnect the driver airbag connector, and
measure the voltage and resistance between
wire harness terminal and ground.
Measure Resistance to Ground

1 - Body Y/R Always More
ground than 1
MΩ
2 - Body Y/B Always More
ground than 1
MΩ
Measure Voltage to Ground

1 - Body Y/R Always Less
ground than 1 V
2 - Body Y/B Always Less
ground than 1 V
NG
OK
3 Inspect driver airbag module
(a) Replace the driver airbag module with a new

one.

least 20 seconds.
248

Result Proceed to
reoccur
Replace airbag module with a new one
4 Inspect clock spring
(a) Disconnect the airbag connector and

disconnect the butt connector between the
clock spring and SRS ECU.
(b) Using a thin plastic sheet, lift the short plate of

the butt connector. Measure the resistance
between 2 terminals on either side of the clock
spring.
(c) Using a thin plastic sheet, lift the short plate of

the butt connector. Measure the resistance
between 2 terminals corresponding to
connectors on both sides of the clock spring.
Terminal Connection Normal Resistance

Value
2 terminals on either side More than 1 MΩ
Terminals corresponding Less than 1 Ω
to connectors on both
sides of clock spring
NG Replace clock spring
OK
5 Inspect if clock spring and airbag wire harness are securely connected
(a) Connect the clock spring and airbag wire

harness.
249

least 20 seconds.

Result Proceed to
reoccur
System is OK (butt wire harnesses connection

poor)
(a) Disconnect the connector G36 of SRS ECU

and the connector of airbag connector.
(b) Using a thin plastic sheet, lift the short plates of

G36-23 and G36-24. Using a multimeter,
measure the resistance between G36-23 and
airbag terminal No.1, and between G36-24 and
airbag terminal No.2.

1-G36-23 Y/R Always Within 1
Ω
2-G36-24 Y/B Always Within 1
Ω
NG
Replace wire harness (clock spring - ECU)
OK
7 Replace SRS ECU
250
Assistant driver front airbag

DTC B1610-00
disconnected
Circuit Diagram
Assist
ant
driver
airbag
Check if butt connector between branch wire of assistant driver airbag module and
1
airbag wire harness is securely connected
(a) Disconnect and securely reconnect the butt
connector between the branch wire of the
assistant driver airbag module and airbag wire
harness.

least 20 seconds.

Result Proceed to
Trouble code does not reoccur A
251

disconnected)
B
2 Inspect assistant driver airbag module (with branch wire)
(a) Connect a new assistant driver airbag module.

least 20 seconds.

Result Proceed to
Replace airbag module (with branch wire)
Inspect assistant driver airbag wire harness for short to GND or power supply (If
3
this occurs, this malfunction will also be displayed)
(a) Disconnect the assistant driver airbag
connector, and measure the voltage and
resistance between wire harness terminal and
ground.

G46-1 - G/R Always More
Body than 1
ground MΩ
G46-2 - W/L Always More
Body than 1
ground MΩ
252
Terminal Wire Measurem Normal

Connection Color ent Value
Condition
G46-1 - G/R Always Less than
Body 1V
ground
G46-2 - W/L Always Less than
Body 1V
ground
NG
Replace airbag wire harness
OK
(a) Using a thin plastic sheet, lift the short plates of

G36-22 and G36-21. Measure the resistance
between terminals G46-1 and G46-2 on one
side of the connector between assistant driver
airbag modules.

G36-22 and G36-21. Measure resistance of the
connector between SRS ECU and assistant
driver airbag module, and the resistance
between G46-1 on one side of the front
occupant airbag module and G36-22 on one
side of the SRS ECU connector wire harness.
(c) Using a thin plastic sheet, lift the short plates of

connector between SRS ECU and front
occupant airbag module, and the resistance
between G46-2 on one side of the front
occupant airbag module and G36-21 on one
side of the SRS ECU connector wire harness.

G46-1 - ---- Always More
G46-2 than 1
MΩ
G46-1 - G/R Always Less
G36-22 than 1 Ω
G46-2 - W/L Always Less
G36-21 than 1 Ω
253
NG
Replace corresponding wire harness or

connector
OK
5 Inspect SRS ECU
(a) Connect a new SRS ECU.

least 20 seconds.

Result Proceed to
reoccur
A Replace SRS ECU
6 Replace airbag wire harness (poor connection caused by airbag wire harness)
254
DTC B1620-00 Driver side airbag disconnected
Circuit Diagram
Front
seat side
airbag
LH
Inspect if butt connector between branch wire of front seat side airbag module LH
1
and airbag wire harness is securely connected
connector between the branch wire of the front
seat side airbag module LH and airbag wire
harness.

least 20 seconds.

255
Result Proceed to
reoccur

disconnected)
B
2 Inspect front seat side airbag module LH (with branch wire)
(a) Connect a new front seat side airbag module

LH.

least 20 seconds.

Result Proceed to
reoccur
A
Inspect wire harness of front seat side airbag module LH for short to GND or
3
power supply (If this occurs, this malfunction will also be displayed)
(a) Disconnect the connector of the front seat side
airbag module LH, and measure the voltage
and resistance between wire harness terminal
and ground.
256

KJ09-2 - L/B Always More
Body ground than 1
MΩ
KJ09-1 - L/R Always More
Body ground than 1
MΩ

KJ09-2 - L/B Always Less
Body ground than 1
V
KJ09-1 - L/R Always Less
Body ground than 1
V
NG
OK
(a) Disconnect connectors KJ09 and G36.
(b) Before inspecting the wire harness, disconnect

and securely reconnect the 2 butt connectors of
the wire harness.

between terminals KJ09-2 and KJ09-1 on one
side of the connector between front seat side
airbag modules LH
(d) Using a thin plastic sheet, lift the short plates of

connector between SRS ECU and front seat
side airbag module LH, and the resistance
between KJ09-2 on one side of the front seat
side airbag module LH and G36-17 on one side
of the SRS ECU connector wire harness
(e) Using a thin plastic sheet, lift the short plates of

257
connector between SRS ECU and front seat

side airbag module LH, and the resistance
side airbag module LH and G20-18 on one side
of the SRS ECU connector wire harness

KJ09-1 - ---- Always More
KJ09-2 than 1
MΩ
KJ09-2 - L/B Always Less
G36-17 than 1
Ω
KJ09-1 - L/R Always Less
G36-18 than 1
Ω
NG

connector
OK
5 Inspect SRS ECU

least 20 seconds.

Result Proceed to
A Replace SRS ECU
258
Assistant driver side airbag

DTC B1630-00
disconnected
Circuit Diagram
airbag RH
Front seat side
Inspect if butt connector between branch wire of front seat side airbag module RH
1
and airbag wire harness is securely connected
connector between the branch wire of the front
seat side airbag module RH and airbag wire
harness.

least 20 seconds.

259
Result Proceed to

disconnected)
B
2 Inspect front seat side airbag module RH (with branch wire)
(a) Connect a new front seat side airbag module

RH.

least 20 seconds.

Result Proceed to
Inspect wire harness of front seat side airbag module RH for short to GND or
3
power supply (If this occurs, this malfunction will also be displayed)
(a) Disconnect the connector of front seat side
airbag module RH, and measure the voltage
and resistance between wire harness terminal
and ground.
260

KJ10-2 - Y/B Always More
Body ground than 1
MΩ
KJ10-1 - Y/R Always More
Body ground than 1
MΩ

KJ10-2 - Y/B Always Less
Body ground than 1
V
KJ10-1 - Y/R Always Less
Body ground than 1
V
NG
OK
(a) Disconnect connectors KJ10 and G36.

between terminals KJ10-1 and KJ10-2 on one
side of the connector between front seat side
airbag modules RH.

connector between SRS ECU and the front
seat side airbag module RH, and the resistance
between the KJ10-2 on one side of the front
seat side airbag module RH and G36-20 on
one side of the SRS ECU connector wire
harness.
(d) Using a thin plastic sheet, lift the short plates of

connector between SRS ECU and the front
seat side airbag module RH, and the resistance
side airbag module RH and K21-19 on one side
261
of the SRS ECU connector wire harness.

KJ10-1 - ---- Always More
KJ10-2 than 1
MΩ
KJ10-2 - Y/B Always Less
G36-20 than 1
Ω
KJ10-1 - Y/R Always Less
G36-19 than 1
Ω
NG

connector
OK
5 Inspect SRS ECU

least 20 seconds.

Result Proceed to
Replace SRS ECU
Driver side curtain shield airbag

DTC B1704-00
disconnected
262
Circuit Diagram
Curt
ain
shiel
d
airba
g LH
1 Inspect if curtain shield airbag LH is securely connected
(a) Disconnect and securely reconnect the

connector of the curtain shield airbag LH.

least 20 seconds.

Result Proceed to

disconnected)
263
Inspect wire harness of curtain shield airbag LH for short to GND or power supply
2
(If this occurs, this malfunction will also be displayed)
(a) Disconnect the connector of the curtain shield
airbag LH, and measure the voltage and
resistance between wire harness terminal and
ground.

K22-2 - Body L/B Always More
ground than 1
MΩ
K22-1 - Body L/R Always More
ground than 1
MΩ

K22-2 - Body L/B Always Less
ground than 1
V
K22-1 - Body L/R Always Less
ground than 1
V
OK
3 Inspect curtain shield airbag module LH
(a) Connect a new curtain shield airbag module LH

least 20 seconds.
(c) Turn the power switch off

code with the diagnostic tester
264
Result Proceed to
4 Replace SRS ECU
265
Assistant driver side curtain shield

DTC B1704-00
airbag disconnected
Circuit Diagram
Curtain
shield
airbag RH
1 Inspect if curtain shield airbag RH is securely connected

connector of the curtain shield airbag RH.

code with the diagnostic tester and wait for
at least 20 seconds.
(d) Turn the power switch on and read the

trouble code with the diagnostic tester.
Result Proceed to
266

disconnected)
B
Inspect wire harness of curtain shield airbag RH for short to GND or power supply
2
(If this occurs, this malfunction will also be displayed)
a Disconnect the connector of the curtain shield
airbag RH, and measure the voltage and resistance
between wire harness terminal and ground.

K08-2 - Body Y/B Always More
ground than 1
MΩ
K08-1 - Body Y/R Always More
ground than 1
MΩ

K08-2 - Body Y/B Always Less
ground than 1
V
K08-1 - Body Y/R Always Less
ground than 1
V
NG
OK
3 Inspect curtain shield airbag module RH
a Connect a new curtain shield airbag module

RH
b Turn the power switch on. Clear the trouble

least 20 seconds.
c Turn the power switch off
267
d Turn the power switch on and read the trouble

code with the diagnostic tester
Result Proceed to
4 Replace SRS ECU
268
DTC B1654-00 Front collision sensor LH disconnected

Circuit Diagram
Front
collisi
on
senso
r LH
1 Inspect if front collision sensor LH is securely connected

connector of the front collision sensor LH.

least 20 seconds.
269

Result Proceed to

disconnected)
2 Inspect front collision sensor LH
(a) Connect a new front collision sensor LH

least 20 seconds.

Result Proceed to
Replace front collision sensor LH
270
(a) Before the following inspections, visually check

the wire harness for severe wear (bellows
outside of it worn out). If so, replacement of a
new wire harness is advised for safety
concerns.
(b) Disconnect connectors on both sides of the

wire harness, and measure the resistance of
the wire harness.

G36-2 - L/W Always Less
C35-2 than 1 Ω
G36-13 - Br/W Always Less
C35-1 than 1 Ω
NG
Replace corresponding wire harness
OK
4 End
271
Short to GND in front collision sensor

DTC B1655-00
LH
Circuit Diagram
Front
collision
sensor
LH
1 Inspect front collision sensor LH
(a) Connect a new front collision sensor LH

least 20 seconds.
272

Result Proceed to
Replace front collision sensor LH
(a) Disconnect the connector G36, and measure

the resistance between wire harness and
ground.

G36-2 - Body L/W Always More
ground than 1
MΩ
G36-13 - Br/W Always More
Body ground than 1
MΩ
NG
OK
3 End
273
Front collision sensor RH

DTC B165D-00
disconnected
Circuit Diagram
Front
collision
sensor
RH
1 Inspect if front collision sensor RH is securely connected

connector of the front collision sensor RH.

least 20 seconds.
274

Result Proceed to

disconnected)
B
2 Inspect front collision sensor RH
(a) Connect a new front collision sensor RH

least 20 seconds.

Result Proceed to
Replace front collision sensor RH
275

concerns.

wire harness, and measure resistance of the
wire harness.

G36-3 - G/B Always Less
C36-1 than 1
Ω
G36-14 - P Always Less
C36-2 than 1
Ω
NG
OK
4 End
276
Short to GND in front collision sensor

DTC B165E-00
RH
Circuit Diagram
Front
collision
sensor
RH
1 Inspect front collision sensor RH
(a) Connect a new front collision sensor RH

least 20 seconds.

277
Result Proceed to
Replace front collision sensor RH
(a) Disconnect the connector G36, and measure

ground.

G36-3 - Body G/B Always More
ground than 1
MΩ
G36-14 - P Always More
Body ground than 1
MΩ
NG
OK
.3 End
278
DTC B1666-00 Side collision sensor LH disconnected

Circuit Diagram
Side
collision
sensor
LH
1 Inspect if side collision sensor LH is securely connected

connector of the side collision sensor LH.

least 20 seconds.

Result Proceed to

disconnected)
279
2 Inspect side collision sensor LH
(a) Connect a new side collision sensor LH.

least 20 seconds.

Result Proceed to
Replace side collision sensor LH

concerns.

wire harness.

K21-19 - R Always Less
K03-2 than 1
Ω
K21-20 - Y/R Always Less
K03-1 than 1
Ω
NG
280
OK
4 End
281
Short to GND in side collision sensor

DTC B1667-00
LH
Circuit Diagram
Side
collisi
on
sens
or LH
1 Inspect side collision sensor LH
(a) Connect a new side collision sensor LH.

least 20 seconds.

Result Proceed to
A
Replace side collision sensor LH
282
(a) Disconnect the connector K03, and measure

ground.

K03-1 - Body Y/R Always More
ground than 1
MΩ
K03-2 - Body R Always More
ground than 1
MΩ
NG
OK
3 End
283
Rear side collision sensor LH

DTC B1676-00
disconnected
Circuit Diagram
Rear side
collision
sensor LH
1 Inspect if rear side collision sensor LH is securely connected

connector of the rear side collision sensor LH.

least 20 seconds.

Result Proceed to
284

disconnected)
2 Inspect rear side collision sensor LH
(a) Connect a new rear side collision sensor LH.

least 20 seconds.

Result Proceed to
Replace rear side collision sensor LH

concerns.

wire harness.

K21-24 - G/Y Always Less than
K06-2 1Ω
K21-25 - L/Y Always Less than
K06-1 1Ω
285
NG
OK
4 End
286
Short to GND in rear side collision

DTC B1677-00
sensor LH
Circuit Diagram
Rear
side
collision
sensor
LH
1 Inspect rear side collision sensor LH
(a) Connect a new rear side collision sensor LH.

least 20 seconds.

Result Proceed to
A
Replace rear side collision sensor LH
287

ground.
Terminal Wire Measurem Normal

Connection Color ent Value
Condition
K06-1 - Body L/Y Always More
ground than 1
MΩ
K06-2 - Body G/Y Always More
ground than 1
MΩ
NG
OK
3 End
288
DTC B166F-00 Side collision sensor RH disconnected

Circuit Diagram
Side collision
sensor RH
1 Inspect if side collision sensor RH is securely connected

connector of the side collision sensor RH.

least 20 seconds.

Result Proceed to
289

disconnected)
2 Inspect side collision sensor RH
(a) Connect a new side collision sensor RH.

least 20 seconds.

Result Proceed to
Replace side collision sensor RH

concerns.

wire harness.

K21-17 - G/B Always Less
K04-2 than 1
Ω
K21-18 - P Always Less
K04-1 than 1
Ω
290
NG
OK
4 End
291
Short to GND in side collision sensor

DTC B1670-00
RH
Circuit Diagram
Side
colli
sion
sens
or
RH
1 Inspect side collision sensor RH
(a) Connect a new side collision sensor RH.

least 20 seconds.

Result Proceed to
292
Replace side collision sensor RH

ground.

K04-1 - Body P Always More
ground than 1
MΩ
K04-2 - Body G/B Always More
ground than 1
MΩ
NG
OK
3 End
293
Rear side collision sensor RH

DTC B167A-00
disconnected
Circuit Diagram
Rear
side
collision
sensor
RH
1 Inspect if rear side collision sensor RH is securely connected

connector of the rear side collision sensor RH.

least 20 seconds.

Result Proceed to
294

disconnected)
2 Inspect rear side collision sensor RH
(a) Connect a new rear side collision sensor RH.

least 20 seconds.

Result Proceed to
Replace rear side collision sensor RH

concerns.

wire harness.

K21-26 - Lg/Y Always Less
K05-2 than 1 Ω
K21-27 - L/Y Always Less
K05-1 than 1 Ω
295
NG
OK
4 End
296
Short to GND in rear side collision

DTC B167B-00
sensor RH
Circuit Diagram
Rear
side
collision
sensor
RH
1 Inspect rear side collision sensor RH
(a) Connect a new rear side collision sensor RH.

least 20 seconds.

Result Proceed to
297
Replace rear side collision sensor RH

ground.

K18-1 - Body L/Y Always More
ground than 1
MΩ
K18-2 - Body Lg/Y Always More
ground than 1
MΩ
NG
OK
3 End
298
9 Special Tool
Tool Name Figure Function
Support for airbag module Secure airbag module
Deployment tool SST Dispose of DAB, PAB and

SAB
For electrical connections

Deployment wire between deployment tool and
DAB, PAB or SAB
Malfunction diagnostic For operations such as read

tester or clear trouble codes of
supplementary restraint
system
Data serial port
Malfunction
diagnostic tester
Puller for steering wheel For removal of steering wheel
299
Insulated gloves, safety Protection tools worn by

goggles technicians
300
10 Removal and Installation

Removal and Installation of Driver
Airbag (DAB)
Removal
10.1 Disconnect negative battery terminal.

10.2 Remove driver airbag
(a) Remove the 2 pads on the left and right

sides under the steering wheel (a) Install the 2 pads.
(b) Using an Allen wrench, loosen the 2 set 10.4 Connect negative battery terminal.
screws as shown in the figure, without
taking them down.
Removal and Installation of ECU
Removal
10.6 Remove lower center protector RH of

dashboard.
10.7 Remove lower center protector LH of
dashboard.
10.8 Remove the 2 nuts between ECU

support and tubular beam.
(c) Disconnect the airbag connector and
electric horn connector and then remove
the airbag.
Installation
10.3 Install driver airbag
a Connect the airbag connector and electric

horn connector.
b Place the airbag on the installation position.

Tight the 2 set screws with an Allen
wrench. 10.9 Remove center air outlet of A/C.
10.10 Remove the reserved cover plate of

passenger side seat belt unfastening
warning.
10.11 Remove shift knob cover plate.
301
10.12 Remove center console box. Removal and Installation of ECU

10.13 Remove multimedia unit.
Removal
10.14 Remove SRS ECU.
10.6 Remove lower center protector RH of
(b) Remove the 3 set screws with an Allen dashboard.
wrench. 10.7 Remove lower center protector LH of
dashboard.
10.8 Remove the 2 nuts between ECU

support and tubular beam.
(c) Remove the SRS ECU.
Installation
10.9 Remove center air outlet of A/C.
1 Install the SRS ECU
(a) Place the SRS ECU on the installation

10.10 Remove the reserved cover plate of
position. passenger side seat belt unfastening
warning.
(b) Install the 3 set bolts.
10.11 Remove shift knob cover plate.
10.12 Remove center console box.
10.13 Remove multimedia unit.
10.14 Remove SRS ECU.
a Disconnect the connector.
b Remove the 3 set screws with an Allen

wrench.
302
(d) Remove the SRS ECU. Removal and Installation of

Installation Passenger Airbag (PAB)
1. Disconnect negative battery terminal.

1 Install the SRS ECU
2. Remove passenger side glove box.
a Place the SRS ECU on the installation
position.
3. Remove passenger airbag.
b Install the 3 set bolts.
c Connect the connector.

(b) Remove a set bolt and 2 set nuts.
2. Install multimedia unit.
(c) Tap open the snap-fits of the passenger
airbag from the inside of dashboard body
3. Install center console box.
and take down the passenger airbag from
the outside.
4. Install shift cover plate.
5. Install center air outlet. Installation

6. Install lower center protectors LH and Install passenger airbag.
RH.
(a) Push the airbag into the installation
7. Connect negative battery terminal. position from the outside of the dashboard
body. Press the snap-fits to the positions
shown in the figure till the airbag is
303
installed in place.
1 Connect the connector.
(b) Install the 3 fixing points. 2 Install passenger side glove box.
3 Connect negative battery terminal.
304
Chapter 9
Electrical Schematic Diagram
Section 1 Instruction for Repair Manual .............................................................................. 306

Section 2 Electrical Equipment Layout ............................................................................... 307
Section 3 Relay and Fuse Layout ....................................................................................... 310
Section 4 Low Voltage Wire Harness Layout ...................................................................... 329
Section 5 Complete Vehicle Ground Position Layout ......................................................... 374
Section 6 Electrical Schematic Diagram ............................................................................. 381
305
Section 1 Instruction for Repair Manual

1.1 Refer to the requirements in 1.4 The configuration in the circuit repair
BYDXS-SG-001-2008 for the numbering diagram of the manual includes 473
rules for the wire harnesses and components electronic injection system (*1), 476ZQA (*2),
in the manual. 476ZQA+DCT (*3) and flagship model (*4).
The components without notes are from the
1.2 Refer to the requirements in luxury or comfortable model. The power drive
BYDXS-SG-001-2008 for the naming of the assembly includes MT-473QE and 476ZQA
connectors and distribution box interfaces series. The ABS system is BOSCH 9 series.
and the coding rules for the circuit elements
in the circuit repair diagram such as the fuses 1.5 In addition to the circuit diagram, the
and relays. circuit repair in this manual also includes the
grounding network diagram for electrical
1.3 The connector whole position in this devices and internal power distribution
manual is defined according to the default diagram of dashboard distribution box.
counting method specified by the Wire
Harness Division of Electrical Department in 1.6 The wire colors in the circuit diagram of
BYD Auto Engineering Research Institute. this manual are described as follows:
However, the special connector whole
position must be defined according to the
requirements in BYDXS-SG-008-2008.
Wire Color Standard
Code
Color Color Blue Brown Green Grey Light green Orange Pink Red Purple White Yellow
green
306
Section 2 Electrical Equipment Layout

2.1 Front Compartment
 Electrical Equipment Layout 1 (Front Compartment)
1 TCU motor power supply module

(476ZQA+6DT25)
2. Front compartment distribution box
3. Electronic injector ECU (476ZQA)
Note: The 473 configuration has no TCU, and the electronic injector ECU is at the same
position as the TCU motor power supply module.
307
2.2 Driver's Cab
 Electrical Equipment Layout 2 (Driver's Cab - Instrument Platform, Floor)
1 Dashboard distribution box and BCM 8 PAB

module
9 Gateway
2 Combination switch
10 KEY ECU
3. Combination instrument
11 Air conditioning panel
4 EPS ECU
12 P gear motor controller
5 DAB
13 Backup radar ECU
6 Multi-display
14 Power amplifier
7 Multimedia machine assembly (Luxury or
flagship model) 15 SRS ECU
308
2.3 Sunroof Panel
 Electrical Equipment Layout 3-1 (Sunroof Panel)
1 Front interior light
2 Rear interior light
3 Antenna amplifier (Flagship model)
4 High-frequency receiver
5 Tire pressure module (Flagship model)
6 Sunroof motor (Luxury model or higher)
309
Section 3 Relay and Fuse Layout
3.1 Dashboard Distributor Box
 Schematic Diagram of Dashboard Distribution Box
(1) Dashboard distribution box
310
3.1.1 Dashboard distribution box assembly
3.1.1.1 Schematic Diagram of Connector No.
I C B D
X N F E H G
R
S Q
J K A
M T P
311
3.1.1.2 No. and Specification of Fuse and Relay (473)
312
Fuses
No. F2/1 F2/2 F2/3 F2/4 F2/5 F2/6 F2/7 F2/8 F2/9 F2/10 F2/11
Specification 20A 7.5A 10A 15A 15A 7.5A 20A 20A 30A 20A 20A
Description Door lock Door Battery Exterior Reserved Rear fog Seat Power Power Power Stand
motor light, power power light heater seat seat seat by
exterior amplifier
light
No. F2/13 F2/14 F2/15 F2/16 F2/17 F2/18 F2/19 F2/20 F2/21 F2/22 F2/23
Specification 7.5A 10A 20A 20A 20A 20A 20A 7.5A 15A 20A 30A
Description Steering (Except Power Left front Right Left rear Right Auxiliary TCU Starter Main
shaft lock DCT) skylight window front window rear power relay 1
unlocked motor window motor window supply
motor motor
No. F2/25 F2/26 F2/27 F2/28 F2/29 F2/30 F2/31 F2/32 F2/33
Specification 15A 15A 10A 15A 7.5A 10A 7.5A 15A 30A
Description Main BMS EPS C Exterior EPB Power SRS Wiper
relay 2 rear-view for
mirror switch
heating 2nd
defroster gear
Relay
No. K2-1 K2-2 K2-3 K2-4 K2-5 K2-6 K2-7 K2-8

Specification 20A 30A 20A 30A 20A 30A 20A
Description Main AT Reserved Main Power Oil pump Starter Flasher
relay 2 relay 1 window relay
313
3.1.1.3. No. and Specification of Fuse and Relay (TI)
314
No. F2/1 F2/2 F2/3 F2/4 F2/5 F2/6 F2/7 F2/8 F2/9 F2/10 F2/11
Specification 20A 7.5A 10A 15A 15A 7.5A 20A 20A 30A 20A 20A
Description Door Door Battery Exterior Reserved Rear fog Seat Power Power Power Stand
lock light, power power light heater seat seat seat by
motor exterior amplifier
light
No. F2/13 F2/14 F2/15 F2/16 F2/17 F2/18 F2/19 F2/20 F2/21 F2/22 F2/23
Specification 7.5A 10A 20A 20A 20A 20A 20A 7.5A 15A 20A 30A
Description Steering (Excep Power Left front Right front Left rear Right Auxiliary TCU Starter Main
shaft t DCT) skylight window window window rear power relay 1
lock motor motor motor window supply
unlocked motor
No. F2/25 F2/26 F2/27 F2/28 F2/29 F2/30 F2/31 F2/32 F2/33
Specification 15A 15A 10A 15A 7.5A 10A 7.5A 15A 30A
Description Main BMS EPS C Exterior EPB Power SRS Wiper
relay 2 rear-view for
mirror switch
heating 2nd
defroster gear
No. K2-1 K2-2 K2-3 K2-4 K2-5 K2-6 K2-7 K2-8

Specification 20A 30A 20A 30A 20A 30A 20A
Description Main AT Reserved Main Power Oil Starter Flasher
relay 2 relay 1 window pump relay
315
3.2 Front Compartment Distribution Box
 Schematic Diagram of Front Compartment Distribution Box
316
(1) Front compartment distribution box
3.2.1 Schematic Diagram of Connector No.
F
E D
G
接蓄电池+
To 接发电机+
To battery
generator
3.2.2 Schematic Diagram of Fuse and Relay (473)
317
318
BYD AUTO
Standby
F1/23-1 F1/21 备用
备用 Standby
K1-1 K1-2 K1-3 Standby
备用
F1/7
备用
F1/23-2 Standby F1/6
F1/12 F1/5
F1/18 F1/16
F1/9
F1/20
F1/4
F1/22-2 F1/11
F1/3
F1/19 F1/17 F1/15
F1/8
F1/10
F1/22-1 F1/2
F1/1
K1-5 K1-4
F1/14
F1/13
备用
Standby
Fuses
No. F1/1 F1/2 F1/3 F1/4 F1/5 F1/6 F1/7 F1/8 F1/9 F1/10 F1/11 F1/12
Specification 10A 10A 10A 10A 15A 15A 7.5A 20A 15A 20/30A 15/20A 7.5A
Description High High Low beamLow beam Reserved/ Side MCU Reserved/ EMS Front fog Daytime Compress
beam RH beam LH RH Daytime lamp Front fog light/Low- running or
LH running light speed light/High-
light radiator speed
fan radiator fan
No. F1/13 F1/14 F1/15 F1/16 F1/17 F1/18 F1/19 F1/20 F1/21 F1/22-1 F1/22-2 F1/23-1
Specification 15A 20A 40A 40A 25A 40A 40A 50A 40A 125A 50A 40A
Description Steering Horn, Rear Illumination ABS Ems ABS Power Blower Main fuse Dashboard Window
warning braking defroster and CAN seat distribution control
light light module box system
auxiliary
power supply
No. F1/23-2
Specification 50A
Description Ignition
switch
Relay
No. K1-1 K1-2 K1-3 K1-4 K1-5

Specification 30A 20 30A 20/30A 15/20A
Description Blower Compressor Rear defroster High-speed High-speed
radiator fan condenser fan
319
3.2.3 Schematic Diagram of Fuse and Relay (TI)
320
No. F1/1 F1/ F1/3 F1/4 F1/5 F1/ F1/ F1/8 F1/9 F1/10 F1/11 F1/12
2 6 7
Specifi 10A 10A 10A 10A 15A 15A 7.5 20A 15A 20/30A 15/20A 7.5A
cation A
Descri High Hig Low Low Reserve Sid MC Reser EMS Front Daytime Comp
ption bea h bea beam d/Dayti e U ved/Fr fog running ressor
m bea m LH RH me lam ont light/Lo light/Hig
RH m running p fog w-speed h-speed
LH light light radiator radiator
fan fan
No. F1/1 F1/ F1/1 F1/16 F1/17 F1/ F1/ F1/20 F1/21 F1/22-1 F1/2 F1/23
3 14 5 18 19 2-2 -1
Specifi 15A 20A 40A 40A 25A 40A 40A 50A 40A 125A 50A 40A
cation
Descri Stee Hor Rear Illumin ABS Em AB Power Blowe Main Dashbo Windo
ption ring n, defro ation s S seat r fuse ard w
warn brak ster and distributi contro
ing ing CAN on box l
light light modul syste
e m
auxilia
ry
power
supply
No. F1/2
3-2
Specifi 50A
cation
Descri Igniti
ption on
switc
h
No. K1-1 K1-2 K1-3 K1-4 K1-5

Specification 30A 20 30A 20/30A 15/20A
Description Blower Compressor Rear High-speed High-speed
defroster radiator fan condenser fan
321
3.3 External Relay Socket and Fuse Box of Dashboard Wire Harness
(473 is the same as TI MT)
 Schematic Diagram of External Relay Socket and Fuse Box for Dashboard Wire Harness

1 External relay socket 1 (Left/right steering light relay)
2 External relay socket 2 (Exterior rear-view mirror heater relay)
External relay socket 1
322
External relay socket 2 (473 and TI MT)
External relay 2 (TI DCT)
323
Small Distribution Box for Dashboard Wire Harness (Only TI+DCT)
1 Small distribution box
预留预留预留预留预留预留
10A 10A 10A
KG4-2 F4/9
EPB
30A
F4/10
P档电
机
F4/11
key
less
F4/12
音响系
统15A
F4/13
预留
25A
F4/14
网关
7.5A
F4/15
P档电机
控制器
F4/16
预留
15A KG4-1
7.5A 7.5A
15A
常电
ACC IG2
F4/2 F4/6 F4/7 F4/8

F4/1 F4/3
辅助 IG2 预留预留
点烟器备用 10A
电源 20A 7.5A
15A 电源
7.5A
F4/4转 F4/5
向轴锁备用
7.5A
324
3.4. External Relay Block for Front Compartment
 Schematic Diagram of Small Relay Block and Fuse Box for Front Compartment
3.4.1 External relay block (TI)
325
3.4.2 External Relay Block (473 with front fog light)
326
3.5. Front Compartment Distribution Box II (Only TI)'
Front compartment distribution box II
327
No. F3/1 F3/2 F3/3 F3/4 F3/5 F3/6

Specification 30A 30A 30A 30A 15A 15A
Description Conde DCT Cooling Vacuum brake Vacuum Coolant
nser equipped, fan pump, coolant brake pump circulation
fan MT circulation (DCT pump
reserved pump equipped,
MT
reserved)
K3-1 K3-2
15A 15A
Vacuum brake pump relay (DCT Coolant circulation pump relay
equipped, MT reserved)
328
Section 4 Low Voltage Wire Harness Layout

 Wire Harness Layout
----5 A Complete Vehicle Wire Harness Layout
No. Content No. Content

Rear windshield heater
1 Left front door wire harness 10
negative cable
Front cross bearer wire
2 Right front door wire harness 11
harness
3 Left rear door wire harness 12 Engine wire harness
4 Right rear door wire harness 13 Rear bumper branch wire
5 Sunroof panel wire harness 14 Transmission ground wire
6 Dashboard wire harness II 15 Negative battery cable
7 Dashboard wire harness 16 Engine ground wire
8 Floor wire harness

Front compartment wire
9
harness
329
 Wire Harness Layout 4.1

---- Left front door wire harness
5 1
10 6
1 2
2 1
1 2
1 10
11 23
1 6
330
Fig. 4.1 Left front door wire harness
No. Coding Description Qty Rem
1 T2K To dashboard distribution box K 1

2 T2J To dashboard distribution box J 1
3 TJ01 To dashboard wire harness GJ04 1
4 TJ02 To magnetic card detection antenna 1
5 T01 To door lock motor 1
6 T02 To left front high pitch speaker 1
7 T03 To left front door window lifter switch 1
8 T04 To door light 1 Flagship

9 T05 To exterior rear-view mirror of left front door 1
10 T06 To window lifter motor 1
11 T07 To left front speaker 1
12 T10 To door handle atmosphere lamp 1 Flagship
331

---- Right front door wire harness
11 4 1
1 1 4
13
12 8 5
22 5 10
14 9
12
1 2
2 1
1 2
1 6
332
Fig. 4.2 Right front door wire harness
1 UJ01 To dashboard wire harness GJ10 1

2 UJ02 To dashboard wire harness GJ09 1
3 UJ03 To exterior magnetic card detection antenna
4 U01 To right front door window lifter switch 1
5 U02 To right front door lock motor 1
6 U03 To right front high pitch speaker 1

7 U04 To door light 1 Flagship
8 U05 To exterior rear-view mirror of right front door 1
9 U06 To window lifter motor 1
10 U07 To right front mid-bass speaker 1
11 U08 To right front camera 1 Flagship
12 U10 To door handle atmosphere lamp 1 Flagship
333
Wire Harness Layout 4.3

---- Left rear door wire harness
1 6
1 2
13 10
1
3
17 14
6 4
20 18
9 21 7
23
1 2
3 6
Fig. 4.3 Left rear door wire harness
1 VJ01 To floor wire harness KJ05 1
334
2 V02 To left rear door mid-bass speaker 1

3 V03 To left rear door window lifter switch 1
4 V04 To left rear door window lifter motor 1
5 V05 To left rear door lock motor 1
6 V06 To door handle atmosphere lamp 1 Flagship
335
 Wire Harness Layout 4.4

---- Right rear door wire harness
1 6
1 2
13 10
1
3
17 14
6 4
20 18
9 21 7
23
1 2
3 6
Fig. 4.4 Right rear door wire harness
336
1 WJ01 To floor wire harness KJ04 1
2 W01 To right rear door mid-bass speaker 1
3 W02 To right rear door lock motor 1
4 W03 To right rear door window lifter switch 1

5 W04 To right rear door window lifter motor 1
6 W06 To door handle atmosphere lamp 1 Flagship
337

---- Sunroof panel wire harness
顶棚线束
PJ01
P2I
P02
1 4
13
8 1 5
5
14 12
9
P03
P06
P04 P05
3 4a 1d 1b 16
1 8
1 O R/B B 3 B Gr
1 2 0.5 0.5
0.5 0.5 0.5
9 16
P08 P07
1e 17
B Gr 17 4d
0.5 0.5 1 Gr R/B 2
0.5 0.5
Fig. 4.5 Sunroof panel wire harness
1 P2I To dashboard distribution box I 1
2 PJ01 To dashboard wire harness KJ02 1
338
3 P02 To sun roof motor 1 Flagship
4 P03 To front interior light 1 Flagship

5 P04 To rear interior light 1
6 P05 To left sun screen switch Flagship
7 P06 To left sun screen light Flagship
8 P07 To right sun screen switch Flagship
9 P08 To right sun screen light Flagship
339

---- Meter Wire Harness II
He01 He02 He03
HeJ01
Fig. 4.6 Meter Wire Harness II
1 HeJ01 To dashboard wire harness GJ08 1

2 He01 To illumination intensity sensor 1
3 He02 To solar sensor 1
3 He03 Multi-display 1
340
HeJ01 He01
2 10 9 8 4 1
7 3 1
B Gr/L L/O W/G
R/L V P
0.5 0.5 0.5 0.5 0.5
0.5 0.5
5 12 11 7 9 10
6 1 L/O 4
13 B B O Y/R 8 Gr/L
Y
0.5 0.5 0.5 0.5 0.5 0.5
0.5
He03
He02
1 2 3 4 5 11 12
8 1 O B 2
1 W/G B P V B
0.5 0.5 0.5 0.5 0.5 0.5 0.5
6 7 8
Y Y/R R/L 16
0.5 0.5 0.5

---- Dashboard Wire Harness
341
342
仪表板线束（1）
G2X G2N
1 6
1 4
7 12
5 11
19
13
12 16 25
20 24
17 19
28 33
27
20 26
34
34 37 38 40
27 33
41 43 44 45
35
36 39
GJ03 GJ01 GJ04

GJ14
1 4
1 3
10 13
1 4
G2M 14
4 17
13 6 1 5
8
5
18 20
7 10
14 9 6
112 9 12 21 23
1 R 3
1.25
G2P
G2Q
113 114 115 118 119 120 121 122 123

1 B/R W Y/G B W/B Y/R R G/R G 14
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.85
413 108 109 125 126 124 237 127 414 129 130 131
15 Y/L L/R Sb P/B P/L L/B W/R L L W/G Gr Y 30
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
343
G39 G2S
G2A G41
1 6
1 2
7 12
GJ08
G45 G2T G2R
1 2
3 6
G16 G59
12
GJ06
GJ13
GJ05
3
13 10
235 234 220 219
1
P G/B Br/W L/W
0.5 0.5 0.5 0.5
17 14
4
6
20 18
9 7
23 21
GJ02 G18 G20
GJ15
1 2
4 1
13
8 5
14 1
9
12
10 5
G40
G21
G25
8
1
1 10 3
9 16
11 20 4 6
344
G65 G24
G57
G27 G03 G10
405 55c
1 B R/B 2
1 4 0.5 0.5
G28 1 4 2 1
G53
3
4
5 8
1 2
1 2
G62 G58
G36
1 1 6
13 24 7
G11B
1 9
10 21
BAT+
G22
G15A
G44
G23
G47 G31
320 316 317 319 322 257

1 W/L W W/B B/Y L R/B
0.5 0.5 0.5 0.5 0.5 0.5
321 408 409 123a 333 318 323 96
9 B B B G Y B G R 18
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
G43
G81 G32 G23 G55
2
1 2
1 3
3 6
345
G06 G29 G60
10 1
20 11
1 4
G35B
5 10 G46
1 2
G07
G42
G38
G63
6
1 4
1 2
7 12
G50
1 6
7 12
GJ09
G49
1
11 13
8
5
9 14 12
12 22
GJ11
16 5
4 1
28 17
Fig. 4.7 Dashboard Wire Harness

01 G2X To dashboard distribution box X 1
02 G2N To dashboard distribution box N 1
03 G2M To dashboard distribution box M 1
04 G2Q To dashboard distribution box Q 1
05 G2A To dashboard distribution box A 1
06 G2T To dashboard distribution box T 1
07 G2R To dashboard distribution box R 1
08 G2S To dashboard distribution box S 1
09 G2P To dashboard distribution box P 1
346
10 G01 To dashboard distribution box II 1

11 G02 To driver intent switch 1 MT
12 G03 To safety air bag wire harness 1
13 G06 To CAN No.1 connector 1
14 G07 To gateway controller 1
15 G08 To No.1 relay socket 1
16 G10 To dashboard wire harness 1
17 G11B To adapter 1
18 G15A To adapter 1
19 G16 To combination instrument 1
20 G18 To braking light switch 1
21 G19 To IG1 relay socket 1
22 G20 To clock spring 1
23 G21 To steering shaft lock 1
24 G22 To cigarette lighter 1
25 G23 To antenna wire harness 1
26 G24 To combination switch 1
27 G25 To spiral coil 1
28 G27 To start button 1
29 To front magnetic card detection
G28 1
antenna

30 G29 To DVD&GPS host A 1

31 G31 To DVD&GPS host C 1
32 G32 To hand brake switch 1
33 G33 To center magnetic card detection antenna 1
34 G35B To adapter 1
35 G36 To safety air bag ECU 1
36 G37 To No.2 relay socket 1
37 G38 To blower governor resistor 1
38 G39 To backlight adjusting switch 1
39 G40 To diagnosis interface 1
40 G41 To power mirror control switch 1
41 G42 To blower motor 1
42 G43 To USB interface assembly 1
43 G44 To emergency warning light switch 1
44 G45 To headlight adjusting switch 1
45 G46 To front occupant safety air bag 1
46 G47 To air conditioning panel 1
47 G48 To backup radar switch 1
48 G49 To keyless system electronic control unit A 1
49 G50 To keyless system electronic control unit B 1
50 G51 To DVD&GPS host D 1
51 G52 To center speaker 1
52 G53 To room temperature sensor 1
347

53 G54 To air conditioning wire harness 1

54 G55 To DVD&GPS host E 1
55 G57 To steering angle sensor 1
56 G58 To shift sensor 1
57 G59 To EPS 1
58 G60 To ESC OFF switch 1
59 G61 To clutch pedal switch 1 MT
60 G62 To gear shift mechanism 1
61 G63 To right step light 1
62 G64 To console box light 1
63 G65 To left step light 1
64 G66 To glove box light switch 1
65 G67 To glove box light switch 1
66 WG49 To ground No.1 1
71 GJ01 To floor wire harness 1
72 GJ02 To sunroof panel wire harness 1
74 GJ04 To left front door wire harness 1
75 GJ05 To front compartment wire harness 1
78 GJ08 To dashboard wire harness II 1
79 GJ09 To right front door wire harness 1
80 GJ10 To right front door wire harness 1
348

---- Floor Wire Harness
349
地板线束（1）
K2F K2E K2H
K21
KJ14
136 137 135 134 92 93 94 95

1 1 O/R Y/B V/R V/B Y/B Y/R L/R L/B 16
7 0.5 0.5 0.5 0.5 0.5 0.5 0.5
0.5
96 97 98 99 81 82 83 84
17 P G/Y L/Y Lg/Y L/Y 32
G/B R Y/R
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
8
16
KJ04 KJ15
KJ07
1
13 10 3
3 1
10 13
17 14 4
6
6
4 14 17
18
7
20 18 20 9
9 7
23 21 21 23
K17
K50
10 1
20 11 1 16
17 32
CANL
K37
K26
KJ08
4 1
151
Gr 13
1 8 5
0.3 8
146 147 148 149 150 152
9 Y/L Y/O Y/G L/W L/O L 18 14 9
0.3 0.3 0.3 0.3 0.3 0.3 12
350
地板线束（2）
K28
K27
KJ02 KJ01
K03
13 10
1 4 1 2
3 1
17 14
6
4 1 2
5 3 6
10 20 18
9
7
23 21
K38 K56
KJ05 K06
1
3
10 13
82 81
4 1 L/Y G/Y 2
6 0.5 0.5
14 17
7
18 20 9
1 2
21 23
K56
KJ08 KJ10
K36
KJ09
59 58
1 Y/L B/Y 2
60 61 173 169 170 0.5 0.5
1 2 168 172 171
1 L/Y L/B 2 132 138 L/B Y G Gr R/B B/W
0.5 0.5 W/R R 0.5 0.5 0.5 0.5 0.5 0.5
1.25 1.25
139 133
B/W B
1.25 1.25 175 177 176 174
B R/B R Y
0.5 0.5 0.5 0.5
K39
KJ06
K42
K04 K05
KJ13
145 26 1 2 1
2
1 Gr B 2
0.5 0.5 1 2 1 2
1 2
K11 K34
1 5
1 16
17 32
KJ11
K12
2 1
15
B/Y
3.0
351
地板线束（3）
K22
K19 K16
K15 KJ12
1 2
1 2 2
1
1 6
7 12
K20 K35
K24
1 2
1 3 1 6
4 6 7 12
K29 K30
K31
K08
1 4
K33
K5
K10
2
1
1 8 1 2
4 3
9 16
1 2
K41
K13
K09 K14
K43
1 3
2 1 2 4 6
141
Gr
140
R
1 3 1
0.5 0.5
K40
KJ03 K18
3 1
1 2
8 4
352
Fig.4.8 Floor Wire Harness

01 K2E To dashboard distribution box E 1

02 K2F To dashboard distribution box F 1
03 K2G To dashboard distribution box G 1
04 K2H To dashboard distribution box H 1
05 KJ01 To dashboard wire harness 1
07 KJ03 To rear bumper branch wire 1
08 KJ04 To right rear door wire harness 1
09 KJ05 To left rear door wire harness 1
10 KJ06 To co-driver seat belt buckle branch wire 1
12 KJ08 To driver seat belt buckle branch wire 1
13 KJ09 To driver safety air bag branch wire 1
14 KJ10 To co-driver safety air bag branch wire 1
15 KJ11 To left rear wheel speed sensor branch wire 1
16 KJ12 To high braking light 1
17 KJ13 To left rear wheel speed sensor branch wire 1
18 K1 To ground 1
19 K2 To ground 1
20 K3 To ground 1
21 K4 To ground 1
22 K5 To ground 1
23 K6 To ground 1
Fig.4.8 Floor Wire Harness

24 K7 To ground 1
25 K31 To mega bass speaker 1
26 K35 To tire pressure monitor module 1
27 K03 To left side collision sensor 1
28 K04 To right side collision sensor 1
29 K05 To right rear collision sensor 1
30 K06 To left rear collision sensor 1
31 K30 To right rear squawker 1
32 K08 To right side air curtain 1
33 K09 To left license plate light 1
34 K10 To trunk micro switch 1
35 K11 To fuel tank 1
36 K12 To rear fan heat wire 1
353
37 K13 To right license plate light 1

38 K14 To right rear grouped light 1
39 K15 To rear trunk light 1
40 K16 To rear magnetic card detection antenna 1
41 K17 To backup radar 1
42 To exterior magnetic card detection
K18 1
antenna
43 K19 To high-frequency reception module 1
44 K20 To siren 1
45 K21 To safety air bag ECU 1
46 K22 To left air curtain 1
Fig. 8 Floor Wire Harness

47 K40 To rear glow LOGO 1

48 K24 To left rear grouped light 1
49 K29 To left rear squawker 1
50 K41 To trunk lock 1
51 K43 To micro switch No. 2 1
52 K34 To P position controller 1
53 K56 To EPB switch 1
54 K37 To external power amplifier D 1
55 K26 To external power amplifier A 1
56 K27 To external power amplifier B 1
57 K28 To external power amplifier C 1
58 K36 To seat motor 1
354

61 K50 To CAN No.2 connector 1
62 K33 To backup camera 1
63 K55 To EPB 1
64 K38 To left front seat belt pretension 1
65 K39 To right front seat belt pretension 1
66 KJ15 To front compartment wire harness 1
355

---- Front Compartment Wire Harness
356
前舱线束
B2D B2C
BJ01
1
7 2
1
8 17 12
3
B1D
1 4
BJ08
B1C
B2B
B1G 5 10
B09
1 4
1 2
5 10 1 2
BJ10
B05
25 38 121 125
Gr
127
G
126
L
128
R 122
1
Gr 0.5 0.5 0.5 0.5 Y 6
131 132 133
1.25
1.25 W
0.5
O
0.5
Y/L
0.5
14 24
123 124
15 G/W W
1 13 1.25 1.25 20
2 12
B06 B08 B01

B02
B1E
1 3
1 2 4
盲盲 6
1 4
堵堵
1 2
BJ06 BJ07
BJ03
BJ02
2 1
1 4
4 3
3 BJ05
1
10 13
2 7
1 8
BJ04
17 9 14
4 14
6
4 1
15 21 22
16
18 20
8 5
7 2 1 23 28
9
21 23 12 9 36
29
30 35
16 13
BJ12
BJ11
B11
5 12
1 4
13 20
1 2
3 4
B03 B04 B14
B1J
55 56
1 G/B
1 P 2
0.5 0.5 1 6
2 3
B1I
1 4
5 10
357
Fig. 4.9 Front Compartment Wire Harness
01 B1C To front compartment distribution box C 1

02 B1D To front compartment distribution box D 1
03 B1E To front compartment distribution box E 1
04 B1G To front compartment distribution box G 1
05 B1I To front compartment distribution box I 1
06 B1J To front compartment distribution box J 1
07 B1B To front compartment distribution box B 1
08 B2B To dashboard distribution box B 1
09 B2C To dashboard distribution box C 1
10 B2D To dashboard distribution box D 1
11 BJ01 To dashboard wire harness 1
15 BJ07 To engine wire harness 1
16 BJ10 To engine wire harness 1
18 BJ12 To floor wire harness 1
19 BJ05 To front cross bearer wire harness 1
20 BJ06 To front cross bearer wire harness 1
21 BJ04 To front cross bearer wire harness
22 B01 To wiper motor branch wire 1
23 B02 To brake fluid level switch 1
24 B03 To air conditioning pressure switch 1
25 B05 To right front wheel speed sensor branch wire 1
26 B06 To ground 1
27 B07 To ABS ECU 1
28 B08 To right front wheel speed sensor branch wire 1
29 B09 To fluid level sensor 1
30 B10 To dashboard distribution box II 1
31 B11 To EPS 1
32 B12 To EPS ground 1
33 B13 To positive fuse block 1
34 B14 To accelerator pedal 1
35 B04 To right front wheel speed sensor 1
358

---- Rear Windshield Heater Negative Cable
Fig. 4.10 Rear Windshield Heater Negative Cable

1 X931 To windshield ground terminal 1
2 W931 Body ground 1
359

---- Front Cross Bearer Wire Harness
360
前横梁线束
C1F
C1H
C02
1 10
11 20
1 2
CJ01 CJ02
C03 C10 C25 C19 C31
1 4
5 8 1 2
1 2
9 12
1 3 1 3
13 16
3 4
C08/C09/C14/C27
C04
C23 C24
C22 C20 C07 C12
37 23 2
29 24 31
1 B W/G 2 48a 4 5 1 B W/R 2 32 21
1.25 1.25 1 R/B L/W B 3 1 B R/L 2
1.25 1.25 B Y/B
0.5 0.5 0.5 0.5 0.5
0.85 0.85
C28
C17 C16 C15(476)

C13 C18
C30/C31
36 22 38 9 1 2
1 2 1 3
B R/G 1 B Br 2
1 2
1.25 1.25 0.5 0.5
C29 C11
C15(473)
C25 C36
1 3
1 2
Fig. 4.11 Front Cross Bearer Wire Harness

01 C1F To front compartment distribution box F 1

02 C1H To front compartment distribution box H 1
361
03 CJ01 To front compartment wire harness 1

06 C01 To relay socket 1
07 C02 To left radiator fan 1 473
08 C03 To left front fog light 1
09 C04 To left front position light 1
10 C07 To left front turn light 1
11 C08 To left electric horn (ground) 1
12 C09 To left electric horn 1
13 C10 To outside temperature sensor 1
14 C11 To engine compartment cover lock 1
15 C12 To left front high beam light 1
16 C13 To right front high beam light 1
17 C14 To right electric horn 1
18 C15 To right radiator fan 1 473
19 To coolant temperature sensor at radiator
C15 1 476
water outlet
20 C16 To right front fog light 1
21 C17 To right front position light 1
22 C18 To right front turn light 1
23 C19 To washer fluid motor 1
24 C20 To left front low beam light 1
25 C22 To right front low beam light 1
26 C23 To right front regulating motor 1
27 C24 To right corner probe 1
28 C25 To left corner probe 1
29 C27 To right electric horn 1
30 C28 To left radiator fan 1 476
31 C29 To right radiator fan 1 476
32 C30 To resistor No.1 1 476
33 C31 To resistor No.2 1 476
34 C32 To left front aiming motor 1
35 C35 To left front collision sensor 1
36 C36 To right front collision sensor 1
37 WC20 To ground 1
38 WC21 To ground 1
39 WC23 To ground 1
362

---- Engine Wire Harness
476
363
476
364
473 Engine
A31 A10
A24
64
49 51 8 7
62 64
1 4
37 48
101 112 50 37 6 5
33
25 36 46 48
89 100 36 23
4 3
17 30
13 24 32
77 88
1 12
65 76
22
1
9
14 2
1
16
A05
AJ01 A01/02/03/04 A35

A36 A05/06/07/08
20j 19
8 1 1 Y/B L/W 2 1 3
2 1 0.5 1 4
14 9 0.5
22
15
28 23
36
29
A21
A12
A29
A28 A22
1 3
1 3
1 4
1 4
4 6
25 28c
Gr/B B/O
1 0.5 0.85 2
A34
A27
A25
A23 A38 A11
A15/A18
1 2 1 2 1 2
1 3 1 3
A26
A16 A20 A19/A17 AJ06
27 26 29
1 Br/W B/R 2 B/W 1 2
1 4 0.5 0.5 3.0
58
B
20.0
Fig. 4.12.1 473 Engine Wire Harness
365
01 AJ01 To front compartment wire harness 1

03 A01 To ignition coil No.1 1
07 A05 To nozzle No. 4 1
08 A06 To nozzle No 3 1
11 A09 To ground No. 1 1
12 A10 To engine ECU 1
13 A11 To crankshaft position sensor 1
14 A12 To camshaft position sensor 1
15 A13 To power assist steering switch 1
16 A15 To terminal B of generator 1
17 A16 To generator 1
18 A17 To oil pressure sensor 1
19 A18 To starter terminal 1
20 A19 To starter 1
21 A20 To knock sensor 1
22 A21 To electronic throttle valve 1
23 A22 To intake pressure/temperature sensor 1
24 A23 To coolant temperature sensor 1
25 A24 To front oxygen sensor 1
26 A25 To back-up light switch 1
27 A26 To positive battery terminal 1
28 A27 To neutral switch 1
29 A28 To charcoal canister control valve 1
30 A29 To rear oxygen sensor 1
32 A32 To ground No.2
33 A34 To compressor clutch
34 A35 To linear EGR valve
35 A36 To MIVEC valve
36 A38 To filter capacitor
37 A1A To distribution box A 1
38 A1B To distribution box B 1
366
476 Engine
A01
A02
A15
72
81 63 82 89
1 2
114 116
62 44 90 97
3 53
117 118 1 3
34
98 105
43 25
4 6
119 121
4 5 106 113
24 6
15
A07/08
A49
A52 A31 A48
1 4
1 4 1 2
59 1 8
1 1 3
5 G/B Sb Br
A34 0.5 0.5 0.5 A35
10 A45
6
1 8
103 102 1 2
B 9
2 L/B 1 16
0.85 0.85
A38
AJ01 AJ02 A27
A20/21/22/23
1 2
1 2
8 1 6 1
14 9
A24
22
15
36
28 23
20 15 1 3
29
1 2
A10 A30 A06

A25 A26 A16/17/18/19 A33
1 3
1 4
A12 1
60 46
L
35
3
1 3
Y G/Y
0.5 0.5 0.5
1 2
1 2 1 2
A37
A55 A41
99
A11 A47 B
A36 20.0
30 97
A43 1 Y/B G 2
A04 0.5 0.5
1 3 9
117 69a 68a 114 113 112 118

10 L P V Y/L W/G G/Y Y 16
0.5 0.5 0.5 0.5 0.5 0.5 0.5
17
3 19 25
1
367
Fig. 4.12.2 476 Engine Wire Harness


05 A04 To engine coolant temperature sensor 1
06 A06 To high fuel pressure sensor 1
07 A07 To intake manifold pressure/temperature sensor 1
08 A08 To intake pipe pressure sensor 1
09 A10 To crankshaft position sensor 1
10 A11 To camshaft position sensor 1
11 A12 To knock sensor 1
12 A15 To electronic throttle valve 1
13 A16 To injection nozzle No. 1 1
17 A20 To ignition coil No. 1 1
21 A24 To fuel pressure control valve 1
22 A25 To boost pressure limit solenoid 1
23 A26 To turbo boost air circulation valve 1
24 A27 To OCV solenoid 1
25 A30 Upstream oxygen sensor 1
26 A31 To downstream oxygen sensor 1
27 A32 To power assist steering switch 1
28 A33 To coolant circulation pump 1
29 A34 To vacuum brake pump 1
30 A35 To charcoal canister control valve 1
31 A36 To oil pressure sensor 1
32 A37 To generator 1
33 A38 To filter capacitor 1
34 A41 To terminal B of generator 1
35 A42 To starter 1
36 A43 To starter 1
37 A44 To positive battery terminal 1
368
38 A45 To brushless motor controller 1 DCT

39 A46 To transmission motor 1 DCT
40 A45 To back-up light switch 1 MT
41 A46 To neutral switch 1 MT
42 A47 To TCU 1 DCT
43 A48 To direction sensor 1 DCT
44 A49 To brake booster pressure sensor 1 DCT
47 A52 To P position motor 1
49 A54 To front compartment relay block 1
50 A55 To compressor clutch 1
369

---- Rear Bumper Branch Wire
1 RJ01 To floor wire harness KJ02 1

2 R01 To back-up probe at left center corner 1
3 R02 To back-up probe at left rear corner 1
4 R03 To back-up probe at right center corner 1
5 R04 To back-up probe at right rear corner 1
370

---- Transmission Ground Wire
Fa02 Fa01
Fig. 4.14 Transmission Ground Wire
1 X911 To transmission assembly 1

371

---- Negative Battery Cable
Ea01
Ea02
Fig. 4.15 Negative battery wire harness
1 X901 To negative battery post 1

372

---- Engine ground wire
Fb02 Fb01
Fig. 4.16 Engine Ground Wire
1 X921 To engine assembly 1

373
Section 5 Complete Vehicle Ground Position Layout

5.1 Front Cross Bearer Wire Harness Ground Position
374
5.2. Front Compartment Wire Harness Ground Position Layout
375
5.3. Engine Wire Harness I Ground Position Layout
376
5.4 Dashboard Wire Harness Ground Point Layout
377
378
379
5.5. Floor Wire Harness Ground Point Layout
380
Section 6 Electrical Schematic Diagram

1.1 476ZQA power supply, starter and generator
1.2 473QE power supply, starter and generator
1.2 473ZQA+DCT power supply, starter and generator
2.1 Multiplex integration control module (1)
3. Relay control module and exterior light control system
4. Horn, warning system, washer and wiper system
5.1 473QE EMS (1)
5.2 473QE EMS (2)
5.3 473QE EMS (3)
5.4 473QE EMS (4)
5.5 473QE EMS (5)
5.6 476ZQA-EMS (1)
5.7 476ZQA-EMS (2)
5.8 476ZQA-EMS (3)
5.9 476ZQA-EMS (4)
5.10 476ZQA-EMS (5)
6.1 Combination instrument (1)
7.1 I-Key system (1)
8. Backup radar system
9. Braking light control system and cigarette lighter system
10.1 Interior light system (trunk light, glove box light, door light, ambient light, foot light, room dome
light and back light) (1)
10.2 Interior light system (trunk light, glove box light, door light, ambient light, foot light, room dome
light and back light) (2)
11. Steering/warning light system
12. Exterior light system (headlamp, position light, fog light, license plate light and back-up light)
control system
13. ABS (BOSCH 9)
14. ESP
15. SRS
16.1 Air conditioning system (including compressor, rear defroster and radiator fan control) (1)
17. Diagnosis interface DLC
18. Gateway controller
19. Power outer rear view mirror control system
20.1 Window control system (1)
21. Combination switch
22. Power seat control system
23. Headlamp leveling
24. CD
25. External power amplifier
26.1 Advanced audio-visual system (1)
26.2 DVD (built-in power amplifier)
27. Multi display
381
28. 476ZQA+DCT
29. EPS
30. Tire pressure monitor system
31. EPB
32. P position motor controller
33. Electronic cooling fan
382
1.1 476ZQA MT power supply, starter and generator
476ZQA MT power supply, starter and generator Battery (Front of main fuse)
Battery (Rear of main fuse)
IG2Power Supply
Compressor
A IG1Power Supply
ACCPower Supply
W
5.0
Combination instrument F1/5

Multiplex integrated G16-35 2#Ignition W F2/13
1 G2A R control module switch 5.0
1 G2M Steering
2.0 20A
MICU-W26 Shaft
3 G2A Lock
Unlock
Y/L 7.5A
0.5 1 B1D
Multiplex integrated W
2 B2B control module GJ11 2.0
MICU-Z4 17 BJ11 BJ01
K2-7 88 86 4 GJ05
F1/12 F2/22 W G W
5.0 Starter relay
Compressor Starter 0.5 W/B 1.25
7.5A 20A 0.5
88a 85
BJ07
2 B1G 31 AJ01 3 1 G08 1 2 G19 6 8 G08
4 G2T 6 2 4 G2A W/B W/R R
0.5 0.5 0.5
F1/23-2 88 86 88 86
KG-3 KG-1 KG-2 9 G2P 10 G2P11 G2P
1#Ignition 5 G2A 2 B2C 32 G2X
ACC IG1 IG2
switch50A Relay Main relay
2 A37 relay MICU-W23
GJ05 2 X335 88a 85 88a 85
Steering Shaft
5 BJ01 Generator FR G S L Lock Power
F1/22-1 Supply
Voltage regulator
Main fuse
BJ07 5 2 4 G374 3 G19 7 10 G37
125A
36 AJ01 MICU-W26 Sun roof position
A54 Front compartment Field coil Rectifier
relay block B11 Reserved B B
0.5 W/R R B/W B/R
EPSMotor 35.0 W/B
A1A 1.25 1.25 5.0 1.25
8 B2D 4 G2P
2.5
B B B B
R A18 A43
6.0 20.0 20.0 6.0
6.0 Starter B S
F5/1 F5/2 F5/3 F5/5

50A 70A Main fuse 50A Solenoid coil
125A M
A42
B+
A15 Engine assembly Transmission assembly
1 X336 Fb01 Fa01
Battery
B B B B B
Ea01 15.0 0.5 0.5 0.5
15.0
B
20.0
B
35.0
Reserved WG47 WG47 Starting Reserved Reserved (To ground)

Ea02 B2C-2 Meter 3# Meter 3# system B2D-8 G2P-4
Ground Ground K2-7-86
383
1.2 473QE power supply, starter and generator
473QEMT power supply, starter and generator

Battery (Front of main fuse)
Battery (Rear of main fuse)
IG2Power Supply
Compressor IG1Power Supply
A
ACCPower Supply
W
5.0
G16-35 F1/5
Multiplex 2#Ignition
integrated F2/13
R switch W Steering
1 G2A control module 20A 1 G2M
2.0 5.0 Shaft Lock
MICU-W26
Unlock
3 G2A Y/L 7.5A
Dashboard 0.5
distributor box 1 B1D
Multiplex GJ11 W
integrated 17 BJ11 2.0
2 B2B control module
MICU-Z4 BJ01
K2-7 88 86 4 GJ05
Y/L
F1/12 F2/22 W 0.5 W
Compressor Starter 5.0 Starter relay W/B W
7.5A 1.25
20A 0.5 1.25
88a 85 BJ11
18 AJ01
2 B1G 3 1 G37 1 2 G19 6 8 G67
6 2 4 G2A W/B W/R R
4 G2T 0.5 0.5 0.5
Y/L 88 86 88 86 9 G2P 10 G2P 11 G2P

F1/23-2 KG-3
5 G2A 0.5 KG-1 KG-2
1#Ignition 2 B2C 32 G2X
ACC IG1 IG2
switch 50A Relay Main Relay
relay MICU-W23
GJ05 2 A16 88a 85 88a 85 Steering
A1B Shaft Lock
5 BJ01 FR G S L
Generator Power
F1/22-1
Voltage regulator Supply
Main fuse
125A BJ04 5 2 4 G37 4 3 G19 7 10 G37
MICU-W26 Sun roof position
1 AJ06
Field coil Rectifier
B
B W/R R B/W B/R
0.5
A1A 20.0 B/W 1.25 1.25 5.0 1.25 8 B2D 4 G2P
3.0
A18 A19
Starter B S
B
20.0
Solenoid
coil
M
M
1.2KW
A26
B+
Battery A15 Engine assembly Transmission assembly
Fb01 Fa01
X901 B B
B
B B 0.5 0.5 0.5
15.0 15.0
B B
35.0 15.0
Reserved Starting Reserved Reserved

WG47
B2C-2 Fa02 WG47 system B2D-8 G2P-4
W901 Meter 3# Ground Fb02
Meter 3# Ground K2-7-86
384
2.476ZQA DCT power supply, starter and generator
Battery (Meter)
Battery (Front of front compartment main fuse)
Battery (Rear of front compartment main fuse)
IG2Power Supply
Compressor IG1Power Supply
A
ACCPower Supply
W
5.0
Multiplex
integrated R
control
G16-35 W F2/13
1 G2A R 5.0 5.0
module 1 G2M Steering
2.0 1 B10
MICU-W26 Shaft
3 G2A To dashboard Lock
distributor boxⅡ Unlock
Y/L 7.5A
0.5
Multiplex
integrated
control
2 B2B GJ11
module
MICU-Z4 17 BJ11
K2-7 88 86
F1/12 F2/22 W Starter relay G
Compressor Starter 5.0 W/B
0.5
7.5A 20A 0.5
88a 85
BJ07
35 G01 2 B1G 24 G01 1 2 G19 27 G01
1 B10 31 AJ01
2 G2A W/B W/R R
4 G2T
0.5 0.5 0.5
F1/22-2 G 88 86 88 86
F1/23-2 KG4-2 KG-1 KG4-1 9 G2P 10 G2P11 G2P
Dashboard 5 G2A 2 B2C 32 G2X 0.5
1#Ignition ACC IG1 IG2
distributor
switch50A Relay Main Relay
boxⅡ
50A 2 A37 relay MICU-W23
GJ05 2 X335 88a 85 88a 85
Steering
5 BJ01 FR G S L Shaft Lock
Generator
F1/22-1 Power
Voltage regulator Supply
Main G23
G31 G01 4 3 G19 28 G01
fuse BJ07
125A 36 AJ01 MICU-W26 Sun roof position
A54 Front compartment Field coil Rectifier
B11 Reserved B B
relay block W/R R B/W B/R
EPSMotor 35.0 0.5
A1A W/B 1.25 1.25 5.0 1.25
8 B2D 4 G2P
2.5
B B B B
R A18 A43
6.0 20.0 20.0 6.0
6.0 Starter B S
F5/1 F5/2 F5/3 F5/5 Solenoid

50A 70A Main fuse 50A coil
125A M
A42
B+
A15 Engine assembly Transmission assembly
1 X336 Fb01 Fa01
Battery
B B B B B
Ea01 15.0 0.5 0.5 0.5
15.0
B
20.0
B
35.0
Starting Reserved Reserved (To ground)

Reserved WG47 WG47
Ea02 B2C-2 Fb02 Fa02 system B2D-8 G2P-4
Meter 3# Ground Meter 3# Ground
K2-7-86
385
Battery (Meter Ⅱ）
IG2Power Supply
IG1Power Supply
ACC Power Supply

Illumination、CNA module、
F1/16 Auxiliary Power Supply F2/31 MCU
A A
Illumination、 Power
CNA B supply
Reserved for
module、
K2G-5 C switch
Auxiliary F2/3
F2/6 F2/1 2nd
Power
Rear Door MICU MICU Power Supplygear
Supply40A 10A
fog light lock Power A 7.5A
7.5A motor Supply MICU Power Supply
20A 10A 10A
B Combination
Instrument
Gateway B
8 B1D B2C-11
Illumination Window control
19 G2N C
intensity sensor Y
3.0
R/Y
3 He01 1 He01 5 K2G 11 B2C
0.5
5 B2B
HeJ01 HeJ01
6 GJ08 5 GJ08
Gr/L L/O
0.5
0.5
8 G2Q 7 G2Q 1 G2Q
Inner rear MICU-W6 MICU-W24 MICU-W25

fog light Electric rearview IG1Electricity
relay mirror
Rear fog light Reversing light

Right front door latch position power supply power supply N position signal N position signal
*1 *2
14 G2Q 18 G2P 19 G2P 3 G2Q 14 G2P 22 G2P 22 G2P
Br/W P/B P/L O O

0.5 0.5 0.5 0.5 0.5
R/W G G
0.85 0.85 0.5
GJ10 GJ16 GJ16
3 14 6 UJ01 21 BJ09 23 BJ02
Br/W P/B P/L BJ07 7 BJ07

0.5 0.5 0.5 34 AJ01 AJ01
Right
6 U02 3 U01 4 U01
front GJ01
右前 UNLOCK LOCK door
5 7 KJ01
Y/R Y/R
门锁
LOCK NULOCK lock 0.5 0.5
电机
main R/W G
2 U02 6 U01 switch 0.85 0.85 1 A46 1 A46
B B integrated Neutral Neutral
0.5 1.25 in position position
switch switch
the
window 2 A46 2 A46
6 UJ02
GJ09 lifter
switch
B B
0.5 0.5
B
1.25 K14-5 K24-5 K14-4
WG48 Exterior light Advanced audio
system system A03 A53
G30-11
386

IG2Power Supply
IG1Power Supply
ACCPower Supply
Auxiliary EMS
Power Supply AJ01-23 Power outer
A rear view Steering
Auxiliary Power Supply Braking light mirror control Independent
B Steering/warning light Interior light system Starting Shaft
F2/20 Start Button system gateway
Auxiliary Power Supply control system Reserved system SRS system Lock<
Auxiliary G2N-11
C G27-13 G27-12 G27-11 G27-7 G27-2 G44-2 G37-5/10 MICU-W27 1 A45 GJ10-8 T04-1 P04-1 G2A-5 G03-8 G2X-2 G2N-34 G07-8 G07-9 G21-3 G21-6
Power
Supply
MT
7.5A Lower reversing B-CAN B-CAN B-CAN
B-CAN
the light H H L
L
left switch 2 A45
and (Closed:
Emergency Reverse)） Y/G
right 0.85
Warning
steering
Light relay AJ01 AJ01
when 26 4 Collision
BJ07 BJ11 unlock
closing *2 *1 signal
a Y/G input
0.85
door
BJ02
21
GJ06 keyless-ECU keyless-ECU
G50-12 G50-6
L Gr/R W/G G/W Y G/R W/G W/L Y/G Y/L O Y/G V P V P
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
23 G2P 24 G2P 26 G2P 6 G2Q 12 G2Q 12 G2P 4 G2Q 27 G2P 9 G2Q 7 T2J 3 P2I 5 G2P 37 G2X 11 G2Q
5 G2T 6 G2T 1 G2T 2 G2T
B-CAN L B-CAN H
MICU-W19 MICU-W27 R position signal Right front door MICU-W7 MICU-W17 MICU-Z4 MICU-W18 MICU-W8 Rear view mirrorMICU-W9 MICU-W10
light drive Left front door Brake signal Rear view mirror returning drive
light drive
input folding drive
Trunk micro
Trunk light
MICU Left rear Right rear
MICU-Z3 MICU-W5 switch MICU-W2 MICU-W4 MICU-W3 door lock door lock
F-CAN-H F-CAN-L switch signal Speed signal input UNLOCK signal MICU-W22 UNLOCK LOCK UNLOCK detection detection
6 G2P 7 G2P 8 G2P 15 G2P 27 G2X 13 K2F 20 G2P 36 G2X 4 K2G 7 T2K 8 G2N 8 K2E 11 K2H 4 K2H 7 G2N 1 K2E 8 T2K 2 T2K 10 K2E 3 G2P 2 G2P
B Y GJ01 Y Y Y/R Y/B Y/B Y/B Y/B Y/G

GJ01 15 GJ01
0.5 11 0.5 0.85 0.85 0.85 0.85 0.85 0.85 0.85 0.85 23 20
KJ01 KJ01 KJ01
W B/R
GJ09 KJ04 0.5 0.5
4 5 KJ05 7 9 KJ05
UJ02 7 VJ01 WJ01 9 VJ01
GJ11 KJ05 KJ04
R 13 VJ01 13
Y/L BJ02 L/B WJ01
0.5 0.85 0.5
Y
0.85 W B/R
1 K10 0.5 0.5
Rear
trunk Y 1 K41 3 K41 Left 6 V05 6 Right
W02
micro 0.5 Trunk Trunk Right rear rear
front UNLOCK UNLOCK
switch lid light Y/R Y/B Y/B door door
2 K10 M switch LOCK LOCK
opener
(Closed:
door Left 0.85 0.85 Left 0.85 Left lock lock
motor L/B lock rear
lid rear front motor motor
0.5 motorY door door
BJ11 open, Y/B door 2 V05 2 W02
28 light 0.85 0.85 lock lock
B AJ01 2 K41 lock
on) motor motor B B
0.5 motor 0.5 0.5
B 4 W02 3 W02 3 V05 4 V05 4 T01 3 T01

4 U02 3 U02 VJ01 WJ01
0.5 8 8
WG49 KJ05 KJ04
M M M M B B
0.85 0.85
Reserved Reserved K7 Engine ECU Interior light Reserved Reserved
K7 Reserved 悬空预留
G2P-6 G2P-7 A10-49 system G2X-36 K2G-4 T2K-7 K2E-10 K3 K4
K15-2
387
IG2Power Supply
IG1Power Supply
ACCPower Supply
Combination
Window ControlWindow Control Combination Combination Instrument
Exterior Power Amplifier No. 1 CAN adapter No. 1 CAN adapter DLC System Switch SRS SRS
System Switch
G06-10 G06-20 G16-4 G16-5 G36-9 G36-8
K26-8 K26-9 G40-3 G40-11 T03-18 T03-17 G24-1 G24-2
B-CAN B-CAN B-CAN B-CAN B-CAN B-CAN B-CAN B-CAN B-CAN B-CAN B-CAN B-CAN B-CAN B-CAN
H L H L H L H L H L H L H L
V P V P V P V P V P V P V P
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
1 K2G 2 K2G 39 G2N 38 G2N 31 G2N 30 G2N 14 T2J 13 T2J 14 G2X 13 G2X 23 G2X 24 G2X 2 G2R 1 G2R 11 B2D 12 B2D
Steering
MICU-W1 Steering shaft lock
Illumination Co-driver's seatBraking light shaft lock control
Door lock motor
MICU-W12 MICU-W11 MICU-W13 MICU-W14 MICU-W15 MICU-W16 ground MICU-W21 MICU-W20 drive belt signal switch signal unlock drive (Hall)
13 K2E 14 K2E 14 K2H 8 K2H 15 G2P 14 K2F 7 K2H 5 K2E 3 G2M 5 G2Q 1 G2P 21 G2P 30 G2P 29 G2P 13 G2Q 16 G2P 17 G2P
G G/Y Lg/R G/W R B R/Y W/R Y Gr W

0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 L/R Sb
0.5 0.5 0.5 0.5
1 KJ01 23 KJ05 18 KJ07 23 KJ04

GJ01 VJ01 GJ07 WJ01
1 KJ08
J01
G Lg/R
0.5 0.5 Driver's
seat 2 X03 3 G18 2 G61
G/Y G/W Brake
5 GJ04 21 GJ10 belt Clutch
TJ01 0.5 UJ01 0.5 light
buckle Pedal
switch Switch
switch (OFF:
(Close: 1 X03 pedal 4 G18 1 G61
Locked) down)
J01 B
2 KJ08 0.5
B
0.5
B
0.5
Exterior
T01-6 V05-1 U02-1 W02-1
Left front Right Right K2H-12 K2-8-4
light
K2-8-5 system G41-9 G41-10
Left rear G21-2 G21-4
door lock door lock front rear door Reserved Reserved Reserved Steering/warning light GJ10-7 Reserved Power outer rear view
motor motor door lock lock G2P-15 K1 K2H-7 K3 G2M-3 G2P-1 WG47 keyless WG47
motor motor
control system G2N-3 mirror control system
388
3. Relay control module and exterior light control system

Battery (MeterⅡ）
IG2Power Supply
IG1Power Supply
ACCPower Supply
F2/31
Power supply for switch Washer system
Combination 2nd gear 7.5A C19-1 Interior light Exterior light
Wiper system F2/33 system Headlamp adjustment F1/6 F1/7
Switch system Reserved
F2/28 Wiper BJ05-1 Front MCU
G24-4 G24-8 B01-2 B01-1 B01-3 30A G25-2 G35B-10 P03-8 T2J-10 K14/24-2 C06-2 C04-2 C05-2 C17-2 position
7.5A
15A lights
G/Y 15A
3 B2D
0.5 低高
速速
Y 6 B2D
6 X991 0.5
时
钟 Y/G Y/G L Y W
弹 0.85 0.85 2.0 2.0 0.5
R/B R R/B
簧
8 G25 0.5 0.5 0.85
1 X992 8 B1E 4 5 B1J 1 B1J
W G/W
0.5 0.5 1 B2C
G/Y
KI1-5
0.5 KI1-2 KI1-1 35 G2N 5 P2I 10 T2J 12 K2F Internal
Relay KI1-3 Internal Internal Gr side
coil Internal wiper light
16 GJ06 15 GJ06 13 GJ06 washer
wiper 2.0
BJ02 BJ02 Horn BJ02 Power switch
2 B1J motor relay
supply motor relay
switch relay
ON relay
P V W G/W G/Y B
3 B1J 0.85
0.5 0.5 0.5 0.5 0.5 20 C1F 4 B2D 10 B1I 10 9 C1H
2 1 7 8 6 B1I 9 B1I R/B R/B R/B

B14 0.85 0.85 0.85
B-CAN H B-CAN L MCU-N18
MCU-N20 MCU-N21 Low level MCU-N17 MCU-N19 MCU-N12 MCU-N10 MCU-N14 MCU-N9 MCU-N8 MCU-N22 MCU-N6 MCU-N11
effective
MCU
MCU-N1 MCU-N16 MCU-N13 MCU-N3 MCU-N27 MCU-N23 MCU-N26
Rear
defroster
heating
control 5 B1I 3 C1H 2 C1H 1 C1H 4 C1H
W/B G/B
0.5 L/B 0.5
0.5
Front
Engine 1 C11
fog
compartment
light
BJ02 cover
14 GJ06 relay 2 CJ02 switch
control BJ05 (Closed:
Cover 2 C11
open)
W/B L/B B
0.5 0.5 0.5
G2N-24
Air Conditioning
Relay control to B1E-7
System Reserved Reserved Reserved
ground WC20
K1-3-85
389
4. Horn, warning system, washer and wiper system
IG2 Power Supply
IG1Power Supply
ACC Power Supply
Horn、 braking light

A
Exterior light Exterior light
F1/14
Keyless-ECU system system Relay control module
Horn、 Reserved
braking
B *1 *2
C12-2 C13-2 C1H-6 C20-2 C22-2 Reserved
light C1F-20 B1J-1 B1J-5 B1J-4
20A
R/Y R/G W/R W/G

1.25 1.25 1.25 1.25
14 5 C1H 6 C1H 13 11 C1H 12 C1H
KI1-7 KI1-6
Internal Internal
KI1-4 KI1-8
F1/2 F1/1 siren F1/3 F1/4 low-
Internal Internal
Left Right relay Left Right beam
electric electric
high- high- low- low- light
horn horn
beam beam relay
relay relay beam beam
light light light light circuit
Wiper
10A 10A 10A 10A Y/G W Y L
reset
0.85 0.5 2.0 2.0
7 8 C1H 4 B1I
L/R G/R Br/Y

1.25 1.25 0.85
1 C19 3 B01 1 B01 2 B01
Front
BJ02
2 GJ06
MCU-N7 MCU-N15 MCU-N25 MCU-N5 MCU-N2 MCU-N4 window HI
M LO Wiper
washer M motor
Br/Y
MCU motor
0.85
2 C19 4 B01
GJ01
6 KJ01
Br/Y
0.85 B B
0.85 2.0
1 C09 1 C27 1 K20

