foton traveller dashboard warning lights

The 89 Most Common Symbols On Your Car’s Dashboard

Updated: March 21, 2024

We’re all familiar with that moment of uncertainty when a warning light flashes on our car’s dashboard. It leaves us scrambling for the manual, attempting to decipher what the illuminated symbol signifies.

In this article, we will guide you through the top 89 most common car dashboard symbols and their meanings, empowering you with knowledge for the next time a warning light appears. By recognizing what these lights indicate, you can sidestep expensive repairs in the future.

Some dashboard symbols and warning lights are more common than others. Some are specific to certain car brands, while others will be seen on most car models on the market. We will begin by showing you the most common dashboard symbols that can be found in most car brands.

Here is a list of the dashboard symbols, and you can click on each name to get more information about the specific warning light.

Engine & Emission

1. Check Engine Light

A Check Engine light indicates an issue with the engine or the emissions. It can be shown either as an engine symbol or as plain text reading “Check Engine”. Read More

2. Anti-lock Braking System

An ABS light indicates there is an issue with your anti-lock brakes or Anti-lock braking system (ABS). Read more

3. Airbag Indicator

An airbag light means that there is an issue with the airbag system. The airbags will not deploy in an accident with the light on. Read more

4. Oil Level Warning Light

A yellow oil level warning light indicates a low engine oil level. The oil level should be checked as soon as possible. Most likely due to an oil leak.

5. Oil Pressure Warning

A red oil pressure light indicates low oil pressure in the engine. Your engine should be switched off immediately to avoid damage when the oil pressure warning light shows. Read more

6. Battery Charge Warning

A battery charge warning symbol means that the generator is not charging the battery properly and that your engine is at risk of shutting down due to low battery capacity. Read more

7. Coolant Temperature Warning Light

An engine temperature warning light means that the engine coolant temperature is high and that the engine should be turned off immediately to avoid further damage. Read more

8. Tire Pressure Warning Light

A tire pressure warning light indicates low air pressure in one or more tires. It can also be caused by a faulty or uncalibrated tire pressure sensor. Read more

9. Traction Control/ESP Light

An ESP or Traction control light indicates an issue with the traction control system. Your traction control system will not work when the light is on, and this can be dangerous. Read More

10. Service Engine Soon

A Service Engine Soon message indicates minor trouble with the engine or low fluid levels. Read more

11. Low Washer Fluid Light

A washer fluid symbol means that the windshield washer fluid level is low or has incorrect measurements.

12. Automatic Shift Lock Symbol

An automatic shift lock symbol indicates the brake pedal is not pressed. The car will not start, and the shifter won’t move out of Park.

13. Reduced Engine Power

A Reduced engine power car light means that there is an issue with the engine and the power is reduced to protect the engine. Read more

14. Lambda Warning Light

A lambda warning light indicates there is an issue with the air-fuel mixture or an issue with the oxygen sensors. This light is more common in older car models.

15. Low Coolant Indicator

A low coolant warning light indicates there is a low coolant level in the coolant reservoir or an issue with the coolant level sensor. Check for leaks around the radiator, radiator cap , coolant hoses, or water pump.

16. Glow Plug Indicator (Diesel)

A glow plug symbol indicates there is an issue with the glow plugs or the glow plug control system.

17. Fuel Filter Level Warning

A fuel filter level warning light means that the water-trap in the fuel level is full and needs to be emptied.

18. Power Steering Level Symbol

A power steering level warning light indicates the power steering fluid level is low, or there is an issue with the level sensor.

19. Electronic Throttle Control Light

An electronic throttle control (ETC) warning light indicates there is an issue with the engine’s electronic throttle body or the system.

20. Particle Filter Warning (Diesel)

A diesel particulate filter warning light indicates there is an issue with the diesel particulate filter system (DPF), or that the particle filter is full and needs regeneration or replacement.

21. Low Fuel Level

A low fuel level symbol means that the fuel tank level is low or that there is an issue with the fuel level measuring system. There could also be an arrow, indicating which side your gas cap is on.

22. Catalytic Converter Warning

A catalytic converter warning light indicates there is an issue with the catalytic converter control system, or the catalytic converter is damaged.

23. Master Warning Light

A master warning light normally shows up together with another warning light and means that there is an issue with your car. Let a mechanic take a look.

24. Blinking Engine Light

A blinking or flashing engine light indicates there is an issue with your engine ongoing right now. A flashing light is normally triggered by a misfiring engine. Read more.

25. Transmission Temperature Warning

A transmission temperature warning light indicates the transmission temperature is too high, or there is an issue with the temperature measurement.

26. Traction Control Off

The traction control off symbol means that the traction control is manually switched off.

27. Powertrain Fault

A powertrain fault symbol indicates there is an issue with the powertrain or drivetrain system, like the 4WD or AWD system, for example.

28. Overdrive Off indicator

An overdrive off symbol means that the automatic transmission overdrive system is switched off. Read more

29. Parking Brake Light

A parking brake warning light indicates the parking brake is engaged, or there is an issue with the parking brake system

30. Differential Temperature Warning

A differential temperature warning light indicates the differential temperature is too high, or there is an issue with the measurement system.

31. DTC Warning Light

A DTC warning light means that there is an issue with the BMW traction control system.

32. ESP BAS

An ESP BAS warning light indicates an issue with the electronic stability program or brake assist program.

33. Automatic Gearbox Warning

An automatic gearbox warning indicates an issue with the automatic transmission or the system controlling it.

34. Brake Pad Warning

A Brake pad warning light means that the front or rear brake pads are worn and need to be replaced.

35. Brake Warning Light

A brake warning light indicates an issue with the brake system. This should be checked immediately because you may lose your brakes otherwise.

36. Service Vehicle Soon

A service vehicle soon symbol indicates there is an issue with the ABS, traction control, or electric suspension system.

37. 4WD Engaged Indicator

A 4WD engaged symbol means that the four-wheel-drive system is engaged.

38. 2WD Engaged Indicator

A 2WD engaged symbol indicates the 4WD system is switched off and the car is sending power to two wheels only.

39. All Wheel Drive (AWD/4WD)

An All Wheel Drive symbol indicates that the AWD or 4WD system is engaged.

40. Hazard Lights On

A hazard lights symbol means that the hazard lights are turned on.

41. Door Ajar Symbol

A door ajar symbol indicates that one of the doors is open or there is an issue with the door switch system.

42. Hood Open

A hood open symbol indicates that the hood is not closed properly. It is very dangerous to drive with a hood that is not secured at higher speeds.

43. Lane Departure Warning

A lane departure warning light indicates the vehicle is moving out from the lane without signaling

44. Forward Collision Warning

A forward-collision warning light means that there is a potential collision detected.

45. SRS Light

An SRS warning light indicates there is an issue with the airbag or supplemental restraint system. Read more

46. Seatbelt Indicator

A seatbelt symbol indicates one or more seat belts are not closed or there is an issue with the system. Check both the driver and passenger sides and the rear seats on some car models.

47. Side Airbag Warning Light

A side airbag warning light indicates the side airbags are turned off or there is an issue with the side airbags.

48. Power Steering Warning Light

A power steering warning light means that there is an issue with the power steering system

49. Icy Road Warning Light

An icy road warning light indicates the outside temperature is cold and that there is a risk of an icy road. Slow down!

50. Distance Warning

A distance warning indicates the front radar detected that your vehicle is too close to the car in front or is being approached too quickly.

51. Bonnet Open

A bonnet open symbol means that the bonnet is not closed properly, or there is an issue with the bonnet lock switch.

52. Headlight Range Control

A headlight range control warning light indicates there is an issue with the headlight range control system

53. Exterior Light Fault

An exterior light warning light indicates an issue with one or more exterior lights, usually faulty light bulbs.

54. Highbeam Light Indicator

A high beam light symbol means that the high beam lights are turned on

55. Auto High Beam Lights

An auto high beam lights symbol means that the auto high beam system is turned on

56. Position Light Indicator

A position light symbol will turn on when the headlights are switched off and the position lights are on

57. Low Beam Indicator Light

A low beam light symbol is turned on when the low beam headlights are turned on

58. Front Fog Lights On

A front fog light symbol is illuminated when the front fog lights are turned on.

59. Rear Fog Light On

A rear fog light symbol is illuminated when the rear fog lights are turned on.

60. Turn Lights Warning Symbol

A turn light warning symbol indicates that there is an issue with the headlight’s turn-light system.

61. Windshield Defrost Indicator

A windshield defrost symbol indicates that the windshield defroster is turned on.

62. Rear Window Defrost

A rear window defrost symbol means that the rear window’s defroster is turned on.

63. Cruise Control On Indicator

A green cruise control symbol indicates the cruise control is switched on and engaged.

64. Cruise Control Warning

A cruise control warning symbol indicates there is an issue with the cruise control or throttle control system.

65. Cruise Control Speed Limiter

A cruise control speed limiter symbol means that the cruise control system will limit the max speed.

66. Cruise Control SET Indicator

A “SET” symbol indicates that the cruise control is set to a fixed speed and trying to hold the speed.

67. Shift Up Indicator

A shift up symbol indicates that it’s time to shift up to a higher gear.

68. Shift Down Indicator

A shift down symbol means that it’s time to shift down to a lower gear.

69. Auto Windshield Wiper

An auto windshield wiper symbol indicates that the auto wiper system is turned on.

70. Recirculated Cabin Air

A recirculated cabin air symbol indicates that the car will recirculate the air inside the car instead of taking air from the outside of the car

71. Heater Blower Fan On

A heater blower fan symbol means that the blower motor is turned on.

72. Heated Seats On

A heated seat symbol indicates that one or more seats’ heating system is turned on.

73. Hill Descent Control

A hill descent control symbol indicates that the hill descent system is turned on and will limit the car’s speed while going downhill.

74. Steering Lock Warning Light

A steering lock warning light means that there is an issue with the steering lock or that the car key is not recognized

75. Brake Fluid Level Warning

A brake fluid level warning indicates that the brake fluid level is too low, or there is an issue with the measurement system.

76. Key Not in Vehicle Indicator

A Key Not in Vehicle symbol indicates the car’s immobilizer system can’t reach or recognize your car key.

77. Immobilizer Indicator

An immobilizer symbol means that it can’t reach or recognize your car key, or there is an issue with the immobilizer system.

78. Ignition Switch Warning

An ignition switch warning symbol indicates that there is an issue with the ignition switch system.

79. Low Electric Battery Charge

A low electric battery charge symbol indicates that it’s time to charge your electric vehicle’s battery.

80. Brake Lights Warning

A brake light warning light indicates that the brake lights are not working.

81. Air Suspension Warning

An air suspension warning symbol means that there is an issue with the air suspension system.

82. Suspension Warning Light

A suspension warning light shows up when there is a malfunction with the electric suspension system.

83. Car on Ramp Mode

A car on ramp mode warning symbol turns on when the car’s tires are raised up in the air or when the repair mode is activated.

84. ECO Mode On Indicator

An ECO Mode on symbol indicates that the Economy system is turned on. Read more

85. Rear Spoiler Warning

A rear spoiler warning light indicates that there is a malfunction in the rear spoiler electric system

86. Lane Assist

A green lane assist symbol indicates that the lane assist system is turned on.

87. Exhaust Fluid (Diesel)

An exhaust fluid warning light means that the exhaust fluid (AdBlue) level is low in your diesel car.

88. Convertible Roof Warning Light

A Convertible Roof Warning Light indicates that the convertible roof system is opening or closing.

89. Blue Coolant Temp Light

A blue engine temperature symbol means that the engine is still cold and you should drive carefully.

Toyota Dashboard Lights
Lexus Warning Lights

Categories: General , Warning Lights

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WCRKSHCP manuaL

VOLUME 1

FOTON WORKSHOP MANUAL - VIEW (CS2 / C2)

Table of Contents

Edition: January 2013 01 INTRODUCTION 07

Printed: February 2013 02 PREPARATION 43

Publication: FWSM-201301 03 SERVICE SPECIFICATIONS 83

Location: China 04 DIAGNOSTICS 123

be reproduced or stored in a retrieval system, or

transmitted in any form, or by any means, electronic,

mechanical, photo-copying, recording or otherwise,

without the prIor written permission of Foton.

VOLUME 2 689

04 DIAGNOSTICS (RHD) 691

Pg.

05 VEHICLE MAINTENANCE 1203

11A ENGINE CONTROL SYSTEM 1263

12A FUEL SYSTEM 1327

13A EMISSION CONTROL 1355

14A INTAKE AIR 1365

15A ENGINE MECHANICAL 1383

16A EXHAUST SYSTEM 1465

17A COOLING SYSTEM 1477

18A LUBRICATION SYSTEM 1503

19A IGNITION SYSTEM 1525

20A STARTING AND CHARGING 1533

VOLUME 3 1567

11B ENGINE CONTROL SYSTEM 1569

12B FUEL SYSTEM 1617

13B EMISSION CONTROL 1669

14B INTAKE AIR 1681

15B ENGINE MECHANICAL 1703

16B EXHAUST SYSTEM 2019

17B COOLING SYSTEM 2035

18B LUBRICATION SYSTEM 2065

19A IGNITION SYSTEM 2091

20B STARTING AND CHARGING 2103

21 SUPERCHARGER 2139

VOLUME 4 2157

11C ENGINE CONTROL SYSTEM 2159

12C FUEL SYSTEM 2171

13C EMISSION CONTROL 2193

14C INTAKE AIR 2199

15C ENGINE MECHANICAL PART 2207

16C EXHAUST SYSTEM 2233

17C COOLING SYSTEM 2241

18C LUBRICATION SYSTEM 2261

20C STARTING AND CHARGING 2271

VOLUME 5 2299

31-32 SUSPENSION SYSTEM 2301

33 TYRE AND WHEEL 2339

34 AXLE AND PROPELLER SHAFT 2351

35-36 BRAKING SYSTEMS 2405

41 TRANSMISSION 2465

42 CLUTCH 2543

51 STEERING COLUMN 2565

52 POWER STEERING 2589

61 HEATER AND AIR CONDITIONING 2625

62 SUPPLEMENTAL RESTRAINT SYSTEM 2713

63 SEAT BELT 2733

64 LIGHTING 2757

65 WIPER AND WASHER 2787

66 AUDIO SYSTEM 2809

71 WIRING 2825

81 COMMUNICATION SYSTEM 3219

82 WINDSHIELDS, MIRRORS & GLASS 3235

83 INSTRUMENT PANEL 3259

84 SEATS 3277

85 DOOR LOCKS 3303

86 SLIDING ROOF 3325

87 DOORS AND ENGINE HOOD 3335

88 EXTERIOR AND INTERIOR TRIM 3357

91 VEHICLE CONTROL SYSTEM 3395

WORKSHOP MANUAL - VIEW CS2 / C2

V O L U M E 1

01 INTRODUCTION 07

02 PREPARATION 43

03 SERVICE SPECIFICATIONS 83

04 DIAGNOSTICS 123

INTRODUCTION

HOW TO USE THIS MANUAL........................................................... 01-1

GENERAL INFORMATION.......................................................... 01-1

IDENTIFICATION INFORMATION..................................................... 01-6

VEHICLE IDENTIFICATION NUMBER (VIN) .............................. 01-6

SERIAL NUMBER (SN) ............................................................... 01-7

REPAIR INSTRUCTION..................................................................... 01-8

PRECAUTION.............................................................................. 01-8

VEHICLE LIFT AND SUPPORT LOCATIONS........................... 01-16

HOW TO TROUBLESHOOT............................................................ 01-18

GENERAL INFORMATION........................................................ 01-18

HOW TO PROCEED WITH TROUBLESHOOTING .................. 01-20

ELECTRONIC CIRCUIT INSPECTION PROCEDURE ............. 01-29

TERMS ............................................................................................. 01-33

ABBREVIATIONS USED IN THIS MANUAL ............................. 01-33

01

HOW TO USE THIS MANUAL

GENERAL INFORMATION

INTRODUCTION - HOW TO USE THIS MANUAL

01-1

1. GENERAL DESCRIPTION.

(a) Carrying out operations described in this manual in the correct sequence may help you improve the

quality and efficiency during servicing.

(b) Generally, service operations can be separated in the following 3 main processes:

• Diagnosis

• Removal / Installation, Replacement, Disassembly / Assembly, (On-vehicle) Inspection and Adjustment

• Final Inspection

process of “Removal / Installation, Replacement, Disassembly / Reassembly, (On-vehicle) Inspection

and Adjustment”, but the 3rd process of “Final Inspection” is not included.

(d) The following essential operations are not written in this manual. However, these operations must be

performed in actual situations.

• Clean a removed part when necessary

• Visual check

2. INDEX.

(a) An alphabetical INDEX section is provided at the end of this chapter as a reference to help you to

understand these abbreviation meaning.

3. PREPARATION.

(a) Special service tools (SST) and special service materials (SSM) may be required depending on the servicing

situation. Be sure to use SST and SSM when they are required and follow the correct operation

sequence. A list of SST and SSM is in the “Chapter 02 preparation”.

4. SERVICING PROCEDURES.

(a) According to chapter content, the components’ illustration is added into chapters.

01-2

(b)

The components’ illustration shows the all parts relationship in the same assy. A table following the

illustration lists the name of each part.

Example:

01-3

(d) In this manual, only items with important points are described in the procedure and the illustration

shows what and where we can do. In the explanations, details of the operational method, standard

value and notices are listed.

(e) Some illustrations in this manual for similar vehicle models may be the same. In this case, some details

in illustration may be different from the actual vehicle.

(f) The procedures are presented in a step-by-step format:

• The illustration shows what to do and where to do it.

• The task title tells us what to do.

• The explanation text tells us how to perform the task and includes other information such as

specifications, service notice and warnings.

01-4

5. SERVICE SPECIFICATIONS.

(a) Specifications are presented in bold type throughout the manual. You never have to leave the servicing

to look for the specifications. The specifications can also be found in the “Chapter 03 service

specifications” for quick reference.

6. TERM DEFINITIONS.

WARNING

CAUTION

NOTE

Indicates the possibility of injury to you or other persons.

Indicates the possibility of damage to the components being

repaired and the equipments being operated.

Provides additional information to help you perform the servicing

efficiently.

7. INTERNATIONAL SYSTEM OF UNITS.

(a) The units used in this manual comply with the International System of Units (SI UNIT) standard.

Torque: 30 N•m

01-5

8. APPLICABLE VEHICLES.

Series

Steering

Wheel

Engine Transmission Model Examples

BJ6549B1PDA-AA 6549B1PDA-AAZA09

6549BDPDA-AAZA01

F2.8 038J2 BJ6549BDPDA-AA

6549BDPDA-AAZ001

BJ6549B1PDA-3

6549B1PDA-03ZA01

widebody

longshaft

LHD

4JB1T ZM001AJD

BJ6549B1PDA-1 6549B1PDA-01ZA05

BJ6549B1PDA-2 6549B1PDA-02ZA02

6549B1PXA-EEZA03

BJ6549B1PXA-EE

4G69

ZM001AD

549B1PXA-EEZA08

BJ6549BDPXA-EE 6549BDPXA-EEZA01

ZM011D BJ6549B1PXA-2 6549B1PXA-02ZA02

F2.8 038J2

BJ6549B1PDA-RA 6549B1PDA-RAZA01

BJ6549B1PDA-R2 6549B1PXA-R2ZA03

RHD

ZM001AJD BJ6549B1PXA-RE 6549B1PXA-REZA02

ZM011D BJ6549B1PXA-R2 6549B1PXA-R2ZA01

4JB1T ZM001AJD BJ6549B1PDA-R1 6549B1PDA-R1ZA01

01-6

INTRODUCTION - IDENTIFICATION INFORMATION

IDENTIFICATION INFORMATION

VEHICLE IDENTIFICATION NUMBER (VIN)

1. VEHICLE IDENTIFICATION NUMBER (VIN).

(a) The Vehicle Identification Number (VIN) is stamped on the vehicle identification number label and

vehicle certification plate as shown in the illustration.

• Vehicle identification number label: Can be found through the windshield at front left corner of the

instrument panel.

• Vehicle certification plate: Can be found after turning over the front vehicel hood.

01-7

SERIAL NUMBER (SN)

1. FINAL DRIVE SERIAL NUMBER.

(a) The final drive serial number is stamped on the rear axle

welding housing.

2. PROPELLER SHAFT SERIAL NUMBER.

(a) The propeller shaft serial number is stamped on the propeller

shaft tube.

01-8

INTRODUCTION - REPAIR INSTRUCTION

REPAIR INSTRUCTION

PRECAUTION

1. BASIC REPAIR NOTE.

(a) Notes on operation.

1 Protection

2 Safe operation

• Be sure to wear a clean uniform.

• Be sure to wear hat and safety shoes.

• Perform safty inspection each other, when 2 or more persons servicing

togehter.

• When working with the engine running, pay attention to the ventilation

of the workshop.

• In case of operating on high temperature parts, rotating, moving and

vibrating parts, protective clothing is necessary and pay attention not

to burn or injury yourself.

• When jacking up the vehicle, be sure to support the vehicle at correct

position and use safe jack.

• When lifting up the vehicle, use a safe and standard equipment.

3

Preparation of tools and

measuring gauge

• Before starting the servicing, prepare a tool stand, SST, gauge, oil,

shop rag and new parts for replacement.

01-9

4

Removal and installstion,

disassembly and assembly

operations

5 Removed parts

• Diagnose problems with a thorough understanding of the trouble

phenomenon and perform effective operations.

• Before removing the parts, check the assembly for general condition:

deformation and damage.

• When the part structure is complicated, take a note or make match

marks so as not to make mistakes that affect the function of the parts.

• Clean and wash the removed parts if necessary, and assemble them

after a thorough inspection.

• Place the removed parts in the correct order to avoid mixing up or

making them dirty.

• As for non-reusable parts such as gasket, O-rings, and self lock nut,

replace them with new one following the instruction of manual.

• Put the old parts into a box and show them to the customer.

(b) Jacking up and supporting vehicle.

• Be carefully when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the

proper locations. (Refer to “Chapter 01 introduction - repair instruction, vehicle lift and support

locations”)

• Precoat removed parts like bolts, nuts, etc. that are coated with sealant at the factory.

• If a precoated part is retightened, loosened or caused to move in any way, it must be recoated with the

sealant.

• When reusing precoated parts, clean the old sealant and dry the part with compressed air. Then apply

the specified sealant to the bolts, nut or threads.

• Sometimes, it is necessary to leave the installed precoated parts for a specified time until the sealant

hardens.

(d) Gasket.

• If necessary, use a sealer or new gasket to prevent leakage.

(e) Bolts, nuts and screws.

• Always tighten the bolts, nuts and screws at the specified torque with a torque wrench.

Perform the torque check with the lower limit value of the torque tolerance.

01-10

(f) Fuse.

• When replacing a fuse, make sure the amperage rating of new fuse is correct. The amperage rating of

new fuse should be the same as old fuse, neither more nor less.

Illustration Symbol Part Name

Fuse

Circuit Breaker

01-11

(g) Clips.

• The removal and installation methods of typical clips used in body parts are shown in the below table.

If the clip is damaged during the servicing, replace with a new one.

Shape (Example)

Removal / Installation

01-12

(h) Removal and installation of vacuum hoses.

• To disconnect the vacuum hoses, pull the hoses by

holding at the end, not at the middle of hose.

• When disconnecting vacuum hoses, use tags to identify

where they should be reconnected.

• After performing the servicing, check carefully whether

the hoses are connected properly.

• When using a vacuum gauge, never force the hose onto

a connector . Always use a adapter to connect hose. The

stretched hose may cause leakage.

01-13

(i) Torque when using a torque wrench with extension tool.

• In case of tightening with a torque wrench which has an

extended length by combining the torque wrench with

SST or extension tool, if you tighten until the reading of

the torque wrench reaches the specified torque value,

the actual value becomes excessive.

• In this manual, only the specified torque is described. In

case of using SST or an extension tool, calculate the

reading of the torque wrench by the following formula.

• Formula: T’ = T × L2 / (L1 + L2)

T’ Reading of torque wrench (N·m)

T

Torque (N•m)

L1

L2

Length of SST or extension tool (mm)

Length of torque wrench (mm)

2. ELECTRONIC CONTROL.

(a) Disconnection and connection of battery terminal.

• Before performing electrical operations, disconnect the

battery negative terminal cable firstly so as to prevent

burnt-out damage by short.

• Disconnect the battery terminal completely without twist

after turning off all switches.

• When the negative (-) terminal cable is disconnected from

the battery, the memory of the clock and audio system will

be cleared. So before servicing, record the necessary data

of the clock and audio system. After servicing, reset the

clock and audio system.

(b) Handling of electronic parts.

• Do not open the cover or case of the module. If the IC

terminals are touched, the IC may be destroyed by static

electricity.

• To disconntect electronic connectors, pull the connector,

not the wire harness.

01-14

• Do not drop electronic components, such as sensors or

relays. If they are dropped on a hard floor, they should be

replaced.

• When cleaning the engine with steam, protect the

electronic components, air filter and emission-related

components from water.

• Never use an impact wrench to remove or install

temperature switches or temperature sensors.

• When checking the wire harness connector, insert the

tester probe carefully to prevent terminals from bending.

• After replacing electronic components, always perform

function check.

3. REMOVAL AND INSTALLATION OF FUEL CONTROL PARTS.

(a) Place for removing and installing of fuel system parts.

• Work in a place with good air ventilation and without anything flammable such as welder, grinder, drill,

electric motor or stove in the surroundings.

• Never work in a place such as a pit or nearby a pit, as there is a place that vaporized fuel is filled in.

(b) Removing and installing of fuel system parts.

• Prepare a fire extinguisher before starting the servicing.

• For prevention of static electricity, connect the fuel changer, vehicle and fuel tank to ground and keep

floor dry to prevent slipping.

• Never use any electric equipment like an electric motor or a working light, as they may cause sparks or

high temperature.

• Never use an iron hammer, as it may cause sparks.

• Dispose the shop rag without any fuel deposit.

4. REMOVAL AND INSTALLATION OF ENGINE INTAKE PARTS.

If any metal chips are into the inlet pass, this may get a bad effect to the engine and turbocharger.

(a)

When removing and installing the inlet system parts,

wrap the opening of engine intake system with clean rag

or tape.

When installing the inlet system parts, check that there is

no mixing of metal chips.

01-15

5. HANDLING OF HOSE CLAMPS.

(a) Before removing the hose, record the depth of the inserting

portion and the old clamp position in order to reinstall it

correctly.

(b) If deformation or dent is found, replace it with a new one.

where it has a clamp track.

(d) For a spring type clamp, adjust it by applying force to the

arrow mark direction after the installation.

6. FOR VEHICLES EQUIPPED WITH CATALYTIC CONVERTER.

If large amount of unburned fuel flows into the converter, it may cause overheating and a fire hazard.

To prevent this, observe the following precautions.

(a) Use only unleaded gasoline (gasoline vehicles).

(b) Avoid running the engine at idle speed for more than 20 minutes.

• Perform a spark jump test only when absolutely necessary. Perform this test as quickly as possible.

• While testing, never race the engine.

(d) Avoid a prolonged engine compression measurement. This operation must be performed as quickly as

possible.

(e) Do not run the engine when the fuel tank is nearly empty. This may cause the engine to misfire and

damage the catalytic converter.

01-16

VEHICLE LIFT AND SUPPORT LOCATIONS

1. NOTICE ABOUT VEHICLE CONDITION WHEN JACKING UP.

(a) According to rules, the vehicle must be unloaded when jacking up. Never jack up or lift up the vehicle

with things of heavy weight loading.

(b) When removing any parts of heavy weight like the engine and transmission, the center of gravity of the

vehicle will be changed. Place a balance weight in vehicle so as to keep it from rolling, or support the

vehicle with jack at the position of specification.

2. NOTICE FOR USING JACK AND 4 POSE LIFT.

(a) Follow the instruction in this manual for a safety operation.

(b) Do not damage tires or wheels with a pry bar.

(d) Shift in the reverse position.

(e) Using a wheel stopper, fix the vehicle.

(f) Jack up the vehicle using a jack with rubber attachment.

Be sure to jack up the vehicle at the correct support location.

01-17

(g) Lift the vehicle up by using a 4 pose lift with rubber attachment.

Be sure to lift up the vehicle at the correct support location.

01-18

INTRODUCTION - HOW TO TROUBLESHOOT

HOW TO TROUBLESHOOT

There are many electronic controlled systems in the vehicle. In general, electronic controlled system is considered

to be very complex and require a high level of technical knowledge and expert skill to troubleshoot.

However, the fact is that if you check the circuits one by one, troubleshooting of these systems is not complex.

If you have adequate understanding of the system and basic knowledge of electricity, the problem can be

accurately found out and comfirmed.

This manual is designed based on the above principle to help service technicians perform accurate and

effective troubleshooting.

The troubleshooting procedures are described on the following chapter.

System

Engine Control System

Anti-lock Brake System

Audio System

Supplemental Restraint System

Heater And Air Conditioning System

Lighting System

Wiper And Washer

Multimedia System

Auxiliary Power

Horn System

Reverse Radar System

Power Windows

Outside Mirror

Defrost System

Instrument Cluster

Power Door Locks

Sliding Roof

Reference

Chapter 04 diagnostics - engine control system-4G69

Chapter 04 diagnostics - engine control system-ISF2.8

Chapter 04 diagnostics - engine control system-4JB1T

Chapter 04 diagnostics - anti-lock brake system

Chapter 04 diagnostics - audio system

Chapter 04 diagnostics - supplemental restraint system

Chapter 04 diagnostics - heater and air condition system

Chapter 04 diagnostics - light system

Chapter 04 diagnostics - wiper and washer

Chapter 04 diagnostics - multimedia system

Chapter 04 diagnostics - auxiliary power

Chapter 04 diagnostics - horn system

Chapter 04 diagnostics - reverse radar system

Chapter 04 diagnostics - power windows

Chapter 04 diagnostics - outside mirrors

Chapter 04 diagnostics - defrost system

Chapter 04 diagnostics - instrument cluster

Chapter 04 diagnostics - power door locks

Chapter 04 diagnostics - Sliding Roof

01-19

FOR USING HAND-HELD TESTER

• Before using the tester, be sure to read thoroughly the tester operating manual.

• Connect the tester to the diagnosis wire harness connector and turn the ignition switch to “ON”

position. If the tester can not communicate with the module, there is a problem on the vehicle

side or tester side.

• If the communication is normal when the tester is connected to another vehicle, inspect the

diagnosis data link or module power circuit of the vehicle.

• If the communication is still impossible when the tester is connected to another vehicle, the

problem is probably in the tester itself, so perform the self test procedures described in the

“Tester Operating Manual”.

01-20

HOW TO PROCEED WITH TROUBLESHOOTING

• Here, only the basic procedures are shown.

• Carry out troubleshooting in accordance with the procedures on the following pages.

• Details are provided in Chapter 04 diagnostics, showing the most effective methods for each

circuit.

• Confirm the troubleshooting procedures firstly for the relevant circuit before servicing.

1. VEHICLE VISITED TO WORKSHOP

2. CUSTOMER PROBLEM ANALYSIS

Ask the customer about the conditions and environment that the problem occurred.

3. SYMPTOM CONFIRMATION AND DTC (INCLUDING DATA STREAM) CHECK

(c)

(d)

Check the battery positive voltage.

Voltage: 11 ~ 14 V (Engine stopped)

Visually check the wire harness, connectors and fuses for open and short, etc.

Warm up the engine to the operating temperature.

Confirm the problem symptoms and conditions and check for DTCs according to the related chart.

Does the DTC display?

YES > Go to next step.

NO > Go to step 5.

4. DTC CHART

(a) Check the results obtained in step 3, then confirm the inspection procedures for the system or the part

which should be checked with the DTC chart.

Go to step 6 directly.

5. PROBLEM SYMPTOMS TABLE

Check the results obtained in step 3, then confirm the inspection procedures for the system or the part

which should be checked with the problem symptoms table.

6. CIRCUIT INSPECTION OR PARTS INSPECTION

(a) Inspect the circuit or parts according to results obtained in step 4 and 5.

(b) Confirm the circuil or parts which should be repaired.

7. REPAIR

(a) Perform adjustment, repair or replacement according to the results obtained in step 6.

8. CONFIRMATION TEST

After servicing, confirm that the problem has been solved.

If the problem does not recur, perform a confirmation test under the same conditions and enviroment

that vehicle fault occurred at the first time.

9. END

01-21

CUSTOMER PROBLEM ANALYSIS

• In troubleshooting, the problem symptoms must be confirmed accurately, meaning that all

preconceptions must be set aside in order to make an accurate judgement.

• Before comfirmation the problem symptoms, it is very important to ask the the customer about

some detail information of problems.

• The following 5 items are important points in the problem analysis.

What?

When?

Where?

Under what conditions?

How did it happen?

Vehicle model, system name

Date, time, occurrence frequency

Road conditions

Running conditions, driving conditions, weather conditions

Problem symptoms

• Past problems and the repair history which are thought to be unrelated may be useful in some

cases. Therefore, as much information as possible should be gathered and its relationship with

the problem symptoms should be correctly ascertained for use as reference in troubleshooting.

01-22

SYMPTOM CONFIRMATION AND DTC (INCLUDING DATA STREAM) CHECK

The diagnosis system in vehicle has various functions.

• The first function is the Diagnostic Trouble Code (DTC) checking. We could check out stored

fault in the module memory.

• Another function is the Input Signal Check, which checks whether the signals from various

switches are sent to the module correctly.

By using these check functions, it is possible to quickly find potential problem areas and

troubleshooting can be performed effectively.

System System Description DTC Signal Check Data Stream Symptom

Engine Control System ○ ○ ○ ○ ○

Anti-lock Brake System ○ ○ - - ○

Supplemental Restraint

○ ○ - - ○

Heater And Air Conditioning - - - - ○

Lighting System - - - - ○

Wiper And Washer - - - - ○

Multimedia System - - - - ○

Auxiliary Power - - - - ○

Horn System - - - - ○

Reverse Radar System ○ - - - ○

Power Windows - - - - ○

Outside Mirror - - - - ○

Defrost System ○ - - - ○

Instrument Cluster - - - - ○

Power Door Locks - - - - ○

Sliding Roof ○ - - - ○

01-23

In the DTC checking, it is very important to determine whether the problem indicated by the DTC is current

fault or stored fault. In addition, during the problem symptom confirmation, a step must be taken

whether the malfunction indicated by the DTC is directly related to the problem symptom or not. For this

reason, the DTC should be checked before problem confirmation. If missing this step, it may result in

unnecessary troubleshooting for systems which are operating normally. It will cause more difficult to

detect the problem area or repair irrelevant areas. Therefore, always follow the procedures in the

correct order and perform the DTC check.

A flow chart showing how to proceed with troubleshooting with the DTC checking is shown below. This

flow chart shows how to use the DTC checking effectively. Throughout this chart flow, we can know

how to process the DTC troubleshooting and the troubleshooting of problem symptoms table.

1. DTC CHECK

2. RECORD AND CLEAR THE DTC

If a fault code is displayed in the initial DTC checking, it indicates that a trouble may have occurred in

a wire harness or connectors in the past. Therefore, check the wire harness and connectors. (Refer to

“Chapter 01 introduction - how to troubleshoot, electronic circuit inspection procedure”)

3. SYMPTOM CONFIRMATION

Do the problem symptoms still exist?

4. SIMULATION TEST WITH THE METHODS OF SYMPTOM SIMULATION (Refer to “Chapter 01

introduction - how to troubleshoot, how to proceed with troubleshooting”)

5. DTC CHECK AGAIN

Does DTC display?

YES > Proceed with DTC chart.

NO > Go to next step.

6. SYMPTOM CONFIRMATION

Does any symptom exist?

NO > The system is normal.

7. PROCEED WITH PROBLEM SYMPTOMS TABLE

The problem beyond the DTC system ability. The fault code displayed in the DTC is either a past

problem or a secondary problem.

8. END

01-24

SYMPTOM SIMULATION

• The most difficult case in troubleshooting is when no symptoms occurs. In such cases, be sure

to carry out a thorough customer problem analysis. Then simulate the same or similar

conditions and enviroment in which the customer’s vehicle was and when the problem

occurred. No matter how much experience and skill a technician has. If he troubleshoot the

problem without the direction, he will tend to miss some important things during servicing and

make some mistakes, which will lead to a standstill.

• For example, for a problem which only occurs when the engine is cold, or for a problem which

occurs due to vibration caused by the road during driving, etc., the problem can never be found

out when the engine is hot or when the vehicle is stopped. Since enviroment problem like

vibration, heat or moisture which is difficult to reproduce, the symptom simulation tests

introduced here are effective measures that the external causes are applied to the vehicle in a

stationary condition.

1. IMPORTANT POINTS IN THE SYMPTOM SIMULATION TEST:

(a) In the symptom simulation test, the problem symptoms should be confirmed and the problem area or

parts must also be found. So, before starting simulation test, connect hand-held tester into the vehivle

firstly in order to reduce the range of testing.

(b) After the step aboved, carry out the symptom simulation test, judging whether the circuit being tested is

defective or normal and also confirming the problem symptoms at the same time. Refer to the problem

symptoms table of each system, find out the possible causes of the problem.

2. VIBRATION METHOD: When vibration seems to be

the major cause.

(a) Part and sensor.

• Apply slight vibration with your finger to the part or the

sensor and check whether the malfunction occurs.

Apply strong vibration to relays may result in open.

(b) Connectors.

• Lightly shake the connector vertically and horizontally.

• Lightly shake the wire harness vertically and horizontally.

The connector joint is the major area that should be checked

thoroughly.

01-25

3. HEAT METHOD: If the problem seems to occur when

the temperature is higher.

(a) Heat the component that is possible cause of the malfunction

with a hair dryer or similar object. Check it if the malfunction

occurs.

• Never heat the components to more than 60 ℃ to

prevent from being damaged.

• Never apply heat directly to the module.

4. WATER SPRINKLING METHOD: When the malfunction

seems to occur on a rainy day or in high-humidity.

(a) Sprinkle water on the vehicle and check whether the

malfunction occurs.

• Never spray water directly on the engine hood. Spray a

mist of water on the radiator front surface to change the

temperature and humidity.

• Never spray water directly on the electronic components.

• If a vehicle is subject to water leakage, the leaking water

may damage the module. When testing a vehicle for

water leakage problem, this factor must be considered.

5. HIGH ELECTRICAL LOAD METHODS: If the malfunction seems to occur when electrical load is

excessive.

(a) Turn on all the electrical equipment including the heater blower, headlights, rear windows defrost, etc.

and check whether the malfunction occurs.

01-26

DTC CHART

Take the engine control system as an example, inspection procedures are shown in the illustration below.

The chart indicates the DTCs of the engine control system and lists the corresponding troubleshooting

procedures. It will be more effective and accurate to proceed with troubleshooting in accordance with the

inspection procedures listed in the chart.

01-27

PROBLEM SYMPTOMS TABLE

The problem symptoms table indicates the suspect circuits or parts for each problem symptom, as shown in

the illustration below. Using this table to troubleshoot the problem when the problem is occuring but no DTC

displayed. The number in the table indicates the procedures of troubleshooting.

When the problem is not detected by the diagnostic system even though the problem symptoms is

present, it may be that the problem is occuring beyond the detection range of the dignostic system.

01-28

CIRCUIT INSPECTION

How to read and use each page is shown below.

01-29

ELECTRONIC CIRCUIT INSPECTION PROCEDURE

1. BASIC INSPECTION.

(a) Resistance measuring condition.

• Unless special instruction, all resistance is measured at an ambient temperature of 20 ℃ .

• The resistance may be out of the specifications when measured at high temperature (such as the

engine is hot). So measurements should be performed when the engine is cooled down.

(b) Handling of connectors.

• When disconnecting the connector, press the connector

in the direction of engagement and remove the lock by

lightly pressing the lock claw.

• When removing the connector, do not pull the wire harness

but pull the connector.

• Make sure there is no deformation, damage or missing

terninals before connecting the connector.

• The connector with a lock should be inspected until hearing

a “click”.

• When checking the connector with a mutimeter, be sure

to check it from the backside (wire harness side) of the

connector by using a mini test lead.

• As a water proof connector can not be checked from

the backside, check it by a connecting the adapter.

• Do not damage the terminals when moving the inserted

tester needle.

Check when the connector is connected:

• Hold the connector and check the inserting condition and

locking efficiency (engaged condition).

Check when the connector is disconnected:

• Pull the wire harness lightly and check the connector for

missing terminal, terminal crimping condition and core

wire break.

• Check visually for any rust, metal chips, water and bent

terminals.

01-30

Check the contact pressure of the terminal:

• Prepare a spare male terminal and insert it into a female

terminal. Check the engaged condition and sliding.

Always use a gold-plated male terminal to test a gold-plated

female terminal.

(d) Repair method of connector terminal.

• If there is dirty on the contact point, clean the contact

point by using an air gun or shop rag. However, never

polish the contact point using sand paper as the plating

may come off.

• In case of abnormal contact pressure, replace the female

terminal. However, if a male terminal is gold-plated (gold

colour), use a gold-plated female termina. If it is silverplated

(silver colour), use a silver-plated female terminal.

(e) Handling of wire harness.

• When removing the wire harness, check the position of

the wire harness and clamps before servicing, reinstall it

• Never twist, pull or loosen the wire harness.

• Never allow the wire harness to cross a area of high-temperature,

rotating, moving, vibrating or sharp (edge of the

panel, tip of the screw, etc.) part.

• When installing parts, never let the wire harness be interfered.

• Never cut or break the cover of the wire harness. If it is

cut or broken, replace it or repair it with electrical tape.

2. CHECK OPEN CIRCUIT.

(a) For the open circuit shown in the illustration, perform a

resistance check in step (b) or voltage check in step (c)

to comfirm fault.

01-31

(b) Check the resistance.

• Disconnect connector A & C and measure the resistance

between them.

Resistance: < 2 Ω

Measure the resistance while lightly shaking the wire harness

vertically and horizontally.

For this circuit:

The resistance between terminal 1 of connector A and terminal

1 of connector C: ≥ 1 MΩ

The resistance between terminal 2 of connecor A and terminal 2

of connector B: < 2 Ω

Therefore, the cause is an open circuit between terminal 1 of

connector A and terminal 1 of connector C.

• Disconnect connector B and measure the resistance

between the connectors.

1 of connector B1: < 2 Ω

The resistance between terminal 1 of connector B2 and terminal

connector B2 and terminal 1 of connector C.

• An open circuit which voltage is applied can be checked by

conducting a voltage check.

• For the open circuit which each connector is still connected

shown in the illustration, measure the voltage orderly

between ground and terminal 1 of connector A at the ECU 5

V output terminal, terminal 1 of connector B and terminal 1 of

connector C.

The voltage between terminal 1 of connector A and ground: 5 V

The voltage between terminal 1 of connector B and ground: 5 V

The voltage between terminal 1 of connector C and ground: 0 V

Therefore, the cause is an open circuit in the wire harness

between terminal 1 of connector B and terminal 1 of connector

C.

01-32

3. CHECK SHORT CIRCUIT.

(a) For the short circuit shown in the illustration, perform a

resistance check in step (b) to locate the section.

between terminal 1 and 2 of connector A and ground.

Resistance: ≥ 1 MΩ

Measure the resistance while lightly shaking the wire

harness vertically and horizontally.

The resistance between terminal 1 of connector A and ground: < 2

Ω

The resistance between terminal 2 of connector A and ground: ≥ 1

MΩ

Therefore, the cause is an short circuit between terminal 1 of

• Disconnect connector B and measure the resistance between

terminal 1 of connector A and B2 and ground.

The resistance between terminal 1 of connector A and ground: ≥ 1 MΩ

The resistance between terminal 1 of connector B2 and ground: < 2 Ω

Therefore, the cause is a short circuit between terminal 1 of

INTRODUCTION - TERMS

01-33

TERMS

ABBREVIATIONS USED IN THIS MANUAL

A/C

Abbreviations

Air Conditioning

Meaning

A/F

ABS

ACC

ASSY

BAT

B-joint

BTDC

CKP

Air-fuel Ratio

Accessory

Assembly

Battery

Ball Joint

Before Top Dead Center

Crankshaft Position

CMP

Camshaft Position

DLC3 Data Link Connector 3

DTC

Diagnostic Trouble Code

ECM

Engine Control Module

ECT

ECU

EFI

EGR

EVAP

GEN

GND

HO2S

HVAC

IAT

ISC

KS

LSP

MAF

MIL

MWP

No.

O2S

Engine Coolant Temperature

Engine Control Unit

Engine Fuel Injection

Exhaust Gas Recirculation

Evaporative Emission

Generator

Ground

Heated Oxygen Sensor

Heater And Air Conditioning

Intake Air Temperature

Idle Speed Control

Knock Sensor

Load Sensing Proportioning

Mass Air Flow

Malfunction Indicator Lamp

Max Working Pressure

Number

Oxygen Sensor

01-34

OBD

PCV

RCM

RPM

SFI

SRS

SSM

SST

TC

TPS

U-joint

On-Board Diagnostic

Positive Crankcase Ventilation

Restraint Control Module

Revolutions Per Minute

Sequential Multiport Fuel Injection

Special Service Materials

Special Service Tools

Turbocharger

Throttle Position Sensor

Universal Joint

PREPARATION

DIAGNOSTICS................................................................................... 02-1

PREPARATION ........................................................................... 02-1

ENGINE CONTROL SYSTEM............................................................ 02-3

PREPARATION ........................................................................... 02-3

FUEL .................................................................................................. 02-4

PREPARATION ........................................................................... 02-4

EMISSION CONTROL........................................................................ 02-5

PREPARATION ........................................................................... 02-5

INTAKE AIR ....................................................................................... 02-6

PREPARATION ........................................................................... 02-6

ENGINE MECHANICAL..................................................................... 02-7

PREPARATION ........................................................................... 02-7

EXHAUST......................................................................................... 02-10

PREPARATION ......................................................................... 02-10

COOLING ......................................................................................... 02-11

PREPARATION ......................................................................... 02-11

LUBRICATION ................................................................................. 02-12

PREPARATION ......................................................................... 02-12

STARTING AND CHARGING .......................................................... 02-14

PREPARATION ......................................................................... 02-14

FRONT SUSPENSION..................................................................... 02-15

PREPARATION ......................................................................... 02-15

REAR SUSPENSION ....................................................................... 02-16

PREPARATION ......................................................................... 02-16

TIRE AND WHEEL........................................................................... 02-17

PREPARATION ......................................................................... 02-17

AXLE AND PROPELLER SHAFT.................................................... 02-18

PREPARATION ......................................................................... 02-18

BRAKE ............................................................................................. 02-21

PREPARATION ......................................................................... 02-21

PARKING BRAKE............................................................................ 02-22

PREPARATION ......................................................................... 02-22

TRANSMISSION .............................................................................. 02-23

PREPARATION ......................................................................... 02-23

CLUTCH ........................................................................................... 02-25

PREPARATION ......................................................................... 02-25

STEERING COLUMN....................................................................... 02-26

PREPARATION ......................................................................... 02-26

POWER STEERING......................................................................... 02-27

PREPARATION ......................................................................... 02-27

HEATER AND AIR CONDITIONING................................................ 02-28

PREPARATION ......................................................................... 02-28

SEAT BELT...................................................................................... 02-30

PREPARATION ......................................................................... 02-30

WIPER AND WASHER .................................................................... 02-31

PREPARATION ......................................................................... 02-31

WINDSHIELD/SIDE WINDOW GLASS/REAR VIEW MIRROR....... 02-32

PREPARATION ......................................................................... 02-32

INSTRUMENT PANEL/INSTRUMENT............................................. 02-33

PREPARATION ......................................................................... 02-33

02

SEAT ................................................................................................ 02-34

PREPARATION ......................................................................... 02-34

DOOR LOCKS.................................................................................. 02-35

PREPARATION ......................................................................... 02-35

DOORS............................................................................................. 02-36

PREPARATION ......................................................................... 02-36

VEHICLE CONTROL SYSTEM........................................................ 02-37

PREPARATION ......................................................................... 02-37

PREPARATION - DIAGNOSTICS

02-1

DIAGNOSTICS

RECOMMENDED TOOLS

Collective Intellegence Scan Tool

ENGINE CONTROL SYSTEM

Digital Multimeter

Test Lead Set

ANTI-LOCK BRAKE SYSTEM

SUPPLEMENTAL RESTRAINT

SYSTEM

HEATER AND AIR

CONDITIONING SYSTEM

LIGHTING SYSTEM

WIPER AND WASHER

MULTIMEDIA SYSTEM

AUXILIARY POWER

HORN SYSTEM

REVERSE RADAR SYSTEM

POWER WINDOWS

OUTSIDE MIRROR

DEFROST SYSTEM

INSTRUMENT CLUSTER

POWER DOOR LOCKS

SLIDING ROOF

19A

Torque Wrench -

EQUIPMENT

Oscilloscope -

02-2

Item Capacity Specification

Thread sealant - 3M No.4171 or equivalent

PREPARATION - ENGINE CONTROL SYSTEM

FUEL INJECTION SYSTEM

IGNITION SYSTEM

SENSOR

ACTUATOR

02-3

02-4

PREPARATION - FUEL

FUEL

Needle Nose Plier

FUEL PRESSURE REGULATOR

Hydraulic Jack

FUEL TANK ASSY

Torque Wrench

FUEL FITER ASSY

FUEL PUMP REMOVER

FUEL PUMP

Fuel injector leakage tester -

Grease - -

EMISSION CONTROL

PREPARATION - EMISSION CONTROL

Air Blow Gun

02-5

VAPER CANISTER

CANISTER CONTROL SOLENOID

VALVE

02-6

INTAKE AIR

PREPARATION - INTAKE AIR

Sealant - Foton sealant

PREPARATION - ENGINE MECHANICAL

02-7

ENGINE MECHANICAL

Camshaft Pulley Spanner Wrench

CAMSHAFT TIMING PULLEY

Cylinder Cover Bolt Spanner

CYLINDER COVER BOLT

Crankshaft Front Oil Seal Guide

CRANKSHAFT FRONT OIL SEAL

Crankshaft Front Oil Seal Installer

Hydraulic Tappet Adjuster Leakage

Tester

HYDRAULIC TAPPET ADJUSTER

Hydraulic Tappet Adjuster Keeper

Hydraulic Tappet Adjuster Wiring

Camshaft Oil Seal Installer

CAMSHAFT OIL SEAL

Pin For Belt Gear

Oil Pan Remover

OIL PAN

02-8

Valve Spring Compressor

VALVE AND INTERRELATED

PARTS

Valve Oil Seal Installer

VALVE OIL SEAL

Crankshaft Rear Oil Seal Installer

CRANKSHAFT REAR OIL SEAL

Crankshaft Pulley Puller

CRANKSHAFT TIMING PULLEY

Piston Disassembling and

Assembling Tool

PISTON

Flywheel Holder

FLYWHEEL

Snap Ring Plier -

ENGINE ASSY

Feeler Gauge -

CLAMP

02-9

V-block -

Coolant 10 L Foton long life coolant

Engine oil

gasoline

diesel

4 L

5 ~ 5.5 L

Temperature -25 ~ 30 ℃

Temperature -20 ~ 40 ℃

Temperature -30 ~ 30 ℃

Temperature -20 ~ 30 ℃

SL 10W-30

SL 15W-40

SL 5W-30

CF-4 or above, 15W-40

CF-4 or above, 15W-30

02-10

PREPARATION - EXHAUST

EXHAUST

Feeler Gauge

EXHAUST MANIFOLD

Exhaust pipe sealant - Foton sealant

PREPARATION - COOLING

02-11

COOLING

Radiator Cap Tester

COOLANT RESERVOIR

Thermometer

THERMOSTAT

Steam cleaner -

02-12

PREPARATION - LUBRICATION

LUBRICATION

Oil Filter Wrench

OIL FILTER

Engine Oil Pressure Switch

Remover

ENGINE OIL PRESSURE SWITCH

Rubber Hammer

Planometer -

02-13

02-14

STARTING AND CHARGING

PREPARATION - STARTING AND CHARGING

GENERATOR

STARTER

Dial Indicator

Vernier Caliper

Puller

Soldering Gun

Snap Ring Plier

Belt Tension Gauge -

Battery Charger -

Discharge Tongs -

PREPARATION - FRONT SUSPENSION

02-15

FRONT SUSPENSION

Wheel alignment instrument -

Tire changer -

Tire dynamic balancer -

02-16

PREPARATION - REAR SUSPENSION

REAR SUSPENSION

Spring Scale -

PREPARATION - TIRE AND WHEEL

02-17

TIRE AND WHEEL

Tire Pressure Gauge

Tire inflater -

Balance block - -

02-18

PREPARATION - AXLE AND PROPELLER SHAFT

AXLE AND PROPELLER SHAFT

TIRE

PROPELLER SHAFT SPLINE

DRIVE AXLE SIDE GEAR

Hammer

Brass Bar

PROPELLER SHAFT U-JOINT

CENTER SUPPORT BEARING

FRONT AXLE HUB GREASE CAP

REAR AXLE HUB BEARING

STEERING KNUCKLE

DIFFERENTIAL PINION SHAFT

Micrometer Calipers

CROSS SPIDER

FRONT AXLE HUB BEARING

DRIVE PINION

CROWN GEAR

DIFFERENTIAL PINION

PINION FLANGE

OUTPUT FLANGE

PROPELLER SHAFT END YOKE

AXLE SHAFT BEARING

DRIVING GEAR BEARING

Grease Gun

02-19

Spring Scale

FRONT AXLE HUB STARTING

TORQUE

REAR AXLE HUB STARTING

COTTER PIN

CENTER SUPPORT BEARING OIL

SEAL

OUTPUT FLANGE OIL SEAL

DRIVE PINON OIL SEAL

Tapeline

REAR AXLE BACK LASH

Allen Wrenchs (Key) -

FINAL DRIVE ASSY

DRIVE AXLE SIDE GEAR THRUST

WASHER

DIFFERENTIAL PINION THRUST

DRIVE PINION ADJUSTING SHIM

DRIVE PINION STARTING

Propeller dynamic balancer -

Vice -

Press machine -

02-20

Red lead - -

Grease

propeller shaft U-joint

center support bearing

front axle hub

axle shaft

output flange oil seal

drive pinion oil seal

-

Lithium base grease No.2

Final drive oil 2.5 L GL-5 80W/90

Sealant

ouput flange

crown gear

differential bearing

LOCTITE 204

PREPARATION - BRAKE

02-21

BRAKE

FRONT BRAKE DISK

REAR BRAKE DRUM

REAR BRAKE SHOE

Nipper Plier

WHEEL BRAKE CYLINDER

BRAKE PAD

BRAKE MASTER CYLINDER

FRONT AXLE HUB

REAR AXLE HUB

FRONT AXLE HUB OIL SEAL

REAR AXLE HUB OIL SEAL

AXLE SHAFT

Brake fluid - V3/V4

02-22

PREPARATION - PARKING BRAKE

PARKING BRAKE

FRONT PARKING BRAKE PULL

CABLE ASSY

REAR PARKING BRAKE PULL

CABLE ASSY LH

CABLE ASSY RH

PREPARATION - TRANSMISSION

02-23

TRANSMISSION

SYNCHRONIZER ASSY

COUNTER SHAFT WASHER

RETURN SPRING

REVERSE IDLER GEAR SHAFT

OUTPUT SHAFT

INPUT SHAFT WASHER

INPUT SHAFT ASSY

OUTPUT SHAFT ASSY

SHIFT MECHANISM

GEARSHIFT FORK

OUTPUT FRONT BEARING

OUTPUT MIDDLE BEARING

OUTPUT REAR BEARING

02-24

Transmission fluid 2 L GL-4 75W/90

Grease - Mitsubishi No.0101011

Sealant -

Mitsubishi No.997740

3M No.4170

PREPARATION - CLUTCH

02-25

CLUTCH

CLUTCH DISK

CLUTCH COVER

CLUTCH MASTER CYLINER ASSY

02-26

STEERING COLUMN

PREPARATION - STEERING COLUMN

OFF TRACK

Allen Wrenchs (Key)

HORN SWITCH ASSY

STEERING WHEEL TURNING

FORCE

STEERING PROPELLER SHAFT

U-JOINT

POWER STEERING

PREPARATION - POWER STEERING

02-27

Steering fluid 1.2 L ATF - Ⅲ

Grease power steering box - QL-5 80W/90

Sealant low-pressure hose - -

02-28

PREPARATION - HEATER AND AIR CONDITIONING

HEATER AND AIR CONDITIONING

Manifold Gauge

REFRIGERANT

COMPRESSOR

Service Hoses

Service Coupler

3-way Joint

Service Tank

Vacuum Pump Connector

Refrigerant Leakage Tester

Eyes Protecter -

ENVIRONMENT TEMPERATURE

Thermistance Type Thermometer

OUTLET TEMPERATURE

Belt Tension Gauge

PULLEY

02-29

Refrigerant Recovery / Recycling

Station

(With this device, vacuum pump is

not required.)

Vacuum Pump

Refrigerant

front and rear A/C

only front A/C

850 ± 25 g

700 ± 25 g

R-134a

Compressor oil 180 ml -

02-30

SEAT BELT

PREPARATION - SEAT BELT

PREPARATION - WIPER AND WASHER

02-31

02-32

PREPARATION - WINDSHIELD/SIDE WINDOW GLASS/REAR VIEW MIRROR

WINDSHIELD/SIDE WINDOW GLASS/REAR VIEW MIRROR

Scraper

WINDSHIELD

SIDE WINDOW

REAR WINDOW

Suction Cup

Knife

Sealer Gun

Protective Tape - -

Block - -

Plastic Paper - -

Steel Wire - -

Nylon Cord - -

Adhesive Tape - -

Primer - Reactive polyester primer, black

Sealant - Polyurethane sealant, black

PREPARATION - INSTRUMENT PANEL/INSTRUMENT

INSTRUMENT PANEL/INSTRUMENT

02-33

Allen Wrenchs (key) -

Pry -

02-34

PREPARATION - SEAT

SEAT

Needle Nose Plier -

DOOR LOCKS

PREPARATION - DOOR LOCKS

02-35

DOOR LOCK CORE

Grease - Lithium base grease No.2

02-36

PREPARATION - DOORS

DOORS

DOOR

VEHICLE CONTROL SYSTEM

PREPARATION - VEHICLE CONTROL SYSTEM

02-37

IGNITION SWITCH ASSY

MEMO

SERVICE SPECIFICATIONS

SPECIFIED TORQUE FOR SPECIFICATION BOLTS...................... 03-1

ENGINE CONTROL SYSTEM............................................................ 03-2

SERVICE DATA........................................................................... 03-2

TORQUE SPECIFICATION ......................................................... 03-3

FUEL .................................................................................................. 03-4

SERVICE DATA........................................................................... 03-4

TORQUE SPECIFICATION ......................................................... 03-4

EMISSION CONTROL........................................................................ 03-5

TORQUE SPECIFICATION ......................................................... 03-5

ENGINE MECHANICAL..................................................................... 03-6

SERVICE DATA........................................................................... 03-6

TORQUE SPECIFICATION ......................................................... 03-9

INTAKE AIR ..................................................................................... 03-10

SERVICE DATA......................................................................... 03-10

TORQUE SPECIFICATION ....................................................... 03-10

EXHAUST......................................................................................... 03-11

SERVICE DATA......................................................................... 03-11

TORQUE SPECIFICATION ....................................................... 03-11

COOLING ......................................................................................... 03-12

SERVICE DATA......................................................................... 03-12

TORQUE SPECIFICATION ....................................................... 03-12

LUBRICATION ................................................................................. 03-13

TORQUE SPECIFICATION ....................................................... 03-13

IGNITION.......................................................................................... 03-14

SERVICE DATA......................................................................... 03-14

TORQUE SPECIFICATION ....................................................... 03-14

STARTING AND CHARGING .......................................................... 03-15

SERVICE DATA......................................................................... 03-15

TORQUE SPECIFICATION ....................................................... 03-16

FRONT SUSPENSION..................................................................... 03-17

SERVICE DATA......................................................................... 03-17

TORQUE SPECIFICATION ....................................................... 03-17

REAR SUSPENSION ....................................................................... 03-18

TORQUE SPECIFICATION ....................................................... 03-18

TIRE AND WHEEL........................................................................... 03-19

SERVICE DATA......................................................................... 03-19

TORQUE SPECIFICATION ....................................................... 03-19

AXLE AND PROPELLER SHAFT.................................................... 03-20

SERVICE DATA......................................................................... 03-20

TORQUE SPECIFICATION ....................................................... 03-21

BRAKE ............................................................................................. 03-23

SERVICE DATA......................................................................... 03-23

TORQUE SPECIFICATION ....................................................... 03-23

PARKING BRAKE............................................................................ 03-24

TORQUE SPECIFICATION ....................................................... 03-24

TRANSMISSION .............................................................................. 03-25

SERVICE DATA ........................................ 03-25

TORQUE SPECIFICATION .............................. 03-26

CLUTCH ........................................................................................... 03-27

SERVICE DATA......................................................................... 03-27

03

TORQUE SPECIFICATION ....................................................... 03-27

STEERING COLUMN....................................................................... 03-28

SERVICE DATA......................................................................... 03-28

TORQUE SPECIFICATION ....................................................... 03-28

POWER STEERING ......................................................................... 03-29

SERVICE DATA......................................................................... 03-29

TORQUE SPECIFICATION ....................................................... 03-30

HEATER AND AIR CONDITIONING................................................ 03-31

SERVICE DATA......................................................................... 03-31

TORQUE SPECIFICATION ....................................................... 03-31

SEAT BELT ...................................................................................... 03-32

TORQUE SPECIFICATION ....................................................... 03-32

LIGHTING......................................................................................... 03-33

TORQUE SPECIFICATION ....................................................... 03-33

WIPER AND WASHER .................................................................... 03-34

TORQUE SPECIFICATION ....................................................... 03-34

SEAT ................................................................................................ 03-35

TORQUE SPECIFICATION ....................................................... 03-35

DOORS............................................................................................. 03-36

SERVICE DATA......................................................................... 03-36

TORQUE SPECIFICATION ....................................................... 03-36

EXTERIOR AND INTERIOR TRIM................................................... 03-37

TORQUE SPECIFICATION ....................................................... 03-37

VEHICLE CONTROL SYSTEM........................................................ 03-38

TORQUE SPECIFICATION ....................................................... 03-38

SERVICE SPECIFICATIONS - SPECIFIED TORQUE FOR SPECIFICATION BOLTS

03-1

SPECIFIED TORQUE FOR SPECIFICATION BOLTS

The range of the tightening torques listed in the following table have already contained the error of the

used tools.

Thread Standard

Torque (N·m)

Grade 8.8 Grade 10.9

M5 9 ~ 11 12 ~ 14

M8

M8 × 1

M10

M10 × 1.25

M10 × 1

M12

M12 × 1.5

M12 × 1.25

M14

M14 × 1.5

M16

M16 × 1.5

M18

M18 × 1.5

M20

M20 × 1.5

21 ~ 25

22 ~ 27

41 ~ 51

45 ~ 55

46 ~ 56

73 ~ 89

75 ~ 92

78 ~ 96

122 ~ 149

126 ~ 154

182 ~ 222

199 ~ 243

243 ~ 285

287 ~ 336

389 ~ 456

396 ~ 465

29 ~ 35

32 ~ 39

58 ~ 71

63 ~ 77

65 ~ 79

105 ~ 128

106 ~ 130

113 ~ 138

160 ~ 195

178 ~ 218

247 ~ 290

265 ~ 311

380 ~ 437

397 ~ 457

486 ~ 548

540 ~ 596

03-2

SERVICE SPECIFICATIONS - ENGINE CONTROL SYSTEM

SERVICE DATA

GASOLINE ENGINE (4G69)

ECT sensor resistance 0 ℃

20 ℃

40 ℃

80 ℃

5.1 ~ 6.5 KΩ

2.1 ~ 2.7 KΩ

0.9 ~ 1.3 KΩ

0.26 ~ 0.36 KΩ

Engine idle speed Standard 750 ± 50 RPM

Idle air control motor coil resistance

Standard 28 ~ 33 Ω ( 20 ℃)

TPS resistance Standard 3.5 ~ 6.5 Ω ( 20 ℃)

IAT resistance 0 ℃

5.3 ~ 6.7 KΩ

2.3 ~ 3.0 KΩ

1.0 ~ 1.5 KΩ

0.30 ~ 0.42 KΩ

CKP resistance Standard 560 Ω ± 10% ( 20 ℃)

Upstream HO2S resistance

Downstream HO2S resistance

Terminal 3 and 4 2.5 ~ 4.5 Ω ( 20 ℃)

Canister solenoid valve Standard 19 ~ 22 Ω ( 20 ℃)

DIESEL ENGINE (ISF2.8)

Coolant temperature sensor (ECT) resistance - 10 ℃

0 ℃

100 ℃

9.397 Ω

5.986 Ω

2.500 Ω

1.175 Ω

0.323 Ω

0.186 Ω

TPS(APPS1)

TPS(APPS2)

Fully opened

Fully closed

0.72 ~ 0.74 V

3.95 V

0.36 ~ 0.37 V

1.97 V

CKP resistance Standard 860 Ω ± 86 Ω ( 20 ℃)

03-3

TORQUE SPECIFICATION

Part Tightened

N•m

ECM × Body 19.6

ECT sensor × Engine cylinder block 20 ~ 25

Idle air control valve × Throttle body 20 ~ 25

TPS × Throttle body 1.7 ~ 2.6

MAP sensor / IAT sensor × Intake manifold -

CKP sensor × flying wheel housing -

Upstream HO2S × Exhaust pipe 40 ~ 60

Downstream HO2S × Exhaust pipe 40 ~ 60

Ignition control module -

Canister solenoid valve x engine bracket -

Odometer sensor × Transmission -

EGR temperature sensor × Engine cylinder block -

Preheat plug -

EGR vacuum regulator -

EGR cooling tube -

Inlet solenoid valve -

03-4

SERVICE SPECIFICATIONS - FUEL

Gasoline engine fuel pressure

Ignition switch ON

Engine idling

Ignition switch OFF

Diesel engine fuel pressure -

Injector electric power parameter

Peak current

Holding current

resistance

Fuel pump filling quantity Standard -

Rear Fuel tank bracket × Fuel tank 41 ~ 51

Fuel hose board retaining bolt × Body 41 ~ 51

Fuel level sensor & bracket assy × Fuel tank 60 ~ 70

Fuel pump × Fuel tank 60 ~ 70

Gasoline engine fuel filter belt bolt 21 ~ 25

Gasoline fuel fliter -

Diesel filter hand pump bolt -

High-pressure tube -

High-pressure tube × Injector -

Injector plate retaining bolt

1st step

2nd step

Lower-pressure filter bracket bolt -

SERVICE SPECIFICATIONS - EMISSION CONTROL

Diesel engine EGR valve × EGR cooling pipe -

Diesel engine EGR valve × Exhaust pipe -

Vacuum regulator bolt Diesel 9 ~ 11

03-5

03-6

GASOLINE ENGINE(4G69)

ENGINE ASSY 4G69

SERVICE SPECIFICATIONS - ENGINE MECHANICAL

Type

Four cylinder in-line, water cooling, four stroke, EFI

Cylinder 4

Combustion chamber

Displacement

Bore

Stroking

Maximum torque

Rated power

Pent-roof combustion chamber

2.378 L

87 mm

100 mm

200 N·m

96 KW (5250 r / min)

Compression ratio 10:1

Lubrication system

Fuel pump type

Water pump type

Pressure, splash compound

Gear type

Centrifugal vane wheel type

TIMING BELT

Tensioner ejector pin herniation amount Standard 12 mm

Tensioner ejector pin displacement ( force 98 ~ 196N)

Standard

≤ 1 mm

ROCKER ARM/ROCKER SHAFT

Rocker arm inner diameter -

Rocker shaft diameter -

Clearance

HYDRAULIC ADJUSTER/VALVE PUSH ROD

Limit

Run-out of push rod Limit -

Hydraulic adjuster external diameter Standard -

Hydraulic adjuster hole diameter Standard -

Fit clearance

CAMSHAFT

Cam height Intake Standard

Exhaust

37.39 mm

36.89 mm

36.83 mm

36.33 mm

03-7

1st camshaft journal Standard -

2nd camshaft journal Standard -

3rd camshaft journal Standard -

4th canshaft journa Standard -

5th camshaft journal Standard -

1st canshaft bearing bore Standard -

2nd canshaft bearing bore Standard -

3rd canshaft bearing bore Standard -

4th canshaft bearing bore Standard -

5th canshaft bearing bore Standard -

axial clearance between thrust plate and 1st camshaft

journal thrust surface

Camshaft run-out Limit -

CYLINDER HEAD

Cylinder head gasket surface flatness Limit 0.2 mm

Edge thickness Intake Standard

1.0 mm

0.5 mm

1.2 mm

0.7 mm

Valve rod diameter

6.0 mm

Crest clearance between valve rod and guide

Intake

0.02 mm ~ 0.05 mm

0.1 mm

0.03 mm ~ 0.07 mm

0.15 mm

Inclination valve Standard 45° ~ 45.5°

Valve rod length Intake Standard

112.30 ~ 111.80 mm

114.11 ~ 113.61 mm

Valve stem guide hole

Oversize 0.05 mm

11.05 mm ~ 11.068 mm

11.25 mm ~ 11.268 mm

11.50 mm ~ 11.518 mm

Valve height Intake Standard

112.30 mm

111.8 mm

114.11 mm

113.61 mm

VALVE SPRING

03-8

Free height

Pre-loading force/operation height km/mm

Center line

51.0 mm

50.0 mm

27.2 Kg/44.2 mm

≤ 2°

4°

Valve spring elastic Standard -

Clearance between piston ring and groove side

Clearance No.1 ring Standard

No.2 ring

Oil ring

0.02 ~ 0.06 mm

0.25 ~ 0.35 mm

0.8 mm

0.40 ~ 0.55 mm

0.1 ~ 0.4 mm

Piston pin bore diameter Standard 22.0 mm

Piston pin outer diameter Standard -

Piston pin bore and piston pin clearance Standard -

piston pin wear limit -

Connecting rod and piston pin clearance Standard -

Depressing force

Depressing temperature

Axial clearance of connecting rods

CRANKSHAFT

Axial clearance of crankshaft

7500 ~ 17500 N

Room temperature

0.1 ~ 0.25 mm

0.4 mm

0.05 ~ 0.18 mm

0.25 mm

Clearacne between main journal and main bearing

0.20 ~ 0.040 mm

Main journal diameter Standard 56.982 ~ 57.000 mm

CYLINDER BLOCK

Upper surface flatness

Upper surface grinding limit

0.05 mm

0.2 mm

03-9

Cylinder hole diameter

Clearance between piston and cylinder Standard 0.020 ~ 0.04 mm

Timing belt cover

Down cover

Middle cover

Upper cover

11

18 ~ 26

Crankshaft pulley (timing) 165

Crankshaft pulley (damping) 25

Rockshaft retaining bolt 31

Valve - chamber cover bolt 4

Camshaft thrust plate 19

Oil pump driving shaft 55

Camshaft pulley 90

Cylinder head assy Step 1

Step 2

Step 3

Connecting rod cap Step 1

78

20

180°

90° ~ 100°

Rear engine block cover 11

Flywheel bolt 135

Crankshaft bearing cap 25

03-10

SERVICE SPECIFICATIONS - INTAKE AIR

Compressor blade and compressor case clearance

Minimum -

Turbocharger rotor axial clearance

Engine cover -

Intake air pipe retaining bolt -

Intake air filter cover bolt -

Intake air filter assy 21 ~ 25

Air straining box bolt -

Air grille bolt -

Intake air manifold bolt -

Throttle body bolt 15 ~ 25

Intake air filter assy -

Exhaust manifold × Turbocharge -

Exhaust pipe × Turbocharge -

Turbocharge oil outlet pipe -

Turbocharge oil inlet pipe -

Intake air connect pipe × Intake manifold -

Intake pipe × EGR -

SERVICE SPECIFICATIONS - EXHAUST

03-11

Exhaust manifold and cylinder block cover flatnes

Front exhaust pipe × Exhaust manifold 41 ~ 51

Front exhaust pipe × Catalytic converter 41 ~ 51

Middle exhaust pipe bolt 41 ~ 51

Muffer × Rear exhaust pipe 41 ~ 51

Exhaust manifold bolt 41 ~ 51

Heat shield 10 ~ 14

Exhaust pipe retaining belt bolt -

Catalytic converter × Exhaust manifold 41 ~ 51

Exhaust manifold bolt -

Exhaust pipe × EGR -

Heat shield -

03-12

SERVICE SPECIFICATIONS - COOLING

Cooling system outlet temperature -

Thermostat valve opening temperature 80 ~ 84 ℃

Thermostat valve lift 8 mm ( At 95 ℃ )

Coolant drain plug -

Coolant filling pipe bolt -

Fan cover upper support bolt 9 ~ 11

Fan cover lower support bolt 9 ~ 11

Coolant reservior bolt 21 ~ 25

Thermostat housing bolt 21 ~ 25

Cooling fan(electrical) bolt 9 ~ 11

Water pump pulley bolt

Gasoline

Diesel

14

Water pump bolt 14

SERVICE SPECIFICATIONS - LUBRICATION

03-13

Drain plug 34 ~ 45

Oil pan 6 ~ 7

Oil strainer bolt 19

Oil filter 13 ~ 15

Drain plug 35 ~ 45

Oil pan -

Oil filter bracket bolt -

Oil pump -

Oil filter 25 ~ 30

Cooler pipe x Oil filter bracket -

03-14

SERVICE SPECIFICATIONS - IGNITION

IGNITION

Spark plug gap

1.1 mm

Spark plug 25

Ignition coil 24

SERVICE SPECIFICATIONS - STARTING AND CHARGING

03-15

Nominal voltage

12 V

Rated current -

Rotation revolution -

Power -

Rotation mode

Polarity

Work mode

Generator rotor coil resistance

Generator rotor diameter

clockwise

Negative ground

continuous rated type

3 ± 0.5 Ω

14.2 mm ~ 14.4 mm

12.8 mm

Pinion-to-stopper clearance Standard 0.5 mm ~ 2.0 mm

Starter commutator run-out

Starter commutator diameter

≤ 0.05 mm

0.10 mm

29.4 mm

28.4 mm

Brush attrition value Limit 7.0 mm

REGULATOR

Type -

Regulation voltage -

Voltage -

Output power -

Direction of rotation -

Battery rated voltage -

03-16

Regulator -

Generator bracket bolt 20 ~ 24

Generator retaining bolt 20 ~ 24

Generator cable nut -

Generator lock bolt 20 ~ 24

Starter pulley bolt -

Starter shell bolt 8 ~ 10

Magnetic switch bolt 8 ~ 10

Magnetic coil nut 14 ~ 16

Starter × Battery cable 18 ~ 20

Starter retaining bolt 68 ~ 72

Battery plate × Body 16 ~ 18

Battery hold down -

Battery cable -

FRONT WHEEL ALIGNMENT

SERVICE SPECIFICATIONS - FRONT SUSPENSION

Front toe-in 2±2 mm (8′±8′)

03-17

Front wheel camber -0°20′±45′ (Difference between left and right ≤ 30′)

Kingpin inclination 13°05′±45′ (Difference between left and right ≤ 30′)

Kingpin caster 2°35′±45′ (Difference between left and right ≤ 30′)

Front shock absorber × Body 30

Front shock absorber × Lower control arm assy 80 ~ 90

Torsion bar × Frame

Rating nut

Locking nut

75 ~ 85

120 ~ 130

Upper control arm assy × Frame 170 ~ 200

Upper control arm ball joint × Upper control arm assy 110 ~ 115

Upper control arm assy × Torsion bar 100 ~ 110

Lower control arm assy × Frame 180 ~ 220

Lower control arm ball joint × Lower control arm assy 110 ~ 120

Stabilizer bar link × Stabilizer bar 40 ~ 60

Stabilizer bar bracket × Frame 110 ~ 130

Strut rod × Lower control arm assy 110 ~ 120

Strut rod × Frame 105 ~ 125

03-18

SERVICE SPECIFICATIONS - REAR SUSPENSION

Rear shock absorber × Anchor plate 60 ~ 80

Rear shock absorber × Frame 55 ~ 65

Shackle pin upper bolt 110 ~ 115

Shackle pin lower bolt 125 ~ 130

Leaf spring pin nut 110 ~ 120

U-bolt nut 85 ~ 105

TIRE PRESSURE

SERVICE SPECIFICATIONS - TIRE AND WHEEL

03-19

195R15C-104S

Front tire

Rear tire

Spare tire

350 KPa

400 KPa

420 KPa

Wheel nut 90 ~ 120

03-20

SERVICE SPECIFICATIONS - AXLE AND PROPELLER SHAFT

PROPELLER ASSY

Propeller tube outer diameter × Thickness

φ 63.5 ×2.5 mm

Operating torque Maximum 1600 N·m

Angle without interference Maximum -

Dynamic unbalance Maximum 20 g.cm (3200 r/min)

Propeller radial run-out

0.3 mm

Clearance between tube yoke and transmission output

shaft spline

Cross spider journal

Clearance between needle bearing and yoke

0 mm (Interferencefit)

Clearance between cross spider and needle bearing -

Axial clearance of cross spider -

AXLE HUB

Back lash

Deviation

Primal rotating force

REAR AXLE

Rear wheel track

Front

Rear

1650 mm

Back lash -

Number of drive pinion teeth 10

Number of crown gear teeth 39

Final ratio 3.9

DIFFERENTIAL ASSY

Crown gear deviation -

Crown gear back lash -

03-21

Contact area between drive pinion and crown gear

Length

Width

Center of the tooth surface. The distance away from

small end ≥ 2 mm

≥ 60% tooth length

≥ 60% tooth width

Drive axle side gear and pinion back lash -

Drive axle side gear clearance -

Radial clearance between differential pinion and pinion

shaft

Radial clearance between drive axle side gear and differential

case

Thickness of drive axle side gear thrust washer

Thickness of differential pinion thrust washer

Pinion flange back lash -

Pinion flange deviation -

Drive pinion primal rotating force -

Final drive pinion flange × Propeller shaft 70 ~ 79

Center support bearing bracket × Frame 60 ~ 70

End yoke retaining bolt -

Front axle hub × Front brake disc 50 ~ 60

Rear wheel brake cylinder × brake tube 21 ~ 24

Steering knuckle × Upper control arm joint 110 ~ 115

Steering knuckle × Lower control arm assy 110 ~ 115

Lower control arm joint × Lower control arm 110 ~ 120

Tie rod × Steering knuckle arm 84 ~ 100

Final drive drain plug -

Final drive filler cap -

Final drive vent plug -

Main retard assy × Final drive assy -

Crown gear × Differential case -

03-22

Differential bearing cap × Differential case -

Pinion nut

Minimum

Increment

Maximum

13

SERVICE SPECIFICATIONS - BRAKE

03-23

BRAKE PEDAL

Height Standard 148 mm

Free play Standard 5 ~ 10 mm

FRONT BRAKE

Thickness of front brake pad

Thickness of front brake disk

Front brake disk run-out

REAR BRAKE

Thickness of rear brake shoe

Brake drum inside diameter

Clearance between rear brake drum and brake shoe

16 ~ 16.1 mm

8 mm

28 ± 0.1 mm

0.03 mm

5 mm

1.5 mm

254 ~ 254.2 mm

Front disk brake caliper bleeding plug 8 ~ 13

Rear wheel brake cylinder bleeding plug 9 ~ 11

Brake master cylinder bolt 20 ~ 26

Brake master cylinder tube connector 21 ~ 24

Front brake disk x front wheel hub 50 ~ 70

Front wheel hub x knuckle 85 ~ 120

Front disk brake caliper mounting bolt 30 ~ 35

Front disk brake caliper bolt 90 ~ 110

Front disk brake caliper fluid tube connector 21 ~ 24

Rear wheel cylinder brake fluid tube connector 21 ~ 24

Rear wheel brake cylinder assy 8 ~ 13

Speed sensor -

ABS pipe connector 21 ~ 24

03-24

SERVICE SPECIFICATIONS - PARKING BRAKE

Parking brake front part assy -

Parking brake swinging arm bracket -

Transmission fluid

SERVICE SPECIFICATIONS - TRANSMISSION

Zomax

Aisin

2.0 L

2.4 L

03-25

1st gear ratio

2nd gear ratio

4.452

3.83

2.398

2.33

3rd gear ratio

1.414

1.436

4th gear ratio 1.000

5th gear ratio

Reverse gear ratio

0.802

0.789

4.473

4.22

Odometer gear ratio (Driven gear / driving gear) Zomax

19/6

32/10

Input shaft gear bearing axial clearance

Output shaft radial run-out

Output shaft journal

A

B

C

D

Axial clearance between od-r synchronizer ring and

gear

Axial clearance between 4th synchronizer ring and

Axial clearance between 3rd synchronizer ring and

Axial clearance between 2nd synchronizer ring and

Axial clearance between 1st synchronizer ring and

Radial clearance between 1st synchronizer ring and

1.0 ~ 1.6 mm

1.0 ~ 2.0 mm

03-26

Clearance between od-r synchronizer sleeve and

gearshift fork

Clearance between 3rd-4th synchronizer sleeve and

Clearance between 1st-2nd synchronizer sleeve and

Drain plug

35 ~ 45

29.8 ~ 44.6

Transmission operation mechanism × Body -

Transmission lifting lug × Transmission 41 ~ 51

Transmission assy × Engine

42.2 ~ 53.9

78 ~ 96 (M6 × 1.25)

45 ~ 55 (M6 × 1.25)

Odometer sensor × Transmission assy -

Backup lamp switch × Transmission assy -

Gear shift connecting rod × Transmission assy 22 ~ 28

Gear select connecting rod × Transmission assy 22 ~ 28

Filler cap

Front bearing retainer × Transmission assy

17 ~ 22

Output shaft rear bearing baffle × Transmission assy

Reverse idler gear shaft plate × Transmission assy

15 ~ 20

Lever housing assy × Transmission assy 14 ~ 26

Extension housing sub-assy × Transmission assy 26 ~ 48

Clutch housing × Transmission assy 16 ~ 21

SERVICE SPECIFICATIONS - CLUTCH

03-27

CLUTCH PEDAL

Height Standard 165 mm

Push rod play Standard 26.4 mm

Clutch disk thickness

Width of diaphragm spring

Height of diaphragm spring

Clutch disk run-out

Flywheel run-out

Limit -

Bleeding plug -

Clutch pedal lock nut 17 ~ 21

Clutch pedal pin nut -

Clutch master cylinder nut 20 ~ 26

Clutch master cylinder fluid tube connector 21 ~ 24

Clutch slave cylinder fluid tube connector 21 ~ 24

Clutch slave cylinder bolt -

Clutch cover bolt 25

03-28

VEHICLE

SERVICE SPECIFICATIONS - STEERING COLUMN

Steering radius Minimum 5.75 m

Off track (30 m,40 Km/h)

STEERING WHEEL

Left

Right

< 2 m

< 1 m

Diameter -

Free play ± 15°

Turning force

Engine stopped

< 200 N

< 45 N

Clearance between cross spider and bearing

≤ 0.15 mm

Steering wheel nut 40 ~ 50

Steering column assy 29 ~ 35

Main retard assy 29 ~ 35

Steering propeller shaft assy × Steering column assy 29 ~ 35

Steering propeller shaft assy × Steering box 29 ~ 35

Steering box 108 ~ 125

SERVICE SPECIFICATIONS - POWER STEERING

03-29

STEERING PUMP BELT

Deflection 5.5 ~ 8.5 mm (98 N)

STEERING FLUID

Operating temperature - 40 ~ 120 ℃

Pressure

Engine idling, valve closed

Engine idling, valve open, steering wheel at lock position

10±0.5 MPa

≤ 10.5 Mpa

Pressure difference

Vavle open, engine running at 1000 and 3000 r/min -

STEERING BOX

Weight -

Number of rack teeth -

Number of pinion teeth -

Module -

Gear ratio -

Rotating angle of rack shaft -

Gross rotating turn of pinion -

Pitch circle of pinion -

Radial run-out of rack -

03-30

Power steering line connector -

Steering box 108 ~ 128

Steering box × Steering propeller shaft assy 29 ~ 35

Steering tie rod × Steering knuckle arm 84 ~ 100

SERVICE SPECIFICATIONS - HEATER AND AIR CONDITIONING

AMOUNT OF COMPRESSOR OIL

03-31

Replace compressor

Replace all pipes

Replace evaporator

Compressor has 180 ml oil, no need added

40 ~ 60 ml

10 ml

Replace condenser

Replace pipes

Gas leakage

Pressure of low side

Pressure of high side

No leakage

Leakage

ON

OFF

5 ml

No need added

80 ml

0.15 ~ 0.25 MPa

1.37 ~ 2.37 MPa

Φ9 aluminium tube, M16×1.5 thread 12 ~ 15

Φ12 aluminium tube, M22×1.5 thread 20 ~ 26

Φ16 aluminium tube, M24×1.5 thread 30 ~ 35

Front evaporator and heater assy bolt -

03-32

SERVICE SPECIFICATIONS - SEAT BELT

Driver / assistant driver seat retractor × Body 50 ~ 55

Driver / assistant driver seat belt lower anchor × Body 50 ~ 55

SERVICE SPECIFICATIONS - LIGHTING

03-33

LIGHTING

Front combination lamp × Frame 2 ~ 3

Rear combination lamp × Frame 2 ~ 3

03-34

SERVICE SPECIFICATIONS - WIPER AND WASHER

Front wiper assy nut -

Rear wiper assy nut -

Front wiper motor with link assy bolt 6 ~ 8

Rear wiper motor with link assy bolt 6 ~ 8

SERVICE SPECIFICATIONS - SEAT

03-35

Driver seat assy bolt 45 ~ 55

Assistant driver seat assy bolt 45 ~ 55

Passenger seat assy bolt 45 ~ 55

03-36

SERVICE SPECIFICATIONS - DOORS

FRONT DOOR

Flatness

SLIDING DOOR

REAR HATCH

Up

From up to down of A pillar

Other

Down

5.5 mm

-2 ~ 0 mm

0 mm

6 mm

10 mm

Flatness -

Front door hinge bolt 28 ~ 32

Front door lock catch screw 28 ~ 32

Sliding door hinge bolt 28 ~ 32

Sliding door concave limiting device bolt 28 ~ 32

Rear hatch bolt 28 ~ 32

Rear hatch concave limiting device bolt 28 ~ 32

SERVICE SPECIFICATIONS - EXTERIOR AND INTERIOR TRIM

EXTERIOR AND INTERIOR TRIM

Sunvisor hook bolt 6 ~ 8

Floor trim strip screw 6 ~ 8

Front bumper assy bolt 6 ~ 8

Rear bumper assy bolt 6 ~ 8

Front wiper bolt 6 ~ 8

03-37

03-38

SERVICE SPECIFICATIONS - VEHICLE CONTROL SYSTEM

Ignition switch assy bolt -

ENGINE CONTROL SYSTEM............................................................ 04-1

PRECAUTION.............................................................................. 04-1

LOCATION................................................................................... 04-4

HOW TO DIAGNOSTICS ANALYSE........................................... 04-6

DIAGNOSTIC HELP - INTERMITTENT FAULT .......................... 04-9

BASIC SERVICE PROCEDURE................................................ 04-11

TERMINALS OF ECM................................................................ 04-12

DIAGNOSTIC SYSTEM............................................................. 04-17

READING AND ERASING DIAGNOSTIC

TROUBLE CODE (DTC)........................................................... 04-19

CAPTURING DATA ................................................................... 04-21

FAIL - SAFE CHART.................................................................. 04-22

DATA STREAM LIST/ACTIVE TEST......................................... 04-24

DIAGNOSTIC TROUBLE CODE CHART.................................. 04-28

DTC DIAGNOSTIC .................................................................... 04-33

PROBLEM SYMPTOMS TABLE................................................ 04-60

ENGINE SYMPTOM DIAGNOSTIC........................................... 04-61

ANTI - LOCK BRAKE SYSTEM....................................................... 04-98

PRECAUTION............................................................................ 04-98

LOCATION............................................................................... 04-100

ABS MODULE CONNECTOR ................................................. 04-101

DIAGNOSTIC TROUBLE CODE CHART................................ 04-102

PROBLEM SYMPTOMS TABLE.............................................. 04-104

PRE - CHECK.......................................................................... 04-105

POWER SUPPY VOLTAGE HIGH OR LOW........................... 04-107

SOLENOID VALVES AND VALVES RELAY FAILURE........... 04-108

PUMP MOTOR FAILURE ........................................................ 04-112

WHEEL SPEED SENSOR SIGNAL FAULT ............................ 04-118

ABS CONTROL IS UNREASONABLE .................................... 04-122

ABS SYSTEM IS INOPERATIVE............................................. 04-125

SUPPLEMENTAL RESTRAINT SYSTEM ..................................... 04-129

PRECAUTION.......................................................................... 04-129

LOCATION............................................................................... 04-130

RESTRAINT CONTROL MODULE (RCM)

CONNECTOR PIN................................................................... 04-131

DIAGNOSTIC TROUBLE CODE CHART................................ 04-133

PROBLEM SYMPTOMS TABLE.............................................. 04-134

8102 - POWER SUPPLY VOLTAGE LOW.............................. 04-135

8201 - DRIVER AIRBAG FAULT - HIGH RESISTANCE ......... 04-139

8202 - DRIVER AIRBAG FAULT - LOW RESISTANCE.......... 04-139

8203 - DRIVER AIRBAG CIRCUIT SHORT TO GROUND...... 04-141

8211 - CO - PILOT SIDE AIRBAG FAULT - HIGH

RESISTANCE .......................................................................... 04-145

8212 - CO - PILOT SIDE AIRBAG FAULT - LOW

RESISTANCE ......................................................................... 04-145

8213 - CO - PILOT SIDE AIRBAG CIRCUIT

SHORT TO GROUND.............................................................. 04-148

8214 - CO - PILOT SIDE AIRBAG CIRCUIT

SHORT TO BATTERY............................................................. 04-150

SRS WARNING LIGHT IS INOPERATIVE .............................. 04-154

04

HEATER AND AIR CONDITIONING SYSTEM.............................. 04-156

PRECAUTION.......................................................................... 04-156

BASIC INSPECTION ............................................................... 04-157

LOCATION............................................................................... 04-158

PROBLEM SYMPTOMS TABLE.............................................. 04-159

A/C SYSTEM IS INOPERATIVE.............................................. 04-162

FRONT BLOWER MOTOR IS INOPERATIVE ........................ 04-166

REAR EVAPORATOR MOTORS ARE INOPERATIVE........... 04-172

FRONT AIR FLOW IS INSUFFICIENT .................................... 04-178

REAR AIR FLOW IS INSUFFICIENT....................................... 04-182

NO COOLING FROM FRONT A/C SYSTEM .......................... 04-184

NO COOLING FROM REAR A/C SYSTEM............................. 04-191

REAR HEATER IS INOPERATIVE OR

INSUFFICIENT HEATING ....................................................... 04-195

LIGHTING SYSTEM ....................................................................... 04-202

PRECAUTION.......................................................................... 04-202

BASIC INSPECTION ............................................................... 04-203

LOCATION............................................................................... 04-204

PROBLEM SYMPTOMS TABLE.............................................. 04-206

LO - BEAM HEADLAMP IS INOPERATIVE (ONE SIDE) ........ 04-212

HI - BEAM HEADLAMP IS INOPERATIVE (ONE SIDE) ......... 04-218

HI - BEAM HEADLAMPS ARE INOPERATIVE

(BOTH SIDES) ........................................................................ 04-220

LO - BEAM AND HI - BEAM HEADLAMPS ARE

INOPERATIVE (ONE SIDE) .................................................... 04-224

ALL HEADLAMPS ARE INOPERATIVE .................................. 04-227

FRONT FOG LAMPS ARE INOPERATIVE ............................. 04-233

FRONT FOG LAMPS ARE ALWAYS ON ................................ 04-238

REAR FOG LAMPS ARE INOPERATIVE................................ 04-241

REAR FOG LAMPS ARE ALWAYS ON .................................. 04-246

ALL FOG LAMPS ARE INOPERATIVE ................................... 04-249

HAZARD WARNING LAMPS ARE INOPERATIVE (TURN SIGNAL

LAMPS ARE NORMAL) ........................................................... 04-256

TURN SIGNAL LAMPS ARE INOPERATIVE (HAZARD WARNING

LAMPS ARE NORMAL) ........................................................... 04-260

HAZARD WARNING AND TURN SIGNAL LAMPS ARE INOPERA-

TIVE ......................................................................................... 04-264

TURN SIGNAL LAMPS ARE INOPERATIVE (ONE SIDE)...... 04-272

HAZARD WARNING LAMPS ARE ALWAYS ON .................... 04-275

ALL STOP LAMPS ARE INOPERATIVE ................................. 04-277

STOP LAMP IS INOPERATIVE (ONE SIDE) .......................... 04-282

HIGH - MOUNTED STOP LAMP IS INOPERATIVE................ 04-284

BACK - UP LAMP IS INOPERATIVE(ONE SIDE) ................... 04-286

BACK - UP LAMPS ARE INOPERATIVE (BOTH SIDES) ....... 04-288

IGNITION SWITCH ILLUMINATION IS INOPERATIVE .......... 04-293

CENTRAL DOME LIGHT IS INOPERATIVE ........................... 04-296

AIR PURIFIER LAMP IS INOPERATIVE ................................. 04-301

STEP LAMP ARE INOPERATIVE ........................................... 04-304

TRUNK LAMP IS INOPERATIVE ............................................ 04-307

FRONT DOME LIGHT IS INOPERATIVE................................ 04-310

ALL INTERIOR ILLUMINATION LAMPS ARE

INOPERATIVE ........................................................................ 04-314

INSTRUMENT CLUSTER ILLUMINATION IS

NOT INOPERATIVE ................................................................ 04-319

DIAGNOSIS SWITCH ILLUMINATION IS

NOT INOPERATIVE ................................................................ 04-322

CIGARETTE LIGHTER ILLUMINATION IS

NOT INOPERATIVE ............................................................... 04-324

A/C CONTROL PANEL ILLUMINATION IS

NOT INOPERATIVE ................................................................ 04-326

RADIO ILLUMINATION IS NOT INOPERATIVE ..................... 04-328

REAR BLOWER FORWARD SWITCH ILLUMINATION IS

NOT INOPERATIVE ................................................................ 04-330

DOME LIGHT SWITCH ILLUMINATION IS

NOT INOPERATIVE ............................................................... 04-332

OUTSIDE MIRROR DEFROSTER SWITCH ILLUMINATION IS

NOT INOPERATIVE ................................................................ 04-334

HEADLAMP DIMMER SWITCH ILLUMINATION IS

NOT INOPERATIVE ............................................................... 04-336

REAR WINDOW DEFROSTER SWITCH ILLUMINATION IS

NOT INOPERATIVE ................................................................ 04-338

INSTRUMENT DIMMER SWITCH ILLUMINATION IS

NOT INOPERATIVE ............................................................... 04-340

HAZARD WARNING SWITCH ILLUMINATION IS

NOT INOPERATIVE ............................................................... 04-342

WIDTH LAMPS IS NOT INOPERATIVE.................................. 04-344

TAIL LAMPS ARE INOPERATIVE........................................... 04-347

LICENSE LAMP IS INOPERATIVE ......................................... 04-350

WIDTH LAMPS TAIL LAMPS AND LICENSE

LAMP ARE INOPERATIVE..................................................... 04-352

WIPER AND WASHER .................................................................. 04-356

PRECAUTION.......................................................................... 04-356

LOCATION............................................................................... 04-357

BASIC INSPECTION ............................................................... 04-358

PROBLEM SYMPTOMS TABLE.............................................. 04-359

WIPERS ARE INOPERATIVE - WINDSHIELD........................ 04-361

WIPERS ARE INOPERATIVE AT

LOW SPEED - WINDSHIELD.................................................. 04-367

HIGH SPEED - WINDSHIELD ................................................ 04-369

WIPERS ARE INOPERATIVE IN INTERMITTENT MODE - WIND-

SHIELD .................................................................................... 04-371

WASHER PUMP IS INOPERATIVE - WINDSHIELD............... 04-374

WHEN THE WIPER SWITCH IS OFF, THE WIPER BLADE DOES

NOT RETRACT........................................................................ 04-378

WIPER IS INOPERATIVE - REAR WINDOW.......................... 04-381

WASHER PUMP IS INOPERATIVE - REAR WINDOW .......... 04-387

AUDIO SYSTEM............................................................................. 04-392

PRECAUTION.......................................................................... 04-392

LOCATION............................................................................... 04-393

BASIC INSPECTION ............................................................... 04-394

PROBLEM SYMPTOMS TABLE.............................................. 04-395

RADIO DOES NOT WORK...................................................... 04-396

RADIO RECEPTION IS POOR................................................ 04-400

POOR SOUND QUALITY....................................................... 04-401

SPEAKER DOES NOT WORK ................................................ 04-402

AUXILIARY POWER...................................................................... 04-406

LOCATION............................................................................... 04-406

PROBLEM SYMPTOMS TABLE.............................................. 04-407

CIGARETTE LIGHTER IS INOPERATIVE .............................. 04-408

INSPECTION PROCEDURE ................................................... 04-409

12V POWER SUPPLY OUTPUT SOCKET IS

INOPERATIVE ......................................................................... 04-411

HORN SYSTEM.............................................................................. 04-415

LOCATION............................................................................... 04-415

PROBLEM SYMPTOMS TABLE.............................................. 04-416

HORN IS INOPERATIVE ......................................................... 04-417

INSPECTION PROCEDURE ................................................... 04-418

HORN IS ALWAYS ON............................................................ 04-422

REVERSE RADAR SYSTEM ......................................................... 04-424

PRECAUTION.......................................................................... 04-424

LOCATION............................................................................... 04-425

SYSTEM DESCRIPTION......................................................... 04-426

PROBLEM SYMPTOMS TABLE.............................................. 04-428

REVERSE RADAR SYSTEM IS INOPERATIVE AT ALL ........ 04-429

REVERSE RADAR SYSTEM IS OPERATIVE WHEN THE SHIFT LE-

VER IS OUT OF REVERSE POSITION .................................. 04-434

REVERSE RADAR SYSTEM IS INOPERATIVE WITHIN SPECIFIED

DISTANCE (BACK - UP LAMP IS NORMAL) ......................... 04-436

REVERSE RADAR SYSTEM IS OPERATIVE BUT THERE IS NO

OBSTACLE BEHIND VEHICLE ............................................... 04-439

BUZZER IS INOPERATIVE OR OPERATIVE INCORRECTLY WITH-

IN SPECIFIED DISTANCE (DISPLAYER IS NORMAL) .......... 04-442

DISPLAYER IS INOPERATIVE WITHIN SPECIFIED DISTANCE

(BUZZER IS NORMAL)............................................................ 04-445

POWER WINDOWS ....................................................................... 04-448

PRECAUTION.......................................................................... 04-448

LOCATION............................................................................... 04-449

DOOR CONTROL SWITCH PIN.............................................. 04-450

WINDOW CONTROL SWITCH RH PIN .................................. 04-451

CENTRAL LOCKING CONTROLLER ASSY A PIN................. 04-452

BASIC INSPECTION ............................................................. 04-453

PROBLEM SYMPTOMS TABLE.............................................. 04-454

ALL POWER WINDOWS ARE INOPERATIVE ....................... 04-456

FRONT POWER WINDOW LH IS INOPERATIVE .................. 04-461

FRONT POWER WINDOW LH DOES NOT OPEN................. 04-464

FRONT POWER WINDOW LH DOES NOT CLOSE............... 04-466

FRONT POWER WINDOW RH IS INOPERATIVE (USE DOOR CON-

TROL SWITCH) ....................................................................... 04-468

FRONT POWER WINDOW RH IS INOPERATIVE (USE WINDOW

CONTROL SWITCH RH) ......................................................... 04-470

OUTSIDE MIRROR ........................................................................ 04-473

LOCATION............................................................................... 04-473

TERMINALS OF OUTSIDE MIRROR SWITCH....................... 04-474

BASIC INSPECTION ............................................................... 04-475

PROBLEM SYMPTOMS TABLE.............................................. 04-476

MIRRORS ARE INOPERATIVE (BOTH SIDES) ..................... 04-477

A SINGLE MIRROR IS INOPERATIVE ................................... 04-480

MIRROR ADJUSTMENT UP/DOWN IS INOPERATIVE ......... 04-483

MIRROR ADJUSTMENT LEFT/RIGHT IS INOPERATIVE...... 04-485

DEFROSTER SYSTEM .................................................................. 04-487

LOCATION............................................................................... 04-487

SYSTEM DESCRIPTION......................................................... 04-489

BASIC INSPECTION ............................................................... 04-490

PROBLEM SYMPTOMS TABLE.............................................. 04-491

REAR WINDOW DEFROSTER IS INOPERATIVE................. 04-492

OUTSIDE MIRROR DEFROSTER IS INOPERATIVE............ 04-497

INSTRUMENT CLUSTER .............................................................. 04-502

PRECAUTION.......................................................................... 04-502

LOCATION............................................................................... 04-503

INSTRUMENT CLUSTER INFORMATION.............................. 04-504

TERMINALS OF INSTRUMENT CLUSTER ............................ 04-507

BASIC INSPECTION ............................................................... 04-510

PROBLEM SYMPTOMS TABLE.............................................. 04-511

MALFUNCTION IN SPEEDOMETER...................................... 04-513

MALFUNCTION IN TACHOMETER ........................................ 04-515

MALFUCTION IN FUEL GAUGE / LOW FUEL WARNING LIGHT

NEVER OR ALWAYS ON........................................................ 04-517

MALFUCTION IN ENGINE COOLANT

TEMPERATURE GAUGE........................................................ 04-520

ENGINE OIL PRESSURE WARNING LIGHT

NEVER / ALWAYS ON ........................................................... 04-523

SEAT BELT WARNING LIGHT

NEVER / ALWAYS ON ........................................................... 04-526

PARKING BRAKE INDICATOR LIGHT

NEVER / ALWAYS ON ........................................................... 04-530

POWER DOOR LOCKS................................................................. 04-533

PRECAUTION.......................................................................... 04-533

LOCATION............................................................................... 04-534

CENTRAL LOCKING CONTROLLER ASSY A........................ 04-535

CENTRAL LOCKING CONTROLLER ASSY B........................ 04-536

BASIC INSPECTION ............................................................... 04-537

PROBLEM SYMPTOMS TABLE.............................................. 04-538

THE FUNCTION OF POWER DOOR LOCKS IS

INOPERATIVE (USING THE KEY).......................................... 04-539

ONE DOOR IS INOPERATIVE (USING THE KEY)................. 04-543

DOOR DOES NOT OPEN / CLOSE (USING

THE REMOTE KEY) ................................................................ 04-545

SLIDING ROOF SYSTEM .............................................................. 04-548

LOCATION............................................................................... 04-548

SYSTEM DESCRIPTION......................................................... 04-549

TERMINALS OF MAIN COMPONENTS.................................. 04-550

BASIC INSPECTION ............................................................... 04-551

PROBLEM SYMPTOMS TABLE.............................................. 04-552

SLIDING ROOF SYSTEM IS INOPERATIVE.......................... 04-553

1. POWER OFF.

DIAGNOSTICS - ENGINE CONTROL SYSTEM

04-1

• The battery negative cable must be disconnected first before removing or installing any electric

appliance and when tools or facilities will touch the exposed terminals. It should be connected

eventually. This will prevent person injured and vehicle damaged.

• The ignition switch must be OFF without any special descriptions.

The ignition and illuminatioin switches must be OFF before disconnecting or connecting the battery

negative cable (the semiconductor maybe damaged without doing that).

Do not leave the key in the vehicle in case the doores are locked before disconnecting the battery negative

cable for the vehicle equipped with remote control central lock.

2. RESET THE ODOMETER AND CLOCK IF DISCONNECTING THE COMBINATION INSTRUMENT

BATTERY NEGATIVE CABLE.

The total course will not be reset.

3. THE SAVING DATA SETTING WILL LOST IF DISCONNECTING THE BATTERY NEGATIVE CABLE.

After connecting the battery negative cable, the audio system shoud be reset.

4. EXPRESSIONS OF IGNITION SWITCH

Switch Type Ignition Switch (position) Ignition Switch (condition)

Ignition switch off LOCK Off

Expression

Ignition switch on (IG) ON On (IG)

Ignition switch on (ACC) ACC On (ACC)

Engine start START Start

5. PRECAUTIONS FOR OVERHAULING THE ENGINE CONTROL SYSTEM FAILURE.

(a) Do not disconnect power circuit while engine is running at high speed in case the instantaneous overvoltage

damage the ECM and sensors.

(b) The ECM should be disconnected when welding on the vehicle body. It is special attention that performing

the repair work beside the ECM or sensors.

faulty components when the connector terminals or the installing state of the components go

out of order.

(d) The high impedance type multimeter should be used to the test except the especial description of the

procedure in place of the traditional analogue types multimeter.

(e) Don’t check any electric appliance connecting the ECM with a test light.

(f) Never connect the negative and positive battery cables wrong. The battery negative cable must be

grounded.

04-2

(g) ECM and sensors must be kept from moisture. No permission damaging the seal device of ECM and

sensors and washing them more.

(h) Prevent human body static electricity from damaging ECM: The operator body must be grounded when

operator checks ECM or replace chips.

(i) In order to identifying the faulty position, we must check the vehicle condition while vehicle goes out of

order. For example, we check the faults through the DTC. We record these faults states before

disconnecting every connector or removing and installing components.

(j) We must remove and install ECM, actuators and independent sensors when the ignition switch is OFF

unless there is additional specification in the checking procedure.

(k) If the removed and installed ECM, actuators and sensors are to be reinstalled, the system should be

checked after completing installation. Using the special diagnosis tool to check DTC.

(l) Check the ECM connector terminals with a multimeter.

• Connect the small probing pin to the probe of a multimeter.

• Check voltage value of terminals referring to the inspection sheet by back probing ECM connectors

(m) When diagnosis, the ignition switch turns “ON” and the connectors are disconnected. DTC of the other

system will be set. After diagnosis, confirm DTC in all systems.Turn the ignition switch “LOCK” when

the connectors are connected and disconnected.

(n) The test probe must not be probed in wire harness. This will reduce the waterproofness. And it also

cause corrossion. Using the test wire, wire connector, measure wire harness and so on.

(o) Check the common connectors when they are in connection status by probing terminals in the wire

harness. If the connector is too small to check, do not force inserting.

(p) If check the common connectors when they are not in connection status (check male connectors):

• Do not short terminals circuit by using a probe. This will damage the interior circuit in ECM.

• The system to be checked and other system will store DTC when they aren’t in connecting status.

(q) If check the common connectors when they are not in connection status (check female connectors):

• Use the special tools to check wire harness.

(r) We shall have a short harness or connectors without taking cautions by wrong insertion. This will

damage wire harness, sensor, ECM and other components So we must carefully handle when

checking.

(s) Do not check with the list order.

• If the check results are different from the standard value, then check related sensors, actuators and

wire harness. Repair or replace if necessary.

• Check with the voltage meter again after repairing or replacing. Confirm if the faults have been

eliminated.

(t) Check resistance and continuity between terminals of ECM with multimeter.

• Ignition switch: OFF

• Disconnect ECM harness connector.

(u) Ground inspection.

• Ground connections are very important to the proper operation of electrical and electronic circuits.

Ground connections are often exposed to moisture, dirt and other corrosive elements. The corrosion

(rust) can become an unwanted resistance. This unwanted resistance can change the way a circuit

works.

• Electronically controlled circuits are very sensitive to proper grounding. A loose or corroded ground can

drastically affect an electronically controlled circuit. A poor or corroded ground can easily affect the

circuit. Even when the ground connection looks clean, there can be a thin film of rust on the surface.

• When inspecting a ground connection follow these rules:

04-3

1 Remove Bolt (Screw)

2

Inspect Mating Surface For Tarnish,

Dirt, Rust, Etc. Clear As Required To

Assure Good Contact.

3 Reinstall Bolt (Screw) Securely

(e)

(f)

Remove the ground bolt or screw.

Inspect all mating surfaces for tarnish, dirt, rust, etc.

Clean as required to assure good contact.

Reinstall bolt or screw securely.

Inspect for “add - on” accessories which may be interfering with the ground circuit.

If several wires are crimped into one ground eyelet terminal, check for improper crimps. Make

sure all of the wires are clean, securely fastened and providing a good ground path. If multiple

wires are cased in one eyelet, make sure no ground wires have excess wire insulation.

04-4

LOCATION

1 Injector

2 Throttle Body

3 Spark Plug

4 Idle Air Control Motor

5

Engine Coolant Temperature (ECT)

Sensor

6 Knock Sensor

7 Crankshaft Position (CKP) Sensor

9

Manifold Absolute Pressure/Intake Air

Temperature (MAP/IAT) Sensor

10 Ignition Control Module

11 Fuel Pressure Regulator

12 PCV Valve

13 Inlet Fuel (From Fuel Pump)

Outlet Fuel (Return Back To Fuel

Tank)

8 Vehicle Speed Sensor

04-5

1 Diagnosis Link Connector (DLC)

2 Brake Lamp Switch

3 Instrument Cluster

4 Accelerator Pedal

5 Muti - media

04-6

HOW TO DIAGNOSTICS ANALYSE

Use diagnostic scan tool to diagnose vehicle.

1. VEHICLE INTO REPAIR SHOP

2. COLLECT AND ANALYSE CUSTOMER’S SYMPTOM

3. CONNECT THE DIAGNOSTIC SCANNER TO DLC3

4. CHECK DTC AND DATA FREEZE - FRAME DATA

5. ERASE DTC

6. VISUAL CHECK

7. CONFIRM FAULT SYMPTOM

Check result (if engine can not start,check following first)

Result

Proceed To

Fault present Step 9

Normal Step 8

8. SIMULATE FAULT SYMPTOM

9. CHECK IF DTC PRESENT

Check result

DTC present

Next step

10. REFER TO DTC TABLE

YES > Go to step 13.

Normal Step 11

04-7

11. BASIC CHECK

Fault can not be confirmed

Fault can be confirmed Step 16

12. REFER TO SYMPTOM TABLE

Fault can be confirmed circuit

Fault can be confirmed part Step 15

13. CHECK ECM POWER SUPPLY CIRCUIT

14. CHECK ELECTRIC CIRCUIT

Fault can be confirmed Step 17

15. CHECK INTERMITTENT FAULT

YES > Go to step 17.

16. CHECK PARTS

17. CONFIRM FAULT

18. ADJUST OR REPAIR

19. PERFORM CONFIRMATION TEST

YES > END.

04-8

THE MAIN POINTS OF REPAIRING BURNED FUSE OUT

DTC cause by burned fuse.

(a) Remove the burned fuse. Check the resistance between

the load side and ground where the fuse burned. Turn off

all the switch that connecting to the fuse. If the resistance

is almost zero, the switch and the load components

circuit must be shorted somewhere. If the resistance is

not zero, there is no circuit for short. But the temporaly

shorted circuit also will cause the fuse burning.

(b) The shortage caused by following:

• Clipped harness

• Damaged harness

• Water seep into connection

• Operation

1 Battery

2 Fuse

3 Load switch

4 Burned fuse

5 Short position

04-9

DIAGNOSTIC HELP - INTERMITTENT FAULT

If an intermittent fault exists, perform diagnosis as follow:

• Intermittent incidents may occur. In many cases, the malfunction resolves itself (the part or

circuit function returns to normal without intervention). It is important to realize that the

symptoms described in the customer's complaint often do not recur on (1st trip) DTC visits.

Realize also that the most frequent cause of intermittent incidents occurrences is poor

electrical connections. Because of this, the conditions under which the incident occurred may

not be clear. Therefore, circuit checks made as part of the standard diagnostic procedure may

not indicate the specific malfunctioning area.

• In this case, the maintenance staff must find out the situation in detail from the customer, ask

the car owner for the details of driving conditions, weather conditions, frequency of occurrence

and symptom of failure, take analysis and simulate the same or similar conditions and

environment, then, determine if the symptom of failure is caused by vibration, temperature or

other factors. No matter how experienced the maintenance staff are, how skilled their technique

is, if analyzing the failure without checking, they would certainly neglect some important factors

during repairing which causes wrong speculation and the repair work will take an indirect route

or can’t go forward. The following checking will help to find out this kind of failure.

1. VIBRATION METHOD.

(a) Connector: Shake the connector lightly in vertical or

horizontal directions, check if the wiring harness

connector connecting the connector and corresponding

parts is loose, the terminal is dirty, rusty, worn or bended

and if the connection is loose because of the terminal

extension.

(b) Harness: Shake the harness lightly in vertical or

horizontal directions, thoroughly check the harness

breakaway condition in the connector connecting

vibration section and engine/cab instruments.

considered as the failure cause lightly with hands, check

them for failure, don't hit the relay with force, otherwise

the relay may be open.

04-10

2. HEATING METHOD.

(a) If one doubtful region is considered to cause a failure, heat the part which is the most possible cause of

failure with an electric blower or the like to check if the failure occurs.

Don’t heat to over 60℃ (the heating temperature should be in the limit of touching the part with hands);

don’t heat the control module.

3. SPRAYING METHOD.

(a) If the failure is considered to occur in rainy day or wet weather, spray water to the vehicle to check if the

failure occurs.

• Don’t spray water to the engine directly to cool the engine, sprinkle water on the front face of

radiator to change the temperature and humidity indirectly.

• Don’t spray water on electronic parts directly.

• Please take extra care to sprinkle water on vehicle leaking water.

4. ELECTRIC APPLIANCE CONNECTED FULLY METHOD.

(a) If the failure is possible to be caused by electric overload, connect all electrical loads, including the

heater blower, the headlamps and the rear - window defroster, to check if the failure occurs. The trouble

location or failure part must be found out while the symptom is confirmed during the failure symptom

simulation test. To do this, narrow the range of circuit which is possible to failure based on the symptom

of failure before starting the test and the pre - connection of connectors, then carry out the symptom

simulation test and judge if the circuit tested is normal. When a puzzling failure occurs, make full use of

troubleshooting and diagnostic code list for fault analysis and diagnosis to narrow the failure range and

find out the trouble location quickly. This method is very practical and effective.

5. DATA FLOW CAPTURE WITH DIAGNOSTIC SCANNER.

(a) Use the function of data flow capture on the diagnostic scanner. When seeing the data flow on the

diagnostic scanner, make the rated data status to simulate the fault conditions based on the freeze -

frame on the diagnostic scanner.

6. OSCILLOSCOPE METHOD.

(a) Using the oscilloscope, capture waveform can be more helpful to find intermittent malfunction.

7. OTHER METHODS.

(a) Before replacing ECM of other electronic control modules in part replacing method, take full diagnosis

for other external causes; ECM or other electronic control modules are expensive products with high

reliability.

When replacing and testing possible damaged ECM or control modules, install the possible damaged

ECM or control modules on a failure - free vehicle for testing; Don’t install new control modules on a

failed vehicle for testing to avoid damaging the control modules.

04-11

BASIC SERVICE PROCEDURE

1. CHECK BATTERY VOLTAGE

Check when engine stops or ignition switch is OFF.

More than 11V

Less than 11V

Charge or change battery

2. CHECK IF THE ENGINE STARTS

Is the check result normal?

NO > Go to fault symptom chart.

3. CHECK FILTER

NO > Replace or clean filter.

4. CHECK IDLE SPEED

5. CHECK FUEL PRESSURE

NO > Eliminate fuel pressure fault, and go to next step.

6. CHECK IGNITION

YES > Go to fault symptom chart.

NO > Eliminate ignition system fault.

04-12

TERMINALS OF ECM

ECM TERMINAL DEFINITION

Terminal No. Terminal Description Color Terminal No. Terminal Description Color

1 Ignition control L 43 - -

2 Ground B 44 Main relay control G - W

3 Ground B 45 - -

4 Ignition control G 46 - -

5 - - 47

6 Injector 1 L - W 48

Upstream oxygen

signal +

Downstream oxygen

7 Injector 3 L - P 49 ECT sensor + W - B

8 Injector 2 L - V 50 - -

9 Pump relay control G 51 Vehicle speed input W - G

10 A/C low voltage output L 52 ECT sensor - W - R

Crankshaft position

sensor -

P 53 - -

12 SVS R - B 54 Air pressure MAP L - Y

13 - - 55 - -

14 - - 56 - -

15 - - 57 - -

16 - - 58 Knock sensor power O - V

17 High fan control W - B 59 Accelerator sensor +

18 Vehicle speed R - W 60 - -

W

O

04-13

19 MIL G - B 61 - -

20 Idle control high A G - Br 62 - -

21 Idle control low A G - Y 63 - -

22 - - 64 EVAP control W - Y

23

24

Heated downstream

oxygen sensor -

Heated upstream

Y - H 65 Low fan control Y

L - R 66

Air temperature/

pressure power

25 Injector 4 L - O 67 ECU continued power W - L

26 A/C MP IN R - W 68 ECU IG power B - G

27 Throttle position signal V - G 69 - -

28 - - 70 Sensor power SB

29 - - 71 Air temperature L - W

30

sensor +

31 - - 73

O 72 - -

Upstream/downstream

oxygen sensor signal -

32 - - 74 Sensor ground Br - R

33 - - 75 ECU K signal R - L

34 - - 76

pressure signal -

35 - - 77 - -

36 - - 78 - -

SB

Br - R

37 Knock signal W - B 79 A/C request Y - B

38 - - 80 - -

39 - - 81 - -

40 - -

41 Idle control high B Y - P

42 Idle control low B Br - Y

13.

04-14

CHECK ECM TERMINAL WITH MULTIMETER

The normal standard voltage of per terminal as follow “normal condition”. The table also points out the

check condition

Terminal No. Terminal Description Detection Condition Specified Condition

6 No.1 Injector

8 No.2 Injector

7 No.3 Injector

25 No.4 Injector

20 Idle air control motor loop A

41 Idle air control motor loop B

Idle: depress accelerator suddenly

Engine: warm condition, start

engine

Voltage: 11 ~ 14 V

Voltage: 0 ~ 3 V

9 Pump relay

64 EVAP solenoid

Ignition switch: ON

Engine: idle

Engine: warm condition, 3000 RPM

Battery voltage

0 ~ 3 V

1 Ignition control: (1 - 4) Engine: 3000 RPM 0.3 ~ 3.0 V

4 Ignition control: (2 - 3) Engine: 3000 RPM 0.3 ~ 3.0 V

68 Continuity power supply

Ignition switch:

79 A/C request signal Engine running, depress A/C switch -

26 A/C feed back signal Engine running, depress A/C switch -

19 MIL Ignition switch: OFF → ON 0 ~ 3 V

44 Main relay

Ignition switch: OFF

Heated upstream oxygen

sensor

Engine: warm condition, idle

Engine: 5000 RPM

Heated downstream oxyge

IAT: 0 ℃

3.2 ~ 3.8 V

66 IAT sensor Ignition switch: ON

IAT: 20 ℃

IAT: 40 ℃

IAT: 80 ℃

2.3 ~ 2.9 V

1.5 ~ 2.1 V

0.4 ~ 1.0 V

04-15

47 Upstream oxygen sensor Engine: warm condition, 2000 RPM 0.1 ~ 0.9 V

48 Downstream oxygen sensor Engine: warm condition, 2000 RPM About 100 mV

49 ECT sensor Ignition switch: ON

ECT: 20 ℃

ECT: 40 ℃

1.3 ~ 1.9 V

70 TPS Ignition switch: ON

ECT: 80 ℃ 0.3 ~ 0.9 V

TPS: idle 0.3 ~ 1.0 V (0 %)

Open widely 4.5 ~ 5.5 V (100 %)

51 VSS

30 CKP sensor

Move forward slowly

Start motor

Idle

0 ~ 5 V (repeat)

0.4 ~ 4.0 V

1.5 ~ 2.5 V

3 Ground - 0 V

04-16

CHECK ECM HARNESS - SIDE TERMINAL WITH A MULTIMETER

Standard normal resistance and continuity as follow:

No. Item Normal Condition (20 ℃ )

1 No.1 injector

2 No.2 injector

3 No.3 injector

13 ~ 16 Ω

4 No.4 injector

5 Idle air control motor loop A, B terminal

6 Idle air control motor loop C, D terminal

28 ~ 33 Ω

7 EGR solenoid valve 36 ~ 44 Ω

8 EVAP solenoid valve 36 ~ 44 Ω

9 ECM ground Continuity

10 Heated oxygen sensor About 12 Ω

5.3 ~ 6.7 Ω

11 IAT sensor

2.3 ~ 3.0 Ω

1.0 ~ 1.5 Ω

0.30 ~ 0.42 Ω

5.1 ~ 6.5 Ω

12 ECT sensor

2.1 ~ 2.7 Ω

0.9 ~ 1.3 Ω

0.26 ~ 0.36 Ω

04-17

DIAGNOSTIC SYSTEM

1. The failure of engine electric control system is

divided into 2 classes:

First is lighting MIL lamp (1); When the instrument MIL

lamp lights, based on relevant requirements of national

rules, it needs to be treated immediately, otherwise the

system will limit the speed of the engine so as to affect

the normal operating of vehicle.

The other is lighting SVS lamp (2), indicating that the

system fails and needs to be repaired in time.

The failures of both classes should be checked with

diagnostic scanner or special equipment with corresponding

functions.

The following matters should be noted during the engine running and service processes.

2. The lighting of SVS lamp and MIL lamp is controlled by ECM; The special lighting of SVS lamp

and MIL lamp after and before starting are described below:

(a) For system without failure, the ignition switch is turned ON, the MIL lamp lights on, SVS lamp lights and

then goes out (system self - checking). The SVS lamp and MIL lamp are off after engine starting and

stalling.

(b) For system with failure, the ignition switch is turned ON, the MIL lamp lights on, the SVS lamp is off and

then lights on after self - checked; After engine starting, if the SVS lamp in failure class is defined as

lighting on mode, the SVS lamp will light on after the requirements for SVS lamp lighting are met; if the

MIL lamp in failure class is defined as lighting on mode, the SVS lamp will light on after the

requirements for MIL lamp lighting are met; After engine stalling, the ignition switch is turned OFF and

goes out after process (90s for the longest).

3. If an engine failure that may involve the fuel injection system - electronic controlled is to be

diagnosed and cleared, first determine if the failure is related with the fuel injection system -

electronic controlled. If the engine fails but the malfunction indicator lamp doesn't light, the failure

is unrelated to the electronic control system generally.

The diagnostic trouble codes record and data related

with sensors and actuators in ECM can be read by

KT600 diagnostic scanner. Additional, the actuator can

be positive driven by the scan tool under specified

conditions.

04-18

DLC - data link connector.

ECM communicate with DLC.

Terminals in DLC arrange according to standard.

Terminal No. Name Check Result

4 Ground Less than 1 Ω

5 Ground Less than 1 Ω

6 Diagnostic signal

Pulse signal (When

commnicate)

7

Diagnostic

communication K

16 Battery positive 9 ~ 14 V

ENGINE CONTROL SYSTEM SELF - DIAGNOTIC ITEM

• Connect the diagnostic scanner cable to DLC. Turn

the ignition switch ON. Try to open it. If displayed

error communication on screen, then the diagnostic

scanner faults .

• If the diagnostic scanner communicates with other

vehicle normally, then check the DLC on the original

vehicle.

Check Item

2 Main Relay

3 Fuel Pump

4 Ignition Coil

5 Oxygen Sensor

6 EVAP Solenoid

7 Knock Sensor

9 Poor Accelerator Sensor

10 CKP Sensor

11 Throttle Position Sensor

12 ECT Sensor

13 MAP/IAT Sensor

04-19

READING AND ERASING DIAGNOSTIC TROUBLE CODE (DTC)

The troubles are tested and determined by the engine control system and stored in the Engine Control

Module (ECM); the system troubles can be current or history.

Current troubles: Exist in ECM currently. For example: The circuit of Engine Coolant Temperature

(ECT) sensor is open. The current troubles must be repaired. Otherwise, they can’t be erased from

memory.

(b) History troubles: Have two storage types.

• The trouble has been repaired and actual trouble has disappeared, but the memory hasn’t been erased

from ECM.

• The trouble occurred once and didn’t exist, but it is possible to occur again. For example: Poor contact

of conducting wire. As the stored troubles are not current ones, it’s unnecessary to repair them before

erased from the memory, or it can be processed referring to the trouble - shooting methods for

intermittent malfunction.

• If the battery voltage is too low and the trouble code can’t be output normally from ECM, the

battery voltage must be tested before checking and the voltage should not be less than 11 V.

• When the battery or ECM connectors are disconnected, the trouble code stored in ECM will be

erased.

• Before connecting or disconnecting KT600 scan tool, be sure to confirm the ignition switch is in

OFF (LOCK) position.

• Using the KT600 collective intelligence scan tool, read DTC.

• Using the KT600 scan tool, perform the reading DTC procedure below:

(a) Check and confirm the following conditions:

• The throttle is closed.

• Turn A/C switch OFF.

• Shift transmission in neutral.

(b) Turn the ignition switch OFF.

(DLC) - use the most current software available.

(d) Turn the ignition switch ON.

(e) Select the item, read dtc.

(f) Check DTC and data stream. After recording, delete it (If

DTC cannot be deleted, then perform the diagnosis

procedure refering to “Diagnostics trouble code check”.

Repair faults ).

(g) Start engine and warm it to normal operating temperature.

(h) Under one of the condition, run engine to MIL ON:

• Simulate DTC setting condition.

• Simulate the customer’s description.

• Simulate the scan tool freeze data.

(i) Use the scan tool to read the DTC in ECM.

04-20

(j)

If there are DTCs, but the data stream is normal or the

function is good, then refer to the diagnostics help. If there

are DTCs, but the stream is abnormal or the function is not

good, then perform diagnosis procedure refering to

“Diagnostics trouble code chart”.

• Use the scan tool to delete DTCs. As soon as DTC is detected, ECM will record the vehicle and

driving conditions as the type of freeze stream. When eliminating faults, the catching function

will help to confirm the condition of the fault, such as warm condition, stop condition and lean

or rich A/F ration and other data.

• DTC setting condition:

(a) Engine speed

(b) VSS

(d) MAP sensor

(e) Barometric sensor

(f) IAT sensor

(g) TPS

(h) EVAP

(i) Fuel pressure adjustment

(j) A/C switch

THE WAY OF CLEAR DTC

1. Using the scan tool, clear DTC:

(a) Turn the ignition switch OFF.

(b) Connect the KT600 scan tool to the Data Link Connector (DLC) - use the most current software

available.

(d) Select the item, clear DTC.

04-21

CAPTURING DATA

Once DTC is captured and stored, ECM records the vehicle and driving conditions information as a

form of rated data. During troubleshooting, the rated data can help determine if the vehicle was

running or parked, and data of other sensors and actuators has been recorded when the trouble

occurred.

If the DTC is detected but the trouble can’t reappear, confirm the freeze - frame rated data. ECM records

the engine condition in form of freeze - frame data at regular intervals. The diagnostic scanner can be

used to read several sets of freeze - frame data respectively. KT600 diagnostic scanner provides

powerful random data flow help function. Select read data flow function menu in engine system, enter

the data flow testing result display interface, click “?Help” button to eject the following windows:

• Driving Record Playback

• Calculator

• Data Range Reference

• Data Capture

• Data Comparisons

• Data Flow Settings

• Data/Waveform Display

• Driving Recorder Menu

The data can be used to simulate the vehicle conditions as the failure occurs. It also can help

determine the cause of trouble and judge if it’s temporary fault. When the engine is running with

trouble, select the menu items, read data flow (Click “?Help”)\Data Capture\Click Record\(Click

“?Help”)\Data Comparisons.

04-22

FAIL - SAFE CHART

When the DTC listed below is detected, the ECM enters fail - safe mode and the MIL lights up.

Number Item Control Contents Period Of Fault

2 Relay

3 Fuel pump

4 Ignition coil

5 Oxygen sensor

6 EVAP solenoid valve

7 KS

8 VSS

9 IAT sensor

• The MIL light will turn on.

• Unstable idle.

• Lack of engine power.

• Poor acceleration.

• Engine will not start.

• Plugged injector.

• System is out of work.

• Can not start engine.

• Noisy fuel pump operation.

• Poor fuel economy.

• Excessive exhaust emissions.

• Weak spark.

• Sluggish acceleration.

• Poor driving capability.

• The engine base fuel closed - loop control self - learning will be shut

off.

• The engine idle air control self - learning will be shut off.

• Unstable idle or high idle.

• The engine produces an engine knock.

• Overheated engine.

• Internal engine damage.

• The engine RPM will be limited.

• No VSS diaplay.

• The IAT is equal to ECT.

04-23

10 Poor accelerator sensor

11 CKP sensor

12 TPS

13 ECT sensor

14 MAP/IAT sensor

• Misfire.

• Rough engine operation.

• Engine is hard to start.

• The engine RPM will be limited after the engine starts.

• The highest RPM is less than 3800 RPM.

• No ignition signal to the ECM.

• The tachometer does not work.

• Engine hard to start when cold.

• Engine hard to start when hot.

• If the sensor circuit is shorted to power, the engine will run under the

default values.

• The temperature gauge indicates too high.

• The temperature gauge indicates too low.

• The cooling fan operates continuously on high speed.

• The high temperature warning lamp will flash when the instrument

panel indicates low temperature.

04-24

DATA STREAM LIST/ACTIVE TEST

1. DATA STREAM LIST.

• Through reading the data stream displayed on scan tool sreen, we can check the sensor,

actuator and switch data value but not removing any components. As the first step, this way is

the best way to short diagnosis period .

• The following arranged the data stream under the normal condition. It only offers to reference.

Don’t judge a component normal or not only depend on these value.

READ DATA STREAM PROCEDURE

Start the engine and warm it to normal operating temperature.

Turn the ignition switch OFF.

Connect the KT600 scan tool to the Data Link Connector (DLC) - use the most current software

Turn the ignition switch ON.

Select the item, read data sream.

The table below lists the data found in inspection items at different states by the KT600 in “DATA LIST”

items.

• If no concrete specification of idle condition, the shift selector lever is in neutral position. The A/C and

accessories switch are in the OFF position.

• Injector driving time means time is taken by crankshaft at speed of less than 250 RPM and power

supply voltage of 11 V.

• For new vehicle (within operation distance of 500 km), sometimes injector driving time is 10% more

than standard time.

• For new vehicle (within operation distance of 500 km), sometimes step length of stepper motor is more

30 steps than standard step length.

04-25

Displayed Item Check Item Specified Condition

Oxygen sensor

• Engine: Warm

• A/F: Mixture is made

leaner when decelerating

richer when accelerating

Engine suddenly decelerate

from 4000 RPM

Engine suddenly accelerate

≤ 0.2 V

0.6 ~ 1 V

• Check A/F with oxygen

Engine: Idle

≤ 0.4 V

2500 RPM 0.6 ~ 1 V

MAP sensor

IAT sensor

• ECT: 80 ~ 95 ℃

• Lamp and all other

accessorie: OFF

• Transmission: Neutral

• Ignition switch: ON

• Or engine is running

Engine: Idle -

2500 RPM -

IAT: - 20 ℃ - 20 ℃

IAT: 0 ℃ 0 ℃

IAT: 20 ℃ 20 ℃

IAT: 40 ℃ 40 ℃

IAT: 80 ℃ 80 ℃

Engine: Idle 0.3 ~ 1 V (0%)

TP open slowly

Increase proportionally

Wide open

4.5 ~ 5.5 V

Power supply Ignition switch: ON System voltage

Ignition switch

Engine: Stop

Engine: Start

ECT sensor

ECT: - 20 ℃ - 20 ℃

ECT: 0 ℃ 0 ℃

ECT: 20 ℃ 20 ℃

ECT: 40 ℃ 40 ℃

ECT: 80 ℃ 80 ℃

Altitude: 0 m

101 kPa

Barometric sensor

Altitude: 600 m

Altitude: 1200 m

95 kPa

88 kPa

Altitude: 1800 m

81 kPa

A/C switch

(Turn A/C switch ON, A/C

compressor works)

A/C switch: OFF

A/C switch: ON

04-26

ECT: 0 ℃

60 ~ 90 ms

Injector

Engine: Running

30 ~ 5 ms

ECT: 80 ℃

6.7 ~ 10.1 ms

• Accessorie: OFF

2.2 ~ 3.4 ms

2500 RPM 1.9 ~ 3.1 ms

Engine runs at high speed

suddenly

Increase

Ignition coil • Engine: Warm

2 ~ 18 BTDC

2500 RPM 27 ~ 47 BTDC

Idle air control

motor

• Engine: Idle

• A/C works

A/C switch: OFF → ON

2 ~ 25 steps

A/C relay

Engine: Warm and idle

Not activate (Compressor

clutch does not work)

Activate (Compressor

clutch works)

• Engine: Running

• Tachometer: Connection

Compare the values read

from tachometer and KT600

respectively

The same

ECT: - 20 ℃

1275 ~ 1475 RPM

CKP sensor

1225 ~ 1425 RPM

1100 ~ 1300 RPM

950 ~ 1150 RPM

650 ~ 850 RPM

2. ACTIVE TEST.

The active test function for us to check the sensor, actuator and switch data value but not removing

any components. We can use the scan tool to perform the test. As the first step, this way is the best

way to short diagnosis period.

The displayed data stream when performing the active test.

(d) Select the item, actice test.

(e) Refer to the following chart, perform the active test. The following chart is the item which in the

“ACTIVE TEST” of the KT600 scan tool.

(f) When performing the function of the “ACTIVE TEST”, if there is fault phenomenon, check and repair.

04-27

(g)

(h)

(i)

After repairing, using the KT600 to perform again.

Clear DTC.

Disconnect KT600 scan tool.

Restart engine to perform test. Confirm the faults has been eliminated.

Displayed Item Test Component Control Area Diagnosis Remark

MIL Control MIL ON/OFF -

EVAP EVAP solenoid valve ON/OFF -

Fuel pump relay Fuel pump relay ON/OFF -

Low fan Control low fan ON/OFF -

High fan Control high fan ON/OFF -

A/C relay Shut off A/C relay ON/OFF -

Idle air control motor Control idle motor steps - -

Idle air control motor Control idle motor speed - -

Idle control motor reset Control Idle motor reset - -

Ignition advance angle Ignition advance angle - -

Gear signal learn 58X learn - -

Injector (A/B/C/D) Shut off fuel injection ON/OFF -

BLM learn - - -

BLM reset - - -

Fuel open control Open control - -

Inspect catalysator at idle Check catalysator at idle - -

Oxygen sensor response Oxygen sensor response - -

04-28

DIAGNOSTIC TROUBLE CODE CHART

Note

If a malfunction code is displayed during the DTC check in the check mode, check the harness or connectors

for the codes listed in the table below. For details of each code, refer to the DTC chart

DTC No. DTC Definition Trouble Area

P0106

P0107

P0108

P0112

P0113

P0117

P0118

P0122

P0123

P0131

MAP / TPS Rationality

MAP Circuit Low Voltage or Open

MAP Circuit High Voltage

IAT Circuit Low Voltage or Open

IAT Circuit High Voltage

Coolant Circuit Low Voltage

Coolant Circuit High Voltage

Throttle Position Low Voltage

Throttle Position High Voltage

Front Oxygen Sensor Short Low

• MAP sensor

• Open or short in MAP sensor harness or

connectors

• ECM

• Short in MAP sensor harness or connectors

• IAT sensor

• Short in IAT sensor harness or connectors

• Open or short in IAT sensor harness or

• ECT sensor

• Short in ECT sensor harness or connectors

• Open or short in ECT sensor harness or

• Throttle position sensor

• Open or short in throttle position sensor

harness or connectors

• Short in throttle position sensor harness or

• Upstream oxygen sensor

• Short in upstream oxygen sensor harness or

04-29

P0132

Front Oxygen Sensor Short High

P0133

Front Oxygen Sensor slow response

• Open or short in upstream oxygen sensor

• Upstream oxygen sensor heater

• Relay

• Air induction system

• Fuel pressure

• Injector

P0134

Front Oxygen Sensor Inadequate

Activeness Or Open

• Open in upstream oxygensensor harness or

P0135

Front Oxygen Heater Fault

• Upstream oxygen heater

• Open or short in upstream oxygen heater

P0137

Rear Oxygen Sensor Short Low

• Open or short in downstream oxygen sensor

P0138

Rear Oxygen Sensor Short High

• Downstream oxygen sensor

P0140

Rear Oxygen Sensor Inadequate

• Open in downstream oxygen sensor harness

or connectors

P0141

Rear Oxygen Heater Fault

• Downstream oxygen heater

• Open or short in downstream oxygen heater

04-30

P0171

P0172

P0201

P0202

P0203

P0204

P0230

P0300

Fuel Trim BLM Learn Too Lean

Fuel Trim BLM Learn Too Rich

Injector 1 Circuit Diagnostic

Injector 2 Circuit Diagnostic

Injector 3 Circuit Diagnostic

Injector 4 Circuit Diagnostic

Fuel Pump Relay Fault

The Engine Misfire Fault

• Injector blockage

• Open or short in oxygen sensor circuit

• Oxygen sensor

• Injector leak or blockage

• Engine coolant temperature sensor

• Gas leakage in exhaust system

• Open or short in oxygen sensor harness or

• Injector 1

• Injector A harness or connectors

• Injector 2

• Injector 3

• Injector 4

• Pump relay

• Pump relay harness or connectors

• Open or short in engine wire

• Ignition system

• Compression pressure

• Valve timing

• PCV hose connection

• PCV hose

04-31

P0324

Knock System Fault

• Knock sensor

• Knock sensor harness or connectors

P0325

P0335

Knock Sensor Fault

CKP Sensor Circuit No Signal

• Open or short in CKP sensor harness or

P0336

CKP Sensor Circuit Noisy Signal

• CKP sensor

• Open or short in CKP sensorharness or

P0351 EST Output #1

P0352 EST Output #2

• Ignition coil 1 harness or connectors

• Ignition coil 1

• Ignition coil 2 harness or connectors

• Ignition coil 2

P0420

P0443

P0480

P0481

P0502

P0506

P0507

Catalyst failure

Purge Solenoid Diagnostic

Fan 1 Fault

Fan 2 Fault

Vehicle Speed Sensor No Signal

Idle Speed Control - Low RPM

Idle Speed Control - High RPM

• Catalyst harness or connectors

• Catalyst

• Purge solenoid diagnostic harness or

connectors open or short

• Purge solenoid diagnostic

• Fan1

• Fan 1 harness or connectors

• Fan 2

• Fan 2 harness or connectors

• Vehicle speed sensor

• Vehicle speed sensor harness or connectors

• Idle motor

• Idle control vale

• Idle motor harness or connectors

04-32

P0562

P0563

P0645

P0650

P0685

P1167

P1171

P1336

P1391

P1392

P1393

P1659

Voltage Low Diagnostics

Voltage High Diagnostics

A/C clutch output circuit fault

Malfunction Indicator Lamp Fault

Main Power Relay Fault

Front Oxygen Sensor Signal Rich in

fuel

Front Oxygen Sensor Signal Lean In fuel

TEC Not Learned

G Sensor Rationality

G sensor short low

G Sensor Short High

SVS Light Fault

• Battery

• Generator

• Power supply harness or connectors

• A/C clutch

• A/C clutch harness or connectors

• Malfunction indicator lamp

• Malfunction indicator lamp harness or

• Main Power Relay

• Main Power Relay harness or connectors

• Engine hood main relay

• Upstream oxygen heater and main relay

• CKP sensor is not installed

• Accelarator

• Short in accelarator harness or connectors

• SVS Light harness or connector

• Instrument Panel

04-33

DTC DIAGNOSTIC

P0107 - MAP CIRCUIT LOW VOLTAGE OR OPEN

P0108 - MAP CIRCUIT HIGH VOLTAGE

P0112 - IAT CIRCUIT LOW VOLTAGE OR OPEN

P0113 - IAT CIRCUIT HIGH VOLTAGE

DESCRIPTION

MT20U2 adopted speed - density air measurement method to check the air intake volume into the engine so

as to control the fuel injection pulse width for the precise control of engine power output. Meanwhile, this

system adopted intake pressure cylinder determination technology and the intake air sensor is installed near

the inlet opening of cylinder 4 intake manifold. At the moment when the throttle is opened, there will be one

instantaneous pressure drop at the sensor, of which the value is about 1 kPa. When the ECM detected and

received this instantaneous pressure drop, the ECM will determine the compression upper dead center signal

after software diagnosis treatment (its functions is similar with the camshaft position sensor of traditional

electric injection system, also referred as phase sensor).

WIRING DIAGRAM

04-34

DTC No. DTC Definition DTC Detection Condition Trouble Area

MAP sensor circuit low

voltage or open

• No TPS faults

• ECM detects that the MAP

input signal is less than

acceptable value

• MAP sensor loose connector

• Open or short in MAP sensor

signal circuit

• Short circuit in MAP sensor

• Open circuit in MAP sensor

5V circuit

• Open in MAP sensor ground

circuit

MAP sensor circuit high

voltage

input signal is higher than

• Short in MAP sensor signal

• Short in MAP sensor 5V

power circuit

IAT sensor circuit low

• Ignition switch: ON.

• 60 seconds since the ignition

switch is turned “ON”, or after

engine starts.

• Sensor output voltage has

continued to be 0.2 V or lower

(corresponding to an intake air

temperature of 125 ℃ or

lower) for 4 seconds.

• Short in IAT sensor 5 V

reference circuit

IAT sensor circuit high

continued to be 4.6 V or

higher (corresponding to an

intake air temperature of - 45

℃ or lower) for 4 seconds.

• Open in IAT sensor 5 V

• While performing electrical diagnosis & testing, assure the ECM ground good contact.

• While performing electrical diagnosis & testing, always refer to the electrical schematics for

specific circuitand component information.

• While performing electrical diagnosis & testing, look for broken, bent, pushed out or corroded

• If any DTC is detected, using the scan tool, select the item, read data stream.

04-35

INSPECTION PROCEDURE

1. READ VALUE AND DTC OF SCAN TOOL

With the KT600 scan tool, perform the DTC confirming procedure.

Perform the reading data stream procedure.

Read IAT value displayed on the KT600 scan tool.

Displayed DTC And Pressure Proceed To Malfunction

• P0108

• About 45 kPa (or 4 V)

Next step Short to voltage

• P0107

• P0107 or P0108

• Pressure normal

Diagnostic help

Open or short to ground

Check for intermittent problems

YES > Go to diagnostic help for checking intermittent problems.

NO > If there an open or short circuit, go to next step.

2. CHECK HARNESS AND CONNECTOR (INTAKE AIR TEMPERATURE PRESSURE SENSOR -

GROUND)

Disconnect the E006 intake air temperature pressure sensor.

(d) Measure the voltage according to the value in the table

below.

Standard voltage

Tester Connection

E006 (2) - Ground

Specified Condition

5.0 ± 0.25 V

NO > Repair or replace harness or connector.

04-36

3. CHECK HARNESS AND CONNECTOR (INTAKE AIR TEMPERATURE PRESSURE SENSOR -

ECM)

Disconnect the E001 ECM connector.

(d) Measure the resistance according to the value in the

table below.

Standard resistance (check for open)

E001 (76) - E006 (4)

E001 (71) - E006 (3)

< 2 Ω

4. CHECK MAP SIGNAL

(b) Disconnect the E006 intake air temperature pressure sensor.

E006(2) - Ground • Idle: 5.0 ± 0.25 V

E006(4) - Ground

• Idle: 1.3 V

• No load condition, opening

throttle slowly: 1.3 V

• Open quickly: 4 V, then return

back to 1.5 V

04-37

5. CHECK HARNESS AND CONNECTOR (INTAKE AIR TEMPERATURE PRESSURE SENSOR -

(e) Measure the voltage according to the value in the table

E006 (4) - Ground

0 V

YES > Replace the ECM.

04-38

P0117 - COOLANT CIRCUIT LOW VOLTAGE

P0118 - COOLANT CIRCUIT HIGH VOLTAGE

1 Electric Appliance Connector

2 Cabinet

3 NTC Resistance

This sensor is one Negative Temperature Coefficient (NTC) thermistance, of which the resistance will reduce

following the increasing of the temperature in non - linear relation. When the coolant temperature is low, the

resistance in the thermistor increases. When the temperature is high, theresistance drops. The variations in

resistance are reflected in the voltage output from the sensor.

The ECM monitors the sensor voltage and uses this value to calculate the engine coolant temperature.

Engine cooling

temperature sensor circuit

low voltage

• 60 seconds since the ignition switch is

turned “ON” or after engine starts

• Sensor output voltage has continued to be

0.2 V or lower (corresponding to an intake

airtemperature of 145 ℃ or higher) for 4

seconds

• Short in ECT

sensor circuit

high voltage

4.6 V or higher (corresponding to an

intakeair temperature of - 45 ℃ or lower)

for 4 seconds

• Open or short in

04-39

• If the ECM detects the DTC P0117 or P0118, it operates the fail–safe function in which the engine

coolant temperature is assumed to be a default value. At the same time, with the ignition switch

ON, the cooling fans will operate at high speed. The fail–safe function will not untill the ECM

detects the acceptance condition.

• If any DTC is detected, using the scan tool, select the item, read the data stream.

Displayed Temperature

Malfunction

- 40 °C Open circuit

140 °C Short circuit

Read sensor value displayed on the KT600 scan tool.

Display DTC And Temperature Proceed To Malfunction

• P0118

• - 40 °C

• P0117

• 140 °C or more

• P0117 or P0118

• 80°C - 100°C

Step 5

Open or short to power

Short to ground

NO > If there is an open circuit, go to next step.

If there is a short circuit, go to step 5.

2. READ VALUE OF KT600 SCAN TOOL

Disconnect the E010 ECT sensor connector

Connect terminals 1 and 2 of the engine coolant temperature sensor connector E010 on the wire

harness side.

Select the item, read data stream.

Read ECT value displayed on the KT600 scan tool.

Temperature value: ≥ 140 °C

04-40

YES > Replace engine coolant temperature sensor, clear the DTC.

3. CHECK HARNESS AND CONNECTOR (COOLANT TEMPERATURE SENSOR - GROUND)

Disconnect the E010 coolant temperature sensor.

E010 (1) - Ground

4.5 ~ 5.0 V

4. CHECK HARNESS AND CONNECTOR (COOLANT TEMPERATURE SENSOR - ECM)

Disconnect the E001 ECM.

E010 (2) - E001 (52)

YES > Replace the coolant temperature sensor.

04-41

P0122 - THROTTLE POSITION LOW VOLTAGE

P0123 - THROTTLE POSITION HIGH VOLTAGE

MT20U2 Throttle Position Sensor (TPS) is used to provide throttle angle, angle speed and engine idle position

information to the ECM, based on which the ECM can obtain the engine load information, operating mode

(such as start, idle, reverse towing, partial load, full load) and acceleration & deceleration information. This

sensor is of three - line type and the ECM will check the throttle open extent by monitoring the voltage

variation.

Throttle position low

• 60 seconds since the ignition switch

is turned “ON”, or after engine starts

• Sensor output voltage has continued

to be 0.2V or lower for 4 seconds

• TPS failed or maladjusted

• Open or short in TPS circuit

Throttle position

• Setting the closed throttle position

switch ON, the sensor output

voltage has continued to be 2 V or

higher for 4 seconds

• Short in TPS circuit

04-42

Using the KT600 scan tool, perform the DTC confirming procedure.

Read TPS value displayed on the KT600 scan tool.

Read TPS signal data displayed on the KT600 scan tool

Displayed DTC And Voltage Proceed To Malfunction

• P0122 ( < 0.2 V) Step 4 Short to voltage

• P0123 ( > 2 V) Next step Open or short to ground

• P0122 or P0123

• TPS signal is normal

NO > If there is an open or short circuit, go to next step.

2. CHECK HARNESS AND CONNECTOR (THROTTLE POSITION SENSOR - GROUND)

Disconnect the E009 throttle position sensor.

Measure the voltage according to the value in the table

E009 (1) - Ground

04-43

3. CHECK THROTTLE POSITION SENSOR SIGNAL

(a) Turn the ignition switch ON.

(b) Jump wire at terminals 2 and 3 of the E009 TPS connector.

Voltage value: 4 V

YES > Go to step 5.

4. CHECK HARNESS AND CONNECTOR (THROTTLE POSITION SENSOR - ECM)

Measure the resistance according to the value in the

E009 (2) - E001 (74)

5. CHECK HARNESS AND CONNECTOR (THROTTLE POSITION SENSOR - GROUND)

E009 (3) - Ground

YES > Replace the throttle position sensor.

04-44

P1167 - FRONT OXYGEN SENSOR SIGNAL RICH IN FUEL

P1171 - FRONT OXYGEN SENSOR SIGNAL LEAN IN FUEL

P0131 - FRONT OXYGEN SENSOR SHORT LOW

P0132 - FRONT OXYGEN SENSOR SHORT HIGH

P0133 - FRONT OXYGEN SENSOR RESPONSE

P0134 - FRONT OXYGEN SENSOR OPEN

P0135 - FRONT OXYGEN SENSOR HEATER FAULT

1 Air

2 Case

3 Solid electrolyte

4 Platinum electrode

5 Heater

6 Lining

7 Exhaust gas

8 Rich

9 Air/fuel ratio

10 Lean

04-45

The Engine Control Module (ECM) supplies a voltage of about 450 mV between the ECM terminals 62 and 6.

The oxygen sensor varies the voltage within a range of about 1V if the exhaust is rich, down to about 0.1 V if

the exhaust is lean. The oxygen sensor is like an open circuit and produces no voltage when it is below 360 ℃

. An open oxygen sensor circuit or a cold oxygen sensor causes open - loop operation.

Front oxygen sensor

short low

• The engine controls system

is in closed loop

• The engine speed is below

6000 RPM

feedback voltage has

continued to be 0.07 V or

lower at least 40 seconds

• Upstream oxygen

• Short in upstream

oxygen sensor

short high

continued to be 4.8 V or

higher for at least 0.2

open

continued to be between

0.42 ~ 0.48 V

• Open in upstream

response

• DTC P0135、 P01167 are

not set

heater fault

• P1171DTC P0133、P01167

are not set

04-46

signal rich in fuel

• DTC P01171、 P0133 are

signal lean in fuel

DIAGNOSIC HELP

• Normal scan tool voltage varies between 0.1 to 1.0 V while in closed - loop.

• Check oxygen sensor harness, maybe the oxygen sensor is not well installed. It touch the exhaust pipe.

• Check if there is intermittent ground existent between ECM and oxygen sensor.

• Perform an injector balance test. Check if the lean mixture was caused by injector blocking.

• The vacuum leaking of crankcase cause lean mixture.

• The out air enter into exhaust pipe and through the oxygen sensor by the leaking of exhaust manifold

wsaher.

04-47

Read oxygen sensor value displayed on the KT600 scan tool.

Engine runs at idle.

P0131 ( < 0.21 V) Step 6 Short to ground

P0132 ( > 4.8 V) Step 7 Short to power

P0134 (0.42 V ~ 0.48 V ) Next step Open

2. CHECK HARNESS AND CONNECTOR (FRONT OXYGEN SENSOR - ECM)

Disconnect the E007 front oxygen sensor.

E007 (1) - E007 (2)

0.45 V

YES > Replace the front oxygen sensor.

3. CHECK HARNESS AND CONNECTOR (FRONT OXYGEN SENSOR - GROUND)

E007 (2) - Ground

04-48

4. CHECK HARNESS AND CONNECTOR (FRONT OXYGEN SENSOR - ECM)

E007 (2) - E001 (47)

E007 (1) - E001 (73)

5. CHECK HARNESS AND CONNECTOR (FRONT OXYGEN SENSOR - GROUND)

Standard resistance (check for short)

E007 (1) - Ground

≥ 1MΩ

04-49

6. CHECK HARNESS AND CONNECTOR (FRONT OXYGEN SENSOR - GROUND)

E007 (4) - Ground

7. CHECK HARNESS AND CONNECTOR (FRONT OXYGEN SENSOR - ECM)

Standard resistance(check for open)

E007 (3) - E001 (24)

04-50

8. CHECK HARNESS AND CONNECTOR (FRONT OXYGEN SENSOR - GROUND)

E007 (3) - Ground

04-51

P0335 - CRANKSHAFT POSITION SENSOR CIRCUIT NO SIGNAL

P0336 - CRANKSHAFT POSITION SENSOR CIRCUIT NOISY SIGNAL

1 Shielded cable

2 Permanent magnet

3 Sensor case

4 Mounting bracket

5 Soft magnet iron core

6 Coil

7 Air clearance

The 58X reference signal is produced by the Crankshaft Position (CKP) sensor. The Engine Control Module

(ECM) uses the 58X reference signal to calculate engine RPM and CKP. The ECM constantly monitors the

number of pulses on the 58X reference circuit and compares them to the number of MAP signal being

received. If the ECM receives and incorrect number of pulses on the 58X reference circuit, DTC P0336 will be

set.

04-52

CKP sensor circuit

noisy signal

• ECM received no or

error signal

• CKP loose connector

• Open or short in CKP sensor

CKP sensor circuit no

signal

• ECM received no signal

04-53

1. READ VALUE AND DTC USING SCAN TOOL

Read CKP sensor value displayed on the KT600 scan tool.

Using scan tool, perform the CKP sensor waveform confirming procedure.

2. CHECK CKP SIGNAL USING THE OSCILLOSCOPE

Using the oscilloscope, check the CKP sensor waveform.

3. CHECK HARNESS AND CONNECTOR (CRANKSHAFT POSITION SENSOR - ECM)

Disconnect the E008 crankshaft position sensor.

E008 (1) - E001 (30)

E008 (2) - E001 (11)

04-54

4. CHECK HARNESS AND CONNECTOR (CRANKSHAFT POSITION SENSOR - GROUND)

E008 (3) - Ground

5. CHECK CRANKSHAFT POSITION SENSOR

Replace the CKP sensor with a known good one.

(b) Using the oscilloscope, check the CKP sensor waveform.

YES > Replace the crankshaft position sensor.

6. CHECK HARNESS AND CONNECTOR (CRANKSHAFT POSITION SENSOR - GROUND)

• Standard resistance (check for short)

E008 (1) - Ground

04-55

7. CHECK HARNESS AND CONNECTOR (CRANKSHAFT POSITION SENSOR - GROUND)

8. CHECK CKP SENSOR SIGNAL PLATE

Check for a problem such as scrap, dirt, foreign body

and loose with the 58X CKP signal plate and signal

tooth.

Check the mounting clearance of the CKP sensor.

Clearance: 0.3 ~ 1.5 mm

9. Is the check result normal?

NO > Remove any foreign obstacles, clean 58X signal tooth. If there is fault present, replace 58X signal

plate.

04-56

P0324 - KNOCK SYSTEM FAULT

P0325 - KNOCK SENSOR FAULT

Item

1 1 ms\DIV

The Knock Sensor (KS) system is used to detect engine detonation, allowing the Engine Control Module

(ECM) to retard ignition control spark timing based on the KS signal being received. The KS produces an AC

signal. The KS signal’s amplitude and frequency depend upon the amount of knock being experienced. The

ECM contains a non - replaceable knock filter module called a Signal - to - noise Enhancement Filter (SNEF)

module. This filter module in the ECM determines whether knock is occurring by comparing the signal level on

the KS circuit with the voltage level on the noise channel. The noise channel allows the ECM to reject any false

knock signal by knowing the amount of normal engine mechanical noise present. Normal engine noise varies

depending on engine speed and load. When the ECM determines that an abnormally low noise channel

voltage level is being experienced, DTC P0324 & P0325 will be set.

04-57

Knock system fault

• ECT is higher than 80 ℃

• Engine RPM is higher than

2,500 RPM

• ECM detect that the KS

signal is out of the range

• KS loose connector

• Open or short in KS circuit

Knock sensor fault

• The knock sensor voltage is

below 0.2 V

• Short in KS circuit

04-58

1. READ VALUE OF KT600 SCAN TOOL

Driving vehicle, read knock sensor value displayed on the KT600 scan tool.

Result: Feed back value change

YES > Check intermittent problems.

2. CHECK HARNESS AND CONNECTOR (KNOCK SENSOR - ECM)

Disconnect the E001 knock sensor connector.

E011 (1) - E001 (58)

E011 (2) - E001 (37)

3. CHECK HARNESS AND CONNECTOR (KNOCK SENSOR - GROUND)

E011 (1) - Ground

E011 (2) - Ground

≥ 1 MΩ

04-59

4. CHECK HARNESS AND CONNECTOR (KNOCK SENSOR - GROUND)

Connect the E001 ECM connector.

5 V

YES > Replace the knock sensor.

04-60

Use the table below to help you find the cause of the problem. The numbers indicate thepriority of the likely

cause of the problem. Check each part in order. If necessary, replace these parts.

ENGINE CONTROL SYSTEM SYMPTOM

Symptom

Check Order

Communication with KT600 is impossible KT600 failed to communicate with ECM. 1

Starting

Idling stability (Improper idling)

Idling stability (Engine stalls)

Driving

Engine cranks, but will not start. 2

When engine is cold, it starts difficultly, body shock. 3

Unstable idle (Rough idle, hunting). 4

Idle speed is high (Improper idle speed). 5

When the engine is cold, it stalls (At idle). 6

The engine stalls when accelerating. 7

Accelerated reaction is slow, acceleraton

disturbance.

Poor acceleration capability. 9

8

ENGINE CONTROL SYSTEM SYMPTOM DESCRIPTION

Idling stability

(Improper idling)

(Engine stalls)

Failed to start

Hard starting

Hunting

Incorrect idle speed

Engine will stall when it is cold (Idle)

Engine stalls when moving

Accelerated reaction is slow,

acceleraton disturbance

Poor acceleration capability

The starter is used to crank the engine, but there is

no combustion within the cylinders, and the engine

does not start.

Engine starts after cranking a while.

Engine speed does not remain constant.

The engine does not idle at the usual correct speed.

Engine stall easily when ECT is low after it start for

a while.

The engine stalls when the accelerator pedal is

depressed.

Hesitation is the delay in response of the vehicle

speed that occurs when the accelerator is

depressed in order to accelerate from the speed at

which the vehicle is now traveling or a temporary

drop in vehicle speed during such acceleration.

Serious hesitation is called “sag”.

Poor acceleration is the inability to obtain an

acceleration corresponding to the degree of throttle

opening (Even though acceleration is smooth) or

the inability to reach maximum speed.

04-61

ENGINE SYMPTOM DIAGNOSTIC

• Some symptom diagnostics require visual and outer inspection. Perform these inspections

first. These inspection can select a problem that needn’t check deeply. And it can save the

expensive time.

• Inquiry customer about the fault after taking over vehicle:

(a) The first time when the faults appear.

(b) The engine temperature when the faults appear.

(d) The road which the customer usually drives.

(e) The vehicle maintenace log.

(f) The vehicle maintenace record.

(g) Is there any aftermarket retrofit device on vehicle? After the inspection, the checking time will be

shorted.

• Perform the primary inspection.

(a) Confirm the engine MIL is normal. If it is not good, repair it first.

(b) Confirm that no DTC exists in the ECM. If DTC exists, refer to the DTC chart to eliminate it.

range.

(d) Confirm the fault and the reason.

(e) When repairing the vehicle, confirm the repair record.

• Visual inspection.

(a) Check the fuel system for any fuel leakage.

(b) Check the vacuum system for any broken, kinked or incorrectly linked vacuum pipes or hoses.

(d) Check the ignition system for any broken or aging spark plug wires and verify the engine firing order is

correct.

(e) Check the engine ground cable and verify a clean and tight connection.

(f) Check the sensors and actuators electrical connectors and verify good contact and tight connection.

• The carbon deposits in the back of the valve will cause the poor engine acceration, unsteady

idling, starting difficulty in cold temperature, ect.

• Valve, carbon deposits in the combustion chamber.

Determined by the ECI (Electronic Controlled Injection) engine control features, the cylinder carries out

the fuel injection first and then the ignition at each running. The ignition is cut off immediately the engine

is shut off, but the petrol injected in this running cycle can’t be recovered and is attached on the intake

valve and the combustion chamber wall. The petrol is volatile, but the waxes and colloids in the petrol

remain. In the long term, the waxes and colloids become thick and hard after repeatedly heated, so the

carbon deposits are formed. If the engine burns oil or the filled petrol quality is poor and with many

impurities, the valve carbon deposits are more severe and the formation rate is faster. As the carbon

deposit structure is similar to the sponge, after the valve carbon deposits are formed, part of fuel

injected into the cylinder every time will be attached, making the air - fuel mixture strength actually into

the cylinder thin, which causes poor engine running, difficult starting, rough idling, poor accelerating,

backfire during emergency fueling, exhaust exceeding the standards, consumption increasing and

other abnormal symptoms. If the carbon deposits are more severe, they may lead to improperly sealed

valve, and the cylinder can't work without cylinder pressure, or even the valve is adhered and can’t

return. Now the motion interference occurs between the valve and the piston which would damage the

engine finally.

04-62

• Carbon deposits in the intake manifold.

As the running of each piston in the whole engine is not synchronous, when the engine is shut off,

some intake valves in some cylinders can’t be fully closed, the unburned fuel evaporates and is

oxidized continuously thus to form some softer black carbon deposits in the intake pipe, especially at

the rear of the throttle valve. On the one hand, the carbon deposits make the intake pipe wall coarse;

the air forms a spiral vortex at the coarse section, affecting the air intake effect and the quality of air -

fuel mixture. On the other hand, the carbon deposits block the idling aisle, making the idling speed

control device clamped or exceeding its regulation range, leading to low idling speed and rough idling.

• If the carbon deposit in the cylinder is too much, usually it will cause the high pressure. But the

vehicle has more mileage, there is much more carbon deposit in the cylinder. Because of the

wear, the cylinder pressure will decline. So it is not the good way to judge if there is the carbon

deposit in the cylinder . The good way is:

(a) With the electronic endoscopy.

(b) Inspect the feedback voltage.

• It’s a gradual process from the carbon deposit formation to aggregation and to affecting engine

normal running. When the engine cold starting is hard and the idling is rough, it shows that the

carbon deposits are quite serious, if further it will cause misfire and cylinder fuel cut, until the

engine unable to start. When the cold starting is hard, check the engine at once, clean the valve

carbon deposits in time after removing other factors to avoid damage caused by removing the

cylinder cover.

• Should pay attention to the following for the danger of the carbon deposit:

(a) Fill with the high quality gasoline.

(b) Don’t idle long.

04-63

COMMUNICATION WITH KT600 IS IMPOSSIBLE

Symptom Diagnosic Logic Suspect Area

Communication with KT600 is

impossible

1. READ VALUE OF SCAN TOOL

• No power supply

• Open in the harness of ECMand

scan tool KT600

• ECM power supply

• Open in the harness of ECM and

(b) Connect the KT600 scan tool to the Diagnostic Link Connector (DLC) - use the most current software

available, press the POWER key to start the KT600.

(d) Using scan tool, select the item, read data stream.

(e) Using the KT600 scan tool, read data stream displayed on the screen.

Whether the ECM data stream can be read?

2. CHECK DLC COMMUNICATION K

(b) Disconnect the E001ECM connector.

Resistance:< 2 Ω

(d) Using the multimeter, check the continuity between the data link connector M002 terminal 7 and

ground.

Resistance:≥ 1 MΩ

(e) Turn the ignition switch ON, using the multimeter, check the voltage between data link connector M002

terminal 7 and ground.

Voltage: 0 V

04-64

ENGINE CRANKS, BUT WILL NOT START

Symptom Condition Diagnosic Logic Suspect Area

Engine cranks, but will not

start

• Engine run normally

• Battery is normal

• MIL is normal

• No phenomenon of

burning when cranking

the engine

• Spark plugs are fouled

defective

• No supply of fuel to the

combustion chamber

is defective

• Cylinder pressure is

not normal

• Malfunction of the

ignition system

• Malfunction of the fuel

pump system

injector

• Leakage or

malfunction of intake

air system

If the engine can’t be started with starting symptom, it shows the ignition system, fuel system and

control system don’t fully lose the functions even though work normally. The cause of this starting

failure is nothing but may be that the high tension sparks are too weak, the ignition is improper, the air/

fuel mixture is too thin or thick, or the cylinder pressure is too low. In general, first check the ignition

system, then the air intake system, the fuel system, the control system, the engine cylinder pressure at

last.

1. INSPECTION MIL AND DTC

(a) Using the KT600 scan tool, perform the reading DTC procedure.

Is the DTC present?

2. VISUAL INSPECTION

(a) Perform the visual inspection.

Is the inspection result normal?

NO > Eliminate the exterior problems.

3. CHECK THE SECONDARY IGNITION SYSTEM

(a) Perform the following to test the secondary ignition system:

• Disconnect the injector fuse.

• Remove any of the 4 spark plugs.

• Connect the spark plug to spark plug wire.

• Ground the spark plug on the cylinder block.

• Crank the engine to test the secondary ignition system with the spark plugs removed.

Normal result: A strong blue spark visible is at each spark plug while cranking the engine

YES > Go to step 6.

04-65

4. CHECK THE SECONDARY IGNITION SYSTEM

(a) Check ignitioin coil resistance, and clear connector terminals.

(b) Check whether there is carbon deposit in plug, carbon tracking, residual current in insulating ceramics

cause of crack, clearance, burned in the positive and negative. And clear the plug.

NO > Clear, replace the faulty components.

5. CHECK IGNITION SPARK PLUG WIRE

(a) Using multimeter, check resistance of the ignition spark wire.

Resistance: ≥ 4 kΩ

NO > Replace the ignition spark wire.

6. CHECK CKP SENSOR

(a) Using scan tool, select the item, read data stream.

(b) Read the displayed CKP sensor value. It should be within the specified value.

NO > Check whether the sensor installion is correct.

7. CHECK THE THROTTLE BODY

(a) Depress the accelerator slightly.

(b) Check whether the engine can start.

Can the engine start?

YES > Check throttle body and idle air path. Clear the carbon deposit. Disconnect the idle air control motor

connector, Check whether there is 12 V. And the resistance value is 28 ~ 33Ω when the temperature is

20 ℃ . Check whether the idle air control motor is clip. If necesasary, repair or replace it.

The carbon and grease beside the throttle and air path change the cross section of the idle air path. It

makes the ECM control the idle air impossilly. And it will cause the A/F too lean or too rich. The

borning will not be normal. And the usual reasons of unnormal borning are: carbon and grease, grease

beside the throttle air path, carbon and grease with the idle air control motor.

8. CHECK ECT SENSOR AND MAP/IAT SENSOR

(a) Check whether the installation of the MAP/IAT is normal.

(b) Check whether the MAP/IAT sensor is dirty.

(e) Read the displayed ECT and MAP/IAT sensor value. It should reach the specified value.

NO > Repair or replace the harness or connector.

04-66

9. CHECK THE FUEL SYSTEM CIRCUIT

(b) Check whether the pump relay and pump operate normally.

10. CHECK THE FUEL SYSTEM PRESSURE

(a) Release the fuel system pressure. (Refer to “Chapter 12A fuel system - precaution”)

(b) Check the fuel system pressure. (Refer to “Chapter 12A fuel system - precaution”)

NO > Repair or replace the fuel system parts and harness:

• If the pressure is higher than 350 kPa, check the return pipe:

(1) If the return pipe is bent or twisted, repair or replace it.

(2) If the return pipe is normal, replace the pressure regulator.

• If the pressure is less than 350 kPa, turn the ignition switch ON, make the pump operate, check

the pressure again:

(1) If the pressure can be established, go to step 12.

(2) If the pressure cannot be established, go to step 13.

11. CHECK INJECTOR

(a) Disconnect the injector connector.

(b) Remove the injector and fuel rail assy.

(d) Check whether every injector can spray even and standard quantity gasline.

If the spraying condition is not normal just as the “cylindrical growth”, or the spraying quantity is not

equal much more under the same condition (more than 5 ml), then replace the injector.

When check the fuel system:

• Place a “Caution - No inflammable” symbol inside the operation area.

• Never smoke while servicing the vehicle.

• Service vehicles in well - ventilated areas and avoid ignition sources.

• Release fuel system pressure before servicing fuel system components.

YES > Go to step14.

NO > Clear the injector. Check the injector operation condition again. If not OK, replace it. Confirm the fault is

not present. If not OK, go to next step.

04-67

12. CHECK FUEL SYSTEM RETURN

(a) Using the fuel return blocker, clamping the return pipe, make the system fuel can not return.

(b) Check whether the system pressure can establish again quickly.

YES > Replace the fuel pressure regulation.

NO > Repair or replace the fuel supply pipe, pump or injector.

13. CHEKC FUEL SYSTEM SUPPLY

Check whether the input pipe leakage or block.

Running the engine, Check connectors for fuel leaks as following:

(b) Turn the ignition switch ON (Do not start the engine). Apply pressure on the fuel pipe. Check whether

fuel leaks at fuel pipe connection.

YES > Repair or replace the inlet fuel pipe.

NO > Replace fuel pump.

14. CHECK CYLINDER PRESSURE

(a) Perform the cylinder compression pressure test. The standard as following:

• Per cylinder pressure: 1270 kPa

• Per cylinder limit: 880 kPa

• Per cylinder difference limit: less than 25%

YES > Go to step16.

15. CHECK ENGINE VALVE - TIMING

(a) Check whether the engine valve - timing gear mark is aligned, damaged. And the belt is loose. Whether

the jumping over teeth exists.

NO > Perform the valve timing align operation.

16. CHECK ENGINE MECHANISM

(a) Perform the engine mechanism inspection:

• Check the cylinder with the endoscopy.

• Inspect the feedback voltage.

• Disassembly the engine inner faults.

NO > Repair the engine inner mechanism faults.

04-68

ENGINE STARTS DIFFICULTILY WHEN IT IS COLD

Engine starts difficultily

when it is cold (idle)

• Engine runs normally

• It needs several times

for engine starts

successfully when it is

cold

1. A/F is not correct

2. Carbon deposit at

valve

3. Operation condition is

not equal between

every cylinder

4. ECT sensor is fault

5. Others:

• MAP/IAT sensor

• Idle step motor

• Fuel quality

• Supply fuel system

• Leakage of the inlet

system

• Cylinder compression

pressure

• Engine management

Hard engine starting refers to that the starter is able to drive the engine to run in normal speed with

clear starting symptom, but the engine only run after continuous starting or the starter driving for a

long time. For the failure of hard starting, determine whether the occurrence is in cold starting or hot

starting, or both of them. The cause of this failure is from the fuel injection system generally. Check it

in the following method.

1. CHECK ENGINE MIL AND DTC

YES > Refer to DTC chart. Perform the diagnostic procedure.

2. CHECK THE VISUAL INSPECTION

(b) Check following after opening the engine hood:

• Air filter.

• Leakage of the intake manifold.

3. CHECK BATTERY

(a) Check the battery voltage when cranking the engine.

Battery voltage: ≥ 9.6 V

NO > Charge or replace battery.

04-69

4. CHECK STARTER

(a) Check whether the starter or the starter circuit exist fault.

5. CHECK CKP SENSOR

(b) Read the displayed CKP sensor value.

6. CHECK ECT SENSOR

(b) With the multimeter to check the ECT sensor or feedback voltage. (or with a 1.5 kΩ resistance, replace

the ECT sensor. Start engine. If OK, it means that the ECT sensor isnot normal).

NO > Replace the ECT sensor.

7. CHECK MAP SENSOR

(a) Check MAP sensor after starting engine successfully.

Pressure value: 35 ~ 55 kPa

NO > Eliminate the leakage of intake system.

8. CHECK THROTTLE BODY

(a) Depress the accelerator slightly. Start egnine.

NO > Go to step 10.

makes the ECM control the idle air impossilly. And it will cause the A\F too lean or too rich. The borning

will not be normal. And the usual reasons are: carbon and grease, grease beside the throttle air

path, carbon and grease with the idle air controlmotor.

9. CHECK IDLE AIR CONTROL MOTOR

(a) Disconnect the idle air control motor connector. Check whether there is 12 V. And the resistance value

is 28 ~ 33 Ω when the temperature is 20 ℃ .

(b) Remove the idle air control motor to test:

• Check expansion of the idle air control motor when turning the ignition switch ON.

• Check whether the idle air control motor can move when turning the ignition switch OFF.

04-70

NO > Repair or replace the idle control motor.

10. CHECK ECT SENSOR AND MAP/IAT SENSOR

(d) Turn the ignition switch ON. Read the displayed ECT and MAP/IAT sensor value.

NO > Replace the MAP/IAT sensor.

11. CHECK THE FUEL SYSTEM PRESSURE

(a) Release the fuel system pressure.

(b) Check the fuel system pressure.

12. CHECK INJECTOR

(a) Remove the injector connector.

If the spraying condition isnot normal just as the “cylindrical growth”, or the spraying quantity is not

YES > Go to step15.

NO > Clean the injector. Check the injector operation condition again. If not OK, replace it. Confirm the fault

isnot present. If not OK, go to next step.

04-71

13. CHECK FUEL SYSTEM RETURN

Using the fuel return blocker, and clamping the return pipe, make the system fuel not return.

Check whether the system pressure can establish again quickly.

14. CHEKC FUEL SYSTEM SUPPLY

Check whether the input pipe leaks or block.

(b) Turn the ignition switch ON (not crank the engine). Apply pressure on the fuel pipe. Check whether fuel

leakage at fuel pipe connection.

15. CHECK THE SECONDARY IGNITION SYSTEM

YES > Go to step18.

16. CHECK THE SECONDARY IGNITION SYSTEM

(b) Check whether there is carbon deposit in plug, carbon tracking,residual current in insulating ceramics

17. CHECK IGNITION SPARK PLUG WIRE

(a) With multimeter, check resistance of the ignition spark wire.

Resistance:≥ 4 kΩ

04-72

18. CHECK CYLINDER PRESSURE

YES > Go to step 20.

19. CHECK ENGINE VALVE - TIMING

(a) Check whether the engine valve - timing gear mark is aligned, damaged and the belt is loose.

NO > Perform the valve timing align operation or replace the timing belt.

20. CHECK ENGINE MECHANISM

• Disassembly the engine.

• Clear the carbon deposit or remove and check the engine cylinder head.

• Check valves, carbon deposit of manifold. For example: the clearance between the cylinder and the

piston ring. The leakage of the cylinder gasket, and loose of the valve guides, carbon deposit of the

valve.

04-73

UNSTABLE IDLE

Unstable idle (Rough idle,

hunting)

The engine cannot keep

stability

• The ignition system,

air - fuel.

• Air ratio

• IAC motor

is too low

• Malfunction of air - fuel

ratio control system

• Malfunction of the IAC

• Poor compression

• Drawing air into intake

The unstable idle is the usually faulty. It has many kinds of types. It includes unstable, misfire, etc.

When performing the diagnosis and elimination, should analyse according to the specific symptom.

YES > Refer to DTC chart. Perform the diagnosis procedure.

(b) Check after opening the engine hood:

(d) Inspect the tachometer if the pointer deviates the idle target value.

(e) Inspect if the idle trembles is normal or load reasons, such as: A/C, lighting, push the lever into gear,

turn the steering wheel, etc.

(f) Check the vacuum system for any broken, kinked or incorrectly linked vacuum pipes or hoses.

(g) Check whether the exhaust pipe emit black smoke.

(h) Check whether there is unburned petrol fumes.

(i) Check whether the throttle cable is adjusted to be appropriate.

3. CHECK THE THROTTLE AND IDLE CONTROL MOTOR

(a) Check throttle body and idle air path. Clear the carbon deposit and greasy dirt.

(b) Start engine and runs at idle.

(d) Perform the idle air control motor test.

• When the scan tool control the rotation of expansion of the idle air control motor, the engine RPM

changes from high to low in synchronism (touching the idle air control motor, can feel vibration).

04-74

(e) Disconnect the idle air control motor connector, Check whether there is 12 V. And the resistance value is

28 ~ 33 Ω when the temperature is 20 ℃ . Check whether the idle air control motor is clip. If necesasary,

repair or replace it.

(f) Remove the idle air control motor . Connect the connector:

• Check whether the idle air control motor can extend - retract when turning the switch off.

• Check whether the idle air control motor can move when turning the ignition switch on.

NO > Repair or replace idle control motor.

4. CHECK ENGINE IGNITION SYSTEM

(a) Engine runs at idle speed.

(b) Brennschluss one by one.

It is better that use the active test function of the scan tool to perform the brennschluss test. If without

the scan tool or the scan tool wirhout the function, the brennschluss period shoul not be too long, if

not, the Three Way Catalytic Converter (TWC) will be damaged.

(d) When brennschluss every cylinder, the same RPM should decline obviously or the same vibration.

YES > Go to step12.

5. CHECK THE SECONDARY IGNITION SYSTEM

• Connect the spark plug to spark plug wire. Ground the spark plug on the cylinder block.

• Start the engine to test the secondary ignition system with the spark plugs removed.

normal result: A strong blue spark visible is at each spark plug while cranking the engine

YES > Go to step 8.

6. CHECK THE SECONDARY IGNITION SYSTEM

(a) Check secondary ignition wire resistance. And clear the connector terminals.

NO > Replace the faulty components.

04-75

7. CHECK IGNITION SPARK PLUG WIRE

With multimeter, check resistance of the ignition spark wire.

8. CHECK THE INJECTOR

(a) Using scan tool, select the item, active test.

(b) Perform the injector active test.

can feel vibration, or with the voice - tool, touch the injector, the action voice should be hearded).

NO > Repair, clear or replace harness or connectors. Every injector can spray even and standard quantity

gasoline. If not OK, replace it.

If the spraying condition isnot normal just as the “cylindrical growth”, or the 4 injectors spraying quantity

is not equal much more under the same condition (more than 5 ml), then replace the injector.

9. CHECK THE FUEL SYSTEM PRESSURE

04-76

10. CHECK FUEL SYSTEM RETURN

Using the fuel return blocker and clamping the return pipe, make the system fuel not return.

11. CHEKC FUEL SYSTEM SUPPLY

Check connectors for fuel leakage as following:

(b) Turn the ignition switch ON (Do not start the engine).

(d) Check whether fuel leaks at fuel pipe connection.

12. CHECK INTAKE AND EXHAUST SYSTEM

(d) Check the sensors and actuators electrical connectors and verify good contact and tight connection.

(e) Check the PCV valve.

(f) Check whether the EVAP system leakage.

(g) Checkif the fuel pressure regulator vacuum pipe broken, kinked or crack.

(h) Check whether the Three - Way Catalytic Converter (TWC) is blocked.

(i) Check whether the throttle body gasket leakage.

(j) Check whether the intake manifold gasket leakage.

NO > Repair or replace the faulty components.

13. CHECK MAP/IAT SENSOR

(a) Check whether the installation of the MAP/IAT is normal?

(b) Remove the MAP/IAT sensor.

(e) Read the scan tool displaied MAP/IAT sensor data stream value.

(f) With the 3 kinds of the basic types: idle tets, accerlerate suddenlly test and blocked test in exhaust

system. Test the vaccum rate in the intake manifold.

NO > Clear and reinstall or repair. If not OK, go to step 15.

04-77

14. CHECK OXYGEN SENSOR

(a) Engine idle.

(b) Inspect the displayed scan tool data stream.

oxygen sensor operate normally.

Oxygen Sensor Normal Value: 0 ~ 1 V. Change 5 ~ 8 times in 10 seconds periodically.

NO > Replace xoygen sensor harness or connector.

15. CHECK CYLINDER PRESSURE

• Per cylinder pressure: 1270 kPa.

• Per cylinder limit: 880 kPa.

• Per cylinder difference limit: less than 25%.

YES > Go to step17.

16. CHECK ENGINE VALVE - TIMING

17. CHECK ENGINE MECHANISM

(b) Check the cylinder with the endoscopy.

(d) Disassembly the engine inner faults.

(e) Clear the carbon deposit or remove and check the engine cylinder head.

(f) Check valves, carbon deposit of manifold. For example: the clearance between the cylinder and the

04-78

IDLE IS TOO HIGH

Idle is too high (The

engine does not idle at the

usual correct speed)

Engine idle speed too

high

The cause is probably that the

intake air volume during idle

is too great

• Malfunction of the Idle

air control motor

throttle body

• Inspect the engine operating condition.

• Inspect the tachometer if the pointer deviates the idle target value.

• Inspect if the idle trembles is normal or load reasons, such as: A/C, lighting, push the lever into gear,

• Check the vacuum system for any broken, kinked or incorrectly linked vacuum pipes or hoses.

• Check whether the exhaust pipe emit black smoke.

• Check whether there is unburned petrol fumes.

• Check whether the throttle cable is adjusted to be appropriate.

3. CHECK THE ACCELERATOR PEDAL

(a) Check whether the accelerator pedal cable blocked.

NO > Adjust or replace the accelerator cable.

4. CHECK RELATED ACCESSORIES

(a) Check EVAP.

(b) Check the fuel pressure vacuum regualtor.

(d) Check whether the braking system vacuum booster pipe installation is reliable.

NO > Adjust or replace.

04-79

5. CHECK IDLE

(b) Gear in N position.

(d) Inspect if the idle speed is too high.

NO > Go to step 7.

6. CHECK THE VACUUM BOOSTER

(a) Blocking the vacuum pipe, inspect if the idle become normal.

NO > Repair or replace the vacuum booster.

7. CHECK PCV VALVE

(a) Clipping the PCV vacuum pipe, inspect if the idle become normal.

(b) Check whether the PCV valve clip. If the opening degree is normal.

NO > Replace PCV valve.

8. CHECK IDLE AIR CONTROL MOTOR

(a) Start engine and runs at idle.

(b) Using scan tool, select the item, active test.

• Disconnect the idle air control motor connector, Check whether there is 12 V. And the resistance value is

28 - 33 Ω when the temperature is 20 ℃ .

(d) Remove the idle air control motor to test:

NO > Replace the idle control motor.

9. CHECK THE INTAKE SYSTEM

(a) Check the vacuum system for any broken, kinked or incorrectly linked vacuum pipes or hoses.

(b) Check the intake air pipe for being jammed, leaking, or damaged.

NO > Repair or replace vacuum pipes.

04-80

(a) Check whether the installation of the MAP/IAT sensor is normal?

(d) Turn the ignition switch ON. Read the displayed ECT and MAP/IAT value. It should be within the specified

value.

YES > Go to step13.

NO > Repair or replace related components of fuel system.

YES > Replace the injector washer.

NO > Clean or replace the injectpor.

04-81

WHEN THE ENGINE IS COLD, IT STALLS

When the engine is cold,

it stalls (At idle)

The cause is probably

that the air/fuel mixture is

inappropriate when the

engine is cold, or that the

intake air

volume is insufficient.

that the intake air volume

during idle is too great

• Check whether the exhaust pipe emit black smoke. Check whether there is unburned petrol fumes.

3. CHECK THE THROTTLE AND IDLE AIR CONTROL MOTOR

makes the ECM control the idle air impossilly. And it will cause the A/F too lean or too rich. The borning

(b) Start engine and run at idle.

(d) Perform the idle air control motor test:

(e) When the scan tool control the rotation of expansion of the idle air control motor, the engine RPM

04-82

(f) Disconnect the idle air control motor connector, Check whether there is 12 V. And the resistance value is

28 - 33 Ω when the temperature is 20 ℃ . Check whether the idle air control motor is clip. If necesasary,

NO > Clean, repair or replace idle control motor.

4. CHECK THE ECT SENSOR

(a) Check the resistance accord with the standard:

20 ℃ : 2.1 ~ 2.7 kΩ

80 ℃ : 0.26 ~ 0.36 kΩ

(b) Using scan tool, select the item, read the data stream.

5. CHECK THE IAT SENSOR

20 ℃ : 2.3 ~ 3.0 kΩ

80 ℃ : 0.3 ~ 0.42 kΩ

NO > Replace the IAT sensor.

6. CHECK THE INJECTOR

gasline. If not OK, replace it.

04-83

7. CHECK THE FUEL SYSTEM PRESSURE

Release the fuel system pressure.

YES > Go to step 10.

(1) If the pressure can be established, go to step 8.

(2) If the pressure cannot be established, go to step 9.

8. CHECK FUEL SYSTEM RETURN

(a) Using the fuel return blocker and clamping the return pipe, make the system fuel not return.

9. CHEKC FUEL SYSTEM SUPPLY

Check connectors for fuel leaks as following:

YES > Repair or replace the intake fuel pipe.

NO > Replace the fuel pump.

10. CHECK CYLINDER PRESSURE

YES > Go to step 12.

04-84

11. CHECK ENGINE VALVE - TIMING

NO > Perform the valve timing align operation or replace timing belt.

12. CHECK ENGINE MECHANISM

NO > Repair the engine mechanism faults.

04-85

THE ENGINE STALLS WHEN ACCELERATING

The engine stalls when

accelerating

the accelerator pedal is

depressed

• Poor power when starting

• Malfunction of the Idle air

control motor

• Malfunction of the throttle

body

• Malfunction of the injector

• Malfunction of the ignition

Start in idling mode: Put into gear without pressing the accelerator pedal, disengage the clutch and

start the engine. This moment, as the throttle valve is closed and the idling electric shock is closed,

ECM considers it as the idling mode. The control of idling mode is a cruise control without any load

signal, namely a steady speed control that the engine is controlled in target speed range. Speed -

raising control is done if with load signal. During starting, the load signal is input into ECM, the later

raises the engine speed, enhances the dynamic property and keeps the idling from the effect of load.

This moment the starting is smoothly and hard to be shut off generally. If the starting is wobbled and

easy to be shut off and the speed falls in idling mode, find the causes from the idling control.

04-86

(e) Disconnect the idle air control motor connector, Check whether there 12 V exists. And the resistance value

is 28 - 33 Ω when the temperature is 20 ℃ . Check whether the idle air control motor is clip. If necesasary,

(f) Remove the idle air control motor. Connect the connector:

NO > Clear, repair or replace idle control motor.

04-87

4. CHECK THROTTLE POSITION

With the scan tool, check whether the throttle is normal.

(b) Check whether the throttle open degree is normal when depressing the accelerator pedal.

NO > Adjust the throttle position.

5. CHECK THE LOAD SIGNAL

(a) Check whether the gear signal is sent to ECM.

(b) Check whether the A/C signal is sent to ECM.

6. CHECK THE IGNITION SYSTEM

(b) Cut off spark plug wire one by one.

It is better that use the active test function of the scan tool to perform the cutoff test. If without the

scan tool or the scan tool wirhout the function, the brennschluss period shoul not be too long, if not,

the TWC will be damaged.

7. CHECK THE SECONDARY IGNITION SYSTEM

04-88

8. CHECK THE SECONDARY IGNITION SYSTEM

Check secondary ignition wire resistance. And clean the connector terminals.

9. CHECK IGNITION SPARK PLUG WIRE

10. CHECK THE INJECTOR

NO > Repair or replace injector

If the spraying condition is not normal just as the “cylindrical growth”, or the 4 injectors spraying

quantity is not equal much more under the same condition (more than 5 ml), then replace the injector.

04-89

NO > Repair or replace the fuel supply pipe, pump, injector.

leaks at fuel pipe connection.

YES > Go to step 16.

• Clear the carbon deposit or remove and check the engine cylinder head. Check valves, carbon deposit

of manifold. For example: the clearance between the cylinder and the piston ring. The leakage of the

cylinder gasket, and loose of the valve guides, carbon deposit of the valve.

04-90

ACCELERATED REACTION IS SLOW, ACCELERATON DISTURBANCE

Accelerated reaction is

slow, acceleraton

disturbance

When the accelerator is

depressed in order to

accelerate from the

speed, the vehicle is now

traveling or a temporary

drop in vehicle speed

during such acceleration.

that ignition system, air -

fuel mixture or

compression pressure is

• Malfunction of fuel

supply system

3. CHECK THE AIR FILTER

(a) Check whether the air filter dirty, grease and blocked.

NO > Clean or replace the air filter.

4. CHECK IDLE

Start engine and runs at idle.

Check whether the idle speed is normal.

04-91

NO > Refer to the symptom chart, eliminate the problems.

5. CHECK MAP/IAT SENSOR

(e) Read the scan tool displayed MAP/IAT sensor data stream value.

6. CHECK TPS

(b) With the analogue mulitimeter to check TPS resistance (resistance should be continuity).

NO > Repair or replace the throttle position sensor.

7. CHECK FUEL SYSTEM PRESSURE

(1) If the pressure can be established, go to step 9.

(2) If the pressure cannot be established, go to step 10.

8. CHECK INJECTOR

04-92

YES > Go to step 11.

NO > Repair or replace the injector.

9. CHECK FUEL SYSTEM RETURN

NO > Repair or replace the fuel supply pipe, pump and injector.

10. CHEKC FUEL SYSTEM SUPPLY

(b) Turn the ignition switch ON (not crank the engine).

(d) Check whether fuel leakage at fuel pipe connection.

11. CHECK EXHAUST SYSTEM

(a) Check the exhaust system and Three - Way Catalytic Converter (TWC).

(b) Check whether the exhaust pipe blocked with the exhaust pressure meter.

NO > Replace or clean the exhaust system.

12. CHECK CYLINDER PRESSURE

YES > Go to step 14.

04-93

13. CHECK ENGINE VALVE - TIMING

(a) Check whether the engine valve - timing gear mark is aligned, damaged. And the belt is loose.

14. CHECK ENGINE MECHANISM

• Disassembly the engine faults.

YES > Repalce the ECM.

04-94

POOR ACCELERATION

Poor Acceleration

Poor acceleration is the

inability to obtain an

acceleration corresponding

to the degree of throttle

opening (even though

acceleration is smooth) or

the inability to reach

maximum speed

Defective ignition system,

abnormal air - fuel ratio, poor

compression, etc are

suspected.

• Poor acceleration

• Clogged exhaust

(a) Using the KT600 scan tool, perform the reading DTC procedure. (Refer to ”Chapter 04 engine control

system - read and clear DTC”)

2. CHECK VISUAL INSPECTION

3. CHECK THROTTLR POSITION SENSOR

(b) With the analogue mulitimeter to check throttle position sensor resistance (resistance should be

continuity).

04-95

4. CHECK MAP/IAT SENSOR

5. CHECK THE FUEL SYSTEM PRESSURE

(1) If the pressure can be established, go to step 7.

(2) If the pressure cannot be established, go to step 8.

6. CHECK INJECTOR

YES > Go to step 9.

NO > Clean or replace the injector.

04-96

7. CHECK FUEL SYSTEM RETURN

(a) Using the fuel return blocker and clamping the return pipe, make the system fuel not return. Check

whether the system pressure can establish again quickly.

8. CHEKC FUEL SYSTEM SUPPLY

9. CHECK THE SECONDARY IGNITION SYSTEM

10. CHECK THE SECONDARY IGNITION SYSTEM

04-97

11. CHECK IGNITION SPARK PLUG WIRE

04-98

DIAGNOSTICS - ANTI - LOCK BRAKE SYSTEM

ANTI - LOCK BRAKE SYSTEM

1. ELECTRONIC CONTROL.

(a). Before removing or installing any electrical device, please disconnect the negative cable to

prevent damage to the device or personal injury.

(b).

Make sure ignition switch is OFF if no specific instructions.

If equipped with central locking, do not leave ignition switch in the car before disconnecting the

battery negative cable.

2. REMOVE INSTRUMENT CLUSTER OR DISCONNECT THE NEGATIVE CABLE WILL RESULT IN

LOSS OF DATA.

Total odometer will not be cleared.

3. WHEN THE BATTERY TERMINAL IS REMOVED, ALL THE MEMORIES OF THE CLOCK, RADIO,

DTCS, ETC. WILL BE ERASED. SO BEFORE REMOVING IT, CHECK THEM AND NOTE THEM

DOWN.

When service is finished, reset the clock and audio systems.

4. EXPRESSIONS OF IGNITION SWITCH.

5. NOTES ABOUT ANTI - LOCK BRAKE SYSTEM.

(a) The system will resumes its normal state temporarily or competely by removing and reinstalling the

suspicious faulty components when the connector terminals or the installing state of the components go

(b) In order to identify the faulty position, we must check the vehicle condition while vehicle goes out of

order. For example, we check the faults through the DTC. And we record these fault states before

(d) After repairing the anti - lock brake system is completed, check the ABS warning light.

(e). Never use the multimeter to measure the terminal of ABS module.

(f). The ABS system must be repaired by technicians trained and mastered maintenance

skills, and only use original parts for replacement.

(g). Before repairing the ABS system, if there are some failures with mechanical braking

system, must be excluded. Such as:

• Brake system noise.

• Brake pedal is excellent.

• Brake pedal or vehicle vibration when pressing pedal.

04-99

• Vehicle deviation.

• Parking brake system failure.

(h). ABS control module (refer to the ABS electronic control unit and hydraulic control unit, not

including brake lines, sensors ,etc.) can only be replaced as assembly, can not be

overhauled or part replacement / swap.

(i). The following two cases show that ABS system failure is detected:

• Turn the ignition switch On, the system self - test is completed, but the warning light

is on.

• The warning light is always on when driving the vehicle.

The driver can stop the vehicle conventionally, but it should be as far as possible to reduce the

braking force to prevent the wheels from locking. Warning lamp lights need to be careful driving

and immediately to the authorized service station overhaul to prevent more failures occurred,

resulting in a traffic accident.

(j). Pay attention to the following points when connect the ABS system connector:

• Turn the igintion OFF before disconnecting ABS wiring harness and connector.

• Ensure that the connector dry and clean, to avoid any foreign objects to enter.

• ABS harness connector is installed in place, must be in the horizontal direction and

a vertical direction to avoid damage to the connectors.

(k). Ensure proper connection when connectiong the ABS system pipes. ABS control module

can not detect that the brake lines are connected properly or not. The error connection

may lead to a serious accident. Connecting the brake lines, must be in compliance with

the ABS assembly on the mark:

• MC1: Brake line 1 connected to the brake master cylinder.

• MC2: Brake line 2 connected to the brake master cylinder.

• FL: Brake line connected the wheel cylinders FL.

• FR: Brake line connected the wheel cylinders FR.

• RL: Brake line connected the wheel cylinders RL.

• RR: Brake line connected the wheel cylinders RR.

(l). There are noise with ABS system in the following cases:

• Vehicle power or start the engine, it will produce a short sound of "Om", this is a

normal phenomenon with the sound of the ABS self - check..

• There will be sound when ABS system work properly, mainly reflected in the

following:

1) Sound made by ABS hydraulic unit motor, solenoid valve and the reflux pump.

2) Sound caused by brake pedal rebounding.

3) Emergency brake caused the crash of the suspension and the body.

04-100

1 Front Brake Pipe RH

2 ABS Control Module

3 Front Brake Pipe LH

4 Rear Brake Pipe LH

5 Rear Brake Pipe RH

04-101

ABS MODULE CONNECTOR

No. Wiring Color Difinition

1 R ABS motor power input

2 - -

3 Y - R EBD warning ligh output

4 L Front sensor signal RH

5 - -

6 R - L Dinostic connector K

7 - -

8 W Front sensor signal LH

9 - -

10 - -

11 - -

12 - -

13 W - B ABS motor ground

14 - -

15 - -

16 G

17 P

Front sensor power

suppy RH

Rear sensor power

18 L - G Rear sensor signal LH

19 B

suppy LH

20 - -

21 - -

22 - -

23 - -

24 - -

25 R - W

ABS solenoid valve

power suppy input

26 - -

27 Y - G ABS warning ligh output

28 R - W ABS - IG input

29 LG Rear sensor signal RH

30 G - W Brake signal

31 Y - W

32 - -

33 - -

34 - -

35 - -

36 - -

37 - -

38 W - B ECU ground

04-102

If a malfunction code is displayed during the DTC checking, check the circuit listed below. For details

of each code, turn to the relevant troubleshooting page in the DTC chart.

DTC No.

C190004

C190104

C100004

C101008

C006B06

C003108

C003200

C00A000

C00A100

C00A900

C003408

C003500

C00A200

C00A300

C00AA00

C003708

C003800

C00A400

C00A500

C00AB00

C003A08

C003B00

C00A600

C00A700

C00AC00

ECU Power Suppy High

ECU Power Suppy Low

Detection Item (DTC Definition)

ECU Malfunction (Hardware, Central Controller Error)

ECU Malfunction (Software Error)

Abs Control Is Unreasonable (Controling Time Too Long)

Front Wheel Speed Sensor LH Output Signal Malfunction: Beyond The Scope Of Loss,

Noise, Intermittent Interruption

Front Wheel Speed Sensor LH Wiring Malfunction: Open

Front Wheel Speed Sensor LH Wiring Malfunction: Short For Ground

Front Wheel Speed Sensor LH Wiring Malfunction: Short For Power Suppy

Front Wheel Speed Sensor LH Malfunction: Unknow

Front Wheel Speed Sensor RH Output Signal Malfunction: Beyond The Scope Of Loss,

Front Wheel Speed Sensor RH Wiring Malfunction: Open

Front Wheel Speed Sensor RH Wiring Malfunction: Short For Ground

Front Wheel Speed Sensor RH Wiring Malfunction: Short For Power Suppy

Front Wheel Speed Sensor RH Malfunction: Unknow

Rear Wheel Speed Sensor LH Output Signal Malfunction: Beyond The Scope Of Loss,

Rear Wheel Speed Sensor LH Wiring Malfunction: Open

Rear Wheel Speed Sensor LH Wiring Malfunction: Short For Ground

Rear Wheel Speed Sensor LH Wiring Malfunction: Short For Power Suppy

Rear Wheel Speed Sensor LH Malfunction: Unknow

Rear Wheel Speed Sensor RH Output Signal Malfunction: Beyond The Scope Of Loss,

Rear Wheel Speed Sensor RH Wiring Malfunction: Open

Rear Wheel Speed Sensor RH Wiring Malfunction: Short For Ground

Rear Wheel Speed Sensor RH Wiring Malfunction: Short For Power Suppy

Rear Wheel Speed Sensor RH Malfunction: Unknow

04-103

C109904

C001004

C001104

C001404

C001504

C001804

C001904

C001C04

C001D04

C109504

C002004

C007208

Wheel Speed Sensor Group Malfunction (Wheel Speed Sensor Interchangeable, Each

Of The Wheel Speed Difference Is Too Large, Wheel Speed Sensors Fault)

Front Inlet Hydraulic Valve LH Failure

Front Outlet Hydraulic Valve LH Failure

Front Inlet Hydraulic Valve RH Failure

Front Outlet Hydraulic Valve RH Failure

Rear Inlet Hydraulic Valve LH Failure

Rear Outlet Hydraulic Valve LH Failure

Rear Inlet Hydraulic Valve RH Failure

Rear Outlet Hydraulic Valve RH Failure

Valve Relay Failure

Reflux Pump Motor Failure

Valve Group Failure (Overheating Protection Signal Is Invalid, Hardw Is Damaged)

04-104

Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely

Symptom Suspect Area Reference

1. Brake pipe leakage,

breakage, etc.

2. Lack of brake fluid -

3. Differential fault

Chapter 34 axle and propeller shaft - differential

assy, check and adjustment

4. Front brake fault Chapter 35 brake - front brake, overhaul

5. Rear brake fault Chapter 35 brake - rear brake, overhaul

ABS is inoperative.

6. Hydraulic regulator assembly

fault

7. Parking light switch fault

8. Brake fluid level sensor fault

9. Brake switch fault

10. Speed sensor fault

11. Stop valve fault

12. Pressure relief valve fault

13. ABS module power supply

14. ABS module ground fault

Chapter 04 diagnostics - instrument cluster,

ABS warning light is inoperative/always on

Chapter 04 diagnostics - anti - lock brake system,

ABS system is inoperative

15. ABS module fault -

04-105

PRE - CHECK

Before diagnosis of the ABS system, check the ABS system failure and easily accessible

components first, visual inspection can quickly determine fault, and thus do not need to do further

diagnosis.

1. CHECK TIRE.

(a). Make sure that the vehicle only install the

recommended size tires and wheels. coaxial style

of tire tread depth must be the same. Specific tire

models, refer to the vehicle owner's manual for

details.

2. CHECK THE ABS HYDRAULIC MODULATOR, BRAKE PIPES AND CONNECTIONS

FOR LEAKING.

3. CHECK ABS SYSTEM FUSES TO ENSURE THAT THE FUSES ARE NOT BURNED,

AND THE MODEL IS CORRECT. ABS SYSTEM HAS THREE FUSES:

• Pump motor fuse (40A)

• Solenoid valve fuse (25A)

• Electronic control unit Fuse (5A)

4. CHECK THE BATTERY VOLTAGE, DETECT WHETHER THE BATTERY TERMINAL

CORROSION OR LOOSE. ABS SYSTEM NORMAL OPERATING VOLTAGE RANGE IS

9.3V - 16.8V.

5. CHECK ABS GROUND.

(a). Check ABS grounding point is loose. The

location is changed or not.

ABS ground has good sealing, in order to avoid

water and moisture in capillary (siphon) effect

through wiring harness of channel infiltration ABS

control module, which cause function failure.

04-106

6. VISUAL INSPECTION OF THE FOLLOWING

ELECTRICAL COMPONENTS:

(a).

ABS system harness and connectors of the

related components are properly connected, to be

pinched or cut or not.

Harness routing is too close to high - voltage or

high - current devices, such as high - voltage or

parts, generators, motors or stereo amplifier.

The high voltage or high current device may cause

the circuit to generate the induced noise, and

thereby interfere with the normal working of the

(c). ABS parts are sensitive to electromagnetic

interference (EMI). Suspected intermittent fault,

check the aftermarket installation of anti - theft

device, lights, or whether the mobile phone is not

installed correctly.

7. IF THE ABS NOISE IS TOO LARGE, IT MAY BE CAUSED BY THE FOLLOWING

REASONS:

(a). Loosening of ABS assembly with bracket.

(b). Loosening of ABS bracket and body.

(c). ABS plastic bracket washer missing or damaged.

04-107

POWER SUPPY VOLTAGE HIGH OR LOW

DIAGNOSTIC TROUBLE CODE:

C190004; C190104

CONDITIONS OF FAULT SETTING

It will be caused failure by one of the following conditions are met when the supply voltage of the

ECU:

(1) Voltage is lower than 4.5V when starting engine.

(2) Voltage is lower than 7.7V or higher than 16.8V when ignition switch is ON.

(3) Voltage is between 7.7V to 9.2V when vehicle speed is higher than 6km/h.

1. PERFORM PRE - CHECK STEPS

NO > Repair or replace related components.

2. INSPECT BATTERY

(a). Turn the ignition switch ON.

(b). Measure the battery voltage.

NO > Repair or replace battery.

3. ABS CONTROL MODULE CROSS - VALIDATION

(a). Turn the ignition switch OFF.

(b). Remove the ABS actuator. (Refer to “Chapter 35 brake - abs actuator, replacement”)

(c). Install the removed ABS to another known vehicle with the same model. (Ensure that ABS

connectors are securely installed without connecting pipes when vehicle was driven. )

(d). Start the engine and to ensure that the vehicle speed is not lower than 20km/h, so that the

ABS dynamic self - check.

YES > Replace ABS module.

NO > Replace the ABS actuator.

04-108

SOLENOID VALVES AND VALVES RELAY FAILURE

C001004; C001104; C001404; C001504; C001804; C001904; C001C04; C001D04; C109504;

(1) Valves power supply failure. (Power supply short for ground or ground open.)

(2) Solenoid valve temperature is too high. (Overheating protection)

(3) Solenoid valve is shorted. (Fuse)

(4) Actuating the corresponding solenoid valve, but no feedback.

(5) Solenoid valve failure.

(6) Valves relay failure.

POSSIBLE CAUSE

(1) Solenoid valve short for power supply or ground, circuit open.

(2) Fuses failure.

(3) Overheating protection (Solenoid valve long working hours, common in vacuum filling and

offline detection)

(4) ABS damaged

1. DETECT THE OCCASIONAL FAULT OF SYSTEM

(b). Disconnect the battery negative cable.

(c). Vehicle was allowed to stand for 5 minutes.

(d). Connect the negative battery cable.

YES > System is normal .

2. PERFORM PRE - CHECK STEPS

04-109

3. READ DTC AND DATA ON THE DIAGNOSTIC TOOL

Selecte diagnostic mode in the disgnostic tool and read data stream.

Detect vehicle speed displayed on the instrument panel and diagnostic tool when vehicle

is running, and compare whether they are consistent.

If speedmeter display shows the speed value and the diagnostic value of error within ± 10%, it belongs

to the normal range.

YES > Clear the DTC(s).

4. INSPECT FUSE

Disconnect the battery negative cable.

(b). Inspect the ABS valve fuse in battery

compartment junction box (A001): 25 A.

(c). Inspect the ABS IG fuse in battery compartment

junction box (A001): 5 A.

NO > Replace the fuse.

5. ABS CONTROL MODULE CROSS - VALIDATION

connectors are securely installed without connecting pipes when vehicle was driven.)

ABS dynamic self - check

04-110

6. CHECK HARNESS AND CONNECTOR (ABS VALVE FUSE - GROUND)

Measure the voltage according to the value(s) in

the table below.

ABS valve fuse - Ground

7. CHECK HARNESS AND CONNECTOR (ABS IG FUSE - ABS MODULE)

Remove the ABS IG fuse (5A) in the battery compartment junction box.

Disconnect the A009 ABS module connector.

(c).

Measure the resistance according to the value(s)

in the table below

ABS IG fuse - A009 (28)

04-111

8. CHECK HARNESS AND CONNECTOR (ABS VALVE FUSE - ABS MODULE)

Remove ABS valve fuse (25A) in the battery compartment junction box.

ABS valve fuse - A009 (25)

YES > Replace ABS MODULE.

04-112

PUMP MOTOR FAILURE

(1) Pump motor is overloaded with work, the temperature is too high. (Overheat protection)

(2) Reflux pump motor relay work over 60ms, reflux pump monitoring is still not detected voltage

signal.

(3) Reflux pump motor relay did not work, reflow pump monitoring detected voltage exceeds

2.5s.

(4) Reflux pump motor relay stops working and the reflux pump monitoring detected voltage

does not drop.

(1) Pump motor is poorly grounded.

(2) System overheating protection.

(3) Pump motor power supply is not normal(Fuse, battery terminal)

(4) Pump motor relay failure.

(5) Pump motor failure.

YES > System is normal

04-113

If speedmeter display shows the speed value and the diagnostic value of error within ±

10%, it belongs to the normal range.

Inspect the ABS pump fusible link in battery

compartment junction box (A001): 40 A.

Inspect the ABS IG fuse in battery compartment

04-114

6. CHECK HARNESS AND CONNECTOR (ABS PUMP FUSIBLE LINK - GROUND)

ABS pump fusible link -

04-115

8. CHECK HARNESS AND CONNECTOR (ABS PUMP FUSIBLE LINK - ABS MODULE)

ABS valve fuse - A009 (1)

04-116

WHEEL SPEED SENSOR CIRCUIT FAULT

C003200; C00A000; C00A100; C00A900; C003500; C00A200; C00A300; C00AA00; C003800;

C00A400;C00A500; C00AB00; C003B00; C00A600; C00A700; C00AC00; C109904

(1) ECU detects wheel speed sensor signal wire is shorted to ground.

(2) Wheel speed sensor circuit open.

(1) Wheel speed sensor circuit is disconnected, patch loosening, fracture.

(2) Wheel speed sensor signal circuit and the power suppy circuit is connected in reverse.

(3) Signal circuit is shorted to ground.

(4) Damage to the sensor head or connector pins.

2. READ DTC AND DATA ON THE DIAGNOSTIC TOOL

(d).

Remove the ABS actuator. (Refer to “Chapter 35 brake - abs actuator, replacement”)

Install the removed ABS to another known vehicle with the same model. (Ensure that ABS

Start the engine and to ensure that the vehicle speed is not lower than 20km/h, so that the

04-117

4. CHECK HARNESS AND CONNECTOR (WHEEL SPEED SENSOR - GROUND)

Disconnect the A010 front wheel speed sensor connector.

(d). Measure the resistance according to the value(s)

A010 (1) - Ground

A010 (2) - Ground

5. CHECK HARNESS AND CONNECTOR (WHEEL SPEED SENSOR - ABS MODULE)

A010 (1) - A009 (8)

A010 (2) - A009 (19)

04-118

WHEEL SPEED SENSOR SIGNAL FAULT

C003108; C00A900; C003408; C00AA00; C003708; C00AB00; C003A08; C00AC00; C109904

1. ECU detects wheel speed sensor signal circuit is shorted to power supply.

2. ECU detects wheel speed sensor power supply circuit is shorted to ground.

3. Wheel speed sensor signal is not normal.

1. Wheel speed sensor circuit is disconnected, patch loosening, fracture.

2. Wheel speed sensor signal circuit is shorted to power supply.

3. Wheel speed sensor power supply is shorted to ground.

4. The ring gear is not installed, missing teeth, dirty dust and installed incorrectly.

5. The gap between the sensor and the ring is too large.

6. The wheel speed sensor is subjected to the external magnetic field interference. (Wheel or

axle is not demagnetization)

7. The wheel speed sensor fault.

8. The number of teeth of the ring gear error.

9. Tire size does not meet specifications

10. ECU is damaged.

2. INSPECT WHEEL SPEED SENSOR

Raise the vehicle.

04-119

(c). Inspect whether the ABS speed sensor

installation is correct or not.

(e).

(f).

Inspect whether the ABS speed sensor connector

is loose or not.

Inspect whether the ABS speed sensor tightening

bolt is loose or not.

Remove ABS speed sensor to inspect whether

the speed sensor is damaged or the surface is

dirty.

NO > Replace wheel speed sensor.

4. INSPECT WHEEL SPEED SENSOR INSTALLATION

(a). Position the front wheel speed sensor RH

properly.

Installation bolts are tightened properly, the sensor

installation position should be flat.

04-120

5. INSPECT WHEEL SPEED SENSOR TIP

Remove the front wheel speed sensor.

(b). Check wheel speed sensor tip.

No scratches or foreign objects on the sensor tip.

6. INSPECT WHEEL SPEED SENSOR ROTOR

Check the sensor serrations.

No scratches, missing teeth or foreign objects.

If foreign object is attached, please remove it. After

reassembling, check the output voltage.

NO > Replace the wheel speed sensor rotor.

7. CHECK HARNESS AND CONNECTOR (WHEEL SPEED SENSOR - GROUND)

04-121

8. CHECK HARNESS AND CONNECTOR (WHEEL SPEED SENSOR - ABS MODULE)

04-122

ABS CONTROL IS UNREASONABLE

ABS received continuous working instruction (more than 1 minute).

(1) Continued brake on ice.

(2) Wheel speed difference is too large.

3. INSPECT WHEEL SPEED SENSOR INSTALLATION

04-123

Inspect whether ABS speed sensor installation is

correct or not.

Position front wheel speed sensor RH properly.

4. INSPECT WHEEL SPEED SENSOR TIP

04-124

5. INSPECT WHEEL SPEED SENSOR ROTOR

6. ABS CONTROL MODULE CROSS - VALIDATION

7. CHECK HARNESS AND CONNECTOR (ABS MODULE - GROUND)

A009 (13) - Ground

A009 (38) - Ground

04-125

ABS SYSTEM IS INOPERATIVE

WIRING DIAGRAM (

04-126

1. INSPECT FUSE

Inspect ABS valve fuse in battery compartment

junction box (A001): 25 A.

Inspect the stop lamp switch fuse in engine room

junction box (A002): 15 A.

2. INSPECT BACK - UP LAMP SWITCH

Disconnect the A025 stop lamp switch connector.

Inspect the stop lamp switch according to the

value(s) in the table below.

Condition

Release stop

lamp switch

Press stop lamp

switch

Specified

1 - 2 ≥ 1 MΩ

1 - 2 < 2 Ω

NO > Replace stop lamp switch.

3. CHECK HARNESS AND CONNECTOR (ABS MODULE - GROUND)

04-127

4. CHECK ABS MODULE POWER SUPPLY

ABS IG fuse - Ground

ABS pump fusible link - Ground

5. CHECK HARNESS AND CONNECTOR (STOP LAMP FUSE - STOP LAMP SWITCH)

04-128

in the table below.

Stop lamp fuse - A025 (2)

6. CHECK HARNESS AND CONNECTOR (ABS MODULE - STOP LAMP SWITCH)

A009 (30) - A025 (1)

DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM

04-129

SUPPLEMENTAL RESTRAINT SYSTEM

• Fail to carry out the service operations in the correct sequence could cause the supplemental

restraint system to unexpectedly deploy during servicing. It may lead to a serious accident.

Furthermore, if a mistake is made in servicing the supplemental restraint system, it is possible

that the SRS will fail to operate when requiring. Before servicing (including removal or

installation of parts, inspection or replacement), be sure to read the following items carefully.

Then follow the correct procedure described in this manual.

• Work must be started after 90 seconds from the time that the ignition switch is turned to the

”LOCK” position and the negative (–) terminal cable is removed from the battery. (The

supplemental restraint system is equipped with a back–up power source, so if work is started

within 90 seconds after disconnecting the negative (–) terminal cable from the battery, the SRS

may deploy.

• Do not directly expose the horn switch assy to hot air or flames.

• Malfunction symptoms of the supplemental restraint system are difficult to confirm, so the

diagnostic trouble codes (DTC) become the most important source of information when

troubleshooting. When repair the supplemental restraint system, always check the diagnostic

trouble codes (DTC) before disconnecting the battery.

• After completion of maintenance work,be sure to erase diagnostic trouble code (s) (DTC);If

diagnostic trouble code (s) (DTC) can’t be erased,replace the restraint control module.Check for

diagnostic trouble code (s) (DTC) again.

• Even in case of a minor collision where the SRS does not deploy, the horn switch assy and

restraint control module should be inspected.

• Before repairing, remove the driver airbag and restraint control module if shocks are likely to be

applied to the airbag and module during repairing.

• Never use SRS related parts from another vehicle. If necessary, replace with new parts.

• Never disassemble and repair the horn switch assy.

• If the horn switch assy has been dropped, or if there are cracks, dents or other defects in the

case, bracket or connector, replace them with new ones.

• Use the multimeter with high impedance (10 kW/V minimum) for troubleshooting of an electrical

• Information labels are attached to the SRS components. Follow the instructions on the notices.

• After working on the supplemental restraint system is completed, check the SRS warning light.

• When the negative (–) terminal cable is disconnected from the battery, memory of the clock and

audio systems will lost. So, before starting work, make a record of the memorized contents in

each memory system. Then, when work is finished, reset the clock and audio systems as

before. To avoid erasing the memory in each memory system, never use a back–up power

supply from another battery.

04-130

1 Restraint Control Module (RCM)

2 Instrument Cluster

3 Driver Airbag

4 Clock Spring

5 Passenger Airbag

6 Driver Side Fuse Box

7 Co - pilot Side Junction Box

8 Ignition Switch

04-131

RESTRAINT CONTROL MODULE (RCM) CONNECTOR PIN

Terminal No. Wiring Color Definition

1 - -

3 - -

4 - -

5 B - O Power Supply

6 W - B Ground

7 B - Y SRS Warning Light

8 - -

9 R - L Diagnosis K

10 Y Airbag +

11 Y - B Airbag -

13 G - B Airbag +

14 G - R Airbag -

16 - -

17 - -

18 - -

19 - -

25 - -

04-132

27 - -

28 - -

29 - -

30 Y Collision Output Interface

04-133

If a malfunction code is displayed during the DTC check, check the circuit listed. For details of each

code, turn to the relevant troubleshooting page in the DTC chart.

DTC No. Detection Item (DTC Definition) Trouble Area

8101 Power supply voltage high

8102 Power supply voltage low

8201 Driver airbag fault - high resistance

8202 Driver airbag fault - low resistance

8203 Driver airbag circuit short to ground

8204 Driver airbag circuit short to battery

• Charging system

• Power source circuit

• Wire harness

• Fuse

• Ignition switch

• Driver airbag circuit

• Driver airbag

• Clock spring

• Restraint control module

8211

8212

8213

8214

Co - pilot side airbag fault - High

Co - pilot side airbag fault - Low

Co - pilot side airbag circuit short to

ground

battery

• Passenger airbag circuit

• Passenger airbag

8610 ACU internal error • Restraint control module

04-134

• If there is no DTC,but supplemental restraint system isn’t normal ,use the table below to check

the circuit.

• Before replacement of restraint control module (RCM) and instrument cluster,turn the ignition

switch OFF,and disconnect the battery negative cable.

• Use the table below to help you find the cause of the problem. The numbers indicate the priority

of the likely cause of the problem. Check each part in order. If necessary, replace these parts.

1. SRS warning light circuit -

SRS warning light is

always on

2. Instrument Cluster

3. Restraint control module

Chapter 83 instrument panel - instrument cluster

, replacement

Chapter 62 supplemental restraint system -

RCM , replacement

inoperative

04-135

8102 - POWER SUPPLY VOLTAGE LOW

CIRCUIT DESCRIPTION

DTC No. DTC Detecting Condition Trouble Area

8102

With vehicle speed at 3 km/h or more, ignition

switch terminal voltage is 10V or below for 10

sec or longer.

04-136

1. CHECK RESTRAINT CONTROL MODULE

Disconnect the negative cable from the battery, and wait at least for 90 seconds.

Disconnect the A027 restraint control module connector.

Connect the battery negative cable.

(e) Measure the voltage according to the value (s) in the

A027 (5) - Ground

YES > Replace restraint control module.

2. INSPECT FUSE (Co - pilot Side Junction Box)

Measure the voltage according to the value (s) in the

Airbag fuse (10A) - Ground

NO > Go to step 4.

04-137

3. CHECK HARNESS AND CONNECTOR (AIRBAG FUSE - RESTRAINT CONTROL MODULE)

Measure the resistance according to the value (s) in the

Airbag fuse (10A) - A027 (5)

04-138

4. CHECK HARNESS AND CONNECTOR (IGNITION SWITCH - AIRBAG FUSE)

Disconnect the I009 ignition switch connector.

I009 (2) - Airbag fuse (10A)

I009 (2) - Ground

YES > Replace ignition switch assy.

04-139

8201 - DRIVER AIRBAG FAULT - HIGH RESISTANCE

8202 - DRIVER AIRBAG FAULT - LOW RESISTANCE

8201

8202

• Short circuit between airbag plus wire harness and

airbag negative wire harness.

• Open circuit between airbag plus wire harness and

• Driver airbag malfunction

• Clock spring malfunction

• Restraint control module malfunction

04-140

1. INSPECT CLOCK SPRING AND DRIVER AIRBAG

Disconnect the I014 clock spring connector.

Relace clock spring and driver airbag.

Connect the battery negative cable.Turn the ignition switch ON.

Dose the systerm work correctly?

YES > Relace clock spring and driver airbag.

2. CHECK HARNESS AND CONNECTOR (CLOCK SPRING - RESTRAINT CONTROL MODULE)

A027 (10) - I014 (3)

A027 (11) - I014 (4)

I014 (3) - Ground

I014 (4) - Ground

04-141

8203 - DRIVER AIRBAG CIRCUIT SHORT TO GROUND

8203

• Short circuit in airbag wire harness (to

ground)

04-142

A027 (10) - Ground

A027 (11) - Ground

04-143

8204 - DRIVER AIRBAG CIRCUIT SHORT TO BATTERY

8204

battery)

04-144

1. CHECK HARNESS AND CONNECTOR (RESTRAINT CONTROL MODULE - CLOCK SPRING)

2. INSPECT CLOCK SPRING AND DRIVER AIRBAG

Does the system work correctly?

NO > Replace restraint control module.

04-145

8211 - CO - PILOT SIDE AIRBAG FAULT - HIGH RESISTANCE

8212 - CO - PILOT SIDE AIRBAG FAULT - LOW RESISTANCE

airbag negative wire harness

• Passenger airbag malfunction

04-146

1. INSPECT PASSENGER AIRBAG

Disconnet the I035 passenger airbag connector.

Replace passenger airbag.

YES > Replace passenger airbag.

2. CHECK HARNESS AND CONNECTOR (PASSENGER AIRBAG - RESTRAINT CONTROL

MODULE)

A027 (13) - I035 (1)

A027 (14) - I035 (2)

04-147

I035 (1) - Ground

I035 (2) - Ground

04-148

8213 - CO - PILOT SIDE AIRBAG CIRCUIT SHORT TO GROUND

04-149

2. CHECK HARNESS AND CONNECTOR (PASSENGER AIRBAG - RESTRAINT CONTROL MODULE)

A027 (13) - Ground

A027 (14) - Ground

04-150

8214 - CO - PILOT SIDE AIRBAG CIRCUIT SHORT TO BATTERY

04-151

2. CHECK HARNESS AND CONNECTOR (RESTRAINT CONTROL MODULE - PASSENGER

AIRBAG)

04-152

SRS WARNING LIGHT IS ALWAYS ON

04-153

1. CHECK HARNESS AND CONNECTOR (INSTRUMENT CLUSTER - RESTRAINT CONTROL

Disconnect the I003 instrument B connector.

A027 (7) - Ground

2. INSPECT INSTRUMENT CLUSTER

Disconnect the I002 instrument A connector.

Replace instrument cluster.

Does the instrument cluster work correctly?

YES > Replace instrument cluster.

04-154

SRS WARNING LIGHT IS INOPERATIVE

04-155

I003 (B27) - A027 (7)

Replace instrument cluster,and keep the I003 instrument connector disconnecting.

Connect Pin B27 of the I003 instrument B connector to ground.

04-156

DIAGNOSTICS - HEATER AND AIR CONDITIONING SYSTEM

HEATER AND AIR CONDITIONING SYSTEM

1. DO NOT DEPOSIT REFRIGERANT IN AN ENCLOSED AREA OR NEAR AN OPEN FLAME.

2. ALWAYS WEAR SAFETY GOGGLES.

3. AVOID CONTACTING WITH LIQUID REFRIGERANT R - 134A.

If liquid refrigerant is in your eyes or on your skin:

(f) Wash the area with lots of cold water.

(g) Apply clean petroleum jelly to the skin.

(h) Immediately go to a hospital or see a physician for professional treatment.

4. DO NOT HEAT CONTAINER OR EXPOSE THE CONTAINER TO OPEN FLAME.

5. DO NOT DROP DOWN CONTAINER OR APPLY PHYSICAL SHOCKS TO IT.

6. DO NOT OPERATE COMPRESSOR WITHOUT ENOUGH REFRIGERANT IN REFRIGERANT

SYSTEM.

(a) If there is not enough refrigerant in A/C system, oil lubrication will be insufficient and the compressor

may be damaged.

7. DO NOT OPEN HIGH PRESSURE MANIFOLD VALVE WHILE COMPRESSOR IS OPERATING.

(a) Open and close only the low pressure valve.

If the high pressure valve is opened, refrigerant flowing in the reverse direction will cause the charging

cylinder to rupture.

8. BE CAREFUL NOT TO OVERCHARGE SYSTEM WITH REFRIGERANT.

(a) If refrigerant is overcharged, it will cause problems such as insufficient cooling, poor fuel economy,

engine overheating, etc.

9. DO NOT OPERATE ENGINE AND COMPRESSOR WITH NO REFRIGERANT.

10. EXPRESSIONS OF IGNITION SWITCH.

04-157

BASIC INSPECTION

Step Condition Action

1

Check the refrigerant.

• Open the cap of release valve.

• Press the release valve.

Yes

No

Go to next step

Charge the refrigerant system

Check the A/C switch.

• Start the engine.

• Press the A/C switch.

• Check the A/C switch.

Go to problem symptoms table

Check the A/C clutch field coil.

• check the A/C clutch field coil.

Check compressor belt.

• Check compressor belt.

Check the compressor.

• Check the compressor cluth for noisy.

6

Check the condenser.

• Check the dirt between the condenser

and radiator.

Clear the dirt or repalce the condenser

Check pressure A/C liquid line.

• Check the line for inhibition or leakage.

Replace or reroute the pressure A/C liquid

line

04-158

1 Rear Blower Forward Switch

2 A/C Switch

3 Blower Control Knob

4 Temperature Control Knob

04-159

1. Fuse -

A/C system is inoperative

2. Relay -

3. Wire harness -

Front blower motor is inoperative

3. A/C control panel

4. Front blower control module

5. Front blower motor

Chapter 61 heater and air

conditioning - multi - media and A/C

controller assy, replacement

conditioning - front blower control

module, replacement

conditioning - front A/C blower,

replacement

6. Wire harness -

Top evaporator blower motors are

3. Top evaporator blower switch

4. Top evaporator blower resistor

5. Rear blower forward switch

6. A/C control panel

conditioning - top evaporator blower

switch, replacement

resistor, replacement

Chapter 83 instrument panel -

dashboard assy, replacement

7. Wire harness -

04-160

Front air flow is insufficient

1. A/C control panel

2. Front blower control module

3. Front blower motor

4. Front A/C vent duct

conditioning - front A/C vent duct ,

5. Wire harness -

Rear air flow is insufficient

1. Rear A/C blower switch

2. Top evaporator blower resistor

conditioning - rear A/C blower

No cooling from front A/C system

3. A/C compressor

4. A/C control panel

5. Refrigerant

6. Triple pressure switch

7. Front evaporator thermistor

conditioning - compressor, overhaul

conditioning - refrigerant

conditioning - A/C pressure switch,

conditioning - front evaporator

thermistor, replacement

8. Wire harness -

04-161

1. Top evaporator temperature

conditioning - top evaporator

temperature sensor, replacement

No cooling from rear A/C system

2. Rear A/C solenoid valve

conditioning - rear A/C shut off

solenoid valve, replacement

3. Relay -

Rear heater is inoperative or insufficient

heating

3. Rear heater blower switch

4. Rear heater solenoid valve

5. Rear heater motor

conditioning - rear heater blower

conditioning - rear heater solenoid

valve, replacement

conditioning - rear heater blower,

overhaul

04-162

A/C SYSTEM IS INOPERATIVE

04-163

04-164

Inspect the A/C fuse (15A) in driver side junction box

(I001).

2. CHECK HARNESS AND CONNECTOR ( A/C CUT OFF RELAY - GROUND)

Remove A/C cut off relay.

Measure the voltage according to the value(s) in the

A/C cut off relay (30) - Ground

04-165

3. CHECK HARNESS AND CONNECTOR ( A/C CUT OFF RELAY - GROUND)

Standard voltage (check for a short to battery)

A/C cut off relay (85) - Ground

04-166

FRONT BLOWER MOTOR IS INOPERATIVE

04-167

Inspect the front blower fusible link (30A) in Co-pilot

Junction Box (A003).

Inspect the A/C controller fuse (7.5A) in Driver Side

Junction Box (I001).

2. INSPECT FRONT BLOWER RELAY

Remove the front blower relay.

Inspect the front blower relay according to the value(s) in

Standard resistance:

Condition Tester Connection Specified Condition

Constant 85 - 86 Continuity

Apply battery

voltage to

terminal 85

and 86

30 - 87 < 2 Ω

NO > Replace the front blower relay.

3. INSPECT FRONT BLOWER CONTROL MODULE

Disconnect the I025 front blower control module connector.

Replace the front blower control module with a new one.

04-168

YES > Replace the front blower motor resistor.

4. INSPECT FRONT BLOWER MOTOR

(a) Disconnect the battery negative cable.

(b) Disconnect the A028 front blower motor connector.

YES > Replace the front blower motor.

5. CHECK HARNESS AND CONNECTOR (FRONT BLOWER RELAY - FRONT BLOWER )

Disconnect the A028 front blower motor connector.

Measure the resistance according to the value(s) in the

Front blower relay (30) - A028 (1)

6. CHECK HARNESS AND CONNECTOR (FRONT BLOWER - FRONT BLOWER CONTROL

Disconnect the A027 front blower connector.

04-169

A028 (2) - I025 (4)

7. CHECK HARNESS AND CONNECTOR (FRONT BLOWER CONTROL MODULE - GROUND)

Disconnect the I025 blower control module connector.