Left Right
bass treble
fanfare Siren
fanfare
horn horn
2 C08 1 C14 2 K20
B B B
1.25 1.25 0.85
WC21 WC20
WC23 B07
390
5.1 473QE EMS (1)
IG2Power Supply
IG1Power Supply
ACCPower Supply
Air
Conditioning
System Brake
System MICU
AJ01-20 G47-5 C1F-3 F2/25
AJ01-7 G47-6 G47-24 G18-1 G2P-21 electronic
injector
F2/24 main
WG49 Fuel relay
pump
215A
15A
F2/26 F1/9
EMS EMS
15A R
15A B
0.5
0.5 5 G2X
R/W G L/Y Y L/B W/B W/R W/G
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
3 B03 86 88
Medium K2-1
voltage 3 G02 DLC3 88 86
Driver electronic
switch of G40-16
15 G2X intent injector
9 B1E
air K2-6 Fuel main
G2X-16 conditioner switch
pump 85 88a
R/G relay 2
Gear shift (Closed: 2 B03 relay
mechanism 1.25 ≥1.47 4 G02
88a 85 30
Mpa) 11 G2X
GJ15 W/G B
3 W W
BJ08 0.85 0.85
0.5 0.5
WG9
Dashboard O O
GJ06 GJ06 GJ06
distributor 0.85 0.85
4 BJ02 5 BJ02 22 BJ02 B/O
R/G box
0.85
0.85 2E 2X
16 K2E 4 G2X
Front 1 A24 4 A29 Rear
oxygen oxygen
G16-14 sensor
G/Y 8 AJ01 sensor
GJ11 GJ11 GJ11 W/R W Combination 1 GJ15
Instrument 0.5 1 BJ08 8 BJ11
15 BJ11 13 BJ11 14 BJ11 0.5 0.5 Y/G
1.25
2 A24 4 A24 2 A29 1 A29 3 A29
3 A24
B/O
GJ06 0.85
6
1 K11 BJ02
Power Fuel
supply R
L/Y Y L/B G/B M pump Gr
0.85 G/W Sb V/W Sb W/B
ON 0.85 0.5 0.5 motor 0.5 0.5 0.5
0.5 0.5 0.5 0.85
G/Y
0.5 Shielding Shielding
5 K11 layer layer
BJ11 BJ11 BJ11 BJ11 BJ11
22 29
AJ01 AJ01 BJ11 BJ11 BJ11 BJ11 B
23 AJ01 21 AJ01 33 AJ01 B
26 AJ01 16 AJ01 25 AJ01 12 AJ01 BJ11 0.5
5 0.5
B AJ01
1.25
Battery
R/G R W/B G W
L/Y Y L/B G/B
0.85 0.5 0.5 0.5 0.5
0.5 0.5 0.5 0.5 G/Y
A09
0.5 A09
A45-1
Reversing light switch
K5
48 A10 33 A10 57 A10 4 A10 55 A10 24 A10 25 A10 29 A10 30 A10 28 A10 17 A10 42 A10 9 A31 40 A31 16 A31 32 A10 40 A10 5 A10
Low speed fan High speed fan A/C Rear defroster A/C permission - Medium voltage Brake Brake signal 1 Driver intent
control control permission compensation Low level effective switch signal 2 High level Switch signal
(Blower effective
compensation)
391
5.2 473QE EMS (2)
IG2Power Supply
IG1Power Supply
ACCPower Supply
F2/12
7.5A
AJ01
15
BJ11
Dashboard Y/B Y/B Y/B
B/O B/O B/O
distributor N/A
0.85 0.85 0.85 1.5 1.5 1.5
box
2D
17 B2D O 2 A38 1 A01 1 A04
Filter
0.85 capacitor
Coolant temperature sensor 2 Camshaft position sensor Phase ICM ICM
2 A36 2 A28 A23 Ignition Ignition
Charcoal coil coil
Canister Linear No. No.
Control EGR 1 2
MIVEC valve t° t°
Valve
Valve
1 A28 1 A35 2 A35 3 A35 4 A35 5 A38 1 A23 3 A23 3 A12 2 A12 1 A12
1 A36
W/B L R/B L/R 3 A04
3 A01 2 A01 2 A04
0.5 0.5 0.5 0.5 Self-owned
support Cylinder
grounded Cylinder No.
Sb O L/R No. 2
0.5 0.5 0.5 1 sparkplug
Gr sparkplug
Br
1.25 1.25
Gr/B
Gr/B
0.5
0.5
B
L Y/W 1.25
0.5 0.5
A09
5 A31 30 A31 7 A31 39 A31 20 A31 37 A31 31 A31 29 A31 34 A31 36 A31 24 A31
392
5.3 473QE EMS (3)
Battery (Meter Ⅱ)

IG2Power Supply
IG1Power Supply
ACCPower Supply
F2/23
EMS
Main F1/18
relay30A EMS
40A
Dashboard
distributor
box
3 B1D
Y/B 88 86 B
1.5 K2-4 4.0
Main
relay 1 B2B
88a 85
Dashboard
distributor
box
Y/B Y/B Y/B Y/B Y/B Y/B
1.5 1.5 1.5 1.5 1.5 1.5
1 A02 1 A03
ICM ICM 2X Intake Pressure/Temperature Sensor
Ignition Ignition 1 A05 1 A06 1 A07 1 A08 17 29 G2X
coil coil Injector Injector Injector Injector
No. No. No. No. No. No.
3 4 1 2 3 4
u t°
2 A05 2 A06 2 A07 2 A08 3 A22 4 A22 1 A22 2 A22
Y/B B/W
3 A02 2 A02 3 A03 2 A03 1.5 0.5
Cylinder Cylinder GJ15 GJ06

No. No. 7 BJ08 20 BJ02 Y/L Br/Y R/L G/P
3 3 0.5 0.5 0.5 0.5
O sparkplug
O sparkplug B/W
1.25 1.25 0.5
Y/B
1.5
BJ11
11
AJ01
BJ11
1
AJ01
L/W V/G G/R B/Y Y/B Y/B B/W
0.5 0.5 0.5 0.5 1.5 1.5 0.5
35 A31 12 A31 4 A31 3 A31 8 A31 10 A31 1 A10 2 A10 18 A10 45 A31 27 A31 21 A31 38 A31
EMS
393
5.4 473QE EMS (4)
Battery (Meter Ⅱ)
IG2 Power Supply
IG1 Power Supply
ACC Power Supply
Gateway Controller
DLC
G2X-27 G15A-3 G15A-20 G15A-17
A32 A09
Power assist
steering switch
（Closed：
Direction killed）
1 A32
Y
0.5
GJ11
accelerator 3
BJ02
pedal
position
crankshaft knock
sensors position S N sensor
sensor
（Engine
Electronic
speed)
3
Throttle A21 4 A21 1 A21 2 A21 5 A21 6 A21 1 B14 6 B14 5 B14 1 A11
2 B14 3 B14 4 B14 2 A11 2 A20 1 A20
Body
W/G G/L L/R Y/R Y/G Y/L

0.5 0.5 0.5 0.5 0.85 0.85
Br Br/W G/W Y L V P
G/Y B/R
0.5 0.5 0.5 0.5 0.5 0.5 0.5
0.5 0.5
twisted twisted
pair pair BJ11 BJ11 BJ11
28 24 2 3
AJ01 AJ01 AJ01
BJ11 BJ11 BJ11 BJ11 BJ11 BJ11
6 AJ01 13 AJ01 14 AJ01 27 AJ01 19 AJ01 17 AJ01
Y/L W/G Y L/G B/O Sb Y L B B B B V P

0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.85 0.85 0.85 0.85 0.5 0.5
speed
signal
outputs
22 A31 13 A31 43 A31 14 A31 11 A31 23 A31 3 A10 47 A10 23 A10 54 A10 46 A10 38 A10 16 A10 33 A31 32 A31 26 A31 25 A31 9 A10 49 A10 35 A10 7 A10 8 A10 47 A3148 A31 36 A10 22 A10
394
5.6 476ZQA EMS (1)
Battery (Meter Ⅱ)
IG2 power supply
IG1 power supply
ACC power supply Air
Conditioning
High-speed Electronic fan System Brake MICU
C1F-3 System G2P-21
electronic fan speed G47-24 G47-5 G47-6
C01-10/C01-20 C01-5/C01-15 G18-1
F2/24
Fuel
15A
F2/26 F1/9
EMS EMS
15A 15A R
0.5
5 G2X
G/B L/W L/B L/Y B/Y W/B W/R W/G
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
Medium
3 B03
空调中压
voltage
88 86
switch of air DLC3 F2/12
开关（闭
conditioner G40-16 oxygen
合：≥1.47Mpa）
(Closed:
9 B1E
≥1.47 K2-6 Sensor
15 G2X
*2 29 BJ07 25 BJ07 *3
Mpa)
Fuel pump 7.5A
2 B03 relay 29 AJ01 25 AJ01
88a 85
Y
0.85 Dashboard
distributor
box
CJ02 CJ02 GJ11 GJ11 GJ11 CJ16 GJ16 Y/B B/O
10 BJ05 9 BJ05 14 BJ11 15 BJ11 13 BJ11 3 BJ09 7 BJ09 0.85 0.85
Y/B Y/B
2E 2X 2D 0.85 0.85
16 K2E 4 G2X 17 B2D
Front 1 A30 后 1 A31 OCV 1 A27

oxygen 级电
sensor Rear
G/B L/W W/R 氧
oxygen 磁
0.5 0.5 0.5 Y/G
sensor
传阀
G/Y
GJ15 1.25 0.5 感
3 BJ08 2 A30 4 A30 3 A30 器 3 A31 4 A31 2 A31 2 A27
1 K11
Y Fuel
GJ16
0.85
R G/B M pump
motor
8 BJ09
0.85 0.5
G/Y
BJ07
5 K11 0.5
23 AJ01
BJ07 BJ07 BJ07 BJ07 BJ07 BJ07 BJ07 BJ07 BJ07 BJ07
24 AJ01 3 AJ01 16 AJ01 12 AJ01 13 AJ01 33 AJ01 5 AJ01 4 AJ01 9 AJ01 10 AJ01
B
1.25
Y
0.5 R G/B L/W L/B L/Y B/Y W/B G G/Y W/G W/R Br Br/Y W B/G
G/B
0.85 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 Sb
A45-1 0.5
Reversing light
switch
54 A01 K5
112 A01 113 A01 40 A01 Low speed
79 A01 fan 61 A01 15 A01 19 A01 18 A01 36 A01 43 A01 62 A01 13 A01 55 A01 56 A01 33 A01 75 A01 81 A01
High speed fan control A/C A/C Medium Rear defroster Brake Brake
control request permission voltage switch compensation signal 2 signal 1
395
5.7 476ZQA EMS (2)
Battery (Meter Ⅱ)
IG2 power supply
IG1 power supply
ACC power supply
F2/25
electronic
injector
main
relay 2
15A
前舱继电器盒
A54
86 88
K2-1
11 A53 13 A53
electronic
injector F3/6
F3/5
main Coolant
85 88a Vacuum
relay 2 circulation
brake
positive pump
pump
30 11 G2X fuse 15A
15A
block 12 A53 14 A53
B 50A
0.85
WG9 B L/Y
8.0 2.0 1 3 A53 8 6 A53
B/O B/O Y/B Y/B Y/B Y/B
B/O B/O B/O
0.85 0.85 2.5 2.5 2.5 2.5
0.85 0.85 0.85 19 A54 86 88 K3-2 88 86
Coolant Vacuum
circulation brake
Boost Turbocharger pump 1 A20
pump 1 A21 1 A22 1 A23
pressure Air relay
relay ICM ICM ICM ICM
pressure 1 A25
Circulation
1 A26 Charcoal 1 A35 85 88a (DCT) 88a 85 2# 3# 4#
1#
1 GJ15 8 AJ01 limiting Valve Canister Ignition Ignition Ignition
8 BJ07 Ignition
1 BJ08 valve Control coil coil coil
15 18 A54 7 9 A54 coil
solenoid Valve
F3/4Pumps,
B/O F3/2 vacuum
2 A25 2 A26 2 A35
0.85 TCU pumps L/B
L/Y 2 A20 3 A20 2 A21 3 A21 2 A22 3 A22 2 A23 3 A23
30A 0.85
0.85 Cylinder Cylinder Cylinder Cylinder
No. 1 No. 2 No. 3 No. 3
4 A54 2 A54 sparkplug sparkplug sparkplug sparkplug
1 A33 2 A34
B B B B
R R
M Turbocharger M Vacuum 1.25 1.25 1.25 1.25
Air Circulation brake pump
2.5 2.5
Valve
A51 A51 A51 A51

3 A33 1 A34
G/W B B L/W
A45-1 A45-9 0.5 0.85 0.85 0.5 Y/W Y/R Y/L Y/G
O Sb Gr/B
0.5 0.5 0.5 DCT 0.5 0.5 0.5 0.5
A53 A53
22 A01 21 A01 78 A01 74 A01 73 A01 99 A01 107 A01 98 A01 106 A01
396
5.8 476ZQA EMS (3)
Battery (Meter Ⅱ )
IG2 Power Supply
IG1 Power Supply
ACC Power Supply
F2/23
EMS
Main F1/18
relay EMS
30A 40A
Dashboard
distributor
box
3 B1D
Y/B Y/B Y/B 88 86 B

2.5 2.5 2.5 K2-4 4.0
Main
relay 1 B2B
1
88a 85
Dashboard
distributor
box
Y/B Y/B
2.5 2.5
Injector
Injector Injector Injector
No.
No. High *3
No. No.
2 A38 1 Brake
2 3 4 2X fuel
17 Coolant temperature sensor Radiator booster
1 A24 29 G2X pressure
Fuel outlet pressure
pressure coolant sensor
sensor
Filter regulating 1 A16 2 A161 A17 2 A18 1 A19 2 A19 temperature （DCT）
2 A17 1 A18
capacitor valve t° sensor t°
2 A24 1 A04 2 A04 1 C15 2 C15 1 A06 3 A06 1 A49 2 A49 3 A49
Y/B B/W 2 A06
3 A23
2.5 0.5
Self-owned
GJ15 GJ06 G B/L
support
7 BJ08 20 BJ09 G/B
grounded 0.5 0.5
0.5
CJ02 CJ02
Y/B B/W 15 BJ05 12 BJ05
2.5 0.5
G B/L
0.5 0.5
BJ07 BJ07 BJ07 BJ07

1 AJ01 21 AJ01 28 AJ01 30 AJ01
L V R/B G/R Y/B Y Y/B B/W Y/W B/Y G B/L B/R G/R G/B Sb Br
1.25 1.25 1.25 1.25 1.25 BJ05-13 0.5 0.5 0.5 0.5 0.5 0.5
Gr/Y 1.25 2.5 0.5 0.5 0.5 0.5
Fan relay
2.5 control
pin power
1 A01 117 A01 121 A01 116 A01 118 A01 115 114 120 119 A01 3 A01 102 A02 31 A01 68 A01 12 A01 69 A01 70 29 A01 95 50 A01 10 A01
ECM
397
5.9 476ZQA EMS (4)
Battery (Meter Ⅱ)
IG2 power supply
IG1 power supply
ACC power supply
controls
the
idle Intake Intake
(发动机转速)
speed manifold manifold
S N temperature temperature
Pressure Pressure
sensor sensor
3 A15 4 A15 1 A15 2 A15 5 A15 6 A15 t° u t° u
1 A10 2 A10 3 A10 electronic 2 B14 1 B14 6 B14 3 B14 4 B14 5 B14 2 A08 1 A08 4 A08 3 A08 2 A07 1 A07 4 A07 3 A07
throttle
Y/L W/G Y L/G B/O Sb

Y L G/Y 0.5 0.5 0.5 0.5 0.5 0.5
0.5 0.5 0.5
BJ07 BJ07 BJ07 BJ07 BJ07 BJ07

17 AJ01 18 AJ01 6 AJ01 2 AJ01 14 AJ01 11 AJ01
Br L/R G/R L L/Y L/Y Y Y Y/L W/G Y L/G B/O G/Y B/W L/Y Gr Gr W G G/W R
Sb
0.5 0.5 0.5 0.5 0.85 0.5 0.85 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
0.5
86 A01 63 47 A01 71 A01 14 A01 88 A02 52 A01 5 A01 59 A01 4 60 A01 97 A01 27 A01 48 A01 87 A01 8 A01 72 A01 32 A01 66 A01 9 A01 89 65 11 A01 53 A01 28 A01 94 A01
398
5.10 476ZQA EMS (5)
399
Battery (Meter Ⅱ)
IG2 Power Supply

IG1 Power Supply
ACC Power Supply
A F2/3 MICU 10A G11B-10

Dashboard
18 G11B 19 G11B
22 G2X wire
harness
W/R adapter
Ⅱ
0.85 Combined
Switch Y
0.5
G24-5
20 G11B
Battery
39 G16 38 G16
Fuel gauge
Water thermometer
ODO/TRIP
gears
ESP failure warning indicator 、ESC OFF
Indicator
Warning light of engine failure
Rear Front Theft Smart Power Supply
Tire pressure warning light fog fog Deterrent High key
Main warning light
buzzer light light
Sidelamp Indicator
beam
system Circuit
Luggage Compartment Open Indicator Indicator indicator
indicator indicator warning
车速转速 light
TFT Incorrect Drive Circuit
Drive Circuit Drive Circuit

CPU
车身-控制器
局域网收发器
B-CAN H B-CAN L
4 G16 5 G16 15 G16 11 G16 37 G16 28 G16 18 G16 19 G16 20 G16 8 G16 9 G16 12 G16
L/W Br/W W Br/W Y/W

G/B B 0.5 0.5 0.5 0.5 0.5
0.5 0.5 B/W B/Y
P V 0.5 0.5
B
0.5 0.5 GJ11 0.5
19 BJ11 12 G25 10 G25 Backlight
Backlight
adjustment GJ01
G/R
adjustment 14 8
+ button ODO/TRIP key KJ01
+ button
0.5
Clock
3 B09 spring
B/W B/Y
B-CAN L reset switch
B-CAN H Tank 12 X991 10 X991 reset switch
0.5 0.5
level R L
60.5X993
sensor 0.5
1 B09 5 X993 3 K11 2 K11
G2X-24 G2X-23 Oil
R1 8.2K level
B Information ENTER
sensor
0.5 toggle
WG47 button R2 15K WG47
steering 上
B07 wheel
R3 27K
下
400
Battery (Meter Ⅱ)
IG2 Power Supply
IG1 Power Supply
ACC Power Supply
Steering/warning light control system
Dashboard
wire
harness
G2N-40 G37-7 G2N-26 G37-2
adapter
Ⅳ 4 G35B 3 G35B 2 G35B 1 G35B
R R/L R/L Br Br
0.5 Left0.5 0.5 0.5
Steer 0.5
G47-22 right
G44-4( Warning turn
G29-9(CD) (Conditioning
Switch )
)
21 G16 33 G16 22 G16
背光调节输出
Backlight adjustment output
Battery
Parking discharge
brake indicator Cruise Indicator
warning SRS SVS control Major light of P/S
ABS Indicator Indicator indicator control driver Indicator
Indicator light indicator seat
of safety
cruise belt Left Right
control turn turn
indicator indicator
CPU
27 G16 23 G16 24 G16 35 G16 34 G16 40 G16

G/O G/R
Indicator light
0.5 0.5 Y/L
of the front 0.5 Passenger
1 KJ06 passenger 29 G2N safety
L
seat belt GJ11 belt indicator
0.5
R/B 5 BJ11 Y/R
0.5 GJ11 0.5
Seat belt 1 17
warning G/R BJ11
0.5 Y/R
sensor （ 27
AJ01
2 0.5 BJ07 GJ11
open ） 28 G2N 1 B02 16 BJ11 GJ08
2 4 HeJ01
branch wire for GJ07 Gr
11 1 A36 Engine oil
assistant driver KJ07 0.5
Brake
fluid level
pressure
seat belt switch switch sensor
Y/R
(Closed ： 1
（ Closed：Buoy (closed:
） 2 B02 0.5
ㄩ
1 G32 sinks engine
R/L
Locked ) stops
open: 0.5
Parking B engine
R/B brake
0.5
ㄘ
switch （ Closed ： pulled runs
0.5 16 foot
B ）
multi-screen
0.5 B07 EMS access
Power
generating He03-16
K4 system
A37-1(476)
A16-2(473)
401
Battery (Meter Ⅱ)
IG2 power supply

IG1 power supply
ACC power supply
F1/14
Horn, braking light
B 20A high-frequency reception module
power
supply
电源 High-frequency
高频数据信号 signalRSSI Gateway
RCV_VC RFDA GND detection
5 K12 3 K19 1 K19 2 K19 controller
F4/11 G07-9 G07-8
2 2 K43 10 B1D 10A G Br
G/L L/W
micro- 0.5 0.5 0.5 0.5 B-CAN No battery mode clock output
R/W B-CAN
Moving 1.25 L H Signal ground
to
1 K43 2 BJ01 No battery mode data input
open GJ05
Start button Power input
Close G10 G01
R/W
1.25
R Gr
0.5 0.5
21 G2N
16 KJ01 KJ01
GJ01 17 *3
GJ01 *1 *2
12 KJ07
20 G2N 4 17 1 GJ07
R Gr R
0.5 0.5 R 0.85 V P Br/Y Sb Br/W Br/B
G G/L Sb L/W
0.85 0.5 0.5 0.5 0.5 0.5 0.5
0.5 0.5 0.5 0.5
3 G50 10 G50 1 G49 1 G49 12 G49 5 G50 7 G50 11 G50 6 G50 12 G50 7 G49 8 G49 3 G49 2 G49
Battery Battery RCV_VC RFDA GND RSSI B-CAN L B-CAN H SCLK GND DATA VCC
keyless-ECU
19 G49 20 G49 13 G49 18 G49 14 G49 4 G49 15 G49 5 G49 11 G49 16 G49 6 G49 17 G49 9 G49 10 G49 8 G50 1 G50 9 G50 2 G50
G/W
G/Y Gr 0.5
Y/L R 0.5 0.5 L/W V/B V/W L/Y
0.5 0.5 0.5 0.5 0.5 0.5 3 GJ04
R/G G/R R/W
Y L O W TJ01
0.5 0.5 0.5
0.5 0.5 0.5 0.5 GJ07
23 8
GJ07 KJ07 GJ04 GJ10
15 6 1 2 TJ01 13 10 UJ01 GJ10
KJ07 16
UJ01
G/Y Gr GJ04 GJ10
4 TJ01 2
0.5 0.5 UJ01
L/W V/B V/W L/Y
0.5 0.5 0.5 0.5
B B R/G
0.5 0.5 0.5 G/R
Y/L R
0.5 0.5 R/W
0.5
0.5
G/R
0.5
5 TJ02 6 UJ03
1 K18 2 K18 1 G28 2 G28 1 G33 2 G33 1 K16 2 K16 1 TJ02 2 TJ02 2 UJ03 1 UJ03 Left Right
Front Front
Door Door
micro micro
6 TJ02 5 UJ03
Moving
Moving to
to open R/G open G/R
Close 0.5 Close 0.5
Detection antenna of exterior magnetic card - Interior magnetic probe Interior magnetic probe Magnetic probe antenna
Trunk antenna - Front
Interior magnetic probe Magnetic probe antenna outside WG46
antenna - Central antenna - rear the car - front left door outside the car - right front
door
402
403
8. Backup radar system
Battery (Meter Ⅱ)
IG2 Power Supply

IG1 Power Supply
ACC Power Supply
No. 1 CAN adapter No. 2 CAN adapter B F2/31
Power supply
Left rear Right Multiplex for switch 2nd
grouped rear integration G06-8 G06-18 K50-1 K50-11 12 G2X
gear
light grouped control module 14 G15A Dashboard
K24-4 light G2P-14 7.5A R/G Wire
K14-4 Harness
0.5
Adapter
CAN-H CAN-L CAN-H CAN-L Ⅲ
*4
G 13 G15A
R/G
0.85
0.5
1 G48
Backup radar switch
7 GJ01
KJ01 4 G48 2
B
V/W
0.5
GJ07 0.5
10 GJ07 14
KJ07 KJ07
G GJ01
21
0.5 KJ01
Backup WG49
signal P V P V V/W
0.5 0.5 0.5 0.5 0.5
5 K17 1 K17 17 K17 1 K17 17 K17 19 K17

High level effective
Power supply
ECU
Signal ground Signal ground Signal ground
28 K17 11 K17 13 K17 15 K17 12 K17 14 K17 29 K17 16 K17 31 K17 30 K17 32 K17
G/W W/R Br/W R Y L Br Y/G B/L B B

0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
KJ03 KJ03 KJ03 KJ03 KJ07

5 KJ03 1 3 4 2 RJ01 19 20 21 22
RJ01 RJ01 RJ01 RJ01 GJ07
G/W W/R Br/W R Y 11 12 9 10 GJ11

0.5 0.5 0.5 0.5 0.5 BJ11
BJ05
5 6 3 4
CJ02
G/W W/R W/R Br/W W/R R W/R L Br G B/L

0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
2 R01 1 R01 1 R02 2 R02 1 R04 2 R04 1 R03 2 R03 1 C25 2 C25 1 C24 2 C24
+ - - + - + - + - + - +
Left rear backup Left rear corner Right rear corner Right rear backup Left front corner 前右角间隙传感
sensor clearance sensor clearance sensor sensor clearance sensor 器
K2
404
9. Braking light control system and cigarette lighter system
Battery (Meter Ⅱ)
IG2power supply
IG1power supply
ACCpower supply
F1/14
Horn, braking light
A 20A
13 G11B Dashboard wire harness adapter Ⅱ
Interior light F4/1 Interior light F1/16

control Cigarette]
control Illumination, CAN module,
lighter15A
G35B-6 G35B-6 auxiliary power supply
B
14 G11B
W/B 11 G11B
1.25 W/B
10 B1D
0.5
R/W 11 G2N
1.25 2N GJ06
1 BJ02 1 G01
2 BJ01 F2/5
GJ05 Dashboard W/B
Cigarette
F2/20
lighter
distributor 2F 0.5 15A ACC
box 8 K2F 7.5A
R/W W/B
0.85 ABS
1.25
B05-30 W/B
KJ08 0.85
21 G2N 10 QJ01
W/B
0.85 88 86
K2-3
20 G2N W/B W/B Cigarette
0.85 0.85 lighter
relay
R Right braking ligh Left braking light
1 K14 1 K24 1 KJ12 88a 85
1.25
High
braking
Braking 2 G18 light
light 12 G2N
switch
130Ω 82Ω 82Ω 82Ω 82Ω 82Ω 82Ω 130Ω 82Ω 82Ω 82Ω 82Ω 82Ω 82Ω
(Closed: 100Ω 100Ω 100Ω
/1W /1W /1W /1W /1W /1W /1W /1W /1W /1W /1W /1W /1W /1W 23 G2N
Pedal
/1W /1W /1W
depressed) 1 G18
2K/0.25W
2K/0.25W
2K/0.25W
2K/0.25W
2K/0.25W
W/B
1.25 R/B W/R R/B W/R
0.5 1.25 0.5 1.25
B
0.5
3 G22 2 G22 3 G22 2 G22

WG49
4W 4W 2W
Cigarette Cigarette
lighter 1.4W lighter 1.4W
6 K14 6 K24 2 KJ12
1 G22 1 G22
B *3 *1 *2
B
0.85 0.85
B B
0.85 B
1.25 1.25
K7
K5 WG46 WG46
EMS Multiplex integration
control module No. 5 meter ground No. 5 meter ground
A01-18
MICU-W18
405
10.1 Interior light system (trunk light, glove box light, door light, ambient light, foot light, room dome light and back light) (1)
Battery (Meter Ⅱ)
IG2power supply
IG1power supply
ACCpower supply
F1/16
A Illumination, CAN
module, auxiliary G2N-35
power supply
40 A
F2/2
Interior illumination
R/B
7.5A R/B R/B R/B R/B R/B R/B R/B
0.5
0.5 0.5 0.5 0.5 0.5 0.5 0.5
4 P2I *4 *4
10 G35B
2 G65 2 G63 7 G25 7 G25 2 G25 3 G48
Right
Left step light step Backup
Clock Clock Clock
6 K2F 9 T2K 22 G2N 26 G2X *4 light *4 radar
Dashboard Wire Harness Adapter Ⅳ
spring spring spring
switch
W/L 6 G48 6 G48 2 X991 2 X991 2 X991 6 G48

0.5 GJ09
3 UJ02
W/L W/L W/L

6 G35B 8 G35B 7 G35B 9 G35B
0.5 0.5 0.5 R R R/B R/B R/B R
0.5 0.5 0.5 0.5 0.5 0.5
1 K15 2 T04 R/B R/B R/B

1 G66 1 U04 R/B R/B
0.5 0.5 0.5 0.5 0.5
2 X993 5 X994 5 X994
Trunk Glove Left Right
light box front front Cruise
5W 3.4W Audio Audio
light light 3.4W light switch
backlight switch switch
W/L W/L 2 K15 1 G67 2 U04 backlight backlight
1 T04 16 G30 21 G47 1 G44 3 G45
0.5 0.5
L/B Y/G 1 X993 4 X994 4 X994
Y/L Automatic Warning Headlamp
0.5 0.5 0.5 DVD A/C switch adjusting
Switch controller backlight switch
backlight
R R R R 22 G47 4 G44 6 G45
UJ01 32 G30
0.5 0.5 0.5 0.5
KJ01 8 GJ10
15
GJ01
Y/G R R R R
0.5 0.5 0.5 0.5 0.5
2 G64
Glove 9 X991 9 X991

box
light Clock Clock 2 G35B 1 G35B
spring spring
1 G64
9 G25 9 G25
R R 4 G35B
B
0.5 0.5
0.5 R
0.5
Cigarette
lighter
T2J-7 G2Q-9 backlight
Multiplex WG46 WG46
T05-6 U05-6 K41-3 power Combination Instrument
integration No. 5 meter ground Reserved No. 5 meter ground
Trunk lock supply
Exterior light control
Multiplex integration G16-21
system illumination module
control module G01-2
G2P-20
BCM(R-5)
406
10.2 Interior light system (trunk light, glove box light, door light, ambient light, foot light, room dome light and back light) (2)
Battery (Meter Ⅱ)
Battery (Front of front compartment mainfuse)
Battery (R ear of front compartment mainfuse)
IG2 pow er supply

IG1 pow er supply
ACC pow er supply
F2/20
Auxiliary Power
A Supply
P2I-5 7.5A
2I
R 4 P2I 2 P2I
0.5
8 P03 9 P03 16 P03

Ambient
light
Emergency Emergency Self-inspection R/B R/B R/B R
rescue rescue & 0.5 0.5 0.5 0.5
Emergency switch indicator fault
rescue light indicator
Reading Reading switch light
Sun Sun Sun Sun light light backlight
roof roof roof roof switch switch
5 G35B 2 P04 2 P05 2 P07 2 P01
open closed up down
Left
Right
sun Inner
Rear sun
screen
screen rear
interior switch
switch
GJ09
view
GJ04 GJ01 light 1 P05 1 P07
R/B R/B 13 UJ02 2 KJ01 8W mirror
6 TJ01
0.5 0.5 direction
4 P03 13 P03 11 P03 12 P03 10 P03 1 P03 OFF
ON display
*4 *4
DOOR
Gr Gr
1 G60 1 G39 2 T10 3 P04 1 P04 0.5 0.5 1 P01
2 U10
KJ05 KJ04 R W Y Y/L Sb B
ESC 10 VJ01
Left Right 2 WJ01 0.5 0.5 0.5 0.5
OFF 3# f ront f ront 0.5 0.5
door door
Switch Switch handle handle
at m os phere at m os phere
block l amp l amp
PJ01 B O B
4 G60 *4 *4 2 P06 2 P08
6 G39 1 T10 1 U10 2 GJ02 0.5 0.5 0.5
2 V06 2 W06 Vanity Vanity

R light
light
Left Right 0.5
R R rear
door
rear
door
0.5 0.5 handle handle 1 P06 1 P08

B at m os phere at m os phere
l amp l amp
0.5
1 V06 1 W06 B B
0.5 0.5
3 G35B B B
DashboardW/B 0.5 0.5
wire 0.5 UJ02
harness 6 GJ09
adapter VJ01 WJ01
Ⅳ 1 KJ05 1 KJ04
B
1.25
B B
0.5 0.5
P02-4 P02-5 P02-6 P02-10

Backlight adjustment
G16-21 Sun roof system
T2K-3 WG48 K4 K3
No. 6 meter No. 4 No. 3 Reserved Reserved P2I-1 MICU
ground floor ground K2E-7 K2G-6 P2I-3
floor ground Ground
407
11. Steering/warning light control system
408
12. Exterior light system (headlamp, position light, fog light, license plate light and back-up light) control system
Battery (Meter Ⅱ)
IG2 power supply

IG1 power supply
ACC power supply
Interior light system
Relay control module T2K-9 G2N-22

F1/8
Front
15 C1F C1H-14 C1H-13 C1H-10 C1H-5 C1H-11 C1H-9 K2F-12 Multiplex integration control module
fog light L
20A 1.25
G2Q-3 G2P-14
G2Q-5
9 C1F
Front
compartment
relay R/B
block 0.85
GJ09
3 UJ02 GJ10
7 UJ01
1 B1E R/Y
W/L W/L
0.5 0.5 3 G2N 0.5 GJ01 GJ01
5 KJ01 7 KJ01
Left 6 T05
Right
6 U05
86 88 ground ground 17 T2J
light light
KC-1
Front 5W 5W
fog 11 T05 11 U05 R/L
light 0.5
relay
85 88a
16 C1F
7 B1E
L L R/Y W/R W/R R/B R/G W/G R/B R/B R/B R/B R/B R/B R/B R/W R/W G G
1.25 1.25 1.25 1.25 0.5 0.85 1.25 1.25 0.5 0.85 0.85 0.85 0.5 0.5 0.5 0.85 0.85 0.85 0.85
Left Left Left Left Right Right Right Right Left Right
front Rear
Right Left front front marker front front marker front rear rear Left Right Left Right Right Left
low-beam glow
front front high-beam low-beam light side high-beam light side side side license license rear rear reversing reversing
light light light light LOGO fog fog
fog fog light light light light plate plate light light
L/B light light light light light light
0.5 2 C16 2 C03 2 C12 2 C20 2 C06 2 C04 2 C13 2 C22 2 C05 2 C17 2 K24 2 K14 2 K09 2 K13 1 K40 5 K24 5 K14 4 K14 2 K24
0.5W 0.5W
55W 55W 55W 55W 55W 5W 55W 55W 5W 5W 5W 5W 5W 21W 21W 16W 16W
1 C16 1 C03 1 C12 1 C20 1 C06 1 C04 1 C13 1 C22 1 C05 1 C17 6 K24 6 K14 1 K09 1 K13 3 K40 6 K24 6 K14 6 K14 6 K24
B B B B B B B B B B B B B B B B B B B
1.25 1.25 1.25 1.25 0.5 0.85 1.25 1.25 0.5 0.85 0.85 0.85 0.5 0.5 0.5 0.85 0.85 0.85 0.85
2 BJ05
CJ02
L/B
0.5
Relay control
module
C1H-3 WC21 K7
WC23 WC21 WC23
409
13. ABS (BOSCH 9)
410
14. ESP
411
15. SRS
412
413
414
17. Diagnosis interface DLC; 18. Gateway controller
Battery (Meter Ⅱ)
IG2Power Supply
IG1 Power Supply
ACC Power Supply
*3
ABS No. 2 CAN adapter G2N-32 TCU TCU
F2/3 G15A-19
Reserved G2N-17 Reserved G15A-16
MICU
K50-14 K50-4 7.5A
F2/24 F2/28
A F4/14 Power
Fuel IG1 Gateway
network
L L pump 15A 7.5A
0.5 0.5 15A
3 G15A 2 G15A 4 G15A 11 B2C G14 G01

Dashboard
5 G2X 2 K2E
Wire
Harness
Adapter R/W
Ⅲ 0.5
Diagnostic
tester
power Shielding
supply
28 BJ11
28 GJ11 layer
1 G15A W/R
0.5
P R/W R/W R/G B V P

L W/G
V
0.5 0.5 0.5 0.5
0.5 0.5 0.5 0.5 0.3 0.3
7 G40 16 G40 5 G07 5 G07 7 G07 11 G07 12 G07 6 G07

1 K35 6 K35 12 K35 IG1 H-CAN L H-CAN H
BAT BAT
Diagnosis interface DLC Tire pressure Gateway Controller

inspection B-CAN L-2 B-CAN H-2 B-CAN L-1 B-CAN H-1
1 G07 9 G07 8 G07 10 G07 4 G07
11 G40 3 G40 4 G40 5 G40 6 G40 14 G40
7 K35
P V
B-CAN B-CAN 0.5
0.5
L H V P V P
B B P V B B
0.5 0.5 0.5 0.5
0.5 0.5 0.5 0.5 0.5 0.5
19 18 GJ06
BJ02
keyless-ECU keyless-ECU
G50-6 G50-12
CAN H CAN L
Body
Start
network network
G2N-31 G2N-30 K6
G2T-5 G2T-6 G06-19 G06-9 B05-26 B05-14
G15A-15 G15A-18
Multiplex integration control WG46 Multiplex integration
No. 1 adapter ESC system
module WG49 WG49 ECU control module
415
19. Power outer rear view mirror control system

IG2 Power Supply

IG1Power Supply
ACCPower Supply Inner rear
G57-3 G21-5 GJ13-9 view
Steering Steering Shaft Multi-display mirror DVD
angle sensor direction host
Lock
F4/6 F2/29 display
*3 IG2 Dashboard Outer rear P2I-2
view F2/20
10A wire
harness 11 12 14 13 G35B mirror 37 G2N 7.5A
adapter heater
G06 G01Ⅳ 25 G2X 7.5A
B/Y Y/R
0.5 0.5
Air
conditioning Air conditioning 13 11 G37
relay coil
ECU G47-40
Y/R
power supply 0.5
GJ11-20 86 88
Outer
Multiplex Multiplex Multiplex Multiplex rear
integration integration integration integration view
control control control control mirror 8 G41
module module module
module defroster 85 88a
G2Q-11 G2X-37 G2P-16 G2P-17 relay
Rear 15 12 G37 Power
Rear
view outer
view B rear Control
mirror mirror
extended
0.5 view Fold Return Left Right Up Down switch
folded
mirror
17 GJ06 regulating
17 BJ02 switch Selection
G L L/R Sb Right Right Left switch
Left
0.5 0.5 0.5 0.5 O
0.5 9 G41 10 G41 6 G41 2 G41 5 G41 3 G41 4 G41 7 G41
B1E-14
2 G2X 34 G2N G/W L/B R W/L W/R B

4 GJ01 0.5 0.5 0.5 0.5 0.5 0.85
4 KJ01 G
0.5
O 6 G2N 4 G2N 5 G2N
0.5 3 K2H 11 T2J 12 T2J GJ10
12 UJ01
Dash
board
distributor
L/W
box
GJ10 0.5
21 T2J 11 UJ01 20 T2J
8 T2J 38 G2X 19 T2J
O O L G/W R/Y W/R

0.5 0.5 0.5 0.5 0.5 0.5 WG49
Exterior light Exterior light Exterior light
Exterior light
system system system
system
T05-1 GJ10 GJ09 U05-1 U05-6
T05-6 9 11 GJ09 10
UJ01 UJ02 UJ02
R/Y G/W W/R G/W

0.5 0.5 0.5 O
0.5 0.5
4 T05 9 T05 3 T05 5 T05 8 T05 2 U05 5 U05 4 U05 9 U05 3 U05
Outer Outer B
rear Outer Side Fold Defroster Left + UP+ Outer rear 0.85
Left+ UP+ Fold GJ09 Side
view rear steering Defroster 12 UJ02 power
steering rear view
mirror view
mirror light M M power M M wire M M light view mirror
of mirror of
left
foot wire
right 6
UJ02
light foot GJ09
front front
Right + Down+ light
door Right + Down+ Return Return door
10 T05 2 T05 G 8 U05 10 U05

0.5 B
1.25
Window B G
Outer Exterior
rear view lifter light 0.5 0.5
mirror switch system WG48 U02-2 U01-6
T05-7 T03-10 T2K-3 Door lock Window
motor lifter switch
416

Battery (Meter Ⅱ)
IG2 power supply
IG1 power supply
ACC power supply
F2/31 Reserved
Power supply for switch
C 2nd gear
7.5A
No. 1 CAN
IG1 adapter 12 B2C
G11B-7 G06-16 G06-6
F1/23-1
Window W/L
F2/15 Control
Sun 3.0
System
roof 50A 3 T2J
20A B2B
V P 1 B1G 4
2B
0.5 0.5
Y
0.5
19 G2X 10 GJ02 9 GJ02
PJ01 PJ01
14 T03
Y
G 0.5
Door lock main switch
1.25
GJ02 GJ02 GJ02

7 PJ01 1 PJ01 3 PJ01 Left
front LOCK UN-
window LOCK
switch
backlight
G Y V P B
1.25 0.5 0.5 0.5 1.25
IG1
To ground
2 P02 8 P02 7 P02 9 P02 1 P02 9 T03 4 T03

17 T03 18 T03
Sun roof control motor P B KEY

V 1.25
W
0.5 0.5 0.5
5 P02 4 P02 6 P02 10 P02
1 T01
Y W R/L Sb B Left front UNLOCK
0.5 0.5 0.5 0.5 1.25 door l LOCK
ock motor
2 T01
B
0.85
B-CAN L B-CAN H
M
T2J-14 T2J-13
T2K-6
Front Front interior light Front interio Front interior light
多路集成控制模块
interior light P03-13 r light P03-10
P03-11 P03-12 WG49
417

Battery (MeterⅡ）
IG2 Power Supply

IG1Power Supply
ACCPower Supply
F2/3
B
MICUPower Supply
F2/16 10A
Left
K2-5 86 88
front Power
window window
motor relay
85 88a 1 T2K
20A
2K W/R
35 G2X 4 T2K 2J 0.5
2 T2J
G/R W/G
1.25 0.5
G2X-2 GJ09-11
Outer rear view mirror system
1 T03 8 T03 19 T03
Backlight Backlight
Backlight
Left front window
Window Right Left rear Right

Backlight main
control
front DN UP window DN UP rear DN UP
window window
Automatic Automatic switch
up down
Up/down
Power window control circuit
DMCU- Door multiplex controller
UP+ DN+
11 T03 23 T03 2 T03 16 T03 15 T03 21 T03 20 T03 22 T03 10 T03
R/B R/Y L/W L/R Br Br/W Br/Y L/O W/B

1.25 1.25 0.5 0.5 0.5 0.5 0.5 0.5 0.85
2 T06 1 T06 6 9 T2J 3 T2K

16 15 4 5 2J 2K
Left
front
M Dashboard
window distributor
lifter box
motor
2N 2E 2H
2 1 G2N 4 9 K2E 9 2 12 K2H
L/W L/R G/B Br Br/W Br/Y L/O B

0.5 0.5 1.25 0.5 0.5 0.5 0.5 2.0
418

Battery (Meter Ⅱ)
IG2 power supply

IG1 power supply
ACC power supply
IG1
G11B-6
GJ09 KJ05 KJ04

1 2 9 GJ10 3 2 4 3 2 KJ04
UJ02 4 VJ01 4 WJ01
UJ01 WJ01
F2/18 F2/19 F2/17 L/W L/R G/B Y Br Br/W Y/L Br/Y L/O Y/L
Right Left Right 0.5 0.5 1.25 0.5 0.5 0.5 1.25 0.5 0.5 1.25
front rear rear
motor" motor motor
20A 20A 20A
2 U01 1 U01 9 U01 10 U01 1 V03 2 V03 4 V03 1 W03 2 W03 4 W03
Right
front Rear-left Left
window window rear
lifter lifter window
switch switch lifter
motor
Dashboard
下上下上下上
Backlight Backlight
distributor Backlight
box
Reserved 2N 2E 2H
41 G2N 12 K2E 10 K2H
G2X-39
Y/L Y/L DN+ UP+ DN+ UP+ DN+ UP+

1.25 1.25 7 U01 5 U01 6 U01 3 V03 3 W03 6 W03 5 W03
6 V03 5 V03
B B B
1.25 1.25 1.25
R/L R L/B R/W L/B R/W

UJ02 VJ01 1.25 1.25 WJ01
1.25 1.25 6 1.25 1.25 1 1
GJ09 KJ05 KJ04
K1
1 U06 2 U06 B 2 V04 1 V04 B 2 W04 1 W04 B

1.25 1.25 1.25
Left Left
Right
front
M rear M rear M
window window
window lifter lifter
lifter motor motor
motor WG48 K3 K4
419
21. Combination switch

Battery (Meter Ⅱ)
IG2 Power Supply

IG1Power Supply
ACC Power Supply
GJ10-4 GJ02-1
G2X-12 Right front Relay control module
Sun roof
window motor
lifter
switch B1I-8 B1I-7
8 6 7 G11B
F2/3 MICU Power Supply
10A G11B-19
High and low wiper
G/W W
0.5 0.5 Headlamp (Low beam)
9 10 5 G11B
W/R Y
0.5 0.5
BJ02
Battery
IG1 15 BJ02
G16-38 GJ08-8 GJ06 16
Combination GJ06
Instrument Multi-display
5 G24 6 G24 8 G24 4 G24
Combination CPU CPU

Switch
2 G24 1 G24 8 2 3 9 11 4 6 12 5 7 3 G24
B
V P 3 st 2 st Dimmer 0.5
Wiper Front fog Turn Side
0.5 0.5 Washer gear gear OFF INT LO Fog light OFF light signal Near OFF light
signal signal 1st signal Rear fog Rear fog signal
OFF switch MIST HI switch Left Right switch AUTO Headlamp
switch ON 4st gear gear switch light light Far Crossing
Ground
CAN L CAN H
G2X-14 G2X-13
Multiplex integration control module

G2N-16
420
22. Power seat control system

Battery (Meter Ⅱ)
IG2 Power Supply

IG1 Power Supply
ACC Power Supply
F1/20
Power
seat
40A F2/10 F2/8
Power Power
seat
F2/11"
seat
R 20A
Power
20A 1 K36 seat
1.25 W/R
2 K36 20A
1.25
9 B1D
L 10 K2F W/R 7 K2F
R
3.0 1.25
1.25
3 B2B
10 X941 4 X941
Driver 11 K2F
seat
electric
Back Forward Upward Downward Tilt Tilt Downward Upward
adjusting ward forward backward
3 G2X
switch 11 X941 7 X941 3 X941 9 X9418 X941 2 X941 6 X941 12 X941 1 X941 5 X941
B/Y Y/G L/B Br W L P

1.25 Y
0.85 0.85 1.25 0.85 0.85 0.85
0.85 0.85 B/W 0.85
B
2 1 1 2 3 K36 4 K36 2 1 1 2
M M M M
Seat horizontal adjustment Seat sink adjustment motor Seat back adjustment motor Seat height adjustment
motor
motor
K1
Reserved
K2F-11
421
23. Headlamp leveling

IG2 Power Supply
IG1Power Supply
ACCPower Supply
Exterior light system Interior light system

B1I-10 G35B-9
R/B R/B
R/B
0.85 0.5
0.5
1 G45 3 G45
1 BJ05
1 CJ02
R/B
0.5
5 G45 4 G45 2 G45 6 G45
Y L/W
0.5 0.5
R/B
0.5 GJ06
8 GJ06 9
BJ02 BJ02
Y L/W
0.5 0.5
8 BJ05 11 BJ05
8 CJ02 11 CJ02
Y L/W
0.5 0.5
B R
0.5 0.5
1 C31 2 C31 1 C23 2 C23
Regulating Regulating
motor motor
LH M RH M
3 C31 3 C23
B B
0.5 0.5
Combination
Instrument
WC21 WC20 G59 G16-21
422
24. CD

IG2Power Supply
IG1Power Supply
ACCPower Supply
F1/16
C Illumination,
CAN module, 16 G35B
Auxiliary Power F2/20 Antenna
Supply 40A Dashboard Auxiliary
A Power
F2/4 wire
Supply Self-owned
Audio-visual harness
7.5A Support
system adapter
Ⅳ
37 G2N C Grounded
15A
17 15 G35B A
L=1.80uH
AM USB&AUX
Q=5.5 heatering
Antenna Amplifier 5V
TV FM C B USB-PWR GND_1 DP_U DM_U GND_4 GND-3 AUX-L AUX-R AUX-DEC GND-2 G43
10 G2N 7 10 9 8 6 1 2 3 4 5
后
A B
除
霜
电 Antenna Antenna
A 加
热
250W
B Feeder
丝 1 X931
Feeder
B/Y
2.0
L=1.80uH
Q=5.5
Antenna B/Y
Antenna
Y/R 2.0
0.5 1 G23 B Br Gr Y W L G R
W931 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3
Illumination, light intensity W/G
sensor, multi-display 0.85 Y/G
branch wire GJ08-1 0.5
4 G29 3 G29 8 G29 10 G31 12 G31 11 G31 5 G31 4 G31 1 G31 2 G31 7 G31 3 G31 6 G31
USB-PWR AUX-L AUX-R AUX-DEC GND-2
BAT ACC Antenna GND_1 DP_U DM_U
power supply
FR+ FR- FL+ FL- RL+ RL- RR- RR+

CD+Radio
KEY-AD2 GND
1 G29 5 G29 2 G29 6 G29 2 G30 6 G30 3 G30 1 G30 7 G29 4 G30 5 G30 9 G29 10 G29 8 G31 9 G31
W L Y B B-CAN L B-CAN H
0.85 0.85 0.85 0.85
V P
0.5 0.5
G/R Br
0.5 0.5
G/Y Gr Lg GJ01 GJ07
G/B 2 3 5 2
0.85 0.85 0.85 KJ01
0.85 KJ07
W L Y B 7 G25 8 G25
时
0.85 0.85 0.85 0.85
钟
弹
13 G2N 14 G2N
GJ09 簧
8 7 Dashboard 2N 2N 7 X991 8 X991
UJ02
distributor
box
2K 2K
10 T2K 11 T2K Y B B R R/B
W L
0.85 0.85 0.85 0.85 0.85 0.5 0.5
3 X994 2 X994
VOL+
G/Y Gr G/B Lg
0.85 0.85 Steering
0.85 0.85 R2 8.2K
VOL-
Wheel
Audio
R4 15K
Control CH+
2 U03 1 U03 2 U07 1 U07 2 T02 1 T02 2 T07 1 T07 Switch Meter Meter
R6 27K
CH- short short
2 K29 1 K29 1 K30 2 K30
WG47 connector connector
Left Right Left Left No. Ⅳ No. Ⅳ
Left Right R6 82K
front front front front MODE G35B-8 G06-14 G06-4
rear rear G35B-2
high door high door
squawker squawker
pitch speaker pitch speaker
speake No. 1 CAN adapter
speaker
423
25. External power amplifier

IG2Power Supply
IG1Power Supply
ACCPower Supply
F1/16
Illumination, CAN module 、 16 G35B
No. 2 CAN adapter
Auxiliary Power
F4/2
K50-3 K50-13 Supply 40A F4/12
Auxiliary Power Supply Dashboard
C 7.5A F2/4 Audio-visual wire
Audio-visual system15A harness
B-CAN B-CAN adapter
system
H L G02 G01 15A Ⅳ
17 15 G35B
G12 G01
R/L W/G
0.5 15 K2E
0.85
GJ14
8 1 2 KJ14
4 GJ01
KJ01
Shielding
Illumination, light intensity layer
B B B B B R/L Y Y Y Y Y sensor, multi-display R/B L/R
P V
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 branch wire 0.5 0.5
0.5 0.5 GJ08-1
5 K26 9 K26 10 K26 11 K26 12 K26 1 K37 2 K37 4 K26 1 K26 2 K26 6 K26 7 K26 8 K26 7 K37 16 K37 17 K37
B-CAN H B-CAN L Battery Battery Battery Battery Battery SPDIF_GND SPDIF+ SPDIF-
ACC
Exterior Power Amplifier
LR+ LR- SL_M+ SL_M- SR_M- SR_M+ RR- RR+ CE+ CE- SW+ SW2+ SW- SW2- LF+ LF- RF+ RF-
1 K28 2 K28 19 K28 18 K28 14 K28 15 K28 8 K28 7 K28 9 K28 10 K28 1 K27 2 K27 3 K27 4 K27 3 K28 4 K28 5 K27 6 K27
G/B Lg G/Y Gr
0.85 0.85 0.85 0.85
W L Y B
0.85 0.85 KJ01 KJ07
0.85 0.85 B/W L L/W B L/B Y 9 3 GJ01 9 3 GJ07
0.85 0.85 0.85 0.85 0.85 0.85
G/B Lg G/Y Gr
0.85 0.85 0.85 0.85
W L Y B 1 G35A 15 G35A
KJ05 0.85 0.85 0.85 0.85 KJ04 KJ07 18 G35A
5 6 6 5 2 5 12 G35A
VJ01 WJ01 GJ07 Dashboard Dashboard
Dashboard wire wire
wire Dashboard
harness harness
W L harness wire
adapter adapter
harness
0.85 0.85 adapter Ⅳ Ⅳ
Ⅳ adapter
Ⅳ
B/W L
Y B 0.85 0.85
0.85 0.85 14 20
2 16
G/B Lg
0.85 0.85 G/Y Gr
0.85 0.85
13 G2N 14 G2N GJ09
2N 2N 8 7 UJ02
Dashboard
distributor
box
2K 2K
10 T2K 11 T2K
G/B Lg
2 K29 1 K29 1 K30 0.85 0.85
2 K30
2 V07 2 U07 1 U03 2 U03
1 V07 1 W01 2 W01 2 G52 1 G52 1 K31 3 K31 2 K31 4 K31 2 T07 1 T07 1 T02 2 T02 1 U07
Right
Left Right Right Left
Rear front
Left rear rear rear Middle front Right
Subwoofer Left door
rear squawker squawker door loudspeaker door front
front speaker
door speaker High high
door
speaker Pitch pitch
speaker
Speaker speaker
424
26.1 Advanced audio-visual system (1)
Batte ry (Fron t of fro nt compa rtme nt m ain fuse)
Batte ry (Rear of fron t co mpartmen t ma in fuse)

Batte ry (Mete rII)
IG2 Powe r Supply

IG1 Powe r Supply
ACC Powe r Supply
F4/12 F2/20 G11B-5
Audio system Auxiliary Power
15A A Supply 7.5A
G12 G01 37 G2N

W/R Y/R Y
0.85 0.5 0.5
1 GJ08
GJ08 8 GJ08
HeJ01 9 HeJ01 HeJ01
W/G
Y/R Y
0.5 0.5
0.5
Battery ACC IG1
1 He03 11 He03 9 He03
Power circuit Co-driver

Co-driver Co-driver
Left Right Backup Co-driver seat seat
Exterior temperature Rear Left radar safety
front front Right Buzzer safety belt safety
time center rear power air bag
siren siren rear air bag indicator indicator
siren siren indicator ON
(Reserved) (Reserved) siren OFF light light
light indicator indicator (White icon)
Stroke segment LCD light light
Multi-display CPU
B-CAN L B-CAN H
8 He03 2 He03 4 He03 3 He03 16 He03
B V P R/L
B
0.5 0.5 0.5 0.5
0.5
3 HeJ01 2 HeJ01
GJ08 GJ08 HeJ01
12 HeJ01 7 HeJ01 4
GJ08 GJ08 GJ08
Co-driver seat belt

signal (Combination
B instrument pin No. 40)
B
0.5
0.5
G16-40
B-CAN B-CAN
H L
G06-17 G06-7
WG47
To No. 1 CAN
adapter
425
26.2 DVD (built-in power amplifier)

Battery (Meter Ⅱ)
IG2 Power Supply

IG1 Power Supply
ACC Power Supply
F1/16
C Illumination, CAN
module, auxiliary 16 G35B No. 1 CAN
power supply 40A adapter Antenna
F2/20
Auxiliary Power Supply G06-4 G06-14
Dashboard
Combination F2/4 A 7.5A
Instrument MICU BCM Pre-distribution wire
Audio Self-owned
G2X-33 harness
G2P-14 G2P-25 system
B-CAN B-CAN Support
adapter
15A
Ⅳ 37 G2N H L
C Grounded
17 15 G35B USB&AUX A
L=1.80uH
AM
Antenna Amplifier
5V Q=5.5 加热
Parking Reversing USB-PWR AUX-L AUX-R AUX-DEC GND-2 TV FM C B
GND_1 DP_U DM_U GND_4 GND-3 G43
signal signal
10 G2N 7 10 9 8 6 1 2 3 4 5
input input 后
除
A B
霜
电
A 加
热
丝 1
250W
X931
B Antenna
B/Y
Antenna lead
2.0
Feeder
L=1.80uH
Q=5.5
Antenna Antenna
L
B/Y
2.0
Y/R
0.5
0.5 B Br Gr Y W L G R 1 G23
0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 W931
Y G Illumination, light intensity W/G

0.5 0.5 sensor, multi-display 0.85 Y/G
branch wire 0.5
13 G31 9 G51 GJ08-1 4 G29 11 G51 10 G51 12 G51 13 G51 14 G51 5 G51 3 G51 2 G51 4 G51 1 G51 7 G51 6 G51 8 G29
14 G31 Pre-distribution 3 G29 AUX-L AUX-R
PAK IN BACK IN USB-PWR GND_1 DP_U DM_U AUX-DEC GND-2 B-CAN H B-CAN L
BAT ACC Antenna
DVD(Interior power amplifier) power supply
FR+ FR- FL+ FL- RL+ RL- RR- RR+ KEY-AD2 GND KEY-AD3
1 G29 5 G29 2 G29 6 G29 2 G30 6 G30 3 G30 1 G30 7 G29 6 G31 16 G31 9 G31 1 G31 10 G31 5 G31 15 G31 3 G31 2 G31 11 G31 4 G55 5 G55 8 G51
W L Y B W
B/Y B W/B
0.85 0.85 0.85 0.85 Shielding 0.5
0.5 0.5 0.5
layer
Shielding
layer
19 10 22 GJ01 GJ01
13 KJ01 18 KJ01 G/R Br Br Sb Sb
0.5 0.5 0.5 0.5 0.5
G/Y Gr Lg GJ01 GJ07
G/B 2 3 5 2
0.85 0.85 0.85 KJ01 L G B W/L
0.85 KJ07
0.5 0.5 0.5 0.5
W L Y B Clock 7 G25 8 G25 16 G25 13 G25 15 G25

18 GJ10 GJ10
0.85 0.85 0.85 0.85 17 20 19 22 spring
UJ01 UJ01 Clock
Clock
spring
spring
13 G2N 14 G2N
GJ09
8 7 2N 2N 7 X991 8 X991 13 X991 16 X991 15 X991
UJ02
Dashboard L G B W/L B/Y B W/B W

distributor 0.5 0.5 0.5
0.5 0.5 0.5 0.5 0.5 Shielding
box
Shielding layer
2K 2K layer
10 T2K 11 T2K Y B B
W L
0.85 0.85 0.85 0.85 0.85
3 X994 2 X994
VOL+
G/Y Gr G/B Lg Steering
0.85 0.85 0.85 0.85 Wheel R2 8.2K
VOL-
Audio
Control
Switch R4 15K 4 X993 3 X993 1 X994
CH+ Steering
2 U03 1 U03 2 U07 1 U07 2 T07 1 T07 1 4 6 3 1 2 3 4 Steering
2 T02 1 T02 U08 K33 wheel R9 4.64K
wheel R7 1K
R6 27K
CH- VIEW on-board HOOK
2 K29 1 K29 1 K30 2 K30 R_C_PWR GND Video ground R_C_CVBS B_C_PWR GND Video B_C_CVBS backup
Right Left WG47 ground camera
phone
control
front front Right front Backup R6 82K control R10 5.2K
OFF switch
R8 2.16K
OFF
door door camera MODE switch
Right camera
Left Right rear squawker
speaker speaker
front front
Left
High High
rear
Pitch Pitch
squawker
Speaker Speaker
426
27. Multi display

Battery (MeterII)
IG2 Power Supply

IG1 Power Supply
ACCPower Supply
F4/12 F2/20 G11B-5
Audio system Auxiliary Power
15A A Supply 7.5A
G12 G01 37 G2N

W/R Y/R Y
0.85 0.5 0.5
1 GJ08
GJ08 8 GJ08
HeJ01 9 HeJ01 HeJ01
W/G Y
Y/R
0.5 0.5
0.5
Battery ACC IG1
1 He03 11 He03 9 He03
Power circuit Co-driver

Co-driver Co-driver
Left Right Backup Co-driver seat seat
Exterior temperature Rear Left radar safety
front front Right Buzzer safety belt safety
time center rear power air bag air bag
siren siren rear indicator indicator
siren siren indicator ON
(Reserved) (Reserved) siren OFF light light
light indicator indicator (White icon)
Stroke segment LCD light light
Multi-display CPU
B-CAN L B-CAN H
8 He03 2 He03 4 He03 3 He03 16 He03
B V P R/L
B
0.5 0.5 0.5 0.5
0.5
3 HeJ01 2 HeJ01
GJ08 GJ08 HeJ01
12 HeJ01 7 HeJ01 4
GJ08 GJ08 GJ08
Co-driver seat belt

signal (Combination
B instrument pin No. 40)
B
0.5 0.5
G16-40
B-CAN B-CAN
H L
G06-17 G06-7
WG47
To No. 1 CAN
adapter
427
28. 476ZQA DCT

Battery (Meter Ⅱ )
IG2 power supply

IG1 power supply
ACC power supply
Gateway Controller
G07-12 G07-6
F2/21
15A
33 G2N
R/L
0.85
GJ15
4 BJ08
GJ06 GJ06
18 BJ02 19 BJ02
EMS
Direction
A54-4 R/L sensor
1.25
V P
0.5 0.5 N
22 BJ07
22 AJ01 S
1 2
BJ07 BJ07 1 2 A48
R/L 19 AJ01 20 AJ01
1.25
V P L Y
0.5 0.5 0.5 0.5
1 A47 12 A47 11 A47 10 16 A47
R/L TCU
1.25
17 18 13 14 15
R R
17 A47 18 A47 13 A47 14 A47 15 A47 2 A47
2.5 2.5
Y/W R/Y Y/L W/G G/Y B
1.25 1.25 0.5 0.5 0.5 1.25
1 A45 9 A45 16 A45 14 A45 15 A45 8 A45 7 A45 6 A45 A60
Transmission motor power module
2 A45 10 A45 3 11 4 12 5 13 A45
B B L L/R G G/R W W/R

1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25
2 3 4 5 6 7 A46
A60 A60
M1 Brushless motor
428
29. EPS

Battery (Meter Ⅱ)
IG2 Power Supply

IG1 Power Supply
ACC Power Supply
F5/2
EPS
motor
Halla torque steering
70A angle sensor
7 G2X
B13 F2/27 4# 8# 5# 1# 7# 3# 6# 2#
EPS
module
10A
R Br Br
6.0 0.5 0.5
W G B R B/G L V B/R
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
D1 D2 D3 D4 D5 D6 D7 D8
1 B11 5 G59 11 G59
TQ1 GND1 TQ2 VCC1_+5V GND2 PWM_P PWM_S VCC2_+5V
Speed signal EPS High current

input Output indicator
6 G59 12 G59 2 G59 8 G59

2 B11
P V
0.5 0.5
V G/W
B 0.5 0.5 B B
6.0 6.0 6.0
GJ06 GJ06
3 BJ02 10 BJ02
BJ07 BJ07
32 AJ01 34 AJ01
G15A-17 G15A-30
G2X-27 Electronic Electronic M
injector injector(Ti)
CAN adapter A01-76 A01-37
EPS motor
B12
429
30. Tire pressure monitor 31. EPB

Battery (Meter Ⅱ)
IG2Power Supply
IG1Power Supply
ACCPower Supply
No. 2 CAN adapter Dashboard wire harness Ⅲ short connector (CAN)
K50-14 K50-4 F4/9

F2/30
G15A-4 G15A-14
30A
EPB
F2/28 10A
A
IG1
15A
G09 G01 9 K2F
2 K2E 9 GJ14 10 GJ14

9 KJ08 10 KJ08
Gr
2.5
13 GJ14
W/R 13 KJ08
0.5
Gr Y/R P W G15A-18 G35B-6 G35B-4

P V 2.5 0.5 0.5 0.5 ⅢShort connector IVShort connector IVShort connector
0.5 0.5
1 K55 11 K55 6 K55 14 K55

BAT+ IG1 CAN-H CAN-L
1 K35 6 K35 12 K35
EPB 11 GJ14 14 GJ14 Side 12 GJ14
11 KJ08 14 KJ08 12 KJ08
light
Tire pressure inspection GND power
8 K55 12 4 10 9 2 3 K55
supply
Y R/B R
7 K35 Gr G 0.5 0.5 0.5
Y B/W R/B L/B
0.5 0.5 0.5 0.5 0.5 0.5
B 4 2 3 6 5 1 K56 12 K56 8 K56

0.5
AUTO HOLD indicator light

R R
B
2.5 EPB switch
R
AUTO HOLD switch
Backlight
K7 7 K56 11 K56
Ground
No. 7 W/B
0.5
K6
K2
Ground No. 2
430
32. P position motor controller

Battery (Meter Ⅱ)
IG2Power Supply
IG1 Power Supply
ACC Power Supply
F4/15
P
position F4/10
motor P
controller 7.5A position
BCM motor
Pre-distribution 15A
G2P-25
G15 G01 G11 G01
Y Y
0.5 1.25
08 G37 06 G37
KG-8 Gr
P 1.25
position
motor
controller 1 KJ15 8 KJ15 7 KJ15 6 GJ15
1 BJ12 8 BJ12 7 BJ12 6 BJ08
10 G37 07 G37
Y W W/R Gr
2 GJ14 3 GJ14 Y/B 1.25 1.25 1.25 1.25
2 KJ08 3 KJ08 0.5
6 BJ10 20 BJ10 15 BJ10 1 BJ10
4 GJ14 6 AJ02 20 AJ02 15 AJ02 1 AJ02
4 KJ08
L Y/R
0.5 Y/B Y/G Y/G Y/G L/B L/B L/B L/R L/R L/R Y W W/R Gr
0.5
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 1.25 1.25 1.25 1.25
17 K34 1 K34 5 K34 31 K34 32 K34 16 K34 11 K34 12 K34 27 K34 28 K34 29 K34 30 K34 7 A52 1 A52 6 A52 2 A52
Pre-distribution Battery Relay drive Phase A Phase A Phase A Phase B Phase B Phase B Phase C Phase C Phase C Phase A Phase B Phase C Motor
drive drive drive drive drive drive drive drive drive drive drive drive power
P position motor controller P position motor
Screen Sensor power

CAN-H CAN-L ground +5V Hall-A Hall-B Hall-C Hall-C Hall-B Hall-A supply
25 K34 24 K34 6 K34 7 K34 26 K34 20 K34 13 K34 14 K34 15 K34 5 A52 4 A52 3 A52 8 A52 9 A52
B B P V R Gr L G G L Gr W/B R
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
3 AJ02 4 AJ02 2 AJ02 5 AJ02

3 BJ10 4 BJ10 2 BJ10 5 BJ10
5 KJ15 2 KJ15 3 KJ15 4 KJ15

9 KJ08 10 KJ08 5 BJ12 2 BJ12 3 BJ12 4 BJ12
9 GJ14 10 GJ14
G15A-4 G15A-14
Ground Ground
K2 Dashboard wire harness Ⅲ short connector (CAN) A02
431
33. Electronic cooling fan

Battery (Meter Ⅱ)
IG2Power Supply
IG1Power Supply
ACCPower Supply
F3/1
F2/23 F3/3 Condenser
EMS Cooling fan
Main Fan 30A
relay30A 30A
3 A54 5 A54
F1/11 F1/10 Reserved
Condenser K1-5 K1-4 1 B1E
Radiator
Condenser Radiator C1F-17
fan fan 88 86 86 88 B/W Y/B
fan fan 2.0 2.0
20A 30A 17 G2X
relay relay
88a 85 85 88a 15 AJ01 29

*3 29 AJ01 22 AJ01
15 BJ07 BJ07 22 BJ07 *2
13 BJ05 B/W Y/B

CJ02 2.0 2.0
14 C1F 16 B1E 7 B1E 16 C1F
1 BJ04 2 BJ04
CJ06 CJ06
G L/Y R/W
0.5 2.0 0.5
L/W
Winding! B/Y B/W B/Y W/R B/Y Y/B
2.0 B/Y
13 B2D 0.5 2.0 0.5 2.0 0.5 2.0 0.5
Dashboard 7 BJ11
AJ01 Y/B
distributor
0.5 3 C01 1 C01 8 C01 6 C01 13 C01 11 C01 18 C01 16 C01
box KC-1 KC-2 KC-3 KC-4Fan
Fan Fan Fan Relay
Relay Relay Relay No. 4
6 G2X No. 1 No. 2 No. 3
G R/W
0.5 0.5
5 C01 2 C01 10 C01 7 C01 9 C01 15 C01 B12 C01 20 C01 17 C01 19 C01
7 GJ06
BJ02 2 C15 2 C02 G/B B/R G L G/Y G/B B/R L/W
L
0.5 0.5 2.0 2.0 0.5 2.0 0.5 2.0 2.0
Radiator 1# 2#
G Condenser fan Regulating Regulating
0.5 fan M motor M Cooling 3 C28 resistor1 C30 Cooling 3 C29 resistor 1 C31
motor Fan Fan
M M
1 C15 1 C02
20 BJ11 1 C28 2 C30 1 C29 2 C31
AJ01
B B
2.0 2.0
10 CJ02
10 BJ05
L/W G/B B B
0.5 0.5 2.0 2.0
16 BJ07 3 BJ07
16 AJ01 3 AJ01
WC20 WC23
Ground No. 2 Ground No. 2
473 EMS 473 EMS
A10-4 A10-57 A01-79 A01-40
G2X-17 Reserved Low speed fan High speed
WC20 WC21 C1F-19 control fan control
432
35. Gear shift mechanism
F2/26
G2X-16 G35B-7
L/R R/B
0.5 0.5
WG61
No. 3 meter ground
B
0.5
1
2
4
7 G79 2 G79 3 G79 4 G79 5 G79 3 G74 5 G74 9 G74 10 G74
5
Manual/automatic
Gear
IG2 Manual/Automatic Manual control + Manual control - Shift Lock Relay Manual
6
converter P
Backlight shift
7
Gear sensor Low level effective switch
mode position
8
Manual upshift/downshift lock mechanism
Automatic switch + - circuit
Gear CANH CANL
GND GND
indicator 1 G79 10 G79 6 G79 8 G79 8 G74 6 G74 4 G74 11 G74
B1 B2 B3 B4 B5 B6 B7 B8
7 G74
panel
G Br Br/Y Br/W R
0.5 0.5 0.5 0.5 0.5
P V
0.5 0.5
B
0.5
WG61
No. 3 meter ground
G15A-1 G15A-11
To adapter III
G35B-1
Note: *1 - 473 Electronic injection system *2 - 476ZQA system *3 - 476ZQA+DCT *4 - Equipped in the flagship model
433
36. CAN topological graph - Comfort CAN

B-CAN H
MCU
B-CAN-H
B-CAN-L B-CAN L
39 G2N 38 G2N 31 G2N 30 G2N 14 T2J 13 T2J 14 G2X 13 G2X 1 K2G 2 K2G 23 G2X 24 G2X 2 G2R 1 G2R 11 B2D 12 B2D 2 B1I 1 B1I
Terminal resistor
V P V P V P V P V P V P P V
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
Air conditioning ECU CD/DVD Sun roof module Multi-display Gateway ECU Diagnosis interface
P02-7 P02-9 He03-4 He03-3 V P
G47-1 G47-2 G31-8/G51-6 G31-9/G51-7 G07-10 G07-4 G40-11 G40-3 0.5 0.5
B-CAN B-CAN B-CAN B-CAN B-CAN B-CAN B-CAN B-CAN B-CAN B-CAN B-CAN B-CAN B-CAN B-CAN
L H L H L H L H L H L H L H
PJ01 PJ01 HeJ01 HeJ01 Terminal resistor

10 GJ02 9 GJ02 3 GJ08 2 GJ08
V P
0.5 0.5 B-CAN B-CAN B-CAN B-CAN B-CAN B-CAN B-CAN B-CAN
H L H L H L H L
Backup radar
K17-17 K17-1 Window
Control Window Control Combination Combination Combination Combination
System System Switch Switch SRS SRS
Switch Switch
T03-18 T03-17 G24-1 G24-2 G16-5 G36-9 G36-8
G16-4
B-CAN B-CAN
L H
Power Tire Backup
KJ07 KJ07
10 GJ07 amplifier pressure radar
14 GJ07
K26-9 K26-8 K35-6 K35-12 K17-1 K17-17
V P V
P
0.5 0.5 0.5
0.5
14 GJ07 10 GJ07
KJ07 KJ07 *4 *4 *4 *4
*4
P V P V P V P V P V P V P V P V
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
G06 3 13 4 14 6 16 7 17 9 19 10 20 5 15 8 18 K50 6 16 5 15 3 13 4 14 1 11
B-CAN-H B-CAN-H B-CAN-H B-CAN-H B-CAN-H B-CAN-H
B-CAN-L B-CAN-L
Meter No. 1 CAN adapte r Floor No. 2 CAN adapter *4
434
36. CAN topological graph - Starting CAN
B-CAN H MICU-W9 MICU-W10

B-CAN L
5 G2T 6 G2T
1 G2T 2 G2T
V P V P
0.5 0.5 0.5 0.5
keyless-ECU keyless-ECU
G50-12 G50-6
B-CAN B-CAN
B-CAN B-CAN
H L
H L
G07-8 G07-9 G21-3 G21-6

Independent gateway Steering Shaft Lock
435
36. CAN topological graph - Power CAN
Gateway ECU
ABS/ESC
G07-6 G07-12 B05-14 B05-26
Terminal resistor
B-CAN B-CAN
H L
BJ02
18 19 GJ06
V P BJ07
20 19 AJ01
0.5 0.5
Terminal resistor
A01-101 A01-109 A47-12 A47-11

ECM TCU
12 G15A 2 G15A
Dashboard wire harness adapter Ⅲ Dashboard wire harness adapter Ⅲ
11 G15A 13 G15A 14 G15A 1 G15A 3 G15A 4 G15A
GJ14
10 9 KJ08
G58-8 G58-6 G57-1 G57-2 G59-12 G59-6

G40-14 G40-6 K34-7 K34-6 K55-6 K55-14
Steering angle sensor EPS
DLC Shift sensor P position ECU EPB
436
37. Grounding network diagram
0.5 0.85 天窗开启继电器

仪表板配电盒N
Dashboard distribution box N Sun roof opener relay
0.85 0.85 Rear interior light

天窗关闭继电器
Sun roof closer relay 后室内灯
诊断接口
Diagnosis interface 0.5 0.5 IG1继电器
IGI relay
0.5 0.5 Sun roof switch

组合仪表
Combination instrument 天窗开关
No.1仪表1#搭铁G57
meter ground G57
Ash tray light

烟灰缸照明灯 0.5 0.85 座椅加热开关 *4 *4
Seat heater switch
鼓风机调速模块
Blower governor module 3.0 1.25 点烟器
Cigarette lighter
No.4 meter ground G61

仪表4#搭铁G61
437
Safety air bag ECU 0.5 0.5 Safety air bag ECU
安全气囊ECU
安全气囊ECU
No.6 meter ground G63

仪表6#搭铁G63
438
Dashboard wire harness

仪表板线束转接头III-5 0.5
connector III-5 AC-ECU
仪表板线束转接头III-4 0.5 室外温度传感器

Dashboard wire harness Outside temperature sensor
connector III-4

仪表板线束转接头III-3 0.5 Room temperature sensor
室内温度传感器
connector III-3

仪表板线束转接头III-2 0.5 Solar sensor
阳光传感器
connector III-2
仪表板线束转接头III-1
Dashboard wire harness 0.5 组合仪表
connector III-1
0.5 Headlamp leveling/washer

仪表板线束转接头III-6 1.25
大灯调节/洗涤开关
connector III-6 switch
Power mirror control switch 0.85 0.5 Backup radar ECU

电动后视镜控制开关倒车雷达ECU
Power mirror control switch Dashboard distribution box

0.5 0.5 仪表板配电盒P
倒车雷达ECU P
仪表2#搭铁G59
No. 2 meter ground G59
439
Steering shaft lock
Start Button
Start Button
USB Interface USB Interface
USB interface shield USB interface shield
DVD+GPS host F ACC relay

（CKM1）
IG2 relay Gateway Controller
High-mounted multi High-mounted multi

display display
No. 3 meter ground G60
440
441
442
左后组合灯
Left rear combination light (turn Right rear combination light
右后组合灯
light, braking light and position
（转向、制动、位置灯） (turn light, braking light and
（转向、制动、位置灯）
light) position light)
High braking light Trunk lock

高位制动灯行李箱锁
Left license plate light Right license plate light

左牌照灯右牌照灯
Siren 左后尾灯
Left rear tail lamp (fog light,
报警器（雾灯、倒车灯）
back-up light)
右后尾灯
Right rear tail lamp (fog light, Liquid crystal solar film ECU
（雾灯、倒车灯）
back-up light)
No. 1 rear trunk ground Q23

后行李箱1#搭铁Q23
443
车载冰箱
On-board refrigerator
1.25
No. 2 rear trunk ground

后行李箱2#搭铁Q24
Q24
444
Oil Pump
油泵
0.85
No. 3 floor ground K35

地板3#搭铁K35
2.0 0.5 Brake

制动液位开关fluid level
雨刮电机
Wiper motor switch
Front compartment
前舱配电盒E 0.85 0.85 前舱配电盒J
Front compartment
distribution box e distribution box j
No. 1 front compartment ground B14

前舱1#搭铁B14
445
4.0 2.5
ABS-ECU-13 ABS-ECU-38
No. 2 front compartment

前舱2#搭铁B15ground B15
Vehicle speed sensor

No. 14 shielding layer 0.5 0.5 车速传感器 *3
前氧14#屏蔽层
of front oxygen
sensor
Air conditioner switch 0.5 0.5 后氧38#屏蔽层

空档开关 *3 No. 38 shielding layer
of rear oxygen sensor
Engine ground Ab14

发动机I搭铁Ab14
446
发动机ECU-3 2.5 0.85 发动机ECU-80

Engine ECU-3 Engine ECU-80
发动机ECU-61 0.85 1.25

Engine ECU-61 TCU-3 *4
1.25
TCU-4 *4
Engine III # ground Ac08

发动机II1#搭铁Ac08
14 shielding layer of front 0.5

前氧14#屏蔽层
No. 0.5 后氧38#屏蔽层
No. 38 shielding layer of
oxygen sensor rear oxygen sensor
Engine ECU-53
发动机ECU-53 0.85 0.85 Engine ECU-51
发动机ECU-51
0.5 凸轮轴位置传感器
Camshaft position sensor
Engine II2 # ground Ac09

发动机II2#搭铁Ac09
447
Body, Chassis, Interior Exterior Trim
Contents
Chapter 1 Body Dimensions..............................................................................................................4
Chapter 2 Body Accessory System .................................................................................................13
Section 1 Seat.................................................................................................................. 14
Section 2 Safety Belt ....................................................................................................... 19
Section 3 Inner Rear View Mirror .................................................................................... 22
Section 4 Washing System Assembly ............................................................................. 23
Section 5 Wiper System Assembly.................................................................................. 24
Section 6 Windshield Glass Assembly ............................................................................ 25
Section 7 Rear Windshields Glass Assembly ................................................................. 28
Section 8 Sun Roof Assembly ......................................................................................... 29
Chapter 3 Door System Repair Manual ..........................................................................................33
Section 1 Door ................................................................................................................. 35
Section 2 Replacement of Outer Rear View Mirror ......................................................... 38
Section 3 Replacement of Outside Handle and Door Lock ............................................. 40
Section 4 Opener ............................................................................................................. 42
Section 5 Removal and Installation of Sealing Mechanism ............................................ 44
Section 6 Adjustment of Four Doors and Two Covers .................................................... 49
Chapter 4 Chassis ...........................................................................................................................51
Part 1 Intake System ................................................................................................................53
Part 2 Exhaust System.............................................................................................................57
Part 3 Cooling System .............................................................................................................60
Section 1 473QE Cooling System ................................................................................... 60
Section 2 476ZQA Cooling System ................................................................................. 62
Part 4 Fuel System...................................................................................................................65
Section 1 Fuel Supply System ......................................................................................... 65
Section 2 Fuel Evaporation and Cleaning System .......................................................... 71
Part 5 Suspension System .......................................................................................................73
Section 1 Components Layout and Description of Suspension System ......................... 73
Section 2 Repair Suspension System (473QE-5T14) ..................................................... 80
Section 3 Repair 5AC/5AI Suspension System............................................................... 85
Section 4 Installation of Relevant Engine Accessories ................................................... 91
Part 6 Suspension System .......................................................................................................92
Section 1 Suspension Overview ...................................................................................... 92
Section 2 Front Suspension............................................................................................. 95
Section 3 Rear Suspension ........................................................................................... 118
Part 7 Power Steering System ...............................................................................................132
Section 1 Special Tools ................................................................................................. 132
Section 2 Diagram of Hydraulic Steering System Component Location....................... 133
1
Section 3 Symptoms and Troubleshooting.................................................................... 135

Section 4 Troubleshooting ............................................................................................. 137
Section 5 Overhauling of Steering Wheel, Steering Column and
Universal Joint Assembly ...................................................................................... 140
Section 6 Power Steering Pump Pressure Test ............................................................ 145
Section 7 Fluid Leakage Detection ................................................................................ 146
Section 8 Steering Fluid Replacement .......................................................................... 148
Section 9 Power Steering Line Replacement ................................................................ 149
Section 10 Pump Replacement ..................................................................................... 151
Section 11 Removal of Power Steering Gear................................................................ 153
Section 12 Installation of Power Steering Gear............................................................. 155
Section 13 Electric Power Steering (EPS) System ....................................................... 157
Part 8 Brake System ..............................................................................................................158
Section 1 Conventional Brake Components.................................................................. 158
Part 9 Drive Half Shaft ...........................................................................................................176
Section 1 Drive Half Shaft (5A\5AI) ............................................................................... 176
Section 2 Drive Half Shaft (BYD476ZQA+6DT25) ........................................................ 179
Part 10 Gear Shift Control System.........................................................................................183
Section 1 Gear Shift Mechanism Replacement (5A-5T14) ........................................... 183
Section 2 Replacement of Gear Shift Mechanism (BYD476ZQA+6T25)...................... 184
Section 3 Gear Shift Control System (BYD476ZQA+6D T25) ...................................... 185
Chapter 5 ABS System..................................................................................................................187
Section 1 Precautions .................................................................................................... 188
Section 2 Malfunction Diagnosis Flow ........................................................................... 192
Section 3 Customer Malfunction Analysis Table ........................................................... 194
Section 4 Diagnostic Check ........................................................................................... 195
Section 5 Trouble Code Table ....................................................................................... 232
Section 6 Component Layout ........................................................................................ 235
Section 7 Definition of ECU Pin ..................................................................................... 236
Section 8 Trouble Symptom .......................................................................................... 242
Section 9 Trouble Code Diagnosis ................................................................................ 245
Section 10 Service Specifications ................................................................................. 286
Chapter 6 Electronic Parking Brake System (EPB) ......................................................................287
Chapter 7 ELECTRIC POWER-ASSISTANT (EPS) SYSTEM ..................................................... 311
Section 1 Outline of the EPS System ............................................................................ 312
Section 2 Schematic Circuit Diagram of the EPS System ............................................ 314
Section 3 Precautions for Maintenance ......................................................................... 316
Section 4 Inspection of the Steering Wheel and Steering Column ............................... 320
Section 5 Self Diagnosis and Troubleshooting of the EPS System .............................. 334
Section 6 Self-Diagnosis and Troubleshooting of the EPS System .............................. 344
Chapter 8 ESP System .................................................................................................................348
Section 1 Precautions .................................................................................................... 350
Section 2 Malfunction Diagnosis Flow ........................................................................... 352
Section 3 Customer Malfunction Analysis Table ........................................................... 353
2
Section 4 Diagnostic Check ........................................................................................... 354

Section 5 ESP 9 System Introduction............................................................................ 356
Section 6 Malfunction Diagnosis ................................................................................... 360
Section 7 Trouble Code Table ....................................................................................... 362
Section 8 Trouble Symptom .......................................................................................... 364
Section 9 Trouble Code Diagnosis ................................................................................ 367
Section 10 Removal and Installation ............................................................................. 379
Section 11 Service Specifications ................................................................................. 381
Chapter 9 Interior and Exterior ......................................................................................................382
Section 1 Front Bumper System .................................................................................... 383
3
Chapter 1 Body Dimensions
Fig. 1
Body Dimension (See Fig. 1) Distance to ground with full load

M K-n L-n l-n M-n A, a H,h K,k N,n
or E-e J-j or or or or M-m
a-M k-N l-N L-N m-N
1537.6 917.6 1584.5 1409.2 1547.5 620.1 1493.0 1505.6 836.8 432.2 783.4 920.1
Hole Location Description Table 1 (See Fig. 1)

Symbol Name Hole Symbol Name Hole
Diameter Diameter
A,a Front fender φ7 H,h Water tank pillar 15×17
mounting nut hole mounting plate
positioning hole
B,b Front shock φ12.5 I,i Water tank pillar outer φ10
absorber mounting panel positioning hole
hole - Inside
C,c Front wheel housing φ10 J,j Lower fender φ7
baffle plate mounting bracket
positioning hole positioning hole
D Front windshield φ7 K,k Water tank upper φ7
lower cross bearer cross bearer assembly
front extension mounting hole
4
panel mounting hole

E,e Front longitudinal φ18 L,l Water tank cross φ10
beam inner panel bearer connecting
positioning hole plate positioning hole
F,f Suspension φ18 M,m Front fender mounting φ7
through-hole nut hole
G,g Water tank upper φ9 N,n Engine compartment φ11
cross bearer cover hinge
through-hole through-hole
Hole Location Measurement Data Table 2 (See Fig. 2)

Measured Dimension Measured Dimension
No. Note No. Note
Area (mm) Area (mm)
1 C-c 1566.8 7 I-i 1163.1
2 D-d 1586.6 8 J-j 1280.1
3 E-e 1327.6 9 K-k 1473.1
4 F-f 1432.4 10 L-l 1588.8
5 G-g 1476.3 11 M-m 1600.8
6 H-h 1476.3

No. Note No. Note
Area (mm) Area (mm)
5
1 E-f or e-F 1528.1 7 F-k or f-K 1665.3

2 E-h or e-H 1668.1 8 H-i or h-I 1646.1
3 E-i or e-I 1391.7 9 C-M or c-m 1095.0
4 E-k or e-K 1670.4 10 D-L or d-l 1130.6
5 F-j or f-J 1820.0 11 G-I or g-i 1071.4
No. Note No. Note
A, a Roof panel corner H, h Door sill match mark

B, b Engine cover hinge mounting hole I, i Top frame match mark
Front door upper hinge mounting
C, c J, j Pillar B match mark
hole
Front door lower hinge mounting
D, d K, k Pillar B match mark
hole
Rear door upper hinge mounting
E, e Pillar A match mark L, l
hole
Rear door lower hinge mounting
F, f Pillar A match mark M, m
hole
G, g Door sill match mark
6
Hole Location Measurement Data Table 3 (See Fig. 3)

No. Note No. Note
Area (mm) Area (mm)
1 N-n 1283.3 5 R-r 1225.0
2 O-o 1473.0 6 S-s 1459.1
3 P-p 1478.1 7 T-t 1524.6
4 Q-q 1147.0

No. Note No. Note
Area (mm) Area (mm)
1 G-p or g-P 1774.8 5 O-r or o-R 1732.9
2 N-p or n-P 1655.9 6 O-s or o-S 1602.6
3 N-r or n-R 1448.1 7 P-q or p-Q 1646.0
4 N-s or n-S 1634.9

No. Note No. Note
N, n Pillar B match mark R, r Pillar C match mark
O, o Pillar B match mark S, s Pillar C match mark
P, p Door sill notch edge T, t Rear door lock mounting hole
Q, q Top frame match mark
7
Body Dimension
E-e F-G or f-g G-g G-h or g-H
1152.0 1272.1 763.7 1611.9
No. Note No. Note
Rear lamp base plate/back panel joint

A, a Roof panel corner E, e
position
Rear floor side panel extension
B, b Side panel/shelf joint position F, f
mounting hole
Rear lamp base plate/rain trough
C, c G, g Pillar B match mark
plate joint position
D, d Rear lamp base plate positioning hole
(Three-dimensional distance)
8
Fig. 5
Body Dimension
B-d or b-D C-e or c-E A-e C-E or c-e G-I 1 2
1148.0 1193.4 1100.5 883.9 736.1 100 100
Fig. 6

Symbol Name Symbol Name
A, a Water tank lower cross bearer H,h Front longitudinal beam standard hole
standard hole
B,b Front sub frame cross bearer nut I,i Front floor standard hole
C,c Front longitudinal beam standard J,j Door sill connecting plate standard
hole hole
D,d Front sub frame mounting nut K,k Rear sub frame mounting hole
E,e Front sub frame mounting nut L,l Rear spring base plate standard hole
F,f Door sill connecting plate M,m Rear floor longitudinal beam front
standard hole section standard hole
G,g Front floor standard hole N,n Rear floor longitudinal beam rear
section standard hole
(Two-dimensional distance)
9
Left
Right
Fig. 7
Wheelbase 2660 1 2
100 100
Imaginary standard line

Fig. 8
Notice: 1 Capital letters indicate left side of vehicle body, small letters indicate right side of vehicle
body;
2 The dimension is indicated in mm.
Whole Location Description Table (See Fig. 8)
Symbol Name Symbol Name

A, a Water tank lower cross bearer I,i Front longitudinal beam standard hole
standard hole
B,b Front sub frame cross bearer nut J,j Front floor standard hole
C,c Front longitudinal beam standard K,k Door sill connecting plate standard hole
hole
D,d Front sub frame mounting nut L,l Rear sub frame mounting hole
E,e Front shock absorber base plate M,m Rear spring base plate standard hole
standard hole
10
F,f Front sub frame mounting nut N,n Rear shock absorber mounting hole
G,g Door sill connecting plate O,o Rear floor longitudinal beam front
standard hole section standard hole
H,h Front floor standard hole P,p Rear floor longitudinal beam rear
section standard hole
11
Front bumper reinforcement
Front shock absorber base plate
12
Chapter 2 Body Accessory System

Contents
Section 1 Seat ..........................................................................................................................14
1.1 Front Seat .................................................................................................................. 14
1.2 Rear Seat ................................................................................................................... 18
Section 2 Safety Belt ................................................................................................................19
2.1 Replacement of front seat belt:.................................................................................. 19
2.2 Replacement of Rear Seat Belt ................................................................................. 20
2.3 Precautions for repair: ............................................................................................... 21
Section 3 Inner Rear View Mirror .............................................................................................22
Section 4 Washing System Assembly......................................................................................23
4.1 Replacement of Washing Nozzle and Washing Hose............................................... 23
4.2 Replacement of Washing Liquid Pot ......................................................................... 23
4.3 Replacement of Washer Motor .................................................................................. 23
Section 5 Wiper System Assembly ..........................................................................................24
5.1 Removal of Wipers .................................................................................................... 24
5.2 Installation of Wiper ................................................................................................... 24
Section 6 Windshield Glass Assembly.....................................................................................25
6.1 Removal and Installation of Windshield Glass .......................................................... 25
Section 7 Rear Windshields Glass Assembly ..........................................................................28
7.1 Removal and Installation of Rear Windshield Glass ................................................. 28
Section 8 Sun Roof Assembly..................................................................................................29
8.1 Trouble Diagnosis of Sun Roof.................................................................................. 29
8.2 Replacement of Sun Roof Glass ............................................................................... 29
8.3 Height Adjustment of Sun Roof Glass ....................................................................... 30
8.4 Replacement of Sun Roof Motor ............................................................................... 30
8.5 Replacement of Water Gutter .................................................................................... 31
8.6 Replacement of Sun Screen...................................................................................... 31
8.7 Replacement of Cam Assembly and Timing Belt ...................................................... 32
13
Section 1 Seat 1.1.1.3. Perform installation in the reverse

order of removal and tighten the bolts to
Diagram of Seat Location the torque of 40 Nm.
1.1.2 Disassembly/Assembly of Front Seat

Co-driver Seat Assembly Rear Seat Assembly
副驾驶座椅总成后排座椅总成
1.1.2.1 Disassembly and Assembly of Driver

(Power) Seat
1.1.2.1.1 Pull out the 6-way adjustment button

and 2-way adjustment button respectively
Driver Seat Assembly in the direction indicated by the arrow.
主驾驶座椅总成
1.1 Front Seat
1.1.1 Removal/Installation of Front Seat
1.1.1.1 Slide the seat to the foremost position,

remove the seat leg braces and remove
the rear mounting bolts of the seat.
1.1.2.1.2 Remove the cross recessed pan

head tapping screw and flat washer
assemblies at the rear of left outer guard
plate of the driver (power) seat and at the
bottom inside front guard plate, and then
1.1.1.2 Slide the seat to the rearmost position remove the left outer guard plate and front
and remove the front mounting bolts of the guard plate together. The structure is
seat as shown. Before removing the power shown below.
seat from the vehicle, it is necessary to
disconnect the power supply harness of
power seat, alarm wiring of seat belt
buckle and wire harness of side safety
airbags. Disconnect the alarm wiring of the
seat belt buckle and wire harness of the
side safety airbags (if any) when removing
the driver seat by hand. Disconnect the
alarm wiring of the seat belt buckle, wire
harness of seat belt unbuckle alarm
sensor and wire harness of the side safety
airbags (if any) when removing the
co-driver seat.
14
1.1.2.1.3 Remove the left outer guard plate, for the operation, remove the seatback
front guard plate and power seat switch. cover first).
Note the snap-fits used to connect the left
outer guard plate and front guard plate
should be disengaged. The structure is
shown below.
1.1.2.1.6 Remove the C screw to take off the

seat back cover and sponge foam.

1.1.2.1.4 Remove 2 cross recessed pan head seat cushion cover and sponge foam.
tapping screw and flat washer assemblies
on the right outer guard plate of driver 1.1.2.1.8 Remove the cross recessed pan
(power) seat, and take off the outer guard head tapping screw and flat washer
plate. When removing the guard plate, assemblies on the left/right lower inner
take care of the plastic snap-fits on it. The guard plates and left/right upper inner
structure is shown below. guard plates of the driver (power) seat,
and take off the left/right lower inner guard
plates and left/right upper inner guard
plates of the driver (power) seat. The
structure is shown below.
1.1.2.1.5 Pull out the front seat head rest.

Then pull 2 buckles of the head rest sliding
sleeve and head rest height adjustment
sliding sleeve assembly outward along the
center of head rest rod while clamping
them with pliers in the direction as shown
to remove them (If this is not convenient
15
1.1.2.1.9 Remove the driver control switch

assembly, seat back adjustment motor
assembly, seat height adjustment motor
assembly and seat pan angle adjustment
motor assembly in order. The structure is
shown below.
1.1.2.2.2 Remove the handle of the height

adjustment mechanism (if the manual seat
is equipped with seat height adjustment
mechanism) and driver seat back
adjustment handle. Note the snap-fits used
to connect the seat back adjustment
1.1.2.1.10 Perform installation in the reverse handle and seat fasteners should be
order of removal disengaged. The structure is shown below.
Notice: Replace any guard plate damaged
during removal.
1.1.2.2 Disassembly/Assembly of Manual Seat
1.1.2.2.1 Remove the handle cover of the

height adjustment mechanism (if the
manual seat is equipped with seat height
adjustment mechanism) and 3 cross
recessed pan head tapping screws used to
install the handle of the height adjustment
mechanism. Note the snap-fits used to
connect the handle cover of the height
adjustment mechanism and handle of
height adjustment mechanism should be
disengaged. The structure is shown below.
1.1.2.2.3 Remove 2 cross recessed pan head

tapping screws and flat washer assemblies
16
on the left outer guard plate of driver

manual seat, and take off the outer guard 1.1.2.2.5 Pull out the front seat head rest.
plate. When removing the guard plate, Then pull 2 buckles of the head rest sliding
take care of the plastic snap-fits on it. The sleeve and head rest height adjustment
structure is shown below. sliding sleeve assembly outward along the
center of head rest rod while clamping
them with pliers in the direction as shown
to remove them (If this is not convenient
for the operation, remove the seatback
cover first).

seat back cover and sponge foam.
1.1.2.2.4 Remove 2 cross recessed pan head
tapping screw and flat washer assemblies
on the right outer guard plate of driver
seat cushion cover and sponge foam.
manual seat, and take off the outer guard
1.1.2.2.8 Remove the left/right upper inner
plate. When removing the guard plate,
guard plate mounting screws of the seat
take care of the plastic snap-fits on it. The
and left/right upper inner guard plate of the
structure is shown below.
co-driver seat. The structure is shown
below.
1.1.2.2.9 Perform installation in the reverse

order of removal.
17
Notice: Replace the guard plate damaged

during removal.
1.2 Rear Seat
1.2.1 Removal/Installation of Rear Seat
1.2.1.1 Remove the rear seat cushion. Pull up

and remove 2 protrusions at the front of
the cushion. Notice: The cushion frame is
easy to deform. To avoid deformation of
the cushion frame, the hands should be
placed near the 2 hooks as shown below.
1.2.1.3 Pull up the rear seat back to separate

the upper hooks of the rear seat back from
the body. The specific structure is shown
below.
1.2.1.2 Remove the rear seat back assembly. 1.2.2 Disassembly/Assembly of Rear Seat
Remove the mounting bolts, hexagonal
head bolt and the flat washer assembly 1.2.2.1 Pull out the left/right and center head
under the rear seat back. The specific rests of the rear seat. Then pull 2 buckles
structure and position are shown below. of the head rest sliding sleeve and head
rest height adjustment sliding sleeve
assembly outward along the center of
head rest rod while clamping them with
pliers in the direction as shown to remove
them (If it is not convenient for operation,
remove the seatback cover first).
18
the set bolts of the connector. The

tightening torque of the bolt is 45 Nm.
1.2.2.2 Remove the C screw to take off the

seat back cover, sponge foam and seat
back frame.
1.2.2.3 Remove the C screw to take off the

seat cushion cover and sponge foam.
Section 2 Safety Belt 2.1.4 Remove the door sill pedal and lower
Diagram of Seat Belt Locations guard plate of the B pillar based on the
removal method of the side lining.
2.1.5 Remove the upper guard plate of the B

pillar, adjuster connecting nut and guiding
element. The tightening torque of the nut is
45 Nm.
2.1 Replacement of front seat belt:
Notice: The entire seat belt assembly must be

replaced when severe accidents occur or the
pretension function is active. Do not damage
the seat belt during removal and installation.
Observe the following procedure to perform
removal and installation.
2.1.1 Disconnect the battery negative cable 2.1.6 The retractor can be removed after
and wait for at least 3 minutes. removing the pretension unit connector
and then the upper/lower set bolts of the
2.1.2 Slide the seat to the foremost position. retractor. The upper set bolt of the retractor
needs to be tightened and the lower set
2.1.3 Turn the bolt cover under the B pillar bolt should be tightened to the torque of 45
outward and remove it, and then remove Nm.
19

2.1.7 Remove the upper and lower set bolts of of removal and tighten the bolts to the
the height adjuster and then height specified torque. Ensure the seat belt
adjuster B. The tightening torque of bolt is connector is correctly connected. Make
45 Nm. sure the seat belt is not twisted or kinked
before the installation of the upper and
lower set bolts. Check the function of the
retractor, buckle locking mechanism,
height adjustment mechanism and seat
belt unbuckle reminder (Refer to detection
section).
2.2 Replacement of Rear Seat Belt
Notice: The entire seat belt assembly must be

replaced when severe accidents occur or the
pretension function is active. Do not damage
the seat belt during removal and installation.
Observe the following procedure to perform
removal and installation.
2.2.1 Remove the rear seat based on the

removal method of the rear seat. The rear
2.1.8 Remove the front seat based on the center seat belt buckle assembly and
removal method of the front seat. lower fixing points of retractor as shown
below can be removed as necessary. The
2.1.9 Pull out the buckle wire harness tightening torque of the bolt is 45 Nm.
connector and disengage the harness tie.
2.1.10 Remove the buckle bolts and then the

seat belt buckle. The tightening torque of
the bolt is 45 Nm.
20
2.3.7 Always keep the belt dry and clean.
2.3.8 Replace the malfunctioning components.
2.3.9 Replace the cut or damaged belts.
2.3.10 Do not fill anything in the trim panel

hole where the seat belt passes.
Observe the following precautions for the seat

belt with pretension function:
2.3.11 In the repair procedure, the "safety

airbag" fuse and trigger circuit of the
safety airbag (gas generator) module
(driver and co-driver) should be
disconnected to avoid unexpected
deployment.
2.3.12 Do not supply power to the safety

airbag system, unless all the
components are powered on or the
2.2.2 Remove the rear partition plate based on diagnostic chart requires energy.
the removal method of the rear partition Otherwise, the DTCs may be set.
plate. Remove the upper fixing points of
the retractor as necessary. The tightening 2.3.13 Never use the components of the
torque of the bolt is 45 Nm. safety airbag removed from other
vehicles.
2.3 Precautions for repair:
2.3.14 If the vehicle is exposed in the
Observe the following precautions before temperature of 93ºC (2000 F) (for
repairing and replacing the seat belt: example, in paint baking process), the
safety airbag system should be
2.3.1 The seat belt should be correctly removed.
connected to the retractor and buckle.
2.3.15 If the components of the safety airbag
2.3.2 The sharp and destructive objects system are hit when repairing, they
should not come close to the seat belt. should be removed.
2.3.3 Do not bend or damage any parts of the 2.3.16 When the welder is used, the
buckle or locking plate. connectors of the safety airbag (gas
generator) and safety belt pretension
2.3.4 Do not bleach or dye the seat belt (clean (driver and co-driver) should be
the belt with only neutral soap and warm removed.
water).
2.3.17 Carefully paint the safety airbag
2.3.5 When installing the seat belts, system and related components to
pre-tighten the threaded rod manually to prevent the wire harness or connectors
avoid entangled threads. from being exposed in the paint mists.
2.3.6 Do not attempt to repair the retractor or Never directly expose the components of
retractor cover. Use the new assembly to safety airbag system in the hot air (Dry or bake
replace the ineffective assembly. the vehicle after painting) or near the flame.
21
Section 3 Inner Rear View Mirror

3.1 Remove the upper front case A in the
direction indicated by the arrow as shown
below;
3.3 Perform installation in the reverse order of

removal.
Notice: Do not apply excessive force

during removal to avoid damaging the wire
harness connector.
3.2 If there is a wire harness in the inner rear
view mirror, disconnect the wire harness
connector B. Push the support in the
direction indicated by the arrow as shown
to remove the inner rear view mirror;
22
Section 4 Washing System Assembly

Diagram of Washing System Assembly
Location
4.2 Replacement of Washing Liquid Pot
4.1 Replacement of Washing Nozzle and 4.2.1 Remove the bumper.

Washing Hose
4.2.2 Pull out the connectors of the washer
4.1.1 Disconnect the washing hose connected motor.
to the motor, and put the port in the
prepared container to store the detergent 4.2.3 Remove 5 assembling bolts fixing the
flowing from the hose. pot.
4.2.2 Remove the washing hose and nozzle 4.2.4 Remove the washing liquid pot after the
from the front nozzle. washer motor is removed from the
washing liquid pot.
4.2.3 Remove the hose mounting bases I and
II with bent nose pliers. 4.2.5 Perform installation of the washing liquid
pot in the reverse order of removal.
4.2.4 Take out 5 hoses.
Notice:
4.2.5 Perform installation of the washer hose
in the reverse order of removal. Check the operation of the washer system
after installation, and check for washing liquid
Notice: leakage around the washer motor and the
connection by washing the hose.
Wipe all the connections and inner wall of the
hose clean before installation and apply 4.3 Replacement of Washer Motor
adhesives. Check if the hose leaks after the
adhesives are dry and the washer is energized. 4.3.1 Remove the washer motor from the
Reinstall the hose if it leaks. washing liquid pot after the washing liquid
pot is removed.
4.3.2 Perform installation of the washer motor

Notice:
Check the operation of the motor after it is
installed and energized to ensure the liquid
can be sprayed.
23
Section 5 Wiper System Assembly

Diagram of Wiper System Assembly Location
5.1.1.3 Remove the front wiper rocker arm

Start the front wiper and make it stay in the
5.1 Removal of Wipers position where the wiper motor
automatically returns. Remove the type 1
5.1.1 The diagram of the wiper assembly hex nut, primary wiper arm and blade
components is as follows: assembly, secondary wiper arm and blade
assembly.
5.1.1.4 Remove the vent cover
5.1.1.5 Remove the wiper connecting rod

5.1.1.1 Remove the protective cover of the assembly
front wiper rocker arm
Disconnect the connector of the wiper
5.1.1.2 Use a straight screwdriver with motor. Remove 2 cross recessed hexagon
protective tape wrapped around its blade, head bolts, wave washer and flat washer
as shown in the figure, to remove the assemblies so that the wiper connecting
protective cover of the front wiper rocker rod assembly can be removed. Mark the
arm. position of the drive link on the base of the
wiper drive shaft and remove the drive link.
5.2 Installation of Wiper
Perform installation of the wiper motor in the

reverse order of removal.
24
Precautions for removal and installation of c Primer Brush

wipers: d Cutting Tool
e Rubber Clamps
5.2.1 Apply grease to all moving components; f Sealant Spray Gun (For filling adhesive)
g Putty Scraper (For trimming adhesive
5.2.2 Replace the damaged retainer as areas)
necessary;
6.1.1.2 The following tools are needed to
5.2.3 Adjust the linkage mechanism to the remove the windshield glass:
marked position and then install the drive a Drill
link; After installation, power on and start b Steel Wire
c Primer Brush
5.2.4 the wiper for one time to make it return to d Cutting Tool
the stop position; e Rubber Clamps
f Sealant Spray Gun (For filling adhesive)
5.2.5 Inspect the working condition of the g Putty Scraper (For trimming adhesive
wiper motor. areas)
Section 6 Windshield Glass Notice:

When the primer and glass cement produced
Assembly by other manufacturers are used, refer to their
operation instructions. If the glass cement is
6.1 Removal and Installation of Windshield neglected or misused during working, the
Glass original adhesiveness will be affected.
Therefore, be sure to read the operation
The windshield glass is installed with instructions and brand provided by the
single-component polyurethane sealing manufacturer of glass cement before working.
adhesive. The replacement of the windshield Use the procedures for the entire working
glass should be performed with an adhesive period and observe all the precautions.
which can provide surface binding strength If the coating is scratched or damaged in other
and proper procedures. ways, be sure to repair the damaged area, or it
will corrode.
6.1.1 Removal of Windshield Glass
6.1.1.3 Removal of Windshield Glass
6.1.1.1 The diagram of windshield glass
assembly is as follows: 6.1.1.3.1 The following parts should be
removed:
a Windshield wiper arm

b Vent cover
c Inner rear view mirror and connector
d Trim strip of windshield glass
6.1.1.3.2 If the glass needs to be reinstalled,

make the alignment mark for the glass and
body with a marker.
6.1.1.3.3 Cover the body area and dashboard

around the glass with tape to avoid
damage.
6.1.1.2 The following tools are needed to 6.1.1.3.4 The windshield sealing strip can be
remove the windshield glass: cut if necessary during removal.
a Drill
b Steel Wire
25
6.1.1.3.5 Drill a hole through the adhesive at 6.1.2.1.3 Using a new brush, apply sufficient
the corner of the windshield glass inside primer with a width of about 15 mm around
the vehicle, and thread a piano wire the surface of the glass to be connected to
through the hole and twine both ends of the body.
piano wire on the wood block.
6.1.2.1.4 Attach the windshield rubber strip to
6.1.1.3.6 An assistant outside the vehicle pulls the proper position around the windshield
the piano wire back and forth. Place the glass and apply adhesive with a spray gun.
piano wire as close to the glass as
possible to avoid scratching the body and 6.1.2.1.5 Hold the rubber clamps and align the
dashboard. Carefully saw off the sealant snap-fits on the inner surface of the glass
and rubber strip of the entire glass. with the holes on the body. Press the glass
into the body and adjust its position to
Notice: Place the piano wire as close to the make it symmetric. Tape the glass surface
glass as possible to avoid damage to the and tape to fit the glass in the body
vehicle. completely.
6.1.1.3.7 Carefully remove the windshield Notice:

glass after the areas in the figure below a Start from the bottom edge of the glass.
are cut (Schematic diagram for cutting
position and direction of windshield glass). b Be careful not to damage the primer, glass
surfaces or the vehicle body.
c Press the glass on the body immediately

after application.
d Use rubber clamps to install and carry the

glass after application.
e Finish steps 5-6 within 10 minutes to

ensure sufficient binding strength.
f For correct operation and drying time,

please refer to instructions from the
6.1.2 Installation of Windshield Glass adhesive manufacturer.
6.1.2.1 The installation steps are as follows: 6.1.2.1 6 Install the tone cover strip, vent cover
and wiper arm.
6.1.2.1 1 Scrape the adhesive stuck on the
vehicle flat with a knife to a width of 2 mm 6.1.2.1 7 After the adhesive becomes hard,
everywhere. spray water from a hose to the windows of
the vehicle to check for any water leakage.
Notice: If there is any, wipe water away from the
Do not scrape the body paint, or the adhesive glass and seal leakages with adhesive.
effect will be reduced. After filling, if there is still leakage, remove
Before fitting the glass back, remove the old the glass and restart installation according
sealing strips and adhesive on the glass. to the above procedures.
6.1.2.1.2 If the glass needs to be reinstalled, 6.1.2.1.8 After the adhesive becomes hard,
clean the inner surface and edge with install the inner rear view mirror and
adhesive applied around the glass with a connector.
sponge soaked in alcohol. Ensure no oil,
grease or water is left and dries them for at Notice:
least 10 minutes. a Do not use high-pressure water.
26
b When drying up adhesive, do not use b If the strip is not fully attached, press it
compressed air directly on parts applied with tape until the parts stuck with
with adhesive. adhesive are fully tight.
c For the drying process, do not use infrared c Each adhesive has its own setting time.
lamps or similar tools. Be sure to refer to the instruction manual
from the manufacturer. Check the setting
6.1.2.2 Observe the following precautions after time of the adhesive used, and observe
the above installation is completed: carefully to take necessary measures
before the parts stuck with adhesive are
a Before the parts stuck with adhesive are fully tight.
fixed tight, the sudden closing of the
door may cause the glass to loosen or Before the parts stuck with adhesive are
come off. Therefore, if a door is opened fully in place, do not drive the vehicle so
or closed before the parts stuck with that the adhesive can fully and completely
adhesive are fully tight, open all the door harden.
glass and use proper methods.
27
Section 7 Rear Windshields Glass Assembly

7.1 Removal and Installation of Rear Windshield Glass
The rear windshield glass is installed with

single-component polyurethane sealing
adhesive. The replacement of the rear
windshield glass should be performed with an
adhesive which can provide surface binding
strength and proper procedures.
7.1.1 Removal of Rear Windshield Glass
7.1.1.1 The diagram of the rear windshield

glass assembly is as follows:
For the removal method of the rear windshield

glass, refer to the removal of windshield glass.
28
Section 8 Sun Roof Assembly

8.1 Trouble Diagnosis of Sun Roof 8.1.5.2 Check if the sun roof switch
malfunctions;
8.1.1 Water Leakage
8.1.5.3 Check the Open/Close - Tilt/Close
8.1.1.1 Check if the sun roof and sealing strip switch;
are installed incorrectly or improperly;
8.1.5.4 Check if the battery voltage is low;
8.1.1.2 Check for gaps between the sun roof
sealing strip and ceiling. 8.1.5.5 Check if the motor malfunctions;
8.1.1.3 Check if the drain pipe and water outlet 8.1.5.6 Check if the relay malfunctions.
are connected tightly and if the clamps are
loose. 8.2 Replacement of Sun Roof Glass
8.1.1.4 Check for looseness between the lock The replacement steps for the sun roof glass
bolts and side wall. are as follows:
8.1.2 Motor Noise 8.2.1 Fully close the sun roof.
8.1.2.1 Check if the motor is loose; 8.2.2 Fully pull the sun screen back.
8.1.2.2 Check if the gear or bearing are worn; 8.2.3 Remove the sleeve, and then remove
the nut and gasket from the cam mounting
8.1.2.3 Check if the timing belt assembly is point as shown
deformed.
8.1.3 The motor rotates but the sun roof does

not move
8.1.3.1 Check if the gear or internal timing belt

is installed incorrectly;
8.1.3.2 Check if foreign materials are stuck

between the guide rail and the slide; 8.2.3.1 Remove the sun roof glass after it is
raised as shown below. Be careful not to
8.1.3.3 Check if the internal timing belt is damage the ceiling.
loose;
8.1.3.4 Check if the timing belt assembly is

installed properly;
8.1.3.5 Check if the clutch is not well adjusted.
8.1.4 Wind noise while driving
Check if the gap between the sun roof

glass sealing strip and ceiling is too large.
8.1.5 The sun roof glass does not move and

the motor does not rotate
8.1.5.1 Check if the fuse is blown;
29
8.2.3.2 Install the sun roof glass in the reverse 8.3.3.2.1 Remove the roof headlining.
order of the removal procedures.
8.3.3.2.2 Place a rag at the front edge of the
8.3 Height Adjustment of Sun Roof Glass sun roof glass and hook a spring scale on
it.
The ceiling should be flush with the sealing
strip of the sun roof glass, and the deviation for 8.3.3.2.3 Press the switch to close the sun roof
compression of the sealing strip should be glass and measure the force desired to
within 1±mm. stop the glass. Read the reading on the
spring scale immediately after the glass
stops moving and then release the switch
and spring scale. The standard closing
force is 200-290 N.
8.3.3.2.4 If the closing force is not within the

specification, remove the sun roof motor
and check the following:
8.3.3.2.4.1 Check if the gear and internal

timing belt are broken or damaged. If the
gear is broken, replace the motor; if the
internal pull wire is damaged, remove the
frame and replace the pull wire assembly.
If the standard value is exceeded, adjust the
height of the sun roof glass as follows: 8.3.3.2.4 .2 Check the sun roof motor. If the
motor does not operate or does not run
8.3.1 Fully open the sun roof glass and smoothly, replace the motor.
remove the glass bracket cover.
8.3.3.2.4.3 Check the opening force.
8.3.2 Loosen the nut and insert the gasket
between the glass frame and glass bracket 8.3.3.3 The opening force of the sun roof glass
to perform adjustment (See figure 3-3-1-2). can be checked as follows:
The maximum thickness of the front and
rear gasket is 2 mm. 8.3.3.3.1 Protect the edge of the sun roof glass
with a rag, and hook a spring scale on the
rag.
8.3.3.3.2 Pull the spring scale to measure the

force desired to open the sun roof glass.
The pulling force should not exceed 40 N.
8.3.3.3 .3 If the measured force is higher than

40 N, check the adjustment condition of
the side clearance and glass height.
Check if the sliding part is broken or
8.3.3 If necessary, repeat the operation for the damaged. If the sliding part is damaged,
opposite side until the height is properly replace it.
adjusted.
8.4 Replacement of Sun Roof Motor
8.3.3.1 Inspection of closing and opening force
of sun roof glass Replacement steps for the sun roof motor:
8.4.1 Remove the roof headlining.
8.3.3.2 The closing force of the sun roof glass
can be checked as follows: 8.4.2 Disconnect and remove the connector as
shown below, and remove the bolts.
30
8.5.5 Perform the installation of the water

gutter in the reverse order of removal.
8.4.3 Remove the sun roof motor.
Observe the following precautions:
8.4.4 Install the motor in the reverse order of
8.5.5.1 When the water gutter is reinstalled, it
the removal procedures. Connect the
should be hooked by the water gutter hook.
connector and check the operation of the
A light click sound can be heard while
motor after installation.
installing.
8.5 Replacement of Water Gutter
8.5.5.2 Check if the glass is flush and adjust
as necessary.
Replacement steps for water gutter:
8.5.5.3 Check for water leakage. Never use a
8.5.1 Remove the sun roof glass.
high-pressure water gun during the test.
8.5.2 Adjust the cam so that the sun roof can
8.6 Replacement of Sun Screen
be closed downward. Then remove the
tightening screws of the water gutter as shown
The replacement steps of the sun screen are
below.
as follows:
8.6.1 Remove the sun roof glass and water

gutter.
8.6.2 Slide the sun screen until 2 slides of the

sun screen are visible. See the figure
below.
8.5.3 Move the water gutter forward to

separate the water gutter from its hook.
8.5.4 Remove the water gutter as shown

below.
31
8.6.3 Remove the rear water outlet 8.7 Replacement of Cam Assembly and
components Timing Belt
8.6.4 Lift the rear of the sun screen and move

it backward. 8.7.1 Remove the sun roof glass assembly
and motor assembly.
8.6.5 Then slide the sun screen out of the slide
way. 8.7.2 Remove the water gutter.
Be careful not to damage the sliding sleeve 8.7.3 Slide the cam assembly backward and
and sun screen. remove it from the frame. Then remove the
left/right timing belt. See the figure below
8.6.6 Separate 2 rear sliding sleeves of the

sun screen from the guide rail of the frame,
and remove the sun screen as shown
below.
8.7.4 Install the cam and timing belt assembly

Precautions for installation:
(a) Replace the damaged components.

8.6.7 Install the sun screen in the reverse
(b) Apply multi-purpose grease on the relative
order of removal.
moving position of the cam and slide and
sliding position of the guide rail.
8.6.8 Check if the glass is flush after the sun
screen is replaced; Check for water
(c) Before the motor is reinstalled, install the
leakage. Be careful not to perform the
frame and glass, and check the opening
water test with a high-pressure water gun.
force.
Also, before the motor is reinstalled,
ensure that the 2 cam assemblies are
parallel and in fully closed position.
32
Chapter 3 Door System Repair Manual
Contents
Section 1 Door .........................................................................................................................35
1.1 Removal and Installation of Power Window .............................................................. 35
1.2 Replacement of Rear Door Glass.............................................................................. 36
1.3 Replacement of Rear Triangular Window Glass ....................................................... 36
1.4 Replacement of Window Regulator ........................................................................... 37
1.5 Adjustment of Front and Rear Door Glasses ............................................................ 37
Section 2 Replacement of Outer Rear View Mirror .................................................................38
2.1 Diagram of Component Locations ............................................................................. 38
2.2 Replacement of Power Outer Rear View Mirror ........................................................ 38
2.3 Replacement of Outer Rear View Mirror Lens .......................................................... 39
Section 3 Replacement of Outside Handle and Door Lock .....................................................40
3.1 Replacement of Front Door Outside Handle and Door Lock .................................... 40
3.2 Replacement of Rear Door Outside Handle and Door Lock ..................................... 41
Section 4 Opener .....................................................................................................................42
4.1 Diagram of Component Locations ............................................................................. 42
4.2 Replacement of Engine Cover Lock .......................................................................... 42
4.3 Replacement of Engine Cover Opening Cable ......................................................... 42
4.4 Replacement of Engine Cover Opening Handle ....................................................... 42
4.5 Replacement of Trunk Lid Lock ................................................................................. 42
4.6 Replacement of Trunk Lid and Oil Filler Cap Opening Cables ................................. 42
4.7 Replacement of Trunk Lid and Oil Filler Cap Opening Handles ............................... 43
Section 5 Removal and Installation of Sealing Mechanism .....................................................44
5.1 Replacement of Front Door Outer Slot Seal.............................................................. 44
5.2 Replacement of Front Door Inner Slot Seal .............................................................. 44
5.3 Replacement of Front Door Sealing Strip.................................................................. 45
5.4 Replacement of Front Door Frame Sealing Strip ...................................................... 45
5.5 Replacement of Front Door Glass Mud Groove ........................................................ 45
5.6 Replacement of Upper and Lower Stop Blocks of Front Door .................................. 45
5.7 Replacement of Rear Movable Guide Rail Assembly of Front Door ......................... 45
5.8 Replacement of Rear Door Outer Slot Seal .............................................................. 46
5.9 Replacement of Rear Door Inner Slot Seal ............................................................... 46
5.10 Replacement of Rear Door Sealing Strip ................................................................ 46
5.11 Replacement of Rear Door Frame Sealing Strip..................................................... 46
5.12 Replacement of Rear Door Glass Mud Groove ...................................................... 47
5.13 Replacement of Rear Door Stop Block ................................................................... 47
5.14 Replacement of Movable Guide Rail of Rear Door ................................................. 47
5.15 Replacement of Vent Cover Sealing Strip RH ........................................................ 47
5.16 Replacement of Front Deck Lid Weather Strip ........................................................ 47
5.17 Replacement of Front Deck Buffer Block ................................................................ 47
33
5.18 Replacement of Trunk Lid Sealing Strip .................................................................. 48

5.19 Replacement of Trunk Lid Hinge Buffer Block, Trunk Lid Stop Block and Side Stop
Block ........................................................................................................................ 48
5.20 Replacement of Left/Right Rear Door Corner Window Weather Strip .................... 48
Section 6 Adjustment of Four Doors and Two Covers .............................................................49
6.1 Adjustment of Front/Rear Door Position.................................................................... 49
6.2 Adjustment of Engine Cover ...................................................................................... 49
6.3 Adjustment of Trunk Lid ............................................................................................. 49
6.4 Replacement of Trunk Lid Torsion Bar...................................................................... 50
34
Section 1 Door
1.1 Removal and Installation of Power Window
Fig. 1-1 Enlarged View of Front Door Accessories
1. Window regulator 2. Door lock 3. Glass guide rail 4. Front door glass 5. Front door outer slot
seal 6. Door sealing strip
7. Glass mud groove 8. Door limiter 9. Door hinge 10. Door buffer
1.1.1 Power Window Parts Location Remove the front door water-proof film.
The power window parts and their locations Turn on the window regulator switch and lower
are shown in figure 1-1. the front door widow to an appropriate position
(Expose two mounting holes of the glass).
1.1.2 Removal of Power Window Remove the glass mounting bolts.
1.1.2.1 Replacement of Front Door Glass Carefully remove the glass through the
window glass channel from outside of the door
1.1.2.1.1. Removal: and lift the rear end of the glass first to prevent
the glass from dropping into the door.
Remove the front door corner guard plate.
1.1.2.1.2. Installation:
Remove the front door window regulator
switch assembly. Install the door glass in the reverse order of
removal and note the following items:
Remove the front door guard plate assembly.
When installing the glass, check if the glass
top contacts with the glass channel evenly.
35
Drag the glass up and down and make sure it the movable guide rail of the glass
can go up and down smoothly without getting carefully, take down the entire glass mud
stuck. groove on the window frame as necessary
and remove the triangular window glass to
Adjust the glass position according to the avoid damage.
actual condition.
1.2.1.5 Take out the glass from inside of the
Securely attach the door water-proof film with door carefully and don't drop it into the
the adhesive. door.
1.1.2.2 Replacement of Window Regulator 1.2.2 Installation:
1.1.2.2.1 Removal: Install the door glass in the reverse order of

removal and note the following items:
1.1.2.2.1 1 Remove the door glass with
reference to the removal procedures of the When installing the glass, check if the glass
"front door glass". top contacts with the glass channel evenly.
1.1.2.2.1.2 Disconnect the motor wire harness Drag the glass up and down and make sure it
of the power window regulator. can move up and down smoothly without
getting stuck.
1.1.2.2.1.3 Remove the window regulator bolts
and take out the window regulator through Adjust the glass position according to the
the hole. actual condition.
1.1.2.2.2 Inspection: Securely attach the door water-proof film with

the adhesive.
1.1.2.2.2.1 Inspect whether the sliding and
rotating parts of the window regulator should
be lubricated.
1.1.2.2.3. Installation:
Install the front window regulator in the reverse

order of removal and note the following:
When installing the glass, check if the glass
top contacts with the glass channel evenly and
if the glass can move up and down steadily.
1.2 Replacement of Rear Door Glass
1.2.1 Removal:
1.2.1.1 Remove the rear door window

regulator switch assembly. Fig. 1-2 Schematic Diagram for Rear Door
Glass Replacement
1.2.1.2 Remove the rear door guard plate
assembly. 1.3 Replacement of Rear Triangular Window
Glass
1.2.1.3 Remove the rear door water-proof film.
Remove the rear door glass with reference to
1.2.1.4 Remove the fasteners A, B and C on the removal procedures of the rear door glass.
the rear door rear glass rear guide rail as
shown in "Fig. 1-2 Schematic Diagram for Hold the rear triangular window glass and
Rear Door Glass Replacement". Take out sealing strip, remove the triangular window
36
glass and sealing strip in the direction from the When installing the glass, check if the glass
vehicle rear to front with even force to avoid top contacts with the glass channel evenly and
injury to your arm. if the glass can go up and down steadily.
Remove the rear triangular window glass from 1.5 Adjustment of Front and Rear Door
the rear triangular window sealing strip. Glasses
Install the rear triangular window glass in the
reverse order of removal and note the 1.5.1 Stop the vehicle on a solid and level
following: ground.
1.3.1 Adjust the angle of the rear triangular 15.2 Remove the following parts:
window glass slightly and make sure the Front and rear door guard plates
gap between the visible lip of the rear Front and rear door water-proof films
triangular window sealing strip and the
window frame is even; 1.5.3 Lift the glass up and down until the
tightening bolts are seen and loosen the
1.3.2 Make sure the rear triangular window tightening bolts.
glass is installed in place;
1.5.4 Move the glass against the guide rail
1.3.3 Spray water around the glass using a near pillar B and then tighten the tightening
water pipe and check for tightness. bolts.
1.4 Replacement of Window Regulator 1.5.5 Check whether the glass can go up and
down smoothly.
1.4.1. Removal:
1.5.6 Fully raise the glass and check whether
1.4.1.1 Remove the rear door glass with the glass contacts with the mud groove
reference to the removal procedures of the evenly.
"rear door glass".
1.5.7 Spray water around the glass using a
1.4.1.2 Disconnect the motor wire harness of hose with an inner diameter of 12 mm to
the power window regulator. check for water leakage. Note the
following:
1.4.1.3 Remove the window regulator bolts
and take out the window regulator through Do not use the injection nozzle;
the hole.
The height of water column should not exceed
1.4.2. Inspection: 0.5 m when the hose is spraying water
upward.
1.4.2.1 Inspect whether the sliding and rotating
parts of the window regulator should be Keep a distance of about 300 mm between the
lubricated. hose outlet and door glass.
1.4.3 Installation:
Install the front window regulator in the reverse

order of removal and note the following:
37
Section 2 Replacement of Outer Rear View Mirror

2.1 Diagram of Component Locations
Fig. 2-1 Diagram of Component Locations
2.2 Replacement of Power Outer Rear View

Mirror
Pull out the front door corner guard plate A in

the direction shown in figure 2-2 and refer to
the removal of interior trims for specific
methods.
Fig. 2-3 Upper Body of Front Door Guard Plate
As shown in figure 2-4, remove three mounting

nuts C on the outer rear view mirror, remove
the high pitch speaker D on the front door and
then remove the outer rear view mirror E and
the cushion under it.
Fig. 2-2 Front Door Corner Guard Plate
Pull out the upper body B of front door guard

plate in the direction shown in figure 2-3 and
refer to the removal of interior trims for specific
methods. Put your hand between the front
door guard plate and the metal plate of the
door to disconnect the wire harness connector
of the outer rear view mirror.
Fig. 2-4 Outer Rear View Mirror
38
Perform installation in the reverse order of

removal.
2.3 Replacement of Outer Rear View Mirror

Lens
Protect the outer rear view mirror case with the

masking tape as shown in figure 2-5, and pry
out the lens directly with a tool.
Install the lens on the tray directly and press it

downward hard to clamp the lens in the tray.
Fig. 2-5 Outer Rear View Mirror Lens
39
Section 3 Replacement of Outside Handle and Door Lock

3.1 Replacement of Front Door Outside Handle and Door Lock
3.1.1 Removal of Front Door Outside Handle and Door Lock
Fig. 3-1 Left Front Door Lock Surrounding Areas
Refer to the figure 3-1 and 3-2 and remove the Install the left front door lock in the reverse
left front door lock according to the following order of the removal:
steps:
3.1.2.1 Install the lock and handle base in the
Remove the screws and bolts shown in figure right position through the through-hole on
3-2. If necessary, remove the corresponding the inner and outer panels of the door and
pastors and covers first; tighten one bolt on the handle base;
Take down the glass mud groove in the glass 3.1.2.2 Install the pull rod in the correct
guide rail and remove the glass guide rail; position on the lock; Install the outside
handle and key cylinder and tighten the
Remove the bolts for fixing the key cylinder bolts on the key cylinder;
through the pastern hole and take out the key
cylinder. Then take out the outside handle and 3.1.2.3 Insert the glass mud groove into the
remove the other bolt on the outside handle. At guide rail in segments;
last, remove the outside handle base;
Tighten all the screws and bolts, and attach
Remove the lock from the through-hole on the the pastern and install the covers.
inner and outer panels of the door.
3.1.3 The outside handle and door lock on the
The right front door lock is removed in the right front door are installed in the same
same way as the left front door lock. way as that on the left front door.
3.1.2 Installation of Left Front Door Lock
40
3.2.2 Installation of Rear Door Outside Handle

and Door Lock
Install the rear door lock in the reverse order of

the removal:
3.2.2.1 Place the lock and handle in the

correct position through the through-hole
on the inner and outer panels of the door;
3.2.2.2 Install the front and rear guard plates to

the outside handle and tighten the bolts;
3.2.2.3 Tighten all the screws and bolts, attach

the pastern and install the covers. The
right rear door lock is installed in the same
Fig. 3-2 Enlarged View of Left Front Door Lock way as the left rear door lock.
Surrounding Areas
3.2.3 Adjustment of Front and Rear Door Lock
3.2 Replacement of Rear Door Outside Handle Strikers
and Door Lock
After the door is positioned and adjusted,
install the lock striker in a position close to the
center of the mounting hole and install the
Fig. 3-3 Diagram of Left Rear Door Lock screws. Do not fully tighten the screws so that
Surrounding Areas the striker can move slightly under stress and
keep still under no stress. Then lock and open
3.2.1 Removal of Rear Door Outside Handle the door to move the lock striker to the correct
and Door Lock position and tighten the lock striker screws.
Refer to the figure 3-3 and 3-4 and remove the

left rear door lock according to the following
steps:
Remove the screws and bolts shown in figure

3-4. If necessary, remove the corresponding
pastors and covers first;
Remove two bolts on the outside handle

through the pastern hole and remove the front
and rear guard plates on the outside handle;
Remove the lock and outside handle from the
through-hole on the inner and outer panels of
the door.
The right rear door lock is removed in the Fig. 3-4 Enlarged View of Left Front Door Lock
same way as the left rear door lock. Surrounding Areas
41
Section 4 Opener
4.1 Diagram of Component Locations Remove the core wire jacket connected to the
engine cover lock from the engine cover lock
so as to remove the engine cover opening
cable.
Install the engine cover opening cable in the

reverse order of the removal and note the
following.
Make sure the core wire jackets on both ends

of the engine cover opening cable are fully
clamped to the slots of the opening handle and
engine cover lock.
4.4 Replacement of Engine Cover Opening

Handle
Replacement of Engine Cover Opening

Fig. 4-1 Diagram of Engine Cover Pull Cable
Handle
Location
Remove the engine cover opening handle
4.2 Replacement of Engine Cover Lock
from the lower body of the instrument panel
and then remove the engine cover pull cable
4.2.1 Removal of Engine Cover Lock
sleeve joint from the opening handle.
The engine cover lock can be removed by
Install the engine cover opening handle in the
removing three mounting bolts from the
reverse order of the removal and note the
mounting surface of the lock and pulling out
following.
the pull cable and wiring harness connector.
Make sure the engine cover pull cable sleeve
4.2 2 Installation of Engine Cover Lock
joint is fully clamped in the slot of the opening
handle.
Connect the wire harness and pull cable, and
install three mounting screws.
4.5 Replacement of Trunk Lid Lock
4.3 Replacement of Engine Cover Opening
4.5.1 Removal of Trunk Lid Lock
Cable
The trunk lid lock can be removed by removing
Replacement of Engine Cover Opening Cable
two mounting bolts from the mounting surface
Remove the following parts
of the lock and pulling out the pull cable and
Left Front Fender
wiring harness connector.
Front Bumper
Left Front Fender
4.5.2 Installation of Trunk Lid Lock
Remove 2 snap-fits from the engine cover
Connect the wire harness and pull cable, and
opening cable with bent nose pliers.
install two mounting screws.
Remove the rubber sleeve near the engine
4.6 Replacement of Trunk Lid and Oil Filler
cover opening handle from the metal plate.
Cap Opening Cables
Remove the core wire jacket connected to the
4.6.1 Replacement of Trunk Lid Opening
engine cover opening handle from the engine
Cable
cover opening handle slot.
42
Remove the following parts 4.6.2.5 Install the opening cable in the reverse
Trunk Lid and Oil Filler Cap Opening Handles order of the removal and note the following:
Left Rear Door Sill Inner Guard Plate Make sure the oil filler cap mounting base
Trunk Inner Panel of opening cable is installed in place and
Trunk Lid Panel the boss limiter can achieve the limiting
function.
Remove the core wire joint from the trunk lid
lock 4.7 Replacement of Trunk Lid and Oil Filler
Cap Opening Handles
Remove the opening cable from the clip and
trunk lid wire harness strapping tape, and pull 4.7.1 Remove the following parts
the opening cable inside the trunk towards the
rear of the vehicle to remove it. Left Front Door Sill Inner Guard Plate
Install the opening cable in the reverse order 4.7.2 Remove the retaining bolts on the trunk
of the removal and note the following: lid and oil filler cap opening handles.
Make sure the opening cable and the core wire
jacket joint used to connect the trunk lock and 4.7.3 The trunk lid and oil filler cap opening
opening handle are fully clamped in the slot. handle can be removed by removing the
core wire jacket joint of pull cable from the
4.6.2 Replacement of Oil Filler Cap Opening trunk lid and oil filler cap opening handle.
Cable
4.7.4 Install the trunk lid and oil filler cap
4.6.2.1 Remove the following parts opening handle in the reverse order of the
Trunk Lid and Oil Filler Cap Opening removal and note the following:
Handles Make sure the sleeve joint of trunk lid and
Left Rear Door Sill Inner Guard Plate oil filler cap opening handle is fully
Trunk Inner Panel clamped in the slot of opening handle.
4.6.2.2 Rotate the oil filler cap mounting base Fig. 4-2 Diagram of Trunk Lid and Oil Filler
from inside of the vehicle and remove it. Cap Pull Cables Locations
4.6.2.3 Remove the converter and snap-fits

from the metal plate.
4.6.2.4 Remove the opening cable from the

clip, and pull the opening cable inside the
trunk towards the rear of the vehicle to
remove it.
43
Section 5 Removal and Installation of Sealing Mechanism

5.1 Replacement of Front Door Outer Slot
Seal
5.1.1 Remove the outer rear view mirror.
5.1.2 Remove the screws (as shown in the Slot Seal End
水切端部
figure) on the front door rear slot seal with
a star screwdriver and pry out the end of
outer slot seal with a straight screwdriver.
When the end is pried, pull it upward and
then remove the entire outer slot seal.
Be careful not to scratch the vehicle body Door
门框
Frame
during the removal.
5.1.3 Install the outer slot seal. Clamp the clip

on the slot seal to the metal plate bordure,
and move the slot seal to the left and right Fig. 5-2 Schematic Diagram for Installation of
to align the screw mounting hole on the Front Door Outer Slot Seal
card with the metal plate hole. Make sure
the slot seal end is flush with the door 5.2 Replacement of Front Door Inner Slot Seal
frame edge. Then install the screw and
outer rear view mirror. 5.2.1 Remove the front door guard plate.
5.2.2 Replace the front door inner slot seal:

Pry one end of the sealing strip outward
using a straight screwdriver and then
remove the other parts successively.
5.2.3 After the front door inner slot seal is

replaced, install the front door guard plate.
Fig. 5-1 Schematic Diagram for Removal of

Front Door Outer Slot Seal

Front Door Inner Slot Seal
44
5.3 Replacement of Front Door Sealing Strip Spray water around the door gap with a water
pipe and check for tightness.
Remove the limiter fastening bolts on the
lower part of pillar A. Remove the snap-fit from 5.5 Replacement of Front Door Glass Mud
the pillar B joint and remove the door sealing Groove
strip cards on both sides of the window frame.
Then remove the nylon fasteners from the Remove the front door guard plate and
door with the flat tongs. Be careful not to water-proof film.
scratch the metal plate of the door.
Remove the front door glass.
Remove the door sealing strip.
Remove the glass mud groove. Remove the
Install the front door sealing strip in the reverse mud groove from the window frame to both
order of the removal. Clamp the front door sides with even force. Be careful not to injure
sealing strip hook on the window frame to the your arms.
corresponding barb on the front door window
frame roller part and note the following: Install the glass mud groove. Install two corner
parts in place first and then install the window
Replace all the front door cards and nylon frame mud groove in place. At last install the
fasteners. mud groove on both sides of the guide rail
from top to bottom and note the following:
Make sure the door sealing strip hook is
installed in the metal plate barb. Make sure the mud groove is installed in
place.
Spray water around the door gap with a water
pipe and check for tightness. Raise and lower the glass several times to
check if the mud groove is installed in place
5.4 Replacement of Front Door Frame Sealing according to the glass movement. If the glass
Strip does not move smoothly, remove and reinstall
the mud groove.
5.4.1 Remove the front door sill inner guard
plate. Spray water around the glass using a water
pipe and check for tightness.
5.4.2 Remove the front door frame sealing
strip from the upper corner close to the 5.6 Replacement of Upper and Lower Stop
pillar B. Blocks of Front Door
5.4.3 Place the seam joint in the center of the 5.6.1 Remove the front door stop block with
door sill guard plate and align the paint plastic cutter pliers.
mark with the upper corner of pillar B.
Then install the door frame strips to the 5.6.2 Install a new stop block in the metal plate
metal plate of the body in order and note buckle.
the following:
5.7 Replacement of Rear Movable Guide Rail
Install the straight part after the corner part is Assembly of Front Door
installed in place.
5.7.1 Remove the front door guard plate and
Do not install the sealing strip in a fixed water-proof film.
direction to prevent the sealing strip from
being extended. The sealing strip cannot be 5.7.2 Remove the front door glass.
installed if it is extended. The door frame
sealing strip should be installed in place after it 5.7.3 Remove the bolt and washer assembly
is positioned properly. on the lower support of the rear movable
guide rail of the front door with a No. 10
sleeve.
45
5.7.4 Remove the movable guide rail.
5.7.5 Install a new movable guide rail in the

reverse order of the above removal.

Rear Door Outer Slot Seal
5.9 Replacement of Rear Door Inner Slot Seal
Refer to the replacement procedure of the

front door inner slot seal for details.
Fig. 5-4 Schematic Diagram for Rear Movable

Guide Rail of Front Door
5.8 Replacement of Rear Door Outer Slot Seal
5.8.1 Remove the outer slot seal. Remove two

screws with a star screwdriver (as shown
in the figure), pry out one card of the outer
slot seal with a straight screwdriver and
then remove the entire outer slot seal
upward with even force.
5.8.2 Install the outer slot seal. Clamp the clip Fig. 5-6 Schematic Diagram for Removal of
on the slot seal to the metal plate bordure, Rear Door Inner Slot Seal
and move the slot seal to left and right to
align the screw holes on both cards of the 5.10 Replacement of Rear Door Sealing Strip
outer slot seal with the metal plate holes.
Tighten the screws to complete the Refer to the replacement procedure of front
installation. door sealing strip for details.
5.11 Replacement of Rear Door Frame

Sealing Strip

front door frame sealing strip for details.
46
5.12 Replacement of Rear Door Glass Mud

Groove

front door glass mud groove for details.
5.13 Replacement of Rear Door Stop Block
Refer to the replacement procedure of front

door stop block for details.
5.14 Replacement of Movable Guide Rail of

Rear Door
5.14.1 Remove the rear door inner guard plate

and water-proof film.
5.14.2 Remove the glass assembly.
5.14.3 Remove the glass mud groove.
5.14.4 Remove the cross recessed

countersunk head screw on the upper Fig. 5-7 Schematic Diagram for Removal of
support of the movable guide rail with a Movable Guide Rail of Rear Door
star screwdriver.
5.15 Replacement of Vent Cover Sealing Strip
5.14.5 Remove the hexagon bolt and washer RH
assembly on the middle and lower
supports of the movable guide rail with a 5.15.1 Align two holes on the vent cover
No. 10 sleeve. sealing strip RH with two special positions
on the mounting plate. Be careful not to
5.14.6 Remove the movable guide rail. fold them.
5.14.7 Install a new movable guide rail in the 5.15.2 Perform the installation in the reverse
reverse order of the above removal. order of the removal. Be careful not to
scratch the vehicle body.
5.16 Replacement of Front Deck Lid Weather

Strip
5.16.1 Remove 8 retainers with the flat tongs

and remove the front deck lid weather
strip.
5.16.2 Perform the installation in the reverse

order of the removal. Be careful not to
scratch the vehicle body.
5.17 Replacement of Front Deck Buffer Block
5.17.1 Remove the front deck buffer block

counterclockwise.
5.17.2 Install the buffer block by turning

clockwise. Adjust the buffer block and
47
make sure there is no flush between the 5.19.2 Replace with a new buffer block (stop
front compartment cover and the fender. block). Press the small end of the buffer
block into the metal plate hole with proper
5.18 Replacement of Trunk Lid Sealing Strip force to complete the installation. Adjust
the buffer block.
Remove the trunk sealing strip and do not
allow the sealing adhesive sticker to flow out. 5.20 Replacement of Left/Right Rear Door
Make sure the joint seam of the trunk sealing Corner Window Weather Strip
strip is in the centerline of the trunk lock ring
and install the trunk sealing strip. Make sure 5.20.1 Remove the inner guard plate and
the sealing strip is installed in place without water-proof film.
being twisted.
5.20.2 Remove the glass assembly.
Check for water leakage.
5.20.3 Remove the glass mud groove.
5.19 Replacement of Trunk Lid Hinge Buffer
Block, Trunk Lid Stop Block and Side Stop 5.20.4 Remove the movable guide rail.
Block
5.20.5 Remove the corner window glass and
5.19 1 Pull out the buffer block (stop block) take out the corner window sealing strip.
with the flat tongs. Be careful not to
scratch the vehicle body. 5.20.6 Install a new sealing strip in the reverse
order of the above removal.
48
Section 6 Adjustment of Four Doors and Two Covers

6.1 Adjustment of Front/Rear Door Position
6.1.1 Open the door, loosen the mounting bolts

of the door hinge and adjust the door as
shown below.
6.1.2 Remove the fender, pillar B guard plate

and front seat belt, loosen the mounting
bolts of the side body hinge and the
mounting nuts of the side body hinge, and
adjust the door as shown below.
Fig. 6-2 Adjustment of the Engine Cover
6.3 Adjustment of Trunk Lid
6.3.1 Remove the following parts
6.3.1.1 Rear carrier
6.3.1.2 Rear decorative panel of the trunk
6.3.2 Loosen each bolt slightly;
6.3.3 Adjust the trunk lid (A) in the following

order;
6.3.3.1 Adjust the trunk lid hinge (B) to the left

and right, front and rear. When loosening
the bolt (C), do not hit the rear windshield;
Fig. 6-1 Adjustment of Front and Rear Door 6.3.3.2 Adjust the trunk lid opening by moving
the lock catch so that the opening is level
6.2 Adjustment of Engine Cover and even.
6.2.1 Operate the engine cover pull cable

opening handle and open the engine
cover;
6.2.2 Operate the engine cover lock to open

the engine cover;
6.2.3 Adjust four mounting bolts on the engine

cover hinge to adjust the engine cover.
The centering bolts on the engine cover
cannot be adjusted. Fig. 6-3 Schematic Diagram for Adjustment of
the Trunk Lid
6.3.4 Tighten each bolt securely.
49
6.3.5 Make sure the trunk lid can be opened 6.4.3 Remove the torsion bar retainer (A) from
normally and locked securely. the body.
6.3.6 Reinstall all the removed parts. 6.4.4 Install the torsion bar in the reverse order
of the removal and note the following:
6.4 Replacement of Trunk Lid Torsion Bar
6.4.4.1 The shape of the right torsion bar (D)
Notice: The special tool (B) is needed and left torsion bar (C) is shown in the
figure. Install them correctly;
6.4.1 Remove the torsion bar (D) and (C) from
the center retainer (A) on the torsion bar. 6.4.4.2 Adjust the torsion bar back and forth
with the torsion bar assembly tool (B);
6.4.4.3 Make sure the trunk lid can be opened

normally and locked securely.
Fig. 6-4 Retainer
6.4.2 Wear a pair of gloves to protect your

hands.
Remove the torsion bars from both hinges on
the trunk lid with a torsion bar assembly tool
(B). Remove the right torsion bar (D) first and
then the left torsion bar (C); Fig. 6-5 Schematic Diagram for Removal of
Trunk
50
Chapter 4 Chassis
Contents
Part 1 Intake System ..............................................................................................................................53
Part 2 Exhaust System ...........................................................................................................................57
Part 3 Cooling System ............................................................................................................................60
Section 1 473QE Cooling System ...........................................................................................60
Section 2 476ZQA Cooling System .........................................................................................62
Part 4 Fuel System .................................................................................................................................65
Section 1 Fuel Supply System .................................................................................................65
Section 2 Fuel Evaporation and Cleaning System ..................................................................71
Part 5 Suspension System .....................................................................................................................73
Section 1 Components Layout and Description of Suspension System .................................73
Section 2 Repair Suspension System (473QE-5T14) .............................................................80
Section 3 Repair 5AC/5AI Suspension System .......................................................................85
Section 4 Installation of Relevant Engine Accessories ...........................................................91
Part 6 Suspension System .....................................................................................................................92
Section 1 Suspension Overview ..............................................................................................92
Section 2 Front Suspension .....................................................................................................95
Section 3 Rear Suspension ................................................................................................... 118
Part 7 Power Steering System .............................................................................................................132
Section 1 Special Tools ..........................................................................................................132
Section 2 Diagram of Hydraulic Steering System Component Location ...............................133
Section 3 Symptoms and Troubleshooting ............................................................................135
Section 4 Troubleshooting .....................................................................................................137
Section 5 Overhauling of Steering Wheel, Steering Column and Universal Joint Assembly 140
Section 6 Power Steering Pump Pressure Test .....................................................................145
Section 7 Fluid Leakage Detection ........................................................................................146
Section 8 Steering Fluid Replacement...................................................................................148
Section 9 Power Steering Line Replacement ........................................................................149
Section 10 Pump Replacement .............................................................................................151
Section 11 Removal of Power Steering Gear ........................................................................153
Section 12 Installation of Power Steering Gear .....................................................................155
Section 13 Electric Power Steering (EPS) System ................................................................157
Part 8 Brake System .............................................................................................................................158
Section 1 Conventional Brake Components ..........................................................................158
Part 9 Drive Half Shaft ..........................................................................................................................176
Section 1 Half Shaft Detection ...............................................................................................176
Section 2 Half Shaft Removal ................................................................................................177
Section 3 Half Shaft Installation .............................................................................................178
Section 1 Half Shaft Detection ...............................................................................................179
51
Section 2 Half Shaft Removal ................................................................................................180

Section 3 Half Shaft Installation .............................................................................................181
Part 10 Gear Shift Control System .......................................................................................................183
Section 1 Gear Shift Mechanism Replacement (5A-5T14) ...................................................183
Section 2 Replacement of Gear Shift Mechanism (BYD476ZQA+6T25) ..............................184
Section 3 Gear Shift Control System (BYD476ZQA+6D T25)...............................................185
52
Part 1 Intake System

1.1 Intake System (473QE)
Fig. 1.1.2 Intake Hose Assembly
1 Q67580
Type A worm driven hose clamp
2 5A-1109311
Intake hose
3 BYDEG-1109118
Crank case vent pipe joint
4 5A-1109312
Crank case vent pipe
5 Q673B12F6
Steel band type elastic clamp
6 5A-1109313
Crank case vent pipe jacket
7 Q673B145F6
Steel band type elastic clamp
Fig. 1.1.1 Schematic Diagram of Intake Removal and Installation

System
1.1.1.1 Loosen the steel band type elastic
1.1.1 Removal/Installation Procedure of Intake clamp 5 and 7 for tightening the crank
Hose Assembly case vent pipe 4 using slip-joint pliers and
pull out the crank case vent pipe 4.
1.1.1.2 Loosen 2 type A worm driven hose

clamps 1 using a screwdriver and take off
the intake hose 2 to remove the intake
hose assembly.
1.1.1.3 Install each part in the reverse order of

removal.
2
1.1.2 Removal/Installation Procedure of Intake
Air Guide Pipe Assembly
3
7 6
53
1
1
4 2 2
2
3
3
3
4
Fig. 1.1.3 Intake Air Guide Pipe Assembly Fig. 1.1.4 Air Filter Assembly
1 5A-1109113 1 5A-1109211
Air Cleaner Joint Sealing Sponge Air Filter Upper Housing
2 Q1840616T1F3 Hexagon Flange Bolt 2 5A-1109212 Air Filter Element
3 5A-1109112 Intake Elbow 3 BYDQ83815 Clamp Spring
4 BYDQ831S02 Snap Fastener 4 5A-1109213

Air Filter Lower Housing
5 5A-1109111 Intake Pipe
5 Q150B0632T1F3
Removal and Installation Hexagon Combination Bolt
1.1.2.1 Remove the snap fastener 4 and take Removal and Installation
off the intake pipe 5;
1.1.3.1 Loosen the clamp spring 3 of upper
1.1.2.2 Remove the bolt 2 and take off the and lower housing fastener and remove
intake elbow 5 to remove the intake air the air filter upper housing 1.
guide pipe assembly;
1.1.3.2 Remove the air filter element 2.
removal. 1.1.3.3 Loosen the fastening bolt 5 on the
lower housing and remove the air filter
1.1.3 Removal/Installation Procedure of Air lower housing 4 to remove the air filter
Filter Assembly assembly.
54
1.1.3.4 Install each part in the reverse order 1.2.1.1.1 Loosen the steel band type elastic
of removal. clamp 9 and pull out the crank case vent
pipe 7;
1.1.4 Replacement of Air Filter Element
1.2.1.1.2 Remove the connecting bolt 6 on the
The element is designed to be used for upper and lower housing, remove the air
20,000 km. It is recommended to clean the filter upper housing 10 and take out the air
element every 5,000 km. The cleaning filter element 5;
method is to tap the element by hand after it
is removed to remove the dust from the 1.2.1.1.3 Remove the bolt 1;
element. Do not allow the dust to enter the
intake elbow and engine throttle valve or 1.2.1.1.4 Remove the air filter lower
attach on the upper surface of the element housing 4;
when the element is cleaned.
1.2.1.1.5 Install each part in the reverse order
Replacement Procedure (Fig. 4): of removal.
1.1.4.1 Loosen the clamp spring 3 of the 1.2.1.2 Replacement of Air Filter Element (Fig.
upper and lower housing fastener and 1.2.2)
remove the air filter upper housing 1.
The element is designed to be used for 20,000
1.1.4.2 Remove the air filter element 4. km. It is recommended to clean the element
every 5,000 km. The cleaning method is to tap
1.1.4.3 Install each part in the reverse order the element by hand after it is removed to
of removal. remove the dust from the element. Do not
allow the dust to enter the intake elbow and
1.2 Intake System (476ZQA) engine throttle valve when the element is
cleaned.
Replacement Procedure:
1.2.1.2.1 Remove the connecting bolt 6 on the

upper and lower housing;
1.2.1.2.2 Remove the air filter element 5 from

the air filter chamber;

of removal.
Fig. 1.2.1 Schematic Diagram of Intake

System
1.2.1 Replacement of Air Filter in Intake

System
I Replacement of Air Filter and Intake Hose
1.2.1.1 Removal/Installation Procedure of Air

Filter in Intake System (Fig. 1.2.2)
Fig. 1.2.2
55
1.2.1.3 Replacement of Intake Hose (Fig.

1.2.2)
1.2.1.3.1 Loosen the steel band type elastic

clamps 11 and 13, and remove the intake
hose 12.

of removal.
1.2.2 Removal and Installation of Intake Pipe

and Cavity Resonator (Fig. 1.2.3)
1.2.2.1 Remove the snap fastener 1, and take

off the intake pipe 2;
1.2.2.2 Remove the bolts 3 and 6 and take off

the rear section of intake guide pipe 4;

removal. Fig. 1.2.3
56
Part 2 Exhaust System

1.1 Exhaust System (473QE)
1.1.1 Removal and Installation of Exhaust Remove the baffle assembly and remove
System the hexagon flange bolt at the connection
between the middle section of the exhaust
1.1.1.1 If the front section of exhaust pipe pipe assembly and the front section of the
assembly needs to be removed: exhaust pipe assembly. Then remove the
hexagon flange bolt at the connection
Remove the oxygen sensor, and then between the middle section of the exhaust
remove the hexagon flange bolt at the pipe assembly and the rear section of the
connection between the front section of exhaust pipe assembly. At last take out the
exhaust pipe assembly and the exhaust middle section of the exhaust pipe
manifold. At last remove the hexagon assembly from the lug;
flange bolt at the connection between the
front section of exhaust pipe assembly and 1.1.1.3 If the rear section of exhaust pipe
middle section of the exhaust pipe assembly needs to be removed:
assembly (Note the front section of the
exhaust pipe assembly is not hung by the Remove the hexagon flange bolt at the
lug); connection between the rear section of
exhaust pipe assembly and the middle
1.1.1.2 If the middle section of exhaust pipe section of the exhaust pipe assembly and
assembly needs to be removed: then take out the rear section of exhaust
pipe assembly from the lug;
57
1.1.1.4 Install each part in the reverse order of b Use the specified mounting grease when
removal. the oxygen sensor is removed and reinstalled;
Notice: c Each section of the exhaust pipe

a The seal ring should be replaced when assembly should be removed first before the
each section of the exhaust pipe assembly is heat-insulating plate is removed.
removed and reinstalled to ensure the
tightness of the exhaust system meets the
requirements;
1.2 Exhaust System (476ZQA)
1.2.1 Removal and Installation of Exhaust section of exhaust pipe assembly (Note
System the front section of the exhaust pipe
assembly is not hung by the lug);
1.2.1.1 Remove the front section of exhaust
pipe assembly: 1.2.1.2 Remove the catalytic converter with
the exhaust pipe assembly:
Remove the rear oxygen sensor, and then
remove the hexagon flange nut at the Remove the wire harness on the front
connection between the front section of oxygen sensor and the catalytic converter
exhaust pipe assembly and the catalytic with the exhaust pipe assembly support.
converter with exhaust pipe assembly. Then remove the nut at the connection
Finally, remove the hexagon flange bolt at between the catalytic converter with the
the connection between the front section exhaust pipe assembly and the front
of exhaust pipe assembly and the middle section of the exhaust pipe assembly, and
58
remove the bolt at the connection between connection between the middle section of
the catalytic converter with the exhaust exhaust pipe assembly and the front
pipe assembly and the engine block. section of the exhaust pipe assembly.
Finally, remove the nut at the connection Then remove the hexagon flange bolt at
between the catalytic converter with the the connection between the middle section
exhaust pipe assembly and the of the exhaust pipe assembly and the rear
turbocharger (Note there is no lug on the section of the exhaust pipe assembly.
catalytic converter with the exhaust pipe Finally, take out the middle section of the
assembly); exhaust pipe assembly from the rubber lug
I;
1.2.1.3 Remove the exhaust pipe baffle
assembly: 1.2.1.5 Remove the rear section of the
exhaust pipe assembly:
The exhaust pipe baffle assembly can be
removed by removing the hexagon flange Remove the hexagon flange bolt at the
bolt for connecting the exhaust pipe baffle connection between the rear section of the
assembly and the body; exhaust pipe assembly and the middle
section of the exhaust pipe assembly, and
1.2.1.4 Remove the middle section of the then take out the rear section of the
exhaust pipe assembly: exhaust pipe assembly from the rubber lug
I;
Remove the exhaust pipe baffle assembly
and remove the hexagon flange bolt at the
59
Part 3 Cooling System

Section 1 473QE Cooling System
1.1 Location of Cooling System Components 1.3 Radiator Test
1.3.1 After the engine cools down, remove the

expansion tank cover carefully and fill the
coolant in the system until the level is
between the MAX marker (A) and MIN
marker (B).
1.3.2 Install the pressure instrument (available

in the market) on the radiator. Connect the
pressure instrument using a small mating
part H-901122-09 (available in the market).
1.3.3 Apply a pressure of 95 to 125 kPa.
1.3.4 Check the coolant for leakage and

pressure decrease.
1.3.5 Remove the instrument and reinstall the

expansion tank cover.
1.2 Expansion Tank Cover Test
1.3.6 Check if the engine oil and the coolant
1.2.1 When the engine and radiator cool down, are mixed.
remove the expansion tank cover (A),
apply some coolant on its seal ring and
then install the seal ring on the pressure
instrument (B) (available in the market).
Install the expansion tank cover using a
small mating part H-901122-09 (C)
(available in the market);
A
1.4 Coolant Inspection B
1.4.1 Expansion Tank Inspection
1.4.1.1 Observe the coolant level in the

expansion tank. Make sure the coolant
1.2.2 Apply a pressure of 95 to 125 kPa; level is between the MAX marker (A) and
the MIN marker (B);
1.2.3 Check if the pressure decreases;
1.4.1.2 If the coolant level in the expansion
1.2.4 If the pressure decreases, replace the tank is at or lower than the MIN marker, fill
expansion tank cover. the coolant in the water overflowing pot
until the MAX marker is reached and then
60
check the cooling system for leakage. 1.4.2.10 Repeat steps (9) and (10) until it is not
necessary to add the coolant;
Notice: The expansion tank level must be
inspected after the vehicle cools down 1.4.2.11 Tighten the expansion tank cover,
completely to avoid being burnt. start the engine again and check for
leakage.
1.4.2 Coolant Replacement
1.5 Replacement of Electronic Cooling Fan,
1.4.2.1 Start the engine and keep it idling until Radiator and Expansion Tank
the thermostat is fully opened. Then stop
the power drive assembly and remove the 1.5.1 Stop the power drive assembly and
key; remove the key;
1.4.2.2 Remove the expansion tank cover after 1.5.2 Open the radiator water drainage valve
the vehicle cools down completely; and drain the coolant after the vehicle
cools down;
1.4.2.3 Loosen the water drainage valve and
drain the coolant; 1.5.3 Disconnect the electronic cooling fan
power connector;
1.4.2.4 After the coolant is drained, tighten the
radiator water drainage valve; 1.5.4 Remove the radiator hoses and
connecting pipes;
1.4.2.5 Remove, drain and reinstall the
expansion tank; 1.5.5 Remove the expansion tank;
1.4.2.6 Fill the expansion tank with the coolant 1.5.6 Remove the heat sink upper suspended
specified by BYD until the MAX marker is assembly, the body upper cross bearer
reached; and the radiator;
Notice: Be sure to use BYD specified coolant. 1.5.7 Remove the electronic cooling fan
Otherwise the components may be corroded, assembly on the radiator;
the pipe lines may be blocked and the cooling
system may operate abnormally or 1.5.8 Remove the overflowed coolant;
malfunction. Coolant refilling volume:
(7000±200) ML. 1.5.9 Install the expansion tank, electronic
cooling fan and radiator in the reverse
1.4.2.7 Install the expansion tank cover order of removal and make sure the upper
loosely; and lower suspension rubber sleeve is
installed in place and fixed reliably;
1.4.2.8 Start the engine at idle speed and
warm up the engine (the fan operates at 1.5.10 Fill the cooling system with coolant and
least twice); bleed the air from the cooling system.
1.4.2.9 Stop the vehicle, inspect the coolant

level in the expansion tank after the
vehicle cools down and add the coolant if
necessary;
61
Section 2 476ZQA Cooling System

1.2.1 Location of Cooling System Components
1.2.2 Expansion Tank Cover Inspection
1.2.2.1 When the engine and radiator cool 1.2.2.4 If the pressure decreases, replace the
down, remove the expansion tank cover expansion tank cover.
(A), apply some coolant on its seal ring
and then install the seal ring on the 1.2.3 Radiator Inspection
pressure instrument (B) (available in the
market). Install the expansion tank cover 1.2.3.1 Remove the high and low temperature
using a small mating part H-901122-09 (C) radiator after the vehicle cools down
(available in the market); completely;
1.2.3 2 Fill the radiator with water, pour the

water out and drip the radiator for 5 min;
1.2.3.3 Block all the holes on the radiator and

immerse it in a water channel of normal
temperature. Fill the radiator with the
compressed air of 225 kPa and keep the
pressure for 60 seconds;
1.2.3.4 Check for air leakage by observing the

air bubbles.
1.2.2.2 Apply a pressure of 140 to 160 kPa; 1.2.4 Cooling Pipeline Inspection
1.2.2.3 Check if the pressure decreases; 1.2.4.1 After the engine cools down, remove
the expansion tank cover carefully and fill
62
the coolant in the system until the level is 1.5.2.1 Remove the expansion tank cover after
between the MAX marker (A) and MIN the vehicle cools down completely;
marker (B);
1.5.2.2 Remove the end of the high and low
1.2.4.2 Install the pressure instrument temperature radiator outlet hose
(available in the market) on the expansion connected to the radiator and drain the
tank. Connect the pressure instrument coolant;
using a small mating part H-901122-09
(available in the market); 1.5.2.3 Connect the high and low temperature
radiator outlet hose to the radiator after the
1.2.4.3 Apply a pressure of 140 to 160 kPa; coolant is drained;
1.2.4.4 Check each cooling water pipe end for 1.5.2.4 Remove, drain and reinstall the
coolant leakage; expansion tank;
1.2.4.5 Remove the instrument and reinstall 1.5.2.5 Fill the expansion tank with the coolant
the expansion tank cover; specified by BYD until the MAX marker is
reached;
1.2.4.6 Check if the engine oil and the coolant
are mixed. Notice: Be sure to use BYD specified coolant.
Otherwise the components may be corroded,
the pipe lines may be blocked and the cooling
system may operate abnormally or
malfunction.
The refilling volume of coolant is about 8.5 L.
1 5.2.6 Install the expansion tank cover

loosely;
A 1.5.2.7 Start the engine at idle speed and

warm up the engine (the fan operates at
B least twice);
1.5.2.8 Stop the vehicle, inspect the coolant

1.2.5 Coolant Inspection level in the expansion tank after the
vehicle cools down and add the coolant if
1.5.1 Expansion Tank Inspection necessary;
1.5.1.1 Observe the coolant level in the 1.5.2.9 Repeat steps (7) and (8) until it is not
expansion tank. Make sure the coolant necessary to add the coolant;
level is between the MAX marker (A) and
MIN marker (B); 1.5.2.10 Tighten the expansion tank cover,
1.5.1.2 If the coolant level in the expansion start the engine again and check for
tank is at or lower than the MIN marker, fill leakage.
the coolant in the expansion tank until the
MAX marker is reached and then check 1.2.6 Cooling System Replacement
the cooling system for leakage.
1.2.6.1 Stop the power drive assembly and
Notice: The expansion tank cover must be remove the key;
removed after the vehicle cools down
completely to avoid being burnt. 1.2.6.2. Remove the end of the high and low
temperature radiator outlet hose
1.5.2 Coolant Replacement connected to the radiator after the vehicle
cools down and drain the coolant;
63
1.2.6.3 Disconnect the electronic cooling fan 1.2.6.8 Remove the overflowed coolant;
power connector;
1.2.6.9 Install the expansion tank, electronic
1.2.6.4 Remove the cooling water pipe; cooling fan and radiator in the reverse
order of removal and make sure the upper
1.2.6.5 Remove the expansion tank; and lower suspension rubber sleeve is
installed in place and fixed reliably;
1.2.6.6 Remove the heat sink upper
suspended assembly and then remove the 1.2.6.10 Fill the cooling system with coolant
radiator; (refer to 3.5.2) and bleed the air from the
cooling system.
1.2.6.7 Remove the electronic cooling fan
assembly on the radiator;
64
Part 4 Fuel System

Section 1 Fuel Supply System
1.1 Release Fuel Pressure
Release the fuel pressure
When the BYD tester or BYD diagnosis

system is used
Before disconnecting the fuel pipeline or hose,

stop the fuel pump using the BYD tester or
BYD diagnosis system to release the fuel
pressure from the system. 1.1.4 Start the engine and keep it idling until it
stalls.
(a) Remove the fuel tank cap.
Notice: If any DTC is stored, clear and ignore
(b) Start the engine and keep it idling. it.
(c) Select "Fuel Pump OFF" in the inspection 1.1.5 Switch the ignition switch to OFF.
menu of the BYD tester or BYD diagnosis
system and then keep the engine idling 1.1.6 Remove the fuel tank cap and release
until the fuel pump stops. the fuel pressure in the fuel tank.
(d) Switch the ignition switch to OFF. 1.1.7 Disconnect the negative cable from
battery (A).
Notice:
The DTCs or temporary DTCs can be set in 1.1.8 Loosen the type A worm clamp (A).
this procedure. Check the DTCs and clear
them if necessary.
When the BYD tester or BYD diagnostic tester

is not used
Before disconnecting the fuel pipeline or hose,

disconnect the fuel pipe in the engine
compartment to release the fuel pressure from
the system.
1.1.1 Make sure the anti-theft password of the

audio and navigation system is known.
Then record the customer's preset radio
frequency. 1.1.9 Place a piece of rag or maintenance
cloth on the hose joint (A).
1.1.2 Switch the ignition switch to OFF.
1.1.10 Remove the hose (A) from the joint and
1.1.3 Remove the pedal and then remove the use a piece of rag or maintenance cloth
PGM-FI main relay 2 (FUEL MAIN) (A) to avoid the remaining fuel flowing out of
from the fuse box/relay case under the the fuel distributor or hose.
dashboard. Do not use any tool, or the hose may be
damaged.
65
1.1.11 After the hose is disconnected, check If the fuel pump runs, go to step 5.
for dirt or damage. If the fuel pump does not run, overhaul the
fuel pump circuit failure (See page
1.1.12 Reconnect the negative cable to the 11-195).
battery and perform the following
operations:
ECM/PCM idle speed learning program;
Power window control device reset

program;
Input the anti-theft password to the radio

and navigation system and then input
the user's preset radio frequency;
Reset the clock.