I025 (8) - Ground

8. CHECK HARNESS AND CONNECTOR (FRONT BLOWER CONTROL MODULE - A/C CONTROL

PANEL)

Disconnect the I021 A/C control panel connector.

04-170

I025 (2) - I021 (35)

I025 (3) - I021 (28)

9. CHECK HARNESS AND CONNECTOR (FRONT BLOWER RELAY - A/C CONTROL PANEL)

Remove front blower relay.

Disconnect the I020 A/C control panel connector.

Front blower relay (86) - I020 (8)

10. CHECK HARNESS AND CONNECTOR ( A/C CONTROL PANEL - GROUND)

04-171

I020 (10) - Ground

I020 (19) - Ground

11. CHECK HARNESS AND CONNECTOR ( A/C CONTROL PANEL - GROUND)

I020 (18) - Ground

I020 (20) - Ground

YES > Replace A/C control panel ( Multi - media and A/C controller assy).

04-172

REAR EVAPORATOR MOTORS ARE INOPERATIVE

04-173

Inspect the rear A/C fusible link (30A) in Co - pilot

2. INSPECT REAR A/C RELAY

Remove the rear A/C relay.

NO > Replace the rear A/C relay.

04-174

3. INSPECT REAR BLOWER FORWARD SWITCH

Disconnect the I023 rear blower forward switch connector.

Inspect the rear blower forward switch according to the

Position Tester Connection Specified Condition

Release 2 - 5 ≥ 1 ΜΩ

Press 2 - 5 < 2 Ω

NO > Replace the rear blower forward switch.

4. INSPECT TOP EVAPORATOR BLOWER SWITCH

Disconnect the L005 top evaporator blower switch connector.

Inspect the top evaporator blower switch according to the

I

II

III

1 - 2

3 - 4

3 - 5

3 - 6

NO > Replace the top evaporator blower switch.

5. INSPECT TOP EVAPORATOR BLOWER RESISTOR

Disconnect the L003 top evaporator blower resistor connector.

Replace a new top evaporator blower resistor.

YES > Replace the top evaporator blower resistor .

04-175

6. CHECK HARNESS AND CONNECTOR (REAR A/C RELAY - GROUND)

Turn the ignition switch ON and press the I023 rear blower forward switch.

Rear A/C relay (30) - Ground

7. CHECK HARNESS AND CONNECTOR (REAR A/C RELAY - TOP EVAPORATOR BLOWER

SWITCH)

Remove rear A/C relay.

Rear A/C relay (86) - L005 (2)

04-176

8. CHECK HARNESS AND CONNECTOR (TOP EVAPORATOR BLOWER SWITCH - GROUND)

L005 (1) - Ground

L005 (3) - Ground

9. CHECK HARNESS AND CONNECTOR (TOP EVAPORATOR BLOWER RESISTOR - TOP

EVAPORATOR BLOWER SWITCH)

L003 (1) - L005 (6)

L003 (2) - L005 (5)

L003 (3) - L005 (4)

10. CHECK HARNESS AND CONNECTOR ( REAR A/C RELAY - LEFT/RIGHT BLOWER)

Disconnect the L001 left blower connector.

Disconnect the L002 right blower connector.

04-177

Rear A/C relay (87) - L001 (1)

11. CHECK HARNESS AND CONNECTOR ( LEFT/RIGHT BLOWER - TOP EVAPORATOR BLOWER

RESISTOR)

Remove the L003 top evaporator blower resistor connector.

L001 (2) - L003 (1)

L002 (2) - L003 (1)

YES > Replace left or right blower.

04-178

FRONT AIR FLOW IS INSUFFICIENT

04-179

1. INSPECT FRONT BLOWER MOTOR RESISTOR

Replace the front blower control moduler with a new one.

YES > Replace the front blower control module.

2. CHECK THE HARNESS AND CONNECTOR (FRONT BLOWER - FRONT BLOWER CONTROL

Disconnect the A028 front blower connector.

3. CHECK HARNESS AND CONNECTOR (FRONT BLOWER CONTROL MODULE - GROUND)

I025 (1) - Ground

04-180

4. CHECK HARNESS AND CONNECTOR (FRONT BLOWER CONTROL MODULE - A/C CONTROL

5. CHECK HARNESS AND CONNECTOR ( A/C CONTROL PANEL - GROUND)

04-181

6. CHECK HARNESS AND CONNECTOR ( A/C CONTROL PANEL - GROUND)

04-182

REAR AIR FLOW IS INSUFFICIENT

04-183

1. INSPECT TOP EVAPORATOR BLOWER SWITCH

NO > Replace the rear evaporator blower switch.

2. CHECK HARNESS AND CONNECTOR (TOP EVAPORATOR BLOWER RESISTOR - TOP

YES > Replace top evaporator blower resistor.

04-184

NO COOLING FROM FRONT A/C SYSTEM

04-185

04-186

1. INSPECT COMPRESSOR RELAY

Remove the compressor relay.

NO > Replace the compressor relay

2. CHECK HARNESS AND CONNECTOR (COMPRESSOR RELAY - GROUND)

Compressor relay (30) - Ground

Compressor relay (85) - Ground

04-187

3. CHECK HARNESS AND CONNECTOR (COMPRESSOR - GROUND)

Disconnect the E013 compressor connector.

Start the engine, turn A/C switch on.

E013 (1) - Ground

YES > Replace the compressor.

4. CHECK HARNESS AND CONNECTOR (COMPRESSOR RELAY - ENGINE ELECTRONIC CON-

TROL MODULE(4G69) / ENGINE ECM(ISF2.8) )

Disconnect the C016 blower switch connector.

Compressor relay (86) - A036 (48)

Compressor relay (86) - E001 (10)

5. INSPECT TRIPLE PRESSURE SWITCH

Disconnect the V017 triple pressure switch connector.

04-188

Inspect the triple pressure switch according to the

V017 (1) - V017 (4)

V017 (2) - V017 (3)

NO > Replace the triple pressure switch.

6. CHECK HARNESS AND CONNECTOR (TRIPLE PRESSURE SWITCH - ENGINE ELECTRONIC

CONTROL MODULE(4G69) / ENGINE ECM(ISF2.8) )

V017 (4) - E001 (79)

V017 (3) - E001 (26)

V017 (4) - A036 (27)

V017 (3) - A036 (11)

7. CHECK HARNESS AND CONNECTOR (TRIPLE PRESSURE SWITCH - A/C CONTROL PANEL)

04-189

V017 (2) - I020 (9)

YES > Go to next step for 4G69, go to step 9 for ISF2.8.

8. CHECK HARNESS AND CONNECTOR (TRIPLE PRESSURE SWITCH - GROUND)(4G69)

V017 (2) - Ground

9. CHECK HARNESS AND CONNECTOR (TRIPLE PRESSURE SWITCH - ENGINE ECM)(ISF2.8)

Disconnect the A036 engine ECM connector.

V017 (2) - A036 (29)

04-190

10. INSPECT FRONT EVAPORATOR THERMISTOR

Disconnect the I026 front evaporator thermistor connector.

Inspect the front evaporator thermistor according to the

Check Condition

Specified Condition (KΩ)

2 ℃ 14.5 ~ 15.2

5 ℃ 12.5 ~ 13.0

10 ℃ 9.7 ~ 10.3

15 ℃ 7.6 ~ 8.1

20 ℃ 6.1 ~ 6.4

25 ℃ 4.8 ~ 5.1

NO > Replace the front evaporator thermistor.

11. CHECK HARNESS AND CONNECTOR (FRONT EVAPORATOR THERMISTOR - A/C CONTROL

Inspect the resistance according to the value(s) in the

I026 (1) - I021 (29)

I026 (2) - I021 (33)

04-191

NO COOLING FROM REAR A/C SYSTEM

04-192

1. INSPECT TOP EVAPORATOR TEMPERATURE SENSOR

Disconnect the L004 top evaporator temperature sensor connector.

Inspect the top evaporator temperature sensor according

to the value(s) in the table below.

NO > Replace the top evaporator temperature sensor.

2. CHECK HARNESS AND CONNECTOR (REAR A/C RELAY - REAR A/C SOLENOID VALVE)

Disconnect the N003 rear A/C solenoid valve connector.

When ignition switch turns ON, press the top evaporator blower switch.

N003 (1) - Ground

04-193

3. CHECK HARNESS AND CONNECTOR (REAR A/C SOLENOID VALVE - A/C CONTROL PANEL)

N003 (2) - I021 (36)

4. CHECK HARNESS AND CONNECTOR (REAR A/C SOLENOID VALVE - GROUND)

Standard resistance

N003 (2) - Ground

YES > Replace rear A/C solenoid valve.

04-194

5. CHECK HARNESS AND CONNECTOR (REAR A/C RELAY - A/C CONTROL PANEL)

Rear A/C relay (86) - I020 (1)

04-195

REAR HEATER IS INOPERATIVE OR INSUFFICIENT HEATING

04-196

Inspect the rear heater fuse (15A) in Co - pilot Junction

Box (A003).

2. INSPECT REAR HEATER RELAY

Remove the rear heater relay.

Inspect the rear heater relay according to the value(s) in

NO > Replace the rear heater relay.

04-197

3. INSPECT WATER VALVE RELAY

Remove the water valve relay.

Inspect the water valve relay according to the value(s) in

NO > Replace the water valve relay.

4. INSPECT REAR HEATER BLOWER SWITCH

Disconnect the A007 rear heater blower switch connector.

L

M

H

NO > Replace the rear heater blower switch.

04-198

5. CHECK HARNESS AND CONNECTOR (REAR HEATER RELAY / WATER VALVE RELAY -

GROUND )

Remove the rear blower relay and water valve relay.

When ignition switch turns ON, press the rear blower forward switch.

Rear heater relay (85) - Ground

Water valve relay (85) - Ground

6. CHECK HARNESS AND CONNECTOR (REAR HEATER BLOWER SWITCH - REAR BLOWER

RELAY/WATER VALVE REALY)

Remove the rear blower relay.

A007 (2) - Rear heater relay (86)

A007 (2) - Water valve relay (86)

04-199

7. CHECK HARNESS AND CONNECTOR (REAR HEATER BLOWER SWITCH - GROUND)

A007 (3) - Ground

A007 (1) - Ground

8. CHECK HARNESS AND CONNECTOR (REAR HEATER SOLENOID VALVE - GROUND)

Disconnect the P001 rear heater solenoid valve connector.

When ignition switch turns ON, press the rear heater blower switch.

P001 (1) - Ground

04-200

9. CHECK HARNESS AND CONNECTOR (REAR HEATER SOLENOID VALVE - GROUND)

P001 (2) - Ground

YES > Replace rear heater solenoid valve.

10. CHECK HARNESS AND CONNECTOR ( REAR HEATER RELAY - REAR HEATER MOTOR )

Disconnect the P002 rear heater motor connector.

When ignition switch turns ON, press the rear heater forward switch and rear heater blower switch.

P002 (2) - Ground

04-201

11. CHECK HARNESS AND CONNECTOR ( REAR HEATER MOTOR - REAR HEATER BLOWER

P002 (4) - A007 (4)

P002 (1) - A007 (5)

P002 (3) - A007 (6)

YES > Replace rear heater motor.

04-202

DIAGNOSTICS - LIGHTING SYSTEM

1. PRECAUTION FOR USING BATTERY DURING INSPECTION.

(a) While using the battery during inspection, do not bring the positive and negative tester probes too close

to each other as a short circuit may occur.

2. PRECAUTION FOR HEADLIGHT BULB REPLACEMENT.

(a) If even a thin film of oil is left on the surface of the halogen light, the bulb may be damaged because the

light will burn at a higher temperature.

(b) Handle any halogen light with great care. Dropping, hitting or damaging the bulb, in any way, may result

in exploding and shattering because the internal pressure is high.

dust and moisture if removed from the vehicle for too long.

(d) Always use a bulb of the same wattage for replacement.

(e) Firmly reinstall the socket after bulb replacement. The lens may become cloudy or the light cavity may

fill with water through the gaps around the socket.

3. EXPRESSIONS OF IGNITION SWITCH.

04-203

Check the battery voltage.

• The voltage should not be below 12 V.

Charge or replace battery. Refer to “Chapter

20A/20B starting and charging - battery,

replacement”

Check the LO - beam lamps.

• Turn the ignition switch ON.

• Check the LO - beam lamps.

Check the HI - beam lamps.

Check the turn signal lamps.

Check the hazard lamps.

Check the Indoor Lamps.

Check harness and connector

04-204

04-205

1 Front Combination Lamp Assy LH

2 Front Fog Lamp Assy LH

3 Front Combination Lamp Assy RH

4 Front Fog Lamp Assy RH

5 Rear Combination Lamp Assy LH

6 High - mounted Stop Lamp Assy

7 License Lamp Assy

8 Rear Combination Lamp Assy RH

04-206

LO - beam headlamp is

inoperative (One side)

2. Wire harness -

LO - beam headlamps are

inoperative (Both sides)

HI - beam headlamp is

4. Combination switch

Chapter 64 lighting - combination switch,

HI - beam headlamps are

3. Combination switch

4. Wire harness -

LO - beam and HI - beam

headlamps are inoperative

(One side)

1. Bulb(s)

Chapter 64 lighting - front combination Lamp

assy, replacement

1. Fuse

(Both sides)

4. Bulb(s)

Front fog lamps are

2. Combination switch

3. Bulb(s)

Chapter 64 lighting - front fog lamp assy,

4. Relay -

04-207

Front fog lamps are always

on

1. Combination switch

2. Front fog lamp relay -

Rear fog lamps are

Chapter 64 lighting - rear combination Lamp

Rear fog lamps are always

2. Rear fog lamp relay -

All fog lamps are

Hazard warning lamps are

inoperative (Turn signal

lamps are normal)

2. Hazard warning switch -

urn signal lamps are

inoperative (Hazard

warning lamps are normal)

3. Hazard warning switch -

Hazard warning and turn

signal lamps are

3. Flasher -

04-208

5. Combination switch

Turn signal lamps are

2. Bulb(s)

1. Hazard warning switch -

2. Flasher -

All stop lamps are

2. Stop lamp switch

Chapter 35 brake - brake pedal,

Chapter 64 lighting - high - mounted stop

lamp assy, replacement

Stop lamp is inoperative

High - mounted stop lamp

is inoperative

Back - up lamps are

inoperative(Both sides)

Back - up lamp is

2. Back - up lamp switch

Chapter 41 transmission - transmission

(yanchengzhongma ZM001), replacement

(tangshanaixin), replacement

04-209

Ignition switch illumination

Central dome light is

Air purifier lamp is

1. Bulb(s) -

2. Central locking controller

assy

Chapter 64 lighting - rear combination lamp,

Chapter 85 door locks - alarm controller,

Chapter 64 lighting - middle dome light assy,

Chapter 64 lighting - step lamp assy,

Step lamp are inoperative

3. Middle door lamp switch

RH

Trunk lamp is inoperative

Front dome light is

3. Rear hatch lock assy -

Chapter 64 lighting - front dome light assy,

All interior illumination

lamps are inoperative

Instrument cluster

illumination is not

2. Instrument cluster

Chapter 83 instrument - instrument cluster,

04-210

Diagnosis switch

wiring diagram

1. Diagnosis switch -

2. Wire harness

Cigarette lighter

1. Cigarette Lighter

Chapter 66 audio system - electric device

accessories, replacement

A/C control panel

Rear blower forward switch

Radio illumination is not

Dome light switch

Outside mirror defroster

switch illumination is not

Headlamp dimmer switch

Rear window defroster

Instrument dimmer switch

Hazard warning switch

WIdth lamps is not

Tail lamps are inoperative

1. Rear blower forward switch -

1. Radio

1. Dome light switch -

1. Outside mirror defroster

1. Headlamp dimmer switch -

1. Rear window defroster

1. Instrument dimmer switch -

Chapter 61 heater and air conditioning -multi -

media And Air - condition Controler Assy,

Chapter 66 audio system - multi - media And

air - condition controler Assy, replacement

Chapter 64 lighting - front combination lamp

LH, replacement

Chapter 64 lighting - rear combination lamp

04-211

License lamp is inoperative

Width lamps tail lamps and

license lamp are

Chapter 64 lighting - licence lamp assy,

04-212

LO - BEAM HEADLAMP IS INOPERATIVE (ONE SIDE)

04-213

• This inspection procedure is an example of lo - beam headlamp LH, lo - beam headlamp RH inspection

procedure is similar.

1. INSPECT BULB

Disconnect the V003 headlamp LH connector.

Replace the headlamp LH bulb.

Does the lo - beam headlamp LH work correctly?

YES > Replace the headlamp LH bulb.

2. CHECK HARNESS AND CONNECTOR (LO - BEAM LH FUSE - HEADLAMP LH)

Lo - beam LH fuse (7.5A) - V003 (3)

V003 (3) - Ground

YES > Replace Lo - beam LH fuse (7.5A) in driver side junction box (I001).

04-214

LO - BEAM HEADLAMPS ARE INOPERATIVE (BOTH SIDES)

04-215

1. INSPECT HEADLAMP BULBS BOTH LH AND RH

Disconnect the V006 headlamp RH connector.

Replace headlamp bulb RH.

Do both lo - beam headlamps work correctly?

YES > Replace headlamp Bulbs both LH and RH.

2. INSPECT LO - BEAM RELAY

Remove lo - beam relay in driver side junction box (I001).

Inspect lo - beamheadlamp relay according to the

Normal

Apply battery voltage to

terminals 85 and 86

85 - 86 breakover

30 - 87

NO > Replace lo - beamheadlamp relay.

04-216

3. INSPECT COMBINATION SWITCH (LIGHT)

Disconnect the I012 combination switch (light) connector.

Inspect the combination switch according to the value(s)

Set the lo - beam headlamp

switch to OFF

switch to ON

8 - 11

NO > Replace the combination switch.

4. CHECK HARNESS AND CONNECTOR (LO - BEAM RELAY - COMBINATION SWITCH (LIGHT))

Lo - beam Relay (86) - I012 (8)

04-217

5. CHECK HARNESS AND CONNECTOR (LO - BEAM FUSES BOTH LH AND RH, LO - BEAM

HEADLAMPS BOTH LH AND RH)

Lo - beam fuse RH (7.5A) - V006 (3)

V006 (3) - Ground

YES > Replace lo - beam headlamp fuse (7.5A) both LH and RH in driver side fuse box (I001).

04-218

HI - BEAM HEADLAMP IS INOPERATIVE (ONE SIDE)

04-219

• This inspection procedure is an example of hi - beam headlamp LH, hi - beam headlamp RH inspection

Does hi - beam headlamp LH work correctly?

2. CHECK HARNESS AND CONNECTOR (HI - BEAM LH FUSE - HEADLAMP LH)

Hi - beam LH fuse (10A) - V003(2)

V003 (2) - Ground

YES > Replace Hi - beam LH Fuse(10A) in driver side junction box (I001).

04-220

HI - BEAM HEADLAMPS ARE INOPERATIVE (BOTH SIDES)

04-221

Replace headlamp Bulb RH.

Do both hi - beam headlamps work correctly?

2. INSPECT HI - BEAM RELAY

Remove hi - beam relay in driver side junction box (I001).

Inspect hi - beamheadlamp relay according to the

value(s) in the table below

Connection

Namal

85 - 86 Breakover

NO > Replace hi - beam relay.

Disconnect the i012 combination switch (light) connector.

04-222

Set the hi - beam headlamp

9 - 11

4. CHECK HARNESS AND CONNECTOR (HI - BEAM RELAY - COMBINATION SWITCH (LIGHT))

hi - beam relay (86) - I012 (9)

04-223

5. CHECK HARNESS AND CONNECTOR (HI - BEAM FUSES BOTH LH AND RH, HI - BEAM

HEADLAMPS BOTH LH AND RH )

Hi - beam LH fuse (10A) - V003 (2)

Hi - beam RH fuse (10A) - V006 (2)

V006 (2) - Ground

YES > Replace hi - beam fuses both LH and RH in driver side box (I001).

04-224

LO - BEAM AND HI - BEAM HEADLAMPS ARE INOPERATIVE (ONE

SIDE)

04-225

• This inspection procedure is an example of hi - beam headlamp and lo - beam headlamp LH, hi - beam

headlamp and lo - beam headlamp RH inspection procedure is similar.

2. CHECK HARNESS AND CONNECTOR (HEADLAMP LH - GROUND)

V003 (1) - Ground

3. CHECK HARNESS AND CONNECTOR (HI - BEAM FUSE AND LOW - BEAM FUSE LH -

HEADLAMP LH)

04-226

Hi - beam LH fuse (10 A) - V003 (2)

Lo - beam LH fuse (7.5 A) - V003 (3)

YES > Replace hi - beam fuse and lo - beam fuse LH in driver side junction box (I001).

04-227

ALL HEADLAMPS ARE INOPERATIVE

04-228

Inspect the headlamp fuse (20A) in driver side junction

box (I001).

2. CHECK HARNESS AND CONNECTOR (COMBINATION SWITCH (LIGHT) - GROUND)

I012 (11) - Ground

04-229

in the table below..

4. INSPECT HEADLAMP BULBS BOTH LH AND RH

Does both headlamp hulbs work correctly?

YES > Replace headlamp bulbs both LH and RH.

5. CHECK HARNESS AND CONNECTOR (HEADLAMP BOTH LH AND RH - GROUND)

V006 (1) - Ground

04-230

6. INSPECT HI - BEAM RELAY AND LO - BEAM RELAY

30 - 87 ≥ 1 MΩ

NO > Replace relays.

7. CHECK HARNESS AND CONNECTOR (HI - BEAM RELAY AND LO - BEAM RELAY -

COMBINATION SWITCH)

04-231

Hi - beam relay (86) - I012 (9)

Lo - beam relay (86) - I012 (8)

8. CHECK HARNESS AND CONNECTOR (HI - BEAM FUSE AND LO - BEAM FUSE BOTH LH AND

RH - HEADLAMP BOTH LH AND RH)

04-232

Lo - beam RH fuse (7.5A) - V006 (3)

YES > Replace hi - beam fuse (10A) and lo - beam fuse (7.5A) both LH and RH in the driver side junction box

04-233

FRONT FOG LAMPS ARE INOPERATIVE

04-234

Inspect front fog lamp fuse (15 A) in driver side junction

YES > Go to step 3.

2. CHECK HARNESS AND CONNECTOR (FRONT FOG LAMP RELAY - FRONT FOG LAMP)

Remove front fog relay in driver side junction box (I001).

Disconnect the C001 front fog lamp LH connector.

Disconnect the C002 front fog lamp RH connector.

Disconnect the I002 instrument cluster A connector.

C001 (1) - Ground

YES > Replace the fuse.

NO > Repair or replace harness or connector,and replace the fuse.

04-235

3. INSPECT FRONT FOG LAMP BULBS

relace front fog lamp bulb LH.

relace front fog lamp bulb RH.

YES > Replace front fog lamp bulb both LH and RH.

4. INSPECT COMBINATION SWITCH (LIGHT)

Disconnect the I012 combination switch connector.

Set the front fog lamp

2 - 4 < 2 Ω

2 - 4 ≥ 1 MΩ

5. CHECK HARNESS AND CONNECTOR (FRONT FOG LAMP RELAY - COMBINATION SWITCH

(LIGHT))

Remove front fog lamp relay in driver side junction box (I001).

04-236

Front fog lamp relay (86) - I012 (2)

6. CHECK HARNESS AND CONNECTOR (FRONT FOG LAMP RELAY - FRONT FOG LAMP)

Front fog lamp relay (87) - C001 (1)

Front fog lamp relay (87) - C002 (1)

04-237

7. CHECK HARNESS AND CONNECTOR (FRONT FOG LAMP - GROUND)

C001 (2) - Ground

C002 (2) - Ground

YES > Replace front fog lamp relay.

04-238

FRONT FOG LAMPS ARE ALWAYS ON

04-239

1. INSPECT COMBINATION SWITCH (LIGHT)

2. CHECK HARNESS AND CONNECTOR (FRONT FOG LAMP RELAY - COMBINATION SWITCH)

I012 (2) - Ground

04-240

3. CHECK HARNESS AND CONNECTOR (FRONT FOG LAMP RELAY - FRONT FOG LAMP)

(b) Remove front fog lamp relay in driver side junction box (I001).

The front fog lamps should not light.

04-241

REAR FOG LAMPS ARE INOPERATIVE

04-242

Inspect rear fog lamp fuse (10A) in driver side junction

2. CHECK HARNESS AND CONNECTOR (REAR FOG LAMP RELAY - REAR FOG LAMP)

Remove rear fog lamp relay in driver side junction box (I001).

Disconnect the F006 rear combination lamp LH connector.

Disconnect the G001 rear combination lamp RH connector.

Disconnect the I003 instrument cluster B connector.

F006 (5) - Ground

04-243

Set the rear foglamp

3 - 4 < 2 Ω

3 - 4 ≥ 1 MΩ

4. CHECK HARNESS AND CONNECTOR (REAR FOG LAMP RELAY - COMBINATION SWITCH (LIGHT))

Rear fog lamp relay (86) - I012 (3)

04-244

5. CHECK HARNESS AND CONNECTOR (REAR FOG LAMP - GROUND)

F006 (2) - Ground

G001 (2) - Ground

6. INSPECT REAR FOG LAMP BULBS

Replace rear fog lamp bulb LH.

Replace rear fog lamp bulb RH.

YES > Replace rear fog lamp bulb both LH and RH.

04-245

7. CHECK HARNESS AND CONNECTOR (REAR FOG LAMP RELAY - REAR FOG LAMP LH)

Rear fog lamp relay (87) - F006 (5)

Rear fog lamp relay (87) - G001 (5)

YES > Replace rear fog lamp relay.

04-246

REAR FOG LAMPS ARE ALWAYS ON

04-247

2. CHECK HARNESS AND CONNECTOR (REAR FOG LAMP RELAY - COMBINATION SWITCH)

I012 (3) - Ground

04-248

3. CHECK HARNESS AND CONNECTOR (REAR FOG LAMP RELAY - REAR FOG LAMP)

(b) Remove rear fog lamp relay in driver side junction box (I001).

The rear fog lamps should not light.

04-249

ALL FOG LAMPS ARE INOPERATIVE

04-250

Inspect the front fog lamp fuse (15 A) in driver side junction

Inspect the rear fog lamp fuse (10 A) in driver side junction

YES > Go to step 4.

NO > If front fog lamp fuse (15 A) is damage,go to next step.

If rear fog lamp fuse (10 A) is damage,go to step 3.

If both front and rear fog lamp fuses are damage,go to step 2 and step 3.

04-251

4. CHECK HARNESS AND CONNECTOR (COMBINATION SWITCH (LIGHT) - GROUND)

I012 (4) - Ground

04-252

5. INSPECT COMBINATION SWITCH (LIGHT)

Set the front foglamp

2 - 4

6. NSPECT BOTH FRONT AND REAR FOG LAMP RELAYS.

Remove rear fog relay in driver side junction box (I001).

Inspect relays according to the value(s) in the table

below.. .

• Front fog lamp relay and rear fog lamp relay have

same pins.

• Both relays shoud be measured.

04-253

7. CHECK HARNESS AND CONNECTOR (FRONT FOG LAMP RELAY AND REAR FOG LAMP

RELAY - COMBINATION SWITCH (LIGHT))

8. CHECK HARNESS AND CONNECTOR (FRONT AND REAR FOG LAMP RELAY - FRONT FOG

LAMP LH AND RE ,REAR FOG LAMP LH AND RH)

04-254

9. CHECK HARNESS AND CONNECTOR (FRONT FOG LAMP LH AND REAR FOG LAMP LH AND

RH - GROUND)

04-255

YES > Replace all fog lamp bulbs.

04-256

LAMPS ARE NORMAL)

04-257

Inspect the hazard warning fuse (15A) in driver side

junction box (I001).

2. CHECK HARNESS AND CONNECTOR (HAZARD WARNING FUSE - HAZARD WARNING SWITCH)

Disconnect the I006 hazard warning switch connector.

I006 (8) - Ground

3. CHECK HARNESS AND CONNECTOR (HAZARD WARNING SWITCH - FLASHER)

Disconnect the I034 flasher connector.

04-258

I006 (6) - I034 (3)

4. CHECK HARNESS AND CONNECTOR (HAZARD WARNING FUSE - HAZARD WARNING SWITCH)

Hazard warning fuse (15A) - I006 (8)

5. CHECK HARNESS AND CONNECTOR (HAZARD WARNING SWITCH - ALL TURN SIGNAL LAMPS)

Disconnect the V004 front turn signal lamp LH connector.

Disconnect the V008 front turn signal lamp RH connector.

04-259

I006 (5) - V004 (2)

I006 (5) - F006 (4)

I006 (4) - V008 (2)

I006 (4) - G001 (4)

YES > Replace hazard warning switch.

04-260

04-261

Inspect the turn signal fuse (10A) in driver side junction

2. CHECK HARNESS AND CONNECTOR (TURN SIGNAL FUSE - HAZARD WARNING SWITCH)

I006 (10) - Ground

3. INSPECT COMBINATION SWITCH (TURN SIGNAL SWITCH)

Disconnect the I012 combination switch (turn signal switch) connector.

04-262

Inspect combination switch (turn signal switch) according

Turn the turn signal

switch OFF

Set turn signal switch to

LEFT

RIGHT

6 - 5

6 - 7

4. CHECK HARNESS AND CONNECTOR (TURN SIGNAL FUSE - HAZARD WARNING SWITCH)

Turn signal fuse (10A) - I006 (10)

5. CHECK HARNESS AND CONNECTOR (FLASHER - COMBINATION SWITCH (TURN SIGNAL SWITCH))

04-263

I034 (3) - I012 (6)

6. CHECK HARNESS AND CONNECTOR (COMBINATION SWITCH (TURN SIGNAL SWITCH) - ALL

TURN SIGNAL LAMPS)

I012 (5) - V004 (2)

I012 (5) - F006 (4)

I012 (7) - V008 (2)

I012 (7) - G001 (4)

04-264

HAZARD WARNING AND TURN SIGNAL LAMPS ARE INOPERATIVE

04-265

NO > If hazard warning fuse (15A) is damage, go to next step.

If turn signal fuse (10A) is damage,go to step 3.

If both hazard warning fuse (15A) and turn signal fuse (10A) are damge,go to step 2 and step 3.

≥ 1 ΜΩ

3. CHECK HARNESS AND CONNECTOR (TURN SIGNAL FUSE - HAZARD WARNING SWITCH)

04-266

4. CHECK HARNESS AND CONNECTOR (HAZARD WARNING SWITCH - FLASHER)

I034 (2) - Ground

5. INSPECT HAZARD WARNING SWITCH

Inspect the hazard warning switch according to the

Set hazard warning

switch ON

7 - 10

7 - 8

6 - 5 - 4

04-267

NO > Relace hazard warning switch.

6. CHECK HARNESS AND CONNECTOR (FLASHER - GROUND)

I034 (1) - Ground

7. CHECK HARNESS AND CONNECTOR (HAZARD WARNING SWITCH - FLASHER)

I006 (7) - I034 (2)

8. CHECK HARNESS AND CONNECTOR (HAZARD WARNING SWITCH - HAZARD WARNING FUSE

AND TURN SIGNAL FUSE)

04-268

I006 (8) - Hazard warning fuse (15A)

I006 (10) - Turn signal fuse (10A)

9. INSPECT FLASHER

Replace flasher.

YES > Replace flasher.

10. CHECK HARNESS AND CONNECTOR (FLASHER - COMBINATION SWITCH)

04-269

11. INSPECT COMBINATION SWITCH

12. CHECK HARNESS AND CONNECTOR (TURN SIGNAL LAMP - GROUND)

04-270

V004 (1) - Ground

V008 (1) - Ground

13. CHECK HARNESS AND CONNECTOR (HAZARD WARNING SWITCH - ALL TURN SIGNAL LAMPS)

04-271

14. CHECK HARNESS AND CONNECTOR (COMBINATION SWITCH (TURN SIGNAL SWITCH) - ALL

YES > Replace 4 turn signal lamp bulbs.

04-272

TURN SIGNAL LAMPS ARE INOPERATIVE (ONE SIDE)

04-273

• This inspection procedure is an example of turn signal lamp LH, turn signal lamp RH inspection

1. INSPECT COMBINATION SWITCH

If only one turn signal lamp is not bright,over this step.

Disconnect the I012 combination switch(turn signal lamp) connector.

• If only turn signal lamps LH is not bright,measure 6 -

5.

• If only turn signal lamps RH is not bright,measure 6 -

7.

2. CHECK HARNESS AND CONNECTOR (COMBINATION SWITCH (TURN SIGNAL SWITCH) - TURN

SIGNAL LAMP)

• If only front turn signal lamps LH is not bright,step d isn’t performed.

• If only rear turn signal lamps LH is not bright,step c isn’t performed.

(b) Disconnect the I012 combination switch(turn signal lamp) connector.

(d) Disconnect the F006 rear combination lamp LH connector.

04-274

• If only front turn signal lamps LH is not bright,measure

I012 (5) - V004 (2) only.

• If only rear turn signal lamps LH is not bright,measure

I012 (5) - F006 (4) only.

3. CHECK HARNESS AND CONNECTOR (TURN SIGNAL LAMP - GROUND)

• If only front turn signal lamps LH is not bright,step c isn’t performed.

• If only rear turn signal lamps LH is not bright,step b isn’t performed.

(b) Disconnect the V004 front turn signal lamp LH connector.

YES > Replace turn signal lamp bulb(s).

V004 (1) - Ground only.

F006 (2) - Ground only.

04-275

HAZARD WARNING LAMPS ARE ALWAYS ON

04-276

1. INSPECT HAZARD WARNING SWITCH

NO > Replace hazard warning switch.

2. CHECK HARNESS AND CONNECTOR (HAZARD WARNING SWITCH - TURN SIGNAL LAMP)

Connect the battery negative cable,check the wire harness for shot to ground,hazard warning lamp is

shoud not be bright.

04-277

ALL STOP LAMPS ARE INOPERATIVE

04-278

Inspect the stop lamp fuse (15A) in engine room junction

box(A002).

2. CHECK HARNESS AND CONNECTOR (BRAKE LAMP FUSE - STOP LAMP SWITCH)

A025 (2) - Ground

3. CHECK HARNESS AND CONNECTOR (STOP LAMP SWITCH - STOP LAMP)

Disconnect the U002 high - mounted stop lamp connector.

04-279

F006 (3) - Ground

4. INSPECT STOP LAMP SWITCH

Inspect the stop lamp switch according to the value(s) in

Set stop lamp switch OFF 1 - 2 ≥ 1 MΩ

Set stop lamp switch ON 1 - 2 < 2 Ω

5. CHECK HARNESS AND CONNECTOR ( BRAKE LAMP FUSE - STOP LAMP SWITCH)

04-280

Stop lamp fuse (15A) - A025 (2)

6. CHECK HARNESS AND CONNECTOR (STOP LAMP SWITCH - STOP LAMP)

A025(1) - F006 (3)

A025(1) - G001(3)

A025(1) - U002 (2)

04-281

7. CHECK HARNESS AND CONNECTOR (STOP LAMP - GROUND)

U002 (1) - Ground

YES > Replace stop lamp bulbs.

04-282

STOP LAMP IS INOPERATIVE (ONE SIDE)

04-283

• This inspection procedure is an example of stop lamp LH, stop lamp RH inspection procedure is similar.

1. CHECK HARNESS AND CONNECTOR (REAR COMBINATION LAMP - GROUND)

2. CHECK HARNESS AND CONNECTOR (STOP LAMP SWITCH - REAR COMBINATION LAMP)

A025 (1) - F006 (3)

YES > Replace stop lamp bulb.

04-284

HIGH - MOUNTED STOP LAMP IS INOPERATIVE

04-285

1. CHECK HARNESS AND CONNECTOR (HIGH - MOUNTED STOP LAMP - GROUND)

2. CHECK HARNESS AND CONNECTOR (STOP LAMP SWITCH - HIGH - MOUNTED STOP LAMP)

A025 (1) - U002 (2)

YES > Replace high - mounted stop lamp bulb.

04-286

BACK - UP LAMP IS INOPERATIVE(ONE SIDE)

04-287

• This inspection procedure is an example of back - up lamp LH, back - up lamp RH inspection procedure

is similar.

Check harness and connector (back - up lamp - ground)

3. CHECK HARNESS AND CONNECTOR (BACK - UP LAMP SWITCH - BACK - UP LAMP)

Disconnect the A021 back - up lamp switch connector.

A021 (2) - F006 (6)

YES > Replace back - up lamp bulb.

04-288

BACK - UP LAMPS ARE INOPERATIVE (BOTH SIDES)

04-289

Inspect the back - up lamp fuse (10A) in driver side

2. CHECK HARNESS AND CONNECTOR (BACK - UP LAMP FUSE - BACK - UP LAMP SWITCH)

A021 (1) - Ground

04-290

F006 (6) - Ground

4. INSPECT BACK - UP LAMP SWITCH

Inspect the back - up lamp switch according to the

Set back - up lamp

NO > Replace back - up lamp switch.

04-291

5. CHECK HARNESS AND CONNECTOR (BACK - UP LAMP FUSE - BACK - UP LAMP SWITCH)

Back - up lamp (10A) - A021

(1)

6. CHECK HARNESS AND CONNECTOR (BACK - UP LAMP SWITCH - BACK - UP LAMP)

A021 (2) - G001 (6)

04-292

7. CHECK HARNESS AND CONNECTOR (BACK - UP LAMP - GROUND)

YES > Replace back - up lamp bulbs.

04-293

IGNITION SWITCH ILLUMINATION IS INOPERATIVE

04-294

1. INSPECT IGNITION SWITCH ILLUMINATION LAMP.

Disconnect the I010 ignition switch illumination connector.

Replace ignition switch illumination lamp.

YES > Replace ignition switch illumination lamp.

2. CHECK HARNESS AND CONNECTOR (DOME LIGHT FUSE - IGNITION SWITCH ILLUMINATION)

Dome light fuse (10A) - I010 (1)

04-295

3. CHECK HARNESS AND CONNECTOR (IGNITION SWITCH ILLUMINATION - CENTRAL LOCKING

CONTROLLER ASSY)

Disconnect the I008 central locking controller assy connector.

I010 (2) - I008 (B1)

4. CHECK HARNESS AND CONNECTOR (CENTRAL LOCKING CONTROLLER ASSY - GROUND)

I008 (B10) - Ground

YES > Replace central locking controller asssy.

04-296

CENTRAL DOME LIGHT IS INOPERATIVE

04-297

04-298

1. CHECK HARNESS AND CONNECTOR (DOME LIGHT FUSE - CENTRAL DOME LIGHT)

Disconnect the F004 central dome light connector.

Dome light fuse (10A) - F004 (1)

If central dome light can’t be contrled by door lamp switch,over

this step.

If central dome light can be contrled by door lamp switch,over

2. CHECK HARNESS AND CONNECTOR (CENTRAL DOME LIGHT - DOME LIGHT SWITCH AND

MIDDLE DOOR LAMP SWITCH RH)

• If central dome light can be contrled by door lamp switch,perform this step.

• If central dome light can’t be contrled by door lamp switch,over this step ,perform the next step.

(b) Disconnect the F004 central dome light connector.

04-299

F004 (3) - I018 (5)

F004 (2) - G003 (1)

YES > Replace central dome light assy.

3. CHECK HARNESS AND CONNECTOR (CENTRAL DOME LIGHT - DOME LIGHT SWITCH)

Disconnect the I018 dome light switch connector.

F004 (2) - I018 (5)

4. INSPECT DOME LIGHT SWITCH

Turn the dome light switch ON.

If the dome light switch has no problem,it should be bright.

NO > Replace dome light switch.

04-300

5. CHECK HARNESS AND CONNECTOR (DOME LIGHT SWITCH - GROUND)

I018 (2) - Ground

04-301

AIR PURIFIER LAMP IS INOPERATIVE

04-302

04-303

1. CHECK HARNESS AND CONNECTOR (DOME LIGHT FUSE - AIR PURIFIER LAMP)

Disconnect the F007 air purifier connector.

Dome light fuse (10A) - F007 (1)

2. CHECK HARNESS AND CONNECTOR (AIR PURIFIER LAMP - DOME LIGHT SWITCH AND

Disconnect the G003 middle door lamp switch RH connector.

F007 (3) - I018 (5)

F007 (2) - G003 (1)

YES > Replace air purifier.

04-304

STEP LAMP ARE INOPERATIVE

04-305

1. INSPECT STEP LAMP

Disconnect the N002 step lamp connector.

Replace step lamp bulb.

Connect the battery negative cable,trun the middle door lamp switch RH ON.

YES > Replace step lamp bulb.

2. CHECK HARNESS AND CONNECTOR (dome light FUSE - STEP LAMP)

dome light fuse (10A) - N002 (1)

04-306

3. CHECK HARNESS AND CONNECTOR (STEP LAMP - MIDDLE DOOR LAMP SWITCH RH)

N002 (2) - G003 (1)

YES > Replace middle door lamp switch RH.

04-307

TRUNK LAMP IS INOPERATIVE

04-308

1. INSPECT TRUNK LAMP

Disconnect the J003 trunk lamp connector.

Replace trunk lamp bulb.

Connect the battery negative cable,turn rear hatch lock assy - switch ON.

YES > Replace trunk lamp bulb.

2. CHECK HARNESS AND CONNECTOR (DOME LIGHT FUSE - TRUNK LAMP)

Dome light fuse (10A) - J003 (1)

3. CHECK HARNESS AND CONNECTOR (TRUNK LAMP - REAR HATCH LOCK ASSY - SWITCH)

Disconnect the J001 rear hatch lock assy - switch connector.

04-309

J003 (2) - J001 (1)

4. CHECK HARNESS AND CONNECTOR (REAR HATCH LOCK ASSY - SWITCH - GROUND)

J001 (2) - Ground

YES > Replace rear hatch lock assy - switch.

04-310

FRONT DOME LIGHT IS INOPERATIVE

04-311

04-312

1. CHECK HARNESS AND CONNECTOR (DOME LIGHT FUSE - FRONT DOME LIGHT)

Disconnect the battery negative cable.front dome light

Disconnect the F001 front dome light connector.

Dome light fuse (10A) - F001 (1)

Dome light fuse (10A) - F001 (2)

2. CHECK HARNESS AND CONNECTOR (FRONT DOME LIGHT - GROUND,FRONT DOOR LAMP

DIODE LH,FRONT DOOR LAMP SWITCH RH,INSTRUMENT CLUSTER)

Disconnect the A029 front door lamp diode LH connector.

Disconnect the A024 front door lamp switch rh connector.

F001 (4) - A029 (1)

F001 (4) - A024 (1)

04-313

F001 (4) - I002 (A30)

F001 (3) - Ground

YES > Replace front dome light assy.

04-314

ALL INTERIOR ILLUMINATION LAMPS ARE INOPERATIVE

04-315

04-316

1. INSPECT LAMPLET RELAY

Remove lamplet relay in driver side junction box (I001).

Inspect lamplet relay according to the value(s) in the

table below

Normal 85 - 86 Breakover

NO > Replace lamplet relay.

2. CHECK HARNESS AND CONNECTOR (LAMPLET RELAY - COMBINATION SWITCH)

remove lamplet relay in driver side junction box (I001).

Lamplet relay (86) - I012 (13)

04-317

3. CHECK HARNESS AND CONNECTOR (COMBINATION SWITCH (LIGHT) - GROUND)

I012 (10) - Ground

inspect lamplet fuse (7.5A) in driver side junction box

inspect switch lighting fuse (7.5A) in driver side junction

YES > Replace the combination switch.

04-318

5. CHECK HARNESS AND CONNECTOR (LAMPLET FUSE - INSTRUMENT CLUSTER)

I002 (A6) - Ground

NO > Repair or replace harness or connector,and go to next step.

6. CHECK HARNESS AND CONNECTOR (SWITCH LIGHTING FUSE - INTERIOR LAMPS)

(k)

(l)

Disconnect the I004 headlamp dimmer switch connector.

Disconnect the I005 instrument dimmer switch connector.

Disconnect the I016 rear window defroster switch connector.

Disconnect the I017 outside mirror defroster switch connector.

Disconnect the I033 cigarette lighter connector.

Disconnect the I031 radio A connector.

Disconnect the I021 A/C control panel B connector.

Disconnect the I019 diagnosis switch connector.

(m)

I006 (2) - Ground

04-319

INSTRUMENT CLUSTER ILLUMINATION IS NOT INOPERATIVE

04-320

Inspect lamplet fuse (7.5A) in driver side junction box

2. CHECK HARNESS AND CONNECTOR (LAMPLET FUSE - INSTRUMENT CLUSTER)

04-321

3. CHECK HARNESS AND CONNECTOR (INSTRUMENT CLUSTER - GROUND)

I002 (A19) - Ground

4. CHECK HARNESS AND CONNECTOR (LAMPLET FUSE - INSTRUMENT CLUSTER)

Lamplet fuse (7.5A) - I002 (A6)

YES > Replace Instrument Cluster.

04-322

DIAGNOSIS SWITCH ILLUMINATION IS NOT INOPERATIVE

04-323

1. CHECK HARNESS AND CONNECTOR (DIAGNOSIS SWITCH - GROUND)

I019 (1) - Ground

2. CHECK HARNESS AND CONNECTOR (SWITCH LIGHTING FUSE - DIAGNOSIS SWITCH)

Switch lighting fuse (7.5A) - I019 (3)

YES > Replace diagnosis switch.

04-324

CIGARETTE LIGHTER ILLUMINATION IS NOT INOPERATIVE

04-325

1. CHECK HARNESS AND CONNECTOR (CIGARETTE LIGHTER - GROUND)

I033 (1) - Ground

2. CHECK HARNESS AND CONNECTOR (SWITCH LIGHTING FUSE - CIGARETTE LIGHTER)

Switch lighting fuse (7.5A) - I033 (3)

YES > Replace cigarette lighter.

04-326

A/C CONTROL PANEL ILLUMINATION IS NOT INOPERATIVE

04-327

1. CHECK HARNESS AND CONNECTOR (A/C CONTROL PANEL - GROUND)

Disconnect the I020 A/C control panel A connector.

2. CHECK HARNESS AND CONNECTOR (SWITCH LIGHTING FUSE - A/C CONTROL PANEL)

Switch lighting fuse (7.5A) - I021 (32)

YES > Replace A/C control panel.

04-328

RADIO ILLUMINATION IS NOT INOPERATIVE

04-329

1. CHECK HARNESS AND CONNECTOR (RADIO - GROUND)

I031 (A8) - Ground

2. CHECK HARNESS AND CONNECTOR (SWITCH LIGHTING FUSE - RADIO)

Switch lighting fuse (7.5A) - I031 (A3)

YES > Raplace radio.

04-330

REAR BLOWER FORWARD SWITCH ILLUMINATION IS NOT INOP-

ERATIVE

04-331

1. CHECK HARNESS AND CONNECTOR (REAR BLOWER FORWARD SWITCH - GROUND)

I023 (1) - Ground

2. CHECK HARNESS AND CONNECTOR (SWITCH LIGHTING FUSE - REAR BLOWER FORWARD

Switch lighting fuse (7.5A) - I023 (3)

YES > Replace rear blower forward switch.

04-332

DOME LIGHT SWITCH ILLUMINATION IS NOT INOPERATIVE

04-333

1. CHECK HARNESS AND CONNECTOR (DOME LIGHT SWITCH - GROUND)

I018 (1) - Ground

2. CHECK HARNESS AND CONNECTOR (SWITCH LIGHTING FUSE - DOME LIGHT SWITCH)

Switch lighting fuse (7.5A) - I018 (3)

YES > Replace dome light switch.

04-334

OUTSIDE MIRROR DEFROSTER SWITCH ILLUMINATION IS NOT

INOPERATIVE

04-335

1. CHECK HARNESS AND CONNECTOR (OUTSIDE MIRROR DEFROSTER SWITCH - GROUND)

I017 (1) - Ground

2. CHECK HARNESS AND CONNECTOR (SWITCH LIGHTING FUSE - OUTSIDE MIRROR DEFROSTER

Switch lighting fuse (7.5A) - I017 (3)

YES > Replace outside mirror defroster switch.

04-336

HEADLAMP DIMMER SWITCH ILLUMINATION IS NOT INOPERA-

TIVE

04-337

1. CHECK HARNESS AND CONNECTOR (HEADLAMP DIMMER SWITCH - Ground)

I004 (6) - Ground

2. CHECK HARNESS AND CONNECTOR (SWITCH LIGHTING FUSE - HEADLAMP DIMMER SWITCH)

Switch lighting fuse (7.5A) - I004 (3)

YES > Replace headlamp dimmer switch.

04-338

REAR WINDOW DEFROSTER SWITCH ILLUMINATION IS NOT

04-339

1. CHECK HARNESS AND CONNECTOR (REAR WINDOW DEFROSTER SWITCH - GROUND)

I016 (1) - Ground

2. CHECK HARNESS AND CONNECTOR (SWITCH LIGHTING FUSE - REAR WINDOW DEFROSTER

Switch lighting fuse (7.5A) - I016 (3)

YES > Replace rear window defroster switch.

04-340

INSTRUMENT DIMMER SWITCH ILLUMINATION IS NOT INOPERA-

04-341

1. CHECK HARNESS AND CONNECTOR (INSTRUMENT DIMMER SWITCH - GROUND)

I005 (6) - Ground

2. CHECK HARNESS AND CONNECTOR (SWITCH LIGHTING FUSE - INSTRUMENT DIMMER SWITCH)

Switch lighting fuse (7.5A) - I005 (3)

YES > Replace instrument dimmer switch.

04-342

HAZARD WARNING SWITCH ILLUMINATION IS NOT INOPERATIVE

04-343

1. CHECK HARNESS AND CONNECTOR (HAZARD WARNING SWITCH - GROUND)

I006 (3) - Ground

2. CHECK HARNESS AND CONNECTOR (SWITCH LIGHTING FUSE - HAZARD WARNING SWITCH)

Switch lighting fuse (7.5A) - I006 (2)

04-344

WIDTH LAMPS IS NOT INOPERATIVE

04-345

1. CHECK HARNESS AND CONNECTOR (WIDTH LAMPS - GROUND)

• If only width lamp LH is not bright,step c isn’t performed.

• If only width lamp RH is not bright,step b isn’t performed.

(b) Disconnect the V002 front position lamp LH connector.

V002 (1) - Ground

V007 (1) - Ground

• If only width lamp LH is not bright,measure V002 (1) -

Ground onlyl.

• If only width lamp RH is not bright,measure V007 (1) -

Ground only.

2. CHECK HARNESS AND CONNECTOR (LAMPLET FUSE - WIDTH LAMPS)

04-346

Lamplet fuse (7.5A) - V002 (2)

Lamplet fuse (7.5A) - V007 (2)

NIOTE

• If only width lamp LH is not bright,measure lamplet

fuse (7.5A) - V002 (2) only.

• If only width lamp RH is not bright,measure lamplet

fuse (7.5A) - v007 (2) only.

YES > Replace width lamp bulbs.

04-347

TAIL LAMPS ARE INOPERATIVE

04-348

1. CHECK HARNESS AND CONNECTOR (TAIL LAMPS - GROUND)

• If only tail lamp LH is not bright,step c isn’t performed.

• If only tail lamp RH is not bright,step b isn’t performed.

(b) Disconnect the F006 rear combination lamp LH connector.

• If only tail lamp LH is not bright, measure F006 (2) -

• If only tail lamp RH is not bright,measure G001 (2) -

2. CHECK HARNESS AND CONNECTOR (LAMPLET FUSE - TAIL LAMPS)

04-349

Lamplet fuse (7.5A) - F006 (1)

Lamplet fuse (7.5A) - G001 (1)

• If only tail lamp LH is not bright, measure Lamplet

Fuse (7.5A) - F006 (1) only.

• If only tail lamp RH is not bright,measure Lamplet

Fuse (7.5A) - G001 (1) only.

YES > Replace tail lamp bulbs.

04-350

LICENSE LAMP IS INOPERATIVE

04-351

1. CHECK HARNESS AND CONNECTOR (LICENSE LAMP - GROUND)

Disconnect the J004 license lamp connector.

J004 (2) - Ground

2. CHECK HARNESS AND CONNECTOR (LAMPLET FUSE - LICENSE LAMP)

Lamplet fuse (7.5A) - J004 (1)

YES > Replace license lamp bulbs.

04-352

WIDTH LAMPS TAIL LAMPS AND LICENSE LAMP ARE INOPERA-

04-353

Inspect the lamplet fuse (7.5A) in driver side junction box

2. CHECK HARNESS AND CONNECTOR (LAMPLET FUSE - LAMPLET)

Disconnect the V002 front position lamp LH connector.

Disconnect the V007 front position lamp RH connector.

V002 (2) - Ground

04-354

3. INSPECT LAMPLET RELAY

4. CHECK HARNESS AND CONNECTOR (LAMPLET RELAY - COMBINATION SWITCH (LIGHT))

Remove the lamplet relay in driver side junction box (I001).

lamplet relay (86) - I012 (13)

04-355

5. CHECK HARNESS AND CONNECTOR (COMBINATION SWITCH (LIGHT) - GROUND)

04-356

DIAGNOSTICS - WIPER AND WASHER

1. EXPRESSIONS OF IGNITION SWITCH.

Ignition Switch (position)

LOCK

START

Ignition Switch (condition)

Ignition switch off

Ignition switch on (IG)

Ignition switch on (ACC)

Engine start

2. POWER OFF.

Before removing or installing any electrical device, please disconnect the nagative battery cable to

04-357

1 Front Wiper Arm Assy LH 2 Front Wiper Arm Assy RH

1 Rear Wiper Arm Assy 2 Rear Wiper Blade Assy

04-358

• The voltage should be above 12 V.

Check the wiper motor in HIGH position.

• Set the wiper and washer switch in HIGH

position.

Does the wiper motor operate in high mode?

Check the wiper motor in LOW position.

• Set the wiper and washer switch in LOW

Does the wiper motor operate in low mode?

Check the wiper motor in INT position.

• Set the wiper and washer switch in INT

Does the wiper motor operate in intermittent

mode?

Check wiper and washer switch

04-359

Wipers are inoperative - windshield

2. Wiper and washer switch

3. Windshield wiper motor

Chapter 51 steering column -

combination switch, replacement

Chapter 65 wiper and washer -

wiper motor, replacement

Wipers are inoperative at low speed

- windshield

1. Windshield wiper motor

Wipers are inoperative at high

speed - windshield

Wipers are inoperative in

intermittent mode - windshield

Washer pump is inoperative -

windshield

1. Wiper and washer switch

2. Windshield wiper motor

When the wiper and washer switch

is OFF, the wiper blade does not

retract

Wiper is inoperative - rear window

1. Rear window wiper motor

04-360

Wiper is inoperative in intermittent

mode - rear window

3. Wire harness

1. Washer pump - rear window -

Washer pump is inoperative - rear

window

04-361

WIPERS ARE INOPERATIVE - WINDSHIELD

04-362

Inspect the windshield wiper fuse in driver side junction

box (I001): 15 A.

2. CHECK HARNESS AND CONNECTOR ( FRONT WIPER FUSE - WINDSHIELD WIPER)

Disconnect the V011 windshield wiper assy connector.

Front wiper fuse - V011(2)

Go to next step.

04-363

3. CHECK HARNESS AND CONNECTOR (FRONT WIPER FUSE - COMBINATION SWITCH)

Disconnect the I013 combination switch (wiper and washer control) connector.

Front wiper fuse - I013 (8)

4. CHECK HARNESS AND CONNECTOR (FRONT WIPER FUSE - FRONT WASHING RESERVOIR

MOTOR)

Disconnect the V010 front washing reservoir motor connector.

Front wiper fuse - V010 (2)

04-364

5. INSPECT RELAY IG2

Pull out the relay IG2.

Inspect relay IG2.

terminal 30 and

87

NO > Replace relay IG2.

6. CHECK HARNESS AND CONNECTOR (WINDSHIELD WIPER - GROUND)

Disconnect the V011 windshield wiper connector.

Windshield wiper(V011) -

04-365

7. CHECK HARNESS AND CONNECTOR (COMBINATION SWITCH - WINDSHIELD WIPER)

Disconnect the I013 combination switch connector.

I013(7) - V011(1)

I013(9) - V011(4)

I013(6) - V011(3)

8. INSPECT WINDSHIELD WIPER

Remove the windshield wiper assy.

Inspect the windshield wiper in high mode.

terminal 4 and 5

4 - 5

Windshield wiper

high - speed operation

Inspect windshield wiper in low mode

terminal 1 and 5

1 - 5

low - speed operation

NO > Repair or replace windshield wiper.

04-366

9. CHECK HARNESS AND CONNECTOR (COMBINATION SWITCH - GROUND)

I013(5) - Ground

YES > Replace combination switch.

04-367

WIPERS ARE INOPERATIVE AT LOW SPEED - WINDSHIELD

04-368

Inspect combination switch (wiper and washer control)

according to the value(s) in the table below.

Set the wiper and washer

switch to LOW

8 - 7 ≥ 1 MΩ

8 - 7 < 2 Ω

2. CHECK HARNESS AND CONNECTOR (COMBINATION SWITCH - WINDSHIELD WIPER)

Standard resisance

YES > Replace windshield wiper.

04-369

WIPERS ARE INOPERATIVE AT HIGH SPEED - WINDSHIELD

04-370

Disconnect the V013 combination switch (wiper and washer control) connector.

switch to HIGH

8 - 9 ≥ 1 MΩ

8 - 9 < 2 Ω

Measure the resisitance according to the value(s) in the

I013 (9) - V011(4)

04-371

SHIELD

04-372

1. INSPECT WINDSHIELD WIPER

Inspect the windshield wiper in INT mode.

voltage to terminal

3 and 5

Battery(+) - 3

Battery( - ) - Ground

Front washing

reservoir motor

operates at low

speed

NO > Replace the windshield wiper.

2. CHECK HARNESS AND CONNECTOR ( COMBINATION SWITCH - GROUND)

I013 (5) - Ground

Is the inspecrtion result normal?

04-373

3. CHECK HARNESS AND CONNECTOR (WINDSHIELD WIPER - GROUND)

V011 (5) - Ground

4. CHECK HARNESS AND CONNECTOR (WINDSHIELD WIPER - COMBINATION SWITCH)

I013 (6) - V011 (3)

I013 (7) - V011 (1)

04-374

WASHER PUMP IS INOPERATIVE - WINDSHIELD

04-375

Inspect the front wiper fuse in driver side junction box

(I001): 15 A.

2. INSPECT COMBINATION SWITCH

switch to WASH

4 - 5 ≥ 1 MΩ

4 - 5 < 2 Ω

04-376

3. CHECK HARNESS AND CONNECTOR (DRIVER SIDE JUNCTION CONNECTOR - FRONT WASHER

PUMP)

Disconnect the V010 front washer pump connector.

Driver side junction connector(87)

- V010 (2)

4. CHECK HARNESS AND CONNECTOR (COMBINATION SWITCH - FRONT WASHER PUMP)

V010 (1) - I013 (4)

04-377

5. CHECK HARNESS AND CONNECTOR (COMBINATION SWITCH - GROUND)

YES > Replace the front washer pump.

04-378

WHEN THE WIPER SWITCH IS OFF, THE WIPER BLADE DOES NOT

RETRACT

04-379

5 - 7 < 2 Ω

5 - 7 ≥ 1 MΩ

2. CHECK HARNESS AND CONNECTOR (COMBINATION SWITCH - WINDSHIELD WIPER )

04-380

3. CHECK HARNESS AND CONNECTOR (COMBINATION SWITCH - WINDSHIELD WIPER)

V011(3) - I013 (6)

YES > Repair or replace windshield wiper.

04-381

WIPER IS INOPERATIVE - REAR WINDOW

04-382

Set the rear wiper and

washer switch to ON

2 - 5 ≥ 1 MΩ

2 - 5 < 2 Ω

2. INSPECT FUSE

Inspect the rear wiper fuse in driver side junction box

(I001): 10 A.

04-383

3. CHECK HARNESS AND CONNECTOR (DRIVER SIDE JUNCTION CONNECTOR - COMBINATION

Disconnect rear wiper relay connector.

Rear wiper relay(86) - I013 (2)

NO > Replace fuse.

4. CHECK HARNESS AND CONNECTOR (DRIVER SIDE JUNCTION CONNECTOR - REAR WIPER)

Rear wiper relay(86) - U001 (2)

04-384

5. INSPECT REAR WIPER RELAY

Disconnect rear wiper relay.

Constant 30 - 87a < 2 Ω

Constant 85 - 86 < 2 Ω

terminal 85 and 86

30 - 87a ≥ 1 MΩ

30 - 87 Continuity

NO > Repair or replace rear wiper relay.

6. INSPECT RELAY

Disconnect relay IG2.

NO > Repair or replace relay.

04-385

7. CHECK HARNESS AND CONNECTOR (REAR WIPER RELAY - REAR WIPER)

Rear wiper relay (30) - U001

(4)

8. CHECK HARNESS AND CONNECTOR (REAR WIPER RELAY - REAR WIPER)

04-386

9. CHECK HARNESS AND CONNECTOR (REAR WIPER - GROUND)

Disconnect the U001 rear wiper relay connector.

U001(3) - Ground

YES > Replace the rear wiper.

04-387

WASHER PUMP IS INOPERATIVE - REAR WINDOW

04-388

Set rear wiper and

washer switch to

SART

5 - 2 < 2 Ω

5 - 2 ≥ 1 MΩ

04-389

3. CHECK HARNESS AND CONNECTOR (REAR WIPER FUSE - REAR WASHING RESERVOIR

Disconnect the V009 rear washing reservoir motor connector.

Rear wiper fuse (87) - V009 (2)

4. CHECK HARNESS AND CONNECTOR (REAR WIPER RELAY - COMBINATION SWITCH)

Disconnect the I001 rear wiper relay connector.

Rear wiper relay (86) - I013 (2)

04-390

5. INSPECT RELAY

6. CHECK HARNESS AND CONNECTOR (DRIVER SIDE JUNCTION CONNECTOR - GROUND)

Disconnect rear relay IG2.

Junction connector - Ground

04-391

7. CHECK HARNESS AND CONNECTOR (COMBINATION SWITCH - GROUND)

8. CHECK HARNESS AND CONNECTOR ( REAR WASHING RESERVOIR MOTOR - COMBINATION

V009(1) - I013(3)

YES > Repair or replace rear washing reservoir motor.

04-392

DIAGNOSTICS - AUDIO SYSTEM

AUDIO SYSTEM

1. IT IS FORBIDDEN TO REFIT THE AUDIO SYSTEM.

2. THE RADIO WAVE BANDS USED IN RADIO BROADCASTING ARE AS FOLLOWS.

Radio wave AM FM

Modulation method Amplitude modulation Frequency modulation

Designation AM1 AM2 FM1 FM2 FM3

Frequency 522 ~ 1620 KHz 87.5 ~ 108 MHz

3. POWER OFF.

(a) Before removing or installing any electrical device, please disconnect the negative battery cable to

prevent the device damage or personal injury.

(b) Ignition switch must be off if no specific instructions.

04-393

1 Rear Speaker Assy RH

2 Rear Speaker Assy LH

3 Radio Assy

4 Front Speaker Assy RH

3 Front Speaker Assy LH

04-394

• The voltage should be above 12V.

Check radio antenna.

• Check whether the antenna is pulled out

and pulled out to end.

• Check whether the antenna is covered

with obstacles.

• Check whether the antenna is bended or

deformation.

Repair or replace the radio antenna assy.

Check radio.

• Press the radio power button, check

whether the radio work well.

Check speaker.

• Set the radio volume level above 5 VOL,

check whether the speaker sounds.

Check the radio broadcasting signal.

Move the vehicle to the place where the

signal is strong.

04-395

Radio does not work

3. Radio Chapter 66 audio system - radio system, replacement

1. Setting impropriety Chapter 04 diagnositics - audio system, radio reception poor

Radio reception is poor

2. Radio broadcasting

Chapter 04 diagnositics - audio system, radio reception poor

3. Antenna malfunction Chapter 04 diagnositics - audio system, radio reception poor

4. Radio Chapter 66 audio system - radio system, replacement

1. Setting impropriety Chapter 04 diagnositics - audio system, sound quality poor

Poor sound quality

Chapter 04 diagnositics - audio system, sound quality poor

3. Antenna malfunction Chapter 04 diagnositics - audio system, sound quality poor

4. Speaker Chapter 04 diagnositics - front speaker assy, replacement

5. Radio Chapter 66 audio system - radio system, replacement

1. Setting impropriety

Chapter 04 diagnositics - audio system, speaker does not

work

Speaker does not work

2. Speaker Chapter 04 diagnositics - front speaker assy, replacement

04-396

RADIO DOES NOT WORK

04-397

Check Radio ACC fuse (7.5 A) in junction box (I001).

Check Radio fuse (10 A) in junction box (I001).

NO > If the dome light fuse is blown, go to next step.

If the radio & cigarette fuse is blown, go to step 3.

2. CHECK HARNESS AND CONNECTOR (RADIO - GROUND)

(b) Disconnect the radio connector.

Do not drop the radio.

A7 - Ground

04-398

3. CHECK HARNESS AND CONNECTOR (RADIO - GROUND)

A4 - Ground

4. CHECK HARNESS AND CONNECTOR (RADIO FUSE - RADIO)

Radio fuse (10 A) - A4

04-399

5. CHECK HARNESS AND CONNECTOR (RADIO ACC FUSE - RADIO)

Radio ACC fuse(15 A) - A4

6. CHECK HARNESS AND CONNECTOR (RADIO - GROUND)

A8 - Ground

YES > Replace radio.

04-400

RADIO RECEPTION IS POOR

1. CHECK RADIO SETTING

Press the radio power button.

Adjust the volume level above 5 VOL.

Turn the button and search the radio station.

Check whether the radio setting is correct?

NO > Reset the radio.

2. CHECK THE RADIO BROADCASTING SIGNAL

Move the vehicle to the place where the signal is strong.

Check whether the radio reception is good?

YES > System is normal.

• There is great difference in the size of the service area for AM, FM monaural, and FM stereo

broadcasting. Thus it may happen that FM broadcast cannot be received even though AM comes in

very clearly. Not only does FM stereo have the smallest service area, but also it picks up static and

other types of interference most easilly.

• AM broadcasts are susceptible to other types of interference, especially at night. This is because AM

radio waves bounce off the ionosphere at night. These radio waves then interfere with the signals from

the same transmitter that reach the vehicle’s antenna directly.

• When a signal from broadcast transmitter antenna bounces off Mountains, tall buildings or other

obstruction, it will interfere with the signal that is received directly.

3. CHECK RADIO ANTENNA

Check whether the antenna is pulled out to the end.

Check whether the antenna is bended or deformation.

Check whether the antenna is breakage.

Check whether the antenna connnector is intalled correct.

Adjust and check the radio antenna. Is the check result normal?

YES > Repair or replace the radio antenna.

NO > Replace the radio.

04-401

POOR SOUND QUALITY

4. CHECK SPERKER

Remove the speaker. (Refer to “Chapter 66 audio system - front speaker assy, replacement”)

Check whether the speaker is around with obstacles.

Check whether the speaker cone diaphragm accumulates dust.

Check the speaker cone diaphragm for damage.

Replace the old speaker with a troubleprool one and check the system.

Check whether the radio sound quality is good?

YES > Repair or replace the speaker.

04-402

SPEAKER DOES NOT WORK

04-403

3. CHECK HARNESS AND CONNECTOR (RADIO - SPEAKER)

Disconnect the speaker connector.

B3 - H001 (1)

H001 (2) - B4

04-404

4. CHECK HARNESS AND CONNECTOR (RADIO - SPEAKER)

B5 - D001 (1)

D001 (2) - B6

5. CHECK HARNESS AND CONNECTOR (RADIO - SPEAKER)

B2 - G002 (2)

G002 (1) - B1

04-405

6. CHECK HARNESS AND CONNECTOR (RADIO - SPEAKER)

B7 - F0025(1)

F005 (2) - B8

7. CHECK SPEAKER

Check the speaker for damage.

YES > Replace the speaker.

04-406

DIAGNOSTICS - AUXILIARY POWER

1 Cigarette Ligter 2 12V Power supply output socket

04-407

Cigarette Ligter is

12V Power supply

output socket is

8. Fuse -

9. Relay -

10.Wire harness -

1. Relay -

2. Fuse -

04-408

CIGARETTE LIGHTER IS INOPERATIVE

04-409

Inspect the cigarette lighter fuse in body junction box

(I001):15 A.

2. CHECK HARNESS AND CONNECTOR (CIGARETTE LIGHTER - GROUND)

I033 (2) - Ground

04-410

3. CHECK HARNESS AND CONNECTOR (CIGARETTE LIGHTER FUSE - CIGARETTE LIGHTER)

Cigarette lighter fuse - I033 (2)

4. CHECK HARNESS AND CONNECTOR (CIGARETTE LIGHTER - GROUND)

YES > Replace the cigarette lighter.

04-411

12V POWER SUPPLY OUTPUT SOCKET IS INOPERATIVE

04-412

(b) Inspect the IG2 fuse in body junction box (I001):15 A .

2. INSPECT HORN RELAY

Remove the IG2 relay.

Inspect IG2 relay.

NO > Replace horn relay.

04-413

3. CHECK HARNESS AND CONNECTOR (INSTRUMENT FUSE - IG2 FUSE)

Disconnect the IG2 relay.

IG2 (40A) - Instrument fuse(60A)

4. CHECKHARNESS AND CONNECTOR (POWER FUSE - 12V POWER SUPPLY OUTPUT SOCKET

FUSE)

Disconnect I015 12V power supply output socket.

Power fuse (15A) - I015(2)

04-414

5. CHECK HARNESS AND CONNECTOR (12V POWER SUPPLY OUTPUT SOCKET FUSE - GROUNUD)

I015(1) - Ground

YES > Replace 12V power supply output socket.

DIAGNOSTICS - HORN SYSTEM

04-415

1 Horn Switch

2 Alt Horn

3 Bass Horn

04-416

6. Horn fuse -

7. Horn relay -

Horn is inoperative

8. Horn switch

9. Clock spring

10.Horn

Chapter 51 steering column - steering wheel,

Chapter 81 communication system - horn,

11.Wire harness -

1. Horn relay -

Horn is always on

2. Horn switch

4. Center Door Lock Controller -

04-417

HORN IS INOPERATIVE

04-418

(b) Inspect the horn fuse in body junction box (I001):15 A.

NO > Replace the horn fuse.

Remove the horn relay.

Inspect horn relay.

04-419

3. CHECK HARNESS AND CONNECTOR (HORN RELAY - CENTRAL LOCKING CONTROLLER B

ASSY)

Disconnect the I008 central locking controller B connector.

I008 (B4) - Horn relay(86)

4. INSPECT CENTRAL LOCKING CONTROLLER B ASSY

(b) Disconnect the battery negative cable.

- power window, replacement”)

(d) Connect the battery negative cable.

(e) Turn the ignition switch ON.

Does the horn sound?

YES > Repair or replace central locking controller B.

5. CHECK HARNESS AND CONNECTOR (HORN RELAY - CLOCK SPRING)

Disconnect the horn relay connector.

Disconnect the clock spring connector.(Refer to“Chapter 62 Supplemental Restraint System - clock

spring, replacement”)

04-420

Horn relay (86) - I014(2)

6. INSPECT CLOCK SPRING

Replace the clock spring. (Refer to“Chapter 62 Supplemental

Restraint System - clock spring, replacement”)

YES > Repair the clock spring.

7. INSPECT HORN SWITCH

Remove the horn switch. (Refer to“Chapter 51 steering column - steering wheel, replacement”)

Check the horn switch for corrosion or damaged pins.

Replace the horn switch. (Refer to“Chapter 51 steering column - steering wheel, replacement”)

Press the horn switch.

YES > Repair or replace the horn switch.

04-421

8. CHECK HARNESS AND CONNECTOR (HORN RELAY - HORN)

Disconnect the V014 alt horn connector.

Disconnect the V013 bass horn connector..

Standard resistance (check for open).

Horn relay - V013(1)

Horn relay - V014(1)

9. CHECK HARNESS AND CONNECTOR (HORN - GROUND)

Disconnect the V013 alt horn connector.

V014(2) - Ground

V013(2) - Ground

YES > Replace horn.

04-422

HORN IS ALWAYS ON

04-423

1. INSPECT HORN RELAY

(b) Remove the horn relay.

2. INSPECT CLOCK SPRING

Replace clock spring. (Refer to“Chapter 62 Supplemental

3. INSPECT HORN SWITCH

(a) Remove the horn switch. (Refer to“Chapter 51 steering column - steering wheel, replacement”)

(b) Check the horn switch for corrosion or damaged pins.

(d) Press horn switch.

YES > Replace the horn.

NO > Replace the horn switch.

04-424

DIAGNOSTICS - REVERSE RADAR SYSTEM

1. UNDER THE FOLLOWING CONDITIONS, THE DETECTION FUNCTION MAY NOT FUNCTION

PROPERLY:

(e) The sensor is covered with foreign matter, such as mud or snow (detection function returns to normal

when the sensor is cleaned).

(f) The sensor is frozen (detection function returns to normal when the temperature of the sensor is going

high).

(g) The sensor is covered with a hand.

(h) In very cold weather where a malfunction display appears, the sensor may not be able to detect

obstacles.

2. THE DETECTION RANGE MAY BE AFFECTED BY THE FOLLOWING CONDITIONS:

(a) The sensor is covered with foreign matter, such as mud or snow.

(b) The vehicle is in an excessively hot or cold area.

3. UNDER THE FOLLOWING CONDITIONS, A DETECTION ERROR MAY OCCUR:

(a) Driving on a bumpy road, an unpaved road, or in tall grass.

(b) Ultrasonic waves from items such as another vehicle's horn, motorcycle engine sounds, a large

vehicle's air brake sound, or another vehicle's sonar are transmitted near the vehicle.

(d) The vehicle is tilted at a large angle.

(e) The vehicle is equipped with a commercial fender pole or a wireless mechanism antenna.

(f) The sensor is covered with foreign matter, such as mud or snow.

(g) The vehicle is moving toward a high curb or the corner of a pointed object.

4. THE SENSOR CANNOT DETECT SOME OBJECTS SUCH AS THE FOLLOWING:

(a) Thin objects, such as wires and ropes.

(b) Materials that absorb ultrasonic waves, such as cotton, snow, etc.

(d) Short objects.

(e) Tall, overhanging objects.

5. OTHER NOTICES:

(a) The sensor cannot detect objects directly under the bumper. (The sensor may detect low objects and

thin poles, and then lose track of the objects.)

(b) The sensor may not be able to detect obstacles that are too close to the sensor.

04-425

Audio (Multi - media And Air - condition

Controler Assy)

2 Reverse Radar Control Unit

3 Reverse Radar Sensor

4 Camera

04-426

SYSTEM DESCRIPTION

1. GENERAL.

This system uses ultrasonic sensors to send ultrasonic waves. The reverse radar sensors receive the

echo. The reverse radar control unit then informs the driver of the distance between the sensors and

the obstacles as well as their positions by indicating them on the combined display and by clearance

warning buzzer.

2. FUNCTION OF COMPONENTS.

Components

Reverse radar sensor

Clearance warning buzzer

Audio (multi - media and air

- condition controler assy)

Reverse radar control unit

Camera

Back - up lamp switch

Function

Detects the distance between the vehicle and an obstacle.

Sounds from the buzzer to motify the driver for the distance between the vehicle

and the obstacle.

Displays the location of the obstacle and the approximate distance between the

vehicle and the obstacle,and image in rear of vehicle.

1. Judges the approximate distance between the vehicle and the obstacle based

on the signals from the reverse radar sensor.

2. Sounds the clearance warning buzzer.

Shoot image information.

Sends the back - up signal to the reverse radar control unit.

3. DETECTION RANGE OF REVERSE RADAR SENSOR.

(a) Detection range of reverse radar sensor (both sides).

Detection range of reverse radar sensor (middle).

4. DISTANCE TO AN OBSTACLE, FREQUENCY AND MODE OF CLEARANCE WARNING BUZZER.

NO. DISTANCE MODE FREQUENCY

A 90 - 150 cm Long & Intermittent 1 Hz

04-427

B 60 - 90 cm Short & Intermittent 2 Hz

C 40 - 60 cm Rapid & Intermittent 4 Hz

D 40 ± 5 cm Continual Continual

5. TERMINALS OF REVERSE RADAR CONTROL UNIT PIN.

Terminal No. Wiring Color Terminal Description

1 B - R Power supply

3 W - R Radar power supply

4 R - W Reverse radar central sensor RH

6 L - B Vehicle speed signal

7 R - G Reverse radar sensor LH

8 R - B Reverse radar central sensor LH

9 Y Parking signal

11 B Sensor ground

13 - -

15 R - L Reverse radar sensor RH

16 W - B Ground

04-428

Reverse radar system is

inoperative at all

2. Reverse radar control unit

3. Back - up lamp switch

Chapter 81 communication system - reverse

radar, replacement

operative when the shift

lever is out of reverse

position

1. Reverse radar sensor

everse radar system is

inoperative within specified

distance (Back - up lamp is

normal)

operative but there is no

obstacle behind the vehicle

Buzzer is inoperative or

operative incorrectly within

specified distance (

displayer is normal)

Display is inoperative

within specified distance

(Back - up lamp is

1. Displayer Chapter 81 communication system - multi -

media and air - condition controler

assy,replacement

2. Camera Chapter 81 communication system - astern

image, replacement

04-429

REVERSE RADAR SYSTEM IS INOPERATIVE AT ALL

04-430

Inspect back - up lamp fuse (10A) in driver side junction

Disconnect the I028 reverse radar control unit connector.

3. INSPECT BACK - UP LAMP SWITCH

04-431

1 - Ground

2 - Ground

NO > Replace back - up lamp switch and fuse.

4. CHECK HARNESS AND CONNECTOR (BACK - UP LAMP SWITCH - REVERSE RADAR

CONTROL UNIT)

A021 (2) - Ground

5. CHECK HARNESS AND CONNECTOR (REVERSE RADAR CONTROL UNIT - GROUND)

I028 (16) - Ground

04-432

6. INSPECT BACK - UP LAMP SWITCH

Inspect back - up lamp switch according to the value(s)

condition

Set shift lever in reverse

Set shift lever out of

reverse position

1 - 2 ≥ 1 ΜΩ

NO > Replace back - up lamp.

7. CHECK HARNESS AND CONNECTOR (BACK - UP LAMP FUSE - BACK - UP LAMP SWITCH)

Back - up lamp fuse (10A) - A021 (1)

04-433

8. CHECK HARNESS AND CONNECTOR (BACK - UP LAMP SWITCH - REVERSE RADAR

A021 (2) - I028 (1)

YES > Replace reverse radar control unit.

04-434

REVERSE RADAR SYSTEM IS OPERATIVE WHEN THE SHIFT

LEVER IS OUT OF REVERSE POSITION

04-435

1. INSPECT BACK - UP LAMP SWITCH

2. CHECK HARNESS AND CONNECTOR (BACK - UP LAMP SWITCH - REVERSE RADAR

I028 (1) - Ground

04-436

DISTANCE (BACK - UP LAMP IS NORMAL)

04-437

1. INSPECT REVERSE RADAR SENSOR

Disconnect the R001 Reverse Radar Sensor LH connector.

Disconnect the R002 Reverse Radar Central Sensor LH connector.

Disconnect the R003 Reverse Radar Central Sensor RH connector.

Disconnect the R004 Reverse Radar Sensor RH connector.

Replace reverse radar sensor.

Set the shift lever in reverse position.

Does reverse radar system work correctly?

YES > Replace reverse radar sensor.

2. CHECK HARNESS AND CONNECTOR (REVERSE RADAR CONTROL UNIT - REVERSE RADAR

SENSOR)

I028 (7) - R001 (1)

I028 (11) - R001 (2)

I028 (8) - R002 (1)

I028 (11) - R002 (2)

04-438

I028 (4) - R003 (1)

I028 (11) - R003 (2)

I028 (15) - R004 (1)

I028 (11) - R004 (2)

04-439

OBSTACLE BEHIND VEHICLE

04-440

Turn the ignition switch OFF..

04-441

04-442

BUZZER IS INOPERATIVE OR OPERATIVE INCORRECTLY WITHIN

SPECIFIED DISTANCE (DISPLAYER IS NORMAL)

04-443

04-444

04-445

(BUZZER IS NORMAL)

04-446

1. CHECK HARNESS AND CONNECTOR (BACK - UP LAMP SWITCH - CAMERA)

Disconnect the J005 camera connector.

A021 (2) - J005 (2)

2. CHECK HARNESS AND CONNECTOR (CAMERA - RADIO)

Disconnect the I029 radio connector.

J005 (3) - I029 (1)

J005 (4) - I029 (2)

04-447

3. CHECK HARNESS AND CONNECTOR (CAMERA - GROUND)

J005 (1) - Ground

4. INSPECT CAMERA

Replace the camera.

Does displayer work correctly?

YES > Replace the camera.

04-448

DIAGNOSTICS - POWER WINDOWS

(a) Before removing or installing any electrical device, please disconnect the negative cable from battery to

To prevent locking the key in the vehicle, do not leave the key in the vehicle when disconnecting the

negative battery cable.

3. DISCONNECTING THE NEGATIVE BATTERY CABLE WILL RESET BOTH THE TRIP ODOMETER

AND THE CLOCK TO ‘0’.

The total odometer can not be reset to ‘0’.

4. THE AUDIO SYSTEM WILL LOSE STORED MEMORY DATA IF THE NEGATIVE BATTERY CABLE

IS DISCONNECTED.

After reconnecting the negative battery cable, the audio system will need to be reset.

04-449

1 Central Locking Controller

2 Door Control Switch

4 Window Control Switch RH

5 Glass Lift Motor RH

3 Glass Lift Motor LH

04-450

DOOR CONTROL SWITCH PIN

Terminal No. Wiring Color Description

1 L - B Door control switch LH (date)

2 L Door control switch LH (clock)

3 L - Y Window control switch RH

4 P - L Window control switch RH

5 L - G Window control switch RH

6 W - B Grond

9 G - R Lamplet illumination

04-451

WINDOW CONTROL SWITCH RH PIN

1 L - G Door control switch

3 P - L Door control switch

4 L - Y Door control switch

04-452

CENTRAL LOCKING CONTROLLER ASSY A PIN

1 W - B Ground

4 G Power window motor LH

5 R Power window motor LH

6 R - L Power window motor RH

7 G - R Power window motor RH

8 W - L Window control power input

11 Y Collision signal

14 R Door - status

15 L - B Door control switch LH (date)

16 L Door control switch LH (clock)

17 W - L Vehicle speed signal

18 R - B Ignition switch

04-453

• The battery voltage should be over than

12 V.

Charge or replace the battery. Refer to

“Chapter 20A starting and charging -

battery”.

Check the front power window motor LH.

• Push or pull the front window switch LH to

operate the fornt window LH open and

close.

Check power window auto open operation.

operate the fornt window LH auto open.

Check power window motor RH.

operate the fornt window RH open and

• ush or pull the front window switch RH to

Replace power window motor.

04-454

Use the table below to help you to find the cause of the problem. The numbers indicate the priority of the likely

All power windows are

inoperative.

1. Power, ground circuits

2. Door control switch

3. Power window motor LH and

Chapter 20A starting and charging - battery,

Chapter 20B starting and charging - battery,

Chapter 82 windshield/windowglass/rear view

mirror - power window, replacement

Front power window

LH is inoperative.

3. Central Locking Controller

4. Power window motor LH

LH does not open.

1. Door control switch

2. Central Locking Controller

LH does not close.

RH is inoperative (use

door control switch).

3. Window control switch RH

04-455

window control switch

RH).

4. Power window motor RH

1. Window control switch RH

3. Power window motor RH

04-456

ALL POWER WINDOWS ARE INOPERATIVE

04-457

Inspect the power window fusible link (20 A) in driver

side junction box (I001).

2. CHECK HARNESS AND CONNECTOR (DOOR CONTROL SWITCH - GROUND)

Disconnect the D005 door control switch connector.

Disconnect the I007 central locking controller assy A connector.

D005 (12) - Ground

3. INSPECT DOOR CONTROL SWITCH

Replace door control switch.

04-458

Does power window work correctly?

YES > Replace door control switch.

4. CHECK HARNESS AND CONNECTOR (POWER WINDOW FUSIBLE LINK - DOOR CONTROL

Power window fusible link (20A) - D005 (12)

5. CHECK HARNESS AND CONNECTOR (POWER WINDOW FUSIBLE LINK - CENTRAL LOCKING

CONTROLLER ASSY A)

Power window fusible link (20A) - I007 (A8)

04-459

6. CHECK HARNESS AND CONNECTOR (DOOR CONTROL SWITCH - GROUND)

D005 (6) - Ground

7. CHECK HARNESS AND CONNECTOR (DOOR CONTROL SWITCH - CENTRAL LOCKING CONTROLLER

ASSY A)

D005 (1) - I007 (A15)

D005 (2) - I007 (A16)

04-460

8. INSPECT POWER WINDOW MOTOR LH AND RH

Disconnect the D002 power window motor LH connector.

Disconnect the H002 power window motor RH connector.

Replace power window motor LH and RH.

YES > Replace power window motor LH and RH.

9. CHECK HARNESS AND CONNECTOR (CENTRAL LOCKING CONTROLLER ASSY A - POWER

WINDOW MOTOR LH AND RH)

I007 (A4) - D002 (2)

I007 (A5) - D002 (1)

I007 (A6) - H002 (2)

I007 (A7) - H002 (1)

YES > Replace central locking controller assy.

04-461

FRONT POWER WINDOW LH IS INOPERATIVE

04-462

1. INSPECT DOOR CONTROL SWITCH

2. CHECK HARNESS AND CONNECTOR (DOOR CONTROL SWITCH - CENTRAL LOCKING

3. INSPECT POWER WINDOW MOTOR LH

Replace power window motor LH.

04-463

4. CHECK HARNESS AND CONNECTOR (CENTRAL LOCKING CONTROLLER ASSY A - POWER

WINDOW MOTOR LH)

04-464

FRONT POWER WINDOW LH DOES NOT OPEN

04-465

2. CHECK HARNESS AND CONNECTOR (DOOR CONTROL SWITCH - CENTRAL LOCKING CONTROLLER

04-466

FRONT POWER WINDOW LH DOES NOT CLOSE

04-467

04-468

TROL SWITCH)

04-469

Does power window RH work correctly?

2. CHECK HARNESS AND CONNECTOR (CENTRAL LOCKING CONTROLLER ASSY A - POWER

WINDOW MOTOR RH)

3. INSPECT POWER WINDOW MOTOR RH

Replace power window motor RH.

Does power windou RH work correctly?

YES > Replace power window motor RH.

NO > Replace central locking controller assy.

04-470

CONTROL SWITCH RH)

04-471

1. INSPECT WINDOW CONTROL SWITCH

Disconnect the H004 window control switch RH connector.

Replace window control switch RH.

YES > Replace window control switch RH.

2. CHECK HARNESS AND CONNECTOR (WINDOW CONTROL SWITCH RH - DOOR CONTROL SWITCH)

H004 (1) - D005 (5)

H004 (3) - D005 (4)

H004 (4) - D005 (3)

04-472

4. INSPECT POWER WINDOW MOTOR RH

5. CHECK HARNESS AND CONNECTOR (CENTRAL LOCKING CONTROLLER ASSY A - POWER

DIAGNOSTICS - OUTSIDE MIRROR

04-473

1 Outside Mirror Assy LH

3 Outside Mirror Remote Control Switch

2 Outside Mirror Assy RH

04-474

TERMINALS OF OUTSIDE MIRROR SWITCH

OUTSIDE MIRROR SWITCH

1 L - R

Left Outside Mirror Left And Right

Adjust Input

3 L - Y

Right Outside Mirror Left And Right

Adjust Output

4 G - R Outside Mirror Switch Power Input

5 R - Y Outside Mirror -

7 R

8 R - L

Left Outside Mirror Up And Down

Right Outside Mirror Up And Down

04-475

Yes Go to step 2

Check the outside mirror.

• Adjust the outside mirror LH and the outside

mirror RH.

Replace the outside mirror. Refer to “Chapter

82 windshield - outside mirror, replacement”

04-476

Use the table below to help you find the cause of the problem. The numbers indicate the probability of the

6. Fuse -

Mirrors are inoperative (Both sides)

7. Outside mirror defrost switch

Chapter 85 door lock - front door

lock - replacement

A single mirror is inoperative

1. Outside mirror defrost switch

2. Outside mirror

Chapter 82 windshield - outside

mirror, replacement

Mirror adjustment UP/DOWN is

2. Outside mirror motor

Mirror adjustment LEFT/RIGHT is

04-477

MIRRORS ARE INOPERATIVE (BOTH SIDES)

04-478

Inspect the radio & ACC fuse (7.5 A) in body junction

box(I001).

2. CHECK HARNESS AND CONNECTOR (RADIO & ACC FUSE - OUTSIDE MIRROR REMOTE

CONTROL SWITCH)

Remote the radio & ACC fuse.

Disconnect the D004 outside mirror remote control switch connector.

Radio & ACC fuse (7.5A) -

D004 (4)

04-479

3. CHECK HARNESS AND CONNECTOR (OUTSIDE MIRROR REMOTE CONTROL SWITCH -

D004 (6) - Ground

YES > Replace the outside mirror remote control switch.

04-480

A SINGLE MIRROR IS INOPERATIVE

04-481

• This inspection procedure is an example of outside mirror assy LH, outside mirror assy RH inspection

procedure are similar.

1. INSPECT OUTSIDE MIRROR REMOTE CONTROL SWITCH

Inspect outside mirror remote control switch according to

the value(s) in the table below.

1 - 6

Outside

Mirror LH

4 - 1

5 - 6

4 - 7

7 - 6

NO > Replace outside mirror remote control switch.

2. CHECK HARNESS AND CONNECTOR (OUTSIDE MIRROR REMOTE CONTROL SWITCH -

OUTSIDE MIRROR LH)

Disconnect the D003 outside mirror connector.

D003 (6) - D004 (7)

D003 (4) - D004 (5)

04-482

D003 (5) - D004 (1)

YES > Replace the outside mirror assy.

04-483

MIRROR ADJUSTMENT UP/DOWN IS INOPERATIVE

04-484

the value(s) in the table below

NO > Replace the outside mirror remote control switch.

YES > Replace the outside mirror assy LH.

04-485

MIRROR ADJUSTMENT LEFT/RIGHT IS INOPERATIVE

04-486

Outside Mirror LH

DEFROSTER SYSTEM

DIAGNOSTICS - DEFROSTER SYSTEM

04-487

04-488

1 Rear Window Defroster

2 Outside Mirror Assy

3 Rear Window Defroster Switch

4 Outside Mirror Defrost Switch

04-489

1. GENERAL

The defroster system consist of rear window defroster and outside mirror defroster(outside mirror assy).

The heating element is the electric heating wire which are integrated in the rear window glass and both

outside mirror glasses and defog the glasses quickly. The rear window defroster switch and outside

mirror defrost switch are integrated on the centre switch panel in the instrument panel and can be operated

separately. When each switch is pressed, the indicator lamp in the switch illuminates to indicate

that the defroster is operating.

2. FUNCTION OF MAIN COMPONENTS

Component

Description

Rear window defroster relay

Outside mirror defrost relay

Outside mirror (outside mirror defroster)

Receives rear defrost control signals from rear window

defrost switch and supplies power to rear window

defroster.

Receives defrost control signal from outside mirror

defrost switch and supplies power to both outside mirror.

Receives power from Rear window defroster relay and

heats defroster.

Receives power from outside mirror defrost relay and

04-490

Check battery voltage.

Check ignition switch.

• The ignition switch should work correctly.

Repair or replace ignition switch. Refer to

“Chapter 91 vehicle control system - assy,

removal & installation and disassembly &

reassembly”

Check fuse.

• Check fuse.

Check rear window defroster switch.

• Press the rear window defroster switch.

• The rear window defrost switch should

work correctly.

Check outside mirror defrost switch.

• Press the outside mirror defrost switch.

• The outside mirror defrost switch should

Check rear window defroster.

• The rear window defrost grid should work

Check outside mirror defroster.

• The outside mirror defroster should work

Yes Go to step 6

Replace rear window defroster switch. Refer

to “Chapter 83 instrument panel - dashboard,

Yes Go to step 7

Yes -

Replace rear window defrost grid. Refer to

“chapter 82 Windshield - windshield,

04-491

2. Rear window defrost relay -

Rear window defroster system is

3. Rear window defrost switch

instrument cluster, replacement

4. Rear window defrost grid

Chapter 82 Windshield - rear window

glass, replacement

2. Outside mirror defrost relay -

Outside mirror defroster system is

3. Outside mirror defrost switch

4. Outside mirror defroster

04-492

REAR WINDOW DEFROSTER IS INOPERATIVE

04-493

Inspect the rear defroster fuse (25 A) in Co - pilot

Inspect the outside mirror defrost fuse (7.5 A) in Co - pilot

NO > If the rear defroster fuse or outside mirror defrost fuse is blown, replace the fuse.

2. INSPECT REAR DEFROSTER RELAY

Remove the rear defroster relay.

Inspect the rear defroster relay according to the value(s)

NO > Replace the rear defroster relay.

04-494

3. INSPECT REAR WINDOW DEFROSTER SWITCH

Inspect the rear window defroster switch according to the

NO > Replace the rear window defroster switch.

4. CHECK HARNESS AND CONNECTOR (REAR WINDOW DEFROSTER SWITCH - GROUND)

I016 (2) - Ground

5. CHECK HARNESS AND CONNECTOR (REAR DEFROSTER RELAY - REAR WINDOW DEFROSTER

04-495

Rear defroster relay (85) - I016 (5)

6. CHECK HARNESS AND CONNECTOR (REAR DEFROST RELAY - GROUND)

Remove the rear defrost relay.

Rear defrost relay (86) - Ground

04-496

7. CHECK HARNESS AND CONNECTOR ( REAR DEFROST HEATING WIRE - GROUND)

Disconnect the S001 rear defrost heating wire connector.

Turn rear window defroster switch ON.

S001 (1) - Ground

8. CHECK HARNESS AND CONNECTOR ( REAR DEFROST HEATING WIRE - GROUND)

Disconnect the T001 rear defrost heating wire connector.

T001 (1) - Ground

YES > Replace the rear defrost heating wire.

04-497

OUTSIDE MIRROR DEFROSTER IS INOPERATIVE

04-498

NO > If the outside mirror defrost fuse is blown, replace the fuse.

Remove the outside mirror defrost relay.

NO > Replace the outside mirror defrost relay.

04-499

3. INSPECT OUTSIDE MIRROR DEFROST SWITCH

Disconnect the I017 outside mirror defrost switch connector.

Inspect the outside mirror defrost switch according to the

NO > Replace the outside mirror defrost switch.

4. CHECK HARNESS AND CONNECTOR (OUTSIDE MIRROR DEFROST SWITCH - GROUND)

I017 (2) - Ground

04-500

5. CHECK HARNESS AND CONNECTOR (OUTSIDE MIRROR DEFROST RELAY - OUTSIDE MIRROR

DEFROST SWITCH)

Disconnect the I017 rear window defrost switch connector.

Rear defrost relay (85) - I017 (5)

6. CHECK HARNESS AND CONNECTOR (OUTSIDE MIRROR DEFROST RELAY - GROUND)

Outside mirror defrost relay (86) - Ground

04-501

7. CHECK HARNESS AND CONNECTOR (OUTSIDE MIRROR DEFROST RELAY - OUTSIDE MIRROR

ASSY LH/RH )

Disconnect the D003 outside mirror assy LH/ H003 outside mirror assy RH connector.

Outside mirror defrost relay (87) - D003(3)

Outside mirror defrost relay (87) - H003(3)

8. CHECK HARNESS AND CONNECTOR (OUTSIDE MIRROR ASSY LH/RH - GROUND )

D003(2) - Ground

H003(2) - Ground

YES > Replace outside mirror assy LH/ outside mirror assy RH.

04-502

DIAGNOSTICS - INSTRUMENT CLUSTER

(a) Before removing or installing any electrical device, please disconnect the negative battery cable to prevent

damage to the device or personal injury.

(b) Make sure ignition switch off if no specific instructions.

2. DISCONNECTING THE NEGATIVE BATTERY CABLE WILL RESET BOTH THE TRIP ODOMETER

AND THE CLOCK TO ‘ 0 ’.

The total odometer can not be reset to ‘ 0 ’.

3. THE AUDIO SYSTEM WILL LOSE STORED MEMORY DATA IF THE NEGATIVE BATTERY CABLE

Switch Type Ignition Switch (position) Engine (condition)

04-503

1 Instrument Cluster

2 Speedometer Sensor

3 Fuel Level Sensor

4 Coolant Temperature Sensor

04-504

INSTRUMENT CLUSTER INFORMATION

GAUGES

No Content Description

1 Speedometer The fuel gauge indicates the approximate fuel level in the tank.

6 Fuel Gauge

12 ECT Gauge

15 Tachometer

Receving signal from coolant temperature indicator, the ECT

gauge indicates the engine coolant temperature.

Receiving signal from the ECM, the tachometer indicates

engine revolutions per minute (RPM).

According to the signal received from the speedometer sensor,

the speedometer indicates the vehicle running speed.

04-505

WARNING / INDICATOR LIGHTS

2 Lamplet indicator light

Lamplet indicator light turns on when lamplet is on and receive

lamplet relay signal.

Engine coolant fluid level

warning light

Engine coolant fluid level warming light turns on when engine

coolant level is lower than specification.

Left turn signal/hazard

indicator light

5 Seat belt warning light

Left turn signal/hazard indicator light flashes when the turn

signal switch or hazard switch is activated.

Seat belt warning light turns on when receiving the seat belt

warning signal.

Engine coolant

temperature indicator light

Engine coolant temperature indicator light will illuminate when

engine coolant temperature is between - 20 ℃ ~ 110 ℃ .

8 Fuel level warning light

9 High beam indicator light

10 Door ajar warning light

11 Brake warning light

13 SRS warning light

Fuel level warning light turns on when fuel level lower than

specified level.

High beam indicator light turns on when high beam is on and

receive headlamp relay signal.

Door ajar warning light turns on when receiving the door ajar

Brake warning light turns on when receiving signals from parking

brake switch or brake fluid level sensor.

SRS warning light will turn on when SRS is detected malfunction.

16

Right turn signal/hazard

Parking brake indicator

light

Right turn signal/hazard indicator light flashes when the turn

Parking Brake indicator light turns on when receiving signals

from parking brake switch.

17 ABS warning light Warning light will turn on when ABS is detected malfunction.

18 EBD warning light

The ABS will illuminate EBD warning light when EBD is

detected malfunction.

19

Engine oil pressure

Engine oil pressure indicator light turns on according to the

signal from engine oil pressure warning switch.

20 Charging warning light Charging warning light turns on when charging system is fault.

21 Malfunction indicator light

The ECM will turn on malfunction indicator light when engine

electronic control system is detected malfunction.

22

25

26

Rear fog lamp indicator

Front fog lamp indicator

SVS indicator light

(Gasoline)

Vacuum warning light

(Diesel)

Rear fog lamp indicator light receive the rear fog lamp relay

signal and turns on when rear fog lamp switch is pressed.

Front fog lamp indicator light receive the front fog lamp relay

signal and turns on when front fog lamp switch is pressed.

SVS indicator light will be illuminated when the ECM detect

general malfunctions. It will be always on until faults resolved.

Vacuum warning light turns on when receiving the vacuum

04-506

LIQUID CRYSTAL DISPLAY

Odometer Display driving distance and can not be reset to “0”.

Clock

Display time and can be reset.

04-507

TERMINALS OF INSTRUMENT CLUSTER

Terminals No. Wiring Color Description

A1 B - L Instrument Power

A2 - -

A3 R Door Lamp Indicator

A4 - -

A5 - -

I002

A6 V - W Lamplet Signal Input

A7 LG Front Fog Lamp Indicator

A8 L Vehicle Speed Output

A9 W - L Vehicle Speed Output

A10 L - B Vehicle Speed Output

A11 - -

04-508

A12 - -

A13 W - G Speed Signal Input

A14 B Lighting Pwm Signal

A15 W - R Door Open Indicator

A16 R Instrument Power Output

A17 - -

A18 - -

A19 W - B Instrument A Ground

A20 R - B Instrument Ground

A21 - -

A22 - -

A23 V Fuel Sensor + Output

A24 Y - B Engine Stop Light

A25 - -

A26 B Vacuum Level Alarm + Input

A27 G - Y Preheat Indicator

A28 BR Engine Maintenance

A29 - -

A30 R - W Front Door Open Indicator

A31 B - W Seat Belt Warning

A32 G - Y Left Turn Indicator

B1 - -

B2 - -

B3 - -

I003

B4 - -

B5 - -

B6 Y Instrument Parking Brake Light

B7 V - B Coolant Level Sensor + Output

B8 - -

04-509

B9 B - W Seat Belt Alarm + Output

B10 V - W Speed Input

B11 - -

B12 - -

B13 - -

B14 - -

B15 - -

B16 Y - G Water Temperature Gauge Sensor

B17 - -

B18 - -

B19 - -

B20 Y - G ABS Fault Light Signal Input

B21 R - Y Rear Fog Lamp Indicator

B22 L - Y Engine Oil Pressure Warning Light

B23 L - W Engine Failure Warning Input

B24 Y - R EBD Warning Light Signal Input

B25 P - L Instrument Charging Indicator Input

B26 - -

B27 B - Y Airbag Warning Lamp Signal Input

B28 R - W Brake Fluid Sensor + Output

B29 - -

B30 W - B Instrument B Ground

B31 R - G High Beam Indicator

B32 G - B Right Turn Indicator

04-510

Do not perform basic inspection until engine temperature reaches the specified value. If on - road test

is needed, must have at least two people to perform the test.

Step Conditions Action

• The battery voltage should above 12 V.

Check tachometer.

• Connect hand - held tester, reading the engine

rotating speed data.

• Reading engine rotating speed data with 1000 ~

2000 r/min and 3000 ~ 6000 r/min.

• The variation of error in ± 100 ~ 200 r/min,± 150

~ 300 r/min.

Check speedometer.

• Connect hand - held tester, reading the vehicle

speed data.

• Reading vehicle speed data with 20 ~ 100 Km/h,

120 Km/h and 140 Km/h.

• The variation of error in + 5, + 6, + 7 Km/h.

• The pointer should be without jump when vehicle

is at constant speed or constant acceleration.

Tire wear and incorrect tire pressure will lead

inaccurate data.

Yes Go to step 2.

Charge or replace the battery.

Refer to “Chapter 20A starting

and charging - battery”.

Yes Go to step 3.

Go to the problem symptoms

table.

Yes Go to step 4.

Check engine oil pressure warning light.

• Engine oil pressure warning light should be illuminated.

• After engine starts, engine oil pressure warning

light should go off.

04-511

Malfunction in speedometer

Malfunction in tachometer

Malfunction in fuel gauge

Malfunction in ECT gauge

MIL never/always on

SRS warning light never/

ABS warning light never/

Engine oil pressure warning

light never/always on

1. Speedometer sensor

2. Speedometer circuits

3. Speedometer

1. CKP sensor

2. Tachometer circuits

3. Tachometer

1. Fuel level sensor

2. Fuel gauge circuits

3. Fuel gauge

1. Engine coolant temperature

2. ECT gauge circuits

3. ECT gauge

1. Engine electronic

control system

2. Malfunction indicator

light circuits

3. Instrument cluster

1. SRS warning light

2. SRS warning light circuits

1. ABS system

2. ABS warning light circuits

1. Engine oil pressure

2. Engine oil pressure

warning light circuits

Chapter 04 diagnostics - instrument cluster, malfunction

in speedometer

in tachometer

in fuel gauge

in ECT gauge

Chapter 04 diagnostics - gasoline engine control

system, diagnostic trouble code chart

Chapter 04 diagnostics - diesel engine control system,

diagnostic trouble code chart

Chapter 04 diagnostics - SRS system, problem

symptoms table

problem symptoms table

Chapter 04 diagnostics - supplemental restraint system,

engine oil pressure warning light never/always

04-512

Seat belt warning light never/

Parking Brake indicator light

never/always on

Turn signal/hazard indicator

High beam indicator light

1. Seat belt warning

2. Seat belt waring

switch circuits

1. Parking brake switch

2. Parking brake circuits

3. instrument cluster

1. Fuses

3. Hazard switch

4. Turn signal/hazard

indicator light circuits

5. Instrument cluster

3. High beam indicator

4. Instrument cluster

seat belt warning light never/always on

parking brake indicator light never/always on

Chapter 04 diagnostics - lighting, problem symptoms

table (If exterior turn signal/hazard lights are

normal, repair turn signal/hazard indicator light circuits

for an open or replace the instrument cluster)

table (If exterior high light are normal, repair

high beam indicator light circuits for an open or

replace the instrument cluster)

04-513

MALFUNCTION IN SPEEDOMETER

04-514

1. CHECK HARNESS AND CONNECTOR (SPEEDOMETER SENSOR - GROUND)

Disconnect the A020 speedometer sensor connector.

A020 (1) - Ground

2. CHECK HARNESS AND CONNECTOR (INSTRUMENT CLUSTER - SPEEDOMETER SENSOR)

Disconnect the I002 instrument cluster connector.

I002 (A13) - A020 (3)

3. INSPECT SPEEDOMETER SENSOR

Remove the speedometer sensor.

Use a good sensor replacement

YES > Replace the instrument cluster.

NO > Replace the speedometer sensor.

04-515

MALFUNCTION IN TACHOMETER

04-516

An abnormal running engine will lead the tachometer pointer instable.

Check if the engine has normal start.

YES > Go to step 1.

NO > Refer to “Chapter 04 diagnostics - gasoline engine control system, problem symptoms table”

1. CHECK HARNESS AND CONNECTOR (INSTRUMENT CLUSTER - ECM)

Disconnect the E001(4G69) / A036(ISF2.8) ECM connector.

I002 (A8) - E001(51)

I002 (A8) - A036(E28)

2. CHECK HARNESS AND CONNECTOR

Start the engine until the engine temperature reaches to normal condition.

Measure the pulse signal between the instrument cluster

connector I002, pin A8 and ground.

Pulse signal: Appr 33.3 Hz (1000 r / min)

04-517

NEVER OR ALWAYS ON

04-518

• Turn the ignition switch ON and ensure fuel tank have enough fuel (more than 1/4 in fuel tank).

• Fuel level warning light will be illuminated when fuel level sensor resistance greater than 96 ± 2.5 Ω.

• Fuel level warning light will turn off when fuel level sensor resistance smaller than 96.5 ± 4 Ω.

1. INSPECT FUEL LEVEL SENSOR

Disconnect the A022 fuel level sensor connector.

Measure the resistance between the fuel level sensor

A022 pin 2 and pin 3.

Remove the fuel level sensor and measure the resistance

following the table below.

Position Empty Warn threshold 1/4 1/2 3/4 Full

Resistance(Ω)

150 ± 2.5 120 ± 2.5 95 ± 2.5 74 ± 2.5 54 ± 2.5 30 ± 2.5

NO > Replace the fuel level sensor..

2. CHECK HARNESS AND CONNECTOR (FUEL LEVEL SENSOR - GROUND)

A022 (2) - Ground

04-519

3. INSPECT FUEL LEVEL SENSOR

A022 (3) - Ground

NO > Replace the fuel level sensor.

4. CHECK HARNESS AND CONNECTOR (INSTRUMENT CLUSTER - FUEL LEVEL SENSOR)

Disconnect the I002 instrument cluster connectors.

Disconnect the A022 fuel level sensor connectors.

Measure the resistanceaccording to the value(s) in the

I002 (A23) - A022 (3)

04-520

MALFUCTION IN ENGINE COOLANT TEMPERATURE GAUGE

04-521

• Ensure engine coolant level within specified value.

• Ensure engine coolant temperature normal.

1. INSPECT ECT INDICATOR

(b) Remove ECT indicator.

Whenever remove the ECT indicator, ensure the engine is cold (Engine coolant temperature lower than

40 ℃ ).

Temperature ( ℃ ) 40 72 105 120

Resistance (Ω) 287.4 ± 30 98 ± 13.5 33 ± 2 21

NO > Replace the ECT indicator.

2. CHECK HARNESS AND CONNECTOR (ECT INDICATOR - GROUND)

Disconnect the E012 (4G69) / E037 (ISF2.8) ECT indicator connector.

E012 (1) - Ground

E037 (1) - Ground

YES > Replace the ECT indicator.

04-522

3. CHECK HARNESS AND CONNECTOR (INSTRUMENT CLUSTER - ECT INDICATOR)

Disconnect the I003 instrument cluster connector.

I003 (B16) - E012 (1)

I003 (B16) - E037 (1)

04-523

ENGINE OIL PRESSURE WARNING LIGHT NEVER / ALWAYS ON

04-524

• When turning the ignition switch ON, the engine oil pressure warning light will turn on.

• Engine oil pressure warning light will turn off after engine starts.

If the engine oil pressure warning light is always on after engine starts. Do not shut off engine immediately.

Check oil level, if oil level is out of specification, it needs to be repaired first.

Check if engine oil pressure warning light is always on or never.

YES > (Always on) Go to step 1.

NO > (Never on) Go to step 3.

1. INSPECT ENGINE OIL PRESSURE WARNING LIGHT

Disconnect the A023 (4G69) / E036 (ISF2.8) engine oil pressure switch connector.

Check if the engine oil pressure warning light turns off.

YES > Replace the engine oil pressure switch.

2. CHECK HARNESS AND CONNECTOR (ENGINE OIL PRESSURE SWITCH - GROUND)

Standard resistance (check for short

A023 (1) - Ground

E036 (1) - Ground

04-525

3. CHECK HARNESS AND CONNECTOR (INSTRUMENT CLUSTER - ENGINE OIL PRESSURE

Standard resistance (check for open

I003 (B22) - A023 (1)

I003 (B22) - E036 (1)

04-526

SEAT BELT WARNING LIGHT NEVER / ALWAYS ON

04-527

• Seat belt warning light will turn on.

• Seat belt warning light will turn off when seat belt is fastened.

Check if seat belt warning light always or never on.

1. INSPECT SEAT BELT WARNING LIGHT

Disconnect the O001 the seat belt warning switch connector.

Check if the seat belt warning light turns off.

YES > Replace the seat belt warning switch.

2. CHECK HARNESS AND CONNECTOR (SEAT BELT WARNING SWITCH - GROUND)

Disconnect the O001 seat belt warning switch connector.

O001 (1) - Ground

04-528

3. CHECK HARNESS AND CONNECTOR (SEAT BELT WARNING SWITCH - GROUND)

O001 (2) - Ground

4. INSPECT SEAT BELT WARNING SWITCH

insert seat belt

buckle

O001 (1) - O001 (2)

NO > Replace the seat belt warning switch.

04-529

5. CHECK HARNESS AND CONNECTOR (INSTRUMENT CLUSTER - SEAT BELT WARNING

Disconnect the O001seat belt warning switch connector.

I002 (A31) - O001 (1)

04-530

PARKING BRAKE INDICATOR LIGHT NEVER / ALWAYS ON

04-531

• Fix four tires.

• Pull and release the parking brake.

Check if parking brake indicator light always/never on.

NO > (Never on) Go to step 2.

1. INSPECT PARKING BRAKE INDICATOR LIGHT

Release the parking brake.

Disconnect the A026 parking brake switch connector.

Check if the parking brake light turns off.

YES > Replace the parking brake switch.

Disconnect the I003 instrument cluster.

A026 (1) - O003 (B6)

04-532

3. CHECK HARNESS AND CONNECTOR (PARKING BRAKE SWITCH - GROUND)

A026 (1) - Ground

DIAGNOSTICS - POWER DOOR LOCKS

04-533

Off

On (ACC)

On (IG)

Start

To prevent the key locked in the vehicle, do not leave the key in the vehicle when disconnecting the

(b) If no specific instructions, the ignition switch must be off.

3. Disconnecting the negative battery cable will reset both the trip odometer data and the clock to

‘ 0 ’.

The total odometer data can not be reset to ‘ 0 ’.

4. The audio system will lose stored memory data if the negative battery cable is disconnected.

04-534

1 Front Door Lock Assy LH

4 Right Side Sliding Door Lock Assy

5 Rear Hatch Lock Assy

3 Front Door Lock Assy RH

04-535

CENTRAL LOCKING CONTROLLER ASSY A

2 R Lock Output

3 G Unlock Output

4 G Driver Side Window Down Output

5 R Driver Side Window Up Output

6 R - L Co - pilot Side Window Down Output

7 G - R Co - pilot Side Window Up Output

8 W - L Window Control Power Input

9 L - O Key Lock Input

10 L - R Key Unlock Input

11 Y Collision Signal Input

12 G - Y Left Turn Light Signal

13 G - B Right Turn Light Signal

14 R Door Lamp Indicator

15 L - B Left Door Assy Switch (Data) Output

16 L Left Door Assy Switch (Clock) Output

17 W - L Vehicle Speed Signal

18 R - B Ignition Switch

04-536

CENTRAL LOCKING CONTROLLER ASSY B

1 W - R Ignition Switch Illumination Control

2 W - L Front Left Door Open Signal Output

3 R Central Locking Spare Power

4 G - R Horn

6 O - L To Engine Hood Switch Output

7 V - W Lamplet Forget To Turn Off Hints

8 O - B Key Detection Switch

10 W - B Ground

04-537

• The battery voltage should be above 12V.

“Chapter 20A starting and charging - battery”

Check basic function

• Using the key in driver‘s door cylinder to

lock, all doors should be locked.

unlock, all doors should be unlocked.

Yes Go to step 3

Go to problem symptoms table.

Check remote control function

• When all doors are closed, using the

remote key to lock the doors, all doors

should be locked.

remote key to unlock the doors, all doors

should be unlocked.

Replace the remote key.

04-538

cause of the problem. Check each part in order. If necessary, replace these parts

The function of power door locks

is inoperative (using the key)

One door is inoperative (using

the key)

Door does not open / close

(using the remote key)

2. Power door lock control unit

3. Harness

1. Harness

2. Door lock actuator

3. Power door lock control unit

1. Power door lock control unit

2. Harness

3. Door lock actuator

4. Remote key

5. Remote keyless entry receiver

Chapter 04 diagnostics - power door

locks, the function of power door locks is

inoperative (using the key)

locks, one door is inoperative (using the

key)

locks, door does not open / close (using

the remote key)

04-539

THE FUNCTION OF POWER DOOR LOCKS IS INOPERATIVE

(USING THE KEY)

04-540

• Before operating this inspection procedure, make sure the door open warning light is operating normally.

• If the door open warning light is inoperative, repair it. Refer to “Chapter 04 diagnostics - instrument

cluster, problem symptoms table”

Inspect the central locking fuse (20A) in driver side

2. CHECK HARNESS AND CONNECTOR (CENTRAL LOCKING FUSE - CENTRAL LOCKING CONTROLLER

Disconnect the I008 central locking controller assy B connector.

Central locking fuse (20 A) - I008 (B3)

04-541

3. CHECK HARNESS AND CONNECTOR (CENTRAL LOCKING CONTROLLER ASSY - GROUND)

I007 (A1) - Ground

4. CHECK HARNESS AND CONNECTOR (CENTRAL LOCKING CONTROLLER ASSY - FRONT

DOOR LOCK ASSY LH)

Disconnect the D006 front door lock assy LH connector.

I007 (A9) - D006 (9)

I007 (A10) - D006 (10)

04-542

5. CHECK HARNESS AND CONNECTOR (FRONT DOOR LOCK ASSY LH - GROUND)

D006 (7) - Ground

6. INSPECT FRONT DOOR LOCK ASSY LH

Replace a new front door lock assy LH.

YES > Replace the front door lock assy LH.

7. CHECK CENTRAL LOCKING CONTROLLER ASSY

Disconnect the I007 central locking controller assy connector.

Use key to unlock A2 - A3 Battery voltage

Use key to lock A3 - A2 Battery voltage

YES > Repair or replace harness or connector.

NO > Replace the central locking controller assy.

04-543

ONE DOOR IS INOPERATIVE (USING THE KEY)

04-544

• This inspection procedure is an example of front door LH, other doors inspection procedure are similar

1. INSPECT FRONT DOOR LOCK ASSY LH

Remove the front door inner guard board LH.

Remove the front door water - proof film LH.

Use key to unlock 4 - 1 Battery voltage

Use key to lock 1 - 4 Battery voltage

NO > Replace the front door lock assy LH.

2. CHECK HARNESS AND CONNECTOR (CENTRAL LOCKING CONTROLLER ASSY - FRONT DOOR

LOCK ASSY LH)

I007 (A2) - D006 (4)

I007 (A3) - D006 (1)

YES > Replace the central locking controller assy.

04-545

DOOR DOES NOT OPEN / CLOSE (USING THE REMOTE KEY)

04-546

1. INSPECT REMOTE KEY

Check the remote key battery. If the battery voltage is low, change the battery. If the problem is also

exist, replace the remote key.

YES > Replace the battery or remote key.

04-547

3. CHECK HARNESS AND CONNECTOR (CENTRAL LOCKING FUSE - CENTRAL LOCKING CONTROLLER

ASSY )

Disconnect the I007 central locking controller assy B connector.

central locking fuse (20 A) - I008 (8)

4. CHECK HARNESS AND CONNECTOR

Use remote key to

lock

unlock

A2 - A3

A3 - A2

04-548

SLIDING ROOF SYSTEM

DIAGNOSTICS - SLIDING ROOF SYSTEM

1 Sliding Roof Assy

2 Sliding Roof Control Motor

3 Sliding Roof Control Switch

4 Sliding Roof ECU

04-549

This system has the following functions:

Manual slide open and close.

Auto slide open and close.

Sliding roof control motor

and sliding roof drive

gear sub - assembly

Sliding roof control

module

Sliding roof control module sends the signal to sliding roof control motor. The sliding

roof control motor is then actived. Sliding roof control module controls sliding roof

motor to rotate forward and backward.

Sliding roof control switch sends the signal to sliding roof control module. The sliding

roof control module analyses the signal and sends it to sliding roof control motor.

3. SYSTEM OPERATION

The sliding roof has the following features:

Manual slide open

and close

Auto slide open and

close

This function enables sliding roof to open (or close) when OPEN/CLOSE switch is pressed

without release. Sliding roof stops as soon as the switch is released.

This function enables sliding roof to fully open (or close) when OPEN/CLOSE switch is

pressed and immediately released.

04-550

TERMINALS OF MAIN COMPONENTS

SLIDING ROOF CONTROL MODULE

1 R

Sliding roof ECU power supply

input

2 G Sliding roof control switch

3 W - B To Sliding roof ECU

4 R - B Sliding roof ECU - ACC input

5 Y Sliding roof control switch

6 - -

04-551

Charge or replace battery. Refer to

“Chapter 20A/20B starting and charging -

battery, replacement”

Check the sliding roof opening operation.

• Press the “OPEN” button.

Does the sliding roof work correctly?

Check the sliding roof closing operation.

• Press the “CLOSE” button.

Replace the sliding roof. Refer to “Chapter 86

sliding roof - sliding roof assy, replacement”

04-552

Sliding roof system is inoperative

3. Sliding roof control switch

4. Sliding roof ECU

5. Sliding rail

6. Sliding roof control motor

Chapter 86 sliding roof - sliding roof

04-553

SLIDING ROOF SYSTEM IS INOPERATIVE

04-554

Inspect the sliding roof fuse (15 A) and cigarette lighter

fuse(15 A) in driver side junction box (I001).

NO > Replace the sliding roof fuse or cigarette lighter fuse.

2. INSPECT SLIDING ROOF CONTROL SWITCH

Disconnect the F003 sliding roof control switch connector.

Replace sliding roof control switch with a new one.

YES > Replace the sliding roof control switch.

3. INSPECT SLIDING ROOF CONTROL MOTOR

Disconnect the sliding roof control motor connector.

Replace sliding roof control motor with a new one.

YES > Replace the sliding roof control motor.

4. CHECK HARNESS AND CONNECTOR (SLIDING ROOF CONTROL SWITCH - GROUND)

04-555

F003 (3) - Ground

F003 (2) - Ground

5. CHECK HARNESS AND CONNECTOR (SLIDING ROOF ECU - GROUND)

Disconnect the F002 sliding roof ECU connector.

F002 (1) - Ground

F002 (4) - Ground

6. CHECK HARNESS AND CONNECTOR (SLIDING ROOF CONTROL SWITCH - SLIDING ROOF

ECU)

F002 (2) - F003 (4)

F002 (5) - F003 (1)

04-556

7. CHECK HARNESS AND CONNECTOR (SLIDING ROOF ECU/SLIDING ROOF CONTROL SWITCH

- GROUND)

F002 (3) - Ground

F003 (5) - Ground

YES > Replace the sliding roof ECU.

ABBREVIATIONS USED IN THIS MANUAL(TERMS) ................01-33

ABS CONTROL IS UNREASONABLE(ANTI-LOCK

BRAKE SYSTEM) ......................................................................04-122

ABS MODULE CONNECTOR(ANTI-LOCK

BRAKE SYSTEM) ......................................................................04-101

(LIGHTING SYSTEM) ................................................................04-301

(LIGHTING SYSTEM) ................................................................04-227

ALL INTERIOR ILLUMINATION LAMPS ARE INOPERATIVE(LIGHT-

ING SYSTEM)............................................................................04-314

(POWER WINDOWS) ................................................................04-456

(LIGHTING SYSTEM) ................................................................04-277

ANTI-LOCK BRAKE SYSTEM .....................................................04-98

AUDIO SYSTEM ........................................................................04-392

AUXILIARY POWER..................................................................04-406

AXLE AND PROPELLER SHAFT .................................... 02-18, 03-20

(LIGHTING SYSTEM) ................................................................04-326

A/C SYSTEM IS INOPERATIVE(HEATER AND AIR CONDITIONING

SYSTEM) ...................................................................................04-162

BASIC INSPECTION(DEFROSTER SYSTEM) .........................04-490

BASIC INSPECTION(HEATER AND AIR CONDITIONING

SYSTEM) ...................................................................................04-157

BASIC INSPECTION(INSTRUMENT CLUSTER)......................04-510

BASIC INSPECTION(OUTSIDE MIRROR) ...............................04-475

BASIC INSPECTION(POWER DOOR LOCKS) ........................04-537

BASIC INSPECTION(WIPER AND WASHER)..........................04-358

BASIC SERVICE PROCEDURE(ENGINE

CONTROL SYSTEM)...................................................................04-11

BRAKE ............................................................................. 02-21, 03-23

IN SPECIFIED DISTANCE (DISPLAYER IS NORMAL)

(REVERSE RADAR SYSTEM) ..................................................04-442

CAPTURING DATA(ENGINE CONTROL SYSTEM)...................04-21

(LIGHTING SYSTEM) ................................................................04-296

(LIGHTING SYSTEM) ................................................................04-324

(AUXILIARY POWER) ...............................................................04-408

CLUTCH........................................................................... 02-25, 03-27

COOLING......................................................................... 02-11, 03-12

DATA STREAM LIST/ACTIVE TEST(ENGINE

CONTROL SYSTEM)...................................................................04-24

DEFROSTER SYSTEM .............................................................04-487

(LIGHTING SYSTEM) ................................................................04-322

INDEX

(ORGNIZED ALPHABETICALLY)

DIAGNOSTIC HELP - INTERMITTENT FAULT(ENGINE CONTROL

SYSTEM)....................................................................................... 04-9

DIAGNOSTIC SYSTEM(ENGINE CONTROL SYSTEM)............ 04-17

DIAGNOSTIC TROUBLE CODE CHART(ENGINE

CONTROL SYSTEM) .................................................................. 04-28

DIAGNOSTIC TROUBLE CODE CHART(SUPPLEMENTAL

RESTRAINT SYSTEM) ............................................................. 04-133

DIAGNOSTICS.............................................................................. 02-1

(LIGHTING SYSTEM) ............................................................... 04-332

DOOR LOCKS............................................................................. 02-35

DOORS ............................................................................ 02-36, 03-36

DTC DIAGNOSTIC(ENGINE CONTROL SYSTEM) ................... 04-33

E

(HOW TO TROUBLESHOOT)..................................................... 01-29

EMISSION CONTROL ......................................................... 02-5, 03-5

ENGINE CONTROL SYSTEM ....................................02-3, 03-2, 04-1

ENGINE MECHANICAL ....................................................... 02-7, 03-6

ENGINE SYMPTOM DIAGNOSTIC ............................................ 04-61

EXHAUST......................................................................... 02-10, 03-11

EXTERIOR AND INTERIOR TRIM.............................................. 03-37

F

FAIL-SAFE CHART(ENGINE CONTROL SYSTEM) .................. 04-22

(LIGHTING SYSTEM) ............................................................... 04-310

(LIGHTING SYSTEM) ............................................................... 04-238

(LIGHTING SYSTEM) ............................................................... 04-233

(POWER WINDOWS) ............................................................... 04-466

(POWER WINDOWS) ............................................................... 04-461

FRONT SUSPENSION..................................................... 02-15, 03-17

FUEL .................................................................................... 02-4, 03-4

G

GENERAL INFORMATION(HOW TO TROUBLESHOOT) ......... 01-18

GENERAL INFORMATION(HOW TO USE THIS MANUAL) ........ 01-1

TIVE(LIGHTING SYSTEM) ....................................................... 04-264

(LIGHTING SYSTEM) ............................................................... 04-275

HAZARD WARNING SWITCH ILLUMINATION IS NOT INOPERA-

(LIGHTING SYSTEM) ............................................................... 04-342

(LIGHTING SYSTEM) ............................................................... 04-336

HEATER AND AIR CONDITIONING................................ 02-28, 03-31

HEATER AND AIR CONDITIONING SYSTEM ......................... 04-156

HI-BEAM HEADLAMP IS INOPERATIVE

(ONE SIDE)(LIGHTING SYSTEM)........................................... 04-218

HORN IS ALWAYS ON(HORN SYSTEM) ................................ 04-422

HORN IS INOPERATIVE(HORN SYSTEM).............................. 04-417

HORN SYSTEM ........................................................................ 04-415

HOW TO DIAGNOSTICS ANALYSE(ENGINE

CONTROL SYSTEM) .................................................................... 04-6

(HOW TO TROUBLESHOOT)..................................................... 01-20

HOW TO TROUBLESHOOT ....................................................... 01-18

HOW TO USE THIS MANUAL ...................................................... 01-1

J

IDENTIFICATION INFORMATION................................................ 01-6

IGNITION..................................................................................... 03-14

(LIGHTING SYSTEM) ............................................................... 04-293

INSTRUMENT CLUSTER ......................................................... 04-502

(LIGHTING SYSTEM) ............................................................... 04-319

TIVE(LIGHTING SYSTEM) ....................................................... 04-340

INSTRUMENT PANEL/INSTRUMENT........................................ 02-33

INTAKE AIR........................................................................ 02-6, 03-10

LICENSE LAMP IS INOPERATIVE(LIGHTING SYSTEM)........ 04-350

LIGHTING.................................................................................... 03-33

LIGHTING SYSTEM.................................................................. 04-202

LO-BEAM AND HI-BEAM HEADLAMPS ARE INOPERATIVE

(ONE SIDE)(LIGHTING SYSTEM)............................................ 04-224

LO-BEAM HEADLAMP IS INOPERATIVE (ONE SIDE)(LIGHTING

SYSTEM)................................................................................... 04-212

LOCATION ................................................................................ 04-473

LOCATION(ANTI-LOCK BRAKE SYSTEM).............................. 04-100

LOCATION(AUDIO SYSTEM)................................................... 04-393

LOCATION(AUXILIARY POWER) ............................................ 04-406

LOCATION(DEFROSTER SYSTEM)........................................ 04-487

LOCATION(ENGINE CONTROL SYSTEM).................................. 04-4

LOCATION(HEATER AND AIR CONDITIONING SYSTEM) .... 04-158

LOCATION(HORN SYSTEM) ................................................... 04-415

LOCATION(INSTRUMENT CLUSTER) .................................... 04-503

LOCATION(LIGHTING SYSTEM) ............................................. 04-204

LOCATION(OUTSIDE MIRROR) .............................................. 04-473

LOCATION(POWER DOOR LOCKS) ....................................... 04-534

LOCATION(POWER WINDOWS) ............................................. 04-449

LOCATION(SLIDING ROOF SYSTEM) .................................... 04-548

LOCATION(SUPPLEMENTAL RESTRAINT SYSTEM)............ 04-130

LOCATION(WIPER AND WASHER)......................................... 04-357

LUBRICATION ................................................................. 02-12, 03-13

MALFUCTION IN FUEL GAUGE / LOW FUEL WARNING LIGHT NEV-

ER OR ALWAYS ON(INSTRUMENT CLUSTER) ..................... 04-517

MALFUNCTION IN TACHOMETER(INSTRUMENT

CLUSTER)................................................................................. 04-515

MIRROR ADJUSTMENT LEFT/RIGHT IS INOPERATIVE(OUTSIDE

MIRROR)................................................................................... 04-485

MIRROR ADJUSTMENT UP/DOWN IS INOPERATIVE(OUTSIDE

MIRROR)................................................................................... 04-483

N

NO COOLING FROM REAR A/C SYSTEM(HEATER AND AIR CON-

DITIONING SYSTEM) ............................................................... 04-191

ONE DOOR IS INOPERATIVE (USING THE KEY)(POWER DOOR

LOCKS)......................................................................................04-543

OUTSIDE MIRROR ...................................................................04-473

INOPERATIVE(LIGHTING SYSTEM)........................................04-334

P

PARKING BRAKE.............................................................02-22, 03-24

POWER DOOR LOCKS ............................................................04-533

POWER STEERING .........................................................02-27, 03-29

POWER WINDOWS ..................................................................04-448

PRE - CHECK(ANTI-LOCK BRAKE SYSTEM) .........................04-105

PRECAUTION(ANTI-LOCK BRAKE SYSTEM)...........................04-98

PRECAUTION(AUDIO SYSTEM)..............................................04-392

PRECAUTION(HEATER AND AIR

CONDITIONING SYSTEM) .......................................................04-156

PRECAUTION(INSTRUMENT CLUSTER)................................04-502

PRECAUTION(LIGHTING SYSTEM) ........................................04-202

PRECAUTION(POWER DOOR LOCKS) ..................................04-533

PRECAUTION(POWER WINDOWS) ........................................04-448

PRECAUTION(REPAIR INSTRUCTION) ......................................01-8

PRECAUTION(REVERSE RADAR SYSTEM) ..........................04-424

PRECAUTION(SUPPLEMENTAL RESTRAINT SYSTEM) .......04-129

PRECAUTION(WIPER AND WASHER)....................................04-356

PREPARATION(AXLE AND PROPELLER SHAFT)....................02-18

PREPARATION(BRAKE).............................................................02-21

PREPARATION(CLUTCH) ..........................................................02-25

PREPARATION(COOLING) ........................................................02-11

PREPARATION(DIAGNOSTICS) ..................................................02-1

PREPARATION(DOOR LOCKS).................................................02-35

PREPARATION(DOORS)............................................................02-36

PREPARATION(EMISSION CONTROL).......................................02-5

PREPARATION(ENGINE CONTROL SYSTEM)...........................02-3

PREPARATION(ENGINE MECHANICAL) ....................................02-7

PREPARATION(EXHAUST)........................................................02-10

PREPARATION(FRONT SUSPENSION)....................................02-15

PREPARATION(FUEL)..................................................................02-4

PREPARATION(HEATER AND AIR CONDITIONING) ...............02-28

PREPARATION(INSTRUMENT PANEL/INSTRUMENT)............02-33

PREPARATION(INTAKE AIR).......................................................02-6

PREPARATION(LUBRICATION).................................................02-12

PREPARATION(PARKING BRAKE) ...........................................02-22

PREPARATION(POWER STEERING)........................................02-27

PREPARATION(REAR SUSPENSION) ......................................02-16

PREPARATION(SEAT BELT) .....................................................02-30

PREPARATION(SEAT) ...............................................................02-34

PREPARATION(STARTING AND CHARGING)..........................02-14

PREPARATION(STEERING COLUMN)......................................02-26

PREPARATION(TIRE AND WHEEL) ..........................................02-17

PREPARATION(TRANSMISSION) .............................................02-23

PREPARATION(VEHICLE CONTROL SYSTEM) .......................02-37

PREPARATION(WINDSHIELD/SIDE WINDOW GLASS/REAR VIEW

MIRROR) .....................................................................................02-32

PREPARATION(WIPER AND WASHER)....................................02-31

PROBLEM SYMPTOMS TABLE(ANTI-LOCK

BRAKE SYSTEM)......................................................................04-104

PROBLEM SYMPTOMS TABLE(DEFROSTER SYSTEM) .......04-491

PROBLEM SYMPTOMS TABLE(ENGINE

CONTROL SYSTEM) ..................................................................04-60

PROBLEM SYMPTOMS TABLE(HEATER AND AIR

CONDITIONING SYSTEM) .......................................................04-159

PROBLEM SYMPTOMS TABLE(INSTRUMENT CLUSTER)....04-511

PROBLEM SYMPTOMS TABLE(OUTSIDE MIRROR) .............04-476

PROBLEM SYMPTOMS TABLE(POWER DOOR LOCKS) ......04-538

PROBLEM SYMPTOMS TABLE(SLIDING ROOF SYSTEM) ...04-552

PROBLEM SYMPTOMS TABLE(SUPPLEMENTAL RESTRAINT

SYSTEM) ...................................................................................04-134

R

(LIGHTING SYSTEM) ................................................................04-328

RADIO RECEPTION IS POOR(AUDIO SYSTEM) ....................04-400

(ENGINE CONTROL SYSTEM)...................................................04-19

ERATIVE(LIGHTING SYSTEM).................................................04-330

(LIGHTING SYSTEM) ................................................................04-241

REAR SUSPENSION....................................................... 02-16, 03-18

REAR WINDOW DEFROST ER IS INOPERATIVE

(DEFROSTER SYSTEM)...........................................................04-492

REAR WINDOW DEFROSTER SWITCH ILLUMINATION IS NOT IN-

OPERATIVE(LIGHTING SYSTEM) ...........................................04-338

REPAIR INSTRUCTION ................................................................01-8

(SUPPLEMENTAL RESTRAINT SYSTEM)...............................04-131

REVERSE RADAR SYSTEM.....................................................04-424

REVERSE RADAR SYSTEM IS INOPERATIVE AT ALL(REVERSE

RADAR SYSTEM)......................................................................04-429

S

SEAT................................................................................ 02-34, 03-35

SEAT BELT...................................................................... 02-30, 03-32

SERIAL NUMBER (SN)(IDENTIFICATION INFORMATION) ........01-7

SERVICE DATA(AXLE AND PROPELLER SHAFT) ...................03-20

SERVICE DATA(BRAKE) ............................................................03-23

SERVICE DATA(CLUTCH)..........................................................03-27

SERVICE DATA(COOLING)........................................................03-12

SERVICE DATA(DOOR)..............................................................03-36

SERVICE DATA(EMISSION CONTROL) ......................................03-6

SERVICE DATA(ENGINE CONTROL SYSTEM) ..........................03-2

SERVICE DATA(EXHAUST) .......................................................03-11

SERVICE DATA(FRONT SUSPENSION) ...................................03-17

SERVICE DATA(FUEL) .................................................................03-4

SERVICE DATA(HEATER AND AIR CONDITIONING)...............03-31

SERVICE DATA(IGNITION) ........................................................03-14

SERVICE DATA(INTAKE AIR) ....................................................03-10

SERVICE DATA(POWER STEERING) .......................................03-29

SERVICE DATA(STARTING AND CHARGING) .........................03-15

SERVICE DATA(STEERING COLUMN) .....................................03-28

SERVICE DATA(TIRE AND WHEEL)..........................................03-19

SERVICE DATA(TRANSMISSION) .............................................03-25

SLIDING ROOF SYSTEM..........................................................04-548

SPECIFIED TORQUE FOR SPECIFICATION BOLTS..................03-1

STARTING AND CHARGING .......................................... 02-14, 03-15

STEERING COLUMN ...................................................... 02-26, 03-28

STEP LAMP ARE INOPERATIVE(LIGHTING SYSTEM) ..........04-304

(LIGHTING SYSTEM) ................................................................04-282

SUPPLEMENTAL RESTRAINT SYSTEM .................................04-129

SYSTEM DESCRIPTION(DEFROSTER SYSTEM) ..................04-489

SYSTEM DESCRIPTION(REVERSE RADAR SYSTEM)..........04-426

SYSTEM DESCRIPTION(SLIDING ROOF SYSTEM)...............04-549

TAIL LAMPS ARE INOPERATIVE(LIGHTING SYSTEM)..........04-347

TERMINALS OF INSTRUMENT CLUSTER(INSTRUMENT CLUS-

TER)...........................................................................................04-507

(OUTSIDE MIRROR) .................................................................04-474

TERMS.........................................................................................01-33

THE FUNCTION OF POWER DOOR LOCKS IS INOPERATIVE (US-

ING THE KEY)(POWER DOOR LOCKS).................................. 04-539

TIRE AND WHEEL ........................................................... 02-17, 03-19

TORQUE SPECIFICATION(AXLE AND PROPELLER SHAFT) . 03-21

TORQUE SPECIFICATION(BRAKE) .......................................... 03-23

TORQUE SPECIFICATION(CLUTCH)........................................ 03-27

TORQUE SPECIFICATION(COOLING)...................................... 03-12

TORQUE SPECIFICATION(DOOR) ........................................... 03-36

TORQUE SPECIFICATION(EMISSION CONTROL) ........... 03-5, 03-9

TORQUE SPECIFICATION(ENGINE CONTROL SYSTEM) ........ 03-3

TORQUE SPECIFICATION(EXHAUST) ..................................... 03-11

TORQUE SPECIFICATION(EXTERIOR AND INTERIOR TRIM)03-37

TORQUE SPECIFICATION(FRONT SUSPENSION) ................. 03-17

TORQUE SPECIFICATION(FUEL) ............................................... 03-4

TORQUE SPECIFICATION(HEATER AND AIR

CONDITIONING)......................................................................... 03-31

TORQUE SPECIFICATION(IGNITION) ...................................... 03-14

TORQUE SPECIFICATION(INTAKE AIR) .................................. 03-10

TORQUE SPECIFICATION(LIGHTING) ..................................... 03-33

TORQUE SPECIFICATION(LUBRICATION) .............................. 03-13

TORQUE SPECIFICATION(PARKING BRAKE)......................... 03-24

TORQUE SPECIFICATION(POWER STEERING) ..................... 03-30

TORQUE SPECIFICATION(REAR SUSPENSION).................... 03-18

TORQUE SPECIFICATION(SEAT BELT)................................... 03-32

TORQUE SPECIFICATION(SEAT)............................................. 03-35

TORQUE SPECIFICATION(STARTING AND CHARGING) ....... 03-16

TORQUE SPECIFICATION(STEERING COLUMN) ................... 03-28

TORQUE SPECIFICATION(TIRE AND WHEEL)........................ 03-19

TORQUE SPECIFICATION(TRANSMISSION)........................... 03-26

TORQUE SPECIFICATION(VEHICLE CONTROL SYSTEM) .... 03-38

TORQUE SPECIFICATION(WIPER AND WASHER) ................. 03-34

TRANSMISSION .............................................................. 02-23, 03-25

TRUNK LAMP IS INOPERATIVE(LIGHTING SYSTEM)........... 04-307

LAMPS ARE NORMAL)(LIGHTING SYSTEM) ......................... 04-260

WASHER PUMP IS INOPERATIVE - REAR WINDOW(WIPER AND

WASHER).................................................................................. 04-387

WASHER PUMP IS INOPERATIVE - WINDSHIELD(WIPER AND

WASHER).................................................................................. 04-374

VEHICLE CONTROL SYSTEM........................................ 02-37, 03-38

VEHICLE IDENTIFICATION NUMBER (VIN)(IDENTIFICATION IN-

FORMATION)................................................................................ 01-6

VEHICLE LIFT AND SUPPORT LOCATIONS(REPAIR INSTRUC-

TION)........................................................................................... 01-16

NOT RETRACT(WIPER AND WASHER) ................................. 04-378

WIDTH LAMPS IS NOT INOPERATIVE(LIGHTING SYSTEM) 04-344

TIVE(LIGHTING SYSTEM) ....................................................... 04-352

WINDSHIELD/SIDE WINDOW GLASS/REAR

VIEW MIRROR............................................................................ 02-32

WIPER AND WASHER .......................................02-31, 03-34, 04-356

(WIPER AND WASHER) ........................................................... 04-381

WIPERS ARE INOPERATIVE - WINDSHIELD(WIPER AND WASH-

ER) ............................................................................................ 04-361

WIPERS ARE INOPERATIVE AT HIGH SPEED - WINDSHIELD(WIP-

ER AND WASHER) ................................................................... 04-369

WIPERS ARE INOPERATIVE AT LOW SPEED - WINDSHIELD(WIP-

ER AND WASHER) ................................................................... 04-367

SHIELD(WIPER AND WASHER) .............................................. 04-371

V O L U M E 2

DIAGNOSTICS(RHD)

HOW TO DIAGNOSTICS ANALYSE........................................... 04-5

DIAGNOSTIC HELP - INTERMITTENT FAULT .......................... 04-8

BASIC SERVICE PROCEDURE................................................ 04-10

TERMINALS OF ECM................................................................ 04-11

DIAGNOSTIC SYSTEM............................................................. 04-16

READING AND ERASING DIAGNOSTIC TROUBLE CODE

(DTC) ......................................................................................... 04-18

CAPTURING DATA ................................................................... 04-20

FAIL-SAFE CHART.................................................................... 04-21

DATA STREAM LIST/ACTIVE TEST......................................... 04-23

DIAGNOSTIC TROUBLE CODE CHART.................................. 04-27

DTC DIAGNOSTIC .................................................................... 04-32

PROBLEM SYMPTOMS TABLE................................................ 04-58

ENGINE SYMPTOM DIAGNOSTIC........................................... 04-59

ANTI-LOCK BRAKE SYSTEM......................................................... 04-96

PRECAUTION............................................................................ 04-96

ABS MODULE CONNECTOR ................................................... 04-98

DIAGNOSTIC TROUBLE CODE CHART.................................. 04-99

PROBLEM SYMPTOMS TABLE.............................................. 04-101

PRE - CHECK.......................................................................... 04-102

POWER SUPPY VOLTAGE HIGH OR LOW........................... 04-104

SOLENOID VALVES AND VALVES RELAY FAILURE........... 04-105

PUMP MOTOR FAILURE ........................................................ 04-109

WHEEL SPEED SENSOR CIRCUIT FAULT........................... 04-113

WHEEL SPEED SENSOR SIGNAL FAULT ............................ 04-115

ABS CONTROL IS UNREASONABLE .................................... 04-119

ABS SYSTEM IS INOPERATIVE............................................. 04-122

SUPPLEMENTAL RESTRAINT SYSTEM ..................................... 04-126

PRECAUTION.......................................................................... 04-126

RESTRAINT CONTROL MODULE (RCM) CONNECTOR

PIN ........................................................................................... 04-127

DIAGNOSTIC TROUBLE CODE CHART................................ 04-129

PROBLEM SYMPTOMS TABLE.............................................. 04-130

8101 - POWER SUPPLY VOLTAGE HIGH ............................. 04-131

8102 - POWER SUPPLY VOLTAGE LOW.............................. 04-131

8201 - DRIVER AIRBAG FAULT - HIGH RESISTANCE ......... 04-133

8202 - DRIVER AIRBAG FAULT - LOW RESISTANCE.......... 04-133

8203 - DRIVER AIRBAG CIRCUIT SHORT TO GROUND...... 04-135

8204 - DRIVER AIRBAG CIRCUIT SHORT TO BATTERY ..... 04-137

RESISTANCE .......................................................................... 04-139

8213 - CO - PILOT SIDE AIRBAG CIRCUIT SHORT TO

GROUND ................................................................................. 04-141

8214 - CO - PILOT SIDE AIRBAG CIRCUIT SHORT TO

BATTERY ................................................................................ 04-143

SRS WARNING LIGHT IS ALWAYS ON ................................. 04-145

SRS WARNING LIGHT IS INOPERATIVE .............................. 04-147

HEATER AND AIR CONDITIONING SYSTEM.............................. 04-149

PRECAUTION.......................................................................... 04-149

BASIC INSPECTION ............................................................... 04-150

PROBLEM SYMPTOMS TABLE.............................................. 04-151

A/C SYSTEM IS INOPERATIVE.............................................. 04-153

FRONT BLOWER MOTOR IS INOPERATIVE ........................ 04-157

FRONT AIR FLOW IS INSUFFICIENT .................................... 04-163

NO COOLING FROM FRONT A/C SYSTEM .......................... 04-167

REAR HEATER IS INOPERATIVE OR INSUFFICIENT

HEATING ................................................................................. 04-174

LIGHTING SYSTEM ....................................................................... 04-181

PRECAUTION.......................................................................... 04-181

BASIC INSPECTION ............................................................... 04-182

LOCATION............................................................................... 04-183

PROBLEM SYMPTOMS TABLE.............................................. 04-185

LO - BEAM HEADLAMP IS INOPERATIVE (ONE SIDE) ........ 04-191

LO - BEAM HEADLAMPS ARE INOPERATIVE

(BOTH SIDES) ......................................................................... 04-193

HI - BEAM HEADLAMP IS INOPERATIVE (ONE SIDE) ......... 04-197

(BOTH SIDES) ......................................................................... 04-199

LO - BEAM AND HI - BEAM HEADLAMPS ARE INOPERATIVE

(ONE SIDE)............................................................................. 04-204

ALL HEADLAMPS ARE INOPERATIVE .................................. 04-207

FRONT FOG LAMPS ARE INOPERATIVE ............................. 04-213

FRONT FOG LAMPS ARE ALWAYS ON ................................ 04-218

REAR FOG LAMPS ARE INOPERATIVE................................ 04-221

REAR FOG LAMPS ARE ALWAYS ON .................................. 04-226

ALL FOG LAMPS ARE INOPERATIVE ................................... 04-229

LAMPS ARE NORMAL) ........................................................... 04-236

LAMPS ARE NORMAL) ........................................................... 04-240

TIVE ......................................................................................... 04-245

TURN SIGNAL LAMPS ARE INOPERATIVE (ONE SIDE)...... 04-254

HAZARD WARNING LAMPS ARE ALWAYS ON .................... 04-258

ALL STOP LAMPS ARE INOPERATIVE ................................. 04-260

STOP LAMP IS INOPERATIVE (ONE SIDE) .......................... 04-265

HIGH - MOUNTED STOP LAMP IS INOPERATIVE................ 04-267

BACK - UP LAMP IS INOPERATIVE(ONE SIDE) ................... 04-269

BACK - UP LAMPS ARE INOPERATIVE (BOTH SIDES) ....... 04-271

IGNITION SWITCH ILLUMINATION IS INOPERATIVE .......... 04-275

CENTRAL DOME LIGHT IS INOPERATIVE ........................... 04-278

AIR PURIFIER LAMP IS INOPERATIVE ................................. 04-283

STEP LAMP ARE INOPERATIVE ........................................... 04-286

TRUNK LAMP IS INOPERATIVE ............................................ 04-288

FRONT DOME LIGHT IS INOPERATIVE................................ 04-291

ALL INTERIOR ILLUMINATION LAMPS ARE INOPERATIVE 04-295

INSTRUMENT CLUSTER ILLUMINATION IS NOT IN

OPERATIVE............................................................................. 04-300

DIAGNOSIS SWITCH ILLUMINATION IS NOT

INOPERATIVE ......................................................................... 04-303

CIGARETTE LIGHTER ILLUMINATION IS NOT

INOPERATIVE......................................................................... 04-305

A/C CONTROL PANEL ILLUMINATION IS NOT

INOPERATIVE......................................................................... 04-307

RADIO ILLUMINATION IS NOT INOPERATIVE ..................... 04-309

REAR BLOWER FORWARD SWITCH ILLUMINATION IS NOT IN-

OPERATIVE ............................................................................ 04-311

DOME LIGHT SWITCH ILLUMINATION IS NOT

INOPERATIVE......................................................................... 04-313

INOPERATIVE......................................................................... 04-315

TIVE ......................................................................................... 04-317

INSTRUMENT DIMMER SWITCH ILLUMINATION IS NOT INOPER-

ATIVE....................................................................................... 04-319

TIVE ......................................................................................... 04-321

WIDTH LAMPS IS NOT INOPERATIVE.................................. 04-323

TAIL LAMPS ARE INOPERATIVE........................................... 04-325

LICENSE LAMP IS INOPERATIVE ......................................... 04-328

TIVE ......................................................................................... 04-330

WIPER AND WASHER .................................................................. 04-334

PRECAUTION.......................................................................... 04-334

BASIC INSPECTION ............................................................... 04-334

PROBLEM SYMPTOMS TABLE.............................................. 04-336

WINDSHIELD........................................................................... 04-338

WIPERS ARE INOPERATIVE - WINDSHIELD........................ 04-339

WIPERS ARE INOPERATIVE AT LOW SPEED -

WINDSHIELD........................................................................... 04-344

WIPERS ARE INOPERATIVE AT HIGH SPEED -

WINDSHIELD........................................................................... 04-345

SHIELD .................................................................................... 04-346

WASHER PUMP IS INOPERATIVE - WINDSHIELD............... 04-348

NOT RETRACT........................................................................ 04-351

REAR WINDOW ...................................................................... 04-353

WASHER PUMP IS INOPERATIVE - REAR WINDOW .......... 04-358

AUDIO SYSTEM............................................................................. 04-361

PRECAUTION.......................................................................... 04-361

BASIC INSPECTION ............................................................... 04-362

PROBLEM SYMPTOMS TABLE.............................................. 04-363

RADIO DOES NOT WORK...................................................... 04-364

RADIO RECEPTION IS POOR................................................ 04-368

POOR SOUND QUALITY....................................................... 04-369

SPEAKER DOES NOT WORK ................................................ 04-370

AUXILIARY POWER...................................................................... 04-374

PROBLEM SYMPTOMS TABLE.............................................. 04-374

CIGARETTE LIGHTER IS INOPERATIVE .............................. 04-375

12V POWER SUPPLY OUTPUT SOCKET IS INOPERATIVE 04-378

HORN SYSTEM.............................................................................. 04-382

PROBLEM SYMPTOMS TABLE.............................................. 04-382

HORN IS INOPERATIVE......................................................... 04-383

HORN IS ALWAYS ON............................................................ 04-389

REVERSE RADAR SYSTEM ......................................................... 04-391

PRECAUTION.......................................................................... 04-391

SYSTEM DESCRIPTION......................................................... 04-392

PROBLEM SYMPTOMS TABLE.............................................. 04-394

REVERSE RADAR SYSTEM IS INOPERATIVE AT ALL ........ 04-395

VER IS OUT OF REVERSE POSITION .................................. 04-400

DISTANCE (BACK-UP LAMP IS NORMAL) ........................... 04-402

OBSTACLE BEHIND VEHICLE ............................................... 04-405

IN SPECIFIED DISTANCE (DISPLAYER IS NORMAL) .......... 04-408

(BUZZER IS NORMAL)............................................................ 04-411

POWER WINDOWS ....................................................................... 04-414

PRECAUTION.......................................................................... 04-414

DOOR CONTROL SWITCH PIN.............................................. 04-415

WINDOW CONTROL SWITCH LH PIN ................................... 04-416

CENTRAL LOCKING CONTROLLER ASSY A PIN................. 04-417

BASIC INSPECTION .............................................................. 04-418

PROBLEM SYMPTOMS TABLE.............................................. 04-419

ALL POWER WINDOWS ARE INOPERATIVE ....................... 04-421

FRONT POWER WINDOW RH IS INOPERATIVE .................. 04-427

FRONT POWER WINDOW LH DOES NOT OPEN................. 04-430

FRONT POWER WINDOW LH DOES NOT CLOSE............... 04-432

FRONT POWER WINDOW RH IS INOPERATIVE (USE DOOR

CONTROL SWITCH) ............................................................... 04-434

FRONT POWER WINDOW LH IS INOPERATIVE (USE WINDOW

CONTROL SWITCH RH) ......................................................... 04-436

OUTSIDE MIRROR ........................................................................ 04-439

TERMINALS OF OUTSIDE MIRROR SWITCH....................... 04-439

BASIC INSPECTION ............................................................... 04-440

PROBLEM SYMPTOMS TABLE.............................................. 04-441

MIRRORS ARE INOPERATIVE (BOTH SIDES) ..................... 04-442

A SINGLE MIRROR IS INOPERATIVE ................................... 04-445

MIRROR ADJUSTMENT UP/DOWN IS INOPERATIVE ......... 04-448

MIRROR ADJUSTMENT LEFT/RIGHT IS INOPERATIVE...... 04-450

OUTSIDE MIRROR DEFROSTER SYSTEM................................. 04-452

SYSTEM DESCRIPTION......................................................... 04-452

BASIC INSPECTION ................................... 04-453

OUTSIDE MIRROR DEFROSTER IS INOPERATIVE............ 04-455

INSTRUMENT CLUSTER .............................................................. 04-461

PRECAUTION.......................................................................... 04-461

LOCATION............................................................................... 04-462

INSTRUMENT CLUSTER INFORMATION.............................. 04-463

LIQUID CRYSTAL DISPLAY ................................................... 04-465

TERMINALS OF INSTRUMENT CLUSTER ............................ 04-466

BASIC INSPECTION ............................................................... 04-469

PROBLEM SYMPTOMS TABLE.............................................. 04-470

MALFUNCTION IN SPEEDOMETER ...................................... 04-472

MALFUNCTION IN TACHOMETER ........................................ 04-474

NEVER OR ALWAYS ON ........................................................ 04-476

MALFUCTION IN ENGINE COOLANT TEMPERATURE

GAUGE .................................................................................... 04-479

ENGINE OIL PRESSURE WARNING LIGHT NEVER / ALWAYS

ON............................................................................................ 04-482

SEAT BELT WARNING LIGHT NEVER / ALWAYS ON.......... 04-485

PARKING BRAKE INDICATOR LIGHT NEVER / ALWAYS

ON............................................................................................ 04-489

POWER DOOR LOCKS................................................................. 04-492

PRECAUTION.......................................................................... 04-492

CENTRAL LOCKING CONTROLLER ASSY A........................ 04-493

CENTRAL LOCKING CONTROLLER ASSY B........................ 04-494

BASIC INSPECTION ............................................................... 04-495

PROBLEM SYMPTOMS TABLE.............................................. 04-496

(USING THE KEY)................................................................... 04-497

ONE DOOR IS INOPERATIVE (USING THE KEY)................. 04-502

DOOR DOES NOT OPEN / CLOSE (USING THE

REMOTE KEY) ........................................................................ 04-504

DIAGNOSTICS(RHD) - ENGINE CONTROL SYSTEM

3. THE SAVING DATA SETTING WILL LOST IF DISCONNECTING THE BATTER NEGATIVE CABLE.

Inspect for “add-on” accessories which may be interfering with the ground circuit.

If several wires are crimped into one ground eyelet terminal, check for improper crimps.

Make sure all of the wires are clean, securely fastened and providing a good ground path.

If multiple wires are cased in one eyelet, make sure no ground wires have excess wire

insulation.

4. CHECK DTC AND DATA FREEZE-FRAME DATA

If one doubtful region is considered to cause a failure, heat the part which is the most possible cause of

heater blower, the headlamps and the rear-window defroster, to check if the failure occurs. The trouble

of failure before starting the test and the pre-connection of connectors, then carry out the symptom

diagnostic scanner, make the rated data status to simulate the fault conditions based on the freezeframe

on the diagnostic scanner.

ECM or control modules on a failure-free vehicle for testing; Don’t install new control modules on a

7 Injector 3 L - P 49 ECT sensor + W - R

10 A/C low voltage output L 52 ECT sensor - W - B

16 - - 58 Knock sensor signal B - W

17 High fan control W - B 59 Accelerator sensor + Br - G

19 MILL G - B 61 - -

L-R 66

37 Knock power O - V 79 A/C request Y - B

38 - 80 - -

39 - 81 - -

40 -

0.3 ~ 0.9 V

CHECK ECM HARNESS-SIDE TERMINAL WITH A MULTIMETER

diagnostic scanner or special equipment with

corresponding functions.

then goes out (system self-checking). The SVS lamp and MIL lamp are off after engine starting and

then lights on after self-checked; After engine starting, if the SVS lamp in failure class is defined as

3. If an engine failure that may involve the fuel injection system-electronic controlled is to be

diagnosed and cleared, first determine if the failure is related with the fuel injection systemelectronic

controlled. If the engine fails but the malfunction indicator lamp doesn't light, the failure

The diagnostic trouble codes record and data related with sensors and actuators in ECM can be read

by KT600 diagnostic scanner. Additional, the actuator can be positive driven by the scan tool under

specified conditions.

DLC- data link connector.

• Connect the diagnostic scanner cable to DLC. Turn the ignition switch ON. Try to open it. If

displayed error communication on screen, then the diagnostic scanner faults .

• If the diagnostic scanner communicates with other vehicle normally, then check the DLC on the

original vehicle.

ENGINE CONTROL SYSTEM SELF-DIAGNOTIC ITEM

erased from the memory, or it can be processed referring to the trouble-shooting methods for

(f) Check DTC and data stream. After recording, delete it (If DTC cannot be deleted, then perform the

diagnosis procedure refering to “Diagnostics trouble code check”. Repair faults ).

(j) If there are DTCs, but the data stream is normal or the function is good, then refer to the diagnostics

help. If there are DTCs, but the stream is abnormal or the function is not good, then perform diagnosis

procedure refering to “Diagnostics trouble code chart”.

If the DTC is detected but the trouble can’t reappear, confirm the freeze-frame rated data. ECM records

the engine condition in form of freeze-frame data at regular intervals. The diagnostic scanner can be

used to read several sets of freeze-frame data respectively. KT600 diagnostic scanner provides

FAIL-SAFE CHART

When the DTC listed below is detected, the ECM enters fail-safe mode and the MIL lights up.

• The engine base fuel closed-loop control self-learning will be shut

• The engine idle air control self-learning will be shut off.

ECT: -20 ℃

(g) After repairing, using the KT600 to perform again.

(h) Clear DTC.

(i) Disconnect KT600 scan tool.

(j) Restart engine to perform test. Confirm the faults has been eliminated.

DFCO

Front Oxygen Sensor Signal Lean In PE

MT20U2 adopted speed-density air measurement method to check the air intake volume into the engine so as

to control the fuel injection pulse width for the precise control of engine power output. Meanwhile, this system

adopted intake pressure cylinder determination technology and the intake air sensor is installed near the inlet

opening of cylinder 4 intake manifold. At the moment when the throttle is opened, there will be one

intake air temperature of -45

following the increasing of the temperature in non-linear relation. When the coolant temperature is low, the

intakeair temperature of -45 ℃ or lower) for

4 seconds

• If the ECM detects the DTC P0117 or P0118, it operates the fail–safe function in which the

engine coolant temperature is assumed to be a default value. At the same time, with the ignition

switch ON, the cooling fans will operate at high speed. The fail–safe function will not untill the

ECM detects the acceptance condition.

-40 °C Open circuit

(a) Start the engine and warm it to normal operating temperature.

(b) With the KT600 scan tool, perform the DTC confirming procedure.

(d) Read sensor value displayed on the KT600 scan tool.

E010 (2) - Ground

E010 (1) - E001 (52)

sensor is of three-line type and the ECM will check the throttle open extent by monitoring the voltage variation.

P1167 - FRONT OXYGEN SENSOR SIGNAL RICH IN DFCO

P1171 - FRONT OXYGEN SENSOR SIGNAL LEAN IN PE

. An open oxygen sensor circuit or a cold oxygen sensor causes open-loop operation.

signal rich in dfco

signal lean in pe

• Normal scan tool voltage varies between 0.1 to 1.0 V while in closed-loop.

ECM contains a non-replaceable knock filter module called a Signal-to-noise Enhancement Filter (SNEF)

Disconnect the E011 knock sensor connector.

injected into the cylinder every time will be attached, making the air-fuel mixture strength actually into

the air forms a spiral vortex at the coarse section, affecting the air intake effect and the quality of air-fuel

mixture. On the other hand, the carbon deposits block the idling aisle, making the idling speed control

device clamped or exceeding its regulation range, leading to low idling speed and rough idling.

• Service vehicles in well-ventilated areas and avoid ignition sources.

15. CHECK ENGINE VALVE-TIMING

(a) Check whether the engine valve-timing gear mark is aligned, damaged. And the belt is loose. Whether

19. CHECK ENGINE VALVE-TIMING

(a) Check whether the engine valve-timing gear mark is aligned, damaged and the belt is loose.

air-fuel.

• Compression

pressure is too low

• Malfunction of air-fuel

• Check whether the idle air control motor can extend-retract when turning the switch off.

can feel vibration, or with the voice-tool, touch the injector, the action voice should be hearded).

(h) Check whether the Three-Way Catalytic Converter (TWC) is blocked.

16. CHECK ENGINE VALVE-TIMING

11. CHECK ENGINE VALVE-TIMING

• Malfunction of air-fuel ratio

signal, namely a steady speed control that the engine is controlled in target speed range. Speedraising

control is done if with load signal. During starting, the load signal is input into ECM, the later

• Inspect if the idle trembles is normal or load reasons, such as: A\C, lighting, push the lever into gear,

Check throttle body and idle air path. Clear the carbon deposit and greasy dirt.

(a) With the scan tool, check whether the throttle is normal.

(a) Check secondary ignition wire resistance. And clean the connector terminals.

that ignition system, airfuel

mixture or

(b) Check whether the idle speed is normal.

Disconnect the injector connector.

Remove the injector and fuel rail assy.

Apply 12 V battery voltage to the injector directly.

Check whether every injector can spray even and standard quantity gasline.

(a) Check the exhaust system and Three-Way Catalytic Converter (TWC).

13. CHECK ENGINE VALVE-TIMING

(a) Check whether the engine valve-timing gear mark is aligned, damaged. And the belt is loose.

abnormal air-fuel ratio, poor

DIAGNOSTICS(RHD) - ANTI-LOCK BRAKE SYSTEM

(a) Before removing or installing any electrical device, please disconnect the negative cable to prevent

(b) Make sure ignition switch is OFF if no specific instructions.

5. NOTES ABOUT ANTI-LOCK BRAKE SYSTEM.

(d) After repairing the anti-lock brake system is completed, check the ABS warning light.

(e) Never use the multimeter to measure the terminal of ABS module.

(f) The ABS system must be repaired by technicians trained and mastered maintenance skills, and only

use original parts for replacement.

(g) Before repairing the ABS system, if there are some failures with mechanical braking system, must be

excluded. Such as:

(h) ABS control module (refer to the ABS electronic control unit and hydraulic control unit, not including

brake lines, sensors ,etc.) can only be replaced as assembly, can not be overhauled or part

replacement / swap.

(i) The following two cases show that ABS system failure is detected:

• Turn the ignition switch On, the system self-test is completed, but the warning light is on.

The driver can stop the vehicle conventionally, but it should be as far as possible to reduce the braking force to

prevent the wheels from locking. Warning lamp lights need to be careful driving and immediately to the

authorized service station overhaul to prevent more failures occurred, resulting in a traffic accident.

(j) Pay attention to the following points when connect the ABS system connector:

• ABS harness connector is installed in place, must be in the horizontal direction and a vertical direction

to avoid damage to the connectors.

(k) Ensure proper connection when connectiong the ABS system pipes. ABS control module can not

detect that the brake lines are connected properly or not. The error connection may lead to a serious

accident. Connecting the brake lines, must be in compliance with the ABS assembly on the mark:

(l) There are noise with ABS system in the following cases:

• Vehicle power or start the engine, it will produce a short sound of "Om", this is a normal phenomenon

with the sound of the ABS self-check..

• There will be sound when ABS system work properly, mainly reflected in the following:

ABS solenoid valve power

suppy input

28 R - W ABS-IG input

Rear sensor power suppy

LH

Front sensor power suppy

Front Wheel Speed Sensor LH Output Signal Malfunction: Beyond The Scope Of Loss, Noise,

Intermittent Interruption

Front Wheel Speed Sensor RH Output Signal Malfunction: Beyond The Scope Of Loss, Noise,

Rear Wheel Speed Sensor LH Output Signal Malfunction: Beyond The Scope Of Loss, Noise,

Rear Wheel Speed Sensor RH Output Signal Malfunction: Beyond The Scope Of Loss, Noise,

Wheel Speed Sensor Group Malfunction (Wheel Speed Sensor Interchangeable, Each Of The

Wheel Speed Difference Is Too Large, Wheel Speed Sensors Fault)

Chapter 04 diagnostics - anti-lock brake system,

Before diagnosis of the ABS system, check the ABS system failure and easily accessible components first,

visual inspection can quickly determine fault, and thus do not need to do further diagnosis.

(a) Make sure that the vehicle only install the recommended

size tires and wheels. coaxial style of tire tread depth

must be the same. Specific tire models, refer to the

vehicle owner's manual for details.

2. CHECK THE ABS HYDRAULIC MODULATOR, BRAKE PIPES AND CONNECTIONS FOR

LEAKING.

3. CHECK ABS SYSTEM FUSES TO ENSURE THAT THE FUSES ARE NOT BURNED, AND THE

MODEL IS CORRECT. ABS SYSTEM HAS THREE FUSES:

4. CHECK THE BATTERY VOLTAGE, DETECT WHETHER THE BATTERY TERMINAL CORROSION

OR LOOSE. ABS SYSTEM NORMAL OPERATING VOLTAGE RANGE IS 9.3V - 16.8V.

(a) Check ABS grounding point is loose. The location is

changed or not.

(b) ABS ground has good sealing, in order to avoid water

and moisture in capillary (siphon) effect through wiring

harness of channel infiltration ABS control module, which

cause function failure.

ABS system harness and connectors of the related

components are properly connected, to be pinched or cut

or not.

Harness routing is too close to high-voltage or highcurrent

devices, such as high-voltage or parts,

generators, motors or stereo amplifier.

The high voltage or high current device may cause the

circuit to generate the induced noise, and thereby interfere

with the normal working of the circuit.

(EMI). Suspected intermittent fault, check the

aftermarket installation of anti-theft device, lights, or

whether the mobile phone is not installed correctly.

7. IF THE ABS NOISE IS TOO LARGE, IT MAY BE CAUSED BY THE FOLLOWING REASONS:

(a) Loosening of ABS assembly with bracket.

(b) Loosening of ABS bracket and body.

It will be caused failure by one of the following conditions are met when the supply voltage of the ECU:

(3) Voltage is between 7.7V to 9.2V when vehicle speed is higher than 6km / h.

1. PERFORM PRE-CHECK STEPS

(b) Measure the battery voltage.

3. ABS CONTROL MODULE CROSS-VALIDATION

(b) Remove the ABS actuator. (Refer to “Chapter 35 brake - abs actuator, replacement”)

are securely installed without connecting pipes when vehicle was driven. )

(d) Start the engine and to ensure that the vehicle speed is not lower than 20km / h, so that the ABS

dynamic self-check.

C001004; C001104; C001404; C001504; C001804; C001904; C001C04; C001D04; C109504; C007208

(3) Overheating protection (Solenoid valve long working hours, common in vacuum filling and offline detection)

(d) Connect the negative battery cable.

2. PERFORM PRE-CHECK STEPS

(a) Selecte diagnostic mode in the disgnostic tool and read data stream.

(b) Detect vehicle speed displayed on the instrument panel and diagnostic tool when vehicle is running,

and compare whether they are consistent.

Inspect the ABS valve fuse in battery compartment

junction box (Z048): 25 A.

Inspect the ABS IG fuse in battery compartment junction

box (Z048): 5 A.

5. ABS CONTROL MODULE CROSS-VALIDATION

are securely installed without connecting pipes when vehicle was driven.)

dynamic self-check

6. CHECK HARNESS AND CONNECTOR (ABS VALVE FUSE- GROUND)

Disconnect the Z062 ABS module connector.

ABS IG fuse - Z062 (28)

ABS valve fuse - Z062 (25)

(2) Reflux pump motor relay work over 60ms, reflux pump monitoring is still not detected voltage signal.

(3) Reflux pump motor relay did not work, reflow pump monitoring detected voltage exceeds 2.5s.

(4) Reflux pump motor relay stops working and the reflux pump monitoring detected voltage does not drop.

Detect vehicle speed displayed on the instrument panel and diagnostic tool when vehicle is running,

(b) Inspect the ABS pump fusible link in battery

compartment junction box (Z048): 40 A.

6. CHECK HARNESS AND CONNECTOR (ABS PUMP FUSIBLE LINK- GROUND)

ABS valve fuse - Z062 (1)

Disconnect the Z059 front wheel speed sensor connector LH.

Z059 (1) - Ground

Z059 (2) - Ground

Z059 (1) - Z062 (8)

Z059 (2) - Z062 (19)

(1) ECU detects wheel speed sensor signal circuit is shorted to power supply.

(2) ECU detects wheel speed sensor power supply circuit is shorted to ground.

(3) Wheel speed sensor signal is not normal.

(2) Wheel speed sensor signal circuit is shorted to power supply.

(3) Wheel speed sensor power supply is shorted to ground.

(4) The ring gear is not installed, missing teeth, dirty dust and installed incorrectly.

(5) The gap between the sensor and the ring is too large.

(6) The wheel speed sensor is subjected to the external magnetic field interference. (Wheel or axle is not

demagnetization)

(7) The wheel speed sensor fault.

(8) The number of teeth of the ring gear error.

(9) Tire size does not meet specifications

(10) ECU is damaged.

Inspect whether the ABS speed sensor installation is

Inspect whether the ABS speed sensor connector is

loose or not.

Inspect whether the ABS speed sensor tightening bolt is

Remove ABS speed sensor to inspect whether the

speed sensor is damaged or the surface is dirty.

Position the front wheel speed sensor RH properly.

Check wheel speed sensor tip.

If foreign object is attached, remove it. After reassembling,

check the output voltage.

Disconnect the Z059 front wheel speed sensor connector.

6. ABS CONTROL MODULE CROSS-VALIDATION

7. CHECK HARNESS AND CONNECTOR (ABS MODULE- GROUND)

Z062 (13) - Ground

Z062 (38) - Ground

Inspect the stop lamp switch fuse in engine room junction

box (Z063): 15 A.

2. INSPECT BACK-UP LAMP SWITCH

Disconnect the Z006 stop lamp switch connector.

3. CHECK HARNESS AND CONNECTOR (ABS MODULE- GROUND)

Stop lamp fuse - Z006 (2)

Z062 (30) - Z006 (1)

DIAGNOSTICS(RHD) - SUPPLEMENTAL RESTRAINT SYSTEM

8101 - POWER SUPPLY VOLTAGE HIGH

1. INSPECT FUSE (Co - pilot Side Junction Box)

2. CHECK HARNESS AND CONNECTOR (AIRBAG FUSE - RESTRAINT CONTROL MODULE)

Disconnect the Z044 restraint control module connector.

Z044 (5) - Ground

Disconnect the Z012 clock spring connector.

Z044 (10) - Z012 (3)

Z044 (11) - Z012 (4)

Z012 (3) - Ground

Z012 (4) - Ground

Z044 (10) - Ground

Z044 (11) - Ground

Disconnet the Z040 passenger airbag connector.

Z044 (13) - Z040 (1)

Z044 (14) - Z040 (2)

Z040 (1) - Ground

Z040 (2) - Ground

Z044 (13) - Ground

Z044 (14) - Ground

Disconnect the Z002 instrument B connector.

Z044 (7) - Ground

Disconnect the Z003 instrument A connector.

Z002 (B27) - Z044 (7)

Replace instrument cluster,and keep the Z002 instrument connector disconnecting.

Connect Pin B27 of the Z002 instrument B connector to ground.

DIAGNOSTICS(RHD) - HEATER AND AIR CONDITIONING SYSTEM

8. DO NOT DEPOSIT REFRIGERANT IN AN ENCLOSED AREA OR NEAR AN OPEN FLAME.

9. ALWAYS WEAR SAFETY GOGGLES.

10. AVOID CONTACTING WITH LIQUID REFRIGERANT R-134A.

11. DO NOT HEAT CONTAINER OR EXPOSE THE CONTAINER TO OPEN FLAME.

12. DO NOT DROP DOWN CONTAINER OR APPLY PHYSICAL SHOCKS TO IT.

13. DO NOT OPERATE COMPRESSOR WITHOUT ENOUGH REFRIGERANT IN REFRIGERANT

(a) If there is not enough refrigerant in the A/C system, oil lubrication will be insufficient and the

compressor may be damaged.

14. DO NOT OPEN HIGH PRESSURE MANIFOLD VALVE WHILE COMPRESSOR IS OPERATING.

15. BE CAREFUL NOT TO OVERCHARGE SYSTEM WITH REFRIGERANT.

16. DO NOT OPERATE ENGINE AND COMPRESSOR WITH NO REFRIGERANT.

17. EXPRESSIONS OF IGNITION SWITCH.

conditioning - multi-media and A/C

Inspect the A/C fuse (15 A) in driver side junction box

(Z043).

Junction Box (Z043).

(b) Disconnect the Z020 front blower control module connector.

(b) Disconnect the Z019 front blower motor connector.

Disconnect the Z019 front blower motor connector.

Front blower relay (30) - Z019 (1)

Disconnect the Z019 front blower connector.

Disconnect the Z020 front blower control module connector.

Z019 (2) - Z020 (4)

Disconnect the Z020 blower control module connector.

Z020 (8) - Ground

Disconnect the Z017 A/C control panel connector.

Z020 (2) - Z017 (35)

Z020 (3) - Z017 (28)

Disconnect the Z023 A/C control panel connector.

Front blower relay (86) - Z023 (8)

Z023 (10) - Ground

Z023 (19) - Ground

Z023 (18) - Ground

Z023 (20) - Ground

YES > Replace A/C control panel ( Multi-media and A/C controller assy).

2. CHECK HARNESS AND CONNECTOR (FRONT BLOWER - FRONT BLOWER CONTROL

Z020 (1) - Ground

table below..

Disconnect the V031 triple pressure switch connector.

V031 (1) - V031 (4)

V031 (2) - V031 (3)

V031 (4) - E001 (79)

V031 (3) - E001 (26)

V031 (4) - A036 (27)

V031 (3) - A036 (11)

V031 (2) - Z023 (9)

V031 (2) - Ground

V031 (2) - A036 (29)

Disconnect the Z039front evaporator thermistor connector.

Z039(1) - Z017 (29)

Z039(2) - Z017 (33)

Inspect the rear heater fuse (15A) in Co-pilot Junction

Box (Z043).

Disconnect the Z047 rear heater blower switch connector.

Z047 (2) - Rear heater relay (86)

Z047 (2) - Water valve relay (86)

Z047 (3) - Ground

Z047 (1) - Ground

P002 (4) - Z047 (4)

P002 (1) - Z047 (5)

P002 (3) - Z047 (6)

DIAGNOSTICS(RHD) - LIGHTING SYSTEM

Disconnect the V020 headlamp LH connector.

Lo - beam LH fuse (7.5A) - V020 (3)

V020 (3) - Ground

YES > Replace Lo - beam LH fuse (7.5A) in co-pilot side junction box (Z043).

Disconnect the V022 headlamp RH connector.

Remove lo - beam relay in co-pilot side junction box (Z043).

terminals 86 and 85

86 - 85 breakover

87 - 30

Disconnect the Z011 combination switch (light) connector.

Lo - beam Relay (85) - Z011 (10)

Lo - beam fuse RH (7.5A) - V022 (3)

V022 (3) - Ground

YES > Replace lo - beam headlamp fuse (7.5A) both LH and RH in driver side fuse box (Z043).

Hi - beam LH fuse (10A) - V020(2)

V020 (2) - Ground

YES > Replace Hi - beam LH Fuse(10A) in co-pilot side junction box (Z043).

Inspect the headlamp fuse (20A) in co-pilot side junction

box (Z043).

3. INSPECT HI - BEAM RELAY

Remove hi - beam relay in co-pilot side junction box (Z043).

Inspect Hi - beamheadlamp relay according to the

9 - 7

5. CHECK HARNESS AND CONNECTOR (HI - BEAM RELAY - COMBINATION SWITCH (LIGHT))

hi - beam relay (86) - Z043 (9)

6. CHECK HARNESS AND CONNECTOR (HI - BEAM FUSES BOTH LH AND RH, HI - BEAM

(d) Measure the resistance according to the value(s) in the

Hi - beam LH fuse (10A) - V020 (2)

Hi - beam RH fuse (10A) - V022 (2)

V022 (2) - Ground

YES > Replace hi - beam fuses both LH and RH in driver side box (Z043).

V020 (1) - Ground

Hi - beam LH fuse (10 A) - V020 (2)

Lo - beam LH fuse (7.5 A) - V020 (3)

YES > Replace hi - beam fuse and lo - beam fuse LH in co-pilot side junction box (Z043).

1. CHECK HARNESS AND CONNECTOR (COMBINATION SWITCH (LIGHT) - GROUND)

Z011 (11) - Ground

2. INSPECT COMBINATION SWITCH (LIGHT)

10 - 7

3. INSPECT HEADLAMP BULBS BOTH LH AND RH

4. CHECK HARNESS AND CONNECTOR (HEADLAMP BOTH LH AND RH - GROUND)

V022 (1) - Ground

5. INSPECT HI - BEAM RELAY AND LO - BEAM RELAY

86 - 85 Breakover

6. CHECK HARNESS AND CONNECTOR (HI - BEAM RELAY AND LO - BEAM RELAY -

Hi - beam relay (86) - Z011 (9)

Lo - beam relay (85) - Z011 (10)

7. CHECK HARNESS AND CONNECTOR (HI - BEAM FUSE AND LO - BEAM FUSE BOTH LH AND

Lo - beam RH fuse (7.5A) - V022 (3)

8. INSPECT FUSE

YES > Replace hi - beam fuse (10A) and lo - beam fuse (7.5A) both LH and RH in the co-pilot side junction

NO > Replace headlamp fuse (20A) and lo - beam fuse (7.5A) both LH and RH in the co-pilot side junction

Inspect front fog lamp fuse (15 A) in co-pilot side junction

Remove front fog relay in co-pilot side junction box (Z043).

Disconnect the Z003 instrument cluster A connector.

Disconnect the Z011 combination switch connector.

3 - 1 < 2 Ω

3 - 1 ≥ 1 MΩ

Remove front fog lamp relay in co-pilot side junction box (Z043).

Front fog lamp relay (86) - Z011 (3)

Z011 (3) - Ground

(b) Remove front fog lamp relay in co-pilot side junction box (Z043).

Inspect rear fog lamp fuse (10A) in co-pilot side junction

Remove rear fog lamp relay in co-pilot side junction box (Z043).

Disconnect the F012 rear combination lamp LH connector.

Disconnect the G004 rear combination lamp RH connector.

Disconnect the Z002 instrument cluster B connector.

F012 (5) - Ground

2 - 1 < 2 Ω

2 - 1 ≥ 1 MΩ

Rear fog lamp relay (86) - Z011 (2)

F012 (2) - Ground

G004 (2) - Ground

Rear fog lamp relay (87) - F012 (5)

Rear fog lamp relay (87) - G004 (5)

Z011 (2) - Ground

(b) Remove rear fog lamp relay in co-pilot side junction box (Z043).

Inspect the front fog lamp fuse (15 A) in co-pilot side

junction box (Z043).

Inspect the rear fog lamp fuse (10 A) in co-pilot side

Z011 (1) - Ground

3 - 1

2 - 1

Remove rear fog relay in co-pilot side junction box (Z043).

Inspect the hazard warning fuse (15A) in co-pilot side

2. CHECK HARNESS AND CONNECTOR (HAZARD WARNING FUSE - FLASHER)

Disconnect the Z007 flasher connector.

Z007(1) - Ground

3. CHECK HARNESS AND CONNECTOR (FLASHER - HAZARD WARNING SWITCH)

Disconnect the Z034 hazard warning switch connector.

Z007 (7) - Z034 (8)

4. CHECK HARNESS AND CONNECTOR (HAZARD WARNING FUSE - FLASHER)

Hazard warning fuse (15A) - Z007 (1)

5. CHECK HARNESS AND CONNECTOR (HAZARD WARNING SWITCH - GROUND)

Z034 (7) - Ground

6. INSPECT HAZARD WARNING SWITCH

YES > Replace the flasher.

Inspect the turn signal fuse (10A) in co-pilot side junction

2. CHECK HARNESS AND CONNECTOR (TURN SIGNAL FUSE - COMBINATION SWITCH (TURN

SIGNAL SWITCH))

Disconnect the Z011 combination switch (turn signal switch) connector.

Z011 (12) - Ground

3. CHECK HARNESS AND CONNECTOR (COMBINATION SWITCH (TURN SIGNAL SWITCH) - FLASHER)

Z007 (12) - Ground

Z007 (5) - Ground

4. INSPECT COMBINATION SWITCH (TURN SIGNAL SWITCH)

12 - 11

12 - 13

5. CHECK HARNESS AND CONNECTOR (TURN SIGNAL FUSE - COMBINATION SWITCH (TURN SIGNAL

SWITCH))

Turn signal fuse (10A) - Z011 (12)

6. CHECK HARNESS AND CONNECTOR (FLASHER - COMBINATION SWITCH (TURN SIGNAL SWITCH))

Z007 (5) - Z011 (11)

Z007 (12) - Z011 (13)

3. CHECK HARNESS AND CONNECTOR (TURN SIGNAL FUSE - COMBINATION SWITCH (TURN

4. CHECK HARNESS AND CONNECTOR (COMBINATION SWITCH (TURN SIGNAL SWITCH) - FLASHER)

5. CHECK HARNESS AND CONNECTOR (FLASHER - GROUND)

Z007 (8) - Ground

6. INSPECT FLASHER

7. INSPECT HAZARD WARNING SWITCH

NO > Relace hazard warning switch,and go to step 11.

8. CHECK HARNESS AND CONNECTOR (HAZARD WARNING SWITCH - FLASHER)

Z034 (8) - Z007 (7)

NO > Repair or replace harness or connector, and go to step 11.

9. CHECK HARNESS AND CONNECTOR (HAZARD WARNING SWITCH - GROUND)

NO > Repair or replace harness or connector,and go to step 11.

10. CHECK HARNESS AND CONNECTOR (HAZARD WARNING FUSE - FLASHER)

11. CHECK HARNESS AND CONNECTOR (TURN SIGNAL FUSE - COMBINATION SWITCH (TURN SIGNAL

12. CHECK HARNESS AND CONNECTOR (FLASHER - COMBINATION SWITCH (TURN SIGNAL SWITCH))

YES > Replace the combination switch (turn signal switch) .

13. CHECK HARNESS AND CONNECTOR (TURN SIGNAL LAMP - GROUND)

Disconnect the V021 front turn signal lamp LH connector.

Disconnect the V025 front turn signal lamp RH connector.

V021 (1) - Ground

V025 (1) - Ground

Z007 (4) - V021 (2)

Z007 (9) - F012 (4)

Z007 (10) - V025 (2)

Z007 (2) - G004 (4)

Disconnect the Z011 combination switch(turn signal lamp) connector.

• If only turn signal lamps LH is not bright,measure 12

- 11.

• If only turn signal lamps RH is not bright,measure 12

- 13.

2. CHECK HARNESS AND CONNECTOR (FLASHER - COMBINATION SWITCH (TURN SIGNAL SWITCH))

3. INSPECT FLASHER

4. CHECK HARNESS AND CONNECTOR (FLASHER - TURN SIGNAL LAMP)

(b) Disconnect the Z007 flasher connector.

(d) Disconnect the F012 rear combination lamp LH connector.

Z007 (4) - V021 (2) only.

Z007 (9) - F012 (4) only.

5. CHECK HARNESS AND CONNECTOR (TURN SIGNAL LAMP - GROUND)

V021 (1) - Ground only.

F012 (2) - Ground only.

7 - 8 ≥ 1 MΩ

2. CHECK HARNESS AND CONNECTOR (HAZARD WARNING SWITCH - FLASHER)

Z034 (8) - Ground

3. CHECK HARNESS AND CONNECTOR (FLASHER - TURN SIGNAL LAMP)

Connect the battery negative cable,check the wire harness for shot to power supply, hazard warning

lamp is shoud not be bright.

box(Z063).

Z006 (2) - Ground

F012 (3) - Ground

Stop lamp fuse (15A) - Z006 (2)

Z006(1) - F012 (3)

Z006(1) - G004(3)

Z006(1) - U002 (2)

Z006 (1) - F012 (3)

Z006 (1) - U002 (2)

Disconnect the Z056 back - up lamp switch connector.

Z056 (2) - F012 (6)

Inspect the back - up lamp fuse (10A) in co-pilot side

Z056 (1) - Ground

F012 (6) - Ground

Back - up lamp (10A) - Z056

Z056 (2) - G004 (6)

Disconnect the Z014 ignition switch illumination connector.

Dome light fuse (10A) - Z014 (1)

Disconnect the Z008 central locking controller assy connector.

Z014 (2) - Z008 (B1)

Z008 (B10) - Ground

Disconnect the F010 central dome light connector.

Dome light fuse (10A) - F010 (1)

(b) Disconnect the F010 central dome light connector.

Disconnect the Z031 dome light switch connector.

F010 (3) - Z031 (5)

F010 (2) - F014 (1)

F010 (2) - Z031 (5)

Z031 (2) - Ground

Disconnect the F011 air purifier connector.

Dome light fuse (10A) - F011 (1)

Disconnect the F014 middle door lamp switch RH connector.

F011 (3) - Z031 (5)

F011 (2) - F014 (1)

Disconnect the Z055 step lamp connector.

dome light fuse (10A) - Z055 (1)

Z055 (2) - F014 (1)

Disconnect the F009 front dome light connector.

Dome light fuse (10A) - F009 (1)

Dome light fuse (10A) - F009 (2)

DIODE RH,FRONT DOOR LAMP SWITCH RH,INSTRUMENT CLUSTER)

Disconnect the Z073 front door lamp diode RH connector.

Disconnect the Z046 front door lamp switch LH connector.

F009 (4) - Z073 (1)

F009 (4) - Z046 (1)

F009 (4) - Z003 (A30)

F009 (3) - Ground

Remove lamplet relay in co-pilot side junction box (Z043).

87 - 30 < 2 Ω

remove lamplet relay in co-pilot side junction box (Z043).

Lamplet relay (86) - Z011 (5)

Z011 (8) - Ground

inspect lamplet fuse (7.5A) in co-pilot side junction box

inspect switch lighting fuse (7.5A) in co-pilot side junction

Z003 (A6) - Ground

Disconnect the Z033 headlamp dimmer switch connector.

Disconnect the Z032 instrument dimmer switch connector.

Disconnect the Z024 outside mirror defroster switch connector.

Disconnect the Z022 rear blower forward switch connector.

Disconnect the Z030 cigarette lighter connector.

Disconnect the Z025 radio A connector.

Disconnect the Z017 A/C control panel B connector.

Disconnect the Z029 diagnosis switch connector.

Z034 (2) - Ground

Inspect lamplet fuse (7.5A) in co-pilot side junction box

Z003 (A19) - Ground

Lamplet fuse (7.5A) - Z003

(A6)

Z029 (1) - Ground

Switch lighting fuse (7.5A) - Z029 (3)

Z030 (1) - Ground

Switch lighting fuse (7.5A) - Z030 (3)

Disconnect the Z023 A/C control panel A connector.

Switch lighting fuse (7.5A) - Z017 (32)

Z025 (A8) - Ground

Switch lighting fuse (7.5A) - Z025 (A3)

Z022 (1) - Ground

Switch lighting fuse (7.5A) - Z022 (3)

Z031 (1) - Ground

Switch lighting fuse (7.5A) - Z031 (3)

Z024 (1) - Ground

Switch lighting fuse (7.5A) - Z024 (3)

Z033 (6) - Ground

Switch lighting fuse (7.5A) - Z033 (3)

Z032 (6) - Ground

Switch lighting fuse (7.5A) - Z032 (3)

Z034 (3) - Ground

Switch lighting fuse (7.5A) - Z034 (2)

(b) Disconnect the V019 front position lamp LH connector.

V019 (1) - Ground

V024 (1) - Ground

• If only width lamp LH is not bright,measure V019 (1) -

• If only width lamp RH is not bright,measure V024 (1) -

Lamplet fuse (7.5A) - V019 (2)

Lamplet fuse (7.5A) - V024 (2)

fuse (7.5A) - V019 (2) only.

fuse (7.5A) - V024 (2) only.

(b) Disconnect the F012 rear combination lamp LH connector.

• If only tail lamp LH is not bright, measure F012 (2) -

• If only tail lamp RH is not bright,measure G004 (2) -

Lamplet fuse (7.5A) - F012 (1)

Lamplet fuse (7.5A) - G004 (1)

Fuse (7.5A) - F012 (1) only.

Fuse (7.5A) - G004 (1) only.

Inspect the lamplet fuse (7.5A) in co-pilot side junction

Disconnect the V019 front position lamp LH connector.

Disconnect the V024 front position lamp RH connector.

V019 (2) - Ground

Remove the lamplet relay in co-pilot side junction box (Z043).

lamplet relay (86) - Z011 (5)

DIAGNOSTICS(RHD) - WIPER AND WASHER

1. EXPRESSIONS OF IGNITION SWITCH

2. POWER OFF

(a) Before removing or installing any electrical device, please disconnect the nagative battery cable to

Does the wiper motor operate in high

Does the wiper motor operate in low

Does the wiper motor operate in

intermittent mode?

box (Z043): 15 A.

NO > If the fuse blows,check the line to normal after replacing the fuse.

Disconnect the V030 windshield wiper assy connector.

Front wiper fuse - V030(3)

Disconnect the Z013 combination switch (wiper and washer control) connector.

Front wiper fuse - Z013 (3)

Disconnect the V028 front washing reservoir motor connector.

Front wiper fuse - V028 (2)

5. CHECK HARNESS AND CONNECTOR (WINDSHIELD WIPER - GROUND)

Disconnect the V030 windshield wiper connector.

V030(6) - Ground

6. CHECK HARNESS AND CONNECTOR (COMBINATION SWITCH - WINDSHIELD WIPER)

Disconnect the Z013 combination switch connector.

Z013(4) - V030(1)

Z013(2) - V030(4)

Z013(5) - V030(2)

7. INSPECT WINDSHIELD WIPER

Inspect the windshield wiper.

Windshield wiper lowspeed

operation

Windshield wiper highspeed

Motor does not

8. CHECK HARNESS AND CONNECTOR (COMBINATION SWITCH - GROUND)

Z013(6) - Ground

V030(1) - Z013(4)

YES > Check windshield wiper, replace windshield wiper if necessary.

2 - 3 ≥ 1 MΩ

2 - 3 < 2 Ω

(d) Measure the resisitance according to the value(s) in the

Z013 (2) - V030(4)

2 and 5

Battery(+) - 2

Battery(-) - Ground

Z013 (6) - Ground

3. CHECK HARNESS AND CONNECTOR (WINDSHIELD WIPER- GROUND)

V030 (5) - Ground

Z013 (5) - V030 (2)

Z013 (4) - V030 (1)

6 - 7 ≥ 1 MΩ

6 - 7 < 2 Ω

2. CHECK HARNESS AND CONNECTOR (DRIVER SIDE JUNCTION CONNECTOR - FRONT

WASHER PUMP)

Disconnect the V028 front washer pump connector.

3. CHECK HARNESS AND CONNECTOR (COMBINATION SWITCH - FRONT WASHER PUMP)

V028 (1) - Z013 (7)

4. CHECK HARNESS AND CONNECTOR (COMBINATION SWITCH - GROUND)

YES > Check the front washer pump, replace the front washer pump if necessary.

switch to other position

3. CHECK HARNESS AND CONNECTOR ( COMBINATION SWITCH - WINDSHIELD WIPER)

V030(2) - Z013 (5)

(Z043): 10 A.

NO > If the fuse blows, check the line to normal after replacing the fuse

9 - 6 ≥ 1 MΩ

9 - 6 < 2 Ω

Rear wiper relay(85) - Z013 (9)

Rear wiper relay(87) - U001 (2)

Constant 85 - 86 90Ω

Apply 12V voltage to

6. CHECK HARNESS AND CONNECTOR (REAR WIPER RELAY - REAR WIPER)

8. CHECK HARNESS AND CONNECTOR ( REAR WIPER - GROUND)

YES > Check the rear wiper, Replace the rear wiper if necessary.

NO > If the fuse blows, check the line to wiring after replacing the fuse.

Disconnect the V029 rear washing reservoir motor connector.

Rear wiper fuse (30)- V029 (2)

Disconnect the Z043 rear wiper relay connector.

Rear wiper relay (85) - Z013

(9)

6. CHECK HARNESS AND CONNECTOR ( REAR WASHING RESERVOIR MOTOR - COMBINATION

V029(1) - Z013(8)

DIAGNOSTICS(RHD) - AUDIO SYSTEM

Check Radio ACC fuse (7.5 A) in junction box (Z043).

Check Radio fuse (10 A) in junction box (Z043).

(b) Disconnect the Z025 radio connector.

Z025(A7) - Ground

Z025 (A4) - Ground

Radio fuse (10 A) - Z025 (A4)

Radio ACC fuse(15 A) - Z025 (A4)

H006 (1) - Z026 (B3)

H006 (2) - Z026 (B4)

D011 (1) - Z026(B5)

D011 (2) - Z026(B6)

G005 (2) - Z026 (B2)

G005 (1) - Z026 (B1)

F013(1) - Z026 (B7)

F013 (2) - Z026 (B8)

DIAGNOSTICS(RHD) - AUXILIARY POWER

(Z043):Refer to “Circuit Guidance” document “the front

passenger side fuse box” fuse F35.

Z030 (2) - Ground

Cigarette lighter fuse - Z030 (2)

Inspect the IG2 fuse in body junction box (Z043):Refer to

“Circuit Guidance” document “the front passenger side

fuse box” fuse F19.

passenger side fuse box” fuse F49.

NO > If the fuse blows, check the line to normal after replacing the fuse.

Constant 85 - 86 90 Ω

Apply 12V

4. CHECK HARNESS AND CONNECTOR (POWER FUSE - 12V POWER SUPPLY OUTPUT SOCKET

Disconnect Z018 12v power supply output socket.

Power fuse (15A) - Z018(2)

5. CHECK HARNESS AND CONNECTOR (12V POWER SUPPLY OUTPUT SOCKET FUSE - GRO-

NUD)

Z018(1) - Ground

YES > Replace 12v power supply output socket.

DIAGNOSTICS(RHD) - HORN SYSTEM

(b) Inspect the horn fuse in body junction box (Z043):15 A.

Disconnect the Z008 central locking controller B connector.

Z008 (B4) - Horn relay(86)

Horn relay (86) - Z012(2)

Disconnect the V027 alt horn connector.

Disconnect the V026 bass horn connector..

Horn relay - V026(1)

Horn relay - V027(1)

Disconnect the V026 alt horn connector.

V027(2) - Ground

V026(2) - Ground

(b) Replace the clock spring. (Refer to“Chapter 62

Supplemental Restraint System - clock spring,

replacement”)

DIAGNOSTICS(RHD) - REVERSE RADAR SYSTEM

Audio (multi-media and aircondition

controler assy)

Back-up lamp switch

Sends the back-up signal to the reverse radar control unit.

3. Back-up lamp switch

distance (Back-up lamp is

(Back-up lamp is normal)

1. Displayer Chapter 81 communication system - multi-media

and air-condition controler assy,replacement

Inspect the back-up lamp fuse (10 A) in co-pilot side

2. CHECK HARNESS AND CONNECTOR (BACK-UP LAMP FUSE - BACK-UP LAMP SWITCH)

Disconnect the Z056 back-up lamp switch connector.

Disconnect the Z042 reverse radar control unit connector.

3. INSPECT BACK-UP LAMP SWITCH

NO > Replace back-up lamp switch and fuse.

4. CHECK HARNESS AND CONNECTOR (BACK-UP LAMP SWITCH - REVERSE RADAR CONTROL

UNIT)

Z056 (2) - Ground

Z042 (16) - Ground

6. INSPECT BACK-UP LAMP SWITCH

Inspect the back-up lamp switch according to the

NO > Replace back-up lamp.

7. CHECK HARNESS AND CONNECTOR (BACK-UP LAMP FUSE - BACK-UP LAMP SWITCH)

Back-up lamp fuse (10A) - Z056 (1)

8. CHECK HARNESS AND CONNECTOR (BACK-UP LAMP SWITCH - REVERSE RADAR CONTROL

Z056 (2) - Z042 (1)

1. INSPECT BACK-UP LAMP SWITCH

NO > Replace back-up lamp switch.

2. CHECK HARNESS AND CONNECTOR (BACK-UP LAMP SWITCH - REVERSE RADAR CONTROL

Z042 (1) - Ground

DISTANCE (BACK-UP LAMP IS NORMAL)

Turn the ignition switch OFF.。

Z042 (7) - R001 (1)

Z042 (11) - R001 (2)

Z042 (8) - R002 (1)

Z042 (11) - R002 (2)

Z042 (4) - R003 (1)

Z042 (11) - R003 (2)

Z042 (15) - R004 (1)

Z042 (11) - R004 (2)

1. CHECK HARNESS AND CONNECTOR (BACK-UP LAMP SWITCH - CAMERA)

Z056 (2) - J005 (2)

Disconnect the Z028 radio connector.

J005 (3) - Z028 (1)

J005 (4) - Z028 (2)

DIAGNOSTICS(RHD) - POWER WINDOWS

1 L - B Door control switch (date)

2 L Door control switch (clock)

3 L - Y Window control switch LH

4 P - L Window control switch LH

5 L - G Window control switch LH

WINDOW CONTROL SWITCH LH PIN

4 G Power window motor RH

5 R Power window motor RH

6 R - L Power window motor LH

7 G - R Power window motor LH

14 R Door-status

Check power window motor LH.

• Push or pull the front window switch RH to

RH is inoperative.

RH does not open.

RH does not close.

3. Window control switch LH

LH is inoperative (use

LH).

1. Window control switch LH

3. Power window motor LH

side junction box (Z043).

Disconnect the H010 door control switch connector.

Disconnect the Z009 central locking controller assy A connector.

H010 (12) - Ground

Power window fusible link (20A) - H010 (12)

Power window fusible link (20A) - Z009 (A8)

H010 (6) - Ground

7. CHECK HARNESS AND CONNECTOR (DOOR CONTROL SWITCH - CENTRAL LOCKING

H010 (1)- Z009 (A15)

H010 (2)- Z009 (A16)

Disconnect the H007 power window motor LH connector.

Disconnect the D007 power window motor RH connector.

Disconnect the H007 power window motor RH connector.

Disconnect the D007 power window motor LH connector.

Z009 (A4) - H007 (2)

Z009 (A5) - H007 (1)

Z009 (A6) - D007 (2)

Z009 (A7) - D007 (1)

FRONT POWER WINDOW RH IS INOPERATIVE

Does power window LH work correctly?

Does power windou LH work correctly?

YES > Replace power window motor LH.

Disconnect the D009 window control switch LH connector.

Replace window control switch LH.

YES > Replace window control switch LH.

2. CHECK HARNESS AND CONNECTOR (WINDOW CONTROL SWITCH LH - DOOR CONTROL SWITCH)

D009 (1) - H010 (5)

D009 (3) - H010 (4)

D009 (4) - H010 (3)

4. INSPECT POWER WINDOW MOTOR LH

DIAGNOSTICS(RHD) - OUTSIDE MIRROR

5 R - Y Outside Mirror-

6 W -B Ground

Inspect the radio & ACC fuse (10 A) in Co-pilot junction

box(Z043).

Remove the radio & ACC fuse.

Disconnect the H009 outside mirror remote control switch connector.

Radio & ACC fuse (10A) -

H009 (4)

H009 (6) - Ground

Disconnect the D008 outside mirror connector.

D008 (6) - H009 (7)

D008 (4) - H009 (5)

D008 (5) - H009 (1)

DIAGNOSTICS(RHD) - OUTSIDE MIRROR DEFROSTER SYSTEM

OUTSIDE MIRROR DEFROSTER SYSTEM

The outside mirror defroster system consists of heating wires, switch, relay, fuse, indicator and wiring

harness. The heating element is the electric heating wire which are integrated in both outside mirror

glasses and defog the glasses quickly. The outside mirror defrost switch is integrated on the centre

switch panel on the instrument panel. When the switch is pressed, the indicator lamp in the switch

illuminates to indicate that the defroster is operating.

OUTSIDE MIRROR DEFROSTER WIRING DIAGRAM

Inspect the outside mirror defrost fuse (7.5 A) in Co-pilot

Junction Box (Z043), refer to “HOW TO USE MANUAL”

in WIRING chapter to identify the fuse.

NO > If the outside mirror defrost fuse is blown, prior to replacing the fuse, inspect the wiring harness.

2. INSPECT OUTSIDE MIRROR DEFROST RELAY

Remove the outside mirror defrost relay (refer to “HOW TO USE MANUAL” in WIRING chapter to

identify the relay).

Disconnect the Z024 outside mirror defrost switch connector.

4. CHECK HARNESS AND CONNECTOR (OUTSIDE MIRROR DEFROST SWITCH CONNECTOR -

POWER SUPPLY)

Z024 (2) - Ground

5. CHECK HARNESS AND CONNECTOR (OUTSIDE MIRROR DEFROST RELAY - OUTSIDE

MIRROR DEFROST SWITCH)

Rear defrost relay (85) - Z024 (5)

Turn ignition switch OFF..

Turn ignition switch ON.

Outside mirror defrost relay (30) - Ground

7. CHECK HARNESS AND CONNECTOR (OUTSIDE MIRROR DEFROST RELAY - GROUND)

8. CHECK HARNESS AND CONNECTOR (OUTSIDE MIRROR DEFROST RELAY - OUTSIDE

MIRROR ASSY LH/RH )

Disconnect the D008 outside mirror assy LH/ H008 outside mirror assy RH connector.

Outside mirror defrost relay (87) - D008(3)

Outside mirror defrost relay (87) - H008(3)

9. CHECK HARNESS AND CONNECTOR (OUTSIDE MIRROR ASSY LH/RH - GROUND )

D008(2) - Ground

H008(2) - Ground

DIAGNOSTICS(RHD) - INSTRUMENT CLUSTER

engine coolant temperature is between -20 ℃ ~ 110 ℃ .

Terminals No Wiring Color Description

Z003

Z002

Do not perform basic inspection until engine temperature reaches the specified value. If on-road test is

needed, must have at least two people to perform the test.

• Connect hand-held tester, reading the engine

• Connect hand-held tester, reading the vehicle

(b) Disconnect the Z057 speedometer sensor connector.

Z057 (1) - Ground

Disconnect the Z003 instrument cluster connector.

Disconnect the Z057 speedometer sensor connector.

Z003 (A13) - Z057 (3)

Install a new speedometer sensor.

Z003 (A8) - E001(51)

Z003 (A8) - Z072(E28)

connector Z003, pin A8 and ground.

Disconnect the Z067 fuel level sensor connector.

Z067 pin 2 and pin 3.

NO > Replace the fuel level sensor.。

Z067 (2) - Ground

Z067 (3) - Ground

Disconnect the Z003 instrument cluster connectors.

Disconnect the Z067 fuel level sensor connectors.

Z003 (A23) - Z067 (3)

Disconnect the Z002 instrument cluster connector.

Z002 (B16) - E012 (1)

Z002 (B16) - E037 (1)

Disconnect the Z078 (4G69) / E036 (ISF2.8) engine oil pressure switch connector.

Z078 (1) - Ground

Z002 (B22) - Z078 (1)

Z002 (B22) - E036 (1)

Disconnect the Z070 the seat belt warning switch connector.

Disconnect the Z070 seat belt warning switch connector.

Z070 (1) - Ground

Z070 (2) - Ground

Z070 (1) - Z070 (2)

Disconnect the Z070seat belt warning switch connector.

Z003 (A31) - Z070 (1)

Disconnect the Z045 parking brake switch connector.

Disconnect the Z002 instrument cluster.

Z045 (1) - Z002 (B6)

Z045 (1) - Ground

DIAGNOSTICS(RHD) - POWER DOOR LOCKS

6 R - L Co-pilot Side Window Down Output

7 G - R Co-pilot Side Window Up Output

Inspect the central locking fuse (20 A) in driver side

2. CHECK HARNESS AND CONNECTOR (CENTRAL LOCKING FUSE - CENTRAL LOCKING

Disconnect the Z008 central locking controller assy B connector.

Central locking fuse (20 A) - Z008 (B3)

Z009 (A1) - Ground

Disconnect the H011 front door lock assy LH connector.

Z009 (A9) - H011 (9)

Z009 (A10) - H011 (10)

H011 (7) - Ground

Disconnect the Z009 central locking controller assy connector.

Remove the front door water-proof film LH.

Disconnect the D010 front door lock assy LH connector.

2. CHECK HARNESS AND CONNECTOR (CENTRAL LOCKING CONTROLLER ASSY - FRONT

Z009 (A2) - D010 (4)

Z009 (A3) - D010 (1)

3. CHECK HARNESS AND CONNECTOR (CENTRAL LOCKING FUSE - CENTRAL LOCKING

CONTROLLER ASSY )

Disconnect the Z009 central locking controller assy B connector.

central locking fuse (20 A) - Z008 (8)

VEHICLE MAINTENANCE

MAINTENANCE SCHEDULE............................................................. 05-1

PRECAUTION.............................................................................. 05-1

MAINTENANCE CONTENT AND SCHEDULE IN GENERAL

CONDITION................................................................................. 05-3

INSPECTION...................................................................................... 05-8

CHECK THE ELECTRICAL SYSTEM WORKING

CONDITION................................................................................. 05-8

CHECK THE BATTERY............................................................... 05-9

CHECK THE AIRBAG................................................................ 05-10

CHECK SEAT BELT .................................................................. 05-11

CHECK PARKING BRAKE, BRAKE PEDAL ............................. 05-13

CHECK DOOR LIMIT, DOOR LOCK AND DOOR HINGE ........ 05-14

CHECK AND CLEAN WINDSHIELD FLUME ............................ 05-16

CHECK ENGINE COMPARTMENT PARTS.............................. 05-17

CHECK TIMING BELT............................................................... 05-18

CHECK ACCESSORY BELT..................................................... 05-20

CHECK THE TIE ROD BALL HEAD AND DUST COVER......... 05-21

CHECK AND TIGHTEN THE CHASSIS BOLT REFER

TO THE PRESCRIBED TORQUE ............................................. 05-22

CHECK HEADLIGHTS............................................................... 05-23

CHECK WINDSHIELD WIPERS, CLEANING DEVICE ............. 05-24

CHECK CHASSIS...................................................................... 05-26

CHECK SUSPENSION COMPONENTS ................................... 05-27

CHECK SUSPENSION BALL JOINT AND DUST COVER........ 05-28

CHECK STEERING FLUID LEVEL............................................ 05-29

CHECK BRAKING SYSTEM...................................................... 05-30

CHECK THE BRAKE DISC, BRAKE DRUM AND BRAKE

FRICTION PLATE...................................................................... 05-31

CHECK TIRES........................................................................... 05-32

CHECK EXHAUST SYSTEM..................................................... 05-33

CHECK COOLANT LEVEL........................................................ 05-34

CHECK THE ENGINE OIL LEVEL (4G69) ................................ 05-35

CHECK THE ENGINE OIL LEVEL (ISF2.8)............................... 05-36

REPLACEMENT............................................................................... 05-37

REPLACE AIR FILTER ELEMENT............................................ 05-37

REPLACE AIR CONDITIONER FILTER ELEMENT.................. 05-38

REPLACE ENGINE OIL (4G69)................................................. 05-40

REPLACE OIL FILTER (4G69).................................................. 05-42

REPLACE ENGINE OIL (ISF2.8)............................................... 05-44

REPLACE OIL FILTER (ISF2.8) ................................................ 05-46

REPLACE SPARK PLUG (4G69) .............................................. 05-48

REPLACE FUEL FILTER ASSEMBLY (4G69) .......................... 05-50

REPLACE FUEL FILTER ELEMENT (ISF2.8)........................... 05-51

REPLACE COOLANT................................................................ 05-52

REPLACE BRAKE FLUID.......................................................... 05-54

REPLACE GEARBOX LUBRICATING OIL................................ 05-56

REPLACE REAR MAIN REDUCER GEAR OIL......................... 05-57

REPLACEMENT ........................................................................ 05-57

05

VEHICLE MAINTENANCE -

MAINTENANCE SCHEDULE

VEHICLE PRECAUTION

MAINTENANCE ATTENTION

05-1

1. SAFETY INFORMATION

(a) Maintenance project preparation.

• Operators shall wear labor insurance shoes, working gloves, goggles, etc if necessary.

• To ensure that the work site is ventilation and clean, tools and instruments are putted in good order,

keep a fire extinguisher when needed.

• Check the safety status of the instrument and equipment using, such as check lifting machine jack, etc.

• Check the safety operation condition of the vehicle driving, ensure that the maintenance can be carried

out smoothly.

(b) Notes in the maintenance process.

• Before driving into the Lift frame, ensure that there is enough distance between the vehicle bottom and

sides with Lift frame, avoid scratch.

• Before lifting the vehicle, ensure the vehicle weight does not exceed the lift rated load.

• When lifting the vehicle, you should select the correct lifting point.

• In the process of lifting vehicle, not allowed to start the engine and shift into gear when the driving

wheel touches the ground. Otherwise the operator and vehicle are in danger.

• Operator should strictly observe all safety rules and user rules in the maintenance process. Otherwise

the operator and vehicle are in danger.

• Replacement parts and consumption goods, to use the Beiqi Foton automobile Co. LTD. approved

products, to ensure the safety and performance of the vehicle.

• After the completion of maintenance, road test must be carried out. Special attention should be paid to

the braking system and the occupant protection system inspection.

• Vehicle should be cleared the failure messages in memory before transferred to the customer.

2. PLANNING ISSUES

(a) Planned maintenance interval, depends on the odometer or time interval, whichever comes first. Such

as the schedule shows.

(b) The next maintenance interval should be equal to the last maintenance interval.

(d) Some parts are particularly important in the maintenance objects. Hose if there is aging or damage

should be replaced immediately. Please note, rubber hose is aging with time, this causing swelling,

bruising or cracking.

(e) Once the off-road passing through sand, mud or water, please check the following parts, and according

to the conditions for maintenance or repair.

• Brake pad and brake drum.

• Brake pad and brake disc.

• Brake pipeline and rubber hose.

• Oil and working fluid used for transmission, transfer case and differential mechanism.

• Air Filter elements.

05-2 VEHICLE MAINTENANCE - MAINTENANCE SCHEDULE

MAINTENANCE CONDITION

1. IN DAILY CONDITIONS, THE VEHICLE NEEDS ACCORDING TO THE ORDINARY MAINTENANCE

PERIOD TO THE IMPLEMENTATION OF THE MAINTENANCE.

2. IF THE VEHICLE IS MAINLY IN THE FOLLOWING ANY ONE OR MORE SPECIAL CIRCUMSTANCES

DRIVING, SOME OF THE PROJECTS MUST BE IMPLEMENTED MAINTENANCE MORE FREQUENTLY

(REFER TO HARSH OPERATION CONDITION).

Road condition:

• Drive on rough, muddy or dissolve snow road.

• Drive on dusty road.

• Drive on saline road.

(b) Driving condition:

• Drag the tail car, use camping frame or roof supporter.

• Repeat within 8 kilometers of the short-range travel, and temperatures below 0 ℃ .

• Vehicle which long term to long distance running at idle or low speed, such as the police car, taxi or

house-to-house delivery truck.

• Often continuous running at very high speed over 2 hours (Traveling at a rate of 80% of the maximum

speed)

The Content Involves Behind “4g69” Is Gasoline Engine Code,"2.8”and “4jb1t” Are Diesel Engine

Codes.

05-3

MAINTENANCE CONTENT AND SCHEDULE IN GENERAL CONDI-

TION

4G69 GASOLINE ENGINE REGULAR INSPECTION AND REPAIR PARTS LIST:

The projects are made clear distance and time (by the month), Check whichever comes first.

I: Inspection, correction, or necessary replacement; R: Replacement, handling or lubrication; L: Lubrication;

Empty: N/A.

Interval (The odometer reading and the number of months of whichever comes first)

Month - 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48

Odometer

reading ×1000

km

The internal inspection of the engine compartment

Check belt for crack,

flying chip, wear, and

adjust its tension

1 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80

I I I I I I I I I

Engine timing belt R R R R R R R R

Check the crankcase

system is normal or not

(Including the crankcase

ventilation air filter

element)

I I I I

Replace the spark plugs R R R R

Check the radiator hoses

for damage, correct

connection

Check the engine

cooling fluid level

Replace engine cooling

fluid

Check whether the air

filter clogging or damage

Other iinspection

Chang

e the

oil

e

filter

General

Harsh

I I I I I I I I

I I I I I I I I I I I I I I I I

5000 kilometers for the first time, since then every 5000 km or 3 month intervals

The replacement mileage with general conditions of use

Repla

ce the

Replace the air filter I I I R I I I R I I I R I I I R

Check the engine idle

05-4 VEHICLE MAINTENANCE - MAINTENANCE SCHEDULE

ventilation hose

ISF2.8 SERIES DIESEL ENGINE PARTS OF PERIODIC INSPECTION AND

REPAIR LIST

Odomete

r reading

×1000

Check belt for crack, flying

chip, wear, and adjust its

tension

Check the engine cooling

fluid level

I I I I I I I I I I I I I I I I I

Check whether the air filter

clogging or damage

Other inspection

Replace

engine oil

Replace oil

diesel filter

Replace air

R Every 20,000 km or every 12 months

R Every 10,000 km

R 10,000 km for the first time, since then every 20,000 km or every 12 months

R 5,000 km, since then every 10000 km or every 6 months

Timing belt

Change every 80,000 km (drain the cooling liquid before disassembly, must use E049377000009 locating bolt in

Installation and adjustment, refer to maintenance manual)

05-5

4JB1T SERIES DIESEL ENGINE PARTS OF PERIODIC INSPECTION AND

I: Check the fluid level, tighten or adjust, replace if necessary; R: replace or lubricate; Empty: N/A.

Month — 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48

reading

×1000 km

tension.

Replace engine timing belt

R Every 100,000 km

ventilation control system

ventilation air filter element)

I Every 5,000 km or every 3 months

R Every 5,000 km or every 3 months

The replacement mileage with general condition

R 2,000 km, check for the first time, since then replace every 10,000 km

R 5,000 km for the first time, since then every 10,000 km or every 6 months

Check the engine idle I I I I I I I I I

05-6 VEHICLE MAINTENANCE - MAINTENANCE SCHEDULE

CHASSIS AND ELECTRICAL COMPONENTS OF PERIODIC INSPECTION AND

I:Check the fluid level, tighten or adjust, replace if necessary; R:replace or lubricate; Empty: N/A.I ★:Inspection

Chassis parts

Brake pedal and hand

brake

Brake lining and brake

drum

Brake pipe and brake hose I I I I I I I I I

Brake fluid (Including clutch

oil)

I I I I I I I I R I I I I I I I R

Power steering fluid I I I I I I I I I I I I I I I I

Manual transmission oil I I I R I I I R

Main reducer and

differential oil

Steering wheel, steering

linkage, steering

I I I R I R

Ball joint and dust cover I I I I I I I I I I I I I I I I

Front and rear suspension

Four wheel alignment I I I I

Tire and pressure I I I I I I I I I I I I I I I I

Drive shaft connected

components

Drive shaft sliding fork R R R R R R R R R R R R R R R R

Wheel bearing and ball pin

grease

I R I R I R I R

Exhaust pipe, silencer I I I I I I I I

Electric system

Light. horn I I I I I I I I I I I I I I I I

Air conditioning system and

refrigerant

SSRS Airbag

First inspection at 120 months after licensed, since than every 24 months

Battery I I I I I I I I I I I I I I I

Clutch pedal I I I I I I I I I I I I I I I I I

Wheel nut

Tighten the wheel nuts at the specified torque, check every 5,000 km or 1,000 km.

HARSH CONDITION MAINTENANCE PERIODIC TABLE

05-7

According to the driving conditions listed in the following table, maintain the project which should

be increase the maintenance frequency (project not listed refer to general condition maintenance

periodic table).

A-1:Driving on rough, muddy or dissolve snow sections

□ Check the brake friction lining and

□ Check the brake pads and brake disc

□ Check the brake line and the hose

□ Check the steering wheel, steering

linkage and gear box oil

□ Replace wheel bearing grease

□ Check front and rear suspension

Every 10,000 km or 6 months

Every 5,000 km or 3 months

The first 1, 000 km, then every 10, 000 km or 6 months

Every 20,000 km or 12 months

□ Tighten chassis and body connection

bolt and nut

A-2:Driving on much dust sections.

□ Check the air filter element

□ Check the brake linings and brake

B-1:Vehicle which long term to long distance running at idle or low speed, such as the police

car, taxi or house-to-house delivery truck

B-2:Often continuous running at very high speed over 2 hours (Traveling at a rate of 80% of the

maximum speed)

□ Replace differential gear oil

05-8 VEHICLE MAINTENANCE - INSPECTION

INSPECTION

CHECK THE ELECTRICAL SYSTEM WORKING CONDITION

• Check the brightness and working conditions of front combination lamps, fog lamp, turn signal

lamp, warning flashes, rear combination lamp, rear fog lamp, backup light and parking lamp.

• Check the working condition of the interior lighting.

• Check the working condition of buzzer, control unit, center tunnel, all switch in dashboard and

horn.

• Check the condition of power window, exterior mirror and central control door lock.

• Check the radio reception conditions and interference immunity, and check the speaker.

CHECK THE BATTERY

05-9

• Keep the battery cable clean and firm installation is benefit to the battery using performance

and life.

• When fastening the battery cable, pay attention to the battery cable installed correctly and

firmly. Otherwise may affect appliances use and battery life.

1. OPEN THE BATTERY CABLE COVER.

2. CHECK THE BATTERY.

(a) Check the battery shell and cable whether they are

corrosion or fracture. Replace it if necessary.

(b) Shaking battery cable to check whether installation is

firm.

Disconnect the battery negative cable first. Tighten

battery positive cable. Reinstall the fastening battery

negative cable nut.

3. CHECK THE BATTERY POWER DISPLAY LAMP

COLOR.

(a) If it displays blue, that indicate the battery is good.

(b) If it displays white, that indicate the battery is in low level,

charge the battery.

shortage, replace the battery.

05-10 VEHICLE MAINTENANCE - INSPECTION

CHECK THE AIRBAG

• No paste or add items on Airbag shell, forbidden to damage or hinder the airbag shell. To

ensure the normal function of the airbag, remind the user.

• Airbag housing is only allowed to use a dry or slightly damp cloth to clean.

CHECK DRIVER SIDE AIRBAG

1. DRIVER SIDE AIRBAG IS LOCATED IN THE

CENTRAL POSITION OF THE STEERING WHEEL,

VISUAL INSPECTION OF PLASTIC SHELL IS INTACT.

CHECK ASSISTANT DRIVER SIDE AIRBAG

1. ASSIATANT DRIVER SIDE AIRBAG IS LOCATED ON

THE GLOVE BOX OF THE VICE CAB, VISUAL

INSPECTION OF PLASTIC SHELL IS INTACT.

CHECK SEAT BELT

05-11

• Check the safety belt completely pulled out of the belt automatic rewind device.

• Check the safety belt is dirty. Clean with neutral soap liquid if necessary.

1. CHECK THE BELT STRAP FOR THE FOLLOWING

DAMAGE, REPLACE IT IF NECESSARY.

(a) The seat belt fracture, torn or abrasion.

The webbing edge is torn down.

Traces of cigarette burns.

One side of the webbing edge is deformation or the seat

belt edge is wavy.

05-12 VEHICLE MAINTENANCE - INSPECTION

2. CHECK THE SEAT BELT LOCK.

Force quickly pulled down the safety belt to check

whether the safety belt lock locking sensitive,replace it,

if can’t be lock fast.

3. CHECK ORIENTED BUCKLE AND LOCK TONGUE.

(a) Check oriented buckle shell for deformation, shedding

and dehiscence, replace it if necessary.

Check the lock tongue for deformation and dehiscence,

replace it if necessary.

Insert the lock tongue into the oriented buckle. Check the

lock tongue can be locked, after cross-checks more than

5 times, the lock tongue once failed to lock in the

oriented buckle, should be replaced.

05-13

CHECK PARKING BRAKE, BRAKE PEDAL

1. CHECK THE PARKING BRAKE, BRAKE PEDAL.

(a) Check the parking brake is flexible, handle pull strength

is normal or not, whether the cable is worn, repair it if

necessary.

Check whether the brake pedal is loose, whether the free

stroke is normal, repair it if necessary.

Free stroke:1 ~ 3 mm

2. ROAD TEST, CHECK THE WORK CONDITION OF THE PARKING BRAKE AND BRAKE PEDAL,

MAINTAIN IT IF NECESSARY.

05-14 VEHICLE MAINTENANCE - INSPECTION

CHECK DOOR LIMIT, DOOR LOCK AND DOOR HINGE

1. CHECK THE DOOR LIMIT.

Check the door limit is in good work condition. Apply

grease to the activity place if lacking of the lubrication.

2. CHECK THE DOOR LOCK, INSURANCE BUTTON,

CHILD SAFETY LOCK.

Lock the door, check the insurance button works normal

Press down the insurance button, then close the door,

the insurance button will upspring to prevent false lock

the door.

Switch the child safety lock from OFF to ON. The child

safety lock locking. In this case the door can only be

opened from the outside.

3. CHECK THE LOCK CORE.

Insert the key into the lock.

Rotate the key left and right, the lock core should be able

to rotate smoothly.

05-15

4. CHECK THE ENGINE HATCH AND REAR HATCH.

(a) Continuously open and close the engine hatch to check

whether the hinge catching, Apply grease to the activity

place if lacking of the lubrication.

Check the rear hatch closed, check the rear hatch look.

Continuously open and close the rear hatch to check

whether the hydraulic pole catching. Apply grease to the

activity place if lacking of the lubrication.

05-16 VEHICLE MAINTENANCE - INSPECTION

CHECK AND CLEAN WINDSHIELD FLUME

1. OPEN THE ENGINE HATCH.

2. CHECK WINDSHIELD FLUME WHETHER HAS

IMPURITIES OR CLOGGED.

3. CHECK THE SEALING STRIP FOR DAMAGE.

4. CLOSE THE ENGINE HATCH.

05-17

CHECK ENGINE COMPARTMENT PARTS

• Troubles once detected should be checked immediately

• Replenish loss fluid timely, exclude leakage in pipes.

2. CHECK THE FOLLOWING CATHETER, HOSE AND LAYUP FOR LEAKS, DAMAGE AND AGING.

CHECK THE INTERSPACE BETWEEN THE PIPELINE AND THE BODY IS REASONABLE.

ADJUST OR REPLACE IF NECESSARY.

(a) Fuel system.

(b) Air conditioning system pipeline and cooling system pipeline.

05-18 VEHICLE MAINTENANCE - INSPECTION

CHECK TIMING BELT

1. TURN THE IGNITION SWITCH OFF.

2. REMOVE THE RETAINING BOLT ON THE TIMING

BELT FRONT COVER. TAKE DOWN THE TIMING

BELT FRONT COVER.

3. CHECK THE TIMING BELT HAS THE FOLLOWING SITUATION, REPLACE IT IF NECESSARY:

• Water or grease adhere to the timing belt can reduce the services life of the belt. If the timing

belt with oil and heavy polluted, do not wash, need to change a new one.

• If the timing belt with traces of oil pollution, should check engine if there is oil leakage.

Inspect the timing belt back rubber for signs of aging and

glistening.

Cracks and stripping in the canvas.

Cracks in the back rubber.

Cracks in the grooves.

Cracks in the side of the belt.

Inspect the timing belt for abnormal abrasion in the side

of the belt.

Timing belt for abnormal abrasion.

Teeth missing from the belt.

05-19

4. INSTALL THE TIMING BELT FRONT COVER,

TIGHTEN BOLTS.

Torque:18 ~ 26N•m

05-20 VEHICLE MAINTENANCE - INSPECTION

CHECK ACCESSORY BELT

2. OPEN THE ENGINE HATCH.

3. CHECK THE ACCESSORY BELT WHETHER THERE

IS A FRACTURE, AGING, ETC. REPLACE IT IF

NECESSARY.

• Water or grease adhere to the belt can reduce the services life of the belt. If the belt with oil and

heavy polluted, do not wash, needs to change a new one.

• If the belt with traces of oil pollution, should check engine if there is oil leakage.

05-21

CHECK THE TIE ROD BALL HEAD AND DUST COVER

1. LIFT THE VEHICLE.

2. SLOSHING THE TIE ROD, SHOULD FEEL NO GAP.

3. CHECK THE TIE ROD BALL HEAD FIXED NUT IS

FIRMLY.

4. CHECK THE TIE ROD DUST COVER AND BALL

HEAD RUBBER FOR DAMAGE. IF THERE IS ANY

DAMAGE, REPLACE IT WITH A NEW ONE.

05-22 VEHICLE MAINTENANCE - INSPECTION

CHECK AND TIGHTEN THE CHASSIS BOLT REFER TO THE PRE-

SCRIBED TORQUE

Pay attention to prevent dust, sand and other debris falling into the eyes when looking up to the

chassis.To tighten the chassis bolts do wear a helmet and gloves and other safety measures.

1. TURN OFF ALL ELECTRICAL APPLIANCES AND IGNITION SWITCH.

2. LIFT THE VEHICLE.

3. CHECK ALL CHASSIS FASTENING BOLTS AND NUTS FOR TIGHTNESS AND CORROSION.

4. RE-TIGHTEN ALL FASTENING BOLTS AND NUTS REFER TO SPECIFIED TORQUE.

05-23

CHECK HEADLIGHTS

1. PREPARATION FOR HEADLIGHTS INSPECTION:

(a) Park vehicle on a flat road.

(b) The driver sitting in the car (or with weight 73 kg), and more than half of the fuel store in the fuel tank.

(d) Headlight internal structure normal.

2. CHECK THE HEADLIGHTS:

(a) Check the headlight assembly for damage and replace if necessary.

(b) Test headlight function. Bulbs burnt out should be replaced. Headlight regulating function is normal or

not.

(d) If the headlight irradiation deviates from the normal range, required to adjust the headlight. (Refer to

“Chapter 64 Lighting-LF combination lamp assembly, adjustment”)

05-24 VEHICLE MAINTENANCE - INSPECTION

CHECK WINDSHIELD WIPERS, CLEANING DEVICE

1. CHECK THE WINDSHIELD WIPER BLADE LIMIT POSITION:

• Check the wiper blade should be located in the rest position, adjust if necessary.

• Wiper arm tightening torque:18 ~ 21N•m.

The driver's side.

• The distance between the wiper blade rubber and the

lower edge of the windscreen is 30mm.

• If necessary, move and adjust the wiper arm.

(b) The front passenger side.

lower edge of the windscreen is 45mm。

2. REPLACE WIPER BLADE.

(a) Place the wiper arm in the maintenance position. Push

the locking button of the wiper blade. Remove the wiper

blade down.

(b) Install wiper blade. Make sure locking button located in

the lock position.

a short-term, stop the windshield wipers back at the

automatic stop position.

3. CHECK THE WINDSHIELD WASHER FLUID.

(a) The windshield washer fluid level should be apart from

the opening about 10cm, add if inadequate.

The windshield washer fluid is consumable liquid. Please

check regularly.