Make sure the combination length of the hose
1.1.12.1 Fuel Pressure Test and hard tube joint is proper and the clamp is
installed securely
1.12.5 Read the readings on the fuel pressure
a Fuel pressure gauge 07406-0040002 gauge. The pressure should be 320-370
b Fuel pressure gauge device kPa.
07ZAJ-S5A0100
a If the fuel pressure is normal, the test
1.1.12.2 Release the fuel pressure. ends.
Disconnect the hose joint (A). Connect the fuel Retaining support: If the fuel pressure does
pressure gauge device and fuel pressure not meet the technical requirements, replace
gauge. the fuel pressure regulator and fuel filter and
then recheck the fuel pressure.
1.12.6 Drain Fuel Tank
Remove the fuel pump assembly.

Pump out the fuel from the fuel tank with a
hand pump, a hose and a container for holding
gasoline.
1.12.7 Fuel Pipeline Inspection
Check the pipeline and hose in the fuel system

for damage, leakage and aging. Replace the
1.1.12.3 Start the engine and keep it idling. damaged parts.
a If the engine is started, go to step 5. Check all the retaining supports and pipe
b If the engine cannot be started, go to step clamps. Tighten them if necessary.
4
Notice: The oil supply hard tube, oil return hard
1.1.12.4 Check if the fuel pump runs. Remove tube, evaporation hard tube clamp and braking
the fuel tank cap and then monitor the fuel hard tube share some clamps which will be
filler. When the ignition switch is turned on clearly indicated in the brake system.
for the first time, the fuel pump should
operate for 2 seconds.
66
Precautions for Fuel Pipeline

The fuel pipeline connects the fuel rail (A) to
the fuel transfer hose (B), connects the fuel
transfer hose (B) to the fuel pipeline (C) and
connects the fuel pipeline (C) to the fuel tank
device (F). When removing or installing the
fuel filter, fuel pump and fuel tank, it is
necessary to disconnect or connect the fuel
pipeline.
Note the following precautions:

The fuel transfer hose (B), fuel pipeline (C),
fuel transfer hose (E) and fast connector (G)
are not heat-resistant. Do not damage these
parts when welding or performing other
heating operations.
The fuel transfer hose (B), fuel pipeline (C),

fuel transfer hose (E) and fast connector (G)
are not heat- resistant. Do not allow the towel
for wiping the battery electrolyte to contact
them. If the electrolyte or other similar liquid
contacts them, they should be replaced.
Do not over bend or twist the fuel transfer hose

(B), fuel pipeline (C), fuel transfer hose (E) and
fast connector (G) when connecting or
disconnecting them. Replace them if
damaged.
Removal of Fuel Pipeline/Fast Connector
1.12.7.1 Release the fuel pressure.
1.12.7.2 Loosen the type A worm clamp (A).
1.12.7.3 Place a piece of rag or maintenance

cloth on the hose joint (A). Remove the
hose (A) from the joint and use a piece of
rag or maintenance cloth to avoid the
remaining fuel flowing out of the fuel
distributor or hose.
1.12.7.4 Hold the male connector with the left

hand, and hold the fast connector with the
right hand. Press the fast connector button
in the direction indicated by the arrow with
two fingers. Remove the male connector
from the fast connector along the axial
direction of the pipe.
67
1.12.9.2 Install the male connector in place

along the axial direction of the fast connector.
·If the male connector deviates from the axis

too much, the O-ring in the fast connector
housing will be inserted obliquely or
misplaced.
·Insert the connector by hand until it is installed
in place and a "click" sound is heard.
1.12.8 Check the contact area (A) of the ·To check if the connector is installed in place,
pipeline (B) for dirt or damage. pull the connector in the opposite direction as
Clean the surface if it is dirty. shown below.
Replace the fuel pump, fuel filter or fuel
transfer pipeline if their surfaces are rusted
or damaged.
1.12.9 To avoid damage or contamination by

foreign matters, cover the disconnected
connector and ends of the pipeline with the
plastic bag (A).
1.2 Replacement of Fuel Filter
When the fuel pressure drops to below the

specified value, replace the fuel filter after
confirming the fuel pump and fuel pressure
regulator are normal.
1.2.1 Release the pressure in the fuel system.
1.2.2 Disconnect the fast connectors of oil inlet

Installation of Fuel Pipeline/Fast Connector and outlet tubes and drain the extra fuel to
1.12.9.1 Check the contact area (A) of the a proper container.
pipeline (B) for dirt or damage. Clean or
replace the pipeline if necessary. 1.2.3 Loosen the mounting bolts for the fuel
filter and support assembly.
1.2.4 Remove the fuel filter and support

assembly from the body.
Installation of Fuel Filter
(a) Remove the new protective cap of the fuel

filter.
68
(b) Install the fuel filter and support assembly 1.4 Replacement of Fuel Tank
on the body with the mounting bolts in the
correct direction. Removal
(c) Tighten the retaining bolts. 1.4.1 Release the fuel pressure.
(d) Connect the oil inlet and outlet tubes to 1.4.2 Remove the fuel tank service hole cover.
both ends of the oil line fuel filter.
1.4.3 Remove the fuel pump electrical
(e) Tighten the fuel tank cap. connector.
(f) Reconnect the battery negative cable. 1.4.4 Disconnect the filling hose (A) and filling
vent hose II (B).
(g) Turn on the ignition switch for 2 seconds,
turn it off for 10 seconds and then turn it on
to check for fuel leakage.
1.3 Replacement of Fuel Transfer Pump
Replace the fuel pump as necessary
1.3.1 Release the fuel pressure
1.3.2 Remove the fuel tank service hole cover
1.3.3 Remove the electrical connector of fuel

transfer pump
1.3.4 Remove the nylon inlet and outlet tubes

of the fuel transfer pump
1.4.5 Disconnect the nylon oil inlet tube I (A)
1.3.5 Remove the elastic collar of the fuel
and the fuel filter (C). Then disconnect the
transfer pump with circle pliers
nylon oil return tube (B) and the oil return
hard tube (D). Finally, disconnect the fuel
1.3.6 Remove the fuel transfer pump from the
evaporation hose III (E) and the oil return
fuel tank
hard tube (F).
Install the new fuel pump in the reverse order

of removal.
Notice: Make sure the O-ring is installed in

place when installing the new fuel pump
69
1.4.6 Remove the hexagon flange bolt (A), fuel 1.4.7 Lower the fuel tank on the ground with
tank fixing band (B) and fuel tank retaining special tools such as the jack or support.
support (C).
Installation
(a) Raise the fuel tank near the floor special

tools such as the jack or support. Align the
mounting holes of the fuel tank retaining
support and fuel tank fixing band with the
mounting holes of the floor, and then
tighten the hexagon flange bolts.
(b) Install other parts in the reverse order of

removal.
70
Section 2 Fuel Evaporation and Cleaning System
2.1 Diagram of Component Locations 2.2.4 Install each part in the reverse order of
removal.
2.2 Replacement of Charcoal Canister
Acceleration Drive System
2.2.1 Disconnect the fuel evaporation exhaust
hose I (A) and fuel evaporation exhaust 2.3 Adjustment of Throttle Cable
hose II (B).
2.3.1 Check the free travel of the pull cable at
the throttle linkage. The free travel of the
pull cable (A) should be 10-12 mm.
2.3.2 If the free travel is not as specified

(10-12 mm), loosen the locking nut (B),
turn the adjusting nut (C) until the
deflection is as specified and then tighten
the locking nut.
2.2.2 Remove the hexagon flange bolts (C).
2.2.3 Replace the charcoal canister (F).
71
2.3.3 After the correct adjustment of the pull

cable, check that the throttle valve fully
opens when the accelerator pedal is
depressed to the floor. Meanwhile, check
that the throttle valve returns to the idling
position when the accelerator pedal is
released.
2.4 Removal/Installation of Throttle Cable
2.4.1 Remove the engine hood.
2.4.2 Loosen the throttle valve completely and

then remove the throttle cable (A) from the
throttle linkage (B).
2.4.5 Perform the installation in the reverse

order of removal.
2.4.6 Keep the engine running at 3,000 rpm

with no load (P or Neutral) until the radiator
fan starts to rotate and then keep the
engine idling.
2.4.7 Hold the throttle cable and remove all the

loose parts from it.
2.4.8 Install a locking nut on the pull cable

2.4.3 Remove the cable sleeve (C) from the support (A) and adjust the adjusting nut (B)
pull cable support (D). so that the free travel is 0 mm.
2.4.4 Remove the throttle cable (A) from the 2.4.9 Remove the pull cable from the throttle
accelerator pedal (B). valve support (A). Reinstall the adjusting
nut (B) and tighten the locking nut (C).
2.4.10 With the correct adjustment of the pull

cable, check that the throttle valve fully
opens when the accelerator pedal is
depressed to the floor. Meanwhile, check
that the throttle valve returns to the idling
position when the accelerator pedal is
released.
72
Part 5 Suspension System

Section 1 Components Layout and Description of Suspension System
1.1 Components Layout
Fig. 1.1.1 473QE-5T14 Suspension Layout
73
Fig. 1.1.4 476ZQA-6T25 Suspension Layout
74
Fig. 1.1.5 476ZQA-6DT25 Suspension Layout
75
Fig. 1.1.6 473QE-5T14 Suspended Front Compartment Layout
Fig. 1.1.9 476ZQA-6T25 Suspended Front Compartment Layout
76
77
1.2 Description of Component Layout BYDQ32O12T13F3C hexagon flange nuts.
Engine front suspension mounting holder Engine rear suspension mounting support
assembly: assembly:
In the model 5A, it is installed on the
In the model 5A, it is installed on the cross transmission housing with three
bearer of the front sub frame with two Q1841025TF3 hexagon flange bolts.
Q1841225TF3 hexagon flange bolts.
In the model 5AA, it is installed on the
Engine front suspension mounting support transmission housing with three
assembly: Q1841225TF3 hexagon flange bolts.
In the model 5A, it is installed on the In the model 5AP, it is installed on the
transmission housing with two Q1841025TF3 transmission housing with three
hexagon flange bolts. Q1841260TF3 hexagon flange bolts.
In the model 5AA, it is installed on the In the model 5A, the rear suspension mounting
transmission housing with two Q1841225TF3 holder and support are connected by a
hexagon flange bolts. BYDQ184D1090TF3 bolt.
In the model 5AP, it is installed on the In the model 5AA, the rear suspension
transmission housing with two Q1841225TF3 mounting holder and support are connected by
hexagon flange bolts. a BYDQ184D1090TF3 bolt.
In the model 5A, the front suspension In the model 5AP, the rear suspension
mounting holder and support are connected by mounting holder and support are connected by
a BYDQ184D10100TF3 bolt and a a BYDQ184D10100TF3 bolt.
BYDQ350A10T13F3 hex nut.
Engine left suspension mounting holder
In the model 5AA, the front suspension assembly:
mounting holder and support are connected by
a BYDQ184D10100TF3 bolt and a In the model 5A, it is installed on the
BYDQ350A10T13F3 hex nut. longitudinal beam welding assembly LH with
four BYDQ1841225TF3 hexagon flange bolts.
In the model 5AP, the front suspension
mounting holder and support are connected by In the model 5AA, it is installed on the
a BYDQ184A10100TF3 bolt and a longitudinal beam welding assembly LH with
BYDQ350A10T13F3 hex nut. four Q1841225TF3 hexagon flange bolts.
Engine rear suspension mounting holder In the model 5AP, it is installed on the
assembly: longitudinal beam welding assembly LH with
In the model 5A, it is installed on the front sub four Q1841225TF3 hexagon flange bolts.
frame with two BYDQ184B1265TF3 hexagon
flange bolts and two BYDQ32O12T13F3C Engine left suspension mounting support
hexagon flange nuts. assembly:
In the model 5AA, it is installed on the front In the model 5A, it is installed on the
sub frame with two BYDQ184B1265TF3 transmission with two Q1841045TF3 hexagon
hexagon flange bolts and two flange bolts and a Q1841035TF3 hexagon
BYDQ32O12T13F3C hexagon flange nuts. flange bolt.
In the model 5AP, it is installed on the front In the model 5AA, it is installed on the
sub frame with two BYDQ184B1265TF3 transmission with four Q32012T13F3C
hexagon flange bolts and two hexagon flange nuts.
78
In the model 5AP, it is installed on the In the model 5AA, it is installed on the body
transmission with three Q1841040TF3 and right suspension mounting base
hexagon flange bolts. respectively with a Q1841225TF3 hexagon
flange bolt and two Q1841025TF3 hexagon
In the model 5A, the left suspension mounting flange bolts. In addition, the right suspension
holder and support are connected by a support is installed on the engine flange bolt
BYDQ18410140TF3 bolt and a with two Q32012T13F3C hexagon flange nuts
Q32010T13F3C hexagon flange nut. and the right suspension mounting base is
installed on the longitudinal beam welding
In the model 5AA, the left suspension assembly RH with two Q1841250TF3 hexagon
mounting holder and support are connected by flange bolts.
a BYDQ184D10110TF3 hexagon flange bolt
and a BYDQ350A10T13F3 hex nut. In the model 5AP, it is installed on the body
and right suspension mounting base with three
In the model 5AP, the left suspension Q1841225TF3 hexagon flange bolts. In
mounting holder and support are connected by addition, the right suspension support is
a BYDQ18412140TF3 hexagon flange bolt. installed on the engine flange bolt with two
Q32012T13F3C hexagon flange nuts and the
Engine right suspension assembly: right suspension mounting base is installed on
the longitudinal beam welding assembly RH
In the model 5A, it is installed on the with three Q1841235TF3 hexagon flange
longitudinal beam welding assembly RH and bolts.
the body with three Q1841225TF3 hexagon
flange bolts. In addition, the right suspension
support is installed on the engine flange bolt
with two Q32010T13F3C hexagon flange nuts.
79
Section 2 Repair Suspension System (473QE-5T14)

shown in figure 2.1.3) so as to remove the
Hang the power drive assembly with a crane engine right suspension mounting holder.
before removing the engine suspension.
2.1 Removal of Engine Right Suspension

Assembly
2.1.1 After 1 bolt is removed from the

expansion tank (as shown in figure 2.1.1),
remove the expansion tank from the
expansion tank support.
Fig. 2.1.3
2.2 Installation of Engine Right Suspension

Assembly
2.2.1 Place the new engine right suspension

mounting holder in the position as shown
Fig. 2.1.1 in figure 2.1.3, and then install and
tighten 3 hexagon flange bolts in the
2.1.2 Remove the steering line clamp (as mounting holes and 2 hexagon flange
shown in figure 2.1.2) from the nuts on the engine flange bolts.
suspension.
2.3 Removal of Engine Left Suspension
Assembly
2.3.1 Loosen the rack band on the intake

elbow near the engine and 2 clamp springs
on the air filter housing (as shown in figure
2.3.1) so as to remove the air filter upper
housing and element.
Fig. 2.1.2
2.1.3 Remove 3 hexagon flange bolts for

connecting the engine right suspension
assembly and the body and 2 hexagon
flange nuts connected to the engine (as
80
Fig. 2.3.3
Fig. 2.3.1 2.3.4 Remove 3 hexagon flange bolts for

connecting the left suspension mounting
2.3.2 Remove 3 bolts of the air filter lower support assembly and the transmission (as
housing from the left suspension holder shown in figure 2.3.4) so as to remove the
(as shown in figure 2.3.2) so as to remove left suspension mounting support
the air filter lower housing. assembly.
Fig. 2.3.2
Fig. 2.3.4
2.3.3 Remove 4 hexagon flange bolts for
connecting the left suspension mounting 2.4 Installation of Engine Left Suspension
holder and the body as well as 1 through Assembly
bolt and 1 hex nut for connecting the
holder and the support (as shown in figure 2.4.1 Place the new engine left suspension
2.3.3) so as to remove the left suspension mounting support assembly in the position
mounting holder. as shown in figure 2.3.4 and then tighten 3
hexagon flange bolts.
2.4.2 Place the new engine left suspension

mounting holder assembly in the position
as shown in figure 2.3.3 and then install
and tighten 4 hexagon flange bolts in the
81
corresponding mounting holes.
2.4.3 Adjust the engine profile to align the

mounting holes of left suspension support
and left suspension holder (as shown in
figure 2.3.3). Insert the bolts and install
and tighten the hex nuts.
2.5 Torque Inspection
2.5.1 Right Suspension
2.5.1.1 The tightening torque of 3 hexagon

flange bolts for connecting the engine right
suspension mounting holder and the body
is 80 Nm (as shown in figure 2.1.3). Fig. 2.6.1
2.5.1.2 The tightening torque of 2 hexagon 2.6.2 After the vehicle is raised with a lift,
flange nuts for connecting the engine right remove 2 hexagon flange bolts for
suspension mounting support and the connecting the front suspension mounting
engine flange bolts is 80 Nm (as shown in holder assembly and the sub frame cross
figure 2.1.3). bearer (as shown in figure 2.6.2) so as to
remove the engine front suspension
2.5.2 Left Suspension mounting holder assembly.
2.5.2.1 The tightening torque of 4 hexagon
flange bolts for connecting the engine left
suspension mounting holder and the body
is 80 Nm (as shown in figure 2.3.3).
2.5.2.2. The tightening torque of 3 hexagon

flange bolts for connecting the engine left
suspension mounting support and the
transmission is 80 Nm (as shown in figure
2.3.4).
2.5.2.3 The tightening torque of 1 through bolt

and 1 hex nut for connecting the engine
left suspension mounting support
assembly and the left suspension
mounting holder assembly is 80 Nm (as
shown in figure 2.3.3).
Fig. 2.6.2
2.6 Removal of Engine Front Suspension
Assembly 2.6.3 Remove 2 hexagon flange bolts for
connecting the front suspension support
2.6.1 After the crane is lowered, remove 1 assembly and the transmission (as shown
through bolt and 1 hex nut for connecting in figure 2.6.3) so as to remove the front
the front suspension mounting support suspension mounting support assembly.
assembly and the front suspension
mounting holder assembly (as shown in
figure 2.6.1).
82
Fig. 2.8.1
Fig. 2.6.3
2.8.2 Remove 1 through bolt and 1 hex nut for
2.7 Installation of Engine Front Suspension connecting the engine rear suspension
Assembly mounting holder and the rear suspension
mounting support and 2 bolts on the
2.7.1 Place the new engine front suspension steering line support (as shown in figure
mounting support assembly in the 2.8.2) so as to remove the engine rear
installation position as shown in figure suspension mounting holder assembly.
2.6.3 and then install and tighten 2
2.7.2 Place the new engine front suspension

mounting holder assembly in the
installation position as shown in figure
2.6.1. Then install 1 through bolt and 1 hex
nut for connecting the front suspension
mounting support assembly and the front
suspension mounting holder assembly.
Finally, install and tighten 2 hexagon
flange bolts for connecting the front
suspension holder and the sub frame
cross bearer as shown in figure 2.6.2.
2.8 Removal of Engine Rear Suspension

Assembly
Fig. 2.8.2
2.8.1 Remove 2 hexagon flange bolts and 2
hexagon flange nuts for connecting the 2.8.3 Remove 3 hexagon flange bolts for
engine rear suspension holder and the connecting the engine rear suspension
front sub frame (as shown in figure 2.8.1). support and the transmission (as shown in
figure 2.8.3) so as to remove the engine
rear suspension mounting support
assembly.
83
2.10.1 The tightening torque of 1 through bolt

and 1 hex nut for connecting the engine
rear suspension mounting support
assembly and the rear suspension
mounting holder assembly is 60 Nm (as
2.10.2 The tightening torque of 2 hexagon

flange bolts and 2 hexagon flange nuts for
connecting the engine rear suspension
mounting holder and the sub frame is 80
Nm (as shown in figure 2.8.1).
2.10.3 After the vehicle is raised, the tightening

Fig. 2.8.3 torque of 2 hexagon flange bolts for
connecting the engine front suspension
2.9 Installation of Engine Rear Suspension mounting holder assembly and the sub
Assembly frame cross bearer is 80 Nm (as shown in
figure 2.6.2).
2.9.1 Place the new engine rear suspension
mounting support assembly in the position 2.10.4 After the vehicle is lowered, the
as shown in figure 2.8.3 and then install tightening torque of 1 through bolt and 1
and tighten 3 hexagon flange bolts. hex nut for connecting the engine front
suspension mounting support assembly
2.9.2 Place the new engine rear suspension and the front suspension mounting holder
mounting holder assembly in the position assembly is 60 Nm (as shown in figure
as shown in figure 2.8.2. Install 1 through 2.6.1).
bolt and 1 hex nut for connecting the rear
suspension mounting support assembly
and the rear suspension mounting holder
assembly as well as 2 bolts on the steering
line support. Then install and tighten 2
hexagon flange bolts and 2 hexagon
flange nuts for connecting the rear
suspension holder and the sub frame as
shown in figure 2.8.1.
84
Section 3 Repair 5AC/5AI Suspension System

Hang the power drive assembly with a crane
before removing the engine suspension (The
following repair procedures are for 5AC/5AI
without special notes).
3.1 Removal of Power Drive Assembly Right

Suspension Assembly
3.1.1 After 2 bolts are removed from the

expansion tank (as shown in figure 3.1.1),
remove the expansion tank from the
expansion tank support.
Fig. 3.1.2
3.1.3 Remove 2 mounting bolts from the

steering fluid pot and 1 bolt of the steering
fluid pot support from the suspension so as
to remove the steering fluid pot support
and move away the steering fluid pot.
Fig. 3.1.1
3.1.2 Remove the bolts for connecting the right

suspension support assembly and the
body as well as the right suspension
support assembly and the right suspension
holder assembly (as shown in figure 3.1.2)
so as to remove the right suspension
support assembly.
Fig. 3.1.3
3.1.4 Remove 2 bolts of the right suspension

holder assembly from the right longitudinal
beam and remove 2 nuts for connecting
the right suspension holder assembly and
the engine flange bolt (as shown in figure
3.1.4) so as to remove the right
suspension holder assembly.
85
Fig. 3.1.4
Fig. 5.3.1
3.2 Installation of Power Drive Assembly Right
Suspension Assembly 3.3.2 Remove 3 mounting bolts from the air
filter (as shown in figure 5.3.2) so as to
3.2.1 Place the new power drive assembly remove the air filter lower housing.
right suspension holder assembly in the
position as shown in figure 3.1.4, and then
install and tighten 2 hexagon flange bolts
and 2 hexagon flange nuts.
3.2.2 Place the steering fluid pot support in the

position as shown in figure 3.1.3, and align
the steering fluid pot mounting holes with
the mounting holes on the support. Then
install and tighten 3 bolts.
3.2.3 Place the right suspension support

assembly in the position as shown in figure
3.1.2, and then install and tighten 2
3.3 Removal of Power Drive Assembly Left

Suspension Assembly
3.3.1 Loosen 2 rack bands on the intake hose, Fig. 3.3.2

and remove 4 bolts installed on the air filter
upper and lower housings (as shown in 3.3.3 Remove the nuts for connecting the left
figure 3.3.1) so as to remove the air filter suspension rubber gasket assembly and
upper housing and element. the left suspension support, and then
remove 4 bolts for connecting the left
suspension rubber gasket assembly and
the left suspension body connecting
support (as shown in figure 3.3.3) so as to
remove the left suspension rubber gasket
assembly.
86
Fig. 3.3.5 (Model 5AC)
Fig. 3.3.3
3.3.4 Remove 2 harness ties from the air filter

support and then remove 4 hexagon
flange bolts of the air filter support from the
left suspension body connecting support
(as shown in figure 3.3.4) so as to remove
the air filter support.
Fig. 3.3.5 (Model 5AI)
3.3.6 Model 5AC: Remove 2 nuts and 1 bolt

for connecting the left suspension support
assembly and the transmission (as shown
in figure 3.3.6-Model 5AC) so as to remove
the left suspension support assembly.
Fig. 3.3.4
3.3.5 Remove 4 hexagon flange bolts of the

left suspension body connecting support
from the left longitudinal beam (as shown
in figure 3.3.5) so as to remove the left
suspension body connecting support.
87
3.4 Installation of Power Drive Assembly Left

Suspension Assembly
3.4.1 Model 5AC: Place the new left

suspension support assembly in the
position as shown in figure 3.3.6-Model
5AC, and install and tighten 2 hexagon
flange nuts and 1 hexagon flange bolt.
Model 5AI: Assemble the new left suspension

support I and II with 2 hexagon flange bolts,
place them in the position as shown in figure
3.3.6-Model 5AI and then install and tighten 3
3.4.2 Position the left suspension body

Fig. 3.3.6 (Model 5AC) connecting support as shown in figure
3.3.5, and then install and tighten 4
Model 5AI: Remove 3 bolts for connecting the hexagon flange bolts.
left suspension support assembly and the
transmission (as shown in figure 3.3.6-Model 3.4.3 Place the air filter support in the position
5AI) so as to remove the left suspension as shown in figure 3.3.4, install and tighten
support assembly. Then remove 2 connecting 4 hexagon flange bolts and install the
bolts from the left suspension support harness tie.
assembly so as to remove the left suspension
support I and II. 3.4.4 Properly place the new left suspension
rubber gasket assembly in the position as
shown in figure 3.3.3, and install 4 bolts
and nuts. Tighten the nuts first and then
the 4 bolts.

flange bolt for connecting the right
suspension support assembly and the
body is 55±5 Nm (as shown in figure
3.1.2).

flange bolt for connecting the right
suspension holder assembly and the right
suspension support assembly is 24±2 Nm
(as shown in figure 3.1.2).

flange bolts for connecting the right
suspension holder assembly and the body
longitudinal beam is 55±5 Nm and the
tightening torque of 2 hexagon flange nuts
Fig. 3.3.6 (Model 5AI) for connecting the right suspension holder
assembly and the engine is 85±5 Nm (as
88
3.5.4 Model 5AC: The tightening torque of 2

hexagon flange nuts and 1 hexagon flange
bolt for connecting the left suspension
support assembly and the transmission is
85±5 Nm .
Model 5AI: The tightening torque of 2 hexagon

flange bolts for assembling the left suspension
support I and II is 55±5 Nm and the tightening
torque of 3 hexagon flange bolts for
connecting the left suspension support
assembly and the transmission is 55±5 Nm.
flange bolts for connecting the left
suspension rubber gasket assembly and
the left suspension body connecting
support is 55±5 Nm and the tightening
torque of 1 hexagon flange nut for
connecting the left suspension rubber
gasket assembly and the left suspension
support is 85±5 Nm.

flange bolts for connecting the left Fig. 3.6.1 (Model 5AC)
suspension body connecting support and
the body longitudinal beam is 85±5 Nm.

flange bolts for connecting the air filter
support and the left suspension body
connecting support is 24±2 Nm (as shown
in figure 5.3.4).
3.6 Removal of Power Drive Assembly Rear

Suspension Assembly
3.6.1 After lowering the engine crane, raise the

vehicle with a lift. Remove 1 hexagon
flange bolt for connecting the rear
suspension holder and rear suspension
support to the transmission, and then
remove 1 hexagon flange bolt for
connecting the rear suspension holder
assembly and the front sub frame as well
as 1 hexagon flange bolt for connecting
the rear suspension support assembly and
the transmission (as shown in figure 5.6.1)
so as to remove the rear suspension
holder assembly and the rear suspension
support assembly.
Fig. 3.6.1 (Model 5AI)
89
3.7 Installation of Power Drive Assembly Rear 3.8 Torque Inspection

Suspension Assembly
3.7.1 Place the rear suspension holder flange bolt for connecting the rear
assembly and rear suspension support suspension holder assembly and the front
assembly in the position as shown in figure sub frame is 110±10 Nm (as shown in
5.6.1, and install the bolts respectively. figure 3.6.1).
Finally, align the mounting holes on the
rear suspension holder assembly and rear 3.8.2 The tightening torque of 1 hexagon
suspension support assembly with the flange bolt for connecting the rear
mounting holes on the transmission, and suspension support assembly and the
then install and tighten each bolt in order. transmission as well as 1 hexagon flange
bolt for connecting the rear suspension
holder assembly and the rear suspension
support assembly to the transmission is
55±5 Nm (as shown in figure 5.6.1).
90
Section 4 Installation of Relevant Engine Accessories

4.1 Installation of Expansion Tank
4.1.1 Align the mounting pin on one side of the

expansion tank with the mounting hole on
the body expansion tank support and then
tighten the bolt for connecting the other
side of the expansion tank with the body
expansion tank support (as shown in figure
4.1.1).
Fig. 4.2.1
4.2.2 Insert the engine intake elbow into the air

filter outlet and tighten the clamp with a
slot-type screwdriver. Then put in the
element, cover the air filter upper housing
Fig. 4.1.1 and tighten 2 snap-fits on the air filter
housing (as shown in figure 5.2.2).
4.2 Installation of Air Filter
4.2.1 Place the removed air filter lower

housing in the installation position as
shown in figure 5.2.1, align 3 mounting
holes of the air filter on the left suspension
mounting holder and tighten 3
corresponding bolts.
Fig. 4.2.2
91
Part 6 Suspension System

Section 1 Suspension Overview
1.1 Diagram of Component Locations Wheel Suspension
positioning
1.1.1 Front Suspension Front Rear
parameter
Kingpin
caster 4.78~6.28 --
angle
Kingpin
10.57~12.47 --
angle
Wheel
-0.86~0.68 -1.88~-0.88
camber
Toe-in 0~2 -0.95~2.05
Inside: 35°45′±2°
Wheel
Outside: --
angle
29°30′±2°
Note:
1.2.1 If the kingpin caster angle and kingpin

angle of the front wheel are not as
specified, check if the suspension
components are twisted or damaged. If the
suspension components are twisted or
damaged, replace the damaged
components. Do not try to repair them by
1.1.2 Rear Suspension tapping or other ways.
1.2.2 If the front and rear wheel camber and

the rear wheel toe-in are not as specified,
check if the suspension components are
twisted or damaged. If the suspension
components are twisted or damaged,
Rear Helical Spring replace the damaged components. Do not
try to repair them by tapping or other ways.
1.2.3 If the front wheel toe-in is normal, but the

steering angle is not as specified or the
inside steering angles are different on both
left and right sides, check if the suspension
components are twisted or damaged. If the
suspension components are twisted or
damaged, replace the damaged
components. Do not try to repair them by
tapping or other ways.
1.2.4 The front wheel toe-in can be adjusted

1.2 Wheel Positioning with the suspension device.
Refer to the following table for wheel 1.2.4.1 Pre-positioning Inspection

positioning parameters:
92
For correct inspection and adjustment of wheel

positioning, please check the following:
1.2.4.1.1 Release the parking brake to avoid

incorrect measurement.
1.2.4.1.2 Make sure the suspension device

has not been modified.
1.2.4.1.3 Check the tire size and pressure

according to tire information.
1.2.4.1.4 Check the wheel run out (Refer to 1.4

for details).
1.2.4.1.5 Check each ball joint of suspension.

(Hold the wheel by hand, and move it up
and down, left and right to check its run 1.2.4.3 Rotate the rack end until the toe-in is
out.) correct.
Notice: Adjust the left and right wheels in the

opposite direction at the same time with the
same force so as to achieve the correct toe-in
and keep the steering wheel straight.
1.2.4.4 After the adjustment, hold the steering

tie rod and tighten the locking nuts. Make
sure the toe-in setting will not be changed.
1.3 Inspection of Wheel Bearing Axial

Clearance
1.3.1 Raise the vehicle, support it securely and

remove the wheel.
1.3.2 Install the proper flat washer (A) and

1.2.4.1.6 Bounce the wheel device up and wheel nuts, then tighten the nuts to the
down several times to stabilize the specified torque of 110 Nm and fix the
suspension brake disk on the wheel hub securely.
1.2.4.2 Adjust the Front Wheel Toe-in
1.2.4.2.1 Center the steering wheel spoke.
1.2.4.2.2 Hold the surface of the steering tie

rod with a wrench and loosen the locking
nuts of steering tie rod.
93
Front: 1.4 Inspection of Wheel Run out
1 4.1 Raise the vehicle and make sure it is

supported securely.
1.4.2 Check if the wheel is twisted or

deformed.
1.4.3 Place the dial gauge as shown in the

figure. Rotate the wheel and measure the
axial run out.
Notice: Standard value of front and rear wheel

axial run out:
Aluminum wheel: 0-0.7 mm

110 Nm Steel wheel: 0-1.0 mm
Usage limit: 2.0 mm
Rear
1.4.4 Place the dial gauge as shown in the

figure and measure the radial run out.
110 Nm
Notice: Standard value of front and rear wheel
radial run out:
1.3.3 Place a dial gauge on the wheel hub
Aluminum wheel: 0-0.7 mm
cover as shown in the figure and measure
Steel wheel: 0-1.0 mm
the bearing axial clearance by moving the
Usage limit: 1.5 mm
brake disk inside and outside.
Notice: Standard value of bearing axial

clearance:
Front wheel: 0.07-0.10 mm;
Rear wheel: -0.01-0.04 mm
1.3.4 If the bearing axial clearance is greater

than the standard value, replace the wheel
bearing.
94
Section 2 Front Suspension

2.1 Replacement of Front Vibration Damper Assembly
2.1.1 Disassemble 1.2.4.2 by Diagram:
95
Notice: The left and right vibration damper 2.1.2.7 Remove the connecting nuts of the
assemblies can be operated according to the transversal stabilizer bar tie rod end and
following steps. the vibration damper.
2.1.2 Removal
2.1.2.1 Disconnect the negative battery

terminal.
2.1.2.2 Remove the items near the installation

position of vibration damper on the body,
including the wiper cover, windshield wiper,
drain assembly, etc.
2.1.2.3 Lift the front compartment cover and

support the cover with a safety support at
the suitable position.
2.1.2.4 Remove the wheel nuts and front 2.1.2.8 Remove the connecting bolts of the
wheel. vibration damper and the steering knuckle.
2.1.2.5 Remove the wheel speed sensor wire

harness from the vibration damper
support.
Notice: Hold the nut using a wrench when

loosening the bolt.
2.1.2.6 Remove the brake hose retaining 2.1.2.9 Remove 3 nuts for connecting the
bracket. vibration damper and the body.
96
2.1.3 Disassembly 2.1.4.1 Check the front vibration damper

assembly
Tips: The disassembly procedures for the left
and right vibration dampers are the same. Compress and stretch the vibration damper
lever and check if there is abnormal resistance
2.1.3.1 Remove the dust cover. or sound during operation. Replace with a new
front vibration damper if any abnormity exists.
2.1.3.2 Remove the piston rod nut.
Install two sets of bolts and nuts on the U

clamp, and hold them using a fixture. Tighten
the spring using the special tools and remove
the piston rod nut (If the special tools are not
available, the iron wire can be used.)
Note:
2.1.3.2.1 To avoid damage to the helical

spring, wrap it with the insulating tape.
2.1.3.2.2 If the iron wire is used, do not loosen

the iron wire until the spring is reinstalled.
Warning:
2.1.3.3 Remove the vibration damper support
unit. 2.1.4.1.1 The gas is colorless, odorless and
harmless.
2.1.3.4 Remove the dust-proof gasket.
2.1.4.1.2 The debris may be scattered due to
2.1.3.5 Remove the front vibration damper the discharged gas, therefore cover the
spring upper seat unit. drilling machine using a piece of
workshop rag or cloth when drilling.
2.1.3.6 Remove the dust cover.
2.1.5 Reassembly
2.1.3.7 Remove the front vibration damper
spring. 2.1.5.1 Install the spring cushion.
2.1.3.8 Remove the buffer unit.
2.1.3.9 Remove the spring cushion.
2.1.4 Inspection and Treatment
97
2.1.5.9 Install the dust cover.
2.1.5.2 Compress the front helical spring using 2.1.5.10 Loosen the special tool (Remove the
the special tools and install the spring on iron wire if it is used).
the vibration damper (Install the spring
directly if it is fastened by the iron wire). 2.1.6 Installation
2.1.6.1 Install the nuts for connecting the

vibration damper and the body, and tighten
the nuts to the torque of 75 Nm.
Note:
2.1.5.2.1 To avoid damage to the helical spring,

wrap it with the insulating tape.
2.1.5.3 Install the buffer unit. 2.1.6.2 Install the connecting bolts of the
vibration damper and steering knuckle.
2.1.5.4 Install the dust cover. Align the mounting holes of the vibration
damper and the steering knuckle, insert
2.1.5.5 Install the front vibration damper spring the bolt, install and tighten the nuts to the
upper seat unit. torque of 235 Nm.
2.1.5.6 Install the dust-proof gasket.
2.1.5.7 Install the vibration damper support

unit.
2.1.5.8 Tighten a new piston rod nut using a

tool, to the torque of 47 Nm.
98
2.1 6.6 Install the front wheel, and tighten the

Notice: Do not tighten at first.
wheel nuts to the torque of 110 Nm.
2.1.6.3 Install the transversal stabilizer bar tie
2.1.6.7 Install the items on the top of the
rod end on the vibration damper using the
vibration damper (drain assembly, wiper,
nuts and tighten the nuts to the torque of
etc.).
80 Nm.
2.1.6.8 Lower the vehicle, and shake the
vehicle by hand several times. Then check
the front wheel camber. If the camber is
correct, tighten the connecting bolts of the
2.1.7 Inspection of Front Wheel Positioning
2.1.7.1 Shake the vehicle by hand several

times and stabilize the suspension.
2.1.7.2 Check the toe-in.
Toe-in:
2.1.6.4 Install the brake oil pipe on the
vibration damper oil pipe support. C-D (mm)
0-2
2.1.6.5 Install the wheel speed sensor wire

harness on the oil pipe support and U
clamp of vibration damper.
Tips: When the toe-in is not within the
99
specified range, adjust the tie rod end.

Camber, caster and kingpin angle:
2.1.7.3 Refer to 1.2.2 for toe-in adjustment.
Kingpin
Camber Caster
2.1.7.4 Check the wheel angle. angle
-0°04′±45′ 5°32′±45′ 11°43′±45′
Notice:
2.1.7.5.1 Keep the vehicle unloaded during

inspection (Leave the spare tire and tool box in
the vehicle).
2.1.7.5.2 The measurement error of camber

and caster of left and right wheels should be
30′ or less.
Tips:
2.1.7.5.3 The camber, kingpin caster angle and

kingpin angle cannot be adjusted.
2.1.7.4.1 Fully turn the wheel to the left and
right and determine the wheel angel. 2.1.7.5.4 If the measured value is not within
the specified range, check the
Wheel angle: suspension device and perform
measurement again. Replace the
Inside wheel Outside wheel suspension components if necessary.
35°45′±2° 29°30′±2°
2.1.7.4.2 If the inside angel of the left and right

wheels is not within the specified range,
check the length of left and right tie rod
end.
2.1.7.5 Check the camber, caster and kingpin

angle.
a Install a camber-caster-kingpin angle

tester in the center of the wheel hub or
drive shaft and place the front wheel on
the position.
b Check the camber, caster and kingpin

angle.
100
2.2 Replacement of Front Suspension Lower Swinging Arm Assembly
2.2.1 Disassembly Diagram
Notice: The left and right lower swinging arm

assemblies can be operated according to the
following steps.
2.2.2 Removal
2.2.2.1 Remove the wheel.
2.2.2.2 Remove the mounting bolts and nuts

on the lower swinging arm and front lower
swinging arm ball pin.
2.2.2.3 Remove the front and rear mounting

bolts of the lower swinging arm and sub
frame.
a Remove the rear mounting bolt on the

lower swinging arm.
101
b Install the rear mounting bolt and nut of

lower swinging arm and tighten it to 280
b Remove the front mounting bolt on the Nm.
lower swinging arm.
Notice: Check the front lower swinging arm

assembly for damage and check the rubber 2.2.3.2 Install the mounting bolt and nut of the
bush for ageing or damage. If the damage or lower swinging arm and front lower
rubber ageing occurs, replace the damaged swinging arm ball pin assembly and
front lower swinging arm or bush assembly tighten them to 120 Nm.
and never try to repair it. For 5AC
configuration, the removal of the right front
mounting bolt is affected by the position of the
power drive assembly, therefore the swinging
arm must be removed after the swinging arm
and the sub frame body are removed as a unit
(Refer to "Sub frame Removal" section for
removal of 5AC sub frame).
2.2.3 Installation
2.2.3.1 Install the front and rear mounting bolts

of the lower swinging arm and sub frame.
a Install the front mounting bolt of the lower

swinging arm and tighten it to 280 Nm.
2.2.3.3 Install the front wheel with the
tightening torque of 110 Nm.
Refer to section 2.1.7.
102
2.3 Replacement of Front Lower Swinging Arm Ball Joint Assembly
103
2.3.2 Removal
2.3.2.1 Remove the front wheel.
2.3.2.2 Remove the wheel speed sensor.
a Remove the wheel speed sensor wire

harness of the vibration damper from the
support.
b Then separate the brake caliper from the

brake disk, and hang the brake caliper with
a string or corresponding device.
b Separate the wheel speed sensor from the

steering knuckle.
2.3.2.4 Remove the split pin (A) from the drive

shaft and loosen the slotted nut (B).
2.3.2.3 Remove the brake caliper.
a Remove the brake oil pipe support from

the vibration damper.
2.3.2.5 Remove the connecting bolts and nuts
of the front lower swinging arm and front
lower swinging arm ball pin.
104
Notice: Do not damage the dust cover.
2.3.2 7 Remove the mounting bolts and nuts of

the vibration damper and steering knuckle.
2.3.2 6 Disconnect the steering tie rod ball joint

from the steering knuckle.
a Remove the split pin.
b Remove the slotted nut.

2.3.2 8 Tap the half shaft end face with a
rubber hammer and take out the steering
knuckle and front lower swinging arm ball
pin assembly.
2.3.2 7 Separate the steering tie rod ball joint

from the steering knuckle using the special
tools.
Notice: Do not tap too hard.
2.3.2.9 Separate the front lower swinging arm

Special ball pin from the steering knuckle with
Tool the special tools.
105
Notice: If the slot of the slotted nut is not

aligned with the ball joint hole, turn the slotted
nut again.
2.4.3.2 Install the brake disk together with the

ball joint on the half shaft.
Notice: Do not damage the dust cover.
2.3.3 Inspection
2.3.3.1 As shown in the figure, turn the ball pin

back and forth 5 times before installing the 2.4.3.3 Install the connecting bolt of the
slotted nut.
2.3.3.2 Turn the nut at a speed of 3 to 5
seconds per round with a torque wrench
and then read the torque for the fifth round.
Torque: 0.5 to 4.9 Nm.
2.4.3.4 Install the steering tie rod ball joint on

the steering knuckle
a Install the slotted nut with the tightening

torque of 50 Nm.
2.3.4 Installation
2.3.4.1 Install the front lower swinging arm ball

pin assembly on the steering knuckle.

torque of 120 Nm.
b Install a new split pin.
106
2.4.3.7 Install the brake caliper.
b Install a new split pin. a Install the brake caliper on the steering
knuckle with the tightening torque of 107
Notice: If the hole of the tie rod ball joint is not Nm.
aligned with the slot of the slotted nut, turn the
slotted nut.
2.4.3.5 Connect the lower swinging arm

assembly and the lower swinging arm ball
pin using the previously removed bolt and
nut with the tightening torque of 120 Nm.
b Install the brake oil pipe on the vibration

damper bracket.
2.4.3.6 Fix the half shaft on the wheel hub

using a slotted nut.
a Install the gasket and slotted nut, with the

2.4.3.8 Install the wheel speed sensor wire

harness.
107
a Install the wheel speed sensor clips on the

vibration damper bracket and U clamp.
b Install the wheel speed sensor on the

steering knuckle. 2.4.3.9 Install the wheel with the tightening
torque of 110 Nm.

108
2.4 Replacement of Stabilizer Bar and Tie Rod End Assembly
109
2.4.2 Removal
2.4.2.2 Remove two mounting nuts on the

stabilizer bar link. Remove the
stabilizer-bar link and ball joint assembly.
2.4.3 Inspection
a As shown in the figure, swing the ball pin

back and forth 5 times before installing the
nut.
b Turn the nut at a speed of 3 to 5 seconds

per round with a torque wrench and then
read the torque for the fifth round. The
2.4.2.3 Remove the left and right lower torque is 0.05 to 1.96 Nm.
swinging arm assembly. Refer to section
2.2.
2.4.2.4 Remove the left and right stabilizer bar

pressure plate.
2.4.4 Installation
2.4.4.1 Install the transversal stabilizer bar.
2.4.2.5 Remove the stabilizer-bar assembly. a Install the transversal stabilizer bar and
bush as shown in the figure.
a Pull out the stabilizer bar together with the
stabilizer bar bush from the sub frame.
b Take out the stabilizer bar from the bush.
110
2.4.4.4 Install two nuts of the transversal

stabilizer bar link with the tightening torque
of 80 Nm.
b Install the transversal stabilizer bar

together with the bush on the relevant
position of the sub frame.
2.4.4.2 Install the left/right transversal

stabilizer bar pressure plate with the 2.4.4.5 Install the wheel and wheel nuts, and
tightening torque of 90 Nm. tighten them to the torque of 110 Nm.
2.4.4.3 Install the front lower swinging arm

assembly. Refer to section 2.2.3.
111
2.5 Replacement of Front Sub frame Body
112
2.5.2 Removal b Remove the slotted nut.
2.5.2.2 Disconnect the steering gear and the

steering column.
2.5.2.3 Disconnect the steering high pressure

oil pipe and the engine steering pump.
2.5.2.4 Raise the vehicle and disconnect the

steering low pressure oil pipe and the
steering gear (separate from the hose).
2.5.2.5 Remove the stabilizer bar and the

stabilizer bar link lower connecting nut.
c Separate the steering tie rod ball joint from

the steering knuckle using the special tool.
2.5.2.6 Remove the mounting bolts and nuts of

the swinging arm and swinging arm ball
pin assembly.
2.5.2.8 Disconnect the sub frame and rear
suspension:
a. Disconnect the non-5AC sub frame and

rear suspension: Remove two bolts and
two nuts for connecting the sub frame
body and engine rear suspension.
2.5.2.7 Disconnect the steering tie rod ball

joint and the steering knuckle.
a Remove the split pin.
113
b. Disconnect the 5AC sub frame and rear

suspension: Remove one bolt for
connecting the sub frame and engine rear
2.5.2.10 Remove two front mounting bolts on
suspension.
the sub frame body and the vehicle body.
2.5.2.9 Support the sub frame body assembly Notice: Pass an extension bar through the
using a lifting device. Remove four swinging arm sleeve to remove the bolts.
connecting bolts of the sub frame body
and longitudinal beam and six connecting 2.5.2.11 Lower the lifting device and lower the
bolts of the front sub frame bracket and the sub frame as well.
body.
2.5.2.12 Remove the front and rear mounting
a Support the sub frame using a small lifter. bolts of the left/right front lower swinging
arm and sub frame.
b Remove the connecting bolts of the
left/right longitudinal beam and sub frame a Remove the rear mounting bolt on the front
as shown in the figure A. lower swinging arm.
c Remove the connecting bolts of the

bracket and body as shown in the figure B.
d Remove the connecting bolt of the bracket

and sub frame as shown in the figure C.
114
2.5.3 Inspection
b Remove the front mounting bolt on the Check the sub frame body assembly for
front lower swinging arm. deformation or cracks and check the rubber
bush for aging or damage. If the sub frame
body assembly is deformed or damaged or the
rubber bush is aged, replace the damaged sub
frame body or bush assembly. Do not try to
repair them.
2.5.4 Installation
2.5.4.1 Install the steering gear with the

tightening torque for two bolts of 90 Nm.
2.5.2.13 Remove the left/right stabilizer bar

bush pressure plate.
2.5.4.2 Install the stabilizer bar together with

the bush on the relative position of the sub
frame.
2.5.2.14 Take out the stabilizer bar and bush
from the sub frame. 2.5.4.3 Install the stabilizer bar bush pressure
plate bolts with the tightening torque of 90
2.5.2.15 Remove two mounting bolts on the Nm.
steering gear.
115
frame body and the vehicle body, with the

2.5.1.4 Install the front and rear mounting bolts

of the left/right front lower swinging arm
and sub frame body. Notice: Pass an extension bar through the
swinging arm sleeve to install the bolt.
a Install the rear mounting bolt of the
swinging arm with the tightening torque of c Install the connecting bolt of the sub frame
280 Nm. bracket and sub frame as shown in the
figure C, with the tightening torque of 160
Nm.
d Install the mounting bolts of the bracket

and body as shown in the figure, with the
e Install the connecting bolts of the left/right

longitudinal beam and sub frame body as
shown in the figure, with the tightening
torque of 110 Nm.
b Install the front mounting bolt of the

swinging arm with the tightening torque of
280 Nm.
2.5.4.5 Install the connecting bolt of sub frame

body.
2.5.4.6 Install the connecting bolts and nuts of
a Align the sub frame with the body the sub frame body and engine rear
mounting hole location and lift them with a suspension, with the tightening torque of
small lifting device. 100 Nm.
b Install the front connecting bolt of the sub
116
2.5.4.9 Install the steering tie rod ball joint on

the steering knuckle.

torque of 50 Nm.
2.5.4.7 Install the mounting bolts and nuts of

the left/right front lowering swinging arm
and lower swinging arm ball pin. The
b Install a new split pin.
Notice: If the hole of the tie rod ball joint is not

aligned with the slot of the slotted nut, turn the
slotted nut slightly.
2.5.4.10 Install the steering low pressure oil

pipe.
2.5.4.8 Install the stabilizer bar and stabilizer 2.5.4.11 Install the wheel with the tightening
bar link lower connecting nuts and the torque of the wheel nut of 110 Nm.
2.5.4.12 Install the steering high pressure oil
pipe and engine steering pump.
2.5.4.13 Refill the steering fluid.

117
Section 3 Rear Suspension

3.1 Replacement of Rear Helical Spring
3.1.1 Disassembly Diagram:
118
3.1.2 Removal a Lower the jack slightly and slowly.
3.1.2.1 Remove the rear wheel. b Remove the helical spring and the
upper/lower cushion of the helical spring.
3.1.2.2 Raise the vehicle.
3.1.2.6 Remove the right rear helical spring.
3.1.2.3 Detach the left rear vibration damper
assembly. Tips: The removal procedures for the right side
are the same as that of the left side.
a Support both ends of the rear torsion beam
with a jack and place a wood block 3.1.3 Installation
between the jack and rear torsion beam to
avoid damage. 3.1.3.1 Install the left rear helical spring.
3.1.3.2 Install the helical spring lower rubber

gasket on the rear torsion beam.
B Remove the bolt and nut, and detach the

left rear vibration damper. 3.1.3.3 Install the helical spring upper cushion
and match its notch with the spring end.
3.1.2.4 Detach the right rear vibration damper

assembly.
3.1.3.4 Install the helical spring on the rear
Tips: The removal procedures for the right side torsion beam.
3.1.2.5 Remove the left rear helical spring.
119
3.1.3.8 Fully tighten the rear vibration damper

assembly. Fully tighten two bolts. The
3.1.3.9 Install the rear wheel. The tightening

torque is 110 Nm.
Notice: The lower part of the helical spring with

the paint mark should be installed in the rear of
the vehicle.
3.1.3.5 Install the right rear helical spring.
Tips: The installation procedures for the right

side are the same as that of the left side.
3.1.3.6 Pre-tighten the left rear vibration

damper assembly.
a Raise the rear torsion beam assembly

slowly and install the vibration damper
(lower end) on the torsion beam.
b Pre-tighten the bolt to the tightening torque

of 115 Nm.
3.1.3.7 Pre-tighten the right rear vibration

damper assembly.

120
3.2 Replacement of Rear Vibration Damper Assembly
121
3.2.2 Removal 3.2.2.4.2 Take out the spring if necessary

to avoid popup.
3.2.2.1 Fold down the rear seat forward.
c Fix the piston rod and remove the nut.
3.2.2.2 Remove the trunk side panel.
Note:
3.2.2.4.3 Fix the bolt by holding an Allen

tool with one hand, and loosen the
nut by holding a wrench with one
hand.
3.2.2.3 Remove the rear wheel.
3.2.2.4 Remove the rear vibration damper

assembly. d Remove the rear vibration damper metal
gasket and upper supporting pad unit.
a Support the rear torsion beam with a jack
and place a wood block between the rear e Remove the rear vibration damper.
torsion beam spring seat and jack to avoid
damage. 3.2.3 Inspection and Treatment
b Remove the connecting bolts and nuts of 3.2.3.1 Check the upper supporting pad unit
the rear vibration damper and torsion and lower supporting pad for any damage.
beam. Replace them if necessary.
3.2.3.2 Check the dust cover for any damage

and check if the buffer block is separated
from the dust cover. Replace the dust
cover assembly if necessary.
3.2.3.3 Check the rear vibration damper.
Compress and stretch the vibration damper

piston rod and check whether there is
abnormal resistance or sound during operation.
Replace with a new rear vibration damper if
any abnormity exists.
Note:
3.2.2.4.1 Support the rear torsion beam

securely and strap the spring with
the iron wire to avoid popup.
122
The tightening torque is 45 Nm.
Notice:
As shown in the figure, tighten the nut until at
least 3 threads can be seen.
Note:
When dealing with the rear vibration damper:
a Fully stretch the vibration damper piston

rod.
b Drill a hole in any position between A and

B with a drilling machine as shown in the
figure to bleed the air.
d Place a wood block between the rear

torsion beam spring seat and jack.
e Raise the rear torsion beam slowly and

Note: install the rear vibration damper with the
bolts. The tightening torque is 115 Nm.
3.2.3.3.1 The gas is colorless, odorless and
harmless.
3.2.3.3.2 The debris may be scattered due to

the discharged gas, therefore cover
the drilling machine using a piece of
workshop rag or cloth when drilling.
3.2.4 Installation
3.2.4.1 Install the rear vibration damper

assembly
a Install the dust cover and lower supporting

pad on the damper.
3.4.3.2 Install the rear wheel.
b Install the damper, upper supporting pad
unit and metal gasket on the body. The tightening torque is 110 Nm.
c Fix the piston rod and install the nut. 3.4.3.3 Install the trunk side panel.
123
3.3 Replacement of Rear Torsion Beam Assembly
124
3.3.2 Removal
3.3.2.1 Detach the negative battery cable.
3.3.2.2 Remove the rear wheel.
3.3.2.3 Drain brake fluid.
Notice: Remove the brake fluid on any painted

surface quickly to avoid corrosion.
3.3.2.4 Remove the fuel tank lower cross

bearer.
c Remove the E-shape clamp.
Tips: The removal procedures for the right side

3.3.2.6 Detach the left rear wheel speed

sensor
a Separate the left rear wheel speed sensor

and brake.
3.3.2.5 Detach the left parking pull cable and

brake caliper.
a Loosen the parking control rod.
b Detach the pull cable from the brake

caliper with needle nose pliers. b Remove the nut and detach two clamps.
125
3.3.2.9 Detach the left rear parking pull cable

and torsion beam.

3.3.2.7 Detach the left rear flexible hose.
a Fix the left rear flexible hose with a wrench Tips: The removal procedures for the right side
and disconnect the brake pipe with a are the same as that of the left side.
connecting nut wrench.
3.3.2.10 Loosen the rear torsion beam
assembly.
Notice: Loosen two bolts, but do not remove

them.
3.3.2.11 Detach the left rear vibration damper

b Remove the nut and detach the left rear assembly
flexible hose.
a Support the left and right ends of the rear
Notice: Do not damage the rear brake pipe torsion beam with a jack and place a wood
and flexible hose. block between the jack and rear torsion
beam spring seat to avoid damage.
3.3.2.8 Detach the right rear flexible hose.
b Remove the bolt and detach the rear
Tips: The removal procedures for the right side vibration damper.
126
3.3.2.16 Remove the rear torsion beam upper

brake pipe.
3.3.2.12 Detach the right rear vibration damper
assembly. a Disconnect the connecting points A, B, C
and D.
3.3.2.13 Remove the left rear helical spring.
a Lower the jack slowly.
b Remove the rear helical spring and upper

and lower cushion.
3.3.2.14 Remove the right rear helical spring.
Tips: The removal procedures for the right side b Remove all pipe lines.
3.3.2.17 Remove the left/right rear brake
3.3.2.15 Remove the rear torsion beam assembly.
assembly.
3.3.3 Bush Replacement
a Remove two bolts and rear torsion beam
assembly. If the bush is damaged, replace it.
3.3.3.1 Remove the left rubber bush.
a Make a marker on the rear torsion beam

and align it with the marker on the bush.
b Twist two parts on the bush fin with a

chisel and hammer.
Tips:
Twist the bush fin until the paw of the special
tool is in the air. Marker
b Support the left and right sides of the

spring seat with the supporting device and
lower it slowly.
127
Tips:
The removal procedures for the right side are
the same as that of the left side.
3.3.3.3 Install the left rubber bush.
a Align the markers on the new bush and

rear torsion beam and then install the
rubber bush.
b Install the bush on the rear torsion beam

Fin with the special tool.
Notice:
a Do not scratch the rubber part of the bush.
b Do not deform the bush fin.
c Remove the bush from the rear torsion

beam with a special tool.
Note:
3.3.3.4 Install the right rear rubber bush
Tips:
The installation procedures for the right side
3.3.4 Installation
3.3.4.1 Install the left/right rear brake

assembly on the rear torsion beam.
Repair the scratches on the rear torsion beam
3.3.4.2 Install the brake oil pipe on the rear
with the paint.
torsion beam. The tightening torque for B
and C is 10 Nm and the tightening torque
3.3.3.2 Remove the right rubber bush.
for A and B is 10 Nm.
128
b Install the helical spring upper cushion and

match its notch with the spring end.
3.3.4.3 Pre-tighten the rear torsion beam

assembly temporarily.
a Support the rear torsion beam with a jack.
b Install the rear torsion beam on the vehicle

and temporarily tighten two bolts.
c Install the helical spring on the rear torsion

beam.
3.3.4.4 Install the left rear helical spring.

Note:
a Install the helical spring lower cushion on
the rear torsion beam.
The lower part of the helical spring with the
paint mark should be installed in the rear of the
vehicle.
3.3.4.5 Install the right rear helical spring.

3.3.4.6 Pre-tighten the left rear vibration

damper assembly.
a Raise the rear torsion beam assembly

slowly and install the vibration damper
(lower end) on the torsion beam.
b Pre-tighten the bolt.
129
3.3.4.7 Pre-tighten the right rear vibration

damper assembly. 3.3.4.9 Install the right rear parking pull cable.
Tips: Tips:
The installation procedures for the right side are the same as that of the left side.
3.3.4.10 Install the left rear brake hose with the
3.3.4.8 Install the left rear parking pull cable. tightening torque of 20 Nm.
a Install the bolts of the brake control cable

and torsion beam with the tightening
torque of 10 Nm.
Note:
Do not damage the rear brake pipe and
b Install a new E-shape clamp and connect flexible hose.
the cable and brake caliper.
3.3.4.11 Install the right rear brake hose to the
body.
Tips:
130
3.3.4.12 Install the left rear wheel speed (14) Fully tighten the left/right rear vibration
sensor. damper assembly. Fully tighten 2 bolts to
the torque of 115 Nm.
a Install the left rear wheel speed sensor on
the brake.
3.3.4.14 Fully fill the brake fluid tank. The

b Install the nuts and tighten them to the brake fluid specification is DOT4
torque of 10 Nm. Then install 2 clamps.
3.3.4.15 Air bleeding: Bleed the air out of the
brake pipe.
3.3.4 16 Inspect the brake fluid level in the

reservoir.
a Check the fluid level and add the brake

fluid if necessary.
b Brake fluid specification: DOT4
3.3.4.17 Install the rear wheel.

side are the same as that of the left side. 3.3.4.18 Connect the wire to the negative
battery terminal.
3.3.4.13 Tighten the rear torsion beam
assembly completely. Fully tighten 2 Tightening torque: 10 Nm
bolts to the torque of 160 Nm.
3.3.4.19 Check if the brake fluid leaks.
3.3.5 Inspection of Rear Wheel Parameters

Refer to section 1.2
131
Part 7 Power Steering System

Section 1 Special Tools
No. Name
(1) Ball Joint Remover 28 mm
(2) P/S Pressure Gauge
132
Section 2 Diagram of Hydraulic Steering System Component Location

1. Models with 473QE engine
133
2. Models with 476ZQA engine
134
Section 3 Symptoms and Troubleshooting

Find the type of symptom in the table below, carry out the procedures in the order as listed until
you find out the reason.
Symptoms and Troubleshooting
Symptom Procedure Other Items for

Inspection
Steering Troubleshooting of the whole system Damaged suspension
Difficulty Tire dimensions, tire
pressure change, air
pressure.
Power Assist Check the steering oil pump
(The steering
wheel is light at
high speed)
Unsmooth 1 Check the steering gear oil reservoir and piping
recovery of for any deformation.
steering wheel 2 Check the wheel alignment.
Uneven or 1 Check the drive belt.
unstable 2 Check if the engine idling speed is too low or
steering abnormal.
3 Check if air enters the power steering system
due to low oil level or if the air leaks from the oil
inlet hose of power steering oil pump.
4 Check if the oil level in the power steering oil
reservoir is low due to leakage in the power
steering system.
5 Check the power steering gear.
Buzzing 1 When there is noise, check: When it is cold, if Oil pump pressure
the noise lasts for 2~3 minutes after the engine is
started, it is normal. When the vehicle is stopped,
if the noise can still be heard while the steering
wheel is turned, it is also normal. The noise is
generated due to oil pressure pulse.
2 Check the high-pressure hose for any contact
with the frame or vehicle body.
3 Check the power steering fluid for any bubbles.
Clicking sounds 1 Check the loose steering components (steering
(of gear racks) tie rod and ball joints) and tighten or replace them
when necessary.
2 Check the steering column and universal joint
assembly. Replace the steering column and
universal joint assembly if it is abnormal.
3 Check the pulley of power steering oil pump. If
the pulley is slack, tension it. If the steering oil
pump shaft is loose, replace the power steering oil
pump.
Hissing sounds 1 Check the oil level. If it is low, replenish oil into There is air in the power
the oil reservoir to a suitable level. steering fluid
2 Check for leakage. Check the oil reservoir for
any leakage.
135
3 Inspect the oil inlet hose of the steering pump for

any cracking and the clamps for any looseness,
either of which may let air into the steering system.
4 Inspect the oil seal of the power steering oil
pump shaft for any leakage.
5 Check the power steering gear. If abnormal
noise occurs at the valve body, replace the power
steering gear assembly.
Pump noise 1 In normal working temperatures, compare the Pressure in the power
differences between the sound of the power steering pump
steering oil pump of the vehicle and that of other There is air in the power
vehicles of the same type. (In cold weather, it is steering fluid
normal for pump noise to last for 2~3 minutes after
the engine is started.)
2 Replace the power steering oil pump.
Howling sounds Check the drive belt.
Oil leakage from Replace the power steering gear.
the power
steering gear
Oil leakage from 1 Oil leakage at the connections of pump piping
piping (connecting nuts): Tighten the connections and
recheck.
2 Oil leakage at damaged parts of pump piping:
Replace the power steering gear.
3 Oil leakage at the connections between the
pump outlet hose or return hose and the valve
(connecting nuts): Tighten the connections and
recheck. If there is still leakage, replace the piping
or pump when necessary.
4 Oil leakage at the connections between the soft
tube and rigid tube of steering oil pipe: Replace
the clamp, and replace the oil pipe when
necessary.
Oil leakage from Replace the power steering pump.
the power
steering pump
Oil leakage from 1 Oil leakage around the cap of oil reservoir: The
the oil reservoir oil level is too high. Release some oil until the oil
level is suitable.
2 There is air in the oil: Inspect the inlet of pump
for any air leakage.
3 Oil leakage from the oil reservoir: Inspect the oil
reservoir for any damage and replace it when
necessary.
Oil leakage from 1 Check the bolts for any looseness.
high-pressure 2 Replace the high-pressure steering oil pipe.
steering oil pipe
Oil leakage from Inspect the oil inlet hose for any damage, aging or
the oil inlet hose incorrect fitting. Perform replacement or repair
of power when necessary.
steering oil
pump
136
Section 4 Troubleshooting
play 2) Suspension arm ball joints
4.1 Troubleshooting Precautions (worn)
3) Intermediate shaft, sliding
4.1.1 Be sure to replace the parts carefully and yoke (worn)
correctly. The incorrect replacement may 4) Front wheel bearing (worn)
reduce the performance of steering system, 5) Steering gear (faulty)
even causing accidents. 1) Power steering fluid (low)
2) Steering knuckles (worn)
4.1.2 Precautions for supplemental restraint Abnormal
3) Power steering vane pump
system (SRS). This vehicle is equipped noise
(faulty)
with a supplemental restraint system 4) Steering gear (faulty)
(SRS), such as the driver safety airbag
and front passenger safety airbag. Failure 4.3 Inspection of Steering Wheel Free Travel
to carry out operations in the correct
sequence may cause the safety airbag to The inspection methods of the steering wheel
unexpectedly deploy during servicing and free travel are as follows:
cause a serious accident. Therefore, be
sure to read the precautions for 4.3.1 Stop the vehicle with the wheels straight
supplemental restraint system before ahead;
servicing (including parts removal or
installation, inspection or replacement). 4.3.2 Gently turn the steering wheel, and
check the steering wheel free travel.
4.2 Troubleshooting
The maximum free travel of the steering wheel
The troubleshooting chart may help find the should be 30 mm as shown in figure 4-1.
cause of malfunction. The numbers in the
chart indicate order of possible trouble cause.
Please check every part in order. Repair or
replace these parts when necessary.
Troubleshoot the steering system as shown in
table 1-1.
Table 1-1 Troubleshooting Chart of Steering

System
Symptom Possible cause

1) Tires (Low tire pressure)
2) Power steering fluid (low)
3) Front wheel alignment
(incorrect) Figure 4-1 Schematic Diagram of Steering
4) Steering knuckle (worn) Wheel Free Travel
Heavy
5) Suspension arm ball joints
steering 4.4 Steering Difficulty
(worn)
6) Steering column (bent)
7) Power steering vane pump 4.4.1 Check Power Assist
(faulty)
8) Steering gear (faulty) Is the starting load greater than 29 N?
1) Tires (Low tire pressure)
2) Front wheel alignment Yes--Go to Step 2.
Poor return (incorrect)
3) Steering column (bent) No--Power assist is normal.
4) Steering gear (faulty)
Excessive 1) Steering knuckles (worn) 4.4.2 When idling, measure the oil pressure of
137
the power steering pump in the stable No--Go to Step 6.

state
4.4.5 Inspect the oil supply pipe and oil return
Is the pressure 1,500 kPa or less? pipe between the power steering pump
and power steering gear for any blockage
Yes--Go to Step 3. or deformation.
No--Go to Step 5. Are the pipes blocked or deformed?
4.4.3 When idling, measure the release Yes--Repair or replace piping.

pressure of power steering pump.
No--There is a fault with the valve or the
Model 473 pump.
Is the pressure 7,500~8,500 kPa or less? 4.4.6 Check if the oil cylinder piping deforms.
Model 476ZQA Is the piping deformed?
Is the pressure 9,000~9,800 kPa or less? Yes--Replace the piping.
Yes--Go to Step 4. No--Go to Step 7.
No-The power steering pump is faulty. 4.4.7 Check if the gear racks are bent.
4.4.4 Use a spring balance to measure power Yes--Replace the power steering gear.
assist in the left and right directions
respectively. No--The valve is faulty. Replace the
steering gear.
Are both measured values less than 29 N?
Yes-The steering gear is faulty. Replace

the steering gear.
138
139
Section 5 Overhauling of Steering Wheel, Steering Column and Universal

Joint Assembly
5.1 Structure of Steering Wheel, Steering 5.2.1 Removal
Column and Universal Joint Assembly
5.2.1.1 Observe the precautions for
See figure 5-1. overhauling the steering system.
5.2.1.2 Disconnect the negative battery

terminal.
5.2.1.3 Make sure the front wheels are facing

straight ahead.
5.2.1.4 Remove the DAB module assembly.
5.2.1.4.1 Align the small holes on both sides of

steering wheel, and loosen 2 Allen screws
with TX30# sleeve. See figure 5-2.
Fig. 5-2
5.2.1.4.2 Remove the DAB module assembly

from the steering wheel.
5.2.1.4.3 Loosen the snap-fit of safety airbag

connector with the paddle, and remove the
safety airbag connector.
Notice: Do not pull the wire harness of the

safety airbag while removing the DAB module
assembly. Make sure the DAB module
assembly is placed with the upper surface
facing upward. Do not disassemble the DAB
module assembly.
5.2.1.5 Remove the steering wheel assembly.
5.2.1.5.1 Disconnect the wire harness

Fig. 5-1 connector.
5.2 Removal and Installation of Steering 5.2.1.5.2 Remove the set bolts of the steering
Wheel, Steering Column and Universal Joint wheel with 14# sleeve as shown in figure 5-3.
Assembly
140
release the angle adjusting handle of

steering column downward and remove
the lower protector. See figure 5-5.
Fig. 5-3
5.2.1.5.3 Make the alignment mark on the

steering wheel assembly, steering column
Fig. 5-5
and universal joint assembly. See figure
5-4.
5.2.1.7 Remove the clock spring.
Remove the connector connected to the clock

spring. The clock spring is installed to the
combination switch with 2 pairs of plastic
snap-fits as shown in figure 5-6. Please
remove the clock spring carefully to avoid
damage.
Fig. 5-4
5.2.1.5.3 Remove the steering wheel

assembly.
5.2.1.5.4 Notice: When removing the steering Fig. 5-6

wheel, avoid damage to the clock spring with
its wire harness entangled with the steering 5.2. 1.8 Remove the combination switch.
wheel.
5.2.1.8.1 Remove the connector connected to
5.2.1.6 Remove the combination switch the combination switch.
protector.
5.2.1.8.2 Loosen 3 mounting screws of the
5.2.1.6.1 The upper and lower combination combination switch (2 on front side, 1 on
switch protectors are engaged with 6 pairs back side) with a cross screwdriver as
of plastic snap-fits. Pull the upper protector shown in figure 5-7, and remove the
open from bottom to top and remove it. combination switch.
5.2.1.6.2 Loosen 3 mounting screws of the

lower protector with a cross screwdriver,
141
Fig. 5-7
5.2.1.9 Remove the connector on the steering Fig. 5-9

shaft lock.
5.2.1.12 Remove the steering column and
5.2.1.10 Remove the universal joint boot universal joint assembly.
assembly I.
5.2.1.12.1 Make sure all the wires connected
Loosen 2 nut-type plastic snap-fits as shown in to the steering column have been
figure 5-8, and remove the boot. disconnected.
5.2.1.12.2 Loosen the nuts at the upper

mounting points of the steering column
and bolts at the lower mounting points as
shown in figure 5-10, and remove the
steering column and universal joint.
Fig. 5-8
5.2.1.11 Disconnect the connection of

countershaft and steering gear input shaft.
Fig. 5-10
5.2.1.11.1 Make match marks on the mounting
surface between the bottom of 5.2.1.13 Remove the steering shaft lock.
countershaft and the steering gear input
shaft as shown in figure 5-9. Loosen 2 anti-theft bolts as shown in figure
5-11, and remove the steering shaft lock.
5.2.1.11.2 At this time, install the steering
wheel and turn it so that the bolts can be
operated easily. Loosen the bolts and pull
out the countershaft.
142
5.2.2.4.1 Install the countershaft to the

steering gear output shaft. Align the match
marks previously made, confirm that the
bolt hole on the countershaft is aligned
with the groove on the steering gear input
shaft, and then insert the bolts.
5.2.2.4.2 Tighten the bolt to 30 Nm.
Precautions: Always tighten the bolt from the

side without thread, otherwise it will cause
Fig. 5-11 connection failure and other consequences.
The thread can be judged by observing the
5.2.2 Installation milled plane on the universal joint yoke. The
side with a milled plane has no thread. See
5.2.2.1 Check for shaft lock malfunction figure 5-12
Connect the removed shaft lock to the

connector. When the start button is pressed to
power up, the steering shaft lock will unlock.
When the start button is pressed to power
down, the steering shaft lock will lock.
If the steering shaft lock operates normally,
remove the connector. If the steering shaft lock
is abnormal, replace it.
5.2.2.2 Install the steering shaft lock
Align the boss of shaft lock with the lock hole

on the steering column. Secure the shaft lock Fig. 5-12
bracket and shaft lock to the steering column
with 2 new anti-theft bolts. Tighten the bolts 5.2.2.5 Install the universal joint boot assembly
until the bolt heads are broken. I
Install the dust cover in place, and engage
5.2.2.3 Install the steering column and the plastic snap-fit.
universal joint assembly
5.2.2.6 Install the combination switch
5.2.2.3.1 Align the lower installation hole, and Align the combination switch, tighten 3
insert the lower mounting bolt. mounting bolts and connect the connector.
5.2.2.3.2 Loosen the angle adjusting handle of 5.2.2.7 Install the clock spring
steering column, align 2 installation holes Make sure the front wheels are straight
of the upper mounting bracket and install 2 ahead. Install the clock spring, engage the
nuts. snap-fit and connect the connector.
5.2.2.3.3 Tighten the bolt at the lower 5.2.2.8 Install the combination switch protector
mounting point to 35 Nm, and tighten the
nut at the upper mounting point to 25 Nm. 5.2.2.8.1 Install the lower protector, and
tighten 3 set bolts.
2.17.4.2.1 Connect the steering shaft lock
connector. 5.2.2.8.2 Install the upper protector, and attach
it to the lower protector.
5.2.2.4 Connect the countershaft and steering
gear input shaft 5.2.2.9 Center the clock spring
143
Notice: The clock spring may be damaged due 5.2.2.11.1 Connect the connector.
to incorrect installation. Therefore, make sure
to center the clock spring. When centering it, 5.2.2.11.2 Align the DAB module, and tighten
first turn the clock spring fully to the left, and the set bolts on both sides to 8.8 Nm.
then to the right and count the number of full
turns. Next, turn it to the left for haft of the total Notice:
turns (if the total number of turns is 7, turn it
back for 3.5 turns) so that the side with 5.2.2.11.2.1 Do not use safety airbag parts
connector on the clock spring faces upward. removed from another vehicle. When
See figure 5-13. replacing parts, be sure to use the new
ones.
5.2.2.11.2.2 Make sure the DAB module

assembly is installed with the specified
torque.
5.2.2.11.2.3 If the DAB module assembly has

been dropped or if any cracks, dents or
other defects are found on the housing or
connector, replace the assembly with a
new one.
Fig. 5-13 5.2.2.11.2.4 When installing the DAB module
assembly, do not allow the wire harness to
5.2.2.10 Install the steering wheel assembly interfere with other parts or be pinched by
them.
Align the match marks previously made on the
steering wheel and steering column, and 5.2.2.12 Connect the negative battery
tighten the retaining nut to 40 Nm. terminal.
5.2.2.11 Install the DAB module assembly 5.2.2.13 Inspect the SRS warning light.
144
Section 6 Power Steering Pump Pressure Test

P/S connector adapter (power steering pump)
P/S connector adapter (hose)
P/S pressure gauge
Measure the oil pressure according to the
following steps to verify whether it is a power
steering pump fault or a power steering gear
fault.
6.1 Check the power steering fluid level (Refer

to Section 6 of the chapter).
6.2 Disconnect the high-pressure steering oil

pipe from the outlet of the pump. Be Fig. 6-2
careful not to splash steering fluid onto the
frame and other components. Fit the P/S 6.6 Open the pressure control valve (B)
connector adapter (power steering pump) completely.
onto the outlet of power steering pump.
6.7 Start the engine and keep it idling.
6.8 Turn the steering wheel from one

stationary point to another to and fro
several times to heat the fluid to a working
temperature of 70ºC.
6.9 When the engine is idling, measure the oil
pressure in the stable state. If the pump is
in a good state, the pressure should not be
greater than 1,500 kPa. If the pressure is
too great, inspect the outflow hose or the
valve (Refer to Section 4 of the chapter).
Fig. 6-1 Increase the engine speed to 3,000 rpm, and
then measure the oil pressure. If the pump is
6.3 Fit the P/S connector adapter (hose) onto in a good state, the pressure should be at least
the P/S pressure gauge, and then connect 1,500 kPa. If the pressure is too high, replace
the outflow hose (A) of the steering pump the power steering pump.
to the P/S connector adapter (hose). 6.10 Decrease the engine speed and keep it
idling. Close the stop valve, and then
6.4 Fit the P/S pressure gauge onto the P/S gradually close the pressure control valve
connector adapter (power steering pump). until the needle of pressure gauge is stable.
Read the pressure value.
6.5 Open the stop valve (A) completely. Notice: The off-time of the stop valve should
be no longer than 5 seconds, otherwise the
pump may get damaged due to overheating.
6.11 Fully open the pressure control valve

immediately. If the pump is in a good state,
the reading on pressure gauge should be:
at least 7,500~8,500 kPa (for model 473),
9,000~9,800 kPa (for model 476ZQA). If
the reading is low, the pump output
pressure is too low for full assist and the
pump should be replaced.
145
Section 7 Fluid Leakage Detection

Model 473QE
146
Model 476ZQA
147
Section 8 Steering Fluid Replacement

Based on normal time intervals, inspect the
power steering oil reservoir (A), and add the
recommended fluid when necessary. Always
use the steering fluid brand of ATF DEXRON
III. The use of power steering fluids or
automatic transmission fluids of other types
may result in accelerated abrasion, and in cold
weather, poor steering performance of the
vehicle.
System capacity: 1 L
Oil reservoir capacity: 0.4 L
Fig. 8-2
8.2 Start the engine and keep it idling. Turn the

steering wheel from one stationary point to
another to and fro several times to drain
the steering fluid remained in the system.
Stop the engine and discard the fluid.
8.3 Reconnect the oil return pipe.
8.4 Add oil into the oil reservoir to the upper

limit level (C).
Fig. 8-1
8.1 Lift the complete vehicle to expose the

disconnected point of oil return pipe,
remove the return hose clamp (B) and
drain the steering fluid from the oil
reservoir and upper oil return pipe. Before
removal, prepare a waste fluid recovery Fig. 8-3
device and place a rag on the surrounding
parts under the disconnected point. Do not 8.5 Start the engine and idle it at high speed.
splash the fluid on the body or parts. Wipe Turn the steering wheel from one
off the splashed fluid immediately. stationary point to another to and fro
several times to discharge air from the
system.
8.6 Recheck the oil level and make sure the

final level is between the upper and lower
limit.
148
Section 9 Power Steering Line Replacement

Observe the following precautions during disconnected.
installation: When connecting the hose, the
hose should contact with the pipeline stop Remove the connecting bolts between the oil
block. Install the pipe clamps at the specified pipe and sub frame. Then remove the
distance (from the hose end) as shown. connecting bolts or clamps between the oil
pipe and the steering pump and between the
Inspect all pipe clamps for any aging or power steering oil reservoir and the power
deformation. If necessary, replace old pipe steering gear.
clamps with new ones. Add the recommended
power steering fluid into the oil reservoir to a When installing the steering oil pipe, install the
specified level and check for any leakage. connecting bolts or clamps between the oil
pipe and the steering pump and between the
Observe the following precautions during power steering oil reservoir and the power
removal: Discharge the fluid from the pipes. steering gear, and then tighten the mounting
The clamp on oil return hose I can be parts.
2.5 ~ 5.5 mm
Model 473
149
Model 476ZQA
150
Section 10 Pump Replacement

Preparation Loosen the connecting bolt (C) of the steering
pump and bracket, and then loose the belt
10.1. Essential tools: Special clamp pliers, through the adjusting bolt (D). Remove the
wrench, sleeve steering pump belt, and take off the fastening
bolts (C), (D) and adjusting slider.
10.2 Cover the sub frame and surrounding
areas under the steering pump before c Disassemble the pump bracket
replacement to avoid steering fluid
splashing on them. Remove the bolts (E) and (F), and take off the
metal plate bracket (H).
10.3 Place a suitable container under the
vehicle and collect the steering fluid. F
10.4 Drain the steering fluid from the oil

reservoir first for the engines with various
configurations.
Models with 473QE engine

E
a Drain the steering fluid from oil reservoir
H
Fig. 10-2
Precautions: Protect the openings of the

power steering pump to avoid foreign objects
from falling into the pump.
d Install the steering pump and adjusting

bracket
Tighten the new steering pump and metal

plate bracket with mounting bolt (E), install the
bolt (F) to the bolt hole of metal plate bracket
and pump and tighten the bolt (E) to the
specified torque. Install the bolts (C) and (D)
through the bracket adjusting slider.
Fig. 10-1
Precautions: Do not tighten the bolts (C) and
Remove the clamp at oil inlet with the special (D) at this time.
clamp pliers, and remove the hollow bolt at oil
outlet with the ratchet wrench. Disconnect the e Install the steering pump to the engine,
inflow hose (A) and high-pressure oil pipe (B) and then install the belt.
from the pump and then plug the nozzle.
Install the pump and adjusting bracket to the
Precautions: (1) Do not splash the fluid on the fixed bracket of pump on the engine with bolt
body or parts. Wipe the splashed fluid off (F). Tighten the bolt (F) until the pump can
immediately; (2) Do not turn the steering wheel rotate freely.
after the oil pipe is disconnected.
Install the pump belt, adjust the belt to
b Disassemble the adjusting bolt of the specified tension through the adjusting bolt (D),
pump bracket and then tighten the bolts (C) and (F) to the
151
specified torque. the power steering belt.
Assembly skill: Install the belt to the pulley and

raise the steering pump upward by hand to
tension the belt. Then tighten bolt (D) by hand
and adjust bolt (D) with tools until the belt
tensioning force is as specified.
Precautions:
(a) Make sure the power steering belt is

correctly positioned on the pulley.
B C
(b) Before installation, wipe off any fluid. Do
not splash any fluid or grease on the belt
and pulley. Fig. 10-4
c Remove the steering pump
Remove the mounting bolt (B) and flat washer

(C) of the pump and take off the steering
pump.
Removal skills: The bolt (B) cannot be taken

out directly due to small space after it is
loosened. Take out the bolt together with the
pump after the bolt is unscrewed from the
thread.
Precautions: Protect the openings of the

Fig. 10-3
power steering pump to avoid foreign objects
from falling into the pump.
a Install the oil pipe
d Install the new steering pump.
Install the high-pressure oil pipe and tighten
the hollow bolts to the specified torque; Install
Install the pump to the engine bracket and
the oil inlet hose of steering pump and elastic
tighten the bolt (B).
clamp.
e Install the belt.
b Add the steering fluid (Refer to Section 7
of the chapter).
f Install the oil pipe.
Models with 476ZQA engine
Install the high-pressure oil pipe and tighten
the hollow bolts to the specified torque. Install
a Drain the power steering fluid from the oil
the oil inlet hose of steering pump and elastic
reservoir (Same as above).
clamp.
b Remove the drive belt of the steering
Add the steering fluid (Refer to Section 7 of the
pump.
chapter).
Refer to the removal and installation method of
152
Section 11 Removal of Power Steering Gear

Special tools needed: Ball Joint Remover 28 countershaft and steering gear input shaft
mm
11.6.1 Make match marks on the mounting
During the process of disassembly, please pay surface between the bottom of
attention to the following: countershaft and the steering gear input
shaft as shown in figure 3-6.
a Clean off the sludge and dust on the valve,
piping and ends of the steering gear with 11.6.2 Turn the steering wheel so that the bolts
solvent and a brush. Blow dry with can be operated easily. Loosen the bolts
compressed air. and pull out the countershaft.
b The steering wheel must be removed

before the universal joint is disconnected.
Otherwise, the clock spring may be
damaged.
11.1 Drain the power steering fluid (Refer to

Section 7 of the chapter).
11.2 Raise the front part of the vehicle.