05-25

4. Check the windshield spray.

(a) The washer fluid sprays on windshield within the range

shown in the illustration.

If the point which the washer fluid sprays on windshield is

not in right position, adjust washer nozzle.

05-26 VEHICLE MAINTENANCE - INSPECTION

CHECK CHASSIS

2. CHECK THE FUEL LINE, BRAKE FLUID LINE FOR LEAKS.

3. CHECK THE BOTTOM COVER, WHEEL COVER AND SIDE BEAM IF THERE IS DAMAGE.

4. VISUAL CHECK THE EXHAUST PIPE LIFTING LUG FOR AGEING AND INSTALLATION FIRMLY.

05-27

CHECK SUSPENSION COMPONENTS

2. CHECK ALL CONNECTING BUSHING FOR AGING OR DAMAGE.

3. TIGHTEN ALL CONNECTING BOLTS AND NUTS BY SPECIFIED TORQUE.

4. CHECK EACH CONNECTING PARTS FOR DEFORMATION AND CRACK.

5. CHECK SHOCK ABSORBER FOR OIL LEAKAGE. CHECK DUST COVER FOR DAMAGE.

05-28 VEHICLE MAINTENANCE - INSPECTION

CHECK SUSPENSION BALL JOINT AND DUST COVER

1. CHECK UPPER ARM BALL JOINT DUST COVER FOR

DAMAGE. IF THERE IS ANY DAMAGE, REPLACE IT

WITH A NEW ONE.

2. CHECK LOWER ARM BALL JOINT DUST COVER FOR

05-29

CHECK STEERING FLUID LEVEL

1. PARK VEHICLE ON A FLAT ROAD.

2. TURN IGNITION SWITCH OFF.

3. TURN FRONT WHEELS TO STRAIGHT POSITION.

4. OPEN THE ENGINE HATCH.

5. UNSCREW POWER STEERING RESERVOIR FILLER

CAP.

6. CHECK THAT THE FLUID LEVEL IS WITHIN THE

RANGE OF MAX AND MIN, ADJUST THE FLUID IF

Steering fluid:ATF- Ⅲ

7. TIGHTEN THE POWER STEERING RESERVOIR

FILLER CAP.

8. CLOSE THE ENGINE HATCH.

05-30 VEHICLE MAINTENANCE - INSPECTION

CHECK BRAKING SYSTEM

• Only use the brake fluid Foton approved.

• Brake fluid can not mixed with other liquid, otherwise it may damage the braking system line

and endanger vehicle.

• Decide whether to add brake fluid according to the wear pattern of braking friction plate.

2. CHECK THE BRAKE FLUID RESERVOIR LEVEL.

(a) When braking friction plate wear close to the limit, brake fluid level should be partial to the lowest line.

(b) When braking friction plate wear little, brake fluid level should be partial to the highest line.

3. CHECK THE FOLLOWING PARTS WHETHER HAVE DAMAGE AND LIQUID LEAKAGE:

(a) Brake master cylinder.

(b) Brake booster.

(d) Braking line.

4. CHECK THE CLEARANCE OF BRAKE HOSE AND BODY, IT SHOULD BE APPROPRIATE. CHECK

BRAKE HOSE IF IT IS ABRADED, CHECK WHETHER BRAKE LINE INTERFACE AND FIXED

INSTALLATION IS FIRMLY.

05-31

CHECK THE BRAKE DISC, BRAKE DRUM AND BRAKE FRICTION

PLATE

If the brake disc, brake drum and brake friction plate thickness wear to limit, must inform the customer,

replace it.

1. CHECK FRONT BRAKE DISC AND THE BRAKE FRICTION PLATE.

(a) Remove front wheel. (Refer to “Chapter 33 tire and wheel - front tire and wheel, replacement”)

(b) Measuring braking friction plate (without rear panel) and

brake disc thickness.

• Standard thickness for brake friction plate (without

rear panel) is: 12mm, limit thickness is: 2mm.

• Standard thickness for brake disc is: 22mm, limit

thickness is: 21mm.

2. CHECK THE REAR BRAKE DRUM AND BRAKE FRICTION PLATE.

(a) Remove rear wheel.

brake drum thickness.

rear panel) is: 7.5mm, limit thickness is: 2.5mm.

• Standard thickness for brake drum is: Φ295mm, limit

thickness is: Φ296mm.

Install the rear wheel (Refer to “Chapter 33 tire and wheel - front tire and wheel, replacement”)

05-32 VEHICLE MAINTENANCE - INSPECTION

CHECK TIRES

When found tire wear to limit or damaged which affect the safe driving, must inform the customer,

change the tire.

1. CHECK THE TIRE ROLLING SURFACE AND SIDE WALL IS DAMAGE OR FOREIGN BODY,

CHECK SIDE WALL IS LOOSE POROUS, INCISION AND FOREIGN BODY PIERCING.

2. CHECK WHETHER THE TIRE ROLLING SURFACE WEAR IS UNILATERAL, IF UNILATERAL

WEAR IS SERIOUS, NEED TO ADJUST BY FOUR-WHEEL LOCATION.

3. CHECK THE TIRE TREAD DEPTH (INCLUDING

SPARE TIRE), ENSURE TREAD GROOVE DEPTH

THAN WEAR MARK THICKNESS, THE SIDE OF THE

TIRE TRIANGLE WEAR MARK MUST NOT WEAR

OUT.

The minimum tread depth is: 1.6mm.

4. Check and adjust tire inflation pressure (including spare tire):

wheel specification Front wheel Rear wheel Spare wheel

195R15C-106R 350 kPa 400 kPa 400 kPa

05-33

CHECK EXHAUST SYSTEM

In the exhaust system operation, pay attention to prevent scalding.

2. CHECK FRONT AND REAR EXHAUST PIPE, THE SILENCER, THE OXIDATION CATALYST SHELL

IF THERE IS ANY BREAKAGE.

3. CHECK IF THE EXHAUST SYSTEM CONNECTION BETWEEN COMPONENTS LEAKS.

4. CHECK THE LIFTING LUGS WHETHER AGEING OR FRACTURE.

05-34 VEHICLE MAINTENANCE - INSPECTION

CHECK COOLANT LEVEL

• In the cooling system operation, pay attention to prevent water and heat steam scalding.

• Can only use the cooling fluid Foton approved.

2. WAIT UNTIL THE ENGINE COOLING TO ROOM TEMPERATURE.

3. OPEN THE ENGINE HATCH.

4. CHECK COOLANT LEVEL LINE, LIQUID LEVEL

SHOULD BE IN MIN AND MAX (ENGINE IS ALREADY

COOLING DOWN).

5. PUT DOWN THE ENGINE HATCH.

05-35

CHECK THE ENGINE OIL LEVEL (4G69)

1. PARK THE VEHICLE ON A FLAT ROAD.

2. PREHEAT THE ENGINE TO NORMAL OPERATING TEMPERATURE.

3. TURN THE IGNITION SWITCH OFF.

4. WAIT FOR ABOUT 3 MINUTES.

5. OPEN THE ENGINE HATCH.

6. PULL OUT OIL SCALE SLOWLY.

7. CHECK THE ENGINE OIL LEVEL, LEVEL SHOULD

BE IN OIL SCALE MARK RANGE.

8. CHECK THE ENGINE OIL, IF OIL IS DIRTY OR THINNED, DEBUGGING AND REPLACE ENGINE

OIL.

9. PUT BACK THE OIL SCALE.

10. PUT DOWN THE ENGINE HATCH.

05-36 VEHICLE MAINTENANCE - INSPECTION

CHECK THE ENGINE OIL LEVEL (ISF2.8)

3. TURN OFF THE IGNITION SWITCH.

BE IN THE SCOPE OF OIL SCALE MARK RANGE.

REPLACEMENT

05-37

REPLACE AIR FILTER ELEMENT

1. REPLACE AIR FILTER ELEMENT.

(a) Remove the 4 air filter fixed buckle from the vehicle

bottom.

(b) Open the air filter lower cover, remove the air filter.

Air filter is made of paper material, if necessary, can use the

high pressure air gun to clean air filter from internal to

external. don't rinse the air filter by water.

2. INSTALL AIR FILTER LOWER COVER AND FASTEN

THE BUCKLE.

When install air filter lower cover, ensure that install air

filter in the right direction, then fasten the buckle.

05-38 VEHICLE MAINTENANCE - REPLACEMENT

REPLACE AIR CONDITIONER FILTER ELEMENT

1. REMOVE THE GLOVE BOX.

2. REMOVE THE AIR FILTER DECORATIVE COVER.

(a) Press on both sides of the lock. take down the decorative

cover.

3. EXTRACT AIR-CONDITIONING FILTER.

4. INSTALL AIR-CONDITIONING FILTER.

Install the air conditioning filter in accordance with the marked

direction at filter lateral.

05-39

5. INSTALL THE AIR FILTER DECORATIVE COVER,

AND LOCK INTO TO THE CORRECT POSITION.

6. INSTALL THE GLOVE BOX.

05-40 VEHICLE MAINTENANCE - REPLACEMENT

REPLACE ENGINE OIL (4G69)

1. START ENGINE AND ENSURE ENGINE COOLANT TEMPERATURE WITHIN 80 ~ 90 ℃ .

2. TURN IGNITION SWITCH OFF AND WAIT FOR 10 MINUTES.

3. OPEN ENGINE COMPARTMENT COVER.

(a) Loosen the driver seat clamp.

(b) Turn over the driver seat and open engine compartment

4. OPEN OIL FILLER CAP.

5. RAISE AND SUPPORT VEHICLE.

6. REMOVE OIL DRAIN PLUG.

(a) Drain engine oil.

• The engine oil maybe hot, be careful, avoid personal

injury.

• Prolonged and repeated contact with engine oil will

cause the skin fat to be removed, resulting in dry

skin, allergies and dermatitis. In addition, used

engine oil contains potentially harmful pollutants

which may cause skin cancer. Therefore, the skin

must be protected in appropriate methods and with

cleaning equipment.

• Using a special container, collect or dispose used oil

as required.

7. REPLACE WITH NEW DRAIN PLUG GASKET AND

TIGHTEN PLUG.

Torque: 34 ~ 45 N.m

05-41

8. LOWER VEHICLE.

9. FILL ENGINE OIL.

Engine oil: 4 L

The Specification of engine oil allowed only is 10W-30 ,15W-40 or SL level as well as 5W-30 (GB11121)

oil used in winter of North China.

10. INSTALL OIL FILLER CAP.

11. PARK THE VEHICLE ON LEVEL GROUND AND START ENGINE UNTIL IT IS WARM. CHECK AND

ENSURE THERE IS NO OIL LEAKAGE.

12. TURN IGNITION SWITCH OFF AND WAIT FOR 10 MINUTES.

13. CHECK OIL LEVEL.

(a) Pull out oil dipstick and wipe it clean .

(b) Insert oil dipstick and pull it out to ensure oil level is

within the range as shown in the figure.

14. PUT DOWN DRIVER SEAT AND LOCK IT.

05-42 VEHICLE MAINTENANCE - REPLACEMENT

REPLACE OIL FILTER (4G69)

Without special circumstances, the oil filter should be replaced with engine oil to avoid oil pollution

and keep engine normal operation.

2. OPEN ENGINE COMPARTMENT COVER.

3. OPEN OIL FILLER CAP.

4. RAISE AND SUPPORT VEHICLE.

5. DRAIN ENGINE OIL. (Refer to “Chapter 18A lubrication - engine oil, replacement”)

6. USING SPECIAL TOOL TO REMOVE OIL FILTER.

7. CLEAN THE CONNECT SURFACE OF OIL FILTER AND OIL FILTER BRACKET.

8. APPLY OIL TO O-RING OF NEW OIL FILTER.

05-43

9. TIGHTEN OIL FILTER BY HAND UNTIL O-RING TOUCHES

OIL FILTER BRACKET. USE A SUITABLE TOOL TO

TIGHTEN OIL FILTER.

Torque: 13 ~ 15 N•m

10. TIGHTEN DRAIN PLUG.

Torque: 34 ~ 45 N•m

11. LOWER VEHICLE.

12. OPEN OIL FILLER CAP AND FILL ENGINE OIL TO SPECIFIED LEVEL.

13. INSTALL OIL FILLER CAP.

14. PARK THE VEHICLE ON LEVEL GROUND AND START ENGINE UNTIL IT IS WARM.

15. CHECK AND ENSURE THERE IS NO OIL LEAKAGE.

16. TURN THE IGNITION SWITCH OFF AND WAIT FOR 10 MINUTES.

17. PULL OUT OIL DIPSTICK TO ENSURE OIL LEVEL IS BETWEEN “MAX” MARK AND “MIN”

MARK.

05-44 VEHICLE MAINTENANCE - REPLACEMENT

REPLACE ENGINE OIL (ISF2.8)

1. PARK VEHICLE IN LEVEL ROAD, SLOWLY PULL OUT OIL DIPSTICK, AND CHECK OIL LEVEL,

OIL LEVEL MUST BE LOCATED WITHIN THE OIL DIPSTICK MARK.

2. CHECK OIL WITHOUT EXCESSIVE POLLUTION, NO PETROL AND LIQUID MIXED. THERE MUST

HAVE ENOUGH CONCENTRATIONS AND VISCOSITY.

3. START ENGINE AND ENSURE ENGINE COOLANT TEMPERATURE WITHIN 80 ~ 90 ℃ .

5. LIFT THE VEHICLE.

The engine oil maybe hot, be careful, avoid personal injury.

7. USING A SPECIAL CONTAINER, COLLECT OR DISPOSE USED OIL AS REQUIRED.

8. REPLACE A NEW DRAIN PLUG GASKET AND TIGHTEN

DRAIN PLUG.

Torque: 35 ~ 45 N.m

9. LOWER VEHICLE.

10. FILL ENGINE OIL.

Engine oil: 5 ~ 5.5 L

The specification of engine oil is CH - 4 level or above (15W-40 in summer and 15W-30 in winter).

11. INSTALL OIL FILLER CAP.

12. PARK THE VEHICLE ON LEVEL GROUND AND START ENGINE UNTIL IT IS WARM.

13. CHECK OIL FILTER OR OTHER PART AND ENSURE THERE IS NO OIL LEAKAGE.

14. TURN IGNITION SWITCH OFF.

05-45

15. AFTER 8 ~ 10 MINUTES, PULL OUT OIL DIPSTICK TO

ENSURE OIL LEVEL IS BETWEEN “MAX” MARK AND

“MIN” MARK.

05-46 VEHICLE MAINTENANCE - REPLACEMENT

REPLACE OIL FILTER (ISF2.8)

2. OPEN ENGINE COMPARTMENT COVER AND THEN OPEN OIL FILLER CAP.

3. RAISE AND SUPPORT THR VEHICLE.

4. REMOVE OIL DRAIN PLUG AND DRAIN ENGINE OIL.

Be careful, the engine oil maybe hot.

5. USING A SPECIAL CONTAINER, COLLECT OR DISPOSE USED OIL AS REQUIRED.

6. USING SPECIAL TOOL, REMOVE OIL FILTER.

7. CLEAN THE SURFACE BETWEEN OIL FILTER AND OIL FILTER BRACKET.

9. FILL CLEAN OIL INTO OIL FILTER.

05-47

10. TIGHTEN OIL FILTER BY HAND UNTIL O-RING TOUCHES

OIL FILTER BRACKET. USING SUITABLE TOOL, TIGHTEN

OIL FILTER.

Torqure: 25 ~ 30 N•m

11. TIGHTEN DRAIN PLUG.

12. LOWER VEHICLE.

13. FILL ENGINE OIL TO SPECIFIED LEVEL.

14. INSTALL OIL FILLER CAP.

15. START ENGINE AND RUN FOR 5 MINUTES WITH THE VEHICLE PARKING ON LEVEL GROUND.

16. CHECK OIL FILTER AND ENSURE THERE IS NO OIL LEAKAGE.

17. TURN IGNITION SWITCH OFF.

18. AFTER 8 ~ 10 MINUTES, PULL OUT OIL DIPSTICK TO

05-48 VEHICLE MAINTENANCE - REPLACEMENT

REPLACE SPARK PLUG (4G69)

1. TURN IGNITION SWITCH OFF.

Loosen the driver seat clamp.

Turn over the driver seat and open engine compartment

3. REMOVE AIR INTAKE HOSE. (Refer to “Chapter 14A intake air - intake air hose, replacement”)

4. REMOVE SPARK PLUG WIRE.

(a) Pull out spark plug wire by slightly turning.

5. REMOVE SPARK PLUG..

(a) Using special socket tool ,remove spark plug.

(b) Take spark plug out.

6. INSTALL SPARK PLUG.

(a) Using special socket tool, tighten spark plug.

Torque: 25 N•m

Install the spark plug, tightening torque to meet the

technical specifications of Foton. Don’t screw it too loose

or too tight to avoid leakage or damage to the spark plug

and Spark plug holes.

05-49

7. INSTALL SPARK PLUG WIRE.

(a) Place spark plug wire on the corresponding position

according to the sequence as shown on igniton module.

(b) Install spark plug wire.

A click can be heard to confirm the spark plug wire is

installed properly.

8. INSTALL INTAKE HOSE. (Refer to “Chapter 14A intake air- intake air hose, replacement”)

9. PUT DOWN DRIVER SEAT AND LOCK IT.

10. START ENGINE AND CONFIRM IT IS IN GOOD CONDITION.

05-50 VEHICLE MAINTENANCE - REPLACEMENT

REPLACE FUEL FILTER ASSEMBLY (4G69)

1. RELEASE FUEL PRESSURE. (Refer to “Chapter 12A fuel - fuel system, fuel system pressure

release process”)

2. RAISE AND SUPPORT THE VEHICLE.

3. REMOVE THE FUEL FILTER.

(a) Disconnect quick connector from both sides of fuel filter.

• Depress the tab on both sides of quick connector,

slide out the connector slowly. Do not pull excessively

to prevent quick connector from damaging.

• Keep the connecting portion clean and avoid damage

and foreign materials, cover them completely with

plastic bags or something similar.

Loosen fuel filter mounting band retaining bolt.

Remove fuel filter.

4. INSTALL NEW FUEL FILTER.

Follow the arrow on the fuel filter when install the fuel filter.

(a) Install fuel filter and tighten the mounting band bolt.

Torque: 21 ~ 25 N•m

(b) Connect both sides quick connector.

Connect fuel tube quick connectors until a click was heard,

then pull the quick connector to check quick connectors

are secured.

5. LOWER THE VEHICLE.

6. CHECK FUEL LINES.

(a) When ignition switch is on, fuel pump will apply fuel pressure to fuel lines. inspect if there is fuel

leakage from pipe connection.

(b) Start engine and rev it up and check there are no fuel leakage at the fuel system tube and hose

connections.

05-51

REPLACE FUEL FILTER ELEMENT (ISF2.8)

1. DIESEL FILTER ASSY DESCRIPTION.

(a) ISF2.8 Engine have a maintainable cylinder-type diesel

filter which contains a integrated WIF sensor and fuel

heater. The diesel filter is located between fuel pump and

tank.

2. RELEASE FUEL PRESSURE. (Refer to “Chapter 12B fuel - fuel system, fuel system pressure

3. REPLACE DIESEL FILTER. (Refer to CUMMINS ISF SERIES ENGINE SERVICE MANUAL )

• If draining water is required frequently, it means that fuel is not qualified or there is water in fuel

tank. Please drive the vehicle to service station for repair.

• In order to ensure fuel clean, in strict accordance with maintenance requirement to operate fuel

filter sechudle maintenance. Replacement cycle: 15,000 km.

4. CHECK AFTER INSTALLATION.

(a) After installation, turn ignition switch on and check the fuel gauge’s conditions in instrument panel. Start

engine and check there are no fuel leakage at the diesel system tube and hose connections.

05-52 VEHICLE MAINTENANCE - REPLACEMENT

REPLACE COOLANT

Do not open the reservior cap when the engine is hot. Coolant temperature should be reduced to 50 ° C

(120 ° F) below, remove the radiator cap. Otherwise, the cooling liquid or vapor emitting heat may

cause personal injury.

1. COOL ENGINE TO NORMAL INDOOR TEMPERATURE.

2. OPEN RESERVOIR CAP TO RELEASE PRESSURE

BY TURN IT COUNTERCLOCKWISE.

Wrap a thick cloth around the reservior cap. Slowly turn it a

quarter of a turn to release built-up pressure. Then turn it all

the way.

3. RAISE AND SUPPORT THE VEHICLE.

4. REMOVE RADIATOR DRAIN PLUG AND DRAIN

COOLANT.

Using a suitable container, hold the coolant. if not to be

used, dispose of them according to the regulations .

5. CHECK ENGINE COOLANT.

(a) Check drained engine coolant for contaminants such as rust, corrosion or discoloration.

(b) If contaminated, flush the engine cooling system.

6. FLUSH ENGINE COOLING SYSTEM.

(a) Install and tighten radiator drain plug.

Always clean coolant drain plug and replace O-ring with new one.

(b) Fill radiator and reservoir with water and reinstall reservior cap.

(d) Rev the engine two or three times under no-load.

(e) Stop the engine and wait until it cools down.

(f) Drain water from the cooling system.

(g) Repeat the precedure above until clear water begins to drain from radiator

7. ADD ENGINE COOLANT.

(a) Install radiator drain plug.

(b) Slowly fill the radiator with ”FOTON Long-effective coolant”.

Standard volume: 13.5 L

fill the coolant.

05-53

(d) Install the radiator cap and coolant reservoir cap.

(e) Start and warm the engine until the cooling fan at high speed.

(f) Stop the engine and check the coolant level.

(g) Check the coolant level in reservoir. If necessary, add the coolant to specified position.

The air in cooling system can be bled automatically.

05-54 VEHICLE MAINTENANCE - REPLACEMENT

REPLACE BRAKE FLUID

Brake fluid damages painted surfaces and irritates skin. If brake fluid is spilled on any painted surfaces

or skin, wash it off immediately with water.

1. FILL THE FLUID RESERVOIR WITH BRAKE FLUID.

Brake fluid: DOT 3 or DOT 4 brake fluid

Brake fluid damages painted surfaces and irritates skin. If

brake fluid is spilled on any painted surfaces or skin, wash

it off immediately with water.

2. BLEED BRAKE MASTER CYLINDER ASSY.

(a) Tighten tubing joint nut fitting brake tube to brake master

cylinder.

If the brake cylinder has been removed or if the brake fluid

reservoir assy becomes empty, bleed the air from the

master cylinder assy.

Rapidly depress the brake pedal and hold it.

Loosen tubing joint nut separately, bleed the air and

fluid,then tighten tubing joint nut immediately.

Repeat steps (b) and (c) 3 or 4 times until all the air in the

fluid has been bled out.

05-55

3. BLEED BRAKE LINE.

(a) Connect the hose to the bleeder plug of rear wheel brake

(b) Rapidly depress the brake pedal several times, then

loosen the bleeder plug.

then release the brake pedal.

Torque: 9 ~ 11 N•m

(d) Repeat steps (b) and (c) 3 or 4 times until all the air in the

Connect the hose to the bleeder plug of front disk brake

caliper.

Rapidly depress the brake pedal several times, then

When brake fluid stops flowing, tighten the bleeder plug,

Torque: 8 ~ 13 N•m

Repeat steps (f) and (g) 3 or 4 times until all the air in the

Repeat the above procedures to bleed the air out of the

brake line for each wheel.

Sequence Of Brake Line Bleeding(sit in driver seat): Rear

RH - Rear LH - Front RH - Front LH

4. CHECK FLUID LEVEL IN BRAKE FLUID RESERVOIR.

(a) Check the fluid level and fill the fluid reservoir with brake

fluid if necessary.

05-56 VEHICLE MAINTENANCE - REPLACEMENT

REPLACE GEARBOX LUBRICATING OIL

1. REMOVE DRAIN PLUG BY DOWNSIDE AND DRAIN

TRANSMISSION FLUID COMPLETELY. TIGHTEN DRAIN

PLUG.

Torque: 35 ~ 45 N•m

• Keep vent plug unblocked and loosen the filler plug

before draining fluid. In order to drain transmission

fluid completely, drain the fluid when it is hot.

• Use special container for transmission fluid when

draining.

2. REMOVE FILLER PLUG AND FILL TRANSMISSION

FLUID. THEN TIGHTEN FILLER PLUG.

CAUTIONN

• According to demand, fill transmission fluid GL- 4

75W/90 for 2.0 L.

• Do not mix different kind of transmission fluid.

• Parking the vehicle on the levelground when

checking fluid level. The fluid level must be flush

with lower edge of oil filler.

05-57

REPLACE REAR MAIN REDUCER GEAR OIL

1. PRECAUTION. (Refer to “Chapter 34 axle and propeller shaft - rear axle, precaution”)

2. DRAIN FINAL DRIVE OIL.

(a) Remove the vent plug.

Using a wrench, remove the drain plug.

Drain the final drive oil completely.

Use a container to collect final drive oil when performing

this operation.

Using a wrench, install the drain plug.

GASOLINE ENGINE CONTROL SYSTEM.....................................11A-1

PRECAUTION............................................................................ 11A-1

SYSTEM OVERVIEW................................................................ 11A-2

INTRODUCTION TO SYSTEM FUNCTION .............................. 11A-6

BASIC PRINCIPLE .................................................................... 11A-8

MAIN COMPONENTS ............................................................. 11A-13

SYSTEM COMPONENTS DESCRIPTION.............................. 11A-14

ENGINE CONTROL MODULE (ECM) ...........................................11A-15

PRINCIPLE .............................................................................. 11A-15

REPLACEMENT ...................................................................... 11A-16

ENGINE COOLANT TEMPERATURE SENSOR...........................11A-18

PRINCIPLE .............................................................................. 11A-18

OVERHAUL ............................................................................. 11A-19

THROTTLE BODY .........................................................................11A-21

THROTTLE BODY CLEANING................................................ 11A-21

THE FIXED SPEED ADJUSTING SCREW (SAS)

ADJUSTMENT......................................................................... 11A-22

BASIC IDLE SPEED ADJUSTMENT....................................... 11A-23

OVERHAUL ............................................................................. 11A-24

IDLE AIR CONTROL MOTOR .......................................................11A-28

PRINCIPLE .............................................................................. 11A-28

ON-VEHICLE INSPECTION .................................................... 11A-29

OVERHAUL ............................................................................. 11A-30

THROTTLE POSITION SENSOR (TPS)........................................11A-32

PRINCIPLE .............................................................................. 11A-32

ON-VEHICLE INSPECTION .................................................... 11A-33

OVERHAUL ............................................................................. 11A-34

MANIFOLD ABSOLUTE PRESSURE/INTAKE

TEMPERATURE SENSOR ............................................................11A-36

PRINCIPLE .............................................................................. 11A-36

ON-VEHICLE INSPECTION .................................................... 11A-37

OVERHAUL ............................................................................. 11A-38

KNOCK SENSOR...........................................................................11A-40

PRINCIPLE .............................................................................. 11A-40

OVERHAUL ............................................................................. 11A-41

CKP SENSOR ................................................................................11A-43

PRINCIPLE .............................................................................. 11A-43

OVERHAUL ............................................................................. 11A-44

UPSTREAM OXYGEN SENSOR ...................................................11A-46

PRINCIPLE .............................................................................. 11A-46

ON-VEHICLE INSPECTION .................................................... 11A-47

OVERHAUL ............................................................................. 11A-48

DOWNSTREAM OXYGEN SENSOR.............................................11A-49

PRINCIPLE .............................................................................. 11A-49

ON-VEHICLE INSPECTION .................................................... 11A-50

OVERHAUL ............................................................................. 11A-51

CANISTER SOLENOID VALVE.....................................................11A-52

PRINCIPLE .............................................................................. 11A-52

ON-VEHICLE INSPECTION .................................................... 11A-53

OVERHAUL ............................................................................. 11A-54

11A

VEHICLE SPEED SENSOR ...........................................................11A-57

PRINCIPLE ..............................................................................11A-57

ON-VEHICLE INSPECTION ....................................................11A-58

OVERHAUL .............................................................................11A-59

IGNITION CONTROL MODULE.....................................................11A-60

PRINCIPLE ..............................................................................11A-60

OVERHAUL .............................................................................11A-61

ENGINE CONTROL SYSTEM -

GASOLINE ENGINE CONTROL

GASOLINE ENGINE CONTROL SYSTEM

11A-1

1. GASOLINE ENGINE CONTROL SYSTEM PRECAUTION.

(a) Power off.

• The battery negative cable must be disconnected at first before removing or installing any electric

appliance and when tools or facilities will touch the exposed terminals. It should be connected eventually.

This will prevent injured person and vehicle damage.

• The ignition switch must be off without any special descriptions.

The ignition and illumination switches must be shut off before removing or installing the battery

negative cable (the semiconductor may be damaged without doing that).

(b) Please do disassembly, assembly and testing in accordance with the provisions introduced in this

manual during maintenance.

sealing face is level and smooth and no greasy dirt on it before the installation. Don’t forget to remove

the sealant on the mounting hole, the threaded hole and the thread.

(d) Tighten the fixing bolts with prescribed torque during installing the sensors, actuators or other parts.

(e) The high impedance type digital multimeter should be used to the test except the especial description

of the procedure in place of the traditional analogue types multimeter.

(f) The oxygen sensor can not contact with water or other liquids.

(g) When installing or carrying the sensor, ensure it not damaged. Any shock or drop may cause great

damage to its performance.

(h) Battery voltage is low or starter failure, not long time starting the engine, so as not to damage the

catalytic converter.

(i) Do not use the needle puncture method to inspect system signal of wire harness.

(j) Fuel pump can not operate for a long time without gasoline, also it can not run in the air.

(k) Because most electric sprayed parts are un-repairable, after confirming the part is damaged, replace it

as necessary.

(l) The system should use anti-type spark plugs and high-voltage, non-resistant phenotype will not only

release high-voltage spark plug and interference wave, but also effect the ignition coil driver module in

the ECM.

(m) ECM can’t be disassembled for test and maintenance.

11A-2 ENGINE CONTROL SYSTEM -

SYSTEM OVERVIEW

1. INTRODUCTION.

The electrically controlled Multi-point Injection (MPI) engine control systems – BJ491EQ – take DELPHI

MT20U2 Engine Control Module (ECM) as the control center and measure various working parameters of the

engine through various sensors mounted on different components of the engine. Then the fuel injection

quantity is controlled precisely via the control injector according to the preset control program in the ECM,

which enables the engine to obtain the mixture with optimal concentration under various working conditions. In

addition, with the control program in the ECM, the electrically controlled fuel injection system can also enable

the functions of start-up enrichment, warm-up enrichment, acceleration enrichment, full-load enrichment,

deceleration dilution, forcible idle cutoff, automatic idle speed control etc, which meets the requirements for

mixture under special working conditions of the engine and enables the engine to obtain good fuel economy

and emission while enhancing the functional performance of the vehicle. In addition, ECM has some fault

diagnosis modes which can simplify the fault location.

2. ENGINE CONTROL SYSTEM FUNCTION.

Knock control

Mileage memory

Over voltage pretection

Fuel pump control

Canister solenoid valve control

ECM control function

Idle air control motor control

Totally main power relay control

A/C, coolant water box fan control

Direct ignition

Closed-loop control multi-point squence fuel injection (MAP sensor pressure

judgement)

Intake pressure speed-density method air measurement

Trouble self-diagnosis function

3. ECM CONTROL STRUCTURE.

11A-3

11A-4 ENGINE CONTROL SYSTEM -

4. ENGINE CONTROL SYSTEM DIAGRAM.

1 Intake

2 Air Filter

3 Idle Air Control Motor

4 Throttle Position Sensor (TPS)

5 Canister Solenoid Valve

6 Canister

7 Fuel Pressure Regulation

8 To Fuel Box

Positive Crankshift Ventilation (PCV)

Valve

10

11 From Fuel Pump

12 Injector

13 Coolant Temperature Sensor

14 Crankshaft Position Sensor

15 Upstream Oxygen Sensor

16 Downstream Oxygen Sensor

17 Three-Way Catalyst (TWC)

11A-5

5. ENGINE CONTROL SYSTEM MAIN COMPONENTS DISTRIBUTION GRAPHIC.

14 Outlet Fuel (Return Back To Fuel Tank)

11A-6 ENGINE CONTROL SYSTEM -

INTRODUCTION TO SYSTEM FUNCTION

1. IDLE SPEED CONTROL.

(a) Idle speed control function refers to system control of engine speed with the throttle valve closed. The

system makes the actual speed consistent with the target idle speed by controlling idle parameters.

(b) The system applies the idle air control motor and realizes high precision idle speed control.

2. AIR METERING OF SPEED-DENSITY METHOD (INTAKE MANIFOLD PRESSURE/ TEMPERATURE

SENSOR).

With intake temperature sensor and intake manifold pressure sensor, ECM calculates and defines the

air quantity entering the cylinder. Furthermore, ECM allows air/fuel ratio to meet the requirements of

various working conditions by controlling the fuel supply.

3. CYLINDER DETECTION SEQUENCE CONTROL.

In order to realize engine sequence control, the system applies intake pressure cylinder detection

technology. The intake pressure sensor is installed near the air inlet of the intake manifold for 4

cylinders. At the moment, when the inlet valve opens, there is an instantaneous pressure drop of which

the value is around 1 kPa at the sensor. ECM detects the instantaneous pressure drop. After receiving

the signal, ECM identifies compression Top Dead Centre (TDC) signal through the software analysis

and processing.

4. CLOSED LOOP CONTROL.

The system applies closed loop control for the engine fuel supply and idle speed. The advantage of

closed loop control is that the system effectively eliminates the difference between the system and

relevant mechanical parts due to the manufacture and usage wear, which enhances the integrated

coherence of the whole vehicle and reduces the emission.

5. GROUPING CONTROL.

The system divides the engine cylinders into two groups of 1-4 and 2-3 which control the ignition

respectively. The grouping control optimizes and simplifies the system structure. Ignition timing and fuel

injection control (crankshaft position sensor) systems determine crankshaft position and measure

engine speed according to 58X gear signal, which controls the engine ignition and fuel injection timing

precisely. The opening and closing of the power transistor control the continuity of the primary current in

the ignition coils. The ignition timing control is aimed to obtain the optimal ignition time so as to meet

the requirements of various working conditions of the engine. ECM determines the ignition time

according to the engine speed, intake vacuum degree, engine cooling water temperature and

atmospheric pressure.

11A-7

6. SELF-DIAGNOSIS.

(a) The system fault self-diagnosis is an essential function for the engine control system. When one or

several parts in the system operate abnormally, the system will inform the vehicle owner to perform

necessary check and repair timely with fault indicator lamp ON. When the fault occurs, the system can

also control the engine operation with temporary emergency mode, so as to ensure the owner can drive

the vehicle to repair.

(b) When certain sensor and actuator is detected abnormal, the engine fault inspection lamp turns on to

remind the driver.

exported.

(d) RAM data related to the sensor and actuator in ECM can be read by fault diagnostic apparatus. In

addition, in certain situation, the actuator can be forcibly driven.

7. OVERVOLTAGE PROTECTION.

When the voltage of the charging system is too high caused by the fault, the system will go to the

protection status to restrict the engine speed to avoid the ECM damage.

8. AIR CONDITIONING COMPRESSOR CONTROL.

When the A/C switch is on, the system will receive a A/C request signal and make preparations for

operating the A/C system based on engine working condition. And then switch on the A/C compressor.

The system will switch on or switch off the A/C according to the protection demand for air-conditioner.

To ensure the power output and protect the engine, the system will cut off the A/C system under

specified working condition.

9. THREE-WAY CATALYTIC CONVERTER.

The function of three-way catalytic converter is to convert harmful exhaust gas from the engine to

harmless gas to exhaust to the atmosphere. The internal structure of three-way catalytic converter

applies the cellular pipeline design. The cellular pipeline wall has precious metal coating on it, including

palladium, rhodium, platinum etc, which acts as catalytic reaction media. The three-way catalytic

converter will cause 3% - 5% of the power consumption to the engine.

10. OVERHEAT SYSTEM PROTECTION FUNCTION FOR THE THREE-WAY CATALYTIC CONVERTER.

The system predicts the rising trend of the engine exhaust temperature according to actual working

condition of the engine and reduces the engine combustion temperature by timely controlling the air/

fuel ratio, so as to protect the three-way catalytic converter.

11. CONTROL OF THE COOLING FAN.

(a) The vehicle is equipped with a silicon oil fan and an electronic fan.

(b) Electrical fan control function: ECM determines to switch on various fans according to the engine

coolant temperature. ECM also judges the temperature meets the condition for switching on the airconditioner

or not, so as to reduce the engine internal power consumption accordingly..

11A-8 ENGINE CONTROL SYSTEM -

BASIC PRINCIPLE

1. PRINCIPLE OF START CONTROL.

(a) When turning the ignition switch on, the fuel pump will stop after running for 1.5 seconds.

(b) When the engine starts to rotate, the fuel pump will start to operate after ECM detected 2 valid 58X

signals.

easy to be disturbed).

(d) Pre-injection: The pre-injection only injects once during the normal start process (if the fuel is absorbed

by the carbon deposition, the mixture dilutes, which makes it difficult to start).

(e) Preliminary stage for starting: The intake manifold internal pressure is displayed as ambient

atmospheric pressure. After the throttle valve closed, ECM specifies a fixed parameter according to the

start temperature.

(f) During the start process, the fuel injection quantity varies according to the change of the engine coolant

temperature. The ignition advance angle also adjusts continually and changes with the engine coolant

temperature, the intake air temperature and the engine speed.

(g) End of the start process: When the engine speed exceeds 600 RPM, the start working condition ends.

2. PRINCIPLE OF FUEL INJECTION CONTROL.

(a) ECM controls the injector driving time and the injection timing, which enables the engine to obtain the

mixture with optimal air/fuel ratio under various working conditions.

(b) Each cylinder is equipped with an injector at the air inlet. The fuel pump in the fuel tank pumps out the

fuel and delivers the fuel to the fuel high pressure rail. The fuel pressure regulator keeps the injection

pressure stable. The injector injects the fuel directly to the air passage of each cylinder. During each

working cycle (when the crankshaft rotates twice) of the cylinder, each cylinder injects the fuel once (the

injection sequence is 1 - 3 - 4 - 2). This injection type is called as sequential injection.

dense mixture, so as to keep good performance. When the engine operates under the normal working

condition (medium or small load), ECM performs closed loop control via the signal fedback by oxygen

sensor to obtain optimal air/fuel ratio, which enables the three-way catalytic converter to get the optimal

purifying effect.

(d) Inject pulse width control

A/F modify

Signal Input ECM Control Output

Closed loop feedback modify

Intake manifold absolute pressure

Air charging temperature

Air charging efficiency

Self-learning modify

Power supply modify

Exhaust cycle

Accelerate deepen

Decelerate fuel reduction

Decelerate fuel cut

Injector parameter

Calculate fuel charge

Inject pulse width

3. CONTROL SIGNAL DESCRIPTION

Modified Item

Content

11A-9

Air/fuel ratio

Closed loop feedback

correction

• Start air/fuel ratio.

• Air/fuel ratio while engine is running.

• Air/fuel ratio at low engine coolant temperature.

• Air/fuel ratio at normal engine coolant temperature.

• Theoretical air/fuel ratio.

• Enriched air/fuel ratio.

• Overheat protection air/fuel ratio.

• Control the actual air/fuel ratio around the theoretical air/fuel ratio via the

feedback signal from the oxygen sensor.

Intake manifold pressure • Read directly via the MAP mounted on the intake manifold.

Self-learning • Modify the engine internal slow change due to long time operation.

Power voltage

• When the battery voltage changes, the voltage modification can ensure the

correct fuel injection quantity.

Acceleration enrichment

Deceleration dilution

Deceleration cutoff

• When ECM detects the intake manifold pressure and the opening value of the

throttle valve increases greatly, the fuel injection quantity is increased to avoid

the engine mixture dilutes momentarily, so as to improve the power

performance.

• When the system detects the vehicle is under deceleration status, it controls

the fuel cutoff to reduce the emission and fuel consumption.

• When the engine speed is above the setting value, fuel cutoff starts.

• When a fault occurs in the ignition system, the fuel cuts off.

Fuel injection parameter • It provides the relation between the engine and the fuel injection quantity.

(a) Modification for the engine mixture:

• Partial load control of the engine is closed loop fuel control at the normal working temperature. Then

the system modifies fuel injection quantity via ECM according to the feedback voltage signal from the

oxygen sensor, so as to adjust the mixture concentration to around the theoretical air/fuel ratio, which

ensures the conversion efficiency of the harmful emission gas by the three-way catalytic converter

reaches the optimal status while ensuring good fuel economy.

• When the engine operates with full-load within the normal working temperature range, it applies the

open loop fuel control. At this time, in order to ensure the engine obtains the optimal power output, the

system will control the fuel injection quantity with a thick air/fuel ratio. Furthermore, with the premise

that no engine knock occurs, the engine will increase the ignition advance angle moderately.

• The system will also control the exhaust gas temperature using the exhaust gas temperature

mathematical model established during calibration, so as to protect the engine and the three-way

catalytic converter. The system determines the full-load condition of the engine according to the signal

supplied by the throttle valve position sensor. When the throttle valve opening is above 80% ~ 90%, the

system considers the engine goes to the full-load status. When the driver presses the accelerator pedal

to accelerate the vehicle, the system will increase the fuel injection quantity moderately to ensure the

power demand when the engine accelerates. The increased fuel injection quantity goes a direct

proportion with the changing rate of the throttle valve opening. When accelerating, ECM will retard the

ignition advance angle moderately, then recover step by step. The aim is to avoid impacting to the drive

train because the torque increases too rapid when the engine accelerates sharply.

11A-10 ENGINE CONTROL SYSTEM -

• When the acceleration working condition is near the engine full-load, the system will automatically

switch off the A/C system temporarily, so as to ensure the engine power output well when accelerating.

Whatever the situation, when the engine speed exceeds the highest speed specified in the system, the

system will cut off the fuel supply to restrict the speed increasing, so as to protect the engine and avoid

the vehicle skidding. When the engine speed returns within specified in the system, the system will

restore the fuel supply immediately.

4. PRINCIPLE OF IGNITION CONTROL.

(a) Start: The engine applies a fixed ignition advance angle when starting, which allows the gas in the

cylinder to ignite and provide the positive torque. When the engine speed increases to certain speed,

ECM caculates the ignition advance angle according to the input signal.

(b) Ignition advance angle control.

ECT modify

IAT modify

Elevation modify

Idle modify

Signal Modify ECM Output Control

Main ignition angle

Decelerate fuel reduction modify

Accelerate modify

Accelerate deepen modify

A/C modify

Calculate ignition advance angle

Ignition advance angle

angle with the throttle valve opening is usually the minimum ignition angle at the optimal torque point.

When the throttle valve closes, the ignition angle should be reduced to obtain the idle speed stability.

(d) Correction of the ignition advance angle:

• Acceleration correction: When the vehicle accelerates, ECM detects the knock and corrects the ignition

advance angle until the knock disappears. Furthermore, it is also used to reduce the engine speed

fluctuation caused by the drive train torsion.

• Power enrichment correction: To obtain better power and torque near the exterior feature point, the air/

fuel ratio is enriched to the thinnest air/fuel ratio with the best torque.

• Deceleration cutoff correction: When the deceleration cutoff exits, correct the ignition advance angle to

get a stable transition.

• A/C correction: Switch off the A/C when the engine is idle. Correct the ignition advance angle, which

allows the speed to get a stable transition.

5. PRINCIPLE OF IDLE CONTROL.

(a) Idle control:

• Control the air flow in the bypass of the throttle valve according to the idle condition and the engine idle

load to maintain the idle speed at the optimal speed. According to the engine coolant temperature and

the A/C load, ECM drives the IAC motor to make the engine operate under the preset target idle speed.

In addition, when the engine operates at idle speed, turn on or turn off the A/C switch. The IAC motor

will regulate the air flow in the bypass according to the engine load to avoid idle speed unstable .

11A-11

Calculate the target idle speed.

Basic target idle speed

Input ECM Output Control

Voltage compensation

Vehicle speed compensation

Fan compensation

Calculate target idle speed

Target idle speed

Headlamp compensation

A/C compensation

Deceleration adjustment

• Voltage compensation: When the voltage is below 12V, the system will automatically increase the target

idle speed to increase the electrical energy production of the generator.

• A/C compensation: Switch on the A/C when parking the vehicle at idle speed. To compensate the

power loss of the compressor, the target idle speed increases by 150 RPM.

• Headlamp compensation: After switching on the low beam, the target idle speed increases by 50 RPM

to compensate the electricity loss.

• Fan compensation: When the coolant temperature increases and the fan operates, the idle speed

increases by 50 RPM to compensate the electricity loss for the fan operation.

• Control of idle air flow.

• Control of fuel injection quantity.

• Control of ignition timing.

(d) Idle speed design control timing:

• Calibration of idle stability.

• Calibration of acceleration working condition.

• Calibration of deceleration working condition.

• Deceleration cutoff.

• Calibration for the fuel supply under engine transient transition working condition.

• Calibration of constant speed driving.

• Calibration of increasing and reducing the mechanical and electricity load.

(e) Decisive factors for the target idle speed:

• When the coolant temperature is low, the system provides a high target idle speed to accelerate the

warm-up.

• When the additional load (e.g. various electrical appliances such as the headlamp, A/C, cooling fan

etc.) opens, the system will raise the idle speed to compensate the increased load and keep the idle

speed stable.

11A-12 ENGINE CONTROL SYSTEM -

6. PRINCIPLE OF CARBON CANISTER SOLENOID VALVE CONTROL.

(a) Used for controlling the air flow of carbon canister cleaning. The carbon canister is controlled by ECM

sending the duration and frequency for the electrical impulse (duty cycle) through integrated

computation according to a series of signals including engine load, engine coolant temperature, and

engine speed etc. When too much gasoline vapor is accumulated in the activated carbon canister, it will

cause the gasoline leakage, which pollutes the environment. Therefore, the effect of carbon canister

solenoid valve is to open at the proper time to allow the excess gasoline vapor to enter the intake pipe

after mixing with the air sufficiently in the carbon canister to involve in the combustion.

(b) The carbon canister will not work in the following conditions:

• During a period after the cold start of the engine.

• When the cooling water temperature is low.

• During the engine idle operation period.

• During the engine big load period.

• When the important sensors of the system have fault.

MAIN COMPONENTS

11A-13

11A-14 ENGINE CONTROL SYSTEM -

SYSTEM COMPONENTS DESCRIPTION

Component Summary Quantity Function

ECM 16 bit CPU 1

Upstream oxygen sensor With heated 1

Downstream oxygen sensor With heated 1

MAP sensor Piezoelectric type 1

ECM optimization control system

depends on the sensor signal.

Check oxygen concentration in

exhaust.

ECM judges whether the TWC is

good comparing the upstream with

downstream oxygen sensor signal.

Check the air inlet quantity and

BTDC.

CKP sensor Magnetron induction coil type 1 Check CKP and engine RPM.

Injector 4 hole type 4

Inject fuel depends on the sensor

Idle air control motor Electromagnetic coil type 1 Control air inlet.

Carbon solenoid valve Electromagnetic type 1

Control the exhaust depending on

the digital pulse wave from ECM.

3- lines type carbon film

resistor sliding indicator

1 Check the open of throttle.

ECT sensor NTC thermal resistance type 1 Check ECT.

IAT sensor NTC thermal resistance type 1 Check IAT.

Vehicle speed sensor Hall effect type 1 Check vehicle speed.

Ignition coil Electromagnetic coil type 1 Ignite mixed gas.

Fuel pump Electromagnetic type pump 1

Supply the enough pressure fuel

for system.

ENGINE CONTROL MODULE (ECM)

PRINCIPLE

11A-15

1. ECM DESCRIPTION.

(a) ECM is the electric engine control center with the micro

processor as the core that having sensor signal input

interface and the executor drive circuit. The ECM

receives and treats the engine status signal that inputted

from all sensors, sends control signal to the executor to

drive the engine running in accordance with the preset

procedures so as to make the engine run under best

status, ensure good power capability, fuel economy and

exhaust capability.

(b) Normal operating voltage: 9 ~ 16V.

(d) ECM has self-protection function. It may result the

ignition failure during repair and it will resume normal

after replacement of ECM. In fact, the ECM doesn’t get

damaged, but just self-protection mode. ECM will

resume normal after certain time period.

11A-16 ENGINE CONTROL SYSTEM - ENGINE CONTROL MODULE (ECM)

2. DISCONNECT BATTERY NEGATIVE CABLE.

When disconnecting or connecting the battery cables, please first turn off the ignition switch and

lighting switch and completely loosen the cable nut. Do not pry up the cable when peforming these

operations.

3. REMOVE ECM MODULE.

(a) Pull passenger seat forward.

(b) Lift the covering behind the assistant driver seat , loosen

the ECM locking knob.

Depress the connector locking tab, pull the latch upward

to the end .

Disconnect ECM connector.

After disconnecting the connector, keep the connection

away from dirt, water and other foreign materials.

Remove 4 ECM mounting bolts.

Remove ECM.

11A-17

• Disconnect battery negative cable first, wait at least

1 minute, then remove ECM.

• Take care not to impact ECM while removing the

ECM.

• Keep ECM away water during operation.

• Be careful of the terminals of ECM.

4. INSTALL ECM.

Tighten 4 ECM mounting bolts.

Torque: 19.6 N•m

Pay attention to electrostatic protection when installation.

Connect ECM connector.

Pull the connector upward, be sure that it is installed in

place properly .

Install ECM cover and tighten the ECM cover locking

knob.

Cover the covering and push passenger seat back to its

original position.

5. CONNECT BATTERY NEGATIVE CABLE.

11A-18 ENGINE CONTROL SYSTEM -

ENGINE COOLANT TEMPERATURE

ENGINE COOLANT TEMPERATURE SENSOR

1. ENGINE COOLANT TEMPERATURE DESCRIPTION.

(a) The Engine Coolant Temperature (ECT) sensor uses a

thermistor to control the signal voltage to the Engine

Control Module (ECM).

(b) This ECT sensor is a 2-line type. Normally a 1-line type is

to provide coolant temperature signal to the instrument.

OVERHAUL

11A-19

2. OPEN THE ENGINE HOOD AND REMOVE THE

COOLANT RESERVOIR PRESSURE CAP.

Do not open the reservoir cap when the engine is hot. Such

as coolant temperature should be reduced to 50 ° C (120 ° F)

below, remove the reservoir cap. Otherwise, the cooling

liquid or vapor emitting heat may cause personal injury.

Drain coolant. (Refer to “Chapter 17A cooling - coolant,

precaution”)

3. RAISE THE VEHICLE, LOOSEN COOLANT DRAIN

PLUG AT THE BOTTOM OF RADIATOR , THEN DRAIN

Using a suitable container, collect the coolant. If do not

reuse, dispose of coolant according to the local laws.

4. REMOVE ECT SENSOR.

(a) Loosen the clamp and remove the hose.

Disconnect ECT connnector.

Remove ECT sensor.

• Clear the installation surface after removing.

• Clear the sensor hole after removing.

• Clear the thread of sensor after removing.

.

11A-20 ENGINE CONTROL SYSTEM -

5. CHECK ECT SENSOR.

(a) Dip the sensing part of ECT sensor into hot water. Using

the multimeter, measure resistance of the sensor.

(b) If the check result is not OK, replace it with a new one.

0 ℃ 9098 ~ 9700 Ω

10 ℃ 5494 ~ 5822 Ω

20 ℃ 3420 ~ 3602 Ω

30 ℃ 2184 ~ 2296 Ω

Don’t let the water go into terminals. After checking, dry the

sensor.

6. INSTALL ECT SENSOR.

(a) Install ECT sensor.

Apply sealant to thread. The specified sealant: 3M NUT

LOCKING PART or the equivalent.

(b) Connect ECT sensor connector .

Attach the hose and tighten the clamp.

7. FILL COOLANT. (Refer to “Chapter 17A cooling - coolant, precaution”)

8. CHECK COOLING SYSTME FOR COOLANT LEAKAGE.

THROTTLE BODY

THROTTLE BODY CLEANING

1. CLEANING STEPS.

(a) Start the engine and warm it up until the coolant is heated to 80 ℃ or higher. then stop the engine.

(b) Remove the air intake hose from the throttle body.

Do not allow cleaning solvent to enter the bypass passage.

11A-21

Spray cleaning solvent into the valve through the throttle

body intake port and leave it for approximately five

minutes.

Start the engine, accelerate it several times and then idle

it for about one minute. if the idle speed becomes

unstable (or if the engine stalls) due to the bypass

passage being plugged, slightly open the throttle valve to

keep the engine running.

If the throttle valve deposits are not removed, repeat

steps d and e.

Unplug the bypass passage inlet.

Connect the air intake hose.

Use the scan tool to erase any diagnostic trouble code.

Adjust the basic idle speed.

If the engine hunts while idling after adjustment of the basic

idle speed, keep the battery negative cable disconnected

for 10 seconds or more, and then reconnect it and run the

engine at idle for about 10 minutes after the engine is

warmed up.

11A-22 ENGINE CONTROL SYSTEM - THROTTLE BODY

THE FIXED SPEED ADJUSTING SCREW (SAS) ADJUSTMENT

1. SINCE FIXED SAS IS ADJUSTED AT FACTORY, PLEASE DO NOT ADJUST “FIXED SAS” IN

NORMAL CASES UNLESS IT IS NECESSARY.

2. IF “FIXED SAS” IS ROTATED RANDOMLY, PLEASE RE-ADJUST ACCORDING TO THE

FOLLOWING STEPS:

Loosen the tension of the acceleration cable.

Loosen the "fixed SAS” lock nut.

Turn the idle switch counterclockwise until the throttle

valve closes.

Screw the “fixed SAS” clockwise until the point (i.e. the

position when throttle is started to be opened) of throttle

rail is reached.

Keep the “fixed SAS” from moving when tightening the

lock nut.

Adjust the acceleration cable tension.

11A-23

BASIC IDLE SPEED ADJUSTMENT

1. THE STANDARD IDLE SPEED HAS BEEN ADJUSTED WITH THE SPEED ADJUSTING SCREW

(SAS) BY THE MANUFACTURER, AND THERE SHOULD BE NO NEED FOR RE-ADJUSTMENT.

2. IF THE ADJUSTMENT HAS BEEN CHANGED BY MISTAKE, THE IDLE SPEED MAYBE COME TOO

HIGH OR TOO LOW WHEN LOADS A/C, DEFOGGER, ETC. ARE PLACED ON THE ENGINE. IF

THIS OCCURS, ADJUST BY THE FOLLOWING PROCEDURE.

If make the adjustment, it should be made after confirming that the spark plugs, the injectors, the idle

air control motor, compression, etc., are all normal.

(a) Place the car in good condition before the inspection and adjustment.

(d) Start the engine and run at idle speed.

(e) Check the idle speed.

Standard value: 750 ± 50 RPM

• The engine speed may be 20 to 100 RPM lower than indicated above for a new vehicle, but this

is normal and no adjustment is necessary.

• If the engine stalls or the engine speed is low even though the vehicle has been driven

approximately 500 km (300 mile) or more, it is probable that deposits are adhered to the throttle

valve, clean it.

If it is not within the standard value range, turn the Speed

Adjusting Screw (SAS) to make the necessary adjustment.

If SAS gets to bottom completely, the idle speed is still more

than standard value, then check if “fixed SAS” was rotated.

If yes, re-adjust “fixed SAS”.

• Turn the ignition switch OFF.

• Disconnect the scan tool.

• Start the engine again and let it idle for about 10 minutes.

Check that the idling condition is normal.

11A-24 ENGINE CONTROL SYSTEM - THROTTLE BODY

2. LOOSEN COOLANT DRAIN PLUG AT THE BOTTOM OF

RADIATOR , THEN DRAIN COOLANT.

(b) Rotate the driver seat and open engine compartment

4. REMOVE AIR INTAKE HOSE. (Refer to “Chapter 14A intake air - intake air hose, replacement”)

5. REMOVE THROTTLE BODY.

(a) Disconnect IAC connector.

Disconnect TPS connector.

11A-25

Loosen accelerator cable locking nut on the throttle body

and remove accelerator cable.

Remove 2 preheating hoses from throttle body.

Remove 4 throttle body mounting bolts.

(f) Remove throttle body.

Check the seal gasket between throttle body and intake

manifold for damage and replace it as necessary.

11A-26 ENGINE CONTROL SYSTEM - THROTTLE BODY

6. REMOVE AIR INTAKE HOSE. (Refer to “Chapter 14A intake air - intake air hose, replacement”)

7. INSTALL THROTTLE BODY.

(a) Tighten 4 throttle body mounting bolts .

Torque:15 ~ 25 N•m

Connect 2 preheating hoses to throttle body.

Connect idle air control motor connector.

Connect TPS connector.

11A-27

Install accelerator cable and keep cable at the proper

tension, then tighten the locking nut.

8. INSTALL AIR INTAKE HOSE. (Refer to “Chapter 14A intake air - intake air hose, replacement”)

9. PUT DOWN ENGINE COMPARTMENT COVER AND LOCK IT.

10. FILL COOLANT. (Refer to “Chapter 17A cooling - coolant, replacement”)

11A-28 ENGINE CONTROL SYSTEM - IDLE AIR CONTROL MOTOR

IDLE AIR CONTROL MOTOR

1. IDLE AIR CONTROL MOTOR DESCRIPTION.

(a) The idle air control motor is essentially one micro motor.

since the motor will revolve in various directions when

the motor coil is supplied with current in various

directions. The motor revolution shaft will drive the

moving of the leading screw so as to control the open

extent of the valve indirectly. ECM will send the

digitalized square wave signal to control the positive

rotation and the reverse rotation of the motor so as to

control the stroke of the idle air control motor.

11A-29

ON-VEHICLE INSPECTION

1. OPERATING SOUND INSPECTION.

(a) Check that coolant temperature of engine is below 20 ℃ .

If coolant temperature of engine is above 20 ℃ , remove the harness connector of engine coolant temperature

sensor, and use the less than 20 ℃ sensor for connection.

(b) Check that when ignition switch is changed into the ON position (do not start engine), the operating

sound of the IAC motor can be heard over the IAC motor.

IAC motor or ECM is suspected.

2. CHECK ENGINE RPM.

(e) Select the item ,perform the idle air control motor test.

(f) When the scan tool control the rotation of expansion of the IAC motor, the engine RPM changes from

high to low in synchronism (vibration can be felt when touching the IAC motor).

(g) If it is not OK, check IAC motor control harness or connector. If harness or connector is OK, check IAC

motor or ECM.

3. CHECK IDLE AIR CONTROL MOTOR STEPS.

(e) Select the item .”

Displayed Item Detection Condition Specified Condition

Idle air control motor

• Accessories: OFF

• Transmission: N

• Engine: idle

• A/C turns ON, A/C

should works

If it is not OK, check idle air control motor, harness, connector or ECM.

Add 10 ~ 70 steps

11A-30 ENGINE CONTROL SYSTEM - IDLE AIR CONTROL MOTOR

3. REMOVE IDLE AIR CONTROL MOTOR.

(a) Disconnect idle air control motor connector.

Remove 2 idle air control motor retaining bolts.

Remove idle air control motor.

• Clear surface after removing.

• Clear the path of the idle.

11A-31

4. CHECK IDLE AIR CONTROL MOTOR COIL RESISTANCE.

(a) Connect special tool (for test).

(b) Check resistance between terminal A and B of idle air

control motor connector.

Standard resistance: 28 ~ 33 Ω (20 ℃ )

(d) If it is not OK, replace it with a new one.

5. INSTALL IDLE AIR CONTROL MOTOR.

(a) Install idle air control motor and tighten 2 idle air control

motor retaining bolts.

• Do not apply any axially type of force to press or pull

out the axle.

• The axle must be in the place of the retreating before

the idle air control motor being installed into the

throttle body.

• After removing battery or ECM, perform the idle air

control motor self-learning.

6. THE IAC MOTOR SELF-LEARNING.

(a) Turn the ignition switch OFF, do not start at once. After 5 seconds, start it again.

7. PUT DOWN ENGINE COMPARTMENT COVER AND LOCK IT.

11A-32 ENGINE CONTROL SYSTEM - THROTTLE POSITION SENSOR (TPS)

THROTTLE POSITION SENSOR (TPS)

1. THROTTLE POSITION SENSOR DESCRIPTION.

Throttle Position Sensor (TPS) is used to provide throttle

angle, angle speed and engine idle position information

to the ECM. Based on this the ECM can obtain the

engine load information, operating mode (such as start,

idle, reverse towing, partial load and full-load) and

acceleration & deceleration information. This sensor is of

3-line type and the ECM will check the throttle open

extent by monitoring the voltage variation.

The throttle position sensor is comprised of carbon film

resistance and slide indicator.

The sensor slide indicator connects with the throttle and

rotates following the shaft. When the throttle open extent

changes following the accelerator pedal, the position of

the slide indicator will also change on the carbon film

resistance, at that moment the resistance output will also

change, which reflects the open extent of the throttle

indirectly.

11A-33

1. START THE ENGINE AND WARM IT TO NORMAL OPERATING TEMPERATURE.

2. TURN THE IGNITION SWITCH OFF.

3. CONNECT THE SCAN TOOL TO THE DATA LINK CONNECTOR (DLC) - USE THE MOST

CURRENT SOFTWARE AVAILABLE.

4. TURN THE IGNITION SWITCH ON.

5. SELECT THE ITEM BELOW.

• Engine stop

Idle position 0.3 ~ 1 V (0%)

Open throttle slowly

Directly proportional with

the open degree

Open widely 4.5 ~ 5.5 V (100%)

6. IF IT IS NOT OK, CHECK TPS, HARNESS CONNECTORS AND ECM.

11A-34 ENGINE CONTROL SYSTEM - THROTTLE POSITION SENSOR (TPS)

3. REMOVE TPS.

(a) Disconnect TPS connector.

Remove 2 TPS retaining bolts.

Remove TPS.

Clear the surface after removing.

11A-35

4. CHECK TPS RESISTANCE.

(a) Measure the resistance between termal 1 and termal 2 of

(a) Measure the resistance between termal 2 and termal 3 of

Terminal 1 and 2 • Resistance: 3.5 ~ 6.5 Ω (20 ℃ )

Terminal 1 and 3 or

Terminal 2 and 3

• Open throttle from idle position to

open wide.The output value is

proportional change to the open

degree.

If the resistance is out of the range and the value

changes unsteadily, replace it.

5. INSTALL TPS.

(a) Install TPS and tighten 2 TPS retaining bolts.

6. PUT DOWN ENGINE COMPARTMENT COVER AND LOCK IT.

11A-36 ENGINE CONTROL SYSTEM -

MANIFOLD ABSOLUTE PRESSURE/

INTAKE TEMPERATURE SENSOR

MANIFOLD ABSOLUTE PRESSURE/INTAKE TEMPERA-

TURE SENSOR

1. MANIFOLD ABSOLUTE PRESSURE/INTAKE TEMPERATURE

SENSOR DESCRIPTION.

(a) The engine control system adopted speed-density air

measurement method to check the air intake volume into

the engine so as to control the fuel injection pulse width

for the precise control of engine power output.

Meanwhile, this system adopted intake pressure cylinder

determination technology and the intake air sensor is

installed near the inlet opening of cylinder 4 intake

manifold. At the moment when the throttle is opened,

there will be one instantaneous pressure drop at the

sensor, of which the value is about 1 kPa. When the

ECM detected and received this instantaneous pressure

drop. The ECM will determine the compression upper

dead center signal after software diagnosis treatment.

(b) Intake air temperature sensor is a Negative Temperature

Coefficient (NTC) of resistance, with the intake air

temperature increases resistance decreases, the engine

ECM contrast through the internal circuitry to detect an

intake air temperature changes.

11A-37

• Engine: running

IAT: -20 ℃ -20 ℃

6. TURN DIGITAL MULTIMETER TO VOLTAGE RANGE.

CHECK VOLTAGE OF MAP SENSOR BETWEEN

TERMINAL A OR D AND GROUND.

(a) When engine runs at idle, terminal 3 is 5 V, terminal 4 is

1.3 V.

(b) When engine runs unload, open throttle slowly, the signal

of terminal 4 is changed little.

4 V, then drop to 1.5 V.

(d) Turn multimeter to voltage range. Black pin to ground,

red pin to terminal 2 of the IAT sensor. Check IAT signal.

IAT: 0 ℃ 3.2 ~ 3.8V

AN

If it is not OK, check MAP/IAT sensor, harness or ECM.

11A-38 ENGINE CONTROL SYSTEM -

3. REMOVE MAP/IAT SENSOR CONNECTOR.

(a) Disconnect MAP/IAT sensor connector.

(b) Remove MAP/IAT sensor retaining bolt.

Remove MAP/IAT sensor.

Clear surface after removing MAP/IAT sensor.

4. CHECK IAT SENSOR RESISTANCE.

(a) Turn digital multimeter to Ohm range. Check resistance

between terminal 2 and 3 of sensor. Using a hairdryer,

blow air to sensor ( IMPORTANT:do not get too close to

the sensor ). Inspect the change of the value, the value

should decline.

(b) If it is not OK, replace it.

11A-39

5.3 ~ 6.7 kΩ

IAT: 10 ℃

IAT: 30 ℃

2.3 ~ 3.0 kΩ

1.0 ~ 1.5 kΩ

0.30 ~ 0.42 kΩ

5. INSTALL MAP/IAT SENSOR.

(a) Tighten MAP/IAT sensor retaining bolt.

(b) Connect MAP/IAT sensor connector.

Do not use any impact tools (such as a hammer, etc.) to

knock sensor into mounting hole.

11A-40 ENGINE CONTROL SYSTEM - KNOCK SENSOR

KNOCK SENSOR

1. PRINCIPLE OF KNOCK SENSOR.

Knock sensor is one vibrating acceleration sensor that

installed on the engine cylinder body, normally between

cylinder 2 and cylinder 3 to facilitate the engine knock

balance.

By means of the vibrating frequency signal output from

the knock sensor, the ECM will judge for engine knock

after the ECM internal wave filter.

In case of the detection of the knock signal, the ECM will

reduce gradually till the elimination of the knock and then

resume gradually till the knock threshold.

Above steps will be repeated again and again.

11A-41

2. RAISE AND SUPPORT VEHICLE.

3. REMOVE KS.

(a) Remove 4 retaining bolts on intake manifold lower bracket

Disconnect KS connector.

Remove knock sensor retaining bolt.

• Clear the surface after removing.

• Don’t contact all kinds of liqulds. For example: oil,

coolant, brake fluid.

4. CHECK KS.

(a) Measure the resistance according to the value in the

Sensor Terminal Terminal Resistance (20 ℃ )

1 2

1 Ground

2 Ground

> 1 MΩ

If the check result is not OK, replace it.

11A-42 ENGINE CONTROL SYSTEM - KNOCK SENSOR

5. INSTALL KNOCK SENSOR.

(a) Tighten knock sensor retaining bolt.

Torque: 15 ~ 25N•m

• Confirm the KS correct direction.

• install it by applying pressure. Any impact tool is not

allowed.

• The metal surface should be pressed against the cylinder

body. Any type of washer is not allowed.

• Don’t let the signal cable resonance. To avoid it

brokn.

(b) Connect knock sensor connector.

6. INSTALL INTAKE MANIFOLD LOWER BRACKET.

(a) Tighten 4 retaining bolts on intake manifold lower

bracket.

7. INSTALL THE INTAKE MANIFOLD. (Refer to “Chapter 14A intake air - intake manifold, replacement”)

CKP SENSOR

11A-43

1. CRANKSHAFT POSITION SENSOR DESCRIPTION.

(a) The 58X reference signal is produced by the Crankshaft

Position (CKP) sensor. The Engine Control Module

(ECM) uses the 58X reference signal to caculate engine

RPM and CKP. The ECM constantly monitors the

number of pulses on the 58X reference circuit and

compares them with the number of MAP signal being

received.

11A-44 ENGINE CONTROL SYSTEM - CKP SENSOR

3. REMOVE CKP.

(a) Disconnect CKP connector.

(b) Remove CKP sensor retaining bolt on flywheel housing .

Remove knock sensor.

Clear the surface after removing knock sensor.

4. CHECK CKP SENSOR.

(a) Turn digital multimeter to Ohm range, connect two

probes to terminal 2 and 3 of sensor. Check resistance.

Standard resistance: 560 Ω ± 10% (20 ℃ )

(b) If the check result is not normal, replace it.

11A-45

5. INSTALL CKP SENSOR.

• Apply a layer of preventative oil on the O-ring of the

CKP sensor.

• Do not use any impact tools (such as a hammer, etc.)

to knock sensor into mounting hole.

(a) Insert CKP sensor into the mounting hole by turning .

Tighten CKP sensor retaining bolt.

Connect the CKP sensor connector..

6. PUT DOWN DRIVER SEAT AND LOCK IT.

11A-46 ENGINE CONTROL SYSTEM - UPSTREAM OXYGEN SENSOR

UPSTREAM OXYGEN SENSOR

1. UPSTREAM OXYGEN SENSOR DESCRIPTION.

This sensor is used to provide the excess oxygen

information after the injected fuel in the cylinder has

passed the full combustion in the sucked air. By means

of this information, the ECM can perform the closed loop

control upon the fuel quantity so that the 3 main toxic

substances in the exhaust, which named Hydrocarbon

(HC), Carbon Oxides (CO) and nitrogen oxides, can be

converted and purified in the three-way catalytic

converter.

11A-47

1. A/F: to be rich when

acceleration

2. A/F: to be lean when

deceleration

6. IF IT IS NOT OK, CHECK SENSOR, HARNESS AND ECM.

Decelerate suddenly

Accelerate suddenly

Engine: 2500 RPM

0.1 ~ 0.9 V

11A-48 ENGINE CONTROL SYSTEM - UPSTREAM OXYGEN SENSOR

3. REMOVE UPSTREAM OXYGEN SENSOR.

(a) Disconnect upstream oxygen sensor connector.

(b) Using wrench, remove upstream oxygen sensor .

Remove the exhaust pipe after cooling completely.

4. CHECK UPSTREAM OXYGEN SENSOR.

(a) Turn digital multimeter to ohm range. Check resistance

between terminal 3 and 4 of the sensor.

Standard resistance: 9.6 ± 1.5 Ω (20 ℃ )

5. INSTALL UPSTREAM OXYGEN SENSOR.

Apply a layer of rust-proof oil on the thread.

Install upstream oxygen sensor.

Torque: 40 ~ 60 N•m

Connect upstream oxygen sensor connector.

6. LOWER THE VEHICLE.

DOWNSTREAM OXYGEN SENSOR

11A-49

1. DOWNSTREAM OXYGEN SENSOR DESCRIPTION.

(a) The purpose of the rear oxygen sensor is to check the

oxygen concentration in the exhaust that passed threeway

catalytic converter and the sensor will convert such

signal to dot signal and transmit to the ECM. After the

comparison of the signals of the upstream/downstream

oxygen sensors, the ECM will judge if the three-way

catalytic converter functions well.

(b) The structure of downstream oxygen sensor is same as

the upstream oxygen sensor.

11A-50 ENGINE CONTROL SYSTEM - DOWNSTREAM OXYGEN SENSOR

Downstream oxygen sensor

• Engine: warm

Engine: running

About 0.1 V

11A-51

2. RAISE AND SUPPORT THE VEHCLE.

3. REMOVE DOWNSTREAM OXYGEN SENSOR.

(a) Disconnect downstream oxygen sensor connector.

(b) Remove downstream oxygen sensor.

4. CHECK DOWNSTREAM OXYGEN SENSOR.

(a) Turn digital multimeter to ohm range, check resistance

5. INSTALL DOWNSTREAM OXYGEN SENSOR.

(a) Install downstream oxygen sensor.

(b) Connect downstream oxygen sensor connector.

11A-52 ENGINE CONTROL SYSTEM - CANISTER SOLENOID VALVE

CANISTER SOLENOID VALVE

1. CARBON CANISTER SOLENOID VALVE DESCRIPTION.

The carbon canister solenoid valve is a kind of solenoid

valve mechanism internally and contrilled by ECM. ECM

will send digitalized square wave control pulse to control

the open extent of the solenoid valve. The open extent of

the carbon canister is different depending on the various

engine operating modes. In case of the great load of

engine or engine idle, the carbon canister solenoid valve

doesn’t operation in order to ensure the engine power

output well.

11A-53

5. CHECK THE ACTION OF CARBON CANISTER SOLENOID VALVE.

(a) Use the “action test” function of the diagnostic apparatus.

• Touch the fuel Evaporative Emission Control (EVAP) system carbon canister solenoid valve with hand.

• Perform the action test of carbon canister solenoid valve with the “action test” function of the diagnostic

apparatus.

• The carbon canister solenoid valve should vibrate slightly. If the carbon canister solenoid valve has no

slight vibration, check solenoid valve, harness and ECM.

(b) Vacuum test method.

• When the engine operates at the idle status, pull out the vacuum hose from the activated carbon

canister and check the vacuum hose for vacuum suction. If the carbon canister solenoid valve operates

normally, the solenoid valve should be closed and there should be no vacuum suction in the vacuum

hose. If there is vacuum suction in the vacuum hose now, remove the socket connector from the

solenoid valve. If there is voltage in the terminals of the harness socket connector in the carbon

canister solenoid valve, it indicates there is a fault in ECM. If there is no voltage, it indicates the carbon

canister solenoid valve is stuck in the opening position.

• Press the accelerator pedal to allow the engine speed reach above 2000 RPM and check the vacuum

hose for the vacuum suction. If the vacuum suction exists, it indicates the carbon canister solenoid

valve operates normally. If no vacuum suction exists in the vacuum hose and the voltage is normal on

the terminal of harness socket connector in the carbon canister solenoid valve, it indicates there is a

fault in the carbon canister solenoid valve. If the voltage is abnormal, it indicates there is a fault in ECM

or harness.

11A-54 ENGINE CONTROL SYSTEM - CANISTER SOLENOID VALVE

4. REMOVE CANISTER SOLENOID VALVE.

(b) Remove fuel pressure regulator vaccum line.

Disconnect canister solenoid valve connector.

Disconnect canister solenoid valve inlet hose clips and

remove the hose ( to canister).

When disconnecting these hoses which used for a long time.

Twist hose to be loosed first, then operate disconnection.

Disconnect canister solenoid valve outlet hose clips and

remove hose ( to intake manifold below throttle body ).

Using screw driver, pry canister solenoid valve away from

mounting bracket and remove it.

11A-55

5. CHECK CANISTER SOLENOID VALVE.

(a) Apply battery voltage to canister solenoid valve. Sound

should be heard. At this time, blow air to the inlet port:

• If air passes, then the canister solenoid valve is OK. If it

is not OK, replace it.

• If no power applied, the solenoid should be closed. No

air pass.

(b) Check carbon control solenoid valve resistance.

• Turn digital multimeter to Ohm range. Check resistance

between terminal A and B of canister solenoid valve.

Standard resistance: 19 ~ 22 Ω (20 ℃ )

• If it is not OK, replace it.

6. INSTALL CANISTER SOLENOID VALVE.

(a) Install canister solenoid valve on mounting bracket.

(b) Connect canister solenoid valve outlet hose clip (to

intake manifold below throttle body).

Connect canister solenoid valve inlet hose clips ( to canister

).

Connect canister solenoid valve connector.

Connect IAC connector.

Connect fuel pressure regulator vaccum line.

11A-56 ENGINE CONTROL SYSTEM - CANISTER SOLENOID VALVE

7. INSTALL AIR INTAKE HOSE. (Refer to “Chapter 14A intake air - intake air hose, replacement”)

8. PUT DOWN DRIVER SEAT AND LOCK IT.

VEHICLE SPEED SENSOR

11A-57

1. VEHICLE SPEED SENSOR DESCRIPTION.

(a) Vehicle speed sensor is the type of hall sensor. It works

together with signal wheel on output shaft. Unified meter

measures digital voltage signal through it and determines

the current speed of the vehicle.

11A-58 ENGINE CONTROL SYSTEM - VEHICLE SPEED SENSOR

3. CONNECT SCAN TOOL TO THE DATA LINK CONNECTOR (DLC) - USE THE MOST CURRENT

SOFTWARE AVAILABLE.

5. DRIVE THE VEHICLE, READ THE SCAN TOOL DATA STREAM: VEHICLE SPEED.

6. VEHICLE SPEED: THE SAME VALUE AS THE ACTUAL VEHICLE SPEED.

7. IF THE DISPLAYED VALUE IS NOT EQUAL TO THE ACTUAL VALUE, CHECK SENSOR, HAR-

NESS AND ECM.

8. RAISE THE VEHICLE.

9. TURN THE IGNITION SWITCH ON AND NOT START ENGINE. CHECK AS FOLLOWING:

Set digital multimeter to voltage range. Check voltage

between terminal 2 and 3 of the sensor. It should be 12V.

If it is not OK, replace it.

Start engine, pull into gear. Using the oscilloscope, check

the wave output of terminal 3 of sensor. If it is not OK,

check harness and sensor.

11A-59

3. REMOVE VEHICLE SPEED SENSOR.

(a) Disconnect vehicle speed sensor connector.

(b) Remove vehcle speed sensor retaining bolt.

Pull out vehcle speed sensor straight by slightly turning.

Clear surface after removeing.

4. INSTALL VEHICLE SPEED SENSOR.

(a) Install vehicle speed sensor and tighten 1 mounting bolt.

(b) Connect vehicle speed sensor connector.

5. LOWER VEHICLE.

6. CHECK AFTER INSTALLATION.

(a) Start the vehicle and check vehicle speed sensor for fluid leakage and confirm that speedometer is

operational.

11A-60 ENGINE CONTROL SYSTEM - IGNITION CONTROL MODULE

IGNITION CONTROL MODULE

1. IGNITION CONTROL MODULE DESCRIPTION.

Adopting group ignition technology, taking advantage of the

theory that the mutual induction of the electromagnetic coils

can generate high energy, controlling the switch-on/switchoff

time of the primary coil, and taking advantage of the high

voltage power of the secondary coil to puncture the spark

plug gap so as to generate strong spark to ignite the mixed

air. Since the air ionization is very great and the resistance

is very low during the engine exhaust process, only low

voltage power is required to puncture the spark plug gap.

Therefore, this system adopts group ignition technology so

as not to waste the energy.

11A-61

4. REMOVE IGNITION CONTROL MODULE.

(a) Disconnect ignition control module connector.

(b) Remove spark plug wires.

Mark spark plug wires in the firing order in order to identify

their positon when installing spark plug wires .

Remove ignition control module retaining bolts.

Remove ignition control module.

5. INSTALL IGNITION CONTROL MODULE.

(a) Tighten ignition control module 2 mounting bolts.

Align the marks made previously and Install spark plug

wire to ignition module.

Connect ignition control module connector.

6. INSTALL AIR INTAKE HOSE. (Refer to “Chapter 14A intake air - intake air hose, replacement”)

FUEL SYSTEM

FUEL SYSTEM.................................................................................12A-1

PRECAUTION............................................................................ 12A-1

FUEL SYSTEM PRESSURE RELEASE PROCESS ................. 12A-2

DRAIN FUEL TANK PROCESS................................................. 12A-2

FUEL TUBE CLEAN .................................................................. 12A-2

PROBLEM SYMPTOMS TABLE................................................ 12A-3

COMPONENTS ......................................................................... 12A-4

FUEL TANK ASSY...........................................................................12A-6

REPLACEMENT ........................................................................ 12A-6

FUEL FILTER ASSY ........................................................................12A-9

REPLACMENT........................................................................... 12A-9

ELECTRIC FUEL PUMP ASSY .....................................................12A-10

REPLACMENT......................................................................... 12A-10

FUEL INJECTOR RAIL ASSY ......................................................12A-12

OVERHAUL ............................................................................. 12A-12

FUEL FILLER DOOR .....................................................................12A-17

REPLACEMENT ...................................................................... 12A-17

FUEL FILLER DOOR LOCK LATCH ASSY .................................12A-18

REPLACEMENT ...................................................................... 12A-18

FUEL FILLER CAP ........................................................................12A-20

INSPECTION ........................................................................... 12A-20

FUEL FILLING TUBE AND BREATHER TUBE ASSY .................12A-21

INSPECTION ........................................................................... 12A-21

ACCELERATE PEDAL ..................................................................12A-25

REPLACEMENT ...................................................................... 12A-25

12A

FUEL - FUEL SYSTEM

12A-1

1. FUEL SYSTEM PRECAUTION.

(a) Before working on fuel system, disconnect battery negative cable.

(b) When removing the fuel hose, use a suitable container to hold the fuel.

Equipment with ventilator at woking area can avoid personal injury.

(d) Fuel in the fuel pump , railway and tubes remain under high pressure. In order to avoid personal injury,

do not loosen tube connector while engine is running.

(e) Keep gasoline away from rubber and leather parts.

(f) Before disconncting any of the fuel system lines or fuel system components, release the fuel system

pressure to prevent accidental spraying of fuel, even when the engine is not running. failure to follow

this instruction may result in serious personal injury.

(g) Check if there is any dirt like mud around the fuel line connector before work. And clean it away,

otherwise it can damage fuel system or engine.

(h) Keep cleaner away from the O-ring of tube connector. Cleaner can corrode the seal of fuel system.

(i) Don’t bend or twist the fuel system tube and pipe by force.

(j) Before connceting fuel system tube, be sure there is no damage, otherwise, replace it with a new tube

assy.

12A-2

FUEL SYSTEM PRESSURE RELEASE PROCESS

(a) Loosen driver seat clamp.

(b) Rotate driver seat and open engine compartment cover.

3. REMOVE FUEL PUMP FUSE.

(a) Remove the lid of battery compartment junction box,

identify the fuel pump fuse with its name labelled inside

the box lid.

(b) Remove the fuse with special puller or plier.

4. START THE ENGINE UNTILL IT STOPS.

5. START THE ENGINE AGAIN FOR 5 SECONDS, ENSURE FUEL RAIL PRESSURE RELEASE

COMPLETELY.

6. TURN IGNITION SWITCH OFF, RE-INSERT FUEL PUMP FUSE BACK INTO BATTERY COMPART-

MENT JUNCTION BOX.

DRAIN FUEL TANK PROCESS

1. CHECK FUEL LEVEL ON FUEL GAUGE.

2. DRAIN FUEL TANK.

(a) Turn ignition switch off.

(b) Insert hose of less than 22mm in diameter into fuel filler hose through fuel filler port to draw fuel in fuel

filler hose.

(d) Insert the hose into fuel tank to draw fuel through fuel tank filler neck.

FUEL TUBE CLEAN

1. USE FUEL TREATMENT THAT FOTON RECOMMENDS TO CLEAN FUEL SYSTEM.

2. USE FUEL ADDITIVES THAT FOTON RECOMMENDS TO CLEAN FUEL SYSTEM.

12A-3

cause of the problem. Check each part in the order shown. If necessary, repair or replace these parts.

Engine does not start

1. Fuel pump (Damaged) Chapter 12A fuel - electric fuel pump assy,

2. Fuel tube (Choked) Chapter 12A fuel - fuel system, precaution

3. Fuel pressure regulator (Fuel

pressure too low)

4. Fuel tank (No fuel) Chapter 12A fuel - fuel tank assy, replacement

5. Fuel pump relay(Damaged) -

6. Fuel injector (Damaged) Chapter 12A fuel - fuel injector rail assy,

1. Fuel tube (Obstructed) Chapter 12A fuel - fuel system, precaution

2. Fuel pressure regulator (Fuel

Chapter 12A fuel - fuel injector rail assy,

Engine start hard

3. Fuel injector (Leaking or

obstructed)

overhaull

4. Fuel pump (Out of order) Chapter 12A fuel - electric fuel pump assy,

Engine idles rough

5. Fuel injector control system (Out

of order)

6. Fuel pressure regulator or fuel

pump (Return valve damaged)

1. Fuel pressure regulator (Fuel

2. Fuel injector (Leaking or

Chapter 04 diagnostics - engine control

3. Fuel tube (Obstructed) Chapter 12A fuel - fuel system, precaution

Engine loss of power

3. Fuel pump (Out of order) Chapter 12A fuel - electric fuel pump assy,

4. Fuel tube (Obstructed) Chapter 12A fuel - fuel system, precaution

5. Fuel (Poor quality) -

12A-4

COMPONENTS

1 Fuel Tank Assy

2 Fuel Tank Rear Bracket

3 Bolt, Spring Washer And Flat Washer

5 Fuel Tank Retaining Belt Assy

6 Fuel Tank Retaining Belt Assy

7 Bolt, Spring Washer And Flat Washer

4 Bolt, Spring Washer And Flat Washer

12A-5

1 Bolt, Spring Washer And Flat Washer

2 Bolt, Spring Washer And Flat Washer

3 Three Line Clip

4 Canister Vent Hose Bracket

5 Fuel Line Clip

6 Fuel Line Clip

7 Single Line Clip

8 Electric Fuel Pump Assy

9 Fuel Filter To Engine Fuel Line Assy

10 Fuel Tank To Engine Fuel Line Assy

11 Canister Vent Hose 1

12 Fuel Filler Hose

13 Bolt, Spring Washer And Flat Washer

14 Fuel Filter

15 Fuel Filter Bracket

16 Nut

17 Bolt, Spring Washer And Flat Washer

18 Canister Vent Hose 2

19 Canister Bracket

20 Canister

21 Fuel Filler Cap

22 Fuel Filter To Engine Rear Fuel Line

23 Bolt, Spring Washer And Flat Washer

24 Bolt, Spring Washer And Flat Washer

25 Band Clamp

26 Fuel Line Clip

27 Fuel Line Clip

28 Dual Line Clip

29 Dual Line Clip

30 Locking Nut

31 Steel Spring Band Clamp

32 Steel Spring Band Clamp

12A-6

FUEL - FUEL TANK ASSY

1. RELEASE FUEL PRESSUE. (Refer to “Chapter 12A fuel - fuel system, fuel system pressure

2. DRAIN FUEL TANK. (Refer to “Chapter 12A fuel - fuel system, drain fuel tank process”)

3. DISCONNECT BATTERY NEGATIVE CABLE.

4. RAISE AND SUPPORT THE VEHICLE IN SUITABLE POSITION.

5. SUPPORT FUEL TANK WITH A JACK.

• The tank may have an uneven surface at the bottom so shims or something similar should be

put on the lower side to keep tank stable when supporting the fuel tank with a jack.

• Support the position that fuel tank retaining belt never engage

6. REMOVE FUEL TANK ASSY.

(a) Remove fuel tank breather pipe clamp.

(b) Remove fuel tank filler tube clamp.

fuel tank assy.

• Disconnect fuel filler tube, check filler port rubber

grommet for improper crack, damage or deterioration,

replace if necessary.

Remove 4 fuel tank retaining belt mounting bolts.

Remove 2 fuel tank rear bracket mounting bolts.

Lower the fuel tank to a suitable position.

Disconnect electric fuel pump assy connector.

Disconnect feed tube quick connector.

Disconnect return tube quick connector.

Disconnect EVAP tube quick connector.

to prevent quick connector from being

damaged.

12A-7

• Mark the fuel tube and quick connector to avoid misassembling.

• Keep the connecting portion clean and avoid

damage and foreign materials, cover them

completely with plastic bags or something similar.

Remove fuel tank assy.

7. INSTALL FUEL TANK ASSY.

Support fuel tank to a suitable position with jack.

Connect electric fuel pump connector.

Connect feed tube, return tube and EVAP tube quick

Connectors.

Connect fuel tube quick connectors until a click is heard,

Install 2 fuel tank retaining belts and tighten 4 mounting

bolts.

Tighten 2 fuel tank rear bracket mounting bolts.

Torque: 41 ~ 51 N•m

Connect fuel tank breather tube, then tighen the clamp.

Connect fuel tank filling tube, then tighen the clamp.

8. LOWER THE VEHICLE.

9. CONNECT BATTERY NEGATIVE CABLE.

10. CHECK FUEL TUBE.

12A-8

When Turning ignition switch on, fuel pump will apply fuel pressure to fuel lines. Inspect if there is fuel

Start engine and rev it up and check there is no fuel leakage at the fuel system tube and hose

FUEL - FUEL FILTER ASSY

12A-9

FUEL FILTER ASSY

REPLACMENT

Install fuel filter and tighten the mounting band bolt.

Connect both sides quick connector.

12A-10

FUEL - ELECTRIC FUEL PUMP ASSY

ELECTRIC FUEL PUMP ASSY

2. DRAIN FUEL TANK AS REQUIRED. (Refer to “Chapter 12A fuel - fuel system, drain fuel tank

process”)

5. REMOVE FUEL TANK. (Refer to “Chapter 12A fuel - fuel tank, replacment”)

6. REMOVE ELECTRIC FUEL PUMP ASSY.

(a) Loosen lock ring counterclockwise with special wrench.

Remove electric fuel pump assy.

Be careful not to bend float arm during removing electric

fuel pump assy.

7. CHECK SEALING RING OF SEALING COVER.

(a) Removing sealing ring as possible as early to avoid

deformation caused by contacting the fuel.

(b) Check seal ring for improper crack, damage or deterioration

and replace if necessary.

12A-11

8. INSTALL ELECTRIC FUEL PUMP ASSY.

(a) Position sealing ring onto the opening of fuel tank until it

seat into place.

(b) Position electric fuel pump assy into fuel tank.

Press installation surface of the electric fuel pump assy

into place, then install lock ring and rotate the lock ring

clockwise.

Tighten lock ring with special wrench to specific torque.

Torque: 60 ~ 70 N•m

When installation, align the mark on the installation surface

of the fuel pump with the corresponding mark on top surface

of fuel tank .

9. INSTALL FUEL TANK. (Refer to “Chapter 12A fuel - fuel tank, replacment”)

10. CHECK AFTER INSTALLATION.

After disconnecting fuel pump connector, connect fuel level sensor connector, turn ignition switch on.

Slide fuel level sensor position manually and then check the fuel gauge’s conditions in instrument

panel.

connections and confirm fuel pump works normally.

12A-12

FUEL - FUEL INJECTOR RAIL ASSY

FUEL INJECTOR RAIL ASSY

3. REMOVE INTAKE AIR PIPE AND HOSE. (Refer to “Chapter 14A intake air- intake air pipe and

hose, replacement”)

4. REMOVE FUEL INJECTOR RAIL ASSY.

(a) Disconnect 4 fuel injector connectors.

Disconnect fuel pressure vaccum hose from fuel pressure

regulator.

Disconnect PCV hose from engine cylinder head cover.

Disconnect feed tube quick connector from fuel injector

rail.

12A-13

Disconnect return tube quick connector from fuel injector

Remove 2 fuel injector rail retaining bolts.

Remove fuel injector rail assy carefully.

Check the O-ring locating between injectors and intake

manifold is in good condition.

5. CHECK FUEL PRESSURE REGULATOR.

(a) Pull clip and remove fuel pressure regulator.

Inspect return spring of fuel pressure regulator operation.

6. REMOVE INJECTOR.

(a) Remove locking clip from the slot of injector.

(b) Turn slightly and pull out inject from fuel injector rail.

Be sure that the O-ring locating between injector and fuel

injector rail is in good condition.

12A-14

7. CHECK INJECTOR.

(a) Use an ohmmeter to measure resistance between two

terminals of injector.

Resistance: 13 ~ 16 Ω

(b) Check if there is any carbon deposition or dirty aroud

injector nozzle, clear it away if blocked.

If necessary, take injector on injector test table, check

injector leakage or not.

8. INSTALL INJECTOR.

(a) Install new insulator to each fuel injector.

• O-ring on both sides of injector are different, do not

misassemble.

• Apply a light coat of spindle oil or gasoline to a new

o-ring, and install it to each fuel injector. Do not use

engine oil or brake fluid.

Install each fuel injector to fuel rail.

Attempt to pull injector out to check the locking clip

secured the injector in place firmly.

9. INSTALL FUEL PRESSURE REGULATORS.

Inspect it if fuel pressure regulator turns smoothly. If not, it means that O-ring is clamped. Reinstall it

with new O-ring.

12A-15

10. INSTALL FUEL INJECTOR ASSY.

(a) Slightly press injector rail to install injector into hole properly.

(b) Tighten 2 fuel injector rail assy retaining bolts.

Connect feed tube to fuel injector rail assy.

are secure.

Connect return tube to fuel injector rail assy.

11. CONNECT 4 INJECTOR CONNECTORS.

12. CONNECT VACCUM HOSE TO FUEL PRESSURE

REGULATIOR.

12A-16

13. CONNECT VACCUM HOSE TO PCV.

14. INSTALL INTAKE AIR PIPE AND HOSE. (Refer to “Chapter 14A intake air- intake air pipe and

15. CHECK AFTER INSTALLATION.

Turn ignition switch “ON” (with engine stopped), and check connections for leakage by applying fuel

pressure to fuel lines

Start engine and rev it up and check there are no fuel leakage at the fuel system tube and hose

FUEL - FUEL FILLER DOOR

12A-17

FUEL FILLER DOOR

1. REMOVE FUEL FILLER DOOR.

(a) Pull fuel filler door handle.

(b) Open fuel filler door.

Remove 2 fuel filler door retaining bolts.

Remove the clip connected to fuel filler cap from fuel filler

door.

Remove fuel filler door.

2. INSTALL FUEL FILLER DOOR.

Install 2 fuel filler door retaining bolts.

Install the clip connected to fuel filler cap to fuel filler

3. ADJUST FUEL FILLER DOOR.

Adjust fuel filler door or 2 retaining bolts position manually

if fuel filler door is not closed completely

12A-18

FUEL - FUEL FILLER DOOR LOCK LATCH ASSY

FUEL FILLER DOOR LOCK LATCH ASSY

1. REMOVE FRONT SIDE WALL GUARD BOARD. (Refer to “Chapter 88 exterior and interior trim

panel - side wall guard board, replacement”)

2. REMOVE LEFT FRONT SEAT LOCK ASSY.

(a) Remove 2 left front seat lock assy retaining bolts.

3. REMOVE FUEL FILLER DOOR LOCK LATCH ASSY.

(a) Open fuel filler door.

(b) Remove lock latch retaining nut.

Remove lock latch assy.

Disconnect fuel filler door cable.

4. INSTALL FUEL FILLER DOOR LOCK LATCH ASSY.

(a) Connect fuel filler door cable to lock latch assy.

12A-19

Position fuel filler door lock latch assy into place inside B

pillar, then tighten retaining nut.

5. CHECK FUEL FILLER DOOR LOCK LATCH ASSY.

(a) Close fuel filler door, then pull fuel filler door handle.

(b) Be sure that fuel filler door lock latch assy is operatonal.

6. INSTALL LEFT FRONT SEAT LOCK ASSY.

(a) Tighten 2 left front seat lock assy retaining bolts.

7. INSTALL FRONT SIDE WALL GUARD BOARD. (Refer to “Chapter 88 exterior and interior trim

12A-20

FUEL - FUEL FILLER CAP

FUEL FILLER CAP

1. PULL FUEL FILLER DOOR HANDLE AND OPEN

FUEL FILLER CAP.

2. REMOVE FUEL FILLER CAP.

(a) Rotate the fuel filler cap counterclockwise to unlock it.

(b) Remove the fixing clip from the plastic ring on the fuel

filler cap.

3. INSPECT FUEL FILLER CAP ASSY.

(a) Visually inspect fuel filler cap and seal ring. If deformed

or damaged, replace with a new one.

(b) Termly lubricate the rotating part.

4. INSTALL THE FUEL FILLER CAP.

(a) Install the fuel filler cap fixing clip into plastic ring.

(b) Rotate the fuel filler cap clockwise until a click is heard.

FUEL - FUEL FILLING TUBE AND BREATHER TUBE ASSY

12A-21

FUEL FILLING TUBE AND BREATHER TUBE ASSY

2. REMOVE BATTERY AND BATTERY TRAY. (Refer to “Chapter 20A starting and charging - battery,

replacement” )

3. OPEN FUEL FILLER DOOR.

4. REMOVE FUEL FILLER CAP.

5. DRAIN FUEL TANK AS REQUIRED. (Refer to “Chapter 12A fuel - fuel system, drain fuel tank

6. REMOVE FUEL FILLER AND BREATHER HOSES.

(a) Remove 3 fuel filler port retaining bolts.

Remove fuel breather hose and fuel filler hose retaining

bolts that are located below battery tray.

Raise and support the vehicle.

Remove upper fuel breather hose bracket retaining nut.

Remove the clamp between upper and lower fuel

breather hoses, then disconnect breather hoses.

Pull upper fuel breather hose out of the hole on sidewall

of the battery compartment .

12A-22

Loosen fuel filler hose retaining clamp at the fuel tank

side, then disconnect fuel filler hose from fuel tank filler

neck.

Remove fuel filler hose retaining bolt from vehicle frame.

Remove upper fuel filler hose retaining bolt from vehicle

frame.

Remove fuel filler hose and upper fuel breather hose.

Remove retaining bolt on the bracket of lower fuel

breather, then pull fuel breather hose out of the hole on

vehicle frame.

(n)

Remove retaining bolt between lower fuel breather hose

bracket and side member NO.2.

Remove fuel breather hose clamp at the fuel tank

breather neck, then disconnect them.

Pull lower fuel breather hose from the side member

NO.2, then remove lower fuel breather hose.

7. INSTALL FUEL FILLER AND BREATHER HOSES.

Position upper fuel filler hose in place.

Tighten 3 fuel filler port retaining bolts.

Engage the groove of seal ring with the lip of fuel filler neck

first securely when installing fuel filler hose assy.

12A-23

Tighten fuel filler hose and upper fuel breather hose

retaining bolt below the battery tray.

Connect upper and lower breather hoses, then tighten

the clamp.

Tighten upper breather hose retaining nut.

Install fuel filler hose through the hole on side member

NO.1.

Connect upper and lower fuel breather hoses, then

tighten retaining clamp.

Tighten the retaining bolt securing breather hose bracket

to side member NO.1.

Install lower breather hose throuth the hole on side

member NO.2.

Tighten retaining bolt securing breather hose bracket to

side member NO.2.

Connect breather hose to fuel tank, then tighten the

clamp.

12A-24

Tighten retaining bolt securing upper fuel filler hose to

(o)

Conncet fuel filler hose to fuel tank filler nect, then

Tighten 1 fuel filler hose retaining bolt.

8. INSTALL BATTERY AND BATTERY TRAY. (Refer to “Chapter 20A starting and charging - battery,

9. CHECK AFTER INSTALLATION.

(a) Fill fuel tank if necessary. Check filling is a smooth flow and no fuel leaks.

10. INSTALL FUEL FILLER CAP, THEN CLOSE THE FUEL FILLER DOOR.

FUEL - ACCELERATE PEDAL

12A-25

ACCELERATE PEDAL

3. REMOVE THROTTLE CABLE.

(a) Push throttle linkage wide open and hold it there to withdraw

throttle cable end from the recess in throttle linkage.

4. REMOVE ACCELERATE PEDAL ASSY.

(a) Remove 2 accelerate pedal retaining nuts.

(b) Remove accelerate pedal with throttle cable and move it

aside.

12A-26

Release locking tab securing throttle cable to accelerate

pedal, then disengage cable end from the recess in the

accelerate pedal so that the cable can be removed

completely.

Remove accelerate pedal assy.

5. INSTALL ACCELERATE PEDAL ASSY.

(a) Engage throttle cabe end into the recess of accelerate

pedal, then install locking tab to lock cable into place.

(b) Position accelerate pedal and tighten 2 retaining nuts.

6. ENGAGE THROTTLE CABLE IN THE THROTTLE

MECHANISM IN THE ENGINE COMPARTMENT.

7. PUT DOWN DRIVER SEAT AND LOCK THE CLAMP.

8. CHECK AFTER INSTALLATION.

(a) After installation, press accelerate pedal to check that the accelerator pedal operates smoothly without

stuck phenomenon.

FUEL FILLER CAP ..........................................................................13A-1

INSPECTION ............................................................................. 13A-1

CHARCOAL CANISTER..................................................................13A-2

OVERHAUL ............................................................................... 13A-2

CANISTER SOLENOID VALVE.......................................................13A-4

OVERHAUL ............................................................................... 13A-4

POSITIVE CRANKCASE VENTILATION VALVE (PCV VALVE)....13A-7

OVERHAUL ............................................................................... 13A-7

EMISSION CONTROL - FUEL FILLER CAP

13A-1

13A

13A-2

CHARCOAL CANISTER

EMISSION CONTROL - CHARCOAL CANISTER

3. REMOVE BATTERY AND BATTERY TRAY. (Refer to “Chapter 20A starting and charging - battery,

4. REMOVE CHARCOAL CANISTER.

(a) Loosen charcoal canister outlet hose clip and disconnect

the hose (to canister solenoid ).

When disconnecting these hoses which are used for a long

time, twist hose first and make them loosed, then perform

the disconnection.

Loosen charcoal canister outlet hose clip and disconnect

The end of EVAP hose connecting to fuel tank identifies

with green mark.

Remove charocal canister directly.

5. CHECK CHAROCAL CANISTER.

(a) Visually check charcoal canister for crack and damage,

replace with a new one if necessary

(b) Blow compressed air into inlet port (to fuel tank), feel

charcoal canister outlet port (to canister solenoid) with

hand and check if air flows from the outlet port.

If no air flows from the outlet port, charcoal canister is

blocked, replace if necessary.

13A-3

6. INSTALL CHARCOAL CANISTER.

(a) Install the hose which connects fuel tank to charcoal

canister and install clip.

Install the hose which connects canister solenoid to

charcoal canister and install clip.

Install charcoal canister on bracket

7. INSTALL BATTERY AND BATTERY TRAY. (Refer to “Chapter 20A starting and charging - battery,

8. PUT DOWN THE DRIVER SEAT AND LOCK IT.

13A-4

EMISSION CONTROL - CANISTER SOLENOID VALVE

13A-5

13A-6

7. INSTALL AIR INTAKE PIPE AND HOSE. (Refer to “Chapter 14A intake air - intake air pipe and

EMISSION CONTROL - POSITIVE CRANKCASE VENTILATION VALVE (PCV VALVE)

13A-7

POSITIVE CRANKCASE VENTILATION VALVE (PCV VALVE)

1. TURN IGNITION SWITCH ON.

2. OPEN ENGINE COMPARTMENT COVER

3. REMOVE PCV VALVE.

(a) Disconnect PCV hose from engine cylinder head cover

(b) Remove PCV valve.

4. INSPECT PCV VALVE.

(a) Disconnect PCV hose from engine cylinder head, start engine at idle speed. put finger at PCV port,

check if vacuum of air intake manifold exits. if not, clean or replace with a new one.

Blow air from port that connect cylinder. Air can flow out

from the other port.

Blow air from port that connect air intake mainfold. Air

can’t flow out from the other port.

13A-8

5. INSTALL PCV VALVE .

(a) Install PCV valve into engine cylinder head cover.

(b) Connect PCV hose to PCV valve.

INTAKE AIR SYSTEM......................................................................14A-1

PRECAUTION............................................................................ 14A-1

INTAKE AIR PIPE AND HOSE ........................................................14A-2

REPLACEMENT ........................................................................ 14A-2

AIR FILTER ASSY ...........................................................................14A-6

REPLACEMENT ........................................................................ 14A-6

INTAKE MANIFOLD................................................................. 14A-10

REPLACEMENT ...................................................................... 14A-10

14A

INTAKE AIR SYSTEM

AIR

1. INTAKE AIR SYSTEM PRECAUTION.

INTAKE AIR - INTAKE AIR SYSTEM

14A-1

Intake air must be filtered to avoid debris and dirt entering the engine. loose and damaged pipe or hose

connection may cause unfiltered air to enter the engine leading to premature engine wear.

The intake manifold hose connection must be reliable enough to avoid gaps and looseness, etc.

Each cushion and bracket connection with intake manifold hose must be reliable. There are no cracks

on the apperance or gaps in the connection portion.

When using the solvent, acid or alkaline material washing, please follow the manufacturers’ advice to

wear protective clothing and goggles to avoid personal injury.

When dealing with corrosive work, use skin and eye protection device to reduce the possibility of

personal injury.

When using compressed air, wear appropriate goggles and protective mask. Both dust particles and

dirt will cause injury.

14A-2

INTAKE AIR - INTAKE AIR PIPE AND HOSE

INTAKE AIR PIPE AND HOSE

1. REMOVE UPPER INTAKE AIR HOSE IN THE ENGINE

COMPARTMENT.

Remove intake air hose clamp on throttle body side.

Remove 2 intake air pipe retaining bolt.

Disconnect crankcase vent hose on intake air pipe.

Remove the clamp at the end of intake air pipe.

Remove upper intake air pipe and hose.

14A-3

2. REMOVE MIDDLE INTAKE AIR PIPE AND HOSE.

(a) Remove middle intake air ripple hose clamp under the

Remove middle intake air ripple hose.

Remove middle intake air pipe retaining bolt by the right

front wheel side.

Remove the clamp connecting middle intake air pipe to

bending hose.

Remove middle intake air pipe.

(f) Remove air filter assy. (Refer to “Chapter 14A intake air -

air filter assy, replacement”)

14A-4

Remove the clamp securing bending hose to air filter

assy, then remove the bending hose.

3. INSTALL MIDDLE INTAKE AIR PIPE AND HOSE.

Install bending hose to air filter outlet pipe and tightnen

Install air filter assy. (Refer to “Chapter 14A intake air - air

filter assy, replacement”)

Positon middle intake air pipe in place, then install

Tighten middle intake air pipe retaining bolt and bending

hose retaining clamp.

Install middle intake air ripple hose.

Tighten ripple hose clamp.

4. INSTALL UPPER INTAKE AIR PIPE AND HOSE IN

THE ENGINE COMPARTMENT.

Tighten the clamp securing intake air pipe to ripple hose.

14A-5

Tighten intake air hose clamp to throttle body side.

Tighten 2 intake air pipe retaining bolts.

Connect crankcase vent hose to intake air pipe, then

tighten clamp.

5. CHECK AFTER INSTALLATION.

(a) After installing air filter, check all parts and parts connection again to make sure engine operates properly.

14A-6

INTAKE AIR - AIR FILTER ASSY

AIR FILTER ASSY

1. REMOVE FRONT GRILLE. (Refer to “Chapter 88 exterior and interior trim - front grille, replacement”)

2. REMOVE FRONT BUMPER. (Refer to “Chapter 88 exterior and interior trim - front bumper assy,

3. REMOVE AIR FILTER INTAKE AIR DUCT.

Remove retaining bolt and clamp of air filter intake air

duct.

Remove intake air duct.

4. REMOVE AIR FILTER ASSY.

Remove retaining clamp securing bending hose to

middle intake air pipe.

14A-7

Remove 3 air filter assy retaining bolts.

Remove air filter together with bending hose.

loosen clamp securing bending hose to air filter and

remove bending hose.

5. INSTALL AIR FILTER ASSY.

Install bending hose to air filter assy outlet pipe, then

Connect the end of benging hose which has a triangle mark

to air filter when installation.

14A-8

Position air filter with bending hose in place.

Connect bending hose to middle intake air pipe, then

Tighten 3 air filter assy retaining bolts.

Torque: 21 ~ 25 N.m

Install air filter intake air duct retaining bolt.

Tighten the clamp securing intake air duct to air filter inlet

pipe.

14A-9

6. INSTALL FRONT BUMPER. (Refer to “Chapter 88 exterior and interior trim - front bumper assy,

7. INSTALL FRONT GRILLE. (Refer to “Chapter 88 exterior and interior trim - front grille, replacement”)

8. REPLACE AIR FILTER ELEMENT.

Release 3 retaining clips from air filter lower cover.

Open air filter lower cover and remove air filter element.

Air filter element is made of paper. If necessary, clear the air

filter element with high pressure air gun. Do not clean it

with water.

Clean or replace air filter element.

Install air filter lower cover and lock the retaining clips.

14A-10

INTAKE MANIFOLD

1. DRIAN THE COOLANT. (Refer to “Chapter 17A cooling - coolant, replacement”)

4. REMOVE INTAKE AIR PIPE AND HOSE. (Refer to “Chapter 14A intake air - intake air pipe and hose,

5. DISCONNECT VACCUM BOOSTER HOSE ON INTAKE

MANIFOLD.

6. REMOVE THROTTLE BODY. (Refer to “Chapter 11A engine control system - throttle body, overhaul”)

7. DISCONNECT ENGINE COOLANT TEMPERATURE

SENSOR CONNECTOR.

14A-11

8. DISCONNECT IGNITION COIL CONNECTOR.

9. REMOVE GROUND HARNESS.

10. DISCONNECT INTAKE TEMPERATURE/ PRESSURE

11. DISCONNECT A/C COMPRESSOR CONNECTOR.

12. DISCONNECT KS CONNECTOR.

13. DISCONNECT STARTER CONTROL WIRE CONNEC-

TOR.

14A-12

14. DISCONNECT 4 INJECTOR CONNECTORS.

Position wire harness aside for easy operation。

15. REMOVE FUEL INJECTOR RAIL ASSY. (Refer to “Chapter 12A fuel - fuel injector rail assy,

16. REMOVE CANISTER SOLENOID VALVE. (Refer to “Chapter 11A engine control system - canister

solenold valve, overhaul”)

17. REMVOE INTAKE MANIFOLD LOWER BRACKET.

(a) Remove 4 intake manifold lower bracket retaining bolts.

18. REMOVE WATER HOSES ON INTAKE MANIFOLD

SIDE.

(a) Remove 4 water hoses retaining clamps.

(b) Disconnect 4 water hoses.

Remove 2 three-way water pipe retaining bolts.

14A-13

Remove three-way water pipe.

Check whether there are sign of coolant leakage for cap

plug and coolant sensor. If it is present, replace cup plug or

coolant sensor shim.

19. REMOVE INTAKE MANIFOLD ASSY.

(a) Remove intake manifold retaining bolts and nuts.

Remove intake manifold assy.

Remove intake manifold sealing gasket.

Always replace a new sealing gasket after removing intake

manifold.

20. INSTALL INTAKE MANIFOLD ASSY.

(a) install intake manifold sealing gasket.

(b) install 9 intake manifold retaining bolts and nuts.

Torque: 15 ~ 18 N.m

14A-14

Install 4 intake manifold lower bracket retaining bolts.

21. INSTALL THREE-WAY WATER PIPE.

(a) Use scraper to remove all old sealant adhering to the

groove on mating surface of three-way water pipe, and

then apply sealant to the groove.

Install 2 three-way water pipe retaining bolts.

Install 4 water hoses.

Tighten 4 water hose clamps.

22. INSTALL FUEL INJECTOR RAIL ASSY. (Refer to “Chapter 12A fuel - fuel injector rail assy,

23. INSTALL CANISTER SOLENOID VALVE. (Refer to “Chapter 11A engine control system - canister

24. INSTALL THROTTLE BODY. (Refer to “Chapter 11A engine control system - throttle body, overhaul”)

14A-15

25. CONNECT INTAKE MANIFOLD VACCUM BOOSTER

HOSE.

26. CONNECT STARTER CONTROL WIRE CONNECTOR.

27. CONNECT KS CONNECTOR.

28. CONNECT A/C COMPRESSOR CONNECTOR.

29. CONNECT ENGINE COOLANT TEMPERATURE SEN-

SOR CONNECTOR.

14A-16

30. TIGHTEN GROUND WIRE.

31. CONNECT IGNITION COIL CONNECTOR.

32. CONNECT INTAKE TEMPERATURE / PRESSURE

33. INSTALL INTAKE AIR PIPE AND HOSE. (Refer to “Chapter 14A intake air - intake air pipe and hose,

34. CONNECT BATTERY NEGATIVE CABLE.

35. FILL COOLANT TO SPECIFIED LEVEL. (Refer to “Chapter 17A cooling - coolant, replacement”)

36. PUT DOWN DRIVER SEAT AND LOCK IT.

37. CHECK AFTER INSTALLATION.

(a) Start the vehicle, check all electrical component is functional and no gas, air and fluid leakage are

found.

ENGINE MECHANICAL PART ........................................................15A-1

PRECAUTION............................................................................ 15A-1

ENGINE ASSY .................................................................................15A-2

REPLACEMENT ........................................................................ 15A-2

TIMING PULLEY CASING .............................................................15A-14

REPLACEMENT ...................................................................... 15A-14

TIMING BELT.................................................................................15A-18

COMPONENTS ....................................................................... 15A-18

OVERHAUL ............................................................................. 15A-19

ROCK ARM, ROCK ARM SHAFT, HYDRAULIC

TAPPET & CAMSHAFT.................................................................15A-37

COMPONENTS ....................................................................... 15A-37

ROCK ARM, ROCK ARM SHAFT & HYDRAULIC TAPPET OVER-

HAUL ....................................................................................... 15A-39

CAMSHAFT OVERHAUL......................................................... 15A-49

CYLINDER HEAD,VALVE .............................................................15A-51

COMPONENTS ....................................................................... 15A-51

CYLINDER HEAD OVERHAUL ............................................... 15A-52

VALVE OVERHAUL................................................................. 15A-54

PISTON & CONNECTING ROD ASSEMBLY................................15A-59

COMPONENTS ....................................................................... 15A-59

PISTON & CONNECTING ROD ASSEMBLY OVERHAUL..... 15A-60

CRANKSHAFT, CYLINDER BLOCK & FLYWHEEL ....................15A-69

COMPONENTS ....................................................................... 15A-69

OVERHAUL ............................................................................. 15A-71

15A

ENGINE MECHANICAL - ENGINE MECHANICAL PART

ENGINE MECHANICAL PART

MECHANICAL

1. EMGINE MECHNANICAL PART PRECAUTION.

Follow the instructions of maintenance methods and regulations to adjust or maintain.

15A-1

(b) Before starting the engine, check the coolant level, fill or drain the coolant if necessary. Check the

engine oil level, fill the engine oil if necessary.

and make the engine work abnormal.

(d) Do not pull up the spark plug wire when the engine is running.

(e) The clearance between ckp sensor and flywheel is 0.8 ~ 1.2 mm. Do not try to adjust it.

(f) The fuel should use ron ≥ 93 unleaded gasoline, otherwise the catalytic converter will be damaged.

(g) Use the oil as requirement, otherwise exacerbate engine wear.

(h) Use the original fittings, otherwise it will damage the engine or affect the engine working condition.

(i) Do not use the high pressure water cannons to wash the ecm shell.

(j) The engine starting time should be less than 5s. Not more than 5 consecutive starting times. Interval

time to next starting should not be less than 15 seconds.

(k) Keep the normal coolant temperature 85 ~ 105 ℃ .

(l) When the engine in high speed or high load, do not turn the ignition switch off. Keep the engine running

in low speed for 3~5 mins that the engine radiates eventually.

(m) Before opening the radiator cap, check the coolant level and must ensure the engine is cool.

(n) Use the sealant scraper to clear the sundries in seal surface. Confirm seal surface flat and smooth, no

oil stain there.

15A-2

ENGINE MECHANICAL - ENGINE ASSY

1. RECOVER REFRIGERANT. (Refer to “Chapter 61 heater and air conditioner - refrigerant,

2. RELEASE FUEL SYSTEM PRESSURE. (Refer to “Chapter 12A fuel - fue system, fuel system

pressure release process”)

4. DRAIN COOLANT. (Refer to “Chapter 17A cooling - coolant, replacement”)

5. DRAIN ENGINE OIL. (Refer to “Chapter 18A lubricantion - engine oil, replacement”)

6. DRAIN TRANSMISSION FLUID. (Refer to “Chapter 41 transmission - transmission assy, replacement”)

7. LOWER THE VEHICLE.

8. OPEN ENGINE COMPARTMENT COVER.

9. DISCONNECT BATTERY NEGATIVE CABLE.

10. REMOVE ASSISTANT DRIVER SEAT. (Refer to “Chapter 84 seat - driver / assistant driver seat,

11. REMOVE ENGINE COMPARTMENT COVER UNDER

ASSISTANT DRIVER SEAT.

(a) Remove front floor covering.

(b) Remove 5 engine compartment cover retaining bolts.

12. REMOVE INTAKE AIR PIPE AND HOSE. (Refer to “Chapter 14A intake air - intake air pipe and

15A-3

13. LOOSEN CLAMP AND DISCONNECT ENGINE WATER

OUTLET HOSE.

14. LOOSEN CLAMP AND DISCONNECT WATER OUT-

LET HOSE AND INLET HOSE TO FRONT HEATER.

15. DISCONNECT WATER INLET HOSE TO REAR HEATER.

16. REMOVE THROTTLE CABLE FROM THE THROTTLE

BODY.

17. REMOVE THE HOSE TO CANISTER SOLENOID VALVE.

18. REMOVE FUEL RETURN TUBE.

19. REMOVE FUEL FEED TUBE.

After disconnecting fuel tubes, cover them completely with

plastic bags or something similar to avoid damage and

foreign materials.

20. REMOVE VACUUM BOOSTER HOSE TO INTAKE

21. REMOVE WATER OUTLET HOSE TO REAR HEATER.

15A-4

22. REMOVE ENGINE WATER INLET HOSE.

23. REMOVE ENGINE ECM HARNESS CONNECTOR.

(a) Remove the clip securing engine harness to cowl panel

at engine compartment.

(b) Pull rubber grommet securing engine harness out of the

hole at ECM compartment sidewall.

Remove ECM compartment cover, then disconnect ECM

connector and the other 2 electrical connectors.

Pull engine harness connectors and 2 electrical connectors

through the hole of ECM compartment.

24. REMOVE GENERATOR POSITIVE CABLE.

25. DISCONNECT HIGH PRESSURE AND LOW PRESSURE

PIPES TO COMPRESSOR.

(a) Loosen 2 nuts securing high pressure and low pressure

pipes to compressor, then disconnect them.

Using clean cloth, block the A/C pipe and A/C compressor

hole to avoid dust entering.

15A-5

26. RAISIE THE VEHICLE.

27. REMOVE 2 FRONT WHEELS. (Refer to “Chapter 33 wheel and tire - wheel, replacement”)

28. REMOVE STARTER POSITIVE CABLE.

29. DISCONNECT THE GROUND CABLE TO ENGINE

BLOCK.

30. REMOVE LEFT FRONT SUSPENSION UNIT.

(a) Separate left front shock absorber from lower control

arm. (Refer to “Chapter 31 front suspension - front shock

absorber, overhaul”)

(b) Separate left front stabilizer bar from lower control arm.

(Refer to “Chapter 31 front suspension - stalilizer bar,

ball joint seat. (Refer to “Chapter 31 front suspension -

lower control arm, replacement”)

(d) Separate left front steering tie rod from the steering

knuckle arm. (Refer to “Chapter 52 power steering -

power steering link assy, replacement”)

31. REMOVE RIGHT FRONT SUSPENSION UNIT.

The procedure to remove right front suspension unit is similar to the procedure above.

32. REMOVE STEERING DRIVE SHAFT ASSY II.

(a) Remove retaining bolts on both sides of steering drive

shaft assy II.

(b) Remove steering drive shaft assy II.

Before disconnecting steering drive shaft assyII, mark

steering drive shaft assy and steering gear output shaft for

easier installation.

33. REMOVE TRANSMISSION FLEXIBLE SHAFT ASSY.

(a) Remove clamp NO.1 retaining bolt securing flexible shaft

assy to sub-frame.

15A-6

Remove clamp NO.2 retaining bolt securing flexible shaft

assy to sub-frame..

transmission flexible shaft to transmission shift

mechanism.

34. REMOVE CLUTCH SLAVE CYLINDER.

(a) Remvoe 2 retaining bolt mounting clutch slave cylinder to

transmission assy.

(b) Remove clutch slave cylinder.

35. REMOVE CATALYTIC CONVERTER. (Refer to“Chapter 16 exhaust - exhaust pipe, replacement”)

36. DISCONNECT VSS AND BACK-UP LAMP SWITCH

HARNESS CONNECTORS.

37. SUPPORT ENGINE SUB-FRAME AND TRANSMISSION ASSY WITH HYDRAUMATIC JACK.

Lower the vehicle in suitable position and support bottom of engine sub-frame and transmission assy

with hydraumatic jack securely.

15A-7

38. REMOVE SUB-FRAME RETAINING BOLTS.

Remove 5 retaining bolts securing sub-frame right side to

(b) Left side is similar to the procedure above. Remove 5

retaining bolts securing sub-frame left side to vehicle

Before removing sub-frame, mark the sub-frame to ensure

align the reference line marked on the sub-frame with

retaining bolts when installing

39. SEPARATE PROPELLER SHAFT FROM TRANSMISSION ASSY. (Refer to “Chapter 34 axle and

propeller shaft - prepeller shaft, overhaul”)

40. REMOVE TRANSMISSION MOUNT.

(a) Remove the retaining nut securing transmission mount to

After supporting the rear of transmission to a suitable

height with jack, pull out the retaining bolt to separate the

transmission mount from the vehicle frame.

41. LOWER THE JACK SLOWLY TO SEPARATE ENGINE SUB-FRAME AND TRANSMISSION ASSY

FROM VEHICLE FRAME.

• Verify all vacuum hoses, fuel and coolant hoses, electrical connectors between engine/

transmission and vehicle are disconnected.

• Lower engine about 150 mm slowly. verify all components between the engine/transmission and

vehicle are disconnected again.

42. SEPARATE ENGINE ASSY FROM TRANSMISSION ASSY. (Refer to “Chapter 41 transmission -

transmission assy, replacement”)

43. DISCONNECT HIGH PRESSURE AND LOW PRESSURE FLUID PIPES FROM POWER STEERING

PUMP. (Refer to “Chapter 52 power steering - power steering link assy, replacement”)

44. FIT ENGINE HOOK AND HANG ENGINE ASSY WITH A HOIST.

45. REMOVE ENGINE MOUNTS ON BOTH SIDES OF

ENGINE.

Remove retaining nut securing left engine mount to subframe

and separter them.

Remove right engine mount, the procedure is similar to

the left side.

46. HOIST ENGINE UP AND SEPARATE ENGINE FROM SUB-FRAME.

15A-8

47. INSTALL ENGINE MOUNTS ON BOTH SIDES OF

Aligning the engine mount bracket with engine mount

stud, lower and position engine onto sub-frame.

Tighten retaining nut securing left engine mount to subframe.

Tighten retaining nut securing right engine mount to subframe.

Torque: 78 ~ 96 N.m

48. CONNECT HIGH PRESSURE AND LOW PRESSURE FLUID PIPES TO POWER STEERING PUMP.

(Refer to “Chapter 52 power steering - power steering link assy, replacement”)

49. CONNECT TRANSMISSION TO ENGINE ASSY. (Refer to “Chapter 41 transmission - transmission

assy, replacement”)

50. POSITION THE HYDRAULIC JACK SUPPORTING ENGINE SUB-FRAME AND TRANSMISSION

ASSY BENEATH THE VEHCLE.

51. RAISE THE HYDRAULIC JACK UNTIL THE SUB-FRAME MOUNTING PIN WAS FULLY SEATED

INTO THE VEHICLE FRAME AND TARANSMISSION MOUNT IS IN RIGHT PLACE.

• Lift up the hydraulic jack slowly, make sure there is no interference with vehicle during raising

the engine and transmission assy.

• During raising slowly, handle lower control arm, steering tie rod and shock absorber related

position with vehicle avoid interference.

52. INSTALL SUB-FRAME RETAINING BOLTS.

(a) Install 5 retaining bolts securing sub-frame left side to

Torque: 150 ~ 170 N.m

(b) Install 5 retaining bolts securing sub-frame right side to

Align the mark on sub-frame while installation.

53. INSTALL RETAINING NUT SECURING TRANSMISSION

MOUNT TO VEHICLE FRAME.

Torque: 126 ~ 154 N.m

15A-9

54. REMOVE GENERATOR RETAINING BOLTS AND

SEPARATE GENERATOR FROM BRACKET.

Connect left front shock absorber to lower control arm.

(Refer to “Chapter 31 front suspension - front shock

Connect left front stabilizer bar to lower control arm.

Connect left front stabilizer bar to lower control arm ball

joint seat. (Refer to “Chapter 31 front suspension - lower

control arm, replacement”)

Connect left front steering tie rod to the steering knuckle

arm.(Refer to “Chapter 52 power steering - power

steering link assy, replacement”)

55. INSTALL RIGHT FRONT SUSPENSION UNIT.

56. INSTALL 2 FRONT WHEEL. (Refer to “Chapter 33 wheel and tire - wheel, replacement”)

57. INSTALL STEERING DRIVE SHAFT ASSY II.

(a) Install steering drive shaft assy II.

(b) Tighten retaining bolts on both sides of steering drive

When installing steering drive shaft assyII, make sure steering

wheel is in the center and front wheel stands straight

ahead of the vehicle.

58. INSTALL CATALYTIC CONVERTER. (Refer to“Chapter 16A exhaust - exhaust pipe,

59. CONNECT PROPELLER SHAFT TO TRANSMISSION ASSY. (Refer to “Chapter 34 axle and

60. INSTALL TRANSMISSION FLEXIBLE SHAFT ASSY.

(a) Install locking nuts and locking clips securing transmission

flexible shaft to transmission shift mechanism.

(b) Tighten 2 clamp retaining bolts securing flexible shaft

15A-10

61. INSTALL CLUTCH SLAVE CYLINDER.

Tighten 2 clutch slave cylinder retaining bolts.

62. CONNECT VSS AND BACK-UP LAMP SWITCH

HARNESS CONNECTOR.

63. CONNECT ENGINE WATER INLET HOSE.

64. INSTALL A/C PIPES TO COMPRESSOR.

(a) Tighten mounting nuts securing high pressure and low

pressure pipes to compressor.

Torque: 20 ~ 26 N•m

Always replace O-ring with new one.

65. CONNECT STARTER POSITIVE CABLE.

66. CONNECT GROUND CABLE TO ENGINE BLOCK.

15A-11

67. CONNECT WATER OUTLET HOSE TO REAR HEATER.

68. CONNECT WATER INLET HOSE TO REAR HEATER.

69. INSTALL THROTTLE CABLE TO THE THROTTLE

70. CONNECT CANISTER SOLENOID VALVE HOSE.

71. CONNECT RETURN TUBE TO FUEL INJECTOR RAIL

ASSY.

72. CONNECT VACCUM BOOSTER HOSE TO INTAKE

73. CONNECT FEED PIPE TO FUEL INJECTOR RAIL

74. CONNECT ENGINE WATER OUTLET HOSE, THEN

TIGHTEN CLAMP.

75. CONNECT WATER OUTLET AND WATER INLET HOSES

TO REAR HEATER, THEN TIGHTEN CLAMPS.

15A-12

76. CONNECT GENERATOR POSITIVE CABLE.

77. INSTALL ENGINE ECM HARNESS.

(a) Route the engine electrical harness throuth the mounting

hole into ECM compartment.

(b) Connect ECM connector and other 2 electrical connectors.

Fasten the tie securing engine harness to cowl panel.

Press the rubber grommet into place.

78. INSTALL INTAKE AIR PIPE AND HOSE. (Refer to “Chapter 14A intake air - intake air pipe and

79. ADD POWER STEERING FLUID TO SPECIFIED LEVEL. (Refer to “Chapter 52 power steering -

steering fluid, replacement”)

80. INSTALL ENGINE COMPARTMENT COVER UNDER

(a) Tighten 5 engine compartment cover retaining bolts.

(b) Cover front floor covering.

15A-13

81. INSTALL ASSISTANT DRIVER SEAT. (Refer to “Chapter 84 seat - driver / assistant driver seat,

82. PUT DOWN DRIVER SEAT AND LOCK IT.

83. FILL COOLANT. (Refer to “Chapter 17A cooling - coolant, replacement”)

84. FILL ENGINE OIL. (Refer to “Chapter 18A lubricantion - engine oil, replacement”)

85. FILL TRANSMISSION FLUID. (Refer to “Chapter 41 transmission - transmission assy, replacement”)

86. SUPPLY REFRIGERANT. (Refer to “Chapter 61 heater and air conditioner - refrigerant, replacement”)

15A-14

ENGINE MECHANICAL - TIMING PULLEY CASING

TIMING PULLEY CASING

1. Switch off the ignition.

2. Disconnect battery negative cable. (Refer to "Chapter 20. Start & charge - battery, replacement")

3. Remove the ignition coil and the spark plug cable. (refere to "Chapter 19A. Ignition - ignition

module, high voltage cable, spark plug, overhaul")

4. Remove the retaining bolts on the front upper cover

of the toothen timing belt and then the cover.

5. Remove the engine accessory belt. (Refer to "Chapter 15A. Engine mechanical system - engine

accessory belt, overhaul")

6. Remove the retaining bolts on the front middle cover

7. Remove the retaining nuts of the water pump belt

pulley and then the pulley.

15A-15

8. Remove the retaining nuts of the crank crankshaft

damper wheel and then the pulley.

9. Remove the retaining bolts on the front lower cover

10. Clean the interior of the toothed timing belt front cover and the impurities at the side.

11. Install the front lower cover of the toothed timing belt

and tighten the retaining bolts.

Torque: 11N·m

15A-16

12. Install the crank shock absorption belt pulley and

tighten the retaining bolts.

Torque: 25 N·m

13. Install the water pump belt pulley and tighten the

retaining nuts.

Torque: 14 N·m

14. Install the front middle cover of the toothed timing

belt and tighten the retaining bolts.

15. Install the engine accessory belt. (Refer to "Chapter 15A. Engine mechanical system - engine

16. Install the front upper cover of the toothed timing

Torque: 18 ~ 26N·m

15A-17

17. Install the ignition coil and the spark plug cable. (refere to "Chapter 19A. Ignition - ignition

18. Connect battery negative cable. (Refer to "Chapter 20. Start & charge - battery, replacement")

15A-18

ENGINE MECHANICAL - TIMING BELT

1 Front Lower Cover of Timing Belt

2 Front Middle Cover of Timing Belt

3 Front Upper Cover of Timing Belt

4 Toothed Camshaft Belt Pulley

5 Harness Bracket

6 Timing Belt

7 Tensioner

8 Tensioner Arm

9 Timing Belt B Tensioner

10 Balancing Shaft Belt Pulley

11 Timing Belt B

12 Flange

13 Idler

14 Crank TImming Belt Pulley B

15 Crank Timing Belt Pulley Gasket

16 Oil Pump Belt Pulley

17 Crank TImming Belt Pulley

18 Automatic Tensioner

15A-19

1. Disconnect negative battery cable. (Refer to "Chapter 20. Start & charge - battery, replacement")

2. Remove the engine harness.

3. Remove the engine accessory belt. (Refer to "Chapter 15A. Engine mechanical system - engine

4. Remove the front cover of toothed engine timing belt. (Refer to "Chapter 15A. Engine

mechanical system - toothed timing belt casing, replacement")

5. Mark down the rotation direction of the toothed

timing belt to faciliate installation.

6. Turn and align the crank to the timing mark:

Align the timing mark of the toothed camshaft belt pulley.

15A-20

Align the timing mark of the toothed oil pump belt pulley.

Align the timing mark of the toothed crankshaft belt

pulley.

7. Use a specific tool to screw into the threaded hole,

until the pin can be inserted into the locking hole on

the automatic tensioner.

8. Insert the pin into the locking hole on the automatic

tensioner.

15A-21

9. Remove the retaining bolts of the automatic

tensioner and then the tensioner.

10. Check the automatic tensioner:

(a) Check whether there is damage or leakage on the automatic tensioner and replace it if necessary.

(b) Check whether there is wear or damage on the rod end and repalce it if necessary.

tensioner. If not qualified, replace it.

Standard: 12 mm

Press the rod down in 98~196N while measuring the

movement. If the value is 1mm less than Item 3) or

above, replace the tensioner.

Standard: ≤ 1mm

15A-22

Hold the tensioner with vise with soft jaws. Turn the plier

handles and push the tensioner rod into it. If it can be

easily inserted, replace the tensioner. You shall feel

certain resistance during the process.

There is a protruded plug at the bottom of the automatic

tensioner. Insert a flat pad between the pliers and the plug

to prevent them from touching each other.

11. Loose the retaining bolts of the tensioner and then

the toothed timing belt.

12. Remove and check the toothed timing belt. Replace it in case of any of the following damages:

• Water or grease on the belt teeth will quickly reduce its useful life. Therefore, after removal,

protect the belt teeth, the toothed belt pulley and the tensioner from water or grease. Do not

clean these parts. In case of heavy contamination, replace it with a new one.

• If any water or grease is found on the parts, check whether there is any leakage on the front

cover oil seal, the crankshaft oil seal and water pump.

Aged and shiny rubber on the back, showing no nail

scratch.

15A-23

(b) Cracked or peeled canvas.

(d) Cracked belt tooth at the bottom.

(e) Cracked belt tooth on the side.

Unusual tear and wear on the side of the belt. If the side

of the tooth belt is as neat as cut, it is normal.

Unusal tear wear of the toothed belt.

Missing tooth.

13. With a tool, remove the retaining bolts of the toothed

camshaft belt pulley and then the pulley.

14. Remove the toothed oil pump belt pulley:

Remove the plug at the side of the cylinder.

15A-24

Insert a screwdriver to fix the left balancing shaft.

Remove the toothed oil pump belt pulley nuts and then

the pulley.

15. Remove the toothed crank timing belt pulley:

(a) Fix the flywheel with a tool.

Remove the retaining bolts of crank shock absorption

belt pulley and toothed crank timing belt pulley, and then

the crank shock absorption belt pulley.

Remove the toothed crank timing belt pulley. Use a tool

in case of difficulty.

15A-25

16. Remove the retaining bolts of the tensioner arm and

then the arm.

17. Mark down the rotation direction of the toothed

balancing shaft belt to faciliate installation.

• Water or grease on the belt teeth will quickly reduce

its useful life. Therefore, after removal, protect the

belt teeth. the toothed belt pulley and the tensioner

from water or grease. Do not clean these parts. In

case of bad contamination, replace it with a new one.

• If any water or grease is found on the parts, check

whether there is any leakage on the front cover oil

seal, the crankshaft oil seal and water pump.

18. Align the timing mark of the toothed balancing shaft

belt pulley.

Align the timing mark of the toothed balancing shaft belt

15A-26

19. Loose the retaining bolts of the toothed balancing

shaft belt tensioner and then the toothed timing belt

20. Remove and check the toothed balancing shaft belt. Replace it in case of any of the following

damages:

Check all parts of the toothed belt carefully and replace it in case of the following damages.

15A-27

Cracked or peeled canvas.

Cracked rubber on the back.

Cracked belt tooth at the bottom.

Cracked belt tooth on the side.

21. Fix the toothed balancing shaft belt pulley with a

tool.

22. Remove the retaining bolts of the toothed balancing

shaft belt pulley and then the toothed balancing

shaft belt pulley and sleeve.

15A-28

23. Remove the toothed timing belt pulley B. Use a tool

24. Install the balancing shaft sleeve.

During installation, face the bevelled side towards the oil

seal.

25. Install the toothed crank timing belt pulley.

26. Fix the toothed balancing shaft belt pulley with a tool

Torque: 42 ~ 48 N·m

15A-29

27. Align the timing mark of the toothed balancing shaft

15A-30

28. Install the toothed balancing shaft belt pulley

according to the rotation direction marked on the

belt before disassembly. Do not allow loose part at

the tension side.

29. Push a finger against the toothed balancing shaft

belt tensioner and impose a force along the arrow

direction, while tightening the retaining bolts and

fixing the tensioner.

Torque: 48N·m

When tightening the bolts, do not allow the shaft turning

along with the toothed belt pulley, which will overly tension

the belt.

30. Confirm that the toothed belt pulley is aligned with

the mark on the front cover. Press the center of the

toothed timing belt B at the tensioner side, measured

at 5 ~ 7 mm.

31. Install the toothed crank timing belt pulley and the crank shock absorption belt pulley:

Fix the flywheel with a tool.

15A-31

Install the toothed crank timing belt pulley and the crank shock absorption belt pulley.

Tighten the retaining bolts of the toothed crank timing

belt pulley and the crank shock absorption belt pulley.

Torque of toothed crank timing belt pulley bolts:

165 N·m

Torque of crank shock absorption belt pulley bolts:

25N·m

32. Install the toothed oil pump belt pulley:

Insert a screwdriver to fix the left balancing shaft. Install

the toothed oil pump belt pulley and tighten the nuts.

Torque: 55N·m

Tighten the plug at the cylinder side.

33. Install the tensioner arm and tighten the retaining

nuts.

Torque: 22N·m

34. Install the automatic tensioner:

(a) If the automatic tensioner is in a protruding position, retract it in the following steps.

15A-32

Hold the tensioner with a pair of pliers with soft jaws.

to prevent them from directly touching each other.

With the pliers, slowly push in the rod until the hole is aligned to that on the tensioner. Insert the bolt into

the holes.

Loose the pliers and remove the automatic tensioner.

35. Install the automatic tensioner and tighten the

Torque: 24N·m

Before adjusting the tension of the toothed timing belt, do

not remove the bolt in the locking hole of the tensioner.

36. Install the retaining bolts of the toothed camshaft

belt pulley with a tool.

Torque: 90N·m

15A-33

37. Align the timing marks:

15A-34

38. Insert a plus screwdriver into the hole. If it goes

beyond 60 mm, it means that it is aligned to the

timing mark. If the distance is less than 20~25mm,

turn the toothed oil pump belt pulley around once

and again align it to the timing mark. Check whehter

it can go beyond 60mm. Keep the screwdriver

inserted until the end of the belt installation.

39. Install the toothed timing blet along the direction

marked before.

Do not move the timing mark during the installation.

40. Impose force to the tensioner along the arrow

direction and temporarily tighten the retaining bolts.

41. Check whether all timing marks are aligned.

15A-35

42. Pull out the inserted screwdriver from the cylinder

body and tighten the cylinder plug.

Torque: 30N·m

43. Turn 1/4 round of the crank counterclockwise and then turn it clockwise, until all timing marks

are realigned. If the timing marks are unable to realign, reinstall the toothed timing belt until

alignment is achieved.

44. Equipped the tensioner belt pulley with the sleeve

and wrench in the toolkit and loose the tensioner

retaining bolts.

Or use a general torque wrench ranging from 0 to 3 N·m.

45. Tighten the tensioner retaining bolts.

Torque: 26 ~ 27N·m

46. Press the toothed timing belt B tensioner by hand,

along the arrow direction, while tightening the

47. Turn the crank clockwise for two rounds and leave it

for 15 minutes. Then check whether the retaining

wire of the automatic tensioner can move freely.

If not, repeat Steps 3-4 until it moves.

48. Remove the retaining bolts of the automatic tensioner.

15A-36

49. Measure the distance between the tensioner arm and

the tensioner body.

Standard: 3.8 ~ 4.5mm

50. Install the engine timing casing. (Refer to "Chapter 15A. Engine mechanical system - engine

51. Install the engine accessory belt. (Refer to "Chapter 15A. Engine mechanical system - engine

52. Reconnect the engine harness.

53. Connect battery negative cable. (Refer to "Chapter 20. Start & charge - battery, replacement")

ENGINE MECHANICAL - ROCK ARM, ROCK ARM SHAFT, HYDRAULIC TAPPET &

ROCK ARM, ROCK ARM SHAFT, HYDRAULIC TAPPET &

15A-37

15A-38

1 Rock Arm cover

2 Rock Arm Cap Gasket

3 Exhaust Rock Arm

4 Intake Rock Arm

5 Hydraulic Tappet

6 Rock Arm Shaft Spring

8 Intake Rock Arm Shaft

9 Rock Arm Shaft Bolt

10 O-ring

11 Thrust Cap

12 Camshaft

13 Camshaft Oil Seal

7 Exhaust Rock Arm Shaft

15A-39

HAUL

1. Disconnect negative battery cable. (Refer to "Chapter 20: Start & Charge - Battery,

Replacement")

2. Remove the engine intake pipe. (Refer to "Chapter 14: Intake air - intake air pipe, replacement")

3. Remove the engine accessory belt. (Refer to "Chapter 15A: Engine mechanical system - engine

4. Loose the accelerator cable adjustment bolts on the

throttle valve and remove the head clip and then the

accelerate cable.

5. Pull out the PCV valve hose on the rock arm cap.

6. Remove the retaining bolts of heater pipe.

15A-40

7. Pull out the spark plug cable.

8. Pull out the ignition coil connector.

9. Unscrew the retaining bolts of the ignition coil.

10. Remove the ignition coil and the spark plug cable assembly.

Before disconnecting the spark plug cable on the ignition coil, mark the cable positions of different

cylinders on the coil, to faciliate installation.

11. Remove the retaining bolts on the front upper cover

of the toothen engine timing belt and then the cover.

15A-41

12. Remove the retaining bolts of the rock arm cap in

numeric sequence.

13. Remove the rock arm cap and the rock arm cap gasket.

The gasket is disposable and replace it with a new one before installation.

14. Remove the oil seal.

15. Remove the retaining bolts of the rock arm shaft in

15A-42

16. Before removing the rock arm and the rock arm shaft

assembly, fix the hydraulic tappet with a tool, to

prevent it from falling during the disassembly.

17. Remove the rock arm shaft and the rock arm assembly.

18. Remove the rock arm shaft spring and separate the rock arm from the rock arm shaft.

19. Remove the hydraulic tappet.

20. Check the rock arm:

(a) Check the roller surface and replace the rock arm in case

of any scratch or other damage.

(b) Check whether the roller can rotate smoothly. If it's stuck

or loose, replace the rock arm.

case of any scratch or other damage.

21. Check and clean the hydraulic tappet and replace it if any damage is detected:

• The hydraulic tappet is a precision component. No dust or impurity is allowed on the surface.

• Do not disassemble the hydraulic tappet.

• Clean the hydraulic tappet with clean diesel.

(a) Prepare 3 containers and almost 5L diesel. Pull enough

diesel into each container so that the tappet is fully

immersed. Then follow the steps below.

Put the hydraulic tappet into Container A to clean its

exterior.

Clear the hard impurities with a nylon brush.

15A-43

Install a tool onto the hydraulic tappet and gently push

the interior balls. Move the tappet plunger for 5-10 travels

until it moves smoothly. In addition, it also eliminates the

sliding resistance and the dirty grease.

• As the steel ball spring is particular soft, do not exert

exceesive force when pushing it with an air-release

metal wire, in order to avoid damaging the hydraulic

tappet.

• If the slide is blocked or the mechanical unit appears

to be abnormal, replace the hydraulic tappet.

(d) Take the hydraulic tappet from the container. Then gently

push the ball and move the tappet plunger to remove

diesel from the pressure vessel.

Install the tool onto the hydraulic tappet. Put it into

Container B. With a tool, gently push the interior ball and

move the tappet plunger for 5-10 travels, until it moves

smoothly. This step cleans the pressure vessel of the

hydraulic tappet.

As the steel ball spring is particular soft, do not exert

exceesive force when pushing it with an air-release metal

wire, in order to avoid damaging the hydraulic tappet.

Take the hydraulic tappet from the container. Then gently

Put it into Container C. And push the interior ball with a

Do not clean the hydraulic tappet in Container C. Otherwise,

contamination may get into the pressure vessel full of

diesel.

15A-44

Hold the hydraulic tappet vertically, with the tappet

plunger at the top. Steady move the plunger downward

up to its maximum travel. Then slowly move back the

plunger. Release the ball so that the pressure vessel is

full of diesel.

Remove the tool.

Take the hydraulic tappet from the container. Hold the

hydraulic tappet vertically, with the tappet plunger at the

top. Steady push the plunger and ensure it can no longer

move. Compare its height to a new one.

If the height is reduced, repeat Steps 7-10 and fill the

hydraulic tappet with diesel. If it is still lower after these

steps, replace it.

Put the hydraulic acid on the tool. When the plunger is

slightly lowered (0.2~0.5 mm), measure the time took for

additional 1 mm.

Standard: 3~20 seconds /1 mm (diesel at 15 ~ 20 ℃ )

If unqualified, replace it.

Install the tool onto the hydraulic tappet. Put the

hydraulic tappet into Container c again and gently push

down the interior balls with a tool. Hold the hydraulic

tappet vertically, with the tappet plunger at the top.

Steady move the plunger downward up to its maximum

travel. Then slowly move back the plunger. Release the

ball so that the pressure vessel is full of diesel.

If the height is reduced, repeat Steps 12-14 and fill the

15A-45

(o) Hold the hydraulic tappet vertically to prevent diesel from

flowing out. Prevent dust or impurity from contaminating

the hydraulic tappet. Install it onto the engine as soon as

• Insert the hydraulic tappet into the rock arm and

make sure the diesel doesn't overflow. Then fix the

hydraulic tappet with a tool to prevent it from falling

during installation.

• If the hydraulic tappet is reusable, clean it first.

22. Install the rock arm onto the rock arm shaft.

23. Temporarily tighten the air inlet rock arm with bolts until all rock arms no longer press the

throttle valve.

24. Install the rock arm shaft spring from the top and

make sure it is vertical to the spark plug duct.

• Install the rock arm shaft spring and then tighten the

air outlet rock arm bolts.

• Align the oil hole on the rock arm shaft to the

cylinder body, to ensure correct installation.

25. Tighten the retaining bolts of the rock arm shaft in

Torque: 31N·m

26. Remove the tools used to retain the hydraulic tappet.

15A-46

27. Ensure the notch on the rock arm shaft is located as

illustrated.

28. Install the oil seal.

29. Install a new rock arm cap gasket.

30. Install the rock arm cap.

31. Tighten the retaining bolts of the rock arm cap in

Torque: 4N·m

15A-47

32. Install the front upper cover of the toothed engine

timing belt and tighten the retaining bolts.

33. Install the spark plug cable to the ignition coil.

Install the spark plug cable as marked.

34. Install the ignition coil and tighten the retaining

35. Install the ignition coil connector.

36. Install the spark plug cable to the rock arm cap.

15A-48

37. Install the retaining bolts of heater pipe.

38. Install the PCV valve hose to the rock arm cap.

39. Install the accelerator cable head clip and tighten the

bolts on the throttle valve.

40. Install the engine accessory belt. (Refer to "Chapter 15A: Engine mechanical system - engine

41. Install the engine intake pipe. (Refer to "Chapter 14: Intake air - intake air pipe, replacement")

42. Connect battery negative cable. (Refer to "Chapter 20: Start & Charge - Battery, Replacement")

15A-49

CAMSHAFT OVERHAUL

1. Remove the cylinder head. (Refer to "Chapter 15A: Engine mechanical system - cylinder head,

throttle, cylinder head overhaul")

2. Remove the retaining bolts of the toothed camshaft

3. Remove the retaining bolts of the camshaft lock cap

and then the cap.

4. Pull out the camshaft.

5. Check the camshaft:

Check whether there is any corrosion, wear or crack on

the surface of the camshaft. Replace it if any.

Measure Camshaft Height

Name Standard Limit

Intake Cam 37.20mm 36.70mm

Exhaust Cam 36.83mm 36.33mm

6. Remove the camshaft oil seal.

Once removed, it is necessary to replace it with a new

camshaft oil seal.

15A-50

7. Install the camshaft.

8. Apply some engine oil on the outside of the camshaft oil seal lips and the front end.

9. With a tool, install a new camshaft oil seal.

10. Install a new camshaft lock cap O-ring.

11. Install the camshaft lock cap and tighten the

Torque: 19N·m

12. Install the toothed camshaft belt pulley and retaining

bolts with a tool.

13. Install the cylinder head. (Refer to "Chapter 15A: Engine mechanical system - cylinder head,

CYLINDER HEAD,VALVE

ENGINE MECHANICAL - CYLINDER HEAD,VALVE

15A-51

1 Valve Spring Lock

2 Upper Valve Spring Retainer

3 Valve Spring

4 Valve Oil Seal

5 Valve Spring Retainer

6 Valve Guide

7 Vavle Seat

8 Valve

9 Cylinder Head

10 Cylinder Head Gasket

15A-52

CYLINDER HEAD OVERHAUL

1. Disconnect battery negative cable. (Refer to "Chapter 20. Start & Charge - Battery,

2. Drain coolant. (Refer to "Chapter 17A. Cooling - coolant, replacement")

3. Remove the engine intake pipe. (Refer to "Chapter 14A. Intake air - intake air pipe, replacement")

4. Remove the engine accessory belt. (Refer to "Chapter 15A: Engine mechanical system - engine

5. Remove the toothed timing belt. (Refer to "Chapter 15A. Engine mechanical system - toothed

timing belt, overhaul")

6. Remove the rock arm and the rock arm shaft. (Refer to "Chapter 15A. Engine mechanical

system - rock arm, rock arm shaft, hydraulic tappet & camshaft, rock arm, rock arm shaft &

hydraulic tappet overhaul")

7. Remove the retaining bolts of the cylinder head in

When loosing the bolts, exert evenl and gradual torque to

ensure balanced force on the cylinder head.

8. Remove the cylinder head and the cylinder head gasket.

9. Clean the cylinder head and check whether there is crack or serious damage. Replace it if

10. Check the evenness of the cylinder head bottom with

a ruler and a feeler blade. In case of excessive

deformation, polish it (both cylinder head and body)

or replace it.

Flatness Standard: 0.03 mm

Flatness Limit: 0.2mm

Correction Limit: 0.2mm

11. Check the height of the cylinder head and replace it if unqualified.

Standard: 119.9 ~ 120.1mm

12. Install a new cylinder head gasket.

DANGER

It is important to correctly install the cylinder gasket, with the hole aligned to that on the cylinder

surface, or it may lead to serious engine damage.

13. Install the cylinder head and fix it until the dowel pin is installed.

15A-53

14. Before installing the cylinder head bolts, ensure the

length is within the standard range and replace them

out of limit.

Standard: 97.4mm

15. Tighten the retaining bolts of the cylinder head in the

following steps and numeric sequence:

• Apply a proper amount of engine oil on the threaded

part and gasket of the cylinder head bolts, to faciliate

tightening.

• In case of excess torque, loose the bolts completely

and re-tighten them.

(a) Tighten the retaining bolts of the cylinder head in numeric

sequence.

Torque: 78N·m

(b) Completely loose all bolts.

Torque: 20N·m

(d) Draw straight lines with paint, as marks on the bolt heads

and the cylinder head.

(e) Tighten the cylinder head bolts to 90° in the sequence of

(f) Tighten the bolts to another 90° in the same sequence

and ensure the mark on the bolt head is aligned to that

on the cylinder head.

16. Install the rock arm and the rock arm shaft. (Refer to "Chapter 15A. Engine mechanical system -

rock arm, rock arm shaft, hydraulic tappet & camshaft, rock arm, rock arm shaft & hydraulic

tappet overhaul")

17. Install the toothed timing belt. (Refer to "Chapter 15A. Engine mechanical system - toothed

18. Install the engine accessory belt. (Refer to "Chapter 15A. Engine mechanical system - engine

19. Install the engine intake pipe. (Refer to "Chapter 14A. Intake air - intake air pipe, replacement")

20. Fill the engine coolant. (Refer to "Chapter 17A. Cooling - coolant, replacement")

21. Connect battery negative cable. (Refer to "Chapter 20. Start & Charge - Battery, Replacement")

15A-54

VALVE OVERHAUL

1. Remove the cylinder head. (Refer to "Chapter 15A. Engine mechanical system - cylinder head,

valve, cylinder head overhaul")

Mark the removed valve, valve spring and other parts with the cylinder number and installation

position. Keep them well to ease installation.

2. Use a appropriate tool to remove the valve lock and

then the upper valve spring retainer, the valve spring

and the valve spring shim.

3. Remove the valve oil seal and then the valve.

The valve oil seal cannot be reused.

4. Check the valve spring:

Measure the free height of the valve spring. Replace it if

below limit.

Standard: 51.0mm

Limit: 50.0mm

Measure the uprightness of the central line of the spring

to the bottom surface. Replace it if beyond limit.

Standard: ≤ 2°

Limit: 4°

15A-55

5. Check the valve:

Check whether the working surface of the valve and the valve seat is airtight. If not, polish it with a valve

polisher. The contact surface of the valve seat shall be consistent with the center of the valve working

face.

Check the thickness at the edge of the valve. Replace it if

unqualified and polish it with a valve polisher:

Thickness at

Edge of Valve

Intake 1.0mm 0.5mm

Exhaust 1.2mm 0.7mm

Check the total height of the valve. Replace it if below

limit:

Total Valve

Height

Intake 112.30mm 111.80mm

Exhaust 114.11mm 113.61mm

6. Check the clearance between the valve guide and the

valve rod. Replace either or both of them if beyond

limit, until the clearance meets the requirement:

Clearance Standard Limit

Intake 0.02 ~ 0.05mm 0.10mm

Exhaust 0.03 ~ 0.07mm 0.15mm

7. Follow the steps to replace the valve guide:

Do not use a new valve guide of the same dimension as the removed one.

(a) Heat the cylinder head and remove the valve seat.

(b) With a tool, drive out the valve guide towards the lower surface of the cylinder head.

guide:

Diameter of Valve Guide Hole

Larger 0.05mm

Larger 0.25mm

Larger 0.50mm

11.05-11.068mm

11.25-11.268mm

11.50-11.518mm

15A-56

Installl a new valve guide by pressing it down the top of

the cylinder head until the protrusion part meets the

requirement.

Standard: 14 ± 0.3mm

• Press down the valve guide from the top of cylinder

head.

• The guides of intake valve and exhaust valve are of

different lengths (intake valve: 45.5mm; exhaust

valve: 50.5mm).

Once installed, insert a new valve and check whether it moves freely along the axis.

8. Assemble the valve and measure the protruded

height of the valve rod between the end of the rod

and the valve spring retainer. Replace the valve seat

if unqualified:

Protruded Height Standard Limit

Intake 49.30mm 49.80mm

Exhaust 49.30mm 49.80mm

9. Finish the valve seat:

(a) Before finishing the valve seat, check the clearance

between the valve guide and the valve rod. Finish it after

replacement if necessary.

(b) Finish the width and angle of the valve seat to the rated

values with a grinder.

together with abrasive. Then measure the protruded

height of the valve rod.

15A-57

10. Replace the valve seat:

(a) Cut part of the valve seat to replace from inside and

remove it.

(b) Finish the valve seat hole on the cylinder head subject to

the outer diameter of the larger valve seat.

Diameter of valve seat:

Intake Valve

Exhaust Valve

Larger Valve Seat

Hole

Larger 0.30mm

Larger 0.60mm

Diameter of Valve

Seat

34.435 ~ 34.455mm

4.735 ~ 34.755mm

31.935 ~ 31.955mm

32.235 ~ 32.255mm

250 ℃ , or chill the seat in liquid nitrogen, to avoid

possible blockage inside the cylinder head.

(d) With a valve seat miller, finish the seat to rated width and

angle.

11. Install the valve as marked during removal.

12. Install the valve spring washer.

13. Install a new valve oil seal with a tool.

14. Install the valve spring.

When installing the valve spring, face the color-coded end towards the upper valve spring retainer.

15. Install the upper valve spring retainer.

15A-58

16. With a tool, install the valve lock.

17. Install the cylinder head. (Refer to "Chapter 15A. Engine mechanical system - cylinder head,

ENGINE MECHANICAL - PISTON & CONNECTING ROD ASSEMBLY

PISTON & CONNECTING ROD ASSEMBLY

15A-59

1 1st Gas Ring

2 2nd Gas Ring

3 Oil Ring

4 Piston Pin

5 Connecting Rod

6 Connecting Rod Bolt

7 Piston

8 Piston & Connecting Rod Assembly

9 Upper Connecting Rod Bearing

10 Lower Connecting Rod Bearing

11 Connecting Rod Cap

12 Nut

15A-60

PISTON & CONNECTING ROD ASSEMBLY OVERHAUL

1. Remove the engine assembly. (Refer to "Chapter 15A. Engine mechanical system - engine

assembly, replacement")

2. Remove the cylinder head. (Refer to "Chapter 15A. Engine mechanical system - cylinder head,

3. Remove the oil tray. (Refer to "Chapter 18A. Lubrication - oil try, overhaul")

4. Remove the engine oil strainer. (Refer to "Chapter 18. Lubrication - engine oil strainer,

replacement")

5. Mark the cylinder number on the larger side of the

connecting rod to faciliate assembly.

Put down the connecting rod, the connecting rod cap and

the connecting rod bearing in the order of the cylinder

numbers, to avoid confusion.

6. Remove the retaining bolts of the connecting rod cap

in sequence.

7. Gently knock out the piston & connecting rod

assembly with a wooden or plastic stick.

8. Separate the connecting rod bearing.

15A-61

9. Remove the piston pin with a tool:

Put down the piston, the piston pin and the connecting rod in the order of cylinder number, to avoid

confusion.

1 Push Rod

2 Guide Block B

3 Guide Block C

4 Guide A

5 Guide A

6 Guide A

7 Guide A

8 Base

Insert the push rod (special tool) into the piston from the

side with arrow and attach the Guide Block C to the end

of the push rod.

Keep the forward mark of the piston upward and install

the piston & connecting rod assembly onto the base of

the piston pin installer.

Press the piston pin out by force.

10. Remove the 1st and 2nd gas rings and the oil ring.

• Clean the carbon residue on the surface of the piston and inside the gas ring, as well as the

grease inside the oil ring.

• Be careful not to scratch the piston surface.

15A-62

11. Check whether there is damage, over wear or crack on the piston ring and replace it if any.

Replace the piston and the piston ring together.

12. Check the side clearance between the piston ring

and the groove. If the limit is exceeded, replace the

ring or both the piston and the ring.

Standard: 0.02 ~ 0.06mm

Limit: 0.1mm

13. Insert the piston ring into the cylinder. Put it into the

correct position against the piston top and measure

the end clearance of the piston ring with a feeler

blade.

Replace the ring if the end play exceeds the limit:

1st Gas

Ring

2nd Gas

Oil Ring

0.25 ~

0.35mm

0.40 ~

0.55mm

0.10 ~

0.40mm

Limit 0.8mm 0.8mm 1.0mm

14. Check the oil clearance of the crankshaft pin with a

plastigage:

(a) Clear the engine oil on the connecting rod neck and

bearing.

(b) Cut the plastigauge into length as wide as the bearing.

Lay the plastigauge across the crankshaft pin, parallel to

its central axis.

nuts to its rated torque.

(d) Carefully remove the connecting rod cap.

15A-63

Using a measuring ruler imprinted on the plastigauge

package, measure the width of the widest part of the

plastigauge and calculate the clearance value.

Standard: 0.02 ~ 0.05mm

15. Install the piston pin:

Measure the following dimensions of the piston, the

piston pin and the connecting rod:

A: Length of piston pin in hole

B: Width of pin socket

C: Length of piston pin

D: Width of connecting rod at smaller end

Put the measurements into the following formula to

calculate L. L = [(A - C) - (B - D)] / 2

After inserting the push rod into the piston pin, install

Guide A at the end of the push rod.

Install the piston and the connecting rod with both

forward marks in the same direction.

Lubricate the external diameter of the piston pin with engine oil.

Once assembled in Step 3, insert the push rod, piston pin and guide assembly into the piston pin hole

from the side with the forward mark.

15A-64

Screw the Guide Block B into Guide A so that the

clearance between Guide Block A and Guide Block B

equals to L (L=((A-C)-(B-D)) / 2) plus 3 mm.

Press the piston pin in by force. If the force is below the

standard, replace the piston pin and the piston assembly,

or the connecting rod.

Standard: 7500 ~ 17500N

16. Once installed, check whether the piston and the

connecting rod move freely.

15A-65

17. Install the oil ring:

• There is no difference between the upper and lower

sides of the oil ring scraper and the main ring.

• The new ring and oil ring scraper are color-coded to

identify their dimensions.

Dimension

Larger 1.00mm

Color Code

N/A

Red

Yellow

18. Install the 1st and 2nd gas rings:

Install the main oil ring.

Put the upper scraper in. During the installation, press

one end of the scraper into the piston oil ring groove and

press the remaining part into the groove with your thumb,

as illustrated.

Do not install the scraper with a pair of piston ring pliers,

which may break the scraper.

(d) Check whether the installed ring can rotate freely.

Install the 1st gas ring after the 2nd gas ring, with a pair

of piston ring pliers.

During installation, turn the mark upward to the top of the

piston.

There are identification marks at the opening of the gas

ring. 1st gas ring: 1R, 2nd gas ring: 2R.

The dimension marks are follows:

Dimension Mark

Larger 0.50 mm 50

Larger 1.00 mm 100

15A-66

19. Adjust the opening directions of the gas rings and the oil ring:

Lubricate the piston ring groove, the gas rings and the oil ring with clean engine oil.

Adjust the openings of the gas rings and the oil ring to

the position shown.

1 Oil ring scraper opening

2 Piston pin position

3 Oil ring lower scraper opening

Sleeve ring and 2nd gas ring

opening

5 1st gas ring opening

6 Crankshaft belt pulley side

20. Turn the crankshaft so that the crankshaft pin is at the center of the cylinder.

21. Before inserting the piston & connecting rod assembly into the cylinder block, take proper

threat protection on the connecting rod bolts. Be careful not to damage the crankshaft pin.

22. During installation, confirm the dot (forward mark)

on the top of the piston faces the side of the toothed

timing belt.

23. Use a proper piston ring compression tool to install

the piston & connecting rod assembly.

• When putting the assembly into the cylinder, be

careful not to damage the crankshaft pin with the

connecting rod cap bolts.

• During the installation, gently press down the

assembly with a wooden or plastic tool, without

overly force, or it may break the piston ring or

crankshaft pin.

24. To replace the connecting rod bearing, choose and install it as follows:

15A-67

Measure the outer diameter of the crankshaft pin, identify

the dimensions with different paint colors as illustrated,

and group them subject to the table below.

The identification mark of the connecting rod bearing is

shown as followes:

Crankshaft Pin

Connecting Rod

Bearing

ID No. Dimension (mm/in) Mark

I 44.995 ~ 45.000 1

II 44.985 ~ 44.995 2

III 44.980 ~ 44.985 3

Inner diameter of connecting rod: 48.000 ~ 48.015mm

If the outer diameter of the crankshaft pin is marked as "1", for example, pick up the bearing marked as

"1" as well. If there is no mark on the crankshaft, measure the outer diameter of the pin and pick up a

connecting rod bearing with the matching bear ("1").

25. Install the connecting rod cap subject to the marks

made during disassembly. If it a new connecting rod

without combination mark, install the grooves of the

upper bearing and the lower bearing on the both

sides as illustrated.

15A-68

26. Measure the axial clearance of the connecting rod at

the larger end with a feeler blade.

Standard: 0.10 ~ 0.25mm

Limit: 0.4mm

27. Install the connecting rod nuts:

Before the installation, if the cylinder head is already in place, remove the spark plug first and install

the connecting rod cap nuts.

(a) Use plastic zone torque technique on the connecting rod bolts and nuts. Check whether there is any

stretch in the bolt before reuse.

How to check: Tighten the nut along the thread of the bolt up to the full length. If the nut cannot be

tightened smoothly, it means that the threaded part of the bolt might be stretched. Replace the bolt.

(b) Lubricate the threaded part of the nuts and the surface with engine oil, before tightening the nuts.

(d) Tighten the nuts for the first time.

(e) Make a paint mark on the head of each nut.

(f) Make a paint mark on the bolt at the position 90° ~ 100°

from that made on the nut in the direction of tightening.

(g) Turn additional 90° ~ 100° to the nut and make sure that

the paint mark on the nut and that on the bolt are in

alignment.

• If the nuts are tightened less than 90°, they may not

hold the caps with sufficient strength. Pay attention

to the angle during tightening.

• If a nut is tightened exceeding 100°, completely

remove all nuts and carry out the installation

procedure again from Step 1.

28. Install the engine oil strainer. (Refer to "Chapter 18. Lubrication - engine oil strainer,

29. Install the oil tray. (Refer to "Chapter 18A. Lubrication - oil try, overhaul")

30. Install the cylinder head. (Refer to "Chapter 15A. Engine mechanical system - cylinder head,

31. Install the engine assembly. (Refer to "Chapter 15A. Engine mechanical system - engine

ENGINE MECHANICAL - CRANKSHAFT, CYLINDER BLOCK & FLYWHEEL

CRANKSHAFT, CYLINDER BLOCK & FLYWHEEL

15A-69

1 Cylinder Block

2 Crankshaft Rear Oil Seal Cap

3 Crankshaft Rear Oil Seal

4 Crankshaft Thrust Bearing

6 Crankshaft

7 Lower Crankshaft Bearing

8 Main Bearing Cap

9 Main Bearing Cap Bolt

5 Upper Crankshaft Bearing

15A-70

1 Flywheel Bolt

2 Ball Bearing

3 Flywheel

4 Rear Cover

5 Bell Housing

6 Crankshaft Rear Oil Seal

7 Crankshaft Rear Oil Seal Cap

8 Cylinder Block

15A-71

3. Fix the engine cylinder block onto the flip frame for disassembly.

4. Remove the oil tray. (Refer to "Chapter 18A. Lubrication - oil try, replacement")

5. Remove the retaining bolts and nuts of the engine oil

strainer and then the strainer.

6. Remove the retaining bolts of the engine oil pump

front cover and then the cover.

7. Fix the flywheel with a tool.

15A-72

8. Remove the retaining bolts of the flywheel in

numeric order and then the flywheel.

9. Remove the retaining bolts then the cover.

10. Remove the crankshaft rear oil seal.

15A-73

11. Remove the retaining bolts of the crankshaft rear oil

seal cap and then the cap.

12. Flip over the engine so that the oil tray faces upward.

13. Remove the retaining bolts of the crankshaft main

bearing cap in numeric sequence.

14. Remove the crankshaft main bearing cap and disassemble the lower crankshaft bearing.

15. Remove the crankshaft and measure the crankshaft

oil clearance with a plastgage:

Clear the oil on the surface of the crankshaft neck and

inside the crankshaft.

Install the crankshaft.

Cut a piece of plastigage of the same width as the

bearing and put it on the crankshaft neck, parallel to the

latter.

Carefully install the crankshaft main bearing cap and

tighten the bolts to the rated toque.

Torque: 25N•m+90° ~ 100°

Remove the retaining bolts of the crankshaft main

bearing cap and then the cap carefully.

15A-74

Use the scale imprinted on the plastigauge package to

measure the width of the widest part of the plastigauge.

Standard: 0.02 ~ 0.04mm

16. Remove the crankshaft and the bearing.

17. Take the engine block assembly from the flip frame

and inspect:

(a) Check for scratches, rust, and corrosion, visually or with

flaw detecting agent. If defects are evident, correct or

(b) Use a straightedge and a feeler gauge to check the block

top surface for warpage. Make sure that the surface is

free from gasket chips and other impurities.

Standard: 0.05mm

limit or replace.

Grinding limit: 0.2mm

Max. sum of cylinder block and cover to grind off:

0.2mm

Block height (new part): 284mm

(d) The cylinder walls should be checked for scratch or other

damage. Finish or replace it if apparent.

(e) Measure the inner diameter and cylindricity of the

cylinder with a cylinder bore. In case of heavy wear,

finish the cylinder to a greater dimension or replace the

piston and the ring with matching dimensions.

Inner Diameter of Cylinder

Cylindricity

87mm

≤ 0.01mm

Choose the diameter of the larger piston subject to the

maximum cylinder diameter.

Mark

Larger 0.50mm 0.50

Larger 1.00mm 1.00

15A-75

Measure the outer diameter of the piston to use, in the

thrust direction as shown.

Follow the above measurement to calculate cylinder bore

dimension:

Cylinder bore dimension = Outer diameter of piston

+ (clearance between piston and cylinder) - 0.02 mm

(grinding volume)

In case of finishing, finish four cylinders to the same

dimension.

(h) Finish the diameters of the cylinders to the said

During finishing, to avoid possible error caused by rising

temperature, perform the operations in the following order:

No.2 -> No.4 -> No.1 -> No.3

(i) Finish it to the final diameter (piston diameter +

clearance between piston and cylinder).

(j) Check the clearance between the piston and the

18. Flip over the cylinder block onto the engine stand so that the oil tray faces upward.

19. Pick up a suitable crankshaft bearing subject to the table below:

Combination of Crankshaft Main Neck and Shaft Bore

Crankshaft Main Neck

Group Mark Outer Dia. (mm)

Mark of Main

Mark of Neck

Bearing 1, 2, 4 &

Bearing 3

0 1 0

I 0 56.994 ~ 57.000

1 2 1

2 3 2

0 2 1

II 1 56.988 ~ 56.994

1 3 2

2 4 3

15A-76

0 3 2

III 2 56.982 ~ 56.988

1 4 3

2 5 4

For example:

(a) If the outer diameter mark the crankshaft neck is "0" and that of the bearing bore is “1”, choose No. 1, 2,

4 or 5 bearing marked as “2” and No.3 bearing marked as “1”.

If there is no mark on the crankshaft, measure the neck and pick up a matching bearing subject to the

measurement.

20. Install the thrust bearing as follows:

(a) Install the bearing with groove at the cylinder block side.

(b) Install the bearing without groove at the bearing cap side.

No.3 main bore of the cylinder block. Lubricate the

surface of the thrust bearing with some engine oil to

faciliate installation.

21. Install the crankshaft main bearing cap.

The arrow on the cap points to the side of the toothed

22. Install the crankshaft bearing cap bolts as follows:

(a) Before tightening the retaining bolts of the bearing cap,

measure the length of the bolts first. If beyond limit,

replce them.

Limit: 71.1mm

(b) Lubricate the threaded part and surface of the bolts with

engine oil.

15A-77

Tighten the retaining bolts of the crankshaft main bearing

cap in numeric sequence.

Mark the bolt heads with paint.

Make a paint mark on the area around the bolt bearing

surface at the position of 90° ~ 100° in the direction of

Turn additional 90° ~ 100° to the bolts and make sure

that the paint mark on the bolts and that on the cover are

in alignment.

hold the caps with sufficient strength. So pay

attention to the angle during tightening.

• If a bolt is tightened exceeding 100°, completely

remove all bolts and carry out the installation

23. After installation, check whether the crankshaft

rotates freely as well as the axial clearance. If

beyond limit, replace the bearing.

Standard: 0.05 ~ 0.18mm

Limit: 0.25mm

15A-78

24. Install the crankshaft rear oil seal with a tool.

25. Install the crankshaft rear oil seal cap.

• Before installation, clear the impurities on the suface of the cap without scratching the surface.

• Apply the sealant (Mistubishi MD970389) or comparable alternative to the surface of the oil seal

cap.

• Quickly install the rear oil seal cap in 15 minutes, before the sealant is dried.

• After installation, keep the sealed parts away from lubricant and coolant for around 1 hour.

26. Install the rear cover and tighten the retaining bolts.

27. Install the flywheel and lock it with a tool.

15A-79

28. Tighten the retaining bolts of the flywheel in numeric

Torque: 135N·m

29. Install the engine oil pump front cover and tighten

the retaining bolts.

30. Install the engine oil strainer and tighten the

Nut torque: 19N·m

Bolt torque: 19N·m

31. Install the oil tray. (Refer to "Chapter 18A. Lubrication - oil try, replacement")

32. Install the cylinder head. (Refer to "Chapter 15A. Engine mechanical system - cylinder head,

33. Install the engine assembly. (Refer to "Chapter 15A. Engine mechanical system - engine

EXHAUST SYSTEM

EXHAUST PIPE ...............................................................................16A-1

PRECAUTION............................................................................ 16A-1

REPLACEMENT ........................................................................ 16A-2

EXHAUST MANIFOLD.....................................................................16A-6

REPLACEMENT ........................................................................ 16A-6

36

16A

EXHAUST - EXHAUST PIPE

16A-1

EXHAUST PIPE

1. BEFORE REMOVING MOUNTING RUBBER, ALWAYS APPLY A SMALL AMOUNT OF GREASE TO

MOUNTING RUBBER FOR REMOVING OR INSTALLING EASILY.

2. WHEN INSTALLING EXHAUST PIPE, ALWAYS USE NEW RING GASKET OTHERWISE GAS

LEAKAGE WILL PRESENT.

3. AFTER A LONG-TIME USED, THE EXHAUST PIPE GASKET WILL BE ADHERED TO EXHAUST

PIPE. AFTER REMOVING THE MUFFLER, USE THE SCRAPER TO CLEAN THE SURFACE OF

EXHAUST PIPE AND REPLACE WITH A NEW GASKET TO AVOID EXHAUST LEAKAGE.

16A-2

Exhaust pipe is a high temperature part. Never work around or attempt to service any parts of the

exhaust system until it cools down.

3. REMOVE REAR MUFFLER ASSY.

Remove 2 rear muffler assy nuts.

Support one end of exhaust pipe with a jack first, and then

remove the other end.

Remove the rear muffler mounting rubber.

Remove rear muffler assy.

4. INSPECT REAR MUFFLER ASSY.

Tap or shake the muffler, check to make sure that broken

element inside the muffler is the cause of unusual noise,

if it is found, replace it.

Check the appearance of muffler for corrosion holes that

caused by moisture in air or from burning, If it is found,

After a long-time used, the exhaust pipe gasket will be

adhered to exhaust pipe. After removing the muffler, use

the scraper to clean the surface of exhaust pipe and replace

with a new gasket to avoid exhaust leakage.

5. REMOVE FRONT MUFFLER ASSY.

(a) Remove front muffler rear mounting rubber.

Support one end of exhaust pipe with a jack, and then

16A-3

Remove 2 front muffler retaining nuts.

Remove 2 support in the front of front muffler.

Remove front muffler assy.

6. INSPECT FRONT MUFFLER ASSY.

(a) Tap or shake the muffler, check to ensure that broken

(b) Check the appearance of muffler for corrosion holes that

7. REMOVE MIDDLE EXHAUST PIPE.

(a) loosen 2 retaining bolts fitting middle exhaust pipe to the

(b) Remove the middle exhaust pipe.

8. REMOVE CATALYTIC CONVERTER ASSY.

(a) Disconnect front and rear oxygen sensor connectors.

16A-4

Remove retaining nut securing catalytic converter mounting

bracket to the rear of transmission.

Loosen 2 retaining nuts securing catalytic converter to

exhaust manifold.

Remove the catalytic converter.

9. INSPECT CATALYTIC CONVERTER.

(a) Tap the catalytic converter, if hear any noise, replace with a new one.

(b) Using a scan tool, check the oxygen sensor signal fluctuation range. If the catalytic converter damage,

oxygen sensor signal fluctuation range will become larger.

• When reinstalling exhaust pipe each time, always replace ring gasket with new one.

• When installing each mounting rubber, avoid twisting or unusual extension in up/down and left/

right directions.

10. INSTALL CATALYTIC CONVERTER ASSY.

(a) Tighten 2 retaining nuts securing catalytic converter to

Torque: 78 ~ 96 N•m

16A-5

Connect front and rear oxygen sensor connectors.

Tighten retainng bolt securing catalytic converter mounting

11. INSTALL MIDDLE EXHAUST PIPE.

(a) Tighten 2 retaining bolts securing middle exhaust pipe to

12. INSTALL FRONT MUFFLER ASSY.

(a) Install 1 mounting rubber at the rear side of front muffler

16A-6

Install 2 support in the front of front muffler.

Install 2 front muffler retaining nuts.

13. INSTALL REAR MUFFLER ASSY.

(a) Install rear muffler rubber support.

Tighten 2 retaining bolts in the front of rear muffler.

14. CHECK AFTER INSTALLATION.

(a) Check clearance between exhaust pipe and rear bumper is uniform gap.

(b) With engine running, check exhaust pipe joints for gas leakage and unusual noises.

installation could result in excessive noise and vibration.

EXHAUST - EXHAUST MANIFOLD

16A-7

Perform the operation with the exhaust system fully cooled down because the system will be hot just

after engine stops.

3. REMOVE CATALYTIC CONVERTER ASSY. (Refer to “Chapter 16A exhaust - exhaust pipe, replacement”)

Ring gaskets are different on both sides of catalytic converter, take care not to misassemble them.

4. LOWER THE VEHICLE.

5. REMOVE OIL DIPSTICK PIPE.

(a) Pull out oil dipstick.

(b) Remove oil dipstick pipe retaining bolt.

6. REMOVE EXHAUSE MANIFOLD HEAT SHIELD.

(a) Remove 4 exhause manifold heat shield retaining bolts,

then take off the exhaust manifold heat shield.

The exhaust manifold heat shield retaining bolts will be

rusted after a long-time running. Be careful to remove these

7. REMOVE EXHAUST MANIFOLD.

(a) Remove 9 exhaust manifold retaining nuts.

The exhaust manifold retaining nuts will be rusted after a

long-time running. Use derusting spray when loosen the

16A-8

Remove the exhaust manifold.

• Check whether parts have any damage or crack.

• CHeck exhaust manifold and cylinder head surface

for flatness by using a ruler and thickness gauge.

Standard: 0.15 mm or less

Limit value: 0.20 mm

• Clean the dirt on exhaust manifold and cylinder head

connect surface

8. INSTALL A NEW EXHAUST MANIFOLD GASKET.

If do not replace with a new gasket, use exhaust sealant to

avoid exhaust leakage.

9. INSTALL EXHAUST MANIFOLD.

(a) Install exhaust manifold retaining nuts.

• Apply rust-inhibiting lubricant on nuts for easier

installation or removal next time.

• Install the exhaust manifold retaining bolts diagonally.

10. INSTALL EXHAUST MANIFOLD HEAT SHIELD.

(a) Install 4 exhaust manifold heat shield retaining bolts.

Torque: 10 ~ 14 N•m

11. INSTALL OIL DIPSTICK PIPE.

(a) Install oil dipstick pipe and tighten 1 retaining bolt.

Replace oil dipstick pipe O-ring with a new one.

(b) Insert oil dipstick completely into the dipstick pipe.

16A-9

12. INSTALL CATALYTIC CONVERTER ASSY. (Refer to “Chapter 16A exhaust - exhaust pipe, replacement”)

13. CHECK AFTER INSTALLATION.

Check to make sure exhaust manifold is installed properly between cylinder head and catalytic converter.

With engine running, check exhaust manifold joints for gas leakage and unusual noises.

COOLING SYSTEM

COOLING SYSTEM .........................................................................17A-1

PRECAUTION............................................................................ 17A-1

COMPONENTS ......................................................................... 17A-2

PROBLEM SYMPTOMS TABLE................................................ 17A-3

ON-VEHICLE INSPECT............................................................. 17A-4

COOLANT ........................................................................................17A-6

REPLACEMENT ........................................................................ 17A-6

RESERVIOR.....................................................................................17A-8

REPLACEMENT ........................................................................ 17A-8

COOLING FAN ASSY....................................................................17A-10

OVERHAUL ............................................................................. 17A-10

RADIATOR.....................................................................................17A-13

REPLACEMENT ...................................................................... 17A-13

THERMOSTAT...............................................................................17A-18

OVERHAUL ............................................................................. 17A-18

COOLANT PUMP...........................................................................17A-23

OVERHAUL ............................................................................. 17A-23

17A

COOLING - COOLING SYSTEM

17A-1

1. COOLING SYSTEM PRECAUTION.

(a) When disconnecting the cooling hose, use a suitable container to recycle the retains of coolant. If it is

not to be used, dispose of them according to the regulations.

(b) When disconnecting the pipes of cooling system, do not let debris go into the pipes of cooling system. It

may damage the cooling system and engine.

nozzle to prevent dirt and impurities.

(d) Coolant is poisonous, always keep it away from children and pets. If it is not to be used, disposal them

according to the regulations.

(e) Do not open the radiator cap when the engine is hot. Coolant temperature should be reduced to 50 ℃

(120 ℉) below, remove the radiator cap. Otherwise, the cooling liquid or vapor emitting heat may cause

(f) Use foton specified coolant, do not use water instead of coolant. Water will damage the engine

because of corrosion.

(g) Clean radiator outside regularly, which can prevent mud and dust deposition from damaging radiator.

17A-2

1 Radiator Assy

3 Fan Cowl

4 Locking Nut

5 Cooling Fan Assy

6 Bolt, Spring Washer And Flat Washer

8 Bolt, Spring Washer And Flat Washer

9 Washer

10 Nut

11 Cooling Fan Bracket

12 Reservoir Refilling Hose

13 Reservoir Assy

14 Bolt, Spring Washer And Flat Washer

15 Clamp

16 Radiator To Reservoir Vent Hose

17 Hose Clip

18 Clamp

17A-3

1. Coolant (Lack or leaking) Chapter 17A cooling - coolant, replacement

2. Coolant (Non-standard) Chapter 17A cooling - coolant, replacement

3. Thermostat (Damaged) Chapter 17A cooling - thermostat, overhaul

Engine overheated

4. Engine (Rough work) -

5. Radiator (Poor cooling) Chapter 17A cooling - cooling system, precaution

6. Cooling fan (Damaged) Chapter 17A cooling - cooling fan assy, overhaul

7. Cooling system (Blocked) -

1. Radiator(Damaged) Chapter 17A cooling - radiator, replacement

Coolant leaking

Engine noise

2. Cooling system hose

(Broken)

3. Coolant pump(Damaged) Chapter 17A cooling - coolant pump, replacement

4. Coolant reservoir(Damaged) Chapter 17A cooling - reservoir, replacement

1. Cooling fan(Damaged) Chapter 17A cooling - cooling fan assy, overhaul

2. Coolant pump(Damaged) Chapter 17A cooling - coolant pump, overhaul

3. Cooling line -

17A-4

ON-VEHICLE INSPECT

1. CHECK WHETHER COOLANT LEVEL IS NORMAL.

2. IF COOLANT LACKS ABNORMALLY, CHECK COOLING SYSTEM FOR LEAKAGE.

Never remove the reservior cap while the engine and radiator are still hot, as fluid and steam can be

blown out.

Fill the reservior with coolant and attach a reservior cap

tester.

Warm up the engine.

Pump it to 110 kPa, and check that the pressure does not

drop.

If the pressure drops, check the hoses, reservior, radiator

or water pump for leakage. If no external leakage is found,

check the heater core, cylinder block and head.

3. CHECK ENGINE COOLANT LEVEL IN COOLANT

RESERVOIR.

(a) When the engine is cool, the engine coolant level should

be between the ”LOW” and ”FULL” line.

4. CHECK ENGINE COOLANT QUALITY.

If the coolant level too low, check for leakage and add

”FOTON Long-effective coolant” or equivalent up to the

”FULL” line.

Do not use water instead of coolant.

(a) Remove the reservior cap.

(b) Place a container under the radiator to bloom the coolant from the coolant drain hole.

scale around the radiator cap and radiator filler hole. The coolant should be free from oil. If excessively

dirty, replace the coolant.

(d) Tighten the drain plug and check the coolant level in the coolant reservoir. Fill the coolant if necessary.

5. INSPECT FINS BLOCKAGE.

(a) If fins are clogged, wash them with water or a steam cleaner and dry them with compressed air.

• If the distance between the steam cleaner and core is too close, there is a possibility of

damaging the fins. So keep the proper injection distance.

17A-5

• Be careful not to spray water directly onto electronic components.

6. INSPECT COOLING FAN.

(a) Disconnect the cooling fan connector.

(b) Connect battery and ammeter to the connector.

Temperature: 20°C

Current: 8.0 ~ 12.0 A

(d) Connect the cooling fan connector.

(e) No abnormal noise except fan itself when the fan is rotating at a high speed.

17A-6

COOLING - COOLANT

COOLANT

17A-7

17A-8

COOLING - RESERVIOR

RESERVIOR

1. DRAIN ENGINE COOLANT. (Refer to “Chapter 17A cooling- coolant, replacement”)

2. REMOVE RESERVIOR.

(a) Open reservior pressure cover by turn it slowly to release

the built-up pressure.

Do not open the reservior cap when the engine is hot.

Coolant temperature should be reduced to 50 ° C (120 ° F)

below, remove the radiator cap. Otherwise, the cooling

Loosen reservior vent hose clamp and disconnect vent

hose.

Remove reservior retaining bolt.

Disconnect coolant fluid level sensor connector.

Loosen reservior refilling hose clamp and disconnect

reservior refilling hose.

Remove reserivor.

Do not lose the rubber grommet located on radiator upper

support when removing reservior. If damaged, replace

them.

17A-9

3. INSTALL RESERVIOR.

Connect reservior refilling hose and tighten retaining

Connect coolant fluid sensor connector.

Position the lower support of reservior into rubber grommet

on upper radiator frame.

Tighten reservior retaining bolt.

Connect reservior vent hose.

(a) Fill the coolant to max level when cold, check coolant fluid level indicator is normal in instrument cluster

and no coolant leakage is found.

17A-10

COOLING - COOLING FAN ASSY

COOLING FAN ASSY

2. DISCONNECT COOLING FAN ASSY CONNECTOR.

3. REMOVE COOLING FAN BRACKET.

(a) Remove 4 cooling fan bracket retaining bolts/nuts.

(b) Remove retaining nut securing A/C pipe clamp to vehicle

Disengage A/C pipes from the dual line clip at the bottom of

cooling fan bracket.

Remove cooling fan bracket carefully.

17A-11

4. REMOVE COOLING FAN ASSY.

Remove 6 cooling fan retaining bolts.

Remove cooling fan assy from the left side under the

5. INSPECT COOLING FAN.

(a) Using an ohmmeter, measure the resistance between the terminals.

Main cooling fan:

• Resistance between white wire and brown wire:1.527±15%Ω ;

• Resistance between white wire and red wire:1.2±15%Ω ;

Secondary cooling fan:

• Resistance between white wire and brown wire:1.562±15%Ω ;

• Resistance between white wire and red wire:1.377±15%Ω ;

(b) Visually inspect cooling fan blade for cracks or unusual bend.

6. INSTALL COOLING FAN ASSY.

(a) Position cooling fan assy into place from under the

(b) Tighten 6 cooling fan retaining bolts.

Torque: 9 ~ 11 N.m

7. INSTALL COOLING FAN BRACKET.

(a) Positon cooling fan bracket properly in the original

positon.

(b) Tighten 4 bracket retaining bolts and nuts.

17A-12

Tighten A/C pipes clamp retaining nut.

8. CONNECT COOLING FAN ASSY CONNECTORS.

Start the vehicle, check cooling fan for normal operation and ensure that no unusual noise is heard

when engine warms up and A/C switch is on.

COOLING - RADIATOR

17A-13

RADIATOR

(120 ° F) below, remove the reservior cap. Otherwise, the cooling liquid or vapor emitting heat may

1. DRAIN ENGINE COOLANT. (Refer to “Chapter 17A cooling - coolant, replacement”)

2. REMOVE RESERVIOR. (Refer to “Chapter 17A cooling - reservior, replacement”)

3. REMOVE COOLING FAN ASSY. (Refer to “Chapter 17A cooling - coolant fan assy, replacement”)

4. REMOVE FRONT GRILLE. (Refer to “Chapter 88 exterior and interior trim - front grille, replacement”)

5. REMOVE FRONT BUMPER. (Refer to “Chapter 88 exterior and interior trim - front bumper,

6. REMOVE ENGINE HOOD LOWER COVER PANEL.

(a) Remove 4 engine hood lower cover panel retaining bolts.

Remove 2 push pins from the back of lower cover panel.

Remove engine hood lower cover panel.

7. REMOVE THE FAN COWL.

(a) Remove 2 retaining bolts in the upper fan cowl.

(b) Remove reservior refilling hose from fan cow fixing clip.

17A-14

Push fan cowl upward until 2 lower support disengage

from radiator lower mounting notch.

Remove lower fan cowl.

8. REMOVE RADIATOR UPPER AND LOWER WATER

HOSES.

Remove engine water outlet hose to upper radiator.

Check water hose for cracks and deterioration, replace if

Remove engine water inlet hose to lower radiator.

9. REMOVE THE RADIATOR UPPER SUPPORT.

(a) Pull out reservior vent hose from fixing clip on radiator

upper support.

(b) Disconnect engine hood switch connector and remove

the wire harness clip from the radiator upper support.

Disconnect washer motor connector.

Remove 2 washer assy retaining bolts.

17A-15

Remove 5 radiator upper support retaining bolts.

Remove radiator upper support and put it aside.

Do not lose the upper mounting rubber installed on radiator

upper mounting pin when removing radiator. if damaged,

replace them.

10. REMOVE THE RADIATOR.

Remove 2 retaining bolts securing upper condenser to

radiator.

Remove 2 retaining bolts securing both upper air

deflector to radiator.

The vehicle was equipped with air deflector depend on

different Model.

Remove 2 retaining bolts securing lower condenser to

Remove 2 retaining bolts securing both lower air

Hang and hold condenser with wire after removing the bolts

securing condenser to radiator to prevent the A/C pipes or

condenser from damaging.

Lift up and remove the radiator.

Do not lose lower mounting rubbers of radiator when

removing radiator and check the mounting rubbers for

damage, replace them as required.

17A-16

11. INSTALL THE RADIATOR.

Make sure lower mounting rubbers are seated onto raditaor

lower support before installing radiator.

Tighten 2 retaining bolts securing upper condenser to

Tighten 2 retaining bolts securing both upper air deflector

to radiator.

The vehicle is equipped with air deflector depending on

Model.

Tighten 2 retaining bolts securing lower condenser to

Tighten 2 retaining bolts securing both lower air deflector

12. INSTALL RADIATOR UPPER AND LOWER WATER

Connect engine water inlet hose to radiator.

Connect engine water outlet hose to radiator.

17A-17

13. INSTALL THE FAN COWL.

(a) Position fan cowl into place from under the vehicle.

(b) Tighten 2 upper fan cowl retaining bolts.

14. INSTALL THE RADIATOR UPPER SUPPORT.

Positon the radiator upper support.

Make sure mounting rubbers are seated onto raditaor upper

support pin.

(b) Tighten 5 radiator upper support retaining bolts.

15. INSTALL ENGINE HOOD LOWER COVER PANEL.

(a) Position engine hood lower cover panel, then install 2

push pins.

Tighten 4 lower cover panel retaining bolts.

16. INSTALL COOLING FAN ASSY. (Refer to “Chapter 17A cooling - cooling fan, overhaul”)

17. INSTALL RESERVIOR. (Refer to “Chapter 17A cooling - reservior, replacement”)

18. INSTALL FRONT BUMPER. (Refer to “Chapter 88 exterior and interior trim - front bumper assy,

19. INSTALL FRONT GRILLE. (Refer to “Chapter 88 exterior and interior trim - front grille, replacement”)

20. FILL COOLANT. (Refer to “Chapter 17A cooling - coolant, replacement”)

21. CHECK AFTER INSTALLATION.

(a) After installing radiator, let engine be running until cooling fan runs at high speed. Check coolant for

leakage.

17A-18

COOLING - THERMOSTAT

2. DRAIN COOLANT. (Refer to “Chapter 17A cooling - coolant, replacement”)

4. DISCONNECT BATTERY NEGATIVE CABLE.

It is recommended that the battery negative cable must be disconnected, prior to thermostat removing,

to avoid touching generator positive retaining nut.

5. INSTALL ASSISTANT DRIVER SEAT. (Refer to “Chapter 84 seat - driver / assistant driver seat,

6. REMOVE ENGINE COMPARTMENT COVER UNDER

17A-19

7. REMOVE ENGINE WATER INLET HOSE NO. 2.

Remove engine water inlet hose NO. 2 clamp.

(b) Disconnect engine water inlet hose NO. 2.

8. REMOVE THERMOSTAT.

Remove 2 thermostat housing retaining bolts.

Remove thermostat housing.

Pull out thermostat.

17A-20

9. INSPECT THERMOSTAT.

(a) The thermostat is numbered with the valve opening

temperature.

Immerse the thermostat in water and gradually heat the

water.

Check the valve opening temperature.

Valve opening temperature:

80 - 84 ℃

If the valve opening temperature is out of the specification,

replace the thermostat.

Check the valve lift.

Valve lift: 8 mm or more, at 95 ℃ .

• If the valve opening temperature is out of the specification, replace the thermostat.

• Check that the valve is fully closed when the thermostat is at low temperature (below 77 ℃ ).

• If it is not closed, replace it with a new one.

10. INSTALL THERMOSTAT.

Always replace with a new thermostat rubber ring when

performing thermostat operation.

17A-21

Install thermostar and rubber ring.

Make sure that rubber ring is fitting to the thermostat properly

and they are fully seated.

Install thermostat housing.

Tighten thermostat housing retaining bolts.

11. CONNECT ENGINE WATER INLET HOSE NO. 2.

(a) Connect engine water inlet hose NO. 2, then tighten

retaining clamp.

12. CONNECT BATTERY NEGATIVE CABLE.

13. FILL COOLANT. (Refer to “Chapter 17A cooling - coolant, replacement”)

(a) After installing thermostat, start the engine until cooling fan runs at high speed. check coolant for

17A-22

15. INSTALL ENGINE COMPARTMENT COVER UNDER

Tighten 5 engine compartment cover retaining bolts.

Cover front floor covering.

16. INSTALL ASSISTANT DRIVER SEAT. (Refer to “Chapter 84 seat - driver / assistant driver seat,

17. PUT DOWN DRIVER SEAT AND LOCK IT.

COOLANT PUMP

COOLING - COOLANT PUMP

17A-23

1. DISCONNECT BATTERY NEGATIVE CABLE.

3. REMOVE GENERATOR BELT. (Refer to “Chapter 20A starting and charging - generator, overhaul”)

4. REMOVE COOLANT PUMP PULLEY RETAINING BOLTS.

5. REMOVE ENGINE TIMING BELT HOUSING.

6. REMOVE ENGINE TIMING BELT.

7. REMOVE COOLANT PUMP.

(a) Remove coolant pump retaining bolt.

(b) Remove coolant pump.

Remove coolant pump gasket.

Using a scraper, clean dirt on coolant pump and engine

block connect surface.

Clean the dirt, do not damage coolant pump and engine

8. INSPECT COOLANT PUMP.

(a) Rotate coolant pump and it should turn smoothly.

(b) There should be no clearance between coolant pump shaft and coolant punp bearing, and no abnormal

noise when it turns.

9. INSTALL COOLANT PUMP.

(a) Install coolant pump gasket. to avoid coolant leaking, use coolant pump sealant if necessary.

17A-24

After using the coolant pump sealant, wait for 15 minutes then fill the coolant.

Install coolant pump retaining bolts.

Torque: 14 N•m

10. INSTALL ENGINE TIMING BELT.

11. INSTALL ENGINE TIMING BELT HOUSING.

12. INSTALL COOLANT PUMP PULLEY RETAINING BOLTS.

13. INSTALL GENERATOR BELT. (Refer to “Chapter 20A starting and charging - generator, overhaul”)

14. CONNECT BATTERY NEGATIVE CABLE.

15. FILL COOLANT. (Refer to “Chapter 17A cooling - coolant, replacement”)

16. CHECK AFTER INSTALLATION.

(a) After replacing coolant pump, let engine be running until cooling fan runs at high speed. check coolant

for leakage.

LUBRICATION SYSTEM

LUBRICATION SYSTEM .................................................................18A-1

PRECAUTION............................................................................ 18A-1

COMPONENT............................................................................ 18A-2

ENGINE OIL .....................................................................................18A-4

REPLACEMENT ........................................................................ 18A-4

OIL FILTER ......................................................................................18A-6

REPLACEMENT ........................................................................ 18A-6

OIL PAN ...........................................................................................18A-8

REPLACEMENT ........................................................................ 18A-8

OIL PUMP ......................................................................................18A-11

OVERHAUL ............................................................................. 18A-11

18A

LUBRICATION - LUBRICATION SYSTEM

18A-1

Prolonged and repeated contact with engine oil will cause the skin fat to be removed, resulting in dry

skin, allergies and dermatitis. In addition, used engine oil contains potentially harmful pollutants which

may cause skin cancer. Therefore, the skin must be protected in appropriate methods and with

1. LUBRICATION SYSTEM PRECAUTION.

(a) Avoid contacting with oil for a long time, especially the used engine oil.

(b) Wear protective clothing including waterproof work gloves.

(d) Never put rags contaminated with oil in pockets.

(e) Avoid eyes contacting with oil, must wear goggles, In addition, equipment must be prepared to clean

the eye. And wrapping the wound must be dealt with immediately.

(f) Frequent use of soap and water can clean, especially before meals, and make sure all the oil has been

removed (skin cleansers can also be used to assist with the nail brush). After cleaning, it is

recommended to replace the natural skin oils cotton suet.

(g) Do not use gasoline, kerosene, diesel, thinner or solvent to clean skin.

(h) Before each work, apply cream to help skin cleaning after work.

(i) If your skin is abnormal, consult a doctor immediately.

18A-2

COMPONENT

1 Drain Plug

2 Oil Pan Bolt

3 Oil Filter

4 Oil Pan

5 Oil Strainer

6 Oil Strainer Gasket

7 Oil Pump Cover Bolt

8 Engine Oil Pressure Switch

9 Relief Plug

10 Gasket

11 Relief Spring

12 Relief Plug

13 Oil Filter Bracket

14 Oil Filter Bracket Gasket

15 Front Case Plug

16 O-ring

17 Front Case Inside Bolt

18 Front Case

19 Front Case Gasket

20 Oil Pump Cover

21 Oil Pump Driven Gear

22 Oil Pump Drive Gear

23 Front Crankshaft Oil Seal

24 Balance Shaft Oil Seal

18A-3

25 Oil Pump Oil Seal

26 Right Balance Shaft

27 Left Balance Shaft

28 Right Balance Shaft Front Bearing

29 Right Balance Shaft Rear Bearing

30 Left Balance Shaft Bearing

18A-4

LUBRICATION - ENGINE OIL

ENGINE OIL

18A-5

18A-6

LUBRICATION - OIL FILTER

5. DRAIN ENGINE OIL .(Refer to “Chapter 18A lubrication - engine oil, replacement”)

Without special circumstances, the oil filter should be replaced with engine oil, avoid oil pollution and

keep engine operation.

18A-7

18. PUT DOWN DRIVER SEAT AND LOCK IT.

18A-8

LUBRICATION - OIL PAN

1. OPEN ENGINE COMPARTMENT COVER.

2. OPEN OIL FILLER CAP.

4. DRAIN ENGINE OIL. (Refer to “Chapter 18A lubrication - engine oil, replacement”)

6. PULL OIL DIPSTICK OUT.

7. REMOVE OIL DIPSTICK PIPE.

(a) Remove oil dipstick pipe mounting bolt.

(b) Pull oil dipstick pipe out.

Check O- ring at the bottom of oil dipstick pipe for damage

and replace it as required.

8. RAISE AND SUPPORT THR VEHICLE.

9. REMOVE OIL PAN.

(a) Remove 4 bolts (or nuts) securing front cover to transmission.

(b) Remove the front cover.

18A-9

Remove the bolts on the rightside of oil pan.

Remove the bolts on the leftside of oil pan.

Remove the bolts in the front of oil pan through the front

crossmember.

Insert proper tool between cylinder block and oil pan,

then separate them by hammer.

Never use screwdriver or chisel to remove the oil pan. It will

damage the oil pan flange and cause oil leakage.

10. CLEAN CONNECT SURFACE OF OIL PAN AND ENGINE BLOCK.

11. APPLY A 4MM WIDE SEALANT TO THE ENTIRE

CIRCUMFERENCE OF OIL PAN FLANGE.

Circle the bolt hole with sealant strips around.

18A-10

12. INSTALL OIL PAN.

(a) Position oil pan and install oil pan mounting bolts.

(b) Tighten the bolt according to the number as shown.

Torque: 6 ~ 7 N•m

Be sure to install the oil pan quickly while the sealant is wet

(within 15 minutes).After installation, keep the sealant area

away from the oil for about one hour.

Install front cover for transmission.

13. INSTALL OIL DIPSTICK PIPE.

14. LOWER VEHICLE.

15. INSERT OIL DIPSTICK.

16. OPEN OIL FILLER CAP AND FILL ENGINE OIL TO SPECIFIED LEVEL.

17. INSTALL OIL FILLER CAP.

18. PARK THE VEHICLE ON LEVEL GROUND AND START ENGINE UNTIL IT IS WARM.

19. CHECK OIL PAN AND ENSURE THERE IS NO OIL LEAKAGE.

20. TURN THE IGNITION SWITCH OFF AND WAIT FOR 10 MINUTES.

21. PULL OIL DIPSTICK OUT AND ENSURE OIL LEVEL IS BETWEEN “MAX” MARK AND THE “MIN”

22. PUT DOWN DRIVER SEAT AND LOCK IT.

LUBRICATION - OIL PUMP

18A-11

OIL PUMP

2. RAISE AND SUPPORT THR VEHICLE.

3. DRAIN ENGINE OIL.(Refer to “Chapter 18A lubrication - engine oil, replacement”)

4. REMOVE OIL PAN.(Refer to “Chapter 18A lubrication - oil pan, replacement”)

5. OPEN ENGINE COMPARTMENT COVER.

7. REMOVE OIL PRESSURE SWITCH.

8. REMOVE OIL FILTER BRACKET MOUNTING BOLT AND

OIL FILTER BRACKET.

9. REMOVE FRONT CASE PLUG WITH SPECIAL TOOL.

18A-12

10. REMOVE PLUG ON THE LEFT SIDE OF CYLINDER

BLOCK AND INSERT A SCREWDRIVER INTO PLUG

HOLE TO LOCK BALANCE SHAFT.

11. REMOVE LEFT BALANCE SHAFT BOLT INSIDE

FRONT CASE PLUG.

12. TAKE OUT SCREWDRIVER FROM THE INSIDE OF PLUG ON THE CYLINDER BLOCK SIDE.

13. REMOVE FRONT CASE RETAINING BOLTS.

14. TAKE FRONT CASE AND BALANCE SHAFT AWAY AND INSPECT IT.

(a) Check oil holes for blocking and clean if necessary.

(b) Check the front case for cracks and other damage. Replace cracked or damaged front case if necessary.

Check balance shaft front bearing section for wear,

damage and seizure. If there are anything damaged with

the section, replace the front case.

18A-13

15. REMOVE OIL PUMP COVER MOUNTING BOLTS.

16. INSPECT OIL PUMP GEAR.

(a) Using rules and feeler gauge, measure the gear

clearance.

Standard:

Drive gear: 0.08 ~ 0.14 mm

Dirven gear: 0.06 ~ 0.12 mm

(b) Install the oil pump gear to the front case and rotate it to

ensure smooth rotation with no looseness.

between the front case and the gear surface of the oil

pump cover.

17. TAKE OIL PUMP DRIVE GEAR AND DRIVEN GEAR AWAY.

18. REMOVE FRONT CRANKSHAFT OIL SEAL, BALANCE SHAFT OIL SEAL AND PUMP OIL SEAL.

Oil seal can not be reused after removal and replace it with new one.

19. USING SPECIAL TOOL, REMOVE BALANCE SHAFT

FRONT BEARING FROM CYLINDER BLOCK.

(a) Check balance shaft front bearing section for wear,

damage and seizure, replace it as required.

20. USING SPECIAL TOOL, REMOVE BALANCE SHAFT

REAR BEARING FROM THE CYLINDER BLOCK.

(a) Check balance shaft rear bearing section for wear,

Remove balance shaft front bearing first, then remove

balance shaft rear bearing .

18A-14

21. INSTALL LEFT BALANCE SHAFT REAR BEARING.

(a) Position tools into cylinder block.

(b) Apply engine oil to the outer surface of bearing and

bearing hole in the cylinder block.

Using special tool, install the rear bearing.

The left rear bearing hasn’t oil holes.

22. INSTALL RIGHT BALANCE SHAFT REAR BEARING.

(a) Align the ratchet ball of the special tool with the oil hole in

the rear bearing to install the bearing of the special tool.

(b) Apply engine oil to the front bearing outer surface and

bearing hole in the cylinder.

Using special tool, install the rear bearing. Make sure

that the oil hole of the bearing is aligned with the oil hole

of the cylinder block.

18A-15

Remove rear bearing installing portion from special tool.

Using special tool, install front bearing.

23. INSTALL OIL PUMP DRIVE GEAR AND OIL PUMP

DRIVEN GEAR.

Apply engine oil generously to the gears and line up the

alignment marks.Oil pump drive gear timing mark as

shown in the figure.

Oil pump driven gear timing mark.

18A-16

24. INSTALL OIL PUMP COVER AND TIGHTEN RETAINING

BOLTS.

25. INSTALL A NEW FRONT CASE GASKET.

26. POSITION FRONT CASE AND TIGHTEN RETAINING

BOLTS TEMPORARILY.

27. USING SPECIAL TOOL, INSTALL OIL PUMP SEAL.

28. USING SPECIAL TOOL, INSTALL BALANCE SHAFT

OIL SEAL.

18A-17

29. USING SPECIAL TOOL, INSTALL FRONT CRANKSHAFT

30. INSTALL OIL FILTER BRACKET SEAL.

31. POSITION OIL FILTER BRACKET AND TIGHTEN

RETAINING BOLTS TEMPORARILY.

32. INSTALL OIL PRESSURE SWITCH.

(a) Clean the thread portion of oil pressure switch and apply

sealant to the thread portion.

Using special tool, tighten the oil pressure switch.

Torque: 10 N•m

18A-18

33. REMOVE PLUG ON THE LEFT SIDE OF CYLINDER

BLOCK. INSERT A SCREWDRIVER INTO PLUG

HOLE TO LOCK BALANCE SHAFT ON THE LEFT

SIDE OF CYLINDER BLOCK.

34. INSTALL LEFT BALANCE SHAFT MOUNTING BOLT

INSIDE FRONT CASE PLUG HOLE.

Torque: 37 N•m

35. INSTALL PLUG ON THE CYLINDER BLOCK SIDE.

Torque: 24 N•m

36. TIGHTEN BOLTS ON THE FRONT CASE OF OIL

PUMP.

37. TIGHTEN OIL FILTER BRACKET MOUNTING BOLT.

Torque: 19 N•m

18A-19

38. USING TOOL, INSTALL FRONT CASE PLUG.

39. INSTALL ENGINE TIMING BELT.

40. INSTALL OIL STRAINER RETAINING BOLTS.

41. INSTALL OIL PAN. (Refer to “Chapter 18A lubrication - oil pan, replacement”)

42. LOWER VEHICLE.

43. FILL ENGINE OIL. (Refer to “Chapter 18A lubrication - enginge oil, replacement”)

44. PUT DOWN DRIVER SEAT AND LOCK IT.

IGNITION SYSTEM ............................................................................ 19-1

COMPONENTS ........................................................................... 19-1

IGNITION MODULE/SPARK PLUG WIRE/SPARK PLUG................ 19-2

OVERHAUL ................................................................................. 19-2

IGNITION - IGNITION SYSTEM

19-1

1 Engine Cylinder Head Cover

2 Ignition Module Bracket

3 Ignition Module

4 Bolt

5 Spark Plug

6 Spark Plug Wire

19-2

IGNITION - IGNITION MODULE/SPARK PLUG WIRE/SPARK PLUG

IGNITION MODULE/SPARK PLUG WIRE/SPARK PLUG

Remove spark plug wire from ignition module in a certain

Remove spark plug wire.

19-3

5. REMOVE IGNITION MODULE

Disconnect ignition module connector.

Remove 2 ignition module retaining bolts.

Remove ignition module.

6. REMOVE SPARK PLUG.

7. INSPECT SPARK PLUG WIRE.

• Check if the spark plug wire has been broken down.

• Make sure the spark plug wire resistance is less than 4 KΩ.

8. CHECK IGNITION MODULE.

• Check if crack exists on the ignition module.

• Check ignition module condition.

(a) Using diagnostic tool, ensure there exists no DTC. If there exists DTC, record it. Ensure that the DTC

fault is resolved even the DTC is unrelated with ignition system.

(b) Pull out fuel pump relay.

19-4

Lightly pull out spark plug wire and remove the spark plug.

Install a new spark plug to the spark plug wire, touch spark plug negative to the engine cylinder block.

Start engine, check the flash over.

If the flash over is weak or no flash over, replace with a new ignition module. After replacing the new

ignition module, if the flash over become strong, we can ensure the ignition module has been damaged.

If there is still no flash over, check the ignition circuit and inspect the spark plug.

Using diagnostic tool, ensure there appears no DTC, except for the DTC record in step (b). Clear all

DTCs.

9. INSPECT SPARK PLUG.

• Check spark plug insulator outer surface for cracks.

• Check spark plug flash over for carbon deposition.

• Check spark plugs for burned off or melted positive and

negative electrode.

• Check spark plug gap.

Standard value: 1 ~ 1.1 mm

10. INSTALL SPARK PLUG.

11. INSTALL IGNITION MODULE.

(a) Install 2 ignition module retaining bolts.

12. INSTALL SPARK PLUG WIRE.

13. INSTALL INTAKE HOSE. (Refer to “Chapter 14A intake air- intake air hose, replacement”)

19-5

15. START ENGINE AND CONFIRM IT IS IN GOOD CONDITION.

STARTING AND CHARGING SYSTEM ..........................................20A-1

PRECAUTION............................................................................ 20A-1

PROBLEM SYMPTOMS TABLE................................................ 20A-2

GENERATOR...................................................................................20A-4

COMPONENTS ......................................................................... 20A-4

OVERHAUL ............................................................................... 20A-5

STARTER.......................................................................................20A-12

COMPONENTS ....................................................................... 20A-12

OVERHAUL ............................................................................. 20A-13

BATTERY.......................................................................................20A-21

COMPONENTS ....................................................................... 20A-21

USE AND MAINTENANCE...................................................... 20A-22

INSPECTION ........................................................................... 20A-24

BATTERY COMMON PROBLEMS, THE CAUSES ANALYSIS AND

TROUBLESHOOTING............................................................. 20A-25

REPLACEMENT ...................................................................... 20A-27

20A

STARTING AND CHARGING - STARTING AND CHARGING SYSTEM

STARTING AND CHARGING SYSTEM

AND CHARGING

1. STARTING AND CHARGING SYSTEM PRECAUTION.

20A-1

Battery may have escaping explosive gas. in order to avoid personal injury, keep ventilated in engine

room before maintaining battery. To avoid electric arc, disconnect battery negative cable first and

connect the negative cable last.

Battery electrolyte is very dangerous. It can damage the machine and cause serious burns. When

maintaining battery, prepare neutralizers concentration soda water, wear safety eyepiece and wear

protective clothing, which can avoid personal injury.

When using compressed air, wear appropriate goggles and protective mask. Dust particles and dirt can

cause injury.

Don't tighten the electrical connectors excessively, which may damage the starter.

Never short two cables of the battery, it will cause a rapid battery fever even an explosion occur. The

escaping gas from battery is easily be burned by the spark, so do not use fire near battery.

After the generator operation, do not try to use spark check whether the generator works. Use bulb or

multimeter to perform the test. Otherwise it will damage the generator diode.

Check the generator silicon rectifier devices, it is strictly forbidden to use multimeter or apply 220V

directly for generator insulation check, otherwise it will make diode breakdown and damaged.

20A-2

Use the table below to help you find the cause of the problem. The numbers indicate the priority of

the likely cause of the problem. Check each part in order. If necessary, replace these parts.

1. Starter switch control circuit (Open) Check wire harness

Starter out of operation

2. Brush and rectifier (Poor

connection)

3. Starter inside circuit (Open or short)

1. Battery (Low voltage)

Chapter 20A starting and charging - starter,

use and maintenance

2. Starter wire (Poor connection) Check wire harness

Starter lacks power,

can not srart engine

Starter keep working

after engine start

3. Rectifier (Surface damaged or

stains)

4. Brush (Wear) or Brush spring (Loss

elastic force)

5. Solenoid switch (Contacts ablation)

6. Bearing (Wear),commutator (Wipe

shell)

1. Starter relay (Copper contacts bond)

2. Starter commutator (Bend or break)

3. Starter gear tooth surface contact

(Roughening or stuck)

-Chapter 20A starting and charging - starter,

1. Generator connect wire (damaged) Check wire harness

Generator out of operation

2. Rotor winding (Open)

3. Rectifier diode (Damaged)

4. Brush (Poor connection)

5. Regulator (Damaged)

Chapter 20A starting and charging - generator,

20A-3

Generator lacks

enough electricity

1. Belt losing tensity

2. Brush (Poor connection) or collector

ring (Smeary)

3. Regulator (Damaged)

Chapter 15A engine mechanical - engine

accessory belt, overhaul

4. Battery lose electrolyte

20A-4

STARTING AND CHARGING - GENERATOR

1 Generator Belt Pulley

2 Rotator Component

3 Rear Bearing

4 Bearing Carrier

5 Front Bearing

6 Front Cover

8 Anchor Plate

9 Regulator And Brush Carriage

10 Brush

11 Brush Ring

12 Rectifier Component

13 Back Cover

7 Stator Component

20A-5

1. TURN IGNITION SWITH OFF.

4. REMOVE A/C COMPRESSOR BELT. (Refer to “Chapter 61 heater and air conditioning - A/C compressor,

5. REMOVE POWER STEERING PUMP BELT. (Refer to “Chapter 52 power steering - power steering

pump and fliud reservior assy, replacement”)

6. REMOVE GENERAOR BELT.

(a) Loosen locking bolt securing belt tensioner.

(b) Loosen adjustment bracket mounting bolt.

Loosen generator lower mounting nut.

(d) Rotate adjustment bolt and adjust generator belt

(e) Remove generator belt.

Check generator belt for crack and replace it as required.

20A-6

7. REMOVE GENERATOR.

(a) Loosen generator positive cable connecting nut.

(a) Disconnect generator connector.

Remove generator adjustment bolt.

Remove generator lower support bolt.

Remove generator.

8. DISASSEMBLE GENERATOR.

Using pneumatic tools, loosen generator belt pulley retaining

nut.

Loosen retaining bolts attaching generator front cover to

stator component.

Insert a screwdriver between front cover and stator then

separate them.

• If it is difficult to be separated, slap the front cover

slightly with rubber hammer and pry it with screwdriver.

• Do not insert screwdriver too deep to prevent stator

component being damaged.

20A-7

Using a electric iron (180 ~ 250 w), remove stator. This

operation should be within 4 seconds to prevent diode

from heat.

Loosen 4 retaining bolts from rectifier.

Using a electric iron, remove rectifier from regulator.

• Ensure that the heat is not transmitted from electric

iron to diode for long time.

• Do not let diode pin bear too much force.

Remove and inspect rotor.

• Check the rotor coil is conductive, and confirm that the

collector rings are conductive. Measure the resistance of

rotor. If the resistance is less than specified value, it

means the rotor is short circuit. If it is not conductive or it

is short circuit, replace the rotor assy.

Specified value: 3 ~ 5 Ω

• Check that rotor coil ground. Confirm that it is insulative

between collector ring and core. If not, replace the rotor

20A-8

• Using a vernier caliper, measure the slip ring diameter.

Standard: 14.2 ~ 14.4 mm

Limit: 12.8 mm

(h) Remove and inspect stator.

• Check the stator for continuity. Confirm that the coil lead

is conductive. If not, replace the stator assy.

• Check the coil ground. Confirm that it is not conductive

between coil and stator core. Replace the stator assy if

conductive.

(i) Inspect stator rectifier.

• Diode group (three diodes) check: Using an ammeter to

connect two ends of each diode, check if three diodes

are conductive. If it is not conductive in both directions, it

means the diodes are broken, and it is required to

replace the rectifier assy.

Get rid of welding point of brush lead, then take out the

brush.

20A-9

If brush is so worn to reach wear limit line, replace brush.

9. ASSEMBLE GENERATOR.

(a) When installing new brush, weld brush lead in the

condition when brush is pressed down to brush bracket

as shown.

Tighten 4 retaining bolts of rectifier.

Weld rectifiers and stator.

Before mounting rotor on rear cover, insert a steel wire

into small hole on rear cap, then erect mounted rotor by

brush, pull out steel wire.

20A-10

Install rotor.

Tighten the retaining bolts attaching generator front

cover to stator component.

10. POSITION GENERATOR BELT PULLY. USING PNEUMATIC TOOLS, INSTALL GENERATOR BELT

PULLEY RETAINING NUT.

11. INSTALL GENERATOR.

(a) place generator into proper position.

(b) Install generator adjustment bolt and lower suppor bolt.

Position adjustment bolt and lower support bolt ,but just

install, do not tighten.

Connect generator connector.

Tighten generator positive cable connecting nut.

12. INSTALL GENERATOR BELT.

(a) Adjust adjustment bolt until generator belt is in proper

20A-11

Tighten belt tensioner locking bolt.

Tighten adjustment bracket mounting bolt.

Torque: 20 ~ 24 N•m

Tighten nut to generator lower support bolt.

13. INSTALL POWER STEERING PUMP BELT. (Refer to “Chapter 52 power steering - power steering

14. INSTALL A/C COMPRESSOR BELT. (Refer to “Chapter 61 heater and air conditioning - A/C compressor,

15. CONNECT BATTERY NEGATIVE CABLE.

16. PUT DOWN ENGINE COMPARTMENT COVER AND LOCK IT.

17. START THE VEHICLE AND CHECK GENERATOR FOR GOOD CONDITION.

20A-12

STARTING AND CHARGING - STARTER

1 Front Bracket

2 Spring

3 Starter Drive Lever

4 Rubber Washer

5 Planetary Gear Bracket

6 Solenoid Component

7 Rubber Washer

8 Steel Ball

9 Planetary Gear

11 Overdrive Clutch

12 Locating Snap Ring

13 Magnet Yoke Assy

14 Commutator

15 Brush

16 Brush Bracket

17 Starter Shell Bolt

18 Rear Bearing

19 Rear Bracket

10 Internal Gear

20A-13

4. REMOVE STARTER.

(a) Disconnect starter control wire connector.

Remove starter positive cable locking nut.

Remove 2 starter retaining bolts.

Remove starter.

5. INSPECT STARTER.

(a) Pinion gap adjustment.

• Disconnect the field coil wire from the M-terminal of the

magnetic switch.

• Connect a 12-volt battery between the S-terminal and M-

terminal.

This test must be performed quickly (less than 10 seconds)

to prevent the coil from being burned.

• When the 12-volt battery is connected between the S-

terminal and M-terminal, the pinion will move out.

20A-14

• Check the pinion-to-stopper clearance (pinion gap) with

a feeler gauge.

Standard: 0.5 ~ 2.0 mm

• If the pinion gap is out of specification, adjust by adding

or removing gasket(s) between the magnetic switch and

front bracket.

(b) Magnetic switch pull-in test.

• When turn ignition switch on, the pinion will move out. If

the pinion moves out, the pull-in coil is good. If it doesn't,

replace the magnetic switch.

• Connect a 12-volt battery between the S-terminal and

body.

• Manually pull out the pinion as far as the pinion stopper

• If the pinion remains out, everything is operating properly.

If the pinion moves in, the hold-in circuit is open.

Replace the magnetic switch.

20A-15

Magnetic switch return test.

• Connect a 12-volt battery between the M-terminal and

to prevent the coil from burning.

• Pull the pinion out and release. If the pinion quickly

returns to its original position, everything is operating

properly. If it doesn't, replace the magnetic switch.

Be careful not to get your fingers caught when pulling out

the pinion.

6. DISASSEMBLE STARTER.

(a) Disconnect magnetic coil lead nut from magnetic switch.

Remove magnetic switch retaining bolts.

Remove starter shell retaining bolts.

20A-16

Disassemble starter as components art shown.

• When removing armature, do not lose the steel ball

mounted in the bearing ends.

• Using a proper control sleeve, push and press the

locating snap ring to the overdrive clutch side, and

make it be away from the clip spring.

• Remove the snap spring with snap ring pliers, then

remove the locating snap ring and overdrive clutch.

7. CLEAN STARTER PARTS.

Do not put the parts in the detergent for cleaning. If the magnet yoke, excitation winding lead or rotor is

immerged in detergent, their insulating ability will be damaged.

Clean starter parts with cloth.

Drive parts can not be immerged in detergent for cleaning. Before delivering out of factory, the

overdrive clutch is greased. If clean it by detergent, its grease might be removed.

Using a brush and dipping with detergent, clean drive parts then dry them with a cloth.

8. INSPECT COMMUTATOR.

(a) Support the commutator with a pair of V block and turn it

to measure the runout of the surface using a dial gauge.

Standard: ≤ 0.05 mm

Limit: 0.1 mm

Measure the diameter of the commutator.

Standard: 29.4 mm

Limit: 28.4 mm

20A-17

Measure the depth of the undercut between segments.

Standard: 0.5 mm

Limit: 0.2 mm

9. INSPECT BRUSH AND BRUSH BRACKET.

(a) Check that it is conductive between brush plate and brush bracket, if not, it is normal.

(b) Check the commutator contact surface of each brush for abnormal roughness. Also check the height of

the brush. Replace the brush holder if the height is lower than the limit.

Limit: 7.0 mm

contact surface with sandpaper wrapping around the commutator.

10. INSPECT OVERDRIVE CLUTCH.

(a) Make sure that the pinion can not be turned counterclockwise

and can be turned clockwise freely.

(b) Check the pinion for abnormal waring and damage.

11. INSPECT ARMATURE COIL.

(a) Set the armature in a growler.

(b) While holding a thin strip of iron against the armature in

parallel with its axis, turn the armature slowly. The

armature is normal if the iron strip is not attracted to the

armature or it does not vibrate.

Clean the surface of the armature thoroughly before performing

the test.

Check the insulation between commutator segments and

armature coils. It is normal if there is not continuity.

20A-18

Check continuity between a segment and another. It is

normal if there is continuity.

12. INSPECT MAGNETIC SWITCH.

(a) Coil open circuit test.

• Check that there is continuity between the M terminal

and body A.

• If there is no continuity, replace the magnetic switch.

Contact fusion check.

• Check that there is no continuity between the B terminal

and M terminal.

• If there is continuity, replace the magnetic switch.

Switch contact check.

• Push the indicated end of the magnetic switch with a

strong force to close the internal contacts. Without

releasing the switch end, check that there is continuity

between the B terminal and M terminal.

13. ASSEMBLE STARTER.

(a) Using a suitable puller, pull stop ring until it gets over

snap ring.

20A-19

Install locating snap ring and overdrive clutch.

Assemble starter as components art shown.

Tighten the starter shell retaining bolts.

Torque: 8 ~ 10 N•m

Tighten the magnetic switch retaining bolts.

Connect the magnetic coil lead nut to magnetic switch.

Torque: 14 ~ 16 N•m

20A-20

14. INSTALL STARTER.

(a) Tighten 2 starter retaining bolts.

Torque: 68 ~ 72 N•m

Connnect and tighten starter positive cable locking nut.

Torque: 18 ~ 20 N•m

Connect starter control wire connector.

15. LOWER THE VEHICLE.

16. CONNECT BATTERY NEGATIVE CABLE.

STARTING AND CHARGING - BATTERY

20A-21

BATTERY

2 Battery Fix Frame

3 Battery Fix Rod

4 Mounting Nut

5 Battery Tray

6 Bolt And Washer

20A-22

USE AND MAINTENANCE

1. CHARGING DEVICE.

DC power supply must be used for battery charging, howerever, what is supplied by power plant is AC

that it must be transformed into DC, After transform, the charging can be performed.

Rectifier.

Controllable silicone voltage regulation charger.

2. CHARGE PRECAUTIONS.

(a) Charging should choose in ventilated dry room, indoor temperature in 5 ℃ ~ 40 ℃ is advisable.

(b) Battery can not be overlap shelved, also do not put them on the ground directly. It should be put on the

wooden support, and cannot be set with alkaline battery or other chemicals.

(d) Liquid temperature should not exceed 45 ℃ and otherwise cooling measures shouldl be taken (by

reducing filling current or stopping sharge or being cooled down in water tank).

3. CHARGE CONNECTION.

(a) The positive pole of charger is to be connected with the positive pole of battery, while the negative pole

of charger should be connected with the negative pole of battery. Never connect them reversely.

(b) Charge of most batteries may be determined based on the size of motor power. Connection for charge

must be firm.

4. CHARGING MODES.

(a) Constant current charge.

(b) Constant voltage charge.

5. AFTER CHARGING, USING THE BELOW METHODS, CHECK THE BATTERY CAPACITY IS

RESTORED TO STANDARD.

(a) Voltage method

Voltage Determination Treatment

above 12.5 v normal go on using

11.5 ~ 12.5 v undercharge additional charge

below 11.5 v over-discharge or internal failure to be further checked after charging

Capacity method

Capacity Tester Display Determination Treatment

white zone fully charged go on using

green zone normal go on using

yellow zone undercharge additional charge

red zone over-discharge to be further checked after charging

20A-23

6. USING AND MAINTENANCE OF BATTERY IN WINTER

Keep the battery is to be maintained under full charge status, avoid the electrolyte from being frozen

arising from drop in density, which may give rise to breakage of container, curve of pole plats, as well as

smash and dropout of active substances, and other failures.

Because the battery capacity reduced in winter, when start the engine in cold status, preheated the

engine and each time start the engine should not more than 15 seconds, two starting interval 2 ~ 3

minutes, if can not start the engine in three times, troubleshooting, then restarting.

20A-24

1. APPEARANCE INSPECTION.

(a) Observe whether the battery appearance in good condition. Check if fixed terminal and wires are

connected firmly.

(b) Observe whether the battery shell and the center partition cracks, and use a wooden beat shell and

center partitions respectively, listen to the sound without breaking, especially the central baffle and shell

side of shell wall at the junction of four, prone to crack, should be carefully examined.

of the following capacity, voltage detection.

2. CAPACITY TEST.

(a) The excel tester is also known as the discharging tongs.

It consists of a DC voltmeter of three volts and one load

resistance.

(b) The tips of the two tongs shall be pressed on the anode

and the cathode tightly and maintain for five seconds in

the measurement. Observe the terminal voltage in the

state of the big load discharging and the discharging

content and the starting ability can be judged correctly.

the current and the voltage shall be read according to the

regulations of the factory manual. Generally, the single

voltage of the battery in good state shall be above 1.5 V

and keep steady within five seconds. If the voltage drops

rapidly within five minutes or the voltage of one single

cell is 0.1 V lower than that of others, it indicates there

are troubles in the battery and it shall be repaired.Below

is the use of excel tester of discharge plan detection

income cross-references.

Display Zone Determination Treatment

3. VOLTAGE TEST.

The following table is derived using the digital multimeter test table.

under 112.5 v over-discharge or internal fault to be further checked after charging

20A-25

TROUBLESHOOTING

1. ELECTRICAL QUALITY OF ONE FULL-CHARGED BATTERY REDUCE WITHOUT USE FOR A

LONG PERIOD.

• Causes analysis:

The full-charged battery without use will lose its electrical quality gradually and this phenomenon is

known as “self-discharge”. The important cause of self-discharge is the impure materials. If there are

impurities in the material of the polar plate or in the electrolyte, there will be a potential difference

between the impurity and the polar plate and between the impurities. A closed “local current” is formed

and would make the discharge of the battery.

• Troubleshooting:

For the battery which has discharged seriously, it can be discharged completely or excessively. This will

enable the impurities on the polar plate into the electrolyte. Then, pour the electrolyte out and clean the

battery with distilled water. Finally, inject the new electrolyte and re-charge the battery.

2. BATTERY EXPLODE.

The water in the electrolyte hydrolyzes into hydrogen or oxygen and a lot of bubbles are generated;

there are short circuit and vulcanization troubles in the battery; the temperature increases while

charging and large amount of water are evaporated. Then if the vent holes of the injection hole cover

are plugged or there are a lot of gases which are unable to escape, the battery will explode when the

inner pressure comes to a limit (or there are sparks).

(a) The vent holes of the injection hole cover shall be cleared.

(b) In order to avoid sparks, the wirings on the polar stud shall be fastened.

(d) Control the charging amount and do not over-charge in order to reduce the releasing amount of the

gases. Open flames are prohibited and the ventilation shall be ensured in the charging room.

3. RAPID DECREASE OF THE LIQUID LEVEL DURING THE USE PROCESS OF THE BATTERY.

(a) Excessive charging current lead to evaporation of water.

(b) Battery shell broken.

(a) Add distilled water.

(b) Repair shell, add the electrolyte.

4. A YELLOW OR WHITE PASTE APPEARS ON BATTERY COVER.

The yellow or white paste surrounding the battery cover and the polar stud is caused by the corrosion of

the polar studs, wiring clip and the fixed frame by the sulfuric acid sprayed.

In order to avoid these pastes, clean the electrolyte sprayed on the battery cover and the shell with a

cloth soaked with the soda solution of 10 percents. Then wipe with water and dry with a clean cloth.

The paste on the wire ends and the studs shall be wiped with the cloth soaked with soda solution. If

there are oxides of poor conductivity, scrape them with a little knife and clean them. It would be best to

smear a coat of Vaseline or butter on the cover after the polar studs and wiring clips are fastened.

20A-26

The vehicle for Foton View CS2 is equipped with maintenance-free battery. If battery is bad, replace the

battery as a unit. To avoid personal injury, it is strictly prohibited to disassemble the battery.

Disassembly is limited to find the cause of the problem and provide information through professional

testing.

20A-27

3. REMOVE BATTERY CABLE.

(a) Open shield and disconnect battery negative cable.

Disconnect the negative cable first when removal.

Open shield and disconnect battery positive cable.

4. REMOVE BATTERY FIX FRAME.

(a) Remove battery fix rod mounting nut.

(b) Remove battery fix frame.

5. REMOVE BATTERY.

Battery should be put up, placing battery upside down is prohibited.

20A-28

6. REMOVE BATTERY TRAY.

(a) Loosen 3 battery tray retaining bolts.

(b) Remove battery tray.

7. INSTALL BATTERY TRAY.

(a) Install 3 battery tray retaining bolts.

Torque: 16 ~ 18 N•m

8. INSTALL BATTERY.

(a) Position battery.

(b) Place battery fix frame and tighten fix rod mounting nut.

Connect battery positive cable, tighten mounting nut and

cover shield.

Connect battery negative cable, tighten mounting nut

and cover shield.

• If terminals has sediments, remove the impurities

then apply thin layer of grease to terminal.

• Connect positive battery cable first when installing.

A SINGLE MIRROR IS INOPERATIVE .....................................04-445

ABS CONTROL IS UNREASONABLE ......................................04-119

ABS MODULE CONNECTOR .....................................................04-98

ABS SYSTEM IS INOPERATIVE...............................................04-122

ACCELERATE PEDAL ............................................................. 12A-25

AIR FILTER ASSY ...................................................................... 14A-6

AIR PURIFIER LAMP IS INOPERATIVE ...................................04-283

ALL FOG LAMPS ARE INOPERATIVE .....................................04-229

ALL HEADLAMPS ARE INOPERATIVE ....................................04-207

INOPERATIVE ...........................................................................04-295

ALL POWER WINDOWS ARE INOPERATIVE .........................04-421

ALL STOP LAMPS ARE INOPERATIVE ...................................04-260

ANTI-LOCK BRAKE SYSTEM .....................................................04-96

AUDIO SYSTEM ........................................................................04-361

AUXILIARY POWER..................................................................04-374

INOPERATIVE ...........................................................................04-307

A/C CONTROL PANEL ILLUMINATION IS NOT INOPERA-

TIVE(LIGHTING SYSTEM) ........................................................04-307

A/C SYSTEM IS INOPERATIVE................................................04-153

BACK - UP LAMP IS INOPERATIVE(ONE SIDE) .....................04-269

BACK - UP LAMPS ARE INOPERATIVE (BOTH SIDES) .........04-271

BASIC IDLE SPEED ADJUSTMENT(THROTTLE BODY) ....... 11A-23

BASIC INSPECTION ...........04-150, 04-182, 04-335, 04-362, 04-418,

04-440, 04-453, 04-469, 04-495

BASIC PRINCIPLE(GASOLINE ENGINE CONTROL

SYSTEM) .................................................................................... 11A-8

BASIC SERVICE PROCEDURE..................................................04-10

BATTERY.................................................................................. 20A-21

IN SPECIFIED DISTANCE (DISPLAYER IS NORMAL) ............04-408

CANISTER SOLENOID VALVE.....................................11A-52, 13A-4

CAPTURING DATA .....................................................................04-20

CENTRAL DOME LIGHT IS INOPERATIVE .............................04-278

CENTRAL LOCKING CONTROLLER ASSY A..........................04-493

CENTRAL LOCKING CONTROLLER ASSY A PIN...................04-417

CENTRAL LOCKING CONTROLLER ASSY B..........................04-494

CHECK ACCESSORY BELT(INSPECTION)...............................05-20

CHECK AND CLEAN WINDSHIELD FLUME(INSPECTION)......05-16

SCRIBED TORQUE(INSPECTION) ............................................05-22

CHECK BRAKING SYSTEM(INSPECTION) ...............................05-30

CHECK CHASSIS(INSPECTION) ...............................................05-26

CHECK COOLANT LEVEL(INSPECTION)..................................05-34

(INSPECTION).............................................................................05-14

CHECK ENGINE COMPARTMENT PARTS(INSPECTION) .......05-17

CHECK EXHAUST SYSTEM(INSPECTION) ..............................05-33

CHECK HEADLIGHTS(INSPECTION) ........................................05-23

CHECK PARKING BRAKE, BRAKE PEDAL(INSPECTION).......05-13

CHECK SEAT BELT(INSPECTION)............................................05-11

CHECK STEERING FLUID LEVEL(INSPECTION) .....................05-29

CHECK SUSPENSION BALL JOINT AND DUST COVER(INSPEC-

TION)........................................................................................... 05-28

CHECK SUSPENSION COMPONENTS(INSPECTION) ............ 05-27

CHECK THE AIRBAG(INSPECTION)......................................... 05-10

CHECK THE BATTERY(INSPECTION)........................................ 05-9

PLATE(INSPECTION)................................................................. 05-31

(INSPECTION) .............................................................................. 05-8

CHECK THE ENGINE OIL LEVEL (ISF2.8)(INSPECTION)........ 05-36

CHECK THE ENGINE OIL LEVEL (4G69)(INSPECTION) ......... 05-35

(INSPECTION) ............................................................................ 05-21

CHECK TIMING BELT(INSPECTION) ........................................ 05-18

CHECK TIRES(INSPECTION) .................................................... 05-32

(INSPECTION) ............................................................................ 05-24

INOPERATIVE .......................................................................... 04-305

CIGARETTE LIGHTER IS INOPERATIVE................................ 04-375

CKP SENSOR ...........................................................................11A-43

COMPONENTS(COOLING SYSTEM) ........................................17A-2

COMPONENTS(CRANKSHAFT, CYLINDER

BLOCK & FLYWHEEL) .............................................................15A-69

COMPONENTS(CYLINDER HEAD,VALVE).............................15A-51

COMPONENTS(EXHAUST PIPE) ..............................................16A-1

COMPONENTS(GENERATOR)..................................................20A-4

COMPONENTS(PISTON & CONNECTING ROD

ASSEMBLY) ..............................................................................15A-59

COMPONENTS(ROCK ARM, ROCK ARM SHAFT, HYDRAULIC

TAPPET & CAMSHAFT) ...........................................................15A-37

COMPONENTS(STARTER)......................................................20A-12

COMPONENTS(TIMING BELT)................................................15A-18

COMPOSITION(BATTERY) ......................................................20A-21

COOLANT ...................................................................................17A-6

COOLANT PUMP......................................................................17A-23

COOLING SYSTEM ....................................................................17A-1

CRANKSHAFT, CYLINDER BLOCK & FLYWHEEL .................15A-69

CYLINDER HEAD OVERHAUL(CYLINDER HEAD,VALVE) ....15A-52

CYLINDER HEAD,VALVE.........................................................15A-51

DATA STREAM LIST/ACTIVE TEST .......................................... 04-23

DEFROSTER SYSTEM............................................................. 04-452

DIAGNOSIS SWITCH ILLUMINATION IS NOT INOPERATIVE04-303

DIAGNOSTIC HELP - INTERMITTENT FAULT............................ 04-8

DIAGNOSTIC SYSTEM .............................................................. 04-16

DIAGNOSTIC TROUBLE CODE CHART ...........04-27, 04-99, 04-129

DIAGNOSTICS GASOLINE ENGINE CONTROL SYSTEM

(BJ491EQ).................................................................................... 04-1

(BUZZER IS NORMAL) ............................................................. 04-411

INOPERATIVE .......................................................................... 04-313

DOOR CONTROL SWITCH PIN ............................................... 04-415

DOOR DOES NOT OPEN / CLOSE

(USING THE REMOTE KEY) .................................................... 04-504

DOWNSTREAM OXYGEN SENSOR........................................11A-49

DTC DIAGNOSTIC...................................................................... 04-32

ENGINE CONTROL MODULE (ECM) ......................................11A-15

ENGINE CONTROL SYSTEM ...................................................... 04-1

ENGINE COOLANT TEMPERATURE SENSOR ......................11A-18

ENGINE MECHANICAL PART....................................................15A-1

ENGINE OIL ................................................................................18A-4

ENGINE OIL PRESSURE WARNING LIGHT NEVER /

ALWAYS ON ............................................................................. 04-482

ENGINE SYMPTOM DIAGNOSTIC ............................................ 04-59

EXHAUST PIPE ..........................................................................16A-1

FAIL-SAFE CHART ..................................................................... 04-21

FRONT AIR FLOW IS INSUFFICIENT...................................... 04-163

FRONT BLOWER MOTOR IS INOPERATIVE.......................... 04-157

FRONT DOME LIGHT IS INOPERATIVE ................................. 04-291

FRONT FOG LAMPS ARE ALWAYS ON ................................. 04-218

FRONT FOG LAMPS ARE INOPERATIVE............................... 04-213

FRONT POWER WINDOW LH DOES NOT CLOSE ................ 04-432

FRONT POWER WINDOW LH DOES NOT OPEN .................. 04-430

CONTROL SWITCH RH) .......................................................... 04-436

FRONT POWER WINDOW RH IS INOPERATIVE ................... 04-427

TROL SWITCH)......................................................................... 04-434

FUEL FILLER CAP........................................................ 12A-20, 13A-1

FUEL FILLER DOOR LOCK LATCH ASSY ..............................12A-18

FUEL FILLING DOOR ...............................................................12A-17

FUEL FILLING TUBE AND BREATHER TUBE ASSY..............12A-21

FUEL FILTER ASSY ...................................................................12A-9

FUEL LEVEL SENSOR ASSY ..................................................12A-10

FUEL SYSTEM............................................................................12A-1

GASOLINE ENGINE CONTROL SYSTEM ........................05-1, 11A-1

GENERATOR..............................................................................20A-4

TIVE........................................................................................... 04-245

HAZARD WARNING LAMPS ARE ALWAYS ON ..................... 04-258

LAMPS ARE NORMAL) ............................................................ 04-236

TIVE........................................................................................... 04-321

TIVE........................................................................................... 04-317

HEATER AND AIR CONDITIONING SYSTEM ......................... 04-149

HI - BEAM HEADLAMP IS INOPERATIVE (ONE SIDE)........... 04-197

HIGH - MOUNTED STOP LAMP IS INOPERATIVE ................. 04-267

HORN IS ALWAYS ON ............................................................. 04-389

HORN IS INOPERATIVE .......................................................... 04-383

HORN SYSTEM ........................................................................ 04-382

HOW TO DIAGNOSTICS ANALYSE ............................................ 04-5

IDLE AIR CONTROL MOTOR...................................................11A-28

IGNITION CONTROL MODULE................................................11A-60

IGNITION SWITCH ILLUMINATION IS INOPERATIVE............ 04-275

INSPECTION................................................................................. 05-8

INSPECTION(BATTERY)..........................................................20A-24

INSPECTION(FUEL FILLER CAP)................................12A-20, 13A-1

INSPECTION(FUEL FILLING TUBE AND BREATHER TUBE

ASSY) ....................................................................................... 12A-21

INSTRUMENT CLUSTER..........................................................04-461

INSTRUMENT CLUSTER ILLUMINATION IS NOT

INOPERATIVE...........................................................................04-300

INSTRUMENT CLUSTER INFORMATION ...............................04-463

TIVE ...........................................................................................04-319

INTAKE AIR PIPE AND HOSE ................................................... 14A-2

INTAKE AIR SYSTEM ................................................................ 14A-1

INTAKE MANIFOLD ................................................................. 14A-10

INTRODUCTION TO SYSTEM FUNCTION(GASOLINE ENGINE

CONTROL SYSTEM) ................................................................. 11A-6

LICENSE LAMP IS INOPERATIVE ...........................................04-328

LIGHTING SYSTEM ..................................................................04-181

LIQUID CRYSTAL DISPLAY .....................................................04-465

(ONE SIDE) ..............................................................................04-204

LO - BEAM HEADLAMP IS INOPERATIVE (ONE SIDE)..........04-191

(BOTH SIDES)...........................................................................04-193

LOCATION.......................................................... 04-4, 04-183, 04-462

LOCATION(SUPPLEMENTAL RESTRAINT SYSTEM) ............04-126

LUBRICATION SYSTEM ............................................................ 18A-1

MAIN COMPONENTS(GASOLINE ENGINE CONTROL

SYSTEM) .................................................................................. 11A-13

TION(MAINTENANCE SCHEDULE) .............................................05-3

MAINTENANCE SCHEDULE ........................................................05-1

GAUGE......................................................................................04-479

ER OR ALWAYS ON .................................................................04-476

MALFUNCTION IN SPEEDOMETER........................................04-472

MALFUNCTION IN TACHOMETER ..........................................04-474

MIRROR ADJUSTMENT LEFT/RIGHT IS INOPERATIVE........04-450

MIRROR ADJUSTMENT UP/DOWN IS INOPERATIVE ...........04-448

MIRRORS ARE INOPERATIVE (BOTH SIDES) .......................04-442

NO COOLING FROM FRONT A/C SYSTEM ............................04-167

OIL FILTER................................................................................. 18A-6

OIL PUMP................................................................................. 18A-11

ON VEHICLE INSPECTION(IDLE AIR CONTROL MOTOR)... 11A-29

ON VEHICLE INSPECTION(THROTTLE POSITION SENSOR

(TPS)) ...................................................................................... 11A-33

ON VEHICLE INSPECT(COOLING SYSTEM)........................... 17A-4

ONE DOOR IS INOPERATIVE (USING THE KEY)...................04-502

ON-VEHICLE INSPECTION(CANISTER SOLENOID

VALVE) ..................................................................................... 11A-53

ON-VEHICLE INSPECTION(DOWNSTREAM OXYGEN

SENSOR).................................................................................. 11A-50

ON-VEHICLE INSPECTION(MANIFOLD ABSOLUTE PRESSURE/IN-

TAKE TEMPERATURE SENSOR) ........................................... 11A-37

ON-VEHICLE INSPECTION(VEHICLE SPEED SENSOR)...... 11A-58

ON-VEHICLE INSPECTION(UPSTREAM OXYGEN

SENSOR).................................................................................. 11A-47

OVERHAUL(CANISTER SOLENOID VALVE)...............11A-54, 13A-4

OVERHAUL(CKP SENSOR) .................................................... 11A-44

OVERHAUL(COOLANT PUMP) ............................................... 17A-23

OVERHAUL(CRANKSHAFT, CYLINDER BLOCK &

FLYWHEEL).............................................................................. 15A-71

OVERHAUL(DOWNSTREAM OXYGEN SENSOR) ................. 11A-51

OVERHAUL(ENGINE COOLANT TEMPERATURE

SENSOR).................................................................................. 11A-19

OVERHAUL(FUEL INJECTOR RAIL ASSY) ............................ 12A-12

OVERHAUL(GENERATOR) ....................................................... 20A-5

OVERHAUL(IDLE AIR CONTROL MOTOR) ............................ 11A-30

OVERHAUL(IGNITION CONTROL MODULE) ......................... 11A-61

OVERHAUL(MANIFOLD ABSOLUTE PRESSURE/INTAKE TEM-

PERATURE SENSOR) ............................................................. 11A-38

OVERHAUL(OIL PUMP)........................................................... 18A-11

OVERHAUL(POSITIVE CRANKCASE VENTILATION VALVE

(PCV VALVE))............................................................................ 13A-7

OVERHAUL(STARTER) ........................................................... 20A-13

OVERHAUL(THERMOSTAT) ................................................... 17A-18

OVERHAUL(THROTTLE BODY).............................................. 11A-24

OVERHAUL(THROTTLE POSITION SENSOR (TPS)) ............ 11A-34

OVERHAUL(TIMING BELT) ..................................................... 15A-19

OVERHAUL(VEHICLE SPEED SENSOR) ............................... 11A-59

OVERHAUL(UPSTREAM OXYGEN SENSOR) ....................... 11A-48

OUTSIDE MIRROR....................................................................04-439

OUTSIDE MIRROR DEFROST ER IS INOPERATIVE..............04-455

INOPERATIVE ...........................................................................04-315

PARKING BRAKE INDICATOR LIGHT NEVER /

ALWAYS ON..............................................................................04-489

PISTON & CONNECTING ROD ASSEMBLY........................... 15A-59

(PISTON & CONNECTING ROD ASSEMBLY) ........................ 15A-60

POOR SOUND QUALITY ..........................................................04-369

POSITIVE CRANKCASE VENTILATION VALVE

(PCV VALVE)............................................................................. 13A-7

POWER DOOR LOCKS.............................................................04-492

POWER SUPPY VOLTAGE HIGH OR LOW.............................04-104

POWER WINDOWS ..................................................................04-414

PRE - CHECK ............................................................................04-102

PRECAUTION...........04-96, 04-126, 04-149, 04-181, 04-334, 04-361,

04-391, 04-414, 04-461, 04-492

PRECAUTION(COOLING SYSTEM).......................................... 17A-1

PRECAUTION(ENGINE MECHANICAL PART) ......................... 15A-1

PRECAUTION(FUEL SYSTEM) ................................................. 12A-1

PRECAUTION(GASOLINE ENGINE CONTROL SYSTEM)....... 11A-1

PRECAUTION(INTAKE AIR SYSTEM) ...................................... 14A-1

PRECAUTION(LUBRICATION SYSTEM) .................................. 18A-1

PRECAUTION(MAINTENANCE SCHEDULE) ..............................05-1

PRECAUTION(STARTING AND CHARGING SYSTEM) ........... 20A-1

PRINCIPLE(CANISTER SOLENOID VALVE) .......................... 11A-52

PRINCIPLE(CKP SENSOR) ..................................................... 11A-43

PRINCIPLE(DOWNSTREAM OXYGEN SENSOR).................. 11A-49

PRINCIPLE(ENGINE CONTROL MODULE (ECM))................. 11A-15

PRINCIPLE(ENGINE COOLANT TEMPERATURE

SENSOR).................................................................................. 11A-18

PRINCIPLE(IDLE AIR CONTROL MOTOR)............................. 11A-28

PRINCIPLE(IGNITION CONTROL MODULE).......................... 11A-60

PRINCIPLE(MANIFOLD ABSOLUTE PRESSURE/INTAKE TEMPER-

ATURE SENSOR)..................................................................... 11A-36

PRINCIPLE(THROTTLE POSITION SENSOR (TPS)) ............. 11A-32

PRINCIPLE(VEHICLE SPEED SENSOR) ................................ 11A-57

PRINCIPLE(UPSTREAM OXYGEN SENSOR) ........................ 11A-46

PROBLEM SYMPTOMS TABLE....... 04-101, 04-130, 04-151, 04-185,

04-336, 04-363, 04-374, 04-382, 04-394, 04-419, 04-441, 04-454,

04-470, 04-496

PROBLEM SYMPTOMS TABLE ................................................. 04-58

PROBLEM SYMPTOMS TABLE(FUEL SYSTEM)......................12A-3

PROBLEM SYMPTOMS TABLE(STARTING AND CHARGING

SYSTEM).....................................................................................20A-2

PUMP MOTOR FAILURE.......................................................... 04-109

RADIATOR ................................................................................17A-13

RADIO DOES NOT WORK ....................................................... 04-364

RADIO ILLUMINATION IS NOT INOPERATIVE....................... 04-309

RADIO RECEPTION IS POOR ................................................. 04-368

(DTC).......................................................................................... 04-18

ERATIVE ................................................................................... 04-311

REAR FOG LAMPS ARE ALWAYS ON.................................... 04-226

REAR FOG LAMPS ARE INOPERATIVE ................................. 04-221

HEATING................................................................................... 04-174

(REPLACEMENT) ....................................................................... 05-38

REPLACE AIR FILTER ELEMENT(REPLACEMENT) ................ 05-37

REPLACE BRAKE FLUID(REPLACEMENT).............................. 05-54

REPLACE COOLANT(REPLACEMENT) .................................... 05-52

REPLACE ENGINE OIL (ISF2.8)(REPLACEMENT)................... 05-44

REPLACE ENGINE OIL (4G69)(REPLACEMENT)..................... 05-40

(REPLACEMENT) ....................................................................... 05-50

(REPLACEMENT) ....................................................................... 05-51

REPLACE GEARBOX LUBRICATING OIL(REPLACEMENT).... 05-56

REPLACE OIL FILTER (4G69)(REPLACEMENT) ...................... 05-42

(REPLACEMENT) ....................................................................... 05-57

REPLACE SPARK PLUG (4G69)(REPLACEMENT) .................. 05-48

REPLACEMENT.......................................................................... 05-37

REPLACEMENT(ACCELERATE PEDAL) ................................12A-25

REPLACEMENT(AIR FILTER ASSY) .........................................14A-6

REPLACEMENT(BATTERY).....................................................20A-27

REPLACEMENT(COOLANT)......................................................17A-6

REPLACEMENT(ENGINE ASSY)...............................................15A-2

REPLACEMENT(ENGINE OIL)...................................................18A-4

REPLACEMENT(ENGINE OIL)(REPLACEMENT) ..................... 05-46

REPLACEMENT(EXHAUST MANIFOLD)...................................16A-7

REPLACEMENT(EXHAUST PIPE) .............................................16A-2

REPLACEMENT(FUEL FILLER DOOR LOCK

LATCH ASSY) ...........................................................................12A-18

REPLACEMENT(FUEL FILLING DOOR)..................................12A-17

REPLACEMENT(FUEL TANK ASSY).........................................12A-4

REPLACEMENT(INTAKE AIR PIPE AND HOSE) ......................14A-2

REPLACEMENT(INTAKE MANIFOLD).....................................14A-10

REPLACEMENT(OIL FILTER) ....................................................18A-6

REPLACEMENT(RADIATOR)...................................................17A-13

REPLACEMENT(REPLACEMENT) ............................................ 05-57

REPLACEMENT(RESERVIOR) ..................................................17A-8

REPLACEMENT(TIMING PULLEY CASING) ...........................15A-14

REPLACMENT(FUEL FILTER ASSY) ........................................12A-9

REPLACMENT(FUEL LEVEL SENSOR ASSY) .......................12A-10

RESERVIOR ...............................................................................17A-8

CONNECTOR PIN .................................................................... 04-127

REVERSE RADAR SYSTEM .................................................... 04-391

REVERSE RADAR SYSTEM IS INOPERATIVE AT ALL ......... 04-395

DISTANCE (BACK-UP LAMP IS NORMAL) ............................. 04-402

REVERSE RADAR SYSTEM IS OPERATIVE BUT THERE IS NO OB-

STACLE BEHIND VEHICLE...................................................... 04-405

VER IS OUT OF REVERSE POSITION.................................... 04-400

HAUL(ROCK ARM, ROCK ARM SHAFT, HYDRAULIC TAPPET &

CAMSHAFT)..............................................................................15A-39

ROCK ARM, ROCK ARM SHAFT, HYDRAULIC TAPPET & CAM-

SHAFT.......................................................................................15A-37

SEAT BELT WARNING LIGHT NEVER / ALWAYS ON ........... 04-485

SOLENOID VALVES AND VALVES RELAY FAILURE ............ 04-105

SPEAKER DOES NOT WORK.................................................. 04-370

SRS WARNING LIGHT IS ALWAYS ON .................................. 04-145

SRS WARNING LIGHT IS INOPERATIVE................................ 04-147

STARTER..................................................................................20A-12

STARTING AND CHARGING SYSTEM......................................20A-1

STEP LAMP ARE INOPERATIVE............................................. 04-286

STOP LAMP IS INOPERATIVE (ONE SIDE)............................ 04-265

SUPPLEMENTAL RESTRAINT SYSTEM................................. 04-126

SYSTEM COMPONENTS DESCRIPTION(GASOLINE ENGINE

CONTROL SYSTEM) ................................................................11A-14

SYSTEM DESCRIPTION ............................................. 04-392, 04-452

SYSTEM OVERVIEW(GASOLINE ENGINE CONTROL

SYSTEM).....................................................................................11A-2

USE AND MAINTENANCE(BATTERY).................................... 20A-22

Z

INOPERATIVE...........................................................................04-378

8101 - POWER SUPPLY VOLTAGE HIGH ...............................04-131

8102 - POWER SUPPLY VOLTAGE LOW................................04-131

8201 - DRIVER AIRBAG FAULT - HIGH RESISTANCE ...........04-133

8202 - DRIVER AIRBAG FAULT - LOW RESISTANCE............04-133

8203 - DRIVER AIRBAG CIRCUIT SHORT TO GROUND .......04-135

8204 - DRIVER AIRBAG CIRCUIT SHORT TO BATTERY.......04-137

RESISTANCE ............................................................................04-139

GROUND ...................................................................................04-141

BATTERY ..................................................................................04-143

TAIL LAMPS ARE INOPERATIVE ............................................ 04-325

TERMINALS OF ECM ................................................................. 04-11

TERMINALS OF INSTRUMENT CLUSTER.............................. 04-466

TERMINALS OF OUTSIDE MIRROR SWITCH ........................ 04-439

THE FIXED SPEED ADJUSTING SCREW (SAS) ADJUST-

MENT(THROTTLE BODY)........................................................11A-22

(USING THE KEY) ................................................................... 04-497

THERMOSTAT..........................................................................17A-18

THROTTLE BODY ....................................................................11A-21

THROTTLE BODY CLEANING(THROTTLE BODY) ................11A-21

THROTTLE POSITION SENSOR (TPS)...................................11A-32

TIMING BELT ............................................................................15A-18

TIMING PULLEY CASING ........................................................15A-14

TRUNK LAMP IS INOPERATIVE.............................................. 04-288

LAMPS ARE NORMAL) ............................................................ 04-240

TURN SIGNAL LAMPS ARE INOPERATIVE (ONE SIDE) ....... 04-254

VALVE OVERHAUL(CYLINDER HEAD,VALVE) ......................15A-54

WASHER PUMP IS INOPERATIVE - REAR WINDOW............ 04-358

WASHER PUMP IS INOPERATIVE - WINDSHIELD ................ 04-348

VEHICLE SPEED SENSOR......................................................11A-57

WHEEL SPEED SENSOR CIRCUIT FAULT ............................ 04-113

WHEEL SPEED SENSOR SIGNAL FAULT.............................. 04-115

NOT RETRACT ......................................................................... 04-351

WIDTH LAMPS IS NOT INOPERATIVE ................................... 04-323

WIDTH LAMPS TAIL LAMPS AND LICENSE LAMP ARE

INOPERATIVE .......................................................................... 04-330

WINDOW CONTROL SWITCH LH PIN .................................... 04-416

WIPER AND WASHER ............................................................. 04-334

WINDSHIELD ........................................................................... 04-345

WINDSHIELD ............................................................................ 04-344

SHIELD...................................................................................... 04-346

UPSTREAM OXYGEN SENSOR ..............................................11A-46

V O L U M E 3

11B ENGINE CONTROL SYSTEM 1571

12B FUEL SYSTEM 1619

13B EMISSION CONTROL 1671

14B INTAKE AIR 1683

15B ENGINE MECHANICAL 1705

16B EXHAUST SYSTEM 2021

17B COOLING SYSTEM 2037

18B LUBRICATION SYSTEM 2067

19A IGNITION SYSTEM 2093

20B STARTING AND CHARGING 2105

21 SUPERCHARGER 2141

电控燃油喷射系统 - 燃油管路 10-1

CONTROL SYSTEM OF ENGINE ..................................................... 11B-1

Precautions ................................................................................... 11B-1

BJ4JB1 Engine System Composition And Principle ................ 11B-2

Table Of Fault Phenomena .......................................................... 11B-4

ENGINE CONTROL SYSTEM MAINTENACNE ............................. 11B-13

General Troubleshooting Procedure ........................................ 11B-13

SERVICING Procedures Of Basic Inspection .......................... 11B-14

General Steps For Fault Diagnosis .......................................... 11B-15

REPAIR FOR SENSOR AND ACTUATOR ..................................... 11B-17

Coolant Temperature Sensor .................................................... 11B-17

Camshaft Position Sensor ......................................................... 11B-20

Mass Air Flow Sensor ................................................................ 11B-23

EGR Vacuum Adjuster ............................................................... 11B-25

Preheat Controller ...................................................................... 11B-28

Rail Pressure Sensor ................................................................. 11B-32

Interior Pressure Control Valve ................................................ 11B-35

Vehicle Speed Sensor ................................................................ 11B-37

Crankshaft Position Sensor ...................................................... 11B-40

Accelerator Pedal Position Sensor .......................................... 11B-42

Electronic Control Module (ECU) ............................................. 11B-45

11B

10- 2 电控燃油喷射系统 - 燃油管路

CONTROL SYSTEM OF ENGINE-CONTROL SYSTEM OF ENGINE

11B-1

CONTROL SYSTEM OF ENGINE

PRECAUTIONS

1. In dismantling the connector of ground wire of electric control system, firstly turn off ignition switch and

disassembly the ground wire of negative pole of battery. If only electric control system will be inspected,

then, it is necessary to turn off ignition switch.

2. Make sure that the power supply system for vehicles have negative ground. In installing battery, pay

special attention to negative pole and positive pole, which cannot be connected reversely.

3. In installing or taking down ECU, operators shall make themselves grounded (contact with vehicle

body). Otherwise, the physical static electricity will damage circuits of computer.

4. When people enter or leave carriage, the static electricity of human body may generate high voltage.

So, make sure to wear iron metal straps while carrying out service for computer operation and digital

instrument or near such instrument with one end is winded to wrist and the other to vehicle body.

5. For the dismantling of any oil line, firstly decompress fuel system.

6. In servicing electric control system, avoid damaging electric control system due to overloading. For this,

pay attention to the following points:

• Do not use test lamp to check the sensors of electric control system and control unit of computer

(including inspection on their terminal blocks).

• In addition to special instructions in testing procedures of some vehicles, generally do not use

analog multimeter to check the resistance of electric control system, but to use high impedance

digital multimeter (above 10MΩ) or special detection instrument for electric control system.

• On the vehicles installed with electric control system, avoid using grounding for fire test or

dismantling wire for fire scrapping to inspect circuits.

7. Do not use water to wash control unit of computer and other electronic device. If there is leakage for

windscreen wiper, repair it timely and pay attention to protecting the control system of computer to

avoid abnormal operation of circuit board, electrical elements and parts, integrated circuit and sensors

due to damp.

8. In general situation, do not open the computer cover, as most faults of electric control engine are faults

of external equipment with a few computer faults. Even if the computer has faults, the opening of

computer cover cannot solve any problems in the situation of without taking detection means

(equipment to detect the oscilloscope and signal generator of computer). On the contrary, the opening

of computer may lead to new faults due to improper operation. In affirming the computer faults,

professional personnel shall be invited for its detection and repair.

9. Do not unplug any line plug (connector) of any sensors while the engine is in operation. Otherwise,

artificial fault code (a kind of pseudo code) will appear in computer, influencing the correct judgment of

repair personnel for fault removal.

11B-2

BJ4JB1 ENGINE SYSTEM COMPOSITION AND PRINCIPLE

1. Electronic Control System Composition

Electronic control system comprises of fuel pump, fuel rail, injector, ECU, accelerator pedal position

sensor, revolution speed sensor and some other sensors and actuators.

1 High-Pressure Pump

2 Interior Pressure Control Valve

3 Fuel Filter

4 Fuel Tank

5 ECU

6 Battery

7 High-pressure Fuel Rail

8 Fuel Rail Pressure Sensor

9 Injector

10 Engine Coolant Temperature Sensor

11 Crankshaft Speed Sensor

12 Accelerator Pedal Position Sensor

13 Camshaft Speed Sensor

14 Mass Air Flow Sensor

15 Turbocharger

16 EGR Valve

17 Vacuum Pump

18 Vacuum Solenoid Valve

11B-3

2. Electronic Control System Operational Principles

ECU can figure out the amount of fuel injection, injection moment, injection frequency and injection

pressure (the rail pressure when injecting) within ECU according to the driver’s demands that are the

position of accelerator pedal position sensor (the signal of accelerator pressure input to ECU) and the

current operational situation of the engine and the vehicle (engine speed, coolant temperature, current

load and etc.). Meanwhile ECU will issue the directives to control the rail pressure within a limit and

make the injector injects according to the calculation result.

11B-4

TABLE OF FAULT PHENOMENA

The following table is helpful for troubleshooting. The serial number stands for the possible order of fault

causes. According to this order, check each part and replace them if necessary.

Phenomenon Possible Part Measures/References

1. Cold start port (does not open)

Chapter 4 Diagnosis - Electric Control

System of Engine (BJ4JB1)

2. Vehicle cold start relay

(unconnected)

Chapter 14B Engine Mechanical

3. Preheat plug (invalid)

System-Engine Disassembly, Disassembly

EGR Controller

4. Main relay (burnt down)

5. Main relay fuse (burnt down)

6. ECU connector (inappropriately

connected)

Diesel engine cannot

start up or start up

difficultly

7. ECU (damaged)

Chapter 11B Engine Control System -

Sensor, Actuator Maintenance, Electronic

Control Module (ECU)

8. ECU(water entering) Blow ECU Dry

9. ECU connector (water entering) Blow Connector Dry

10. ECU (unmatched type)

11. Fuel water separator (blocked)

12. Sensor harness connector (become

loose)

13. Fuel filter (blocked)

14. Fuel line (the curvature is too small

or bent)

Chapter 12B Fuel System - Fuel Filter (Fine

Filter) And Replacement

Filter) and Replacement

Chapter 12B Fuel System - Fuel Lines and

Replacement

11B-5

15. Low pressure fuel lines (interior

diameter becomes small)

16. Low pressure fuel lines (air flows in)

17. Inlet and outlet fuel lines (reversely

18. Fuel tank (run out of fuel or short of

fuel)

Chapter 12B Fuel System - Fuel Tank,

Service

19. Harness (badly connected)

20. Camshaft and crankshaft sensor

(incredible signal)

21. Camshaft sensor clearance (quite

poor)

22. Camshaft sensor (absorb foreign

body or damaged)

Chapter 11B Engine Control Systems -

Sensor, Actuator Maintenance, Camshaft

Position Sensor

23.Crankshaft sensor clearance (quite

24. Camshaft sensor (absorb foreign

25. Accelerator pedal position sensor

System Of Engine (BJ4JB1)

26. Air intake heater (ECU port does not

open)

27. Preheat device (burnt down)

28. Injector (Needle valve blocked and

does not work)

Chapter 14B Engine Mechanical System -

Engine Disassembly

11B-6

29. Injector solenoid valve (burnt down)

30. Ignition lock (damaged)

31. Battery (under voltage)

Chapter 91 Vehicle Control System -

Ignition Switch, Replacement

Chapter 20B Start Up and Charge –

Battery Assembly And Replacement

32. Fuel (wrong type) Fuel Replacement

1. Fuel (wrong type)

2. Fuel water separator (blocked)

Chapter 12B Fuel System - Fuel Filter

(Fine Filter) and Replacement

3. Main diesel filter (blocked)

(Rough Filter)

4. Low pressure fuel lines (curvature is

too small or bent)

Engine lack of power

5. Low pressure lines (interior diameter

becomes small)

6. Low pressure fuel lines (air flows in)

7. Low pressure fuel lines (inlet and

outlet reversely connected)

8. Low pressure fuel lines (connector

become loose and air flows in)

(Fine Filter) And Replacement

9. Camshaft sensor (absorb foreign

body)

Chapter 12B Engine Control System -

10. Camshaft sensor (wrong gap)

11B-7

11. Coolant temperature sensor

(damaged)

12. Coolant temperature sensor

(connector become loose or cut off)

13. Thermostat (blocked or temperature

is too high)

14. Accelerator pedal position sensor

(wrong signal)

15. Injector solenoid valve (damaged)

16. Injector (cut off or connector

becomes loose)

17. Injector (Harness short circuits)

Chapter 11B Engine Control

Systems-Sensor, Actuator Maintenance,

Camshaft Position Sensor

1. ECU (damaged)

2. ECU (interior or connector water

entering)

3. ECU (connector become loose)

Blow Dry

Engine turns off

automatically

4. ECU (overheating protection)

5. ECU (ground wire cut off)

6. ECU main relay (burnt down)

7. Main relay fuse (burnt down)

11B-8

8. High pressure pump timing gear

9. Accelerator pedal position sensor

(not the regulated type)

10. Rail pressure sensor (damaged)

11. Rail pressure sensor (connector

12. Low pressure fuel lines (aging hose

and sucked flat)

13.Low pressure fuel lines (too much

air)

14. Harness (cut off or short circuits)

System-Engine Disassemble, Injector

Pump Assembly and Disassembly

Sensor, Actuator Maintenance, Accelerator

Throttle Pedal Position Sensor

Sensor, Actuator Maintenance, Rail

Pressure Sensor

15. Fuel ( low quality) Fuel Replacement

1. Fuel (low quality) Fuel Replacement

Too thick smoke of

When the accelerator

throttle pedal reached

its highest position, the

maximum speed is not

obtained

2. Valve (wrong clearance)

3. Injector (needle valve stuck or

wears out)

4. ECU (program runs disorderly)

1. Accelerator pedal (lines connected

wrong)

2. Accelerator pedal (connecting lines

become loose)

System-Engine Disassembly

11B-9

When the

accelerator throttle

pedal reached its

highest position,

the maximum

speed is not

3. Accelerator pedal position sensor

4. Accelerator throttle pedal

(non-calibrated)

Chapter 11B Engine Control System - Sensor,

Actuator Maintenance, Accelerator Throttle Pedal

1. Accelerator throttle pedal (lines

connected wrong)

Chapter 4 Diagnosis - Electric Control System of

Engine (BJ4JB1)

2. Accelerator throttle pedal

(connecting lines become loose)

3. Accelerator throttle pedal position

sensor (damaged)

4. Rail pressure sensor (damaged)

Actuator Maintenance, Rail Pressure Sensor

5. Low pressure fuel lines (blocked)

Lame home (speed

and power

decrease)

6. Fuel metering unit (damaged)

7. Metering valve (stuck, blocked)

Actuator Maintenance, Metering Valve

8. Low pressure fuel lines (blocked)

9. Fuel water separator (blocked or

too much water)

Chapter 12B Fuel System - Fuel Filter (Fine Filter)

and Replacement

10. Diesel filter (blocked)

Chapter 12B Fuel System - Fuel Filter (Rough

Filter)

11. Low pressure fuel lines (bent or

curvature is too small)

Chapter 12B Fuel System - Fuel Lines And

12. Low pressure fuel lines (interior

diameter is too small)

11B-10

13. Low pressure fuel lines (air flows in)

14. Return pipe (blocked)

Lame home (speed and

power decrease)

15. Inlet and outlet fuel pipes (reversely

16. ECU (poor cooling)

17. ECU (loose connection, heavy

vibration)

1. Harness (short circuit or cut off)

2. ECU (supply state does

nonconforming to calibrated data)

Fault light is always on

3. AC (line is not connected with ECU)

4. Preheat relay (not connected with

5. Fuel water separator (lines are not

correctly connected)

6. Water sensor (nonconforming to

requirements of ECU)

Sensor, Actuator Maintenance, Water

Level Sensor

Idle speed too high

1. Accelerator pedal (connectors water

2. AC request switch (Is always on)

Chapter 61 Heater and AC-AC and

Maintenance

1. ECU (the calibrated data does

Wrong fuel water

separator signal (water

nonconforming to vehicle practical

status)

information)

2. Harness (cut off or wrong

11B-11

1. Fuel (wrong type) Fuel Replacement

2. Fuel (contain air or water)

(Fine Filter), Discharge Water

Abnormal sound of

deflagration

3. Injector return fuel pipe fitting (fuel

pore is too small)

4. Injector return fuel pipe one-way

valve (stuck)

Chapter 12B Fuel System - Injector

Overhaul

5. Return fuel jack (fuel does not return

smoothly)

1. Accelerator throttle pedal harness

(cut off)

Chapter 04 Diagnose-Engine Electric

Control System ( BJ4JB1)

During

accelerator pedal

driving,

2. Crankshaft and camshaft sensor

(too dirty or wear out)

3. ECU (poor cooling)

Sensor and Actuator Maintenance

Sensor, Actuator Maintenance,

Electronic Control Module (ECU)

4. ECU (heavy vibration during driving)

1. Fuel water separator (inlet and

outlet fuel pipes reversely

Hand fuel pump does

not work

3. Fuel water separator fuel pipes (too

long)

4. Fuel tank pipes (blocked)

5. Fuel tank pipes (bent or curvature is

too small)

11B-12

Rail pressure is too low

1. Low pressure fuel lines (blocked)

2. Fuel water separator (blocked or

contains too much water)

3. Diesel filter (blocked)

4. Low pressure fuel pipes (bent or

5. Low pressure fuel pipes (interior

6. Low pressure fuel pipes (air flows in)

7. Fuel return pipe (blocked or does

not return smoothly)

8. Inlet and outlet fuel pipes (reversely

CONTROL SYSTEM OF ENGINE-ENGINE CONTROL SYSTEM MAINTENACNE

11B-13

ENGINE CONTROL SYSTEM MAINTENACNE

GENERAL TROUBLESHOOTING PROCEDURE

11B-14

SERVICING PROCEDURES OF BASIC INSPECTION

According to diagram fswx110041, carry out fault diagnosis for electric control engine. In order to determine

the nature and position of fault and avoid many necessary operations, after visual inspection on engine, carry

out basic inspection according to procedures shown in diagram fswx110042. In the basic inspection, the water

temperature of engine must reach normal operating temperature (about above 80℃). Meanwhile, close all

attached electrical device of vehicle, such as AC). What is more, carry out inspection adjustment before

cooling fan is started for operation to avoid energy consumption of fan, which will influence the accuracy of

inspection.

11B-15

GENERAL STEPS FOR FAULT DIAGNOSIS

△ Tip:

• The common faults of electric control engine are as follows: difficult starting, stop at once after starting,

unstable idle speed, too high idle speed, powerless travelling, poor acceleration, tempering explosion,

shaking and surging, smoking and large fuel consumption.

General steps for fault diagnosis of electric control engine are as follows:

1. Firstly, affirm whether there are faults of engine

General methods to judge the operation of engine are as follows:

• The engine cannot be started or in normal operation after starting, or there is explosion of exhaust

pipe and tempering of intake pipe in the operation of engine, or there is obvious abnormal

phenomenon like the obvious knocking sound. Then, it can be affirmed that there are faults for

engine.

• See whether the warning indicator of engine (check engine) installed with electric control system is

on. If the indicator is on, this shows that there are faults for the electric control system of engine.

• If large changes occur to the performance of engine in a short term, it can be affirmed that there

are certain faults for engine, such as the power of engine is reduced greatly and its fuel

consumption is obviously increased.

• If the changes occurring to performance of engine are not obvious, the following methods can

used for test: let engine operate in various simulated working conditions and carefully listen to that

whether there is abnormal sound for exhaust pipe and intake pipe in the operation of engine, feel

the vibrating situation of engine and whether there is obvious shaking and metal knocking sound

and observe the changing situation of engine speed.

NOTE:

Slowly depress accelerator pedal and increase the engine speed from low to high gradually. Pay

attention to judging whether above said phenomenon is existent. If they are existent, this shows that

there may be faults for engine. It is necessary to carry out test repeatedly to provide basis for correct

judgment of fault. Depress accelerator pedal suddenly and observe whether there are above said

phenomenon and the increasing rate of engine speed is ideal. If there is abnormal situation or the

increasing rate of engine speed is too slow, this shows that there are faults for engine. If under the

above two situations, any abnormal phenomenon of engine is not found, then, loose accelerator pedal

and observe the idle speed operation situation of engine. See whether the rotating speed in idle speed

is too high or unstable and whether the shaking of engine is serious or not.

Through above operations, if any abnormal phenomenon is not found, this shows the normal operation of

engine. If carry out careful inspection on the dynamic property, economical efficiency and exhausting situation

of engine, it is necessary to use detection line or special detection instrument to carry out fault inspection and

2. Secondly, determine the nature of faults

If there are faults for electric control engine, firstly observe the situation of self diagnosis warning

indicator (CHECKENGINE) in electric control system of engine. If the indicator is on in the operation

process of engine, this shows that there are faults monitored by the self diagnosis system of electric

control engine. Faults are usually related with electric control system. At this moment, through certain

11B-16

methods, acquire the fault code in internal storage of computer and then find out the fault causes

according to fault code. If there are faults for engine indeed, warning indicator “check engine” of engine

on instrument panel is not on in the operation of engine, this shows that self diagnosis system of

electric control unit cannot identify such faults for engine. At this moment, according to fault

phenomenon, make initial diagnosis result like the way to diagnose traditional engine and analyze the

possible fault causes. According to the principles of starting from the outside to inside, from the simple

to the complex, carry out deep diagnosis. Under such situation, make sure not to disassembly the

electric control system casually. Only after affirming the faults of electric control system, firstly check

electric control system. Otherwise, check the other parts firstly.

3. Carry out visual inspection

Firstly check whether plugs of wire are loose in poor contact, open circuit and short circuit. Then,

observe whether there is gas leakage and oil leakage for each intake pipe, vacuum pipe and oil way

and carry out further inspection again.

4. Locate the failed part

In order to reduce the working quantity to remove faults, the method of reducing 1/2 can be used if

there is abnormal response of engine. Narrow the suspected parts in the scope of 1/2. For this, firstly

affirm whether there are faults for oil way or circuit. Most faults of engine are caused by oil way or

circuit. So, if there are faults for engine and you can affirm the faults of oil way or circuit definitely, 1/2

working quantity can be reduced and concentrate your energy in the scope of 1/2. For this, carry out

the following steps.

(a). For the fault judgment of oil way or circuit, as it is easy to carry out fault diagnosis for circuit visually,

start to check whether there are faults for circuit. Unplug the central high tension line of ignition system

and carry out spark over test for cylinder body to affirm whether the parts of high pressure ad low

pressure are normal. If spark without high voltage or spark is too weak, faults of ignition system can be

affirmed. If above said inspection is normal, unplug the high tension line of distributor of spark plug and

check whether there is distributed fire. If there is no such fire, then there are faults for wire from the

central high tension line to live wire of distributor. If above said inspection is normal and there is

distributed fire in each cylinder, then circuits are normal. So, faults are mostly caused by oil way.

(b). In order to judge whether faults are caused by poor operation of individualized cylinder or all cylinders,

poor operation of engine, start from the analysis and inspection on the causes for the poor operation of

individualized cylinder if individualized cylinder does not operate or in poor operation. If all cylinders of

engine are in operation, but their operations are not very obvious, then start from the causes for the

poor operation of all cylinders of engine. So, 1/2 working quality for diagnosis can be reduced. For this,

carry out the following steps: start engine and let it operate in idle speed. After reaching normal

temperature, carry out discontinuous fire cutoff test between distributed fire line and observe the

response situation of engine. If intermittent fire cutoff and re-firing test are carried out discontinuously

for single cylinder, but the operation of engine does not have any response, then, the cylinder is poor

operation. Next, analyze and inspect the causes of poor operation of single cylinder in concentration. If

intermittent fire cutoff and re-firing test are carried out for each cylinder, but there is no obvious change

for the operating situation of engine, then, the operating situation of each cylinder is the similar. So,

start from the causes for abnormal operation of each cylinder of engine.

CONTROL SYSTEM OF ENGINE-REPAIR FOR SENSOR AND ACTUATOR

11B-17

REPAIR FOR SENSOR AND ACTUATOR

COOLANT TEMPERATURE SENSOR

1. Profile

2. Location

It is installed under the engine’s thermostat block.

3. Instructions to parts

It is used in the electronic fuel injection device to detect the engine coolant temperature, send the

voltage signal to electronic control module which is taken as the load signal of the engine so as to

evaluate the operational situation of the engine.

4. Composition and principle

The operational principle of coolant temperature sensor is sealed in a thermister with a negative

temperature coefficient. By the temperature sensitive characteristics of the thermister, the change of

environment temperature will be converted into the change of the thermal resistance and then

converted to be voltage signal which will be sent to the electronic control unit.

5. Technical parameters

(a). Limit data

Item Value Unit

Rated voltage

Only 5+0.15 of the rated voltage

can be operated by ECU

V

20 ℃ rated resistance 2.5±6% KΩ

100 ℃ rated resistance 0.186±2% KΩ

Operation temperature range -40~130 ℃

Allowable vibration acceleration 300 m/s2

11B-18

6. Replacement

(a). Park the vehicle on stable and flat ground.

After stopping the vehicle, turn off engine and shift into neutral gear and pull up the parking brake lever.

Lift the handle of bracing and locking wire of engine

compartment cover up.

Lift the engine compartment cover up.

Discharge appropriate amount of coolant by a water drain

switch until the engine is cooled down.

Disconnect the connector of coolant temperature sensor.

Remove the coolant temperature sensor and take it

down.

11B-19

(g). Install and tighten the coolant temperature sensor.

△Tip:

The temperature sensor can be screwed into the tapped hole of

thermostat block using the hexagon head on the socket with

threads.

(h).

(i).

Connect the connector of coolant temperature sensor.

Add coolant.

(j). Lift the engine compartment cover up to make the

support bar move away from the support hole of

compartment cover and clip the support bar into the slot.

(k). Lower the room cover slowly and loose your hands

when the room cover is about 20cm away from lock-up

position and let it fall freely.

When closing engine compartment cover, people cannot

stand in the rotating scope to avoid the personal injury.

11B-20

CAMSHAFT POSITION SENSOR

Position sensor PG is installed at the end of camshaft,

cooperating with speed sensor and distinguishing

compression TDC and exhaust TDC on No.1 cylinder.

Position sensor is to detect the engine timing valve which is realized by the detection of camshaft

sensor angle.

Position sensor PG comprises of one Hall sensor and one signal rotor (semi-circular iron magnet). The

rotation of camshaft will drive the rotation of the signal rotor installed at the end. By using Hall principles,

when the signal rotor blade goes into the gap of permanent magnet circuit of Hall sensor, Hall sensor

switch is in the position of “OFF” and the corresponding circuit output is high level. When the signal

rotor blade goes into the gap of permanent magnet circuit of Hall sensor, Hall sensor switch is in the

position of “ON” and the corresponding circuit output is low level. The corresponding rotation of the

crankshaft has signal while the other one does not have it which then can distinguish the different TDC.

Ambient Temperature

Limit Life Expectancy

-40~150℃

Ambient temperature in operation is 150℃

Ambient temperature without operation is 160℃

1000h

250h

Speed range 0~4500rpm (camshaft speed)

11B-21

After stopping the vehicle, turn off engine and shift into neutral gear and pull up the parking brake

lever.

(b). Open the engine compartment cover and hold it. (Refer to Chapter 11B Engine Control System –

Repair for Sensor and Actuator, Coolant Temperature Sensor).

Disconnect the connector of camshaft position sensor.

Remove the fixing bolts of camshaft position sensor.

Take down the camshaft position sensor.

Place the camshaft position sensor to mounting position.

11B-22

(g).

Tighten the fixing bolts of camshaft position sensor.

Torque: 8±0.5 N·m

Connect the connector of camshaft position sensor.

Close the engine compartment cover. (Refer to Chapter

11B Engine Control System – Repair for Sensor and

Actuator, Coolant Temperature Sensor).

11B-23

MASS AIR FLOW SENSOR

It is installed behind the engine air filter while before the

engine turbocharger inlet.

3. Composition and principle

Inlet mass sensor is a heat flux sensor which comprises of inlet air temperature sensor and air mass flow

sensor. It is used to detect the engine inlet temperature and inlet mass flow. By reporting the detection of inlet

air mass to the electronic unit and its participation in control, the control of EGR system in the closed loop can

be realized.

4. Technical parameters

Parameters

Value

Minimum Standard Maximum

Unit

Temperature tolerance -40 120 ℃

Transient temperature tolerance limit 120 130 ℃

Operational voltage 7.5 14 17.0 V

Pressure drop 15 hPa

5. Replacement

11B-24

Disconnect the connector of mass air flow sensor.

Remove 2 A-type worm drive hose clamps.

Take down the mass air flow sensor.

(f). Place the mass air flow sensor to mounting position, and

install 2 A-type worm drive hose clamps.

The airflow direction is required to be consistent with the

arrow direction on the sensor case when installing the

sensor. Otherwise, the power is limited and the system

operation degrades.

Connect the connector of mass air flow sensor.

11B-25

EGR VACUUM ADJUSTER

It is installed in the engine compartment.

It can control the pulse width, switching on time of EGR valve, control EGR rate, reduce NOx pollutants

and optimize the emission.

Operational voltage 10 12 16 V

Mass air flow 30 L/h

Switch on response time 1 s

Switch off response time 0.2 s

Operational temperature range -30 130 ℃

Output resistance 14 Ω

11B-26

Disconnect the vacuum line of EGR vacuum adjuster.

Disconnect the connector of EGR vacuum adjuster.

Remove the fixing bolts of EGR vacuum adjuster.

(f). Take down the EGR vacuum adjuster.

Prevent contact with alkali-metal impurity and avoid

invalidation due to entering the inner cavity of vacuum

adjuster.

11B-27

Place the EGR vacuum adjuster to mounting position.

Tighten the fixing bolts of EGR vacuum adjuster.

Torque: 6 N·m

Connect the connector of EGR vacuum adjuster.

(j).

(k).

11B-28

PREHEAT CONTROLLER

(a) Preheat control unit (GCU) is controlled by electronic control unit (EDC) and it has the following

functions:

• By the input of the signal from ST and K port, GCU is applicable to 4, 5, or 6-cylinder engine.

• Electronic control unit (EDC) control the switch signal of 4, 5 or 6 preheat plug of GSK.

• Overcurrent cut off protection (electronic protection)

• Preheat plug invalidity diagnose

• Small volume and can be installed in the engine compartment.

• High potential protection from electronic control unit (EDC).

11B-29

Limit data

Preheat time 4 200 s

Temperature tolerance of 200s maximum preheat time,

the accumulated life expectancy is shorter than 1000h.

Temperature tolerance of non-preheat, the

accumulated life expectancy is shorter than 5000h.

Temperature tolerance of non-preheat with heat load,

the accumulated life expectancy is shorter than 5000h.

-40 85 ℃

-40 125 ℃

Power supply voltage of normal operation 8 12 16 V

Allowable minimum voltage at the starting up stage 6 8 V

Input current at 66 port ≤1000 mA

Control current at ST/K port 1 50 mA

Signal current at DI port 1 10 mA

Operational current at 30 port 60 180 A

Operational current at G port 10 30 A

Energy consumption 10 18 W

Output resistance at DI port 10±5 % KΩ

Preheat pressure drop of each cylinder ≤250 mV

11B-30

Disconnect the connector of preheat controller.

Remove the fixing bolts of preheat controller.

Take down the preheat controller.

Place the preheat controller to mounting position.

Install the fixing bolts of preheat controller.

Torque: 5±1 N·m

Broken torque: >7 N·m

11B-31

Connect the connector of preheat controller.

11B-32

RAIL PRESSURE SENSOR

It is installed at the ends of fuel rail.

It is to detect the rail pressure and offer the input signal to electronic control unit.

Symbol

Operational temperature T -40 130 ℃

Pressure range P 0

150

180

200

MPa

Operational power supply voltage Us 4.75 5.0 5.25 V

Current when Us=5V Is 12 15 A

Load resistance when 0.1US

11B-33

Park the vehicle on stable and flat ground.

Disconnect the connector of rail pressure sensor.

Remove the rail pressure sensor.

Take down the rail pressure sensor.

Place the rail pressure sensor to mounting position.

11B-34

Install the rail pressure sensor and tighten.

Connect the connector of rail pressure sensor.

11B-35

INTERIOR PRESSURE CONTROL VALVE

It is installed on the fuel pump.

3. Components

Pressure control valve is connected to high-pressure pump by a mounting flange. In order to ensure

that the gap between the high-pressure and the low-pressure section is well sealed, the pivot makes a

ball valve resist against the seal gasket. Two forces act on the pivot: one is the spring force; the other is

the acting force produced by electromagnet. In order to ensure lubrication and cooling, fuel must flow

through the pivot.

Pressure control valve comprises of two closed-loop control:

• One is the electronic control loop used to set the low speed of the changing average common rail

pressure.

• The other is the mechanical hydraulic control loop used to compensate the quick-acting of

high-frequency pressure fluctuations.

11B-36

Disconnect the connector of interior pressure control

(d). Remove the interior pressure control valve.

Remove using the inner offset wrench.

Install the interior pressure control valve.

Connect the connector of interior pressure control valve.

11B-37

It is installed at the rear end of the transmission.

Vehicle speed sensor is installed on output shaft of gearbox with mechanical gears transforming to

electric pulse signal. Then, use wire to send electric pulse signal to odometer with pulse frequency

indicating speed and pulse counter accumulating mileage.

The vehicle speed sensor is to measure the vehicle speed in the travelling of car and it is also signal

output part to accumulate total travelling mileage of vehicle.

4. Components and principles

Closed magnetic circuit revolution speed sensor is composed of external gear, internal gear, coil and

permanent magnet installed on revolving shaft. Internal and external gears have the same number of

teeth. If revolving shaft is connected to the shaft for measurement to revolution together, magnetic

resistance will change due to relative motion of internal and external gears. So, AC induction potential

will be generated in coil. Through the potential value, the corresponding revolving speed can be

worked out.

5. Common faults

• Vehicle speed odometer does not move.

• Vehicle speed odometer does not move at times.

6. Operating characteristics

Rated operating voltage: 12 V

Power voltage scope (Vcc): 8 V~16 V

Injection current at output end (lsink): ≤25 mA

Power supply current (lcc): 10 mA (max)

Output low level (Vol): 0.5 V (max)

Output high level (Vol): Vcc-0.5 V (min)

The number of signal pulses: 8 P (pulses/round)

11B-38

Operating temperature: - 40 ℃~120 ℃

Maximum revolving speed of sensor: 3000 r/min

7. Replacement

· Turn off engine, remove the key and start parking brake to make sure that the vehicle does not move when

dismantling.

· When pulling out the connector of harnesses, press and hold the snap rings of connector and pull them

out slowly to avoid pulling the lead to result in poor contact or open circuit.

Disconnect the connector of vehicle speed sensor.

Remove the fixing bolts of vehicle speed sensor.

Take down the vehicle speed sensor.

Install the vehicle speed sensor.

11B-39

Tighten the fixing bolts of vehicle speed sensor.

Connect the connector of vehicle speed sensor.

11B-40

CRANKSHAFT POSITION SENSOR

It is installed on the clutch housing.

It is used to check the engine speed, so, it is also known as revolving speed sensor. It is also used to

check the position of top dead center of piston, so, it is also known as top dead center sensor, including

checking of top dead center signal of each cylinder for ignition control and top dead center of first

cylinder for sequence control of fuel injection.

Crankshaft position sensor is electromagnetic sensor and 58X tooth top and tooth space pass sensor

with different clearances. Sensor can induct the changes of magnetic resistance. Then, the alternating

magnetic resistance will generate alternating output signal. ECM makes use of the signal to determine

the revolving position and speed of crankshaft.

• There is no contact or in poor contact for crankshaft position sensor.

Operating clearance: 0.25~1.75 mm

Coil resistance: 560 Ω

11B-41

Disconnect the connector of crankshaft position

Remove the crankshaft position sensor and take it down.

(d). Install the crankshaft position sensor and tighten.

Clean the mounting position of sensor and the sensor when

installing. Otherwise, the clearance between sensor and gears

will be influenced to affect the signals sent to electronic control

module.

Torque: 7~9 N·m

Connect the connector of crankshaft position sensor.

11B-42

ACCELERATOR PEDAL POSITION SENSOR

It is installed on the accelerator pedal.

Transfer the driver’s expectation of the vehicle to ECU. ECU will determine the basic demands of

injection and torque according to the signal.

• Operational voltage: 5 V±2%

• Operational temperature: - 40~85 ℃

• Signal current: maximum 20 mA

• Short-circuit protection: 16 V,20 min

• Output error:

11B-43

Disconnect the connector of accelerator pedal position

Remove the fixing screws of accelerator pedal position

Take down the accelerator pedal position sensor.

Install the accelerator pedal position sensor.

Tighten the fixing screws of accelerator pedal position

11B-44

Connect the connector of accelerator pedal position

11B-45

ELECTRONIC CONTROL MODULE (ECU)

It is installed under the driver’s seat.

ECU is to receive the input signal of sensor and carry out calculation according to designed programs

to generate corresponding control signal output and drive each actuator to carry out different actions.

Meanwhile, make the engine operate according to specific control strategy.

ECU (electronic control unit) is also known as “travelling computer” and “auto computer”. From its

functions, it is special micro computer controlled for vehicle. So, it is also called special single-chip for

vehicle. Like the ordinary single-chip, it is composed of microprocessor (CPU), memory (ROM and

RAM), input/output interface (I/O), AD converter (A/D), shaping and driving large scale integrated

circuit. Electronic control unit is to calculate process and make judgments on the input information of air

flow meter and various sensors according to its memorized programs and data and then output orders

to provide electric pulse signal of certain width for fuel injector to control fuel injection quantity.

Electronic control unit is composed of microcomputer, input, output and control circuits.

(a). Faults of power circuit.

(b). Faults of output circuit.

(c). Memory faults.

Nominal operating voltage: DC12 V

Operating voltage scope: 6.5~16 V

Maximum operating current: 5 A

Operating temperature: - 30 ℃~85 ℃

-MEMO-

After stopping the vehicle, turn off engine, place the transmission to empty gear, start parking brake

system and disconnect the negative cable of battery.

(b). Remove the driver’s seat (See Chapter 84 Seats - Main Driver’s Seat and Replacement).

(c). Remove the connector of ECU.

Lift the fixing clips for connector of ECU up, and then pull

out the connector of ECU.

(d). Remove the fixing bolts of ECU assembly.

(e). Take down the ECU assembly.

When taking down the ECU assembly, do not impact the

ECU to avoid damaging the ECU.

Place the ECU assembly to mounting position, install the

fixing bolts and tighten.

Torque: 5 N·m

(g). Connect the connector of ECU.

When connecting the connector of ECU, align the mounting

position to avoid damaging the pins. When the ECU is

inserted completely, pull up the clips to lock the connector

of ECU.

(h). Connect the negative cable of battery.

(i). Install the main driver’s seat (See Chapter 84 Seats –

MainDriver’s Seat and Replacement).

模板 00

FUEL SYSTEM .................................................................................. 12B-1

Overview ........................................................................................ 12B-1

Precautions ................................................................................... 12B-2

System Composition and Its Principles..................................... 12B-3

Diagram of Components .............................................................. 12B-7

FUEL INJECTOR (ELECTRONIC).................................................. 12B-13

Precautions ................................................................................. 12B-13

Parameter of Technical Characteristics ................................... 12B-14

Service ......................................................................................... 12B-15

FUEL INJECTOR (MECHANICAL)................................................. 12B-19

Diagram of Components ............................................................ 12B-19

Testing ......................................................................................... 12B-20

Disassembly and Cleaning ........................................................ 12B-21

Service ......................................................................................... 12B-23

Assembly and Adjustment ........................................................ 12B-25

HIGH PRESSURE FUEL RAIL ....................................................... 12B-26

Overview ...................................................................................... 12B-26

Replacement ............................................................................... 12B-27

FUEL INJECTION PUMP (VE PUMP) ............................................ 12B-31

Adjustment .................................................................................. 12B-31

FUEL PIPELINE (ENGINE PART) .................................................. 12B-33

Precautions ................................................................................. 12B-33

Replacement ............................................................................... 12B-34

FUEL TANK ..................................................................................... 12B-37

Service ......................................................................................... 12B-37

FUEL FILTER (COARSE FILTER) .................................................. 12B-42

Replacement ............................................................................... 12B-42

FUEL FILTER (FINE FILTER) ......................................................... 12B-44

Drainage of Water ....................................................................... 12B-44

Replacement ............................................................................... 12B-46

12B

FUEL-FUEL SYSTEM

12B-1

OVERVIEW

1. Introduction

4JB1 EuroⅢ diesel engine fuel system matched with Sapupika diesel engine series is electronically

controlled high pressure common rail system, and 4D20 diesel engine fuel system matched with it is

electronically controlled VE pump system.

2. Function of fuel system

Function of fuel system is to inject diesel into combustion chamber at rated time, quantity and

pressure to provide necessary conditions for good combustion of diesel and automatically adjust fuel

delivery according to load condition of diesel engine to ensure steady running of diesel engine.

12B-2

1. Safety precautions

(a). Before service of fuel supply system, turn off the ignition switch first and disconnect negative terminal

cable of battery. Open the fuel filler cap for short periods and screw it up.

(b). When removing and installing the fuel tank, the vehicle should be stopped on a horizontal plane, and

fuel in the tank should not occupy 3/4 of the gross capacity. If needed, empty the fuel tank.

(c). Before the service, fix a plug-in emission hose of fuel vapor near installation port of fuel tank to empty

the fuel vapor.

If there is no fuel vapor emission device, you can use a centrifugal blower with over 15m 3 /h gas delivery.

(d). Maintenance of the fuel tank and related accessories must be away from fire, the maintenance site

should be well-ventilated and appropriate fire fighting equipment should be prepared.

(e). The connection of fuel pipe and connectors should be reliable without any loosening, so as to avoid

pipeline leakage.

(f). Use the plastic strip assembly to fix with pipeline for each 250mm intervals in the frame, while use the

tank band to fix the forepart of return pipe, so as to prevent friction with the stringer.

(g). Add spiral protective sleeve at the contact part of pipeline and fuel tank, fuel tank bracket, frame to

protect the pipe.

(h). The pipe should be unified with the direction of harness, brake pipelines after entering the frame, and

should keep the maximum distance with the harnesses and then fix.

(i). Release the oil pump pressure (pressure relief) firstly when repairing the fuel system, in order to

prevent the fuel injection causing the environment and human damages.

(j). When starting the engine after installation of injection system, ensure the oil delivery pump and filter

full of fuel. If needed, keep pressing on the start button to make it in active state.

High pressure connection part of fuel system needs no deflation for the high pressure common rail

will emit air automatically under high pressure. If loosen tight cap of the high pressure fuel pipeline,

fuel will leak out under pressure.

2. Cleaning precautions

(a). Clean thoroughly the connector and its nearby before switching off it.

(b). The removed parts should be put on the clean surface and covered up. Don’t use fuzzy cloth.

(c). Cover or lock up the open parts if you don’t repair them immediately.

(d). Only clean parts can be assembled. Take out spare parts only before assembling. Don’t use scattered

parts (for instance, in the tool box).

12B-3

SYSTEM COMPOSITION AND ITS PRINCIPLES

1. Composition of fuel system

(a). Fuel system composition of 4JB1 Euro Ⅲ high pressure common rail diesel engine

It consists of diesel tank, diesel pipe, diesel filter, high pressure fuel pump, fuel rail, high pressure fuel

pipe and fuel injector, etc. (See the following figure)

1 High pressure fuel pipe

2 Diesel pipe (fuel delivery)

3 high pressure fuel pump

4 Diesel pipe

5 Fuel filter

6 Diesel pipe (fuel delivery)

7 Fuel tank

8 Strainer

9 Fuel injector

10 Diesel pipe (fuel return)

11 Diesel pipe (fuel return)

12 High pressure fuel rail

13 High pressure fuel pipe

12B-4

Fuel system composition of 4D20 electronically controlled VE pump diesel engine:

It consists of diesel tank, diesel pipe, oil-water separator, diesel filter, fuel injector pump assembly,

high pressure fuel pipe, fuel injector, etc.

1 Fuel filter

2 Diesel pipe(fuel delivery)

3 Fuel injector pump

4 Fuel return pipe

5 Fuel injector

6 High pressure fuel pipe

7 High idle speed solenoid valve

Manual pump handle of oil-water

separator

9 Oil-water separator

10 Fuel tank

11 Diesel pipe (fuel delivery)

12 Diesel pipe (Fuel return)

12B-5

2. Working principle of fuel system

Working principle of 4JB1 Euro III high pressure common rail diesel engine.

• High pressure part

With continuous work of electronically controlled high pressure fuel pump, fuel is injected into the high

pressure fuel rail, in which it accumulates pressure, and ECU controls the fuel pressure in the rail with fuel

pump actuator in the pump. Rail pressure sensor in the rail feeds back information of rail pressure to form

a closed-loop control for ECU. For high pressure fuel rail accumulates high pressure fuel at any time, ECU

calculates proper fuel according to the inner rated data when it needs the injection of some vat and make

the injector inject the calculated fuel according to the calculated time by controlling the magnetic solenoid

valve of the fuel injector.

• Low pressure part

Low pressure fuel rail is divided into oil-inlet part and fuel return part. Fuel inlet means fuel is transferred

from fuel tank into coarse filter, fuel filter and high pressure fuel pump. Fuel return means fuel return of fuel

injector, high pressure fuel rail and electronically controlled high pressure pump connects together and

fuel returns to the fuel tank.

12B-6

Fuel system Working principle of 4D20 electronically controlled VE pump diesel engine.

Raise the diesel pressure by the work of fuel injection pump and provide high pressure fuel for combustion

chamber at rated time, quantity and pressure according to the working requirements of diesel engine.

from fuel tank into coarse filter, fuel filter and fuel injection pump. Fuel return means Fuel return of injector

and fuel injection pump connects together and fuel returns to the fuel tank.

12B-7

DIAGRAM OF COMPONENTS

High pressure common rail fuel system (Engine Part)

12B-8

1 Fuel injector

2 O-ring

3 Fuel injector pad

Fuel injector and Fuel return pipe

assembly

5 High pressure clamp

6 Fuel injector Fuel return rubber hose

7 Fuel return T-pipe weldment

8 High pressure clamp

Fuel injection pump Fuel return rubber

hose

10 High pressure fuel pipe 1

11 High pressure fuel pipe 2

12 High pressure fuel pipe 3

13 High pressure fuel pipe 4

14 Bolt

15 High pressure fuel rail

High pressure fuel pipe (from fuel

injection pump to fuel rail)

17 Fuel rail support

18 Bolt

19 Nut

20 Bolt

21

Fuel injection pump pulley pressure

plate

22 Woodruff key

23 Fuel injection pump pulley

24 Fuel injection pump flange

25 Bolt

26 Fuel injection pump

12B-9

Electric VE pump fuel system (Engine Part)

12B-10

1 Fuel injection pump flange seal ring

2 Bolt

3 Fuel injection pump gear

4 Flange plate

5 Fuel injection pump parts

6 Bolt

7 Fuel injection pump support

8 Fuel injection pump rear support

9 Large washer

10 Bolt

11 Bolt

12 Idle lift valve parts

13 Bolt

14 High pressure fuel pipe parts 1

15 High pressure fuel pipe parts 2

16 High pressure fuel pipe parts 3

17 High pressure fuel pipe parts 4

18

High pressure fuel pipe punch holder

High pressure fuel pipe die holder

21 Fuel injector

22 O-ring

23 Fuel injector pad

24 Fuel injector fuel return pipe assembly

25 Fuel return pipe clip

26 Fuel injector Fuel return pipe

27 Low pressure fuel pipe seal head

12B-11

Fuel system I (Body Part)

1 Cross recess head screw

2 Large washer

3 Fuel filler cap assembly

4 Spring hose clamp

5 Rubber hose

6 Rubber hose

7 Air valve

8 Nylon cable tie

9 Fuel filler lower pipe

10 EFI fuel hose II

11 Rubber hose

12 Diesel coarse filter

13 Diesel settler support welding

14 Rubber hose

15 Fuel pipe clamp (blue)

16 A-type worm drive hose clamp

17 Fuel tank front pressure plate assembly

18 All-metal hexagon flange lock nut

19 Rubber hose

20 Rubber hose

21 Fuel return pipe

22 Fuel delivery pipe

12B-12

Fuel system II (Body Part)

1 High pressure clamp

2 Rubber hose

3 Spring washer

4 Rubber hose

5 Hexagon bolt

6 Flat washer

7 Fine filter support

8 Rubber hose

9 Cross recess head screw

10 Large washer

11 Fuel filler cap assembly

12 Spring hose clamp

13 Rubber hose

15 Air valve

16 Nylon cable tie

17 Fuel filler lower pipe

18 A-type worm drive hose clamp

19 Fuel tank front pressure plate assembly

20 Spring washer

21 Type 1 hexagon nut

22 Fuel filler cap assembly

23 Fuel return pipe

24 Fuel delivery pipe

25 Fuel pipe clamp

26 Fine filter

FUEL-FUEL INJECTOR (ELECTRONIC)

12B-13

FUEL INJECTOR (ELECTRONIC)

1. Replace fuel injector assembly if there is any fault of fuel injector solenoid valve. Don’t remove the

valve by yourself.

2. Keeping fuel injector clean is the first requisite for normal operation of solenoid valve.

3. Avoid short circuit of solenoid valve binding post and the engine.

4. Take out protective cap only before assembling and cover the connector up immediately after

removing. Ensure there is some spared clean protective cap and clean the used protective cap with

ultrasonic wave.

5. Grease all the O-ring with engine oil or diesel before assembling.

6. Don’t overly bend or squeeze the cable or connect with sharp ends. Avoid vibration of circuits.

7. Don't use any tool when installing and removing fuel return pipe.

8. Fuel injector clamp bracket: don’t take it out or bend it.

9. Don’t assemble fuel return pipe without clamp bracket or the fuel will leak out.

10. If clamp bracket is removed by mistake, please replace with a new one.

11. Bigger bend, rotation or deformation will narrow the fuel return pipe. All these should be avoided.

12. Hose part of fuel return pipe should not be removed or loosened from the fuel return plug for it cannot

ensure complete assembling. If something happens as above, the whole fuel return pipe must be

13. When loosening high pressure pipe nut, ensure no pressure is on the connector. If the high pressure

connector is already loosened, the whole fuel injector must be replaced.

14. Replace with a new bronze seal ring after each fuel injector is removed. And all the nuts that need

fastening must be replaced.

12B-14

PARAMETER OF TECHNICAL CHARACTERISTICS

Due to various types of diesel engine matched with Sapupika, the following chart of technical characteristics

parameter of the 4JB1 EuroⅢ diesel engine fuel injector is just for reference, and the practical maintenance

of engine should be subject to parameter of technical characteristics supported by the suppliers based on

different types of engines.

Parameter

Minimum Typical Maximum

Remark

Peak current A 17.5 18 18.5

Holding current A 11.5 12 12.5

20~70℃ measuring

resistor

Ω 0.215 0.255 0.295

Current on time Μs 4000 (Starting stage 300-450μs)

Cold start Μs 6000

Maximum 60s,frequency is lower than

5Hz

Pre-injection and

main injection

minimum interval

μs 800

Interval of current on time (from

conclusion of pre-injection current signal

to starting of main-injection current signal)

Working pressure Bar 250 1450 Rail pressure

Fuel return pressure

(relative pressure)

Bar 0.3 0.8 Relative to external pressure

String leak pressure Bar 1700 1800 No current, eigenvalue

nozzle opening

pressure caused by

combustion

Bar 120 Eigenvalue, no system pressure

Fuel temperature ℃ -30

Fuel temperature ℃ 115

In cold start condition, measurement

point: fuel inlet of fuel injector

working area, permitted temperature

amounts to 135℃ in 15min, working time

exceeding 100 hours, measurement point:

fuel inlet of fuel injector

Fuel return

temperature

℃ 125

Permitted temperature amounts to 145℃

in 15min, working time exceeding 100

hours, measurement point: fuel outlet of

fuel injector

External temperature ℃ -30 120

Permitted temperature amounts to 130℃

hours, measurement point: solenoid valve

head of fuel injector

12B-15

SERVICE

After the engine stalls, any installation must be prohibited in 30s. For fuel is inflammable, the

operating area should keep away from fire and should be equipped with ventilators when servicing

the fuel system.

1. Park the vehicle on steady road

Switch off the engine after parking, shut down the ignition switch, change the transmission into

neutral gear and start parking braking system.

2. Lift engine compartment cover assembly

(a). Lift engine compartment cover lock cable handle.

(b). Lift engine compartment cover.

Reach your hand into the front of engine compartment cover,

move the lock operation handle upward when touching it, then

the hood is completely open. Finally, raise the hood with efforts

and find the support bar to plug it into fixed position.

3. Remove fuel injector

(a). Disconnect the connector of fuel injector.

Don’t pull the lead directly when pulling the connector or it

will cause short circuit or open circuit.

12B-16

(b). Switch off the connector of high pressure fuel pipe and

high pressure fuel rail.

Block the fuel pipe up with plug after removing, or the dirt will

influence function of fuel system.

(c). Switch off high pressure fuel pipe connecting between

fuel injector and high pressure fuel rail.

Use two wrenches to remove high pressure fuel pipe. Block the

fuel pipe up with plug after removing, or the dirt will influence

function of fuel system.

(d). Push the fuel return pipe fixing clip to the direction of

the opening and take out the fuel pipe.

Don’t remove or loosen the hose part of fuel injector fuel

return pipe, if something happens as the above, please

replace the whole fuel return pipe.

(e). Remove fuel injector pressure plate fixing bolt.

(f). Take out fuel injector pressure plate.

Pull the fuel injector pressure plate backward before taking it

out to make the removal easier.

(g). Take out the fuel injector in sequence.

4. Check the fuel injector

(a). Fix fuel injector on the calibration stand to control fuel

pressure, voltage and current duration and determine

whether the fuel injector is normal by observing the

pulverization of fuel injector and amount of fuel

injection.

Fuel injector is precise hence non-professionals must not

remove or maintain it.

12B-17

5. Install fuel injector

(a). Assemble fuel injector and fuel injector pressure plate

together.

To prevent bronze washer shedding off when installing fuel

injector, grease the bronze washer with some lithium-based

lubricants.

(b). Install fuel injectors in corresponding holes in

(c). Install firmly fixing nuts of fuel injector pressure plate.

Fastening of fuel injector pressure plate bolts is divided into

two steps: first, rotate it for 7.5~9 N·m; then rotate it for 40~45

degrees.

(d). Connect the connector of each fuel return pipe and fuel

injector.

Directly press the connector of fuel return pipe and fuel injector

onto the installation hole or clip will be stuck after being

pressed down.

(e). Connect high pressure fuel pipe with fuel injector and

fasten the nuts.

Fasten each high pressure fuel pipe in couple.

(f). Connect the connector of each fuel injector.

You can hear a sound of clatter when installing the connector.

Slowly pull it up after installation to ensure it is installed in

place.

12B-18

6. Close the engine compartment cover

(a). Put the engine compartment cover support bar down into

the clip slot.

(b). Lower the compartment cover gently at the height of

20cm from the lock and then drop it to fall free.

Lock the compartment cover firmly for safety. Check whether

the compartment cover is locked after closing it. The engine

compartment cover must be flush with the vehicle’s body

nearby.

FUEL INJECTOR (MECHANICAL)

FUEL-FUEL INJECTOR (MECHANICAL)

12B-19

1 Clip

2 Fuel injector

3 O-ring

4 Fuel injector pad

12B-20

TESTING

1. Remove fuel injector assembly

(a). Removal of fuel injectors (See Chapter 15B Mechanical Part of Engine - fuel pipeline, fuel injector,

removal)

2. Detection of fuel injectors

(a). Fix the fuel injector on the test stand and move the

stand handle at the speed of 4~6 times/s. Check if

there is any particle flying out, dripping backward or

spraying abnormally, etc. Keep fuel injection pressure

below 21.0MPa, if there is no leakage, it works well.

The opening pressure is 27~28MPa, if it is abnormal,

restore or replace parts of fuel injectors.

3. Injection of fuel injectors

(a). See the left figure of injection of fuel injectors.

(b). Adjust and service it if the pulverization is abnormal.

12B-21

DISASSEMBLY AND CLEANING

1. Clean the fuel injector

(a). Brush the fuel injector’s outer surface clean in the fuel

basin.

Be cautious of head of pin valve. Brush it with banister

2. Remove fuel injectors

(a). Fasten the fuel injector on table vice placed with a

copper sheet and make the nozzle upward.

If the pin valve is stuck in the nozzle nut by carbon deposit,

it should be dipped in the diesel oil and taken out without

being tapped or pulled.

3. Clean parts of fuel injectors

(a). Clean nozzle fixing nut, fuel injection body, pushing rod,

lock nut, adjusting screw and pressure adjusting spring

with clean diesel oil or kerosene.

(b). Clean the oil passage of fuel injector body with copper

needle.

Clean the carbon deposit outside the pin valve with

banister brush or thin copper wire.

12B-22

Clean the oil passage of pin valve with copper needle.

(f). Stretch the brass angle scraper into the pressure

chamber and rotate it to scrape off the carbon deposit

in the pressure chamber of pin valve.

(g). Clean up the matching parts of pin valve again with

clean diesel oil.

Matching parts of pin valve cannot be replaced or pieced

12B-23

1. Check fuel injector body

Ensure that the precise plate matched with matching parts of

pin valve is flat and smooth without scratches. All screw

threads are complete without scratches, the bearing pad is flat

and all the inner holes are clean, unblocked. If it is not qualified,

please replace it.

2. Check fixing nuts of fuel injector nozzle

Inside and outside surface are clean without scratches; the

screw threads are complete without scratches; the matching

parts of pin valve are clean without damage. If it is not qualified,

3. Check the pushing rod

The rod is upright; connection part with pin valve has no

scratches. If it is not qualified, please replace it.

4. Check the spring

Both ends are flat with not overly abrasion, of good elasticity,

and with no scratches on the surface. If it is not qualified,

12B-24

5. Check the pin valve

Ways of checking as follows:

Do sliding testing of the cleaned matching parts of pin valve to

see whether it is still available. The checking method is that put

the pin valve spotted with clean diesel oil into the valve body,

tilt the matching parts of pin valve for 45 degrees, extract 1/3

pin valve of the whole length and drop it to let it slide down

slowly and smoothly by its own weight without blockage or

detention. If the matching parts of pin valve are seriously

defective, please replace them. As for those which are not

seriously defective, such as due to the poor surface of pin

valve and its body, the sliding testing fails, we can restore them

by grinding.

12B-25

ASSEMBLY AND ADJUSTMENT

1. Assemble fuel injectors

(a). Fasten fuel injector body on the table vice placed with

copper sheet and install the gasket, spring, pushing

rod, spacer, fuel injection nozzle and fuel injector

nozzle fixing nut in sequence.

Fasten fuel injector nozzle fixing nut to meet the

standards.

2. Adjust the fuel injector

(a). Fix fuel injector on the testing stand and observe the

condition of fuel injection by raising the pressure.

Regulate gaskets properly until the pulverization is in

good condition.

(b). Take out the fuel injector after adjustment, fasten it on

the table vice placed with copper sheet, and fasten

fuel injector nozzle nuts to meet the standards.

12B-26

FUEL-HIGH PRESSURE FUEL RAIL

HIGH PRESSURE FUEL RAIL

1. The fuel rail is integrated with rail pressure sensors. The fuel rail is for storage of high pressure fuel.

Fluctuation of pressure caused by fuel supply and fuel injection of high pressure pump can be

controlled in the common rail. Rail pressure sensor feeds back information of current rail pressure for

ECU, with which the inner pressure control valve in the pump controls the rail pressure.

2. High pressure common rail means several fuel injectors share the same high pressure rail. Rail

pressure is created by high pressure pump.

3. The fuel injection system eliminates mutual influence between creation of pressure and fuel injection

in traditional fuel supply system. In this system, creation of injection pressure does not completely rely

on rotation rate of the engine and fuel delivery and fuel stored in the high pressure fuel rail under

pressure is ready to be injected at any time.

4. Electronically controlled high pressure common rail diesel engine is completely controlled by ECU.

ECU determines the running condition of engine according to the present rotation rate, coolant

temperature, atmospheric pressure and throttle position (that is driver’s needs), etc.

5. For the electronically controlled high pressure common rail system provides the ideal mixture of air

and fuel, it hugely increases the whole noise of vehicle, driving comfort, dynamics and emission, etc

compared with traditional diesel engine.

12B-27

Block the fuel pipe up with plug after removing, or the dirt will enter in.

3. Remove high pressure fuel rail assembly

(a). Disconnect the connector of rail pressure sensors.

(b). Disconnect nuts of high pressure fuel pump and high

pressure fuel pipe.

Use two wrenches to remove.

12B-28

Disconnect nuts of high pressure fuel pipe and high

pressure fuel rail.

(d). Disconnect nuts of fuel injectors and high pressure fuel

Remove fixing nuts of high pressure fuel rail assembly.

Take out high pressure fuel rail support assembly.

(g). Remove fixing bolts of high pressure fuel rail and the

support.

(h). Check if the high pressure fuel rail is damaged, if it is,

Rail pressure sensor is fixed by hexagon surface according to

specific torque and supplied with fuel rail and it cannot be

replaced personally. Try to avoid touching connector of the

sensor in case of damage when installing the fuel rail.

4. Install high pressure fuel rail assembly

(a). Install the high pressure fuel rail on the support and

fasten it with fixing bolts.

12B-29

Install fixing bolts of high pressure fuel rail assembly.

Install nuts connecting high pressure fuel pipe and high

(d). Install nuts connecting fuel injector and high pressure

fuel pipe.

Use two wrenches to install.

(e). Install nuts connecting high pressure fuel pump and

high pressure fuel pipe.

Connect rail pressure sensor connector.

12B-30

5. Close the engine compartment cover

Fg

FUEL INJECTION PUMP (VE PUMP)

ADJUSTMENT

FUEL-FUEL INJECTION PUMP (VE PUMP)

12B-31

1. Adjust fuel supply timing

(a). Check if the notch line of fuel injection pump flange

aligns with that of pump body.

(b). Rotate the crankshaft and align the piston of the first

cylinder with TDC position on compression stroke until

the TDC reticle 1 on crankshaft pulley align with timing

mark 2.

Check intake valve of the first cylinder and idle stroke of

exhaust valve push rod. If there is idle stroke of first

cylinder intake valve and valve push rod, the piston of first

valve is on the TDC position of compression stroke.

Remove cone screw plug of lower plunger hole end

from fuel injection pump.

Install measurement instrument3 of fuel supply

advance angle. Detector of the instrument should be

pressed inward for about 1mm.

Rotate crankshaft and adjust the dial gauge to zero

when the first cylinder piston is on the 30-40 degrees

position of TDC. Slowly rotate crankshaft pulley at both

directions and check the reading of dial gauge.

12B-32

Rotate the crankshaft clockwise and check the reading

on the instrument when the TDC mark of crankshaft

pulley aligns with timing mark of gear cover.

If fuel supply timing is incorrect, do the following steps.

• Loosen fixing nuts of fuel injection pump and

bracket bolts.

• Adjust fuel supply advance angle.

If the advance angle is too big or small, loosen bolts of

high pressure fuel pump connection plate and adjust it.

If the advance angle is too big, turn the high pressure

fuel pump for a proper angle counter-clockwise.

If the advance angle is too small, turn the high pressure

fuel pump for a proper angle clockwise.

Fasten the three bolts. Check the fuel supply advance

angle again.

Install high pressure fuel pipe of the first cylinder.

FUEL-FUEL PIPELINE (ENGINE PART)

12B-33

FUEL PIPELINE (ENGINE PART)

1. Don't use any tool when installing and removing fuel return pipe.

2. Don’t assemble fuel return pipe without clamp bracket or the oil will leak out.

3. Hose part of fuel return pipe should not be removed or loosened from the fuel return plug for it cannot

4. When loosening nuts of high pressure fuel pipe, switch off the power and operate after 30s.

5. Cover the removed fuel pipe with protective cap to prevent the dirt from entering.

12B-34

For fuel is inflammable, the operating area should keep away from fire and should be equipped with

ventilators to decrease harm or death of personnel. Block the fuel pipe and parts pipe up with cap

after removing, or the dirt will influence function of fuel system.

3. Remove high pressure fuel pipe

(a). Disconnect nuts of high pressure fuel pump and high

12B-35

(c). Disconnect nuts of fuel injectors and high pressure fuel

4. Remove Fuel return fuel pipe

(a). Push fuel return fuel pipe clamp to the opening

direction and take it out from fuel injectors.

Hose part of fuel injectors should not be removed or

loosened from the fuel return plug. If something happens

as above, the whole fuel return pipe must be replaced.

Disconnect fuel return fuel pipe and high pressure fuel

pump.

5. Install fuel return fuel pipe

(a). Install connectors of fuel return pipe and each fuel

injector in place.

12B-36

Fasten the spring hose clamp of fuel return fuel pipe

and high pressure fuel pump.

6. Install high pressure fuel pipe

(a). Install fixing nuts connecting high pressure fuel pipe

and fuel rail.

When installing the high pressure fuel pipe, put high pressure

fuel pipe down from the lower end of intake manifold.

(b). Install firmly fixing nuts connecting high pressure fuel

pipe and fuel injectors.

Use two wrenches when installing. Fasten each high pressure

fuel pipe in couple.

Install firmly fixing nuts connecting high pressure fuel

pump and high pressure fuel pipe.

7. Close the engine compartment cover

FUEL-FUEL TANK

12B-37

FUEL TANK

1. Exhaust fuel

(a). Park the vehicle on the lifter and pull the parking braking handle to the braking position.

(b). Switch off negative terminal cable of the battery.

(c). Open the fuel filler cap.

The switch of fuel filler cap is at the lower left of driver’s seat.

Pull up the switch and the fuel filler cap will open automatically.

Screw down the fuel tank cap.

Lay oil drum or equivalent container down drain bolts

under the fuel tank.

Remove the drain bolts under the fuel tank.

2. Check

(a). Before removing the fuel tank, visually check whether there are leakage or leakage trace on the fuel

tank, fuel tank pipeline and connector, make it for future maintenance and replacement if any.

3. Remove the fuel tank

(a). Remove the fixing screws of fuel tank filling pipe

assembly with a screwdriver.

(b). Put the bracket to the bottom of fuel tank.

12B-38

(c). Remove the fixing bolts of fuel tank assembly.

After removing the fixing bolts of fuel tank assembly, drag it

with the bracket, and lower the bracket to a proper position.

Disconnect the connector of the fuel level sensor lead.

(e). Loose the fixing clips of fuel inlet and outlet pipes, pull

out the fuel inlet and outlet pipes.

After disconnect the pipe, the pipe and the fuel inlet and

outlet shall be blocked, and then mark on the fuel inlet and

outlet pipes, so as to prevent wrong installation.

(f). Lower the bracket to the appropriate position, and pull

out the fuel tank.

Disconnect all the pipes connecting with the fuel tank

and check whether the pipes are aged or fractured,

please replace if damaged.

12B-39

(h). Remove the fuel pump.

• Remove the fuel pump gland with special wrench.

• Remove the fuel pump.

Check whether the fuel stand pipe filter has any dirt, blockage

or crack, if there is any dirt or blockage, clean it up with brush

and petrol and if there is any crack, please replace it.

(i). Remove the fuel level sensor.

When removing the fuel level sensor, move up the sensor a

little, and then incline to one side to remove it, must be careful

not to damage the oil level float.

4. Clean the fuel tank

(a). Clean the fuel tank inner part from all angles with high

pressure water jet, ensure no dirt and impurities remain

in the fuel tank

• When cleaning, the waste water should be collected

from the fuel outlet, in order to avoid environmental

contamination.

• The high pressure water jet can be put into the fuel

tank to ensure that all parts could be cleaned.

(b). Use compressed air to dry the fuel tank inner part

5. Install the fuel tank assembly

(a). Install the fuel level sensor.

Do not damage the oil level float during installation.

12B-40

Install the fuel pump.

• Place the fuel pump in installation position.

• The fuel pump gland should be installed and

fastened using special tools.

Connect all the pipes connected with the fuel tank and

use the flexible clip or A-type worm drive hoop to

fasten.

Place the fuel tank on the bracket and drag the fuel

tank to the appropriate position of installation position

under the car body.

(e). Connect intake and outlet fuel pipes.

Install according to the tag, do not install the fuel inlet and

outlet pipes wrongly.

(f). Connect the connector of fuel level sensor lead.

When connecting the connector of fuel level sensor lead,

it should sound "click", and gently pull back to ensure it

installed in place.

12B-41

Install the fixing bolts of fuel tank.

Torque: 45~55 N·m

(h). Install the screws of fuel tank filling pipe assembly and

(i). Refill the fuel.

Check whether the fuel drain plug of the fuel tank installed

in place.

(j). Fasten the fuel tank cap.

Clockwisely rotate the fuel tank cap until it “click”, which

means the fuel tank cap has been fastened.

(k). Close the fuel filler cap.

12B-42

FUEL-FUEL FILTER (COARSE FILTER)

FUEL FILTER (COARSE FILTER)

1. Remove fuel filter assembly

(a). Switch off the fuel inlet hose and fuel outlet hose on the

fuel filters.

Check fuel inlet and outlet hoses, if there is any

efflorescing, erosion or crack, please replace them.

Take out the filter element with special tools of the filter.

Remove the fuel filter base.

2. Install fuel filter assembly

(a). Install the fuel filter base.

• Install firmly the fixing bolts of the fuel filter base.

Torque:45~55 N·m

12B-43

(b). Install the filter element with special tools of the filter.

When installing the fuel filter, inject proper clean fuel into

the filter and grease the filter seal ring with some

Hook the fuel inlet and outlet pipes with elastic clips on

the inlet and outlet positions of the filter and fasten

12B-44

FUEL-FUEL FILTER (FINE FILTER)

FUEL FILTER (FINE FILTER)

DRAINAGE OF WATER

When the engine fault indicator lights up, check whether there is any water in the diesel fine filter, if there is

any, drain completely all the water in the drainer.

3. Water drainage of diesel fine filter

(a). Loosen the water drain valve of diesel fine filter.

Put drainage pipe of water drain valve into a vessel before

loosening the water drain valve to prevent the drained water

from polluting the environment.

Don't switch off the diesel fine filter water drain valve but

loosen it. When the clean fuel comes out from the pipe, all

the water in the fine filter is drained. Fasten the screws of

water drain valve immediately.

12B-45

4. Close the engine compartment cover

12B-46

3. Remove the fuel fine filter

(a). Drain the fuel in the fuel fine filter by drainage of the

fuel fine filter.

(b). Disconnect fuel inlet and outlet pipes of the filter.

Put fuel inlet and outlet pipes into the fuel in the drainage

pipeline in the vessel after switching off them. Seal it up

with the cap after drainage. Check the fuel inlet and outlet

hoses, if there is any efflorescing, erosion or crack, please

(c). Disconnect the connector of fine filter lead.

Don’t pull the lead directly when disconnecting the

connector of fine filter.

(d). Remove fine filter sensors.

12B-47

Remove the fine filter element with special tools of the

filter.

Remove the fine filter base.

4. Install the fuel filter

(b). Install the fine filter element with special tools of the

Grease the filter seal ring with some engine oil to lubricate

when installing the filter. If the fuel filter is screwed too

firmly, it will cause the deformation of threads of screws,

or the damage of the filter element or gasket or can.

(c). Install the fuel fine filter sensors.

(d). Connect the connector of fine filter lead.

The connector of fuel fine filter lead must be installed in

12B-48

Hook the fuel inlet and outlet hoses of fine filter with the

spring hose clamp and fasten them up.

5. Drainage

(a). Remove the air exhaust bolts of the fuel filter.

Air exhaust of fuel pipeline must be operated after

maintaining the pipelines of fuel system or replacing the

(b). Operate the manual fuel pump of the filter several times

for the exhaust of fuel system.

Don’t overexert when operating the manual fuel pump in

case of damage.

Drainage is completed until the fuel appears in the

exhaust hole of the filter without bubbles.

12B-49

驻车制动 - 驻车制动系统

27-1

EGR SYSTEM ·····································································13B-1

Overview ········································································13B-1

Working principle ····························································13B-2

Diagram of Components···················································13B-3

EGR PIPE ··········································································13B-4

Service ···········································································13B-4

EGR VALVE········································································13B-7

Service ···········································································13B-7

13B

EMISSION CONTROL--EGR SYSTEM

13B-1

EGR SYSTEM

1. EGR system is also called Exhaust Gas Recirculation system which mainly comprises of ECU, vacuum

adjuster, EGR valve, valve position sensor, coolant temperature sensor, speed sensor, throttle position

sensor, pressure maintaining valve, exhaust gas recirculation pipeline and vacuum connecting pipeline

and etc. Its main functions are: make part of the exhaust gas in the exhaust pipe re-circulate into the

intake manifold and mix with the fresh air to flow into the combustor so as to reduce the combustion

temperature,reduce the generation of oxynitride and finally reduce the pollution of atmosphere.

2. The function of EGR valve is to control the opening of vacuum valve by vacuum degree so as to control

the mass of exhaust gas flow. The opening of the valve is sent back to ECU by valve position sensor. If

EGR valve is seriously stuck, the engine will produce black smoke.

3. When the car has driven for each 4000-5000km, check whether each nut on the exhaust connecting

pipe is loose, there is any flaw or hole for the exhaust gas connecting pipe, and any damage or erosion

for the gasket.

13B-2

WORKING PRINCIPLE

EGR will prohibit the generation of NOx, CO and some other pollutants in the emission by guiding a small

amount of engine exhaust gas to the intake manifold, diluting the fresh air to decrease the peak of combustion

pressure and temperature. When the engine is working, throttle position sensor, speed sensor, coolant

temperature sensor and etc. will input the signal of engine instant state to ECU and ECU will judge the instant

operational situation according to these signals, and based on the data which has been stored in it, ECU can

adjust different vacuum degree by vacuum adjuster. EGR valve will control the valve opening according to

different vacuum degree. The valve opening is then sent back to ECU by the valve position sensor. During the

whole operational process, each operational situation of the engine will have a perfect EGR rate (the ratio of

mass of exhaust gas recirculation - mE and mass of fresh air - mA, that is, mE/mA).

1 Joint of diagnostic tool

2 Vacuum adjuster

3 Pressure maintaining valve

4 Vacuum pump

5 Vacuum connecting pipe

6 EGR valve

7 ECU

8 Coolant temperature sensor

9 Speed sensor

10 Throttle position sensor

11 Exhaust gas connecting pipe

13B-3

1 Rubber plug

2 Pressure maintaining valve

3 Hose

4 Hose

5 Three-way

6 Idling lift valve connecting hose

7 770 hose

8 EGR pipe connecting bolt

9 EGR valve

10 EGR pipe gasket

11 EGR pipe

12 Type 1 hexagon nut

13 Spring washer

14 Small washer

15 Vacuum adjuster

16 Stud

17 ECU

13B-4

EMISSION CONTROL-EGR PIPE

EGR PIPE

1. Disassemble EGR pipe

(a). Disassemble the nut connecting EGR pipe and intake

Disassemble bolt connecting EGR pipe and EGR valve.

Take down EGR pipe.

2. Clean and check EGR pipe

(a) Clean the sealing surface of EGR pipe and intake pipe

by relieving tool.

13B-5

Clean the sealing surface of EGR pipe and EGR valve

(c). Clean EGR pipe by vapor.

When using the vapor cleaner, you shall put on safety

glasses or protective mask and clothing as hot vapor may

cause severe personal injury.

Check whether the sealing surface of EGR pipe is

perfect. There shall be no severe flaw on the sealing

surface.

Check whether the gasket of EGR is perfect. If there is

any wear or damage, it shall be replaced.

3. Install EGR pipe

(a) Put the EGR pipe in the installation position.

13B-6

Fasten the nut connecting the EGR pipe and intake pipe.

Fasten the bolt connecting the EGR pipe and EGR

EGR VALVE

EMISSION CONTROL-EGR VALVE

13B-7

1. Disassemble EGR pipe (see chapter 13B Emission control-EGR pipe, service)

2. Disassemble EGR valve

(a) Disassemble fixing bolt of EGR valve

Take down EGR valve.

3. Clean and check EGR valve

(a) Clean the sealing surface of EGR valve by relieving tool.

Two sealing surfaces of EGR valve shall be cleaned.

Clean the dirt and debris in the EGR valve by blowing

high-pressure gas.

13B-8 EMISSION CONTROL-EGR VALVE

Check whether the sealing surface of EGR valve is

perfect. The sealing surface shall have no severe flaw.

Check whether the gasket of EGR valve is perfect. If

there is any wear or damage, it shall be replaced.

(e). Provide EGR valve with 15Kpa vacuum degree by

manual vacuum pump and EGR valve shall be able to be

switched on.

When no vacuum degree is provided to EGR valve, EGR

valve shall be able to be switched off.

4. Install EGR valve

(a). Put EGR valve in the installation position.

Install and fasten the fixing bolt of EGR valve.

13B-9

5. Install EGR pipe (see chapter 13B Emission control-EGR pipe, service)

-MENO-

INTAKE SYSTEM

INTAKE SYSTEM .............................................................................. 14B-1

Overview ........................................................................................ 14B-1

Precautions ................................................................................... 14B-2

Working Principle ......................................................................... 14B-3

INTAKE MANIFOLD .......................................................................... 14B-4

Diagram of Components .............................................................. 14B-4

Service ........................................................................................... 14B-5

INTAKE PIPELINE ........................................................................... 14B-12

Diagram of Components ............................................................ 14B-12

Replacement ............................................................................... 14B-13

AIR FILTER ...................................................................................... 14B-17

Service ......................................................................................... 14B-17

14B

INTAKE-INTAKE SYSTEM

14B-1

1. The intake system mainly includes air filter, intake manifold and relevant hose, which supplies pure air

for each cylinder.

2. The function of intake system is to evenly supply combustible mixture or pure air for each cylinder as

much as possible.

3. The intake manifold distributes the pure air to the inlet of each cylinder.

4. The function of air filter is to filter out the impurities and dust in the air, in order to avoid accelerating

the cylinder wear, and reduce the service life of engine, while the air filter could reduce the intake

noise.

14B-2

1. Safety cautions

(a). The operation should not be conducted at the road side or crowded places, the car should be parked

on the flat ground if possible.

(b). Ensure the parking brake lever is placed on the parking location.

(c). Fix the wheel with a wedge or bunk block, wedge or bunk block should be placed in the position close

to both sides of the tire, it’s preferred to fix on both sides of the rear wheels.

(d). When maintaining and replacing the filter element, the car should be parked in a place without wind,

dirt and dust.

2. Important tips

(a). The tightness of intake pipeline and air filter connection should be check frequently, any leakage

should be dealt with timely, fasten the connector to avoid the abnormal wear.

(b). After 4,000 ~ 5,000km drive, the exhaust pipe of the car should be checked as follows:

• If any nut is loosen. Fasten the nuts of exhaust pipe with uniform force, or it may cause air

• If there is any crack or perforation for exhaust pipe, and any damage or erosion for gasket.

• The exhaust pipe gasket is suggested to use once only; in order to ensure the air tightness,

timely replace the damaged gasket.

(c). Unless replacing the filter element, do not Disassemble (or clean) the inner filter element (safe filter

element) in the dual snorkel air filter.

(d). When replacing the outer filter element, if the inner filter element is damaged originally, the inner filter

element must be replaced.

14B-3

The outside air enters compressor room of turbocharger after being filtered by air filter, and enters intake

manifold through intake connecting pipe after being compressed by turbocharger, then is distributed to inlet of

each cylinder by intake manifold. The burned gas is discharged from exhaust manifold. The formed exhaust

gas flow will impact turbine of turbocharger so that it can rotate at a high speed. The exhaust gas through

turbine is finally discharged to the exterior by exhaust tail pipe. Part of exhaust gas in the exhaust manifold is

discharged from EGR valve. Then this exhaust gas enters intake connecting pipe through EGR pipe, and is

sent back to engine combustor for combustion again to suppress the generation of oxynitride.

1 Exhaust tail pipe

2 EGR pipe

3 EGR valve

4 Intake connecting pipe

5 Intake manifold

6 Exhaust manifold

7 turbocharger

8 Intake pipe

9 Air filter

14B-4

INTAKE-INTAKE MANIFOLD

1 Double wire clamp 66

2 Intake hose 2

Hexagon head bolt and spring washer

4 Flange bolt

5 Intake connecting pipe bracket

6 Type 1 hexagon nut

7 Spring washer

8 Flat washer

9 stud

10 Intake connecting pipe

11 Intake elbow gasket

12 Intake manifold

Hexagon head bolt, spring washer

and flat washer assembly

14 Harness clamp

15 Intake manifold gasket

14B-5

1. Disassemble the intake manifold assembly

(a). Disassemble the connecting bolts between EGR pipe

and intake connecting pipe.

Disassemble the connecting bolts between EGR pipe

and EGR valve.

Remove the EGR pipe.

Disassemble the breather outlet hose clamp.

• Remove the breather outlet hose.

14B-6

Disassemble the fixing bolts of turbocharger intake

connecting pipe assembly bracket.

Remove the turbocharger intake connecting pipe

assembly.

Disassemble the fixing bolts of exhaust pipe bracket.

Disassemble the fixing bolts of intake connecting pipe.

Remove the intake connecting pipe.

Disassemble the fixing bolts of oil level gauge bracket

and remove the oil level gauge assembly.

Disassemble the fixing bolts of oil cooling water pipe

14B-7

(l).

Disassemble the fixing nuts of high-pressure oil pipe

and remove the high-pressure oil pipe.

(m).

Disassemble the fixing nuts of intake manifold.

(n).

Remove the intake manifold.

• Remove the intake manifold gasket.

2. Clean and check all the parts

(a). Clean the sealing surface that combines cylinder head

and intake manifold with a relieving tool and a clean

cloth.

Prevent the sealing materials and other impurities from

entering the intake port.

When cleaning the sealing surface with a relieving tool, it is

preferred to plug the intake port with a clean cloth, and prevent

the dirt and debris from entering the intake manifold.

14B-8

Clean the sealing surface that combines intake

connecting pipe and intake manifold with a relieving

Clean the sealing surface of intake pipe connector and

the interior of intake manifold connector with a clean

Check the intake connecting pipe. If there is any crack

or any severe defect for sealing surface, repair or

replace it with a new.

Clean the sealing surface of intake manifold with a

relieving tool and a clean cloth.

Blow away the dirt and debris in the intake manifold

with high-pressure gas.

14B-9

Measure the junction surface flatness of intake

manifold and cylinder head with high-precision ruler

and feeler (or on the plat calibration console). If the

flatness exceeds technical range, the intake manifold

shall be machined or replaced.

3. Install the intake manifold

(a). Install the intake manifold gasket.

(b). Place the intake manifold to installation position.

Replace a new intake manifold gasket when installing the

intake manifold connector.

Install and fasten the fixing bolts of intake manifold.

Install and fasten the nuts of high-pressure oil pipe.

Install the oil cooling water pipe and fasten the fixing

bolts of oil cooling water pipe.

14B-10

Install the oil level gauge and fasten the fixing bolts of

oil level gauge assembly.

Install the intake connecting pipe and fasten the fixing

bolts of intake connecting pipe.

Install and fasten the fixing bolts of exhaust pipe

(i). Install the turbocharger intake connecting pipe

assembly and fasten the fixing bolts of turbocharger

intake connecting pipe assembly.

Install the breather outlet hose.

Install the breather outlet hose clamp.

14B-11

Install the EGR pipe.

Install the connecting bolts between EGR pipe and

EGR valve.

intake connecting pipe.

14B-12

INTAKE-INTAKE PIPELINE

INTAKE PIPELINE

3 Hexagon head bolt

4 Air filter assembly

Intake pipe with resonance box

6 Air filter bracket 2

7 Air filter bracket 1

8 A-type worm drive hose clamp

9 Intake connecting pipe assembly

10 Air flow meter

11 A-type worm drive hose clamp

12 Intake bellows

14B-13

1. Park the car on flat and stable road

Flame out the engine after parking the car, the transmission should be located in neutral, and enable

the parking brake system

2. Lift the engine compartment cover assembly

(a). Pull up the lock line handle of engine compartment

Lift the engine compartment cover.

3. Disassemble the intake pipe

(a). Loose the A-type worm drive hose clamp connecting

between the intake rubber hose of turbocharger and

turbocharger.

Loose the A-type worm drive hose clamp connecting

the intake bellows.

14B-14

(c). Remove the bolts of intake rubber hose clamp for

(d). Remove the intake rubber hose of turbocharger.

It is necessary to block the turbocharger outlet port with plug

after removing the intake rubber hose of turbocharger to

prevent the dirt from entering the engine.

between the intake bellows and air flow meter.

Remove the intake bellows.

Disconnect the connector of air flow meter.

between air flow meter and intake connecting pipe

Remove the air flow meter.

between intake connecting pipe assembly and air filter

14B-15

4. Check the intake pipeline

(a). Check whether the intake bellows aged, fractured or

cracked, replace the intake bellows if any.

5. Install the intake pipeline

(a). Install the intake connecting pipe assembly.

• Fasten the A-type worm drive hose clamp

connecting between the intake connecting pipe

assembly and the air filter assembly.

Clean the pipeline before installation.

Install the air flow meter.

connecting between air flow meter and intake

connecting pipe assembly.

(c). Install the intake bellows.

connecting between intake bellows and air flow

meter.

(d). Install the intake rubber hose of turbocharger.

• Install the A-type worm drive hose clamp

connecting between intake rubber hose of

turbocharger and intake bellows.

14B-16

turbocharger and turbocharger.

Install the intake rubber hose clamp of turbocharger

and fasten the bolts.

Connect the connector of air flow meter.

6. Cover the engine compartment cover

Lower the support bar of engine compartment cover, and cover the engine compartment cover.

AIR FILTER

INTAKE-AIR FILTER

14B-17

The filter element of air filter should be cleaned for every 10,000Km drive, and the filter element of air filter

should be replaced for every 20,000Km drive.

1. Disassemble the intake pipe with resonance box

between intake pipe with resonance box assembly and

air filter device.

Disassemble the fixing bolts of intake pipe with

resonance box assembly.

Remove the intake pipe with resonance box assembly.

2. Check the dust exhausting bag

(a). Press the dust exhausting bag of the air filter with hand,

check whether there is any dust blew out.

If any dust blew out, checking and maintenance are needed.

3. Disassemble the air filter assembly

(a). Lift the fixing lock catch of air filter upper cover.

14B-18

Remove the filter element.

Remove the fixing bolts of filter bracket.

(d). Disassemble the fixing bolts of the filter device.

(e). Remove the filter device lower part

The operation procedure for c and d is performed when the

filter device is replaced as a unit.

Clean the dust in the housing and dust on the cover

and surface of gasket for air filter.

(g). Clean the filter element.

The filter element should be cleaned periodically, do not use

compressed air to clean the filter element from the outside, this

may cause dust entering the filter element, rotate the filter

element with hands and use compressed air (below 7kg/cm2)

to blow the dust on the surface inside the filter element at the

same time.

4. Install the air filter assembly

(a). Install the fixing bolts of filter device.

14B-19

Install and fasten the fixing bolts of filter bracket.

Install the filter element.

Lock the fixing lock catch on air filter upper cover.

5. Install the intake pipe with resonance box

(a). Place the intake pipe with resonance box assembly to

installation position.

(b). Install the fixing bolts of intake pipe with resonance box

Install and fasten the A-type worm drive hose clamp

connecting between intake pipe with resonance box

assembly and air filter device.

ENGINE ASSEMBLY ......................................................................... 15B-1

Overview ........................................................................................ 15B-1

Precautions ................................................................................... 15B-2

Diesel Engine Fault Diagnosis .................................................... 15B-3

ENGINE MAINTENANCE ................................................................ 15B-63

Precautions ................................................................................. 15B-63

Operations ................................................................................... 15B-66

Maintenance ................................................................................ 15B-70

Basic Maintenance ..................................................................... 15B-74

DISASSEMBLY/INSTALLATION OF COMPLETE ENGINE .......... 15B-77

Precautions ................................................................................. 15B-77

Disassembly Procedure ............................................................. 15B-79

Installation Procedure ................................................................ 15B-84

Instruction of Essentials ............................................................ 15B-90

PRESERVATION OF COMPLETE ENGINE ................................... 15B-91

Precautions ................................................................................. 15B-91

Maintenance ................................................................................ 15B-91

DISASSEMBLY OF ENGINE (4JB1) .............................................. 15B-92

Instruction of Disassembly ....................................................... 15B-92

Disassembly of Pipeline and Harness ..................................... 15B-93

Disassembly of High and low Pressure Fuel Pipes and Fuel

Injector ......................................................................................... 15B-95

Disassembly of dipstick and Breather ..................................... 15B-97

Disassembly of Turbocharger, Intake Manifold and Exhaust

Manifolds ..................................................................................... 15B-99

Disassembly of Cylinder Head Cover and Rockshaft .......... 15B-101

Disassembly of Tappet and Cylinder Head ........................... 15B-103

Disassembly of Thermostat Assembly and Valve ................ 15B-104

Disassembly of Hook and A/C Bracket .................................. 15B-106

Disassembly of starter motor and High Pressure Fuel Rail 15B-107

Disassembly of oil Filter and Generator ................................ 15B-108

Disassembly of fan and Crankshaft Pulley ............................ 15B-110

Disassembly of Observation Chamber Cover and Water Pump

Pulley Chamber Cover Assembly ............................................ 15B-111

Disassembly of Pressure Plate and Timing Belt.................... 15B-112

Disassembly of Injection Pump Assembly ............................. 15B-114

Disassembly of Idle Pulley and Camshaft Gear ..................... 15B-115

Disassembly of Clutch Components and Flywheel Assembly ...... 15B-118

Disassembly of oil pan and Gear Chamber ........................... 15B-120

Disassembly of Camshaft and Engine support .................... 15B-122

Disassembly of oil Pump, oil Injection Pipe and Tappet ...... 15B-123

Disassembly of Piston and Crankshaft.................................. 15B-125

15B

Assembly of Engine (4JB1)........................................................ 15B-128

Instruction of Assembly ················································15B-128

Installation of Crankshaft and Piston······························15B-129

Installation of Tappet, oil Injection Pipe and oil Pump ······15B-137

Installation of Engine support and Camshaft ···················15B-139

Installation of Gear Chamber and oil Pan ························15B-141

Flywheel Assembly and Clutch Components ··················15B-143

Camshaft Gear and Idle Pulley ······································15B-145

Installation of Injection Pump Assembly ·························15B-148

Installation of Timing Belt and Pressure Plate ·················15B-149

Installation of Water Pump Pulley Chamber Cover Assembly

and Observation Chamber Cover .......................................... 15B-151

Installation of the Crankshaft Pulley and the Fan ·············15B-152

Installation of High Pressure Fuel Rail and starter motor ··15B-153

Installation of Hook and A/C Bracket ······························15B-154

Installation of Valve and Thermostat Assembly ···············15B-155

Installation of Cylinder Head and Tappet ························15B-158

Installation of Rockshaft and Cylinder Head Cover ··········15B-160

Installation of Intake and exhaust MANIFOLDS and

Turbocharger ······························································15B-162

Installation of Breather and dipstick ·······························15B-164

Installation of Fuel Injector and High & low Pressure Fuel

Pipe ···········································································15B-166

Generator and oil Filter ·················································15B-168

Installation of Pipeline and Harness ·······························15B-170

Disassembly of Engine (4D20)................................................... 15B-172

Installation of Disassembly ···········································15B-172

Disassembly of Heater Water Inlet/Outlet Pipe Weldment ·15B-173

Disassembly of Cylinder Head Cover ·····························15B-174

Disassembly of EGR Controller ·····································15B-175

Disassembly of Intake and exhaust MANIFOLDS and

Turbocharger ............................................................................ 15B-177

Disassembly of Generator and Breather ·························15B-180

Disassembly of fan, fan Pulley and Crankshaft Pulley ······15B-183

Disassembly of dipstick ················································15B-185

Disassembly of High & low Pressure Fuel Pipe and Fuel

Injector ·······································································15B-186

Disassembly of Rockshaft and Tappet ····························15B-188

Disassembly of Cylinder Head ·······································15B-189

Disassembly of the Water Outlet Pipe Connector, Valve and

Hook ··········································································15B-190

Disassembly of oil Filter and oil Radiator ·······················15B-192

Disassembly of Clutch Components and Flywheel

Assembly ····································································15B-194

Disassembly of oil pan and oil Pump ..................................... 15B-196

Disassembly of oil Seal Cover and oil Seal ........................... 15B-198

Disassembly of Gear Chamber Cover, Fuel Injection Pump

and Water Pump Assembly ..................................................... 15B-199

Disassembly of Camshaft Gear and Crankshaft Gear.......... 15B-202

Disassembly of Camshaft, Piston and Crankshaft ............... 15B-204

Assembly of Engine (4D20)......................................................... 15B-208

Introduction of Assembly ........................................................ 15B-208

Installation of Crankshaft, Piston and Camshaft .................. 15B-209

Installation of oil Seal and oil Seal Cover .............................. 15B-218

Installation of Crankshaft Gear and Camshaft Gear ............. 15B-219

Installation of Fuel Injection Pump and Gear Chamber

Cover ··········································································15B-220

Installation of oil Pump and oil Pan ....................................... 15B-222

Installation of Flywheel Assembly and Clutch Components 15B-224

Installation of oil Radiator and oil Filter................................. 15B-226

Installation of Hook, Valve, and Water Outlet Pipe

Connector .................................................................................. 15B-228

Installation of Cylinder Head ................................................... 15B-231

Installation of Tappet and Rockshaft ...................................... 15B-233

Pipe ············································································15B-234

Installation of dipstick .............................................................. 15B-236

Installation of Crankshaft Pulley, fan and fan Pulley ............ 15B-237

Installation of Breather and Generator .................................. 15B-238

Installation of Intake and exhaust Manifolds and

Turbocharger ........................................................................... 15B-241

Installation of EGR Controller ................................................. 15B-244

Installation of Cylinder Head Cover ....................................... 15B-246

Installation of Heater Water Inlet/Outlet Pipe Weldment ...... 15B-247

Cylinder Head Cover .................................................................... 15B-248

Diagram of Components .......................................................... 15B-248

Service ········································································15B-250

Rocker Assembly ......................................................................... 15B-255

Diagram of Components .......................................................... 15B-255

Service ········································································15B-256

Cylinder Head ............................................................................... 15B-262

Diagram of Components .......................................................... 15B-262

Service ········································································15B-264

Valve .............................................................................................. 15B-269

Overview .................................................................................... 15B-269

Adjustment ................................................................................ 15B-270

Service ········································································15B-273

Camshaft and Tappet ................................................................... 15B-282

Diagram of Components ···············································15B-282

Service ·······································································15B-283

Piston and Connecting Rod Assembly ..................................... 15B-292

Diagram of Components ···············································15B-292

Service ·······································································15B-293

Crankshaft and Flywheel Assembly .......................................... 15B-301

Diagram of Components ···············································15B-301

Service ·······································································15B-302

Cylinder Block ............................................................................. 15B-307

Diagram of Components ···············································15B-307

Service ·······································································15B-309

ENGINE MECHANICAL PART-ENGINE ASSEMBLY

15B-1

ENGINE ASSEMBLY

This chapter analyzes and resolves the common faults of diesel engine and provides solutions for these

common faults of the diesel engines equipped on the SUP product series.

During the operation of the diesel engine, due to the causes such as the wear and deformation or the

improper use and technical maintenance of the parts, the technical status is gradually deteriorated in various

portions of the diesel engine. When any technical index is out of the allowable limit, it indicates that the diesel

engine is malfunctioned. In event of the fault of the diesel engine, the diesel engine may not continue for

normal functioning if such fault is not timely and correctly resolved. This will not only lead to the reduction of

power and economy, the deterioration of the operation performance, and the reduction of exhaust level, but

also cause the early wear of parts.

Some faults of the diesel engine, such as the air contained in the fuel system, blockage of filter, and loose

drive belt, can be resolved by means of the necessary technical maintenance and adjustment. However,

some faults, such as the defect of the mechanisms, can’t be resolved by means of the regular maintenance

and adjustment, which include the damage of cylinder gasket, serious wear of piston ring, wear of valve cone,

and excessive wear of bearing bush. Such faults shall be resolved by removing the diesel engine and

repairing or replacing some parts of the diesel engine.

Generally speaking, the engine fault is complex, and one fault is influenced by various reasons; when a fault

happens, by no means should we disassemble the parts blindly, but we should firstly have a clear

understanding of the whole condition of the car, then analyze the possible reasons according to the specific

phenomena, and investigate the faults one by one in an order from easy to complicated.

15B-2

1. Collect all the actual condition of the fault phenomena.

2. Thoroughly analyze the fault.

3. Connect the fault symptom with basic engine system and parts.

4. Consider whether the recent maintenance and repair measurements are related to the fault

phenomena.

5. Recheck once more carefully before any disassembly work.

6. Judge the fault type, use the fault diagnosis table, and firstly choose the easiest problem to resolve.

7. Confirm the fault cause and repair.

8. After the repair, start the engine and ensure the fault cause has been thoroughly removed.

15B-3

DIESEL ENGINE FAULT DIAGNOSIS

1. The engine cannot be started

Generally, the reasons why the engine cannot be started are mainly the problems of fuel system, electric

system, the compressing pressure in the cylinder, oil, fuel supply advance angle and ambient temperature.

The fuel system goes wrong

The details are as follows:

• There is no fuel in the fuel tank or the drain switch is not turned on.

• There is the air in the fuel system.

• Fuel pipe or the fuel filter is blocked.

• The fuel delivery pump does not supply oil or interruptedly supply oil.

• The advance angle is not correct.

• The fuel injection atomization is bad.

• The draw bar does not return to the maximum fuel supply position.

The electric system goes wrong

• The circuit connection is wrong or there is a bad contact.

• The power of the battery is not adequate.

• The carbon brush of the starter motor and the commutator are in a bad contact.

• The generator does not work.

The viscosity of the oil is too high and causes the reducing of the starting speed.

The ambient temperature is too low.

The compressing pressure in the cylinder is low.

• The cylinder liner, piston and piston ring are worn.

• The valve and the valve seat do not match closely.

• There is no valve clearance.

• The valve stem is stuck in the conduit.

• The cylinder head gasket leaks air.

• The fuel injector seat hole leaks air.

• Valve timing is not correct.

When the engine cannot be started, firstly consider whether it is caused by misoperation or lack of

maintenance.

15B-4

(f). Fault diagnosis and troubleshooting

Check the possible causes for the difficult start or start failure of the engine one by one as per procedure

below. Check in an order from easy to complicated, in order to effectively save the diagnosis time. Any cause

clearly unlikely to occur through analysis may be omitted directly. This diagnosis procedure is for reference

only.

Step Diagnosis Description Measure

Check whether the ambient

temperature is too low

Add hot water or adopt the preheating start

No Go to Step 2

Check whether the starting circuit is in

a good contact

Yes Go to Step 3

Screw down the circuit connection screw

Check whether the battery voltage is

normal

Yes Go to Step 4

Charge the battery according to the technical

requirements

Check whether there is diesel in the

fuel tank or whether the drain switch

is not turned on

Add diesel or turn on the switch

No Go to Step 5

Yes Go to Step 6

Check whether the fuel draw bar has

returned to the maximum fuel supply

When the engine is started, more tension shall

be added to the speed adjusting lever to make

the draw bar return to the maximum fuel supply

Check whether the fuel pipe or the

diesel filter is blocked

Clean the fuel pipe and clean or replace the

diesel filter to solve the blockage problem

No Go to Step 7

Use the manual pump to remove the air. And

Check whether there is any air in the

fuel system

check whether there is air leakage at each

connecting pipe and solve the problem

No Go to Step 8

15B-5

Check whether there is air leakage at the fuel

inlet pipe, and whether the filter screen at the

Check whether the fuel delivery pump

dose not supply fuel or interruptedly

supply fuel

connector of the fuel inlet pipe is blocked; Check

whether the fuel supply solenoid valve is open;

turn on and off the switch and listen, if there is

any sound of movement, the solenoid valve shall

be replaced.

No Go to Step 9

Check whether the fuel injection

atomization is bad

Clean the nozzle parts, adjust the fuel injection

pressure or replace the fuel injector

No Go to Step 10

Check whether the fuel supply

Readjust the fuel supply advance angle

advance angle meets the

requirement

No Go to Step 11

Check whether the connection is

correct and stable

Yes Go to Step 12

No Reconnect and screw down

12

Whether the carbon brush of the

starter motor and communtator are

in a bad contact

Repair or replace carbon brushes and use

Yes sand paper to clean the surface of the

communtator and blow off.

No Go to Step 13

Whether the generator does not

Yes Repair or replace

No Go to Step 14

Check whether the viscosity of the

oil is too high and makes the

Turn the crankshaft for several turns with the

handle or add preheated oil

starting speed too low

No Go to Step 15

15

Check whether the air valve

contains no clearance or the

Adjust the air valve clearance according to the

clearance is too small

No Go to Step 16

Check whether the valve stem is

stuck in the conduit

Yes Clean carefully with kerosene or diesel

No Go to Step 17

17 Check whether the air valve and the Yes Grind the air valve, and replace the damaged

15B-6

air valve seat do not match closely.

air valve spring.

No Go to Step 18

Check whether the nut is screwed down;

Check whether there is air leakage

at the fuel injector seat hole

whether the fuel injector gasket is undamaged;

replace the damaged parts

No Go to Step 19

or blow-by phenomena at the

cylinder head gasket

Check whether the valve timing is

incorrect

Fasten according to the Torque of the cylinder

head bolt; replace the cylinder head gasket

No Go to Step 20

Yes Adjust the timing according to the timing mark

No Go to Step 21

Check whether the cylinder liner,

piston and piston ring are worn

Replace the cylinder liner, piston and piston

ring; remove the reason causing wear

Check carefully according to the above steps,

find out the fault position and remove timely

15B-7

2. Low temperature start difficulty of diesel engine

(a). The diesel goes wrong

When the winter comes or after we enter the severe cold region and do not choose the diesel

according to the requirement, diesel becomes turbid and solidified under the condition of low

(b). The lubricating oil goes wrong

When the winter comes or after we enter the severe cold region and do not choose the oil according

to the requirement, the viscosity of the oil is too high under the condition of low temperature, and

internal friction increased, and starting resistance moment of the diesel engine increased.

(c). The battery goes wrong

When working at the severe cold region, and do not choose the battery according to the requirement,

the battery capacity is less than 100Ah.

(d). The preheating system goes wrong

The electrical element fault makes the preheating system does not work, the preheat plug is

unheated.

15B-8

(e). Fault diagnosis and troubleshooting

Check the causes for the difficult start of the engine one by one as per procedure below, check in an order

from easy to complicated, in order to effectively save the diagnosis time. Any cause clearly unlikely to occur

through analysis may be omitted directly. This diagnosis procedure is for reference only.

When the winter comes or after we enter the

severe cold region, whether choose the diesel

according to the requirement, the diesel

becomes turbid and solidified under the condition

of low temperature

Choose low condensing point diesel

No according to the ambient temperature

in which the diesel engine works

Yes Go to Step 2

Choose low viscosity oil according to

severe cold region, whether choose the oil

according to the requirement, the viscosity of

the ambient temperature in which the

diesel engine works to reduce the

the oil is too high under the condition of low

power required for the start

temperature, and internal friction increased,

and starting resistance moment of the diesel

engine increased

Go to Step 3

When working at the severe cold region,

whether choose the battery according to the

requirement, the battery capacity is less than

100Ah

Choose low temperature battery with

capacity higher than 100Ah according

to the ambient temperature in which

the diesel engine works

Check the voltage of each preheat

The electrical element fault makes the

preheating system does not work, whether the

plug in preheating system, and judge

whether it is the preheat plug fault or

the circuit fault

preheat plug is heated

Check carefully according to the

above steps; find out the fault position

and remove timely

15B-9

3. Low engine power

Low engine power means that the engine power can’t reach the design requirement so that the vehicle lacks

of power, with poor color of exhaust emission, while driving under heavy load or climbing an abrupt slope.

The reasons causing low engine power are mainly problems of fuel system, intake system, exhaust system,

cooling system, low compressing pressure in the cylinder, abnormal oil temperature, incorrect fuel supply

advance angle and low ambient temperature and so on.

When the intake system goes wrong, it generally represents as: at the urgent acceleration, the engine

revolution speed cannot be accelerated to the corresponding speed, and the exhaust pipe exhausts

blue smoke with sharp flavor of the incomplete combustion of the diesel.

• The dust in the filter element of the air filter is too much and causes blockage.

• The intake pipe of the air filter is damaged.

• The intake pipe is not sealed closely.

When the exhaust system goes wrong, it generally represents as: at the acceleration, the exhaust

pipe muffler makes abnormal sound and sometimes there is abnormal dense smoke exhausted from

the exhaust port.

• The exhaust pipe or muffler is damaged and causes blockage.

• The turning radius of the exhaust pipe is too small or there are too many bends.

• Exhaust brake has faults, and the brake valve is normally closed.

When the fuel system goes wrong, it generally represents as: after the acceleration is increased, the

power or revolution speed still cannot be increased, and the engine tends to flameout.

• No fuel in the fuel tank or the fuel level is too low.

• There is air in the fuel system.

• The fuel pipe or diesel filter is blocked.

• The fuel supply of the fuel injector pump is low.

• The atomization of fuel injector is bad.

• The fuel injection pressure is low.

• Few fuel injectors are blocked.

• The fuel injector pump accelerate handle is not properly adjusted.

Fuel supply advance angle changes, revolution speed and performance of each gear decrease.

• The fuel supply advance angle is changed.

• The air valve clearance is incorrect.

The abnormal oil temperature generally represents as: the oil warning light flickers or is normally on;

too high or too low oil temperature will cause the oil deterioration and bad lubrication; this kind of

phenomenon can be caused by problems of ambient temperature, engine cooling system or engine

internal machine.

• Oil filling amount cannot meet the standard.

• Oil brand is not suitable for the ambient temperature.

• The abnormal engine cooling system causes the too high oil temperature.

• The ambient temperature is too low.

15B-10

Low compressing pressure in the cylinder generally represents as: phenomena of low engine power,

decreased performance, air leakage, black smoke and abnormal knocking sound.

• Air vale and air vale seat do not match closely.

• There is no air valve clearance.

Diesel engine is overheated

• The temperature of air coolant is too high.

• The temperature of oil is too high.

• The temperature of exhaust gas is too high.

Cylinder head fault: at this time, not only the power is low and the performance is decreased, but also

there are phenomena of air leakage, black smoke and abnormal knocking sound.

• The joint surface of cylinder head and the engine body leaks air, the cylinder head bolt is loose or

the cylinder gasket is damaged.

• Intake valve and exhaust valve leak air.

• The fuel injector hole leaks air or the copper washer is damaged.

Crank-link mechanism fault

• Connecting rod small end copper sleeve is seized with piston pin.

The low engine power often comes with start difficulty, they are closely related; we can take it as a

reference to analyze, but we shall firstly consider whether it is caused by lack of maintenance.

15B-11

(j). Fault diagnosis and troubleshooting

Tip:

Check the possible causes for the low engine power one by one as per procedure below. Check in an order

Check whether the filter element of

Clean or replace the air filter element.

the air filter is blocked because of

dirtiness.

Check whether the intake pipe of the

air filter is damaged.

Replace the damaged pipe and clean the dust

and other things in the undamaged pipe.

No Go to Step 3

Check whether the intake pipe is well

sealed.

Fasten the pipe connector clamp according to

the technical requirements

Check whether the fixing bolt at the

Yes Go to Step 5

connector of exhaust gas pipe is fixed

firmly

Fasten the loose blot to specified torque.

Check whether the exhaust gas pipe

or the muffler is blocked.

Remove the exhaust gas pipe and muffler to

clean; replace the muffler if necessary.

No Go to Step 6

Whether the modified exhaust gas

pipe caused low exhaust gas amount

or too small turning radius and too

many bends.

Install the exhaust gas pipe according to factory

design to ensure the free flowing of exhaust gas.

Check whether fault happens to

Remove the brake valve fault.

exhaust gas brake or the brake valve

is normally closed

Check whether the fuel in the fuel tank

is sufficient.

Yes Go to Step 9

Fill fuel which suits for local climate condition

15B-12

Loosen the oil return valve on the fuel injector

pump or the air bleeding bolt on the diesel filter,

Check whether there is air in the fuel

pipe

and use the fuel delivery pump to pump the fuel

and bleed the air. Ensure there is no air in the

fuel pipe and fasten the air bleeding bolt.

Check whether the fuel pipe and fuel

filter are blocked

Clean the fuel pipe and replace the fuel filter if

necessary

Check whether the fuel supply of the

fuel injection pump is sufficient

Check, repair and replace the fuel injection

No Go to Step 12

Check whether the atomization of the

fuel injector is bad

Check the fuel injector and repair or replace the

fuel injector with bad atomization

pressure is low

Use the adjusting hot gasket to adjust the fuel

injection pressure

Check whether few fuel injector is

stuck

Yes Repair or replace fuel injector couple

advance angle is changed

Yes Adjust the fuel supply advance angle

clearance is correct

Yes Go to Step 17

No Adjust the air valve clearance

17

pump acceleration handle is well

adjusted

Adjust the acceleration handle to the maximum

Yes fuel supply amount according to the requirement;

check the fuel injection pump if necessary

15B-13

Yes Go to Step 19

Check whether the oil meets the

standard

If the oil amount is low, add more; if the amount

is too high, discharge the redundant oil and find

out the reason of the redundance.

Check whether the oil brand is not

suitable for the ambient temperature

Check whether there is any fault at the

engine coolant level and the cooling

system and causes too high engine

Whether the too low ambient

temperature made the viscosity of the

oil too high and caused the bad

lubrication

Check whether the air valve stem is

Check whether the air valve well

matches with the air valve seat

Replace with the oil suitable for local climate

Fill the coolant to the standard level and find out

Yes the reason of the high temperature and remove

the fault

Replace the oil suitable for the local climate

Yes condition; add suitable warm-keeping

components in front of the radiator

No Go to Step 22

No Go to Step 23

Grind the air valve; replace the damaged air

valve spring

No Go to Step 24

Check whether the fuel injector seat

hole leaks air.

Check whether the nut is screwed down and the

fuel injector gasket is undamaged; replace the

damaged parts

Check there is air leakage or blow-by

phenomena at the cylinder head gasket

correct

No Go to Step 25

Fasten according to the Torque of cylinder head

bolt; replace the cylinder head gasket

No Go to Step 26

No Go to Step 27

15B-14

27

Check whether the cylinder liner, piston

and piston ring are worn.

Replace the cylinder liner, piston and piston ring;

remove the reason causing wear.

No Go to Step 28

Check the cooling system; clean the scale; check

28

Check whether the coolant temperature

is too high

the tightness of the belt and adjust; check the

thermostat

No Go to Step 29

Check the oil amount, add more if it is low; if the

29

Check whether the oil temperature is

too high

bearing bush or one moving member radiates,

find out the radiation part and the reason, and

remove it

No Go to Step 30

Check and revise the static fuel supply advance

Check whether the exhaust

temperature is too high

angle, fuel injection pressure and atomization

condition of the fuel injector

31

Check whether there is air leakage at

the joint surface of cylinder head and

the engine body, and whether the

cylinder head bolt is loosen or the

cylinder gasket is damaged.

No Go to Step 31

Screw down the cylinder head bolt according to

Yes the specified torque or replace the cylinder

gasket

No Go to Step 32

Disassemble and check the intake, exhaust

32

the intake, exhaust valves

valves; grind the air valve or grind the joint

surface of the air valve seat

No Go to Step 33

33

34

Check whether the air valve clearance

is correct

Check the air leakage of the fuel

injector hole or whether the copper

gasket is damaged

Yes Go to Step 34

Revise the air valve clearance to the specified

value

Remove, service, clean and replace the

No Go to Step 35

15B-15

Remove the oil pan, check whether the

35

Check the seizure of the connecting

rod small end copper sleeve and the

piston pin

connecting rod big end can conduct the axial

wobble, if not, remove the connecting rod of the

piston and service

15B-16

4. Engine sudden flameout

Engine sudden flameout means that in the normal work of engine, it suddenly shuts down and cannot run

again. There are two situations for engine sudden flameout: one is that it can start again after the flameout

but cannot run normally, which means the fuel supply system fault; another one is that it cannot start again

after the flameout, even with the starter driving it, which means the machine part fault caused by the bad

internal lubrication of the engine.

When a fault happens in the fuel supply system, it generally represents as after the flameout, when

restart and increase the accelerator, the engine is about to start and there are a little blue smoke

discharged from the exhaust gas pipe, but it stopped if the ignition switch is loosen.

• The fuel in the fuel tank ran out.

• The fuel filter or pipe is blocked.

• The diesel contains water.

The engine internal parts fault generally represents as when restart the engine after the flameout, the

engine cannot run with the starter or runs very slowly.

• The oil pressure is too low or too little.

• Oil pump has faults.

• The piston is stuck with the cylinder liner.

• The connecting rod small end or connecting rod bearing bush is seized with crankshaft.

• Crankshaft main bearing bush is seized.

When the engine suddenly shut down, first use tool to turn the start claw to judge whether the engine

can run, if it can run and runs normally, it means the fuel system goes wrong; if it can not run, it

means the seizure phenomenon appears on the engine internal parts, then disassemble and check to

avoid unnecessary loss.

15B-17

(c). Fault diagnosis and troubleshooting

Check the possible causes for the engine sudden flameout one by one as per procedure below, and check in

an order from easy to complicated, in order to effectively save the diagnosis time. Any cause clearly unlikely

to occur through analysis may be omitted directly. This diagnosis procedure is for reference only.

Check whether the fuel in the fuel

tank ran out

Fill the fuel and bleed the air in the fuel pipe

Go to Step 2

Check whether the fuel system

contains air

Find out the reason of air admission and remove

it; bleed the air in the fuel pipe

Check whether the fuel filter or the

pipe is blocked

Clean the fuel pipe, replace the fuel filter if

No Go to Step 4

Check whether the fuel contains

water

Drain the fuel in the fuel tank and add new fuel,

or deposit the drained fuel and use it again

Check whether the lack of oil caused

Fill the fuel to the standard scale, use tool the

the bad lubrication of the engine parts

turn the start claw and start the engine after it

which caused the slight damage

(there is damping when use tool to

turn the start claw but it can be

turned)

runs smoothly

Go to Step 6

Disassemble the oil pan and check

whether the oil pump goes wrong

Replace or repair the oil pump; repair the worn

parts

Check whether the piston is stuck

with the cylinder liner

Replace the damaged piston and cylinder liner

and find out the reason and remove it

15B-18

Check whether the connecting rod

small end or connecting rod bearing

bush is seized with the crankshaft

Replace the damaged parts, find out the reason

and remove it

Check whether the crankshaft main

bearing bush is seized with the

crankshaft

Replace the main bearing bush; repair or replace

the crankshaft

15B-19

5. Engine abnormal sound

Engine abnormal sound means the obvious knocking or impact sound inside of or on the top of the engine

that can be heard during the normal working. The size and the frequency of such sound increase following

the increasing of the engine rotation speed. Once occurred, such sound is hard to disappear without the

adoption of the remedy measure. Firstly differentiate the type of the engine abnormal sound as the impact

sound arising from the abnormal detonation or from the abnormal movement of parts and then find out the

root cause depending on the noise characteristic and portion of noise source in combination with the

structure theory.

(a). Air valve mechanism abnormal sound. It generally represents as: in the running process of the car,

there is obvious abnormal sound at the upper part of the engine, and the volume and frequency of the

sound will increase along with the increase of the engine revolution speed; once the sound happens,

it is difficult to vanish without taking any measurements.

• The viscosity of the oil is too dilute.

• The air valve tappet contains no oil.

• The air valve clearance is too large.

• The rocker or the rockshaft is worn.

• The air valve is stuck; the air valve seat is inclined or contains too much carbon deposit.

(b). Fuel supply time too early or too late abnormal sound. When the fuel supply is too early, it generally

represents as that it makes clear metal knocking sound form the cylinder at the urgent acceleration;

while when the fuel supply is too late, it generally represents as that it makes low and deep but not

clear knocking sound from the cylinder; and generally it exhausts air with dense smoke.

• The fuel supply time is too early.

• The fuel supply time is too late.

• The fuel injector is stuck.

(c). Piston and piston ring abnormal sound. It generally represents as grinding sound “Da Da Da” from the

upper part of the cylinder block and the cylinder head, the sound and frequency will increase with the

increase of the engine revolution speed, and it comes out with possible exhaust gas and blue smoke

and decreased engine power.

• The piston ring is severely worn.

• The piston is severely worn.

• The cylinder barrel is severely worn.

• The clearance between the cylinder barrel and the piston is too large.

(d). The piston pin and connecting rod small end bush match loosely. It generally represents as that the

engine will make slight and blunt sound when it is running, and this kind of sound is particularly clear

at the idle operation.

• The connecting rod small end bush is worn.

• The piston pin is worn.

(e). The clearance between the piston and cylinder liner is too large. It generally represents as that a

crashing sound can be heard from the outer wall of the engine when it is running, and the sound will

15B-20

be louder when the revolution speed increases.

The air valve and piston crash abnormal sound. It generally represents as that it makes deep, uniform

and rhythmed knocking sound form the upper part of the cylinder block and cylinder head.

• The valve timing is incorrect.

• The clearance of the air valve is too small.

The transmission gear is worn, and the clearance is too large. It generally represents as that it makes

abnormal sound from the gear chamber, and a crashing sound can be heard at sudden decreased

speed.

The wear of the connecting rod bearing bush and the main bearing bush makes the clearance too

large. It generally represents as that when the engine is running, a crashing sound can be heard at

the crank case and it becomes louder when the revolution speed increases.

The clearance of intake valve and exhaust valve are too large. It generally represents as that a loud

and rhythmed sound can be heard at the cylinder head.

When the engine makes abnormal sound and fault sound, we shall not let it continue to work; after

hearing the abnormal sound, we shall urgently stop the car, check and diagnose, judge the reason

and position of the fault and timely remove it to avoid unnecessary loss.

15B-21

Check the possible causes for the sudden flameout of engine one by one as per procedure below, and check

in an order from easy to complicated, in order to effectively save the diagnosis time. Any cause clearly

unlikely to occur through analysis may be omitted directly. This diagnosis procedure is for reference only.

Replace the lubricating oil suitable for the climate

Check whether the viscosity of the oil

is too dilute

condition; check the engine parts damage

caused by the too dilute oil and replace them

Check whether the air valve tappet is

severely worn because of the lack of

Fill engine lubricating oil; replace the damaged

air valve tappet

Rumble sound can be heard at the

intake or exhaust port, meaning

whether the clearance of the air valve

is too large

Adjust all air valve clearance according to the

Check whether the rocker are or

rockshaft is worn

Replace the damaged parts; readjust the air

Clean the stuck air valve, replace the air valve

Check whether the air valve is stuck,

the air valve seat is inclined or

contains too much carbon deposit

Yes seat and grind the air valve; find out the reason

of too much carbon deposit and remove it

Adjust the static fuel supply advance angle,

Check whether the fuel supply time is

too early.

check the fuel injection condition of the fuel

injector, repair or replace if necessary

too late

8 Check whether few fuel injectors are Yes Replace or repair the damaged fuel injector

15B-22

stuck No Go to Step 9

Check whether the piston ring is

severely worn.

Check whether the piston is severely

worn

Check whether the cylinder barrel is

severely worn

Check whether the too large

clearance between the cylinder barrel

and the piston caused the crashing

sound

Replace the piston ring; if necessary, replace the

piston, too.

Replace the damaged piston and cylinder liner;

find out the reason and remove it

Replace the damaged cylinder barrel; if

necessary, replace the piston, too.

Replace the damaged parts; if necessary,

replace the whole set

Replace the damaged piston and cylinder liner,

find out the reason and remove it.

small end bush is worn

Replace the connecting rod small end bush; if

necessary, replace the piston or the connecting

rod

16 Check whether the piston pin is worn

Replace the piston pin; if necessary, replace the

connecting rod small end bush

15B-23

Whether the clearance between the

piston and cylinder liner is too large, a

crashing sound can be heard at the

outer wall of the engine body while

running and it becomes louder when

the revolution speed increases

Replace the piston, or replace the cylinder liner

according to the wear condition

No Adjust the timing gears

clearance is too small or closed

Check whether the transmission

gears are worn and caused too large

clearance

bearing bush and the main bearing

bush are worn and caused the too

large clearance

Check the gear clearance, replace the gear

Disassemble and check the bearing bush; if

Yes necessary, replace and keep the required fit

Whether the clearance of intake valve

and exhaust valve is too large and a

loud and rhythmed sound can be

heard at the cylinder head

Revise the air valve clearance again

15B-24

6. The oil pressure is abnormal

Whether the oil pressure is too high or too low belongs to abnormal situation, in which the too low oil pressure

is rather common. When the pressure is too low, the oil pressure alarm will flicker, meaning the oil pressure is

low or there is no oil. There are many reasons causing oil pressure problems, and the driver or maintenance

personnel shall treat seriously, check the reason of the fault carefully and remove the fault.

The oil pressure sensor or the oil gauge is damaged.

The oil level is too low.

The viscosity of the oil is too dilute.

• The oil brand is not suitable for the local climate condition.

• The temperature of the engine is too high.

• The cylinder head gasket is damaged and the coolant is mixed into the oil.

• The water-blocking seal ring of the cylinder barrel is damaged, and the coolant is mixed into the

oil.

• The cylinder head or cylinder block is cracked and the coolant is mixed into the oil.

The oil filter is blocked

The clearance between the main bearing bush and the connecting rod bearing bush is too large

Oil pump fault

• The inner and outer rotors of the oil pump are severely worn or it leaks oil.

• The oil inlet pipe of the oil pump is blocked.

• The pressure regulating valve of the oil pump has a fault or the lubricating oil pipe is cracked

• The oil filter gasket is installed in the reverse direction.

When the oil pressure is abnormal, we shall not let the engine continue to work, we shall urgently

stop the car after we find it, shut down the engine, check the reason and position of the fault and

timely remove it to avoid unnecessary loss.

15B-25

(g). Fault diagnosis and troubleshooting

Check the possible causes for the abnormal oil pressure one by one as per procedure below, and check in an

order from easy to complicated, in order to effectively save the diagnosis time. Any cause clearly unlikely to

occur through analysis may be omitted directly. This diagnosis procedure is for reference only.

Check whether the oil pressure sensor or the oil

gauge is damaged

Replace the oil pressure sensor or the

oil gauge

2 Check whether the oil level is too low

Add suitable amount of oil, and find

out the reason causing the too low oil

level and remove it

Judge the reason causing too high or too low

engine temperature and whether the oil is

deteriorated influencing by the ambient

Replace the oil suitable for the local

climate temperature condition

Check whether the cylinder head gasket is

damaged and whether the damaged cylinder

Replace the cylinder head gasket and

the oil

gasket makes the coolant mixed into the oil

Check whether the water-blocking seal ring of

the cylinder barrel is damaged, and whether the

damaged water-blocking seal ring of the cylinder

Replace the water-blocking seal ring

of the cylinder barrel and replace the

barrel makes the coolant mixed into the oil

Check whether the cylinder head of the cylinder

block is cracked and whether the cracked

cylinder head of cylinder block makes the coolant

mixed into the oil

Replace the damaged parts and the

7 Check whether the oil filter is blocked

Replace the oil filter; if necessary,

replace the oil

15B-26

Replace the main bearing bush or the

The clearance between the main bearing bush

and the connecting rod bearing bush is too large

connecting bearing bush; if

necessary, replace or repair the

connecting rod or the crankshaft

The oil filter gasket is installed in the reverse

direction

Yes Reinstall or replace

10 Check whether the oil pump goes wrong

Replace or repair the oil pump

Check whether the inner and outer rotors of the

oil pump are severely worn or leaks oil.

12 The oil inlet pipe of the oil pump is blocked

Dredge the oil inlet pipe of the oil

pump and replace the filter screen of

the oil inlet pipe

Replace or repair the damaged parts

The pressure regulating valve of the oil pump or

the lubricating oil pipe is cracked

above steps, find out the fault position

15B-27

7. Engine overheating or supercooling

The overheating or supercooling of the engine will influence the overall performance of the engine. Engine

overheating is rather common, and it generally represents as that the pointer of the coolant temperature

gauge points at the red dangerous scale, the radiator is easy to boil, and vapor can be seen from the radiator

when the engine cover is opened. Drivers or maintenance personnel shall treat it seriously, check the reason

of the fault carefully, and remove the fault.

The cooling system overheating

• The water tank lacks water.

• The cooling pin out of the water tank is blocked with sundries.

• The scale in the water tank is too much and caused blockage and bad circulation.

• The belts of the fan and water pump are too loose, causing that the output volume of the water

pump and fan is too little.

• The distance between the water tank and the fan is inappropriate.

• The water inlet and outlet pipes are deformed and blocked.

• The valve of the thermostat cannot be opened.

• Water pump has faults.

• The fuel supply timing is not correct.

Engine supercooling

• The valve of the thermostat cannot be closed.

• The coolant temperature gauge does not work.

The fuel injection is too late or the fuel injector leaks oil.

• The timing phase is not correct.

• Engine operates with overload for a long time.

• In event of engine overheating, do not stop the engine or add the coolant immediately, or it will

lead to personal injuries or damage of parts. In such case, release the accelerator pedal, run under

unloaded condition or splash a small amount of water onto the surface of coolant tank. After the

coolant in the cooling system cools down, stop the engine for checking.

• Do not remove the cap of coolant tank while the engine is still hot, in order to prevent scalding.

While refilling the coolant, special caution shall be taken.

• If the causes for engine overheating can’t be found and resolved, contact the service station or

service plant immediately, or it will lead to damage of other parts.

15B-28

(d). Fault diagnosis and troubleshooting

Check the causes for the engine overheating or supercooling one by one as per procedure below, and check

1 Check whether the engine lacks coolant

Remove the reason of losing coolant

and fill the coolant

Clean the sundries with hairbrush and

Check whether the cooling pin of the water tank

is blocked because of too much dust or sundries

clean the dust in the cooling pin with

compressed gas

Add aqueous alkali into the water tank

(ten liters of water with 750 grams of

Check whether the scale in the water passage is

too much

washing soda), run the engine for 4-8

hours and drain the water, and

cyclically clean the water passage

with the clean water

Check whether the belts of the fan and the water

pump are too loose or fractured

Adjust the tightness of the belts; if

necessary, replace the belts

Check whether the distance between the water

tank and the fan is not installed properly

Adjust the distance between the water

tank and the fan properly

Check whether the water inlet and outlet pipes

(rubber hoses) are deformed

Replace the deformed rubber hoses

Check whether the thermostat valve does not

work normally

Replace the thermostat

8 Check whether the water pump goes wrong

Replace or repair

15B-29

9 Check whether the fuel supply timing is correct

Yes Go to Step 10

Adjust the fuel supply timing correctly

Check the temperature of the coolant,

Check whether the coolant temperature gauge

does not work

replace the coolant temperature

gauge and sensor

Adjust the fuel supply timing, check

Check whether the fuel injection of the fuel

injector is too late or the fuel injector leaks oil

the fuel injector and replace if

13 Check whether the timing phase is correct

Yes Go to Step 14

Readjust the timing phase

Properly decrease the load to operate

Whether the long time overloading operation of

engine caused the high temperature

15B-30

8. The smoke color of the exhaust gas of the engine is abnormal

Observing the color of the exhaust gas of the engine and judge whether the engine goes wrong is an easy

and effective way. If the engine is under the normal working temperature, its exhaust gas color shall be

colorless or light gray, (the so-called colorless does not mean completely colorless like the diesel engine, but

colorless with slight gray) this is the normal exhaust gas color. The exhaust gas color of the diesel engine

under idle operation, urgent acceleration and high speed and high loading will be darker, the abnormal

exhaust gas colors generally contain: exhaust gas with blue smoke, exhaust gas with white smoke and

exhaust gas with black smoke; more observation of the normal exhaust gas color at ordinary time will be

helpful for having a clearly understanding of the abnormal exhaust gas color.

Engine exhaust gas with blue smoke (oil entersthe cylinder)

• The piston ring and the cylinder liner are worn; the piston ring is bonded or the piston ring gap

• The conduit hole near the exhaust valve is worn.

• The oil level in the oil pan is too high.

• The piston ring is stuck or excessively worn, the elasticity is low; the piston chamfer is reversely

installed and makes the oil enters the combustor.

• With long time low loading operation, the clearance between the piston and cylinder liner is

rather large and makes the oil enters the combustor.

Engine exhaust gas with white smoke (the diesel is not completely combusted under the condition of

engine supercoolling and low loading)

• The fuel supply of the fuel injector is too much.

• The fuel atomization is bad, and the fuel injection is too low.

• The fuel supply is too late.

• The cylinder compressing pressure is too low.

• The diesel contains water or the cylinder contains water.

• When the diesel engine is just started, no combustion in few cylinders (especially in winter)

Engine exhaust gas with black smoke (uncompleted combustion)

• The diesel engine works with overloading.

• The diesel is not atomized well or there is an oil leakage phenomenon.

• The intake pipe or the air filter is blocked.

• The fuel injection quantity is too much.

• The fuel supply amount of each cylinder is not equal.

• The air valve clearance is not correct and the bad sealed air valve caused the air leakage of the

exhaust valve.

• The too small fuel supply advance angle and the too late fuel injection make part of the fuel

combusted in the exhaust gas pipe.

• The cylinder liner and the piston ring are severely worn.

• The EGR system solenoid valve is damaged.

15B-31

• The EGR valve cannot be closed well.

• The fuel injector is damaged.

When the smoke color of the engine exhaust gas is abnormal, firstly consider whether it is caused by

improper operation or lack of maintenance.

Check the possible causes for the abnormal smoke color of engine exhaust gas one by one as per procedure

below, and check in an order from easy to complicated, in order to effectively save the diagnosis time. Any

cause clearly unlikely to occur through analysis may be omitted directly. This diagnosis procedure is for

reference only.

• Exhaust gas with blue smoke fault diagnosis and troubleshooting

Check whether the exhaust gas with blue smoke

is caused by the wear of piston and cylinder liner,

the bonding of piston ring, the low elasticity or the

piston ring gap alignment

Repair carefully, and replace the worn

parts if necessary

Check whether the conduits of the intake and

exhaust pipes are worn

Replace the worn parts and grind the

air valve

Check whether the oil level in the oil pan is too

Exhaust the excessive oil

Check whether the piston ring is stuck or

excessively worn, and whether the elasticity is

Disassemble and check the piston

ring, replace if necessary

low

Whether the long time low loading operation and

the rather large clearance between the piston

and cylinder liner make the oil enter the

combustor

Properly increase the loading or

disassemble, check and repair

15B-32

• Diagnosis and troubleshooting of exhaust gas with white smoke.

Check whether the fuel supply of the fuel

injection pump is too much

Adjust the fuel supply amount of the

Check whether atomization and pressure of

fuel injector is normal.

Check and adjust pressure of the

fuel injector, and replace the fuel

injector when necessary.

Check whether fuel supply of fuel injection

pump is too late.

Adjust fuel supply advance angle.

Service cylinder liner, piston, piston

Check whether the compressing pressure of

the cylinder is too low

ring , grind the air valve, and

replace the worn parts when

5 Check whether there is water in the diesel

Replace diesel, and replace fuel

Whether there is combustion in few cylinders

immediately when the diesel engine starts

(Especially in winter).

above steps, find out the fault

position and remove timely

Properly increase the rotation speed

and the load, and run it for more

time.

15B-33

• Diagnosis and troubleshooting of exhaust gas with black smoke

Make sure whether it is caused by overload work

of the diesel engine

Decrease the load.

Check and adjust the fuel injector

Check whether the fuel injector atomization is

bad or leaks oil.

pressure and replace the fuel

Check whether the fuel supply of the oil pump is

Yes Adjust the fuel supply advance angle.

Clean the air filter and intake pipe and

Check whether the intake pipe or air filter is

blocked.

replace the filter element when

Adjust the amount of fuel supply, and

Check whether the amount of fuel supply is too

much.

check the fuel injection pump when

Yes Go to Step 7

Check whether the fuel supply amount of each

cylinder is equal.

Adjust the amount of fuel supply in the

cylinders of each injection pump and

make them equal.

Check whether the valve clearance is correct,

and whether the valve is not sealed well and

caused the air leakage of the exhaust valve

Adjust the valve clearance and check

the sealing cone.

Check whether fuel supply advance angle is too

small and whether fuel injection is too late which

can makes few fuel combusted in the exhaust

Yes Adjust the static fuel supply advance

15B-34

Check whether the cylinder liner and piston ring

are seriously worn

Replace the piston ring and the

cylinder liner

Unplug the hose between the

solenoid valve and EGR valve at the

Check whether the solenoid valve in ERG

system is broken.

ERG valve end, and if the pheromone

of smoke disappears, it means the

solenoid valve is broken, then replace

new part

11 Check whether ERG valve is not closed well.

Disassemble the ERG valve and

clean the carbon deposition

12 Check whether the fuel injector is broken.

To decide which fuel injector goes

wrong using the cylinder fuel cut

method, and the details are as

follows.

15B-35

9. Fault of the fuel injection pump

The fuel injection pump is the main part for the fuel supply to engine, so the problems in the fuel pump can

influence the normal working of the engine directly. The faults in engine resulting from the problems of the fuel

injection pump are as follows: the engine cannot get started, improper engine idling, runaway in engine and

knocking of the engine. The driver should take these seriously, and the injection pump is precise unit and

non-professionals cannot disassemble and adjust it.

(a). The injection pump does not supply oil.

• The delivery valve is worn or is lined with dirt and stains

• The delivery valve spring or plunger spring is deformed or broken off.

• The adjustment spring is dropped.

• The adjustment arm and the shifter fork are struck.

• The mandril of the delivery pump is struck.

(b). The fuel injection pump does not stop supplying fueland causes runway in engine”(The engine

rotation speed cannot be reduced or is not controlled by the accelerator pedal)

• The oil shifting yoke is blocked.

• The adjustment arm is dropped.

• The shaft sleeve of governor is burned because it is not lubricated well.

• The draw bar stroke is not enough.

• The fly hammer components are loose.

• The draw bar spring is dropped.

(c). The speed governing rate is too high.

• The speed governing torsional spring is deformed or worn or the stiffness is too large.

• The corrector plays a part too early.

(d). The fuel supply is not stable.

• There is air or water in the fuel

• The fuel delivery pump is broken.

• The plunger spring is fractured.

(e). Engine hunting

• Frictional resistance in the governor is too large.

• The axial clearance in camshaft is too large.

• The lubricating oil is too much.

(f). The rated oil amount is not enough.

• The plunger and barrel assembly or the delivery valve is worn.

• The corrector is adjusted improperly.

• The high speed limit is incorrect.

15B-36

The fuel supply amount of each cylinder is not equal suddenly.

• The adjustment arm is loose.

• There is dirt and stains in the delivery valve and fuel nozzle.

Low speed and unstability

• Idle speed adjustment screw is not adjusted properly.

• The low speed oil amount is not equal.

15B-37

(i). Fault diagnosis and troubleshooting

Check the reason causing the fault of the fuel injection pump one by one according to the following steps.

Check in an order from easy to complicated, in order to effectively save the diagnosis time. Any cause clearly

• Fuel njection pump not pumping oil fault diagnosis and troubleshooting.

Check whether the delivery valve is worn or

lined with dirt and stains

Replace the delivery valve or clean it.

Check whether the delivery valve spring or

the plunger spring is deformed or broken off.

Replace the damaged components.

Check whether the adjustment spring is

dropped.

Replace and compress the adjustment

arm tightly.

Check whether the adjustment arm and the

shifter fork is struck

Replace or repair.

Check whether the mandril of the delivery

pump is struck.

Check carefully according to the above

steps, find out the fault position and

remove timely

·

15B-38

• The diagnosis and troubleshooting of the “runway in engine”caused by continuous fuel supply of the fuel

injection pump

Check whether the adjustment arm or

Check whether the adjustment arm is

dropped. .

Check whether the governor shaft

sleeve is burned resulted from the

improper lubrication.

Check whether the draw bar stroke

is too small.

Check whether the fly hammer

components are loose.

Yes Replace or repair

Replace and compress the adjustment arm

tightly.

Yes Adjust the draw bar stroke

Yes Fasten the loose components.

Check whether the draw bar circlip is

Install the circlip and readjust

• The diagnosis and troubleshooting of the too high speed governing rate

Check whether the speed governing

torsional spring is deformed or worn

or the stiffness is too large.

Replace the speed governing torsional spring.

Check whether the oil pump corrector

works too early.

Readjust the corrector.

15B-39

• Unstable fuel supply amount diagnosis and troubleshooting.

Check whether there is air or water in

the fuel tank.

Check whether the fuel delivery

pump is damaged.

Yes Bleed the air or water.

Yes Replace or repair the fuel delivery pump.

Check whether plunger spring is

damaged or fatigue.

Replace the plunger spring and check the fuel

injection pump.

• The diagnosis and troubleshooting of engine hunting

Check whether the frictional

resistance in the governor is high.

Yes Repair and remove the fault.

Check whether the axial clearance in

camshaft is too large.

Yes Readjust the axial clearance

Yes Replace the speed governing torsional spring

Fasten the loose components to the specified

standard.

Check whether the lubricating oil is

too much.

Add the lubricating oil according to the standard.

15B-40

Check whether the plunger elements

or the delivery valve is worn

Check whether the corrector is

adjusted improperly.

Replace the plunger elements or whether the

delivery valve is worn

Yes Readjust the corrector

Check whether the high speed limit is

Readjust the high speed limit screw.

loose.

Check whether the plunger spring is

fractured.

Yes Anew replace and compress it tightly.

Check whether the delivery valve is

worn or is lined with dirt and stains.

Check whether is the position of idle

speed fixing bolt is adjusted

incorrectly.

Renew adjust the idle speed fixing screw.

fuel injection pump at a low speed is

wrong

Check the fuel injection pump and adjust the

amount of fuel supply at a low speed.

15B-41

10. Coolant temperature in the cooling system of diesel engine is abnormal ,there is short of

coolant and there is noise.

Diesel engine overheating

• The coolant level is too low (lack of liquid)

• The fan belt is loose or fractured.

• The thermostat valve cannot be opened.

• The water pump has faults.

• Fuel supply timing is not correct.

• The core of radiator is blocked.

Diesel engine supercooling

• The thermostat valve cannot be closed completely.

• The coolant temperature gauge is out of order.

Frequent lack of water.

• The radiator leaks.

• The hose connector of radiator is loose or the hose is damaged.

• The water pump leaks.

• The hose connector of heater is loose or the hose is damaged.

• When meet the engine overheating, you should not stop the diesel engine from working

immediately or add coolant suddenly. You should decrease the accelerator and make it operate

with no load. Check after flameout when the coolant temperature in the cooling system falls.

• When the diesel engine is still hot, do not take down the filler cover in case of scald. Pay special

attention to safety when adding the coolant.

• If the overheat reason cannot be found and removed, you should contact with the service station

or the service plant, or it will lead to damage of the parts.

15B-42

Check whether the coolant level is too

low (lack of liquid)

Replenish the coolant and check whether there

is leakage. Repair according to the demand.

Check whether the fan belt is loose or

Adjust or replace the fan belt.

Check whether the thermostat valve

can be opened.

Replace the thermostat assembly

Check whether there is fault of the

water pump

Replace the water pump assembly.

Check whether the fuel supply timing

is correct.

Adjust correctly the fuel supply timing.

Check whether the core of radiator is

Clean the radiator.

can be closed completely

Yes Go to Step 8

Replace the thermostat.

Check whether the coolant

temperature gauge is out of order.

Measure the coolant temperature, and replace

the coolant temperature gauge.

Check whether there is leakage of

radiator

Repair or replace the radiator

Check whether the hose connector of

Fastening the connectors or replace the hose.

radiator is loose or the hose is

11 Check whether there is leakage of Yes Replace the water pump assembly.

15B-43

water pump. No Go to Step 12

Fastening or replace the hose.

heater is loose or the hose is

15B-44

11. Fuel consumption of lubricating system of diesel engine is large with low pressure.

Consumption of oil is too large.

• Use the oil without conforming to requirements.

• Gasket and oil seal are invalid, causing oil leakage.

• Piston ring or ring slot is damaged.

• Piston ring is clamped in stagnation.

• Oil seal of valve guide pipe, valve guide pipe or valve stem are damaged.

• Cylinder is worn.

The pressure of oil is too low.

• Safety valve is clamped in stagnation.

• Screen filter of oil pump is blocked.

• Driving gear and driven gear of oil pump are worn.

• Oil pipe is cracked or broken or connectors are loosing.

• Faults of oil pump.

• Main bush or connecting rod bearing bush is worn excessively.

• Oil pressure gauge is damaged.

Oil cannot reach valve system.

• Oil hole between cylinder block and cylinder head is blocked.

• Oil hole on rockshaft is blocked.

• Oil hole on the support of rockshaft is blocked.

• Oil hole on rocker is blocked.

If the oil pressure is too lower for lubricating system, diesel engine cannot be operated. In such

situation, stop vehicle at once for inspection and Disassembly of faults.

15B-45

Check whether oil without

conforming to requirement is used.

Replace the oil of specified brand

Check whether gasket and oil seal

are invalid and whether there is oil

Replace gasket and oil seal

Check whether piston ring or ring

slot is worn.

Replace piston ring or piston

Check whether piston ring is

clamped in stagnation

Check whether oil seal of valve

guide pipe, valve guide pipe or

valve stem are worn.

Replace oil seal, valve or valve guide pipe

6 Check whether cylinder is worn.

Repair cylinder bore or replace cylinder liner

Check whether safety valve is

clamped in stagnation.

Yes Replace safety valve

Check whether screen filter of oil

pump is blocked.

Yes Clean or replace screen filter.

Check whether driving gear and

driven gear of oil pump are worn.

Replace oil pump assembly

Check whether oil pipe is cracked or

broken or connectors are loosing.

Repair or replace

15B-46

Check whether there are faults for

oil pump

Check whether main bush or

connecting rod bearing bush is worn

excessively.

Check whether oil pressure gauge

is damaged.

Check oil hole on cylinder block and

cylinder head is blocked.

Check whether oil hole on rockshaft

is blocked.

Check whether oil hole on the

support of rockshaft is blocked.

Yes Replace oil pump assembly

Replace main bush or connecting rod bearing

bush

Yes Repair or replace the oil pressure gauge.

Yes Clean or repair.

Clean or repair.

Check whether oil hole of rocker is

find out the fault position and remove faults in

time

15B-47

12. Faults of supercharging system of diesel engine.

(a). Inadequate power.

• Impurities in oil are accumulated at the seal of turbine.

• Oil temperature is too high and fuel supply is not adequate. Floating bearing is damaged by

burning.

• Oil return pipe of turbocharger is blocked or deformed to cause oil leakage from turbine and shaft

end of compressor.

• Gasket of turbocharger is damaged or invalid.

• Rotor of turbine shaft loses balance.

• Turbine blade and compressor blade are in friction and damaged.

• Air filter is blocked (too dirty).

• Air guide pipe of supercharging compensator is broken.

• There is too much dirt for intake pipe and exhaust pipe or connecting parts have air leakage.

• Turbocharger is in poor operation or damaged.

(b). Fuel injection pump does not supply fuel or provide inadequate fuel.

• The connection of delivery valve is poor or delivery valve is stuck.

• Mebrane of supercharging compensator is damaged.

(c). Fuel consumption is too large.

• There is too much dirt on intake pipe and exhaust pipe or connecting parts have air leakage.

• The property of turbocharger is poor.

• Fuel injector is in poor operation.

• Piston ring is worn.

(d). Consumption of oil is too large.

• Seal ring of turbocharger is worn or damaged.

• There is oil leakage at impeller end of compressor.

• Screws at the connecting place of intake pipe and oil return pipe are loosing and gasket is

• Oil is in poor quality.

(e). Abnormal sound

• There is too much dirt at air channel for turbine and turbine is obviously reduced.

• There is too much dirt at compressor and air channel is reduced obviously.

• The wear of floating bearing is too large and friction is generated among turbine, impeller of

compressor and shell.

(f). Friction is generated among turbine, impeller of compressor and shell to produce vibration.

• Entrance of foreign matter

• The wear of floating bearing is too large.

• Dynamic balance of turbine shaft is weak.

15B-48

• In the process to remove faults and disassemble and install diesel engine, prevent the entrance of

foreign matter to intake and exhaust system strictly, as the rotor of turbocharger is rotating at a

extremely high speed and the clearance between rotor and shell is very small. The entrance of no

matter what kind of foreign matter to impeller will influence the operation of rotor and damage

blade. If the blade is damaged, turbocharger will produce abnormal vibration and noise. At this

moment, stop the vehicle for service of turbocharger.

• If there is oil leakage for turbocharger, but the impeller of spindle does not touch inner shell and

rotates flexibly, do not replace turbocharger casually, but to remove the fault of oil leakage for

continuing use.

15B-49

Check whether impurities in oil are accumulated

at the seal of turbine.

Replace oil and repair turbocharger.

Check whether the oil temperature is too high

and fuel supply is adequate and whether floating

bearing is damaged by burning.

Check fuel supply system and repair

Check whether oil return pipe of turbocharger is

blocked or deformed to cause oil leakage from

turbine and shaft end of compressor.

Repair and replace oil return pipe.

Check whether the seal ring of turbocharger is

damaged or invalid.

Replace seal ring.

Check whether rotor of turbine shaft loses

Repair and replace the rotor of turbine

shaft.

Check whether the turbine blade and

compressor blade are in friction or damaged.

7 Check whether the air filter is blocked (too dirty)

Repair or replace turbine blade and

compressor blade.

Maintain air filter and replace filter

element.

Check whether the air guide pipe of

supercharging compensator is broken.

Service or replace air guide pipe.

Check whether there is too much dirt on intake

pipe and exhaust pipe or connecting parts have

air leakage.

Clean, service or replace intake pipe

and exhaust pipe.

15B-50

Check whether the operation of turbocharger is

good or whether it is damaged.

Check whether the connection of delivery valve

is poor or delivery valve is stuck.

Check whether the mebrane of supercharging

compensator is damaged.

Check whether the turbocharger is in good

operation.

Yes Service or replace turbocharger.

Yes Repair or replace parts

Yes Repair and replace mebrane

Yes Clean, adjust or replace turbocharger.

14 Check whether fuel injector is in good operation.

Repair or replace the fuel injector or

nozzle.

15 Check whether piston ring is damaged.

Check or replace piston ring.

worn or damaged.

Yes Replace seal ring.

Check whether there is oil leakage for the

impeller of compressor.

Yes Service

Check whether the screws at the connecting

place of intake pipe and oil return pipe are

loosing and whether gasket is damaged.

Yes Service and replace gasket.

19 Whether the quality of oil is weak.

Replace oil according to

requirements.

Whether there is too much dirt at the air channel

and turbine is becoming smaller obviously.

Yes Clean and replace

15B-51

Check whether there is too much dirt at

compressor and air channel is becoming smaller

obviously.

Whether the wear of floating bearing is too large

and whether friction is generated among turbine,

impeller of compressor and shell.

Check whether there is entrance of foreign

matter.

Yes Replace the floating bearing

Service or replace turbine shaft.

Check whether the dynamic balance of turbine is

weak.

and remove faults in time

15B-52

13. The capacity of battery is inadequate with difficult starting and too large self discharge.

The capacity of battery is inadequate and it is difficult to start diesel engine.

• The level of electrolyte is too low.

• Short circuit between polar plates

• Vulcanization of polar plate

• Connectors of wire are in poor contact and there is too much oxide on polar column with

inadequate charging.

Self discharge of battery is too large.

• There are impurities in electrolyte.

• There is short circuit at external wire of battery.

• There is electrolyte spilling out at the surface of battery to cause short circuit of passive and

negative polar column.

• Place metal tools or rod between positive polar column and negative polar column, causing

serious short circuit.

• Active substance of polar plate is at loss. Too much accumulation makes polar plate in short

circuit. The damage of clapboard causes short circuit form polar plate. The warping of polar plate

causes short circuit for positive and negative plates.

• It is easy for the discharged gas of battery to be burnt by sparks. In service and maintenance of

battery, avoid striking fire, open fire and smoking. In repair, do not let electrolyte of battery contact

skin and clothes and wear goggles.

• Do not make the two connecting poles of battery become short circuit. Otherwise, the battery will

be heated rapidly and may cause explosion.

• In order to prevent short circuit, dismantle the bond strap of battery firstly in removing and

installing electrical equipment. But in changing bulb, it is only necessary to cut off related

switches.

• In removing battery, firstly disassemble bond strap and then disassemble positive pole line. Next,

disassembly battery baffle and take battery out from the support. The order to install battery is

opposite to the order of disassembly.

15B-53

According to requirements, add the distilled

Check whether the level of electrolyte

is too low.

water or dilute sulfuric acid solution with its

density of 1.1.

Check whether there is short circuit

between polar plates.

Remove sediment and replace electrolyte.

Check whether vulcanization occurs to

polar plates.

Carry out charging and discharging repeatedly to

remove vulcanization.

Check whether line connectors are in

Fasten connection and remove oxide.

good contact, there is too much oxide

on pole column and whether the

charging is adequate.

Go to Step 5

Check whether there are impurities in

electrolyte.

According to regulations, inject electrolyte made

of chemical pure sulfuric acid and distilled water.

Check whether there is short circuit for

external wire of battery.

Check the part of short circuit and remove faults.

Use alkaline water or warm water to clean pole

Check whether there is electrolyte

spilling on the surface of battery to

cause short circuit for negative and

positive pole column.

column head of battery surface and keep the

outside clean. (water cannot be leaked into

15B-54

Whether serious short circuit is caused

by placing metal tool or rods between

positive pole column and negative pole

column.

Do not place metal tools or rods on the surface of

battery.

Whether the active substance of polar

plate is at loss and too much

accumulation causes short circuit of

polar plate. Damage of clapboard also

causes short circuit of polar plate.

Warping of polar plate causes short

circuit for positive pole plate and

negative pole plate.

Repair or replace the battery

15B-55

14. Faults of starter

Starter is used to transfer the electric energy of battery to mechanical energy and generate electromagnet to

drive engine to operate at regulatory rotation speed and make engine start and operate. The fault of starter is

usually reflected as follows: turn on ignition switch, but starter does not operate and the starting of starter is

powerless to make starter in empty operation. In starting, there is abnormal sound for driving gear and

approach action of flywheel ring gear.

(a). Turn of ignition switch, but starter does not operate.

• The wire is in poor contact.

• Battery is lack of electricity seriously or there is short circuit inside.

• There is short circuit inside starter.

• Bearing or bushing of starter is worn.

• The line is broken for control circuit of starting switch.

• Carbon brush is in poor contact with commutator.

(b). Starter is powerless.

• The charging of battery is not adequate.

• There is short circuit for the lead of starter.

• Battery terminal is corrosive or wiring clip is loosing.

• There is short circuit for field winding of starter or armature winding.

• The assembly of starter is too tight or there is sweeping phenomenon.

• The resistance of engine is too large.

• Capacity of battery is not adequate.

• There is burning damage or oily dirt on the surface of commutator.

• Carbon brush is worn excessively or elasticity of carbon brush is not adequate, causing its poor

contact with commutator.

• Main contact of electromagnetic switch is ablated, causing poor contact.

• Bearing wear is serious and armature is in contact with shell.

(c). Idle operation of starter.

• One-way clutch is damaged.

• Check whether the electromagnetic switch of starter is damaged.

(d). There is abnormal sound for driving gear and approach action of flywheel ring gear.

• Driving gear or flywheel ring gear is worn seriously.

• Electromagnetic switch of starter is damaged.

(e). Diesel engine is started, but starter is still in idle operation and sound sharp noise.

• Inner copper contact disc of starter relay is in adhesion with two contacts.

• Armature shaft of starter is broken or bended.

• Sgraffito of gear surface is stuck.

15B-56

Do not exceed 15s in starting starter for operation and the time interval of two starting shall be more

than 2 minutes to avoid too hot starter damaging internal parts. If it can not be started for three times

continuously, check engine, fuel system, electromagnetic switch, starter, battery and wiring terminal

and re-start it after removing faults. Loose the ignition switch right away once engine is started for

operation and back the self meshing position of engine gear and stop operation.

Fault diagnosis and troubleshooting

• Diagnosis and removal for the non-operation of starter

Check whether there is poor contact

in connecting line.

Check whether battery is lack of

electricity serious or open circuit

inside.

Check whether the internal line of

starter is broken.

Whether there is short circuit for

internal line of starter.

Fasten the connectors of line and replace

connectors if necessary.

Charge the battery and replace battery if

Repair of replace starter

Repair or replace starter.

5 Check whether fuse is broken.

Check whether the bearing or

bushing of starter is seriously worn.

Yes Replace the fuse.

Yes Repair or replace starter.

Check whether the line of starting

switch and control circuit is broken.

Check whether the circuit is in reliable

connection.

Check whether carbon brush is in

good contact with commutator.

Adjust the spring pressure of carbon brush and

clean commutator.

15B-57

• Diagnosis and Disassembly of powerlessness of starter

Check whether battery charging is

adequate.

Yes Charge the battery

Check whether the connectors of lead of

started is in good contact or short circuit.

them if necessary.

Check whether the wiring terminal of

battery is corrosive or wiring clip is loosing.

Remove the corrosive and fasten the fixing

bolt of wiring clamp.

field winding or armature winding of starter.

Check whether the assembly of starter is

too tight or swept.

Repair starter and replace the worn parts if

Check whether the resistance of engine is

too high.

Yes Remove the resistance causes of engine.

Check whether the capacity of battery is

Check whether there is burning damage or

oily dirt on the surface of commutator.

Charge the battery according to

regulations.

Polish the surface of commutator or

remove the oily dirt.

Whether the wear of carbon brush is too

much or the spring elasticity of carbon

brush is inadequate, causing its poor

Replace carbon brush or adjust the spring

pressure of carbon brush.

Check whether the main contact of

electromagnetic switch is ablated to poor

contact.

Yes Use “0” non-metal sand paper for polishing.

15B-58

Check whether the bearing is worn

seriously and whether the armature

touches the shell.

Replace the bearing

remove faults in time

• Diagnosis and Disassembly of idle operation of starter

1 Check whether one-way clutch slips.

Replace one-way clutch

Replace electromagnetic switch of starter.

Check whether electromagnetic switch of

starter is damaged.

• Diagnosis and Disassembly of abnormal sound for driving gear and approach action of flywheel ring gear

Check whether driving gear or flywheel

ring gear is worn seriously.

Replace the worn parts

Replace the electromagnetic switch of

starter.

15B-59

• Start the diesel engine and starter continues to operate, then, carry out diagnosis and Disassembly of

sharp noise.

Check whether copper contact disc in

starter relay is in adhesion with two

contacts.

Cut off power at once, check the line and

repair contacts.

Check whether the armature shaft of

starter is broken or bended.

Cut off power at once and replace starter.

Cut off power at once and trim gear surface

Check whether sgraffito of gear surface

is stuck.

15B-60

15. Faults of generator

(a). Generator does not generate power.

• The line is in poor contact, wrong connector or broken.

• The line of stator and rotor is in short circuit or broken.

• The rectifying valve is damaged, causing short circuit or open circuit.

• Electric brush is in poor contact, there is oily dirt for slip ring and the belt of generator is too

loosing.

• Regulator is damaged.

(b). Charging of generator is inadequate.

• The transmission belt is loose.

• Carbon brush is in poor contact and there is oily dirt for slip ring.

• There is too little electrolyte for battery of the vulcanization of polar plate is too serious or it is too

aged.

(c). Charging current is not stable.

• Short circuit is to occur to rotor coil and stator coil.

• Electric brush is in poor contact, spring pressure of electric brush is small and line is in poor

(d). Generator produces abnormal sound.

• The installation of generator is not proper and bearing is damaged.

• Rectifying valve and rotor coil are in short circuit.

15B-61

• Diagnosis and Disassembly of the faults for no power generation of generator

Check whether line is in poor contact or wrong

Check and repair

Check whether rotor coil and stator coil is in short

Service or replace

Check whether rectifying valve is damaged,

causing short circuit or open circuit.

Repair or replace as a unit.

Check whether electric brush is in poor contact,

there is oily direct for slip ring and belt of

generator is too loosing.

Repair or clear or adjust the tension of

belt.

Repair or replace regulator.

5 Check whether the regulator is damaged.

• Diagnosis and removal for the faults of inadequate charging of generator

1 Check whether transmission belt is loose.

Adjust the tension rate of belt.

Check whether carbon brush is in poor contact or

there is oily dirt for slip ring.

Adjust and clean

3 Check whether regulator is damaged.

Replace regulator

15B-62

Supplement electrolyte to regulatory

Check whether there is too little electrolyte for

battery of vulcanization of polar plate is serious

height. For the battery without

recoverable vulcanization of polar

plate, replace it.

or it is too aged.

• Diagnosis and removal for unstable charging current

Check whether short circuit occurs to rotor coil

and stator coil.

Check whether electric brush is in poor contact

and the spring pressure of electric brush is too

small and line is in poor contact

position and remove faults in time

Check whether the installation of generator is

proper and bearing is damaged.

Check whether rectifying valve and stator

coil are in short circuit.

ENGINE MECHANICAL PART-ENGINE MAINTENANCE

15B-63

ENGINE MAINTENANCE

1. General Precautions

During the operation, perform the adjustments and maintenances in accordance with the

maintenance methods and various regulations specified in the manual.

The new engine or the engine after being serviced shall not be allowed to run with full load at high

speed. The engine shall run for 45h from at a low speed with no-load to a high speed with full load,

and then the engine shall run with normal load.

The fuel which is used by the engine shall be precipitated for a week or be filtered by a silk before it is

used.

The normal coolant temperature shall be 80 ℃ -90 ℃ and the normal oil pressure shall be

280-400kPa.

During the process of running, if a abnormal phenomenon is found out, stop the car and check it.

2. Precautions for Running and stop of Engine

Gradually and equably perform the engine’s load and rotation speed and car’s running speed

increasing and decreasing. Except in special circumstances, do not suddenly change the load and

During the process of engine’s running and the car’s running, pay attention to whether the registration

of each meter is normal or the running conditions of engine (running sound and the discharge smoke

color). If the registration is abnormal, please take measures or stop running.

The running coolant temperature shall be about 358K (85℃) and the oil pressure is 196~490kPa

under normal circumstances.

The car cannot adopt the operational approach of “accelerate-shut down-neutral position’s

slide-ignite by putting the clutch into gear”.

The reasons are as follows:

• The engine suddenly shuts down with high speed and high temperature, the oil pump and water

pump will stop working, which can not make the lubricating oil and coolant carry off the heat of the

• For the ignition by putting the clutch into gear, if the speed is about 40km per hour, it indicates that

the engine starts at a rotation speed of 1300r/min with large impact force, which is harmful to the

Before stopping the car, the engine shall decrease the load and speed. After the car stops, the engine

will run for 3-5min and then stops. The aim is to gradually and equably cool down the engine to avoid

overheating the engine and damaging some parts.

3. Precautions for Generator

The center of the generator pulley shall be aligned with that of the drive wheel and the tension of the

belt shall not be too tight or too loose, or it will impair the reliability and service life of the generator.

The generator shall be in parallel connection with the battery and shall be matched with appropriate

model of regulator, in which the wiring shall be secure and reliable.

Both the generator and the battery shall be negative grounded (earthed), or it will burn out the

generator and the regulator.

15B-64

Use a multi-meter, instead of using the test method of ignition to ground, to check whether the

generator is generating power.

Frequently remove the dust and oil sludge from the generator and maintain the good wiring.

Maintain the generator at interval of 1,000h. Check the electric brush for presence of wear, clean the

bearings and add an appropriate amount of lubricating oil (The amount added shall be 2/3 of the

bearing chamber). No maintenance is required for the double sealed bearing.

During the running of the generator, it’s absolutely prohibited to disconnect the connecting wires, in

order to prevent short-circuit from burning out the silicone rectifying unit

When the silicone rectifying unit is connected with the stator coil, it’s absolutely prohibited to check

the insulation status of the generator with mega-meter or 200V AC, or it will lead to puncture of diode

and damage

4. Precautions for vacuum pump

The pressure oil connects with the connector of oil inlet, the vacuum pump connects with the

connector of exhaust gas and the engine body connects with the connector of oil return. Each

connector shall be sealed.

Check whether the pump body and pump base have crack and whether the pump core and generator

spline shaft fit and the inner working face have wear and scratches. If any damage is found out, and

then replace them.

The blade width shall be ≥3mm, which can ensure the exhaust gas property. If any damage is found

out, and then replace them.

If the oil leak is found, find out the place of leaking oil and then maintain and replace it.

Ensure the lubricating oil’s cleanness and proper viscosity during its use. Do not make the engine

work without lubricating oil, or else it can seriously damaging the vacuum pump.

5. Precautions for starter motor

Before the use, check the engine and use the starter motor after it’s determined that the engine can

run normally.

When connecting the starter’s circuit, the copper wire sectional area for connecting electric power

storage shall not be less than 25mm2 , the sectional area for connecting switch wire shall not be less

than 4mm2 and the wire shall be short as much as possible. Before starting, check whether the starter

circuit connection is correct, the connection is tight and whether the battery is fully charged.

After the preparations, press down the electromagnetic switch, the starter’s gear meshes starter’s

flywheel ring gear, and then it begins to run. Under normal circumstances, it can be started once. If it

cannot be started once, after the starter’s armature and gear are completely at a standstill, it can be

started for the second time, or else the starter will fiercely hit against the starter ring gear and the

starter will be damaged.

In cold days, pre-warm the engine, and then use it.

The start time for starter shall not be more than 15s, and the interval between two times of start shall

be more than 2min to avoid overheating the starter.

When the starter cannot normally start for consecutive three times, please eliminate fault and then

start the starter.

When the starter begins to run, please immediately loosen the switch button to make starter gear

return from meshing position and stop running in order to avoid damaging the starter.

Frequently check whether the connection of starter’s fastening pieces are tight, whether the lead

15B-65

connection is tight. And eliminate the pollution, put a little vaseline to avoid corrosion.

(h). Frequently check whether the wire insulation is damaged.

(i). Disassemble dustproof belt at regular intervals to check whether the surface of commutator is bright

and clean and whether the brush has hysteresis phenomenon and the spring pressure is normal.

Clean the dust, and if the brush wears a lot, the surface of commutator singes and other faults are

found out, please immediately disassemble it to make repairs and supply replacements.

(j). The starter motor shall be overhauled once a year. Depending on the actual condition, the overhaul

interval may be shortened or prolonged appropriately.

6. Precautions for turbocharger

(a). The lubrication of floating bearing of turbocharger shall use CF-4 lubricating oil. Clean the oil filter at

regular intervals and replace the lubricating oil.

(b). After starting diesel engine, immediately decrease the accelerator to make the diesel engine run at

low speed. When the oil pressure rises, accelerate “heating of turbine”.

(c). The diesel engine shall not suddenly stop with high load at high speed.

(d). The new diesel engine or the diesel engine after being repaired, replaced diesel engine or the engine

with cleaned turbocharger, replaced oil or with cleaned filter shall screw off the oil inlet connector of

turbocharger and turn off the injection pump before start. Drive the diesel engine by starting engine for

few seconds (less than 10s), screw up the diesel engine when lubricating oil spills from the oil inlet

connector of turbocharger. Fill 60~100ml lubricating oil (oil) in the oil inlet of turbocharger, and then

start the diesel engine.

(e). Frequently check the tightness of intake pipeline and exhaust pipeline to avoid air leakage.

(f). Pay attention whether the turbocharger has abnormal sound during the running of diesel engine.

(g). If the diesel engine’s rotation speed is not stable during the running, turbocharger fiercely shake and

the intake pipe has rumble sound, which means that the turbocharger surges, please clean the air

filter element and intake pipeline.

15B-66

OPERATIONS

1. Fuel, Oil, and Coolant

Fuel

User can select diesel according to local ambient temperature. In summer 0# light diesel oil is be

suitable and in winter -10# light diesel oil is suitable in general area in China. In cold area, -35# and

-20# light diesel can be used.

• When the working temperature for diesel is low, wax material shall be separated out if using

incorrect grade, then the oil line will be blocked. Therefore, the diesel with correct grade shall be

determined according to ambient temperature.

• Do not fill oil in the fuel tank when the diesel engine is running. If the car runs in hot weather, the

fuel tank cannot be fully filled, or else the fuel will spill because of expansion. Once the fuel spills,

clean it immediately.

Oil

Please respectively select lubricating oil with viscosity grades of 5W/50 ( used in the temperature

range of -30℃~+ 40℃) and 10W/30 ( used in the temperature range of -25℃~+40℃), property

grade of CD, CE or higher grade according to local atmospheric temperature. The Great Wall brand,

Uniform brand and Kunlun brand are recommended. Disassemble the filter cap from the cylinder

head cover and then fill oil in the engine. Disassemble the oil outlet bolts from the oil pan and then let

the oil out.

• After the diesel engine is supercharged by air turbine, both mechanical load and thermal load are

greatly raised. The turbocharger which is a precision running component with high speed and

high temperature has strict requirements for the quality of lubricating oil. Therefore, the clean oil

according to required brand cannot be replaced by low grade or poor quality oil to avoid faults

such as scuffing of cylinder bore, bush burning and turbocharger damaged.

• The oil in the diesel engine shall not include impurities and moisture. When changing oil for

technical service, the old and new oil can be mixed to use.

Water coolant

The water which is processed by anti-erosion and anti-corrosion can be taken as coolant in the area

with temperature of more than 0℃. This kind of coolant contains the anti-erosion and restrainable

type of glycol. The anti-corrosion inhibitor adopts sodium nitrite/ sodium benzoate. Anti-freezing

mixed liquor shall be characterized by good cooling property and shall provide anti-corrosion

protection under any ambient temperature. The specification of anti-freezing mixed liquor at least

meets the requirements of BS6580 or MODAL39. When the engine is used under the ambient

temperature of lower than 0℃, avoid the coolant to be frozen to make the relevant parts frost crack.

The engine which adopts closed cycle coolant system can use antifreeze solution with proper

condensation point or fill hot water before start according to ambient temperature. But when it stops,

please immediately turn on the water.

• Anti-freeze solution is poisonous, so the anti-freeze shall be stored in the original container to

avoid contacting people.

15B-67

2. Preparation before start

(a). Check whether each connection for starter is tight and whether the operating handle (accelerator and

shutdown handle and etc.) are flexible.

(b). Rotate the crank a few rotation to check whether the motion parts are flexible without being stopped

phenomenon.

(c). Check whether the oil pan and oil surface of oil pump are in upper limit position in the range of oil

gauge’s scale.

(d). Check whether the water tank is full and whether each water pipe connector leaks.

(e). Check whether the fuel tank is full of diesel, the fuel line is unblocked and whether each oil pipe

connector is sealed or has no leakage.

(f). Check whether the engine accessories’ connection is dependable (fuel injection pump, diesel filter, oil

filter, water pump, fan, generator and generator support, fan belt, starter, water tank and etc. )

(g). Check whether each connector of electrical system is correct, tight and dependable. The battery shall

be sufficient and silicon rectification generator’s negative pole shall be grounded. Pay attention that

the battery wiring’s negative pole shall be grounded.

3. Start diesel engine

Do not start the diesel engine until the preparations before start are fulfilled. Before starting the engine, check

the surrounding area of the diesel engine for the presence of any article obstructing the working of the diesel

engine. Start the engine only after such article is kept away.

(a). Start with normal temperature (higher than -5℃)

• Shift the gearshift lever of the transmission to neutral position. ·

• Put the lock switch on the position “ON”, and then pause for about 2-3 seconds and then check

whether each meter display is normal. Please power up ECU. The engine shall not be directly

stared without electricity.

• When the fault lamp is on, stop the car immediately, and then contact the service station to treat

fault and eliminate the fault code.

• If the diesel engine does not start, the electric switch lock shall return “OFF” position. After the

starter motor stops rotating, start the diesel engine.

• ·After the diesel starts, keep the diesel engine run at idle speed. Check whether the oil pressure is

normal, whether the turbocharger has no abnormal sound and vibration, the oil pressure shall be

less than 0.1MPa. The supercharged and cooling diesel engine shall not run at idle speed for 5

(b). Start with low temperature (lower than -5℃)

• Put the gear lever of transmission in the neutral position and depress the clutch pedal to reduce

starting load.

• Put the lock switch in ON position, pause for 2-3 seconds at least, then check whether each meter

display is normal. Please power up ECU. The engine shall not be directly stared without electricity.

• When the coolant temperature is lower, the preheating indicator on the fascia is usually on, which

indicates that the preheating system is working and the heater plug powers on and is preheated.

After finishing preheating, the preheating indicator is off, then the operator can start diesel engine.

If the operator does not start the diesel engine timely, turn off the switch lock for 20 seconds, and

15B-68

then repeat the above steps to preheat and start again.

• When the heater plug finishes preheating and the preheating indicator is off, depress the clutch

pedal, put the ignition switch in START position to start the diesel engine.

• If the diesel engine does not start smoothly, the electric switch lock shall return OFF position. After

the starter motor stop running, try to start the diesel engine again. When the diesel engine stops to

start again, the interval time shall be more than 60 seconds.

• After the diesel engine successfully starts, put the lock switch on the ON position from START

• When the temperature is lower than -25℃ and there is trouble for start, let the anti-freezing and

anti-corrosion solution out and then preheat the diesel engine with boiled water. Fill higher than

90℃ hot water in radiator, after the water becomes cool then let the water out, fill hot water again

to start and run, and then let hot water out again, finally fill anti-freezing and anti-corrosion solution

again. During the period of preheating, after the diesel engine starts, the coolant’s cycle shall not

pass through radiator because the thermostat valve is closed. Therefore, in order to reduce the

chance of coolant’s freeze in the radiator, adopt hot water and put a radiator blind in front of the

• After the diesel engine starts, keep the diesel engine running at idle speed and check whether the

oil pressure is normal and turbocharger has abnormal sound and vibration. The oil pressure shall

be no less than 0.1Mpa. But the supercharging and cooling diesel engine shall not run at idle

speed for more than 5 minutes. When the temperature is lower than -25℃, after start the diesel

engine, the diesel engine shall run with no load at low and medium speed and preheat for several

minutes to “heat the engine”. In order to raise the coolant temperature as much as possible, do not

turn on the heater switch when heat the engine. When the coolant and lubricating oil temperature

is higher than 50℃ and each system is in normal working condition, turn on the heater switch and

allow the diesel engine works with full load at the maximum rotation speed.

NOTE;

• The time for each start shall not exceed 15 seconds in order to protect the starter motor and

battery. If one start fails, wait for at least 2min before retry. If the engine can't be started by three

consecutive starts, find out and resolve the cause before retry.

• When starting the diesel again, please return the lock in OFF position, else the ECU fault will

happen.

4. Run diesel engine

When the cooling coolant temperature is higher than 50℃, the diesel engine can work with load. The

outlet coolant temperature shall be higher than 80℃ when using rated power.

The increasing and decreasing for engine’s load and rotation speed shall be gradually and uniformly

carried on. Under general circumstance, do not suddenly increase or decrease the load.

During the period of running, please pay much attention whether meter reading is normal, whether

fuel, cooling system and lubrication system have leakage and pay much attention to the discharged

smoke color and running sound. If there is abnormal sound, please stop the car and check it.

15B-69

5. Stop diesel engine running

(a). Before the diesel engine stops running, please decrease load and reduce the rotation speed to idle

speed and the coolant temperature shall be lower than 75℃, and then operate the shutdown handle

to make the diesel engine stop running.

(b). After the engine stops running, screw the ignition switch in neutral position.

(c). When the ambient temperature is lower than 5℃ in winter, then the engine shall stop running after

the coolant temperature is lower than 60℃. Switch on the water drain switch of engine body and

water tank, let the coolant out to avoid frost crack. If the antifreeze solution is used, and then do not let

the water out.

15B-70

MAINTENANCE

1. Regular Maintenance

In order to increasing the diesel engine’s service life, the following procedures shall be adopted for

maintenance during the process of service.

Check whether the oil level in the oil pan is in the position between two scribed lines of dipstick. Fill oil

in the new engine or the engine which stops running for a long time until the oil being at the scribed

line, then make the engine run at a low speed for 5-10 minutes and stop the engine diesel, and then

measure the oil level height with dipstick.

Check the water amount of water tank.

Check the injection pump and oil level of governor, if the oil is not enough, then supplement the oil

until the oil level is at specified position.

Check and eliminate the phenomena of oil leak, water leakage and air leakage.

Check each accessory’s tightness of engine.

Check the tightness of engine’s bracket and coupling.

Keep the engine clean and eliminate the greasy dirt and dust and specially keep the electric

equipment dry and clean.

After the new engine runs in with light load for 45 hours, please timely replace the oil (including the oil

in injection pump and governor) and please clean oil filter element.

Eliminate all abnormal phenomena which are founded out.

2. Maintenance after running for 100 hours

Replace the oil in the oil pan.

Clean or replace the oil filter element.

Clean or replace diesel filter element (or carry on after accumulative total 200 hours)

Check the tightness of bolts of cylinder head.

Check whether the value clearance is in accordance with the regulations. If necessary, please adjust

it.

Check the tension of fan belt. If necessary, please adjust it.

Eliminate the dust on intake pipe and air filter.

Check the situation of fuel injection pressure and fuel injection after accumulative 200 hours. If

necessary, please clean and adjust it.

(i). Check battery voltage. The electrolyte proportion shall be 1.28-1.29 (atmospheric temperature is 15℃)

and shall not lower than 1.27. Check whether the electrolyte liquid level is 10-15mm higher than pole

plate, or else the distilled water shall be supplemented.

Replace coolant according to the water quality’s turbidity. Take out thermostat, reinstall outlet water

pipe and start the engine while changing rotation speed from time to time. Wash the precipitate of

cooling system with coolant’s flow velocity and then stop the engine running, open the water tank and

switch on the water drain switch to let water out. Continuously inject clean water from the water tank

and then start the engine to run at idle speed to make the water flow. Check water quality timely until

the water is clean. Switch off each water drain switch and stop the engine running and then reinstall

the thermostat.

Reassemble the parts and components which are maintained in correct installation position.

15B-71

3. Maintenance after running 500 hours

The maintenance after running 500 hours includes the procedures of maintenance after 100 hours and shall

contain the following procedures too.

(a). Check the fuel injection pressure of fuel injector and observe atomization quality. Clean and adjust it.

(b). Check fuel injection advance angle. If necessary, please adjust it.

(c). Disassemble cylinder head and eliminate carbon deposit. Check the tightness of air valve, if it is not

accordance with the requirements, and then grind it.

(d). Check the tightness of connecting rod bolts, main bearing bolts and flywheel bolts.

(e). Re-screw up cylinder head bolts in order and adjust the valve clearance according to regulations.

(See Chapter 08 Assembly of Engine)

(f). Clean or replace air filter element (according to the amount of environmental dust, perform the

“maintenance after 100 hours” in advance or after shorter time)

(g). Replace the oil of injection pump and governor.

(h). Clean the cooling system. The cleanout fluid consists of 150g caustic soda (Na OH) and 1L water.

Before cleaning, let all water of cooling system out, and then fill cleanout fluid. When the coolant

temperature reaches the working temperature, stop the engine, let the cleanout liquid out to avoid the

water scale which floats in the cleanout fluid precipitating and then clean the cooling system with

clean water.

(i). Check the working situation of thermostat.

(j). Check each part of electric equipment for start. Check whether the fastening pieces are tight and

whether the contact of wire is tight. If there is burned mark, please replace it.

(k). Check each parts of engine. If necessary, please maintain and adjust them.

The user can carry out more careful maintenance according to situation in addition with the above regular

4. Seal up for safekeeping

(a). Thoroughly clean engine appearance.

(b). The fuel system can be full of common fuel, but when the storage period expires, let the fuel out. And

the fuel and the fuel’s filter element are declared worthless.

(c). Run the engine until the engine is hot, and then discharge fuel. When the engine stops running, let

lubricating oil of oil pan out.

(d). Replace lubricating oil filter element.

(e). Fill the new clean lubricating oil in the oil pan until the dipstick has full scale.

(f). Fill the antifreeze solution which has anti-corrosion function in order to avoid the cooling system

corrode.

(g). Run the engine for a short time to cycle the engine’s lubricating oil and coolant.

(h). Clean the engine’s air-pipe and seal the pipe ends.

(i). Disassemble the air filter. If necessary, disassemble the connecting pipe between the air filter and

intake manifold and seal the intake manifold with waterproof tape.

(j). Seal the intake manifold, fuel tank’s air pipe and with waterproof tape.

(k). Disconnect the battery and then store the battery after the battery is fully charged. Before storing the

battery, carry out anti-corrosion treatment for battery.

(l). Disassemble the transmission belt of generator and store it well.

15B-72

5. Running in

Make the new engine running in before it is used to make each kinematic pair operate normally and to avoid

abnormal wear and damaged. The experience proves that the service life of engine, economical efficiency

and dependability of work are greatly determined by the situation of running in for engine at the initial

operation, so please strictly carry out the maintenance regulations for running in.

(a). Running in specification

• Running in period:

The running period is about 50 hours; the whole car can carry out running in together. The running

in mileage is 1500~2500 kilometers.

• The running in period’s requirements for load and speed are as follows:

Mileage (kilometer) Highest load Highest speed

0~200 No load —

300~1000 50% rated load 70% rated speed

1000~1500 75% rated load 75% rated speed

1500~2000 Full load Not faster than the highest speed

15B-73

Running maintenance content and standard:

Number Content Standard

1 Replace lubricating oil of oil pan

The brand shall be selected according to ambient

Clean the oil pan and replace the paper oil

filter element

The parts and components shall be produced by

formal accessory manufacturers

3 Clean the air filter element

4 Replace paper diesel filter element

5 Check connecting rod bolt torque 155N·m

6 Check cylinder head bolt torque 75N·m

7 Check and adjust valve clearance

8 Check fan belt tension

9 Check fuel supply advance angle

Cold car, Inlet valve 0.2mm

Exhaust valve 0.45mm

Add 45N force on vertical single belt, deflection

is10 mm

According to requirements of Operating Instruction

Manual

10 Fasten the exposed bolts and nuts According to requirements

Clean oil inlet filter screen of fuel delivery

pump

No dirt and no damage

15B-74

BASIC MAINTENANCE

1. Determine the maintenance period

Growth rate of oil consumption

Suppose that the new oil consumption rate (mileage every hour or the running hours) is 100%, when

the oil consumption rate reduces to 50%, and then the engine shall be maintained.

Growth rate of fuel consumption

Suppose that the new engine fuel consumption (mileage every hour or the running hours) is 100%,

when the oil consumption rate reduces to 60%, and then the engine shall be maintained.

The inside has abnormal sound

There are various reasons for abnormal sound, for example, the engine has lots of wear or is

overheated or the operation and maintenance are improper. So the engine shall be maintained early.

2. Determine cylinder bed quality

The cylinder head gasket is placed on the connection of cylinder head’s bottom and the engine body’s top

surface to form air sealed chamber under the function of high strength cylinder bolt and to make burning

gasses push forward the pistons work and not leakage outward. At the same time, it can carry out seal

function for cycling coolant and pressure oil which leads to cylinder head and lubrication rocker mechanism.

There are high requirements for cylinder gasket’s tightness and heat resistance, so the engine adopts

composite plate cylinder gasket and the cylinder hole edge is sealed with steel plate. And the inside has steel

wire protecting ring, and the edges of water hole and oil hole are sealed with copper sheet or are processed

specially. They have good tightness and longer service life.

(a). Check whether the cylinder bed has cracks and whether the water hole and oil hole are connected

together. If yes, then replace the cylinder bed.

(b). Measure the clearance of piston head when replacing cylinder, and the piston head clearance shall

be in the range of 0.9~1.1mm.

3. Adjust the valve clearance

Check and adjust the valve clearance when the engine is serviced or maintained.

(a). Check and screw up the nuts of valve rockshaft bracket when removing the cylinder head.

(b). Rotate the crank in the dead center of the first cylinder piston, at the this moment the observation

mark of flywheel housing is rightly aligned with “O” scribed line of flywheel or the “O” scribed line of

crankshaft pulley is aligned with the indicator of timing gears cap.

(c). Insert a thickness gauge thinness gauge into the first cylinder, exhaust valve and rocker respectively.

Check and adjust the inlet valve clearance and exhaust valve clearance. The clearances are

respectively 0.2 and 0.45mm when cold starting. Rotate the cranks of four cylinders 180°according to

working order of 1-3-4-2 and adjust each cylinder’s valve clearance.

15B-75

4. Adjust the fuel supply advance angle

In order to obtain the most economic fuel consumption and good running property, properly adjust fuel supply

advance angle.

(a). Eliminate the air of fuel system and repeatedly rotate the crank to make the injection pump full of fuel.

(b). Disassemble the first cylinder’s high-pressure oil pipe and pull the accelerator operating handle in the

position with maximum fuel supply amount. Rotate the crank in a clockwise direction from engine

head to make the first cylinder piston is at compressed dead center.

(c). Rotate the crank more than 60°in reverse direction, then slowly rotate the crank in clockwise direction

and observe the oil outlet situation of outlet valve support. When the oil level begins to wave, it

indicates that the first cylinder begins to supply oil. At this moment, please stop rotating the crank and

check the difference between the scribed line of timing gear chamber cover and the scribed line of

pulley to determine the fuel supply advance angle. If the scribed line of pulley is in front of the scribed

line of timing gear chamber cover, it indicates fuel supply in advance. If the scribed line of pulley is on

the back of the scribed line of timing gear chamber cover, it indicates fuel supply hysteresis. The

engine’s fuel supply advance angle shall be 10°±1°.

(d). If the fuel supply advance angle does not meet the requirements, loosen the bracket of injection pump

and the nuts of pump end flange and adjust it by using the of pump end flange. When the pump body

is close to the engine body, then the fuel supply advance angle is increased. And when the pump end

body is far away the engine body, then the fuel supply advance angle is reduced. The outer edge of

pump body flange rotates 1mm arc length, and the fuel supply advance angle is increased or reduced

about 1°of crank angle.

5. Adjust fuel injector

The fuel injector is tested and adjusted on the tester of fuel injector to adjust the fuel injection pressure and to

observe the atomization quality and to treat faults. When the fuel injection pressure of injector is too high or

too low and the fuel injection is abnormal and the parts are damaged, the engine will appear faults, such as

pouring up smoke, the power and rotation are reduced, discharging temperature rises or piston slap. The

method of stop cylinder in turn can be adopted to determine the fuel injector with fault. The method is:

gradually loosen the coupling nut between fuel injector and high-pressure oil pipe and stop fuel injection, at

the same time observe the exhaust smoke color. If the fuel injector has fault, the exhaust will stop smoking,

and the engine rotation has no change or little change. Rotate the flywheel to listen to injection sound of each

cylinder one by one, when the ringing injection sound is not heard, it indicates that the fuel injector may have

fault.

(a). Install the fuel injector in the tester of fuel injector.

(b). The gauge pressure shall be 180×10pa by manual pump. Continuously slowly press the manual

pump to raise the gauge pressure to 200×10pa and to inject oil. Observe the fuel spray nozzle’s oil

hole and make it has no oil drip and leakage. If after test for many times, if there is also oil drip,

disassemble the injection nozzle couple to clean. After checking and grinding it, please test again.

(c). Adjust the fuel injection pressure, disassemble the pressure regulating nut of fuel injector, and then

unscrew or screw up the pressure regulating bolts to make the fuel injection pressure is 200×10pa.

Screw the pressure regulating nut and test it again.

15B-76

Observe atomization quality and carry out atomization test with fuel injection speed every minute. The

oil mist shall be fine mist. And the splashed oil which can be seen with naked eyes shall not be

appeared, and the phenomena of uneven concentration and one side’s fuel injection shall not be

appeared. And the ringing sound shall be heard when cutting off the fuel.

The abnormal fuel injection is normally caused by inflexible motion of injection nozzle. Oil drip of jet

orifice is caused by damaged seal surface. Oil injection branch is caused by the head carbon deposit

and thermal deformation of injection nozzle.

6. Adjust oil pressure

(a). Loosen the lock nut.

(b). Twist the pressure regulating bolts with wrench to make the oil is 280~400kpa (the oil can be higher

when cold starting).

(c). After adjustment, screw up the nut.

7. Adjust injection pump

The injection pump has already been adjusted and checked before factory. If the injection pump needs to be

adjusted again, the injection pump shall be adjusted on the professional injection pump tester with standard

fuel injector and standard length of high-pressure oil pipe.

8. Adjust the fan pulley

(a). Add 45N force on the single belt which is in the middle position of two wheels and the deflection is

about 10mm.

If the fan pulley is not accordance with the requirements, please adjust it with the following method.

• Loosen the adjusting screw of the bracket of engine.

• Pry out the generator from the outboard of engine with strength pipe and then lock the screw of bracket of

generator until it is up to the standard.

9. Exhausting of fuel system

If the pipeline from fuel tank to fuel delivery pump has air, please exhaust it when replacing diesel filter

(a). Screw the manual oil pump handle out, press up and down to supply oil for fuel system.

(b). Loosen the small oil return pipe of fuel filter and exhausting bolt of injection pump and continue to

supply oil with manual oil pump until the oil runs out and no bubble exhausts.

(c). Screw the bolts and screws and at the same time screw the manual oil pump handle.

ENGINE MECHANICAL PART-DISASSEMBLY/ASSEMBLY OF COMPLETE ENGINE

15B-77

DISASSEMBLY/INSTALLATION OF COMPLETE ENGINE

1. Park the vehicle on the vehicle trough or the vehicle service bench.

2. Shift the parking brake lever to parking position.

3. Block the wheels with triangular wood or wedge. The triangular wood or the wedge shall be placed

closely before and after the wheels, preferable the rear wheels.

4. Switch off of ignition switch before removing the complete engine (the ignition switch shall be at OFF

position) and take down the ignition lock.

5. Put a warning sign “No start” in steering wheel or the driver’s seat when working under the car.

6. Keep away from the fire source while removing the complete engine.

7. When disconnecting each connecting pipeline of engine or assembly component, put the

disconnected pipeline or assembly component in the position where has no influence on the position

of removing the engine and make the corresponding mark for installation. Fix the air condition

compressor, clutch slave cylinder assembly on the frame with a rope to avoid falling off and

damaging.

15B-78

DISASSEMBLY PROCEDURE

1. Open the engine hood

2. Discharge the engine lubricating oil and discharge

the engine coolant

• When the engine temperature is higher, do not open

the radiator’s pressure cap or discharge coolant. The

radiator’s pressure cap can be opened when the

coolant temperature reduces to lower than 50℃, or

else the coolant with high temperature and erupted

steam may cause personal injury.

• The coolant is poisonous, so the coolant shall be

stored in the original container to avoid contacting

people.

• When replacing coolant, waste treatment shall be

carried out according to local regulations.

• Whether to maintain the engine determines whether to

discharge lubricating oil.

3. Disconnect the battery’s positive and negative wire

and disconnect the ground wire, generator and

connecting wire of starter

• Disassemble battery negative pole first when removing to

avoid the ground producing spark and causing losses and

damage.

• After disconnect the battery’s negative pole, wait for 60s

then disassemble other electric equipment.

The battery may have explosive gas escapes. Therefore, in

order to avoid damaging human body, good ventilation

shall be ensured for engine compartment before

maintaining battery.

15B-79

4. Disassemble fuel inlet pipe and fuel return pipe

which connects the engine

After removing the fuel pipeline, please seal it to ensure no fuel

leakage takes place.

• The fuel is inflammables, so it will far away from naked

flame, work light and power connector and etc.

• The disassembly shall be made with good ventilation

to avoid damaging human body and property losses.

5. Disconnect all cooling pipelines which connect

with the engine. If necessary, disassemble the

cooling pipeline gradually.

Disassemble the engine’s inlet pipe and outlet pipe possibly to

avoid blocking or damaging them when removing the complete

6. Disassemble the fixing clamp of intake hose and

take down the intake hose.

After take down the intake hose, the intake manifold port shall

be sealed.

7. Disconnect the connection of heater water pipe

15B-80

8. Disassemble the fixing clamp of engine assembly,

pull out the connector of the main harness and take

down the main harness

9. Disconnect the vacuum connecting pipe of EGR

10. Disconnect the connection between exhaust pipe

and turbocharger

Disassemble the front section of pipeline of exhaust pipe

possibly in order to conveniently disassemble the complete

11. Remove the fan

Avoid collision and damaging the fan when removing.

12. Disconnect the ground wire from the transmission

and at the same time remove the generator

connecting lead.

15B-81

13. Disconnect the lead connection of starter and

disassemble the starter.

14. Remove the A/C compressor assembly.

15. Disassemble power steering pump assembly and

hang the assembly on the frame

16. Remove the propeller Shaft from the transfer case

and at the same time remove the propeller Shaft on

the other side of transfer case (Refer to Chapter 33

Propeller Shaft)

17. Disconnect the lead of clutch and the connection of

odometer lead

15B-82

18. Remove the transfer case.

19. Disconnect the lead of reverse gear switch and the

connection of lead of vehicle speed sensor

20. Remove the shift lever (Refer to Chapter 31

Transmission).

21. Remove the clutch slave cylinder.

Once removed, fix the clutch slave cylinder onto the

crossbeam, in order to prevent the trouble of empty drainage.

22. Remove the fixing bolts between the transmission

and the suspension.

To prevent the tilting of the engine, lift the tail of the engine with

jack while removing the transmission suspension.

15B-83

23. Remove the fixing bolts between engine and

transmission

24. Remove the fixing bolts for connecting the engine

suspension and the frame

25. Hoist the engine steadily to lift the engine suspension from the suspension bracket and slowly

move the engine to an appropriate angle. Pull the hoist to move the engine from the

installation location of the frame and slowly place and fix the engine assembly onto the

disassembly stand.

Before removing the engine, recheck whether all connections on all sides of the engine are disconnected.

15B-84

INSTALLATION PROCEDURE

1. Lift the engine with hoist and move the hoist to position the engine at the engine installation

location.

• As the engine assembly is really heavy, to prevent the occurrence of accidents, it’s preferable to perform

the installation by two or more operators.

• By adjusting the adjusting bolts of the hoist, slowly lower the engine in such manner that the engine

suspension closes to the suspension bracket on the crossbeam and aligns with the fixing bolt holes

2. Install and fasten the fixing bolts of the engine front

suspension.

Lift the tail of the engine with jack, in order to prevent the tilting

of the engine.

3. Install and fasten the fixing bolts for connecting the

engine and the transmission.

4. Install and fix the fixing bolts for connecting the

transmission and the suspension.

5. Install and fasten the clutch slave cylinder and its

fixing bolts.

15B-85

6. Install the shift lever (Refer to Chapter 41

Transmission)

7. Connect the leads of reverse gear switch and

vehicle speed sensor.

8. Install and fasten the fixing bolts of transfer case

9. Connect the leads of the transfer case and the

odometer.

10. Install and fasten the fixing bolts and propeller

shaft (see Chapter 34 Transaxle and Propeller Shaft

- Propeller Shaft Assembly, Assembly Service for

Detail)

15B-86

11. Install power steering pump and fasten the fixing

12. Install A/C compressor assembly

13. Install the starter motor and connect the starter

motor lead.

14. Install and fasten the engine ground wire onto the

transmission housing

15. Install the fan.

15B-87

16. Connect the connection of exhaust pipe and

turbocharger and fasten the connecting bolts

17. Install the lead of generator on the corresponding wiring terminal or in the connector

18. Connect the vacuum connecting pipe of EGR valve

19. Install the clamps of engine’s main harness and

plug the main harness’s connector

20. Install the heater water pipe

15B-88

21. Install the intake hose of engine

22. Install engine’s fuel inlet pipe and fuel return pipe

• Fuel pipeline shall be evacuated when removing the fuel

pipeline.

• Make sure that there is no air in the fuel pipeline and then

the engine can normally start.

23. Install the cooling pipeline of engine and fasten the

fixing clamps of hose.

24. Fill the lubricating oil with the right amount. Make sure the lubricating oil is enough by

observing the dipstick and fill the coolant until the coolant is up to standard level.

25. Observe the surrounding connecting pieces of engine to make sure that the installation is firm

and dependable. Make sure to put the transmission in the neutral position and then test the

26. Connect the battery leads.

While installing the battery leads, firstly install the positive

wiring terminal and fix, seal and insulate the bolt before

installing the negative wiring terminal and fixing, sealing, and

insulating the bolt.

15B-89

27. Turn on the ignition switch, and observe the instruments to ensure that all functions are

normal, and then start the engine.

After the engine is started, observe the instruments to ensure that the readings of oil pressure gauge and the

coolant temperature gauge are normal and enter into the vehicle trough to observe the surrounding area of

the engine for the presence of water leakage, oil leakage, and gas leakage. In event of any leakage, stop the

engine immediately and resolve the malfunctions.

28. Cover the engine hood

15B-90

INSTRUCTION OF ESSENTIALS

1. Disconnection and Connection Instruction of

Battery Ground Wire

Instruction:

• Before the Disassembly of the engine, firstly disconnect the

negative wire of the battery.

• In order to ensure that all disassembly works of the engine

are fulfilled under power cut condition.

• After all operation are finished, check all again. After all is

right and then connect the battery’s negative pole.

2. Disassembly and Installation Instruction of Fuel

Pipes

• While removing the fuel pipes, it’s necessary to cover the

connectors disconnected with fuel pipe caps.

• The fuel is one flammable substance. While handling the

fuel system, make sure to keep the cigarette, open fire,

indicator lamp, electric arc equipment, and switch away

from the operation area and equip with ventilation

equipment in the operation area, in order to minimize the

possibility of serious personal injuries or even death

3. Instruction of Engine Protection Measures

The presence of minor foreign materials inside the engine will

often lead to engine failure for normal functioning or even lead

to serious harm of the engine. Therefore, while disconnecting

all connecting pipes of the engine, it’s necessary to cover all

openings of the engine, in order to prevent the ingress of dirt or

scrap into the engine.

4. Instruction of Disassembly of Engine and Installation Mode

Disassemble the complete engine from engine compartment with lifting frame when removing. And when

installing, lift the complete engine with lifting frame from the top of engine compartment.

ENGINE MECHANICAL PART- PRESERVATION OF COMPLETE ENGINE 15B-91

PRESERVATION OF COMPLETE ENGINE

1. Make the coolant of radiator, cylinder blocks and water pump exhausted.

2 Disassemble the battery.

3. Screw out each cylinder’s heater plug and fill 30g oil in each cylinder. Rotate the crank for 15~20

times and then install the heart plug.

4. Put the dehydration vaseline (heat to 100~200℃) on the contact of electric equipment, connector and

some metal surface which are not painted.

5. Fill lubrication in each lubricating point.

6. Loosen the fan belt.

7. Make the diesel of diesel tank exhausted and clean the fuel tank.

8. Wrap the engine with protective materials (such as canvas, waterproof cloth and oiliness) to avoid

dust.

9. The room for storing engine shall be clean, warm and keep out of the sun, the indoor temperature

shall not lower than 5℃ and the relative humidity is 40~70%.

1. Charge the battery with 5~12A current once every month.

2. Screw out the heater plug and fill 30g oil every 12 months and rotate the crank for 15~20 times to

avoid inside corrosion and install the heater plug again.

3. Eliminate the lubricating grease on the lubricant housings every 12 months and replace the

lubricating grease.

15B-92

ENGINE MECHANICAL PART- DISSASSEBLY OF ENGINE

DISASSEMBLY OF ENGINE (4JB1)

INSTRUCTION OF DISASSEMBLY

1. This section provides one complete set of procedure for disassembly of diesel engine. The

disassembly mode is illustrated in both graphs and texts step by step from top to bottom and from

outside to inside.

2. Before removing the engine, place the engine assembly onto the disassembly stand or place it on one

clean and level ground and prepare the necessary disassembly tools and professional container or

environment for placement of parts.

3. The disassembly environment shall be kept away as far as possible from the fire source and other

objects (such as children) that impair the safety.

15B-93

DISASSEMBLY OF PIPELINE AND HARNESS

1. Disassemble EGR pipeline

(a). Disassemble two fixing bolts which connect EGR pipe

and intake pipe.

All bolts removed shall be centrally placed, in order to prevent

loss.

(b). Disassemble the fixing bolts which connect EGR pipe

2. Disassemble breather pipe

(a). Disassemble the connectors between breather exhaust

pipe and intake pipe of turbocharger and disconnect

the connector of breather intake pipe.

15B-94

Disassemble the connectors between breather exhaust

pipe and breather and disconnect and take down the

breather intake pipe.

Disassemble the clamps between breather intake pipe

and valve chamber cover and disconnect the connector

of breather intake pipe.

and breather and disconnect and take down the

3. Disassemble intake pipe of turbocharger

(a). Disassemble the fixing bolts of intake pipe of

turbocharger, disassemble the fixing bolts which

connect intake pipe of turbocharger and turbocharger

and then take down the intake pipe of turbocharger.

4. Disassemble intake pipe

(a). Disassemble the fixing bolts between intake pipe and

intake manifold and take down the intake pipe.

5. Disassemble the engine’s harness

(a). Disassemble the engine’s ECU harness connector

from the installation position and take it down.

15B-95

DISASSEMBLY OF HIGH AND LOW PRESSURE FUEL PIPES AND

FUEL INJECTOR

The fuel is one flammable substance. While handling the fuel system, make sure to keep the cigarette,

open fire, indicator lamp, electric arc equipment, and switch away from the operation area and equip

with ventilation equipment in the operation area, in order to minimize the possibility of serious

personal injuries or even death.

1. Disassemble the high pressure fuel pipe

(a). Disconnect the connection between injection pump and

Disconnect the connection between injection nozzle

and high pressure fuel rail.

(c). Disconnect the connection between the high pressure

fuel pipe and high pressure fuel rail and take down the

When removing the high pressure fuel pipe, take down the high

pressure fuel pipe from the lower end of intake manifold, cover

the connector cover of high pressure fuel pipe and install the

high pressure fuel pipe with clean plastic packing bag.

2. Disassemble the low pressure oil pipe

(a). Disassemble and take down the low pressure oil pipe.

Push the connectors of low pressure oil pipe towards the

opening position and take it down from the fuel injector.

15B-96

3. Disassemble the fuel injector

(a). Disassemble the fixing bolts of the pressure plate of

fuel injector and take down the pressure plate of fuel

injector and the fuel injector.

15B-97

DISASSEMBLY OF DIPSTICK AND VENTILATOR

1. Disassemble the dipstick

(a). Disconnect the oil return pipe connectors which

connect the dipstick and breather and disassemble the

fixing bolts of dipstick.

Take down the dipstick.

2. Disassemble the breather assembly

(a). Disassemble the fixing bolts of breather.

Take down the breather assembly

15B-98

(c). Disassemble the fixing bolts of breather support.

Take down the breather support.

15B-99

DISASSEMBLY OF TURBOCHARGER, INTAKE MANIFOLD AND

EXHAUST MANIFOLDS

1. Disassemble the turbocharger

(a). Disassemble fuel inlet pipe and oil return pipe of

(b). Disassemble heat insulating pad assembly and

disassemble the fixing bolts of turbocharger.

Take down the turbocharger assembly.

2. Disassemble exhaust manifold

(a). Disassemble the fixing bolts of exhaust manifold.

15B-100

Take down the exhaust manifold.

3. Disassemble the intake manifold

(a). Disassemble the fixing bolts of intake manifold.

(b). Take down the intake manifold.

After taking down the intake manifold, block the exit and

entrance with sealed cap or equivalent to prevent other things

from entering.

15B-101

DISASSEMBLY OF CYLINDER HEAD COVER AND ROCKSHAFT

1. Remove the cylinder head cover.

(a). Remove the fixing nuts of the cylinder head cover.

All nuts removed shall be centrally placed, in order to prevent

loss

Take down the cylinder head cover assembly.

2. Disassemble electric heater plug assembly

(a). Disassemble and take down four electric heater plugs.

3. Remove the rockshaft.

(a). Remove the fixing bolts of the rocker assembly

15B-102

Remove the rockshaft assembly

15B-103

DISASSEMBLY OF TAPPET AND CYLINDER HEAD

1. Disassemble tappet

(a). Take down all valve tappets one by one from

Put all tappets which are taken down together to avoid losses.

2. Remove the cylinder head.

(a). Remove the fixing bolts of the cylinder head

Screw off the bolts of cylinder head many times according

to the order on the left and assembly the bolts.

(b). Remove the cylinder head assembly.

This assembly is really heavy. To prevent causing serious

personal injuries, make sure to ask another operator for

assistance or use appropriate lifting equipment to hoist this part

or assembly

15B-104

DISASSEMBLY OF THERMOSTAT ASSEMBLY AND VALVE

1. Disassemble the thermostat assembly

(a). Disassemble the fixing bolts of water pipe assembly

and take down the water pipe assembly.

Take down the thermostat.

(c). Disassemble and take down the fixing bolts of

thermostat housing assembly.

2. Remove the valve.

(a). Disassemble the valve lock clamp.

Please wear goggles to avoid damaging persons.

15B-105

Disassemble the spring bottom seat of valve, valve

spring and the spring upper seat of valve and

disassemble the valve oil seal.

Take down the valve and knock out the valve guide

pipe from the bottom of cylinder head with special tools.

15B-106

DISASSEMBLY OF HOOK AND A/C BRACKET

1. Disassemble hook

(a). Disassemble the fixing bolts of hook

Take down the hook

2. Disassemble the A/C bracket

(a). Disassemble the fixing bolts of A/C bracket and take it

15B-107

DISASSEMBLY OF STARTER MOTOR AND HIGH PRESSURE FUEL

RAIL

1. Disassemble the starter motor

(a). Disassemble the fixing bolts of starter motor

Take down the starter motor.

2. Disassemble the high pressure fuel rail

(a). Disassemble fixing bolts of high pressure fuel rail

Take down the high pressure fuel rail assembly

15B-108

DISASSEMBLY OF OIL FILTER AND GENERATOR

1. Disassemble the oil filter assembly

(a). Disconnect the connection of coolant pipe of oil filter.

(b). Disassemble the fixing bolts of oil filter assembly.

Take down the oil filter assembly.

2. Disassemble the generator

(a). Disconnect the connection of vacuum pump oil inlet

pipe and oil outlet pipe at the rear end of generator.

15B-109

(b). Disassemble the adjusting bolts of generator and

release all belt tension.

Take down the generator belt.

Disassemble the fixing bolts at the low end of generator

and take down the generator assembly.

While removing the fixing bolts, pull the generator with

hand to prevent the fall-off of generator due to loss of

bracket from damaging the generator.

15B-110

DISASSEMBLY OF FAN AND CRANKSHAFT PULLEY

1. Disassemble the fan

(a). Disassemble the fixing bolts of fan assembly

Make the studs reverse stuck with screwdriver when removing

and at the same time disassemble the near nuts with wrench.

Take down the fan assembly

2. Disassemble the crankshaft pulley

(a). Disassemble the fixing bolts of crankshaft pulley

Take down the crankshaft pulley

15B-111

DISASSEMBLY OF OBSERVATION CHAMBER COVER AND

COVER ASSEMBLY OF WATER PUMP PULLEY CHAMBER

1. Disassemble the observation chamber cover

(a). Disassemble the fixing bolts of observation chamber

Take down the observation chamber cover.

2. Disassemble the cover assembly of water pump

pulley chamber

(a). Disassemble the fixing bolts of cover assembly of water

pump pulley chamber .

loss.。

Take down the cover assembly of water pump pulley

chamber.

15B-112

DISASSEMBLY OF PRESSURE PLATE AND TIMING BELT

1. Disassemble the pressure plate

(a). Disassemble the fixing bolts of camshaft pulley

pressure plate.