Support the vehicle with safety support at
a suitable location.
11.3 Remove the front wheels.
11.4 Remove the steering wheel (Refer to

Section 13 of the chapter).
Fig. 11-2
11.5 Remove the universal joint boot assembly
11.7 Remove and discard the split pin (A) on
I.
the ball head nut (B) of steering tie rod,
and then loosen the nut.
Loosen 2 nut-type plastic snap-fits as shown
and remove the boot.
Fig. 11-3
11.8 Separate the ball head of the steering tie

rod and steering knuckle.
Fig. 11-1
11.9 Remove the hollow bolt (A) of the
11.6 Disconnect the connection of
153
high-pressure oil pipe and clamp (B) of the

E F G
oil return pipe. Disconnect the hose and
`
hard tube at the oil return pipe clamp.
Then remove the sub frame (Refer to Sub
frame Repair Manual).
H E
B
Fig. 11-6
11.12 Remove the mounting bolt (I) of the

steering gear, and take off the mounting
nut (J) and steering gear.
Fig. 11-4
11.10 Remove the mounting bolt (C) of heat

shield, and take off the heat shield (D). J
C
D
Fig. 11-7
11.13 Remove the dust cover (A) at the top of

the valve.
Fig. 11-5
11.11 Remove the mounting bolt (E) of heat A

shield support and oil pipe bracket, and
then take off the heat shield support (F)
and (G). Disconnect the connection (H) of
high-pressure oil pipe and oil return pipe to
steering gear, and take off the
high-pressure oil pipe and oil return pipe.
Fig. 11-8
154
Section 12 Installation of Power Steering Gear

12.1 Install the dust cover, steering gear, rear
suspension, steering oil pipe, heat shield
support and heat shield in the reverse
order of the steering gear removal. Install
the sub frame and tighten the hollow bolts
of the high-pressure oil pipe and pump to
the specified torque. Connect the oil return
pipe and install the clamp.
12.2 Install the steering gear input shaft dust

cover (A). Put the claw (B) of the metal
retaining support to the cowl panel, and
then press the spring clamp (C) in the cowl
panel.
Fig. 12-2
12.5 Make the wheels face straight ahead, and

slide the lower end of the steering
universal joint to the pinion shaft (B).
12.6 Align the bolt hole (A) on the universal

joint with the groove on the pinion shaft,
and then install the universal joint bolt (B).
Install the lock bolt to the groove on the
pinion shaft securely. Pull the universal
joint to make sure it is in place. Tighten the
lock bolt (B) to the specified torque.
Fig. 12-1
12.3 Locate the steering rack in the center of

travel.
12.4 Install the steering column universal joint

A.
Fig. 12-3
12.7 Install the dust cover I.
12.8 Install the front wheels and make the

wheels face straight ahead.
155
12.9 Center the clock spring as follows: Rotate stationary point to another to and fro
the clock spring clockwise until it cannot be several times to heat the steering fluid.
turned, and then rotate it counterclockwise Check the power steering gear for leakage
(about 3.5 turns) until the arrow on the (Refer to Section 6 of the chapter).
label points upward. Loosely install the
steering wheel (Refer to Section 14 of the 12.11.2 Check the turning angle of the steering
chapter). wheel. If the left and right turning angles
are not equal (the steering wheel and gear
12.10 Fill the power steering fluid in the rack are not centered), remove and center
system. Discharge air from the system the steering wheel (Center the steering
(Refer to Section 7 of the chapter). wheel while slowly driving the vehicle in a
straight line), and then fix the steering
12.11 Perform the following checks after wheel.
installation
Inspect the toe-in and perform the four
12.11.1 Start the engine and keep it idling. wheel alignment again when necessary
Turn the steering wheel from one (Refer to Section 1 of Chapter 16).
156
Section 13 Electric Power Steering (EPS) System

Refer to electric maintenance section for overhauling -- EPS Repair Manual.
157
Part 8 Brake System

Section 1 Conventional Brake Components
1.1 Diagram of Component Locations
1.1.1 Inspection of Components
Component Inspection Procedures Other Items for Inspection

Check for any damage or oil
leakage:
The oil seal on the cover of oil cup
Brake Master ● Oil cup or oil cup seal
bulges due to contamination by
Cylinder ● Pipe connector
mineral oil
● Between the brake master
cylinder and vacuum booster
leakage:
● Flat connector at the connection
Brake Hose The pipe is bulged, twisted or bent
of pipe and brake
● Hose and pipe. Check for twist
or damage
leakage:
Brake Caliper ● Piston seals The brake caliper pin is stuck
● Flat connector of brake hose
● Screws of exhaust valve
leakage:
ABS Control Unit
● Pipe connector
● Hydraulic unit
158

leakage:
ESP Control Unit
● Pipe connector
● Hydraulic unit
Check for any damage:
● Housing
EPB Control Unit
1.1.2 Brake System Test times or more.
When the brake is applied, the brake pedal (b) Switch on the power supply for the whole
goes down/gradually fails. vehicle, raise the vehicle with the lifting
machine and turn four wheels by hand.
1.1.2.1 Power on the complete vehicle, start
the engine and wait for the vacuum Inspect the wheels for any brake dragging.
booster to be vacuumized. Yes Go to step 3
No Look for other reasons for the wear on
1.1.2.2 Stick a light-tight adhesive tape of 2 brake pads, a too high brake pedal or
inches on the lower part of the steering vehicle vibration.
wheel and draw a horizontal reference line
on the adhesive tape. (c) Switch off power supply for the whole
vehicle, pump the brake pedal several
1.1.2.3 Gently push down the brake pedal and times to deplete the vacuum in the brake
keep this state (about the pressure needed booster, and then turn the wheels again to
for slow motion of the vehicle with A/T), check for any brake dragging.
then release the parking brake.
Inspect the wheels for any brake dragging.
1.1.2.4 While stepping on the brake pedal, nip Yes Go to step 4
the end of the tape measure behind it. No Replace the vacuum booster
Then pull the tape measure upwards until
the steering wheel. Pay attention to where (d) Without removing the brake line, loosen
the tape measure is in alignment with the the bolts and separate the brake master
reference line you have drawn on the cylinder and booster. Then turn the wheels
piece of tape. to check for any brake dragging.
1.1.2.5 Apply a stable pressure on the brake Inspect the wheels for any brake dragging.
pedal and maintain this state for 3 minutes. Yes Go to step 5
No Check the adjustment of the brake
1.1.2.6 Observe the tape measure. pedal position switch and the free
travel of the brake pedal.
1.1.2.6.1 If the offset is less than 10 mm, the
brake master cylinder is up to standard. (e) Loosen the hydraulic piping on the brake
master cylinder, and then turn the wheels
1.1.2.6.2 If the offset is more than 10 mm, to check for any brake dragging.
replace the brake master cylinder.
Inspect the wheels for any brake dragging.
Brake pads wear away quickly, and the vehicle Yes Go to step 6
vibrates (after running for a long time) or the No Replace the brake master cylinder.
brake pedal is too high to step on.
(f) Loosen the screws of the exhaust valve on
(a) Drive the vehicle until there is brake each brake caliper, and then turn the
dragging, or until the brake pedal is too wheels to check for any brake dragging.
high to step on. In a long test drive, you
may need to step on the brake pedal 20 Inspect the wheels for any brake dragging.
159
Yes Dismantle the brake caliper from the cut-out in the insulator to the left side of the
wheel with brake dragging and repair brake pad (B).
the failure.
No Inspect the seal ring of brake master Standard pedal height (with the carpet
cylinder cover for any expansion, removed): MT: 141 mm
whether the brake fluid in the brake AT: 153 mm
master cylinder discolors or is
contaminated and whether there is any 1.3.1.3 Loosen the lock nut of the push rod (A),
damage to the brake pipe. and screw the push rod in or out using
pliers until the standard pedal height from
In case any of the above items is damaged, the floor is reached. After adjustment,
please make a replacement. If all of the above tighten the lock nut.
items are intact, replace the ABS (or ESP)
control unit. Notice: Do not adjust the height of the brake
pedal with the push rod pressed down.
1.3 Adjustment of Brake Pedal and Brake
Pedal Lamp Switch
13.1 Height of Brake Pedal
1.3.1.1 Turn the brake pedal lamp switch (A)

counterclockwise until there is no contact
between it and the brake pedal.
1.3.2. Brake Pedal Switch Clearance
1.3.2.1 Loosen the nut C, rotate the braking

light switch until there is a clearance of 1-2
mm between A and B and then lock the nut
C. Make sure the brake indicator goes off
once the pedal is released.
1.3.2.2 Inspect the free travel of brake pedal.

1.3.1.2 Roll up the carpet and measure the
height (C) of the brake pedal from the
160
1.3.3 Free Travel of Brake Pedal
1.3.3.1 Stop the engine; push the pedal by

hand to inspect the free travel (A) of the
brake pedal (B).
Free Travel: 1-5 mm
(c) Remove the bolt (D) and gasket (E) used

to connect the tubular beam from the
brake pedal bracket.
(d) Disconnect the connector (F) of brake

1.3.3.2 In case the free travel of the brake pedal position switch.
pedal does not meet technical
requirements, adjust the brake pedal (e) Remove the brake pedal and bracket (G)
position switch (C). Insufficient travel of the together.
brake pedal may cause brake dragging.
(f) Perform the installation in the reverse
1.4 Brake Pedal Replacement order of removal.
(a) Remove the dashboard. (g) Adjust the brake pedal and brake pedal
position switch.
(b) Take off the lock pin (A), pin roll (B) and
spring (C). 1.5 Inspection and Adjustment of Parking
Brake
1.5.1 Inspection
1.5.1.1 Pull the parking brake lever (A) with a

force of about 230 N to achieve the full
parking brake. The parking brake lever
should be locked in the specified tooth No.
(B).
The brake level should be locked in: Tooth

12 to 14
Pull up with a force of about 230 N
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1.5 1.2 If the tooth No. in which the parking

brake lever is locked does not meet the
technical requirements, adjust the parking 1.5.2.5 Release the parking brake handle
brake. completely. Check for parking brake
dragging while the rear wheels are turned.
1.5.2 Adjustment If so, perform adjustment again.
Notice: After the maintenance of the rear 1.5.2.6 Make sure the parking brake is fully
wheel brake, loosen the adjusting nut of the applied when the parking brake handle is
parking brake. Start the engine and depress pulled up.
the brake pedal several times to adjust the
clearance of the self-adjusting parking brake 1.5.2.7 Reinstall the console cover.
prior to the adjustment of the parking brake.
Disassembly Diagram
1.5.2.1 Raise the rear of the vehicle and make
sure the vehicle is securely supported. 1.6 Parking Brake Cable Replacement
1.5.2.2 Remove the console cover (Refer to 1.6.1 Removal Steps for Hand Brake Cable
Removal and Installation of Auxiliary
Instrument Panel). 1.6.1.1 Remove the auxiliary instrument panel.
1.5.2.3 Pull the parking brake handle up a 1.6.1.2 Loosen the adjusting nut of the pull
tooth (A click sound can be heard). cable and remove the pull cable from the
balancer.
1.6.1.3 Lift the vehicle and remove the parking

brake cable from the brake caliper.
1.6.1.4 Remove the fastener and take off the

parking brake cable.
1.6.2 Installation Steps for Parking Brake

Cable
1.6.2.1 Pass the parking brake cable through

the body and position it with the rear end
installed to the rear brake caliper.
1.6.2.2 Tighten the fastener and secure the

1.5.2.4 Tighten the adjusting nut (A) until the parking brake cable.
parking brake drags slightly when the rear
wheels are turned. 1.6.2.3 Lower the vehicle and connect the
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parking brake cable to the parking brake

handle.
1.6.2.4 Adjust the parking brake according to

the adjustment method of parking brake.
1.6.2.5 Install the auxiliary instrument panel.
1.7 Brake System Bleeding maximum level (Upper level). Check the
brake caliper after bleeding.
Note
1.7.5 Replenish the brake fluid as specified.
1.7.1 The discharged brake fluid cannot be
reused. (a) Make sure the brake fluid level in the
reservoir is at the maximum level ("MAX"
1.7.2 Always use the original DOT 4 brake upper level).
fluid. Failure to use the specified brake
fluid may cause corrosion and shorten the (b) Connect a clean drain pipe to the bleed
life time of the system. screw.
1.7.3 Do not splash the brake fluid on the (c) The assistant slowly depresses the brake
vehicle, or the paint may be damaged. If pedal several times and then applies
the brake fluid has been splashed on the constant force.
paint, wash it off with water immediately.
(d) Loosen the bleed screws of the brake from
1.7.4 When bleeding, the level in the reservoir the left rear to release air in the system,
of brake master cylinder must be at the and then tighten the bleed screws.
163
again to the "MAX" (Highest Level) line.

(e) Perform the above operations on each
wheel in the order as shown, until no
bubbles are visible in the brake fluid
flowing from the drain pipe.
Draining order
(f) Fill the reservoir of brake master cylinder
1.8 Schematic Diagram of Brake System Indicator Circuit
1.9 Detection of Parking Brake Switch
164
1.9.1 Remove the console, and disconnect the

parking brake switch connector (A) at the
switch (B).
1.11 Detection of Brake Hose and Pipe
1.11.1 Inspect the brake hose for any damage,

aging, leakage, mutual interference or
distortion.
1.11.2 Inspect the brake line for any damage,

1.9.2 Check the continuity between the rusting or leakage. Inspect if the brake line
positive terminal and body ground. is bent.
1.9.2.1 Continuity exists when the brake lever 1.11.3 Inspect the hose, pipe connectors and
is pulled up. connections for any leakage, and do
retightening where necessary.
1.9.2.2 Continuity does not exist when the
brake lever is pressed down. 1.11.4 Inspect the brake master cylinder and
ABS/ESP control unit for any damage or
1.10 Detection of Brake Fluid Level Switch leakage.
Check the continuity of terminal (1) when the
float is in lower and upper positions. Notice: Once the brake line is overhauled,
replace the brake line clamp.
1.10.1 When all the brake fluid is discharged
from the reservoir, the float goes down and 1.12 Brake Hose Replacement
there is continuity between terminals.
Note:
1.10.2 When the brake fluid is filled in the
reservoir to reach the "MAX" (Highest 1.12.1 Before fitting the brake hose again,
Level) line (A), the float will go up and the inspect all components. There should be
terminals are disconnected. no dust or other foreign objects on the
surfaces.
1.12.2 Replace the components according to

the rules.
1.12.3 Do not splash the brake fluid on the

vehicle, or the paint may be damaged. If
the brake fluid has been splashed on the
paint, wash it off with water immediately.
(a) Please replace the brake hose (A) if it is

distorted or cracked, otherwise there will
be leakage.
165
(b) Remove the brake hose from the brake

line (B) with a 10 mm pipe wrench.
(g) Install the brake hose (A) to the upper
(c) Remove the brake hose clamp (B) from bracket (B) of the brake hose with a new
the brake hose (A) and discard it (See the E-shape clamp (C) (See the figure below).
figure below).
D
17.5 Nm
(h) Connect the brake line (D) to the brake

hose.
(i) After the brake hose is installed, bleed the

brake system according to 1.8 of the
(d) Remove the brake hose (A) and separate chapter.
the brake hose from the brake caliper.
(n) Perform the following inspections:
(e) Remove the brake hose from the
suspension (See the figure above). 1.12.3.1 Inspect the brake hose and pipe
connectors for any leakage. Do some
(f) First install the brake hose (A) to the tightening when necessary.
suspension with the fastening bolt (B), and
then connect the brake hose and brake 1.12.3.2 Inspect the brake hose for any mutual
caliper with the connecting bolt (C) and interference or distortion.
new sealing washer (D) (See the figure
below). Required torque:
Rigid brake line to brake hose: 17.5 Nm
166
Brake master cylinder to brake line: 17.5 Nm
Brake hose to brake caliper (connecting bolt):

32 Nm
1.13 Inspection and Replacement of Front

Brake Pad
Special Notes
The components of brake pads
contain poisonous substances.
Frequent inhalation of dust and
detritus from such substances is 1.13.1.3 If the thickness of either brake pad is
hazardous to your health. less than the repair limit, you should
● Avoid inhaling dust and replace the whole pair of brake pads.
detritus from brake pads.
● No suction hoses or hair 1.13.2 Replacement
brushes can be used for the
cleaning of brake assembly. 1.13.2.1 Raise the front part of the vehicle.
Instead, a vacuum cleaner Support the vehicle with safety support at
should be used. a suitable location. Remove the front
wheels.
1.13.1 Detection
1.13.2.2 Remove the mounting bolts of the
1.13.1.1 Raise the front part of the vehicle. brake hose.
a suitable location and remove front 1.13.2.3 Clamp the pin with the wrench and
wheels. remove the flange bolt (A). The pin should
be clamped carefully to avoid damage to
1.13.1.2 Check the thickness of inner and the protective sleeve of pin. Screw out the
outer brake pads. The thickness of brake caliper (B) upward. Inspect the hose
gaskets is not included. and protective sleeve of the pin for any
damage or aging.
Brake pad thickness:
Detection of inner brake pad
1.13.2.4 Remove the brake pad (A).
Outer brake pad
167
1.13.2.9 Fit the brake pad correctly, and install

the brake pad with the wear alarm (B)
1.13.2.5 Remove the brake pad boot (A)
inside.
1.13.2.10 Push in the piston (A), and clamp

the brake caliper on the brake plate.
Make sure the protective sleeve of the
piston is in place to avoid damage to the
piston when the brake caliper is turned
downward.
1.13.2.6 Completely clean the brake caliper,

remove all the rusting and check for
grooves and cracks.
1.13.2.7 Inspect the brake disc for any

damage or cracks.
1.13.2.8 Clean and install the brake plate boot. 1.13.2.11 Turn the brake caliper (B) downward
until it is in place. Install the flange bolt
(C), clamp the pin with the wrench and
tighten the flange bolt with the specified
torque. Be careful not to damage the
protective sleeve.
1.13.2.12 Install the set bolts of the brake hose,

and tighten them with the specified
torque.
168
disc to measure the run-out at 10 mm from

1.13.2.13 Depress the brake pedal several the outer edge of the brake disc.
times and make sure the brake functions
normally. Then road test the vehicle. 1.14.1.6 If the run-out of the single brake disc
exceeds the repair limit of 0.03 mm, repair
Notice: A newly fitted set of brake pads may the brake disc with the on-board brake
need a large stroke for its brake pedal. The lathe. The repair limit: 24 mm.
stroke of the brake pedal can be restored to
normal by stepping on the pedal several times. 1.14.1.7 If the wear on the brake disc has
exceeded the limit value for repair, the
1.13.2.14 After fitting the brake pads, check brake disc should be replaced.
the hose and pipe connections or
connecting mechanisms for any leakage, 1.14.2 Thickness and Parallelism
and tighten them if necessary.
1.14.2.1 Raise the front part of the vehicle.
1.14 Detection and Replacement of Front Support the vehicle with safety support at
Brake Disk a suitable location. Remove the front
wheels.
1.14.1 Run-out
1.14.2.2 Remove the brake pad.
1.14.1.1 Raise the front part of the vehicle.
Support the vehicle with safety support at 1.14.2.3 Use a micrometer to measure the
a suitable location and remove the front thickness of the brake disc at 8 points 10
wheels. mm from the outer edge of the brake disc
with an interval of about 45°between each
1.14.1.2 Remove the brake pad two adjacent points. If the minimum value
measured is less than the repair limit,
1.14.1.3 Inspect the brake disc surface for any replace the brake disc.
damage or cracks. Clean the brake disc
thoroughly and get rid of all rust and Brake disc thickness:
corrosion. Standard: 25.9-26.1 mm
Repair limit: 24 mm
1.14.1.4 Fit suitable flat washers (A) and Maximum Deviation of Brake Disk Parallelism:
wheel nuts, and tighten the nuts to the 0.05 mm
specified torques to make the brake disc Notice: This is the maximum deviation allowed
touch the wheel hub closely. for the measurement of the thickness of the
brake disc.
108 Nm
1.14.1.5 Place the dial gauge near the brake 1.14.2.4 If the minimum value measured is
169
less than the repair limit, replace the brake

disc.
1.14.2.5 If the parallelism of the brake disc
exceeds the repair limit, repair the brake
disc with on-board brake lathe.
1.14.3 Front Brake Disc Replacement
Removal steps for front brake disc:
1.14.3.1 Remove the brake caliper;
1.14.3.2 Remove the brake disc. 95 Nm
Required torque:
Notice: Use an antirusting agent during
Connecting bolt of brake caliper and steering
removal. Do not remove the brake disc from
knuckle: 95 Nm
the hub forcibly, or the brake disc may be
Connecting bolt of wheel hub unit and steering
damaged. Polish both disc surfaces evenly
knuckle: 95 Nm
before installing the brake disc to ensure
sufficient wear margin. Notice: 2 brake discs
1.16 Replacement of Vacuum Booster with
on the same axle should be replaced at the
Master Cylinder Assembly
same time.
Notice: Do not splash the brake fluid on the
vehicle, or the paint may be damaged. If the
1.15 Replacement of Front Wheel Hub Unit
brake fluid has been splashed on the paint,
Assembly
wash it off with water immediately.
Remove the front wheel hub unit assembly
a Remove the battery assembly of the front
and fender:
compartment;
(a) Raise the vehicle;
b Remove the air filter assembly of the front
compartment;
(b) Remove the front wheels;
c Remove the wiper assembly;
(c) Remove the front brake caliper (B);
d Remove the vent cover assembly;
(d) Remove the front brake disc (A);
e Remove the wiper motor assembly;
(e) Loosen the bolt (C), and remove the front
hub unit assembly (E) and fender (D);
f Remove the gutter channel assembly;
(f) Perform installation in the reverse order of
g Open the reservoir cover, and drain the
removal.
brake fluid from the reservoir of the brake
master cylinder;
Remove the connector of the brake fluid level

alarm switch;
Take off the fixing pin roll and lock pin, and
then remove the connecting nut (A) of the
vacuum booster and brake pedal;
170
reservoir, bleed the brake system and adjust

the height of the brake pedal.
Required torque:
Brake line to brake master cylinder: 17.5 Nm
Connecting nut of vacuum booster and brake
pedal: 22 Nm
1.17 Detection of Vacuum Booster
1.17.1 Install a check valve between the

vacuum booster and vacuum reservoir
A 22 Nm with its direction from the vacuum booster
to vacuum reservoir. Install the vacuum
gauge A between the vacuum booster and
check valve.
Disconnect the brake line (A) from the brake

master cylinder.
Wrap the hose connector with a rag or service
towel to avoid splashing;
(g) Remove the vacuum pipe (B);
1.17.2 Start the engine, adjust the engine

speed through the accelerator pedal to
maintain the reading of the vacuum gauge
within 40.0-66.7 kPa, and then turn off the
engine.
1.17.3 Read the readings of vacuum gauge. If

the vacuum readings reduce by 2.7 kPa or
more after 30 seconds, check the following
components for leakage.
A 17.5 Nm a Vacuum hose and pipe
(h) Loosen the bolts and nuts of the b Sealing element

ABS/ESP mounting bracket, and slowly
move the ABS/ESP module to one side c Vacuum booster
to leave enough space for removing the
vacuum booster with the master cylinder d Brake master cylinder.
assembly; Be careful not to damage and
bend the brake line;
(i) Perform installation in the reverse order

of removal.
Observe the following precautions:

After the vacuum booster and brake master
cylinder are installed, fill new brake fluid in the
171
1.18 Detection and Replacement of Rear wheels.

Brake Pad
1.18.2.2 Clamp the pin (B) with the wrench,
Notice: and remove the flange bolt (A). Be careful
The components of brake pads not to damage the protective sleeve of the
contain poisonous substances. pin. Remove the brake caliper (C). Inspect
Frequent inhalation of dust and the hose and protective sleeve of the pin
detritus from such substances is for any damage or aging.
hazardous to your health.
● Avoid inhaling dust and detritus
from brake pads.
● No suction hoses or hair brushes
can be used for the cleaning of
the brake assembly. Instead, a
vacuum cleaner should be used.
1.18.1 Detection
1.18.1.1 Raise the rear part of the vehicle.

a suitable location. Remove rear wheels.
1.18.1.2 Check the thickness of inner (A) and

outer (B) brake pads. The thickness of
gaskets is not included. Brake pad
thickness: 1.18.2.3 Remove the brake pad (A).
1.18.2.4 Remove the brake pad boot (A)
1.18.1.3 If the thickness of either brake pad is

less than the repair limit, you should
replace the whole pair of brake pads.
1.18.2 Replacement

Support the vehicle with the safety support
at a suitable location. Remove the rear
172
1.18.2.5 Completely clean the brake caliper,

remove all the rusting and check for
grooves and cracks.
1.18.2.6 Inspect the brake disc for any

damage or cracks. 1.18.2.10 Install the brake caliper in place.
Install the flange bolt (B), clamp the pin
1.18.2.7 Clean and install the brake plate boot. (C) with the wrench and tighten the
flange bolt with the specified torque. Be
1.18.2.8 Fit the brake pad correctly, and install careful not to damage the protective
the brake pad with the wear alarm (B) sleeve.
inside.
1.18.2.11 Depress the brake pedal several
times and make sure the brake functions
normally. Then road test the vehicle.
Notice: A newly fitted set of brake pads may

need a large stroke for its brake pedal. The
stroke of the brake pedal can be restored to
normal by stepping on the pedal several times.
1.18.2.12 After fitting the brake pads, check

the hose and pipe connections or
connecting mechanisms for any leakage,
and tighten them if necessary.
1.19 Detection and Replacement of Rear

Brake Disc
1.19.1 Run-out

1.18.2.9 Push in the piston (A), and clamp the Support the vehicle with the safety support
brake caliper on the brake pad. Make sure at a suitable location. Remove the rear
the protective sleeve of the piston is in wheels.
place to avoid damage to the brake caliper
when it is installed. 1.19.1.2 Remove the brake pad
1.19.1.3 Inspect the brake disc surface for any

damage or cracks. Clean the brake disc
173
thoroughly and get rid of all rust and with an interval of about 45°between each
corrosion. two adjacent points. If the minimum value
measured is less than the repair limit,
1.19.1.4 Fit suitable flat washers (A) and replace the brake disc.
wheel nuts, and tighten the nuts with Brake disc thickness:
specified torques to make the brake disc Standard: 9.9-10.1 mm
touch the wheel hub closely. Repair limit: 8 mm
Maximum Deviation of Brake Disk
Parallelism: 0.05 mm
Notice: This is the maximum deviation allowed

for the measurement of the thickness of the
brake disc.
1.19.1.5 Place the dial gauge near the brake

disc to measure the run-out at 10 mm from
the outer edge of the brake disc.
Single brake disc run-out repair limit: 0.03
mm
1.19.1.6 If the run-out of the brake disc

exceeds the repair limit, repair the brake 1.19.2.4 If the parallelism of the brake disc has
disc with the on-board brake lathe. exceeded the repair limit, repair or adjust
Repair limit: 8 mm the brake disc.
Note: Notice: If the brake disc parallelism has

1.19.1.6.1 If the wear on the brake disc has exceeded the repair limit, the brake disc
exceeded the limit value for repair, the should be replaced.
brake disc should be replaced.
1.20 Replacement of Rear Wheel Hub Unit
1.19.1.6.2 If the run-out of single brake disc is Assembly
more than 0.03 mm, adjust the brake disc.
Remove the rear wheel hub unit assembly and
1.19.2 Thickness and Parallelism fender:
1.19.2.1 Raise the rear part of the vehicle. 1.20.1 Raise the vehicle;
Support the vehicle with the safety support
at a suitable location. Remove rear 1.20.2 Remove the rear wheels;
wheels.
1.20.3 Remove the wire harness of the rear
1.19.2.2 Remove the brake pad. wheel speed sensor;
1.19.2.3 Use a micrometer to measure the 1.20.4 Loosen the bolt (A), and remove the
thickness of the brake disc at 8 points 10 rear brake caliper (B);
mm from the outer edge of the brake disc
174
1.20.5 Remove the rear brake disc (C);
95 Nm

of removal.
1.20.6 Rotate the rear wheel hub unit flange
(A), loosen the bolt (C) via the hole (D) Required torque:
with the sleeve (B), and then take off the Connecting bolt of brake caliper and mounting
rear wheel hub unit (A) and fender (E); plate: 95 Nm
Connecting bolt of wheel hub unit and
mounting plate: 95 Nm
175
Part 9 Drive Half Shaft

Section 1 Drive Half Shaft (5A\5AI)
1 Half Shaft Detection
1.1 Inspect the inner dust cover (A) and outer 1.2 Rotate the half shaft by hand to make sure
dust cover (B) on the half shaft (C) for any the outer spine (E) and inner spine of the
cracks, damage, grease leakage and differential are not engaged loosely.
inspect the dust cover clamp (D) for
looseness. If any defect is found, replace 1.3 Make sure there is no distortion, corrosion
the dust cover and dust cover clamp. or cracks on the half shaft, otherwise the
half shaft should be replaced.
1.4 The inner and outer ball cages should

swing or slide flexibly without sticking,
otherwise the half shaft should be
replaced.
176
2 Half Shaft Removal
2.1 Lightly unscrew the wheel nuts.
2.2 Raise the front part of the vehicle, and

support the vehicle with a safety stand at
the proper locations.
2.3 Remove the wheel nuts and front wheels.
2.4 Remove the split pin (B) from the half shaft
nut (A), and then remove the nut (A).
2.7 Pry out the inner ball cage (A) from the
differential with a crow bar, and remove the
half shaft as an assembly. Do not pull the
half shaft (B) forcibly, as the inner ball cage
dust cover may be broken. Pull out the half
shaft directly after the inner ball cage (A) is
pried out with a crow bar to avoid damage
to the oil seal.
2.7.1 Left half shaft
2.5 Remove the connecting bolt A of the lower

swinging arm ball joint and nut B of the ball
joint connection rod to separate the
steering knuckle and lower swinging arm.
2.7.2 Right half shaft
2.6 Pull the steering knuckle outward, and

then remove the outer ball cage from the
front wheel hub with a plastic hammer.
177
3 Half Shaft Installation

swinging arm ball joint and nut of the ball
3.1 Install the new retaining ring in the joint connection rod to 90 Nm.
retaining ring groove of the half shaft.
3.2 Thoroughly wash the contact area of the

half shaft and differential with solvent or
brake detergent, and then blow dry with 3.5 Install the new half shaft nut (A), and
compressed air. Insert the inner ball cage tighten it to the specified torque. Install the
end (A) of the half shaft into the differential new split pin (C) in the pin hole, and then
(B), until the retaining ring (D) is locked in bend the split pin as shown. If the split pin
the groove (E). cannot be inserted into the groove and pin
hole, properly tighten the nut to align the
groove and pin hole instead of loosening
the nut.
3.3 Install the outer ball cage (A) to the front

wheel hub (B).
3.6 Clean the mating surface of the brake disc

and front wheel, and then install the front
wheels with wheel nuts.
3.7 Rotate the front wheels by hand to confirm

the clearance between the half shaft and
surrounding parts.
3.8 Check the front wheel alignment and

adjust as needed.
3.4 Tighten the connecting bolt of the lower
178
Section 2 Drive Half Shaft (BYD476ZQA+6DT25)

1 Half Shaft Detection
1.1 Inspect the inner dust cover (A) and outer 1.2 Rotate the half shaft by hand to make sure
dust cover (B) on the half shaft (C) for any the inner spine (E) and outer spine of the
cracks, damage, grease leakage and differential are not engaged loosely.
inspect the dust cover clamp (D) for
looseness. If any defect is found, replace 1.3 Make sure there is no distortion, corrosion
the dust cover and dust cover clamp. or cracks on the half shaft, otherwise the
half shaft should be replaced.
1.4 The inner and outer ball cages should

swing or slide flexibly without getting stuck,
otherwise the half shaft should be
replaced.
179
2 Half Shaft Removal
2.1 Lightly unscrew the wheel nuts.
2.2 Raise the front part of the vehicle, and

support the vehicle with a safety stand at
the proper locations.
2.3 Remove the wheel nuts and front wheels.
2.4 Remove the split pin (C) from the half shaft
nut (B), and then remove the nut (B) and
washer (A).
2.7 Pry out the inner ball cage (A) from the
output shaft of the transmission with a
crow bar, and remove the half shaft as an
assembly. Do not pull the half shaft (B)
forcibly, as the inner ball cage dust cover
may be broken. Pull out the half shaft
directly after the inner ball cage (A) is pried
out with a crow bar.
2.7.1 Left half shaft
2.5 Remove the connecting bolt A of the lower

swinging arm ball joint and nut B of the ball
joint connection rod to separate the
steering knuckle and lower swinging arm.
2.7.2 Right half shaft
2.6 Pull the steering knuckle outward, and

then remove the outer ball cage from the
front wheel hub with a plastic hammer.
180
3 Half Shaft Installation
3.1 Install the new retaining ring in the

retaining ring groove on the output shaft of
the transmission.
3.4 Tighten the connecting bolt of the lower

swinging arm ball joint and nut of the ball
joint connection rod to 90 Nm.
3.2 Thoroughly wash the contact area of the

half shaft and differential with solvent or
brake detergent, and then blow dry with
compressed air. Install the inner ball cage
3.5 Install the new half shaft nut (A), and
end (A) of half shaft into the output shaft (B)
tighten it to the specified torque. Install the
of the transmission, until the retaining ring
new split pin (B) in the pin hole, and then
(C) is locked in the inner ball cage.
bend the split pin as shown. If the split pin
cannot be inserted into the groove and pin
hole, properly tighten the nut to align the
groove and pin hole instead of loosening
the nut.
3.3 Install the outer ball cage (A) to the front

wheel hub (B).
181
the clearance between the half shaft and

3.6 Clean the mating surface of brake disc and surrounding parts.
front wheel, and then install the front
wheels with wheel nuts. 3.8 Check front wheel alignment and make
adjustment as needed.
3.7 Rotate the front wheels by hand to confirm
182
Part 10 Gear Shift Control System

Section 1 Gear Shift Mechanism Replacement (5A-5T14)
1.1. Removal order: c. Fix the pull cable on the transmission

support with the E-shape clamp (Part No.
After the auxiliary instrument panel is removed, 14), clamp the connector at the pull cable
remove the gear shift control system in the transmission to the transmission swinging
following order: arm and install the split pin (Part No. 12);
1 - Split pin (Part No. 12); d. Fix the connector at the pull cable gear
2 - E-shape clamp (Part No. 14); shift mechanism on the gear shift
3 - Hexagon combination bolt (Part No. 13); mechanism holder, and attach the E-shape
4 - Pull cable support (Part No. 16, 17, 18); clamp (Part No. 14)
5 - Rubber dust cover and metal cover plate
assembly (Part No. 15); e. Clamp the connector on the swinging arm
6 - Combination bolt (Part No. 10); of the gear shift mechanism, and clamp
7 - Gear shift operating mechanism assembly the split lock pin at the same time.
(Part No. 1, 2, 3, 4, 5, 6, 7, 8, 9, 11);
1.3 Installation of Gear Shift Operating
1.2. Installation of Gear Shift Cable: Mechanism:
a. Fix the pull cable support on the body (Part Install each bolt in the correct mounting hole
No. 16, 15 Nm); after the gear shift mechanism is adjusted.
Pretension each bolt by applying small torque,
b. Fix the rubber pull cable dust cover and and then tighten the bolt (22 Nm) diagonally.
metal cover plate assembly (Part No. 15) Install the auxiliary instrument panel and
on the body with the hexagon combination clamp the hog ring of the dust cover.
bolt (Part No. 13, 15 Nm);
183
Section 2 Replacement of Gear Shift Mechanism (BYD476ZQA+6T25)
Tighten the nuts with

torque of 15 Nm
Tighten the bolts with

torque of 22 Nm
2.1. Removal order the connector at the pull cable transmission

end on the transmission swinging arm (The
2.1.1 The required torque for hexagon flange transmission has been fixed in first gear), and
bolt is 22 Nm clamp the connector at the transmission end
on the connecting lock pin (as shown by 6);
2.1.2 Gear shift operating mechanism
assembly (Part No. 1) Fix the connector at the pull cable gear shift
mechanism end on the gear shift mechanism
Transmission connection end of the gear shift holder and attach the E-shape clamp (as
cable assembly shown by 7). Clamp the gear shift connector of
pull cable on the swinging arm of the gear shift
The required torque for the hexagon flange nut mechanism, clamp the pull cable gear shift
(Part No. 4) is 15 Nm mechanism on the gear shift mechanism
swinging arm after adjusting its length, and
E-shape clamp spring of transmission support clamp the lock pin at the same time (The shift
(Part No. 5) lever of gear shift mechanism has been fixed
in first gear).
(6) Gear shift cable assembly (Part No. 2)
2.3. Installation of Gear Shift Operating
2.2 Installation of the Gear Shift Cable: Mechanism:
Fix the pull cable bracket on the body with the Install each bolt in the correct mounting hole,
hexagon flange nut (2 in the figure), and install pretension each bolt by applying small torque,
the sealing gasket to the body; and then tighten the bolts diagonally to a
Fix the pull cable on the transmission support torque of 22 Nm.
with the spring plate (as shown by 5), clamp
184
Section 3 Gear Shift Control System (BYD476ZQA+6D T25)

The figure 1 is the schematic diagram of the
gear shift control system.
Figure 3
Fig. 1
Assembly:
3.1 Removal and Installation of Gear Shift
Fix the gear shift cable on the gear shift
Operating Mechanism
mechanism as shown in elliptical frame 1 and
3 of figure 3, and then tighten 4 hexagon
Removal:
flange bolts on the floor as shown in figure 2 to
20 Nm.
Remove 4 hexagon flange bolts connected to
the gear shift mechanism floor as shown in
3.2 Removal and Installation of Gear Shift
figure 2.
Cable
Removal:
A. Remove the connection of the gear shift
cable and gear shift mechanism as shown
in figure 3;
B. Remove 3 hexagon flange nuts of gear
shift cable sealing gasket as shown in
figure 4;
Figure 2
The gear shift mechanism can be removed by

removing the gear shift cable from the elliptical
frame 1 and 3 in figure 3.
Figure 4
C. Remove 2 connecting nuts of the gear shift

cable bracket and front deck as shown in
figure 5;
185
Assembly:
After positioning the shift lever of the gear shift

mechanism and gear shift swinging arm of the
transmission in P, assemble the gear shift
cable in the reverse order of the above
removal from D to A. Finally tighten the
adjusting bolt as shown in figure 7.
Figure 5
d. The entire gear shift cable can be removed

by removing the connecting ball joint of
gear shift cable and transmission gear shift
swinging arm as shown in figure 6;
Figure 7
Figure 6
186
Chapter 5 ABS System

Contents
Section 1 Precautions ............................................................................................................188
1.1 Precautions for Repair and Diagnosis ..................................................................... 189
Section 2 Malfunction Diagnosis Flow ...................................................................................192
2.1 ABS System with EBD ............................................................................................. 192
Section 3 Customer Malfunction Analysis Table ....................................................................194
3.1 Customer Malfunction Analysis Table ..................................................................... 194
Section 4 Diagnostic Check ...................................................................................................195
4.1 Preliminary Check .................................................................................................... 195
4.2 On-vehicle Check .................................................................................................... 197
4.3 Check with diagnostic tester .................................................................................... 198
Section 5 Trouble Code Table ...............................................................................................232
Section 6 Component Layout.................................................................................................235
Section 7 Definition of ECU Pin .............................................................................................236
7.1 Circuit Diagram for ABS Hydraulic Regulator with ECU ......................................... 236
7.2 Circuit Diagram for ESP Hydraulic Regulator with ECU ......................................... 237
7.3 Pins of ABS and ESP Hydraulic Regulator with ECU ............................................. 238
7.4 ABS9 Brake Line Connection Diagram ................................................................... 240
7.5 ABS9 Schematic Diagram ....................................................................................... 241
Section 8 Trouble Symptom...................................................................................................242
8.1 Trouble Symptom Table .......................................................................................... 242
8.2 Intermittent Trouble Symptom Table ....................................................................... 242
Section 9 Trouble Code Diagnosis ........................................................................................245
Section 10 Service Specifications ..........................................................................................286
10.1 General Specifications ........................................................................................... 286
10.2 Torque (Unit: N·M) ................................................................................................. 286
187
Section 1 Precautions
(c) EPB automatic pull up function: When the
ABS (Anti-lock Brake System) vehicle is turned off or the shift position is
in P, EPB will be pulled up automatically
and the indicator light in the meter will
come on.
(d) Release EPB manually: Turn the vehicle

on and press the switch downward
while depressing the brake pedal until the
indicator light in the meter turns off. It
indicates that the electronic parking brake
has been released.
(e) Release EPB automatically when the

vehicle starts: When EPB is pulled up, if
the vehicle starts and the accelerator
The hydraulic system of ABS-actuated pedal is depressed, EPB will be released
brake has 2 individual circuits. Each circuit automatically and the indicator light in
passes through the vehicle in a diagonal the meter will turn off.
direction (left front wheel brake is
connected to right rear wheel brake). If one (f) Hill start: The automatic release function of
circuit malfunctions, two wheels can still be EPB makes the vehicle start easily on a hill.
braked. To prevent the vehicle from slipping when
starting on a hill, the system will
When the brake is applied suddenly or the automatically release EPB after the engine
brake is applied while driving on a wet has enough power.
road, the ABS can help prevent wheel lock
or slippage, thus enabling you to keep (g) Emergency braking function: Even if the
steering control. brake pedal fails, the vehicle can still be
braked forcibly with the EPB switch. In
EPB (Electronic Parking Brake system) case of an emergency, pull up the EPB
switch and apply the parking brake. in
The electronic parking brake system is the meter will come on and the alarm
used instead of the conventional hand sounds.
brake. It can be pulled up or released
manually/automatically. ESP (Electronic Stability Program)
(a) Electronic Parking Switch ESP functions when the engine is started.
Three functional modules (ABS, VDC and
TCS) and two value-added sub functions
(HHC and HBA) are integrated in ESP.
VDC (Vehicle Dynamics Control)

When swerving suddenly while driving, the
VDC system determines the driver's intent
based on the steering angle and vehicle
(b) Pull up EPB manually: When the
speed and continuously compares it with
switch in the illustration is pulled up, the
the actual vehicle condition. If the vehicle
indicator light in the meter will flash deviates from the normal driving route,
and then come on. It indicates that EPB VDC will correct the condition by applying
has been pulled up. the brake of the applicable wheel to help
the driver control skidding and keep the
188
directional stability. system is operating.
TCS (Traction Control System) Disable ESP system
TCS can prevent the slippage of the If the vehicle is stuck in snow or mud, the
drive wheels during accelerating by ESP system may decrease the power
reducing the engine power. If necessary, output to the wheels from the engine. You
the brake will be applied to prevent the may need to turn off the system to free the
drive wheel spinning. Under unfavorable stuck vehicle.
conditions, TCS enables the vehicle to
start, accelerate and climb the hill easily. Restart ESP system after turning off the
engine
HHC (Hill-start Assist Control)
After turning off the ESP system, restarting
When the brake pedal is released, HHC the engine will automatically turn on the
can keep the brake pressure applied by ESP system again.
the driver for up to 2 seconds. So the
driver can switch the foot from brake pedal ESP system activation linked with vehicle
to the accelerator pedal to prevent the speed
vehicle from slipping on the hill.
If ESP system is turned off, the vehicle will
HBA (Hydraulic Brake Assist) become extremely unstable when the
vehicle speed increases and exceeds the
When the driver depresses the brake threshold (80Km/h). At this time the ESP
pedal quickly, HBA will determine the system will start automatically.
vehicle is in an emergency. Increase the
brake pressure to the maximum quickly to 1.1 Precautions for Repair and Diagnosis
enable ABS, so as to shorten brake
distance effectively. ABS is a component related to driving
safety. When conducting repair and
When ESP system is operating diagnosis on it, observe the following
diagnosis precautions in addition to
If there is risk of slippage or reversing general safety and preventive measures.
when starting the vehicle on a slope, or
any drive wheel is spinning, the ESP
indicator light flashes, indicating ESP
189
(a) ABS system should only be repaired by

technicians who have received professional
training and mastered repair skills. Its parts
should only be replaced with original parts of the
manufacturer.
(b) Before diagnosing the ABS system, the regular

brake system must work normally.
(c) Before and while driving the car, ABS ECU

constantly monitors whether all electric elements
related to ABS work normally.
(d) Before turning on the vehicle, the ABS and brake

system warning lamp must be turned on and then
turned off after several seconds.
(e) The system fault is detected when any of the

following conditions occurs.
a) The warning lamp remains on after the

vehicle is turned on.
b) While driving the car, the light does not turn

off.
ABS Warning lamp Brake system
warning lamp
In these cases, the driver can conduct regular
braking and needs to reduce the braking
force to avoid wheel locking. Therefore, drive
carefully when the warning lamp turns on.
Retaining bolt (4) Repair the ABS system at an authorized
service station to avoid severe faults which
APS control unit
(with return pump might lead to an accident.
motor and solenoid
valve relay)
(f) ABS hydraulic regulator with ECU has the
Solenoid valve
(8) (4 oil inlet following parts:
valves and 4 oil Hydraulic
controller
outlet valves)
Return pump
a) ABS ECU: with return pump motor relay
motor and solenoid valve relay
b) Solenoid valve (8): includes 4 oil inlet

valves and 4 oil outlet valves
c) Return pump and accumulator
d) Others: motor, bolts, etc.
They can only be replaced as a whole and cannot

190 be disassembled or replaced partly. Bosch does
not provide separate spare part, and does not
warranty the disassembled ABS with hydraulic
(h) Connection of ABS ECU
a) Before removing the ABS ECU connector,

the engine must be turned off.
b) Keep the ABS ECU connector dry and clean

and remove any foreign substance.
c) ABS ECU connector must be installed in

place: the bottom is flush with the base.
d) ABS ECU connector must be installed in

place: the side is vertical to the base.
(i) ABS hydraulic regulator with ECU must be

properly earthed. If the wire harness is not
properly earthed, water or moisture will penetrate
the ABS ECU connector through the holes in the
wire harness under the capillary (siphon) effect,
thus causing functional failure.
Measures: apply sealant on the exposed end of

Apply sealant on the exposed end of wire
wire harness and use a shrinkable tube sleeve.
harness and use shrinkable tube sleeve
Recommended sealant: Raychem sealant.
(j) Ensure the connection of the ABS brake line is

correct. ABS ECU cannot judge whether the
brake line is correctly connected, and it will not
perform fail safe. Incorrect connection may lead
to a severe accident.
The marker on the ABS hydraulic controller may

vary depending on its place of origin.
MC1: connected to brake line 1 of the brake

master cylinder;
MC2: connected to brake line 2 of brake master

cylinder;
FL: connected to brake line of left front brake 191

wheel cylinder;
Section 2 Malfunction Diagnosis Flow

2.1 ABS System with EBD
Malfunction Diagnosis Flow
2.1.1 Vehicle Brought to Workshop
2.1.2 Customer Problem Analysis
2.1.3 Read the trouble codes
DTC is output Go to step 4
DTC is not
Go to step 9
output
2.1.4 Record DTC, and then clear malfunction memory.
2.1.5 Confirm and duplicate malfunction: simulate malfunction condition. Read DTC again.
DTC is Current DTC.

output
Go to step 8
DTC is Current DTC.

not output
Go to step 6
2.1.6 Is it related to malfunction symptoms?
Yes Intermittent
malfunction.
Go to step 7
No Eliminated malfunction.
Go to step 9
2.1.7 Perform malfunction simulation again.
192
2.1.8 Perform troubleshooting in accordance with trouble code table. Go to step 10.
2.7.9 Perform troubleshooting in accordance with trouble symptom table.
2.1.10 Confirm the malfunction has been eliminated.
End
2.1.11 Prevent it from occurring again
193
Section 3 Customer Malfunction Analysis Table

3.1 Customer Malfunction Analysis Table
ABS Check Table Quality Inspector
License Plate
Owner Number
Name
Model
Contact
Chassis No.
Number
Date of
/ / Odometer km
Entry
Date of
/ /
Malfunction Occurrence
Condition Frequency of
 Often  Sometimes ( times/day)
Occurrence
 ABS does not work well  ABS does not work
 EBD does not work well  EBD does not work

Symptom
ABS warning lamp is
 Remains on  Does not turn on
abnormal
EBD warning lamp is
 Remains on  Does not turn on
abnormal
 Normal Code  Current DTC (Code: )

First Time
 History DTC (Code: )
Troublesho
oting
Second  Normal Code  Current DTC (Code: )
Time  History DTC (Code: )
194
Section 4 Diagnostic Check

4.1 Preliminary Check
It refers to the inspection of accessible Visual inspection and appearance inspection

components which may cause ABS system procedures can confirm the malfunction
malfunction. quickly, with no need for further diagnosis.
(a) Be sure to install tires and wheels of the

recommended size on the vehicle. The
coaxial tread pattern and depth must be
same.
Original standard tire: 205/65 R15 94V
Original optional tire: 205/60 R16 92V
(b) Check the hydraulic regulator, brake lines

and connectors for leakage.
Fuse
(c) Check ABS fuses -- 10 A, 25 A and 40A.
Fusible
Link
(d) Make sure the battery is fully charged.
(e) Check if the battery connection is corroded
or if the post is loose.
195
(f) Perform visual inspection and appearance

inspection on the following electric
Ignition
Coil/Distributor/ elements:
Sparkplug
a) Whether the wire harness and pin of
Gear Ring the ABS component are correctly
connected, pinched or cut.
Generator
d) Whether the wire harness route is too
Wheel Speed Sensor close to high-voltage or high-current
equipment, such as:
High-voltage ignition component

Motor and generator
After sales stereo amplifier
Electro Magnetic
Interference
Important Notes: High-voltage or
high-current equipment may cause the
circuit to generate induced noise, thus
interfering with normal operation of the
circuit.
c) The connectors of ABS system related

components are not well connected, or
Electro Magnetic
the pins are not fully inserted into the
Interference connector housing.
d) ABS components are sensitive to

Electro Magnetic Interference (EMI). If
Hydroplaning there is any doubt about the intermittent
Hydroplaning
malfunction, check if the after sales
Water Source
anti-theft device, lights or cell phone
Could not
are incorrectly installed.
(g) ABS is an active safety system. It is mainly

used to maintain maneuverability of vehicle
direction and driving stability when braking.
Meanwhile, the maximum deceleration can
be achieved, thus minimizing the braking
distance. The tire wear is even and small.
, This is because the adhesion force
between the tires and road is applied based
on the adhesion coefficient limit when ABS
is applying the brake. However, when the
vehicle speed exceeds the limit while
cornering or driving at high speed on
slippery roads, ABS cannot prevent the
creep movement.
196
4.2 On-vehicle Check
(a) Release the parking brake lever.
(b) Check warning lamp.

When the vehicle is turned on, check ABS warning
lamp and brake system warning lamp.
They should turn off after illuminating for several

seconds.
Note:
When the parking brake is applied or the brake fluid
level is too low, the brake system warning lamp will
come on.
If the warning lamp does not operate normally,
perform troubleshooting on the ABS warning lamp
circuit and brake system warning lamp circuit.
Brake system ABS warning

When the vehicle is turned on, ABS warning lamp and brake warning lamp lamp
system warning lamp should turn on.
If the system is normal, the warning lamp should turn off after
about 3 seconds.
The system is normal after a self-check.
a) ABS has current malfunction that has been repaired

ABS stops operating. EBD still functions.
For example: Only one wheel speed sensor
malfunctions.
b) ABS has wheel speed sensor and return pump motor
current DTC
Vehicle speed < 12 km/h: ABS warning lamp comes on,
ABS stops operating
Vehicle speed ≥ 12 km/h: ABS warning lamp turns off
after no malfunction is detected
Current DTC is converted to history DTC
a) Diagnose ABS with diagnostic tester
Vehicle speed < 10 km/h: All diagnostic functions of ABS

operate normally
Vehicle speed > 10 km/h: Both lamps turns off if normal,
ABS control is normal and diagnosis interrupts
automatically.
b) EBD malfunctions
ABS and EBD stop operating.
For example: Three or more wheel speed sensor
malfunctions.
The brake fluid level is too low or the parking brake lever is
not released
ABS and EBD electrical devices operate normally.
To cancel the speed limit, refer to Page 34 "4.3.6 Set/Unset Diagnostic Communication Speed
Limit"
197
4.3 Check with diagnostic tester
Method to connect diagnostic tester:
(a) Turn the vehicle off
(b) Connect the diagnostic tester to

diagnostic socket in the vehicle
(c) Turn the vehicle on
(d) Select Bosch ABS9 system
198
After performing a test on ABS with the

diagnostic tester, road test the vehicle
and clear the trouble codes if necessary
to ensure that ABS and the regular brake
system operate normally.
4.3.1 Read Computer Version
Bosch ABS9 system Computer version Description:

1 Read computer To ensure system safety and correct
version diagnosis, confirm the computer version
2 Read system No. is in accord with the model before
malfunctions performing diagnosis on a BYD Sari
3 Clear the trouble vehicle.
Manufacturer
codes Incorrect or mixed use of ABS hydraulic
hardware No.:
4 Read data flow unit with ECU may cause incorrect
026255422
5 Off-line test routine diagnosis and repair, resulting in severe
Diagnosis system
6 Set/unset diagnostic accidents.
marker: abc
communication speed
ABS type: ABS9
limit
System hardware
7 Change filling status
No.: 0123456789
Note:
System software
Under normal conditions,
No.: 123
the communication
Software version:
between diagnostic tester
0.1.2.3
and ABS ECU will be
interrupted forcibly when
the vehicle speed exceeds
a specified value to ensure
safety.
Press [↑] key to move up Press [Esc] key to
Press [↓] key to move exit
down Press [F2] to print
Press [OK] key to execute current contents
Press [Esc] key to exit
4.3.2 Read system malfunctions
Bosch ABS9 system Read system malfunctions Current DTC and history DTC
1 Read computer version 1. C0032XX (Current): can be read via "Read System
2 Read system Left front wheel sensor Malfunction" option. At this time,
malfunctions signal or circuit current and history DTCs can be
3 Clear the trouble malfunctions. cleared via "Clear Trouble
codes Codes" option.
199
4 Read data flow 2. COO1104 (History):

5 Off-line test routine Left front oil outlet valve
6 Set/unset diagnostic of hydraulic regulator
communication speed malfunctions.
limit
Note:
the communication
between the diagnostic
tester and ABS ECU will be
safety.
Press [↑] key to move up Press [Esc] key to exit
Press [↓] key to move
down
Press [OK] key to execute
Bosch ABS9 system Read system malfunctions If the system is normal, "System
1 Read computer is OK" appears.
version
2 Read system
malfunctions
3 Clear the trouble
codes
4 Read data flow
5 Off-line test routine
6 Set/unset diagnostic
communication speed
System is OK
limit
Note:
the communication
tester and ABS ECU will
be interrupted forcibly
when the vehicle speed
exceeds a specified value
to ensure safety.
Press [↑] key to move up Press any key to return
Press [↓] key to move
down
4.3.3 Clear the trouble codes
Clear the trouble Current and history DTCs can be

Bosch ABS9 system
codes cleared via "Clear Trouble Codes"
1 Read computer Trouble codes option.
200
version cleared Note:

2 Read system The trouble codes cannot be cleared
malfunctions by removing the battery.
3 Clear the trouble Make sure the battery voltage is
codes normal before clearing the trouble
4 Read data flow codes.
communication speed
limit
Note:
the communication
safety.
Press [↑] key to move up Press any key to
Press [↓] key to move down return
4.3.4 Data flow
Bosch ABS9 system Read data flow Description:

1 Read computer version 1. Wheel speed The values of various switches,
2 Read system signal sensors and actuators can be read
malfunctions 2. Analog status from the data flow of the diagnostic
3 Clear the trouble codes 3. Digital status tester without the need to remove or
4 Read data flow 4. Hydraulic unit install any element.
5 Off-line test routine filling status Therefore, reading data flow before
6 Set/unset diagnostic malfunction diagnosis is one way to
communication speed limit shorten repair time and perform
7 Change filling status effective repair.
Note:
the communication
safety.
Press [↑] key to move up Press [↑] key to move
Press [↓] key to move down up
Press [OK] key to execute Press [↓] key to move
Press [Esc] key to exit down
Press [OK] key to
execute
201
For safety, when the vehicle speed is

Bosch ABS9 system more than 10 km/h, ABS ECU will
interrupt the communication with the
Initialization Failure diagnostic tester, including stopping
Please check if the circuit is correctly connected data flow output.
But the limit can be canceled.
For details on setting method and
Press any key to return precautions, refer to Page 34 of the
repair manual.
Available data flow:
Displayed
Classification Item Normal condition Note
value/range
Left front Actual wheel See Page 34
0~350 km/h
wheel speed speed*
Left rear wheel Actual wheel See Page 34
0~350 km/h
Wheel Speed speed speed*
Signal Right front Actual wheel See Page 34
0~350 km/h
wheel speed speed*
Right rear Actual wheel See Page 34
0~350 km/h
wheel speed speed*
Analog Status Battery 0~+20.40 V 3.9 V~16.9 V
Voltage
Left front oil Power Related to ABS
inlet valve On/Off working condition:
Left front oil Power Pressure increase: Oil
outlet valve On/Off inlet valve - Power off
Right front oil Power Oil outlet
Digital Status Turn the vehicle
inlet valve On/Off valve - Power off
on: Power Off
Right front oil Power Pressure hold: Oil inlet
Other working
outlet valve On/Off valve - power
condition:
Left rear oil Power on Oil outlet
Depending on
inlet valve On/Off valve - Power
control
Left rear oil Power off
outlet valve On/Off Pressure decrease:
Right rear oil Power Oil inlet valve - Power
inlet valve On/Off on
Right rear oil Power Oil outlet
outlet valve On/Off valve - Power on
Braking light Power Depress the
status On/Off brake pedal:
Power on
Release the
brake pedal:
Power off
Return pump Power
motor status On/Off
Solenoid valve Power Turn the vehicle
relay status On/Off on: Power on
Hydraulic New ABS Filled completely New part will display
Filling Status regulator filling hydraulic and normal "New ABS Hydraulic
status unit has Unit"
202
been filled
and
normal/New
ABS
hydraulic
unit has
been filled
and
abnormal.
*: When the speed is less than 2.6 km/h and the vehicle is stationary, the diagnostic tester will
display O km/h.
Read data flow Wheel Speed Signal Read wheel speed sensor
signal data.
√1. Wheel speed signal Left front wheel speed: 8.2km/h Note:
□2. Analog status Right front wheel speed: 8.2km/h a. Please refer to Page
□3 Digital status Left rear wheel speed: 8.2km/h 34 "Set/Unset Diagnostic
□4. Hydraulic unit filling Right rear wheel speed: 8.2km/h Communication Speed
status Limit"
Press [↑] key to move up Press [F2] to print current contents b.* When the speed is
Press [↓] key to move Press [Esc] key to return less than 2.6 km/h and the
down vehicle is stationary, the
Press [OK] key to execute diagnostic tester will
Press [Esc] key to exit display O km/h.
Read data flow Analog Status Read analog status data.
□1. Wheel speed signal Battery Voltage: 12.2V Normal value: 9.3 V~17.5
√2. Analog status V.
□3. Digital status If it is not within the range,
□4. Hydraulic unit filling see Page 63~65.
status
Press [↑] key to move up Press [F2] to print current contents
Press [↓] key to move Press [Esc] key to return
down
Read data flow Digital Status Read digital status data.
□1. Wheel speed signal Left front oil inlet valve: Power off Normal Value: See Page
□2. Analog status Left front oil outlet valve: Power off 11.
√3. Digital status Right front oil inlet valve: Power off
□4. Hydraulic unit filling Right front oil outlet valve: Power
status off
Left rear oil inlet valve: Power off
Left rear oil outlet valve: Power off
Right rear oil inlet valve: Power off
Right rear oil outlet valve: Power
off
Braking light status: Power on
Return pump motor status: Power
on
Solenoid valve relay status: Power
on
203
Press [↑] key to move up Press [F2] to print current contents

Press [↓] key to move Press [Esc] key to return
down
Read data flow Hydraulic Unit Filling Status Read hydraulic unit filling
□1. Wheel speed signal Hydraulic Unit Filling Status: Filled status data.
□2. Analog status completely and normal. At this time, 5 status can
□3. Digital status be displayed:
√4. Hydraulic unit filling 1 Filling is complete;
status 2 Invalid value -
Press [↑] key to move up Press [F2] to print current contents Memorize incorrect
Press [↓] key to move Press [Esc] key to return values;
down 3 New ABS hydraulic
Press [OK] key to execute unit;
Press [Esc] key to exit 4 Filled completely and
normal;
5 Filled completely and
abnormal.
New ABS hydraulic unit
with ECU will display "New
ABS Hydraulic Unit".
If "Invalid value -
Memorize incorrect
values" is displayed, ABS
memory is damaged.
To change filling status,
see Page 35.
4.3.5 Off-line Detection Routine
Bosch ABS9 system Off-line test routine Role:

Send command to ABS ECU via the
1 Read computer version √1. Vacuumizing
diagnostic tester for service personnel to
2 Read system and Filling Test
diagnose malfunction.
malfunctions 2. Brake Bleeding
Off-line test routine includes the following
3 Clear the trouble codes 3. Dynamic Test
functions:
4 Read data flow 4. Action Test
1. Vacuumizing and Filling Test
5 Off-line test routine 5. Wheel Speed
2. Brake Bleeding
6 Set/unset diagnostic Sensor Test
3. Dynamic Test
communication speed
4. Action Test
limit
5. Wheel Speed Sensor Test
Note:
the communication
tester and ABS ECU will
be interrupted forcibly
when the vehicle speed
exceeds a specified value
to ensure safety.
Press [↑] key to move up Press [↑] key to
Press [↓] key to move move up
down Press [↓] key to
204
Press [OK] key to execute move down

Press [Esc] key to exit Press [OK] key to
execute
Press [Esc] key to
exit
4.3.5.1 Vacuumizing and Filling Test
Off-line test routine Vacuumizing and The diagnostic tester does not support
Filling Test vacuumizing and filling test function.
√1. Vacuumizing and
Filling Test
2. Brake Bleeding (The diagnostic
3. Dynamic Test tester does not
4. Action Test support the function)
5. Wheel Speed Sensor
Test
Press [↑] key to move up Press any key to
Press [↓] key to move return
down
4.3.5.2 Brake Bleeding
Bosch ABS9 system Off-line test routine Description:

1 Read computer version √1. Vacuumizing and ·When opening the hydraulic brake line
2 Read system Filling Test or replacing the dry ABS hydraulic
malfunctions 2. Brake Bleeding regulator with ECU, bleeding must be
3 Clear the trouble codes 3. Dynamic Test performed.
4 Read data flow 4. Action Test ·During brake bleeding, the brake fluid in
5 Off-line test routine 5. Wheel Speed the brake fluid reservoir may decrease
6 Set/unset diagnostic Sensor Test due to outflow of brake fluid. Make sure
communication speed there is enough brake fluid during the
limit process.
7 Change filling status ·The operation needs at least two
Note: persons. One person fills brake fluid into
Under normal conditions, brake fluid reservoir on the ground, and
the communication the other person performs diagnostic
between diagnostic tester tester communication and depresses the
and ABS ECU will be brake pedal on the raised vehicle.
interrupted forcibly when ·Before bleeding, move the shift lever in
the vehicle speed P (AMT Type) or N (MT Type) and apply
exceeds a specified value parking brake.
to ensure safety. ·Brake fluid is toxic. If it contacts with
Press [↑] key to move up Press [↑] key to skin, wash it off.
Press [↓] key to move move up ·In most cases, perform bleeding with
down Press [↓] key to regular methods. When any of the
Press [OK] key to execute move down following conditions occurs, perform the
Press [Esc] key to exit Press [OK] key to recommended automatic bleeding
execute procedure:
Press [Esc] key to 1 Regular brake system bleeding does
exit not achieve ideal pedal height or foot
feel;
205
2 Serious loss of brake fluid;

3 The auxiliary oil line of hydraulic
regulator assembly may have air
resistance. Use diagnostic tester only
when air in the brake line cannot be bled
using regular methods.
4.3.5.2.1 Preparation
(a) Turn the vehicle off.
(b) Fill sufficient brake fluid in the brake fluid

reservoir.
Note:
Brake fluid type: DOT3, DOT4. Do not mix
them.
During bleeding, check if the brake fluid in the
brake fluid reservoir is sufficient and refill in
time.
(c) Connect the diagnostic tester to the

diagnostic socket.
(d) Turn on the vehicle and start the engine
as necessary.
(e) Enter "Digital Status" option in BOSCH

ABS system.
(g) Read data flow and confirm:
Solenoid valve relay status: Power on
Return pump motor status: Power off
Normal: The above requirements are satisfied.
Normal
4.3.5.2.2 Connect brake filling and bleeding device
Off-line test routine Brake Bleeding (a) Please note the prompt
on the diagnostic tester.
1. Vacuumizing and Preconditions and precautions:
Filling Test l. Two persons are needed for Press [OK] key to go to next
√2. Brake Bleeding the operation; step.
3. Dynamic Test 2. Fill 2 bar pressure in the
4. Action Test brake fluid reservoir of the
5. Wheel Speed vehicle;
Sensor Test 3. Life the vehicle safely;
206
4. Turn on the vehicle and start

the engine as necessary;
5. ABS system has no
malfunction; Return pump
motor stops operating;
Solenoid valve relay is on;
6. After pressing [OK] key, the
service personnel in the
vehicle should depress and
release the brake pedal
every 3 seconds and
generates a pressure of
higher than 15 bar.
Press [↑] key to move up Press [OK] key to execute
Press [↓] key to move Press [Esc] key to exit
down
Press [OK] key to
execute
207
(b) Precautions:
(i) Bleeding order for brake wheel

cylinder: left rear → left front → right
front → right rear.
(ii) Release the drain screw and tighten it

as specified until no bubble
discharges.
(iii) The brake pedal may vibrate violently

when bleeding the brakes of the right
front wheel and right rear wheel. It is
a normal phenomenon. Please
continue releasing and depressing
the brake pedal.
(iv) Make sure the brake fluid in the

reservoir is sufficient during the entire
process. Add as necessary.
(c) Tips:
The pressure of 2 bar is needed for
bleeding the hydraulic unit. Therefore, the
pressure regulator of the bleeding device
should be checked.
(d) Refer to the Instrument User Manual for

connection with the brake fluid reservoir of
the vehicle.
Next
4.3.5.2.3 Drain the first circuit using left rear wheel drain screw
Brake Bleeding Left rear brake (a) Press [OK] key.

bleeding (b) Enter phase 1: Drain the first
Preconditions and precautions: Release the drain circuit using left rear wheel
l. Two persons are needed for screw of left rear drain screw.
the operation; wheel cylinder
2. Fill 2 bar pressure in the while pressing
brake fluid reservoir of the [OK] key
208
vehicle;
3. Lift the vehicle safely;
4. Turn on the vehicle and start
the engine as necessary;
5. ABS system has no
malfunction; Return pump
motor stops operating;
Solenoid valve relay is on.
6. After pressing [OK] key, the
service personnel in the
vehicle should depress and
release the brake pedal every
3 seconds and generates a
pressure of higher than 15
bar.
Press [OK] key to execute Press [OK] key to
Press [Esc] key to exit execute
Press [Esc] key to
exit
Left rear brake bleeding Left rear brake (c) Press [OK] key to enter
bleeding bleeding procedure.
Release the drain screw of the left Bleeding left rear
rear wheel cylinder while pressing brake…
[OK] key Please wait for 25
seconds
Press [OK] key to execute Press [OK] key to
Press [Esc] key to exit execute
Press [Esc] key to
exit
(d) The service personnel in the
vehicle should release and
depress the brake pedal
every 3 seconds during the
entire process.
(e) The service personnel
outside the vehicle should
release the drain screw of the
left rear wheel immediately.
Left rear brake bleeding (f) After 25 seconds, the screen

shows prompts.
Observe the discharged brake fluid until no bubble (g) Observe the discharged
exists. Then tighten the drain screws of the left and right brake fluid until no bubble
wheels. exists.
Press [OK] key to go to next step.
209
(h) Tighten the drain screw.
Torque: 12~14 Nm
(i) Press [OK] key to continue
Next
4.3.5.2.4 Drain the first circuit using left front wheel drain screw
(a) The service personnel in

Left front brake bleeding the vehicle presses [OK]
Release the drain screw of the left front wheel cylinder while key:
pressing [OK] key. Meanwhile, the service
personnel outside the
vehicle should release the
Press [OK] key to execute drain screw of the left front
Press [Esc] key to exit wheel cylinder
immediately.
(b) Enter phase 2:
Left front brake bleeding
Drain the first circuit using the
Bleeding left front brake… left front wheel drain screw.
Please wait for 25 seconds
(c) The service personnel in
the vehicle continue to
release and depress the
brake pedal every 3
seconds.
(d) After 25 seconds, the

Left front brake bleeding screen shows prompts.
(e) Observe the discharged
Observe the discharged brake fluid until no bubble exists.
brake fluid until no
Then tighten the drain screw of the left front wheel.
bubble exists.
210

(f) Tighten the drain screw.
Torque: 12~14 Nm
(g) Press [OK] key to
continue
Next
4.3.5.2.5 Drain the first/second circuit using right front wheel drain screw
(a) The service

Right front brake bleeding personnel in the
Release the drain screw of the left front wheel cylinder while vehicle presses [OK]
pressing [OK] key. key:
Description: When performing this step, the brake pedal may Meanwhile, the
vibrate violently. It is a normal phenomenon. Please keep service personnel
releasing and depressing the brake pedal. outside the vehicle
should release the
Press [OK] key to execute drain screw of the
Press [Esc] key to exit right front wheel
cylinder immediately.
(b) Enter phase 3:
Right front brake bleeding Drain the first/second
circuit using right
Bleeding right front brake… front wheel drain
Please wait for 99 seconds screw.
211
(c) The service

personnel in the
vehicle continue to
release and depress
the brake pedal every
3 seconds.
Special tips: At this
time, the operating
sound of the return
pump motor can be
heard and the brake
pedal vibrates
violently. It is a
normal phenomenon.
(d) After 99 seconds, the

Right front brake bleeding screen shows
prompts.
(e) Observe the
Then tighten the drain screw of the left front wheel.
discharged brake
fluid until no bubble
Press [OK] key to execute exists.
(f) Tighten the drain
screw.
Torque: 12~14 Nm

continue
Next
4.3.5.2.6 Drain the first/second circuit using right rear wheel drain screw
(a) The service

Right rear brake bleeding personnel in the
Release the drain screw of the left front wheel cylinder while vehicle presses
pressing [OK] key. [OK] key:
Description: When performing this step, the brake pedal may Meanwhile, the
vibrate violently. It is a normal phenomenon. Please keep service personnel
releasing and depressing the brake pedal. outside the vehicle
212
should release the

Press [OK] key to execute drain screw of right
Press [Esc] key to exit front wheel cylinder
immediately.
(b) Enter phase 3:
Right rear brake bleeding Drain the
first/second circuit
Bleeding right front brake… using right rear
Please wait for 79 seconds wheel drain screw.
(c) The service
personnel in the
vehicle continue to
release and
depress the brake
pedal every 3
seconds.
Special tips: At this
time, the operating
sound of the return
pump motor can be
heard and the brake
pedal vibrates
violently. It is a
normal
phenomenon.
(d) After 79 seconds,

Right front brake bleeding the screen shows
prompts.
(e) Observe the
Then tighten the drain screw of left front wheel.
discharged brake
fluid until no bubble
Press [OK] key to execute exists.
(f) Tighten the drain
screw.
Torque: 12~14 Nm

continue
Next
213
4.3.5.2.7 Bleeding End
Brake bleeding ends (a) Press any key to exit.