Take down the camshaft pulley plate.

(c). Disassemble the fixing bolts of injection pump pulley

Take down the injection pump pulley pressure plate.

15B-113

2. Disassemble the timing belt

(a). Disassemble the fixing bolts of tensioning pull rod.

(b). Adjust the tightness of timing belt through tensioning

pull rod through special tool and loosen the fixing bolts

of the low idle pulley.

Firstly screw up the fixing nuts of tensioning pull rod and then

adjust the tightness of timing belt through the tensioning pull

rod.

Take down the timing belt.

15B-114

DISASSEMBLY OF INJECTION PUMP ASSEMBLY

1. Disassemble the injection pump

(a). Disassemble the fixing bolts of injection pump

(b). Take down the injection pump pulley, injection pump

flange and injection pulley.

Take down the injection pump pulley, injection pump flange and

injection pulley together.

15B-115

DISASSEMBLY OF IDLE PULLEY AND CAMSHAFT GEAR

1. Disassemble the idle pulley

(a). Disassemble and take down the fixing bolts of

tensioning pull rod.

(b). Disassemble the positioning bolts and take down the

tension pulley assembly.

(c). Disassemble and take down the fixing bolts of idle

2. Disassemble the camshaft gear

(a). Disassemble the fixing bolts of camshaft pulley.

• When removing the bolts of camshaft gear, the camshaft

gear will rotate. Therefore the camshaft gear can be

positioned with special positioned.

• The camshaft gear can be also positioned with tools like

screwdriver or solid wrench according to actual situation.

15B-116

Take down the camshaft gear.

(c). Disassemble the fixing bolts of pressure plate.

Take down the pressure plate.

Take down the flange of camshaft pulley.

(f). Disassemble the fixing bolts of the front oil seal seat of

camshaft.

Before removing the front oil seal seat of camshaft, first

disassemble the flat key of camshaft.

15B-117

Take down the front oil seal seat of camshaft.

15B-118

DISASSEMBLY OF CLUTCH COMPONENTS AND FLYWHEEL

ASSEMBLY

1. Disassemble the clutch components

(a). Remove the fixing bolts of the clutch components.

Disassemble the clutch friction plate and clutch

2. Remove the Flywheel assembly

(a). Disassemble the flywheel bolts and the flywheel bolt

Take down the flywheel.

15B-119

Disassemble the fixing bolts of the rear joint plate. Take

down the rear joint plate and pry out the rear crank oil

seal with screwdriver.

• All bolts removed shall be centrally placed, in order to

prevent loss.

• The oil seal which is disassembled cannot be used again.

Please replace oil seal.

15B-120

DISASSEMBLY OF OIL PAN AND GEAR CHAMBER

1. Remove the oil pan

(a). Roll over the engine body

(b). Remove the fixing bolts of oil pan.

• Do not disassemble a bolt randomly. The fixing bolts of oil

pan shall be crossly disassembled with the method of from

the middle to both sides or from both sides to the middle.

Remove the oil pan.

2. Disassemble the gear chamber

(a). Disassemble the fixing bolts of timing gear chamber .

Take down the timing gear chamber.

15B-121

(c). Take down the gear chamber gasket.

The gear gasket which is disassembled cannot be used again.

Please replace gear chamber gasket.

15B-122

DISASSEMBLY OF CAMSHAFT AND ENGINE SUPPORT

1. Remove the camshaft.

(a). Pull out the camshaft from the installation location.

Slowly rotate and pull out the camshaft.

2. Remove the engine support.

(a) Remove 4 fixing bolts of engine support.

Take down the engine support.

15B-123

DISASSEMBLY OF OIL PUMP, OIL INJECTION PIPE AND TAPPET

1. Disassemble the oil pump

(a). Disassemble 2 fixing bolts of oil pump.

Disconnect the connection of oil outlet pipe of oil pump

and oil pump.

Take down the oil pump.

2. Disassemble the oil Injection pipe

(a). Disassemble the fixing bolts of oil Injection pipe and

pressure-limiting valve components.

15B-124

(b). Take down the oil Injection pipe assembly.

Make sure that the oil Injection pipe is clean especially the

nozzle shall be clean.

3. Disassemble the tappet

(a). Attract the tappets one by one from the installation

position with high performance magnet.

Put the tappets which are taken down in the clean container.

15B-125

DISASSEMBLY OF PISTON AND CRANKSHAFT

1. Remove the piston assembly.

(a) Rotate the crankshaft to position the journal of

connecting rod to be removed at bottom dead center.

(b). Disassemble the fixing bolts of with kilo wrench.

Screw off the bolts in pairs.

(c). Lightly shake and pull out the connecting rod cover.

(d). Take down the connecting rod bearing bush.

Pay attention not to damage the connecting rod bearing

bush.

(e). Eliminate the carbon deposition of piston cylinder.

• Please abide by the use recommendations of the

manufacturer while using the solvent, acid or alkaline

material for cleaning. Please wear the goggles and

protective clothing to prevent causing personal

injuries.

• Some solvents are flammable and toxic. Please read the

manual of the manufacturer before use.

15B-126

(f). Push out the piston assembly

Push out the piston assembly with wooden or rubber object. Do

not use metallic object, in order to prevent damaging the end

face of connecting rod.

Remove the piston assembly from the other side.

(h). Install the disassembled pistons together and put the

mark number in a clean container.

(i). Disassemble the pistons in other cylinders with the

same method.

If the piston is not used immediately, mark the number on each

piston and connecting rod assembly with label and put the

connecting rod and pistons in the contained to avoid being

2. Remove the crankshaft assembly.

(a) Loosen the bolts of main bearing cap in turn.

Loosen all bolts in turn in diagonal manner, but do not remove

the bolts.

Remove the bolts as per disassembly sequence shown in

the left figure.

15B-127

(b). Remove the main bearing cap and the main bearing

cap bolts and arrange them in order and remove the

main bearing bush.

• Grasp the bolts of main bearing cap with two hands, shake

the main bearing cap or knock loose with rubber hammer,

and then remove the main bearing cap.

• The top of each main bearing cap has marking to help the

remembering.

(c). Remove the crankshaft.

This part is a little heavy. To prevent causing serious

personal injuries, make sure to lift this part or assembly

with the assistance of other operators or with appropriate

lifting equipment.

(d). Remove the upper bushes of the main bearing bushes.

Take out each upper bearing bush and mark the number on the

movable lug and write down the installation position and the

front and back side.

15B-128

ENGINE MECHANICAL PART-ASSEMBLY OF ENGINE

ASSEMBLY OF ENGINE (4JB1)

INSTRUCTION OF ASSEMBLY

1. This section provides one complete set of procedure for assembly of diesel engine. The assembly

mode is illustrated in both graphs and texts step by step from bottom to top and from inside to outside.

2. The assembly environment shall be kept away as far as possible from the fire source and other

3. During the assembly, install the parts removed to the original positions, without part shortage and

missing part.

4. During the assembly, replace all paper gaskets and never reuse these paper gaskets.

5. During the assembly, make sure that the parts installed are intact and contamination-free and ensure

that every part is installed securely in place.

15B-129

INSTALLATION OF CRANKSHAFT AND PISTON

1. Install the crankshaft.

(a) Face upward the cylinder block crankcase and place

steadily.

Make sure that there is no foreign material within the

crankcase.

(b). Install the upper bearing bush of main bearing bush in

the specified position.

• Carefully install the upper bushes of the main bearing

bushes to the specified positions in turn and ensure that the

back faces of the bearing bushes are clean without any

scrap. The upper bush of each main bearing bush shall be

in the center position of the bearing bush groove and the top

faces of all bearing bushes shall be level.

• After installation, uniformly put oil with right amount or the

equivalent lubricating oil on the inside of bearing pad’s

arched surface.

During the installation, make sure that the positioning lug

is aligned with the positioning groove of the main bearing

bush cylinder saddle.

(c). Install the crankshaft thrust bearing in the specified

In this engine, there are two thrust bearings installed at the 3rd

main bearing bush of the cylinder block.

During the installation of the thrust bearings, notice to

face the oil grooves outward

15B-130

(d). Drip clean oil or equivalent lubricating oil to the inner

side of the main bearing bushes.

Do not drip oil to the outer side of the main bearing

bushes.

(e). Install the crankshaft to the specified position.

N OTE:

• This part is a little heavy. To prevent causing personal

injuries, make sure to lift this part or assembly with the

assistance of other operators or with appropriate lifting

equipment.

• Install the crankshaft with care, in order to prevent

damaging the crankshaft main bearing, specially the

thrust/main bearing journals. The damage of the

crankshaft will shorten the service life of the engine.

(f). After installing the crank, put the clean oil or the

equivalent lubricating oil on the main bearing journals

of crank.

(g). Apply the oil to the lower bushes of the main bearing

bushes and install onto the main bearing cap.

Slide the lower bushes of the main bearing bushes from one

side into the main bearing bush cap and press level the end

faces.

15B-131

During the installation, make sure that the positioning lugs

of bearing bushes are aligned with the positioning

grooves of the main bearing cap.

(h). Install the main bearing cap in turn.

Install the main bearing cap to the original position as per

markings and do not wrongly install any part.

Each main bearing cap of the crankshaft is marked with

identification number. Install the bearing caps in order and do

not wrongly install any one.

Install the main bearing caps of the crankshaft onto the

main bearing block of the crankcase and ensure that the

arrow of each main bearing cap points to the front

direction (pulley direction).

(i). Install the fixing bolts of the main bearing caps to

specified installation holes in turn and fasten lightly with

hand

Put oil with the right amount on the head bolt of main bearing

Screw up the main bearing bolts according to assigned

order and torque.

15B-132

• Fasten the bolts to the specified torque by several times,

instead of fastening by one time.

• Fasten the fixing bolts of the main bearing as per specified

sequence (as shown in left figure).

2. Install the piston assembly.

(a) Install the connecting rod bolts to the connecting rod.

(b). Install the upper bush of piston connecting rod bearing

• Before assembly, all parts shall be clean.

• Clean the connecting rod and bearing brush with a clean

and non-cottony cloth.

• Make sure that the back faces and side faces of the

connecting rod and connecting rod bearing are clean,

without any scrap.

• Do not lubricate the back face and side face of the

connecting rod bearing.

grooves of the connecting rod.

15B-133

Drip clean oil or equivalent lubricating oil to the inner

side of the bearing bushes.

Use clean oil to lubricate the piston ring and the piston

skirt.

(e). As shown in the figure, rotate and adjust the positions

of the piston ring openings.

Each opening of piston ring shall not align at the piston pin and

other openings of piston rings. If the opening position of piston

ring is not correct, then the piston ring cannot correctly be

(f). Use piston ring compressor to compress the piston

rings to the working position.

An annular cylinder can be self made with iron sheet if without

special tools.

Rotate the crankshaft to position the journal of

connecting rod to be installed at bottom dead center.

15B-134

Put a thin clean oil on the wall of cylinder block.

(i). Insert the connecting rod into the cylinder bore, till the

piston ring compressor comes into contact with the top

of the cylinder block

• Align at the arrows of the top of piston to make it point at the

front of engine.

• The long end of connecting rod and the gap of piston skirt

shall be on the exhaust side of engine, if not, please make

sure that the piston is installed on the connecting rod.

The engine will be seriously damaged if not according to

the above operational steps.

(j). Press the piston ring compressor to the cylinder block,

insert the piston into the cylinder bore through the

piston ring compressor, and align with the installation

position of the connecting rod.

If the piston can’t move smoothly, remove the piston and

check the piston rings for breakage or damage.

15B-135

(k). Install the lower bush of the connecting rod bearing

bush onto the connecting rod bearing bush cap.

connecting rod cover and connecting rod bearing are

clean, without any scrap. Do not lubricate the back face

and side face of the connecting rod bearing.

• If not replaced with new one, install the old bearing

onto the original connecting rod cover from which it’s

removed.

grooves of the connecting rod cover.

Use clean oil to lubricate the inner side of the lower

bush of the connecting rod bearing bush.

Install each connecting rod cover to corresponding

journal of the crankshaft.

15B-136

The middle portion of the connecting rod and the head of

the connecting rod cap are forged with markings. During

assembly, face these markings towards the front of the

engine (Pulley end)

(n). Install and fasten the connecting rod nuts.

• Fasten the nuts many times with torque wrench with the

method of angle fastening.

• Check whether the piston assembly is installed correctly.

• Measure the gap between the connecting rod body and the

crankshaft and the protrusion amount of the piston top

respectively.

If the piston, crankshaft, connecting rod or cylinder block

is ever changed/replaced, it’s necessary to measure the

protrusion amount of the piston on the combustion face of

the cylinder block.

The procedure is as below:

• Install micrometer on the cylinder head and reset to

zero.

• Move the micrometer right above the top of the piston,

in order to eliminate all lateral movements.

• Rotate the crankshaft to the top dead center and then

rotate the crankshaft clockwise and counter-clockwise,

find out the maximum reading of the micrometer, and

record the measurement result.

15B-137

INSTALLATION OF TAPPET, OIL INJECTION PIPE AND OIL PUMP

1. Install tappet

(a). Put clean oil and the equivalents on the tappet and

tappet holes.

(b). Install eight tappets on the installation holes one by

one.

• Make sure that the surface is clean and has no scratches

before installation.

• When installing the tappets, make sure that when

installation holes incline at an angle of 45°~60°, the tappet

slowly slide and do not have blockade phenomenon.

2. Install oil Injection pipe

(a). Install the oil Injection pipe in the specified position.

Make sure the oil Injection pipe is clean especially the nozzle.

Install the fixing bolts of oil Injection pipe and

15B-138

3. Install the oil pump assembly

(a). Install the oil pump assembly in the specified position.

When installing, put the lubricating oil on the oil pump gear.

Connect the connection between oil pump’s oil outlet

pipe and engine body.

Install and fasten the fixing bolts of oil pump assembly.

15B-139

INSTALLATION OF ENGINE SUPPORT AND CAMSHAFT

1. Install the engine support.

(a). Install the engine right support to the specified position.

Install and fasten four fixing bolts of the engine support.

Install the left support with the same method.

2. Install the camshaft.

(a). Apply an appropriate amount of lubricating grease or

equivalent lubricant onto the inner walls of the

installation bore of the rear camshaft.

When installing the camshaft, the engine can be placed

vertically in order to avoid sliding the tappet and the

engine body shall be placed with certain angle.

(b). Apply an appropriate amount of lubricating grease or

equivalent lubricant onto the cam of the camshaft and

the journal.

Before the installation, make sure that all machined surfaces

are clean without any scratch.

15B-140

(c). Slowly install the camshaft in the specified position.

• Before installing the camshaft, make sure that the

tappet inserts completely in the tappet holes. If the

tappets do not insert completely, the camshaft may be

damaged when installing.

• Rotate the camshaft and carefully insert the camshaft

into the camshaft sleeve. When each camshaft journal

passes through the sleeve, slightly lower the camshaft

to fix the camshaft cam into the sleeve. Rotate the

camshaft to separate the cam from the restraint of the

sleeve, in order to install the camshaft smoothly.

15B-141

INSTALLATION OF GEAR CHAMBER AND OIL PAN

1. Install the gear chamber

(a). Install the gasket of gear chamber

The gear chamber’s gasket shall be replaced. Clean the

incomplete gaskets of engine body before replacing gasket.

Install the timing gear chamber in the specified

(c). Install and fasten the fixing bolts of timing gear

Do not excessively screw up a bolt. The fixing bolts of timing

gear chamber shall be screwed up alternately and gradually.

2. Install oil pan

(a). Paint sealant on the front and rear ends of oil pan.

15B-142

Paint sealant with right amount on the contact surface between

oil pan and engine body.

Install the front and rear ends of oil pan on the oil pan.

(c). Install the oil pan to the specified position.

Clean and check the thread and the sealing surface of the

drainage screw plug and replace the damaged one (if any).

During the installation of oil pan, use the front and rear fixing

bolts of the oil pan to help the orientation.

(d). Install and fasten the fixing bolts of oil pan.

Cross fasten the fixing bolts of oil pan from the middle to the

sides or from the sides to the middle, instead of excessively

fastening any bolt by one time.

15B-143

FLYWHEEL ASSEMBLY AND CLUTCH COMPONENTS

1. Install the Flywheel assembly.

(a). Install the rear oil seal of crank in the specified position with special oil seal installer.

The crank is sealed with frame oil seal with good sealing property and thread groove.

Install the rear joint plate in the specified position and

install the fixing bolts of rear joint plate.

Install flywheel and flywheel bolt plate in the specified

(d). Install the flywheel bolt in the specified position and

fasten it.

• Install the flywheel at the rear end of crank with 8 bolts to

ensure the dependable installation strength.

• When installing flywheel bolts, paint oil on bolts and contact

surface then fasten them according to diagonal.

2. Install the clutch components

(a). Install the clutch friction plate and clutch plate in the

specified position with positioning tool.

15B-144

Install the fixing bolts of clutch in the specified position

and fasten them.

15B-145

CAMSHAFT GEAR AND IDLE PULLEY

When installing the gear, one shall strictly align the gear with the mark without any mistake in case of

the non-start, power decrease, oil consumption increase and even the unnecessary loss which may

cause the damage of distribution device parts. When the marks of gears are indistinct or wear, the

gear mechanism shall be displaced as a set or be repaired in a maintenance station of Beijing Foton

Environment Engine Co., Ltd if necessary.

1. Install the camshaft gear

(a). Install the front oil seal of camshaft gear on the

camshaft gear.

(b). Fasten the fixing bolt of camshaft gear front oil seal

seat.

After installing the front oil seal seat of camshaft gear, the

flat key of camshaft gear also shall be installed on the

camshaft in case of omission.

(c). Install the camshaft pulley flange plate on the front oil

seal seat of camshaft.

Install the camshaft pulley flange plate correctly and make the

location pin through pin hole.

Install the pressure plate onto the specified position.

15B-146

Fasten the bolt of pressure plate.

(f). Install the camshaft gear to the specified position.

When installing the camshaft gear, the groove of camshaft

gear shall be aligned and the pin hole of camshaft shall be

installed align with the location pin.

(g). Fasten the fixing bolt of camshaft pulley.

• When fastening the camshaft gear bolt, the camshaft gear

will revolve with it. For this reason, one shall locate the

camshaft gear with special locator instead of wrench.

• According to the actual situation, one may also use tools

such as screwdriver and solid wrench to locate the

2. Install the idle pulley

(a). Install the bolt equipped with location skirt and the

timing belt transition wheel assembly together.

Install the location skirt and the timing belt transition

wheel assembly into the gear chamber.

15B-147

Fasten the location skirt bolt.

Install the tensioner assembly and hexagon flange locating bolt

into the gear chamber with the same method and fasten them.

The tensioned shall be fastened again when installing in

order to facilitate the following adjustment of belt. It

means to slightly fastening it.

Install the tensioning pull rod onto the gear chamber.

When installing the tensioning pull rod, one shall install the

internal teeth serrated lock washer, hexagon flange nut and the

bolt equipped with locating rod onto the tensioning pull rod all

15B-148

INSTALLATION OF INJECTION PUMP ASSEMBLY

1. Install the injection pump assembly

(a). Install the injection pump pulley, injection pump flange

and injection pump onto the gear chamber.

Install the injection pump onto the gear chamber from the rear

of gear chamber.

The timing marks on the injection pump pulley shall be

installed aligning with the timing marks on gear chamber.

Fasten the fixing bolt of injection pump assembly.

15B-149

INSTALLATION OF TIMING BELT AND PRESSURE PLATE

1. Install the timing belt

(a). Install the timing belt to the specified position.

(b). Adjust the tension of timing belt with special tools and

When the tension of belt being adjusted to proper position, one

shall just Fasten the hexagon flange locating bolt.

Fasten the fixing bolt of tensioning pull rod.

2. Install the pressure plate

(a). Install the pressure plate of injection pump pulley.

15B-150

Install and fasten the fixing bolt of injection pump pulley

Install the pressure plate of camshaft pulley.

Install and fasten the fixing bolt of camshaft pulley

15B-151

INSTALLATION OF WATER PUMP PULLEY CHAMBER COVER

ASSEMBLY AND OBSERVATION CHAMBER COVER

1. Install the cover assembly of water pump pulley

chamber

(a). Install the cover assembly of water pump pulley

chamber onto the gear chamber.

Install and fasten the fixing bolt of water pump pulley

chamber cover assembly.

2. Install the observation room cover

(a). Install the observation room cover to the specified

Install and fasten the fixing bolt of observation room

15B-152

INSTALLATION OF THE CRANKSHAFT PULLEY AND THE FAN

1. Install the crankshaft pulley

(a). Install the crankshaft pulley to the specified position.

When installing the crankshaft pulley, in order to avoid the

Disassembly of crankshaft pulley due to the crankshaft pulley

rotating together with it, one shall firstly secure the flywheel

with flywheel locator or other equivalent objects. Meanwhile,

one shall smear oil onto the bolt threads.

Install and fasten the crankshaft pulley bolt.

2. Install the fan

(a). Install the fan assembly to the specified position.

(b). Install and fasten the fixing nuts of fan assembly.

Clamp the double-end strut backward with screwdriver and

fasten the sideward nut with wrench.

15B-153

INSTALLATION OF HIGH PRESSURE FUEL RAIL AND STARTER

MOTOR

1. Install the high pressure fuel rail assembly

(a). Install the high pressure fuel rail assembly to the

specified position

Install and fasten the fixing bolt of high pressure fuel

rail assembly.

2. Install the starter motor

(a). Install the starter motor onto the rear cover plate of

cylinder block.

When installing the starter motor, the bolt hole of starter motor

shall be aligned to the bolt hole of cylinder block rear cover

Install and fasten the fixing bolt of starter motor.

15B-154

INSTALLATION OF HOOK AND A/C BRACKET

1. Install the hook.

(a). Install the hook to the specified position and ensure the

alignment of it with the installation hole.

Install and fasten the fixing bolt of hook.

2. Install the A/C bracket

(a). Install the A/C bracket to the specified position and

ensure the alignment of it with the installation hole.

(b). Install and fasten the fixing bolt of A/C bracket.

15B-155

INSTALLATION OF VALVE AND THERMOSTAT ASSEMBLY

1. Install the valve assembly

(a). Lubricate the valve guide pipe hole and the outer wall

of valve guide pipe which are required to be replaced

with lubricating oil.

The lubrication for the outer wall of air guide pipe is conducted

to make it installing into the cylinder head guide pipe hole.

(b). Knock the valve guide pipe into the inside from the top

of cylinder head with special tool.

The outer surface of valve guide pipe shall be covered

with oil when installing. Also, one shall install the valve

guide pipe and check the height of it.

(c). Lubricate all the valve guide pipe hole and the valve

stem with oil.

• Without the lubrication for the valve guide pipe and valve

stem, the valve guide will be worn early.

• Before installing the valve, one shall lubricate the valve

(d). Install the valve and install the valve oil seal onto the

valve guide pipe with installer for valve oil seal.

• If the valve isn’t replaced, one shall install the valve at

the same position of the valve disassembly.

• If the cylinder head will not be applied immediately, one

shall also lubricate the valve stem with assembly

lubricating agent or equivalent object.

• The valve oil seal shall be replaced when it is

disassembled.

15B-156

Install the lower seat of upper valve spring, valve spring

and the upper seat of valve spring.

Compress the valve spring with the valve

springcompressor to expose the installation position of

valve lock clamp.

(g). Install the upper valve lock clamp, release the valve

spring and lock the valve with valve lock clamp.

After assembly, one shall knock the valve spring seat with

rubber hammer to ensure the correct installations of locking

• If the lock clamp is installed improperly, the lock clamp

will dash off when knocking the valve spring seat with

plastic hammer.

(h). Install all the valves with the same method.

2. Install the thermostat assembly

(a). Install and fasten the thermostat housing assembly and

fixing bolt to the specified position.

15B-157

Install the thermostat.

Install and fasten the outlet pipe assembly and fixing

bolt.

15B-158

INSTALLATION OF CYLINDER HEAD COVER AND TAPPET

1. Install the cylinder head assembly.

(a) Lubricate the bolts with clean oil.

Install the gasket of the cylinder head to the specified

(c). Align the installed cylinder head with the specified

or assembly.

(d). Install and fasten the fixing bolts of the cylinder head

Lubricate the threads and lower part of end of fixing bolt with

clean oil.

15B-159

Fasten the fixing bolts of the cylinder head to the specified

torque by several times as per sequence shown in left

figure.

2. Install the tappet

(a). Fill clean oil into the installation position hole of each

valve tappet.

(b). Install the valve tappets to the specified position one by

Be sure that the installation position and removing position of

each valve tappet are same.

15B-160

INSTALLATION OF ROCKSHAFT AND CYLINDER HEAD COVER

1. Install the rockshaft assembly.

(a). Before installing the rocker assembly, the clean oil shall

be dropped into each bowl-shape groove of tappet.

(b). Install the rocker assembly to the specified position.

It shall be handled with care when installing. The alignment

with installation hole shall also be ensured.

(c). Install the fixing bolt of rocker assembly.

Temporarily, the installed bolt will not be fastened in order till

the installation completion of the fixing nut of rocker assembly.

(d). Adjust the clearance of valve (see Chapter 15B Valve

of Engine Mechanical Part, Adjustment)

2. Install the electric heater plug assembly

(a). Install and fasten four electric heater plug assemblies.

15B-161

3. Install the cylinder head cover assembly

(a). Install the cylinder hear cover assembly to the specified

Install and fasten the fixing nuts of the cylinder head

15B-162

INSTALLATION OF INTAKE AND EXHAUST MANIFOLDS AND

TURBOCHARGER

1. Install the intake and exhaust manifolds

(a). Install the intake manifold gasket and the intake

manifold to the specified position.

The gasket of intake manifold shall be replaced by a new

Install and fasten the fixing bolt of intake manifold.

(c). Install the exhaust manifold gasket and exhaust

manifold to the specified positions.

One shall remember to install the ring and heat shield fixed

together with the exhaust manifold when installing the exhaust

Install and fasten the fixing bolt of exhaust manifold to

15B-163

2. Install the turbocharger

(a). Install the turbocharger assembly to the specified

Install the heat shield assembly.

Install the turbocharger into the oil return pipe.

15B-164

INSTALLATION OF BREATHER AND DIPSTICK

1. Install the breather

(a). Install the breather bracket to the specified position.

Install and fasten the fixing bolt of breather bracket.

(c). Install the breather onto the breather bracket.

The breather is installed inside the starter.

Install and fasten the fixing bolt of breather.

15B-165

2. Install the dipstick

(a). Install the dipstick to the specified position.

Plug the lower port of dipstick assembly in the installation hole

of dipstick when installing.

Install the fixing bolt of dipstick and connect the

connection of dipstick and the oil return pipe of

breather.

15B-166

INSTALLATION OF FUEL INJECTOR AND HIGH & LOW PRESSURE

FUEL PIPE

1. Install the fuel injector

(a). Install the fuel injector and the pressure plate of fuel

injector together, install them to the specified position

and install the fixing bolt fastening the fuel injector

In case of unnecessary troubles caused by the falling off of

copper washer when installing the fuel injector, the copper

washer shall be covered with a little lithium oil when installing.

2. Install the low pressure fuel pipe

(a). Install the low pressure fuel pipe to the specified

Push the clamp of low pressure fuel pipe in the direction of

openness, install it onto the fuel injector and connect the

connection of low pressure fuel pipe and fuel injector.

3. Install high pressure fuel pipe

(a). Connect the connection of high pressure fuel pipe and

fuel rail.

As for the installation of high pressure fuel pipe, one shall

embed the lower end of intake manifold into the high pressure

fuel pipe and shall not remove the cover of high pressure fuel

pipe connector early.

(b). Connect the connectors of high pressure fuel pipe and

fuel injector and fasten the nut.

Currently, the high pressure fuel pipe can be fastened couple

by couple.

15B-167

Install the high pressure fuel pipe between the injection

pump and the high pressure fuel rail and fasten the nut.

15B-168

GENERATOR AND OIL FILTER

1. Install the generator

(a). Install the generator assembly to the specified position

and install the fixing bolt fastening the lower end of

generator.

When installing the fixing bolt, one shall hold up the

generator with a hand in case of the damage of generator

caused by falling of generator due to the lack of bracing

force.

Adjust the position of generator and install the

generator belt.

(c). Install the adjusting bolt on the upper end of generator.

Do not screw up the adjusting bolt of the generator too tightly

when installing to facilitate the adjustment of generator belt.

(d). Adjust the belt tension by adjusting the position of

Press the generator belt with great force to check whether the

belt is installed in place.

Reference Standard: 39N. The deflection is about 10~15mm.

15B-169

Be sure the generator belt is installed in place and

fasten the adjusting bolt of generator.

Connect the oil inlet and outlet pipe of vacuum pump at

the rear end of generator.

2. Install the oil filter assembly.

(a) Install the oil filter assembly to the specified position.

Install and fasten the fixing bolts of oil filter assembly.

Connect the connection of oil filter coolant pipe.

15B-170

INSTALLATION OF PIPELINE AND HARNESS

1. Install the harness of engine

(a). According to the installation position relation, the

generator ECU harness shall be installed in place one

by one.

2. Install the intake connecting pipe

(a). Install the intake connecting pipe to the specified

position and fasten the fixing bolt of it.

3. Install the turbo-supercharging intake pipe

(a). Install and fasten the turbocharger intake connecting

pipe assembly and the fixing bolts of it.

4. Install the breather pipeline

(a). Install and connect the intake pipe of breather.

15B-171

Install and connect the exhaust pipe of breather.

Install the clamp connecting the exhaust pipe of

breather and the intake hose of turbocharger and

connect to the connector of breather intake hose.

5. Install the EGR pipeline

(a). Install the EGR pipe to the specified position.

Install and fasten the fixing bolt connecting with the

EGR pipe and exhaust pipe.

Install 2 fixing nuts connecting with the EGR pipe and

intake pipe.

15B-172

ENGINE MECHANICAL PART-DISASSEMBLY OF ENGINE

DISASSEMBLY OF ENGINE (4D20)

2. Before removing the engine, place the engine assembly onto the disassembly stand or place on one

ENGINE MECHANICAL PART- DISASSEMBLY OF ENGINE

15B-173

DISASSEMBLY OF HEATER AND WATER OUTLET-INLET PIPE

WELDMENT

1. Disassemble the weldment of heater and water

outlet-inlet pipe

(a). Disassemble the fixing bolt of heater and water

outlet-inlet pipe weldment.

Disassemble the rubber hose connecting with the

heater and water outlet-inlet pipe weldment and the

thermostat.

Take down the heater and water outlet-inlet pipe

weldment.

15B-174

DISASSEMBLY OF CYLINDER HEAD COVER

1. Disassemble the cylinder head cover

(a). Disassemble the fixing nut of cylinder head cover.

15B-175

DISASSEMBLY OF EGR CONTROLLER

1. Disassemble the EGR controller

(a). Disconnect the connection of EGR valve vacuum

Disconnect the connection of preheat controller oil inlet

(c). Disassemble the fixing bolt of air compressor bracket

and take down the fixing bracket of air compressor.

• In order to facilitate the disassembly, the air compressor

fixing bracket and EGR controller shall be taken down

Before taking down the air compressor bracket, the

connection between the generator and EGR controller

vacuum pipeline shall also be disconnected.

15B-176

(d). Disassemble the fixing bolt of EGR controller and take

down EGR controller.

15B-177

DISASSEMBLY OF INTAKE AND EXHAUST MANIFOLDS AND

1. Disassemble the intake and exhaust manifolds

(a). Disassemble the fixing bolt of intake and exhaust

manifolds.

(b). Disassemble the fixing bolt connecting with EGR valve

connecting pipe weldment and the exhaust manifold.

(c). Disassemble the fixing bolt connecting with EGR valve

and intake manifold.

Take down EGR valve connecting pipe weldment.

15B-178

(e). Disassemble the fixing bolt of turbocharger oil inlet pipe

Disconnect the connection of turbocharger oil return

rubber hose.

(g). Take down the intake and exhaust manifolds and

In order to facilitate the Disassembly of generator, the intake

and exhaust manifolds and turbocharger shall be taken down

altogether.

(h). Take down the washers of intake and exhaust

It is not proper to reuse the disassembled washers. They shall

be replaced by new washers.

Disassemble the rubber hose clamp connecting with

turbocharger and intake manifold and disconnect its

15B-179

Take down the intake manifold assembly.

2. Disassemble the turbocharger

(a). Disassemble the fixing bolt of turbocharger air inlet

port.

(b). Disassemble the fixing bolt connecting with the

turbocharger and its bracket.

Take down the turbocharger and its gasket.

15B-180

DISASSEMBLY OF GENERATOR AND BREATHER

1. Disassemble the generator assembly

(a). Disassemble the fixing bolt of vacuum pump oil inlet

pipe assembly.

Disassemble the fixing clamp of vacuum pump oil

return pipe and disconnect the connection of oil return

Disassemble the adjusting bolt of generator and

release the whole tension of belt.

(d). Disassemble the fixing bolt of generator.

• In order to prevent the direction of bolt rotating with the force

when removing, one shall firstly lock the bolt and then

disassemble the nut of fixing bolt.

• When removing the fixing bolt, one shall hold up the

generator with a hand in case of generator damages or

personal injuries caused by the falling off of generator due

to the lack of bracing force.

15B-181

Take down the generator assembly.

Disassemble the fixing bolt of generator bracket and

take down the bracket on generator.

take down the generator lower bracket.

2. Disassemble the breather

(a). Disassemble the fastening clamp of lower oil return

pipe of breather and disconnect the connection of lower

oil pipe.

(b). Disassemble the fixing bolt of breather.

15B-182

15B-183

DISASSEMBLY OF FAN, FAN PULLEY AND CRANKSHAFT PULLEY

(a). Disassemble the fixing nut of fan assembly.

• When removing, the fan will rotate in the direction of force.

In order to prevent this, the stud shall be clamped in a

reverse direction with a screwdriver.

• All nuts removed shall be centrally placed, in order to

prevent loss

Take down the fan pulley.

Take down the fan and its pulley.

(a). Disassemble the fixing bolt of crankshaft pulley.

15B-184

Take down the crankshaft pulley.

15B-185

DISASSEMBLY OF DIPSTICK

(a). Disassemble the fixing bolt of dipstick bracket.

Remove the dipstick

15B-186

DISASSEMBLY OF HIGH & LOW PRESSURE FUEL PIPE AND FUEL

INJECTOR

(a). Disconnect the connection with high pressure fuel pipe

and fuel injector.

Disconnect the connection of high pressure pipeline

and high pressure oil pump.

Take down the high pressure fuel pipe.

Disconnect the connection with low pressure rubber

15B-187

Take down each low pressure rubber fuel pipe

connecting to fuel injectors successively.

2. Disassemble the fuel injector

(a). Disassemble the fixing bolts of fuel injector pressure

plate successively.

Take down the fuel injector pressure plate and fuel

injector successively.

15B-188

DISASSEMBLY OF ROCKSHAFT AND TAPPET

1. Disassemble the rockshaft

(a). Disassemble the fixing bolts and nuts of rockshaft.

• Do not disassemble a certain bolt or nut at a time. On e shall

uniformly disassemble the fixing bolts or nuts of rockshaft

for several times.

• All bolts and nuts removed shall be centrally placed, in order

to prevent loss.

Take down the rockshaft.

2. Disassemble the tappet

(a). Take out the tappets successively and place them

centrally.

15B-189

DISASSEMBLY OF CYLINDER HEAD

1. Disassemble the cylinder head

(a). Disassemble the connecting hose clamp of oil radiator

and cylinder head, disconnect the hose connection and

take down the hose.

Disassemble the rubber hose connecting with the water

pump and thermostat.

(c). Disassemble the fixing bolt of cylinder head.

When removing, the cylinder head bolt shall be

disassembled once a couple for several times as the

sequence from middle to two sides.

(d). Remove the cylinder head assembly

15B-190

DISASSEMBLY OF THE WATER OUTLET PIPE CONNECTOR,

VALVE AND HOOK

1. Remove the water outlet pipe connector.

(a). Remove the fixing bolts of water outlet pipe connector.

Remove the water outlet pipe connector.

2. Remove the valve

(a). Compress the valve spring with valve spring

compressor to expose the installation location of valve

lock clamp.

(b). Remove the valve lock clamp

To prevent causing personal injuries, please wear the

goggles.

15B-191

(c). Remove the valve spring upper seat, valve spring, and

valve spring lower seat and remove the valve oil seal.

The oil seal removed can’t be reused and shall be replaced

with new one.

Remove the valve

(e). Remove the valve guide with special disassembly tool.

The valve guide removed can’t be reused. Therefore, remove

the valve guide depending on the actual condition.

3. Remove the hook.

(a). Remove the fixing bolts of front hook.

Remove the front hook.

Remove the rear hook as per same method.

15B-192

DISASSEMBLY OF OIL FILTER AND OIL RADIATOR

1. Disassemble the oil filter

(a). Disassemble the connecting pipe weldment fixing bolt

of oil radiator and oil filter.

(b). Disassemble the fixing bolt of oil filter.

Take down the oil filter.

(d). Disassemble the fixing bolt connecting with the

connecting pipe weldment and oil radiator.

15B-193

(e). Take down the O-ring of weldment and the weldment of

connecting pipe.

It is not proper to reuse the disassemble O-ring. It shall be

replaced by a new one.

(f). Disassemble the fixing bolt of oil radiator.

Take down the oil radiator.

15B-194

1. Remove the Clutch Components.

(a) Remove the fixing bolts of clutch.

Remove the clutch disc and clutch cover components.

2. Remove the flywheel assembly.

(a). Remove the fixing bolts of clutch.

(b). Remove the flywheel assembly.

Caution shall be taken during the removal, as the flywheel has

certain weight.

15B-195

(c). Remove the fixing bolts of support rear cover.

Remove the support rear cover.

Remove the sealing strip of rear oil seal cover.

15B-196

DISASSEMBLY OF OIL PAN AND OIL PUMP

1. Remove the oil pan.

(a). Overturn the engine body.

The oil shall be completely discharged in prior of the

Disassembly of oil pan.

(b). Disassemble the fixing bolt of oil pan.

• When removing, the fixing bolt of oil pan shall be

disassembled in a crossing way as the sequence from

middle to two sides and then the sequence from two sides

to middle.

Take down the oil pan.

2. Disassemble the oil pump

(a). Disassemble the fixing bolt of oil pump driving gear

chamber cover.

15B-197

Take down the cover and take out the driving gear of oil

(c). Disassemble the fixing bolt of oil pump.

(d). Take out the oil pump.

Take out slowly and avoid the impact.

15B-198

DISASSEMBLY OF OIL SEAL COVER AND OIL SEAL

1. Remove the oil seal cover and oil seal.

(a). Remove the fixing bolts of the oil seal cover.

Remove the oil seal and the oil seal cover.

Separate the oil seal from the oil seal cover.

15B-199

DISASSEMBLY OF GEAR CHAMBER COVER, INJECTION PUMP

AND WATER PUMP ASSEMBLY

1. Disassemble the gear chamber cover

(a). Disassemble the fixing bolt of gear chamber cover.

(b). Take down the injection pump gear chamber cover.

(c). Take down the gear chamber cover and the gasket.

2. Disassemble the injection pump

(a). Disassemble the fixing bolt of injection pump gear.

15B-200

Disassemble the injection pump gear with an extractor.

(c). Disassemble the fixing bolt of injection pump.

(d). Disassemble the fixing bolt connecting with injection

pump and injection pump bracket.

• When removing, the injection pump shall be hold up with a

hand in case of damage or personal injuries due to the

falling of pump.

(e). Take down the injection pump.

Take it out carefully and avoid the impact.

3. Remove the water pump components

(a). Remove the fixing bolts of the water pump

components.

15B-201

(b). Remove the water pump components and water pump

gasket.

It is not proper to reuse the disassembled gasket. It shall be

15B-202

DISASSEMBLY OF CAMSHAFT GEAR AND CRANKSHAFT GEAR

1. Disassemble the camshaft gear

(a). Disassemble the fixing bolt of camshaft gear.

(b). Take down the camshaft gear.

Do not forget to take down the woodruff key.

(c). Disassemble the fixing bolt of camshaft pressure plate.

Take down the pressure plate of camshaft.

15B-203

2. Disassemble the crankshaft gear

(a). Take down the oil baffle disk.

(b). Take down the crankshaft gear and the woodruff key.

• Do not forget to take down the woodruff key.

• All woodruff keys removed shall be centrally placed, in

order to prevent loss.

15B-204

DISASSEMBLY OF CAMSHAFT, PISTON AND CRANKSHAFT

1. Disassemble the camshaft

(a). Turn over the engine body and take out the camshaft.

• Take out the camshaft without influencing the tappet.

• The camshaft shall be taken out by slowly revolving.

(b). Take out the tappets successively.

• Draw out the tappets from their installation positions

successively with high performance magnet.

• The tappet taken out shall be put in a clean vessel.

2. Disassemble the piston assembly

(a). Rotate the crankshaft to locate the journal of

disassembled connecting rod on the bottom dead

center.

(b). Disassemble the fixing nut of connecting rod cover.

Unscrew every two nuts a time.

15B-205

Lightly shake and pull out the connecting rod cover and

remove the connecting rod bearing bush.

Remove the carbon deposit from the piston cylinder.

(e). Push out the piston assembly

face of connecting rod

(f). Remove the piston assembly from the other side.

Install the piston assembly removed together, add the marking,

and place into a clean container.

(g). Remove the pistons of other cylinders as per same

method.

3. Remove the crankshaft assembly.

(a). Loosen the bolts of main bearing cap in turn.

15B-206

(b). Take down the main bearing cap and align them in

Take down the main bearing bush.

(d). Lift out the crankshaft

This part is a little heavy. To prevent causing serious personal

(e). Remove the upper bushes of the main bearing bushes.

Take out every upper bush successively and mark the cylinder

number at the movable lug.

15B-207

(f). Take down the crankshaft thrust halfring.

Take down the crankshaft thrust halfring and mark the

installation position and its front and back to facilitate the

correct installation when assembling.

15B-208

ENGINE MECHANICAL PART- ASSEMBLY OF ENGINE

ASSEMBLY OF ENGINE (4D20)

INTRODUCTION OF ASSEMBLY

15B-209

INSTALLATION OF CRANKSHAFT, PISTON AND CAMSHAFT

(a). Face upward the cylinder block crankcase and place

(b). Install the thrust halfring of crankshaft

There are only two thrust halfrings for this engine, installing at

the 4th main bearing bush of cylinder block.

The oil groove shall face outward when installing the

thrust halfrings.

(c). Install the upper bushes of the main bearing bushes to

the specified positions.

bushes to the specified positions in turn and ensure that

the back faces of the bearing bushes are clean without

any scrap. The upper bush of each main bearing bush

shall be in the center position of the bearing bush groove

and the top faces of all bearing bushes shall be level

• After installation, the inside of bearing bush arching

surface shall be evenly covered with proper amount of oil

or equivalent.

15B-210

(d). Drip clean oil or equivalent to the inner side of the main

bearing bushes.

(f). After the installation of crankshaft, drop clean oil or

equivalent onto the main journal of the crankshaft and

rotate the crankshaft to lubricate its surfaces.

15B-211

(h). Install the main bearing cap and its fixing bolts in order.

• Install the main bearing cap to its original position when

removing as the mark without any mistake.

• There are identification numbers on main bearing cap of

each crankshaft. The installation shall be conducted in order

without any mistake.

When placing the crankshaft main bearing cap onto the

main bearing seat of crank case, the arrow on each cover

shall point to the front (the direction of pulley)

(i). Screw up the main bearing bolt according to some

sequence and torque.

• Do not screw up the bolt at one time. The bolt shall be

screwed up a little and generally be fastened to the

specified torque.

• The main bearing bolt shall be fastened according to a

certain sequence (see left diagram)

15B-212

(a). Install the connecting rod bolts to the connecting rod.

In prior of assembly, the cylinder block and all of the parts shall

be clean. The connecting rod and bearing bush shall be

cleaned with a piece of clean and lint-free cloth.

Make sure that the back faces and side faces of the

without any scrap. Do not lubricate the back face and side

face of the connecting rod bearing.

Drip clean oil or equivalent oil to the inner side of the

15B-213

The opening of each piston ring can’t be aligned with the

opening of the piston pin or other piston rings, otherwise the

piston rings can’t achieve correct sealing effect.

One can make a piston ring with iron sheet without any special

Side overturn the cylinder block and apply one film of

clean oil onto the walls of the cylinder block

15B-214

Insert the connecting rod into the cylinder bore, till the

• Align the arrow on the top of the piston with the front of the

• The longer end of the connecting rod and the notch on the

piston skirt shall be at the exhaust side of the engine. If not,

verify whether the piston is at the correct installation

position on the connecting rod.

The failure to install as per above procedure will lead to

serious damage of the engine.

15B-215

(m). Install each connecting rod cover to corresponding

The middle portion of the connecting rod and the head of the

connecting rod cap are forged with markings. During assembly,

face these markings towards the front of the engine (Pulley

end).

(n). Install the connecting rod nuts.

Use torque wrench to fasten the nuts by two times as per

angular fastening method.

Specified Torque:

(o). Check whether the piston assembly is installed

correctly

• Measure the gap between the connecting rod body

and the crankshaft and the protrusion amount of the

piston top respectively.

Measure the gap between the connecting rod body and the crankshaft and the protrusion amount of the

If the piston, crankshaft, connecting rod or cylinder block is ever changed/replaced, it’s necessary to

measure the protrusion amount of the piston on the combustion face of the cylinder block.

• Install micrometer on the cylinder head and reset to zero.

• Move the micrometer right above the top of the piston, in order to eliminate all lateral movements.

15B-216

• Rotate the crankshaft to the top dead center and then rotate the crankshaft clockwise and

counter-clockwise, find out the maximum reading of the micrometer, and record the measurement

result.

The volume of bulge on the top of piston

3. Install the camshaft assembly

(a). Install the tappet into a specified installation hole

successively.

When installing the camshaft, instead of being placed

vertically, the engine body shall be placed at a certain

angle in case of gliding downward of tappet.

(c). Apply an appropriate amount of lubricating grease or

(d). Rotate and install the camshaft to the specified

to fix the camshaft cam into the sleeve.

• Rotate the camshaft to separate the cam from the

restraint of the sleeve, in order to install the camshaft

smoothly.

15B-217

Install the camshaft pressure plate to a specified

(f). Install and fasten the fixing bolt of camshaft pressure

Rotate the camshaft to check whether the cam shaft can rotate

freely

If the camshaft can’t rotate freely, do not rotate the

camshaft with force, or it will damage the camshaft sleeve.

Analyze the cause and reassemble the camshaft.

15B-218

INSTALLATION OF OIL SEAL AND OIL SEAL COVER

1. Install the oil seal and the oil seal cover.

(a) Install the oil seal and the oil seal cover together.

Apply oil onto the lips of the oil seal.

Install the oil seal and the oil seal cover to the specified

positions.

(d). Install and fasten the fixing bolts of the oil seal cover.

Cross fasten the bolts from the middle to the sides or from the

sides to the middle, instead of excessively fastening any bolt

by one time.

15B-219

INSTALLATION OF CRANKSHAFT GEAR AND CAMSHAFT GEAR

Environment Engine Co., Ltd when necessary.

1. Install the crankshaft gear

(a). Install the crankshaft gear to the specified position.

When installing the crankshaft gear, the woodruff key shall

be installed to the specified position. Also, it shall be

installed aligning with the installation mark to ensure the

correctness of installation.

Install the oil baffle disk to a specified position.

2. Install the camshaft gear

(a). Install the camshaft gear to a specified position.

Before installing the camshaft gear, the woodruff key of

camshaft shall be installed to the specified position.

Install and fasten the fixing bolt of camshaft gear.

15B-220

INSTALLATION OF INJECTION PUMP AND GEAR CHAMBER

1. Install the injection pump

(a). Install the injection pump to the specified position

The marks made when removing shall be aligned with

when installing to ensure the installation correctness.

(b). Install and fasten the fixing bolt of injection pump.

One shall hold up the injection pump with a hand when

installing in case of the damages or personal injuries caused

by the falling of pump.

Install and fasten the fixing bolt connecting with

injection pump and its bracket.

(d). Install the injection pump gear to the specified position.

The installation marks shall be aligned with when installing to

ensure the installation correctness.

15B-221

Install and fasten the fixing nut of injection pump gear.

2. Install the gear chamber cover

(a). Install the gear chamber gasket and gear chamber

cover to the specified position.

The gasket of gear chamber shall be replaced by a new one.

Install and fasten the fixing bolt of gear chamber.

Install the injection pump gear chamber cover to the

specified position and Install and fasten the fixing bolt.

15B-222

INSTALLATION OF OIL PUMP AND OIL PAN

1. Install the oil pump assembly.

(a). Install the oil pump assembly to the specified position.

(c). Install the oil pump driving gear to the specified position

and install the oil pump driving gear cover.

Be sure the oil pump driving gear and the oil pump propeller

shaft are all installed in place.

Install and fasten the fixing bolt of cover.

15B-223

2. Install the oil pan.

(a). Install the oil pan to the specified position.

• Before installation, the surface of contact position of oil pan

and cylinder block are covered by sealant.

• Before smearing the sealant, one shall be sure that the

used sealant on the oil pan and engine block shall be

cleaned up.

(b). Install and fasten the fixing bolts of oil pan.

• When installing the fastening bolt on oil pan, one shall

lubricate each fastening bolt with oil.

• Cross fasten the fixing bolts of oil pan from the middle to the

15B-224

INSTALLATION OF FLYWHEEL ASSEMBLY AND CLUTCH

1. Install the flywheel assembly

(a). Install the sealing strip of the rear oil seal cover to the

specified position.

Install the support rear cover to the specified position.

Install and fasten the fixing bolts of the support rear

(d). Install the flywheel to the specified position.

One shall be careful when installing for the weight of flywheel.

15B-225

(e). Install and fasten the fixing bolts of flywheel.

While installing the flywheel bolts, apply oil to the threads and

the contact face and then fasten in diagonal manner.

3. Install the Clutch Components.

(a). Install the clutch disc and the clutch cover assembly

with installation positioning tool to the specified

Install and fasten the fixing bolts of clutch.

15B-226

INSTALLATION OF OIL RADIATOR AND OIL FILTER

1. Install the oil radiator

(a). Install the oil radiator and its gasket to the specified

The oil radiator gasket shall be replaced by a new one.

(b). Install the O-ring to the specified position.

O-ring shall be replaced by a new one.

Install and fasten the fixing bolt of oil radiator.

Install the connecting pipe weldment of oil radiator and

oil filter and install the fixing nut.

15B-227

2. Install the oil filter

(a). Install the oil filter to the specified position.

Apply sealant onto the oil filter installation position of the

cylinder block and replace with new gasket.

Install and fasten the fixing bolt f oil filter.

Install and fasten the fixing bolt connecting the

weldment and oil filter.

15B-228

INSTALLATION OF HOOK, VALVE, AND WATER OUTLET PIPE

CONNECTOR

1. Install the hooks.

(a) Install the front hook to the specified position.

Install and fasten the fixing bolts of hook.

Install the rear hook in place as per same method.

2. Install the valves.

(a). Knock in the valve guide from the top of the cylinder

head with special tool.

Before the installation, apply oil to the outer surfaces of

the valve guide. After the installation, check the height of

the valve guide.

(b). Lubricate all valve guide bores and the valve stems.

Lubricate with oil, otherwise it will lead to early wear of valve

guides

15B-229

(c). Install valve to the specified position.

• If the installed valve and disassembled valve are same,

the valve shall be installed on the position at which the

valve is disassembled.

• If the cylinder head can’t be used immediately, lubricate

the valve stems with assembly lubricant or equivalent.

(d). Install the valve oil seal and install the valve spring

lower seat, valve spring, and valve spring upper seat.

The valve spring upper seat for intake valve is different from

that for exhaust valve.

Replace with new valve oil seal.

(e). Compress the valve spring with valve spring

(f). Install the valve lock clamp and then release the valve

spring to enable the valve lock clamp to lock the valve.

After the assembly, knock the valve spring seat with rubber

hammer to ensure the correct installation of locking plate.

If the lock clamp is not installed correctly, the lock clamp

will fly out while knocking the valve spring seat with

plastic hammer. To minimize the possibility of the

personal injuries, please wear the goggles.

Install all valves as per same method.

15B-230

3. Install the water outlet pipe connector.

(a) Install the water outlet pipe connector assembly to

Install and fasten the fixing bolts of the water outlet pipe

connector assembly.

15B-231

INSTALLATION OF CYLINDER HEAD

1. Install the cylinder head

(a). Install the cylinder head gasket and cylinder head to

• For the heavy cylinder head, it shall be lifted with assistant

and proper hoisting equipment to prevent severe personal

(b). Install and fasten the fixing bolts of the cylinder head.

Before the installation, lubricate the threads of the fixing bolts

of cylinder head and the lower portion of the bolt head with

During installation, the cylinder head bolt shall be

disassembled in pairs for several times as the sequence

from middle to two sides.

Install the rubber hose connecting the water pump and

thermostat and install the fastening clamp.

Install the oil radiator and cylinder head connecting

hose to the specified position.

15B-232

Fasten the hose clamp and ensure the fastness of

15B-233

INSTALLATION OF TAPPET AND ROCKSHAFT

1. Install the tappet

(a). Fill clean oil into the installation hole of each valve

(b). Install the valve tappet to the specified position.

Put the valve tappet into the installations hole as the reversed

sequence of disassembly.

2. Install the rockshaft

(a). Install the rocker assembly to the specified position.

(b). Install the fixing bolt and fixing nuts of rockshaft.

Do not disassemble a certain bolt or nut at a time. One shall

uniformly disassemble the fixing bolts or nuts of rockshaft for

several times.

15B-234

(a). Install the fuel injector and its pressure plate to the

Ensure the fuel injector and its pressure plate is installed in

Install and fasten the fixing bolt of fuel injector pressure

Install the low pressure rubber fuel pipe connecting to

each fuel injector in order and fasten the clamp.

Connect the connection of low pressure rubber fuel

15B-235

2. Install the high & low pressure fuel pipe

(a). Install the high pressure fuel pipe to the specified

Fasten the fixing bolt connecting the high pressure fuel

pipe and high pressure oil pump.

Connect the connection of high pressure fuel pipe and

fuel injector and ensure the fastness of connection.

15B-236

INSTALLATION OF DIPSTICK

1. Install the dipstick.

Ensure the dipstick is installed in place.

Install and fasten the fixing bolts of dipstick.

15B-237

INSTALLATION OF CRANKSHAFT PULLEY, FAN AND FAN PULLEY

Install and fasten the fixing bolt of crankshaft pulley.

2. Install the fan and its pulley

(a). Install the fan and its pulley to the specified position.

(b). Install and fasten the fixing bolt of fan assembly.

When installing, the fan will rotate in the direction of force. In

order to prevent this, the stud shall be clamped in a reverse

direction with a screwdriver.

15B-238

INSTALLATION OF BREATHER AND GENERATOR

(a). Install the breather assembly to a specified position.

Connect the connection of lower oil pipe of breather

and the breather and install the fastening clamp.

2. Install the generator

(a). Install the lower bracket of generator to the specified

position and install the fixing bolt fastening the lower

bracket of generator.

ENGINE MECHANICAL PART- INSTALLATION OF BREATHER AND GENERATOR

15B-239

Install the upper bracket of generator to the specified

position and install the fixing bolt fastening the upper

Install the generator assembly to the specified position.

(d). Install the lower fixing bolt of generator.

when installing, one shall firstly lock the bolt and then

• When installing the fixing bolt, one shall hold up the

(e). Install the adjusting bolt of generator.

The adjusting bolt shall be fastened after the fan belt is

(f). Adjust the tension of belt and fasten the adjusting bolt

of generator.

Adjust the tension of fan belt through the generator adjusting

15B-240

Install the hose clamp of vacuum pump oil return pipe

and connect the connection of oil return pipe.

Connect the connection of vacuum pump oil inlet pipe

and generator and fasten the fixing bolt.

15B-241

1. Install the intake and exhaust manifolds and

turbocharger

(a). Install the turbocharger gasket and turbocharger onto

the exhaust manifold pipe.

turbocharger and turbocharger bracket.

Install and fasten the fixing bolt of turbocharger air inlet

Install the intake manifold assembly.

15B-242

(e). Install the rubber hose connecting the turbocharger and

intake manifold, Fasten the clamp and ensure the

fastness of installation.

Ensure the assembly of intake and exhaust manifolds and

turbocharger is correct and secure.

(f). Install the intake and exhaust manifolds gaskets to the

The gaskets of intake and exhaust manifolds shall be replaced

by new ones.

(g). Install the intake and exhaust manifolds and

turbocharger to the specified positions.

In order to facilitate the installation of generator, the intake and

exhaust manifolds and turbocharger shall be installed all

Connect the connection of turbocharger oil return

rubber hose and cylinder block.

Install the turbocharger oil inlet pipe weldment to the

specified position and install the fastening and fixing

15B-243

Install EGR valve connecting pipe weldment to the

connecting pipe weldment and intake manifold.

Install and fasten the intake and exhaust manifolds bolt.

15B-244

INSTALLATION OF EGR CONTROLLER

1. Install EGR controller

(a). Install EGR controller onto the fixing bracket of air

compressor and install the fastening and fixing bolt.

(b). Install EGR controller equipped with air compressor

bracket to the specified position and install the fixing

bolt which can fasten the air compressor bracket.

For the convenience of disassembly, the air compressor fixing

bracket and EGR controller shall be taken down all together.

Connect the connection of generator and EGR

controller vacuum pipeline.

Connect the connection of preheat controller and the

controller oil inlet pipe.

15B-245

Connect the connection of EGR valve vacuum pipeline.

15B-246

INSTALLATION OF CYLINDER HEAD COVER

1. Install the cylinder head cover

(a). Install the cylinder head cover to the specified position.

Install and fasten the fixing nut of cylinder head cover.

15B-247

INSTALLATION OF HEATER AND WATER OUTLET-INLET PIPE

1. Install the weldment of heater and water outlet-inlet

(a). Install the weldment of heater and water outlet-inlet

pipe to the specified position.

Install the rubber hose connecting the weldment of

heater and water outlet-inlet pipe and the thermostat.

Install and fasten the fixing bolt of weldment of heater

and water outlet-inlet pipe.

15B-248

ENGINE MECHANICAL PART-CYLINDER HEAD COVER

CYLINDER HEAD COVER

ENGINE MECHANICAL PART- CYLINDER HEAD COVER

15B-249

Anti-vibration cover plate assembly of

valve chamber cover

Anti-vibration pad of valve chamber

cover

5 Oil filler cap

7 Gasket of valve chamber cover

8 Gasket of valve chamber cover nut

9 Fixing nut of valve chamber cover

10 Crankshaft vent valve component

11 Spring washer

12 Cross recess head screw

6 Valve chamber cover assembly

15B-250

During the disassembly, the parts of valve assembly shall be concentrated together and marked with

identification code to return to their own origin positions when reinstalling; one shall conduct a

compression test and record its result before removing the cylinder head from generator and

disintegrating the valve mechanism.

1. Preliminarily check the engine.

(a). Clean the outside of generator with steam or high

pressure gun.

Hot steam may cause serious personal injuries. While

using the steam cleaner, please wear the safety goggles or

protective mask and wear the protective clothing

Run the engine at low idle speed and check for leakage

of oil or coolant between cylinder head and engine

(c). Listen whether there is “chirp” sound between the

cylinder head and the engine cylinder block.

Fill water into the coolant tank, till the overflow pipe within the

coolant tank is immersed. Then, run the engine at high idling

speed, till the thermostat turns on. In such case, observe the

water solvent for the presence of steam bubbles, which will

determine whether there is leakage in the combustion

Upon the detection of leakage, disassemble and check the

cylinder head and all related parts.

2. Remove the cylinder head cover assembly (Refer to Chapter 15B Engine Mechanical system –

Disassembly of Engine 4JB1).

15B-251

3. Disassemble and service the cylinder head cover

(a). Take down the oil filler cap

As required, screw off the oil filler cap.

(b). Dismantle the fixing bolt of anti-vibration cover plate

assembly of valve chamber cover.

Disassemble the anti-vibration cover plate assembly of

Check the anti-vibration cover plate assembly of valve

chamber cover to see whether it is damaged. If it is,

please replace the damaged one.

Disassemble the anti-vibration pad of valve chamber

15B-252

Check the anti-vibration pad of valve chamber cover to

see whether it is aging, corroded or deformed. If any of

those phenomena occurs, it shall be replaced by a new

Disassemble the fixing bolt of crankcase vent valve

component with cross screwdriver and take down the

crankcase vent valve component

(h). Check the oil filler cap for the presence of cracking and

corrosion. If yes, replace with new one.

Observe for the presence of water vapor within the oil filler cap.

If yes, it indicates the ingress of coolant into the cylinder block.

In such case, carefully check the cylinder gasket, cylinder head,

and waterway for damage. If yes, maintain or replace the

damaged parts.

(i). Clean the cylinder head cover with solvent, acid or

alkaline material.

material for cleaning.

• Please wear the goggles and protective clothing to

prevent causing personal injuries.

15B-253

(j). Blow dry the cylinder head cover with compressed air.

While using the compressed air, please ware appropriate

goggles and protective mask to prevent the scraps and

dirt splashed from causing personal injuries.

Check the cylinder head cover for presence of damage.

If yes, replace with new one.

Check the gasket of cylinder head cover for aging,

corrosion or deformation. If yes, replace with new one.

4. Install the cylinder head cover assembly.

(a). Install the crankcase vent valve component to the

specified position and install the fixing bolt of crankcase

vent valve component.

Install the anti-vibration pad of valve chamber cover.

15B-254

Install the anti-vibration cover plate assembly of valve

Install and fasten the fixing bolt of valve chamber cover

anti-vibration cover plate assembly.

Install the oil filler cap

5. Install the cylinder head cover assembly (Refer to Chapter 15B Engine Mechanical system –

Assembly of Engine 4JB1)

ENGINE MECHANICAL PART-ROCKER ASSEMBLY

15B-255

ROCKER ASSEMBLY

1 Rockshaft plug

2 Retainer ring

3 Rocker assembly

4 Valve adjusting bolt

5 Valve adjusting nut

6 Rockshaft seat

7 Small washer

8 Hexagon head stud

9 Rocker spring washer

10 Rockshaft spring

11 Rockshaft

12 Rockshaft bearing bolt

13 Long hexagon stud

15B-256

If any excessively worn or damaged part is detected during the service, perform the necessary

adjustment, repair and replacement.

1. Remove the rockshaft assembly (Refer to Chapter 15B Engine Mechanical system –

2. Clean and Test for the electric heater plug

(a). Clean the electric heater plug by washing.

Test the electric heater plug as shown in left diagram.

• When the electric heater plug connecting with

battery, if A end emits heat, it means that the

electric heater plug is working well.

battery, if A end doesn’t emit heat, it means that

the electric heater plug is damaged.

3. Disassemble the rockshaft assembly (see Chapter 15B Engine Mechanical System –

Disassembly of Engine 4JB1)

4. Disassemble the rockshaft assembly.

(a). Disassemble the rockshaft plug and take down the

circlip at the rocker assembly end with circlip pliers.

15B-257

(b). Take down the rocker processing assembly and rocker

When taking out the rocker processing assembly, the revolving

method is a relatively easy way.

Take out the rockshaft.

Disassemble the adjusting nut of valve and disintegrate

the rocker assembly assembly.

(e). Disassemble the shaft seat and rocker assembly.

• The position of each disassembled one shall be marked.

• During the installing, it shall be installed at the origin

position and in the origin direction when removing.

3. Check the rocker assembly.

(a). Clean all parts with high concentration detergent and

hot water solvent.

15B-258

Clean off the deposits on rocker seat and rocker

assembly with steel brush and mild steel wire rotary

(c). Blow dry all parts with compressed air.

Check the adjusting bolt and fixing nut of valve

clearance to see whether there are cracks or

deformation of threads. If there is one of phenomena

mentioned above, it shall be replaced.

Check whether the adjustable threads of valve

clearance is deformed or the wear condition of bolt with

fillister head. If there is one of phenomena mentioned

above, it shall be replaced.

Check the rocker bore for the presence of cracking or

excessive wear. If yes, replace with new one.

15B-259

Check whether the oil holes on the rocker are blocked.

If yes, clean the oil holes on the rockshaft with

compressed air.

(h). Measure the inside diameter of the rocker with vernier

caliper or micrometer.

The parameters are shown in the table below:

Engine Model

Specified Value mm

4JB1 19.010~19.030

4D20 19.010~19.030

(i). Measure the external diameter with dial indicator at the

position of rocker swing on the rockshaft.

Specified Value: mm

4JB1 18.980~19.000

4D20 19.979~20.000

(j). Place the rockshaft onto the V-blocks and measure the

radial run-out in the middle of the rockshaft with

micrometer.

Note:

If the radial run-out is minor, the bench press may be used

to correct the radial run-out of the rockshaft. If the run-out

is out of the specified range, replace the rockshaft.

15B-260

4. Install the rockshaft assembly.

(a). Lubricate the rockshaft with clean oil.

Lubricate the rocker and the inner bore of rocker seat

with clean oil.

Install the rocker assembly, valve adjusting bolt and

adjusting nut together.

(d). Install the rocker, rocker spring, rockshaft bracket into

the rockshaft in the reversed sequence of disassembly.

The rocker, rockshaft bracket hole and rockshaft surface shall

be covered with clean oil.

(e). Install the rocker retainer ring and rockshaft plug with

circlip pliers.

As an elastic part, the retainer ring is likely to rush out. For

this reason, it is recommended to wear goggles and

handle this part carefully.

15B-261

5. Install the rocker assembly (Refer to Chapter 15B Engine Mechanical system – Assembly of

Engine 4JB1).

15B-262

ENGINE MECHANICAL PART-CYLINDER HEAD

15B-263

1 Hexagon head bolt assembly

3 A/C bracket

4 Bowl-Bowl-shaped tabular plug 12

5 Type 1 hexagon nut

6 Stud

Pressure plate cushion block of fuel

8 Pressure plate of fuel injector

Pressure plate bolt gasket of fuel

10 Pressure plate bolt

11 Valve key

12 Valve spring upper seat

13 Valve spring

14 Valve guide pipe oil seal

15 Valve spring lower seat

16 Intake and exhaust valve guide pipes

17 Bowl-Bowl-shaped tabular plug 22

18 Cylinder Head

19 Cylinder head bolt

20 Bowl-Bowl-shaped tabular plug 45

21 Electric heater plug

22 Preheat plug pad

23 Rear hook of generator

25 Spring washer

26 Plain washer

27 Stud

28 Exhaust valve seat

29 Exhaust valve

30 Exhaust valve

31 Intake valve seat

32 Bowl-Bowl-shaped tabular plug 18

33 Cylinder head bolt

15B-264

1. Remove the tappet (Refer to Chapter 15B Engine Mechanical system – Disassembly of Engine

4JB1)

2. Remove the cylinder head assembly (Refer to Chapter 15B Engine Mechanical system –

3. Check the bolts of cylinder head.

(a). Clean the bolts with diesel engine solvent.

Thoroughly remove the sediment from the bolt stems and the

threads with wire brush, soft wire wheel brush, or non-abrasive

sand blasting.

• Do not clean the bolts with alkaline or acid solvent, or it

will lead to damage of bolts.

(b). Visually observe the bolts of the cylinder head for

corrosion and observe the threads for damage. If yes,

replace with new ones.

4. Disassemble the thermostat assembly (see Chapter 15B Engine Mechanical System –

5. Remove the valves (see Chapter 15B Engine Mechanical System – Disassembly of Engine

6. Preliminarily clean the cylinder head.

(a). Clean the sealing surfaces of the cylinder head and the

15B-265

Clean the combustion surfaces of the cylinder block

and cylinder head.

7. Deep cleaning and maintenance for the cylinder

head

(a). Clean up the carbon deposits on the fuel injector seat

with fuel injector pore brush or equivalent tools.

Clean the valve retainer with brush.

(c). Clean the foreign materials with compressed air

(d). Immerse the cylinder head into the acid solvent tank to

remove the sediments.

Firstly remove the expansion plug. If necessary, clean the

sediment from the coolant way.

15B-266

(e). After the cleaning, clean the cylinder head combustion

surface with hand grinding pad or equivalent cleaning

pad and solvent.

manual of the manufacturer before use

(f). Clean the valve seat and valve guide

• While cleaning the carbon deposit, wear the goggles to

prevent personal injuries.

• The rotation of wire wheel will damage the valve seat.

Therefore, it’s necessary to machine the new valve seat

or install new valve retainer.

• Poor quality wire wheel will drop wires during the

working, which will lead to additional contamination.

Use quality wire wheel installed onto the drill or the

mould polishing machine to remove the carbon deposit

from the valve guide.

(g). Remove the sediment from the installation hole of the

valve retainer with wire brush and solvent (The valve

seat is already removed)

(h). Blow dry the surfaces of cylinder head with

15B-267

Clean the cylinder head with hot soapy solvent and

then flush the cylinder head with clean water.

(j). Blow dry the cylinder head with compressed air.

8. After the cleaning, recheck the cylinder head.

(a). Check the cylinder head for the presence of cracking,

corrosion and discoloration. If any cracking, corrosion,

or discoloration detected will influence the further

service, replace with new cylinder head.

Pay close attention to the following areas of the cylinder

head:

Combustion surfaces, valve seat, and valve guide.

• The cylinder head can be further used if the cracking

detected does not extend to the valve seat.

• If the cracking extends to the valve seat or passes through

the valve seat, replace the cylinder head, otherwise such

cracking will lead to fall-off of the valve retainer and further

lead to damage of engine.

If the cylinder head is not replaced, the cracks extending

to or passing by the valve seat pore may lead to the falling

off of the valve retainer and further lead to the damage of

15B-268

Check the valve seat for presence of cracking and

ablation points. If yes, depending on the working

surface and the lower limit of the valve retainer, replace

the valve retainer.

Check the threaded holes on the rockshaft bracket and

the cylinder head to see whether the threads are

damaged or deformed; if they are, the chambering or

repair will be conducted if possible and be replaced

when necessary.

(d). Measure the length of diagonal line of the cylinder head

lower surface to decide whether the housing cap is

deformed.

If the 2 diagonal lines are not equal, it means the cylinder

head is deformed and required to be replaced.

(e). Clean the oil passage and water passage on the top of

the cylinder head with water gun.

Carefully clean the oil passage holes and water passage

holes in turn

9. Install the valve assembly (Refer to Chapter 15B Engine Mechanical System– Assembly of

10. Install the thermostat assembly (Refer to Chapter 15B Engine Mechanical System– Assembly

of Engine 4JB1).

11. Install the cylinder head assembly (Refer to Chapter 15B Engine Mechanical System–

Assembly of Engine 4JB1).

12. Install the tappet (Refer to Chapter 15B Engine Mechanical System– Assembly of Engine

4JB1).

ENGINE MECHANICAL PART- VALVE

15B-269

1. The valve distribution mechanism is of direct influence over the normal functioning of the engine. The

valve distribution mechanism shall guarantee that the clean air can timely enter into the cylinder with

maximum inflation amount during the intake stroke and the exhaust gas in the cylinder can be timely

drained from the cylinder and the residual exhaust gas can be minimized as far as possible during the

exhaust stroke. Meanwhile, the valves shall be tightly closed during the compression and power

strokes.

2. Within the valve distribution mechanism, some parts are subject to the impact of high temperature gas

and the impact load and some parts are poorly lubricated. Under long-term service, these parts get

worn, ablated, or deformed so that the technical performance and fit relationship are impaired to

cause malfunction and failure of parts.

15B-270

The valve clearance plays an important role in the technical state of diesel engine, so the valve clearance

shall be checked in accordance to the maintenance regulate or actual operation condition. The cold state

clearance of intake valve shall be about 0.40±0.050mm, while the cold state clearance of exhaust valve shall

be about 0.40±0.050mm. The adjustment methods are as follows:

1. Rotate the crankshaft till the pulley scale marks of crankshaft vibration damper shall aligning

with timing indicator. Currently, the 1st cylinder piston or the 4th cylinder piston locates at the

dead center of compression travel.

The engine is in cold state.

2. Judge whether is the piston of the 1st cylinder or

the piston of the 4th cylinder locating at the dead

center of compression travel.

Shake the exhaust valve rocker of the 1st cylinder or the 4th

cylinder, if there is clearance when shaking the 1st cylinder

valve rocker, it means that the 1st cylinder is locating on the

dead center of compression travel; if the rocker of the 1st

cylinder valve cannot shake, then one shall shake the rocker of

4th cylinder valve; if there is clearance on the rocker of 4th

cylinder, it means the 4th cylinder is locating at the dead center

of compression travel.

(a). When the 1st cylinder is at the dead center of

compression travel, the valve clearance shall be

checked with feeler gauge.

Engine Value for Clearance of Value for Clearance of

Model Intake Valve mm Exhaust Valve mm

4JB1 0.4 0.4

4D20 0.35 0.35

15B-271

(b). When the clearance of valve is too small, one shall

anticlockwise rotate the adjusting bolt of valve

clearance till the feeler gauge can be inserted into it

and meet a little resistance.

When adjusting the valve clearance and revolving the

adjusting bolt of valve clearance, it is recommended to

conduct the adjustment with a screwdriver and a wrench.

When the valve clearance is too large, one shall

clockwise rotate the adjusting bolt of valve clearance till

the feeler gauge can be inserted into it and meet a little

When the 1st cylinder is at the dead center of

compression travel, the adjustment sequence is as

shown on the left diagram: 1, 2, 3 and 6 valve

clearances.

Rotate the crankshaft 360°, align the crankshaft

anti-vibration pulley mark with the timing indicator and

adjust the other clearances of valve.

When the 4th cylinder is at the top dead center in

compression travel the valve clearance shall be

checked by feeler gauge.

When the clearance of valve is too small, one shall

15B-272

When the clearance of valve is too large, one shall

When the 4th cylinder is at the dead center of

shown on the left diagram: 4, 5, 7 and 8 valve

After the valve clearance has been adjusted for two times, one

shall recheck the adjusting bolt and locking nut of valve to see

whether they are fastened properly and recheck the valve

clearance with feeler gauge when necessary to ensure the

valve clearance has already reached the specified standard.

15B-273

1. Disassemble the valve (see Chapter 15B Engine Mechanical System - Disassembly of Engine

2. Service the valve parts.

(a). Check the valve lock clamp for the presence of

cracking and damage. If yes, replace with new one.

(b). Measure the perpendicularity of valve spring with steel

square.

4JB1 ≤1.7

4D20 ≤1.7

If the measurement is out of the specified range, replace the

valve spring.

(c). Compress the spring to the installation height with

spring tester and measure the tension of the

compression spring

Spring Height When

Assembly is

Completed mm

Spring Tension When

Completed N

4JB1 38.9 272~320

4D20 39 279~314

15B-274

If the tension measurement is below the specified limit,

replace the valve spring.

(d). Measure the free height of valve spring with vernier

4JB1 48

4D20 50

If the measurement is out of the specified range, replace

the valve spring.

(e). Polish the valve stems with grinding pad and solvent.

Visually observe the tip of the valve stems for presence

of excessive wear. If yes, replace the valve.

If the cylinder head and valve seat are excessively

worn, replace with new ones.

15B-275

(h). Measure the valve thickness with steel square. If the

measurement is below the specified limit, replace the

valve and valve guide in pair.

Specified value: mm

4JB1 2.25±0.075

4D20 2±0.075

(i). Measure the contact conical angle of the valve seat. If

the measurement is out of the specified range, replace

the valve, valve guide, and valve seat in group.

4JB1 Inlet valve 30°, Exhaust valve 45°

4D20 Inlet valve 30°, Exhaust valve 45°

(j). Measure the outside diameter of valve stems with

Engine

Model

Specified Value for

4JB1 7.946~7.961 7.921~7.936

4D20 7.945~7.960 7.945~7.960

Measure and record the result.

15B-276

(k). Measure the radial run-out of each valve cone with dial

gauge and V-block.

4JB1 0.02 0.02

4D20 0.02 0.02

This measurement is intended to guarantee the air-tightness

between valve and valve seat.

(l). Polish the valve seat

Polish the valve seat by two steps. Firstly apply coarse

polishing paste onto the valve surfaces and then apply fine

polishing paste. Polish the surfaces with regular polishing

method after each application of polishing paste.

After the polishing, wipe away the polishing paste from the

surfaces of the valve and valve seat and use red lead to

perform the contact inspection. Make sure to check that

the contact color belt is within the width of the valve seat,

without any gap. If necessary, install the cylinder head and

the valve parts and adjust the valve gap.

(m). Measure the drop amount of the valve from the bottom

face of the cylinder head with depth gauge or ruler. If

the measurement is out of the specified range, make

sure to replace the valve seat.

4JB1 0.50~0.80

4D20 0.55~0.85

15B-277

(n). Check the roughness and unevenness of the valve

contact surface. If the measurement is out of the

specified range, make sure to replace the valve seat.

4JB1 3.2

4D20 3.2

3. Service the valve guide.

(a). Measure the outside diameter of the valve stem and

the inside diameter of valve guide with micrometer.

The valve and the valve guide shall be replaced in pair. While

measuring the outside diameter of the valve stems, measure

the inside diameter of valve guide with micrometer and

subtract the measured inside diameter of the valve guide by

the measured outside diameter of the valve stem. If the above

difference is out of the specified limit, replace the valve and

valve guide in pair.

Engine Model 4JB1 4D20

Gap between intake valve and valve guide mm 0.039 ~ 0.071 0.015~0.045

Gap between exhaust valve and valve guide mm 0.064~0.096 0.015~0.045

15B-278

If the valve guide needs to be replaced, knock out the

valve guide from the bottom of the cylinder head with

special tool.

4. Install the valve guide. (see Chapter 15B Engine Mechanical System – Assembly of Engine

5. Service the valve seat.

(a). Check the valve seat for presence of wear. If yes,

remove and replace the valve seat. Removal method of

valve seat: Perform the arc welding at the inner side of

the valve seat, cool down the valve seat, and pry out

the valve seat with screwdriver.

During disassembly, caution shall be taken to prevent

damaging the cylinder head.

6. Install the valve seat.

(a). Install the valve seat.

During the installation, apply force onto the accessory

gradually with bench press to press the valve seat in place.

Do not apply excessive force with bench press, otherwise

it will lead to damage of valve seat.

(b). Remove the carbon deposit from the surfaces of the

valve seat and machine with valve milling tool to

minimize the area of scratch and other rough surfaces,

which can restore the contact width to standard value.

Only machine away the scratch and rough portions and do

not machine away too much.

15B-279

(c). Measure the drop amount of the valve from the

bottom face of the cylinder head with depth gauge or

ruler. If the measurement is out of the specified range

7. Grind the valve seat.

(a). Brush a small amount of oil or Prussian blue onto the

surfaces of the valve seat

Use new or repaired valve to check whether the fit between the

valve and the valve seat is perfect.

Install the valve

Rotate leftward and rightward by 1/4 turn for several

times.

15B-280

Remove the valve.

(e). Observe the contact face with the valve seat.

The valve seat shall be uniformly covered with oil or Prussian

blue, which shall form a complete color belt.

If the contact color belt fails to meet the requirement

and is situated on the upper portion of the valve cone,

repair the valve seat with 30ºand 45ºmilling tool.

and is situated on the lower portion of the valve cone,

repair the valve seat with 60ºand 45ºmilling tool.

Apply polishing paste onto the surfaces of valve seat.

15B-281

Polish the valve, till the valve and valve seat achieves

perfect fit.

After the polishing, thoroughly clean the valve, valve

seat, and valve guide.

8. Install the valve (see Chapter 15B Engine Mechanical System – Assembly of Engine 4JB1)

15B-282

ENGINE MECHANICAL PART-CAMSHAFT AND TAPPET

CAMSHAFT AND TAPPET

1 Camshaft gear bolt

2 Upper idler shaft pressure plate

3 Timing pulley assembly of camshaft

5 Camshaft front oil seal component

6 Camshaft flat key

7 Camshaft

8 Tappet

9 Tappet weldment

15B-283

1. Service the tappet

(a). Take out the tappets in order

Carefully clean off all the oil, soot and carbon deposit on

the cylinder head bolt and cylinder head. The electronic

metallic brush cannot be applied to the gasket.

Wash and clean the tappet with hot soap-suds.

(c). Blow dry the tappets with compressed air.

Check the two ends of tappet to see whether they are

worn, pulled or damaged with other causes.

15B-284

Visually check the tappet to see whether it is crooked. If

it is obviously crooked, it shall be replaced directly.

(f). If it is not obviously crooked or likely crooked, one shall

check its straightness by rolling it on a horizontal

If the tappet is crooked, replace it.

2. Remove the camshaft (Refer to Chapter 15 Engine Mechanical Part – Disassembly of Engine

3. Service the camshaft.

(a). Clean the parts with solvent.

Remove the sediment from the camshaft with wire

brush and soft wire wheel brush.

15B-285

(c). Clean the camshaft by blowing it with compressed air.

Check the bore of camshaft for the presence of

cracking and blockage and check the inner side of the

camshaft for the deposit of oil or oil sludge. If yes, clean

and when necessary replace with new one.

(e). Place the camshaft onto the V-blocks and measure the

radial run-out of camshaft with micrometer. If the radial

run-out is out of the specified range, replace the

4JB1 0.02

4D20 0.025

15B-286

(f). Measure the outside diameter of each camshaft journal

with screw micrometer in two directions perpendicular

with each other respectively. If any measurement is

below the specified limit, replace the camshaft.

Standard Value: mm

4JB1 49.945~49.975

4D20 43.897~43.910

(g). Measure the height of each cam with micrometer. If the

4JB1 26.2635

4D20 21.8±0.03

Visually check the surfaces of the camshaft for the

presence of corrosive pitting, cracking or other

abnormalities. If yes, replace the camshaft.

15B-287

4. Service on the camshaft gear

(a). Clean the camshaft gear with solvent

Clean off the deposits on camshaft gear with steel

brush and mild steel wire rotary brush.

(c). Clean the camshaft gear by blowing it with compressed

air.

Check the bolt hole on the camshaft gear to see

whether there are cracks or corrosion. If there are,

repair it or replace it when necessary.

Check the gear teeth of camshaft to see whether there

is corrosion or cracks. If there is, repair it or replace it

15B-288

(f). Use the grinding pad to remove the corrosion, burr and

bulge metal from the camshaft

If the corrosion, burr and bulge metal can’t be removed by the

grinding pad, replace the camshaft

5. Service on the front oil seal seat part of camshaft

(a). Clean the front oil seal seat part of camshaft with

solvent.

Clean off the deposits on the front oil seal seat part of

camshaft with steel brush and mild steel wire rotary

Clean the front oil seal seat part of camshaft by blowing

it with compressed air.

Check the front oil seal seat part of camshaft and the

bolt hole to see whether there is corrosion or cracks. If

there is, repair it or replace it when necessary.

15B-289

(e). Use the grinding pad to remove the corrosion, burr and

bulge metal from the camshaft timing sprocket

grinding pad, replace the gear.

6. Remove and service the tappets

(a). Draw out the tappets from their installation positions

The tappets taken out shall be put in a clean vessel.

(b). Clean the tappet with solvent.

(c). Blow dry the tappet with compressed air.

(d). Check the tappet seat, lever handle and tappet surface

for presence of wear and cracks. If yes, repair or

replace when necessary.

• Normal contact (increasing)

• Do not continue to use in irregular contact.

15B-290

(e). Check the surface of tappet for cavitation.

The following standards define the allowable range of the

cavitation on the surface of tappet.

• Single cavitation point shall not beyond 2mm.

• The cavitations are not allowed to gather to one piece.

• The total diameter of accumulated cavitations shall not

beyond 6mm or 4% of the area of tappet gauge.

• The cavitations of tappet are not lowed to exist above or

under the wear surface.

(f). Measure the outside diameter of the tappets with screw

micrometer

Measure the inner diameter of tappet hole with micrometer

calipers and subtract the inner diameter value of tappet hole

from the outer diameter value of tappet. If the D-value is more

than the specified limiting value, it means the tappet shall be

Specified outside diameter of tappet mm 12.927~12.990 12.666~12.684

Specified inside diameter of tappet mm 13.000~13.018 12.7~12.718

Specified limit mm 0.010~0.041 0.016~0.052

7. Install the tappets

(a). Cover the tappet and tappet hole with oil or equivalent.

15B-291

Install 8 tappets into the installation holes one by one.

8. Install the camshaft assembly (see Chapter 15B Engine Mechanical System – Assembly of

Engine 4JB1)

15B-292

ENGINE MECHANICAL PART-PISTON AND CONNECTING ROD ASSEMBLY

PISTON AND CONNECTING ROD ASSEMBLY

1 Top compression ring

2 Second compression ring

3 Coil spring oil ring

4 Piston

5 Piston pin

6 Snap ring of piston

7 Connecting rod body

8 Connecting rod bearing bushing

9 Connecting rod bolt

10 Connecting rod bearing bush

11 Connecting rod cap

12 Connecting rod nut

15B-293

1. Remove the piston assembly (Refer to Chapter 15 Engine Mechanical Part – Disassembly of

2. Disassemble the piston assembly.

(a). Remove three piston rings with the special piston ring

remover.

Disassemble the retainer rings on both sides of piston

(2 retainer rings).

Punch out the piston pin with punch bar.

3. Service the connecting rod bearing bush

(a). Check the connecting rod bearing bush for presence of

sink erosion, peeling-off, corrosion, damage of locking

piece, and scratch. If yes, replace with new one.

15B-294

4. Service the connecting rod

(a). Measure the inside diameter of the smaller end bore of

the connecting rod and measure the outside diameter

of the piston pin.

Outside diameter of piston pin mm 30.995~31.000 27.994~28.000

Inside diameter of connecting rod bore mm 34.000~34.025 30.987~31.000

Inner diameter of connecting rod bushing mm 31.008~31.015 28.025~28.038

Specified gap mm 0.008~0.020 0.025~0.045

If the gap between the smaller end bore of the connecting rod and the piston pin is out of the specified range,

replace the bush and the piston pin and when necessary replace the connecting rod.

(b). Remove the bush with bar and hammer.

• The hammer can be used during the installation. The oil

hole of the bush shall be aligned with that of the

connecting rod.

• After the new bush is installed, grind the bush bore with

pin bore grinding machine.

(c). Clean the connecting rod with solvent.

• Please wear the goggles and protective clothing to prevent

causing personal injuries.

15B-295

(d). Clean the contact surface between the connecting rod

and the connecting rod cap with nylon hairbrush.

The contact surface between the connecting rod and the

connecting rod cap is not a machined surface. Cautions

shall be taken during the handling, in order to prevent

damaging the parts.

(e). Thoroughly clean the connecting rod with compressed

• The pressure of the compressed air used for cleaning

shall not exceed 207KPa.

(f). Check the connecting rod cap for the presence of wear,

cracking, burr, scratch, or wear. If yes, replace with new

In event of obvious wear at any portion of the connecting

rod or the connecting rod cap, replace one part as a whole

(g). Check the connecting rod for the presence of wear,

(h). Check the contact surface between the connecting rod

and the connecting rod cap

connecting rod cap is not a machined surface. Unless

there is really deep wear or cracking on the surface, the

contact surface can be further used, instead of being

considered as damaged.

15B-296

(i). Check the piston pin bore of the connecting rod for

damage. If yes, replace with new one.

There is no oil passage to be aligned with the bush hole

within the smaller end bore of the connecting rod. The

bore on the bush is only used during the manufacturing.

5. Service the piston pin.

(a). Visually check the piston pin for presence of cracking,

scratch, or other damages and when necessary

replace with new one.

(b). Measure the outside diameter of the piston pin with

micrometer at three different positions in two different

directions.

4JB1 30.995~31.000

4D20 27.994~28.000

6. Service the piston.

(a). Immerse the piston into cold cleaning fluid.

Generally, immersing the piston for a whole night can loosen

the carbon deposit.

• Do not clean the piston with sand blasting, as the sand

blasting material will embed into the aluminum and

thus lead to damage of piston.

• Do not clean the piston in the acid solvent tank, or it will

lead to damage of piston.

15B-297

(b). Use the mixture from high concentration detergent and

hot water to clean the piston.

Do not use the wire brush, or the wire brush will damage

the piston ring grooves.

(c). Again clean the piston with detergent fluid or solvent

and rinse the piston with clean hot water.

• Do not clean the piston or connecting rod in the acid

solvent tank. Otherwise it will damage the piston and

(d). Blow dry the piston with compressed air.

Check the skirt, pin bore, head, and ring grooves of the

piston for presence of damage and wear. If yes, replace

15B-298

Measure the piston outer diameter with screw

micrometer at other positions of piston assembly.

Group 1

value:

mm

Group 2

Group 3

Group 4

Group 5

Group 6

Group 7

Group 8

4JB1

93.025~9

3.034

93.015~9

3.024

93.005~9

3.014

92.995~9

3.004

92.985~9

2.994

92.975~9

2.984

92.965~9

2.974

92.955~9

2.964

4D20

85.930~8

5.940

85.940~8

5.950

85.950~8

5.960

- - - - -

(g). Insert the piston pin into the piston pin seat bore and

rotate.

If the piston pin rotates smoothly without any gap, it indicates

that the gap is normal. If there is a gap or the rough rotation can

be felt, the gap needs to be measured. If the gap measured is

out of the specified range, replace both the piston and the

piston pin.

4JB1 0.002~0.015

4D20 -0.05~0.018

(h). Install the piston ring into the cylinder sleeve and

measure the opening gap with feeler gauge.

It may use the piston head to push the piston rings in the

direction perpendicular to the cylinder walls to the minimum

bore diameter position of the cylinder sleeve.

15B-299

(i). Measure the gap between the piston ring grooves and

the piston rings with feeler gauge

If the gap between the piston ring grooves and the piston rings

is out of the specified range, replace the piston rings. If the

new piston rings installed still can’t meet the specified gap,

replace the piston.

The piston rings shall be replaced in set

Standard gap between 1st piston ring and piston ring groove mm 0.090~0.125 0.06~0.10

Standard gap between 2nd piston ring and piston ring groove mm 0.050~0.085 0.04~0.08

Standard gap between oil ring and piston ring groove mm 0.030~0.070 0.02~0.06

7. Check the piston rings

(a). Check the abrasive wear of the piston rings

If the frontal black grinding painting of the piston rings is

reduced or even becomes invisible sometimes, it indicates that

the abrasive wear occurs in the middle ring. Generally, it can

be considered as the complete wear of the ring surface. The

reduced painting generally will keep sharp the bottom edge of

the middle ring. In addition, the central longitudinal wear on the

top ring indicates the occurrence of the abrasive wear.

The following causes may lead to abrasive wear:

• Suction of grinding material.

• Incomplete cleaning during previous services.

• Particles embedded in the cylinder bore.

• Prolonged oil drainage interval so that the soot content in

the oil becomes high.

• Wear and scratch.

(b). Check the oil ring for blocking

The phenomenon of oil ring blocking is caused by the deposits

existing in oil ring groove.

The oil ring blocking may be caused by the following reasons:

• The operating temperature of engine is relatively low;

long-time idling or the fault of cooling system.

• The replacement interval of oil is extended.

• The grade of applied oil is improper.

• The quality of oil is poor.

15B-300

The oil return blocking of oil ring limits the return of oil, make the area of piston ring full of oil and

cause the defect in terms of oil control.

8. Install the piston assembly (Refer to Chapter 15 Engine Mechanical Part – Assembly of Engine

ENGINE MECHANICAL PART-CRANKSHAFT AND FLYWHEEL ASSEMBLY

15B-301

CRANKSHAFT AND FLYWHEEL ASSEMBLY

1 Crankshaft pulley bolt

2 Crankshaft pulley

3 Crankshaft timing pulley

4 Crankshaft flat key

5 Crankshaft

6 Rolling bearing 6203-Z

7 Flywheel ring gear

8 Pin

9 Flywheel

10 Cylindrical pin

11 Flywheel bolt plate

12 Flywheel bolt

15B-302

1. Remove the flywheel (Refer to Chapter 15 Engine Mechanical Part – Disassembly of Engine

2. Service the flywheel.

(a). Visually check the working surfaces of the flywheel. In

event of any wear, grooving, or gear ring wear, repair

and, when necessary, replace with new one.

Visually check the flywheel gear teeth. If the gear teeth

are worn or broken, please repair them. If necessary,

please replace them.

3. Preliminarily measure the axial gap of the

crankshaft.

(a). Measure the axial gap of crankshaft with micrometer

and magnetic base.

Standard value mm

4JB1 0.040~0.201

4D20 0.14~0.25

The sizes of the thrust bearing and the crankshaft journal

determine the size of the axial gap.

4. Remove the main bearing bush and crankshaft (Refer to Chapter 15 Engine Mechanical Part –

15B-303

5. Service the main bearing bush and the main

bearing cap

(a). Clean the parts such as main bearing caps with steam

or hot soapy solvent.

The hot steam may cause serious personal injury. So wear

safety goggles or protective mask and protective clothing

when using steam to clean things.

(b). Blow dry the parts with compressed air.

(c). Check whether all main bearing caps and main bearing

cap bolts have scratches or overheating phenomenon.

If the main bearing cap is damaged, replace the cylinder

block.

(d). Check whether the main bearing bush have cracks,

scratches or overheating phenomenon.

If the main bearing bush is damaged, replace the complete

set of main bearing bush.

(e). Check the mating surface of the bearing bush seat for

presence of scratch and burr.

In event of scratch or burr, grind with grinding pad. If the

scratch or burr can’t be removed by the grinding pad or

equivalent, replace the bearing.

15B-304

Check the rear main bearing cap to make sure the

annular location pin is installed.

6. Service the crankshaft.

(a). Clean the crank with hot suds.

Clean the oil holes with non-metallic hard brush.

(c). Blow dry the crankshaft with compressed air

Make sure that the water drips are blown out from the threaded

holes and oil passage on each end of the crankshaft.

Please wear proper goggles and protective mask when

using compressed air to avoid the splashing chips and dirt

causing personal injury.

(d). Check whether the screw threads on both ends of

crank are damaged. If they are damaged, please

replace the crank.

The threads of crank shall not need dressing, or else the

engine will be seriously damaged.

15B-305

Visually check whether the middle of crank arm, crank

arm and the top end of connecting rod journal have

scratches or cracks. If they have, please replace them.

Measure multiple points on the same cross section of

the crankshaft with outside diameter micrometer.

Specified outside diameter of crankshaft main journal mm 69.917~69.932 70.904~70.920

Specified inside diameter of crankshaft main bearing bush mm 69.838~69.899 69.811~69.859

Specified gap mm 0.033~0.079 0.061~0.093

The main journal of the crankshaft is to be fitted with the bore of main bearing bush. While measuring the

outside diameter of the crankshaft main journal, measure the inside diameter of the main bearing bush bore

with micrometer as well. If the difference between two measurements is out of the specified range, replace

the main bearing bush in pair.

15B-306

(g). Place the crankshaft onto the V-blocks, rotate the

crankshaft slowly, and measure the radial run-out. If the

radial run-out of the crankshaft is out of the specified

range, replace or correct by cold pressing the crankshaft.

4JB1 0.03

(h). Correct the crankshaft.

To correct the bending of the crankshaft, knock the

non-machined surfaces of the crank arm to deform the crank

so that the axis of the crankshaft is displaced to fulfill the

correction.

7. Install the crankshaft (Refer to Chapter 15 Engine Mechanical Part – Assembly of Engine 4JB1)

8. Measure the axial gap of the crankshaft.

determine the size of the axial gap

9. Install the flywheel (Refer to Chapter 15 Engine Mechanical Part – Assembly of Engine 4JB1)

ENGINE MECHANICAL PART-CYLINDER BLOCK

15B-307

15B-308

1 Front bush of crankshaft

2 Middle and rear bush of crankshaft

3 Cylindrical pin

4 Blocked oil passage

5 Fuel supply connector of vacuum pump

6 Hexagon head bolt and spring washer

8 Water inlet pipe weldment

9 Water inlet pipe gasket

Cylinder block and cylinder head’s

location pin

11 Cylinder liner

12 aluminum plug

13 Bowl-Bowl-shaped tabular plug 36

14 Bowl-shaped tabular plug 18

15 Bowl-shaped tabular plug 38

16 Bowl-shaped tabular plug 56

17 Cylinder head gasket

18 Hexagon bolt with location pin

19 Back plate of cylinder block

20 Flat washer

21 Heavy spring washer

22 Nut M10×1.25

23 Cylindrical pin

24 Fixing bolts of rear joint plate

25 Rear oil seal of crankshaft

26 Bowl-shaped tabular plug 36

27 Bowl-shaped tabular plug 16

28 Bowl-shaped tabular plug 32

29 Harness clamp

Hexagon head bolt, spring washer and

flat washer assembly

31 Bowl-shaped tabular plug 45

32 Water drainage plug screw

33 Plug screw gasket

34 oil pressure sensor plug

35 Oil pressure sensor head

36 Oil Injection pipe weldment

37 Red copper gasket

38 Pressure-limiting valve components

39 Crankshaft upper bearing bush

40 Crankshaft low bearing bush

41 The fifth main bearing cap

42

The first, second and fourth

bearing caps

43 The third main bearing cap

44 Thrust bearing

45 Main bearing bolts

46

47

main

48 Cylinder block

15B-309

1. Disassemble the cylinder block (See Chapter 15B Engine Mechanical System - Disassembly of

Engine)

2. Remove the cylinder gasket.

(a). Remove the cylinder head gasket

The gasket which is disassembled cannot be used again.

Please replace the gasket.

(b). Measure the bore diameter of the cylinder sleeve with

inside diameter micrometer in two or more different

directions and record each measurement result.

Specified value mm

4JB1 93.020~93.061

4D20 86.000~86.030

If the measurement results are out of the specified range, bore

the cylinder or replace the cylinder block.

For measuring the external diameter of cylinder liner and

cylinder hole diameter, it can be effective to measure the

smooth surface of top and bottom section.

(c). Disassemble cylinder liner.

Install the cylinder-liner dismantling gear in the cylinder liner.

Check whether the base of cylinder-liner dismantling gear is

firmly connected with the bottom edge of cylinder liner and then

slowly rotate the dismantling bearing hand wheel

counterclockwise to pull the cylinder liner out.

15B-310

3. Service the cylinder block.

(a). Put the cylinder block in the cleaning tank to clean.

• Clean with solvent that will not damage the camshaft

sleeve.

• Please abide by the operation instructions of the

manufacturer for the operations of the cleaning tank.

• Please abide by the instructions of the solvent

manufacturers while using the solvent.

(b). Thoroughly clean the cylinder block with steam and

then blow dry the cylinder block with compressed air.

• To minimize the damage of the engine, make sure to

remove all scraps from the threaded holes and the oil

passage.

• If the cylinder block will not be used immediately, apply

one film of protective oil for anti-rusting protection and

cover the cylinder block to guard against the

contamination of dirt to the oil.

(c). After the cleaning, recheck the cylinder block for

presence of cracking, corrosion, and discoloration and

check the camshaft bore for presence of scratch, wear,

and excessive wear.

If the bore is damaged to beyond the allowable range, replace

the cylinder block

15B-311

(d). Measure the length for four sides and diagonal lines of

If the degree of damage for hole exceeds the allowable limit,

replace the cylinder block. If the dimension of cylinder block

does not be changed, then the cam bush can be still used.

(e). Measure the lengths for four sides and diagonal lines of

If the measurement results are out of the specified range,

replace the cylinder block.

(f). Measure the surface levelness of the cylinder block with

ruler and feeler gauge.

Planeness:0.06,Depth of Parallelism:0.06

Planeness:0.05,Depth of Parallelism:0.08

repair the cylinder block and when necessary replace the

Visually check whether the cylinder head gasket is

damaged or has cracks. If the gasket if damaged or

has cracks please replace it.

15B-312

Visually check the gasket of the cylinder head for

presence of cracking and damage. If yes, replace the

After taking down all accessories of cylinder block,

clean the oil passage and water passage of cylinder

block with water syringe.

4. Install cylinder liner

(a). Install cylinder liner with special tools.

• Before installation, thoroughly clean the surface of cylinder

liner and cylinder hole with new kerosene or diesel and blow

dry the surface of cylinder liner and cylinder hole.

• Eliminate all other things carefully on the cylinder liner and

cylinder hole before installing cylinder liner.

5. Install the cylinder block (Refer to Chapter 15 Engine Mechanical Part – Assembly of Engine

491EQ1 and 491EQ3).

EXHAUST SYSTEM ............................................................................... 16B-1

Overview ............................................................................................ 16B-1

Precautions ....................................................................................... 16B-2

Working Principle ............................................................................. 16B-3

EXHAUST MANIFOLD ........................................................................... 16B-4

Diagram of Components (Exhaust System) ................................... 16B-4

Service ............................................................................................... 16B-5

EXHAUST PIPE ..................................................................................... 16B-9

Diagram of Components .................................................................. 16B-9

Removal and Installation ................................................................ 16B-10

16B

EXHAUST-EXHAUST SYSTEM

16B-1

1. Exhaust system consists of the exhaust manifold, muffler and exhaust manifold welding assembly,

and other related lug bracket, in order to reduce the exhaust noise and exhaust energy.

2. The exhaust manifold is an important component collecting the exhausts of engine cylinders and

discharging.

3. The function of muffler is to reduce the exhaust noise through gradually decreasing the exhaust

pressure and exhaust pressure pulsation.

4. The working principle of muffler is that the exhaust gas flows to the expansion chamber and

resonance chamber through the porous tube, and the exhaust gas continually changes the flow

direction during this process, gradually decreases and relieves the exhaust pressure and exhaust

pressure pulsation, consumes the energy and ultimately reduce the exhaust noise.

16B-2

(a). Ensure the parking brake lever is placed on the parking location.

(b). Fix the wheel with a wedge or corner block, wedge or corner block should be placed in the position

close to both sides of the tire, it’s preferred to fix on both sides of the rear wheels.

(c). If operates under the car, the engine should and ignition switch should be turned off..

(a). Ensure the engine turned off when repairing the exhaust system, the maintenance work should only

be conducted after the exhaust system completely cooled.

(b). The exhaust pipeline should be checked frequently, any leaks should be dealt with immediately,

tighten the connectors to avoid unnecessary losses.

(c). After 4,000 ~ 5,000km drive, the exhaust pipe of the vehicle should be checked in the following

aspects:

• Whether any bolts and nuts are loosen. To tighten the bolts and nuts of exhaust pipe with uniform

force, fastening the bolts in diagonal, or it may cause air leaks.

• Whether there are any exhaust pipe cracks and perforations, and any damage or erosion for

• The exhaust pipe gasket is suggested to be used once only; in order to ensure the tightness of

exhaust system, timely replace the damaged gasket.

16B-3

each cylinder by intake manifold. The burned gas drains from exhaust manifold. The formed exhaust gas flow

will impact turbine of turbocharger so that it can rotate at a high speed. The exhaust gas through turbine

finally drains to the exterior by rear exhaust pipe. Part of exhaust gas in the exhaust manifold drains from

EGR valve. Then this exhaust gas enters intake connecting pipe through EGR pipe, and is sent back to

engine combustor for combustion again to suppress the generation of oxynitride.

1 Rear exhaust pipe

7 Turbocharger

16B-4

EXHAUST-EXHAUST MANIFOLD

DIAGRAM OF COMPONENTS (EXHAUST SYSTEM)

1 Exhaust manifold gasket component

2 Exhaust manifold

Hexagon head bolt and flat washer

4 Heat insulation plate assemblyⅡ

5 Flat washer

6 Spring washer

7 Bolt

8 Booster bracket bolt

9 Heat insulation plateⅠ

10 Exhaust manifold bracket

11 Flat washer

12 Heavy spring washer

13 Hexagon head bolt

16B-5

1. Remove the turbocharger assembly (Refer to Chapter 21 Booster System - Booster, Service).

2. Remove the EGR valve assembly (Refer to Chapter 22 EGR System - EGR Valve, Service)

3. Remove the heat insulation plate assemblyⅡ

(a). Dismantle 2 fixing bolts of heat insulation plate

assembly II.

• Remove the heat insulation assembly II.

4. Remove the turbocharger bracket

(a). Dismantle 2 fixing bolts of turbocharger bracket.

• Remove the turbocharger bracket.

• Remove the heat insulation plate I.

5. Remove the exhaust manifold bracket

(a). Remove the fixing bolts of exhaust manifold bracket.

• Remove the exhaust manifold bracket.

6. Remove the exhaust manifold

(a). Remove the fixing bolts of exhaust manifold.

•Remove the exhaust manifold.

16B-6

7. Check and clean the exhaust manifold

(a). Clean the sealing surface that combines exhaust

manifold and turbocharger with a scraper knife and a

clean cloth.

Please prevent foreign matters from entering into the

exhaust port

Clean the sealing surface that combines exhaust

manifold and cylinder head with a scraper knife

and a clean cloth.

Clean the carbon deposit on the sealing surface of

exhaust manifold with a crocus cloth.

(d). Clean the exhaust manifold with vapor.

When cleaning the exhaust manifold with vapor, wear the

protective goggles, protective masks and protective

clothing to avoid personnel injury.

Dry the exhaust manifold with compressed air.

16B-7

Check whether the sealing surface of exhaust manifold

and turbocharger exists cracks and other damages. If

severe damages exist, replace the exhaust manifold.

and cylinder head exists cracks or other damages. If

Check the flatness of exhaust manifold installation

surface with a precision scale and a feeler gauge. If

the unevenness exceeds technical scope, the exhaust

manifold shall be machined or replace it with a new one.

8. Install the exhaust manifold assembly

(a). Place the exhaust manifold in the installation position the

fixing bolts on it and fasten.

The slinger ring and heat insulation plate set with exhaust

manifold together shall be installed when installing the exhaust

(b). Place the exhaust manifold bracket in the

installation position the fixing bolts on it and fasten.

16B-8

Place the heat insulation plate Ⅰ and turbocharger

bracket in the installation position the fixing bolts on it

and fasten.

Place the heat insulation plate assembly Ⅱ in the

installation position 2 fixing bolts on it and fasten.

9. Install the EGR valve assembly (Refer to Chapter 22 EGR System - EGR Valve, Service)

10. Install the turbocharger assembly (Refer to Chapter 21 Booster System - Booster, Service)

EXHAUST-EXHAUST PIPE

16B-9

1 Exhaust pipe gasket assembly

2 Front exhaust pipe welding

4 Spring washer

6 Gasket

7 Hexagon head bolt

8 Hoop support plate

9 Middle exhaust pipe assembly

10 second connection rubber

11 Muffler front gasket

12 Hexagon head bolt

13 Flat washer

14 Spring washer

15 Type 1 hexagon nut

16 Muffler assembly

17 Rear exhaust pipe assembly

18 Exhaust pipe third bracket

19 third connection rubber

20 Hexagon head bolt

21 Large washer

22 Hoop

23 Fourth connection rubber

16B-10

REMOVAL AND INSTALLATION

As the exhaust pipe is relatively heavy, certain protective measures should be taken during the disassembly,

it is preferred to be operated by two persons.

1. Preparations

Drive the car into the inspection pit or onto the car lift.

Turn off the engine after stopping the car, disconnect the battery negative, place the transmission in

neutral position, and turn on the parking brake system. Operate only after the exhaust system fully

cooled.

2. Disassemble the exhaust system assembly

(a). Remove the connection nuts of front exhaust pipe

welding and engine.

• Remove the exhaust pipe gasket assembly.

Remove the connecting bolts between front exhaust pipe

welding and middle exhaust pipe assembly.

• Remove the gasket.

Remove the fixing bolts of hoop support plate.

• Remove the front exhaust pipe welding.

(d). Remove the connecting bolts between middle exhaust

pipe assembly and muffler assembly.

• Remove the muffler front gasket.

Support the muffler assembly with safety bench to avoid falling;

otherwise it may cause personal injury.

16B-11

Remove the second connection rubber between

middle exhaust pipe assembly and frame.

• Take out the second connection rubber.

• Remove the middle exhaust pipe assembly.

(f). Remove the connecting bolts between muffler

assembly and rear exhaust pipe assembly.

• Remove the muffler assembly.

Remove the fixing bolts of exhaust pipe third bracket.

Remove the fourth connection rubber of rear exhaust

• Remove the rear exhaust pipe assembly.

16B-12

3. Check the exhaust system

(a). Check whether there are too many gray or carbon

particles inside the muffler, it should be cleaned if

any.

Cleaning method:

• Purge the muffler assembly with compressed air until

there is no heavy smoke emitted.

Wear masks and goggles before cleaning, to avoid injury.

(b). Check whether there are too much gray or carbon

particle inside the front, middle and rear exhaust

pipe assembly; if any, please remove and clean it.

The cleaning method is the same as the previous step

4. Install the exhaust system assembly

(a). Place the rear exhaust pipe assembly and fourth

connection rubber in the installation position, and

install the connection rubber to the frame.

Install the fixing bolts of the exhaust pipe third bracket.

(c). Place the muffler assembly in the installation position;

connect the bolts between the muffler assembly and

rear exhaust pipe and fasten.

Replace the gasket assembly of exhaust pipe.

16B-13

Place the middle exhaust pipe assembly and second

connection rubber in the installation position, and install

the second connection rubber to the frame.

(e). Connect the bolts between the middle exhaust pipe

assembly and muffler assembly and fasten.

Replace the front gasket of muffler.

(f). Place the front exhaust pipe welding in the installation

position, connect the bolts of hoop support plate and

(g). Connect the bolts between front exhaust pipe welding

and middle exhaust pipe assembly and fasten.

The gasket shall be replaced.

(h). Fasten the connection nuts of front exhaust pipe

The exhaust pipe gasket assembly shall be replaced.

COOLING SYSTEM........................................................................... 17B-1

Overview ............................................................................................. 17B-1

Precautions ........................................................................................ 17B-2

Working Principle .............................................................................. 17B-3

Diagram of Components ................................................................... 17B-4

THERMOSTAT ................................................................................... 17B-7

Service ................................................................................................ 17B-7

TRANSMISSION BELT ................................................................... 17B-11

Service .............................................................................................. 17B-11

PULLEY AND FAN .......................................................................... 17B-14

Service .............................................................................................. 17B-14

WATER PUMP ................................................................................. 17B-16

Service .............................................................................................. 17B-16

OIL COOLER ................................................................................... 17B-19

Service .............................................................................................. 17B-19

EXPANSION TANK ......................................................................... 17B-21

Replacement ..................................................................................... 17B-21

COOLING PIPELINE ....................................................................... 17B-23

Replacement ..................................................................................... 17B-23

RADIATOR ....................................................................................... 17B-25

Replacement ..................................................................................... 17B-25

17B

COOLING-COOLING SYSTEM 17B-1

1. The main functions for cooling system are to timely radiate some heat which is absorbed by heated

parts to ensure that the engine works under the condition of the most appropriate temperature.

2. The thermostat controls temperature of engine coolant. When coolant temperature is lower than

engine functioning temperature, the engine coolant reflows the inlet of water pump through the

bypass to make the coolant temperature is the same with engine functioning temperature. When the

engine coolant temperature is the same with the functioning temperature, the thermostat opens and

the bypass is closed, which makes engine coolant flow into the radiator to make the coolant

temperature is the same with the functioning temperature.

3. The centrifugal water pump consists of impeller, water pump housing, bearing and water seal. The

water pump is driven by crank pulley and fan belt. When water seal is damaged and the dripping

phenomenon is very serious, the water seal shall be replaced. Do not allow to block the outlet when

water leakage, or else the water will enter the bearing to make the bearing quickly wear down. If there

is abnormal noise in the bearing during running, then the bearing shall be considered to be replaced.

4. The fan is induced draught plastic fan. The tensioning degree of fan belt shall be checked regularly

according to the requirements of “technical maintenance” and the fan belt shall be adjusted. The

adjustment shall be carried out manually with a force of 70~80N to press the belt between the fan and

generator pulley. The proper pressing distance is the range of 7~8mm (for new belt is 6~7mm).

5. Silicon oil fan clutch takes silicon oil as medium and makes use of silicon oil’s high viscosity to

transmit the torque. The separation and joint of fun clutch are automatically controlled by temperature

detector when making use of the atmosphere temperature on the back of radiator.

Temperature-sensing elements are thermometal coiled spring temperature sensors. When the

temperature of air which is flowing through the radiator increases, thermal deformations of

thermometal temperature sensors occur and the valve plate shaft is forced to rotate to open the oil

supply hole on the driven plate. The silicon oil that stored between the driven plate and the front cover

flows into the operating cavity between the drive plate and driven plate and the clutch engages, fan

speed increases. The opening of oil supply hole shall be larger with higher air temperature and the

fan speed is higher; however, when the temperature of air which is flowing through the radiator

reduces, thermometal temperature sensors shall be reinstated, valve plate close the oil supply hole.

With the effect of centrifugal force, silicon oil returns to oil chamber from the operating cavity through

oil return hole. The clutch disengages and fan speed reduces to a very low one.

6. The drain screw is for the drain of the engine’s coolant in coolant change.

7. Oil cooler is used for oil cooling in order to maintain the oil temperature in proper rang for better

engine performance and longer service life of the engine. In the case of oil in engine coolant, carry out

service for oil cooler immediately.

8. The radiator is pressure water tank which is the device sending out the coolant heat to the

atmosphere. The functions of radiator: enlarge radiating area and accelerating the water cooling.

9. The expansion tank is to reduce the losses of coolant of cooling system.

10. Two water level scales on the surface of expansion tank express limiting altitude on the liquid surface

17B-2 COOLING-COOLING SYSTEM

1. Safety precaution

(a). Make sure to place the parking brake handle in the parking position.

(b). Fasten the wheel with corner blocks or wedge and the corner blocks or wedge shall be placed on two

sides of wheel. And the two sides of rear wheel shall be fixed better.

(c). The engine shall be shut down and the switch of ignition lock shall be shut down when working at the

bottom of the car.

(a). When disconnecting the cooling system pipeline, do not make the coolant overflow. If it cannot be

continuously used, it shall be abandoned according to the regulations.

(b). When disconnecting the cooling system pipeline, do not make the chips enter the cooling system

pipeline, because the chips which enter the cooling system pipeline will damage the cooling system

and engine.

(c). The coolant is poisonous and if it cannot be continuously used, dispose of the coolant according to

the regulations.

(d). When maintaining the cooling system, pay attention to coolant temperature. If the temperature is too

high, the operation shall be carried on after the coolant temperature is lower.

(e). Reasonably use antifreeze solution. The antifreeze solution is poisonous and can irritate to the skin

and inner organs. Do not suck the antifreeze solution when using it. Clean hands if the hands touch

the antifreeze solution and timely wash the eyes if the antifreeze solution enters eyes.

COOLING-COOLING SYSTEM 17B-3

When the temperature of engine coolant is higher than the nominal temperature of thermostat, coolant flows

out through engine water outlet and gets into the radiator through open thermostat then it flows through oil

cooler and gets into the water pump through the water inlet of the pump to complete internal circulation in

engine body. However, when the temperature of engine coolant is lower than the nominal temperature of

thermostat, because the thermostat is closed and bypass is open, the coolant flows into the water inlet of

water pump through bypass pipe to complete internal circulation in engine body. Part of coolant in engine

body may flow into heater through heater water inlet pipe and then get into water pump water inlet through

heater water return pipe, finally it shall return to engine body for internal circulation.

1 Radiator

2 Oil cooler

3 Oil filter

4 Heater water outlet pipe

5 Fan heater

6 Heater water inlet pipe

7 Expansion tank

8 Thermostat

9 Engine water outlet pipe

10 Bypass pipe

11 Water pump

17B-4 COOLING-COOLING SYSTEM

(Thermostat)

1 Plug

2 Copper backing

3 Screw plug

5 Water outlet pipe

6 Thermostat

7 Water outlet pipe gasket

8 Housing gasket

9 Harness clamp

10 Short circle pipe joint

11 Heating pipe clamp

12 Bypass hose

13 Hexagon tapered screw plug

14 Thermostat housing

15 Heater water inlet pipe

16 Heater water pipe

Water outlet rubber hose at thermostat

end

Water return rubber hose at thermostat

19 Machine cooler steel pipe welding part

21 Heater opening cap

(Fan and water pump pulley chamber cover assembly)

COOLING-COOLING SYSTEM 17B-5

1 Fan component

2 Silicon oil clutch component

3 Type 1 hexagon nut

7 Water pump pulley

8 Fan belt

9 Water pump O ring

Water pump pulley chamber cover

12 Spring washer

16 Bolt

17 Bolt

18 Harness clamp

17B-6 COOLING-COOLING SYSTEM

(Radiator)

1 Radiator assembly

2 Spring hose clamp

3 Connecting hose

4 Nylon cable tie

5 Engine water inlet hose

6 Type A worm drive hose clamp

Hexagon head bolt, Spring washer and

Flat washer assembly

8 Engine water outlet hose

11 Expansion tank assembly

12 Protective fan housing assembly

COOLING-THERMOSTAT

17B-7

1. Thermostat Dismantle

(a). Dismantle fixing bolts of thermostat cap, take down

bolts and Harness clamp.

(b). Take down thermostat cap.

Take down thermostat cap and housing gasket at the same

Take out the thermostat.

2. Checking and Cleaning

(a). Check the appearance of thermostat for damage.

• Check for the existence of crack, embedded scrap,

loss of one-way valve, ball seat damage and other

damages.

• In the case of discovery of damage, replace the

17B-8

Shovel the remained gasket at the contact surface

between the thermostat housing and thermostat cap.

Clean the installation surface of thermostat housing.

Check the installation surface of thermostat housing for

crack and damage.

• In the case of discovery of crack and scars,

replace the thermostat housing.

3. Measure

(a). If the thermostat is considered to have fault, measure

thermostat temperature of turning on the thermostat,

and place thermostat and a thermometer with 100℃ of

measuring range into a water container.

Do not make thermostat or thermometer contact the

container.

17B-9

(b). Heat the water and check the thermostat according to

• Heat the water in the container to the temperature

which is higher than nominal working temperature

of thermostat and then the thermostat will

automatically turn on.

• If the thermostat cannot automatically turn on

when the temperature for water in the container is

higher than the nominal working temperature, it

indicates that the thermostat is damaged or the

model is not right and then the thermostat shall be

Thermostat is marked with nominal working temperature.

4. Install thermostat

(a). Apply sealant on the installation surface of thermostat

housing.

(b). Replace with a new gasket.

No matter whether the gasket is damaged, please replace

the gasket.

Install thermostat.

17B-10

(d). Install the thermostat cap.

Sealant shall be applied on the installation surface of

thermostat cap.

Screw on fixing bolts and Harness clamps for

thermostat cap and tighten them.

TRANSMISSION BELT

COOLING-TRANSMISSION BELT

17B-11

1. Dismantle fan and silicon oil clutch

(a). Dismantle the nuts on the flange of silicon oil clutch.

(b). Slowly take down fan and silicon oil clutch.

The fan and silicon oil clutch which are not separated can be

taken down.

2. Dismantle fan pulley and fan belt

(a). Loosen the generator bracket and dismantle the fan

belt pulley and fan belt.

3. Check belt appearance

(a). Carefully check each part of belt. If there are the

following damages, please replace the pulley.

• The rubber on the back is ageing and light-reflective,

in the case of nail scratching, there is no scratch and

the rubber is inelastic.

17B-12

• There is crack of the rubber on the back.

• There is crack on toothed bottom.

4. Install fan pulley and fan belt

(a). Place the fan belt to installation position and install the

After belt installation, check the belt tension firstly and then

adjust the position of generator for proper belt tension.

5. Check and adjust belt tension

(a). Press down the belt between water pump and

generator pulley with hands to check the belt

deflection.

Press down the belt with 70~80N of force and the belt

deflection shall be 7~8mm (the new belt deflection shall be

6~7mm)

Unscrew fixing bolts of generator bracket; adjust belt

tension by changing the position of generator. After that,

check the belt deflection. Tighten fixing bolts of bracket

until proper belt tension has been reached.

17B-13

6. Install fan and silicon oil clutch

(a). Place the fan and silicon oil clutch in the installation

(b). Tighten all nuts for studs.

Rotate the fan and check whether the installation is correct.

17B-14

COOLING-PULLEY AND FAN

PULLEY AND FAN

1. Dismantle the fan and silicon oil clutch (refer to Chapter 17B Cooling-Drive Belt, Dismantle)

2. Separate the fan and silicon oil clutch

(a). Dismantle the fixing bolts on the fan.

Push down the silicon oil clutch backward slowly to

separate the fan and silicon oil clutch.

3. Cleaning the pulley

(a). Clean the pulley with solvent.

In cleaning with solvents, acid or alkali materials please

follow the instructions of the manufacturer. Wear safety

goggles and protective clothing to avoid personal injury.

Check the bolt hole and its surrounding area of fan

pulley for crack and check damage in the contact

surface with drive belt.

• Fan belt in the case of discovery of pulley damage,

the fan belt shall be checked, too.

17B-15

4. Check the fan

(a). Check whether there is crack or incomplete

phenomenon in cooling fan.

• In the case of crack or incomplete phenomenon,

please replace the fan.

5. Assemble the fan and silicon oil clutch

(a). Align the fan bolt holes with corresponding bolt holes of

the silicon oil clutch and tighten all nuts of the fan.

17B-16

COOLING-WATER PUMP

WATER PUMP

1. Preliminary check

(a). Clean external water pump of generator with steam or

hydraulic giant.

Wear safety goggles and protective mask and protective

clothing when using the steam to clean. The hot steam is

possible to lead to serious personal injury.

(b). Make the engine run at low idle speed to check

whether the water pump leaks.

2. Dismantle the water pump assembly

(a). Dismantle the fixing bolts of crank position sensor and

take down the sensor.

Dismantle the fixing bolts of crank pulley and take down

Dismantle the fixing bolts of sight hole and take down

the sight-hole cover.

17B-17

(d). Dismantle all remained fixing bolts on water pump

pulley chamber cover.

There is a fixing bolt on the rear housing of crank pulley.

Take down the water pump pulley chamber cover

3. Clean and continuously check

(a). Clean the water pump pulley chamber cover assembly.

with solvent.

Please keep to the manufacturer’s suggestions for use

when using solvent, acid or basic materials. Wear goggles

and protective clothing to avoid personal injury.

(b). Dry the water pump pulley chamber cover assembly.

with compressed air.

Wear proper goggles and protective mask to avoid flying

chips and dirt to avoid personal injury.

Check the water pump pulley chamber cover assembly

for crack. In the case of obvious damage, replace the

water pump pulley chamber cover assembly.

17B-18

Check the water pump impeller for pitting and crack. In

the case of obvious damage, replace the water pump

pulley chamber cover assembly.

4. Install the water pump assembly

(a). Place the water pump pulley chamber cover assembly.

To installation position, put on bolts and tighten.

Place the sight-hole cover to installation position, put

on bolts and tighten.

Place the crank pulley to installation position, put on

bolts and tighten.

Place the crank position sensor to installation position,

put on bolts and tighten.

COOLING-OIL COOLER

17B-19

OIL COOLER

1. Dismantle the oil cooler.

(a). Drain the coolant.

(b). Disconnect the water inlet and outlet pipes of oil cooler.

Dismantle center bolts of oil cooler and take down the

oil cooler.

2. Check the oil cooler

(a). Plug the water outlet pipe of the oil cooler, connect the

water inlet pipe with inflator and put them into water

basin with the oil cooler submerged in the water

In the case of bubbles appearing in the water basin, replace

with a new oil cooler.

3. Install the oil cooler

(a). Place the oil cooler to installation position and tighten

its center bolts.

17B-20

Connect the water inlet and outlet pipes of the oil

cooler.

COOLING-EXPANSION TANK

17B-21

EXPANSION TANK

1. Dismantle expansion tank

(a). Disconnect the connection between radiator and

connecting hose.

Loosen Nylon cable tie and lock iron sheet on the

Disconnect the connection between expansion tank

and connecting hose.

Dismantle the fixing bolts of expansion tank assembly.

Take down the expansion tank assembly.

2. Check whether there is crack and leakage phenomenon, if yes, then replace it.

17B-22

3. Install the expansion tank

(a). Place the expansion tank in the correct installation

(b). Install and fasten the fixing bolts of expansion tank.

Correctly connect the connecting hose and expansion

Correctly connect the connecting hose and radiator.

(e). Fill the antifreeze solution to the suitable height.

In antifreeze solution filling, it is preferable to place a flared

vessel under the opening of expansion tank.

User can choose different marks of antifreeze solution

according to the local atmosphere temperature.

(f). Fasten the water outlet hose of expansion tank with

nylon cable tie and lock iron sheet.

After finishing installation, start the engine, and then observe

the liquid level height in the expansion tank when the water

temperature in the engine rises to 80℃. If the coolant is

insufficient, then add the coolant according to the scale of

expansion tank.

COOLING-COOLING PIPELINE

17B-23

COOLING PIPELINE

1. Open the front cabin cover

2. Place coolant

(a). Dismantle the drainage bolt of radiator and drain the

coolant of cooling pipeline empty and place the

container under the radiator to storage antifreeze

coolant.

Do not dismantle cooling pipeline and drain the coolant when

the engine water temperature is higher than 50℃ to avoid

scald and engine part damage.

Screw off the cover of radiator and shorten the

drainage time.

3. Dismantle cooling hose

(a). Screw off A-type worm drive hose clamp which

connects radiator water inlet hose and water inlet or

water outlet hose and water outlet.

Screw off A-type worm drive hose clamp which

connects radiator water inlet hose and engine water

outlet or water outlet hose and engine water inlet.

• Take down the radiator water inlet and outlet

hoses.

17B-24

4. Check cooling hose

(a). Check whether the cooling hose has crack or

expansion, if yes, and then replace the cooling hose

5. Install cooling pipeline

(a). Install the radiator water outlet hose in the engine water

inlet and install the radiator water inlet hose in engine

water outlet, and fasten the A-type worm drive hose

Install the radiator water outlet hose in the water outlet

and install the water inlet hose in water inlet, and fasten

the A-type worm drive hose clamp.

Install and fasten the drainage bolts and seal washer in

the drainage hole which is at the bottom of radiator.

(d). Fill the antifreeze coolant in the proper position and

screw on the cover of radiator.

COOLING-RADIATOR

17B-25

1. Dismantle the radiator assembly

(a). Dismantle the drainage bolts on the radiator and drain

coolant in the radiator and cooling pipeline. Place a

container at the bottom of radiator to storage antifreeze

Screw out the cover of radiator and shorten the

drainage time in order to be conveniently dismantled.

Disconnect the connection between the radiator and

expansion tank and radiator connecting pipe assembly.

17B-26

Dismantle the connecting bolt between radiator and fan

shroud.

Dismantle the fixing bolts of radiator.

Take down radiator assembly.

2. Clean and detect radiator

(a). Block up other water outlets of radiator. Fill certain

pressure water in the radiator and make sure that each

part of radiator has no leakage.

In the case of leakage for radiator, please timely service or

If there are foreign matters on the radiator, the heat

radiating ability for the cooling system will be reduced.

Check whether the radiating fin is blocked off. If it is

blocked off, clean the radiator surface with compressed

air or with not high water pressure.

Thoroughly clean the inner radiator with water.

17B-27

3. Install radiator assembly

(a). Place the radiator in the correct installation position.

(b). Install and fasten the fixing bolts on both sides of

Install and fasten the connecting bolts between radiator

and fan shroud.

A-type worm drive hose clamp.

Connect the radiator and expansion tank to the radiator

drainage hole which is at the bottom of radiator.

17B-28

(g). Fill the antifreeze coolant in the proper position and

润滑系统 - 润滑系统 16B-1

LUBRICATION SYSTEM .......................................................................... 18B-1

Overview ............................................................................................... 18B-1

Flow Process Diagram ........................................................................ 18B-3

Diagram of Components I ................................................................... 18B-4

Diagram of Components II .................................................................. 18B-5

Measurement ........................................................................................ 18B-6

Discharge .............................................................................................. 18B-8

Checking ............................................................................................... 18B-9

Injection .............................................................................................. 18B-10

OIL DIPSTICK ......................................................................................... 18B-12

Service ................................................................................................ 18B-12

OIL PAN ................................................................................................... 18B-14

Service ................................................................................................ 18B-14

OIL PUMP ................................................................................................ 18B-17

Service ................................................................................................ 18B-17

OIL FILTER .............................................................................................. 18B-22

Service ................................................................................................ 18B-22

18B

18B-1

1. The lubrication system consists of oil suction filter, oil pump, oil filter, oil dipstick and pipelines.

2. Because of different operation conditions of engine moving parts, the required lubrication strengths are

also different, so are the applied lubrication methods. There are three types of lubrication methods:

pressure lubrication, splash lubrication and gravity lubrication.

• With the pressure lubrication method, the lubrication oil will be send to each friction surface forcibly

by oil pump. Generally, the part which is bearing heavy load in operation or with high kinematic

velocity, such as crankshaft main bearing and wheel bearing etc., shall adopt this pressure

lubrication method. Moreover, as for the parts such as valve rocker arm shaft and others, the

pressure lubrication method shall be adopted because the light bearing load and its mounting

position on the cylinder head.

• With the splash lubrication method, the lubrication is carried out by oil mist formed by the lubrication

oil thrown out by rod journal and main journal and the lubrication oil thrown out by special oil jet.

Generally, the parts which are bearing light load or with low kinematic velocity, such as cam running

surface, tappet etc., shall adopt the splash lubrication method. In addition, although the working

load of cylinder wall is heavy, it is not advised to apply excessive lubrication oil in case of oil flowing

to the combustion chamber and the working deterioration of engine. For this reason, the cylinder

wall shall be lubricated with splash lubrication method.

• The gravity lubrication method carries out the lubrication with the gravitational flow of lubrication oil

itself, for example, the lubrication for air rod and push rod along rocker arm is carried out by swaying

the rocker arm with the gravity of lubrication oil.

3. Passing through the oil suction filter, the oil stored in oil pan will be sucked into oil pump by means of oil

inlet pipe and carried to oil filter after pressurization. The filtered oil can access to the main oil gallery of

engine block by three ways:

• One way passing by the main bearing, crankshaft oil hole and reaching the connecting rod bearing.

• One way passing by the camshaft bush, eccentric oil groove of cam journal and interruptedly

supplying oil to the rocker arm shaft bush.

• One way passing by the bearing of correct timing idle gear.

4. The scientific name of oil is lubrication oil which plays an significant role in normal operation of engine.

Lubrication action: lubricate the surface of moving part, reduce the frictional resistance and abrasion

and decrease the power consumption of engine.

Cleanup action: the oil will constantly circulate in lubrication system, clean the friction surface and take

away abrasive dust and other foreign matters.

Cooling action: the oil will constantly circulate in lubrication system, take away the fricative heat of parts

and carry out the cooling performance.

Sealing action: there will be an oil film between each two moving parts. This is helpful to increase their

leak proofness and avoid air leakage or oil leakage.

Anti-corrosion action: there will be an oil film on the surface of part to protect the part’s surface and

avoid corrosion and rusting.

Hydraulic pressure action: the lubrication oil can be used as hydraulic oil, such as hydraulic tappet, to

carry out the function of hydraulic pressure.

18B-2

Damping and buffer action: there will be an oil film on the surface of moving part to absorb the impact,

reduce small vibration, attenuate the shock and realize the buffer action.

18B-3

FLOW PROCESS DIAGRAM

18B-4

DIAGRAM OF COMPONENTS I

1 Spin-on filter element and seal ring

2 Oil filter seal ring

3 Oil filter seat component

4 Flat washer

5 Spring washer

6 Hexagon head bolt

7 Oil cooler component

combination

9 Connection hose

10 Oil cooler outlet hose

11 Oil cooler inlet hose

12 Oil pump part

flat washer combination

14 Seal ring

15 Oil pump outlet pipe component

18B-5

DIAGRAM OF COMPONENTS II

Hexagon head bolt, spring washer and flat

washer combination

2 Oil drain plug

3 Sealing gasket

4 Small oil pan

5 Oil pan gasket

and flat washer combination

7 Aluminum oil pan assembly

9 Aluminum oil pan rear gasket

10 Aluminum oil pan front gasket

18B-6

MEASUREMENT

Measure the oil level in the oil pan to see whether it is between two scale marks of oil dipstick.

• When measuring, the automobile shall be parked at the level position and the engine shall be

stopped. One shall pull out the oil dipstick when the oil level is static, wipe out the oil on oil dipstick

with clean cotton cloth, plug the oil dipstick into oil pan again till the end of dipstick and then pull

out the oil dipstick to check the oil level.

• When the filled oil of new gasoline engine or the one which is not used for a long time reaches the

upper scale mark, one shall park the automobile after running for 5-10min at low speed and

remeasure the oil level with oil dipstick.

1. Check the oil level

(a). Park the automobile on the road with level surface and turn

off the engine.

• If the automobile service time is not long, the engine

shall be started to run for a few minutes.

• Turn off the engine, wait at least 5min and then check

the oil level.

Open the automobile engine hood.

Take out the oil dipstick.

18B-7

(d). Check the oil level

There are upper and lower scale marks on oil dipstick in order to

facilitate checking the oil level. The oil level shall not be lower

than the lower scale mark in case of that the oil pump cannot

suck up oil. The oil is also not appropriate to be higher than the

upper scale mark in case of the impact of crank of crankshaft

to oil surface leading to excessive oil mist and splash oil drop in

crank case and serious carbon deposit on the top of piston and

combustion chamber walls. Meanwhile, there are some faults

such like that the piston ring is stuck by coking, the diesel engine

generates smokes and oil seal leakage and the increase of oil

consumption. For these reasons, besides paying attention to the

oil pressure, one shall also check the oil level before driving or

for every 300~500Km running distance of automobile.

Besides paying attention to the oil pressure while operation,

one shall also check the oil level before driving.

18B-8

DISCHARGE

1. Dismantle the engine assembly. (Refer to Chapter 15A Engine Mechanical Part - Disassembly of

Engine.)

2. Dismantle the oil drain bolt

• Do not reuse the disassembled bolt gasket and please

replace it with a new one.

Before discharging the oil, the engine shall continue

running till the oil temperature reaching approximate 80°C

to ensure that all oil and suspended dirt are discharged.

3. Discharge the oil in oil pan

• One shall prevent his/her skin from contacting the hot oil

when discharging oil in order to avoid scalding.

• One shall properly handle the used oil to protect the

environment.

4. Lubrication oil drain bolt

When placing the lubrication oil drain bolt, the clean oil is

required.

5. Install and fasten the oil drain bolt

Whenever the oil drain bolt is dissembled, the oil drain bolt

washer shall be replaced by a new one.

18B-9

CHECKING

1. Check the oil drain bolt on oil pan to see whether it

is loose. If it is loose, the bolt shall be screwed up.

2. Check the threads of oil drain bolt to see whether it

is damaged. If it is damaged, the bolt shall be

3. Check the threads of oil drain bolt to see whether it

is damaged. If it is damaged, the bolt shall be tapped

or the hole shall be expanded and maintained.

4. Check the fixing bolt on oil pan to see whether it is

loose. If it is loose, the bolt shall be screwed up or

be replaced when necessary.

18B-10

INJECTION

1. Unscrew the oil filler cap

(a). Take down the oil filler cap.

The oil filler shall be cleaned by wiping prior to taking down the

oil filler cap to avoid access of foreign matters.

2. Change oil

When using for a long time, not only foreign matter or dust will exist in oil, but some unburned fuel oil will also

mix with oil to reduce the oil density. Moreover, there will be eroded parts due to oil deterioration when bringing

in part of exhaust gas with acid anhydride etc. For this reason, when used for a period, the oil shall be

discharged completely and changed with fresh oil.

Replace it every 5,000Km.

• Use the diesel oil of grade CF-4 or above that conforms to the Q/SH038.202-1997 specification for

the Great Wall Oil Company.

• Select the oil according to ambient temperature when using.

18B-11

3. Fill the oil

If the oil quantity of oil pan is unknown, the filled oil shall reach to

the minimum volume of oil pan. Then one shall conduct the

filling several times and fill a certain amount of oil each time till

the oil level reaching the upper oil level mark on oil dipstick.

Record the filling amount for knowing the oil volume when the

next time replacement of oil.

• Do not fill till overflow in case of air inflation of oil or the

loss of oil pressure.

• The filled oil shall not be mixed with moisture and

foreign matters.

• It is prohibited to use the mixture of oils with different

brands and manufacturers.

4. Screw up the oil filler cap

(a). Install the oil filler cap.

As for every time of oil change, the diesel engine shall run with

no load for a short period to ensure sufficient oil providing to the

lubrication system and its parts which require the oil supply.

Meanwhile, one shall also check the oil leakage phenomena of

oil drain bolt, fuel filter and surrounding parts.

(b) Check the oil level.

such like that the piston ring is stuck by coking, the gasoline

engine generates smokes and oil seal leakage and the increase

of oil consumption. For these reasons, besides paying attention

to the oil pressure, one shall also check the oil level before

driving or for every 300~500Km running distance of automobile.

18B-12

LUBRICATION - OIL DIPSTICK

OIL DIPSTICK

1. Service the oil dipstick

(a). Clean the ambient dusts of oil dipstick with compressed

Disengage the connection of oil dipstick pipe and engine

Dismantle the oil dipstick pipe upper bracket fixing bolt.

Dismantle the oil dipstick pipe lower bracket fixing bolt.

18B-13

Take out the oil dipstick assembly.

Install the oil dipstick assembly onto the specified

Install the oil dipstick pipe lower bracket fixing bolt.

Install the oil dipstick pipe upper bracket fixing bolt.

Connect the connection of oil dipstick pipe and engine

18B-14

The oil in oil pan shall be ensured to be discharged completely before dismantling the oil pan.

1. Dismantle the oil pan

(a). Turn over the engine body.

(b). Dismantle the fixing bolt of oil pan.

2. Disassemble the oil pan assembly

(a). Disassemble the small oil pan fixing bolt.

(b). Take down the small oil pan and small oil pan gasket.

Do not reuse the removed oil pan gasket and please replace it

with a new one.

18B-15

3. Clean and check the oil pan.

(a). Scrape all the remaining sealing materials on the oil pan

and cylinder block, and clean the oil pan with vapor, dry

the oil pan with compressed air.

No.5 and No.7 machine oil (light spindle oil) can also be used

when the oil pan is cleaned, and never use gasoline or kerosene

to clean.

• Please wear safety glasses or protective mask and

protective clothing to avoid serious personal injuries

caused by hot vapor.

• When using the compressed air, please wear proper

safety glasses and protective mask to avoid personal

injuries caused by splash scraps and dirt.

(b). Check the oil pan to see whether it can still be used.

• The oil pan is used to store the oil and dissipate the heat of oil.

Dints and cracks are not allowed on oil pan.

• When the cracks are not serious, the oil pan can still be

reused instead of being replaced.

4. Install the oil pan assembly

(a). Install the small oil pan and gasket to designated

Install and fasten the small oil pan fixing bolt.

18B-16

Install the oil pan assembly to a designated position.

Install and fasten the fixing bolts of oil pan.

Overturn and adjust the engine block.

18B-17

1. Dismantle the oil pan assembly. (Refer to Chapter 18B Lubrication-Oil Pan, Service.)

2. Dismantle the oil pump assembly

(a). Dismantle 2 fixing bolts of oil pump.

Disconnect the connection of oil pump outlet pipe and oil

Take down the oil pump and oil pump outlet pipe.

3. Disassemble the oil pump

(a). File the rivet point of pinion stopper pin.

18B-18

Drift the pinion out with a pivot-end drift pin.

Take down the pinion.

Dismantle the fixing bolt of oil pump cover and take

down the oil pump cover.

Put the mark on the rotor to confirm the correct direction

when assembling and dismantle the rotor.

4. Service for the oil pump

(a). Check the clearance between rotor and oil pump cover

with a feeler gauge. If there is severe wear, replace the

inside and outside rotors or the oil pump assembly.

Standard value: 0.06 mm

Limit value: 0.15 mm

18B-19

Check the clearance between rotor and oil pump with a

feeler gauge. If there is severe wear, replace the oil

pump assembly.

Standard value: 0.14 mm

Check the clearance of main drive shaft and pump oil.

• Check the main drive shaft external diameter with

screw micrometer.

• Measure the internal diameter of pump body with

internal dial indicator.

• The oil pump assembly shall be replaced if the

clearance between main drive shaft and oil pump

body exceeds the specified limit value.

Standard value: 0.04 mm

Check whether the oil pump cover and strainer are

broken or blocked and replace them when necessary.

5. Assemble the oil pump

(a). Install the rotor.

Install the rotor corresponding to the mark put previously.

18B-20

Install the oil pump cover to designated position, and

install and fasten the oil pump cover fixing bolt.

Install the pinion to designated position and install the

pinion drift pin.

6. Test the oil pump

(a). When reassembling the oil pump, the oil pump shall be

put into the clean oil pan and rotate the pump shaft

clockwise till the oil flowing out from oil outlet of oil pump.

One shall block the oil outlet with a hand and continue to

rotate the pump shaft. If the rotational resistance

increases, the operation condition is normal.

The oil pump pressure can be measured with oil

pressure gauge if necessary.

7. Install the oil pump assembly

(a). Install the oil pump and oil pump outlet pipe to

designated position.

18B-21

Connect the connection of oil pump outlet pipe and oil

Install and fasten 2 fixing bolts of oil pump.

8. Install the oil pan assembly. (Refer to Chapter 18B Lubrication-Oil Pan, Service.)

18B-22

1. Dismantle the oil filter assembly

(a). Disconnect the connection of oil cooler inlet and outlet

hoses and oil cooler.

One shall place a vessel under the oil filter when disassembling

to receive the spilled oil.

Dismantle the fixing bolt of oil filter assembly.

(c). Take down the oil filter assembly and oil filter washer.

Do not reuse the removed oil filler washer.

2. Disassemble the oil filter assembly

(a). Dismantle the oil cooler fixing bolt with special tools and

take down the oil cooler.

One shall place a clean vessel under the filter to receive the

spilled oil.

18B-23

(b). Dismantle the oil filter element with special tools in the

counterclockwise direction.

One shall place a clean vessel under the filter when dismantling

the filter element to receive the spilled oil.

Spin-on filter element is a disposable part that can’t be

reused.

3. Check the oil filter seat

(a). Check and clean the oil filter seat and ensure the fitness

of new oil filter element.

4. Assemble the oil filter assembly

(a). Apply a thin layer of oil on the surface of O-ring, and

screw up the new filter element to the filter seat until the

resistance is felt.

(b). Rotate in the clockwise direction to install the oil filter

element with special tools.

Rotate it by 3/4 circle clockwise.

• Spin-on filter element is a disposable part that can’t be

• When the oil filter is disassembled and installed, it must

be noticed that do not damage the rubber seal ring to

prevent impacting the sealing performance and resulting

in oil leak.

18B-24

(c). Install the oil cooler to designated position and install the

oil cooler fixing nut with special tools.

Apply a thin layer of oil to the surface of O-ring.

5. Install the oil filter assembly

(a). Install the oil filler assembly and filter washer to the

washer in designated position.

Apply clean oil to the new oil filter washer before installing.

Install and fasten the fixing bolt of oil filter assembly.

Connect the connection of oil cooler inlet and outlet

IGNITION SYSTEM ................................................................................... 19-1

Overview ............................................................................................... 19-1

Precautions .......................................................................................... 19-2

Check on Board ................................................................................... 19-3

SPARK PLUG ............................................................................................ 19-4

Detection .............................................................................................. 19-4

Service .................................................................................................. 19-5

HIGH TENSION WIRE .............................................................................. 19-8

Service .................................................................................................. 19-8

IGNITION COIL ......................................................................................... 19-9

Service .................................................................................................. 19-9

CRANKSHAFT POSITION SENSOR ..................................................... 19-10

Service ................................................................................................ 19-10

In order to generate high-voltage electric sparks regularly, the gasoline engine is equipped with special

ignition device, engine ignition system. Making the engine work by igniting combustible gas mixture, the

ignition system can duly, accurately and reliably generate electric spark in cylinder under any working

condition or service condition of engine. Generally, the ignition system consists of battery, ignition switch,

ignition coil, spark plug and fuse.

1. When the engine is started and working, do not touch the ignition coil and high tension wire in

case of high-voltage electric shock.

2. When conducting the high-voltage trial ignition, it recommends that the high tension wire

shall be clamped with insulation rubber clamp. Do not directly touch the high tension wire

with hands in case of electric shock and the damage of ignition system high tension circuit.

During the trial ignition, one shall firstly plug a high tension wire into a standby spark plug,

then ground the spark plug and observe the spark-over situation between electrodes of spark

plug.

3. When inspecting the service condition of each cylinder with the method of cut-out cylinder by

cylinder, the high tension wire of cut-out cylinder shall be grounded by short-circuit method

instead of open-circuit method.

4. Ignition timing exerts a tremendous influence on engine functioning. For this reason, when

the engine is in bad service or disassembled, one shall pay attention to check the ignition

timing.

5. While the spot welding operation on board, the ground wire of battery shall be disassembled.

6. If the wire of ignition system (including the disassembly and connection of test instruments) is

required to be disassembled or connected, the ignition switch shall be shut off primarily.

7. While cleaning the engine, the ignition switch shall be shut off primarily.

8. If the high tension wire is required to be unplugged, one shall pull the connecting part (such

as the connecting sleeve of spark plug) instead of pulling the wire.

CHECK ON BOARD

1. Check the ignition coil

(a). Turn off the ignition switch and unplug the terminal

wiring harness connectors and high tension wires from

ignition coil kit.

(b). Respectively measure the resistance between B

terminal and A & C terminals of 3-terminal- connector

on the ignition coil kit with ohmmeter (primary coil

resistance).

Primary resistance value: 0.52±0.05 Ω

The ignition coil kit shall be replaced if the resistance of ignition

coil is out of the specified range.

(c). Measure the resistance between high-voltage output

terminals of Cylinder 2 & Cylinder 3 and Cylinder 1 &

Cylinder 4.

Secondary resistance value: 9840±980 Ω

2. Spark over test.

If the engine can rotate but not be started, one shall conduct the spark over test for it. The procedure

is: unplug the high tension wire from the spark plug and assemble an ignition alignment tester onto

the high tension wire. Connect the clamp of tester onto the bolt or support of engine, rotate the engine

and observe the spark over situation at the end of tester. If there is no ignition alignment tester, one

shall hold the high tension wire end with insulating tool, keep the end terminal 6mm distant from the

proper ground position, revolve the engine and observe the spark over situation at the end of tester. If

there are continuous and uniform blue sparks, one shall check or replace the spark plug; if no spark or

the spark is weak or intermittent, one shall check the ignition coil kit (intermediate terminal) to see

whether it gets sufficient battery voltage and check ignition high tension wire, ignition coil and ignition

IGNITION - SPARK PLUG

SPARK PLUG

DETECTION

1. Detect the spark plug

Method of automobile check

● Method of touch: Start the engine, make it idling and touch the ceramic insulating part of spark plug.

If the temperature increases to a very high level and at a fast speed, the spark plug is working

normally, otherwise, it is abnormal.

● Method of short circuit: Start the engine, make it idling and short out the spark plug with

screwdriver cylinder by cylinder and listen to the revolving speed and sound variation of engine. If

the variation of revolving speed and sound is obvious, the spark plug is working normally,

otherwise, it is abnormal.

● Method of spark-over: Screw off the spark plug and put it on the cylinder block. Conduct the trial

ignition with high tension wire, if no spark or the spark is weak, it means the spark plug has a fault

of current leakage or it does not work.

Method of observing color

● Disassemble the spark plug and observe it, the color of russet or rust means the spark plug is

normal; if it seems like oil stains, it must be the clearance maladjustment of spark plug, excessive

gasoline, short circuit or open circuit; if it is smoky black, the selection for soft plug or hard plug

must be wrong, or there’s a high concentration of gas mixture and the engine oil will go upward; if

there are deposits between the top and electrode, especially if they are oily deposits, it means the

oily smoke is unrelated with spark plug, and if they are black deposits, it means spark plug is

accumulated by carbon deposits and bypassed, and if they are grey deposits, it means the ignition

miss due to addition agent covering electrode. If the ablation is serious, such as scars on the top,

black rupture pattern and melt of electrode, it means the spark plug is damaged.

The following issues shall be noted for the disassembly or installation of spark plug.

(a). Before dismantling the spark plug, one shall gently pull out the connector of each cylinder instead of

pulling the high tension wire with great force to avoid damaging the high tension wire or the

connection terminals of spark plug which is likely to be damaged.

(b). As for the disassembly of spark plug, one shall firstly blow off the dirt around spark plug with a thin

hose in case of dirt falling into the cylinder after screwing off the spark plug.

(c). One shall disassemble the spark plug when the engine is cooled. One shall not shake the spark plug

with great force during operation to avoid damaging the sealing property of spark plug.

(d). During installation, the threads, electrodes and sealing gasket of spark plug shall be cleaned, dried

and without oil stains in case of current leakage, air leakage, spark weakening and other faults.

(e). When screwing in the spark plug, the bolt shall be screwed in by 1/2 of its total length with hands and

then fastened by a jack lever. If the bolt cannot be screwed in smoothly, one shall quit the operation

and check the spark plug to see whether it is aligned with screw or whether there are foreign matters

in threads. One shall not aimlessly apply force on it and fasten it to avoid damaging screw hole or

cylinder head.

(f). If a flat-seat-type spark plug is selected, it shall be equipped with a sealing gasket, of which the

quantity shall be adequate. Carbon deposit is likely to exist if the sealing deposit is excessive, while

for sealing’s sake, no-sealing–gasket is not permitted. If a conical-seat-type spark plug is selected, no

sealing gasket shall be equipped.

(g). The spark plug shall be screwed up as required, because loose spark plug will lead to air leakage,

while the excessively tight spark plug will also lead to air leakage due to elasticity lack.

1. Disassemble the spark plug

(a). Disassemble the spark plug with special tools.

When the spark plug hole is opened, please prevent foreign matters from entering the combustion

2. Service the spark plug

(a). Check the edge of electrodes of spark plug and replace

the spark plug if it is worn.

19-6

(b). Check the gap between central electrode and

grounding electrode with a spark plug gap gauge to see

whether it is within the specified range.

Electrode gap of spark plug: 1.1±0.1 mm

Please use special gauge for spark plug to measure the spark

plug gap.

1: Spark plug gap gauge

2: Grounding electrode

3: Central electrode

Check the insulator to see whether there are flaws or

the damages of terminal corrosion or threads. If there

are, replace the spark plug.

If there are moist carbons, one shall dry it and clean it

with cleaning agent specially applied to spark plug.

3. Adjust the spark plug gap

(a). Put the grounding electrode into the gap part of spark

plug gap gauge and bend the grounding electrode to

adjust the gap.

When bending the grounding electrode, the gap gauge of

spark plug shall not touch the insulator in order to ensure

the insulator shall not be ruptured. Also, one shall not pull

or knock the central electrode.

4: Insulator

5: Before adjustment

19-7

4. Assemble the spark plug

(a). Assemble the spark plug with special tools.

Torque: 20~30 N·m

19-8

IGNITION-HIGH-TENSION WIRE

HIGH TENSION WIRE

1. Disassemble the high tension wire

The engine shall be shut off in prior of dismantling the high tension wire.

2. Detect the high tension wire with multimeter.

(a). Measure the resistance of high tension wire with an

multimeter, if it is not within the specified range, replace

the high tension wire.

3. Assemble the high tension wire

(a). Plug the connector of high tension wire and spark plug into the spark plug and ensure its security.

(b). Insert the connector of high tension wire and ignition coil into the ignition coil and ensure its security.

IGNITION - CRANKSHAFT POSITION SENSOR

19-9

IGNITION COIL

(a). Turn off the ignition switch and unplug the terminal wire

harness connectors and high tension wires from the

(b). Disassemble the fixing bolt of ignition coil and take

down the ignition coil.

(c). Respectively measure the resistance between B

(d). Measure the resistance between high-voltage output

2. Assemble the ignition coil

(a). Assemble the ignition coil to the mounting position and

tighten the fixing bolt.

Torque: 10~15 N·m

(b). Connect the high tension wires to the ignition coil.

(c). Assemble the terminal harness connectors of ignition

coil in place.

19-10

IGNITION-HIGH-CRANKSHAFT POSITION SENSOR

1. Service the crankshaft position sensor

(a). Detect for the voltage between two terminals. One shall

test the voltages between each two of terminals A, B,

and C, 3 terminals of sensor with voltage grade of

multimeter. When the ignition switch is “ON”, the

voltage value between A-C terminals is about 8V; the

voltage value between B-C terminals will vary in the

range of 0.3-5V when the engine is running. And its

value varies like pulse: the maximum voltage is 5V, and

the minimum one is 0.3V. If the actual results are not in

accordance with the results, the crankshaft position

sensor shall be replaced.

A: Signal+ B: Signal- C: Screening Layer

电器系统 - 发电机 14-

GENERATOR ......................................................................................... 20B-1

Overview ............................................................................................ 20B-1

Diagram of Components .................................................................. 20B-2

Testing Generator ............................................................................. 20B-3

Disassembly and Installation of Generator .................................... 20B-6

STARTER ............................................................................................. 20B-10

Overview .......................................................................................... 20B-10

Diagram of Components ................................................................. 20B-11

Testing Starter ................................................................................. 20B-12

Disassembly and Installation of Starter ........................................ 20B-15

BATTERY ASSEMBLY ......................................................................... 20B-17

Overview .......................................................................................... 20B-17

Structure .......................................................................................... 20B-18

Working Principle ........................................................................... 20B-22

Working Characteristics ................................................................. 20B-23

Precautions ..................................................................................... 20B-24

Common Faults and Troubleshooting for Battery ....................... 20B-25

Diagram of Components ................................................................ 20B-28

Replacement .................................................................................... 20B-29

USE OF MAINTENANCE FREE BATTERY ........................................ 20B-32

Checking of Technical Condition .................................................. 20B-32

Charge The Maintenance Free Battery ......................................... 20B-33

20B

20B-1

Generator is the main power supply for electric equipment of automobiles. During the period of automobile

normal operation, generator powers the other electric equipment for starter, and also charges the battery.

Please pay much attention to the following problems for the use and maintenance of alternator.

1. The bonding of battery shall be in accordance with the polarity of alternator. The bonding shall be

negative or else the battery will discharge through diode of silicon rectifier to burn up the diode.

2. The method of make the output terminal of generator’s grounded (ground) cannot be used to check

whether the generator generate electricity.

3. When the generator runs at a high speed, do not dismantle the main electric equipment of battery to

avoid producing overvoltage and damaging the diode, adjuster or other electric equipment.

4. Inspect whether the wiring between the generator and battery is fixed and dependable.

5. Inspect the tension of generator belt to judge whether it is in accordance with the ex-factory

regulations. If the belt is too loose, the battery will undercharge; if the belt is too tight, the belt and

generator bearing will be easily damaged.

6. Once the generator is found out to work abnormally, check it timely, find out and remove the fault.

7. Maintain the generator regularly. Generally speaking, check and inspect the generator’s electric brush,

rectifier element, adjuster, bearing and other vulnerable elements one time after the generator runs

for 750h or after the automobile travels for 30000Km.

20B-2

1 Belt tension arm

2 Generator fastening bolt washer

3 Heavy spring washer

4 Hexagon head bolt

5 Generator component

6 Connector bolt

7 Vacuum pump inlet tube assembly

8 Copper washer

9 Vacuum pump return tube

10 Return tube clip

11 Nut

16 Generator bracket

17 Generator fastening bolt

18 Hexagon head bolt

20B-3

TESTING GENERATOR

1. Checking generator’s output direct voltage

(a). Start the generator and make the generator run at idle

(b). Measure the voltages on both terminal s of storage with

digital multimeter. The voltage registration shall be

between 13 V and 15V (the detailed registration shall

be set according to the set value of adjuster). When the

generator rotate speed rises, the output direct voltage

of generator basically

2. AC component test of generator’s output voltage

Adjust the digital multimeter to the AC voltage and connect it on the positive and negative poles of battery and

measure the generator’s output AC voltage (normal value shall be ≤0.4V).

The specific steps are as follows:

(a). Start the generator and make the generator run at 2000rpm.

(b). Turn on the headlamp and apply certain load for the generator.

Adjust the digital multimeter to the AC voltage and

connect it with the positive and negative poles and read

the AC voltage value. If the voltage is ≤0.4V, it indicates

that the rectifier of generator works normally. If the

voltage is not in the range of ≤0.4V, it indicates that the

rectifier of generator has fault.

3. Checking the charging system voltage drop

The voltage drop test is mainly for checking whether the wiring between generator and battery is in good

The specific methods are as follows:

(a). Start the generator and make it runs at 2000rpm of the rotate speed.

(c). Adjust the digital multimeter to the AC voltage and measure the voltage drop between the generator’s

output terminal and battery’s positive pole. The normal value is ≤0.4V. If the value is higher than

0.4V, it indicates that the resistance of the wire connection point is too high.

The following is only the schematic diagram.

20B-4

(d). Adjust the digital multimeter to the direct voltage and measure the voltage drop between the

generator casing and battery’s negative pole. The normal value is ≤0.3V. If the value is higher than

0.3V, it indicates that the wire connection becomes loose and the resistance of connection point is too

high.

The following is only the schematic diagram

20B-5

4. Checking single machine of generator

(a). Measure whether the generator’s guide terminal is

conductive with ohmmeter.

Respectively insert ohmmeter hand in two needles of the

generator’s guide terminal. If the display value on the

ohmmeter is infinite, it indicates that the wire harness inside

the generator disconnects, the generator is damaged and shall

be replaced. If the display value on the ohmmeter is minimum,

it indicates that the wire harness of generator is in good

condition.

(b). No-load test

Disconnect the switch K, rapidly rise generator’s rotate speed,

make the battery’s positive wire contact the wiring terminal of

generator of magnetic field for the excitation of generator.

When the generator voltage is 18V, the rotate speed of

generator is 1000rpm.

The generator shall run flexibly when it is moved by hands

and there shall be no hysteresis and scraping phenomena.

1: Magnetic field 2:Armature 3: Neutral point

(c). Load test

• Adjust the load resistance of circuit to the maximum.

• When the alternator voltage is 28 V for the load test,

the switch shall be switched on to make the

generator output the current outward.

• Gradually reduce the load resistance to increase the

output current and raise the rotate speed to make

the generator voltage keep 28V.

Output current/A Voltage of electric machine/V Generator speed/(rpm)

20B-6

DISASSEMBLY AND INSTALLATION OF GENERATOR

1. Turn off the ignition switch when the car stops stably.

2. Disconnect the lead of battery pole

(a). Disconnect the negative terminal of battery.

Disconnect the vacuum pump inlet and outlet tubes

behind generator and the generator connector.

Loosen the adjusting bolt above generator.

Release the whole belt tension and remove the belt.

20B-7

(e). Remove the generator fixing bolt.

Remove the generator fixing bolt with two wrenches together.

Remove the adjusting bolt above and the generator.

3. Disassemble generator assembly

(a). Remove the vacuum pump fixing bolt.

Remove the vacuum pump.

4. Install generator assembly

(a). Place the vacuum pump to generator installation

20B-8

Install and tighten the vacuum pump fixing bolt.

5. Install generator assembly

(a). Place the repaired generator to engine bracket.

(b). Install the upper adjusting bolt.

The upper adjusting bolt is not tightened to install and adjust

Install the generator fixing bolt.

Adjust the generator position, install the generator belt

and adjust the drive belt tension.

(e). Install the adjusting bolt above generator.

Do not tighten the adjusting bolt above generator excessively

to adjust generator belt.

20B-9

Firmly press the generator belt and check if the belt is

Reference standard: force of 39 N and deflection of

approximately 10 ~ 15 mm

Confirm the generator belt is installed in place and

tighten the generator adjusting bolt.

Torque: 19 N·m

Connect the vacuum pump inlet and outlet tubes

Connect the battery.

20B-10

The starter mainly consists of three components: DC series motor, driving mechanism for one -way clutch

and battery switch. The three components can smoothly finish the start of engine by organic combination and

cooperative work.

The detailed working process is as follows:

Connect the starting ignition → starting relay has electricity → solenoid switch electrifies →produce

electromagnetic tension → Push off the isolator through shifting fork to mesh it with the flywheel; at the same

time, transfer the battery’s electric energy to the motor → wheel gear isolator rotates → produce the

electromagnetic torque to start the engine.

20B-11

1 1 type hexagon nut

2 Spring washer

3 Flat washer

4 Starter motor

5 Hexagon head bolt

20B-12

TESTING STARTER

1. Testing voltage drop of starting system

Testing voltage drop is mainly to check the connection condition of lead wire of main circuit for starter. Adjust

the digital multimeter in the direct voltage, measure it according to the following diagram. Each part’s

measured voltage value shall be ≤0.2V. if the measured voltage value of one part is >0.2V, it indicates that

the wiring of the part has problem.

2. Testing starter

Judge the starter’s performance and technical condition by no-load test, brake test and performance test of

solenoid switch.

(a). No-load test

Connect the circuit to observe whether the starter runs normally. Connect the ampere meter in series

with the circuit. Read the current value and the current value shall not be >90A.

Idling time of starter shall not be more than 1 min.

20B-13

Brake (locked) test

The brake test shall be performed on the starter’s test station. Check whether the inner circuit of

starter has fault with the method of measuring torque which is produced when braking and consumed

current. And also check whether the meshing gear can slip. When performing the brake test, the

starter shall be proved by no-load test to be in good condition. The test method is as follows.

• Clamp the starter on the brake fixture of universal

test stand and clamp three gears of pinion gear with

clamp splice which is on the brake connecting rod.

• Connect the wiring of test stand and starter.

1: Starter

20B-14

• Press down the button SB on the universal test

stand (press the button tight and then loosen it), the

starter is braked. Rapidly read the voltage value and

current value respectively from the voltmeter’s dial

and ampere meter’s dial and then read the torque

value from the weight beam. Compare the voltage

value, current value and torque value with the

standard value to analysis and judge whether the

starter has fault.

The time of processing circuit shall be not more than 5s. If

it shall be tested again, the battery shall have a rest for 1~

2min to avoid reducing the service life of battery.

3. Performance test of solenoid switch

(a). Remove the wiring between M terminal and motor.

(b). Connect the battery’s negative pole with the starter housing and connect the positive pole with S

terminal. At this moment, although the coil is kept to be electrified, the electromagnetic force is too

small and the armature cannot move.

(c). Connect the negative pole and M terminal to hear that the solenoid switch making pick-up sound and

the driving gear is pushed out.

(d). Move away the negative pole from M terminal, the solenoid switch keeps pick-up, and the resistance

between two electric shocks of solenoid switch is “0”

20B-15

DISASSEMBLY AND INSTALLATION OF STARTER

1. Disassemble starter assembly

(a). Disconnect the battery.

Disconnect each lead wire of starter’s wiring terminal

Disassemble the fixing bolts of starter.

Take down the starter.

20B-16

2. Install starter assembly

(a). Install the starter in the corresponding position

Install and fasten the fixing bolts of starter.

Torque: 81 N·m

Connect each connecting lead wire of starter’s wiring

STARTING AND CHARGING - BATTERY ASSEMBLY

20B-17

BATTERY ASSEMBLY

Battery, a device of converting the chemical energy into electric energy, is a reversible direct-current power

supply with low voltage and is referred as “battery”. The maintenance free battery is a battery which cannot

be maintained during the service period under the specified service conditions. For lead battery for

automobile, the maintenance free battery is a battery which cannot be added distilled water during the service

period.

Functions of battery:

1. When start the engine, power the main power supply equipment, such as starter, ignition system and

so on.

2. When there is too much electric equipment or when the electricity consumption is more than the

starter’s capacity of electric power supply, the battery will assist the starter to power the electric

3. The battery can stabilize the voltage. The battery is considered to be a big capacitor which can absorb

the momentary overvoltage in the circuit and can protect electric equipment.

4. When the storage electricity of battery is insufficient and the generator’s load is less, the battery can

convert the generator’s electric energy as chemical energy to be stored (it means charging)

5. The battery is considered as a capacitor with big capacity. When the generator speed and load

change, the battery can keep the system voltage of automobile electric equipment relatively stable. At

the same time, the battery can absorb momentary overvoltage which is produced by generator to

protect the automobile electric elements from being damaged. Therefore, the generator cannot be run

when it is without the battery.

20B-18

STRUCTURE

The automobile type of SUP series adopts lead battery. The battery of 12V consists of 6 unit cell battery in

series. The nominal for each unit cell of battery is 2V, and it is 2.1 V when the battery is filled.

The lead battery consists of battery plate, battery plate group, and separator, acid electrolyte liquid and

1 Battery housing

2 Battery electrolyte liquid

3 Battery plate and plate group

4 Battery separator

20B-19

1. Plate and plate group

The battery plate is divided into positive plate and negative plate. The positive plate and negative plate take

the comb rack which is poured by lead-antimony alloy as the skeleton. Fill the active material on the comb

rack to manufacture the plate

The plate frame consists of comb rack which is the attachment

of active material.

The active material is filled on the comb rack. The active

material on the positive plate is nigger-brown lead dioxide

(PbO 2 ) and the active material on the negative plate is spongy

caesious pure lead (Pb)

There are two kinds of comb rack which are adopted by the

battery: one is the common type as shown in the left diagram.

The other is radiative type as shown in the right diagram.

The radiative type comb rack, which is characterized by high

output current, low internal resistance, and is used in the

new-type battery.

20B-20

In order to increase the capacity of battery, each unit cell

battery has multiple positive and negative plates to form plate

group, as shown in the left diagram.

Reason:

Each positive plate is located between negative plates to

equally charge and discharge both terminals of positive plate.

2. Separator

Functions of separator:

The insulating separator shall be installed between the

battery’s positive and negative poles to avoid the short circuit

of plates.

• The separator is characterized by porosity, which is convenient for electrolyte to freely permeate.

• The separator is made by adopts acid resistance and alkali resistance woodiness, microfoam rubber,

micropore plastic and impregnated resin paper material.

• The micropore plastic separator is made in bags and is tightly wrapped on the external of positive plate to

avoid falling off the active material.

3. Acid electrolyte

The electrolyte is the sulfate water solution which is allocated by certain proportion of sulfate (H 2 SO 4 ) and

distilled water (H 2 O) .

The density is 1.24~1.31g/m 3

The electrolyte density has great influence on the capacity and service life of battery. The big density can

raise the capacity of battery and can reduce the possibility of freeze; when the viscosity increases, the fluidity

becomes poor to make the capacity of battery reduce and to make the corrosiveness strengthen, as a result,

the service life of plate and separator is reduced.

20B-21

4. Housing

The housing adopts acid resistance, heat resistance and aseismatic hard rubber or polypropylene plastic to

make overall structure. The housing is divided into 6 unit cells which are not connected with each other.

The housing bottom has the raised rid which supports the plate group and make the active materials drop in

the groove from the plate to avoid short circuit of plate.

20B-22

The battery is an electrochemical power source and the charging and discharging process is a kind of

reversible chemical reaction.

1. Establish electromotive force

(a). On the positive plate, PbO 2 and sulfate produce lead

ion (Pb 4+ ) ascending and descending on the positive

plate with positive charge to make the positive plate

has about 2V positive potential.

(b). On the negative plate, the lead ionization contains lead

ion(Pb 2+ ) and electron (2e) , the two electrons leave on

the negative plate to make the negative plate has about

–0.1V negative potential.

2. Discharge battery

The electrolyte can be diluted and water increases when

chemical reaction with load is processed.

(a). The positive and negative plates can produce lead

sulfate (PbSO 4 ) to increase water in the electrolyte.

(b). When the discharge is processed, the electrolyte

density will be reduced.

3. Charge battery

The two electrons return the negative pole from the positive

pole with the function of external power to form the charging

current flowing from the positive plate to the negative plate.

(a). The lead sulfate on the plate revert to lead oxide and

lead and the water in electrolyze reverts to sulfate.

(b). The sulfate in electrolyze increases and the electrolyze

density increases when charge is processed.

20B-23

WORKING CHARACTERISTICS

1. Internal resistance of battery

The internal resistance reflects the load capacity of battery. The lower the battery is, the higher the

output current is. The internal resistance includes plate resistance, separator resistance and

electrolyte resistance.

The plate resistance is very low when it is fully charged. But when the battery’s discharge degree

increases and the lead sulfate which is covered on the plate surface increases, the plate resistance

increases too. The separator resistance is determined by the separator’s material, thickness and

porosity. The micropore plastic separator’s resistance is lower in the common separator.

The electrolyze resistance is related to electrolyze temperature and density. When the temperature

falls, the electrolyze viscosity increases and the penetrating power drops, which makes that the

resistance increases. When the electrolyze density is too high or too low, the resistance will increase.

2. Discharging characteristic of battery

(a). The discharging characteristic of battery means that

the changing law of battery terminal’s voltage Uf and

electrolyze density P 25 ℃with the discharging time

changing during constant current discharging.

3. Charging characteristic of battery

(a). The charging characteristic of battery means the

changing law of battery’s charge voltage and

electrolyze density P 25 ℃ with the charging time

changing during constant current charging.

20B-24

1. The selection of battery shall have the same capacity with that of the automobile.

2. Keep the vent plug in tightened state to avoid spilling the acid resistance liquor.

3. When the battery need to charge again, the supplemental current is 11A. When the battery is fully

charged it has the following phenomena (do not allow being overcharged):

Phenomenon 1: the voltage and electrolyze density shall not have obvious change within continuous

2h.

Phenomenon 2: the inner battery produces strong bubble and electrolyze has “ebullition”

4. The battery is not allowed to be stored for a long time. If the battery shall be stored, then the battery

shall be charged every three months (the supplement current is 11A and the voltage is 18 V).

5. Electrolyze of battery contains sulfate which seriously damages the skin, eye and clothes. Prevent

electrolyze from spilling when moving electrolyze. When the accident happens, the following methods

can be properly adopted:

(a). Immediately wash the external which is infected.

(b). If the electrolyze enters the mouth, immediately rinse the mouth and drink lots of water or milk

then go to see a doctor.

Precautions for maintenance:

1. Do not make two wiring terminals of battery short circuit, or else the battery will rapidly become hot

even may burst. In addition, the gas which is dissipated from the battery will be easily to be lighted by

sparks. Therefore, do not use naked flame near the battery.

2. When disassembling and installing the electric equipment, first disassemble the ground wire of

battery in order to avoid short circuit. When replacing bulb, turn off all relevant switches.

3. When disassembling battery, disassemble the ground wire, then disassemble positive wire and then

disassemble the battery baffle. Take out the battery from the rack. The installation of battery is in the

reverse order of disassembly.

20B-25

COMMON FAULTS AND TROUBLESHOOTING FOR BATTERY

Phenomenon 1: Housing broken

Housing broken is the most serious destructive fault during the use of battery. After the housing is broken,

electrolyze in the battery will leak and run off. If the housing is interval damage, the adjacent unit cell will be

short circuit together to make the terminal voltage drop obviously so that the battery cannot properly work.

Causes:

1. Improper use and maintenance. For example, the fixed frame is too tight.

2. Rubber anti-vibration pad is too tight or is not installed.

3. The automobile fiercely vibrates and impacts during the driving.

4. The external force hits the battery housing.

5. Air vent on the plug screw is blocked.

6. In winter then electrolyze density is too low or the temperature is too low or it freezes.

Treatment:

1. After the housing is broken, immediately disassemble the battery from the automobile. The battery

shall be considered to be repaired or discarded as useless according to the condition.

Phenomenon 2: Plate vulcanizing

The battery is undercharge or cannot be charged for a long time after discharging, there is gradually a layer of

white coarse grain lead sulfate on the plate. This lead sulfate cannot be transferred into lead dioxide in

normal charge. This phenomenon is called “lead sulfate hardening” which is called “vulcanization” for short.

The electrical conductivity of this kind of lead sulfate is very bad, which makes the battery’s internal

resistance increase; when the volume increase, the pore space of active material is blocked and the

electrolyze is blocked to permeate. Then the effective active material on the plate is reduced, and the

discharge capacity is reduced, and the battery cannot provide enough start current, as a result, the engine

cannot be started.

1. When the battery is undercharge for a long time or is not charged timely after being discharged, some

lead sulfate on the plate will be dissolved in electrolyze. The higher the temperature is, the bigger the

solubility is. But when the temperature reduces, the solubility is smaller, and the lead sulfate will

separate out again and crystallize again on the plate and form vulcanization.

2. Electrolyze liquid level is not checked for a long time. The liquid level is too low, which makes the

exposed liquid level on the upper of plate contact with the air and produce strong oxidation.

3. The battery is overcharged for a long time or the low current is deeply discharged, which makes the

active material’s long hole in the deep of plate produce lead sulfate so it cannot be easily to recover

when charging.

4. The new battery is not thoroughly charged and the active material does not get full recovery.

5. Electrolyze density is a little higher, the composition is not very pure and external temperature

changes fiercely.

1. When the plate is slightly vulcanization, the low current is used.

2. Do not use the method of charging for a long time. Eliminate the vulcanization with the method of

eliminating vulcanization and charge when the vulcanization is serious.

20B-26

3. When the vulcanization is too serious, please abandon it.

Phenomenon 3: Internal short circuit

Internal short circuit means that battery’s positive and negative plates directly contacts or the plates are

lapped by other electric conduction.

1. The separator is damaged to make the positive and negative poles directly contact.

2. The active material deposits a lot and contacts the below of plate group.

3. The plate group bends.

4. The conductive material falls off in the battery to make the positive and negative plate group internal

short circuit.

1. Replace the damaged separator, eliminate deposited active material and check or replace the bended

plate group.

Phenomenon 4: A lot of active materials come off

When the battery is used, the active materials on the positive plate will gradually come off. It is because when

charging or discharging, the volume of active material will continuously change, then it is easily to come off. If

the battery is improperly used, a large number of active materials will come off, which makes the positive

plate is prematurely damaged.

1. The charging current of battery is too high and electrolyze temperature is too high, which makes

active materials expand, floppy and easy to come off.

2. The battery usually are overcharged, so a lot of gas emits from plate pore space which builds up

pressure in the plate pore space, as a result, the active materials come off.

3. The plate is so bended and deformed.

4. Electrolyte freezes in winter.

5. The vibration and bumping for automobile’s driving.

1. For lead battery whose plate active materials come off, when there is little deposit, the battery can be

continuously used after eliminating the deposit.

2. When there is much deposit, please timely replace the plate and electrolyte.

Phenomenon 5: Positive plate grid’s corrosion

The positive plate will be rotted by oxide etch when the battery is used.

1. The active material lead dioxide on the positive plate is a membrane which cannot compactly and

completely cover the grid, so the grid will be corroded when charging.

2. The acids or organic salt which have corrosion function for positive plate grid are mixed in electrolyte.

3. The battery usually is overcharged.

4. Electrolyze density and temperature are too high.

1. For the battery with lighter corrosion, if there are impurities in electrolyte, pour out the electrolyte,

clean the inner with distilled water again and again, add standard electrolyte and then the battery can

be used after charging.

2. For the battery with serious corrosion, if the electrolyte density is too high, adjust the density to the

20B-27

specified value, and then the battery can be continuously used even if it is not charged.

3. For the battery with serious corrosion, if grid is broken and active materials come off in bulk, and then

replace the plate.

Phenomenon 6: Plate bending

Plate bending appears on the positive plate and seldom appears on the negative plate. If plate bending

occasionally appears on the negative plate, it is because the positive plate is excessively bended to make the

negative plate bend.

1. The plate quality is not good, which is because the filling lead paste is not uneven when

manufacturing.

2. The battery usually discharge with large current (for example, usually use the starter), because each

part’s current density on the plate surface is different, the volumes of active materials change

differently.

3. The battery is overcharged. The lead sulfate which is produced in the deep of plate cannot recover

when charging to expand the inner plate and to bend the plate.

1. Take down and correct the bended plate group.

Phenomenon 7: Polarity reversal of unit cell battery

The battery with 6 unit cells, if there is one single battery has polarity reversal, and then the voltage is not 12V

rather than 8V.

1. The main reason for single battery’s polarity reversal is that the single battery is not found out fault

timely (for example, plate’s short circuit, active materials’ falling off). When the battery discharges, the

single battery will discharge to zero, then when the battery continuously discharges, other single

batteries’ discharging current will charge it, so polarity reversal happens.

1. Please replace the plate for single battery with polarity reversal.

Phenomenon 8: Self-discharge

The battery which is fully charged will lose electric quantity when it is not used. This phenomenon is called

“self-discharged”.

1. The plate materials are not pure and the electrolyte is impure.

2. There is electrolyte on the cover of battery and the electrolyte can conduct the positive and negative

piles.

3. The battery is placed for a long time and sulfate sinks, which make the upper and lower of the plate

produce potential difference.

1. For the battery with little self-discharge, normally discharge the battery, pour out electrolyte, clean it

with distilled water repeatedly, and then inject the new electrolyte. As a result, the battery can be used

after it is fully charged.

2. The battery with serious self-discharge shall be disassembled to be serviced or shall be replaced.

20B-28

2 1 type hexagon nut

3 Pull rod assembly

4 Battery rack assembly

5 Hold-down strip assembly

6 Pull rod assembly

20B-29

1. Stop the automobile on the even pavement, turn off the ignition switch and power supply main

(a). Open dust cover of lead of battery pole.

Screw off the fixing bolts of lead of battery pole, rock

the pole around then take out the lead.

3. Take out the battery

(a). Screw off the fixed nuts from the battery clamp with

wrench.

(b). Take down the clamping plate of battery and take out

the battery upward.

Check the usability of battery with checking tools. If the

battery cannot be used, please replace it.

20B-30

4. Install the full-charged or the new battery

5. Install the fixed mount of battery

(a). Place the battery in the tray of battery.

Confirm directions of battery’s positive and negative poles and

pole to compare the directions with the directions of

disassembling and to avoid installing the positive and negative

poles reversed to damage the circuit and components.

Install the fixed pull rod and clamping plate of battery.

Screw up the clamping plate nuts.

6. Install the lead wire of pole for battery

(a). Connect the lead of battery pole on the pole.

20B-31

(b). Screw up the fixing bolts of the lead of battery pole and

fix the dust cover.

When installing the lead of battery pole, first install the

positive terminal and then install the negative terminal.

20B-32

STARTING AND CHARGING - USE OF MAINTENANCE FREE BATTERY

USE OF MAINTENANCE FREE BATTERY

CHECKING OF TECHNICAL CONDITION

1. Usually keep the external clean when using the maintenance free battery.

2. Usually check the color of electrolyte densimeter indicator inside.

If the electrolyte densimeter indicator is black, take down the battery from the automobile for additional

charge. If the electrolyte densimeter indicator is yellow, check whether the storage housing has crack or is

damaged and whether electrolyte is leaked.

3. Before replacing the battery, pay much attention to check whether there is fault for charging

4. Load test for battery is to inspect the load capacity.

Respectively connect two poles for battery on the carbon pole of carbon pile, add 300A of load current

15s.

Close the load, stop for 15s to wait for voltage recovery.

Set the load of carbon pile as the load trial value specified on the label of battery.

Apply load to test for 15s, read the voltage value of battery and judge whether the battery is good.

Close the load.

20B-33

CHARGE THE MAINTENANCE FREE BATTERY

Additional charging

1. If the automobile is not used for a long time or there is fault in the charging system, and if the load

voltage of battery is lower than 10V and the load voltage is lower than 12.4 V, the battery is in need of

charging.

2. The charging method for maintenance free battery is the same with that of the common battery. And

the additional charge adopts constant current charge.

3. For the first stage of charging, charge the battery with 10% current of battery capacity and the

charging current is 6A. When each battery voltage is 16A, and then the second stage of charging

begins.

4. For the second stage of charging, charge the battery with x0.045 current of battery capacity. When

each battery voltage is 16V, and then continue charging the battery for about 3~5h.

5. If the electrolyze temperature is higher than 40℃ when charging, stop charging, reduce the current or

carry on physical cooling. When the temperature is 45℃, please stop charging.

6. Keep the battery in good ventilation when charging. Keep away from naked flame and inflammables.

7. The standard of full charging: the charging indicator is green.

Quick charging

1. Quick charging is only used as emergency measure when the automobile cannot start. If the time

allows, use the common charger.

2. The current for quick charging is 3/10 of battery capacity.

3. The time for quick charging is not more than 2h.

SUPERCHARGER

SUPERCHARGING SYSTEM .............................................................. 21-1

Overview ........................................................................................... 21-1

Working Principle ............................................................................ 21-2

Diagram of Components ................................................................. 21-4

TURBOCHARGER ............................................................................... 21-5

Service .............................................................................................. 21-5

SUPERCHARGING SYSTEM-SUPERCHARGING SYSTEM

21-1

SUPERCHARGING SYSTEM

1. This engine is equipped with an exhaust turbocharger. The exhaust turbine of turbocharger is

assembled on the same shaft with gas compressor, driving by the exhaust gas exhausted by engine

and driving the gas compressor to compress the air sucked into the air filter to increase the air density

in cylinder, the air inflow, air supply of fuel for injection pump and the output of engine.

2. The turbocharger consists of turbine, radial-flow compressor, middle casing, rotor assembly, bypass

valve etc. The turbine and gas compressor shall be respectively installed on both ends of shaft and

own their own cast casings. The shaft is installed in the middle casing and supported by the middle

casing.

3. The turbine part mainly consists of turbine casing and single stage radial-flow turbine. They form an

energy converter. When the exhaust gas exhausted from the diesel engine blows to turbine impeller

in a fixed direction after entering the nozzle through turbine casing, the heat energy and pressure

energy of exhaust gas will turn to kinetic energy and rotate the turbine at a high speed.

4. The intermediate is an intermediate support which supports the rotor assembly, fixed turbine casing

and compressor casing. It is also a lubricating oil tank which can lubricate and cool the floating

bearing rotor.

5. The gas compressor mainly consists of centrifugal-flow compressor impeller, diffuser and gas

compressor casing. Passing by the air filter, the air will be sucked into the compressor impeller

revolving at a high speed which will increase the air velocity and the pressure. The air will then passes

diffuser and compressor casing to transform the kinetic energy of air current to pressure energy which

will enter the cylinder through diesel engine intake pipe after increasing and cause the increase of air

density in the cylinder of diesel engine.

6. Air evacuation valve and air release valve are used to ensure the best coordination performance of

the diesel engine in the range of low and intermediate speed and the turbocharger. This best

performance can facilitate the diesel engine in terms of gaining sufficient air, being corresponding with

the increasing of fuel supply amount, enlarging the low speed torque, improving the fuel consumption

and evacuating or releasing the air in high speed range (a part of exhaust gas can directly enter into

the exhaust pipe without passing turbine) to avoid the excessive combustion pressure in cylinder due

to the over speed of turbocharger rotor and the excessive supercharging pressure and mechanical

load aggravation of diesel engine etc. The open and close of air evacuation and release valve is

automatically controlled by supercharging pressure. When the supercharging pressure reaches or

exceeds the specified value, the diaphragm will be against the left spring force, move to the left with

linkage push rod, and push the rocker arm to rotate around the pin roll, make the air release valve

open, realize the exhaust bypass deflation and raise the turbocharger speed.

21-2

The heat and exhaust gas under a certain pressure exhausted from engine will enter the nozzle diaphragm in

turbine casing from exhaust manifold. The area of nozzle diaphragm will generally shrink. For the reason, the

pressure and temperature of exhaust gas will drop, the speed and kinetic energy will increase and the

exhaust gas flow will impact the turbine in the specified direction to make it rotate at a high speed. Then the

turbine will drive the centrifugal-flow compressor impeller on same shaft to rotate at the same speed with

turbine, and the air passed through air filter will be sucked into compressor casing. The compressor impeller

rotating at a high speed will toss the air to edge of impeller, increase the speed and pressure of air and make

it entering into diffuser. Because of the form of diffuser: a small inlet and a large outlet, the airflow velocity will

drop and the pressure will increase. The pressure of air current will continue increasing by passing through

the ring form compressor casing (with cross sections of all sizes). The compressed air will enter the cylinder

by passing the intake pipe of engine. By this way, the air inflow of engine will increase, and the output of

engine will also increase. Passing the turbine, the exhaust gas will finally be injected to the atmosphere.

21-3

1 Exhaust pipe

2 Shaft

3 Nozzle Diaphragm

4 Turbine

5 Turbine casing

6 Bearing

7 Diffuser

8 Compressor impeller

9 Ring-form gas compressor casing

10 Intake pipe

21-4

1 Tail pipe of turbocharger

2 Stud

Nut washer assembly of

and exhaust pipe

4 Bracket bolt of turbocharger

5 Large washer

6 Tail pipe bracket

7 Combination nut

8 Connecting stud of tail pipe

9 Tail pipe gasket of turbocharger

10 Turbocharger components

11 Connecting bolt of turbocharger

intake pipe

Exhaust pipe-connector gasket of

13 Exhaust pipe nut

14 Jointing stud of turbocharger

15 Flange gasket of oil return pipe

17 Oil return pipe of turbocharger

18 Heating water pipe clamp

19 Oil return rubber hose of turbocharger

Insulation jacketing of turbocharger oil

return hose

21 B-type worm drive hose clamp

Turbocharger intake connecting pipe

24 Oil inlet bolt A

25 Copper washer

26 Oil inlet pipe weldment of turbocharger

27 Oil inlet bolt B

28 Copper washer

SUPERCHARGING SYSTEM-TURBOCHARGER

21-5

1. Disassemble the turbocharger assembly from the

(a). Disassemble the connecting bolt of the EGR pipe and

the intake connecting pipe assembly of turbocharger.

Disassemble the connecting bolt of the EGR pipe and

Take down the EGR pipe.

Disassemble the vent hose clamp of breather.

● Take down the vent hose of breather.

21-6

Disassemble the bracket fixing bolt of turbocharger

Disassemble the A-type worm drive hose clamp

connected to turbocharger and its intake connecting

● Take down the intake connecting pipe assembly of

Disassemble the fixing bolt of intake connecting pipe.

(h). Disassemble the bracket fixing bolt of intake

Disassemble the clamps of intake connecting pipe and

connecting rubber hose of turbocharger.

● Take down the intake connecting pipe of engine.

21-7

Disassemble the oil inlet bolt A of oil inlet pipe

weldment of turbocharger.

Disassemble the oil inlet bolt B of oil inlet pipe

Take down the oil inlet pipe weldment of turbocharger.

Disassemble the oil return pipe spring hose clamp of

(n). Disassemble the fixing bolt of turbocharger.

(o). Take down the turbocharger from engine.

Disassemble the turbocharger assembly from engine. Do

not lift the turbocharger with linkage push rod.

2. Disassemble the turbocharger assembly

The turbocharger is a precise machine which will revolve at a high speed. The turbocharger assembly

shall not be disassembled casually except for necessary situation.

21-8

Disassemble the connecting bolt of turbocharger oil

return pipe and turbocharger components and take

down the oil return pipe.

Disassemble the bolt connecting with turbocharger tail

pipe and turbocharger components.

(c). Disassemble the turbocharger tail pipe.

Take down the tail pipe gasket of turbocharger.

Disassemble the bleed-air pipe.

Take out the linkage push rod circlip with pliers.

21-9

Loosen the fixing bolt of linkage push rod with wrench.

Take down the regulator device of air release valve.

(h). Take down the fixing bolt connecting the compressor

casing and intermediate.

Disassemble the fixing bolt connecting the impeller casing and

intermediate, disassemble the impeller casing and

intermediate and take out the rotor assembly and two

impellers.

One shall not impact the impeller during disassembly. If

the impeller is impacted and deformed, it shall not

continue to be used after alignment.

3. Clean and check the turbocharger assembly

(a). Clean the turbine casing with vapor.

Clean the compressor casing and two impellers with vapor.

When using the vapor cleaner, one shall ware safety glasses or

protective mask and protective clothing in case of serious

personal injuries caused by hot vapor. If the impeller is

impacted and deformed, it shall not continue to be used after

21-10

Check the tail pipe gasket of turbocharger to see

whether it is abraded. If it is, the washer shall be

(c). Measure the axial clearance of impeller shaft with dial

indicator.

Standard Value: 0.06~0.09 mm

Limiting Value: 0.11 mm

Alternately apply the force of 0.12N on the end of compressor

impeller and the end of turbine impeller.

Measure the clearance between impeller shaft and

Standard Value: 0.11~0.18 mm

Limiting Value: 0.215 mm

(e). Check the radical clearance of rotor.

Minimum Clearance: ≥0.1 mm

Depress the compressor impeller with a hand in radical

direction and measure the minimum clearance between

compressor impeller and compressor casing. If the measured

value is smaller than the required minimum clearance value,

the floating bearing shall be replaced.

21-11

(f). Check the axial clearance of rotor.

Axial clearance value: 0.1 mm

Limiting value: ≤0.25 mm

One can fix the magnetic base onto the discharge flange facing

of turbine casing, contact the dial indicator with the end face of

turbine rotor shaft and push or pull the turbine rotor along axial

direction. The measured D-value is the axial clearance value. If

the axial clearance value of compressor is higher than the

applied limiting value, the assembly shall be disassembled and

the wore-out parts shall be replaced. Before determining and

eliminating the causes of turbocharger damage, one shall not

replace the turbocharger.

4. Assemble the turbocharger assembly

(a). Install the impeller and rotor assembly with special

tools.

(b). Put the turbine casing and compressor casing on the

installation position and screw up the fixing bolt.

Put the air release valve regulator device onto the

Install the fixing bolt of linkage push rod.

21-12

(e). Install the linkage push rod circlip.

One shall not adjust the length of linkage push rod

installing the air release valve regulator. As for the

adjustment, one shall refer to the related delivery

information.

Install the bleed-air pipe.

(g). Put the turbocharger tail pipe onto the installation

position of turbocharger components.

Do not forget to install the turbocharger tail pipe gasket when

installing the turbocharger tail pipe.

Install and fasten the connecting bolt of turbocharger

tail pipe and turbocharger components.

5. Install the turbocharger assembly on the engine.

(a). Put the turbocharger assembly onto the installation

position and fasten its fixing bolt.

21-13

Install the oil return pipe spring hose clamp of

Put the oil inlet pipe weldment of compressor into the

Install and fasten the oil inlet bolt B of turbocharger oil

inlet pipe weldment.

Install and fasten the oil inlet bolt A of turbocharger oil

Put the intake connecting pipe of engine on the

● Fasten the clamps of engine intake connecting pipe

and turbocharger connecting rubber hose.

Install and fasten the fixing bolt of intake connecting

pipe bracket.

21-14

(i). Put the intake connecting pipe assembly of

turbocharger onto the installation position.

● Fasten the A-type worm drive hose clamp

connecting with turbocharger intake connecting pipe

assembly and turbocharger.

Install and fasten the fixing bolt of turbocharger intake

Fasten the vent hose clamp of breather.

Put the EGR pipe into the installation position

21-15

Install and fasten the connecting bolt between EGR

pipe and EGR valve.

pipe and intake connecting pipe assembly of

V O L U M E 4

11C ENGINE CONTROL SYSTEM 2161

12C FUEL SYSTEM 2173

13C EMISSION CONTROL 2195

14C INTAKE AIR 2201

15C ENGINE MECHANICAL PART 2209

16C EXHAUST SYSTEM 2235

17C COOLING SYSTEM 2243

18C LUBRICATION SYSTEM 2263

20C STARTING AND CHARGING 2273

DIESEL ENGINE CONTROL SYSTEM............................................11C-1

PRECAUTION............................................................................11C-1

ENGINE CONTROL MODULE (ECM) .............................................11C-2

PRINCIPLE ................................................................................11C-2

REPLACEMENT ........................................................................11C-3

ACCELEARTOR PEDAL POSITION SENSOR...............................11C-5

PRINCIPLE ................................................................................11C-5

INSPECTION ON VEHICLE ......................................................11C-6

OVERHAUL ...............................................................................11C-7

VEHICLE SPEED SENSOR.............................................................11C-8

PRINCIPLE ................................................................................11C-8

OVERHAUL ...............................................................................11C-9

11C

ENGINE CONTROL SYSTEM - DIESEL ENGINE CONTROL SYSTEM

DIESEL ENGINE CONTROL SYSTEM

11C-1

1. DIESEL ENGINE CONTROL SYSTEM PRECAUTION.

This will prevent injuring person and vehicle damage.

The ignition and illumination switches must be shut off before removing or installing the battery negative

cable (the semiconductor maybe damage without doing that).

sealing face is level and smooth and no greasy dirt on it before installation. Don’t forget to remove the

sealant on the mounting hole, the threaded hole and the thread.

(d) Paint some sealant evenly on the prescribed diameters to surround the mounting hole. The sealant not

hardened yet can be scraped away. Install it in place when the sealant is wet (within 15 minutes). Take

care not to stick the sealant to the place where it's not desired during installation. Wait the sealant to be

very hardened (1 hour or so) after installation. Don’t apply oil on the painted parts or wet or start the

engine during this time.

(e) Tighten the straining bolts with prescribed torque during installing the sensors, actuators or other parts.

Ensure the diesel engine is always in clean and complete state. Clean or wipe up the parts to ensure

the clean parts and the assembly quality before removing and assembling the parts. The complicated

adjustment and maintenance should be taken indoors to avoid the diesel engine being polluted by the

(f) When installing and handling sensors, handle them gently to avoid damage, any impact or falling may

cause severe damage.

(g) Don’t test the system electrical signal by use of a fine needle to pierce the harness.

(h) Take a visual inspection to check if the sensing element at the head of sensor is damaged or color

changed; Replace it if it's damaged or the color is severe changed.

11C-2

ENGINE CONTROL SYSTEM - ENGINE CONTROL MODULE (ECM)

1. ENGINE CONTROL MODULE DESCRIPTION.

(a) ECM is the electric control engine control center with the

micro processor as the core that having sensor signal

input interface and the executor drive circuit. The ECM

(b) ECM has self protection function, it may result the

after replacement of ECM, therefore we may deem as

the ECM trouble. in fact, the ECM doesn’t get damaged

but just enters into self protection mode. ECM will

resume normal after flashing programming or “active” on

factory.

11C-3

(a) Pull assistant driver seat forward.

(b) Lift the covering behind assistant driver seat , then

loosen ECM locking knob .

Remove 2 ECM electrical connectors.

Remove ECU.

11C-4

4. INSTALL ECU.

Tighten 4 ECU mounting bolts.

Connect ECU connector.

Pull ECU connector upward, comfirm that it is installed in

Install ECU cover and tighten locking knob.

Cover the covering and push assistant driver seat back

to the original position.

ENGINE CONTROL SYSTEM - ACCELEARTOR PEDAL POSITION SENSOR

11C-5

ACCELEARTOR PEDAL POSITION SENSOR

1. ACCELERATOR PEDAL POSITION SENSOR.

(a) The electric accelerator pedal position sensor (APPS) is

mounted on the pedal bracket. it is 2 three-line types of

potentiometer sensor. The ECU applies a 5 V reference

voltage to the sensor.

(b) The sensor slide indicator connects with the accelerator

and rotates following the shaft. When the accelerator

pedal changes, the position of the slide indicator will also

change on the carbon film resistance, at such moment

the resistance output will also change, which reflects the

open extent of the accelerator indirectly.

11C-6

INSPECTION ON VEHICLE

APPS

• Engine turn off

APPS1

APPS2

• Key ON (the throttle is

closed): 0.899 V

fully open): 3.548 V

closed): 0.572 V

fully open): 1.608 V

6. IF IT IS NOT OK, CHECK APPS, HARNESS OR ECU.

11C-7

2. REMOVE APPS.

(a) Disconnect APPS connector.

(b) Loosen 3 APPS mounting nuts.

3. CHECK APPS RESISTANCE.

(a) Using the analogue multimeter, measure the continuity of

the APPS resistance.

(b) The pins of the multimeter connect to terminal 4 and 3 of

APPS respectively. Turn the shaft of the APPS. The

value changes linearly varied with the opening of the

acceperator. When connecting to terminal 2 and 4, the

value is opposite.

Resistance

(3) - (4)

(2) - (4)

(5) - (6)

(1) - (6)

Turn the shaft of the

APPS. The value changes

linearly varied with the

opening of the accelerator

The resistance value is continuity.

If the ckeck result is not OK, replace it.

4. INSTALL APPS.

(a) Tighten 3 APPS retaining bolts.

(b) Connect APPS connector.

11C-8

ENGINE CONTROL SYSTEM - VEHICLE SPEED SENSOR

Vehicle speed sensor is the type of hall sensor. It works

together with signal wheel on output shaft. ECM detects

digital voltage signal through it and determines the current

speed of the vehicle.

11C-9

Clear surface after removing.

(a) Install vehicle speed sensor and tighten mounting bolt.

Do not allow any impact tools (such as a hammer, etc.) to

6. CHECK AFTER INSTALATION.

under normal operation.

FUEL SYSTEM.................................................................................12C-1

PRECAUTION............................................................................12C-1

FUEL SYSTEM PRESSURE RELEASE PROCESS .................12C-2

FUEL SYSTEM BLEEDING.......................................................12C-2

DRAIN FUEL TANK PROCESS.................................................12C-2

FUEL TUBE CLEAN ..................................................................12C-3

COMPONENTS .........................................................................12C-4

FUEL TANK ASSY...........................................................................12C-6

REPLACEMENT ........................................................................12C-6

DIESEL FILTER ASSY.....................................................................12C-9

REPLACEMENT ........................................................................12C-9

FUEL LEVEL SENSOR AND BRACKET ASSY............................12C-10

REPLACMENT.........................................................................12C-10

FUEL FILLER DOOR .....................................................................12C-12

REPLACEMENT ......................................................................12C-12

FUEL FILLER DOOR LOCK LATCH ASSY .................................12C-13

REPLACEMENT ......................................................................12C-13

FUEL FILLER CAP ........................................................................12C-15

INSPECTION ...........................................................................12C-15

FUEL FILLING TUBE AND BREATHER TUBE ASSY .................12C-16

INSPECTION ...........................................................................12C-16

ELECTRONIC ACCELERATOR PEDAL......................................12C-20

REPLACEMENT ......................................................................12C-20

12C

12C-1

(a) Before working on fuel system, disconnect battery negative cable if necessary.

(b) When removing the fuel hose, use a suitable container to hold the diesel.

(d) Fuel in the VE dispensing pump and tubes remain under high pressure. In order to avoid personal

injury, do not loosen tube connector while engine is runing.

(e) Keep diesel away from rubber and leather parts.

(f) Diesel injection equipment is designed to very precise tolerances and fine clearances. To prevent fuel

system damage, it is essential that absolute cleanliness is oberved when working with these

components. Always install fuel system caps to any open orifices or tubes.

(g) Before disconncting any of the fuel system tubes or fuel system components, relieve the fuel system

pressure to prevent accidental spraying of fuel, even when the engine is not running. Failure to follow

(h) Check if there is any dirt like mud around the fuel tube connector before this work. And clean dirt away,

(i) Keep cleaner away from the O-ring of tube connecter. Cleaner can harm seal of fuel system.

(j) Don’t bend or twist the fuel system tube and pipe by force.

(k) Before connceting fuel system tube, be sure there is no damage to tube connector. If there is damage,

crack or dirt on surface. replace it with a new tube assy.

(l) Wearing eyeshield equipment is needed when working on fuel system compoments. Failure to follow

this instruction may result in personal injury.

(m) The metal parts like zn, cu, mn are easily dissolved in diesel. coking may appears in fuel injector which

reduces the injected diesel to cylinder. So the matal parts above should not be used in high-pressure

common rail fuel system.

(n) It is essential to keep fuel system clean. especially it can not contain any impurity, such as corrosion,

welding spatter. Otherwise, these impurity can block fuel tube, engine shut down suddenly. The

common rail parts are even damaged.

12C-2

• Fuel pressure in fuel pump, high pressure fuel pipe and fuel rail is high enough to cause serious

injury to the skin.

• Don't loosen any pipe joint when engine is running. waiting for at least 10 minutes after engine

is off. when oil pressure dropps to a lower level, loosen the high pressure fuel system pipe joint.

2. BEFORE REPAIRING FUEL SYSTEM, LOOSEN THE

LOCKING NUT ON FUEL RAIL TO RELEASE FUEL

PRESSURE.

3. WHEN REMOVING LOCKING NUT, LEAVE YOU

HAND FAR AWAY FROM THE CONNECTING JOINT.

Fuel will spurt from the pipe joint to the engine block side

along the groove in fuel rail.

4. TIGHTEN FUEL RAIL LOCKING NUT.

FUEL SYSTEM BLEEDING

• When servicing or replacing feed / high-pressure fuel system parts, fuel system will still

preserve a certain amount of air. Press manual pump to bleed air for fuel system.

• It is not necessary to bleed air before starting the engine. When cranking engine, mechanical

fuel pump applies fuel to fuel system.

1. FUEL SYSTEM BLEEDING. (Refer to CUMMINS ISF

SERIES ENGINE SERVICE MANUAL )

12C-3

12C-4

12C-5

3 Dual Line Clip

4 Fuel Filler Cap Assy

5 Bolt, Spring Washer And Flat Washer

7 Guide Pin

8 Fuel Level Sensor And Bracket Assy

9 Dual Line Clip

10 Bolt, Spring Washer And Flat Washer

11 Return Line

12 Fuel Tank To Diesel Filter Fuel Line

14 Fuel Filler Hose Assy

15 Diesel Filter Assy

16 Diesel Filter To Engine Fuel Line

17 Diesel Filter Bracket

18 Guide Pin

12C-6

1. RELEASE FUEL PRESSUE. (Refer to “Chapter 12B fuel - fuel system, fuel system pressure

2. DRAIN FUEL TANK. (Refer to “Chapter 12B fuel - fuel system, drain fuel tank process”)

Lower the fuel tank to a suitiable position.

12C-7

12C-8

(a) When Turning ignition switch on, fuel pump will apply fuel pressure to fuel lines. inspect if there is fuel

(b) Start engine and rev it up and check there is no fuel leakage at the fuel system tube and hose

FUEL - DIESEL FILTER ASSY

12C-9

DIESEL FILTER ASSY

12C-10

FUEL - FUEL LEVEL SENSOR AND BRACKET ASSY

FUEL LEVEL SENSOR AND BRACKET ASSY

1. RELEASE FUEL PRESSURE. (Refer to “Chapter 12B fuel - fuel system, fuel system pressure

2. DRAIN FUEL TANK AS REQUIRED. (Refer to “Chapter 12B fuel - fuel system, drain fuel tank

5. REMOVE FUEL TANK. (Refer to “Chapter 12B fuel - fuel tank, replacment”)

6. REMOVE FUEL LEVEL SENSOR AND BRACKET

Remove fuel level sensor and bracket assy.

Be careful not to bend float arm during removing fuel level

sensor and bracket assy.

(b) Check sealing ring for improper crack, damage or deterioration

12C-11

8. INSTALL FUEL LEVEL SENSOR AND BRACKET

Place sealing ring into place on the opening of fuel tank.

Position fuel level sensor and bracket assy into fuel tank.

Press installation surface of fuel level sensor and bracket

assy into place, then install lock ring and rotate the lock

ring clockwise.

9. INSTALL FUEL TANK. (Refer to “Chapter 12B fuel - fuel tank assy, replacment”)

After disconnecting fuel level sensor and bracket connector, connect fuel level sensor and bracket

connector, turn ignition switch on. Slide fuel level sensor and bracket position manually and then check

the fuel gauge’s conditions in instrument panel.

connections and confirm fuel level sensor is functional.

12C-12

(a) Install 2 fuel filler door retaining bolts.

(b) Install the clip connected to fuel filler cap to fuel filler

12C-13

1. REMOVE LEFT B LOWER PANEL. (Refer to “Chapter 88 inner and outer trim panel - left panel,

(a) Remvoe 2 left front seat lock assy retaining bolts.

Take out lock latch assy.

Remove fuel filler door cable.

(a) Install fuel filler door cable to lock latch assy.

12C-14

7. INSTALL LEFT FRONT B PILLAR LOWER PANEL. (Refer to “Chapter 88 inner and outer trim

panel - left panel, replacement”)

12C-15

Visually inspect fuel filler cap and seal ring. If deformed

Termly lubricate the rotating part.

12C-16

2. REMOVE BATTERY AND BATTERY TRAY. (Refer to “Chapter 20B starting and charging - battery,

5. DRAIN FUEL TANK AS REQUIRED. (Refer to “Chapter 12B fuel - fuel system, drain fuel tank

12C-17

12C-18

12C-19

8. INSTALL BATTERY AND BATTERY TRAY. (Refer to “Chapter 20B starting and charging - battery,

12C-20

FUEL - ELECTRONIC ACCELERATOR PEDAL

ELECTRONIC ACCELERATOR PEDAL

2. REMOVE ELECTRONIC ACCELERATOR PEDAL.

Disconnect electronic accelerator pedal harness connector.

Remove 3 electronic accelerator pedal retaining nuts.

3. INSTALL ELECTRONIC ACCELERATOR PEDAL.

(a) Install 3 electronic accelerator pedal retaining nuts.

(b) Connect electronic accelerator pedal harness connector.

(a) After installation, depress accelerator pedal to check that the accelerator pedal operates smoothly

without stuck phenomenon.

FUEL FILLER CAP ..........................................................................13C-1

INSPECTION .............................................................................13C-1

EGR VALVE .....................................................................................13C-2

REPLACEMENT ........................................................................13C-2

DIESEL OXIDATION CATALYST....................................................13C-3

COMPONENTS .........................................................................13C-3

REPLACEMENT ........................................................................13C-4

13C

13C-1

(a) Install the fuel filler cap fixing clip into ring.

13C-2

EMISSION CONTROL - EGR VALVE

1. EGR VALVE DESCRIPTION.

EGR valve is located on the top of exhaust manifold

which was actuated by the electric motor controlled by

ECM. EGR valve is an lift valve designed to control EGR

flow to EGR cooler .

EGR motor can not be repaired, if damaged, the entire EGR

valve must be replaced as a unit.

2. REPLACE EGR VALVE. ( Refer to CUMMINS ISF SERIAL ENGINE SERVICE MANUAL)

EMISSION CONTROL - DIESEL OXIDATION CATALYST

DIESEL OXIDATION CATALYST

13C-3

1 Diesel Oxidation Catalyst (DOC)

2 DOC upper bracket

3 bolt

5 bolt

6 bolt

7 DOC front grasket

4 bolt

13C-4

3. REMOVE FRONT EXHAUST PIPE. (Refer to “Chapter 16B exhaust - exhaust pipe, replacement”)

4. ISF 2.8 USES DIESEL OXIDATION CATALYST (DOC)

TO REDUCE HC AND CO2 EMISSION.

5. REPLACE DIESEL OXIDATION CATALYST. ( Refer to CUMMINS ISF SERIAL ENGINE SERVICE

MANUAL )

Post - processing system of diesel oxidation catalyst core are made by brittle materials. DO not drop

or impact post-processing system side, because this conditon will result in serious damage for postprocessing

diesel oxidation catalyst core .

6. INSTALL DIESEL OXIDATION CATALYST. ( Refer to CUMMINS ISF SERIAL ENGINE SERVICE

INTAKE AIR SYSTEM......................................................................14C-1

PRECAUTION............................................................................14C-1

COMPONENTS .........................................................................14C-2

INTAKE AIR PIPE AND HOSE ........................................................14C-4

REPLACEMENT ........................................................................14C-4

AIR FILTER ASSY ...........................................................................14C-7

REPLACEMENT ........................................................................14C-7

INTERCOOLER INTAKE AIR PIPE...............................................14C-11

REPLACEMENT ......................................................................14C-11

14C

14C-1

14C-2

1 Spring Clamp

2 Intercooler Intake Air Hose

3 Intercooler Rear Ripple Hose

4 Intercooler Rigid Clamp

5 Intercooler Inlet Rigid Pipe

6 Intercooler Outlet Rigid Pipe

7 Intercooler Assy

9 Bolt, Spring Washer And Flat Washer

11 Bolt, Spring Washer And Flat Washer

14C-3

1 Band Clamp

2 Middle Intake Air Pipe

4 Bending Hose

5 Mass Air Flow Sensor

6 Screw

7 Air Filter Assy

11 Washer

12 Band Clamp

13 Intake Air Duct

14 Band Clamp

15 Turbocharger Intake Air Ripple Hose

8 Air Filter Assy Bracket

14C-4

2. REMOVE ASSISTANT DRIVER SEAT. (Refer to “Chapter 84 seat - driver / assistant driver seat,

3. REMOVE ENGINE COMPARTMENT COVER UNDER

(a) Remove 5 engine compartment cover retaining bolts.

(b) Remove engine compartment cover.

4. REMOVE TURBOCHARGER INTAKE AIR RIPPLE

(a) Remove band clamps on both sides of turbocharger

intake air ripple hose.

(b) Remove turbocharger intake air ripple hose.

14C-5

5. REMOVE MIDDLE INTAKE AIR PIPE.

(a) Remove 2 middle intake air pipe retaining bolts.

(b) Remove retaining clamp on middle intake air pipe side.

6. REMOVE BENDING HOSE.

(a) Remove air filter assy. (Refer to “Chapter 14B instake air

- air filter assy, replacement”)

Remove retaining clamp securing bending hose to air

filter assy.

Remove bending hose.

7. INSTALL BENDING HOSE.

(a) Connect bending hose to air filter assy outlet pipe, then

tighten the retaining clamp.

Connect one end of benging hose with triangle mark to air

filter when installation.

(b) Install air filter assy. (Refer to “Chapter 14B instake air -

14C-6

8. INSTALL MIDDLE INTAKE AIR PIPE.

Position middle intake air pipe.

Connect middle intake air pipe to bending hose and

tighten retaining.

Tighten 2 retaining bolts securing middle intake air pipe

to body frame.

9. INSTALL TURBOCHARGER INTAKE AIR RIPPLE HOSE.

(a) Position turbocharger intake air ripple hose.

(b) Tighten band clamps on both sides of turbocharger

(a) After installing air intake pipe and hose, check all parts and parts connection and start the engine to

make sure engine operates properly.

11. INSTALL ENGINE COMPARTMENT COVER UNDER

12. INSTALL ASSISTANT DRIVER SEAT. (Refer to “Chapter 84 seat - driver / assistant driver seat,

13. PUT DOWN DRIVER SEAT AND LOCK IT.

14C-7

(a) Remove retaining bolt and clamp for air filter intake air

(b) Remove intake air duct.

(a) Remove retaining clamp securing bending hose to

14C-8

Disconnect mass air flow sensor connector, then remove

air filter together with bending hose.

Disconnect air filter and bending hose, remvoe air filter

(b) Position air filter with bending hose, then connect MAF

connector.

14C-9

Tighten clamp securing bending hose to middle intake air

6. INSTALL INTAKE AIR DUCT.

(a) Tighten the clamp securing intake air duct to air filter inlet

14C-10

7. INSTALL FRONT BUMPER. (Refer to “Chapter 88 exterior and interior trim - front bumper assy,

8. INSTALL FRONT GRILLE. (Refer to “Chapter 88 exterior and interior trim - front grille, replacement”)

9. REPLACE AIR FILTER ELEMENT.

• The clean intake air has a great effect on diesel engine. Do not operate the engine without

installing the air filter element.

• Air filter element blocking will cause oil leakage from turbocharger. Therefore, the maintenance

or replacement of air filter element must be performed periodically.

INTAKE AIR - INTERCOOLER INTAKE AIR PIPE

14C-11

INTERCOOLER INTAKE AIR PIPE

3. REMOVE INTERCOOLER ASSY.

(a) Remove retaining spring clamp securing intercooler inlet

pipe to intercooler intake air hose.

Remove retaining spring clamp securing intercooler outlet

pipe to intercooler rear ripple hose.

Remove 4 intercooler assy retaining spring bolts.

Separate intercooler from intake air hose and rear ripple

Remove intercooler assy.

14C-12

4. INSTALL INTECOOLER ASSY.

Positon intercooler assy and connect intercooler inlet

and outlet pipe to intake air hose and rear ripple hose,

then tighten 2 retaining band clamp.

Tighten 4 intercooler assy retaining bolts.

5. REMOVE INTERCOOLER INTAKE AIR RIGID PIPE.

(a) Remove retaining clamp securing intercooler inlet rigid

pipe to intake air hose.

Remove retaining bolt securing underbody intercooler

inlet rigid pipe.

Remove spring clamp, disconnect intercooler inlet rigid

pipe from intake air hose.

Remove 4 intercooler assy retaining bolts.

14C-13

Remove intercooler inlet rigid pipe.

6. INSTALL INTERCOOLER INLET RIGID PIPE.

Connect intercooler inlet rigid pipe to intake air hose on

turbocharger side.

Tighten retaining clamp.

Tighten intercooler inlet rigid pipe retaining bolt.

Tighten retaining clamp securing intercooler inlet rigid

Install intercooler assy. (Refer to “Chapter 14B intake air

- intercooler intake air pipe, replacement”)

14C-14

7. REMOVE INTERCOOLER OUTLET RIGID PIPE.

Remove retaining clamp securing intercooler outlet rigid

pipe to rear ripple hose.

outlet rigid pipe.

Loosen retaining bolts on both sides of steering drive

shaft assy II, then remove the bolt on steering gear side

as shown in the figure.

Separate steering drive shaft assy II from steering gear

Remove retaining clamp, disconnect intercooler outlet

rigid pipe from rear ripple hose.

Remove 4 intercooler assy retainng bolts..

14C-15

Remove intercooler outlet rigid pipe.

8. INSTALL INTERCOOLER OUTLET RIGID PIPE.

Connect intercooler outlet rigid pipe to rear ripple hose

on throttle actuator side.

Tighten intercooler outlet rigid pipe retaining bolt from

the vehicle beneath.

Connect steering drive shaft assyII to steering gear

output shaft, then tighten both bolts.

Align marks when installing steering drive shaft assyII.

14C-16

Connect intercooler outlet rigid pipe to rear ripple hose,

then tighten retaining clamp.

(a) After installing intercooler intake air pipe, check all parts and parts connection and start the engine to

10. INSTALL FRONT BUMPER. (Refer to “Chapter 88 exterior and interior trim - front bumper assy,

11. INSTALL FRONT GRILLE. (Refer to “Chapter 88 exterior and interior trim - front grille, replacement”)

ENGINE MECHANICAL PART ........................................................15C-1

PRECAUTION............................................................................15C-1

ENGINE ASSY .................................................................................15C-2

REPLACEMENT ........................................................................15C-2

ENGINE ACCESSORY BELT........................................................15C-12

OVERHAUL .............................................................................15C-12

15C

15C-1

(a) Follow the instructions of maintenance methods and regulations to adjust or maintain.

(b) Before starting the engine, check the coolant level, fill or drain the coolant if necessary. check the

(d) Use the oil as requirement. otherwise exacerbate engine wear.

(e) Use the original fittings, otherwise it will damage the engine or affect the engine working condition.

(f) Do not use the high pressure water cannons wash the ecm shell.

(g) The engine starting time should be less than 5s. Not more than 5 consecutive starting times. The

interval time to next starting should not be less than 15 seconds.

(h) Keep the normal coolant temperature 85 ~ 105 ℃ .

(i) When the engine in high speed or high load, do not turn the ignition switch off. Keep the engine running

in low speed for 3~5 mins, so that the engine radiates eventually.

(j) Before opening the radiator cap, ensure the engine is cool.

(k) Use the sealant scraper to clear the sundrise in seal surface. Confirm seal surface flat and smooth, no

pollution and foreign bodies.

(l) Disassembly sequence should be generally from inner to outer, assembly to parts. In order to improve

the efficiency and ensure the assembly and disassembly correct, pay attention to checking and making

mark. Removed parts should be cleaned and inspected. The parts can be reused according to the

classification. Precision parts should be separated with general parts. Put them in clean containers.

(m) Assembly sequence should be from inside to outside, parts to components, components to assembly.

Pay attention to the size, location, clearance, torque, etc. When assembling, avoid the missing,

mistaking, scratching and foreign parts into machine. Assemble bolts, nuts with suitable wrench,

uniform properly. Use anti-losseness device correctly. According to regulations, appropriately use split

cotters, spring washer, thrust washers, etc. In addition, in the assembly process, must pay attention to

the marks to ensure the good position.

(n) Ensure the diesel engine always in the state of complete cleaness. Before removing or assembling,

parts should be cleaned to ensure clean and high quality assembly. More complicated adjustment and

maintenance should be done indoor to prevent diesel engine internal parts from environmental

pollution.

(o) Pay attention to the security when repairing or dismantling. Improper tool or engine starting suddenly

will result in injury.

15C-2

2. RECOVER REFRIGERANT. (Refer to “Chapter 61 heater and air conditioner - refrigerant,

3. RELEASE FUEL SYSTEM PRESSURE. (Refer to “Chapter 12B fuel - fue system, fuel system

4. RAISE AND SUPPORT THE VEHICLE.

5. DRAIN COOLANT. (Refer to “Chapter 17B cooling - coolant, replacement”)

6. DRAIN ENGINE OIL. (Refer to “Chapter 18B lubricantion - engine oil, replacement”)

7. DRAIN TRANSMISSION FLUID. (Refer to “Chapter 41 transmission - transmission assy, replacement”)

9. OPEN ENGINE COMPARTMENT COVER.

10. DISCONNECT BATTERY NEGATIVE CABLE.

11. REMOVE ASSISTANT DRIVER SEAT. (Refer to “Chapter 84 seat - driver / assistant driver seat,

12. REMOVE ENGINE COMPARTMENT COVER UNDER

15C-3

13. DISCONNECT GENERATOR POSITIVE CABLE.

14. DISCONNECT GENERATOR CONNECTOR.

15. REMOVE TURBOCHARGER INTAKE AIR RIPPLE HOSE. (Refer to “Chapter 14B intake air -

intake air pipe and hose, replacement”)

16. REMOVE MASS AIR FLOW SENSOR CONNECTOR. (Refer to “Chapter 14B intake air - air filter

17. REMOVE INTERCOOLER OUTLET STEEL PIPE. (Refer to “Chapter 14B intake air - intercooler

intake air pipe, replacement”)

18. REMOVE A/C PIPE FROM COMPRESSOR.

(a) Remove the retaining bolt securing high pressure and

low pressure pipes to compressor.

19. REMOVE AIR INTAKE PIPE.

(a) Disconnect ECM wire harness connectors and additonal

one electrical connector in the ECM compartment.

(b) Pull engine wire harness and ECM rubber grommet out

of the hole on the sidewall of ECM compartment.

20. REMOVE GROUND CABLE MOUNTED ON ENGINE

THROTTLE ACTUATOR.

21. DISCONNECT VACUUM BOOSTER HOSE FROM

INAKE MANIFOLD.

15C-4

22. DISCONNECT ENGINE WIRE HARNESS CONNEC-

TORS THROUGH THE HOLE ON THE SIDEWALL OF

BATTERY COMPARTMENT FROM BATTERY COM-

PARTMENT FUSE BOX CONNECTOR RECEPTACLE.

23. DISCONNECT ENGINE WATER OUTLET HOSE.

24. DISCONNECT ENGINE BLEEDING HOSE.

25. REMOVE POWER STEERING FLUID RESERVIOR

FROM THE BRACKET. (Refer to “Chapter 52 power

steering - power steering pump with fluid reservior,

26. REMOVE INTERCOOLER INLET STEEL PIPE. (Refer to “Chapter 14B intake air - intercooler

27. RAISE AND SUPPORT THE VEHICLE.

28. REMOVE FRONT WHEELS. (Refer to “Chapter 33 wheel and tire - wheel, replacement”)

30. REMOVE RIGHT FRONT SUSPENSION UNIT.

29. REMOVE LEFT FRONT SUSPENSION UNIT.

15C-5

31. REMOVE STEERING DRIVE SHAFT ASSY II.

32. DISCONNECT ENGINE WATER INLET HOSE.

33. DISCONNECT ENGINE FUEL DELIVERY LINE FROM

DIESEL FILTER ASSY.

34. DISCONNECT FUEL RETURN TUBE.

35. REMOVE STARTER POSITIVE CABLE.

36. REMOVE TRANSMISSION FLEXIBLE SHAFT ASSY. (Refer to “Chapter 41 transmission -

37. REMOVE CLUTCH SLAVE CYLINDER. (Refer to “Chapter 42 clutch - clutch slave cylinder,

38. REMOVE FRONT EXHAUST PIPE. (Refer to “Chapter 16B exhaust - exhaust pipe, replacement”)

39. DISCONNECT VSS AND BACK-UP LAMP SWITCH HARNESS CONNECTORS. (Refer to “Chapter

41 transmission - transmission assy, replacement”)

40. SUPPORT ENGINE SUB-FRAME AND TRANSMISSION ASSY WITH HYDRAUMATIC JACK.

15C-6

41. REMOVE SUB-FRAME RETAINING BOLTS.

Remove 5 retaining bolts from right side of sub-frame.

The left is similar as the above, remove 5 retaining bolts

from left side of sub-frame.

retaining bolts when installing.

42. SEPARATE PROPELLER SHAFT FROM TRANSMISSION ASSY. (Refer to “Chapter 34 axle and

43. REMOVE TRANSMISSION MOUNT.

height with jack, pull the retaining bolt for separating the

44. LOWER THE JACK SLOWLY TO SEPARATE ENGINE SUB-FRAME AND TRANSMISSION ASSY

transmission and vehicle are disconnected before lowering engine sub-frame and transmission

45. SEPARATE ENGINE ASSY FROM TRANSMISSION ASSY. (Refer to “Chapter 41 transmission -

46. DISCONNECT HIGH PRESSURE AND LOW PRESSURE FLUID PIPES FROM POWER STEERING

47. FIT ENGINE HOOK AND HANG ENGINE ASSY WITH A HOIST

48. REMOVE ENGINE MOUNTS LOCATED ON BOTH SIDES OF ENGINE.

49. HOIST ENGINE UP AND SEPARATE ENGINE FROM SUB-FRAME.

50. INSTALL BOTH ENGINE MOUNTS ON ENGINE.

51. CONNECT HIGH PRESSURE AND LOW PRESSURE FLUID PIPES TO POWER STEERING PUMP.

52. INSTALL TRANSMISSION ASSY ONTO ENGINE. (Refer to “Chapter 41 transmission -

53. PLACE THE HYDRAULIC JACK SUPPORTING ENGINE SUB-FRAME AND TRANSMISSION ASSY

UNDER THE VEHCLE.

54. RAISE THE HYDRAULIC JACK UNTIL THE SUB-FRAME RETAINING GUDIES ARE FULLY

SEATED INTO THE VEHICLE FRAME AND TRANSMISSION MOUNT IS POSITIONED IN PLACE

PROPERLY.

15C-7

55. INSTALL SUB-FRAME RETAINING BOLTS.

Install 5 retaining bolts securing sub-frame right side to

The left is similar as the above, install 5 retaining bolts

securing sub-frame left side to vehicle frame.

56. INSTALL RETAINING NUT SECURING TRANSMISSION

57. REMOVE GENERATOR RETAINING BOLTS AND

58. INSTALL RIGHT FRONT SUSPENSION UNIT.

59. INSTALL FRONT WHEEL. (Refer to “Chapter 33 wheel and tire - wheel, replacement”)

15C-8

60. INSTALL STEERING DRIVE SHAFT ASSY II.

When installing steering drive shaft assy II, make sure

steering wheel is in the center and front wheel stands

straight ahead of the vehicle.

61. INSTALL TRANSMISSION FLEXIBLE SHAFT ASSY. (Refer to “Chapter 41 transmission -

62. INSTALL CLUTCH SLAVE CYLINDER. (Refer to “Chapter 42 clutch - clutch slave cylinder,

63. INSTALL FRONT EXHAUST PIPE. (Refer to“Chapter 16B exhaust - exhaust pipe, replacement”)

64. CONNECT PROPELLER SHAFT TO TRANSMISSION ASSY. (Refer to “Chapter 34 axle and

65. CONNECT VSS AND BACK-UP LAMP SWITCH HARNESS CONNECTOR. (Refer to “Chapter 41

transmission - transmission assy, replacement”)

66. CONNECT ENGINE WATER INLET HOSE.

67. INSTALL INTERCOOLER INLET STEEL PIPE. (Refer to “Chapter 14B intake air - intercooler

68. INSTALL INTERCOOLER OUTLET STEEL PIPE. (Refer to “Chapter 14B intake air - intercooler

69. CONNECT ENGINE FUEL DELIVERY LINE TO DIESEL

FILTER ASSY.

70. CONNECT FUEL RUTURN TUBE.

71. CONNECT STARTER POSITIVE CABLE.

72. LOWER THE VEHICLE.

15C-9

73. CONNECT ENGINE WATER OUTLET HOSE AND

74. CONNECT ENGINE BLEEDING HOSE AND TIGHTEN

CLAMP.

75. INSTALL POWER STEERING FLUID RESERVIOR TO

THE BRACKET. (Refer to “Chapter 52 power steering

- power steering pump with fluid reservior,

76. CONNECT WATER INLET AND WATER OUTLET

HOSE TO FRONT HEATER, THEN TIGHTERN THE

CLAMPS.

77. INSTALL A/C PIPES TO COMPRESSOR.

(a) Install the retaining bolt securing high pressure and low

Torque: 40 ~ 45 N•m

Always install O-ring with new one.

78. INSTALL MASS AIR FLOW SENSOR CONNECTOR. (Refer to “Chapter 14B intake air - air filter

79. INSTALL TURBOCHARGER INTAKE AIR RIPPLE HOSE. (Refer to “Chapter 14B intake air - intake

air pipe and hose, replacement”)

80. CONNECT GERERATOR CONNECTOR AND TIGHTEN

GENERATOR POSITIVE CABLE RETAINING NUT.

15C-10

81. INSTALL ENGINE WIRE HARNESS.

(a) Connect engine ECM harness connectors and additional

one electrical connector through the hole on the sidewall

of engine compartment.

(b) Press the rubber grommet into place.

82. INSTALL GROUND CABLE TO THE THROTTLE

ACTUACTOR SIDE.

83. CONNECT VACUUM BOOSTER HOSE TO INTAKE

84. CONNECT ENGINE WIRE HARNESS TO BATTERY COM-

85. INSTALL ENGINE COMPARTMENT COVER UNDER

86. INSTALL ASSISTANT DRIVER SEAT. (Refer to “Chapter 84 seat - driver / assistant driver seat,

87. PUT DOWN DRIVER SEAT AND LOCK IT.

88. FILL COOLANT. (Refer to “Chapter 17B cooling - coolant, replacement”)

15C-11

89. FILL ENGINE OIL. (Refer to “Chapter 18B lubricantion - engine oil, replacement”)

90. ADD POWER STEERING FLUID TO SPECIFIED LEVEL. (Refer to “Chapter 52 power steering -

91. FILL TRANSMISSION FLUID. (Refer to “Chapter 41 transmission - transmission assy, replacement”)

92. SUPPLY REFRIGERANT. (Refer to “Chapter 61 heater and air conditioner - refrigerant, replacement”)

15C-12

ENGINE MECHANICAL - ENGINE ACCESSORY BELT

ENGINE ACCESSORY BELT

2. Open the engine hood.

3. Wait until the engine cools down.

4. Drain the coolant. (Refer to "Chapter 17B. Cooling - coolant, replacement")

5. Unscrew the clip screw and pull out the engine water

outlet hose.

6. With the toolkit, turn the accessory belt tensioner

bolt clockwise, until the accessory belt is completely

7. Remove and examine the accessory belt. Replace it in case of any of the following damages:

• Water or grease on the belt will quickly reduce its service life. Therefore, after removal, protect the belt,

the belt pulley and the tensioner from water or grease. Do not wash these parts. In case of heavy

contamination, replace it with a new one.

• If any water or grease is found on these parts, check whether there is fluid leakage in the engine.

(a) Aged and shiny rubber on the back, showing no nail

15C-13

Unusal tear wear of the belt.

8. Put the accessory belt around all the belt pulley,

tensioner and idler, except for the generator belt

pulley. With the toolkit, turn the tensioner bolts

clockwise, so that the accessory belt wraps around

the generator belt pulley. Loose the tensioner.

After the installation of the accessory belt, check whether it

is properly installed around each pulleys. If any malposition

between the belt and the pulley, turn the tensioner nuts with

the toolkit and slightely loosen the accessory belt, before

further adjustment.

15C-14

9. Install the engine water outlet hose and tighten the

clip screw.\

10. Fill up the coolant. (Refer to "Chapter 17B. Cooling - coolant, replacement")

11. Restore the engine hood.

EXHAUST PIPE ...............................................................................16C-1

COMPONENTS .........................................................................16C-1

PRECAUTION............................................................................16C-2

REPLACEMENT ........................................................................16C-3

16C

16C-1

1 Rubber Support

2 Rear Muffler Assy

3 Nut

4 Spring Washer

5 Exhaust Piper Seal Gasket

7 Front Muffler Assy

8 Front Exhaust Pipe Assy

9 Front Rubber Support

16C-2

16C-3

3. REMOVE REAR MUFFLER ASSY.PRECAUTION

4. CHECK REAR MUFFLER ASSY.

(a) Tap or shake the muffler, check to make sure that broken

(a) Remove front muffler rear mounting rubber

16C-4

7. REMOVE FRONT EXHAUST PIPE ASSY.

(a) Remove front exhaust pipe mounting rubber.

(b) Remove 2 retaining bolts securing front exhaust pipe to

diesel oxidation catalyst.

8. REMVOE DIESEL OXIDATION CATALYST. (Refer to CUMMINS ISF SERIES ENGINE SERVICE

MANUAL)

9. INSTALL DIESEL OXIDATION CATALYST. (Refer to CUMMINS ISF SERIES ENGINE SERVICE

• When installing heat shield, avoid large gaps or interference between heat shield and each

exhaust pipes.

16C-5

10. INSTALL FRONT EXHAUST PIPE ASSY.

(a) Install front exhaust pipe rubber support.

(b) Tighten 2 retaining bolts securing front exhaust pipe to

Torque: 45 ~ 55 N•m

11. INSTALL FRONT MUFFLER ASSY.

Install 1 mounting rubber at the rear side of front muffler

12. INSTALL REAR MUFFLER ASSY.

(a) Install rear muffler mounting rubber.

16C-6

COOLING SYSTEM .........................................................................17C-1

PRECAUTION............................................................................17C-1

COMPONENTS .........................................................................17C-2

PROBLEM SYMPTOMS TABLE................................................17C-4

ON-VEHICLE INSPECT.............................................................17C-5

COOLANT ........................................................................................17C-7

REPLACEMENT ........................................................................17C-7

RESERVIOR.....................................................................................17C-9

REPLACEMENT ........................................................................17C-9

COOLING FAN ASSY....................................................................17C-11

OVERHAUL .............................................................................17C-11

RADIATOR.....................................................................................17C-14

REPLACEMENT ......................................................................17C-14

17C

17C-1

(f) Use foton specified coolant, do not use water instead of coolant. Water will damage the engine because

of corrosion.

17C-2

17C-3

2 Hose Clamp

3 Engine Inlet Hose No. 2

5 Engine Inlet Pipe

6 Engine Inlet Hose

7 Hose Clamp

8 Engine Outlet Hose No. 2

9 Engine Outlet Pipe

10 Engine Outlet Hose

11 Hose Clamp

18 Single Line Clip

19 Engine Bleeding Hose

20 Single Line Clip

21 Clamp

22 Hose Clamp

17C-4

1. Coolant (Lack or leaking) Chapter 17B cooling - coolant, replacement

2. Coolant (Non-standard) Chapter 17B cooling - coolant, replacement

3. Thermostat (Damaged) Chapter 17B cooling - thermostat, overhaul

5. Radiator (Poor cooling) Chapter 17B cooling - cooling system, precaution

6. Cooling fan (Damaged) Chapter 17B cooling - cooling fan, overhaul

1. Radiator(Damaged) Chapter 17B cooling - radiator, replacement

2. Cooling system hose(Blocked) -

3. Coolant pump(Damaged) Chapter 17B cooling - coolant pump, replacement

4. Coolant reservoir(Damaged) Chapter 17B cooling - coolant, replacement

Engine room noise

1. Cooling fan(Damaged) Chapter 17B cooling - cooling fan assy, overhaul

2. Cooling line -

17C-5

blown out under pressure.

17C-6

• Be careful not to spary water directly onto electronic components.

17C-7

17C-8

17C-9

1. DRAIN ENGINE COOLANT. (Refer to “Chapter 17B cooling - coolant, replacement”)

(a) Open reservior cover by turn it slowly to release the

Remove reservior vent hose clamp and disconnect vent

Remove reservior refilling hose clamp and disconnect

17C-10

Locate the lower support of reservior into rubber sleeve

17C-11

(a) Remove 4 cooling fan bracket retaining bolts and nuts.

(b) Remove retaining nut securing A/C pipe clamp.

17C-12

(b) Resistance between white wire and red wire:1.377±15%Ω ;

(d) Rotate cooling fan by hand, the blades should be rotated smoothly.

17C-13

Tighten A/C pipe clamp retaining nut.

17C-14

2. REMOVE RESERVIOR.(Refer to “Chapter 17B cooling - reservior, replacement”)

3. REMOVE COOLING FAN ASSY. (Refer to “Chapter 17B cooling- cooling fan assy, replacement”)

4. REMOVE FRONT GRILLE. (Refer to “Chapter 88 exterior amd interior trim - front grille, replacement”)

5. REMOVE FRONT BUMPER. (Refer to “Chapter 88 exterior amd interior trim - front bumper,

(b) Pull out reservior refilling hose from fan cow fixing clip.

17C-15

Pull out reservior vent hose from fixing clip on radiator

Disconnect engine hood switch connector and remove

17C-16

17C-17

(a) Connect engine water inlet hose to radiator.

17C-18

16. INSTALL COOLING FAN ASSY. (Refer to “Chapter 17B cooling - cooling fan, overhaul”)

17. INSTALL RESERVIOR. (Refer to “Chapter 17B cooling - reservior, replacement”)

20. FILL COOLANT. (Refer to “Chapter 17B cooling - coolant, replacement”)

(a) After installing radiator, let engine be running until cooling fan runs at high speed. check coolant for

LUBRICATION SYSTEM .................................................................18C-1

PRECAUTION............................................................................18C-1

ENGINE OIL .....................................................................................18C-2

REPLACEMENT ........................................................................18C-2

OIL FILTER ......................................................................................18C-4

REPLACEMENT ........................................................................18C-4

OIL PAN ...........................................................................................18C-6

REPLACEMENT ........................................................................18C-6

OIL PUMP ........................................................................................18C-7

REPLACEMENT ........................................................................18C-7

18C

18C-1

skin, allergies and dermatitis. In addition, used engine oil contains potentially harmful pollutants may

cause skin cancer. Therefore, the skin must be protected in appropriate methods and with cleaning

Avoid contacting with oil for a long time, especially the used engine oil.

Wear protective clothing, including waterproof work gloves.

Avoid contaminated clothing, especially underwear containing the oil.

Never put rags contaminated with oil in pockets.

Avoid eyes contact with oil, must wear goggles, In addition, equipment must be prepared to clean the

eyes and wrapping the wound must be dealt with immediately.

Frequent use of soap and water can clean, especially before meals, and make sure all the oil have

been removed (skin cleansers can also be used to assist with the nail brush). After cleaning, it is

Do not use gasoline, kerosene, diesel, thinner or solvent to clean skin.

Before each work, apply cream to help skin cleaning after work.

If your skin is abnormal, consult a doctor immediately.

18C-2

4. OPEN ENGINE COMPARTMENT COVER.

5. OPEN OIL FILLER CAP.

6. LIFT THE VEHICLE.

7. REMOVE OIL DRAIN PLUG.

8. USING A SPECIAL CONTAINER, COLLECT OR DISPOSE USED OIL AS REQUIRED.

9. REPLACE A NEW DRAIN PLUG GASKET AND TIGHTEN

10. LOWER VEHICLE.

11. FILL ENGINE OIL.

12. INSTALL OIL FILLER CAP.

18C-3

13. PARK THE VEHICLE ON LEVEL GROUND AND START ENGINE UNTIL IT IS WARM.

14. CHECK OIL FILTER OR OTHER PART AND ENSURE THERE IS NO OIL LEAKAGE.

15. TURN IGNITION SWITCH OFF.

16. AFTER 8 ~ 10 MINUTES, PULL OUT OIL DIPSTICK TO

18C-4

Without special circumstances, the oil filter should be

replaced with engine oil to avoid oil pollution and keep

engine normal operation.

18C-5

19. PUT DOWN DRIVER SEAT AND LOCK IT.

18C-6

1. OPEN OIL FILLER CAP.

3. REMOVE OIL DRAIN PLUG.

Be careful, the engine oil may be hot.

4. USING A SPECIAL CONTAINER, COLLECT OR DISPOSE USED OIL AS REQUIRED.

5. REMOVE OIL PAN. ( Refer to CUMMINS ENGINE ISF SERIAL SERVICE MANUAL )

6. CLEAN SURFACE BETWEEN LADDER FRAME AND ENGINE BLOCK.

7. INSTALL OIL PAN. ( Refer to CUMMINS ENGINE ISF SERIAL SERVICE MANUAL )

8. TIGHTEN DRAIN PLUG.

9. LOWER VEHICLE AND FILL ENGINE OIL TO SPECIFIED LEVEL.

18C-7

1. ISF 2.8 ENGINE USES INNER GEAR TYPE OIL PUMP WHICH IS LOCATED INSIDE FRONT GEAR

CHAMBER COVER AND DRIVED BY CRANKSHAFT DIRECTLY.

2. REPLACE OIL PUMP.(Refer to CUMMINS ENGINE ISF SERIAL SERVICE MANUAL )

STARTING AND CHARGING SYSTEM ..........................................20C-1

PRECAUTION............................................................................20C-1

PROBLEM SYMPTOMS TABLE................................................20C-2

GENERATOR...................................................................................20C-4

OVERHAUL ...............................................................................20C-4

STARTER.......................................................................................20C-10

COMPONENTS .......................................................................20C-10

OVERHAUL .............................................................................20C-11

BATTERY.......................................................................................20C-18

COMPONENTS .......................................................................20C-18

USE AND MAINTENANCE......................................................20C-19

INSPECTION ...........................................................................20C-21

TROUBLESHOOTING.............................................................20C-22

REPLACEMENT ......................................................................20C-24

20C

20C-1

(a) Battery may have escaping explosive gas. in order to avoid personal injury, keep ventilated in engine

(b) Battery electrolyte is very dangerous. It can damage the machine and cause serious burns. When

(d) Don't tighten the electrical connectors excessively, which may damage the starter.

(e) Never short two cables of the battery, it will cause a rapid battery fever even an explosion occur. The

(f) After the generator operation, do not try to use spark check whether the generator works. Use bulb or

(g) Check the generator silicon rectifier devices, it is strictly forbidden to use multimeter or apply 220V

20C-2

Chapter 20B starting and charging - starter,

4. Brush (Wear) or Brush spring

(Loss elastic force)

1. Bearing (Wear) Chapter 20B starting and charging - starter,

after engine start.

2. Starter relay (Copper contacts

bond)

3. Starter commutator (Bend or break)

4. Starter gear tooth surface contact

1. Generator connect wire Check wire harness

Chapter 20B starting and charging - generator,

20C-3

2. Brush (Poor connection) or Collector

Chapter 15B engine mechanical - engine

4. Battery lose electrolyte or battery

plate (Damaged)

20C-4

4. REMOVE ASSISTANT DRIVER SEAT. (Refer to “Chapter 84 driver / assistant driver seat - replacement”)

5. REMOVE ENGINE COMPARTMENT COVER UNDER

ASSISTANT DRIVER SEAT .

(a) Open front surfacing on engine compartment cover.

(b) Remove 5 engine compartment cover mounting bolts.

driver seat.

6. REMOVE ENGINE BELT. (Refer to CUMMINS ENGINE ISF SERIAL SERVICE MANUAL)

7. REMOVE GENERATOR. (Refer to CUMMINS ENGINE ISF SERIAL SERVICE MANUAL)

(a) Using pneumatic tools, loosen generator belt pulley retaining

20C-5

20C-6

20C-7

20C-8

11. INSTALL GENERATOR.(Refer to CUMMINS ENGINE ISF SERIAL SERVICE MANUAL)

12. INSTALL GENERATOR BELT.(Refer to CUMMINS ENGINE ISF SERIAL SERVICE MANUAL)

13. CONNECT BATTERY NEGATIVE CABLE.

20C-9

14. INSTALL ENGINE COMPARTMENT COVER UNDER

(a) Place engine compart cover in proper position.

(b) Tighten 5 engine compartment cover mounting bolts.

15. INSTALL ASSISTANT DRIVER SEAT.(Refer to “Chapter 84 driver / assistant driver seat - replacement”)

16. PUT DOWN DRIVER SEAT AND LOCK IT.

20C-10

20C-11

4. REMOVE STARTER. (Refer to 《CUMMINS ENGINE ISF SERIAL SERVICE MANUAL》 )

5. INSPECT STARTER

20C-12

Magnetic switch hold-in test.

20C-13

20C-14

20C-15

(b) Contact fusion check.

20C-16

20C-17

14. INSTALL STARTER. (Refer to CUMMINS ENGINE ISF SERIAL SERVICE MANUAL)

20C-18

20C-19

(a) Rectifier.

(b) Controllable silicone voltage regulation charger.

2. CHARGE PRECAUTIONS

20C-20

20C-21

20C-22

20C-23

20C-24

20C-25

8. INSTALL BATTERY .

V O L U M E 5

31-32 SUSPENSION SYSTEM 2303

33 TYRE AND WHEEL 2341

34 AXLE AND PROPELLER SHAFT 2353

35-36 BRAKING SYSTEMS 2407

41 TRANSMISSION 2467

42 CLUTCH 2545

51 STEERING COLUMN 2567

52 POWER STEERING 2591

61 HEATER AND AIR CONDITIONING 2627

62 SUPPLEMENTAL RESTRAINT SYSTEM 2715

63 SEAT BELT 2735

64 LIGHTING 2759

65 WIPER AND WASHER 2789

66 AUDIO SYSTEM 2811

71 WIRING 2827

81 COMMUNICATION SYSTEM 3221

82 WINDSHIELDS, MIRRORS & GLASS 3237

83 INSTRUMENT PANEL 3261

84 SEATS 3279

85 DOOR LOCKS 3305

86 SLIDING ROOF 3327

87 DOORS AND ENGINE HOOD 3337

88 EXTERIOR AND INTERIOR TRIM 3359

91 VEHICLE CONTROL SYSTEM 3397

SUSPENSION SYSTEM

FRONT SUSPENSION............................................................. 31-1

FRONT WHEEL ALIGNMENT ................................................... 31-08

FRONT SHOCK ABSORBER.................................................... 31-10

TORSION BAR........................................................................... 31-12

UPPER CONTROL ARM............................................................ 31-15

LOWER CONTROL ARM........................................................... 31-18

STABILIZER BAR...................................................................... 31-20

STRUT ROD............................................................................... 31-23

REAR SUSPENSION ............................................................... 32-1

REAR SHOCK ABSORBER .......................................................... 32-4

REAR LEAF SPRING ASSY.......................................................... 32-6

FRONT SUSPENSION....................................................................... 31-1

PRECAUTION.............................................................................. 31-1

PROBLEM SYMPTOMS TABLE.................................................. 31-2

ROAD TEST ................................................................................ 31-4

COMPONENTS ........................................................................... 31-5

ON-VEHICLE INSPECTION ........................................................ 31-7

FRONT WHEEL ALIGNMENT ........................................................... 31-8

ADJUSTMENT............................................................................. 31-8

FRONT SHOCK ABSORBER.......................................................... 31-10

OVERHAUL ............................................................................... 31-10

TORSION BAR................................................................................. 31-12

REPLACEMENT ........................................................................ 31-12

UPPER CONTROL ARM.................................................................. 31-15

REPLACEMENT ........................................................................ 31-15

LOWER CONTROL ARM................................................................. 31-18

REPLACEMENT ........................................................................ 31-18

STABILIZER BAR............................................................................ 31-20

REPLACEMENT ........................................................................ 31-20

STRUT ROD..................................................................................... 31-23

OVERHAUL ............................................................................... 31-23

SUSPENSION

1. FRONT SUSPENSION PRECAUTION

FRONT SUSPENSION - FRONT SUSPENSION

31-1

When installing rubber parts, the tires must be on the ground in no-load condition at final tightening.

Lubricating oil will shorten the life of rubber liner. Must clean the spilled lubricating oill.

After installing the suspension parts, check wheel alignment. If necessary, adjust it.

Lock nut is not reusable. Use new one at every installation. When replacing new parts, do not clean the

lubrication oil on the lock nut before tightening it.

31-2

Use the table below to help you find the cause of the problem. The numbers indicate the priority of the

likely cause of the problem. Check each part in order. If necessary, replace these parts

1. Lubrication oil (Excess) -

Shock absorber

oil leakage

2. Seals (Failure or damaged) -

3. Shock absorber (Failure) Chapter 31 front suspension - front shock absorber,

Pulling to one side

1. Tire (Worn or improperly inflated)

2. Wheel alignment (Incorrect)

3. Steering linkage (Loose or worn)

4. Hub bearing (Worn)

5. Steering gear (Maladjusted or

damaged)

6. Suspension parts (Worn)

Chapter 33 wheel and tire - wheel and tire assy, onvehicle

inspection

Chapter 31 front suspension - front wheel alignment,

adjustment

Chapter 51 steering column - steering column assy,

Chapter 51 steering column - steering propeller

shaft assy, overhaul

Chapter 34 axle and propeller shaft - front wheel

hub, overhaul

Chapter 52 power steering - steering box, overhaul

Chapter 31 front suspension - front suspension, onvehicle

1. Vehicle (Overloaded) -

Bottoming

Sways/tilt

2. Shock absorber (Worn or

2. Steering linkage (Loose or worn)

3. Stabilizer bar (Bent or broken)

4. Shock absorber (Worn or

Chapter 31 front suspension - front shock absorber,

Chapter 31 Rear suspension - Rear shock absorber,

Chapter 33 wheel and tire - wheel and tire assy,

Chapter 31 front suspension - stabilizer bar,

31-3

2. Wheel (Out of balance)

3. Shock absorber (Worn or

4. Wheel alignment (Incorrect)

Front wheel

shimmy

5. Ball joint (Worn or damaged)

Chapter 31 front suspension - upper control arm,

Chapter 31 front suspension - lower control arm,

6. Hub bearing (Worn)

Chapter 34 axle and propeller shaft - hub and

steering knuckle, on-vehicle inspection

7. Steering linkage (Loose or worn)

8. Steering gear (Maladjusted or

1. Wheel alignment (Incorrect)

Abnomal tire wear

2. Tire (Worn or improperly inflated)

3. Wheel (Out of balance)

Chapter 33 wheel and tire - wheel and tire assy, on

vehicle inspection

4. Shock absorber (Worn or damaged)

31-4

ROAD TEST

This is a flow chart for vehicle pull.

31-5

1 Front Shock Absorber Assy

3 Flat Washer

4 Lower Damping Block Assy

5 Bolt

6 Lower Control Arm Assy RH

7 Flat Washer

8 Bolt

9 Stabilizer Bar Mounting Bracket RH

11 Sping Washer

12 M10 Nut M10

13 Lower Control Arm Camshaft Assy

14 Nut

15 Lower Control Arm Cam

16 Flat Washer

17 1 Style-Nut

18 Front Stabilizer Bar Assy

19 Bolt

20 Stabilizer Bar Mounting Bracket LH

21 Nut

22 Upper Damping Block Assy

23 Bolt

24 Sping Washer

25 2 Style-Nut

26 Strut Rod Assy

31-6

1 Torsion Bar RH

5 Sping Washer

2 Short Mounting Bolt of Torsion Bar Seat

3 Long Mounting Bolt of Torsion Bar Seat

6 Flat Washer

7 Upper Control Arm Assy

31-7

1. CHECK TIRES FOR WEAR AND INFLATION PRESSURE.

For vehicles equipped with 195R15C-106R tires, the front tire pressure is 350 kPa and rear tire pressure is 400

kPa. The allowable variation is ±5 kPa. The maximum of the same axle tires pressure shall not exceed 10 kPa.

2. CHECK TIRES FOR RADIAL RUNOUT ERROR. The quantity of wheel sway is less than 1.2 mm.

3. CHECK FRONT WHEEL BEARING FOR LOOSENESS.

4. CHECK FRONT SUSPENSION PARTS FOR LOOSENESS AND DAMAGE.

5. CHECK STEERING ROD FOR LOOSENESS.

6. CHECK EVERY BALL JOINT FOR TOO LOOSENESS.

7. PERFORM A STANDARD FLEXIBILITY TEST AND CHECK IF SHOCK ABSORBER WORKS NORMALLY

8. MEASURE HEIGHT OF UNLOADED VEHICLE.

(a) Park the vehicle onto an inspection platform and bounce the vehicle to set the suspension system.

Bounce the front bumper for 5~10 times, then keep the bumper in free state. Measure ground

clearance at bumper center. Repeat the steps for another time. The difference between two

measurements should be no more than 10 mm.

(b) For vehicles equipped with 195R15C-106R tires, measure the ground clearance at front center point of

lower arm adjusting bolt (also use a self-made measurable tool to measure height in pit). If the

measured value is not within specified value, adjust the torsion mounting bolt to meet the specified

31-8

FRONT SUSPENSION - FRONT WHEEL ALIGNMENT

1. INSPECT TIRE. (Refer to “Chapter 33 wheel and tire - wheel and tire assy, on-vehicle

inspection”)

2. MEASURE HEIGHT OF WHEELS.

For vehicles equipped with 195R15C-106R tires, measure the ground clearance at front center point of

• Before inspecting the wheel alignment, adjust the vehicle height to meet the specified value and

maintain steering wheel center.

• If the vehicle height is not within the specified value, try to adjust it by pushing down or lifting

the body.

3. INSPECT TOE-IN.

Toe-in (total): 2 ± 2mm (8′ ± 8′)

If toe-in value is out of the specification, adjust toe-in by the left

and right tie rods.

4. ADJUST TOE-IN.

(a) Loosen tie rod lock nut.

(b) Turn the outer tie rod RH/LH by an equal amount to

adjust the toe-in within the specified value.

Measure the length of the left and right tie rod, and make

them in the same length. Length difference between the

right and left tie rod: 3.0 mm or less.

Torque: 40 ~ 50 N·m

5. INSPECT FRONT WHEEL CAMBER, KINGPIN INCLINATION

AND KINGPIN CASTER.

Front wheel camber, kingpin inclination and kingpin caster:

Front Wheel

Camber

Kingpin Inclination

Kingpin Caster

-0°20′±45′ (Difference between left and

right < 30′)

13°05′±45′(Difference between left and

2°35′±45′(Difference between left and

31-9

If the kingpin caster is out of the specified value, adjust it by turing

the strut rod nut.

The range of adjusting bolt from the initial position can be

no more than 3 thread. Rotating one revolution is equal to a

change of approx 30′ in kingpin caster.

6. ADJUST CAMBER.

(a) Adjust the front camber by rotating cam. Each scale of

cam means a 18′ change in camber. It is not allowed to

rotate cam from the center line over 4.5 scales.

31-10

FRONT SUSPENSION - FRONT SHOCK ABSORBER

FRONT SHOCK ABSORBER

1. REMOVE FRONT WHEEL LH ASSY. (Refer to “chapter 33 wheel and tire - front wheel and tire,

2. REMOVE FRONT SHOCK ABSORBER LH.

(a) Remove 1 mounting nuts attaching the front shock

absorber LH to frame.

(b) Remove the mounting bolt attaching front shock

absorber LH to the lower control arm.

3. CHECK SHOCK ABSORBER FOR OIL LEAKAGE.

(a) Check shock absorber for oil leakage.if the oil leaks from the shock absorber, replace it with a new one.

4. CHECK SHOCK ABSORBER CONNECTING PARTS.

(a) Check the shock absorber connecting rod, bushing or other connecting parts for damage. If there is any

damage, replace it with a new one.

5. CHECK SHOCK ABSORBER EFFICIENCY.

(a) Compress and extend the shock absorber rod for 2~3 times and then check that there is no abnormal

resistance or unusual noise during operation. If there is any abnormality, replace the shock absorber

31-11

6. INSTALL FRONT SHOCK ABSORBER LH.

Place the shock absorber,tighten the mounting bolt

attaching the shock absorber to the lower control arm.

Be sure to use new nut bolt.

Torque: 80 ~ 100 N•m

Tighten 1 nut attaching front shock absorber LH to frame.

Be sure to use new nut.

Torque: 25 ~ 35 N•m

7. INSPECT AFTER INSTALLATION.

(a) After the vehicle is assembled, drive it on a bad road for a distance about 10 KM and park it, then touch

the surfaces of the two shock absorbers with hands. If difference in temperature of the two shock

absorbers is large, correspondingly, difference in resistance of them is also large and the absorber with

a low temperature has small resistance. If the temperature of the two shock absorbers doesn’t exceed

air temperature, it indicates that the shock absorbers have no resistance and disabled. It is necessary

to replace with a new one.

(b) When the vehicle is running slowly and given an emergent brake, if the vehicle has an excessive

vibration, it indicates that there is a fault on shock absorber. Disassemble and erect the shock absorber,

keep the lower part jointing ring clamping the vise, pull and press the shock absorber rod for several

times. It should have stable resistance,the pull-up (restoration) resistance should be no less than pulldown

resistance. If the resistance is unstable or there is no resistance, the shock absorber may lack of

oil or the valve part is damaged. It is necessary to replace it with a new shock absorber.

spring, frame or shaft, rubber washer is damaged or fallen off, and dust wrapper is deformed and oil is

insufficient. It is necessary to find out the root of the fault and replace it.

(d) If it is impossible to conduct a test, we can take some experiential measures to check it: let an iron bar

passing through the lower hoisting ring, step the two ends with feet, hold the hoisting ring and pull up

and down for 2-4 times with hands. If there is large resistance when pulling up and almost no resistance

when pulling down, stretching resistance is restored compared with resistance before repair, and you

don’t feel no-running status, it indicates that the shock absorber is in normal condition.

8. REMOVE AND INSTALL FRONT SHOCK ABSORBER RH.

Remove and install the Front RH side by the same procedures as the Front LH side.

31-12

FRONT SUSPENSION - TORSION BAR

TORSION BAR

1. REMOVE THE FUEL TANK. (Refer to “Chapter 12A fuel - fuel tank assy, replacement”)or(Refer to

“Chapter 12B fuel - fuel tank assy, replacement”)

It is necesary to remove the fuel tank only before removing the torsion bar LH.

2. REMOVE TORSION BAR ASSY LH.

As the illustration shows, measure the length of the

extension bolt end A.

When adjusting the vehicle hight, value A will serve as

reference. At the end of the torsion bar, there are left and

right indicator. Do not install it to opposite direction.

Remove the locking nut and adjustment nut of the torsion

bar LH.

31-13

Remove 2 mounting bolt attaching the torsion bar to the

upper control arm.

Pull out the torsion bar backward.

3. INSTALL TORSION BAR ASSY LH.

Place the torsion bar LH,tighten 2 mounting bolt attaching

the torsion bar to the upper control arm.

扭矩 :Torque: 110 ~ 120 N•m

Tighten the locking nut and adjustment nut of the torsion

• Tighten adjustment nut of torsion bar LH.

• Tighten locking nut .the length of the extension bolt end

must be the same as the measure value A.

Torque: 120 ~ 130 N•m

31-14

4. INSPECT VEHICLE HEIGHT. IF THE HEIGHT IS OUT OF STANDARD, USE TORSION BAR

ADJUSTING NUT TO ADJUST.

5. REMOVE AND INSTALL TORSION BAR ASSY RH.

Remove and install the RH side by the same procedures as the LH side.

Be careful not to be scalded by hot exhaust pipe.

FRONT SUSPENSION - UPPER CONTROL ARM

31-15

UPPER CONTROL ARM

1. REMOVE FRONT WHEEL ASSY LH. (Refer to “Chapter 33 wheel and tire - front wheel and tire,

2. REMOVE FRONT DISC BRAKE LH. (Refer to “Chapter 35 brake - front disc brake, overhaul”)

3. REMOVE TORSION BAR LH. (Refer to Chapter 31 front suspension - torsion bar, replacement”)

It is not necessary to poll out the torsion bar LH and remove the fuel tank.

4. REMOVE UPPER CONTROL ARM LH.

Remove mounting bracket mounting bolt of front wheel

speed sensor cable.

Remove the cotter pin located at slotted nut.

Removed cotter pin must not be use again.

Removed the slotted nut attaching upper control arm ball

pin to steering knuckle.

Remove 3 bolts attaching upper control arm to frame.

31-16

Take out the upper control arm assy.

5. INSTALL UPPER CONTROL ARM ASSY LH.

(a) Place upper control arm,tighten 3 bolts attaching upper

control arm to frame.

Torque: 170 ~ 200 N•m

Tighten the slotted nut attaching upper control arm ball

Torque: 105 ~ 125 N•m

Install the cotter pin located at slotted nut.

New cotter pin must be used.

Place the mounting bracket of wheel speed sensor

cable,Tighten mounting bolt.

6. INSTALL TORSION BAR LH. (Refer to chapter 31 front suspension - torsion bar, replacement”)

7. INSTALL FRONT DISC BRAKE LH. (Refer to “Chapter 35 brake - front disc brake, overhaul”)

8. INSTALL FRONT WHEEL ASSY LH. (Refer to “Chapter 33 wheel and tire - front wheel and tire,

31-17

9. REMOVE AND INSTALL UPPER CONTROL ARM RH.

10. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT. (Refer to “Chapter 31 front suspension -

front wheel alignment, adjustment”)

31-18

FRONT SUSPENSION - LOWER CONTROL ARM

LOWER CONTROL ARM

3. REMOVE LOWER CONTROL ARM ASSY LH.

(a) Remove bumper block assy.

(b) Remove the mounting bolt attaching atabilizer bar link LH

to lower control arm.

lower contrlo bar.

Remove 4 nuts and bolts attaching ball joint seat to lower

control arm.

4 blots including 2 strut rod mounting nuts and bolts.

(e) Remove the mounting nut attaching lower control arm to

subframe.

Take out the lower control arm assy LH carefully.

4. INSTALL LOWER CONTROL ARM ASSY LH.

(a) Place lower control arm.

(b) Tighten the mounting nut attaching lower control arm to

Torque: 180 ~ 220 N•m

joint seat to lower contrlo arm.

Torque: 100 ~ 120 N•m

(d) Tighten the mounting bolt attaching ball joint seat to

lower control arm.

31-19

Tighten the mounting bolt attaching shock absorber to

TIghten the mounting bolt attaching stabilizer bar link to

Place the lower pumper block assy,tighten 2 mounting

nut at the bottom.

Totque: 40~ 60 N•m

5. INSTALL FRONT DISC BRAKE LH. (Refer to “Chapter 35 brake - front disc brake, overhaul”)

6. INSTALL FRONT WHEEL ASSY LH. (Refer to “Chapter 33 wheel and tire - front wheel and tire,

7. REMOVE AND INSTALL LOWER CONTROL ARM RH.

8. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT. (Refer to “Chapter 31 front suspension -

31-20

FRONT SUSPENSION - STABILIZER BAR

STABILIZER BAR

1. REMOVE STABILIZER BAR.

(a) Remove the mounting bolt attaching stabilizer bar link

ball joint LH to stabilizer bar.

(b) Remove the mounting bolt attaching stabilizer bar link

ball joint RH to stabilizer bar.

Remove 2 mounting bolt attaching stabilizer bar bracket

LH to frame.

RH to frame.

31-21

Take down stabilizer bar carefully.

2. INSPECT STABILIZER BAR BUSHING.

Inspect the stabilizer bar bushing for ageing. If there is any ageing, replace the bushing with new one.

3. INSTALL STABILIZER BAR.

(a) Place stabilizer bar.

(b) Tighten 2 mounting bolt attaching stabilizer bar bracket

Torque: 40 ~ 50 N•m

31-22

Tighten the mounting bolt attaching stabilizer bar link ball

joint LH to stabilizer bar.

joint RH to stabilizer bar.

4. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT. (Refer to “Chapter 31 front suspension -

FRONT SUSPENSION - STRUT ROD

31-23

STRUT ROD

1. REMOVE STRUT ROD LH.

(a) Remove the nut attaching the strut rod LH to the

Using a wrench, lock the head of bolts attaching the strut

rod LH to the lower control arm LH.

Remove the mounting nut attaching the strut rod LH to

the lower control arm LH.

Take out the the strut rod LH.

2. CHECK THE RUBBER BUSHING OF THE STRUT ROD FOR DAMAGE.

31-24

3. INSTALL STRUT ROD LH.

(a) Place strut rod,and install rubber bushing and baffle plate

to strut rod.

(b) Using a wrench,lock the head of bolts attaching the strut

rod to the lower contrlo arm.

Tighten the nut attaching the strut rod to the lower control

arm.

Tighten connecting mounting nut attaching the strut rod

to the subframe.

Torque: 115 ~ 135 N•m

4. REMOVE AND INSTALL STRUT ROD RH.

Remove the RH side by the procedure as the same procedure as the LH side.

5. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT. (Refer to “Chapter 31 front suspension -

REAR SUSPENSION ......................................................................... 32-1

PROBLEM SYMPTOMS TABLE.................................................. 32-1

COMPONENTS ........................................................................... 32-2

ON-VEHICLE INSPECTION ........................................................ 32-3

REAR SHOCK ABSORBER .............................................................. 32-4

OVERHAUL ................................................................................. 32-4

REAR LEAF SPRING ASSY.............................................................. 32-6

OVERHAUL ................................................................................. 32-6

REAR SUSPENSION - REAR SUSPENSION

32-1

likely cause of the problem. Check each part in order. If necessary, replace these parts.

Shock absorber oil leakage

3. Shock absorber (Failure) Chapter 32 rear suspension - rear shock

absorber, overhaul

1. Shock absorber (Failure) Chapter 32 rear suspension - rear shock

Suspension noise

2. Leaf spring (Worn or damaged) Chapter 32 rear suspension - rear leaf

spring, overhaul

3. Bushing (Worn or damaged) Chapter 32 rear suspension - rear leaf

4. Shock absorber and leaf spring

mounting bolt (Loosen or

Chapter 32 rear suspension - rear shock

Abnomal rear tire wear,

vehicle deviation

1. Leaf spring pin (Over worn) Chapter 32 rear suspension - rear leaf

2. U-bolt (Worn or damaged) Chapter 32 rear suspension - rear leaf

3. Leaf spring (Elastic decline or

stiffness inconsistent)

Chapter 32 rear suspension - rear leaf

4. Leaf spring (Broken) Chapter 32 rear suspension - rear leaf

1. Tire (Worn or improperly

inflated)

Chapter 33 wheel and tire - wheel and tire

assy, on-vehicle inspection

2. Wheel (Out of balance) Chapter 33 wheel and tire - wheel and tire

assy, adjustment

32-2

1 Rear Leaf Spring Assy

Leaf Spring Shackle Outer Plate Welded

Assy

3 Leaf Spring Shackle Inner Bushing

4 Leaf Spring Shackle Inner Plate

5 Spring Washer

6 Leaf Spring Pin Nut

7 Rear Damping Block Assy

8 Spring Washer

10 U-bolt

11 Leaf Spring Mounting Plate Welded Assy

12 Rear Shock Absorber Assy

13 Spring Washer

15 Leaf Spring Pin Shaft

16 Spring Washer

9 Bolt

32-3

1. ON-VEHICLE INSPECTION

(a) Check shock absorber for oil leakage.

(b) Check shock absorber ring rubber bushing for aging, cracking, deforming. Replace it if necessary.

(d) Check U-bolt for cracking, flaw, thread for damage. replace it if necessary.

(e) U-bolt should be tightened in uniform cross tightened method and step by step tight U-bolt to specified

value. Tighten the U-bolts again when the leaf spring laminating closely with the car full loaded. In some

cases that leaf springs can not be compacted because of the bolts and nuts being rusted. Replace it

with the new U-bolts and nuts if necessary.

(f) For slide-type leaf spring, a layer of lubricating grease should be applied between the leaf spring and

shackle bracket to reduce the wear and tear of the slide-type leaf spring.

32-4

REAR SUSPENSION - REAR SHOCK ABSORBER

REAR SHOCK ABSORBER

1. REMOVE SHOCK ABSORBER RL.

(a) Remove the lower mounting bolt for the shock absorber

RL.

Remove the upper mounting bolt for the shock absorber

Take out the shock absorber RL with caution.

2. CHECK SHOCK ABSORBER FOR OIL LEAKAGE.

(a) Check the shock absorber for oil leakage,If the oil leaks from the shock absorber, replace it with a new

3. CHECK SHOCK ABSORBER CONNECTING PARTS.

(a) Check the shock absorber connecting rod ,rubber bushing or others for damage,replace it with a new

one if necessary.

4. CHECK SHOCK ABSORBER EFFICIENCY.

(a) Compress and extend the shock absorber rod and then check that there is no abnormal resistance or

unusual noise during operation. If there is any abnormality, replace the shock absorber with a new one.

5. INSTALL SHOCK ABSORBER RL.

(a) Place shock absorber RL.

(b) Tighten the upper mounting bolt for the shock absorber

Torqre: 55 ~ 65 N·m

32-5

Tighten the lower mounting bolt for the shock absorber

Torqre: 60 ~ 80 N·m

6. REMOVE AND INSTALL REAR SHOCK ABSORBER RH.

Remove and install the REAR RH side by the same procedures as the REAR LH side.

(a) After installation,drive it on a bad road for a distance about 10 KM and park it, then touch the surfaces

of the two shock absorbers with hands. If difference in temperature of the two shock absorbers is large,

correspondingly, difference in resistance of them is also large and the absorber with a low temperature

has small resistance. If the temperature of the two shock absorbers doesn’t exceed air temperature, it

indicates that the shock absorbers have no resistance and disabled. It is necessary to replace with a

new one.

insufficient. It is necessary to find out the root of the fault and repair it.

32-6

REAR SUSPENSION - REAR LEAF SPRING ASSY

REAR LEAF SPRING ASSY

1. REMOVE REAR SHOCK ABSORBER LH. (Refer to “Chapter 32 rear suspension - rear shock

2. REMOVE REAR LEAF SPRING ASSY LH.

Using proper jacks, withstand the center of the rear leaf spring.

Remove bolts for the Parking Brake cable fixed shelf.

Remove 4 U-bolts and nuts.

Before removing the nuts,suport the rear axle with lifting

jack.

Lowering the jack which holds the leaf spring slowly,remove

the U-bolts and rear leaf spring anchor plate.Check U-

bolts,if there are any damaages such as deformation and

flaw ,replace it in time.

Remove the mounting nut which install the front leaf

spring axis pin to the frame.

Remove upper mounting nut of leaf spring shackle pin.

32-7

Remove lower mounting nut of leaf spring shackle pin.

Remove shackle inner&outer plates and shackle pin.

Remove rear leaf spring LH with caution.

3. CHECK LEAF SPRING FOR AGING, FLAW AND SERIOUS RUSTING. IF THERE IS ANY ONE,

REPLACE IT WITH A NEW ASSEMBLY.

4. CHECK SHACKLE BUSHING OF LEAFING SPRING FOR WEARING,AGING ,DAMAGE.IF THERE

IS ANY ONE ,REPLACE IT WITH A NEW ONE.

5. CHECK LEAF SPRING ARCH HEIGHT, H = 128 ± 5 mm,Replace new leaf spring if necessary.

• The defference value of left and right sagitta should not be more than 5 mm, or it will cause

body sway.

• The new spring leaf must be as same as the other side (both leaf springs ara “+”or”-”at the

same time).

6. INSTALL REAR LEAF SPING ASSY LH.

Install shackle inner&outer plates and shackle pin.

Tighten upper mounting nut of leaf spring shackle pin.

Torque: 105 ~ 125 N·m

Tighten lower mounting nut of leaf spring shackle pin.

32-8

Tighten the mounting nut which install the front leaf

Torque: 110 ~ 120 N·m

Lift the center of rear leaf spring LH with jack

slowly, make U-bolts cross the rear leaf spring boltholes

and tighten the nuts with hand.

Tighten the U-bolt nuts.

Torque: 85~ 105 N·m

Tighten bolts for the Parking Brake cable fixed shelf.

Move the jack and lifting jack.

7. INSTALL REAR SHOCK ABSORBER LH. (Refer to “Chapter 32 rear suspension - rear shock

absorber, overhaul”).

8. TIGHTEN U-BOLTS NUTS AGAIN AFTER DRIVING 3 ~ 5 KM.

9. REMOVE AND INATALL REAR LEAF SPRING ASSY RH.

TYRE AND WHEEL

TIRE AND WHEEL ASSY .................................................................. 33-1

PRECAUTION.............................................................................. 33-1

COMPONENTS ........................................................................... 33-2

PROBLEM SYMPTOMS TABLE.................................................. 33-3

ON-VEHICLE INSPECTION ........................................................ 33-4

ADJUSTMENT............................................................................. 33-7

FRONT WHEEL AND TIRE................................................................ 33-8

REPLACEMENT .......................................................................... 33-8

REAR WHEEL AND TIRE.................................................................. 33-9

REPLACEMENT .......................................................................... 33-9

TIRE AND WHEEL ASSY

WHEEL AND TIRE

1. TIRE AND WHEEL ASSY PRECAUTION

WHEEL AND TIRE - TIRE AND WHEEL ASSY

Use special tools to remove the tires. Do not remove them by huge hammers or sharp tools.

33-1

Do not use tires with different types, sizes, tread patterns, pressure and load index on the same axle.

Please pay attention to the mark of rolling direction when installing directional tread pattern tires.

Must swap each tire once after runing 5000 ~ 6000 km, make each tire wear well evenly.

After swaping tires, reset proper inflation pressure according to the tire position.

Operate inflation according to this manual’s specification, and measure tire pressure at cold state by

tire gauge. Before inflating, check the tire valve whether matching valve core flatly and then clean the

dirt. Inflating air is not allowed to contain water and oil. After inflating, tighten the tire valve core, and

check the tire leakage.

Check inflation pressure according to the standard service data. The tire pressure must be within the

specified value.

Regularly check front wheel toe-in to avoid unnecessary increased resistance of running, fuel

consumption and excessive tire wear.

33-2

1 Tire

2 Wheel Rim

3 Tubeless Tire Valve

4 Wheel Hub Nut

5 Axle Cover

33-3

Symptom Suspect Area Suspect Area

1. Wheel toe-in (Improper value)

Chapter 31 front suspension - front wheel

alignment, adjustment

2. Tire ( Improperly inflated) Chapter 33 wheel and tire - wheel and tire

3. Wheel (Out of balance) Chapter 33 wheel and tire - wheel and tire

4. Steering system (Distortion) Chapter 51 steering system - steering box,

1. Front wheel (Different tire

pressure)

Front wheel swing or vibration

3. Shock absorber (Wear or fault) Chapter 31 front suspension - front shock

4. Steering system (Over Wear)

Chapter 51 steering system - steering box,

Uncomfortableness when

running

1. Tire (Exceed specified pressure) Chapter 33 wheel and tire - wheel and tire

2. Shock absorber (Failure)

Chapter 31 front suspension - front shock

3. Coil Spring (Failure) Chapter 31 front suspension - torsion bar,

spring assy, overhaul

Front wheel side slipping

1. Wheel toe-in (It is not within

specified value)

2. Tire (Inflating pressure is not

within specified value)

33-4

1. MEASURE TIRE TREAD DEPTH.

Depth ≥ 1.6 mm

If the tire tread depth is less than 1.6 mm, replace it with a new one.

Replace a pair of tires at the both wheel side.

2. CHECK TIRES ABNORMAL WEAR.

(a) Visually inspect the tires shoulder wear. If the tire wears,

measure the inflation pressure. Inflate and swap the

wheel if tire pressure is lower or overload.

Visually inspect the wear tires at center. If the tire wears,

release extra pressure and swap the wheel assy.

33-5

Visually inspect the tire inner edge (shoulder) wear. The

inner Edge (shoulder) wear is usually caused by excessive

toe-out and/or excessive negative camber, suspension

parts loose. Avoid turning at high speed. Swap the wheel

assy after adjustment.

Visually inspect the tire outer edge (shoulder ) wear. The

outer edge (shoulder) wear is usually caused by excessive

toe-in and/or excessive positive camber, suspension parts

loose. Avoid turning at high spped. Swap the wheel assy

after adjustment.

Visually inspect the tire feathering wear that occurs along

both inside and outside shoulder ribs. This kind of wear

is usually caused by abnomal toe-in. Check/adjust the

wheel alignment and Swap the wheel assy.

33-6

Visually inspect the tire corrugate wear. This kind of wear

is caused by improper inflation pressure, wheel out of

balance, hub bearing loose or worn and rim deformation.

Swap the wheel assy after adjustment.

3. MEASURE COLD TIRE INFLATION PRESSURE.

Tire Specification Front wheel Rear wheel Spare tire

195R15C-106R 350 kPa 400 kPa 420 kPa

If tire size or inflation pressure doesn’t match standard service data, adjust or replace it with a new wheel as

4. INSPECT TIRE CROWN, TIRE SHOULDER, TIRE EDGE.

Replace the tire with a new one, if bent, cut, cracked, dented, deformation and abrasion exists.

5. INSPECT TIRE VALVE.

If air leaks from tire valve, replace it with a new one.

6. INSPECT RIM.

Replace the rim with a new one If it is found deformation, corrosion and crack.

7. INSPECT WHELL NUTS.

Check the tightening torque one by one according to the standard service data.

33-7

1. TIRE SWAP.

Illustration arrow shows the driving direction o.

Illustration A is cross swap every tire with spare tire.

Illustration B is cross swap every tire without spare tire.

2. WHEEL ASSEMBLY OF THE DYNAMIC BALANCE.

Clean dirt, stones and used balance weights from measured

wheel.

Measure tire pressure and inflate as recommended.

Select the match cone based on size of rim center hole

to tighten by fast nut.

Turn on the balance tester power.

Measure rim width.

Measure tire diameter.

Measure the distance between the rim edge and the

balance tester.

Pull off wheel protect cover and then start test.

After test completed, fix balance weights based on

measurement result.

Repeat aforementioned procedure, adjust till the data to

match specification.

Demount wheel assy.

3. FRONT WHEEL TOE-IN. (Refer to Chapter 31 front suspention - front wheel alignment ,

adjustment )

4. TIRE REPAIR SHOULD BE PERFORMED IN COMPLIANCE WITH LOCAL REGULATIONS.

33-8

WHEEL AND TIRE - FRONT WHEEL AND TIRE

FRONT WHEEL AND TIRE

1. LIFT VEHICLE.

2. REMOVE LH FRONT WHEEL.

Remove 6 hub nuts of LH front wheel.

Undo all front hub nuts diagonally.

Remove LH front wheel.

3. INSTALL LH FRONT WHEEL.

Replace LH front wheel.

Tighten 6 hub nuts of LH front wheel.

Toque: 100 ~ 120 N·m

Tighten all front hub nuts diagonally.

4. REMOVE AND INSTALL RH FRONT WHEEL.

Remove and install the wheel FRONT RH by the same procedures as the LH front wheel.

WHEEL AND TIRE - REAR WHEEL AND TIRE

33-9

REAR WHEEL AND TIRE

2. APPLY PARKING BRAKE.

3. REMOVE LH REAR WHEEL.

(a) Remove 6 hub nuts of LH rear wheel.

Loosen all front wheel nuts diagonally.

Remove LH rear wheel.

4. INSTALL LH REAR WHEEL.

Replace LH rear wheel.

Tighten 6 hub nuts of LH rear wheel.

Torque: 100 ~ 120 N·m

5. REMOVE AND INSTALL RH REAR WHEEL.

Remove and install the RH rear wheel by the same procedures as the LH rear wheel.

6. LOWER VEHICLE.

PROPELLER SHAFT ASSY .............................................................. 34-1

PRECAUTION.............................................................................. 34-1

PROBLEM SYMPTOMS TABLE.................................................. 34-2

COMPONENTS ........................................................................... 34-3

INSPECTION ............................................................................... 34-4

OVERHAUL ................................................................................. 34-5

U-JOINT ............................................................................................. 34-8

OVERHAUL ................................................................................. 34-8

CENTER SUPPORT BEARING ....................................................... 34-12

OVERHAUL ............................................................................... 34-12

AXLE HUB AND STEERING KNUCKLE......................................... 34-16

PROBLEM SYMPTOMS TABLE................................................ 34-16

ON-VEHICLE INSPECTION ...................................................... 34-18

FRONT HUB..................................................................................... 34-20

OVERHAUL ............................................................................... 34-20

REAR AXLE HUB ............................................................................ 34-24

OVERHAUL ............................................................................... 34-24

STEERING KNUCKLE..................................................................... 34-28

OVERHAUL ............................................................................... 34-28

REAR AXLE ..................................................................................... 34-34

PRECAUTION............................................................................ 34-34

PROBLEM SYMPTOMS TABLE................................................ 34-36

ON-VEHICLE INSPECTION ...................................................... 34-37

FINAL DRIVE OIL ............................................................................ 34-40

REPLACEMENT ........................................................................ 34-40

AXLE SHAFT ASSY......................................................................... 34-43

OVERHAUL ............................................................................... 34-43

REAR AXLE HOUSING WELDING ASSY....................................... 34-44

OVERHAUL ............................................................................... 34-44

DRIVE PINION ................................................................................. 34-50

INSPECTION ............................................................................. 34-50

AXLE AND PROPELLER SHAFT - PROPELLER SHAFT ASSY

PROPELLER SHAFT ASSY

34-1

1. PROPELLER SHAFT ASSY PRECAUTION

(a) Do not disassemble the propeller shaft assy unless absolutely necessary.

(b) If disassembly of propeller shaft assy is required, be sure to clean all separated parts before assembly.

perform repairing or replacing when necessary.

34-2

1. Propeller shaft assy (Loose)

Chapter 34 axle and propeller shaft - propeller

2. Lubrication (Insufficient) -

Abnormal noise of

propeller shaft assy

Propeller shaft assy

vibration

3. U-joint (Worn or damaged)

4. Center support bearing (Worn or

5. Slip spline (Worn)

2. U-joint yoke (Incorrect installation)

3. Propeller shaft assy (Bent or

twisted)

4. Propeller shaft assy (Unbalanced)

5. Center support bearing rubber

grommet (Aging or damaged)

6. Center suppor bearing (Worn or

Chapter 34 axle and propeller shaft - U-joint,

Chapter 34 axle and propeller shaft - center

support bearing, overhaul

shaft assy, inspection

Center support

bearing overheat

1. Center support with rubber

grommet (Incorrect installation)

3. Oil seal (Too tight)

34-3

1 Propeller Shaft Assy

Bolt , Spring Washer and Flat Washer

Set

5 Propeller Shaft Nut

3 Propeller Shaft Bolt

34-4

1. INSPECT VIBRATION OF POWERTRAIN.

(a) Check front wheels for dynamic balance. (Refer to “Chapter 33 wheel and tire - wheel and tire assy,

adjustment”)

(b) Check rear wheels for dynamic balance. (Refer to “Chapter 33 wheel and tire - wheel and tire assy,

2. INSPECT PROPELLER SHAFT ASSY DIAMETER RUNOUT.

(a) Using V-block and dial indicator, measure the diameter

runout of propeller shaft assy.

Limit: ≤ 0.5 mm

If the diameter runout is out of the specification, correct the

propeller shaft assy using press machine. If the diameter runout

is still out of the specification after correction, replace with a new

propeller shaft assy. (Chapter 34 axle and propeller shaft -

propeller shaft assy, overhaul)

3. INSPECT PROPELLER SHAFT ASSY DYNAMIC BALANCE.

(a) Using dynamic balancer, check the propeller shaft assy.

Dynamic unbalance: ≤ 20 g.cm ( 3200 r/min)

If the dynamic unbalance is out of the specification, weld balance

weight at the corresponding position on the both ends of propeller

shaft assy.

• It is no more than 3 balance weight at each end if welding.

• Perform step (a) again to check whether dynamic

unbalance is within the specification.

4. INSPECT SLIP SPLINE CLEARANCE.

(a) Using feeler gauge, measure the tangential clearance

between sleeve yoke and spline on transmission output

Standard: 0.15 mm

Limit: 0.3 mm

If the clearance is out of the specification, replace with a new

propeller shaft assy. (Refer to “Chapter 34 axle and propeller

shaft - propeller shaft assy, overhaul”)

34-5

1. PRECAUTION. (Refer to “Chapter 34 axle and propeller shaft - propeller shaft assy, precaution”)

2. REMOVE PROPELLER SHAFT ASSY.

(a) Mark on the front propeller shaft U-joint and transmission

dust-proof cover.

Make sure the marks are clear.

Mark on the rear propeller shaft U-joint and final drive

flange.

Remove the 4 sets of nuts and bolts attaching propeller

shaft to final drive flange.

Discard the removed nuts and bolts.

Lower the propeller shaft and set it aside.

When performing this operation, another operator who holds the

propeller shaft up is required.

34-6

Remove the 2 bolts fixing center suport bearing bracket.

• Discard the removed bolts.

• When performing this operation, another operator who

holds the propeller shaft up is required.

Lower the center support with rubber grommet.

Pull out the sleeve yoke from transmission dust-proof

cover and remove the propeller shaft assy.

Be sure to save the propeller assy carefully.

3. INSPECT PROPELLER SHAFT ASSY. (Refer to “Chapter 34 axle and propeller shaft - propeller

shaft assy, inspection”)

4. INSPECT U-JOINT. (Refer to “Chapter 34 axle and propeller shaft - U-joint, overhaul”)

5. INSTALL PROPELLER SHAFT ASSY.

(a) Insert the sleeve yoke into transmission dust-proof cover

according to the marks.

• Before assembly, internal and external spline should

be applied with car general lithium grease.

• Be sure to perform this operation according to the

marks.

34-7

Position the center support with rubber grommet properly

Tighten the 2 bolts fixing center suport bearing bracket.

Torque: 60 ~ 70 N•m.

• Be sure to use new bolts.

Position the propeller shaft properly according to the marks.

• Align the marks by rotating the pinion flange when

Install the 4 sets of nuts and bolts attaching propeller

Torque: 70 ~ 79 N·m

Be sure to use new nuts and bolts.

34-8

AXLE AND PROPELLER SHAFT - U-JOINT

2. REMOVE PROPELLER SHAFT ASSY. (Refer to “Chapter 34 axle and propeller shaft - propeller

shaft assy, overhaul”)

3. DISASSEMBLE MIDDLE U-JOINT OF PROPELLER

SHAFT ASSY.

(a) Mark on the end yoke, cross spider and tube yoke.

Using snap ring pliers, remove the 4 snap rings.

Discard the removed snap rings.

Using copper rod and hammer, remove the round

Do not hammer the round bearing and do not clamp the

propeller shaft with vice directly.

34-9

Remove the 4 round bearings and the 4 dust-proof

covers.

Discard the removed dust-proof cover.

(e) Remove the cross spider.

(f) Separate the end yoke from tube yoke.

4. DISASSEMBLE FRONT U-JOINT OF PROPELLER SHAFT ASSY.

Disassemble the front U-joint by the same procedures as the middle U-joint.

5. DISASSEMBLE REAR U-JOINT OF PROPELLER SHAFT ASSY.

Disassemble the rear U-joint by the same procedures as the middle U-joint.

6. INSPECT CROSS SPIDER.

(a) Check the cross spider for wear and tear.

Cross spider doesn’t need maintenance, has no grease mouth, and should be rotated flexibly.

(b) Using the micrometer caliper, measure the cross spider

journal.

Standard: 16.3 mm

Limit: 16.248 mm

If the cross spider is excessively worn, replace with a new part.

round bearing and yoke.

Clearance: 0 mm (Interference fit)

If clearance exits, replace with new round bearing and yoke.

Insert the round bearing into yoke. Measure the clearance

by shaking bearing along radial direction lightly.

34-10

(d) Using the vice and the dial indicator, measure the radial

clearance between round bearing and cross spider.

Radial clearance: 0.01 ~ 0.055 mm

If the radial clearance is out of the specification, replace with

new round bearing and cross spider.

Wrap the cross spider with rag to prevent the spider that is

clamped by vice from being damaged.

Hitch the cross spider with round bearing. Measure the

radial clearance by shaking bearing along radial direction

lightly.

(e) Using dial indicator, measure the axial clearance

between round bearing and cross spider.

Axial clearance: 0.01 ~ 0.055 mm

If the axial clearance is out of the specification, replace with new

round bearing and cross spider.

axialclearance by shaking bearing along axial direction

7. ASSEMBLE MIDDLE U-JOINT OF PROPELLER SHAFT ASSY.

(a) Apply the grease on the mating surfaces of cross spider and round bearing.

Grease: lithium base grease No.2

• Only apply the grease on the mating surface of cross spider and round bearing.

• If the applying grease is excessive, it will cause problem for further operations.

(b) Position the end yoke and tube yoke properly according

to the marks.

at ouside of yoke.

(d) Install the cross spider at inside of yoke.

(e) Using the copper rod and the hammer, install the 4 round

bearings and the 4 dust-proof covers properly.

• Be sure to use new dust-proof covers.

34-11

Using snap ring pliers, install the 4 snap rings.

Be sure to use new snap rings.

8. ASSEMBLE FRONT U-JOINT OF PROPELLER SHAFT ASSY.

Reassemble the front U-joint by the same procedures as the middle U-joint.

9. ASSEMBLE REAR U-JOINT OF PROPELLER SHAFT ASSY.

Reassemble the rear U-joint by the same procedures as the middle U-joint.

10. INSTALL PROPELLER SHAFT ASSY. (Refer to “Chapter 34 axle and propeller shaft - propeller

34-12

AXLE AND PROPELLER SHAFT - CENTER SUPPORT BEARING

3. DISASSEMBLE MIDDLE U-JOINT OF PROPELLER SHAFT ASSY. (Refer to “Chapter 34 axle and

propeller shaft - U-joint, overhaul”)

4. REMOVE END YOKE.

(a) Remove the nut.

Discard the removed nut.

Remove the flat washer.

Mark on the end yoke and spline.

• Make sure the marks are clear.

• Make sure the yoke direction of U-joint is consistent.

Using a puller, remove the end yoke.

34-13

5. REMOVE CENTER SUPPORT WITH RUBBER GROMMET

Do not damage the rubber grommet.

6. REMOVE CENTER SUPPORT BEARING.

(a) Using a puller, remove the center support bearing assy.

Remove the 2 oil seals on both side.

Discard the removed oil seals.

Using hammer and copper rod, remove the center

support bearing from bearing cup.

7. INSPECT CENTER SUPPORT BEARING.

(a) Check whether the center support bearing can be rotated freely.

(b) Check whether the center support bearing is worn excessively.

8. INSTALL CENTER SUPPORT BEARING ASSY.

(a) Apply the grease on the center support bearing and bearing cup.

34-14

Using hammer and copper rod, install the center support

bearing to bearing cup.

Apply the grease on the oil seal lip.

Be sure to use new oil seals.

Install the 2 oil seals on both side.

Install the center support bearing assy with hammer and

copper rod.

9. INSTALL CENTER SUPPORT WITH RUBBER GROMMET

Do not damage the rubber grommet during operation.

10. INSTALL END YOKE.

(a) Position the end yoke properly according to the marks.

34-15

Install the flat washer.

Tighten the nut.

Be sure to use a new nut.

11. INSPECT CENTER SUPPORT BEARING.

(a) Check whether the center support with rubber grommet can be rotated freely without deviation when

rotating it by hands.

(b) Replace with new center support bearing, bearing cup and support with rubber grommet assy if

12. ASSEMBLE MIDDLE U-JOINT OF PROPELLER SHAFT ASSY. (Refer to “Chapter 34 axle and

13. INSTALL PROPELLER SHAFT ASSY. (Refer to “Chapter 34 axle and propeller shaft - propeller

34-16

AXLE AND PROPELLER SHAFT - AXLE HUB AND STEERING KNUCKLE

AXLE HUB AND STEERING KNUCKLE

See the table below to help you find the cause of the problem. The numbers indicate the priority of the likely

Wandering / Pulling

1. Tire type (Incorrect)

2. Tire (Worn)

3. Tire pressure (Incorrect)

5. Axle hub bearing (Worn)

6. Front shock absorber

(Damaged)

7. Suspension (Loose or

Chapter 34 axle and propeller shaft - axle hub and

8. Steering tie rod (Loose or worn) Chapter 52 power steering - steering box, overhaul

Wheel vibration

9. Stabilizer bar (Bent or fractured)

1. Wheel (Unbalanced or worn

excessively)

2. Axle hub bearing (Worn)

4. B-joint (Worn)

Chapter 32 rear suspension - rear shock absorber,

Chapter 34 axle and propeller shaft - steering

knuckle, overhaul

5. Steering tie rod (Loose or worn) Chapter 52 power steering - steering box, overhaul

6. Steering box (Damaged) Chapter 52 power steering - steering box, overhaul

34-17

1. Power steering fluid level (Low)

2. Steering knuckle (Worn)

Chapter 52 power steering - power steering system,

on-vehicle inspection

Chapter 52 power steering - steering

fluid,replacement

Abnormal noise

3. Steering propeller shaft (Worn)

4. Power steering pump (Worn or

Chapter 52 power steering - power steering pump

5. Steering box (Damaged) Chapter 52 power steering - steering box, overhaul

34-18

1. INSPECT FRONT AXLE HUB BEARING.

Remove the front wheel assy. (Refer to “Chapter 33 wheel and tire - front wheel and tire, replacement”)

Remove the front disk brake caliper assy. (Refer to “Chapter 35 brake - front brake, overhaul”)

Open the lock-edge, loosen retaining snap ring.

Be sure to take care to operate,don’t destroy retaining snap

ring.

Use special tool to loosen retaining snap ring.

(d) Remove oil seal.

Discard the removed oil seal.

(e) Using dial indicator, measure the back lash around the

center of front axle hub.

Back lash: ≤ 0.2 mm

If the back lash is out of the specification, replace with new front

axle hub bearings.

• Measure the back lash by shaking the front axle hub

along the axial direction lightly.

• When performing the measurment, make the dial

indicator be close to the center of axle hub.

(f) Using dial indicator, measure the deviation at the edge of

front axle hub.

Deviation: ≤ 0.2 mm

If the deviation is out of the specification, replace with a new

• Measure the deviation by rotating the front axle hub

slowly.

• When performing the measurement, make the dial

indicator be close to the edge of axle hub.

34-19

Install oil seal.

Be sure to use new oil seal.

(h) Tighten retaining snap ring of hub bearing,lock the retaining

Don’t destroy the retaining snap ring

(i) Install the front disk brake.. (Refer to “Chapter 35 brake -

front brake, overhaul”)

(j) Install the front wheel assy. (Refer to “Chapter 33 wheel

and tire - front wheel and tire, replacement”)

2. INSPECT REAR AXLE HUB BEARING.

Check rear axle hub bearing when removed.

34-20

AXLE AND PROPELLER SHAFT - FRONT HUB

FRONT HUB

1. REMOVE THE FRONT WHEEL ASSY LH. (Refer to “Chapter 33 wheel and tire - front wheel and

tire, replacement”)

2. REMOVE THE FRONT DISK BRAKE CALIPER ASSY LH. (Refer to “Chapter 35 brake - front

brake, overhaul”)

3. REMOVE FRONT HUB LH.

(a) Open the lock-edge, loosen retaining snap ring.

Be sure to take care to operate, don’t destroy retaining

Remove tone wheel.

34-21

Remove internal hub bearing and oil seal of front hub,

wash and inspect internal hub bearing, if necessary,

Discard the removed internal bearing oil seal.

(d) Remove retaining plate.

(e) Remove external hub bearing, wash and inspect it, if

necessary, replace it.

Rear axle hub LH and axle shaft is an assy.

4. INSTALL FRONT HUB LH.

(a) Apply grease on steering knuckle LH.

• Be sure to use Alvania - RL3 grease.

• Apply the grease to the entire surface of steering knuckle LH.

Install external bearing.

Fill the grease into the bearings for more than 1/2.

(d) Apply grease to inside of retaining plate.

• The total amount of grease is 14 ~ 16 gram.

(e) Install external bearing.

34-22

(f) Fill the grease into the bearings for more than 1/2.

LH along the axial direction lightly.

indicator be close the center of axle hub.

(h) Install tone wheel.

Tighten retaining snap ring of hub bearing.

Don’t destroy retaining snap ring.

Install the front disk brake caliper assy LH. (Refer to

“Chapter 35 brake - front brake, overhaul”)

34-23

(k) Using dial indicator, measure the deviation at the edge of

front axle hub LH.

LH slowly.

indicator close to the edge of axle hub.

(l) Rotate the front axle hub LH by 2 ~ 3 turns.

(m) Using spring scale, measure the primal rotating force of

Primal rotating force: 5 N·m

If the primal rotating force is out of the specification, adjust the

front axle hub nut.

5. Install the front wheel assy LH. (Refer to “Chapter 33 wheel and tire - front wheel and tire,

6. REMOVE AND INSTALL FRONT AXLE HUB RH.

34-24

AXLE AND PROPELLER SHAFT - REAR AXLE HUB

1. Remove the rear wheel and tire assy LH. (Refer to “Chapter 33 wheel and tire - rear wheel and

2. REMOVE REAR BARE LH.(Refer to “Chapter 35 brake - rear brake, overhaul”)

3. REMOVE REAR HUB WITH AXLE SHAFT ASSY LH.

(a) Remove 2 mounting bolts attaching cable of parking

brake operation rear assy LH to brake backing plate.

Remove bolts from the front of the brake backing plate.

Remove tubing joint nut of rear brake LH, take out oil

tube of rear brake LH.

Undo bolt, remove wheel speed sensor.

Remove 4 nuts.

34-25

Remove rear axle hub with axle shaft LH and rear brake

backing plateLH.

4. INSTALL REAR AXLE HUB WITH AXLE SHAFT ASSY

LH.

(a) Using dial indicator, measure the back lash around the

center of rear axle hub LH.

If the back lash is out of the specification, replace with new rear

• Measure the back lash by shaking the rear axle hub

Insert the rear wheel hub and axle shaft into the rear axle

Apply No. 2 lithium base grease on six convex platform

plane of brake backing plate, don’t pollute working surface

of brake drum and brake shoes.

Tighten 4 mounting nuts.

Toque: 65 ~ 80 N·m6

(d) Using dial indicator, measure the deviation at the edge of

rear axle hub LH.

• Measure the deviation by rotating the rear axle hub

34-26

Position rear wheel speed sensor LH, tighten mounting

Connect rear brake fluid tube to rear wheel brake cylinder

LH, tighten the tubing joint nut.

Torque:21 ~ 24 N·m

Position the cable of parking brake operation rear assy

LH to brake backing plate,tighten 2 mounting bolts.

Install bolts from the front of the brake backing plate.

5. INSTALL REAR BRAKE LH. (Refer to “Chapter 35 brake - rear brake, overhaul”)

6. MEASURE THE PRIMAL ROTATING FORCE.

(a) Rotate the rear axle hub LH by 2 ~ 3 turns.

(b) Using spring scale, measure the primal rotating force of

7. INSTALL THE REAR WHEEL ASSY LH. (Refer to “Chapter 33 wheel and tire - rear wheel and tire,

34-27

8. BRAKE SYSTEM REFILLING AND BLEEDING. (Refet to “Chapter 35 braking system - brake fluid,

bleeding”)

9. REMOVE AND INSTALL REAR AXLE HUB RH.

34-28

AXLE AND PROPELLER SHAFT - STEERING KNUCKLE

2. REMOVE THE FRONT BRAKE DISK WITH AXLE HUB ASSY LH. (Refer to “Chapter 35 brake -

3. REMOE FRONT WHEEL SPEED SENSOR LH AND

BRACKET.

4. REMOVE STEERING KNUCKLE LH.

(a) Separate the steering tie rod B-joint LH from the steering

knuckle arm LH.

• Remove the cotter pin.

Discard the removed cotter pin.

• Remove the slotted nut.

Discard the removed slotted nut.

• Set the steering tie rod LH aside.

(b) Remove the lower control arm B-joint LH.

34-29

• Loosen the 4 sets of bolts and nuts.

Discard the removed bolts and nuts.

• Using hammer and copper rod, remove the lower control

arm B-joint LH.

34-30

Separate the steering knuckle LH from the upper control

• Loosen the slotted nut.

• Using hammer and copper rod, remove the steering

knuckle LH.

5. INSPECT B-JOINT.

(a) Check the contact area between steering tie rod B-joint

and steering knuckle arm.

• Apply red lead evenly to the steering tie rod B-joint shaft

and hole of steering knuckle arm.

• Insert the steering tie rod B-joint shaft into the hole of

steering knuckle arm, then pull it out again. Check the

contact area.

Standard: red area ≤ 3/4 shaft length,evenly

34-31

If any problem is found, replace with a new steering box and

steering knuckle arm. (Refer to “Chapter 52 power steering -

steering box, overhaul”)

(b) Check the contact area between lower control arm B-

joint and steering knuckle.

• Apply red lead evenly to the lower control arm B-joint

shaft and hole of steering knuckle.

• Insert the lower control arm B-joint shaft into the hole of

steering knuckle, then pull it out again. Check the contact

area.

If any problem is found, replace with a new lower control arm B-

joint and steering knuckle. (Refer to “Chapter 31 front

suspension - lower control arm, replacement”)

• Apply red lead evenly to the upper control arm B-joint

• Insert the upper control arm B-joint shaft into the hole of

If any problem is found, replace with a new lower control arm B -

suspension - upper control arm, replacement”)

6. INSTALL STEERING KNUCKLE LH.

(a) Install the upper control arm B-joint LH.

• Using hammer and copper rod, position the steering

knuckle LH properly.

• Tighten the slotted nut.

Torque: 110 ~ 115 N·m

Be sure to use a new slotted nut.

34-32

• Install the cotter pin.

Be sure to use a new cotter pin.

(b) Install the lower control arm B-joint LH.

• Using hammer and cooper rod, position the lower control

arm B-joint LH properly.

Align the holes of B-joint and lower control arm LH.

• Tighten the 2 sets of bolts and nuts fixing lower B-joint

with lower control arm .

Be sure to use new bolts and nuts.

and lower control arm and strut rod.

• Tighten the slotted nut fixing lower B-joint and steering

knuckle.

34-33

Connect the steering tie rod LH to the steering knuckle

arm LH.

• Insert the steering tie rod B-joint LH into the hole in

steering knuckle arm LH.

Torque: 84 ~ 100 N·m

7. INSTALL FRONT WHEEL SPEED SENSOR LH AND

9. INSTALL FRONT WHEEL ASSY LH. (Refer to “Chapter 33 wheel and tire - front wheel and tire,

10. REMOVE AND INSTALL STEERING KNUCKLE RH.

11. INSPECT FRONT WHEEL ANGLE. (Refer to “Chapter 31 front suspension - front wheel

alignment, adjustment”)

34-34

AXLE AND PROPELLER SHAFT - REAR AXLE

1. PRECAUTION ON MAITAINING FINAL DRIVE OIL.

(a) Be sure to use the specified final drive oil.

Final drive oil:

Type Grade Viscosity Capacity

Gear oil for weight-load

GL - 5 SAE 80W/90 2.5 L

(b) Be sure to replace the final drive oil regularly. (Refer to “Chapter 34 axle and propeller shaft - final drive

oil, replacement”)

• Replace with new final drive oil during the primal Level 2 maintenance.

• Replace with new final drive oil in the primal 40000 Km or 24 months.

• Replace with new final drive oil in the primal 80000 Km or 48 months. Then repeat this operation in

each following 50000 Km.

• Check the final drive oil for discolouration, thinning, etc.

If any fault is found, replace with new final drive oil. (Refer to “Chapter 34 axle and propeller shaft - final

drive oil, replacement”)

2. PRECAUTION ON MAINTAINING FINAL DRIVE ASSY.

(a) Be sure to check the vent plug regularly. Clean it when

• Remove and clean the vent plug during each level1

• The stuck vent plug may raise the oil pressure inside

the final drive assy, even cause leakage.

• Wash vent plug, check the final drive oil level

simultaneously.

(b) Disassemble and clean the final drive assy during the

Level 3 maintenance. Then assemble the final drive assy

according to the specification.

wear and tear. (Refer to “Chapter 35 brake - rear brake,

on-vehilce inspection”)

3. SERVICING PRECAUTION ON FINAL DRIVE ASSY.

(a) Be sure to replace the mating parts as a set.

34-35

(b) Discard all removed rubber parts (O-rings, oil seal, grommet, etc. ).

Uneven wear Eccentric wear Scratch Crack

Deformation Bend Bend Rusting

Discolouration

Invalidation or weakness

(Spring)

Abnormal noise (Bearing)

Deterioration (Brake

shoes)

When assembling the final drive assy, make sure all parts are clean without oil fouling and metal scrap.

Without special introduction, apply the final drive oil on the parts for lubrication before performing

Type Type Viscosity Capacity

4. PRECAUTION ON VEHICLE DRIVING.

(a) Never overload when driving vehicle.

(b) Never release the clutch pedal too quickly when vehicle driving.

Releasing the clutch pedal too quickly will strick the gear and cause damage.

34-36

Symptom Suspect area Reference

Continuous

knocking

(Turning)

(At high speed)

(Accelerating)

Intermittent

(Running)

(Final drive)

主减速器过热

Overheat

1. Side pinion thrust washer (Worn)

2. Side pinion (Worn)

1. Drive pinion, crown gear

(Excessive back lash or worn)

2. Drive pinion, crown gear

(Undersize back lash)

1. Axle shaft spline (Excessive back

lash or worn)

3. Final drive assy (Impurity entry)

1. Vent plug (Jam)

2. Final drive oil level (High)

3. Bolts (Loose or worn)

4. Final drive housing (Crack or

fracture)

1. Final drive oil level (Low)

3. Differential bearing (Too tight)

assy, overhaul

assy, inspection and adjustment

Chapter 34 axle and propeller shaft - axle shaft

Chapter 34 axle and propeller shaft - final drive oil,

Chapter 34 axle and propeller shaft - rear axle,

precaution

Chapter 34 axle and propeller shaft - final drive, onvehicle

Chapter 34 axle and propeller shaft - drive pinion,

4. Rear brake (Stuck) Chapter 35 brake - rear brake, overhaull

34-37

1. INSPECT DRIVE AXLE BASH LASH.

(a) Park the vehicle on level road with parking brake applied.

(b) Move transmission to neutral position and fully apply the parking brake.

(d) Separate the propeller shaft assy from pinion flange.

• Mark on the rear propeller shaft U-joint and pinion flange.

Make the marks are clear.

• Remove the 4 sets of nuts and bolts.

• Lower the propeller shaft and set it aside.

Support the propeller shaft with a bracket.

(e) Measure the drive axle back lash.

• Rotate counterclockwise the pinion flange by hand until it

becomes hard to rotate.

• Mark on the final drive housing and pinion flange.

34-38

• Rotate clockwise the pinion flange by hand until it

• The distance between the 2 marks is the drive axle back

lash.

(f) Connect the propeller shaft to pinion flange.

• Position the propeller shaft properly according to the

• Tighten the 4 sets of nuts and bolts.

2. CHECK FINAL DRIVE OIL LEVEL.

(a) Using a wrench, remove the filler plug.

Check the distance between the filler hole of final drive

and final drive oil level.

• Higher and lower final drive oil level can cause

problem.

• Fill or drain the final drive oil when necessary. (Refer

to “Chapter 34 axle and propeller shaft - final drive

34-39

Using a wrench, install the filler plug.

Torque: 15 ~ 25 N·m

3. CHECK FINAL DRIVE HOUSING.

(a) Check the final drive housing for crack, leakage, etc. Replace it when necessary.

34-40

AXLE AND PROPELLER SHAFT - FINAL DRIVE OIL

FINAL DRIVE OIL

Toque: 50 ~ 55 N·m

34-41

3. FILL FINAL DRIVE OIL.

Fill the final drive oil.

Check final drive oil level.

• Higher and lower gear oil level can cause problem.

Toque: 15 ~ 25 N·m

34-42

Install the vent plug.

AXLE SHAFT ASSY

AXLE AND PROPELLER SHAFT - AXLE SHAFT ASSY

34-43

1. REMOVE AXLE SHAFT ASSY LH.

(a) Remove the rear wheel assy LH. (Refer to “Chapter 33 wheel and tire - rear wheel and tire,

(b) Remove the rear brake LH. (Refer to “Chapter 35 brake - rear brake, overhaul”)

overhaul”)

Rear axle hub LH and axle shaft is a assy.

2. INSPECTION AXLE SHAFT ASSY.

runout of the axle shaft assy and flange end face runout.

Diameter runout: ≤ 0.3 mm

End face runout: ≤ 0.1 mm

If the diameter runout and end face runout are out of the

specification,correct the axle shaft assy. Replace the new one if

(b) Using magnetic testing method, inspect axle shaft

whether there is crack.

If any fault is detected, replace with a new axle shaft assy.

3. INSTALL REAR AXLE HUB LH.(Refer to “Chapter 34 axle and propeller shaft - rear axle hub,

4. REMOVE AND INSTALL AXLE SHAFT ASSY RH.

5. BRAKE FLUID REFILL AND BLEEDING. (Refer to “Chapter 35 brake system - brake fluid,

34-44

AXLE AND PROPELLER SHAFT - REAR AXLE HOUSING WELDING ASSY

REAR AXLE HOUSING WELDING ASSY

3. REMOVE REAR WHEEL ASSYS. (Refer to “Chapter 33 wheel and tire - rear wheel and tire,

4. REMOVE REAR BRAKES. (Refer to “Chapter 35 brake - rear brake, overhaul”)

5. DRAIN FINAL DRIVE OIL. (Rrefer to “Chapter 34 axle propeller shaft - final drive oil,

6. REMOVE REAR BRAKE TUBES ,PARKING CABLE

AND WHEEL SPEED SENSOR.

Before removing rear brake tubes, operate brake bleeding

firstly.

(a) Remove 2 bolts attaching cable of parking brake rear

assy LH to brake backing plate, remove cable bracket

mounting bolts and set the cable aside.

Remove 2 bolts attaching cable of parking brake rear

assy RH to brake backing plate, remove cable bracket

Remove brake tubing joint nut LH of rear axle, wheel

speed sensor mounting bolt and mounting bracket LH of

brake tube and wheel speed sensor.

34-45

Remove brake tubing joint nut RH of rear axle, wheel

Remove mounting bolt of upper brake tube and tubing

joint nuts LH .

Remove mounting bolts of brake tubes and wheel speed

sensor cable brackets that are located at the top and

center(LH and RH) of rear axle.

Take down and place brake tubes, wheel speed sensors

and brackets aside.

Make sure to prevent the brake tubes from deformation.

7. REMOVE AXLE HUB ASSYS LH AND RH. (Refer to “Chapter 34 axle and propeller shaft - rear

axle hub, overhaul”)

8. REMOVE AXLE SHAFT ASSY LH AND RH.(Refer to “Chapter 34 axle and propeller shaft - axle

9. REMOVE MAIN DIFFERENTIAL.

(a) Separate the propeller shaft assy from pinion flange.

34-46

Remove nuts and the final drive assy.

10. REMOVE REAR SUSPENSION. (Refer to “Chapter 32 rear suspension - rear leaf spring assy,

Support the propeller shaft with a bracket before removing.

11. REMOVE THE REAR AXLE WELDING HOUSING

12. INSPECT THE REAR HOUSING ASSY.

(a) Check rear axle welding housing for surface crack and oil leakage, replace it if nessary.

34-47

13. INSTALL REAR AXLE WELDING HOUSING ASSY.

(a) Support the housing to correct position with a bracket.

14. INSTALL REAR SUSPENSION. (Refer to “Chapter 32 rear suspension - rear leaf spring assy,

15. INSTALL MAIN DIFFERENTIAL.

(a) Position the final drive assy, tighten 10 mounting nuts.

Toque: 27 ~ 32 N•m

Install the propeller shaft properly according to the

Tighten the 4 set of nuts and bolts.

Toque: 70 ~ 79 N•m

Remove lifting and supporting devices.

16. INSTALL AXLE SHAFT ASSY LH AND RH.(Refer to “Chapter 34 axle and propeller shaft - axle

17. INSTALL AXLE HUB ASSYS LH AND RH. (Refer to “Chapter 34 axle and propeller shaft - rear

34-48

18. INSTALL REAR BRAKE TUBES ,PARKING CABLE

Position brake tubes, wheel speed sensor cables and

brackets.Tighten mounting bolts of brake tubes and

wheel speed sensor cable brackets that are located at

the top and center(LH and RH) of rear axle.

Tighten mounting bolt of upper brake tube and tubing

joint nuts LH.

Tighten brake tubing joint nut RH of rear axle, wheel

speed sensor mounting bolt and install mounting bracket

LH of brake tube and wheel speed sensor.

Torque: 21 ~ 24 N•m

Tighten brake tubing joint nut LH of rear axle, wheel

Tighten 2 bolts attaching cable of parking brake rear assy

RH to brake backing plate.Tighten cable bracket mounting

34-49

(f) Tighten 2 bolts attaching cable of parking brake rear

assy LH to brake backing plate.Tighten cable bracket

mounting bolts.

19. INTALL THE REAR BRAKE. (Refer to “Chapter 35 brake - rear brake, overhaul”)

20. INSTALL REAR WHEEL ASSYS. (Refer to “Chapter 33 wheel and tire - rear wheel and tire,

21. FILL THE FINAL DRIVE OIL. (refer to “Chapter 34 axle and propeller shaft - final drive oil,

22. FILL BRAKE FLUID. (Refer to “Chapter 35 brake system - brake fluid, bleeding”)

23. CONNECT BATTERY NEGATIVE CABLE.

34-50

AXLE AND PROPELLER SHAFT - DRIVE PINION

1. INSPECT PINION FLANGE.

(a) Using dial indicator, measure the pinion flange back lash.

Back lash: ≤ 0.1 mm

If the back lash is out of the specification, replace with new

pinion inner and outer bearing and collapsible spacer. (Refer to

“Chapter 34 axle and propeller shaft - drive pinion, overhaul”)

(b) Using dial indicator, measure the pinion flange deviation.

Deviation: ≤ 0.1 mm

pinion flange. (Refer to “Chapter 34 axle and propeller shaft -

drive pinion, overhaul”)

2. INSPECT PRELOAD.

(a) Open the lock plate.

(b) Loosen the pinion nut.

34-51

Tighten the pinion nut.

Torque: 196 N·m

Using a torque wrench, measure the primal rotating force

of drive pinion.

Primal rotating force: 1.3 ~ 2.2 N·m

Never loosen the pinion nut to reduce the primal rotating

force of drive pinion.

• If the primal rotating force is more than the specification,

replace with a new collapsible spacer. (Refer to “Chapter

34 axle and propeller shaft - drive pinion, overhaul”)

• If the primal rotating force is less than the specification,

perform the following operations.

Tighten the pinion nut further.

Torque (Increment): 13 N·m

Torque (Maximum): 343 N·m

of drive pinion again.

• If the primal rotating force is still less than the

specification, repeat step (e) ~ (f) until the primal

rotating force is within the specification.

specification when the pinion nut retaining torque

exceeds the maximum, replace with a new collapsible

spacer. (Refer to “Chapter 34 axle and propeller shaft

- drive pinion, overhaul”)

34-52

Fold the lock plate up.

BRAKING SYSTEMS

BRAKE SYSTEM ....................................................................... 35-1

PROBLEM SYMPTOMS TABLE ................................................ 35-02

BRAKE FLUID............................................................................. 35-04

BRAKE PEDAL........................................................................... 35-06

CYLINDER ASSY........................................................................ 35-14

VACUUM BOOSTER LINE ......................................................... 35-18

FRONT BRAKE........................................................................... 35-20

REAR BRAKE............................................................................. 35-26

ABS ACTUATOR ........................................................................ 35-37

WHEEL SPEED SENSOR........................................................... 35-40

PARKING BRAKE...................................................................... 36-1

PROBLEM SYMPTOMS TABLE................................................... 36-1

FRONT PARKING BRAKE OPERATION ASSY........................... 36-4

REAR PARKING BRAKE OPERATION ASSY ............................. 36-8

BRAKE SYSTEM ............................................................................... 35-1

PRECAUTION.............................................................................. 35-1

PROBLEM SYMPTOMS TABLE ....................................................... 35-2

BRAKE FLUID.................................................................................... 35-4

BLEEDING................................................................................... 35-4

BRAKE PEDAL.................................................................................. 35-6

COMPONENTS ........................................................................... 35-6

ADJUSTMENT............................................................................. 35-7

REPLACEMENT .......................................................................... 35-9

VACUUM BOOSTER WITH BRAKE MASTER

CYLINDER ASSY............................................................................. 35-14

OVERHAUL ............................................................................... 35-14

VACUUM BOOSTER LINE .............................................................. 35-18

REPLACEMENT ........................................................................ 35-18

FRONT BRAKE................................................................................ 35-20

OVERHAUL ............................................................................... 35-20

REAR BRAKE.................................................................................. 35-26

ON-VEHICLE INSPECTION ...................................................... 35-26

OVERHAUL ............................................................................... 35-27

ABS ACTUATOR ............................................................................. 35-37

REPLACEMENT ........................................................................ 35-37

WHEEL SPEED SENSOR................................................................ 35-40

REPLACEMENT ........................................................................ 35-40

BRAKE SYSTEM

BRAKE - BRAKE SYSTEM

35-1

1. BRAKE PRECAUTION

(a) Care must be taken to replace each part properly, because it could affect the performance of the brake

system and result in a driving hazard, replace with the parts which have the same part number or

equivalent.

(b) It is very important to keep parts and the area clean when repairing the brake system.

compressed air. Only use a water dampende towel to clean brake components.

(d) When removing or installing brake lines, use the pipeline nut wrench.

(e) Always tighten brake lines when installing.

35-2

BRAKE - PROBLEM SYMPTOMS TABLE

1. Brake fluid (Lacking) Chapter 35 brake - brake fluid, bleeding

2. Brake system (Leaking) -

Low pedal or spongy

pedal

3. Brake pad (Worn) Chapter 35 brake - front brake, overhaul

4. Brake master cylinder assy

(Failure)

Chapter 35 brake - vacuum booster with brake

master cylinder assy, overhaul

5. Brake system (Air in system) Chapter 35 brake - brake fluid, bleeding

6. Brake caliper (Failure) Chapter 35 brake - front brake, overhaul

1. Brake tube(Block) -

2. Brake cylinder (Sticking) Chapter 35 brake - rear brake, overhaul

Brake drag

3. Brake caliper (Sticking) Chapter 35 brake - front brake, overhaul

4. Axle hub bearing (Loose)

Chapter 34 axle and propeller shaft - axle hub

and steering knuckle, on vehicle inspection

5. Brake pedal free play (Out of

adjustment)

1. Tire (Improperly inflated)

Chapter 35 brake - brake pedal, adjustment

on vehicle inspection

2. Brake shoe (Oily) -

3. Brake shoe (Worn) Chapter 35 brake - rear brake, overhaul

4. Brake pad (Oily) -

Pull to one side

5. Brake pad (Worn) Chapter 35 brake - front brake, overhaul

6. Brake disk (Warped) Chapter 35 brake - front brake, overhaul

7. Brake drum (Warped) Chapter 35 brake - rear brake, overhaul

8. Brake caliper (Brake force

unequal)

9. Brake cylinder (Brake force

Chapter 35 brake - front brake, overhaul

Chapter 35 brake - rear brake, overhaul

1. Brake pad (Worn) Chapter 35 brake - front brake, overhaul

2. Brake caliper (Bolt loose) Chapter 35 brake - front brake, overhaul

Braking instability

3. Brake caliper mounting (Bolt

4. Brake caliper (Sticking) Chapter 35 brake - front brake, overhaul

5. Brake cylinder (Sticking) Chapter 35 brake - rear brake, overhaul

35-3

Lack of braking force

2. Brake shoe (Worn) Chapter 35 brake - rear brake, overhaul

3. Brake lines (Air in system) Chapter 35 brake - brake fluid, bleeding

35-4

BRAKE - BRAKE FLUID

BRAKE FLUID

BLEEDING

If any work is done on the brake system or if air in the brake lines is suspected, bleed the air from the

system.

Brake fluid: DOT3 or DOT4 brake fluid

35-5

35-6

BRAKE - BRAKE PEDAL

1 Flat Pin

2 Cotter Pin

5 Nut

3 Brake Pedal Assy

35-7

1. INSPECT BRAKE PEDAL HEIGHT.

(a) Inspect the height between brake pedal and floor.

Specification: 148 mm

2. ADJUST BRAKE PEDAL HEIGHT.

(a) Remove the stop lamp switch. (Refer to “Chapter 35 brake - brake pedal, replacement”)

(b) Disconnect the push rod from the brake pedal. (Refer to “Chapter 35 brake - brake pedal,

Loosen the lock nut, then adjust the brake pedal by

truning the push rod clevis. Tighten the lock nut after

adjusting.

(d) Connect the push rod to the brake pedal. (Refer to

“Chapter 35 brake - brake pedal, replacement”)

(e) Install stop lamp switch. (Refer to “Chapter 35 brake -

brake pedal, replacement”)

(f) Push the brake pedal down about 5 ~ 10 mm and turn

the stop lamp switch in the position where the stop lamp

goes off, then tighten the lock nut.

(g) After installation, check that stop lamp comes on when

depressing the brake pedal about 5 ~ 10 mm.

35-8

3. INSPECT BRAKE PEDAL FREE PLAY.

(a) Stop the engine and depress the brake pedal several

times until there is no more vacuum left in the vacuum

booster.

(b) Depress the brake pedal until the pedal resistance

begins to be felt, then inspect the brake pedal free play L.

Specification: 5 ~ 10 mm

35-9

2. REMOVE THE DASHBOARD(Refer to “Chapter 83 instrument panel - dashboard, replacement”)

3. REMOVE STOP LAMP SWITCH.

(a) Disconnect the connector from stop lamp switch.

(b) Loosen the lock nut from stop lamp switch.

4. DISCONNECT THE CONNECTION BETWEEN PUSH

ROD CLEVIS AND BRAKE PEDAL.

Remove the cotter pin and flat pin, then disconnect the

push rod clevis from brake pedal.

35-10

5. REMOVE BRAKE PEDAL AND BRACKET.

(a) Remove 4 mounting bolts of bracket and 4 lock nuts of

(b) Tack down the brake pedal and bracket.

6. REMOVE BRAKE PEDAL.

(a) Loosen the return spring.

The return spring is under great pressure. To avoid injury,

use caution when removing the return spring.

(b) Remove the lower mounting bolt attaching pedal to

35-11

Remove the brake pedal.

7. INSTALL BRAKE PEDAL.

Position the brake pedal.

Tighten mounting bolts attaching the pedal to bracket.

Install return spring and shaft sleeve, tighten return

spring bolts.

35-12

8. INSTALL BRAKE PEDAL AND BRACKET.

(a) Position brake pedal and bracket.

(b) Tighten 4 mounting bolts of bracket.

Diagonally tighten 4 bolts.

9. CONNECT PUSH ROD CLEVIS TO BRAKE PEDAL.

(a) Install the cotter pin roll and flat pin.

Make sure to use new cotter pin.

35-13

10. INSTALL STOP LAMP SWITCH.

(a) Install the stop lamp switch and tighten the lock nut of

stop lamp switch.

(b) Connect the connector to stop lamp switch.

Adjust the distance between stop lamp switch and brake

pedal. (Refer to “Chapter 35 brake - brake pedal,

11. INSPECT AND ADJUST BRAKE PEDAL HEIGHT. (Refer to “Chapter 35 brake - brake pedal,

12. INSPECT BRAKE PEDAL FREE PLAY. (Refer to “Chapter 35 brake - brake pedal, adjustment”)

35-14

BRAKE - VACUUM BOOSTER WITH BRAKE MASTER CYLINDER ASSY

VACUUM BOOSTER WITH BRAKE MASTER CYLINDER

2. DRAIN BRAKE FLUID COMPLETELY.

3. REMOVE WASHER ASSY.(Refer to “Chapter 65 wiper and washer - wssher assy, replacement”)

4. REMOVE VACUUM BOOSTER WITH BRAKE

MASTER CYLINDER ASSY.

(a) Disconnect the connector of Brake liquid level sensor,

and remove the sensor wire from bracket.

(b) Remove the brake fluid hosepipe from clutch master

(d) Pull out the vaccum booster pipe.

Remoe 4 mounting lock nuts of vaccum booster and

brake master sylinder assy.

35-15

Remove vaccum booster with brake master sylinder assy

and fluid reservior.

5. DISASSEMBLE VACCUM BOOSTER WITH BRAKE

MASTER SYLINDER ASSY AND FLUID RESERVIOR.

Remove 2 mounting nuts of brake master sylinder.

Disassemble vaccum booster and brake master cylinder.

Pull out mounting clip of brake fluid reservior.

Separate brake fluid reservior and brake master cylinder.

Brake masrer cylinder and fluid reservior can be removed

independently when brake fluid is drained completly.

35-16

6. CHECK BRAKE MASTER CYLINDER.

(a) Check the cylinder and seal ring for damage.

7. ASSEMBLE VACCUM BOOSTER WITH BRAKE

(a) Position brake fluid reservior.

(b) Insert the mountiong clip.

Connect vaccum booster and brake master cylinder.

Tighten 2 mounting nuts.

8. INSTALL VACCUM BOOSTER WITH BRAKE MASTER

SYLINDER ASSY.

(a) Position vaccum booster with brake master cylinder

(b) Tighten 4 lock nuts of vaccum booster with brake master

cylinder assy.

rod clevis to brake pedal.

35-17

Connect vaccum booster pipe.

Position brake tubes and tighten tubing joint nuts.

Connect the brake fluid hosepipe which connect to clutch

master cylinder and tighten the clamp.

Connect the connector of Brake liquid level sensor,and

fix the sensor wire to bracket.

9. INSTALL WASHER ASSY. (Refer to “Chapter 65 wiper and washer - wssher assy, replacement”)

10. FILL THE FLUID RESERVOIR WITH BRAKE FLUID.

11. BLEED BRAKE MASTER CYLINDER ASSY. (Refer to “Chapter 35 brake - brake fluid, bleeding”)

12. BLEED BRAKE LINES. (Refer to “Chapter 35 brake - brake fluid, bleeding”)

13. INSPECT AND ADJUST BRAKE PEDAL HEIGHT. (Refer to “Chapter 35 brake - brake pedal,

14. INSPECT AND ADJUST BRAKE PEDAL FREE PLAY. (Refer to “Chapter 35 brake - brake pedal,

15. CHECK FLUID LEVEL IN BRAKE FLUID RESERVOIR.

16. CHECK BRAKE FLUID FOR LEAKING.

17. CONNECT BATTERY NEGATIVE CABLE.

35-18

BRAKE - VACUUM BOOSTER LINE

VACUUM BOOSTER LINE

1. REMOVE WASHER ASSY.(Refer to “Chapter 65 wiper and washer - wssher assy, replacement”)

2. REMOVE VACCUM BOOSTER PIPE.

(a) Pull out the vaccum booster pipe from brake vaccum

(b) Loosen clamp,disconnect vaccum booster from clutch

vaccum booster.

Loosen clamp,disconnect vaccum booster from intake

mainfold of engine.

Along the pipeline end, loosen all fixed clamp.

Remove vaccum booster pipe.

Vaccum booster pipe is made up of two pipes,each one can

be replaced independently.

35-19

3. INSTLL VACCUM BOOSTER PIPE.

(a) Position vaccum booster pipe.

(b) Connect vaccum booster pipe to brake vaccum booster.

booster,and tighten clamp screw.

Connect vaccum booster pipe to intake mainfold of

engine,and tighten clamp screw.

(e) Along the pipeline end, fix all clamp.

4. INSTALL WASHER ASSY. (Refer to “Chapter 65 wiper and washer - wssher assy, replacement”)

35-20

BRAKE - FRONT BRAKE

1. REMOVE FRONT WHEEL LH. (Refer to “Chapter 33 wheel and tire - front wheel and tire,

3. REMOVE FRONT DISK BRAKE CALIPER ASSY LH.

(a) Remove screw and disconnect brake tube from front disk

brake caliper assy LH.

(b) Remove the 2 mounting bolts and front disk brake caliper

assy LH.

4. CHECK FRONT DISK BRAKE CALIPER ASSY FOR LEAKING,RUSTING AND SCORING,

REPLACE IF NECESSARY.

5. REMOVE FRONT BRAKE PAD ASSY LH.

(a) Remove outer brake pad assy LH.

35-21

Remove inner brake pad assy LH.

6. INSPECT BRAKE PAD THICKNESS.

(a) Measure the brake pad thickness.

Specification: 16 mm ~ 16.1 mm

Limit: 8 mm

7. REMOVE FRONT DISK BRAKE CALIPER MOUNTING

(a) Remove the 2 bolts and front disk brake caliper mounting.

35-22

8. INSPCTE DISK THICKNESS.

(a) Measure the disk thickness.

Specification: 28 ± 0.1 mm

(b) Measure the disk thickness difference.

The thickness difference of the plane in the same

circle ≤ 0.01mm

9. INSPECT FRONT DISK RUNOUT.

(a) Temporarily fasten the front disk with knuckle bolts.

(b) Measure the disk runout at the position where is 10 mm

away from the outer edge of the disk.

Ultimate value: 0.03 mm

maximum value, inspect the clearance of axle hub and

axle hub runout. If the clearance of axle hub and axle

hub runout is nomal, adjust the disk runout or grind it on

a “On-vehical” brake lathe.

10. REMOVE FRONT DISK LH.

(a) Remove 4 mounting bolts.

(b) Remove front disk with front axle hub.

35-23

Remove 6 mounting bolts.

Remove disk.

11. INSTALL FRONT DISK LH.

Select the installation position which the front disk has the

minimum runout.

(a) Install front disk to front axle hub,tighten 6 bolts.

Torque: 50 ~ 70 N•m

Checked the inner bearing, replace with a new axle hub if

necessary. (Refer to “Chapter 34 axle and propeller shaft -

Postion front disk with front axle hub and hub bearing,Tighten

4 mounting bolts.

Torque: 85 ~ 120 N•m

35-24

12. INSTALL FRONT DISK BRAKE CALIPER MOUNTING

(a) Install front disk brake caliper mounting and tighten 2

Torque: 30 ~ 35 N•m

13. INSTALL FRONT BRAKE PAD ASSY.

Install inner brake pad assy.

• Replace the anti-squeal shim when replacing the

brake pad.

• Keep the friction surface of brake pad and front disk

away from oil and grease.

Install outer brake pad assy LH.

35-25

14. INSTALL FRONT DISK BRAKE CALIPER LH.

Using a suitable tool, push the brake cylinder piston back.

Install the front disk brake caliper assy LH and tighten

the 2 nuts.

Torque: 90 ~ 110 N•m

Install brake tube and tighten plug.

15. REMOVE AND INSTALL FRONT BRAKE RH.

16. FILL THE FLUID RESERVOIR WITH BRAKE FLUID.

17. BLEED BRAKE MASTER CYLINDER ASSY. (Refer to “Chapter 35 brake - brake fluid, bleeding”)

18. BLEED BRAKE LINES. (Refer to “Chapter 35 brake - brake fluid, bleeding”)

19. CHECK FLUID LEVEL IN BRAKE FLUID RESERVOIR.

20. CHECK BRAKE FLUID FOR LEAKING.

21. INSATLL FRONT WHEEL LH. (Refer to “Chapter 33 wheel and tire - front wheel and tire,

35-26

BRAKE - REAR BRAKE

1. CHECK BRAKE SHOE THICKNESS.

(a) Remove the brake lining inspection hole plug and check

the brake shoe thickness through the brake lining

inspection hole.

35-27

1. RELEASE PARKING BRAKE.

2. REMOVE REAR WHEEL LH. (Refer to “Chapter 33 wheel and tire - rear wheel and tire,

3. DRAIN BRAKE FLUID COMPLETELY.

4. REMOVE REAR BRAKE DRUM AND WASHER LH.

5. REMOVE ADJUSTMENT SHEET AND TENSION

SPRING FOR PARKING BRAKE .

(a) Loosen tension spring of parking brake adjustment

sheet.

Remove adjustment sheet and tension spring for parking

brake.

6. LOOSEN BRAKE SHOE TENSION SPRING FROM

LEADING SHOE .

The parking brake tension spring is under great pressure.

To avoid injury, use caution when removing the parking

brake tension spring.

35-28

7. REMOVE LOWER TENSION SPRING ,RETAINING

PLATE AND RETURN SPRING.

Loosen lower tension spring from RH side.

Loosen lower tension spring and retaining plate from LH

side.

Remove lower tension spring and retaining plate.

Remove return spring.

8. REMOVE LEADING SHOE.

(a) Remove the leading shoe hold spring.

The leading shoe hold spring is under great pressure. To

avoid injury, use caution when removing the leading shoe

hold spring.

35-29

Remove the leading shoe.

9. INSPECT BRAKE SHOE THICKNESS.

Specification: 5 mm

Ultimate value: 1.5 mm

If the thickness is at the ultimate thickness or less, or if it

appears severe uneven wear, replace with a new brake

shoe.

10. REMOVE TRAILING SHOE.

(a) Remove the trailing shoe hold spring.

The trailing shoe hold spring is under great pressure. To

avoid injury, use caution when removing the trailing shoe

Remove the parking brake cable.

35-30

Remove the trailing shoe.

Remove parking brake shoe strut set and tension spring.

11. REMOVE REAR BRAKE AUTOMATIC ADJUSTING

LEVER AND PARKING BRAKE SHOE LEVER.

Remove the C-washer.

Remove the rear brake automatic adjusting lever.

Remove parking brake shoe lever.

35-31

12. INSPECT BRAKE SHOE THICKNESS.

13. INSPECT REAR BRAKE DRUM INSIDE DIAMETER.

Ultimate value: 254 ~ 254.2 mm

If the inside diameter is outside ultimate value, replace with

a new rear brake drum.

14. INSPECT REAR BRAKE DRUM AND BRAKE SHOE

FOR PROPER CONTACT.

Apply chalk to the inside of the rear brake drum, then

grind brake shoe on the surface of the drum. If the

contact between the rear brake drum and the brake shoe

is improper, repair brake shoe by a brake shoe grinder or

replace the rear brake drum.

15. REMOVE REAR WHEEL BRAKE CYLINDER ASSY

(a) Loosen tubing joint nut and disconnect the brake fluid

tube from rear wheel brake cylinder.

Remove the bleeder plug.

35-32

Remove the 2 bolts from rear wheel brake cylinder.

Remove rear wheel brake cylinder.

16. INSTALL REAR WHEEL BRAKE CYLINDER ASSY LH.

(a) Install the 2 bolts to rear wheel brake cylinder.

Install the bleeder plug.

Connect the brake fluid tube to rear wheel brake cylinder

and tighten the tubing joint nut.

35-33

17. INSTALL REAR BRAKE AUTOMATIC ADJUSTING

Install the rear brake automatic adjusting lever.

Install the parking brake shoe lever.

Install the C-washer.

18. INSTALL TRAILING SHOE.

(a) Install parking brake shoe strut set and tension spring to

trailing shoes.

(b) Connect the parking brake cable to parking brake shoe

spring.

Apply No. 2 lithium base grease on contact surface of

trailing shoe and wheel brake cylinder when installing

trailing shoe,Don’t pollut the working surface of brake drum

and shoe .

avoid injury, use caution when installing the trailing shoe

19. INSTALL LEADING SHOE.

(a) Install parking brake tension spring to leading shoe.

To avoid injury, use caution when installing the parking

(b) Install leading shoe to wheel brake cylinder,and install

parking brake shoe strut set to leading by rotating

leading shoe.

leading shoe and wheel brake cylinder when installling

leading shoe,Don’t pollut the working surface of brake

drum and shoe .

35-34

avoid injury, use caution when installing the leading shoe

20. INSTALL RETURN SPRING AND LOWER TENSION

SPRING , RETAINING PLATE .

(a) Install return spring.

The brake shoe return spring is under great pressure. To

Install retaining plate and lower tension spring.

The lower tension spring is under pressure. To avoid injury,

use caution when installing the leading shoe hold spring.

21. INSTALL ADJUSTMENT SHEET AND TENSION SPRING

FOR PARKING BRAKE.

(a) Install adjustment sheet for parking brake.

(b) Install tension spring of adjustment sheet.

The tension spring of adjustment sheet is under pressure.

To avoid injury, use caution when installing the leading

shoe hold spring.

35-35

22. INSPECT BRAKE SHOES AND REAR BRAKE DRUM

INSTALLATION.

Check that each part is installed properly.

Measure the inside diameter of rear brake drum and the

diameter of brake shoes. Inspect the clearance between

rear brake drum and brake shoes.

Specification: 0.5 mm

There should be no oil or grease adhering to the friction

surface between brake shoe and rear brake drum.

23. ADJUST CLEARANCE BETWEEN REAR BRAKE

DRUM AND BRAKE SHOES.

Remove the hole plug behind brake backing plate.

Adjust the clearance between brake shoes and rear

brake drum.

24. INSTALL REAR BRAKE DRUM AND WASHER LH.

35-36

25. FILL BRAKE FLUID INTO RESERVIOR.

26. BLEED BRAKE MASTER CYLINDER ASSY. (Refer to “Chapter 35 brake - brake fluid, bleeding”)

27. BLEED BRAKE LINE. (Refer to “Chapter 35 brake - brake fluid, bleeding”)

28. CHECK FLUID LEVEL IN BRAKE FLUID RESERVOIR. (Refer to “Chapter 35 brake - brake fluid,

29. CHECK BRAKE FLUID FOR LEAKING.

30. INSTALL REAR WHEEL LH. (Refer to “Chapter 33 wheel and tire - rear wheel and tire,

31. REMOVE AND INSTALL REAR BRAKE DRUM RH.

BRAKE - ABS ACTUATOR

35-37

ABS ACTUATOR

3. REMOVE FRONT BUMPER ASSY.(Refer to “Chapter 88 exterior and interior trim - front bumper,

4. REMOVE ABS ACTUATOR ASSY.

(a) Disconnect the connect from ABS actuator.

Remove 6 brake tubes from ABS actuator.

Make marks on the ABS actuator connecting fluid tube assy

in order to install them properly.

35-38

Remove ABS actuator.

Don’t destroy rubber washer of core pin at the bottom of

actuator and mounting nuts.

5. INSTALL ABS ACTUATOR.

(a) Position ABS actuator.

(b) Tighten 2 mounting nuts of ABS actuator.

as the marks show, and tighten tubing joint nuts.

Connect the connector to ABS actuator.

6. INSTALL FRONT BUMPER ASSY.(Refer to “Chapter 88 exterior and interior trim - front bumper,

7. CONNECT BATTERY NEGATIVE CABLE

8. FILL THE FLUID RESERVOIR WITH BRAKE FLUID.

9. BLEED BRAKE MASTER CYLINDER ASSY. (Refer to “Chapter 35 brake - brake fluid, bleeding”)

10. BLEED BRAKE LINE. (Refer to “Chapter 35 brake - brake fluid, bleeding”)

35-39

11. CHECK FLUID LEVEL IN BRAKE FLUID RESERVOIR. (Refer to “Chapter 35 brake - brake fluid,

12. CHECK BRAKE FLUID FOR LEAKAGE.

13. INSPECT ABS ACTUATOT BY SCAN TOOL. (Refer to “Chapter 04 diagnostics - anti-lock brake

system, pre-check”)

35-40

BRAKE - WHEEL SPEED SENSOR

WHEEL SPEED SENSOR

2. REMOVE FRONT WHEEL SPEED SENSOR LH.

(a) Remove mounting bolts of front wheel speed sensor LH.

(b) Disconnect the connector of wheel speed sensor LH.

(d) Remove front wheel speed sensor LH.

3. REMOVE REAR WHEEL SPEED SENSOR LH.

(a) Remove mounting bolts of rear wheel speed sensor LH.

Disconnect the connector of rear wheel speed sensor

Remove the clamp of rear wheel speed sensor wire LH.

Remove rear wheel speed sensor LH.

35-41

4. INSTALL REAR WHEEL SPEED SENSOR LH.

Install rear wheel speed sensor LH and tighten mounting

Connect the connector of rear wheel speed sensor LH.

Install the clamp and wire of rear wheel speed sensor

5. INSTALL FRONT WHEEL SPEED SENSOR LH.

Install front wheel speed sensor LH,tighten mounting

Connect the connector of front wheel speed sensor LH.

Install the clamp and wire of front wheel speed sensor

6. REMOVE AND INSTALL FRONT WHEEL SPEED SENSOR RH.

Remove and Install the RH side by the same procedures as the LH side.

7. REMOVE AND INSTALL REAR WHEEL SPEED SENSOR RH.

8. CONNECT BATTERY NEGATIVE CABLE.

9. INSPECT WHEEL SPEED SENSOR SIGNAL.

PARKING BRAKE SYSTEM.............................................................. 36-1

PROBLEM SYMPTOMS TABLE.................................................. 36-1

ADJUSTMENT............................................................................. 36-2

COMPONENTS ........................................................................... 36-3

FRONT PARKING BRAKE OPERATION ASSY............................... 36-4

REPLACEMENT .......................................................................... 36-4

REAR PARKING BRAKE OPERATION ASSY ................................. 36-8

REPLACEMENT .......................................................................... 36-8

PARKING BRAKE - PARKING BRAKE SYSTEM

36-1

PARKING BRAKE SYSTEM

1. Parking Brake cable(Sticking) -

2. Brake shoe clearance (Out of

3. Return spring (Damaged)

4. Parking brake tension spring

Chapter 36 parking brake - parking brake system,adjustment

Chapter 36 parking brake - front parking brake

operation assy, replacement

5. Parking brake return spring

36-2

1. REMOVE REAR WHEEL LH. (Refer to “Chapter 33 wheel and tire - rear wheel and tire,

2. INSPECT BRAKE SHOES AND REAR BRAKE DRUM INSTALLATION. (Refer to “Chapter 35 brake

- rear brake, overhaul”)

3. ADJUST SINGLE CLEARANCE BETWEEN REAR BRAKE DRUM AND BRAKE SHOES. (Refer to

“Chapter 35 brake - rear brake, overhaul”)

4. INSTALL REAR WHEEL LH. (Refer to “Chapter 33 wheel and tire - rear wheel and tire,

5. ADJUST BOTH CLEARANCE BETWEEN REAR

BRAKE DRUM AND BRAKE SHOES.

(a) Adjust both clearance between rear brake drum and

brake shoes at the same time by adjustment screw at the

parking brake rocker arm with bracket assy,until both

clearance pass muster.

36-3

Parking Brake Operation Handle With

Cable Assy

6 Clamp

7 Cable Bracket

Parking Brake Rocker Arm With Bracket

36-4

PARKING BRAKE - FRONT PARKING BRAKE OPERATION ASSY

FRONT PARKING BRAKE OPERATION ASSY

2. REMOVE PARKING BRAKE SHIELD ASSY. (Refer to “Chapter 83 instrument panel - dashboard,

3. REMOVE PARKING BRAKE SWITCH.

(a) Disconnect the connector from parking brake switch.

(b) Remove the parking brake switch.

4. REMOVE PARKING BRAKE OPERATION HANDLE

WITH CABLE ASSY.

Remove 2 upper mounting bolts.

Remove 2 lower mounting nuts

Remove 2 lower mounting bolts LH.

36-5

Disconnect cable of parking brake operation handle

with cable assy from parking brake rocker arm with

bracket assy.

Along the end of front parking brake operation assy,

remove all clamps, remove the clamp between front

parking brake cable and frame and the clamp between

front parking brake and the other cables.

Remove parking brake operation handle with cable

5. REMOVE PARKING BRAKE ROCKER ARM WITH

BRACKET ASSY.

(a) Disconnect cable of parking brake operation handle

(b) Remove return spring.

Disconnect cable of rear parking brake operation assy

LH/RH from parking brake rocker arm with bracket

Remove 2 mounting bolts fitting parking brake rocker

arm with bracket assy to frame.

Remove parking brake rocker arm with bracket assy.

6. INSTALL PARKING BRAKE ROCKER ARM WITH

Position parking brake rocker arm with bracket assy,

tighten 2 mounting bolts.

Connect cable of rear parking brake operation assy LH

to parking brake rocker arm with bracket assy.

36-6

Install return spring.

Connect cable of parking brake operation handle with

cable assy to parking brake rocker arm with bracket

7. INSTALL ARKING BRAKE OPERATION HANDLE WITH

CABLE ASSY.

(a) Position parking brake operation handle with cable assy

and tighten 2 lower mounting bolts LH.

Tighten 2 lower mounting nuts.

36-7

install the clamp between front parking brake cable and

frame and the clamp between front parking brake and

the other cables.

8. INSTALL PARKING BRAKE SWITCH.

(a) Install parking brake switch.

(b) Connect the connector to parking brake switch.

9. INSTALL PARKING BRAKE SHIELD ASSY. (Refer to “Chapter 83 instrument panel - dashboard,

10. CONNECT BATTERY NEGATIVE CABLE.

36-8

PARKING BRAKE - REAR PARKING BRAKE OPERATION ASSY

REAR PARKING BRAKE OPERATION ASSY

2. REMOVE REAR BRAKE LH. (Refer to “Chapter 35 barake - rear brake, overhaul”)

3. REMOVE REAR PARKING BRAKE OPERATION ASSY LH.

Disconnect the connecting between rear parking brake operation assy LH and rear brake actuator

lever. (Refer to” Chapter 35 brake - rear brake, overhaul”)

Remove 2 bolts fitting rear parking brake operation assy

LH to brake backing plate.

Remove bolts from the front of brake backing plate.

Disconnect rear parking brake operation assy LH from

parking brake rocker arm with bracket assy.

all brackets.

Remove rear parking brake operation assy LH.

4. INSTALL REAR PARKING BRAKE OPERATION ASSY

(a) Install 2 mounting bolts fitting rear parking brake operation

assy LH to brake backing plate.

Install bolts from the front of brake backing plate.

36-9

Connect rear parking brake operation assy LH to parking

brake rocker arm with bracket assy.

Connect rear parking brake operation assy LH to all

brackets.

Connect rear parking brake operation assy LH to rear

brake actuator lever. (Refer to” Chapter 35 brake - rear

5. INSTALL REAR BRAKE LH. (Refer to “Chapter 35 barake - rear brake, overhaul”)

6. INSTALL REAR WHEEL LH. (Refer to “Chapter 33 wheel and tire - rear wheel and tire,

7. REMOVE AND INSTALL REAR PARKING BRAKE OPERATION ASSY RH.

ABS ACTUATOR .........................................................................35-37

ADJUSTMENT(BRAKE PEDAL)....................................................35-7

ADJUSTMENT(FRONT WHEEL ALIGNMENT) ............................31-8

ADJUSTMENT(PARKING BRAKE SYSTEM) ...............................36-2

AIR FILTER ASSY ...................................................................... 14C-7

AXLE SHAFT ASSY.....................................................................34-43

BATTERY.................................................................................. 20C-18

BLEEDING(BRAKE FLUID) ...........................................................35-4

BRAKE FLUID................................................................................35-4

BRAKE PEDAL ..............................................................................35-6

BRAKE SYSTEM ...........................................................................35-1

CENTER SUPPORT BEARING...................................................34-12

COMPONENTS(BRAKE PEDAL) ..................................................35-6

COMPONENTS(COOLING SYSTEM)........................................ 17C-2

COMPONENTS(EXHAUST PIPE).............................................. 16C-1

COMPONENTS(FUEL SYSTEM) ............................................... 12C-4

COMPONENTS(INTAKE AIR SYSTEM) .................................... 14C-2

COMPONENTS(REAR SUSPENSION) ........................................32-2

COMPONENTS(STARTER) ..................................................... 20C-10

COMPOSITION(BATTERY)...................................................... 20C-18

COOLANT................................................................................... 17C-7

COOLING SYSTEM.................................................................... 17C-1

DIESEL ENGINE CONTROL SYSTEM ...................................... 11C-1

DRIVE PINION.............................................................................34-50

ELECTRONIC ACCELERATOR PEDAL .................................. 12C-20

ENGINE ACCESSORY BELT................................................... 15C-12

ENGINE CONTROL MODULE (ECM) ........................................ 11C-2

ENGINE MECHANICAL PART ................................................... 15C-1

ENGINE OIL................................................................................ 18C-2

FRONT BRAKE............................................................................35-20

FRONT PARKING BRAKE OPERATION ASSY............................36-4

FRONT SUSPENSION ..................................................................31-1

FRONT WHEEL ALIGNMENT .......................................................31-8

FRONT WHEEL AND TIRE ...........................................................33-8

FUEL FILLER CAP ....................................................... 12C-15, 13C-1

FUEL FILLER DOOR ................................................................ 12C-12

FUEL FILLER DOOR LOCK LATCH ASSY.............................. 12C-13

FUEL FILLING TUBE AND BREATHER TUBE ASSY ............. 12C-16

FUEL LEVEL SENSOR AND BRACKET ASSY ....................... 12C-10

FUEL SYSTEM ........................................................................... 12C-1

GENERATOR..............................................................................20C-4

INSPECTION(BATTERY)..........................................................20C-21

INSPECTION(DRIVE PINION).................................................... 34-50

INSPECTION(FUEL FILLER CAP) ...............................12C-15, 13C-1

INSPECTION(FUEL FILLING TUBE AND BREATHER

TUBE ASSY) .............................................................................12C-16

INSPECTION(PROPELLER SHAFT ASSY) ................................. 34-4

INTAKE AIR PIPE AND HOSE....................................................14C-4

INTAKE AIR SYSTEM.................................................................14C-1

INTERCOOLER INTAKE AIR PIPE ..........................................14C-11

LUBRICATION SYSTEM.............................................................18C-1

OIL FILTER .................................................................................18C-4

OIL PAN ......................................................................................18C-6

OIL PUMP ...................................................................................18C-7

ON VEHICLE INSPECT(COOLING SYSTEM) ...........................17C-5

ON-VEHICLE INSPECTION(FRONT SUSPENSION) .................. 31-7

ON-VEHICLE INSPECTION(REAR BRAKE) .............................. 35-26

ON-VEHICLE INSPECTION(REAR SUSPENSION)..................... 32-3

ON-VEHICLE INSPECTION(TIRE AND WHEEL ASSY) .............. 33-4

OVERHAUL(AXLE SHAFT ASSY).............................................. 34-43

OVERHAUL(CENTER SUPPORT BEARING) ............................ 34-12

OVERHAUL(ENGINE ACCESSORY BELT) .............................15C-12

OVERHAUL(FRONT BRAKE)..................................................... 35-20

OVERHAUL(GENERATOR)........................................................20C-4

OVERHAUL(OIL PUMP) .............................................................18C-7

OVERHAUL(REAR BRAKE) ....................................................... 35-27

OVERHAUL(REAR LEAF SPRING ASSY) ................................... 32-6

OVERHAUL(REAR SHOCK ABSORBER).................................... 32-4

OVERHAUL(STARTER)............................................................20C-11

OVERHAUL(VACUUM BOOSTER WITH BRAKE MASTER CYLIN-

DER ASSY) ................................................................................. 35-14

PARKING BRAKE SYSTEM ......................................................... 36-1

PRECAUTION(BRAKE SYSTEM)................................................. 35-1

PRECAUTION(COOLING SYSTEM) ..........................................17C-1

PRECAUTION(DIESEL ENGINE CONTROL SYSTEM).............11C-1

PRECAUTION(ENGINE MECHANICAL PART)..........................15C-1

PRECAUTION(FRONT SUSPENSION)........................................ 31-1

PRECAUTION(FUEL SYSTEM)..................................................12C-1

PRECAUTION(INTAKE AIR SYSTEM).......................................14C-1

PRECAUTION(LUBRICATION SYSTEM)...................................18C-1

PRECAUTION(PROPELLER SHAFT ASSY)................................ 34-1

PRECAUTION(STARTING AND CHARGING SYSTEM)............20C-1

PRINCIPLE(VEHICLE SPEED SENSOR) ..................................11C-8

PROBLEM SYMPTOMS TABLE ................................................... 35-2

PROBLEM SYMPTOMS TABLE(PARKING BRAKE SYSTEM) ... 36-1

PROBLEM SYMPTOMS TABLE(REAR SUSPENSION) .............. 32-1

PROBLEM SYMPTOMS TABLE(STARTING AND CHARGING SYS-

TEM)............................................................................................20C-2

PROBLEM SYMPTOMS TABLE(TIRE AND WHEEL ASSY) ....... 33-3

PROPELLER SHAFT ASSY.......................................................... 34-1

RADIATOR ................................................................................17C-14

REAR BRAKE ............................................................................. 35-26

REAR LEAF SPRING ASSY ......................................................... 32-6

REAR SHOCK ABSORBER.......................................................... 32-4

REAR SUSPENSION .................................................................... 32-1

REPLACEMENT(ABS ACTUATOR) ........................................... 35-37

REPLACEMENT(AIR FILTER ASSY) .........................................14C-7

REPLACEMENT(BATTERY).....................................................20C-24

REPLACEMENT(BRAKE PEDAL) ................................................ 35-9

REPLACEMENT(COOLANT)......................................................17C-7

REPLACEMENT(ELECTRONIC ACCELERATOR PEDAL) .....12C-20

REPLACEMENT(ENGINE ASSY)...............................................15C-2

REPLACEMENT(ENGINE OIL)...................................................18C-2

REPLACEMENT(EXHAUST PIPE) .................................16C-2, 16C-3

REPLACEMENT(FRONT PARKING BRAKE

OPERATION ASSY)...................................................................... 36-4

REPLACEMENT(FRONT WHEEL AND TIRE) ............................. 33-8

LATCH ASSY) ...........................................................................12C-13

REPLACEMENT(FUEL FILLING DOOR)..................................12C-12

REPLACEMENT(FUEL LEVEL SENSOR AND BRACKET

ASSY)........................................................................................12C-10

REPLACEMENT(INTAKE AIR PIPE AND HOSE) ......................14C-4

REPLACEMENT(INTERCOOLER INTAKE AIR PIPE) .............14C-11

REPLACEMENT(OIL FILTER) ....................................................18C-4

REPLACEMENT(OIL PAN) .........................................................18C-6

REPLACEMENT(RADIATOR)...................................................17C-14

REPLACEMENT(RESERVIOR) ..................................................17C-9

REPLACEMENT(VACUUM BOOSTER LINE) ............................ 35-18

REPLACEMENT(WHEEL SPEED SENSOR) ............................. 35-40

RESERVIOR ...............................................................................17C-9

STARTER..................................................................................20C-10

STARTING AND CHARGING SYSTEM......................................20C-1

TIRE AND WHEEL ASSY ............................................................. 33-1

ASSY........................................................................................... 35-14

VEHICLE SPEED SENSOR........................................................11C-8

WHEEL SPEED SENSOR .......................................................... 35-40

USE AND MAINTENANCE(BATTERY) ....................................20C-19

TRANSMISSION OPERATION MECHANISM ASSY ........................ 41-1

COMPONENTS ........................................................................... 41-1

REPLACEMENT .......................................................................... 41-3

TRANSMISSION ASSY(YANCHENGZHONGMA ZM001)................ 41-8

DIAGRAM OF COMPONENTS.................................................... 41-8

REPLACEMENT ........................................................................ 41-10

DISASSEMBLY AND ASSEMBLY............................................. 41-15

CLUTCH CASE ................................................................................ 41-39

DIAGRAM OF COMPONENTS.................................................. 41-39

SERVICE ................................................................................... 41-40

REAR PART ASSEMBLY................................................................ 41-43

DIAGRAM OF COMPONENTS.................................................. 41-43

SERVICE ................................................................................... 41-44

FORK SHAFT ASSEMBLY.............................................................. 41-48

DIAGRAM OF COMPONENTS.................................................. 41-48

SERVICE ................................................................................... 41-49

INPUT SHAFT ASSEMBLY ............................................................. 41-51

DIAGRAM OF COMPONENTS.................................................. 41-51

SERVICE ................................................................................... 41-52

OUTPUT SHAFT ASSEMBLY ......................................................... 41-54

DIAGRAM OF COMPONENTS.................................................. 41-54

SERVICE ................................................................................... 41-55

COUNTER SHAFT ASSEMBLY ...................................................... 41-62

DIAGRAM OF COMPONENTS.................................................. 41-62

SERVICE ................................................................................... 41-63

REVERSE SHAFT ASSEMBLY....................................................... 41-67

DIAGRAM OF COMPONENTS.................................................. 41-67

SERVICE ................................................................................... 41-68

SERVICE FOR OTHER IMPORTANT COMPONENTS OF TRANS-

MISSION.................................................................................... 41-70

TRANSMISSION ASSY(TANGSHANAIXIN) ................................... 41-73

REPLACEMENT ........................................................................ 41-73

41

TRANSMISSION - TRANSMISSION OPERATION MECHANISM ASSY

TRANSMISSION OPERATION MECHANISM ASSY

41-1

1 Shifting Control Lever Ball Assy

2 Dust Cover

3 Big Washer

4 Bolt And Spring Washer Set

5 Operation Mechanism Assy

41-2

1 Flexible Shaft Assy

2 Flexible Shaft Bracket Assy No.1

Bolt,spring Washer And Flat Washer

6 Flexible Shaft Bracket Assy No.2

7 Flexible Shaft Bracket Assy No.3

41-3

1. STOP THE ENGINE AND PARK THE VEHICLE ON LEVEL GROUND WITH PARKING BRAKE.

2. REMOVE TRANSMISSION SHIFTING CONTROL LEVER

BALL ASSY AND DUST COVER.

Using plastic ripping bar,pry off retaining trim frame of

transmission Shifting Control Lever dust cover.

Don’t destroy dust cover.

Remove shifting control lever ball assy by turning it

counterclockwise, and remove dust cover.

3. REMOVE DASHBOAD. (Refer to “Chapter 83 instrument panel - darshboad, replacement”)

4. REMOVE TRANSMISSION OPERATION MECHANISM

ASSY AND CABLES.

Disconnect flexible shaft of gear shifting cable from

transmission operation mechanism assy, then remove

cable clamp from transmission operation mechanism

Disconnect flexible shaft gear selecting cable from

41-4

Remove 4 mounting bolts of transmission operation

mechanism assy.

Remove transmission operation mechanism assy.

Remove 2 bolts fitting cables to lower body.

41-5

Remove cotter pin,disconnect flexible shaft of gear

shifting cable and flexible shaft of gear selecting cable

from transmission assy.

(g) Remove cables from brackets located at transmission

Along the end of cables,remove 1 cable clamp located at

the bottom of body and 2 clamps located at subframe.

Remove gear shifting cable and gear selecting cable

5. INSTALL TRANSMISSION OPERATION MECHANISM

(a) Position cables.

(b) Connect flexible shaft of gear shifting cable and flexible

shaft of gear selecting cable to transmission assy.

Tighten 2 bolts fitting cables to lower body.

41-6

Along the end of cables, install 1 cable clamp located at

Position transmission operation mechanism assy.

Tighten 4 mounting bolts.

(h) Install gear selecting cable clamp to transmission

operation mechanism assy,then connect flexible shaft of

gear selecting cable to transmission operation

• Make sure that the transmission operation mechanism

is in neutral position before connecting the flexible

shaft to it, or adjust it.

• Apply lithium base grease NO.3 to joint of transmission

operation michanism assy and flexible shaft of cable.

(i) Install gear shifting cable clamp to transmission

gear shifting cable to transmission operation mechanism

shaft to it,or adjust it.

6. INSTALL DASHBOAD. (Refer to “Chapter 83 instrument panel - darshboad, replacement”)

41-7

7. INSTALL TRANSMISSION SHIFTING CONTROL LEVER

Install dust cover, turn shifting control lever ball clockwise

in order to install it.

Install retaining trim frame of dust cover.

Don’t detroy dust cover.

8. INSPECT TRANSMISSION OPERATION MECHANIZE ASSY FOR SMOOTH SHIFTING, NO

STICKING AND LOOSENING.

41-8

TRANSMISSION - TRANSMISSION ASSY(YANCHENGZHONGMA ZM001)

TRANSMISSION ASSY(YANCHENGZHONGMA ZM001)

41-9

1 Ball head washer

2 Control lever cover assembly

3 Locating pin

4 Breather plug

5 Shift extension bar assembly

6 Dust cover

7 Shift lever spring cover

8 Shift lever spring

9 Sealing washer

10 Positioning mechanism assembly

11 Odometer driven gear assembly

12 Oil guiding groove

13 Shift block

14 Locating bolt of shift block

15 Steel ball

16 Self-locking spring

17 Plug

18 Oil storage box

19 Stopper pin

20 Shift shaft

21 Shift fork, lock and pin assembly

22 Shift lever

23 Odometer drive pinion retainer ring

24 Odometer drive pinion

25 Stopper

26 Stopper spring

27 Stopper shaft

28 Intermediate plate assembly

29 Case

30 Hexagon head plug

31 Sealing washer

32 Reverse switch assembly

33 Hexagon head screw plug

34 Front cover oil seal

35 Front cover

36 Bowl-shaped expansion plug

37 Clutch release fork assembly

38 Clutch release fork shield

39 Clutch case

40 Clutch release fork stud

41 Release bearing assembly

41-10

1. STOP THE ENGINE. PARK VEHICLE ON LEVELGROUND WITH PARKING BRAKE AND SHIFT IN

NEUTRAL POSITION.

3. LIFT VEHICLE.

4. REMOVE DRAIN PLUG BY DOWNSIDE AND DRAIN

5. DISCONNECT TRANSMISSION ASSY FROM OTHER

PARTS,THEN REMOVE TRANSMISSION ASSY.

(a) Remove crankshaft position sensor located at the top of

transimission.

Be careful not to be scalded by exhaust pipe.

Remove vehicle speed sensor located at the left of

transmission.

41-11

Remove the back-up lamp switch located at the right of

Remove the clutch slave cylinder assy. (Refer to “Chapter

42 clutch - clutch slave cylinder assy, replacement”)

Remove back nuts,disconnect flexible shaft of gear

Remove 2 mounting bolts of cable bracket and cable

bracket located at transmission case.

Remove 2 mounting bolts and 2 nut bolts of transmission

front cover and transmission front cover.

Remove starter. (Refer to “Chapter 20A starting and

charging - starter, overhaul”)

Remove propeller shaft assy. (Refer to “Chapter 34 axle

and propeller shaft - propeller shaft assy, overhaul”)

41-12

Remove 4 nuts and disconnect the transmission from

lifting lug.

• Use jack to support transmission assy and engine

before operation.

• Be careful not to be scalded by exhaust pipe.

Remove 5 bolts and disconnect transmission assy from

engine. Remove the transmission assy.

There are five bolts,one is used for retaining air condition

pipe, another one which isn’t installed temporarily is used

for retaining gear shifting cable bracket.

6. INSTALL TRANSMISSION ASSY, AND CONNECT OTHER

PARTS TO TRANSMISSION ASSY.

Support the transmission assy by jack and shift in one of

forward gears. Rotate the input shaft and align with the

spline of clutch disk at the same time. Then insert the

input shaft completely and shift in neutral position.

Adopt protective measures to prevent from injuring when

supporting by jack.

(b) Install bolts with hand to connect transmission to engine.

Support the transmission assy by jack and connect the

transmission assy to lifting lug. Install 4 bolts with hand.

(d) Tighten 4 nuts of lifting lug.

Torque:41 ~ 51N•m

41-13

Tighten bolts to connect transmission assy to engine.

Torque: 42.2 ~ 53.9 N•m

Diagonally tighten all bolts in order to install closely.

Install propeller shaft assy. (Refer to “Chapter 34 axle

Install starter. (Refer to “Chapter 20A starting and

Position transmission font cover,tighten 2 mounting bolts

and 2 nut bolts.

Torque: 7.8 ~ 9.8 N•m

Position cable bracket located at transmission case and

Tighten the through bolt which is used to connect transmission

to engine to 42.2 ~ 53.9 N•m.

(j) Position flexible shaft of gear shifting cable and flexible

shaft of gear selecting cable,then tighten mounting nuts.

Make sure the shift rocker arm in neutral before installation.

Torque: 22 ~ 28 N•m

Remove jack.

Install the clutch slave cylinder assy. (Refer to “Chapter

42 clutch - clutch slave cylinder assy,replacement”)

Install the back-up lamp switch located at the right of

41-14

Install vehicle speed sensor located at the left of

Install vehicle speed sensor located at the top of

7. REMOVE FILLER PLUG AND FILL TRANSMISSION

10. TRANSMISSION RUNNING - IN TEST.

(a) Keep the rotate speed around 1500 r/min; keep the fluid temperature upper 15 centidegree; without

load; keep transmission run more than 15 min in neutral position; keep transmission run more than 20

min in other positions.

(b) Inspect the transmission for smooth shifting.

(d) Check there is no leakage around trasmission.

(e) Drain out transmission fluid and clean inside of transmission after running-in test. Fill transmission fluid.

41-15

DISASSEMBLY AND ASSEMBLY

1. Place the transmission assembly on the

disassembling table, and shift the transmission in

neutral

Before disassembling the transmission assembly, drain the

lubricating oil inside, and disassemble the transmission after

cleaning the surface.

2. Dismantle the clutch case assembly

(a) Pull out the clutch release fork outward slightly, make the

clutch release fork leave the release bearing locating

snap spring.

(b) Push the clutch release fork outward for a certain

distance, which makes it released from the clutch

release fork spherical support pillar.

remove the separate bearing from input shaft gland.

Dismantle the fixing bolts connecting the clutch case and

transmission case.

When dismantling, evenly loose the fixing bolts along the

diagonal direction, and avoid omitted dismantlement.

Remove the clutch case assembly.

If the clutch case tightly connects with the transmission case,

knock the proper part of clutch case with rubber hammer, so as

to remove the clutch case.

41-16

3. Dismantle the front cover assembly

(a) Dismantle the fixing bolts on the transmission front cover.

Remove the front cover assembly.

If the front cover assembly tightly connects with the transmission

case, knock the proper part of front cover with rubber hammer,

so as to remove the clutch case.

4. Dismantle the variable speed control cover assembly

(a) Dismantle the locating mechanism components of gear

selecting lever and gear shifting lever, and remove the

sealing washer.

The locating mechanism components of gear selecting lever and

gear shifting lever should be two symmetrical components,

dismantle the two simultaneously as much as possible to

facilitate the dismantling of the following components.

Dismantle the fixing bolts of variable speed control cover

and rear part assembly.。

41-17

Remove the variable speed control cover assembly.

5. Dismantle the transmission rear part assembly

Dismantle the locating bolts of shift lever.

Dismantle the stopper spring plug, remove the stopper

spring and steel balls of fifth gear fork shaft with the bar

magnet.

Dismantle the fixing bolts of odometer driven gear

41-18

Remove the odometer driven gear assembly.

Dismantle the fixing bolts of rear case assembly

diagonal direction, and avoid deforming the case.

Remove the transmission rear case assembly.

Firstly, slowly remove a certain distance until the rear case

assembly released from the locating pin and the shift lever could

be seen, reverse the rear case assembly, make the shift lever

leave the groove of shift fork shaft, and then remove the rear

case assembly.。

6. Dismantle the transmission front case assembly

(a) Remove the input shaft and counter shaft front bearing

stop ringwith calipers.

41-19

Remove the transmission case assembly towards the

direction of input shaft end.

Slightly knock the transmission case with rubber hammer if

necessary, so as to separate the bearing from the case.。

7. Dismantle the odometer drive pinion

(a) Dismantle the outer retainer ring of odometer drive pinion

with calipers.

Remove the odometer drive pinion; dismantle the inner

retainer ring of odometer drive pinion.

8. Dismantle the control part of the intermediate plate

(a) Dismantle each locating bolt of fork shaft with Allen

wrench, remove the spring and steel ball with magnet

one by one.

41-20

Dismantle each fork, lock and pin assembly, elastic

cylindrical pin, locating screws of first and second shift

fork, clamping retainer ring.

When dismantling the shift fork, lock, pin and elastic cylindrical

pin, the available punch could be less than Φ5 (such as Φ4. 5),

the pin should be struck out from the other side of the figure.

When dismantling the fork shaft retainer ring or elastic cylindrical

pin assembly, avoid vigorous knocking, which may cause the

fork shaft bent or damaged.

the fifth gear shift fork, interlocking ball of fifth reverse

fork shaft.

Pull out fifth reverse lead block fork shaft and remove the

fifth reverse shift lead block.

Remove the interlock ball inside the intermediate plate

assembly with the bar magnet, dismantle the reverse

shift shaft and reverse shift block rocker assembly, and

after dismantling the reverse shift shaft, remove the

interlock pin.

41-21

Remove the interlock pin, dismantle the shift shafts of

first and second gears, remove the interlock pin inside

the intermediate plate assembly with the bar magnet.

Pull out the short interlock pin; dismantle the shift shafts

of third and fourth gears.

Remove the shift forks of first and second gears, and

shift forks of third and fourth gears upward.

9. Dismantle the moving part of intermediate plate

(a) Dismantle the retainer ring of fifth gear synchronous

bevel on the rear end of fifth counter shaft with calipers.

41-22

Remove the fifth gear synchronous bevel gear of the

counter shaft.

Dismantle the fifth gear synchronizer and fifth gear input

gear assembly of the counter shaft.

Remove the fifth gear needle bearing, fifth gear thrust

washer and locking ball (Φ6. 35) of the counter shaft.

Dismantle the retainer ring of output shaft fifth gear, and

remove the fifth gear. Dismantle the fixing bolts of output

shaft rear bearing backing plate with Allen wrench and

remove the output shaft rear bearing backing plate.

41-23

Dismantle the fixing bolts of the reverse gear rocker arm

bracket group.

Remove the reverse gear rocker arm bracket group.

Dismantle the fixing bolts of reverse gear idler shaft

pressing plate with wrench and remove the reverse gear

idler shaft pressing plate.

Pull out the reverse gear idler assembly and the reverse

gear idler shaft.

41-24

Dismantle the rear bearing stop rings of the output shaft

and counter shaft with calipers.

Dismantle the rear bearing of counter shaft with bearing

puller.

(l) Dismantle the counter shaft assembly from the

intermediate plate assembly.

Pull out the input shaft assembly (the roller pin inside the

shaft should not missed), and the gear ring of third and

fourth gears synchronizer.

41-25

Pull out the output shaft assembly, finish part of the

assembly disassembly.

10. Install the moving part of the intermediate plate

Vertically fix the intermediate plate assembly on the

working table, hold one end of the output shaft assembly,

knock the intermediate plate assembly with rubber

hammer at the same time, and install the output shaft

assembly into intermediate plate assembly.

Install the output shaft rear bearing stop ringwith snap

ring plier.

The stop ringshould be stuck with the intermediate plate

assembly, and avoid the excessive axial clearance of output

Press mount the input shaft bearing onto the input shaft;

install the input shaft retainer ring with snap ring plier.

41-26

Coat the lithium base grease in the input shaft needle

bearing hole, install the needle into the input shaft needle

bearing hole, install the third and fourth gear

synchronizer gear ring onto the input shaft.

The input shaft has totally 13 needle bearings, avoid any

omission.

Install input shaft onto the output shaft, and install the

three grooves of synchronizer ring corresponding with

the three slide blocks on the synchronizer.

Rotate the input shaft for several circles after installation, and

check whether it smooth and with proper clearance, if any

abnormal, pull out the input shaft and check whether the needle

bearings are working well.

Install the counter shaft into the intermediate plate

assembly and hold the counter shaft, install the counter

shaft rear bearing.

The bearing ring groove should be installed outward and avoid

reversely installing.

Install the count shaft rear bearing stop ringwith snap

assembly, and avoid the excessive clearance damaging other

parts.

41-27

Install the reverse gear idler assembly and the reverse

Rotate the idler shaft and make the pressing plate

corresponding with the idler shaft groove, and make the

pressing plate holes corresponding with the fixing bolt

holes of intermediate plate assembly, install the

connecting bolts of screw locking glue smeared idler

shaft locking tab and fasten to specified torque.

Torque: 15~20 N·m

Install the two hollow locating pins to the intermediate

plate assembly, and install the upper rocker arm bracket.

Smear appropriate screw locking glue on the fixing bolts

of rocker arm bracket assembly, install the intermediate

plate assembly from the other side and fasten.

Torque: 17~22 N·m

41-28

Smear the screw locking glue on the connecting bolts of

output shaft rear bearing, install the rear bearing

pressing plate with torque socket wrench and fasten the

screws.

Torque: 17~22 N·

Install fifth gear shaft retainer ring and output shaft fifth

gear.

Install the locking ball and fifth gear thrust washer.

After smearing the gear oil on counter shaft fifth gear

needle bearing, install in onto counter shaft.

(p)

Install counter shaft fifth gear input gear and fifth gear

synchronizer assembly.

Because the input gear needle bearing of counter shaft fifth gear

is semicircle bearing, avoid falling and omission when installing

the gear.

41-29

(q)

Cover the conical surface of fifth gear coupling gear with

synchronizer gear ring, install the fifth gear coupling gear,

align the synchronizer ring groove with the synchronizer

slide block and install.

(r)

Select a fifth gear synchronizer retainer ring which may

minimizes the axial clearance, install the fifth gear

synchronizer retainer ring with calipers.

(s)

Measure the axial clearance of counter shaft fifth gear

with feeler.

Standard clearance: 0. 1~0. 3 mm

Maximum clearance: 0. 3 mm

11. Install the control part of the intermediate plate

(a) Install the shift fork of first and second gears, and third

and fourth gears.

(b) Install the intermediate plate assembly and shift fork into

the shift shaft of third and fourth gears.

41-30

Knock the elastic cylindrical pin assembly into the third

and fourth gear shift fork with punch and hammer (the

opening direction of elastic cylindrical pin should be

towards the fork shaft axis).

Avoid vigorous knocking when installing the fork shaft retainer

ring or elastic cylindrical pin assembly, so as to prevent fork

shaft bent or damaged, and the fork shaft retainer ring or elastic

cylindrical pin assembly could also be installed in place by pliers.

Smear the interlock pin with grease, and install it on the

first and second gear shift shaft.

Install the short interlock pin into the intermediate plate

with the bar magnet, install the first and second gear shift

shaft into first and second gear shift fork and

Install the fixing bolts of first and second gear shift, fasten

Torque: 13~17 N·m

Smear the screw locking glue on the fixing bolts.

41-31

Install the reverse block, reverse lever and two E-rings

on the reverse gear rocker arm, the reverse arm open

end should be installed on the reverse gear rocker arm

Smear the grease on the interlock pin, and install it on

reverse shift shaft.

Install the interlock pin into intermediate plate assembly

with the bar magnet, and install the reverse shift shaft

into reverse lever and intermediate plate assembly.

Knock the elastic cylindrical pin assembly into the

reverse shift fork with punch and hammer (the opening

direction of elastic cylindrical pin should be towards the

fork shaft axis).

cylindrical pin assembly could also be installed in place by

pliers.。

Install the lock ball into the fifth reverse gear lead block

with the bar magnet, and install the fifth gear shift shaft.

Install the interlock ball into the intermediate plate

assembly with the bar magnet, install the fifth gear shift

shaft into the intermediate plate assembly.

41-32

Install fifth gear shift fork.

Knock the elastic cylindrical pin assembly into the fifth

gear shift fork one by one with punch and hammer (the

Install the fifth reverse shift shaft into the fifth reverse

shift block and intermediate plate assembly.

reverse shift block with punch and hammer (the opening

41-33

Knock the shift shaft retainer ring with steel bar or

hammer.

(r) Install the gear locating ball and spring (4 balls and 4

springs) into the intermediate plate assembly.

Install the short spring (fifth gear) into the bottom of intermediate

plate assembly, smear the screw locking glue on each hexagon

socket head bolts, fasten the plug to specified torque with Allen

12. Install the odometer drive pinion

(a) Install the retainer ring in odometer drive pinion in place

with calipers, put in the locking ball of odometer drive

pinion, and install the odometer drive pinion.。

Install the retainer ring in odometer drive pinion in place

41-34

13. Install transmission case

(a) Evenly smear the antioxidant sealant on the contacting

surface of transmission front case and intermediate plate

Install the transmission case on the intermediate plate

assembly, and ensure the shift fork shaft aligning with the

object lead hole. Knock the hard part of the front case

with rubber hammer if necessary, which could make it

install in place.

Install 2 stop rings on the input shaft bearing and counter

shaft front bearing with snap ring plier.

14. Install the case assembly, shift shaft and shift block

(a) Install the components inside the rear case before the

assembly, such as limiting mechanism, oil guiding

groove, and evenly smear antioxidant sealant on the

contacting surface of rear case and intermediate plate

When installing the rear case, align the select and shift lever with

select and shift lever shaft with hands and install in place, do not

fasten the fixing bolts of select and shift gear right now. Insert

the select and shift lever arm into the third and fourth gear fork

shaft groove, align the fifth reverse shift shaft with the rear case

installation hole, and push the rear case.

41-35

Install and fasten the fixing bolts on rear case.

Torque: 30~45 N·m

Vertically install the driven gear assembly of odometer.

nstall the fixing bolt of odometer driven gear assembly

and fasten to specified torque.

Install the fifth reverse guide block locating ball, self

locking spring and smear appropriate screw locking glue

on the threads of the hexagon socket head bolts and

41-36

Smear appropriate screw locking glue on the threads of

shift block locating bolt, install and fasten the shift block

fixing bolt.

15. After assembling the transmission front and rear housing, the followings should be checked.

(a) Check whether the input shaft and output shaft could rotate flexibly.

(b) Check whether each gear is clear and reliable, and whether there is reverse lock function.

16. Install the left locating mechanism components.

(a) Install the seal washer on the locating mechanism

Distinguish the left one and right one when installing, the left

locating mechanism components have smaller elastic force

(look the input shaft from the transmission output shaft).

(b) Fasten the locating mechanism components.

Torque: 30~50 N·

17. Install the transmission control lever cover

(a) Smear appropriate antioxidant sealant on the contacting

surface of transmission control lever cover and rear

case.

Install the fixing bolts of transmission control lever cover

41-37

18. Install the transmission front bearing cover

Install the oil seal into the front bearing cover.

Evenly smear the antioxidant sealant on the contacting

surface of transmission front bearing cover and front

case, and install the front bearing cover.

Smear appropriate sealant on the threads of hexagon

head bolt.

Install the bolts and fasten to specified torque.

19. Install the clutch cover

(a) Align and install the clutch case location hole to the

Install the fixing bolt of clutch case and fasten to

When fastening the bolts, diagonally fasten the bolts in several

times as much as possible, and avoid the case deformation or

case damage caused by unevenly forced bolts.

41-38

Install the clutch release fork, fork housing and release

20. Install the reverse switch, filling plug, drain plug

Torque: 30~50 N·m

21. Finish the disassembly and assembly of transmission assembly

CLUTCH CASE

TRANSMISSION - CLUTCH CASE

41-39

1 Clutch release fork housing

2 Clutch release fork assembly

4 Clutch release fork stud

5 Release bearing subassembly

3 Clutch case

41-40

1. Dismantle the clutch case assembly

(a) Unlock the spring fastener connecting the clutch release

bearing and the clutch release fork.

release fork support pillar.

release fork from the clutch case. This could avoid

dismantling the dust cover of clutch release fork.

Dismantle the coupling bolts connecting the clutch case

and the transmission case.

If the clutch case is tightly connected with the transmission case,

the rubber hammer could be used for knocking the clutch case,

Dismantle the clutch release fork support pillar.

41-41

Dismantle the clutch release fork housing

The clutch housing is soft gelatinous material, avoid using sharp

knives when dismantling

2. Install the clutch case assembly

(a) Install the clutch release fork housing.

Install the clutch release fork stud and fasten to specified

torque.

Align and install the location hole of clutch case to

41-42

Install the clutch case fixing bolt and fasten to specified

When installing, fasten the bolts evenly along the diagonal

direction for several times, and avoid housing deformation

during fastening.

3. Finish the service of clutch case

REAR PART ASSEMBLY

TRANSMISSION - REAR PART ASSEMBLY

41-43

5 Sealing washer

6 Locating mechanism components

7 Odometer driven gear assembly

8 Steel ball

9 Self-locking spring

10 Plug

15 Stopper pin

16 Shift shaft

17 Shift fork, lock and pin assembly

18 Shift lever

19 Stopper block

20 Stopper spring

21 Stopper shaft

11 Oil storage box

41-44

1. Dismantle the transmission rear part assembly.

(a) Pull out the gear selecting shaft and gear shifting shaft,

and remove the gear shifting block assembly.

Dismantle the fixing bolt of oil guiding groove.

Remove the oil guiding groove.

Dismantle the fixing bolts of oil storage box and remove

the oil storage box.

41-45

Dismantle the plug cover bolts of elastic cylindrical pin

with Allen wrench, and dismantle the elastic cylindrical

pin with proper drift pin.

Pull out the reverse limit assembly.

Strike out the shift fork, lock and pin assembly with

hammer and drift pin, dismantle the shift shaft and shift

Strike out the reverse limit pin with hammer and drift pin,

and dismantle the stopper block, stopper spring and

stopper shaft.

41-46

Check the wearing value of shift block; replace it if the

requirements are not satisfied.

Check the wearing of shift lever head; replace it if the

2. Assemble the transmission rear part assembly

(a) Assemble the stopper block, stopper spring and stopper

shaft, install the stopper pin in place with copper bar.

(b) Install the reverse limit assembly in place.

Install the plug cover bolts of elastic cylindrical pin in

place with Allen wrench.

41-47

of oil storage box, install the oil storage box and fasten

the fixing bolts to specified torque.

Torque: 5~10 N·m

Smear appropriate screw locking glue oil on the bolts of

guiding groove, install the oil guiding groove, and fasten

the fixing bolt to specified torque.

3. After assembling the rear case or transmission case, the followings should be checked

(a) Check whether the rotations of input shaft and output shaft are flexible.

4. Finish the service of transmission rear part assembly

41-48

FORK SHAFT ASSEMBLY

TRANSMISSION - FORK SHAFT ASSEMBLY

1 Elastic cylindrical pin

2 Fifth gear shift fork

3 Shift fork, lock and pin assembly

4 Fifth reverse gear shift guide block

5 Clamping ring

6 Short interlock pin

7 First and second gear shift shaft

8 Interlock guide pillar

9 Fifth reverse shift shaft

10 Third and fourth gear shift shaft

11 Interlock pin

12 Reverse gear shift fork shaft

13 Steel ball

14 Fifth gear shift fork shaft

15 Stopper spring screw plug

16 Stopper spring

17 Intermediate plate

18 First and second gear shift fork

19 Third and fourth gear shift fork

20 Reverse gear shift lever

Locating screw of first and second gear

shift fork

22 Reverse gear shift block

Reverse gear rocker arm bracket

24 Reverse gear rocker arm

25 Split washer

41-49

During the motion, the car jump to neutral, different to engage a gear, out of gear etc. it may be caused by:

• The fork axis circular groove excessively worn, the interlock pin excessively worn, the spring generated

elastic deformation.

• The fork working surface is excessively worn.

Due to these reasons, the following checks should be performed to the components of fork shaft assembly.

1. Check the free length of the self locking spring

Standard value: 31. 6 mm

Limitation value: 30. 1 mm

2. Check the wearing of locking ball.

3. Check the fork head thickness of fork

Standard value: 10. 00 mm

Limitation value: 9. 00 mm

4. Check the wearing of the connection between

moving shaft and intermediate plate assembly

41-50

5. Replace the damaged parts in time after checking.

6. Finish the service of fork shaft assembly

INPUT SHAFT ASSEMBLY

TRANSMISSION - INPUT SHAFT ASSEMBLY

41-51

1 Bearing shaft retainer ring

2 Bearing stop ring

4 Input shaft assembly

5 Needle bearing

3 Bearing

41-52

1. Dissemble the input shaft assembly

(a) Remove the needle bearings inside the input shaft one

by one, and place them in the proper places to avoid

missing.

Disassemble the snap ring inside the input shaft bearing

Pull out the input shaft bearing with bearing extractor.

2. Check the radial runout of input shaft bearing

Reference value of limitation: 0. 2 mm

41-53

3. Check the input shaft

(a) Check whether the shaft diameter of input shaft end worn

with vernier caliper; please replace the input shaft if

worn.

(b) Check whether the input shaft spline damaged; please

replace the input shaft if damaged.

4. Assemble the input shaft assembly

(a) Punch the input shaft bearing onto the input shaft, install

the input shaft retainer ring with snap ring plier.

Smear appropriate lithium base grease in the input shaft

needle bearing, install the needle into the input shaft, and

then install the third and fourth gear synchronizer gear

synchronizer ring trislot with the synchronizer block

andinstall.

5. Ensure the flexible rotation after installation.

6. Finish the service of input shaft assembly

41-54

OUTPUT SHAFT ASSEMBLY

TRANSMISSION - OUTPUT SHAFT ASSEMBLY

1 Fifth gear shaft retainer ring

2 Fifth gear

3 Output shaft rear bearing baffle plate

4 Output shaft rear bearing stop ring

5 Output shaft rear bearing

6 Intermediate plate

7 Steel ball

8 Output shaft

9 First gear

10 First gear bushing

11 First gear needle bearing

12 First-second gear synchronizer ring

First-second gear synchronizer spring

spreader ring

First-second gear synchronizer gear

hub

First-second gear synchronizer slide

block

sleeve

17 Second gear needle bearing

18 Second gear assembly

19 Third gear needle bearing

20 Third gear assembly

Third-fourth gear synchronizer gear

ring

Third-fourth-fifth gear synchronizer

spring spreader ring

Third-fourth gear synchronizer slide

26 Third-fourth gear hub retainer ring

41-55

1. Take out output shaft assembly from connecting

Take out the shaft and avoid damage of gears.

2. Disassembling output shaft assembly

(a) Fix the output shaft on the connecting plate.

(b) Disassemble the third-fourth gear hub retainer ring with

Take out third-fourth gear synchronizer.

Take out third gear assembly.

41-56

Take out third gear needle bearing.

Fix the output shaft upside down on the connecting plate.

Take out first speed gear.

Take out first speed gear needle bearing and first speed

gear bushing.

Take out first-second gear synchronizer assembly.

41-57

Take out second gear and second gear needle bearing.

3. Check on critical components on output shaft

According to Table of Fault Phenomena and analysis of possible damaged part, it needs to service certain part

as below:

Use dial indicator to check radial runout of second shaft.

Maximum: 0.1mm

Check the diameter of gear hole by bore dial indicator.

Reference wear maximum: 0.12mm

Other gears need to be checked with same way.

41-58

Check the gears and replace new one if there’s

excessive wear or snaggletooth.

Use thickness gauge to check the space between

synchronizer hub and synchronizer stopping plate.

Reference Maximum: 0.09~0.31 mm

Check the space between synchronizer geared teeth and

engaging teeth.

Standard value: 1. 0~1. 6 mm

Limit value: 0. 8 mm

Check the radial runout of output shaft rear bearing.

Reference Maximum: 0. 2mm

41-59

4. Assemble the output shaft assembly

When assembling, it’s necessary to dip lubrication oil on each

part in order to protect and assemble the parts easily.

(a) Fix the output shaft upside on the connecting plate and

assemble second gear assembly and second gear

needle bearing

Assemble first-second gear synchronizer according to

pictures.

The direction of first-second gear synchronizer is opposite to the

direction of output shaft. The side with fork groove should toward

to connecting plate. Two spring spreader ring should be

staggered to each other.

Fix first-second gear synchronizer assembly and firstsecond

gear synchronizer geared ring.

Dip lubrication oil on first speed gear bearing bush and

locking ball (Φ6.35) and assemble them on output shaft,

then assemble first speed needle bearing.

41-60

Install first speed gear.

Assemble third gear needle bearing.

Assemble third gear assembly.

Assemble third-fourth gear synchronizer and third-fourth

The side with 45° terrace of third -fourth gear synchronizer gear

hub should toward to input shaft. The side with big chamfer of

third -fourth gear synchronizer sleeve should toward to input

shaft. Two spring spreader rings should be staggered to each

other.

41-61

Fix third -fourth gear hub retainer ring with pliers.

Check axial clearance of each gears to see if it’s within

Axial clearance: 0. 1~0. 25 mm

5. Check the flexibility of input shaft and output shaft

6. Accomplish the process of servicing on output shaft

41-62

TRANSMISSION - COUNTER SHAFT ASSEMBLY

COUNTER SHAFT ASSEMBLY

Fifth gear synchronizer gear hub

retainer ring

2 Fifth gear connection gear

Third, fourth and fifth gear synchronizer

gear ring

Fifth gear synchronizer meshing gear

6 Counter shaft fifth gear assembly

7 Fifth gear synchronizer slide block

8 Middle fifth gear needle bearing

10 Counter shaft rear shaft retainer ring

11 Counter shaft rear bearing

12 Intermediate plate

14 Counter shaft

15 Counter shaft connecting gear

16 Counter shaft front bearing

17 Counter shaft front bearing stop ring

Counter shaft front bearing shaft

9 Fifth gear thrust washer

41-63

1. Dismantle the counter shaft assembly

Dismantle the counter shaft front bearing snap ring with

calipers.

Press out the counter shaft front bearing with pressure

Bearing extractor could be used for dismantling the bearing.

Check the counter shaft front bearing radial runout.

41-64

(d) Press out the counter shaft connecting gear with

pressure bracket.

2. Check on critical components on counter shaft

Use dial indicator to check radial runout of counter shaft.

Maximum: 0. 1mm

Reference wear maximum: 0. 12mm

Other gears need to be checked with same way

41-65

excessive wear or snaggletooth

Reference Maximum: 0. 09~0. 31 mm

3. Assemble the counter shaft assembly

(a) Press the counter shaft connecting gear in place with

41-66

Press the counter shaft front bearing in place with

Install the counter shaft front bearing snap ring in place

4. Check whether the counter shaft operate flexibly after installation.

5. Finish the service for counter shaft assembly

REVERSE SHAFT ASSEMBLY

TRANSMISSION - REVERSE SHAFT ASSEMBLY

41-67

1 Reverse gear idler shaft pressing plate

2 Reverse gear idler shaft

3 Reverse idler assembly

4 Intermediate plate

41-68

1. Dismantle the reverse shaft assembly

(a) Dismantle the fixing bolts of reverse gear idler shaft

pressing plate and remove the pressing plate of reverse

Rotate and pull out the reverse gear idler assembly and

the reverse gear idler shaft.

2. Check the parts of reverse shaft

According to Table of Fault Phenomena and analysis of possible damaged part, it need to service certain part

Use vernier caliper to check whether the gear bushing

bore worn, replace the gear bushing if any worn.

Check whether there is gear tooth worn, fatigue and

spalling, corrosion and spots, broken and etc. , please

replace the reverse gear if any.

41-69

Check whether the reverse shaft parts worn, replace it if

seriously worn.

3. Install the reverse gear idler shaft

(a) Install the reverse gear idler shaft assembly and the

reverse gear idler shaft.

(b) Rotate the idler shaft to make the pressing plate

pressing plate holes align with the intermediate plate

assembly fixing bolt hole. Install the idler shaft locking

plate smeared screw locking glue and fasten to specified

4. Finish the service for reverse shaft

41-70

SERVICE FOR OTHER IMPORTANT COMPONENTS OF TRANSMIS-

SION

According to Table of Fault Phenomena and analysis of possible damaged part, it’s needed to service certain

part as below:

1. Service for the front case

(a) Check the flatness of front case and intermediate plate

assembly contacting surface with steel ruler or feeler,

replace timely if could not meet the requirements, so as

to prevent transmission oil leakage.

When checking, please check with the steel ruler or feeler at

different directions and measure for several times, in order to

obtain an accurate value.

2. Service for the front cover

(a) Check the flatness of front cover and front case

contacting surface with steel ruler or feeler, replace

timely if could not meet the requirements, so as to

prevent transmission oil leakage.

Check the wearing extent of the front cover core

diameter with the vernier caliper, repair or replace timely

if could not meet the requirements.

41-71

3. Service for the rear case

(a) Check the flatness of rear case and transmission control

lever cover with steel ruler or feeler, replace timely if

could not meet the requirements, so as to prevent

transmission oil leakage.

(b) Check the flatness of check rear case and

intermediateplate assembly with steel ruler or feeler,

4. Service for the intermediate plate assembly

(a) Check the flatness of intermediate plate assembly with

steel ruler or feeler, replace timely if could not meet the

requirements, so as to prevent transmission oil leakage.

41-72

Check the wearing extent of the connecting holes on

intermediate plate assembly shafts with the vernier

caliper, repair or replace timely if could not meet the

5. Service for the variable speed control cover

(a) Check the wearing extent of the core diameter of variable

speed control cover with the vernier caliper, repair or

replace timely if could not meet the requirements.

6. Service for the clutch case

(a) Check the flatness of clutch case and front case

TRANSMISSION - TRANSMISSION ASSY(TANGSHANAIXIN)

41-73

TRANSMISSION ASSY(TANGSHANAIXIN)

4. REMOVE LOWER DRAIN PLUG RH AND DRAIN

TRANSMISSION FLUID COMPLETELY. TIGHTEN

Torque: 29.8 ~ 44.6 N•m

(a) Remove vehicle speed sensor located at the right of

(b) Remove the back-up lamp switch located at the upper of

transmission RH.

Remove nuts,disconnect flexible shaft of gear shifting

cable and flexible shaft of gear selecting cable from

(d) Remove 2 mounting bolts of cable bracket and cable

Remove the clutch slave cylinder assy. (Refer to

“Chapter 42 clutch - clutch slave cylinder assy,

Remove starter.(Refer to “Chapter 20B starting and

41-74

Remove 10 bolts and disconnect transmission assy from

2 bolts that is used for retaining starter include in these 10

removed bolts.

6. INSTALL TRANSMISSION ASSY, AND CONNECT

OTHER PARTS TO TRANSMISSION ASSY.

(b) Install 10 bolts with hand to connect transmission and

Two bolts that are used for retaining starter are not installed

temporarily.

41-75

M6 X 1.25

M10 X 1.25

Torque

78 ~ 96 N•m

45 ~ 55 N•m

(f) Install propeller shaft assy. (Refer to “Chapter 34 axle

(g) Install starter. (Refer to “Chapter 20B starting and

(h) Remove jack.

(i) Install the clutch slave cylinder assy. (Refer to “Chapter

Position flexible shaft of gear shifting cable and flexible

41-76

Install the back-up lamp switch located at the upper of

Remove vehicle speed sensor located at the right of

7. FILL TRANSMISSION FLUID AND TIGNTEN FILLER

75W/90 for 2.4 L.

• Parking the vehicle on the levelground when checking

fluid level. The fluid level must be with in 5 mm from

the lowest position of the filler plug.

CLUTCH SYSTEM ............................................................................. 42-1

PRECAUTION.............................................................................. 42-1

PROBLEM SYMPTOMS TABLE.................................................. 42-2

CLUTCH FLUID.................................................................................. 42-3

BLEEDING................................................................................... 42-3

CLUTCH PEDAL................................................................................ 42-4

COMPONENTS ........................................................................... 42-4

ADJUSTMENT............................................................................. 42-5

REPLACEMENT .......................................................................... 42-6

VACUUM BOOSTER WITH CLUTCH MASTER

CYLINDER ASSY............................................................................... 42-8

REPLACEMENT .......................................................................... 42-8

CLUTCH SLAVE CYLINDER........................................................... 42-11

REPLACEMENT ........................................................................ 42-11

CLUTCH SUB - ASSY...................................................................... 42-13

COMPONENTS ......................................................................... 42-13

OVERHAUL ............................................................................... 42-14

CLUTCH - CLUTCH SYSTEM

42-1

CLUTCH SYSTEM

1. CLUTCH SYSTEM PRECAUTION.

(a) To avoid spreading clutch dust, do not clean any clutch components with sand paper, dry brush or

compressed air. Only use a water dampened towel to clean clutch components.

42-2

1. Clutch pedal free play(Out of

Chapter 42 clutch - clutch pedal, adjustment

2. clutch driven disk (Worn) Chapter 42 clutch - clutch subassy, overhaul

Clutch slips

3. Flywheel ( Warped) Chapter 42 clutch - clutch subassy, overhaul

4. Clutch pressure plate with

cover assy (Warped)

Chapter 42 clutch - clutch subassy, overhaul

5. Diaphragm spring (Failure) Chapter 42 clutch - clutch subassy, overhaul

1. Clutch pedal free play (Out of

2. Diaphragm spring (Failure) Chapter 42 clutch - clutch subassy, overhaul

3. Clutch master cylinder

(Leaking)

Chapter 42 clutch - vacuum booster with

clutch master cylinder assy, replacement

Clutch does not disengage

4. Clutch slave cylinder (Leaking)

Chapter 42 clutch - clutch slave cylinder assy,

5. Clutch line (Air in line) Chapter 42 clutch - clutch fluid, bleeding

6. clutch driven disk (Worn) Chapter 42 clutch - clutch subassy, overhaul

7. Clutch pressure plate with

8. Clutch release bearing (Worn) Chapter 42 clutch - clutch subassy, overhaul

9. Clutch release fork (Worn) Chapter 42 clutch - clutch subassy, overhaul

1. Torsion spring (Fracture) Chapter 42 clutch - clutch subassy, overhaul

Clutch noisy

2. Clutch driven disk(Worn) Chapter 42 clutch - clutch subassy, overhaul

3. Clutch release bearing (Loose) Chapter 42 clutch - clutch subassy, overhaul

4. Clutch pedal (Warped) Chapter 42 clutch - clutch pedal, replaecment

1. Clutch driven disk (Worn or

warped)

2. Flywheel (Worn) Chapter 42 clutch - clutch subassy, overhaul

Clutch chatters

3. Clutch pressure plate with

cover assy(Worn)

4. Torsion spring (Fracture or

5. Diaphragm spring (Warped) Chapter 42 clutch - clutch subassy, overhaul

6. Engine mount (Loose) -

CLUTCH - CLUTCH FLUID

42-3

CLUTCH FLUID

1. FILL THE FLUID RESERVOIR WITH CLUTCH FLUID.

Clutch fluid: DOT3 or DOT4 brake fluid

Clutch fluid will damage painted surfaces and irritate skin. If

clutch fluid is spilled on any painted surfaces or skin, wash

2. BLEED CLUTCH SLAVE CYLINDER ASSY.

(a) Connect a hose to the bleeder plug.

(b) Depress the clutch pedal several times, then loosen the

bleeder plug with the pedal held down.

then release the clutch pedal.

(d) Repeat steps (b) and (c) until all the air in the system has

been bled out.

3. CHECK FLUID LEVEL IN FLUID RESERVOIR.

(a) Check the fluid level and fill the fluid reservoir with clutch

42-4

CLUTCH - CLUTCH PEDAL

1 Clutch Pedal Assy

2 Flat Pin

3 Cotter Pin

42-5

1. INSPECT CLUTCH PEDAL HEIGHT.

(a) Inspect the height H between the clutch pedal and floor.

Specification: 165 mm

2. ADJUST CLUTCH PEDAL HEIGHT.

(a) Loosen the lock nut and turn the stop bolt until the height

is correct. Tighten the lock nut.

Torque: 17 ~ 21 N•m

3. INSPECT CLUTCH PEDAL FREE PLAY AND PUSH

ROD PLAY.

(a) Depress the clutch pedal until the pedal resistance

begins to be felt. Inspect the clutch pedal free play L1.

(b) Gently depress the pedal until the pedal resistance

begins to increase a little. Inspect push rod play L2.

4. ADJUST CLUTCH PEDAL FREE PLAY AND PUSH

(a) Loosen the lock nut and turn the push rod until the clutch

pedal free play and push rod play are correct, and then

tighten the lock nut.

(b) After adjusting the pedal free play, inspect the clutch

pedal height.

42-6

2. REMOVE SREERING LOWER COVER. (Refer to “Chapter 83 instrument panel - darshboad,

3. REMOVE ALARM CONTROLLER. (Refer to “Chapter 85 door locks - alarm controller,

4. REMOVE FLAT PIN OF CLUTCH MASTER CYLINDER

PUSH ROD.

(a) Remove cotter pin of clutch master cylinder push rod.

Discard removed cotter pin.

(b) Remove flat pin of clutch master cylinder push rod.

5. REMOVE CLUTCH SWITCH.

(a) Disconnect the connector of clutch switch.

(b) Loosen nut,and remove clutch switch.

6. REMOVE CLUTCH PEDAL AND BRACKET.

(a) Remove 2 nuts of bracket in cab.

(b) Remove mounting bolt of bracket located at the top of

cab.

42-7

7. INSTALL CLUTCH PEDAL AND BRACKET.

(a) Position clutch pedal and bracket, tighten 2 mounting

nuts of bracket in cab.

(b) Tighten mounting bolt of bracker located at the top of the

8. INSTALL CLUTCH SWITCH.

(a) Position clutch switch.

(b) Tighten lower mounting nut.

9. INSTALL FLAT PIN OF CLUTCH MASTER CYLINDER

Install flat pin of clutch master cylinder push rod.

Install cotter pin of clutch master cylinder push rod.

10. INSTALL ALARM CONTROLLER. (Refer to “Chapter 85 door locks - alarm controller,

11. INSTALL SREERING LOWER COVER. (Refer to “Chapter 83 instrument panel - darshboad,

12. INSPECT AND ADJUST THE CLUTCH PEDAL HEIGHT. (Refer to “Chapter 42 clutch - clutch

pedal, adjustment”)

13. INSPECT AND ADJUST THE CLUTCH PEDAL FREE PLAY AND PUSH ROD PLAY. (Refer to

“Chapter 42 clutch - clutch pedal, adjustment”)

42-8

CLUTCH - VACUUM BOOSTER WITH CLUTCH MASTER CYLINDER ASSY

VACUUM BOOSTER WITH CLUTCH MASTER CYLINDER

4. REMOVE WASHER ASSY. (Refer to “Chapter 65 wiper and washer - washer assy, replacement”)

5. DRAIN CLUTCH FLUID COMPLETELY.

Clutch fluid will damage painted surfaces and irritate skin. If clutch fluid is spilled on any painted

surfaces or skin, wash it off immediately with water.

6. REMOVE VACUUM BOOSTER WITH CLUTCH MASTER

CYLINDER ASSY.

(a) Loosen the clamp,then disconnect the hose from vacuum

(b) Loosen the clamp,then disconnect the hose from fluid

reservoir.

Loosen the tube joint nut and disconnect the tube from

the clutch master cylinder.

Remove the cotter pin and flat pin of vacuum booster

with clutch master cylinder assy push rod.

(e) Remove 2 mounting nuts of vacuum booster with clutch

42-9

Remove vacuum booster with clutch master cylinder

7. DISASSEMBLE VACCUM BOOSTER WITH CLUTCH

MASTER SYLINDER ASSY.

Loosen the 2 retaining nut connect vacuum booster and

clutch master cylinder.

Disassemble vaccum booster and clutch master cylinder.

Clutch master cylinder can be replaced independently.

8. ASSEMBLE VACCUM BOOSTER WITH CLUTCH

MASTER SYLINDER ASSY

Assemble vaccum booster and clutch master sylinder.

9. INSTALL VACUUM BOOSTER WITH CLUTCH MASTER

Position vacuum booster with clutch master cylinder assy

and tighten 2 mounting nuts.

Install the cotter pin and flat pin of vacuum booster with

clutch master cylinder assy push rod.

42-10

Install the clutch master cylinder tube and tighten the

tube joint nut.

Install hose to fluid reservoir, and install clamp.

Install hose to vacuum booster,and install clamp.

10. FILL THE FLUID RESERVOIR WITH CLUTCH FLUID,THEN BLEED AIR FROM CLUTCH SYSTEM.

(Refer to “Chapter 42 clutch - clutch fluid, bleeding”)

11. INSPECT AND ADJUST THE CLUTCH PEDAL HEIGHT. (Refer to “Chapter 42 clutch - clutch

12. CHECK FLUID LEVEL IN CLUTCH FLUID RESERVOIR. (Refer to “Chapter 42 clutch - clutch fluid,

13. INSTALL WASHER ASSY. (Refer to “Chapter 65 wiper and washer - washer assy, replacement”)

14. INSTALL ALARM CONTROLLER. (Refer to “Chapter 85 door locks - alarm controller,

15. INSTALL SREERING LOWER COVER. (Refer to “Chapter 83 instrument panel - darshboad,

CLUTCH - CLUTCH SLAVE CYLINDER

42-11

CLUTCH SLAVE CYLINDER

1. DRAIN CLUTCH FLUID COMPLETELY.

2. REMOVE CLUTCH SLAVE CYLINDER ASSY.

(a) Loosen the screw, then disconnect the hose from clutch

slave cylinder.

Remove 2 bolts from the clutch slave cylinder.

Remove the clutch slave cylinder.

3. INSTALL CLUTCH SLAVE CYLINDER ASSY.

(a) Install clutch slave cylinder and tighten 2 bolts .

42-12

Connect the hose to the clutch slave cylinder and tighten

the screw.

Be sure to use a new washer.

4. FILL THE FLUID RESERVOIR WITH CLUTCH FLUID,THEN BLEED AIR FROM CLUTCH SYSTEM.

5. CHECK FLUID LEVEL IN CLUTCH FLUID RESERVOIR. (Refer to “Chapter 42 clutch - clutch fluid,

CLUTCH SUB - ASSY

CLUTCH - CLUTCH SUB - ASSY

42-13

1 Bolt

2 Spring Washer

Clutch Pressure Plate With Cover

5 Driven Disk Assy

6 Locating Pin

42-14

1. REMOVE TRANSMISSION ASSY. (Refer to “Chapter 41 transmission (YANCHENGZHONGMA

ZM001) - transmission assy, replacement”,“Chapter 41 transmission (TANGSHANAIXIN) -

2. REMOVE CLUTCH RELEASE BEARING AND CLUTCH

RELEASE FORK.

Remove clutch release bearing hub clip.

Remove clutch release bearing.

Remove clutch release fork.

3. REMOVE CLUTCH RELEASE FORK DUST BOOT.

42-15

4. REMOVE CLUTCH PRESSURE PLATE WITH COVER

Make sure the marks on the clutch pressure plate with

cover assy align with the one on the flywheel.

Diagonally loosen each bolt one turn at a time until

spring tension is released. Then remove 6 bolts.

Remove clutch pressure plate with cover assy.

Do not drop the clutch driven disk assy.

5. REMOVE CLUTCH DRIVEN DISK ASSY.

Keep the clutch driven disk away from oil and grease.

6. INSPECT CLUTCH DREVEN DISK ASSY.

(a) Measure the rivet head depth with a vernier caliper.

Replace the clutch dreven disk assy if necessary.

42-16

Measure the runout of the clutch dreven disk assy with a

dial indicator.

Check the surface of the disk for loose rivets, uneven

contact or adhesion of oil or grease. Replace with a new

part if necessary.

Check the torsion spring for clearance and wear. Replace

with a new part if necessary.

7. INSPECT CLUTCH PRESSURE PLATE WITH COVER

Measure the depth and width of diaphragm spring for

wear with a vernier caliper.

Measure the height of the diaphragm spring. Replace the

clutch pressure plate with cover assy if necessary.

Inspect the surface of the clutch pressure plate with

cover assy for wear and cracks. Replace clutch pressure

plate with cover assy if necessary.

Inspect the strap plate rivets for looseness. Replace the

8. INSPECT FLYWHEEL.

(a) Measure the runout of flywheel with a dial indicator.

Replace with a new part if necessary.

42-17

9. INSPECT CLUTCH RELEASE BEARING.

(a) Inspect the clutch release bearing for wear, noise or

improper rotation. Inspect the friction surface between

the clutch release bearing and the diaphragm spring for

wear.

The bearing is permanently lubricated and requires no

cleaning or lubrication.

• Inspect the inside and outside surface for wear or

damage. Replace with new part if necessary.

• Inspect the friction surface of clutch release bearing

and release fork for wear. Replace with new part if

10. INSPECT CLUTCH RELEASE FORK.

(a) Inspect the position of the clutch release fork as shown

by arrows for wear and shape change. Replace if

11. INSTALL CLUTCH DRIVEN DISK ASSY.

(a) Install the clutch driven disk assy with a special tool.

Take care not to install the clutch driven disk assy in the

wrong direction.

(b) Apply 2 lithium grease to spline of cltch driven disk, don’t

pollute other parts of driven disk and pressure plate .

42-18

12. INSTALL CLUTCH PRESSURE PLATE WITH COVER

Install the clutch pressure plate with cover assy with a

Diagonally tighten all 6 bolts of clutch ressure plate with

cover assy.

13. INSPECT AND ADJUST CLUTCH PRESSURE PLATE WITH COVER ASSY.

(a) Inspect the height of the diaphragm spring after installation. Adjust the tip of the diaphragm spring if

14. INSTALL CLUTCH RELEASE FORK DUST BOOT.

42-19

15. INSTALL CLUTCH RELEASE BEARING AND CLUTCH

Apply grease to the release fork in the areas indicated by

the arrows.

Lubricating grease: Mitsubishi pure lubricating

grease NO. 0101011 or same product.

Install clutch release fork.

Install the clutch release fork to the release fork support.

Apply grease to the friction surface between the clutch

release bearing and the release fork before installation.

(d) Install clutch release bearing hub clip.

16. INSTALL TRANSMISSION ASSY. (Refer to “Chapter 41 transmission (YANCHENGZHONGMA

ZM001) - transmission assy, replacement”,“Chapter 41 transmission (TANGSHANAIXIN)-

STEERING SYSTEM.......................................................................... 51-1

PRECAUTION.............................................................................. 51-1

PROBLEM SYMPTOMS TABLE.................................................. 51-2

COMPONENTS ........................................................................... 51-5

ON-VEHICLE INSPECTION ........................................................ 51-6

STEERING WHEEL ASSY................................................................. 51-7

ADJUSTMENT............................................................................. 51-7

OVERHAUL ................................................................................. 51-8

COMBINATION SWITCH ASSY ...................................................... 51-12

COMPONENTS ......................................................................... 51-12

REPLACEMENT ........................................................................ 51-13

STEERING COLUMN ASSY............................................................ 51-16

OVERHAUL ............................................................................... 51-16

STEERING PROPELLER SHAFT ASSY......................................... 51-19

REPLACEMENT ........................................................................ 51-19

51

STEERING SYSTEM

COLUMN

STEERING COLUMN - STEERING SYSTEM

51-1

1. STEERING SYSTEM PRECAUTION.

(a) Take care when replacing parts, always comply with the instructions of this manual.

(b) Incorret replacement may affect the performance of the steering system and result in traffic accident.

2. PRECAUTIONS ON SRS SYSTEM.

(a) Some vehicles are equipped with SRS (Supplemental Restraint Sysem) such as the driver airbag.

(b) Failure to carry out service operation in the correct sequence could cause the SRS to unexpectedly

deploy during servicing, even a serious accident.

to read the precaution for the supplemental restraint system. (Refer to “Chapter 62 supplemental

restraint system - supplemental restraint system, precaution”)

51-2

1. Front axle (Overloaded) -

2. Tire (Insufficient pressure)

3. Power steering fluid (Low)

Chapter 33 tire and wheel - tire and wheel, onvehicle

Chapter 52 power steering - steering fluid,

4. Steering fluid reservior (Filter jammed) -

Steering heavily

5. Hydraulic circuit (Leaking)

6. Steering pump belt (Loose or skid)

7. Front wheel alignment (Incorrect)

8. Steering knuckle (Worn)

9. Steering knuckle arm (Worn)

10. Ball joint (Worn)

11.Steering column (Bent)

12.Steering propeller shaft (Deformed)

13.Power steering pump (Worn or

14.Steering box (Damaged)

15.Power steering line assy (Jammed)

Chapter 52 power steering - steering box,overhaul

Chapter 52 power steering - power steering

system, on-vehicle inspection

Chapter 51 steering column - steering column

shaft assy, overhual

pump, replacement

Chapter 52 power steering - steering box,

overhual

line assy, replacement

51-3

1. Power steering fluid (Low)

2. Tire (Different pressure)

3. Steering knuckle (Loose or worn)

instability

4. Steering knuckle arm (Loose or worn)

5. Steering column (Loose or worn)

6. Steering propeller shaft (U-joint loose or

worn)

7. Steering box (Loose or damaged)

1. Tire (Insufficient pressure)

2. Steering pump belt (Loose or skid)

3. Hydraulic circuit (Invading air)

4. Return hose (Curving or jammed)

assy, overhual

bleeding

Poor return

5. Front wheel alignment (Incorrect)

6. Steering column (Bent)

7. Steering propeller shaft (Deformed)

8. Power steering pump (Worn or

9. Steering box (Damaged)

51-4

Excessive

steering wheel

free play

1. Steering wheel (Worn)

2. Steering propeller shaft (loose or worn)

3. Steering knuckle (Worn)

4. Ball joint (Worn)

5. Front hub bearing (Worn)

6. Steering box (Loose or damaged)

Chapter 51 steering column - steering wheel

Chapter 34 axle and propeller shaft - axle hub,

2. Steering fluid reservior (Filter jam) -

Steering not

smooth

4. Steering knuckle (Worn)

5. Steering propeller shaft (Worn)

6. Power steering pump (Worn or

7. Steering Box (Damaged)

8. Power steering line assy (Jam)

2. Hydraulic circuit (Invading air)

3. Steering column (Worn)

4. Steering propeller shaft (Worn)

5. Steering box (Worn or damaged)

51-5

1 Nut

2 Steering Wheel Assy

3 Steering Column Assy

6 Steering Propeller Shaft Assy I

8 Screw

9 Cloumn Base Frame Assy

10 Bolt, Spring Washer

12 Steering Propeller Shaft Assy II

13 Steering Retarder Assy

7 Steering Propeller Shaft Protection Cover

51-6

1. CHECK STEERING WHEEL FREE PLAY.

(a) Stop the vehicle.

(b) Turn the steering wheel to its straight position and face the

tires straight ahead.

steering wheel free play.

Free play: ± 10 °

If the free play is out of the specification, then:

• Inspect interrelated parts. (Refer to ”Chapter 51 steering

column - steering system, problem symptoms table”)

• Inspect the maximum front wheel steering angle, adjust it if

necessary. (Refer to “Chapter 31 front suspension - front

wheel alignment, adjustment”)

2. CHECK THE VEHICLE DEVIATION.

(a) Drive straightly the vehicle and along the center line of the road at 50Km/h speed.

(b) Release the steering wheel and continue traveling straightly for 100 m.

Offset LH: < Half Car Body

Offset RH: < Half Car Body

If the checking value is out of specification, there is fault on the off track for this vehicle.

STEERING COLUMN - STEERING WHEEL ASSY

51-7

STEERING WHEEL ASSY

1. STEERING WHEEL UP-DOWN ADJUSTMENT.

(a) Pull the handle down to position as shown.

Adjust the steering wheel up and down.

Adjustable distance: 27 mm

• Be sure to adjust the steering wheel towards your

chest, instead of the head or neck.

• Simultaneously adjust the driver seat. make sure the

distance between steering wheel and your chest.

(Refer to “Chapter 84 seat - Driver / assistant driver

seat, adjustment”)

• Do not perform this operation when the vehicle is

running.

Make sure the steering wheel is locked completely without

51-8

1. PRECAUTION. (Refer to “Chapter 51 steering column - steering system, precaution”)

2. DISCONNECT BATTERY NEGATIVE CABLE. (Refer to “Chapter 20 starting and charging -

battery, replacement”)

3. DISCONNECT BATTERY POSITIVE CABLE. (Refer to “Chapter 20 starting and charging - battery,

4. REMOVE DRIVER AIRBAG ASSY.

(a) Turn the steering wheel to its straight position and face the

Using a inner hex spanner, loosen 2 bolts at the bottom

of steering wheel.

Turn the driver airbag assy over.

Disconnect the driver airbag connector.

• Do not drag the clock spring wire harness.

• Do not disassemble the driver airbag assy.

• Driver airbag assy should be stored with the top

surface upward. Also, do not put any things on top

surface of driver airbag assy.

51-9

5. REMOVE STEERING WHEEL ASSY.

(a) Disconnect the driver airbag connector.

(b) Loosen the nut.

Store it carefully to prevent it from being missing.

Mark on the steering wheel and steering column assy.

(d) Pull out the steering wheel from the steering column.

6. INSPECT STEERING WHEEL ASSY.

(a) Check the steering wheel for warp, micro-cracks or fracture.

(b) Check the spline for deformation or damaged above 2 teeth. If any fault is detected, replace it with a

new steering wheel.

7. INSTALL STEERING WHEEL ASSY.

(a) Align the marks on the steering wheel assy and steering

column assy.

(b) Install the steering wheel to steering column.

• Be sure to perform this procedure according to the

• Make sure the tires face ahead straightly.

51-10

(d) Connect the clock spring wire harness connector.

8. INSPECT STEERING WHEEL TURNING FORCE.

(a) Using a spring scales, pull the steering wheel rim tangentially,

measure the steering wheel turning force (engine stopped).

Steering wheel turning force (engine stopped): < 300 N

If steering wheel turning force exceeds the maximum, inspect

interrelated parts. (Refer to “Chapter 51 steering column -

steering system, problem symptoms table”)

For measurment, turn the steering wheel to both sides in

the range of 80°.

9. INSTALL DRIVER AIRBAG ASSY.

(a) Connect the driver airbag connector.

WANING

• Never use the airbag parts removed from another

vehicle. When replacing, use a new one.

• If the driver airbag assy has been dropped, or there

are cracks, dents or any faults in the case or connector,

replace the driver airbag assy with a new one.

• Do not drag the clock spring wire harness. Make

sure the wire harness does not interfere with parts

around.

If hear a “click”, the connector is connected completely.

Install the driver airbag assy to steering wheel.

51-11

• There should be no interference between the driver

airbag assy and steering wheel.

• The clearance should be uniform all the way around

when the driver airbag assy is installed on the

steering wheel.

Using a inner hex spanner, tighten 2 bolts at the bottom

10. CONNECT BATTERY POSITIVE CABLE.(Refer to “Chapter 20 starting and charging - battery,

11. CONNECT BATTERY NEGETIVE CABLE. (Refer to “Chapter 20 starting and charging - battery,

12. INSPECT SRS WARNING LIGHT.

51-12

STEERING COLUMN - COMBINATION SWITCH ASSY

COMBINATION SWITCH ASSY

1 Light Switch Assy

2 Wiper Switch Assy

3 Combination Switch Upper Cover

5 Ignition Switch Assy

6 Combination Switch Lower Cover

7 Screw

4 Ignition Switch Keyring Assy

51-13

4. REMOVE DRIVER AIRBAG ASSY. (Refer to “Chapter 51 steering column - steering wheel assy,

5. REMOVE STEERING WHEEL ASSY. (Refer to “Chapter 51 steering column - steering wheel assy,

6. REMOVE COMBINATION SWITCH ASSY.

(a) Loosen 2 screws.

Remove combination switch upper and lower cover.

Disconnect the front combination lamp switch connector.

Remove the front combination lamp switch.

51-14

Disconnect the wiper and washer switch connector.

Remove the wiper and washer switch.

7. INSTALL COMBINATION SWITCH ASSY.

(a) Install the wiper and washer switch.

(b) Connect the wiper and washer switch connector.

Install the front combination lamp switch.

Connect the front combination lamp switch connector.

Install combination switch upper and lower cover.

Make sure the covers are positioned properly.

Tighten 2 screws.

51-15

8. INSTALL STEERING WHEEL ASSY. (Refer to “Chapter 51 steering column - steering wheel assy,

9. INSTALL DRIVER AIRBAG ASSY. (Refer to “Chapter 51 steering column - steering wheel assy,

10. CONNECT BATTERY POSITIVE CABLE. (Refer to “Chapter 20 starting and charging - battery,

11. CONNECT BATTERY NEGATIVE CABLE. (Refer to “Chapter 20 starting and charging - battery,

12. INSPECT COMBINATION SWITCH ASSY FUNCTION.

51-16

STEERING COLUMN - STEERING COLUMN ASSY

STEERING COLUMN ASSY

3. DISCONNECT BATTERY POSITIVE CABLE.

6. REMOVE CLOCK SPRING. (Refer to “Chapter 62 supplemental restraint system - clock spring,

7. REMOVE COMBINATION SWITCH ASSY. (Refer to “Chapter 51 steering column - combination

switch assy, replacement”)

8. REMOVE STEERING COLUMN LOWER COVER.

(a) Remove store content box.

(b) Remove the steering column lower cover.

9. REMOVE IGNITION SWITCH ASSY. (Refer to “Chapter 91 vehicle control system - removal&installation and

disassembly&reassembly”)

10. REMOVE STEERING COLUMN ASSY.

(a) Mark on the steering column and steering propeller shaft

I.

Remove the bolt.

51-17

Pull the steering propeller shaft I down from the steering

Remove 3 bolts.

Remove 2 harness clips.

Remove the steering column assy.

• When storage, cover the splines with gum cap or soft cloth

on the both sides to prevent damage.

• Be sure to store the steering column carefully, especially

the splines.

11. INSPECT STEERING COLUMN ASSY.

(a) Check the spline shaft.

• Check for rusting, crack and fracture.

• Check for deformation or damage for more than 2 teeth.

• If any fault is detected, replace with a new steering column assy.

12. INSTALL STEERING COLUMN ASSY.

(a) Positon the steering column assy properly.

(b) Tighten 3 nuts.

Torque: 29 ~ 35 N·m

Install the steering propeller shaft to the steering column

assy according to the marks.

Be sure to perform this operation according to the marks.

51-18

(e) Tighten the bolt.

13. INSTALL IGNITION SWITCH ASSY. (Refer to “Chapter 91 vehicle control system - removal&installation

and disassembly&reassembly”)

14. INSTALL STEERING COLUMN LOWER COVER.

(a) Install the steering column lower cover.

(b) Install the steering propeller shaft cover.

15. INSTALL CLOCK SPRING. (Refer to “Chapter 62 supplemental restraint system - clock spring,

16. INSTALL STEERING WHEEL ASSY. (Refer to “Chapter 51 steering column - steering wheel assy,

17. INSTALL DRIVER AIRBAG ASSY. (Refer to “Chapter 51 steering column - steering wheel assy,

18. CONNECT BATTERY POSITIVE CABLE. (Refer to “Chapter 20 starting and charging - battery,

19. CONNECT BATTERY NEGATIVE CABLE. (Refer to “Chapter 20 starting and charging - battery,

20. INSPECT SRS WARNING LIGHT.

STEERING COLUMN - STEERING PROPELLER SHAFT ASSY

51-19

STEERING PROPELLER SHAFT ASSY

1. REMOVE THE STEERING COLUMN ASSY.(Refer to “Chapter 51 steering column - steering wheel assy,

2. REMOVE STEERING PROPELLER SHAFT I ASSY.

Mark on the steering propeller shaft I and the steering

retarder.

Pull the steering propeller shaft I up.

Disconnect from the steering retarder.

Be sure to store the steering propeller shaft carefully to

prevent damage, expecially the splines.

3. REMOVE STEERING PROPELLER SHAFT COVER ASSY.

(a) Loosen 4 mounting nuts.

(b) Remove steering propeller shaft cover assy.

4. REMOVE STEERING RETARD ASSY.

(a) Loosen 3 mounting bolts.

(b) Remove steering retard support.

51-20

Remove steering retard assy mounting bolts.

Loosn the steering propeller shaft II upper bolt.

Remove the steering retard assy.

prevent damage, expecially the splines, do not turn the

steering drive shaft.

5. REMOVE STEERING PROPELLER SHAFT II ASSY.

(a) Remove the bolt.

(b) Disconnect the steering propeller shaft II and steering

gear assy.

6. INSPECT THE STEERING COLUMN ASSY.

(a) Check the steering column assy for bend.

Replace with a new steering propeller shaft if necessary.

(b) Inspect the splines, splined sleeves and U-joint yoke.

• Check for warp, micro-cracks or fracture.

If any fault is detected, replace with a new steering propeller shaft assy.

• Check whether the U-joint rolls smoothly.

• Check bearing seals and cover failure.

• Check universal joint cross shaft journal indentation, flaking, eccentric wear and cracks.

• Check universal joint smooth rotation.

Replace with a new steering propeller shaft when necessary.

• Measure the clearance between the cross shaft necks and bearings.

Clearance: ≤ 0.2 mm

If the clearance exceeds the manximum, replace with a new steering propeller shaft.

51-21

7. INSTALL THE SEERING PROPELLER SHAFT II ASSY.

Install the steering propeller shaft II to the steering gear

assy to the marks.

Tighten the bolt.

8. INSTALL STEERING RETARD ASSY.

(a) Install the steering propeller shaft II to the steering retard

(b) Tighten 1 bolt.

Tighen 2 steering retard assy mounting bolts.

Tighten 3 steering retard assy cover bolts.

9. INSTALL STEERING PROPELLER SHAFT COVER ASSY.

(a) Tighten 4 steering propeller shaft mounting bolts.

51-22

10. INSTALL STEERING PROPELLER SHAFT I.

and the steering retard according to the marks.

11. INSTALL THE STEERING COLUMN ASSY.(Refer to “Chapter 51 steering column - steering wheel

assy, overhaul”)

POWER STEERING SYSTEM ........................................................... 52-1

PRECAUTION.............................................................................. 52-1

PROBLEM SYMPTOMS TABLE.................................................. 52-2

COMPONENTS ........................................................................... 52-5

ON-VEHICLE INSPECTION ........................................................ 52-7

STEERING FLUID............................................................................ 52-13

REPLACEMENT ........................................................................ 52-13

BLEEDING AND PURIFYING.................................................... 52-15

POWER STEERING PUMP WITH FLUID RESERVIOR ASSY....... 52-17

REPLACEMENT ........................................................................ 52-17

POWER STEERING LINE ASSY..................................................... 52-22

REPLACEMENT ........................................................................ 52-22

STEERING GEAR ASSY ................................................................. 52-28

OVERHAUL ............................................................................... 52-28

STEERING FLUID RESERVIOR...................................................... 52-33

REPLACEMENT ........................................................................ 52-33

52

POWER STEERING -

POWER STEERING SYSTEM

STEERING

52-1

1. PRECAUTION ON POWER STEERING SYSTEM.

(b) Incorrect replacement may affect the performance of the steering system and result in driving

dangerously.

2. PRECAUTION ON MAINTAINING THE POWER STEERING SYSTEM.

(a) Be sure to use the specified steering fluid.

Steering fluid: ATF- Ⅲ

(b) Replace the steering fluid and clean the fluid reservior filter in the primal 2500 Km for a new steering

gear assy. Then repeat these two operations in each following 5000 Km or 1 year. (Refer to “Chapter 52

power steering - steering fluid, replacement”)

(Refer to “Chapter 52 power steering - power steering system, on-vehicle inspection”)

(d) Regularly check at least each 5000 Km.

• Check for loose.

• Check steering system operation.

52-2 POWER STEERING - POWER STEERING SYSTEM

1. Overloaded -

3. Power steering fluid level (Low)

5. Hydraulic Circuit (Leaking)

6. Steering Pump (Loose or skid)

10. B-joint (Worn)

11. Steering column (Bent)

12. Steering propeller shaft (Deformed)

13. Power steering pump (Worn or

14. Steering gear assy (Damaged)

15. Power steering line assy (Jammed)

Chapter 52 power steering - steering gear

Chapter 31 front suspension - lower control

arm, replacement

Chapter 51 steering column - steering

propeller shaft assy, overhaul

52-3

Steering instability(Can

not keep

straight lane)

steering gear assy

overheat

(It exceeds the

enviromental

temperature more

than 65 ℃ )

3. Steering knuckle (Loosen or worn)

4. Steering knuckle arm (Loosen or worn)

6. Steering propeller shaft (U-joint loose

or worn)

7. steering gear assy (Loose or

1. Overload -

2. Operation (Incorrect)

(Residence more than 4 seconds at the

limit position on both sides)

3. Power steering pump (Exsessive flow)

4. Power steering line assy (Deformed or

jammed)

3. Hydraulic cicuit (Invading air)

bleeding and purifying

assy, inspection

9. steering gear assy (Damaged)

52-4 POWER STEERING - POWER STEERING SYSTEM

2. Steering propeller shaft (U-joint loose

6. steering gear assy (Loose or

2. Steering fluid reservior (Filter jammed) -

7. steering gear assy (Damaged)

8. Power steering line assy (Jammed)

pump, overhaul

2. Hydraulic circuit (Invading air) Chapter 52 power steering - steering fluid,

Steering irregularity

3. Steering column (Worn) Chapter 51 steering column - steering column

4. Steering propeller shaft (Worn) Chapter 51 steering column - steering

5. steering gear assy (Worn or damaged)

52-5

GASOLINE VEHICLES(4G69)

1 Split Pin

2 Slotted Nut

3 Steering Gear Assy

4 Flat Washer

7 Bolt, Spring Washer

9 Tensioner With Bracket Assy.

11 Clamp

12 Flat Washer

14 Washer

15 Bolt

16 Ribbed Belt

17 High-pressure Line Assy

18 Low-pressure Line Assy

19 Steering Propeller Shaft Assy

Power Steering Pump With Fluid Reservior

20 Engine Crankshaft Belt Pulley

52-6 POWER STEERING - POWER STEERING SYSTEM

DIESEL VEHICLES (ISF2.8)

1 Bolt, Spring Washer

High-pressure And Low-pressure Line

3 Ribbed Belt

4 Nut

5 Copper Washer

6 Copper Washer

9 Fluid Reservior

11 Clip

13 Pipeline

14 Clip

15 Socket

17 Nut

18 Bolt, Spring Washer

19 Steering Pump Bracket Assy

21 Belt Pulley

22 Tensioner With Bracket Assy

23 Bolt, Spring Washer

12 Power Steering Pump

52-7

2. CHECK STEERING FLUID LEVEL.

(a) Park the vehicle on a flat road.

1. INSPECT DRIVE BELT.

(a) Visual check for exsessive wear, etc.

If any fault is found, replace the drive belt.

Cracks on the rib side of a belt are considered acceptable. If

the missing chunks from the ribs are found on the belt, it

should be replaced.

(b) Check the deflection.

• Apply a force of 98 N to push the middle of the drive belt

and adjust deflection if necessary.

Deflection (Gasoline vehicle) : 5.5 ~ 8.5 mm

Deflection (Diesel vehicle) : 5.5 ~ 8.5 mm

Make sure the engine is stopped before performing this

(b) Check the steering fluid level.

• Fill the steering fluid if necessary. (Refer to “Chapter 52

Steering fluid: ATF - Ⅲ

• Make sure the egnine is stopped.

• Check that the fluid level is within the COLD range, if

the fluid is cold.

• Check that the fluid level is within the HOT range, if

the fluid is hot.

Start the engine and run it at idle.

Turn the steering wheel fully to the right and left several

times to get fluid temperature high.

Fluid temperature: - 40 ~ 120 ℃

52-8 POWER STEERING - POWER STEERING SYSTEM

Make sure the time when steering wheel stays at full lock

position will not exceed 4 seconds, otherwise it will damage

the power steering pump.

Check fluid for foam and emulsification.

If foam or emulsification is identified, bleed the power

steering sysytem. (Refer to “Chapter 52 power steering -

steering fluid, bleeding”)

With the engine idling, check the steering fluid level in

the fluid reservior.

Check that the fluid level is within the HOT range, if the fluid

is hot.

(g) Stop the engine.

(h) Wait a few minutes, check the steering fluid level in the

fluid reservior again.

(i) Then check steering fluid level .

Steering fluid level difference: ≤ 5 mm

If the difference is out of the specification, bleed the power

steering system. (Refer to “Chapter 52 power steering - steering

fluid, bleeding and purifying”)

Check the steering fluid level finally and fill the steering

52-9

3. CHECK STEERING FLUID PRESSURE.

Gasoline vehicles (4G69)

(a) Separate the high-pressure tube from power steering pump.

Be sure to keep it clean and prevent dirt entry

Diesel vehicles (ISF2.8)

Separate the high-pressure tube from power steering pump.

Be sure to keep tube clean and prevent dirt entry.

Gasoline vehicles.

Diesel vehicles.

(b) Connect the special tool as shown in the illustration..

SPECIAL TOOL:

• Be sure to keep it clean and prevent dirt entry.

• Check that the valve of the SST is in “OPEN” position.

Connect the SST by the same procedures as the gasoline

vehicles, although look different.

power steering - steering fluid, bleed and purifying”)

(d) Start the engine and run it at idle.

52-10 POWER STEERING - POWER STEERING SYSTEM

Lift front wheels off the ground with jack or lift.

(f) With the engine idling, close the valve of the special tool.

(g) Observe the reading on the special tool.

(h) The max pressure of steering system is (10±0.5)MPa.

• Do not close the valve for more than 4 seconds.

• Do not let the fluid temperature become too high.

With the engine idling, open the valve of the SST.

Measure the fluid pressure when engine is running at

1000 rpm and 3000 rpm.

Do not turn the steering wheel.

With the engine idling and the valve fully opened, turn

the steering wheel to full lock position.

Observe the reading on the SST.

The max pressure of steering system is (10±0.5)MPa.

Disconnect the SST

52-11

(o) Connect the high-pressure tube to power steering pump.

Be sure to keep it clean and prevent dirt entry.

Diesel vehicles. (ISF2.8)

Connect the high-pressure tube to power steering pump

(q) Bleed the power steering system. (Refer to “Chapter 52

power steering - steering fluid, bleeding and purifying”)。

4. INSPECT STEERING WHEEL TURNING FORCE.

Turn the steering wheel to its straight position and face the

Remove the driver airbag assy. (Refer to “Chapter 51 steering

column - steering wheel assy, overhaul”)

Using a torque wrench, measure the steering wheel turning

force (engine idling)

Steering wheel turning force (engine stop): < 300 N

Take the tire type, pressure and contact surface into your

consideration before diagnosis.

52-12 POWER STEERING - POWER STEERING SYSTEM

Tighten the steering wheel lock nut.

Install the driver airbag assy. (Refer to “Chapter 51 steering

5. CHECK THE OFF TRACK.

(a) Driving straightly (50Km/h) along the center line of the road.

Offset LH: < Half car body

Offset RH: < Half car body

If the measurement value is out of the specification, there is fault on the off track for this vehicle.

52-13

1. PRECAUTION. (Refer to “Chapter 52 power steering - power steering system, precaution”)

2. DRAIN STEERING FLUID.

(a) Lift front wheels off the ground with jack or lift.

(b) Remove the steering fluid reservior cap when turning it

counterclockwise.

Loosen the clamp and separate the low- pressure hose

from steering gear assy.

Drain the steering fluid.

times until steering fluid is drained fully.

• Do not perform this operation for more than 10 seconds.

• Make sure the time when steering wheel stays at full

lock position will not exceed 4 seconds, otherwise it

will damage the power steering pump.

3. FILL STEERING FLUID.

(a) Connect the low-pressure hose to steering gear assy

and tighten the clamp.

52-14 POWER STEERING - STEERING FLUID

Fill the steering fluid.

Volumn: 1.2 L

times until the fluid will not be emulsifiable and the level

will no longer drop down.

Check the steering fluid level and fill the steering fluid if

necessary. (Refer to “Chapter 52 power steering - power

steering system, on-vehicle inspection”)

Install and turn clockwise the reservior cap..

Stop the engine.

Lower the vehicle.

52-15

BLEEDING AND PURIFYING

1. PRECAUTION. (Refer to “Chapter 52 power steering - power steering system”)

2. BLEED POWER STEERING SYSTEM.

Turn counterclockwise and remove the steering fluid

reservior cap.

(e) Turn the steering wheel.

• Turn the steering wheel to left full lock position for 2 ~ 3

seconds, then turn to the opposite full lock position for 2

~ 3 seconds.

• Repeat the previous procedure several times.

(f) Stop the engine.

Check for foam or emulcification.If foam or emulsification

is identified, Turn the steering wheel fully to the right and

left several times until the fluid will not be emulsifiable

and the level will no longer drop down.

If the system has to be bled twice becauce of foam or

emulcification, check for fluid leakage in the system.

52-16 POWER STEERING - STEERING FLUID

Install and turn clockwise the reservior cap.

(j) Stop the engine.

(k) Lower the vehicle.

3. PURIFY POWER STEERING SYSTEM.

(b) Start the engine and run it at idle.

Make sure the time when steering wheel stays at full lock position will not exceed 4 seconds, otherwise it will

damage the power steering pump.

(d) Check for abnormal noise.

If abnormal noise is identified, bleed the power steering system. (Refer to “Chapter 52 power steering -

steering fluid, bleeding and purifying”)

(e) Turn the steering wheel fully to the right and left several times until the noise disappears.

(g) Lower the vehicle.

(h) Check for jam and dirt in the steering fluid reservior filter.

Clean or replace the filter if necessary.

POWER STEERING PUMP WITH FLUID

RESERVIOR ASSY

POWER STEERING PUMP WITH FLUID RESERVIOR ASSY

GASOLINE VEHICLE (4G69)

52-17

• Generally, treat the power steering pump with fluid reservior assy as a whole. Do not separate

the fluid reservior from the power steering pump unless absolutely necessary.

• Do not disassemble the power steering pump because of its high precision.

• If damaged, replace the new steering oil pump assy.

2. DRAIN FLUID. (Refer to “Chapter 52 power steering - steering fluid, replacement”)

3. SEPARATE POWER STEERING LINE ASSY.

(a) Separate the high-pressure tube from the power steering

(b) Separate the low-pressure hose from the steering fluid

reservior.

4. REMOVE DRIVE BELT.

(a) Loosen the retaining bolt from the tensioner.

Adjust the tensioner adjusting bolt to loosen the drive

52-18 POWER STEERING -

5. REMOVE POWER STEERING PUMP WITH FLUID

RESERVIOR ASSY.

Remove the pulley nut.

Remove the power steering pump pulley.

Remove 2 bolts and 1 nut.

Remove the power steering pump with fluid reservior

52-19

6. INSTALL POWER STEERING PUMP WITH FLUID

(a) Position the power steering pump with fluid reservior

assy properly.

Install the power steering pump pulley temporarily, check

whether the pump pulley is on the same plane with the

engine crankshaft pulley and tensioner .

Tighten 2 bolts and 1 nut.

Install the power steering pump pulley.

Make sure the power steering pump pulley is on the same

plane with the engine crankshaft pulley and tensioner.

Install the pulley nut.

7. INSTALL DRIVE BELT.

(a) Install the drive belt (ribbed belt).

52-20 POWER STEERING -

(b) Tighten the adjusting bolt, tension steering oil pump belt.

check the deflection. Adjust the tensioner adjusting bolt if

Deflection : ≤ 5 mm

Be sure to make sure the egnine is stopped before

performing this operation

Tighten the retaining nut to the tensioner.

8. CONNECT THE HIGH-PRESSURE TUBE.

(a) Connect the high-pressure tube to power steering pump.

Torque: 40 ~ 45 N·m

(b) Connect the low-pressure hose to fluid reservior and

tighten the clamp.

9. FILL FLUID. (Refer to “Chapter 52 power steering - steering fluid,replacement”)

52-21

1. REMOVE DIESEL VEHICLES THE POWER STEERING BUMP WITH FLUID RESERVIOR ASSY.

(Refer to 《COMMINS ISF SERVICES ENGINE MANUAL,SECTION 9- drive)

52-22 POWER STEERING - POWER STEERING LINE ASSY

POWER STEERING LINE ASSY

3. REMOVE POWER STEERING LINE ASSY.

(a) Loosen 2 power steering line assy retaining bolts.

Separate the power steering line assy:Steering pump

• Separate the high-pressure tube from the power

steering pump.

• Loosen the clamp and separate the low-pressure

hose from the steering fluid reservior.

• Separate the high-pressure tube from the steering

hose from the steering gear assy.

Remove the power steering line assy.

Loosen 3 bolts to separate the high-pressure line assy

from the low-pressure line assy.

52-23

4. INSTALL POWER STEERING LINE ASSY.

(a) Tighten 3 bolts attaching the hig-pressure line assy to the

low-pressure line assy.

(b) Position the power steering line assy properly.

Connect the power steering line assy to the power

steering pump and the steering fluid reservior.

• Connect the high-pressure tube to power steering

• Connect the low-pressure hose to fluid reservior and

Connect the power steering line assy to the steering gear

• Connect the hig-pressure tube to the steering gear

• Connect the low-pressure hose to the steering gear

assy and tighten the clamp.

52-24 POWER STEERING - POWER STEERING LINE ASSY

Tighten 1 bolts attaching power steering line assy to

power steering line assy.

5. FILL FLUID. (Refer to “Chapter 52 power steering - steering fluid, replacement”)

52-25

(a) Loosen 1 power steering line assy retaining bolts.

Disconnect the power steering line from power steering

pump side.

Separate the high-pressure tube from the power steering

Loosen the clamp and separate the low-pressure hose

from the steering fluid reservior.

Separate the power steering line assy from the steering

52-26 POWER STEERING - POWER STEERING LINE ASSY

Connect the power steering line assy:Steering pump

Tighten the clamp and connect the low-pressure hose

52-27

Tighten 1 bolt attaching power steering line assy to

6. BLEED POWER STEERING SYSTEM.(Refer to “Chapter 52 power steering - steering fluid, bleeding

and purifying”)

52-28 POWER STEERING - STEERING GEAR ASSY

STEERING GEAR ASSY

3. TURN STEERING WHEEL STRAIGHTLY.

tires to straight ahead.

4. SEPARATE STEERING TIE ROD FROM STEERING

KNUCKLE.

Separate the steering tie rod LH from the steering knuckle

Remove the split pin.

Loosen the slotted nut.

Do not reuse the removed split pin.

Remove the left side steering gear rod ball and socket

joints from the knuckle arm.

Separate the steering tie rod RH from the steering knuckle

RH.

Separate the RH side by the same procedures as the LH

52-29

5. SEPARATE POWER STEERING LINE ASSY FROM

STEERING GEAR ASSY.

(a) Separate the high-pressure tube from the steering gear

(b) Loosen the clamp and separate the low- pressure hose

from the steering gear assy..

Loosen 1 retaining bolt from power steering line assy.

6. SEPARATE STEERING PROPELLER SHAFT FROM

(a) Mark on the steering propeller shaft and the steering

(b) Loosen the bolt.

7. REMOVE STEERING GEAR ASSY.

(a) Remove 4 bolts.

52-30 POWER STEERING - STEERING GEAR ASSY

Remove the steering gear assy.

Take care because the steering gear assy is quite heavy.

8. INSPECT STEERING GEAR ASSY.

(a) Check the steering gear assy for crack by magnetic testing.

If any fault is detected, replace with a new steering gear assy.

(b) Check the contact area between steering tie rod B-joint

steeering knuckle arm, then pull it out again. Check the

Standard: red area ≤ 3/4 shaft length

The red area is out of specification, replace with a new steering

gear assy and steering knuckle arm. (Refer to “Chapter 52 power

steering - steering gear assy, overhaul”, “Chapter 34 axle and

propeller shaft - steering knuckle, overhaul”)

9. INSTALL STEERING GEAR ASSY.

(a) Position the steering gear assy properly.

Tighten 4 bolts.

Torque: 108 ~ 125 N•m

52-31

10. CONNECT STEERING PROPELLER SHAFT TO STEERING

GEAR ASSY.

(a) Install the steering propeller shaft to the steering gear

(b) Tighten the bolt.

Torque: 29 ~ 35 N•m

11. CONNECT POWER STEERING LINE ASSY TO STEERING GEAR ASSY.

Connect the high-pressure tube to steering gear assy

(b) Connect the low-pressure hose to steering gear assy

steering gear assy.

Make sure the line assy does not be bended.

12. CONNECT STEERING TIE ROD TO STEERING KNUCKLE.

(a) Connect the steering tie rod LH to the steering knuckle LH.

(b) Insert the steering tie rod LH B-joint shaft into the

steering knuckle arm LH hole.

52-32 POWER STEERING - STEERING GEAR ASSY

Tighten the slotted nut.

Install the cotter pin.

Torque: 84 ~ 100 N•m

Connect the steering gear trolley ball and socket joints

Connect the RH side by the same procedures as the LH

13. FILL FLUID. (Refer to “Chapter 52 power steering - power steering system, replacement”)

14. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT. (Refer to “Chapter 31 front suspension -

STEERING FLUID RESERVIOR

52-33

3. REMOVE STEERING FLUID RESERVIOR.

(a) Loosen clip and separate the steering low pressure hose

(b) Remove the steering fluid reservior from the support.

4. INSTALL STEERING FLUID RESERVIOR.

(a) Position the steering fluid reservior to the support.

(b) Connect the steering low- pressure hose.

6. BLEED THE POWER STEERING SYSTEM. (Refer To “chapter 52 Power Steering - Steering Fluid,

Bleeding and purifying”)

7. PRECAUTION. (Refer to “Chapter 52 power steering - power steering system, precaution”)

HEATER AND AIR CONDITIONING SYSTEM................................. 61-1

PRECAUTION.............................................................................. 61-1

PROBLEM SYMPTOMS TABLE.................................................. 61-3

ON-VEHICLE INSPECTION ........................................................ 61-7

REFRIGERANT.................................................................................. 61-8

ON-VEHICLE INSPECTION ........................................................ 61-8

REPLACEMENT ........................................................................ 61-14

COMPRESSOR OIL......................................................................... 61-17

INSPECTION ............................................................................. 61-17

REPLACEMENT ........................................................................ 61-18

MULTI-MEDIA AND A/C CONTROLLER ASSY ............................. 61-19

REPLACEMENT ........................................................................ 61-19

REAR HEATER BLOWER CONTROL SWITCH............................. 61-21

REPLACEMENT ........................................................................ 61-21

REAR A/C BLOWER SWITCH ........................................................ 61-23

REPLACEMENT ........................................................................ 61-23

FRONT HEATER CORE .................................................................. 61-25

REPLACEMENT ........................................................................ 61-25

REAR HEATER CORE..................................................................... 61-35

REPLACEMENT ........................................................................ 61-35

FRONT EVAPORATOR CORE....................................................... 61-39

REPLACEMENT ........................................................................ 61-39

TOP EVAPORATOR CORE............................................................. 61-42

REPLACEMENT ........................................................................ 61-42

FRONT EVAPORATOR THERMISTOR .......................................... 61-46

REPLACEMENT ........................................................................ 61-46

TOP EVAPORATOR TEMPERATURE SENSOR............................ 61-47

REPLACEMENT ........................................................................ 61-47

FRONT EXPANSION VALVE .......................................................... 61-49

REPLACEMENT ........................................................................ 61-49

REAR EXPANSION VALVE............................................................. 61-50

REPLACEMENT ........................................................................ 61-50

FRONT A/C BLOWER ..................................................................... 61-52

OVERHAUL ............................................................................... 61-52

REAR A/C BLOWER........................................................................ 61-53

OVERHAUL ............................................................................... 61-53

REAR HEATER BLOWER............................................................... 61-55

OVERHAUL ............................................................................... 61-55

FRONT BLOWER CONTROL MODULE ......................................... 61-56

REPLACEMENT ........................................................................ 61-56

REAR HEATER BLOWER RESISTOR............................................ 61-57

REPLACEMENT ........................................................................ 61-57

TOP EVAPORATOR BLOWER RESISTOR.................................... 61-59

REPLACEMENT ........................................................................ 61-59

FRONT A/C VENT DUCT................................................................. 61-60

REPLACEMENT ........................................................................ 61-60

REAR A/C VENT DUCT................................................................... 61-62

REPLACEMENT ........................................................................ 61-62

RECIRCULATION DOOR MOTOR.................................................. 61-63

REPLACEMENT ........................................................................ 61-63

61

BLEND DOOR MOTOR ................................................................... 61-65

REPLACEMENT ........................................................................ 61-65

MODE DOOR MOTOR ..................................................................... 61-67

REPLACEMENT ........................................................................ 61-67

FRONT A/C FILTER......................................................................... 61-69

REPLACEMENT ........................................................................ 61-69

REAR A/C FILTER SCREEN ........................................................... 61-71

REPLACEMENT ........................................................................ 61-71

A/C PRESSURE SWITCH................................................................ 61-72

REPLACEMENT ........................................................................ 61-72

REAR A/C SHUT-OFF SOLENOID VALVE..................................... 61-73

REPLACEMENT ........................................................................ 61-73

REAR HEATER SOLENOID VALVE ............................................... 61-75

REPLACEMENT ........................................................................ 61-75

COOLING FAN ASSY ...................................................................... 61-77

REPLACEMENT ........................................................................ 61-77

COMPRESSOR(4G69)..................................................................... 61-78

OVERHAUL ............................................................................... 61-78

COMPRESSOR(ISF2.8) ................................................................... 61-80

OVERHAUL ............................................................................... 61-80

CONDENSER ................................................................................... 61-83

OVERHAUL ............................................................................... 61-83

A/C RECEIVER DRIER FILTER ELEMENT .................................... 61-85

REPLACEMENT ........................................................................ 61-85

HEATER AND AIR CONDITIONING -

AND AIR CONDITIONING

1. HEATER AND AIR CONDITIONING PRECAUTION.

(a) Expressions of ignition switch.

61-1

(b) Power off.

• Before removing or installing any electrical devices, please disconnect the negative cable to prevent

For the vehicle equipped with the power door locks, before disconnecting the negative battery cable,

do not leave the key in the vehicle and avoid the door to be locked.

• Make sure ignition switch is OFF if no specific instructions.

When work is finished, reset the audio systems as they were before. ( Refer to “Audio system owner

manual”)

Do not handle refrigerant in an enclosed area or near

the flame.

Do not do welding operation to the parts filled with

refrigerant.

Always wear eye protection glasses.

(g) Be careful not to get liquid refrigerant in your eyes or on

your skin.

If liquid refrigerant gets in your eyes or on your skin:

• Wash the area with cool water.

Do not rub your eyes or skin.

• Apply clean petroleum jelly to the skin.

• Go to a physician or hospital immediately for professional

treatment.

61-2 HEATER AND AIR CONDITIONING -

Never heat container or expose it to naked flame.

Be careful not to drop container and not to apply physical

shocks to it.

Do not operate compressor without enough refrigerant in

refrigerant system.

If there is no enough refrigerant in the refrigerant system,

oil lubrication will be insufficient and compressor will be

burned out. So take care to avoid this condition.

Do not open high pressure manifold valve while

compressor is operating.

If the high pressure valves opened, refrigerant flows in

the reverse direction and could cause the charging

cylinder to rupture. So only open and close the lower

pressure valve.

(l) Be careful not to overcharge system with refrigerant.

If refrigerant is overcharged, it causes problems such as insufficient cooling, poor fuel economy, engine

overheating, etc.

(m) When removing refrigerant components from a vehicle, immediately cap (seal) the component to

minimize the entry of moisture from the atmosphere.

(n) When installing refrigerant components to a vehicle, do not remove the caps (unseal) until just before

connecting the components. Connect all refrigerant loop components as quickly as possible to

minimize the entry of moisture into the system.

(o) Only use the specified compressor oil from a sealed container. Immediatedly reseal containers of

compressor oil. Without proper sealing, compressor oil will become moisture saturated and should not

be used.

(p) Avoid breathing A/C refrigerant and compressor oil vapor or mist. Exposure may irritate eyes, nose and

throat. Remove R-134a from the A/C system using certified service equipment meeting requirements of

R-134a recycling equipment. If accidental system discharge occurs, ventilate work area before

resuming service. Additional health and safety information may be available from refrigerant and

compressor oil manufacturers.

(q) Do not allow compressor oil to contact with styrofoam parts. Otherwise, damage may occurr.

(r) Do not store or heat refrigerant containers above 52 ℃ .

(s) Do not intentionally drop, puncture, or incinerate refrigerant containers.

(t) Do not do pressure test or leakage test R-134a service equipment and/or vehicle air conditioning

systems with compressed air during repairing. Some mixtures of air and R-134a have been proved to

be combustible at high pressure. These mixtures, if ignited, may cause injury or property damage.

Additional health and safety information may be available from refrigerant manufacturers.

61-3

1. COOLING SYSTEM DOES NOT FUNCTION.

1. Fuse (Burned) -

2. Belt (Loose) -

3. A/C clutch (Damaged) -

4. A/C cut relay (Damaged) -

Air flow normal,

compressor not

5. Multi-media and A/C controller

assy (Damaged)

6. A/C pressure switch (Damaged)

8. A/C clutch relay (Damaged) -

9. A/C relay (Damaged) -

10.ECM (Damaged) -

11.Harness (Open or short) -

Chapter 61 heater and air conditioning - multi-media

and A/C controller assy, replacement

Chapter 61 heater and air conditioning - A/C

pressure switch, replacement

Chapter 61 heater and air conditioning - front

evaporator thermistor, replacement

12.Compressor (Damaged)

Chapter 61 heater and air conditioning -compressor,

Front blower inoperative

Top blower inoperative

1. Fuse (Damaged) -

2. Harness (Open or short) -

3. Multi-media and A/C controller

5. Front blower motor (Damaged)

Chapter 61 heater and air conditioning - front blower

control module, replacement

Chapter 61 heater and air conditioning - front A/C

blower, replacement

1. Top evaporator blower resistor Chapter 61 heater and air conditioning - top

evaporator blower resistor, replacement

2. Rear A/C blower

Chapter 61 heater and air conditioning - rear A/C

Cooling insufficient

(air flow normal,

compressor work)

3. Rear A/C blower switch

1. Refrigerant (Leaking)

2. Compressor (Damaged)

blower switch, replacement

Chapter 61 heater and air conditioning - refrigerant,

61-4 HEATER AND AIR CONDITIONING -

2. COOLING SPORADIC.

1. Harness (Poor contact) -

2. Relay (Poor contact) -

Air flow sporadic

4. Multi-media and A/C controller

5. Front blower control module

6. Vent duct (Blocked)

blower switch, replacemrnt

Chapter 61 heater and air conditioning - vent duct,

1. Belt (Slipping) Chapter 61 heater and air conditioning -compressor,

Compressor work

sporadic

2. A/C clutch (Slipping)

4. A/C pressure switch (Damaged)

5. Compressor (Damaged)

6. Harness (Poor contact) -

Blower and

compressor

normal, but cooling

1. Front evaporator thermistor

(Loose)

2. System block intermittently -

3. COOLING INSUFFICIENT.

Air abnormal

61-5

abnormal

Pressure low on

both low and high

pressure sides

1. A/C clutch (Slipping) Chapter 61 heater and air conditioning -compressor,

2. Belt (Slipping)

3. Harness (Poor contact) -

4. Compressor (Damaged)

2. Evaporator (Frosting)

Pressure high on

1. Refrigerant (Redundancy)

2. Air mixed in refrigerant system

3. Condenser (Surface filth

blocked)

4. Expansion valve (filth blocked)

Chapter 61 heater and air conditioning - condenser,

expansion valve, replacement

Pressure too high

on low pressure

side,

Pressure too low

on high pressure

Others

1. Compressor (Damaged)

2. Condenser (Blocked)

3. Pipeline between compressor

and reciever tank (Blocked)

1. Temperature control knob

2. Blend door motor (Damaged)

4. COOLING SYSTEM BIG NOISE.

1. Belt (Loose) Chapter 61 heater and air conditioning -compressor,

2. Compressor bracket (Damaged) -

System outer noise

3. Compressor (Damaged)

4. Compressor oil (Less than

specification)

5. A/C clutch (Slipping)

Chapter 61 heater and air conditioning -compressor

oil, replacement

61-6 HEATER AND AIR CONDITIONING -

System inner noise

1. Refrigerant (Incorrect)

(Slipping)

5. NO HEATING OR HEATING INSUFFICIENT.

1. Rear heater motor (Damaged)

Chapter 61 heater and air conditioning - rear heater

blower, overhaul

2. Blower relay (Damaged) -

No heating

3. Blend door motor (Damaged)

5. Rear heater solenoid valve

(Damage)

Chapter 61 heater and air conditioning - blend door

motor, replacement

and A/C controller assyr, replacemrnt

1. Coolant (Insufficient) -

Heating insufficient

2. Front heater core (Deformation)

3. Rear heater core (Deformation)

4. Heater hose (Fouling or air in

hose)

5. Rear heater solenoid

valve(Damage)

6. Blend door motor (Damaged)

Chapter 61 heater and air conditioning - front heater

core, replacemrnt

61-7

1. COMPRESSOR ASSY WITH CLUTCH.

(a) Connect the positive pole from the battery to cable and negative lead to the body ground.

(b) Check the clutch energized or not.

If operation is not as specified, replace the compressor assy.

2. HEATER CORE.

Add coolant to heater core and then check for leakage.

3. A/C PIPE.

Water immersion: With dry nitrogen pipe inside, high-pressure pipe is 3.5 MPa and low-pressure is 1.67 MPa.

Immerse them in the water for 5 minutes to see whether there is bubble on the surface.

4. EVAPORATOR.

Water immersion: Pump 1.67 MPa pressure into the evaporator, then immerse it in the water for 5 minutes to

see whether there is bubble on the surface.

5. CONDENSER.

Water immersion: Pump 3.5 MPa pressure into the condenser, then immerse it in the water for 3 minutes to

61-8 HEATER AND AIR CONDITIONING - REFRIGERANT

1. INSPECT REFRIGERANT PRESSURE WITH MANIFOLD GAUGE SET.

(a) This is a method in which the trouble is located by using a manifold gauge set. Read the manifold

gauge pressure when these conditions are established.

Test conditions:

• Temperature at the air inlet is 30 ~ 35 ℃ .

• Engine running at 1500 RPM.

• Blower switch at “HI” position.

• Temperature control switch at “COOL” position

• A/C switch ON.

• Full open doors.

These gauge indications are shown when the refrigerant system has been opened and the refrigerant

charged without vacuum purging.

• Normally function refrigerant system.

Gauge reading:

Low pressure side: 0.15 ~ 0.25 MPa

High pressure side: 1.37 ~ 2.37 MPa

• Moisture present in refrigerant system (Condition: Periodically cools and then fails to cool)

Symptom Probable Cause Diagnosis Remedy

During operation,

pressure on low pressure

side sometimes becomes

a vacuum and sometimes

normal.

Moisture in refrigerating

system freezes at

expansion valve orifice

causing a temporary stop

of cycle. However, when it

melts, normal state is

restored.

1. Reciever tank in

oversaturated state

2. Moisture in

refrigerating system

freezes at expansion

valve orifice and

blocks circulation of

1. Replace condenser

2. Remove moisture in

cycle by repeatedly

evacuating air

3. Supply proper amount

of new refrigerant

61-9

• Insufficient cooling (Condition: Cooling system does not function effectively.)

Pressure low on both low

and high pressure sides

Insufficient cooling

performance

Gas leakage in

refrigeration system

Insufficient refrigerant

Refrigerant leakage

• Poor circulation of refrigerant (Condition: Cooling system does not function effectively.)

1. Check for gas leakage

and repair if necessary

2. Supply proper amount

3. If indicated pressure

value is closed to 0

when connecting to

gauge, create the

vacuum after

inspecting and

repairing location of

leak

Frost on pipe from

condenser to unit

Refrigerant flow

obstructed by dirt in

reciever tank

Reciever tank clogged

Replace reciever tank

61-10 HEATER AND AIR CONDITIONING - REFRIGERANT

• Refrigerant does not circulate (Condition: Cooling functions intermittently.)