Bleeding ends. (b) Please perform necessary road test to
Please perform necessary road test to ensure ensure the brake system operates normally.
the brake system operates normally.
Press any key to exit.
Next
4.3.5.2.8 Repeat step 3 to 7 for 3 to 5 times as necessary.
Precautions
Under normal conditions, the air in

the ABS hydraulic unit with ECU can
Right front Right rear
be bled by performing one
procedure. If the bleeding needs to
be performed again, wait for 5
Front minutes to cool down the solenoid
valve before proceeding to the next
bleeding procedure. Or the solenoid
valve may be burned.
Left front Left rear
4.3.5.3 Dynamic Test
Bosch ABS9 system Off-line test routine Role:

 Check if the traditional brake force is
1 Read computer version 1. Vacuumizing normal
2 Read system and Filling Test  Check if the brake line is connected
malfunctions 2. Brake Bleeding normally
3 Clear the trouble codes √3. Dynamic Test  Check if ABS solenoid valve
4 Read data flow 4. Operation Test operates normally
5 Off-line test routine 5. Wheel Speed  Check the operation of wheel speed
6 Set/unset diagnostic Sensor Test sensor
communication speed Connect diagnostic tester to the vehicle
limit to be tested, and select "Dynamic Test"
Note:
the communication
between diagnostic tester
214
and ABS ECU will be

safety.
Press [↑] key to move up Press [↑] key to
Press [↓] key to move down move up
Press [OK] key to execute Press [↓] key to
Press [Esc] key to exit move down
Press [OK] key to
execute
Press [Esc] key to
exit
Preconditions and precautions:
(a) Drive the vehicle until front wheels
are on the brake test bed which can
drive two wheels separately
(b) Turn on the power supply of the
brake test bed and drive the wheels
(c) Depress the brake pedal until the
displayed brake force value of brake
test bed is:
Left front wheel:
1500N<F<2000N
Right front wheel:
1500N<F<2000N
The brake force of brake test bed should
meet the requirements.
Off-line test routine Front wheel dynamic test Role: Check if the regular brake system
1. Vacuumizing Preconditions and operates normally.
and Filling Test precautions: Normal: Press [OK] key to go to
2. Brake Bleeding (a) Drive the vehicle until next step
√3. Dynamic Test front wheels are on the
4. Action Test brake test bed which Abnormal: Press [Esc] key to exit
5. Wheel Speed can drive two wheels
Sensor Test separately
Check and repair the regular brake
(b) Turn on the power system malfunction:
supply of the brake test
bed and drive the (a) Brake system malfunctions
wheels
(b) Brake booster has no vacuum
(c) Depress the brake pressure
pedal until the
displayed brake force (c) When deterioration or air resistance
value of the brake test occurs
bed is:
Left front wheel: (d) Gross vehicle weight increases due
1500N<F<2000N to passenger or load weight
Right front wheel:
1500N<F<2000N (e) Brake shoe friction sheet may be
wet
215
Press [↑] key to Press [OK] key to execute

move up Press [Esc] key to exit (f) When the friction coefficient
Press [↓] key to between the tire and brake drum
move down changes
Press [OK] key to
execute Role: Check if oil inlet valves of both front
Press [Esc] key to wheels in ABS operate normally
exit
Normal : Press [OK] key to go to next step
Front wheel Bosch ABS9 system
dynamic test
Preconditions and Brake pedal: Abnormal:
precautions:
Firmly depressed Check ABS hydraulic unit with ECU and
(a) Drive the replace as necessary.
vehicle until the ABS hydraulic unit status:
front wheels are
on the brake Left front wheel: Pressure
test bed which increase
can drive two
wheels Right front wheel: Pressure
separately increase
(b) Turn on the
power supply of Observe the displayed brake
the brake test force value:
bed and drive
the wheels Left front wheel:
(c) Depress the 1500N<F<2000N
brake pedal
until the Right front wheel:
displayed brake 1500N<F<2000N
force value of
the brake test
bed is:
Left front wheel:
1500N<F<2000N
Right front wheel:
1500N<F<2000N
Press [OK] key to Press [OK] key to perform

execute next step
Press [Esc] key to Press [Esc] key to exit
exit
Bosch ABS9 system Role: Check if left front wheel solenoid
valve in ABS and return pump motor
Brake pedal:
operate normally
Firmly depressed
Normal: Press [OK] key to go to next
ABS hydraulic unit status:
step
Left front wheel: Pressure decrease
Right front wheel: Pressure increase
Abnormal: Press [Esc] key to exit
Observe the displayed brake force value:
Check:
Left front wheel: 0N<F<400N
(a) ABS hydraulic unit with ECU
Right front wheel: 1500N<F<2000N
(b) Brake line and its connection
Press [OK] key to perform next step
216
Front wheel ABS dynamic test Role: Check if right front wheel solenoid valve in ABS and
Brake pedal: return pump motor operate normally
Firmly depressed Normal: Press [OK] key to go to next step
Left front wheel: Pressure
increase Abnormal: Press [Esc] key to exit
Right front wheel: Pressure Check:
decrease
Observe the displayed brake (a) ABS hydraulic unit with ECU
force value: (b) Brake line and its connection
Left front wheel: 1000N<F
Right front wheel: 0N<F<400N Role: Check if solenoid valves of both front
wheels in ABS operate normally
Press [OK] key to perform
next step
Press [Esc] key to exit Normal: Press [OK] key to go to next step
Front wheel ABS dynamic test
Brake pedal: Check:
Firmly depressed (a) ABS hydraulic unit with ECU
Left front wheel: Pressure Role: Check if solenoid valves of both front wheels in ABS
increase operate normally and if brake drag occurs
Right front wheel: Pressure Normal: Press [OK] key to go to next step
increase
Observe the displayed brake Abnormal: Press [Esc] key to exit
force value: Check:
Left front wheel: 1000N<F
Right front wheel: 1000N<F (a) ABS hydraulic unit with ECU
Press [OK] key to perform (b) Brake drag
next step
Press [Esc] key to exit Front wheel ABS dynamic test ends.
Front wheel ABS dynamic test Please stop brake test bed and drive the vehicle off the brake
Brake pedal: test bed.
Release Press [OK] key to read test results
Solenoid valve stops Difference between left and right wheels is within 5%
operating Normal:
Observe the displayed brake Press [OK] key to go to next step
force value:
Left front wheel: 0N<F<200N
Right front wheel: 0N<F<200N Abnormal: Press [Esc] key to exit
next step Check:
Front wheel ABS dynamic test 1. Wheel speed sensor body
Front wheel ABS dynamic test 2. Wheel speed sensor is incorrectly connected
ends.
Please stop brake test bed 3. If wheel speed sensor signal is interrupted
and drive the vehicle off the
brake test bed. 4. If the clearance between wheel speed sensor and gear
Press [OK] key to perform ring is too wide (Displacement caused by vibration)
next step
Press [Esc] key to exit 5. If wheel speed sensor and holder are corroded
Dynamic test result
217
Left front wheel speed 6 Gear ring malfunction (dirty, or tooth on the gear ring are
variation: 5km/h damaged)
Right front wheel speed
variation: 5km/h 7 Tire: size, pressure, tread pattern and depth
Left rear wheel speed
variation: 0km/h 8 Brake test bed: power train, cylinder condition, etc.
Right rear wheel speed
variation: 0km/h
Press [F2] key to print current
contents
next step
218
Rear wheel dynamic test

Preconditions and precautions:
(a) Drive the vehicle until the rear wheels are
Preconditions and precautions
1. Drive the vehicle until rear wheels are on on the brake test bed which can drive two
the brake test bed which can drive two
wheels separately wheels separately
2. Turn on the power supply of brake test
bed and drive the wheels
3. Depress the brake pedal until the
displayed brake force value of brake test
bed is:
(b) Turn on the power supply of the brake test
Left rear wheel: 1000N<F<1500N
Right rear wheel: 1000N<F<1500N
bed and drive the wheels
(c) Depress the brake pedal until the displayed

Press｛ok｝key to execute brake force value of brake test bed is:
Press｛ESC｝key to exit

Right rear wheel:1000N<F<1500 N
The brake force of brake test bed should meet

the requirements.
Role: Check if the regular brake system

operates normally.
Brake test bed Abnormal: Press [Esc] key to exit
Normal: Press [OK] key to go to next step
Check and repair the regular brake system

malfunction:
Rear wheel ABS dynamic test
Brake pedal:
(a) Brake system malfunctions
Firmly depressed
ABS hydraulic unit status
Left rear wheel: Pressure increase

(b) Brake booster has no vacuum pressure
Right rear wheel: Pressure increase

(c) When deterioration or air resistance occurs
Right rear wheel::1000N<F<1500N
(d) Gross vehicle weight increases due to

Press｛ok｝key to perform next step
Press｛ESC｝key to exit passenger or load weight
(e) Brake shoe friction sheet may be wet

Rear wheel ABS dynamic test
(f) When the friction coefficient between the
Brake pedal tire and brake drum changes
Firmly depressed
ABS hydraulic unit status
Left rear wheel: Pressure decrease
Right rear wheel: Pressure increase
Left rear wheel： 0N<F <1500N
Right rear wheel :1000N < F <1500N
Press｛ok｝key to perform next step

219
Role: Check if oil inlet valves of both rear

wheels in ABS system operate normally.
Abnormal Press [Esc] key to exit

:
Check ABS hydraulic unit with ECU and replace
as necessary.
Role: Check if left rear wheel solenoid valve in

ABS and return pump motor operate normally
Check:
Role: Check if right rear wheel solenoid valve in

ABS and return pump motor operate normally
Check:
220
Role: Check if solenoid valves of both rear

wheels in ABS operate normally
Check: ABS hydraulic unit with ECU

Role: Check if solenoid valves of both rear
wheels in ABS operate normally and if brake
drag occurs.
Check:
(b) Brake drag
Rear wheel ABS dynamic test ends.
Please stop brake test bed and drive the vehicle

off the brake test bed.
Press [OK] key to read test results
Rear wheel ABS dynamic test ends
Please stop brake test bed and drive the vehicle

off the brake test bed.
Difference between left and right wheels is

within 5%
If abnormal, check:
1) Wheel speed sensor body
2) Wheel speed sensor is incorrectly

connected
3) If wheel speed sensor signal is interrupted
4) If the clearance between wheel speed

sensor and gear ring is too wide
(Displacement caused by vibration)
221
5) If wheel speed sensor and holder are

corroded
6) Gear ring malfunction (dirty, or tooth on the
gear ring are damaged)
7) Tire: size, pressure, tread pattern and
depth
8) Brake test bed: power train, cylinder
condition, etc.
222
4.3.5.4 Component Operation Test
Role:
Off-line test routine
Bosch ABSS system Perform component operation test on the
1. Vacuumizing and Filling
1.
2.
Read computer version
Read
malfunction
computer
2.
Test
Brake Bleeding
actuator controlled by ABS to determine if
3.
4.
5.
Clear the trouble codes
Read data flow
3.
4.
5.
Dynamic Test
Action Test
Wheel Speed Sensor Test
it can operate.
6. Set/unset diagnostic
communication speed limit
7. Change filling status
Note Under normal conditions, the

communication between diagnostic tester
and ABS ECO will be interrupted forcibly
when the vehicle speed exceeds a
specified value to ensure safety.
Press｛↑｝key to move up Press｛↑｝key to move up

Press｛↓｝key to move down Press｛↓｝key to move down
Press｛ok｝key to execute Press｛ok｝key to execute
Press｛ESC｝key to exit Press｛ESC｝key to exit
Items that can be detected

Off-line test routine Component Operation Test
1. Vacuumizing and Filling 1. ABS warning lamp

Test 2. ERD warning lamp
2. Brake Bleeding
3. Return pump motor relay
3. Dynamic Test
4. Component Operation Test 4. Left front oil inlet valve
5. Wheel Speed Sensor Test 5. Left front oil outlet valve
6. Right front oil inlet valve
7. Right front oil outlet valve
8. Right rear oil inlet valve
9. Right rear oil outlet valve
10 .Left rear oil inlet valve
11. Left rear oil outlet valve
12. Overheat protection
13 Cut off solenoid valve relay
Press｛↑｝key to move up
Press｛↓｝key to move down
4.3, 5.4.1 ABS warning lamp operation
Press｛ok｝key to execute
Press｛ESC｝key to exit test
Preconditions:
Component Operation Test ABS warning lamp

(a) Turn the vehicle on
1. ABS warning lamp ABS warning lamp operation test
(b) Battery Voltage > 11 V
2. ERD warning lamp
On
Off
(c) Diagnostic tester is correctly
4. Left front oil inlet valve
5. Left front oil outlet valve
connected and communication is
normal
10 .Left rear oil inlet valve
13 Cut off solenoid valve relay
Normal:
Press｛↑｝key to move up Press｛↑｝key to move up
When [OK] key is pressed after "On" is
selected, ABS warning lamp will turn on;
When [OK] key is pressed after "Off" is

selected, ABS warning lamp will turn off;
Abnormal:
(a) Check ABS warning lamp circuit

(b) Check the meter and bulb of ABS
warning lamp
(c) Check ABS hydraulic unit with ECU
ABS warning lamp
223
Component Operation Test ERD warning lamp

4.3.5.4.2 EBD warning lamp operation test
Use [↑] and [↓] key to select and then press [OK]
1. ABS warning lamp ERD warning lamp
2. ERD warning lamp On
3. Return pump motor relay Off
5. Left front oil outlet valve key to confirm.
10. Left rear oil inlet valve
Preconditions:
13. Cut off solenoid valve relay
(c) Diagnostic tester is correctly connected and
communication is normal
(d) The brake fluid in the brake fluid reservoir is
sufficient and level sensor is normal
(e) The parking brake is released
Description:
Brake fluid low warning lamp/parking brake

engage warning lamp/EBD warning lamp share
one light
Brake system warning lamp
Normal:
When [OK] key is pressed after "On" is selected,

Return pump motor relay
EBD warning lamp will turn on;
1. ABS warning lamp
2. ERD warning lamp Operate
3. Return pump motor relay Stop
When [OK] key is pressed after "Off" is selected,
8. Right rear oil inlet valve EBD warning lamp will turn off;
Abnormal:
Press｛↑｝key to move up Press｛↑｝key to move up (a) Check EBD warning lamp circuit
Press｛↓｝key to move down Press｛↓｝key to move down
Press｛ESC｝key to exit (b) Check the meter and bulb of EBD warning
lamp
4.3.5.4.3 Return pump motor relay
Use [↑] and [↓] key to select and then press [OK]
key to confirm.
Preconditions:

communication is normal
224
Normal:
When [OK] key is pressed after "Operate" is

selected, return pump relay will be turned on and
return pump will operate:
When [OK] key is pressed after "Stop" is selected,

return pump relay will be turned off and return
pump will stop:
Abnormal:
(a) Check the fuse of ABS hydraulic unit with

ECU
(b) Check the earth wire of ABS hydraulic unit
with ECU
225
4.3.5.4.4 Left front oil inlet valve operation test
Component Operation Test Left front oil inlet valve Use [↑] and [↓] key to select and then press [OK]
1. ABS warning lamp Left front oil inlet valve operation test
Power On
key to confirm.
2. ERD warning lamp Power Off
5. Left front oil outlet valve Preconditions:
Press｛↓｝key to move down communication is normal
Press｛ok｝key to execute Press｛ok｝key to execute
Normal:
When [0K] key is pressed after "Power On" is

selected, a "clatter" sound can be heard;
When [OK] key is pressed after "Power Off" is

selected, a "clatter" sound can be heard.
Abnormal:
(a) Check the fuse of ABS hydraulic unit with

ECU
(b) Check the earth wire of ABS hydraulic unit
with ECU
Component Operation Test Left front oil outlet valve

4.3.5.4.5 Use the same method to check:
1. ABS warning lamp Left front oil outlet valve operation
test
2. ERD warning lamp
Power On
Power Off (a) Left front oil outlet valve
(b) Right front oil inlet valve
(c) Right front oil outlet valve
(e) Right rear oil inlet valve
12. Overheat protection (f) Right rear oil outlet valve
(g) Left rear oil inlet valve
(h) Left rear oil outlet valve
Press｛ESC｝key to exit (i) Overheat protection
226
4.3.5.5 Wheel Speed Sensor Test
Bosch ABSB system

Role:
1 Read computer version

2 Read system 1 Vacuumizing and Filling
malfunctions
3 Clear the trouble codes
Test
2 Brake Bleeding
3 Dynamic Test
It can detect the mechanical malfunction of gear
4Read data flow
4 Action Test
5 Wheel Speed Sensor Test ring based on the calculated change of each
7. Change filling status signal, such as gear clearance and tooth
Note:
Under normal conditions, the
communication between
diagnostic tester and ABS ECU
malfunction.
will be interrupted forcibly when
the vehicle speed exceeds a
specified value to ensure safety.
(a) Connect diagnostic tester to diagnostic
socket.
(b) Turn the vehicle on and initialize ECU. Read
the trouble codes.
If no malfunction is memorized, proceed to
step (d)
(c) Clear the trouble codes. If they cannot be
cleared, perform "Trouble Code Diagnosis".
Proceed to step (b)
(d) Drive the vehicle until front wheels are on the
Brake test
bed brake test bed.
(e) Turn on the brake test bed to rotate front

wheels freely.
Front wheel speed sensor test

1 Drive the vehicle until front wheels
are on the brake test bed which can
drive two wheels separately
2 Do not depress the brake pedal
during testing.
3 Turn on the power supply of brake
test bed and drive the wheels

(f) Then press [OK] key to perform test
Performing wheel speed sensor test
227
4.3.5.5 Wheel Speed Sensor Test
Front wheel speed sensor test (g) Generally, the cylinder needs to rotate 3 to
5 turns
(h) Stop the brake test bed
ends. (i) Press [OK] key to read test results
Press｛ok｝key to read test
results
Press｛ok｝key to continue
(j) Normal value
New car: Allowable difference < 6%

Old car: Allowable difference < 6%
Front wheel speed sensor test results If the difference is too large, please check:
Maximum speed of left front
- Tire diameter
wheel:5.1km/h
Minimum speed of left front
wheel :5.1km/h
- Hub bearing clearance
Maximum speed of right front
wheel :5.1km/h
Minimum speed of right front
- If the gear ring rotates freely or it is
wheel :5.1km/h
Maximum speed of left rear wheel :0
km/h
deformed, missing tooth and damaged
Minimum speed of left rear wheel :0
km/h
Maximum speed of right rear wheel :0 - If iron chips or other foreign materials are
km/h
Minimum speed of right rear wheel:0
km/h attached on each wheel speed sensor
- If each wheel speed sensor is aligned with
the gear ring during installation
- Each wheel speed sensor
- Circuit and connector of each wheel speed
sensor
- Brake test bed: including cylinder and
power train
(m) Turn on the brake test bed to rotate rear

Brake test bed
wheels freely.

1. Drive the vehicle until rear
wheels are on the brake test
bed which can drive two
wheels separately
2. Do not depress the brake
pedal during testing
3. Turn on the power supply of
brake test bed and drive the
wheels
228
Rear wheel speed sensor test (n) Then press [OK] key to perform test
results
Performing wheel speed sensor test (o) Generally, the cylinder needs to rotate 3 to 5
turns
(p) Stop the brake test bed
(q) Press [OK] key to read test results
(r) Normal value

New car: Allowable difference < 6%
Old car: Allowable difference < 6%
Rear wheel speed sensor test results
If the difference is too large, please check:

- Tire diameter
Rear wheel speed sensor test end
Press [OK] key to read test results - Hub bearing clearance
- If the gear ring rotates freely or it is
deformed, missing tooth and damaged
- If iron chips or other foreign materials are
attached on each wheel speed sensor
- If each wheel speed sensor is aligned with
Press｛ok｝key to continue
Press｛ESC｝key to return
the gear ring during installation
- Each wheel speed sensor
- Circuit and connector of each wheel speed
sensor
Rear wheel speed sensor test results
- Brake test bed: including cylinder and power
train
Maximum speed of left front wheel: 0km/h
Minimum speed of left front wheel: 0km/h
Maximum speed of right front wheel: 0km/h
Minimum speed of right front wheel: 0km/h
Maximum speed of left rear wheel 5.1 km/h
(s) Press [Esc] key to return and drive the
Minimum speed of left rear wheel 5.1 km/h
Maximum speed of right rear wheel: 5.1 km/h
Minimum speed of right rear wheel5.1 km/h
vehicle off the brake test bed.
(t) Clear the trouble codes as necessary.
Press｛F2｝key to print current page

Bosch ABSB system Read the trouble
1. Read computer version

2. Read system malfunctions
3. Clear the trouble codes
4. Read data flow
5. Off-line test routine
6. Set/unset diagnostic
Note: Under normal conditions, the

communication between diagnostic
tester and ABS ECD will be interrupted
forcibly when the vehicle speed
exceeds a specified value to ensure
safety
Press｛↑｝key to move down

Press｛↓｝key to move up Press any key to continue
229
4.3.6 Set/Unset Diagnostic Communication Speed Limit
Role:
Bosch ABSB system
Set/unset diagnostic communication
speed limit
For safety, do not diagnose ABS ECU when the
1. Computer version
tester and ABS ECD will be
the
vehicle speed exceeds 10 km/h.
4. Read data flow interrupted forcibly when the vehicle
5. Off-line test routine speed exceeds a specified value to
6. Set/unset diagnostic ensure safety
The function will cancel the limit. After
the vehicle speed exceeds the limit,
the wheel speed signal can be read
When some special repair and diagnosis are
tester and ABS ECD will be
and ABS stops operating, causing the
safety performance to reduce
Do you want to continue the test?
needed, the limit can be cancelled.
interrupted forcibly when the vehicle Note: When exiting the diagnosis, the
speed exceeds a specified value to diagnostic communication speed limit
ensure safety function will resume automatically.
Press｛↑｝key to move down Press {ok} key to cancel diagnostic

Special Notes: After the limit is cancelled,
Press｛↓｝key to move up
Press｛ESC｝key to resume diagnostic
communication speed limit improper operation may cause severe accident.
Therefore, adequate safety measures should be
taken and spacious test site should be used.
After the operation, ABS stops control.

Operation completed
After turning off the vehicle, exiting ABS
diagnosis or performing "Resume" command,
ABS ECU will reset the limit value.
Press any key to continue

Preconditions for setting: Vehicle speed < 10
km/h.
Setting:
Press [OK] key to cancel diagnostic

Left front wheel speed: 35.2km /h
Right front wheel speed 35.1 km/h
Left rear wheel speed 35.2km/h
Right rear wheel speed: 35.2km/h
Press [Esc] key to resume diagnostic

Special Notes:
Press｛F2｝key to print current contents
After the limit is cancelled, improper operation

may cause severe accident. Therefore, adequate
safety measures should be taken and spacious
test site should be used.
After the speed limit is cancelled, each wheel

speed signal can display 0~350 km/h.
Wheel speed judgment method:
When the vehicle is driving straight on dry road

while accelerating evenly, the displayed vehicle
speed value increases constantly without
jumping after the speed exceeds 3 km/h.
For the allowable difference value of each wheel
speed, refer to:
"Setting Conditions" on Page 41 "Wheel Speed
Sensor or Signal Malfunction".
Note: When the speed is less than 2.6 km/h and
the vehicle is stationary, the diagnostic tester will
display O km/h.
230
4.3.7 Change Filling Status
Description:
Bosch ABSB system
Change filling status
1 After ABS hydraulic regulator with ECU
1. Computer version
ABS hydraulic unit
is replaced, the operation must be
4. Read data flow Filled completely and normal performed to prevent unexpected
5. Off-line test routine
6. Set/unset diagnostic communication speed
limit
Filled completely and abnormal
accidents.
2 It only allows "New ECU" to be
changed to "Filled completely and
communication between diagnostic tester and
ABS ECD will be interrupted forcibly when the
normal".
vehicle speed exceeds a specified value to
ensure safety 3 Though the data flow displays "Filled
completely and normal", actually it does
Press｛↑｝key to move down Press｛↑｝key to move down
not indicate hydraulic regulator is filled
completely and normal.
Make sure brake fluid is filled completely

and the brake system operates normally.
After selecting "Filled completely and
normal", press [OK] key to change. Then
Change filling status Change filling status
press any key to exit.
ABS hydraulic unit
Filled completely and normal Read data flow to ensure successful

Filled completely and abnormal
Operation completed change.

Read data flow

Hydraulic Unit Filling Status
1. Wheel Speed Signal

2. Analog Status
Hydraulic Unit Filling Status
3. Digital Status
4. Hydraulic Unit Filling Status Filled completely and normal

Press｛ok｝keytotomove
Press｛↑｝key execute
down
Press｛ESC｝key
Press｛↓｝key to exitup
to move
231
Section 5 Trouble Code Table

Notice:
The vehicle must be turned off before removing parts.
Description:
Read DTCs with the diagnostic tester.
If no malfunction is detected during elements inspection, check ABS hydraulic regulator with
ECU and its earth point/power cables.
If a DTC is memorized, check the circuit indicated by the DTC. Refer to the applicable chapter
for the specific repair procedure of each DTC.
When two or more DTCs are memorized, first check the DTC and circuit related to the
malfunction.
Pag
DTC Detection Item Possible Fault Area
e
Left front wheel speed sensor signal Left front wheel speed sensor
C003108 malfunction Left front wheel speed sensor circuit
48
C003204 Left front wheel speed sensor circuit Left front wheel speed sensor gear
malfunction ring
Right front wheel speed sensor
C003408 signal malfunction
circuit 48
C003504 Right front wheel speed sensor
circuit malfunction
gear ring
Left rear wheel speed sensor signal Left front wheel speed sensor
C003708 malfunction Left front wheel speed sensor circuit
48
C003804 Left rear wheel speed sensor circuit Left front wheel speed sensor gear
malfunction ring
C003A0 Right rear wheel speed sensor
8 signal malfunction
circuit 48
C003B0 Right rear wheel speed sensor
4 circuit malfunction
gear ring
Left front oil inlet valve of hydraulic
C001004 ABS hydraulic regulator with ECU 50
regulator malfunction
Left front oil outlet valve of hydraulic
Right front oil inlet valve of hydraulic
Right front oil outlet valve of
hydraulic regulator malfunction
Left rear oil inlet valve of hydraulic
Left rear oil outlet valve of hydraulic
C001C0 Right rear oil inlet valve of hydraulic
ABS hydraulic regulator with ECU 50
4 regulator malfunction
232
C001D0 Right rear oil outlet valve of

ABS hydraulic regulator with ECU 50
4 hydraulic regulator malfunction
Return pump motor malfunction: ABS hydraulic regulator with ECU
C002004 Unable to rotate or unable to stop ABS hydraulic regulator with ECU 60
rotating ground/power
ABS hydraulic regulator with ECU
Solenoid valve relay circuit
malfunction
ground/power
Wheel speed sensor
C024501 Wheel speed sensor malfunction Wheel speed sensor circuit 48
Wheel speed sensor gear ring
Battery
C055000 ABS ECU malfunction 71
power/ground
Battery
C080001 Voltage Low ABS hydraulic regulator with ECU
76
C080002 Voltage High power/ground
Circuit control valve 1 malfunction
C000104 ESP hydraulic regulator with ECU
(For ESP only)
Circuit control valve 2 malfunction
(For ESP only)
High pressure switching valve 1
malfunction (For ESP only)
High pressure switching valve 2
C100104 CAN hardware malfunction Module
U100004 CAN bus off Gateway Controller
Common valve malfunction
C007204 ABS hydraulic regulator with ECU
(Overheat protection)
Pressure sensor malfunction (For
ESP only)
SAS (Steering Angle Sensor) CAN
U012604 Steering angle sensor circuit
communication timeout
Steering angle sensor circuit
U012608 SAS CAN data damaged
Steering angle sensor
C046008 SAS signal malfunction
Steering angle sensor calibrated Steering angle sensor circuit
C106600
incorrectly or not calibrated Steering angle sensor
Lateral acceleration sensor signal
Longitudinal acceleration sensor
signal malfunction (For ESP only)
Yaw rate position sensor signal
Integrated inertia sensor malfunction
C019604 (Hardware, temperature, range, ESP hydraulic regulator with ECU
internal malfunction)(For ESP only)
Integrated inertia sensor not
C00A80
calibrated or calibrated incorrectly ESP hydraulic regulator with ECU
0
(For ESP only)
U010004 ECM communication timeout (For ECM module and circuit
233
ESP only) ESP ECU and circuit

ECM CAN data damaged (For ESP
U010004 ECM module
only)
U014004 Gateway communication timeout Gateway controller circuit
U014008 Gateway data damaged Gateway Controller
C004C0 ESP switch malfunction (For ESP
ESP switch and its circuit
4 only)
Variable code malfunction (For ESP
only)
Brake pedal switch signal
C004008 Brake pedal switch and circuit
malfunction
Meter
C008208 Brake system malfunction indicator
ABS circuit
C108008 Clutch signal malfunction (HHC) Clutch switch and circuit
C108C0 Reverse gear switch signal
Reverse gear switch and circuit
8 malfunction (HHC)
U010104 Lost communication with TCU TCU module and circuit
U010108 Received TCU data incorrect TCU module and circuit
EPB CAN communication timeout
U100308 EPB module and circuit
EPB CAN data damaged
C040008 EPB signal incorrect EPB module and circuit
234
Section 6 Component Layout
I
llustration
1 Brake Pedal
2 Vacuum Booster
3 Brake Master Cylinder
4 Brake Fluid Reservoir
5 ESP Control Unit
6 Brake Hose
7 Brake Wheel Cylinder with Brake
8 Wheel Speed Sensor
9 ABS Control Unit
10 ABS Warning Lamp
11 Diagnostic Socket
235
Section 7 Definition of ECU Pin

7.1 Circuit Diagram for ABS Hydraulic Regulator with ECU
236
7.2 Circuit Diagram for ESP Hydraulic Regulator with ECU
237
7.3 Pins of ABS and ESP Hydraulic Regulator with ECU
Wire Harness
Side
Pin ABS Code Meaning Inspection Condition Working Note

Voltage
1 UBMR 12 V power supply, GND(38) All 9.3-16.9 V
40 A fuse
2 WSO_FR Right front wheel GND(38) Power ON -
speed signal output
3 NEBD Active EBD warning GND(38) Power ON 9.3-16.9 V
lamp
4 WSS_FR Right front wheel GND(38) Power ON 4.5-20 V
speed sensor power
supply voltage
6 DIAGNOS CAN bus diagnostic - Power ON -
TIC interface
8 WSS_FL Left front wheel GND(38) Power ON 4.5-20 V
speed sensor power
supply voltage
12 ESP_OFF Electronic stability GND(38) Power ON 9.3-16.9 V Use with
procedure OFF ESP
switch installed
13 GND_MR Return pump motor Battery Power ON < 0.5 V
ground negative
14 CAN_L CAN low - Power ON - -
15 CLUTCH Driver intent switch - Power ON - Use with

ESP
installed
238
16 WSP_FR Right front wheel GND(38) Power ON Pulse

speed sensor output signal
17 WSP_RR Right rear wheel GND(38) Power ON Pulse
18 WSS_RL Left rear wheel GND(38) Power ON 9.3-16.9 V
speed sensor power
supply voltage
19 WSP_FL Left front wheel GND(38) Power ON Pulse
25 UB_VR Solenoid valve GND(38) All 9.3-16.9 V
power supply voltage
26 CAN_H CAN high - Power ON - -
27 NABS Active ABS warning GND(38) Power ON 9.3-16.9 V
lamp
28 IGNITION Ignition switch GND(38) Power ON 9.3-16.9 V
29 WSS_RR Right rear wheel GND(38) Power ON Pulse
speed sensor power signal
supply voltage
30 BLS Braking light switch GND(38) Power ON 9.3-16.9 V
or 0
31 WSP_RL Left rear wheel GND(38) Power ON Pulse
38 GND_ECU ABS or ESP ECU Battery All < 0.5 V
ground negative
239
7.4 ABS9 Brake Line Connection Diagram
Applicable for front wheel drive BYD Sari vehicles with brake lines in a diagonal direction
240
7.5 ABS9 Schematic Diagram
241
Section 8 Trouble Symptom

8.1 Trouble Symptom Table
If a malfunction occurs even if no Notice:

malfunction is memorized when reading ·Before checking and repairing ABS, make
DTC, check the circuit for each trouble sure the regular brake system operates
symptom based on the order and normally.
reference page listed in the table below. ·If ABS hydraulic regulator with ECU,
sensors and others need to be replaced,
first turn the vehicle off.
Refere
Trouble Symptom Inspection Area nce
Page
If the malfunction still exists when the following 1~4 are
normal, replace ABS hydraulic regulator with ECU: 10
1. Read trouble codes and confirm malfunction memory
ABS does not work 2. Start button power UZ (Pin 32) circuit 37
3. Wheel speed sensor circuit 30, 42
4. Check ABS with diagnostic tester. If abnormal, check if the
22
brake line leaks
normal, replace ABS hydraulic regulator with ECU:
10
1. Read trouble codes and confirm no malfunction is
memorized
ABS does not work
3. Check ABS with diagnostic tester. If abnormal, check if the
well 6
brake line leaks
4. Read "Hydraulic Regulator Filling Status" with diagnostic
11
tester
5. Make sure the mounting bracket is secured correctly
(Driving comfort will reduce)
1. ABS warning lamp circuit 27, 37
ABS warning lamp
2. ABS hydraulic regulator with ECU 60
is abnormal
3. Battery voltage is low 62
normal, replace ABS hydraulic regulator with ECU: 37
Trouble codes
1. ABS hydraulic regulator with ECU power/ground wire
cannot be read
2. DIAGK (Pin 17) wire of ABS hydraulic regulator with ECU 37
3. Diagnostic tester
8.2 Intermittent Trouble Symptom Table
Description:
If one of the following conditions occurs,
the malfunction is intermittent.
a The malfunction does not always occur;
b The malfunction cannot be duplicated;
c There is no current DTC, but history DTC
exists in memory.
242
Inspecti
Operation
on
· Perform "Preliminary Inspection"
· Collect information about intermittent malfunction from the customer, such as:
· The speed range when the malfunction occurs.
· Does the malfunction occur after the after sales electric device is used?
· Does the malfunction occur when driving on rough or slippery roads?
· If the wheel speed sensor malfunctions only when driving on the slippery road,
Prelimin
check whether water enters the wheel speed sensor circuit. If the DTC is not
ary
output, perform the following operations to simulate the slippery road:
1. Mix 2 teaspoons of salt and 35 ml of water.
2. Spray the saline water on the suspected area.
3. Road test the vehicle on various roads.
4. Accelerate the vehicle to more than 40 km/h for at least 30 seconds.
5. If a current DTC is set by the suspected wheel speed sensor, refer to the
applicable trouble code table.
Check the intermittent malfunction using diagnostic tester as follows:
· Observe the data flow of detected circuit on diagnostic tester while swinging
the suspected wire harness and connector of ABS components. If the reading
on diagnostic tester fluctuates during the operation, check if the circuit
Check connection is loose.
with · Road test the vehicle under the conditions in which intermittent malfunctions
diagnos occur, and let the assistant observe the suspected specifications on the
tic tester diagnostic tester.
· When the malfunction occurs, capture and store the data using the snapshot
mode. The stored data can be played at low speed to assist diagnosis. The
signals can also be detected with an oscilloscope.
· Operate the suspected ABS components using the component test function of
diagnostic tester to test the operation of these components.
The following conditions may cause the warning lamp to illuminate intermittently
without setting the trouble codes.
· Electro Magnetic Interference (EMl) caused by fault components (for example,
relay).
· The after sales electric devices are abnormal or installation position is
incorrect, such as:
Warning
· Mobile phone
lamp
· Theft deterrent siren
· Light
· Radio equipment
· Audio amplifier
· The warning indicator light circuit is short to ground intermittently.
· ABS hydraulic regulator with ECU or meter ground point is loose.
· The speed is slow.
· Visually check if the wheel speed sensor and magnetic ring is loose, damaged,
and dirty or installed incorrectly. Replace the damaged component, remove
Wheel any foreign materials or fix the loose component.
Speed · Check if the route of front wheel speed sensor wire is correct. Make sure the
Sensor front wheel speed sensor wire is not close to the distributor.
· With help of the assistant, monitor the displayed wheel speed sensor data on
the diagnostic tester while road testing the vehicle. Check if there is wheel
speed sensor displaying abnormal speed range.
Addition · Check if the after sales electric devices are installed correctly. For example:
al test · Mobile phone
243
· Light
· Radio equipment
· Audio amplifier
· Check if there is Electro Magnetic Interference (EMI) caused by fault
components (for example: when the relay or solenoid coil is energized).
· When the relay or solenoid coil is energized, test the air conditioner
compressor clutch and some relays containing clamp diode or resistance.
· When the relay or solenoid coil is energized, check if the generator rectifier
bridge has malfunction which causes air conditioner noise to enter the
electronic control unit circuit.
244
Section 9 Trouble Code Diagnosis
DTC C003108 Left front wheel speed sensor signal malfunction
DTC C003408 Right front wheel speed sensor signal malfunction
DTC C003708 Left rear wheel speed sensor signal malfunction
DTC C003A08 Right rear wheel speed sensor signal or circuit malfunction
DTC C024501 Wheel speed sensor malfunction
Circuit description:
The wheel speed sensor detects the

wheel speed and sends the relevant
signals to ABS ECU. These signals are
used to control ABS operation.
Each wheel has a sensor and each

drive shaft has a gear ring with 48 teeth.
The model uses DF11 type active wheel
speed sensor. ABS ECU supplies
12-volt DC power to the wheel speed
sensor to operate.
The wheel speed sensor uses hall

effect to output a square wave with
constant amplitude and duty cycle of
50%: low voltage is 0.5 V and high
voltage is 1 V; The frequency increases
with the speed. ABS ECU calculates the
wheel speed based on the frequency.
245
Malfunction Diagnosis Flow. DTC: C003108, C003408, CO03708, C003A08, C024501
A. Wheel speed sensor or its signal malfunction
Test Possible Fault

DTC Setting Condition
Condition Area
1 Monitor if the sensor power voltage is too 1 Wheel speed
All working
low sensor body
conditions
2 Monitor if the sensor signal wire is normal 2 Wheel speed
after the
3 The wheel speed signal of malfunction sensor is
vehicle is
wheel cannot be detected after the vehicle incorrectly
turned on
speed exceeds 2 km/h while driving connected
1 At least one wheel speed is 5 km/h higher 3 Wheel speed
than the reference speed for 18 s sensor signal is
Monitor
2 The speed difference of two wheels on the interrupted
wheel speed
same side (for example, left front and left 4 The clearance
a. The
rear) exceeds 6 km/h, the speed difference between wheel
reference
of coaxial wheels (for example, left front speed sensor
speed is
and right front) exceeds 10 km/h, or the and gear ring is
between
speed difference of diagonal wheels (for too wide
2~100 km/h
example, left front and right rear) exceeds (Displacement
14 km/h caused by
1 The speed difference of two wheels on the vibration)
same side exceeds 6% of reference 5 The wheel
b. Reference speed, the speed difference of coaxial speed sensor
speed wheels exceeds 6% of reference speed and holder are
> 100 km/h plus 4 km/h, or the speed difference of corroded
diagonal wheels exceeds 6% of reference 6 Gear ring
C003108 malfunction
speed plus 8 km/h
C003408 (dirty, or tooth
1 If the signal malfunction of one or two
CO03708 on the gear
wheel speed sensors occurs, the
C003A08 ring are
malfunction is detected again after 20
CO24501 damaged)
seconds (brake pedal depressed) or 5
Long-term 7 Tire: size,
seconds (brake pedal not depressed)
monitoring pressure, tread
2 If the signal malfunction of three or four
wheel speed sensors occurs at the same pattern and
time, the malfunction is detected again depth
after 1 second
Wheel slip
monitoring
a. Vehicle The absolute speed difference of fastest and
speed < slowest wheels exceeds 3 km/h
50 km/h The absolute speed difference of fastest and
b. Vehicle slowest wheels exceeds 6%
speed >
50 km/h
Gear ring
When the vehicle speed is with 10~80 km/h
monitoring
and ABS is not operating, the wheel speed
For
sensor circuit is open for 6 times during each
example:
turn of the wheel
missing
tooth
Dynamics If the vehicle speed is more than 43 km/h, the
monitoring wheel speed signal will not be received for
246
10~20 ms within an interval of 60 ms.
B Wheel speed sensor circuit malfunction
Test
DTC Setting Condition Possible Fault Area
Condition
When the following malfunctions
1 The connectors are
occur for more than 200 ms:
defective, dirty or wet
C003108 2 The wheel speed sensor
All working 1 The sensor circuit is open, short to
C003408 connectors are loose or
conditions ground or power supply
CO03708 broken
after the 2 The sensor connectors are loose
C003A08 3 The sensor circuit is short
vehicle is
CO24501 to ground
turned on At this time, the wheel speed sensor
4 The insulating layer of
current is out of range: the current is
sensor circuit is damaged
less than 1.1 mA or more than 39 mA
247
248
The following may be caused after a malfunction occurs:
Braking Strategy Failure Protection

The applicable wheels cannot be controlled as the correct
· The system is switched to
wheel speed sensor signal cannot be received. After the
EBD emergency control
malfunction occurs, the front wheel pressure increases while
mode
the rear wheel pressure decreases, until the vehicle is turned
· ABS warning lamp turns on
off
If the malfunction of one or two wheel speed sensors is · The system is switched to
detected during ABS control, the system will be switched to EBD emergency control
EBD emergency control mode, until the control ends. mode
· The brake system enters
conventional braking mode
If the malfunction of three or four wheel speed sensors is
· ABS warning lamp and
detected
brake system warning lamp
turn on
Note:
a After troubleshooting, turn the
vehicle off again. When the trouble
codes are not cleared, the warning
lamp will turn off only after the
vehicle speed exceeds 12 km/h.
b If two or more malfunctions are

detected, the DTC with highest
priority will be displayed first. After
the troubleshooting, the next DTC
with higher priority will be displayed.
c If the power supply voltage is lower

than 7.1 V or higher than 17.4 V, the
system will stop monitoring the
wheel speed sensor.
249
a Malfunction Confirmation
(a) Connect diagnostic tester to read and
record DTCs.
(b) Clear DTCs: Follow the instructions on
the diagnostic tester.
Note:
The trouble codes cannot be cleared by

removing the battery.
Make sure the battery voltage is normal

before clearing the trouble codes.
(c) Perform malfunction simulation.

(d)
Does the malfunction occur again?
Yes Current malfunction, go to step 3
No History malfunction, go to next

step
b Diagnosis of Intermittent Malfunction

(a) Inspect the circuit from ABS hydraulic
regulator with ECU to wheel speed
sensor and all connectors.
For inspection methods and steps, refer to

04 - Inspection before Diagnosis
(b) Inspect the hub bearing free travel.

Normal value of hub bearing free travel: O
mm.
Is the problem resolved?
Yes
Yes Go to step 11
No Go to step 4
250
c Appearance Inspection
(a) Inspect the circuit from ABS hydraulic
regulator with ECU to wheel speed
sensor and all connectors. Replace as
necessary.
(b) Check the tires.
1 Check the specification of all tires,
and replace as necessary.
Standard: 20s/05R1594V
Optional: 205`60 R16 92V
2 Check if the tire and hub are
damaged. Repair or replace as
necessary.
3 Check the pressure of all tires, and
correct as necessary.
No
Normal Value:
15-inch tire: Front wheels 230 kPa, Rear

wheels 220 kPa
16-inch tire: Front wheels 240 kPa, Rear

wheels 230 kPa
4 Check if the tire tread is worn

abnormally (eccentric, excessive
and uneven wear) and if the wheels
are balanced. Replace as necessary
and/or perform tire balance, four
wheels alignment and cross
member correction.
Is the problem resolved?
Yes Go to step 10
251
d Use the diagnostic tester to read each wheel speed data flow
(a) Connect diagnostic tester to read data

flow.
(b) Drive the vehicle straight at constant

speed on flat road while observing the
data flow.
To cancel the communication limit between

ABS ECU and diagnostic tester when the
vehicle speed exceeds 10 km/h, refer to
Page 34 of the repair manual.
Normal: The displayed speed for each
wheel is similar.
Tips: The deviation of ±10% is allowed by
the speedometer in the meter
Nor Go to step 8
mal
e Check wheel speed sensor

(a) Remove the wheel speed sensor
connector. Measure the internal
resistance of wheel speed sensor.
Sensor side Normal: 3 MΩ ~5 MΩ
(b) Measure the resistance between wheel

speed sensor circuit and ground.
Pin 1: Signal wire

The sensor circuit The sensor circuit is white
is black (closed) (closed)
Normal
f Ensure the wheel speed sensor circuit is correctly connected
Measure resistance of the following circuits using

a multimeter.
Connection Normal: ≈0Ω
side
Pin of
ABS Pin of
hydraulic wheel
Position Function
regulator speed
with sensor
ECU
Signal 22 1
Left front
Power
wheel 34 2
Supply
252
Right Signal 6 1
front Power
18 2
wheel Supply
Signal 20 1
Left rear
Power
wheel 33 2
Supply
Right Signal 31 1
rear Power
19 2
wheel Supply
g Check the wheel speed sensor and its wave form using an oscilloscope.
When a junction box is used:
(a) Connect the junction box to the connector of

ABS hydraulic regulator with ECU.
(b) Connect the wire as follows:
Connect the red probe to the signal wire.
Ground Pin for measurement

Left front wheel 22
Sensor side Right front wheel 6
Left rear wheel 20
Right rear wheel 31
Connect the black probe to GND wire: Pin 38

When a junction box is not used:
(a) Remove the wheel speed sensor connector.
(b) Connect one end of the sensor to 12-volt

battery, and the other end to the red probe of
oscilloscope.
Note: The ground wire of oscilloscope should be

connected to the ground wire of battery.
Drive carefully and make sure the circuit does
not interfere with the moving parts of the
vehicle.
253
Wave form description:
When the vehicle is stationary, the

oscilloscope will display:
≈0.5 V: The sensor faces tooth top
≈1.0 V: The sensor faces gear

clearance
Wave form description:
The wave form is displayed when

the wheel is rotated by hand one
turn per second (equivalent to 2
km/h) while the vehicle is lifted.
The wave form is displayed when

the vehicle is driving at a speed of
about 30 km/h. The faster the
speed, the higher the frequency.
Note:
If the wave form distortion, voltage

incorrectness and too much noise
wave occur, the rotor may be
damaged, loose or containing
foreign materials. Refer to step 9.
Wave Replace ABS hydraulic

form regulator with ECU
normal
254
h Check wire harness of wheel speed sensor
The wheel speed sensor uses a twisted pair

of wires to provide effective shield, helping
protect the sensitive electronic elements
from electrical interference.
To prevent the performance of connected

components from decreasing due to
electrical interference, keep the following
specifications correct when repairing the
twisted pair of wires:
(a) Wrap the wire for at least 9 turns every

310 mm along the length direction.
(b) The outer diameter of the twisted pair of

wires should not exceed 6.O mm.
Abnormal Repair the malfunction. Go to

step 12.
Normal
i Check the installation of wheel speed sensor

(a) Check if the wheel speed sensor is
installed in place.
Normal: The bolts are correctly

tightened, and there is no gap between
the sensor and base.
Air Gap
(b) The air gap between the wheel speed
sensor and gear ring is proper.
Front wheel sensor gap: 1.2 mm max.

Rear wheel sensor gap: 0.9 mm max.
Abnormal Repair the malfunction. Go to step

11
Normal
j Check the wheel speed sensor head
(a) Remove the wheel speed sensor
(b) Check the wheel speed sensor head
The head does not have damage

Normal: or foreign materials
255
Abnor Clean or replace the wheel speed

mal sensor
Normal
k Check the wheel speed sensor rotor

(a) Remove the wheel speed sensor gear
ring.
(b) Check the gear ring condition
Normal: No damage, missing tooth and
foreign materials
Tips: If there are foreign materials on the
gear ring, reinstall it after cleaning and check
its output wave form
Abno Clean or replace the wheel speed

rmal sensor
Normal
Check and replace ABS hydraulic regulator with ECU
l Final Inspection. Confirm troubleshooting.
(a) Clear the trouble codes
(b) (Except DTC C024501) In 30 seconds after starting the vehicle, drive it straight at a speed of
more than 30 km/h for at least 10 seconds.
(DTC C024501) Accelerate the vehicle from 0 to 60 km/h, or drive the vehicle at a speed of 30
km/h for at least 7 seconds
After normal driving, turn the vehicle off. Confirm ABS does not memorize DTCs 30 seconds
after the vehicle is turned on.
DTC C001104 Left front oil outlet valve circuit of hydraulic regulator
malfunction
DTC C001004 Left front oil inlet valve circuit of hydraulic regulator
malfunction
DTC C001504 Right front oil outlet valve circuit of hydraulic regulator
malfunction
DTC C001404 Right front oil inlet valve circuit of hydraulic regulator
malfunction
DTC C001904 Left rear oil outlet valve circuit of hydraulic regulator
malfunction
DTC C001804 Left rear oil inlet valve circuit of hydraulic regulator
malfunction
256
DTC C001D04 Right rear oil outlet valve circuit of hydraulic regulator
malfunction
DTC C001C04 Right rear oil inlet valve circuit of hydraulic regulator
malfunction
After the vehicle is turned on, the solenoid valve relay in the ABS hydraulic unit with ECU is
energized to supply battery voltage to one end of hydraulic regulator solenoid valve. When the
vehicle is turned off and ABS system is disabled, the solenoid valve relay keeps energized.
Its role is:
ABS ECU controls the solenoid valve operation by controlling the grounding of each solenoid
valve so as to adjust the brake pressure of each brake circuit.
Oil inlet valve: pulse width modulation type.
Oil outlet valve: switch type.
DTC Test Condition Setting Condition Possible Fault Area

C001104 Synchronize 1. Synchronized solenoid valve 1 The solenoid
C001004 with ABS ECU has no feedback valve in ABS
C001504 initialization 2 After the vehicle is turned on, hydraulic
C001404 and self check: ABS ECU detects the applicable regulator with
C001904 The vehicle is solenoid valve is permanently or ECU
C001804 stationary or intermittently short to power malfunctions:
C001D04 vehicle speed supply or ground brake oil line,
C001C04 is 15 km/h or 3 While driving, the malfunction of electrical devices
more solenoid valve coil or its
connector is detected: 2.Hydraulic/mechanic
- When the brake pedal is not al malfunction
depressed: the vehicle is
stationary
- When the brake pedal is
depressed: vehicle speed≈15
km/h
4 The oil line of ABS hydraulic
regulator with ECU malfunctions
under all the working conditions
257
Malfunction Diagnosis Flow. DTC: C000104, C000204, C000304, C000404
258

a Solenoid valve relay malfunction: The a The brake system enters conventional
solenoid valve operation can not be braking mode
controlled b ABS warning lamp and brake system
b When the solenoid valve does not warning lamp turn on
operate, the wheels may be locked. If
the operation is incorrect, the applicable
wheel may have no oil pressure.
1 Check ABS hydraulic regulator with ECU when the vehicle is stationary
(a) Turn the vehicle off for more than 10 s.
(b) Turn the vehicle on for more than 30 s.

Do not depress the brake pedal at this
time.
(c) Check if the ABS and brake system

warning lamps turn on. Read DTCs using
diagnostic tester as necessary
Normal: ABS/brake system warning lamps

ABS warning lamp brake system should turn off and no current DTC exists.
warning lamp
Abno Go to step 3
rmal
Normal
2 Perform component test on the solenoid valve in ABS hydraulic regulator with ECU using
diagnostic tester
(a) Refer to Page 22-26: 4.3.5.3 Dynamic

Test
259
(b) Refer to Page 27: 4.3.5.4 Solenoid

Valve Test in Component Operation
Test
Next
260
Malfunction Diagnosis Flow. DTC: C001104, C001004, C001504, C001404, C001904,

C001804, C001D04, C001C04
2 Check pin voltage of ABS hydraulic regulator with ECU (Voltage of pin 25)
(a) Connect the junction box to the connector

of ABS hydraulic regulator with ECU.
(b) Connect the wires of voltmeter and

oscilloscope as follows:
Connect the red probe to pin 25

Connect the black probe to pin 38
(c) Road test the vehicle under various

working conditions and read the voltage.
Normal: U=9.3~16.9 V
Wire When a multimeter is used:

Harness
Side
(b) Remove the connector of ABS hydraulic

regulator with ECU.
(c) Measure the voltage between power

terminal (25) and ground terminal (38) of
the solenoid valve using the multimeter.
Note:
If the junction box is not used, normal test of

the procedure can not be ensured.
Norm Replace ABS hydraulic regulator

al with ECU
Abnormal
261
4 Check the connecting wire, connector and (c) DTC C001104, C001004, C001504,
40 A fuse C001404, C001904, C001804, C001D04
and C001C04 do not occur again 30 s
(a) Check if 25 A fuse is normal after the vehicle is turned on
(b) Check the charging system: (d) Perform step 2 in the diagnosis flow, and
generator/battery and their connecting the test result is normal
wire
(c) Ensure the ground terminal (38) is well

grounded
Abno Replace or repair the connecting

rmal wire/connector and fuse
Normal
Perform next inspection according to "Trouble

Symptom Table".
5 Final Inspection
(b) ABS and brake system warning lamps turn

off within a short time after the vehicle is
turned on
262
DTC C002004 Return pump motor malfunction: Unable to rotate or unable to stop
rotating
ABS hydraulic unit with ECU integrates the return pump and return pump motor. When ABS does
not perform adjustment, the return pump relay will stop operating and the return pump is at rest.
When ABS is performing pressure reduction, ABS ECU controls the operation of return pump
motor by controlling the grounding of return pump relay.
Its role is:
ABS pressure reduction phase: The return pump operates to pump the brake fluid in the brake
wheel cylinder of locked wheel into the pipe of brake master cylinder, thus reducing the pressure in
brake wheel cylinder.
EBD pressure reduction phase: The accumulator stores the brake fluid returned from rear wheels.
However, if the accumulator is fully filled with brake fluid and the rear wheels decelerate more
quickly than the front wheels, ABS ECU will control the operation of return pump to pump the
excessive brake fluid into the pipe of brake master cylinder.

CO02004 Synchronize with ABS 1 After the return pump 1 "Return pump motor
ECU initialization and motor relay operates circuit" in ABS
self check: The vehicle for 60 ms, the return 2 Return pump motor
is stationary or vehicle pump monitoring can relay circuit open
speed is 5 km/h or not detect the voltage 3 Return pump motor
more signal relay malfunction
2 The return pump motor 4 Return pump motor
relay does not operate, connecting wire
and the return pump malfunction
monitoring detects 5 Poor ground
voltage for 2.5 seconds 6 Poor power supply
3 The return pump motor 7 Return pump motor
relay stops operating, malfunction
and the return pump
monitoring detects
voltage does not drop

· The return pump relay malfunction: The return · The brake system enters
pump can not operate conventional braking mode
· The wheel brake force control is stopped as the · ABS warning lamp and brake
return pressure can not be generated. The system warning lamp turn on
system enters conventional braking mode.
Note:
After troubleshooting, restart the vehicle and ABS and brake system warning lamps will turn off
automatically after the vehicle speed exceeds 12 km/h.
263
Malfunction Diagnosis Flow. DTC: C002004
Circuit Diagram
264
1 Check ABS hydraulic regulator with ECU when parking

(a) Turn the vehicle off for more than 10 s.
(b) Check if sounds from ABS hydraulic

regulator can be heard.
Normal: ABS return pump should stop

operating.
Abno Go to step 4
rmal
Normal
2 Check ABS hydraulic regulator with an ECU self-check and initialization procedure
(a) Start the engine.
(b) Do not depress the brake pedal and drive

at the speed of 10~15 km/h.
(c) Check if ABS warning lamp turns on.

Read DTCs with the diagnostic tester as
necessary.
Normal: ABS warning lamp turns off. ABS ECU

does not memorize trouble codes
Abnormal
If the trouble code is memorized, is there any
other DTC (except C0110)?
Yes Repair other DTCs

first
No Go to step 4
Normal
265
3 Perform component test on ABS hydraulic regulator with ECV using diagnostic tester
(b) Connect the diagnostic tester to DLC.
(c) Turn on the vehicle, but do not start the

engine.
(d) Enter "Component Operation Test" function

in the diagnostic tester to operate the return
pump
Normal: The operating sound of ABS return

pump can be heard
Note: Refer to Page 28 of the repair manual for
detailed detection procedure.

(b) Connect the wires of voltmeter/oscilloscope

as follows:


When a multimeter is used:
(b) Remove the connector of ABS

hydraulic regulator with ECU.
(d) Measure the voltage between power

the return pump using the multimeter.
Note:
If the junction box is not used, normal test
of the procedure cannot be ensured.
266
Normal Replace ABS hydraulic

regulator with ECU
Abnor
mal
5 Check the connecting wire, connector and 4O A fuse
(a) Check if the 40 A fuse is normal
(b) Check the charging system: generator/battery and their connecting wire
(c) Ensure the ground terminal (1) is well grounded
Abnorm Replace ABS hydraulic

al regulator with ECU
Normal
Perform next inspection according to "Trouble Symptom Table".
6 Final Inspection
(b) ABS warning lamp and brake system warning lamp turn off within a short time after the vehicle
is turned on
(c) DTC C002004 does not occur again after the vehicle is started for 30 s
(d) Drive the vehicle at a speed of 10~15 km/h, and do not depress the brake pedal. DTC
C002004 does not occur again
DTC C012104 Solenoid valve relay circuit malfunction
After the vehicle is turned on, the ABS solenoid valve relay with hydraulic controller is
energized to supply battery voltage to one end of hydraulic regulator solenoid valve. When the
vehicle is turned off or ABS system is disabled, the solenoid valve relay keeps energized.
Its role is:
ABS ECU controls the solenoid valve operation by controlling the grounding of each solenoid
valve so as to adjust the brake pressure of each brake circuit.
267

C01210 When the vehicle is "Solenoid valve voltage" is short 1 "Solenoid valve
4 turned on and during for Uz or ground, circuit open or relay circuit" in
malfunction testing fuse blowout malfunction ABS
During ABS "Solenoid valve voltage". 2 Poor power
operation The voltage supplied to the supply
solenoid valve is less than 0.8*Uz 3 Short circuit
(≈8.0V) for more than 0.8 4 Circuit
seconds.

 Solenoid valve relay malfunction: The  ABS system enters conventional braking
solenoid valve cannot operate mode
 ABS warning lamp and brake system
warning lamp turn on
 The solenoid valve relay cannot stop  The system is switched to EBD
operating due to triode malfunction in emergency control mode
ECU  ABS warning lamp turns on
268
269
(a) Turn the vehicle off for more than 10
seconds.
(b) Turn the vehicle on for more than 30

seconds. Do not depress the brake
pedal at this time.
(c) Check if the ABS warning lamp and

brake system warning lamp turn on.
Read DTCs using diagnostic tester as
necessary

should turn off and no current DTC exists.
Abnor Go to step 3
mal
Normal
2 Perform component test on the solenoid valve in ABS hydraulic regulator with ECU using
diagnostic tester
(a) Refer to Page 22~26: 4.3.5.3 Dynamic

Test
270
(b) Refer to Page 27: 4.3.5.4 Solenoid Valve

Test in Component Operation Test
Next
3. Check pin voltage of ABS hydraulic regulator with ECU (Voltage of pin 25)

(b) Connect the wires of voltmeter and

oscilloscope as follows:


(b) Remove the connector of ABS hydraulic

regulator with ECU
(c) Measure the voltage between power

the solenoid valve using the multimeter.
Note:
If the junction box is not used, normal test of the
procedure cannot be ensured.
Norm Replace ABS hydraulic

271
Abnormal
4 Check the connecting wire, connector and Perform next inspection according to "Trouble
40 A fuse Symptom Table"
(a) Check if the 25 A fuse is normal 5 Final Inspection
(b) Check the charging system: (a) Clear the trouble codes
generator/battery and their connecting
wire (b) ABS and brake system warning lamps turn
off within a short time after the vehicle is
(c) Ensure the ground terminal (4) is well turned on
grounded
(c) DTC C012104 does not occur again after
Abnor Replace or repair the the vehicle is started for 30 seconds
connecting wire/connector
mal and fuse (d) Perform step 2 in the diagnosis flow, and
Normal the test result is normal
DTC C004008 Brake pedal switch circuit malfunction
Braking light switch is a normally open switch.
When the brake pedal is depressed, the switch will be closed and the braking light switch will
supply +12 V signal voltage to the braking light signal circuit (BLS).
ABS ECU monitors the signal voltage of braking light switch to confirm the brake engagement time
and detect the braking light switch circuit.

C00400  Start the 1 The brake pedal is depressed 1 Braking light switch
8 engine under the following working 2 Braking light switch
 Battery conditions: circuit
voltage > 8 V Vehicle speed > 40 km/h 3 Braking light switch
 Vehicle speed Vehicle acceleration > 8 km/h2 connector
> 16 km/h 2 The brake pedal is released 4 ABS ground
under the following working 5 ABS hydraulic
conditions: regulator with ECU
Vehicle speed > 24 km/h
Vehicle deceleration > 11.5 km/h2
272
Circuit Diagram:
273
1 Check braking light switch components
(a) Check the braking light by depressing

the brake pedal.
When the brake pedal is depressed: The

braking light turns on
Braking
Light Switch When the brake pedal is released: The
braking light turns off
Note: When diagnosing the braking light

switch using this method, ensure the braking
light and its circuit are normal.
Digital Status
(b) Check the braking light switch through
the data flow of diagnostic tester.
Left front oil inlet valve: Power off
Left front oil outlet valve: Power off
Right front oil inlet valve: Power off When the brake pedal is depressed: The
Right front oil outlet valve: Power off
Left rear oil inlet valve: Power off diagnostic tester displays "Engaged"
Left rear oil outlet valve: Power off
Right rear oil inlet valve: Power off
When the brake pedal is released: The
Right rear oil outlet valve: Power off
Braking light status: On
diagnostic tester displays "Disengaged"
Return pump motor status: Power on
Solenoid valve relay status: Power on
Abnormal Go to step 4
Press [F2] key to print current contents
Press [ESC] key to return
Normal
2 Check pin voltage of ABS hydraulic regulator with ECU (Voltage between pin 30 and 38)
(b) Remove the connector of ABS with

hydraulic regulator.
(c) Turn the vehicle on.
(d) Measure the voltage between braking

light switch terminal (30) and ground
terminal (38) using the multimeter.
When the brake pedal is depressed:

Voltage < 2 V → The braking light turns
on
When the brake pedal is released:
Voltage > 4.5 V → The braking light turns
off
274
Normal Replace ABS with hydraulic

regulator
Abnormal
3 Check the connecting wire and connector (Braking light switch to ABS hydraulic regulator with
ECU)
(a) Check if the connecting wire and connector between the braking light switch and ABS
hydraulic regulator are short or open.
Abnor Replace or repair the connecting

mal wire/connector
Normal
Perform next inspection according to "Trouble Symptom Table"
4 heck the connecting wire and connector (Braking light switch circuit)
(a) Check if the braking light switch circuit

is short or open.
Normal Replace the braking light switch
Abnorm
al
Replace the connecting wire or connector
5 Final Inspection
(a) Connect diagnostic tester to clear the memorized DTCs.
(b) When driving at a speed of more than 20 km/h, confirm the malfunction does not occur again.
275
DTC C055000 ABS ECU malfunction
ABS ECU installed in ABS hydraulic regulator with ECU is the control center of the entire ABS
system. ABS system stores the desired program and calibration data in the ROM of ABS ECU.
ABS ECU performs the self-check continuously to detect and monitor if ABS system malfunctions.

Start the vehicle Detect the malfunction 1 ABS hydraulic regulator
C05500 The engine runs immediately with ECU
0 under all working Detect the malfunction 2 Circuit
conditions immediately
Detect the power supply of

wheel speed sensor is short to
Uz

·Stop operating ·ABS system enters conventional braking mode
·ABS warning lamp and brake system warning lamp turn on
276
Circuit Diagram:
277
Malfunction Diagnosis Flow. DTC: CO55000
(a) Turn the vehicle off for more than 10
seconds.
(b) Turn the vehicle on for more than 30

seconds. Do not depress the brake pedal at
this time.
(c) Check if the ABS and brake system warning

lamps turn on. Read DTCs using diagnostic
tester as necessary

should turn off and no current DTC exists.
Normal
The test result is normal. Perform
Normal inspection according to
"Precautions"
Other Diagnose and repair other DTCs

DTCs first
C055000 still
occurs
2 Test system circuit

(a) Check all the ground circuits of ABS
hydraulic regulator with ECU for high
resistance and open circuit.
(b) Check the ABS fuse and replace as

necessary.
(c) Check the ABS battery power supply

voltage circuit for high resistance, open
circuit or short to ground.
(d) Check if the power cables of wheel speed

sensor are short to main power cables.
(e) Check if electromagnetic interference exists.
Is the malfunction repaired?

Yes Go to step 4
278
No
3 Replace ABS hydraulic regulator with ECU

Replace the entire ABS hydraulic regulator with
ECU
4 Final Inspection. Confirm troubleshooting.
(b) After the engine is started for 30 seconds, ABS does not memorize any DTC.
DTC C080001 Voltage Low

C080002 Voltage High
ABS ECU monitors the battery power voltage supplied to ABS ECU via Uz (Pin 32). If the voltage
supplied to ABS ECU is not within the specification, the following malfunctions may occur.
If the voltage supplied to ABS ECU is too low, ABS system operates abnormally.
If the voltage supplied to ABS ECU is too high, ABS components will be damaged.
The normal system operation voltage is 9.3 V~16.9 V when the return pump motor operates.
DTC Test Setting Condition Possible Fault Area

Condition
a The DTCs are memorized and ABS a The battery is
C080001 The is turned off via software when ABS depleted or damaged
C080002 ignition does not operate and the voltage is b The voltage regulator
switch is lower than 9.6 V or when ABS (charging system)
turned on operates and the voltage is lower malfunctions
than 9.3 V. c The fuse, connector
b The DTCs are memorized and ABS and body ground are
is turned off via hardware if the poor or have contact
voltage is constantly monitored to be resistance
lower than 7.6 V or higher than 16.9
V.
c The DTCs are memorized if the
voltage supplied to the wheel speed
sensor is lower than 7.1 V or the
279
voltage is always lower than 7.8 V.

d If the power supply voltage is higher
than 17.5 V, the system will stop
operating to avoid overload.

· The normal operation of return pump · ABS system enters conventional braking
motor and solenoid valve cannot be mode
ensured · ABS warning lamp and brake system
warning lamp turn on
· When the voltage is too low · The system is switched to EBD emergency
control mode
· ABS warning lamp turns on
· When the voltage is too low, the voltage · The system exits EBD emergency operation
Uz is higher than 9.8 V mode
· Restore the normal operation of ABS
280
Circuit Diagram
281
Malfunction Diagnosis Flow. DTC: C080001, C080002
1 Check fuses
Fuse (a) Check if the 15 A, 25 A and 40 A fuses of ECU

powered by ABS operate normally.
Normal: Continuity
No Check if all the wire harness and
Fusible Link components connected to the fuses
are short
Yes
2 Check battery voltage with a multimeter
(a) Check the battery voltage under all working

conditions:
1 Idling: Turn on the headlamp, switch the

air conditioner to Max. Cool/adjust the
blower to highest speed;
2 Parking: Turn off all the electrical devices
and increase the speed to 3500 rpm for
about 30 seconds;
3 Braking while driving;
Normal: 10~16.9 V
No Check the charging system
Yes
3 Read the battery voltage using diagnostic tester

(a) Connect the diagnostic tester and read the
battery voltage under all working conditions.
1 Idling: Turn on the headlamp, switch the

air conditioner to Max. Cool/adjust the
blower to highest speed;
2 Parking: Turn off all the electrical devices
and increase the speed to 3500 rpm for
about 30 seconds;
Diagnostic 3 Braking while driving;
Socket
Normal: 10~16.9 V
Yes Yes Intermittent malfunction which needs

further inspection.
Go to step 5.
282
Malfunction Diagnosis Flow. DTC: C080001, C080002
4 Check the voltage of ABS power cables and ground wire
When the junction box and oscilloscope are used:
The malfunction area can be determined quickly and

correctly only when using the junction box and
oscilloscope.
(a) Turn off the ignition switch
(b) Connect the junction box to the connector of

ABS hydraulic regulator with ECU.
Ground (c) Connect the diagnostic tester
(d) Turn the vehicle on
(e) Enter the component test function of diagnostic

tester to control the operation of return pump
motor and measure the voltage between the
junction box pins using an oscilloscope or
multimeter
Connect the wires and measure the voltage as

follows:
Connect the red Connect the Working condition Normal

probe to the black probe Value
signal wire to the wire
Measu To Pin Mea To
re sure Pin
Return UBMR 1 MGN 13 When the return 9.3 V~16.9
pump motor D pump motor V
voltage operates
Solenoid UBMR 25 GND 38 Various working 9.3 V~16.9
valve conditions V
voltage
ECU power UZ 32 GND 38 Various working 9.3 V~16.9
supply conditions V
voltage
Return MGND 13 Battery Various working < 0.5 V
pump motor negative conditions
ground
ECU ground GND 38 Battery Various working < 0.5 V
negative conditions
Tips: When the return pump motor is controlled to measure UZ voltage, turn on and off
the electrical devices with higher power consumption (such as air conditioner,
headlamp) to observe the voltage change.
283
Wire Harness Side

(b) Remove the connector of ABS
hydraulic regulator with ECU.
(c) Turn the vehicle on and measure
the voltage of pins below using
the multimeter:
Connect the red probe to Connect the black Normal

the signal wire probe to the wire Value
Measure To Pin Measure To Pin
Return pump UBMR 1 MGND 13 9.3 V~16.9 V
motor voltage
Solenoid valve UBMR 25 GND 38 9.3 V~16.9 V
voltage
ECU power UZ 32 GND 38 9.3 V~16.9 V
supply voltage
Return pump MGND 13 Battery negative < 0.5 V
motor ground
ECU ground GND 38 Battery negative < 0.5 V
Tips: When measuring UZ voltage, turn on and off the electrical devices with higher power
consumption (such as air conditioner, headlamp) to observe the voltage change
Normal Abnormal Check and repair the circuit
Malfunction Diagnosis Flow. C080001,C080002
5 Reconfirm the malfunction
(a) Simulate and reconfirm the malfunction.
(b) Read the trouble codes.
Normal: No malfunction memorized
Abnorm Replace ABS hydraulic

Normal
6 Intermittent Malfunction
284
(a) Intermittent malfunction. Return the

vehicle to the customer. The malfunction
area cannot be confirmed.
(b) If the same malfunction occurs again, ask

the customer to record the malfunction
condition:
Speed? Is the brake pedal depressed?

Weather? Road condition?
Others
7 Perform final inspection to confirm the malfunction is repaired.