Vacuum indicated on low

pressure side, very low

pressure indicated on

high pressure side

Frost or dew seen on pipe

before and after reciever

tank or expansion valve

1. Refrigerant flow

obstructed by moisture

or dirt in refrigerant

2. Refrigerant flow

obstructed by gas

leaked from expansion

Refrigerant not circulate

1. Check expansion

2. Clean out dirt in

expansion valve by air

blowing

3. Replace condenser

4. Evacuate air and

supply proper amount

of new refrigerants

5. For gas leakage from

expansion valve,

replace expansion

• Refrigerant overcharged or insufficient cooling of condenser (Condition: Cooling system does not

function effectively.)

Pressure too high on both

low and high pressure

sides

1. Unable to develop

sufficient performance

due to excessive use

of refrigeration system

2. Insufficient cooling of

condenser

1. Excessive refrigerant

in cycle

2. Condnser cooling

insufficient condenser

fins

3. Clogged at cooling fan

1. Clean condenser

2. Check cooling fan with

cooling fan

dooroperation

3. If 1 and 2 are in normal

state, check refrigerant

and supply proper

amount of refrigerant.

61-11

• Air present in refrigeration system (Condition: Cooling system does not function.)

The low pressure pipe

overheated

Air entered in refrigeration

1. Air present in

2. Insufficient vacuum

purging

• Expansion valve trouble (Condition: Refrigerant functions insufficient.)

1. Check compressor oil

to see if it is dirty or

insufficient

2. Vacuumize and supply

new refrigerant

Frost or large amount of

dew on pipe of low

pressure side

Trouble in expansion

in low pressure pipe

2. Expansion valve

opened too wide

Check and replace

expansion valve

61-12 HEATER AND AIR CONDITIONING - REFRIGERANT

• Compressor failure (Condition: Refrigerant is not effective.)

Pressure too high on low

Pressure too low on high

Internal leakage in

1. Compressor failure

2. Leakage from

damaged valve or

broken sliding parts

Gauge reading (Reference)

1 Blower LO Zone 2 Blower HI Zone

2. LEAKAGE DETECTION WITH SOAP SOLUTION.

For a large amount of leakage on refrigerant pipe connection, leakage can be detected by spraying

soap liquid around the connection with a sprayer to check whether any bubble appears. This is a simple

and convenient method for leakage detection, but it is unable to detect minor leakage.

3. LEAKAGE DETECTION WITH NON-SELECTIVE DETECTOR.

This detector can detect leakage of all kinds of liquid and gas regardless of chemical composition of the

detected material. It has advantages of easy using, stable performance and low cost, etc., but it cannot

be used for area detection of leakage.

61-13

4. LEAKAGE DETECTION WITH HALOGEN LEAKAGE DETECTOR.

(a) It equipped with special sensor which can detect air compounds containing a small amount of fluorine,

chlorine, bromine and iodine without interference of other materials. The great advantage of this

instrument is its high sensitivity which can reduce error. Its minimum detection limit is less than 5g per

year for area detection of leakage and 1.5g per year for leak-point detection (for leak-point, which leaks

1.5g per year).

5. LEAKAGE DETECTION WITH SPECIAL ELECTRONIC LEAKAGE DETECTOR.

(a) This instrument is complicated and expensive which can detect certain compounds without interference

of other materials. R-134a, a kind of special electronic leakage detector with high sensitivity and

selectivity, can not only detect leak-point correctly, but also can identify whether refrigerant is R-134a

type. Because it has high sensitivity, pay attention to pollution around the instrument when using it,

otherwise, it may cause error report.

6. LEAKAGE DETECTION WITH FLUORESCENT DYE.

(a) Fluorescent dye can produce fluorescence under the irradiation of ultraviolet light. Therefore, if add this

kind of dye to compressor oil or refrigerant, the leak-point can be detected through irradiating outer part

of the system when the system has a leakage.

61-14 HEATER AND AIR CONDITIONING - REFRIGERANT

1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM.

(a) Turn the A/C switch ON.

(b) Operate the compressor at the engine RPM 1000 for 5 to 6 minutes to circulate the refrigerant and

collect compressor oil remaining in each component into the compressor as many as possible.

Recover the refrigerant.

Do not release the refrigerant into the air.

2. PUMP VACUUM.

Connect high pressure and low pressure gauge hoses to

maintenance valve on compressor, and connect central

hose to vacuum pump.

Open high and low pressure valves of manifold pressure

gauge, and then open the vacuum pump valve.

minutes to make vacuum value below -760 mmHg. Shut

manual valves at both high and low pressure sides and

stop vacuumizing to detect leakage.

3. INSPECT LEAKAGE OF REFRIGERANT.

(a) Shut valves, the gauge value shall not increase within 5 minutes. If the value increases, repair where

leaks, then pump vacuum again.

4. SUPPLY REFRIGERANT.

(a) If there is no leakage, connect central filling hose of manifold pressure gauge with refrigerant tank.

(b) Loosen the nut of manifold pressure gauge central hose, and retighten it until white gas refrigerant

flows out and a “fizz” sound is heard, which indicates that air in central hose is exhausted.

Open high pressure manual valve, and turn refrigerant tank

upside down to SUPPLYliquid refrigerant into refrigeration

system. Do not start air conditioning system at this moment

to avoid back flow. Add at least 200g of refrigerant each

61-15

Shut high pressure manual valve and open low pressure

manual valve to allow gas refrigerant to enter refrigeration

system. Start the engine. The refrigerant entering from low

pressure manual valve must be gasified because liquid

refrigerant will cause liquid impact in compressor and

damage the unit.

(e) Add refrigerant according to the specified amount of the

A/C system. If there is no specified amount, observe the

high and low pressure gauges and the peephole of the

refrigerant flow state (clear, sparkling, turbidity) to

estimate the adding time.

Specified value:

Front and rear A/C:850 + 0/- 25 g

Front A/C:700 ± 25 g

When estimating refrigerant adding amount, set the

basic conditions:

• Radiator water temperature: maintain stable state

• A/C switch: ON

• Temperature regulator: adjust inner circulation air

temperature to 25 ~ 30 ℃

• Fan swtich: HI position

• Change inner and outer air: Inner circulation

• Door: full open

• Window: full open

• Estimate the adding amount

(f) After finishing the adding process, turn the HVAC switch

to OFF and wait to balance pressure condition, reopen

the A/C switch to ON and begin to judge.

Sparkling condition: gas and liquid refrigerant mixed

state with bubble.

Clear conditon: it is clear condition when all refrigerant is

liquid.

Turbidity condition: when the oil and refrigerant separae

with each other, it shows thin ivory.

Sparkling and turbidity condition: gas refrigerant and

separated oil mixing state, it shows thin ivory and

sparkling

61-16 HEATER AND AIR CONDITIONING - REFRIGERANT

Refrigerant Adding Amount

Peephole Condition (After Turn

On The HVAC Switch About 1

Minute )

High Side Pressure

Suitable

1.8 ~ 2.5 MPa

> 2.5 MPa

Insufficient

1.2 MPa

Above peephole conditions are visible general condition. When it is hard to judge the peephole

condition due to the reasons such as external condition, it must be confirmed to inspect the pressure

variation of the high pressure side (excessive adding when pressure sharply up).

When adding refrigerant, pay attention to refrigerant condition variation in peephole and high side

pressure variation in the pressure gauge.

Shut low pressure manual valve and remove maintenance valve, then cap the valve quickly to avoid

gas leakage.

5. WARM UP ENGINE.

6. CHECK REFRIGERANT FOR LEAKAGE. (Refer to “Chapter 61 heater and air conditioning -

refrigerant, on-vehicle inspection”)

COMPRESSOR OIL

61-17

1. CORRELATION METHOD:

Take fresh compressor oil into test tube as the standard oil and also take old compressor oil into test

tube, then compare the two tubes. If the color of the old compressor oil is light yellow or orange, it can

be used. If it turns to bronzing turbid liquid, it can not be used.

2. PAPER METHOD:

Drip a drop of compressor oil on a clean white paper. After a while, check the color of the oil. If the color

is light and uniform, which shows it is no impurity and can be used. If the center of the oil has black

spot, which shows the oil is metamorphous and can not be used.

61-18 HEATER AND AIR CONDITIONING - COMPRESSOR OIL

1. RECOVER REFRIGERANT. (Refer to “Chapter 61 heater and air conditioning - refrigerant,

2. DRAIN OUT COMPRESSOR OIL.

(a) Remove the compressor. (Refer to “Chapter 61 heater and air conditioning - compressor, overhaul”)

(b) Pour out the oil from the compressor.

3. SUPPLYCOMPRESSOR OIL.

(a) Install the compressor. (Refer to “Chapter 61 heater and air conditioning - compressor, overhaul”)

(b) SUPPLYthe oil into the compressor as the specified value.

Specified value: 180 mL

• Generally, it is no need to add oil to new A/C system, because new compressor has the whole amount

of the oil for the system (14% ~ 18% amount of the refrigerant ). If the A/C system has more than two

times repairment or other causes the lack of compressor oil, it is need to add compressor oil. After

replacing the A/C system, add compressor oil as necessary.

Part Name

Amount of oil

Compressor -

Evaporator

Reciever tank

5 ~ 10 ml

Condenser

Pipe

No leakage -

4. SUPPLY REFRIGERANT. (Refer to “Chapter 61 heater and air conditioning - refrigerant, replacement”)

MULTI-MEDIA AND A/C CONTROLLER

MULTI-MEDIA AND A/C CONTROLLER ASSY

61-19

2. REMOVE FRAME BEZEL OF MULTI-MEDIA AND A/C

CONTROLLER ASSY.

Pry frame bezel out with prying tool, be careful not to

scratch frame bezel and dashboard.

3. REMOVE MULTI-MEDIA AND A/C CONTROLLER

Remove 4 mounting screws securing multi-media and A/C

controller assy into the centre opening of dashboard.

Pull multi-media and A/C controller assy out far enough

to disconnect antenna cable, multi-media wire harness

connectors and A/C controller wire harness connectors.

Remove GPS antenna attached to the top of multi-media

and A/C controller assy.

Remove multi-media and A/C controller assy.

61-20 HEATER AND AIR CONDITIONING -

4. INSTALL MULTI-MEDIA AND A/C CONTROLLER ASSY.

(a) Attach GPS antenna to the top surface of multi-media

and A/C controller assy and fit the GPS connector into

corresponding socket.

(b) Place multi-media and A/C controller assy to the centre

opening of dashboard and connect wire harness

connectors to multi-media and A/C controller connector

receptacle.

Install multi-media and A/C controller assy into place,

then tighten 4 mounting screws.

Install the frame bezel and press it into place.

6. INSPECT MULTI-MEDIA AND A/C CONTROLLER ASSY AND RESET RADIO STATIONS.

7. CHECK TO ENSURE THAT MULTI-MEDIA AND A/C CONTROLLER ASSY WORKS PROPERLY.

REAR HEATER BLOWER CONTROL

SWITCH

REAR HEATER BLOWER CONTROL SWITCH

61-21

2. REMOVE FRONT SIDE WALL GUARD BOARD. (Refer to “Chapter 88 inner/outer trim panel - left

panel, replacement”)

3. REMOVE REAR HEATER BLOWER SWITCH.

(a) Pull out rear heater blower switch cap.

Disconnect rear heater blower switch connector.

Remove 2 rear heater blower switch bracket retaining

screws from the back of front side wall guard board.

Seperate rear heater blower switch from rear heater

blower switch bracket.

Remove rear heater blower switch.

61-22 HEATER AND AIR CONDITIONING -

4. INSTALL REAR HEATER BLOWER SWITCH.

(a) Install rear heater blower switch until it snaps into

bracket, then position them on rear of front side wall

guard board.

(b) Tighten 2 retaining screws.

Install rear heater blower switch cap.

5. INSTALL FRONT SIDE WALL GUARD BOARD. (Refer to “Chapter 88 inner/outer trim panel - left

(a) Turn rear heater blower switch on, confirm blower switch is functional in all positons.

REAR A/C BLOWER SWITCH

61-23

2. REMOVE REAR A/C BLOWER SWITCH.

(a) Pry up rear A/C blower switch control panel along its

edge.

(b) Disconnect rear A/C blower switch connector from the

back of rear A/C blower switch control panel.

Pull rear A/C blower switch cap out, then seperate rear

A/C blower switch from rear A/C blower switch control

3. INSTALL REAR A/C BLOWER SWITCH.

(a) Position rear A/C blower switch on rear A/C blower

switch control panel, and snap it into place.

Connect the wire harness connector which extends from

the mounting opening of roof panel to connector

receptacle of the rear A/C blower switch integrated on

rear of A/C blower switch control panel.

61-24 HEATER AND AIR CONDITIONING - REAR A/C BLOWER SWITCH

Position rear A/C blower switch control panel onto the

opening of the roof panel and press it into place, then

plug the blower switch cap.

FRONT HEATER CORE

61-25

3. RECOVER REFRIGERANT. (Refer to “Chapter 61 heater and air conditioning - refrigerant,

4. REMOVE DASHBOARD. (Refer to “Chapter 83 instrument panel - dashboard, replacement”)

5. REMOVE FRONT DASHBOARD BEAM ASSY AND

INSTRUMENT PANEL WIRE HARNESS.

(a) Remove 5 dashboard stay retaining bolts.

Remove 2 retaining bolts securing hand brake bracket to

dashboard assy.

Disconnect 5 electrical connectors from the left and

lower side of the driver side junction box.

Loosen power connecting nut in driver side junction box.

Release the tab on top of driver side junction box to

remove it from the dashboard beam assy.

Disconnect 5 electrical connectors from the rear and

right side of driver side junction box.

61-26 HEATER AND AIR CONDITIONING - FRONT HEATER CORE

Remove 3 retaining bolts mounting steering column to

dashboard beam assy.

Remove 1 retaining bolt securing clutch pedal bracket to

Remove 2 retaining bolts securing A/C unit assy to dashboardb

beam assy.

Remove 1 retaining bolt securing A/C unit assy to dashboard

Disconnect recirculation door motor connector.

Remove 2 electrical wire harness ties at the bottom of

the A/C unit assy.

61-27

Remove 1 electrical harness tie on one side of the ac

Disconnect evaporator temperature sensor connector.

Disconnect blend door motor connector.

Disconnect blower control module connector.

Disconnect mode door connector.

Loosen 2 retaining bolts securing dashboard beam assy

to left A pillar.

to right A pillar.

61-28 HEATER AND AIR CONDITIONING - FRONT HEATER CORE

(t)

(u)

Remove front windshield lower trim cover and front wiper

motor assy. (Refer to “Chapter 65 wiper and washer

system - wiper link with motor assy, replacement”)

Remove 2 bolts located in dedicated holes below the

wiper motor that secure dashboard beam assy to front

dash panel.

(v)

Remove dashboard beam and wire harness.

Remove dashboard beam out of the vehicle carefully, do

not scratch the trim panel and relevant component inside

the vehicle.

6. REMOVE A/C ASSY.

(a) Remove the bolt securing high and low pressure pipes to

evaporator core, then separate them

(b) Remove clamps and separate inlet and outlet hoses from

front heater core.

Disconnect drain hose from A/C unit assy.

61-29

Remove 2 retaining bolts mounting the bottom of A/C

unit assy to the body.

(e) Remove A/C unit assy.

Do not drag or damage relevant component while removing

the A/C unit assy from the inside of the vehicle.

7. REMOVE HEATER CORE.

(a) Remove 3 heater core cover retaining screws.

(b) Slide heater core.

8. CHECK HEATER CORE.

Check heater core for dust contamination and coolant

leaks, if necessary, clean or replace it.

9. INSTALL HEATER CORE.

(a) Insert heater core into heater unit assy carefully.

(b) Position heater core cover and tightern 3 retaining

61-30 HEATER AND AIR CONDITIONING - FRONT HEATER CORE

10. INSTALL A/C UNIT ASSY.

(a) Position A/C unit assy in vehicle until it is located in place

(b) Tighten 2 retaining bolts at the bottom of A/C unit assy.

Connect drain hose to the A/C unit assy.

Position high and low pressure pipes in place, then

tighten 1 mounting bolt.

Always use a new O-ring for high-pressure and low-pressure

pipes before installing A/C pipes.

Attach inlet and outlet hoses to the front heater core,

then tighten 2 clamps.

11. INSTALL DASHBOARD BEAM ASSY AND WIRE HARNESS.

(a) Position dashboard into vehicle.

Position dashboard beam in vehicle, do not scratch interior trim panel and related part or drag wire

harness hard.

61-31

Tighten 2 retaining bolts mounting dashboard beam assy

to front dash panel in the holes on dash panel.

Tighten 2 retaining bolts mounting A/C unit assy to dashboard

61-32 HEATER AND AIR CONDITIONING - FRONT HEATER CORE

Tighten 3 retaining bolts mounting steering column to

Tighten 1 retaining bolt securing clutch pedal bracket to

Tighten 3 retaining bolts securing steering column to

Connect evaporator temperature sensor connector.

Connect blend door motor connector.

Connect blower and blower control module connectors.

Fasten 1 electrical wiring harness tie to one side of the A/C

Fasten 2 electrical wire harness ties to the bottom of A/C

Connect recirculation door motor connector.

61-33

Connect 5 electrical wire harness connectors to the back

and right side of the driver side junction box.

Fix the driver side junction box in place.

Connect 5 electrical wire harness connectors on one

side and bottom of the driver side junction box.

Tighten power connecting nut located on lower driver

side junction box.

Tighten 2 retaining bolts mounting hand brake bracket to

Tighten 5 dashboard stay retaining bolts.

61-34 HEATER AND AIR CONDITIONING - FRONT HEATER CORE

12. INSTALL DASHBOARD. (Refer to “Chapter 83 instrument panel - dashboard, replacement”)

13. INSTALL FRONT WINDSHIELD LOWER TRIM COVER AND FRONT WIPER MOTOR ASSY. (Refer

to “Chapter 65 wiper and washer system - wiper link with motor assy, replacement”)

REAR HEATER CORE

61-35

4. REMOVE REAR HEATER ASSY.

(a) Loosen water inlet and outlet hoses clamps.

(b) Separate inlet and outlet hoses from rear heater pipes

extending to the vehicle beneath through the floor.

Disconnect rear heater assy connector.

Remove 1 retaining screw in the front of rear heater assy.

Remove 2 retaining screws on the back of rear heater

Remove rear heater assy.

5. REMOVE REAR HEATER CORE.

(a) Remove 2 heater core upper cover retaining screws.

61-36 HEATER AND AIR CONDITIONING - REAR HEATER CORE

Remove 3 blower cover retaining screws and 1 inlet and

outlet pipes retaining screw on one side of heater assy.

Remove blower upper cover.

Disconnect blower connector.

Remove 3 blower retaining screws.

Remove blower.

Slide rear heater core.

61-37

6. CHECK REAR HEATER CORE.

Check rear heater core for dust contamination and coolant

leakage, if necessary ,clean or replace it.

7. ASSEMBLE REAR HEATER ASSY.

(a) Place rear heater core into rear heater assy.

Position blower and then tighten 3 retaining screws.

Connect blower connector.

Install blower cover.

Tighten 3 blower cover retaining screws and 1 screw on

one side of the inlet and outlet pipes.

61-38 HEATER AND AIR CONDITIONING - REAR HEATER CORE

Install 2 blower upper cover retaining screws.

8. INSTALL REAR HEATER ASSY.

(a) Position rear heater assy under the passenger seat.

(b) Tighten 2 retaining screws on the back of rear heater

(d) Connect rear heater assy connector.

Attach inlet and outlet hoses to rear heater core under

9. FILL COOLANT. (Refer to “Chapter 17A cooling - coolant, replacement”)

(a) Start the engine until it is warm, confirm rear heater is functional and no coolant leaks.

FRONT EVAPORATOR CORE

61-39

3. RECOVER REFERGRIATANT. (Refer to “Chapter 61 heater and air conditioning - refrigerant,

5. REMOVE DASHBOARD BEAM ASSY AND DASHBOARD WIRE HARNESS. (Refer to “Chapter 61

heater and air conditioning - front heater core, replacement”)

6. REMOVE A/C UNIT ASSY. (Refer to “Chapter 61 heater and air conditioning - front heater core,

7. REMOVE FRONT HEATER CORE. (Refer to “Chapter 61 heater and air conditioning - front heater

core, replacement”)

8. REMOVE BLOWER ASSY.

(a) Remove 3 blower assy retaining screws.

Remove 2 blower assy retaining screws.

Remove blower assy.

9. REMOVE HEATER ASSY.

(a) Remove 5 heater assy retaining screws.

(b) Remove heater assy.

61-40 HEATER AND AIR CONDITIONING - FRONT EVAPORATOR CORE

10. REMOVE EVAPORATOR CORE.

(a) Remove 9 evaporator core retaining screws.

(b) Remove Front Evaporator Thermistor. (refer to “Chapter

61 heater and air conditioning - front evaporator thermistor,

replacement “)

11. CHECK EVAPORATOR CORE.

Check evaporator core for dust contamination and

refrigerant leakage, if necessary, clean or replace it.

12. INSTALL EVAPORATOR CORE.

(a) Position evaporator core into evaporator assy .

(b) Tighten 9 retaining screws.

13. INSTALL FRONT EVAPORATOR THERMISTOR. (Refer to “Chapter 61 heater and air conditioning -

front evaporator thermistor, replacement”)

14. INSTALL HEATER ASSY.

(a) Position heater assy into place.

(b) Tighten 5 heater assy retaining screws

61-41

15. INSTALL BLOWER ASSY.

(a) Position blower assy.

(b) Tighten 3 blower assy retaining screws.

Tighten 2 blower assy retaining screw.

16. INSTALL A/C ASSY. (Refer to “Chapter 61 heater and air conditioning - front heater core,

17. INSTALL DASHBOARD BEAM ASSY. (Refer to “Chapter 61 heater and air conditioning - front

heater core, replacement”)

18. INSTALL DASHBOARD. (Refer to “Chapter 83 instrument panel - dashboard, replacement”)

19. FILL COOLANT. (Refer to “Chapter 17A cooling - coolant, replacement”)

20. SUPPLY REFERGENANT. (Refer to “Chapter 61 heater and air conditioning - refrigerant,

Start the vehicle and turn A/C switch on, check that A/C system is functional and no refrigerant leaks.

61-42 HEATER AND AIR CONDITIONING - TOP EVAPORATOR CORE

TOP EVAPORATOR CORE

2. RECOVER REFRIGERANT. (Refer to “Chapter 61 heater and air conditioning - refrigerant, replacement”)

3. REMOVE ROOF PANEL. (Refer to “Chapter 88 exterior and interior - roof panel, replacement”)

4. REMOVE TOP EVAPORATOR ASSY.

Remove high-pressure and low-pressure pipes on top

evaporator.

Disconnect right drain hose.

Disconnect top evaporator assy connector.

Disconnect left drain hose.

Remove 2 retaining bolts in the front of top evaporator

Remove 3 retaining bolts in the back of top evaporator

Remove top evaporator assy.

61-43

5. REMOVE TOP EVAPORATOR CORE.

Remove 19 top evaporator assy housing retaining screws.

Remove top evaporator assy upper housing.

Remove 1 retaining screw from the clamp securing highpressure

and low-pressure pipes to lower housing.

Remove top evaporator core.

6. REMOVE TOP EVAPORATOR TEMPERATURE SENSOR AND FILTER SCREEN.

7. CHECK TOP EVAPORATOR CORE.

8. INSTALL TOP EVAPORATOR TEMPERATURE SENSOR. (Refer to “Chapter 61 heater and air

conditioning - top evaporator temperature sensor, replacement”)

61-44 HEATER AND AIR CONDITIONING - TOP EVAPORATOR CORE

9. INSTALL TOP EVAPORATOR CORE.

Position top evaporator core into top evaporator housing

Tighten retaining screws on clamp securing high-pressue

Install top evaporator assy upper housing, then tighten

19 retaining screws.

Position top evaporator on mounting bracket of roof.

Tighten 5 top evaporator assy retaining bolts.

61-45

Replace O-ring for top evaporator high-pressure and

lower-pressure pipes, then tighten high-pressure and

low-pressure pipes nut.

Connect right drain hose.

Connect top evaporator assy wire harness connector.

Connect left drain hose.

10. SUPPLY REFRIGERRANT. (Refer to “Chapter 61 heater and air conditioning - refrigerant, replacement”)

11. INSTALL ROOF PANEL. (Refer to “Chapter 88 exterior and interior - roof panel, replacement”)

12. CHECK AFTER INSTALLATION.

(a) Start the vehicle and turn A/C switch on, check that A/C system is functional and no refrigerant leaks.

61-46 HEATER AND AIR CONDITIONING - FRONT EVAPORATOR THERMISTOR

FRONT EVAPORATOR THERMISTOR

1. DISCONNECT BATTERY NEGATIVE CABLE .

2. REMOVE DASHBOARD. (Refer to “Chapter 83 instrument panel - dashboard, replacement”)

3. RECOVER REFRIGERANT. (Refer to “Chapter 61 heater and air conditioning - refrigerant, replacement”)

4. REMOVE FRONT A/C ASSY.(Refer to “Chapter 61 heater and air conditioning - front heater core,

5. REMOVE FRONT EVAPORATOR THERMISTOR.

(a) Remove blower assy and heater assy.(refer to )

Remove front evaporator thermistor carefully.

6. INSTALL FRONT EVAPORATOR THERMISTOR.

Position front evaporator thermistor on original position,

and run out thermistor wire along the slot on evaporator

Install front evaporator thermistor carefully to avoid

damage to the thermistor.

7. ASSEMBLE A/C ASSY. (Refer to “Chapter 61 heater and air conditioning - front heater core,

8. SUPPLY REFRIGERANT. (Refer to “Chapter 61 heater and air conditioning - refrigerant,

9. INSTALL DASHBOARD. (Refer to “Chapter 83 instrument panel - dashboard, replacement”)

TOP EVAPORATOR TEMPERATURE

TOP EVAPORATOR TEMPERATURE SENSOR

61-47

2. REMOVE TOP EVAPORATOR CORE. (Refer to “Chapter 61 heater and air conditioning - top

evaporator core, replacement”)

3. REMOVE TOP EVAPORATOR TEMPERATURE SENSOR.

Disconnect top evaporator temperature sensor connector.

Pry out top evaporator temperature sensor clamp.

61-48 HEATER AND AIR CONDITIONING -

Remove top evaporator temperature sensor.

4. INSTALL TOP EVAPORATOR TEMPERATURE SENSOR.

(a) Position front evaporator temperature sensor on original

position and remove sensor wire along the slot on evaporator

Install evaporator temperature sensor carefully and avoid

damage to sensor element.

5. INSTALL TOP EVAPORATOR ASSY. (Refer to “Chapter 61 heater and air conditioning - top evaporator

6. SUPPLY REFRIGERANT. (Refer to “Chapter 61 heater and air conditioning - refrigerant,

FRONT EXPANSION VALVE

61-49

2. OPEN ENGINE HOOD.

4. REMOVE FRONT EXPANSION VALVE.

(a) Remove 1 retaining bolt securing front A/C high-pressure

and low-pressure pipes to expansion valve.

Remove 2 bolts securing expansion valve to evaporator

core

Remove expansion valve.

5. INSTALL EXPANSION VALVE.

(a) Install expansion valve to evaporator core.

(b) Tighten 2 retaining bolts.

Always use new O-ring and lubricate it with compressor oil.

Install high-pressure and low-pressure pipes to expansion

valve, then tighten retaining bolt.

61-50 HEATER AND AIR CONDITIONING - REAR EXPANSION VALVE

REAR EXPANSION VALVE

2. RECOVER REFRIGERANT. (Refer to “Chapter 61 heater and air conditioning - refrigerant,

4. REMOVE REAR EXPANSION VALVE.

(a) Disconnect rear A/C shut off solenoid.

(b) Remove retaining bolt securing rear A/C high-pressure

Remove high-pressure and low-pressure pipes and shut

off solenoid valve.

Remove 2 rear expansion valve retaining bolts.

Remove rear expansion valve.

5. INSTALL REAR A/C EXPANSION VALVE.

Install rear A/C expansion valve to rear A/C pipes.

Always use new O-ring and lubricate it with compressor oil

Tighten 2 retaining bolts.

61-51

Install rear A/C high-pressure and low-pressure pipes

below rear A/C expansion valve, then tighten retaining

Connect rear A/C shut off solenoid valve connector.

Connect high-pressure and low-pressure pipes to rear A/C

pipes assy, then tighten nut to standard torque.

Torque: 12 ~ 15 N.m

Torque: 20 ~ 26 N.m

61-52 HEATER AND AIR CONDITIONING - FRONT A/C BLOWER

FRONT A/C BLOWER

2. REMOVE FRONT A/C BLOWER.

Disconnect front A/C blower connector from behind the

glove box.

3. CHECK BLOWER.

(a) Rotate the blade of the blower by hand, no stuck phenomenon

is found.

(b) Visually inspect blade of the blower, no abnormal wear

is present.

4. INSTALL FRONT A/C BLOWER..

(a) Place front A/C blower into blower unit and tighten 3

retaining screws.

(b) Connect blower connector.

(a) Turn front A/C switch on, confirm that blower works normally and no noise is heard.

REAR A/C BLOWER

61-53

2. REMOVE ROOF PANEL. (Refer to “Chapter 88 exterior and interior - roof panel, replacement”)

3. REMOVE LEFT TOP BLOWER.

(a) Remove 3 blower cover retaining screws.

(b) Remove blower cover.

Remove 3 blower retaining screws in top evaporator

Remove blower and disconncet blower connector.

4. REMOVE RIGHT TOP BLOWER.

The precedure to remove right top blower is similar to the precedure above.

5. CHECK BLOWER.

(b) Visually inspect blade of the blower, no abnormal wear is

present.

6. INSTALL LEFT BLOWER.

(a) Position blower into top evaporator housing in place.

(b) Tighten 3 retaining screws.

61-54 HEATER AND AIR CONDITIONING - REAR A/C BLOWER

Install blower cover and tighten 3 retaining screws.

7. INSTALL RIGHT BLOWER.

The precedure to install right blower is similar to the precedure above.

(a) Turn top evaporator blower switch on, check blower works normally and no abnormal noise is heard.

9. INSTALL ROOF PANEL. (Refer to “Chapter 88 exterior and interior - roof panel, replacement”)

REAR HEATER BLOWER

61-55

2. REMOVE REAR HEATER CORE. (Refer to “Chapter 61 heater and air conditioning - rear heater

3. REMOVE REAR HEATER BLOWER. (Refer to “Chapter 61 heater and air conditioning - rear

4. CHECK BLOWER.

5. INSTALL REAR HEATER BLOWER. (Refer to “Chapter 61 heater and air conditioning - rear

6. INSTALL REAR HEATER CORE (Refer to “Chapter 61 heater and air conditioning - rear heater

7. CHECK AFTER INSTALLATION.

(a) Turn rear heater blower switch on, check blower works normally and no abnormal noise is heard.

61-56 HEATER AND AIR CONDITIONING - FRONT BLOWER CONTROL MODULE

FRONT BLOWER CONTROL MODULE

2. REMOVE FRONT BLOWER CONTROL MODULE.

Disconnect front blower control module connector under

the glove box.

Remove 2 front blower control module retaining screws.

Remove front blower control module.

3. INSTALL FRONT BLOWER CONTROL MODULE.

(a) Insert front blower control module into blower housing.

(b) Tighten front blower control module retaining screws.

(a) Turn front blower switch on, check front blower is operational in all positions.

REAR HEATER BLOWER RESISTOR

61-57

2. REMOVE REAR HEATER BLOWER RESISTOR.

(a) Remove 3 rear heater blower resistor upper cover

Disconnect rear heater blower resistor connector.

Remove 2 rear heater blower resistor retaining screws.

Remove rear heater blower resistor.

3. INSTALL REAR HEATER BLOWER RESISTOR.

(a) Install rear heater blower resistor.

61-58 HEATER AND AIR CONDITIONING - REAR HEATER BLOWER RESISTOR

Install blower resistor upper cover.

Tighten 3 retaining screws.

(a) Turn rear heater blower switch on, check rear heater blower is operational in all positions.

TOP EVAPORATOR BLOWER

RESISTOR

TOP EVAPORATOR BLOWER RESISTOR

61-59

3. REMOVE TOP EVAPORATOR BLOWER RESISTOR.

(a) Disconnect blower resistor connector.

(b) Remove blower resistor retaining screw.

Remove blower resistor.

4. INSTALL TOP EVAPORATOR BLOWER RESISTOR.

(a) Insert blower resistor into top evaporator housing.

(b) Tighten 1 retaining screw.

(a) Turn top evaporator blower switch on, check top evaporator blower is operational in all positions.

6. INSTALL ROOF PANEL. (Refer to “Chapter 88 exterior and interior - roof panel, replacement”)

61-60 HEATER AND AIR CONDITIONING - FRONT A/C VENT DUCT

FRONT A/C VENT DUCT

1. INSTRUMENT PANEL VENT DUCT.

(a) Remove instrument panel. (Refer to “Chapter 83

instrument panel - dashboard, replacement”)

A/C front and side vent duct are an integral part of

instrument panel and can not be serviced or replaced

separately.

2. INSTALL DASHBOARD VENT DUCT. (Refer to “Chapter 83 instrument panel - dashboard,

3. REMOVE LEFT FOOT DUCT.

(a) Remove dashboard. (Refer to “Chapter 83 instrument panel - dashboard, replacement”)

(b) Remove 4 transmission operation mechanism retaining bolts. (Refer to “Chapter 41 transmission - transmission

operation mechanism assy, replacement”)

Remove 3 left foot duct mounting bolts and disengage

the pawls.

Remove left foot duct.

4. INSTALL LEFT FOOT DUCT.

(a) Position left foot duct to front A/C assy and engage the

pawls.

(b) Tighten 3 retaining bolts.

Install 4 transmission operation mechanism retaining

bolts. (Refer to “Chapter 41 transmission - transmission

Install dashboard. (Refer to “Chapter 83 instrument panel

- dashboard, replacement”)l

61-61

5. REMOVE RIGHT FOOT DUCT.

(a) Remove glove box to get access to right foot duct.

(b) Disengage the pawl.

6. INSTALL RIGHT VENT DUCT.

(a) Engage right vent duct with front A/C assy.

(b) Install glove box.

(a) Turn front blower switch on, check rear heater blower is operational in all positions.

61-62 HEATER AND AIR CONDITIONING - REAR A/C VENT DUCT

REAR A/C VENT DUCT

1. REMOVE REAR A/C VENT DUCT.

(a) Remove roof panel. (Refer to “Chapter 88 exterior and

interior - roof panel, replacement”)

Rear A/C vent duct is an integral part of roof panel and can

not be serviced separately.

2. INSTALL REAR A/C VENT DUCT.

(a) Install roof panel. (Refer to “Chapter 88 exterior and interior - roof panel, replacement”)

RECIRCULATION DOOR MOTOR

61-63

2. REMOVE GLOVE BOX.

(a) Pull glove box upward to disengage the pawl on its lower

side from the latch on dashboard.

(b) Remove glove box.

3. REMOVE REVERSE RADAR CONTROL UNIT.

(a) Disconnect reverse radar control unit connector and

remove retaining bolt.

(b) Remove reverse radar control unit.

4. REMOVE RECIRCULATION DOOR MOTOR.

(a) Disconnect recirculation door motor connector and

remove 3 retaining screws.

Remove recirculation door motor.

61-64 HEATER AND AIR CONDITIONING - RECIRCULATION DOOR MOTOR

5. INSTALL RECIRCULATION DOOR MOTOR.

(a) Position recirculation door motor.

(b) Tighten 3 recirculation door motor retaining screws and

connect the connector.

6. INSTALL REVERSE RADAR CONTROL UNIT.

(a) Tighten 1 reverse radar control unit retaining bolt.

(b) Connect reverse radar control unit connector.

7. INSTALL GLOVE BOX.

(a) Position glove box with its pawl and latch on dashboard

aligned.

(a) Install glove box into place.

(a) Turn A/C switch on, confirm that recirculation door motor works normally.

BLEND DOOR MOTOR

61-65

3. DRAIN COOLANT. (Refer to “Chapter 17A cooling - coolant, replacement”)

4. RECOVER REFRIGERANT. (Refer to “Chapter 61 heater and air conditioning - refrigerant,

5. REMOVE DASHBOARD. (Refer to “Chapter 83 instrument panel - dashboard, replacement”)

6. REMOVE FRONT A/C ASSY. (Refer to “Chapter 61 heater and air conditioning - front heater

7. REMOVE BLEND DOOR MOTOR.

(a) Disassemble front A/C assy. (Refer to “Chapter 61 heater

and air conditioning - front evaporator core, replacement”)

(b) Remove 3 blend door motor retaining screws.

Remove blend door motor.

61-66 HEATER AND AIR CONDITIONING - BLEND DOOR MOTOR

8. INSTALL BLNED DOOR MOTOR.

Tighten 3 blend door motor retaining screws.

Assemble front A/C assy. (Refer to “Chapter 61 heater

9. INSTALL A/C ASSY. (REFER TO “CHAPTER 61 HEATER AND AIR CONDITIONING - FRONT

HEATER CORE, REPLACEMENT”)

10. INSTALL DASHBOARD. (Refer to “Chapter 83 instrument panel - dashboard, replacement”)

11. CONNECT BATTERY NEGATIVE CABLE.

12. FILL COOLANT. (Refer to “Chapter 17A cooling - coolant, replacement”)

13. SUPPLY REFRIGERANT. (Refer to “Chapter 61 heater and air conditioning - refrigerant,

(a) Turn A/C switch on, confirm blend door motor works normally.

MODE DOOR MOTOR

61-67

3. REMOVE DASHBOARD. (Refer to “Chapter 83 instrument panel - dashboard, replacement”)

BEFORE REMOVING DASHBOARD, ENSURE THE VENT BUTTON ON A/C CONTROLLER IS SELECTED

AND AIR COMES OUT FROM THE CENTER ONLY.

4. REMOVE MODE DOOR MOTOR.

(a) Remove 3 mode door motor retaining screws.

Remove mode door motor.

5. INSTALL MODE DOOR MOTOR.

(a) Tighten 3 mode door motor retainng screws.

When installation, ensure the upper ventilator door in A/C

assy is in a position where air comes out only from the

61-68 HEATER AND AIR CONDITIONING - MODE DOOR MOTOR

6. INSTALL DASHBOARD. (Refer to “Chapter 83 instrument panel - dashboard, replacement”)

7. CONNECT BATTERY NEGATIVE CABLE.

(a) Turn A/C switch on, confirm that mode door motor works normally.

FRONT A/C FILTER

61-69

1. REMOVE GLOVE BOX.

2. REMOVE A/C FILTER COVER.

(a) Release locking tab on both sides of filter cover, then

remove cover.

3. SLIDE A/C FILTER.

4. INSTALL A/C FILTER.

Install A/C filter according to arrow direction marked on one

61-70 HEATER AND AIR CONDITIONING - FRONT A/C FILTER

5. INSTALL A/C FILTER COVER AND SNAP IT INTO

PLACE.

6. INSTALL GLOVE BOX.

REAR A/C FILTER SCREEN

61-71

1. REMOVE ROOF PANEL. (Refer to “Chapter 88 exterior and interior - roof panel, replacement”)

3. REMOVE TOP EVAPORATOR. (Refer to “Chapter 61 heater and air conditioning - top evaporator

4. REMOVE REAR A/C FILTER SCREEN.

(a) Remove top evaporator. (Refer to “Chapter 61 heater

and air conditioning - top evaporator core, replacement”)

(b) Remove adhesive tape, then remove filter screen.

Replace filter screen or clean filter screen with water, then

dry it with compressor air.

5. INSTALL REAR A/C FILTER SCREEN.

(a) Secure filter screen to the top A/C evaporator with adhesive tape.

6. INSTALL TOP EVAPORATOR ASSY. (Refer to “Chapter 61 heater and air conditioning - top evaporator

7. SUPPLY REFRIGERANT. (Refer to “Chapter 61 heater and air conditioning - refrigerant,

8. INSTALL ROOF PANEL. (Refer to “Chapter 88 exterior and interior - roof panel, replacement”)

61-72 HEATER AND AIR CONDITIONING - A/C PRESSURE SWITCH

A/C PRESSURE SWITCH

3. REMOVE FRONT GRILLE. (Refer to “Chapter 88 exterior amd interior trim - front grille, replacement”)

4. REMOVE FRONT BUMPER. (Refer to “Chapter 88 exterior amd interior trim - front bumper assy,

5. REMOVE A/C PRESSURE SWITCH .

(a) Disconnect A/C pressure switch connector.

Remove A/C pressure switch with suitable wrench.

6. INSTALL A/C PRESSURE SWITCH.

Always use new O-ring and apply compressor oil to it.

Tighten A/C pressure switch to specified torque.

Torque: 20 ~ 26 N·m

(a) Turn A/C switch on, check that electronic fan speed is varied with the pressure in A/C line, then comfirm

A/C pressure switch is functional.

9. INSTALL FRONT BUMPER. (Refer to “Chapter 88 exterior amd interior trim - front bumper assy,

10. INSTALL FRONT GRILLE.(Refer to “Chapter 88 exterior amd interior trim - front grille, replacement”)

REAR A/C SHUT-OFF SOLENOID

REAR A/C SHUT-OFF SOLENOID VALVE

61-73

3. REMOVE REAR A/C SHUT OFF SOLENOID VALVE.

(a) Open engine ECM compartment cover behind assistant

(b) Disconnect rear A/C shut off solenoid valve connector.

Remove high pressure pipe above the rear A/C shut off

solenoid valve.

Remove A/C pipe locking nut under the vehicle.

Remove rear A/C pipe and rear A/C shut off solenoid

Separate rear A/C shut off solenoid valve from high

pressure pipe.

Remove shut off solenoid valve.

4. INSTALL REAR A/C SHUT OFF SOLENOID VALVE.

(a) Connect rear A/C shut off solenoid valve to upper highpressure

pipe. then tighten the union nut to standard

(b) Connect rear A/C pipes assy to lower high-pressure

pipe, then tighten the connection nut to standard torque.

Install the rear A/C shut off solenoid valve according to the

arrow direction marked on it.

61-74 HEATER AND AIR CONDITIONING -

Connect rear A/C shut off solenoid connector.

5. SUPPLY REFRIGERANT. (Refer to “Chapter 61 heater and air conditioning - refrigerant,

(a) Start the vehicle and turn A/C switch on, check that rear A/C system is functional and no refrigerant

leakage was present.

REAR HEATER SOLENOID VALVE

61-75

3. REMOVE REAR HEATER SOLENOID VALVE.

(a) Disconnect rear heater solenoid valve connector.

Remove 2 clamps on both sides of heater hose, then

separate them from rear heater solenoid valve.

Remove 2 rear heater solenoid valve retaining screws.

Remove rear heater solenoid valve.

61-76 HEATER AND AIR CONDITIONING - REAR HEATER SOLENOID VALVE

4. INSTALL REAR HEATER SOLENOID VALVE.

(a) Position rear heater solenoid valve, then tighten 2

Note the water flow direction and do not reverse direction

when installation.

Attach heater hoses to solenoid valve, then tighten

clamps.

Connect rear heater solenoid valve connector.

(a) Fill coolant, start engine until it is warm, check both sides of solenoid valve for coolant leaks.

(b) Turn rear blower switch on, confirm that rear heater is functional.

61-77

1. REMOVE COOLING FAN ASSY. (Refer to “Chapter 17 cooling - cooling fan assy, replacement”)

2. DISASSEMBLE COOLING FAN ASSY.

(a) Remove 3 cooling fan locking nuts.

Remove retaining nut mounting fan blade to fan motor.

3. ASSEMBLE COOLING FAN ASSY.

(a) Tighten retaining nut mounting fan blade to fan motor.

Tighten 3 cooling fan locking nuts.

4. INSTALL COOLING FAN ASSY. (Refer to “Chapter 17 cooling - cooling fan assy, replacement”)

61-78 HEATER AND AIR CONDITIONING - COMPRESSOR(4G69)

COMPRESSOR(4G69)

4. REMOVE COMPRESSORE BELT.

(a) Loosen idler locking nut.

(b) loosen idler adjustment bolt by turning it counterclockwise.

5. REMOVE COMPRESSOR ASSY.

Disconnect compressor connector.

Loosen 2 retaining nuts mounting high-pressure and lowpressure

pipes to compressor.

Separate high-pressure and low-pressure pipes from

compressor.

Remove 4 compressor retaining bolts.

Reomve compressor assy.

6. CHECK COMPRESSOR OIL.

(a) If replace the compressor with a new one, remove the refrigerant gas from the service valve, drain the

following amount of oil from the new compressor before installing.

Oil capacity inside new compressor - remaining oil amount in the removed compressor = oil

amount to be drained out when replacing.

61-79

• When checking the compressor oil level, observe the precautions on the compressor removal/

installation.

• Compressor oil will remain in the pipes of the vehicle. If a new compressor is installed without

draining out some oil inside, too much oil will affect heat exchange in the refrigerant cycle and

cause refrigerant failure.

• If the remaining oil in the removed compressor is too little in volume, oil leakage checking is

• Be sure to use the right compressor oil.

7. INSTALL COMPRESSOR ASSY.

(a) Position the compressor properly, then tighten 4 retaining

(b) Install high-pressure and low-pressure pipes, then

tighten 2 retaining nuts.

• Check compressor for specified oil level.

• Always use new O-rings and sufficiently apply

compressor oil to them.

8. Connect the connector.

(a) Install compressor belt.

(b) Rotate adjustment bolt clockwise to keep compressor

belt in proper tensiton.

9. SUPPLY REFRIGERANT. (Refer to “Chapter 61 heater and air conditioning - refrigerant,

(a) Start engine until it is warm, then turn A/C switch on, check compressor works normally and no refrigerant

leaks.

61-80 HEATER AND AIR CONDITIONING - COMPRESSOR(ISF2.8)

COMPRESSOR(ISF2.8)

(b) Turn over driver seat and open engine compartment

It is recommended that the battery negative cable must be disconnected, prior to compressor

removing, to avoid touching generator positive retaining nut.

5. REMOVE ASSISTANT DRIVER SEAT. (Refer to “Chapter 84 seat - drive / assistant driver seat,

6. OPEN ENGINE COMPARTMENT COVER UNDER

(a) Open front floor covering.

(b) Remove 5 retaining bolts.

7. REMOVE INTAKE CORRUGATED HOSE TO TURBO

CHARGER.

(a) Remove band clamps from both sides of intake ripple

(b) Remove intake ripple hose.

8. DISCONNECT COMPRESSOR CONNECTOR.

61-81

9. REMOVE HIGH PRESSURE AND LOW PRESSURE

PIPES ON COMPRESSOR SIDE.

(a) Remove retaining bolt mounting high pressure and low

Cover the inlet and outlet holes on compressor and the

opening of high pressure and low pressure pipes with a

clean cloth to avoid dust entering.

10. REMOVE ENGINE BELT. (Refer to CUMMINS ISF SERIAL ENGINE SERVICE MANUAL)

11. REMOVE COMPRESSOR ASSY. (Refer to CUMMINS ISF SERIAL ENGINE SERVICE MANUAL)

12. CHECK COMPRESSOR OIL.

13. INSTALL COMPRESSOR ASSY. (Refer to CUMMINS ISF SERIAL ENGINE SERVICE MANUAL)

14. INSTALL COMPRESSOR ASSY.

(a) Install high pressure and low pressure pipes to compressor.

Torque: 40 ~ 45 N.m

Always use a new O - ring to A/C pipes.

15. CONNECT COMPRESSOR CONNECTOR.

61-82 HEATER AND AIR CONDITIONING - COMPRESSOR(ISF2.8)

16. INSTALL INTAKE RIPPLE HOSE TO TURBOCHARGER.

Position intake ripple hose to turbocharger.

Tighten the band clamp on both sides of intake ripple

17. INSTALL ENGINE BELT. (Refer to CUMMINS ISF SERIAL ENGINE SERVICE MANUAL)

18. INSTALL BATTERY NEGATIVE CABLE.

19. SUPPLYREFRIGERANT. (Refer to “Chapter 61 heater and air conditioning - refrigerant,

20. CHECK REFRIGERANT FOR LEAKAGE. (Refer to “Chapter 61 heater and air conditioning -

21. INSTALL ENGINE COMPARTMENT COVER UNDER

Cover surfacing to front floor.

22. INSTALL ASSISTANT DRIVER SEAT. (Refer to “Chapter 84 seat - drive / assistant driver seat,

23. PUT DOWN DRIVER SEAT AND LOCK IT.

CONDENSER

61-83

1. REMOVE FRONT GRILLE. (Refer to “Chapter 88 exterior amd interior trim - front grille, replacement”)

2. REMOVE FRONT BUMPER. (Refer to “Chapter 88 exterior amd interior trim - front bumper assy,

4. REMOVE CONDENSER.

(a) Loosen A/C high pressure and low pressure pipes retaining

(b) Disconnect high pressure and low pressure pipes from

condenser.

Loosen 4 retaining bolts mounting condenser to radiator.

Remove the condenser with caution.

The condenser is a heat exchanger. It has many vulnerable

parts (especially the heat sink) in structure and material.

When removing and installing, pay attention not to

dropping, colliding or scraping.

5. INSTALL CONDENSER.

(a) Position condenser on radiator.

(b) Tighten 4 retaining bolts securing condenser to radiator.

Add 20 ml compressor oil to condenser when replacing

with a new condenser.

61-84 HEATER AND AIR CONDITIONING - CONDENSER

Install high pressure pipe to condensser, then tighten the

retaining bolt.

Install low pressure pipe to condensser, then tighten the

Always use new O - rings and apply compressor oil to them

before installing high pressure and low pressure pipes.

6. SUPPLY REFRIGERANT. (Refer to “Chapter 61 heater and air conditioning - refrigerant, replacement”)

7. WARM UP ENGINE.

8. CHECK REFRIGERANT FOR LEAKAGE. (Refer to “Chapter 61 heater and air conditioning -

A/C RECEIVER DRIER FILTER

ELEMENT

A/C RECEIVER DRIER FILTER ELEMENT

61-85

3. REMOVE CONDENSER. (Refer to “Chapter 61 heater and air conditioning - condenser, replacement”)

4. REMOVE A/C RECEIVER DRIER FILTER ELEMENT.

(a) Remove locking bolt from the bottom of A/C receiver

drier with special wrench.

Remove filter element, filter screen and locking bolt.

Always use new O - ring and apply compressor oil to it

before installing filter element and filter screen.

5. INSTALL A/C RECEIVER DRIER FILTER ELEMENT.

(a) Install new filter element and filter screen.

(a) Tighten locking bolt.

Torque: 30 - 35 N.m

6. INSTALL CONDENSER.(Refer to “Chapter 61 heater and air conditioning - condenser,

7. SUPPLY REFRIGERANT. (Refer to “Chapter 61 heater and air conditioning - refrigerant, replacement”)

8. CHECK AFTER INSTALLATION .

(a) Turn A/C switch on, check that A/C system works normally and no refrigerant leaks.

SUPPLEMENTAL RESTRAINT SYSTEM ......................................... 62-1

PRECAUTION.............................................................................. 62-1

SYSTEM PRINCIPLES................................................................ 62-2

SYSTEM PERFORMANCE ......................................................... 62-3

ON-VEHICLE INSPECTION ........................................................ 62-4

HORN SWITCH ASSY ....................................................................... 62-6

REPLACEMENT .......................................................................... 62-6

DISPOSAL ................................................................................... 62-9

CLOCK SPRING .............................................................................. 62-13

REPLACEMENT ........................................................................ 62-13

RCM.................................................................................................. 62-16

REPLACEMENT ........................................................................ 62-16

62

SUPPLEMENTAL RESTRAINT SYSTEM - SUPPLEMENTAL RESTRAINT SYSTEM

62-1

RESTRAINT SYSTEM

• Some vehicles are equipped with SRS (Supplemental Restraint System), which contains a driver

airbag. Failure to carry out service operations in the correct sequence could cause the SRS to

unexpectedly deploy during servicing. It may lead to a serious accident. Furthermore, if a

mistake is made in servicing the SRS, it is possible that the SRS may fail to operate when

required. Before servicing (including removal or installation of parts, inspection or

replacement), be sure to read the following items carefully, then follow the correct procedures

described in the service manual.

• Operation must be started 90 seconds after the ignition switch is turned to the “LOCK” position

and the negative (-) cable and positive (+) cable are disconnected from the battery. (The SRS is

equipped with a back-up power source. If operation is started within 90 seconds after

disconnecting the battery negative (-) cable and positive (+) cable, the SRS may deploy.)

• Do not expose the horn switch assy (with driver airbag) directly to hot air or flames.

• Malfunction symptoms of the SRS are difficult to confirm, so the DTCs become the most

important source of information when troubleshooting. When troubleshooting the SRS, always

inspect the DTCs before disconnecting the battery.

• Even in case of a minor collision that the SRS does not deploy, the horn switch assy should be

inspected. (Refer to “Chapter 62 supplemental restraint system - horn switch assy, replacement”,

“Chapter 62 supplemental restraint system - RCM, replacement”)

• Before repairing, remove the RCM first if shocks may be applied to it during repairs.

• Never use SRS related parts from another vehicle. Be sure to replace them with new parts when

• Do not disassemble and repair the horn switch assy.

• If the horn switch assy has been dropped, or there are cracks, dents or other faults, replace it

• Use a multimeter with high impedance (10 kΩ/V minimum) for troubleshooting of the SRS electrical

circuits.

• Information labels are attached to the SRS components. Be sure to follow the instructions on

the labels when performing operations.

• After repairing on the SRS system, perform the inspection of airbag warning light. (Refer to

“Chapter 04 diagnostics - supplemental restraint system, precheck”, “Chapter 04 diagnostics -

supplemental restraint system, SRS warning light is always on”, “Chapter 04 diagnostics -

supplemental restraint system, SRS warning light is inoperative”)

• When the negative (-) cable is disconnected from the battery, the memory of the clock and audio

system will be cleared. So before repairing, record the necessary data of the clock and audio

system. After repairing, reset the clock and audio system. Never use a back-up power supply

from another battery to avoid erasing the memory in each memory system. The back-up power

supply will supply power to the SRS system. It could cause the SRS to unexpectedly deploy

during servicing.

62-2

SYSTEM PRINCIPLES

1. SYSTEM STRUCTURE.

(a) The SRS system contains steering wheel assy, driver airbag, airbag wire harness, clock spring and

RCM.

2. SYSTEM SELF-CHECK.

(a) After turning the ignition switch to the “ON” position to start the SRS, the RCM will perform self-check

by the preset programme.

• If the airbag warning light goes out 4 seconds after lighting up, it means that the system is normal and

has passed the self-check. then the RCM enters monitoring status.

• If the airbag warning light does not light up,flashes or stays on, it means that the system is abnormal

and fail to pass the self-check.

System temperature: - 35 ~ 85 ℃

System volt: 12 ± 3 V

3. SYSTEM PRINCIPLES.

(a) When driving normally (including all kinds of road condition and interference), the RCM will not output

the ignition signal. The drive airbag is nonoperative.

(b) When the vehicle is involved in a serious frontal impact, the RCM will output the ignition signal timely to

deploy the driver airbag.

• The SRS airbag just provides a further protection besides the seat belt.

• To achieve the perfect protection, the driver must fasten the seat belt correctly and keep a good

posture.

• The technical parameters of airbag and RCM is matched each other. Never use airbag or RCM

components of other brands with this product together.

• It’s forbidden to maintenance in unauthorized dealer or by non-professional operators.

• Never use a multimeter to measure the resistance of airbag. to prevent airbag deployed unexpectedlly.

62-3

SYSTEM PERFORMANCE

1. AIRBAG.

(a) Fuzzy state (or critical condition)

• If the vehicle frontal collision strength, lower than the vehicle 23 ± 1 Km/h speed driving straight frontal

walls can not be moved and will not be deformed collision strength (perpendicular to the vehicle direction),

the airbag will be operative timely.

• If the vehicle frontal collision strength, more than the vehicle 23 ± 1 Km/h speed driving straight frontal

• If the strength of the frontal impact is within the strength of impact against unmovable and underformable

walls (perpendicular to the driving direction) when driving in straight line at the speed between 13±

1 Km/h and 23 ± 1 Km/h, the system will be in fuzzy control state, which is normal weather or not the

airbags are deployed.

(b) When a collision described below, the airbag must be deployed timely to protect the driver. In addition,

the relevant laws and regulations should be complied with.

impact from, the airbag will not expand in the design.

(d) If the vehicle suffers a serious collision which is from the bottom, the airbag will be deployed possibly.

62-4

1. INSPECT HORN SWITCH ASSY (VEHICLE DOES NOT SUFFER A COLLISION).

(a) Check the diagnostic system. (Refer to “Chapter 04 diagnostics - supplemental restraint system,

precheck”)

(b) Visual check.

• Check for cuts, micro-cracks or marked discoloration on the horn switch assy surface and in

the grooved portion.

• Make sure there is no interference between the horn switch assy and steering wheel.

• Make sure the clearance between the horn switch assy and steering wheel is uniform.

• If any fault is found, replace with a new part if necessary. (Refer to “Chapter 62 supplemental

restraint system, horn switch assy, replacement”, “Chapter 51 steering column - steering wheel

2. INSPECT HORN SWITCH ASSY (VEHICLE SUFFERS A COLLISION BUT AIRBAG IS NOT

DEPLOYED).

(a) Check the diagnostic system.

(b) Remove the horn switch assy. (Refer to “Chapter 62 supplemental restraint system, horn switch assy,

• Check for cuts, micro-cracks or marked discoloration on

the horn switch assy surface and in the grooved portion.

• Check for cuts and cracks in wire harness and chipping

in connectors.

• Check for deformation on the steering wheel assy.

• Check whether the clock spring is damaged.

If any fault is found, replace with a new part if necessary. (Refer

to “Chapter 62 supplemental restraint system, horn switch assy,

replacement”, ”Chapter 62 supplemental restraint system - clock

spring, replacement”, “Chapter 51 steering column - steering

wheel assy, replacement”)

(d) Install the horn switch assy. (Refer to “Chapter 62

supplemental restraint system - horn switch assy,

• Make sure there is no interference between the horn

switch assy and steering wheel.

• Make sure the clearance between the horn switch

assy and steering wheel is uniform.

62-5

If any fault is found, replace with a new part for necessary.

(Refer to “Chapter 62 supplemental restraint system, horn

switch assy, replacement”, “Chapter 51 steering column -

steering wheel assy, replacement”)

3. INSPECT HORN SWITCH ASSY. (VEHICLE SUFFERS A COLLISION AND AIRBAG IS NOT DEPLOYED)

(b) Replace the horn switch assy, clock spring, SRS wire harness and RCM with new parts. (Refer to

“Chapter 62 supplemental restraint system - horn switch assy, replacement”, “ Chapter 62

supplemental restraint system - clock spring, replacement”, “Chapter 62 supplemental restraint system

- RCM, replacement”)

If the airbag is deployed, be sure to replace all of the horn switch assy, clock spring, SRS wire harness

and RCM together.

4. INSPECT RCM .(VEHICLE DOES NOT SUFFER A COLLISION)

5. INSPECT RCM. (VEHICLE SUFFERS A COLLISION BUT AIRBAG IS NOT DEPLOYED)

6. INSPECT RCM .(VEHICLE SUFFERS A COLLISION AND AIRBAG IS DEPLOYED)

“Chapter 62 supplemental restraint system - horn switch assy, replacement”, “Chapter 62 supplemental

restraint system - clock spring, replacement”, “Chapter 62 supplemental restraint system - RCM,

62-6

SUPPLEMENTAL RESTRAINT SYSTEM - HORN SWITCH ASSY

1. PRECAUTION. (Refer to “Chapter 62 supplemental restraint system - supplemental restraint

system, precaution”)

4. REMOVE HORN SWITCH ASSY.

(a) Turn the steering wheel to its straight position and face

the tires straight ahead.

Using a hex spanner, loosen 2 inner hex bolts at the

bottom of the steering wheel.

Turn the horn switch assy over.

Disconnect the horn switch wire harness connector.

Remove the horn switch assy.

62-7

• Do not disassemble the horn switch assy.

• When removing the horn switch assy or handling a

new horn switch assy, it should be placed with the

pad top surface upward. Placing it with the pad top

surface downward may lead to a serious accident if

the airbag accidently inflates. Also, do not place

horn switch assy on top of one another.

5. INSPECT HORN SWITCH ASSY.

(a) Visually check for cuts, micro-cracks and marked discolouration on the horn switch assy top surface

and in the grooved portion.

62-8

6. INSTALL HORN SWITCH ASSY.

(a) Connect the horn switch wire harness connector.

• Never use SRS parts from another vehicle. Be sure to

replace them with new parts when replacing.

• If the horn switch assy has been dropped, or there

are cracks, dents or other faults, be sure to replace it

• Do not drag the clock spring wire harness and make

sure there is no interference between wire harness

and parts around.

If you hear a clicking sound, the connector is connected

(b) Position the horn switch assy properly.

Using a hex spanner, tighten 2 inner hex bolts at the

Torque: 5~7 N·m

7. CONNECT BATTERY POSITIVE CABLE.(Refer to “Chapter 20 starting and charging - battery,replacement”)

8. CONNECT BATTERY NEGATIVE CABLE.(Refer to “Chapter 20 starting and charging - battery,replacement”)

9. INSPECT SRS WARNING LIGHT

62-9

DISPOSAL

• Never dispose of the horn switch assy with an undeployed airbag.

• The airbag produces a sizable exploding sound when being deployed. So be sure to perform the

operations outdoor where it will not create a nuisance to nearby residents.

• When deploying the airbag, be sure to use the

specified SST (SRS Airbag Deployment Tool) and

perform the operations in a place away from

electrical noise.

• When deploying a airbag, be sure to perform the

operation at least 10 m away from horn switch assy.

• The horn switch assy is very hot when the airbag is

depoyed. So leave it at least 30 minutes after

deployment.

• Use gloves and goggles when handling a horn

switch assy with the deployed airbag.

• Do not apply water, etc. to a horn switch assy with

the deployed airbag.

• Be sure to wash your hands with water after

completing the operation.

When disposing of the horn switch assy, be sure to follow the correct procedures described below to

deploy the airbag.

62-10

1. CHECK FUNCTION OF SST.

(a) Prepare a battery for the power supply to deploy the

airbag.

(b) Connect the SST to the battery.

Do not connect the yellow connector which will be

connected to the airbag.

Press the SST activation switch, check whether the

illumination lights up.

Standard: Light up

If the illumination lights up when the activation switch is

not pressed, SST malfunction is probable. Never use this

SST.

Disconnect the SST from the battery.

2. DISPOSE OF HORN SWITCH ASSY.

• When disposing of the horn switch assy (with airbag), never use the customers’ vehicle to

• Be sure to follow the procedures described below when deploying the airbag.

(a) Prepare a battery for the power supply to deploy the airbag.

(b) Remove the horn switch assy. (Refer to “Chapter 62 supplemental restraint system - horn switch assy,

Tighten 2 bolts to the 2 bolt holes of the horn switch assy.

• Tighten the bolts by hands until the bolts become

hard to turn.

• Do not tighten the bolts too much.

• The bolts should be long enough.

Connect the SST to the horn switch assy.

62-11

Prepare a steel rim with tire and place it level.

Separately tie the left and right sides of the horn switch

assy to the steel rim through the hub nut holes.

• Be sure to tie down the horn switch assy with the

pad surface upward.

• Make sure the horn switch assy is tied down tightly.

• To avoid damaging the SST connector and wire

harness, secure some slack for the SST wire harness

inside the steel rim.

Connect the SST to the battery.

Move the SST at least 10 m away from the horn switch

Cover the horn switch assy with a carton or tires.

• Make sure the horn switch assy is covered

• Weight the carton down with at least 20 Kg.

• Place at least 3 tires. In addition, always use the

redundant tires which may be marked by the airbag

Press the activation switch to deploy the airbag.

Make sure nobody is within 10 m away from the horn switch

The airbag is deployed simultaneously when the LED of the

SST activation switch lights up.

62-12

Remove the horn switch assy from the steel rim.

Put the horn switch assy in a plastic bag and tie the end

tightly. Dispose of it in the same way as other general

parts disposal.

SUPPLEMENTAL RESTRAINT SYSTEM - CLOCK SPRING

62-13

CLOCK SPRING

4. REMOVE HORN SWITCH ASSY. (Refer to “Chapter 51 steering column - steering wheel assy,

6. REMOVE COMBINATION SWITCH COVER. (Refer to “Chapter 51 steering column - combination

7. REMOVE CLOCK SPRING.

(a) Disconnect 2 connectors:

Remove the clock spring with 3 clips.

8. INSTALL CLOCK SPRING.

(a) Install the clock spring with 3 clips.

62-14

Connect 2 connectors:

9. CENTER CLOCK SPRING.

(a) Make sure the ignition switch is in the “LOCK” position.

(b) Make sure the battery positive and negative cables are

disconnected.

Do not start the operation within 90 seconds after

diconnecting the cables.

There is an information label on the clock spring. Follow

the instructions on the label.

becomes hard to turn.

Rotate the cable clockwise about 3 turns to align the

The cable will rotate above 3 turns to either left or right off

the center.

For a new clock spring:

• It is located at the center position by clip.

• Do not forget to remove the clip after installing a new

clock spring.

62-15

10. INSTALL COMBINATION SWITCH UPPER COVER. (Refer to “Chapter 51 steering column - combination

11. INSTALL STEERING WHEEL ASSY. (Refer to “Chapter 51 steering column - steering wheel assy,

12. INSTALL HORN SWITCH ASSY. (Refer to “Chapter 51 steering column - steering wheel assy,

13. CONNECT BATTERY POSITIVE CABLE. (If airbag is equipped, refer to “Chapter 20 starting and

charging - battery, replacement”)

14. CONNECT BATTERY NEGATIVE CABLE. (Refer to “Chapter 20 starting and charging - battery,

15. INSPECT SRS WARNING LIGHT.

62-16

SUPPLEMENTAL RESTRAINT SYSTEM - RCM

4. REMOVE INSTRUMENT CENTER COVER.

(a) Loosen 3 screws and 2 bolts to remove the instrument

center cover.

The instrument cover is on the front carpet assy which is in

front of the middle platform assy and under the dashboard

ashtray assy.

5. REMOVE RCM.

(b) Make sure the battery positive and negative cables are disconnected.

• Do not start the operation within 90 seconds after diconnecting the cables.

• Never strike the RCM when it is energized.

Disconnect the RCM wire harness connector.

Loosen 3 bolts and remove the RCM.

6. INSTALL RCM.

62-17

(d) Tighten 3 bolts by the sequence shown in the illustration.

Torque: 8 ~ 10 N·m

Position the RCM along the direction shown in the

information label.

Connect the RCM wire harness connector.

7. INSTALL INSTRUMENT CENTER COVER.

Tighten 3 screws and 2 bolts to install the instrument

8. CONNECT BATTERY POSITIVE CABLE. (Refer to “Chapter 20 starting and charging - battery,

9. CONNECT BATTERY NEGATIVE CABLE. (Refer to “Chapter 20 starting and charging - battery,

10. INSPECT SRS WARNING LIGHT.

SEAT BELT SYSTEM ........................................................................ 63-1

PRECAUTION.............................................................................. 63-1

SEAT BELT WARNING SYSTEM...................................................... 63-2

PROBLEM SYMPTOMS TABLE.................................................. 63-2

INSPECTION ............................................................................... 63-3

DRIVER / ASSISTANT DRIVER SEAT BELT ................................... 63-4

COMPONENTS ........................................................................... 63-4

PASSENGER SEAT BELT ................................................................ 63-5

COMPONENTS ........................................................................... 63-5

SEAT BELT CATCH ASSY................................................................ 63-9

REPLACEMENT .......................................................................... 63-9

RETRACTOR ASSY......................................................................... 63-15

OVERHAUL ............................................................................... 63-15

63

SEAT BELT - SEAT BELT SYSTEM

63-1

SEAT BELT SYSTEM

BELT

• Once any fault is found in the system, be sure to replace the parts (including belt, retractor, lock

catch & latch, bolt and nut).

• The seat belt which is not used in a collision should also be inspected and replaced if found any

damage or working improperly.

63-2

SEAT BELT - SEAT BELT WARNING SYSTEM

SEAT BELT WARNING SYSTEM

Use the table below to help you find the cause of the problem. The numbers indicate the prioity of the likely

1. Fuse (Burnt) -

Seat belt warning light does not

light up

2.Intument cluster (Damaged)

3.Electric lock catch assy (Damaged)

Chapter 83 instrument panel-instrument

cluster, replacement

Chapter 63 seat belt - seat belt

warning system, inspection

4. Wire harness (Open or short) -

63-3

1. INSPECT ELECTRIC LOCK CATCH ASSY.

(a) Check the resistance.

Driver seat belt

latch plate

Terminal

Pull out 1-2 < 2Ω

Insert 1-2 > 1MΩ

63-4

SEAT BELT - DRIVER / ASSISTANT DRIVER SEAT BELT

DRIVER / ASSISTANT DRIVER SEAT BELT

1 Driver Seat Belt With Retractor Assy

2 Webbing Lock Catch Assy

3 Electric Lock Catch Assy

Assistant Driver Seat Belt With Retractor

SEAT BELT - PASSENGER SEAT BELT

63-5

PASSENGER SEAT BELT

LEFT PASSENGER SEATS (2+2+2+2)

1 Belt With Latch Plate Assy

2 Dual Webbing Catch Assy

Belt With Latch Plate And Webbing Catch

63-6

RIGHT PASSENGER SEATS (1+1+1)

1 Seat Belt With Retractor 2 Webbing Catch Assy

63-7

LEFT PASSENGER SEATS (3+3)

1 Belt With Latch Plate Assy 2 Dual Lock Catch Assy

63-8

RIGHT PASSENGER SEATS (1+1+2)

1 Belt With retractor Assy

2 Webbing Catch Assy

3 Dual Lock Catch Assy

Belt With Latch Plate And Lock Catch

SEAT BELT - SEAT BELT CATCH ASSY

63-9

SEAT BELT CATCH ASSY

1. REMOVE ELECTRIC LOCK CATCH ASSY.

Remove the driver seat assy. (Refer to “ Chapter 84 seat - driver / assistant driver seat, removal &

installation and disassembly & reassembly”)

Loosen the screw of the seat side tirm cover.

Remove the reclining adjuster trim cover electric lock

catch side by the sequence shown in the illustration.

• Move the trim cover backward to separate 2 slots.

• Pull outward and remove the trim cover.

Loosen completely the bolt attaching the electric lock

catch to the driver seat reclining adjuster.

63-10

Remove the electric lock catch assy.

Pull out the electric lock catch wire harness through the

aperture between cushion pad and reclining adjuster.

Be careful. Do not damage the electric lock catch wire harness

2. REMOVE LOCK CATCH ASSY.

• Remove the lock catch assy by the same procedures as the electric lock catch assy.

• Remove the lock catch assy in step (e).

• Skip step (f).

3. REMOVE LEFT REAR PASSENGER SEAT WEBBING

CATCH ASSY.

(a) Turn over the left coner of the middle seat cushion.

63-11

4. REMOVE THE MIDDLE REAR SEAT WEBBING CATCH.

Remove seat cushion regulating handle.

Loosen retaining screw.

Remove the reclining adjuster trim cover.

Loosen webbing catch retaining bolt.

Remove webbing catch assy.

5. REMOVE RIGHT REAR SEAT WEBBING CATCH ASSY.

Remove the right rear seat webbing catch assy by the same procedures as the middle rear seat

webbing catch assy

63-12

6. INSTALL ELECTRIC LOCK CATCH ASSY.

Put the electric lock catch wire harness connector

through the aperture between cushion pad and reclining

Position the electric lock catch assy properly.

Torque: 50 ~ 55 N·m

Install the reclining adjuster trim cover electric lock catch

sie by the sequence shown in the illustration.

• Push the trim cover inward to align the slots.

• Move the trim cover forward to position it properly.

Tighten the screw.

7. INSTALL LOCK CATCH ASSY.

• Install the lock catch assy by the same procedures as the electric lock catch assy.

• Position the lock catch assy properly in step (b).

63-13

• Skip step (a).

8. INSTALL THE LEFT REAR PASSENGER SEAT WEBBING

CATCH.

Position the webbing catch assy.

Position the seat cushion.

9. INSTALL THE MIDDLE REAR PASSENGER SEAT

WEBBING CATCH.

(a) Position the webbing catch assy.

Install the webbing catch side trim.

63-14

Insert seat cushion regulating handle.

10. INSTALL RIGHT REAR SEAT WEBBING CATCH ASSY.

Install the right rear seat webbing catch assy by the same procedures as the middle rear seat webbing

catch assy.

SEAT BELT - RETRACTOR ASSY

63-15

RETRACTOR ASSY

1. REMOVE DRIVER SEAT BELT WITH RETRACTOR

Turn up the trim cover, loosen the bolt.

Remove the lower belt retaining bolt.

exterior and interior trim - quarter panel guard board,

Loosen the bolt.

Remove the driver seat belt retractor assy.

Never disassemble the retractor.

2. REMOVE ASSISTANT DRIVER SEAT BELT WITH RETRACTOR ASSY.

Remove the assistant driver seat belt with retractor by the same procedures as the driver seat belt with

retractor assy.

63-16

3. INSPECT RETRACTOR.

(a) Check whether the seat belt is locked when tilting the

retractor.

• Within 15° of tilt in all the directions, check that the

seat belt should not be locked.

• Over 45° of tilt in all the directions, check that the

seat belt should be locked.

If the operation is out of the specification, replace with a new

driver / assistant driver seat belt with retractor assy. (Refer to

“Chapter 63 seat belt - retractor assy, overhaul”)

4. REMOVE LEFT REAR PASSENGER SEAT BELT WITH RETRACTOR ASSY.

(a) Remove left rear passenger seat assy. (Refer to “Chapter 84 seat - driver / assistant driver seat,

remove & installion and disassembly & reassemlby”)

Remove seat belt with retractor assy trim cover.

Loosen retractor retaining bolt, remove retractor assy.

Loosen belt lower retaining bolt.

Be careful not to lose gasket.

Remove the belt upper retaining bolt.

Remove seat belt with retractor assy.

63-17

5. REMOVE MIDDLE REAR PASSENGER SEAT BELT

WITH RETRACTOR ASSY.

Remove retractor housing.

Remove the retractor retaining bolt.

Remove 4 belt retaining screws.

63-18

Turn over the middle rear seat cushion.

Loosen belt bolt.

6. REMOVE RIGHT REAR ASSISTANT DRIVER SEAT BELT WITH RETRACTOR ASSY.

Remove the right rear assistant driver seat belt with retractor by the same procedures as the left rear

assistant driver seat belt with retractor assy.

7. INSTALL DRIVER SEAT BELT RETRACTOR ASSY.

(a) Position the driver seat belt retractor assy.

exterior and interior trim - quarter panelquarter panel guard

board, replacement”)

Make sure the seat belt is flat, do not kink or winding.

Install belt lower retaining bolt.

63-19

Torque:50 ~ 55 N·m

Install the trim cover.

8. INSTALL ASSISTANT DRIVER SEAT BELT WITH RETRACTOR ASSY.

Install the assistant driver seat belt with retractor by the same procedures as the driver seat belt with

9. INSTALL LEFT REAR PASSENGER SEAT BELT WITH

RETRACTOR ASSY.

(a) Position the belt upper retaining bolt.

(b) Tighten the belt upper retaining bolt

Tighten belt lower retaining bolt.

Position the retractor.

Tighten the retractor retaining bolt.

Install belt retractor trim cover.

63-20

10. INSTALL MIDDLE REAR SEAT RETRACTOR.

(a) Turn over the middle rear seat cushion.

(b) Tighten the belt bottom retaining bolt.

Install seat cushion.

Tighten 4 belt retaining screws.

Position the seat belt with retractor.

Tighten seat belt with retractor retaining bolt.

63-21

Position the belt retractor housing.

Install the belt retractor housing.

11. INSTALL RIGHT REAR SEAT BELT WITH RETRACTOR ASSY.

Install the right rear passenger belt with retractor by the same procedures as the left rear passenger

belt with retractor assy.

12. Inspect driver / assistant driver seat belt with retractor assy.

(a) Check belt locking operation.

• The belt should be locked when being dragged quickly.

(b) Check children protection operation.

• After extracting the belt out of the retractor completely, the retractor enters LOCK mode. In this mode,

the belt only can be contracted.

• When the belt contracts fully, the retractor will recover to NORMAL mode from LOCK mode.

This function is used for the children protector applied to the vehicle.

If the operation is out of the specification, replace with a new driver / assistant driver seat belt with retractor

assy. (Refer to “Chapter 63 seat belt - retractor assy, overhaul”)

LIGHTING SYSTEM........................................................................... 64-1

PRECAUTION.............................................................................. 64-1

FRONT COMBINATION LAMP ASSY............................................... 64-2

COMPONENTS ........................................................................... 64-2

REPLACEMENT .......................................................................... 64-3

ADJUSTMENT............................................................................. 64-7

FRONT FOG LAMP ASSY................................................................. 64-8

REPLACEMENT .......................................................................... 64-8

REAR COMBINATION LAMP ASSY............................................... 64-10

COMPONENTS ......................................................................... 64-10

REPLACEMENT ........................................................................ 64-11

LICENCE LAMP ASSY .................................................................... 64-14

REPLACEMENT ........................................................................ 64-14

HIGH-MOUNTED STOP LAMP ASSY............................................. 64-16

REPLACEMENT ........................................................................ 64-16

FRONT DOME LIGHT ASSY ........................................................... 64-17

REPLACEMENT ........................................................................ 64-17

MIDDLE DOME LIGHT ASSY.......................................................... 64-19

REPLACEMENT ........................................................................ 64-19

REAR DOME LIGHT ASSY ............................................................. 64-22

REPLACEMENT ........................................................................ 64-22

STEP LAMP ASSY........................................................................... 64-25

REPLACEMENT ........................................................................ 64-25

COMBINATION SWITCH ASSY ...................................................... 64-27

REPLACEMENT ........................................................................ 64-27

64

1. LIGHTING SYSTEM PRECAUTION.

LIGHTING - LIGHTING SYSTEM

64-1

Even if a thin film of oil is left on the surface of the halogen lamp, its service life will be shortened because

the lamp will be burned at a higher temperature.

Handle any halogen lamp with great care. Dropping, hitting or damaging the bulb in any way may result

in exploding and scattering because the internal pressure is high.

Always use a bulb of the same wattage for replacement. Be sure not to touch the bulb immediately.

Reinstall the socket firmly after bulb replacement. The lens may become cloudy or the light cavity may

be filled with water through the gaps around the socket.

64-2

LIGHTING - FRONT COMBINATION LAMP ASSY

FRONT COMBINATION LAMP ASSY

6 Support Holder

7 Support Holder

64-3

2. REMOVE FRONT COMBINATION LAMP ASSY LH.

(a) Remove the front grille. (Refer to “Chapter 88 exterior and interior trim - front grille, replacement”)

(b) Remove the front bumper assy. (Refer to “Chapter 88 exterior and interior trim - front bumper assy,

Loosen 3 screws.

Disconnect the 3 connectors and remove front combination

lamp assy LH.

3. REMOVE FRONT COMBINATION LAMP ASSY RH.

Remove the RH side by the same procedures as the LH side.

4. REMOVE HEADLAMP BULB LH.

(a) Remove the cap .

64-4

Remove the steel wire.

Remove the headlamp bulb.

5. REMOVE HEADLAMP BULB RH.

6. REMOVE LAMPLET BULB LH.

Remove the lamp socket.

Remove the lamplet bulb.

7. REMOVE LAMPLET BULB RH.

Remove the RH side by the same procedures as the LH side

64-5

8. REMOVE SIDE TURN SIGNAL LAMP BULB.

Side turn signal lamp bulb is LED (Light emitting diode) it can not be replaced without the lamp socket.

9. INSTALL HEADLAMP BULB LH

Install the headlamp bulb, Tighten the steel wire.

Install the cap.

10. INSTALL HEADLAMP BULB RH.

Install the RH side by the same procedures as the LH side

11. INSTALL LAMPLET BULB LH.

Install the lamplet bulb.

Install the lamp socket.

12. INSTALL LAMPLET BULB RH.

64-6

13. INSTALL FRONT COMBINATION LAMP ASSY LH.

(a) Connect the 3 connectors to front combination lamp assy

(b) Install the front combination lamp LH and tighten the 3

exterior and interior trim - front bumper assy,

(d) Install the front grille. (Refer to “Chapter 88 exterior and

interior trim - front grille, replacement”)

14. INSTALL FRONT COMBINATION LAMP ASSY RH.

Install the RH side by the same procedures as the LH side.

64-7

1. ADJUST THE HEADLAMP AIMING.

(a) Park the vehicle in the following conditions.

• The area around the headlight is not deformed.

• The vehicle is parked on a level surface.

• Tire inflation pressure is in the specified value. (Refer to “Chapter 33 tire and wheel - tire and wheel

system, on-vehicle inspection,”)

• A driver is in the driver’s seat or let something weighs 73 Kg on the seat of the vehicle; the vehicle is

ready for driving. (with a tank full)

(b) Check the headlamp aiming.

• Park the vehicle at the flat field and make the lens surface

of the headlamps be 10m away from the screen.The

curtain or flat wall can be used as the screen.

• Turn the headlamps on.

• Check that the headlamps properly strike the position

A and B shows the position of the headlamps; H shows the

height of the headlamps; L1 and L2 shows the distance

between the center of headlamps and the center of the

• Adjust the headlamps if necessary.

Adjust the adjusting screws to adjust the headlamp aiming

to be within the specified range.

64-8

LIGHTING - FRONT FOG LAMP ASSY

FRONT FOG LAMP ASSY

2. REMOVE FRONT FOG LAMP ASSY LH.

(a) Remove the front bumper assy. (Refer to “Chapter 88 exterior and interior trim - front bumper assy,

Disconnect the connectors from the front fog lamp assy.

Loosen 3 nuts and remove the front fog lamp assy LH.

3. REMOVE FRONT FOG LAMP BULB LH.

(a) Remove the cap.

(b) Remove the steel wire.

4. REMOVE FRONT FOG LAMP ASSY RH.

64-9

5. INSTALL FRONT FOG LAMP BULB LH.

(a) Install the front fog lamp bulb.

(b) Install the steel wire.

6. INSTALL FRONT FOG LAMP ASSY LH.

(a) Install the front fog lamp assy and tighten 3 nuts.

Connect the connectors to front fog lamp assy.

Install the front bumper assy. (Refer to “Chapter 88 exterior and interior trim - front bumper assy,

7. INSTALL FRONT FOG LAMP ASSY RH.

64-10

LIGHTING - REAR COMBINATION LAMP ASSY

REAR COMBINATION LAMP ASSY

1 Rear Combination Lamp Assy LH

2 Support Holder

3 Bolt

4 Support Holder

5 High-mounted Stop Lamp Assy

7 License Plate Lamp Assy

9 Rear Combination Lamp Assy RH

10 Sealing Gasket LH

11 Sealing Gasket RH

6 Nut

64-11

2. REMOVE REAR COMBINATION LAMP ASSY LH.

(a) Remove the 3 bolts.

Disconnect the connector and remove rear combination

3. REMOVE BULBS OF REAR COMBINATION LAMP ASSY

(a) Remove the lamp sockets.

Remove the bulbs.

64-12

4. REMOVE REAR COMBINATION LAMP ASSY RH.

5. INSTALL BULBS OF REAR COMBINATION LAMP

ASSY LH.

Install the bulbs.

Install lamp sockets.

6. INSTALLE REAR COMBINATION LAMP ASSY LH.

(a) Connect the connector to rear combination lamp assy

Install the rear combination lamp assy LH and tighten the

3 bolts.

64-13

7. INSTALL REAR COMBINATION LAMP ASSY RH.

64-14

LIGHTING - LICENCE LAMP ASSY

LICENCE LAMP ASSY

2. REMOVE LICENCE LAMP ASSY LH.

(a) Remove 2 screws of licence lamp assy LH.

Remove the lampshade.

Disconnect the connector.

Remove the bulb of licence lamp.

3. REMOVE LICENCE LAMP ASSY RH.

4. INSTALL LICENCE LAMP ASSY LH.

(a) Install the bulb of licence lamp.

64-15

Install the lampshade.

Connect the connector.

5. INSTALL LICENCE LAMP ASSY RH.

6. CONNECT BATTERY NEGATIVE CABLE.

64-16

LIGHTING - HIGH-MOUNTED STOP LAMP ASSY

HIGH-MOUNTED STOP LAMP ASSY

2. REMOVE HIGH-MOUNTED STOP LAMP ASSY.

Remove the rear hatch upper guard board. (Refer to

“Chapter 88 exterior and interior trim - vehicle door inner

guard board, replacement”)

Loosen 2 screws.

Remove the high-mounted stop lamp assy.

3. INSTALL HIGH-MOUNTED STOP LAMP ASSY.

(b) Connect the connector .

4. CONNECT THE BATTERY NEGATIVE GABLE.

LIGHTING - FRONT DOME LIGHT ASSY

64-17

FRONT DOME LIGHT ASSY

2. REMOVE FRONT DOME LIGHT BULB.

Be carefully, do not damage interior trim.

Remove the front dome light.

Remove the front dome light bulb.

3. INSTALL FRONT DOME LIGHT.

(a) Position the front dome light bulb.

64-18

4. CONNECT BATTERY NEGATIVE CABLE.

LIGHTING - MIDDLE DOME LIGHT ASSY

64-19

MIDDLE DOME LIGHT ASSY

2. REMOVE MIDDLE DOME LIGHT ASSY.

Loosen 2 screws

Remove the middle dome light assy.

3. INSTALL MIDDLE DOME LIGHT ASSY.

(a) Connect the connector.

64-20

Tighten 2 screws

4. REMOVE MIDDLE DOME LIGHT BULB.

Turn up the leaf spring.

Remove the dome light.

Be carefully, do not damage the light.

5. INSTALL MIDDLE DOME LIGHT BULB.

(a) Turn up the leaf spring.

(b) Install the dome light.

64-21

64-22

LIGHTING - REAR DOME LIGHT ASSY

REAR DOME LIGHT ASSY

2. REMOVE REAR DOME LIGHT ASSY.

Hold on both side, remove the cover of air purifier.

Loosen 8 screws and 2 bolts.

Disconnect 3 connectors.

Remove rear dome light socket.

64-23

Remove rear dome light bulb.

3. INSTALL REAR DOME LIGHT BULB.

Position the rear dome light bulb.

Connect 3 connectors

Tighten 8 screws and 2 bolts.

64-24

Install the cover of air purifier.

LIGHTING - STEP LAMP ASSY

64-25

STEP LAMP ASSY

2. REMOVE STEP LAMP ASSY.

Use a screwdriver to remove step lamp assy.

Remove the step lamp assy.

3. INSTALL STEP LAMP ASSY.

Install step lamp assy.

64-26

4. REMOVE STEP LAMP BULB.

Remove the step lamp lampshade.

Remove the step lamp bulb.

Be careful do not damage the step lamp.

5. INSTALL STEP LAMP BULB.

(a) Install the step lamp bulb.

(b) Install the step lamp lampshade.

LIGHTING - COMBINATION SWITCH ASSY

64-27

2. REMOVE COMBINATION SWITCH ASSY.

(a) Remove the steering wheel assy. (Refer to “Chapter 51 steering column - steering wheel assy,

Loosen the 2 screws.

Remove the upper and lower cover.

Disconnect combination switch connector.

Remove combination switch assy.

3. INSTALL COMBINATION SWITCH ASSY.

(a) Position the combination switch.

(b) Connect the combination switch connector.

Install the upper and lower cover.

Tighten the 2 screws.

(e) Install the steering wheel assy. (Refer to “Chapter 51

steering column - steering wheel assy, overhaul”)

64-28

WIPER AND WASHER SYSTEM....................................................... 65-1

PRECAUTION.............................................................................. 65-1

PROBLEM SYMPTOMS TABLE.................................................. 65-2

COMPONENTS ........................................................................... 65-4

WIPER ASSY ..................................................................................... 65-5

REPLACEMENT .......................................................................... 65-5

WIPER LINK WITH MOTOR ASSY ................................................... 65-9

REPLACEMENT .......................................................................... 65-9

WIPER BLADE WITH BRACKET ASSY ......................................... 65-13

REPLACEMENT ........................................................................ 65-13

WASHER NOZZLE........................................................................... 65-15

INSPECTION ............................................................................. 65-15

ADJUSTMENT........................................................................... 65-16

WASHER ASSY ............................................................................... 65-17

REPLACEMENT ........................................................................ 65-17

WASHER PUMP ASSY.................................................................... 65-19

REPLACEMENT ........................................................................ 65-19

65

WIPER AND WASHER - WIPER AND WASHER SYSTEM

WIPER AND WASHER SYSTEM

AND WASHER

1. PRECAUTION ON WASHER FLUID.

(a) Usually use ordinary washer fluid for window glass.

(b) Sometimes use water instead of the washer fluid temporarily.

(d) Never use the coolant for engine or other substitutes to prevent damage on body paint.

65-1

65-2

Wipers do not operate

2. Wiper switches (Damaged)

3. Wiper motor (Damaged)

combination switch assy,

wiper motor assy, replacement

Front wipers do not operate in LO

or HI

1. Front wiper switch (Damaged)

2. Front wiper motor (Damaged)

3. Wire harness (Open or short) -

Front wipers do not operate in

INT

2. Solid state timer (Damaged) -

3. Front wiper motor (Damaged)

Rear wiper does not operate

1. Rear wiper and washer switch

2. Wire harness (Open or short) -

Wiper arms do not stop automatically

or not in correct position

(Wiper switch turned off)

1. Wiper arms (Installed incorrectly)

2. Wiper motor (Damaged)

wiper assy, replacement

1. Worm (Rusty or unlubricated)

2. Wiper link (Worn or deformed)

3. Wiper blade assy (Aging or

cracked)

wiper link assy, replacement

wiper blade with bracket assy,

65-3

Wiper less effective

1. Front and rear windshield (Be

soiled by oil or wax)

2. Washer fluid (Poor quality) -

3. Wiper blade assy (Incorrect type) -

4. Wiper blade assy (Aging or

5. Wiper arms (Deformed or

Washers do not operate

6. Wiper arms (Spring force

declined)

2. Rear wiper and washer switch

3. Washer motor with pump assy

1. Washer fluid (Low) -

2. Washer fluid (Frozen) -

Washer fluid does not spray or

spray powerlessly

Incorrect point where washer fluid

spray on front / rear windshield

3. Washer fluid hose (Curving or

jam)

4. Washer nozzle (Blocking)

5. Washer motor with pump assy

1. Washer nozzle (Adjustment

required)

washer nozzle, inspection

washer nozzle, adjustment

65-4

VEHICLE WITH REAR WIPER ASSY

1 Front Wiper Assy RH

2 Front Wiper Assy LH

4 Washer

5 Front Link With Motor Assy

6 Front Washer Assy

8 Washer

9 Rear Washer Assy

10 Rear Wiper Assy

12 Rear Link With Motor Assy

WIPER AND WASHER - WIPER ASSY

65-5

WIPER ASSY

1. REMOVE FRONT WIPER ASSY LH.

(a) Remove the front wiper arm cap.

Do not perform this operation when the windshield is dry to prevent

scoring.

Loosen the nut and remove the spring washer.

Remove the front wiper assy LH.

Upturn the front wiper arm LH before performing this operation.

2. REMOVE FRONT WIPER ASSY RH.

65-6

3. REMOVE REAR WIPER ASSY.

(a) Remove the rear wiper arm cap.

Loosen the nut

Remove the rear wiper assy.

Upturn the rear wiper arm before performing this procedure.

4. INSTALL FRONT WIPER ASSY LH.

(a) Scrape off the spline part of the wiper arm with a round

file or equivalent.

(b) Clean the wiper pivot spline with the wire brush.

Position the front wiper assy LH properly.

Install the spring washer and tighten the nut.

Torque:6 ~ 8 N·m

• The front wiper blade assy LH should be located

along lower edge of the windshield.

• Upturn the front wiper arm LH before performing this

procedure.

65-7

Install the front wiper arm cap.

• Turn the front wiper arm LH down after performing

this procedure.

• Make sure the front wiper blade assy LH is located

along lower edge of the rear windshield.

(f) Check the automatic stop position of front wiper assy LH.

• Set the front wiper switch to the “INT / LO / HI” position to

activate the front wiper assy.

Do not perform this operation when the windshield is dry to

prevent scoring.

• Set the front wiper switch to the “OFF” position to stop

the front wiper assy at the automatic stop position.

• Check whether the front wiper blade assy LH is located

5. INSTALL FRONT WIPER ASSY RH.

6. INSTALL REAR WIPER ASSY.

(a) Scrape off the serration part of the wiper arm with a

round file or equivalent.

(b) Clean the wiper pivot serration with the wire brush.

Position the rear wiper assy properly.

• The rear wiper blade assy should be located along

the lower edge of the rear window.

• Turn the rear wiper arm up before performing this

65-8

Install the rear wiper arm cap.

• Turn the rear wiper arm down after performing this

• Make sure the rear wiper blade assy is located along

lower edge of the rear window.

Check the automatic position of rear wiper assy.

• Set the rear wiper switch to the “INT/ON” position to

activate the rear wiper assy.

Do not perform this operation when the rear window is dry

to prevent scoring.

• Set the rear wiper switch to the “OFF” position to

stop the rear wiper assy at the automatic stop

• Check whether the rear wiper blade assy is located

along lower edge of the rear window.

WIPER AND WASHER - WIPER LINK WITH MOTOR ASSY

WIPER LINK WITH MOTOR ASSY

1. STOP WIPER ASSY AT AUTOMATIC STOP POSITION.

(a) Stop the front wiper assy at the automatic stop position.

• Set the front wiper switch to the “INT / LO / HI” position to activate the front wiper assy.

65-9

Do not perform this operation when the windshield is dry in order to prevent the windshield from

• Set the front wiper switch to the “OFF” position to stop the front wiper assy at the automatic stop

(b) Stop the rear wiper assy at the automatic stop position.

• Set the rear wiper switch to the “INT / ON” position to activate the rear wiper assy.

Do not perform this operation when the rear window is dry in order to prevent the windshield from

• Set the rear wiper switch to the “OFF” position to stop the rear wiper assy at the automatic stop

3. REMOVE FRONT WIPER LINK WITH MOTOR ASSY.

(a) Open the engine hood and support it with the hood rod.

Remove windshield lower trim cover side rubber strip.

Loosen retaining buckles.

Remove windshield lower trim cover.

65-10

Disconnect front wiper motor connector.

Loosen 2 wiper link bolts.

Remove front wiper link with motor assy.

4. REMOVE REAR WIPER MOTOR WITH LINK ASSY.

(a) Remove the rear wiper assy. (Refer to “Chapter 65 wiper and washer - wiper assy, replacement”)

Remove the rear wiper arm shaft seal.

Remove the nut.

Disconnect the rear wiper motor with link assy connector.

65-11

Loosen 3 bolts.

Remove rear wiper motor with link assy.

Store the rear wiper motor with link assy carefully. Do not

rotate the rocker arm of rear wiper motor with link assy.

5. INSTALL FRONT WIPER LINK WITH MOTOR ASSY.

(a) Tighten front wiper link with motor 2 bolts.

(b) Connect motor connector.

Position the windshield lower trim cover.

Install clips and windshield lower trim cover.

Install windshield lower trim side rubber strip.

Be sure change new clips.

6. INSTALL REAR WIPER MOTOR WITH LINK ASSY.

(a) Position the rear wiper motor with link assy properly.

(b) Tighten 3 bolts.

Connect the rear wiper motor with link assy connector.

65-12

Install the rear hatch upper guard board. (Refer to

Install the rear wiper arm shaft seal.

Install the rear wiper assy. (Refer to “Chapter 65 wiper

and washer - wiper assy, replacement”)

7. CONNECT BATTERY NEGATIVE CABLE. (Refer to “Chapter 20 starting and charging - battery,

replacement”).

8. CHECK AUTOMATIC STOP POSITION OF WIPER ASSY.

(a) Check automatic stop position of the front wiper assy LH.

• Check whether the front wiper blade assy LH is located along lower edge of the windshield.

(b) Check the automatic position of rear wiper assy.

• Check whether the rear wiper blade assy is located along lower edge of the rear window.

WIPER AND WASHER - WIPER BLADE WITH BRACKET ASSY

65-13

WIPER BLADE WITH BRACKET ASSY

1. REMOVE FRONT WIPER BLADE WITH BRACKET ASSY LH.

(a) Upturn the front wiper blade bracket assy LH.

Press the latch plate.

2. REMOVE FRONT WIPER BLADE WITH BRACKET ASSY RH.

3. REMOVE REAR WIPER BLADE WITH BRACKET ASSY.

Remove the rear side by the same procedures as the front side.

4. INSTALL FRONT WIPER BLADE WITH BRACKET

(a) Position the front wiper blade with bracket assy LH.

(b) Turn the front wiper blade bracket assy LH down.

65-14

Install the front wiper blade with bracket assy LH.

If hear a “click”, the front wiper blade assy is connected to

the front wiper link assy completely.

Turn the front wiper blade with brackte assy LH down.

5. INSTALL FRONT WIPER BLADE WITH BRACKET ASSY RH.

6. INSTALL REAR WIPER BLADE WITH BRACKET ASSY.

Install the rear side by the same procedures as the front side.

WIPER AND WASHER - WASHER NOZZLE

65-15

WASHER NOZZLE

1. INSPECT WASHER NOZZLE.

(a) Set the front washer switch to the “ON” position. Check the point which the washer fluid sprays on

windshield is in the range shown in the illustration.

Set the rear wiper and washer switch and check the point which the washer fluid spray on rear window

is in the range shown in the illustration.

65-16

1. ADJUST WASHER NOZZLE.

(a) Check the point which the washer fluid sprays on windshield and rear window. (Refer to “Chapter 65

wiper and washer - washer nozzle, inspection”)

(b) Insert a needle or equivalent into the nozzle to adjust until the point which the washer fluid sprays on

windshield and rear window is within the range specified.

WIPER AND WASHER - WASHER ASSY

65-17

WASHER ASSY

1. REMOVE WASHER ASSY.

(b) Disconnect washer pump connector and water pipe.

Remove the washer assy.

2. INSTALL WASHER ASSY.

Position the washer assy.

65-18

Connect washer pump connector and water pipe.

Tighten 2 screws, install the washer assy.

WIPER AND WASHER - WASHER PUMP ASSY

65-19

WASHER PUMP ASSY

1. REMOVE WASHER PUMP ASSY.

(a) Disconnect washer pump connector.

(b) Remove washer assy.(Refer to “Chapter 65 wiper and

washer - washer assy, replacement”)

(d) Remove washer pump.

Do not reuse the seal ring again.

2. INSTALL WASHER PUMP ASSY.

(a) Replacement the seal ring.

(b) Position the washer pump.

Connect washer pump pipe.

Install washer assy.(Refer to “Chapter 65 wiper and

65-20

Connect the washer pump connector.

AUDIO SYSTEM................................................................................. 66-1

COMPONENTS ........................................................................... 66-1

MULTI-MEDIA AND AIR-CONDITON CONTROLLER ASSY ........... 66-2

REPLACEMENT .......................................................................... 66-2

FRONT SPEAKER ASSY .................................................................. 66-4

REPLACEMENT .......................................................................... 66-4

MIDDLE SPEAKER ASSY................................................................. 66-6

REPLACEMENT .......................................................................... 66-6

REAR SPERKER ASSY..................................................................... 66-8

REPLACEMENT .......................................................................... 66-8

TELESCOPIC ANTENNA ASSY...................................................... 66-10

REPLACEMENT ........................................................................ 66-10

ELECTRIC DEVICE ACCESSORIES .............................................. 66-12

REPLACEMENT ........................................................................ 66-12

66

AUDIO SYSTEM - AUDIO SYSTEM

66-1

1 Telescopic Antenna Mounting Bolt

2 Telescopic Antenna Assy

3 Telescopic Antenna Clamp

4 Water Pipe Inner Rubber Block

Multi-media and Air-condition Controller

7 Spring Washer

8 Flat Washer

9 Screw and Big Washer Set

10 Front Speaker Assy

11 Screw and Flat Washer Set

12 Plastic Nut

13 Speaker Assy RR

14 Speaker Assy RL

66-2

AUDIO SYSTEM - MULTI-MEDIA AND AIR-CONDITON CONTROLLER ASSY

MULTI-MEDIA AND AIR-CONDITON CONTROLLER ASSY

2. REMOVE EXTERIOR FRAME OF MULTI-MEDIA AND

AIR-CONDITION CONTROLLER ASSY.

Pry out the frame with plastic trim stick, be careful not damage

exterior frame and panel.

3. REMOVE MULTI-MEDIA AND AIR-CONDITION CON-

TROLLER ASSY.

Remove 4 mounting screws of Multi-media and aircondition

controller assy.

Take out Multi-media and air-condition assy,disconnect

connector of Multi-media and air-condition controller assy

with telescopic antenna,power supply,signal wire,aircondition

wire.

Remove GPS antenna.

Remove Multi-media and air-condition controller assy.

66-3

4. INSTALL MULTI-MEDIA AND AIR-CONDITION CONTROLLER

Install GPS antenna.

Reconnect connector of multi-media and air-condition

controller assy with telescopic antenna, power supply,

signal wire, air-condition wire.

Replace multi-media and air-condition controller assy, tighten

4 mounting screws of multi-media and air-condition controller

5. INSTALL EXTER-FRAME OF MULTI-MEDIA AND AIR-

CONDITION CONTROLLER ASSY.

6. RECONNECT BATTERY NEGATIVE CABLE.

7. INSPECT MULTI-MEDIA AND AIR-CONDITION CONTROLLER ASSY, RESET THE STATIONS.

8. INSPECT MULTI-MEDIA AND AIR-CONDITION CONTROLLER ASSY FOR ITS PROPER

OPERATION.

66-4

AUDIO SYSTEM - FRONT SPEAKER ASSY

FRONT SPEAKER ASSY

2. REMOVE FRONT DOOR INNER GUARD PLATE ASSY LH. (Refer to “Chapter 88 exterior and

interior trim - vehicle door inner guard board, replacement”)

3. REMOVE FRONT SPEAKER ASSY LH.

(a) Remove the 3 screws from front speaker assy LH.

Take down the front speaker assy LH and disconnect the

Remove the front speaker assy LH.

4. INSTALL FRONT SPEAKER ASSY LH.

(a) Reconnect conector of front speaker LH.

66-5

Position front sperker LH, tighten 3 mounting screws.

5. INSTALL FRONT DOOR INNER GUARD PLATE ASSY LH. (Refer to “Chapter 88 exterior and

7. INSPECT FRONT SPEAKER ASSY LH FOR ITS PROPER OPERATION.

8. REMOVE AND INSTALL FRONT SPEAKER ASSY RH.

66-6

AUDIO SYSTEM - MIDDLE SPEAKER ASSY

MIDDLE SPEAKER ASSY

2. REMOVE ROOF GUARD BOARD.(Refer to “Chapter 88 exterior and interior trim - roof guard

board inner trim, replacement”)

3. Remove middle speaker assy LH.

(a) Remove 2 mounting screws of middle speaker LH.

Take down middle speaker assy LH, disconnect connector

of middle speaker LH.

Remove the middle speaker assy LH.

4. INSTALL MIDDLE SPEAKER ASSY LH.

(a) reconnect the connector of middle speaker assy LH.

66-7

Position middle speaker assy LH, tighten 2 mounting

5. INSTALL ROOF GUARD BOARD.(Refer to “Chapter 88 exterior and interior trim - roof guard

7. INSPECT MIDDLE SPEAKER ASSY LH FOR ITS PROPER OPERATION.

8. REMOVE AND INSTALL MIDDLE SPEAKER ASSY RH.

66-8

AUDIO SYSTEM - REAR SPERKER ASSY

REAR SPERKER ASSY

2. REMOVE SIDE WALL REAR LOWER GUARD BOARD LH. (Refer to “Chapter 88 exterior and

interior trim - side wall guard board, replacement”)

3. REMOVE REAR SPEAKER ASSY LH.

(a) Remove 3 screws from rear speaker assy LH.

Take down rear speaker assy LH, disconnect the

connector of rear speaker assy LH.

Remove the rear speaker assy LH.

4. NSTALL REAR SPEAKER ASSY LH.

(a) Reconnect the connector of the rear speaker assy LH.

66-9

Position the rear speaker assy LH,Tighten 3 mounting

5. INSTALL SIDE WALL REAR LOWER GUARD BOARD LH. (Refer to “Chapter 88 exterior and

7. INSPECT REAR SPEAKER ASSY LH FOR ITS PROPER OPERATION.

8. REMOVE AND INSTALL REAR SPEAKER RH.

66-10

AUDIO SYSTEM - TELESCOPIC ANTENNA ASSY

TELESCOPIC ANTENNA ASSY

2. REMOVE MULTI-MEDIA AND AIR-CONDITION CONTROLLER ASSY.(Refer to “Chapter 66 audio

system - Multi-media and Air-condition controller assy, replacement”)

3. REMOVE DASHBOARD. (Refer to“Chapter 88 instrument panel-dashboard,replacement)

4. REMOVE TELESCOPIC ANTENNA ASSY.

(a) Release 7 retaining clips of telescopic antenna.

Remove 2 mounting bolts of telescopic antenna, pull out

the telescopic antenna.

Telescopic antenna should prevent from break when you

pull out it.

5. INSTALL TELESCOPIC ANTENNA ASSY.

(a) Insert telescopic antenna from outside, replace it, tighten

2 mounting bolt of external telescopic antenna.

66-11

Engage 7 retaining clips of telescopic antenna.

6. INSTALL DASHBOARD. (Refer to“Chapter 88 instrument panel-dashboard,replacement)

7. INSTALL MULTI-MEDIA AND AIR-CONDITION CONTROLLER ASSY. (Refer to “Chapter 66 audio

66-12

AUDIO SYSTEM - ELECTRIC DEVICE ACCESSORIES

ELECTRIC DEVICE ACCESSORIES

2. REMOVE CIGARETTE LIGHTER ASSY.

(a) Pull out cigarette lighter connector.

Pull out cigarette lighter body from dash board by using

Disconnect cigarette lighter connector.

Remove cigarette lighter assy.

66-13

3. REMOVE 12 V POWER SOCKET ASSY.

Loosen rear retaining ring.

Disconnect connector of power suply line.

Remove 12V power socket assy.

4. INSTALL 12 V POWER SOCKET ASSY.

Reconnect connector of power suply line.

Position12V power socket assy, tighten rear retaining

66-14

5. INSTALL CIGARETTE LIGHTER ASSY.

Make sure that conduction aperture has already install to

the dash board.

Install cigarette lighter to conduction aperture.

Install the cigarette lighter.

6. INSTALL CIGARETTE LIGHTER.

7. INSPECT ELECTRIC DEVICE ACCESSORIES FOR ITS PROPER OPERATION.

WIRING

HOW TO USE THIS MANUAL........................................................... 71-1

INTRODUCTION.......................................................................... 71-1

SYSTEM WIRING DIAGRAM SECTION EXAMPLE ................... 71-2

POWER SOURCE SECTION EXAMPLE .................................... 71-5

CONNECTOR VIEWS SECTION EXAMPLE .............................. 71-6

GLOSSARY OF TERMS AND SYMBOLS................................... 71-7

FUSE AND RELAY LOCATIONS ................................................ 71-9

WIRING DIAGRAM .......................................................................... 71-18

POWER SOURCE ..................................................................... 71-18

ENGINE CONTROL SYSTEM................................................... 71-24

STARTING SYSTEM ................................................................. 71-37

CHARGING SYSTEM................................................................ 71-39

ANTI-LOCK BRAKE CONTROL SYSTEM ................................ 71-41

HEATER AND CONDITIONING CONTROL SYSTEM.............. 71-44

LIGHT SYSTEM......................................................................... 71-52

WIPER AND WASHER.............................................................. 71-77

MULTIMEDIA SYSTEM ............................................................. 71-80

POWER SOCKET...................................................................... 71-83

COMMUNICATION SYSTEM .................................................... 71-85

POWER MIRROR...................................................................... 71-90

WINDOW DEFROSTER ............................................................ 71-93

INSTRUMENT CLUSTER.......................................................... 71-96

ANTI-THEIF SYSTEM.............................................................. 71-103

SLIDING ROOF ....................................................................... 71-108

RESTRAINT CONTROL SYSTEM .......................................... 71-110

CONNECTOR VIEWS .................................................................... 71-112

A - CHASSIS & FRAME WIRE HARNESS ............................ 71-112

B - BATTERY WIRE HARNESS .............................................. 71-125

C - FRONT BUMPER WIRE HARNESS.................................. 71-126

D - FRONT DOOR LH WIRE HARNESS................................. 71-127

E - ENGINE WIRE HARNESS................................................. 71-130

F - ROOF WIRE HARNESS 1.................................................. 71-142

G - ROOF WIRE HARNESS 2................................................. 71-146

H - FRONT DOOR RH WIRE HARNESS ................................ 71-148

I - INSTRUMENT PANEL WIRE HARNESS............................ 71-150

J - REAR HATCH WIRE HARNESS........................................ 71-166

K - REAR HATCH TRANSITION WIRE HARNESS................. 71-168

L - REAR EVAPORATOR WIRE HARNESS ........................... 71-169

M - DIAGNOSIS WIRE HARNESS .......................................... 71-170

N - STEP LAMP WIRE HARNESS .......................................... 71-171

O - DRIVER SEAT BELT WIRE HARNESS ............................ 71-172

P - REAR HEATER WIRE HARNESS ..................................... 71-173

Q - REAR BUMPER TRANSITION WIRE HARNESS ............. 71-174

R - REAR BUMPER WIRE HARNESS .................................... 71-175

S - REAR DEFROST RH WIRE HARNESS ............................ 71-176

T - REAR DEFROST LH WIRE HARNESS ............................. 71-177

U - HIGH-MOUNTED STOP LAMP WIRE HARNESS........... 71-178

V - FRONT WIRE HARNESS................................................. 71-179

X - PREHEATING WIRE HARNESS ....................................... 71-185

71

WIRE HARNESS & CONNECTOR LOCATION VIEWS................ 71-186

C - FRONT BUMPER WIRE HARNESS.................................. 71-186

V - FRONT WIRE HARNESS .................................................. 71-186

D - FRONT DOOR LH WIRE HARNESS................................. 71-188

H - FRONT DOOR RH WIRE HARNESS ................................ 71-189

A - CHASSIS & FRAME WIRE HARNESS .............................. 71-190

E - ENGINE WIRE HARNESS ................................................. 71-193

I - INSTRUMENT PANEL WIRE HARNESS............................ 71-196

M - DIAGNOSIS WIRE HARNESS .......................................... 71-196

B - BATTERY WIRE HARNESS .............................................. 71-199

O - DRIVER SEAT BELT WIRE HARNESS ............................ 71-199

P - REAR HEATER WIRE HARNESS ..................................... 71-199

X - PREHEATING WIRE HARNESS ....................................... 71-199

F - ROOF WIRE HARNESS 1.................................................. 71-201

L - REAR EVAPORATOR WIRE HARNESS ........................... 71-202

N - STEP LAMP WIRE HARNESS .......................................... 71-203

G - ROOF WIRE HARNESS 2 ................................................. 71-204

J - REAR HATCH WIRE HARNESS ........................................ 71-204

K - REAR HATCH TRANSITION WIRE HARNESS................. 71-204

Q - REAR BUMPER TRANSITION WIRE HARNESS ............. 71-204

R - REAR BUMPER WIRE HARNESS .................................... 71-204

S - REAR DEFROST RH WIRE HARNESS ............................ 71-204

T - REAR DEFROST LH WIRE HARNESS ............................. 71-204

U - HIGH-MOUNTED STOP LAMP WIRE HARNESS............. 71-204

WIRING - HOW TO USE THIS MANUAL

71-1

This manual provides information on the electrical circuits installed on vehicles by dividing them into electrical

systems. The actual wiring of each system wiring diagram is shown from the point where the power source is

received from the battery to each ground point. (All wiring diagrams are shown with the switches in the OFF

position.)

When troubleshooting any problem, firstly, make sure you understand the operation of the circuit where the

problem was detected (see System Wiring Diagram Section). Secondly, understand the power source supplying

to that circuit (see Power Source Section). Finally, understand the direction of current flow (see System

Description).

When the circuit operation is understood, begin troubleshooting of the suspected circuit to find out the cause.

(Based on relays, controllers, accessory, inlines, sensors, actuators, switches, ground points, connection location

of each system wiring diagram and wire harness location.)

71-2

SYSTEM WIRING DIAGRAM SECTION EXAMPLE

*The system wiring diagram shown here is an EXAMPLE ONLY. It is different to the actual circuit

shown in the SYSTEM WIRING DIAGRAM SECTION.

71-3

No. Name Description

1 System Title Distinguish between different systems and functions, easy to query.

Indicates the

wire color

Wire colors are indicated by an alphabetical code,easy to query.

The first letter indicates the basic wire color and the second letter indicates

the color of the stripe.

R (Red)

L-B (Blue and Black)

component name

component number

Name of electrical component, easy to query.

An electrical component can only have one name.

Number of electrical component, easy to query.

An electrical component has one or more numbers.

Female and male connectors have different numbering rules.

The two examples below are viewed from terminal side when connectors are

unplugged.

Female - Numbered in order from upper right to lower left.

Indicates the pin number

of

connector

Male - Numbered in order from upper left to lower right.

This rules also applied to inline connector number.

6 Indicates a ground point

The first letter of the code for each ground point(s) indicates the component’s

Indicates related

Indicates inline

connector number

Indicate that other system(s) associated with this system.

A group of inline has two connector numbers, one is the female and the other

is the male.

Male:

gender

Female:

71-4

10 System Description Describe the current flows and how the system works.

11 Service Hints Describe the component's value and principle. Refer in the service process.

12 Parts Location Indicate the wire harness showing the parts location on the vehicle.

13 Inline Indicate the inline two parts gender and the connected wire harness types.

14 Ground Points Indicate the ground location of each wire harness.

71-5

POWER SOURCE SECTION EXAMPLE

The “POWER SOURCE” section describes how the current flows and each part power feed conditions. In the

POWER SOURCE wiring diagram, the conditions when battery power is supplied to each system are explained.

Since all system wiring diagrams start from the power source, the power source system must be fully

understood.

71-6

CONNECTOR VIEWS SECTION EXAMPLE

*The connector views shown here is an EXAMPLE ONLY. It is different to the actual connector views

shown in the CONNECTOR VIEWS SECTION.

1 Connector Face Indicate connector face and pin order.

2 Component Name

3 Component Number

4 Connector Information Indicate pin number, wire color and function.

71-7

GLOSSARY OF TERMS AND SYMBOLS

Stores chemical energy and converts it into electrical energy.

Provides DC current for the auto’s various electrical circuits.

GROUND

The point at which wiring attaches to the body, thereby providing a

return path for an electrical circuit. Without a ground, current cannot

flow.

FUSIBLE LINK

FUSE

In high amperage circuits, a heavy gauge wire burns when it is overloaded

to protect the connected components.

A thin metal strip burns when too much current flows through it,

thereby it can stop current flow and protect a circuit from damage.

COIL

When the magnetic field engenders fluctuations, the coil circuit is

induced electromotive force.

SOLENOID

An electromagnetic coil which forms a magnetic field when current

flows, to move a plunger, etc.

SINGLE FILAMENT

LAMPS

Current flow causes a headlight filament to heat up and emit light. A

headlight may have either a single filament or double filaments.

DOUBLE FILAMENT

A power unit which converts electrical energy into mechanical

energy, especially rotary motion.

SPEED MOTOR

INLINE

Indicate the connector joining wire harness and wire harness.

DIODE

A semiconductor which allows current flow in only one direction.

LED (LIGHT EMITTING DIODE)

Upon current flow, these diodes emit light without producing the

heat of a comparable light.

71-8

HORN

An electric device which sounds a loud audible signal.

THERMISTOR SENSOR

A resistor which varies its resistance with temperature.

TAPPED RESISTOR

SLIDE RHEOSTAT

An electrical component with a fixed resistance, placed in a circuit to

reduce voltage to a specific value.

A resistor which supplies two or more different non-adjustable

resistance values.

A controllable resistor with a variable rate of resistance. Also called

a potentiometer or rheostat.

POWER SOCKET (CIGARETTE LIGHTER)

An electric resistance heating element.

MANUAL SWITCH

Opens and closes circuits, stops or allows current flow.

IGNITION SWITCH

A key operated switch with several positions which allows various

HEATER

RELAY(4Pin)

RELAY

Basically, an electrically operated switch which may be normally

closed or open. Current flow through a small coil to create a magnetic

field which either opens or closes an attached switch.

RELAY(5Pin)

71-9

FUSE AND RELAY LOCATIONS

POSITIVE JUNCTION BOX

No. Amps Function

F1 60A Instrument Panel Fusible Link

F2 120A Charge Fusible Link

F4 60A Battery Fusible Link

F5 50A Engine Room Fusible Link

F3 120A Pre-heat Fusible Link

71-10

BATTERY COMPARTMENT JUNCTION BOX LOCATION

F9 30A AM2 Fusible Link F10 40A ABS Pump Fusible Link

71-11

F2 7.5A Start Fuse

F3 5A ABS IG Fuse

F4 15A Accessory Fuse

F5 15A Fuel Pump/Diesel Filter Fuse

F6 30A ECM Main Fuse

F7 10A Diagnosis Fuse

F8 25A ABS Valve Fuse

R1

R2

Fuel Pump/Diesel Filter Heating Relay

Starter Relay

71-12

ENGINE ROOM JUNCTION BOX LOCATION

F1 30A Low-speed Fan Fusible Link F2 30A High-speed Fan Fusible Link

71-13

F7 15A Stop Lamp Fuse

F11 15A Injector Fuse

F12 15A Ignition Coil Fuse

\\\RELAY

Low-speed Fan 1 Relay

R5

High-speed Fan 2 Relay

R3

Low-speed Fan 2 Relay

R6

Main Relay

R4

High-speed Fan 1 Relay

71-14

CO - PILOT SIDE JUNCTION BOX LOCATION

F6 30A Rear A/C Fusible Link F13 30A Front Blower Fusible Link

71-15

F8 15A Rear Heater Fuse

F9 10A Airbag Fuse

F10 7.5A Outside Mirror Defrost Fuse

F11 25A Rear Defroster Fuse

Compressor Relay

R7

Water Valve Relay

Rear A/C Relay

R8

A/C Cut Off Relay

Outside Mirror Defrost Relay

R9

Front Blower Relay

Rear Heater Relay

R10

Rear Defroster Relay

71-16

DRIVER SIDE JUNCTION BOX LOCATION

F28 20A AM1 Fusible Link

F30 40A IG2 Fusible Link

F29 20A Power Window Fusible Link

71-17

F1 15A A/C Fuse

F2 5A ECU IG Fuse

F3 15A Power Fuse

F4 10A Back-up Lamp Fuse

F7 15A Sliding Roof Fuse

F8 10A Rear Wiper Fuse

F9 10A Turn Signal Fuse

F10 15A Cigarette Lighter Fuse

F11 15A Front Wiper Fuse

F14 7.5A Lo-beam RH Fuse

F15 7.5A Lo-beam LH Fuse

F16 7.5A Radio ACC Fuse

F17 7.5A Instrument IG Fuse

F18 7.5A Lamplet Fuse

F19 7.5A Switch Lighting Fuse

F20 10A Hi-beam RH Fuse

F21 10A Hi-beam LH Fuse

F22 20A Headlamp Fuse

F23 10A Rear Fog Lamp Fuse

F24 10A Central Locking Fuse

F25 7.5A A/C Controller Fuse

F26 15A Front Fog Lamp Fuse

F27 15A Horn Fuse

F32 10A Radio/Outside Mirror Fuse

F33 10A Instrument Cluster Fuse

F34 10A Dome Light Fuse

F35 15A Hazard Warning Fuse

Rear Wiper Relay

Front Fog Lamp Relay

IG2 Relay

Horn Relay

Hi-beam Relay

Rear Fog Lamp Relay

Lo-beam Relay

Lamplet Relay

71-18

POWER SOURCE

WIRING - WIRING DIAGRAM

71-19

71-20

71-21

71-22

71-23

Service Hints

• I009 Ignition Switch

AM1 - ACC: Closed with the ignition switch at ACC/ON position.

AM1 - IG1: Closed with the ignition switch at ON/ST position.

AM2 - IG2: Closed with the ignition switch at ON/ST position.

AM2 - ST2: Closed with the ignition switch at ST position.

Parts Location

Code Wire Harness Code Wire Harness

A017 Chassis & Frame Wire Harness I009 Instrument Panel Wire Harness

B001

Battery Wire Harness

Connector Joining Wire Harness and Wire Harness

Code Code Wire Harness (Connector Location)

A101

A102

A104

A106

A111

I110

I104

I106

I111

E101

I109

M101

Chassis & Frame Wire Harness & Instrument Panel Wire Harness

(Under the Driver Side Junction Box)

(Right Side of the Driver Side Junction Box)

Chassis & Frame Wire Harness & Engine Wire Harness

(Manhole After the Co-pilot Seat)

(Under the Right Side of the Instrument Panel)

Instrument Panel Wire Harness & Diagnosis Wire Harness

(Under the Left Side of the Central Instrument Panel)

Ground Points

Code Ground Points Location Code Ground Points Location

B201 Engine Block Side B202 Car Body Side of the Battery Compartment

71-24

ENGINE CONTROL SYSTEM - WITH 4G69 ENGINE

71-25

71-26

71-27

71-28

System Description

Engine control system of 4G69 engine is based on Engine Control Module (ECM) of Delphi MT20U2 as the

center system. The engine control system mainly consists of sensor signal input, engine control module (ECM)

and executive control.

• Sensor Signal Input

Manifold Absolute Pressure/Intake Air Temperature (MAP/IAT) Sensor

Manifold absolute pressure/intake air temperature (MAP/IAT) sensor integrates functions of manifold absolute

pressure sensor with those of intake air temperature sensor, while achieving the functions of feedback

manifold absolute pressure and intake air temperature.

Manifold absolute pressure sensor measures engine inhaled air volume, which is a critical element that forms

method of speed-density type air flow measurement. The sensor directly senses manifold absolute pressure

state inside the engine intake manifold. The engine control module (ECM) takes this reference signal as the

basis to adjust the basic fuel supply sprayed into the engine.

Intake air temperature sensor uses NTC (negative temperature coefficient) thermistor sensor, with which the

engine control module (ECM) measures the air temperature in the engine cylinder and modifies the engine

fuel supply.

Engine Coolant Temperature Sensor

Engine coolant temperature sensor is used for detecting engine operating temperature. The engine control

module (ECM) provides the optimum control solution for the engine according to different temperatures.

Engine coolant temperature sensor uses NTC thermistor sensor, with engine coolant temperature rising and

resistance value decreasing.

Crankshaft Position Sensor

As magnetoelectric sensor, crankshaft position sensor works with gear ring of crankshaft. The sensor detects

the change of reluctance while the crankshaft rotates and alternating reluctance generates alternating output

signal. The notch positions on the gear ring correspond to top dead center (TDC) in the engine. The engine

control module (ECM) uses this signal to determine the rotation position and speed of the crankshaft.

Knock sensor is a vibration acceleration sensor, equipped at the engine knock induction-sensitive parts and

used for sensing the knock generated by the engine. The engine control module (ECM) uses knock intensity

detected by the knock sensor to modify ignition advance angle and achieve the effective control of the knock,

so as to optimize engine power performance, fuel economy and reduce emissions.

Throttle position sensor consists of carbon film resistor and sliding pointer driven by throttle shaft. When the

throttle opening changes, the signal that the sensor feeds back to the engine control module (ECM) also

varies. The control module determines real-time engine load and dynamic change condition based on the

sensor signal value and its rate of change.

Upstream (Downstream) Oxygen Sensor

Oxygen sensor is an important symbolic component of closed loop fuel control system. With its adjustment

and keeping the desired air-fuel ratio, the three-way catalytic converter can

achieve the best conversion efficiency. The zirconium oxide in oxygen sensor is heated (> 300 ℃ ) for

activation. The sensor changes the output voltage according to the presence or absence of oxygen in the

exhaust and determines the oxygen content in the exhaust. If the oxygen content in the exhaust is increased,

output voltage of oxygen sensor will be decreased; on the other hand, the output voltage will be increased,

thus providing feedback of the actual air-fuel ratio conditions for the engine control module (ECM). Usually,

when the sensor has the theoretical air-fuel ratio (14.6:1), it will result in dramatic change of voltage amplitude,

helping the engine control module (ECM) to accurately determine the air-fuel ratio.

Odometer Sensor

Odometer sensor is Hall effect sensor, working with signal wheel on the transmission output shaft. The engine

control module (ECM) measures digital voltage signal through the sensor. In order to determine the current

vehicle speed.

71-29

• Executive Control

Fuel injection Control

The system uses the speed density method to make multi-point sequential injection, i.e., each engine cycle

implements accurate fuel supply through main pulse width and amended pulse width, which has closed-loop

control and self-learning function.

Oil pump is single-stage electric turbine pump, and its operation is controlled by the engine control module

(ECM) through the pump relay. When ignition switch is turned on, the pump will run for 1.5 seconds. If the

crankshaft position signal is not received, the pump will stop running. If the crankshaft position signal is

detected, the oil pump starts to work. Upon loss of crankshaft position signal, the pump will stop running.

Mounting Position: in the fuel tank.

Fuel injector is a ball valve device with solenoid switch. The coil in injector is controlled grounded by the

engine control module (ECM) to produce magnetic force and pull up spool. The fuel is ejected from the pilot

hole in the form of mist. The main factors affecting changes in fuel injection pulse width include air-fuel ratio,

manifold absolute pressure, intake air temperature, closed loop feedback correction, acceleration

concentration, deceleration cutoff, self-learning and correction.

Ignition Control

The system uses grouping ignition. Ignition coil is divided into two groups, each group providing the ignition

energy for two cylinder spark plugs with 360-degree crankshaft angle difference.

Idle Control

The system uses the idle air control, achieving high-precision idle speed control.

The idle stepping motor controls circulation area of throttle body bypass air duct to adjust control volume in the

engine. The engine control module (ECM) controls the amount of movement (forward / backward) for the

stepping motor through the digital square wave signal.

Canister Solenoid Valve Control

The engine control module (ECM) controls volume of gasoline vapor in intake manifold flowing from canister

through the canister solenoid valve control. The opening of canister solenoid valve is determined by the

engine control module (ECM) according to the duty cycle signal based on the state of engine.

Fan Control

The engine control module (ECM) monitors the level of coolant temperature and whether the air-conditioning

works properly to determine the operating state of each fan.

• Malfunciton Diagnosis Function

When the system comes into operation, the engine control module (ECM) controls the operation of all parts of

the system and conducts detection in real time. Once the system or parts have faults, the system will switch on

the malfunction indicator light (MIL) to remind drivers of repair in time. When the system is in failure, the

engine control module (ECM) will start backup emergency control program.

• E010 Engine Coolant Temperature Sensor

1 - Ground: Approx. 5 volts

1 - 2: Approx. 29 KΩ (-20 ℃ )

Approx. 9 KΩ (0 ℃ )

Approx. 3 KΩ (20 ℃ )

Approx. 0.3 KΩ (80 ℃ )

• E015 Idle Speed Control Valve

1 - 2: Approx. 53 Ω

3 - 4: Approx. 53 Ω

• E002 Fuel Injector 1, E003 Fuel Injector 2, E004 Fuel Injector 3, E005 Fuel Injector 4

1 - Ground: Approx. 12 volts

• E009 Throttle Position Sensor

2 - Ground: Approx. 5 volts

71-30

• E007 Upstream Oxygen Sensor, A019 Downstream Oxygen Sensor

• E006 Manifold Absolute Pressure/Intake Air Temperature (MAP/IAT) Sensor

4 - Ground: Approx. 5 volts

A001 Chassis & Frame Wire Harness E006 Engine Wire Harness

A002 Chassis & Frame Wire Harness E007 Engine Wire Harness

A004 Chassis & Frame Wire Harness E009 Engine Wire Harness

A006 Chassis & Frame Wire Harness E010 Engine Wire Harness

A014 Chassis & Frame Wire Harness E011 Engine Wire Harness

A019 Chassis & Frame Wire Harness E015 Engine Wire Harness

A022 Chassis & Frame Wire Harness E016 Engine Wire Harness

A105 Chassis & Frame Wire Harness E017 Engine Wire Harness

A106 Chassis & Frame Wire Harness I002 Instrument Panel Wire Harness

E001 Engine Wire Harness I003 Instrument Panel Wire Harness

E002 Engine Wire Harness I011 Instrument Panel Wire Harness

E003 Engine Wire Harness I020 Instrument Panel Wire Harness

E004 Engine Wire Harness M002 Data Link Connector

E005 Engine Wire Harness V107 Front Wire Harness

A107

I102

E102

V102

(Right Side of the Driver side Junction Box)

Instrument Panel Wire Harness & Front Wire Harness

(Left Side of the Driver side Junction Box)

71-31

Instrument Panel Wire Harness & Data Link Connector

(Under the Left Side of the CentralInstrument Panel)

A202

Left Front Wheel Cover Plate Side

Plates

I201

Left Side of the Instrument Panel

A203

Right Front Wheel Cover Plate Side

I205

Central of the Instrument Panel

71-32

ENGINE CONTROL SYSTEM - WITH ISF2.8 ENGINE

71-33

71-34

71-35

Engine control system of ISF2.8 engine is based on Engine Control Module (ECM) of Bosch CM2220 as the

Mounting Position: on the flywheel housing perpendicular to the crankshaft position.

A001 Chassis & Frame Wire Harness E026 Engine Wire Harness

A002 Chassis & Frame Wire Harness E027 Engine Wire Harness

A004 Chassis & Frame Wire Harness E028 Engine Wire Harness

A006 Chassis & Frame Wire Harness E029 Engine Wire Harness

A015 Chassis & Frame Wire Harness E030 Engine Wire Harness

A016 Chassis & Frame Wire Harness E031 Engine Wire Harness

A025 Chassis & Frame Wire Harness E032 Engine Wire Harness

A030 Chassis & Frame Wire Harness E033 Engine Wire Harness

A031 Chassis & Frame Wire Harness E035 Engine Wire Harness

A033 Chassis & Frame Wire Harness E034 Engine Wire Harness

A034 Chassis & Frame Wire Harness E036 Engine Wire Harness

A035 Chassis & Frame Wire Harness I001 Instrument Panel Wire Harness

71-36

A036 Chassis & Frame Wire Harness I002 Instrument Panel Wire Harness

E018 Engine Wire Harness I003 Instrument Panel Wire Harness

E019 Engine Wire Harness I019 Instrument Panel Wire Harness

E020 Engine Wire Harness M001 Data Link Connector

E021 Engine Wire Harness M002 Data Link Connector

E022 Engine Wire Harness V017 Front Wire Harness

E023 Engine Wire Harness X001 Pre-heater Wire Harness

E024 Engine Wire Harness X002 Pre-heater Wire Harness

E025 Engine Wire Harness X003 Pre-heater Wire Harness

A113

B003

Chassis & Frame Wire Harness & Battery Wire Harness

(Battery Compartment)

B202

Car Body Side of the Battery

Compartment

71-37

STARTING SYSTEM

71-38

• Starting System

a. When ignition switch is turned to ST, the current flows through battery fusible link positive in junction box, to

AM2 fusible link in battery compartment junction box, through the AM2 fusible box. The current flows from pin

ST2 of ignition switch through starter fuse and accessory fuse in battery compartment junction box to pin 85 of

starter relay, and through coil to ground at pin 86 of starter relay. Coil then creates a magnetic field, and switch

is activated.

b. The current flows through AM2 fusible link, through starter relay, to solenoid switch of starter. Solenoid

switch creates a magnetic field, and starter is activated.

c. The current flows through the terminal of starter, to starter motor, and to crank the engine.

AM2 – IG2: Closed with the ignition switch at ON/ST position.

AM2 – ST2: Closed with the ignition switch at ST position.

B001 Battery Wire Harness E014 Engine Wire Harness

B002 Battery Wire Harness I009 Instrument Panel Wire Harness

B101

Code

Ground Points Location

Left Front Wheel Cover Plate Side Plates

71-39

CHARGING SYSTEM

71-40

• Charging System

a. 4G69 engine: When ignition switch is turned to ON/ST, the current flows output from ignition switch to ignition

fuse in engine room junction box, through the fuse, to IG terminal of generator connector A018.

b. When ignition switch is ON/ST, the current flows output from ignition switch, to instrument panel fuse in

driver side junction box, through the fuse, to pin A20 of instrument cluster. The current flows through charging

warning light of instrument cluster, from pin B25 of instrument cluster, to pin L of generator connector A018, to

field winding of generator. Field winding creates a magnetic field. Rotation of the excited field coil generates

AC voltage in the stator. The alternation current is rectified through diodes to DC voltage, to pin 1 of generator

connector A017, to charge fusible link and charge a battery, at the same time, supply electrical energy to other

electrical devices.

• A018 Generator

1 - Ground:12 volts with the ignition switch at ON position and engine not running.

A002 Chassis & Frame Wire Harness I002 Instrument Panel Wire Harness

A017 Chassis & Frame Wire Harness I003 Instrument Panel Wire Harness

A018

Chassis & Frame Wire Harness

71-41

ANTI-LOCK BRAKE CONTROL SYSTEM

71-42

ABS control system uses vehicle speed sensor to detect vehicle speed and transmits the speed signal to the

control module. The control module controls wheel slipping rate by repeatedly increasing or decreasing the

wheel brake pressure according to the input vehicle speed, keep the wheels rotating. The system enables the

vehicle in braking state to prevent the wheels locking and have the steering capability, guaranteeing stability in

the braking direction and preventing side-slipping and deviation.

• Power Input

The current flows through battery fusible link in positive junction box to ABS valve fuse and ABS pump fusible

link in battery compartment junction box, to pin 1 and 25 of ABS module. System is then powered.

• Ignition signal

When ignition switch is ON/ST, current flows through ABS IG fuse in driver side junction box, to pin 20 of ABS

module and ABS system getss ignition signal.

• Speed Signal

Speed sensor provide the alternating signal to the ABS module. The signal from 4 sensors: front wheel speed

sensor LH, front wheel speed sensor RH, rear wheel speed sensor LH and rear wheel speed sensor RH.

• Brake Signal

a. 4G69 engine: The current flows through battery fusible link in positive junction box, to ECM main fuse in battery

compartment junction box, to stop lamp fuse in engine room junction box, to pin 2 of stop lamp switch.

When the brake pedal is depressed, the current flows from pin 1 of stop lamp switch, to pin 30 of ABS module,

and provide the brake signal to the ABS module.

b. ISF2.8 engine: The current flows through engine room fusible link in positive junction box, to stop lamp fuse

in engine room junction box, to pin 2 of stop lamp switch. When the brake pedal is depressed, the current

flows from pin 1 of stop lamp switch, to pin 30 of ABS module, and provide the brake signal to the ABS

• Malfunction Diagnosis Function

When the system comes into operation, ABS module detects the operation of all parts of the system. Once the

system or parts have faults, the system will switch on the ABS warning light to remind drivers of repair in time.

• A025 Stop Lamp Switch

1 - 2:Closed when the brake pedal depressed.

A009 Chassis & Frame Wire Harness A025 Chassis & Frame Wire Harness

A010 Chassis & Frame Wire Harness I002 Instrument Panel Wire Harness

A011 Chassis & Frame Wire Harness I003 Instrument Panel Wire Harness

A012 Chassis & Frame Wire Harness M002 Diagnosis Wire Harness

A013

71-43

A201

71-44

HEATER AND CONDITIONING CONTROL SYSTEM

FRONT AND REAR AIR CONDITIONING CONTROL SYSTEM

71-45

71-46

71-47

• Ignition Switch At On/st, A/C System Power Supply

a. When ignition switch is turned to ON/ST, current flows through A/C fuse in driver side junction box, to pin 30

of A/C cut off relay, through the relay, battery output from the pin 87a of cut off relay, to pin 10 of A/C controller,

pin 85 of front blower relay, pin 30 and 85 of compressor relay (ISF2,8 engine) and pin 2 of rear blower forward

switch, then A/C system getss the operation power.

b. When ignition switch is turned to ON/ST, current flows through ignition fuse in engine room junction box, to

pin 86 of main relay, pass the the pin 85 of main relay, to pin 10 of the ECM module, the ECM module control

the main relay working. When the pin 85 of main relay is controlled by ECM to connect the ground, coil then

creates a magnetic field, and switch is activated. The current flows through battery fusible link in positive junction

box, to main fuse in battery cmpartment junction box, to main relay, through the relay, to injector fuse, pass

the fuse and connect the pin 85 of compressor relay (4G69 engine).

• Ignition Switch At St, A/C System Power Supply

When ignition switch is turned to ST, current flows through starter fuse in battery compartment junction box, to

pin 85 of A/C cut off relay, through the coil to pin 86 and connect the groud. Coil then creates a magnetic field,

and switch is open, cut off the power of A/C system to sure the starter motor have more power to crank the

• Front A/C Control

a. blower control: current flows from the pin 87a of A/C relay, to pin 86 of front blower relay, through coil of

relay, output from the pin 86 of relay to pin 8 of A/C control panel; A/C control panel make the coil of relay to

connect the ground, coil creates a magnetic field, and switch is closed. Current outputs from the pin 30 of A/C

relay, to pin 1 of the front blower, through the pin 2 of the blower, to pin 4 of blower control module. A/C control

panel control the front blower by controlling the blower control module.

b. A/C clutch control: Working inquire signal of the front A/C system outputs from pin 9 of A/C control

panel, to pin 1 of triple pressure switch, the signal through switch and connect to engine ECM. If the

pressure of refrigerant in A/C pipe meet the specification as design, ECM will control the A/C relay

coil to connect the ground.Coil then creates a magnetic field, and switch is activated. Current flows into A/C

clutch solenoid and A/C compressor clutch engage and front A/C system begin to work

c. servo motor (internal & external circulation) control: Current flows from pin 6 of A/C control panel, to pin 6

of circulation motor, outputs from pin 5 of circulation motor, to pin 7 of A/C control panel. Motor is working, the

front A/C system is internal circulation mode, on the contrary, system is external circulation mode.

d. servo motor (temperature) control: Current flows from pin 5 and 4 of A/C control panel, to pin 5 and 6 of

servo motor to control the motor operation. The current flows through the potentiometer in servo motor and

return to A/C control panel from pin 3 and 1 of servo motor to pin 26 and 27 of A/C control panel. The signal

current outputs from pin 2 of motor, to pin 23 of A/C control panel, feedback the position signal of servo

motor(step motor).

e. servo motor (mode) control: Current flows from pin 1 and 3 of A/C control panel, to pin 5 and 6 of servo

motor to control the motor operation. The current flows through the potentiometer in servo motor and return to

A/C control panel from pin 3 and 1 of servo motor to pin 26 and 27 of A/C control panel. The signal current outputs

from pin 2 of motor, to pin 24 of A/C control panel, feedback the position signal of servo motor(step

motor).

f. Current flows from pin 29 of A/C control panel, to pin 1 of evaporator thermistor, through thermister, outputs

from pin 2 of thermister, to pin 33 of A/C control panel. The A/C sustem getsss the temperature Info of evaporator.

• Rear A/C Blower Control

Press the switch of rear blower, current flows pin 2 of switch and outputs from pin 5 of switch, through pin 85 of

rear A/C relay; Coil then creates a magnetic field, and switch is activated. Current flows from A/C cut off relay

and outputs from pin 30 of rear A/C relay, to pin 1 of rear left blower and pin 1 of rear right blower, through the

blowers, to pin1 of blower resistor and outputs:

a. blower at lower speed: Current flows from pin 2 of right and left blower, to pin 1 of blower resistor, through

resistor, outputs from pin 3 of blower resistor, to pin 4 of top evaporator blower switch, through switch, connect

the ground at pin 3 of switch.

b. blower at middle speed: Current flows from pin 2 of right and left blower, to pin 1 of blower resistor, through

resistor, outputs from pin 2 of blower resistor, to pin 5 of top evaporator blower switch, through switch, connect

c. blower at higher speed: Current flows from pin 2 of right and left blower, to pin 1 of blower resistor, through

resistor, outputs from pin 4 of blower resistor, to pin 6 of top evaporator blower switch, through switch, connect

71-48

• Rear A/C Solenoid Control

Press the button of rear A/C in A/C control panel, switch on the rear blower forward switch and top evaporator

blower switch. The signal of rear A/C request outputs from pin 2 of top evaporator blower switch, to pin 36 of

A/C control panel; Rear A/C relay coil creates a magnetic field, and switch is activated, blowers are working;

The power of rear A/C solenoid outputs from pin 87 of A/C control panel, to pin 1 of rear A/C solenoid, through

solenoid, to pin 1 of A/C control panel and conrtol panel control the operation of rear A/C soleniod.

• A/C Cut Off Relay

30 - 87a:Open with the ignition switch at ST position.

• Rear A/C Relay

30 - 87:Closed when rear A/C system is working.

• compressor Relay

30 - 87:Closed when fron A/C system is working.

A028 Chassis & Frame Wire Harness I026 Instrument Panel Wire Harness

A036 Chassis & Frame Wire Harness I027 Instrument Panel Wire Harness

E001 Engine Wire Harness L001 Rear Evaporator Wire Harness

E013 Engine Wire Harness L002 Rear Evaporator Wire Harness

I020 Instrument Panel Wire Harness L003 Rear Evaporator Wire Harness

I021 Instrument Panel Wire Harness L004 Rear Evaporator Wire Harness

I022 Instrument Panel Wire Harness L005 Rear Evaporator Wire Harness

I023 Instrument Panel Wire Harness N003 Step Lamp Wire Harness

I024 Instrument Panel Wire Harness V017 Front Wire Harness

I025

Instrument Panel Wire Harness

A108

N101

Chassis & Frame Wire Harness & Step Lamp Wire Harness

(Under the B-Pillar RH)

71-49

A112

E103

F101

I107

Roof Wire Harness 1 & Instrument Panel Wire Harness

(Above the Left Side of the Instrument Panel)

F106

L101

Roof Wire Harness 1 & Rear Evaporator Wire Harness

(in Front Roof)

(Left Side of the Driver Side Junction Box)

A202 Left Front Wheel Cover Plate Side Plate I204 Central of the Instrument Panel

71-50

REAR HEATER CONTROL

71-51

• Rear Blower Forward Switch control

When ignition switch is turned to ON/ST, current flows through pin 30 of A/C cut off relay in co-pilot side junction

box, through the relay, to pin 87a of cut off relay and outputs:

a. to pin 30 of water valve relay.

b. to pin 2 of rear blower forward switch, press the switch, the current flows from pin 5 of switch to 85 pin of

water valve relay and pin 85 of rear heater relay.

• Rear Heater Blower Operation

When switch on the rear blower forward switch and rear heater blower switch, the rear heater relay is at operating

status; Current flows through charge fusible link and instrument panel fusible link in positive junction box,

to rear heater fuse in co-pilot side junction box, to rear heater relay, coil then creates magnetic field, and switch

is activated, current flows through relay to pin 2 of rear heater blower, the speed of blower is controlled by

resistor:

a. Current outputs from pin 4 of rear heater blower, to pin 4 of rear heater blower switch, through the switch,

connect to the ground at the pin 1 of switch. Blower is at higher speed.

b. Current outputs from pin 1 of rear heater blower, to pin 5 of rear heater blower switch, through the switch,

connect to the ground at the pin 1 of switch. Blower is at middle speed.

c. Current outputs from pin 3 of rear heater blower, to pin 6 of rear heater blower switch, through the switch,

• Water valve operation

When switch on the rear blower forward switch and rear heater blower switch, water valve is at operating status;

Current flows through coil and creates magnetic field, and switch is activated, current flows through relay

to pin 1 of rear heater water valve and connect to ground at pin 2 of valve, water valve is working.

A007 Chassis & Frame Wire Harness P001 Rear Heater Wire Harness

I023 Instrument Panel Wire Harness P002 Rear Heater Wire Harness

A109

P101

Chassis & Frame Wire Harness & Rear Heater Wire Harness

(At the Left Side of the Chassis)

A202 Left Front Wheel Cover Plate Side Plates I201 Left Side of the Instrument Panel

A204 Right Front Wheel Cover Plate Side Plates I203 Left Side of the Instrument Panel

71-52

LIGHT SYSTEM

HEADLAMP

71-53

• Headlamp (Low Beam)

The current flows through charge and instrument panel fusible link, to pin 85 of lo-beam relay, through coil of

relay, and then to pin 8 of combination switch. When the combination switch is set headlamp (Low Beam)

position, the current output from pin 11 of combination switch to connect the ground. The coil of relay creates a

magnetic field, and switch is activated. The current flows through switch of relay, to lo-beam fuse (LH) and lobeam

fuse (RH) in dirver side junction box, and pass then to pin 3 of left lamp and pin 3 of right headlamp and

through light of headlamp (Low Beam). The power is ground at pin 1 of left and right headlamp. This enables

headlamp (Low Beam) to operate.

• Headlamp (High Beam)

The current flows through charge and instrument panel fusible link, to headlamp fuse in driver side junction

box, to pin 85 and pin 30 of hi-beam relay, through coil of relay, and then to pin 9 of combination switch. When

the combination switch is set headlamp (High Beam) position, the current output from pin 11 of combination

switch to connect the ground. The coil of relay creates a magnetic field, and switch is activated. The current

flows through switch of relay, to hi-beam fuse (LH) and hi-beam fuse (RH) in driver side junction box, and pass

then to pin 2 of headlamp LH and pin2 of headlamp RH, and through light of headlamp (High Beam). The

power is ground at pin 1 of left and right headlamp. This enables headlamp (High Beam) to operate.

• High Beam Indicator

When the combination switch is set headlamp (High Beam) position, the current flows through hi-beam (LH),

to instrument cluster, and through high beam indicator. This enables high beam indicator to operate.

• Flash to Pass

the combination switch is set flash to pass position, the current output from pin 11 of combination switch to

connect the ground. The coil of relay creates a magnetic field, and switch is activated. The current flows

through switch of relay, to hi-beam fuse (LH) and hi-beam fuse (RH) in driver side junction box, and pass then

to pin 2 of headlamp LH and pin2 of headlamp RH, and through light of headlamp (High Beam). The power is

ground at pin 1 of left and right headlamp. This enables flash to pass to operate.

• Headlamp Adjusting

When low beam lamp is under working condition, current through right low beam lamp fuse, to pin 1 of front

left/right adjusting motor, to supply power for adjusting motor. Pin 2 of front left/right adjusting motor connect to

the pin 4 and pin 5 of the adjusting switch, adjusting motor control the adjusting motor.

• I012 Combination Switch (Light Control)

8 - 9:Closed with the combination switch at Headlamp position ( Low Beam).

9 - 11:Closed with the combination switch at Headlamp position (High Beam and Flash to Pass).

9 - 11:Closed with the combination switch at Flash to Pass position.

I004 Instrument Panel Wire Harness V003 Front Wire Harness

I012 Instrument Panel Wire Harness V005 Front Wire Harness

V001 Front Wire Harness V006 Front Wire Harness

71-54

71-55

I201 Left Side of the Instrument Panel V201 Left Side of the Longitudinal Beam Flank

I202 Left Side of the Instrument Panel V203 Right Side of the Longitudinal Beam

71-56

LAMPLET

71-57

• Width Light

The current flows through charge and instrument panel fusible link in positive junction box, to pin 85 of lamplet

relay in driver side junction box, pass the coil of relay and then to pin 13 of combination switch. When the

combination switch is set lamplet light or headlamp (Low Beam/High Beam) position, the current flows output

pin 10 of combination switch to connect the ground. The coil of lamplet relay creates a magnetic field, and

switch is activated. The current flows through switch of relay, and through the lamplet fuse in driver side

junction box, to pin 2 of front position lamp LH and pin 2 of front position lamp RH. The power is ground at pin

1 of front position lamp LH and pin 1 of front position lamp RH. This enables width light to operate.

• Tail Light

junction box, to pin 1 of front combination lamp LH and pin 1 of front combination lamp RH. The power is

ground at pin 2 of front combination lamp LH and pin 2 of front combination lamp RH. This enables tail light to

operate.

• License Light

junction box, to pin 1 of license light. The power is ground at pin 2 of license light. This enables license light to

13 - 10:Closed with the combination switch at Headlamp and lamplet position.

F006 Roof Wire Harness 1 J004 Rear Hatch Wire Harness

G001 Roof Wire Harness 2 V002 Front Wire Harness

I012 Instrument Panel Wire Harness V007 Front Wire Harness

F103

G103

G101

K101

Roof Wire Harness 1 & Roof Wire Harness 2

(Left Side of the Top Cap Rear Beam)

Roof Wire Harness 2 & Rear Hatch Transition Wire Harness

(Right Side of the Top Cap Rear Beam)

71-58

J101

K102

Rear Hatch Wire Harness & Rear Hatch Transition Wire Harness

(Under the Right Side of the Rear Hatch)

F201 Rear Inner Panel of the Left Gusset J201 Under the Right Side of the Right Door

G201 Rear Inner Panel of the Right Gusset V201 Left Side of the Longitudinal Beam Flank

I201 Left Side of the Instrument Panel V203 Right Side of the Longitudinal Beam

71-59

STOP LAMP

71-60

• 4G69 Engine

The current flows through battery fusible link in positive junction box, to ECM main fuse in battery compartment

junction box, to stop lamp fuse in engine room junction box, to pin 2 of stop lamp switch. The stop lamp

switch is closed with the brake pedal depressed. The current then flows from pin 1 of stop lamp switch to pin 3

of rear combination lamp LH, pin 3 of rear combination lamp RH and pin 2 of high-mounted stop lamp. The

power is ground at pin 2 of rear combination lamp LH, pin 2 of rear combination lamp RH and pin 1 of highmounted

stop lamp. This enables stop lamp and high-mounted stop lamp to operate.

• ISF 2.8 Engine

The current flows through engine room fusible link in positive junction box, to stop lamp fuse in engine room

junction box, to pin 2 of stop lamp switch. The stop lamp switch is closed with the brake pedal depressed. The

current then flows from pin 1 of stop lamp switch to pin 3 of rear combination lamp LH, pin 3 of rear

combination lamp RH and pin 2 of high-mounted stop lamp. The power is ground at pin 2 of rear combination

lamp LH, pin 2 of rear combination lamp RH and pin 1 of high-mounted stop lamp. This enables stop lamp and

high-mounted stop lamp to operate.

1 - 2:Closed with the brake pedal depressed.

A025 Chassis & Frame Wire Harness G001 Roof Wire Harness 2

F006 Roof Wire Harness 1 U002 High-mounted Stop Lamp Wire Harness

F105

U101

Roof Wire Harness 1 & High-mounted Stop Lamp Wire Harness

F201 Rear Inner Panel of the Left Gusset G201 Rear Inner Panel of the Right Gusset

71-61

BACK-UP LAMP

71-62

When ignition switch is ON/ST, the current flows throug back-up lamp fuse in driver side junction box, to pin 1

of back-up lamp switch. The current flows from pin 2 of back-up lamp switch, and then to the circuit as follows:

a. The current pass through pin 6 of rear combination lamp LH, and ground at pin 2 of rear combination lamp

LH. This enables rear back-up lamp LH to operate.

b. The current pass through pin 6 of rear combination lamp RH, and ground at pin 2 of rear combination lamp

RH. This enables rear back-up lamp RH to operate.

c. The current pass through the reverse radar control unit. Reverse radar control unit is then powered.

d. The current pass through the multimedia system. Multimedia system is then powered.

• A021 Back-up Lamp Switch

1 – 2: Closed with the shift lever in “R” position.

A021 Chassis & Frame Wire Harness F006 Roof Wire Harness 1

G001 Roof Wire Harness 2

F201 Rear Inner Panel of the Left Gusset I201 Left Side of the Instrument Panel

G201

Rear Inner Panel of the Right Gusset

71-63

TURN SIGNAL AND HAZARD WARNING LAMPS

71-64

• Turn Signal Lamp Working Condition

Current flows through hazard waring fuse in driver side junction box, to pin 1 of flasher, to supply power for

flasher.

When ignition switch is ON/ST, the current flows through turn signal fuse in driver side junction box, to pin 6 of

combination switch. When operating the combination switch, the current flow output from pin 7 and pin 5 of

combination switch, to pin 12 and pin 5 of flasher, vehicle turning lamp is under working condition.

• Turn Signal Lamp LH

When the combination switch is in Left Turn position, the current flows output from pin 9 and pin 4 of flasher,

the circuit as follows:

a. The current flows through pin 2 of front turn signal lamp LH, and ground at pin 1 of front turn signal lamp LH.

This enables front turn signal lamp LH to operate.

b. The current flows through pin 4 of rear combination lamp LH, and ground at pin 2 of rear combination lamp

LH. This enables rear turn signal lamp LH to operate.

c. The current flows to pin A32 of instrument cluster and ground at pin B30 of instrument cluster. This enables

left turn signal/hazard indicator to operate.

• Turn Signal Lamp RH

When the combination switch is in Right Turn position, the current flows output from pin 10 and pin 2 of flasher,

a. The current flows to pin 2 of front turn signal lamp RH, and ground at pin 1 of front turn signal lamp RH. This

enables front turn signal lamp RH to operate.

b. The current flows through pin 4 of rear combination lamp RH, and ground at pin 2 of rear combination lamp

RH. This enables rear turn signal lamp RH to operate.

c. The current flows to pin B32 of instrument cluster and ground at pin B30 of instrument cluster. This enables

right turn signal/hazard indicator to operate.

• Hazard Warning Lamp

When hazard warning switch is pressed, the signal flows from pin 8 of hazard warning switch, to pin 7 of

flasher. Flasher is working condition; The current flows output from pin 4 , 2, 9, 10 of flasher.

Power from pin 9 and pin 4 of flasher:

Power from pin 10 and pin 2 of flasher:

• I006 Hazard Warning Switch

7 - 10:Closed with the hazard warning switch released.

7 - 8:Closed with the hazard warning switch pressed.

4 - 5 - 6:Closed with the hazard warning switch pressed.

• I012 Combination Switch

5 - 6:Closed with the combination switch at Left Turn position.

6 - 7:Closed with the combination switch at Right Turn position.

71-65

F006 Roof Wire Harness 1 I012 Instrument Panel Wire Harness

G001 Roof Wire Harness 2 I034 Instrument Panel Wire Harness

I002 Instrument Panel Wire Harness I039 Instrument Panel Wire Harness

I003 Instrument Panel Wire Harness I040 Instrument Panel Wire Harness

V008 Front Wire Harness V004 Front Wire Harness

I006

F201 Rear Inner Panel of the Left Gusset V201 Left Side of the Longitudinal Beam Flank

G201 Rear Inner Panel of the Right Gusset V203 Right Side of the Longitudinal Beam

71-66

FOG LAMP

71-67

• Front Fog Lamp

Operation requirement: Always turn on lamplet or headlamp.

relay, pass the coil of relay and then to pin 13 of combination switch. When the combination switch is set lamplet

or headlamp (Low Beam/High Beam) position, the current flows output pin 10 of combination switch to

through switch of relay, from the pin 87 of relay to front fog relay coil, to pin 2 of ombination switch. When front

fog lamp switch is closed, the current flows output from pin 4 of combination switch to connect the ground. The

coil of front fog lamp relay creates a magnetic field, and switch is activated. The current flows through fog lamp

fuse in driver side junction box, to front fog lamp relay, and through switch of front fog lamp relay, to pin 1 of

front fog lamp LH and pin 1 of front fog lamp RH, the power is ground at pin 2 of front fog lamp LH and pin 2 of

front fog lamp RH. This enables front fog lamp LH and front fog lamp RH to operate.

• Rear Fog Lamp

The current flows through charge and instrument panel fusible link in positive junction box, to rear fog lamp

fuse in driver side junction box, to rear fog lamp relay. When front low beam lamp work and rear fog lamp

switch is closed, the current flows output from pin 4 of combination switch to connect the ground. The coil of

rear fog lamp relay creates a magnetic field, and switch is activated. The current flows through rear lamp fuse

in driver side junction box, to rear fog lamp relay, and through switch of rear fog lamp relay, to pin 5 of rear

combination lamp LH and pin 5 of rear combination lamp RH, the power is ground at pin 2 of rear combination

lamp LH and pin 2 of rear combination lamp RH. This enables rear fog lamp LH and rear fog lamp RH to operate.

• Fog Lamp indicator

a. Front fog lamp indicator: When front fog lamp is woring, the current flows to pin A7 of instrument cluster and

ground at pin B30 of instrument cluster. This enables front fog lamp indicator to operate.

b. Rear fog lamp indicator: When rear fog lamp is working, the current flows to pin B21 of instrument cluster

and ground at pin B30 of instrument cluster. This enables rear fog lamp indicator to operate.

10 - 13:Closed with the combination switch at Lamplet and Headlamp position

C001 Front Bumper Wire Harness I002 Instrument Panel Wire Harness

C002 Front Bumper Wire Harness I003 Instrument Panel Wire Harness

C101

V110

Front Bumper Wire Harness & Front Wire Harness

(Left Front Combination Lamps Positioning Plate Side)

71-68

Instrument Panel Wire Harness & Roof Wire Harness 1

G201 Rear Inner Panel of the Right Gusset V202 Left Side of the Longitudinal Beam

71-69

INTERIOR LAMPS

71-70

71-71

• Front Dome Light

The current flows through charge and instrument panel fusible link in positive junction box, to dome light fuse

in driver side junction box, to pin 1 and 2 of front dome light. Front dome light is working condition.

a. Press front dome light switch, and the power is ground by the switch. This enables front dome light to

b. Dome light switch is at DOOR postion; If any front door is not closed, the front door ajar switch will turn to

ON. The current flows from pin 4 of front dome lamp, to front door ajar switch. The power is ground by ajar the

switch. This enables front dome light to operate.

• central dome Light

in driver side junction box, to pin 1 of central dome light. central dome light is working condition.

a. When central dome light is at ON position; The current flows from pin 3 (high equipped) or 2 (low equipped)

of central dome light, to pin 5 of central dome light switch, press the switch, and the power is ground by the pin

2 of switch. This enables central dome light to operate.

b. When central dome light is at DOOR position (high equipped); If sliding door is not closed, the door ajar

switch will turn to ON. The current flows from pin 2 of central dome lamp, to door ajar switch. The power is

ground by ajar the switch. This enables central dome light to operate.

• Step lamp

in driver side junction box, to pin 1 of step light and output from pin 2 of step light; If sliding door is not closed,

the door ajar switch will turn to ON. The current flows from pin 2 of step light, to door ajar switch. The power is

ground by ajar the switch. This enables step light to operate.

• Ignition Switch Illumination

in driver side junction box, to pin 1 of ignition switch illumination; The current outputs from the pin 2 of ignition

switch illumination, to pin B1 of central locking controller, the central locking controller control the ignition

switch illumination to operation.

• Trunk lamp

in driver side junction box, to pin 1 of trunk lamp and output from pin 2 of trunk lamp; If rear hatch door is not

closed, the door ajar switch will turn to ON. The current flows from pin 2 of trunk lamp, to door ajar switch. The

power is ground by ajar the switch. This enables trunk lamp to operate.

• Door open Indicatior

If any door is not closed, the door ajar switch will turn to ON. The ground signal input pin A15 and A30 of

instrument cluster and this enables indicatior to operate.

A008 Chassis & Frame Wire Harness I008 Instrument Panel Wire Harness

A024 Chassis & Frame Wire Harness I010 Instrument Panel Wire Harness

A029 Chassis & Frame Wire Harness I018 Instrument Panel Wire Harness

F001 Roof Wire Harness 1 I036 Instrument Panel Wire Harness

F004 Roof Wire Harness 1 I037 Instrument Panel Wire Harness

F007 Roof Wire Harness 1 J001 Rear Hatch Wire Harness

G003 Roof Wire Harness 2 J003 Rear Hatch Wire Harness

I002 Instrument Panel Wire Harness N002 Step Lamp Wire Harness

71-72

I203

71-73

ILLUMINATION

71-74

71-75

The current flows from charge and instrument panel fusible link, to pin 85 of lamplet relay, through the coil of

tail light relay, and then to pin 13 of combination switch. When the combination switch is set lampet or

headlamp (Low Beam/High Beam) position, the current flows output pin 10 of combination switch to connect

the ground. The coil of lamplet relay creates a magnetic field, and switch is activated. The current flows

through switch of relay and through the lamplet and switch light fuse in driver side junction box and the system

getsss the power to operation.

• Instrument Cluster Illumination

When the combination switch is set lamplet or headlamp position, the current flows output lamplet fuse in

driver side junction box, to pin A6 of instrument cluster. This enables instrument cluster illumination to operate.

• Hazard Warning Switch Illumination

driver side junction box, to pin 2 of hazard warning switch, to pin 3 of hazard warning switch, the power is

ground at pin 3 of hazard warning switch. This enables hazard warning switch illumination to operate.

• Headlamp Dimmer Switch Illumination

When the combination switch is set lamplet or headlamp position, the current flows output switch light fuse in

driver side junction box, to pin 3 of headlamp dimmer switch illumination, to pin 6 of headlamp dimmer switch

illumination, the power is ground at pin 6 of headlamp dimmer switch illumination. This enables headlamp

dimmer switch illumination to operate.

• Instrument Dimmer Switch Illumination

driver side junction box, to pin 3 of instrument dimmer switch illumination, to pin 6 of instrument dimmer

switch illumination, the power is ground at pin 6 of instrument dimmer switch illumination. This enables

instrument dimmer switch illumination to operate.

• Rear Window Defroster Switch Illumination

driver side junction box, to pin 3 of rear window defroster switch illumination, to pin 1 of rear window defroster

switch illumination, the power is ground at pin 1 of rear window defroster switch illumination. This enables

rear window defroster switch illumination to operate.

• Outside Mirror Defroster Switch Illumination

driver side junction box, to pin 3 of outside mirror defroster switch illumination, to pin 1 of outside mirror

defroster switch illumination, the power is ground at pin 1 of outside mirror defroster switch illumination.

This enables outside mirror defroster switch illumination to operate.

• Rear Blower Forward Switch Illumination

driver side junction box, to pin 3 of rear blower forward switch illumination, to pin 1 of rear blower forward

switch illumination, the power is ground at pin 1 of rear blower forward switch illumination. This enables

rear blower forward switch illumination to operate.

• Dome Light Switch Illumination

driver side junction box, to pin 3 of dome light switch illumination, to pin 1 of dome light switch illumination,

the power is ground at pin 1 of dome light switch illumination. This enables dome light switch illumination

to operate.

• Cigarette Lighter Illumination

driver side junction box, to pin 3 of cigarette lighter illumination, to pin 1 of cigarette lighter illumination,

the power is ground at pin 1 of cigarette lighter illumination. This enables cigarette lighter illumination to

• Radio Illumination

driver side junction box, to pin A3 of radio illumination, to pin A8 of radio illumination, the power is ground

at pin A8 of radio illumination. This enables radio illumination to operate.

71-76

• A/C Control Panel llumination

driver side junction box, to pin 32 of A/C control panel llumination, to pin 20 of A/C control panel

llumination, the power is ground at pin 20 of A/C control panel llumination. This enables A/C control

panel llumination to operate.

• Diagnosis Switch llumination

driver side junction box, to pin 3 of diagnosis switch llumination, to pin 1 of diagnosis switch llumination,

the power is ground at pin 1 of diagnosis switch llumination. This enables diagnosis switch llumination to

10 - 13:Closed with the combination switch at Lamplet or Headlamp position.

I002 Instrument Panel Wire Harness I018 Instrument Panel Wire Harness

I004 Instrument Panel Wire Harness I019 Instrument Panel Wire Harness

I005 Instrument Panel Wire Harness I020 Instrument Panel Wire Harness

I006 Instrument Panel Wire Harness I021 Instrument Panel Wire Harness

I012 Instrument Panel Wire Harness I023 Instrument Panel Wire Harness

I016 Instrument Panel Wire Harness I031 Instrument Panel Wire Harness

I017 Instrument Panel Wire Harness I033 Instrument Panel Wire Harness

I201 Left Side of the Instrument Panel I204 Central of the Instrument Panel

I202 Left Side of the Instrument Panel I205 Central of the Instrument Panel

71-77

71-78

When ignition switch is ON/ST, the current flows through front wiper fuse and rear wiper fuse in driver side

junction box. System is then powered.

• Front Wiper Switch LO

When the front wiper switch of combination switch is in LO position, the current flows from front wiper fuse, to

pin 8 of combination switch, and output from pin 7 of combination switch, to pin 1 of front wiper motor, and

through wiper motor to ground. This enables front wiper to operate at low speed.

• Front Wiper Switch MIST

• Front Wiper Switch HI

When the front wiper switch of combination switch is in HI position, the current flows from front wiper fuse, to

pin 8 of combination switch, and output from pin 9 of combination switch, to pin 4 of front wiper motor, and

through wiper motor to ground. This enables front wiper to operate at high speed.

• Front Wiper Switch INT

When the front wiper switch of combination switch is set INT, The intermittent current flows from pin 7 of

combination switch, to front wiper motor. This enables front wiper to operate in the intermittent mode.

• Front Washer switch ON

When the front washer switch is in ON position, the current flows output from pin 2 of front washer pump, and

through the front washer pump, output from pin 1 of front washer pump, to pin 4 of combination switch, and

ground at pin 5 of combination switch. This enables front washer to function.

• Rear Wiper Switch ON

The current flows output from rear wiper fuse, to pin 85 and 87 of rear wiper relay, and then output from pin 30

of rear wiper relay. When the rear wiper switch is in ON position, the current flows into pin 2 of combination

switch, and then to ground at pin 5 of combination switch; The current flows into coil of rear wiper relay. The

coil of relay creates a magnetic field, and switch is activated. The current flows through switch of relay, from

the pin 30 of relay, to pin 4 of rear wiper motor, and through the rear wiper motor, to ground at pin 3 of rear

wiper motor. This enables rear wiper to operation.

• Rear Washer Switch ON

When the rear wiper switch is in ON position, the current flows from rear wiper fuse, to pin 2 of rear washer

pump, and output from pin 1 of rear washer pump, to pin 3 of combination switch, and ground at pin 5 of

combination switch. This enables rear washer to operation.

I013 Instrument Panel Wire Harness V010 Front Wire Harness

U001 High-mounted Stop Lamp Wire Harness V011 Front Wire Harness

V009

Front Wire Harness

F102

I108

71-79

I101

V101

F201 Rear Inner Panel of the Left Gusset I202 Left Side of the Instrument Panel

I201 Left Side of the Instrument Panel V202 Left Side of the Longitudinal Beam

71-80

71-81

• I031 Radio

A4 - Ground Points:Approx.12 V with the ignition switch at ACC/ON position.

A7 - Ground Points:Approx. 12 V

• D001 Front Speaker LH

1 - 2:Approx. 4 Ω

• H001 Front Speaker RH

• F005 Rear Speaker LH

• G002 Rear Speaker RH

A026 Chassis & Frame Wire Harness I029 Instrument Panel Wire Harness

D001 Front Door LH Wire Harness I030 Instrument Panel Wire Harness

F005 Roof Wire Harness 1 I031 Instrument Panel Wire Harness

G002 Roof Wire Harness 2 I032 Instrument Panel Wire Harness

H001 Front Door RH Wire Harness J005 Rear Hatch Wire Harness

D103

F104

H103

V106

G102

V109

Front Door LH Wire Harness & Front Wire Harness

(Under the Left Side of the Door Flame)

Front Door RH Wire Harness & Front Wire Harness

(Under the Right Side of the Door Flame)

71-82

G201 Rear Inner Panel of the Right Gusset I205 Central of the Instrument Panel

71-83

POWER SOCKET

71-84

• Cigarette Lighter

When ignition switch is ACC/ON, the current flows through cigarette lighter fuse in driver side junction box, pin

2 of cigarette lighter. When pressing the cigarette lighter, the current flows output from pin 1 of cigarette lighter,

and ground at pin 1 of cigarette lighter. This enables cigarette lighter to operate.

• 12V Power Output Socket

When ignition switch is ON/ST, the current flows through cigarette lighter fuse in driver side junction box, pin 2

of power output socket. When pressing the power output socket, the current flows output from pin 1 of power

output socket, and ground at pin 1 of power output socket. This enables power output socket to operate.

I015 Instrument Panel Wire Harness I033 Instrument Panel Wire Harness

I201 Left Side of the Instrument Panel I203 Left Side of the Instrument Panel

71-85

COMMUNICATION SYSTEM

71-86

• horn control

The current flows through charge and instrument panel fusible link in positive junction box, to horn fuse in

driver side junction box, to pin 85 of horn relay, and through the coil of horn relay, and then to the circuit as

follows:

a. High equipped: Current flows from 2 pin of clock spring, to horn switch, when pressing the horn switch, the

power is ground by switch. The coil of horn relay creates a magnetic field, and switch is activated. The current

then flows through switch of horn relay, to pin 1 of horn, and to ground at pin 2 of horn. This enables horn to

b. low equipped: Current flows to horn switch, when pressing the horn switch, the power is ground by switch.

The coil of horn relay creates a magnetic field, and switch is activated. The current then flows through switch

of horn relay, to pin 1 of horn, and to ground at pin 2 of horn. This enables horn to operate.

• Horn of Anti-thief System

Pin 86 of horn relay is controlled by pin B4 of central locking controller to coonect the ground; When pin 86 of

relay to connect the ground, The coil of horn relay creates a magnetic field, and switch is activated. The

current then flows through switch of horn relay, to pin 1 of horn, and to ground at pin 2 of horn. This enables

horn to operate.

I008 Instrument Panel Wire Harness V013 Front Wire Harness

I014 Instrument Panel Wire Harness V014 Front Wire Harness

I038

V202

Left Side of the Longitudinal Beam

71-87

71-88

When ignition switch is ON/ST, the current flows through back-up lamp fuse in driver side junction box, to pin 2

of back-up lamp switch. When shift lever in “R” position, the current flows from pin 1 of back-up lamp switch to

pin 1 of reverse radar control unit. The reverse radar control system is then powered.

• Reverse Radar Sensor LH

The current outputs from pin 7 of reverse radar control unit, to pin 1 of reverse radar sensor LH, and through

the sensor, output from pin 2 of reverse radar sensor LH, to pin 11 of reverse radar control unit, this detects the

obstacle in rear left side.

• Reverse Radar Central Sensor LH

The current outputs from pin 8 of reverse radar control unit, to pin 1 of reverse radar central sensor LH, and

through the sensor, output from pin 2 of reverse radar central sensor LH, to pin 11 of reverse radar control unit,

this detects the obstacle in rear left central side.

• Reverse Radar Central Sensor RH

The current outputs from pin 4 of reverse radar control unit, to pin 1 of reverse radar central sensor RH, and

through the sensor, output from pin 2 of reverse radar central sensor RH, to pin 11 of reverse radar control

unit, this detects the obstacle in rear right central side.

• Reverse Radar Sensor RH

The current outputs from pin 15 of reverse radar control unit, to pin 1 of reverse radar sensor RH, and through

the sensor, output from pin 2 of reverse radar sensor RH, to pin 11 of reverse radar control unit, this detects

the obstacle in rear right side.

1 - 2:Closed with the shift lever in “R” position.

A021 Chassis & Frame Wire Harness R001 Rear Bumper Wire Harness

A026 Chassis & Frame Wire Harness R002 Rear Bumper Wire Harness

I002 Instrument Panel Wire Harness R003 Rear Bumper Wire Harness

I028 Instrument Panel Wire Harness R004 Rear Bumper Wire Harness

A103

A110

I105

Q102

Chassis & Frame Wire Harness & Rear Bumper Transition Wire Harness

(Left Rear Side of the Car Body)

71-89

Q101

R101

Rear Bumper Transition Wire Harness & Rear Bumper Wire Harness

(Left Side of the Rear Bumper)

71-90

POWER MIRROR

71-91

When ignition switch is ACC/ON, the current flows through radio ACC fuse in driver side junction box, to pin 4

of outside mirror switch. System is then powered.

• Outside Mirror LH (Up/Down)

The current flows from pin 4 of electric outside mirror switch and output from pin 7 of electric outside mirror

switch, to pin 6 of outside mirror LH, through motor, the current flows from pin 4 of outside mirror LH, to pin 5

of electric outside mirror switch, and ground at pin 6 of electric outside mirror switch. This enables outside

mirror LH to go up.

The current flows from pin 4 of electric outside mirror switch and output from pin 5 of electric outside mirror

switch, to pin 4 of outside mirror LH, through motor, the current flows from pin 6 of outside mirror LH, to pin 7

mirror LH to go down.

• Outside Mirror RH (Up/Down)

The current flows from pin 4 of electric outside mirror switch and output from pin 8 of electric outside mirror

switch, to pin 6 of outside mirror RH, through motor, the current flows from pin 4 of outside mirror RH, to pin 5

mirror RH to go up.

switch, to pin 4 of outside mirror RH, through motor, the current flows from pin 6 of outside mirror RH, to pin 8

mirror RH to go down.

• Outside Mirror LH (Left/Right)

TThe current flows from pin 4 of electric outside mirror switch and output from pin 5 of electric outside mirror

switch, to pin 4 of outside mirror LH, through motor, the current flows from pin 5 of outside mirror LH, to pin 1

mirror LH to turn to left.

The current flows from pin 4 of electric outside mirror switch and output from pin 1 of electric outside mirror

switch, to pin 5 of outside mirror LH, through motor, the current flows from pin 4 of outside mirror LH, to pin 5

mirror LH to turn to right.

• Outside Mirror RH (Left/Right)

switch, to pin 4 of outside mirror RH, through motor, the current flows from pin 5 of outside mirror RH, to pin 3

mirror RH to turn to left.

The current flows from pin 4 of electric outside mirror switch and output from pin 3 of electric outside mirror

switch, to pin 5 of outside mirror RH, through motor, the current flows from pin 4 of outside mirror RH, to pin 5

mirror RH to turn to right.

D003 Front Door LH Wire Harness H003 Front Door RH Wire Harness

D004

Front Door LH Wire Harness

D101

D102

V104

V105

71-92

V107

H101

Front Wire Harness & Front Door RH Wire Harness

71-93

WINDOW DEFROSTER

71-94

• Rear Window Defrost

When ignition switch is ON/ST, the current flows through outside mirror defrost fuse in co-pilot side junction

box, to pin 2 of rear window defroster switch, when press the switch, pin 5 and pin 2 of rear window defroster

switch connected, the current flows to pin 85 of rear defroster relay, through the coil in rear defroster relay, and

output from pin 86 of rear defroster relay. The coil of rear defroster relay creates a magnetic field, and switch is

activated. The current flows through switch of rear defroster relay, to pin 1 of rear window defrost grid and

ground. This enables rear window defroster to operate.

• Outside Mirror Defrost

box, to pin 2 of outside mirror defroster switch, when press the switch, pin 5 and pin 2 of outside mirror

defroster switch connected, the current flows to pin 85 of outside mirror defroster relay, through the coil in outside

mirror defroster relay, and output from pin 86 of outside mirror defroster relay. The coil of outside mirror

defroster relay creates a magnetic field, and switch is activated. The current flows from outside mirror defrost

fuse, through switch of outside mirror defroster relay, to pin 1 of outside mirror defrost grid and ground at pin 2

of grid. This enables outside mirror defroster to operate.

• I016 Rear Window Defrost Switch

2 - 5:Closed with the rear window defrost switch in operation.

• I017 Outside mirror Defrost Switch

2 - 5:Closed with the outside mirror defrost switch in operation.

D003 Front Door LH Wire Harness I017 Instrument Panel Wire Harness

H003 Front Door RH Wire Harness S001 Rear Defrost RH Wire Harness

I016 Instrument Panel Wire Harness T001 Rear Defrost LH Wire Harness

71-95

S101

U103

Rear Defrost RH Wire Harness & High-mounted Stop Lamp Wire Harness

(Above the Right Side of the Rear Hatch)

T101

U102

Rear Defrost LH Wire Harness & High-mounted Stop Lamp Wire Harness

(Above the Left Side of the Rear Hatch)

A201 Left Front Wheel Cover Plate Side Plates V202 Left Side of the Longitudinal Beam

71-96

71-97

71-98

71-99

71-100

• instrument cluster power

a. ISF 2.8 engine: When ignition switch is ON/ST, the current flows through instrument IG fuse in driver side

junction box, to pin A1 and A20 of instrument cluster. System is then powered.

b. 4G69 engine: The instrument cluster IG power of circuit as follows: When ignition switch is ON/ST, the current

flows through instrument IG fuse in driver side junction box, to pin A20 of instrument cluster. System is

then powered. When ignition switch is ON/ST, current flows through main relay and output from pin 87 of relay,

to pin A1 of intrument cluster. System is then powered.

• Engine Coolant Fluid Level Warning Light

The current flows through engine coolant fluid level warning light in instrument cluster, and output from pin B7

of instrument cluster, to pin 2 of engine coolant level sensor, and ground at pin 1 of engine coolant level

sensor. This enables engine coolant fluid level warning light to operate.

• Engine Coolant Temperature Indicator

The current flows from pin B16 of instrument cluster, to pin 1 of engine coolant temperature sensor, and

ground at pin 2 of engine coolant temperature sensor (ISF2.8) or itself (4G69). This enables engine coolant

fluid temperature indicator to operate.

• Engine Oil Pressure Warning Light

The current flows through engine oil pressure warning light in instrument cluster, and output from pin B22 of

instrument cluster, to pin 1 of engine oil pressure switch, and then to ground. This enables engine oil pressure

warning light to operate.

• Low Fuel Indicator and Warning Light

The current flows through low fuel warning light in instrument cluster, and output from pin A23 of instrument

cluster, to pin 3 of fuel level sensor, and then ground at pin 2 of level sensor. This checks the fuel leveland

shows the fuel level in instrument cluster, if the fuel is less, the warning light will be activated.

• ABS Warning Light

The current flows into pin A20 of instrument cluster, through ABS warning light in instrument cluster, and

output from pin B20 of instrument cluster, to 15 of ABS module. If ABS system is fault, this enables ABS

• EBD Warning Light

The current flows into pin A20 of instrument cluster, through EBD warning light in instrument cluster, and

output from pin B24 of instrument cluster, to 14 of ABS module. If ABS system is fault, this enables EBD

• Charging Warning Light

The current flows into pin A20 of instrument cluster, through charging warning light in instrument cluster, and

output from pin B25 of instrument cluster, to pin 1 of generator. This identifies if the generator operates or not.

• Safe Belt Indicator

The current flows into pin A20 of instrument cluster, through safe belt indicator in instrument cluster, and

output from pin A31of instrument cluster, to pin 1 of driver seat belt warning switch. If driver do not fasten the

safe belt, switch will close, this enables safe belt indicator to operate.

• Buzzer of Safe Belt

The current flows through buzzer in instrument cluster, and output from pin B9 of instrument cluster, to pin 1 of

driver seat belt warning switch. If driver do not fasten the safe belt, switch will close, this enables buzzer to

• Air Bag System Warning Light

The current flows into pin A20 of instrument cluster, through warning light in instrument cluster, and output

from pin B27 of instrument cluster, to pin 7 of RCM. If Air bag system is fault, this enables air bag system

warning light to operate

• Parking Indicator

The current flows into pin A20 of instrument cluster, through indicator in instrument cluster, and output from pin

B6 of instrument cluster, to pin 1 of parking brake switch. Through switch to ground, this enables parking indicator

to operate

• Brake Warning Light

The current flows into pin A20 of instrument cluster, through brake warning light in instrument cluster, and

output pin B28 of instrument cluster, to pin 1 of brake fluid level sensor, and ground at pin 2 of brake fluid level

sensor. This checks the brake fluid level.

71-101

• Lamplet indicator

The current flows into pin A6 of instrument cluster, through indicator in instrument cluster, and output pin B30

of instrument cluster to ground. If lamplet or interior lamp work, the indicator will be activated.

• Enging Pre-heating indicator

ISF2.8 engine: The current flows into pin A1 of instrument cluster, through indicator in instrument cluster, and

output pin A27 of instrument cluster, to pin 35 of ECM. If pre-heating system is working, the indicator will be

activated.

• Malfunction Indicator

The current flows into pin A1 of instrument cluster, through malfunction indicator in instrument cluster, and

output from pin B23 of instrument cluster, to pin 19 of ECM (4G69) or 22 of ECM (ISF2.8). If engine control

system fault exist, this enables malfunction indicator to operate.

• Maintenance Indicator

The current flows into pin A1 of instrument cluster, through indicator in instrument cluster, and output from pin

A28 of instrument cluster, to pin 12 of ECM (4G69) or 36 of ECM (ISF2.8). If engine need to service, this

enables indicator to operate.

• Engine Stop Indicator

ISF 2.8 engine: The current flows into pin A20 of instrument cluster, through indicator in instrument cluster,

and output from pin A24 of instrument cluster, to pin 49 of ECM. ECM control the stop indicator.

• Vacuum Warning Light

ISF 2.8 engine: The current flows from pin A26 of instrument cluster, through indicator in instrument cluster, to

pin 1 of vacuum warning switch. Through the switch to connect ground, this enables the warning light to operate.

A009 Chassis & Frame Wire Harness E012 Engine Wire Harness

A018 Chassis & Frame Wire Harness E036 Engine Wire Harness

A020 Chassis & Frame Wire Harness E037 Engine Wire Harness

A022 Chassis & Frame Wire Harness I002 Instrument Panel Wire Harness

A023 Chassis & Frame Wire Harness I003 Instrument Panel Wire Harness

A026 Chassis & Frame Wire Harness I005 Instrument Panel Wire Harness

A027 Chassis & Frame Wire Harness O001 Driver Seat Belt Wire Harness

A032 Chassis & Frame Wire Harness V012 Front Wire Harness

A036 Chassis & Frame Wire Harness V016 Front Wire Harness

E001

Engine Wire Harness

71-102

A105

O101

Chassis & Frame Wire Harness & Driver Seat Belt Wire Harness

(Above the B-Pillar LH)

A202 Left Front Wheel Cover Plate Side Plates I203 Left Side of the Instrument Panel

A204 Right Front Wheel Cover Plate Side Plates V202 Left Side of the Longitudinal Beam

71-103

ANTI-THEIF SYSTEM

71-104

71-105

The current flows through charge and instrument panel fusible link in positive junction box, to driver side junction

box and circuit as follows:

a. Through the central locking fuse, to pin B3 of central locking controller, system getsss the power of central

locking.

b. Through power window fusible link, to pin A8 of central locking controller, system getsss the power of electrical

window.

c. Through power window fusible link, to pin 12 of door control switch, switch is then powered.

• Key Lock Signal

a. When key lock switch is LOCK position, the current flows output from pin A6 of central locking controller, to

pin 9 of front door lock actuator assembly LH and through the key lock switch, to ground at pin 7 of front door

lock actuator assembly LH. This enables closed with door of all with mechanical operate.

b. When key lock switch is OPEN position, the current flows output from pin A7 of central locking controller, to

pin 10 of front door lock actuator assembly LH, and through the key lock switch, to ground at pin 7 of front door

lock actuator assembly LH. This enables opened with door of all with mechanical operate.

• Status of Front Door LH

Current flows from pin B2 of central locking controller, to pin 1 of front door LH switch, through switch to

ground, system getss the signal of front door status.

• Status of Hood

Current flows from pin B6 of central locking controller, to pin 1 of hood switch, through 2 pin of switch to

ground, system getss the signal of hood status.

• Collision Signal

Signal is from pin 30 of restraint control module, to pin A11 of central locking controller. System getssgetss the

Info of collision.

• vehicle speed signal

Signal is from pin A9 of instrumen cluster, to pin A17 of central locking controller. When the vehicle speed

attach the value as design, system will lock all door that unlocked before.

• Key Insert signal

Current flows from pin B8 of central locking controller, to pin 3 of key insert switch, through the switch and

ground at pin 4 of switch. System getss the key insert signal.

• Door control switch

Pin 1 and 2 of door control switch connect the pin A15 and A16 of central locking controller, through this

connection, the controller getsss the signal that control the door window and lock from door control swith.

• Door Actuator Control

a. Front door LH unlock: The current flows output from pin A3 of central locking controller, to pin 1 of front door

lock actuator assembly LH, and through the motor in front door lock actuator assembly LH, output from pin 4 of

front door lock actuator assembly LH, to pin A2 of central locking controller. This enables front door LH open.

On the contrary, the front door LH is closed.

b. Front door RH unlock: The current flows output from pin A3 of central locking controller, to pin 1 of front door

lock actuator assembly RH, and through the motor in front door lock actuator assembly RH, output from pin 4

of front door lock actuator assembly RH, to pin A2 of central locking controller. This enables front door RH

open. On the contrary, the front door RH is closed.

c. Sliding door unlock: The current flows output from pin A3 of central locking controller, to pin 2 of sliding door

lock actuator assembly, and through the motor in sliding door lock actuator assembly, output from pin 4 of sliding

door lock actuator assembly, to pin A2 of central locking controller. This enables sliding door open. On the

contrary, the sliding door is closed.

d. Rear hatch unlock: The current flows output from pin A3 of central locking controller, to pin 2 of rear hatch

lock actuator assembly, and through the motor in door lock actuator assembly, output from pin 4 of lock

actuator assembly, to pin A2 of central locking controller. This enables rear hatch open. On the contrary, the

rear hatch is closed.

• Power Window Control

a. Power window LH up: The current flows output from pin A5 of central locking controller, to pin 1 of power

window LH, and through the motor, output from pin 2 of power window LH, to pin A4 of central locking

controller. This enables power window LH up. On the contrary, power window LH is down.

b. Power window RH up: The current flows output from pin A7 of central locking controller, to pin 1 of power

window RH, and through the motor, output from pin 2 of power window RH, to pin A6 of central locking

controller. This enables power window RH up. On the contrary, power window RH is down.

71-106

A008 Chassis & Frame Wire Harness I002 Instrument Panel Wire Harness

A027 Chassis & Frame Wire Harness I007 Instrument Panel Wire Harness

D002 Front Door LH Wire Harness I008 Instrument Panel Wire Harness

D005 Front Door LH Wire Harness I010 Instrument Panel Wire Harness

D006 Front Door LH Wire Harness I011 Instrument Panel Wire Harness

H002 Front Door RH Wire Harness J002 Rear Hatch Wire Harness

H004 Front Door RH Wire Harness N001 Step Lamp Wire Harness

H005 Front Door RH Wire Harness V015 Front Wire Harness

H102

V108

71-107

I103

V103

I202 Left Side of the Instrument Panel V202 Left Side of the Longitudinal Beam

71-108

71-109

• System power

a. When ignition switch is ACC: The current flows through cigarette lighter fuse in driver side junction box, pin

4 of sliding roof ECU and pin 2 of sliding roof switch. Then system is powered.

b. When ignition switch is ON/ST: The current flows through sliding roof fuse in driver side junction box, pin 1

of sliding roof ECU and pin 3 of sliding roof switch. Then system is powered.

• System Control

ECU getss the operation signal from the switch and control the motor to operate. All operation is accordance

with user want.

F002 Roof Wire Harness 1 F003 Roof Wire Harness 1

71-110

RESTRAINT CONTROL SYSTEM

71-111

When a car collides with an obstacle, it will quickly open an airbag filled with air, so that the occupants can

throw themselves on the airbag when moving due to inertia, thereby easing the impact on occupants and

absorbing collision energy to reduce personal injuries.

When ignition switch is ON/ST, the current flows through airbag fuse in co-pilot side junction box, to pin 5 of

restraint control module. System is then powered

• Deployment of Airbag

When vehicle is in a frontal collision exceeding a specified level, the current flows from pin 10 of restraint

control module, to pin 3 of clock spring, to driver airbag. Current then flows from driver airbag, to pin 4 of clock

spring, and back to pin 11 of restraint control module. Driver airbag is then activated.

When vehicle is in a frontal collision exceeding a specified level, the current flows from pin 13 of restraint

control module, to pin 1 of passenger airbag. Current then flows from pin 2 of passenger airbag, and back to

pin 14 of restraint control module. Passenger airbag is then activated.

• All Door Unlock

When vehicle is in a frontal collision exceeding a specified level, the current flows from pin 30 of restraint

control module, to pin A11 of central locking controller. Central locking controller getss the sginal of collision

and unlock the all door.

When the system comes into operation, restraint control module detects the operation of all parts of the

system. Once the system or parts have faults, the system will switch on the SRS warning light to remind

drivers of repair in time.

A027 Chassis & Frame Wire Harness I014 Instrument Panel Wire Harness

I002 Instrument Panel Wire Harness I035 Instrument Panel Wire Harness

I003 Instrument Panel Wire Harness M002 Diagnosis Wire Harness

I007

A205

Left Side of the Airbag Module

71-112

WIRING - CONNECTOR VIEWS

CONNECTOR VIEWS

A - CHASSIS & FRAME WIRE HARNESS

A004 to Positive Junction Box A

Code Color Function Qualifier

1 W

2 W-G

Battery Compartment

Junction Box Power

Input

Engine Room

A007 Rear Heater Blower Switch

1 W-B

2 P

3 W-B

Rear Heater Air Flow

Switch Ground

Switch Input

4 B Rear Heater Motor H

A005 to Positive Junction Box C

5 W Rear Heater Motor M

6 L Rear Heater Motor L

1 R-B Generator Output B+

A008 Front Door Lamp Switch LH

A006 to Positive Junction Box D

1 W-L Switch Input

to Positive Junction

Box D Power Input

71-113

A009 ABS Module

Code Color Function Qualifier Code Color Function Qualifier

ABS Motor Power

2 - - 21 - -

3 Y-R

EBD Warning Lamp

Signal Output

Front Right Wheel

Speed Sensor-

5 - - 24 - -

6 R-L Data Link Connector k 25 R-W

ABS Solenoid Valve

Power Input

7 - - 26 - -

8 W

Front Left Wheel

27 Y-G

ABS Fault Light

9 - - 28 R-W ABS-IG Input

10 - - 29 LG

Rear Right Wheel

11 - - 30 G-W Brake Signal Input

12 - - 31 Y-W

Rear Left Wheel

Speed Sensor+

13 W-B Ground 32 - -

14 - - 33 - -

15 - - 34 - -

18 L-G

38 W-B Ground

71-114

A010 Front Wheel Speed Sensor LH

2 B

A013 Rear Wheel Speed Sensor RH

1 LG

A011 Front Wheel Speed Sensor RH

1 L

2 G

A014 Acceleration Sensor

1 Br-R

2 Br-G

3 SB

Acceleration Sensor

Signal-

Signal+

Power+

A012 Rear Wheel Speed Sensor LH

1 L-G

2 Y-W

A015 Secondary Fan Motor

1 W Secondary Fan+

2 Y

Secondary Fan Low

Speed+

Secondary Fan

71-115

A016 Main Fan Motor

1 R-W Fan High Speed+

2 R-B Fan Low Speed+

3 W-B Main Fan Ground

A019 Downstream Oxygen Sensor

1 B

2 O

Downstream Oxygen

3 Y-B

4 G

Heating

Sensor+

A017 Generator B+

A020 Odometer Sensor

1 R-B Sensor Power

A018 Generator Excitation (Gasoline)

1 P-L Generator Excitation

2 L IG End

2 W-B

3 W-G

Vehicle Speed Signal

Output

A021 Back-up Lamp Switch (Gasoline)

A018 Generator (Diesel)

2 P-L Generator Excitation

1 W-L

2 B-Y

Back-up Lamp Power

Reverse Power

71-116

A021 Back-up Lamp Switch (Diesel)

A024 Front Door Lamp Switch RH

1 R-W Front Door Lamp+

A025 Stop Lamp Switch

A022 Fuel Sensor/Fuel Pump

1 Br

Fuel Pump Relay Pin

Fuel Pump,Fuel

Sensor Ground

1 G-W Brake Power Output

2 W-R

3 L-Y

Stop Lamp Power

Engine ECM Brake

Switch Output

4 W-B SW RET

3 V Fuel Sensor+ Input

4 W-B Ground

A026 Parking Brake Switch

A023 Engine Oil Pressure Sensor

1 Y Parking Brake Switch

1 L-Y

Engine Oil Pressure

Warning Light

71-117

A027 Restraint control module (RCM)

1 - - 16 - -

2 - - 17 - -

3 - - 18 - -

4 - - 19 - -

5 B-O Airbag Power Input 20 - -

6 W-B Airbag Ground 21 - -

7 B-Y

Airbag Warning Lamp

8 - - 23 - -

9 R-L Airbag K 24 - -

10 Y

11 Y-B

Airbag Drive Low-side

Interface ACU

Airbag Drive Highside

12 - - 27 - -

13 G-B

14 G-R

High-side

Low-side

15 - - 30 Y

Collision Signal

71-118

A028 Front Blower

1 R-W Front Blower+

A032 Vacuum Level Alarm Switch (Diesel)

1 B -

2 G-W Front Blower-

A029 Front Door Lamp Diode LH

2 W-L Diode-

A033 Data Link Connector 120 Resistance

1 G-B -

2 G-O -

A030 Diesel Filter Heater (Diesel)

1 Br -

2 W-B -

A034 Clutch Switch (Diesel)

3 W-B -

4 L-B -

A031 Preheating Relay Coil (Diesel)

1 L-Y -

2 L-B -

71-119

A035 Electronic Throttle (Diesel)

3 W -

2 L-G -

4 Y -

5 W-R -

6 Y-G -

A036 ECM (Diesel)

E1

W-R

Engine ECU Power

E30 - -

E2 W-B Engine ECU Ground E31 - -

E3

E32 - -

E4 W-B Engine ECU Ground E33 W-B

High-speed Fan

Control Input Pin 86

E5

E34

B-W

Low-speed Fan

Control Feedback Pin

86

E6 W-B Engine ECU Ground E35 G-Y

Preheat Indication

E7 - - E36 Br Engine Maintenance

E8 - - E37 - -

E9 V-W Speed Output E38 - -

E10

B-Y

Diagnosis Switch

E39 L-B Clutch Control Output

71-120

E11

R-W

Medium Pressure

Switch + Output

E40 - -

E12 - - E41 B-G ECU-IG

E13 - - E42 Y-G Throttle Sensor 2+

E14 G-B CAN-H E43 W-R Throttle Sensor 2

E15 G-O CAN-L E44 L-G Throttle Sensor 1

E16 - - E45 - -

E17 - - E46 L-B

Preheating Relay Coil

E18 - - E47 R-Y Fan Low-speed Diode

E19 - - E48 L

A/C Low Level

Approval Output

E20 - - E49 Y-W Engine Stop Light

E21

L-Y

E50 - -

E22 L-W MILL Light E51 - -

E23 - - E52 L-Y

Engine ECU Brake

E24 - - E53 - -

E25 - - E54 - -

E26 - - E55 Y Throttle Sensor 2-

E27 Y-B A/C Request Input E56 B Throttle Sensor 1-

E28 L Vehicle Speed Input E57 W Throttle Sensor 1+

E29 W-B SW RET E58 - -

A101 to Instrument Panel Wire Harness A

5 L -

1 B-W -

2 B -

6 Y -

7 V -

8 Y-B -

9 Y-R -

10 Y-G -

11 W-G -

71-121

12 V-W -

13 P-L -

14 R-W -

15 L-W -

16 Y-W -

17 L-Y -

18 Y-G -

19 Br -

20 G-Y -

A102 to Instrument Panel Wire Harness B

11 G-W -

13 W-L -

14 R-Y -

15 W-L -

16 B-Y -

17 R -

18 G -

21 W-L -

21 R-B -

22 R-B -

4G69 Left

ISF2.8

Left Hand

A103 to Instrument Panel Wire Harness C

1 Y-B -

2 Y -

1 R-B

2 B-G

3 R-W

4 R

5 G-B -

6 R -

7 W-B -

9 W-L -

10 R-L -

3 G-L -

4 Br-L -

5 B-Y -

7 Y-L -

8 B -

9 G-B -

10 G-R -

12 B -

14 B -

15 R-G -

71-122

16 R-B -

17 R-W -

18 R-L -

A106 to Engine Wire Harness 1 (Gasoline)

6 R-W -

7 Y -

8 W-B -

9 L -

10 R -

11 L -

12 W-L -

A104 to Instrument Panel Wire Harness D

1 R -

13 G-B -

15 V-W -

16 L -

A105 to Driver Seat Belt Warning Wire

Harness Assy

A107 to Engine Wire Harness 2 (Gasoline)

2 Br-R -

3 Br-G -

4 SB -

5 G -

2 L-W -

3 Y-G -

5 Y-B -

9 R-L -

10 B -

11 Y-B -

12 O -

14 B-G -

71-123

15 G-W -

16 G -

A108 to Step Lamp Wire Harness

1 G -

2 L -

3 R -

5 R -

6 Gr -

7 R-Y -

A110 to Rear Bumper Transition Wire

Harness

1 R-G -

2 R-B -

3 R-L -

4 R-W -

5 B -

A109 to Rear Heater Wire Harness

1 W -

3 L -

4 B -

5 W-B -

6 W-L -

71-124

A112 to Engine Wire Harness A (Diesel)

A111 to Instrument Panel Wire Harness E

2 Gr -

5 R-B -

6 Gr-R -

7 G-W -

2 G-B -

6 L-Y -

10 G -

11 LG -

12 L -

A113 to Battery Wire Harness B (Diesel)

1 W-B -

2 R -

71-125

B - BATTERY WIRE HARNESS

B001 Starter

B R -

B101 to Chassis & Frame Wire Harness B

B002 Starter Excitation

71-126

C - FRONT BUMPER WIRE HARNESS

C001 Front Fog Lamp LH

1 LG Fog Lamp Power

2 W-B Ground

C101 to Front Wire Harness

C002 Front Fog Lamp RH

4 LG -

6 LG -

71-127

D - FRONT DOOR LH WIRE HARNESS

D001 Front Speaker LH

1 V

Front Left Speaker

2 P Front Left Speaker-

D004 Electric Outside Mirror Switch

1 L-R

Left Outside Mirror

Left And Right Adjust

Right Outside Mirror

Left and Right Adjust

D002 Power Window Motor LH

4 G-R

Outside Mirror Switch

5 R-Y Outside Mirror-

6 W-B Ground

Driver Side Window

Up Input

Down Input

8 R-L

Left Outside Mirror Up

And Down Adjust

Up And Down Adjust

output

D003 Outside Mirror Assy LH

3 B

Outside Mirror Assy

LH Ground

Defroster Power Input

4 R-Y Left Outside Mirror-

5 L-R

6 R

D005 Door Control Switch

1 L-B

2 L

4 P-L

5 L-G

Left Side Door Assy

Control Switch Input

Right Side Window

Control Switch Output

71-128

6 W-B

Door Control Switch

9 G-R

Lamplet Control

12 W-L

D101 to Front Wire Harness A

2 L-R -

3 L-Y -

4 G-R -

6 L-O -

8 R-L -

D006 Front Door Lock Assy LH

1 G

Front Left Door Lock

Unlock Input

Latch Input

7 W-B

Front Door Lock Assy

9 L-O Key Lock Output

10 L-R Key Unlock Output

D102 to Front Wire Harness B

1 L-B -

2 L-Y -

3 P-L -

4 W-L -

6 L -

7 G-R -

8 L-G -

71-129

D103 to Front Wire Harness C

2 P -

5 V -

6 G -

71-130

E - ENGINE WIRE HARNESS

E001 ECM

1 L Ignition Coil 42 Br-Y

Idle Speed Control B

Low

2 B Ground 43 - -

3 B Ground 44 G-W Main Relay Control

4 G Ignition Coil 45 - -

5 - - 46 - -

6 L-W Injector A- 47 W

7 L-P Injector C- 48 O

8 L-V Injector B- 49 W-R

Upstream Oxygen

Sensor Signal+

Coolant Temperature

9 G

10 L

Fuel Pump Relay

ECU Control

Air Conditioning Low

Level Approval Output

50 - -

51 L Vehicle Speed Input

11 P

Sensor-

52 W-B

12 Br Engine Maintenance 53 - -

13 - - 54 L-Y Air Pressure MAP

14 - - 55 - -

15 - - 56 - -

16 - - 57 - -

17 W-B

Control

58 B-W Knock Sensor

18 V-W Vehicle Speed 59 Br-G Acceleration Sensor+

19 L-W MIL 60 - -

20 G-Br

Idle Speed Control A

High

61 - -

71-131

21 G-Y

62 - -

22 - - 63 - -

23 Y-B

Sensor Heating-

64 W-Y

Canister Solenoid

Valve-

24 L-R

65 Y

Starter Excitation

Power Output

25 L-O Injector D- 66 SB

Intake Air

Temperature

Power 2

26 R-W

27 V-G

Switch

67 W-L ECU Power

68 B-G ECU-IG

28 - - 69 - -

29 - - 70 SB

Power

30 O

71 L-W Air Temperature

31 - - 72 - -

32 - - 73 B

33 - - 74 Br-R

Upstream And

Throttle Position Sen-

sor-

34 - - 75 R-L ECU-K Line

35 - - 76 Br-R

36 - - 77 - -

37 O-V Knock Sensor 78 - -

38 - - 79 Y-B AC Request

39 - - 80 - -

40 - - 81 - -

41 Y-P

71-132

E002 Injector A

1 G Injector+

2 L-W Injector A-

E006 Mainfold Absolute Pressure/Intake Air

Temperature Sensor

1 L-Y Air Pressure MAP

2 SB

3 L-W Air Temperature

E003 Injector B

2 L-V Injector B-

4 Br-R

E007 Upstream Oxygen Sensor

E004 Injector C

2 L-P Injector C-

2 W

3 L-R

Sensor Signal-

E005 Injector D

2 L-O Injector D-

E008 Crankshaft Position Sensor

1 O

71-133

3 - Ground

E012 Engine Coolant Temperature Sense

Plug

1 Y-G

Water Temperature

Gauge Sensor

E009 Throttle Position Sensor

1 SB

2 Br-R

3 V-G

Throttle Position

E013 Compressor

1 G-B

Compressor Excitation

E010 Engine Coolant Temperature Sensor

E014 Starter Coil

Starter Excitation Output

E015 Idle Air Control Valve

E011 Knock Sensor

1 O-V Knock Sensor

2 B-W Knock Sensor

1 Br-Y

2 Y-P

71-134

3 G-Y

4 G-Br

E017 Ignition Coil

1 G Ignition Coil

2 L Ignition coil+

3 L Ignition Coil

E016 Canister Solenoid Valve

1 W-Y Canister Valve-

2 G Canister Valve+

E018 Engine Electronic Control Module

1 P

Cylinder 3 Fuel

Injector Solenoid

Valve Drive Signal

49 B

Cylinder 1 Fuel

Valve Drive Circuit

Cylinder 2 Fuel

50 P

3 - - 51 - -

4 - - 52 - -

5 P EGR Valve Motor+ 53 P

Intake Throttle

Actuator Motor-

6 - - 54 - -

7 - - 55 - -

71-135

8 - - 56 - -

9 - - 57 - -

10 - - 58 - -

11 - - 59 - -

12 - - 60 - -

13 R

Engine Crankshaft

Position 5V power

14 B

Position Circuit

62 L

Engine Camshaft

Position Signal

15 G

SAE J1939 Data

Communication

Interface+

63 B

Circuit

Interface-

64 B

Atmospheric Pressure

17 - - 65 B

18 - - 66 B

19 - - 67 B

20 - - 68 B

21 - - 69 L

22 - - 70 L

Intake Manifold

Pressure/

Temperature Circuit

EGR Valve Position

Actuator Position

Fuel Rail Pressure

Signal

Pressure Signal

23 L

Temperature Signal

71 - -

24 - - 72 L

25 B

73 B

26 B

74 P

Cylinder 4 Fuel

27 - - 75 - -

28 - - 76 - -

71-136

29 P EGR Valve Motor- 77 P

Actuator Motor+

30 - - 78 - -

31 B

Fuel Pump Actuator

79 - -

32 P

80 R

Air Mass Flow 12V

33 - - 81 - -

34 - - 82 - -

35 - - 83 - -

36 - - 84 - -

37 L

38 L

85 - -

86 L Air Mass Flow Signal

39 - - 87 R

40 B Air Mass Flow Circuit 88 R

41 - - 89 R

42 - - 90 R

Position Sensor 5V

power

5V Power

Intake manifold

Temperature 5V

43 B

Engine Coolant

91 R

Actuator Position 5V

44 B

Fuel Moisture Content

92 R

Fuel Rail Pressure 5V

45 - - 93 - -

46 L

94 - -

47 L

95 L

48 - - 96 L

71-137

E019 Crankshaft Position Sensor

1 R 5V Signal

2 B Circuit

3 L Signal

E022 Intake manifold Pressure/

1 L Pressure Signal

2 R 5V Power

3 L Temperature Signal

4 B Circuit

E020 Camshaft Position Sensor

1 R 5V Power

E023 Atmospheric Pressure Sensor

E021 Fuel Rail Pressure Sensor

1 B Circuit

2 L Signal

3 R 5V Power

E024 Engine Coolant Temperature Sensor

71-138

E025 Fuel Moisture Content Sensor

1 L Sensor Signal

2 B Sensor Circuit

E028 SAE J1939 Data Communication

Interface

Data Communication

E026 Engine Oil Pressure Switch

E029 Injector 1

1 B Drive Circuit

2 P Drive Signal

E027 Fuel Pump Actuator

1 P Signal

E030 Injector 2

71-139

E031 Injector 3

E034 Intake Throttle Actuator

E032 Injector 4

5 P

E035 EGR Valve

E033 Air Mass Flow Sensor

1 L Signal

2 B 12V Power

3 R Circuit

1 P EGR Valve Motor-

2 P EGR Valve Motor+

3 L

4 B

5 R

71-140

E101 to Chassis Wire Harness 1

E036 Engine Oil Pressure Switch (IC)

1 L-Y Signal

8 W-B

9 L

10 R

11 L Ignition Coil+

12 W-L ECU Power

Compressor

Excitation

E037 Engine Coolant Temperature Sensor

(IC)

15 V-W Vehicle Speed

16 L Vehicle Speed Input

1 Y-G Signal Input

2 W-B Signal Output

E102 to Chassis Wire Harness 2

1 Br Engine Maintenance

2 L-W MILL

3 Y-G

5 Y-B AC Request

6 R-W

3 Br-G Acceleration Sensor+

4 SB

5 G

Sensor Power

Injector,Oxygen

Sensor,Canister

Solenoid Valve+

9 R-L ECU-K Line

7 Y

10 B

71-141

12 O

14 B-G ECU-IG

15 G-W Main Relay Control

E103 to Chassis Wire Harness A (Diesel)

71-142

F - ROOF WIRE HARNESS 1

F003 Sliding Roof Control Switch

F001 Front Dome Light

2 R

Front Dome Light

Central Dome Light

3 W-B Ground

2 R-B

3 R

Sliding Roof ACC

Sliding Roof Switch

4 G Sliding Roof Switch

5 W-B

4 R-W Front Dome Light-

F004 Central Dome Light (High Equipped)

F002 Sliding Roof ECU

Sliding Roof ECU

2 G Sliding Roof Switch

Trunk Lighting Power

2 R-Y Central Dome Light-

3 Y

Dome Light Power

4 R-B

to Power Sliding Roof

ECU-

Sliding Roof ECU-

ACC Input

5 Y

Sliding Roof Control

F004 Central Dome Light (Low Equipped)

1 R Lighting Power Input

2 Y Power Output

1 Y Sliding Roof Switch

71-143

F005 Rear Speaker LH

1 Y

Rear Left Speaker

2 B Rear Left Speaker-

F007 Air Purifier

F006 Rear Combination Lamp LH

1 V-W Rear Left Lamplet+

Rear Left Combination

Lamp Ground

3 G-W Rear Left Stop Lamp+

4 G-Y

5 R-Y

6 B-Y

Rear Left Turn Signal

Rear Left FogLamp

Rear Left Back-up

Lamp+

F101 to Instrument Panel Wire Harness A

1 V-W -

2 G-W -

3 Br -

4 Y-W -

7 L -

9 R -

10 R-W -

12 R-Y -

13 R-B -

15 G-B -

16 G-Y -

Illumination Power

2 R-Y Dome Light-

71-144

F103 to Roof Wire Harness 2A

9 R-Y -

F102 to Instrument Panel Wire Harness B

1 Y -

10 V-W -

11 R -

12 G -

4 R-B -

6 W -

7 R -

8 G-W -

9 G-O -

11 Br -

12 G-Y -

13 B -

F104 to Roof Wire Harness 2B

4 R -

5 W -

6 G-W -

1 G-W -

4 G-B -

6 R-Y -

8 B-Y -

F105 to High-mounted Stop Lamp Wire

3 G-Y -

8 Br -

71-145

F106 to Rear Evaporator Wire Harness

3 Y-W -

4 Br -

71-146

G - ROOF WIRE HARNESS 2

G001 Rear Combination Lamp RH

1 V-W Rear Right Lamplet+

G101 to Roof Wire Harness 1A

3 G-W

4 G-B

Rear Right

Combination Lamp

Rear Right Stop

Rear Right Turn

Signal Power Input

Rear Right Fog Lamp

Rear Right Back-up

G002 Rear Speaker RH

Rear Right Speaker

2 R Rear Right Speaker-

G102 to Roof Wire Harness 1B

G003 Sliding Door Ajar Switch RH

1 R-Y

Right Middle Door

Lamp Power Input

71-147

G103 to Rear Hatch Transition Wire

2 V-W -

4 B-Y -

6 R-B -

7 G -

8 R -

10 G-W -

71-148

H - FRONT DOOR RH WIRE HARNESS

H001 Front Speaker RH

H004 Window Control Switch RH

Front Right Speaker

2 L-G Front Right Speaker-

3 P-L

4 L-Y

H002 Power Window Motor RH

1 G-R

2 R-L

Co-pilot Side Window

H005 Front Door Lock Assy RH

Front Right Door Lock

H003 Outside Mirror Assy RH

4 R-Y Right Outside Mirror-

5 L-Y

6 R-L

71-149

H101 to Front Wire Harness A

4 R-L -

H103 to Front Wire Harness C

3 G-R -

5 L-G -

6 R-L -

H102 to Front Wire Harness B

4 P-Y -

71-150

I - INSTRUMENT PANEL WIRE HARNESS

I002 Instrument Cluster A

A26

Vacuum Level Alarm

+ Input

A1 W-L Instrument Power

A27 G-Y Preheat Indicator

A28 Br Engine Maintenance

A30

Front Door Open

Indicator

A31 B-W Seat Belt Warning

A32 G-Y Left Turn Indicator

A6 V-W Lamplet Signal Input

A7

LG

Front Fog Lamp

A9 W-L Vehicle Speed Output

A10 L-B Vehicle Speed Output

A13

W-G

A14 B Lighting PWM Signal

A15 W-R Door Open Indicator

A16

Instrument Power

A19 W-B Instrument A Ground

A20 R-B Instrument IG Ground

A24 Y-W Engine Stop Light

I003 Instrument Cluster B

B6

Y

B7 V-W

Instrument Parking

Brake Light

Coolant Level Sensor

+ Output

B9

Seat Belt Alarm +

B10 V-W Speed Input

71-151

B16

Y-G

B20

B21

R-Y

Signal Input

Rear Fog Lamp

I004 Headlamp Dimmer Switch

3 G

4 LG

5 Br

Headlamp Dimmer

Lighting

to Front Left

Headlamp Adjustment

Motor

to Front Right

B22

B23

B24

B25

L-W

Y-R

P-L

Engine Failure

Warning Input

EBD Warning Light

Instrument Charging

Indicator Input

B27

B28 R-W

Brake Fluid Sensor +

B30 W-B Instrument B Ground

B31 R-G High Beam Indicator

I005 Instrument Dimmer Switch

Instrument Dimmer

Switch Lamplet

5 B Lighting PWM Signal

B32 G-B Right Turn Indicator

I006 Hazard Warning Switch

to Front Right Low

Beam Fuse

Hazard Warning

Switch Lighting

Instructions

71-152

7 W-B Ground

I007 Central Locking Controller Assy A

Left Door Assy

Switch(Clock) Output

A17 W-L Vehicle Speed Signal

A18 R-B Ignition Switch

8 G-R Switch Signal Output

I008 Central Locking Controller Assy B

A1 W-B Ground

A2 R Lock Output

A3 G Unlock Output

A4

A5

Down Output

Up Output

B1

B2

B3

W-L

Ignition Switch

Illumination Control

Front Left Door Open

Central Locking Spare

B4 G-R Horn

O-L

to Engine Hood

A6

R-L

B7

V-W

Lamplet Forget to

Turn Off Hints

A8

G-R

Window Control

A9 L-O Key Lock Input

A10 L-R Key Unlock Input

B8 O-B Key Detection Switch

B9 - -

B10 W-B Ground

A11 Y Collision Signal Input

A12 G-Y Left Turn Light Signal

G-B

Right Turn Light

A14 R Door Lamp Indicator

A15

L-B

Switch(Data) Output

71-153

I009 Ignition Switch

Ignition Switch AM1

2 R IG1 Power Output

3 R ACC Output

5 R-B

Start Control Power

Ignition Switch AM2

6 L Ignition Switch IG2

I010 Ignition Switch Illumination

I012 Combination Switch (Light)

2 B-W

4 W-B Light Switch Ground

5 G-V Left Turn Switch

6 Y-B Turn Signal Switch

7 G-W Right Turn Switch

8 W-R to Low Beam Relay

9 L-R to High Beam Relay

10 W-B Light Switch Ground

11 W-B Light Switch Ground

13 G-R

Lamplet Relay Control

2 W-R to Central Lock Unit

I013 Combination Switch (Wiper)

I011 Key Insert Switch

3 O-B Switch Input

4 W-B Switch Ground

2 W Rear Wiper

3 P

Rear Washing Motor

4 Y-W Front Washing Motor-

5 W-B Wiper Switch Ground

6 Y

Wiper Intermittent

71-154

7 L-W

8 G-R

9 L-R

Wiper Low Speed

Wiper Switch Power

Wiper High Speed

I016 Rear Window Defroster Switch

2 Y-L

Rear Window

Defroster Switch

I014 Clock Spring

2 G-R Horn Switch

5 Br-L

4 Y-B

I017 Outside Mirror Defroster Switch

I015 12V Power Output Socket

1 W-B Ground

2 R-Y 12V Power Output

5 G-L

Defroster Control

71-155

I020 A/C Control Panel A

I018 Dome Light Switch

Dome Light Switch

Illumination

6 R Indicator Power Input

1 Gr

2 L-B

Rear AC Solenoid

Valve-Input

Servo Motor (Mode)

Defrost

Blowing Face

Warm Damper

5 L-R Cold Damper Control

6 G-W Internal Circulation

7 G External Circulation

8 G

Blower Relay Control

9 G-B AC Request Output

10 R-B AC IG Power

I019 Diagnosis Switch

1 W-B Switch Ground

2 W-B Switch -

3 G Illumination Power

5 B-Y Switch Input

6 R-B Switch Power

18 W-B Ground

19 R-G

Front Air Conditioning

Controller Battery

20 W-B Ground

71-156

I022 Servo Motor (Temperature)

I021 A/C Control Panel B

21 Y-W

Rear Temperature

23 L-O

24 L-G

Mix Damper

Feedback

Mode Feedback

Servo Motor

(Mode)/

(Temperature) 5V

2 L-O

(Temperature)

Internal Temperature

6 L

27 W-B

28 Y-G Front Blower-

29 V

Front Evaporator

Temperature Sensor+

30 - -

31 - -

32 G

Controller Back

33 Br Temperature Sensor-

35 Y Blower Feedback

I023 Rear Blower Forward Switch

Rear Blower Forward

Switch Power Input

5 Gr-R

Solenoid Valve Power

36 LG

Rear AC Switch

Request Output

71-157

I024 Servo Motor (Mode)

2 L-G

I026 Front Evaporator Thermistor

2 Br Temperature Sensor-

5V Output

5 L-B

6 L-Y

I027 Servo Motor (Internal & External

Circulation)

I025 Blower Control Module

5 G External Circulation

2 Y Blower Feedback

3 Y-G Blower Control

4 G-W Front Blower-

I028 Reverse Radar Control Unit

1 B-R Reverse Power Input

2 G-R

3 W-L

Front Right Reverse

Radar Sensor Output

Reverse Radar

Sensor Power Input

71-158

4 R-W

Central Right Sensor

6 L-B Vehicle Speed Signal

7 R-G

8 R-B

Sensor LH Output

Central Left Sensor

9 Y Parking Signal

10 G-O

Front Left Reverse

I030 CD Player-C2

1 B-Y Reverse Detection

2 Y Parking Signal

11 B

15 R-L

Sensor RH Output

16 W-B Ground

I031 Radio A

A1 - -

A3 G Radio illumination

A4 G-R Radio ACC Input

I029 CD Player-C1

1 G-W VIDEO GND Input

2 G-O VIDEO+ Output

A6 - -

A7 R Radio Power Input

A8 W-B Ground

71-159

I032 Radio B

B2 R Rear Right Speaker-

B4 L-G Front Right Speaker-

B5

B6 P Front Left Speaker-

B8 B Rear Left Speaker-

I034 Flasher

1 B-Y Power

2 G-B

Rear Right Turning

Lamp Power

4 R-Y

5 G-V

Front Left Turning

Left Turning Signal

7 G-R

Hazard Warning/Turn

8 W-B Ground

9 G-Y

Rear Left Turning

10 R-L

Front Right Turning

12 G-W

Right Turning Signal

I033 Cigarette Lighter

Cigarette Lighter

I035 Passenger Airbag Assy

71-160

I039 Right Turn Signal Lamp Diode

I036 Right Side Sliding Door Lamp Diode

1 W-R

2 R-Y

Diode - Door Open

Indicator Output

I040 Left Turn Signal Lamp Diode

I037 Rear Hatch Lamp Switch Diode

1 G-Y

Rear Hatch Lamp

Indicate Output

I101 to Front Wire Harness A

I038 Horn Switch

1 G-R Signal Output

5 P -

6 G-Y -

7 G-O -

71-161

8 G-R -

9 B -

10 O-L -

17 G-R -

18 B -

20 G-R -

22 L-O -

23 L-R -

24 L -

25 L-B -

26 G -

27 R -

I102 to Front Wire Harness B

7 L-G -

8 V-W -

9 R-W -

11 G-B -

14 LG -

15 W-B -

16 Y-B -

17 R-L -

18 R-Y -

19 R-B -

20 R-G -

21 G-B -

22 L-B -

23 G-R -

24 L-W -

25 L-R -

26 Y -

27 Y-W -

1 LG -

2 Br -

3 B -

I103 to Front Wire Harness C

71-162

I104 to Chassis & Frame Wire Harness A

5 G-R -

21 R-B

(LH)

I105 to Chassis & Frame Wire Harness C

71-163

I106 to Chassis & Frame Wire Harness B

1 R-B -

2 B-G -

3 R-W -

19 G-O -

20 G-B -

I107 to Roof Wire Harness Assy 1A

I108 to Roof Wire Harness Assy 1B

71-164

I110 to Data Link Connector

5 R-L -

6 G-O -

7 G-B -

I109 to Chassis & Frame Wire Harness E

71-165

I111 to Chassis & Frame Wire Harness D

71-166

J - REAR HATCH WIRE HARNESS

J001 Rear Hatch Lock Assy-Switch

J004 License Lamp

Rear Hatch/Trunk

Lights Power Input

Rear Hatch Lock

1 V-W Power

J005 Camera

J002 Rear Hatch Lock Assy-Motor

Rear Hatch Latch

Rear Hatch Unlocking

1 W-B Camera Ground

2 B-Y Camera Power Input

3 G-W Video Output

4 G-O Video Input

J003 Trunk Lamp

Trunk Lamp Power

71-167

J101 to Rear Hatch Transition Wire Harness

1 B-Y -

3 V-W -

5 G-W -

8 G -

9 R-B -

10 W-B -

71-168

K - REAR HATCH TRANSITION WIRE HARNESS

K101 to Roof Wire Harness 2

K102 to Rear Hatch Wire Harness

71-169

L - REAR EVAPORATOR WIRE HARNESS

L001 Left Blower

1 R +

L004 Temperature Sensor

1 B-W Ground

2 W Sensor+

L002 Right Blower

1 L +

L005 Top Evaporator Blower Switch

1 B Ground

2 R-B A/C signal

3 B Ground

4 L-G L Position

5 L-R M Position

6 R-B H Position

L003 Blower Resistor

1 L-W to Blower-

2 L-R M Position

3 L-G L Position

4 R-B H Position

L101 to Roof Wire Harness 1

4 B-W -

71-170

M - DIAGNOSIS WIRE HARNESS

M001 Data Link Connector Resistance

1 G-B CAN-H

2 G-O CAN-L

M101 to Instrument Panel Wire Harness

M002 Data Link Connector

5 W-B Ground

6 G-B CAN-H

7 R-L

Data Link Connector

K

14 G-O CAN-L

16 W-L Power Input

71-171

N - STEP LAMP WIRE HARNESS

N001 Right Side Sliding Door Lock Assy

Right Side Sliding

Door Unlocking Input

Door Locking Input

N101 to Chassis & Frame Wire Harness

N002 Step Lamp

Step Lamp Power

Right Sliding Door

Light Switch Output

N003 Rear A/C Solenoid Valve

2 Gr

Rear A/C Solenoid

Valve Power Input

Valve Output

71-172

O - DRIVER SEAT BELT WIRE HARNESS

O001 Driver Seat Belt Warning Switch

O101 to Chassis & Frame Wire Harness

71-173

P - REAR HEATER WIRE HARNESS

P001 Rear Heater Solenoid Valve

P002 Rear Heater Motor

1 W Rear Heater Motor M

P101 to Chassis & Frame Wire Harness

Rear Heater Motor+

3 L Rear Heater Motor L

71-174

Q - REAR BUMPER TRANSITION WIRE HARNESS

Q101 to Rear Bumper Wire Harness

1 R-W -

2 R-L -

3 R-B -

4 R-G -

Q102 to Chassis & Frame Wire Harness

71-175

R - REAR BUMPER WIRE HARNESS

R001 Reverse Radar Sensor LH

R004 Reverse Radar Sensor RH

1 R-G

Reverse Radar Sensor

LH Input

1 R-L

Sensor RH Input

Sensor RH Ground

R002 Reverse Radar Central Sensor LH

Reverse Radar Central

Left Sensor Input

R101 to Rear Bumper Transition Wire

R003 Reverse Radar Central Sensor RH

1 R-W

Right Sensor

71-176

S - REAR DEFROST RH WIRE HARNESS

S001 Rear Defrost Heating Wire RH

Rear Right Defrost

S101 to High-mounted Stop Lamp Wire

71-177

T - REAR DEFROST LH WIRE HARNESS

T001 Rear Defrost Heating Wire LH

T101 to High-mounted Stop Lamp Wire

71-178

U - HIGH-MOUNTED STOP LAMP WIRE HARNESS

U101 to Roof Wire Harness 1

U001 Rear Wiper

1 Br Rear Wiper Return

2 G-Y

Rear Wiper Power

Relay to The Rear

Wiper Power Output

U102 to Rear Defrost LH Wire Harness

U002 High-mounted Stop Lamp

2 G-W

High-mounted Stop

Lamp-

U103 to Rear Defrost RH Wire Harness

71-179

V - FRONT WIRE HARNESS

V001 Left Headlight Dimming Motor

V004 Front Turn Signal Lamp LH

1 G-B Motor Power

2 LG

Left Headlamp

Adjusting Signal

Dimming Motor

Front Turn Signal

Lamp LH Ground

Lamp LH Power Input

V005 Right Headlight Dimming Motor

V002 Front Position Lamp LH

2 Br

Right Headlamp

2 V-W

Front Left Position

Right headlamp

V003 Headlamp LH

2 R-G Front Left High Beam

3 R-B Front Left Low Beam

V006 Headlamp RH

Front Right High

Beam

3 G-B

Front Right Low

71-180

V007 Front Position Lamp RH

V010 Front Washing Reservoir Motor

1 Y-W Front Washing Motor-

2 V-W Front Position Lamp+

Front Washing

Motor+

V008 Front Turn Signal Lamp RH

V011 Windshield Wiper Assy

Lamp RH Ground

Lamp RH Power Input

1 L-W

Front Wiper Lowspeed

2 G-R Front Wiper+

V009 Rear Washing Reservoir Motor

4 L-R

Front Wiper

Intermittent Input

Front Wiper Highspeed

Windshield Wiper

Assy Ground

V012 Brake Fluid Level Sensor

Brake Fluid Level

Sensor + Input

71-181

V013 Bass Horn

1 B Horn+

V016 Coolant Level Sensor

2 V-B

V014 Alt Horn

V017 Triple Pressure Switch

1 G-B AV Request Input

Switch-

Switch+ Input

4 Y-B AV Request Output

V015 Engine Hood Switch

1 O-L

Engine Hood Switch

V101 to Instrument Panel Wire Harness

assy A

71-182

V102 to Instrument Panel Wire Harness

assy B

4 V -

71-183

V103 to Instrument Panel Wire Harness

assy C

V105 to Driver Door Wire Harness Assy B

V104 to Driver Door Wire Harness Assy A

V106 to Driver Door Wire Harness Assy C

71-184

V107 to Co-Driver Door Wire Harness Assy

V109 to Co-Driver Door Wire Harness Assy

V110 to Front Bumper Wire Harness Assy

V108 to Co-Driver Door Wire Harness Assy

4 P-L -

2 G-R -

3 G-O -

71-185

X - PREHEATING WIRE HARNESS

X001 Pre-heater

1 B Pre-heater+

X003 Pre-heater Relay B

1 R Pre-heater Relay B

X002 Pre-heater Relay L

1 B Pre-heater Relay L

71-186

WIRING - WIRE HARNESS & CONNECTOR LOCATION VIEWS

WIRE HARNESS & CONNECTOR LOCATION VIEWS

C Front Bumper Wire Harness - Connector

C001 Front Fog Lamp LH C002 Front Fog Lamp RH

C Front Bumper Wire Harness- Inline

71-187

V Front Wire Harness - Connector

00

V001

Left Headlight Dimming Motor

V010

Front Washing Reservoir Motor

V002

V003

Front Position Lamp LH

Headlamp LH

V011

V012

Windshield Wiper Assy

Brake Fluid Level Sensor

V004

V005

Front Turn Signal Lamp LH

Right Headlight Dimming Motor

V013

V014

Bass Horn

Alt Horn

V015

V007

Front Position Lamp RH

V016

Coolant level Sensor

V008

Front Turn Signal Lamp RH

V017

Triple Pressure Switch

Rear Washing Reservoir Motor

V Front Wire Harness - Inline

to Instrument Panel Wire Harness assy A

to Driver Door Wire Harness Assy C

to Instrument Panel Wire Harness assy B

to Co-Driver Door Wire Harness Assy A

to Instrument Panel Wire Harness assy C

to Co-Driver Door Wire Harness Assy B

to Driver Door Wire Harness Assy A

to Co-Driver Door Wire Harness Assy C

to Driver Door Wire Harness Assy B

to Front Bumper Wire Harness Assy

V Front Wire Harness - Ground

V201

Front Wire Harness Left Side Ground

V203

Front Wire Harness Right Side Ground

Front Wire Harness Central Ground

71-188

D Front Door LH Wire Harness - Connector

D001

Front Speaker LH

Electric Outside Mirror Switch

D002

Power Window Motor LH

D005

D003

Outside Mirror Assy LH

D006

Front Door Lock Assy LH

D Front Door LH Wire Harness - Inline

to Front Wire Harness A

to Front Wire Harness C

to Front Wire Harness B

71-189

H Front Door RH Wire Harness - Connector

H001

Front Speaker RH

H004

Window Control Switch RH

H002

Power Window Motor RH

H005

Front Door Lock Assy RH

H003

Outside Mirror Assy RH

H Front Door RH Wire Harness - Inline

71-190

A Chassis & Frame Wire Harness - Connector

A004

to Positive Junction Box A

A025

Stop Lamp Switch

A005

to Positive Junction Box C

A026

Parking Brake Switch

A006

to Positive Junction Box D

A027

Restraint control module (RCM)

A010

Front Wheel Speed Sensor LH

A028

Front Blower

A011

Front Wheel Speed Sensor RH

A029

Front Door Lamp Diode LH

A014

A031

Preheating Relay Coil (Diesel)

A015

Secondary Fan Motor

A032

Vacuum Level Alarm Switch (Diesel)

A016

Main Fan Motor

A034

Clutch Switch

Generator Excitation

A035

Electronic Throttle

A023

Engine Oil Pressure Sensor

71-191

A Chassis & Frame Wire Harness - Inline

to Instrument Panel Wire Harness B

to Rear Heater Wire Harness

to Instrument Panel Wire Harness C

to Instrument Panel Wire Harness D

to Engine Wire Harness A (Diesel)

to Driver Seat Belt Warning Wire Harness

to Engine Wire Harness 1 (Gasoline)

to Battery Wire Harness B (Diesel)

A Chassis & Frame Wire Harness - Ground

Airbag Ground

71-192

A007

Rear Heater Blower Switch

A008

Front Door Lamp Switch LH

A009

ABS Module

A021

A022

A024

A030

A033

A036

Back-up Lamp Switch

Fuel Sensor/Fuel Pump

Front Door Lamp Switch RH

Diesel Filter Heater (Diesel)

Data Link Connector 120 Resistance

ECM (Diesel)

A020

to Instrument Panel Wire Harness A

to Step Lamp Wire Harness

to Engine Wire Harness 2 (Gasoline)

to Rear Bumper Transition Wire Harness

Engine Room Left Side/ABS Ground

A204

Engine Room Right Side Ground

Engine Room Left Side Ground

Electronic Fan Ground

71-193

ENGINE 4G69

E Engine Wire Harness - Connector

E010

E002

Injector A

E011

E003

Injector B

E012

Engine Coolant Temperature Sense Plug

E004

Injector C

E013

E005

Injector D

E014

Starter Coil

E006

E007

E008

Mainfold Absolute Pressure/Intake Air

Upstream Oxygen Sensor

E015

E016

E017

Idle Air Control Valve

Canister Solenoid Valve

Ignition Coil

E009

E Engine Wire Harness - Inline

E101 to Chassis Wire Harness 1 E102 to Chassis Wire Harness 2

71-194

E Engine Wire Harness - Ground

E201 Ground (Near the Thermostat)

71-195

ENGINE ISF2.8

E018

E019

E020

E021

E022

E023

E024

E025

Engine Electronic Control Module

Fuel Rail Pressure Sensor

Intake manifold Pressure/Temperature

Atmospheric Pressure Sensor

Fuel Moisture Content Sensor

E028

SAE J1939 Data Communication

E033

E034

E035

E036

Air Mass Flow Sensor

Intake Throttle Actuator

EGR Valve

Engine Oil Pressure Switch (IC)

E026

E027

E037

to Chassis Wire Harness A (Diesel)

71-196

I Instrument Panel Wire Harness - Connector

Instrument Cluster A

I019

Instrument Cluster B

I020

A/C Control Panel A

I004

Headlamp Dimmer Switch

I021

A/C Control Panel B

I005

Instrument Dimmer Switch

I022

Servo Motor (Temperature)

Hazard Warning Switch

I023

Rear Blower Forward Switch

Central Locking Controller Assy A

I024

I008

Central Locking Controller Assy B

Blower Control Module

I012

Combination Switch (Light)

I026

Front Evaporator Thermistor

I013

I014

I015

I016

I017

I018

Combination Switch (Wiper)

Clock Spring

12V Power Output Socket

Rear Window Defroster Switch

Outside Mirror Defroster Switch

I027

I028

I029

I030

I031

Servo Motor (Internal & External

Reverse Radar Control Unit

CD Player-C1

CD Player-C2

Radio A

71-197

I032

Radio B

I035

Passenger Airbag Assy

I033

Horn Switch

I Instrument Panel Wire Harness - Inline

to Roof Wire Harness Assy 1A

to Chassis & Frame Wire Harness E

to Roof Wire Harness Assy 1B

M Diagnosis Wire Harness - Connector

M001 Data Link Connector Resistance M002 Data Link Connector

M Diagnosis Wire Harness - Inline

to Instrument Panel Wire Harness

69

71-198

I009

I036

Right Side Sliding Door Lamp Diode

I010

Ignition Switch Illumination

I037

Rear Hatch Lamp Switch Diode

I011

Key Insert Switch

I039

Right Turn Signal Lamp Diode

I034

Flasher

I040

Left Turn Signal Lamp Diode

to Chassis & Frame Wire Harness C

to Chassis & Frame Wire Harness B

to Data Link Connector

to Chassis & Frame Wire Harness A

to Chassis & Frame Wire Harness D

I Instrument Panel Wire Harness - Ground

I201 Instrument Panel Signal Ground

I202 Instrument Panel Power Ground

I204

Instrument Panel Power Ground

A/C System Ground

Radio/Data Link Connector Ground

71-199

B Battery Wire Harness - Connector

B001 Starter B002 Starter Excitation

B Battery Wire Harness - Inline

B Battery Wire Harness - Ground

B201 Engine Ground in Engine Room B202 Body Ground (Battery Side)

O Driver Seat Belt Wire Harness - Connector

O001

Driver Seat Belt Warning Switch

71-200

O Driver Seat Belt Wire Harness - Inline

to Chassis & Frame Wire Harness

P Rear Heater Wire Harness - Connector

P001 Rear Heater Solenoid Valve P002 Rear Heater Motor

P Rear Heater Wire Harness - Inline

X Preheating Wire Harness - Connector

X001

Pre-heater

X003

Pre-heater Relay B

X002

Pre-heater Relay L

71-201

F Roof Wire Harness 1 - Connector

F001

F004

Central Dome light (Low Equipped)

F002

F005

Rear Speaker LH

F003

Sliding Roof Control Switch

F006

Rear Combination Lamp LH

Central Dome light (High Equipped)

F007

Air Purifier

F Roof Wire Harness 1 - Inline

to Roof Wire Harness 2A

to High-mounted Stop Lamp Wire

to Rear Evaporator Wire Harness

to Roof Wire Harness 2B

F Roof Wire Harness 1 - Ground

F201

Roof Wire Harness Rear Left Department

71-202

L Rear Evaporator Wire Harness - Connector

L001

Left Blower

L004

L002

Right Blower

L005

Top Evaporator Blower Switch

L003

Blower Resistor

L Rear Evaporator Wire Harness - Inline

71-203

N Step Lamp Wire Harness - Connector

N001

Right Side Sliding Door Lock Assy

N003

Rear A/C Solenoid Valve

N002

Step Lamp

N Step Lamp Wire Harness - Inline

71-204

G Roof Wire Harness 2 - Connector

G001

Rear Combination Lamp RH

G003

Sliding Door Ajar Switch RH

G002

Rear Speaker RH

G Roof Wire Harness 2 - Inline

to Roof Wire Harness 1A

to Rear Hatch Transition Wire Harness

to Roof Wire Harness 1B

71-205

G Roof Wire Harness 2 - Ground

Roof Rear Right Department Ground

J Rear Hatch Wire Harness - Connector

J001

J002

Rear Hatch Lock Assy-Switch

Rear Hatch Lock Assy-Motor

J004

J005

License Lamp

J003

Trunk Lamp

J Rear Hatch Wire Harness - Inline

J Rear Hatch Wire Harness - Ground

J201

Rear Hatch Internal Ground

Q Rear Bumper Transition Wire Harness - Inline

Q101 to Rear Bumper Wire Harness Q102 to Chassis & Frame Wire Harness

R Rear Bumper Wire Harness - Connector

R001

Reverse Radar Sensor LH

R003

Reverse Radar Central Sensor RH

R002

Reverse Radar Central Sensor LH

R004

Reverse Radar Sensor RH

R Rear Bumper Wire Harness - Inline

S Rear Defrost RH Wire Harness - Connector

S001

Rear Defrost Heating Wire RH

S Rear Defrost RH Wire Harness - Inline

to High-mounted Stop Lamp Wire Harness

T Rear Defrost LH Wire Harness - Connector

T001

Rear Defrost Heating Wire LH

71-206

T Rear Defrost LH Wire Harness - Inline

U High-mounted Stop Lamp Wire Harness - Connector

U001 Rear Wiper U002 High-mounted Stop Lamp

U High-mounted Stop Lamp Wire Harness - Inline

to Rear Defrost RH Wire Harness

to Rear Defrost LH Wire Harness

WIRING(RHD)

WIRING DIAGRAM .......................................................................... 71-19

POWER SOURCE ..................................................................... 71-19

ENGINE CONTROL SYSTEM................................................... 71-23

STARTING SYSTEM ................................................................. 71-35

CHARGING SYSTEM................................................................ 71-37

ANTI-LOCK BRAKE CONTROL SYSTEM ................................ 71-39

HEATER AND CONDITIONING CONTROL SYSTEM.............. 71-42

LIGHT SYSTEM......................................................................... 71-49

WIPER AND WASHER.............................................................. 71-73

MULTIMEDIA SYSTEM ............................................................. 71-76

POWER SOCKET...................................................................... 71-79

COMMUNICATION SYSTEM .................................................... 71-81

POWER MIRROR...................................................................... 71-85

WINDOW DEFROSTER ............................................................ 71-88

INSTRUMENT CLUSTER.......................................................... 71-90

ANTI-THEIF SYSTEM................................................................ 71-97

RESTRAINT CONTROL SYSTEM .......................................... 71-102

CONNECTOR VIEWS .................................................................... 71-104

B - BATTERY WIRE HARNESS .............................................. 71-104

C - FRONT BUMPER WIRE HARNESS.................................. 71-105

D - FRONT DOOR LH WIRE HARNESS................................. 71-106

E - ENGINE WIRE HARNESS................................................. 71-108

F - ROOF WIRE HARNESS 1.................................................. 71-119

G - ROOF WIRE HARNESS 2................................................. 71-122

H - FRONT DOOR RH WIRE HARNESS ................................ 71-124

J - REAR HATCH WIRE HARNESS........................................ 71-127

K - REAR HATCH TRANSITION WIRE HARNESS................. 71-129

M - DIAGNOSIS WIRE HARNESS .......................................... 71-130

P - REAR HEATER WIRE HARNESS ..................................... 71-131

Q - REAR BUMPER TRANSITION WIRE HARNESS ............. 71-132

R - REAR BUMPER WIRE HARNESS .................................... 71-133

U - HIGH-MOUNTED STOP LAMP WIRE HARNESS........... 71-134

V - FRONT WIRE HARNESS................................................. 71-135

X - PREHEATING WIRE HARNESS ....................................... 71-141

Z - Main Wire Harness ............................................................. 71-142

WIRE HARNESS & CONNECTOR LOCATION VIEWS................ 71-166

C - FRONT BUMPER WIRE HARNESS.................................. 71-166

V - FRONT WIRE HARNESS .................................................. 71-166

D - FRONT DOOR LH WIRE HARNESS................................. 71-168

H - FRONT DOOR RH WIRE HARNESS ................................ 71-169

Z - MAIN WIRE HARNESS(CHASSIS & FRAME SECTION) 71-170

E - ENGINE WIRE HARNESS................................................. 71-172

Z - MAIN WIRE HARNESS(INSTRUMENT PANEL

SECTION) ............................................ 71-175

M - DIAGNOSIS WIRE HARNESS .......................................... 71-175

B - BATTERY WIRE HARNESS .............................................. 71-179

P - REAR HEATER WIRE HARNESS ..................................... 71-179

X - PREHEATING WIRE HARNESS ....................................... 71-179

F - ROOF WIRE HARNESS 1.................................................. 71-181

G - ROOF WIRE HARNESS 2 ................................................. 71-182

J - REAR HATCH WIRE HARNESS ........................................ 71-182

K - REAR HATCH TRANSITION WIRE HARNESS................. 71-182

Q - REAR BUMPER TRANSITION WIRE HARNESS ............. 71-182

R - REAR BUMPER WIRE HARNESS .................................... 71-182

U - HIGH-MOUNTED STOP LAMP WIRE HARNESS............. 71-182

WIRING(RHD) - HOW TO USE THIS MANUAL

F6 30A ECU Main Fuse

F19 40A IG2 Fusible Link

F20 20A Power Window Fusible Link

F21 20A AM1 Fusible Link

F25 30A Rear A/C Fusible Link

F27 30A Front Blower Fusible Link

F2 7.5A Radio Fuse

F3 7.5A A/C Controller Fuse

F5 10A Instrument Cluster Fuse

F7 10A Rear Fog Lamp Fuse

F9 15A Horn Fuse

F11 15A Front Fog Lamp Fuse

F12 15A Hazard Warning Fuse

F13 10A Dome Light Fuse

F14 20A Headlamp Fuse

F15 20A Central Locking Fuse

F17 15A Rear Heater Fuse

F28 7.5A Small Lamp Fuse

F29 7.5A Switch Lighting Fuse

F30 10A Left High Beam Fuse

F31 10A Right High Beam Fuse

F32 7.5A left Low Beam Fuse

F33 7.5A Right Low Beam Fuse

F34 10A Radio/Outside Mirror Fuse

F35 15A Cigarette Lighter Fuse

F36 7.5A Instrument IG Fuse

F37 15A Front Wiper Fuse

F43 10A Turn Signal Fuse

F44 10A Rear Wiper Fuse

F46 10A Airbag Fuse

F48 10A Back-up Lamp Fuse

F49 15A Power Fuse

F50 5A ECU IG Fuse

F51 15A A/C Fuse

F52 7.5A Outside Mirror Defrost Fuse

R14

Low Beam Relay

R16

R18

R19

R20

R21

High Beam Relay

R22

R11

WIRING(RHD) - WIRING DIAGRAM

• Z015 Ignition Switch

B001 Battery Wire Harness Z050 Main Wire Harness

Z015 Main Wire Harness Z051 Main Wire Harness

Z049 Main Wire Harness Z074 Main Wire Harness

Z111

Z113

Main Wire Harness & Engine Wire Harness

(Manhole After the Driver Seat)

Main Wire Harness & Diagnosis Wire Harness

(Under the Right Bottom Side of the Instrument Panel)

Z203

Instrument Panel Signal Ground

E001 Engine Wire Harness E002 Engine Wire Harness

E003 Engine Wire Harness E004 Engine Wire Harness

E005 Engine Wire Harness E006 Engine Wire Harness

E007 Engine Wire Harness E008 Engine Wire Harness

E009 Engine Wire Harness E010 Engine Wire Harness

E011 Engine Wire Harness E015 Engine Wire Harness

E016 Engine Wire Harness E017 Engine Wire Harness

M002 Diagnosis Wire Harness V031 Front Wire Harness

Z002 Main Wire Harness Z003 Main Wire Harness

Z023 Main Wire Harness Z043 Main Wire Harness

Z048 Main Wire Harness Z050 Main Wire Harness

Z051 Main Wire Harness Z063 Main Wire Harness

Z064 Main Wire Harness Z065 Main Wire Harness

Z067 Main Wire Harness Z076 Main Wire Harness

Z077

Main Wire Harness

Z101

Z112

V112

Engine Wire Harness & Main Wire Harness

Diagnosis Wire Harness & Main Wire Harness

Main Wire Harness & Front Wire Harness

(Right Side of the Instrument Panel)

E201 Ground (Near the Thermostat) Z203 Instrument Panel Signal Ground

Z204 Radio/Data Link Connector Ground Z208 Vehicle Frame Left Side Ground

Z209

E038 Engine Wire Harness E039 Engine Wire Harness

E040 Engine Wire Harness E041 Engine Wire Harness

E042 Engine Wire Harness E043 Engine Wire Harness

E044 Engine Wire Harness E045 Engine Wire Harness

E046 Engine Wire Harness E047 Engine Wire Harness

E048 Engine Wire Harness E049 Engine Wire Harness

E050 Engine Wire Harness E051 Engine Wire Harness

E052 Engine Wire Harness E053 Engine Wire Harness

E054 Engine Wire Harness E055 Engine Wire Harness

E056 Engine Wire Harness M001 Diagnosis Wire Harness

X001 Preheating Wire Harness X002 Preheating Wire Harness

X003 Preheating Wire Harness Z001 Main Wire Harness

Z006 Main Wire Harness Z029 Main Wire Harness

Z037 Main Wire Harness Z043 Main Wire Harness

Z051 Main Wire Harness Z053 Main Wire Harness

Z054 Main Wire Harness Z063 Main Wire Harness

Z068 Main Wire Harness Z072 Main Wire Harness

Z107

Battery Wire Harness & Main Wire Harness

(Car Body Side of the Battery Compartment)

B201 Engine Ground in Engine Room Z208 Vehicle Frame Left Side Ground

B001 Battery Wire Harness B002 Battery Wire Harness

E014 Engine Wire Harness Z015 Main Wire Harness

Main Wire Harness & Battery Wire Harness

Z208

Vehicle Frame Left Side Ground

b. When ignition switch is ON/ST, the current flows output from ignition switch, to instrument panel fuse in copilot

side junction box, through the fuse, to pin A20 of instrument cluster. The current flows through charging

warning light of instrument cluster, from pin B25 of instrument cluster, to pin L of generator connector Z066, to

connector Z074, to charge fusible link and charge a battery, at the same time, supply electrical energy to other

• Z066,Z074 Generator

Z043 Main Wire Harness Z049 Main Wire Harness

Z063 Main Wire Harness Z066 Main Wire Harness

Z074

• Ignition Signal

When ignition switch is ON/ST, current flows through ABS IG fuse in co-pilot side junction box, to pin 28 of

ABS module and ABS system getss ignition signal.

system or parts have faults, the system will switch on the ABS warning light and the EBD warning light to

remind drivers of repair in time.