(b) After the vehicle is turned on for 30 s, ABS does not memorize any DTC.
285
Section 10 Service Specifications

10.1 General Specifications
Model BYD Sari

Brake line layout X type
Drive type Front wheel drive
System Bosch ABS 9
Brake fluid type Specified by BYD Mixed use is forbidden
No. of gear ring tooth 48
Internal resistance of wheel 3M  ~5M 
speed sensor
Air gap between the wheel 0.1~0.9 mm
speed sensor and gear ring
Front wheel
Rear wheel 0.2~0.7 mm
Standard: 205/65 R15 94V
Tire type Optional: 205/65 R16 92V
10.2 Torque (Unit: N·M)
Brake line joint on ABS ECU 14~18

ABS set bolts 12
Front wheel speed sensor set bolts 10
Rear wheel speed sensor set bolts 10
286
Chapter 6 Electronic Parking Brake System (EPB)

Contents
Section 1 System Overview ...................................................................................................288
Section 2 Diagnosis Flow .......................................................................................................289
Section 3 Trouble Code Table ................................................................................................291
Section 4 ECU Terminals .......................................................................................................293
Section 5 Removal and Installation........................................................................................308
287
Section 1 System Overview

The electronic parking brake system uses simple electronic parking switch instead of conventional
manual pull rod and achieves parking function through the motor cable control by ECU. The
system can also assist safe driving.
The electronic parking brake system features the following main functions:
Automatic parking: When the vehicle is turned off or the shift position is in P, the system will start
automatic parking.
Manual parking: When the electronic parking switch is pulled up by hand, the system will start
parking.
Automatic release parking: With the parking system on, when the vehicle is started and the
accelerator pedal is lightly depressed, the parking system will release automatically.
Manual release parking: With the parking system on, when the electronic parking switch is
pressed down by hand, the system will cancel parking.
Emergency braking function: While driving, the electronic parking brake system can be used to
apply brakes forcibly when the brakes are ineffective.
Main components:
 Electronic Parking Switch
 Electronic Braking Module
Notice:
 While driving, never operate the electronic parking switch unless emergency braking is
necessary.
 Do not drive with the parking brake applied.
 Contact the dealer immediately after the parking indicator light turns on.
 Never allow anyone who is not familiar with EPB to operate it to prevent accidents.
288
Section 2 Diagnosis Flow
2.1 Vehicle brought to workshop
Next
2.2 Customer problem analysis and symptom inspection
Next
2.3 Inspect battery voltage
Standard voltage:
11 to 14 V

Next
2.4 Inspect DTC*
Result
Result Proceed to
No DTC is output A
DTC is output B
B Go to step 8
2.5 Problem Symptoms Table
Result
Result Proceed to
289
Go to step 8
B
A
2.6 Overall analysis and troubleshooting
(a) ECU terminals

Next
2.7 Adjustment, repair or replacement
Next
2.8 Confirmation test
Next
End
290
DTC Malfunction Description Scope of Malfunction

Switch
Switch power cable - Short to
C113014 Wire harness
ground or open
EPB
Switch
Switch pulled up detection -
Short to power supply
EPB
Switch
Invalid signal
EPB
Switch
Short to ground or open
EPB
Switch
Switch release detection - Short
to power supply
EPB
Switch
Switch release detection -
Invalid signal
EPB
Switch
Switch release detection - Short
to ground or open
EPB
Switch
Switch stuck when pulled up -
C11352A Wire harness
Switch stuck
EPB
Switch
Switch stuck when released -
C11362A Wire harness
Switch stuck
EPB
Wire harness
C110017 Voltage high - ECU over-voltage
EPB
Wire harness
C110016 Voltage low - ECU under-voltage
EPB
Wire harness
C110116 IGN wire disconnected
EPB
291
EPB
C11A071 Actuator stuck
Cable
EPB
U007388 CAN bus OFF
Wire harness
EPB
U010087 Lost communication with EMC
EMC
EPB
U010187 Lost communication with TCU
TCU
EPB
U012987 Lost communication with BCS
TCU
EPB
U014087 Lost communication with BCM
TCU
EPB
U015387 Lost communication with ACM
ACM
EPB
U040186 Receive invalid data from EMS
EMS
EPB
U048186 Receive invalid data from BSM
BSM
C11A172 Motor Mosfet failure EPB
C11A113 Motor disconnection or failure EPB
Motor position sensor
C111029 EPB
circuit/signal
C11A11D Motor over-current EPB
Current sensor
C111115 EPB
disconnection/short circuit
C111129 Invalid current sensor signal EPB
C111286 Incorrect force sensor hardware EPB
C111229 Incorrect force sensor signal EPB
C116009 ECU hardware EPB
Equipped RUN-IN-EPB not
C116200 EPB
calibrated
C11A217 Motor operation time too long EPB
EPB
C110060 Power reboot
Wire harness
292
Section 4 ECU Terminals
1. The illustration below shows wire terminals
(a) Lead the wire from the rear of connector.
(b) Check the voltage or resistance of each

terminal.
Wire
Color
K55-1 - Body
Gr Constant voltage power Always 11-14 V
ground
K55-2 - Body
R/B Switch signal Power ON 11-14 V
ground
K55-3 - Body
L/B Switch signal Power ON 11-14 V
ground
K55-4 - Body
Y Switch signal Power ON 11-14 V
ground
K55-6 - Body
P CAN_H Always Approx. 2.5 V
ground
K55-8 - Body
B Ground Always Less than 1 V
ground
K55-9 - Body
B/W Switch signal Power ON 11-14 V
ground
K55-10 - Body
G Switch signal Power ON 11-14 V
ground
K55-11 - Body
Y/R IG1 Power ON 11-14 V
ground
K55-12 - Body
Gr Switch signal Power ON 11-14 V
ground
K55-14 - Body
V CAN_L Always Approx. 2.5 V
ground
293
DTC C11A113 Motor disconnection or failure
DTC C11A172 Motor Mosfet failure
DTC C11A217 Motor operation time too long
Circuit Diagram
Constant Voltage
7# ground
4.1 Check power supply
(a) Disconnect the connector K55.
(b) Measure the voltage of wire harness side.
Normal
Terminal Wire Color
Condition
294
K55-1 - Body
Gr 11-14 V
ground
K55-11 (Power
Y/R 11-14 V
ON) - Body ground
K55-8 - Body Less than 1
B
ground Ω
Abnormal
Check or replace the power supply harness
Normal
4.2 Check EPB
(a) Connect the connector K55
(b) Clear the trouble codes
(c) Start and release EPB once
(d) Read the trouble codes
Normal: Trouble codes do not reoccur
Abnormal Replace EPB
Normal
4.3 The system is normal, tighten connectors.
295
DTC C11A11D Motor over-current
DTC C11A071 Actuator stuck
DTC C111286 Force sensor signal
DTC C111229 Incorrect force sensor signal
DTC C111029 Incorrect motor position sensor signal
DTC C111115 Current sensor disconnection/short circuit
DTC C111129 Invalid current sensor signal
4.4 Check EPB external cables
(a) Check if EPB external parking cables, brackets

and brake assembly are stuck.
Normal: The cables and brake assembly are normal
Abnormal
Repair the cable and brake assembly

Normal
4.5 Replace EPB
296
DTC C110017 Voltage high - ECU over-voltage
DTC C110016 Voltage low - ECU under-voltage
DTC C110060 Power reboot
Circuit Diagram
Constant
Voltage
7# ground
4.6 Check input voltage
(a) Disconnect EPB connector K55.
(b) Check the voltage between terminals using a

multimeter.
(c) Select the right side external rear view mirror

(turn the switch to R)
297
Test condition Normal

Terminal
(switch) Value
K55-1-K55-8 Constant Voltage 11-14 V
K55-11-K55-8 ON position 11-14 V
Abnormal
Check the battery voltage and ground wire
Normal
4.7 Check EPB connector
(a) Check if EPB connector is secured.
Abnormal Secure the connector
Normal
4.8 Replace EPB
298
DTC C110116 IGN wire disconnected
Circuit Diagram
Constant
Voltage
7# ground
4.9 Check the communication
(a) Switch the power to ON position.
(b) Read the trouble code using diagnostic tester

and check if other communication DTC outputs.
Check ECU communication

No
Yes
299
4.10 Check IG power supply
Test
Wire Normal
Terminal conditi
Color Condition
on
K55-11 - Body Power
Y/R 11-14 V
ground ON
Normal
4.11 Replace EPB
300
DTC C113312 Switch pulled up short to power supply
DTC C113314 Switch pulled up short to ground or open
DTC C113386 Switch pulled up signal invalid
DTC C113312 Switch released short to power supply
DTC C113314 Switch released short to ground or open
DTC C113386 Switch release signal invalid
DTC C113014 Switch power cable short to ground or open
Circuit Diagram
III short connector IV short connector IV short connector
Lamp
power
supply
indicator
light
switch
switch
Backlight
2# ground
301
4.12 Check EPB switch
(a) Disconnect EPB switch K56.
(b) Measure the switch pins using a multimeter.
Test Normal
Terminal
condition Condition
K56-1-K56-4- Less than 1 Ω
Switch is
K56-2-K56-3 not Less than 1 Ω
operated
K56-5-K56-6 Less than 1 Ω
More than 10
K56-2-K56-3 Switch is kΩ
pulled up
Switch is
pressed More than 10
K56-5-K56-6
kΩ
Abnormal Replace the switch
Normal
4.13 Check wire harness
(a) Disconnect the connectors K55 and K56.
(c) Measure the voltage of wire harness side.
Wire Normal
Terminal
Color Condition
K56-1-K55-3 L/B Less than 1 Ω
K56-2-K55-4 Y Less than 1 Ω
302
K56-3-K55-10 G Less than 1 Ω

K56-4-K55-12 Gr Less than 1 Ω
K56-5-K55-2 R/B Less than 1 Ω
K56-6-K55-9 B/W Less than 1 Ω
Normal
4.14 Replace EPB
303
DTC C11352A Switch stuck when pulled up
DTC C11362A Switch stuck when released
4.15 Check EPB switch
(a) Start and release EPB once.
(b) Check if the switch resets.
Normal: Switch resets
Abnormal Replace the switch
Normal
4.16 Replace EPB
304
DTC C116009 ECU hardware malfunction
4.17 Check the operating status
(b) Operate EPB to check if it operates normally.
Normal: Operates normally
Normal
4.18 Normal system
305
DTC C116200 Assembly not calibrated
4.19 Diagnostic tester calibration
(b) Perform program collating and writing using

diagnostic tester.
(c) Start and release EPB
Normal: Operates normally
Normal
4.20 System calibration is normal
306
DTC U007388 CAN bus off
DTC U010087 Lost communication with EMS
DTC U010187 Lost communication with TCU
DTC U012987 Lost communication with BCS
DTC U014087 Lost communication with BCM
DTC U015187 Lost communication with SRS
DTC U040186 Receive invalid data from EMS
DTC U040286 Receive invalid data from TCU
DTC U048186 Receive invalid data from BCS
Circuit Diagram
Dashboard wire harness III short connector
4.21 Check the trouble codes
307
(b) Read the trouble codes using diagnostic tester

and check if all communications malfunction.
No
Check the modules which lost communication
Yes
4.21 Inspect CAN line
(b) Measure the CAN line voltage using a

multimeter.
Test Normal
Wire
Terminal condition Conditio
Color
n
K55-6 - Body Constant Approx.
P
ground Voltage 2.5 V
K55-14 - Body Constant Approx.
V
ground Voltage 2.5 V
Abnormal Repair CAN line
Normal
4.22 Replace EPB
Section 5 Removal and Installation 5.1.1.1 Turn the vehicle start button to ON
position or turn the ignition switch on
Removal method
5.1.1.2 Keep depressing the brake pedal
5.1 Removal method for repair
5.1.1.3 Press and hold EPB switch for 10
5.1.1 Fully release EPB (The connecting cable seconds and then release (After releasing,
is removable) EPB brake warning lamp begins flashing
for 5 seconds)
Method 1:
5 1.1.4 Within 5 seconds after the last
Using the diagnosis tool, enter [EPB operation ends (during warning lamp
Electronic Parking Brake System] -- flashing), press the EPB switch once (EPB
[Component Operation Test] -- [Release] brake warning lamp flashes continuously)
to release EPB.
Method 2: 5.1.1.5 EPB is fully released (EPB brake
warning lamp remains on)
308
5.1.1.6 Press EPB switch once, and release

the brake pedal
5.1.1.7 Stop the engine within 3 seconds after

completing step (6).
Method 3:
When the two methods above do not work,

release EPB manually
1.1.2.2 Remove EPB bracket mounting bolts
(a) Remove EPB front parking brake cable (A) and take off EPB module and lower
thread bushing (B) using M24 Open bracket (B);
Wrench (A);
Take off the seal plug (A) and turn the cable 5.1.2.3 Using M5 inner hexagon wrench,
rivet head (C) clockwise using M5 inner remove EPB module mounting bolts (A)
hexagon wrench (B), until it can be removed; and take off EPB module (B);
5.2 Installation Method

5.1.2 EPB Removal
5.1.2.1 Remove the connecting wire connector 5.2.1 Install the EPB and lower bracket with
(A); torque of 6 Nm;
5.2.2 Install EPB upper and lower brackets
with torque of 9 Nm;
5.2.3 Install the connecting wire connector;
5.2.4 Install the front parking brake cable

thread bushing with torque of 6 Nm;
309
5.2.5 Check if the dust cover is installed 5.3 Precautions for installation
properly. If it is broken, repair it to prevent
water entering, causing the module 5.3.1 Before installing EPB, make sure the
damage; entire vehicle is powered off;
5.2.6 Initialize the module using diagnosis tool 5.3.2 When EPB is installed, perform
after other components (including left and initialization after the vehicle is powered on.
right cables) are installed. The specific operation is as follows. Using
the diagnosis tool, enter [EPB Electronic
Description: When the EPB module, EPB Parking Brake System] -- [Component
caliper, wires or brake disk (optional) are Operation Test] -- [Initialization] to perform
replaced, it is necessary to release and initialization.
initialize EPB to ensure the normal
operation of EPB.
310
Chapter 7 ELECTRIC POWER-ASSISTANT (EPS) SYSTEM

Contents
Section 1 Outline of the EPS System ....................................................................................312
1.1 Function of the EPS System .................................................................................... 312
1.2 Operating principles of the EPS System ................................................................. 312
Section 2 Schematic Circuit Diagram of the EPS System .....................................................314
2.1 Definitions of the EPS System and Electrical Interface for
Complete Vehicle Wiring ....................................................................................... 315
Section 3 Precautions for Maintenance .................................................................................316
3.1 Precautions for Inspection ....................................................................................... 316
3.2 Troubleshooting Chart ............................................................................................. 318
3.3 General Maintenance Information for Malfunctions ................................................ 319
Section 4 Inspection of the Steering Wheel and Steering Column ........................................320
4.2 Maintenance of Steering Gear with Tie Rod Assembly........................................... 326
Section 5 Self Diagnosis and Troubleshooting of the EPS System ......................................334
5.1 Troubleshooting Method of the Diagnostic Tester .................................................. 334
Section 6 Self-Diagnosis and Troubleshooting of the EPS System ......................................344
6.1 Calibration of the EPS Torque and Steering Angle Signal Neutral Point ................ 344
311
Section 1 Outline of the EPS System

vehicle speed sensitive, namely, the target
The EPS (Electric Power-assistant Steering) current of the motor varies with the vehicle
system is a steering system that uses the speed as the steering moment input is same.
motor to provide power and assist the driver to Thus, both ease and road feel are achieved.
perform the steering operation. Like any other The power assist characteristic of the EPS
control system, the system consists of sensors system is the sectional type. The motor will not
(torque sensor, steering wheel angle sensor operate when the steering moment applied by
and vehicle speed sensor), controller (EPS the driver is in the dead zone. When the
ECU), actuator (power-assistant motor) and steering moment is out of the dead zone, the
relevant mechanical components. motor will apply assist torque according to
direction deviation of the steering wheel, to
1.1 Function of the EPS System ensure the ease of steering when driving at
Based on the mechanical steering system, the low speed and the stability of operation when
EPS system adopts the latest power electronic driving at high speed, and to achieve excellent
and advanced motor control technologies for road feel.
the vehicle steering system. In the EPS
system, the original vehicle steering system is 1.1.2. Return ability control function
modified and the following parts are added in:
Electronic control unit, Torque sensor, and The steering wheel has the kingpin caster
Power-assistant motor. The power train of the angle and kingpin angle which can provide
system uses motor-drive to replace the automatic return effect when turning. Based on
conventional mechanical hydraulic mechanism, the mechanical steering mechanism, motor
which can provide real-time steering wheel and speed reducing mechanisms are added to
power assist for the driver in various the EPS system. The EPS system performs
environmental conditions. the steering return ability control for the motor
by the EPS ECU, and takes the steering return
The EPS system usually consists of the ability action of the vehicle together with the
following parts: (a) Torque sensor and steering aligning torque generated by the front wheel
angle sensor, (b) Vehicle speed sensor, (c) alignment. It does this so that it can align the
EPS ECU, (d) Motor, (e) Relevant mechanism. steering wheel quickly, suppress the vibration
The power assist of the EPS system is of the steering wheel, maintain the road feel,
provided by the motor, and the amount is improve the steering sensitivity and stability,
adjusted and controlled by the EPS electronic optimize the steering alignment characteristic
control unit (ECU) in real time. According to and shorten the convergent time. The return
the vehicle speed, different power assists are ability control function adjusts the return ability
provided-to improve the steering characteristic, offset current to generate the torque of the
to reduce the handling effort when parking and alignment effect. The torque then turns the
driving at low speed, to increase the stability of steering wheel back to the neutral position.
the steering operation when driving at high
speed-thus the active safety of the vehicle is 1.1.3. Damping Control Function
improved.
When the vehicle is driven at high speed,
The EPS system features the following damping control is performed by controlling
functions: the damping offset current to improve the
driver’s road feel and the steering stability
1.1.1. Assist control function under high speed.
The power assist characteristic of EPS is
1.2 Operating principles of the EPS System
When the vehicle is turning, the torque sensor sends the detected torque signal and the value &
312
direction of the steering wheel angle signal to EPS ECU after processing. At the same time, EPS
ECU will also receive the vehicle speed signal, detected by the vehicle speed sensor. Then, the
rotation direction of the motor and the amount of power assist torque will be determined according
to the signal of the vehicle speed sensor and torque sensor. In addition, the current sensor will
inspect the current of the circuit and monitor the drive circuit. Finally, it will operate the motor via
the drive circuit and perform power assist steering. This operation is shown in fig. 1-1.
Torque Sensor Steering

and Steering Wheel
Wheel Angle
Sensor
E
Vehicle Speed C Steering
Signal U Drive EPS Mechanism
Circuit Motor
Drive Current
Signal
Fig. 1-1 Operation of EPS System
313
Section 2 Schematic Circuit Diagram of the EPS System
Repair Circuit
EPS Motor
EPS Motor
Halla Torque Angle Sensor
EPS ECU
Speed Signal Input Indication of High Current Out
Electronic Electronic
Adapter Injector Injector EPS Motor
A01-37 A01-76
Fig. 2-1 Schematic Circuit Diagram of the EPS System
314
2.1 Definitions of the EPS System and Electrical Interface for Complete Vehicle Wiring
Fig. 2-2 EPS ECU (Wire Inlet Side View)
Table 2-1 Definition of the EPS ECU Pin
Wiring Measuring
Test Terminal Terminal Description Standard Value
Color Conditions
C1 - Body R Power (+) Always 9-16VDC
Resistance between it
C2 - Body B Ground Always and the body is less than
1Ω
C3 - Body None Vacant None None
C4 - Body None Vacant None None
A1 - Body B Motor (-) Power supply ON 0-12 V
A2 - Body R Motor (+) Power supply ON 0-12 V
B1 - Body None Vacant None None
The pulse signals are
B2 - Body V Speed signal Starting engine
input
B3 - Body None None None None
B5 - Body Br Ignition signal Power supply ON 10-14 V
B6 - Body P CAN_H Power supply ON 2.5 V or 3.5 V
Indication of high current High level is above 7 V,
B8 - Body G Power supply ON
out, low level effective low level is below 3 V
B9 - Body None None None None
B11 - Body Br Ignition signal Power supply ON 10-14 V
B12 - Body V CAN_L Power supply ON 1.5 V or 3.5 V
B4/B7/B10 -
-- -- -- --
Body
D1 - Body W Torque sensor signal 1 Power supply ON 0.5-4.5 V
D3 - Body B Torque sensor signal 2 Power supply ON 0.5-4.5 V
D4 - Body R Power supply signal 1 Power supply ON 5VDC
D6 - Body L PWM_P
D7 - Body V PWM_S
D8 - Body B/R Power supply signal 2 Power supply ON 5VDC
Resistance between it
D2/D5 -
Gr Ground wire Power supply ON and the body is less than
Body
1Ω
Notice: The connector should correspond with the wire terminal B - G59 C - B11
315
Section 3 Precautions for Maintenance

3.1 Precautions for Inspection
3.1.1 Condition of the Start Button
The keyless start button is shown in the figure on the right. The meanings of its light color are
shown in table 3-1.
Fig. 3-1 Start Button Position Diagram
Table 3-1 Condition of Start Button
Vehicle Condition
Description of Button Condition
Color of Indicator Light Engine Condition
The smart key is detected in the vehicle
Green OFF
and the engine can be started
The smart key is not detected in the vehicle
No light, OFF OFF
and the engine cannot be started
ACC/ON Gear Orange OFF
Engine started No light, OFF Start
3.1.2 Precautions for EPS Steering Column section 6)

Maintenance
3.1.2.2 The power assist steering system of
3.1.2.1 Precautions for SRS airbag system this vehicle provides the self-alignment
Operation control. After removing and replacing any
component of the steering system
This vehicle is equipped with a (including power assist steering column,
supplemental restraint system (SRS), intermediate shaft assembly, mechanical
which includes the front passenger steering gear, EPS ECU, steering wheel,
double-stage airbag, side airbag and etc.), please reset the steering wheel
curtain shield airbag. Failure to carry out angle signal in strict accordance with
operations in the correct sequence may following conditions:
lead the airbag to unexpectedly deploy
during servicing and cause a serious 3.1.2.2.1 After removing and replacing the
accident. Before servicing (including column assembly of the power assist
removal or installation of parts, inspection steering, drive the vehicle in a straight line
or replacement), do read the precaution at low speed to center the steering wheel.
for the airbag system. (For details, see After parking, reset the steering wheel
316
angle signal with a tester and clear the 3.1.2.3.3 Do not release the angle adjusting
trouble code. handle before the installation of the
steering column assembly is complete in
3.1.2.2.2 After removing and replacing the the vehicle.
intermediate shaft assembly, drive the
vehicle in a straight line at low speed to 3.1.2.4 When disconnecting or reconnecting
center the steering wheel. After parking, the steering column assembly:
reset the steering wheel angle signal with
a tester and clear the trouble code. 3.1.2.41 Before disconnecting the steering
column or intermediate shaft from the
3.1.2.2.3 After removing and replacing the steering gear, the wheels should be
steering gear, perform four-wheel straight ahead with power off in the
alignment to adjust toe-in and drive the vehicle. Otherwise, the clock spring on the
vehicle in a straight line at low speed to steering column will deviate from the
center the steering wheel. After parking, neutral position and be damaged.
reset the steering wheel angle signal with
a tester and clear the trouble code. 3.1.2.4.2 Before disconnecting the steering
column or intermediate shaft, the vehicle
3.1.2.3 When operating the steering column should be powered off. After
assembly: disconnecting the components above, do
not move the wheels. Failure to observe
3.1.2.3.1 Avoid any impact to the steering these procedures may cause certain
column assembly, especially the motor component misalignment during
and reduction mechanism. If the steering installation.
column assembly is dropped or subjected
to a strong impact, replace it with a new 3.1.2.4.3 Do not hold the steering wheel in the
one. full turn position for more than 5 seconds,
otherwise damage to the motor may
3.1.2.3.2 Do not pull the wire harnesses when occur.
moving the steering column assembly.
317
3.2 Troubleshooting Chart
The troubleshooting chart can help you find the cause of the malfunction. The numbers in the chart
indicate possible order when a malfunction occurs. Please check every part in order.
Repair/replace faulty parts or perform adjustments if necessary.
Troubleshoot the steering system as shown in table 3-2.
Table 3-2 Troubleshooting Chart of the Steering System
Symptom Possible cause Symptom Possible cause

1) Tires (improperly inflated) 1) Steering knuckles (worn)
2) Front wheel alignment 2) Suspension arm ball joints
(incorrect) (worn)
Excessive
3) Steering knuckles (worn) 3) Intermediate shaft, sliding
play
Heavy 4) Suspension arm ball joints yoke (worn)
steering (worn) 4) Front wheel bearing (worn)
5) Steering column assembly 5) Steering gear (faulty)
(faulty) 1) Reduction mechanism
6) Steering gear (faulty) (worn)
Abnormal
7) EPS ECU (faulty) 2) Steering knuckles (worn)
noise
1) Tires (improperly inflated) 3) EPS motor (faulty)
2) Front wheel alignment 4) Steering gear (faulty)
Poor (incorrect) 1) EPS motor (faulty)
Steering
return 3) Steering column (bent) 2) Steering column assembly
wheel
4) Steering gear (faulty) (faulty)
vibrates
5) EPS ECU (faulty) 3) EPS ECU (faulty)
318
3.3 General Maintenance Information for 3.4.2 Gently turn the steering wheel right or left,
Malfunctions and check the steering wheel free travel.
The maximum free travel of the steering
EPS Indicator Light wheel should be no more than 30 mm as
shown in the figure 3-2.If the free travel
After starting the engine, the EPS indicator exceeds the maximum, inspect the
light will remain on for 2 to 3 seconds, and steering system.
then go off. It indicates that the EPS indicator
light and the system are operating normally.
After starting the engine, if there is any

malfunction in the system, the MIL should be
illuminated instantly. Meanwhile, the cause of
the respective malfunction can be judged by
the flicker frequency of the light.
3.4 Inspection of the Steering Wheel Free

Travel
The inspection methods of the steering wheel

free travel are as follows:
3.4.1 Park the vehicle with the tires straight

ahead; Fig. 3-2 Schematic Diagram of Steering Wheel
Free Play
319
Section 4 Inspection of the Steering Wheel and Steering Column

4.1.1 Construction of the Steering Wheel and Steering Column Assembly
See figure 4-1.
Fig. 4-1 Construction Figure of the Steering Wheel and Steering Column Assembly
320
4.1.2 Removal and Installation of the Steering Notice: Do not pull the airbag wire while
Wheel and Steering Column Assembly removing the DAB module assembly. Place
the DAB module assembly with the upper
4.1.2.1 Removal surface upward. Do not disassemble the DAB
module assembly.
Some service operations may affect the SRS
airbag system. Do read the precautionary 4.1.2.1.4 Remove the steering wheel
notices of the SRS airbag system before assembly.
servicing the steering column. (For the
removal procedures of the safety air bag, see 4.1.2.1.4.1 Pull out the remaining wire
chapter 6-8) connectors.
4.1.2.1.1 Check that the front wheels are 4.1.2.1.4.2 Loosen the hexagon flange bolt
straight ahead; that is securing the steering wheel. See
figure 4-3.
4.1.2.1.2 Disconnect the negative battery
terminal;
4.1.2.1.3 Remove the DAB module (driver

airbag module).
Notice:
When the airbag ECU detects that there is a

malfunction in any airbag component or airbag
system circuit, it will store a trouble code in the
memory and send the information to the
combination meter to turn on the airbag
malfunction indicator lamp. If the airbag
connector is disconnected with the ignition
switch on, a trouble code will be recorded.
4.1.2.1.3.1 Loosen the 2 Allen screws through

the small holes on both sides of the
Fig. 4-3
steering wheel with a tool. See figure 4-2.
4.1.2.1.4.3 Match-mark on the steering wheel
assembly and the steering shaft of the
steering column assembly as shown in
figure 4-4.
4.1.2.1.4.4 Remove the steering wheel

assembly with special tools.
Fig. 4-2
4.1.2.1.3.2 Take out the DAB module

assembly from the steering wheel.
4.1.2.1.3.3 Loosen the snap fit of the airbag

connector with the paddle, and take down
the airbag connector.
321
4.1.2.1.6.2 Loosen the 3 installation bolts of

the combination switch (2 on front side, 1
on back side) with a cross screwdriver as
Match mark shown in figure 4-6, and remove the
combination switch.
Fig. 4-4
4.1.2.1.5 Remove the combination switch

protector.
4.1.2.1.5.1The upper and lower combination

switch protectors are engaged by the
plastic snap-fits. Open the upper protector Fig. 4-6
from bottom to top and remove it.
4.1.2.1.7 Remove the connector on the
4.1.2.1.5.2 Loosen the 3 installation screws of steering shaft lock.
the lower protector with a cross
screwdriver and then release the angle 4.1.2.1.8 Remove the joint boot assembly I
adjusting handle of the steering column
downward, then take the lower protector Loosen the 2 nut-type plastic snap-fits as
down. See figure 4-5. shown in figure 4-7 and remove the joint boot
assembly I.
Fig. 4-5 Fig. 4-7
4.1.2.1.6 Remove the clock spring and the 4.1.2.1.9 Disconnect the connection of the
combination switch. intermediate shaft assembly and long
shaft assembly.
4.1.2.1.6.1 Remove all connectors connected
to the clock spring and combination 4.1.2.1.9.1 Match-mark on the fitting surface
switch. between the bottom of the intermediate
322
shaft and the input shaft of the steering

gear as shown in figure 4-8.
4.1.2.1.9.2 At this time, install the steering

wheel and turn it to get the bolt in the
appropriate position that is easier to
operate. Loosen the bolt and pull out the
intermediate shaft.
Fig. 4-10
4.1.2.1.11 Remove the steering column

Match mark assembly.
4.1.2.1.11.1 Pull out the motor connector and

torque sensor connector from the EPS
ECU.
Fig. 4-8
4.1.2.1.11.2 Remove the braking light switch
4.1.2.1.10 Remove the intermediate shaft
as shown in figure 4-11.
assembly.
4.1.2.1.10.1 Match-mark on the fitting surface

between the steering column assembly
and the intermediate shaft assembly as
Fig. 4-11
(a) Loosen the hexagon flange bolt for

bracket-mounting on the steering column
as shown in figure 4-12.
Match mark
Fig. 4-9
4.1.2.1.10.2 Loosen the service bolt between

the steering column assembly and the
intermediate shaft assembly as shown in
figure 4-10.
Fig. 4-12
323
4.1.2.1.12 Remove the steering shaft lock. installation bolt, 35 Nm.
Loosen the 2 theft deterrent bolts shown in 4.1.2.2.3.4 Connect the steering shaft lock
figure 4-11, and remove the steering shaft lock. connector.
4.1.2.2.4 Connect the steering column

assembly and the intermediate shaft
assembly.
4.1.2.2.4.1Install the intermediate shaft

assembly to the output shaft of the
steering column assembly. Align the match
marks and make sure that the bolt hole on
the intermediate shaft is aligned with the
groove on the output shaft of the steering
column assembly. Then the intermediate
shaft assembly is installed in place.
Fig. 4-11 4.1.2.2.4 .2 Tighten the bolt to 30 Nm.
4.1.2.2 Installation Notice:
4.1.2.2.1 Inspect for shaft lock malfunction. Do tighten the bolt from the side without thread.
Connect the removed shaft lock to the Tightening from the other side will result in
connector. When pressing down the start failure, and an accident may occur. There is a
button to power on, the steering shaft lock milled plane on the side without thread of the
will be unlocked. When pressing down the universal joint assembly. Tighten the bolt from
start button to power off, the steering shaft this side. See figure 4-12.
lock will be locked.
If the steering shaft lock operates normally,

install the removed connector to the
steering column. If not, replace the shaft
lock.
4.1.2.2.2 Install the steering shaft lock.

Align the boss of the shaft lock with the
lock hole on the steering column. Fix the
shaft lock bracket and shaft lock on the
steering column with 2 new theft deterrent
bolts. Tighten the bolts until the bolt heads
break off.
4.1.2.2.3 Install the steering column assembly.

Fig. 4-12
4.1.2.2.3.1 Align with the lower installation hole,
and insert the lower installation bolt. 4.1.2.2.5 Connect the intermediate shaft
assembly and long shaft assembly.
4.1.2.2.3.2 Loosen the angle adjusting handle
of the steering column. Align the 2 4.1.2.2.5.1 Install the intermediate shaft to the
installation holes of the upper mounting long shaft assembly. Align the match
bracket and tighten the 2 nuts. marks and make sure that the bolt hole on
the intermediate shaft is aligned with the
4.1.2.2.3.3 The tightening torque for the upper groove on the long shaft assembly. Then
installation nut is 35 Nm, and for the lower the intermediate shaft is installed in place.
324
back for 2.5 turns) to face the side with

4.1.2.2.5.2 Tighten the bolt to 30 Nm. the connector on the clock spring upward.
See figure 4-14.
Notice: Do tighten the bolt from the side
without thread. Tightening from the other side
will result in failure, and an accident may occur.
There's a milled plane on the side without
thread of the universal joint assembly, tighten
the bolt from this side. See figure 4-13.
Fig. 4-14
4.1.2.2.10 Install the steering wheel assembly
Align the match-marks on the steering

wheel and the steering column. Tighten
Fig. 4-13 the nut to 40 Nm.
4.1.2.2.6 Install the joint boot assembly I 4.1.2.2.11 Install the DAB module assembly
Install the dust cover in place, and engage 4.1.2.2.11.1 Connect the connector.
the plastic snap-fit.
4.1.2.2.11 2 Align with the position of the DAB
4.1.2.2.7 Install the combination switch and module, and tighten the set bolts on both
clock spring. sides to 8.8 Nm.
Align with the position of the combination Notice:

switch, tighten 3 installation bolts and
connect the connector. (a) Do not use airbag parts removed from
another vehicle. When replacing parts, be
4.1.2.2.8 Install the combination switch sure to use new ones.
protector.
(b) Make sure that the DAB module
4.1.2.2.8.1 Install the lower protector, and assembly is installed with the specified
tighten the 3 set bolts. torque.
4.1.2.2.8.2 Install the upper protector, and (c) If the DAB module assembly has been
attach it to the lower protector. dropped or if any cracks, dents or other
defects are found on the housing or
4.1.2.2.9 Center the clock spring. connector, replace the assembly with a
new one.
Notice: Incorrect installation of the clock
spring may damage it. Make sure to (d) When installing the DAB module
center it. When centering it, first turn the assembly, do not allow the wire
clock spring fully to the left, then fully to harnesses to interfere with other parts or
the right and count the number of full be pinched by them.
turns. Next, turn it to the left in half turns
(if the total number of turns is 5, turn it 4.1.2.2.12 Connect the negative battery
325
terminal. Notice:
4.1.2.2.13 Inspect the SRS warning light. The motor wire harness should face the
correct direction, see Fig 4-16.
4.1.3 Inspection of the EPS Motor
Before tightening the bolts, turn the motor
Notice: During the removal and installation, do 45°to left and right for 2~3 times and
not allow any foreign matter such as dirt or check the contact situation of the motor
dust to enter the housing of the reduction fitting surface. Alternately tighten the
mechanism. Do not power on if the motor is bolts. Secure the motor.
not connected. Tightening torque: 25 Nm.
4.1.3.1 Removal
4.1.3.1.1 Remove the steering column

assembly by the method above.
4.1.3.1.2 Remove the 2 bolts and remove the

motor from the steering column as shown
in figure 4-15.
Fig. 4-16
After installation, start the engine and run it idly.

Turn the steering wheel from the left limit to
the right limit several times. Confirm that the
EPS indicator light is working normally.
Notice:
After replacing the motor, perform the

following inspection:
(a) Park the vehicle on a common road

outdoors.
(b) Start the engine.
Fig. 4-15 (c) Turn the steering wheel 2 to 3 times at

the rate of 1 turn per second (the noise
4.1.3.1.3 Check if the motor rotates smoothly should be smaller than the engine sound
without an abnormal smell. If the motor and not easily perceived).
rotates with seizure or an abnormal smell, During the above inspection, if there is
replace it with a new one. any abnormal noise or vibration in the
motor, the motor may be deteriorated.
4.1.3.2 Installation Replace it with a new one and re-inspect
it.
Install each removed component in a
reverse order of the removal procedures.
4.2 Maintenance of Steering Gear with Tie Rod Assembly
326
4.2.1 Construction of Steering Gear with Tie Rod Assembly
See figures 4-1, 4-2 and 4-3.
327
328
4.2.2 Removal
4.2.2.1 Face the front wheels straight ahead. 4.2.2.10 Remove the rear under cover RH of
the engine.
4.2.2.2 Secure the steering wheel.
4.2.2.11 Remove the lower reinforcement of
(a) Secure the steering wheel in place with the engine front mounting bracket.
the seat belt to prevent rotation.
4.2.2.12 Remove the reinforcement LH of the
Tips: front suspension cross bearer.
This operation helps prevent damage to the 4.2.2.13 Remove the reinforcement RH of the
spiral cable. front suspension cross bearer.
4.2.2.3 Remove the upper boot assembly of 4.2.2.14 Remove the front stabilizer link
the joint. assembly LH.
4.2.2.4 Disengage the lower steering shaft. 4.2.2.15 Remove the front stabilizer link
assembly RH.
4.2.2.5 Disengage the lower boot assembly of
the joint. 4.2.2.16 Disengage the outer link assembly LH
and the steering knuckle.
(a) Disengage the clips A and B of the joint
lower boot frame from the body. (a) Remove the split pin and hexagon slotted
nut.
Notice:
(b) Disengage the outer link assembly LH
Do not damage the clips of the frame. from the steering knuckle.
4.2.2.17 Disengage the outer link assembly

4.2.2.6 Remove the front wheels. RH and the steering knuckle.
4.2.2 7Disengage the rear suspension Tips:

assembly and front sub frame assembly.
Perform the same procedure as the LH side.
4.2.2.8 Remove the under cover of the engine.
4.2.2.18 Disengage the lower arm assembly of
4.2.2.9 Remove the rear under cover LH of the the front suspension LH.
engine.
329
Match mark
4.2.2.19 Disengage the lower arm assembly of 4.2.2.25 Remove the mechanical steering
the front suspension RH. gear with tie rod assembly.
Tips: (a) Remove 2 bolts, 2 nuts and mechanical

steering gear with tie rod assembly from
Perform the same procedure as the LH side. the front sub frame assembly.
4.2.2.20 Remove the rear support of the front

suspension cross bearer LH.
4.2.2.21 Remove the rear support of the front

suspension cross bearer RH.
4.2.2.22 Remove the front sub frame

assembly.
4.2.2.23 Remove the joint lower boot

assembly.
(a) Remove the joint boot assembly from the

mechanical steering gear with tie rod 4.2.2.26 Secure the mechanical steering gear
assembly. with tie rod assembly.
4.2.2.24 Remove the lower steering shaft. 4.2.2.27 Remove the outer link assembly LH.
(a) Match-mark on the lower steering shaft (a) Match-mark on the outer and inner link
and steering gear box. assembly LH.
(b) Remove the lower steering shaft from the (b) Remove the outer link assembly LH and
mechanical steering gear with tie rod the lock nut of the link.
assembly.
4.2.2.28 Remove the outer link assembly LH.
Tips:
Perform the same procedure as the LH side.
330
check that the dust covers LH/RH expand

4.2.3 Inspection and contract smoothly.
4.2.3.1 Inspect the sub-assembly of the tie rod Tips:

outer end LH. If the rack bellows-type dust covers do not
expand or contract smoothly, replace them
(a) Hold the sub-assembly of the tie rod outer with new ones as well as new clamps.
end LH in a vise.
4.2.3.5 Check the dust cover of the ball joint
Notice: end on steering tie rod.
Do not over tighten the vise!
Firmly press the dust cover with a finger,
(b) Fix the nut to the stud bolt. and check for any crack or damage on the
dust cover.
(c) Shake the bolt back and forth 5 times.
Tips:
(d) Set a torque wrench to the nut, turn the If there is any crack or damage on the dust
ball joint continuously at a rate of 3 to 5 cover, replace the outer end of the steering tie
seconds per turn, and check the torque on rod.
the 5th turn.
Standard torque: 0.5-3.5 Nm 4.2.4 Installation
Tips: 4.2.4.1 Install the outer link assembly LH.

If the torque is not within the specified range,
replace a new sub-assembly of the tie rod (a) Connect the lock nut of the link and the
outer end LH. outer link assembly LH to the mechanical
steering gear till the match-marks are
4.2.3.2 Check the sub-assembly of the tie rod aligned.
outer end RH.
Tips:
Tips:
After adjusting the toe-in, screw up the lock
Perform the same procedure as the LH side. nut.
4.2.3.3 Check the no-load torque of the

steering gear. Match mark
Check the no-load torque of the steering

gear with a torque wrench.
Standard torque: 0.5-1.1 Nm
4.2.4.2 Install the outer link assembly RH.
Notice:
Check around the steering gear rack center. Tips:
Tips: Perform the same procedure as the LH side.

If the total pre-tensioning force is not within the
specified range, replace the steering gear 4.2.4.3 Install the mechanical steering gear
assembly with a new one. with tie rod assembly.
4.2.3.4 Check the bellows-type dust covers. (a) Install the mechanical steering gear with
tie rod assembly to the front sub frame
Rotate the pinion with a special tool, and assembly with 2 bolts and 2 nuts.
331
Pre-tensioning torque: 138 Nm
4.2.4.4 Install the lower steering shaft.
(a) Align with the match-marks and install the

lower steering shaft to the mechanical 4.2.4.6 Install the front sub frame assembly.
steering gear with tie rod assembly.
4.2.4.7 Install the rear support of the
(b) Install the bolt. suspension cross bearer LH.
Pre-tensioning torque: 35 Nm 4.2.4.8 Install the rear support of the front

suspension cross bearer RH.
Match mark 4.2.4.9 Connect the lower arm sub-assembly
of the front suspension LH.
4.2.4.10 Connect the lower arm sub-assembly

of the front suspension RH.
4.2.4.11 Connect the outer link assembly LH.
(a) Connect the outer link assembly LH to the

steering knuckle with the hexagon slotted
nut.
4.2.4.5 Install the joint lower boot.
Notice:
(a) Align the hole on the lower dust cover of
universal joint with the boss on the
Further tighten the nut 60°if the holes for the
steering gear housing to install the
split pin are not aligned.
manhole cover.
(b) Install a new split pin.
4.2.4.12 Connect the outer link assembly RH.
Tips: Perform the same procedure as the LH

side.
4.2.4.13 Install the link assembly of the front

transversal stabilizer bar LH.
332
4.2.4.14 Install the link assembly of the front (a) Connect the clips on the frame of the
transversal stabilizer bar RH. lower boot assembly to the body front
panel.
4.2.4.15 Install the reinforcement of the front
suspension cross bearer LH. 4.2.4.23 Connect the joint assembly and lower
steering shaft.
4.2.4.16. Install the reinforcement of the front
suspension cross bearer RH. 4.2.4.24 Install the joint upper boot.
4.2.4 17 Install the lower reinforcement of the 4.2.4.25 Install the front wheels.
engine front suspension bracket.
4.2.4.18 Install the under cover of the engine
rear LH. 4.2.4.26. Adjust the four-wheel alignment.
4.2.4.19 Install the rear under cover of the Tips:

engine RH. After four-wheel alignment, tighten the lock nut
of the link.
4.2.4.20 Install the engine under cover No.1. Pre-tensioning torque: 74 Nm
4.2.4.21 Install the engine under cover No.2.
4.2.4.22 Connect the lower boot assembly of

the joint
333
Section 5 Self Diagnosis and Troubleshooting of the EPS System

5.1 Troubleshooting Method of the Diagnostic Tester
When the EPS system is malfunctioning, read the trouble code (ED400) using a special hand-held
tester. Read the type of malfunction based on the tester.
a Connect the tester to the data link connector (DLC3) as shown in the figure below.
Table 5-1
A1 - Body B Motor (-) Power supply ON 0-12 V
A2 - Body R Motor (+) Power supply ON 0-12 V
Fig. 5-1
b Read the diagnostic trouble code (DTC) according to the display on the tester
The troubleshooting methods are as follows:
5.1.1 Troubleshooting Method of Trouble Code
Table 5-2 Troubleshooting Method of Each Trouble Code

Malfunc
DTC Malfunction
tion Troubleshooting Procedures
NO. Analysis
Type
1. Check the connector for looseness or
disconnection. Yes: Retighten; No: 2
Assist power
2. Check for an open or short circuit in the wire
Assist supply abnormal,
harness. Yes: Repair the wire harness; No: 3
Current assist motor
3. Check if the assist power supply is abnormal.
C1B00 Output malfunction, wire
Yes: Repair the circuit; No: 4
Malfunc harness open or
4. Check the assist motor for malfunctions. Yes:
tion short, EPS ECU
Replace the assist motor. No: 5
internal error
5. There is a malfunction in EPS ECU, and
replace it.
Power Assist power 1. Check the connector and EPS ECU for
C1B01 Supply supply abnormal, looseness or disconnection. Yes: Retighten;
Voltage wire harness open No: 2
334
Malfunc or short, EPS ECU 2. Check whether the wire harness between EPS
tion internal error and battery is open. Yes: Repair the wire
harness; No: 3
3. Check whether the assist power supply is
abnormal or whether the battery voltage is too
low. Yes: Repair the power supply or replace a
new battery; No: 4
4. There is a malfunction in EPS ECU, replace it.
EPS ECU internal 1. Check the connector for looseness or
EPS error, system disconnection. Yes: Retighten; No: 2
ECU power supply 2. Check for an open or short circuit in the wire
C1B02
Malfunc abnormal, wire harness. Yes: Repair the wire harness; No: 3
tion harness open or 3. There is a malfunction in EPS ECU, replace it.
short
Assist motor 2. Check for an open or short circuit in the wire
malfunction, assist harness. Yes: Repair the wire harness; No: 3
Motor power supply 3. Check whether the assist power supply is
C1B03 Malfunc abnormal, wire abnormal or whether the battery voltage is too
tion harness open or low. Yes: Repair the circuit or replace with a
short, EPS ECU new battery; No: 4
internal error 4. Check the assist motor for malfunctions. Yes:
Replace the assist motor; No: 5
Torque sensor disconnection. Yes: Retighten; No: 2
malfunction, 2. Check for an open or short circuit in the wire
Torque mechanical harness. Yes: Repair the wire harness; No: 3
Sensor assembly stuck or 3. Check whether the mechanical assembly is
C1B04
Malfunc loose, wire stuck or loose. Yes: Repair the malfunction;
tion harness open or No: 4
short, EPS ECU 4. Check the torque sensor for malfunctions.
internal error Yes: Replace the torque sensor; No: 5
1. Whether or not the steering wheel is turned for
Turning the
a long time in place. Yes: Stop turning, and
System steering wheel for wait until the EPS ECU cools down; No: 2
Temper a long time, EPS
2. Check for a short circuit in the wire harness.
C1B05 ature ECU internal
Yes: Repair the wire harness; No: 3
Too error , assist motor
3. Check the assist motor for malfunctions. Yes:
High or wire harness
Replace the motor; No: 4
short
Vehicle disconnection. Yes: Retighten; No: 2
Speed CAN line open or 2. Check for an open or short circuit in the wire
C1B06 Sensor short, EPS ECU harness. Yes: Repair the wire harness; No: 3
Malfunc internal error 3. Check ABS for malfunctions. Yes: Check ABS
tion system; No: 4
Engine Engine speed 1. Check the connector for looseness or
C1B08
Speed sensor, wire disconnection. Yes: Retighten; No: 2
335
Sensor harness open or 2. Check for an open or short circuit in the wire
short, EPS ECU harness. Yes: Repair the wire harness; No: 3
internal error 3. Check the engine speed sensor for
malfunctions. Yes: Replace the sensor; No: 4
4. There is a malfunction in EPS sensor, replace
the EPS ECU.
Torque
No factory 2. Check for an open or short circuit in the wire
Sensor
calibration for the harness. Yes: Repair the wire harness; No: 3
C1B09 Calibrati
torque sensor is 3. Check the torque sensor for malfunctions.
on
performed Yes: Replace the torque sensor; No: 4
Undone
4. There is a malfunction in EPS sensor, replace
the EPS ECU.
Rotatio No calibration is
2. Whether the calibration can be performed with
n Angle performed for the
a diagnostic tester. Yes: calibrate the zero
Signal zero point of the
C1B0A point of the rotation angle; No: 3
Calibrati rotation angle
3. The calibration failed several times. Yes:
on signal when the
Replace the steering column; No: 4
Undone vehicle is offline
4. There is a malfunction in EPS controller,
replace the EPS ECU.
Malfunc 1. Check for an open or short circuit in the wire
Wire harness open
tion in harness. Yes: Repair the wire harness; No: 2
U0134 or short, EPS ECU
Module 2. There is a malfunction in EPS sensor, replace
internal error
Itself the EPS ECU.
5.1.2 Inspection for Power Supply Voltage Malfunction
Circuit Diagram
336
Repair Circuit
EPS Motor
EPS
Module
EPS ECU
Fig. 5-2
Inspection for Power Supply Voltage Malfunction

Steps Diagnostic Operation Standard Value Yes No
Check whether the connector B11
Go to next
1 and EPS ECU are connected normal or not Go to step 3
step
normally
completed or
2 Secure the connector Go to step 8
not
Check whether the voltage of B11-1
Go to next
3 in EPS ECU is 10-14 V, and whether normal or not Go to step 7
step
B11-2 is well grounded.
Check whether there is continuity in
fuse F5/5 and whether the resistance continuity or not Go to next
4 Go to step 6
between B11-2 and B12 is less than step
1Ω
completed or
5 Replace the fuse or wire harness Go to step 8
not
Check whether there are other short Repair the Repair the
6 or open circuits in relevant wire normal or not power supply wire
harnesses system harness
337
completed or
7 Replace EPS ECU Go to next step
not
trouble code
Clear the diagnostic trouble code System is
8 still present or Go to step 7
with a diagnostic tester OK
not
5.1.3 EPS ECU Malfunction
Circuit Diagram
Fig. 5-3
Inspection of EPS ECU Malfunction

Check whether the connector G59
Go to next
step
normally
2 Secure the connector completed or not Go to step 8
338
Check whether the voltages of

G59-5 and G59-11 in EPS ECU Go to next
3 normal or not Go to step 7
are 10-14 V, and whether B11-2 is step
well grounded.
Check whether there is continuity
in fuse F2/27 and whether the Go to next
4 continuity or not Go to step 6
resistance between B11-2 and step
B12 is less than 1 Ω
5 Replace the fuse or wire harness completed or not Go to step 8
Repair the
Check whether there are other Repair the
power
6 short or open circuits in relevant normal or not wire
supply
wire harnesses harness
system
Go to next
7 Replace EPS ECU completed or not
step
Clear the diagnostic trouble code trouble code still System is
8 Go to step 7
with a diagnostic tester present or not OK
5.1.4 Current Malfunction
Inspection of Current Malfunction

Check whether the connector B11
Go to next
step
normally
Go to step
2 Secure the connector completed or not
11
Check whether the voltage of
Go to next
3 B11-1 in EPS ECU is 10-14 V, and normal or not Go to step 7
step
whether B11-2 is well grounded.
Go to step
5 Replace the fuse or wire harness completed or not
11
Repair the
power
supply
system
Check the assist motor for Go to next
malfunctions step
Go to step
8 Replace the assist motor completed or not
10
Go to next
step
Does the trouble
Clear the diagnostic trouble code System is
10 code still occur or Go to step 1
with a diagnostic tester OK
not
339
5.1.5 Inspection of Torque Sensor Malfunction
Circuit Diagram
Halla Torque Angle Sensor
EPS ECU
Fig. 5-4
Inspection for Torque Sensor Malfunction
1 Check whether the connector and normal or not Go to step 3 Go to next
EPS ECU are connected normally step
2 Secure the connector completed or not Go to step 9
3 Check for an open or short circuit normal or not Go to step 5 Go to next
in the torque sensor wire harness step
4 Repair the wire harness completed or not Go to step 9
malfunction
5 Check whether the mechanical normal or not Go to step 7 Go to next
assembly is stuck or loose step
6 Replace the steering column completed or not Go to step 9
7 Check whether the torque sensor normal or not Go to step 6 Go to next
signal is normal with all the EPS step
ECU connectors connected
8 There is a malfunction in EPS completed or not Go to step 9
ECU, replace it
9 Clear the diagnostic trouble code trouble code still Go to step 1 System is
with a diagnostic tester occurs or not OK
340
5.1.6 Inspection of Motor Malfunction
Circuit diagram
Fig. 5-5
Inspection for Motor Malfunction

Check whether the connector and Go to next
EPS ECU are connected normally step
Go to step
2 Secure the connector completed or not
11
Check whether the voltage of
Go to next
3 B11-1 in EPS ECU is 10-14 V, and normal or not Go to step 7
step
whether B11-2 is well grounded.
Go to step
5 Replace the fuse or wire harness completed or not
11
Check whether there are other Repair the Repair the
6 normal or not
short or open circuits in relevant power wire
341
wire harnesses supply harness

system
Check the assist motor for Go to next
malfunctions step
Go to step
8 Replace the assist motor completed or not
10
Go to next
step
Clear the diagnostic trouble code trouble code still System is
10 Go to step 1
with a diagnostic tester occurs or not OK
Repair the
power
supply
system
5.1.7 Inspection of Other Signal Wire
Circuit Diagram
Fig. 5-6
Inspection of Other Signal Wire

1 System self-diagnosis completed or not Go to next Go to step 4
342
procedure step
2 1. Battery load test whether the Go to next Go to step 5
2. Charging system load test voltage is 10-14 V step
3 1. Turn off the power switch. normal or not Go to step 6 Go to step 4
2. Disconnect the wire
connectors in the EPS ECU
3. Check the connection
between connector B11-2 of
EPS ECU and body
4 Check the self-test circuit completed or not Go to step 1 Repair
5 Repair the battery or normal or not Go to step
charging system 10
6 Inspection of vehicle speed normal or not Go to next Go to step 9
input signal wire harness, step
measure the resistance
1. Is the resistance of
connector terminal
G59-2-A01-37 always less
than 1Ω
7 Inspection of malfunction normal or not Go to next Go to step 9
warning signal wire harness, step
measure if the resistances of
connector terminals
G2X-17-G59-2 and
A01-76-G59-8 are always
less than 1Ω
8 Inspection of wire harness of normal or not Go to step Go to step 9
CAN line 10
Remove the connector G59,
and measure the voltages of
wire harness terminals
G59-6 and G59-12
1. whether the voltage
between G59-6 and body
ground is always 2.5-3.5 V
2. whether the voltage
between G59-12 and body
ground is always 1.5-2.5 V
9 Replace the wire harness normal or not Go to next
step
10 Clear the diagnostic trouble trouble code still Go to step 1 System is
code with a diagnostic tester occurs or not OK
343
Section 6 Self-Diagnosis and Troubleshooting of the EPS System

6.1 Calibration of the EPS Torque and Steering Angle Signal Neutral Point
The EPS sensor is an integrated Hall sensor refer to the calibration process of the
for torque signal and steering angle signal. To steering angle signal in figure 2.
avoid abnormal EPS power assist due to
torque signal and steering angle signal 6.1.2.3 Clear the trouble codes. Due to the
calibration undone, the standard process of steering angle signal calibration undone,
the signal calibration is provided. EPS ECU will record this malfunction.
Therefore, the trouble codes recorded by
6.1.1 When a signal calibration is needed: the ECU should be cleared after steering
angle calibration. Clear remaining trouble
a) After four-wheel alignment with the codes after the vehicle is finally assembled
vehicle finally assembled and offline, the and offline. And it is very important for the
torque and steering angle signal further maintenance and troubleshooting
calibrations are needed; of the vehicle.
b) After replacement of power assist steering
column, the torque and steering angle
signal calibrations are needed;
c) After replacement of EPS ECU or update
of its software programs, the torque and
steering angle signal calibrations are
needed;
d) After removal or replacement of steering
wheel, joint and steering gear, the
steering angle signal calibration is
needed.
6.1.2 Calibration process

After four-wheel alignment for the vehicle,
calibrate the EPS torque signal and
steering angle signal in the following
steps.
6.1.2.1 Calibrate the torque signal.

Inconsistent side-to-side steering assist of
EPS caused by torque signal not centered
during assembly of steering column can be
avoided. During calibrating, make sure that
the steering wheel is free from external
force so that there is no residual torque for
sensor. For details, refer to the calibration
process of the torque signal in figure 1.
6.1.2.2 Calibrate the steering angle signal.

There is no mechanical zero position in the
steering angle signal of the Hall sensor.
Therefore, with the vehicle offline, a tester
is required to inform the EPS ECU to
memorize and save the neutral point of the
steering, so that this initial position value
can be recalled for future use when the
system is powered up again. For details,
344
Fig. 1 Calibration process for torque signal:
The steering wheel is free from

external force (very important)
Enter the screen of model 5A

using a tester (with power supply
ON)
□ 1.……
□ 2.……
……
■ 6. BYD EPS
□ 7.……
Select diagnostic screen
of BYD EPS
□ 1. Read computer version

□ 2. Read system malfunctions
□ 3. Clear the error codes
□ 4. Adjust parameters
□ 5. steering angle signal calibration
■ 6. torque signal calibration
Select
■ 6. Torque signal
calibration Enter the
screen of torque signal
calibration
□ 1. Read the current zero point

■ 2. Set the current torque as
zero point
Select
■ 2. Set the current Perform signal
torque as zero point calibration manually
Operation Tester display:

Yes No
successful Operation error/command error
Press any button to calibration has failed many times

return the previous
screen
Replace the steering column/Replace the EPS controller/Check if
the CAN network of the complete vehicle operates normally
345
Fig.2 Calibration process for steering angle signal

After four-wheel alignment for the vehicle, the
steering wheel and tires should be in the
neutral position, and the steering wheel free
from external force (very important)
Enter the screen of model 5A

using a tester (with power supply
ON)
□ 1.……
□ 2.……
……
■ 6. BYD EPS
□ 7.……
of BYD EPS

□ 3. Clear the error codes
■ 5. Steering angle signal calibration
□ 6. Torque signal calibration
Select
■ 5. Steering angle signal
calibration Enter the
screen of steering angle
signal calibration
□ 1. Read the zero point of
steering angle
■ 2. Set the current steering
angle as zero point
Select
■ 2. Set the current steering angle as zero point
Perform the calibration of the steering angle
neutral point
Perform signal
calibration manually
Tester display: Operation

successful Successful
Tester display:
Yes operation information No
Operation error/command error
Press any button to return the on the display
previous screen
Calibration has failed many times
Replace the steering column/Replace the EPS controller Check if

the CAN network of the complete vehicle operates normally
346
Fig. 3 Process of error code clearing
□ 1.……
□ 2.……
……
■ 6. BYD EPS
□ 7.……
of BYD EPS

■ 3. Clear the error codes
□ 5. Steering angle signal calibration
□ 6. Torque signal calibration
Select
■ 3. Clear the error
codes
Tester display:
Clear the error codes
Press any button to
return the previous
screen
Select
■ 2. Read system
malfunctions
Tester display:
System is OK
Clear the error

codes successfully
347
Chapter 8 ESP System

Contents
Section 1 Precautions ............................................................................................................350
1.1 Precautions for Repair and Diagnosis ..................................................................... 350
Section 2 Malfunction Diagnosis Flow ...................................................................................352
Section 3 Customer Malfunction Analysis Table ....................................................................353
3.1 Customer Malfunction Analysis Table ..................................................................... 353
Section 4 Diagnostic Check ...................................................................................................354
4.1 Preliminary Check .................................................................................................... 354
Section 5 ESP 9 System Introduction ....................................................................................356
5.1 ESP System Components ....................................................................................... 356
5.2 ESP 9 Hydraulic Scheme ........................................................................................ 357
5.3 ESP 9 ECU Interface Circuit.................................................................................... 358
Section 6 Malfunction Diagnosis ............................................................................................360
6.1 Non-DTC Malfunction Repair .................................................................................. 360
6.2 Occasional Malfunction Repair ................................................................................ 361
Section 7 Trouble Code Table ................................................................................................362
Section 8 Trouble Symptom ...................................................................................................364
8.1 Trouble Symptom Table .......................................................................................... 364
8.2 Intermittent Trouble Symptom Table ....................................................................... 365
Section 9 Trouble Code Diagnosis ........................................................................................367
9.1 Power Supply Voltage High and Low ...................................................................... 367
9.2 Solenoid Valve and Valve Bank Relay Malfunction ................................................ 367
9.3 Solenoid Valve and Valve Bank Relay Malfunction ................................................ 368
9.4 Wheel Speed Sensor Circuit Malfunction ................................................................ 369
9.5 Wheel Speed Sensor Signal Malfunction ................................................................ 369
9.6 ECU Malfunction ...................................................................................................... 370
9.7 CAN Bus Malfunction............................................................................................... 371
9.8 Pressure Sensor Malfunction .................................................................................. 372
9.9 Steering Angle Sensor Malfunction ......................................................................... 372
9.10 Yaw Rate Sensor (Integrated Sensor) Malfunction ............................................... 373
9.11 ECM Malfunction ................................................................................................... 374
9.12 Gateway Malfunction ............................................................................................. 374
9.13 EPB Malfunction .................................................................................................... 375
9.14 ESP PATA Switch Malfunction .............................................................................. 375
9.15 ESP Configuration Information Malfunction .......................................................... 376
9.16 Braking Light Switch (BLS) Malfunction ................................................................ 376
9.17 Abnormal ESP Operation ...................................................................................... 376
9.18 Abnormal Clutch Signal ......................................................................................... 377
9.19 Abnormal Reverse Gear Signal ............................................................................. 378
Section 10 Removal and Installation .....................................................................................379
348
10.1 Removal Procedure for ESP Assembly................................................................. 379

10.2 Installation Procedures for ESP Assembly ............................................................ 379
10.3 Bleeding Instruction ............................................................................................... 379
10.4 Instructions for Integrated Sensor Calibration (ESP9i System) ............................ 379
Section 11 Service Specifications ..........................................................................................381
11.1 General Specifications ........................................................................................... 381
11.2 Torque (Unit: N·M) ................................................................................................. 381
349
Section 1 Precautions
1.1 Precautions for Repair and Diagnosis
ESP is a component related to driving safety. When conducting repair and diagnosis on it, observe
the following diagnosis precautions in addition to general safety and preventive measures.
(a) ESP system should only be repaired by (c) The ESP assembly (ESP electronic
technicians who have received professional control unit and hydraulic regulator
training and mastered repair skill. Its parts assembly, excluding brake lines and
should only be replaced with original parts sensors, etc.) can only be replaced as a
of the manufacturer. whole and cannot be disassembled or
replaced partly. Bosch does not provide
individual spare parts or warranty the
disassembled ESP assembly. It is not
responsible for any consequence
caused by disassembly or partial
replacement of ESP hydraulic regulator.
(d) The ESP system fault is detected when

any of the following conditions occurs.
1.1.1 The warning lamp remains on after

turning on the vehicle.
1.1.2 The warning lamp remains on when

driving.
(b) Before diagnosing the ESP system,
perform troubleshooting on the brake In these cases, the driver can conduct
system malfunctions, such as: regular braking and need to reduce
· Brake system noise. braking force as much as possible to
· Brake pedal feels hard. avoid wheel locking. Therefore, drive
· The brake pedal or vehicle vibrates carefully when the warning lamp turns
during regular braking. on. Repair the ESP system at an
· The vehicle pulls to one side when authorized service station to avoid
braking. severe fault which might lead to an
· Parking brake system malfunction. accident.
(e) Note the following when connecting the

ESP and sensor wires: Before removing
the ESP and sensor wires, the vehicle
must be powered off.
Make sure the connectors are dry and

clean and prevent any foreign materials
from entering.
The ESP wire harness connector must

be installed in place horizontally and
vertically to prevent damage.
350
(g) ESP noise will be generated in the

following conditions:
 After the vehicle is powered on or

the engine is started, a short "buzz"
sound will be heard. But this is a
normal phenomenon which
indicates ESP is performing a
self-check. Moreover, a short "buzz"
sound will also be heard when
accelerating the vehicle to about 15
km/h. But this is a normal
phenomenon which indicates ABS is
performing a dynamic self-check.
 When the ESP operate normally, the

following sounds may occur:
1.1.2.1 The operating sound from the

motor, solenoid valve and return
pump in ESP hydraulic unit.
1.1.2.2 The sound caused by brake

(e) Ensure the ESP brake lines are pedal rebound.
correctly installed. ESP ECU cannot
judge whether the brake line is 1.1.2.3 The sound caused by the
correctly connected, and it will not suspension and body clashing due
perform fail safe. Incorrect connection to emergent braking.
may lead to severe accident.
The marker on the ESP hydraulic

controller may vary depending on its
place of origin:
MC1: connected to brake line 1 of brake

master cylinder;
MC2: connected to brake line 2 of brake

master cylinder;
FL: connected to brake line of left front

brake wheel cylinder;
FR: connected to brake line of right front

RL: connected to brake line of left rear

RR: connected to the brake line of the

right rear brake wheel cylinder.
351
Section 2 Malfunction Diagnosis Flow

Malfunction Diagnosis Flow
2.1 Vehicle brought to workshop
2.2 Customer Problem Analysis
2.3 Read the trouble codes

Go to step 4
DTC is output
DTC is not output Go to step 6
2.4 Record DTC, and then clear malfunction memory.
2.5 Confirm and reproduce the malfunction: When the vehicle is restarted, accelerate it to
15 kHz and then read the DTCs.
DTC is output Current DTC.

Go to step 7
DTC is not output History DTC. Go
to step 8
2.6 Repair the non DTC malfunction, and then go to step 9.
2.7 Perform troubleshooting in accordance with trouble code table, and then go to step 9.
2.8 Repair the occasional malfunction, and then go to step 9.
2.9 Confirm the malfunction has been eliminated.
2.10 Prevent the malfunction End

reoccurring.
352
Section 3 Customer Malfunction Analysis Table

3.1 Customer Malfunction Analysis Table
ESP Inspection Table
Quality Inspector
License Plate
Owner Number
Name
Model
Contact
Chassis No.
Number
Date of
/ / Odometer km
Entry
Date of
/ /
Occurrence
Malfunction
Condition Frequency
of  Often □Sometimes ( times/day)
Occurrence
 ESP does not work well  ESP does not work
 EBD does not work well  EBD does not work

Symptom
ESP warning lamp is
 Remains on □Off
abnormal
EBD warning lamp is
 Remains on □Off
abnormal
 Normal Code  Current DTC (Code: )

First Time
 History DTC (Code: )
Troubleshooting
Second  Normal Code  Current DTC (Code: )

Time  History DTC (Code: )
353
Section 4 Diagnostic Check

4.1 Preliminary Check
Before diagnosing the ESP system, first check the accessible components that may cause ESP
system malfunction. Visual inspection and appearance inspection procedures can confirm the
malfunction quickly with no need for further diagnosis.
(a) Be sure to install tires and wheels of

recommended size on the vehicle. The
tread pattern and depth of coaxial tires
must be same.
Original standard tire: 205/65 R15 94V
Original optional tire: 205/60 R16 92V

Ignition Coil /Distributor/ Sparkplug
(b) Check the hydraulic regulator, brake

lines and connectors for leakage.
(c) Check the ESP system fuses to ensure

they are not blown and their type is
Fuse
correct. ESP system has three fuses as
follows:
· Pump motor fuse (40 A)
Fusible · Solenoid valve fuse (25 A)
Link · Electronic control unit fuse (5 A)
(d) Make sure the battery is fully charged

and check the battery voltage.
(e) Check if the battery connection is
corroded or if the post is loose.
The normal operation voltage range of ESP
system is 9.3 V-16.8 V.
(f) Check if the ground point of ESP ground

wire is loose and if the ground position is
changed.
354
(g) The ESP ground wire must be well

sealed to prevent water or moisture from
penetrating the ESP ECU connector
through the holes in the wire harness
under capillary (siphon) effect, thus
causing functional failure.
Measures: apply sealant on the exposed end

of wire harness and use shrinkable tube
sleeve
(h) Perform visual inspection and
Apply sealant on the exposed end of wire harness appearance inspection on the following
and use shrinkable tube sleeve.
electric elements:
1 Whether the wire harness and pin of
ESP component are correctly
Ignition Coil /Distributor/ Spzarkplug connected, pinched or cut.
2 Whether the wire harness route is too
close to high-voltage or high-current
Gear Ring
equipment, such as:
Generator High-voltage ignition component
Motor and generator
After sales stereo amplifier
Wheel Speed Sensor Important Notes: High-voltage or
high-current equipment may cause the
circuit to generate induced noise, thus
interfering with normal operation of the
circuit.
Electro Magnetic Interference
3 Whether the connectors of ESP system
related components are not well
connected, or the pins are not fully
inserted into the connector housing.
4 ESP components are sensitive to Electro
Magnetic Interference (EMI). If there is
any doubt about the intermittent
malfunction, check if the after sales
anti-theft device, lights or cell phone are
incorrectly installed.
Electro Magnetic Interference
(g) ESP is an active safety system. It is
mainly used to maintain vehicle
maneuverability and driving stability by
maximum use of road adhesive force.
Hydroplaning However, when the vehicle speed exceeds
Hydroplaning
the physical limit or driving at high speed on
slippery road, ESP can not prevent the creep
movement.
Cannot be blocked
(h) The loud ESP noise may be caused by

the followings:
· The fasteners between ESP assembly
and bracket are loose.
· The fasteners between ESP bracket and
body are loose.
· The plastic washers on ESP bracket are
missing or damaged.
355
Section 5 ESP 9 System Introduction

5.1 ESP System Components
ESP 9 consists of hydraulic module with electronic control unit and various sensors as shown
below.
1 ESP hydraulic regulator module with

electronic control unit ESP assists steering via braking: ECU
calculates the desired control parameters
2 Wheel speed sensor for keeping stability and the hydraulic
module applies the brake of each wheel
3 Steering angle sensor separately and quickly as desired. In
addition, ESP can also reduce the torque
4 Yaw rate sensor (The model uses ESP9i output of engine via communication with
system and the yaw rate sensor is the engine management system.
integrated in the ESP module)
Steering angle sensor:
5 Communication with the engine
management system 5.1.1 The steering angle sensor can be used
separately or integrated in ESP system;
ESP monitors the driver intent: The driver
intent can be identified via the steering 5.1.2 Function: Measure the steering angle
wheel position, wheel speed, accelerator and output standard CAN signals.
pedal position and brake pressure.
Notice: The steering angle sensor should
ESP identifies the vehicle status: ECU be calibrated after installed on the vehicle
calculates and identifies the vehicle status to confirm the central position of steering
via yaw velocity and lateral force wheel.
(acceleration).
356
5.2 ESP 9 Hydraulic Scheme
The brake system uses X type layout as shown below. ESP 9 hydraulic regulator consists of a
motor, 2 return pumps, 2 accumulators, a pressure sensor and 12 solenoid valves.
The meanings of abbreviations in the illustration are as follows:
MC1 Brake master cylinder first FLAV Left front wheel oil outlet
circuit valve
MC2 Brake master cylinder FREV Right front wheel oil inlet
second circuit valve
M Motor FRAV Right front wheel oil outlet
valve
RP1 Return pump 1 RLEV Left rear wheel oil inlet
valve
RP2 Return pump 2 RLAV Left rear wheel oil outlet
valve
A1 Accumulator 1 RREV Right rear wheel oil inlet
valve
A2 Accumulator 2 RRAV Right rear wheel oil outlet
valve
FL Left front wheel HSV1 High pressure valve
FR Right front wheel HSV2 High pressure valve
RL Left rear wheel USV1 Guide valve
RR Right rear wheel USV2 Guide valve
FLEV Left front wheel oil inlet P/U Pressure sensor
valve
357
5.3 ESP 9 ECU Interface Circuit
5.3.1 ESP 9 ECU Circuit Diagram
5.3.2 ESP 9 ECU Pin Definition
Pin Function Pin Function

1 Power terminal (Positive) of motor 20 Not defined
2 Wheel speed sensor output (Right 21 Not defined
front)
3 EBD warning lamp (reserved) 22 Not defined
4 Signal terminal of wheel speed 23 Not defined
sensor (Right front)
5 Wheel speed sensor output (Right 24 ESP OFF indicator light
front) (reserved)
6 Diagnosis K wire (reserved) 25 Power terminal of valve relay
7 Not defined 26 CAN_H
8 Signal terminal of wheel speed 27 ABS warning lamp (reserved)
sensor (Left front)
9 Gear position signal (reserved) 28 Power terminal of ECU (ignition
power cable)
10 Vehicle speed output (reserved) 29 Signal terminal of wheel speed
sensor (Right rear)
11 Not defined 30 Braking light switch
12 ESP OFF switch 31 Power terminal of wheel speed
sensor (Left rear)
13 Ground terminal of motor 32 Not defined
14 CAN_L 33 ESP warning lamp (reserved)
15 Clutch signal (reserved) 34 Not defined
16 Power terminal of wheel speed 35 Not defined
358
sensor (Right front)

17 Power terminal of wheel speed 36 Not defined
sensor (Right rear)
18 Signal terminal of wheel speed 37 Not defined
sensor (Left rear)
19 Signal terminal of wheel speed 38 Ground terminal of ECU
sensor (Left front)
5.3.3 SP OFF Switch Pin Definition
Pin Function
1 Backlight positive
2 Signal input
3 Ground
4 Backlight negative
The switch can be used to turn on and off

the vehicle stability system.
When ESP OFF is pressed, the ESP

system indicator light in the meter turns on,
indicating the ESP system is on;
When ESP OFF is pressed again, the ESP

system indicator light in the meter turns off,
indicating the ESP system is off.
359
Section 6 Malfunction Diagnosis

6.1 Non-DTC Malfunction Repair
If the brake system malfunctions, but ESP 6.1.6 Booster malfunction (May cause the
does not store any DTC, the malfunction is hard or spongy feeling of brake pedal,
called non-DTC malfunction. Non-DTC long brake pedal travel, or even loss of
malfunction is usually caused by basic brake effectiveness)
brake system malfunctions, such as:
The brake line is connected incorrectly
6.1.1 Brake fluid leakage (May cause the (May cause ESP performance to reduce,
spongy feeling of brake pedal, long tailing and long braking distance). For
brake pedal travel, or even loss of correct installation method, refer to the
brake effectiveness) label near oil hole on the ESP hydraulic
regulator module: (MC1 represents No. 1
6.1.2 Brake fluid of poor quality is used Master Cylinder Pipeline; MC2 represents
(The brake fluid of poor quality may No. 2 Master Cylinder Pipeline; FL
cause the brake line and internal represents Left Front Wheel Cylinder
components of ESP hydraulic Pipeline; FR represents Right Front Wheel
regulator module to corrode, or even Cylinder Pipeline; RL represents Left Rear
loss of brake effectiveness) Wheel Cylinder Pipeline; RR represents
Right Rear Wheel Cylinder Pipeline)
6.1.3 Air in the brake line (May cause the
spongy feeling of brake pedal, or even Notice: When no power is supplied to ESP
loss of brake effectiveness) or the power supply is interrupted, ABS
and ESP warning lamps will remain on, but
6.1.4 The brake line is blocked (May cause no DTC is output.
hard feeling of brake pedal, or even
loss of brake effectiveness) Troubleshooting suggestion: Check the
applicable components related to the
6.1.5 Excessive wear of brake disk (May malfunction, and perform troubleshooting
cause the spongy feeling of brake according to the vehicle repair manual.
pedal and long brake pedal travel)
360
6.2 Occasional Malfunction Repair
In the electrical system, poor contact may occur temporarily in the electrical circuit or the
position where signals are input and output, thus causing occasional malfunction. Sometimes,
the failure cause may disappear automatically so that it is hard to find the problem. When the
occasional malfunction occurs, simulate the malfunction as follows to check if it reoccurs.
No. Possible Cause Malfunction Simulation Note

1 When the main cause Shake the ESP ECU connector The wire harness must be
is vibration lightly up and down, left and replaced with a new one if
right it is twisted or broken due
Shake the ESP wire harness to hard pulling.
lightly up and down, left and When the vehicle moves,
right open/short circuit may
Shake the sensor lightly up and occur temporarily in the
down, left and right wire harness of wheel
Shake other moving speed sensor with the up
components (such as wheel and down movement of
bearing) lightly suspension system.
Therefore, the wire
harness of sensor must be
checked while driving.
2 When the main cause Heat the possible fault parts
is temperature with a blower
Check for cold welding with
cold spray
3 When the main cause All the electrical switches are
is excessive electrical turned on to make vehicle
load power operate at high load,
including headlamp and
windshield wiper
If the malfunction does not occur at this time, the diagnosis and repair must be performed
next time when it reoccurs. Generally, the occasional malfunction may become
reproducible malfunction which will not disappear automatically.
361

Notice: If a DTC is memorized, check the circuit
indicated by the DTC. Refer to the applicable
The vehicle must be turned off before chapter for the specific repair procedure of
removing parts. each DTC.
Description: When two or more DTCs are memorized, first

check the DTC and circuit related to the
Read DTCs with the diagnostic tester. malfunction.
If no malfunction is detected during elements

inspection, check the ESP hydraulic regulator
with ECU and its earth point/power cables.
DTC Detection Item Possible Fault Area Page
Left front wheel speed sensor

Left front wheel speed
C003108 Left front wheel speed sensor circuit
sensor signal malfunction
Left front wheel speed sensor gear ring
Left front wheel speed sensor
Left front wheel speed
C003204 Left front wheel speed sensor circuit
sensor circuit malfunction
Left front wheel speed sensor gear ring
C003408 Right front wheel speed sensor circuit
Right front wheel speed sensor gear ring
C003504 Right front wheel speed sensor circuit
Left rear wheel speed sensor
C003708 Left rear wheel speed sensor circuit
Left rear wheel speed sensor gear ring
Left rear wheel speed sensor
C003804 Left rear wheel speed sensor circuit
Left rear wheel speed sensor gear ring
C003A08 Right front wheel speed sensor circuit
C003B04 Right front wheel speed sensor circuit
Left front oil inlet valve of
C001004 hydraulic regulator ESP hydraulic regulator with ECU
malfunction
Left front oil outlet valve of
malfunction
Right front oil inlet valve of
malfunction
Right front oil outlet valve of
malfunction
362
Left rear oil inlet valve of

malfunction
Left rear oil outlet valve of
malfunction
Right rear oil inlet valve of
C001C04 hydraulic regulator ESP hydraulic regulator with ECU
malfunction
Right rear oil outlet valve of
C001D04 hydraulic regulator ESP hydraulic regulator with ECU
malfunction
Motor malfunction: Unable ESP hydraulic regulator with ECU
C002004 to rotate or unable to stop ESP hydraulic regulator with ECU
rotating ground/power
ESP hydraulic regulator with ECU
Solenoid valve relay circuit
malfunction
ground/power
Wheel speed sensor
Wheel speed sensor
C024501 Wheel speed sensor circuit
malfunction
Wheel speed sensor gear ring
Battery
ESP hydraulic regulator with ECU power
C055000 ESP ECU malfunction
and ground
Battery
C080001 Under-voltage malfunction
and ground
Battery
C080002 Over-voltage malfunction
and ground
Circuit control valve 1
malfunction
Circuit control valve 2
malfunction
High pressure switching
valve 1 malfunction
High pressure switching
valve 2 malfunction
C100104 CAN hardware malfunction ESP ECU
U100004 CAN bus off Gateway Controller
Common valve malfunction
(Overheat protection)
C004601 Pressure sensor malfunction ESP hydraulic regulator with ECU
SAS (Steering Angle
U012604 Sensor) CAN Steering angle sensor circuit
communication timeout
U012608 SAS CAN data damaged
C046008 SAS signal malfunction
C106600 Steering angle sensor Steering angle sensor circuit
363
calibrated incorrectly or not Steering angle sensor

calibrated
Lateral acceleration sensor
signal malfunction
Longitudinal acceleration
Yaw rate position sensor
signal malfunction
Integrated inertia sensor
malfunction (Hardware,
temperature, range, internal
malfunction)
Integrated inertia sensor not
C00A800 calibrated or calibrated ESP hydraulic regulator with ECU
incorrectly
ECM communication ECM module and circuit
U010004
timeout ESP ECU and circuit
U010008 ECM CAN data damaged ECM module
Gateway communication
U014004 Gateway controller circuit
timeout
U014008 Gateway data damaged Gateway Controller
C004C04 ESP switch malfunction Switch and switch circuit
C121208 Variable code malfunction ESP hydraulic regulator with ECU
Brake pedal switch signal Brake pedal switch circuit, brake pedal
C004008
malfunction switch
Brake system malfunction Meter
C008208
indicator ESP ECU circuit
Clutch signal malfunction
C108008 Clutch switch and circuit
(HHC)
Reverse gear switch signal
C108C08 Reverse gear switch and circuit
malfunction (HHC)
U100100 DCT module and circuit
gear controller (DCT)
U010104 TCU module and circuit
TCU
Received TCU data
U010108 TCU module and circuit
incorrect
EPB CAN communication
U100304 EPB module and circuit
timeout
U100308 Abnormal data from EPB EPB module and circuit
C040008 EPB signal incorrect EPB module and circuit
Section 8 Trouble Symptom

8.1 Trouble Symptom Table
If a malfunction occurs even if no malfunction is memorized when reading DTC, check the circuit
for each trouble symptom based on the order and reference page listed in the table below.
Notice:
8.1.1 Before checking and repairing ESP, make sure the regular brake system operates normally.
8.1.2 ESP hydraulic regulator with ECU, sensors and others need to be replaced, first turn the
364
vehicle off.
Trouble
Inspection Area Reference Page
Symptom
normal, replace ESP hydraulic regulator with ECU: 10
1. Read trouble codes and confirm malfunction memory
ESP does not
work 2. Start button power UZ (Pin 32) circuit 37
4. Check ESP with diagnostic tester. If abnormal, check
22
if the brake line leaks
normal, replace ESP hydraulic regulator with ECU:
10
1. Read trouble codes and confirm no malfunction is
memorized
ESP does not
3. Check ESP with diagnostic tester. If abnormal, check
work well 6
if the brake line leaks
4. Read "Hydraulic Regulator Filling Status" with
11
diagnostic tester
5. Make sure the mounting bracket is secured correctly
(Driving comfort will reduce)
ESP warning 1. ESP warning lamp circuit 27, 37
lamp is 2. ESP hydraulic regulator with ECU 60
abnormal 3. Battery voltage is low 62
normal, replace ESP hydraulic regulator with ECU: 37
Trouble codes 1. ESP hydraulic regulator with ECU power/ground wire
cannot be read 2. DIAGK (Pin 17) wire of ESP hydraulic regulator with
37
ECU
3. Diagnostic tester
8.2 Intermittent Trouble Symptom Table
Description:
If one of the following conditions occurs, the malfunction is intermittent.
8.2.1 The malfunction does not always occur;

8.2.2 The malfunction cannot be duplicated;
8.2.3 There is no current DTC, but history DTC exists in memory.
Inspection Operation
· Perform "Preliminary Inspection"
· Collect information about intermittent malfunction from the customer, such as:
· The speed range when the malfunction occurs.
· Does the malfunction occur after the after sales electric device is used?
· Does the malfunction occur when driving on rough or slippery roads?
Preliminary
· If the wheel speed sensor malfunctions only when driving on the slippery road,
check whether water enters the wheel speed sensor circuit. If the DTC is not
output, perform the following operations to simulate the slippery road:
1. Mix 2 teaspoons of salt and 35 ml of water.
2. Spray the saline water on the suspected area.
3. Road test the vehicle on various roads.
365
4. Accelerate the vehicle to more than 40 km/h for at least 30 seconds.

5. If a current DTC is set by the suspected wheel speed sensor, refer to the
applicable trouble code table.
Check the intermittent malfunction using diagnostic tester as follows:
· Observe the data flow of detected circuit on diagnostic tester while swinging
the suspected wire harness and connector of ESP components. If the reading
on diagnostic tester fluctuates during the operation, check if the circuit
connection is loose.
Check with
· Road test the vehicle under the conditions in which intermittent malfunctions
diagnostic
occur, and let the assistant observe the suspected specifications on the
tester
diagnostic tester.
· When the malfunction occurs, capture and store the data using the snapshot
mode. The stored data can be played at low speed to assist diagnosis. The
signals can also be detected with an oscilloscope.
· Operate the suspected ESP components using the component test function
of diagnostic tester to test the operation of these components.
The following conditions may cause the warning lamp to illuminate intermittently
without setting the trouble codes.
· Electro Magnetic Interference (EMl) caused by fault components (for example,
relay).
· The after sales electric devices are abnormal or installation position is
incorrect, such as:
Warning
· Mobile phone
lamp
· Light
· Radio equipment
· Audio amplifier
· The warning indicator light circuit is short to ground intermittently.
· ESP hydraulic regulator with ECU or meter ground point is loose.
· The speed is slow.
· Visually check if the wheel speed sensor and magnetic ring is loose,
damaged, and dirty or installed incorrectly. Replace the damaged component,
Wheel remove any foreign materials or fix the loose component.
Speed · Check if the route of front wheel speed sensor wire is correct. Make sure the
Sensor front wheel speed sensor wire is not close to the distributor.
· With help of the assistant, monitor the displayed wheel speed sensor data on
the diagnostic tester while road testing the vehicle. Check if there is wheel
speed sensor displaying abnormal speed range.
· Check if the after sales electric devices are installed correctly. For example:
· Mobile phone
· Light
· Radio equipment
Additional · Audio amplifier
test · Check if there is Electro Magnetic Interference (EMI) caused by fault
components (for example: when the relay or solenoid coil is energized).
· When the relay or solenoid coil is energized, test the air conditioner
compressor clutch and some relays containing clamp diode or resistance.
· When the relay or solenoid coil is energized, check if the generator rectifier
bridge has malfunction which causes air conditioner noise to enter the
electronic control unit circuit.
366
9.1.2 The voltage is lower than 7.7 V or higher

Section 9 Trouble Code Diagnosis than 16.8 V when the power gear is in ON
position.
9.1 Power Supply Voltage High and Low
9.1.3 The voltage is between 7.7 V and 9.2 V
DTC: C080001, C080002 when the vehicle speed is higher than 6
km/h.
Malfunction setting conditions
The malfunction occurs when the ECU power Possible cause
supply voltage satisfies one of the following
conditions: (a) The battery voltage is too high or too low.
9.1.1 The voltage is lower than 4.5 V when the (b) The ECU is damaged.
vehicle is powered on.
Diagnostic steps:
Steps Operation Yes No

1 Is the preliminary check performed Perform Perform
step 2 preliminary
check
2 Measure the voltage of ECU power supply pin in the Perform Perform step 3
connector, and check the connector, wire harness and step 4
ground wire. Is the malfunction detected and repaired?
For pin definition, refer to the circuit diagram.
3 Perform cross validation on ESP. If ECU is damaged, Perform --
replace ESP. Is the malfunction repaired? step 4
4 Perform diagnosis again and check if the malfunction -- Diagnosis
reoccurs. ends
9.2 Solenoid Valve and Valve Bank Relay Malfunction
DTC: C001004, C001104, C001404, 9.2.4 Synchronized solenoid valve has no

feedback.
C001504, C001804, C001904, C001C04,
C001D04, C000104, C000204, C000304, 9.2.5 The solenoid valve itself malfunctions.
C000404, C012104, C007204 9.2.6 The valve bank relay malfunctions.
Malfunction setting conditions Possible Cause
9.2.1 The valve power supply malfunctions. (a) The solenoid valve is short to power or
(The power supply is short to ground or ground, or open circuit.
open)
(b) Fuse malfunction
9.2.2 The temperature of solenoid valve is too
high. (Overheat protection) (c) System overheat protection
9.2.3 More than 5 solenoid valves are short. (d) ESP is damaged.
(Fuse)
367
Diagnostic steps

1 Stop the vehicle for 5 minutes to see if the -- Perform step 2
malfunction is repaired?
2 Is the preliminary check performed? Perform Perform
step 3 preliminary check
3 Measure the voltage of solenoid valve power Perform Perform step 4
supply pin in the connector, and check the step 5
connector, wire harness and ground wire. Is
the malfunction detected and repaired? For
pin definition, refer to the circuit diagram
4 Perform cross validation on ESP. If ESP is Perform --
damaged, replace it. Is the malfunction step 5
repaired?
5 Stop the vehicle after accelerating it to 15 -- Diagnosis ends

km/h. Perform diagnosis again and check if
the malfunction reoccurs.
9.3 Solenoid Valve and Valve Bank Relay Malfunction
Pump Motor Malfunction 9.3.4 The return pump motor relay stops
operating, and the return pump monitoring
DTC: C002004 detects voltage does not drop.
9.3.1 The pump motor operates at excessive (a) System overheat protection.
load and the temperature is too high.
(Overheat protection) (b) The power supply of pump motor is
abnormal.
9.3.2 After the return pump motor relay
operates for 60 ms, the return pump (c) The pump motor relay malfunctions
monitoring cannot detect the voltage (Fuse, external relay).
signal.
(d) The pump motor malfunctions.
9.3.3 The return pump motor relay does not
operate, and the return pump monitoring (e) The pump motor is poorly grounded.
detects voltage for more than 2.5 s.
Diagnostic steps

1 Stop the vehicle for 5 minutes to see if the -- Perform step
malfunction is repaired? 2
step 3 preliminary
check
3 Measure the voltage of pump motor power supply Perform Perform step
pin in the connector, and check the connector, wire step 5 4
harness and ground wire. Is the malfunction
detected and repaired? For pin definition, refer to
the circuit diagram.
368
4 Perform cross validation on ESP. If ESP is Perform --

damaged, replace it. Is the malfunction repaired? step 5
5 Stop the vehicle after accelerating it to 15 km/h. -- Diagnosis
Perform diagnosis again and check if the ends
malfunction reoccurs.
9.4 Wheel Speed Sensor Circuit Malfunction
DTC: C003204, C003504, C003804, (a) The wheel speed sensor circuit is
C003B04 disconnected, and the connector is loose
and broken.
(b) The signal wire and power cable of wheel
9.4.1 ECU detects the signal wire of wheel speed sensor are reversed.
speed sensor is short to ground.
(c) The signal wire is short to ground.
9.4.2 The wheel speed sensor circuit is open.
The air gap exceeds the specifications
Possible Cause
Diagnostic steps

1 Is the preliminary check performed? Perform step Perform
2 preliminary
check
2 Check if the connector of wheel speed sensor is Perform step Perform step
in good condition and if the wheel speed sensor 4 3
circuit is open or short. Is the malfunction
detected and repaired? For pin definition, refer to
the circuit diagram.
3 Perform cross validation on ESP. If ESP is Perform step --
damaged, replace it. Is the malfunction repaired? 4
4 Stop the vehicle after accelerating it to 15 km/h. -- Diagnosis
Perform diagnosis again and check if the ends
malfunction reoccurs.
9.5 Wheel Speed Sensor Signal Malfunction
DTC: C003108, C003408, C003708, Possible Cause

C003A08, C024501
(a) The wheel speed sensor circuit is
Malfunction setting conditions disconnected, and the connector is loose
and broken.
9.5.1 ECU detects the signal wire of wheel
speed sensor is short to power supply. (b) The signal wire of wheel speed sensor is
short to power supply.
9.5.2 ECU detects the power cable of wheel
speed sensor is short to ground. (c) The power cable of wheel speed sensor is
short to ground.
9.5.3 The wheel speed sensor signal is
abnormal. (d) The gear ring is not installed, missing tooth,
dirty, demagnetizing and eccentric.
369
(e) The air gap between the sensor and gear

ring is too wide. (h) The number of gear ring tooth is incorrect.
(f) The wheel speed sensor is disturbed by (i) The tire size is not as specified.
outside magnetic field. (The wheel or axle
does not demagnetize) (j) The ECU is damaged.
(g) The wheel speed sensor body

malfunctions.
Diagnostic steps

1 Is the preliminary check performed? Perform step 2 Perform
preliminary
check
2 Check if the connector of wheel speed sensor Perform step 6 Perform step
is in good condition and if the wheel speed 3
sensor circuit is open or short. Is the
malfunction detected and repaired? For pin
definition, refer to the circuit diagram.
3 Check the air gap between the wheel speed Perform step 6 Perform step
sensor and gear ring for dirt, foreign materials 4
and missing tooth and check if the number of
gear ring tooth is correct. Is the malfunction
detected and repaired?
4 Raise the vehicle with a lift, rotate the wheels Replace the wheel Perform step
and check if the wheel speed sensor signal speed sensor and 5
output is as specified using an oscilloscope. Is perform step 6
the malfunction detected?
5 Perform cross validation on ESP. If ECU is Perform step 6 --
damaged, replace ESP. Is the malfunction
repaired?
6 Stop the vehicle after accelerating it to 15 -- Diagnosis
km/h. Perform diagnosis again and check if ends
the malfunction reoccurs
9.6 ECU Malfunction
DTC: C055000 Possible Cause
Malfunction setting conditions (a) ESP wire harness malfunctions.
9.6.1 ECU power supply malfunctions. (b) The fuse malfunctions.
9.6.2 The ECU is damaged. (c) ECU malfunctions.
370
Diagnostic steps

2 preliminary
check
2 Check the connector, wire harness and ground Perform step Perform
wire. Is the malfunction detected and repaired? 4 step 3
3 Perform cross validation on ESP. If ECU is Perform step --
damaged, replace ESP. Is the malfunction 4
repaired?
4 Perform diagnosis again and check if the -- Diagnosis
malfunction reoccurs. ends
9.7 CAN Bus Malfunction
DTC: C100104, U100004
The vehicle CAN bus communication, configuration information and wire harness malfunction.
Possible Cause
9.7.1 CAN controller malfunctions.
9.7.2 CAN configuration information does not match.
9.7.3 CAN off
Diagnostic steps

2 preliminary
check
2 Diagnose the CAN bus hardware and software. For Perform step Perform
details, refer to the vehicle repair manual. Is the 4 step 3
malfunction detected and repaired?
3 Perform cross validation on ESP. If ECU is Perform step --
damaged, replace ESP. Is the malfunction 4
repaired?
371
9.8 Pressure Sensor Malfunction
DTC: C004601
9.8.1 The pressure signal is interrupted.
9.8.2 The pressure value is abnormal. (Less than the original value)
Possible Cause
(a) The pressure sensor malfunctions.
(b) The ESP module malfunctions.
Diagnostic steps

step 2 preliminary
check
2 Perform cross validation on ESP (For detailed Perform --
procedures, refer to "Removal and Installation"). If step 3
ECU is damaged, replace ESP. Is the malfunction
repaired?
9.9 Steering Angle Sensor Malfunction

9.9.3 The steering angle sensor signal is
interrupted.
DTC: U012604, U012608, C046008,
C106600 The steering angle sensor CAN
communication malfunctions.
9.9.1 The steering angle sensor is not (a) The sensor is not calibrated.
calibrated or fails to calibrate (such as
steering wheel return, wheels return and (b) The sensor circuit is short or open.
four wheels alignment).
(c) The sensor is damaged or installed
9.9.2 The steering angle sensor signal is improperly.
abnormal or the sensor is not installed
properly. (d) ESP malfunctions.
372
Diagnostic steps

1 Is the preliminary check performed? Perform step 2 Perform preliminary
check
2 Calibrate the steering angle sensor. Perform step 5 Perform step 3
Is the malfunction repaired?
3 Check the wire harness of steering Perform step 5 Perform step 4
angle sensor. Is the malfunction
repaired?
4 Perform cross validation on the Perform step 5 --
steering angle sensor or reinstall the
steering angle sensor. (Replace the
steering angle sensor and perform
calibration again) Is the malfunction
repaired?
5 Perform diagnosis again and check -- Diagnosis ends
if the malfunction reoccurs.
9.10 Yaw Rate Sensor (Integrated Sensor) Malfunction
For ESP9 system, the yaw rate sensor is 9.10.2 The yaw rate sensor signal is abnormal.
installed outside. For ESP9i system, the yaw
rate sensor is installed inside (i.e. integrated 9.10.3 The yaw rate sensor malfunctions.
sensor).
Possible Cause
The yaw rate sensor contains lateral
acceleration signal, longitudinal acceleration (a) The sensor is not calibrated or calibration
signal and yaw velocity signal. is not as specified (It should be calibrated
on a flat ground).
DTC: C006108, C006208, C006308,
C019604, C00A800 (b) The installation error of sensor (i.e. ESP
module assembly) is great.
Malfunction setting conditions (c) The sensor is damaged.
9.10.1 The yaw rate sensor is not calibrated.
Diagnostic steps

preliminary
check
2 Calibrate the yaw rate sensor (integrated Perform step 6 Perform step 3
sensor). Is the malfunction repaired?
3 Check the wire harness of yaw rate sensor. Perform step 6 Perform step 4
(Ignore the step for integrated sensor) Is the
malfunction repaired?
4 Reinstall the yaw rate sensor/ESP9i module and Perform step 6 Perform step 5
perform calibration. Is the malfunction repaired?
5 Perform cross validation on the ESP9i module. Perform step 6 --
(It should be calibrated again) Is the malfunction
373
repaired?
9.11 ECM Malfunction
DTC: U010004, U010008 Possible Cause
Malfunction setting conditions (a) CAN bus line malfunction.

(b) ECM software versions do not match.
9.11.1 ECM message timeout. (c) ECM is damaged.
9.11.2 ECM message error.
Diagnostic steps

preliminary
check
2 Diagnose the CAN bus hardware and software. Perform step 5 Perform step 3
Is the malfunction detected and repaired?
3 Diagnose the ECM version information. For Perform step 5 Perform step 4
details, refer to the vehicle repair manual. Is the
4 Perform cross validation on ECM. If ECM is Perform step 5 --
damaged, replace it. Is the malfunction
repaired?
9.12 Gateway Malfunction
DTC: U014004, U014008

9.12.3 CAN bus line malfunction.
9.12.4 Gateway software versions do not
9.12.1 Gateway message timeout. match.
9.12.2 Gateway message error. The gateway is damaged.
Possible Cause
Diagnostic steps

preliminary
check
374
For details, refer to the vehicle repair manual. Is

the malfunction detected and repaired?
3 Diagnose the gateway version information. Is Perform step 5 Perform step 4
4 Perform cross validation on the gateway. If the Perform step 5 --
gateway is damaged, replace it. Is the
9.13 EPB Malfunction
DTC: U100304, U100308, C040008 Possible Cause
Malfunction setting conditions (a) CAN bus line malfunction.
9.13.1 EPB message timeout. (b) EPB software versions do not match.
9.13.2 EPB message error. (c) EPB is damaged.
9.13.3 EPB signal malfunction.
Diagnostic steps

preliminary
check
For details, refer to the vehicle repair manual. Is
3 Diagnose the EPB version information. For Perform step 5 Perform step 4
details, refer to the vehicle repair manual. Is the
4 Perform cross validation on EPB. If EPB is Perform step 5 --
repaired?
9.14 ESP PATA Switch Malfunction
DTC: C004C04
Possible Cause
(a) The PATA switch is covered by some
9.14.1 Press and hold the PATA switch for items.
more than 10 seconds.
(b) The PATA switch is damaged.
9.14.2 The PATA activation signal is monitored
for more than 2 seconds during ignition.
Diagnostic steps
375
1 Check if the PATA switch is covered or Perform step 4 Perform step 2

attached by some items. If so, put them in
order. Is the malfunction repaired?
2 Check the wire harness of PATA switch. Is Perform step 4 Perform step 3
3 Perform cross validation on the PATA switch. Perform step 4 --
If the PATA switch is damaged, replace it. Is
the malfunction repaired?
9.15 ESP Configuration Information Malfunction
DTC: C121208 9.15.2 The configuration information does not

match.
Possible Cause
9.15.1 The configuration information is not
written in. The ESP configuration information is not
written in or written incorrectly.
Diagnostic steps

1 Write in the ESP configuration information using Perform step 2 --
a diagnosis device. Is the malfunction repaired?
9.16 Braking Light Switch (BLS) Malfunction
Malfunction setting conditions (a) BLS circuit is short or open.
9.16.1 BLS signal is abnormal (b) BLS is installed incorrectly.
9.16.2 BLS signal is interrupted. (c) BLS is damaged.
Diagnostic steps

preliminary
check
2 Check the installation of BLS, clamps and wire Perform step 4 Perform step 3
harness to see if the malfunction is repaired.
3 Perform cross validation on BLS. If BLS is Perform step 4 --
repaired?
9.17 Abnormal ESP Operation
376
Malfunction setting conditions (a) The wheel speed difference is too big.
9.17.1 ESP receives a command to operate (b) The sensor signal is incorrect.
continuously (more than 10 seconds).
The signals of steering angle sensor and
yaw velocity sensor are abnormal.
Diagnostic steps

2 preliminary
check
2 Check the wheel speed sensor and gear ring to Perform step Perform step
see if the malfunction is repaired. 5 3
3 Check the installation of steering angle sensor Perform step Perform step
and yaw rate sensor to see if the malfunction is 5 4
repaired.
4 Perform cross validation on ESP (For detailed Perform step --
procedures, refer to "Removal and Installation"). 5
If ECU is damaged, replace ESP. Is the
9.18 Abnormal Clutch Signal
DTC: C108008 (a) The clutch switch circuit malfunctions.
Malfunction setting conditions (b) The clutch switch malfunctions.
9.18.1 The clutch signal is abnormal. (c) Driving habits of some drivers (The clutch
pedal is depressed for more than 5
Possible Cause minutes while driving).
Diagnostic steps

2 preliminary
check
2 Diagnose the clutch switch circuit. For details, refer Perform step Perform
to the vehicle repair manual. Is the malfunction 5 step 3
detected and repaired?
3 Diagnose the clutch switch hardware. For details, Perform step Perform
refer to the vehicle repair manual. Is the 5 step 4
malfunction (contact points damaged, abnormal
return, etc.) detected and repaired?
4 Perform cross validation on the clutch switch. If the Perform step --
clutch switch is damaged, replace it. Is the 5
377

9.19 Abnormal Reverse Gear Signal
DTC: C108C08 Possible Cause
Malfunction setting conditions (a) The reverse gear switch malfunctions.
9.19. 1 The reverse gear signal is "1" when the (b) BCM communication malfunctions.
vehicle is moving forward.
(c) The reverse gear signal wire
9.19.2 The reverse gear signal is "0" when the malfunctions.
vehicle is reversing.
Diagnostic steps

2 preliminary
check
2 Diagnose the reverse gear switch circuit. Is the Perform step Perform
malfunction detected and repaired? 4 step 3
3 Diagnose the BCM and body gateway circuit. For Perform step --
details, refer to the vehicle repair manual. Is the 4
Note: For diagnosis and repair, refer to ABS repair manual.
378
Section 10 Removal and Installation

10.1 Removal Procedure for ESP Assembly
10.2.4 The configuration information must be
10.1.1 Turn the vehicle off and disconnect the written in after ESP assembly is replaced.
battery negative. (If any)
10.1.2 Remove the wire harness from the ESP 10.2.5 The steering angle sensor and yaw rate
assembly. sensor (integrated sensor) must be
calibrated after the ESP assembly is
10.1.3 Fully depress the brake pedal and hold replaced.
it with the pedal bracket to prevent the
brake fluid outflow after the brake line is 10.3 Bleeding Instruction
removed from the brake master cylinder.
10.3.1 After the brake system components are
10.1.4 Remove the brake line and plug the replaced by the customer (when the brake
threaded hole on the ESP assembly and fluid, brake line or hydraulic unit is
the oil hole on the brake line to prevent replaced) or when the brake pedal feels
foreign materials from entering. spongy, the bleeding must be performed.
Remove the retaining bracket from ESP. 10.3.2 The hydraulic unit replaced by the
customer must be the fully filled ESP
10.2 Installation Procedures for ESP hydraulic regulator with ECU.
Assembly
10.3.3 When bleeding, ensure the brake
10.2.1 Install the ESP assembly to the bracket system structure is complete and the
and tighten it to 8±2 Nm. entire high-pressure hydraulic unit is well
connected.
10.2.2 Unplug the ESP threaded hole and
brake line, connect the brake line to ESP 10.3.4 The parking brake should be applied
assembly and tighten it to 16±2 Nm. before bleeding.
10.2. 3 Fill the brake fluid in the reservoir to the 10.3.5 The brake fluid is corrosive. If it
Max position and bleed using specified contacts your skin, wash it off.
methods.
10.4 Instructions for Integrated Sensor Calibration (ESP9i System)
ESP9i system integrates the yaw rate sensor which requires high installation precision. The
installation error must be less than ±5°when replacing, or the calibration cannot be performed.
Integrated sensor calibration

Operator Test bed/test device
Turn the steering wheel to straight forward Calibrate the integrated inertia sensor offset
position
The wheels of vehicle must be straight on the

test device.
Preconditions for sensor offset calibration
a The maximum inclination of the test bed must be within the allowable range (The
inclination must meet the requirements in both calibration directions. For details, refer to
the chart below)
379
b The test bed must be stationary
c Turn the steering wheel to straight forward position
d Correct tire pressure
e Normal load condition
f Low vehicle tank volume is allowed
g The vehicle is supported by its wheels
h The driver must sit in the vehicle
i Additional interferences (such as closing the door or engine hood) are not allowed
g The calibration can be performed on the hub tester or flat surface.
Note the maximum allowable inclination when performing IIS calibration! ±0.57°
Note
The delivered ESP has stored the predetermined offset in its EEPROM. During calibration,
ECU will write the newly measured data in EEPROM for use by ESP. ESP cannot determine
the above mentioned preconditions, so the customer must ensure the above calibration
conditions are satisfied. If the offset is too big, the system will reject the calibration. The vehicle
needs to be returned to the dealership for repair. IIS calibration must be performed after ESP9i
is replaced.
Vehicle Side View (IIS calibration)
Vehicle Front View (IIS calibration)
380
Section 11 Service Specifications

11.1 General Specifications
Model BYD 5 A
Brake Line Layout X type
Drive type Front wheel drive
System Bosch ESP 9
Brake fluid type Specified by BYD Mixed use is forbidden
No. of gear ring tooth 48
Internal resistance of wheel 3 M  ~5 M 
speed sensor
Air gap between the wheel 0.1~0.9 mm
speed sensor and gear ring
Front wheel
Rear wheel 0.2~0.7 mm
Standard: 205/65 R15 94V
Tire type Optional: 205/65 R16 92V
11.2 Torque (Unit: N·M)
Brake line joint on ESP ECU 14~18

ESP set bolts 12
Front wheel speed sensor set bolts 10
Rear wheel speed sensor set bolts 10
381
Chapter 9 Interior and Exterior
Contents
Section 1 Front Bumper System ............................................................................................383
1.1 Front Bumper ........................................................................................................... 383
1.3 Fender ...................................................................................................................... 390
1.4 Installation/Removal of Vent Cover ......................................................................... 393
1.5 Interior and Exterior Components............................................................................ 394
1.6 Auxiliary Instrument Panel Assembly ...................................................................... 406
1.7 Side Body................................................................................................................. 414
1.8 Back Trim ................................................................................................................. 418
1.9 Removal/Installation of Door Guard Plate ............................................................... 420
1.10 Removal/Installation of Sun Screen Assembly ..................................................... 427
1.11 Removal and Installation of Roof Handrail ............................................................ 428
1.12 Removal/Installation of Ceiling .............................................................................. 428
1.13 Removal/Installation of Carpet .............................................................................. 429
1.14 Removal/Installation of Heat Insulation Layer ....................................................... 430
1.15 Removal and Installation of Trunk System ............................................................ 431
1.16 Rear License Plate Lamp Trim Strip Assembly..................................................... 434
382
Section 1 Front Bumper System

1.1 Front Bumper
1.1.1 Front Bumper Components
前LOGO
Front LOGO
前格栅
Front Grille
前保险杠右支架
Front Bumper Front Bumper
前保险杠左支架
Support RH Support LH
前格栅网格
Front Grille Mesh
Front Bumper
前保险杠
Left Front Fog

右前雾灯装饰板
Right Front Fog Front Bumper Intake 左前雾灯装饰板
Light Trim Panel
Light Trim Panel 前保险杠进气网格
Mesh
Front前保险杠右牵引口盖板
Bumper Right Towing Eyelet 前保险杠左牵引口盖板
Front Bumper Left Towing
Cover Plate Eyelet Cover Plate
Front Bumper System Components
383
Precautions for removal:
1.1.1.1 Be careful not to scratch the front

bumper and body when removing;
1.1.1.2 Wrap the screwdriver with protective

tape when prying with a flat tip driver to
avoid damage;
1.1.1.3 Wear a pair of gloves to protect your

hands;
1.1.1.4 An assistant is needed to assist in the

removal and installation of front bumper.
Figure 4-1-1-3 Removal of Front Wheel
1.1.2 Removal of Front Bumper Components Fender
1.1.2.1 Loosen the left front wheel fender
1.1.2.1.1 Remove 2 combination screws to

loosen the front bumper and left front
wheel fender as shown in figure
4-1-1-3.
1.1.2.1.2 Remove the snap fasteners

connecting the front bumper corner
and left front wheel fender;
1.1.2.1.3 Remove the E shape snap-fits

connecting the front bumper corner
and left front wheel fender.
Figure 4-1-1-2 Removal of Grille Upper Cover 1.1.2.3 Loosen the right front wheel fender
Plate
Tips: The removal method is the same as 2.
1.1.2.1 Remove the grille upper cover plate
1.1.2.1.1 Remove 4 snap fasteners

installed on the front grille and grille
upper cover plate;
1.1.2.1.2 Remove 6 snap fasteners

installed on the grille upper cover plate
and water tank upper cross member as
shown in figure 4-1-1-2;
1.1.2.1.3 Remove the grille upper cover

plate.
Figure 4-8-1-4 Removal of Front Bumper
1.1.2.4 Remove the front bumper assembly
384
1.1.2.4.1 Remove 2 combination screws Front Bumper Left

installed on the front grille and water tank Fog Light Trim Panel
upper cross member as shown in figure
4-8-1-4;
1.1.2.4.2 Remove 4 combination screws

installed on the front bumper and engine
lower fender;
1.1.2.4.3 Attach protective tape on the fender

to prevent the body paint from being
scratched by the screwdriver during
removal; Figure 4-1-1-6 Removal of Front Fog Light
Mounting Holder
1.1.2.4.4 Loosen 8 hooks on both left and right
side of front bumper carefully with a 1.1.2.6 Remove the front bumper left and right
screwdriver; fog light trim panels
1.1.2.4..5 Loosen the engine lower fender as 1.1.2.6.1 Loosen the mounting clamps as
shown in figure 4-8-1-4; shown in figure 4-1-1-6 and pull the
outside of fog light trim panel outward.
1.1.2.4.6 Remove the front bumper assembly. Push the inside of fog light trim panel
outward after loosening the clamps. The
front bumper left and right fog light trim
panels each have 5 clamps;
1.1.2.6.2 Remove the left and right fog light

trim panels.
Figure 4-1-1-5 Removal of Front Grille
1.1.2.5 Remove the front grille assembly
1.1.2.5.1 Remove 6 snap fasteners installed

on the front bumper and front grille as
shown in figure 4-1-1-5;
1.1.2.5.2 The front grille can be removed by

pushing the entire front grille backward to Figure 4-1-1-7 Removal of Front Bumper
separate it from the front bumper. Support
1.1.2.7 Remove the front bumper support LH
Remove 2 combination screws connecting the

front bumper support LH and left fender using
a cross screwdriver. Then remove the
385
mounting bolts connecting the front bumper

support LH and left headlamp. The left 1.1.2.9.2.2 Be careful not to scratch the front
connecting support can be removed by bumper and body, and wear a pair of
carefully prying the support from the body gloves to protect your hands;
metal plate using a flat tip driver. See figure
4-1-1-7. 1.1.2.9.2.3 Replace the damaged fasteners;
1.1.2.8 Remove the front bumper support RH 1.1.2.9.2.4 Confirm the front bumper assembly
parts and front bumper assembly can be
Tips: The removal method is the same as 8. well connected with the surrounding parts.
1.1.2.9 Remove the front bumper left and right

towing eyelet cover plates
Front Bumper Left Towing

Eyelet Cover Plate
Figure 4-1-1-8 Removal of Front Bumper

Towing Eyelet Cover Plate
1.1.2.9.1 Loosen the mounting clamps as

shown in figure 4-1-1-8 and pull the
outside of towing eyelet cover plate
outward. Push the inside of towing eyelet
cover plate outward after loosening the
clamps. The front bumper left and right
towing eyelet cover plates each have 2
clamps;
1.1.2.9.2 Remove the front bumper left and

right towing eyelet cover plates.
At this time, the front bumper system

components have been removed completely
from the body.
The installation of front bumper is in reverse

order of removal, which will not be described
herein.
1.1.2.9.2.1 An assistant is needed to assist in

the installation of front bumper assembly;
386
1.2.3 Rear Bumper System
1.2.4 Rear Bumper System Overview
1.25 Bumper
Rear Bumper Support RF

Rear Bumper Support LF
Rear Bumper Support RR

Rear Bumper Support LR
Rear Bumper Inlet Assembly
Rear Bumper Body
Reflex Reflector
Figure 1.2.1 Rear Bumper System Components
Precautions for removal:
a. Be careful not to scratch the rear bumper

and body when removing;
b. Wrap the screwdriver with protective tape

when prying with a flat tip driver to avoid
components damage;
c. Wear a pair of gloves to protect your

hands;
d. An assistant is needed to assist in the

removal of rear bumper.
387
1.2.6 Removal of Rear Bumper Components
Figure 1.2.4 Removal of Rear Bumper Support

LH
1.2.6.2 Remove the rear bumper supports LH

and RH
Figure 1.2.2 Removal of Rear Bumper The rear bumper support LH is divided to front
Assembly and rear supports (The front support is longer).
The left support is shown in figure 1.2.1.
1.2.6.1 Remove the rear bumper assembly Remove 2 cross recessed pan head tapping
screws from the left front support and 2 cross
(a) Remove 2 hexagon flange bolts recessed pan head tapping screws from the
connected to back metal plate (at trunk left rear support, and then remove the cross
cover) from outside; recessed hexagon head tapping screws from
the left rear support and left rear headlamp.
(b) Remove 4 snap fasteners A from the The left support can be removed by carefully
bottom. The connecting snap-fit can be prying the support from the body metal plate
removed by prying the male part from using a flat tip driver. The operation for right
the center using a flat tip driver and support is the same as that of left support.
take off the female part. Never damage
them forcibly;
(c) Remove 2 snap fasteners B on both

left and right of the body connected to
rear fenders using a cross head
screwdriver;
(d) Slightly pull the bumper along both

sides of rear bumper to separate it
from the body (The rear bumper
support has several clamps. Never pull
them out forcibly); slowly pull them out
to protect the rear bumper structure
and possible backup radar circuit;
Figure 1.2.3 Removal of Bumper Inlet
(e) Disconnect the backup radar
connector on the rear bumper and 1.2.6.3 Remove the rear bumper inlet
then pull the rear bumper rearward
(Skip the procedure for models without The inlet is secured on the body with clips.
backup radar). Then pry the inlet from the body metal plate
using a straight screwdriver wrapped with
protective tape. Ensure the force is applied
evenly when prying the inlet.
388
Figure 1.2.5 Removal of Reflex Reflector
1.2.6.4 Remove the reflex reflector
The reflex reflector can be removed only after

the rear bumper assembly is removed.
Unscrew 2 cross tapping screws on both sides
with a cross screwdriver. Then slightly loosen
the clips of reflex reflector by hand and push
them outward to remove the reflex reflector.
At this time, the rear bumper system

components have been removed completely
from the body.
1.2.7 Installation of Rear Bumper System
The installation of rear bumper is in

reverse order of removal, which will not be
described herein.
1.2 7.1 An assistant is needed to assist in the

installation of rear bumper assembly;
1.2.7.2 Be careful not to scratch the rear

bumper and body, and wear a pair of
gloves to protect your hands;
1.2.7.3 Replace the damaged components

and fasteners;
1.2.7.4 Confirm the rear bumper assembly

parts and rear bumper assembly can be
well connected with the surrounding parts.
389
1.3 Fender
1.3.1 General
The fender can be removed easily by removing several sets of fasteners.
1.3.2 Removal/Installation of Front Wheel Fender
To remove the front wheel fender, remove 4 cross recessed pan head tapping screw and big
washer assemblies indicated by 6 in the figure with a cross screwdriver.
Then remove 8 snap fasteners as shown in figure 5. Remove the male part by prying it with a
straight screwdriver.
Remove 1 E-shape snap-fit indicated by 4 in the figure with a straight screwdriver.
Remove 2 cross recessed hexagon head tapping screws and big washer assemblies indicated
by 3 in the figure with a cross screwdriver.
The front fender can be taken off after the above fasteners are removed.
The front wheel inner plate can be taken off when another 5 snap fasteners indicated by 1 in the
figure are removed.
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The installation is in the reverse order of removal.
1.3.3 Removal/Installation of Rear Wheel Fender
To remove the rear wheel fender, remove 1 cross recessed pan head tapping screw and big
washer assembly indicated by 1 in the figure with a cross screwdriver. Then the rear wheel lower
plate can be taken off.
Then remove 10 snap fasteners from the rear wheel fender indicated by 2 in the figure. Remove
the male part by prying it with a straight screwdriver.
Then remove 3 snap fasteners indicated by 3 and 4 in the figure.
Remove the male part by prying it with a straight screwdriver.
Remove 1 cross recessed pan head tapping screw and big washer assembly indicated by 5 in the
figure with a cross screwdriver.
Then the rear wheel fender and rear wheel small fender can be removed.
391
1.3.4 Removal/Installation of Engine Lower Fender
The removal of engine lower fender can be performed after the front wheel fender is removed. Due
to the special position of fender, the body should be raised with professional lifting devices for
convenient operation.
First, remove the engine lower rear fender indicated by 4 in the figure. The method is as follows:
Remove 2 hexagon head tapping screw and big washer assemblies indicated by 5 in the figure
with a sleeve. Then remove 5 snap fasteners indicated by 6 in the figure with a straight
screwdriver. Remove the male part by prying it with a straight screwdriver. At this time, the engine
lower rear fender can be taken off.
Second, remove the engine lower front fender indicated by 2 in the figure. Remove 2 cross
recessed pan head tapping screw and big washer assemblies indicated by 1 in the figure with a
cross screwdriver. Then remove 8 hexagon head tapping screw and big washer assemblies
indicated by 3 in the figure with a sleeve to take off the engine lower front fender.
392
1.4 Installation/Removal of Vent Cover
Note: Be careful not to scratch the windshield and body.
Wear a pair of gloves to protect your hands.
1.4.1 Remove the windshield wiper arm.
1.4.2 Press the male part and remove the snap fastener A with a cross screwdriver.
1.4.3 Pull up the right vent cover near the front compartment to separate the clips from the metal
plate slot. Then use the same method to separate the left vent cover clips from the metal plate
slot. Then rotate the separated ends of left and right vent covers upward for proper angle and
then pull them along the front compartment to move the left and right vent covers away from
the windshield at the same time. Do not apply too much force, or the clips may be damaged.
1.4.4 Install the vent covers in the reverse order of the removal procedures.
A子母扣
Snap Fastener A
雨刮器检
Windshield
Wiper Access Right Vent Cover Upper
修盖板右通风盖板上封板
Cover Plate
A 右通风盖板
Right Vent Cover
左通风盖板
Left Vent Cover A
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described below.
1.5 Interior and Exterior Components
1.5.1 Removal/Installation of Combination
Dashboard Assembly Switch Upper/Lower Protector
Figure 1.5.2 Combination Switch

Upper/Lower Protector
Figure 1.5.1 Schematic Diagram of
Dashboard Assembly Removal:
The removal order for dashboard
assembly components is as follows: 1.5.1.1 Adjust the combination switch
upper/lower protector to the lowest
position before removing;
Before removing the dashboard interior, the
steering wheel, driver seat safety airbag and 1.5.1.2 Hold the end openings of
front compartment cover release handle combination switch upper/lower
must be replaced. (For details, refer to protector with hands and then pull
relevant section) them up with even force to remove the
upper protector;
Notice:
1.5.1.3 Remove 3 screws as shown in the
(a) Wear a pair of gloves to protect your figure with a cross screwdriver and
hands before removing and installing; take off the lower protector.
(b) Before removing and installing,

understand the structure of parts to be
disassembled to avoid unnecessary
damage during disassembly.
(c) During removal, wrap the straight

screwdriver with flexible tape when
prying to avoid damage.
Product surface;
(d) After installation, the clearance fit and
flush of all parts should meet the
requirements in appearance tolerance
table.
The removal and installation methods for

dashboard assembly components are
394
Figure 1.5.3 Schematic Diagram for Figure 1.5.5 Console Box Trim Strip (2)
Removal of Combination Switch
Removal:
Upper/Lower Protector
Installation: Pry all the snap-fits and clips from bottom to
top along the side seam of trim strip with a
(a) Install the combination switch lower straight screwdriver wrapped with flexible
protector, ensure both sides of lower tape as shown in figure 1.5.5. Pull up the
protector are attached to the trim strip by hand carefully to prevent the
combination switch body and tighten 3 snap-fits and clips from being broken.
screws;
Installation:
(b) Install the combination switch upper
protector, ensure the clips on the 1.5.2.1 Check if the removed snap-fit
upper and lower protector are aligned (BYDQ836A01) is installed in its
and carefully tap them until firmly original position;
secured.
1.5.2.2 Align 2 snap-fits on the top with the
1.5.2 Removal/Installation of Console Box mounting holes, and then align the
Trim Strip single-side clips in order;
1.5.2.3 Tap the trim strip by hand while

keeping the direction of trim strip
stable;
1.5.2.4 Tap all the clips and snap-fits into

the mounting holes and ensure they
are assembled securely with excellent
appearance.
1.5.3 Removal/Installation of Acoustic Panel
Figure 1.5.4 Console Box Trim Strip (1)
Figure 1.5.6 Schematic Diagram for

Installation of Acoustic Panel
1.5.3.1 Removal/Installation of Dashboard

Left Lower Acoustic Panel
Removal:
395
1.5.3.2.2 Slowly pull out the acoustic panel

1.5.3.1.1 Remove 2 screws with a cross in horizontal direction, until the rear
screwdriver; oblique pins are separated from the
mounting holes completely.
1.5.3.1.2 Slowly pull out the single-side
clips in front of acoustic panel; Installation:
1.5.3.1.3 Slowly pull out the acoustic panel (a) Install the rear oblique pins of acoustic
in horizontal direction, until the rear panel to the mounting holes;
oblique pins are separated from the
mounting holes completely. (b) Slightly raise the front of acoustic
panel to align 3 front single-side clips
Installation: and mounting holes, and tap the clips
until they are assembled securely;
(a) Install the rear oblique pins of acoustic
panel to the mounting holes;
(b) Slightly raise the front of acoustic

panel to align the front single-side clips
and mounting holes, and tap the clips
until they are assembled securely;
(c) Fasten 2 screws with a cross

screwdriver.
Figure 1.5.8 Dashboard Right Lower

Acoustic Panel Components
1.5.4 Removal/Installation of Combination

Instrument Hood Panel
Figure 1.5.7 Dashboard Left Lower

Acoustic Panel
1.5.3.2 Removal/Installation of Dashboard

Right Lower Acoustic Panel Components
Removal:
The removal method of right lower acoustic

panel is similar to that of left lower acoustic
panel.
Figure 1.5.9 Assembly Status of
1.5.3.2.1 Pull out 3 front single-side clips; Combination Instrument Hood Panel
Removal:
396
1.5.4 .1 It is not recommended to use the

straight screwdriver when removing
the product, or the outer surface may
be damaged.
1.5.4.2 Put your hands in the position

indicated by the arrow in figure 1.5.10,
and slowly move the part in the arrow
direction until the assembled structure
is disconnected.
Figure 1.5.11 Glove Box Assembly
Removal:
1.5.5.1 Open the glove box and then

locate the glove box pneumatic spring
on the right side of glove box. The
pneumatic spring can be removed by
Figure 1.5.10 Schematic Diagram for compressing the snap-fit used to
Removal of Combination Instrument Hood install the pneumatic spring to the
Panel glove box. Disconnect the pneumatic
spring from the glove box assembly as
Installation: shown in figure 1.5.11.
(a) Check if 2 removed snap-fits 1.5.5.2 Remove the limited posts on both
(BYDQ836A01) are installed in the sides of glove box by compressing
original positions; them so that the lower body will not
limit the glove box;
(b) Align the structures to be installed
horizontally; 1.5.5.3 The glove box assembly can be
removed by disconnecting the hinge of
(c) Tap each assembly area until they are glove box assembly from the
fixed securely with excellent dashboard lower body.
appearance.
Installation:
1.5.5 Removal/Installation of Glove Box
Assembly The installation of glove box assembly is in
1.5.6 Removal/Installation of Right Lower

Storage Compartment Air Spring Assembly
397
Protector Assembly
Removal:
1.5.7.1 The dashboard left lower protector

is connected to the surrounding parts
with snap-fits (BYDQ836A01) and
hemming.
1.5.7.2 The cover plate can be removed by

carefully moving it outward by hand,
until all the single-side clips and
snap-fits in the figure are pulled out.
Notice:
The electrical device button and wire

harness should not be damaged during
Figure 1.5.12 Storage Compartment Air removal.
Spring Assembly
Installation:
The installation and removal methods of Put the top hemming into proper slot, align
pneumatic spring and lower body are the each snap-fit with its snap-fit hole and
same as that of pneumatic spring and glove carefully tap it in. Check if the exterior
box assembly. clearance is as specified after installation.
The installation of pneumatic 1.5.8 Removal/Installation of Dashboard Air

spring assembly is in reverse order Inlet Assembly
of removal.
1.5.7 Removal/Installation of Left Lower

Guard Assembly
Figure 1.5.14 Dashboard Air Inlet

Assembly Layout
Figure 1.5.13 Dashboard Left Lower
398
Figure 1.5.15 Left Dashboard Air Inlet

Assembly Figure 1.5.16 Center Cover Plate
Assembly Layout
Removal:
1.5.8.1 Pry the contact edge of dashboard

air inlet assembly and dashboard
upper body with a straight screwdriver
so that 4 clips of the air inlet will be
separated from the dashboard;
1.5.8.2 Pull the dashboard air inlet

assembly out of the dashboard by
hands in a straight line.
Installation:
Align the air inlet with air duct, align each

clip with its mounting position and tap them
in by hands. Check the clearance after
installation to ensure excellent appearance.
1.5.9 Removal/Installation of Center Cover

Plate Assembly
Figure 1.5.17 Schematic Diagram of
Center Cover Plate Structure
Removal:
1.5.9.1 Pry a gap which can accommodate

a finger along the contact edge of
dashboard center cover plate
assembly and surrounding parts with a
straight screwdriver;
1.5.9.2 Hold both sides of center cover

plate by hands and slowly pull it up
until all the snap-fits (BYDQ836A01)
and single-side clips in the figure are
399
pulled out completely; Installation:
1.5.9.3 Lift the center cover plate, (a) Check if the removed snap-fit
disconnect the connector of (BYDQ836A01) is installed in its
emergency alarm switch and then pull original position.
out the dashboard center cover plate
assembly. (b) Align each clip with its snap-fit hole
and tap it until assembled securely.
Installation:
(a) Check if 2 removed snap-fits 1.5.11 Removal/Installation of Left/Right

(BYDQ836A01) are installed in the Dashboard Trim Strip
original positions;
(b) Align the structures to be installed 1.5.11.1 Left Dashboard Trim Strip
horizontally;
(c) Tap each assembly area until they are

fixed securely with excellent
appearance.
1.5.10 Removal/Installation of Keyless Start

Panel
Figure 1.5.19 Left Dashboard Trim Strip

Notice:
The left air inlet and left lower protector

should be removed first as they are
connected with the left trim strip.
Figure 1.5.18 Keyless Start Panel
Removal:
Removal:
(a) Remove the left air inlet and left lower
1.10.1 Remove the combination protector in accordance with service
instrument hood panel and center instructions;
cover plate assembly as instructed.
(b) The left trim strip can be removed by
1.10.2 Slowly pull the panel outward by carefully pulling the left trim strip
hands until the snap-fits and outward with both hands until the
single-side clips are pulled out snap-fits (BYDQ836A01) and clips are
completely. Note the start button in the pulled out completely.
middle of panel and connected wire
harness should not be damaged. Installation:
400
The left trim strip should be installed prior to

the left air inlet and left lower protector, align
each snap-fit with its snap-fit hole and
carefully press them in by hands. Check if
the clearance is good after installation.
1.5.11.2 Right Dashboard Trim Strip
Figure 1.5.21 Dashboard Center Upper

Cover Plate
Figure 1.5.20 Right Dashboard Trim Strip

Notice:
The right air inlet should be removed first as

it is connected with the right trim strip.
Removal:
(a) Remove the right air inlet in

accordance with the service
instructions and open the glove box; Figure 1.5.22 Schematic Diagram for
Removal of Center Upper Cover Plate
(b) The right trim strip can be pulled out
from right to left in several times. Removal:
Carefully pull out the trim strip with
both hands. The left trim strip can be (a) Pry a gap which can accommodate a
removed with the elastic deformation finger along the contact edge of
of snap-fit. dashboard center cover plate
assembly and dashboard upper body
Installation: with a straight screwdriver;
The right trim strip should be installed prior (b) Hold both left and right sides of center
to the right air inlet, align each snap-fit with upper cover plate by hands, and
its snap-fit hole and carefully press them in slowly pull it up until 5 clips as shown
by hands. Check if the clearance is good in the figure are pulled out completely.
after installation.
Installation:
1.5.12 Removal/Installation of Center Upper Align each clip with its mounting position
Cover Plate and tap them until they are fixed securely
with excellent appearance.
401
1.5.13 Removal/Installation of Upper Body Assembly
Figure 1.5.23 Schematic Diagram for Removal of Dashboard Upper Body
402
Notice:
(1) Ensure all the related wire harnesses are

disconnected before removal.
(2) Before removing the dashboard upper

body, the left/right A pillar upper protector,
center cover plate assembly, left/right air
inlet assembly, left lower guard assembly
and left/right trim strip should be
removed and related wire connectors
should be disconnected.
Removal:
(a) Remove 3 screws (Q2734216AF31) as

shown with a cross screwdriver;
Figure 1.5.24 Safety Airbag Reserved Cover
(b) Raise the mounting base of 1 clip and 7 Plate
plastic snap-fits on the dashboard upper
body in the direction indicated by the Depending on the vehicle configuration, the
curved arrow to separate them from the safety airbag system or safety airbag cover
dashboard lower body. Do not apply too plate (PAB cover plate) may be used. The
much force, or the plastic snap-fits and repair method of safety airbag cover plate is as
dashboard may be damaged; follows:
(c) Take out the dashboard upper body Notice: The tip of screwdriver must be
assembly in the direction indicated by wrapped with flexible tape to avoid damaging
the straight arrow. the product surface.
Installation: Removal:
The installation of dashboard upper body is in The PAB cover plate can be removed by
reverse order of removal. prying 10 single-side clips along the clearance
between the cover plate and upper body with a
1.5.14 Removal/Installation of Safety Airbag straight screwdriver wrapped with flexible
Reserved Cover Plate tape.
Installation:
The clips can be installed by aligning them

with the mounting position and pressing them
in. After installation, check if the clearance is
even and within the tolerance range.
403
1.5.15 Removal/Installation of Dashboard flange bolt (Q1840816) with a hexagon

Lower Body Assembly socket (No. 10).
1.5.16.3 Separate the tubular beam

assembly from the air conditioner
assembly, and remove 1 hexagon flange
bolt (Q1840616) with a hexagon socket
(No. 8).
1.5.16.4 Separate the fasteners connecting

the tubular beam assembly and body
side metal plate, and remove 2 hexagon
flange bolts (Q1840816) on both left and
right sides with a hexagon socket (No.
Figure 1.5.25 Lower Body Assembly 10).
Removal: 1.5.16.5 Reconfirm the steering column,

other related electrical elements and
(1) Understand the dashboard lower body wire harness are disconnected from the
structure and each fastener position tubular beam and dashboard lower body.
before removing (Refer to figure 5-16-1). After reconfirmation, the tubular beam
and dashboard lower body can be
(2) Remove 9 cross recessed pan head removed from the body by disengaging
tapping screws (Q2216319AF31) with a the left positioning hook as shown in
cross screwdriver, and remove 2 figure 1.5.27 and right positioning hook
hexagon bolts (Q1400616T1F31) with a as shown in figure 1.5.28.
hexagon socket (No. 10).
1.5.16.6 After taking off the tubular beam
(3) After all the wires are disconnected, and wire harness, remove the wire
remove the dashboard lower body in the harness from the tubular beam.
direction indicated by the arrow in figure
5-16-1. Installation:
Installation: The installation of tubular beam assembly is in

Install the locators on the back of dashboard
lower body into the proper positioning holes
and tighten the screws and bolts.
1.5.16 Removal/Installation of Tubular Beam

Assembly
Removal:
1.5.16.1 Separate the tubular beam

assembly from the fasteners of front
compartment metal plate, and remove 2
hexagon flange bolt (Q1840816) with a
hexagon socket (No. 10).
1.5.16.2 Turn over the carpet under the

dashboard, separate the tubular beam
assembly from the fasteners of body
floor metal plate, and remove 2 hexagon
404
Figure 1.5.26 Tubular Beam Assembly
Figure 1.5.27 Dashboard Cross member Retaining Support Components (Left)
405
Figure 1.5.28 Dashboard Cross member Retaining Support Components (Right)
1.6 Auxiliary Instrument Panel Assembly
1.6.1 Diagram of Component Locations
Figure 1.6.1 Auxiliary Instrument Panel Assembly
406
As shown in figure 1.6.1: The auxiliary

instrument panel consists of the following
components, such as left front guard assembly,
right front guard assembly, gear shift operating
mechanism cover plate components, front ash
receptacle box assembly, auxiliary instrument
panel body assembly and auxiliary instrument
panel rear mounting bracket components.
Figure 1.6.3 Auxiliary Instrument Panel Body

Assembly 2
1.6.2 Removal/Installation of Auxiliary

Instrument Panel Assembly Related
Components
Notice:
Figure 1.6.2 Auxiliary Instrument Panel Body
Assembly 1 (a) All personnel for disassembly must be
very familiar with the structure of the
product to avoid any unexpected
As shown in figure 1.6.2 and 1.6.3: The circumstances during the process of
auxiliary instrument panel body assembly disassembly;
consists of the following components, such as
the auxiliary instrument panel body, auxiliary (b) The tip of straight screwdriver must be
instrument panel handrail components, central wrapped with flexible tape when prying
storage box spring switch mechanism to avoid damaging the product surface;
subassembly, rear ashtray subassembly, cup
holder hog ring assembly, cup holder (c) Ensure all the related wire harnesses are
ornament, hand brake sealing strip and rear disconnected before removal.
trim panel. (It also contains the auxiliary
instrument panel storage box rubber cushion, (d) Be careful during removal and
auxiliary instrument panel front/rear carpet cup installation to avoid scratching.
holder, and cup holder rubber cushion and
storage box carpet.)
1.6.2.1 Removal/Installation of Left/Right
Front Guard Assembly
407
tap all the clips in with proper force while

ensuring the appearance requirements
are met.
Figure 1.6.4 Removal of Left Front Guard

Assembly
1.6.2.1.1 Hold the auxiliary instrument panel

body with right hand, and pull the upper
edge of left front guard outward with left
hand to separate 3 clips as shown in
Figure 1.6.5 Removal of Gear Shift
figure 1.6.4. Then pull the cover plate
Operating Mechanism Cover Plate
rearward. See figure 1.6.4 (The removal
Components
and installation of right front guard
assembly are the same as that of left 1.6.2.3 Removal/Installation of Front Ash
front guard assembly). Receptacle Box Assembly
1.6.2.1.2 Installation: Insert the front clips of

Loosen and remove 2 screws (Q2724213
left front guard into the fitting hole of air
cross recessed pan head tapping screw) fixing
conditioner casing, and then align 3 rear
front ash receptacle box and dashboard lower
clips on the left front guard with the
body with a screwdriver. Pry the edge of ash
mounting holes on the auxiliary ashtray
receptacle box base and auxiliary instrument
instrument panel body. Install the
panel body mounting points with a straight
snap-fits with proper force and ensure
screwdriver to separate 2 clips from the
excellent appearance.
mounting holes, and then pull out the clips
completely by hands and remove the ash
1.6.2.2 Removal and Installation of Gear receptacle box assembly. See figure 1.6.6;
Shift Operating Mechanism Cover Plate
Components
1.6.2.2.1 Pry a gap which can accommodate
a finger along the mounting points of
cover plate edge with a straight
screwdriver, then hold and pull out the
cover plate with both hands in the gear
shifting lever direction as shown in figure
1.6.5;
1.6.2.2.2 Installation of gear shift operating

mechanism cover plate components:
Align the positioning clips on the gear
shift operating mechanism cover plate Figure 1.6.6 Removal of Front Ash
with the snap-fits on the auxiliary Receptacle Box Assembly
instrument body from rear to front. Then
408
Installation of front ash receptacle box mechanism of auxiliary instrument panel

assembly: body. At this time, the ashtray can be
removed. See figure 1.6.8;
Align 2 rear positioning clips on the front ash
receptacle box with the mounting holes of
auxiliary instrument panel. Then tap the clips
in place with proper force;
Ensure the front ash receptacle box is aligned

correctly with the screw mounting holes of
dashboard lower body, and then tighten the
screws.
1.6.2.4 Removal/Installation of Rear Trim

Panel
Hold the lower edge of rear trim panel with a
hand, separate all the clips from the snap-fits Figure 1.6.8 Removal of Rear Ashtray
from bottom to top and then take off the rear Subassembly
trim panel. See figure 1.6.7:
1.6.2.5.2 The installation is in reverse order

of removal.
1.6.2.6 Removal/Installation of Auxiliary

Instrument Panel Body Assembly
1.6.2.6.1 The removal of console box trim

strip will not be described herein, as it
has been introduced in relevant sections.
1.6.2.6.2 Removal of USB mounting plate

and wire harness:
Figure 1.6.7 Removal of Rear Trim Panel
1.6.2.5 Removal/Installation of Rear Ashtray

Subassembly
1.6.2.5.1 Remove the rear trim panel, press

up the center of rear ashtray lower edge
and mounting points of auxiliary
instrument panel body from the rear of Figure 1.6.9 Removal of USB Mounting
auxiliary instrument panel body, and then Plate a
rotate the top of ashtray for specified
angle while holding the bottom with left
hand to separate the top from the locking a) Open the armrest to upright position,
409
take out the items in the storage box and

disconnect all the electrical elements Figure 1.6.11 Removal of USB Mounting Plate
from the USB interface. So the USB c
mounting plate is visible. See figure
1.6.9; (1) Remove the storage box carpet from the
storage box, loosen and remove 2 bolts
(Q1400620T1F31 hexagon bolt and flat
washer assembly) fixing the auxiliary
instrument panel body and rear
mounting bracket with the long-handle
No. 10 hexagon socket, and then return
the armrest to its original state. See
figure 1.6.12;
Figure 1.6.10 Removal of USB Mounting

Plate b
b) Carefully pry the mounting plate along
the joint of USB mounting plate and
auxiliary instrument panel body with a
straight screwdriver, and turn it backward
to remove the USB mounting plate. See
figure 1.6.10;
Figure 1.6.12 Removal of Auxiliary
Instrument Panel Set Bolts
c) Disconnect the wire harness from the
USB interface, remove the mounting
(2) Loosen and remove 4 screws (2
plate and lay it aside. See figure 1.6.11;
Q2734216F31 cross recessed pan head
tapping screws and 2 Q2734813F31
cross recessed pan head tapping screws)
fixing the auxiliary instrument body with a
cross screwdriver. See figure 1.6.13;
(3) Shift the gear shifting lever in neutral

position, and pull the hand brake to the
lock position of top dead center.
410
instrument panel body properly so that

the hand brake and gear shifting lever
can pass through the opening on the
body;
c) Connect the USB cable and install the

USB mounting plate;
d) Ensure the mounting holes of auxiliary

instrument are aligned and then tighten
the bolts and screws in order.
Notice: When the above operations are

performed, ensure the auxiliary instrument
panel is not scratched by other items or does
not scratch other parts.
Figure 1.6.13 Removal of Auxiliary Instrument
Panel Set Screws 1.6.2.7 Removal/Installation of Auxiliary
Instrument Rear Mounting Bracket
(4) Slowly move the auxiliary instrument
panel body assembly towards the rear of 1.6.2.7.1 Loosen and remove 3 bolts
vehicle for proper distance so that the (Q1410820T1F3 hexagon bolt and taper
front of auxiliary instrument panel and washer assembly) fixing the auxiliary
dashboard are separated. instrument panel rear mounting bracket
with No. 10 hexagon socket. See figure
(5) Slowly raise the rear of auxiliary 1.6.15;
instrument panel body by hand so that it
has a proper angle with the floor. 1.6.2.7.2 The installation is in reverse order
Meanwhile, raise the entire body, slowly of removal.
pass the gear shift mechanism and hand
brake through the through-holes on the
auxiliary instrument panel body, and then
remove the body. See figure 1.6.14;
Figure 1.6.14 Removal of Auxiliary

Instrument Panel Body
(6) Installation of auxiliary instrument panel
body:
a) Ensure the gear shifting lever is in Figure 1.6.15 Auxiliary Instrument Panel
neutral position and the hand brake is in Rear Mounting Bracket
the lock position of top dead center;
b) Adjust the inclination of auxiliary
411
1.6.3 Removal/Installation of Auxiliary

Instrument Panel Body Assembly Components
Notice:
(a ) All personnel for disassembly must be

circumstances during the process of
disassembly;
(b) The tip of straight screwdriver must be

wrapped with flexible tape when prying
to avoid damaging the product surface.
1.6.3.1 Removal/Installation of Cup Holder

Hog Ring Assembly and Cup Holder Figure 1.6.17 Removal of Cup Holder
Ornament Ornament
(3) Installation of cup holder hog ring
(1) Removal of cup holder hog ring assembly and cup holder ornament:
assembly: The cup holder hog ring
assembly can be removed directly from a) Install the cup holder hog ring assembly
the cup holder in the direction as shown in the reverse order of removal.
in figure 1.6.16.
b) Installation of cup holder ornament: Align
the positioning clips with mounting
positions from rear to front, and then
install the clips with proper force while
ensuring the appearance requirements
are met.
1.6.3.2 Removal/Installation of Central Storage

Box Spring Switch Mechanism Subassembly
1.6.3.2.1 Open the armrest to upright

position; Loosen 2 screws
(Q2203513T1F31 cross recessed pan
head tapping screw and flat washer
Figure 1.6.16 Removal of Cup Holder assembly) fixing the switch mechanism
Hog Ring with a cross screwdriver, and remove the
(2) Removal of cup holder ornament: Slowly switch mechanism. See figure 1.6.18;
pry the joint edge of cup holder ornament
and auxiliary instrument panel body with
a straight screwdriver until all the clips
(10) are separated, and then remove the
cup holder ornament by hand. See figure
1.6.17;
412
(a) Loosen 2 screws (Q2734216AF31 cross

recessed pan head tapping screw) fixing
the handrail turnover hinge and handrail
inner panel with a cross screwdriver, and
remove the handrail turnover hinge;
Then loosen 4 screws (Q2783595AF31
cross recessed countersunk head
tapping screw) fixing the handrail inner
and outer panels with a cross
screwdriver, and remove the handrail
inner and outer panels. See figure 1.6.20
and 1.6.21;
Figure 1.6.18 Removal of Central Storage

Box Spring Switch Mechanism Subassembly
1.6.3.2.2 The installation of central storage

box spring switch mechanism
subassembly is in reverse order of the
above removal.
1.6.3.3 Removal/Installation of Auxiliary

Instrument Panel Handrail Components
1.6.3.3.1 Open the handrail component to

upright state, loosen 2 screws
(Q2214216F31 cross recessed pan head Figure 1.6.20 Disassembly of Auxiliary
tapping screw and big washer assembly) Instrument Panel Handrail Component 1
fixing the handrail component with a
cross screwdriver and remove the entire
handrail component. See figure 1.6.19;
Figure 1.6.21 Disassembly of Auxiliary

Instrument Panel Handrail Component 2
(a) The auxiliary instrument panel

handrail covering is bound on the
handrail outer panel with staples;
Figure 1.6.19 Removal of Auxiliary (b) Pull out the storage box cushion
Instrument Panel Handrail Component from the handrail inner panel. See
figure 1.6.22;
413
tape to separate the plastic snap-fit from the

metal plate. Then remove the pins of A pillar
lower protector from the mounting holes of
dashboard so that the A pillar upper protector
can be removed.
Schematic diagram for removal of A pillar

upper protector:
Figure 1.6.22 Disassembly of Auxiliary

Instrument Panel Handrail Component 3
(a) The assembly of auxiliary instrument

panel handrail component is in reverse
order of the above disassembly.
Tips:
1.7 Side Body
1.7.1 Before removal, wrap the flat tip driver
with soft tape to avoid scratching the
protector. (The same below)
1.7.2 The damaged plastic snap-fits must be

replaced during installation.
1.7.2 Removal/Installation of Front/Rear Door

Sill Inner Protector
Pry the clips connecting the protector with A

pillar lower protector and B pillar lower
protector from inside with a straight
screwdriver or by hands, separate the
protector from A pillar lower protector and B
pillar lower protector by applying force upward
from both ends, and then separate the
Removal and Installation protector from the E-shape snap-fit.
Tools: essential special tools, operating Schematic diagram for removal of front door
equipment, tester and auxiliary tools sill inner/outer protector:
The following removal method is for left

side of the vehicle. The removal and
installation of right side of the vehicle is the
same as that of left side.
1.7.1 Removal/Installation of A Pillar Upper

Protector
Remove the sealing strip, and pry out the front

section of A pillar upper protector with a
Tips:
straight screwdriver wrapped with protective
414
The front door sill inner protector with

damaged clamps should be replaced, and
then perform installation.
The removal method of left rear door inner

protector is the same as that of front door sill
inner protector. The schematic diagram is as
follows:
Tips: During assembly, the door sill inner and

outer protector with damaged clips should be
replaced.
1.7.4 Removal/Installation of A Pillar Lower

Protector
Tear the sealing strip and remove the front

door sill protector. Then remove the plastic
bolt type plastic snap-fit 1. At last, disengage
the snap-fit 2 with a flat tip driver so that the A
1.7.3 Removal/Installation of Left Front/Rear pillar lower protector can be removed.
Door Sill Inner Protector
The left front door sill outer protector is only

fitted on the metal plate. Pry the protector
along the gap with a straight screwdriver, and
then remove the protector by applying force
upward by hand. To prevent scratching the
metal plate, the straight screwdriver must be
wrapped with tape or cloth.
Tips: Replace the damaged plastic

snap-fit during installation
The removal method of rear door sill inner 1.7.5 Removal/Installation of B Pillar Lower
protector is the same as that of front door sill Protector
inner protector. The schematic diagram is as
follows: Remove the front seat and font/rear door sill
protector and tear the sealing strip. Disengage
the snap-fits on the B pillar lower protector and
clips fixed on the upper protector so that the B
pillar lower protector can be removed.
415
Tips: Replace the damaged plastic snap-fit

1.7.7 Removal/Installation of C Pillar Lower

Protector Assembly
Remove the rear seat and rear door sill

protector and disengage the snap-fit 1 and 2
connecting C pillar lower protector and metal
plate. Meanwhile, remove the clamp 3
connected to C pillar upper protector so that C
pillar lower protector can be removed.
Tips: Replace the damaged plastic

snap-fit during installation.
1.7.6 Removal/Installation of B Pillar Upper

Protector Assembly
Remove the screw 1 and 2 with a cross

screwdriver and disengage the snap-fit 3
connecting B pillar upper protector and metal
plate with a flat tip driver. The B pillar upper
protector assembly can be removed by
applying force in Y direction. At last, remove
the square nuts on the metal plate. Tips: Replace the damaged plastic snap-fit
1.7.8 Removal/Installation of C Pillar Center

Protector Assembly
The C pillar center protector can be removed

by applying force in the direction indicated by
the arrow in the figure below to disengage the
C pillar center protector from the upper
protector.
416
The C pillar upper protector can be removed

by taking out the structure connected to
carrier.
1.7.9 Removal/Installation of C Pillar Upper

Tips: Replace the damaged plastic snap-fit
Protector
Carrier
Disengage the snap-fit connecting C pillar
upper protector and metal plate by applying
force in the arrow direction with a flat tip driver.
417
1.8 Back Trim
418
1.8.1 Removal/Installation of Shelf Assembly the shelf mounting holes.
1.8.1.1 Confirm the C pillar left/right protector 1.8.1.3 The assembly of shelf is in reverse
and seats has been removed before order of removal and the damaged snap-fit
removing the shelf. Release the safety belt should be replaced. The left and right child
from the shelf opening as follows: safety lock covers can be operated in
random order.
1.8.2 Removal and Installation of Back Pedal

Assembly and Trunk Tool Box
The shelf can be removed.
Removal of Back Pedal
1.8.2.1 Remove the vane snap-fits and then

disengage 4 clips on the side from the
metal plate holes by applying force from
inside of pedal (in the direction indicated
Figure 1.8.1 Safety Belt Layout by 1). The protector can be removed by
pulling up the protector and separating 2
The shelf is assembled on the back metal clips on the top from the metal plate.
plate with 4 snap-fits and 5 pins. Separate
4 snap-fits from the shelf metal plate holes
by applying force near the front of shelf in
the direction indicated by arrow 1. Then
pull out the shelf in the direction indicated
by arrow 2 to separate the pins from the
reinforced cross member mounting holes.
Figure 1.8.2 Rear Shelf Mounting Points
1.8.1.2 Removal of Child Safety Lock Cover
Figure 1.8.5 Schematic Diagram for Removal

of Back Pedal

of Child Safety Lock Cover
Open the child safety lock cover (in the

direction indicated by arrow 1), and then push Figure 1.8.5 Schematic Diagram for Removal
the lock cover rotating shaft to one side along of Back Pedal
the rotating shaft direction to disengage it from
To separate the clamps from the metal plate
419
mounting holes smoothly, the pedal should be

rotated for certain angle during removal (in
arrow direction).
1.2 Removal of Back Pedal Lock Ring Cover
Right Trunk
Panel
Trunk Tool
Box Back Pedal
The assembly of back panel assembly

components is in reverse order of removal and
the damaged vane snap-fit should be
replaced.
Figure 1.8.4 Back Pedal Layout
1.9 Removal/Installation of Door Guard Plate
Pry the cover up in the illustrated position with
a straight screwdriver, and then remove the 1.9.1 Removal/Installation of Front Door
cover by pulling it out in the direction indicated Guard Plate
by arrow 2.
1.9.1.1 Remove the inner handle cover plate
with a flat tip screwdriver wrapped with
protective tape. The edge of inner handle
cover plate has a notch to make removal
easier. Do not scratch the switch panel
and door guard plate.

of Back Pedal Lock Ring Cover
(a) Removal of Trunk Tool Box
The tool box is installed on the trunk panel by

its clips and it can be removed by pulling it up
directly.

of Trunk Tool Box
420
Figure 1.9.3 Window Control Panel
Figure 1.9.1 Inner Handle Cover Plate The circled areas in the above figure
are connected with snap-fits.
1.9.1.2 Remove the inner wedging block cover
plate with a flat tip driver wrapped with 1.9.1.4 Pull out the wire harness connectors
protective tape. Do not scratch the inner on the window control panel in the
wedging block handle and lock button. direction indicated by the arrow.
Figure 1.9.4 Window Control Panel Connector

Figure 1.9.2 Inner Wedging Block Cover Plate
1.9.1.5 Remove the screw in the inner handle
1.9.1.3 Remove the window control switch with a cross screwdriver.
from rear to front with a flat tip driver
wrapped with protective tape. Do not
scratch the window control panel and door
guard plate. There is a large fastener on
both front and rear of window control panel.
More force may be needed when removing
the window control panel. Do not scratch
the handrail covering, window control
panel and door guard plate during
removal.
421
Figure 1.9.7 Removal of Door Guard Plate
The door guard plate and metal plate are

connected by the snap-fits in the above figure.
Figure 1.9.5 Inner Handle Screw
1.9.1.8 Remove the door guard plate in the
1.9.1.6 Remove the screw in inner wedging direction indicated by the arrow. The
block base. Do not scratch the wedging wedging block base has not been
block handle and door guard plate. disengaged from the door lock wire
harness. The removal of door guard plate
assembly can be completed by separating
the door lock wire harness from the
wedging block base.
Figure 1.9.6 Inner Wedging Block Screw
Please properly store the screw to avoid

missing.
1.9.1.7 Pry the door guard plate in the position Figure 1.9.8 Removal of Door Guard Plate
indicated by the arrow with a flat tip driver
wrapped with protective tape and remove 1.9.1.9 Pull out the unlocking cable from the
it from the door metal plate. The front door wedging block base in the direction
guard plate is connected by 10 snap-fits indicated by arrow 1, and then pull out the
which needs more force to remove. Do not pin at end of door lock wire harness from
scratch the door guard plate and metal the inner wedging block handle hole.
plate.
422
Figure 1.9.11 Removal of Corner

Figure 1.9.9 Removal of Unlocking Cable Guard Plate
1.9.1.10 Remove the locking cable. The 1.9.1.12 The front door guard plate of luxury
removal and installation methods are the and flagship models has a door lamp.
same as that in the above figure.
Press the button on the connector in the
Ensure the position of 2 wire harnesses is direction indicated by arrow 1, and then pull
correct during assembly. Do not mix them. out the connector from the door lamp in the
direction indicated by arrow 2.
Figure 1.9.10 Removal of Locking Cable Figure 1.9.12 Removal of Door Lamp
1.9.1.11 Removal/installation of corner guard After the above procedure is completed,

plate remove the front door guard plate from the
Pull out the corner guard plate from the door metal plate and lay it on a flat surface to
metal plate in the direction as shown. avoid scratching the front door guard plate and
window control panel. Do not bend it during
removal to avoid wrinkling or breakage.

removal and observe the following
precautions:
Replace any damaged plastic snap-fit;
Make sure the door lamp is installed securely,
423
and the inner wedging block cable and

connectors of window control panel are
connected correctly;
Check if the window and power door lock

function normally.
Notice: Please properly store the removed

components to avoid missing.
The installation of door guard plate is in

Do not mix the wire harness of cable and

locking wire harness to avoid unnecessary Figure 1.9.14 Inner Wedging Block Cover
consequences caused by incorrect installation. Plate
1.9.2 Removal/Installation of Rear Door Guard 1.9.2.3 Remove the window control switch
Plate from rear to front with a flat tip driver
wrapped with protective tape. Do not
1.9.2.1 Remove the inner handle cover plate scratch the window control panel and door
with a flat tip screwdriver wrapped with guard plate. There is a large fastener on
protective tape. The edge of inner handle both front and rear of window control panel.
cover plate has a notch to make removal More force may be needed when removing
easier. Do not scratch the switch panel the window control panel. Do not scratch
and door guard plate. the handrail covering, window control
panel and door guard plate during
removal.
Figure 1.9.13 Inner Handle Cover Plate

Figure 1.9.15 Window Control Panel
1.9.2.2 Remove the inner wedging block cover
plate with a flat tip driver wrapped with The circled areas in the above figure are
protective tape. Do not scratch the inner connected with plastic snap-fits.
wedging block handle and lock button.
1.9.2.4 Pull out the wire harness connectors
on the window control panel in the
direction and order indicated by the arrow.
424
Figure 1.9.18 Inner Wedging Block Screw

Figure 1.9.16 Window Control Panel Please properly store the screw to avoid
Connector missing.
1.9.2.5 Remove the screw in the inner handle 1.9.2.7 Pry the door guard plate in the position
with a cross screwdriver. indicated by the arrow with a flat tip driver
wrapped with protective tape and remove
it from the door metal plate. The rear door
guard plate is connected by 8 snap-fits
which needs more force to remove. Do not
scratch the door guard plate and metal
plate.
Figure 1.9.17 Inner Handle Screw
1.9.2.6 Remove the screw in inner wedging

block base. Do not scratch the wedging
block handle and door guard plate.
1.9.2.8 Remove the door guard plate in the

direction indicated by the arrow. The
wedging block base has not been
disengaged from the door lock wire
harness. The removal of door guard plate
assembly can be completed by separating
the door lock wire harness from the
wedging block base.
425
Figure 1.9.22 Removal of Locking Cable

After the above procedure is completed,
1.9.2.9 Pull out the unlocking cable from the remove the rear door guard plate from the
wedging block base in the direction door metal plate and lay it on a flat surface to
indicated by arrow 1, and then pull out the avoid scratching the front door guard plate and
pin at end of door lock wire harness from window control panel. Do not bend it during
the inner wedging block handle hole. removal to avoid wrinkling or breakage.

removal and observe the following
precautions:
Replace any damaged plastic snap-fit;
Make sure the inner wedging block cable and

connectors of window control panel are
connected correctly;
Check if the window and power door lock

function normally.
Figure 1.9.21 Removal of Unlocking Cable
Notice: Please properly store the removed
1.9.2.10 Remove the locking cable. The components to avoid missing.
removal and installation methods are the
same as that in the above figure. The installation of door guard plate is in
Ensure the position of 2 wire harnesses is
correct during assembly. Do not mix them. Do not mix the wire harness of cable and
locking wire harness to avoid unnecessary
consequences caused by incorrect installation.
426
1.10 Removal/Installation of Sun Screen

Assembly
1.10.1 Diagram of Sun Screen Component

Locations
Figure 1-10-3 Disassembly of Sun Screen

Components 2
1.10.2.4 Remove the front sun screen support

Figure 1-10-1 Schematic Diagram of Sun after the removal of sun screen. Rotate
Screen Components the front sun screen support 90 degree
around its own center and pull it out in
1.10.2 Removal/Installation of Sun Screen the direction indicated by the arrow.
Assembly
1.10.2.1 Turn the sun screen from unused

state to approximate vertical state.
1.10.2.2 The mounting screw can be seen by

prying open the mounting base cover plate
with a straight screwdriver as show below.

Components 3
1.10.3 Installation of Sun Screen Assembly
The installation of sun screen assembly is in


Components 1
1.10.2.3 Remove the mounting screw with a

cross screwdriver and then pull out the sun
screen revolving sleeve from the front sun
screen support. At this time, the entire sun
screen can released and removed.
427
1.11 Removal and Installation of Roof

Handrail
The installation structure of 3 roof handrails

is the same. Perform removal and
installation according to the following steps.
1.11.1 The bolts can be seen by opening the

holder cover plate.
Figure 1-12-1 Schematic Diagram for

Removal of Ceiling (with sun roof)
Figure 1-11-1 Disassembly of Roof Handrail

1
1.11.2 Unscrew the mounting screws and

remove the safety handle.
Unscrew the mounting bolts

(BYDQ184D0645T1F3 Hexagon Flange Bolt)
with a socket and remove the entire safety
handle.
1.11.3 The installation of roof handrail is in

1.12 Removal/Installation of Ceiling

Removal of Ceiling (without sun roof)
As shown in figure 1-12-1: High-profile

ceiling (with sun roof);
As shown in figure 1-12-2: Low-profile ceiling

(without sun roof). The installation method is
the same.
Removal and installation of ceiling assembly:
428
The ceiling can be removed only after the

front door frame sealing strip, rear door
frame sealing strip, A pillar inner guard plate,
B pillar inner guard plate, C pillar inner guard
plate, inner rear view mirror, front interior
light, rear interior light, sun screen and safety
handle (For removal method, refer to
relevant sections).
Notice:
1.12.1 All personnel for disassembly must be

circumstances during the process of
Carpet Assembly
disassembly;
1.13.2 Removal/Installation of Carpet
1.12.2 The tip of straight screwdriver must be
wrapped with flexible tape when prying to
The carpet can be removed after the
avoid damaging the product surface.
auxiliary instrument panel, front seat, rear
seat, electrical cover of carpet (L3 flagship
1.12.3 For models with a sun roof, the
version), A pillar lower guard plate, B pillar
removal and installation of ceiling should
lower guard plate, C pillar lower guard plate,
be performed according to step (1) and
front door sill guard plate, rear door sill guard
(2); for models without sun roof, the
plate and quarter lower guard plate (For
removal and installation of ceiling should
removal method, refer to relevant sections)
be performed only according to step (2).
are removed.
(a) Pry open the sealing strip at the sun
1.13.2.1 Removal procedures:
roof;
a. Carpet retainer: Pry the head of
(b) The ceiling can be removed by
snap-fit lightly with a straight
locating 3 mounting snap-fits on the
screwdriver, and then take it out by
rear of ceiling (See the above figure
hand. The snap-fit in figure 1-13-2
1-12-1 and 1-12-2) and pry them off
can be removed by using the same
the tonneau cover with a straight
method. Hold the rear edge of
screwdriver.
carpet with both hands, and then
slowly pull out the carpet
(c) The installation of ceiling is in
horizontally until the entire carpet
assembly can be taken out.
1.13 Removal/Installation of Carpet
1.13.1 Diagram of Carpet Component

Locations
429
Figure 1-13-2 Structure Figure of removed. For detailed removal

Carpet method, refer to relevant sections.
b. The carpet can be removed after b. Remove all the components fixed on
taking out the foot rest, carpet foam the heat insulation layer of front
pad, lower spacer of carpet and compartment, and then separate the
rear spacer of carpet as shown in heat insulation layer of front
figure 1-13-3. compartment from the metal plate
(Note: The nut type plastic snap-fits
must be removed before the removal
of upper heat insulation layer of front
compartment).
1.14.1.2 Installation of Heat Insulation Layer

of Front Compartment:
Attach the heat insulation layer of front

compartment to the front of cowl panel, and
then fix the heat insulation layer after
installing other components on the cowl
panel.
Figure 1-13-3 Schematic Diagram for 1.14.2 Removal/Installation of Cowl Heat
Carpet Spacer insulation layer
1.13.2.2 The installation of carpet assembly
is in reverse order of the above removal.
1.14 Removal/Installation of Heat Insulation

Layer
1.14.1 Removal and Installation of Front

Compartment Heat Insulation Layer
Figure 1-14-2 Schematic Diagram for Cowl

Heat Insulation Layer
1.14.2.1 Removal procedures
Figure 1-14-1 Schematic Diagram for Heat a. Before the removal of cowl heat
Insulation Layer of Front Compartment insulation layer, the dashboard
assembly, auxiliary instrument panel
1.14.1.1 Removal of Heat Insulation Layer of assembly, carpet, tubular beam, and
Front Compartment DV, air conditioner and wire harness
installed on the tubular and
a. The power drive assembly, brake line, dashboard, brake pedal, clutch pedal,
wire harness of front compartment accelerator pedal and steering
and vacuum booster pump should be column should be removed; For
removed before the heat insulation removal method, refer to relevant
layer of front compartment is sections.
430
b. Pry open the E-shape snap-fit with a

flat tip driver. Loosen and remove 6
vane snap-fits on both sides (As
shown in figure 1-15-2). Separate the
upper edge of heat insulation layer
from the hangers of metal plate and
then pull the cowl heat insulation
layer backward from the metal plate.
1.14.2.2 The installation of cowl heat

insulation layer is in reverse order of the
above removal.
1.14.3 Removal and Installation of Heat

Insulation Layer of Auxiliary Instrument
Panel Figure 1-14-4 Schematic Diagram for Heat
Insulation Layer of Front Compartment
1.14.4.1The heat insulation layer of front

compartment cover can be removed by
opening the front compartment cover,
lightly prying the press-in type plastic
snap-fit with a straight screwdriver and
pulling it up by hand.
1.14.4.2 The installation of heat insulation

layer of front compartment is in reverse
order of the above removal.
1.15 Removal and Installation of Trunk

System
(a) Diagram of Trunk System Component

Locations
Figure 1-14-3 Schematic Diagram for Heat
Insulation Layer of Auxiliary Instrument Panel
1.14.3.1 The heat insulation layer of auxiliary

instrument panel can be removed after
the auxiliary instrument panel, hand
brake components, gear shift
mechanism, carpet and related wire
harness (For removal method, refer to
relevant sections). The removal is
completed after the spacer of heat
insulation layer is taken off.
1.14.3.2 The installation of heat insulation

layer of auxiliary instrument panel is in
1.14.4 Removal and Installation of Heat Figure 1-15-1 Schematic Diagram for Trunk
Insulation Layer of Front Compartment System
431
(b) Removal/Installation of Trunk System
1.15.1 Components that can be taken out

directly (Without fixing by fasteners)
In the trunk, the trunk cover plate is on the

top and the trunk tool box is on the left (as
shown in figure 1-13-6). They can be taken
out directly.
1.15.2 Removal/Installation of Back Pedal
Figure 1-15-3 Structure Figure of Trunk

Maintenance Cover
(a) Pry position A in the figure with a straight

screwdriver to loosen the clamps. The
entire component can be removed by
pulling a short distance in the indicated
direction.
(b) The removal for trunk maintenance cover

on both sides is same.
Figure 1-15-2 Structure Figure of Back Pedal (c) The installation of trunk maintenance
cover is in reverse order of removal.
(a) The back pedal can removed after the 1.15.4 Removal/Installation of Left/Right
trunk cover plate assembly and trunk tool Trunk Panel
box are taken out:
Pry the head of snap-fit lightly with a straight

screwdriver, and then take it out by hand.
The back pedal can be removed after 2
snap-fits in the figure are removed. Notice:
The back pedal itself has clamps. Do not
damage the product during removal.
(b) The installation of back pedal is in

1.15.3 Removal of Trunk Maintenance Cover
Figure 1-15-4 Structure Figure of Left Trunk
432
Panel
1.15.5.1 The trunk lid panel can be taken off
1.15.4.1 The panel can removed after the after prying and removing all the
trunk cover plate, trunk back pedal and snap-fits with a straight screwdriver.
trunk tool box are taken out:
1.15.5.2 The installation is in reverse order of
1.15.4.2 Pry the head of snap-fit lightly with a removal.
straight screwdriver, and then take it out
by hand. The panel can be taken out
after 5 snap-fits in the figure are
removed.
1.15.4.3 The removal of right trunk panel is

the same as above.
1.15.4.4 The installation of left/right trunk

panel is in reverse order of removal.
1.15.5 Removal/Installation of Upper Spacer

of Trunk Wheel Housing
1.15.5.1 The upper spacers of trunk wheel

housing on both left and right sides can
be taken out after removing the trunk
cover plate, trunk cowl pedal and
left/right trunk panel.
1.15.5.2 The installation is in reverse order of

removal.
1.15.6 Removal/Installation of Trunk Lid

Panel
BYDQ320S05
Figure 1-15-5 Structure Figure of Trunk Lid

Panel
433
1.16 Rear License Plate Lamp Trim Strip Assembly
1.16.1 General
The structure and assembly position of rear license plate lamp trim strip are shown in the figure
below:
1.16.2 Specific removal procedures for rear

license plate lamp trim strip assembly: Figure 1-16-1
Prepare the remover, socket M8, M10 and flat Remove 6 hexagon flange nuts (as shown in
tip driver before removal. Please wear a pair of figure 1-16-2) with socket M8 or other tools.
gloves before removal to protect your hands.
Be careful not to scratch the body during
removal. Perform the removal according to the
following steps:
1.16.2.1 Open the trunk lid and remove 3

hexagon flange nuts (as shown in figure
1-16-1) from the inside of trunk lid with
Figure 1-16-2
socket M10 or other tools. 2 nuts are used
by trunk lock I and 1 nut is used by trunk
1.16.2.2 Remove the connector of trunk lid
lock II.
lock I and trunk lid lock II.
After the hexagon flange nuts are removed,

remove the connector of trunk lid lock I by
hand along the direction indicated by the arrow
in figure 1-16-3. Remove 2 mounting points
shared by rear license plate lamp trim strip and
trunk lid lock II, and remove the lock from the
trim strip.
434
Figure 1-16-3
1.16.2.3 Remove the snap-fits for plate on

both ends of rear license plate lamp trim
strip
Remove the snap-fits for plate (as shown in Figure x1-16-4

figure 1-16-4) on both ends of trim strip with a
flat tip driver, slightly swing the trim strip to 1.16.2.4 The removal of trim strip can be
remove it, and then remove the trim strip with completed by removing the trunk lid lock I,
trunk lock I from the metal plate. 6 square-head bolts, and 2 snap-fits for
plate, seal ring, trim strip cap and sealing
strip from the trim strip.
1.16.2.5 The installation of trim strip is in

reverse order of removal, which will not be
described herein.
Notice: Do not scratch the outer surface of trim

strip during removal. Before removing the rear
license plate lamp trim strip, disconnect the
connectors related to the electrical devices to
avoid connector breakage.
435

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BYD AUTO BYD Suri Maintenance & Repair Manual

Engine & Transmission

Section 4 Transmission Assembly ................................................................................. 193

Chapter 1 BYD473Q Engine

Part 1 Engine .................................................................................................................................... 4

5th gear 0.730

1.2 Technical Specifications for Maintenance

Engine Cylinder Head

Engine Cylinder Block

1.3 BYD473QE/QB Tightening Torque Table of Gasoline Engine

Tightened Tightening Torque

1.4 BYD473Q List of Different Elements of Gasoline Engine

Part Number BYD473QB BYD473QE

Front Lambda Sensor BYD473QA-3611080 BYD473QE-1211100

Section 2 Cylinder Head

2.1.1 Remove the cylinder head cover.

2.1.2 Turn the crankshaft and place 1

2.1.6 Tighten the adjusting lock nut and

2.1.7 Turn the crankshaft clockwise. Align

2.1 4 Insert a feeler gauge between the

2.1.5 If the resistance is too big or small,

2.2 Removal and Installation of

Remove bolts on the crankshaft damper pulley

2.3.4 Turn the crankshaft damper pulley and

2.2.3 Tighten the bolts on the pulley to 90°.

2.3 Removal and Installation of Timing

Note: Keep the timing chain away from the

Removal 2.3.6 Remove the cylinder head cover.

2.3.9 Support the engine from the cylinder

2.3.10 Keep the generator away from the

2.3.11 Apply engine oil on the surface of the

2.3.14 Remove the timing chain.

Note: Keep the timing chain away from the

2.3.14.5 Apply engine oil on the threads of the

2.3.14.6 Install the tensioner seat and then

2.3.14.4 Install the timing chain on the

2.3.14.13 Install the timing cover.

2.3.14.9 Check the crankshaft front seal of the

2.3.14.10 Remove the old flange sealant on

2.3.14.11 Clean the timing cover's mating

Note: 2.3.14.17 Install the water pump pulley.

The parts should be installed within 4

2.3.14.20 Install and adjust the belt. 34.5 mm -35.2 mm

2.4 Installation of Crankshaft Front Seal

2.6 Removal of Cylinder Head

a Use a fender cover to avoid damaging

b To avoid damage, hold the connectors

c To avoid damaging the cylinder head,

d To avoid wrong connection, do mark

e Keep the timing chain away from the

2.6.1 Drain engine coolant.

2.6.9 Remove the engine wire harness

2.6.9.1 Engine coolant temperature sensor

2.6.9.2 Camshaft phase sensor connector

2.6.9.4 Knock sensor

2.6.10 Remove the connected wire harnesses,

2.6.11 Remove the water outlet tube

2.6.12 Remove the cylinder head cover.

2.6.16 Remove the water pump pulley.

2.6.17 Remove the crankshaft damper pulley.

2.6.18 Support the engine from the bottom of

Note: Do not place the jack on the center

2.6.19 Remove the ground cable and then