• Z006 Stop Lamp Switch

M002 Diagnosis Wire Harness Z002 Main Wire Harness

Z003 Main Wire Harness Z006 Main Wire Harness

Z043 Main Wire Harness Z048 Main Wire Harness

Z050 Main Wire Harness Z058 Main Wire Harness

Z059 Main Wire Harness Z060 Main Wire Harness

Z061 Main Wire Harness Z062 Main Wire Harness

Z063

(Under the Right Bottom Side of the Instrument Panel

Z207

ABS Ground

• Ignition Switch At On/St, A/C System Power Supply

a. When ignition switch is turned to ON/ST, current flows through A/C fuse in co-pilot side junction box, to pin

30 of A/C cut off relay, through the relay, battery output from the pin 87a of cut off relay, to pin 10 of A/C controller,

pin 85 of front blower relay, pin 30 and 85 of compressor relay and pin 2 of rear blower forward switch,

then A/C system getss the operation power.

a. blower control: current flows from the pin 87a of A/C relay, to pin 85 of front blower relay, through coil of

relay, output from the pin 86 of relay to pin 8 of A/C control panel A; A/C control panel make the coil of relay to

b. A/C clutch control: Working inquire signal of the front A/C system outputs from pin 9 of A/C control panel, to

pin 1 of triple pressure switch, the signal through switch and connect to engine ECM. If the pressure of refrigerant

in A/C pipe meet the specification as design, ECM will control the A/C relay coil to connect the

ground.Coil then creates a magnetic field, and switch is activated. Current flows into A/C clutch solenoid and

A/C compressor clutch engage and front A/C system begin to work.

c. servo motor (internal & external circulation) control: Current flows from pin 6 of A/C control panel A, to pin

5 of circulation motor, outputs from pin 6 of circulation motor, to pin 7 of A/C control panel A. Motor is working,

the front A/C system is internal circulation mode, on the contrary, system is external circulation mode.

d. servo motor (temperature) control: Current flows from pin 5 and 4 of A/C control panel A, to pin 5 and 6 of

return to A/C control panel from pin 3 and 1 of servo motor to pin 26 and 27 of A/C control panel B. The signal

current outputs from pin 2 of motor, to pin 23 of A/C control panel B, feedback the position signal of servo

e. servo motor (mode) control: Current flows from pin 2 and 3 of A/C control panel, to pin 5 and 6 of servo

A/C control panel from pin 3 and 1 of servo motor to pin 26 and 27 of A/C control panel B. The signal current

outputs from pin 2 of motor, to pin 24 of A/C control panel B, feedback the position signal of servo motor(step

f. Current flows from pin 29 of A/C control panel B, to pin 1 of evaporator thermistor, through thermister, outputs

from pin 2 of thermister, to pin 33 of A/C control panel B. The A/C sustem getsss the temperature Info of

• Compressor Relay

E001 Engine Wire Harness E013 Engine Wire Harness

F008 Roof Wire Harness 1 V031 Front Wire Harness

Z017 Main Wire Harness Z019 Main Wire Harness

Z020 Main Wire Harness Z021 Main Wire Harness

Z022 Main Wire Harness Z023 Main Wire Harness

Z038 Main Wire Harness Z039 Main Wire Harness

Z041 Main Wire Harness Z043 Main Wire Harness

Z051 Main Wire Harness Z069 Main Wire Harness

Z072

F107

Z108

Z103

Engine Wire Harnes & Main Wire Harness

Roof Wire Harness 1 & Main Wire Harness

(Left Side of the Instrument Panel)

Z203 Instrument Panel Signal Ground Z204 Radio/Data Link Connector Ground

Z205

P001 Rear Heater Wire Harness P002 Rear Heater Wire Harness

Z022 Main Wire Harness Z043 Main Wire Harness

Z047 Main Wire Harness Z048 Main Wire Harness

Z051 Main Wire Harness Main Wire Harness

Z109

Main Wire Harness & Rear Heater Wire Harnesss

(Left Side of the Chassis)

Z202 Instrument Panel Power Ground Z204 Radio/Data Link Connector Ground

Z205 A/C System Ground Z210 Engine Room Right Side Ground

The current flows through charge and instrument panel fusible link, to pin 86 and 87 of lo-beam relay in copilot

side junction box, through coil of relay, and then to pin 10 of combination switch. When the combination

switch is set headlamp (Low Beam) position, the current output from pin 7 of combination switch to connect

the ground. The coil of relay creates a magnetic field, and switch is activated. The current flows through switch

of relay, to lo-beam fuse (LH) and lo-beam fuse (RH) in dirver side junction box, and pass then to pin 3 of left

lamp and pin 3 of right headlamp and through light of headlamp (Low Beam). The power is ground at pin 1 of

left and right headlamp. This enables headlamp (Low Beam) to operate.

The current flows through charge and instrument panel fusible link, to headlamp fuse in co-pilot side junction

the combination switch is set headlamp (High Beam) position, the current output from pin 7 of combination

flows through switch of relay, to hi-beam fuse (LH) and hi-beam fuse (RH) in co-pilot side junction box, and

pass then to pin 2 of headlamp LH and pin2 of headlamp RH, and through light of headlamp (High Beam).

The power is ground at pin 1 of left and right headlamp. This enables headlamp (High Beam) to operate.

the combination switch is set flash to pass position, the current output from pin 7 of combination switch to connect

the ground. The coil of relay creates a magnetic field, and switch is activated. The current flows through

switch of relay, to hi-beam fuse (LH) and hi-beam fuse (RH) in co-pilot side junction box, and pass then to pin

2 of headlamp LH and pin2 of headlamp RH, and through light of headlamp (High Beam). The power is

• Z011 Combination Switch (Light Control)

10 - 7:Closed with the combination switch at Headlamp position ( Low Beam).

9 - 7:Closed with the combination switch at Headlamp position (High Beam and Flash to Pass).

V018 Front Wire Harness V020 Front Wire Harness

V023 Front Wire Harness Z011 Main Wire Harness

Z033 Main Wire Harness Z043 Main Wire Harness

Z051

Z105

V111

V205 Front Wire Harness Left Side Ground V206 Front Wire Harness Right Side Ground

Z201 Instrument Panel Power Ground Z203 Instrument Panel Signal Ground

The current flows through charge and instrument panel fusible link in positive junction box, to pin 85 and 87 of

lamplet relay in co-pilot side junction box, pass the coil of relay and then to pin 5 of combination switch. When

the combination switch is set lamplet light or headlamp (Low Beam/High Beam) position, the current flows

output pin 8 of combination switch to connect the ground. The coil of lamplet relay creates a magnetic field,

and switch is activated. The current flows through switch of relay, and through the lamplet fuse in co-pilot side

5 - 8:Closed with the combination switch at Headlamp and lamplet position.

F012 Roof Wire Harness 1 G004 Roof Wire Harness 2

J004 Rear Hatch Wire Harness V019 Front Wire Harness

V024 Front Wire Harness Z011 Main Wire Harness

Z043 Main Wire Harness Z051 Main Wire Harness

G104

G105

F109

Roof Wire Harness 2 & Roof Wire Harness 1

(Top Cap of the Rear Beam Left Side)

(Top Cap of the Rear Beam Right Side)

Main Wire Harness & Roof Wire Harness 1

F202

G202

Roof Wire Harness Rear Right Department

J201 Rear Hatch Internal Ground V205 Front Wire Harness Left Side Ground

V206 Front Wire Harness Right Side Ground Z203 Instrument Panel Signal Ground

2 - 1:Closed with the brake pedal depressed.

U002 High-mounted Stop Lamp Wire Harness Z006 Main Wire Harness

F111

Groundt

When ignition switch is ON/ST, the current flows throug back-up lamp fuse in co-pilot side junction box, to pin

1 of back-up lamp switch. The current flows from pin 2 of back-up lamp switch, and then to the circuit as

• Z056 Back-up Lamp Switch

Z056

Instrument Panel Signal Groundt

Current flows through hazard waring fuse in co-pilot side junction box, to pin 1 of flasher, to supply power for

When ignition switch is ON/ST, the current flows through turn signal fuse in co-pilot side junction box, to pin 12

of combination switch. When operating the combination switch, the current flow output from pin 11 and pin 13

of combination switch, to pin 5 and pin 12 of flasher, vehicle turning lamp is under working condition.

When the combination switch is in Left Turn position, the current flows output from pin 4 and pin 9 of flasher,

When the combination switch is in Right Turn position, the current flows output from pin 2 and pin 10 of flasher,

flasher. Flasher is working condition; The current flows output from pin 2 , 4, 9, 10 of flasher.

Power from pin 4 and pin 9 of flasher:

Power from pin 2 and pin 10 of flasher:

• Z034 Hazard Warning Switch

• Z011 Combination Switch

12 - 11:Closed with the combination switch at Left Turn position.

12 - 13:Closed with the combination switch at Right Turn position.

V021 Front Wire Harness V025 Front Wire Harness

Z007 Main Wire Harness Z011 Main Wire Harness

Z034 Main Wire Harness Z035 Main Wire Harness

Z036 Main Wire Harness Z043 Main Wire Harness

Z202 Instrument Panel Power Ground Z203 Instrument Panel Signal Ground

relay, pass the coil of relay and then to pin 5 of combination switch. When the combination switch is set lamplet

or headlamp (Low Beam/High Beam) position, the current flows output pin 8 of combination switch to connect

switch of relay, from the pin 30 of relay to front fog relay coil, to pin 3 of ombination switch. When front fog lamp

switch is closed, the current flows output from pin 1 of combination switch to connect the ground. The coil of

front fog lamp relay creates a magnetic field, and switch is activated. The current flows through fog lamp fuse

in co-pilot side junction box, to front fog lamp relay, and through switch of front fog lamp relay, to pin 1 of front

fog lamp LH and pin 1 of front fog lamp RH, the power is ground at pin 2 of front fog lamp LH and pin 2 of front

fog lamp RH. This enables front fog lamp LH and front fog lamp RH to operate.

fuse in co-pilot side junction box, to rear fog lamp relay. When front low beam lamp work and rear fog lamp

in co-pilot side junction box, to rear fog lamp relay, and through switch of rear fog lamp relay, to pin 5 of rear

8 - 1:Closed with the combination switch at Lamplet and Headlamp position

C001 Front Bumper Wire Harness C002 Front Bumper Wire Harness

Z011 Main Wire Harness Z043 Main Wire Harness

V120

Front Wire Harness & Front Bumper Wire Harness

V204 Front Wire Harness Central Ground Z203 Instrument Panel Signal Ground

in co-pilot side junction box, to pin 1 and 2 of front dome light. Front dome light is working condition.

a. Press front dome light switch, and the power is ground by the pin 3 of switch. This enables front dome light

in co-pilot side junction box, to pin 1 of central dome light. central dome light is working condition.

in co-pilot side junction box, to pin 1 of step light and output from pin 2 of step light; If sliding door is not closed,

in co-pilot side junction box, to pin 1 of ignition switch illumination; The current outputs from the pin 2 of ignition

in co-pilot side junction box, to pin 1 of trunk lamp and output from pin 2 of trunk lamp; If rear hatch door is not

F009 Roof Wire Harness 1 F010 Roof Wire Harness 1

F011 Roof Wire Harness 1 F014 Roof Wire Harness 1

J001 Rear Hatch Wire Harness J003 Rear Hatch Wire Harness

Z003 Main Wire Harness Z004 Main Wire Harness

Z005 Main Wire Harness Z008 Main Wire Harness

Z014 Main Wire Harness Z031 Main Wire Harness

Z043 Main Wire Harness Z046 Main Wire Harness

Z051 Main Wire Harness Z055 Main Wire Harness

Z071 Main Wire Harness Z073 Main Wire Harness

G106

tail light relay, and then to pin 5 of combination switch. When the combination switch is set lampet or headlamp

(Low Beam/High Beam) position, the current flows output pin 8 of combination switch to connect the ground.

The coil of lamplet relay creates a magnetic field, and switch is activated. The current flows through the pin 87

of lamplet relay and through the lamplet and switch light fuse in co-pilot side junction box and the system

When the combination switch is set lamplet or headlamp position, the current flows output lamplet fuse in copilot

side junction box, to pin A6 of instrument cluster. This enables instrument cluster illumination to operate.

side junction box, to pin 2 of hazard warning switch, to pin 3 of hazard warning switch, the power is

co-pilot side junction box, to pin 3 of headlamp dimmer switch illumination, to pin 6 of headlamp dimmer

switch illumination, the power is ground at pin 6 of headlamp dimmer switch illumination. This enables

headlamp dimmer switch illumination to operate.

co-pilot side junction box, to pin 3 of instrument dimmer switch illumination, to pin 6 of instrument dimmer

co-pilot side junction box, to pin 3 of rear window defroster switch illumination, to pin 1 of rear window

defroster switch illumination, the power is ground at pin 1 of rear window defroster switch illumination. This

enables rear window defroster switch illumination to operate.

co-pilot side junction box, to pin 3 of outside mirror defroster switch illumination, to pin 1 of outside mirror

co-pilot side junction box, to pin 3 of rear blower forward switch illumination, to pin 1 of rear blower

forward switch illumination, the power is ground at pin 1 of rear blower forward switch illumination. This

enables rear blower forward switch illumination to operate.

co-pilot side junction box, to pin 3 of dome light switch illumination, to pin 1 of dome light switch

illumination, the power is ground at pin 1 of dome light switch illumination. This enables dome light switch

illumination to operate.

co-pilot side junction box, to pin 3 of cigarette lighter illumination, to pin 1 of cigarette lighter illumination,

co-pilot side junction box, to pin A3 of radio illumination, to pin A8 of radio illumination, the power is ground

co-pilot side junction box, to pin 32 of A/C control panel llumination, to pin 20 of A/C control panel

co-pilot side junction box, to pin 3 of diagnosis switch llumination, to pin 1 of diagnosis switch llumination,

5 - 8:Closed with the combination switch at Lamplet or Headlamp position.

Z003 Main Wire Harness Z011 Main Wire Harness

Z017 Main Wire Harness Z022 Main Wire Harness

Z023 Main Wire Harness Z024 Main Wire Harness

Z025 Main Wire Harness Z029 Main Wire Harness

Z030 Main Wire Harness Z031 Main Wire Harness

Z032 Main Wire Harness Z033 Main Wire Harness

Z034 Main Wire Harness Z043 Main Wire Harness

Z201 Instrument Panel Power Ground Z202 Instrument Panel Power Ground

When ignition switch is ON/ST, the current flows through front wiper fuse and rear wiper fuse in co-pilot side

pin 3 of combination switch, and output from pin 4 of combination switch, to pin 1 of front wiper motor, and

pin 3 of combination switch, and output from pin 2 of combination switch, to pin 4 of front wiper motor, and

When the front wiper switch of combination switch is set INT, The intermittent current flows from pin 5 of

through the front washer pump, output from pin 1 of front washer pump, to pin 7 of combination switch, and

The current flows output from rear wiper fuse, to pin 86 and 87 of rear wiper relay, and then output from pin 30

of rear wiper relay. When the rear wiper switch is in ON position, the current flows into pin 9 of combination

switch, and then to ground at pin 6 of combination switch; The current flows into coil of rear wiper relay. The

pump, and output from pin 1 of rear washer pump, to pin 8 of combination switch, and ground at pin 6 of

U001 High-mounted Stop Lamp Wire Harness V028 Front Wire Harness

V029 Front Wire Harness V030 Front Wire Harness

Z013 Main Wire Harness Z043 Main Wire Harness

F108

Z106

V204

• Z025 Radio A, Z026 Radio B

• D011 Front Speaker LH

• H006 Front Speaker RH

• F013 Rear Speaker LH

• G005 Rear Speaker RH

D011 Front Door LH Wire Harness F013 Roof Wire Harness 1

G005 Roof Wire Harness 2 H006 Front Door RH Wire Harness

J003 Rear Hatch Wire Harness Z025 Main Wire Harness

Z026 Main Wire Harness Z027 Main Wire Harness

Z028 Main Wire Harness Z043 Main Wire Harness

Z045 Main Wire Harness Z051 Main Wire Harness

F110

V116

V119

D106

H106

Rear Hatch Transition Wire Harness & Rear Hatch Wire Harness

Front Wire Harness & Front Door LH Wire Harness

Z204

• Z030 Cigarette Lighter

When ignition switch is ACC/ON, the current flows through cigarette lighter fuse in co-pilot side junction box,

pin 2 of cigarette lighter. When pressing the cigarette lighter, the current flows output from pin 1 of cigarette

lighter, and ground at pin 1 of cigarette lighter. This enables cigarette lighter to operate.

• Z018 12V Power Output Socket

When ignition switch is ON/ST, the current flows through cigarette lighter fuse in co-pilot side junction box, pin

2 of power output socket. When pressing the power output socket, the current flows output from pin 1 of

power output socket, and ground at pin 1 of power output socket. This enables power output socket to

Z018 Main Wire Harness Z030 Main Wire Harness

Z202

• Horn Control

The current flows through charge and instrument panel fusible link in positive junction box, to horn fuse in copilot

side junction box, to pin 85 of horn relay, and through the coil of horn relay, and then to the circuit as

Current flows from 2 pin of clock spring, to horn switch, when pressing the horn switch, the power is ground by

switch. The coil of horn relay creates a magnetic field, and switch is activated. The current then flows through

switch of horn relay, to pin 1 of horn, and to ground at pin 2 of horn. This enables horn to operate.

Pin 86 of horn relay is controlled by pin 4 of central locking controller to coonect the ground; When pin 86 of

V026 Front Wire Harness V027 Front Wire Harness

Z008 Main Wire Harness Z012 Main Wire Harness

When ignition switch is ON/ST, the current flows through back-up lamp fuse in co-pilot side junction box, to pin

1 of back-up lamp switch. When shift lever in “R” position, the current flows from pin 2 of back-up lamp switch

to pin 1 of reverse radar control unit. The reverse radar control system is then powered.

R001 Rear Bumper Wire Harness R002 Rear Bumper Wire Harness

R003 Rear Bumper Wire Harness R004 Rear Bumper Wire Harness

Z003 Main Wire Harness Z042 Main Wire Harness

Z043 Main Wire Harness Z045 Main Wire Harness

Z051 Main Wire Harness Z056 Main Wire Harness

Z110

Main Wire Harness & Rear Bumper Transition Wire Harness

(Left Side Of the Rear Bumper)

Z203 Instrument Panel Signal Ground Z205 A/C System Ground

When ignition switch is ACC/ON, the current flows through radio ACC fuse in co-pilot side junction box, to pin

4 of outside mirror switch. System is then powered.

D008 Front Door LH Wire Harness H008 Front Door RH Wire Harness

H009 Front Door RH Wire Harness Z043 Main Wire Harness

D104

V117

V114

H104

V118

H105

defroster switch connected, the current output from pin5, then flows to pin 85 of outside mirror defroster

relay,and ground at pin 86. Then through the coil in outside mirror defroster relay pin30, and output from pin 87

of outside mirror defroster relay. The coil of outside mirror defroster relay creates a magnetic field, and switch

is activated. The current flows from outside mirror defrost fuse, through switch of outside mirror defroster relay,

to pin 3 of outside mirror defrost grid and ground at pin 2 of grid. This enables outside mirror defroster to

• Z024 Outside mirror Defrost Switch

Z024 Main Wire Harness Z043 Main Wire Harness

Z102

V113

a. When ignition switch is ON/ST, the current flows through instrument IG fuse in co-pilot side junction box, to

pin A1 and A20 of the instrument cluster. System is then powered.

b.The current flows through charge and instrument panel fusible link in positive junction box, to co-pilot side

junction box and then to pin A16 of instrument cluster. System is then powered.

The current flows through engine coolant fluid level warning light in instrument cluster, and output from pin B16

of instrument cluster, to pin 1 of engine coolant temperature sensor, and ground at pin 2 of engine coolant

temperature sensor (ISF2.8) or itself (4G69). This enables engine coolant fluid level warning light to operate.

output from pin B20 of instrument cluster, to 27 of ABS module. If ABS system is fault, this enables ABS

output from pin B24 of instrument cluster, to 3 of ABS module. If ABS system is fault, this enables EBD

output from pin A31 of instrument cluster, to pin 1 of driver seat belt warning switch and ground at pin 2. If

driver do not fasten the safe belt, switch will close, this enables safe belt indicator to operate.

driver seat belt warning switch and ground at pin 2. If driver do not fasten the safe belt, switch will close, this

enables buzzer to operate.

• Brake Fluid Warning Light

E001 Engine Wire Harness E012 Engine Wire Harness

E036 Engine Wire Harness E037 Engine Wire Harness

V032 Front Wire Harness V033 Front Wire Harness

Z032 Main Wire Harness Z043 Main Wire Harness

Z044 Main Wire Harness Z045 Main Wire Harness

Z051 Main Wire Harness Z057 Main Wire Harness

Z062 Main Wire Harness Z066 Main Wire Harness

Z067 Main Wire Harness Z070 Main Wire Harness

Z072 Main Wire Harness Z078 Main Wire Harness

Z210

• System Power

The current flows through charge and instrument panel fusible link in positive junction box, to co-pilot side

junction box and circuit as follows:

a. When key lock switch is LOCK position, the current flows output from pin A9 of central locking controller, to

pin 9 of front door lock actuator assembly RH and through the key lock switch, to ground at pin 7 of front door

lock actuator assembly RH. This enables closed with door of all with mechanical operate.

b. When key lock switch is OPEN position, the current flows output from pin A10 of central locking controller,

to pin 10 of front door lock actuator assembly RH, and through the key lock switch, to ground at pin 7 of front

door lock actuator assembly RH. This enables opened with door of all with mechanical operate.

• Status of Front Door RH

Current flows from pin B2 of central locking controller, to pin 1 of front door RH switch, through switch to

Signal is from pin 30 of restraint control module, to pin B8 of central locking controller. System getssgetss the

lock actuator assembly, and through the motor in door lock actuator assembly, output from pin 1 of lock

a. Power window LH up: The current flows output from pin A7 of central locking controller, to pin 1 of power

window LH, and through the motor, output from pin 2 of power window LH, to pin A6 of central locking

b. Power window RH up: The current flows output from pin A5 of central locking controller, to pin 1 of power

window RH, and through the motor, output from pin 2 of power window RH, to pin A4 of central locking

D007 Front Door LH Wire Harness D009 Front Door LH Wire Harness

D010 Front Door LH Wire Harness H007 Front Door RH Wire Harness

H010 Front Door RH Wire Harness H011 Front Door RH Wire Harness

J002 Rear Hatch Wire Harness V034 Front Wire Harness

Z003 Main Wire Harness Z008 Main Wire Harness

Z009 Main Wire Harness Z010 Main Wire Harness

Z014 Main Wire Harness Z043 Main Wire Harness

Z044 Main Wire Harness Z051 Main Wire Harness

Z052 Main Wire Harness Z071 Main Wire Harness

V115

D105

(Right Side of the Instrument Panel )

V204 Front Wire Harness Central Ground Z201 Instrument Panel Power Ground

When vehicle is in a frontal collision exceeding a specified level, the current flows from pin 11 of restraint

control module, to pin 4 of clock spring, to driver airbag. Current then flows from driver airbag, to pin 3 of clock

spring, and back to pin 10 of restraint control module. Driver airbag is then activated.

Z003 Main Wire Harness Z009 Main Wire Harness

Z012 Main Wire Harness Z040 Main Wire Harness

Z043 Main Wire Harness Z044 Main Wire Harness

M010

Z203 Instrument Panel Signal Ground Z206 Airbag Ground

WIRING(RHD) - CONNECTOR VIEWS

B101 to Main Wire Harness

D009 Window Control Switch LH

Left Side Window

D007 Power Window Motor LH

1 G-R SIde Window Up

2 R-L Side Window Down

D010 Front Door Lock Assy LH

D008 Outside Mirror Assy LH

Front Left Door

Unlock

4 R Front Left Door Lock

D011 Front Speaker LH

Power +t

2 P Front Left Speaker -

D104 to Front Wire Harness A

3 L-R -

D106 to Front Wire Harness C

D105 to Front Wire Harness B

3 L-YL -

49 R-G

Injector -

2 R-W

50 R-Y

5 B EGR Valve Motor+ 53 B

13 R Sensor + 61 - -

14 B Sensor - 62 Y-Br

15 R CAN + 63 B Sensor -

16 B CAN - 64 B

Sensor -

17 - - 65 B Sensor -

18 - - 66 B Sensor -

19 - - 67 B Sensor -

21 - - 69 Y-Br

23 P-B

24 - - 72 Y-Br

25 W-V

73 W-L

26 R-L

74 W-Y

29 B EGR Valve Motor - 77 B

31 B Inlet Metering Valve - 79 - -

32 B Inlet Metering Valve + 80 B Sensor +

37 Y-Br

38 Y-Br

86 B Air Mass Flow Signal

39 - - 87 R Sensor +

40 B Sensor - 88 R

Sensor +

41 - - 89 R Sensor +

42 - - 90 B Sensor +

91 B Sensor +

46 W-Y

+

47 W-Y

95 B

48 - - 96 B

E039 Inlet Metering Valve

1 B Inlet Metering Valve +

2 B Inlet Metering Valve -

E040 Coolant Temperature Sensor

1 B Sensor -

2 W-Y Sensor +

E041 Water in Fuel Sensor

1 W-Y

E044 Accuumulator Pressure Sensor

2 Y-Br Pressure Signal

3 R Sensor -

E042 Oil Pressure Switch

1 Y-Br Pressure Signal

E045 Ambient Air Pressure Sensor

1 R Sensor +

2 B Sensor -

3 Y-Br Pressure Signal

E043 CAN Datalink

1 R CAN +

2 B CAN -

E046 Intake Manifold Press/Temp Sensor

Presure Signal

2 R Sensor +

3 P-B

Intake Manifold Air

4 B Sensor -

E047 Camshaft Position Sensor

E050 Injector 2

1 R-L Injector 2 -

2 R-W Injector 2 +

3 Y-Br

E051 Injector 3

E048 Crankshaft Position Sensor

1 W-V Injector 3 -

2 W-L Injector 3 +

E052 Injector 4

1 W-L Injector 4 -

2 W-Y Injector 4 +

E049 Injector 1

1 R-G Injector 1 -

2 R-Y Injector 1 +

E053 Air Mass Flow Sensor

1 B Signal

2 B Sensor +

3 B Sensor -

E056 CAN Resistor

1 R Resistor +

2 B Resistor -

E054 Intake Throttle Actuator

4 B Sensor +

5 B

E055 EGR Valve

1 B EGR Control Valve -

2 B EGR Control Valve +

5 B Sensor +

E101 to Main Wire Harness 1

E102 to Main Wire Harness 2

E103 to Main Wire Harness A (Diesel)

F008 Rear Evaporator Module

2 L Power Input

3 Y-W

4 Br Temperature Sensor -

5 L Power Input

6 Lg

Rear Evaporator Air

Flow Switch Power

F010 Central Dome Light (High Equipped)

F010 Central Dome Light (Low Equipped)

F009 Front Dome Light

F011 Air Purifier

F012 Rear Combination Lamp LH

F107 to Main Wire Harness A

F013 Rear Speaker LH

F014 Sliding Door Ajar Switch LH

1 V-W Switch Signal Output

F108 to Main Wire Harness B

F110 to Roof Wire Harness 2B

F109 to Roof Wire Harness 2A

F111 to High-mounted Stop Lamp Wire

G104 to Roof Wire Harness 1A

G004 Rear Combination Lamp RH

G105 to Roof Wire Harness 1B

G005 Rear Speaker RH

G106 to Rear Hatch Transition Wire

H006 Front Speaker RH

D009 Electric Outside Mirror Switch

H007 Power Window Motor RH

1 R Side Window Up

2 L Side Window Down

H008 Outside Mirror Assy RH

D010 Door Control Switch

Right Side Door Assy

H104 to Front Wire Harness A

H011 Front Door Lock Assy RH

1 G Front Right Door Lock

Front Right Door

9 L-O Key Lock

10 L-R Key Unlock

H105 to Front Wire Harness B

H106 to Front Wire Harness C

P101 to Main Wire Harness

Q102 to Main Wire Harness

V018 Left Headlight Dimming Motor

V021 Front Turn Signal Lamp LH

V022 Headlamp RH

V019 Front Position Lamp LH

V020 Headlamp LH

V023 Right Headlight Dimming Motor

1 G-R Motor Power

V027 Alt Horn

V024 Front Position Lamp RH

V028 Front Washing Reservoir Motor

V025 Front Turn Signal Lamp RH

V029 Rear Washing Reservoir Motor

1 P Washing Motor -

2 G-Y Washing Motor +

V026 Bass Horn

V030 Windshield Wiper Assy

3 G-R Power

V034 Engine Hood Switch

V031 Triple Pressure Switch

V111 to Main Wire Harness A

2 LG -

3 P -

V032 Vacuum Warning Switch

1 B Switch + Input

7 R-G -

8 G-B -

9 L-B -

10 L-Y -

12 R-L -

V033 Brake Fluid Level Sensor

13 R-Y -

14 V-W -

15 G-R -

16 LG -

17 P -

18 G-Y -

19 Y-W -

21 G-R -

22 R-L -

23 R -

24 G -

V113 toMain Wire Harness D

2 G -

7 L-R -

V112 to Main Wire Harness C

8 O-L -

9 G-R -

1 G-R -

2 R-W -

4 W-B -

5 R-W -

6 L-W -

8 L-R -

9 Y-B -

10 G-B -

12 L-G -

V114 to Front Door LH Wire Harness A

V115 to Front Door LH Wire Harness B

V117 to Front Door RH Wire Harness A

V116 to Front Door LH Wire Harness C

V118 to Front Door RH Wire Harness B

V119 to Front Door RH Wire Harness C

V120 to Front Bumper Wire Harness

Z - Main Wire Harness

Z002 Instrument Cluster B

Z001 Electronic Throttle

1 B Throttle Sensor 1 -

2 L-G Throttle Sensor 1

3 W Throttle Sensor 1+

4 Y Throttle Sensor 2 -

5 W-R Throttle Sensor 2

6 Y-G Throttle Sensor 2 +

B7 - -

B10 V-W Speed Output

Z003 Instrument Cluster A

A1 R-B Instrument IG Power

A8 L Vehicle Speed Input

Z004 Rear Hatch Lamp Switch Diode

Door Open Indicator

A16 R Instrument Power

A20 R-B Instrument IG Power

Z005 Left Side Sliding Door Lamp Diode

Z006 Stop Lamp Switch

4 W-B Switch -

Z008 Central Locking Controller Assy B

Open Signal Output

Z007 Flasher

Z009 Central Locking Controller Assy A

Z011 Combination Switch (Light)

3 B-W

5 G-R

Door Assy

A18 R-B IG Power

6 W to Day light Relay

10 W-R to Low Beam Relay

11 G-V Left Turn Switch

12 B-R Turn Light Power

13 G-W Right Turn Switch

Z010 Key Insert Switch

Z012 Clock Spring

Z013 Combination Switch (Wiper)

2 L-R

3 G-R

4 L-W

Z015 Ignition Switch

7 Y-W Front Washer Motor -

8 P Rear Washer Motor -

9 W Rear Wiper

Z017 A/C Control Panel B

Z014 Ignition Switch Illumination

Z020 Blower Control Module

Z021 Servo Motor (Temperature)

Z018 12V Power Output Socket

5 L

Z019 Front Blower

6 L-R Cold Damper Control

Z023 A/C Control Panel A

Z022 Rear Blower Forward Switch

Z024 Outside Mirror Defroster Switch

Z026 Radio B

Z025 Radio A

Z027 CD Player-C2

Z028 CD Player-C1

Z031 Dome Light Switch

Z029 Diagnosis Switch

Z032 Instrument Dimmer Switch

Z030 Cigarette Lighter

Z033 Headlamp Dimmer Switch

1 G-B Power

Front Left Headlamp

Adjustment

Front Right

Z034 Hazard Warning Switch

Z036 Turn Signal Lamp Diode LH

Z037 Clutch Switch

3 W-B Clutch Switch

4 L-B Switch Control Output

Z035 Turn Signal Lamp Diode RH

Z038 Servo Motor (Mode)

6 L-B

Z041 Servo Motor (Internal & External

Z039 Front Evaporator Thermistor

5 G-W Internal Circulation

6 G External Circulation

Z042 Reverse Radar Control Unit

Z040 Passenger Airbag Assy

Z044 Restraint control module (RCM)

Z045 Parking Brake Switch

Z047 Rear Heater Blower Switch

Z046 Front Left Door Lamp Switch

Door Open signal

Z049 to Positive Junction Box C

Z050 to Positive Junction Box A

Z053 Diesel Filter Heater

1 Br Power

Z054 Preheating Relay Coil

Z051 to Positive Junction Box D

1 L-Y Coil Output

2 L-B Coil Input

Z055 Step Lamp

Z052 Left Side Sliding Door Lock Assy

1 R Step Lamp Power

2 R-Y Door Control Output

2 G Unlock

4 R Lock

Z056 Back-up Lamp Switch (Gasoline)

Z056 Back-up Lamp Switch (Diesel)

Z059 Front Wheel Speed Sensor LH

Z057 Odometer Sensor

Z060 Rear Wheel Speed Sensor RH

Z061 Rear Wheel Speed Sensor LH

Z058 Front Wheel Speed Sensor RH

Z062 ABS ECU

Z064 Secondary Fan Motor

Z066 Generator (Diesel)

Z067 Fuel Sensor/Fuel Pump

Z065 Main Fan Motor

1 Br Fuel Pump Power

3 V Fuel Sensor Signal

Z068 Data Link Connector 120 Resistance

Z066 Generator Excitation (Gasoline)

1 L IG End

Z069 Rear A/C Solenoid Valve

Z070 Driver Seat Belt Warning Switch

1 B-W Switch Signal Output

A008 Front Door Lamp Switch RH

Z072 ECM (Diesel)

E28 L Vehicle Speed Signal E57 W Throttle Sensor 1+

Z073 Front Door Lamp Diode RH

1 R-W Diode +

2 W-L Diode -

Z077 Acceleration Sensor

Z074 Generator B+

Z078 Engine Oil Pressure Sitch

Z076 Downstream Oxygen Sensor

Z101 to Front Wire Harness C

Z103 to Roof Wire Harness 1A

Z102 to Front Wire Harness D

Z105 to Front Wire Harness A

Z106 to Roof Wire Harness 1B

11 Br

12 G-Y

Z107 to Battery Wire Harness B

Z108 to Engine Wire Harness A

Z109 to Rear Heater Wire Harness

Z111 to Engine Wire Harness 1

Z110 to Rear Bumper Transition Wire

Z112 to Engine Wire Harness 2

Z113 to Data Link Connector

WIRING(RHD) - WIRE HARNESS & CONNECTOR LOCATION VIEWS

V018

V027

V019

V020

V028

V029

V021

V030

V031

V023

V032

Vacuum Warning Switch

V024

V033

V025

V034

V026

to Main Wire Harness A

to Front Door LH Wire Harness C

to Main Wire Harness C

to Front Door RH Wire Harness A

to Main Wire Harness D

tto Front Door RH Wire Harness B

to Front Door LH Wire Harness A

to Front Door RH Wire Harness C

to Front Door LH Wire Harness B

to Front Bumper Wire Harness

V206

V205

D007

D010

D008

D011

D009

Window Control Switch LH

H006

H009

H007

H010

H008

H011

Z - MAIN WIRE HARNESS(CHASSIS & FRAME SECTION)

Z Main Wire Harness - Connector

Z049

Z064

Z050

Z065

Z066

Z054

Preheating Relay Coil(Diesel)

Z069

Z058

Z059

Z078

Z Main Wire Harness - Inline

to Battery Wire Harness B(Diesel)

to Engine Wire Harness A

to Engine Wire Harness 1(Gasoline)

Z046

Z047

Z052

Z053

Z055

Z057

Z060

Z061

Front Left Door Lamp Switch

Left Side Sliding Door Lock Assy

Diesel Filter Heater

Rear Wheel Speed Sensor RH

Rear Wheel Speed Sensor LH

Z062

ABS ECU

Z067

Z071 Front Door Lamp Switch RH

Z112 to Engine Wire Harness 2(Gasoline) Z110 to Rear Bumper Transition Wire Harness

Z Main Wire Harness - Ground

E101 to Main Wire Harness 1 E102 to Main Wire Harness 2

71-Wiring.fm

E038

E039

E040

E041

E042

E043

E044

E045

Inlet Metering Valve

Coolant Temperature Sensor

Water in Fuel Sensor

Oil Pressure Switch

CAN Datalink

Accuumulator Pressure Sensor

Ambient Air Pressure Sensor

E047

E048

E053

E054

E055

E056

CAN Resistor

to Main Wire Harness A (Diesel)

Z - MAIN WIRE HARNESS(INSTRUMENT PANEL SECTION)

Z006

Z008

Z009

Z010

Z015

Z017

Z023

Z033

Z034

Z036

Turn Signal Lamp Diode LH

Z038

Z101 to Front Wire Harness C Z102 to Front Wire Harness D

Z201 Instrument Panel Power Ground Z204 Radio/Data Link Connector Ground

to Main Wire Harness

Z001

Z022

Z024

Z004

Z025

Z005

Left Side Sliding Door Lamp Diode

Z026

Z007

Z027

Z011

Z028

Z012

Z029

Z013

Z014

Z018

Z019

Z020

Z021

Z030

Z031

Z032

Z037

Z039

Z040

Z041

Z042

Z044

Z045

Restraint control module(RCM)

Z206

P001

P002

Rear Heater Solenoid Valve

Rear Heater Motor

F008

Rear Evaporator Module

F012

F009

F013

F010

Central Dome light

F014

Sliding Door Ajar Switch LH

F011

to Main Wire Harness B

G004 Rear Combination Lamp RH G005 Rear Speaker RH

Q101 to Rear Bumper Wire Harness Q102 to Main Wire Harness

HORN ................................................................................................. 81-1

PROBLEM SYMPTOMS TABLE.................................................. 81-1

COMPONENTS ........................................................................... 81-2

REPLACEMENT .......................................................................... 81-3

MULTI-MEDIA AND AIR-CONDITON CONTROLER ASSY ............. 81-4

COMPONENTS ........................................................................... 81-4

REPLACEMENT .......................................................................... 81-5

REVERSE RADAR............................................................................. 81-7

PROBLEM SYMPTOMS TABLE.................................................. 81-7

COMPONENTS ........................................................................... 81-8

REPLACEMENT .......................................................................... 81-9

ASTERN IMAGE .............................................................................. 81-11

REPLACEMENT ........................................................................ 81-11

81

COMMUNICATION SYSTEM - HORN

81-1

1. Horn (Damaged)

2. Horn switch (Damaged)

3. Harness (Damaged) -

1. Horn switch (Damaged)

Chapter 51 steering column - combination

switch assy, replacement

2. Harness (Damaged) -

3. Horn (Damaged) Chapter 81 communication system - horn,

4. Center Door Lock Controller

81-2

1 Alt Horn

2 Bass Horn

5 Horn Transition Bracket Assy2

3 Horn Transition Bracket Assy1

81-3

1. REMOVE FRONT BUMPER. (Refer to “Chapter 88 exterior and interior trim - front bumper,

replacememt”)

2. REMOVE HORN.

(a) Disconnect the horn connector.

Remove the horn retaining bolt.

Remove the horn.

3. INSTALL HORN.

(a) Tighten the horn retaining bolt.

Connect the horn connector.

4. INSTALL FRONT BUMPER. (Refer to “Chapter 88 exterior and interior trim - front bumper,

5. CHECK HORN OPERATION AFTER INSTALLATION.

Check horn volume and quality is normal or not.

MULTI-MEDIA AND AIR-CONDITON CONTROLER ASSY

Multi-Media And Air-Conditon controler

5 Flat Washer

3 Screw

COMMUNICATION SYSTEM - MULTI-MEDIA AND AIR-CONDITON CONTROLER ASSY

81-5

1. REMOVE MULTI-MEDIA AND AIR-CONDITION CON-

TROLER ASSY.

(a) Pry-out the edge of multi-media and air-condition controler

assy with a screwdriver, and then put out.

Dip a cloth into screwdriver to prevent damage to exterior

frame and panel.

Loosen 4 multi-media and air-conditon controler retaining

Disconnect 4 connectors.

Remove multi-media and air-conditon controler assy.

2. INSTALL MULTI-MEDIA AND AIR-CONDITION ASSY.

(a) Connect 4 connectors.

81-6

Tighten 4 retaining screws.

Install exterior frame of multi-media and air-condition

controler assy.

3. CHECK MULTI-MEDIA AND AIR-CONDITION CONTROLER ASSY OPERATION AFTER INSTAL-

LATION.

(a) Display resolution for 800X480.

(b) Multi-media and air-condition controler assy button work normal.

REVERSE RADAR

COMMUNICATION SYSTEM - REVERSE RADAR

81-7

1. Buzzer (Damaged)

Chapter 81 communication system -

reverse radar, replacement

There is no chime within

specified distance

Chime sounds when the

vehicle

is out of specified distance

2. Harness between sensor and

controller (Damaged)

3. Controller (Damaged)

1. Sensor (Incorrect installation)

2. Sensor (Damaged)

81-8

1 Reverse Radar Sensor Assy

2 Reverse Radar Sensor Assy

3 Reverse Radar Controller Assy

81-9

REVERSE RADAR SENSOR ASSY

1. REMOVE REAR BUMPER. (Refer to “Chapter 88 exterior and interior trim - rear bumper, replacement”)

2. REMOVE REVERSE RADAR SENSOR ASSY.

(a) Disconnect the reverse radar sensor connector.

(b) Separate both side of the reverse radar externa bush,

release the reverse radar from the inside of the rear

bumper.

• Do not damage the painted surface of rear bumper.

• Do not damage the reverse radar externa bush.

3. INSTALL REVERSE RADAR SENSOR ASSY.

(a) Position the reverse radar externa bush assy.

Position the reverse radar sensor assy.

81-10

Connect the reverse radar sensor connector.

4. INSTALL REAR BUMPER. (Refer to “Chapter 88 exterior and interior trim - rear bumper, replacement”)

81-11

REVERSE RADAR CONTROL UNIT

1. REMOVE GLOVE BOX.(Refer to “Chapter 83 Instrument Panel - glove box, replacememt”)

2. REMOVE REVERSE RADAR CONTROL UNIT.

(a) Disconnect the reverse radar control unit connector.

Loosen reverse radar control unit screws.

Remove reverse radar control unit.

3. INSTALL REVERSE RADAR CONTROL UNIT.

(a) Tighten reverse radar control unit screws.

Connect the reverse radar control unit connector.

4. INSTALL GLOVE BOX.(Refer to “Chapter 83 Instrument Panel - glove box, replacememt”)

81-12

COMMUNICATION SYSTEM - ASTERN IMAGE

ASTERN IMAGE

1. REMOVE REAR HATCH UPPER GUARD BOARD.(Refer to “Chapter 88 exterior and interior trim

- vehicle door inner guard board, replacememt”)

2. REMOVE ASTERN IMAGE.

(a) Loosen 4 rear hatch outside handle retaining screws.

Pry-out both side buckle of the outside handle.

• Be carefull not to damage body paint.

• Be carefull not to damage rear hatch outside handle.

Disconnect the astern image connector.

Loosen 2 astern image retaining screws.

Remove astern image.

81-13

3. INSTALL ASTERN IMAGE

(a) Position the astern image and tighten 2 retaining screws.

Connect astern image connector.

Position the rear hatch outside handle and then retaining

both side buckle.

Tighten 4 retaining screws and install rear hatch outside

handle.

4. INSTALL REAR HATCH UPPER GUARD BOARD.(Refer to “Chapter 88 exterior and interior trim

WINDSHIELDS, MIRRORS & GLASS

WINDOW GLASS............................................................................... 82-1

COMPONENTS ........................................................................... 82-1

POWER WINDOW.............................................................................. 82-2

INSPECTION ............................................................................... 82-2

REPLACEMENT .......................................................................... 82-3

WINDSHIELD ..................................................................................... 82-7

REPLACEMENT .......................................................................... 82-7

REAR WINDOW GLASS.................................................................. 82-12

REPLACEMENT ........................................................................ 82-12

SIDE WINDOW GLASS ................................................................... 82-15

REPLACEMENT ........................................................................ 82-15

OUTSIDE MIRROR .......................................................................... 82-17

REPLACEMENT ........................................................................ 82-17

82

WINDSHIELD/WINDOWGLASS/REAR

VIEW MIRROR -

WINDOW GLASS

WINDSHIELD/WINDOWGLASS/REAR VIEW MIRROR

1 Windshield

2 Rear Window Glass

3 Power Window LH

4 Front Glass LH

5 Middle Glass LH

6 Rear Glass LH

7 Power Window RH

8 Slip Door Glass

9 Middle Glass RH

10 Rear Glass RH

82-1

82-2

POWER WINDOW

Inspect the RH side by the same procedures as the LH side.

1. CHECK POWER WINDOW LIFT FOR DEFORMATION.

(a) If there is any deformation, replace it with a new one.

2. CHECK ROLLER FOR WEAR AND DEFORMATION.

(a) Check roller for wear and deformation.

(b) If there are any wear and deformation, replace the power window lift with a new one.

82-3

Replace the RH side by the same procedures as the LH side

2. REMOVE FRONT DOOR CONTROLLER COVER.

(a) Remove 2 retaining screws of the front door controller

(b) Using a screwdriver, pry up the front door controller

Be careful not to damager interior trim.

Disconnect front door controller connector LH.

3. REMOVE FRONT DOOR LOCK INNER HANDLE

Remove the retaining screw.

82-4

4. REMOVE FRONT DOOR INNER GUARD PLATE ASSY

Using a screwdriver, pry the front door inner triangle

plate LH.

Be careful, not to damager interior trim.

5. REMOVE FRONT DOOR INNER GUARD PLATE.

(a) Using a screwdriver, pry the front door inner guard plate

6. REMOVE FRONT POWER WINDOW LIFT LH.

(a) Loosen retaining screw, remove inner guard.

(b) Disconnect the connector of the front door lock LH.

Connect front door controller connector, lower the glass

to a proper position.

The position you can see 2 window glass motor retaining

Loosen 2 retaining bolts of the power window LH.

Carefully take out the glass.

82-5

Turn the ignition switch OFF and disconnect the front

door controller connectors

Remove retaining bolts of the front power window lift LH.

Disconnect front power window lift connector.

Take out the power window lift assy.

7. INSTALL FRONT POWER WINDOW LIFT LH ASSY.

(a) Position the front power window lift LH assy.

(b) Tighten the retaining screw of the front power window lift

LH assy.

Torque: 6.5 ~ 8.5 N·m

Position the power window glass carefully.

Tighten 2 retaining screws of power window LH.

Install front door inner guard LH.

82-6

8. INSTALL FRONT DOOR INNER GUARD PLATE ASSY.

(a) Install front door inner guard plate assy.

Always use new clips when installing the guard plate

9. INSTALL FRONT DOOR INNER TRIANGLE PLATE

Install front door inner triangle plate LH.

10. INSTALL FRONT DOOR LOCK INNER HANDLE ASSY

Install the retaining screw.

11. INSTALL FRONT DOOR CONTROLLER COVER LH.

Connect connectors.

Position the front door controller cover properly.

Install 2 retaining screws of the front door conreoller LH.

82-7

1. REMOVE ENGINE HOOD. (Refer to “Chapter 87 engine hood and doors - engine hood, replacement”)

2. REMOVE FRONT WIPER ARM ASSY. (Refer to “Chapter 65 wiper and washer - wiper assy,

3. REMOVE WINDSHIELD LOWER TRIM. (Refer to “Chapter 65 wiper and washer - front wiper link

4. REMOVE REAR VIEW MIRROR ASSY. (Refer to “Chapter 82 windshield - rear view mirror,

5. REMOVE A PILLAR UPPER INNER GUARD BOARD. (Refer to “Chapter 88 exterior and interior

trim - side wall guard board, replacement”)

6. REMOVE FRONT WINDSHIELD.

(a) Using a special tool, remove the windshield moulding.

Mark the windshield and body position as shown in the

illustration.

It is no need to mark if the windshield is not resued.

Insert the piano wire between the body and the glass.

Attach wooden blocks to both ends of the piano wire.

Pull the piano wire around the glass and cut off the sealant.

• To prevent vehicle paint damage, use adhesive tape

on painted surfaces during windshield removal.

• Place a plastic cover between the piano wire and the

instrument panel to prevent the instrument panel

from being scuffed when removing the glass.

82-8

Using 2 suckers, remove the windshield.

Remove the front windshield glass.

• Be carefully not to drop off the windshield.

• Leave as much sealant as possible on the body

when removing the front windshield.

7. CLEAN WINDSHIELD.

(a) Remove the sealant on the windshield with a knife.

Do not damage the windshield.

(b) Clean the windshield outer circle with cleaning solvent.

• Do not touch the glass surface after cleaning.

• Even if you use new windshield, you should also

clean the windshield with cleaning solvent.

8. CLEAN BODY SURFACE.

(a) Remove the rough harden sealant left on the body with a

knife and clean with a rag soaked with cleaning slovent.

• Do not damage the body.

• Even if the entire sealant has been cleared, you

should also clean the body surface.

Cut the sealant with the knife around the glass frame.

Leave 2 mm in thickness of sealant.

Do not completely cut curing sealant without necessary. Do

not damage the surface of the body paint. If the paint is

damaged, brush paint or antirusting paint on the damaged

surface

Clean the windshield primer with the alcohol.

82-9

Apply a layer of primer at the outside of the windshield.

• Do not touch the contact surface by hand after

applying the primer.

• Do not brush body primer on the windshield.

• Do not touch water, dust or rarity on the brushing

82-10

9. INSTALL WINDSHIELD.

(a) Position the windshield preperly.

• Position the windshield properly with sucker as shown in

the illustration.

• Check and ensure the contact surface of the windshield

edge is flat.

• Align the reference marks on the glass and the body.

Reaction type polyurethane black primer with a brush in

a mounting surface of the windshield.

• Do not apply too much primer.

• Dry the primer coat for 5 minutes or more.

• Do not save the opened primer for later use.

• Wipe the excess primer off with a clean rag before it

dries.

gun in a defined area.

• Wipe the excess sealant off with a clean rag before it

(d) Position the windshield preperly.

• Before installation, torn off the paper of the double-sided

adhesive on the windshield.

• Using a sucker, position the glass so that the reference

marks are aligned.Press it in gently along the rim.

• Lightly press the glass front surface for close contact.

• Using a scraper, remove any excess or protruding

• Fasten the glass with rubber tape before the sealant has

hardened.

• Remove the rubber tape after 4 hours later.

• Check that the stoppers are attached to the body

• Check the clearance between the body and glass.

82-11

10. INSPECT FOR LEAKAGE AND REPAIR .

(a) Perform the leakage test after the hardening period.

(b) Seal any leaks with the porper sealant.

11. INSTALL FRONT WIPER ARM ASSY. (Refer to “Chapter 65 wiper and washer - wiper assy,

12. INSTALL WINDSHIELD LOWER TRIM. (Refer to “Chapter 65 wiper and washer - front wiper link

13. INSTALL ENGINE HOOD. (Refer to “Chapter 87 engine hood and doors - engine hood,

14. INSTALL REAR VIEW MIRROR ASSY. (Refer to “Chapter 82 windshield - rear view mirror,

82-12

REAR WINDOW GLASS

1. REMOVE REAR WIPER ARM ASSY. (Refer to “Chapter 88 exterior and interior trim - spoiler

2. REMOVE REAR WINDOW DEFROST WIRING CONNECTOR.

3. REMOVE REAR WINDOW GLASS BY THE SAME PROCEDURES AS FRONT WINDSHIELD.

4. CUT THE SEALANT WITH THE KNIFE AROUND THE GLASS BRACKET. LEAVE 2 MM IN THICKNESS OF

SEALANT.

Do not completely cut curing sealant without necessary. Do not damage the surface of the body paint.

If the paint is damaged, brush paint or antirusting paint on the damaged surface.

5. REMOVE THE ROUGH HARDEN SEALANT LEFT ON THE BODY WITH A KNIFE AND CLEAN WITH A RAG

SOAKED WITH CLEANING SLOVENT.

6. POSITION THE REAR WINDOWSHIEDL, MARK THE REAR

WINDOW AND BODY POSITION AS SHOWN IN THE

ILLUSTRATION.

7. APPLY A LAYER OF PRIMER AT THE INSIDE OF THE

REAR WINDOW GLASS INSERTION STRIP.

• Do not brush body primer on the rear windowglass.

8. APPLY THE SEALANT AROUND THE WINDOW GLASS.

82-13

Apply sealant within 5 minutes after applying the primer.

9. APPLY THE PRIMER ON THE GLASS INSTALLING

SURFACE. AFTER 10 MINUTES INSTALL REAR

WINDOW GLASS.

10. USING SPEICAL TOOLS, INSTALL THE REAR

WINDSHIELD ON THE MOUNTING FRAME.

11. USING A SCRAPER, REMOVE ANY EXCESS OR

PROTRUDING SEALANT.

12. AFTER FOUR HOUR, PERFORM THE TEST FOR REAR

WINDOW WATER LEAKAGE.

82-14

13. FOUND LEAKING, COATED WITH A SEALANT AFTER THE LEAKING PARTS DRY.

• After installing rear window glass, wait one hour or more to let sealant hardened.

• After installing rear window glass, place the vehicle on a flat ground for more than four hours. If

need to run the car this moment, slowly drive the car in eight hours.

• When all the windows are closed, do not close the door furiously.

• After installing rear window glass, do not be over-load in two to three days. (As drive in

irregular, uneven road.)

SIDE WINDOW GLASS

82-15

1. REMOVE SIDE WALL INNER GUARD BOARD. (Refer to “Chapter 88 exterior and interior trim -

side wall inner guard board, replacement”)

2. REMOVE SIDE WINDOW GLASS BY THE SAME PROCEDURES AS WINDSHIELD.

3. CUT THE SEALANT WITH THE KNIFE AROUND THE GLASS FRAME. LEAVE 2mm IN

THICKNESS OF SEALANT.

4. REMOVE THE ROUGH HARDEN SEALANT PORTIONS ON THE BODY WITH A KNIFE AND CLEAN WITH A

RAG SOAKED WITH CLEANING SLOVENT.

5. MARK THE SIDE WINDOW AND BODY POSITION AS

SHOWN IN THE ILLUSTRATION.

6. STICK RUBBER FENDER AROUND THE GLASS TO AVOID SEALANT SPILLED WHEN INSTALLING.

7. INSTALL SIDE WINDOW GLASS TRIM STRIP WITHOUT ANY CLEARENCE.

8. APPLY A LAYER OF PRIMER AT THE OUTSIDE OF THE

SIDE WINDOW GLASS INSERTION STRIP.

applying the primer

9. APPLY THE SEALANT AROUND THE WINDOW GLASS.

82-16

10. APPLY THE PRIMER ON THE SIDE BOARD WIDOW-

GLASS FRAME. AFTER 10 MINUTES INSTALL SIDE

11. USING SPECIAL TOOLS, POSITION THE GLASS SO

THAT THE REFERENCE MARKS ARE ALIGNED.

12. USING A SCRAPER, REMOVE ANY EXCESS OR

13. AFTER FOUR HOURS, PERFORM THE TEST FOR

REAR WINDOW WATER LEAKAGE.

14. FOUND LEAKING, COATED WITH A SEALANT AFTER THE LEAKING PARTS DRY.

• After installing side window glass, wait one hour or more to let sealant hardened.

• After installing side window glass, place the vehicle on a flat ground for more than four hours. If

• After installing side window glass, do not be over-load in two to three days. (As drive in

82-17

1. REMOVE FRONT DOOR INNER GUARD BOARD LH.

(Refer to “Chapter 88 exterior and interior trim -

vehicle door inner guard board, replacement”).

(a) Remove front door inner guard board LH.

2. REMOVE OUTSIDE MIRROR LH.

Disconnect connector.

Loosen 3 retaining nuts.

Remove the outside mirror LH.

3. DISMASSEMBLE OUTSIDE MIRROR LH.

(a) Remove 3 bolts from the mirror base

(b) Remove the mirror body.

82-18

Disconnect the connector of the mirror heating.

Remove the mirror.

• Adjust the outside mirror to limit position, then pry

out the mirror from the back of the outside mirror.

• Be careful when disconnect the connector of the

outside mirror.

Loosen 3 retaining screws of the mirror motor.

Disconnect the connector of the mirror motor.

4. REMOVE THE OUTSIDE MIRROR CONTROLLER.

(a) Loosen 2 front door controller cover.

(b) Remove the front door controller cover.

Disconnect the connector of the front door controller

switch.

82-19

Remove the outside mirror control switch from the bottom

of the controller cover.

5. INSTALL THE OUTSIDE MIRROR CONTROLLER.

(a) Connect the front door controller switch connector.

(b) Install the front door controller switch.

Position the front door controller switch connector.

Tighten 2 retaining screws.

6. ASSEMBLE MIRROR.

(a) Connect the harness of the mirror motor.

Connect the connector of the mirror heating.

Install the outside mirror.

82-20

Tighten 3 bolts from the mirror base.

7. INSTALL OUTSIDE MIRROR ASSY.

Tighten 3 retaining nuts.

8. INSTALL FRONT DOOR INNER GUARD BOARD LH.

9. REMOVE INSIDE REAR VIEW MIRROR.

(a) Remove inside rear view mirror cover.

(b) Extraction the inside rear view mirror from the base.

82-21

10. INSTALL INSIDE REAR VIEW MIRROR.

(a) Install inside rear view mirror.

(b) Install inside rear view mirror cover.

11. REMOVE REAR LOWER VIEW MIRROR.

(a) Use a screwdriver, pry out rear view mirror cover from the

base.

Remove 4 retaining screws from the rear lower view

mirror.

Remove the rear lower view mirror.

12. INSTALL REAR LOWER VIEW MIRROR.

(a) Tighten 4 retaining screws of rear lower view mirror.

Install the rear lower view mirror cover.

INSTRUMENT PANEL

INSTRUMENT CLUSTER .................................................................. 83-1

PRECAUTION.............................................................................. 83-1

COMPONENTS ........................................................................... 83-2

REPLACEMENT .......................................................................... 83-3

DASHBOARD..................................................................................... 83-5

PRECAUTION.............................................................................. 83-5

COMPONENTS ........................................................................... 83-6

REPLACEMENT .......................................................................... 83-7

MIDDLE PLATFORM................................................................. 83-15

REPLACEMENT ........................................................................ 83-15

83

INSTRUMENT PANEL -

83-1

PANEL

(a) Before removing or installing any electrical devices,please disconnect the battery negative cable first

to avoid device damage or personal injury.

(b) Make sure ingition switch is OFF if no specific instructions.

83-2 INSTRUMENT PANEL - INSTRUMENT CLUSTER

1 Instrument Cluster Assy

2 Screw

4 Oil Pressure Switch

5 Coolant Sensor

3 Odometer Sensor

83-3

2. ADJUST STEERING WHEEL TO THE LOWEST POSITION.

3. REMOVE INSTRUMENT CLUSTER COVER ASSY.

(a) Remove 2 instrument cluster cover mounting screws.

(b) Using trim stick, pry out instrument cluster cover from the

dashboard.

disconnect dimming switch connector on the left side of

instrument cluster cover.

Disconnect hazard warning switch connector on the

right side of instrument cluster cover.

Disconnect headlight height adjusting switch connector

on the right side of instrument cluster cover.

Remove instrument cluster cover.

Care not to scratch the dashboard and take instrument

cluster cover out from the right side of steering wheel.

83-4 INSTRUMENT PANEL - INSTRUMENT CLUSTER

4. REMOVE INSTRUMENT CLUSTER ASSY.

Remove 2 mounting bolts at the bottom of instrument

cluster.

Pull instrument cluster out.

Turn instrument cluster over and disconnect 2 instrument

cluster connectors.

Remove instrument cluster through the space between

steering wheel and dashboard.

Take instrument cluster out from the right side of steering

wheel, be careful not to scratch the dashboard and instrument

5. INSTALL INSTRUMENT CLUSTER ASSY.

(a) Connect 2 instrument cluster connectors.

Position instrument cluster assy and fix instrument

cluster into proper place.

Tighten 2 instrument cluster mounting screws.

6. INSTALL INSTRUMENT CLUSTER COVER ASSY.

(a) Connect connectors at either side of instrument cluster

(b) Place instrument cluster cover inside and fix it into place.

DASHBOARD

83-5

1. WHEN REMOVING INSTRUMENT PANEL, THE MEMORY OF THE AUDIO SYSTEM WILL BE

LOST.

It is recommended that reset the audio systems when work is finished.

(a) Before removing or installing any electrical devices, please disconnect the battery negative cable to

83-6 INSTRUMENT PANEL - DASHBOARD

1 Dashboard Body Assy

3 Center Lower Panel Bracket

4 Screw

5 Instrument Cluster Cover

6 Tapping Screw

7 Center Panel Assy

8 Center Control Panel

9 Steering Column Lower Cover

10 Parking Brake Shield Assy

11 Glove Box Assy

12 Left Defost Vent Assy

13 Right Defost Vent Assy

14 Right Outlet Vent Panel Assy

15 Center Lower Panel Assy

16 Screw base

83-7

1. PLACE TEH VEHICLE ON LEVEL GROUND OR LIFTER AND FACE TIRES STRAIGHT AHEAD.

When disconnecting or connecting the battery cables, please turn off the ignition switch first and

lighting switch and loosen the cable nut completely. Do not pry up the cable when peforming these

operations。

4. REMOVE STEERING WHEEL ASSY. (Refer to “Chapter 51 steering column - steering wheel assy,

5. REMOVE STEERING COLUMN LOWER COVER.

6. REMOVE COMBINATION SWITCH UPPER AND LOWER COVER.

8. REMOVE INSTRUMENT CLUSTER ASSY. (Refer to “Chapter 83 instrument panel - instrument

cluster , replacement”)

9. REMOVE MULTI-MEDIA AND A/C CONTROLLER. (Refer to “Chapter 61 heater and air conditioner

- multi-media and A/C controller assy , replacement”)

10. REMOVE CENTER SWITCH PANEL.

(a) Remove 4 center switch panel mounting screws.

(b) Pull center switch panel out.

Disconnect 4 electrical connectors from the rear.

Remove centre switch panel.

11. REMOVE CIGARETTE LIGHTER.

(a) Disconnect connector from the back of cigarette lighter.

(b) Remove cigarette lighter. (Refer to “Chapter 66 audio

system - electric device accessories , replacement”)

83-8 INSTRUMENT PANEL - DASHBOARD

12. REMOVE ASHTRAY.

(a) Depress release latch, pull ashtray out.

13. REMOVE TRANSMISSION SHIFTING CONTROL LEVER BALL ASSY AND DUST COVER. (Refer

to “Chapter 41 transmission - transmission operation mechanism assy, replacement”)

14. REMOVE BOTH SIDE DEFOST VENT.

(a) Using trim stick, pry up left defost vent assy.

(b) The procedure to remove right defost vent assy is similar

to the left side.

15. REMOVE OUTLET VENT PANEL.

(a) Using trim stick, along the edge pry outlet vent panel out.

(b) Remove outlet vent panel.

16. REMOVE GLOVE BOX ASSY.

83-9

17. REMOVE CENTRE LOWER PANEL ASSY.

(a) Remove 5 mounting screws on both and top side of the

centre lower panel.

18. REMOVE PARKING BRAKE SHIELD.

(a) Using trim stick, pry up parking brake shield along its

19. REMOVE CENTRE PANEL ASSY.

(a) Remove 3 centre panel mounting screws.

(b) Using trim stick, pry up centre panel.

20. REMOVE 12V POWER OUTLET SOCKET.

(a) Disconnect 12V power outlet connect from the inside of

(b) Remove 12V power outlet socket from dashboard. (Refer

to “Chapter 66 audio system - electric device accessories

, replacement”)

21. REMOVE DIAGNOSTIC SOCKET.

(a) Loosen 2 diagnostic socket mounting screws.

(b) Remove diagnostic socket from the dashboard.

83-10 INSTRUMENT PANEL - DASHBOARD

22. REMOVE ENGINE HOOD AND FUEL FILLER DOOR

HANDLE.

Remove engine hood handle from dashboard.

Remove fuel filler door handle from dashboard.

23. REMOVE BOTH A-PILLAR HANDLES AND A PILLAR UPPER GUARD BOARDS. (Refer to

“Chapter 88 exterior and interior - roof panel, replacement”)

24. REMOVE DASHBOARD ASSY.

Remove 11 mounting bolts/screws as shown.

Remove instrument cluster carefully.

Because there are many harnesses in the instrument panel,

when removing the instrument panel, be careful not to hook

the harness, so as not to damage the harness.

25. INSTALL DASHBOARD ASSY.

83-11

Position the dashboard body properly.

Put the inside harness in order and wait for using when

installing dashboard accessories.

Tighten 11 mounting bolts/screws.

26. INSTALL CENTRE PANEL ASSY.

(a) Place centre panel into dashboard properly.

(b) Tighten 3 mounting screws.

27. INSTALL OUTLET VENT PANEL ASSY.

(a) Position outlet vent panel and press outlet vent panel

evenly into place.

28. INSTALL INSTRUMENT CLUSTER AND COVER. (Refer to “Chapter 83 instrument panel -

instrument cluster , replacement”)

29. INSTALL TRANSMISSION SHIFTING CONTROL LEVER BALL ASSY AND DUST COVER. (Refer

83-12 INSTRUMENT PANEL - DASHBOARD

30. INSTALL CIGARETTE LIGTHTER.

(a) Install cigarette lighter, and connect the connector to the

back of cigarette lighter.

31. INSTALL CENTRE SWITCH PANEL.

(a) Connect centre switch panel connector.

Tighten 4 centre switch panel mounting screws.

32. INSTALL MULTI-MEDIA AND A/C CONTROLLER ASSY. (Refer to “Chapter 61 heater and air conditioner

- multi-media and A/C controller assy, replacement”)

33. INSTALL 12V POWER OUTLET SOCKET.

(a) Install 12V power outlet socket. (Refer to “Chapter 66

audio system - electric device accessories , replacement”)

(b) Connect 12V power outlet socket connector.

83-13

34. INSTALL GLOVE BOX ASSY.

35. INSTALL PARKING BRAKE SHIELD ASSY.

(a) Position parking brake shield, then press it on dashboard

into place.

36. INSTALL CENTRE LOWER PANEL ASSY.

(a) Position centre lower panel assy, then tighten 5 mounting

screws on both and top side.

37. INSTALL ENGINE HOOD AND FUEL FILLER DOOR

(a) Install engine hood and fuel filler door handle into place.

(b) Pull engine hood and fuel filler door handle to confirm it is

working properly.

38. INSTALL BOTH A-PILLAR HANDLES AND A PILLAR UPPER GUARD BOARDS. (Refer to

39. REMOVE COMBINATION SWITCH ASSY. (Refer to “Chapter 51 steering column - combination

40. REMOVE STEERING WHEEL ASSY. (Refer to “Chapter 51 steering column - steering wheel assy,

41. REMOVE STEERING COLUMN LOWER COVER. (Refer to “Chapter 51 steering column - steering

column assy, overhaul”)

42. CONNECT BATTERY NEGATIVE CABEL.

83-14 INSTRUMENT PANEL - DASHBOARD

43. CHECK AFTER INSTALLATION.

(a) Check electrical switches on instrument panel are functional and combination switch works normally.

83-15

MIDDLE PLATFORM

1. REMOVE MIDDLE PLATFORM ASSY.

(a) Open centre glove box lid, remove rubber pad NO.1, and

then remove 2 internal retaining bolts.

(b) Remove cup holder rubber pad and then remove 2

internal retaining bolts.

remove 2 interal retaining bolts.

(d) Remove middle platform assy.

2. INSTALL MIDDLE PLATFORM ASSY.

(a) Position the middle platform assy properly.

(b) Tighten all bolts inside glove box and cup holder.

(d) Close glove box lid.

SEATS

SEATS................................................................................................ 84-1

PRECAUTION.............................................................................. 84-1

DRIVER / ASSISTANT DRIVER SEAT.............................................. 84-2

COMPONENTS ........................................................................... 84-2

ADJUSTMENT............................................................................. 84-3

REMOVAL & INSTALLATION AND

DISASSEMBLY & ASSEMLBY.................................................... 84-7

PASSENGER SEAT......................................................................... 84-15

REPLACEMENT ........................................................................ 84-15

PASSENGER SEAT......................................................................... 84-20

COMPONENTS ......................................................................... 84-20

84

SEAT - SEAT

84-1

• Never adjust the seat when vehicle is moving.

• After adjusting the seat position fore-and-aft, be sure to attempt to slide the seat with track

handle released and make sure the seat is locked completely.

• After adjusting the angle of backrest, be sure to attempt to recline the backrest backward and

make sure the backrest is locked completely.

• Never move the vehicle before all pasengers sitting down properly.

• When vehicle is moving, make sure the backrest is locked completely. Be sure to wear seat belt

correctly and lean the backrest. Never sit on a folding seat or in the trunk.

• Do not stand and ambulate when vehicle is moving.

• Never place objects under the seat. Otherwise it will affect the performance of seat adjuster,

even cause the seat slide unexpectedly.

84-2

SEAT - DRIVER / ASSISTANT DRIVER SEAT

DRIVER / ASSISTANT DRIVER SEAT

1 Driver Seat Assy 2 Assistant Driver Seat Assy

84-3

1. PRECAUTION. (Refer to “Chapter 84 seat - seat, precaution”)

2. PRECAUTION ON DRIVER SEAT ADJUSTMENT.

Slide the driver seat backward as much as possible on the premise that the driver can push the pedal

comfortably.

If necessary, adjust the angle of driver seat backrest to keep the distance between steering wheel and

your chest above 250 mm.

Adjust the steering wheel towards your chest, instead of the head or neck. (Refer to “Chapter 51

steering column - steering wheel assy, adjustment”)

3. ADJUST HEADREST HEIGHT.

(a) Press the lock button and hold it.

Move the headrest up or down to the comfortable position.

Release the lock button.

84-4

Attempt to move the headrest up and down to make sure

the headrest is locked completely.

If hear a “click”, the headrest is locked completely.

4. ADJUST FORE AND AFTER POSITION.

Pull the handle up and hold it.

Slide the seat forward or rearward to the comfortable position.

Release the handle.

Attempt to slide the seat forward and rearward to make

sure the seat is locked completely.

If hear a “click”, the seat is locked completely.

84-5

5. ADJUST BACKREST RECLINING.

(a) Pull the reclining adjuster handle up.

Recline the backrest forward or rearward to the comfortable

84-6

Release the reclining adjuster handle.

Attempt to recline the backrest forward and rearward to

The backrest can not be moved if it locked completely.

84-7

REMOVAL & INSTALLATION AND DISASSEMBLY & ASSEMLBY

1. DISCONNECT BATTERY NEGATIVE CABLE. (Refer to “Chapter 20 starting and charging- battery,

2. REMOVE DRIVER SEAT ASSY.

(a) Slide the driver seat assy to the back end.

Loosen the 2 bolts.

Slide the driver seat assy to the front end.

• Turn over the driver seat assy backward carefully and

• Do not drag the electric lock catch wire harness.

• Do not move the tracks to prevent malposition.

84-8

Disconnect the electric lock catch wire harness connector.

Using a screwdriver, pry the electric lock catch wire harness

connector from the driver seat.

If the connector is broken, replace the electric lock catch

assy. (Refer to “Chapter 63 seat belt - lock catch assy,

Remove the driver seat assy.

3. REMOVE ASSISTANT DRIVER SEAT ASSY.

Care must be taken because the seat assy is quite heavy.

• Do not score the surfaces of parts around.

• Do not move the tracks when storing to prevent malposition.

• Remove the assistant driver seat assy by the same procedures as the driver seat assy.

• Skip step (e) and (f).

4. DISASSEMBLE DRIVER SEAT ASSY.

(a) Pull out the reclining adjuster handle cover.

84-9

Loosen the screw.

Remove the reclining adjuster trim cover handle side by

the sequence shown in the illustration.

• Move the trim cover backward first.

• Then pull the trim cover outward.

• Move forward and remove the trim cover.

• Then pull outward and remove the trim cover.

84-10

Loosen the bolt attaching the electric lock catch to the

driver seat reclining adjuster.

hole between cushion pad and reclining adjuster.

Be careful not to damage the electric lock catch wire harness

Turn the clips.

(j) Turn the cushion pad, remove the clips.

(k) Remove the cushion pad.

Replace the clips with a new one.

Loosen 4 retaining screws.

Remove the driver seat bottom plate.

84-11

Loosen 4 retaining bolts.

Remove the rail block.

5. DISASSEMBLE THE ASSISTANT DRIVER SEAT ASSY.

• Disassemble the assistant driver seat assy by the same procedures as the driver seat assy.

• Step (g), remove lock catch assy.

• Skip step (h).

6. ASSEMBLE DRIVER SEAT ASSY.

(a) Position the rail block.

(b) Tighten 4 retaining bolts.

Install driver seat bottom plate.

Position the cushion pad properly.

Install clips.

84-12

Put the electric lock catch wire harness connector through the

Install the electric lock catch side reclining adjuster trim

cover and screw.

side by the sequence shown in the illustration.

84-13

Install the reclining adjuster handle cover.

7. ASSEMBLE ASSISTANT DRIVER SEAT ASSY.

• Assemble the assistant driver seat assy by the same procedures as the driver seat assy.

• Position the lock catch assy properly in step (k).

• Skip step (j).

8. INSTALL DRIVER SEAT ASSY.

(a) Position the driver seat assy.

Care must be taken because the driver seat assy is quite heavy.

Install the electric lock catch wire harness connector to

mounting hole on the driver seat.

Connect the electric lock catch wire harness connector.

• Do not score surfaces of parts around

If the connector is broken, replace with a new one. (Refer to

“Chapter 63 seat belt - lock catch assy, replacement”)

84-14

Tighten 2 bolts.

• Make sure the driver seat assy is at the back end.

• Move the seat assy carefully and slowly then position it on

the top of the base welding assy.

• Do not move the sliding tracks to prevent malposition.

9. INSTALL ASSISTANT DRIVER SEAT ASSY.

• Install the assistant driver seat assy by the same procedures as the driver seat assy.

• Skip step (b) and (c).

10. CONNECT BATTERY NEGATIVE CABLE. (Refer to “Chapter 20 starting and charging - battery,

11. ADJUST DRIVER / ASSISTANT DRIVER SEAT ASSY. (Refer to “Chapter 84 seat- driver / assistant

driver seat, adjustment”)

SEAT - PASSENGER SEAT

84-15

PASSENGER SEAT

1. REMOVE PASSENGER SEAT ASSY.

(a) Loosen 4 seat trim cover clips.

(b) Remove the side trim cover.

Remove 4 retaining bolts and 2 nuts.

Remove passenger seat assy LH.

• Do not lost screw washer.

• Care must be taken because the seat assy is quite

heavy.

2. REMOVE THE THIRD/FOURTH/FIFTH ROW PASSENGER SEAT ASSY LH.

Remove the third/fourth/fifth row passenger seat assy by the same procedures as the second row passenger

seat assy.

3. REMOVE THE PASSENGER SEAT ASSY RH.

(a) Loosen 4 seat trim cover clasps.

(b) Remove the seat trim cover.

Remove 3 retaining bolts and 1 nut.

Remove passenger seat assy RH.

84-16

4. REMOVE THE THIRD/FOURTH/FIFTH ROW PASSENGER SEAT ASSY RH.

5. DISASSEMBLE THE PASSENGER SEAT ASSY RH.

(a) Pry up the clasp from the each side of the seat.

Pry up the clasp from the right side first, otherwise the seat

will be damaged.

(b) Remove the cushion.

Remove reclining adjuster.

Remove reclining coil spring device.

Loosen 2 handle retaining screws.

Remove the handle.

Remove the seat rear trim cover.

84-17

Press the lock button and remove the headrest.

Make the zipper open.

Remove the backrest.

6. ASSEMBLE THE PASSENGER SEAT ASSY RH.

(a) Position the seat backrest.

(b) Make the zipper close.

Install the headrest.

Position the seat rear trim cover.

Tighten 2 handle retaining screws.

Install the handle.

84-18

Tighten 4 retaining bolts.

Install reclining coil spring device.

Install reclining adjuster.

Position the cushion.

Install seat retaining clips.

Install passenger seat assy RH.

7. DISASSEMBLE THE PASSENGER SEAT ASSY LH.

Disassemble the passenger seat assy LH by the same procedures as the passenger seat assy RH.

8. INSTALL PASSENGER SEAT ASSY LH.

Tighten 4 retaining bolts and 2 nuts.

84-19

Position the seat trim cover.

Install 4 seat trim cover retaining clips.

9. INSTALL THE THIRD/FOURTH/FIFTH ROW PASSENGER SEAT ASSY LH.

Install the third/fourth/fifth row passenger seat assy LH by the same procedures as the second row

passenger seat assy LH.

10. INSTALL PASSENGER SEAT ASSY LH.

(a) Tighten 3 retaining bolts and 1 nuts.

Install the seat trim cover.

11. INSTALL THE THIRD/FOURTH/FIFTH ROW PASSENGER SEAT ASSY RH

Install the third/fourth/fifth row passenger seat assy RH by the same procedures as the second row

passenger seat assy RH.

84-20

PASSEBGER SEAT LH

1 Seat Assy

3 Clips

2 Seat Trim Cover

84-21

84-22

PASSEBGER SEAT RH

1 Seat Assy1 2 Seat Assy2

84-23

2 Clips

3 Seat trim Cover

FRONT DOOR LOCKS ...................................................................... 85-1

COMPONENTS ........................................................................... 85-1

REPLACEMENT .......................................................................... 85-2

SLIDING DOOR LOCKS.................................................................... 85-7

COMPONENTS ........................................................................... 85-7

REPLACEMENT .......................................................................... 85-8

REAR HATCH LOCK....................................................................... 85-12

COMPONENTS ......................................................................... 85-12

REPLACEMENT ........................................................................ 85-13

ENGINE HOOD LOCK ..................................................................... 85-17

COMPONENTS ......................................................................... 85-17

REPLACEMENT ........................................................................ 85-18

ALARM CONTROLLER................................................................... 85-19

REPLACEMENT ........................................................................ 85-19

85

FRONT DOOR LOCKS

DOOR LOCKS - FRONT DOOR LOCKS

85-1

1 Outside Handle Assy

2 Lock Catch Assy

3 Inner Handle Assy

4 Lock Block

85-2

• When disconnecting or connecting the battery cable, first turn off the ignition switch and

lighting switch and completely loosen the cable nut. Do not pry up the cable when peforming

these operation.

• For the vehicle equipped with the power door locks, before disconnecting the battery negative

cable, do not leave the key in the vehicle to avoid the door being locked.

3. REMOVE FRONT DOOR CONTROLLER COVER LH.

(a) Remove 2 retaining screws of the front door conreoller

(b) Using a screwdriver, pry up the front door controller cover.

Disconnect 2 connectors.

4. REMOVE FRONT DOOR LOCK INNER HANDLE ASSY LH.

(a) Remove 1 retaining screw.

85-3

5. REMOVE FRONT DOOR INNER GUARD PLATE ASSY

Using a screwdriver, pry out the front door inner triangle

Using a screwdriver, pry out the front door inner guard

plate assy LH.

6. REMOVE FRONT DOOR LOCK LH.

7. REMOVE FRONT POWER WINDOW LIFT LH. (Refer to “Chapter 82 windshied/window glass/

outside mirror , replacement”)

8. REMOVE FRONT DOOR LOCK LH.

(a) Disconnect the front door lock actuator LH connector.

Remove retaining screws cover from the front door outer

handle LH.

85-4

Remove retaining screws from the front door outer

handle LH

Remove front door outer handle carefully.

Remove 1 retaining screw front door lock body LH

Remove front door lock cylinder.

Disconnect the front door lock connecting rods from the

front door lock body LH.

Do not damage the connecting rods plastic clamp.

Remove 3 retaining screws from the front door actuator

Remove the front door actuator LH.

9. INSTALL FRONT DOOR LOCK LH.

(a) Install front power window lift LH. (Refer to “Chapter 82

windshied/window glass/outside mirror , replacement”)

(b) Position the front door lock actuator properly.

Install front door outer handle assy.

Connect the front door lock connecting rods from the

85-5

Connect the front door lock actuator LH connectors.

10. INSTALL FRONT DOOR INNER GUARD PLATE ASSY

Slap it by hand until all clips lock into position.

Always use the new clips when installing the guard plate.

Position the front door inner triangle plate LH properly

and slap it by hand until all clips lock into position.

11. INSTALL FRONT DOOR LOCK INNER HANDLE ASSY

Install 1 retaining screw.

12. INSTALL FRONT DOOR CONTROLLER COVER LH.

(a) Connect 2 connectors.

85-6

14. INSPECT FRONT DOOR LOCK.

• For the vehicle equipped with the power door locks, when inspecting front door LH lock and

unlock, both the slidind door and the front door RH should be activated simultaneously.

SLIDING DOOR LOCKS

DOOR LOCKS - SLIDING DOOR LOCKS

85-7

1 Screw

Sliding Door Electric Control Concave

Limiting Device

3 Lower Damping Block

4 Sliding Door Welding Assy

5 Sliding Door Concave Limiting Device

6 Sliding Door Convex Limiting Device

7 Sliding Door Glass Assy

8 Sliding Door Lock Assy

9 Sliding Door Lower Guard Board

10 Sliding Door Middle Guard Board

11 Sliding Door Upper Guard Board

Sliding Door Electric Control Convex

85-8

For the vehicle equipped with the power door locks, before disconnecting the battery negative cable,

do not leave the key in the vehicle to avoid the door being locked.

3. REMOVE SLIDING DOOR LOWER GUARD BOARD ASSY

Remove 2 sliding door inner handle retaining screws.

Remove the sliding door lower guard board assy.

Remove the water-proof film.

Disconnect the sliding door inner handle connecting rod.

Loosen the sliding door inner handle screws.

Remove sliding door inner handle.

85-9

4. REMOVE SLIDING DOOR LOCK ACTUATOR.

(a) Disconnect the sliding door lock actuator connector.

Disconnect the connecting rods from the sliding door

lock actuator.

Remove 5 retaining bolts from the sliding door lock

actuator.

Remove the sliding door lock actuator.

5. REMOVE SLIDING DOOR LOCK ASSY.

(a) Disconnect the sliding door lock connecting rods.

Loosen 3 retaining screws from the sliding door lock.

Remove the sliding door lock.

85-10

6. INSTALL SLIDING DOOR LOCK.

(a) Position the sliding door lock properly.

(b) Tighten 3 sliding door lock retaining screws.

7. INSTALL SLIDING DOOR LOCK ACTUATOR.

(a) Position the sliding door lock actuator properly.

(b) Tighten 5 sliding door lock actuator retaining bolts.

Connect the sliding door lock actuator connector.

Connect the connecting rods to the sliding door lock actuator.

(e) Connect the connecting rod to the sliding door inner handle .

Install the sliding door inner handle.

85-11

8. INSTALL SLIDING DOOR GUARD BOARD ASSY.

Install the water-proof film.

Install sliding door lower guard board assy.

Tighten the sliding door inner handle screws.

10. INSPECT SLIDING DOOR LOCK/UNLOCK WITH KEY.

85-12

REAR HATCH LOCK

DOOR LOCKS - REAR HATCH LOCK

1 Rear Hatch License Plate Lamp Shield

2 Rear Hatch Upper Gaurd Board

4 Rear Hatch Lock Catch

5 Rear Hatch Lower Gaurd Board

3 Rear Hatch Lock

85-13

2. REMOVE REAR HATCH LOCK ASSY.

(a) Remove 3 rear hatch lock retaining screw.

(b) Remove rear hatch lock assy.

3. REMOVE REAR HATCH LOWER GUARD BOARD ASSY.

(a) Remove rear hatch inner handle retaining screw.

Remove rear hatch lower guard board.

4. REMOVE REAR HATCH LOCK ACTUATOR ASSY.

(a) Disconnect the rear hatch lock actuator connector.

85-14

Disconnect the rear hatch lock actuator connecting rods.

Loosen the rear hatch lock actuator 3 retaining bolts.

Remove the rear hatch lock actuator.

5. REMOVE REAR HATCH LOCK CYLINDER ASSY.

(a) Disconnect the rear hatch lock cylinder connecting rod.

(b) Loosen 2 rear hatch lock cylinder retaining bolts.

6. REMOVE REAR HATCH INNER HANDLE LOCK .

(a) Disonnect the rear hatch inner handle lock connecting

(b) Remove 3 rear hatch inner handle lock retaining screws.

7. INSTALL REAR HATCH INNER HANDLE LOCK .

(a) Install 3 rear hatch inner handle lock retaining screws.

(b) Connect the rear hatch inner handle lock connecting rod.

85-15

8. INSTALL REAR HATCH LOCK CYLINDER ASSY.

(a) Position the rear hatch lock cylinder assy.

(b) Install rear hatch lock cylinder connecting rod.

9. INSTALL REAR HATCH LOCK ACTUATOR ASSY.

(a) Position the rear hatch lock actuator assy properly.

(b) Tighten 3 rear hatch lock actuator retaining bolts.

Connect the rear hatch lock actuator connecting rods.

Connect the rear hatch lock actuator connector.

10. INSTALL REAR HATCH LOWER GUARD BOARD ASSY.

Install the rear hatch lower guard board.

85-16

Install the rear hatch lower inner handle screw.

11. INSTALL REAR HATCH LOCK BLOCK.

(a) Position the rear hatch lock block.

(b) Tighten 3 rear hatch lock block retaining bolts.

12. INSPECT REAR HATCH LOCK.

ENGINE HOOD LOCK

DOOR LOCKS - ENGINE HOOD LOCK

85-17

1 Engine Hood Buffer Block

2 Engine Hood Lock Assy

4 Engine Hood Support Bar

5 Engine Hood Support Bar Clip

3 Engine Hood Assy

85-18

2. REMOVE FRONT GRILLE.(Refer to “Chapter 82 exterior and interior trim front grille , replacement”)

3. REMOVE ENGINE HOOD LOCK ASSY.

(a) Remove 3 retaining bolts from the engine hood lock.

(b) Remove the engine hood lock.

Disconnect the engine hood lock cable.

4. INSTALL ENGINE HOOD LOCK ASSY.

(a) Connect the engine hood lock cable.

Position the engine hood lock properly.

Install 3 retaining bolts to the engine hood lock.

5. INSTALL FRONT GRILLE.(Refer to “Chapter 82 exterior and interior trim front grille , replacement”)

DOOR LOCKS - ALARM CONTROLLER

85-19

ALARM CONTROLLER

2. REMOVE STEERING WHEEL LOWER TRIM COVER.

3. REMOVE ALARM CONTROLLER ASSY.

(a) Disconnect the alarm controller connector.

Loosen 2 alarm controller retaining bolts.

Remove alarm controller.

4. INSTALL ALARM CONTROLLER ASSY.

(a) Tighten 2 alarm controller retaining bolts.

Connect the alarm controller connector.

5. INSTALL STEERING WHEEL LOWER TRIM COVER.

SLIDING ROOF ASSY ....................................................................... 86-1

PROBLEM SYMPTOMS TABLE.................................................. 86-1

COMPONENTS ........................................................................... 86-2

OVERHAUL ................................................................................. 86-3

SLIDING ROOF ASSY

SLIDING ROOF - SLIDING ROOF ASSY

Symptom Suspect Reference

86-1

1. Sliding rail (Insufficient lubrication) Chapter 86 sliding roof - sliding roof assy, overhaul

Abnormal

working

2. Sliding rail (Dusty) Chapter 86 sliding roof - sliding roof assy, overhaul

3. Sliding roof control switch (Failure) Chapter 86 sliding roof - sliding roof assy, overhaul

Sliding roof

assy leakage

4. Sliding roof control switch (Damage) Chapter 86 sliding roof - sliding roof assy, overhaul

1. Sliding roof weatherstrip (Aging) Chapter 86 sliding roof - sliding roof assy, overhaul

2. Sliding roof weatherstrip (Improper

installation)

Chapter 86 sliding roof - sliding roof assy, overhaul

3. Sliding roof assy (Improper installation) Chapter 86 sliding roof - sliding roof assy, overhaul

4. Sliding roof assy (Maladjusted) Chapter 86 sliding roof - sliding roof assy, overhaul

86-2

1 Front Sliding Roof

2 Front Ceiling Insulation Felt

4 Front Sliding Roof Switch Panel

5 Front Sliding Roof Switch

3 Front Ceiling Trim Cover

86-3

2. REMOVE SLIDING ROOF CONTROL SWITCH.

(a) Remove the sliding roof control switch carefully.

Be careful, do not damage the interior.

Disconnect the connector and remove the sliding roof

control switch.

3. REMOVE SLIDING ROOF WEATHERSTRIP.

Remove the sliding roof weatherstrip slowly.

4. REMOVE ROOF GUARD BOARD. (Refer to "Chapter 88 exterior and interior trim - roof guard

board, replacement")

5. REMOVE SLIDING ROOF CONTROL MOTOR.

(a) Disconnect the connector of the sliding roof control

motor.

86-4

Remove 2 bolts and sliding roof control motor.

6. REMOVE SLIDING ROOF CONTROLLER.

(a) Disconnect the connector of the sliding roof controller.

Loosen 2 controller retaining screws.

Remove the sliding roof controller.

7. REMOVE THE SLIDING ROOF ASSY.

(a) Loosen 4 sliding roof visor retaining screws.

(b) Remove sliding roof visor assy.

r

Loosen 12 sliding roof retaining cover retaining screws.

86-5

Raise the sliding roof glass and guide assy gently.

Rotation and remove the sliding roof assy.

8. INSPECT SLIDING RAIL. CLEAN UP AND LUBRICATE THE SLIDING ROOF RAIL IF NECESSARY.

9. INSPECT SLIDING ROOF CONTROL MOTOR.

(a) Check the sliding roof control motor operates smoothly. If it isn’t operating smoothly, replace the sliding

roof control motor with a new part.

10. INSPECT SLIDING ROOF CONTROL SWITCH.

(a) Gently press the ”open” then release the button, the sliding roof should be completely opened.

(b) Gently press the ”close” then release the button, the sliding roof should be completely closed.

(d) Press and hold down the ”close” then the sliding roof will operate untill you release the button.

11. INSTALL SLIDING ROOF ASSY.

(a) Position the sliding roof assy.

(b) Install the sliding roof retaining cover.

Torque:9 ~ 11 N·m

(d) Position the sliding roof visor.

(e) Tighten the sliding roof visor retaining screws.

86-6

12. INSTALL SLIDING ROOF CONTROL MOTOR.

(a) Install the sliding roof control motor and tighten 2 bolts.

Install the connector of the sliding roof control motor.

13. INSTALL SLIDING ROOF CONTROLLER.

(a) Tighten 2 controller retaining screws.

Connect the connector of the sliding roof controller.

14. INSTALL ROOF GUARD BOARD. (Refer to "Chapter 88 exterior and interior trim - roof guard

86-7

15. INSTALL THE SLIDING ROOF WEATHERSTRIP.

The weatherstrip has a direct influence on the body sealing

performance. Inspect the weatherstrip from aging, cracking

and damage before installing them. Replace with new

weatherstrip if necessary.

16. INSTALL THE SLIDING ROOF CONTROL SWITCH.

(a) Connect the connector and install the sliding roof control

18. INSPECT WHETHER SLIDING ROOF CONTROL MOTOR OPERATES SMOOTHLY OR NOT.

19. INSPECT WHETHER SLIDNG ROOF ASSY IS INSTALLED PROPERLY OR NOT.

20. INSPECT FOR LEAKAGE.

(a) Inspect the sliding roof for leakage after operating the sliding roof many times. Readjust the position of

the sliding roof assy if necessary. (Refer to “Chapter 86 sliding roof - sliding roof system, overhaul”)

DOORS & ENGINE HOOD

ENGINE HOOD .................................................................................. 87-1

ADJUSTMENT............................................................................. 87-1

REPLACEMENT .......................................................................... 87-3

FRONT DOOR.................................................................................... 87-4

COMPONENTS ........................................................................... 87-4

ADJUSTMENT............................................................................. 87-5

REPLANCEMENT........................................................................ 87-7

SLIDING DOOR.................................................................................. 87-9

COMPONENTS ........................................................................... 87-9

ADJUSTMENT........................................................................... 87-10

REPLACEMENT ........................................................................ 87-13

REAR HATCH .................................................................................. 87-15

COMPONENTS ......................................................................... 87-15

ADJUSTMENT........................................................................... 87-16

REPLACEMENT ........................................................................ 87-18

DOORS - ENGINE HOOD

87-1

ENGINE HOOD

1. INSPECT HOOD.

(a) Check that the clearance is within the specified value.

Hood -Fender Clearance

Hood-Headlamp Clearance

4.0 mm

4.5 mm

2. ADJUST HOOD.

(a) Asjust the engine hood horizontally.

• Loosen the hood side hinge bolts.

• Move the hood to adjust the clearance within the specified

Specified Value: 4.0 mm

• After adjusting, tighten the hood side hinge bolts.

Torque: 28 ~ 32 N·m

87-2

Adjust the hood by turning the rubber damper.

• Adjust the rubber damper so as to align the hood

with the fender.

Turn the rubber to let it move up and down.

87-3

1. REMOVE ENGINE HOOD.

Remove 2 retaining bolts from the engine hood hinge LH.

Remove 2 retaining bolts from the engine hood hinge

Remove engine hood.

Be careful, the engine hood is too heavy, pay attention to

prevent contact with the windshield lift under.

2. INSTALL ENGINE HOOD.

(a) Tighten 2 retaining bolts to the engine hood hinge LH.

Torque: 28 ~ 32 N·m.

Tighten 2 retaining bolts to the engine hood hinge RH.

3. ADJUST ENGINE HOOD.(Refer to “Chapter 87 engine hood and doors - engine hood, adjustment”)

87-4

DOORS - FRONT DOOR

1 Front Door Glass Assy LH

2 Front Door Adjustment Assy

10 Front Door Power Lift Assy

11 Front Door Glass Sealing Strip LH

3 Front Door Glass Guide Slot Assy LH

4 Front Door Sealing Strip LH

5 Front Door Cylinder Assy

6 Front Door Inner Triangle Plate LH

7 Left Fender Plug Strip Assy

8 Front Door Glass Inner Weather Bar LH

12 Maintenance Panel II

13 Front Door Controller Cover LH

14 Front Door Inner Guard Board LH

15 Screw

16 Screw

17 Front Door Lock Assy LH

9 Front Door Glass Outer Weather Bar LH

87-5

Adjust the RH side by the same procedures as the LH side

1. INSPECT FRONT DOOR LH.

Front Door- Fender

Front Door- Quarter Panel

5.5mm

5.0mm

2. ADJUST FRONT DOOR LH.

(a) Adjust the door vertically and horizontally by loosening

the body side hinge bolts.

(b) After adjusting, tighten the body hinge bolts.

87-6

Adjust the striker position by slightly loosening the striker

mounting screws .

After adjusting, tighten the striker mounting screws.

87-7

REPLANCEMENT

1. REMOVE THE FRONT BUMPER.(Refer to“Chapter 88 interior and exterior trim- front bumper,

replacement)

2. REMOVE FRONT DOOR ASSY.

Disconnect front door connector from the front bumper

Remove retaining bolts from the front door limiting device

Remove 4 retaining bolts from the front door hinge LH.

Remove the front door assy.

Use new parts when installing.

3. REMOVE FRONT DOOR HINGE RH.

4. INSTALL FRONT DOOR HINGE LH.

(a) Position the front door LH properly. After adjusting the

front door clearance, tighten 4 retaining bolts to the front

door hinge LH.

87-8

Install front door limiting device LH.

Connect front door connector from front bumper bracket.

5. ADJUST FRONT DOOR LH.(Refer to “Chapter 87 engine hood and doors - front door, adjustment”)

6. INSTALL THE FRONT BUMPER.(Refer to“Chapter 88 interior and exterior trim- front bumper,

7. CONNECT THE BATTERY NEGATIVE CABLE.

8. INSTALL THE RRONT DOOR RH.

DOORS - SLIDING DOOR

87-9

1 Sliding Door Upper Inner Guard Board RH

Sliding Door Middle Inner Guard Board

3 Sliding Door Glass Assy RH

4 Sliding Door Slide Weatherstrip RH

5 Sliding Door Slide Cover

6 Sliding Door Glass Weatherstrip RH

7 Sliding Door Weatherstrip

8 Sliding Door Waterproof

10 Screw

Sliding Door Lower Slideway Bracket

Assy RH

11 Sliding Door Lock Assy RH

12 Sliding Door Lower Inner Guard Board

87-10

1. INSPECT SLIDING DOOR.

Front Of Sliding Door

Rear Of Sliding Door

87-11

Upper Of Sliding Door

Lower Of Sliding Door

2. ADJUST SLIDING DOOR.

(a) Loosen the sliding door upper bracket nut.

(b) Adjust the sliding door position.

Loosen the sliding door lower bracket bolts.

Adjust the door vertically.

After adjusting, tighten the sliding door bracket bolts.

6.5 ~ 8.5 N·m(small bolts)

87-12

Adjust the middle convex limiting device by slightly loosening

the middle convex limiting device mounting screws

and hitting the middle convex limiting device with a plastic

Adjust the lock catch by slightly loosening the lock catch

mounting bolts and hitting the lock catch with a plastic

Adjust the middle concave limiting device by slightly

loosening the middle concave limiting device mounting

bolts and hitting the middle concave limiting device with a

After adjusting, tighten those bolts and screws.

87-13

1. REMOVE SLIDING DOOR RH.

(a) Remove 3 mounting bolts from the sliding door lower

Remove 2 mounting bolts from the sliding door middle

Remove 2 mounting nut from the sliding door upper

Slid out the sliding door.

Remove the sliding door.

2. INSTALL SLIDING DOOR RH.

(a) Tighten mounting nut to upper bracket.

87-14

Install 2 mounting bolts from the sliding door middle

Install 3 mounting bolts from the sliding door lower

3. ADJUST SLIDING DOOR RH. (Refer to “Chapter 87 engine hood and doors - sliding door,

DOORS - REAR HATCH

87-15

1 License Plate Lamp Shield

7 Nut

2 Rear Hatch Upper Guard Board Assy

3 Gas Prop Assy LH

4 Clip

5 Gas Prop Assy RH

6 Gas Prop Adjustment Assembly

8 Rear Window Glass Assy

9 Rear Hatch Sealing Strip

10 Rear Hatch lower Guard Board Assy

11 Rear Hatch Waterproof Film

12 Rear Hatch Lock Assy

87-16

1. INSPECT REAR HATCH..

Check that the clearance is within the specified value.

Rear Hatch - Quarter Panel

Rear Hatch - Rear Bumper

87-17

2. ADJUST REAR HATCH.

(a) Adjust the lock catch and limiting device by slightly

loosening the lock catch and limiting device mounting

(b) After adjusting, tighten the lock catch mounting bolts

Loosen the rear hatch hinge mounting bolts to adjust the

rear hatch position.

After adjusting, tighten the rear hatch hinge mounting

87-18

1. REMOVE ROOF PANEL ASSY. (Refer to “Chapter 8 Interior and Exterior - Roof panel assy,

2. REMOVE GAS PROP ASSY RH.

Disconnect the rear washer hose and the connector.

Remove 2 upper mounting bolts from the gas prop assy

Remove 2 lower mounting bolts from the gas prop assy

Remove gas prop.

• Do not disassemble it or throw it into fire.

• Using a drill, make a hole in the gas prop to

discharge the gas inside.

3. REMOVE GAS PROP LH.

Remove the LH side by the same procedures as the RH side.

4. REMOVE REAR HATCH HINGE.

(a) Hold the rear hatch and remove rear hatch hinge

mounting bolts LH.

Remove rear hatch hinge mounting bolts RH.

Remove rear hatch.

87-19

5. INSTALL REAR HATCH.

(a) Tighten 4 rear hatch hinge mounting bolts.

Position the gas prop properly and tighten the snap ring.

Connect the rear hatch connector.

Connect the rear washer hose.

6. INSTALL ROOF PANEL ASSY. (Refer to “Chapter 8 Interior and Exterior - Roof panel assy,

7. ADJUST REAR HATCH. (Refer to “Chapter 87 engine hood and doors - rear hatch, adjustment”)

FRONT GRILLE ................................................................................. 88-1

COMPONENTS ........................................................................... 88-1

REPLACEMENT .......................................................................... 88-2

FRONT BUMPER ASSY .................................................................... 88-3

COMPONENTS ........................................................................... 88-3

REPLACEMENT .......................................................................... 88-4

WHEEL MUDGUARD......................................................................... 88-7

REPLACEMENT .......................................................................... 88-7

REAR BUMPER ASSY .................................................................... 88-10

COMPONENTS ......................................................................... 88-10

REPLACEMENT ........................................................................ 88-11

SUN VISOR ASSY ........................................................................... 88-13

COMPONENTS ......................................................................... 88-13

REPLACEMENT ........................................................................ 88-14

STEP BOARD .................................................................................. 88-15

COMPONENTS ......................................................................... 88-15

REPLACEMENT ........................................................................ 88-16

VEHICLE DOOR INNER GUARD BOARD...................................... 88-18

REPLACEMENT ........................................................................ 88-18

QUARTER PANEL GUARD BOARD............................................... 88-23

REPLACEMENT ........................................................................ 88-23

FLOOR DECORATIVE PARTS........................................................ 88-27

COMPONENTS ......................................................................... 88-27

REPLACEMENT ........................................................................ 88-28

ROOF PANEL .................................................................................. 88-31

COMPONENTS ......................................................................... 88-31

REPLACEMENT ........................................................................ 88-32

88

FRONT GRILLE

EXTERIOR AND INTERIOR TRIM - FRONT GRILLE

88-1

1 Front Grille 2 Bolt

88-2

1. REMOVE FRONT GRILLE.

(a) Remove 2 front grille screws.

Pull out front grille, remove 9 clips.

Remove front grille.

2. INSTALL FRONT GRILLE.

(a) Position the front grille, install 9 clips.

Install 2 screws.

FRONT BUMPER ASSY

EXTERIOR AND INTERIOR TRIM - FRONT BUMPER ASSY

88-3

2 Clip

3 Front Grille

4 Front Bumper

5 Front Bumper Support LH

7 Front Bumper Support RH

88-4

2. REMOVE FRONT GRILLE. (Refer to “Chapter 88 exterior and interior - front grille, replacement”)

3. REMOVE FRONT BUMPER ASSY.

(a) Disconnect the front fog lamper connector.

Remove 2 bolts from front bumper assy by upside.

Remove 3 bolts from front bumper assy by downside.

88-5

(e) Remove the both side front step board cover .

Remove the clip RH.

Remove the clip LH.

Remove the front bumper assy.

4. INSTALL FRONT BUMPER ASSY.

(i) Position the front fog lamps assy.

(j) Tighten front step board cover retaining screw RH.

Tighten front step board cover retaining screw LH.

Tighten 3 bolts from front bumper assy by downside.

88-6

Tighten 3 bolts from front bumper assy by upside.

Tighten 3 screws from front bumper assy.

Connect the connectors to front fog lamps.

5. INSTALL FRONT GRILLE. (Refer to “Chapter 88 exterior and interior trim - front grille, replacement”)

EXTERIOR AND INTERIOR TRIM - WHEEL MUDGUARD

88-7

WHEEL MUDGUARD

1. REMOVE FRONT WHEEL MUDGUARD LH.

(a) Remove 3 screws and front wheel mudguard LH.

2. REMOVE FRONT WHEEL MUDGUARD RH.

3. REMOVE REAR WHEEL MUDGUARD LH.

(a) Remove 4 screws and rear wheel mudguard LH.

4. REMOVE REAR WHEEL MUDGUARD RH.

5. REMOVE ENGINE MUDGUARD LH.

(a) Loosen 4 clips, remove the engine mudguard LH.

6. REMOVE ENGINE MUDGUARD RH.

88-8

7. REMOVE FRONT WHEEL FRONT MUDGUARD LH.

Loosen 3 clips, remove the front wheel front mudguard

8. INSTALL FRONT WHEEL FRONT MUDGUARD LH.

Tighten 3 clips, install the front wheel front mudguard LH.

9. INSALL ENGINE MUDGUARD LH.

Tighten 4 clips, install the engine mudguard LH.

10. INSTALL ENGINE MUDGUARD RH.

11. INSTALL FRONT WHEEL MUDGUARD LH.

Install the front wheel mudguard LH and install 3 screws.

12. INSTALL FRONT WHEEL MUDGUARD RH.

Intsall the RH side by the same procedures as the LH side.

88-9

13. INSTALL REAR WHEEL MUDGUARD LH.

(a) Install the rear wheel mudguard LH and install 4 screws.

14. INSTALL REAR WHEEL MUDGUARD RH.

88-10

REAR BUMPER ASSY

EXTERIOR AND INTERIOR TRIM - REAR BUMPER ASSY

1 Wheel mudguard Clip

2 Wheel mudguard Clip Cover

3 Clip

5 Rear Bumper Support RH

6 Rear Bumper Support LH

7 Rear Bumper Body Assy

8 Rear Bumper Support Clip

9 Rear Bumper Lower Side Support

88-11

1. REMOVE REAR BUMPER ASSY.

(a) Remove 6 bolts from rear bumper assy by upside.

Remove 4 clips from rear bumper assy by downside.

Pull out the rear bumper slowly.

Be careful, not to damage the rear bumper.

Disconnect the reverse radar connector.

Remove the rear bumper assy.

2. INSTALL REAR BUMPER ASSY.

(a) Connect the reversing radar connector.

(b) Position the rear bumper and install the clips.

88-12

Install 6 bolts from rear bumper assy by upside.

Install 4 clips from rear bumper assy by downside.

SUN VISOR ASSY

EXTERIOR AND INTERIOR TRIM - SUN VISOR ASSY

88-13

1 Sun Visor Assy RH

2 Sun Visor Assy LH

88-14

1. REMOVE SUN VISOR ASSY LH.

(a) Remove 2 bolts from the hook.

(b) Remove 2 bolts from sun visor assy.

2. REMOVE SUN VISOR ASSY RH.

3. INSTALL SUN VISOR ASSY LH.

(a) Position the sun visor assy, install the hook.

(b) Install 2 bolts to sun visor assy.

4. INSTALL SUN VISOR ASSY RH.

STEP BOARD

EXTERIOR AND INTERIOR TRIM - STEP BOARD

88-15

1 Step Board LH

2 Step Board RH

5 Jack Cover

6 Sliding Door Step Board Assy

88-16

1. REMOVE FRONT STEP BOARD COVER ASSY LH.

(a) Remove 2 upside clips from the step board LH.

Change new clip, when installation.

Remove 2 downside clips from the step board LH

Remove the step board LH.

2. REMOVE STEP BOARD COVER RH.

3. REMOVE SLIDING DOOR STEP BOARD COVER

ASSY RH.

(a) Loosen 11 covers and screws.

Disconnect the step lamp connector.

Remove the sliding door step board cover RH.

88-17

4. INSTALL STEP BOARD LH.

(a) Position the step board LH.

(b) Install 2 upside clips to step board LH.

Install 2 downside clips to step board LH.

5. INSTALL FRONT STEP BOARD COVER ASSY RH.

6. INSTALL SLIDING DOOR STEP BOARD COVER ASSY

(a) Connect the step lamp connector

(a) Position the sliding door step board cover

Install 11 covers and screws.

88-18

EXTERIOR AND INTERIOR TRIM - VEHICLE DOOR INNER GUARD BOARD

VEHICLE DOOR INNER GUARD BOARD

1. REMOVE FRONT DOOR INNER GUARD PLATE ASSY

Remove the clip from front door inner triangle plate LH.

Remove the front door inner triangle plate LH.

Loosen 2 screws to remove the front door controller

cover LH.

Disconnect 2 front door controller cover connectors.

Remove front door controller cover.

Remove the screw of front door lock inner handle assy

Remove 2 door lock connecting rods, then remove front

inner handle LH.

88-19

Disengage 13 clips, remove the front door inner guard

Change new clips when installation.

2. REMOVE FRONT DOOR INNER GUARD PLATE ASSY RH.

3. REMOVE SLIDING DOOR UPSIDE INNER GUARD

BOARD.

Disengage 13 clips and remove the sliding door upside

inner guard board.

4. REMOVE SLIDING DOOR MIDDLE GUARD BOARD.

(a) Disengage 3 clips and remove the sliding door middler

5. REMOVE SLIDING DOOR DOWNSIDE INNER GUARD

(a) Remove 2 sliding door lock retaining scerws.

88-20

Disengage 18 clips and remove the sliding door downside

6. REMOVE REAR HATCH UPPER GUARD BOARD.

(a) Disengage 17 clips and remove the rear hatch upper

Be carful not to damage the rear hatch upper guard board.

7. REMOVE REAR HATCH LOWER GUARD BOARD.

(b) Remove blot of rear hatch handle, remove the rear hatch

Disengage 12 clips and remove the rear hatch upper

Be carful not to damage the rear hatch lower guard board.

8. INSTALL FRONT DOOR INNER GUARD PLATE ASSY

(a) Install the front door lock inner handle assy LH with the

screw.

88-21

Install 2 door lock connecting rods, then install front inner

Install the door lock inner handle assy LH with the screw.

Connect the connector of the front door controller cover

Position the front door controller cover LH.

Install the front door inner triangle plate LH.

9. INSTALL FRONT DOOR INNER GUARD PLATE ASSY RH.

10. INSTALL SLIDING DOOR LOWER GUARD BOARD.

Install the sliding door lower guard board with 13 clips.

88-22

11. INSTALL SLIDING DOOR MIDDLER GUARD BOARD

Install the sliding door middler guard board with 3 clips.

12. INSTALL SLIDING DOOR UPPER GUARD BOARD

Install the sliding door upper guard board with 18 clips.

13. INSTALL REAR HATCH UPPER GUARD BOARD

Install the rear hatch upper guard board with 17 clips.

14. INSTALL REAR HATCH LOWER GUARD BOARD

(a) Install the sliding door lower guard board with 12 clips.

(b) Install the rear hatch handle bolt.

EXTERIOR AND INTERIOR TRIM - QUARTER PANEL GUARD BOARD

QUARTER PANEL GUARD BOARD

1. CONNECT BATTERY NEGATIVE CABLE.

88-23

2. REMOVE REAR QUARTER PANEL GUARD BOARD

Remove passengers seat assy.

Remove driver seat meshbelt with retractor assy.(Refer to

“Chapter 63 seat belt-anchor adjuster assy, replacement”)

Disengage 17 clips and remove the rear quarter panel

guard board LH.

3. REMOVE REAR QUARTER PANEL GUARD BOARD RH.

4. REMOVE MIDDLE QUARTER PANEL GUARD BOARD

Loosen the retaining screw.

Remove passenger seat meshbelt with retractor assy.

(Refer to “Chapter 63 seat belt -anchor adjuster assy,

Disengage 6 clips and remove the middle quarter panel

5. REMOVE MIDDLE QUARTER PANEL GUARD BOARD RH.

6. REMOVE FRONT QUARTER PANEL GUARD BOARD

7. REMOVE FRONT QUARTER PANEL GUARD BOARD RH.

(a) Pull out front and sliding door sealing strip RH.

(b) Loosen 2 retaining screwsm, remove B pillar handle.

(d) Disengage 17 clips and remove the front quarter panel guard board LH.

Remove driver seat meshbelt with retractor assy. (Refer

to “Chapter 63 seat belt -anchor adjuster assy,

Remove driver seat assy.

Disengage 17 clips and remove the front quarter panel

Remove engine compartment cover.

Remove front quarter panel guard board LH.

88-24

8. REMOVE B PILLAR UPPER GUARD BOARD LH.

(a) Remove driver seat belt upper bolt.

(b) Pull out front door sealing strip.

(d) Disengage 3 clips and remove B pillar upper guard board

9. REMOVE B PILLAR UPPER GUARD BOARD RH.

• Remove the RH side by the same procedures as the LH side.

10. REMOVE OTHER SIDE PILLAR INNER GUARD BOARD.

• Remove other side pillar inner guard board by the same procedures as the LH side.

• Skip step (c)and(d).

• Add step“ Remove side pillar inner guard board screw”.

11. REMOVE A PILLAR UPPER GUARD BOARD LH.

(a) Pull out front door sealing strip.

(b) Use a screwdriver to remove the bolt covers of A pillar

Remove A pillar handle.

Remove A pillar guard board.

12. REMOVE A PILLAR UPPER GUARD BOARD RH.

88-25

13. INSTALL FRONT QUARTER PANEL GUARD BOARD

Install 17 clips and install the front quarter panel guard

board LH.

Install driver seat belt upper bolt.

Install engine compartment cover.

14. INSTALL FRONT QUARTER PANEL GUARD BOARD RH.

(a) Install 6 clips and install the front quarter panel guard board RH

(b) Tighten 2 retaining screwsm, install B pillar handle.

15. INSTALL MIDDLE QUARTER PANEL GUARD BOARD

Install 6 clips and install the middle quarter panel guard

Install passenger seat meshbelt with retractor assy.

16. INSTALL MIDDLE QUARTER PANEL GUARD BOARD RH.

17. INSTALL REAR QUARTER PANEL GUARD BOARD

Install 17 clips and install the rear quarter panel guard

Install rear hatch sealing strip

18. INSTALL REAR QUARTER PANEL GUARD BOARD RH.

88-26

19. INSTALL B PILLAR UPPER GUARD BOARD LH.

(a) Install 3 clips and install B pillar upper guard board LH.

(b) Remove the engine compartment cover support point.

(d) Install rear hatch sealing strip

20. INSTALL B PILLAR UPPER GUARD BOARD RH.

21.

• Install other side pillar inner guard board by the same procedures as the LH side.

• Add step“ Tighten side pillar inner guard board screw”.

22. INSTALL A PILLAR UPPER GUARD BOARD LH.

(a) Install 3 clips and install A pillar upper guard board LH.

Position the A pillar handle, install 2 bolts.

Install the bolt covers of A pillar handle.

Install the front door sealing strip.

23. INSTALL A PILLAR UPPER GUARD BOARD RH.

EXTERIOR AND INTERIOR TRIM - FLOOR DECORATIVE PARTS

FLOOR DECORATIVE PARTS

88-27

1 Stop Plate

2 Front Floor Covering

3 Stop Plate Cover LH

4 Stop Plate Cover RH

5 Assisant Driver Step Board Trim Strip

6 Engine Compartment Covering

7 Driver Step Board Trim Strip

8 Engine Compartment Cover Holder Belt

9 Screw

10 Air Filter Cover Switch Assy

11 Screw

12 Clip

13 Screw

15 Sliding Door Lower Trim Strip

16 Sliding Door Step Board Covering

17 Sliding Door Upper Trim Strip

18 Wheel Casing Carpet LH

19 Rear Hatch Floor Trim Strip

20 Wheel Casing Carpet RH

21 Rear Floor Covering

22 Engine Rear Stop Plate Covering

23 Clip

24 Screw

25 Clip

88-28

1. REMOVE ENGIEN COMPARTMENT COVER.

Remove driver seat assy.(Refer to “Chapter 84 seat - driver/assisant driver seat, removal & installation

and disassembly &reassemlby)

Remove middle platform.(Refer to “Chapter 83 instrument panel - middle platform, replacement”)

Remove driver step board trim strip, remove the driver side covering.

Remove the quarter panel front lower guard board cover,

remove the nut.

Loosen 3 retaining bolt.

Remove engine compartment cover assy.

2. REMOVE ENGIEN COMPARTMENT COVER UNDER ASSISTANT DRIVER SEAT.

• Remove engine compartment cover under assistant driver seat by the same procedures as the

engine compartment cover.

• Skip step (d)

3. REMOVE FRONT FLOOR COVERING.

(a) Remove driver and assistant driver seat assy.(Refer to “Chapter 84 seat-driver/assistant driver seat

,removal & installation and disassembly &reassemlby”)

(b) Remove middle platform.(Refer to “Chapter 83 instrument panel - middle platform, replacement”)

Remove driver step board trim strip.

Remove front floor covering.

4. REMOVE ENGINE REAR STOP PLATE COVERING.

(a) Remove 9 engine rear stop plate covering retaining clips.

(b) Remove engine rear stop plate covering.

88-29

5. REMOVE REAR FLOOR COVERING.

(a) Remove passenger seat.(Refer to “Chapter 84 seat- passenger seat,replacement”)

(b) Remove quarter panel guard board.(Refer to “Chapter 88 exterior and interior trim-quarter panel guard

board,replacement”)

(d) Remove rear floor covering.

6. INSTALL ENGINE COMPARTMENT COVER.

(a) Tighten 3 retaining bolts.

(b) Tighten the nut, install the engine comparement cover.

Install driver step board trim strip, install assistant driver

covering.

7. INSTALL ENGINE COMPARTMENT COVER UNDER ASSISTANT DRIVER SEAT.

• Install engine compartment cover under assistant driver seat by the same procedures as the

8. INSTALL FRONT FLOOR COVERING.

(a) Position the front floor covering.

Install driver step board trim strip.

Install middle platform. (Refer to “Chapter 83 instrument

panel - middle platform, replacement”)

Install driver and assistant driver seat assy.(Refer to “Chapter

84 seat-driver/assistant driver seat ,removal & installation and

disassembly &reassemlby”)

88-30

9. INSTALL ENGINE REAR STOP PLATE COVERING.

(a) Position the engine rear stop plate covering.

(b) Install 9 retaining clips.

10. INSTALL REAR FLOOR COVERING.

(a) Position the rear floor covering.

(b) Install rear hatch floor trim strip.

11. INSTALL QUARTER PANEL GUARD BOARD LH.(Refer to “Chapter 88 exterior and interior trim -

quarter panel guard board, replacement”)

12. INSTALL PASSENGER SEAT. (Refer to “Chapter 84 seat - passenger seat, replacement”)

ROOF PANEL

EXTERIOR AND INTERIOR TRIM - ROOF PANEL

88-31

2 Front Insulating Felt

3 Front Trim Cover

6 Front Visor LH

7 Front Visor RH

10 Rear Insulating Felt

11 Rear Trim Cover

12 Bolt

88-32

2. REMOVE MIDDLE INDOOR LAMP ASSY. (Refer to“Chapter 64 lighting - middle indoor lamp

assy,replacement”)

3. REMOVE PASSENGER SEAT BELT UPPER REAINING BOLT.(Refer to “Chapter 63 belt -

Retractor Assy,Replacement.”)

4. REMOVE UPPER GUARD BOARD.(Refer to “Chapter 88 Exterior and interior trim - quarter panel

5. REMOVE SLIDING ROOF SEALING STRIP.

6. REMOVE REAR AIR PURIFIER ASSY.

(a) Pass on both side, remove air purifier cover.

Remove air filter.

88-33

Remove the air purifier.

7. INSTALL REAR AIR PURIFIER ASSY

Position the air filter.

88-34

Install air purifier cover..

8. REMOVE REAR ROOF GUARD BOARD ASSY.

(a) Disconnect the sealing strip of rear hatch.

(b) Disengage 30 clips.

• Be careful, the roof guard board assy is too heavy.

• Be careful, do not damage the interior trim.

• Be sure change new clips when installation.

9. REMOVE FRONT ROOF GUARD BOARD ASSY.

(a) Remove 2 safety hammer retaining screws.

Pry out air conditioning control switch.

Disconnect the air conditioning control switch connector.

Remove the air conditioning control switch.

Remove the front visors.

Remove front indoor lamp assy.

88-35

Remove the front handle.

Disengage 6 clips.

Remove the front roof guard board assy.

Be sure change new clips when installation.

10. INSTALL FRONT ROOF GUARD BOARD ASSY.

(a) Install 6 clips and intsll front roof guard board.

Install the front handle.

Install the front visors.

Install front indoor lamp assy.

88-36

Connect the air conditioning control switch connector.

Install 2 safety hammer retaining screws.

11. INSTALL FRONT ROOF GUARD BOARD ASSY.

(a) Install 30 clips and intsll rear roof guard board.

(b) Install rear hatch sealing strip.

12. INSALL UPPER GUARD BOARD.(Refer to “Chapter 88 Exterior and interior trim - quarter panel

13. INSTALL MIDDLE INDOOR LAMP ASSY. (Refer to“Chapter 64 lighting - middle indoor lamp

14. INSTALL REAR INDOOR LAMP ASSY. (Refer to“Chapter 64 lighting - rear indoor lamp

15. INSTALL SLIDING ROOF SEALING STRIP.

16. INSTALL PASSENGER SEAT BELT UPPER REAINING BOLT.(Refer to “Chapter 63 belt -

17. CONNECT BATTERY NEGATIVE CABLE

IGNITION SWITCH ASSY.................................................................. 91-1

INSPECTION ............................................................................... 91-1

DISASSEMBLY & ASSEMBLY.................................................... 91-2

91

VEHICLE CONTROL SYSTEM - IGNITION SWITCH ASSY

91-1

1. INSPECT IGNITION SWITCH ASSY.

(a) Test the resistance and the continuity of all pins using the

following table.

Switch position Terminal Specified condition

LOCK AM1 - ACC - IG1 - AM2 - IG2 - ST ≥ 1 MΩ

ACC AM1 - ACC < 2 Ω

ON AM1 - ACC - IG1, AM2 - IG2 < 2 Ω

START AM1 - IG1 , AM2 - IG2 - ST < 2 Ω

If the resistance is out of the specification, replace the ignition switch assy. (Refer to “Chapter 91

vehicle control system - ignition switch assy, removal & installation and disassembly & assembly”)

91-2

REMOVAL & INSTALLATION AND DISASSEMBLY & ASSEMBLY

3. REMOVE STEERING WHEEL ASSY. (Refer to “Chapter 51 steering column - steering wheel assy,

4. REMOVE STEERING COLUMN PANEL.

5. REMOVE CLOCKSPRING. (Refer to “Chapter 62 Supplemental Restraint System - clock spring,

8. REMOVE IGNITION SWITCH HARNESS.

(a) Disconnect ignition switch connector.

(b) Disconnect ignition key switch connector.

Using prying tool remove 2 harness ties.

9. REMOVE STEERING COLUMN.

(a) Remove 3 steering column retaining bolts as shown in

the figure.

It is recommended to remove steering column for easier

91-3

10. REMOVE IGNITION SWITCH ILLUMINATION LIGHT.

(a) Pry out lock slot on both sides of illumination light as

(b) Remove illumination light.

11. REMOVE IGNITION SWITCH ASSY.

(a) Remove 2 ignition switch anti-theft bolts.

Using special chisel, cut out a groove on top surface of

anti-theft bolts, then remove them.

(b) Remove ignition switch assy.

12. DISASSEMBLE IGNITION SWITCH ASSY.

Insert the ignition key, then turn the ignition switch to the

“ACC” position.

Using a stick, press the lock latch of ignition switch.

Pull out the ignition switch body.

91-4

Remove 2 screws.

Remove the ignition switch connector.

13. ASSEMBLE IGNITION SWITCH ASSY.

Install the ignition switch connector.

Insert and turn it to align the key sets.

91-5

Install the ignition switch body.

If hear a “click”, the ignition switch is installed properly.

Align the lock slot on the steering column assy and the latch

block on the ignition switch assy.

The ignition switch lock latch will extrude only when the

ignition key is pulled out.

(f) Position the ignition switch assy properly, then tighten 2

anti-theft bolts with a suitable tool.

After installation, using a special tool, strike the top surface

of anti-theft bolts where there is a groove into a flat surface.

14. INSTALL IGNITION SWITCH ILLUMINATION LIGHT.

(a) Press the illumination light until lock slots snap in place

91-6

15. INSTALL STEERING COLUMN ASSY.

Position steering column, then tighten 3 retaining bolts.

16. CONNECT IGNITION SWITCH HARNESS CONNECTOR.

17. INSTALL STEERING COLUMN PANEL. (Refer to “Chapter 51 steering column - steering column

18. INSTALL COMBINATION SWITCH ASSY. (Refer to “Chapter 51 steering column - combination

19. INSTALL CLOCKSPRING. (Refer to “Chapter 62 Supplemental Restraint System - clock spring,

20. INSTALL COMBINATION SWITCH UPPER AND LOWER COVER.

21. INSTALL STEERING WHEEL ASSY. (Refer to “Chapter 51 steering column - steering wheel assy,

22. CONNECT BATTERY NEGATIVE CABLE.

23. CHECK AFTER INSTALLATION.

(a) Insert ignition key into ignition lock cylinder and switch the ignition key in the ACC ,ON and LOCK

positions so that confirm ignition switch works normally .

A - CHASSIS & FRAME WIRE HARNESS(CONNECTOR

VIEWS) ........................................................................ 71-112, 71-104

A - CHASSIS & FRAME WIRE HARNESS(WIRE HARNESS & CON-

NECTOR LOCATION VIEWS)...................................................71-190

ADJUSTMENT(CLUTCH PEDAL) .................................................42-5

ADJUSTMENT(DRIVER / ASSISTANT DRIVER SEAT) ...............84-3

ADJUSTMENT(ENGINE HOOD) ...................................................87-1

ADJUSTMENT(FRONT COMBINATION LAMP ASSY) ................64-7

ADJUSTMENT(REAR HATCH) ...................................................87-16

ADJUSTMENT(SLIDING DOOR) ................................................87-10

ADJUSTMENT(STEERING WHEEL ASSY)..................................51-7

ADJUSTMENT(WASHER NOZZLE)............................................65-16

ANTI-LOCK BRAKE CONTROL SYSTEM(WIRING

DIAGRAM) ....................................................................... 71-41, 71-39

ANTI-THEIF SYSTEM(WIRING DIAGRAM) .................. 71-103, 71-97

AUDIO SYSTEM ............................................................................66-1

A/C RECEIVER DRIER FILTER ELEMENT ................................61-85

B - BATTERY WIRE HARNESS(CONNECTOR

VIEWS) ........................................................................ 71-125, 71-104

B - BATTERY WIRE HARNESS(WIRE HARNESS & CONNECTOR

LOCATION VIEWS) ..................................................... 71-199, 71-179

BLEEDING(CLUTCH FLUID).........................................................42-3

C - FRONT BUMPER WIRE HARNESS(CONNECTOR

VIEWS) ........................................................................ 71-126, 71-105

C - FRONT BUMPER WIRE HARNESS(WIRE HARNESS & CON-

NECTOR LOCATION VIEWS)..................................... 71-186, 71-166

CHARGING SYSTEM(WIRING DIAGRAM) .................... 71-39, 71-37

CLOCK SPRING ..........................................................................62-13

CLUTCH FLUID .............................................................................42-3

CLUTCH PEDAL............................................................................42-4

CLUTCH SLAVE CYLINDER.......................................................42-11

CLUTCH SUB - ASSY .................................................................42-13

CLUTCH SYSTEM.........................................................................42-1

COMBINATION SWITCH ASSY ...................................... 51-12, 64-27

COMMUNICATION SYSTEM(WIRING DIAGRAM)......... 71-85, 71-81

COMPONENTS(AUDIO SYSTEM)................................................66-1

COMPONENTS(CLUTCH PEDAL)................................................42-4

COMPONENTS(CLUTCH SUB - ASSY) .....................................42-13

COMPONENTS(COMBINATION SWITCH ASSY)......................51-12

COMPONENTS(DASHBOARD) ....................................................83-6

COMPONENTS(DRIVER / ASSISTANT DRIVER SEAT BELT) ...63-4

COMPONENTS(DRIVER / ASSISTANT DRIVER SEAT) .............84-2

COMPONENTS(FLOOR DECORATIVE PARTS) .......................88-27

COMPONENTS(FRONT BUMPER ASSY)....................................88-3

COMPONENTS(FRONT COMBINATION LAMP ASSY)...............64-2

COMPONENTS(FRONT DOOR LOCKS)......................................85-1

COMPONENTS(FRONT DOOR)...................................................87-4

COMPONENTS(FRONT GRILLE).................................................88-1

COMPONENTS(INSTRUMENT CLUSTER)..................................83-2

COMPONENTS(PASSENGER SEAT BELT) ................................63-5

COMPONENTS(POWER STEERING SYSTEM) ..........................52-5

COMPONENTS(REAR BUMPER ASSY) ....................................88-10

COMPONENTS(REAR COMBINATION LAMP ASSY) ...............64-10

COMPONENTS(REAR HATCH LOCK) ...................................... 85-12

COMPONENTS(REAR HATCH) ................................................. 87-15

COMPONENTS(ROOF PANEL) ................................................. 88-31

COMPONENTS(SLIDING DOOR LOCKS) ................................... 85-7

COMPONENTS(SLIDING DOOR) ................................................ 87-9

COMPONENTS(SLIDING ROOF ASSY) ...................................... 86-2

COMPONENTS(STEERING SYSTEM) ........................................ 51-5

COMPONENTS(STEP BOARD) ................................................. 88-15

COMPONENTS(SUN VISOR ASSY) .......................................... 88-13

COMPONENTS(TRANSMISSION OPERATION MECHANISM

ASSY)............................................................................................ 41-1

COMPONENTS(WIPER AND WASHER SYSTEM) ..................... 65-4

COMPRESSOR OIL.................................................................... 61-17

COMPRESSOR(ISF2.8).............................................................. 61-80

COMPRESSOR(4G69) ............................................................... 61-78

CONDENSER.............................................................................. 61-83

CONNECTOR VIEWS.................................................. 71-112, 71-104

(HOW TO USE THIS MANUAL).................................................... 71-6

D - FRONT DOOR LH WIRE HARNESS(CONNECTOR

VIEWS)......................................................................... 71-127, 71-106

D - FRONT DOOR LH WIRE HARNESS(WIRE HARNESS & CON-

NECTOR LOCATION VIEWS) ..................................... 71-188, 71-168

DASHBOARD................................................................................ 83-5

DRIVER / ASSISTANT DRIVER SEAT ......................................... 84-2

DRIVER / ASSISTANT DRIVER SEAT BELT ............................... 63-4

(CONNECTOR VIEWS) ............................................... 71-130, 71-108

E - ENGINE WIRE HARNESS(WIRE HARNESS & CONNECTOR

LOCATION VIEWS) ..................................................... 71-193, 71-172

ELECTRIC DEVICE ACCESSORIES ......................................... 66-12

ENGINE HOOD ............................................................................. 87-1

(CONNECTOR VIEWS) ............................................... 71-142, 71-119

F - ROOF WIRE HARNESS 1(WIRE HARNESS & CONNECTOR

LOCATION VIEWS) ..................................................... 71-201, 71-181

FLOOR DECORATIVE PARTS................................................... 88-27

FRONT BUMPER ASSY ............................................................... 88-3

FRONT COMBINATION LAMP ASSY .......................................... 64-2

FRONT DOME LIGHT ASSY ...................................................... 64-17

FRONT DOOR .............................................................................. 87-4

FRONT DOOR LOCKS ................................................................. 85-1

FRONT GRILLE ............................................................................ 88-1

FRONT HEATER CORE ............................................................. 61-25

FRONT SPEAKER ASSY.............................................................. 66-4

FUSE AND RELAY LOCATIONS(HOW TO USE

THIS MANUAL) ............................................................................. 71-9

(CONNECTOR VIEWS) ............................................... 71-146, 71-122

G - ROOF WIRE HARNESS 2(WIRE HARNESS & CONNECTOR

LOCATION VIEWS) ..................................................... 71-204, 71-182

GLOSSARY OF TERMS AND SYMBOLS(HOW TO USE THIS

MANUAL) ...................................................................................... 71-7

(CONNECTOR VIEWS) ............................................... 71-148, 71-124

H - FRONT DOOR RH WIRE HARNESS(WIRE HARNESS &

CONNECTOR LOCATION VIEWS) ............................. 71-189, 71-169

HEATER AND AIR CONDITIONING SYSTEM ............................. 61-1

(WIRING DIAGRAM) ........................................................ 71-44, 71-42

HIGH-MOUNTED STOP LAMP ASSY ........................................ 64-16

HORN SWITCH ASSY .................................................................. 62-6

HOW TO USE THIS MANUAL ...................................................... 71-1

I - INSTRUMENT PANEL WIRE HARNESS(WIRE HARNESS &

CONNECTOR LOCATION VIEWS) .......................................... 71-196

J - REAR HATCH WIRE HARNESS(WIRE HARNESS &

CONNECTOR LOCATION VIEWS) ............................. 71-204, 71-182

IGNITION SWITCH ASSY............................................................. 91-1

INSPECTION(COMPRESSOR OIL) ........................................... 61-17

INSPECTION(IGNITION SWITCH ASSY) .................................... 91-1

INSPECTION(POWER WINDOW)................................................ 82-2

INSPECTION(WASHER NOZZLE) ............................................. 65-15

INSTRUMENT CLUSTER ............................................................. 83-1

INSTRUMENT CLUSTER(WIRING DIAGRAM)............... 71-96, 71-90

INTRODUCTION(HOW TO USE THIS MANUAL) ........................ 71-1

K - REAR HATCH TRANSITION WIRE HARNESS(WIRE HARNESS

& CONNECTOR LOCATION VIEWS).......................... 71-204, 71-182

L - REAR EVAPORATOR WIRE HARNESS(WIRE HARNESS &

CONNECTOR LOCATION VIEWS) ............................. 71-202, 71-181

LICENCE LAMP ASSY................................................................ 64-14

LIGHT SYSTEM(WIRING DIAGRAM).............................. 71-52, 71-49

LIGHTING SYSTEM...................................................................... 64-1

M - DIAGNOSIS WIRE HARNESS(WIRE HARNESS & CONNECTOR

LOCATION VIEWS) ..................................................... 71-196, 71-175

MIDDLE PLATFORM .................................................................. 83-15

MIDDLE SPEAKER ASSY ............................................................ 66-6

MULTI-MEDIA AND AIR-CONDITON CONTROLLER ASSY ....... 66-2

MULTI-MEDIA AND A/C CONTROLLER ASSY ......................... 61-19

MULTIMEDIA SYSTEM(WIRING DIAGRAM) .................. 71-80, 71-76

N - STEP LAMP WIRE HARNESS(WIRE HARNESS & CONNECTOR

LOCATION VIEWS) ..................................................... 71-203, 71-181

O - DRIVER SEAT BELT WIRE HARNESS(CONNECTOR

VIEWS)...................................................................................... 71-172

O - DRIVER SEAT BELT WIRE HARNESS(WIRE HARNESS & CON-

NECTOR LOCATION VIEWS) .................................................. 71-199

ON-VEHICLE INSPECTION(HEATER AND AIR CONDITIONING

SYSTEM) .......................................................................................61-7

ON-VEHICLE INSPECTION(REFRIGERANT)..............................61-8

ON-VEHICLE INSPECTION(STEERING SYSTEM) .....................51-6

ON-VEHICLE INSPECTION(SUPPLEMENTAL RESTRAINT

SYSTEM) .......................................................................................62-4

OVERHAUL(CLUTCH SUB - ASSY) ...........................................42-14

OVERHAUL(COMPRESSOR(ISF2.8))........................................61-80

OVERHAUL(COMPRESSOR(4G69))..........................................61-78

OVERHAUL(CONDENSER)........................................................61-83

OVERHAUL(RETRACTOR ASSY)..............................................63-15

OVERHAUL(STEERING COLUMN ASSY) .................................51-16

OVERHAUL(STEERING GEAR ASSY).......................................52-28

OVERHAUL(STEERING PROPELLER SHAFT ASSY) ..............51-19

OVERHAUL(STEERING WHEEL ASSY) ......................................51-8

OUTSIDE MIRROR .....................................................................82-17

(CONNECTOR VIEWS)................................................71-173, 71-131

P - REAR HEATER WIRE HARNESS(WIRE HARNESS &

CONNECTOR LOCATION VIEWS)..............................71-199, 71-179

PASSENGER SEAT ....................................................................84-15

PASSENGER SEAT BELT ............................................................63-5

POWER MIRROR(WIRING DIAGRAM) ...........................71-90, 71-85

POWER SOCKET(WIRING DIAGRAM) ...........................71-83, 71-79

POWER SOURCE SECTION EXAMPLE(HOW TO USE THIS

MANUAL).......................................................................................71-5

POWER SOURCE(WIRING DIAGRAM) ..........................71-18, 71-19

POWER STEERING LINE ASSY ................................................52-22

RESERVIOR ASSY .....................................................................52-17

POWER STEERING SYSTEM ......................................................52-1

POWER WINDOW.........................................................................82-2

PRECAUTION(CLUTCH SYSTEM)...............................................42-1

PRECAUTION(DASHBOARD) ......................................................83-5

PRECAUTION(HEATER AND AIR CONDITIONING

SYSTEM) .......................................................................................61-1

PRECAUTION(INSTRUMENT CLUSTER)....................................83-1

PRECAUTION(LIGHTING SYSTEM) ............................................64-1

PRECAUTION(POWER STEERING SYSTEM) ............................52-1

PRECAUTION(SEAT BELT SYSTEM)..........................................63-1

PRECAUTION(SEAT)....................................................................84-1

PRECAUTION(SUPPLEMENTAL RESTRAINT SYSTEM) ...........62-1

PRECAUTION(WIPER AND WASHER SYSTEM) ........................65-1

PROBLEM SYMPTOMS TABLE(CLUTCH SYSTEM)...................42-2

CONDITIONING SYSTEM) ...........................................................61-3

PROBLEM SYMPTOMS TABLE(POWER STEERING

SYSTEM) .......................................................................................52-2

PROBLEM SYMPTOMS TABLE(SLIDING ROOF ASSY).............86-1

PROBLEM SYMPTOMS TABLE(STEERING SYSTEM)......51-1, 51-2

PROBLEM SYMPTOMS TABLE(WIPER AND WASHER

SYSTEM) .......................................................................................65-2

Q

Q - REAR BUMPER TRANSITION WIRE HARNESS(CONNECTOR

VIEWS) .........................................................................71-174, 71-132

Q - REAR BUMPER TRANSITION WIRE HARNESS(WIRE

HARNESS & CONNECTOR LOCATION VIEWS)........71-204, 71-182

QUARTER PANEL GUARD BOARD...........................................88-23

R - REAR BUMPER WIRE HARNESS(CONNECTOR

VIEWS) .........................................................................71-175, 71-133

R - REAR BUMPER WIRE HARNESS(WIRE HARNESS & CONNEC-

TOR LOCATION VIEWS) ............................................ 71-204, 71-182

RCM .............................................................................................62-16

REAR BUMPER ASSY ................................................................88-10

REAR COMBINATION LAMP ASSY ...........................................64-10

REAR HATCH..............................................................................87-15

REAR HATCH LOCK ...................................................................85-12

REAR HEATER CORE ................................................................61-35

REAR SPERKER ASSY ................................................................66-8

REAR WINDOW GLASS .............................................................82-12

REFRIGERANT .............................................................................61-8

REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEM-

BLY(IGNITION SWITCH ASSY) ....................................................91-2

REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEML-

BY((DRIVER / ASSISTANT DRIVER SEAT)) ................................84-7

REMOVAL & INSTALLATION(PASSENGER SEAT) ..................84-15

REPLACEMENT(A/C RECEIVER DRIER FILTER

ELEMENT) ...................................................................................61-85

REPLACEMENT(CLOCK SPRING).............................................62-13

REPLACEMENT(CLUTCH PEDAL) ..............................................42-6

REPLACEMENT(CLUTCH SLAVE CYLINDER) .........................42-11

REPLACEMENT(COMBINATION SWITCH ASSY)......... 51-13, 64-27

REPLACEMENT(COMPRESSOR OIL) .......................................61-18

REPLACEMENT(DASHBOARD) ...................................................83-7

REPLACEMENT(ELECTRIC DEVICE ACCESSORIES).............66-12

REPLACEMENT(ENGINE HOOD) ................................................87-3

REPLACEMENT(FLOOR DECORATIVE PARTS) ......................88-28

REPLACEMENT(FRONT BUMPER ASSY) ..................................88-4

REPLACEMENT(FRONT DOME LIGHT ASSY) .........................64-17

REPLACEMENT(FRONT DOOR LOCKS) ....................................85-2

REPLACEMENT(FRONT GRILLE)................................................88-2

REPLACEMENT(FRONT HEATER CORE) ................................61-25

REPLACEMENT(FRONT SPEAKER ASSY).................................66-4

REPLACEMENT(HIGH-MOUNTED STOP LAMP ASSY) ...........64-16

REPLACEMENT(HORN SWITCH ASSY) .....................................62-6

REPLACEMENT(INSTRUMENT CLUSTER) ................................83-3

REPLACEMENT(LICENCE LAMP ASSY)...................................64-14

REPLACEMENT(MIDDLE PLATFORM)......................................83-15

REPLACEMENT(MIDDLE SPEAKER ASSY)................................66-6

REPLACEMENT(MULTI-MEDIA AND AIR-CONDITON CONTROL-

LER ASSY) ....................................................................................66-2

REPLACEMENT(MULTI-MEDIA AND A/C CONTROLLER

ASSY) ..........................................................................................61-19

REPLACEMENT(OUTSIDE MIRROR) ........................................82-17

REPLACEMENT(POWER STEERING LINE ASSY) ...................52-22

REPLACEMENT(POWER STEERING PUMP WITH FLUID RESER-

VIOR ASSY).................................................................................52-17

REPLACEMENT(POWER WINDOW) ...........................................82-3

REPLACEMENT(QUARTER PANEL GUARD BOARD)..............88-23

REPLACEMENT(RCM)................................................................62-16

REPLACEMENT(REAR BUMPER ASSY)...................................88-11

REPLACEMENT(REAR COMBINATION LAMP ASSY) ..............64-11

REPLACEMENT(REAR HATCH LOCK)......................................85-13

REPLACEMENT(REAR HATCH) ................................................87-18

REPLACEMENT(REAR HEATER CORE)...................................61-35

REPLACEMENT(REAR SPERKER ASSY) ...................................66-8

REPLACEMENT(REAR WINDOW GLASS) ................................82-12

REPLACEMENT(REFRIGERANT) ..............................................61-14

REPLACEMENT(ROOF PANEL).................................................88-32

REPLACEMENT(SEAT BELT CATCH ASSY) ..............................63-9

REPLACEMENT(SIDE WINDOW GLASS)..................................82-15

REPLACEMENT(SLIDING DOOR LOCKS) ..................................85-8

REPLACEMENT(SLIDING DOOR)..............................................87-13

REPLACEMENT(STEERING FLUID) ..........................................52-13

REPLACEMENT(STEP BOARD).................................................88-16

REPLACEMENT(SUN VISOR ASSY) .........................................88-14

REPLACEMENT(TELESCOPIC ANTENNA ASSY) ....................66-10

REPLACEMENT(TRANSMISSION ASSY

(TANGSHANAIXIN)) ....................................................................41-73

(YANCHENGZHONGMA ZM001)) .............................................. 41-10

REPLACEMENT(TRANSMISSION OPERATION MECHANISM

ASSY)............................................................................................ 41-3

REPLACEMENT(VACUUM BOOSTER WITH CLUTCH

MASTER CYLINDER ASSY)......................................................... 42-8

REPLACEMENT(VEHICLE DOOR INNER GUARD BOARD) .... 88-18

REPLACEMENT(WHEEL MUDGUARD) ...................................... 88-7

REPLACEMENT(WINDSHIELD)................................................... 82-7

REPLACEMENT(WIPER ASSY)................................................... 65-5

REPLACEMENT(WIPER BLADE WITH BRACKET ASSY)........ 65-13

REPLACEMENT(WIPER LINK WITH MOTOR ASSY) ................. 65-9

RETRACTOR ASSY.................................................................... 63-15

ROOF PANEL ............................................................................. 88-31

S - REAR DEFROST RH WIRE HARNESS(CONNECTOR

VIEWS)...................................................................................... 71-176

S - REAR DEFROST RH WIRE HARNESS(WIRE HARNESS &

CONNECTOR LOCATION VIEWS) .......................................... 71-204

SEAT ............................................................................................. 84-1

SEAT BELT CATCH ASSY ........................................................... 63-9

SEAT BELT SYSTEM ................................................................... 63-1

SIDE WINDOW GLASS .............................................................. 82-15

SLIDING DOOR ............................................................................ 87-9

SLIDING DOOR LOCKS ............................................................... 85-7

SLIDING ROOF ASSY .................................................................. 86-1

STARTING SYSTEM(WIRING DIAGRAM) ...................... 71-37, 71-35

STEERING COLUMN ASSY ....................................................... 51-16

STEERING GEAR ASSY ............................................................ 52-28

STEERING PROPELLER SHAFT ASSY .................................... 51-19

STEERING WHEEL ASSY............................................................ 51-7

STEP BOARD ............................................................................. 88-15

SUN VISOR ASSY ...................................................................... 88-13

SUPPLEMENTAL RESTRAINT SYSTEM..................................... 62-1

SYSTEM PERFORMANCE(SUPPLEMENTAL RESTRAINT

SYSTEM)....................................................................................... 62-3

SYSTEM PRINCIPLES(SUPPLEMENTAL RESTRAINT

SYSTEM)....................................................................................... 62-2

SYSTEM WIRING DIAGRAM SECTION EXAMPLE(HOW TO

USE THIS MANUAL)..................................................................... 71-2

T - REAR DEFROST LH WIRE HARNESS(CONNECT

VIEWS)...................................................................................... 71-177

T - REAR DEFROST LH WIRE HARNESS(WIRE HARNESS & CON-

NECTOR LOCATION VIEWS) .................................................. 71-204

TELESCOPIC ANTENNA ASSY ................................................. 66-10

TRANSMISSION ASSY(TANGSHANAIXIN)............................... 41-73

TRANSMISSION ASSY(YANCHENGZHONGMA ZM001) ........... 41-8

TRANSMISSION OPERATION MECHANISM ASSY ................... 41-1

V - FRONT WIRE HARNESS(CONNECT VIEWS) ...... 71-179, 71-135

V - FRONT WIRE HARNESS(WIRE HARNESS & CONNECTOR

LOCATION VIEWS) ..................................................... 71-186, 71-166

U - HIGH-MOUNTED STOP LAMP WIRE HARNESS(CONNECT

VIEWS)......................................................................... 71-178, 71-134

U - HIGH-MOUNTED STOP LAMP WIRE HARNESS(WIRE HAR-

NESS & CONNECTOR LOCATION VIEWS) ............... 71-204, 71-182

ASSY ............................................................................................. 42-8

WASHER NOZZLE...................................................................... 65-15

VEHICLE DOOR INNER GUARD BOARD ................................. 88-18

VEHICLE WITH REAR WIPER ASSY(COMPONENTS) .............. 65-4

WHEEL MUDGUARD.................................................................... 88-7

WINDOW DEFROSTER(WIRING DIAGRAM) ................. 71-93, 71-88

WINDSHIELD ................................................................................ 82-7

WIPER AND WASHER SYSTEM.................................................. 65-1

WIPER AND WASHER(WIRING DIAGRAM)................... 71-77, 71-73

WIPER ASSY ................................................................................ 65-5

WIPER BLADE WITH BRACKET ASSY ..................................... 65-13

WIPER LINK WITH MOTOR ASSY............................................... 65-9

WIRE HARNESS & CONNECTOR LOCATION

VIEWS.......................................................................... 71-186, 71-166

WIRING DIAGRAM .......................................................... 71-18, 71-19

X

X - PREHEATING WIRE HARNESS(WIRE HARNESS & CONNEC-

TOR LOCATION VIEWS)............................................. 71-199, 71-179

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DIAGNOSTICS - LIGHTING SYSTEM 04-21

DIAGNOSTICS - LIGHTING SYSTEM 04-22

DIAGNOSTICS - LIGHTING SYSTEM 04-23

DIAGNOSTICS - LIGHTING SYSTEM 04-24

DIAGNOSTICS - LIGHTING SYSTEM 04-25

DIAGNOSTICS - LIGHTING SYSTEM 04-26

DIAGNOSTICS - LIGHTING SYSTEM 04-27

DIAGNOSTICS - LIGHTING SYSTEM 04-28

DIAGNOSTICS - LIGHTING SYSTEM 04-29

DIAGNOSTICS - LIGHTING SYSTEM 04-30

DIAGNOSTICS - LIGHTING SYSTEM 04-31

DIAGNOSTICS - LIGHTING SYSTEM 04-32

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DIAGNOSTICS - WIPER AND WASHER 04-3

DIAGNOSTICS - AUDIO SYSTEM 04-393 L

DIAGNOSTICS - AUDIO SYSTEM 04-395 P

DIAGNOSTICS - AUDIO SYSTEM 04-397 I

DIAGNOSTICS - AUDIO SYSTEM 04-399 5

DIAGNOSTICS - AUDIO SYSTEM 04-401 P

DIAGNOSTICS - AUDIO SYSTEM 04-403 I

DIAGNOSTICS - AUDIO SYSTEM 04-405 6

DIAGNOSTICS - AUXILIARY POWER 04-40

DIAGNOSTICS - AUXILIARY POWER 04-41

HORN SYSTEM LOCATION DIAGNOSTICS -

DIAGNOSTICS - HORN SYSTEM 04-417 HO

DIAGNOSTICS - HORN SYSTEM 04-419 3.

DIAGNOSTICS - HORN SYSTEM 04-421 8.

DIAGNOSTICS - HORN SYSTEM 04-423 IN

DIAGNOSTICS - REVERSE RADAR SYSTEM

DIAGNOSTICS - POWER WINDOWS 04-449

DIAGNOSTICS - POWER WINDOWS 04-451

DIAGNOSTICS - POWER WINDOWS 04-453

DIAGNOSTICS - POWER WINDOWS 04-455

DIAGNOSTICS - POWER WINDOWS 04-457

DIAGNOSTICS - POWER WINDOWS 04-459

DIAGNOSTICS - POWER WINDOWS 04-461

DIAGNOSTICS - POWER WINDOWS 04-463

DIAGNOSTICS - POWER WINDOWS 04-465

DIAGNOSTICS - POWER WINDOWS 04-467

DIAGNOSTICS - POWER WINDOWS 04-469

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DIAGNOSTICS - OUTSIDE MIRROR 04-475

DIAGNOSTICS - OUTSIDE MIRROR 04-477

DIAGNOSTICS - OUTSIDE MIRROR 04-479

DIAGNOSTICS - OUTSIDE MIRROR 04-481

DIAGNOSTICS - OUTSIDE MIRROR 04-483

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DEFROSTER SYSTEM LOCATION DIAGNOSTI

DIAGNOSTICS - DEFROSTER SYSTEM 04-4

DIAGNOSTICS - DEFROSTER SYSTEM 04-5

DIAGNOSTICS - INSTRUMENT CLUSTER 04

DIAGNOSTICS - POWER DOOR LOCKS 04-5

DIAGNOSTICS - SLIDING ROOF SYSTEM 0

A ABBREVIATIONS USED IN THIS MANUAL

PROBLEM SYMPTOMS TABLE(SUPPLEMENTAL

WORKSHOP MANUAL - VIEW CS2 / C2 V O

DIAGNOSTICS(RHD) ENGINE CONTROL SYS

CIGARETTE LIGHTER ILLUMINATION IS N

MALFUCTION IN ENGINE COOLANT TEMPER

ENGINE CONTROL SYSTEM DIAGNOSTICS(R

DIAGNOSTICS(RHD) - ENGINE CONTROL S

DIAGNOSTICS(RHD) - ANTI-LOCK BRAKE

DIAGNOSTICS(RHD) - SUPPLEMENTAL RES

DIAGNOSTICS(RHD) - HEATER AND AIR C

LIGHTING SYSTEM PRECAUTION DIAGNOST

DIAGNOSTICS(RHD) - LIGHTING SYSTEM

DIAGNOSTICS(RHD) - WIPER AND WASHER

DIAGNOSTICS(RHD) - AUDIO SYSTEM 04-

DIAGNOSTICS(RHD) - AUXILIARY POWER

DIAGNOSTICS(RHD) - HORN SYSTEM 04-3

REVERSE RADAR SYSTEM PRECAUTION DIA

DIAGNOSTICS(RHD) - REVERSE RADAR SY

DIAGNOSTICS(RHD) - POWER WINDOWS 04

DIAGNOSTICS(RHD) - OUTSIDE MIRROR 0

DIAGNOSTICS(RHD) - OUTSIDE MIRROR D

DIAGNOSTICS(RHD) - INSTRUMENT CLUST

DIAGNOSTICS(RHD) - POWER DOOR LOCKS

VEHICLE MAINTENANCE MAINTENANCE SCH

VEHICLE MAINTENANCE - MAINTENANCE S

CHECK THE BATTERY VEHICLE MAINTENAN

CHECK SEAT BELT VEHICLE MAINTENANCE

VEHICLE MAINTENANCE - INSPECTION 05

VEHICLE MAINTENANCE - (g) (h) INSPE

VEHICLE MAINTENANCE - REPLACEMENT 0

VEHICLE MAINTENANCE - 14. TURN IGNI

ENGINE CONTROL SYSTEM GASOLINE ENGI

ENGINE CONTROL SYSTEM - GASOLINE EN

ENGINE CONTROL SYSTEM - 3. ECM CONT

ENGINE CONTROL SYSTEM - 3. CONTROL

MAIN COMPONENTS ENGINE CONTROL SYST

ENGINE CONTROL SYSTEM - ENGINE CONT

ENGINE CONTROL SYSTEM - (g) ENGINE

OVERHAUL ENGINE CONTROL SYSTEM - 1.

ENGINE CONTROL SYSTEM - THROTTLE BO

ENGINE CONTROL SYSTEM - IDLE AIR CO

ENGINE CONTROL SYSTEM - THROTTLE PO

ENGINE CONTROL SYSTEM - ON-VEHICLE

ENGINE CONTROL SYSTEM - MANIFOLD AB

ENGINE CONTROL SYSTEM - KNOCK SENSO

CKP SENSOR PRINCIPLE ENGINE CONTROL

ENGINE CONTROL SYSTEM - CKP SENSOR

ENGINE CONTROL SYSTEM - DOWNSTREAM

ENGINE CONTROL SYSTEM - CANISTER SO

ENGINE CONTROL SYSTEM - VEHICLE SPE

ENGINE CONTROL SYSTEM - IGNITION CO

FUEL SYSTEM FUEL SYSTEM............

FUEL SYSTEM PRECAUTION FUEL - FUEL

FUEL - FUEL SYSTEM 12A-3 PROBLEM SY

FUEL - FUEL SYSTEM 12A-5 12A 12A 12

FUEL - FUEL TANK ASSY 12A-7 • Mar

FUEL - FUEL FILTER ASSY 12A-9 FUEL

FUEL - ELECTRIC FUEL PUMP ASSY 12A-

FUEL - FUEL INJECTOR RAIL ASSY 12A-

FUEL - FUEL FILLER DOOR 12A-17 FUEL

FUEL - FUEL FILLER DOOR LOCK LATCH

FUEL - FUEL FILLING TUBE AND BREATH

FUEL - ACCELERATE PEDAL 12A-25 ACCE

EMISSION CONTROL FUEL FILLER CAP ..

EMISSION CONTROL - FUEL FILLER CAP

EMISSION CONTROL - CHARCOAL CANISTE

EMISSION CONTROL - CANISTER SOLENOI

EMISSION CONTROL - POSITIVE CRANKCA

INTAKE AIR INTAKE AIR SYSTEM.......

INTAKE AIR SYSTEM AIR PRECAUTION 1.

INTAKE AIR - INTAKE AIR PIPE AND HO

INTAKE AIR - AIR FILTER ASSY 14A-7

INTAKE AIR - AIR FILTER ASSY 14A-9

INTAKE AIR - AIR FILTER ASSY 14A-11

INTAKE AIR - AIR FILTER ASSY 14A-13

INTAKE AIR - AIR FILTER ASSY 14A-15

ENGINE MECHANICAL ENGINE MECHANICAL

ENGINE MECHANICAL - ENGINE MECHANIC

ENGINE MECHANICAL - ENGINE ASSY 15A

ENGINE MECHANICAL - TIMING PULLEY C

ENGINE MECHANICAL - TIMING BELT 15A

ENGINE MECHANICAL - ROCK ARM, ROCK

CYLINDER HEAD,VALVE COMPONENTS ENGI

ENGINE MECHANICAL - CYLINDER HEAD,V

ENGINE MECHANICAL - PISTON & CONNEC

ENGINE MECHANICAL - CRANKSHAFT, CYL

EXHAUST SYSTEM EXHAUST PIPE .......

EXHAUST - EXHAUST PIPE 16A-1 EXHAUS

EXHAUST - EXHAUST PIPE 16A-3 (b) (c

EXHAUST - EXHAUST PIPE 16A-5 (b) Co

EXHAUST - EXHAUST MANIFOLD 16A-7 EX

EXHAUST - EXHAUST MANIFOLD 16A-9 12

COOLING SYSTEM COOLING SYSTEM .....

COOLING SYSTEM PRECAUTION COOLING -

COOLING - COOLING SYSTEM 17A-3 PROB

COOLING - COOLING SYSTEM 17A-5 •

COOLING - COOLANT 17A-7 (c) Push th

COOLING - RESERVIOR 17A-9 3. INSTAL

COOLING - COOLING FAN ASSY 17A-11 4

COOLING - RADIATOR 17A-13 RADIATOR

COOLING - RADIATOR 17A-15 (e) Remov

COOLING - RADIATOR 17A-17 13. INSTA

COOLING - THERMOSTAT 17A-19 7. REMO

COOLING - THERMOSTAT 17A-21 (a) Ins

COOLANT PUMP OVERHAUL COOLING - COO

LUBRICATION SYSTEM LUBRICATION SYST

LUBRICATION SYSTEM PRECAUTION LUBRI

LUBRICATION - LUBRICATION SYSTEM 18

LUBRICATION - ENGINE OIL 18A-5 7. R

LUBRICATION - OIL FILTER 18A-7 9. T

LUBRICATION - OIL PAN 18A-9 (d) Rem

LUBRICATION - OIL PUMP 18A-11 OIL P

LUBRICATION - OIL PUMP 18A-13 15. R

LUBRICATION - OIL PUMP 18A-15 (d) R

LUBRICATION - OIL PUMP 18A-17 29. U

LUBRICATION - OIL PUMP 18A-19 38. U

IGNITION SYSTEM IGNITION SYSTEM ...

IGNITION SYSTEM COMPONENTS IGNITION

IGNITION - IGNITION MODULE/SPARK PL

STARTING AND CHARGING STARTING AND

STARTING AND CHARGING - STARTING AN

STARTING AND CHARGING - GENERATOR 2

STARTING AND CHARGING - STARTER 20A

STARTING AND CHARGING - BATTERY 20A

A A SINGLE MIRROR IS INOPERATIVE ..

OVERHAUL(CANISTER SOLENOID VALVE)..

电控燃油喷射系统 -

CONTROL SYSTEM OF ENGINE-CONTROL SY

CONTROL SYSTEM OF ENGINE-ENGINE CON

CONTROL SYSTEM OF ENGINE-REPAIR FOR

模板 00 FUEL SYSTEM FUEL SYSTEM

FUEL-FUEL SYSTEM 12B-1 FUEL SYSTEM

FUEL-FUEL SYSTEM 12B-3 SYSTEM COMPO

FUEL-FUEL SYSTEM 12B-5 2. Working p

FUEL-FUEL SYSTEM 12B-7 DIAGRAM OF C

FUEL-FUEL SYSTEM 12B-9 Electric VE

FUEL-FUEL SYSTEM 12B-11 Fuel system

FUEL-FUEL INJECTOR (ELECTRONIC) 12B

FUEL INJECTOR (MECHANICAL) DIAGRAM

FUEL-FUEL INJECTOR (MECHANICAL) 12B

FUEL-HIGH PRESSURE FUEL RAIL 12B-27

FUEL-HIGH PRESSURE FUEL RAIL 12B-29

FUEL INJECTION PUMP (VE PUMP) ADJUS

FUEL-FUEL PIPELINE (ENGINE PART) 12

FUEL-FUEL TANK 12B-37 FUEL TANK SER

FUEL-FUEL TANK 12B-39 (h). Remove t

FUEL-FUEL TANK 12B-41 (g). Install

FUEL-FUEL FILTER (COARSE FILTER) 12

FUEL-FUEL FILTER (FINE FILTER) 12B-

驻车制动 - 驻车制动

EMISSION CONTROL--EGR SYSTEM 13B-1

EMISSION CONTROL--EGR SYSTEM 13B-3

EMISSION CONTROL-EGR PIPE 13B-5 (b)

EGR VALVE SERVICE EMISSION CONTROL-

EMISSION CONTROL-EGR VALVE 13B-9 5.

1 INTAKE SYSTEM INTAKE SYSTEM .....

INTAKE-INTAKE SYSTEM 14B-1 INTAKE S

INTAKE-INTAKE SYSTEM 14B-3 WORKING

INTAKE-INTAKE MANIFOLD 14B-5 SERVIC

INTAKE-INTAKE MANIFOLD 14B-7 (l). D

INTAKE-INTAKE MANIFOLD 14B-9 (g). M

INTAKE-INTAKE MANIFOLD 14B-11 (l).

INTAKE-INTAKE PIPELINE 14B-13 REPLA

INTAKE-INTAKE PIPELINE 14B-15 4. Ch

AIR FILTER SERVICE △ Tip: INTAKE-

INTAKE-AIR FILTER 14B-19 (b). (c).

ENGINE MECHANICAL PART ENGINE ASSEM

Disassembly of oil pan and oil Pump

ENGINE MECHANICAL PART-ENGINE ASSEM

ENGINE MECHANICAL PART-ENGINE MAINT

ENGINE MECHANICAL PART-DISASSEMBLY/

ENGINE MECHANICAL PART- PRESERVATIO

ENGINE MECHANICAL PART- DISSASSEBLY

ENGINE MECHANICAL PART-ASSEMBLY OF

ENGINE MECHANICAL PART- DISASSEMBLY

ENGINE MECHANICAL PART- ASSEMBLY OF

ENGINE MECHANICAL PART- INSTALLATIO

ENGINE MECHANICAL PART- CYLINDER HE

ENGINE MECHANICAL PART-ROCKER ASSEM

ENGINE MECHANICAL PART-CYLINDER HEA

ENGINE MECHANICAL PART- VALVE 15B-2

ENGINE MECHANICAL PART-CAMSHAFT AND

ENGINE MECHANICAL PART-PISTON AND C

ENGINE MECHANICAL PART-CRANKSHAFT A

ENGINE MECHANICAL PART-CYLINDER BLO

1 EXHAUST SYSTEM EXHAUST SYSTEM ...

EXHAUST-EXHAUST SYSTEM 16B-1 EXHAUS

EXHAUST-EXHAUST SYSTEM 16B-3 WORKIN

EXHAUST-EXHAUST MANIFOLD 16B-5 SERV

EXHAUST-EXHAUST MANIFOLD 16B-7 (f).

EXHAUST PIPE DIAGRAM OF COMPONENTS

EXHAUST-EXHAUST PIPE 16B-11 (e). Re

EXHAUST-EXHAUST PIPE 16B-13 (d). Pl

COOLING SYSTEM COOLING SYSTEM......

COOLING-COOLING SYSTEM 17B-1 COOLIN

COOLING-COOLING SYSTEM 17B-3 WORKIN

(Fan and water pump pulley chamber

COOLING-THERMOSTAT 17B-7 THERMOSTAT

COOLING-THERMOSTAT 17B-9 (b). Heat

TRANSMISSION BELT SERVICE COOLING-T

COOLING-TRANSMISSION BELT 17B-13 6.

COOLING-PULLEY AND FAN 17B-15 4. Ch

COOLING-WATER PUMP 17B-17 (d). Dism

COOLING-OIL COOLER 17B-19 OIL COOLE

COOLING-EXPANSION TANK 17B-21 EXPAN

COOLING-COOLING PIPELINE 17B-23 COO

COOLING-RADIATOR 17B-25 RADIATOR RE

COOLING-RADIATOR 17B-27 3. Install

润滑系统 - 润滑系统 1

LUBRICATION - OIL DIPSTICK 18B-13 (

LUBRICATION - OIL PAN 18B-15 3. Cle

LUBRICATION - OIL PUMP 18B-17 OIL P

LUBRICATION - OIL PUMP 18B-19 (b).

LUBRICATION - OIL PUMP 18B-21 (b).

LUBRICATION - OIL FILTER 18B-23 (b)

IGNITION - IGNITION SYSTEM 19-1 IGN

IGNITION - IGNITION SYSTEM 19-3 CHE

IGNITION - SPARK PLUG 19-5 SERVICE

IGNITION - SPARK PLUG 19-7 4. Assem

IGNITION - CRANKSHAFT POSITION SENS

电器系统 - 发电机 14- S

STARTING AND CHARGING - STARTER 20B

STARTING AND CHARGING - BATTERY ASS

STARTING AND CHARGING - USE OF MAIN

SUPERCHARGER SUPERCHARGING SYSTEM .

SUPERCHARGING SYSTEM-SUPERCHARGING

SUPERCHARGING SYSTEM-TURBOCHARGER 2

ENGINE CONTROL SYSTEM DIESEL ENGINE

ENGINE CONTROL SYSTEM - DIESEL ENGI

ENGINE CONTROL SYSTEM - ACCELEARTOR

FUEL - FUEL SYSTEM 12C-3 FUEL TUBE

FUEL - FUEL SYSTEM 12C-5 12C 1 Bolt

FUEL - FUEL TANK ASSY 12C-7 (g) (h)

FUEL - DIESEL FILTER ASSY 12C-9 DIE

FUEL - FUEL LEVEL SENSOR AND BRACKE

FUEL - FUEL FILLER CAP 12C-15 FUEL

EMISSION CONTROL - DIESEL OXIDATION

INTAKE AIR - INTAKE AIR SYSTEM 14C-

INTAKE AIR - AIR FILTER ASSY 14C-7

INTAKE AIR - AIR FILTER ASSY 14C-9

INTAKE AIR - INTERCOOLER INTAKE AIR

ENGINE MECHANICAL - ENGINE ASSY 15C

ENGINE MECHANICAL - ENGINE ACCESSOR

EXHAUST PIPE COMPONENTS EXHAUST - E

EXHAUST - EXHAUST PIPE 16C-3 REPLAC

EXHAUST - EXHAUST PIPE 16C-5 10. IN

COOLING SYSTEM COOLING PRECAUTION C

COOLING - COOLING SYSTEM 17C-3 17C

COOLING - COOLING SYSTEM 17C-5 ON-V

COOLING - COOLANT 17C-7 COOLANT REP

COOLING - RESERVIOR 17C-9 RESERVIOR

COOLING - COOLING FAN ASSY 17C-11 C

COOLING - COOLING FAN ASSY 17C-13 (

COOLING - RADIATOR 17C-15 (c) (d) P

COOLING - RADIATOR 17C-17 11. INSTA

LUBRICATION - ENGINE OIL 18C-3 13.

LUBRICATION - OIL FILTER 18C-5 10.

LUBRICATION - OIL PUMP 18C-7 OIL PU

STARTING AND CHARGING - STARTER 20C

STARTING AND CHARGING - BATTERY 20C

SUSPENSION SYSTEM FRONT SUSPENSION.

FRONT SUSPENSION FRONT SUSPENSION..

FRONT SUSPENSION SUSPENSION PRECAUT

FRONT SUSPENSION - FRONT SUSPENSION

FRONT SUSPENSION - FRONT WHEEL ALIG

FRONT SUSPENSION - FRONT SHOCK ABSO

FRONT SUSPENSION - TORSION BAR 31-1

FRONT SUSPENSION - UPPER CONTROL AR

FRONT SUSPENSION - LOWER CONTROL AR

FRONT SUSPENSION - STABILIZER BAR 3

FRONT SUSPENSION - STRUT ROD 31-23

REAR SUSPENSION REAR SUSPENSION ...

REAR SUSPENSION - REAR SUSPENSION 3

REAR SUSPENSION - REAR SHOCK ABSORB

REAR SUSPENSION - REAR LEAF SPRING

TYRE AND WHEEL TIRE AND WHEEL ASSY

TIRE AND WHEEL ASSY WHEEL AND TIRE

WHEEL AND TIRE - TIRE AND WHEEL ASS

WHEEL AND TIRE - REAR WHEEL AND TIR

AXLE AND PROPELLER SHAFT PROPELLER

AXLE AND PROPELLER SHAFT - PROPELLE

AXLE AND PROPELLER SHAFT - U-JOINT

AXLE AND PROPELLER SHAFT - CENTER S

AXLE AND PROPELLER SHAFT - AXLE HUB

AXLE AND PROPELLER SHAFT - FRONT HU

AXLE AND PROPELLER SHAFT - REAR AXL

AXLE AND PROPELLER SHAFT - STEERING

AXLE AND PROPELLER SHAFT - FINAL DR

AXLE SHAFT ASSY OVERHAUL AXLE AND P

AXLE AND PROPELLER SHAFT - DRIVE PI

BRAKING SYSTEMS BRAKE SYSTEM ......

BRAKE BRAKE SYSTEM ................

BRAKE SYSTEM PRECAUTION BRAKE - BRA

BRAKE - PROBLEM SYMPTOMS TABLE 35-3

BRAKE - BRAKE FLUID 35-5 3. BLEED B

BRAKE - BRAKE PEDAL 35-7 ADJUSTMENT

BRAKE - BRAKE PEDAL 35-9 REPLACEMEN

BRAKE - BRAKE PEDAL 35-11 (d) Remov

BRAKE - BRAKE PEDAL 35-13 10. INSTA

BRAKE - VACUUM BOOSTER WITH BRAKE M

BRAKE - VACUUM BOOSTER LINE 35-19 3

BRAKE - FRONT BRAKE 35-21 (b) Remov

BRAKE - FRONT BRAKE 35-23 (c) Remov

BRAKE - FRONT BRAKE 35-25 14. INSTA

BRAKE - REAR BRAKE 35-27 OVERHAUL 1

BRAKE - REAR BRAKE 35-29 (b) Remove

BRAKE - REAR BRAKE 35-31 12. INSPEC

BRAKE - REAR BRAKE 35-33 17. INSTAL

BRAKE - REAR BRAKE 35-35 22. INSPEC

BRAKE - ABS ACTUATOR 35-37 ABS ACTU

BRAKE - ABS ACTUATOR 35-39 11. CHEC

BRAKE - WHEEL SPEED SENSOR 35-41 4.

PARKING BRAKE PARKING BRAKE SYSTEM.

PARKING BRAKE - PARKING BRAKE SYSTE

PARKING BRAKE - FRONT PARKING BRAKE

PARKING BRAKE - REAR PARKING BRAKE

PROBLEM SYMPTOMS TABLE(STARTING AND

TRANSMISSION TRANSMISSION OPERATION

TRANSMISSION - TRANSMISSION OPERATI

TRANSMISSION - TRANSMISSION ASSY(YA

CLUTCH CASE DIAGRAM OF COMPONENTS T

TRANSMISSION - CLUTCH CASE 41-41 (g

REAR PART ASSEMBLY DIAGRAM OF COMPO

TRANSMISSION - REAR PART ASSEMBLY 4

TRANSMISSION - FORK SHAFT ASSEMBLY

INPUT SHAFT ASSEMBLY DIAGRAM OF COM

TRANSMISSION - INPUT SHAFT ASSEMBLY

TRANSMISSION - OUTPUT SHAFT ASSEMBL

TRANSMISSION - COUNTER SHAFT ASSEMB

REVERSE SHAFT ASSEMBLY DIAGRAM OF C

TRANSMISSION - REVERSE SHAFT ASSEMB

TRANSMISSION - TRANSMISSION ASSY(TA

CLUTCH CLUTCH SYSTEM ..............

CLUTCH - CLUTCH SYSTEM 42-1 CLUTCH

CLUTCH - CLUTCH FLUID 42-3 CLUTCH F

CLUTCH - CLUTCH PEDAL 42-5 ADJUSTME

CLUTCH - CLUTCH PEDAL 42-7 7. INSTA

CLUTCH - VACUUM BOOSTER WITH CLUTCH

CLUTCH - CLUTCH SLAVE CYLINDER 42-1

CLUTCH SUB - ASSY COMPONENTS CLUTCH

CLUTCH - CLUTCH SUB - ASSY 42-15 4.

CLUTCH - CLUTCH SUB - ASSY 42-17 9.

CLUTCH - CLUTCH SUB - ASSY 42-19 15

STEERING COLUMN STEERING SYSTEM....

STEERING SYSTEM COLUMN PRECAUTION S

STEERING COLUMN - STEERING SYSTEM 5

STEERING COLUMN - STEERING WHEEL AS

STEERING COLUMN - COMBINATION SWITC

STEERING COLUMN - STEERING COLUMN A

STEERING COLUMN - STEERING PROPELLE

POWER STEERING POWER STEERING SYSTE

POWER STEERING - POWER STEERING SYS

POWER STEERING - ON-VEHICLE INSPECT

POWER STEERING - STEERING FLUID 52-

POWER STEERING - POWER STEERING PUM

POWER STEERING - DIESEL VEHICLES (I

POWER STEERING - POWER STEERING LIN

POWER STEERING - STEERING GEAR ASSY

POWER STEERING - STEERING FLUID RES

HEATER AND AIR CONDITIONING HEATER

HEATER AND AIR CONDITIONING - HEATE

HEATER AND AIR CONDITIONING - ON-VE

HEATER AND AIR CONDITIONING - REFRI

HEATER AND AIR CONDITIONING - COMPR

HEATER AND AIR CONDITIONING - MULTI

HEATER AND AIR CONDITIONING - REAR

HEATER AND AIR CONDITIONING - FRONT

HEATER AND AIR CONDITIONING - (n) F

HEATER AND AIR CONDITIONING - TOP E

HEATER AND AIR CONDITIONING - RECIR

HEATER AND AIR CONDITIONING - BLEND

HEATER AND AIR CONDITIONING - MODE

HEATER AND AIR CONDITIONING - COOLI

HEATER AND AIR CONDITIONING - CONDE

HEATER AND AIR CONDITIONING - A/C R

SUPPLEMENTAL RESTRAINT SYSTEM SUPPL

SUPPLEMENTAL RESTRAINT SYSTEM - SUP

SUPPLEMENTAL RESTRAINT SYSTEM - HOR

SUPPLEMENTAL RESTRAINT SYSTEM - CLO

SUPPLEMENTAL RESTRAINT SYSTEM - RCM

SEAT BELT SEAT BELT SYSTEM ........

SEAT BELT - SEAT BELT SYSTEM 63-1 S

SEAT BELT - SEAT BELT WARNING SYSTE

SEAT BELT - PASSENGER SEAT BELT 63-

SEAT BELT - SEAT BELT CATCH ASSY 63

SEAT BELT - RETRACTOR ASSY 63-15 RE

SEAT BELT - RETRACTOR ASSY 63-17 5.

SEAT BELT - RETRACTOR ASSY 63-19 (e

SEAT BELT - RETRACTOR ASSY 63-21 (g

LIGHTING LIGHTING SYSTEM...........

LIGHTING SYSTEM PRECAUTION 1. LIGHT

LIGHTING - FRONT COMBINATION LAMP A

LIGHTING - FRONT FOG LAMP ASSY 64-9

LIGHTING - REAR COMBINATION LAMP AS

LIGHTING - LICENCE LAMP ASSY 64-15

LIGHTING - FRONT DOME LIGHT ASSY 64

LIGHTING - MIDDLE DOME LIGHT ASSY 6

LIGHTING - REAR DOME LIGHT ASSY 64-

LIGHTING - STEP LAMP ASSY 64-25 STE

LIGHTING - COMBINATION SWITCH ASSY

WIPER AND WASHER WIPER AND WASHER S

WIPER AND WASHER - WIPER AND WASHER

WIPER AND WASHER - WIPER ASSY 65-5

WIPER AND WASHER - WIPER ASSY 65-7

WIPER AND WASHER - WIPER LINK WITH

WIPER AND WASHER - WIPER BLADE WITH

WIPER AND WASHER - WASHER NOZZLE 65

WIPER AND WASHER - WASHER ASSY 65-1

WIPER AND WASHER - WASHER PUMP ASSY

AUDIO SYSTEM AUDIO SYSTEM..........

AUDIO SYSTEM SYSTEM COMPONENTS AUDI

AUDIO SYSTEM - MULTI-MEDIA AND AIR-

AUDIO SYSTEM - FRONT SPEAKER ASSY 6

AUDIO SYSTEM - MIDDLE SPEAKER ASSY

AUDIO SYSTEM - REAR SPERKER ASSY 66

AUDIO SYSTEM - TELESCOPIC ANTENNA A

AUDIO SYSTEM - ELECTRIC DEVICE ACCE

WIRING HOW TO USE THIS MANUAL......

WIRING - HOW TO USE THIS MANUAL 71-

WIRING - WIRING DIAGRAM 71-19 71 71

WIRING - WIRING DIAGRAM 71-21 71 71

WIRING - WIRING DIAGRAM 71-23 Servi

WIRING - WIRING DIAGRAM 71-25 71 71

WIRING - WIRING DIAGRAM 71-27 71 71

WIRING - WIRING DIAGRAM 71-29 • E

WIRING - WIRING DIAGRAM 71-31 I110

WIRING - WIRING DIAGRAM 71-33 71 71

WIRING - WIRING DIAGRAM 71-35 Syste

WIRING - WIRING DIAGRAM 71-37 START

WIRING - WIRING DIAGRAM 71-39 CHARG

WIRING - WIRING DIAGRAM 71-41 ANTI-

WIRING - WIRING DIAGRAM 71-43 I110

WIRING - WIRING DIAGRAM 71-45 71 71

WIRING - WIRING DIAGRAM 71-47 Syste

WIRING - WIRING DIAGRAM 71-49 Code

WIRING - WIRING DIAGRAM 71-51 Syste

WIRING - WIRING DIAGRAM 71-53 Syste

WIRING - WIRING DIAGRAM 71-55 Groun

WIRING - WIRING DIAGRAM 71-57 Syste

WIRING - WIRING DIAGRAM 71-59 STOP

WIRING - WIRING DIAGRAM 71-61 BACK-

WIRING - WIRING DIAGRAM 71-63 TURN

WIRING - WIRING DIAGRAM 71-65 F006

WIRING - WIRING DIAGRAM 71-67 Syste

WIRING - WIRING DIAGRAM 71-69 INTER

WIRING - WIRING DIAGRAM 71-71 Syste

WIRING - WIRING DIAGRAM 71-73 ILLUM

WIRING - WIRING DIAGRAM 71-75 Syste

WIRING - WIRING DIAGRAM 71-77 WIPER

WIRING - WIRING DIAGRAM 71-79 Code

WIRING - WIRING DIAGRAM 71-81 Servi

WIRING - WIRING DIAGRAM 71-83 POWER

WIRING - WIRING DIAGRAM 71-85 COMMU

WIRING - WIRING DIAGRAM 71-87 REVER

WIRING - WIRING DIAGRAM 71-89 Code

WIRING - WIRING DIAGRAM 71-91 Syste

WIRING - WIRING DIAGRAM 71-93 WINDO

WIRING - WIRING DIAGRAM 71-95 Code

WIRING - WIRING DIAGRAM 71-97 71 71

WIRING - WIRING DIAGRAM 71-99 71 71

WIRING - WIRING DIAGRAM 71-101 •

WIRING - WIRING DIAGRAM 71-103 ANTI

WIRING - WIRING DIAGRAM 71-105 Syst

WIRING - WIRING DIAGRAM 71-107 Code

WIRING - WIRING DIAGRAM 71-109 Syst

WIRING - WIRING DIAGRAM 71-111 Syst

WIRING - CONNECTOR VIEWS 71-113 71

WIRING - CONNECTOR VIEWS 71-115 71

WIRING - CONNECTOR VIEWS 71-117 71

WIRING - CONNECTOR VIEWS 71-119 A03

WIRING - CONNECTOR VIEWS 71-121 A10

WIRING - CONNECTOR VIEWS 71-123 A10

WIRING - CONNECTOR VIEWS 71-125 B -

WIRING - CONNECTOR VIEWS 71-127 D -

WIRING - CONNECTOR VIEWS 71-129 71

WIRING - CONNECTOR VIEWS 71-131 E00

WIRING - CONNECTOR VIEWS 71-133 E00

WIRING - CONNECTOR VIEWS 71-135 E01

WIRING - CONNECTOR VIEWS 71-137 71

WIRING - CONNECTOR VIEWS 71-139 71

WIRING - CONNECTOR VIEWS 71-141 E10

WIRING - CONNECTOR VIEWS 71-143 F00

WIRING - CONNECTOR VIEWS 71-145 71

WIRING - CONNECTOR VIEWS 71-147 71

WIRING - CONNECTOR VIEWS 71-149 71

WIRING - CONNECTOR VIEWS 71-151 B15

WIRING - CONNECTOR VIEWS 71-153 I00

WIRING - CONNECTOR VIEWS 71-155 I01

WIRING - CONNECTOR VIEWS 71-157 71

WIRING - CONNECTOR VIEWS 71-159 71

WIRING - CONNECTOR VIEWS 71-161 I10

WIRING - CONNECTOR VIEWS 71-163 71

WIRING - CONNECTOR VIEWS 71-165 71

WIRING - CONNECTOR VIEWS 71-167 71

WIRING - CONNECTOR VIEWS 71-169 L -

WIRING - CONNECTOR VIEWS 71-171 N -

WIRING - CONNECTOR VIEWS 71-173 P -

WIRING - CONNECTOR VIEWS 71-175 R -

WIRING - CONNECTOR VIEWS 71-177 T -

WIRING - CONNECTOR VIEWS 71-179 V -

WIRING - CONNECTOR VIEWS 71-181 71

WIRING - CONNECTOR VIEWS 71-183 71

WIRING - CONNECTOR VIEWS 71-185 X -

WIRING - WIRE HARNESS & CONNECTOR L

WIRING(RHD) HOW TO USE THIS MANUAL.

WIRING(RHD) - HOW TO USE THIS MANUA

WIRING DIAGRAM POWER SOURCE WIRING(

WIRING(RHD) - WIRING DIAGRAM 71-21

WIRING(RHD) - WIRING DIAGRAM 71-23

WIRING(RHD) - WIRING DIAGRAM 71-25

WIRING(RHD) - WIRING DIAGRAM 71-27

WIRING(RHD) - WIRING DIAGRAM 71-29

WIRING(RHD) - WIRING DIAGRAM 71-31

WIRING(RHD) - WIRING DIAGRAM 71-33

WIRING(RHD) - WIRING DIAGRAM 71-35

WIRING(RHD) - WIRING DIAGRAM 71-37

WIRING(RHD) - WIRING DIAGRAM 71-39

WIRING(RHD) - WIRING DIAGRAM 71-41

WIRING(RHD) - WIRING DIAGRAM 71-43

WIRING(RHD) - WIRING DIAGRAM 71-45

WIRING(RHD) - WIRING DIAGRAM 71-47

WIRING(RHD) - WIRING DIAGRAM 71-49

WIRING(RHD) - WIRING DIAGRAM 71-51

WIRING(RHD) - WIRING DIAGRAM 71-53

WIRING(RHD) - WIRING DIAGRAM 71-55

WIRING(RHD) - WIRING DIAGRAM 71-57

WIRING(RHD) - WIRING DIAGRAM 71-59

WIRING(RHD) - WIRING DIAGRAM 71-61

WIRING(RHD) - WIRING DIAGRAM 71-63

WIRING(RHD) - WIRING DIAGRAM 71-65

WIRING(RHD) - WIRING DIAGRAM 71-67

WIRING(RHD) - WIRING DIAGRAM 71-69

WIRING(RHD) - WIRING DIAGRAM 71-71

WIRING(RHD) - WIRING DIAGRAM 71-73

WIRING(RHD) - WIRING DIAGRAM 71-75

WIRING(RHD) - WIRING DIAGRAM 71-77

WIRING(RHD) - WIRING DIAGRAM 71-79

WIRING(RHD) - WIRING DIAGRAM 71-81

WIRING(RHD) - WIRING DIAGRAM 71-83

WIRING(RHD) - WIRING DIAGRAM 71-85

WIRING(RHD) - WIRING DIAGRAM 71-87

WIRING(RHD) - WIRING DIAGRAM 71-89

WIRING(RHD) - WIRING DIAGRAM 71-91

WIRING(RHD) - WIRING DIAGRAM 71-93

WIRING(RHD) - WIRING DIAGRAM 71-95

WIRING(RHD) - WIRING DIAGRAM 71-97

WIRING(RHD) - WIRING DIAGRAM 71-99

WIRING(RHD) - WIRING DIAGRAM 71-101

WIRING(RHD) - WIRING DIAGRAM 71-103

WIRING(RHD) - CONNECTOR VIEWS 71-10

WIRING(RHD) - CONNECTOR VIEWS 71-11

WIRING(RHD) - CONNECTOR VIEWS 71-12

WIRING(RHD) - CONNECTOR VIEWS 71-13

WIRING(RHD) - CONNECTOR VIEWS 71-14

WIRING(RHD) - CONNECTOR VIEWS 71-15

WIRING(RHD) - CONNECTOR VIEWS 71-16

WIRING(RHD) - WIRE HARNESS & CONNEC

COMMUNICATION SYSTEM HORN .........

COMMUNICATION SYSTEM - HORN 81-1 HO

COMMUNICATION SYSTEM - HORN 81-3 RE

COMMUNICATION SYSTEM - MULTI-MEDIA

REVERSE RADAR PROBLEM SYMPTOMS TABL

COMMUNICATION SYSTEM - REVERSE RADA

COMMUNICATION SYSTEM - ASTERN IMAGE

WINDSHIELDS, MIRRORS & GLASS WINDOW

WINDSHIELD/WINDOWGLASS/REAR VIEW MI

INSTRUMENT PANEL INSTRUMENT CLUSTER

INSTRUMENT PANEL - INSTRUMENT CLUST

INSTRUMENT PANEL - DASHBOARD 83-5 D

INSTRUMENT PANEL - DASHBOARD 83-7 R

INSTRUMENT PANEL - DASHBOARD 83-9 1

INSTRUMENT PANEL - DASHBOARD 83-11

INSTRUMENT PANEL - DASHBOARD 83-13

INSTRUMENT PANEL - DASHBOARD 83-15

SEATS SEATS........................

SEAT - SEAT 84-1 SEATS PRECAUTION W

SEAT - DRIVER / ASSISTANT DRIVER SE

SEAT - PASSENGER SEAT 84-15 PASSENG

SEAT - PASSENGER SEAT 84-17 (j) Pre

SEAT - PASSENGER SEAT 84-19 (b) (c)

SEAT - PASSENGER SEAT 84-21 PASSEBG

SEAT - PASSENGER SEAT 84-23 PASSEBG

DOOR LOCKS FRONT DOOR LOCKS .......

FRONT DOOR LOCKS DOOR LOCKS COMPONE

DOOR LOCKS - FRONT DOOR LOCKS 85-3

DOOR LOCKS - FRONT DOOR LOCKS 85-5

SLIDING DOOR LOCKS COMPONENTS DOOR

DOOR LOCKS - SLIDING DOOR LOCKS 85-

DOOR LOCKS - REAR HATCH LOCK 85-13

DOOR LOCKS - REAR HATCH LOCK 85-15

ENGINE HOOD LOCK COMPONENTS DOOR LO

DOOR LOCKS - ALARM CONTROLLER 85-19

SLIDING ROOF SLIDING ROOF ASSY ....

SLIDING ROOF ASSY SLIDING ROOF PROB

SLIDING ROOF - SLIDING ROOF ASSY 86

DOORS & ENGINE HOOD ENGINE HOOD ...

DOORS - ENGINE HOOD 87-1 ENGINE HOO

DOORS - ENGINE HOOD 87-3 REPLACEMEN

DOORS - FRONT DOOR 87-5 ADJUSTMENT

DOORS - FRONT DOOR 87-7 REPLANCEMEN

SLIDING DOOR COMPONENTS DOORS - SLI

DOORS - SLIDING DOOR 87-11 87 87 Up

DOORS - SLIDING DOOR 87-13 REPLACEM

REAR HATCH COMPONENTS DOORS - REAR

DOORS - REAR HATCH 87-17 2. ADJUST

DOORS - REAR HATCH 87-19 5. INSTALL

EXTERIOR AND INTERIOR TRIM FRONT GR

FRONT GRILLE EXTERIOR AND INTERIOR

FRONT BUMPER ASSY COMPONENTS EXTERI

EXTERIOR AND INTERIOR TRIM - FRONT

EXTERIOR AND INTERIOR TRIM - WHEEL

EXTERIOR AND INTERIOR TRIM - REAR B

SUN VISOR ASSY COMPONENTS EXTERIOR

STEP BOARD COMPONENTS EXTERIOR AND

EXTERIOR AND INTERIOR TRIM - STEP B

EXTERIOR AND INTERIOR TRIM - VEHICL

EXTERIOR AND INTERIOR TRIM - QUARTE

EXTERIOR AND INTERIOR TRIM - FLOOR

ROOF PANEL COMPONENTS EXTERIOR AND

EXTERIOR AND INTERIOR TRIM - ROOF P

VEHICLE CONTROL SYSTEM IGNITION SWI

VEHICLE CONTROL SYSTEM - IGNITION S

INDEX (ORGNIZED ALPHABETICALLY) A A

R - REAR BUMPER WIRE HARNESS(WIRE H

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Peugeot Traveller Dashboard Warning Lights Meaning

Navigating through the sea of dashboard lights on your Peugeot Traveller can sometimes feel like cracking a secret code. From the moment you turn the key, a symphony of lights illuminates your dashboard, each with its unique message and level of urgency. But what do they all mean?

Among these, the indicator lights play a crucial role, serving as the vehicle’s way of communicating vital information to you. Whether it’s a gentle reminder to buckle up or a stern warning about engine trouble, each dashboard light carries its significance.

However, interpreting these dashboard symbols can be a manageable task. With a little knowledge and attention to detail, you can master the language of your Peugeot Traveller’s dashboard lights, ensuring a safer and smoother driving experience. So, buckle up, and let’s dive into the world of dashboard enlightenment!

Hybrid Service Alert Warning Light

The appearance of a wrench intertwined with a lightning bolt (or zig-zag pattern) on your dashboard is a clear indicator that the hybrid system of your Peugeot Traveller requires attention. Various elements could trigger this alert, from the vehicle’s mileage and age to the system identifying a potential malfunction. To address this issue promptly and accurately, it is highly recommended to seek the expertise of a mechanic specializing in Peugeot Traveller vehicles, as they possess the necessary skills and knowledge to handle the intricate nature of hybrid systems.

Power Steering Alert

Observing a red steering wheel icon accompanied by an exclamation point on your dashboard typically signals a problem with the electric power-assisted steering system of your Peugeot Traveller. In such a scenario, it is advisable to safely pull over, turn off the vehicle entirely, and then restart it. If the warning light persists upon restarting the vehicle, it is crucial to contact a skilled mechanic or visit a Peugeot Traveller dealership for professional assistance.

Security/Anti-Theft Alert

A solitary red dot illuminating your dashboard’s instrument cluster may indicate a malfunction within the security or anti-theft system, potentially affecting components like the immobilizer or alarm system (if installed). If this light remains active while driving, it is a clear sign of an issue requiring inspection and resolution by a certified mechanic.

Airbag Alert

The visual cue of a passenger encircled by a large, illuminated red circle on your dashboard is your vehicle’s way of alerting you to a potential problem with one or more airbags in your Peugeot Traveller. Addressing this issue promptly is vital, and it is recommended to take the vehicle to a qualified mechanic or an authorized Peugeot Traveller dealership.

Seat Belt Reminder

An image of a passenger restrained by a belt, set against a red light on your dashboard, serves as a reminder to ensure all passengers have securely fastened their seat belts. This feature operates through a weight-detection system in the seats, meaning items like shopping bags or luggage could also trigger the alert. Additionally, an auditory warning is typically activated once the vehicle is in motion.

Transmission Oil Overheat Alert

A red warning light on your dashboard resembling a thermometer inside a wavy circle (or possibly flower petals) indicates an overheating issue with your transmission oil. This could stem from aged oil that is no longer performing effectively or from your Peugeot Traveller ‘s transmission being subjected to excessive strain. It is imperative to pull over at the earliest opportunity to let the oil cool down before continuing your journey. Should the issue persist, professional help from a trained mechanic or a Peugeot Traveller dealership is recommended.

Engine Temperature Alert

A red backlight illuminating a series of waves with a floating thermometer above them on your dashboard is a critical alert from your Peugeot Traveller, warning that the engine temperature is excessively high. The waves symbolize the engine’s coolant, typically monitored for temperature. Potential causes for this issue range from overworking the engine to a leak or other malfunction. Immediate action is required:

Allow the engine to cool.
Seek assistance from a Peugeot Traveller dealership or a trained mechanic if the problem is unresolved.

Oil Temperature Alert

When an oil can icon accompanied by a floating thermometer appears on your dashboard, it is a clear signal from your Peugeot Traveller that the engine oil is excessively hot. This warning is particularly prevalent in performance-oriented models, which are designed to endure rigorous driving conditions. The overheating could be attributed to vigorous acceleration or, in more severe cases, an oil loss. Given that this is a red warning light, it is imperative to pull over immediately and allow the engine to cool down. If the issue persists, seeking assistance from a professional mechanic is advisable.

Brake System Alert

The appearance of the brake warning light may vary depending on the region where your Peugeot Traveller was purchased. Generally, the brake warning is displayed as the word “BRAKE,” but in Canada, it may be represented by an exclamation point encircled by brake pads. The latter can be misleading as it also resembles the handbrake symbol found in many vehicles. Regardless of the region or the specific icon displayed, a red brake warning light necessitates an immediate response: pull over and halt the vehicle. The issue could range from fluid pressure anomalies to malfunctions in brake assistance programs. It is crucial to seek professional help from a Peugeot Traveller dealership or an independent garage when this warning light is illuminated.

Charging System Alert

A red warning light shaped like a battery (or possibly a Lego brick), with a positive and a negative symbol on opposite sides, indicates a charging system malfunction. If this light illuminates your dashboard, it means the battery is not receiving a charge from the engine. Given the severity of this issue, as indicated by the red light, it is essential to stop driving and pull over as soon as possible. Common causes include a malfunctioning alternator or loose wires connecting to the battery. Continuing to drive with a potentially depleted battery could lead to a loss of critical vehicle systems, posing a severe risk. In such cases, it is advisable to seek immediate assistance from an independent mechanic or a Peugeot Traveller dealership.

Oil Pressure Alert

The red warning light in the shape of Aladdin’s lamp, standing alone, signals low oil pressure in the engine. This could be due to a rapid oil leak from beneath the engine or oil being burned inside the engine and expelled through the exhaust. As this is a critical alert, it is not recommended to continue driving until the light goes off. Operating the vehicle with the low oil pressure light on can cause damage to the engine due to inadequate lubrication, potentially leading to overheating and excessive wear.

Master Warning Light

A triangular warning symbol with a central exclamation mark is a universal indicator of a significant vehicle fault. If this warning light briefly illuminates, it could signal that the vehicle momentarily lost traction, prompting an automatic correction. However, if the light remains on after restarting the vehicle, it is crucial to seek assistance from a Peugeot Traveller dealership or a qualified mechanic.

Adaptive Cruise Control Alert

A warning light featuring a speedometer and a car, accompanied by an exclamation mark, pertains to a potential fault in the adaptive cruise control system. Alternatively, this alert may be displayed using “ACC” in a yellow or red hue. This system relies on radars and cameras to monitor the traffic ahead and adjust the vehicle’s speed accordingly. If this warning light activates, attempt restarting the vehicle to see if the issue resolves. If the problem persists, professional assistance from a trained mechanic or a Peugeot Traveller dealership is recommended.

Lane Sense Alert

A warning light resembling a car veering across broken or solid lines is your vehicle’s way of indicating a potential lane departure. An auditory signal may accompany this alert, and it functions properly only when the vehicle’s camera or other technology can detect lane markings. Certain Peugeot Traveller models are equipped with advanced features that enable the vehicle to autonomously adjust steering to ensure the vehicle remains centered within its current lane.

Forward Collision Detection Disabled

When a warning light on your dashboard depicts two cars with a star (symbolizing a collision) above the word “OFF,” it indicates that the forward collision detection system is deactivated. Unless you have intentionally turned off this system, it is advisable to consult with a trained mechanic or visit a Peugeot Traveller dealership to resolve this issue and reactivate this crucial safety feature.

Forward Collision Detection Alert

A warning light showing two cars nearby, with one car marked by an exclamation point and an arrow, pertains to the forward collision detection system. This system alerts you to a potential collision risk, initiating adjustments to the brakes, suspension, and seatbelts to mitigate the threat. If this warning light remains on continuously, it is crucial to seek assistance from a trained mechanic or a Peugeot Traveller dealership.

Key-Fob Detection Indicator

The image of a key surrounded by waves on your dashboard indicates that the vehicle’s key fob has been detected, signifying that the car is ready to be started, especially if it is equipped with a keyless system. If this indicator fails to appear when the key fob is inside the car, the fob’s battery may be depleted.

A conspicuous warning light featuring the letters “ABS” encircled by a ring and accompanied by a representation of brake pads serves to alert you of a malfunction in the ABS (Anti-lock Braking System). While the vehicle’s standard braking functionality might remain unaffected, it is essential to address this issue promptly by seeking the expertise of a trained mechanic or visiting a Peugeot Traveller dealership.

Stability/Traction Control Deactivated

Like the stability (or traction) control warning symbol, this version includes the word “OFF” to indicate that the system is currently disabled. Deactivating stability control typically requires more than an accidental button press; it usually necessitates holding down a button for several seconds. If you have not intentionally turned off this system, the vehicle may be experiencing a malfunction, necessitating a visit to a trained mechanic for a thorough inspection and resolution.

Stability Control Alert

When the stability control system activates, you may notice an orange or yellow warning light on your dashboard, depicting a car with swirls beneath it. This is typically accompanied by an auditory alert, signaling that the vehicle has intervened to regain traction. If the light remains illuminated despite no apparent traction issues, this could indicate a malfunction within the system of your Peugeot Traveller. In such cases, it is advisable to seek assistance from a trained mechanic or an authorized Peugeot Traveller dealership, especially if the warning light persists.

Low Fuel Indicator Warning Light

An orange or yellow light shaped like an old-fashioned fuel pump signals that your vehicle is running low on fuel. Should this light continue to illuminate even after refueling, consult with a trained mechanic or visit your dealership to address any potential issues.

Low Washer Fluid Warning

A warning light resembling a windshield (or an open book) with a water fountain in the middle is your vehicle’s way of informing you that the washer fluid is running low. Refilling is typically straightforward, with the refill cap under the hood marked with a similar symbol. If the light does not extinguish after topping up and waiting a few minutes, professional assistance is recommended.

Loose Gas Cap Warning

A warning light showing a car with a segment removed and a screw hovering nearby indicates that the gas cap may be loose. After ensuring that the gas cap is securely fastened, if the light remains on, a mechanic should inspect the vehicle for potential issues. A loose gas cap or a leak in the system can cause pressure irregularities in modern engines, particularly diesel-powered ones, potentially leading to erratic engine behavior.

Check Engine Light Alert

The check engine light is a multifaceted warning that can signal anything from a minor issue to a significant problem with your Peugeot Traveller. The symbol may appear as an engine outline, with or without text inside. Upon noticing this light, it is recommended to pull over and restart the engine, as transient fluctuations can sometimes trigger the alert unnecessarily. A flashing light, as opposed to a steady one, indicates a severe issue that necessitates immediate attention, and the vehicle should be turned off as quickly as safely possible. Utilizing an OBD2 reader to retrieve a fault code is a common diagnostic step, which can be done by a mechanic or yourself with an affordable reader.

Hybrid Power Limitation Alert

A yellow or orange light featuring a turtle inside a circle is an alert from your Peugeot Traveller indicating that the hybrid system is low on power. This could result from depleted batteries due to extensive use or, more concerning, damage to the batteries themselves. Suppose you notice this warning light staying on longer than usual. In that case, it is advisable to have the hybrid system of your vehicle thoroughly tested to ensure everything is functioning as it should.

Electronic Throttle Control Alert

A warning light depicting a lightning bolt (zig-zag) situated between two curved lines signals a potential issue with the electronic throttle control system in your Peugeot Traveller. The first course of action to try to resolve this issue is to pull over and restart the vehicle safely. If the problem persists, it is crucial to consult with a trained mechanic to ensure safe and optimal vehicle performance.

Tire Pressure Alert

Most Peugeot Traveller vehicles today have a tire pressure monitoring system, represented by an orange light on the dashboard’s instrument cluster. This light illuminates when the tire pressure drops, signaling the need for immediate attention. A flashing indicator suggests a rapid decrease in pressure, necessitating an urgent response to pull over and address the issue. The loss of tire pressure could stem from various factors, including a puncture, wear and tear around the rim, or sudden temperature changes. Neglecting to maintain proper tire pressure can lead to dangerous driving conditions, impacting both braking and handling, with the worst-case scenario being a tire burst at high speeds. You must inflate the tires or seek professional assistance from a tire shop or a Peugeot Traveller service center.

Auto Stop-Start Alert

An illuminated circle featuring an arrow and the letter “A” in the center, or possibly an exclamation mark, indicates a malfunction within the auto stop-start system of your vehicle. While the car might still function normally, it is advisable to restart the vehicle to see if the issue is resolved. If the warning light remains, professional assistance should be sought. However, it’s important to note that the vehicle’s overall performance may be fine, apart from losing this specific fuel economy feature.

Cruise Control Indicator

A green warning light showing a speedometer with an arrow pointing towards it indicates that the cruise control system is activated. Depending on the Model, this symbol may also appear in yellow, accompanied by an icon of a car shape next to it, signifying the system’s active status.

High Beam Indicator

The vehicle’s high beam lights are on when a blue (or sometimes yellow) semi-circle with straight lines emanating from the side is displayed. These lights provide a stronger and more focused beam of light, aiding visibility, particularly during nighttime driving. However, it is essential (and a legal requirement in some regions) to deactivate the high beams when approaching other road users to prevent glare. The high beams are typically controlled using a forward and backward motion on the light stalk behind the steering wheel.

Fog Lamp Indicator

A warning light resembling a semi-circle adjacent to a series of wavy lines indicates that your fog lamps are active. These additional lights enhance visibility in foggy conditions when you have your main lights turned on. To deactivate the fog lamps, you can use the control located near your steering wheel and lights.

Hybrid Ready Indicator

On the dashboard of a Peugeot Traveller, a green box containing the word “READY” signals that the hybrid system is fully charged and ready for operation. This means the batteries have enough charge to power the motors, allowing the vehicle to run in electric mode.

Brake Pad Warning Light

An illuminated yellow brake disc symbol, accompanied by an exclamation mark, warns that your brake pads may be wearing thin. This feature is increasingly common in modern vehicles, providing drivers ample time to address the issue before the brake pads become dangerously thin.

Engine Coolant Warning

A warning light displaying waves with a floating thermometer, set against a red background, indicates the engine is overheating. The waves represent the engine’s coolant, crucial for maintaining an optimal temperature. Causes for this overheating can vary, ranging from excessive engine strain to a leak or other malfunction. In such cases, it is imperative to pull over, allow the engine to cool, and seek professional assistance from a trained mechanic or a Peugeot Traveller service center.

Powertrain/Drivetrain Warning

The powertrain or drivetrain of your Peugeot Traveller encompasses the mechanical components responsible for transmitting power from the engine to the wheels. This includes the transmission, clutch, differentials, axles, and potentially other driving aids. Suppose a warning light related to the powertrain or drivetrain illuminates and remains on after restarting the vehicle. In that case, it is crucial to address this issue promptly as it could indicate a severe problem, potentially making driving unsafe.

Heads Up Display Warning Light

A warning light on your Peugeot Traveller ‘s dashboard resembling a caterpillar or a long tube with flashing lines may be related to the heads-up display system. If no corresponding error message appears on the separate heads-up display unit, this could indicate a system malfunction. In such cases, it is advisable to consult with a Peugeot Traveller mechanic or visit a dealership to conduct diagnostics and resolve the issue.

Electronic Parking Brake Alert

Modern Peugeot Traveller models have transitioned to an electronic parking brake, typically engaged via a button rather than the traditional handbrake lever near the gear shifter. This system may be represented by a yellow warning light displaying a “P” enclosed within it. If the system encounters a fault, a red warning light featuring brake pads surrounding a circle with a lightning bolt inside will appear. Given that an electronic system provides less tactile feedback compared to a mechanical handbrake, this warning is crucial. Operating the vehicle with this warning light could be hazardous, and it is strongly recommended to seek assistance from a Peugeot Traveller dealership.

Blind Spot Monitoring System Deactivated

A warning light showing two side-by-side cars with a radar effect between them, accompanied by the word “OFF” above, indicates that the blind spot monitoring system is turned off. The blind spot is the area outside of a driver’s immediate line of sight, and this system aids in detecting vehicles within that area. If you did not manually deactivate this system and the warning persists after restarting the car, it is advisable to consult with a trained mechanic.

Hood Open Alert

The hood ajar warning is a critical alert that should not be ignored. Ensure that the hood of your Peugeot Traveller is securely closed by opening it fully and then closing it firmly to engage the locking mechanism. Driving with an unsecured hood is extremely dangerous, as it could open while the vehicle is in motion, obstructing your view and causing severe damage.

Trunk Open Warning Light

A car silhouette with an open trunk flap on the right-hand side indicates that the trunk of your vehicle is not properly closed. Ensure that the trunk is securely shut before driving, as ignoring this warning could lead to more severe alerts, including auditory alarms. If the trunk appears closed yet the warning persists, there may be an issue with the sensor, necessitating professional inspection.

Engine Air Filter Alert

A clogged engine air filter can hinder performance and fuel efficiency, and it is essential to replace it promptly. Some Peugeot Traveller models are equipped with sensors that detect when the air filter is blocked, providing a warning before it becomes a significant issue. This warning is represented on the dashboard by a series of circles with a gust of wind flowing through them. Replacing the air filter is a relatively simple and affordable maintenance task.

Water in Fuel Warning Light

In most diesel engines, the fuel filters are designed to separate and remove any traces of water from the fuel to prevent damage to the engine. If water can bypass this system, you may see a warning light on your dashboard, usually as a fuel pump next to water droplets or rain. Water in the fuel can cause severe damage to the engine, so it’s crucial to address this issue promptly. You should refer to your car’s owner’s manual, which will provide detailed instructions on resolving this issue if this warning light appears.

Glow Plug Warning

For diesel engines, a glow plug is a crucial component that aids in starting the engine, especially in cold conditions. The glow plug warning light usually represented as a coiled wire or string in yellow, illuminates briefly when you turn on the ignition, indicating that the glow plug is warming up. This light should disappear quickly, signaling that the glow plug has reached the necessary temperature. If the light remains illuminated, it indicates a potential issue with the glow plug, and you should seek assistance from a Peugeot Traveller mechanic.

Service Reminder

Some Peugeot Traveller models have a service reminder feature triggered after a specific number of miles or months since the last service. This reminder is typically displayed as a spanner with an exclamation mark passing through it on the dashboard. While this is usually just a friendly reminder and not an indication of a malfunction, it’s advisable to schedule a service soon to maintain your vehicle in optimal condition.

Brake Override Warning

Engaging the brake and accelerator pedals simultaneously can cause damage to the vehicle and increase the risk of an accident. Some vehicles feature a warning light on the dashboard to alert the driver when both pedals are being pressed simultaneously, urging them to adjust their driving for safety reasons. In some models, the vehicle may even intervene to resolve the issue. If this warning light is flashing, it indicates a malfunction in the system, necessitating immediate attention from a professional.

Adblue Warning

Adblue® is an additive in some modern diesel engines to reduce emissions and pollution. When the Adblue® level is low, a warning light will appear on the dashboard, displaying the word “Adblue” or an image of an emptying bottle. If the Adblue® reservoir can run empty, the engine may not start. Adblue® fluid is readily available at various retailers, including fuel and service stations, and can be easily replenished by the vehicle owner.

Headlight/Taillight Malfunction Indicator

Modern Peugeot Traveller vehicles may be equipped with a convenient warning system designed to alert you when a headlight or taillight is not functioning properly. Since a burnt-out light can be challenging to detect from the driver’s seat, this feature is invaluable for maintaining safe driving conditions. The warning typically appears as an illuminated light bulb encircled by two smaller semi-circles on your dashboard. Addressing this issue promptly ensures optimal visibility and compliance with traffic regulations.

Immobilizer System Alert

The immobilizer is a vital security feature in your car, designed to thwart potential car thieves by preventing the engine from starting without the proper key. It achieves this by cutting off the fuel pump’s power supply. The system operates by detecting your car’s authorized key inside the vehicle, thereby enabling the engine to start. If an issue arises with the immobilizer, your car may fail to start, and you will see a warning icon resembling a car with a large key inside of it on your dashboard. In such a case, it is advisable to seek assistance from a trained Peugeot Traveller mechanic to diagnose and resolve the issue.

Air Suspension Alert

Some car models, particularly those capable of off-road driving, have an air suspension system that allows the driver to adjust the vehicle’s height. While innovative, this system has numerous components and relies on piping prone to damage. A warning light depicting the outline of a car with arrows pointing up and down indicates a potential issue with the air suspension system. Given that driving with a faulty air suspension can be hazardous, it is crucial to consult with a trained mechanic as soon as possible.

Automatic Transmission Fault Indicator

An automatic transmission enhances the driving experience by simplifying gear changes, but it is also a complex component that can be expensive to repair if problems arise. A warning light resembling a cog with an exclamation mark indicates a potential fault in the gearbox. Addressing this issue promptly is imperative, and it may be advisable only to drive or at least push the vehicle too hard until a professional has resolved the issue.

Oil Service Reminder

A yellow oil symbol on your dashboard generally signals that it’s time for an oil service, indicating either a need for an oil change or a drop in oil levels. Some modern vehicles provide explicit dashboard messages such as “oil service required” or “oil change required.” To resolve this issue, schedule an oil change and consider replacing the oil filter simultaneously to remove any lingering contaminants from the system. While topping off the oil levels may provide a temporary solution, it is not a substitute for a proper oil service.

foton traveller dashboard warning lights

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